Project Book.pdf

UNIFIED WHEEL NUT REMOVER MINI PROJECT REPORT Submitted In the partial fulfillment of the requirement for the award of the degree of

BACHELOR OF TECHNOLOGY In MECHANICAL ENGINEERING By Name 1

13241A0

Name 2

13241A0

Name 3

13241A0

DEPARTMENT OF MECHANICAL ENGINEERING GOKARAJU RANGARAJU INSTITUTE OF ENGINEERING & TECHNOLOGY BACHUPALLY, KUKATPALLY, HYDERABAD-500090 INDIA APRIL 2016

DEPARTMENT OF MECHANICAL ENGINEERING GOKARAJU RANGARAJU INSTITUTE OF ENGINEERING AND TECHNOLOGY (Affiliated to JNTUH,kukatpally,hyderabad)

HYDERABAD Bonafide Certificate This is to certify that the project report Unified wheel nut remover that is being submitted by Name 1 (13241A0), Name 2 (13241A0), Name 3 (13241A0) in partial fulfillment for the award of B.Tech in Department of Mechanical Engineering from Gokaraju Rangaraju Institute of Engineering and Technology, affiliated to JNTU, Hyderabad is a record of bonafide work carried out by him/her under the guidance and supervision .

The results embodied in this thesis have not been submitted to any other University or Institute for the award of any degree or diploma.

Dr. RAM SUBBAIAH

Dr. RAM SUBBAIAH

Project Guide

Project co-ordinator

Associate Professor

Associate Professor

Dr.L.JAYAHARI Professor Head of the Department

Mechanical Engineering

Mechanical Engineering

Mechanical Engineering

GRIET, Hyderabad

GRIET, Hyderabad

GRIET, Hyderabad

2

DECLARATION

This to certify that the Mini project titled Unified wheel nut remover is a Bonafied work done by us in partial fulfillment of the requirements for the award of the B.Tech in Mechanical Engineering and submitted to the Department of Mechanical Engineering .Gokaraju Rangaraju Institute of Engineering and Technology.

We also declared that this project is a result of our own effort and has not been copied or imitated from any source . citations from any websites are mention in the references.

Name 1 (Reg.No) Name 2 (Reg.No) Name 3 (Reg.No)

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ACKNOWLEDGEMENT

Successful completion of any task would be incomplete without the expression or appreciation of simple gratitude to all people who made this project possible with sincere thanks, honor and veneration, we acknowledge all those whose guidance and encouragement have helped us complete this project.

We express our sincere thanks to our college Director Prof. P. S Raju, Principal Dr. Jandhyala .N. Murthy for their encouragement and support.

We thank Dr.L.JayaHari, Head of Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology for permitting to undertake the project work.

We have immense pleasure in expressing our thanks and deep sense of gratitude to our guide/ Project Co-ordinator Dr. Ram Subbaiah, Associate Professor in Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad. Under whose guidance and encouragement this project has been successfully completed.

We are also thankful to all the staff members of Mechanical Engineering Department of GRIET for their invaluable support.

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ABSTRACT Vehicle is an important machine in human daily life. Nowadays, each family has at least one car to make the transportation easy and faster. Today the life of man is simple and comfortable as various resources are available for each and process that a person has to perform in his day to day life, and these resources and equipments helps the person to perform his work in efficient and less time consuming manner. Four wheelers are available for more than 70% peoples in urban areas. For a car, the tool set-up for each vehicle is a Tnut wrench and car jacker which is hard to use for a women or teen to open their car’s nut. There are many equipments are designed so that any operation required to be done on a car can be done easily and in a shorter period of time as possible. There is a problem that can be considered as time consuming and requires more effort which is the opening of wheel of a car for its replacement or any other operation. Today the unit of a wheel are opened by one of which requires more efforts and consume a lot of time. For this problem the unified wheel opener is a adaptable solution. In conventional method, certain torque has to be applied to remove a single nut. Unified wheel opener is a special purpose tool made to open/close all the nuts of a wheel in one time less effort. Although various methods of opening nuts are used, but they require a lot of effort to open a single nut one by one. With the help of Unified Wheel opener we made arrangement to open/close all the nuts by amplifying the torque. The main objective of work is to develop a mechanism in one assembly, which can be made in automobiles. The main objective of work is to develop a single tool with multiple mechanisms, which can be made use during assembling and dismantling of wheels in automobiles. It can be successfully used as a standard tool irrespective of the model of the vehicle. Also it can be used in assembly line of automobiles, garages, workshops and service stations. We have developed a gear planetary mechanism to reduce the time and effort for the above mentioned task. Mild steel is used as the main material as tool to fabricate a gearing system. For this project, this tire nut removal has been improved about the weight, cost of production and the gear ratio. Design is simple, easily workable, and economical and tries to satisfy all the aspects of design consideration 5

TABLE OF CONTENT

Chapter

Description

Page No

No Abstract

05

List of contents

06

List of tables

08

List of figures

09

Introduction

1

2

3

10

1.1 Over view of project

10

1.2 Basic Gear Theory

11

1.3 Spur Gear Terminology

12

1.4 Application of unified wheel opener

14

Literature Review

15

2.1 Literature Survey

15

2.2 Tools Used Earlier To Remove Nuts and Bolts

18

2.3 Problem Statement

20

System model

21

3.1 Selection of materials

21

3.2 Engineering Material for Product Design

21

3.3 Selection Criteria

22

3.4 Cost of the Material

22

3.5 Availability

22

3.6 Properties of the Material

22

3.7 Components used in the project

23

3.7.1 Shaft

23

3.7.2 Gears

24

3.7.3 BoxTtools

25

3.7.4 Screw and Nuts

25

3.7.5 Square pipes

26

6

4

5

6 7 8

Design Procedures

27

4.1 Design Aspects

27

4.2 Design Abbrevations

28

4.3 Design Procedure for Gear and Pinion

28

Implementation of the project

31

5.1 Practical Implementation

31

5.2 Comparitive Cost Estimation

31

5.3 Bill of material

31

Conclusion

32

Future Enhancements References

7

33 34

LIST OF TABLES

Table No

Description

Page No

2.1

Tools Used Earlier To Remove Nuts and Bolts

18

4.1

Abbrevations used for Design Calculation

28

5.1

Bill of Material

31

8

LIST OF FIGURES Fig No

Description

Page No

1.1

Spur Gear Terminology

14

3.1

Shaft

24

3.2

Spur Gear

24

3.3

Box Tool

25

3.4

Screw and Nut

25

3.5

Square pipes

26

4.1

3D Model of the Project

27

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CHAPTER 1 INTRODUCTION

1.1 OVERVIEW OF THE PROJECT Engineering in general, and Mechanical engineering in particular, deals with a wide spectrum of products, ranging from large and complex systems comprising of numerous elements down to a single component. Apart from being a physical object, a product can also be a service that requires the application of engineering knowledge, skills and devices to be useful to society. A service falls under the category of a system in that it is carried out with the help of personnel, facilities and procedures. The service offered by an automobile maintenance and repair garage would be a typical example from mechanical engineering. Even computer software could be treated as an engineering product. It is also created using engineering knowledge and skills. In the following, the term product when used alone denotes the object to be designed and made with the help of engineering knowledge and skills, irrespective of whether it is a large system, a simple machine, a component or a service. Specific reference to design of computer software is not attempted in the following although many of the generalities apply to it also. Today’s world is of the fast and rapid process. Everybody wants to save time and effort by inventing some newer technique or mechanism and implement them in the daily life. The main objective of this project is to atomize the labor work in tightening or losing the nuts one by one. This project focuses on the minimization of human effort and time consumed for fixing all four nuts of the four wheeler tire with a single stroke of lever by using multiple operated spanner. This is achieved by developing a planetary gear mechanism as such ours which reduced the time and effort for the above mentioned task that is losing or tighten the nut of the car wheel. If we consider a four wheeler removing and replacing the car wheel is a very frequent job performed by the worker. Normally each of the four nuts is removed/ tightened individually by simultaneously applying the spanner/lever.

Car is not a symbol of luxurious anymore. It is a need for every family. People need car due to several reasons. The problem occurs the most during car operation is the problem with tyre puncture. The main tyre has to be replaced with spare tyre. Therefore, drivers need to know basic knowledge of tyre replacement procedure if such problem occurs. In order to 10

change the flat tyre, one requires minimal skills. Virtually every car has a tyre replacement tools such as the L-shaped nut remover and jack supplied by the manufacturer.

It is difficult for women and the elderly drivers due to high required torque to remove the wheel nuts. In addition, if the nuts are successfully removed, the problem to retighten the nuts will follow. Here is the solution to the problem mentioned above by Adjustable Unified Wheel Opener, it is a special tool designed for opening a wheel with ease. It is so designed that it can open all the four nuts of a car wheel in one time. And the most desired achievement is that, the total effort and time needed in the process is very less. It can open and also refit the wheel with the same tool easily. Tool is simple in design, easy to use and easily portable along with the vehicle. The tool used to remove the wheel nuts should be designed for ergonomic, easy to handle and requires small space for storage. With the help of the mechanism developed we can loosen or tight all four nut at a time and at the single stroke of the motor operated lever.

1.2 BASIC GEAR THEORY Here are some basic gear theories to help in this project. From the last tire nut removal, they have used some gears as the system. We have list out the basic theory for gear in this section and the information will be used as the guideline to this project.

Author

Year

About Gear applies torque from other rotating members of the drive train and used to multiply torque. As gears with different numbers

Shigley, Mischke

2003

of teeth mesh, each rotates at different speed and torque. Torque is calculated by multiplying force with the distance from the center of the shaft to the point the force was exerted.

1.Spur gear has teeth parallel to the axis of rotation and used to Shigley, Mischke

2003

transmitted motion from one shaft to another.

2. Helical gear has teeth inclined to the axis of rotation. Same

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applications as spur gear with more gradual engagement of teeth during meshing cause no noise as spur gear. Sometimes helical gears are used to transmit the motion between nonparallel shafts.

3. Bevel gear have teeth formed on conical surface and are used mostly for transmitting motion between intersecting shafts.

4. Worm gear resembles a screw and the direction of the rotation called worm wheel depends upon the direction of rotation and whether the worm cut is right-hand and left-hand.

Gear ratios express the mathematical relationship between gears. Gear ratio is varied by diameter and number of teeth of the gears. Torque multiplication also expressed by gear ratio. Gear ratio is ratio between diameter or number of teeth of driven gears by the Waldron, Kinzel

2004

diameter or number of teeth of drive gears. This gear ratio tells how many times the driving gear must turn to rotate the driven gear once. Gear ratio for planetary gear use different formulas. Gear ratio = (driven gear + driven gear) / driven gear

1.3 SPUR GEAR TERMINOLOGY

1) Pitch surface: The surface of the imaginary rolling cylinder (cone, etc.) that the toothed gear

may be considered to replace.

2) Pitch circle: A right section of the pitch surface. 3) Addendum circle: A circle bounding the ends of the teeth, in a right section of the gear. 4) Root (or dedendum) circle: The circle bounding the spaces between the teeth, in a right section of the gear. 5) Addendum: The radial distance between the pitch circle and the addendum circle. 6) Dedendum: The radial distance between the pitch circle and the root circle. 7) Clearance: The difference between the dedendum of one gear and the addendum of the mating gear. 8) Face of a tooth: That part of the tooth surface lying outside the pitch surface. 12

9) Flank of a tooth: The part of the tooth surface lying inside the pitch surface. 10) Circular thickness (also called the tooth thickness): The thickness of the tooth measured on the pitch circle. It is the length of an arc and not the length of a straight line. 11) Tooth space: The distance between adjacent teeth measured on the pitch circle. 12) Backlash: The difference between the circle thickness of one gear and the tooth space of the mating gear. 13) Backlash =Space width – Tooth thickness 14) Circular pitch p: The width of a tooth and a space, measured on the pitch circle. 15) Diametral pitch P: The number of teeth of a gear per inch of its pitch diameter. A toothed gear must have an integral number of teeth. The circular pitch, therefore, equals the pitch circumference divided by the number of teeth. The diametral pitch is, by definition, the number of teeth divided by the pitch diameter. 16) Module m: Pitch diameter divided by number of teeth. The pitch diameter is usually specified in inches or millimeters; in the former case the module is the inverse of diametral pitch. 17) Fillet : The small radius that connects the profile of a tooth to the root circle. 18) Pinion: The smaller of any pair of mating gears. The larger of the pair is called simply the gear. 19) Velocity ratio: The ratio of the number of revolutions of the driving (or input) gear to the number of revolutions of the driven (or output) gear, in a unit of time. 20) Pitch point: The point of tangency of the pitch circles of a pair of mating gears. 21) Common tangent: The line tangent to the pitch circle at the pitch point. 22) Base circle: An imaginary circle used in involute gearing to generate the involutes that form the tooth profiles.

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Fig 1.1 – Spur Gear Terminology

1.4 APPLICATION OF UNIFIED WHEEL OPENER Application domain of unified Wheel Opener is in automobile industries. According to our preplanned project we describe the following places where it can be used successfully: •

It can be used as standard equipment provided with a new vehicle for the purpose of opening and refit a punctured wheel in the midway.

•

It can be used in workshops to open a wheel in place of using pneumatic guns which are restricted to the availability of light and compressed air; it can be easily operated with hands.

•

It can be used in assembly line of automobiles where more time is

consumed in

tightening all the four nuts one by one. As it takes less time to fit a new tyre, it will lead to increase productivity.

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CHAPTER 2 LITERATURE REVIEW 2.1 LITERATURE SURVEYS Known torque-responsive power screw drivers which are driven by electric motors or pneumatically have a relatively high speed of rotation in order to obtain a short screwing in time. Since the maximum moment of tension for the screw to be screwed requires a determined torque, the driving power of the screw driver must likewise be made high in accordance with the relatively high speed of rotation, although a high torque is required for only a short time during the tightening of the screw, unless some shock action is utilized for the purpose of producing this peak degree. The limitation of the degree of tightening of the screw is usually effected by means of ratchet couplings or striking mechanism.

When screwing in expansion screws, this degree of tightening must be kept constant within very narrow, since these screws, are stressed almost to their yield point during screwing in. Torque-responsive screwing drivers having a shock effects are useless for this purpose. The degree of tightening achieved is greatly dependent on the number of blows applied, which however cannot be kept constant because of the rapid succession of blows, while in addition the power of the individual blow is variable within wide limits because of the indeterminable reaction of work piece, screw and screwing tool on the striking operation.

Torque-responsive screwdrivers having striking mechanisms are impractical where accurate tensioning of a screw is necessary. It has moreover been found that, at the high speeds used, ratchet couplings also apply a powerful shock action and are therefore likewise unsuitable for tightening expansion screws. A lot of research activities has been carried out on gears mechanisms since very first gear was manufactured. A gear transmits the power from one shaft to another in various relative position. Many engineers and designers put there efforts in this field and succeeded also. They put all of their knowledge and the studies about gears on papers, with the use of these papers anyone can know about advancement of the research carried out by them. With these research papers, we come to know various aspects about gear. These papers explore how a mechanism can be driven at uniform speed and non–uniform speed. 15

Also these papers tells about selection of material for a gear depending upon requirement. There are a number of different gears which have different application areas. The research papers helps in choosing the appropriate type of gear. Wen-Hsiang Hsie in his paper “An experimental study on cam- controlled planetary gear trains” describes that a mechanism is driven by a motor at uniform speed. However, more and more researches indicate that there are many advantages if a mechanism can be driven at non- uniform speed, and this kind of mechanism is called a variable input mechanism. The purpose of this work is to propose a novel approach for driving a variable speed mechanism by using a cam-controlled planetary gear train, and to investigate its feasibility by conducting prototype experiments. First, the geometrical design is performed. Then, the kinematic equations and the cam profile equations are derived based on the geometry of the mechanism. Ligang Yao Jian S. Dai Guowu Wei and Yingjie Cai “Comparative analysis of meshing characteristics with respect to different meshing rollers of the toroidal drive”. In their paper it has been stated that investigates meshing characteristics of the toroidal drive with different roller shapes, examines the effect on the characteristics from roller shapes and produces a comprehensive comparative study”. Based on the coordinate transformation, the paper introduces the generic models of meshing characteristics and characterizes the meshing to introduce both undercutting and meshing limit curves. The paper further develops meshing functions and their derivatives with respect to each drive type with a different roller shape. This leads to a comprehensive examination of each meshing characteristics against each drive type of a roller shape. The comparative study focuses on the effect of contact curves, tooth profile, undercutting, meshing limit curves and the induced normal curvature.

The toroidal drive offers the advantages such as a high horsepower-to- weight ratio, coaxial configurations, compactness, and high operating efficiencies. It combines most of the positive attributes of a circular worm- gear drive and an epicyclic gear drive without their negative aspects due to the introduction of rollers in meshing contact with rolling movement between a sun-worm and planet worm-gears, and between a stationary internal gear and planet worm-gears.

16

Using rollers as meshing media is popular in mechanical transmissions such as ball screws, roller gear cams, roller enveloping worm drives, cycloid drives, and the toroidal drives. Meshing via rollers which leads to rolling contact has the advantages of lower noise and higher transmission efficiency. It has a substantial effect on meshing characteristics.

Gordon R. Pennock and Jeremiah J. Alwerdt in their paper “Duality between the kinematics of gear trains and the statics of beam systems” describes about the geometric insight into the duality between the first-order kinematics of gear trains and the statics of beam systems. The two devices have inherent geometrical relationships that will allow the angular velocities of the gears in a gear train to be investigated from a knowledge of the forces acting on the beams of the dual beam system, and vice versa. The primary contribution of the paper is the application of this duality to obtain the dual beam system for a given compound planetary gear train, and vice versa. The paper develops a systematic procedure to transform between the first-order kinematics of a gear train and the statics of the dual beam system. This procedure provides a simple and intuitive approach to study the speed ratios of a planetary gear train and the force ratios of the dual beam system. It is interesting to note that planetary gear trains (commonly referred to as epicyclic gear trains) were known, and in use, at least 2000 years ago. Despite the antiquity and widespread applications in machinery, however, the principles of operation of planetary gear trains are not generally understood. Also, the literature devoted to planetary gear trains is scarce at best although a comprehensive treatise on the theory of epicyclic gears and epicyclic change-speed gears was written by Levai. Planetary gear trains offer advantages over ordinary gear trains, for example, for the same speed ratio they can be smaller in size and have less weight. There are several techniques that are commonly applied to the kinematic analysis of planetary gear trains; for example, the instant center method, the principle of superposition using a tabular method, and identifying the fundamental circuits of the train. Also, an analogy between planetary gear trains and beam systems using one-dimensional vectors was presented by Kerr. The available methods, however, do not provide geometrical insight into the gear train in a direct manner that is suitable for a specific application.

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2.2 TOOLS USED EARLIER TO REMOVE NUTS AND BOLTS

Table 2.1 - Tools Used Earlier To Remove Nuts And Bolts S.No

Name of the Tool

Description A one-piece wrench with a U-shaped opening that grips two opposite faces of the bolt or nut. This wrench is often double-ended, with a different-sized opening at each end.

1

open-ended spanner

The ends are generally oriented at an angle of around 15 degrees to the longitudinal axis of the handle. This allows a greater range of movement in enclosed spaces by flipping the wrench over. A one-piece wrench with an enclosed opening that grips the faces of the bolt or nut. The recess is generally a sixpoint or twelve-point opening for use with nuts or bolt heads with a hexagonal shape. The twelve-point fits onto

2

ring spanner

the fastening at twice as many angles, an advantage where swing is limited. Eight-point wrenches are also made for square-shaped nuts and bolt heads. Ring spanners are often double-ended and usually with offset handles to improve access to the nut or bolt. A double-ended tool with one end being like an open-end wrench or open-ended spanner, and the other end being

3

combination wrench like a box-end wrench or ring spanner. Both ends generally fit the same size of bolt. A wrench that is used for gripping the nuts on the ends of

4

flare-nut wrench

tubes. It is similar to a box-end wrench but, instead of encircling the nut completely, it has a narrow opening

18

just wide enough to allow the wrench to fit over the tube, and thick jaws to increase the contact area with the nut. This allows for maximum contact on plumbing nuts, which are typically softer metals and therefore more prone to damage from open-ended wrenches. A type of ring spanner, or box wrench, whose end section ratchets. Ratcheting can be reversed by flipping over the wrench, or by activating a reversing lever on the wrench. This type of wrench combines compact design of a box wrench, with the utility and quickness of use of a ratchet 5

ratcheting box wrench wrench. A variety of ratcheting mechanisms are used, from simple pawls to more complex captured rollers, with the latter being more compact, smoother, but also more expensive to manufacture. The one pictured also features a drift pin on the tail. A wrench used to turn screw or bolt heads designed with a hexagonal socket (recess) to receive the wrench. The

7

Allen key wrenches come in two common forms: L-shaped and Thandles

2.3 PROBLEM STATEMENT

From the introduction, the tire nut removal has been studied about the problems. This tire nut removal is designed for facilitate the four nut car user. There are two major problems that can avoid the tire nut removal from marketing. The problems are the tire nut removal is too heavy where it’s hard for a women user to use the tool. Then the materials for this tire nut removal are quite expensive and are not suitable for marketing.

Taking the idea from all research paper which are included in the literature review. We came to a point that by using gear-train mechanism we can make a system which is used 19

to open the nut of a wheel with minimum torque so, as to eliminate the hard-work of person with minimum time. In all research paper idea is given that how gear train works, and how the power transmission take place.

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CHAPTER 3 SYSTEM MODEL 3.1 SELECTION OF MATERIALS The selection of a material for a particular application is governed by the working condition to which it will be subjected, ease of Manufacturing and the cost considerations, pure metals find few applications in pure condition and secondly they generally have poor strength in pure form. Various desired and special properties can be achieved by addition of different material to form alloys. Alloy comprises of a base metal and one or more alloying elements. The typical properties associated with working condition are tenacity elasticity toughness and hardness, toughness and typical properties associated with manufacturing process is ductility, malleability and plasticity. The various properties can be determined by testing techniques e.g. tensile test resistance to abrasion by hardness test toughness by impact test and other special properties like fatigue and creep test.

3.2 ENGINEERING MATERIAL FOR PRODUCT DESIGN All physical objects are made out of some material substance or other. Mother Nature has her own set of building material for the objects of her creation, living or non-living. Over the millennia, man has observed and adapted many of these for making objects of his invention and design. For engineering purposes, we now use a very wide spectrum of materials. These generally fall under the following categories:•

Materials as found in nature used after only very minor preparation

such as cutting

to size, sun-drying, mixing with water. Some examples are coal, wood and stones. •

Natural materials that are modified/ refined before use through some

physical,

chemical or thermal processes that improve their utilization. • •

Synthesized materials that are rarely found freely in nature. These are derived from one or more natural raw materials through major transformation processes. Most of the materials used in modern mechanical engineering belong to this category.

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3.3 SELECTION CRITERIA The designer selects the materials of construction for his product based on several criteria such as its cost, the desirable properties that it should possess, its availability, the preferred manufacturing processes that are to be employed, etc. The overall economy is influenced by all these factors. In special cases, essentiality and /or urgency of the need for the product can supersede the economic considerations. The main criteria for material selection are discussed below.

3.4 COST OF THE MATERIAL The amount of raw materials, their composition, quality, any special heat- treatment that is required, etc. influence the unit cost of materials. The unit cost generally depends also on the quantity of raw material that is purchased in a single lot. Special steel materials, for example, cost much more in the market when purchased in small quantities from a retailer than in bulk directly from the steel mill/stockyard. 3.5 AVAILABILITY The material should be readily available in adequate quantities. Material availability is closely linked with the variety and level of technology obtained in a given geographic location. Procuring materials from far and wide can be expensive, due to the additional cost for transport, for transporter taxes and duties etc. 3.6 PROPERTIES OF THE MATERIAL The desired function and performance of any product depends to a great extent on the use of materials with the right physical and chemical properties. In general mechanical engineering these properties can be classified into different categories depending on how a particular property affects the function and life of a component. The main property groups are:•

Chemical Composition, specifying the contents of all the different elements contained.

•

Properties of state, such as solid, liquid or gas, density, porosity, temperature. 22

•

Strength related properties, such as ultimate strengths in tension,

compression and

shear, yield strength/ 0.2% strength, fatigue strength, notch sensitive, hardness, impact strength, effect of high/low temperatures on strength, etc. •

Strain related properties, such as elongation at fracture, elastic

moduli, ductility,

malleability etc. these help to ensure the desired rigidity/ elasticity, formability etc. •

Wear related properties, that determine the erosion, abrasion, friction etc. between components in contact/ relative motion.

3.7 COMPONENTS USED IN THE PROJECT 3.7.1 SHAFT Drive shaft, a shaft for transferring torque is used to transfer to the nut from the primary gears (sun gear)which is in mesh with the secondary gears (planetary gear) which remove the nuts using the removing tools. A shaft is a rotating or stationary component which is normally circular in section. A shaft is normally designed to transfer torque from a driving device to a driven device. If the shaft is rotating, it is generally transferring power and if the shaft is operating without rotary motion it is simply transmitting torque and is probably resisting the transfer of torque. Mechanical components directly mounted on shafts include gears, couplings, pulleys, cams, sprockets, links and flywheels. A shaft is normally supported on bearings. The torque is normally transmitted to the mounted components using pins, splines, keys, clamping bushes, press fits, bonded joints and sometimes welded connections are used. These components can transfer torque to from the shaft and they also affect the strength of the shaft an must therefore be considered in the design of the shaft. Shafts are subject to combined loading including torque (shear loading), bending (tensile & compressive loading), direct shear loading, tensile loading and compressive loading. The design of a shaft must include consideration of the combined effect of all these forms of loading. The design of shafts must include an assessment of increased torque when starting up, inertial loads, fatigue loading and unstable loading when the shaft is rotating at critical speeds (whirling)

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Fig 3.1 – Shaft 3.7.2 GEARS A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part in order to transmit torque, in most cases with teeth on the one gear being of identical shape, and often also with that shape on the other gear. Two or more gears working in tandem are called a transmission and can produce a mechanical advantage through a gear ratio and thus may be considered a simple machine. Geared devices can change the speed, torque, and direction of a power source. The most common situation is for a gear to mesh with another gear; however, a gear can also mesh with a non-rotating toothed part, called a rack, thereby producing translation instead of rotation. In our project, we have used sun gear as primary gear and planetary gear as secondary gears. The gears are manually driven with the help of a lever.

Fig 3.2 – Spur Gear

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3.7.3 BOX TOOLS

Fig 3.3 – BOX TOOL A tube with six-sided sockets on both ends. It is turned with a short length of rod (tommy bar or T bar) inserted through two holes in the middle of the tube. It is Upset forged from high grade manganese steel. Scientifically heat treated to give maximum strength, wear resistance and long life. It is Available with bright finish in Nickle Chrome and black phosphate finish for protection from corrosion.

3.7.4 SCREWS AND NUTS

Fig 3.4 – SCREW AND NUT

A screw is a type of fastener, sometimes similar to a bolt, typically made of metal, and characterized by a helical ridge, known as a male thread (external thread) or just thread. The most common uses of screws are to hold objects together and to position objects. A screw will usually have a head on one end that contains a specially formed shape that allows it to be turned, or driven, with a tool. Common tools for driving screws include screwdrivers and wrenches. The head is usually larger than the body of the screw, which keeps the screw from being driven deeper than the length of the screw and to provide a bearing surface. The distance between each thread is called the "pitch".

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A nut is a type of fastener with a threaded hole. Nuts are almost always used opposite a mating bolt to fasten a stack of parts together. The two partners are kept together by a combination of their threads' friction, a slight stretch of the bolt, and compression of the parts. In applications where vibration or rotation may work a nut loose, various locking mechanisms may be employed: Adhesives, safety pins or lock wire, nylon inserts, or slightly oval-shaped threads. The most common shape is hexagonal, for similar reasons as the bolt head - 6 sides give a good granularity of angles for a tool to approach from tight spots. 3.7.5 SQUARE PIPES:

Fig 3.5 – SQUARE PIPES

They are produced by cold forming flat rolled steel into tubular shapes and electricresistance welded into solid wall tubing. Controls during the cold forming to square or rectangular shapes prevent irregularities in structure or loss of physical properties across the weld area. Since it begins as a flat rolled product, the finished tube has a uniform wall thickness and equal strength throughout. It is easy to machine and fabricate, using all common machining and fabricating operations. It can be bent or drawn, flattened or flared, expanded or swaged, drilled or punched easily. It is easily mechanically joined or welded using all the commonly used practices. Because of ease of fabrication, and a surface suitable for painting or plating, Structural Steel Square and Rectangular tube has almost unlimited applications.

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CHAPTER 4 DESIGN PROCEDURES 4.1 DESIGN ASPECTS Spanners are used to open the wheel. Spanners in the use are of various types. The different kinds of spanners in use are shown infigure One thing is very common for all these spanners: only a single nut is opened in a single time. This causes wastage of precious time and since to open all the nuts spanner is to engaged and disengaged again and again till the last nut is unscrewed or screwed. Thus in this work a large amount of power is required to perform the requisite operation. These disadvantages are removed in unified wheel opener. The idea is to reduce time when release the wheel or put it on. By using this device, wheel nuts can be opened simultaneously at one time. The supposed design of the unified wheel opener is shown below. On pictures, we can handle, casing/gears housing, and wheel nut connectors. Wheel nut connectors are connected to wheel nut, and the number of connector depends on the number of studs. So it will be different according to wheel type and size. Inside the Casing, there are simple gears mechanisms, causing one rotation of The Handle to make two rotations of the wheel nuts.

Fig 4.1 3D MODEL OF PROJECT

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4,2 DESIGN ABBREVATIONS Table 4.1 – Abbreviations Used For Design Calculations S. No Symbol Abbreviation/Nomenclature 1

m

Module

2

M

bending moment

3

Dp

Pitch circle diameter of pinion

4

Dg

Pitch circle diameter of gear

5

Dg

Diameter of gear shaft

6

Wt

Tangential load

7

Wr

Resultant load

8

Yp

Lewis form factor

9

σ

Allowable stress

10

T

Twisting moment

11

Te

Equivalent twisting moment

12

Tp

Number of teeth on pinion

13

Tg

Number of teeth on gear

4.3 DESIGN PROCEDURE FOR GEAR & PINION: Torque required for one nut = 70N-m Total torque required

= 4×70N-m = 280N-m

Let input torque

=30N-m

Maximum Tangential force on pinion (WT) =2×Ti/Dp =2×30×1000/25 =2400 N For 200 stub teeth system,

Lewis Factor for pinion, Yp = 0.175-(0.841×m/25) = 0.175-(0.03×m)

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Also, maximum tangential force on pinion (Wt) = σ×b×n×m×Yp For Cast Steel σ = 325MPa (Assume: b= 5×m) WT = 2400 = 325 × (5 × m) ×π × m (0.175 - 0.03 × m) Solving By Hit & Trial Method, We Get Module, (m) =2mm

Now, as we know Number of teeth on pinion (Tp)= Dp/m Also, Number of teeth on gear (Tg) =Dg/m Therefore, Tp = 25/2 =12.5 or 13 (say) Tg = 114/2 = 57

Other dimensions for pinion &gear are as: Addendum =0.943×m=1.886 Dedendum =1.257×m=2.514 Minimum total depth = 2.200×m = 4.400 Minimum clearance = 0.314×m = 0.628 Backlash = 0.157×m = 0.314 Thickness of tooth = 1.493×m =2.986 Outside diameter of pinion = (Tp+2 )×m =30 Outside diameter of gear = (Tg+2) ×m = 118 And twisting moment on shaft due to WT is T T = WT×Dp/2 =30000N-mm Equivalent twisting moment is Te = (M2+T2)0.5 = 156225N-mm Let Dp be the diameter of pinion shaft Dp =π×ζ×dp3 =14.7or 15mm (say)

Design For Output Shaft Max. Tangential force on output gear, WT’ = (WT×Dg/Dp) = 10945N

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Normal load acting on tooth, Wn = WT’/CosØ =10945/Cos200 =11645N

Weight of gear, WP =0.00118×Tg×b×m2 =0.00118×57×10×22 =2.7N

Therefore resultant load on gear, Wr = (Wn2+Wp2+2×Wn×Wp×Cos Ø)0.5 = 11648N

Assuming gear is overhung on shaft at 5mm Therefore bending moment on shaft due to WR is M M = WR×5 = 11648×5 = 58238N-mm

And twisting moment on shaft due to WT is T T = WT×DG/2 = 10945×114/2 = 623865N-mm And equivalent twisting moment is Te, Te = (M2+T2)1/2 = 626577N-mm Let dg = Diameter of gear shaft, Let Te= (π/16)×ζ×Dg3

626577 = (π/16)×230×dG3 So, dG = 23.7 mm or 24 mm(say) All the component are designed to serve their functions properly and taking into account the various consideration such as material, labour, availability of technology, economic, safety, usage, reliability, maintainability, functionality etc. These components will be manufactured according to their design specifications.

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CHAPTER 5 IMPLEMENTATION OF THE PROJECT 5.1 PRACTICAL IMPLEMENTATION After checking the feasibility conditions, (i.e. economic feasibility, operational feasibility and technical feasibility) adjustable unified wheel opener is designed and it is implemented in real world problems. It worked successfully and finally the output is obtained as such as what is desired. 5.2 COMPARATIVE COST ESTIMATION Now-a-days for loosening and tightening nuts in the car, a commonly used tool is four way car wheel nut wrench brace spanner which costs about Rs.800 – Rs 1000, where it need more effort in doing the works as well as it increases the time. But with our project, all four nuts in a car wheel can be simultaneously removed. The total cost involved for the fabrication of our project is almost equal to the tool commonly used. Costs have been estimated based on the cost of the materials that are being purchased, machining costs and other parameters that are involved in the fabrication of the project. Approximate cost estimation has been done and it has been listed as a

5.3 BILL OF MATERIAL

Table 5.1 - BILL OF MATERIAL S.No

DESCRIPTION

No’s

COST (in Rs)

1

Main Planetary Spur Gear

4

Rs 400

2

Sun (spur) Gear

1

Rs 100

3

Shafts

4

Rs 20

4

Square Pipes (30 cm appx)

8

Rs 100

5

Box Tools

4

Rs 250

6

Bolts, Screws & Nuts

4

Rs 50

7

Welding charges

---

Rs 100

Total

Rs 1020

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CHAPTER 6

CONCLUSION In this mechanism, a sun and planet gear system are used. Sun gear is smallest gear and planetary gears are placed exactly in the position of the lug nuts in the pitch circle diameter according to the number of lug nuts. Pitch circle diameter is the diameter of the circle in which lug nuts are positioned. This invention reduces the time consumed in removing the lug nuts. In conventional method, certain torque has to be applied to remove a single lug nut. In this invention, the torque applied for removing/tightening of one lug nut is adequate for removing/tightening of all the lug nuts in the wheel. So the process of replacement of the wheels can be done so faster and it reduces the time. This device can be operated manually and no external power is consumed. It doesn't cost more as compared to hydraulic and pneumatic devices. Thus the fabrication of Adjustable Unified Wheel Opener is successfully done. This project is practically implemented in a four wheeler and it is found that the results are positive. The project is working as what it is expected. Thus the project is economical, and it sustains all the required feasibilities. It has been found that adjustable wheel opener is a perfect tool for assembling and dismantling a wheel in a four wheeler.

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CHAPTER 7

FUTURE ENHANCEMENTS

The project has been fabricated which is purely mechanical. All the operations are done manually. To further extend our project as a useful tool, a motor has to be attached to its drive. Such that by providing a motor, it reduces all the human effort in tightening and loosening the wheel’s nut.

1) Improvement in the system by making automatic operation with the help of pneumatic system which is clean and hazardous free. 2) To design and fabricate the complete assembly of the multiple operated spanner to be fitted to all vehicle wheels by adjusting pitch circle diameter by making pinion gear small or large as per wheel’s pitch circle diameter. 3) It is also suggested to operate it with different gear arrangements with less power required.

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CHAPTER 8 REFERENCES 1) Abd Aziz “Improvement and Optimization of Tire Nut Removal with 100 PCD”.University Malaysia Pahang, Thesis Degree, 2008. 2) M. F. AbdRahim “Design, Development and Fabrication of Tyre Lug Wrench”. University Technical Malaysia Melaka (UTeM), Thesis Degree, 2007. 3) R.

Abdul

Rahman,

C.

A.

Che

Ismail

and

M.

Y.

Abdullah

“MechanicalMachines”.University Technology Malaysia Publisher, 2003. 4) V. Sarkar “Mechanics of Machines”. Tata McGraw-Hill, 2004. 5) E. Oberg, F. D. Jones, H. L. Horton and H. H. Ruffle (2008) “Machinery’s Handbook 28thEdition”.Industrial Press, 2008. 6) Abdullah, M.A, Shaharuzaman, M.A, Jenal, R., Boejang, H.,MatIdera, I.H. and MohdRazi, M.Z., Development of Conceptual Vehicle All-Wheel-Nuts Remover, Proceeding for the 2ndInternational Conference on Design and Concurrent Engineering(iDECON2012), Malacca, Malaysia, (October 15thto 16th, 2012), 199202 (2012). 7) B.D.Shivalkar ,Design data Book,S.Chand Publication. 8) R.S.Khurmi,J.KGupta,Machin,Design,S.Chand Publication. 9) Different tools, Source: http://www.williamtool.com. 10) Dr. P.C. Sharma- A text book of production technology-1996 11) Fasteners, Source: http://www.laytonfasteners.com. 12) Gordon R. Pennock and Jeremiah J. Alwerdt, “Duality between the kinematics of gear trains and the statics of beam systems”, Science direct journal, Volume 42, page 1527-1546

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13) Hiroyuki Kato, Ken Iwanami, Hiroshi Arai, Koji Asanotells, “Running safety and comfort”, International journal, Volume 28, page 541-578 14) Ligang Yao Jian S. Dai Guowu and Yingjie, “Meshing characteristics of toroidal drive”, Science direct journal, Volume 47, page 827-854 15) Nuts and bolts standards, Source: http://www.nutsandboltsstandings.com. 16) PSG design data book, Second edition-1999 17) Shigley.J.E and Mischke C.R. - Mechanical Engineering Design-2008 18) Stefan Staicu, “Inverse dynamics of a planetary gear train for robotics”, Research gate journal, Volume 47, page 728-767 19) Tadashi takeuchi and Kazuhide togai, “Meshing transmission error”,Scribd, digital document library,Source: http://www.pdfcoke.com/doc/Gear20) Whine-Prediction-With-CAE-for-AAM 21) V.B.B. Bhandari, “Design of machine elements”, Second edition-1994 22) Wen-Hsiang Hsie, “An experimental study on cam- controlled planetary gear trains”, Science direct journal, Volume 24, page 513-525.

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PHOTOGRAPHY OF THE PROJECT

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