Review Paper on Design and Development of Coupling Torque Endurance Test Machine with Variable Torque and Chamber Adjustment 1. Mr. Borude S.C.(P.G. Student, JSPM s ICOER, Pune), 2.Prof. Biradar N.S.(HOD Dept. of MECH. JSPM s ICOER, Pune),3.Mr. Ghanwat B.V.(CEO, BVG Tech, Pune ) NCADOMS-2016 Special Issue 1 Page 356
Abstract- Purpose of the test machine is to torque and specified speed, and specified angle (+/- 20 kg-m torque and 180 cpm, at 7 inclination). introduce various physical mathematical, scientific, and engineering principles associated with testing of Rubber- Metal Bonding of Coupling used in 3-wheeler. The project will be completed under the guidance of JSPM s ICOER, Wagholi, Pune & BVG Tech, Bhosari, Pune. Here, the scientific concepts in physics, mechanics and mathematics are combined with a hands-on experiment to demonstrate Thus, it is very much necessary for the designers to provide not only a better design of parts having maximum reliability but also of minimum weight and cost, keeping design safe, under all loading conditions. From initial concept building to final product is done. FEA approach can be applied for the optimization. 3D model of a test machine will be drawn in CATIA V5R17. Model will be fabricated and testing will be testing of Coupling for torque Endurance test. The done for the test sample is in scope. The suggestion after test experiment is conducted on a small-scale highly result is not in scope. instrumented test machine. The experimental measurements and physical observations are used to II.LITERATURE REVIEW confirm the manufacturing process used. The mathematical and engineering models used to design and to build full size Coupling Endurance Test Machine. The test gives the reliability of coupling when subjected to specified torque and specified speed, and specified angle (+/-108 kgm torque and 190 cpm, 7 inclination). As per reference from Indian standards IS:3400 (Part14)-1984 which gives the methods of test for Vulcanized rubbers Three methods have been prescribed in this standard: Method A covers the procedure for testing the strength of rubber to metal bonds by separation action where the rubber part is adhering to a metal surface I.INTRODUCTION Coupling is device used to connect two shafts together at their ends, for purpose of transmitting power. Coupling does not allow disconnection of two shafts during operation, however there are torque limiting couplings which can slip or disconnect when some torque limit is exceeded. The primary purpose of the coupling is to join two pieces of while method B, covers the procedure for measuring the force required to cause the rupture of a unit of standard dimensions, comprising rubber bonded to two parallel metal plates. Method C which has been included in this revision specifies a method for measuring the static vulcanized adhesion strength of rubber compound where test piece is composed of two conical ends of a rigid rotating equipment while permitting some degree of material joined by a cylinder of rubber.specialty misalignment or end movement or both. Adhesives Rubber-To-Metal Bonding Agents The Rubber coupling is used in 3 wheeler which is Technical Guide Bonding Performance In this paper, prepared with the rubber molding process. It consists of rubber author has given Methods of Estimating Bond metal bonding. Metal strips, for actual clamping of sample on Performance Bonding performance is analyzed by desired location, and in between rubber allows for flexible assessing bond strength in tension, peel or shear, or power transmission. The Coupling (Piaggio) Torque depending on the shape of the test piece. The rubber-tometal Endurance Test Machine is designed to test which gives the reliability of coupling when subjected to specified bond is sometimes subjected to a combination of stresses. The results of static and dynamic tests are largely NCADOMS-2016 Special Issue 1 Page 357
dependent on the size and shape of the components, the load conditions to which they are exposed and the test method. Tensile Strength Our tests are conducted similar to ASTM D 429 and DIN 53531, with a test specimen consisting of two steel discs with even, parallel surfaces of 5 cm2, bonded to a rubber buffer of the same diameter, 20 mm thick. According to this test method, the adhesive value (tearing strength) and pattern of rupture are evaluated. The upper limit of the adhesion value naturally depends on the quality of the compounds. The break pattern, however, indicates that the strength of the bond is higher than that of the rubber compound. Design And Development Of An Economical Torsion Testing Machine A project was started by GLENN E. VALLEE, Assistant Professor Mechanical Engineering and Robert Short Western New England College Springfield Massachussets. A low cost torsion testing machine capable of determining the shear properties of materials according to ASTM specifications is developed. The machine provides an economical means of performing the standard ASTM torsion experiment which is integrated into the Mechanical Engineering laboratory sequence to augment the usual ASTM tensile test. Developed as part of a capstone. Mechanical Engineering senior design project, the torsion tester provides students with the means to observe and study the internal drive mechanism, torque load cell and rotational potentiometer within the machine, thus allowing students to calculate the performance characteristics of the machine prior to using it in an actual experiment. The result is a more comprehensive understanding of the laboratory experience, as the technology behind the testing apparatus, the test methodology and the response of materials loaded in torsion are explored. The machine provides a low cost solution for engineering and engineering technology programs that wish to expand their material testing capabilities but are not capable of funding the acquisition of commercially available torsion testing machines. The torsion testing machine developed in this work has proven to be a valuable and cost effective tool for enhancing understanding of the shear properties of materials and methods of determining these properties. The design of the torque load cell and rotational potentiometer provided a means of analyzing the function of the machine which in turn provided students with insights into its function. Students indicated that this made the experiment more interesting than the more typical experiment where the design and internal function of the testing machine is never addressed. Future plans involve including the machine as a component of the machine design course, as the design of the torque load cell would fit well into the mechanics of materials review, and the chain drive could be studied as part of the drive mechanism portion of the course. The Biomedical Engineering Department has also expressed an interest in using the machine to study shear failures of bone and other biomechanical materials. This would fit well within the Biomechanical Engineering lab sequence. Finally, the project has been so successful that the author has offered a similar senior design project which involves the design and fabrication of a Charpy Impact testing machine. It is expected that this practical method of designing affordable yet accurate test equipment will continue to expand the mechanical testing capabilities at Western New England College. III. GENERAL CHARACTERISTICS OF TEST MACHINE First, before starting any work, the actual mounting condition of coupling is observed. The coupling which is driven by ti-rod from differential gearbox which having NCADOMS-2016 Special Issue 1 Page 358
engine propeller shaft. The test should be conducted at same situation with different torque conditions. Along with the torque condition, the effect of chamber angle is also major affecting factor for the life of coupling. When a system accelerate mass in one direction, the accelerated mass produce opposite force of equal magnitude but opposite direction on that system. The force applied on a rotary part in a direction of motion is called torque. Torque is measured in the SI Units as the Newtonmeter (N-m). Torque is physical quantity which required to move vehicle through some distance on frictional surface. Toque is related to the distance of force in direction of motion from axis of rotation. Torque is generated by the engines is transmitted to wheel through power transmission system consisting of different components. In the machine, general required torque is going to generate through pulley and motor arrangement. The final required torque value can be achieve with adjusting the eccentricity on the machine. The eccentricity (i.e. torque) is converted the deflection value. S = r * θ This deflection is indicated on the dial provided at front. The speed can be adjusted with the variable frequency drive for the motor. The set number of cycle can be performed by mechatronics control system. The magnitude of the torque depends on the set eccentricity. The required maximum torque is generated with different combination of pulley arrangement. The final torque is provided to the coupling through connecting provided. Fig.1 Actual Coupling A connecting push forward by the final torque value. The torque of equal in magnitude, but opposite in direction also acts on the coupling through another end which is fixed. The main parameters to be tested are the effect of torque acting on rubber metal boding for number of cycles. The test machine consists of following important components/systems: 1. Coupling, mounted on two of holder. 2. Test rig fabricated in mild steel. 3. Coupling with holding both sides, for angle transmission and twisting mechanism. 4. Eccentric plate and Connecting Link. 5. Slotting Arrangement to set different angle. 6. 4 V-Belt Transmission. 7. 4 Plumber Block to support arrangement. 8. Control panel. IV.METHODOLOGY This chapter will cover the details explanation of methodology that is being used to make this project complete and working well. The method is use to achieve the objective of the project that will accomplish perfect result in order to evaluate the working project. There are generally three major step of methodology to complete the project, which is planning, implementing and analysis. All the methods used for finding, analyze and finalizing project related data. NCADOMS-2016 Special Issue 1 Page 359
Literature Review CAD Model Generation Determination of loads on different maneuvers Hand Calculations Analysing result & Redesign Manufacturing & Assembly Testing & Validation Results and Conclusion Fig. 2 Flowchart for Steps of Methodology The machine consists of two main arrangements are used. First one is torque adjustment technique & other is chamber angle adjustment technique. Both will be developed by us. These techniques are as below. 1. Adjustable Torque Transmission: By Using Adjustable Eccentricity of connecting member. 2. Chamber Angle Adjustment: By using adjustable fixture arrangement.. 1. Adjustable Torque Transmission Arrangement: In this arrangement, the clamped coupling connected through the actual fixture mounted in the vehicle with additional fixture arrangement. The rotating end of coupling is connected to power transmission system. These two system are connected through connecting link whose one end having adjustable eccentricity mechanism. This adjustable mechanism allow to transfer required torque to the coupling. Fig.3 Schematic diagram of impulse (roller) thrust measurement system. 2. Chamber Angle Adjustment Arrangement: This is simple technic used to give the chamber inclination to the coupling. The fixed side of coupling can be fixed in the slot or holes provided for required chamber angle inclination. The square bar and flat with slotting is used for this type of arrangement. The above figure shows the mechanical arrangement of the thrust cradle with linear ball bearing thrust arrangement system. To accomplish this, the following steps are followed: Starts concept building with help literature review. Prepare a CAD model from input parameters: specifications, sketch, photographs and hand NCADOMS-2016 Special Issue 1 Page 360
measurements, using 3D Designing software Tool. Analyze its practical Boundary conditions and recommend required changes for design optimization. Finalization of fabricated test machine with required control panel for testing of sample. There should not be cracking and collapsing. If this should happen at highway speeds you could lose control of the vehicle. V.CONCLUSION This is the new developing technique for testing coupling of the 3-wheeler that will be developed by us. In this system the torque transfer arrangement with adjustable chamber is developed with adjustable eccentricity. It is more flexible with more and more universal approach of solution for actual test condition for the testing. VI. REFERENCES [1] Design And Development Of An Economical Torsion Testing Machine By Glenn E. Vallee Assistant Professor Mechanical Engineering [2] American Society for Testing and Materials, Standard Test Method for Shear Modulusat Room Temperature, NCADOMS-2016 Special Issue 1 Page 361