DESIGN, ANALYSIS AND FABRICATION OF UNIVERSAL

ENGINE STAND
Matin Bagwan1, Subham Sarwade2, Dayanand Dhavane 3, Jalinder Shinde4, Prof.M.D.Salunke5
1,2,3,4
UG Students Department of mechanical engineering
Bhagwant Institute of Technology, Barshi, Distict: solapur, India
5
Guide, Department of mechanical engineering
Bhagwant Institute of Technology, Barshi, Distict: solapur, India

Abstract I. INTRODUCTION
In the Indian market thousand of two wheeler There is no device for holding engine
sell delay, thousands of vehicle is goes for probably when the repair them when the
maintenance in workshop and garage. In on disassemble engine, it is difficult to handling
vehicle the main part or heart of vehicle is an engine because its complexity and the weight.
engine. Without engine vehicle have no meaning Near about is 20kg average weight of any
in the workshop or garage. Engine repairing is company engine. These is cause to difficult
most difficult work because of its complexity. handling for repairing the worker our engine stand
The repairing or maintaining for the resolve above problem of handling engine and
doing repairing and handling of engine is more make safe environment for the worker.
complicated for preventing the problem we
decide to make universal engine stand on We decided to provide this engine to garage
universal engine stand is a concept on which we worker with low cost. For eliminating or reducing
held the sell companies vehicle engine in one cost we use hellow plain carbon steel material for
stand. We try to solve above problem of making engine stand. We also use the design
mechanic with making stand in sample parameter and calculation for minimising the
construction low cost.from this project we learn weight of engine stand. Here used latest
design concept and software skill.under the simulations software for analysis our result.
guidance of college staff. Universal engine stand is holding all types
To better handling of engine used of engine with different manufacturer, with
“Universal Engine Stand” is to be designed dimensions this device is very useful for can
based on the working principle of different garage worker.due to this simple construction
bikes. An engine stand is a tool commonly used worker easily hold engine on this stand and
to repair large heavy gasoline or diesel engines, perform the requiring operation.
but motorcycle engine works on locally All the material, dimensions, parameters figure
arrangement to holding engine has working to shows the simple constructional details of
universal stand.
be done.
Keyword: Universal Engine Stand, Design
Calculation, FEA,

 
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IV. DESIGN CALCULATION

Plain carbon steel C45*
C, Plain carbon steel
45, Average carbon content in hundredth
of a percent.
*, Any of the following.
W, Fusion weldable
WP, Pressure weldable
Wr, Resistance weldable
Ws, Spot weldable
C45
Fig.1 constructional Details
II. PROBLEM DEFINITION Condition Tensile Yield Input
Selection of this project because there is no Strength Strength Value
reliable device for holding engine properly when N/mm² N/mm² I20d
the engine repairing. There is no device for holding Nm
vertical as well as horizontal engine on a stand. Bars and
Both the engine holding arrangement is forgings, 600-750 380
different, so it’s difficult to making universal Hardened and
stand. So we select this project for preventing or Tempered 520 340 41
eliminating this problem. Tubes, cold
When one person doing repair work it is very drawn and 700 600
difficult to handling engine because of its anneled
complexity as well as weight, so select this topic.
Engine had number of parts, it may be near about
Table: 1 Property Of Materials
100-150 parts (including nuts bolts). When
Material:-
repairing this part or handling chances to damage
Select Tubes, cold drawn and annealed
or missing these parts.all part in engine is do it’s
function, it was very important for this problem Therefore yield strength 340 N/mm²
here provide the tray at bottom of stand for gather
this parts properly. Syt = Yield sterngth
Weight of engine P = 50 Kg
III. LITERATURE REVIEW
Near about 15 to 20 differunt companies making = 50 * 9.81
the two wheller in India. Sell of these companies
= 490 N
bikes per day in showroom 2 to 3. Like Bajaj, Hero,
Honda, Yamaha, TVS, Mahindra etc. And near σc = Compression Stress
about 1 bike for full engine maintenance in
workshop. There are twotypes of engine in σc = Syt/ fos
commonly used for making bikes are vertical and Assume FOS = 2
second horizontal. In local workshop or showroom
service center there is no proper fixture for holding σt = σc = 340/2 = 170 N/mm²
engine is present in now day. Due to the Design of holding pin
complicated construction and weight engine
handling is difficult for the worker. Now a day
workers repaire engine on a tyre or ground surface, τ=
on the surface problem is handling of engine. Due τ = P/2(π/4 d²)
to the engine oil floor makes oilly causes dirty and
slipary envirnment. τ = 490/2(π/4 d²)
 
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But τ = 0.5*340/2 = 85 N/mm² Load 490 N = 0.49 KN
d² = 490/(2* π/4*85) 760 mm = 0.760 m
d=2 # Support Reaction [upward ↑ +ve,
downward ↓ -ve]
Take d = 5mm
The body has Φ12mm hole so use Φ12mm pin but Σv = 0
design shown it require only Φ5mm so design is
safe with using Φ12 mm to provide high fitting. Therefor RA + RB –WL = 0
Therefore d = 12mm RA + RB = 0.49 * 0.76
Bolt (pin) for plate fitting RA + RB = 0.3724
τ = P/2A
85 = 490/2(π/4*do²) ΣMA = 0 [Clockwise +ve, Anticlockwise –
do = 2mm ve]
Hence standard nut of Φ6mm can be used. WL * L/2 – RB * L = 0
Design of clamps vertical bar tensile
stress 0.49 * 0.76 *0.76/2 = RB * 0.76
σt = P/A
[RB = 0.1862]
= 245/(25.4²- 19.4²)
= 0.91 N/mm² [RA = 0.1862]
½
(σmax = # Shear Force Calculations
= ½ *340
= 170 N/mm² SF at just left of A = SAL = 0
0.91 is less than σmax = 170 Hence design SF at just right of A = SAR = 0.1862
is safe.
Top pin design on shear stress SF at just left of B = SBL = 0.1862– WL
Assume from weight 6 Kg.
= 0.17297 – 0.34594
τ = P/A
85 = 245+6*9.81/ π/4 d² = -0.1862
d² = 303.86/ π/4 *85
d = 2.13 SF at just right of B = SBR = -0.1862+
[d = 5mm] 0.1862
Finding Bending Moment =0
# Bending Moment Calculations
BM at A = 0
BM at B = 0
# Maximum Bending Moment
SF at point C
x be the distance of C from A
SF at C = 0
WL – W*x
W* L/2 = Wx
Fig: 2 Shear Strees Daigram and Bending
Moment Daigram W*L/2*W = x
 
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[L/2 = x] Finding Bending Stress
M = σb * D^4 – d^4/6D
Bending Moment at point C 35.378*10³ = σb * (25.4^4 –
RA *x – Wx. x/2 19.4^4)/(25.4*6)
σb = 35.378*10³/1801.7360
0.1862* 0.38 – 0.49 * 0.38²/2 [σb = 19.63 N/mm²]
0.035378 KNm Which is less than σmax = 170 N/mm²
[Hence design is safe]
# Maximum B.M 0.035378 and it occur at
mid point, where SF changes its sign. Shear failure of pin in plate
τ = P/A
The BMD is a parabola
85 = 303.86/ π/4 d²
d = 2.13mm
d = 5 mm

V. Welding Calculations:-
# welded joint subjected to bending
moment
A cantilever beam of rectangular cross
section is welded to support by means of two
fillet welds W1 and W2 as shown in fig.
According to the principle of applied
mechanics the eccentric force P can be
replaced by an equal and similarly directes
force P acting through the plane of welds
InputLength (l): 760 mm aolng with a couple. Mb = P*e as shown in
Load (q): 0.49kN/m fig. the force P through the plane of welds
causes the primary shear stress τ1, which is
Material: Steel given by
Profile: Rect. tube τ1 = P/A …. (1)
Outside width b: 25.4 mm Where A is the threat area of all welds. The
Outside height h: 25.4 mm moment Mb causes bending stresses are
given by
Thickness w: 3 mm
σb = Mby/A….(2)
Moment of Resistance Wx: 1802 mm³
Where,
Moment of Inertia Ix: 22882 mm³
I = moment of inertia of all welds based on
Modulus of Elasticity E: 210000 N/mm² the threat area
Results y = distence of the point in weld based on the
point in weld from the neutral-axis.
Max. (Bending) moment: 0.04 kNm
The bending stresses are assumed to act
Max. Stress: 19.6N/mm²
normal to the threat area. The resultant shear
Max. Deflection distance: 0.4 mm stress in the welds is given by

 
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Since the permissible shear stress in the weld
τ= 1 ² …..(3) is 80 N/mm²
.
b = 25.4 = 80
d = 25.4 .
t=
Permissible shear stress in weld is 80 N/mm²
t = 0.88
The total area of the horizontal and
vertical weld is given by t = 1 mm
A = [bt + dt] And
= [25.4t + 25.4t]
= 101.6t h= = = 1.41 = 21mm
. .
The primary shear stress in the weld is
givan by
Welding calculations of C channel
. A = Area
τ1 = = N/mm² ……. (i)
.
A = 2[bt + dt]
Reffering to figure the moment of inertia of
= 2[25.4t+25.4t]
four welds about x-axis is given by,
= 101.6t
³
Ixx = t Ixx = t ]
Ixx = 10924.70t mm
Substituting the value .
τ= ----- (i)
.
. ∗ . . ²
Ixx = ] σb =
. ∗ ∗ .
= 81.93532 + 2731.17 =
.
.
= 10924.70 t mm² = N/mm² ----- (ii)

From eqution (3
From eqution (2) Max shear stress in weld is given by
σb =
τ= √ ²
y = 12.7
. ∗ ∗ . . .
= =
.
. = 1824.99 + 1.44
= N/mm² .
= N/mm²
Maximum shear stress in weld is given by Permissible shear stress in the weld is 80
N/mm²
.
τ= 1 = = 80

. . t = 0.5341 mm
=

= 4990.7160 + 2.25 = 1 mm
.
= N/mm² h= = 1.41 mm
.

= 2 mm
 
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VI. PROJECT OBJECTIVE

To construct unique designed
engine maintenance stand.
i. To virtual design in the
engine stand in MDT 6.
ii. To manufacture stand
with accuracy for safety
use.
iii. To analyze the design
safety in Autodesk
Inventors with
following Fig.4 Von Mises stresses on steel
a] Static structural analysis.
b] Factor of safety (FOS)
c] To test and validate the
design.

VII. ANALYSIS OF ENGINE STAND

1. Total Displacement
As observing image of Inventor solution of
displacement, we can get exact location of
deformation at the loaded body.

Fig.5 Von Mises stresses on Aluminum

3. Safety Factor
The project mainly focuses on study safety factor
plays an important role as deciding factor for
thickness of material.

Fig.3 Displacement of the steel

2. Von Mises (Yield) Stress
Von mises stress defines the maximum yielding
stress at the particular location which useful before
manufacturing in actual practice.

Fig.6 Safety Factor for the Steel

 
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materials. so with increasing stud dimension
reduce the stress.
3. Minimum Safety Factor for the steel is 2.01604
and for Aluminum 0.529 on stud.

IX.CONCLUSION
From the above theoretical and analytical study
conclude that
1.Due to the maximum safety factor of Steel
compairing with Aluminum, steel is useful for
making stand
2.Maximum stresses are produced on the stud and
Fig.7 Safety Factor for the Aluminum chance of failure first stud. But the design load
at 490N with factor of safety 2 the stud does not
fail so stand design is safe.
3.From all the calculation parameter steel is better
with compaire to aluminum so for making stand
select steel material.
4. On actual fabricated Engine Stand vetical as
well as horizontal engine are holded and tested
.no dout it's called the Universal Engine Stand
as vetical and horizontal engine engines can
hold and worked comfort.

X.ACKNOWLEDGEMENTS
It gives us a great pleasure to thank all those
people who helped us in successful completion
of project. First of all we would like to express
our deep sense of gratitude and sincere thanks to
Fig 8 Final fabricated engine stand our respected principal Dr. A.K. Deshmane for
VIII. RESULTS AND DISCUSSIONS his constant inspiration and motivation towards
of the project. We express our thanks to Prof.
Parameters Steel Aluminum V.L. Mundhe, Head of Department of
mechanical engineering for his motivation and
min max min max
permission for avail the workshop facilities.
Von mises 0 102.7 0 103.8
stress
We are very much thankful to our guide Prof.
displacement 0 1.196 0 3.81
M.D. Salunke, for his timely advice, highest
Safety Factor 2.02 15 0.53 15
level of co-operation and valuable suggestions
Table: 2 Results helped us to put our efforts in satisfactory
1. Maximum Displacement due tensile force 490 manner and for the completion of the report.
N is 1.19mm for steel and Maximum Last but not least we thank all those who have
Dislacement due to force 490 N is 3.81mm helped directly or indirectly for the completion
2. Maximum Von mises stresses found in steel is of our project.
102.676 MPa which is observed on the stud.
Maximum Von mises stresses found in
Aluminum is 103.786 MPa which is observed
on the stud. Maximum von mises stress
indicates that stud will first start yielding in both

 
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3. Long, Tony (30 August 2007), "August 30,
1885: Daimler Gives World First 'True'
Motorcycle", Wired, ISSN 1059-1028
4. Falco, Charles M.; Guggenheim Museum
Staff (1998), "Issues in the Evolution of the
Motorcycle", in Krens, Thomas; Drutt,
Matthew, The Art of the Motorcycle, Harry
N. Abrams, pp. 24–31, ISBN 0-89207-207-5
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XI.REFERENCES
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motorcycling facts and feats, Guinness publisher
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