EXPERIMENTAL ANALYSIS OF CHAIN SPROCKET USING METAL … · 2018-12-01 · In this study ,chain sprocket is designed and analysed ... particle reinforcement on the mechanical properties

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 11, November 2018, pp. 890–901, Article ID: IJMET_09_11_090

Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=9&IType=11

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

EXPERIMENTAL ANALYSIS OF CHAIN

SPROCKET USING METAL MATRIX

COMPOSITES

*Prakash Kanna G, Vignesh K and Mohamed Nasrulla S

Assistant Professor / Mechanical Engineering, PSNA College of engineering and technology,

Dindigul.

*Corresponding author

ABSTRACT

Aluminium matrix composites (AMCs) have received considerable attention for

military, automobile and aerospace application because of their low density, high

stiffness and high strength. In this project Al 2024 alloy reinforced with boron carbide

and zinc. It is fabricated by conventional stir casting method. The addition of ceramic

reinforcements (B₄C) has raised the performance of the Al (2024) alloys. This aluminium

matrix has good wear resistance, low weight and density. In this investigation mechanical

properties have been conducted by varying mass fraction of B₄C and Zn with aluminium

2024. Conventional materials like steel, brass, aluminium etc., will fail without any

indication. Now a day to overcome this problem, conventional material is replaced by

aluminium composite materials. In this project microstructure study, tensile behaviour,

hardness, impact and wear characteristics of B₄C and Zn particulate reinforced with

Al2024 alloy composites have been reported. This composite material is proposed to use

for chain sprocket in two wheelers. The designing and modelling of chain sprocket is done

by CATIA software.

Keywords: Aluminium alloys; metal matrix composites; boron carbide; zinc, stir casting

process.

Cite this Article Prakash Kanna G, Vignesh K and Mohamed Nasrulla S, Experimental

Analysis of Chain Sprocket Using Metal Matrix Composites, International Journal of

Mechanical Engineering and Technology, 9(11), 2018, pp. 890–891.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=11

1. INTRODUCTION

A composite material (also called a composition material or shortened to composite, which is the

common name) is a material made from two or more constituent materials with significantly

different physical or chemical properties that, when combined, produce a material with

characteristics different from the individual components. The individual components remain

separate and distinct within the finished structure. The new material may be preferred for many

Prakash Kanna G, Vignesh K and Mohamed Nasrulla S


reasons: common examples include materials which are stronger, lighter, or less expensive when

compared to traditional materials.

1.Ebhota Williams S, Ademola Emmanuel, Oghenekaro Peter “Fundamentals of Sprocket

Design and Reverse Engineering of Rear Sprocket of a Yamaha CY80 Motorcycle”, International

Journal of Engineering and Technology Volume 4 No. 4, April, 2014.This study involves the

fundamentals of sprocketdesign and manufacturing of a Yamaha CY80 motorcycle rear sprocket

through reverse engineering approach. It discusses dimensioning, drafting, chemical

composition, material selection, choice of manufacturing process, heat treatment, surface finish

and packaging as the eight steps that need to be followed sequentially in this reverse engineering

approach. In this work, universal milling machine was used to produce thesprocket from the

blanked medium carbon steel (AISI 1045) with chemical composition of C=0.45%,

Mn=0.75%,P=0.03% max, S=0.04%. Induction heat treatment was applied to move the material

hardness from 13 HRC to 45 HRC as shown by hardness test. 2.

SwapnilGhodake,PrashantDeshpande,“Optimization of Excavator Sprocket and it's Validation

by Test Rig Concept”, 2014. Conf. on Advances In Engineering And Technology, ISBN: 978-1-

63248-028-6 In an excavator, a sprocket is a toothed wheel that engages with a chain or track to

transmit rotary motion. Sprocket, track and idler form an assembly to cause the motion of

excavator. Optimization is a methodology of making something (as a design, system, or decision)

as fully perfect, functional, or effective as possible to maximize productivity or minimizes waste.

In this paper, sprocket weight optimization is done with reducing material to get optimized design

which can perform well under torque condition keeping same constraints. For this purpose, an

FEM tool is used for analysing existing and optimized sprocket with different types of FEA

techniques. Strain Gauging is done for correlation with FEA virtual strain to confirm the loadings.

Conceptual Test rig is proposed to validate the optimized sprocket.3. Chandraraj Singh Baghel,

Abhishek Jain, Dr. A.K. Nema and Anil Mahapatra “Software ANSYS Based Analysis on

Replacement of Material of Sprocket Metal to Plastic Material PEEK”.In this paper, conventional

sprocket replace to plastic PEEK (polyether ether ketone),2013. 4. Nikhil p. ambole, P.R kale

“Design and analysis of carbon fibre sprocket”,2016. Sprocket is made up of carbon fibre

material. Drawing and drafting is done using CAD software. FEA software is used for analysis

sprocket chain. With different properties of mild steel and carbon fibre, stress and deformation

of sprocket is compared. 5. Gopalkrishna U, srinivasarao K, vasudeva B “Effect of boron carbide

reinforcement on aluminium matrix composite”,2013.. In this paper aluminium 6061 matrix with

boron carbide was combined by stir casting method. In this project aluminium and boron carbide

was completely successful. 6. ParagNikam,Rahultanpure “Design and optimization of chain

sprocket using finite element analysis”,2016. In this study ,chain sprocket is designed and

analysed using finite element analysis for safety and reliability. Ansys software is used for static

and fatigue analysis of sprocket design using the result optimization of sprocket weight reduction

hasbeen done.7. S.Thipprakmas “Improving wear resistance of sprocket parts using a fine-

blanking process “,2010.In this work ,a surface hardness and wear resistance of a fine-blanked

sprocket are compared with those sprockets that made using hobbing process. Based on the result

the material cost of sprocket could be reduced by using low carbon steel instead of medium

carbon steel. 8. Vladislavdomnich,sarareynaud, Richard .A haber, manishchhowalla “Boron

carbide: structure ,properties and stabilities under stress”,2011.In this paper it provides a

comprehensive review of recent advances in understanding of structure and chemical variation in

boron carbide sand their influence on electronic, optical, vibrational , mechanical and ballistic

properties.9. Chintaneelimadevi,V .mahesh and N. selva raj, “Tensile and impact behaviour of

AL-Sic-Zn-Cu metal matrix composites”,2014. In this paper AL-Sic-Zn-Cu are varied by

different proportion. Mainly zinc(2,4,6,8)% and Copper(2,4,6,8)%. The tensile strength is

increase in increase with zinc composition. Percentage of elongation decreases with increase in

copper percentage. 10. Ronaksuthar, “Analysis of sprocket strength using finite element

Experimental Analysis of Chain Sprocket Using Metal Matrix Composites


analysis”,2017. In this project the existing sprocket material compare with carbon – fibre

material. The drawing and analysis done by CAD and ANSYS software. The result of the project

is a carbon fibre has less density, cheap, easily available and also low machining cost. 11.

Vengatesh .D , Chandra mohan .V, “Aluminium alloy metal matrix composite :survey

paper,2014. In this paper the discuss about the recent composite technology and performance

behaviour and also discussed about metal matrix composites, the material mixed with non-metal

and analysed in this mechanical properties and fabrication technique. 12. Vipin K sharma ,R . C

singh , Rajiv chaudhary, “Effect of fly ash particles with aluminium melt on the wear aluminium

metal matrix composites”,2017. In this paper fly ash content mix with aluminium with different

composition (2, 4, 6)%.It observes metal matrix composite with 6% weight of fly ash has less

wear 0.32g and 4% weight of fly ash given low coefficient of friction 0.12.Wear resistance

increase with increase content of fly ash. 13. Johnyjames .S ,Venkadesan .K , kuppan .P and

Raamanujam . R “Hybrid aluminium metal matrix composite reinforced with Sic and

TiB2”,2014. It has proved from wear analysis that Ti B2 particles increase the wear resistance in

the behaviour of hybrid aluminium metal matrix. 14. k.Punithgowda .J.N .Prakash, “Effect of

particle reinforcement on the mechanical properties of Al2024-metal matrix composite”,2015.

In this paper the work reserves the stud of mechanical properties of Al2024-tungsten carbide. By

increasing the carbide content with increasing the ductility NTS, compressive strength , However

hardness value decreased. 15. Preetamkulkarni, “Effect of mechanical properties of Al2024based

hybrid metal composites”,2015. In this paper Al2024 is used for metal matrix composite due to

its high strength weight ratio as well as good fatigue resistance .but it has poor corrosion

resistance.it can overcome by adding zinc to the Al2024 composites.

2. MATERIAL SELECTION

Selecting the right material for sprocket involves many factors, including the cost as well as the

material performance required.Sprocket can be also supplied in various cast material, with or

without harden teeth.

1. Aluminium 2024

2. Boron carbide

3. Zinc

2.1. Aluminium 2024

Aluminium 2024 is an aluminium alloy, with copper as the primary alloying element. It is used

in applications requiring high strength to weight ratio, as well as it has good fatigue resistance. It

is welded only through friction welding, and has average machinability. Due to

poor corrosion resistance on the al2024 it is often clad with aluminium or Al-1Zn for protection,

although this may reduce the fatigue strength in the material composition.

The material used here is Aluminium 2024 alloy of theoretical density of 2.78 gm /cm3. B4C

micro particles of average size 80 microns were used as the reinforcement particles with density

of 2.52 gm/cm3.

2.2. Boron carbide

Boron carbide is the extremely hard boron carbon ceramic used in bullet proof vests. It has high

wear resistance. It also has a good chemical resistance and also a low density. Due to its hardness

it is used as abrasive material. Vickers hardness about >30 GPa. Boron carbide is known as a

robust material having high hardness, high cross section for absorption of neutrons (i.e. good

shielding properties against neutrons), stability to ionizing radiation and most chemicals.

Its Vickers hardness (38GPa), Elastic Modulus (460GPa) and fracture toughness (3.5 MPa·m1/2)

approach the corresponding values for diamond (1150GPa and 5.3 MPa·m1/2).As of 2015, boron



carbide is the third hardest substance known, after diamond and cubic boron nitride, earning it

the nickname "black diamond".

2.3. Zinc

Zinc is bluish white metal .It is mostly used as anti-corrosion element. Zinc is the hardest

materialand also have high heat capacity.A widely used zinc alloy is brass, in which copper is

alloyed with anywhere from 3% to 45% zinc, depending upon the type of brass. Brass is generally

more ductile and stronger than copper, and has superior corrosion resistance.

Table3.1. Material Properties

MATERIAL DENSITY (g/cm³) HARDNESS

(Vickers)

MODULUS OF

ELASTICITY (Gpa)

MELTING POINT

( ᵒ C )

ALUMINIUM

2024 2.78 167 73.1 502

ZINC 7.10 30 108 419

BORON CARBIDE 2.52 38 460 2763

3. COMPOSITION

MMCs are made by dispersing a reinforcing material into metal matrix composites. In this project

the material like aluminium 2024, boron carbide, zinc are mixed with appropriate composites.

There are two different composites are selected with aluminium as major contribution. The

composition-1 has aluminium 2024 as 84%, boron carbide as 8% and zinc as 8%.

3.1 Casted Sample A

Figure.3.1 Sample specimen A

Figure 3.2 Chart for Composition A

Composition A

Aluminium

2024 80%

Boroncarbide

8%

Zinc 8%



3.2 Casted Sample B

The composition -2 has aluminium 2024 as 80%, boron carbide as 10% and zinc as 10%.

Figure.3.3 Sample specimen B

Figure 3.4 Chart for composition B

4. CAD MODELLING

Dimensions are required for calculating the boundary conditions. Hence computer aided model

is necessary. The conventional sprocket model is taken as the Bajaj pulsar 180 is used. Input for

making the design o the sprocket is taken from rear wheel of Bajaj pulsar 180. CAD model then

is made by the commands in CATIA V5 R19 of pad, pocket, fillet, and geometrical selection in

part design module. This drawing will help to get the dimensions useful for the force calculation

in static loading.

Input Bajaj pulsar 180 rear wheel sprocket

4.1. DIMENSIONS

• Number of teeth = 42

• Sprocket diameter = 170mm

• Chain pitch = 12.7mm

• Roller diameter = 8.51mm

• Sprocket thickness = 7.2mm

Creating 2D profile of sprocket using CATIA, the geometrical view has been shown below

the diagram.

Composition B

Aluminium 2024

80%

Boron carbide

10%

Zinc 10%



Figure 4.1 2D Profile of teeth

Modelling the teeth of the sprocket in 2D, the dimensional over view can be used as shown

below the diagram. Pitch sizes were used as the calculation of number of teeth as per the diameter

of the sprocket.

Figure 4.2 2D Profile of sprocket

To create the sprocket model, the dimensions to be concluded for the purpose of relative

model of sprocket in which accordingly suitable chain drives of the vehicles.

Figure 4.3 2D Profile of sprocket



4.2. CATIA MODEL SPROCKET

Figure 4.1 CATIA Model of sprocket

The sprocket dimensions were included in to the software and that is designed for our

considerable design. The study of CATIA used to design the sprocket. This design in

conventional sprocket which already used in automobile industries. Mechanical engineering

terms using in this of two wheeler chain sprocket.

5. PREPARATION AND TESTING METHODS

Test specimen for analysis of different mechanical and wear properties like abrasive wear ,tensile

strength and hardness were prepared as per ASTM standard and its description is given below

5.1. Tensile test

The test process involves fitting the tensile specimen in the testing machine and gradually

increasing until it reaches it fracture state. During the tensile test, the elongation of tensile

specimen is in the applied force.

A tensile test strength specimen as per ASTM standard is prepared for this purpose is based

on the following equations

L0= 5.65(A0)1/2

Where,

• L0= gauge length

• A0=cross sectional area

Figure.5.1 specimen for tensile strength test

5.2. Abrasive wear and hardness test

The abrasive wear and hardness is determined from the same specimen. A standard specimen of

dimension (ɸ150mm and 50mm length) of the aluminium composition is prepared for the sample

purpose.



Figure.5.2 Specimen for the abrasive wear and hardness test

5.3. Specimen for impact test

Impact test specimen as per ASTM standard is prepared for the same purpose having the

following dimensions

Length =550mm

Width =10mm

Thickness=10mm

Notch depth =5mm

Figure 5.3 Failure Specimens on impact test

The sample pieces were taken to the testing process of hardness, impact, tensile strength, and

wear testing. Sample pieces were made up of composite materials.

6. RESULTS AND DISCUSSION

6.1 COMPOSITION –A and B PROPERTIES TEST REPORT

The composition-A has the metal matrix of Al2024 reinforced with 8% of B4C, 8% of Zn.

Table7.1. Impact test for specimen A and B

Composition Impact Testing (Izod)

(JOULES)

Brinell Hardness

HBW

Composition-A

(Aluminium84%-Boron

carbide8%-Zinc8%)

2

98

Composition-B

Aluminium80%-Boron

carbide10%-Zinc10%)

2

86



Figure 6.1 Hardness value for boron carbide %

The composition both A&B are have same impact value but in the composition A has higher

hardness value so composition A is only used for further tensile and wear testing due to its higher

hardness value.

In this Test report of composition-A Aluminium composites (Al2024, B4C and Zn) the tensile

test is conducted by UTM machine, wear test is conducted by pin on wear testing machine,

hardness and impact test is done by brinell and izod test.

In this composition B has the metal matrix 80% of Aluminium that reinforced with 10% of

Boron carbide and10% of Zinc.In this Test report of composition-B Aluminium composites

(Al2024,B4C and Zn) the impact test is calculated by Izod test and hardness test is calculated by

Brinell hardness test.

6.3. MICROSTRUCTURE VIEW OF COMPOSITION-A

The optical micrograph of cast Al 2024 reinforced with 8% of B4C, 8% of Zn.

Figure.6.3. Microstructure analysis of composition A

In this microstructure of Al 2024 alloy composites revealed the uniform distribution of B4C,

Zn particulates in the matrix and no void and discontinuities were observed. Common casting

defects such as porosity and shrinkages were not found in the micrographs .There was a good

interfacial bonding between the B4C particles, Zn particles and Al 2024 alloy.

6.4. ABRASIVE WEAR TEST

The material considered for this experiment with dimensions Φ150 mm&500 mm length. The

test was conducted on a Pin on disc machine.

80

83

86

89

92

95

98

0 8 10

Har

dn

ess

(HB

W)

Boron Carbide %

Brinell Hardness

Hardness curve



6.4.1. Wear rate calculation (mild steel)

Result of abrasive wear test for carburized mild steel, at load 9.8N

Table 6.2 Wear rate calculation (mild steel)

Carburizing

Condition

Tempering

condition Weight loss(g)

Wear

volume

cm3x10-2

Wear rate

cm2x10-7

Wear

resistance

cm-2x107

Temp

(0C)

Soak

time

(hrs)

Temp

(0C)

Soak

time

(hrs)

Simple

mild steel - - - 0.210 2.67 3.92 0.255

850 2 200 0.5 0.133 1.69 2.48 0.403

900 2 200 0.5 0.118 1.5 2.20 0.455

950 2 200 0.5 0.109 1.38 2.02 0.493

6.4.2 Parameters to be considered (composition-A)

Table6.3. Parameters considered (composition-A)

Material of coarser abrasive sheet 60 GRADE

Equivalent revolution 84 times

Rotational frequency 40±1rpm

Load applied 1 Kg

6.4.3. Wear rate calculation (composition-A)

Table 6.4.Wear rate for aluminium composites

Sample Initial weight(g) Final weight(g) Abrasive loss (g) %

A 6.6278 6.5238 0.1040 1.57

Comparing these results the aluminium metal matrix has the high wear resistant also it has

the good corrosion resistant.

6.5 STRESS-STRAIN RELATIONSHIP CURVE (TENSILE TEST)

Figure 6.4 Tensile test for specimen A



6.5.1. RESULTS BASED ON GRAPH (TENSILE TEST)

Table 6.5. Results based on graph

FMAX 3.76Kn

UTS 85.35Mpa

%EL 3.03%

Yield stress(YS) 71.26Mpa

6.6. COMPARISON OF MATERIAL PROPERTIES

Table 6.6. Comparison of material properties

Properties Mild Steel Composition-A

Abrasive loss(g) 0.308 0.1040

Hardness(HBW) 100 98

Weight of sprocket(g) 700 250

Based on the table value our composition-A has the higher hardness, less in weight. So

compare to conventional mild steel composition-A is the optimum one.

7. CONCLUSION

From the analysis results and comparison of properties existing of materials, it is found that

aluminium composition is having better hardness and high wear resistance and also it is easily

available and reasonable cost as compared to other alternate materials. Hence it is the best suited

alternate material for sprocket and it is expected to perform better with 64.2% of weight

reduction.

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Documents

EXPERIMENTAL ANALYSIS OF CHAIN SPROCKET USING METAL … · 2018-12-01 · In this study ,chain sprocket is designed and analysed ... particle reinforcement on the mechanical properties