Midterm Report on maruti suzuki

DEVELOPMENT, DESIGN AND FABRIC FABRICAT ATION ION OF A UNIVERSAL UNIVERSAL WELDING FIXTURE FOR TIPPERS

 A Graduate Project Project Report submitted to Manipal Manipal University in partial  fulfilment of the requirement requirement for the award award of the degree degree of

BACHELOR OF ENGINEERING In Automobil En!in"in! Submitted by

Ani# Ali $%&&'()&'*+ Under the guidance of  M" Um-n-n.- / V A00i0t-nt P"o100o"

DEPARTMENT OF AERONAUTICAL AND AUTOMOBILE ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOG2 (A Constituent College of Manipal University) MANIPAL – 5761!" #A$NA% # A$NA%A#A" A#A" IN&IA IN&I A M-"34 5&%)

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DEPARTMENT OF AERONAUTICAL AND AUTOMOBILE ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOG2 (A Constituent College of Manipal University) MANIPAL – 576 1! (#A$NA%A#A)" IN&IA

Manipal 1''1!

CERTIFICATE

%*is is to +ertify t*a t*at t*e pro,e ro,e+t +t title- DEVELOPM DEVELOPMENT ENT,, DESIGN DESIGN AND FABRICA FABRICATI TION ON OF A UNIVERSAL UNIVERSAL WELDING WELDING FIXTURE FIXTURE FOR TIPPERS TIPPERS is a

re+orre+or- of t*e .onafi.onafi-ee /or0 /or0 -one .y ANI6 ALI ( Reg  Reg !o "##$%&#$' ) su.itte- in  partial fulfilent of t*e re2uireents for t*e a/ar- of t*e &egree of 3a+*elor of  4ngi 4ngin neeri eerin ng (34) (34) in AUTOMOBILE ENGI Manipa pall Inst Instit itut utee of  ENGINE NEER ERIN ING G of Mani %e+*nology Manipal" #arnata0a" (A Constituent College of Manipal University)" -uring t*e a+a-ei+ year '1 1!

MR UMANANDA / V

Project Guide

P"o1 D" RAMAMOHAN PAI PAI

()*+ Aero , Auto M-.+ M- .+ MA!-P MA!- PA/

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AC/NOWLEDGMENT n t*e very outset of t*is report" I /oul- li0e to e8ten- y sin+ere 9 *eartfelt o.ligation to/ar-s all t*e personages /*o *ave *elpe- e in t*is en-eavour :it*out t*eir a+tive gui-an+e" *elp" +ooperation 9 en+ourageent" I /oul- not *ave a-e *ea-/ay in t*e  pro,e+t

I a ineffa.ly in-e.te- to Mr ;a,anan
I a e8treely t*an0ful an- pay y gratitu-e to y fa+ulties espe+ially y pro,e+t entor Mr Uanan-a #> for *is valua.le gui-an+e an- support

I e8ten- y gratitu-e to t*e ?ea- of our &epartent" &r $aao*an Pai for giving e t*is opportunity to present t*is pro,e+t

ANI@ ALI

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ABSTRACT A fi8ture is a /or0 *ol-ing -evi+e /*i+* *ol-s an- positions t*e /or0" .ut -oes not itself gui-e" lo+ate or position t*e tool i8tures are use- to re-u+e t*e pro-u+tion +ost an- tie to in+rease pro-u+tivity /it* less use of la.our to ensure a8iu effi+ien+y an- safety %*e ol- pro+ess involve- *ol-ing an- aligning t*e ,o. anually /*ile /el-ing to aintain  perpen-i+ularity =o t*e *elpers *a- to *ol- t*e ,o. an- siultaneously t*e /el-er use- to /el- all t*e +orners %*is +oproise- t*e pro-u+tivity an- 2uality of t*e ,o. an- safety of t*e /or0ers %*e +oponent involve- /as to .e /el-e- /it* pre+ision an- spee-" /*ile +onsi-ering its alignent" /el-ing effe+ts" la.our involve- an- finis*ing As initially t*e pro+ess /as a anual one" a /el-ing fi8ture /as to .e -esigne- for proper an- se+ure +laping" alignent" /el-ing sipli+ity an- goo- finis* of t*e +oponent %*ree types of fi8tures are use- for t*e anufa+ture of t*e su.fraes of t*e Ma*in-ra anMAN tru+0 tippers .ase- on t*eir -iensions an- -esign %*e pro,e+t is .ase- on t*e +opre*ensive -esign an- anufa+turing of a universal fi8ture /*i+* +oul- in+orporate t*e  pro-u+tion of all t*e tippers

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LIST OF TABLES T-bl No T-bl Titl 1

=U3$AM4 &IM4N=IN=

P-! No 1!

v

LIST OF FIGURES Fi!u" No 1 '  ! 5 6 7  D 1

Fi!u" Titl

MANN %IPP4$ %IPP4$ IN 4B%4N&4& P=I%IN %IPP4$ %$AIL4$= :4L∈
P-! No 1 ' ' 5   D D 1 1'

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Contnt0 A+0no/le-geent A.stra+t List f %a.les List f igures

Page No iii iv v vi

C4-7t" %

INTRODUCTION

%

C4-7t" 5

LITERATURE REVIEW

)

C4-7t" ( C4-7t" )

BAC/GROUND THEOR2 Mt4o.olo!9 RESULT ANAL2SIS

8 %% %5

C4-7t" :

CONCLUSION AND FUTURE SCOPE

%)

REFERENCES

%:

vii

INTRODUCTION %o-ay t*e /orl- is -epen-ent on transportation %*e use of transporting eans su+* as tru+0s an- trailer eans /e +annot transport goo-s /it*out it %ipper tru+0s t*at /e .ring fort* for our +ustoers are e8tensively use- for transporting +oal" san- inerals" ores" gravel an- -irt 3asi+ally a tipper is -evi+e t*at +onsists of parts su+* as si-e panel" su.frae an- gate .o8 .ippers 0)n Rigid 1hassis2 %*ese tippers are a-e on +*assis anufa+ture- .y -ifferent tru+0 anufa+turers li0e %A%A" Ma*in-ra" MAN tru+0s" 4i+*er" As*o0 Leylan- et+ %*e tippers *ave t*eir .o-y +u.e *inge- at rear an- *y-rauli+ +ylin-er fitte- at front %*is ensures to tilt t*e .o-y +u.e to -is+*arge t*e aterial insi-e t*e +u.e %*is tilting operation is -one .y operating a *y-rauli+ +ylin-er /*i+* is in turn fe- .y a *y-rauli+ pup po/ere- .y t*e tru+0 engine

FIG % MANN TIPPER 

.ipper .railers3 ?ere t*e tippers are ounte- on a trailer %*is type of a tipper trailer is use- for *ig*er volue an- *ig*er loa- +arrying an- -is+*arge  Application areas3 •

Constru+tion in-ustries

•

Mining in-ustries

•

:aste anageent in-ustries

•

%ransportation in-ustries

1

FIG 5 TIPPER IN EXTENDED POSITION

FIG ( TIPPER TRAILER 

'

.ipper 4odies %ippers +an .e +lassifie- as .o8 tippers an- ro+0 .o-y tippers 3o8 tippers are use- for transportation of san- gravel an- ot*er loose aterial %*e ro+0 .o-y tippers are use- in ining appli+ations /*ere .ig .oul-ers an- ro+0s are nee-e- to .e transporte- an- -upe- %*e 3o8 tippers are a-e of =% 5' aterial /*i+* *as *ig* yiel- strengt* Also tippers are a-e of *ig* strengt* steel li0e &oe8 7 *aving yiel- strengt* of 6 Mpa %*e Mining tippers are +alle- ro+0 .o-y tippers %*e ain re2uireent of t*ese tippers is t*e insi-e fa+e of t*e tipper +oing in +onta+t /it* t*e ro+0s an- .oul-ers s*oul- .e /ear resistan+e or t*is t*e aterial use- is ?ar-o8 or $ae8 %*is *as e8+ellent /ear resistan+e property +ouple/it* goo- yiel- strengt*

.ipper ?y-rauli+ %ipper %ru+0s are /i-ely use- to transport loose aterial (su+* as +oal san-" inerals" ores" gravel" or -irt) In or-er to allo/ t*e +ontents to .e -eposite- on t*e groun .e*in- t*e tru+0 at t*e site of -elivery" t*ese tru+0s are e2uippe- /it* a *y-rauli+ally operate- open.o8 .e- *inge- at t*e rear" t*e front of /*i+* +an .e lifte- up %*e Close %ipper %ru+0s are anufa+ture- /it* t*e finest 2uality ra/ aterials en-o/e- /it* +utting e-ge te+*nology



LITERATURE SURVE2; INTRODUCTION TO

!

A ,ig ay.e -efine- as a -evi+e /*i+*" *ol-s an- positions t*e /or0" lo+ate or gui-e t*e +utting tool relative to t*e /or0 pie+e an- is usually not fi8e- to t*e a+*ine ta.le It is usually lig*ter in +onstru+tion

I; !:4L∈
A fi8ture is /or0 *ol-ing -evi+e /*i+* *ol-" an- position t*e /or0 .ut -oes not itself gui-e" lo+ate or position t*e +utting tool" %*e setting of tool is -one .y a+*ine a-,ustent an- a setting .lo+0 or .y using slip gauges A fi8ture is .olte- or +lape- to t*e a+*ine ta.le it is usually *eavy in +onstru+tion
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BAC/GROUND THEOR2 •

P"o=3t D03"i7tionE %o &esign an- &evelop a i8ture +oon for all o-els of tipper for anufa+turing of su. fraes

%*e ol- pro+ess involve- t*e use of t*ree /el-ing fi8tures for t*e anufa+turing of t*e various su.fraes of t*e Ma*in-ra an- MAN tru+0 tippers %*is resulte- in in+rease- +ost an- la.our %*e pro+ess /as tie +onsuing All t*ese fa+tors /ere enoug* for t*e +opany to re2uire a ne/ fi8ture /*i+* +oul- in+orporate all t*e o-els of su.fraes to in+rease  pro-u+tivity an- -e+rease +ost After stu-ying t*e ol- pro+ess t*oroug*ly" t*e ai /as to over+oe all t*e -ra/.a+0s an-evelop an- -esign a ne/ /el-ing fi8ture ?ig*er pro-u+tivity an- 2uality along /it* safety an- sipli+ity /ere t*e priary o.,e+tive /*ile +onsi-ering t*e -esign of fi8ture

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%*ere are -ifferent siFes an- s*ape of t*e su.fraes anufa+ture- at %ransport =olutions In-ia Pvt Lt- /*i+* are as follo/sE

T-bl No %% SUBFRAME DIMENSIONS SPECIFICATIONS BOD2 T2PE

LENGTH$mm+

ANGLE POSITION$mm+

WIDTH$mm+

11' CUM $I3L4==

551

D56

6!

1! CUM $C# 3&G

617D

1D

6!

16 3&G MANL

617D

1D

6!

16 CUM $C# 3&G 1 $C# 3&G 1 $C# 3&G

617D 675

1D !165

6! 7

!1!

'6

76'

MANL

%*e +oponent /as of varie- siFes ranging .et/een t*e iniu an- a8iu lengt* of D1 an- 5!! respe+tivelyH an- t*e .rea-t* .et/een '15 an- 15! As t*ere /as no parti+ular or-er or fas*ion in /*i+* t*e -enoinations of t*e +oponents /ere re+eive- for /el-ing" a fle8i.le /el-ing fi8ture /as to .e -esigne- %*is /as re2uire- to a++oo-ate an- fi8 t*e +oponent" /*atever t*e siFe +oponent %*us" t*e fi8ture is suggeste- to .e in+orporate- /it* a set of ova.le an- fi8e- supports

=oe of t*e su.frae -esigns are as s*o/nE 7

I; 5 16 CuM .o8 .o-y

I; 6 1! CuM ro+0 .o-y



I; 7 1 CuM ro+0 .o-y

I;  1 CuM 3B .o-y

D

I; D 16 CuM .o8 an- 16 ri.less

METHODOLOG2 1

%*e o.,e+tive /as to .uil- a universal fi8ture t*at +oul- in+orporate t*e pro-u+tion of all t*e types of su.fraes an- *elp in re-u+ing t*e +ost an- a0es t*e pro+ess faster %*e follo/ing pro+e-ure /as lai- -o/n for t*e -esign" -evelopent an- fa.ri+ation of t*e fi8tureE 1) #no/ing a.out t*e various +oponents of a tipper an- t*eir role %/o /ee0s spent on t*e anufa+turing line of a tipper ') Learning ore into t*e parti+ular +oponent ie su.frae an- e8ploring t*e -ifferent -esigns of t*e su.fraes use- in t*e various o-els of tippers ) Noting -o/n t*e -iensions an- easureents of various paraeters su+* as Lengt*" /i-t* an- angular position !) &esigning a fi8ture /it* ova.le supports at appropriate positions an- realising /*at 0inof +laps to .e use- 5) =eeing over t*e anufa+turing of t*e universal fi8ture an- .eing put to use

RESULT ANAL2SIS 11

%*e follo/ing -esign /as propose- to t*e 4ngineering *ea- regar-ing t*e -esign of t*e Universal fi8ture

I; 1 Propose- &esign In t*e figure" t*e supports A" 3" C an- & are t*e supports for t*e /or0 pie+e %*ey are .olte- at -ifferent positions for -ifferent siFes of su.fraes

Supports positioning3 1'

%*e follo/ing are t*e -eviations fro t*e noral positions t*at t*e various supports ta0e for -ifferent su.fraes

1 $C# 3&G Move AJ supports in/ar- .y a -istan+e of 5!  ea+* 3J" CJ" &J supports in/ar-s .y a -istan+e of   ea+* 16 $C# 3&G 1! $C# 3&G Move AJ" 3J" CJ supports in/ar-s .y a -istan+e of 5!  ea+* 16 3B 3&G MAN Move &J supports in/ar- .y a -istan+e of  ea+*

CONCLUSION AND FUTURE SCOPE OF WOR/ 

1

%*e -esign for t*e universal fi8ture is un-er revie/ an- inute +*anges *ave to .e a-e still It in+orporates all t*e various su.frae siFes into one an- re-u+es tie an- is ore e+onoi+al Less la.our /ill .e nee-e- t*an .efore %*e ne8t step of t*e pro,e+t is to -esign t*e fi8ture on AU%CA& an- see over t*e fa.ri+ation of t*e universal fi8ture an- put into use

REFERENCES

1!

1) ////el-ingfi8turein ') ///tsi+oin ) Paper on I%%IN; =UP4$=%$UC%U$4=J   ///ras0onefiive+o

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