DESIGN AND FABRICATION OF MULTI SPINDLE VARIABLE DISTANCE

NUT RUNNER

A PROJECT REPORT

Submitted by

V.MALOLA KRISHNAN

S.KUMARA GURU

MOHAMMED JIBRAN

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

EASWARI ENGINEERING COLLEGE,RAMAPURAM

ANNA UNIVERSITY:CHENNAI 600025

APRIL 2021

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 ANNA UNIVERSITY: CHENNAI 600089

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF MULTI

SPINDL VARIABLE DISTANCE NUT RUNNER” is the bonafide work of
“V.MALOLA KRISHNAN (310618114058), S.KUMARA GURU
(310618114055), MOHAMMED JIBRAN (310618114066)” who carried out the
project under my supervision.

HEAD OF THE DEPARTMENT SUPERVISOR

Dr. M. VETRIVEL SEZHIAN, Ph.D., Dr .S. Prasanna Raj Yadav

Professor & Head Associate Professor

Mechanical Engineering Mechanical Engineering

Easwari Engineering College Easwari Engineering College

Ramapuram, Ramapuram,

Chennai 600089 Chennai 600089

Submitted for the project and viva examination held on……………………

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLDGEMENT

We express our sincere thanks to our beloved principal Dr. R. S. Kumar, who has
given the opportunity to carry out the project work and completing the same.

We express our sincere and kind gratitude to Dr. M. VETRIVEL SEZHIAN, Ph.D.,
Head of the department of Mechanical Engineering for his kind permission to carry
out this project work. And are also much obliged to our guide for his excellent
guidance that inspired us t the very height of sincerity leading us to this goal.

We also express our sincere thanks to all others who have helped us to complete this
project a grand success and our special thanks to teaching and non-teaching staff
members of the department and our friends for the kind help in this project

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 ABSTRACT

The growth of Indian manufacturing sector depends largely on its productivity &
quality. Productivity depends upon many factors, one of the major factors being
manufacturing efficiency with which the operation /activities are carried out in the
organization. Productivity can be improved by reducing the total machining time,
combining the operations etc. In case of mass production where variety of jobs is less
and quantity to be produced is huge, it is very essential to produce the job at a faster
rate. This is not possible if we carry out the production by using general purpose
machines. The best way to improve the production rate (productivity) along with
quality is by use of special purpose machine. Usefulness and performance of the
existing radial Multi-spindle nut runner will be increased by designing and
manufacturing of Multi-spindle variable distance nut runner. This paper deals with
design and development of Multi-spindle variable distance nut runner using flexible
shafts for improved performance.

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 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

ABSTRACT 4

TABLE OF CONTENTS 5

LIST OF FIGURES 6

LIST OF TABLES 7

1 INTRODUCTION 8

2 LITERATURE REVIEW 11

3 PROBLEM IDENTIFICATION 14

4 METHODOLOGY 15

5 MULTI SPINLDE VARIABLE 16

DISTANCE NUT RUNNER

5.1 Major Component Used

5.1.1 Gear Arrangement

5.1.2 Ball Bearings

5.1.3 Frame

5.1.4 Flexible Shaft

6 WORKING PRINCIPLE 19

7 DESIGN AND CALCULATIONS 20

8 WEIGHT ESTIMATION 25

9 COST ANALYSIS 26

10 CONCLUSION 27

11 REFERENCES 28

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 LIST OF FIGURES

Fig 1.1 Swift dezire tyre

Fig 1.2 Spur Gear

Fig 1.3 Ball Bearings

Fig 1.4 Flexible Shafts

Fig 1.5 3D Model of MSVDNR

Fig 1.6 2D Model of MSVDNR

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 LIST OF TABLES

Table 2.1 WEIGHT ESTIMATION

Table 2.2 COST ESTIMATION

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 CHAPTER 1

INTRODUCTION

Vehicle is an important machine in human daily life. Nowadays, each family has at
least one car to make the transportation easier and faster. For a car, the tool set-up for
each vehicle is a T-nut wrench and car jacker which is hard to use for a women or
teen to open their car’s nut. One of the problems of a vehicle is tire problem. If the
vehicle tires have some problem then the user must remove the tires and fix the
problem. And for a car user, it’s difficult to remove tire’s nut especially for women
users. The disadvantages are waste of time and force needed. In India and other
countries automotive market there is no tool that is easy to use to remove the nuts.
The time to open a car’s tire nut is too long and the car user’s time is wasted with
utilization of high force and especially this is big hurdle for women users. To
overcome the waste of time and high force needed, a tool have been designed to
remove four nuts of a tire in single time with decremented applied force.CAR is not a
symbol of luxury anymore. It is a need for every family. People need car due to
several reasons. Some of them are, to go to a destination, to travel conveniently, to do
daily job and to move things to a greater distance. The problem occurs the most
during car operation is the problem with tire puncture. The punctured tire needed to
be replaced with spare tire. Therefore, drivers need to know basic knowledge of tire
replacement procedure if such problem occurs. In order to change the tire, one
requires minimal skills. Virtually every car has a tire replacement tools such as the L-
shaped nut remover and jack supplied by the manufacturer accurate tensioning of a
screw is necessary. It has moreover been found that, at the high speeds used, ratchet
couplings also apply a powerful shock action and are therefore likewise unsuitable for
tightening expansion screws.

Today’s world is of fast and rapid process. Everybody wants to save time and effort
by inventing some newer technique or mechanism and implanting them in the daily
life. Car is not a symbol of luxurious anymore. It is need for every family. People
need car due several reasons. Some of them are, to get to a destination, to travel
conveniently, to do daily job and to move things to a greater distance. The problem
occurs the most during car operation is problem with tyre failure. To overcome the
above problem, we design vehicle all wheel nut removing tool. The main objective of
this project is to atomize the labor work in tightening or loading the nuts one by one.
This project focuses on the minimization of human effort and time consumed for
fixing all four nuts of the four wheeler tire with a single stroke of lever by using
multiple operated spanners. This is achieved by developing a planetary gear
mechanism as such occurs which reduced the time and effort for the above mentioned
task that is losing or tighten the nut of the car wheel.

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If we consider a four wheeler removing and replacing the car wheel is a very frequent
job performed by the worker. Normally each of the four nuts is removed individually
by simultaneously applying the spanner. But with the help of the mechanism
developed we can loosen or tight all four nut at a time and at the single stroke. To
avoid time wasting and a lot of energy used to change the tyre, a special tool is
designed and fabricated to allow driver or machine to remove four nuts of wheel at
once with less energy consumption. The design is based on standard PCD of 100mm
for most of cars available. For this project, the 100 PCD cars has been the guide. This
chapter will give all the information on 100 PCD and all part that will be used in this
project. In this chapter, type of tire nuts car, the nut removal steps, type tools needed,
basic gear theory, spur gear terminology, standard gear calculation, standard spur gear
tooth, the project calculation, and material specification will be analyzed and shown.
This information has been collected from books, journals, company’s websites, and
market survey.

In India there are many of cars with nut such as 3 nuts, 4 nuts, 5 nuts and 6 nuts. We
have chosen 100mm PCD having 4 nuts, many of the cars in India with that pitch
size. For the tester, we have chosen Maruti Suzuki swift esire where there are 4 bolts
with 100 PCD. Figure shows the sample of Maruti Suzuki swift esire Wheel.

Fig.1.1 Swift esire tyre

For removing or changing the car tire, some steps must to be done. The steps must be
followed by the procedure to keep the changing process inline. All the steps and the
procedure have been studied and listed out.
There are some steps for removing tire nuts and change the car tyre. Below are the
methods of change the car tire.
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1. Tools selection (locate tyre spare, jack and tire nut removal)
2. Lug the nuts (loose up the nuts before jack the car up)
3. Jack the car (locate the jacking point to body car to lift the car)
4. Remove the tire (removes the nuts and changes the tyre)
5. Get new tire (get the new tire and replace the old tyre)
6. Jack the car (let the car down off jack and tighten the nuts)

Instead of using above method for wheel removal we can used multi nut removing
tool. A special tool is designed and fabricated to allow driver to remove four nuts of
wheel at once with less energy consumption.
It works on the principle wheel is a very frequent job performed by the worker.
Normally each of the four nuts is losing or tightens individually by simultaneously
applying the spanner. Either with the help of mechanism developed that one can
loosen or tight all four nuts at a time and at the single stroke of the hand operated or
motor operated lever. This is done by adjusting the five gears between two side plates
operated only by lever or input pinion shaft.

OBJECTIVE:

The objective is to design and fabricate the wheel nut runner for 100mm PCD with
the following properties,

1. To make the wheel nut removal tool lighter.

2. To use less expensive materials.
3. To reduce the production cost.
4. To apply the less human effort.
5. To make the multi spindle nut runner applicable for variable distanced nuts.

CHAPTER 2
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 LITERATURE REVIEW
Known torque-responsive power screw drivers which are driven by electric motors or
pneumatically have a relatively high speed of rotation in order to obtain a short
screwing in time. Since the maximum moment of tension for the screw to be screwed
requires a determined torque, the driving power of the screw driver must likewise be
made high in accordance with the relatively high speed of rotation, although a high
torque is required for only a short time during the tightening of the screw, unless
some shock action is utilized for the purpose of producing this peak degree. The
limitation of the degree of tightening of the screw is usually effected by means of
ratchet couplings or striking mechanism. When screwing in expansion screws, this
degree of tightening must be kept constant within very narrow, since these screws, are
stressed almost to their yield point during screwing in. Torque-responsive screwing
drivers having a shock effects are useless for this purpose[5-10]. The degree of
tightening achieved is greatly dependent on the number of blows applied, which
however cannot be kept constant because of the rapid succession of blows, while in
addition the power of the individual blow is variable within wide limits because of the
indeterminable reaction of work piece, screw and screwing tool on the striking
operation. In addition, the shock effect causes rapid wear on the striking surface,
which results in a considerable variation of the face of the blows and a relatively short
life of the Torque-responsive screwdrivers having striking mechanisms are
impractical where accurate tensioning of a screw is necessary. It has moreover been
found that, at the high speeds used, ratchet couplings also apply a powerful shock
action and are therefore likewise unsuitable for tightening expansion screws.

[1] Ahmad Farudzi Bin Azib

Changing a large truck wheel is more difficult than changing out a car wheel due to
the size and weight of the wheel. For changing the wheel require loosening and
remove the lug nut. Therefore, to loosen the lug nut with lug wrench or wheel wrench
requires more than manpower and takes a long time. Hence necessity hydraulic
extension lug wrench for reduce the problems encountered for the loosening lug nut
in commonly with lug wrench. Usually force and torque require

for loosening and tightening the nut and screw. For lug nut many wrench can doing
the loosening and tightening using man power to produce the force or power tool be
related fluid power. Fluid power as air and fluid or electrical energy to produce torque
energy. Lug wrench or a socket wrench used to turn lug nuts on automobile wheels.
For lug wrench or wheel wrench heavy vehicle different light vehicle as strength,
material and size socket. Furthermore the lug nut for heavy vehicle extremely built
tough because “torque value” (torque is the twisting force applied to a threaded
component such a bolt or nut) for lug nut around 450Nm to 600Nm. Generally,
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human power cannot produce against the torque value lug nut heavy vehicle.
Excluding lug wrench connection with long hollow pipe and more than one human
power. These process harm or weary to human and taken a time. Rotary wrench
designed with its own internal gear. Purpose of this tool is to do the work loosen the
nuts by turning the crank tool. The gear is easy to failure and using human power. A
spindle rotate given the force and external gear produce more torque to rotating the
socket wrench or nut. The spurs gear built in rotary wrench own ratio for more force
and torque. Furthermore the rotary wrench own debility because require man power
to rotate spindle. The pneumatic torque wrench is sometimes confused with a
standard impact wrench, because it looks similar, but is actually a totally different
tool. A pneumatic torque wrench is driven by continuous gearing, and not by the
Hammers of an impacting wrench. This is why a pneumatic torque wrench has very
little vibration, and excellent repeatability and accuracy. Torque capabilities of
pneumatic torque wrenches range from 118Nm, up to a maximum of
47,600Nm.Using pneumatic torque wrench is a limited power in the workshop alone
in doing work to loosen and tighten the nut. Air compression for this operation is on
10 Bar and built in jack hammer. Require two stage air compression for operation
because air compression for pneumatic require high air pressure The pneumatic
torque wrench cannot use for breakdown case because require air compressed as
power source.

[2] Nitesh L. Gomase, Pankaj R. Chawhan

This project aims to design and fabrication of four wheeler multiple-opening spanner
for tightening and removing of the four nuts in a single stroke of a hand operated
lever. Nowadays everybody wants to save time and effort by inventing some newer
technique or mechanism and implement them in the daily life. We have developed a
gear planetary mechanism to reduce the time and effort for the above mentioned task.
In our project we have tried to focus on the minimization of human effort and time
consumed for fixing all four nuts of the ø100mm PCD tire with a single stroke of
lever. If we consider a four wheeler removing and replacing the car wheel is a very
frequent job performed by the worker. Normally each of the four nuts is removed or
tightened individually by simultaneously applying the spanner/lever. But with the
help of the mechanism developed we can loosen or tight all four nut at a time and at
the single stroke of the motor operated lever. The multi nut remover is used to remove
multiple nuts in a single use. These are commonly used to remove the wheel nuts and
hence the mechanical effort required for removing the wheel is very less.

12
Working principle
Works on the principle wheel is a very frequent job performed by the worker.
Normally each of the four nuts is losing/tighten individually by simultaneously
applying the spanner/lever. Either with the help of mechanism developed that one can
loosen or tight all four nuts at a time and at the single stroke of the hand operated or
motor operated lever. This is done by adjusting the five gears between two side plates
operated only by lever or input pinion shaft.

CHAPTER 3
PROBLEM IDENTIFICATION
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The concept of improving time efficient products from time to time is the forerunner
of technological advancements in the field of engineering. This project is undertaken
after considering such parameters and focused on improving the scope of time
efficiency and improved usability of a temporary joint fixation.

FIXED MULTI NUT RUNNER VARIABLE MULTI NUT RUNNER

1. Time efficient only for one type of 1.Time efficient for all types of nuts
nut arrangement 2. Requires little to no skill to mount
2. Requires skill to mount on nut 3. Multiple applications
3. Limited application 4. Can be used as a drill bit also
4. Can be used for nut running only

The current trends of technology development is more focused on the time

management of existing devices- the introduction of automated milling and drilling
system to do the same work as done by a human in small amount of time and with
higher accuracy. Adhering to current trends in mechanical engineering we have our
project focused on improving the efficiency of the existing models and also reducing
the amount of skill required to handle such devices.

A survey taken in India suggests that the number of people using a typical spanner to
remove a tyre in a car rates the work involved as a tedious process and would suggest
improving the existing nut runners as to reduce the work rate involved in doing the
same job. Women users generally find the former technology impossible to use as the
torque required to remove such nuts are very high.

This project focuses on such problems and work on decreasing the further scope in
the same field.

CHAPTER 4

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 METHODOLOGY

CONSTRUCTION:

1. Finding the most common Pitch Circle Diameter for wheels and for that pitch
circle find the current running cars name.
2. The design calculation for vehicle all wheel nut removing tool with chosen
pitch circle diameter.
3. Designing the vehicle all wheel nut removing tool for the above chosen pitch
circle diameter.
4. Material selection on basis of design and calculation.
5. Analysis vehicle all wheel nut removing tool by design calculations.
6. Fabrication of vehicle all wheel nut removing tool.
7. Testing of vehicle nut removing tool.
8. Results, discussion and conclusion.
9. Validation by actual performance of the tool
10. Report writing
DESIGN PROCEDURE:

11.The frame is fixed and it is made of mild steel and made in such a way that it is
ergonomic to handle.
12.The gear transmission is made in such a way that a single gear input transmits
to four other gear outputs.
13.The 6202 bearings are used to mount the gear onto the frame through a 11mm
shaft.
14.The flexible shafts are connected to the other end of the shafts and the project
is thus complete.

CHAPTER 5

15
 MULTI SPINDLE VARIABLE DISTANCE NUT RUNNER

5.1 MAJOR COMPONENTS USED

5.1.1 GEAR ARRANGEMENTS:

The model consists of a single pinion gear of 54mm diameter and
four 64mm spur gears made of mild steel which is used to transmit the
input torque to the output.

Fig 1.2 Spur gear

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5.1.2. BALL BEARINGS:
Four 6202 Ball Bearings are used to attach the gear
arrangement onto the frame. Its dimensions are 15*35*11 and are made of
mild steel.

Fig 1.3 Ball Bearings

5.1.3 FRAME:
The frame is made up of mild steel sheet of 2 mm thickness and is
designed in P shape as the help the user to handle the device easily.

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5.1.4 FLEXIBLE SHAFTS:
The flexible shafts are the ones that are used to transmit the
power through variable distances. It is the key part of the project as it the
difference between the existing model and our model

Fig 1.4 Flexible Shafts

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 CHAPTER 6

WORKING PRINCIPLE

 The basic fundamentals of law of gearing have to be followed in designing the

spur gears. The Fundamental law of gearing states that, “For a pair of gear to
transmit constant angular velocity ratio, the tooth profiles of these mating
gears must be designed in such a way that the common normal (line n-n) or
the line of action passes through a fixed point, or also known as the pitch
point, on the line of centers.”

 The input is given via the pinion gear that is mounted centrally in the ‘P’
section of the frame and the input can be either through a manual spanner or
through an automated drilling machine.

 The input is then transmitted via four spur gears and the input torque is
calculated in such a way that the output torque satisfies the torque required to
tighten a car nut.

 The spur gears are connected to the flexible shaft spanners using the ball
bearings through a 11mm shaft which is used to transmit power from the spur
gears to the flexible shafts.

 The flexile shaft spanner is then mounted on the nuts that need to tightened and
then the input is given in such a way that it satisfies the torque required to
tighten the nuts.

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 CHAPTER 7
DESIGN AND CALCULATIONS

Fig 1.5 3-D Model of MSVDNR

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 Fig 1.6 2-D Model of MSVDNR

CALCULATIONS:
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• Normal load acting on pinions tooth

(Wn) = WT /cosΦ = 3070 / cos 20(Pressure angle)=7522

• Weight of gear

(Wg) = 0.00118* Tg*b*m2 = 0.00118*24*10*2.452 =1.7 N

• Therefore resultant load on gear,

(WR) = (Wn^2+ Wg^2+2* Wg* Wn*cosΦ)^0.5

= (75222+1.72+2*7522*1.7*cos20)^0.5

WR =7523 N

• Assuming pinion is overhung on shaft at 30 mm Bending moment on shaft due

to WR is M Then we take

M = WR* 30 = 7523*30 =225707 N-mm

• Twisting moment on shaft due to WT is T

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 T = WT * Dg / 2 = 3070*59 /2 = 90565 N

• Equivalent twisting moment is

Te= (M2+ T2) ^0.5 = (2257072 +905652) ^ 0.5

Te= 243198 N-mm

• Let Dg be the diameter of gear shaft Then

Te= π*τ* dg 3 /16 (τ is taken from data hand book)

dg ^3 =243198*16/(π*250)

dg= 18mm (say)

This implies that the bore diameter required to withstand the maximum input torque

is 18mm

• From the calculations assuming standard spur gear industrial module m= 2.5

mm and Number of teeth Z= 24,Z=22 and pitch circle diameter of a car=118

mm and Gear ratio=1.5

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 • Gears:

Diameter of the pinion (Dp) = 54mm

Number of teeth’s on pinion (Tp) =22

Diameter of the gear (DG) =64 mm

Number of teeth’s on gear (TG) =26

• Bearings:

Type of Bearing = Ball bearing

Bore diameter = 16mm

Diameter of the bearing =40mm

NOTE:Since Mild steel is used E=2* (10^5)

CHAPTER 8

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 WEIGHT ESTIMATION

Sl.No Name of the Number of Weight of each Total

Component components component(Kg) weight

1 Spur Gear 4 0.885 3.54

2 Pinion Gear 1 0.775 0.775

3 Ball Bearings 5 0.04 0.04

4 Flexible shafts 4 0.3 1.2

5 Frame 1 1 1

TOTAL 6.555
WEIGHT

TABLE 2.1 Weight Estimation

CHAPTER 9

COST ANALYSIS
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Sl.No Name of the Number of Cost of each Total
Component components component(Rs. Cost(Rs.)
)

1 Spur Gear 4 150 600

2 Pinion Gear 1 150 150

3 Ball Bearings 5 60 300

4 Flexible shafts 4 250 1000

5 Frame 1 70 70

TOTAL COST 2120

TABLE 2.2 COST ESTIMATION

CHAPTER 10

CONCLUSION
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Existing models of multi spindle nut runners are focused on single nut at a
time and is very time consuming and the cost is almost equivalent to that
of our model. For those with very less amount of space requirement when
it comes to models in respect to nut runners, our model will be of the
highest suitability. The skill required to operate this model is little to none.
The whole objective of the project is towards an automated and time
managing perspective and will be achieved in the fabrication of this model.

The removing of car tyres is a tedious process, However this project does
not totally eliminate all the difficulties involved in a tyre removal process
but is step towards the goal that is required to be achieved.

CHAPTER 11

REFERENCES
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[1] Ahmad Farudzi Bin Azib, „The Extension Hydraulic Wheel Wrench‟,
“International Journal of Applied Science and Technology” Volume 4 No. 1; January
2014.

[2] Nitesh L. Gomase, Pankaj R. Chawhan, „Design & Fabrication of Four Wheeler
Opening Spanner‟, “International Journal for Scientific Research & Development
Vol. 3, Issue 02, 2015.

[3] Vaibhav Chowki, Sarvesh Mhatre, „Multinut Opener Cum Tightner for Four
Wheeler‟ “International Journal of Scientific and Research Publications”, Volume 6,
Issue 3, March 2016.

[4] C.Veeranjaneyulu, U. Hari Babu, „Design And Structural Analysis Of Differential

Gear Box At Different Loads‟, “International Journal Of Advanced Engineering
Research And Studies”.

[5] Design data book, Revised edition 1978, Kalaikathir Achchagam Publication.

[6] R.S. Khurmi, J. KGupta,Machin,Design, S.Chand Publication.

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