AUTOMATION OF MAIN BEARING BOLT AND CAP LOOSENING MACHINE FOR AUTOMOBILE CRANKSHAFT

International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 2, February 2017, pp. 41 49, Article ID: IJMET_08_02_006 Available online at http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=8&itype=2 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 IAEME Publication AUTOMATION OF MAIN BEARING BOLT AND CAP LOOSENING MACHINE FOR AUTOMOBILE CRANKSHAFT S. Arun Assistant Professor, Mechanical Department, Veltech, Avadi, Chennai, India SK. Nagoorvali Assistant Professor, Mechanical Department, Veltech, Avadi, Chennai, India K. Sunil Kumar Assistant Professor, Mechanical Department, Veltech, Avadi, Chennai, India G.S. Mohan Assistant Professor, Mechanical Department, T.J.S. Engineering College, Gummidipoondi, India ABSTRACT As the time consumed for the loosening of the bolt manually requires more time and reduces the rate of production. The Automation is done. It saves a lot of time and also increases the rate of production. The manual loosening of main bearing bolt and cap is not only a time consuming process but it is also quite tedious and prone to human errors.hence automation is done to reduce the errors. The Automation of Main Bearing Bolt and Cap loosening reduces the part damage and increases the efficiency of the product. The thread chip-off and operator errors are also reduced. And also the requirement of skilled technician is reduced, which automatically reduces the time consumed for various allowances. Key words: Automobile crankshaft assembly, automobile bolt design, crankshaft assembly. Cite this Article: S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan. Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft. International Journal of Mechanical Engineering and Technology, 8(2), 2017, pp. 41 49. http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=8&itype=2 1. INTRODUCTION The scope of this project confines to the assembly line AUTOMATION OF MAIN BEARING BOLT AND CAP LOOSENING MACHINE". The main bearing bolt and cap that are fixed in the MIP (Made In Part) section is removed in the assembly to facilitate the insertion of the crank shaft. This is done manually using pneumatic gun and other special tools. This might Cause damage to bolt head, missing of process, human fatigue, time delay and less productivity [1]. So Automation is done which is results in reduction of time consumed, avoid human error and also increase the efficiency [3]. All of which leads to increase the http://www.iaeme.com/ijmet/index.asp 41 editor@iaeme.com

S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan production known as AUTOMATION OF MAIN BEARING BOLT AND CAP LOOSENING MACHINE. 2. DESCRIPTION In Engine plant all operations are done by Automation Process. But the Main Bearing Bolt and Cap loosening is done manually. As it (The Bolt and Cap loosening) is done manually as shown in the figure 1.There are various problems that occurs, moreover it is not completely reliable as there are chances of human errors due to fatigue and other factors and also the time consumed on the process is more[4]. Hence Automation is done. 3. PROBLEM IDENTIFICATION Figure 1 Manual Main Bearing Bolt loosening 3.1. Quality The manual operation affects the quality in the form of part damage and thread chip-off in bolt. This is due to the loosening of the bolt in main bearing cap. 3.2. Ergonomics Ergonomics is said to be relationship between men and machine during manual operation. The ergonomics is affected due to human fatigue, operational errors and the time consumed for various allowances. 3.3. Scrap Scrap is also increased during manual operation and it causes Bolt damage and thread chip off and it leads to increase in burr. http://www.iaeme.com/ijmet/index.asp 42 editor@iaeme.com

Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft 4. METHODOLOGY REDUCED PRODUCTION RATE INCREASED CYCLE TIME TIME REQUIRE MORE TO LOOSEN THE BOLT SINCE IT IS DONE MANUALLY AUTOMATION OF MAIN BEARING BOLT LOOSENING 5. PROCESS INVOLVED Figure 2 Methodology Figure 3 front view of automation of main bearing bolt and cap loosening machine It works on Hydro-Pneumatic pressure.the block is input to the conveyor by the pick and place robot and the block moves to the various sections through the conveyor. In the main bearing bolt and cap loosening session the block is raised and the bolt and cap are loosened by the hydro-pneumatic system[7].it automatically loosens the main bearing nut and cap in cylinder block and also it is sensed automatically by the sensor. And it is consist of 10 spindle and each spindle operates simultaneously for bolt loosening [9]. And it is consisting of 5 clamps for loosening the main bearing cap. Its takes only less time for operation. When compare to manual operation time. http://www.iaeme.com/ijmet/index.asp 43 editor@iaeme.com

S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan 5.1. 2D Designs Layout Figure 4 2D Machine view 5.2. 2D Machine View Figure 5 2D Machine View 5.3. 3D Machine View Figure 6 3D Machine view http://www.iaeme.com/ijmet/index.asp 44 editor@iaeme.com

Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft 5.4. 3D Model Figure 7 3D Design of main bearing bolt loosening machine 5.5. Solid Works Model in Assembled View 6. CALCULATION i) To find Mass of plate/self weight: Mass of the plate = density * volume =3*130*100*2.7=91.26*10³gm ii) To find Bending Moment in Maximum:(M max) M max= WL² / 8 To find W: (consider the load as 2500N) W= (91.26+2500)*9.81/1300 = 23.32 N Therefore M max = 23.32*(1.3)² / 8 = 4.92Nm iii) To find Maximum Deflection (Y max) Y max = (5/384)*(WL4 / EI) Figure 8 3D Assembly http://www.iaeme.com/ijmet/index.asp 45 editor@iaeme.com

iv) To find Moment of inertia (I): I = bd³/12 = 1000*30³/12 =2250*10³ mm4 Therefore, Y max = (5/384) *(23.32*(1300^4)/70*10³*2250*10³) = 5.506 Nm v) To Find Maximum Load Bearing Capacity Force considered as 107.5N ٦max = force/area Force =107*30* *1000 = 3.22MN The stress due to load ٦max= (2500+91.26)*9.81/(30*1000) =1.01 N/mm² S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan 7. DESIGN CALCULATION FOR COLUMN Figure 9 Column i) To find moment of Inertia about X-X axis IXX = (b1d³1 b2d³2)/ 12 = (135*115³-115*95³ ³)/12 = 8.89*10^6 mm4 ii) Moment of Inertia about Y-Y-axis: IYY= (115*135³-95*115³)/12 = 11.53*10^6 mm4 Slenderness Ratio= L/rc Where, I=Arc² Therefore 11.53*10^6= 4500*r² rc=50.61mm Therefore slenderness ratio = 1285/50.61= 25.39 http://www.iaeme.com/ijmet/index.asp 46 editor@iaeme.com

Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft Hence, slenderness ratio is less than 40 column is a short column s. So Euler s theory cannot be used. And Euler s theory it s only applicable for long column. iii) Determination of Rankine value: 1/Pr = 1/Pe + 1/ Pc Where, Pe= Buckling load Pc= crushing load iv) To find Buckling load Pe= (4*3.14*3.14*EI)/Le² = (4*3.14*3.14*1.4*10^5*11.52*10^6) / 1285 =5.0779*10^6N Pe=2.09*10^7N v) To find crushing load: Stress=Pc/A Stress= 152N/mm² for ASTM A36 steel bar Therefore, stress=152*(135*115-95*115)=2.34*10^6 1/Pr=1/(5.0779*10^10) + 1/( 2.34*10^6) Pr=1.97MN 8. DESIGN CALCULATION FOR UPPER FRAME Assuming the top frame as a Fixed Beam which has uniform distributed load about 2500kg and the load gets equally distributed. i) To find self weight Self weight = density* volume Volume=1350*(140*95-120*95) =5805cm³ Density = 7.85 gm/cc for A36 Steel bar Therefore, self weight = 5805*7.85=45.56*10³ gm ii) To find Maximum Deflection Y max: Y max = WL³/384EI = (1250+45.56)*9.81*1070³/(384*2*10³*578.4*10³) = 0.09 mm iii) To find maximum bending moment M max= WL/24 = ((1250+4556)*9.81*1070)/24 = 506.63 Nm Figure 10 Upper frame http://www.iaeme.com/ijmet/index.asp 47 editor@iaeme.com

iv) To find stress due to load Max.stress = load/area Load carrying capacity = 1250*(140*95-120*75) =0.5375*10^7 N = 5.37MN Max.Stress = (1250+45.56)*9.81/(140*95-120*75) = 0.5741 N/mm² S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan 9. DESIGN CALCULATION FOR BOLT LOOSENING Figure 11 Bolt loosening Machine view Force = Torque/distance Torque required for loosening the Bolt in main bearing cap so, torque about 5 to 6 kgfm In this torque formula we find the force value: We considered the torque value is 5.5 kgfm Force =5.5/ (0.01) = 5393.66 N. 9.1. Process Time Calculation for Manual & Automation Loosening Tabular Column SI.NO Manual of Bolt loosening Automation of Bolt loosening Table 1 Process time calculation Manual of Cap loosening Automation of Cap loosening Time saving for bolt loosening Time saving for Cap loosening 1 15.75 8.73 33.68 12.64 7.02 21.04 2 16.12 7.53 32.15 13.72 8.59 18.43 3 14.28 8.39 30.01 13.14 5.89 16.87 http://www.iaeme.com/ijmet/index.asp 48 editor@iaeme.com

Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft 10. CONCLUSION Success full implementation of Main Bearing Bolt and Cap loosening machine resulted in transformation from manual processing to automatic processing, hence eliminating the workmen s fatigue. The achievements on implementation of the main bearing bolt and cap loosening machine is Improved overall efficiency Avoid scrap and burr Avoid part damage Thus the existence of main bearing bolt and cap loosening machine turns up the statistics friendlier to higher standards. REFERENCES [1] Ligier, J.L.; Dutfoy, L. Modelling and prediction of a simplified seizure mechanism occurring in conrod bearings. Méc. Ind. 2011, 12, 265 273. [2] Bravo, A.E.; Durán, H.A.; Jacobo, V.H.; Ortiz, A.; Schouwenaars, R. Towards new formulations for journal bearing alloys. Wear 2013, 302, 1528 1535. [3] Khonsari, M.M.; Booser, E.R. Effect of contamination on the performance of hydrodynamic bearings. In Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, Baton Rouge, LA, USA, 1 May 2006; IMechE: London, UK, 2006; Volume 220. [4] Gangopadhyay, A.; McWatt, D.G. The effect of novel surface textures on tappet shims on valve trainfriction and wear. In Proceedings of the STLE/ASME 2006 International Joint Tribology Conference, San Antonio, TX, USA, 2008; Volume 51, pp. 221 230. [5] Ciulli, E. A review of internal combustion engine losses. Part 2: Studies for Global Evaluations.Proc. Inst. Mech. Eng. D J. Automob. Eng. 1993, 207, 229 240. [6] Ruchik D. Trivedia*, Dhaval B. Shahb, Kaushik M Patel 3D Parametric Modeling for Product Variants Using Case Study on Inner Ring of Spherical Roller Bearing science direct 2012. [7] Ronkainen, H.; Valkonen, A.; Kapulainen, M.; Simo, V.; Hokkanen, A.; Stuns, I. Embedded optical sensor for oil film pressure measurement in journal bearings. In Proceedings of the NORDTRIB2008, Tampere, Finland, 10 13 June 2008. [8] Tala-Ighil, N.; Maspeyrot, P.; Fillon, M.; Bounif, A. Effects of surface texture on journal-bearing characteristics under steady-state operating conditions. Proc. Inst. Mech. Eng. J J. Eng. Tribol. 2007,221, 623 633. [9] Adatepe, H.; Biyikhoglu, A.; Sofuoglu, H. An investigation of tribological behaviors of dynamically loaded non-grooved and micro-grooved journal bearings. Tribol. Int. 2013, 58, 12 19. [10] Ronkainen, H.; Valkonen, A.; Kapulainen, M.; Simo, V.; Hokkanen, A.; Stuns, I. Embedded optical sensor for oil film pressure measurement in journal bearings. In Proceedings of the NORDTRIB. 2008, Tampere, Finland, 10 13 June 2008. [11] Pawan Kumar Singh, Dr. L. P. Singh, Vicky Lad and Anil Kumar Vishwakarma, Modelling of Crankshaft by CAD Tool and Finite Element Analysis Using Ansys Software. International Journal of Mechanical Engineering and Technology, 7(4), 2016, pp. 205 211. [11] Praveen Padagannavar and Manohara Bheemanna, Automotive Computational Fluid Dynamics Simulation of A Car Using Ansys International Journal of Mechanical Engineering and Technology, 7(2), 2016, pp. 91 104. http://www.iaeme.com/ijmet/index.asp 49 editor@iaeme.com