A PROJECT REPORT [10ME85L] ON ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO Submitted in partial fulfillment of the requirement for award of degree in Bachelor of Engineering (Mechanical Engineering) Of VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELGAUM HITESH KUMAR (1NH10ME019) RAHUL (1NH11ME036) SHRAY SHAH (1NH10ME051) VIGNESHWAR. S (1NH11ME060) Project work carried out at NEW HORIZON COLLEGE OF ENGINEERING, BANGALORE Under the Guidance of Dr. M.S. Ganesha Prasad Head of Department, Department of Mechanical Engineering, NHCE Department of Mechanical Engineering NEW HORIZON COLLEGE OF ENGINEERING (Accredited by NBA, Permanently Affiliated to VTU) A Recipient of Prestigious Rajyotsava State Award 2012 by the Government of Karnataka Ring Road, Kadubisanahalli, Bellandur Post, Near Marathalli, Bangalore -560 103 Tel.: +91-80-6629 7777. Fax: +91-80- 28440770 Web: www.newhorizonindia.edu 2014-2015 NEW HORIZON COLLEGE OF ENGINEERING (Accredited by NBA, Permanently Affiliated to VTU) A Recipient of Prestigious Rajyotsava State Award 2012 by the Government of Karnataka Ring Road, Kadubisanahalli, Bellandur Post, Near Marathalli, Bangalore -560103 Tel.: +91-80-6629 7777. Fax: +91-80- 28440770 Web: www.newhorizonindia.edu Certificate This is to certify that the project Report ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO [10ME85L] Is a bonafide work carried out by HITESH KUMAR (1NH11ME019) RAHUL (1NH11ME036) SHRAY SHAH (1NH11ME051) VIGNESHWAR. S (1NH11ME060) In partial fulfillment for the award of degree of Bachelor of Engineering in Mechanical of the Visvesvaraya Technological University, Belgaum during the year 2014 - 2015. It is certified that all corrections/suggestions indicated for Internal Assessment have been incorporated in the Report deposited in the departmental library. The project report has been approved as it is satisfies the academic requirements in respect of Project Work prescribed for the Bachelor of Engineering degree. Signature of the Guide Signature of the HOD Signature of the Principal Mr. SRINIVAS AYALURI Dr. M S GANESHA PRASHAD Dr. MANJUNATHA Aeronautical Development Professor and HOD, Principal, Agency Dept. of Mech Engg NHCE, NHCE, Bangalore Bangalore External Viva. Name of the examiners. Signature with date. 1. ……………………………………….. …………………………………… 2. ……………………………………….. ……………………………………. ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO 2014-15 Chapter 1 Introduction This chapter introduces the Tata Nano car details. The chapter details about Tata Nano specification, project area details, objective of project, project schedule and organization of the report. 1.1The Tata Nano The Tata Nano is a city car manufactured by Tata Motors. The Nano was initially launched with the price tag of Rs 100,000, which was increased with time .Designed to lure India‟s middle classes away from two wheelers, it received by publicity. The Nano (2012) is a 38 PS (28 kW, 37 hp) car with a two- cylinder 624 cc rear engine. The car complies with Bharat Stage 4 Indian Emission Standards, which are roughly equivalent to Euro 4 and thus can meet European Emission Standards as well.[1] Figure 1.1: Tata Nano in Verkehrszentrun des Deutschem Museum Department of Mechanical Engineering, NHCE Bangalore Page 1 ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO 2014-15 1.2 Specifications [2] ENGINE Fuel type : Gasoline Type : 4 Stroke, water cooled, multipoint fuel injection system, SOHC, 2V/Cylinder Cubic capacity : 624 cc Made of : Alloy head, cast iron block Installation : Front, transverse, front wheel drive Max power : 38 PS at 5500 +/-250 rpm Max torque : 51Nm at 4000 +/-500 rpm Redline : 6000 rpm Bore/stroke : 73.5 mm x 73.5 mm Compression ratio : 10.3: 1 Valve gear : 2valves per cylinder, SOHC CHASSIS AND BODY Construction : 4 Door Monocoque Kerb weight : 600kg (For STD), 615kg (For CX), 635 (For LXM) Wheels Made of : Steel Tyre size : Front: 135/70R12 (Radial Tubeless), Rear: 155/65R12 (Radial Tubeless) Spare : 135/70R12 (Radial Tubeless) Spare wheel : Steel, 135/70/R12 SUSPENSION Front : Independent, Lower wishbone, McPherson Strut type, with anti-roll bar. Rear : Independent, Semi-trailing arm with coil spring and hydraulic shock absorbers. Department of Mechanical Engineering, NHCE Bangalore Page 2 ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO 2014-15 TRANSMISSION Type : Synchromesh on all forward gears, sliding mesh for reverse gear Gearbox : 4 forward & 1 reverse Ratios: 1st : 3.45 3rd : 1.26 2nd : 1.95 4th : 0.838 REV : 3.07 Final drive ratio : 4.2 STEERING TYPE Turning circle radius : 4 m Type : Mechanical Rack & Pinion steering gear with steering column. Steering Wheel : 360 mm dia. Ratio :16:1 BRAKES Front :180 mm dia. drum brake Rear : 180 mm dia. drum brake Parking Brakes : Lever type, Cable operated mechanical linkages acting on rear wheels. Safety Features : Front- 3 point seat belt, Rear-Lap belt EXTERIOR DIMENSIONS Wheel Base : 2230mm Front Overhang : 464mm Rear Overhang : 405mm Overall Length : 3099mm Max. Width : 1495mm - over body, 1620mm - Over ORVM Overall Height : 1613mm Ground Clearance : 180mm Fuel Tank capacity : 15litres Department of Mechanical Engineering, NHCE Bangalore Page 3 ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO 2014-15 1.3 Statement of the Problem This project is started with the assumption that Tata Nano car front steering components are overdesigned. For any design higher mass of part is not recommended. The steering components are studied with respect to dimensions. The parts are analyzed to optimize the current design. Different linkages in steering mechanism are studied to understand relative displacement and load carrying capacity. Studies were carried out as an opportunity to optimize the dimensions of the steering components. 1.4 Objective of the Project Thus the objective is to optimize the Tata Nano car steering and front axle components. The critical component of the front axle system is the Stub Axle. The Stub axle is studied for design (dimension) optimization. 1.5 Project work schedule The project is carried out in several steps. Its starts from stating the problem to proposing the optimized design. It has many folds such as understanding the existing design with the dimensional details, the loading conditions and analyzing the proposed design under same loading condition. The detailed activity with estimate duration is shown below. Department of Mechanical Engineering, NHCE Bangalore Page 4 ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO 2014-15 Department of Mechanical Engineering, NHCE Bangalore Page 5 ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO 2014-15 1.6 Brief Description of the Project report The entire project report is detailed under five chapters. Each chapter has its own significance. The brief content of each chapter is highlighted as below. Chapter one introduces Tata Nano car product, technical specifications, overall dimensions, engine details and steering mechanism. The main focus has been given to the objective of the project, statement of the problem which lead to do this project along with the project schedule with different milestones and estimated duration. Chapter two focuses on project specific details, explains on the steering components, linkages, front axle arrangement and its mechanism. The main critical component Stub axle is introduced and its dimension, working and functionality are explained. The literature survey on Stub Axle is briefly shared along with the outcome of survey. The theoretical discussions are also detailed in this chapter. Chapter three explains about detailed work done in understanding the existing Stub Axle design, material property, loading conditions, assumptions and boundary conditions. The mesh sensitivity study is also incorporated. The various tools used to perform the analysis are emphasized. Chapter four details on various loading conditions that the Stub Axle is subjected to and the result under each category is explained. The Stub Axle under Static, Torsional loading for existing and proposed optimized design is explained. The relative study and the analysis results are described and acceptance of new dimensionally optimized Stub Axle is discussed. Chapter five describes briefly about the objective of the project and the methodology adopted to perform the project. The summary of the results are highlighted and the conclusion are discussed in detail. This chapter also emphasizes on the scope of the current project and future scope of work in terms of further dimensional changes or material change or complete design change or link aging change. Department of Mechanical Engineering, NHCE Bangalore Page 6 ANALYSIS AND OPTIMIZATION OF STUB AXLE OF TATA NANO 2014-15 Chapter 2 Literature Survey The literature survey was carried on Stub Axle and Front Axle steering system. The important points were noted. A stub axle is an axle that is connected to an assembly that mounts on one side of a trailer. It does not go all the way across the trailer like a typical straight axle does. The stub axle typically is a part of an assembly that includes the spring and shock mounts and is connected so that it can move freely as an integral part of the trailer's suspension. By using a stub axle assembly on a trailer, it is able to traverse rough roads without disturbing its load. The axle works much like an independent suspension on a sports car and allows each tire and wheel assembly to move independently. This drastically improves cornering as well as braking characteristics, especially on slippery roads. Most units are cast into the axle assembly and the entire piece is one single part, although others are independent assemblies that fit into a receptable on the trailer and is a separate component. In either case, the axle typically has a single wheel and tire bolted to it. Occasionally, this axle can be used in a dual-wheel application as well. The stub axle, in most cases, is easily replaced if broken. Most axles are bolted into a mounting assembly and can be simply removed by loosening a few bolts and sliding the broken stub out of the housing. In the cast units, the entire unit with stub must be replaced.