EXPERIMENTAL ANALYSIS OF PROPERTIES OF SPRING MATERIAL

A PROJECT REPORT Submitted by

V. MANJUNATH B. MUBARAK ALI V. MUKESH M. S. PRAVEEN KUMAR

090111504028 090111504034 100411504002 100411504005

In partial fulfillment for the award of the degree Of

BACHELOR OF ENGINEERING
IN

MECHANICAL ENGINEERING

P.S.V COLLEGE OF ENGINEERING & TECHNOLOGY KRISHNAGIRI

ANNA UNIVERSITY : CHENNAI 600 025

APRIL 2013

ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE
Certified that this OF project report EXPERIMENTAL is the ANALYSIS bonafide work OF of

PROPERTIES

SPRING

MATERIAL

MANJUNATH. V, MUBARAK ALI. B, MUKESH. V, PRAVEEN

KUMAR. M. S who carried out the project work under my supervision.

SIGNATURE Mr. N. Mohammed Yusuf, M.E, M.B.A. HEAD OF THE DEPARTMENT Mechanical department, P.S.V. College of Engg & Tech, Krishnagiri.

SIGNATURE Mr. T. Bhuvanesh Kumar M.E, (P.hD) SUPERVISOR Mechanical department, P.S.V. College of Engg &Tech, Krishnagiri.

Submitted for the University examination held on _______________

Internal Examiner

External Examiner

ACKNOWLEDGEMENT

At the very outset, we wish to express our sincere thanks to all those who involved in the project. Our most sincere salutations go to Anna University that gave me an opportunity to have sound basis for Mechanical Engineering. We solely devote my honorable thanks for our to Dr.P.SELVAM, M.A.,
B.Ed., M.Phil., Ph.D Chairman and Mr. S.VIVEK, M.A., M.B.A., Secretary of P.S.V.

College of Engineering & Technology, Krishnagiri for their showering of blessings and encouragement through out my studies. We express our sincere graduate to Dr.K.RANGASAMY, M.E., M.B.A., Ph.D., Principal, P.S.V.College of Engineering and Technology, to give us this opportunity to do this project. We offer our sincere thanks to Prof. Mr.N.MOHAMMED YUSUF, ME.,
M.B.A., Head of the Department, Department of Mechanical Engineering for giving

this opportunity and his full encouragement. We consider it as a great privilege to place a record our deep sense of gratitude to our Internal Guide Mr. T. Bhuvanesh Kumar M.E.,(P.hD)., Assistant Professor in Department of Mechanical Engineering for his valuable guidance throughout course of this project. We thank with genuine conscious to my entire Department staff who gave their valuable participation to build up my career. Finally we would like to thank all those who behind all those who were behind the screen, build and played very important role in completion of this project work.

DEDICATED TO OUR BELOVED PARENTS AND FRIENDS.

TABLE OF CONTENTS

CHAPTER NO.

TITLE ABSTRACT LIST OF TABLE LIST OF FIGURES LIST OF SYMBOLS

PAGE NO. i ii iii v 1 2 3 3 3 3 3

1.

INTRODUCTION 1.1 Springs 1.2 Types of Springs 1.2.1 Coil Springs 1.2.2 Leaf Springs 1.2.3 Torsion Bar 1.2.4 Air Spring

2.

LITERATURE SURVEY

2.1

Literature Survey

3.

SPECIAL PURPOSE

3.1 3.2 3.3 3.4

Heat Treatment Normalizing / Stress Relieving Hardening Tempering

7 7 7 8

4.

FAILURE MODE AND EFFECT ANALYSIS

4.1 4.2 4.3

Failure Mode of a Spring Ductile Fracture Cyclic Mode of a Spring Operation 4.3.1 Failure Modes 4.3.2 Fatigue Stress 4.3.3 Spring Relaxation

10 13 15 15 15 17 18 19

4.4 4.5

Miscellaneous Failure Mode FMEA

5.

QUENCHING FUNDAMENTALS AND PROPERTIES 21

5.1

Quenching Oil Fundamentals 5.1.1 Viscosity 5.1.2 Soot 5.1.3 Salt 5.1.4 Water 5.1.5 Hydraulic Fluid 5.1.6 Oxidation

22 23 23 24 24 24 24 25 25 25 25 25

5.2

Precautions 5.2.1 Percent Water 5.2.2 Flash Point 5.2.3 Percent Sludge 5.2.4 Percent Ash

5.2.5 Kinetic Viscosity 5.2.6 Neutralization Number 5.2.7 Quenching Speed 5.3 Quenching Bath 5.3.1 Oil Quenching Bath 5.3.2 Tank for Quenching Bath 5.4 5.5 5.6 5.7 Water Quenching Objectives of Heat Treatment Furnace Tensile Test

25 25 26 26 29 29 31 33 34 35

6.

FORMULA

41

6.1

Formula 6.1.1 Stress & Strain Relationship 6.1.2 Youngs Modulus 6.1.3 Yield Strength 6.1.4 Ultimate Tensile Strength 6.1.5 Elongation

42 42 43 43 44 45

7.

METHODOLOGY

47

7.1 7.2 7.3

Methodology about the testing centre Graphs 7.3.1 Graphs For 8 Mm 7.3.2 Graphs For 8 Mm

48 49 52 53 54

7.4

Software Analysis 7.4.1 Analytical Report For 8 Mm 7.4.2 Analytical Report For 9 Mm

55 56 57

8.

COST ACCOUNTING

58

9.

CONCLUSION

60

10.

REFERENCES

62

ABSTRACT

Most of the automobile applications are based upon the spring action, so designing a spring which can withstand more load has become a necessity. This study was carried out to investigate the effect of heat treatment on the mechanical properties of spring steel material. The material used in this study was a commercial grade II of heavy duty spring steel. The materials were made from spring steel rod having a diameter of 8 mm and 9 mm. The springs were then subjected to various heat treatment processes which included; normalizing, hardening and tempering. The heat treated springs were then subjected to various test in other to determine their mechanical properties, these included; Yield Strength, Tensile Strength, and Elongation. Oil quench and water quench offer enormous advantages to the heavy duty spring production because its treatment results can reveal optimum combination of toughness and ductility, and also improves fatigue life of the spring material. In the process, selected material was heated up to temperatures like 300C, 350C, 450C, 500C and 550C for each time one hour interval and quenched in oil and water. The experimental results revealed that mechanical properties of selected materials were significantly changed by heat treatment. By increasing the tempering time the strength of the material increases and the life of the spring increases.

LIST OF TABLES

TABLE NO

TITLE

PAGE NO

7.1

Tabulated values of the Tensile test.

50

ii

LIST OF FIGURES

FIGURE NO

TITLE

PAGE NO

4.1 4.2 4.3

Unidirectional Stress Reversed Stress Stages in formation of cup-cone fracture Oil Quenching Tanks for Quenching Bath Water Quenching Ordinary Type of Quenching tank Heat Treatment Furnace Layout of UTM Stress Strain Curve Engineering Stress Strain Curve UTM Machine Specification of UTM Machine

12 12

13 28 30 31

5.1 5.2 5.3 5.4

32 33 34 35 36 38 51 51

5.5 5.6 5.7 5.8 5.9 7.1 7.2

iii

7.3

Yield Strength vs Temperature (Graph Dia 8mm) Tensile Strength vs Temperature (Graph Dia 8mm) Elongation vs Temperature (Graph Dia 8mm) Yield Strength vs Temperature (Graph Dia 9mm) Tensile Strength vs Temperature (Graph Dia 9mm) Elongation vs Temperature (Graph Dia 9mm) Analytical Diagram for Stress Analysis Dia 8 mm Analytical Diagram for Stress Analysis Dia 9 mm

53

7.4

53

7.5

53

7.6

54

7.7

54

7.8

54

7.9

57

7.10

58

iv

LIST OF SYMBOLS is the engineering stress e is the engineering strain P is the external axial tensile load Ao is the original cross-sectional area of the specimen Lo is the original length of the specimen Lf is the final length of the specimen E is the Young's modulus T s is the Ultimate Tensile Strength, Y is the Yield Strength,