SYNOPSIS PRESENTATION

ON

CONCURRENT DESIGN AND PROTOTYPING

OF COMPOSITE ACCELERLATOR PEDAL
Submitted In Partial Fulfillment of Requirement for the Award of Master Degree

MASTER OF TECHNOLOGY
IN
(I.P.D&M)

SUPERVISOR SUBMITTED BY
Puneet Katyal Pankaj

Assistant Professor Regn. No. 09161010

DEPARTMENT OF MECHANICAL ENGINEERING

GURU JAMBHESHWAR UNIVERSITY OF SCIENCE & TECHNOLOGY
HISAR
CONTENTS
INRTRODUCTION
LITERATURE REVIEW
PROBLEM FORMULATION
OBJECTIVES OF PROPOSED
WORK
METHODOLOGY
REFERENCES
INTRODUCTION

Most of the products we see are made from monolithic materials. i.e. they

consist of a single material .
Composite materials, on the other hand, consist of two or more materials
combined in such a way that the individual materials are easily
distinguishable
Individual materials are combined so to get better mechanical and thermal
properties then metals, non metals and ceramics .
Types of composite
Polymeric matrix composite .
Metal matrix composite.
Ceramic matrix composite .
Applications of Composites

•Automotive
•Aircraft
•Space
•Marine
•Electrical & Electronics
PURPOSE OF ACCERLETOR PEDAL

Accelerator pedal should be capable of being depressed gently for gradual

acceleration or deceleration by control of fuel and air supply to the
automobile's engine, has a fail-safe design in that it automatically returns to
the idle position when not depressed by the driver
Demerits of a Merits of Composite

Conventional Accelerator Accelerator pedal

pedal
 They have high specific
modulus and strength.
They have less specific
 Reduced weight.
modulus and strength.
 Due to the weight reduction, fuel
 Its corrosion resistance is less
consumption will be reduced.
as compared with composite
 They have good corrosion
materials.
resistance.
 Increased weight.
 Less costly.
 Costly.
 Longer fatigue life than steel or
aluminum pedal
Introduction to Concurrent
Engineering
Material
Selection

Product
Component Design
Design Specification

Concurrent
Engineering

Design Manufacture
Analysis
Literature Survey

John W. Weeton et al. [1] described the application

possibilities of composites automotive industry springs to
manufacture composite elliptic springs, leaf springs and drive
shafts .

C.J. Morris [2] Explained FRP as potential structural

materials for automotive applications and describes the
design, fabrication, weight analysis and testing of a composite
integrated rear suspension in a Ford Escort vehicle.
.
Jack Zhou et al. [3] Investigated Concurrent Engineering (CE)
reduces product time to market, cutting down the total cost, and
improving quality. This paper describes a newly developed CE
course which employs the method of concurrent education.

Frank M. Hull et. al. [4] Proposes a “composite” form of

organization as best for reducing product development time and costs.
This composite is a meld of three sets of concurrent engineering (CE)
practices: early simultaneous influence (ESI) in product design
decisions by multiple functions, in-process design controls (IDC), and
computer and information technology (CIT).
Michael J. Tari et al. [5] Investigated a methodology for the
rapid process development of resin transfer molding (RTM) in
order to reduce product development cycle time and lower the
cost of developing composite parts. Uses laminated object
manufacturing (LOM), to fabricate molds.
Ramesh K.C et al. [6] Studied the automotive industry need
for materials substitution, offering outstanding properties in
a number of engine components including engine poppet
valves. Since the valves control the gas flow, valve size,
timing and overlap, they all influence volumetric efficiency.

The valve train is designed to achieve maximum

volumetric efficiency at the desired level of engine
performance. Research work envisages carrying out some
studies on Al-SiC and Al-TiC composites as possible
alternative materials for engine poppet valves by powder
Weihong Zhong et al. [7] investigated the continuous fiber reinforced
composite by rapid prototyping/part manufacturing process (RP&M). The
effects of the fiber’s moving speed, the fiber’s tension force, and the
viscosity of the resin on the content of resin in the resulting composite,
and the impregnation between the fiber and the resin were studied.
H. A. Al-Qureshi [8] presents a general study on the analysis, design and
fabrication of composite springs. From this viewpoint, the suspension
spring of a compact car, a jeep was selected as a prototype. A single leaf,
variable thickness spring of glass fiber reinforced plastic (GFRP) with
similar mechanical and geometrical properties to the multi leaf steel
spring, was designed, fabricated (molded and hoop wound) and tested.
Denise Carlson et al.[9] Investigated, the
recyclability of automotive parts based upon these
environmental requirement and demonstrated a new
recycle technology for polyamide using one of the
largest automotive applications, the radiator end tank
which has been previously viewed as degraded
material due to hydrolysis and deemed as shredder
residue.
D. Karalekas and K. Antonio [10] Investigated
Stereolithography and vacuum casting as two well-
established techniques for producing complex parts for
rapid prototyping purposes and studied effects of the
addition of nonwoven glass fibre mats, and of various
thicknesses, on the mechanical properties of laser solidified
and vacuum moulded specimens.
Marcia Kurcz et.al [11] Proposes Glass-mat thermoplastic (GMT) composites
to replace steel in spare-wheel well (SWW) applications. This application has
been successfully translated across multiple OEMs, tier suppliers, platform
types
S.M. Sapuan & M.A. Maleque [12] Presents a conceptual design approach to
the development of polymeric-based composite automotive bumper system,
various methods of creativity, such as mind mapping, product design
specifications, brainstorming, morphology chart, analogy and weighted
objective methods are employed for the development of composite bumper
fascia and for the selection of materials for bumper system.
S.M. Sapuan [13] studied the conceptual design for polymeric
based composite automotive pedal and describes the importance of
concurrent engineering and finally evaluated the conceptual design
of composite pedal box system with common shaft for the three
pedals & compared the results
Eric jaarda and Manish Chaturvedi [14] Proposes Basic
automotive steering wheel armature design. A cast aluminum or
magnesium armature is typically used to provide stiffness and
strength with an over molded polyurethane giving shape and
occupant protection.
H.M. Shedi and C.I. Ajuwa [15] Investigated composite composite wheel
of this nature weighs less than the conventional whole cast iron or steel
alloy wheel and hence, develops lower inertia loads at a given speed.
Improves low speed acceleration
Erica R.H. Fuchs & Frank R. Field [16] studies the materials choice
in automotive bodies have looked at both composite and aluminum
alternatives, but have always found steel to be the most cost-effective
option at the production volumes found in the overwhelming majority of
vehicle models. This study finds composites to have significant economic
potential when considering emerging advances in the polymer composite
Aljibori, Hakim S. Sultan [18] investigated an increasing demand
in the use of composite materials for the automotive, aerospace and
rail industry. When using composite in the body structure of a
vehicle, considerable weight reductions can be achieved compared
to conventional isotropic structures, which leads to reduced fuel
consumption and consequently lower carbon dioxide emissions.
Alemu Moges Belay [19] this paper focuses on the two of new
product development methods (DFM and CE). The aim of this
paper is to see and analyze different product development methods
specifically on Design for Manufacturability and Concurrent
Engineering.
A.R. Ismail et al. [20] this study shows how the effect of implementation
of the Design for Manufacture and Assembly (DFMA) in product
development process. Pressure vessel was selected as the example in this
case study.
G. Savage [21] Investigated engineering structure, irrespective of its
intended purpose, must be made of one or more materials. More often it
is the choice and behavior of those materials that determine its
mechanical performance and Introduces fibre reinforced composite
chassis of Grand Prix motor racing.
C. Alves et al. [22] Investigates the environmental improvements related
to the replacement of glass fibers for natural jute fibers, to produce a
structural frontal bonnet of an off-road vehicle (Buggy). Results pointed
out the advantages of applying jute fiber composites in Buggy enclosures.
PROBLEM FORMULATION

As Literature review shows that composites automobile

components are good substitute for the Conventional monolithic
automobile components.
So, it is need to design composite Accelerator pedal to take
place of existing conventional Accelerator having less weight and
better mechanical properties easy and cheap to manufacture and to
study the concurrent engineering approach for the purpose.
OBJECTIVES OF PROPOSED WORK

To Develop a conceptual prototype composite

Accelerator Pedal as a substitute of metal Accelerator
lower in weight due to density , high strength , stiffness,
corrosion resistant by Rapid prototyping Using
concurrent engineering approach
Methodology
Material
Selection based
on manufacture ,
technique, Cost
,analyses
Designing by PDS on basis
3d –modeling of existing /
software patents/
,using PDS, market
Composite investigation
Analyses
Accelerator
pedal

Design Analysis Manufacture

using FEM on By rapid
actual operating prototyping
condition using : SLS ,
3D-printing
 Work Flowchart
Development of composite Accelerator pedal

Material selection Use of IT Tools

Product design specification 1.3d modeling software
(CATIA/Solid Works /Ansys)
Operating parameters
2.Finite Element Analysis

Final Design

Rapid Prototyping Techniques can be used

1. Stereo lithography
2. 3D Printer
3. Fused Deposition Modeling

Comparison of final result

 References

[1] John W. Weeton et al. (1986),’Engineers guide to composite materials’, American Society for
Metal, New York.
[2] C.J. Morris (1986) ‘Composite integrated rear suspension Composite Structures’, volume 5 issue 3,
1986, Pages 233-242
[3] Jack Zhou, Shlomo Carmi, Alan Lau, and Spiros Koulas (1986),’Concurrent Engineering
Concepts Applied to Concurrent Education and Research’, ISPE International Conference on
Concurrent Engineering, Research and Applications (CE96/ISPE) August 26-28, 1996
[4] Frank M. Hull, Paul D. Collins and Jeffrey K. Liker (1996),’Composite Forms of Organization as
a Strategy for Concurrent Engineering Effectiveness,’ IEEE transactions on engineering management.
vol. 43. No. 2. May 1996
[5] Michael J. Tari, Andre Bals, Joon Park, Mark Y. Lin and H. Thomas Hahn (1998), ‘Rapid
prototyping of composite parts using resin transfer molding and laminated object manufacturing
Composites Part A’, Applied Science and Manufacturing, Volume 29, Issues 5-6, 1998, Pages 651-661
[6] Ramesh K.C and Sagar.R (1999),’  Fabrication of metal matrix composite automotive parts’,
International journal advance manufacturing Technology,1999, vol. 15,number 2, pp. 114-118 (4 ref.)
[7] Weihong Zhong, Fan Li, Zuoguang Zhang, Lulu Song and Zhimin Li(2001) Research on rapid-
prototyping/part manufacturing (rp&m) for the continuous fiber reinforced composite , Materials
and Manufacturing Processes, Volume 16, Issue 1 January 2001 , pages 17 – 2
[8] Al-Qureshi H.A. (2001), ‘Automobile leaf springs from composite materials’, Journal of Materials
Processing Technology, Vol. 118 No. 1, pp. 58-61.
[9] Denise Carlson -Hiroyuki Yamazaki - Sunao Fukuda - Denso Corp. Christian Leboeuf - H.Peter
Kasserra (2003),’ Application of Nylon Composite Recycle Technology to Automotive Parts ‘,SAE paper
Paper Number: 2003-01-0794 DOI: 10.4271/2003-01-0794
[10] D. Karalekas and K. Antonio (2004),’ Composite rapid prototyping: overcoming the
drawback of poor mechanical properties’, Journal of materials Processing Technology volume 10
November 2004, Pages 526-530
[11] Marcia Kurcz ,Burak Baser  Harri Dittmar - Joachim Sengbusch -Hans Pfister –
(2005)‘Replacing Steel with Glass-Mat Thermoplastic Composites in Automotive Spare-Wheel
Well Applications’, SAE paper, Paper Number: 2005-01-1678DOI: 10.4271/2005-01-1678
[12] Sapuan, S.M., Maleque, M.A., Hameedullah, M.Suddin, M.N., and Ismail, N. (2005), ‘A note
on the conceptual design of polymeric composite automotive bumper system’, Journal of Materials
Processing Technology, vol. 159, no. 1, pp. 145-151
[13] Sapuan S.M.(2005),’.A conceptual design of the concurrent engineering design system for
polymeric-based automotive pedal’, American journal of applied science 2 (2) :514 -525, 2005 ISN
1546-9239
[14] Eric jaarda and Manish Chaturvedi (2007),’Prototype Design and Testing of a Thermoplastic
Steering Wheel Armature’, SAE paper Number: 2007-01-1218 DOI: 10.4271/2007-01-1218
[15] Ajuwa, C.I. and H.M. Sheidi, (2008),’Design of high performance vehicle composite flywheel.’
Res. J. Applied Sci., 3: 44-50
[16] Erica R.H. Fuchs, Frank R. Field, Richard Roth and Randolph E. Kirchain (2008),’ Strategic
materials selection in the automobile body’, Economic opportunities for polymer composite design
Composites Science and Technology Volume 68, Issue 9, July 2008, Pages 1989-2002
[17] Chung Hae Park, Abdelghani Saouab, Joel Breard, Woo Suck Han, Alain Vautrin and Woo
Il Lee(2009), ‘An integrated optimization for the weight, the structural performance and the cost of
composite structures’, Composites Science and Technology Volume 69, Issues 7-8, June 2009, Pages
1101-1107
[18] Aljibori , Hakim S. Sultan (2009), ‘Fibre reinforced composite (FRC) structures with
potential applications: literature review. International journal of applied engineering research
October1,2009,  http://www.thefreelibrary.com/Fibre+reinforced+composite+(FRC)
+structures+with+potential...-a0216041279”
[19] Alemu Moges Belay (2009),’ Design for Manufacturability and Concurrent Engineering for
Product Development’, World Academy of Science, Engineering and Technology 49 2009
[20] A.R. Ismail A.H.A.A. Manap D.A. Wahab,R. Zulkifli ,N.K. Makhtar and K. Sopian
(2009) ‘Concurrent Engineering Approach in Designing Pressure Vessel’, European Journal of
Scientific Research ISSN 1450-216X Vol.30 No.2 (2009), page no.245-252
[21] G.Savage (2010),’ Formula 1 composite Engineering’, Papers presented at the 25th meeting
of the Spanish Fracture Group volume17, issue 1 ,January 2010, Pages 92-115
[22] C. Alves, P.M.C. Ferrao, A.J. Silva, L.G. Reis, M. Freitas, L.B. Rodrigues and D.E.
Alves(2010),‘Eco design of automotive components making use of natural jute fiber composites’,
journal of Cleaner production issue 4 ,March 2010, Pages 313-327