1 Chapter 1: ABSTRACT An Inspection Tool is basically a Gauge which is the main aspect of this project. The component to be tested on it is a Yoke Shaft, a product being manufactured in Mahindra Sona Limited, Nasik. Various applications are being related to yoke shaft, out of which transmission plays an important role, also in automobiles, etc. Focussing these factors it is the prime requirement to design a gauge which will take into account the parameters like compatibility, super finishing of the tool, proper material selection, tribological considerations, overcoming failures, and reducing cycle time for inspection, high accuracy and easy handling located near to the machines. Currently the inspection process consumes lot of iterations and time. Efforts have been done to throw light on the design of a highly precise gauge which will check if the offset distance between the axis of splines and bores is within the prescribed tolerance zone, as well as the centrality of bores simultaneously. This accuracy needs to be kept throughout the hobbing process. Further, this check will ensure the proper lubrication and alignment during the assembly of the component with other parts. Manufacturing of the proposed design is the next step after computing number of iterations. These gauges will ultimately emphasis on the dimensional accuracy and efficiency of the product.
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Design, Manufacturing of Inspection Tool to Chech Angularity in Yoke Shaft
A project conducted in Mahindra Sona, Nashik includes design & manufacturing of a gauge which would determine whether the plane containing two diametrically opposite splines on a yoke shaft is within the tolerance limits, from angularity point of view, wrt fork end bores
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1
Chapter 1: ABSTRACT
An Inspection Tool is basically a Gauge which is the main aspect of this project.
The component to be tested on it is a Yoke Shaft, a product being manufactured in
Mahindra Sona Limited, Nasik. Various applications are being related to yoke shaft,
out of which transmission plays an important role, also in automobiles, etc.
Focussing these factors it is the prime requirement to design a gauge which will
take into account the parameters like compatibility, super finishing of the tool, proper
material selection, tribological considerations, overcoming failures, and reducing cycle
time for inspection, high accuracy and easy handling located near to the machines.
Currently the inspection process consumes lot of iterations and time.
Efforts have been done to throw light on the design of a highly precise gauge
which will check if the offset distance between the axis of splines and bores is within the
prescribed tolerance zone, as well as the centrality of bores simultaneously. This accuracy
needs to be kept throughout the hobbing process. Further, this check will ensure the
proper lubrication and alignment during the assembly of the component with other parts.
Manufacturing of the proposed design is the next step after computing number of
iterations. These gauges will ultimately emphasis on the dimensional accuracy and
efficiency of the product.
2
Chapter 2: COMPANY PROFILE
MAHINDRA SONA LTD.
Address: - Mahindra Sona Limited,
Plot No. 89/1, MIDC,
Satpur, Nashik -422 101
.
The manufacturing unit is situated at Nashik about 180 km North-east of Mumbai
and employs about 370 people. Its constructed area is around 10000 Sq. meters. The
Nashik plant commenced production in 1979 following a technical and financial joint
venture between Mahindra & Mahindra Limited and Dana Corporation USA, named
Mahindra Spicer Limited.
In 1984, Mahindra Spicer Limited merged with its parent company Mahindra &
Mahindra Limited and became MSL Division of the parent company. In March 1995,
Mahindra & Mahindra Limited and Sona Koyo Steering Systems Ltd. formed a new
company MAHINDRA SONA LIMITED to take over the automotive component
business of MSL Division of Mahindra & Mahindra Ltd.
The company is engaged in designing and manufacturing a wide range of auto
ancillary products such as propeller shafts, clutches, universal joint kits, steering joints,
steering column parts and axle shafts. The company is original equipment supplier to
almost all vehicle manufacturers in India and caters to the spare parts market through a
wide distribution network.
The company has been certified for ISO-9001 in 1995 and QS-9000 in1999. The
company firmly believes that the high standards of quality can only be achieved through
strong systems and the support of its people.
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Mahindra Sona Limited manufactures Yoke shafts, Propeller Shafts and
components for Automotive Applications like Passenger Cars, Multi Utility Vehicles,
Sport Utility Vehicles, Light Commercial Vehicles, Medium Commercial Vehicles and
Heavy Commercial Vehicles. MSL Drive Shafts also cater to wide Industrial
Applications like Earth Moving Equipment, Engine Dynamometer Testing, and Radiator
Fan Drive for Railways, Steel Rolling Mills, and Printing Machineries etc, MSL’s other
products include Steering Universal Joints for. Automotive Applications like Passenger
Cars, Multi Utility Vehicles and Heavy Commercial Vehicles.
The other product line of Mahindra Sona Limited is for the Automotive Clutches.
This includes the worlds latest Diaphragm Type and the convential lever type for
Passengers Cars, Multi Utility Vehicles, Sport Utility Vehicles, Light Commercial
Vehicles, Medium Commercial Vehicles, Heavy Commercial Vehicles and Farm
Tractors.
4
Chapter 3: THEORY OF GAUGE
The gauges used in the industries have been used to perform various functions for
controlling the quality of the components like shafts, keys, joints. The gauges are actually
dimension measuring instruments. The dial gauges are specifically designed for this
purpose.
1st Principle Method
The existing system for checking the angularity of a splined yoke shaft is a tedious
job. In the 1st principle method, the Yoke shaft is mounted between the two centres. Thus,
now it has only rotational degree of freedom. With the help of a height gauge the bore
axis is made horizontal. With reference to this position the angularity of the splines is
measured by using a dial gauge.
The procedure for the 1st principle method is:
1. The Yoke shaft is placed between the two centres.
2. The height gauge is used at both the bores of the yoke shaft to make it perfectly
horizontal w.r.t. the platform.
3. Then using a dial gauge the angularity is measured at a roughly horizontal spline.
4. Then the angularity is measured at a diametrically opposite spline..
5. The difference between the two readings is the angularity for the Yoke shaft.
Use of 1st principle method
Although the 1st principle method sounds simple, it is not so. It requires a very
skilled person for the measurement. It is tedious for the operator.
The company required a method or a gauge which was simpler in operation. The
gauge should be such that anyone should be able to use it, also it should be within the
reach of the operator.
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Concept for the gauge3
Inspite of advancement in machine tool technology, it is impossible to achieve
dimensional perfection due to various reasons such as human error, vibrations, tool wear,
deflection,..etc.
It has been realised that perfect components are difficult to produce and any
attempt towards perfection will result in extra cost of the component. If the dimensions
are to be maintained within a very close degree of accuracy, lot of time will be consumed.
The functional aspects of the component can be achieved even without going for its exact
dimensions. As no two things are identical in nature a kind of permitted variations has a
significant importance.
A comparator gauge is used to find out by how much the dimensions of a given
component differ from that of a known datum. A dial indicator forms an integral part of
the comparator gauge. If the dimension is greater or less than the standard, then the
difference will be shown on the dial.
Yoke Shaft
A die cast of Yoke shaft is procured from the vendors. The company performs
operations like Boring, Drilling, Grooving, Coating and Grinding on the die cast. Thus a
finished product is obtained.
The Yoke shaft is used along with the propeller shaft of the vehicles. We designed
a gauge for the Yoke Shaft No. 3382901. This Yoke shaft is supplied to JCB,Ashok
Leyland, Nissan and other such heavy vehicle Companies.
Chapter 4: PROBLEM STATEMENT
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Design and Manufacture the gauge to check the angularity of Yoke shaft which
should fulfil the following requirements:
1. The system should be simple in working.
2. The time required for measurement should be minimum.
3. The system should be within reach.
4. The gauge should be easy to operate for anyone.
5. A few changes made, the gauge can be used to check other yoke shafts.
[Fig. 1] Courtesy MSL
Chapter 5: DESIGN OF VARIOUS COMPONENTS
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5.1 BED
Material SAE8620 / 20MnCr5
Basic size 500mm x 200mm x 20mm
Quantity: 1
No. Specification Function
1 Case Hardening Creates a hard, wear resistant skin but preserving
a tough and ductile interior.
2 Length 500mm Long Enough to slide the job
.
3 Width 200mm Ease of loading the job, as the width is 50%
more than the maximum width of the job.
4 Thickness 20mm Guide plates are bolted to the Base plate using
M6 x 20 screws.
5 4 x M8 Tap, holes For fixing the Guide Plates to the Base plate
using Allen screws.
6 4 x Ø7 Dowell holes For accurate positioning of the Guide Plates on
the Base plate.
7 Super finishing on the upper
surface.
To reduce wear and tear due to the sliding
motion of the Locator.
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5.2 GUIDE PLATES
Material SAE8620 / 20MnCr5
Basic size 261mm x 24mm x 20mm
Quantity: 2
No. Specification Function
1 Case Hardening Creates a hard, wear resistant skin but preserving
a tough and ductile interior.
2 Length 261mm Length of the Guide Plates is 1.25 times that of
the Locator for easy in sliding and rotating.
3 Guide plate is provided with
a step.
For proper mating with the Locator and sliding
in a determined path.
4 2 C’Holes, M14x1 For fixing the Guide Plates to the Base plate
using Allen screws.
5 2 x Ø7 Dowell holes For accurate positioning of the Guide Plates on
the Base plate.
6 Super finishing on the
mating surfaces.
To reduce wear and tear due to the sliding
motion of the Locator.
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5.3 MALE PART
Material SAE8620 / 20MnCr5
Basic size 100mm x 30mm x 100mm
Quantity: 1
No. Specification Function
1 Height 100mm It comes in contact with the Alignment Mandrel
at its diameter.
2 1 x Ø10 hole with C’ Bore. For attaching the Mandrel to the Male Part.
3 Housing, Ø20
For mounting of spring.
4 Super finishing on the
mating surfaces.
To reduce wear and tear due to the sliding
motion of the Locator.
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5.4 FEMALE PART
Material SAE8620 / 20MnCr5
Basic size: 140mm x 20mm x 180mm (rect. Plate)
40mm x 30mm x 180mm (guide plates, 2 nos.)
No. Specification Function
1 A rectangular plate For sliding of male part.
2 Thickness 30mm It matches exactly with the step of the male part
provided for sliding.
3 2 C’ Bore, M7 x 1 Provided for fixing the female part to bed.
4 2 C’ Bore, M14 x 1 For attaching the guide plates to the rect. Plate.
5 2 x Ø7 Dowell holes For accurate positioning of the Guide Plates on
the rectangular plate.
5 Super finishing on all the
mating surfaces.
To reduce wear and tear due to the sliding
motion over the Base plate.
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5.5 RING
Material SAE8620 / 20MnCr5
Basic size ID Ø40, 5mm thick
Quantity: 1
No. Specification Function
1 ID Ø 40 To accommodate the spline locator.
2 Thickness 5mm For attaching the cantilever strips.
3 Cantilever strips.
50mmx15mmx10mm: 3nos.
These are welded at the circumference of the
ring to transfer the response.
4 Super finishing on the inner
surface.
To reduce wear and tear and to help in easy press
fit of the Ring in the Locator.
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5.6 SPLINE HOLDER
Material SAE8620 / 20MnCr5
Basic size 60mm x 30mm x 144mm (rect. Block)
167mm x 100mm x 12mm (rect. Plate)
Quantity: 1
No. Specification Function
1 Bore, Ø40 To accommodate the spline locator.
2 Height 144mm So that the dial gauge comes in plane with the
top surface of the cantilever strips.
3 2 C’ Bore, M7 x 1 Provided for fixing the rectangular block to the
rectangular plate.
4 Chamfer, 2 x 450
To avoid sharp edges for safety precautions.
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5.7 SPLINE LOCATOR
Material SAE8620 / 20MnCr5
Specification: 16x Ømm x 25mm
Quantity: 1
No. Specification Function
1 Case Hardening Creates a hard, wear resistant skin but preserving
a tough and ductile interior.
2 Minor Diameter Ø12 So that the spline locator will accommodate the
splines of yoke shaft.
3 Outer Diameter Ø12 To accommodate the hole in spline holder
4 Super finishing on the outer
surface.
As it comes in contact with the Alignment
Mandrel
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5.8 ALIGNMENT MANDREL
Material SAE8620 / 20MnCr5
Basic size Ø34.7mm x 155mm
Quantity: 1
No. Specification Function
1 Case Hardening Creates a hard, wear resistant skin but preserving
a tough and ductile interior.
2 Diameter Ø34.7 So that the Yoke Shaft is inserted in to the
alignment mandrel.
4 Chamfer, 2 x 450 To avoid sharp edges for safety Precautions
5 Super finishing on the outer
surface.
As it comes in contact with the Yoke Shaft.
OTHER STANDARD COMPONENTS
Spring: Ø20 Mean Dia., 1.5mm Wire Dia.
Bolts: M6, M7, M10, M14
Dial Indicator: Make- Baker Co.
Least Count: 1 µm
25
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Chapter 6: MANUFACTURING OF VARIOUS COMPONENTS
6.1 BED:
Material: SAE8620 / 20MnCr5
Qty: 1
Raw Material Size: 500mm x 200mm x 20mm
Weight: 15 kg
Raw Material Cost: Rs. 1000
Process time: 8 hrs
Manufacturing Cost: Rs. 440
Component cost: Rs. 1440
No. Operation Description Machine Used Machine Tool Rate