air cylinder

Module1-Reverse Engineering 1 2011 Batch

automotive SOPautomotive SOP

2011 Batch

Project Report for Module-1: Reverse Engineering November / December 2011

NAME

ROLE

Vimal Raj.P.V Project Leader

Gowtham.S Part Designer

Vignesh.M Part Designer

Prabhu Rajan.R Part Designer

Munez Kumar.T Part Designer

PRODUCT: AIR CYLINDER (EXHAUST BRAKING SYSTEM)


automotive SOPautomotive SOPAcknowledgement

To,

Automotive SOP Coordinators and Initiators

SAE INDIA Southern Section.

We, the students of Rajalakshmi Engineering College are thankful to the

Initiators of Automotive SOP. It’s a wonderful learning experience rendered to us

by great minds from WABCO.The learning process was so tedious and of course

more informative. The guest lectures, the training aids and the teaching faculty

were all high-end. We thank all these great people for caring us and for making us

grasp new concepts in a very short span of time.

We are greatly thankful to Mr.S.Shanmugam and Mr.Selvamani for taking

pains to make us finish our project within time in a precise manner.

Thank You,

Yours truly,

Vimal Raj.P.V

Gowtham.S

Vignesh.M

Prabhu Rajan.R

Munez Kumar.T


automotive SOPautomotive SOPTable of contents

S.No Contents

1. Summary

2. Background Information

3. Product Structure

4. Function Block Diagrams

5. Product Function

6. Section View

7. Part Details

8. Bill of Materials

9. Conclusions and learning

10. References

11. Bibliography



Summary

December 2011

Sun Mon Tue Wed Thu Fri Sat

29

Pro-E Learning

tutorial initiated

30 1 2 3

4 5 6 7

8

Pro-E Learning tutorial

Completion

9

Departure to Yelagiri

10

11

Arrival from

Yelagiri

12

Module –I initiated.

Dismantled Air

Cylinder

13

Measurements and Part

Modeling of Air Cylinder

14

Assembly Modeling

15

Material Analysis and

Report Documentation

16

Function Analysis

17

Function Analysis

18

Bill of materials

19

Mates Table and

Liaison Matrix

20

Function Deployment

and Cost Analysis

21

Report Completion

22

23

Report Submission

24

25 26 27 28 29 30 31


automotive SOPautomotive SOPBackground Information

There are only two main kinds of air cylinders: Double acting, and single acting. They come in all variations, shapes and sizes. Both kinds are useful for haunt work. Double acting cylinders are useful when you need to push in both directions, and single acting cylinders are useful when only a push in one direction is needed. And, sometimes 'in a pinch', you can adapt a double to act as a single, and a single to act as a double.

Air cylinders are measured by three main values: "pressure rating", the "bore", and "stroke"

Pressure rating

This is the maximum pressure the air cylinder can safely handle.

Bore The interior diameter of the cylinder.

Stroke The range of movement of the air cylinder's rod.

Air Cylinders are vital component of an Exhaust Air Brake System. The purpose of EBS is as follows.

1. Increases safety by reducing load on foundation brakes..

2. Improves cold weather operation, reduces thermal stress on intake valves, and allows

prolonged idling in extreme cold weather.

3. Aids in shifting of some engine, transmissions combinations.

4. Increases brake lining life.

5. Less noise, no additional muffling necessary.

6. Butterfly design minimizes weight and envelope size.

7. Guillotine design for heavy duty industrial applications.

8. Adjustable opening stop allows system tuning to your engine and exhaust system.

9. Actuating cylinder assembled with hi-temperature components and stainless steel shell.


automotive SOPautomotive SOPProduct Structure

Air Cylinder

Housing Piston Assembly Spring

Guide

Spring

Circlip Plate Washer Nut

Mounting Bush

Lip Seal Piston

Grommet

Filter Washer

Knuckle

Joint

Lock Pin Lever lock Pin



Functional Block Diagrams

HOUSING

LOCK PIN BALL JOINT NUT

MOUNTING BUSH PISTON ASSEMBLY

FILTER WASHER GROMMET SPRING GUIDE

PLATE WASHER

CIRCLIP

SPRING

LIP SEA

L


automotive SOPautomotive SOPWorking of Air Cylinder


automotive SOPautomotive SOPPart Details

S.No DESCRIPTION QUANTITY

1. HOUSING 1

2. PISTON 1

3. SPRING 1

4. BALL JOINT 1

5. CIRCLIP 1

6. SPRING GUIDE 1

7. PLATE WASHER 1

8. LIP SEAL 1

9. GROMMET 1

10. NUT 1

11. LOCK PIN 1

12. MOUNTING BUSH 1



88. Part Details

Process : Casting

Surface Finish: Chromating

Housing

The Housing usually renders protection to various components enclosed

by it.Inspite of protection it also helps to mount the overall assembly to a

butterfly valve assembly through a push rod in EBS.

Functions

1. It gives protection as well as mechanical support to all the components

enclosed by it.

2. It also provides sealing for piston assembly


automotive SOPautomotive SOPFunction Deployment

Part Description HOUSING

Part Number 1

Functional Deployment

S.No Function Source Drawing Reference

1. Contain the parts Basic Function Bore diameter

2. Receive inlet port Basic Function Port thread size and thread depth

3. Guide the piston Mate_Linear slide Bore diameter

4. Limit the piston Mate_Limit Length of the bore

5. Interfere with Lip seal Mate_Interference Bore diameter

6. Guiding the spring Mate_Linear slide Bore diameter

7. Limit the spring Mate_Limit Bore length

8. Guide the spring guide Mate_Linear slide Bore diameter

9. Guide the filter Mate_Linear slide Bore diameter

10. Guide the washer Mate_Linear slide Bore diameter

11. Receive circlip and circlip getting snapped to housing

Mate_snap

Mate_Recieve

Circlip groove diameter and width

Bore diameter

12. Mounting bush snapped with housing Mate_snap Mounting cylinder ID

13. Housing breakage Failure Mode Material, Thickness and FEA, Theoretical calculations

14. Housing crack Failure Mode Material, Thickness and FEA, Theoretical calculations

15. Inlet port crack Failure mode Port outer diameter, Material and Thread size

16. Worn out of bore (Spring and piston) Failure Mode Bore diameter, material , surface roughness and surface protection

17. Corrosion of housing Failure Mode Surface Coating

18. Leak at lip seal area Failure Mode Bore diameter, Surface roughness

19. Leak at housing bore (Any point) Failure Mode Bore outer diameter, material, Porosity note



Part Detail

Process:Machining and Insert moulding

Piston Assembly

The piston rod is typically cold-rolled steel which attaches to the piston

and extends from the cylinder through the rod-end head. In double rod-

end cylinders, the actuator has a rod extending from both sides of the

piston and out both ends of the barrel.

Functions

1. They prevent the pressurized air from passing by the piston to the chamber on the opposite side


automotive SOPautomotive SOP Function Deployment

Part Description PISTON

Part Number 2



1. Controls the air cylinder assembly

Basic function Piston OD and length

2. Guided by the housing Mate_Linear Slide Piston OD

3. Limited by the Housing Mate_Limit Length of the Piston

4. Locate the spring Mate_Locate Piston butting OD

5. Lip seal snapped with the piston neck

Mate_Snap Piston neck OD and length

6. Limit the spring Mate_Limit

Distance between piston butting surface to spring guide butting surface

7. Guide the spring guide Mate_Linear Slide Diameter of the piston rod

8. Limited by the spring guide Mate_Limit

Distance between piston butting surface to spring guide butting surface

9. Guide the grommet Mate_Linear Slide Diameter of the piston rod

10. Guide the Filter washer Mate_Linear Slide Diameter of the piston rod

11. Guide the Plate Washer Mate_Linear Slide Diameter of the piston rod

12. Limit the nut Mate_Limit Thread length on the piston

13. Nut gets threaded on the piston Mate_Screw Thread size, Depth

14. Ball joint gets threaded on the piston

Mate_Screw Thread size, Depth

15. Piston breakage Failure Mode Piston rod diameter, Material selection

16. Corrosion of Piston rod Failure Mode Surface Coating

17. Piston rattling Failure Mode Piston OD


automotive SOPautomotive SOP18.

Wear and tear of piston (top and bore guiding surface)

Failure Mode Piston OD,Material Selection

19. Seperation of piston rod and piston

Failure Mode Projections on the piston rod

20. Leakage of Lip seal(at piston interface)

Failure Mode Surface Finish of piston

21. Buckling of piston rod Failure Mode Piston rod OD,Material Selection



Part Detail

Process : Coiling

Surface Finish: Zinc Plating

Spring

1. A spring is an elastic object used to store mechanical energy. Springs are usually made out of spring steel.

Functions

1. Compression coil springs, designed to resist being compressed. - base function

2. To transfer the pressure force




Part Description SPRING

Part Number 3



1. Return action for the piston Basic Spring tension

2. Guided by the housing Mate_Linear Slide Spring OD

3. Limited by the Housing Mate_Limit Length of the spring

4. Located by the piston Mate_Linear Slide Inner diameter of the spring

5. Limited by the piston Mate_Limit Length of compressed spring

6. Guided by the Spring guide Mate_Linear Slide Spring ID

7. Limited by the Spring guide Mate_Limit Distance between guide butting surface to piston butting surface

8. Spring breakage Failure Mode Length of the spring, Material Selection, Pitch of the spring

9. Corrosion of spring Failure Mode Surface coating

10. Spring Buckling Falure Mode Length of the Spring


automotive SOPautomotive SOPPart Detail

Process: Machining

Functions

1. Receives Customer interface

2. Absorbs vibrations

Ball joint

A hinged joint in which a pin fastens the ends of two rods, one of which has a eye that fits between the two perpendicular projective of the other modes of failure of knuckle joint


automotive SOPautomotive SOPFunctional Deployment

Part Description BALL JOINT

Part Number 4



1. Connects to customer interface

Basic Bore diameter and depth

2. Screwed to the piston Mate_Screw Thread size and depth

3. Limited by the nut Mate_Limit Thread depth

4. Lock pin snapped with Ball joint neck

Mate_Snap Neck diameter and width

5. Corrosion of ball joint Failure Mode Surface coating

6. Wear and tear of Ball joint(Inner surface)

Failure Mode Bore diameter, Material Selection

7. Breakage of ball joint Failure Mode Neck OD



Process : Punching

Internal Circlip:

1. Circlip - type of fastener - consists of a semi-flexible metal ring with open ends which can be snapped into a machined groove on a dowel pin or other part to permit rotation but to prevent lateral movement.

Functions

1. Circlips are often used to secure pinned connections.- base function


automotive SOPautomotive SOPFunctional Deployment

Part Description CIRCLIP

Part Number 5



1. Limits all the parts Basic Circlip ID

2. Snapped in the housing Mate_Snap Circlip OD and thickness

3. Limit the plate washer Mate_Limit Circlip ID

4. Breakage of Circlip Failure mode Thickness of the circlip and material selection

5. Corrosion of Circlip Failure Mode Surface Coating

6. Breakage of CIrclip(At holes) Failure Mode Hole diameter

7. Inflexibility of CIrclip Failure Mode Surface Finish, Distance between the holes



Process : Injection moulding

Spring Guide:

1. Spring guide is used to maintain the spring positional constrained

Functions

1. When pneumatic source is applied to supply port, actuator stem or piston

assembly do not retract from its position



Part Description SPRING GUIDE

Part Number 6



1. Guiding the spring Basic Butting surface Diameter and rib thickness

2. Prevents vacuum formation inside the housing

Basic Hole Diameter in the spring guide butting surface

3. Guided by the housing Mate_Linear Slide Butting surface OD

4. Guided by the piston Mate_Linear Slide Spring guide ID

5. Limit the piston Mate_Limit

Distance between spring guide butting surface to piston butting surface

6. Grommet snapped with spring guide

Mate_Snap Depth of the step and Step diameter

7. Locate the filter washer Mate_Locate OD of the spring guide equals to OD of the washer

8. Wear and tear (At ribs and butting surfaces)

Failure mode Butting surface OD and rib thickness

9. Breakage of spring guide (at butting surface)

Failure Mode Thickness of spring guide head, Material Selection

10. Rattling of spring guide with housing

Failure Mode OD of spring guide butting surface



1

Process: Punching

Plate Washer

The plate cylinder washer is a small flat ring made of rubber, metal or plastic

placed between two surfaces

Functions

.

1. The cylinder washer is a small flat ring made of metal, rubber, or

plastic fixed under a nut or the head of a bolt to spread the pressure

when tightened or between two joining surfaces as a spacer or seal

for the hollow tube in an engine, shaped like a cylinder, inside which

the piston moves



Part Description PLATE WASHER

Part Number 7



1. Uniformly distributes force Basic OD of plate washer

2. Prevents vacuum formation Basic Hole diameter

3. Guided by the housing Mate_linear slide Plate washer OD

4. Guide the piston Mate_linear slide Plate washer ID

5. Locate the filter washer Mate_locate Plate washer OD equal to OD of filter washer

6. Limited by the circlip Mate_limit OD of plate washer

7. Plate washer breakage Failure mode Thickness of plate washer, material selection

8. Bending of plate washer Failure mode Thickness of plate washer, material selection

9. Corrosion of plate washer Failure mode Surface coating

10. Wear of plate washer (at round surface)

Failure mode OD of plate washer, material selection

11. Plate washer holes breakage Failure mode Hole diameter and thickness of plate washer



Process : Moulding

Lip Seal

Elastomeric seals made from nitrile rubber or other materials are best in lower

temperature environments, while seals made of Viton are better for higher

temperatures.

Functions

1) Seal provides long lasting sealing efficiency -base function

2) Provides air tight seal - base function



Part Description LIP SEAL

Part Number 8



1. Seals air Basic OD of the lip seal

2. Guided by the housing Mate_linear slide Lip seal OD

3. Interference with the housing Mate_interference Lip seal OD

4. Snapped with the piston Mate_snap Height and ID of lip seal

5. Wear and tear of lip seal Failure mode Clearance width and material selection

6. Leakage at housing and piston interface

Failure mode Lip seal OD and surface finish at inner surface of lip seal



Process : Moulding

Grommet

1. They are usually made in rubber material

2. Grommets are used in place on the rubber or plastics or

plate.

Functions

1. They are used for preventing tearing or abrasion of the pieced material, to cover sharp edges of piercing or both- base function




Part Description GROMMET

Part Number 9



1. Prevents water and dirt to enter into the housing

Basic OD ,ID and step height of the grommet

2. Guided by the piston Mate_linear slide ID of grommet

3. Snapped with the spring guide Mate_snap OD ,ID and step height of the grommet

4. Locate the filter washer Mate_locate ID of grommet equals ID of filter washer

5. Wear and tear at the inner surface of the grommet

Failure mode ID of grommet,material selection

6. Leakage at the grommet spring guide interface

Failure mode Surface finish


automotive SOPautomotive SOP8. Part Details

Process : Machining

Nut

Nut is a type of hardware fastener with the threaded holes

Functions

1. To limit the ball joint

2. To adjust the spring length



Part Description NUT

Part Number 10



1. For locking the ball joint Basic ID of nut

2. Screwed with piston Mate_screw Pitch and thread size

3. Limit the ball joint Mate_limit Thread depth

4. Wear and tear of thread Failure mode Thread size, Material selection

5. Corrosion of nut Failure mode Surface coating, material selection

6. Breakage due to over tightening

Failure mode Thickness and material selection


automotive SOPautomotive SOP Part Details

Process : Bending

Lock Pin

A peg or pin that is inserted through a hole or holes and locks two

parts together

Functions

1. Used to arrest or lock the lever in ball joint



Part Description LOCK PIN

Part Number 11



1. For locking the customer interface with the air cylinder

Basic Diameter of the lock pin

2. Snapped with the ball joint Mate_snap ID of lock pin and diameter of lock pin

3. Bending of lock pin Failure mode Diameter of lock pin

4. Insert failure Failure mode ID of lock pin, material selection

5. Corrosion of lock pin Failure mode Surface coating



Process : Moulding

Mounting Bush

Functions

1. For holding the cylinder in position

2. Provides grip



Part Description MOUNTING

BUSH

Part Number 12



1. Provides grip at the customer interface

Basic OD of the mounting bush

2. Protects the housing mounting part by avoiding metal to metal contact

Basic Thickness of mounting bush

3. Snapped with the housing Mate_snap OD of mounting bush

4. Wear and tear of mounting bush at inner surface

Failure mode ID of mounting bush and material selection



Filter Washer

Filter Washer is a thin plate with a hole

Functions

1. Prevents the dust particles to pass



Part Description FILTER WASHER

Part Number 13



1. Retains dirt from entering into the housing

Basic OD and ID of the filter washer

2. Locate the plate washer Mate_locate OD of filter washer

3. Guided by the housing Mate_linear slide Filter washer OD

4. Located by the grommet Mate_locate ID of the filter washer

5. Located by the spring guide Mate_locate OD of the filter washer

6. Blocks atmospheric air from entering into the housing while the piston returns

Failure mode Porosity ,OD and ID of the filter washer


automotive SOPautomotive SOPBill of materials

S.No Part

Volume(m3

)

X10 -9

Mass(Kg) Density(Kg/m3

)

Material

Quantity

1. Housing 57065.5 0.145 2540.94 Aluminum 1

2.

Piston Assembly

14956.9 0.062 7850 1089.89

Steel

Plastic 1

6799.2 8157.70 0.053 0.009 1

3. Lip Seal 1991.28 0.002 1004.38 Rubber

1

4. Spring 5433.87 0.043 7913.33 Steel 1

5. Spring Guide

4752.13 0.005 1052.16 Plastic 1

6. Grommet 602.606 0.001 1111.83 Rubber 1

7. Plate Washer

435.953 0.003 6881.48 Steel 1

8. Circlip 377.9 0.002 5292.41 Steel 1

9. Nut 683.020 0.003 4392.46 Titanium 1

10. Ball Joint 4350.24 0.029 6666.3 Steel 1

11. Mounting Bush

2320.66 0.0026 1120.37 Rubber 1

TOTAL

93880.8 0.298 - -


automotive SOPautomotive SOPCost Analysis

S.No Part Name

Raw Material Cost

(Rs)

Manufacturing Cost

(Rs)30 %

Over heads cost

(Rs)20%

Transportation cost

(Rs)5%

Quantity

Direct Part Cost/component

(Rs)

1. Housing 19.00 6.00 4.00 1.00 1 30.00

2. Piston Assembly

9.50 3.00 2.00 0.50 1 15.00

3. Lip Seal 0.50 0.50 0.25 0.25 1 1.50

4. Spring 2.50 0.75 0.50 0.50 1 4.25

5. Spring Guide

3.50 1.00 0.75 0.50 1 5.75

6. Grommet 0.25 0.50 0.25 0.25 1 1.25

7. Plate Washer

0.50 1.00 0.50 0.25 1 2.25

8. Circlip 0.50 0.50 0.25 0.25 1 1.50

9. Nut 3.25 1.00 1.00 0.25 1 5.50

10. Ball Joint Assembly

1.50 0.50 0.50 0.50 1 3.00

11. Mounting Bush

0.50 0.25 0.25 0.25 1 1.25

12. Overall Cost 71.25



Conclusion and Learning

We learnt about various terminologies in the industrial and corporate sectors.

We studied how to analyze a component and to create a model through pro-

engineer software.

We analyzed the working of every part within the component.

We are now able to deploy the function of a component.


automotive SOPautomotive SOP References

http://www.matbase.com/

http://www.engineeringtoolbox.com/

http://www.ehow.com/how_8486269_calculate-manufacturing-cost-per-unit.html

http://www.wikipedia.org/

http://en.wikipedia.org/wiki/Exhaust_brakes

http://www.matweb.com/

http://www.matbase.com/

http://www.engineeringtoolbox.com/

http://www.ehow.com/how_8486269_calculate-manufacturing-cost-per-unit.html

http://www.wikipedia.org/

http://en.wikipedia.org/wiki/Exhaust_brakes

http://www.matweb.com/



Bibliography

1) Donald R.Askeland (a), Pradeep P.Fulay (b), D.K.Bhattacharya

(2007)."Materials Science and Engineering"- Cengage Publication.

2) Rao. (2005)."Handbook of Mechanical, Civil, Electronics"

3) PSG College of Technology (Publication) (2009)."Design data book"

4) R.K.Bansal (2003)."Strength of Material”

5) Gupta (1995)."Strength of Material"

6) V.Ganesan (3rd edition)."Internal Combustion Engines"- "Tata McGraw Hill"

7) John.B.Heywood." Fundamentals of Internal Combustion Engines”

8) Kirpal Singh."Automotive Engineering 1 & 2”

air cylinder

Documents