Design and Manufacturing Semi-Automatic Machine for Battery Tray Riveting Operation

Abstract

The successful implementation of any manufacturing sector is largely depending upon the quality and its productivity. In traditional machining process for performing the one side riveting, machine’s required which becomes a time consuming also the inaccuracy in productivity due to involvement of human error which affects to productivity cannot be get improved at a faster rate. The main purpose of this project to design and manufacture semi-automatic machine for battery tray riveting. Which leads to improve the quality and productivity by minimising the time period in all Mahindra and Mahindra’s vehicles battery is fitted with the help of battery tray. While placing the battery tray two side rivets are required in current situation while fitted tray only one side riveting operation is performed. We are designing a semi-automatic machine which will perform riveting operation to both sides at once which will improve the productivity.

Introduction

I. INTRODUCTION

The latest trend in the automobile industry is to common the production line for different parts. Because now a single vehicle has different variants available in the market for each variant has different components according to their functionality, therefore in the automotive industry it is difficult to maintain multimodal production lines for most of the different parts with the same functionality but a different design for different variations. These processes are very much time consuming and due to which the production losses are observed which leads to delay in vehicle launch, so for this we have fabricated the semi-automatic machine for battery tray riveting. The objective is to design and fabrication of the riveting machine which reduces the operation as well as transportation time required for completing the job. Riveting operation is till now performed manually, but by using semi-automatic Riveting Machine it can be performed automatically. The purpose of this machine is to replace manual hammering into automation, to increase productivity in operation also to reduce cost and time required. It is more beneficial to use in workshops, industries where riveting operations can perform simultaneously on both sides.

II. PROBLEM STATEMENT

In bolero pickup the battery is fitted with the help of battery tray. While placing the battery tray two side rivets are required in current situation while fitted tray only one side riveting operation is performed. We are designing a semi-automatic machine which will perform riveting operation to both sides at once which will improve the productivity.

III. OBJECTIVE

1. To DESIGN the semi automation machine for battery tray riveting both sides simultaneously.
2. To MANUFACTURE the machine which can rivet both sides of the battery tray simultaneously.
3. To ANALYZE the time reduction in process by this automation.

IV. METHODOLOGY

V. DESIGN AND ANALYSIS

A. Material Selection

Mild steel is a type of low carbon steel. Carbon steels are metals that contain a small percentage of carbon (max 2.1%) which enhances the properties of pure iron. The carbon content varies depending on the requirements for the steel. Low carbon steels contain carbon in the range of 0.05 to 0.25 percent.

Due to the following physical properties of Mild steel’s material used for the fabrication of machine:-

1. High tensile strength.
2. High impact strength.
3. Good ductility and weld ability.
4. A magnetic metal due to its ferrite content.
5. Good malleability with cold-forming possibilities.
6. Not suitable for heat treatment to improve properties.

Table no.1: Properties of Material

B. Specification  

Table 2. Part specification

VI. ANALYSIS

In this model usually performed a static structural analysis on a geometric model. The performed analysis is same for three different various material. The main focus during entire simulation had observed is that, on how various material changes a value of desired parameter such as total deformation and maximum principle stress. A tested model is on the Ansys Workbench. The Ansys analysis performed on the materials are aluminium, gray cast iron and mild steel from that analysis mild steel is selected for the model development.

A. Head

1. Total Deformation of Head

It is found that total deformation alone x-axis1.316* 10-6   Maximum. Total deformation generated on mild steel while 1.4622*10-7 Minimum

2. Maximum Principle Stress of Head

It is found that Maximum Principle Stress alone x-axis 2.2435*106 Maximum amount of stress generated on mild steel while -3.0162*106 Minimum.

B. End Cap

1. Total deformation of End Cap: It is found that total deformation alone x axis1.052* 10-7 Maximum. Total deformation generated on mild steel while 1.1694*10-8 Minimum.

2. Maximum Principle Stress of End Cap: It is found that Maximum Principle Stress alone x-axis 8.371*105 Maximum amount of stress generate on mild steel while -2.1957*105 Minimum.

C. Bush

1. Total deformation of Bush: It is found that total deformation alone x-axis1.1074* 10-6 Maximum. Total deformation generated on mild steel while 1.2305*10-7 Minimum.

2. Maximum Principle Stress of Bush: It is found that Maximum Principle Stress alone x-axis 1.1122*107 Maximum amount of stress generated on mild steel while -2.5922*106 Minimum.  

D. Anti Rotating Plate

1. Total deformation of Anti- rotating Plate: It is found that total deformation alone x-axis 6.1183*10-8 Maximum. Total deformation generated on mild steel while 1.3596*10-8 Minimum.

2. Maximum Principle Stress of Anti- rotating Plate: It is found that Maximum Principle Stress alone x-axis 1.1637*106 Maximum amount of stress generated on mild steel while -1.1816*105 Minimum.

VII. RESULT

Table 3. Part List with material

Conclusion

The main purpose of this project to developed semi-automatic machine for battery tray riveting which leads to improve the quality and productivity by minimizing the production cycle time. This machine increases the efficiency and accuracy of object. The machine atomized by using pneumatic system. This machine is to replace manual hammering into automation to increase the productivity in operation to reduce cost and time required. It is more beneficial to use in workshop industry which operation can be perform both sides simultaneously.

References

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Copyright

Copyright © 2023 Priti Navale, Sarita Padavi, Rohit Patil, Dhiraj Pandit, Prof. R. S. Khandare. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.