DESIGN AND DEVELOPMENT OF TORQUE ROD ...DESIGN AND DEVELOPMENT OF TORQUE ROD (CRIMPED TYPE) FOR...

DESIGN AND DEVELOPMENT OF TORQUE ROD (CRIMPED TYPE)

FOR HEAVY DUTY VEHICLE

Ashok Mane 1, Prof. Mr. V. N. Patil2, Prof. Mrs. Sheetal Patel3

1P. G Student, Department of Mechanical Engineering, Bharti Vidyapeeth College of Engineering, Kharghar, Navi Mumbai, Maharashtra, India.

2,3Professor in Mechanical Engineering Department, Bharati Vidyapeeth College of Engineering, Kharghar, Navi Mumbai, Maharashtra, India.

--------------------------------------------------------------------------***------------------------------------------------------------------------

Abstract - The primary objective of Project is the design of Torque rod based on the forces and the stresses developed in the component.

This project work, Design and Development of

Crimped Torque Rod, is the requirement of customer of heavy-duty vehicles industrial sector (MAN TRUCK). For the first time company has taken this kind of project to design and develop Crimped Torque Rod. Torque Rod is used in various applications which may fail due to excessive loads, forces and stresses developed in it during its operation. Significant Testing is utmost to justify customer requirement.

For long term relation with the existing and future

customers, company must give its best in terms of the successful implementation of this project work. This may act as the benchmark for Future reference.

Key Words: Crimped Torque Rod, Suspension

link, Resins, wheel carrier, etc.

1. INTRODUCTION

Torque Rod - A Torque rod (also called a radius arm or a torque arm) is a suspension link intended to control wheel motion in the longitudinal direction. The link is connected (with a rubber or solid bushing) on one end to the wheel carrier or axle, on the other to the chassis of the vehicle. Radius rods are also sometimes used in aircraft with fixed (no retractable) undercarriages. The Torque Rod has multi-functional role in truck and trailer suspensions. It controls driveline angles of the vehicle restrains rotation of the axle housing while accelerating and braking locates the axle and maintains alignment and absorb leaning and cornering.

Fig-1: Torque Rod Bush Assembly

Fig-2: Torque Rod Position in Truck

Bush - A bushing or rubber bushing is a type of vibration isolator. It provides an interface between two parts, damping the energy transmitted through the bushing. A common application is in vehicle suspension systems, where a bushing made of rubber (or, more often, synthetic rubber or polyurethane) separates the faces of two metal objects while allowing a certain amount of movement. This movement allows the suspension parts to move freely. A rubber bushing may also be described as a flexible mounting or ant vibration mounting. These bushings often take the form of an annular cylinder of flexible material inside a metallic casing or outer tube.

Fig-3: Bush

Hydraulic Press Machine - Hydraulic presses are a powerful class of machine tools; they derive the energy they deliver through hydraulic pressure. Fluid pressure, in a chamber, can be increased or decreased using pumps, and valves. Sometimes devices and systems may be used to increase the capacity of the pumps in more powerful presses. These presses can operate over a long distance and at a constant speed. Hydraulic presses are generally slower relative to other press machine types.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 08 Issue: 01 | Jan 2021 www.irjet.net p-ISSN: 2395-0072

© 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 2019

Fig-4: Hydraulic Press Machine

2. LITERATURE SURVEY

Apicit Tantaworrasilp et al. [1] “Design and Development of Torque rod bushing Testing System” This paper presents the design and development process of a torque rod bushing testing system which is intended to be used in Part Industry 1999 Company Limited (PMCO1999). PMCO1999 manufactures automotive parts and torque rod bushing is one of the important products of the company. The company would like to improve the quality of the torque rod bushing thus a test process for assessing the quality of the torque rod bushing is required. The company developed an in house solution for the testing problem.

Prathap Kairan et al. [2] “Design and Development of an Assembly Fixture for Mounting a Circlip to the Piston.” This paper describes about designing an assembling fixture for mounting circlip to the groove provided in the piston pin hole. After careful study of assembly components, a few concepts of fixtures were designed. Among these concepts the best concept is developed by using concept scoring technique. The detail design of the selected concept is done by using 3D software, Pro-E wildfire. Based on the detail design, 2D draft drawings are generated and supplied for manufacturing of the fixture. The implementation of the fixture is able to assemble 2160 number of pistons with the circlip in a day.

Wenku Shi et al. [3] “Based on Linear Cumulative Damage Thrust Rod Fatigue Life Prediction” In order to predict the fatigue life of heavy-duty commercial vehicles thrust rod, dumbbell specimens made of rubber material and uniaxial

tensile fatigue test. According to the specimen measured data, based on linear cumulative fatigue damage rule to the maximum principal strain injury parameters established rubber uniaxial fatigue Life prediction model. In the longitudinal tension and compression loading, fatigue life V rod were predicted, and by the uniaxial fatigue test verification, the results show that the maximum principal strain prediction model, the maximum error is less than 10% predicted better results. Show that the method based on fatigue cumulative damage, establish spherical hinge rubber life model, can predict the fatigue life of the thrust rod. The method used in this paper for the design and improvement of the thrust rod.

Tushar Joshi et al. [4] “Design and Analysis of Suspension and Steering Components of F1 Prototype” The objective of this paper is to discuss a design methodology and FEA of suspension components of a F1 prototype vehicle including wishbones, bell cranks, push rods, knuckle and hub. The paper deals with various methodologies for analysis of components so as to check all possible failure possibilities and main aim is to describe an approach for analysis of different components. The 2014 Supra car of college of technology is used as an example in this paper.

Dr. R.G.Todkar et al. [5] “Design, analysis of A-type front lower suspension arm in Commercial vehicle” In this project work mainly focused on the finite element based stress analysis of A – Type lower suspension arm. The main objective of this study is to calculate working life of the component under static loading. The A – Type lower suspension arm was developed by using CAD software. Actual model was manufacture as per Design by using AISI 1040 material.

3. PROBLEM STATEMENT

The Problem Statement for this project to Design and Develop Torque Rod as per Customer Specification & perform the test as per Customer requirements. The customer has provided all specifications for development.

Specific Requirements of Customer -

Static Test – Radial (Max. 5 mm) Static Test – Axial (Max. 10 mm) Static Test – Torsional (Min. 500 Nm) Static Test – Conical (Min. 500 Nm) Pulling Strength Load – 260 KN (Min.) Buckling load – 250 KN (Min.) Torque Test – 1700 N-m (Min.) Durability Test – 1409-1878 Cycles.

4. METHODOLOGY

The design of the component to be achieved using

Creo 3.0 Design & Development of Crimping Tool Manufacturing of components.




PAGE : 1 OF 1

PFD No.: PFD -

OE 400.665

Customer : Part Name TORQUE ROD

ASSY.OPERATION

Rev.No. & Date:

00 & 05/02/2017

Part No. Mansons Drg. No. OE 400.665 TRANSPORTATIN INSPECTION

Rev.No. &

Date:Rev. No. & Date : 2 & 25.01.2017 TOGETHER STORAGE

Core Team :

OPRN. NOPROCESS FUNCTION / STEP /

REQUIREMENTS

SPECIAL

CHARACTERI

STICS

PRODUCT

CHARACTERISTICS

PROCESS

CHARACTERISTICS ACTIVITY / PROCESS SYMBOL LOCATION

10Rubber, Carbon, Oil & Chemicals

Receipt , Inspection & Storage

Material, Ash content ,

Moisture content

Density

Calibrated testing

eauipments &

Proper storaging location

MIPL UNIT- 4

20 Preparation of Compound Batch -

A) Weighing of Polymer, Carbon ,

Oil & Chemicals

Correct weighment of

polymer, Carbon, Oil

& Chemicals

Calibrated Weighing

scaleMIPL UNIT- 4

B) Master Batch Preparation

Properly mixed

compound to meet the

Specification

Mixing Time

Mixing SequenceMIPL UNIT- 4

C) Final Batch Preparation

Properly mixed

compound to meet the

Specification

Mixing Time

Dump TemperatureMIPL UNIT- 4

30Moulding Specimens Speciment to meet the

Physical Properties

Curing Time

Curing Temperature

Clamping Pressure

MIPL UNIT- 4

40 Testing of final batch Compound

Hardness,

Specific Gravity,

etc &

Rheological Prperties

Calibrated Testing

EauipmentsMIPL UNIT- 4

50Receipt, Verification & Storage of

Final Batch Compound

Batch Card,

FIFO

Temperature & Proper

storaging locationMIPL UNIT- 3

60 Metal Insert - Receipt ,

Inspection & Storage

Dimensions &

Material Test Report

Calibrated Measuring

Instruments &


MIPL UNIT- 3

70Surface Preparation of Inner

Metal Insert

A) Shotblasting

Uniform Surface

Roughness

Grid Size, Time,

Qty.MIPL UNIT - 6

B) Adhesive Agent Application

Uniform Adhesive

Application with

Specified Thickness

Viscosity MIPL UNIT - 6

80 Moulding

Properly Moulded part to

meet the Drawing

Requirements such as

Functional, Dimensional

& Visual.

Curing Time

Curing Temperature

Hydraulic Pressure

Loading Weight, etc.

MIPL UNIT- 3

90 Post Moulding Operation

A) DeflashingUniform deflashing as per

drawing requirement

Trained Operator

Work Instruction

100 Final Inspection

Dimension & Visual

Inspected parts as per

the requirement

Inspection Method

Calibrated InstrumentMIPL UNIT- 3

110Torque Rod(OE 400.665.1)

-Receipt,inspection storage

Dimensions &

Material Test Report

Calibrated Measuring

Instruments &


MIPL UNIT - 1

120 Crimping

Part to meet the Drawing



& Visual.

Crimping tool< Induction

Heating & Hydraulic

Pressure

MIPL UNIT - 6

130 PaintingUniform Painting(black),

Coating thicknessSpray Gun MIPL UNIT - 6

140

Assembly of Bushes into the

Torque Rod

(720.019.220)

Proper Assembly part to

meet the Drawing



& Visual.

Hydraulic Pressure,

Proper Guide To the child

part during assembly,

etc.

MIPL UNIT - 1

150 Final Inspection

Dimension & Visual

Inspected parts as per

the requirement

Inspection Method

Calibrated InstrumentMIPL UNIT- 1

160 Packing , Labeling & StorageBox size

Correct Labelling

No. of pieces per box

As per standaredMIPL UNIT- 1

170 Dispatch & ShippingDespatch mode agreed

with customer

Trained Operator

Work InstructionMIPL UNIT- 1

Rev.No. Revision Date Approved By

0 5/2/2017 KDP

MARPL/F/NPD/06 REV. NO/DATE: 00 / 01.12.2014

MIPL UNIT- 3

Transportation of Torque Rod End & Pipe from MIPL UNIT-1 to MIPL UNIT-6

Transportation of Torque Rod Bush 900.543 from MIPL UNIT-3 to MIPL UNIT-1

Transortation of Adhesive applied Metal inner pin from MIPL Unit - 6 to MIPL UNIT-3

Transportation of Torque Rod End & Pipe from MIPL UNIT-6 to MIPL UNIT-1

Approved By : KDP Risk Assessment : HIGH / MEDIUM / LOW

Revision Details

KDP, DALISH, SK, VS,YM ,VIPUL, RAVI

Transportation of Metal inner pipe from MIPL UNIT-3 to MIPL UNIT-6

Prepared By : Ashok Mane

Initial Release

Transportation of Rubber compound from MIPL UNIT-4 to MIPL UNIT-3

MANSONS INTERNATIONAL PVT LTD

PROCESS FLOW DIAGRAM

MAN TRUCKS

OE 400.665

----

Sample Inspection of Components Assembly of Components. Testing of component. Check for optimization of component.

4.1 Process Flow Diagram

A Process Flow Diagram (PFD) is a type of flowchart that illustrates the relationships between major components at an industrial plant. It's most often used in chemical engineering and process engineering, though its concepts are sometimes applied to other processes as well. It’s used to document a process, improve a process or model a new one. Depending on its use and content, it may also be called a Process Flow Chart, Flowsheet, Block Flow Diagram, Schematic Flow Diagram, Macro Flowchart, Top-down Flowchart, Piping and Instrument Diagram, System Flow Diagram or System Diagram.

Table-1: Process Flow Diagram

4.2 Design of Torque Rod

Design has drawn with reference of Mansons & customer drawing

Material selection and other parameters are defined by customer.

Revision is done to fulfil customer requirements. Previously Developed Product

a) Torque Rod Bush b) Internal Circlip

New Product for Development a) Eye End (Forging) b) Pipe (Extrusion) c) Torque Rod (Assembly of Pipe & Eye End)

Fig-5: Torque Rod Bush Assembly

Reference Drawings - The all below drawings provided only for reference. The customer requirement are mentioned in drawings. Testing are defined in drawings. Other drawings are Torque Rod Bush and Internal Circlip.

Customer Requirement Drawing

Fig-6: Customer Requirement Drawing





Torque Rod Bush

Fig-7: Torque Rod Bush

Internal Circlip

Fig-8: Internal Circlip

New Product Design- The Eye End Design, Pipe Design &

Torque Rod design done as per customer requirement and

taking approval from customer for Development

Eye End Design

Fig-9: Eye End Design

Pipe Design

Fig-10: Pipe Design




Torque Rod Design

Fig-11: Torque Rod Design

4.3 Design & Development of Crimping Tool

Fig-12: Tool Design

Crimping Tool is design by Company’s Tool Design Team, with reference to Torque Rod design

Tool Material – D2 Steel - D2 steel is an air hardening, high-carbon, high-chromium tool steel. It has high wear and abrasion resistant properties. It is heat treatable and will offer hardness in the range 55-62 HRC and is machinable in the annealed condition. D2 steel shows little distortion on correct hardening. D2 steel’s high chromium content gives it mild corrosion resisting properties in the hardened condition.

5. DEVELOPMENT OF TORQUE ROD

The Pipe is easily available in Market. Eye end is made with Forging & Machining Process which we get from supplier.

Manufacturing Process

Tool in Open Condition

Fig-13: Tool in Open Condition

Torque Rod End place on Crimping Tool as shown




Fig-14: Torque Rod End place on Crimping Tool

Induction heated pipe end fixed in Torque Rod End

Fig-15: Pipe End fixed in Torque Rod End

Fig-16: Induction heating of Pipe

Heating time to set up 90 Sec. Maintain machine temperature up to 35°c Machine shall be stopped beyond this

temperature Induction Heating done at 180 amp.

Crimping is done with Pressing Machine

Fig-17: Crimping with Press Machine




Open the Tool

Fig-18: Open Tool

Do Same for another end

Fig-19: Crimping of Torque Rod

Final Product

Fig-20: Crimped Torque Rod




MINIMUM MAXIMUM 1 2

1 SLOT WIDTH mm 3.15 3.29 3.19 3.15 OK

2 DISTANCE mm 56.85 57.85 56.89 56.86 OK

3 DISTANCE mm 4.90 5.1 5.08 5.09 OK

4 DIAMETER mm 94.85 95.15 94.98 95.03 OK

5 DIAMETER mm 85.50 86.5 85.90 85.96 OK

6 DIAMETER mm 98.75 99.1 99.06 99.00 OK

7 DISTANCE mm 69.5 70.5 69.98 69.99 OK

8 SYMMETRICITY mm 0.01 0.05 OK

9 PIPE THICKNESS mm 58.4 58.52 OK

10 C TO C mm 584 586 585.2 585.32 OK

11 DIAMETER mm 120.64 120.40 OK

OK

OK

OK

OK

OK

14 WEIGHT kg 10.00 kg 10.00 kg OK

OBSERVED OK

-

-

OBSERVED OK

0.5

58.00 × 5 THICK

120

EYE END - EN9-BS970/CK45

OBSERVED OK

TUBE DIN 2391-S355GT-

NBK(ST 52 NBK)58×5

OR DIN2391-S355-J2G3-

NBK(ST52-3 NBK)58×5

12

13

MATERIAL

SPECIFICATION

SURFACE FINISH

EPOXY POWDER COATING

(BLACK GLOSSY) EXCEPT

MACHINED SURFACE

WITH MIN THICKNESS OF

REJECTED

ACCEPTED UNDER DEVIATION

RESULT

INSPECTED BY : Ashok Mane APPROVED BY : KDP

10.000 kg

CONCLUSION ACCEPTED

-

SPECIFICATION OBSERVATIONS ( Sample No / Cavity No )SR.NO/

BALOO

N NO

UOM SC REMARK

SAMPLE SUBMISSION NO. 1 REFERENCE DOCUMENT : MANSONS DRAWING PRODUCTION SHIFT

MEASURING

INSTRUMENTCHARACTERESTICS

-

PART DESCRIPTION TORQUE ROD SAMPLE SIZE 2 CAVITY NO -

REV.NO. & DATE (0) 15/09/2016 QUANTITY 2 nos. NO. OF CAVITY

-

MANSONS PART NO. OE400.665.1 CUSTOMER / SUPPLIER CODE - TOOL / MOULD NO. -

CUSTOMER PART NO - SUPPLIER / CUSTOMER NAME MIPL 6 GRN NO.

PART INSPECTION REPORT INSPECTION STAGE (Please √ on Applicable stage)

INSPECTION DATE 8/9/2016 INVOICE / CHALLAN NO. & DATE - INSPECTION REPORT NO SAM/4248/9

SAMPLES PILOT LOT REGULAR SUPPLY FIRST OFF INPROCESS LAST OFF PDIR LAYOUT

Sample Inspection Report (SIR) of Torque Rod

Table-2: Torque Rod Inspection Report

6. EXPERIMENTAL EVALUATION

Static Test - Radial

Fig-21: Radial Test Setup

Table-3: Radial Test

Observations: Sample -1 => @ 50 KN, Deflection = 0.45 mm Sample -2 => @ 50 KN, Deflection = 0.48 mm

Static Test – Axial

Test Condition Specifications 1. Apply Load 3

times to ball joint assembly to max 125KN (F radial) loaded & Unloaded

1. All measurements to be taken at 23±3°C

2. Stabilization Time : Minimum 16 hours

3. Rest time between every measurement 24hrs.

2. Initial Load of 100N to be applied & load indicator to be set on ‘0’ setting

3. Test speed 10 mm/min

4. Ball joint assembly to be loaded with 50KN & measurement (deflection) to be recorded.

Fig-22: Axial Test Setup




Table-4: Static Test - Axial

Observations: Sample -1 => @ 100 KN, Deflection = 4.05 mm Sample -2 => @ 100 KN, Deflection = 4.12 mm

Static Test - Torsional

Fig-23: Torsional Test Setup

Table:5: Static Test - Torsional

Observations: Sample -1 => @ 10˚, Torque = 874 N-m Sample -2 => @ 10˚, Torque = 870 N-m

Static Test – Conical

Fig-24: Torsional Test Setup

Test Condition Specifications

1. Apply Load 3 times to ball joint assembly to max 125KN (F axial) loaded & Unloaded

1. All Measurements to be taken at 23±3°C



2. Initial Load of 100N to be applied & load indicator to be set on ‘0’ setting

3. Test speed 10 mm/min

4. Ball joint assembly to be loaded with 100KN & Measurement (deflection) to be recorded.


1. Apply Load 3 times to ball joint assembly to max ±10°




2. Initial Load of 1Nm to be applied & angle indicator to be set on ‘0’ setting

3. Test speed V=20°/min

4. Ball joint assembly to be twisted by 10° & Torque to be recorded.




Table-6: Static Test - Conical

Observations: Sample -1 => @ 10˚, Torque = 625 N-m Sample -2 => @ 10˚, Torque = 675 N-m

Dynamic Testing Machine

Fig-25: Dynamic Testing Machine

Fig-26: Torque Rod Assembly Test Setup

Dynamic Test Machine Specification Axial Direction: Load=260KN Stroke Length=100mm Frequency= up to 50Hz Radial Direction: Load=260KN Stroke Length=100mm Frequency= up to 50Hz Torsional: Torque=2KN-m Rotational Angle=100° Frequency=25Hz Conical: Torque=2KN-m Rotational Angle=100° Frequency=25Hz

Pull-Out Strength Test

Table-7: Pull-Out Test

Observations: Sample -1 => Up to 280 KN, No Separation Noticed. Sample -2 => Up to 270 KN, No Separation Noticed.

Buckling Load Test Table-8: Buckling Load Test


1. Apply Load 3 times to ball joint assembly to max ±10°




2. Initial Load of 1Nm to be applied & angle indicator to be set on ‘0’ setting

3. Test speed V=20°/min

4. Ball joint assembly to be twisted by 10° & Torque to be recorded.


260KN (Minimum) There should not be Separation


250KN(Minimum) There should not be buckling or Distortion




Observations: Sample -1 => Up to 250 KN, No Buckling Noticed Sample -2 => Up to 260 KN, No Buckling Noticed

Torque Test

Table-9: Torque Test

Observations: Sample -1 => Up to 1700 Nm, No Separation Noticed. Sample -2 => Up to 1700 Nm, No Separation Noticed.

Durability Test Test Parameters: Radial Load: ± 150 KN 3 Load Alterations ± 100 KN 10 Load Alterations ± 70 KN 200 Load Alterations Test Frequency: 2 Hz

No. of Repeat Cycles: 1878 (400000 Load Alteration)

Chart-1: Durability Test Graph

Observations: Sample -1 => No Damage Observed. Sample -2 => No Damage Observed.

Planning Chart

Chart-2: Planning Chart

7. RESULTS AND DISCUSSIONS

Table-10: Results


1700Nm (Minimum) There should not be Separation

Test Sample 1 Sample 2 Requirements Safe or

not Static Test – Radial at 50 KN (Deflection)

0.45 mm 0.48 mm Max. 5 mm Safe

Static Test – Axial at 100 KN (Deflection)

4.05 mm 4.12 mm Max. 10 mm Safe

Static Test – Torsional at 10° (Torque)

874 N-m 870 N-m Min. 500 N-m Safe

Static Test – Conical at 10° (Torque)

625 N-m 675 N-m Min. 500 N-m Safe

Pull out Strength

No Separation Noticed


Min. 260 KN Safe

Buckling Load



Min. 250 KN Safe

Torque Test



Min. 1700 N-m Safe

Durability Test

No Damage Observed

No Damage Observed

1409-1878 Cycle

Safe




From above Result we can say that Torque Rod is completely safe for Truck Application.

It fulfils Customer requirements.

8. CONCLUSIONS

From above results it clearly shows that the Crimped Torque Rod is capable to full fill customer requirement.

Static Tests like Radial, Axial, Torsional & Conical gives an idea about the strength of Torque rod, and it shows that Torque Rod is capable of sustain such lodes.

No Damage after completion of 1878 Repeat cycles (400000 Load Alteration)

This gives the idea about statistical tool like SPC (Statistical Process Control) & MSA (Measurement System Analysis)

Drawing revisions shows that the how many changes require as per customer

Feasibility of product is very important which is discussed in APQP (Advance Product Quality Planning).

This data is so much useful to company for future customer to fulfil their requirement.

This act as the Benchmark for the similar kind of project.

9. REFERENCES

[1] Apicit Tantaworrasilp and Wutthiphat Covanich, “Design and Development of Torque rod bushing Testing System”, SICE Annual Conference 2013 September 14-17, 2013, Nagoya University, Nagoya, Japan, pp. 973-978.

[2] By Prathap kairan and P.V. Srihari, “Design and Development of an Assembly Fixture for Mounting a Circlip to the Piston.” International Journal of Engineering Research and Applications (IJERA)

ISSN: 2248-9622 www.ijera.com Vol. 2, Issue4, July-August 2012, pp.1476-1479.

[3] Wenku Shi and Henghai Zhang, “Based on Linear Cumulative Damage Thrust Rod Fatigue Life Prediction” 2016 the 2nd International Conference on Control, Automation and Robotics, pp. 249-252.

[4] Tushar Joshi and Vaibhav Joshi, “Design and Analysis of Suspension and Steering Components of F1 Prototype” Imperial Journal of Interdisciplinary Research (IJIR) Vol-2, Issue-4, 2016 ISSN: 2454-1362, www.onlinejournal.in pp.595-602.

[5] Mr. Balasaheb Gadade and Dr. R.G.Todkar, 766 “Design, analysis of A-type front lower suspension arm in Commercial vehicle” International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 02 Issue: 07 | Oct-2015 www.irjet.net p-ISSN: 2395-0072, pp.759-766.




http://www.ijera.com/

http://www.onlinejournal.in/

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