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A PROJECT REPORT ON

DESIGN OF LATERAL STEERING AXLE AND LOW COST MOUNTINGS. AT

M/s. Godrej & Boyce Mfg.Co.Ltd.

VIKHROLI
Mumbai- 400 079

Submitted in partial fulfillment of requirement of BACHELORS DEGREE IN PRODUCTION ENGINEERING To UNIVERSITY OF MUMBAI By Mr. BARHALE PADMANABH U. & Mr. CHETTIAR RAJESH R.

DEPARTMENT OF PRODUCTION ENGINEERING In the year 2008-2009

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CONTENTS CHAPTER NO. DESCRIPITION

INTRODUCTION TO THE COMPANY

PAGE NO.

1.1 INTRODUCTION TO GODREJ & BOYCE MFG.CO.LTD. 1.2 PROGRESS MILESTONES OF GODREJ. 1.3 THE GODREJ WAY OF LIFE. 1.4 DIVISIONS OF GODREJ.

INTRODUCTION TO MATERIAL HANDLING EQUIPMENT DIVISION (PLANT 16)

2.1 PRINCIPLES OF MATERIAL HANDLING. 2.2 NEED OF MATERIAL HANDLING EQUIPMENT. 2.3 HISTORY OF M.H.E DIVISION. 2.4 DIFFERENT DEPARTMENTS OF M.H.E. DVISION. 2.5 THE DESIGN DEPARTMENT. 2.6 PLANT LAYOUT. 2.7 PRODUCT RANGE. 2.8 FORKLIFT ATTACHMENTS.

DESIGN OF NEW STEERING AXLE.

3.1 STEERING MECHANISM OF FORLIKTS TRUCKS. 3.2 HYDROSTATIC STEERING UNIT (ORBITROL). 3.3 HYDRAULIC CIRCUIT. 3.4 HYDRAULIC LINE WITH-LOAD SENSING. 3.5 STEER AXLE. 3.6 WORKING OF THE LATERAL STEERING MECHANISM.

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3.7 CONDITION FOR TRUE ROLLING. 3.8 DESIGN OF NEW STEERING AXLE. 3.9 SIGNIFICANCE OF VARIABLES IN STEERING MECHANISM. 3.10 SATISFYING TRUE ROLLING CONDITION. FORCE CALCULATION AND DESIGN OF STEERING CYLINDER 4.1 4.2 4.3 4.4 FORCE CALCULATIONS. STEERING CYLINDER. DESIGN OF STEERING CYLINDER. ADVANTAGES OF NEW AXLE.

AXLE MOUNTING

5.1 MOUNTING OF AXLE. 5.2 MOUNTING OF AXLE WITH RUBBER BLOCK AND OVAL PIN. 5.3 DESIGN OF OVAL PIN. 5.4 RUBBER BLOCK AND U-CLAMP. 5.5 MOUNTING OF AXLE WITH PLUMMER BLOCK. 5.6 DESIGN OF PIN. 5.7 PLUMMER BLOCK ASSEMBLY. 5.8 COMPARISON BETWEEN RUBBER MOUNTING AND PLUMMER BLOCK MOUNTING

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TABLE OF FIGURES FIG. NO.

2.1 2.2 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.1 3.11 3.12 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5.1 5.2 5.3

DESCRIPTION
MANUFACTURING SETUP M.H.E. DIVISION A TYPICAL FORKLIFT TRUCK HYDROSTATIC STEERING UNIT DISTRIBUTOR VALVE CHECK VALVE HYDRAULIC LINE WITH-LOAD SENSING CONDITION FOR TRUE ROLLING WHEN WHEELS ARE IN NEUTRAL POSTION WHEN WHEELS ARE IN TURNED POSTION TURNING RADIUS INCLUDING COUNTERWEIGHT LINK LEFT HAND KNUCKLE RIGHT HAND KNUCKLE AXLE BODY REAR AXLE OF A 3 TONNE TRUCK F.B.D OF KNCUKLE AND WHEEL F.B.D OF LINK F.B.D OF PISTON ROD F. B. D WHEN WHEEL IS ROTATED AT 80 O F. B. D WHEN WHEEL IS ROTATED AT 58 O LATERAL STEERING CYLINDER HOOP STRESS STEER AXLE ASSEMBLY AXLE ASSEMBLY F. B. D. OF OVAL PIN OVAL PIN RUBBER BLOCK

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5.4 5.5 5.6 5.7 5.8 5.9 5.1 5.11 5.12 5.13 5.14 5.15

U-CLAMP LOCKING PLATE MOUNTING PIN ASSEMBLY FRAME WITH RUBBER MOUNTING F. B. D. OF PIN PLUMMER BLOCK PLUMMER BRCAKET MTG PLATE FRONT PLUMMER BRCAKET MTG PLATE REAR LOCK PLATE PLUMMER BLOCK MOUNTING FRONT PLUMMER BLOCK MOUNTING REAR FRAME WITH PLUMMER BLOCK

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AKNOWLEDGEMENT
This is not a mere formality, but a means to express my heartfelt gratitude. Throughout my endeavor to make this inplant training a success, many people have always provided me copious support. I acknowledge from the bottom of my heart those who were solicitous and benevolent enough to guide me through out the period.

First and foremost I would like to thank our college for providing such an experience, which has really exposed us to the industrial environment. This training has taught me a lot of lessons such as to be self reliant on performing the tasks assigned to you, to be concentrated on the work while doing which other wise causes many losses both to ourselves and others. Hence as a trainee, this training has enhanced my scope of thinking and has made me mature enough to appreciate things that are merely on papers during my academic curriculum.

I am deeply grateful to Mr. V. G. KULKARNI (Senior General Manager, DESIGN, M.H.E division) for rendering me all facilities required in plant. I owe sincere thanks to Mr. S. D. MISTRY (Assistant General Manager), my project guide for continuously guiding me through my project. Also I would like to render my deepest regards to Mr. ANAND S. TAWDE (Deputy Manager-M.H.E Division. I would also like to thank Prof. SREEHARI, my college guide for their guidance and timely help.

Finally, I thank all the people who knowingly or unknowingly helped me to make this training period a success.

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ABSTRACT
In plant training is a direct exposure to industry to understand how work should be performed and should be presented in a technical way. It in turn improves our logical or practical thinking by performing tasks individually. Its a very helpful experience for budding engineers. It gives us an opportunity to co-relate our theory by practically performing it with our own hands

My training in GODREJ & BOYCE MFG. CO. LTD. was indeed a very nice learning experience and exposure to the industry. I was placed in M.H.E. DIVISION in Design department. Here the work was not same all the time which played a major role in making this a period a fruitful one. You will get a new task every time in which you can learn new thing everyday.

Forklift Truck is one of the major products of M.H.E division in Godrej & Boyce mfg. co. ltd. During my training, I was working on GX 300D Model. I was working on the lateral steering axle 3 ton and 2 ton capacity forklifts.

My job was to design a new steering axle with increase in its turning angles, which would cause reduction in turning radius. My second project was low cost mounting of new steering axle with Rubber block and a Plummer block. I also learnt 3D modeling which was a must in order to visualize how

I successfully completed my project and learned many lessons while performing it. This report contains various activities, which I did during training.

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1.1 INTRODUCTION TO GODREJ & BOYCE MFG.CO.LTD. :

VIKHROLI BRANCH, MUMBAI-400079.

GODREJ & BOYCE MFG. CO. LTD.

Godrej has been active in India for more than 100 years and is amongst the front line companies in the domestic and office equipment industries. Godrej covers a wide spectrum of products exacting to international standards. Besides standard domestic equipments like store well, refrigerators, steel furniture, locks and office ware like filing cabinets, typewriters, printers Godrej is also in the field of manufacturing of industrial equipments like machine tools, fork lifts, pressure vessels, boilers, press tools, industrial storage systems etc.

Mr. Ardeshir Godrej

Mr. Pirojshah Godrej

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The Godrej story began way back in 1897 when Ardeshir Burjorjee Godrej, a lawyer by profession, stepped into the manufacturing industry by producing high quality surgical instrument. These were so good that a reputed pharmacist wanted to sell them under a foreign brand name. Ardeshir Godrej rejected the offer and decided to manufacture the best locks in the world. Safes then followed locks. And both products by virtue of their superior quality held highest esteem. Thus Ardeshir Godrej built the foundation block of the Godrej Empire. If Ardeshir was the artist who initiated the painting, then it was his younger brother, Pirojshah Godrej, who enlarged the canvas to stunning and rewarding proportions.

1.2 PROGRESS MILESTONES OF GODREJ:

1897: Ardeshir Burjorjee Godrej at the age of 29 laid the foundation of the company in

Lalbaugh, and started manufacturing the indigenous lock of India, i.e. GODREJ locks. His brother Seth Pirojshah Burjorjee Godrej enlarged the laid canvas to stunning and rewarding proportion. 1902: Started manufacturing of Safes/Security Equipment 1918: GODREJ Soaps was incorporated. 1923: Stores & Filing Cabinets. 1935: Safe Deposits Vaults. Tool room division. Hospital Equipment & Library Stacks. 1942: Mechanical Press & Press Brakes manufacturing. 1948: 3000 Acres of land acquired in Vikhroli. 1952: First Plant at Vikhroli (Stores). - 10 -

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Housing Colony Complex started. 1955: Manual typewriters. Udayachal School, Pragati Kendra. 1956: Multiplex Storage Systems. Steel Doors & Windows ERW Tubes. 1958: Manufacturing of Refrigerators started. 1961: Forklift Trucks (Material Handling Equipment). Service division started. 1965: Steel Foundry started at Plant-13 (Closed 1990). 1967: Process Equipment Division started. 1985: Electronic Typewriter manufacturing started. 1987: PUF Concept in Refrigerators. 1989: Dot Matrix Printers. 1992: Fax Machines. Divisionalisation Refrigerator division became as an independent Co. Washing Machine introduced in the market. GODREJ KIS started. Friskers started

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Locks Goa Ltd. Godrej Telecom Ltd. Air Conditioners & Cooking Ranges introduced. 1999: Godrej InfoTech Ltd.

1.3 The GODREJ Way of Life MISSION

Enriching the quality of life, everyday, everywhere

VALUES:-Integrity, Trust, To Serve, Respect Environment VISION: -Godrej in every home and Workplace POSITIONING: -Market Leadership

PROPOSITION: - Value for Money INCORPORATION: - Establish in 1897, the Company was incorporated with limited liability on March 3, 1932, under the Indian Companies Act, 1913

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1.4 DIVISIONS OF GODREJ:

The following will give u a brief description of the plants present in the GODREJ with their achievements in their respective fields.

PRECISION ENGINEERING SYSTEMS:

It supplies the other O.E. division plants with blanks; roll formed sections and punched blanks (i.e. material in semi-processed form).

SECUIRTY EQUIPMENT DIVISION:

This is the prime division in Office Equipment Division group. It manufactures safe deposit lockers, cash boxes, safes, and fireproof doors; fire resisting filing cabinets and record cabinets, etc.

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APPLIANCE DIVISION:
This was previously in collaboration with General Electric. It manufactures various household appliances such as refrigerators, washing machines, air conditioners, cooking ranges, etc. This particular group comprises of plants 11, 2, 3, 5 & plant 10.

GODREJ INTERIO:
It comes under the specialized group of O.E. division and manufactures steel furniture. It also manufactures multiplex systems, heavy-duty systems, mezzanine floor systems, compactors, sliding door units, industrial locker units, etc.

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LOCKS DIVISION:
This plant is instrumental in manufacturing door locks and safety latches. The most creditable aspect of this division is its undoubtedly superior quality of service rendered to its customers.

STORAGE SOLUTION GROUPS AND GODREJ EFACEC:

This is also a part of Office Equipment Division group. It manufactures storage systems for industrial purposes such as filing cabinets, cupboards, bookcases, credenza and different types of tables.

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TOOLING DIVISION:
This division manufactures a wide range of sheet metal processing machines for example, presses, press brakes, shears and coil-processing lines. It also manufactures plastic processing machines such as injection molding machines and die casting machines.

MATERIAL HANDLING EQUIPMENT DIVISION:

It manufactures forklift trucks with lifting capacities up to 40 Metric Tones (M.T.) in diesel engine powered versions and up to 2 M.T. in electric powered versions.

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PROCESS EQUIPEMENT DIVISION:

This division is located in Plant 15 and it designs and fabricates a large range of custommade sophisticated equipment for chemicals, petrochemicals and fertilizer industries such as heat exchangers, boiler shells, tower internals, etc., as well as equipment for nuclear and aerospace applications such as parts of atomic reactor, cryogenic engines and projects of ISRO (Indian Space Research Organization).

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CH. 2: INTRODUCTION TO PLANT 16.

M.H.E. DIVISION

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INTRODUCTION TO MATERIAL HANDLING EQUIPMENT DIVISION (PLANT 16)

OVERVIEW

14,000 sq. m. Floor Space

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2.1 PRINCIPLES OF MATERIAL HANDLING:

Material handling is an activity for modern manufacturing concern. The main purpose of material handling is to achieve an effective and economical handling system, right from the introduction of raw materials to the time when the products are finally put to use.

Definition: Material handling can be defined as the technique employed to move, transport, store or distribute materials with or without aid of mechanical appliances. It may also be designated as the Art and Science of moving, packing and storing products in any form. Its general objective can be summarized in the aphorism, Getting the right goods safely to the right place at right time and right cost. In short material handling equipments are used to LIFT and SHIFT loads (products).

2.2 NEED OF MATERIAL HANDLING EQUIPMENT:

1. Material handling equipment is a solution for optimizing storage space.

2. It provides solutions for space utilization & product selectivity.

3. It helps free up substantial amount of floor space by allowing one to Stack loads three to four high pallets high. 4. It products are not scattered all over ones facility, taking up valuable Floor space.

5. It products can be arranged efficiently & reached at quickly.

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IMPROVES SPACE UTILIZATION

1. Eliminates clutter, wasted space efficiently.

2. Reduces possibility of product damage.

3. Effective utilization of space helps you to benefit of additional floor space.

4. Eliminates cost and trouble of building or leasing additional space.

IMPROVES PRODUCT SELECTIVITY

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1. Eliminates need to move multiple products when the products needed are buried three or more deep.

2. Stacking on an organized rack system allows quick access to each individual Product.

3. Product selectivity improvements help you plan a better workflow and more efficient duty cycle.

IMPROVES WORKMEN PRODUCTIVITY AND SAFETY

1. Simplifies routine store maintenance.

2. Manual tools such as ladders are replaced.

3. Operators get the work done faster and safer.

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IMPROVES MOVEMENT OF PRODUCTS

1. Operators can lift, lower and move bulky or heavy loads with ease.

2. Material handling challenges can be solved quickly & economically.

3. Space can be saved and products can be organized for faster access.

2.3 HISTORY OF M.H.E DIVISION

1963: Godrej began manufacturing Electric Forklifts in collaboration with Clark of U.S.A. 1968: Diesel Forklift manufacturing commenced. 1970: Manufacturing commences in independent set-up at Plant 10. 1976: Export of 50 Diesel Trucks to the U.S.S.R. 1982: Manufacturing of Medium /Heavy Diesel Forklifts commenced. 1987: Manufacturing activities shifted to Plant 16. 1994: Warehousing Equipment added to the product range.

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1999: GX model launched. 2000: LPG forklifts launched. 2001: Exploration of foreign markets undertaken.

2.4 DIFFERENT DEPARTMENTS OF M.H.E DIVISION

Plant no.16 is mainly divided into following departments:

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Assembly Department CNC Department Axle and transmission Department Development Department Truck Department Upright Department Maintenance Department Materials Department Marketing Department Purchase Department Design Department Planning Department Inspection Department Service Department

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2.5 THE DESIGN DEPARTMENT:

The basic requirement for the manufacture of any machine part is a diagram of the part. The Design Department is concerned with the designing of machines and their various parts. They make use of software programs like,

1. AUTOCAD 2. I-DEAS 3. PHOTO EDITOR 4. PRO-E etc.

As mentioned earlier the basic purpose of the design department is to design machines and their associated parts. The diagrams are updated by making changes and specifications as required for serving various needs.

Machines are designed for multipurpose use hence designed uniquely; a machine can be upgraded by adding other functions or facilities to improve its performance. But this requires the necessary structural changes to be made by the design department. If a machine sometimes falls short of the required need due to its structure or attachments, the design department minutely observes the shortcoming and modifies the machines making it suitable for the purpose.

The design department follows the following design procedure, 1. Recognition of need. 2. Specifications and Requirement. 3. Feasibility study. 4. Creative design synthesis. 5. Detailed design. 6. Prototype building and testing. 7. Design for prototype. 8. Product release.

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FIG. 2.1 MANUFACTURING SETUP M.H.E. DIVISION

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2.6 PLANT LAYOUT

The plant has a rectangular shape and the production is flow type. The plant is divided into the following 5 BAYS: -

2.6.1 BAY 1: AXLE AND TRANSMISSION:

The axle and transmission assembly is done here in four levels. The first level receives all the castings and the raw material. The second level concerns itself with the processing and production of the individual parts like gears, shafts; control covers etc. Level three deals with the making of sub-assemblies of the differential, clutch pack and control cover. The individual components of these assemblies are either bought out or made in the machine shop or routed through the CNC department. The fourth level is where the assembly of the transmission mechanism is done. The final product of this bay is the assembly of the axle adapter to the transmission.

2.6.2 BAY 2: ENGINE AND INSPECTION DIVISION:

2.1 ENGINE SECTION:

This section receives the complete bought out engine (TELCO or SIMPSON) and conducts various tests on it. It also mounts the torque converter and axle transmission to the engine.

2.2 INSPECTION DEPARTMENT:

It inspects all the incoming and the in-process material. Statistical techniques are employed to exercise quality control.

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2.3 TOOL CRIB:

All the tools in the plant are stored and maintained in this section. Four toolgrinding machines are used for this purpose.

2.4 STEERING AXLE SECTION:

This division assembles the steering axle assembly with the wheels and routes it top the main assembly section.

2.5 STORES:

It is responsible for the storage of the raw materials as well as finished products.

2.6 MACHINE SHOP:

This shop is the extension of the machine shop at bay 1.

2.6.3 BAY 3: ASSEMBLY DIVISION

This division is engaged in the complete assembly of the truck. From the main assembly section, the truck id moved to the final assembly section where fine adjustments are made according to customer requirements. The quality control section then performs various tests on the forklift before sending it to dispatch.

2.6.4 BAY 4: UPRIGHT DIVISION

This division deals with the making of uprights (masts) and all other lifting components like the lift cylinder, rods, and etc. the section is further divided into these sections.

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Fabrication section Machine shop Assembly division.

2.6.5 BAY 5: TRUCK FABRICATION DIVISION

The output of this division is the frame of the truck. The frame or chassis of the truck and its counterweight are both completely fabricated by the welding process. From this bay, the body is sent for painting and then to the assembly section.

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2.7 PRODUCT RANGE

2.7.1 MATERIAL HANDLING EQUIPMENTS:

Forklift Stacker Industrial Trucks Cranes Hoists Monorail Conveyors Pallet trucks Platform trucks etc.

2.7.2 GODREJ MATERIAL HANDLING EQUIPMENT RANGE:

Counter-balanced trucks Warehousing products Tyre handlers ROUGH terrain trucks Forklifts with attachments and accessories

Here in the M.H.E. division, Forklifts, Stackers, Pallet trucks, Platform Trucks are manufactured. Amongst which Forklifts are the main material handling equipments, which are manufactured. Followed by Stackers.

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GODREJ FORKLIFT

GODREJ STACKER

HAND PALLET TRUCK

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FIG.2.2 A TYPICAL FORKLIFT TRUCK

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2.8 FORKLIFT ATTACHMENTS:

SIDE SHIFTER WITH FORK POSITIONER

RAM ATTACHMENT

PAPER ROLL CLAMP

PARROT BEAK ATTACHMENT

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TYRE HANDLER

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CHAPTER NO: 3

DESIGN OF NEW STEERING AXLE.

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3.1 STEERING MECHANISM OF FORLIKTS TRUCKS:

3.1.1 INTRODUCTION:

The Godrej forklift trucks have a unique steering system, which enables it to be minimum effort and maximum maneuverability. The steer axle is mounted on the rear side of the forklift trucks, unlike the conventional vehicle where the steer axle is mounted on the front side. This enables forklift trucks to achieve a smaller turning radius, which is of great help in congested areas.

Another important factor is the ease with which steering can be carried out. This is due to hydrostatic steering unit, the physical effort on the part of operator is greatly reduced and steering the truck becomes smooth and comfortable. The steering cylinder is mounted along the body of the truck.

3.1.2 COMPONENTS OF HYDROSTATIC STEERING AXLE:

1. Hydrostatic steering unit. 2. Steering cylinder. 3. Steer axle.

3.2 HYDROSTATIC SEERING UNIT:

This unit is the heart of the steering system and is called the DANFOSS unit. This unit provides great safety and comfort to the operator by controlling the high steering forces. The operation of this unit is hydrostatic, which means there is no mechanical link between the steering column and wheels. Instead there are hydraulic pipes and hoses between the steering unit and steering cylinder. When the steering hand wheel is turned, the steering unit meters the oil whose volume is proportional to the amount of turn. This volume is fed into the appropriate side of the piston in the steering cylinder, actuating the

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linkages and giving the desired turn. The steering automatically turns to the neutral position when the steering is completed due to the presence of a neutral positioning spring in the unit.

3.3 HYDRAULIC CIRCUIT:

The Godrej forklifts trucks are equipped with a hydraulic system, which provides the power needed to operate the lifting and tilting and steering circuits. The entire hydraulic system is divided into two broad categories, which functions independently.

3.3.1 MAIN HYDRAULIC CIRCUIT:

This circuit is used for lifting and tilting operation. It consists of a pump, suction strainer, hydraulic valve, tilt lock valve, lift and tilt cylinder etc.

3.3.2 STEERING CIRCUIT:

This system consists of a hydrostatic steering unit, the priority valve and the steering cylinder. It is supplied with oil by the same pump as in main hydraulic circuit.

3.3.3 PRIORITY VALVE:

This valve is also called the flow divider and is provided in the hydraulic circuit to divide the flow from the pump into two parts supplying oil to the main hydraulic circuit and the hydrostatic steering unit. The valve derives its name from the fact that it gives priority to the steering unit by ensuring that it gets the minimum amount oil necessary for its operations. The valve receives a supply of 14 gpm from the gear pump as input. Out this priority is given to hydrostatic steering unit and 4.5 gpm (approx. 16 lpm) is supplied to it the remainder is supplied to hydraulic valve for lifting and tilting circuits.

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Priority valve comprises of a spring loaded spool operating in a valve body. An orifice at the end of the spool, help in regulating the flow of oil to various circuits.

3.3.4 HYDROSTATIC STEERING UNIT

It is a hydraulic circuit consisting of distributor valve and a rotary meter, which can be schematically represented as follows.

FIG. 3.1 HYDROSTATIC STEERING UNIT

Hydrostatic power steering means no direct mechanical connection between the steering column and the steered wheels. Instead, the steering wheel controls the flow of pressurized oil, which in turn provides the necessary force on a piston to steer the wheels. Such type of steering is used in forklift trucks where the driver or helmsman must control

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the high steering forces and where safety and comfort are demanded. In Godrej forklifts this is achieved by means of placing a hydrostatic steering unit on the steering column, which supplies oil to the steering cylinder at appropriate times.

3.3.5 CONTROL ELEMENTS:

3.3.5.1 DISTRIBUTOR VALVE:

FIG. 3.2 DISTRIBUTOR VALVE This valve in all has six working lines. The central rectangle represents the position of the valve in un-actuated state. The other two rectangles represent the connections that will be made when the valve switches to the corresponding positions of the spool. The arrow indicates the direction of the flow of oil through the lines joined by it.

3.3.5.2 CHECK VALVE:

FIG. 3.3 CHECK VALVE

This valve allows movement of oil flow in one direction only. The flow takes place only if the pressure of oil at point 2 is greater than at point 1.

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3.3.5.3 GENERATED ROTOR PUMP:

These pumps have a pair of gear shaped elements, one within the other, mounted in the pump casing. The inner rotor element is connected to the drive shaft and drives the outer generated rotor.

The g-rotor device I soften built into other machines in a cartridge form to provide lubrication, fluid transfer or hydraulic power. The ring gear rather than the pinion can be driven when this facilities the design of machine structure.

Operation of the rotor elements is as follows. The inner element has one tooth less than the outer element. The tooth form of each element is always in sliding contact with the surface of the outer element. Each meshing pair of the teeth of the two elements engages at just one place in the pump i.e. at X. At the right hand side of the point of mesh, pockets of increasing size are formed as gear rotates, while on the other side the pockets decrease in size. The pockets of increasing size are suction pockets and those of decreasing size are discharge pockets. The inner and outer elements travel slowly with respect to each other even the drive shaft is rotating rapidly. This type of pump may be connected in a series of stages for higher pressure. The generated rotor element is also used in e modified from as a hydraulic motor displacement

3.3.5.3.1 WORKING:

When the truck moves in a straight line, the distributor valve spool is in the center. In this position, pressurized oil flows directly into the tank by passing the cylinder. Hence this called open center unit. When the steering unit is turned in any direction the corresponding position of the valve spool is obtained and appropriate connections are established a metered volume of the oil, proportional to the amount of turn, is led to the appropriate side of the position in the steering cylinder.

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Prior to this the oil is passed through a generated rotor pump. This g rotor plays the part of a hand pump in case the main pump fails. In this case, effort required to steer the vehicle is greater but can be provided by an operator of average physique.

As soon as steering action is complete, the distributor valve is brought to the neutral position by means of a centering spring in the unit. This prevents any further flow of oil to or the road wheels thus holding the wheels in turned position. It also prevents external forces on the road wheels from producing reactions in the steering wheels.

3.4 HYDRAULIC LINE WITH-LOAD SENSING

3.4.1 INTRODUCTION:

The hydraulic line with load sensing unit is the new hydraulic system used in Godrej forklift trucks. It has its advantages over the old hydraulic system with priority valve. In the old system priority valve used to provide oil, which was required for steering even when vehicle is not being steered. So, that amount of oil was not utilized for the other operations in forklift trucks. But load sensing hydraulic line provides oil to the steering cylinder only when it is required otherwise entire oil is provided for the lifting and tilting operation which is carried out by the mechanically operated directional control valve.

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FIG. 3.4 HYDRAULIC LINE WITH-LOAD SENSING

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3.4.2 CONSTRUCTION:

This hydraulic circuit consists of a hydraulic tank, hydraulic pump, and load sensing orbitrol, which is connected below the steering column. The two ports of the load sensing valve is connected to the steering cylinder which is double acting cylinder, one port is connected to directional control valve and one more port is connected to hydraulic return line. It also has a 2 spool, mechanically operated directional control valve, which is mainly used for lifting and tilting. The valve has two levers; left lever is for lifting and the right one is for tilting. The inlet port is connected to loading sensing valve. Two ports of DCV are connected to the tilt cylinder, which is a double acting cylinder, and one port is connected to lift cylinder, which is a single acting cylinder through throttle valve. There is one more port, which is connected to the return line. Inlet of hydraulic tank has a low-pressure filter and outlet has strainer, which just like a sieve.

3.4.3 WORKING:

The oil from the tank goes to the hydraulic pump. From the pump oil goes to the orbitrol, which divides the flow of the oil depending on the rotation of the steering wheel. The volume of oil that goes to the steer cylinder is directly proportional to the rotation of the steering wheel. So if truck is not being steered then entire oil can go to directional control valve were it could be used for lifting or tilting. The orbitrol has a relief valve whose pressure is set at 140 bars. The orbitrol dispenses the oil required for steering by sensing the rotation of the steering wheel and by speed of rotation. Hence this circuit is called as load sensing circuit. So the main advantage of this hydraulic line is that the oil is used for steering only when required and in exact amount. So entire oil provided by the pump is properly utilized. But this circuit is used in all the Godrej trucks, but since it is very costly it is not used in low cost forklift trucks.

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3.5 STEER AXLE:

3.5.1 INTRODUCTION:

The steer axle is the assembly of all the members, which are necessary to cause steering of the wheel. The lateral steering cylinder is mounted on steer axle. There are three important components of this steering mechanism. 1. Lateral steering cylinder. 2. Steering knuckle 3. Link. These three members form a simple slider crank mechanism were cylinder acts as slider and knuckle is a crank, which rotates about kingpin to give rotational motion to the wheel. This steer axle along with all the members is mounted on the forklifts frame.

3.6 WORKING OF THE LATERAL STEERING MECHANISM:

As the steering wheel is turned, the hydrostatic steering unit meters a proportional quantity of oil to the appropriate side of the piston. This oil being pressurized exerts a force on piston rod, which in turn is transferred to the link, which is connected between piston rod and the steering knuckle. The wheel is mounted on other side of the steering knuckle. The knuckle being pivoted at the kingpin of the vehicle, any linear movement of the connecting link is converted into rotary motion of the steered wheels.

3.7 CONDITION FOR TRUE ROLLING:

For steering of any four wheel vehicle, satisfying the Ackermans true rolling equation is very necessary so that the vehicle will not slip or drag while turning. All four wheels of the truck must turn about a common centre to avoid slipping this centre is called the Instantaneous centre of rotation. Hence, it can be visualized that the wheels turn through different angles. Here, it is essential to comment on minimum turning radius

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achievable, this is an important factor while buying a forklift truck. It is also noticeable that as the turning angle increases turning radius reduces. At present the turning angles of the wheels are 68o and 48o and turning radius is 2600 mm for GX 300 D forklift truck.

FIG. 3.5 CONDITION FOR TRUE ROLLING

Now, the true rolling equation, Cot Cot = c/b. where, = Turning angle of inner wheel. = Turning angle of outer wheel. c = Kingpin distance. b = Wheel base. I = Instantaneous centre of rotation. (Turning radius calculated from I.)

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3.8 DESIGN OF NEW STEERING AXLE:

While designing a new steer axle the few important parts have to be designed. The important notations that should be considered while designing new steering axle are: 1. 2. 3. 4. 5. 6. L LINK LENGTH. R KNUCKLE ARM LENGTH. P CENTRE-TO-CENTRE DISTANCE OF PISTON ROD. D OFFSET BETWEEN CYLINDER AXIS AND AXLE CENTRE. KNUCKLE ANGLE. X DISTANCE BETWEEN KINGPIN CENTRES.

3.8.1 MATHEMATICAL MODEL:

To arrive at the various proportions of the linkage certain mathematical relationship are developed, which are to be satisfied for the smooth working. From the geometry of the figure below, we can derive the following equation for the neutral position of the wheels.

3.8.2 WHEN WHEELS ARE IN NEUTRAL POSTION.

FIG. 3.6 WHEN WHEELS ARE IN NEUTRAL POSTION.

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X1 = P + 2 [(L2 (R SIN D)2) R COS ].

(i)

So by assuming suitable values for L, P, D, R AND we get the X so if kingpin distance is not a constraint then directly kingpin distance can be obtained. Assuming, P = 600 mm. D = 60 mm. R = 94 mm. L = 104.5 mm. = 80o. X1 = 600 + 2 [( (104.5) 2 (94 SIN 80 60) 2) 94 COS 80]. X1 = 765.94 mm. (When wheels are in neutral position.)

3.8.3 WHEN WHEELS ARE IN TURNED POSITION.

FIG. 3.7 WHEN WHEELS ARE IN TURNED POSTION. X2 = P [ R - (L2 D2) ] + (L2 - (R SIN x D)2 )+ R COS x. (ii). Putting values in eq. (ii), we get, X2 = 765.84 mm. (When wheels are turned through 80o). Therefore, X1 X2. The kingpin-to-kingpin distance of the axle is 765.84 mm.

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3.9 SIGNIFICANCE OF VARIABLES IN STEERING MECHANISM:

Significance of offset between cylinder axis & axle centre, knuckle arm length, knuckle arm angle. The offset between cylinder axis & axle centre is very important since as you decrease this distance your mechanism becomes very sensitive & for same amount of stroke you get more turning angle. Knuckle arm length should be suitably selected because if the arm length is more you get more torque but at the same time care must taken that arm must not interfere with the wheel rim. There are three possibilities for knuckle arm angle, it can be acute angled or right angled or obtuse angled with respect to horizontal axis where wheel is mounted.

1. When the knuckle angle is acute, the link angle is more horizontal, which is desirable since axial force acting on piston rod reduces. But more acute angle of knuckle arm can interfere with the wheel rim. The major advantage of this type of knuckle arm is as angle is becomes more acute for less amount of stroke we can get desired turning angles. 2. When the angle is 90o, this is the most convenient from manufacturing point of view but possibility of arm interfering with rim is more since R-value is higher. 3. When arm angle is obtuse it allows more freedom for selection of R, but causes link angle at neutral position to be slightly higher. Thus radial force on cylinder becomes higher it may cause cylinder to bend. And also stroke required to obtain particular angle is more as compared to acute angle arm since their decrease in link length.

The link angles in neutral and the extreme position should be such that it should not create a deadlock, in these positions. Another parameter to be checked is whether the piston rod length is sufficient to accommodate required stroke.

Hence, proper combination of all these variables should be selected so that smooth working of entire mechanism is possible. In this way the entire geometry of the axles is decided by lots of trial and error.

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3.10 SATISFYING TRUE ROLLING CONDITION:

The true rolling condition has to be checked for given wheelbase and calculated kingpin-to-kingpin distance.

FIG. 3.8 TURNING RADIUS INCLUDING COUNTERWEIGHT. According to Ackermans true rolling eq.: Front tread = 1035 mm. (GX- 300D). Wheelbase = 1700 mm. (GX- 300D). X = 765.84 mm. = 80o =? Cot Cot = c/b.

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Cot Cot 80o = 765.84 / 1700. = 57.92o 58o. Therefore, other wheel should turn through 58 so that vehicle does not skid while turning.

3.10.1 CALCULATION OF TURNING RADIUS:

Turning radius is calculated from the instantaneous centre. For forklift trucks if turning radius is less it is a major asset since it well take less space to turn which is desirable in industries and warehouses were space is of major concern. Here for new turning angles the outer turning radius is 2330 mm and inner turning radius is 165 mm. Hence, turning radius is reduced by almost 270 mm and at the same time since axles distance has increased rear tread is increased and stability in also increased. But there is a constraint on tyre out to out distance; it cannot exceed 1120 mm because for 4 in 1 forklifts maximum width is 1120 mm. The new axle satisfies this condition.

ANGLE V/s STROKE

90 80 70 60

ANGLES

50 40 30 20 10 0 10 20 30 40 50 STROKE 60 70 80 91.4

ANGLE V/S STROKE:

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This comparison between angle and stroke is important, since smooth working of mechanism is based on the linearity of graph that is plotted against angle vs. stroke. The main reason is, for equal amount of stroke, the angular rotation of wheel must be same at all the time. This is the ideal condition. If this relation is linear than there wont be any sudden jerk while turning the wheel. Hence mechanism will work smoothly.

FIG.3.9 LINK

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FIG. 3.10 LEFT HAND KNUCKLE

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FIG. 3.11 RIGHT HAND KNUCKLE

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FIG. 3.12 AXLE BODY

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CHAPTER NO: 4

FORCE CALCULATION AND DESIGN OF STEERING CYLINDER.

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4.1 FORCE CALCULATIONS:

The axle that is being designed would be used for GX 300D model. The service weight of this forklift is approximately 4200 kg. Approximately sixty percent of this weight falls on the rear axle therefore; the load that acts on the centre of the rear axle is 2500 kg.

The steering of the forklift truck requires maximum effort, when it is stationary and in unloaded condition. The load is maximum on the rear axle in the unloaded condition and the static coefficient of friction between the tyres and the road is greater than the dynamic coefficient of friction. Thus, the calculations have been made for these conditions.

FIG. 4.1 REAR AXLE OF A 3 TONNE TRUCK

The load on the rear axle in the unloaded condition is (2500/2) = 1250 kg. It is a simply supported beam with symmetric loading (assumption), so half the load comes on each wheel. But designing it for impact loading we consider 2 x 1250 = 2500 kg. The coefficient of friction between the tyre and the road is taken as 0.5. Friction force will act opposite to the motion of the wheel.

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Let Ff = mg. where, = 0.5. mg = 2500 kg. therefore, Ff = 0.5 x 2500. Ff = 1250 kg. Ff = 12262.5 N.

4.1.2 WHEN LINKAGE IN NEUTRAL POSITION:

The force acting on the knuckle arm to turn the wheel is found by taking moment at the kingpin centre.

FIG. 4.2 F.B.D OF KNCUKLE AND WHEEL

Ff x a = F1 x b. 1250 x 99.61 = F1 x 82.87.

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F1 = 1502.50 kg.

FORCE ALONG THE LINK (F1):

The force acting on knuckle will act along the link, thus force F1 will act along the link.

FIG. 4.3 F.B.D OF LINK The horizontal force acting on link will be F1 cos 1 and vertical force on link is F1 sin 1. where, 1 = 18o. Therefore, F1 cos 1 = 1502.50 cos 18. F1 cos 1 = 1428.96 kg.

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Similarly, F1 sin 1 = 1502.50 sin 18. F1 sin 1 = 464.30kg.

FORCE ALONG THE PISTON ROD (FP):

FIG. 4.4 F.B.D OF PISTON ROD Now, the horizontal force F1 cos 1 will act on cylinder. Hence force required to turn the wheel will be FP = F1 cos 1 = 1428.96 kg. Since the geometry is symmetrical same force will act on other side of piston rod. Therefore, F1 cos 1 = 1428.96 kg. Thus total horizontal force on piston rod = F1 cos 1 + F1 cos 1. FP = 1428.96 + 1428.96. FP = 2857.92 kg. FP = 28036.19 N.

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4.1.3 WHEN WHEEL IS TURNED THROUGH 80O ANGLE:

FIG. 4.5 F. B. D WHEN WHEEL IS ROTATED AT 80 O

Ff x a = F2 x c. 1250 x 99.61 = F2 x 54. F2 = 2305.78 kg. This force F2 will act along the link, were link forms angle of 35o with the piston. Hence, at 2 = 35o. F2 cos 35 = 1888.78 kg. F2 sin 35 = 1322.54 kg. This horizontal force will act on piston rod. F2 cos 35 = 1888.78 kg.

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4.1.4 WHEN OTHER WHEEL IS TURNED THROUGH 58O ANGLE:

FIG. 4.6 F. B. D WHEN WHEEL IS ROTATED AT 58 O

Ff x a = F3 x d. 1250 x 99.61 = F3 x 65. F3 = 1915.57 kg. This force F3 will act along the link, which makes angle of 2o with the piston. Hence, at 3 = 2o. F3 cos 2 = 1914.41 kg. F3 sin 2 = 66.85 kg. Therefore, total horizontal force acting on piston will be = F2 cos 35 + F3 cos 2. = 1888.78 + 1914.41. = 3804.35 kg. = 37320.67 N.

Hence force required to turn the wheel from extreme position to neutral position is more than force required to turn the wheel from neutral position to extreme position.

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Stroke V/S Forces

4000 3500 3000
Forces in kgf

2500 2000 1500 1000 500 0 0 10 20 30 40 50 60 70 80 91.36 Stroke in mm Axial Resultant force Bending force

The axial force on piston rod increases as stroke increases (i.e. turning angle of wheel increases). So the force acting on piston rod when it is at neutral position is 2856.282 kgf. And the force acting on piston rod at the extreme end is 3807.963 kgf. So force required, to turn the wheels when it is in the extreme position is more then the force required to turn the wheels when it is in the neutral position. Hence the piston rod should be designed to withstand maximum axial force to avoid buckling. Bending force or Radial force acts perpendicular to the piston rod and its minimum when the angle of link with piston rod is zero. As the trend shows the radial force is decreasing and again increasing this is because the angle made by link with the piston rod is reducing and it is minimum at stroke of 50.78mm and then it again increases.

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4.2 STEERING CYLINDER:

The steering cylinder is a double acting one, which receives oil under pressure from the steering unit and provides the mechanical push to the steer axle. It is basically a piston cylinder arrangement provided with adequate sealing. The two ports of the steering unit are connected to the corresponding opening in the cylinder. Hydraulic oil enters the Danfoss steering unit, and when the steering is not done, this oil returns to the tank through the ports. When the steering wheel is turned the Danfoss unit directs the oil to the required side of the cylinder.

4.3 DESIGN OF STEERING CYLINDER

FIG. 4.7 LATERAL STEERING CYLINDER

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4.3.1 DESIGN OF CYLINDER BARREL:

The cylinder barrel acts like a pressure vessel. Hence it is designed for two stresses one is circumferential stress or a hoop stress and other is radial stress. But intensity of hoop stress is almost twice that of radial stress. Therefore we design our cylinder barrel only for hoop stress.

Material of barrel is ST-52, which is kind of structural steel. The tensile strength of this material is 360 Mpa. t = 360 Mpa. Also, t = PD/2t Were, P = maximum allowable pressure. = 140 bars. D = Bore diameter of barrel. = 80 mm (Assumed). t = Wall thickness of barrel. Factor of safety = 2.

Here bore dia. is assumed to be 80 mm because of dimensional constraint. So, 360 = (14 x80)/2t t = 3.1 mm.

O.D = I.D + 2t. = 80 + 2 x 3.1 = 86.22 mm. The O.D of out barrel is 94 mm which safe.

FIG. 4.8 HOOP STRESS

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4.3.2 DESIGN OF PISTON ROD OF STEERING CYLINDER:

The piston rod should be designed to withstand two forces first the horizontal force or axial force, which can cause buckling of the piston rod, and other force is the radial force, which can cause rod to bend.

4.3.2.1 DESIGN FOR BUCKLING: So design for buckling is done by Eulers formula were we assume that piston rod is fixed at one end when entire stroke is taken and other end is hinged which is actually a pin joint. Peuler = (2 EI)/ le2 = (22 EI)/ l2 le = l/2. (For one end fixed and other end hinged.)

Therefore, l = 221 mm (stroke + distance of hole) (184 + 37). E = 2.1 x 105 N/mm2 (Modulus of elasticity) I = Moment of inertia. Peuler = 37320.67 N. (F2 cos 35 + F3 cos 2.) This is the maximum axial force acting on the piston rod. Therefore, 37320.67 = (2 2 x 2.1 x 105 x [( x d4)/64])/2212 d = 9.72 10 mm.

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4.3.2.2 DESIGN FOR BENDING

Design for bending depends on maximum radial force acting on the piston rod. This is when the wheels are turned through 80o at the extreme position.

So, F2 sin 35 is the maximum radial force acting on the piston rod, which is 1322.54 kg or 12974.12 N. By applying bending moment equation.

We get, M/I = t/y. where, M = Bending moment I = Moment of inertia. y = Centre of gravity. Yield strength. = 460 Mpa. Factor of safety = 2. t = 460/2 = 230 Mpa.

(12974.12 x 221) / [( x d4)/64] = 230/ (d/2). d = 50.26mm. 50 mm.

Hence diameter of piston rod should be 50 mm.

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FIG. 4.9 STEER AXLE ASSEMBLY

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26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Sr.No.

SPRING WASHER BEARING BUSH TOP AND BOTTOM THRUST BEARING CASTLE NUT CAP HUB HUB BOLT WHEEL MOUNTING SPRING WASHER BOLT M6 SPACER BEARING BEARING LOCKING BOLT M10 LOCK NUT M10 BOLT M16 LOCKING PLATE PIVOT PIN KING PIN HOLLOW DOWEL BOLT M16 LINK KNUCKLE L.H KNUCKLE R.H CYLINDER AXLE MACHINING DESCRIPTION PART LIST

4 4 4 2 2 2 2 10 12 12 2 2 2 2 2 4 4 4 2 2 4 2 1 1 1 1 QTY.

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COMPARISON OF NEW AND EXISTING STEERING AXLE:

Parameters Kingpin (mm) 'X' Cyl C-C (mm) 'P' Stroke (mm) Knuckle Arm 'R', '' Angles (degrees) D (mm) Outer Turning Radius (mm) Inner Turning Radius (mm) Tyre out to out (mm)

EXISTING 698.5 502.8 135 74.6mm, 69o 50, 68 65 2500/2600 489.11 1048

NEW AXLE 765.84 600 184 94mm, 80o 58, 80 60 2330 165 1116

4.4 ADVANTAGES OF NEW AXLE:

1. There is increase in kingpin distance. Hence, rear tread has increase so the vehicle will have better stability. 2. Knuckle arm length has increase so more torque is generated for same amount force. But torque required to rotate the wheel is constant so force will reduce as R increases. Hence force acting on cylinder will be less, which will increase the life of cylinder rod. 3. Due to increase in knuckle angle the chances of arm interfering with the rim reduces.

4. There is increase in turning angles of the wheels, with proper satisfaction of true
rolling condition. This reduces turning radius of forklift to 2330 mm, 270mm less as compared to existing axle.

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FIG. 4.10 AXLE ASSEMBLY

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CHAPTER NO: 5

AXLE MOUNTING

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5.1 MOUNTING OF AXLE

Mounting of steering axle is one of the important aspects that need to be considered. The mounting of steer axle is done on the rear side of the forklift. The main reason for mounting it on the rear side is that on the front side forks are fitted, which carriers the load, so if steering axle on the front side, while turning it is possible that the load may topple. So the front side needs to be fixed. Also it gives more maneuverability and reduced turning radius for working in congested areas.

In Godrej forklift trucks steer axle is mounted using silent blocks, where the silent blocks are bolted on both the sides of the axle. Then a threaded shaft, which is protruding out, is bolted to frame using a castle nut. The silent block assembly consists of a block, shaft and between this a rubber coating is done to compensate any misalignment. While mounting care must be taken that both the mounting holes must be coaxial, any misalignment will not allow axle to mount on frame. This is a very old technique used for mounting. Now a days new technique are adopted for steer axle mounting, which are more effective and cheap. The major disadvantage of silent block mounting is that it is very costly.

5.2 PIN:

MOUNTING OF AXLE WITH RUBBER BLOCK AND OVAL

This is new method adopted by many companies; here the axle contains an oval pin, which is welded on front plate and web of an axle. It is very compact design where forged pin is used. It also consists of a rubber block with a hole, and pin is inserted between this holes. A U clamp is used to mounting this axle, this clamp is welded to the frame. This type of mounting has its advantages:

1. It is much cheaper as compare to silent block mounting. 2. Rubber block, because of its shape can compensate for little misalignment. 3. Because of rubber block shock resistant is more. - 72 -

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4. Oval pin also provides limited amount of articulation. 5. Design is more compact.

5.3 DESIGN OF OVAL PIN:

The minimum diameter of oval pin should be able withstand the forces that are acting on it. So we design diameter for three criteria Bending, Crushing and Shearing. Material used for this pin is SAE 8620 or Mild steel.

FIG. 5.1 F. B. D. OF OVAL PIN

5.3.1 For SAE 8620,

Weight on axle is = 1.25 tons, And considering impact loading it will be twice of 1.25 that is 2.5 tons.

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Tensile strength = 536 Mpa, Yield strength = 357 Mpa, Factor of safety = 2, L = 103 / 2 = 51.5 mm.

Safe stress = Tensile strength/ Factor of safety, t = 357/2, = 178.5 N/mm2. s (Shear strength) = 0.5 t, = 89.25 N/mm2. c (Crushing Strength) = 1.2 x t = 214.2 N/mm2.

DESIGN FOR BENDING: According to bending moment equations M/I =t /y. [2.5 x 104 x L] / [( x d4)/64] = 178.5/(d/2). Therefore, [2.5 x 104 x 51.5] / [( x d4)/64] = 178.5/(d/2). d = 41.88 42 mm.

Now checking CRUSHING STRESS value for this diameter. c = F / (L X D). c = 2.5 x 104/ (103 x 42) c = 5.77 N/ mm2. < 214.2 N/mm2. Hence, it is safe for the given CRUSHING STRESS.

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Now checking SHEAR STRESS value for this diameter. = F / [( x d2)/4]. = 18.04 N/mm2. < 89.25 N/mm2. Hence, it is safe for the given SHEAR STRESS.

5.3.2 For Mild Steel,

Weight on axle is = 1.25 tons, And considering impact loading it will be twice of 1.25 that is 2.5 tons. Yield strength = 280 Mpa, Factor of safety = 2, L = 103/ 2 = 51.5 mm.

Safe stress = Tensile strength/ Factor of safety, t = 280/2, = 140 N/mm2. s (Shear strength) = 0.5 t, = 70 N/mm2. c (Crushing Strength) = 1.2 x t = 168 N/mm2.

DESIGN FOR BENDING: According to bending moment equations M/I =t /y. [2.5 x 104 x 51.5] / [( x d4)/64] = 140 / (d/2). d = 45.41 mm. 50 mm.

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Now checking CRUSHING STRESS value for this diameter. c = F / (L X D). c = 2.5 x 104/ (103 x 50). c = 4.85 N/ mm2. < 168 N/mm2. Hence, it is safe for the given CRUSHING STRESS.

Now checking SHEAR STRESS value for this diameter. = F / [( x d2)/4]. = 12.73 N/mm2. < 70 N/mm2. Hence, it is safe for the given SHEAR STRESS.

The two materials that are selected for oval pin both have some advantages and some disadvantage. SAE 8620 is a strong material with good weldability. But it cannot be forged and is costly. M.S on other hand can be forged with decent weldability and is also very cheap. So since there is not much of difference in min. diameter and also this type of mounting is being done to reduce the cost, we use mild steel for oval pin.

5.4 RUBBER BLOCK AND U-CLAMP:

A rubber block is used for mounting with the help U- clamp and a plate. A vendor supplies a rubber block and size of rubber block is fixed. So clamp and plate must be designed accordingly. A clamp with flanges is not possible due to dimensional constraint so a U clamp is designed which has slot. In this slot a stud is welded and then this clamp is again welded to frame. Then after assembling the axle a lock plate is used, which is bolted to the studs. It is very important that clamps must be welded is line and distance between them should be maintained. This is necessary because if this distance is not maintained properly, axle mounting will be impossible. Also clamp must be 2 mm smaller then rubber block. So that while bolting a lock plate rubber is compressed.

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FIG. 5.2 OVAL PIN

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FIG. 5.3 RUBBER BLOCK

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FIG. 5.4 U-CLAMP

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FIG. 5.5 LOCKING PLATE

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FIG. 5.6 MOUNTING PIN ASSEMBLY

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FIG. 5.7 FRAME WITH RUBBER MOUNTING

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5.5 AXLE MOUNTING WITH PLUMMER BLOCK:

The plummer block mounting is a very compact mounting. This type of mounting is usually used in Korean forklifts. Here a mounting pin is welded to front and the backside of axle, and then plummer block is fitted around this pin. Entire assembly is mounted on rear frame with the help of the studs. It also has a bush, which avoids damage of plummer block during articulation. Plummer block is cheaply available. It can be manufactured by using gas-cutting operation. A standard plate can be easily cut by using gascut machine.

This type of mounting has its advantages: 1. It is much cheaper as compare to silent block mounting and also rubber block mounting. 2. It can be easily manufactured. 3. This design is more compact. 4. Mounting pin need not be forged one, so cost of forging is reduced. 5. Plummer block is much cheaper as to rubber block.

5.6 DESIGN OF PIN:

The minimum diameter of pin should be able withstand the forces that are acting on it. So we design diameter for three criteria Bending, Crushing and Shearing. Material used for this pin is SAE 8620 or Mild steel.

5.6.1 For SAE 8620, Weight on axle is = 1.25 tons, And considering impact loading it will be twice of 1.25 that is 2.5 tons. Tensile strength = 536 Mpa, Yield strength = 357 Mpa, Factor of safety = 2, L = 42 mm. (total length / 2). Safe stress = Tensile strength/ Factor of safety,

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t = 357/2, = 178.5 N/mm2. s (Shear strength) = 0.5 t, = 89.25 N/mm2. c (Crushing Strength) = 1.2 x t = 214.2 N/mm2.

FIG.5.8 F. B. D. OF MOUNTING PIN

DESIGN FOR BENDING: According to bending moment equations M/I =t /y. [2.5 x 104 x L] / [( x d4)/64] = 178.5/ (d/2). Therefore, - 84 -

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[2.5 x 104 x 42] / [( x d4)/64] = 178.5/ (d/2). d = 39.13 40 mm.

Now checking CRUSHING STRESS value for this diameter. c = F / (L X D). c = 2.5 x 104/ (84 x 40). c = 7.44 N/ mm2. < 214.2 N/mm2. Hence, it is safe for the given CRUSHING STRESS.

Now checking SHEAR STRESS value for this diameter. = F / [( x d2)/4]. = 19.89 N/mm2. < 89.25 N/mm2. Hence, it is safe for the given SHEAR STRESS.

5.6.2 For Mild Steel,

Weight on axle is = 1.25 tons, And considering impact loading it will be twice of 1.25 that is 2.5 tons. Yield strength = 280 Mpa, Factor of safety = 2, L = 84 / 2 = 42 mm.

Safe stress = Tensile strength/ Factor of safety, t = 280/2, = 140 N/mm2. s (Shear strength) = 0.5 t, = 70 N/mm2. c (Crushing Strength) = 1.2 x t = 168 N/mm2.

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DESIGN FOR BENDING: According to bending moment equations M/I =t /y. [2.5 x 104 x 42] / [( x d4)/64] = 140 / (d/2). d = 42.43 mm. 45 mm.

Now checking CRUSHING STRESS value for this diameter. c = F / (L X D). c = 2.5 x 104/ (84 x 45). c = 6.61 N/ mm2. < 168 N/mm2. Hence, it is safe for the given CRUSHING STRESS.

Now checking SHEAR STRESS value for this diameter. = F / [( x d2)/4]. = 15.71 N/mm2. < 70 N/mm2. Hence, it is safe for the given SHEAR STRESS.

The two materials that are selected for pin both have some advantages and some disadvantages. SAE 8620 is a strong material with good weldability. But it cannot be forged and is costly. M.S on other hand can be forged with decent weldability and is also very cheap. But since SAE 8620 bars are available so we can use SAE 8620 instead of M.S. Direct machining can be done on SAE bars which reduces the forging cost that is involve in oval pin mounting. But even though diameter obtained through calculation is 45 mm, we take mounting diameter to be 50 mm. So that same axle can be used for both the mountings.

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5.7 PLUMMER BLOCK ASSEMBLY:

Plummer block is a semi circular block with flanges. These flanges are bolted to the plate, which has been welded to the frame. The plummer can be profile cut on gascut machine. Hence, it is quite easy to manufacture. It also has a drilled hole, which has a bush. It has a small lock plate, which avoids bush from coming out of the hole and a small hole for greasing. This entire assembly of plummer is fitted on mounting pin, which is welded on a steer axle, and then axle is mounted on frame with the help of studs. While mounting special care should taken so that both the holes are concentric. Axle is mounted properly in a straight line.

5.8 COMPARISON BETWEEN RUBBER MOUNTING AND PLUMMER BLOCK MOUNTING.

1. The plummer block mounting is cheaper as compared to rubber mounting. The main reason for this is that plummer block can be made through simple gascut operation, while rubber block has to be molded in a special die, which increases its cost. 2. But in rubber mounting due to presence of rubber, it has better shock resistance as compared to plummer mounting which has a bush. 3. Any misalignment while drilling the holes or while welding the clamp can be compensated in rubber block mounting. But for plummer block mounting it should accurately drilled. 4. Elliptical pin needs to be forged while round pin is machined from a bar stock. Hence cost involved in forging in higher compared to cost involve in machining. 5. But elliptical pin has its advantages over round pin. Because oval pin limits the articulation of an axle. 6. Welding area is also more in elliptical pin so it is more sturdy and rigid.

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FIG. 5.9 PLUMMER BLOCK

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FIG. 5.10 PLUMMER BRCAKET MTG PLATE FRONT

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FIG. 5.11 PLUMMER BRCAKET MTG PLATE REAR

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FIG. 5.12 LOCK PLATE

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FIG. 5.13 PLUMMER BLOCK MOUNTING FRONT

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FIG. 5.14 PLUMMER BLOCK MOUNTING REAR

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FIG. 5.15 FRAME WITH PLUMMER BLOCK

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FUTURE SCOPE FOR IMPROVEMENT:

There is still scope for development in both the projects. The turning angles of wheels can be increased which can further reduce the turning radius. But while doing that, care must be taken regarding dragging of the wheel. Kingpin distance can be increased, which will increase the stability of the vehicle. This is always important in any vehicle. The box type construction can be adopted, so that the section modulus of axle increases and it becomes sturdy. At present axle has a C section but box type axles have rectangular section, which always has better load carrying capacity. At the same time fabrication and machining will cost increases.

Axle mounting has huge scope for improvement. The two mountings mentioned above must be implemented, because these mountings are more compact compared to silent block mounting and also these mountings are cheaper. The frame of forklift can be modified by reducing the members, which will definitely reduce the cost of frame. So a low cost frame can be design. This type of project is started. The net weight of the frame is same but gross weight has reduced. If rubber mounting and low cost frame both the things are implemented together, then cost is fairly reduce. The Plummer block mounting can further reduce the cost. But machining require for such type of mounting must be accurate. Any error in machining can led to problem during mounting.

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CONCLUSION:
ADVANTAGES:
The turning angles of steering axle have increased from 68o to 80o. There is remarkable increase in steering angles. Hence turning radius has reduced from 2600 mm to 2330 mm. This axle satisfies true rolling condition much better than the existing axle. Therefore there is less dragging of wheels. The stability is also good and a vehicle turns smoothly without skidding. The kingpin-to-kingpin distance has increase, so rear tread of an axle has increase, which results in better stability. Link between cylinder and the knuckle is like a plate. Therefore, link is much easy and cheap to manufacture. Spherical bearing was use in cylinder or a knuckle, because forks were present in a link. But now link is just like a plate so on both the side bearing can be used, which gives proper support to the entire mechanism.

The new mountings that are proposed have huge advantage, as these mountings are very cheap as compare to silent block mounting. These mountings are very compact. In rubber mounting the rubber absorbs the shocks and while mounting the axle if any misalignment is their, it can be adjusted. This type of mounting reduces the cost that is involved in silent block and shaft machining.

LIMITATIONS:
The initial cost for casting of a knuckle and machining of a cylinder is high. A prototype is made and tested to determine any technical difficulties or error associated with design. If during this testing some problem occurs then entire pattern has to change, so it becomes a costly affair. During mounting of an axle proper care must be taken while machining the two holes. These holes must be inline otherwise axle mounting would be very difficult. While

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mounting the rubber block on oval pin proper care must be taken so that rubber block in not mounted in inverted position. Otherwise entire assembly will be shifted. So till these mountings are standardized one must be careful.

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