Submitted In Partial Fulfillment of Requirement for the Award of Master Degree

MASTER OF TECHNOLOGYIN

(I.P.D&M)

SUPERVISOR SUBMITTED BYPuneet Katyal Pankaj

Assistant Professor Regn. No. 09161010

DEPARTMENT OF MECHANICAL ENGINEERINGGURU JAMBHESHWAR UNIVERSITY OF SCIENCE & TECHNOLOGY

HISAR

SYNOPSIS PRESENTATIONON

CONCURRENT DESIGN AND PROTOTYPING CONCURRENT DESIGN AND PROTOTYPING OF COMPOSITE ACCELERLATOR PEDALOF COMPOSITE ACCELERLATOR PEDAL

CONTENTSINRTRODUCTION

LITERATURE REVIEW

PROBLEM FORMULATION

OBJECTIVES OF PROPOSED

WORK

METHODOLOGY

REFERENCES

INTRODUCTION

Most of the products we see are made from monolithic materials. i.e. they

consist of a single material .

Composite materials, on the other hand, consist of two or more materials

combined in such a way that the individual materials are easily

distinguishable

Individual materials are combined so to get better mechanical and thermal

properties then metals, non metals and ceramics .

Types of composite

Polymeric matrix composite .

Metal matrix composite.

Ceramic matrix composite .

Applications of Composites

•Automotive

•Aircraft

•Space

•Marine

•Electrical & Electronics

PURPOSE OF ACCERLETOR PEDAL

Accelerator pedal should be capable of being depressed gently for gradual

acceleration or deceleration by control of fuel and air supply to the

automobile's engine, has a fail-safe design in that it automatically returns to

the idle position when not depressed by the driver

Demerits of a

Conventional Accelerator

pedal

Merits of Composite

Accelerator pedal

They have less specific

modulus and strength.

Its corrosion resistance is less

as compared with composite

materials.

Increased weight.

Costly.

They have high specific

modulus and strength.

Reduced weight.

Due to the weight reduction, fuel

consumption will be reduced.

They have good corrosion

resistance.

Less costly.

Longer fatigue life than steel or

aluminum pedal

Concurrent Engineering

Design Analysis

Material Selectio

n

Component

Design

Product Design

Specification

Manufacture

Introduction to Concurrent Engineering

Literature Survey

John W. Weeton et al. [1] described the application

possibilities of composites automotive industry springs to

manufacture composite elliptic springs, leaf springs and drive

shafts .

C.J. Morris [2] Explained FRP as potential structural

materials for automotive applications and describes the

design, fabrication, weight analysis and testing of a composite

integrated rear suspension in a Ford Escort vehicle. .

Jack Zhou et al. [3] Investigated Concurrent Engineering (CE)

reduces product time to market, cutting down the total cost, and

improving quality. This paper describes a newly developed CE

course which employs the method of concurrent education.

Frank M. Hull et. al. [4] Proposes a “composite” form of

organization as best for reducing product development time and costs.

This composite is a meld of three sets of concurrent engineering (CE)

practices: early simultaneous influence (ESI) in product design

decisions by multiple functions, in-process design controls (IDC), and

computer and information technology (CIT).

Michael J. Tari et al. [5] Investigated a methodology for the

rapid process development of resin transfer molding (RTM) in

order to reduce product development cycle time and lower the

cost of developing composite parts. Uses laminated object

manufacturing (LOM), to fabricate molds.

Ramesh K.C et al. [6] Studied the automotive industry need

for materials substitution, offering outstanding properties in

a number of engine components including engine poppet

valves. Since the valves control the gas flow, valve size,

timing and overlap, they all influence volumetric efficiency.

The valve train is designed to achieve maximum

volumetric efficiency at the desired level of engine

performance. Research work envisages carrying out some

studies on Al-SiC and Al-TiC composites as possible

alternative materials for engine poppet valves by powder

metallurgy (PM).

Weihong Zhong et al. [7] investigated the continuous fiber reinforced

composite by rapid prototyping/part manufacturing process (RP&M). The

effects of the fiber’s moving speed, the fiber’s tension force, and the

viscosity of the resin on the content of resin in the resulting composite,

and the impregnation between the fiber and the resin were studied.

H. A. Al-Qureshi [8] presents a general study on the analysis, design and

fabrication of composite springs. From this viewpoint, the suspension

spring of a compact car, a jeep was selected as a prototype. A single leaf,

variable thickness spring of glass fiber reinforced plastic (GFRP) with

similar mechanical and geometrical properties to the multi leaf steel

spring, was designed, fabricated (molded and hoop wound) and tested.

Denise Carlson et al.[9] Investigated, the

recyclability of automotive parts based upon these

environmental requirement and demonstrated a new

recycle technology for polyamide using one of the

largest automotive applications, the radiator end tank

which has been previously viewed as degraded

material due to hydrolysis and deemed as shredder

residue.

D. Karalekas and K. Antonio [10] Investigated

Stereolithography and vacuum casting as two well-

established techniques for producing complex parts for

rapid prototyping purposes and studied effects of the

addition of nonwoven glass fibre mats, and of various

thicknesses, on the mechanical properties of laser solidified

and vacuum moulded specimens.

Marcia Kurcz et.al [11] Proposes Glass-mat thermoplastic (GMT) composites

to replace steel in spare-wheel well (SWW) applications. This application has

been successfully translated across multiple OEMs, tier suppliers, platform

types

S.M. Sapuan & M.A. Maleque [12] Presents a conceptual design approach to

the development of polymeric-based composite automotive bumper system,

various methods of creativity, such as mind mapping, product design

specifications, brainstorming, morphology chart, analogy and weighted

objective methods are employed for the development of composite bumper

fascia and for the selection of materials for bumper system.

S.M. Sapuan [13] studied the conceptual design for polymeric

based composite automotive pedal and describes the importance of

concurrent engineering and finally evaluated the conceptual design

of composite pedal box system with common shaft for the three

pedals & compared the results

Eric jaarda and Manish Chaturvedi [14] Proposes Basic

automotive steering wheel armature design. A cast aluminum or

magnesium armature is typically used to provide stiffness and

strength with an over molded polyurethane giving shape and

occupant protection.

H.M. Shedi and C.I. Ajuwa [15] Investigated composite composite wheel

of this nature weighs less than the conventional whole cast iron or steel

alloy wheel and hence, develops lower inertia loads at a given speed.

Improves low speed acceleration

Erica R.H. Fuchs & Frank R. Field [16] studies the materials choice

in automotive bodies have looked at both composite and aluminum

alternatives, but have always found steel to be the most cost-effective

option at the production volumes found in the overwhelming majority of

vehicle models. This study finds composites to have significant economic

potential when considering emerging advances in the polymer composite

Aljibori, Hakim S. Sultan [18] investigated an increasing demand

in the use of composite materials for the automotive, aerospace and

rail industry. When using composite in the body structure of a

vehicle, considerable weight reductions can be achieved compared

to conventional isotropic structures, which leads to reduced fuel

consumption and consequently lower carbon dioxide emissions.

Alemu Moges Belay [19] this paper focuses on the two of new

product development methods (DFM and CE). The aim of this

paper is to see and analyze different product development methods

specifically on Design for Manufacturability and Concurrent

Engineering.

A.R. Ismail et al. [20] this study shows how the effect of implementation

of the Design for Manufacture and Assembly (DFMA) in product

development process. Pressure vessel was selected as the example in this

case study.

G. Savage [21] Investigated engineering structure, irrespective of its

intended purpose, must be made of one or more materials. More often it

is the choice and behavior of those materials that determine its

mechanical performance and Introduces fibre reinforced composite

chassis of Grand Prix motor racing.

C. Alves et al. [22] Investigates the environmental improvements related

to the replacement of glass fibers for natural jute fibers, to produce a

structural frontal bonnet of an off-road vehicle (Buggy). Results pointed

out the advantages of applying jute fiber composites in Buggy enclosures.

PROBLEM FORMULATION

As Literature review shows that composites automobile

components are good substitute for the Conventional monolithic

automobile components.

So, it is need to design composite Accelerator pedal to take

place of existing conventional Accelerator having less weight and

better mechanical properties easy and cheap to manufacture and to

study the concurrent engineering approach for the purpose.

OBJECTIVES OF PROPOSED WORK

To Develop a conceptual prototype composite

Accelerator Pedal as a substitute of metal Accelerator

lower in weight due to density , high strength , stiffness,

corrosion resistant by Rapid prototyping Using

concurrent engineering approach

Methodology

Composite Accelerator

pedal

Design Analysis

using FEM on actual operating condition

Material Selection based on

manufacture , technique,

Cost ,analyses

Designing by 3d –

modeling software ,

using PDS,

Analyses

PDS on basis of

existing / patents/ market

investigation

Manufacture

By rapid prototyping using : SLS , 3D-printing

Use of IT Tools

1.3d modeling software (CATIA/Solid Works /Ansys)

2.Finite Element Analysis

Development of composite Accelerator pedal

Material selection

Product design specification

Operating parameters

Final Design

Comparison of final result

Rapid Prototyping Techniques can be used

1. Stereo lithography

2. 3D Printer

3. Fused Deposition Modeling

Work Flowchart

References

[1] John W. Weeton et al. (1986),’Engineers guide to composite materials’, American Society for

Metal, New York.

[2] C.J. Morris (1986) ‘Composite integrated rear suspension Composite Structures’, volume 5 issue 3,

1986, Pages 233-242

[3] Jack Zhou, Shlomo Carmi, Alan Lau, and Spiros Koulas (1986),’Concurrent Engineering

Concepts Applied to Concurrent Education and Research’, ISPE International Conference on

Concurrent Engineering, Research and Applications (CE96/ISPE) August 26-28, 1996

[4] Frank M. Hull, Paul D. Collins and Jeffrey K. Liker (1996),’Composite Forms of Organization as

a Strategy for Concurrent Engineering Effectiveness,’ IEEE transactions on engineering management.

vol. 43. No. 2. May 1996

[5] Michael J. Tari, Andre Bals, Joon Park, Mark Y. Lin and H. Thomas Hahn (1998), ‘Rapid

prototyping of composite parts using resin transfer molding and laminated object manufacturing

Composites Part A’, Applied Science and Manufacturing, Volume 29, Issues 5-6, 1998, Pages 651-661

[6] Ramesh K.C and Sagar.R (1999),’ Fabrication of metal matrix composite automotive parts’,

International journal advance manufacturing Technology,1999, vol. 15,number 2, pp. 114-118 (4 ref.)

[7] Weihong Zhong, Fan Li, Zuoguang Zhang, Lulu Song and Zhimin Li(2001) Research on rapid-

prototyping/part manufacturing (rp&m) for the continuous fiber reinforced composite , Materials

and Manufacturing Processes, Volume 16, Issue 1 January 2001 , pages 17 – 2

[8] Al-Qureshi H.A. (2001), ‘Automobile leaf springs from composite materials’, Journal of Materials

Processing Technology, Vol. 118 No. 1, pp. 58-61.

[9] Denise Carlson -Hiroyuki Yamazaki - Sunao Fukuda - Denso Corp. Christian Leboeuf - H.Peter

Kasserra (2003),’ Application of Nylon Composite Recycle Technology to Automotive Parts ‘,SAE paper

Paper Number: 2003-01-0794 DOI: 10.4271/2003-01-0794

[10] D. Karalekas and K. Antonio (2004),’ Composite rapid prototyping: overcoming the

drawback of poor mechanical properties’, Journal of materials Processing Technology volume 10

November 2004, Pages 526-530

[11] Marcia Kurcz ,Burak Baser  Harri Dittmar - Joachim Sengbusch -Hans Pfister –

(2005)‘Replacing Steel with Glass-Mat Thermoplastic Composites in Automotive Spare-Wheel

Well Applications’, SAE paper, Paper Number: 2005-01-1678DOI: 10.4271/2005-01-1678

[12] Sapuan, S.M., Maleque, M.A., Hameedullah, M.Suddin, M.N., and Ismail, N. (2005), ‘A note

on the conceptual design of polymeric composite automotive bumper system’, Journal of Materials

Processing Technology, vol. 159, no. 1, pp. 145-151

[13] Sapuan S.M.(2005),’.A conceptual design of the concurrent engineering design system for

polymeric-based automotive pedal’, American journal of applied science 2 (2) :514 -525, 2005 ISN

1546-9239

[14] Eric jaarda and Manish Chaturvedi (2007),’Prototype Design and Testing of a Thermoplastic

Steering Wheel Armature’, SAE paper Number: 2007-01-1218 DOI: 10.4271/2007-01-1218

[15] Ajuwa, C.I. and H.M. Sheidi, (2008),’Design of high performance vehicle composite flywheel.’

Res. J. Applied Sci., 3: 44-50

[16] Erica R.H. Fuchs, Frank R. Field, Richard Roth and Randolph E. Kirchain (2008),’ Strategic

materials selection in the automobile body’, Economic opportunities for polymer composite design

Composites Science and Technology Volume 68, Issue 9, July 2008, Pages 1989-2002

[17] Chung Hae Park, Abdelghani Saouab, Joel Breard, Woo Suck Han, Alain Vautrin and Woo

Il Lee(2009), ‘An integrated optimization for the weight, the structural performance and the cost of

composite structures’, Composites Science and Technology Volume 69, Issues 7-8, June 2009, Pages

1101-1107

[18] Aljibori , Hakim S. Sultan (2009), ‘Fibre reinforced composite (FRC) structures with

potential applications: literature review. International journal of applied engineering research

October1,2009,  http://www.thefreelibrary.com/Fibre+reinforced+composite+(FRC)

+structures+with+potential...-a0216041279”

[19] Alemu Moges Belay (2009),’ Design for Manufacturability and Concurrent Engineering for

Product Development’, World Academy of Science, Engineering and Technology 49 2009

[20] A.R. Ismail A.H.A.A. Manap D.A. Wahab,R. Zulkifli ,N.K. Makhtar and K. Sopian

(2009) ‘Concurrent Engineering Approach in Designing Pressure Vessel’, European Journal of

Scientific Research ISSN 1450-216X Vol.30 No.2 (2009), page no.245-252

[21] G.Savage (2010),’ Formula 1 composite Engineering’, Papers presented at the 25th meeting

of the Spanish Fracture Group volume17, issue 1 ,January 2010, Pages 92-115

[22] C. Alves, P.M.C. Ferrao, A.J. Silva, L.G. Reis, M. Freitas, L.B. Rodrigues and D.E.

Alves(2010),‘Eco design of automotive components making use of natural jute fiber composites’,

journal of Cleaner production issue 4 ,March 2010, Pages 313-327