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Vehicles
BY
Adarsh K Das
Amit Sharma
Ritesh
CHANDIGARHG-160019 (INDIA)
December, 2014
CERTIFICATE
We hereby certify that the work which is being presented in the B.E. Minor
Project Report entitled A Novel Design of Steering System for Vehicles, in partial
fulfillment of the requirements for the award of the Bachelor of Engineering in
Mechanical Engineering and submitted to the Department of Mechanical Engineering of
Chandigarh College of Engineering and Technology (Degree Wing), Chandigarh is an
authentic record of my own work carried out during a period from July 2014 to
December 2014 under the supervision of Pankaj Rana, ME Department.
The matter presented in this thesis report has not been submitted by us for the
award of any other degree elsewhere.
Signature of Candidate
Adarsh K Das (CO11101)
Ritesh (CO11153)
Signature of Supervisor
Date:
Signature
Jatinder Madan,
Head of Mechanical Engineering Department
Chandigarh College of Engineering and Technology (Degree Wing), Chandigarh
Abstract
A noble design of Steering system for automotive vehicles is introduced
and tested in this study. The steering system introduced is light weight and can be
manufactured at a fraction of cost of rack and pinion and is ideal for vehicles like Go-kart,
Lawn Mover, Golf Carts, Efficycle and many other such vehicles.
During motion of a vehicle a large amount of forces is transferred from
ground to the chassis. These forces result in stresses in the structure and deteriorate the
comfort level of the vehicle. In order to reduce these forces suspension system is used. Use of
suspension requires a steering system which can allow for the up and down motion of tires
while satisfying to Ackerman Geometry. Existing steering systems were either too heavy to be
used or do not allow for the up and down motion of the tire. Thus, inorder to solve this
problem a new noble design was invented.
A revolute joint linkage model of this design is created and analyzed in
MSC Adams View. Both Dynamic and kinematic analysis of this design is carried out. The
Hilber-Hughes-Taylor (HHT) method is used in MSC Adams View to solve for Kinematics and
Dynamics. In order to reduce the Ackerman error in the Geometry and for having Ackerman
Percentage of 100 at maximum turning angle of the tires, various linkages of this designed
steering system were optimized for their length and angles. A Detailed study of Ackerman
geometry of this noble steering is carried out and the result of this current study is compared
with that of the prototype developed.
Acknowledgement
I wish to express my profound gratitude and indebtedness to Mr. Pankaj Rana,
Department of Mechanical Engineering, Chandigarh College of Engineering and
Technology for his inspiring guidance, constructive criticism and valuable suggestion
throughout the project work.
Last but not least, my sincere thanks to all our friends who have
patiently extended all sorts of help for accomplishing this undertaking.
Adarsh K Das
(CO11101)
Dept. of Mechanical Engineering
Chandigarh College of Engineering and Technology
CONTENTS
1.
INTRODUCTION
1.1 TYPES OF STEERING LINKAGES
1.1.1 RACK AND PINION LINKAGE
1.1.2 PARALLEL LINKAGE
1.1.2 HALTENBERGER LINKAGE
1.1.2 PARALLELOGRAM LINKAGE
1.2 STEERING GEOMETRY TEERMINOLOGY
1.3 PROBLEM STATEMENT
1.4 OBJECTIVE
1.5 OVERVIEW
2.
CONCEPTUAL DESIGN
2.1 DESIGN METHODOLOGY
2.2 CAD DESIGN
2.3 SUMMARY
3.
4.
PROTOTYPE
5.
6.
REFERENCES
1. Introduction
Steering system, in automobiles is used to control the direction of a vehicle's
motion. Because of friction between the front tires and the road, especially in parking, effort
is required to turn the steering wheel. To lessen the effort required, the wheel is connected
through a system of gears to components that position the front tires. The gears give the
driver a mechanical advantage, i.e., they multiply the force he applies, but they also increase
the distance through which he must turn the wheel in order to turn the tires a given amount.
Various types of gear assemblies, none with any decisive advantages over the others,
are used, although some manufacturers prefer a rack-and-pinion system. In faster, heavier
cars the amount of force required to turn the tires can be very great. Many of these cars use
a power-steering system.
Steering System also helps to achieve better maneuverability, reducing the turning
circle radius of the car and to reduce the drivers steering effort. The added benefit of a
steering system is to absorb road shocks thereby preventing them from getting transmitted
to the drivers hands hence making the driver achieve maximum possible comfort during long
drives.
The main disadvantages of rack and pinion linkage are a relatively low
carrying capacity and inflexibility when it comes to packaging and space
within the car.
Figure 1
1.1.2
Parallel Linkage
As the driver turns the steering wheel the shaft which runs from the steering
wheel to a steering gear (1) rotates causing the pitman arm (2) to rotate. The
pitman arm is connected to a center link (3), which will move side to side.
This side to side motion will cause the tie rod end/sleeve assembly (4) and
steering arms (5) to move thus turning the wheels in appropriate direction.
The idler arm (6) connects the steering linkage to the frame and keeps
everything parallel and aligned properly.
Advantages of this system include precise geometry, high load carry
capability, and package friendly; meaning it can be designed easily to work
around obstacles such as an oil pan.
The main disadvantage of parallel linkage is a relatively higher weight and
cost.
Figure 2
Figure 3
Figure 4
Steering Angle: The steering angle is defined as the angle between the front of the
vehicle and the steered wheel direction as shown in Figure
Figure 5
Steering Ackerman: Steering Ackerman describes the angle difference between the
outside and inside tire of a vehicle. The steering sensitivity of the vehicle is greatly
affected by the amount of Ackerman designed into the suspension.
Figure 6
Turn Radius: The turning radius of a vehicle is the radius of the smallest circular turn
(i.e. U-turn) that the vehicle is capable of making.
Figure 7
Ackerman Error: The difference between the measured Ackerman angle and the
theoretical Ackerman angle can also be expressed as an Ackerman Error.
Ackerman Error= (measured Ackerman angle) (theoretical Ackermann angle)
( )
( )
100%
1.4. Objectives
1.4.3
Prototype Design:
The idea which had been designed and optimized in the virtual world now had
to be brought to life. During this process it was necessary that the manufacturing of
the steering system is according to the design parameters and there are no errors in
the manufacturing process. At the end of the manufacturing, it is required we check
that there is no deviation between the theoretical design values and the actual
design values. The manufacturing process was carried out using tools and common
manufacturing processes.
1.5. Overview
This research is organized in the following manner. Chapter 2
overviews about the design of the new steering system and the methodology
adopted to design the new steering system. It also describes how the conceptual
design model was made and the different steps that were taken in order to design a
new type of steering system. Chapter 3 overviews the methodology adopted to
optimize the currently made CAD design. It also describes the use of Adams to
optimize the steering design. Chapter 3 also gives us the theoretical values of
different steering parameters and also tells us about the forces on steering column
during the movement of vehicle and during bump travel and also the forces on
steering column and wheel while cornering of the vehicle. Chapter 4 describes the
fabrication of the prototype model. The methodology used to fabricate the steering
system. This chapter also gives us the actual behavior of steering column under
different conditions and gives us results to compare it with the theoretical results.
Chapter 5 overviews the results of the above research and the conclusions that
were taken out of the research.
2.
Conceptual Design
In this section the complete CAD design of the conceptual design is presented. Various
concepts were considered and based upon these concepts, the best design was found
based on various constrained satisfaction. The design which met the design constraints
was parameterized and a CAD model is created.
Figure 8
Figure 9
a. Steering Wheel
Steering wheel is a component used to give direction to a vehicle. Rotational
movement of steering wheel gives movement to wheels which causes the
motion of vehicle in desired direction.
b. Linkage To Steering Wheel
This linkage is used to connect steering wheel to the circular arm link. It may
consists of one or two universal joints in order for proper alignment of steering
wheel according to the driver.
c. Circular Arm Link
Circular arm link consists of three holes drilled on a metal plate. Linkage to
steering wheel is connected to the center of the circular arm link. Motion of
steering wheel results in the rotational motion of circular arm link.
d. U-Clamp-Circular Arm Linkage Tie Rod
It is a linkage which consists of two tie rods connected on both ends used to
connect circular arm link with the U-Clamp.
e. U-Clamp
U-Clamp is fixed and mounted on the vehicles body on u-clamp mounting
points. U-Clamp moves with the movement of circular arm link to give desired
direction to the wheels.
f.
2.3. Summary
A complete CAD Design methodology and its implementation in the design
of a Novel design of steering system to meet the aforesaid objective has been presented in
this chapter. Among all the available conceptual design, the design shown in this chapter
meets all the objectives. This design is not only light but also less costly and also allows for
the use of the suspension. But before this design is finalized it is very important to check for
the performance and optimization of this design.
3.
a.
b.
c.
d.
Figure 10
Figure 11 and Figure 12 shows the variation of steer angle for right and left front
wheels as the length of the U-Link rod is increased. As the U-link rod length is
increased the maximum steering angle also increase as can be seen from the figures.
As the length is increased the time i.e. the angle by which the steering wheel is
required to be turn for maximum vehicle wheel steer angle, also decreases. It can be
seen that after a particular value of the wheel steer angle, the slope of the outside
vehicle wheel steer angle attains an zero value while the slope of the curve of the
inner wheel steer angle curve continue to increase.
Thus it could be seen that the best and optimized value for the steering linkage rod is
best for Steering Test 6.
Figure 11
Figure 12
3.2.2
Figure 13 and Figure 14 shows the variation of steer angle for right and left front
wheels as the length of the steering linkage rod is decreased. As the Steering Linkage
rod length of knuckle is decreased the maximum steering angle Absolute value also
increases as can be seen.
As the length is decreased the time i.e. the angle by which the steering wheel is
required to be turn for maximum vehicle wheel steer angle, also decreases
significantly. It can be seen that after a particular value of the wheel steer angle, the
slope of the outside vehicle wheel steer angle attains an zero value while the slope of
the curve of the inner wheel steer angle curve continue to increase.
Thus it could be seen that the best and optimized value for the steering linkage rod is
best for Steering Test 14.
Figure 13
Figure 14
3.2.3
Ackerman Geometry:
The steering system is necessary to meet the Ackerman geometry. The figure 15 shows
the graph of Ackerman error with respect to the percentage Ackerman. It can be seen from the graph that
beyond the percentage Ackerman of 40%, the Ackerman error starts to increase parabolic and then
decreases parabolic to zero error value at the maximum Ackerman percentage of 100%.
Also at the maximum value of steer angle, the turning radius for inner Tyre is found to
be 2.7 m while that for the outer Tyre is found to be 4.8 m. The design successfully meets the Ackerman
geometry at the maximum value of steering system designed for the best available design from the above
section.
Thus, the design is fully optimized for the maximum turning angle while meeting for the
Ackerman geometry.
Figure 15
Figure 16
Figure 17
3.3. Summary
An optimization of the Steering Design presented in Chapter 2 has been
carried out in this chapter. From the various graphs we can see that if we decrease
the length of the steering linkage rod of the knuckle, the maximum wheel steer
angle is increased. At the maximum steering angle the percentage Ackerman is
100%. The Ackerman error for the final design for final design is increasing zero for
maximum turning angle, whereas for angle between the maximum and minimum it
increase parabolic. Thus, as the Ackerman error is least in this design and the
Ackerman percentage at the maximum turning angle is 100% thus, this design is
most suitable and is ready for manufacturing.
4. Prototype Design
The idea which had been designed and optimized in the virtual world now had
to be brought to life. The first step during the prototype design was to fabricate the knuckle
according to the design specifications. After the knuckle has been fabricated, it is verified
that it matches the optimized design thereafter the fabrication of U-link is carried out. This
component is then scrutinized for its closeness to the original design.
The circular arm link fabrication is carried out after the U-link fabrication. The
circular arm link is one of the major components of the steering system hence proper care
has to be taken so that it is built according to the specifications of the design.
Following this we move on to the concoction of various linkage tie rods namely U-clampCircular Arm linkage tie rod and U-clamp-Steering Arm linkage tie rod. These tie rods held us
in the adjustment of the steering geometry angles hence it is necessary that these are
designed with utmost care.
The various components after the manufacturing process are assembled and a
final check is done so that it satisfies our final theoretical design. After it is verified that the
design is meets all the required design parameters, setting of tie rods is done to adjust the
toe in and toe out angles so that the actual design mimics the virtual design.
The Ackerman percentage for the prototype is found to be 100% at the
maximum steer angle. Also the Ackerman error is in close proximity to that of the virtually
optimized design.
5.2 Conclusions
From the above made design, following conclusions were made:
1. That the newly manufactured was best suited for light vehicles and the
project is very usefully for driver while driving the vehicle. This project has
also reduced the cost involved in the concern. Project has been designed to
perform the entire requirement task which has also been provided. Vehicle
can be turned with great effectiveness with minimum drivers effort and
also provides a self-locking mechanism which restricts the damage of
steering linkages. The cost involved with the steering is also less compared
to all other steering mechanisms, thus gives it greater flexibility of use in
different automobiles without increasing weight and cost of that particular
vehicle. Also the methods used for the fabrication of steering linkages are
very simple and does not require any special equipment for its fabrication
which is also a great benefit for this steering system.
2. That the steering can be used for wide range of vehicles reducing the cost of
those vehicles. These vehicles include
a.
b.
c.
d.
e.
Go-karts
Lawn movers
Trikes
Quad-bikes
Golf karts
3. That the above made steering in general cannot be used in cars and jeeps
due to heavy transmission of stresses and loads on the steering linkages
which may cause to failure of the steering system but by making subtle
changes in the material and optimizing the design it can be effectively
installed in cars and heavy vehicles.
6. References
1. Design Optimization of Steering System for Bump and Brake Steer using Adams, Girish
R Rane, A.S Dhekane, IJSRD, Vol. 2, Issue 03, 2014
2. Vehicle Handling and Stability investigation into causes of vehicle drift during Straightline Braking, Nihal Mirza, Khalid Hussain, Andrew J. Day, Society of Automotive
Engineers, Inc. 01-0797, 2006.
3. Effect of wheel Geometry parameters on vehicle steering, R.P Rajvardhan,
S.R.Shankpal, S.M. Vijaykumar, SSA TECH Journal, volume 9, Issue 2, pp. 11-18,
September 2010.
4. The truck steering system from Hand Wheel to Road Wheel John W. Durstine, Societ of
Automotive Engineers, 1973.
5. Steering System modelling, Niklas Philipson, The modellica Association, Inc,010227,2008
6. A Simple, Cost Effective, Method of Evaluating Bump and Brake Steer and Achieving
correlation with ADAMS analysis, Vinay A. Upadhyay, K. GopalaKrishnan, Ajau R.
Kshirsagar.
7. On the Dynamics of Automobile Drifting, Mujahid Abdulrahim, Society of Automotive
Engineers, Inc. 01-1019,2006