International Journal of Vehicle Structures and Systems

Open Access Open Access  Restricted Access Subscription Access

Root Cause Analysis for Failure of Door Lock Case Assembly during Caulking Process


Affiliations
1 Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
2 Dept. of Mechatronics Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
3 Dept. of Mechatronics Engg., ISHIK University, ERBIL, KRG, Iraq
 

   Subscribe/Renew Journal


This paper details the failure analysis of deformed passenger car door lock case and presents a solution to avoid the part deformation during caulking process. This failure was observed during the assembly of case and its cover by caulking process. Mechanical properties and chemical composition of case (Zn Al4 material) has been checked by universal testing machine and spectra material analyser. The material composition having less aluminium content leads to the casting strength and cast ability losses. In order to get the exact load requirement for caulking process, analysis has been carried out by using finite element method. In finite element method, the case and case cover model has created by AUTODESK INVENTOR and stress analysis was carried using same software. The induced stress and deflection are obtained for various load conditions. The experimental measurement was taken from the machine by using load cells. By comparing the experimental data with FEM data we found that the problem happened due to the overload. From this result data the machine design was optimized by changing booster and cylinder which is used to generate the load. The hydro pneumatic circuit of the caulking machine has been optimized and redesigned to avoid future problems.

Keywords

Caulking Process, Failure Analysis, Finite Element Method, Redesign, Stress Analysis.
User
Subscription Login to verify subscription
Notifications
Font Size

  • L. Shen, Y. Tang and B. Jiang. 2014. Failure analysis of the conical press-fit connections in a locomotive drives system, Engg. Failure Analysis, 44, 158-167. http://dx.doi.org/:10.1016/j.engfailanal.2014.04.019.

  • E. Zdravecka, M. Onda, J. Tkacova, M. Vojtko and J. Slota. 2015. Failure analysis of the pulleys during the press-fit assembling process, Case Studies in Engg. Failure Analysis, 3. 34-38. http://dx.doi.org/10.1016/j.csefa.2014.11.002.

  • T.L Anderson. 2005. Fracture mechanics, fundamentals and applications, 3rd Ed. CRC Press/Taylor & Francis Group 640. https://doi.org/10.1201/9781420058215.

  • J. Parka, J. Parkb, S. Choic, K. Nac and Y. Kimd. 2008. Application of FE analysis for optimal design of caulking process, J Materials Processing Tech., 198(1-3), 471-477. https://doi.org/10.1016/j.jmatprotec.2007.07.029.

  • Y. Zhu, Y. Wang and Y. Huang. 2014. Failure analysis of a helical compression spring for a heavy vehicle’s suspension system, Case Studies in Engg. Failure Analysis, 2(2), 169-173. http://dx.doi.org/10.1016/j.csefa.2014.08.001.

  • S.P.S.S. Sivam, V.G Uma Sekar, S. Mishra, A. Mishra and A. Mondal. 2016. Orbital cold forming technology- combining high quality forming with cost effectiveness -A review, Indian J. Sci. and Tech., 9(38), 1-7. https://doi.org/10.17485/ijst/2016/v9i38/91426.

  • S.P.S.S. Sivam, M. Gopal, S. Venkatasamy and S. Singh. 2015. Application of forming limit diagram and yield surface diagram to study anisotropic mechanical properties of annealed and unannealed sprc 440e steels, Int. Conf. on Recent Advancement In Mech. Engg. & Tech., J. Chemical and Pharm. Sci., 9, 15-22.

  • P. Sivam, Singh et al. 2017. Multi response optimization of setting input variables for getting better product quality in machining of magnesium AM60 by grey relation analysis and anova, Periodica Polytechnica Mech. Engg., 62(2), 118-125. https://doi.org/10.3311/PPme.11034.

  • S.P.S.S. Sivam, V.G. Uma Sekar, K. Saravanan, S.R. Kumar, P. Karthikeyan and K.S. Moorthy. 2016. Frequently used anisotropic yield criteria for sheet metal applications: A review, Indian J. Sci. and Tech., 9(47). https://doi.org/10.17485/ijst/2015/v8i1/92107.


Abstract Views: 772

PDF Views: 226




  • Root Cause Analysis for Failure of Door Lock Case Assembly during Caulking Process

Abstract Views: 772  |  PDF Views: 226

Authors

S. P. Sundar Singh Sivam
Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
K. Saravanan
Dept. of Mechatronics Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
Ganesh Babu Loganathan
Dept. of Mechatronics Engg., ISHIK University, ERBIL, KRG, Iraq
D. Kumaran
Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India
S. Rajendra kumar
Dept. of Mech. Engg., SRM Institute of Sci. and Tech., Kattankulathur, Tamil Nadu, India

Abstract


This paper details the failure analysis of deformed passenger car door lock case and presents a solution to avoid the part deformation during caulking process. This failure was observed during the assembly of case and its cover by caulking process. Mechanical properties and chemical composition of case (Zn Al4 material) has been checked by universal testing machine and spectra material analyser. The material composition having less aluminium content leads to the casting strength and cast ability losses. In order to get the exact load requirement for caulking process, analysis has been carried out by using finite element method. In finite element method, the case and case cover model has created by AUTODESK INVENTOR and stress analysis was carried using same software. The induced stress and deflection are obtained for various load conditions. The experimental measurement was taken from the machine by using load cells. By comparing the experimental data with FEM data we found that the problem happened due to the overload. From this result data the machine design was optimized by changing booster and cylinder which is used to generate the load. The hydro pneumatic circuit of the caulking machine has been optimized and redesigned to avoid future problems.

Keywords


Caulking Process, Failure Analysis, Finite Element Method, Redesign, Stress Analysis.

References





DOI: https://doi.org/10.4273/ijvss.11.1.03