MANUFACTURING OF STEERING COMPONENTS FOR A RACE CAR

Transcription

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 6, June 2017, pp , Article ID: IJMET_08_06_022 Available online at aeme.com/ijmet/issues.asp?jtype=ijmet&vtyp pe=8&itype=6 ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed MANUFACTURING OF STEERING COMPONENTS FOR A RACE CAR Subramanyam B, P. Bridjesh and Madhu S Department of Mechanical Engineering, MLR Institute of Technology, Hyderabad, India ABSTRACT Automotive vehicles require a range of steering activity; one extreme is highway driving with negligible turning. Another is steering during U-turn maneuvers, which calls for agile turning and a small turning radius to increase vehicle stability. To manufacture of steering components of a Race Car this paper presenting how to manufacture the components based on the design and analysis of steering components for a Race Car. By using various production techniques like; Gear cutting, Broaching, Heat treatment, Milling, Turning, Tig Welding and Grinding operations the manufacturing of steering components for a race car has to be done. Key words: Broaching, Gear cutting, Pinion, Rack and Steering Arm. Cite this Article: Subramanyam B, P. Bridjesh and Madhu S. Manufacturing of Steering Components for a Race Car. International Journal of Mechanical Engineering and Technology, 8(6), 2017, pp MET/issues.asp?JType=IJMET&VType=8&ITy ype=6 1. INTRODUCTION Based on the mathematical and numerical analysis performed in the previous study the manufacturing of steering components of a race car has to be done. In this manufacturing process various manufacturing methods like; Gear cutting, Broaching, Heat treatment, Milling, Turning, Tig Welding and grinding operations/methods to be performed. The gear ratio reduces the torque required. This force, thus torque, may still be substantial and so it is common for theree to be a reduction gear immediately before this by either a gear or worm gear reduction. Rack gears have a higher ratio, thus require a greater driving torque, than screw actuators.en27 steel materials are used for the selection of material. 2. MANUFACTURING METHODS OF STEERING COMPONENTS FOR A RACE CAR By using broaching, gear cutting, heat treatment, milling, turning, TIG welding Methods the components are manufactured with the material of EN27 and EN28 steel editor@iaeme.com

2 Manufacturing of Steering Components for a Race Car Broaching The rack and pinion of steering system is manufactured by using broaching operation as shown in fig.1 and fig.2. Heat Treatment The most common application is metallurgical. Heat treatment techniques are annealing, case hardening, precipitation strengthening, tempering, normalizing and quenching. Milling The milling process removes material by performing many separate, small cuts. This is accomplished by using a cutter with many teeth, spinning the cutter at high speed, or advancing the material through the cutter slowly; most often it is some combination of these three approaches. The speeds and feeds used are varied to suit a combination of variables. The speed at which the piece advances through the cutter is called feed rate, or just feed; it is most often measured in length of material per full revolution of the cutter. By using the CNC milling the manufacture the steering arm has carried out as shown in fig.3. Turning The turning processes are carried out on a lathe, considered to be the oldest machine tools, and can be of four different types such as straight turning, taper turning, profiling or external grooving. Those types of turning processes can produce various shapes of materials such as straight, conical, curved, or grooved work piece. In general, turning uses simple single-point cutting tools. Steering shaft will be manufactured by using turning operation on lathe machine as shown in fig.4. Splines Splines are made on steering shaft to attach steering wheel. TIG Welding The TIG welding of steering component are shown in fig.5. Grinding It is an abrasive machining process that uses a grinding wheel as the cutting tool. Grinding practice is a large and diverse area of manufacturing and tool making. 3. ASSEMBLY OF STEERING COMPONENTS The assembly of all the components has to be done with proper alignments. The manufacturing methods of steering components are familiar to this assembly of steering components. Assembly of steering components is shown in fig.6 and fig editor@iaeme.com

3 Subramanyam B, P. Bridjesh and Madhu S 4. FIGURES Figure 1 Manufacturing of Rack by using Broaching operation Figure 2 Manufacturing of Pinion by using Broaching operation Figure 3 Manufacturing of Steering arm by using Milling operation Figure 4 Manufacturing of Steering shaft by using Turning operation editor@iaeme.com

4 Manufacturing of Steering Components for a Race Car Figure 5 Manufacturing of Steering component by using TIG Welding Figure 6 Steering wheel to housing assembly Figure 7 Housing to steering arm assembly 5. CONCLUSIONS The manufacturing methods are succeeded to the assembly of all the manufacturing components for the steering components of a race car. The numerical and simulated values of the pre study and analysis of all the components are satisfied and withstander the manufacturing requirements editor@iaeme.com

5 Subramanyam B, P. Bridjesh and Madhu S REFERENCES [1] Rushikesh D. Savant, S. Y. Gajjal, V. G. Patil, Review on Disc Brake Squeal, International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 12 - Mar 2014 [2] Subramanyam. B, P.Bridjesh, Design and Analysis of Student Formula Car Roll Cage, Indian Journal of Science and Technology, Volume (48). DOI: /ijst/2016/v9i48/105996, December [3] Rushikesh D. Savan, Shekhar Y. Gajjal, Finite Element Modelling and Analysis of Brake Squeal, International Journal of Research and Scientific Innovation, Volume I Issue VIII. [4] Robertson, Dennis, and George J. Delagrammatikas. The suspension system of the 2009 cooper union FSAE vehicle: A comprehensive design review. No SAE Technical Paper, [5] V. B. Bhandari Design of Machine Elements McGraw Hill Education India Pvt. Ltd., vol. 3, 11th Edition, 20. [6] Dhiraj Malu, Nikhil Katare, Suraj Runwal, Saurabh Ladhe, Design Methodology for Steering System of an ATV. International Journal of Mechanical Engineering and Technology, 7(5), 2016, pp [7] Mandar Soman, Sumit Sonekar, Saurabh Upadhye and Prof. Pathan Farha Mubeen. Designing and Manufacturing of Foot Operated Steering For Disabled People, International Journal of Mechanical Engineering and Technology, 6(12), 2015, pp editor@iaeme.com