1.

INTRODUCTION

1.1 Introduction

CAR is not a symbol of luxurious anymore. It is a need for every family. People need car
due to 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 the problem with tyre puncture. The flat tyre needed to be replaced with spare tyre.
Therefore, drivers need to know basic knowledge of tyre replacement procedure if such problem
occurs. In order to change the flat tyre, one requires minimal skills. Virtually every car has a tyre
replacement tools such as the L-shaped nut remover and jack supplied by the manufacturer.

The tool used to remove the wheel nuts should be designed for ergonomic, easy to handle
and requires small space for storage. The tool is also function as wheel nuts tightener.
Nonetheless, it is difficult for women and the elderly drivers due to high required torque to
remove the wheel nuts. In addition, if the nuts are successfully removed, the problem to retighten
the nuts will follow. If the required torque is not applied in tightening the nuts, the nuts will lose,
and this will jeopardize the driver’s safety.

Impact wrench used to remove wheel nuts is also consuming time in automotive
maintenance industry. For these reasons, 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 mechanic to remove
four wheel nuts at once with little energy consumption. The design is based on standard PCD of
100 mm for most of the cars available
Sr. No. Component No. of parts
1.2 List of Parts
1 Spur Gear(Pinion) 4
Table no.1.1 List
of part 2 Spur Gear(Sun) 1
3 Taper Roller 4
Bearing
4 Shafts 4
5 Socket Spanner(Box) 5
6 Nut and Bolt 4
7 Base or Cover Plate 2
9 washer 12 Page | 1

10 Handel 1

11 Door handle 2
1.3Application

Application domain of Multi nut remover is in automobile industries. According to our

preplanned project we describe the following places where it can be used successfully:

o It can be used as standard equipment provided with a new vehicle for the purpose of
opening and refit a punctured wheel in the midway.

o It can be used in workshops to open a wheel in place of using pneumatic guns which are
restricted to the availability of light and compressed air; it can be easily operated with
hands.

o It can be used in assembly line of automobiles where more time is consumed in

tightening all the four nuts one by one. As it takes less time to fit a new tyre, it will lead
to increase productivity.

1.4 Objective

A simple mechanism if used properly can lead to a great success. M.N.R. is a tool which
is made for automobile field. Aim of our project is to save time and human effort. We have tried
our best to adopt the design having minimum input torque and required output torque which is
not possible without using M.N.R.

1.5 Organization at Work

Completion of any work requires proper planning and management from the initial stage.
From case study to fabrication different steps are involved. First of all we decide the aim of our
project. Application of our design, benefits and other aspects are discussed in the first chapter.

In the second lap of our work we finalize about the material required for the fabrication
of different parts. A lot of engineering materials are studied before the selection of material.
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 After the selection of material the big work is to design each and every part of the project.
Design of gears, shafts, axles, sprockets, pinion and other parts are described in third chapter.

2. METHODOLOGY

The design of the vehicle multi-nuts remover tool is performed by commercial computer
aided design (CAD) software as shown by Figure 1.

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 Fig no. 2.1 MNR tool conceptual design.

Several static load analyses are also performed in order to find the safety factor of the
design. Theoretical calculation analysis is carried out with the purpose of validation. The force
required for removing four numbers of nuts is,

F = 4τ / (l RG)

Where, F is the applied force, τ is the torque required to remove one nut, l is the length of
level and RG is the gear ratio of central gear and driven gears of the tool.

In the fabrication of MNR tool, two processes are performed; milling and fitting. Since
the gears are not available in the market, custom designed gears need precision milling and
fitting processes. Once the tool is ready, an experiment is performed with the intention to find the
time required to remove the nuts. This result is then compared with the time required using
ordinary L-shaped wrench. Experiment using impact wrench is also performed.

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 3. MATERIAL SELECTION

3.1 Introduction to Engineering Materials

` The selection of a material for a particular application is governed by the working
condition to which it will be subjected, ease of Manufacturing and the cost considerations, pure
metals find few applications in pure condition and secondly they generally have poor strength in

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pure form. Various desired and special properties can be achieved by addition of different
material to form alloys. Alloy comprises of a base metal and one or more alloying elements. The
typical properties associated with working condition are tenacity elasticity toughness and
hardness, toughness and typical properties associated with manufacturing process is ductility,
malleability and plasticity. The various properties can be determined by testing techniques e.g.
tensile test resistance to abrasion by hardness test toughness by impact test and other special
properties like fatigue and creep test.

3.2 Engineering Material for Product Design

All physical objects are made out of some material substance or other. Mother Nature has her
own set of building material for the objects of her creation, living or non-living. Over the
millennia, man has observed and adapted many of these for making objects of his invention and
design. For engineering purposes, we now use a very wide spectrum of materials. These
generally fall under the following categories:-

o Materials as found in nature used after only very minor preparation such as cutting to
size, sun-drying, mixing with water. Some examples are coal, wood and stones.
o Natural materials that are modified/ refined before use through some physical, chemical
or thermal processes that improve their utilization.
o Synthesized materials that are rarely found freely in nature. These are derived from one
or more natural raw materials through major transformation processes. Most of the
materials used in modern mechanical engineering belong to this category.

3.3 Selection Criteria

The designer selects the materials of construction for his product based on several criteria
such as its cost, the desirable properties that it should possess, its availability, the preferred
manufacturing processes that are to be employed, etc. The overall economy is influenced by all
these factors. In special cases, essentiality and /or urgency of the need for the product can

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supersede the economic considerations. The main criteria for material selection are discussed
below:
3.3.1Cost of the Material
The amount of raw materials, their composition, quality, any special heat-treatment that is
required, etc. influence the unit cost of materials. The unit cost generally depends also on the
quantity of raw material that is purchased in a single lot. Special steel materials, for example,
cost much more in the market when purchased in small quantities from a retailer than in bulk
directly from the steel mill/stockyard.

3.3.2 Availability
The material should be readily available in adequate quantities. Material availability is
closely linked with the variety and level of technology obtained in a given geographic location.
Procuring materials from far and wide can be expensive, due to the additional cost for transport,
for transporter taxes and duties etc.

3.3.3 Manufacturing Process

Facilities for shaping and treating the selected material into the finished product or
component must be available for economic production. Otherwise, the production cost goes up.
For example, the selection of forged alloy steel for a connecting rod design necessarily assumes
that suitable forging facility is available along with the necessary dies and other accessories. If
the alloy is of a rare quality, then facilities for its heat treatment might not be available.

3.3.4 Properties of the Material

The desired function and performance of any product depends to a great extent on the use
of materials with the right physical and chemical properties. In general mechanical engineering
these properties can be classified into different categories depending on how a particular property
affects the function and life of a component. The main property groupware:-

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 o Chemical Composition, specifying the contents of all the different elements contained.
o Properties of state, such as solid, liquid or gas, density, porosity, temperature.
o Strength related properties, such as ultimate strengths in tension, compression and shear,
yield strength/ 0.2% strength, fatigue strength, notch sensitive, hardness, impact strength,
effect of high/low temperatures on strength, etc.
o Strain related properties, such as elongation at fracture, elastic moduli, ductility,
malleability etc. these help to ensure the desired rigidity/ elasticity, formability etc.
o Wear related properties that determine the erosion, abrasion, friction etc. between
components in contact / relative motion.

3.4 Material Specification (used for project)

3.4.1 EN8 Steel
(Used for gear and shaft)
. EN8 is an unalloyed medium carbon steel grade with reasonable tensile strength. It is
normally supplied in the cold drawn or as rolled condition. Tensile properties can vary but are
usually between 500-800 N/mm². EN8 is widely used for applications which require better
properties than mild steel but does not justify the costs of an alloy steel. EN8 can be flame or
induction hardened to produce a good surface hardness with moderate wear resistance

 Analysis:-

Table no 3.1 EN8 chemical composition

Material Percentage
Carbon 0.35-0.45%
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 Manganese 0.60-1.00%
Silicon 0.05-0.35%
Phosphorous 0.06% max
Sulphur 0.06% max

Hardening Heat the component slowly to 820-860°C and allow it to be heated through.
Quench in oil or water.

3.4.2 Mild Steel

(Used for gear and Plate)

o Low carbon steel contain unto 0.30% C. The largest category of this class of steel is
flat-rolled products (sheet or strip), usually in the cold –rolled and annealed condition

o The carbon contain for these high-formability steel is very low less than 0.10% Mn.

o Typical uses are in automobile body panels, tin plate, and wire products.

o For rolled steel structural plates and sections, the carbon content may be increased to
approximately 0.30%, with higher manganese content unto 1.5%.

o These materials may be used for stamping, forgings, seamless tubes, and boiler plate

 Applications:

• Sheet and strip for presswork

• Wire and rod for nails and screw

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 • Concrete reinforcement bar

• Steel plate and sections used for structural work

4. DESIGN PROCEDURE

4.1 Design and Product Cycle

All engineering activities necessarily begin with some ideas with high or low innovative
content, translated into definite plans for their realization in the form of products. This is the
essence of design engineering. The ultimate success depends on a thorough consideration of how

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the product will be made and used as well as on the attention to detail paid by the design
engineering. This is applicable equally for a minor redesign of an existing product or for a most
innovative one. A good understanding of how the various phases of the product cycle can
influence the design is therefore essential. The Product Cycle can be better understood by fig. 1.

4.2 The Challenges of Design Engineering

The present day industry bases economy is founded on the consumption of as many
different products as possible by as much number of user’s as possible. It serves as an engine
driving technology. The numbers put manufacturing under pressure; the numbers as well as the
variety put greater pressure on design engineering. This is manifested by

o Short time available for design, development and testing of the product before it
reaches the user.

o Demands from the users for affordable cost combined with high quality of
performance and appearance.

o Increasing number of competition who can supply a product of equivalent value.

On one side, the scientific cooperation and exchange of information have become
international. On the other side, industrial activities and communications network
have become globalized. Given the present day ease of access to technology,
major breakthrough in product innovation and design are not really essential for
industries to produce and prosper

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 FIG 4.1 Life Cycle of a Product

4.3 Qualities of a Good Design

A good product design should satisfy the expectations of the customer/user. These can be
summarized in the following conditions. The product must

o Carry out the desired functions reliably.

o Appeal both technologically and psychologically.

o Be economical to acquire and to use.

o Be easy and safe to use.

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 o Be easy to maintain in working order.

In order to ensure the conditions, not only must the design concept be novel and sound
but the design must be well engineered. This engineering part of design consists of

o Drawing up the main parameters for function and performance.

o Deciding the material, shape and dimensions of the components.

o Ensuring that the component dimensions satisfy the functional and strength
requirement.

o Ensuring the feasibility to manufacture or otherwise procure all the necessary

components, assemble them together and test them.

o Preparing the component and assembly drawing for guiding manufacture and
inspection.

4.4 Introduction to Design

Spanners are used to open the wheel. Spanners in the use are of various types. The
different kinds of spanners in use are shown in figure one thing is very common for all these
spanners: only a single nut is opened in a single time. This causes wastage of precious time and
since to open all the nuts spanner is to engaged and disengaged again and again till the last nut is
unscrewed or screwed. Thus in this work a large amount of power is required to perform the
requisite operation. Below. Fig.4.

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 Angular Spanner Four way wheel Spanner

Box Spanner Telescopic spanner

Fig no 4.2. Types of Spanner

These disadvantages are removed in unified wheel opener. The idea is to reduce time
when release the wheel or put it on. By using this device, wheel nuts can be opened
simultaneously at one time. The supposed design of the unified wheel opener is shown below. On
pictures, we can see handle, casing/gears housing, and wheel nut connectors. Wheel nut
connectors are connected to wheel nut, and the number of connector depends on the number of
studs. So it will be different according to wheel type and size. Inside the Casing, there are simple
gears mechanisms, causing one rotation of The Handle to make two rotations of the wheel nuts.

4.5 Designing
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 Abbreviations Used:

Table no 4.1 Abbreviations Used

M Module
M bending moment
DP Pitch circle diameter of pinion
Ds Pitch circle diameter of sun
ds Diameter of gear shaft
WT Tangential load
‫ﺡ‬ Allowable stress

TE Equivalent twisting moment

TPG Number of teeth on pinion

TSG Number of teeth on sun

4.5.1 Design Procedure for Gear & Pinion:

Torque required for one nut=140N-m

Total torque required= 4×140N-m

= 560N-m

Module, (m) =1.59mm

Now, as we know
Number of teeth on pinion (TP) = DP/m

=60/1.59

=37.73 ≈ 38

Also, Number of teeth on sun gear (TS) =DS/m

=40/1.59

=25.1 ≈ 25
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Other dimensions for pinion &gear are as:

Addendum=0.943×m=1.49

Deddendum=1.257×m=1.99

Minimum total depth= 2.200×m = 3.498

Minimum clearance= 0.314×m = 0.499

Backlash= 0.157×m = 0.249

Thickness of tooth= 1.493×m =2.37

Outside diameter of pinion =65

Outside diameter of sun= 45

4.5.2 Design for sun Shaft

Torque Transmitted (T)

T=1609.4*(40/2)

=32188 N-mm

Weight of pinion (WP) = 0.00118Tp×b×m2

=0.00118*(25)*15*1.5*2

=1.325N

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∑Fy= 0

Therefore, Ra+Rb= 1.3275

Taking movement about A

0=1.3275*19-(Rb*36.5)

Rb=1.3275*19/36

Rb=0.69N

Ra=1.3275-0.69

=0.6375

Maximum bending movement (M)

M=Ra*90

=0.6375*90

=12.1125
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Equivalent torque (Te)

Assume Kb=Kt=1

Te=√ ((Kb*M) 2 + (Kt*T) 2)

=√ ((1*12.1125)2+ (1*32188)2)

Te=32188N-mm

The Equivalent twisting movement is given by,

Te = (π/16)*d3*‫ﺡ‬

=‫ ﺡ‬Syt/FOS

=465/4

=58.125

Te = (π/16)*d3*‫ﺡ‬

32188= (π/16)*d3*58.125

d3= (32188*16)/ (58.125*π)

d=14.1286

d ≈15mm

4.5.3 Design for Pinion Shaft

Torque Transmitted (T)

T=1609.4*(40/2)

=32188 N-mm

Weight of pinion (WP) = 0.00118Tp×b×m2

=0.00118*(38)*15*1.5*2

=2.0178N

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∑Fy= 0

Therefore, Ra+Rb= 2.0178N

Taking movement about A

0=2.0178*26.5-(Rb*45)

Rb=2.0178*26.5/45

Rb=1.18826N

Ra=2.0178-1.18826

=0.82954N

Maximum bending movement (M)

M=Rb*18.5

=1.18826*18.5

=21.98821

≈22N-mm
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Equivalent torque (Te)

Assume Kb=Kt=1

Te=√ ((Kb*M) 2 + (Kt*T) 2)

=√ ((1*22)2+ (1*32188)2)

Te=48282N-mm

The Equivalent twisting movement is given by,

Te= (π/16)*d3*‫ﺡ‬

=‫ ﺡ‬Syt/FOS

=465/7

=33.21

Te= (π/16)*d3*‫ﺡ‬

48282= (π/16)*d3*33.21

d3= (48282*16)/( 33.21 *π)

d=19.45mm

d ≈20mm

All the component are designed to serve their functions properly and taking into account the
various consideration such as material, labour, availability of technology, economic, safety,
usage, reliability, maintainability, functionality etc. These components will be manufactured
according to their design specifications.

5. MANUFACTURING PROCESS

5.1 Gears

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 The commonly used generating processes used for the generation of gear teeth are:-

1. Gear Shaper Process

2. Rack Planning Process

3. Gear Milling

4. Hobbing Process.

5.1.1 Gear Shaper Process

In this process a pinion shaped cutter is used which carries clearance on the tooth face
and sides. It carries a hole in the center for mounting on the stub arbor or spindle of the machine.
The cutter is mounted with the axis vertical and is reciprocated up and down by sliding the
spindle head along the vertical ways on the machine. In addition to the reciprocating motion, the
cutter and the gear blank both are rotated slowly their own axis. The relative speed of rotation of
the two is the same as the gear to be cut will have with a pinion of the same number of teeth as
the cutter. It is accomplished by providing a gear train between the cutter spindle and the work
spindle. The cutter in its rotation generates the tooth profile on the gear blank. All gears cut by
the same cutter will mesh correctly. This is specific advantage of this process over the forming
process using rotary cutters. Also it is a much faster process than rotary cutting.

5.1.2 Gear Planning

In this process rack type cutters for generating of spur. Involutes rack has straight edges
and sharp corners and hence can be manufactured easily and accurately. The cutters generate as
they are cut and as the name implies, the machine cuts the teeth by reciprocating planning action
of the

Cutter. This is a true generating process since it utilizes the principle that an involute
curve can be formed by a straight generator when a gear blank is made to roll without slip
relative to the generator.

5.1.3 Gear Milling

Milling is one of the metal removal process best known for making gear. Here a firm
cutter is passed through the gear blank to affect the tooth gap, helical gear, worm & worm wheel
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and bevel gear can be manufactured by milling. Gear milling is less costly and less accurate
process and it is employed for the following:-

o Coarse pitch gear

o Racks of all pitches

o Worms

o Toothed parts as sprockets and ratchets.

The production capacity in this method is low since each space is machined separately
and the time is lost in retuning the job to its initial position and in indexing for each tooth. In
actual practice a series of cutters are selected for a number of teeth to be milled.

5.1.4 Gear Hobbing

In this process, the gear blank is rolled with a rotating cutter called the HOB. A majority
of the involute gears are produced by this method. A gear hob looks like a worm, but carries a
number of straight flutes (gashes), cut all around, parallel to its axis. This results in the
production of separate cutting teeth and cutting edges. In operation, the hob is rotated at as
suitable speed and fed into the gear blank. The blank also rotates simultaneously. The speeds of
the two are so synchronizes that the blank rotates through one pitch distance for each complete
revolution of the hob. There is no intermittent motion of the two and the generating continues
steadily. The hob teeth are just like screw threads, i.e. having a definite helix angle. The hob is,
therefore tilted to its own helix angle while cutting the gear so that its teeth are square with the
blank and produces a true involute shape.

Out of all above processes we select the Gear Hobbing for the manufacturing of all the gears.
The various reasons for selection of this process are as following:-

o This process of making gears is continuous process.

o Very good accuracy.

o It is very fast process than other.

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5.2 Shaft

In the manufacturing of the shaft following operations are used:-

o Turning

o Facing

5.2.1 Turning

It may be defined as the machining the operation for generating external surfaces of the
revolution by the action of the cutting tool on a rotating work piece. When the same action is
applied to internal surfaces of the revolution, the process is termed as boring.

5.2.2 Facing

Facing operation machines the ends of the work piece. It provides a surface which is square with
the axis of the work piece from which to start the job. Facing is done by feeding the cross slide
or compound in or out. In facing the cutting tool moves from the center of the job towards its
periphery and vice – versa. Facing is primarily used to smooth off a saw- cut end of a piece of
bar stock or to smooth the face of rough casting.

5.3 Cover or Base Plate

In the manufacturing of the Cover or Base Plate following operations are used:-
1. Drilling
2. Plasma arc cutting Machine
5.3.1 Drilling

Drilling is the process of making holes in a work piece. Either the work piece rotate or
drill is stationary or vice-versa. When drilling on the lathe is being done, generally the work
piece rotates in the chuck and the drill held in the tail stock is fed into the work piece by means
of the hand wheel on the outer end of the tail-stock assembly. It is possible to do drill by holding
and rotating the drill in the lathe spindle while keeping the work stationary, supported by a
special pad mounted in tail-stock quill. Since drill feed is by hand, care must be taken,
particularly in drilling small holes. Coolant should be withdrawn occasionally to clear chips from
the hole and to aid in getting coolant to cutting edges of the drill.

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5.4 Plasma arc cutting Machine
The plasma arc cutting process is illustrated in Fig. The basic principle is that the arc formed
between the electrode and the work piece is constricted by a fine bore, copper nozzle. This
increases the temperature and velocity of the plasma emanating from the nozzle. The temperature
of the plasma is in excess of 20 000°C and the velocity can approach the speed of sound. When
used for cutting, the plasma gas flow is increased so that the deeply penetrating plasma jet cuts
through the material and molten material is removed in the efflux plasma.

Fig.5.1.1 The plasma arc cutting process

The process differs from the oxy-fuel process in that the plasma process operates by using the arc
to melt the metal whereas in the oxy-fuel process, the oxygen oxidises the metal and the heat
from the exothermic reaction melts the metal. Thus, unlike the oxy-fuel process, the plasma
process can be applied to cutting metals which form refractory oxides such as stainless steel,
aluminum, cast iron and non-ferrous alloys.

6. WORKING PRINCIPLE AND CONSTRUCTION

6.1 Construction
o The multi nut tightner/remover consists of one sun gear in center and 4 pinion gears around
it.
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o The sun gear having pitch circle diameter 40mm and pinion gears pitch circle diameter
60mm.the distance between the centers of gears is 100mm.

o The gears are made EN8 by gear hobbing process, and were also harden after manufacturing.

o Each gear is has respective shaft having diameter 15 mm for sun gear and 20mm for pinion
gears.

o The shaft are fixed in taper roller bearing which is fixed to the casing (cover)

o Handle is attached to the sun gear and box spanner to the pinion gears.

6.2 Working

o When sun gear rotates by human effort the 4 pinion gears also rotates in opposite direction of
sun gear.

o Thus, torque obtained at 4 pinion gears is transmitted to box spanner by shafts.

o Therefore, the 4 nuts of car wheel are tighten or removed at a time and effort and time
required by the user are reduced.

6.2 Components required

6.2.1 Spur gear:-

Spur gears are simple, easily manufactured gears and are usually the first choice when
exploring gear options. Transmitting power between parallel axes, the teeth project radially on
the disc
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 Spur gears are regularly used for speed reduction or increase, torque multiplication,
resolution and accuracy enhancement for positioning systems. The teeth run parallel to the gear
axis and can only transfer motion between parallel-axis gear sets. Spur gears mate only one tooth
at a time, resulting in high stress on the mating teeth and noisy operation.

 Dimension Specifications
Gears mate via teeth with very specific geometry. Pitch is a measure of tooth spacing
and is expressed in several ways.

o Diametric pitch (DP) is the ratio of the number of teeth to the pitch diameter of a gear; a
higher DP therefore indicates finer tooth spacing. It is easily calculated by the formula
DP= (N+2) ÷ OD, where N is the number of teeth, and OD represents the
circumferential measurement.

o Circular pitch (CP) is a direct measurement of the distance from one tooth center to
the adjacent tooth center. It can be measured by the formula CP= Π ÷ DP.
o Module (M) is a typical gear discipline and is a measurement of the size and teeth
number of the gear. Gears measured in inches earn 'English module' distinction to
prevent confusion. M = OD ÷ N
o Pressure angle is the angle of tooth drive action, or the angle between the line of
force between meshing teeth and the tangent to the pitch circle at the point of mesh.
Typical pressure angles are 14.5° or 20°

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 Fig 6.1 Spur gear dimension specification

 Mounting Specifications

Consider the gear center, bore diameter and shaft diameter. The gear center can be a
bored hole or an integral shaft. The bore diameter is the diameter of the center hole. The shaft
diameter is the diameter of the shaft for gears with an integral shaft. Helical gears can be
mounted on a hub or shaft. A hub is a cylindrical projection on one or both sides of a helical gear,
often for the provision of a screw or other shaft attachment mechanism. Hub less gears are
typically attached via press fit, adhesive or internal keyway.

Shaft mounting choices include the following:

Table no 6.1 Type of shaft mounting

Keyway: One or more square

cutouts exist in the gear bore for
exact mounting on the shaft.

Image credit: Direct Industry

Hub Clamping Screws: The gear

is attached with a screw that
squeezes the inner diameter of the
hub to a tight fit around the shaft.
Image credit: SDP/SI

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 Split: The hub is split into several
pieces that are tightened down by
a separate clamp to grip the shaft.

Image credit: SDP/SI

Simple bore: A straight bore

designed for adhesive attachment

Image credit: QTC

 Applications
The following application requirements should be considered with the workload and
environment of the gear set in mind.
o Power, velocity and torque consistency and output peaks of the gear drive so the gear
meets mechanical requirements. Spur gears' design constraints limit their ability to
transfer energy at high speeds and torques.
o Inertia of the gear through acceleration and deceleration. Heavier gears can be harder to
stop or reverse.

o Precision requirement of gear, including gear pitch, shaft diameter, pressure angle
and tooth layout.
o Gear lubrication requirements. Some gears require lubrication for smooth, temperate
operation.
o Mounting requirements. Application may limit the gear's shaft positioning.
o Noise limitation. Commercial applications may value a smooth, quietly meshing
gear. Spur gears are particularly noisy in operation.

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 o Corrosive environments. Gears exposed to weather or chemicals should be especially
hardened or protected.
o Temperature exposure. Some gears may warp or become brittle in the face of
extreme temperatures.
o Vibration and shock resistance. Heavy machine loads or backlash, the deliberate
surplus space in the circular pitch, may jostle gearing.
o Operation disruption resistance. It may be necessary for some gear sets to function
despite missing teeth or misalignment.
6.2.2 Shaft:-

A shaft is a rotating or stationary component which is normally circular in section. A shaft

is normally designed to transfer torque from a driving device to a driven device. If the shaft is
rotating, it is generally transferring power and if the shaft is operating without rotary motion it is
simply transmitting torque and is probably resisting the transfer of torque. Mechanical
components directly mounted on shafts include gears, couplings, pulleys, cams, sprockets, links
and flywheels. A shaft is normally supported on bearings. The torque is normally transmitted to
the mounted components using pins, splines, keys, clamping bushes, press fits, bonded joints and
sometimes welded connections are used. These components can transfer torque to/from the shaft
and they also affect the strength of the shaft and must therefore be considered in the design of the
shaft. Shafts are subject to combined loading including torque (shear loading), bending (tensile
& compressive loading), direct shear loading, tensile loading and compressive loading. The
design of a shaft must include consideration of the combined effect of all these forms of loading.
The design of shafts must include an assessment of increased torque when starting up, inertial
loads, fatigue loading and unstable loading when the shaft is rotating at critical speeds (whirling)

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 Fig 6.2 Shaft
It is important that a shaft should not only have the strength to transmit the specified
torque and load without the risk of failure but also that shaft deflections due to bending and
torque are within acceptable limits. The limiting of the angular /radial deflection is required by
the need to reduce vibration and ensure reliable operation of the related components including
gears, splines bearings etc. The design procedure for a shaft should therefore include an appraisal
of the resulting deflections when the shaft is loaded.
6.2.3 Taper Roller Bering:-

Fig 6.3 Taper Roller Bering

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Definition and capabilities

Definition:-

Tapered roller bearings with a single row of rollers are always mounted opposing another

Bearing of the same type to provide rigid assemblies, particularly when preloaded.

 Cages:-

Tapered roller bearings are usually equipped with a pressed steel cage. In some cases with
a synthetic material cage.

 Contact angle:-

The rings of this bearing are detachable: the outer ring (cup) is not joined to the rest of
the bearing which is made up of the inner ring (cone) and rollers held on the cone by the cage. A
tapered roller bearing can accept axial loads in one direction only. It must be mounted in
opposition with a bearing of the same type. ISO 355 Standard defines the different series of
tapered roller bearings with contact angles of 10 to 30°. For a given radial load, the greater the
angle of the cup, the greater the axial load that the bearing can withstand. SNR has adopted
designations in accordance with this standard for the new "intermediate" series and has kept the
former designations for the other series.

Capabilities:-

 Loads and speeds

The tapered roller bearing is an angular contact bearing that can withstand high radial and
axial loads.
 Misalignment

The shape of the contacting profiles allows misalignment in the range of 0.06°.

6.2.4 Ball Bering:-

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 A ball bearing is a type of rolling-element bearing that uses balls to maintain the
separation between the bearing races.

The purpose of a ball bearing is to reduce rotational friction and support radial and axial
loads. It achieves this by using at least two races to contain the balls and transmit the loads
through the balls. In most applications, one race is stationary and the other is attached to the
rotating assembly (e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to
rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if
two flat surfaces were sliding against each other.

Ball bearings tend to have lower load capacity for their size than other kinds of rolling-
element bearings due to the smaller contact area between the balls and races. However, they can
tolerate some misalignment of the inner and outer races.

Fig 6.4 Ball Bering

6.2.5 Bolt and Nut:-

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 Fig 6.5 Bolt and Nut

As nuts and bolts are not perfectly rigid, but stretch slightly under load, the distribution of
stress on the threads is not uniform. In fact, on a theoretically infinitely long bolt, the first thread
takes a third of the load, the first three threads take three-quarters of the load, and the first six
threads take essentially the whole load. Beyond the first six threads, the remaining threads are
under essentially no load at all. Therefore, a nut or bolt with six threads acts very much like an
infinitely long nut or bolt (and it's a lot cheaper).

Thread Sum
No
% %
1 34% 34%
2 23% 55%
3 16% 71%
Stress on bolt threads. Note how the majority of 4 11% 82%
the stress is on the first thread to the left.
5 9% 91%
6 7% 98%

There is little point in having more than six threads in anything. Nuts with National
Coarse threads typically have 5 threads in them, whereas nuts with National Fine threads have
about 8 threads. Nuts are usually stronger than the bolts they are on, which is to say that the bolt
will usually break before the nut strips.

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 It is often said that two threads must be exposed above a nut. The reason for this is that
the first two threads of a bolt are often poorly formed, and may not engage the nut properly. If
they're not doing their share, the other threads in the nut will be overloaded, and the nut may
strip

6.2.6 Socket Spanner:-

A spanner consisting of a steel cylinder with a hexagonal end that fits over a nut: used
esp. to turn nuts in positions that are recessed or difficult of access

Spanner which is very similar in design to a box spanner is the socket spanner. It is
similar in the sense that the socket head of the spanner covers the nut/bolt completely and the
handle is not fixed to the head. However it is different in that it does not have a Tommy bar type
arrangement, but the socket itself has a projection which is either square shaped or hexagonal
shaped. This projection fits into the appropriately sized cavity on top of the key or the handle
which can be used for the application of force.

Fig no 6.6 Socket Spanner

6.2.6 Cover or Base plate:-

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 Base plate is used to hold the gears and to withstand the forces the gears and the shaft
extensions to hold the tool. It increases the weight and stability of the removing tool. It is a plate
made of M.S

Fig 6.7 Cover or Base plate

7. ASSEMBLY

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o First of all Gears, Bearing, Shafts were taken.
o Swash block and Hammer were used to press fit Gear and Bearing into the shaft The
pinion gears was press fitted in the shaft 11mm from slotted end (square section) of the
shaft At the another end of shaft Bearing was press fitted (fig7.1)

Fig 7.1 Gear, shaft and bearing

o Then Base Plate was taken and in the holes ( diameter of 47mm) of cover bearing covers
was fitted by using mixture of araldite and m-seal (fig 7.2)

Fig7.2 Base plate with bearing cover

o Then take the sun gear and fitted at 11mm from one end of shaft .another end of ball
bearing was fitted at 10 mm distance.
o Then whole the assembly of taper bearing, gear and shaft will be fitted in the covers of
bearing fitted to the base plate and ball bearing will be fit in the hole (diameter 32 mm) of
base plate. All outer gear will be mashed with internal gear.(fig 7.3)

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 Fig 7.3 Shaft or gear assembly mounted on base plate

o After mashing of gears washer will be placed on the gears; after this upper cover plate
was joined.(fig 7.4)

Fig 7.4 Mashing of gear washer will be place

o Then upper and lower cover plate will fixed tightly by using nut-bolts. Our Multi Nut
Tighter will be ready for use.( fig 7.5 or 7.6)

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Fig 7.5 Multi nut remover

Fig 7.6 Multi nut remover

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 8. COSTING

Now-a-days for loosening and tightening nuts in the car, a commonly used tool is four
way car wheel nut wrench brace spanner which costs about Rs.700. It has four different size box
spanners (17mm, 19mm, 21mm, 23mm) for removing different nuts, but it suffers with the
disadvantage that only one nut can be removed at a time. And so it is a time consuming process.
But with MNR tool all four nuts in a car wheel can be simultaneously removed. The total cost
involved for the fabrication of MNR is around Rs.4134. Costs have been estimated based on the
cost of the materials that are being purchased, machining costs and other parameters that are
involved in the fabrication of the project. Approximate cost estimation has been done and it has
been listed as a Table.

Table no 8.1 material costing

Sir No. Component Prize

1 Spur Gear (pinion) 1800
2 Spur Gear (sun) 350
3 Taper Roller 600
Bearing
4 Shafts 500
5 Socket Spanner(Box) 300
6 Nut and Bolt 20
7 Base or Cover Plate 100
8 Welding 50
9 washer 10
10 Handel or Door 150
handle
11 Grease 50
12 M-Seal and Araldite 154

13 Ball Bering 50

Total 4344
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 9. FUTURE ENHANCEMENTS

The project has been fabricated which is purely mechanical. All the operations are done
Manually. To further extend our project as a useful tool, a motor has to be attached to its drive.
Such that by providing a motor, it reduces all the human effort in tightening and loosening the
wheel’s nut. Thus the project can be made an indispensable tool in assembling and dismantling
wheels in cars.

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 10. CONCLUSION
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. The Multi nut remover can be used in automobile units and manufacturing
units. The weight of the model can be reduced by using a light weight material base plate. The
wheel nuts can be easily removed using the multi nut remover
The design and fabrication of MNR tool is proposed. The static load analysis is
performed. The fabrication of MNR tool is completed by milling, welding and fitting processes.
The MNR tool is successfully manufactured and fully functional either tested manually using
lever or by using impact wrench. From the results of analyses and experiments, the tool is
possible to be improved and prototyped for mass production. For future development and
improvement of the MNR tool, light and strong material is expected to be available and applied.
MNR is easily dismantling and assembling during maintains

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 11. REFERENCES

1) R.S.Kurmi and J.K.Gupta – Machine Design – S.CHAND Publication – First Multicolor

Edition –2005– page no 1021 to 1065

2) R.S.Kurmi and J.K. Gupta – Teary of Machine – S.CHAND Publication –14th Revised
Edition –2004– page no 382 to 419
3) http://quickgear.bizland.com/id11.html
4) http://www.gizmology.net/gears.htm
5) http://www. Wikipedia.com

6) S.D.Ambaatkar – Design of machine – Tech-max Publication – page no (3-124 to3-131)

7) http://www.wtools.com.tw/STANDARD-BOLT-TIGHTENING-TORQUE.shtml

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12. APPENDIX

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