on the degree, length, location of the taper (internal or external), and the number of pieces to be done, the operator will either use the compound rest, offset the tailstock, or use the taper attachment. With any of these methods the cutting edge of the tool bit must be set exactly on center with the axis of the workpiece or the work will not be truly conical and the rate of taper will vary with each cut. 3.6.3 Threading: Thread cutting on the lathe is a process that produces a helical ridge of the uniform section on the workpiece. This is performed by taking successive cuts with a threading tool bit the same shape as the thread form required. 3.7 Metal arc welding: Shielded metal arc welding (SMAW), also known as manual metal arc welding (MMA or MMAW), flux shielded arc welding, or informally as stick welding, is a manual arc welding process that uses a consumable electrode covered with a flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. The workpiece and the electrode melts forming a pool of molten metal (the weld pool) that cools to form a joint. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination. Equipment: Shielded metal arc welding equipment typically consists of a constant current welding power supply and an electrode, with an electrode holder, a ground clamp, and welding cables (also known as welding leads) connecting the two. 37
Electrode The choice of the electrode for SMAW depends on some factors, including the weld material, welding position, and the desired weld properties. The electrode is coated in a metal mixture called flux, which gives off gases as it decomposes to prevent weld contamination, introduces deoxidizers to purify the weld, causes weld-protecting slag to form, improves the arc stability, and provides alloying elements to improve the weld quality. Electrodes can be divided into three groups those designed to melt quickly are called \"fast-fill\" electrodes, those designed to solidify quickly are called \"fast-freeze\" electrodes, and intermediate electrodes go by the name \"fill-freeze\" or \"fast-follow\" electrodes. Fast-fill electrodes are designed to melt quickly so that the welding speed can be maximized, while fast-freeze electrodes supply filler metal that solidifies quickly, making welding in a variety of positions possible by preventing the weld pool from shifting significantly before solidifying. The composition of the electrode core is generally similar and sometimes identical to that of the base material. But even though some feasible options exist, a slight difference in alloy composition can strongly impact the properties of the resulting weld. This is especially true of alloy steels such as HSLA steels. Likewise, electrodes of compositions similar to those of the base materials are often used for welding nonferrous materials like aluminum and copper. However, sometimes it is desirable to use electrodes with core materials significantly different from the base material. For example, stainless steel electrodes are sometimes used to weld two pieces of carbon steel and are often utilized to weld stainless steel workpieces with carbon steel workpieces. Electrode coatings can consist of some different compounds, including rutile, calcium fluoride, cellulose, and iron powder. Rutile electrodes, coated with 25%–45% TiO2, are characterized by ease of use and good appearance of the resulting weld. However, they create welds with high hydrogen content, encouraging embrittlement and cracking. Electrodes containing calcium fluoride (CaF2), sometimes known as basic or low-hydrogen electrodes, are hygroscopic and must be stored in dry conditions. They produce strong welds, but with a coarse and convex- shaped joint surface. Electrodes coated with cellulose, especially when combined with rutile, provide deep weld penetration, but because of their high moisture content, special procedures must be used to prevent the excessive risk of cracking. Finally, iron powder is a common coating additive that increases the rate at which the electrode fills the weld joint, up to twice as fast. 38
To identify different electrodes, the American Welding Society established a system that assigns electrodes with a four- or five-digit number. Covered electrodes made of mild or low alloy steel carry the prefix E, followed by their number. The first two or three digits of the number specify the tensile strength of the weld metal, in thousand pounds per square inch. The penultimate digit generally identifies the welding positions permissible with the electrode, typically using the values 1 (normally fast-freeze electrodes, implying all position welding) and 2 (normally fast-fill electrodes, implying horizontal welding only). The welding current and type of electrode covering are specified by the last two digits together. When applicable, a suffix is used to denote the alloying element being contributed by the electrode Common electrodes include the E6010, a fast-freeze, all-position electrode with a minimum tensile strength of 60 ksi (410 MPa) which is operated using DCEP and provides deep weld penetration with a forceful arc capable of burning through light rust or oxides on the workpiece. E6011 is similar except its flux coating allows it to be used with alternating current in addition to DCEP. E7024 is a fast-fill electrode, used primarily to make flat or horizontal fillet welds using AC, DCEN, or DCEP. Examples of fill-freeze electrodes are the E6012, E6013, and E7014, all of which provide a compromise between fast welding speeds and all-position welding. 3.8 LIST OF MACHINES USED IN PROJECT 1.) LATHE MACHINE: - Tabular 3.1 Centre height 170 mm Distance between center 600 mm Maximum speed 2000 mm 39
Motor Power 500 kW 2.) DRILL MACHINE:- 50 mm Tabular 3.2 35-195 rpm Capacity 412 * 412 mm Range of Spindle Speed Working space on the base Push cut horizontal type 175-900 mm 3.) SHAPER MACHINE:- 0.2-5 mm Tabular 3.3 500 kW Type Stroke 180 mm Power Feed 125 mm Motor 75-150 mm 4.) HACKSAW MACHINE: - 350 mm Tabular 3.4 1 HP Maximum dia. Of root of cut Maximum square section to cut Stroke Blade Size Motor 40
5.) ARC WELDING MACHINE: - ARC Welding Machine - DC ARC Welding Machine - (Inverter Based - 3Phase) Specifications QIM-400 Input Supply 380-440 V, 3Ph, 50/60Hz Welding Current (A) 20 - 400 O. C V 65 - 75 V DC Max. Rated (KVA) 17 Tabular 3.5 3.9 LIST OF HAND TOOLS AND EQUIPMENT USED • Single point cutting tool • Drill bit • Vernier Calliper • Hacksaw • Files • Measuring Tap • Hammers • Punch • Screw Driver • Hand grinding machine • Hand Drilling machine • T joint 41
• Oxy-Acetylene gas welding system • Grease and oil • Paint 42
CHAPTER-4 IMPLEMENTATION While performing the project it was divided into stages of the procession. The stages are as follows: 1. Making a blueprint 2. Manufacturing of Transmission components 3. Fabrication of Chassis 4. Assembly Stage 1: Making a Blueprint Making a Blueprint the first phase of the project involves all layout's processing the project. Initially it was very to make an outline or a blueprint of a project so that could be forecasted. The only thing is that was found in the forecasting of the project was undetermined body weight. The Blueprint was mainly to observe the design output. Hence the design output was in favor of the project and is a sign of continuity towards the project Fig 4.1 Mono bike schematic view 43
Fig 4.2C-FRAME Fig 4.3 TRANSMISSION 44
Fig 4.4 PROFILE OF BOTTOM FRAME Fig 4.5 ROLLERS Stage 2: Manufacturing of transmission components After the successful accomplishment of the project blueprint, the project was ready to process and further process is to begin. The second stage of the project consists of the following processes, they are: Transmission DRUM Rollers 45
Rollers calculations From bending moment equation ������ = ������ where z = ������ ������ 4 )������4������ 0− ( ������ 32 ������0 M= bending movement = ������������ 4 ������ = bending stress Bending stress of steel pipe is 240 mpa Tension in tire = 71612.7 N The tire tension is acting as load on pipe so the Torque = Tension of tire * ½ of length of pipe Assuming length is 160 mm and outer dia is 90 mm Torque = 5729.01 NM Bending moment M = ������������ = 5729.01∗0.16 = 229.1 Nm 4 4 Di = ((������∗32∗������0) - ������04)14 ������∗������ Di = 88 mm From hoop stress ������������ = T (������022(���−���0)������2������2) T = Torque ������0=������������������������������ ������������������������������������=0.045 ������ ������������=������������������������������ ������������������������������������=0.043 ������ ������������ = 131.83 ������������ ������2 Longitudinal stress of cylinder ������������ = T ((������0)(2������0−)(2������������)2) σl = 65.91 N/m2 So the longitudinal stress and hoop not exceed the normal stress. Hence design is safe 46
4.0 Crawler (Tire) Fig 4.6 Purchased tire overview Fig 4.7 Cutting the tire into as per required 47
Fig 4.8 after removing the outermost layer 265/65R17 these are the tire dimension we purchased in the second-hand spare market In open words, it is a tire of Toyota Fortuner car Calculating tension in tire Tire dimension w= 0.245 m t = 0.02 m l = 4.87 m Density of rubber ρ = 1140 ������������/������3 Allowable stress in rubber σ = 15*106 N/������2 Speed N = 837 rpm Drum dia = 0.19n Velocity v = ������������������ = ������∗0.1690∗837= 8.33 m/sec 60 Coefficient of friction ������ = 0.54- 42.6 = 0.275 152.67+������ θ angle of contact between the belt and each pulley ������ = 2.61 ������������������ θ = 2.07 rad 48
Maximum tension in tight side of the belt T= ������. ������ = 15 ∗ 245 ∗ 20 = 73500 ������ Mass of the belt per meter length M= a*l*ρ= 27.20 kg/m Centrifugal tension ������������ = ������������2 = 1887.3 N Tension in tight side of belt ������1= T - ������������ = ������1 71612.7 N We know 2.3 log (������1) = ������������ ������2 ������1 = 2.758 by Antilog ������2 ������2 = tension in slack sight of the belt ������2 = 25965.4 N Total tension in slack side ������3= 27852.7 N 49
4.1 Building the transmission drum: Fig 4.9 ALUMINUM DRUM AFTER CASTING The transmission drum is made up of aluminum by a process called casting. The drum rotates the crawler by the use of surface contact friction. It consists of a metal plate inside in it with the diameter of 170 mm and thickness of 15mm and a 40mm hole is drilled inside in it for placing a shaft of material EN 31 STEEL ALLOY with a diameter of 20mm and length of 330mm, to its both ends a ball bearing 6203 2 RS is connected which is fixed to the chassis. The metal plate is connected to the aluminum drum from the inside at the center, by using countersink screws M 8 of 5. In between the shaft a sprocket and chain system are connected to the engine transmission system. 50
Fig 4.10 AFTER LATHE OPERATIONS Fig 4.11 MAKING HOLES Fig 4.12 51
Fig 4.13 4.2 Rollers In this project we have used IDLER type of rollers, which is used to aid in supporting of weight and impact of materials being transported along the belt. They also assist in a smooth and continuous movement of material along the belt and they can self-align and assist in maintaining the belt tracking. Fig 4.14 We made these rollers by taking a hollow 90mm mild steel round pipe and cutting them into 5 equal pieces over a length of 160mm and then we have created flanges at both ends and drilled to 18mm and bore to the length of 40mm and press-fitted Deep groove ball bearings 6203 2 RS 17x40x12mm at both ends of 5 pieces with hydraulic press fit and welded the flanges at the ends of the roller. Then we inserted deep groove cut to ensure that it is locked with an external 52
circlip of Diameter 17mm at the ends to an MS rod of Diameter 17mm and length of 400mm into the roller and threaded from end to the middle for the length of 80mm. Fig 4.15 Stage 3: Fabrication of Chassis After the manufacturing of the main elements of the project which is a transmission section, then it comes to the essential part of the project, that is Chassis: A vehicle frame, also known as its chassis, is the main supporting structure of a motor vehicle, to which all other components are attached, comparable to the skeleton of an organism. The main functions of a frame in motor vehicles are: 1. To support the vehicle's mechanical components and body 2. To deal with static and dynamic loads, without undue deflection or distortion. Typically, the material used to construct vehicle chassis and frames is carbon steel; or aluminum alloys to achieve a more light-weight construction. In the case of a separate chassis, the frame is made up of structural elements called the rails or beams. These are ordinarily made of steel channel sections, made by folding, rolling, or pressing steel plate. There are three main designs for these. If the material is folded twice, an open-ended cross- section, either C-shaped or hat-shaped (U-shaped) results. \"Boxed\" frames contain closed chassis rails, either by somehow welding them up or by using premanufactured metal tubing. 53
The third stage of the project consists of chassis building, as is it is the major part of the project as it was consisting of many different frames as follows: C- frame Engine frame Bottom frame C-frame: The c-frame will be the frontier part of a mono bike where the three (3) rollers will be placed making it a crucial part of the chassis. Fig 4.16 The c-frame is usually built by a process called bending, on a machine called ROLL BENDING MACHINE, where the curvature radius is about 300mm, and the distance between two ends when bent 420mm whose OD is 30mm and ID is 24mm of 2 pieces. They are joined together by the two rectangular section pipes of length 270mm. 54
Fig 4.17 Engine frame: The engine frame consists of an adjustable system with box pipes of MS in which one end 40*40 mm is joined to c-frame and another end 50*50mm welded to the engine cover. Fig 4.18 ENGINE COVER It is a very significant element in the chassis where it holds the total seating arrangement, where the rider weight is directly applied to it. It is also a connection between the c-frame and supports the transmission system, making it a vital element. 55
Fig 4.19 Bottom frame: The bottom frame carries two rollers in which it also connects the c-frame which is the frontier part of the mono bike. The suspension is connected to it. it completes the whole chassis. Fig 4.20 Bottom frame 56
Engine frame calculation • The material used in engine frame is mild steel • The yield strength of MS is 248 mpa • Assuming the factor of safety is 4 • The allowable stress σa = 65 N/mm2 • Assuming the engine frame as simply supported beam 1079 N CB A 196 N RB 175 mm 450 mm • From the diagram The Bending Movement M= 20.94*10 N/mm • Area of cross section A = 50-44 = 564 mm • Movement of inertia I = 50-44/12 = 208.49*10 mm • From bending equation M/I = σ/y σ= bending stress , y = 1/b = 25 mm, σ= m*y/I σ= 20.94*10*25/208.49*10 σ= 2.51 N/mm • Hence the bending stress is not exceeded than the allowable stress, so the design is safe Cross section of frame 57
Stage 4: Assembling The 2-stroke 69 ccs (Cubic centimeter) auto transmission, which was not in the working condition was purchased and was replaced by the essential parts that made the engine alive by making it again in the working condition. Fig 4.21 ENGINE Fig 4.22 after turning into working condition 58
The following parts are replaced: Spark plug and spark plug cap Ignition lock Coil power wire Carburetor float pin Fuel pipe Carburetor jet Air filter Wiring kit Magnetic cover Engine cover fan The rollers were built in a total of five (5) pieces. The three rollers were placed in the frontier part of the mono bike that is c-frame. The two of the rollers were placed in the bottom frame by using the nut and nut M17. We have joined the chassis parts that are c-frame, engine frame, and bottom frame by using the welding process called arc welding. the transmission drum is also connected to the engine frame by welding. The suspension system is fixed on the bottom frame. The transmission shaft of the engine and transmission drum shaft is connected with a chain sprocket system of diameter 215mm of the driven sprocket and the diameter of driver sprocket is 60mm Transmission shaft assemble To transmitted the power from engine to crawler we used chain mechanism. The driven chain sprocket is placed on the shaft where on that shaft drum is also mounted. both chain sprocket and drum are locked by square key. The two ends of the shaft were mounted plumber blocks as shown in the below figure. 59
Fig 4.23 TRANSMISSION ASSEMBLE 4.24 Inserting flange hub into chain sprocket 60
Fig 4.25 building the chassis Fig 4.26 Assemble of transmission and chassis 61
Chapter 5 CONCLUSION & FUTURE WORK 5.1 CONCLUSION Conclusion for the futuristic scope Monowheel or Monobike is a personal transporter that can carry a person to move from one place to another within large areas like industries, space centers, shopping complex, outdoor stadiums like (Cricket, Golf area, football, etc..) not only stick with large areas we hope for small areas too like going to neighbors home, essential goods, Mini Works, etc. and also big hope for Serious transportation too if everything runs smoothly. We have built a compact, efficient, powerful, and cheaper version with keeping budget in mind This Monobike is an extremely affordable budget variant and any person can get hands-on it. Since it has fewer components it can be easily dismantled and also less maintenance cost We contribute our efforts for nations proud by building like such futuristic models ahead and learning great concepts and critical analyzing if we got good sponsorship and encouragement 5.2 FUTURE WORK These are the most amazing innovative bikes, here we step into the future with those who love blending style and functionality with pioneering design and technology. They are designed from scratch to inspire awe, keeping production feasibility. Some of them may even hit the roads of reality in the coming future. It’s not what we create and force on the market, it’s how we allow ourselves to be changed by the act of creation looking back at earlier cultures where stone tools evolved to a highly refined art form as a testimony to the stable culture that must have existed then. An Engineer's passion is in how the culture we should be building now, might offer the same stability for a wider range of people. As a Mechanical Engineer we could say They’re all beautiful. we hope they hurry up and manufacturing these concepts into tangibility. 62
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