Advance Luggage Carrier

INTRODUCTION The idea behind making any product is to fulfill the requirements of society. During year more than three months, we searched for idea, which would help in creation of new product. These days, we can see around us there are thousands of bikes running on road. Bike is important in our daily life. Because using vehicle his time is reduced for reaching are place to another. It is good for travelling but while travelling there can be possibility of conveying luggage or any kind of load and also there can be chances of unbalancing the luggage. What should be do when he has to carry some luggage. An alternative for this he will choose like autorickshaw, rickshaw, bus or any other conveyance. But he will doesn’t so on bike, because doesn’t provide luggage carrying facility.

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PRODUCT DESIGN AND DEVELOPMENT Customer need 'NEED' the word which has given rise to inventions, discoveries, hand work and also ideas from the day living organisms are known to exist. This is the thing that has made living organisms adopt to changes for their own interests. The same is the case with us. But thinking like some engineers of today's era we took it in a broad sense calling it as customers need of which we also are a part. A person never be a difficulty until and unless he himself is caught into it. The need is of carrying load area two wheeler when a single person it driving it. Moreover the attachment should be such that it should neither affect the balance of the vehicle causing ballistic movements while driving, carrying maximum load neither should be it a permanent fixture so that it might cause difficulty when two persons are travelling. Thus the design is such that the customer need is fulfilled to its peak point. Luggage can be carried easily and then attachment can be shifted back to its normal position.

Market Research Recognizing the real of the customer are decided to continue our work in that direction. Therefore use confirmed our project to design such a carrier which will fulfill the needs of the customers. But as use all know the customer buys the product from the market. Moreover the designer and the producers both are affiliated to the changes and

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the requirements in the market. It consists of two parts i.e. before introducing the product in the market and after introducing the product in the market. The later is called marketing and the previous is called market research. After selecting 'carrier' as our project, use thought that - is this really a customer's need? For this use decided to go for a research in the market, without satisfying the customers need designer or manufacturer or whoever can never make a successful product. Market research is the tool available to solve the problems of the manufacturer, concerning the product. Especially market research is carried out regarding proposed new product which the case with us. Our idea was new but still confirmation was necessary whether already such type of carrier exists in the market ! In that view we visited different showrooms of two wheelers in our city as well as the cities near by. To our expectations there was none of a carrier even a single percent similar to our idea.

Trouble in carrying loads, luggage. The figure shows line represent of a bike chassis. A post consist of handle, B- part main part of chassis where center of gravity of bike lies is the part where usually load is carried. If load is placed on post and the bike is running fill the vibration of bike due to road conditions case transferred to the end as front side is get pressure due to handling action and B - Part on which a driver seats. The vibrations at end are dangerous because, they can unbalance, the bike if speed is more than average and load adds self properties of vibrating in any possible weak

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direction. And it is not advisable to carry loads through bags hooked at the handle that will district the motion of handle. And if the load is carried through one side post of rear post, that will not give safe drive to others.

Compromise Design Today’s market is a customers market, what customer demands is the subject of concern of manufacturers due to vast competition in every field of product. Before this decades the scenario was different. The manufacture used to designed the product according to his own concept and way, the customer was not much kept into mind while designing and manufacturing procedure. The reason for this is the limited competition.

Later the producer knew that whatever new thing they launch

customer has to except it by taking beside what the customers needs. But today the picture is different. The traditional concept of marketing is changed. Customers point of views is concern in abundant in designing and manufacturing. Let us take the bike for example as customer feel there is a need for fuel indicator besides the tank. Hero Honda and some of leading companies brought this concept in actual. Similar is the case with side stand . It is dangerous when it is not off the position while driving. The Company adds a sensor to its new model Eliminator. There are the cases of customer marketing while adopting such policy. The views of customers are collected through surveying or some special offers of suggest and win type by taking actual demonstration of the product by replacement offers.

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But the manufacturers have some limitation. They can not satisfy each an every demand due to manufacturing limitation. Considering other processing aspect, cost and its reliabilities. Then instead of dropping the idea the producer may find a mid way in between both customers view and manufacturing aspect. The design prepared by such compromise is called compromise design. Up to some extent customer is satisfied and manufacturer are also satisfied for what they produce, customers are accepting.

Versatility Versatility is basically a quality of a taking to have different uses. Now is this concerned with our project ? This was because if use designed the carrier for a single bike then limited people would be benefited. On the second option was to have different carriers for different models of bike. But this would neither suit the producers nor the suppliers. So we decided to make the carrier versatile. During the market research use had also taken measured of different bikes, i.e. of their chassis, seat length, distance and of various possible points for damping arrangements. For our relief we found that the basic structures of all the bikes were near about similar with some fluctuations. But after some study we found that if use work harder we can find out a common design out of it and use did it. Our first preference was to the Honda CD-100 & SS bikes which are usually used in the rural areas. But the carrier also suits other bikes and vehicles like the Honda Splendor, KB-100, Hero-Puch Suzuki which are mostly used in to days market. This confirmed the case to mass production and versatility of our project.

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CARIER ELEMENTS, MATERIAL & PROCESSES Clamps Types of clamps 1. Lever or strap clamps 2. Screw clamp 3. Cam-action clamps 4. Hinge Clamps 5. Toggle action clamps

Toggle Clamps These are fast acting clamps. These have the natural ability to move completely free of the work allowing for faster insertion/taking out of parts. The holding force of toggle clamps compared to the application force is very high Fig. shows the four basic clamping actions, viz. hold down pull, squeeze, and straight line action.

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Positive lock ensure below centre

Pressure

Pressure

When clamp retracted centres move

Toggle Action Toggle clamps operate on a system of levers and three pivot points. When the clamp is locked, the pivots are nearly in line, the central pivot being slightly below the center to insure positive lock. . When retracted, the pivots and levers are positioned as shown in fig. These toggle clamps can be used in a variety of ways with the special mounts, spindles, handles etc.

Rivets A rivet is a short cylindrical bar with a head integral to it. The cylindrical portion of the rivet is called shank or body and lower portion of shank is known as tail, as shown in Fig. The rivets are used to make permanent fastening between the plates such as in structural work, ship building, bridges, tanks and boiler shells. The riveted joints are widely used for joining light metals.

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The fastenings (i.e., joints) may be classified into the following two groups : 1. Permanent fastenings, and

Head

shank or body

2. Temporary or detachable fastenings. The permanent fastenings are those fastenings which

Tail

can not be disassembled without destroying the connecting components. The examples of permanent fastenings in order of

Rivet part

strength are soldered, razed, welding and riveted joints. The temporary or detachable fastenings which can not be disassembled without destroying the connecting components. The examples of permanent fastenings are those fastenings which can be disassembled without destroying the connecting components. The examples of temporary fastenings are screwed, keys, cotters, pins and splined joints. Methods of Riveting The function of rivets in a joint is to make a connection that has strength and' tightness. The strength is necessary to prevent failure of the joint. The tightness is necessary in order to contribute to strength and to prevent leakage as in a boiler or in a ship hull. When two plates are to be fastened together by a rivet as shown in Fig., the holes in the plates are punched and reamed or drilled. Punching is the cheapest method and is used for relatively thin plates and in structural work. Since punching injures the material around the hole, therefore drilling is used in most pressure-vessel work. In structural and pressure vessel

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riveting, the diameter of the rivet hole is usually 1.5 mm larger that the nominal diameter of the rivet. The plates are drilled together and then separated to remove any burrs or chips so as to have a tight flush joint between the plates. A cold rivet or a red hot rivet is introduced into the plates and the point (i.e., second head) is then formed. When a cold rivet is used, the process is known as cold riveting and when a hot rivet is used, the process is known as hot riveting. The cold riveting process is used for structural joints while hot riveting is used to make leak proof joints. The riveting may be done by hand or by a riveting machine. In hand riveting, the rivet head is backed up by, a hammer or heavy bar and then the die or set, as shown in fig. is placed against the end to be headed and the blows are applied by a hammer. This causes the shank to expand thus filling the hole and the tail is converted into a point as shown in fig. As the rivet cools, it tends to contract. The lateral contraction will be slight, but there will be a longitudinal tension introduced tension introduced in the rivet which holds the plate firmly together.

Die

Point

Tail

Original head Backing up Bar

Initial Position

Final Position Methods of riveting

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Types of Rivet Heads According to Indian standard specification, the rivets heads are classified into the following types :  Rivet heads for general purpose (below 12 mm diameter ) as shown in fig. according to IS : 2115 – 1982.

Snap Head

Snap Head

Pin Head

Pin Head

Mushroom Head

Pan Head with Tapered neck

Types of Rivet Heads

Columns and Struts A machine part subjected to an axial compressive force is called a strut. A strut may be horizontal, inclined or even vertical. But a vertical strut is known as a column, pillar or stanchion. The machine members that must be investigated for column action are piston rods, valve push rods, connecting rod & screw jack, side links of toggle jack etc. In

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this chapter, we 'shall discuss the design of piston rods, valve push rods and connecting rods. Failure of a Column or Strut It has been observed that when a column or a strut is subjected to a compressive load and the loud is gradually increased, a stage will reach when the column will be subjected to ultimate load. Beyond this, the column will fail by crushing and the load will be known as crushing load. It has been experienced, that when sometimes, a compression member does not fail entirely by crushing, but also by bending i.e. buckling. This happens in the case of long columns. It has also a been observed, that all the short columns fail due to their crushing. But, if a long column is subjected to a compressive load, it is subjected to a compressive stress. If the load is gradually increased, the column will reach a stage, when it will start buckling. The load, at which, the column tends to have lateral displacement or tends to buckle is called buckling load, critical load, or crippling load and the column is said to have developed an elastic instability. The buckling takes place about the axis having minimum radius of gyration or least moment of inertia. It may be noted that for a long column, the value of buckling load will be less than the crushing load. Moreover, the value of buckling load is low for long columns, and relatively high for short columns.

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Types of End Conditions of Columns In actual practice, there are a number of end conditions for columns. But we shall study the Euler's column theory on the following four types of end conditions, which are important from the subject point of view : 1. Both the ends hinged or pin jointed as shown in Fig. 2. Both the ends fixed as shown in fig. 3. One end is fixed and other is hinged as shown in fig. 4. One end is fixed and the other free as shown in fig. P

P

P

P

Types of end conditions of columns

Selection of Mild Steel for bike carrier purpose For making structural frame of bike carrier low carbon or mild steel is selected because of following desired objectives. 1. Availability is more 2. Cost is minimum 3. Physical properties and mechanical properties.

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Density

Meting Point

7850 Kg/m3

15100 6

Flow ability, bending & weldability electro plating properly

Material properties Properties of mild steel :1. It can be magnetised permanently. 2. It can be readily forged and welded. 3. 0It can not be readily hardened and tempered. 4. It has fibrous structure. 5. It is malleable and ductile. 6. It is not easily attacked by salt water. 7. It is tougher and more elastic than wrought - iron. 8. It is used for all types of structural work. 9. It rusts easily and rapidly. 10.

Its melting point is about 1400 0C.

Processes Bending Bending is the cold working process involving plastic deformation in which the total surface area remains constant. Bending of pipe, tube, rolled or extruded shapes involves practices and theories of the simple supported beams, the cantilever beam and many of the problems of forming and deep drawing. In bending flow of metal occurs in plastic range, and there is a permanent change in shape. Thinning of outer wall of a bent tube or other hollow section and corresponding thickening of the inner wall of the bend arc

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noticeable effects of plastic flow. The neutral axis also gets displaced. When bending thin walled tubes, the material has a tendency to buckle and wrinkle which can be avoided by supporting the material by a shoe which is located opposite to the direction of die pressure. It is

observed that bent material tends to recover elastically when the deforming force is

removed. This spring-back can be overcome by ending the metal a few degrees more than the desired angle or by setting the punch travel so that it compresses the bent metal beyond its yield stress (this operation being known as polishing).

In sheet metal work

bending is sometimes called forming also. In this case, a plastic deformation of metal takes place and the metallic sheet is stressed in both tension and compression. The bottommost layer is under tension and topmost layer under compression, when the punch is forced over the sheet. The metal must be bent at right angles to its fiber. The sheet is more liable to fail along the direction of fibers, i.e. along the length of impurities, than across them. Hand brake and press brake dies are most commonly used for bending operations. Ram

Wing dies

Die-bending

Press bending

Folding

In addition to the above two dies forming dies of different designs are also used for various forming operations. Forming is also similar to bending operation with the difference that a number of bends are formed about the linear axis by making the metal

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confine to die shape. Operation of-bending can be done on ram-type machine or rotary type machine. The ram bending machine follows the principle of simple supported beam closely. In this machine two pressure dies are mounted in fixed positions on the frame of the machine, and are free to rotate about their own mounting pins, while the form is mounted directly to the piston rod of the hydraulic cylinder. Welding Shielded Metal Arc Welding (SMAW). It is a manual arc welding using coated electrodes. Since the electrode melts and joints the weld pool, it is classed under consumable arc welding method. The coaling on the electrode burns along with metal of electrode and produces a dense smoke which covers or shields the weld pool, preventing oxidation and absorption of nitrogen by the metal. The electrode coating after melting forms a slag cover over the molten pool. This process is very versatile and flexible and can be used in difficult places.

SMAW can be performed both on AC and DC source with drooping characteristic, highest current rating being about 600 amperes. Selection of proper electrode is essential for best results. A rough guide is given in Fig about the size of

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electrode and cur- rent For different thickness of plates to be welded. However it is advisable to consult recommendations of electrode supplier. In DC welding, arc starting is easy and the arc is steady and smooth. Straight polarity (electrode - ve) is used for welding thin sheets and for plates with wide gaps. Reverse polarity (electrode +ve) produces maximum penetration and is used for root passes and out-of-position welding. Due to high voltage drop in cables, cable length should be short. AC arc welding requires more skill on the part of operator. It is difficult to start.

Less drop in cable, less arc blow are suited for thicker plates. Shielded Metal Arc

Welding (SMAW) Electrode: Mild steel electrodes are classified as (i)

fast freeze,

(ii)

fast fill

(iii)

fill freeze, and

(iv)

low-hydrogen-types. Fast freeze electrodes arc cellulose coating electrodes. Due to their fast

freezing action, puddle solidifies rapidly after being deposited from the electrode. Their shielding atmosphere is rich in hydrogen and thus they produce intense heat and deep biting action. It is well suited for maintenance work because these burn through rust, grease, or used steel. These are also well suited for out-of-position welding due to their excellent puddle control an rapid solidification. These electrodes call for whipping motion (whip-and-pause technique) for good results. Fast-till electrodes contain iron powder in the flux coating which helps create the high deposition rate. Because of their highly fluid

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puddle, these are used for flat and horizontal positions only. Fill-freeze electrodes have the characteristics of both fast-fill and fast-freeze electrodes. They solidify faster than fast-fill class and they have higher deposition rates than fast-freeze class. Precautions in arc welding. Because of the intensity of heat and light rays from the electric arc, the operators hands, face, and eyes are to be protected, while the arc is in use. Heavy gloves are worn, and a hand shield or a helmet with the window of coloured glass should be used to protect the face and eyes from the glaring effect of the arc-rays. Also the space for the electric arc welding should be screened off from the rest of the building to safe guard other workmen from the glare of arc. Precautions to be Observed in Arc Welding. Arc welder should be clear of the hazards likely to occur from are welding and should take all precautions to avoid them. These hazards are radiation (ultraviolet and infrared rays) from the arc, flying sparks, globules of molten metal, electric shock, fumes, burns, etc. One should never look at arc till eyes are protected with welders helmet or face shields with approved lenses.

Face,

hands, arms and other skin surfaces must be covered by wearing gloves and clothing of sufficient weight to shut off the rays from the arc. Flammable materials like matches, celluloid combs, fountain pens etc. should be removed from pockets. Floor should be dry and electrode holder insulated. Proper ventilation equipment should be used. Fuses of right capacity should be fitted in the main switch and ampere adjustment should be set to minimum. Correct size electrodes should be selected. Before starting arc, the machines should be; carefully inspected, cleaned and oiled. All connections should be tight. Electrode holder and ground electrode cables

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should be inspected and electrode holder hung on a wood or fiber hanger away from the work to be welded. Brushes should not arc heavily incase of motor generator unit. The machine should never be started with the electrode holder on a table or base metal, since this closes the arc welding circuit and causes arc welder to start under a full load, which is hard on most machines. The machine should be adjusted for proper current setting depending on base metal and electrode sire, by switching off main power supply. After running a few beads, it may be necessary to make fine adjustment to obtain more perfect weld. Resistance Welding For manufacturing this design we use manual metal arc welding process. But for mass production the resistance welding process is available. Outline of resistance welding is given below. Resistance welding is a group of welding processes wherein coalescence is produced by the heat obtained from resistance of the work to the flow of electric current in a circuit of which the work is a part and by the applications of pressure. No Filler metal is needed. The two factors or variables mainly responsible for resistance arc welding. 1. The generation of Heat at the place where two pieces are to be joined. 2. The application of pressure at the place where a weld joint is to be formed.

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Advantages of resistance welding 1. Fast rate of production. 2. No filler rod is needed 3. Less skilled workers can do the job can be welded. 4. High reliabilty & producibility are obtained. 5. More general dimination of warping or distortion of parts. Drilling Drilling is a process of making hole or enlarging a hole in an object by forcing a relating tool called drill. Drilling machine is one of the simples moderate and accurate machine tool used in production shop and tool room. Troubles in drilling and their remedial measures. The various trouble experienced in drilling operation and their remedial measures are given below. i)

Rough hole :

ii)

Oversize hole :

iii)

Breaking of drill :

iv)

Chipped cutting lips :

Precautions in Drilling operations i)

Machine tool must be rigid enough otherwise parts may be deformed by the cutting forces given rated. Drill feeding arrangement must be directionally stable.

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ii)

Accurately ground drill should be used so that uniform chips are produced by both cutting edges; otherwise the unbalanced forces may deflect the tool during machining.

iii)

Axis of spindle, adapter and tool must coincide, otherwise errors and in accuracies as described below may occur.

iv)

Work piece must be held very rigidly.

Grinding To grind means 'to abrade' to wear away by 'friction' or 'to sharper'. i)

Grinding is the operation of removing metal in the form of minute chips by feeding the work against a rotating abrasive wheel known as the grinding wheel. Both internal and external surface of a work piece may be ground by using a special attachment mounted on the cross slide.

Grinding Faults : Two common faults due to incorrect choice of wheel or incorrect grinding condition are : i)

loading & ii) glazing. Loading occurs when spaces between the abrasive grains become clogged

with particles of the metal being ground. Glazing is easily recognised by shiny appearance on the face of the wheel. It occurs due to abrasive grains becoming dull and not breaking away from the bond. Surface finishing process : In a manufacturing plant, a product may be shaped, turned, milled or drilled and lift in that condition as being satisfactory for use. But nowadays greater attention is

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paid towards the appearance of the product. This is because the performance of the product will be judged only when it is selected, thus appearance stands first in the process of selection of the product by the customer. So if better finish is desired for looks, for accuracy, for wearing qualities or for any other reasons different microfinishing operations may be employed. The one which we selected was → Electroplating Electroplating or electropolishing is the process by which the coating metal is deposited on the base metal by passing a direct current through an electrolytic solution containing the soluble salt and the coating metal. The base metal to be plated is made the cathode and the electrolytic cell ; whereas the anode is either the coating metal itself or an inert material of good electrical conductor (like graphite). During electrolysis electrons are introduced from an external source. Thus, in principle, electroplating the reverse of corrosion i.e., in electroplating metal is deposited from solution; while in corrosion metal is dissolved in solution. Corrosion always occurs at the anode and electroplating always occurs at the cathode.

Plating occurs at cathode

Electroplating of Cr. electrons

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The properties of the electroplate coating depends on: (i) the deposition of the plating solution, (ii) current density, (iii) agitation, (iv) the temperature of the electrolytic bath ; and (v) pH of bath. Moreover, the protective value of the electroplate coating depends on its uniformity and porosity. Coating usually contains small visible pores, pinholes, etc. unless excessively thick coatings are applied. Electroplating is probably the most frequently applied method protective coating of metals. The electroplating metals most frequently used are zinc, nickel, chromium, tin, and copper. Cadmium, lead and precious metals (like Ag, Au, Rhodium, Pt and Pd) are platted to somewhat smallest extent. Recently certain alloys (such as lead- tin, tin-copper, tin-zinc and tin-nickel) have been used increasingly in electroplating. Nickel plating on iron are applied mostly. Being catholic to iron, nickel coating must be of sufficient thickness ; otherwise corrosion at the coating pores and pinhole will occur, thereby making the surfaces rusty. Nickel coatings, apart from their good corrosion resistance. Shows relatively hard wear resistance surfaces which makes them useful in building up and surfacing worn and mismachined parts.

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MANUFACTURING PROCESS SEQUENCE The sequential stepwise program like method of preparing finished job before going out to the market is given here. In this following processes are involved. 1) Cutting 2) Bending 3) Drilling 4) Welding 5) Electroplating First of all we cut the 90 mm bar of mild steel for making the main frame of carrier using cutter also the limbs of the frame are made up to the dimension by cutting. Then hammering is done at the ends of the limbs. Then slight bend of procedure is done for 2nd limb also. Then for clamping of limb with the rod of bike the clamp is prepared by using bending and drilling and then a nut of drill size is used at the drill hole of clamp from inner side. Next process is for the preparation of the clamps used for rotating motion of the main frame. For this bush of 10 mm inner diameter is prepared by drilling on lathe the rod of 16 mm diameter. Also clamp is prepared which we already prepared for limbs. Then bush is welded to the clamps and then the final clamp is prepared. The clamp which is used for holding the carrier at the backside while it is in unused condition is prepared by drilling. Nextly the final weld is made. Here we used manual metal arc welding. (MMAW). After this job is prepared for surface finishing process. Electroplating is done after cleaning the whole job. Above is the sequence of the job preparation. Advanced Luggage Carrier

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DESIGN ANALYSIS Design of Rivet Thickness of plate = 4 mm Load or pull = 50 kg = 490.5 N Area A=π/4 d2 (since d – required diameter of rivet) Maximum permissible shear stress for rivet = 86 N/mm2 (From design data book) We have

P = Fs × A

4905 = 86 × π/4 d2 ∴d2 = 7.26 ∴d = 2.69 Taking the stand diameter d = 4 Failure For Lap joint considering failure due to shearing as shown in figure. –4 –

4 mm

P P Shear stress induced Fs1

= P/A 490

= π ×d 2 4

Fs1 = 39 N/mm2 Shear stress induced is less than maximum permissible shear stress i.e. Fs1 < Fs

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∴ Design of rivet is safe.

Design of Bolt : Major Diameter of bolt do = 16 mm Stress Area of bolt As = 20.1 mm2 (from data book) Permissible shear stress Fs = 20 N/mm2 (from data book) Load acting = 50 Kg = 490.5 N

Shear stress induced , Fs1 =

P 2 × As

Fs1 =

4905 2 × 20.1

(2 is due to double shear)

Fs1 = 12.20 N/mm2 Fs1 < Fs As shear stress induced in bolt is less than permissible value, the design is safe. As length of bolt is small there is no changes of bending failure.

Design of column support Advanced Luggage Carrier

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As length of strut is 60 mm which is less than 8 times the diameter 8 mm. The strut is treated as short column. Hence, there is no chances of backing or coupling. Failure will be due to crushing. Cross section of column

8 mm

160mm 8mm

b = h = 8 mm. Crushing stress for steel σc = 320 N/mm2 (From Design data book) Load on column W = 490.5 N ∴Cross section require is calculated as below. σc = W/A A = W/σc = W/σc A = 490.5/320 ∴

b2 = 1.532

A = 1.532 ∴

b = 1.23 mm

But the standard size available are 6 mm & 8 mm. ∴

For safety purpose, we select b = 8.

Failure due to crushing

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∴

Crushing stress induced, σc1 = W/A = 490.5/ 64 = 7.66 N/mm2 As σc1 << σc

Crushing stress induced is much less than maximum permissible hence design is safe.

Design of carrier frame For Analysis purpose the carrier frame. It is supported to be simply supported beam with uniformly distributed load as show in fig. W = wl B

B

M1

M2 l

W = 490.5

l = 260 mm

w = 1.88 N/mm

Max. permissible bending stress for msσ max. = 100 N/mm2 Reactions & A & B RA = RB = 245.25 N Moment of inertia I = πd4/ 64 Max. Bending Moment MMAX

= 1/24 W .l at x = l/2 = 1/24 490.5 × 260

MMAX = 5.313 × 105 mm2 Z = I/y × πd3/ 32 = z Y = d/2 The bending stress is given by

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σmax = M/I × y 5.313 × 10 3 d × 100 = 2 πd 4 64 d3 =

5.313 ×10 3 × 64 π × 2 ×100

d3 = 541.24 ∴d = 8.149 mm ∴ We take standard dimension d = 10 mm Failure Bending failure. We know that Bending moment is in the frame. σ1

= M/I × y 5.313 × 10 3 =

π(10) 64

4

×

10 2

σ1 = 54.11 N/mm2 as σmax > σi ∴ Design of frame is same. Failure of frame rod in bush. Shear area A = 2 × π/4 d2 = π/2 × 102 A = 157 mm2 (since 2 is due to double shear ) Advanced Luggage Carrier

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In bush the frame rod may get failed due to shearing at shown in fig.

Allowable shear stress for mild steel Fs = 50 N/mm2 Applied load is P = 490.5 N (50kg) Shear stress induced Fs1 = P/A Fs1 = 490.5 / 157 Fs1 = 3.12 N/mm2 Induced shear stress is much less than maximum permissible shear stress i.e. Fs1 << Fs The design is safe. Failure of rod in tensile loading considering bush as a short cylindrical shell. t P

d = 16

l = 22

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P = Pressure / load intensity. F F = P = A π(10) 2 4 =

490.5 78.5

P = 6.24 N/mm2 l = length of Bush t = 22 mm. t = thickness of Bush t = 3mm σ t = Hoop stress or circumferential stress. σ t = 42

MPa = 42 N/mm2

The hoop stress induced in bush. σti =

=

P×d 2t

6.24 × 10 2×3

σti = 10.4 N/mm2 σ ti < σ t

As induced tensile area is much i.e.

∴ The design is safe.

Failure of welding join of Bush & clamp t = throat thickness. s = leg length of weld = 3 mm (Standard from data book) l = length of weld σ t = permissible tensile stress = 55 N/mm2 (From data book)

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t = 5 × sin45 = 2.8 mm The failure will occur due to tensile loading & shear loading.

t = 2.12 C S=3

45

S = 3mm t = 2.12mm

16 A

B

Minimum Area of weld, A=t×l

A = 2.12 × 16

A = 33.92

Tensile stress induced in welded joints σ1=

P 490.5 = A 33.92

σ1 = 14.46 N/mm2 Induce tensile stress is less than the maximum tensile stress i.e. σ1 < σ

∴ design is safe.

Dynamic Design factor When the bike is loaded with luggage on carrier the weight is supposed to be increased by 1.5 times than the actual. ∴

Maximum dynamic load capacity of carrier will become 735.75 N (75 kg). For which all designing factors are safe.

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φ21, 2mm thick R15

2 in Nos.

φ10 φ16

22 Sq.bar 8mm

FV

φ6, 3Nos.

30

4 thick

SV 15

24 60

sq. bar 8

45

Bar φ10

280

306

TV

DRAWING ASSEMBLY

1. Bush (2)

3. Clamp

4. Nut

Bolt

φ16

2 φ16

φ6

φ10

2. Clamp (2) Clamp

21

5. Rivet φ 21

φ10

φ6 45 φ6

6.

45 ASSEMBLY ELEMENTS

TESTS The multipurpose carrier is expected to possess certain service - related capabilities. These carriers are generally required to carry loadings of various types in which the carrier subjected to stress of either a simple or complex character. It is therefore necessary to find out how satisfactory the carrier is. For this purpose certain tests had to be carried out to estimate the expected performance of the carriers.

Carrier Testing : Testing, specifically refers to the physical performance of operations to determine qualitative measure of certain properties. It aims to determine quality, i.e. to discover facts regardless of the implications of the results. The different tests which were carried out can be put under 2 leadings. 1) Different types of load 2) Different road conditions The different types of loads on the carrier for which the tests were carried out are - ( all weighted upto 120 kg. a) Unit load b) Sack load c) Gas cylinders

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The different road conditions were a) National highway b) Rural areas c) Hilly roads The tests were carried out with all possible combinations of the above mentioned heads. This was necessary because use want this useful advanced carrier to be useful to people living in any part. It should work satisfactorily in all conditions. After the successful design of the carries these tests added pleasure to us due to satisfactory performance under various conditions. The carrier performed superbly on highways. Its performance in rural roads and hilly roads was equally good. There were no dilutions during the ride, no deformations, no bends in carrier during or after the ride. I did not create any type of in balance during the course of its performer. Moreover it did not disturb any part of the vehicle neither its mileage - overall the results were just which are expected and wanted.

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PROPOSED DESIGNS The various designs are considered while selecting they are 1) Folding type which will otherwise used as a saree guard. 2) An insertion type which will be then brought down in the space between rare end & steel frame of rod.

In use condition

F.V F.V.

As a saree guard T.V.

Folding type

In use condition

T.V. Non use condition

But considering the factors of rigidity & simplicity we come to a final design that has been worked out. These designs are very new & complex to design. No. change is suggested regarding to all four designs in company model. A four bar chain design This is an most suitable design but the length height of carrier will disturb its flexibility & versatility.

In used condition

In unused condition

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COST ESTIMATION Material cost

100.00

Labour cost

150.00

Electroplating cost

100.00 350.00

This not includes the accessorial cost & travelling allowances & other expenditure. The cost given is marketing oriented.

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CONCLUSION Carrying load on the new era bikes is a common problem for any owner. To days bikes have accessories for the purpose but they affect the balance of the vehicles while carrying any type of loads. The objective of our project was to provide a rigid and safe platforms for carrying various loads without change in any standard design the bikes. Moreover it should be economical for every clay of society. Find it has been attained successfully. As from the complete report is fulfills the customer needs and provides versatility. Moreover as it is a new product it will promote employment and vast field for development for new engineers in to days period of industrial recession.

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REFERENCES 1. Machine design – R.S. Khurmi. 2. Production Technology – P.C.Sharma. 3. Mechanical Engineering – Jeorge Dietel 4. www.howstuffworks.com 5. Applied chemistry – Jain and Jain 6. Manufacturing data book – Madhavan.

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