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CHAPTER 1: INTRODUCTION

A controlling wheel is additionally called as a driving wheel or hand haggle is a kind of directing control in all vehicles and vessels ships and pontoons.

Directing wheels are utilized in nearly of all the cutting edge vehicles, including all the large scale manufacturing autos and transports, light and substantial trucks and tractors. The controlling wheels is the piece of the directing framework, which is controlled by the driver to the remainder of the guiding framework reacts to such driver inputs. This can be through the direct mechanical contact as a recycling ball or rack and pinion guiding apparatus, with or without the help of the water driven power guiding, HPS or in a portion of the cutting edge generation autos with help of PC controlled engines which are known as Electric Power Steering.

Close to the beginning of the eighteenth century, an enormous number of ocean vessels showed up as the ship's wheel structure, yet students of history are misty that the way to deal with guiding wheel was first utilized. The main vehicles were controlled with a tiller, yet in 1894 Alfred Vacheron partook in the Paris–Rouen race with a Panhard 4 hp model which he had fitted with a guiding wheel. That is accepted to be one of the most punctual jobs of guideline.

From 1898, the Panhard Levassor vehicles was outfitted as a standard with directing wheel. Charles Rolls presented the principal vehicle in Britain fitted with the guiding wheel when he imported the 6 hp Panhard from France in 1898.

Arthur supplanted the tiller with a slanted guiding wheel for Panhard vehicle as he intended for the 1898 Paris Amsterdam Paris race which ran 7–13 July 1898. In 1898, Thomas B Jeffery and one of his child Charles T. Jeffery, built up a two progressed trial vehicles highlighting of front-mounted motor, just as a directing wheel that was mounted on the left-hand drive. Be that as it may, the early automaker received the more regular back motor and tiller-guiding format for the main created mass-delivered Ramblers in 1902.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 1 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS The after year Rambler Model was to a great extent unaltered, aside from it came furnished with a tiller right off the bat in the years, yet with a directing wheel before the finish of 1903. By 1904 all Ramblers highlighted controlling wheels. Inside 10 years, the guiding wheel had completely supplanted the tiller in nearly autos. At the request of Thomas B. Jeffery, the situation of the driver was additionally moved to one side hand drive of the vehicle amid the year 1903 Rambler creation started. A large portion of the other vehicle creators started offering autos with left-hand drive, in 1910. Not long after the vast majority of the autos in the U.S. changed over to left hand drive.

Directing wheels for traveler autos are structured commonly round and are mounted to guiding segment by the assistance of a center point associated with the external ring of the controlling wheel by at least one spokes ie. single talked wheels being a fairly uncommon special case. In nations where vehicles must be drive in the left hand side the controlling wheel is regularly on the correct hand side of the vehicle ie. right-hand drive or RHD the opposite applies in nations where autos drive on the correct side of the street ie. left-hand drive or LHD. Notwithstanding the utilization of directing, the controlling wheel is the typical area for a catch to initiate horn. The directing wheels are inflexible and mounted on the non-collapsible controlling section. This course of action expanded the danger of skewering the driver if there should arise an occurrence of serious accident.

The principal collapsible guiding segment was designed in the year 1934 ,yet was never effectively promoted. By 1956 Ford left with a security directing wheel that was set high over the post with spokes would flex, however the segment was still in unbending. In 1968, United States guidelines executed concerning the adequate rearward development of the controlling wheel if there should arise an occurrence of the accident. Collapsible directing sections was required to satisfy the guideline.

Current power directing has practically all generally depended on pressure driven framework, albeit electrical frameworks are consistently supplanting the innovation. Mechanical power guiding frameworks have been created in 1952, however their weight and intricacy invalidate the advantages that they can give.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 2 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Tilt Wheel

The first tilt wheel was worked by Edward James Lobdell in the year mid 1900s. A seven position tilt wheel was first presented by General Motors in 1963 for all traveler vehicle divisions aside from, Chevrolet which got the tilt wheel in 1964.This tilt wheel was provided to the next US automakers (with the exception of Ford). Initially an extravagance choice in vehicles encourages the tilt capacity to modify the guiding wheel by moving the wheel through bend in an all over movement. Tilt Steering Wheels will depend upon a fastener joint situated in guiding segment just beneath directing wheel. By dis-connecting with the wrench lock to the wheel can be balanced upward or descending while the controlling segment stays stationary beneath the joint.

A few structures place the rotate marginally forward to the segment, taking into account the decent measure of vertical development of controlling wheel with the little real tilt, while different plans place a turn practically inside the directing wheel permitting to alteration of the point of the guiding wheel with no adjustment in its stature.

Traveler vehicle guidelines executed by the U.S. Division of Transportation required the locking of guiding wheel pivot or transmission secured park to prevent engine vehicle burglary in many vehicles, this is cultivated when the start key is expelled from the start lock.

There are two kinds of intensity guiding frameworks utilized in vehicles. The rack and pinion guiding framework and the regular or fundamental directing apparatus framework. The rack and pinion controlling framework is the most usually utilized power guiding framework in the present vehicles. The guiding shaft turns a rigging that proceeds onward the rack side to side, using a power unit manufactured straightforwardly in the rack get together. The guiding apparatus framework is for the most part utilized frequently by trucks, as it has a progression of steel balls that go about as moving strings between the controlling shaft and the rack cylinders. The controlling wheel shaft interfaces with apparatus get together and a progression of connections or arms to turn the wheels to one side or right.

Adjustable steering column

Interestingly a customizable directing section permits controlling wheel tallness to be balanced with just a little measure of helpful change in tilt. The vast majority of the

Department of Mechanical Engineering, NHCE, Bengaluru. Page 3 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS frameworks work with the pressure locks and electric engines rather than the wrench components, the last might be fit for moving the retained position when a given driver utilizes the vehicle, climbing and forward for section or exit.

Telescope wheel

Numerous British autos were offered an extending directing wheels that was required releasing the locknut before alteration, many utilizing the Douglas Adjustable Steering Wheel. In 1949, the Jaguar XK120 was presented another directing wheel provided by the Bluemel that was a driver-customizable, by just releasing the sleeve around a section by hand. The 1955-1957 Ford Thunderbird had a comparative plan with 3 crawls of the absolute travel. In 1956, the movement was confined to 2 inches as it were.

A patent was recorded in regards to the extending guiding wheel in the year July 1942 by Bernard Maurer, of Saginaw Steering Gear Division of General Motors currently called as Nexteer Automotive, yet GM would not offer their very own extending wheel until the introduction of the tilt or telescope wheel was offered as an alternative in 1965 Cadillacs. The GM section was discharged by contorting the locking ring encompassing a middle center point and offered to a 3 inch scope of alteration.

Swing-away steering wheel

Presented on the 1961 Ford Thunderbird and made accessible on other Ford items all through the 1960s, the Swing-without end guiding wheel permitted the controlling wheel to move nine creeps to right when the transmission selector was in Park, to make driver exit and passage simpler.Presented by Ford in 1967 updates after to the Federal Motor Vehicle Safety Standards necessities. However, it was an update to the swing- ceaselessly controlling wheel, which did not satisfy refreshed wellbeing guidelines it offers constrained development yet added comfort because of the programmed fly over capacity over its antecedent.

Tilt-away steering wheel

Introduced by Ford in 1967 after updates to Federal Motor Vehicle Safety Standards requirements. Though, it was an update to the swing-away steering wheel, which did not meet updated safety standards it offers limited movement but added convenience due to the automatic pop over function over its predecessor.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 4 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Quick release hub steering wheel

Some controlling wheels can be mounted on a separable center a brisk discharge center. The directing wheel would thus be able to be expelled without the utilization of apparatuses, basically by squeezing a catch. The framework is abundantly used to the thin divided hustling vehicles, for encouraging the driver to get in and out, and in different autos additionally, as an enemy of robbery gadget.

Fig 1.1 Steering wheel Armature Ring

Directing proportion, alludes to a proportion between the turn of controlling wheel in degrees or handlebars and the turn of wheels. The controlling proportion is a proportion of the quantity of degrees to turn of the directing wheel to various degrees the wheel(s) turn thus. In cruisers, delta tricycles and bikes, the controlling proportion is alluded as constantly 1:1, in light of the fact that the guiding wheel is fixed to front wheel. A directing proportion of x:y intends to that of a turn of the guiding wheel x degree(s) causes the wheel(s) to turn in y degree(s). In the majority of the traveler vehicles, the

Department of Mechanical Engineering, NHCE, Bengaluru. Page 5 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS proportion is somewhere in the range of 12:1 and 20:1. For instance, on the off chance that one complete turn of the guiding wheel is, 360 degrees which makes the wheels turn in 24 degrees, the proportion is then considered as 360:24 = 15:1.

A higher guiding proportion implies, that directing wheel is gone more to get the wheels turning, however it will be a lot simpler to turn the controlling wheel. A lower directing proportion implies that, the guiding wheel is gone less to get the wheels going to be more enthusiastically to turn the controlling wheel. Bigger and heavier vehicles will frequently have a higher guiding proportion, which will make the directing wheel to turn simpler. In the event that a truck has a low controlling proportion, it would be difficult to turn the directing wheel. In typical and lighter vehicles, the wheels are simpler to turn so as the guiding proportion doesn't need to be high. In race autos the proportion is ordinarily low in light of the fact that the vehicle must react to the controlling information a lot quicker than in ordinary autos. The controlling wheel is along these lines harder to turn.

Steering wheel dimensions:

 Armature Dia – 362mm

 Hub – OD (30mm) ID (15mm)

 4* and 8* clock spoke – 12mm

 Base plate – 1mm thickness

Department of Mechanical Engineering, NHCE, Bengaluru. Page 6 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

CHAPTER 2: LITERATURE REVIEW

1. Experimental Investigation on Corrosion Effect onMechanical Properties of Buried Metal Pipes

Yingbo Hou,1 Deqing Lei,1 Shujin Li,1 Wei Yang,1 and Chun-Qing Li2

Pipelines are fundamental foundation that assume a huge job in a country's economy, and personal satisfaction. The greater part of funnels are made with metals, cast iron and steel, and found underground in soil. It is evaluated that 85% of the water dissemination funnels are solid metal and steel materials. Because of the long haul administration and introduction to forceful condition in soil, maturing and decay of metal funnels, have brought about a surprising high rate of disappointments. As is all around refreshing, the outcome of pipe disappointments will be socially, monetarily, and ecologically cataclysmic, bringing about enormous interruption of every day life, extensive financial misfortune, boundless flooding, and consequent natural contamination and even losses and thus forward. In this manner, we require a well- supported need to completely research the reasons for pipe disappointments. Experience and examination of pipe disappointments recommend to the consumption of metals, both cast iron and steel, is the most prevalent reason for pipe disappointments. Since erosion is perspective to practically all pipe disappointments, it has turned into a worldwide issue for all partners, specifically architects and resource administrators of covered metal channels. All things considered, extensive research has been embraced in the previous couple of decades on consumption of metal channels, for cast iron funnels, as spoke to prominently by Doleac et, Dean Jr. what's more, Grab, O'Dea et al., Randall- Smith et al., Kirmeyer et, Camarinopoulos et al., Sadiq et, Panossian et.. Because of various conditions, the instruments of erosions are distinctive for inside and outer surfaces of the pipe. Pipe erosion in soil is a communication between the pipe materials and soil environment.Moisture, temperature, pH esteems, mineral salt substance, sulfides, organics, hastens, etc are contributing main considerations that reason to outer consumption. It additionally relies upon the physical and concoction qualities of the dirts. Little research has been attempted with the impact of consumption in mechanical

Department of Mechanical Engineering, NHCE, Bengaluru. Page 7 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS property change of pipe materials, and no examination has been led on erosion impact to the crack durability of pipe materials.

As it is outstanding, it is the mechanical properties of the pipe materials that administer the conduct and possible disappointment of the channels. It is in this way basic to altogether look at the impact with metal consumption on its mechanical properties. The comprehension and information of consumption prompted weakening of mechanical properties on metals can avert future disappointments of metal channels. There are two primary methods of pipe disappointment by break and because of the decrease of the divider thickness of the funnels and by crack because of the pressure fixation at the tip of cracks,corrosion pits or as a rule to absconds in the channels. The mechanical properties comparing to the two disappointment modes are rigidity and crack durability of the metals. A review of disappointments of trunk mains in administration uncovers that most solid metal central conduit disappointments are of break type that is, the disappointment is brought about by the development of a split and ensuing breakdown of the pipe. It is in this way basic to contemplate the weakening of rigidity and crack strength of the metals to empower more and exact forecast of pipe disappointments.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 8 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 2. Corrosion Studies Of Selected Metals From Industrial Effluent In Pune Midc, India Lolage Y P , Pawar P R , Yannawar V B And Bhosle A B

Consumption is the incomplete disintegration of the materials with the metallic channels erosion. Water spillage in drinking establishing the treatment and supply frameworks, tanks, water dispersion frameworks is a major issue for channels, valves and siphons. Significant issue concerning both general wellbeing and Corrosion is of the etiological variables of spillage and practical viewpoints .Corrosion is of the etiological elements of spillage a dun represented water in conveyance systems of water identified with its pH, alkalinity, hardness, temperature, broke down oxygen, carbon dioxide, all out disintegrated solids and other physical, compound and organic elements .Corrosion in steel or cast iron water appropriation channels, isn't in charge of the decimation of pipe material yet in addition for crumbling of consumable water quality because of undesirable concoction and biochemical responses happening in the dissemination frameworks .

Corrosion estimations could perform by immediate or circuitous techniques. The circuitous strategies incorporate translating information from water testing and examination, buyer protests and erosion files, to decide consumption inclination, rather than genuine estimating of erosion rates.The three noteworthy issues emerging from uncontrolled procedure waters are biofouling, erosion and scale stores. Metal pipes materials are bound to erode if the water has a low pH (is acidic) or if the alkalinity (the capacity of the water to balance out the pH) is excessively low. The connection among pH and alkalinity and how they are factors in deciding if water is destructive, scale- framing, or impartial.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 9 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

3. Corrosion Protection of Iron Alloy Using Peganum harmala Extract as Inhibitor in Acidic Solution Khulood Abid Al-Saadie1*, Hayfaa Ameer Abas1, Haider Abdulkareem Yousif Almashhdani2

Erosion is perceived as the main life restricting plant corruption component and displayed by most building materials in about all conditions. There are various strategies for controlling the erosion of metals however the utilization of inhibitors is as yet a standout amongst the best techniques for ensuring metals against consumption. Numerous natural mixes are utilized as erosion inhibitors for metals in acidic situations. Erosion inhibitors are substance that when adsorbed onto the metal-arrangement interface, hinders the destructive material from coming into contact with metal.The extricates from the leaves, seeds heartwood, bark root and product of the plant have been accounted for to restrain metallic consumption in the acidic media. The plant separates become significant as eco-accommodating, efficient, promptly accessible and inexhaustible wellsprings of powerful erosion inhibitors.Pergamum harmala is discovered developing wild in the center and northern piece of Iraq. The plant is wealthy in the alkaloids and contains up to 4% of alkaloids. The concoction structures of these mixes. Seeds and roots contain the most elevated amounts of alkaloids with low dimensions in stems and leaves, and missing in blossoms. Harmine and harmaline aggregated in dry seeds at 4.3% and 5.6% (w/w), individually and 0.6% of harmalol. Carbon steel is one of the significant development materials broadly in substance and associated ventures for treatment of corrosive, soluble base and salt arrangements and generally utilized in the greater part of the concoction businesses because of its ease and accessibility for manufacture of different response vessels. It experiences serious erosion in forceful condition. Accordingly, the need emerges to look at their consumption conduct in order to diminish or stop their erosion. Corrosive has been utilized for boring activity, pickling shower and in de-scaling process.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 10 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 4. Corrosion study of mild steel, tor steel and CRS steel by weight loss method V. R. Rathi, b S. D. Nirmal* and a S. J. Kokate

Corrosion is the ruinous assault on a metal or a metal compound by concoction or electrochemical response with its condition. Iron is utilized as tempered steel for making cutlery, clinic and nourishment administration gear. Carbon steel is the most widely recognized, least expensive and most adaptable metal utilized in industry. Because of wide scope of utilizations of combination in our everyday life. The erosion investigation of metal in an explanatory significance. Erosion is crumbling of material into its constituent molecule because of substance response with its environment. Debilitating of iron because of oxidation in the iron iotas is an outstanding case of electrochemical erosion.

Most basic alloys erode just from presentation to the dampness present in air. In any case, the procedure can be emphatically influenced by the introduction to specific substances. Erosion can be thought locally to frame a pit or split, of it can stretch out over a wide territory to create general crumbling. There are various components impacting erosion, for example, acids, oxidizing operators, and temperature. Despite the fact that various components are in charge of early misery in strengthened solid structure it is seen that in most of cases it is on the grounds that erosion of steel.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 11 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 5. Energy Absorption Properties Of A Steering Wheel Armature During Impact William Altenhof, and Saverio Paonessa

The vitality assimilation capacities of explicit locales of a three talked aluminum armature is examined in this exploration through limited component techniques. Test sway testing, utilizing a drop to testing gadget, was led to research impacts between an inflexible plate and a three talked guiding wheel armature. To increase further understanding into the vitality retention abilities of the armature, very nitty gritty limited component models were created and reenacted under indistinguishable testing parameters. Notwithstanding give stacking and relocation data, the numerical reproductions can deliver an essentially more measure of data amid the effect, particularly concerning vitality ingestion. This examination delineates numerical reproductions can precisely foresee tentatively discoveries and, above all, the vitality consumed by specific districts of the controlling wheel armature is reliant on the effect stacking conditions.

The structure and advancement of high vitality engrossing controlling wheel armatures is the essential purpose behind this examination. The guiding wheel armature is the "skeleton" of the directing wheel which underpins most gadgets connected to the controlling wheel (counting the airbag, horn, car switches, and so forth.). This work centers around better understanding the vitality retaining capacities of a directing wheel armature and how the vitality engrossing limit fluctuates over the armature. Despite the fact that work has been directed in the past on structure enhancement of armatures for vitality assimilation, practically zero work has been distributed examining the vitality engrossing capability of different areas of the armature.

This examination is led in two stages: right off the bat, approval of limited component models (FEM) is performed and after that an investigation on the vitality engrossing qualities of the skeleton is led. The approval of a three talked guiding wheel armature. FEM is practiced by examinations with exploratory testing results. The discretization of the FEM of the three talked guiding wheel skeleton is then performed and an examination into the vitality engrossing capacities of the different areas are explored.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 12 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 6. Effect of Ti on the Mechanical Properties and Corrosion of Cast AZ91 Magnesium Alloy Xiulan Ai* and Gaofeng Quan

As the a large portion of the promising lightweight materials, magnesium composites have high explicit quality and explicit firmness, great yield quality, fantastic machinability and great damping limit. So increasingly more magnesium amalgam items have been utilized in the vehicles, aviation and correspondence ventures. AZ and AM arrangement of amalgams contribute about 90% of every auxiliary utilization of magnesium. AZ91D composite has been utilized to manufacture an assortment of car parts, for example, cam covers, bewilders, oil connectors, grasp lodgings, directing wheels, etc. AM60 and AM50 amalgams are every now and again utilized to make the instrument boards, guiding wheel armatures, and seat risers and so on. Be that as it may, complex hard and weak stages for the most part shaped at grain limits they weakened the mechanical properties of magnesium composites. At same time consumption constrains the utilization of magnesium compounds. A few investigations have demonstrated that the erosion conduct is essentially affected by microstructure, especially the sum and appropriation of the intermetallic stages - Mg17Al12 .

Ti component has an amazing properties, for example, high erosion opposition and great mechanical properties etc.Previous work demonstrated Ti component could refine the as-cast microstructure and changed the morphology of stages. The present examination is focused on the considering impact of Titanium component in microstructure mechanical properties and consumption conduct of cast AZ91 amalgams.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 13 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 7. Real Time Non-Destructive Testing Methods of Welding Paul Kah

In light of the need to advance the weld quality, conventional assessing takes quite a while which causes an expansion in the expense of items and once in a while makes reviewing impossible.Solution to this is constant examination which can distinguish the nature of weld following or at the season of creation. Non-dangerous testing (NDT) strategies recognize breaking, porosity, deficient infiltration, considerations, just as an absence of sidewall combinations and comparable imperfections. The nature of welds is ending up progressively significant according to the client desires. Items and parts are relied upon to be of high caliber and not to bomb startlingly. Thus researchers and architects have concentrated towards discovering quick, proficient, and practical strategies for weld quality assessment and early imperfection identification.

The point of this work is to for the most part research the ideas of various techniques for non-damaging testing for the welding business, for example, radiography, vortex flow strategy, and ultrasonic testing. These techniques are sufficiently adaptable to distinguish a wide range of imperfections.. Every technique is given a point by point portrayal. The favorable circumstances and detriments of the strategies light up the advantages and potential uses of every strategy. The last piece of the work incorporates an examination of the considerable number of strategies as far as their standards, ease of use and plausibility for suggestion in various welding forms.

The consequences of the examination demonstrates that an ideal technique for testing ought to be picked for each welding application. The decision of an ideal strategy relies upon the variables, for example, welded materials, joint geometry, and the welding procedure and so forth. The exploration will enable the welding to build to choose an appropriate technique for a creation line. This examination can motivate further investigations in the subject and become a beginning stage for the further logical work.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 14 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 8. Evaluation Of Defects In The SS – L Material By Using Non Destruction Examination Techniques Syed Mobin Baba1, Shaik Azgerpasha2, Shaik Fayaz3

Non-Destructive Examination (NDE) is gatherings of investigation strategies are utilized in numerous protection and airplane business to assess the properties of a material, Non Destructive Examination systems (NDE) are significant in testing materials for deformities without adjusting their physical properties. It doesn't forever change the article being reviewed. Consequently, the material that is being tried is saved. It is exceptionally significant system that can spare both cash and time in item assessment and it is a standout amongst the best appropriate techniques in breaking down the impacts of maturing in mechanical and common structures. Non-damaging Examination is one piece of the capacity of Quality Control and is reciprocal to other since a long time ago settled strategies. Non-damaging Examination is utilized to test the materials, for surface, inside imperfections or metallurgical condition, without meddling in at any rate with the uprightness of the material or its reasonableness for the administration. The procedure can be connected to an examining reason for the examination of an individual or can be utilized for 100% checking of material in a creation Quality Control System.Non-damaging Testing isn't only a strategy for dismissing the unsatisfactory material. On-ruinous Testing is one piece of the capacity of Quality Control and is correlative to other since quite a while ago settled techniques.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 15 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 9. Ulitimate Strength Capacity Of Welded Joints In High Strength Steels Zuheir Barsouma , Mansoor Khurshida

Auxiliary honesty is significant in numerous modern parts where welding is an essential system for joining. In various structures welds are distinguished as basic segments and inclined to mechanical failures.To effectively execute HSS in mechanical structures it is significant that various parts are combined without imperfections in the weld and accordingly accomplishing adequate static and weakness qualities. The speed of growing new steels is a lot higher than the speed of growing new filler materials of higher quality. As the yield quality of steel achieves 960MPa, it winds up hard to discover filler materials of comparative quality which is one of the obstacles in using higher quality steels as base materials. Because of liquefying of the steel, microstructural changes happen close to the weld which results in the advancement of HAZ. For steels of higher yield quality particularly more noteworthy than 500MPa this zone is evident and can result in lower hardness than the base material and weld metal. This zone may constrain the worldwide quality of the joint and the quality of base material won't be used to full limit. Along these lines, the objective of higher pay load limit probably won't be accomplished. The correlation is just founded on the yield qualities of the accessible steels and filler materials. Filler materials of comparable yield quality are once in a while accessible as the yield quality of base material achieves 960 MPa. This make steels of yield quality more prominent than 700MPa to be welded with under-coordinating filler. Accordingly the static quality of the joint is restricted to the quality of filler material. Utilizing steel of yield quality more noteworthy than 700MPa in such circumstance probably won't be a suitable decision if the weld isn't appropriately structured.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 16 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 10. Improvement of Welding Penetration in MIG Welding Abrar Zaidi¹, Prof. K. R. Madavi²

This examination is to survey the method of utilizing initiated transition for ideal entrance and hardness of MIG welding. Two sort of motions, Al2O3 and Fe2O3 utilized on a gentle steel plates of 50mm x 50mm square and 8 mm thick. The motions utilized were stuffed in controlled structure and connected through a meager layer of transition.

MIG (Metal Inert Gas) welding, otherwise called MAG (Metal Active Gas) and in the USA as GMAW (Gas Metal Arc Welding), is a welding procedure that is currently broadly utilized in welding the assortment of materials, ferrous and non-ferrous. In gas protected circular segment welding both the bend and the liquid weld pool are protected from the air by a flood of gas. The circular segment might be delivered between a consistently feed wire and the work piece. The protecting gas can be both idle gas like argon, and dynamic gases like argon-oxygen blend and carbon-dioxide, which are synthetically responsive. It tends to be utilized to almost all metals including carbon steel, hardened steel, composite steel and aluminum and so forth. Circular segment travel speed is normally between 30-38 cm/moment and weld metal affidavit rate fluctuates from 1.25 kg/hr when welding out of position to 5.5 kg/hr in level position. Metal exchange over the curve is of various sorts shortcircuiting exchange, globular exchange, shower exchange, beat splash exchange.

The weld metal exchange is dictated by the accompanying welding current, terminal size, cathode sythesis, anode stand out, protecting gas and so forth. Joint sort in MIG welding, is the most usually utilized joint sort. butt joint, corner joint, edge joint, lap joint and T-joint are generally utilized. Here, in MIG the curve is kept up between a consumable anode and the work piece in a dormant gas environment. MIG welding gives a lot more prominent infiltration and higher speeds between the materials. It is quick and more affordable and productive than TIG (Tungsten Inert Gas) Welding

Department of Mechanical Engineering, NHCE, Bengaluru. Page 17 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 11. Recent development in aluminium alloys for the automotive industry W.S. Miller a,*, L. Zhuang a, J. Bottema , A.J. Wittebrood a, P. De Smet bA. Haszler c, A. Vieregge c

Weight decrease is especially significant in light of the fact that normal vehicle weight is relied upon to increment since the car business will keep on showcasing new models with expanded extravagance, comfort, execution and security as requested by their clients. Security highlights, for example, against square frameworks, air sacks, and expanding wellbeing body structure add to vehicle weight gain. In spite of the fact that, the vehicle organizations have reacted to this by improving structure and power train productivity, these steady upgrades have not yet empowered a noteworthy decrease in by and large weight. In the event that this is to be accomplished, there should be an extreme increment in the utilization of lightweight materials. A standard guideline is that 10% of the weight decrease around equivalents a 5.5%improvement in mileage of the vehicles. A significant certainty is that weight decrease will have an expansive influence on eco-friendliness. With this expansive influence, it is assessed to have 10% of vehicle weight decrease results in 8–10% of efficiency improvement. All in all, car materials will have a significant effect in the earth. The utilization of the light weight materials can help diminish the vehicle weight and improves efficiency.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 18 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 12. Magnesium and its alloys applications in automotive industry Mustafa Kemal Kulekci

Magnesium is the lightest between all the designing metals, with having a thickness of 1.74 g/cm3. Magnesium is 35% lighter than aluminum (2.7 g/cm3) and more than multiple times lighter than steel (7.86 g/cm3). The physical properties of Mg, Al and Fe are given.Each cubic meter of the ocean water contains around 1.3 kg (0.3%) magnesium. It has a decent flexibility, better commotion and vibration hosing qualities than aluminum and magnificent cast ability.Alloying magnesium with aluminum, manganese, uncommon earths, thorium, zinc or zirconium builds the solidarity to weight proportion making them significant materials for applications where weight decrease is significant, and where it is basic to lessen inertial powers. On account of this property, denser material like not just steels, cast iron and copper base combinations, however even aluminum composites are likewise supplanted by magnesium-based amalgams. The necessity to lessen the heaviness of vehicle segments because of enactment restricting discharge has made reestablished enthusiasm for magnesium.

Vehicle producing organizations have made the greater part of the innovative work on Mg and its composites. Volkswagen was the primary organization to apply magnesium in the car business on its Beetle model, which utilized 22 kg magnesium in every vehicle of this model. Porsche first worked with a magnesium motor in 1928. Magnesium normal use and assessed utilization development per vehicle are given as 3 kg, 20 kg, and 50 kg for 2005, 2010 and 2015, separately. In past aluminum and some plastic have been utilized as the favored material for a portion of the car parts. Lately magnesium applications in the auto division have been expanding. Ongoing innovative work investigations of magnesium and magnesium composites have concentrated on the weight decrease in the vehicles, vitality sparing and constraining natural effect. Notwithstanding specialized, biological and monetary necessities, fundamental prerequisites that are given for vehicle segments must be met to accomplish these objectives.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 19 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 13. Magnesium for Automotive Applications: Primary Production Cost Assessment Sujit Das

Magnesium has the most reduced thickness property of the regular designing metals, and its job in specific car applications is developing in spite of its surprising expense and constrained supply of materials. Car applications in which magnesium has picked up an undeniably observable offer in parts, for example, cross-vehicle instrument board bars, guiding wheels, and valve covers. The market for magnesium parts in car has developed quickly, about 15% every year amid the 1990s, and development is required to proceed as new applications are created in the vehicles. The normal magnesium use content in the 2002 model autos was 4 kg, contrasted and 3.8 kg for the past model year. This expansion is primarily because of the utilization of magnesium in instrument board bolster bars, driver-side instrument board bolster castings and controlling wheel armatures, cam covers, guiding section coats, and directing segment/pedal section underpins in game utility vehicles, for example, the Ford Explorer, Chevrolet Trailblazer, and GMC Envoy.Magnesium use in autos has been mostly constrained to pass on castings of auxiliary items, for example, the greater expense of metal balanced by the lower cost of creating kick the bucket throwing parts. Also, a moderately higher level of waste in the materials add to the high material expenses of magnesium parts It is thusly essential to break down the generation cost of essential magnesium so as to investigate the present cost structure and different chances to be more financially savvy against other contending materials in the car business.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 20 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 14. A Brief Review On Mg Alloys Their Properties And Application Gopal Sahu1, Prof. Brijesh patel2

Magnesium is a superb metal as it is promptly accessible monetarily and it is the lightest of all the basic metals having a thickness of 1.7g/cm3; it likewise has great warmth dispersal, great damping and great electro-attractive shield. It is most generally found in the world's ocean.Magnesium has a decently low liquefying temperature making it simpler to soften for throwing. At last magnesium powder gets touched off effectively when warmed in air and should be dealt with in all respects cautiously in a powdered structure. Likewise, combination types with the prologue to covering securities will be examined. Magnesium and its amalgams are fundamentally utilized in aeronautical and car industry with having wide assortment of basic attributes as a result of their positive blend of having rigidity (160–365MPa), versatile modulus (45 GPa), and low thickness (1740 kg/m3, which is 66% of that to the aluminum). Magnesium combinations will in general have high solidarity to-weight proportions (elasticity/thickness), equivalently to those of other auxiliary materials. Magnesium has generally great electrical conductivity and warm conductivity. It additionally has a high damping limit that implies, the capacity to assimilate versatile vibrations. Composites containing yttrium display great erosion opposition. Unadulterated magnesium is utilized once in a while in assembling of aviation and car parts. So as to be utilized in assembling, it is alloyed with different metals. The absolute most basic alloyed components in business combinations are: aluminum, zinc, cerium,silver, thorium, and zirconium and so on. So as to name magnesium compounds, the American Society for Testing Materials built up another technique for assigning the composites.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 21 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

CHAPTER 3:

OBJECTIVE

One of the important control mechanism of the automobile is steering wheel. The stability of the vehicle is entirely depend on the condition of the steering wheel. The manufacturing of steering wheel at M/S Autoliv India Pvt Ltd is analyzed and for the betterment of steering wheel with necessary objectives are mentioned. Following are the objectives of this study for testing of steering wheels, as there will be 2% production of the steering wheels tested per day.

 To analyze different steering wheel sample for their physical and chemical characteristics. To study the corrosion rate for selected metals using salt spray test method for different time period.  To analyze the steering wheel sample for bending tests to improve and check the strength, failure points between the armature ring and the spoke joints for the durability.  To analyze the steering wheel sample for welding penetration test to improve and check the penetration of welding between two materials and to see the, failure points between the hub and the base plate for prevention of the failure.  The above tests are done to analyze and determine the causes of failure and to improve the process with root cause analysis and to prevent the failure.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 22 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

CHAPTER 4:

STEERING WHEEL TESTING METHODS

4.1 CORROSION TESTING METHODS

4.1.1 Humidity Testing

The dampness test is a standout amongst the most dependable tests for measuring consumption opposition in view of the relationship with field execution and the nonappearance of controllable factors. All things considered, the outcomes are relative on the grounds that there are such a significant number of factors to control.

A run of the mill stickiness test bureau is impermeable and dampness verification and highlights a top that inclines to the other side. The inclined design,directs the buildup that gathers on the top to rundown the side of the bureau as opposed to sprinkling down on the parts being tried.

4.1.2 Cyclic Corrosion Testing

Thus cyclic tests convey preferable relationship to outside conditions over ordinary salt splash tests. They are incredible for assessing galvanic and hole consumption among others.Cyclic consumption testing is a progressively sensible technique for performing salt splash tests than conventional enduring state testing. Since genuine climatic exposures, more often than exclude both wet and dry conditions it bodes well to design quickened research facility testing to be steady with these conditions. Research demonstrates that consumption rates accomplished with cyclic erosion tests are reliable with open air conditions.

4.1.3 Immersion Testing

Inundation tests include submerging the painted boards in water for a specific timeframe and searching for early indications of rankling, like the stickiness testing depicted before. The most well-known methodology is to submerge the boards in refined or de-ionized water that is kept at 95 to 100° degrees Fahrenheit.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 23 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 4.1.4 Conical Mandrel Testing

This test includes a steel cone that is mounted on a remain in a flat position. The cone limits from around 2 creeps in width toward one side to about l/4-inch at the opposite end. A steel bar keeps running along the cone's length and is balanced somewhat only a small amount of an inch from the outside of the cone and can be moved around yet dependably in a parallel and the long way position. The board that is being tried is held in an installation close by the cone and is twisted to comply with the state of the cone by the steel.

4.1.5 Salt Spray Testing (ASTM – G85)

There are such huge numbers of factors related with salt splash tests that the outcomes are even less solid than stickiness tests. The general appearance is comparative yet aside from that salt splash cupboards are bigger than the mugginess cupboards. With salt splash cupboards there is a trough loaded up with water that folds over the edge of the top lip where the top keeps the salt mist from getting away. It works this way, Water is included into a saturator tower and afterward transported via air and extinguished through a spout situated inside the bureau. The spout is mounted on a siphoning valve which suctions a salt arrangement from a supply.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 24 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 4.2 SALT SPRAY TESTING (ASTM G-85)

There are such a significant number of factors related with salt splash tests that the outcomes are even less solid than mugginess tests. The general appearance is comparative, then again, actually salt shower cupboards are bigger than the stickiness cupboards. With salt splash cupboards, there is a trough loaded up with water that folds over the edge of the top lip where the cover keeps the salt mist from getting away. It works like this Water is included into a saturator tower and afterward transported via air and extinguished through a spout situated inside the bureau. The spout is mounted on a siphoning valve, which suctions a salt arrangement from a store. The salt arrangement, is then blended with the approaching water-immersed air delivering a salt mist in the bureau. The haze is gathered in a flagon and tried by the ideal fixation.

At first, tests utilizing a 20 percent salt arrangement were viewed as satisfactory, yet a 5 percent arrangement is an increasingly thorough test and has turned into the business standard test among metal completing organizations. This is on the grounds that the salt's substance movement increments as the volume of water increments. When directing salt splash tests, make certain the salt is free of iodine and that the best possible pH is created when it's blended with refined water or de-ionized water. Some time prior ASTM determinations were amended to join programmed water level controls and to move the misting spout to a pinnacle situated in the focal point of the salt splash bureau to improve salt haze dispersion. Already the spout was situated close to the base and toward one side of the bureau.

The salt arrangement in the repository ought to be renewed like clockwork, and the bureau ought to work consistently at 95°, give or take 2°. It's obvious that even before factors related with getting ready and watching the boards are considered, there are various elements that impact the bureau's exhibition water level, gaseous tension, pH level, area of the misting spout and its neatness, how every now and again the salt arrangement is invigorated, the kind of salt being utilized, the grouping of salt arrangement and the bureau temperature.

Salt splash testing is prominent in light of the fact that it is generally modest, fast with very much institutionalized, and sensibly repeatable. In spite of the fact that it might have a feeble relationship between's the length in salt shower test and expected the life

Department of Mechanical Engineering, NHCE, Bengaluru. Page 25 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS of a covering in specific coatings, for example, hot excited steel, test has increased overall prevalence because of minimal effort and snappy outcomes. The majority of the Salt Spray Test Chambers today are not being utilized to anticipate the erosion opposition of a covering, yet to keep up the covering procedures, for example, pre- treatment and painting, electroplating, exciting, and on a relative premise.

For instance, pre-treated + painted segments must pass 96 hours Neutral Salt Spray, to be acknowledged for creation. Inability to meet this prerequisite suggests flimsiness in the substance procedure of the pre-treatment, or the paint quality, which must be tended to promptly, with the goal that the forthcoming groups are of the ideal quality.The guideline use of the salt splash test is in this manner empowering brisk correlations with be made among genuine and anticipated consumption opposition. Most usually, the time taken for oxides to show up on the examples under test is contrasted with desires, to decide if the test is passed or fizzled. Therefore the salt splash test is frequently sent in a quality review job, where, it tends to be utilized to check the viability of a creation procedure, for example, surface covering of a metallic part. The salt splash test has little application in foreseeing how materials or surface coatings will oppose consumption in reality since it doesn't make, imitate or quicken true destructive conditions. Cyclic erosion testing is more qualified to this sort of procedure.

Modified Salt Spray Tests

ASTM G85, is the most prevalent test standard which is covering changed salt shower tests. There are five kinds of tests by and large, alluded to ASTM G85 standard as annexure A1 through to A5.Most of the changed tests initially emerge with the specific business area, so as to address the need of an erosion test equipped for duplicating the impacts of normally happening consumption and quickening these impacts. This increasing speed emerges using the salt shower arrangements, regularly joined with other test atmospheres in the most cases, the moderately fast cycling of the test atmospheres after some time. Albeit famous in a portion of the enterprises, changed salt shower testing has by and large been supplanted by Cyclic erosion testing (CCT). The kind of natural test chambers utilized for the altered salt splash testing to ASTM G85 are commonly like the test chambers utilized for testing to standard ASTM B117, yet will

Department of Mechanical Engineering, NHCE, Bengaluru. Page 26 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS frequently have some extra highlights, for example, programmed atmosphere cycling control framework in the vehicles.

ASTM G85 annexure A1 – Acetic Acid Salt Spray Test (non-cyclic):

This test will be utilized to decide the relative protection from decide consumption of enhancing chromium plating on steel and zinc based bite the dust throwing when it is presented to an acidic corrosive salt splash atmosphere at a raised high temperature. This test is additionally alluded to as ASS test. Test examples are set in the encased chamber presented to the persistent aberrant splash of salt water arrangement, arranged as per the prerequisites of test standard and fermented to pH 3.1 to 3.3, by expansion of the acidic corrosive. This shower is set to drop out on to the examples at a rate of 1.0 to 2.0ml/80 cm²/hour, in a chamber temperature of +35°C. The test term is variable.

ASTM G85 annexure A2 – Acidified Salt Fog Test (cyclic):

This test will be utilized to decide the relative opposition for consumption of the aluminum compounds when presented to the changing atmosphere of acidic corrosive salt splash, trailed via air drying, high mugginess, all at a raised high temperatures. This test is additionally alluded as a Mastmaasis test. Test examples are put in the encased chamber, and presented to the changing of atmosphere that contains the accompanying 3 section rehashing cycle. 0.75 hrs presentation with consistent circuitous splash of salt water arrangement, arranged as per the prerequisites of the test standard and fermented upto pH 2.8 to 3.0 by the expansion of acidic corrosive. This splash is good to go to drop out on the examples at the rate of 1.0 to 2.0ml/80 cm²/hour. This is trailed by 2.0 hrs presentation to the air drying atmosphere. This is trailed by the 3.25 hrs presentation to the high dampness atmosphere which step by step emerges to somewhere in the range of 65%RH and 95%RH. The whole test cycle is at the steady chamber temperature of +49C. The quantity of cycles rehashes and accordingly the test length shifts.

ASTM G85 annexure A3 – Seawater Acidified Test (cyclic):

This test will be utilized for determing the relative protection from consumption of covered or uncoated aluminum compounds and different metals, when presented to the

Department of Mechanical Engineering, NHCE, Bengaluru. Page 27 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS changing atmosphere of fermented engineered seawater splash, pursued with a high stickiness, both at a raised temperature. This test is additionally alluded as SWAAT test. Test examples are put in the encased chamber, and presented to the changing atmosphere that includes with the accompanying 2 section rehashing cycle. 30 minutes introduction of a consistent backhanded shower of engineered seawater arrangements, arranged with the necessities of the test standard and fermented to pH 2.8 to 3.0, by the expansion of acidic corrosive. This shower is set to drop out on to the examples at a rate of 1.0 to 2.0ml/80 cm²/hour. This is trailed by the hour and a half introduction to a high moistness atmosphere of above 98%RH. The whole test cycle is kept up at a consistent chamber temperature of +49°C might be decreased to +24 to +35C for naturally covered examples. The quantity of cycle rehashes and in this manner the test term changes.

ASTM G85 annexure A4 – SO2 Salt Spray Test (cyclic):

This test can be utilized to test the relative protection from consumption of item tests that are probably going to experience a consolidated SO2(sulfur dioxide)/salt splash/corrosive downpour condition amid their typical administration life. Test examples are set in an encased chamber and presented to the conceivable changing climatic cycles. The presentation to salt shower might be salt water splash or engineered ocean water, arranged as per the prerequisites of the test standard. The most suitable test cycle and shower answers for be concurred between gatherings.

The main atmosphere cycle involves a constant roundabout splash of impartial pH 6.5 to 7.2 ph salt water arrangements which drops out with the examples at a rate of 1.0 to 2.0ml/80 cm²/hour. Amid this showering, the chamber is dosed with SO2 gas at a rate of 35 cm³/minute/m³ of chamber volume, for 1 hour in at regular intervals of spraying.The whole test cycle will convey at a steady chamber temperature of +35°C. The quantity of cycle rehashes and in this way the test span differs.

The second atmosphere cycle involves 0.5 long stretches of cuyindirect shower of pH 6.5 to 7.2 salt water or manufactured seawater arrangements, which drops out on the examples at the rate of 1.0 to 2.0ml/80 cm²/hour. This cycle is trailed by 0.5 long periods of dosing with SO2 gas at a rate of 35cm³/minute/m³ of chamber volume. This is trailed by 2.0 long periods of high moistness splash. The whole test cycle is kept up at a steady

Department of Mechanical Engineering, NHCE, Bengaluru. Page 28 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS chamber temperature of +35°C. The quantity of cycle rehashes and in this way the test term differs.

ASTM G85 annexure A5 - Dilute Electrolyte Salt Fog/Dry Test (cyclic):

It is a mainstream test in which the surface coatings industry, where it is likewise alluded to as the PROHESION test. Test examples are set in an encased chamber, and presented to a changing atmosphere that involves the accompanying 2 section rehashing cycle. 1.0hr presentation to a persistent backhanded splash of salt water arrangement, arranged as per the prerequisites of the test standard and fermented (to pH 3.1 to 3.3) by the expansion of acidic corrosive. This shower is set to drop out on to the examples at a rate of 1.0 to 2.0ml/80 cm²/hour, in an encompassing chamber temperature (21 to 27°C). This is trailed by 1.0hr introduction to an air drying (cleanse) atmosphere, in a chamber temperature of +35°C. The quantity of cycle rehashes and in this way the test term differs.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 29 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

Fig 4.1 Salt Spray Testing Equipment

Department of Mechanical Engineering, NHCE, Bengaluru. Page 30 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 4.3 SW TENSILE TEST METHOD

The flexural quality is having worry at a disappointment in bowing. It is equivalent or somewhat bigger than disappointment worry in strain.

Flexural quality, otherwise called modulus of break, or curve quality or transverse crack quality, is a material property characterized as the worry in a material just before it yields in a flexure test. The flexural quality shows the most astounding pressure experienced inside the material at its snapshot of relocation. It is estimated as far as stress, given by the image sigma.

A testing machine is known with the name all inclusive testing machine utilized for testing the elasticity and compressive quality of materials. The name "all inclusive" demonstrates that it can perform the vast majority of the standard elastic and pressure tests on materials, parts, and structures at the end of the day, it is adaptable.

Fig 4.2 Universal Testing Machine

Department of Mechanical Engineering, NHCE, Bengaluru. Page 31 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 4.4 WELDING

Welding is unmistakable from lower temperature metal-joining systems, for example, brazing and binding which don't dissolve the base metal. Notwithstanding the liquefying of the base metal, a filler material is commonly used to the joint and to frame a pool of liquid material that cools and structures a joint, in light of weld design butt, fullpenetration, filet, which can be more grounded than the base material ie ,parent metal. Weight can likewise be utilized related to warm, to deliver a weld. Welding additionally requires a type of shield to shield filler metals or dissolved metals from being presented to tainting or oxidized.

Numerous other vitality sources can be utilized for welding, including a gas fire, an electric circular segment (electrical), a laser, an electron pillar, rubbing, and ultrasound. While frequently a modern procedure, welding might be performed in a wide range of situations incorporating into an outside, submerged ,and in space too. Welding process is a perilous procedure, so safety measures are required to evade consumes, electric stun, vision harm, inward breath of toxic gases and vapor, and presentation to extreme bright raditation and so on.

Until the finish of nineteenth century, the main welding process accessible was manufacture welding, which metalworkers were utilizing for centuries to join iron and steel by warming and pounding. Welding innovation before long got progressed rapidly amid the mid twentieth century as the world wars drove the interest for reasonable joining strategies. Following wars, a few present day welding strategies were created, including manual techniques, for example, protected metal bend welding, presently which is a standout amongst the most famous welding techniques, just as self-loader procedure and programmed procedures, for example, gas metal circular segment welding, submerged curve welding, motion cored welding and electro slag welding. Advancements began to proceed with the development of laser shaft welding, electron pillar welding, attractive heartbeat welding, and rubbing welding in the last 50% of the century. Today the science keeps on progressing.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 32 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS A standout amongst the most widely recognized kinds of circular segment welding is protected metal curve welding (SMAW) it is otherwise called manual metal bend welding (MMAW) or stick welding. Electric flow is utilized to weld a curve between the base material and consumable anode bar, which is comprised of filler material and is secured with a transition which shields the weld territory from oxidation by delivering carbon dioxide (CO2) gas amid the welding procedure. The anode center itself goes about as a filler material, making a different filler pointless.

The procedure is adaptable so it very well may be performed moderately with modest gear, making it fit to shop employments and field work. An administrator can turn out to be sensibly capable with an unassuming procedure of preparing and can accomplish the most with experience. Weld times are moderate because of the consumable cathodes which will be oftentimes supplanted and the slag buildup from the motion, must be worn down in the wake of welding. Moreover, the procedure is commonly constrained to welding ferrous materials, however extraordinary cathodes have made conceivable the welding of cast iron, nickel, aluminum, copper, and different metals.

Gas metal circular segment welding (GMAW), is otherwise called metal inactive gas or MIG welding, which is a self-loader or programmed process that utilizes a constant wire feed as a terminal, and a latent gas blend to shield the weld from defilement or oxidation. Since the cathode is ceaseless, welding speeds are more prominent for GMAW than SMAW. A related procedure, called as transition cored circular segment welding process utilizes comparable gear yet utilizes wire which comprises of a steel terminal encompassing a powder filled material. The cored wire is more costly than the strong wire which can create exhaust and slag, yet it licenses higher welding speed and more prominent metal infiltration. Gas tungsten bend welding (GTAW) or tungsten latent gas (TIG) welding is a manual procedure that utilizes a non consumable tungsten terminal, and a dormant gas blend, and a different filler materials.

GTAW procedure can be utilized in almost all weldable metals, however it is frequently to tempered steel and light metals. Usually utilized with the quality welds are critical, in bike air ship and maritime applications. A related procedure, plasma circular segment welding, additionally utilizes a tungsten terminal however utilizes plasma gas to make curve. The circular segment is more focused than the GTAW bend making transverse

Department of Mechanical Engineering, NHCE, Bengaluru. Page 33 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS control progressively basic, along these lines commonly limiting the procedure to an automated procedure. In light of its steady current, the technique can be utilized on a more extensive scope of material thicknesses than the GTAW procedure and it is a lot quicker. It tends to be connected to all indistinguishable materials from GTAW aside from magnesium and its composites mechanized welding of treated steel is one of the significant use of the procedure. A variety of the procedure in plasma cutting is a productive steel cutting procedure.

Submerged curve welding (SAW) is a high-profitability welding strategy in which the circular segment is struck underneath the covering layer of motion. This expands curve quality, since the contaminants in the climate are ensured by the transition. The slag that shapes on the weld by and large stops independent from anyone else, and joined with the utilization of a persistent wire feed, the weld statement rate is high. Working conditions are progressively improved over other circular segment welding process, since the motion shrouds the bend and no smoke is genetrated. This procedure is normally utilized in industry, particularly for huge items and in the assembling of welded weight vessels. Other bend welding process incorporates nuclear hydrogen welding, electroslag welding (ESW), electro gas welding, and stud curve welding process. ESW is an exceptionally beneficial, single pass welding process for thicker materials between 1 inch (25 mm) and 12 inches (300 mm) in a vertical or near vertical positions. The most widely recognized gas welding process is oxyfuel welding which is otherwise called oxyacetylene welding. This procedure is a standout amongst the most flexible welding forms, yet lately it has turned out to be least mainstream in mechanical applications. It is still broadly utilized for welding channels and cylinders, just as fix work process. The hardware utilized is moderately economical and straightforward, adding to the burning of acetylene in oxygen gas to build up a welding temperature of about 3100°C.The fire, since it is less thought than the electric bend, grows slower weld cooling, which can prompt more prominent lingering stresses and weld contortion, however it facilitates to welding of high compound steels. A comparable procedure, by and large called as oxyfuel cutting, is utilized to cut metal.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 34 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 4.5 TYPES OF WELDING:

4.5.1 Shielded Metal Arc Welding (SMAW):

This sort of specific welding, the welder pursues a manual procedure of stick welding. This stick utilizes an electric flow to frame an electric bend between the stick and the metals which should be joined. This sort is regularly utilized in development of steel structures and in the mechanical manufacture to weld iron and steel materials.

4.5.2 Gas Metal Arc Welding (GMAW):

This style of welding is additionally alluded to as a Metal Inert Gas (MIG). It utilizes a securing gas alongside the wire terminal, which warms up the two metals that should be joined. This strategy requires a steady supply of voltage and direct-current power source, and is the most widely recognized modern welding process. It has four essential techniques for metal exchange, globular, short out, shower and beat splash.

4.5.3 Flux Cored Arc Welding (FCAW):

This procedure was created as a choice to shield welding. The self-loader bend weld is frequently utilized in development ventures, because of its high welding rate and transportability.

4.5.4 Gas Tungsten Arc Gas Welding (GTAGW):

Welding thick segments of tempered steel or non-ferrous metals is the most widely recognized use for this technique. It is likewise utilized as a bend welding process that utilizes a tungsten anode to create the weld. This procedure is considerably more tedious contrasted with the other three and substantially more unpredictable as well.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 35 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 4.6 METAL INERT GAS WELDING:

Gas metal arc welding (GMAW), known by its subtypes metal inactive gas (MIG) welding or metal dynamic gas (MAG) welding, is a welding procedure where electric circular segment frames between a consumable wire terminal and the workpiece metals, which warms up the workpiece metals making them liquefy and join the materials. Alongside wire terminal a securing gas bolsters through the welding firearm which shields the procedure from contaminants noticeable all around. The procedure can be self-loader or automatic.There are four bosic strategies for metal move in GMAW process, which is known as globular, hamper ,and beat shower individual to which is having particular properties and relating points of interest and restrictions.

Initially process created in the late 1940s for welding aluminum and other non-ferrous metals, GMAW process was before long connected to steels and different metals since it gives quicker welding time contrasted with other welding process. The expense of the dormant gas constrained its utilization in steels until quite a long while, when the utilization of semi-idle gases, for example, carbon dioxide wound up normal. Further improvements during the 1960s gave the procedure greater flexibility and accordingly, it was utilized as a profoundly utilized mechanical procedure. Today, GMAW is the most utilized mechanical welding process, favored for its flexibility, speed and different parameters due to adjusting the procedure to the mechanical mechanization. Not at all like other welding process that don't utilize an ensuring gas, for example, protected metal bend welding, it is once in a while utilized outside. A related procedure, transition coded curve welding , frequently does not utilize a protecting gas, however rather utilizes an anode wire that is empty and loaded up with motion.

The workpiece to be welded and the consumable anode are associated with the Power Supply. At whatever point the consumable anode is brought close to the workpiece (with a little hole), a bend is created. This curve softens the anode. The liquefied anode fills similarly over the required districts of the workpiece. An idle gas supply is given around the terminal amid the procedure (consequently the name 'Metal Inert Gas Welding') amid the welding procedure. It shapes a gas shield around the bend and the weld. This is expected to shield the weld from an outer environment.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 36 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS EQUIPMENT:

Welding gun and wire feed unit

Welding firearm and wire feed unit .The normal GMAW welding weapon has various key parts a control switch, a contact tip, a power link, a gas spout, a cathode course and liner and a gas hose. The control switch when squeezed by the administrator, starts the preparing of wire feed electric power and the protecting gas stream, making an electric circular segment be create between the materials. The contact tip, ordinarily made of copper and some of the time other synthetically treated to decrease scatter is associated with welding power supply source through the power link and transmits the electrical vitality to anode while preparing it to the weld zone. While in transit to the contact tip the wire is protected and guided by the anode liner, which avoids clasping process and keep up a continuous wire nourishing. The gas spout coordinates the securing gas similarly into the welding zone. Bigger spouts will give more noteworthy protecting gas stream which is helpful for high current welding activities which will build up a bigger liquid weld pool. A gas hose from the tanks of ensuring gas will supply the gas to the spout. A water hose is likewise worked in the welding weapon, cooling the firearm and in the high warmth tasks.

The wire feed unit will supply the cathode to the work piece, guiding it through the channel and to the contact tip. The greater part of the models give the wire at a consistent feed rate yet further developed machines can change their feed rate because of the curve length and voltage. Some wire feeders can achieve feed rates as high as 30m/min (1200in/min), yet feed rates for self-loader GMAW ordinarily go from 2 to 10m/min (75–400 in/min).

Tool style

The most well-known anode holder is a self-loader holder. Packed air circles through it to keep up the moderate temperatures. It is utilized to bring down current dimensions for welding lap or butt joints. The second most regular sort of cathode holder is self- loader water-cooled, where the main contrast is that water replaces air. It utilizes higher current dimensions for welding T joints or corner joints. The third regular holder type is a water cooled programmed cathode holder which is normally utilized with the computerized hardware.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 37 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Power supply

Most uses of gas metal circular segment welding usees a steady voltage control supply. Accordingly, any adjustment in the bend length will results in a huge change in warmth info and supply current. A shorter bend length causes an a lot more noteworthy warmth input, which makes the wire terminal dissolve to all the more rapidly and there by reestablish the first circular segment length. This causes administrators to keep the circular segment length reliable notwithstanding when physically welding with the handheld welding weapons. To get a comparable impact once in a while a consistent current power supply is utilized alongside a curve voltage controlled wire feed unit. For this situation, an adjustment in circular segment length makes the wire feed rate to modify and keep up a generally consistent bend length. In uncommon conditions, a consistent current power source and a steady wire feed unit rate may be coupled, particularly for the welding the metals with high warm conductivities, for example, aluminum. This allows the administrator extra command over the warmth contribution to the weld, however requires huge ability to perform effectively.

Substituting current is infrequently utilized with GMAW rather direct current is utilized and the anode is usally decidedly charged. Since the anode watches out for a more prominent warmth fixation, will results in quicker dissolving of the wire feed which builds welding entrance and welding speed. The extremity can be switched just when a unique emissive-covered wire cathodes are utilized however since these are not mainstream, a contrarily charged anode is seldom utilized.

Electrode

The cathode is a metallic combination wire, called as MIG wire whose determination amalgam and size, depends on fundamentally the creation of the metal being welded, the procedure variety being utilized to joint plan and the material surface conditions. Terminal determination extraordinarily impacts the mechanical properties of the weld and is a key factor of weld quality. By and large, the completed weld metal ought to have mechanical properties like that of the base material without any deformities, for example, discontinuities, entrained contaminants or porosity inside the weld. To accomplish these objectives a wide assortment of terminals exist. All economically accessible terminals contain deoxidizing metals, for example, silicon, manganese, Department of Mechanical Engineering, NHCE, Bengaluru. Page 38 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS titanium and aluminum metals in little rates to help anticipate oxygen porosity. A few anodes contain denitriding metals, for example, titanium and zirconium to dodge nitrogen porosity. Contingent upon the procedure variety and base material being welded the distances across of the cathodes utilized in GMAW commonly extending from 0.7 to 2.4mm (0.028 – 0.095in) however can be as huge as 4mm(0.16 in). The littlest cathodes, for the most part having thickness up to 1.14mm (0.045 in) are related with the short out metal exchange process, while the most normally utilized shower exchange process made up of terminals are as a rule at any rate 0.9mm (0.035 in).

Shielding gas

Protecting gases are important for gas metal circular segment welding procedure to shield the welding region from a portion of the environmental gases, for example, nitrogen and oxygen, which can make combination imperfections, porosity, and weld metal embrittlement on the off chance that they interact with the electrode,arc, or the welding metal. This issue is regular in all bend welding forms; for instance, in the more established Shielded Metal Arc Welding process (SMAW), the anode is covered with a strong motion which builds up a defensive haze of carbon dioxide when dissolved by the circular segment. In GMAW process be that as it may, the wire cathode does not have a transition covering around the surface, and a different ensuring gas is utilized to secure the weld.

The decision of a protecting gas relies on a few components, most usally the kind of material that is being welded and the procedure variety being utilized. Unadulterated idle gases, for example, argon and helium are utilized for nonferrous welding; with steel they don't give satisfactory weld infiltration (argon) or cause a whimsical circular segment and energize scatter (with helium). Unadulterated carbon dioxide, then again, takes into consideration the profound infiltration of welds between the materials however supports oxide arrangement, which antagonistically influences the mechanical properties of the weld. lts ease settles on it an appealing decision, but since of the reactivity of the bend plasma, scatter is unavoidable and welding dainty materials is troublesome. By and large, in short out GMAW, higher carbon dioxide content expands the weld warmth and vitality when all other weld parameters such as(volts, current, terminal sort and distance across) are held the equivalent. As the carbon dioxide content

Department of Mechanical Engineering, NHCE, Bengaluru. Page 39 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS increments over 20% shower exchange GMAW turns out to be progressively troublesome, particularly with littler cathode distances across.

Argon is most regularly blended with different gases, for example, oxygen, helium, hydrogen and nitrogen. The expansion of up to 5% oxygen (like the higher convergences of carbon dioxide) can be useful in welding treated steel, anyway in many applications carbon dioxide is liked. Expanded oxygen causes the ensuring gas to oxidize the anode, which can prompt porosity in store of the cathode and it doesn't contain adequate deoxidizers. Excessive oxygen, especially when it is used in the application for which it is not prescribed, can lead to brittleness in the heat affected zone area. Argon-helium mixtures are extremely inert gases, and can be used on nonferrous materials. A helium concentration of 50–75% raises the required voltage and increases the heat in the arc, due to helium's higher elevated ionization temperature. Hydrogen is sometimes added to argon gas in small concentrations (up to about 5%) for welding nickel and thick stainless steel material workpieces. In higher concentrations (up to 25% hydrogen), it may be used for welding conductive materials such as copper materials. Welding flat surfaces requires higher flow than welding grooved materials since gas disperses more quickly. Faster welding speeds, in general mean that more gas must be supplied to the process to provide adequate coverage. Additionally, higher current requires greater flow, and generally more helium is required to provide adequate coverage than if argon shielding gas is used. Perhaps most importantly, the four primary variations of GMAW have different shielding gas flow requirements for the small weld pools of the short circuiting and pulsed spray modes, about 10L/min is generally suitable, whereas for globular transfer around 15L/min is preferred. The spray transfer variation normally requires more flow of shielding-gas because of its higher heat input and thus larger weld pool. Typical gas-flow amounts are approximately 20–25L/min.

The type of electrode used and the shielding gas used primary depends on the material to be welded. If many workpieces are to be welded continuously an electrode spool is used. Consumable electrode is continuously supplied from this spool by a suitable feeding equipment using mechanism. Commonly servo mechanisms are used in the process for feeding long electrodes.In MIG Welding, consumable electrode itself acts as a filler metal. So no separate filler rod or filler wire is needed.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 40 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Advantages of Metal Inert Gas Welding (MIG Welding):

1. Consumable electrodes are easy to feed. 2. No filler rod is needed. 3. Welding is simple. 4. Inert gas shield protects the weld automatically.

Disadvantages of Metal Inert Gas Welding (MIG Welding):

1. Improper welding may lead to the floating of solid impurities over the liquid weld. 2. If not handled properly, weld may become porous. 3. MIG Welding exposes welders to hazardous gases. 4. Care must be taken to avoid the formation of less ductile welds. 5. Workpieces and Electrodes should be kept clean before welding.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 41 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 4.7 WELDING PENETRATION TEST:

Weld entrance is the separation that the combination line reaches out underneath the outside of the material that is being welded. Welding current is of essential significance to entrance process. Weld infiltration is straightforwardly identified with welding current. An expansion or abatement in the present will releatively increment or decline the weld infiltration individually. Nonetheless, we have seen that the supply of welding current can be adjusted without changing the wire feed speed, in particular through the variety of the tip-to-work remove between the metals. The impact of tip-to-work remove on welding entrance is inverse in nature to that of welding current. An expansion in the tip-to-work separation will releatively diminish supply of welding current and entrance. Obviously, the opposite is additionally valid. In certain applications, numerous administrators have discovered this as accommodating to utilize this property to control entrance. Changing the tip-to-work separate amid the welding procedure counteracts copy through when there are arrangements of discontinuities in material thicknesses or joint hole.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 42 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

CHAPTER 5:

EXPERIMENTATION AND INSTRUMENTATION

In order to analyze the failures affecting the steering wheel armature experimentation is conducted using testing instruments. The experimentations conducted are described below:

5.1 WELDING PENETRATION TEST

Equipment used: WELDING MICROSCOPE

This framework can be utilized to quantify every single dimensional estimation (2D) like length, separate between, edge, span, distance across, and territory and so forth. The framework even offers programmed/programmable estimation and is completely adjustable where can characterize own parameters to be estimated.

Fig 5.1 Welding Microscope

Department of Mechanical Engineering, NHCE, Bengaluru. Page 43 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Some of the salient features of the system are:

 Supports all dimensional measurements.  Programmable (Automatic) measurement.  Supports all types of weld quality parameters like depth/penetration, %penetration, leg lengths, throat lengths, root penetration etc.  Can measure parameters like length, area, angle, diameter, radius, circumference in addition to weld penetration measurement.  Can define the Component and parameters to be measured.  Can set expected values and tolerances for each parameter.  Automatic edge detection.  Component level reporting.  Free life-time support for the software for any new features. Specifications:

 MIAS Trinocular Stereo Microscope.  Trinocular Stereo Zoom Microscope on large stage equipped with transmitted light, Incident light.  Magnification: 6.2 to 50X (field of view: 34mm, 2.1mm).  Zoom Range: 0.62 - 5X.  Eyepiece: Wide field 10x (WFH10X).  Working Distance: 80mm (With 1x Objective).  Inter pupillary Distance: 52mm to 75mm.  Stand Type: Fan style base & track stand with HF width coarse and fine focusing hand Wheel.  Incident Light: 6V / 15W Halogen.  Imaging System For Welding Penetration Studies.

Camera specification:

Resolution: 1280x1024 Color Format: Color Chip Size : ½ inch Lens mount : C mount

Department of Mechanical Engineering, NHCE, Bengaluru. Page 44 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Procedure:  The armature ring sample will be taken to test based upon the autoliv standard.  Robo welding will be done according to customer requirements.  The armature ring will be cut into different parts after welding with the cutting machine.  The parts will be subjected to the grinding to remove the burrs created while cutting.  Spokes welded with the armature ring portion will be cut and kept aside.  Hub welded with the base plate will be cut and kept aside.  Hub welded with base plate will be cut into two halves for checking the welding penetration of the two materials.  Light adjustments and the part adjustments for the visualizations will be done.  The welding depth will be find out with help of the welding microscope equipment and the thickness of welding and distance will be determined.  The graph for the test done will be put taking the image from microscope.  The testing of the sample will be done for 2% of the production every day.

Results: Welding penetration of the two materials Hub and base plate is determined by taking a photograph with a microscope and putting the graph and determing the thickness of the welding between two materials. Test 1: 1. P1 Depth of Weld is 1.18mm 2. P2 Depth of Weld is 0.82mm 3. L1 Length of Weld is 3.025mm 4. L2 Length of Weld is 4.471mm

Test 2:

1. P1 Depth of Weld is 1.16mm 2. P2 Depth of Weld is 0.74mm 3. L1 Length of Weld is 3.25mm 4. L2 Length of Weld is 4.531mm

Department of Mechanical Engineering, NHCE, Bengaluru. Page 45 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Test 1:

Fig 5.2 Microscopic view of Welding Penetration

Department of Mechanical Engineering, NHCE, Bengaluru. Page 46 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Test 2:

Fig 5.3 Microscopic view of Welding Penetration

Department of Mechanical Engineering, NHCE, Bengaluru. Page 47 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 5.2 TENSILE TEST

Equipment used: UNIVERSAL TESTING MACHINE (UTM)

The most well-known sort of testing machine utilized in pliable testing is widespread trying machine. This sort of machine will have two crossheads one is balanced for the length of the example and the other is headed to apply strain to the test example. There are two kinds of machines, water powered fueled and electromagnetically controlled machines. The machine ought to have the best possible abilities for testing the example being tried. There are four principle parameters: power limit, speed, exactness and accuracy. Power limit alludes to that the machine must most likely produce enough power to break the example. The machine must almost certainly apply the power rapidly or gradually to appropriately mirror the real application. At long last the machine must almost certainly precisely and accurately measure the check length and powers that are connected.

The test procedure includes in setting the test example in the machine and gradually expanding it until the break. Amid this procedure the extension of the measured

Strain = L-L0 / L0 where ΔL is the change in gauge length, L0 is the initial gauge length, and L is the final length. The force measurement is used to calculate the engineering stress, σ, using the following equation: sigma = F / A where F is the tensile force and A is the nominal cross-section of the specimen.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 48 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

Fig 5.4 UTM With SW Testing Fixture

Department of Mechanical Engineering, NHCE, Bengaluru. Page 49 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Specifications:  Piston movement resolution of 0.01mm.  180º bend test attachment.  10000 KGF capacity.

Procedure:

 The armature ring sample will be taken to test based upon the autoliv standard.  Parts welded will be filed for the removal of burrs.  Test slot will be booked for the testing of the equipment.  Previously mounted seat belt fixture will be removed.  Fixture for testing of steering wheel sample will be changed in the UTM machine.  Spokes welded to armature ring of two sides will be placed in the fixture and the tensile load will be applied.  Gradually strength decreases with the increase in the load applied.  At the maximum load the bend will break and the load will be recorded.  The failure load and the welding strength of the spoke and the armature ring will be determined.  The testing of the sample will be done for 2% of the production every day.

Results: Welding Strength of the armature ring and the spokes will be determined with UTM and the max load will be determined by Tensile strength. Room temperature of the test conducted is 25º C. Speed of the Lever moving is 100mm/min. Load vs Displacement Graph will be obtained to find the Load distributions.

Test :

1. Maximum Load Applied is 8065 N. 2. Maximum Load Applied is 6265 N.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 50 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Test 1:

Fig 5.5 Load vs Displacement Graph for Spoke 1

Department of Mechanical Engineering, NHCE, Bengaluru. Page 51 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Test 2 :

Fig 5.6 Load vs Displacement Graph for Spoke 2

Department of Mechanical Engineering, NHCE, Bengaluru. Page 52 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 5.3 CORROSION TEST

Equipment used: SALT SPRAY TESTING EQUIPMENT

The mechanical assembly for testing the example comprises of a shut testing chamber, where a salt water arrangement (5% NaCl) is atomized by methods for a shower spout utilizing pressurized air. This creates a destructive domain of thick salt water mist (likewise alluded to as a shower) in the chamber, so the test tests presented to this condition are liable to seriously destructive conditions. Chamber volumes change from provider to provider. On the off chance that there is a base volume required by a specific salt splash test standard hardware results are spoken to in for the most part as the testing hours in NSS without appearance of erosion items.

Salt spray tests are the most commonly used tests for finding the corrosive nature of the product and the testing time and specifications depends upon the customer requirement.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 53 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

Fig 5.7 Salt spray Test Equipment

Department of Mechanical Engineering, NHCE, Bengaluru. Page 54 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Specifications:

 Continuous spraying nozzle.  Salt spray tank dimensions.

Length- 77cm

Width- 46cm

Height- 71cm

 2 bar pressure.  245 liters capacity tank.  35 - 55°c temperature.  1.0 to 2.0 ml/80cm2/hr spray quantity.

Procedure:

 Testing equipment arrangement will be done as per the customer requirements.  Continuously liquid will be sprayed on the testing equipment for 48 hrs or customer requirements.  Testing sample will be removed and checked for every 24hrs for rusting.  Coating materials and uncoated materials will be differentiated for the rusting.  Uncoated materials will tend to rust by the continuous spray of the salt spray solution.  Red rust will be formed if the material is not coated properly.  White color rust will be formed if the coating thickness is between 10 to 15 microns.  Red rust will be formed if the coating thickness is less than 10 micron.  Red rust will be formed if the material is uncoated properly and exposed to the salt spray solution rust will be formed.  If the sample is white rust then it will be accepted and if the sample is formed with the red rust then the part will be rejected.  The testing of the sample will be done for 2% of the production every day.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 55 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS Results: Steering wheel armature sample subjected for corrosion testing are shown below in the table. The minimum thickness of the coating for the armature should be 10µ.The room temperature at the time of testing was 45°c.Continous salt spray solution was sprayed through nozzle and solution will be in the ratio [Salt : Water :: 10 : 1].Sample was kept under the chamber for 48hrs as per customer requirement.

SL NO COATING THICKNESS RUST TYPE ACCEPT/REJECT

1 ZINC IRON 14µ White Rust Accept

2 ZINC IRON 18µ No Rust Accept

3 ZINC IRON 9µ Red Rust Reject

Table 5.1 Result Table For Corrosion Testing

Department of Mechanical Engineering, NHCE, Bengaluru. Page 56 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

CHAPTER 6:

CONCLUSION

Steering wheel armature ring has been tested for different tests under different specifications. Armature ring has been tested for different areas with different equipments to find out the failure points and to determine the specifications in which the welding and coatings of the metal to be done to prevent the failure of welding and corrosion of the armature ring. Armature ring has been exposed to degreasing method to prevent the dust and moisture particles of the sample while testing. The armature ring tested will be used for the Ashok Leyland “DOST”. After considering the requirements from the customer for the two spoke armature ring of steering wheel it has been designed and manufactured for the customer. As there is no Airbag system installed in the steering wheel it is moulded with the PU material. Following are the suggestions made for betterment of welded joints.

1. The area of teach should be increased and minimum it should be 6mm of outside thickness for the Hub and base plate portion as it holds the most important area for transferring the mechanical action. Welding current should be 120-150A. Tip and work distance should be 12-15mm. CO2 gas flow should be 15 -20 L/min. Welding wire dia is 1.2mm. Thickness at the ring and spoke should also be at the same process.

Thickness of weld Fig 6.1 Sectional View Of Welding Area

Department of Mechanical Engineering, NHCE, Bengaluru. Page 57 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS 2. Elimination of the red rust corrosion can be done for the steering wheel armature ring by increasing the coating thickness from 15-20 µ and the testing of the sample for other corrosion testing methods. Degreasing process can also be done after the testing process again also so that the water spraying at the high speed for 100sec can be eliminated in the process for prevention of the corrosion.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 58 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

CHAPTER 7:

SCOPE OF FUTURE WORK

Following are the future scope of work for steering wheel tested:

1) To study the use of magnesium or aluminium materials for the production of armature ring. 2) To study the physical and chemical characteristics of magnesium and aluminium materials for use in Ashok Leyland Armature Ring. 3) To determine the level of corrosion rust with different types of tests. 4) The future scope of this project is to reduce the size and improve the shape, aesthetic properties of the steering wheel. 5) The future scope of this project is to optimize the weight and cost by changing the material to composite materials such as plastic fibres.

Department of Mechanical Engineering, NHCE, Bengaluru. Page 59 EXPERIMENTAL ANALYSIS ON FAILURE OF STEERING WHEELS

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