A Mini Project 12

A MINI PROJECT

Report submitted in partial fulfillment of requirement for the award of the degree of

BACHELOR OF TECHNOLOGYIN

MECHANICAL ENGINEERINGSUBMITTED

By

K ANIL KUMAR(09N81A0325)

DEPARTMENT OF MECHANICAL ENGINEERINGSPOORTHY ENGINEERING COLLEGE

(Approved by AICTE, Affiliated to JNTU, Hyd.)Nadergul vill, near vanasthalipuram,sagar road saroornagar mndl,R.R Dist – 05

ACKNOWLEDGEMENT

It is a great pleasure to present this mini project report carried out in the CENTRAL

INSTITUTE OF TOOL DESIGN, HYDRABAD. I express my heartily gratitude to Mr.

Shujayat khan (Principal Director) CITD who gave us an opportunity to undergo mini project in

CENTRAL INSTITUTE OF TOOL DESIGN.

I am very thankful to Mr. V. Krishnaswami (Director) CITD for extending his co-

operation throughout the project.

I would like to express my sincere gratitude to Mr.Vijaya Kumar (Asst. Director) CITD

who has initiated the concept of our project and affectionate disposition extended to enable us to

complete this project work.

I also express my sincere thanks to regards to Mr. Bullaiah for his excellent guidance

and co-operation for the successful completion of my project.

INDEX

CERTIFICATE

ACKNOWLEDGEMENT

ABSTRACT

LIST OF FIGURES

LIST OF TABLES

COMPANY PROFILE

1. Introduction

1.2 Radial Engine

1.3 Classification of Radial Engine

1.3 Applications of Radial Engine

2. PRO E Software

2.1 Benefits Of Usage Of ProE

3. Designing procedure of Radial Engine in pro E software

4. Conclusion

5. References

ABSTRACT

Radial engine was used in all U.S. Bombers and transports aircraft and in the most of the

other categories of aircrafts. A single row radial engine has an odd number of cylinders extending

radially from the centre line of the crank shaft. The number of cylinders usually ranges from 5 to

9 cylinders. The radial engine are arranged evenly in the same circular plane and all the pistons

are connected to a single throw 360o crankshaft thus reducing the both the number of working

parts and the weight.

The radial engine has the lowest weight to horsepower ratio of all the different types of

piston engines. It has the advantage of greater during because of the area preserved to the air, and

it eliminates some problem in cooling. Dependability and efficiency of engine have made it most

widely used type of large aircraft equipped with reciprocating engine.

The modeling of the radial engine components are modeled and assembled by using

modeling package (PRO E). It is the most advanced Three Dimensional Interactive Power Tool

in modeling. By using Pro E Software, it optimizes the design and modeling time with accuracy

compared to other modeling packages.

The finite element analysis of radial engine components are performed by using Ansys

12.1 (Advanced Numerical system simulation). In ansys software, we can perform structural &

thermal analysis under various loading condition.

The stress levels & deformations of components at various loading conditions are

obtained for the safe design consideration.

COMPANY PROFILE

CENTRAL INSTITUTE OF TOOL DESIGN (CITD)

Established in 1968 by the Govt. of India with the assistance of UNDP and ILO, is a

pioneering institution in the field of Tool Engineering in the Country. The Institute was initially

established d as an United Nations Development Programme (UNDP) Project and was executed

by International Labour Organisation (ILO). The Precision machinery and equipment was

donated by UNDP and the faculty was trained abroad in the area of Tool Engineering. The

UNDP Experts stayed at CITD for about 5 years and trained Officers, faculty & Staff of CITD in

manufacture and design of tooling.

Hydraulics Trainer with PID Controls, PLC Trainer, Sensors Technology Trainer,

Modular Production System with Testing, Processing, Handling and Sorting Stations, Cut

Section models of various Elements, Transparent working models of Hydraulics element etc.,

The CAD/CAM Centre is equipped with latest hardware like Compaq workstations.

IBM, DELL Systems, Pentium IV Systems and Software like Auto CAD, MDT ideas NX11,

Pro-E Wildfire, CATIA V5, UG, ANSYS, NASTRAN, Hyper mesh, Master Cam, Del Cam,

Solid Work, Solid edge etc. The institute has a special Library with collection of technical books

in Tool Engineering field and subscribes to various International Journals like CIRP Annals,

American Machinist, Journal of Engineering Materials & Technology (ASME), Precision

Engineering ( JAPAN) and Precision Tool Maker etc., The Documentation Centre collects and

organizes information and data useful for the technological advancement in Tool Engineering.

For the dissemination of information, the centre publishes a computerized current awareness

abstracting bulleting and provides technical enquiry service. Ds The Institute also extends its

services to the developing countries by imparting knowledge and necessary skills to their

personnel in the field of Tool Design, CAD/CAM and Low Cost Automation Techniques.

ACTIVITIES: CITD conducts several regular and part-time training programmers in the field of Tool

Design & Manufacture, Low Cost Automation, Macaronis and Computer Aided Design &

Computer Aided Manufacture for the benefit of National & International Participants. It also

conducts short term courses, Special Purpose Clinics in Tool Engineering, Seminars, Tailor-made

programmers, in various disciplines for the benefit of working personnel Apart from training,

CITD has been making significant contribution in meeting the needs of industries in design and

manufacturing of quality tools.

CITD provides full-fledged consultancy and servicing facility to large, medium and

small scale industries in the country. This includes assistance in design and development of tools

for various purposes and it also recommends measures to standardize tools and tooling elements,

components of jigs & fixtures, Dies and Moulds and other tools. CITD is a member on various

technical committees of Bureau of India Standards.

CITD conducts several regular and part-time training programme in the field of Tool

Design & Manufacture, Low Cost Automation, Mechatronics and Computer Aided Design &

Computer Aided Manufacturer for the benefit of National & International participants. It also

conducts Short-term courses, Special Purpose Clinics in Tool Engineering, Seminars, Tailor-

made Programmes, in various disciplines for the benefit of working personnel.

Apart from training, CITD has been making significant contribution in meeting the needs

of industries in design and manufacturing of quality tools. CITD provides full-fledged

consultancy and servicing facility to large, medium and small scale industries in the country.

This includes assistance in design and development of tools for various purposes and it

also recommends measures to standardize tools and tooling elements, components of jigs &

fixtures, Dies and Moulds and other tools. CITD is a member on various technical committees of

Bureau of Indian Standards.

OBJECTIVEThe objective of the institute is to meet the requirements of the Industries in the field of

Tool Design and manufacture and to train the technical personnel in these fields. The Institute

has strong links with industries to impart practical knowledge by way of undertaking tooling

assignments.

FACILITIESThe Institute has a well equipped Tool Room with sophisticated CNC machines like CNC

EDM ( Charmilles Roboform 54), CNC Wirecut EDM ( AGIE Cut Classic –III & Electronics),

4-Axis & 5-Axis High-Speed Machining centres, Kellenberger CNC Cylindrical Grinding

Machine and 3D Coordinate Measuring Machine with Scanning and Digitization facilities. The

Institute is equipped with latest versions of EMCO Table Top CNC turning and Milling

machines with dosed loop systems to impart training in CNC Programming. The Calibration

laboratory is set up in CITD with Universal Horizontal metroscope ULM OPAL 600 Carl Zeiss

Technology, Germany and slip Guage Measuring Unit 826 with Millitron 1240, Mahr, Germany,

to Calibrate Limit Guages, Micrometers, Dial Indicators, etc. The automation Centre is equipped

with various simulator training kits like advanced Pneumatics Trainer, Advanced Electro

Pneumatics Trainer with PID Controls, Advanced Hydraulics Trainer, Advanced Electro

Hydraulics Trainer, Closed loop.

DOCUMENTATION & LIBRARYDOCUMENTATION CENTRE;

The documentation centre is the recent addition to the CITD. This has started functioning

from 1984 onwards. Subscription is made to about 29 National and International periodicals in

the field of tooling (tool design & manufacture). The documentation provides abstract service to

the industry/faculty/trainees with the selective dissemination of knowledge in the field of tool

design and tool

manufacture. The facilities of library/documentation is open for reference to all interested

engineers including trainees/faculty and personnel from industry.

LIBRARYCITED has a full-fledged special library with a collection of 6000 technical books on

various disciplines of Tool engineering and allied subjects. CITD has published 250 books on

related subjects prepared by ILO Experts and CITD Faculty. CITD is the member of many

professional bodies such as American Society for Metals, Die Casting Society of India, Indian

Society of Tool Engineers, Indian Standards Institution, Indian Society of Manufacturing

Engineers, Indian society for Technical Education, Fluid Power Society of India. The Library has

got standards, reports, films, Photostat documents for reference. The Library subscribes to

National and International Periodicals for the benefit of trainees & Clientele. For effective

functioning of the Tool Room, better performance of the Faculty in their respective classes and

the relevant machines, the library is the living agency which feeds them with selective

dissemination of knowledge in right time with right technical literature. This library is open for

reference to all interested engineers.

CAD/CAM CoursesCourses on CAD/CAM

• “Post graduate” diploma in CAD/CAM for tool engineering “ PGDCTE”

• Master Certificate in Computer Aided tool engineering ( MCTE)

• Master Certificate in CAD/CAM( M-CAD-CAM)

• Mechanical CAD/CAM

• Mechanical CADD

INTRODUCTION

The radial engine has been the work horse of military & commercial air craft ever since the 1920’s and the world war-I. Radial engine was used in al U.S. Bombers and transports aircraft and in the most of the other categories of aircrafts. They were developed to a peak of efficiency and dependability and even today. In the jet age, many are still in operation throughout the world in all types of duty.

The radial e Radial engines reached their Zenith during WWII (World War II). There are some radial engines around today, but they are not that common. Most propeller-driven planes today use more traditional engine configurations (like a flat four-cylinder) or modern gas turbine engines. Gas turbines are much lighter than radial engines for the power they produce.The radial engine idea is very simple; it takes the pistons and arranges them in a circle around the crankshaft.

You can see in the illustration that this is a five cylinder engine-radial engines typically have anywhere from three to nine cylinders. The radial engine has the same sort of pistons, valves and spark plugs that any four-stroke engine has. The big difference is in the crankshaft.

Instead of the long shaft that’s used in a multi-cylinder car engine, there is a single hub all of the piston’s connecting rods connect to this hub. One rod is fixed, and it is generally known as the Master rod. The others are called Articulating rods. They mount on pins that allow them to rotate as the crankshaft and the pistons moves.

Figure:Radial Engine (5 Cylinder)

Figure:5 Cylinder Radial Engine

Figure:Diesel Radial Engine

Figure:Usage Of Radial Engine In Two Different Fields

Figure:Radial engine with propeller

1.1 RADIAL ENGINE

The radial engine has the lowest weight to horse power ratio of all the different types of

piston engines. It has the advantages of greater during because of the area preserved to the air,

and it eliminates some problem in cooling. However dependability and efficiency of engine have

made it mostly widely used type of large aircraft equipped with reciprocating engine.

A Single row radial engine has a odd number of cylinders extending radially from the

centre line of the crank shaft. The number of cylinders usually ranges from 5 to 9 cylinders. The

radially engine are arranged even ally in the same circular plane, and all the pistons are

connected to a single throw 360o crankshaft thus reducing the both the number of working parts

and the weight.

A double row radial engine resembles two single-low engine combined on a single

crankshaft the cylinders are arranged in radially in two rows, and each row has an odd members

cylinders used in either 14 or 18, which means that the same effect is produced as having either

two even cylinders engines or two nine cylinder engines joined on one crankshaft. A two throw

180deg crankshaft is used to permit the cylinder in each row to be alternating staggered on

common crank case that is the cylinders of the rear row are located directly behind the space

between the cylinders. Both rows receive ram air for the necessary cooling.

1.2 TYPES OF RADIAL ENGINE’S:

• 3-CYLINDER ENGINE (Szekely SR-3L)

• 5-CYLINDER ENGINE (Kinner K5)

• 6- CYLINDER ENGINE( Curtiss Challenger R-600)

• 7- CYLINDER ENGINE( Jacobs R-755)

• 9- CYLINDER ENGINE( Wright Cyclone r-1820)

Figure:3 Cylinder Radial Engine

Figure:5 Cylinder Radial Engine

Figure:6 Cylinder Radial Engine

Figure:7 Cylinder Radial Engine

Figure:9 Cylinder Radial Engine1.3. DOUBLE ROW ENGINE:

• 14-CYLINDER ENGINE ( Wright Cyclone R-2600)

• 18-CYLINDER ENGINER ( Wright Cyclone R-3350)

Figure: 14 Cylinder Radial Engine

Figure: 18 Cylinder Radial Engine

1.4 MULTI-ROW RADIALS

Originally radial engines had but one row of cylinders, but as engine sizes increased it

became necessary to add extra rows. Most did not exceed two rows, but the largest radial engine

ever built in quantity, the Pratt & Whitney Wasp Major, was a 28-cylinder 4-row radial engine

used in many large aircraft designs in the post-World War II period. The USSR also built a

limited number of Zvezda 42-cylinder diesel boat engines featuring 6 rows with 7 banks of

cylinder, bore of 160 mm, and total displacement of 144.5 liters. The engine produced4500 KW

at 2500 rpm.

Figure: Multi row engine

\

APPLICATIONS

Radial engines have a relatively low maximum rpm (rotation per minute) rate, so they

can often drive propellers without any sort of reduction. Most propeller-driven planes today use

more traditional engine configuration (like a flat four-cylinder) or modern gas turbine engines.

Gas turbines are much lighter than reduction gearing.

• Because all of the pistons are in the same plane, they all get even cooling and normally

can be air-cooled. That saves the weight of water-cooling.

• They can produce a lot of power.

Introduction

Getting Started with Pro/ENGINEER Wildfire is a tutorial-based

introduction to creating parts, assemblies and drawings in

Pro/ENGINEER. If you follow the complete series of procedures, you

will learn how Pro/ENGINEER passes 3D design information to and

from every design stage, from solid part creation, to part assembly, to the

output of mechanical drawings.

These procedures also introduce basic techniques of using

Pro/ENGINEER in each design phase. Familiarity with all phases of

Pro/E design will help you to understand your particular role within a

team effort.

Pro/ENGINEER Concepts

Becoming a Pro/ENGINEER user means learning to think in terms of

how the components of a design interact, and to think ahead to how those

interactions may change. At the simplest level, these components may be

the discrete geometric shapes, called features, that comprise a solid part:

extrusions, holes, or chamfers, for example. At a higher level they may be

the individual parts of your assembly, joined together in an

interdependent way. At all levels, this component interaction toward a

common purpose is called the design intent. This chapter describes how

the principle of design intent is passed through all phases of the design,

from conception to final documentation.

Assembly In Pro EIn this chapter, you will learn how to place the parts of the cell phone

model into an assembly file. Assembly mode lets you assemble parts by

locating them in reference to other parts, or to non-part objects like datum

planes, datum points, or coordinate systems.

You’ll start assembling the cell phone parts by placing a “base

component” into an empty assembly file. You will then use placement

constraints to add each subsequent part and orient it to the base

component. These constraints determine whether surfaces and edges are

aligned, mated, or offset, and by what values or limits.

After you complete the assembly of the cell phone, you’ll learn some

modification techniques to make changes to the model. You’ll see how the

changes to your assembly are automatically passed back to the parts.

Assembly Constraints

Constraints in an assembly are similar to those used in Sketcher in that

there must be enough of them to complete the placement of a part in

relation to another part in 3D. You must establish references in two

directions, define a surface or edge relationship (mate or align with an

offset if required), and enter values for the references. When enough

constraints are on a part in an assembly, the part is considered fully

constrained. A part can be added to an assembly without it being fully

constrained. In this case, the part is considered packaged.

You can interactively import, place, and constrain parts to build an

assembly object by object. You can also use automatically determined

placement constraints to speed up the process. The procedures on

assembling the cell phone demonstrate both methods.

When you start a new assembly, you must first determine which part

should be the base component. All of the subsequent components that you

assemble reference this component either directly or indirectly. For this

5-2 Getting Started with Pro/ENGINEER Wildfire

reason you should always use a part that you are not likely to remove

from the assembly. For this assembly, you’ll use the front cover as the base

component.

Pro/ENGINEER provides many placement constraints to assemble your

parts. You’ll see that the Automatic option selects only the best suited

constraint for the particular situation. The constraints in the following

table are accessible from the Component Placement dashboard:

Constraint Description

Mate Position two surfaces or datum planes so they face each other. Mate type may

be Coincident or Offset.

If the offset is set to Orient, the facing surfaces have a constantly varying

offset.

Align Make two surfaces or datum planes face the same direction, two axes coaxial,

or two points coincident.

Align may be set to Offset or Coincident. If the offset is set to Orient, the

surfaces face the same direction with a constantly varying offset.

Insert Insert one revolved surface into another revolved surface, making their

respective axes coaxial.

Coord Sys Make two datum coordinate systems coincident to each other.

Tangent Control the contact of two surfaces at their point of tangency.

Pnt On Line Control the contact of an edge, axis, or datum curve with a point.

Pnt On Srf Constrain two surfaces to mate so that a datum point on one surface is in

contact with the other surface.

Edge On Srf Constrain an edge to contact a surface.

Angle Fix the rotation of the aligned axes or edges.

Place the Base Component

The first step in creating an assembly is importing a base component and

automatically aligning its part coordinate system with the assembly’s

coordinate system.

1. Click File > New. The New dialog box opens.

2. Select Assembly under Type and enter a name for the assembly. Use

the default template.

3. Click OK. The Pro/ENGINEER main window opens and displays the

default assembly datum planes, all marked with the prefix ASM_.

4. Click Insert > Component > Assemble on the main menu. The Open

dialog box opens.

5. Select front_cover.prt. The front cover of the cell phone model

appears and the Component Placement dashboard appears.

6. Click the Default constraint set from the Automatic constraint set list

to assemble the front cover in the default constraint position. This

constraint aligns the part coordinate system with the assembly

coordinate system. You will see the part’s Front, Right, and Top part

datum planes align with their respective assembly datum planes. The

STATUS line indicates that the base component is fully constrained.

7. Accept and save the assembly.

Benefits of ProE Usage

1) The Mechanical Engineer creates a PCB board inside an assembly that mounts to

their existing hardware.

2) Mounting holes are created.

3) Keeping/Keep out areas are created.

4) Connectors (from the ECAD library) are placed on the PCB board.

5) File is exported to an IDF 3.0 file.

6) The IDF file is read into the PCB layout program.

7) Components are added observing the keep in and keep out areas on the board.

8) The file is exported out of the PCB layout program back to an IDF 3.0 file.

9) The Mechanical Engineer opens up their existing PCB board and appends the new

IDF file. New components are added and existing components are automatically

moved because of the PCB layout engineer’s design change.

This is a single iteration, but this can continue until the board is fully designed.

Interference checks can be run and thermal analysis is one step away because of a fully

designed PCB board.

Sr no

Component’s

required

component Quantity

01 Master Rod 01

02 Articulated rod 04

03 Piston 05

04 Master rod Bearing 01

05 Rod lower bush 04

06 Rod upper bush 05

07 Piston pin 05

08 Piston ring 20

09 Link pin 10

CONCLUSION

• Modeling of radial engine is done by using the PRO E software, by which the modeling

time is reduced.

• Very accurate design is be achieved by PRO E software.

• Assembly by PRO E software is so easy.

REFERENCES

• Machine Design by R.S. KHURMI and J.K. Gupta

• www.wikipedia.com

• www.encyclopedia

• www.google.com

• http://seminarprojects.com