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6 1. Turning on lathe to achieve 2 inch diameter2. Facing on lathe to achieve 0.5 inch thickness3. Drilling on lathe with 10 mm drill-bit T E E T H C U T T I N G Teeth-cutting was performed by a horizontal milling operation with an involute cutter .Indexing was done with help of dividing head . Following calculations are critical to bemade before the operation.A 12 teeth per inch DP cutter was available. Hence, on a 2 inch diameter blank, number of teeth was found as 22 earlier.Pitch is given as inchesOn the column and knee type milling machine, the blank was mounted in a horizontalmilling arrangement. An involute cutter of specifications 12 DP, 21-25 teeth was mountedon the arbor.Indexing was done with the help of dividing head . For making the equal spaced markingson the blank, the indexing plate had to be set so that exactly 22 teeth would be obtained at the end of this procedure. The gear ratio of the indexing gear to the gear to bemanufactured is where N = No. of teeth to be cut = 22.This gives the number , such that the denominator is number available on theindexing plate. The indexing arm was moved to cover one entire revolution plus 63 holes after every tooth was marked or cut.The depth of cut was 0.166 inch and was adjusted by raising the table by the requiredamount before the cutting operation.Thus a pinion with 22 teeth and 12 teeth per inch was

obtained.R A C K The rack is a straight rod which is driven by the pinion in translational motion. The rack isactually a gear of infinite pitch diameter 1 1 Mechanical Engineering Design by Shigley in a common spur gear arrangement.

7 MATERIALAs discussed before, Mild Steel is most commonly available steel and easily machinable.Further, as per our design, a 22 mm thick and 24 inch long rod was required . A one inchthick rod was easily available in workshop store.PROCEDUREP R E P A R A T I O N O F R O D Cutting: Available rod of one inch from the store was cut out to 26 inches (2 inches extra holding in head stock) with the help of power hack-saw. Turning: It was turned on the lathe for achieving the desired thickness of 22 mm andfinished with flat file. Smooth movement of rod inside pipe is very critical, so this operationwas essential.F L A T S U R F A C E P R E P A R A T I O N As previously discussed, a rack of 6.3 inches was to be cut on the rod. For the involuteprofile to be cut accurately a flat surface was required to be made on this rod. This flat surface was required to be 0.5 inches thick to match with the pinion thickness.Hence, the depth to be cut can be calculated asThus, X is equal to 2mm. This is the depth to be cut.The shaping was done in four passes of 0.5 mm depth of cut each during pass.T E E T H C U T T I N G For appropriate meshing of teeth the pitch of both components has to be equated as Linear Pitch = Circular Pitch = 0.262 inches The teeth on the rack were cut using the column and knee type milling machine in thehorizontal arrangement. Involute cutter of 12 DP, 21-25 teeth was mounted on the arbor. Preparationof the rod Cutting Turning Flat surfacepreparation Shaping Teeth cutting Involutegear cuttingon millingmachine Assembly Internalthreadcutting Tapping

11 6.35

8 In this case in dexing was simply done by moving the table by 0.262 inches after ev ery toothwas marked or cut. A depth of cut of 0.166 inches was given by raising the table. Thus, a length of 6.3 inches resulting in 22 teeth for the above mentioned pitch was obtained.A S S E M B L Y The rack rod is connected to the ball-joint at the ends through a threaded joint. Ball-jointswere obtained from the old SAE BAJA 2009 vehicle part which had a Lotus Elise steering assembly. The ball-joint has an external threaded end which connects to the rack-rod.For this purpose, an internal thread had to be made on the ends. This was done by drilling,internal threading and tapping, in sequence. Appropriate measurements had to be takenbeforehand. Measurement: The minor diameter was measured with vernier callipers to be 10 mm .Pitch was measure with a metric thread gauge and found to be 1.25 mm. Referring to thefine-pitch, metric threads table 2 C A S I N G , we can obtain the specifications for design purpose (as discussed earlier). Drilling was done with the help of a 10 mm drill-bit mounted on tail-stock of lathe. Threading was done with a boring tool and automatic feed by engaging the split-nut of arbon with the lead screw on lathe.

Tapping was done with a tapping tool of requiredthread size mentioned above.This set of operations was performed on each side of the rack-rod. Thus, operations on thiscomponent were complete, and the rod was readied for assembly.Casing is the covering on the rack in which the rack moves to and fro when the steeringwheel is turned. It is also used as a carrier of the lubricant for the rack to move smoothly.MATERIALThe casing is generally a cast product. But due to limitations and difficulties in casting, a G.I. (Galvanised Iron) pipe of required dimension is used. Galvanized metal has a zinc coating on it to protect it from rust. Further, the inner diameter of the casing is critical as it shouldbe just larger than rack diameter with radial clearance given for lubrication. Pipe selection: The inner diameter of the casing should just enough to allow themovement of the rack inside itself. We can evaluate the ID of the required pipe as: Casing inner diameter = rack diameter +2* radial clearance = 22 + 2 x 1.7 = 25.4 mm = 1 2 Table 81, Pg. 398, Shigley, Mechanical Engineering Design

9 PROCEDURE Cutting to appropriate length: Calculation of appropriate length of pipe was critical andan interesting proble m. Consider 6.3 inches of teeth on the rack -rod section. Therequirement is that (as shown in figure below), the rack length should be completely exhausted when the last tooth on the corresponding side reaches the pinion. Thus,Casing length = rack-rod length rack length = 24 6.3 = 17.7 inches. Slot-making: A wide slot was to be made in the casing through which the pinion engageswith the rack. The width of the slot is determined by a minimum width equal to 0.5 inch,which is the thickness of pinion. Beyond this width, the depth the slot from the topbecomes critical for engagement of gear-teeth.Hence, end-milling was done after opening up the casing by drilling holes in its surface.End-milling was performed on the Column and Knee type milling machine , in the vertical milling arrangement . End-milling cutter was used and feed given was along bothX and Y coordinates, for obtaining a rectangular slot of 1 inch x 2 inch dimensions. Joining of Casing and Pinion Housing (Reducer): After the pinion-housing was completed (discussed below) in parallel, both parts we re welded together after exhaustiveedge-preparation by grinding. Engagement of Rack & Pinion: For proper engagement of the gear-teeth, generally aspring-lock system is provided just opposite to the pinion, however, since such a systemcould not be fabricated, two semi-circular sleeves were provided below the rack, to push it onto the pinion teeth. This pair of sleeves (on either side, on each end) were gas-weldedwith brass as filler material . Cutting toappropriatelength Power hack-saw

Slot making Drilling and EndmillingJoining withpinion housing Grinding Arc-weldingEngagement of gear-teeth Sleeve-making Gas-Welding 6.3

10 B E A R I N G A N D P I N I O N H O U S I N G The pinion is engaged on the rack inside a housing arrangement. This housing alsosupports a bearing behind the pinion. The pinion and bearing are mounted on a shaft ,which connects to the Universal cross joint . On the other side of this joint, is the steeringrod. The outer-case of the housing assembly was welded to the pipe-casing.MATERIALThe entire casing for engagement of rack and pinion is usually a cast product. However,considering the difficulty of casting, an alternate plan was considered wherein the pinioncasing would be substituted by a reducer (2.25:1.5) .Since, the smaller section of the reducer was 1.5

(38.1 mm) , a ball bearing of appropriateOD was to be selected. A Single-Row O2 Series deep groove ball bearing of bore 17 mm,width 12 mm and OD 40 mm. As mentioned, a shaft was required to be made for mounting the pinion and bearing. An MSrod of one inch thickness was taken from scrap.PROCEDURE Cutting & welding of reducer: The reducer was cut, by a hand hack-saw, on the broaderside to provide an opening for the pinion to engage with the rack. This cut reducer wasground in successive iterations for ensuring exact engagement of the rack and pinion andfinally welded above the slot in the casing-pipe. Turning of shaft: The one inch thick rod was turned to achieve a 17 mm thickness for tight fitting the bearing and 10 mm thickness, on the other side, for mounting of pinion. Modification of reducer Cutting withhand hack-sawEdge preparation Hand-grindingJoining of casing-pipe and reducer Arc-welding

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