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An alternate cost effective material for rocker arm used in heavy commercial vehicles

VE Commercial Vehicles Ltd-Kaarthic Kaundabalaraman, Suresh Kumar Kandreegula, Hemantkumar Rathi
VE Commercial Vehicles, Ltd.-Sonu Paroche
  • Technical Paper
  • 2019-28-2550
To be published on 2019-11-21 by SAE International in United States
Rocker arm in internal combustion engine is very important part which transfer the cam motion and force to the valve. In heavy commercial vehicles, the engine components are design for an infinite life (considerable higher than other components). Recently industries are working for light weight and optimized cost material. Hence it is required to have an optimized cost effective design of rocker arm without affecting its performance. A rocker arm should meet the stiffness and strength requirement. The objective of this study is to find out the alternate material for rocker arm which can provide the similar strength & stiffness as conventional rocker arm material. To achieve the performance and cost target, alternate material cast iron has been evaluated for rocker arm. Cast iron is lighter than the forged steel rocker arm, also it has a good frictional characteristic. Further bush is eliminated from the rocker arm assembly due to self-lubricant property of the cast iron rocker arm. This is significant reduce in cost of material and assembly procedure. A 2-d simulation and finite element…
 

Optimization of the critical parameters affecting the fuel lid performance

Maruti Suzuki India, Ltd.-PIYUSH KUMAR PAREEK
  • Technical Paper
  • 2019-28-2413
To be published on 2019-11-21 by SAE International in United States
Fuel lid is one of the parts which are mostly operated mechanically by the end user while filling the fuel. Therefore part design should be done in such a manner that it can be operated smoothly without any hassles. The conventional steel fuel filler doors are of two types: Three-piece type fuel filler doors also known as the dog-leg type and two-piece type fuel filler doors also known as the butterfly type. Both types of fuel filler doors have a pin that acts as a rotational hinge axis about which the fuel filler door opens and closes. Depending on the styling and shape of the side body outer, fuel lid type is decided. In the current study, dog-leg type fuel lid is considered. The factors that primarily affect the opening-closing performance are the weight of fuel lid, hinge axis, and the friction at the hinge area. The orientation of the hinge axis is derived from the profile of the side body outer panel. The fuel lid weight and hinge axis are decided in the initial…
 

FABRICATION AND WEAR CHARACTERISTICS BASALT FIBER REINFORCED POLYPROPYLENE MATRIX COMPOSITES

Dhanalakshmi Srinivasan Institute of Tec-Thirugnana Sambandha T, Arun R
Dhanalakshmi Srinivasan institute of tec-Krishnaraj M
  • Technical Paper
  • 2019-28-2570
To be published on 2019-11-21 by SAE International in United States
Generally brake pads are manufacturing by use of asbestos materials, these materials are chemically harmful and toxic, affects human health. The present investigation fabricates polypropylene composites with mixing constant volume [5 Vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt fibre by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition using pin on disc apparatus configuration with hardened steel counter-face at elevated temperature. The load was applied 30N to 70N with the interval of 20N and varying of sliding speed 300 rpm to 900rpm with the interval of 300rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and also increases the frictional force for the effect of basalt fibre content present in the composites. The co-efficient of friction was increases from 0.1 to 0.66 under normal loading condition.
 

STATISTICAL ANALYSIS OF LOW CYCLE FATIGUE PROPERTIES IN METALS FOR ROBUST DESIGN

GM Global Technical Center, USA-Abolhassan Khosrovaneh
General Motors Technical Center India-Karthigan Ganesan, Biswajit Tripathy
  • Technical Paper
  • 2019-28-2576
To be published on 2019-11-21 by SAE International in United States
Objective: In ground vehicle industry, strain life approach is commonly used for predicting fatigue life. This approach requires use of fatigue material properties such as fatigue strength coefficient (σf'), fatigue strength exponent (b), fatigue ductility coefficient (εf'), fatigue ductility exponent (c), cyclic strength coefficient (K′) and cyclic strain hardening exponent (n′). These properties are obtained from stable hysteresis loop of constant amplitude strain-controlled uniaxial fatigue tests. Usually fatigue material properties represent 50th percentile experimental data and doesn't account possible material variation in the fatigue life calculation. However, for robust design of vehicle components, variation in material properties need to be taken into account. In this paper, methodology to develop 5th percentile (B5), 10th percentile (B10) and 20th percentile (B20) fatigue material properties are discussed. Possible material variation in fatigue life prediction is included as B5, B10 and B20 fatigue material properties. Methodology: Fatigue strength coefficient (σf') and fatigue strength exponent (b) are obtained by performing a linear regression on true stress amplitude (∆σ/2) versus reversals to failure (2Nf) in log-log scale. Fatigue ductility coefficient (εf')…
 

High rigidity and light weight bumper material development in India

Honda Cars India Limited-manu sharma
  • Technical Paper
  • 2019-28-2553
To be published on 2019-11-21 by SAE International in United States
Vehicle weight reduction becomes important at the view point of fuel efficiency improvement and CO2 reduction in India also as well as developed countries. With this background, High tensile and Super high tensile steel application has become increasing. Similary, weight reduction of big plastic parts like bumper face is one of the most important items, so Honda has developed Thin-wall and light weight bumper face. In the development of light weight bumper, rigidity, impact strength and flowability which are main requirement are cotradictory property. It is necessary to develop new material to achieve this technical concern. Moreover, we verified part shape and thickness optimization to achieve part requirement. Established high property material and part manufacturing technology were applied for current CITY firstly, and it has been expanded to other models sequentially to contribute weight reduction for Honda vehicles. In this report, we report the analysis and verification result example of high rigidity and light weight bumper material development in India.
 

Multi Characteristics Optimization of Treated Drill Tool in Drilling Operation Key Process Parameter Using TOPSIS and ANOVA Technique

SRM Institute of Science and Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Aishik Banerjee, Avanti Kulkarni
  • Technical Paper
  • 2019-28-0055
To be published on 2019-10-11 by SAE International in United States
To survive in the present global competitive world, the manufacturing sectors have been making use of various tools to achieve the high quality products at a comparatively cheaper price. Appropriate cutting set up must be used to further better the machinability of a work piece material. A longer life of the tools and equipments are important factors in any industry. Since the inception of the machine tool industry, cutting tool life and tool wear remain a subject of deep interest to study its failure and improvement. The present study finds out the optimum cutting results in drilling of AM60 magnesium alloy using different cryogenically treated cutting inserts. The Utility concept coupled with Taguchi with Multi response approach (TOPSIS) was employed. According to Analysis of variance (ANOVA) results, the feed was the major dominating factor followed by the cutting speed. This work deals with optimization approaches for the determination of the optimum process parameters by cryogenically treated drill HSS tools which minimizes surface roughness, torque, tool life, entry burr and tool cost, and maximizes material removal…
 

Stress and Model Analysis of Upper and Lower Bolster Components of Molten Steel Transfer Vehicle

Vellore Institute of Technology-Darla Siva Prasad, Chooriyaparambil Damodaran Naiju, Posam Naveen Kumar
  • Technical Paper
  • 2019-28-0119
To be published on 2019-10-11 by SAE International in United States
The transportation of hot metal from blast furnaces to melting shops is carried out by molten steel transfer vehicle such as Torpedo ladle car in the steel plants. In need to design Torpedo ladle car within size limitation, capacity requirement and withstanding the impact, static, thermal shock and abrasion conditions, structural analysis is essential for validation. In this paper, stress and model analysis for upper and lower bolsters of Torpedo Ladle Car is carried out. The components are modelled in CAD and analysed using finite element method using software with the required boundary conditions. The results of structural analysis of bolster components are presented and discussed.
 

Assessment of tribo meter study of 20MnCr5 alloy steel under case hardened and shot peened condition

Shanthi Gears Limited-Vignesh Nataraj
Sri Krishna College of Engg. and Tech.-Soundararajan Ranganathan, Janarthanan Prakash, Dinu Mathew
  • Technical Paper
  • 2019-28-0098
To be published on 2019-10-11 by SAE International in United States
This research is constrained to study the strength and wear resistance of 20MnCr5 (SAE 5120) alloy steel under monolithic, case hardened and case hardened with shot peening processing condition. Improve the hardness of the material by enhancing the core and surface strength of case hardened with shot peened sample. The principle goal of this proposed work is to conduct the tribo meter test for the three test samples by differing the load of 5, 10, 15 and 20N and sliding speed of 290,580,870 rpm respectively. The impact on tribo meter process parameters on wear rate and co-efficient of friction be calculated and recorded for this study. Less wear rate and nominal co-efficient of friction was observed for case hardened with shot peened sample. Load and sliding distance increases wear rate decreases and co-efficient of friction increases for all the tested samples due to oxide layer formation. After reaching certain load and sliding speed the curve goes linear because of more contact between pin and disc, so that mechanical amalgamation layer will be framed. On the…
 

Tensile and Fatigue behavior of shallow cryogenically treated En19 alloy steel

BSACIST-Loganathan Sekar, Tamil Arasan
SRM Institute of Science and Technology-Rajendran Raj
  • Technical Paper
  • 2019-28-0100
To be published on 2019-10-11 by SAE International in United States
Wear, tensile and axial fatigue tests were conducted on shallow cryogenically treated En19 medium carbon alloy steel to investigate its mechanical behavior. The test samples are conventionally heat treated then oil quenched at 34 ˚C. Followed by the samples were kept under shallow cryogenic treatment to -80˚C for 12 hours using liquid nitrogen. Then the samples were tempered in a muffle furnace to relieve the induced residual stresses. Wear, Tensile and axial fatigue test was carried out on both treated and non-treated samples to measure its wear resistance, tensile strength and fatigue behavior respectively. Microscopic examination also done using scanning electron microscope to compare the effect of shallow cryogenic treatment on its microstructure. The results exposed that there is a reduction in the tensile strength and fatigue life of shallow cryogenically treated samples over base metal and improved wear resistance.
 

Mechanical and Metallurgical analysis of HSLA steel for Gas Tungsten Arc Welding with different shielding gases

CSI College of Engineering-Dhanraj Gurusamy, Prashanth Murthy, Senthilkumar Ramakrishnan, Sivakumar Nanjappan
Sri Krishna College of Engineering and Technology-Soundararajan Ranganathan
  • Technical Paper
  • 2019-28-0069
To be published on 2019-10-11 by SAE International in United States
The special designed HSLA (High Speed Low Alloy) Steel is most commonly used in Naval Steel Structures and aircraft structures due to its indigenous properties. The aim of this paper is used to investigate the effect of shielding gas in the Gas Tungsten Arc Welding process. The sheet plate of size 300mmx150mmx10mm is taken and welded by GTAW process using argon and helium on the shielding gas. DMR 249A plates are welded by GTAW by using helium and argon as shielding gas with a flow rate of 16 L/min, the interpass temperature is 140ᵒ C and the heat input is less than 1.2KJ/min which is maintained to get a balanced phases of α and γ where the impact toughness, Tensile and micro hardness was studied with different shielding gas and the metallurgical properties were analysed in the base metal, heat affected zones and weld zones. The sheets contain 1.9%Ti and 6.2% Ni and the weld beads were studied for both the type of shielding gases. The study reveals that for helium gas the penetration is…