INTRODUCTION

The idea behind making any product is to fulfill the requirements of society.

During year more than three months, we searched for idea, which would help in creation of

new product.

These days, we can see around us there are thousands of bikes running on

road. Bike is important in our daily life. Because using vehicle his time is reduced for

reaching are place to another. It is good for travelling but while travelling there can be

possibility of conveying luggage or any kind of load and also there can be chances of

unbalancing the luggage. What should be do when he has to carry some luggage. An

alternative for this he will choose like autorickshaw, rickshaw, bus or any other

conveyance. But he will doesn’t so on bike, because doesn’t provide luggage carrying

facility.

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 PRODUCT DESIGN AND DEVELOPMENT

Customer need

'NEED' the word which has given rise to inventions, discoveries, hand work

and also ideas from the day living organisms are known to exist. This is the thing that has

made living organisms adopt to changes for their own interests.

The same is the case with us. But thinking like some engineers of today's

era we took it in a broad sense calling it as customers need of which we also are a part. A

person never be a difficulty until and unless he himself is caught into it.

The need is of carrying load area two wheeler when a single person it

driving it. Moreover the attachment should be such that it should neither affect the balance

of the vehicle causing ballistic movements while driving, carrying maximum load neither

should be it a permanent fixture so that it might cause difficulty when two persons are

travelling.

Thus the design is such that the customer need is fulfilled to its peak point.

Luggage can be carried easily and then attachment can be shifted back to its normal

position.

Market Research

Recognizing the real of the customer are decided to continue our work in

that direction. Therefore use confirmed our project to design such a carrier which will

fulfill the needs of the customers. But as use all know the customer buys the product from

the market. Moreover the designer and the producers both are affiliated to the changes and

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the requirements in the market. It consists of two parts i.e. before introducing the product

in the market and after introducing the product in the market. The later is called marketing

and the previous is called market research.

After selecting 'carrier' as our project, use thought that - is this really a

customer's need? For this use decided to go for a research in the market, without satisfying

the customers need designer or manufacturer or whoever can never make a successful

product. Market research is the tool available to solve the problems of the manufacturer,

concerning the product. Especially market research is carried out regarding proposed new

product which the case with us.

Our idea was new but still confirmation was necessary whether already such

type of carrier exists in the market ! In that view we visited different showrooms of two

wheelers in our city as well as the cities near by. To our expectations there was none of a

carrier even a single percent similar to our idea.

Trouble in carrying loads, luggage.

The figure shows line represent of a bike chassis. A post consist of handle,

B- part main part of chassis where center of gravity of bike lies is the part where usually

load is carried. If load is placed on post and the bike is running fill the vibration of bike

due to road conditions case transferred to the end as front side is get pressure due to

handling action and B - Part on which a driver seats.

The vibrations at end are dangerous because, they can unbalance, the bike if

speed is more than average and load adds self properties of vibrating in any possible weak

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direction. And it is not advisable to carry loads through bags hooked at the handle that will

district the motion of handle.

And if the load is carried through one side post of rear post, that will not

give safe drive to others.

Compromise Design

Today’s market is a customers market, what customer demands is the

subject of concern of manufacturers due to vast competition in every field of product.

Before this decades the scenario was different. The manufacture used to

designed the product according to his own concept and way, the customer was not much

kept into mind while designing and manufacturing procedure. The reason for this is the

limited competition. Later the producer knew that whatever new thing they launch

customer has to except it by taking beside what the customers needs.

But today the picture is different. The traditional concept of marketing is

changed. Customers point of views is concern in abundant in designing and manufacturing.

Let us take the bike for example as customer feel there is a need for fuel indicator besides

the tank. Hero Honda and some of leading companies brought this concept in actual.

Similar is the case with side stand . It is dangerous when it is not off the position while

driving. The Company adds a sensor to its new model Eliminator.

There are the cases of customer marketing while adopting such policy. The

views of customers are collected through surveying or some special offers of suggest and

win type by taking actual demonstration of the product by replacement offers.

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 But the manufacturers have some limitation. They can not satisfy each an

every demand due to manufacturing limitation. Considering other processing aspect, cost

and its reliabilities. Then instead of dropping the idea the producer may find a mid way in

between both customers view and manufacturing aspect. The design prepared by such

compromise is called compromise design.

Up to some extent customer is satisfied and manufacturer are also satisfied

for what they produce, customers are accepting.

Versatility

Versatility is basically a quality of a taking to have different uses. Now is

this concerned with our project ? This was because if use designed the carrier for a single

bike then limited people would be benefited. On the second option was to have different

carriers for different models of bike. But this would neither suit the producers nor the

suppliers. So we decided to make the carrier versatile.

During the market research use had also taken measured of different bikes,

i.e. of their chassis, seat length, distance and of various possible points for damping

arrangements. For our relief we found that the basic structures of all the bikes were near

about similar with some fluctuations. But after some study we found that if use work

harder we can find out a common design out of it and use did it.

Our first preference was to the Honda CD-100 & SS bikes which are

usually used in the rural areas. But the carrier also suits other bikes and vehicles like the

Honda Splendor, KB-100, Hero-Puch Suzuki which are mostly used in to days market.

This confirmed the case to mass production and versatility of our project.

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 CARIER ELEMENTS, MATERIAL & PROCESSES

Clamps

Types of clamps

1. Lever or strap clamps

2. Screw clamp

3. Cam-action clamps

4. Hinge Clamps

5. Toggle action clamps

Toggle Clamps

These are fast acting clamps. These have the natural ability to move

completely free of the work allowing for faster insertion/taking out of parts. The holding

force of toggle clamps compared to the application force is very high Fig. shows the four

basic clamping actions, viz. hold down pull, squeeze, and straight line action.

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 Positive lock ensure below
centre

Pressure Pressure

When clamp retracted

centres move

Toggle Action

Toggle clamps operate on a system of levers and three pivot points. When

the clamp is locked, the pivots are nearly in line, the central pivot being slightly below the

center to insure positive lock. . When retracted, the pivots and levers are positioned as

shown in fig. These toggle clamps can be used in a variety of ways with the special

mounts, spindles, handles etc.

Rivets

A rivet is a short cylindrical bar with a head integral to it. The cylindrical

portion of the rivet is called shank or body and lower portion of shank is known as tail, as

shown in Fig. The rivets are used to make permanent fastening between the plates such as

in structural work, ship building, bridges, tanks and boiler shells. The riveted joints are

widely used for joining light metals.

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 The fastenings (i.e., joints) may be classified into the following two groups :

1. Permanent fastenings, and Head

2. Temporary or detachable fastenings. shank or

body
The permanent fastenings are those fastenings which
Tail
can not be disassembled without destroying the connecting

components. The examples of permanent fastenings in order of Rivet part

strength are soldered, razed, welding and riveted joints.

The temporary or detachable fastenings which can not be disassembled

without destroying the connecting components. The examples of permanent fastenings are

those fastenings which can be disassembled without destroying the connecting

components. The examples of temporary fastenings are screwed, keys, cotters, pins and

splined joints.

Methods of Riveting

The function of rivets in a joint is to make a connection that has strength

and' tightness.

The strength is necessary to prevent failure of the joint. The tightness is necessary in order

to contribute to strength and to prevent leakage as in a boiler or in a ship hull. When two

plates are to be fastened together by a rivet as shown in Fig., the holes in the plates are

punched and reamed or drilled. Punching is the cheapest method and is used for relatively

thin plates and in structural work. Since punching injures the material around the hole,

therefore drilling is used in most pressure-vessel work. In structural and pressure vessel

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riveting, the diameter of the rivet hole is usually 1.5 mm larger that the nominal diameter

of the rivet.

The plates are drilled together and then separated to remove any burrs or

chips so as to have a tight flush joint between the plates. A cold rivet or a red hot rivet is

introduced into the plates and the point (i.e., second head) is then formed. When a cold

rivet is used, the process is known as cold riveting and when a hot rivet is used, the process

is known as hot riveting. The cold riveting process is used for structural joints while hot

riveting is used to make leak proof joints.

The riveting may be done by hand or by a riveting machine. In

hand riveting, the rivet head is backed up by, a hammer or heavy bar and then the die or

set, as shown in fig. is placed against the end to be headed and the blows are applied by a

hammer. This causes the shank to expand thus filling the hole and the tail is converted into

a point as shown in fig. As the rivet cools, it tends to contract. The lateral contraction will

be slight, but there will be a longitudinal tension introduced tension introduced in the rivet

which holds the plate firmly together.

Point
Die
Tail

Original head
Backing up Bar

Initial Position Final Position

Methods of riveting

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Types of Rivet Heads

According to Indian standard specification, the rivets heads are classified

into the following types :

 Rivet heads for general purpose (below 12 mm diameter ) as shown in fig. according to

IS : 2115 – 1982.

Snap Head Pin Head Mushroom Head

Snap Head Pin Head Pan Head with Tapered neck

Types of Rivet Heads

Columns and Struts

A machine part subjected to an axial compressive force is called a strut. A

strut may be horizontal, inclined or even vertical. But a vertical strut is known as a column,

pillar or stanchion. The machine members that must be investigated for column action are

piston rods, valve push rods, connecting rod & screw jack, side links of toggle jack etc. In

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this chapter, we 'shall discuss the design of piston rods, valve push rods and connecting

rods.

Failure of a Column or Strut

It has been observed that when a column or a strut is subjected to a

compressive load and the loud is gradually increased, a stage will reach when the column

will be subjected to ultimate load. Beyond this, the column will fail by crushing and the

load will be known as crushing load.

It has been experienced, that when sometimes, a compression member does

not fail entirely by crushing, but also by bending i.e. buckling. This happens in the case of

long columns. It has also a been observed, that all the short columns fail due to their

crushing. But, if a long column is subjected to a compressive load, it is subjected to a

compressive stress. If the load is gradually increased, the column will reach a stage, when

it will start buckling. The load, at which, the column tends to have lateral displacement or

tends to buckle is called buckling load, critical load, or crippling load and the column is

said to have developed an elastic instability. The buckling takes place about the axis having

minimum radius of gyration or least moment of inertia.

It may be noted that for a long column, the value of buckling load will be

less than the crushing load. Moreover, the value of buckling load is low for long columns,

and relatively high for short columns.

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Types of End Conditions of Columns

In actual practice, there are a number of end conditions for columns. But we

shall study the Euler's column theory on the following four types of end conditions, which

are important from the subject point of view :

1. Both the ends hinged or pin jointed as shown in Fig.

2. Both the ends fixed as shown in fig.

3. One end is fixed and other is hinged as shown in fig.

4. One end is fixed and the other free as shown in fig.

P P P P

Types of end conditions of columns

Selection of Mild Steel for bike carrier purpose

For making structural frame of bike carrier low carbon or mild steel is

selected because of following desired objectives.

1. Availability is more

2. Cost is minimum

3. Physical properties and mechanical properties.

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 Density Meting Point Flow ability, bending & weldability

7850 Kg/m3 15100 6 electro plating properly

Material properties

Properties of mild steel :-

1. It can be magnetised permanently.

2. It can be readily forged and welded.

3. 0It can not be readily hardened and tempered.

4. It has fibrous structure.

5. It is malleable and ductile.

6. It is not easily attacked by salt water.

7. It is tougher and more elastic than wrought - iron.

8. It is used for all types of structural work.

9. It rusts easily and rapidly.

10. Its melting point is about 1400 0C.

Processes

Bending

Bending is the cold working process involving plastic deformation in which

the total surface area remains constant. Bending of pipe, tube, rolled or extruded shapes

involves practices and theories of the simple supported beams, the cantilever beam and

many of the problems of forming and deep drawing. In bending flow of metal occurs in

plastic range, and there is a permanent change in shape. Thinning of outer wall of a bent

tube or other hollow section and corresponding thickening of the inner wall of the bend arc

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noticeable effects of plastic flow. The neutral axis also gets displaced. When bending thin

walled tubes, the material has a tendency to buckle and wrinkle which can be avoided by

supporting the material by a shoe which is located opposite to the direction of die pressure.

It is observed that bent material tends to recover elastically when the deforming force is

removed. This spring-back can be overcome by ending the metal a few degrees more than

the desired angle or by setting the punch travel so that it compresses the bent metal beyond

its yield stress (this operation being known as polishing). In sheet metal work

bending is sometimes called forming also. In this case, a plastic deformation of metal

takes place and the metallic sheet is stressed in both tension and compression. The bottom-

most layer is under tension and topmost layer under compression, when the punch is forced

over the sheet. The metal must be bent at right angles to its fiber. The sheet is more liable

to fail along the direction of fibers, i.e. along the length of impurities, than across them.

Hand brake and press brake dies are most commonly used for bending operations.

Ram

Wing dies

Die-bending Press bending Folding

In addition to the above two dies forming dies of different designs are also

used for various forming operations. Forming is also similar to bending operation with the

difference that a number of bends are formed about the linear axis by making the metal

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confine to die shape. Operation of-bending can be done on ram-type machine or rotary

type machine. The ram bending machine follows the principle of simple supported beam

closely. In this machine two pressure dies are mounted in fixed positions on the frame of

the machine, and are free to rotate about their own mounting pins, while the form is

mounted directly to the piston rod of the hydraulic cylinder.

Welding

Shielded Metal Arc Welding (SMAW). It is a manual arc welding using

coated electrodes. Since the electrode melts and joints the weld pool, it is classed under

consumable arc welding method. The coaling on the electrode burns along with metal of

electrode and produces a dense smoke which covers or shields the weld pool, preventing

oxidation and absorption of nitrogen by the metal. The electrode coating after melting

forms a slag cover over the molten pool. This process is very versatile and flexible and can

be used in difficult places.

SMAW can be performed both on AC and DC source with drooping

characteristic, highest current rating being about 600 amperes. Selection of proper

electrode is essential for best results. A rough guide is given in Fig about the size of

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electrode and cur- rent For different thickness of plates to be welded. However it is

advisable to consult recommendations of electrode supplier. In DC welding, arc starting is

easy and the arc is steady and smooth. Straight polarity (electrode - ve) is used for welding

thin sheets and for plates with wide gaps. Reverse polarity (electrode +ve) produces

maximum penetration and is used for root passes and out-of-position welding. Due to high

voltage drop in cables, cable length should be short.

AC arc welding requires more skill on the part of operator. It is difficult to

start. Less drop in cable, less arc blow are suited for thicker plates. Shielded Metal Arc

Welding (SMAW) Electrode:

Mild steel electrodes are classified as

(i) fast freeze,

(ii) fast fill

(iii) fill freeze, and

(iv) low-hydrogen-types.

Fast freeze electrodes arc cellulose coating electrodes. Due to their fast

freezing action, puddle solidifies rapidly after being deposited from the electrode. Their

shielding atmosphere is rich in hydrogen and thus they produce intense heat and deep

biting action. It is well suited for maintenance work because these burn through rust,

grease, or used steel. These are also well suited for out-of-position welding due to their

excellent puddle control an rapid solidification. These electrodes call for whipping motion

(whip-and-pause technique) for good results. Fast-till electrodes contain iron powder in

the flux coating which helps create the high deposition rate. Because of their highly fluid

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puddle, these are used for flat and horizontal positions only. Fill-freeze electrodes have the

characteristics of both fast-fill and fast-freeze electrodes. They solidify faster than fast-fill

class and they have higher deposition rates than fast-freeze class. Precautions in arc

welding. Because of the intensity of heat and light rays from the electric arc, the operators

hands, face, and eyes are to be protected, while the arc is in use. Heavy gloves are worn,

and a hand shield or a helmet with the window of coloured glass should be used to protect

the face and eyes from the glaring effect of the arc-rays. Also the space for the electric arc

welding should be screened off from the rest of the building to safe guard other workmen

from the glare of arc.

Precautions to be Observed in Arc Welding. Arc welder should be clear of

the hazards likely to occur from are welding and should take all precautions to avoid them.

These hazards are radiation (ultraviolet and infrared rays) from the arc, flying sparks,

globules of molten metal, electric shock, fumes, burns, etc. One should never look at arc

till eyes are protected with welders helmet or face shields with approved lenses. Face,

hands, arms and other skin surfaces must be covered by wearing gloves and clothing of

sufficient weight to shut off the rays from the arc. Flammable materials like matches,

celluloid combs, fountain pens etc. should be removed from pockets. Floor should be dry

and electrode holder insulated. Proper ventilation equipment should be used. Fuses of

right capacity should be fitted in the main switch and ampere adjustment should be set to

minimum. Correct size electrodes should be selected.

Before starting arc, the machines should be; carefully inspected, cleaned

and oiled. All connections should be tight. Electrode holder and ground electrode cables

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should be inspected and electrode holder hung on a wood or fiber hanger away from the

work to be welded. Brushes should not arc heavily incase of motor generator unit. The

machine should never be started with the electrode holder on a table or base metal, since

this closes the arc welding circuit and causes arc welder to start under a full load, which is

hard on most machines. The machine should be adjusted for proper current setting

depending on base metal and electrode sire, by switching off main power supply. After

running a few beads, it may be necessary to make fine adjustment to obtain more perfect

weld.

Resistance Welding

For manufacturing this design we use manual metal arc welding process.

But for mass production the resistance welding process is available. Outline of resistance

welding is given below.

Resistance welding is a group

of welding processes wherein coalescence is

produced by the heat obtained from resistance

of the work to the flow of electric current in a

circuit of which the work is a part and by the

applications of pressure. No Filler metal is needed.

The two factors or variables mainly responsible for resistance arc welding.

1. The generation of Heat at the place where two pieces are to be joined.

2. The application of pressure at the place where a weld joint is to be formed.

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Advantages of resistance welding

1. Fast rate of production.

2. No filler rod is needed

3. Less skilled workers can do the job can be welded.

4. High reliabilty & producibility are obtained.

5. More general dimination of warping or distortion of parts.

Drilling

Drilling is a process of making hole or enlarging a hole in an object by

forcing a relating tool called drill.

Drilling machine is one of the simples moderate and accurate machine tool

used in production shop and tool room.

Troubles in drilling and their remedial measures.

The various trouble experienced in drilling operation and their remedial

measures are given below.

i) Rough hole :

ii) Oversize hole :

iii) Breaking of drill :

iv) Chipped cutting lips :

Precautions in Drilling operations

i) Machine tool must be rigid enough otherwise parts may be deformed by the cutting

forces given rated. Drill feeding arrangement must be directionally stable.

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ii) Accurately ground drill should be used so that uniform chips are produced by both

cutting edges; otherwise the unbalanced forces may deflect the tool during

machining.

iii) Axis of spindle, adapter and tool must coincide, otherwise errors and in accuracies

as described below may occur.

iv) Work piece must be held very rigidly.

Grinding

To grind means 'to abrade' to wear away by 'friction' or 'to sharper'.

i) Grinding is the operation of removing metal in the form of minute chips by feeding

the work against a rotating abrasive wheel known as the grinding wheel. Both

internal and external surface of a work piece may be ground by using a special

attachment mounted on the cross slide.

Grinding Faults : Two common faults due to incorrect choice of wheel or incorrect

grinding condition are :

i) loading & ii) glazing.

Loading occurs when spaces between the abrasive grains become clogged

with particles of the metal being ground. Glazing is easily recognised by shiny appearance

on the face of the wheel. It occurs due to abrasive grains becoming dull and not breaking

away from the bond.

Surface finishing process :

In a manufacturing plant, a product may be shaped, turned, milled or drilled

and lift in that condition as being satisfactory for use. But nowadays greater attention is

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paid towards the appearance of the product. This is because the performance of the product

will be judged only when it is selected, thus appearance stands first in the process of

selection of the product by the customer. So if better finish is desired for looks, for

accuracy, for wearing qualities or for any other reasons different microfinishing operations

may be employed.

The one which we selected was →

Electroplating

Electroplating or electropolishing is the process by which the coating metal

is deposited on the base metal by passing a direct current through an electrolytic solution

containing the soluble salt and the coating metal. The base metal to be plated is made the

cathode and the electrolytic cell ; whereas the anode is either the coating metal itself or an

inert material of good electrical conductor (like graphite). During electrolysis electrons are

introduced from an external source. Thus, in principle, electroplating the reverse of

corrosion i.e., in electroplating metal is deposited from solution; while in corrosion metal

is dissolved in solution. Corrosion always occurs at the anode and electroplating always

occurs at the cathode.

Plating occurs at cathode Electroplating of Cr. electrons

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 The properties of the electroplate coating depends on: (i) the deposition of

the plating solution, (ii) current density, (iii) agitation, (iv) the temperature of the

electrolytic bath ; and (v) pH of bath. Moreover, the protective value of the electroplate

coating depends on its uniformity and porosity. Coating usually contains small visible

pores, pinholes, etc. unless excessively thick coatings are applied.

Electroplating is probably the most frequently applied method protective

coating of metals. The electroplating metals most frequently used are zinc, nickel,

chromium, tin, and copper. Cadmium, lead and precious metals (like Ag, Au, Rhodium, Pt

and Pd) are platted to somewhat smallest extent. Recently certain alloys (such as lead- tin,

tin-copper, tin-zinc and tin-nickel) have been used increasingly in electroplating.

Nickel plating on iron are applied mostly. Being catholic to iron, nickel

coating must be of sufficient thickness ; otherwise corrosion at the coating pores and

pinhole will occur, thereby making the surfaces rusty.

Nickel coatings, apart from their good corrosion resistance. Shows

relatively hard wear resistance surfaces which makes them useful in building up and

surfacing worn and mismachined parts.

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 MANUFACTURING PROCESS SEQUENCE
The sequential stepwise program like method of preparing finished job

before going out to the market is given here.

In this following processes are involved.

1) Cutting 2) Bending 3) Drilling 4) Welding 5) Electroplating

First of all we cut the 90 mm bar of mild steel for making the main frame of

carrier using cutter also the limbs of the frame are made up to the dimension by cutting.

Then hammering is done at the ends of the limbs. Then slight bend of procedure is done for

2nd limb also. Then for clamping of limb with the rod of bike the clamp is prepared by

using bending and drilling and then a nut of drill size is used at the drill hole of clamp

from inner side.

Next process is for the preparation of the clamps used for rotating motion of

the main frame. For this bush of 10 mm inner diameter is prepared by drilling on lathe the

rod of 16 mm diameter. Also clamp is prepared which we already prepared for limbs. Then

bush is welded to the clamps and then the final clamp is prepared.

The clamp which is used for holding the carrier at the backside while it is in

unused condition is prepared by drilling.

Nextly the final weld is made. Here we used manual metal arc welding.

(MMAW).

After this job is prepared for surface finishing process. Electroplating is

done after cleaning the whole job.

Above is the sequence of the job preparation.

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 DESIGN ANALYSIS

Design of Rivet

Thickness of plate = 4 mm

Load or pull = 50 kg = 490.5 N

Area A=π/4 d2 (since d – required diameter of rivet)

Maximum permissible shear stress for rivet = 86 N/mm2 (From design data book)

We have P = Fs × A

4905 = 86 × π/4 d2

∴d2 = 7.26 ∴d = 2.69

Taking the stand diameter d = 4

Failure

For Lap joint considering failure due to shearing as shown in figure.

–4 – 4 mm

Shear stress induced Fs1 = P/A

490
= π ×d 2
4

Fs1 = 39 N/mm2

Shear stress induced is less than maximum permissible shear stress i.e.

Fs1 < Fs

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∴ Design of rivet is safe.

Design of Bolt :

Major Diameter of bolt do = 16 mm

Stress Area of bolt As = 20.1 mm2 (from data book)

Permissible shear stress Fs = 20 N/mm2 (from data book)

Load acting = 50 Kg = 490.5 N

Shear stress induced ,

P
Fs1 = (2 is due to double shear)
2 × As

4905
Fs1 =
2 × 20.1

Fs1 = 12.20 N/mm2

Fs1 < Fs

As shear stress induced in bolt is less than permissible value, the design is safe.

As length of bolt is small there is no changes of bending failure.

Design of column support

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 As length of strut is 60 mm which is less than 8 times the diameter 8 mm. The strut

is treated as short column.

Hence, there is no chances of backing or coupling.

Failure will be due to crushing.

Cross section of column

8 mm

160mm
8mm

b = h = 8 mm.

Crushing stress for steel σc = 320 N/mm2 (From Design data book)

Load on column W = 490.5 N

∴Cross section require is calculated as below.

σc = W/A

A = W/σc = W/σc

A = 490.5/320 A = 1.532

∴ b2 = 1.532 ∴ b = 1.23 mm

But the standard size available are 6 mm & 8 mm.

∴ For safety purpose, we select

b = 8.

Failure due to crushing

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∴ Crushing stress induced,

σc1 = W/A = 490.5/ 64 = 7.66 N/mm2

As σc1 << σc

Crushing stress induced is much less than maximum permissible hence design is safe.

Design of carrier frame

For Analysis purpose the carrier frame. It is supported to be simply

supported beam with uniformly distributed load as show in fig.

W = wl

B B

M1 M2

W = 490.5 l = 260 mm w = 1.88 N/mm

Max. permissible bending stress for msσ max. = 100 N/mm2

Reactions & A & B

RA = RB = 245.25 N

Moment of inertia I = πd4/ 64

Max. Bending Moment MMAX = 1/24 W .l at x = l/2 = 1/24 490.5 × 260

MMAX = 5.313 × 105 mm2

Z = I/y × πd3/ 32 = z

Y = d/2

The bending stress is given by

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σmax = M/I × y

5.313 × 10 3 d
×
100 = πd 4 2
64

5.313 ×10 3 × 64
d3 =
π × 2 ×100

d3 = 541.24

∴d = 8.149 mm

∴ We take standard dimension d = 10 mm

Failure

Bending failure.

We know that

Bending moment is in the frame.

σ1 = M/I × y

5.313 × 10 3 10
×
π(10)
4
= 2
64

σ1 = 54.11 N/mm2

as σmax > σi

∴ Design of frame is same.

Failure of frame rod in bush.

Shear area A = 2 × π/4 d2 = π/2 × 102

A = 157 mm2 (since 2 is due to double shear )

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In bush the frame rod may get failed due to shearing at shown in fig.

Allowable shear stress for mild steel

Fs = 50 N/mm2

Applied load is P = 490.5 N (50kg)

Shear stress induced

Fs1 = P/A

Fs1 = 490.5 / 157

Fs1 = 3.12 N/mm2

Induced shear stress is much less than maximum permissible shear stress i.e.

Fs1 << Fs The design is safe.

Failure of rod in tensile loading considering bush as a short cylindrical shell.

t
P d = 16

l = 22

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P = Pressure / load intensity.

F F
=
P = A π(10) 2
4

490.5
=
78.5

P = 6.24 N/mm2

l = length of Bush t = 22 mm.

t = thickness of Bush t = 3mm

σ t = Hoop stress or circumferential stress.

σ t = 42 MPa = 42 N/mm2

The hoop stress induced in bush.

P×d
σti =
2t

6.24 × 10
=
2×3

σti = 10.4 N/mm2 As induced tensile area is much i.e.

σ ti < σ t ∴ The design is safe.

Failure of welding join of Bush & clamp

t = throat thickness.

s = leg length of weld = 3 mm (Standard from data book)

l = length of weld

σ t = permissible tensile stress = 55 N/mm2 (From data book)

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t = 5 × sin45 = 2.8 mm

The failure will occur due to tensile loading & shear loading.

t = 2.12
C S = 3mm
S=3 45 t = 2.12mm
16
A B

Minimum Area of weld,

A=t×l A = 2.12 × 16 A = 33.92

Tensile stress induced in welded joints

P 490.5
σ1= =
A 33.92

σ1 = 14.46 N/mm2

Induce tensile stress is less than the maximum tensile stress i.e.

σ1 < σ ∴ design is safe.

Dynamic Design factor

When the bike is loaded with luggage on carrier the weight is supposed to

be increased by 1.5 times than the actual.

∴ Maximum dynamic load capacity of carrier will become 735.75 N (75 kg).

For which all designing factors are safe.

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 φ21, 2mm thick
R15 2 in Nos.

φ10 22
φ16

Sq.bar
8mm

FV
30 φ6, 3Nos. 4 thick
SV

15 24
60 sq. bar 8

45

280 Bar φ10

TV
306
DRAWING ASSEMBLY
1. Bush (2) 3. Clamp 4. Nut
Bolt
φ16 2

φ16
φ6

φ10 21

2. Clamp (2) 5. Rivet 6.

Clamp
φ 21 φ10

φ6

45
φ6
45
ASSEMBLY ELEMENTS
 TESTS
The multipurpose carrier is expected to possess certain service - related

capabilities. These carriers are generally required to carry loadings of various types in

which the carrier subjected to stress of either a simple or complex character.

It is therefore necessary to find out how satisfactory the carrier is. For this

purpose certain tests had to be carried out to estimate the expected performance of the

carriers.

Carrier Testing :

Testing, specifically refers to the physical performance of operations to

determine qualitative measure of certain properties. It aims to determine quality, i.e. to

discover facts regardless of the implications of the results.

The different tests which were carried out can be put under 2 leadings.

1) Different types of load

2) Different road conditions

The different types of loads on the carrier for which the tests were carried

out are - ( all weighted upto 120 kg.

a) Unit load

b) Sack load

c) Gas cylinders

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 The different road conditions were

a) National highway

b) Rural areas

c) Hilly roads

The tests were carried out with all possible combinations of the above

mentioned heads. This was necessary because use want this useful advanced carrier to be

useful to people living in any part. It should work satisfactorily in all conditions.

After the successful design of the carries these tests added pleasure to us

due to satisfactory performance under various conditions. The carrier performed superbly

on highways. Its performance in rural roads and hilly roads was equally good. There

were no dilutions during the ride, no deformations, no bends in carrier during or after the

ride. I did not create any type of in balance during the course of its performer. Moreover it

did not disturb any part of the vehicle neither its mileage - overall the results were just

which are expected and wanted.

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 PROPOSED DESIGNS
The various designs are considered while selecting they are

1) Folding type which will otherwise used as a saree guard.

2) An insertion type which will be then brought down in the space between rare end &

steel frame of rod.

In use
condition F.V

F.V.
As a saree guard
T.V.

T.V.
Folding type In use condition Non use condition

But considering the factors of rigidity & simplicity we come to a final

design that has been worked out.

These designs are very new & complex to design. No. change is suggested

regarding to all four designs in company model.

A four bar chain design

This is an most suitable design but the length height of carrier will disturb

its flexibility & versatility.

In used condition In unused condition

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 COST ESTIMATION
Material cost 100.00

Labour cost 150.00

Electroplating cost 100.00

350.00

This not includes the accessorial cost & travelling allowances & other

expenditure.

The cost given is marketing oriented.

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 CONCLUSION

Carrying load on the new era bikes is a common problem for any owner. To

days bikes have accessories for the purpose but they affect the balance of the vehicles

while carrying any type of loads.

The objective of our project was to provide a rigid and safe platforms for

carrying various loads without change in any standard design the bikes. Moreover it

should be economical for every clay of society. Find it has been attained successfully.

As from the complete report is fulfills the customer needs and provides

versatility. Moreover as it is a new product it will promote employment and vast field for

development for new engineers in to days period of industrial recession.

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 REFERENCES
1. Machine design – R.S. Khurmi.

2. Production Technology – P.C.Sharma.

3. Mechanical Engineering – Jeorge Dietel

4. www.howstuffworks.com

5. Applied chemistry – Jain and Jain

6. Manufacturing data book – Madhavan.

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