UNIFIED WHEEL NUT REMOVER

MINI PROJECT REPORT

Submitted

In the partial fulfillment of the requirement for

the award of the degree of

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING
By

Name 1 13241A0

Name 2 13241A0

Name 3 13241A0

DEPARTMENT OF MECHANICAL ENGINEERING

GOKARAJU RANGARAJU INSTITUTE OF ENGINEERING &

TECHNOLOGY

BACHUPALLY, KUKATPALLY, HYDERABAD-500090

INDIA

APRIL 2016
 DEPARTMENT OF MECHANICAL ENGINEERING
GOKARAJU RANGARAJU INSTITUTE OF

ENGINEERING AND TECHNOLOGY

(Affiliated to JNTUH,kukatpally,hyderabad)

HYDERABAD

Bonafide Certificate
This is to certify that the project report Unified wheel nut remover that is
being submitted by Name 1 (13241A0), Name 2 (13241A0), Name 3
(13241A0) in partial fulfillment for the award of B.Tech in Department of
Mechanical Engineering from Gokaraju Rangaraju Institute of Engineering and
Technology, affiliated to JNTU, Hyderabad is a record of bonafide work carried
out by him/her under the guidance and supervision .

The results embodied in this thesis have not been submitted to any other
University or Institute for the award of any degree or diploma.

Dr. RAM SUBBAIAH Dr. RAM SUBBAIAH Dr.L.JAYAHARI

Project Guide Project co-ordinator Professor

Associate Professor Associate Professor Head of the Department

Mechanical Engineering Mechanical Engineering Mechanical Engineering

GRIET, Hyderabad GRIET, Hyderabad GRIET, Hyderabad

2
 DECLARATION

This to certify that the Mini project titled Unified wheel nut remover is a Bonafied work done
by us in partial fulfillment of the requirements for the award of the B.Tech in Mechanical
Engineering and submitted to the Department of Mechanical Engineering .Gokaraju
Rangaraju Institute of Engineering and Technology.

We also declared that this project is a result of our own effort and has not been copied or
imitated from any source . citations from any websites are mention in the references.

Name 1 (Reg.No)

Name 2 (Reg.No)

Name 3 (Reg.No)

3
 ACKNOWLEDGEMENT

Successful completion of any task would be incomplete without the expression or

appreciation of simple gratitude to all people who made this project possible with sincere
thanks, honor and veneration, we acknowledge all those whose guidance and encouragement
have helped us complete this project.

We express our sincere thanks to our college Director Prof. P. S Raju, Principal Dr.
Jandhyala .N. Murthy for their encouragement and support.

We thank Dr.L.JayaHari, Head of Department of Mechanical Engineering, Gokaraju

Rangaraju Institute of Engineering and Technology for permitting to undertake the project
work.

We have immense pleasure in expressing our thanks and deep sense of gratitude to our guide/
Project Co-ordinator Dr. Ram Subbaiah, Associate Professor in Mechanical Engineering,
Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad. Under whose
guidance and encouragement this project has been successfully completed.

We are also thankful to all the staff members of Mechanical Engineering Department of
GRIET for their invaluable support.

4
 ABSTRACT

Vehicle is an important machine in human daily life. Nowadays, each family has at
least one car to make the transportation easy and faster. Today the life of man is simple and
comfortable as various resources are available for each and process that a person has to
perform in his day to day life, and these resources and equipments helps the person to
perform his work in efficient and less time consuming manner. Four wheelers are available
for more than 70% peoples in urban areas. For a car, the tool set-up for each vehicle is a T-
nut wrench and car jacker which is hard to use for a women or teen to open their car’s nut.
There are many equipments are designed so that any operation required to be done on a car
can be done easily and in a shorter period of time as possible. There is a problem that can be
considered as time consuming and requires more effort which is the opening of wheel of a car
for its replacement or any other operation. Today the unit of a wheel are opened by one of
which requires more efforts and consume a lot of time. For this problem the unified wheel
opener is a adaptable solution.

In conventional method, certain torque has to be applied to remove a single nut.

Unified wheel opener is a special purpose tool made to open/close all the nuts of a wheel in
one time less effort. Although various methods of opening nuts are used, but they require a
lot of effort to open a single nut one by one. With the help of Unified Wheel opener we made
arrangement to open/close all the nuts by amplifying the torque. The main objective of work
is to develop a mechanism in one assembly, which can be made in automobiles.

The main objective of work is to develop a single tool with multiple mechanisms,
which can be made use during assembling and dismantling of wheels in automobiles. It can
be successfully used as a standard tool irrespective of the model of the vehicle. Also it can be
used in assembly line of automobiles, garages, workshops and service stations. We have
developed a gear planetary mechanism to reduce the time and effort for the above mentioned
task. Mild steel is used as the main material as tool to fabricate a gearing system. For this
project, this tire nut removal has been improved about the weight, cost of production and the
gear ratio. Design is simple, easily workable, and economical and tries to satisfy all the
aspects of design consideration

5
 TABLE OF CONTENT

Chapter Description Page No

No
Abstract 05
List of contents 06
List of tables 08
List of figures 09

Introduction 10
1.1 Over view of project 10
1 1.2 Basic Gear Theory 11
1.3 Spur Gear Terminology 12
1.4 Application of unified wheel opener 14
Literature Review 15
2.1 Literature Survey 15
2 2.2 Tools Used Earlier To Remove Nuts and Bolts 18
2.3 Problem Statement 20
System model 21
3.1 Selection of materials 21
3.2 Engineering Material for Product Design 21
3.3 Selection Criteria 22
3.4 Cost of the Material 22
3.5 Availability 22
3 3.6 Properties of the Material 22
3.7 Components used in the project 23
3.7.1 Shaft 23
3.7.2 Gears 24
3.7.3 BoxTtools 25
3.7.4 Screw and Nuts 25
3.7.5 Square pipes 26

6
 Design Procedures 27
4.1 Design Aspects 27
4 4.2 Design Abbrevations 28
4.3 Design Procedure for Gear and Pinion 28
Implementation of the project 31
5.1 Practical Implementation 31
5 5.2 Comparitive Cost Estimation 31
5.3 Bill of material 31
6 Conclusion 32
7 Future Enhancements 33
8 References 34

7
 LIST OF TABLES

Table No Description Page No

2.1 Tools Used Earlier To Remove Nuts and Bolts 18
4.1 Abbrevations used for Design Calculation 28
5.1 Bill of Material 31

8
 LIST OF FIGURES
Fig No Description Page No
1.1 Spur Gear Terminology 14
3.1 Shaft 24
3.2 Spur Gear 24
3.3 Box Tool 25
3.4 Screw and Nut 25
3.5 Square pipes 26
4.1 3D Model of the Project 27

9
 CHAPTER 1

INTRODUCTION

1.1 OVERVIEW OF THE PROJECT

Engineering in general, and Mechanical engineering in particular, deals with a wide

spectrum of products, ranging from large and complex systems comprising of numerous
elements down to a single component. Apart from being a physical object, a product can also
be a service that requires the application of engineering knowledge, skills and devices to be
useful to society. A service falls under the category of a system in that it is carried out with
the help of personnel, facilities and procedures. The service offered by an automobile
maintenance and repair garage would be a typical example from mechanical engineering.
Even computer software could be treated as an engineering product. It is also created using
engineering knowledge and skills. In the following, the term product when used alone
denotes the object to be designed and made with the help of engineering knowledge and
skills, irrespective of whether it is a large system, a simple machine, a component or a
service. Specific reference to design of computer software is not attempted in the following
although many of the generalities apply to it also.

Today’s world is of the fast and rapid process. Everybody wants to save time and
effort by inventing some newer technique or mechanism and implement them in the daily
life. The main objective of this project is to atomize the labor work in tightening or losing the
nuts one by one. This project focuses on the minimization of human effort and time
consumed for fixing all four nuts of the four wheeler tire with a single stroke of lever by
using multiple operated spanner. This is achieved by developing a planetary gear mechanism
as such ours which reduced the time and effort for the above mentioned task that is losing or
tighten the nut of the car wheel. If we consider a four wheeler removing and replacing the car
wheel is a very frequent job performed by the worker. Normally each of the four nuts is
removed/ tightened individually by simultaneously applying the spanner/lever.

Car is not a symbol of luxurious anymore. It is a need for every family. People need
car due to several reasons. The problem occurs the most during car operation is the problem
with tyre puncture. The main tyre has to be replaced with spare tyre. Therefore, drivers need
to know basic knowledge of tyre replacement procedure if such problem occurs. In order to

10
change the flat tyre, one requires minimal skills. Virtually every car has a tyre replacement
tools such as the L-shaped nut remover and jack supplied by the manufacturer.

It is difficult for women and the elderly drivers due to high required torque to
remove the wheel nuts. In addition, if the nuts are successfully removed, the problem to
retighten the nuts will follow. Here is the solution to the problem mentioned above by
Adjustable Unified Wheel Opener, it is a special tool designed for opening a wheel with ease.
It is so designed that it can open all the four nuts of a car wheel in one time. And the most
desired achievement is that, the total effort and time needed in the process is very less. It can
open and also refit the wheel with the same tool easily. Tool is simple in design, easy to use
and easily portable along with the vehicle. The tool used to remove the wheel nuts should be
designed for ergonomic, easy to handle and requires small space for storage. With the help of
the mechanism developed we can loosen or tight all four nut at a time and at the single stroke
of the motor operated lever.

1.2 BASIC GEAR THEORY

Here are some basic gear theories to help in this project. From the last tire nut removal,
they have used some gears as the system. We have list out the basic theory for gear in this section
and the information will be used as the guideline to this project.

Author Year About

Gear applies torque from other rotating members of the drive

train and used to multiply torque. As gears with different numbers

Shigley, Mischke 2003 of teeth mesh, each rotates at different speed and torque. Torque
is calculated by multiplying force with the distance from the
center of the shaft to the point the force was exerted.

1.Spur gear has teeth parallel to the axis of rotation and used to

Shigley, Mischke 2003 transmitted motion from one shaft to another.

2. Helical gear has teeth inclined to the axis of rotation. Same

11
 applications as spur gear with more gradual engagement of teeth
during meshing cause no noise as spur gear. Sometimes helical
gears are used to transmit the motion between nonparallel shafts.

3. Bevel gear have teeth formed on conical surface and are used
mostly for transmitting motion between intersecting shafts.

4. Worm gear resembles a screw and the direction of the rotation

called worm wheel depends upon the direction of rotation and
whether the worm cut is right-hand and left-hand.

Gear ratios express the mathematical relationship between gears.

Gear ratio is varied by diameter and number of teeth of the gears.
Torque multiplication also expressed by gear ratio. Gear ratio is
ratio between diameter or number of teeth of driven gears by the
Waldron, Kinzel 2004
diameter or number of teeth of drive gears. This gear ratio tells
how many times the driving gear must turn to rotate the driven
gear once. Gear ratio for planetary gear use different formulas.
Gear ratio = (driven gear + driven gear) / driven gear

1.3 SPUR GEAR TERMINOLOGY

1) Pitch surface: The surface of the imaginary rolling cylinder (cone, etc.) that the
toothed gear may be considered to replace.
2) Pitch circle: A right section of the pitch surface.
3) Addendum circle: A circle bounding the ends of the teeth, in a right section of
the gear.
4) Root (or dedendum) circle: The circle bounding the spaces between the teeth, in
a right section of the gear.
5) Addendum: The radial distance between the pitch circle and the addendum circle.
6) Dedendum: The radial distance between the pitch circle and the root circle.
7) Clearance: The difference between the dedendum of one gear and the addendum
of the mating gear.
8) Face of a tooth: That part of the tooth surface lying outside the pitch surface.

12
9) Flank of a tooth: The part of the tooth surface lying inside the pitch surface.
10) Circular thickness (also called the tooth thickness): The thickness of the tooth
measured on the pitch circle. It is the length of an arc and not the length of a
straight line.
11) Tooth space: The distance between adjacent teeth measured on the pitch circle.
12) Backlash: The difference between the circle thickness of one gear and the tooth
space of the mating gear.
13) Backlash =Space width – Tooth thickness
14) Circular pitch p: The width of a tooth and a space, measured on the pitch circle.
15) Diametral pitch P: The number of teeth of a gear per inch of its pitch diameter. A
toothed gear must have an integral number of teeth. The circular pitch, therefore,
equals the pitch circumference divided by the number of teeth. The diametral
pitch is, by definition, the number of teeth divided by the pitch diameter.
16) Module m: Pitch diameter divided by number of teeth. The pitch diameter is
usually specified in inches or millimeters; in the former case the module is the
inverse of diametral pitch.
17) Fillet : The small radius that connects the profile of a tooth to the root circle.
18) Pinion: The smaller of any pair of mating gears. The larger of the pair is called
simply the gear.
19) Velocity ratio: The ratio of the number of revolutions of the driving (or input)
gear to the number of revolutions of the driven (or output) gear, in a unit of time.
20) Pitch point: The point of tangency of the pitch circles of a pair of mating gears.
21) Common tangent: The line tangent to the pitch circle at the pitch point.
22) Base circle: An imaginary circle used in involute gearing to generate the involutes
that form the tooth profiles.

13
 Fig 1.1 – Spur Gear Terminology

1.4 APPLICATION OF UNIFIED WHEEL OPENER

Application domain of unified Wheel Opener is in automobile industries. According

to our preplanned project we describe the following places where it can be used successfully:

• It can be used as standard equipment provided with a new vehicle for the purpose of
opening and refit a punctured wheel in the midway.

• It can be used in workshops to open a wheel in place of using pneumatic guns which
are restricted to the availability of light and compressed air; it can be easily operated
with hands.

• It can be used in assembly line of automobiles where more time is consumed in

tightening all the four nuts one by one. As it takes less time to fit a new tyre, it will
lead to increase productivity.

14
 CHAPTER 2

LITERATURE REVIEW

2.1 LITERATURE SURVEYS

Known torque-responsive power screw drivers which are driven by electric motors or
pneumatically have a relatively high speed of rotation in order to obtain a short screwing in
time. Since the maximum moment of tension for the screw to be screwed requires a
determined torque, the driving power of the screw driver must likewise be made high in
accordance with the relatively high speed of rotation, although a high torque is required for
only a short time during the tightening of the screw, unless some shock action is utilized for
the purpose of producing this peak degree. The limitation of the degree of tightening of the
screw is usually effected by means of ratchet couplings or striking mechanism.

When screwing in expansion screws, this degree of tightening must be kept constant
within very narrow, since these screws, are stressed almost to their yield point during
screwing in. Torque-responsive screwing drivers having a shock effects are useless for this
purpose. The degree of tightening achieved is greatly dependent on the number of blows
applied, which however cannot be kept constant because of the rapid succession of blows,
while in addition the power of the individual blow is variable within wide limits because of
the indeterminable reaction of work piece, screw and screwing tool on the striking operation.

Torque-responsive screwdrivers having striking mechanisms are impractical where

accurate tensioning of a screw is necessary. It has moreover been found that, at the high
speeds used, ratchet couplings also apply a powerful shock action and are therefore likewise
unsuitable for tightening expansion screws.

A lot of research activities has been carried out on gears mechanisms since very first
gear was manufactured. A gear transmits the power from one shaft to another in various
relative position. Many engineers and designers put there efforts in this field and succeeded
also. They put all of their knowledge and the studies about gears on papers, with the use of
these papers anyone can know about advancement of the research carried out by them.

With these research papers, we come to know various aspects about gear. These
papers explore how a mechanism can be driven at uniform speed and non–uniform speed.
15
Also these papers tells about selection of material for a gear depending upon requirement.
There are a number of different gears which have different application areas. The research
papers helps in choosing the appropriate type of gear.

Wen-Hsiang Hsie in his paper “An experimental study on cam- controlled planetary
gear trains” describes that a mechanism is driven by a motor at uniform speed. However,
more and more researches indicate that there are many advantages if a mechanism can be
driven at non- uniform speed, and this kind of mechanism is called a variable
input mechanism. The purpose of this work is to propose a novel approach for driving a
variable speed mechanism by using a cam-controlled planetary gear train, and to investigate
its feasibility by conducting prototype experiments. First, the geometrical design is
performed. Then, the kinematic equations and the cam profile equations are derived based on
the geometry of the mechanism.

Ligang Yao Jian S. Dai Guowu Wei and Yingjie Cai “Comparative analysis of
meshing characteristics with respect to different meshing rollers of the toroidal drive”. In
their paper it has been stated that investigates meshing characteristics of the toroidal drive
with different roller shapes, examines the effect on the characteristics from roller shapes and
produces a comprehensive comparative study”. Based on the coordinate transformation, the
paper introduces the generic models of meshing characteristics and characterizes the meshing
to introduce both undercutting and meshing limit curves. The paper further develops meshing
functions and their derivatives with respect to each drive type with a different roller shape.
This leads to a comprehensive examination of each meshing characteristics against each drive
type of a roller shape. The comparative study focuses on the effect of contact curves, tooth
profile, undercutting, meshing limit curves and the induced normal curvature.

The toroidal drive offers the advantages such as a high horsepower-to- weight ratio,
coaxial configurations, compactness, and high operating efficiencies. It combines most of the
positive attributes of a circular worm- gear drive and an epicyclic gear drive without their
negative aspects due to the introduction of rollers in meshing contact with rolling movement
between a sun-worm and planet worm-gears, and between a stationary internal gear and
planet worm-gears.

16
 Using rollers as meshing media is popular in mechanical transmissions such as ball screws,

roller gear cams, roller enveloping worm drives, cycloid drives, and the toroidal drives. Meshing via

rollers which leads to rolling contact has the advantages of lower noise and higher transmission

efficiency. It has a substantial effect on meshing characteristics.

Gordon R. Pennock and Jeremiah J. Alwerdt in their paper “Duality between the kinematics
of gear trains and the statics of beam systems” describes about the geometric insight into the
duality between the first-order kinematics of gear trains and the statics of beam systems. The
two devices have inherent geometrical relationships that will allow the angular velocities of
the gears in a gear train to be investigated from a knowledge of the forces acting on the
beams of the dual beam system, and vice versa. The primary contribution of the paper is the
application of this duality to obtain the dual beam system for a given compound planetary
gear train, and vice versa. The paper develops a systematic procedure to transform between
the first-order kinematics of a gear train and the statics of the dual beam system. This
procedure provides a simple and intuitive approach to study the speed ratios of a planetary
gear train and the force ratios of the dual beam system.

It is interesting to note that planetary gear trains (commonly referred to as epicyclic

gear trains) were known, and in use, at least 2000 years ago. Despite the antiquity and
widespread applications in machinery, however, the principles of operation of planetary gear
trains are not generally understood. Also, the literature devoted to planetary gear trains is
scarce at best although a comprehensive treatise on the theory of epicyclic gears and epicyclic
change-speed gears was written by Levai. Planetary gear trains offer advantages over
ordinary gear trains, for example, for the same speed ratio they can be smaller in size and
have less weight. There are several techniques that are commonly applied to the kinematic
analysis of planetary gear trains; for example, the instant center method, the principle of
superposition using a tabular method, and identifying the fundamental circuits of the train.
Also, an analogy between planetary gear trains and beam systems using one-dimensional
vectors was presented by Kerr. The available methods, however, do not provide geometrical
insight into the gear train in a direct manner that is suitable for a specific application.

17
2.2 TOOLS USED EARLIER TO REMOVE NUTS AND BOLTS

Table 2.1 - Tools Used Earlier To Remove Nuts And Bolts

S.No Name of the Tool Description

A one-piece wrench with a U-shaped opening that grips

two opposite faces of the bolt or nut. This wrench is often

double-ended, with a different-sized opening at each end.

1 open-ended spanner The ends are generally oriented at an angle of around 15

degrees to the longitudinal axis of the handle. This allows

a greater range of movement in enclosed spaces by

flipping the wrench over.

A one-piece wrench with an enclosed opening that grips

the faces of the bolt or nut. The recess is generally a six-

point or twelve-point opening for use with nuts or bolt

heads with a hexagonal shape. The twelve-point fits onto

2 ring spanner the fastening at twice as many angles, an advantage

where swing is limited. Eight-point wrenches are also

made for square-shaped nuts and bolt heads. Ring

spanners are often double-ended and usually with offset

handles to improve access to the nut or bolt.

A double-ended tool with one end being like an open-end

wrench or open-ended spanner, and the other end being

3 combination wrench
like a box-end wrench or ring spanner. Both ends

generally fit the same size of bolt.

A wrench that is used for gripping the nuts on the ends of

4 flare-nut wrench tubes. It is similar to a box-end wrench but, instead of

encircling the nut completely, it has a narrow opening

18
 just wide enough to allow the wrench to fit over the tube,

and thick jaws to increase the contact area with the nut.

This allows for maximum contact on plumbing nuts,

which are typically softer metals and therefore more

prone to damage from open-ended wrenches.

A type of ring spanner, or box wrench, whose end section

ratchets. Ratcheting can be reversed by flipping over the

wrench, or by activating a reversing lever on the wrench.

This type of wrench combines compact design of a box

wrench, with the utility and quickness of use of a ratchet

5 ratcheting box wrench
wrench. A variety of ratcheting mechanisms are used,

from simple pawls to more complex captured rollers,

with the latter being more compact, smoother, but also

more expensive to manufacture. The one pictured also

features a drift pin on the tail.

A wrench used to turn screw or bolt heads designed with

a hexagonal socket (recess) to receive the wrench. The

7 Allen key
wrenches come in two common forms: L-shaped and T-

handles

2.3 PROBLEM STATEMENT

From the introduction, the tire nut removal has been studied about the problems.
This tire nut removal is designed for facilitate the four nut car user. There are two major
problems that can avoid the tire nut removal from marketing. The problems are the tire nut
removal is too heavy where it’s hard for a women user to use the tool. Then the materials for
this tire nut removal are quite expensive and are not suitable for marketing.

Taking the idea from all research paper which are included in the literature review.
We came to a point that by using gear-train mechanism we can make a system which is used
19
to open the nut of a wheel with minimum torque so, as to eliminate the hard-work of person
with minimum time. In all research paper idea is given that how gear train works, and how
the power transmission take place.

20
 CHAPTER 3

SYSTEM MODEL

3.1 SELECTION OF MATERIALS

The selection of a material for a particular application is governed by the working

condition to which it will be subjected, ease of Manufacturing and the cost considerations,
pure metals find few applications in pure condition and secondly they generally have poor
strength in pure form. Various desired and special properties can be achieved by addition of
different material to form alloys. Alloy comprises of a base metal and one or more alloying
elements. The typical properties associated with working condition are tenacity elasticity
toughness and hardness, toughness and typical properties associated with manufacturing
process is ductility, malleability and plasticity. The various properties can be determined by
testing techniques e.g. tensile test resistance to abrasion by hardness test toughness by impact
test and other special properties like fatigue and creep test.

3.2 ENGINEERING MATERIAL FOR PRODUCT DESIGN

All physical objects are made out of some material substance or other. Mother Nature has her
own set of building material for the objects of her creation, living or non-living. Over the
millennia, man has observed and adapted many of these for making objects of his invention
and design. For engineering purposes, we now use a very wide spectrum of materials. These
generally fall under the following categories:-

• Materials as found in nature used after only very minor preparation such as cutting
to size, sun-drying, mixing with water. Some examples are coal, wood and stones.
• Natural materials that are modified/ refined before use through some physical,
chemical or thermal processes that improve their utilization.
• Synthesized materials that are rarely found freely in nature. These are
• derived from one or more natural raw materials through major transformation
processes. Most of the materials used in modern mechanical engineering belong to
this category.

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3.3 SELECTION CRITERIA

The designer selects the materials of construction for his product based on several
criteria such as its cost, the desirable properties that it should possess, its availability, the
preferred manufacturing processes that are to be employed, etc. The overall economy is
influenced by all these factors. In special cases, essentiality and /or urgency of the need for
the product can supersede the economic considerations. The main criteria for material
selection are discussed below.

3.4 COST OF THE MATERIAL

The amount of raw materials, their composition, quality, any special heat- treatment
that is required, etc. influence the unit cost of materials. The unit cost generally depends also
on the quantity of raw material that is purchased in a single lot. Special steel materials, for
example, cost much more in the market when purchased in small quantities from a retailer
than in bulk directly from the steel mill/stockyard.

3.5 AVAILABILITY

The material should be readily available in adequate quantities. Material availability is

closely linked with the variety and level of technology obtained in a given geographic
location. Procuring materials from far and wide can be expensive, due to the additional cost
for transport, for transporter taxes and duties etc.

3.6 PROPERTIES OF THE MATERIAL

The desired function and performance of any product depends to a great extent on the
use of materials with the right physical and chemical properties. In general mechanical
engineering these properties can be classified into different categories depending on how a
particular property affects the function and life of a component. The main property groups
are:-

• Chemical Composition, specifying the contents of all the different elements

contained.
• Properties of state, such as solid, liquid or gas, density, porosity, temperature.

22
 • Strength related properties, such as ultimate strengths in tension, compression and
shear, yield strength/ 0.2% strength, fatigue strength, notch sensitive, hardness, impact
strength, effect of high/low temperatures on strength, etc.

• Strain related properties, such as elongation at fracture, elastic moduli, ductility,

malleability etc. these help to ensure the desired rigidity/ elasticity, formability etc.

• Wear related properties, that determine the erosion, abrasion, friction etc. between
components in contact/ relative motion.

3.7 COMPONENTS USED IN THE PROJECT

3.7.1 SHAFT

Drive shaft, a shaft for transferring torque is used to transfer to the nut from the
primary gears (sun gear)which is in mesh with the secondary gears (planetary gear) which
remove the nuts using the removing tools. A shaft is a rotating or stationary component which
is normally circular in section. A shaft is normally designed to transfer torque from a driving
device to a driven device. If the shaft is rotating, it is generally transferring power and if the
shaft is operating without rotary motion it is simply transmitting torque and is probably
resisting the transfer of torque. Mechanical components directly mounted on shafts include
gears, couplings, pulleys, cams, sprockets, links and flywheels. A shaft is normally supported
on bearings. The torque is normally transmitted to the mounted components using pins,
splines, keys, clamping bushes, press fits, bonded joints and sometimes welded connections
are used. These components can transfer torque to from the shaft and they also affect the
strength of the shaft an must therefore be considered in the design of the shaft. Shafts are
subject to combined loading including torque (shear loading), bending (tensile & compressive
loading), direct shear loading, tensile loading and compressive loading. The design of a shaft
must include consideration of the combined effect of all these forms of loading. The design of
shafts must include an assessment of increased torque when starting up, inertial loads, fatigue
loading and unstable loading when the shaft is rotating at critical speeds (whirling)

23
 Fig 3.1 – Shaft

3.7.2 GEARS
A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which
mesh with another toothed part in order to transmit torque, in most cases with teeth on
the one gear being of identical shape, and often also with that shape on the other gear.
Two or more gears working in tandem are called a transmission and can produce a
mechanical advantage through a gear ratio and thus may be considered a simple
machine. Geared devices can change the speed, torque, and direction of a power source.
The most common situation is for a gear to mesh with another gear; however, a gear can
also mesh with a non-rotating toothed part, called a rack, thereby producing translation
instead of rotation.
In our project, we have used sun gear as primary gear and planetary gear as
secondary gears. The gears are manually driven with the help of a lever.

Fig 3.2 – Spur Gear

24
3.7.3 BOX TOOLS

Fig 3.3 – BOX TOOL

A tube with six-sided sockets on both ends. It is turned with a short length of rod (tommy
bar or T bar) inserted through two holes in the middle of the tube. It is Upset forged from high grade
manganese steel. Scientifically heat treated to give maximum strength, wear resistance and long life.
It is Available with bright finish in Nickle Chrome and black phosphate finish for protection from
corrosion.

3.7.4 SCREWS AND NUTS

Fig 3.4 – SCREW AND NUT

A screw is a type of fastener, sometimes similar to a bolt, typically made of metal,

and characterized by a helical ridge, known as a male thread (external thread) or just thread.
The most common uses of screws are to hold objects together and to position objects. A
screw will usually have a head on one end that contains a specially formed shape that allows
it to be turned, or driven, with a tool. Common tools for driving screws include screwdrivers
and wrenches. The head is usually larger than the body of the screw, which keeps the screw
from being driven deeper than the length of the screw and to provide a bearing surface. The
distance between each thread is called the "pitch".

25
 A nut is a type of fastener with a threaded hole. Nuts are almost always used
opposite a mating bolt to fasten a stack of parts together. The two partners are kept together
by a combination of their threads' friction, a slight stretch of the bolt, and compression of the
parts. In applications where vibration or rotation may work a nut loose, various locking
mechanisms may be employed: Adhesives, safety pins or lock wire, nylon inserts, or slightly
oval-shaped threads. The most common shape is hexagonal, for similar reasons as the bolt
head - 6 sides give a good granularity of angles for a tool to approach from tight spots.

3.7.5 SQUARE PIPES:

Fig 3.5 – SQUARE PIPES

They are produced by cold forming flat rolled steel into tubular shapes and electric-
resistance welded into solid wall tubing. Controls during the cold forming to square or
rectangular shapes prevent irregularities in structure or loss of physical properties across the
weld area. Since it begins as a flat rolled product, the finished tube has a uniform wall
thickness and equal strength throughout. It is easy to machine and fabricate, using all
common machining and fabricating operations. It can be bent or drawn, flattened or flared,
expanded or swaged, drilled or punched easily. It is easily mechanically joined or welded
using all the commonly used practices. Because of ease of fabrication, and a surface suitable
for painting or plating, Structural Steel Square and Rectangular tube has almost unlimited
applications.

26
 CHAPTER 4

DESIGN PROCEDURES

4.1 DESIGN ASPECTS

Spanners are used to open the wheel. Spanners in the use are of various types. The
different kinds of spanners in use are shown infigure One thing is very common for all these
spanners: only a single nut is opened in a single time. This causes wastage of precious time
and since to open all the nuts spanner is to engaged and disengaged again and again till the
last nut is unscrewed or screwed. Thus in this work a large amount of power is required to
perform the requisite operation.
These disadvantages are removed in unified wheel opener. The idea is to reduce time
when release the wheel or put it on. By using this device, wheel nuts can be opened
simultaneously at one time. The supposed design of the unified wheel opener is shown below.
On pictures, we can handle, casing/gears housing, and wheel nut connectors. Wheel nut
connectors are connected to wheel nut, and the number of connector depends on the number
of studs. So it will be different according to wheel type and size. Inside the Casing, there are
simple gears mechanisms, causing one rotation of The Handle to make two rotations of the
wheel nuts.

Fig 4.1 3D MODEL OF PROJECT

27
4,2 DESIGN ABBREVATIONS

Table 4.1 – Abbreviations Used For Design Calculations

S. No Symbol Abbreviation/Nomenclature
1 m Module
2 M bending moment
3 Dp Pitch circle diameter of pinion
4 Dg Pitch circle diameter of gear
5 Dg Diameter of gear shaft
6 Wt Tangential load
7 Wr Resultant load
8 Yp Lewis form factor
9 σ Allowable stress
10 T Twisting moment
11 Te Equivalent twisting moment
12 Tp Number of teeth on pinion
13 Tg Number of teeth on gear

4.3 DESIGN PROCEDURE FOR GEAR & PINION:

Torque required for one nut = 70N-m

Total torque required = 4×70N-m
= 280N-m
Let input torque =30N-m
Maximum Tangential force on pinion (WT) =2×Ti/Dp
=2×30×1000/25
=2400 N
For 200 stub teeth system,

Lewis Factor for pinion,

Yp = 0.175-(0.841×m/25) = 0.175-(0.03×m)

28
Also, maximum tangential force on pinion (Wt) = σ×b×n×m×Yp

For Cast Steel σ = 325MPa (Assume: b= 5×m)

WT = 2400 = 325 × (5 × m) ×π × m (0.175 - 0.03 × m)

Solving By Hit & Trial Method, We Get

Module, (m) =2mm

Now, as we know
Number of teeth on pinion (Tp)= Dp/m

Also, Number of teeth on gear (Tg) =Dg/m

Therefore, Tp = 25/2 =12.5 or 13 (say)

Tg = 114/2 = 57

Other dimensions for pinion &gear are as:

Addendum =0.943×m=1.886
Dedendum =1.257×m=2.514
Minimum total depth = 2.200×m = 4.400
Minimum clearance = 0.314×m = 0.628
Backlash = 0.157×m = 0.314
Thickness of tooth = 1.493×m =2.986
Outside diameter of pinion = (Tp+2 )×m =30
Outside diameter of gear = (Tg+2) ×m = 118
And twisting moment on shaft due to WT is T
T = WT×Dp/2 =30000N-mm
Equivalent twisting moment is Te = (M2+T2)0.5 = 156225N-mm
Let Dp be the diameter of pinion shaft
Dp =π×ζ×dp3 =14.7or 15mm (say)

Design For Output Shaft

Max. Tangential force on output gear,
WT’ = (WT×Dg/Dp) = 10945N

29
Normal load acting on tooth,
Wn = WT’/CosØ =10945/Cos200 =11645N

Weight of gear, WP =0.00118×Tg×b×m2 =0.00118×57×10×22 =2.7N

Therefore resultant load on gear, Wr = (Wn2+Wp2+2×Wn×Wp×Cos Ø)0.5 = 11648N

Assuming gear is overhung on shaft at 5mm

Therefore bending moment on shaft due to WR is M
M = WR×5 = 11648×5 = 58238N-mm

And twisting moment on shaft due to WT is T

T = WT×DG/2 = 10945×114/2 = 623865N-mm

And equivalent twisting moment is Te,

Te = (M2+T2)1/2 = 626577N-mm
Let dg = Diameter of gear shaft, Let Te= (π/16)×ζ×Dg3
626577 = (π/16)×230×dG3
So, dG = 23.7 mm or 24 mm(say)

All the component are designed to serve their functions properly and taking into account the
various consideration such as material, labour, availability of technology, economic, safety,
usage, reliability, maintainability, functionality etc. These components will be manufactured
according to their design specifications.

30
 CHAPTER 5

IMPLEMENTATION OF THE PROJECT

5.1 PRACTICAL IMPLEMENTATION

After checking the feasibility conditions, (i.e. economic feasibility, operational feasibility and
technical feasibility) adjustable unified wheel opener is designed and it is implemented in real
world problems. It worked successfully and finally the output is obtained as such as what is
desired.

5.2 COMPARATIVE COST ESTIMATION

Now-a-days for loosening and tightening nuts in the car, a commonly used tool is four way
car wheel nut wrench brace spanner which costs about Rs.800 – Rs 1000, where it need more
effort in doing the works as well as it increases the time. But with our project, all four nuts in
a car wheel can be simultaneously removed. The total cost involved for the fabrication of our
project is almost equal to the tool commonly used. Costs have been estimated based on the
cost of the materials that are being purchased, machining costs and other parameters that are
involved in the fabrication of the project. Approximate cost estimation has been done and it
has been listed as a

5.3 BILL OF MATERIAL

Table 5.1 - BILL OF MATERIAL

S.No DESCRIPTION COST (in Rs)
No’s
1 Main Planetary Spur Gear 4 Rs 400
2 Sun (spur) Gear 1 Rs 100
3 Shafts 4 Rs 20
4 Square Pipes (30 cm appx) 8 Rs 100
5 Box Tools 4 Rs 250
6 Bolts, Screws & Nuts 4 Rs 50
7 Welding charges --- Rs 100
Total Rs 1020

31
 CHAPTER 6

CONCLUSION

In this mechanism, a sun and planet gear system are used. Sun gear is smallest gear
and planetary gears are placed exactly in the position of the lug nuts in the pitch circle
diameter according to the number of lug nuts. Pitch circle diameter is the diameter of the
circle in which lug nuts are positioned.

This invention reduces the time consumed in removing the lug nuts. In conventional
method, certain torque has to be applied to remove a single lug nut. In this invention, the
torque applied for removing/tightening of one lug nut is adequate for removing/tightening of
all the lug nuts in the wheel. So the process of replacement of the wheels can be done so
faster and it reduces the time. This device can be operated manually and no external power is
consumed. It doesn't cost more as compared to hydraulic and pneumatic devices.

Thus the fabrication of Adjustable Unified Wheel Opener is successfully done. This
project is practically implemented in a four wheeler and it is found that the results are
positive. The project is working as what it is expected. Thus the project is economical, and it
sustains all the required feasibilities. It has been found that adjustable wheel opener is a
perfect tool for assembling and dismantling a wheel in a four wheeler.

32
 CHAPTER 7

FUTURE ENHANCEMENTS

The project has been fabricated which is purely mechanical. All the operations are
done manually. To further extend our project as a useful tool, a motor has to be attached to its
drive. Such that by providing a motor, it reduces all the human effort in tightening and
loosening the wheel’s nut.

1) Improvement in the system by making automatic operation with the help of

pneumatic system which is clean and hazardous free.

2) To design and fabricate the complete assembly of the multiple operated spanner to

be fitted to all vehicle wheels by adjusting pitch circle diameter by making pinion

gear small or large as per wheel’s pitch circle diameter.

3) It is also suggested to operate it with different gear arrangements with less power

required.

33
 CHAPTER 8

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34
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35
PHOTOGRAPHY OF THE PROJECT

36