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Front Axle
The front axle (Fig. 27.1) is designed to transmit the weight of the automobile from the
springs to the front wheels, turning right or left as required. To prevent interference due
to front engine location, and for providing greater stability and safety at high speeds by
lowering the centre of gravity of the road vehicles, the entire centre portion of the axle is
dropped. As shown in Fig. 27.1, front axle includes the axle-beam, stub-axles with brake
assemblies, u ack-rod and stub-axle arm.
Front axles can be live axles and dead axles. A live front axle contains the differential
mechanism through which the engine power flows towards the front wheels. For steering
the front wheels, constant velocity joints are contained in the axle half shafts. Without
affecting the power flow through the half shafts, these joints help in turning the stub axles
around the king-pin.
The front axles are generally dead axles, which does not transmit power. The front wheel
hubs rotate on antifriction bearings of tapered-roller type on the steering spindles, which
are an integral part of steering knuckles. To permit the wheels to be turned by the steering
gear, the steering spindle and steering knuckle assemblies are hinged on the end of axle.
The pin that forms the pivot of this hinge is known as king pin or steering knuckle pin.
Generally dead front axles are three types. In the Elliot type front axles the yoke for king
spindle is located on the ends of I-beam. The axle ends are forked to hold the steering
knuckle extension between them. The reverse Elliot front axles have hinged spindle yoke
on spindle itself instead of on the
axle. The forked portion is integral with the steering knuckle. This type is commonly
used as this facilitates the mounting of brake backing plate on the forged legs of the
steering knuckle. In the Lemoine type front axle, instead of a yoke type hinge, an L-
shaped spindle is used which is attached to the end of the axle by means of a pivot. It is
normally used in tractors.
The shear stress in the axle is due to braking torque and its magnitude (as shown in Fig.
27.2)
27.1.1.
Non-driving Hub.
Figure 27.4A illustrates a typical bearing arrangement for a non-driving hub. This
consists of a stub-axle, an externally cylindrical sleeve hub, a pair of taper-roller
bearings, a grease-seal, a castellated adjustment nut and split-pin, a washer, and a dust-
cap (Fig. 27.7).
A centrally flanged cylindrical sleeve hub is fitted over small outer and large inner taper-
roller bearings, which are supported on the stub axle. The hub is made of malleable iron
or steel cast. The bearings are designed to absorb both radial and axial loads when
assembled. The slackness between the taper rollers and the inner and outer races are
taken up by spinning the hub assembly while at the same time tightening the adjustment
nut until all the free lay has been taken up. The bearings are then preloaded by tightening
the nut with a torque wrench to some predetermined torque setting. The nut is then
slackened slightly until one of the slots in the nut aligns with the hole in the stub-axle.
The split pin is then inserted through and bent over to secure the nut in position.
fig.27.4. Front bearing-hub assembly. A. Taper roller type. B. Ball bearing type.
For more accurate setting, some manufactures recommend to tighten the adjusting nut to
a specified torque before releasing the nut a given amount. This operation, however,
should not be confused with preloading. As hub bearing withstands heat from the brakes,
a running clearance is provided, which is quite different to that obtained after a bearing
has been preloaded. The flanged hub supports the road wheels and a brake drum or a
brake disc. A dust cap with a central vent hole is used to enclose the end of the hub. This
area of the hub sliouid not be filled with grease.
An alternative bearing arrangement is presented in Fig. 27.4B, which uses two angular
contact type ball races held apart by a rigid spacer. The nut on this non-adjustable hub are
tightened fully to the correct torque value.
Driving Hub.
Figure 27.5 illustrates a typical hub arrangement used for a front-wheel drive car. The
stub axle housing uses two bearings, which support both the wheel hub and driving shaft.
The type of bearing used is decided based on the load carrying capacity of the road
wheel.
The other loads acting on knuckle-pin bearing are those due to the rolling resistance and
road shocks. These loads are proportional to the static load and hence can be accounted
for.
27.1.3.
Bearing Lubrication
The whole hub assembly is partially packed with grease. A radial-lip grease-seal is
pressed inside the hub next to the larger bearing. The lip of the seal faces this bearing and
fits over the cylindrically machined surface on the stub-axle.
Over packing bearing hubs with grease causes churning and develops very high running
temperatures. Due to high temperatures and excessive mechanical working the grease
breaks down and becomes soft. The centrifugal force acting on the grease in the hub
pushes soft grease outwards, so that it flows towards the lip seal and seeps past the seal
lips. Bearing greases are based on mineral oil and to thicken the oil soaps of calcium,
sodium, or lithium compounds are added. The consistency of a grease depends on the
viscosity of the base oil as well as on the structure and properties of the metallic soap
added. The three most important properties of a grease includes
(i) the melting temperature, at which the grease loses its semi-solid state,
(ii) its resistance to contamination and dilution by water, and
(Hi) its ability to withstand mechanical working before the grease breaks. The relative
operating properties of commonly used bearing greases are provided in Table 27.1.
For checking the bearing and seal, the split-pin and the castellated nut on the end of the
stub-axle are removed and the hub assembly is withdrawn. All parts are thoroughly
washed in paraffin, and the bearing rollers and tracks are examined for wear and damage.
Before replacing the hub, the inside of the hub and the bearings are applied with grease
(Fig. 27.7).
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When the shock absorbers of motorcycles get compression due to the movement of the motorcycles,
through the needle valves (combination of return valves and compression valves), the fluid starts to flow in
the piston road. During rapid compression, when the velocity of the piston is high, the needle valves are not
sufficient for the flowing of the fluid. In this case the fluid starts to flow through the shims, which are present
just beneath the piston. The fluid is forced into the external fluid chamber, which is displaced through the
piston rod. A separate compressive valve is used through which the fluid is being force into the external fluid
chamber. Although, this valve is attached with the shims, which open during the high piston velocity.
2. To keep the suspension of the vehicle in full extended position, raise the rear end of the vehicle.
3. Either from the lower edge of the rear mud guard or from any point just above the rear wheel axle
marked by a piece of tape, the distance is measured (R1).
4. Similar measurement is done on the front axle also. (Between bottom of the upper fork crown and
the front wheel axle) (F1).
5. For applying load on the springs, the motorcycle or the bike is allowed (With our rider). The
measurement process is repeated (R2, F2).
6. In this step, take the measurements (same as step E), but this time the measurement is taken with
rider (R3, F3).
Inspection & Maintenance of Two-Wheeler Shock Absorbers
• Soft detergent can be used for external wash of these shock absorbers.
• The place used for cleaning the shock absorbers, should be clean.
• Frequent oil spray should be applied on these shock absorbers and these should keep clean.
• Detergent never be used for cleaning these absorbers, because detergent may erode the external
surface.
• Brake cleaner and thinner can be used for quick drying-up of the surface of these absorbers.
• Normally, the pressure of gas of the absorbers should not be changed of altered. Some special
purpose equipments can be used for altering the gas pressure of these absorbers.
• For more frequent and smoother play, the ball joints should be checked regularly.
• For preventing any leakage and damage, the piston shafts of the absorbers should be checked.
• The external reservoirs of the absorbers must also be checked.
• Prevent the excessive wear and tear of different rubber equipments present within the absorbers.
• Ensure the secure and tight fastening of the shock-absorbers in the two-wheelers.
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