Innovative Design of Modern Spanner Tool

A MINOR PROJECT REPORT (M-705)

SUBMITTED BY

1. Hardeep Singh(30/17)
2. Jasmeet Singh(41/17)
3. Pratham Sharma(77/17)
4. Ashish Chib(81/17)
5. Mohit Sharma(140/17)

GUIDED BY:

Asstistant Professor Mr. Mandeep Singh

Dept. of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

MAHANT BACHITTAR SINGH COLLEGE OF ENGINEERING & TECHNOLOGY

UNIVERSITY OF JAMMU
April 2021
 ACKNOWLEDGEMENT
We are highly grateful to the Principal, MBS College of Engineering and Technology,

Jammu, for providing this opportunity to carry out the present Minor Project work.

The constant guidance and encouragement received from Mr. Mandeep Singh and Assistant

Professor, Department of Mechanical Engineering, MBS College of Engineering and

Technology, has been of great help in carrying the present work and is highly acknowledged.

We would like to express a deep sense of gratitude and thanks profusely to Abhijit Saini,

Assistant Professor, Department of Mechanical Engineering, MBS College of Engineering

and Technology.

Without his wise counseling and able guidance, it would have been impossible to complete

the Minor Project work in this manner. His enthusiasm and optimism made this experience

both rewarding and enjoyable. His feedback and editorial comments were also valuable for

writing this Minor Project work. We feel lucky to have an opportunity to work with him. Not

only understanding the subject.

We express gratitude to other faculty members of Mechanical Engineering Department, MBS

College of Engineering and Technology, for their intellectual support throughout the course

of this work.

On personal note, we thank our family for being there when we needed them especially our

parents for teaching us the values of hard work, resourcefulness and dedication.

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 ABSTRACT
T he i m p o r t a nc e o f ma c h i ne i nd u s t r y i s i nc r e a s i ng d a y b y d a y a s k i ng fo r
t he e nha nc e m e nt o f t o o l d e s ig n t o ma n i fo ld t he e f f ic i e nc y. D e s ig n ne e d s
t o be mo d i f i e d fo r t he t o o l e n ha nc e m e nt . T he " M o d e r n S p a nne r t o o l"
p r o d u ct d e s ig n c o u ld be t a k e n a s a n e xa mp le . F o r t h is c ha l l e ng e t he ne w
p u r po s e d t o o l d e s ig n i s co mp a c t , l ig ht w e ig ht , e a s y t o c a r r y a nd e a s y t o
use.
T he ne w D e s ig n o f S p a nne r s ho u ld a l l t he t he o r ie s o f i n no va t io n o f a
m a nu a l s p a n ne r a nd co nc lu d e s w it h n e w mo d i f i c a t io ns , pr i nc i p le s a nd
d e s ig n p r o c e s s . A D e s ig n ha s be e n a t t e nd e d a nd t o be e va lu a t e d a ft e r
D e t a i l a na l ys i s i n t he so ft w a r e.

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 TABLE OF CONTENT
ACKNOWLEDGEMENT………………………………………………………...……i

ABSTRACT……………………………………………………………………………ii

Chapter1 INTRODUCTION
1.1 Spanner……………………………………………………………………………..1
1.2 Types of Spanner……………………………………………………………………2
1.3 Size of spanner……………………………………………………………………...15
1.4 Material Used……………………………………………………………………….16
1.5 What are spanner coated with?................................................................................16
1.6 How are spanner manufactured…………………………………………………….17
Chapter2 Literature Review
2.1 Literature Review…………………………………………………………………..19
Chapter3 Field survey, Problem Formulation and Objective
3.1 Field survey………………………………………………………………………….26
3.2Problem Formulation…………………………………………………………………26
3.3Objective………………………………………………………………………………26
Chapter 4 Design Procedure and Software used for Designing
4.1 Design procedure……………………………………………………………………27
4.2 Definition of Design ………………………………………………………………..28
4.3 Solid Work…………………………………………………………………………..29
4.4 Modeling technology………………………………………………………………..31
4.5Solid Work Simulation……………………………………………………………….33
4.6 The Aircraft keel Project……………………………………………………………..33
4.7 Standard mesh control………………………………………………………………..35
4.8 Curvature Based meshing…………………………………………………………….38
4.9Blended Curvature-Based meshing……………………………………………………40
4.10Local Mesh Control…………………………………………………………………..41
4.11 Design of new spanner tool………………………………………………………….43
Chapter5 Conclusion……………………………………………………………………44
References
 CHAPTER 1
INTRODUCTION
1.1SPANNERS
A wrench or spanner is a tool used to provide grip and mechanical advantage in
applying torque to turn objects—usually rotary fasteners, such as nuts and bolts or keep them
from turning.
Multi jaw wrench is an extension of a simple wrench and is used for fastening and
unfastening nuts of a car wheel simultaneously. A wrench (or spanner) is a tool used to
provide grip and mechanical advantage in applying torque to turn objects usually rotary
fasteners, such as nuts and bolts or keep them from turning. In British English, spanner is the
standard term. The most common shapes are called open-ended spanner and ring spanner.
The term wrench refers to various types of adjustable spanner. In American English, wrench
is the standard term. The very most common shapes are called open-end wrench and box-end
wrench. In American English, spanner refers to a specialized wrench with a series of pins or
tabs around the circumference. (These pins or tabs fit into the holes or notches cut into the
object to be turned.) In American commerce, such a wrench may be called a spanner wrench
to distinguish it from the British sense of spanner. Higher quality wrenches are typically
made from chromium-vanadium alloy tool steels and are often drop-forged.
We use tools to make things easier. So that we can do the work quickly and very easily.
Similarly, the tool we use to tighten and open nuts and bolts is called spanner or wrench. In
simple language, we also call it the spanner or the key. Wrench is a tool that is used to apply
force on any curved object. We are told a lot about tools in diplomas or degrees like ITI
Polytechnic or engineering.
Because here we get to see more practical. That is why you are also made to work with tools.
If you want to know more about any tool, then you have to try it using force, only then you
will know how it is and how it works and where it can be used. In this post, we are telling
you about common wrenches. Which is commonly used. Pana is such a common tool. Which
we can also use in our house because in our house too. Which we cannot open by hands,
that's why we can use Pana there.
In the UK, Ireland, Australia, and New Zealand spanner is the standard term. The most
common shapes are called open-ended spanner and ring spanner. The term wrench is
generally used for tools that turn non-fastening devices (e.g. tap wrench and pipe wrench), or
may be used for a monkey wrench—an adjustable pipe wrench.
In North American English, wrench is the standard term. The most common shapes are
called open-end wrench and box-end wrench. In American English, spanner refers to a
specialized wrench with a series of pins or tabs around the circumference. (These pins or tabs
fit into the holes or notches cut into the object to be turned.) In American commerce, such a
wrench may be called a spanner wrench to distinguish it from the British sense of spanner.
Higher quality wrenches are typically made from chromium-vanadium alloy tool steels and
are often drop-forged. They are frequently chrome-plated to resist corrosion and for ease of
cleaning.
Hinged tools, such as pliers or tongs, are not generally considered wrenches in English, but
exceptions are the plumber wrench (pipe wrench in British English) and Mole
wrench (sometimes Mole grips in British English).

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10 Things You Need to Know about Combination Spanners
1. The spanner is a hand-held tool used to provide grip and tighten or loosen fasteners. It
gives a mechanical advantage in applying torque to turn objects. The tool is used in turning
rotary fasteners like nuts and bolts.

2. Spanners are made of a metal shaft with a profile opening on one end. The profile head, or
the jaw, is the part that fits over, around or into the fastener to grip it. Many spanners in the
market are double-ended tools with two profile heads on both ends of the shaft.

3. The combination spanner is among the most commonly used hand tools in a household. As
the name suggests, it is a combination of two spanner types: the open-ended spanner and ring
spanner.

4. The open-ended spanner has a U-shaped profile with a fixed width to fit the nut or bolt
head. The head has two flat sides that grip on opposite sides of a fastener for tightening or
loosening it.

5. The ring spanner has a ring-shaped profile like an enclosed loop. The loop is placed over
the head of a fastener for turning it clockwise or anti-clockwise.

6. Combination spanners are double-ended tools. It has an open-ended profile on one end and
a closed loop on the other end.The two heads are usually at a 15 degree angle to the shaft for
better access to the nuts or bolts. This single tool serves the functions of two spanners at
once.

7. For the purpose of turning fasteners, the open-ended head is stronger than the ring head. It
is advised to use the open-ended head for the final tightening of a fastener or for the first few
turns of loosening one, while the ring head can be used for the main part of the task. This is a
benefit of using the combination spanner.

8. Combination spanner will work for only one size of nut or bolt. Both the profile heads are
of the same fastener size. The heads usually range from 4mm to 50mm. As the fastener size
increases, the length of the spanner will also increase.

9. Before picking a combination spanner for any task, check the length of the shaft. Longer
spanners provide a stronger turning force, so they can be used for larger or stiffer fasteners.

10. The profile head of a spanner determines how easily it can be worked with. The looped
end of a combination spanner comes in contact with all sides of a fastener, thus, it provides a
much better grip and is less likely to slip while turning. This is why the closed profile is more
preferred for turning fasteners when tightening or loosening a nut or bolt. The open-ended
end is used only for the first few turns when loosening or for the final tightening.

Etymology

The original spanner had a square hole for turning the shaft (r.) of the wheel, which tensioned
the mainspring.
'Wrench' is derived from Middle English wrench, from Old English wrenċ, from Proto-
Germanic wrankiz ("a turning, twisting"). First used in 1790.

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'Spanner' came into use in the 1630s, referring to the tool for winding the spring of a wheel-
lock firearm. From German Spanner, from spannen ("to join, fasten, extend, connect"),
from Proto-Germanic spannan, from PIE root (s)pen- ("to draw, stretch, spin").

History
Wrenches and applications using wrenches or devices that needed wrenches, such as pipe clamps
and suits of armor, have been noted by historians as far back as the 15th century. [5] Adjustable
coach wrenches for the odd-sized nuts of wagon wheels were manufactured in England and
exported to North America in the late eighteenth and early nineteenth centuries. The mid 19th
century began to see patented wrenches that used a screw for narrowing and widening the jaws,
including patented monkey wrenches.
Most box end wrenches are sold as 12-point because 12-point wrenches fit over both 12-point and
6-point bolts. 12-point wrenches also offer a higher number of engagement points over 6-point.
However, 12-point wrenches have been known to round off 6-point bolts as they provide less
contact space.
Spanners first appeared in the 15th century in the form of a box spanner. There was no
standard size and each fastener and spanner would have been made individually by a
blacksmith.
It is thought that the first spanners were used to wind up crossbow strings, tightening them so
they were much more taut than a human hand could produce.
At the beginning of the 16th century, wheel-lock guns were invented which required a box
spanner to fire. The spanner primed the gun by spring-loading a wheel. When the trigger was
pressed, the spring was released and the wheel spun, causing sparks which fired the gun.
t wasn’t until the late 18th century that spanners diversified in type and usage to include all
the types we have today. With the onset of the industrial revolution, the wrought iron
spanners made by blacksmiths were replaced with cast iron versions produced on a larger
scale.
Standard sizes for fasteners and spanners were developed by 1825 so that nuts, bolts and
spanners could be interchangeable and did not have to be made as a set.
This meant pieces of machinery could be swapped around, spanners could be used on
multiple fasteners and nuts could be used on more than one bolt. It also meant any mechanic
could work on a machine with his own set of standardised spanners instead of the machine
always travelling with a specific set.
The accuracy of the production of this equipment was quite poor, only accurate to within
1/1,000″ at best. By 1841, an engineer named Sir Joseph Whitworth had developed a way of
increasing the accuracy to 1/10,000″ and then, with the invention of the bench micrometer,
1/1,000,000″.

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1.2Types of Spanners

Following are different types of spanners:

Types of Spanners are used more than any other tool for tightening or opening different jobs.
These are generally made of drop forge steel or carbon steel. These are made in different
shapes and sizes, according to requirements.

Apart from that, screwdrivers are also used to tightening and loosening to any given job
or screw. Also, check out the types of hammers used in the workshop. In the workshops,
usually, the following types of spanners are used.A variety of spanners and wrenches exist
that are used for tightening and loosening bolts, nuts, and fixings. Spanners manufacturing
Spanners are made of carbon steel or drop-forge steel, and you can use them manually. All
spanners come in a variety of shapes and sizes, and you can use them as per your
requirements. Your DIY project can be done easily with the help of the right type of spanner.

Spanners are used most often more than any other tool for tightening or opening different
jobs. Spanners are constructed of (material of construction) generally forged steel or carbon
steel. These spanners are found in very wide range in shapes & their sizes respectively as per
the different job requirements. Apart from that, screwdrivers are also used to tightening &
loosening to any given job or screw.

1. Open ended

a. Single ended spanner

b. Double open ended spanner

2. Combination Spanner

3. Ring Spanner

4. Socket spanner

5. Box spanner

6. Hook spanner

7. Adjustable spanner

8. “T” Socket spanner

9. Magneto spanner

10. Allen key

11. Pin face adjustable spanner

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1. Open ended spanner
a) Single ended spanner

In open end spanners, as the name suggest one end is open which provides to hold the nuts or
bolts heads or grip that to either tight or loose it. Open end spanner is also known as single
end spanners their known size is basically difference between their respective jaws. The
selection of spanner would be the subject of based on the nut & bolts sizes to be used.
In these types of spanners, only one end is open, in which nut or bolt head is gripped to loose
to tight it. It is also known as a single end spanner. Their size is taken from the distance
between their jaws. Thus the selection of a spanner is made according to the distance between
the opposite sides of nut or bolt.

Open-ended spanners are versatile, single-piece tools that can be used on most types of
fasteners around the home and across the industries. They are the characteristic spanner type!
Their head has two jaws forming a U-shaped profile with two parallel flat sides.
The opening between the jaws is the width of the fastener head so the tool can be slipped
around the fastener from the side. This width indicates the size of the tool in metric and AF
(‘across flats’) imperial measurements.

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. 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.

Fig 1: Open ended spanner

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b). Double open ended spanner

In these types of spanners, open ends are made at both ends to hold nuts or bolts heads in
them. These two ends are made at angles of 15 to 30 from the in-between body. These types
of spanners are most widely used.

Open-ended spanners have U-shaped jaws with an opening the width of the nut or bolt head.
They have two flat sides which grip opposite sides of a fastener in order to loosen or tighten
it.

One of the most common types of spanners found in toolboxes, the open-ended spanner has
two U-shaped ends, with one being slightly bigger than the other. They are used for hard-to-
reach nuts and bolts, and the open design makes it possible to attach them either vertically or
horizontally onto the target fitting.

The most commonly used spanners, they confirm specification referred is : 2028-1981
standards and are useful in places. the sizes start from 6×7 to 30×32 mm sizes and also
provides jumbo sizes (the range start in 30×36 to 75×80 mm sizes) & sets (the sets are 6×7 to
27x32mm). these types of products are manufactured from carbon steel/chrome vanadium
steel, hardened and tempered. nickel chrome plated.

Fig 2: Double open ended spanner

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2. Combination Spanner
On one end of this spanner an open-end spanner and on the other end a ring spanner is made.
At both ends, the spanners are of equal size.

If box-ended spanners and open-ended spanners had children, the combination spanner would
be the result. One side is a closed loop for hexagonal or square nuts, while the other end is an
open U-shape.

Used most often for difficult nuts, the closed end loosens the nut so that the open end can be
used to quickly unscrew it. Like sockets, combination spanners are usually sold in sets
containing a variety of spanner sizes.

The most commonly used spanners, they confirm specification referred is : 6389-1972
standards and are useful in places. the sizes start from 6 to 32 mm sizes and also provides
jumbo sizes (the range start in 33mm to 45mm sizes) & sets (the sets are 8 to 32mm). these
types of products are made from din 3113 each hand set at 15° angle, chrome vanadium
steel/Carbon Steel, matt finish, elliptical model matt finish.

In these types of spanners, open ends are made at both ends to hold nuts or bolts heads in
them. These two ends are made at angles of 15 to 30 from the in-between body. These types
of spanners are most widely used.

Fig 3: Combination Spanner

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3. Ring Spanner
In these types of spanners one or both ends are rounds rings that are made up for grip nut &
bolt in order to tight or loose them. These rings are constructed downward & upwards to each
other at their respective different ends. Inside of these rings (each) teeth are constructed for
hexagonal heads so nuts &bolts can be gripped easily. There are some types of rings spanners
which are not bent.
What are the different types of ring spanner?

The most common ring spanner profile is the 12-point (or ‘bi-hex’) profile, so-called because
it has 12 points and troughs.

12-point profiles allow spanners to lock onto fasteners in a smaller space than a 6-point
(hexagonal) profile does, allowing the fastener to be turned further before the spanner needs
to be readjusted.
6-point profiles can only be used on hexagonal fasteners while 12-point profiles can be used
on hexagonal or square fasteners. Other profile shapes are available but they tend to be
specialised for one job, such as an immersion heater spanner.

Fig 4: Ring spanner

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4. Socket spanner

Socket spanners are found in the form of round socket at the one end square hole is formed
while on to the other end of socket spanner grooves are provided with respect to the sizes of
nuts & bolts as likes of spanner. Inside of the square hole tommy bar is fixed whose shape is
also square. These are available in sixes in all forms of sets. These types of spanners are in
the form of a round socket. On one end of this spanner, a square hole is made. On the other
end, grooves are cut outside in nut-bolt size, as in a ring spanner.

In the square hole, the Tommy bar is fixed whose shape is also square. These spanners are
used where because of the paucity of space e ring spanners cannot be used. Besides this,
socket spanners are also used where nut bolts are to be tightened by measuring them with a
torque wrench.

These are available in small and big sizes in the form of sets. Tommy bar, Universal Tommy
and Ratchet Tommy along with these spanners. With their help nut bolts of slanting, straight
or congested space can be made tight or loose. A socket set is a great way to have a
collection of tools for tackling nuts and bolts. They are a great replacement for a spanner set
and can be more compact and easier to carry around. They do tend to be a little more
expensive and sometimes hard to use in awkward to reach places.

Socket sets generally come with a ratchet, which is a big help and will save a lot of time as it
avoids the need to constantly take a spanner off of a nut or bolt ready for the next turn. The
more expensive they are the more sockets and fittings that you will get, but it is possible to
get a socket set relatively cheaply that will cover pretty much every domestic situation.

Fig 5: Socket spanner

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5. Box spanner

These are made of thick or thin pipes. On one end or both, the ends of this spanner six sides
are made, in which nut bolts with six phases are easily gripped. Holes are made across the rod
on one or both the ends in which a rod can be put and used as a handle. It is used in deeper
spaces.

Box spanners are made from metal tubing. They usually have two profiles, one at each end.
Because the profiles are at right-angles to the shaft, the tool can reach into confined spaces
easily. A ‘tommy bar’ is usually used to turn them.

Fig 6: Box spanner

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6. Hook spanner

These spanners are made for those nuts which no nut have holes on their periphery. These are
no faces on these nuts. Thus the pin of this spanner gets fixed in the hole and performs the
function of revolving it for opening or tightening it.
They are of three types:
1. Adjustable hook spanner
2. Pin spanner
3. Face pin spanner

Fig 7: Different types of Hook spanner

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7. Adjustable spanner

Adjustable spanners are special types of spanner tool. These are also known as screw wrench.
It jaws can be expanded or narrowed down to tight or lose the nut. They are used for those
nuts where no other spanner fits well enough for better operation performance.
Adjustable spanners can be used to fit a wide range of screws and bolts so save you having to
carry around a wide range of different sized spanners. The issue is that they can be tricky to
use as they might not lock tight onto the nut or bolt.

Aside from this small drawback they are very handy to have in the tool box for one good
reason – More often than not you may only have one of each size spanner and when it comes
to un-doing or doing up a nut or bolt they are great for holding bolt heads while you tighten
the nut with a spanner.

Fig 7: Adjustable spanner

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8. “T” Socket spanner

These types of spanners are almost similar to the box spanner but it has a fixed hand on the
top and in the bottom, a socket is built. These sockets are of different sizes. They are used in
deep spaces.

Fig 9:” T” socket spanner

9. Cross wheel spanner

This aptly-named tool is either “L” shaped with a single socket opening at the end or a large,
“X” shaped design (also called a spider wrench) with four sockets of different sizes.They are
used to tighten or loosen lug nuts on cars, earning them the nickname of “wheel brace”.

The longer the lug wrench, the more torque can be generated when applying force to either
tighten or untighten. Works similar to a breaker bar with a socket at the end.

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This spanner is useful for the wheels of a car and this spanner is made from high grade
carbon steel. crv steel, fully hardened/socket hardened, chrome plated/zinc plated/powder
painted/satin finish, with/without reinforcement plate, durable welded construction, cross
design provides extra leverage and torque, din 3119, iso 6788 and sizes are available
17,18,19,21 (dia 15mm), 17,19,21,23 (dia 15mm).

Fig 10: Cross wheel spanner

10. Allen key

These are thin steel rods with six faces that are bent at 90° angles from one end. These are
used to open such bolts whose heads are made round.

They have a hole of six faces on the upper side. Such bolts perform the function of tightening
while keeping the surface of the job equal. These are available in numbers and sets of
different sizes.

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 Fig 11: Allen key spanner

11. L-Type Spanner

These are made from carbon steel and available with or without tyre lever.

Fig 12 : L type spanner

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1.3 Size of the Spanner
All kinds of spanner are used to dismantle or tight nut or bolts of a specific size. All spanners
are in units of mm, inches and ww. Millimetre spanners are available in 1/16 and double-
ended and ring spanners are mostly in sets of 6, 8, 12 and 36.

In a set of 6 spanners in inch spanners, the double ended and ring spanners are available in
the following sizes.

Similarly, millimetre spanners are in numbers. In double-ended and ring spanners on the one
side one number is written and on the other one number more than that is written. Socket
spanners are available in different sizes.

1.4 Material used for spanner

Spanners are made from steel. Steel is an alloy (mixture) of mainly iron and carbon with
small quantities of other elements.

Increasing the amount of carbon makes the steel harder but brittle (more likely to
break). Adding manganese to the alloy makes it less brittle and improves its ability to be
shaped with a hammer when hot.

Many spanners are made from chrome vanadium steel. Chromium and vanadium are metal
elements that are added to steel to increase the metal’s strength. Chromium also increases the
steel’s resistance to rusting.
The overall chromium content of chrome vanadium steel is usually between 12% and 20%
while the overall content of vanadium is generally between 0.2% and 1%.

Vanadium is expensive so cheaper chrome vanadium steel products often have a very low
vanadium content, as low as 0.1%. The product description of the tool should provide the
standard the tool has been tested to and so give an indication of the material’s quality. Ideally
it should be tested to the most recent German DIN (Deutsches Institut für
Normung) standard. ASME (American Society of Mechanical Engineers) is the American
standard and is also reliable.

Some high quality spanners designed for regular use, such as scaffold spanners, are made
from titanium. Titanium is as strong as steel but much lighter and longer-lasting. These tools
are expensive but worth the investment if your spanner is an essential part of your everyday
work.

1.5 What are spanners coated with?

The metal parts of all spanners are given some form of coating to reduce the risk of corrosion.

16
A rust inhibitor solution is applied to all spanners towards the end of the manufacturing
process. Some spanners are plated with either nickel or chromium or both. Nickel and
chromium are more corrosion-resistant than steel and the layer protects the iron from reacting
with oxygen to produce rust. They are also used as they give the tool an attractive finish.

Black oxide is another coating that can be used as extra protection against corrosion.

The tool is immersed in a chemical bath which reacts with the iron in the outer layer of steel,
creating a black layer. Because the iron has reacted with the chemicals, it won’t react with
oxygen to form rust. This sort of coating is called a ‘conversion’ coating because the outside
layer of steel has been converted to another material.

1.6 How are spanners manufactured?

Shop for Spanners

Drop forging process is the most common method for manufacturing spanners. Most types of
spanner are made using the drop forging process. Steel billets are run through an induction
coil which heats the metal up to make spanners. Steel rods are cut into short lengths, called
billets, and each one is passed through an induction heating coil which uses electromagnetism
to heat the metal to about 1000 degrees Celsius.

Drop forging machinery showing the ram, anvil and dies which form the spanner shape. The
billet is placed in three dies (also known as ‘moulds’) in succession. The upper die drops onto
the billet, forcing it into shape. The first die provides the rough shape of the spanner, the
second the finished shape and the third trims the excess metal from the formed spanner.

Information (manufacturer, product number, size) stamped on spanner surface with hydraulic
press. The ‘trim line’ (the place where the two halves of the die come together) is ground
down to produce a smooth surface and a hydraulic press stamps the manufacturer’s name and
the product details into the spanner’s surface.

Bent head of ring spanner bent using a press machine at about 15 degrees. If the spanner has
an angled head, a machine bends the end of the spanner into shape.

Vertical milling machine or broach machine, cutting and sizing spanner heads. If the spanner
has a ring or flare nut head, a vertical milling machine cuts a hole through the centre of the
head ready for shaping and sizing with a broach machine.

Steel tubing is used to make box and spark plug spanners. Box and spark plug spanners are
not made by drop forging. They are made from steel tubing that is shaped with forming tools
which push into the ends of the tube, creating the profiles.

17
Heating and cooling of spanners increases their strength, known as tempering. The spanners
are then tempered to increase the steel’s strength. Tempering is a specific sequence of heating
and cooling which is slightly different for each type of steel.

Flare nut section of ring head removed with a cutting blade. Flare nut heads are created after
tempering by cutting a small section out of the front of the head.

Ceramic stones are used to polish and prepare the metal spanners for plating. The spanners
are left in a constantly moving tub of ceramic stones and chemicals for half a day to prepare
the surface of the tools for coating.

Electroplating spanners with nickel and cadmium to increase corrosion resistance and
cosmetic look. Some spanners are electroplated by being dipped in a sequence of baths
containing nickel and chromium solutions. Electricity passing through the spanner causes
particles of metal to stick to the tool, creating a very thin layer of metal on the surface.

Black oxide is a magnitite coating created by the iron in the steel reacting with a chemical.
Others are coated with black oxide by being immersed in a chemical solution which reacts
with the iron in the steel, producing a covering of magnetite which protects the steel from
corrosion.

Rust inhibitor is used to coat the tool to protect is from corrosion. Spanners are also dipped in
a rust inhibitor solution for extra corrosion protection.

Extra components need to be fitted to the spanner. If the spanner has multiple components,
they are fitted together, often by hand. For example, rivets are fitted to hold the heads of flex-
head spanners in place and plastic gears, made using injection moulding, are fitted into the
heads of ratchet spanners.

Injection moulding process used to make extra components and handles for the spanners.
Injection-moulded components are made in a mould into which molten plastic is pushed
under pressure. Once the piece is set it can be removed and ground down to smooth it into the
finished component.

Plastic covered, using injection moulding process, insulated spanner. Fully insulated spanners
are made by placing the spanner in an injection mould and injecting molten plastic into a
cavity surrounding the tool so the spanner emerges with a plastic coating.

Spanners are tested for strength. Finally, each tool is tested to ensure it is strong enough to
meet the manufacturer’s standards.

18
CHAPTER 2

LITERATURE REVIEW AND PROBLEM FORMULATION

2.1 LITERATURE REVIEW

A large volume of literature is available in journals and books explaining the process of

Reverse Engineering and its applications in the various fields. In this chapter, a review of

relevant literature has been made. The survey of literature was based on the applications of

Reverse Engineering in automotive and mechanical parts, and other related parts. There are

many studies which are contributed by many researchers and engineers regarding the

applications of Reverse Engineering, some of which are as follows:

1) Paul Williams et. Al, (17 December 2002): -Inter-organizational frameworks of

intervention dominate the resolution of complex societal problems facing the UK and many

other countries. Strategic alliances, joint working arrangements, networks, partnerships and

many other forms of collaboration across sectoral and organizational boundaries currently

proliferate across the policy landscape. However, the discourse is positioned at an

institutional and organizational level, and comparatively little attention is accorded to the

pivotal role of individual actors in the management of inter-organizational relationships. This

paper attempts to redress this balance by focusing on the skills, competencies and behaviour

of boundary spanners. A critical review of the relevant literature, both from an institutional

and relational perspective, is undertaken. This is complemented by some new empirical

research that involves an engagement with groups of particular types of boundary spanner

using a combination of surveys and in-depth interviews. Finally, a discussion makes

connections between the existing literature and the research findings and offers suggestions

for future areas of enquiry.

19
2)JinhuiKatoh et. al. (2007): - Geometric spanner is a fundamental structure in

computational geometry and plays an important role in many geometric networks design

applications. In this paper, we consider a generalization of the classical geometric spanner

problem (called segment spanner): Given a set S of disjoint 2-D segments, find a spanning

network G with minimum size so that for any pair of points in S, there exists a path in G with

length no more than t times their Euclidean distance. Based on a number of interesting

techniques (such as weakly dominating set, strongly dominating set, and interval cover), we

present an efficient algorithm to construct the segment spanner. Our approach first identifies

a set of Steiner points in S, then construct a point spanner for them. Our algorithm runs in

O(|Q| + n 2 logn) time, where Q is the set of Steiner points. We show that Q is an O(1)-

approximation in terms of its size when S is relatively “well” separated by a constant. For

arbitrary rectilinear segments under L 1 distance, the approximation ratio improves to 2.

3)N.B. Simpson et. al. (03 July 2009): - We numerically model the axial trapping forces

within optical tweezers arising from Laguerre–Gaussian laser modes. For an 8 μm diameter

sphere suspended in water, the higher-order modes produce an axial trapping force several

times larger than that of the fundamental. Partial absorption results in a transfer of the orbital

angular momentum from the Laguerre–Gaussian mode to the trapped particle. This results in

the rotation of the particle by what may be called an optical spanner (wrench). For an

absorption coefficient of α = 5700 m−1 and a laser power of 10 mW, we find that an 8 μm

diameter sphere would acquire an angular acceleration of 10 × 10 4 rad s−2 and a limiting

angular velocity of 0.2 rad s−1.

20
4)Xiao Ping Chen et. al. (September 2011): - Machinery industry changes with each

passing day, asking for the more and more importance of the machinery industry

performance. The innovative design needs to be used to tools designing for improving the

work more efficiency. Take the wrench product designing as an example, this article analyses

the issue of the mechanical products innovation, applies the theories of innovation to a

manual wrench innovative design and puts forward the thought of the wrench innovative

design scheme, principles and the design process. In the end, the design scheme is evaluated,

which indicates that the innovative design approach can be applied to a manual wrench

design.

5)Ashish Kumar Srivastava et. al (May 2013): -The importance of machine industry is

increasing day by day asking for the enhancement of tool design to manifold the efficiency.

Design needs to be modified for the tool enhancement. The "multi jaw wrench" product

design could be taken as an example. This article explores the issues of mechanical products

innovation, applies the theories of innovation to a manual wrench and concludes with new

modifications, principles and design process. This paper presented a proposed design of multi

jaw wrench over the conventional wrench, analysis in terms of forces, effort applied and

feasibility and also presented the comparative study of conventional wrenches by the new

proposed design. The experimental study and the analysis have been done by using 3D

modelling software Solid Works and Ansys. The obtained result shows that the effort has

been reduced to 80% and the force and stress has been reduced to an optimum level which

tends to feasibility of the product in the market.

6)James C Corbett et. al (August 2013): -Spanner is Google’s scalable, multiversion,

globally distributed, and synchronously replicated database. It is the first system to distribute
data at global scale and support externally-consistent distributed transactions. This article

21
describes how Spanner is structured, its feature set, the rationale underlying various design
decisions, and a novel time API that exposes clock uncertainty. This API and its
implementation are critical to supporting external consistency and a variety of powerful
features: nonblocking reads in the past, lock-free snapshot transactions, and atomic schema
changes, across all of Spanner.

7)Wiefu Wang et. al. (May 2015): -This paper introduces a fast weighted streaming
spanner algorithm (WSS) that trims edges from roadmaps generated by robot motion
planning algorithms such as Probabilistic Roadmap (PRM) and variants (e.g. k-PRM*) as the
edges are generated, but before collision detection; no route in the resulting graph is more
than a constant factor larger than it would have been in the original roadmap. Experiments
applying WSS to k-PRM* were conducted, and the results show our algorithm’s capability to
filter graphs with up to 1.28 million vertices, discarding about three-quarters of the edges.
Due to the fact that many collision detection steps can be avoided, the combination of WSS
and k-PRM* is faster than k-PRM* alone. The paper further presents an online directed
spanner algorithm that can be used for systems with non-holonomic constraints, with proof of
correctness and experimental results.

8)Tarun Gupta et. al. (June 2016): -One of the most common hand tool wrench used today
does not come equipped with a handle facilitating a comfortable grip for its extended use.
The purpose of this study was to create an ergonomic design for a hand tool (a wrench) that is
commonly used in a wide range of industries all around the Globe. The overall goal of the
project involved first designing ergonomic profiles for the wrench handles with grip diameter
suitable for ninety-five percentile user population. These handle profiles were created using
CAD to prototype subsequently using a 3D printing system. A conventional wrench was then
assembled with each of the three handle profiles for ergonomic testing & evaluation. By
choosing random male subjects, we compared a standard wrench (with regular handle) with
(identical) wrench assembled with the three different profiles of the handle. The maximum
amount of torque that the test subjects could apply on each handle was measured using a
torque tester; we also measured the muscle activity with each of the handles for each subject

22
with the help of EMG (Electromyography). The experimental data obtained from this process
then were analysed to infer about the performance of the three wrench handle with a standard
handle in order to determine one most efficient ergonomic design for the wrench handle
profile.

9)Nico Bruno et. al. (9 May 2017): -Spanner is a globally-distributed data management
system that backs hundreds of mission-critical services at Google. Spanner is built on ideas
from both the systems and database communities. The first Spanner paper published at
OSDI'12 focused on the systems aspects such as scalability, automatic sharding, fault
tolerance, consistent replication, external consistency, and wide-area distribution. This paper
highlights the database DNA of Spanner. We describe distributed query execution in the
presence of resharding, query restarts upon transient failures, range extraction that drives
query routing and index seeks, and the improved block wise-columnar storage format. We
touch upon migrating Spanner to the common SQL dialect shared with other systems at
Google.

10)Mats Ehrnrooth et. al. (15 May 2019): -Boundary spanners play an important role
in multinational corporation (MNC), yet it is unclear who these valuable individuals are and
why certain individuals, and not others, perform this role. We advance a ‘recognition’
perspective based on whether and how relevant others on both sides on the boundary
experience positive impact. A dynamic integrated mixed method analysis of 118 individuals
involved in headquarters-subsidiary interactions in four MNCs, shows that only a minority
are ‘recognized boundary spanners’, experienced by others to positively impact intergroup
relations. We identify different categories and mechanisms of recognition, and make a
methodological contribution by integrating qualitative and quantitative analysis.

11) A Ramadhan et. al. (May 2020): -Increasing demand for the use of bionic grip locks as
well as customers and markets is increasing day by day, requiring improved design of
technical tools to increase efficiency and effectiveness. Supporting tools design needs to be
modified for the tools capability improvement and to provide new ways of working. The

23
concept of innovative design can be applied to tools designing for up living the work way
more productive in order to boost the manufacturing and service performances, meeting the
mounted up customer demand. Taking the wrench product design as an example of
observation and improvement initiative opportunity, this article discovers the chance of the
mechanical and machinery products innovation, with the project methodology presented in
applying the theories of product redesign from a manual conventional wrench to an advance
design and puts forward the thought of the wrench innovative engineering design, principles
and the process to electrical and mechanical mechanism. As a result, the proposed design
scheme is evaluated, which indicates that the optimized design approach can be applied to a
manual wrench design.

12)Vignesh Azhagarsamy et. al. (December 2020): -Fasteners become the essential
component
in our day-to-day life. These fasteners are mainly used in providing the linkage between the
components, parts, members, etc. Therefore the fasteners, are fastened by the application of
the wrench or spanner. Conventional Spanner is made of the typical Chromium Vanadium
alloy material; later they are additionally chrome plated to resist the corrosion. So, In order to
eliminate these additional operations, the material of the spanner is altered. In the paper, the
material of the spanner is modified with the structural steel and Cobalt Chromium. The
Spanner is modeled by the Solid works software and thereby maintain the design
specifications. Then the Finite element analysis is carried out in the Abaqus software.
Furthermore, the outcome is acquired, shows that the material cobalt-chromium can be
utilized for the Spanner. Since it might have a high resistance to corrosion and it may have
high wear resistance.

13)Deying Li et. al. (5 February 2021): - Following the recent advances in the Internet of
Things (IoT), it is drawing lots of attention to design distributed algorithms for various
network optimization problems under the SINR (Signal-to-Interference-and-Noise-Ratio)
interference model, such as spanner construction. Since a spanner can maintain a linear

24
number of links while still preserving efficient routes for any pair of nodes in wireless
networks, it is important to design distributed algorithms for spanners. Given a
constant t>1 as the required stretch factor, the problem of our concern is to design an
efficient distributed algorithm to construct a t -spanner of the communication graph under
SINR such that the delay for the task completion is minimized, where the delay is the time
interval between the time slot that the first node commences its operation to the time slot that
all the nodes finish their task of constructing the t-spanner. Our main contributions include
four aspects. First, we propose a proximity range and proximity independent set (PISet) to
increase the number of nodes transmitting successfully at the same time in order to reduce the
delay. Second, we develop a distributed randomized algorithm SINR-Spanner to construct a
required -spanner with high probability. Third, the approximation ratio of SINR-Spanner is
proven to be a constant. Finally, extensive simulations are carried out to verify the
effectiveness and efficiency of our proposed algorithm.

25
Chapter-3
FIELD SURVEY, Problem Formulation and Objection
3.1 Field Survey
Repair are required when parts are broken, bent, worn out our do not meet specification. The
information about the different problems will be collected from different workshops of
Maruti Suzuki Ltd., Peak Motor and many other local shops where different types of cars
and bikes are repaired. Data from Honda cars and Hero bikes are also be collected from their
Work Shops and other local workshops etc.

3.2 Problem Formulation

It is difficult to work on different Spanner tools at the same times it also consume lot of time.
Our proposed design will be easy to use , saves time and money . As it is light in weight and
compact and can be easily place in a two wheeler or any other automobile as it will solve a
lot of problem domestically.

3.3 Objective
The main objective of the research is to make the new purposed spanner compact, light
weight, easy to carry and easy to uses.

26
CHAPTER -4

DESIGN PROCEDURE & SOFTWARE USED FOR

DESIGNING

4.1 Design procedure: The design process is an iterative process that ensures the

compatibility of design. The general design process includes six steps

• Recognition of need: Occurs when one recognizes the need of a solution to a problem

or situation.

• Problem definition: This step defines the problem to determine what features a

product will contain. Customer surveys also are taken. Characteristics, cost, quality

are all defined in this step.

• Synthesis: Research is done and preliminary ideas are given. If the same product is

available in the market, then unique and better approaches may be taken into

consideration.

• Analysis and optimization: The product gets analyzed constantly to identify

opportunities for optimization. Customer feedback is also solicited so that production

errors can be reduced and improved.

• Evaluation: This step involves design testing through a prototype of a product. The

quality and reliability of the product is also evaluated.

• Presentation: This step shows the final product drawings and specifications and

involves presentation of modules, 2D diagrams, and 3D diagrams.

27
 Fig 3: Design Processes Flow Chart

4.2 Definition of Design

• Mechanical design means the design of components and systems of a mechanical nature—

machines, products, structures, devices and instruments.

• For the most part mechanical design uses mathematics, materials, and the engineering-

mechanics sciences.

• Additionally, it uses engineering graphics and the ability to communicate verbally to

clearly express your ideas.

28
• Mechanical engineering design includes all mechanical design, but it is a broader study

because it includes all the disciplines of mechanical engineering, such as the thermal fluids

and heat transfer sciences too.

• Aside from the fundamental sciences which are required, the first studies in mechanical

engineering design are in mechanical design, and that is the approach taken in this course.

SOFTWARE USED FOR DESIGNING

4.3 Solid Work

SolidWorks is a solid modelling computer- aided design (CAD) and computer-aided

engineering (CAE) computer program published by Dassault Systems , that runs primarily
on Microsoft Windows. While it is possible to run SolidWorks on an Intel-based Mac with
Windows installed, the application's developer recommends against this. SolidWorks does
not support macOS.
According to the publisher, over two million engineers and designers at more than 165,000
companies were using SolidWorks as of 2013. Also, according to the company, fiscal year
2011–12 revenue for SolidWorks totaled $483 million.

History
SolidWorks Corporation was founded in December 1993 by Massachusetts Institution of
Technology graduate Jon Hirschtick. Hirschtick used $1 million he had made while a
member of the MIT Blackjack Team to set up the company. Initially based
in Waltham, Massachusetts, United States, Hirschtick recruited a team of engineers with the
goal of building 3D CAD software that was easy-to-use, affordable, and available on the
Windows desktop. Operating later from Concord, Massachusetts, SolidWorks released its
first product Solid work 95, in November 1995. In 1997 Dassault, best known for
its CATIA CAD software, acquired SolidWorks for $310 million in stock. Jon Hirschtick
stayed on board for the next 14 years in various roles. Under his leadership, SolidWorks grew
to a $100 million revenue company.
SolidWorks currently markets several versions of the SolidWorks CAD software in addition
to eDrawings, a collaboration tool, and DraftSight, a 2D CAD product.
SolidWorks was headed by John McEleney from 2001 to July 2007 and Jeff Ray from 2007
to January 2011. The current CEO is Gian Paolo Bassi from Jan 2015. Gian Paolo Bassi
replaces Bertrand Sicot, who is promoted Vice President Sales of Dassault Systems’ Value
Solutions sales channel.

Table showing releasing date and different version of SolidWork software:

29
 Version Version
Name/Version Release Date
History Value
Number

SolidWorks 95 1 46 November 1995[1]

SolidWorks 96 2 270 Early 1996

SolidWorks 97 3 483 Late 1996

SolidWorks 97Plus 4 629 1997

SolidWorks 98 5 817 1997

SolidWorks 98Plus 6 1008 1998

SolidWorks 99 7 1137 1998

SolidWorks 2000 8 1500 1999

SolidWorks 2001 9 1750 2000

SolidWorks 2001Plus 10 1950 2001

SolidWorks 2003 11 2200 2002

SolidWorks 2004 12 2500 2003

SolidWorks 2005 13 2800 2004

SolidWorks 2006[9] 14 3100 2005

SolidWorks 2007 15 3400 2006

SolidWorks 2008 16 3800 July 1, 2007

SolidWorks 2009 17 4100 January 28, 2008

SolidWorks 2010 18 4400 December 9, 2009

SolidWorks 2011 19 4700 June 17, 2010

SolidWorks 2012 20 5000 September, 2011

SolidWorks 2013 21 6000 September, 2012

SolidWorks 2014 22 7000 October 7, 2013

30
 SolidWorks 2015 23 8000 September 9, 2014

SolidWorks 2016 24 9000 October 1, 2015

SolidWorks 2017 25 10000 September 19, 2016

SolidWorks 2018 26 11000 September 26, 2017

SolidWorks 2019 27 12000 October 9, 2018

SolidWorks 2020 28 13000 September 18, 2019

SolidWorks 2021 September 22, 2020[10]

Fig : Release history table of SolidWork

(https://en.wikipedia.org/wiki/SolidWorks)

4.4 Modeling Technology

SolidWorks is a solid modeler, and utilizes a parametric feature-based approach which was
initially developed by PTC (Creo/Pro-Engineer) to create models and assemblies. The
software is written on Parasolid-kernel.
Parameters refer to constraints whose values determine the shape or geometry of the model
or assembly. Parameters can be either numeric parameters, such as line lengths or circle
diameters, or geometric parameters, such as tangent, parallel, concentric, horizontal or
vertical, etc. Numeric parameters can be associated with each other through the use of
relations, which allows them to capture design intent.

Design intent is how the creator of the part wants it to respond to changes and updates. For
example, you would want the hole at the top of a beverage can to stay at the top surface,
regardless of the height or size of the can. SolidWorks allows the user to specify that the hole
is a feature on the top surface, and will then honor their design intent no matter what height
they later assign to the can.

Features refer to the building blocks of the part. They are the shapes and operations that
construct the part. Shape-based features typically begin with a 2D or 3D sketch of shapes
such as bosses, holes, slots, etc. This shape is then extruded to add or cut to remove material

31
from the part. Operation-based features are not sketch-based, and include features such as
fillets, chamfers, shells, applying draft to the faces of a part, etc.
Building a model in SolidWorks usually starts with a 2D sketch (although 3D sketches are
available for power users). The sketch consists of geometry such as points, lines, arcs, conics
(except the hyperbola), and splines. Dimensions are added to the sketch to define the size and
location of the geometry. Relations are used to define attributes such as tangency, parallelism,
perpendicularity, and concentricity. The parametric nature of SolidWorks means that the
dimensions and relations drive the geometry, not the other way around. The dimensions in the
sketch can be controlled independently, or by relationships to other parameters inside or
outside the sketch.
In an assembly, the analog to sketch relations are mates. Just as sketch relations define
conditions such as tangency, parallelism, and concentricity with respect to sketch
geometry, assembly mates define equivalent relations with respect to the individual parts or
components, allowing the easy construction of assemblies. SolidWorks also includes
additional advanced mating features such as gear and cam follower mates, which allow
modeled gear assemblies to accurately reproduce the rotational movement of an actual gear
train.
Finally, drawings can be created either from parts or assemblies. Views are automatically
generated from the solid model, and notes, dimensions and tolerances can then be easily
added to the drawing as needed. The drawing module includes most paper sizes and standards
(ANSI, ISO, DIN, GOST, JIS, BSI and SAC).

Fig. No. 1.6 Solid Model of Steering

Knuckle(https://www.google.com/search?q=Solid+Model+of+Steering+Knuckle+in+scaning

&tbm=isch&)

32
4.5 SOLIDWORK SIMULATION

SOLIDWORKS Simulation is an add-in to the SOLIDWORKS program from

DassaultSystèmes. It provides a finite element analysis (FEA) capability within the traditional
CAD environment. This is attractive to design engineers and others who are familiar with the
SOLIDWORKS user interface.

A wide range of FEA solutions are available, from linear static to non-linear dynamic
analysis. However, a potential purchaser needs to work closely with their SOLIDWORKS
reseller to define the precise range of solution capabilities needed. The segmentation of the
CAD functionality interleaved with the FEA functionality can be very confusing.

The origins of the FEA solution within SOLIDWORKS stem from the COSMOS FEA
solver, a different solver from the advanced nonlinear Abaqus solver found within the
DassaultSystèmes SIMULIA product family.

4.6 The Aircraft Keel Project

The FEA task in this review is to carry out a static analysis study of the aircraft keel section
shown in Fig. 1. In part one of this overview, I focus on the initial setup and the solid
meshing controls.

The keel section is on the lower centerline of a combat aircraft fuselage. It transmits
undercarriage loads into the fuselage. It also provides a load path through the lower fuselage
section in overall bending and torsion loading due to maneuvers. The geometry has been
created in SOLIDWORKS. Many of the smaller fillet radii have been defeatured in
preparation.

The Simulation add-in has been invoked in Fig. 1. Two new tabs appear in the Command
Manager area; the Simulation tab and the Analysis Preparation tab. The Simulation tools are
shown. The Study Advisor icon is selected, and a new Simulation Study is set up. This is a
static analysis study; undercarriage_case1.

33
 Fig. 1: The aircraft keel section geometry.

(https://www.digitalengineering247.com/article/solidworks-simulation-overview)

Multiple studies can be created in a SOLIDWORKS file and each will have a tab on the
bottom of the screen. To switch between the simulation study and the geometry model, click
on the Study or the Model tab. The Analysis Preparation tab contains a useful subset of
geometry tools to manipulate the geometry ready for analysis.

The feature tree in the left-side panel contains icons that give access to required FEA entities.
Right mouse-clicking on the top Study icon provides a menu that includes the analysis
Properties selection. Fig. 2 shows the resultant dialog box.

Within the highlighted Solver Selection drop-down are a range of FEA solver options,
including Direct and Iterative solvers. The optimum choice of solvers is complex, dependent
on solution type, model size and available system memory. I checked the Automatic Solver
Selection option.

This adopts the best method based on the characteristics noted. I recommend reviewing the
documentation carefully and carrying out benchmarks to decide which solver setting is most
applicable. There can be big differences in runtime, so time spent tuning will be worthwhile.

34
 Fig. 2: Static analysis properties dialog box.
(https://www.digitalengineering247.com/article/solidworks-simulation-overview)

Within the highlighted Solver Selection drop-down are a range of FEA solver options,
including Direct and Iterative solvers. The optimum choice of solvers is complex, dependent
on solution type, model size and available system memory. I checked the Automatic Solver
Selection option. This adopts the best method based on the characteristics noted. I
recommend reviewing the documentation carefully and carrying out benchmarks to decide
which solver setting is most applicable. There can be big differences in runtime, so time spent
tuning will be worthwhile.

4.7 Standard Mesh Control

The mesh icon in Fig. 1 pops up a dialog box, as shown in Fig. 3 on the left, from which I
selected the Standard mesh method. The mesh density is controlled with a slider bar, or by
inputting two parameters: maximum and minimum element size. The default, specific to my
model, is a medium density setting with maximum and minimum element sizes set to 0.782
in. and 0.039 in. The 20:1 ratio is the default. It is important to know your critical geometry
dimensions and the implications within the settings. Fig. 4 shows the overall mesh and the
local mesh around the critical stress area.

35
Fig. 3: Standard (left), curvature (center) and blended-curvature based options in the Meshing
menu. (https://www.digitalengineering247.com/article/solidworks-simulation-overview)

I ran an exploratory analysis (not shown) to confirm the high stress areas. These are the fillet
radii seen in the inset of Fig. 4, which need a fine mesh. The adjacent bolt hole needs a
coarser mesh and is typical of the rest of the structure.

Fig. 4: Default mesh using Standard method, withdetail inset.

(https://www.digitalengineering247.com/article/solidworks-simulation-overview)

36
The bolt hole periphery is 3.14 in. (0.5-in. radius). The fillet periphery is 1.57 in. (1.0-in.
radius). The default maximum element size forces two elements around the fillet radius, nine
around the bolt hole. The mesh shown in Fig. 4 is generally too coarse, and far too coarse at
the fillet. The model has 61,701 degrees of freedom (DOF).

The “Fine” setting gives maximum and minimum element sizes of 0.39 in. and 0.019 in. Now
four elements are forced around the fillet and nine around the bolt hole. This mesh is shown
at top right in Fig. 4. The general mesh size is acceptable now, but the fillet is still far too
coarse. The model has 210,501 DOF.

I have progressively halved maximum element size by manually setting to 0.195 and 0.0975
in., as shown in Fig. 5, bottom left and right. The model sizes are 1,234,647 DOF and
7,687,593 DOF. For a converged stress at the fillet, the local mesh size needs to be around
0.0975 in., as shown in the last model, but this is clearly not an acceptable solution. My
desktop with 64GB RAM hit a wall here and took 23 minutes to mesh!

Fig. 5: Standard mesh control with decreasing element size as shown.

(https://www.digitalengineering247.com/article/solidworks-simulation-overview)

This academic exercise shows the need for alternative meshing strategies, and
SOLIDWORKS offers three approaches: curvature-based meshing, local mesh control and
adaptive meshing. The first two methods are based on user-defined controls. Adaptive
meshing uses a series of automatically created analyses that update the mesh to minimize

37
stress jumps between adjacent elements. The program seeks out stress concentrations and
refines the local mesh.

4.8 Curvature-Based Meshing

In the curvature-based option of the mesh dialog box (Fig 3, center), the slider bar controls
maximum and minimum element size, as before. The default element size is coarser. The key
parameter is the minimum number of elements around a circle (curvature control), shown by
the pentagon-shaped icon. The range is between 4 (default) and 36 (maximum).

The default curvature setting of 4 gives a very coarse mesh of 56,097 DOF, as shown in Fig.
6.

Fig. 6: Effect of curvature-based controls.

(https://www.digitalengineering247.com/article/solidworks-simulation-overview)

Successive curvature controls of 8:18:36 are also shown in Fig. 3, center. The model sizes are
106,563 DOF, 195,252 DOF, and 252,768 DOF. There is little difference in the meshes
beyond curvature control 18. The fillet and bolt hole element numbers are stuck, because the
minimum element size has not been changed. The fillet periphery is 1.57 in., the minimum
element size is 0.312 in., hence five elements are allowed. Similar math shows the limit
around the bolt hole of 10 elements. Without this insight, use of the curvature-based meshing
can be frustrating, as it appears to stall.

38
If we back-calculate, nine elements around the 90° fillet give a minimum element size of
1.57/9 = 0.174 in. This is the maximum in curvature-based meshing control (36 around a full
circle). Using a smaller element size does not allow for a higher number.

Using these settings, a reasonable mesh is created, shown in Fig. 7, labeled Growth Rate 1.1.
The model has 732,612 DOF. The maximum element size of 1.56 in. is the default, but the
largest elements in the figure are much smaller than that. It would be useful to be able to
further coarsen the mesh away from the fillet. The clue is the Growth Rate parameter, shown
as a series of triangles in the menu. The value of 1.1 is the size multiplier on each successive
element layer. A value of 1.1 gives a very slow growth rate from the fillet. The effect of
growth rate is shown in Fig. 7.

Fig. 7: Effect of growth rate on curvature-based meshing.

(https://www.digitalengineering247.com/article/solidworks-simulation-overview)

Setting the value to 1.3 gives a useful gradation from the fillet to the edge and a model with
411,282 DOF. Over 300,000 DOF are saved. The next mesh at Growth Rate of 1.5 shows
how sensitive this parameter is, since the model size has dropped to 287,964 DOF. Finally, a
setting of 2.0 on Growth Rate gives 173,685 DOF. The fillet local mesh size has remained
constant during these meshing runs.

The keel structure is relatively “narrow” in all places, so the Growth Rate does not have
enough element rows to achieve the maximum element size of 1.56 in. The maximum

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element size is redundant here, but in a “wide” structure where many element rows exist,
away from controlling curvature-based features, the mesh can coarsen to the target value.

To sum up the Curvature-based mesh strategy:

1. Select critical curved features and calculate the element size for 36 elements in a 360º
circle.

2. Set this as minimum element size.

3. Set growth rate to 1.5.

4. Set the largest target element size in the coarse mesh region.

5. Adjust the Growth Rate until you find a gradation you like.

4.9 Blended Curvature-Based Meshing

This is an automated version of the curvature-based meshing. The dialog box is shown in Fig.
3, right.

The highlighted button in the dialog box activates a calculator that finds the smallest
curvature-based feature in the model. The blended curvature-based smallest element size is
0.0435 in., because of 0.25-in. radius bolt holes that are present. The other parameters remain
the same, using settings from the previous exercise. Fig. 8 shows the resultant mesh.

Fig. 8: Blended curvature-based meshing.

(https://www.digitalengineering247.com/article/solidworks-simulation-overview)

40
Interestingly, the blended mesh overrides the limit of 36 elements around a circle, using the
new smaller minimum for all curved surfaces! This produces a good mesh around the fillet—
but is overkill in other non-critical curved regions. The model has 674,685 DOF.

This method could be used as an additional “step 6,” after normal curvature-based meshing
settings are established. The blended mesh minimum element size, entered manually, would
“nudge” up the number of elements around key features.

4.10 Local Mesh Controls

After curvature-based meshing, the fillet has reached its limiting size. This is frustrating as
we need a finer mesh at the fillet. Local mesh control now plays a key role.

Right mouse-clicking on the mesh icon allows Apply Mesh Control to be selected. Fig. 9
shows the menu and the fillet surfaces chosen.

Fig. 9: Local mesh control menu and selected filletsurfaces.

(https://www.digitalengineering247.com/article/solidworks-simulation-overview)

I have halved the “stalled” fillet mesh size. The resultant mesh is shown in Fig. 10.

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 Fig. 10: Local mesh control.

(https://www.digitalengineering247.com/article/solidworks-simulation-overview).

The local mesh control is highly selective. It allows good mesh refinement at the fillet region,
while keeping the model size to 385,899 DOF.Individual mesh controls can be set.

Using these as fine control adjustments on a sound baseline mesh provides a powerful
technique.

Setting the value to 1.3 gives a useful gradation from the fillet to the edge and a model with
411,282 DOF. Over 300,000 DOF are saved.

The next mesh at Growth Rate of 1.5 shows how sensitive this parameter is, since the model
size has dropped to 287,964 DOF. Finally, a setting of 2.0 on Growth Rate gives 173,685
DOF. The fillet local mesh size has remained constant during these meshing runs.

The keel structure is relatively “narrow” in all places, so the Growth Rate does not have
enough element rows to achieve the maximum element size of 1.56 in.

42
4.11 DESIGN FOR NEW SPANNER TOOLS

Modern Spanner Tool is a advance version of the spanner tools, it has the different sizes of
the profile that can open different sizes of nut easily and make the work of the mechanic easy.

Design of New Spanner tool

43
Conclusion
As you know Spanner is a tool used to provide mechanical grip and advantage in applying
torque to turn nuts and bolts. So now, we hope that we have clear all your doubts about
Spanner

44
References
 https://onlinelibrary.wiley.com/doi/abs/10.1111/1467-9299.00296
 https://www.researchgate.net/publication/270220133_Innovative_Design_of_Multi_J
aw_Wrench_and_its_Analysis
 https://www.researchgate.net/publication/289881173_Spanner
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rical_Ergonomic_Bionic_Grip_Wrench
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nch_Tool_Innovative_Design_Method
 https://www.researchgate.net/publication/309417587_Research_Study_and_Analysis
_of_Ergonomic_Design_of_Conventional_Wrench_Handle
 www.researchgate.net/publication/309417587_Research_Study_and_Analysis_of_Er
gonomic_Design_of_Conventional_Wrench_Handle
 https://www.farinia.com
 https://www.researchgate.net/publication/270220133_Innovative
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nch_Tool_Innovative_Design_Method
 https://link.springer.com/article/10.1007/s00170-018-3133-0
 https://wiki.co.in
 Workshop book by Swarn Singh
 https://www.researchgate.net/publication/341712325_Design_and_Analysis_of_Elect
rical_Ergonomic_Bionic_Grip_Wrench

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