A PROJECT REPORT ON MONO BIKE Submitted in partial fulfillment for the award of Degree of BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING By MEKAPOTHULA.PAVAN KALYAN Roll Nos.-177Z5A0311 MOHAMMAD YAKUB SHAREEF Roll Nos. –177Z5A0312 MUNJA LAXMAN Roll Nos.-177Z5A0315 NIMMANAGOTI MUKESH Roll Nos.-177Z5A0320 VALIGONDA DEEKSHITH SAI Roll Nos.-177Z5A0324 Under the Supervision Of T. SWETHA ASSISTANT PROFESSOR DEPARTMENT OF MECHANICAL ENGINEERING SCHOOL OF ENGINEERING NALLA NARASIMHA REDDY [14] EDUCATION SOCIETY’S GROUP OF INSTITUTIONS [12] (Affiliated to J.N.T.U.H, Approved By AICTE, New Delhi, Accredited by NBA & NAAC) Chowdariguda (V), Korremula X-Road Ghatkeshar (M) Medchal-Malkajgiri (D), Hyderabad, Telangana.-500088 April 2020, i
DEPARTMENT OF MECHANICAL ENGINEERING CERTIFICATE This is to certify that the project titled “MONO BIKE” is the bonafide work carried out by MOHAMMAD YAKUB SHAREEF (177Z5A0312) in partial fulfillment of the requirements for the award of the degree of Bachelor of Technology in Mechanical Engineering during 2019-20. The work is carried out by them under my guidance and supervision. The results embodied in this project have not been submitted to any other University or Institute for the award of any degree. Internal Guide Head of Department Mr.’s. T. SWETHA, Mr. Dr. G.Janardhana Raju Dean School Of Engineering Asst. Professor Principal ii
ACKNOWLEDGEMENT We are extremely thankful to our beloved Chairman Sri. Nalla Narasimha Reddy Garu & Director Dr. C.V Krishna Reddy for providing necessary infrastructure and resources for the accomplishment of our project work at Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad. We are highly indebted to Dr. G.Janardhana Raju, Dean-School of Engineering & HOD- Mechanical Engineering Department, NNRG for his support during the tenure of the project. We are very much obliged to our beloved guide Mrs. T. SWETHA, Assistant Professor for providing the opportunity to undertake this project and encouragement in the completion of this project. We would like to express our special thanks & gratitude to Mr. P.Srinivas, Associative Professor & all the Staff members of the Mechanical Engineering Department who have cooperated in making our project a success. Nevertheless, we express our gratitude toward our parents and friends for their kind co-operation and encouragement which helps us in the completion of this project. MEKAPOTHULA.PAVAN KALYAN Roll Nos.-177Z5A0311 MOHAMMAD YAKUB SHAREEF Roll Nos.-177Z5A0312 MUNJA LAXMAN Roll Nos.-177Z5A0315 NIMMANAGOTI MUKESH Roll Nos.-177Z5A0320 VALIGONDA DEEKSHITH SAI Roll Nos.-177Z5A0324 iii
DECLARATION We hereby pledge that the project report entitled “MONO BIKE” is submitted in the partial fulfillment of the requirement for the award of the degree of Bachelor of the Technology in Mechanical Engineering. This is a record of bonafide work carried out by us under the guidance of Mr’s. T.Swetha, Assistant Professor, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad. The results embodied in this project report have not been submitted to any other University or Institute for the award of any degree. MEKAPOTHULA.PAVAN KALYAN Roll Nos.-177Z5A0311 MOHAMMAD YAKUB SHAREEF Roll Nos.-177Z5A0312 MUNJA LAXMAN Roll Nos.-177Z5A0315 NIMMANAGOTI MUKESH Roll Nos.-177Z5A0320 VALIGONDA DEEKSHITH SAI Roll Nos.-177Z5A0324 iv
ABSTRACT When it comes to self-balancing personal transportation devices, it looks like the Solo wheel, Honda U3X, Uno, and Segway could all be in for a little competition. A monowheel/bike is a one-wheeled single-track vehicle similar to a unicycle. Instead of sitting above the wheel as in a unicycle, the rider sits either within the wheel or next to it. Usually driven by smaller wheels pressing against its inner rim. Most are single-passenger vehicles, though multi-passenger models have been built. The goal of this project is to design, analyze, and build a self-balancing single wheel bike for use as a transportation tool for someone traveling short distances. The project consists of a research phase in which similar systems have been investigated to help determine a sensible design approach and to establish appropriate design specifications; a design phase in which a model was designed with certain assumptions to meet the aforementioned specifications and a construction phase, in which the vehicle was built and tested. Monowheel looks like something out of a science fiction movie, but monowheel is, in fact, real, today, mono wheels are generally built but from the 1860s through to the 1930s, they were proposed for use as serious transportation. The idea may sound extreme, but the science behind monowheels is solid, at present, because of the surging consciousness of pollution and energy shortage crises, automobiles and motorcycles are no longer the best for transportation. As the price of petroleum products growing nowadays, there is a need for a cheaper and more efficient form of transport. v
TABLE OF CONTENTS Title Page no CERTIFICATE………………………………………………...……………………… ii ACKNOWLEDGEMENT……...………………………………………………………iii DECLARATION……………………………………………………………………….iv ABSTRACT……...……………………………………………………………………..v TABLE OF CONTENTS …………………………………...………….......................vi-ix LIST OF FIGURES …………………………………………..……………………... x-xiii LIST OF TABLES ……………………………………………………...….…………..xiv CHAPTER-1 INTRODUCTION CHAPTER-2 LITERATURE REVIEW & PROBLEM IDENTIFICATION 2.1 HISTORY …………………………………………………………………………..3 2.2STEERING ………………………………………………………………………….4 2.3 OTHER ISSUES …………………………………………………………………...5 2.4 VARIANTS AND RELATED VEHICLES ………………………………………. 6 2.5 CAN THESE COOL MONO WHEELS REVOLUTIONISE TRANSPORT ……..7 2.5.1 MCLEAN WHEEL ………………………………………………………………8 2 5.2 MCLEAN 5 HP WHEEL ………………………………………………………...8 2 5.3 SOLO WHEEL GLIDE 3 ………………………………………………………..9 2 5.4 RYNO ………………………………………………………………………….. 10 2 5.5 ONEWHEEL + XR…………………………………………………………….. 10 2 5.6 SEGWAY ONE S1 ……………………………………………………………...11 -13 2 5.7 LEXUS SLIDE ………………………………………………………………….14 2.6 ENGINE SPECIFICATIONS ……………………………………………………15 vi
2.6.1 TWO-STROKE ENGINE ……………………………………………………...16 2.6.2 COMPRESSION STROKE …………………………………………………...16 2.6.3 POWER STROKE ……………………………………………………………..16-17 2.7 MATERIALS ……………………………………………………………………17 2.7.1 PROPERTIES OF MILD STEEL ……………………………………………..17-18 2.7.2 PHYSICAL PROPERTIES OF MILD STEEL. ……………………………….18 2.7.3 CHEMICAL COMPOSITION ………………………………………………. 18 2.7.4 MECHANICAL PROPERTIES CHART ……………………………………. 19 2.7.5 PHYSICAL PROPERTIES…………………………………………………. 19 2.7.6 ELECTRICAL PROPERTIES……………………………………………… 20 2.8 EN31 ALLOY STEEL……………………………………………………….. 21-22 2.9 ALUMINIUM MATERIAL ………………………………………………….23 2.10 SUSPENSION SYSTEM…………………………………………………... 24 2.11 TYPES OF SUSPENSION SPRINGS ……………………………………... 24 2.11.1 LEAF SPRING ……………………………………………………………24 2.11.2 HELICAL OR COIL SPRING ……………………………………………25 2.11.3 TORSION BAR…………………………………………………………… 25 2.11.4 RUBBER SPRING ………………………………………………………..26 2.11.5 THE VARIOUS TYPES OF RUBBER SPRINGS USED ……………….26 2.11 (A) COMPRESSION SPRINGS …………………………………………….26 2.11(B) COMPRESSION SHEAR SPRING ……………………………………..26 2.11 (C) STEEL REINFORCED SPRING ………………………………………27 2.11 (D) PROGRESSIVE SPRING ……………………………………………...27 vii
2.12 REVERSE ENGINEERING METHOD …………………………………..28 2.13 CONCEPT DESIGN ………………………………………………………29-30 2.14 CAD MODEL PREPARATION ………………………………………….30-32 CHAPTER-3 METHODOLOGY 3.1 FABRICATION……………………………………………………………. 33 3.2 CASTING …………………………………………………………………. 33-34 3.3 POWER HACK SAW ……………………………………………………...34-35 3.4 ELECTRIC POWER CUTTER …………………………………………...35 3.5 ROLL BENDING …………………………………………………………35 3 5.1 ROLL BENDING OPERATION ……………………………………….36 3.6 LATHE MACHINE OPERATION ………………………………………36 3.6.1 TURNING……………………………………………………………… 36 3.6.2 TAPER TURNING …………………………………………………….36-37 3.6.3 THREADING ………………………………………………………….37 3.7 METAL ARC WELDING ……………………………………………….37-38 3.8 LIST OF MACHINES USED IN PROJECT …………………………… 39-41 3.9 LIST OF HAND TOOLS AND EQUIPMENT USED ………………….41-42 CHAPTER-4 IMPLEMENTATION STAGE 1 MAKING A BLUEPRINT……………………………………… 43-45 STAGE 2 MANUFACTURING OF TRANSMISSION COMPONENTS …45-46 4.0 CRAWLER…………………………………………………………….. 47-49 4.1 BUILDING THE TRANSMISSION DRUM …………………………..50-52 4.2 ROLLERS ……………………………………………………………….52-53 STAGE 3 FABRICATION OF CHASSIS ………………………………….53 viii
CHASSIS ……………………………………………………………………53-54 C FRAME …………………………………………………………………...54-55 ENGINE FRAME …………………………………………………………...55-56 BOTTOM FRAME ………………………………………………………….56-57 STAGE 4 ASSEMBLING …………………………………………………58 ENGINE ……………………………………………………………………58-59 TRANSMISSION SHAFT ASSEMBLE ………………………………….59-61 CHAPTER-5 RESULT ANALYSIS CONCLUSION & FUTURE WORK 5.1 CONCLUSION………………………………………………………...62 5.2 FUTURE WORK………………………………………………………62 REFERENCE……………………………………………………………..63-64 ix
LIST OF FIGURES FIGURE NUMBER NAME PAGE NUMBER 2.1 HEMMING'S UNICYCLE 3 2.2 1931 MONOWHEEL BY 5 GOVENTOSA 2.3 A MONOWHEEL RIDER IN THE 7 2011 DOODAH PARADE, COLUMBUS, OHIO 2.4 MCLEAN WHEEL 8 2.5 MCLEAN 5 HP MONO WHEEL 8 2.6 SOLO WHEEL GLIDE 9 2.7 RYNO MONO BIKE 10 2.8 ONEWHEEL+ XR 10 2.9 ONEWHEEL+ XR 11 2.10 SEGWAY ONE S1 11 2.11 SEGWAY ONE S1 12 2.12 RPF GETS SEGWAY TO 13 PATROL x
2.13 RPF GETS SEGWAY TO 13 PATROL 2.14 LEXUS SLIDE 14 2.15 LEXUS SLIDE 14 2.16 TVS XL SUPER ENGINE 15 2.17 2-STROKE INTERNAL 16 COMBUSTION ENGINE 2.18 MS MATERIAL OVERVIEW 18 2.19 EN31 ALLOY STEEL 21 2.20 LEAF SPRING 24 2.21 HELICAL SPRING OR COIL 25 SPRING 2.22 TORSION BAR 25 2.23 COMPRESSION SPRINGS 26 2.24 COMPRESSION SHEAR 26 SPRINGS 2.25 STEEL REINFORCED SPRING 27 2.26 PROGRESIVE SPRING 27 3.1 FINAL CASTING PRODUCT 28 xi
3.2 CUTTING BOX PIPE BY USING 29 A POWER HACK SAW MACHINE 4.1 MONO BIKE SCHEMATIC VIEW 37 4.2 C-FRAME 38 4.3 TRANSIMISSION SHAFT 38 4.4 PROFILE OF BOTTOM FRAME 39 4.5 ROLLERS 39 4.6 PURCHASED TIRE OVERVIEW 40 4.7 CUTTING THE TIRE INTO AS 40 PER REQUIRED 4.8 AFTER REMOVING THE 41 OUTERMOST LAYER 4.9 ALUMINUM DRUM AFTER 41 CASTING 4.10 ALUMINUM DRUM AFTER 42 LATHE OPERATIONS 4.11 MAKING HOLES ON AL DRUM I 42 SECTION PLATE 4.12 MAKING HOLES ON AL DRUM I 43 SECTION PLATE 4.13 AFTER PLACING I SECTION 43 PLATE INSIDE THE DRUM WITH STUDS AROUND xii
4.14 ROLLERS AFTER 44 MANUFACTURED ROLLERS AFTER 44 4.15 MANUFACTURED 4.16 C-FRAME AFTER WELDING 46 4.17 FIXING ROLLERS TO C-FRAME 46 4.18 WELDED ENGINE HOLDING 47 COVER FRAME 4.19 FIXED THE COVER FRAME TO 47 ENGINE 4.20 BOTTOM FRAME 48 4.21 SCRAP 2 STROKE ENGINE 48 4.22 AFTER REPAIRS (IN WORKING 49 CONDITION ENGINE) 4.23 TRANSMISSION ASSEMBLE 50 4.24 INSERTING FLANGE HUB INTO 50 CHAIN SPROCKET 4.25 BUILDING THE CHASSIS 51 4.26 ASSEMBLE OF TRANSMISSION 51 AND CHASSIS xiii
LIST OF TABLES TABLE NUMBER TABLE NAME TABLE PAGE NUMBER 2.1 ABOUT 15 2.2 ENGINE SPECIFICATION 2.3 CHEMICAL 18 2.4 2.5 COMPOSITION OF MILD 2.6 2.7 STEEL 3.1 3.2 MECHANICAL 19 3.3 PROPERTIES CHART 3.4 3.5 PHYSICAL PROPERTIES 20 OF MILD STEEL 20 ELECTRICAL 22 PROPERTIES OF MILD STEEL ROCKWELL C TEST ALUMINIUM MATERIAL 23 PROPERTIES CHART LATHE MACHINE 34 SPECIFICATION DRILLING MACHINE 35 SPECIFICATION SHAPER MACHINE 35 SPECIFICATION HACK SAW MACHINE 35 SPECIFICATION ARC WELDING MACHINE 36 SPECIFICATION xiv
CHAPTER-1 INTRODUCTION 1.1 INTRODUCTION A Mono bike (Monowheel bike) is a single-track vehicle consisting of a single crawler (Wheel). The main aim of Mono bike is that it reduces space occupied when a single occupied vehicle is necessary and for transportation of short distances. This may sound fictional but as going through history, The first mono bike designs appeared as early as the 1860s. In 1869 the Craftsman Rousseau of Marseilles built the first monocycle. Several of these featured a seat for a rider with pedals connected to the outside wheel. The rider pedals the small wheel, creating motion even at that time, the monowheel was recognized as a difficult means of transportation. The project proposes a monowheel bike, which was the serious mode of transportation back in the 1800s to 1900s. So we have chosen this idea of a vehicle because of a very simple thought of that, -” The technology revolves around itself ”- for example, Back in the days when the mobile phones where invented, the size of the phones where same as the size which we are using today and who would have thought that hoverboards will be the future replacing the roller skates. The very common thing we can notice in these inventions is, the design stayed at the origin but the performance and the high-power output increased in terms of 100 times better. This makes us believe in what are we doing now. So, when it comes to design for a self-balancing automobile, we have got many reference designs for a monowheel bike, but then a company called RYNO an Oregon based Portland company is currently in the idea of launching its very own one wheel electric bike in which its estimated price will be 2,70,000 INR (3600 USD) Although carrying a high price tag, the PORTLAND police department has already made a deal with the RYNO MOTORS – “Validates the bike as being rugged and reliable and seen as having a useful purpose” - They stated, so in this term we can say it is an extension of an automobile technology keeping the design originality with its benefits, considering to the futuristic scope of automobiles. 1
So, with the same idea of design, we have built a compact, efficient, powerful and cheaper version, with our design and fabrication – The Indian version of the mono bike. We have made this mono bike in an extremely affordable budget where every Indian can get hands-on it. It is cheap, efficient and can be built within a short time, making its production rate also can be higher, than any other corporate company is manageable with. OUR VISION: “To build a compact solo automobile also for the needs of daily life and making it affordable.” These types of MONOBIKES are used in bigger industries and companies, no thanks to its size and body weight It is used in the Portland police department. By the application of self-balancing sensors, it will balance on its own by making the rider feel comfortable. For a monowheel, both direction and speed are controlled through, the same physical apparatus this generally makes steering more difficult. The most common steering problem is that the rider must lean towards his intended direction of travel to turn and then centralize his weight again once the turn is complete makes it a bit difficult. 2
CHAPTER 2 LITERATURE REVIEW 2.1 HISTORY A monowheel is a one-wheeled single-track vehicle similar to a unicycle. Instead of sitting above the wheel as in a unicycle, the rider sits either within the wheel or next to it. The wheel is a ring, usually driven by smaller wheels pressing against its inner rim. Most are single- passenger vehicles, though multi-passenger models have been built. Hand-cranked and pedal-powered monowheels were patented and built in the late 19th century; most built in the 20th century have been motorized. Some modern builders refer to these vehicles as mono vehicles, though that term is also sometimes used to describe motorized unicycles. Today, monowheels are generally built and used for fun and entertainment purposes, though from the 1860s through to the 1930s, they were proposed for use as serious transportation. The world speed record for a motorized monowheel is 98.464 km/h (61.18 mph). Fig 2.1 Hemming's Unicycle 3
Hemming's Unicycle, or \"Flying Yankee Velocipede\", was a hand-powered monowheel patented in 1869 by Richard C. Hemming. 2.2 STEERING In a two-wheel mode of transportation, two systems (wheels) affect motion. Typically one wheel provides the force to control speed, while the other handles changes in direction: steering. For a monowheel, both direction and speed are controlled through the same physical apparatus; this generally makes steering more difficult. In a majority of systems, change in direction is effected by the rider shifting their weight, or in the sudden movement creating a shearing force between a handhold and the axis that the driver is settled on. Better control can usually be achieved at lower speeds. Because of the steering problem, monowheels have never caught on as a widely accepted mode of transportation. A change in direction can be effected in several ways including: Leaning. The most common steering solution is that the rider must lean towards their intended direction of travel to turn, and then centralize their weight again once the turn is complete. Turning a gyroscope to provide turning force. Outboard skids to provide friction drag on one side. At speeds faster than a walk, lightly dragging a foot on the ground will cause the wheel to lean to the opposite side. Drag the other foot to bring it back upright. Small wheels used for steering, either one to each side or a single unit either in front of or behind the vehicle. It is a matter of debate as to whether such a vehicle would still properly be called a monowheel. The steerable propeller, which could provide both steering and power to move the vehicle. It has been noted that having a propeller operating near pedestrians could be quite unsafe. Steerable tail surfaces, similar to those on airplanes. This solution would not work at low speeds. 4
2.3 OTHER ISSUES Fig 2.2 1931 monowheel by Goventosa Limited horizontal stability. A single wheel can fall over, unless it is quite wide or has some form of active stabilization, such as a gyroscope. Some designs have used outrigger skids or small wheels to address this. In many one-person designs, being at a stop requires the driver to put their feet on the ground, the same way as on a motorcycle. Limited capacity. Monowheels tend to be larger than a car of similar carrying capacity. Most have been kept small by being built to carry only one rider and with little or no space for baggage. Risk of \"gerbiling\". In most designs, if the driver accelerates or brakes too hard, it is possible that the force applied overcomes the force of gravity keeping the rider at the bottom of the wheel, sending the rider spinning around the inside of the wheel. This is known as gerbiling because it has some similarity to the situation of a gerbil running too quickly inside of a hamster wheel Visibility issues. In driver-inside designs, the rider is always facing the inner rim of the wheel, which can obstruct the view of oncoming hazards from all angles. 5
2.4 VARIANTS AND RELATED VEHICLES There have been many proposals for variants or uses, such as a horse-drawn monowheel or a monowheel tank. A variant was proposed that placed two riders outside of the wheel itself, with one person on each side to provide for balance. An electric monowheel called Dynasphere was tested in 1932 in the United Kingdom. One variant called a RIOT wheel was presented at Burning Man in 2003. It involves the passengers sitting in front of the wheel and being balanced by a heavy counterweight inside the wheel. Rather than the typical ring drive, this vehicle is powered through a sprocket attached to the spokes. A company in the Netherlands began taking custom orders of a monocycle configured variant called the Wheelsurf in 2007. A related vehicle is a wheel or the bicycle, in which the rider is suspended between or inside of a pair of large wheels placed side by side. An example of this would be the character Axel from the Twisted metal series of video games published by Sony. In 1971, an American inventor named Kerry McLean built his first monocycle (aka monowheel). In 2000, he built a larger version, the McLean Rocket Roadster powered by a Buick V-8 engine, which subsequently crashed in 2001 during the initial test run. McLean survived and proceeded to build over 25 different variations of his version of the monocycle, from pedal-powered models, 5HP models, all the way up to V8 powered models. In 2010, Nokia utilized two of McLean's monocycles in their commercials promoting the new Nokia SatNav smartphone. In McLean's latest creation, the 2011 McLean V8 Drag Wheel, the wheel itself was machined out of a single piece of high-strength aircraft-grade aluminum billet. 6
Fig 2.3 A monowheel rider in the 2011 Doo Dah Parade, Columbus, Ohio The Pasadena Doo Dah Parade is a popular farcical and flamboyant parade held in Pasadena, California, about once a year, usually in the fall or winter, although in recent years it has moved to the nearest Saturday to May Day. The event has been copied by the Columbus, Ohio, Ocean City, New Jersey, and Kalamazoo, Michigan, Doo Dah Parades. 2.5 Can these Cool Mono-wheels Revolutionise Transport? We are not sure if mono-wheel locomotion can one day revolutionize modern transport, but these innovations are fascinating. 2.5.1 McLean Wheel Remember the monocycles chase in Men in Black 3? McLean Wheel is the closest you can get to ride the monocycle Agent J and Agent K used to chase the ruthless alien Boris. Kerry McLean’s 5hp McLean Wheel and V8 powered Rocket Roadster are not used in the movie, but the monocycles are equally impressive — the design makes you sit within the stable wheel and ride around in style. 7
Fig 2.4 McLean Wheel 2.5.2 McLean 5 hp Mono Wheel Fig 2.5 McLean 5 hp Mono Wheel 8
The McLean Wheel is a 5HP model that is smaller and easier to learn to ride. Kerry designs and hand builds each one he has made. An excellent example of American ingenuity. In the video below, Kerry is seen riding the McLean Wheel at a local college campus. The latest Hollywood flick to hit the big screens, Men in Black 3, features the extremely interesting and fancy mode of transportation, a monocycle in its futuristic form. 2.5.3 Solowheel Glide 3 Fig 2.6 solo wheel glide It is a self-balancing electric unicycle that packs an impressive 50 km of range with a max speed of 31 kmph. The 16-inch wheels can roll over rough terrain, but you may have to work hard to tame its self-balancing mechanism at first. You can also ride it in the rain. 9
2.5.4 RYNO Fig 2.7 Ryno mono bike Riding a powerful self-balancing Micro-cycle is a rare experience the RYNO offers. The single-wheeled personal transportation bike’s motion-sensor technology detects subtle inputs from the rider to help him sit comfortably and naturally upright. 2.5.5 Onewheel + XR Fig 2.8 Onewheel+ XR 10
Fig 2.9 Onewheel+ XR This self-balancing electric skateboard, the company says, can be your favorite transport for on and off-road journeys between 20-28 km. It may not look high on tech, but it has air-filled tires, powerful braking, and the ability to ride on pavement, gravel, dirt, grass, and even on the beach. 2.5.6 SEGWAY ONE S1 Fig 2.10 Segway one S1 11
Fig 2.11 Segway One S1 The One S1 is not for everyone. Riders with a certain skillset, combined with a fearless mindset, can learn to ride it in about an hour. The one-wheel self-balancing personal transporter is compact, weighing around 11 kg and can accommodate up to 99 kgs. Its lithium-ion batteries deliver sustainable power and allow riders to travel up to 24 km, depending on payload. 12
In India RPF (RAILWAY PROTECTION FORCE) personnel at Mumbai railway stations now have segways for crowd control, patrolling the Western Railway provided six Segway to the officials deployed at major railway stations in Mumbai including Mumbai Central, Churchgate, Bandra Terminus, Borivali and Andheri for patrolling. Fig 2.12 Fig 2.13 13
2.5.7 LEXUS SLIDE If you believe wheels are a thing of the past and you want none, consider this hoverboard that can slide over land and water. The Lexus Slide uses magnetic levitation to achieve amazing frictionless movement. Liquid nitrogen cooled superconductors and permanent magnets combine to allow Lexus to create the impossible. Fig 2.14 Lexus Slide Fig 2.15 14
2.6 ENGINE SPECIFICATIONS Engine Type 2 Stroke Single Cylinder Displacement 69.9 cc Max Power 3.5 bhp @ 5000 rpm Max Torque 5 Nm @ 3750 rpm Cooling System Air Cooled Starting Kick Start Only Fuel Supply Carburetor Clutch Centrifugal Wet Type Ignition Fly wheel magneto 12V, 50W Transmission Automatic Gear Box Automatic Bore 46 mm Stroke 42 mm Table 2.1 about engine specs Fig 2.16 TVS XL SUPER ENGINE 15
2 6.1 Two-stroke engine Fig 2.17 A 2-stroke internal combustion engine As the name implies, the two-stroke engine only requires two-piston movements (one cycle) to generate power. The engine can produce power after one cycle because the exhaust and intake of the gas occur simultaneously, as seen in Figure 1. There is a valve for the intake stroke that opens and closes due to changing pressures. Besides, due to its frequent contact with moving components, the fuel is mixed with oil to add lubrication, allowing smoother strokes. Overall, a two-stroke engine contains two processes: 2 6.2 Compression stroke: The inlet port opens, the air-fuel mixture enters the chamber and the piston moves upwards compressing this mixture. A spark plug ignites the compressed fuel and begins the power stroke. 2 6.3 Power stroke: The heated gas exerts high pressure on the piston, the piston moves downward (expansion), waste heat is exhausted. The thermal efficiency of these gasoline engines will vary depending on the model and design of the vehicle. However in general, gasoline engines convert 20% of the fuel (chemical) energy to mechanical energy—in which only 15% will be used to move the wheels (the rest is lost to friction and other mechanical elements). Compared to four-stroke engines, two strokes are lighter, more efficient, can use lower-grade fuel, and more cost-efficient. Therefore, the lighter engines result in a higher power-to-weight ratio (more power for less weight). However, they lack the maneuverability possible in four- stroke engines and require more lubrication. This makes two-stroke engines ideal for ships 16
(need to carry a lot of cargo), motorcycles, and lawnmowers—whereas a four-stroke would be ideal for automobiles like cars and trucks. 2.7 MATERIALS 2 7.1 PROPERTIES OF MILD STEEL Fig 2.18 Mild steel, also called plain-carbon steel, is a type of steel alloy which is the most common high volume steel in production. Mild steel contains a small amount of carbon and provides material properties that are acceptable for many applications. For steel to be considered low carbon, there are certain characteristics it must meet. For example, the steel has to have less than 0.3% carbon in its total make-up to be considered low carbon. Mild steel is considered the most common form of steel as the cost is comparatively small, so it is generally used when large amounts of steel are needed. Low carbon steel properties include; it is easily workable and easier to form straight from the forming process, whether that process is hot forming or cool forming. Unlike other grades of carbon steel, which tend to be brittle, mild steel is very hard, yet malleable, making it the perfect choice for construction materials, car manufacturing, motorcycle frames, construction of pipelines, and many other everyday products like cookware. Although Mild Steel can be known to rust due to its poor corrosion resistance, it is usually painted and/or protected to prevent any rusting. 17
Mild Steel can be easy to shape and machine because it is very flexible and can be hardened by a heat treatment process called carburizing. This makes it a suitable material for producing a variety of products in the consumer industry. When it comes to welding, low carbon steel is one of the most easily welded metals. The reason for this is due to the low carbon content. Where more strength is needed for i.e. structural uses, more carbon is added to the metal. However the harder the steel gets the more likely it is to crack when you weld it. High carbon steels like stainless steel require special techniques to weld the material and are likely to break when used in some construction projects when flexibility is needed, which is why Mild Steel is commonly used. Mild Steel is in huge demand across the UK and internationally and can be supplied from several metal companies. Take a look at the wide range of our Mild Steel products. 2 7.2 Physical Properties of Mild Steel High tensile strength. High impact strength. Good ductility and weldability. A magnetic metal due to its ferrite content. Good malleability with cold-forming possibilities. Not suitable for heat treatment to improve properties. Specific manufacturing controls are used for surface preparation, chemical composition, rolling and heating processes. All these processes develop a supreme quality product that is suited to fabrication processes such as welding, forging, drilling, machining, cold drawing, and heat treating. 2 7.3 Chemical Composition table 2.2 nt Content Carbon, C 0.14 - 0.20 % Iron, Fe 98.81 - 99.26 % (as remainder) Manganese, Mn 0.60 - 0.90 % Phosphorous, P ≤ 0.040 % Sulfur, S ≤ 0.050 % 18
2 7.4 MECHANICAL PROPERTIES CHART MECHANICAL PROP METRIC IMPERIAL 145 145 Hardness, Knoop (Converted from Brinell hardness) 71 Hardness, Rockwell B (Converted from 71 131 Brinell hardness) 63800 psi 53700 psi Hardness, Vickers (Converted from 131 15.0 % Brinell hardness) 40.0 % 29700 ksi Tensile Strength, Ultimate 440 MPa 20300 ksi 0.290 Tensile Strength, Yield 370 MPa 70 % 11600 ksi Elongation at Break (In 50 mm) 15.0 % 126 Reduction of Area 40.0 % 19 Modulus of Elasticity (Typical for steel) 205 GPA Bulk Modulus (Typical for steel) 140 GPA Poissons Ratio (Typical For Steel) 0.290 Machinability (Based on AISI 1212 70 % steel. as 100% machinability) Shear Modulus (Typical for steel) 80.0 GPa Hardness, Brinell 126 Table 2.3 Mechanical properties chart
2 7.5 PHYSICAL PROPERTIES PHYSICAL PROP METRIC IMPERIAL Density 7.87 g/cc 0.284 lb/in3 Table 2.4 physical properties 2 7.6 ELECTRICAL PROPERTIES ELECTRICAL METRIC ENGLISH COMMENTS PROP Electrical resistivity 0.0000159 Ω-cm 0.0000159 Ω-cm annealed condition @0°C (32°F) @100 °C/ 212 °F 0.0000219 Ω-cm 0.0000219 Ω-cm annealed condition @ 200 °C/392 °F 0.0000293 Ω-cm 0.0000293 Ω-cm annealed condition Table 2.5 Electrical properties 20
2.8 EN31 Alloy Steel Fig 2.19 fountainhead Alloy produces EN 31 Alloy Steel round rods, EN31 Alloy Steel forging, sheet, coil and profiled strip, Deformed steel, flat steel, mold, steel wire, have all specifications. With production experience, strict control EN31 Alloy Steel chemical composition and EN31 Alloy Steel mechanical properties. From casting, forging, steel to the hot and cold rolling process, heat treatment, etc, we have the control of professional engineers. We have advanced precision machining equipment, according to the requirements of users machining. to achieve the most satisfied with the user requirements. 2 8.1 Forging Forge at 1000°/1050°C. Heat slowly, allowing sufficient time at the forging temperature for the steel to be thoroughly soaked through. Re-heat as often as necessary to keep the temperature above 850°C. After forging cool very slowly, preferably in a furnace. 2 8.2 Annealing Heat uniformly to 800°C, equalize, then furnace cool. (Hardness about 229 Brinell). 2 8.3 Stress Relieving If machining operations have been heavy or if the tool has an unbalanced section, remove stresses before hardening by heating up to 700°C, equalize, then cool slowly. 2 8.4 Hardening 21
Heat uniformly to 800/820°C until heated through. Allow 30 minutes per inch of the ruling section and quench immediately in oil. 2 8.5 Tempering Heat uniformly and thoroughly at the selected tempering temperatures and hold for at least one hour per inch of the total thickness. Table 2.6 Rockwell C test Tempering °C 100 150 200 250 300 350 HRC 64/63 63/62 62/61 60/59 57/56 54/53 2 8.6 Mechanical properties EN31 Alloy Steel Mechanical properties, Our production completely according to the EN31 Alloy Steel standards to meet the EN31 Alloy Steel mechanical performance, can also according to the customer request, to meet the requirements of customers of EN31 Alloy Steel mechanical properties. 2 8.7 Heat treatment EN31 Alloy Steel Heat treatment, Our production completely according to the EN31 Alloy Steel standards to meet the EN31 Alloy Steel Heat treatment, can also according to the customer request, to meet the requirements of customers of EN31 Alloy Steel Heat treatment. 2 8.8 Machining EN31 Alloy Steel Machining, Our production completely according to the EN31 Alloy Steel standards to meet the EN31 Alloy Steel Machining, can also according to the customer request, to meet the requirements of customers of EN31 Alloy Steel Machining. 2 8.9 Welding performance EN31 Alloy Steel Welding performance, Our production completely according to the EN31 Alloy Steel standards to meet the EN31 Alloy Steel Welding performance, can also according to the customer request, to meet the requirements of customers of EN31 Alloy Steel Welding performance. EN 31 SAE 52100 Silver Steel DIN 100Cr6 Round Bars, Bright Round Bars, Annealed Bright Round Bars, Hot Rolled Round Bars, Bearing Steel Round Bars, Bearing Steel Bright Round Bars, Bearing Steel Sphero Annealed Round Bars. 22
2.9 ALUMINIUM MATERIAL Aluminium is used in a huge variety of products including cans, foils, kitchen utensils, window frames, beer kegs, and airplane parts. This is because of its particular properties. It has low density, is non-toxic, has high thermal conductivity, has excellent corrosion resistance, and can be easily cast, machined, and formed. It is also non-magnetic and non- sparking. It is the second most malleable metal and the sixth most ductile. It is often used as an alloy because aluminum itself is not particularly strong. Alloys with copper, manganese, magnesium, and silicon are lightweight but strong. They are very important in the construction of airplanes and other forms of transport. Group 13 Melting point 660.323°C, 1220.581°F, 933.473 K Period 3 Boiling point 2519°C, 4566°F, 2792 K Block p Density (g cm−3) 2.70 Atomic number 13 Relative atomic mass 26.982 State at 20°C Solid Key isotopes 27Al Electron configuration [Ne] 3s23p1 CAS number 7429-90-5 Table 2.7 aluminium flow chart Aluminum is a good electrical conductor and is often used in electrical transmission lines. It is cheaper than copper and weight for weight is almost twice as good a conductor. When evaporated in a vacuum, aluminum forms a highly reflective coating for both light and heat. It does not deteriorate as a silver coating would. These aluminum coatings have many uses, including telescope mirrors, decorative paper, packages and toys Light Weight. Aluminum is a very light metal with a specific weight of 2.7 g/cm3, about a third of that of steel. ... Corrosion Resistance. ... Electrical and Thermal Conductivity. ... Reflectivity. ... Ductility. ... Strength at Low Temperatures. ... Impermeable and Odorless. ... Non-magnetic. 23
2.10 SUSPENSION SYSTEM We know that any system used in vehicles to reduce road shocks and vibration known as a suspension system. Springs, shock absorber torsion bar etc. are components of the suspension system. Due to the irregularity of roads when a vehicle runs, it feels a lot of vibration due to road irregularity and engine vibration. So if the car is perfectly rigid this vibration transmitted into the whole body of the car which causes damage to its body parts and also it is uncomfortable for the passengers too. So the Suspension Springs are used to separate the Wheel of the vehicle to the body so when the vehicle feels those vibrations it transfer to the spring and the spring start oscillating without transmitting this vibration to the vehicle body. So these springs are the main component of suspension systems. Today we used various types of vehicles according to load capacity and luxuriousness. So there are different types of spring and suspension systems used in those different vehicles. 2.11 TYPES OF SUSPENSION SPRINGS 2 11.1 LEAF SPRING Fig 2.20 leaf spring Semi elliptic leaf springs are almost used in commercial vehicles. It is also used in cars for the rear suspension. The spring consists of several leaves called blades. The blades vary in length and connected as shown in the figure. These springs based on the theory of beam of uniform strength. This spring is mounted on the axle by the U bolt and the one end of spring is mounted on the frame and the other is connected with a shackle that allows changing in length between the eye of spring when the vehicle comes across a projection of road and upward movement of a wheel. When there is a wide range of loading on vehicle helper spring is also provided with the leaf spring which increases the weight loading capacity of the vehicle. These springs are made by 24
the Chrome-Vanadium Steel, Silico-Manganese Steel or Carbon Steel as per requirement. These spring are noisy and do not use where luxuriousness is necessary. 2 11.2 HELICAL SPRING OR COIL SPRING Fig 2.21 We all have seen coil spring in our daily routine many times. The helical spring used is the suspension system is the same as we see. It is mainly used in the independent suspension. It is also used in the conventional rigid axle suspension as it can be well accommodated in restricted spaces. The energy stored per unit volume is almost double in the case of coil spring than the leaf springs. These spring do not have noise problems but they do not take torque reaction and side thrust for which alternative arrangements have to be provided. 2 11.3 TORSION BAR Fig 2.22 25
It is simply a rod that acting under the torsion and taking shear stresses. It is often used with independent suspension. One end of the bar is fixed to the frame and the other end is fixed to the end of the wheel arm and supported in the bearing. The other end of the wheel arm is connected to the wheel hub. When the wheel strikes a bump it starts vibrating up and down, thus torque on the torsion bar which acts as springs. 2.11.4 RUBBER SPRING The rubber springs are also used in suspension because it stores greater energy per unit weight than the steel. So it is more compact than other springs. It has also excellent vibration damping property. One more advantage of using rubber is that it does not suddenly fail like steel so there is less risk. 2 .11.5 The various types of rubber springs used. 2.11(a) Compression springs: Fig 2.23 This type of spring is still being used because it is reliable, simple in construction, can resist occasional overload of large magnitude, and have a large damping effect. 2 .11(b) Compression shear spring: Fig 2.24 In this type of spring the load is carried partly by shear and partly by compression. 26
2.11(c) Steel reinforced spring: Fig 2.25 It consists of steel helical spring bonded in a rubber body. The steel spring carrying only 20% of the load. 2.11(d) Progressive spring: Fig 2.26 It has initially an exceedingly small rate which rises rapi9dly as the central cavity closes 27
2.12 REVERSE ENGINEERING METHOD • Reverse engineering, also called back engineering, is the process by which a man- made object is deconstructed to reveal its designs, architecture, or to extract knowledge from the object. • Reverse-engineering is used for many purposes: as a learning tool; as a way to make new, compatible products that are cheaper and better version than what's currently on the market. • Adaptive design is the process in which the parameters of the existing design or engineering device is slightly modified to improve quality or to suit a new trend in the market. • So the role of Adaptive Engineering in our project is that, Mainly after having many concepts of MONO BIKE, we have adapted the only concept we have chosen to build and carried away with the further procedure as production drawing, CAD model preparation, Structural diagram design, design calculation for structural dimensions and other calculations Developed a Structural design from finalized existing Model image with the help of AUTO- CAD SOFTWARE by some entities like spline curve, line, circle 28
2.13 CONCEPT DESIGN • Conceptual design is an early phase of the design process, in which the broad outlines of function and form of something are articulated. It includes the design of interactions, experiences, processes, and strategies. It involves an understanding of people's needs - and how to meet them with products, services, and processes. • Common artifacts of conceptual design are concept sketches and models. • As it may refer to the early stage of designs, we were drawing the different kinds of concepts all over the work place which our college allotted us for project work place like these are the early outlines of our project on the Work Table, Black Board & on the Paper Sheet too. Drawn Master Plan on Black Board & used it as Bulletin Board Create an outline layout of a Mono Bike Aerial view on a table 29
The conceptual design of MONO BIKE 2.14 CAD MODEL PREPARATION AUTO CAD SOFTWARE is mainly used for detailed engineering of 3D models or 2D drawings of physical components, but it is also used throughout the engineering process from conceptual design and layout of products, through strength and dynamic analysis of assemblies to definition of manufacturing methods of components. So after completing the production drawing successfully, now it was the time to make a digital design output through CAD model preparation by AUTOCAD. These are the CAD images of the essential components of our project ROLLER 30
C- FRAME MODEL 31
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CHAPTER-3 METHODOLOGY 3.1 FABRICATION Metal fabrication is the creation of metal structures by cutting, bending, and assembling processes. It is a value-added process involving the creation of machines, parts, and structures from various raw materials. Typically, a fabrication shop bids on a job, usually based on engineering drawings, and if awarded the contract, builds the product. Large workshops employ a multitude of value-added processes, including welding, cutting, forming, and machining. As with other manufacturing processes, both human labor and automation are commonly used. A fabricated product may be called a fabrication, and shops specializing in this type of work are called fabrication shops. The end products of other common types of metalworking, such as machining, metal stamping, forging, and casting, may be similar in shape and function, but those processes are not classified as fabrication. 3.2 CASTING Fig 3.1 Final product Casting is a 7,000year-old process. Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. 33
The most versatile method for producing aluminum products is sand casting. The process starts with a pattern that is a replica of the finished casting. Virtually any pattern can be pressed into a fine sand mixture to form the mold into which the aluminum is poured. The pattern is slightly larger than the part to be made, to allow for aluminum shrinkage during solidification and cooling. As compared to die and permanent mold casting, sand casting is a slow process but usually more economical for small quantities, intricate designs, or when a very large casting is required. 3.3 Power hack saw: Fig 3.2 Cutting box pipe by using a power hack saw machine Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting diameters of more than 10/15mm is very hard work with a normal handheld hacksaw. Therefore, power hacksaws have been developed to carry out difficult and time-consuming work. The heavy ‘arm’ moves backward and forwards, cutting on the backward stroke. The metal to be cut is held in a machine vice which is an integral part of the base. Turning the handle tightens or loosens the vice. The vice is very powerful and locks the metal in position. When cutting is taking place, the metal and especially the blade heats up quickly. Coolant should be fed onto the blade, cooling it down and lubricating it as it cuts through the metal. Without the use of coolant, the blade will overheat and break/snap. This can be dangerous as the blade can break with a powerful force, shattering. 34
Blades of power hacksaws are graded according to the material they are made from and the number of teeth per inch. Top-quality blades are manufactured from High-Speed Steel. although there are cheaper alternatives such as carbon steel blades. In general, the number of teeth per inch (TPI) ranges from 14 to 24. The more teeth per inch - the smoother the cut Power hacksaws have electric motors that power the blade through a pulley system. Some have ratchet systems. The pulley system shown below shows how rotary power is transferred from the motor and changed to reciprocating motion, allow the blade to cut through the material. Most power hacksaws have two pulley wheels. If the belt is placed on the smaller pulley wheel the speed of cut will be fast. Changing the belt so that it runs around the larger pulley wheel will reduce the speed. 3.4 Electric power cutter: The electric power cutter is used to cut the metal plates as per the required dimensions. 3.5 Roll bending A roll bender is a mechanical jig having three rollers used to bend a metal pipe into a circular arc. The rollers freely rotate about three parallel axes, which are arranged with uniform horizontal spacing. Two outer rollers, usually immobile, cradle the bottom of the material while the inner roller, whose position is adjustable, presses on the top side of the material. Roll bending may be done to both sheet metal, bars, and tubes of metal. If a pipe is used, it is assumed to have a uniform cross-section, but not necessarily rectangular, as long as there are no overhanging contours, i.e. positive draft. Such bars are often formed by extrusion. The material to be shaped is suspended between the rollers. The end rollers support the bottom side of the bar and have a matching contour (inverse shape) to maintain the cross-sectional shape. Likewise, the middle roller is forced against the topside of the bar and has a matching contour to it. 35
3.5.1 Roll bending Operation: After the pipe is initially inserted into the jig, the middle roller is manually lowered and forced against the pipe with a screw arrangement. This causes the pipe to undergo both plastic and elastic deformation. The portion of the pipe between the rollers will take on the shape of a cubic polynomial, which approximates a circular arc. The rollers are then rotated moving the pipe along with them. For each new position, the portion of the pipe between the rollers takes on the shape of a cubic modified by the end conditions imposed by the adjacent sections of the pipe. When either end of the pipe is reached, the force applied to the center roller is incrementally increased, the roller rotation is reversed and as the rolling process proceeds, the pipe shape becomes a better approximation to a circular arc, gradually, for the number of passes required to bring the arc of the pipe to the desired radius. 3.6 Lathe machine operations: A lathe is one of the most versatile and widely used machine tools all over the world. It is commonly known as the mother of all other machine tools. The main function of a lathe is to remove metal from a job to give it the required shape and size. The job is securely and rigidly held in the chuck or in between centers on the lathe machine and then turn it against a single- point cutting tool which will remove metal from the job in the form of chips. 3.6.1Turning Turning is a machining process in which a cutting tool, typically, a non-rotary tool bit, describes a helix toolpath by moving more or less linearly while the workpiece rotates. the general process of turning involves rotating a part while a single-point cutting tool is moved parallel to the axis of rotation.[1] Turning can be done on the external surface of the part as well as the internal surface (the process known as boring). The starting material is generally a workpiece generated by other processes such as casting, forging, extrusion, or drawing. 3.6.2 Taper Turning: When the diameter of a piece changes uniformly from one end to the other, the piece is said to be tapered. Taper turning as a machining operation is the gradual reduction in diameter from one part of a cylindrical workpiece to another part. Tapers can be either external or internal. If a workpiece is tapered on the outside, it has an external taper; if it is tapered on the inside, it has an internal taper. There are three basic methods of turning tapers with a lathe. Depending 36
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