Modeling and Analysis of Toggle Mechanism
- 1. Dr T Thimmaiah Institute of Technology (Affiliated to Visvesvaraya Technological University Belgaum) 2023 -2024 DEPARTMENT OF MECHANICAL ENGINEERING KISHORE H (1GV21ME404) PRASANTH J ( 1GV21ME406) SANJAY P (1GV21ME408) SATHISH N (1GV21ME409)) Modeling and Numerical Analysis of Toggle Mechanism for Side Impact Testing Machine PRESENTED BY: UNDER THE GUIDANCE OF: Dr. Manjunatha Babu N S Associate Professor & HOD PROJECT ON
- 2. Introduction In the realm of automotive safety engineering, the robustness and resilience of vehicle structures during side impacts are critical parameters that determine the survivability and protection of occupants. Side impacts account for a significant portion of severe injuries and fatalities in road accidents, necessitating rigorous testing and evaluation of vehicle designs. Traditional side impact testing methods involve complex setups and expensive equipment, often leading to high costs and time-consuming procedures. To address these challenges, the development of a toggle mechanism for side impact testing machines offers a promising solution by simplifying the testing process and reducing costs while maintaining accuracy and reliability. Fig.1 Toggle Mechanism
- 3. Objectives and Methodology Fig.2 Objectives of the Project Fig.3 Methodology
- 4. Principal and constraint functions Fig.4 Principal and constraint functions
- 5. Modelling Cam profile Spring Cylinder and cam follower arrangements Guide ways
- 6. Design of cam profile Cam profile: here the type of cam profile used is snail drop cam. The cam made of cast iron 1. Hardness, Toughness, Ductility, Elasticity, The design of cam is to rise the follower up to 2. 6cm.when the follower rises up to 6cm and sudden falls takes place. lifting the follower from 3. 0 to 300 degree and dwell period is 60 degree. These are the design dimension of cam profile. 4. Fig.5 CAM motion
- 7. Cylinder and spring arrangement Fig.6 Spring and Cylinder Table.1 Spring Parameters for Different Materials
- 8. Design of links Link 1 is constrained at x direction and has a motion only in y direction Link 2 and 3 are constrained at y direction and has a motion only in x direction Fig.7 Links
- 9. Material Selection Metallic Links (Bars): Material: Aluminium Reasoning: Aluminium is chosen for its lightweight properties, making it easier to handle and assemble the machine components. Additionally, aluminium offers good strength-to-weight ratio and corrosion resistance, suitable for the application's requirements. Cams: Material: Cast Iron Reasoning: Cast iron is selected for its high hardness, toughness, and wear resistance properties, which are essential for withstanding the repeated contact and sliding motion between the cam and the follower. These properties ensure the durability and longevity of the cam component. Springs: Material: Music Wire Reasoning: Music Wire is preferred for its excellent elastic properties, allowing the spring to deform and return to its original shape repeatedly without permanent deformation. This property is crucial for the spring to store and release energy efficiently during the testing process. Table.2 Material Properties
- 10. FEA Analysis with Aluminium
- 11. FEA Analysis with Mild Steel
- 12. FEA Analysis with Cast Iron
- 13. FEA Analysis with Copper
- 15. The present work was mainly focused on toggle mechanism and its working principle. Based on the literature review and research works carried out by various authors for different application. Like rock crushing, our work was totally involved the conceptual design of the toggle based side impact testing machine and its implementation in future. The work was initially started with the study on design parameter to decide tentative dimension of the element used for side impact testing machine. The dimensions are chosen as per the specific standard dimension, the respective components were created using solid edge software and old model was constituted through assembly. The model which created will be subjectto finite elementanalysis in order to test it adequacy through stress induced over each part in future. Later, the model will fully developed through fabrication and tested for validation. Conclusion
- 16. Our future scope of work involves: Fabrication of the model followed by the testing for different trials. Development of the actual prototype model. Scope of Future Work
- 17. Thanks