Srinivasan Ramasamy et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Int J Adv Engg Tech/Vol. VII/Issue II/April-June, 2016/542-545

Research Paper

STRENGTH OF HOLLOW SECTION AND INTER LOCK WELD IN AUTOMOBILE POWER TRANSMISSION JOINT

Srinivasan R*a and Jayaraman.Mb

Address for Correspondence

*a Assistant Professor, Automobile Engineering, Paavaai Group of Institutions, Namakkal, Tamilnadu, India bProfessor, Mechanical Engineering, Velalar College of Engineering and Technology, Erode, Tamilnadu

ABSTRACT: The important role of torsional strength in hollow beams under torsion in mechanical engineering application is the research work area. The research area includes practical usage in drilling pipe of bore wells and civil engineering structural applications. The space occupied by the hollow beam is a restricted constraint. In such case, even a small excess in angle of twist of hollow beam results is dangerous causing malfunctioning of the machine or civil structure because of mismatching of components in total assembly. This research paper deals with hollow beams of geometrical cross sections namely square and circular hollow sections, with same outer dimensions. The hollow beams are tested for torsional strength and the angle of twist developed is found using torsion testing machine. The specimens of circular and square cross sections made up of different metals like mild steel, copper and aluminum are tested. The experimental results are compared with results from theoretical calculation and also verified by the finite element analysis method using ANSYS tool. The hollow square or circular section with better torsion rigidity is identified. The second part of research is on the slip joint in transmission shaft of multi wheeler automobile. This research paper also suggests the new type of interlock weld to minimize the failure hollow circular slip joint in automobile transmission and to increase the strength of welded joint. KEYWORDS: Angle of twist, Torque, Torsion test, Slip joint, Hollow section.

1 INTRODUCTION

The significance of research in the hollow metallic beams of circular and square cross sections in various practical applications namely mechanical and automobile components, civil structures, bridges, roller coaster and structural frames. The hollow metallic beams used to carry torque load resist angular twist with improved torsional rigidity .To meet the requirements of mechanics, ship building and construction industry, the torsional rigidity of hollow beam members is an important factor to be analyzed. The hollow circular slip joint in transmission shaft in multi wheeler automobile is meant for adjusting the variation in length of shaft. The functioning of the multi wheel automobile like a truck, depends on the welding joint strength of critical components in the vehicle .The research paper determines the failure of hollow circular slip joint in transmission line of the multi wheeler automobile. The research works is done for design improvement of hollow beams at various perspectives. Ismail et al found the stress intensity factor of the surface cracks in round bars subjected to combination of bending and torsion with finite element model. [1] The remarkable research on circular cylindrical thin shells used in pumps and turbines by Rayblin Salahifar et al found that the cylindrical finite element which is computationally efficient for long pipelines. [2] Seval Pinarbasi did research in lateral torsional buckling of narrow rectangular cantilever beams and narrow rectangular simply supported beams with varying beam length, with variation iteration algorithms. [3] Pure torsional behavior of rectangular concrete beam with glass fiber reinforced polymer is studied by Prabahar A et al by considering the parameters like grade of concrete beam and longitudinal reinforcement ratio. The results are based on analysis, agreed with results of space truss analogy in which shear stresses is considered as constant over a finite thickness around periphery of a beam. [4]

The results show that the increase in torsional strength and angle of twist will cause increase in grade of concrete and percentage of reinforcements used. The glass fiber reinforced polymer concrete beams produced more angle of twist than conventional reinforcements due to their higher tensile strain values. Zhihuazhao et al proposed the finite element beam with Euler Bernoulli’s assumption that the cross section is rigid during deformation. The newly proposed beam element allowed large value of bending and torsional deformation. [5] G.J.Nieetal found the analytical solution for plane strain static deformation of hollow circular cylinder, subjected to axis symmetric and non-axis symmetric loads at inner and outer surfaces. The results show that the effect of variation of Poisson ratio on radial displacement is considerably more than that of stresses. [6] The torsion of anisotropic cross section is investigated by Pascal swider et al by calculation of stress function using the energy method with validated results. The aspect ratio of cross section is important with strain energy distribution and torsional behavior of thin section. [7] The new method of analyzing flexure torsion problem of De saint venant cylindrical beam was developed by Maria Di Paola et al. The stress is related to potential function through a procedure named ‘Element less method’ involving symmetric matrices. The approach based on finite element method is limited to shape of elements resulting in complex meshing process. But the boundary element method needed discretization of boundary which resulted in line elements like De saint venant beam. The novel method called line element less method never needed a meshing procedure. The method is exact in solving and satisfying boundary condition for circular, elliptical and equilateral triangular elements. [8] The problem of thin walled composite box beams subjected to axial load and end moments under vibration and buckling is done by Thucpuongvo et al based on classical lamination theory. [9]

Srinivasan Ramasamy et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Int J Adv Engg Tech/Vol. VII/Issue II/April-June, 2016/542-545

A. Ziolkowski et al worked in the buckling load drop in columns. The estimation of safety in the column, under accidental damage under limited buckling was studied experimentally. Nonlinear governing equations are derived and solved by thucpuongvo et al using Newton rapson method and one dimensional finite element model was developed. The effect of fiber orientation, laminate stacking sequence in thin walled composite beam under vertical load is done based on classical lamination theory. [10], [11] The ultimate strength of rectangular steel box beams using finite element analysis program ‘ABAQUS’ is done by the researchers Kungsikkim et al. Nonlinear incremental analysis is conducted, considering the residual stresses. Predictor equations were proposed through regression analysis. The suggested equations have shown reduced ultimate strengths due to combined loads of bending, shear and torsion. [12] J.Louglan et al examined structural performance of multicellular fiber composite box beam with constraints of torsional load, through the analytical procedure. In the analytical process, elastic couplings in beam between bending, torsion and axial effects are eliminated by using thin walled laminates. The torsional rigidity of composite multicellular beam is calculated in the research work. [13] Progressive collapse analysis work by jeomKee Paik et al examined the maximum load carrying capacity of box columns. The novel method by name idealized structural unit method was used for progressive analysis of short, medium and long box columns until and after reaching the ultimate state. [14] JeomKee Paik conducted research the ultimate strength characteristics of perforated steel plates used in ships under water pressure subjected to combined biaxial compression and edge shear loads. Ansys results of various plate dimensions are drawn and empirical formula for ultimate strength of perforated plate with circular hole with combined loads are derived. [15] The formula for calculating the bending stress, deflection and shear effect of symmetric single-cell thin walled composite laminated box beam, under bending load is estimated by Wu yapping et al based on the principle of complementary energy. [16] Thucpuongvo et al made the analytical model of composite box beams subjected to vertical and torsional load by classical lamination theory. The governing equations are derived from the principle of stationary value of total potential energy. The model predicted accurate deflection and angle of twist with various boundary conditions. [17] Based on nonlinear fiber element analysis method, Quingquanliang et al calculated the ultimate strength and behavior of concrete thin walled box columns with local buckling. The effects of width to thickness ratio and compressive strength on ultimate strength and ductility of concrete filled box columns are investigated using newly developed computational technique. The fiber element analysis program predicted the ultimate strength and ductility in concrete filled steel box columns with local buckling effect. [18] A.S.A.L. Nuaimi et al idealized reinforced concrete hollow beams using two dimensional plane elements. The beam filled with concrete at ends form solid end diaphragms to prevent local distortion. [19]

Yaping Wu et al investigated the ultimate load of thin walled box beam with limited plastic strain and shear lag effect. The formulae of strength increase coefficient, flange effective width ratio and shear lag coefficient of thin walled box beam is derived. Ya ping wu et al conducted research worked on the procedure of analyzing the mechanical behavior of laminated thin walled composite box beam under torsional load, based on the theory of composite laminate plates .The calculation formulae for torsion angle are derived based on the concept of torsion without external restraint. [20] 2 MATERIALS AND METHODS

2.1 TORSION STRENGTH OF HOLLOW BEAMS WITH

SAME DIMENSIONAL GEOMETRY The hollow circular or square component fits in the assembly without any displacement in the relative positions which affects the functioning of the assembly. This research paper deals with the effect of torsional rigidity of hollow metal beams with same outer dimensions under space constraint. The experimental results are compared and torsion stress analysis is done with ANSYS 10.0 software. The theoretical formulae for angle of twist of hollow square section and the angle of twist of hollow circular section are applied for the stipulated conditions.

Outer diameter of hollow circular section = Outer side of hollow square section

Wall thickness of hollow circular section = Wall thickness of hollow square section

Fig 1 Comparative size of hollow sections

The angle of twist of hollow square section is lesser than angle of twist of hollow circular section.

t=Wall thickness of hollow section r=Inner radius of hollow circular section

Fig 2 Aluminum and steel specimens for

torsion test

Fig 3 Testing aluminum hollow circular and

square specimens

Fig 4 Steel hollow circular and square

specimens

Srinivasan Ramasamy et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Int J Adv Engg Tech/Vol. VII/Issue II/April-June, 2016/542-545

2.2 FINITE ELEMENT ANALYSIS RESULTS

FOR HOLLOW SQUARE BEAM

Fig 5 Total Shear in hollow square mild steel

beam specimen

2.3 COMPARATIVE ANALYSIS IN HOLLOW

BEAM

Fig 6 Torque variation in mild steel hollow

circular beam

Fig 7 Experimental and theoretical torque in

mild steel hollow beam

Fig 8 Angle of twist variation with hollow

beam wall thickness

2.2 AUTOMOBILE TRANSMISSION LINE WITH

INTER LOCK WELD

Fig 9 Inter lock weld in automobile

power transmission

Fig 10 Interlock weld type slip joint

Fig 11 Slip joint specimen under testing

Fig 12 Slip joint specimen in compression test

3 RESULTS AND DISCUSSION The research work on torsion strength of hollow beams of same dimensional geometry concludes that the angle of twist of square beam is lesser than the hollow circular beam of same outer diameter. In case of the hollow beams in practical application, the space occupied by beam is a restricted constraint. The distortion about beam axis is restricted to minimum value of less than one percentage. The results suggest that the hollow square section is preferred than the hollow circular section for given torque .The results are also confirmed with tests in beams made of materials like mild steel, copper and aluminium. The theoretical prediction is visualized graphically. [Fig 5] For the different specimens made of particular material for test with same modulus of rigidity and with varying wall thickness, the value of ratio of angle of twist is calculated for applied torque. The graph is plotted for given outer diameter of circle or outer side of square.[Fig 1],[Fig 2],[Fig 3],[Fig 4] The graphical results show that the increase in wall thickness of specimens result in decrease in the ratio

Srinivasan Ramasamy et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Int J Adv Engg Tech/Vol. VII/Issue II/April-June, 2016/542-545

of angle of twist calculated for mild steel, copper and aluminium specimens at given applied conditions. The experimental results of mild steel aluminum and copper hollow beams of square and circular sections confirm the theoretical results. The finite element modeling of hollow beam also confirms the calculated and experimental results. [Fig 6], [Fig 7], [Fig 8] Compression test is done on transmission shaft in automobile, both the experimental and software analysis result proved that suggested inter lock welding improved the compressive strength of the hollow slip joint in automobile transmission shaft.[Fig 9],[Fig10],[Fig 11] The comparison of hollow beam results conclude as the increase in wall thickness of specimen results in the decrease in the ratio of angle of twist calculated for mild steel, copper and aluminium specimens. Compression test is done on transmission shaft in automobile conclude that both the experimental and software analysis conclude that the inter lock welding improved the strength of the hollow slip joint in the transmission shaft. REFERENCES

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