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Pelton, Francis turbine</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/governing-of-hydraulic-turbines-pelton-francis-turbine/">Governing of Hydraulic Turbines &#8211; Pelton, Francis turbine</a></p></header><div class="excerpt"><p>Governing of Hydraulic Turbines  “The governing of a turbine is defined as the operation by which the speed of the turbine is kept constant under all working conditions (irrespective of the...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/governing-of-hydraulic-turbines-pelton-francis-turbine/" aria-label="View Post: Governing of Hydraulic Turbines &#8211; Pelton, Francis turbine">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Governing of Hydraulic Turbines &#8211; Pelton, Francis turbine","url":"\/\/www.gunkrazy.com\/governing-of-hydraulic-turbines-pelton-francis-turbine\/","articleBody":"Governing of Hydraulic Turbines\r\n\r\n \t\u201cThe governing of a turbine is defined as the operation by which the speed of the turbine is kept constant under all working conditions (irrespective of the load variations).\u201d\r\n \tThe governing of a turbine is necessary as, a turbine is directly coupled to an electric generator, which is required to run at a constant speed under all fluctuating loads conditions.\r\n \tIt is done automatically by means of a governor, which regulates the rate of flow through the turbines according to the changing load conditions on the turbine.\r\n \tThe governor used in hydraulic turbines should be very strong as it has to deal with the water coming at a very large force and huge quantity.\r\n\r\nAll type of turbines use oil pressure governor, which consists of the following parts:\r\n\r\n \tOil sump\r\n \tOil pump (Gear pump), which is driven by the power obtained from the turbine. It supplies oil at high pressure.\r\n \tThe servo motor, also known as a relay cylinder, which consists of a cylinder in which piston reciprocates under the action of oil pressure. It is connected at both ends with the distributor valve through the pipelines.\r\n \tThe distributor valve or control valve or relay valve, which slides whenever load changes and thereby allows the oil to go to either side of the servomotor.\r\n \tThe centrifugal governor or actuator, which is connected to the turbine main shaft through a belt or gears.\r\n\r\nGoverning of Pelton Wheel - Governing of Impulse Turbine\r\n\r\n \tIn Pelton wheel turbine, the quantity of water supplied by the nozzle can be regulated by anyone of the following methods:\r\na) Spear Regulation\r\nb) Deflector Regulation\r\nc) Double Regulation\r\n\r\nAll these methods are operated by oil pressure governor.\r\n\r\na) Spear Regulation\r\n\r\n \tIt consists of a nozzle in which spear moves to and fro by the action of the servomotor piston and controls the quantity of water at changing demands.\r\n \tThis movement is useful when the fluctuations in load are small. But when the load changes suddenly, a sudden change in the nozzle area causes a water hammer in the penstock. Therefore a simple regulation system is not used in modern turbines where fluctuations in the load are sudden.\r\n\r\nb) Deflector Regulation\r\n\r\n \tIt is a plate, pivoted outside the nozzle, and is connected to oil pressure governor through levers.\r\n \tWhen the load drops it deflects a part of the jet and thus controls the quantity of water striking the buckets.\r\n \tIn this system a large amount of water goes into waste but there are no chances of water hammer in the penstock. \u00a0\r\n \tThis system is also not widely used due to wastage of large amount of water.\r\n\r\nc) Double Regulation\r\n\r\n \tThis method is widely used by all modern Pelton wheels because it has the advantages of both spear as well as deflector regulation system.\r\n \tIf load on the turbine drops suddenly, then deflector comes into action immediately and obstructs a part of water reaching to the buckets. In the meantime, spear gradually comes forward to its new position and thus the risk of water hammer is avoided.\r\n \tAs this type of governing controls the speed of turbine and pressure (i.e. water hammer) in the penstock by the combination of spear and jet deflector, this system is known as \u201cDouble Regulation\u201d.\r\n\r\nWorking of Governing Of Impulse turbine ( Pelton Wheel ):\r\n\r\n \tWhen the load on the generator decreases, the speed of the generator increases. Hence the speed of the turbine also increases beyond the normal speed.\r\n \tThe centrifugal governor which is connected to the turbine main shaft will be rotating at an increased speed and hence centrifugal force on the fly ball increases and it moves upward. The sleeve of the governor will also move upward.\r\n \tAs the sleeve moves upward, a horizontal lever turns about the fulcrum, and the piston rod of the control valve moves downward. This closes the valve V1 and opens the valve V2 as shown in Fig.\r\n\r\nGoverning of Pelton wheel - ( Impulse turbine )\r\n\r\n \tThe oil pumped from the oil pump to the control valve under pressure will flow through the valve V2 to the servomotor and will exert force on the face A of the piston of the relay cylinder.\r\n \tPiston along with piston rod and spear will move towards the right. This will decrease the area of flow of water at the outlet of the nozzle and it will reduce the rate of flow to the turbine which consequently reduces the speed of the turbine.\r\n \tMeanwhile, the bell crank lever moves downward, the jet deflector will operate and divert the whole or part of the jet away from the buckets.\r\n \tAs soon as speed becomes normal, the fly balls, sleeves, lever and piston rod come to its normal position.\r\n\r\nGoverning of Francis Turbine - Governing of Reaction Turbine\u00a0\r\n\r\n \tThe guide blades of the Francis turbine are pivoted and connected by levers and links to the regulating ring. The regulating ring is attached with two regulating rods connected to the regulating lever. Thus regulating lever, in turn, is connected with regulating shaft, which is operated by the piston of servomotor.\r\n\r\ngoverning of Francis turbine- ( Reaction turbine )\r\n\r\n \tWhen the load on the turbine decreases, speed tends to increase, which moves fly balls upwards and thus raises sleeves. The main lever on the other side of the fulcrum pushes down the control valve rod and opens port V1. Oil under pressure enters the servomotor from left and pushes the piston to moves towards right.\r\n \tWhen the piston of the servomotor moves towards the right, regulating the ring is rotated to decrease the passage between the guide vanes by changing guide vane angles. Thus the quantity of water reaching the runner blades reduces and speed decreases to the\r\nnormal speed.\r\n \tSudden reduction in passage between the guide blades may cause a water hammer which can be prevented by providing a relief valve near the turbine which diverts the water directly to the tailrace. Thus it functions similar to that of jet deflector as in the Pelton wheel. Thus double regulation is also well performed in Francis turbine.\r\n\r\n\r\n\r\n\r\nRead More :\u00a0\r\n\r\n \tPelton Wheel - Parts, Working, Diagram, Applications, Advantages\r\n \tFrancis Turbine - Diagram, Working, Parts, Advantages, Applications\r\n\r\n\r\n\r\n\r\nMore Resources \/articles\r\nThermal Engineering - Articles , Notes , Interview Q &amp; A\r\nFluid Power System - Hydraulic and Pneumatic Notes\r\nMechanical Subjectwise Basic Concept Notes ,Articles\r\n\r\n\r\n\r\n\r\n&nbsp;","headline":"Governing of Hydraulic Turbines &#8211; Pelton, Francis turbine","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2020-05-21","mainEntityOfPage":"False","dateModified":"May 21, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/05\/governing-of-pelton-wheel-impulse-turbine--300x212.jpg","height":212,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/scroll-compressors-parts-diagram-working-advantages-application/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/05/scroll-compressor-diagram-300x96.jpg')"></div><span class="sr-only">link to Scroll Compressors &#8211; Parts, Diagram, Working, Advantages, Application</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/scroll-compressors-parts-diagram-working-advantages-application/">Scroll Compressors &#8211; Parts, Diagram, Working, Advantages, Application</a></p></header><div class="excerpt"><p>Scroll Compressors
A Scroll compressor is a type of rotary type compressor. They are a positive displacement machine that uses the compression action provided by two intermeshing spiral-shaped...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/scroll-compressors-parts-diagram-working-advantages-application/" aria-label="View Post: Scroll Compressors &#8211; Parts, Diagram, Working, Advantages, Application">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Scroll Compressors &#8211; Parts, Diagram, Working, Advantages, Application","url":"\/\/www.gunkrazy.com\/scroll-compressors-parts-diagram-working-advantages-application\/","articleBody":"Scroll Compressors\r\nA Scroll compressor is a type of rotary type compressor. They are a positive displacement machine that uses the compression action provided by two intermeshing spiral-shaped scrolls, in which one is fixed and the other orbiting, (ASHRAE, 2004).\r\n\r\nAccording to ASHRAE\u2019s HVAC Systems and Equipment Handbook, \u201cScroll compressors are orbital motion, positive-displacement machines that compress with two interfitting, spiral-shaped scroll members.\u201d\r\n\r\nTypical scroll compressors for automobile air conditioning system consists of the following components: Scrolls, Casing, shaft, bearing, refrigerant chamber, rubber seal, balancing spring, magnetic clutch and pressure valve\r\nConstruction of Scroll Compressor :\r\n\r\n \tIt is rotary, orbital motion, and a positive displacement compressor with hermetic motor.\r\n \tThe motor shaft bearings and the orbiting scroll journal bearings are lubricated by oil supplied by a centrifugal pump which is submerged in the oil sump.\r\n \tIt has two inter fitting matching spiral-shaped scrolls assembled 1800 out of phase configuration to perform the gas compression.\r\n \tA scroll is an involute spiral open at one end of the vane and bound by a base plate on the other.\r\nWhen the two scrolls are placed together; they form a series of gas pockets between the two mating spirals.\r\n \tOne of the two scrolls, the fixed scroll is held stationary, while the other, the orbiting scroll is made to orbit, but not rotates around a fixed point on the stationary scroll. (Refer Fig. )\r\n\r\n scroll compressor diagram\r\n\r\n \tThe flanks of the scroll remain in contact, although the contact locations move progressively inwards.\r\n \tRelative motion between the pair is prevented by interconnecting couplings; which maintains a relative angle between the pair of scrolls.\r\n \tThe scroll tips are fitted with seals that ride on the surface of the opposing scroll and act like piston rings, providing a gas seal at the mating surface.\r\n \tThe intake of the suction gas occurs at the outer edge of the scroll assembly and discharge occurs through the port at the center of the stationary scroll.\r\n \tThe center of the scroll journal bearing and the center of the motor shaft of the drive assembly are offset and this offset imparts an eccentric or orbiting motion to the driven scroll.\r\n\r\nScroll Compressor Animation :\r\n Scroll Mechanism Animation\r\nWorking of Scroll Compressor :\r\n\r\n \tThe orbiting motion causes the mated scrolls to form gas pockets and as the orbiting continues, the relative movement between the orbiting scroll and the fixed scroll causes the scroll to move towards the discharge port at the center of the assembly with constantly decreasing and increasing the pressure of the gas.\r\n\r\n(i) First shaft revolution (Suction phase):\r\n\r\n \tWhen the shaft rotates, the orbiting scroll orbits and opens suction port creates space between two scrolls.\r\n \tAt the completion of the first revolution, the scroll lateral surfaces again meet; forming gas pockets. [Refer Fig. (a)].\r\n\r\n scroll compressor working - first revolution\r\n\r\n(ii) Second shaft revolution (Compression phase):\r\n\r\n \tFurther rotation of shaft; by sealing suction gas in pockets of given volume at the outer periphery of the scrolls; and the volume of the gas pockets is progressively reduced and the gas is compressed.\r\n \tAt the completion of the second revolution produces maximum compression of gas occurs. [Refer Fig. (b)].\r\n\r\n scroll compressor working - second revolution\r\n\r\n(iii) Third revolution (Discharge phase):\r\n\r\nDuring the third revolution of shaft; the compressed gas is discharged through the discharge port.\r\n\r\n \tAt the completion of the third revolution, the volume of the gas pockets is reduced to zero, squeezing the remaining gas from the scrolls.\r\n \tIn the complete cycle, the three phases intake, compression, and discharge occurs simultaneously in an on-going sequence. [Refer Fig. (c)].\r\n\r\n scroll compressor working - third revolution\r\nAdvantages of scroll Compressor:\r\nScroll compressor advantages are as follows,\u00a0\r\n\r\n1) It has very high compression, mechanical and volumetric efficiency; thus it has a higher energy efficiency ratio also.\r\n2) It has fewer moving parts and hence lower mechanical losses.\r\n3) It can handle liquid refrigerant flooding back from the evaporator during fluctuating operating conditions and design to start at full load.\r\n4) It does not require a crankcase heater and\/or suction line accumulator.\r\n5) It has almost laminar\/uniform\/continuous flow of refrigerant and hence lower noise level as well as no need for discharge muffler.\r\n6) As the suction, compression, and discharge processes take place simultaneously; thus the smooth flow of gas reduces gas pulsations and lower the flow losses.\r\n7) No metal to metal contact.\r\n8) No suction and discharge valves; thus lower noise level and lesser chances of compressor ceasing &amp; compressor motor failure.\r\n9) Compact in size and weight hence easy to handle and maintain.\r\n10) The system is perfectly balanced; thus extremely low vibrations &amp; noise.\r\nDisadvantages of Scroll Compressor :\r\nDespite of all the above advantages scroll compressor has some disadvantages as follows,\r\n\r\n \tCompressor cannot be disassembled in the field for maintenance\r\n \tIncremental capacity control on systems with multiple compressors \r\n\r\nApplications of scroll Compressor :\u00a0\r\nApplications of scroll compressors are as follows,\u00a0\r\n\r\n1) In residential and commercial refrigeration &amp; air conditioning.\r\n2) Central heat pump.\r\n3) Automotive air-conditioning.\r\n\r\n\r\n\r\nMore Resources \/articles\r\nProduct Ideas , Innovative Machine Ideas Projects\r\nFluid Power System - Hydraulic and Pneumatic Notes\r\nRAC \/ HVAC - Articles , Notes , Que and Answers\r\nMechanical Subjectwise Basic Concept Notes ,Articles\r\n\r\n\r\n\r\n\r\n&nbsp;","headline":"Scroll Compressors &#8211; Parts, Diagram, Working, Advantages, Application","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2020-05-21","mainEntityOfPage":"False","dateModified":"May 21, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/05\/scroll-compressor-diagram-300x96.jpg","height":96,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/total-quality-management-definition-principles-advantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/05/tqm-approach-300x206.jpg')"></div><span class="sr-only">link to Total Quality Management : Definition, Principles , Advantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/total-quality-management-definition-principles-advantages/">Total Quality Management : Definition, Principles , Advantages</a></p></header><div class="excerpt"><p>Introduction to Total Quality Management:-  Total quality management is defined as the management approach of an organization centered on quality, based on the participation of all its members...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/total-quality-management-definition-principles-advantages/" aria-label="View Post: Total Quality Management : Definition, Principles , Advantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Total Quality Management : Definition, Principles , Advantages","url":"\/\/www.gunkrazy.com\/total-quality-management-definition-principles-advantages\/","articleBody":"Introduction to Total Quality Management:-\r\n\r\n \tTotal quality management is defined as the management approach of an organization centered on quality, based on the participation of all its members and aiming at long term success through customer satisfaction and benefits to all members of the organization and to society.\r\n \tThe expression \u201call its members\u201d, means personnel in all departments and at all levels of the organizational structure.\r\n \tIn total quality management, the concept of quality relates to the achievement of all managerial objectives.\r\n \tThe concept \u201cbenefits to society\u201d, implies, as applicable, fulfillment of the requirements of society. The strong and persistent leadership of top management and the education and training of all members of the organization are essential for the success of this approach.\r\n\r\nDefinitions of TQM\r\n\r\n \tTQM can be defined as, \u201c The act or manner of handling, controlling made up by the whole system to achieve a degree of excellence that a product or service provides for the whole.\r\n \tTotal: - made up by the whole for the whole.\r\n \tQuality: - The degree of excellence a product or a service provides.\r\n \tManagement: - Act, art, or manner of handling and controlling.\r\n \tAs per Indian Statistical Institute: TQM is an integrated organizational approach in delighting customers by meeting their expectations continuously through everyone involved with the organization working on continuous improvement in all products, services, and processes with proper problem-solving methodology\r\n \tAs per the Quality Forum of USA: - TQM is a people-focused management system that aims at continually increasing customer satisfaction at a continually lower cost. TQM is a total system approach and an integral part of high level strategy; it works horizontally across functions and departments involving all employees top to bottom and exceeds backward and forwards to include the supply chain and the customer chain.\r\n \tTQM as Philosophy and ISO-9000 quality system model: - TQM is a concept that goes beyond ISO 9000. It must be immediately made clear that TQM and ISO 9000 are not two different choices to be made. There is no contradiction between the two.\r\n \tAccording to CII (Confederation of Indian Industries): - TQM is an approach for effective management of business enterprise through the focus on its people and the process by a company-wide customer-driven relationship.\r\n\r\nTQM approach\r\nComponents of TQM\r\nComponents of TQM are:\r\n1. Continuous improvement\r\n2. Customer focus\r\n3. Zero defects\r\n4. Training and development\r\n5. Total employee involvements\r\n6. Long-term commitment\r\n7. Leadership\r\n\r\n1. continuous improvement:\r\n\r\n \tThere is no limit to continuous improvement.\r\n \tThis is beneficial in improving quality standards.\r\n \tUnder TQM, there is continuous improvement in processes, products, work culture, services, etc.\r\n \tThis pattern of continuous improvement explorers good things from the organization.\r\n \tThis makes the organization competent and updated.\r\n\r\n2. Customer focus:\r\n\r\n \tThe customer is the center point under TQM.\r\n \tVarious factors are taken to run the organization with focus at a customer.\r\n \tCustomer moods, needs, and requirements are understood through market research.\r\n \tCustomers are classified into internal customers and external customers. Employees of the organization are internal customers and outside stakeholders are external customers.\r\n \tAll customers are carefully handled by providing suitable services. Customer care system is designed to make the customer happy.\r\n \tServices provided to customers are of a high standard and this is maintained all the time.\r\n\r\n3. Zero defects:\r\n\r\n \tProduct\/service should be perfect. This is seriously considered in TQM.\r\n \tUnder TQM efforts are made to reduce the defects to zero.\r\n \tZero defects give excellence in product\/service.\r\n \tSystems are designed throughout the organization for zero defects.\r\n\r\n4. Training and development:\r\n\r\n \tTQM cannot be implemented in one shot.\r\n \tFor effective implementation of TQM, employees are given training.\r\n\r\n5. Total employee involvements:\r\n\r\n \tAll the employees from top to bottom are included in TQM implementation.\r\n \tTQM can be weak if even a section of the organization is not involved in the process.\r\n \tAll are informed about the importance of TQM individually or as an organization.\r\n\r\n6. Long-term commitment:\r\n\r\n \tTQM is not an event.\r\n \tIt is not a periodic activity.\r\n \tIt is a path for continuous growth.\r\n \tHence for success in TQM, there is an expectation of long-term commitment.\r\n\r\n7. Leadership:\r\n\r\n \tTQM needs consistent and disciplined leadership.\r\n \tIt is teamwork, but this team can only work when there is someone who gives direction.\r\n \tAt each level also, such leadership is expected from department heads or center heads.\r\n \tLeadership keeps TQM in track in the respective organization.\r\n\r\nPrinciples of TQM: -\r\nTQM is based on the following principles:\r\n\r\n1. The employees are not just the resources, they are for a purpose.\r\n2. A company hires a total man with the body, mind, and intellect and not just the hands.\r\n3. The problems are with the system not with the people.\r\n4. The variance analysis focuses on what, how, why, and not who.\r\n5. The aim is to utilize the full potential of all the employees.\r\n6. The total employee\u2019s involvement is essential for the customers\u2019 satisfaction.\r\n7. TQM is led by the top management.\r\n8. The system is focused on satisfying customers.\r\n9. Process approach to management.\r\n10. Based on error\/ failure prevention strategy.\r\n11. Aimed at continual improvement.\r\n12. Built on cooperative, trustful relationship to have a win-win situation.\r\n13. Team working to ensure functioning as effective groups.\r\n14. Fact-based management.\r\n15. Largely aimed at long term goals.\r\n16. Systematic and methodical.\r\n17. Geared towards public responsibility.\r\n18. A holistic approach.\r\nCharacteristics of TQM : -\r\nThe essential characteristics of an effective TQM system are: -\r\n\r\n1. Every company member, from the CEO to the lowest level employee is focused on product or service quality. If management is not behind TQM, then it will fail.\r\n2. Everyone must have the required training and be familiar with the necessary TQM techniques.\r\n3. Anyone can suggest areas for improvement- as general operatives will be more familiar with their workstation than anyone else is, valuable ideas for improvement at a production line level can, in many cases, come from line workers.\r\n4. All departments are expected to focus on quality and productivity improvement and implement changes for their area.\r\n5. In addition, all departments interact with each other to fix common problems in the product or process.\r\n6. Collaboration on external issues (end-users defects for example) is expected from all departments.\r\n7. Decisions made are based on the best solutions, not on hidden agendas for favoritism.\r\n8. Quality becomes a governing part of operations, with decisions that impact on quality, rejected immediately, despite perceived cost-savings involved.\r\nAdvantages of TQM : -\r\nThe benefits of TQM can classify into three separate areas: -\r\n\r\nA. The major benefits of TQM in terms of cost savings include: -\r\n\r\n1. Elimination of non-confirmation and repetitive work.\r\n2. Elimination of waste of costs and reject products.\r\n3. Elimination of repairs and reworks.\r\n4. Reduced warranty and customer support costs.\r\n5. Process efficiency leading to improved profit per product or service.\r\n6. Fiscal discipline through the elimination of unnecessary steps and wasteful expenditure.\r\n\r\nB. TQM free up management time from redressing problems and directs management time and effort to: -\r\n\r\n1. Increase production.\r\n2. Extend the range of products.\r\n3. Improve existing products.\r\n\r\nC. TQM and customer satisfaction: -\r\n\r\n1. Reduction of waiting time by changing the method of appointment scheduling or client handling.\r\n2. Making changes to the delivery process so that the product reaches the customer faster.\r\n3. Better quality products requiring no repairs improving customer loyalty.\r\nKey elements of TQM: -\r\n1. Foundation: - includes ethics, integrity, and trust.\r\n2. Building bricks: - includes training, teamwork, and leadership.\r\n3. Binding mortar: - includes communication.\r\n4. Roof: - includes recognition.\r\n\r\n\r\n\r\nMore Resources \/articles\r\nTechnical Mechanical Interview Question and Answers\r\nIndustrial Engineering Notes , Articles , Interview Que &amp; Ans\r\nProduction Engineering Notes , article , Interview Que and Ans\r\n\r\n\r\n\r\n\r\n&nbsp;","headline":"Total Quality Management : Definition, Principles , Advantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2020-05-17","mainEntityOfPage":"False","dateModified":"May 17, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/05\/tqm-approach-300x206.jpg","height":206,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/electronic-fuel-injection/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/05/electronic-fuel-injector-diagram-235x300.jpg')"></div><span class="sr-only">link to Electronic fuel injection System : Parts ,Types, Working , Advantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/electronic-fuel-injection/">Electronic fuel injection System : Parts ,Types, Working , Advantages</a></p></header><div class="excerpt"><p>EFI System - Electronic Fuel Injection System : 
In Electronic Fuel Injection System, carburetors were replaced with throttle body fuel injection systems, also known as single point or central fuel...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/electronic-fuel-injection/" aria-label="View Post: Electronic fuel injection System : Parts ,Types, Working , Advantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Electronic fuel injection System : Parts ,Types, Working , Advantages","url":"\/\/www.gunkrazy.com\/electronic-fuel-injection\/","articleBody":"EFI System - Electronic Fuel Injection System :\u00a0\r\nIn Electronic Fuel Injection System, carburetors were replaced with throttle body fuel injection systems, also known as single point or central fuel injection systems. That incorporated electrically controlled fuel-injector valves into the throttle body. Those were almost a bolt-in replacement for the carburetor, so the automakers didn't have to make any drastic changes to their engine designs.\r\nDifference Between Electronic Fuel Injection and Carbureted fuel system\r\n\n\n\n\n\tSr no.Electronic Fuel InjectionCarbureted fuel system\n\n\n\n\n\t1.Uniform distribution of charge.Mal-distribution of charge.\n\n\n\t2.Improvement in volumetric efficiency due to less resistance in the intake manifold.Due to resistance in the intake manifold, volumetric efficiency is lower\n\n\n\t3.Accurate metering of chargeInaccurate metering of charge.\n\n\n\t4.The formation of ice on the throttle plate is eliminated.Carburetor Icing may take place\n\n\n\t5.Atomization of fuel is independent of cranking speed therefore cranking is easier.Fuel atomization depends upon the velocity of air in the venture.\n\n\n\t6.Better atomization and vaporization will make the engine less knock prone.Less atomization and vaporization will make the engine more knock prone.\n\n\n\t7.Less volatile fuel can be used.Fuel needs to be more volatile\n\n\n\t8.Fuel being injected into or close to the cylinder.Fuel injection is take place inside the manifold.\n\n\n\n\r\nTypes Of Electronic Fuel injection System:\r\n\r\n \tSingle-Point or Throttle Body Injection\r\n \tPort or Multi-Point Fuel Injection\r\n \tSequential Fuel Injection\r\n \tDirect Injection\r\n\r\nSingle point injection System:\r\nDefinition: \r\n\r\nA type of electronic fuel injection system that uses a single injector or pair of injectors mounted in a centrally located throttle body. The throttle unit resembles a carburetor except that there is no fuel bowl float or metering jets. Fuel is sprayed directly into the throttle bore(s) by the injector(s).\r\n\r\nWith single-point injection it is possible to achieve a lambda regulated exhaust emission control using only a few components.\r\n\r\nSensors\r\n\r\n \tInductive pickup - position of the crankshaft and speed of the engine;\r\n \tLambda probe;\r\n \tTemperature sensors for cooling water system and air intake system; Throttle potentiometer;\r\n\r\nActuators\r\n\r\n \tFuel injector; - The fuel injector acts as the fuel dispensing nozzle. It injects liquid fuel directly into the engine's air stream. The injection is controlled by the ECU. It determines the amount of fuel to injected and in some system if the engine is cold, turns on an \u201cextra\u201d injector which only works while the system is cold. This injector only works for a short period of time determined by the ECU.\r\n \tThrottle plate control- This is system is used to control the minimum airflow during idle speed. It actuates directly in to the Throttle plate, this is normally done by a small electric motor applied directly to the throttle plate.\r\n\r\nElectronic Fuel Injector (Unit Injector):\r\n\r\n \tA vacuum-powered fuel pressure regulator at the end of the fuel rail ensures that the fuel pressure in the rail remains constant relative to the intake pressure. For a gasoline engine, fuel pressure is usually on the order of 35-50 psi. Fuel injectors connect to the rail, but their valves remain closed until the ECU decides to send fuel into the cylinders.\r\n \tUsually, the injectors have two pins. One pin is connected to the battery through the ignition relay and the other pin goes to the ECU.\r\n \tThe ECU sends a pulsing ground to the injector, which closes the circuit, providing the injectors solenoid with current. The magnet on top of the plunger is attracted to the solenoids magnetic field, opening the valve. Since there is a high pressure in the rail, opening the\r\nvalve sends fuel at a high velocity through the injectors spray tip. \r\n \tThe duration that the valve is open and consequently the amount of fuel sent into the cylinder depends on the pulse width (i.e. how long the ECU sends the ground signal to the injector).\r\n \tWhen the plunger rises, it opens a valve and the injector sends fuel through the spray tip and into either the intake manifold, just upstream of the intake valve, or directly into the cylinder.\r\n\r\nelectronic fuel injector diagram\r\nThrottle body injection (TBI) system - Working of electronic fuel injection system\u00a0\r\nThe throttle body injection (TBI) system uses one or two injector valves mounted in a throttle body assembly. The injectors spray fuel into the top of the throttle body air horn The TBI fuel spray mixes with the air flowing through the air horn. The mixture is then pulled into the engine by intake manifold vacuum. The throttle body injection assembly typically consists of the following: throttle body housing, fuel injectors, fuel pressure regulator, throttle positioner, throttle position sensor, and throttle plates.\r\n\r\nThrottle Body Injection is an electronically controlled injection system in which an electronic fuel injector injects the fuel intermittently in to the intake manifold at a central point ahead of the throttle valve. The central- injection unit operates at low pressure (0.7 to 1 bar) so; an inexpensive hydrodynamic electric fuel pump can be used (generally in the form an in-tank unit). The injector is flushed continuously by the fuel flowing through it in order to prevent the formation of air bubbles. The injector is a solenoid \u2013 controlled valve. The central injection unit uses the throttle valve to meter the intake air while injecting the fuel intermittently above the throttle valve. The intake manifold then\r\ndistributes the fuel to the individual cylinders. Various sensors monitor all important engine-operating data, which are then used to calculate the triggering signals for the injectors and other system actuators.\r\n\r\nthrottle body injection system\r\nTesting of Electronic Fuel Injector :\r\nOhm-meter test for electronic fuel injector.\u00a0\r\nFollowing are the steps of the Ohmmeter test for electronic fuel injector:\r\n\u2022 An ohmmeter is connected across the injector terminals to check the injector windings after the injector wires are disconnected.\r\n\u2022 If the ohmmeter reading is infinite, the injector winding is open.\r\n\u2022 An ohmmeter reading below the specified value indicates that the injector winding is shorted.\r\n\u2022 A satisfied injector winding should have resistance between 0.3 to 0.4 ohms.\r\n\u2022 Replace the injector if the results do not have the resistance as specified by the manufacturer.\r\n\r\nelectronic fuel injector testing\r\nSound test for testing electronic fuel injector\r\nProcedure for sound test for testing electronic fuel injector:\r\n\r\nThe use of auto fuel injectors is a sophisticated way to provide the right fuel and air mix to an engine for a vehicle. The small cylindrical fuel injectors play a specific role in a larger fuel intake system, along with other elements like the fuel pump and the fuel tank. Over time, fuel injectors may need to be maintained or checked for proper functioning.\r\n\r\n1) The electronic fuel injection system relies on electronic signals that control how these items operate\r\n2) Along with checking a fuel injector electronically, you can listen for certain kinds of sounds that will tell you when a fuel injector might not be working correctly.\r\n3) A clunking sound or similar warning sound may show that the fuel injector is not functioning the way it should.\r\n4) If the injector electrical leads are difficult to access, an injector power balance test is hard to perform. As an alternative, start the engine and use a technician stethoscope to listen for correct injector operation.\r\n5) A good injector makes a rhythmic clicking sound as the solenoid is energized and de-energized\u00a0several times each second.\r\n6) If clunk- clunk instead of steady click-click is heard, chances are the problem injector has been found.\r\n7) Cleaning or replacement is in order.\r\n8) If an injector does not produce any clicking noise, the injector, connecting wires, or PCM may be defective.\r\n9) When the injector clicking noise is erratic, the injector plunger may be sticking.\r\n10) If there is no injector clicking noise, proceed with the injector resistance test and light to locate the cause of the problem.\r\n11) If a stethoscope is not handy, use a thin steel rod, wooden dowel, or fingers to feel for a steady on\/off pulsing of the injector solenoid.\r\nAdvantage of an electronic fuel injection system:\u00a0\r\n1. Improved power output.\r\n2. Better fuel efficiency over a wide range of engine speeds.\r\n3. Quick warm-up of engine.\r\n4. Reduced engine emission that meets strict emission norms.\r\n5. Better throttle response of the engine.\r\n6. Better pick- up (acceleration).\r\n7. Compact design of the fuel supply system.\r\n8. Modular design.\r\n9. Engine performance is maintained under various loads and atmospheric pressures (altitude).\r\n10. Engine need not be tuned from time to time as in the case of a carbureted engine fuel supply system.\r\n11. Engine idle speed is controlled by a microprocessor and so precisely controlled.\r\n12. The vapor lock problem does not occur, as EFI system uses an electric fuel feed pump. The pump maintains sufficient pressure in the fuel line to avoid vapor lock in hot weather.\r\n13. Improved atomization. Fuel is forced into the intake manifold under pressure that helps break fuel droplets into a fine mist.\r\n14. Better fuel distribution. Equal flow of fuel vapors into each cylinder.\r\n15. Smoother idle. Lean fuel mixture can be used without rough idle because of better fuel distribution and low-speed atomization.\r\n16. Lower emissions. Lean efficient air-fuel mixture reduces exhaust pollution.\r\n17. Better cold-weather drivability. Injection provides better control of mixture enrichment than a carburetor.\r\n18. Increased engine power. Precise metering of fuel to each cylinder and increased airflow can result in more horsepower output.\r\n19. Fewer parts. Simpler, late model, electronic fuel injection system have fewer parts than modern computer-controlled carburetors\r\nDisadvantages of Electronic Fuel Injection System :\r\n\r\n \tThe biggest disadvantage with electronic fuel injection systems is that they are expensive. \r\n \tEFI conversions are not cheap, in fact they are usually expensive. Steer clear of modern car's EFI systems, they aren't readily programmable and are difficult to get working correctly.\r\n\r\n\r\n\r\n\r\nMore Resources \/articles\r\nMechanical Subjectwise Basic Concept Notes ,Articles\r\nAutomobile Trends , News articles , Notes\r\nAutomobile Engineering Parts and System Notes , Article\r\n\r\n\r\n\r\n\r\n&nbsp;","headline":"Electronic fuel injection System : Parts ,Types, Working , Advantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2020-05-16","mainEntityOfPage":"False","dateModified":"May 17, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/05\/electronic-fuel-injector-diagram-235x300.jpg","height":300,"width":235},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/stress-concentration/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/05/Reduction-of-Stress-Concentration-due-to-V-notch-stress-concentration-reduction-300x174.jpg')"></div><span class="sr-only">link to Stress Concentration &#8211; Definition, Causes, Remedies</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/stress-concentration/">Stress Concentration &#8211; Definition, Causes, Remedies</a></p></header><div class="excerpt"><p>Stress Concentration - Definition
Whenever the machine component changes the shape of its cross-section the stress distribution pattern no longer holds good and the neighborhood of the discontinuity...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/stress-concentration/" aria-label="View Post: Stress Concentration &#8211; Definition, Causes, Remedies">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Stress Concentration &#8211; Definition, Causes, Remedies","url":"\/\/www.gunkrazy.com\/stress-concentration\/","articleBody":"Stress Concentration - Definition\r\nWhenever the machine component changes the shape of its cross-section the stress distribution pattern no longer holds good and the neighborhood of the discontinuity is different. The stresses induced in the neighborhood are much higher than the stress induced in the other part of the component. This abrupt change in cross-section or the discontinuity form is called stress concentration.\r\n\r\nIt occurs for all kind of stresses in the presence of fillets, notches, holes, key-ways, splines, surface roughness are scratches etc\r\n\r\nIt is for all kinds of stresses caused due to keyways, grooves, notches, roughness, or scratches.\r\n\r\nstress concentration\r\n\r\nConsider a member with different cross-sections under a tensile load as shown in the figure. It shows that nominal stress in the right and left-hand sides will be uniform but in the region where the cross-section is changing, a redistribution of the force lines within the member must take place. The material near the edges is stressed considerably higher than the average value. The maximum stress occurs at the same point on the fillet and is directed parallel to the boundary at that point.\r\nCauses of Stress Concentration\r\n1. Variation in Properties of Materials:\r\n\r\n \tIn the design of machine components, it is assumed that the material is homogeneous throughout the component\r\n \tIn practice, there is a variation in material properties from one end to another due to the following factors:\r\n(a) Internal cracks and flaws like blow holes;\r\n(b) Cavities in welds;\r\n(c) Air holes in steel components; and\r\n(d) Nonmetallic or foreign inclusions.\r\n \tThese variations act as discontinuities in the component and cause stress concentration.\r\n\r\n2. Load Application:\r\n\r\n \tMachine components are subjected to forces.\r\n \tThese forces act either at a point or over a small area of the component.\r\n \tSince the area is small, the pressure at these points is excessive. This results in stress concentration.\r\n\r\nThe examples of these load applications are as follows:\r\n\r\n(a) Contact between the meshing teeth of the driving and the driven gear\r\n(b) Contact between the cam and the follower\r\n(c) Contact between the balls and the races of ball bearing\r\n(d) Contact between the rail and the wheel\r\n(e) Contact between the crane hook and the chain\r\n\r\n \tIn all these cases, the concentrated load is applied over a very small area which results in stress concentration.\r\n\r\n3. Abrupt Changes in Section:\r\n\r\n \tIn order to mount gears, sprockets, pulleys, and ball bearings on a transmission shaft, steps are cut on the shaft and shoulders are provided from assembly considerations.\r\n \tAlthough these features are essential, they create change of the cross-section of the shaft.\r\n \tThis results in stress concentration at these cross-sections.\r\n\r\nAbrupt Changes in Section\r\n4. Discontinuities in the Component:\r\n\r\n \tCertain features of machine components such as oil holes or oil grooves, keyways and splines, and screw threads result in discontinuities in the crosssection of the component.\r\n \tThere is stress concentration in the area of these discontinuities.\r\n\r\n5. Machining Scratches:\r\n\r\n \t\u00a0Machining scratches, stamp marks or inspection marks are surface irregularities, which cause stress concentration.\r\n\r\nMethods to Reduce Stress Concentration\r\n1. Additional Notches and Holes in Tension Member\r\n\r\n \tA flat plate with a V-notch subjected to tensile force is shown in Fig. (a).\r\n \tIt is observed that a single notch results in a high degree of stress concentration.\r\n \tThe severity of stress concentration is reduced by three methods: (a) Use of multiple notches, (b) Drilling additional holes; and (c) Removal of undesired material.\r\n\r\nReduction of Stress Concentration due to V-notch - stress concentration reduction\r\n\r\n \tThese methods are illustrated in Fig. (b), (c) and (d) respectively.\r\n \tIn these three methods, the sharp bending of a force flow line is reduced and it follows a smooth curve.\r\n\r\n2. Fillet Radius, Undercutting and Notch for Member in Bending: \r\n\r\n \tA bar of circular cross-section with a shoulder and subjected to bending moment is shown in Fig.\u00a0 (a).\r\n \tBall bearings, gears or pulleys are seated against this shoulder.\r\n \tThe shoulder creates a change in the cross-section of the shaft, which results in stress concentration.\r\n \tThere are three methods to reduce stress concentration at the base of this shoulder.\r\n\r\nReduction of Stress Concentration due to abrupt change in cross-section - stress concentration reduction\r\n\r\n \tFig.\u00a0 (b) shows the shoulder with a fillet radius r. This results in a gradual transition from a small diameter to a large diameter.\r\n \tThe fillet radius should be as large as possible in order to reduce stress concentration.\r\n \tIn practice, the fillet radius is limited by the design of mating components.\r\n \tThe fillet radius can be increased by undercutting the shoulder as illustrated in Fig. (c).\r\n \tA notch results in stress concentration.\r\n \tCutting an additional notch is an effective way to reduce stress concentration. This is illustrated Fig. (d).\r\n\r\n3. Drilling Additional Holes for Shaft: \r\n\r\n \tA transmission shaft with a keyway is shown in Fig. (a).\r\n \tThe keyway is a discontinuity and results in stress concentration at the corners of the keyway and reduces torsional shear strength.\r\n \tIn addition to giving fillet radius at the inner corners of the keyway (as shown in Fig. (c)), there is another method of drilling two symmetrical holes on the sides of the keyway.\r\n\r\nReduction of Stress Concentration in shaft with keyway\r\n\r\n \tThese holes press the force flow lines and minimize their bending in the vicinity of the keyway. This method is illustrated in Fig. (b).\r\n\r\n4. Reduction of Stress Concentration in Threaded Members:\r\n\r\n \tA threaded component is shown in Fig.\u00a0 (a).\r\n \tIt is observed that the force flow line is bent as it passes from the shank portion to the threaded portion of the component. This results in stress concentration in the transition plane.\r\n \tIn Fig. (b), a small undercut is taken between the shank and the threaded portion of the component and a fillet radius is provided for this undercut.\r\n\r\nReduction of Stress Concentration in threaded components\r\n\r\n \tThis reduces the bending of the force flow line and consequently reduces stress concentration.\r\n \tAn ideal method to reduce stress concentration is illustrated in Fig. (c), where the shank diameter is reduced and made equal to the core diameter of the thread.\r\n \tIn this case, the force flow line is almost straight and there is no stress concentration\r\n\r\n5. The methods of reducing stress concentration in cylindrical members with shoulders hole, subjected to tensile load.\r\nReduction of Stress Concentration in cylindrical members with holes\r\nTheoretical Stress Concentration factor \r\n\r\n \tIn order to consider the effect of stress concentration and find out localized stresses, a factor called theoretical stress concentration factor is used.\r\n \tIt is denoted by Kt and defined as,\u00a0 \r\n\r\nKt= Highest value of actual stress near discontinuity \/ Nominal stress obtained by elementary equation.\r\n\r\nEffect of stress concentration on the material in case of static loading and cyclic loading.\r\n\r\n \tIn static loading, stress concentration in ductile materials is not so serious as in brittle materials, because in ductile materials local deformation or yielding takes place which reduces the concentration. In brittle materials, cracks may appear at these local concentrations of stress which will increase the stress over the rest of the section.\r\nIt is, therefore, necessary that in designing parts of brittle materials such as castings, care should be taken. In order to avoid failure due to stress concentration, fillets at the changes of section must be provided. \r\n \tIn cyclic loading, stress concentration in ductile materials is always serious because the ductility of the material is not effective in relieving the concentration of stress caused by cracks, flaws, surface roughness, or any sharp discontinuity in the geometrical form of the member.If the stress at any point in a member is above the endurance limit of the material, a crack may develop under the action of repeated load and the crack will lead to failure of the member.\r\n\r\n\r\n\r\n\r\nMore Resources \/articles\r\nMachine Design Notes , article , Interview Que. and Ans.\r\nMechanical Subjectwise Basic Concept Notes ,Articles\r\nTechnical Mechanical Interview Question and Answers\r\n\r\n\r\n\r\n\r\n&nbsp;","headline":"Stress Concentration &#8211; Definition, Causes, Remedies","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2020-05-16","mainEntityOfPage":"False","dateModified":"May 16, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/05\/Reduction-of-Stress-Concentration-due-to-V-notch-stress-concentration-reduction-300x174.jpg","height":174,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/types-of-mechanical-springs-advantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/05/Conical-spring-and-Volute-casing-266x300.jpg')"></div><span class="sr-only">link to Springs &#8211; Types, Diagram, Design, Material, Advantages, Application</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/types-of-mechanical-springs-advantages/">Springs &#8211; Types, Diagram, Design, Material, Advantages, Application</a></p></header><div class="excerpt"><p>Introduction to Spring  Springs are elastic bodies (generally metal) that can be twisted, pulled, or stretched by some force. They can return to their original shape when the force is released....</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/types-of-mechanical-springs-advantages/" aria-label="View Post: Springs &#8211; Types, Diagram, Design, Material, Advantages, Application">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Springs &#8211; Types, Diagram, Design, Material, Advantages, Application","url":"\/\/www.gunkrazy.com\/types-of-mechanical-springs-advantages\/","articleBody":"Introduction to Spring\r\n\r\n \tSprings are elastic bodies (generally metal) that can be twisted, pulled, or stretched by some force. They can return to their original shape when the force is released. In other words it is also termed as a resilient member.\r\n \tIt can take any shape and form depending upon the application\r\n\r\nDefinition of Springs :\u00a0\r\n\r\n \tSpring is defined as an elastic machine element that deflects under the action of the load and returns to its original shape when the load is removed.\r\n\r\nSpring is a resilient member capable of providing large elastic deformation. Spring is defined as an elastic body whose function is to distort when loaded and to recover its original shape when the load is removed. \r\nDifferent functions Of Springs :\r\n\r\n \tTo absorb shocks and vibrations. - Used in Vehicle suspension springs, Railway buffer springs, Buffer springs in elevators, Vibration mounts for machinery\r\n \tTo store energy - Used in Springs used in clocks, toys. Movie-cameras, circuit breakers, and starters\r\n \tTo measure force - Used in Springs used in weighing balance and engine indicators\r\n \tTo control Motion - Used in the cam and follower mechanism, spring is used to maintain contact between two elements.\r\n \tTo apply force - Used in In engine valve mechanism, spring is used to return the rocker arm to its normal position when the disturbing force is removed. The spring used in the clutch provides the required force to engage the clutch.\r\n\r\n Types of springs\r\nFollowing are important types of springs according to their shape:\r\n1. Helical springs\r\n2. Conical and volute springs\r\n3. Torsion springs\r\n4. Laminated or leaf springs\r\n5. Disc or Belleville springs\r\n1. Helical Springs\r\n\r\n \tThe helical spring is made from a wire, usually of circular cross-section, that is bent in the form of a helix.\r\n \tThere are two basic types of helical springs: compression spring and tension spring.\r\n \tIn helical compression spring, the external force tends to shorten the spring. In other words, the spring is compressed.\r\n \tIn helical tension spring, the external force tends to lengthen the spring. In other words, the spring is elongated.\r\n\r\nhelical spring diagram\r\n\r\n \tIt should be noted that although the spring is under compression, the wire of helical compression spring is not subjected to compressive stress.\r\n \tAlso, the wire of helical tension spring is not subjected to tensile stress although the spring is under tension.\r\n \tIn both cases, torsional shear stresses are induced in the spring wire.\r\n \tThe words compression and tension are related to total spring and not the stresses in spring wire.\r\n\r\nThe helical springs have the following advantages:\r\n\r\n \tThese are easy to manufacture.\r\n \tThese are available in a wide range.\r\n \tThese are reliable.\r\n \tThese have a constant spring rate.\r\n \tTheir performance can be predicted more accurately.\r\n \tTheir characteristics can be varied by changing dimensions.\r\n\r\nApplication Of Helical Tension Spring :\r\n\r\n1) Garage door assemblies\r\n2) Vise-grip pilers\r\n3) carburetors\r\n\r\nApplication Of Helical Compression Spring :\r\n\r\n1) Ballpoint pens\r\n2) Pogo sticks\r\n3) Valve assemblies in engines\r\n2. Conical and Volute Springs\r\n\r\n \tThe conical and volute springs are used in special applications where a telescoping spring or a spring with a spring rate (load required per unit deflection) that increases with the load is desired.\r\n\r\nConical spring and Volute casing\r\n\r\n \tThe conical spring is wound with a uniform pitch whereas the volute springs are wound in the form of a paraboloid with constant pitch and lead angles.\r\n \tThis characteristic is sometimes utilized in vibration problems where springs are used to support a body that has a varying mass.\r\n\r\n3.Torsion Springs\r\n\r\n \tThe construction of this spring is similar to that of compression or tension spring, except that the ends are formed in such a way, that the spring is loaded by a torque, about the axis of the coils.\r\n \tHelical torsion spring is used to transmit torque to a particular component in the machine or the mechanism.\r\n \tHelical torsion spring is used in door-hinges, brush-holders, starters, and door locks.\r\n\r\nhelical torsion spring\r\n\r\n \tFor example, the spring transmits a torque of (P x r).\r\n \tThe helical torsion resists the bending moment (P x r) that tends to wind up the spring.\r\n \tThe bending moment induces bending stresses in the spring wire.\r\n \tThe term torsion spring is somewhat misleading because the wire is subjected to bending stresses, unlike torsional shear stresses induced in helical torsion or tension springs.\r\n\r\nApplication Of torsion Spring :\r\n\r\n \tMouse tracks\r\n \tRocker switches\r\n \tDoor hinges\r\n \tClipboards\r\n \tAutomobile starters\r\n\r\nSpiral torsion spring:\r\n\r\n \tIt is made of a band of steel wrapped around itself several times to create a geometric shape as shown in the figure.\r\n \tIts inner end is attached to an arbor and the outer end is attached to a retaining drum.\r\n \tIt has a few rotations and also contains a thicker band of steel.\r\n \tIt releases power when it unwinds.\r\n\r\nSpiral Springs\u00a0\r\n\r\nApplication of Spiral Spring :\u00a0\r\n\u2022 Alarm timepiece\r\n\u2022 Watch\r\n\u2022 Automotive seat recliners\r\n4. Laminated Leaf Springs\r\n\r\n \tMulti-leaf spring is widely used for the suspension of trucks and railway wagons.\r\n \tIt consists of a series of flat plates, usually of semi-elliptical shape. The flat plates are called leaves of the spring.\r\n \tThe leaf at the top has a maximum length. The longest leaf at the top is called a master leaf.\r\n \tThe leaves have graduated lengths. The length gradually decreases from the top leaf to the bottom leaf.\r\n \tIt is bent at both ends to form the spring eye. Two bolts are inserted through these eyes to fix the leaf spring to the automobile body.\r\n \tThe leaves are held together utilizing two U-bolts and a center clip.\r\n\r\nleaf spring\r\n\r\n \tRebound clips are provided to keep the leaves in alignment and prevent lateral shifting of the leaves during operation.\r\n \tAt the center, the leaf spring is supported on the axle.\r\n \tMulti-leaf springs are provided with one or two extra full leaves in addition to master leaf.\r\n \tThe extra full-length leaves are stacked between the master leaf and the graduated length leaves.\r\n \tThe extra full-length leaves are provided to support the transverse shear force.\r\n\r\nTypes of leaves:\r\n\r\n1. Full length leave\r\na. Full length leaves with eye,\r\nb. Full length leave without eye.\r\n2. Graduated leave\r\n\r\nApplications of leaves:-\r\n\r\n1. It is used in semielliptical leaf spring,\r\n2. It is used in quarter elliptical leaf spring,\r\n3. It is used in three-quarter elliptical leaf spring,\r\n4. It is used in full elliptical leaf spring.\r\n\r\nNipping of Leaf Springs\r\n\r\n \tThe stresses in extra full-length leaves are more than the stresses in graduated-length leaves.\r\n \tOne of the methods of equalizing the stresses in different leaves is to prestress the spring.\r\n\r\nnipping of leaf spring\r\n\r\n \tThe pre-stressing is achieved by bending the leaves to the different radius of curvature before they are assembled with the clip.\r\n \tAs shown in the above figure, the full-length leaf is given a greater radius of curvature than the adjacent leaf.\r\n \tThe radius of curvature decreases with shorter leaves.\r\n \tThe initial gap C between the extra full-length leaf and the graduated-length leaf before the assembly is called a nip.\r\n \tSuch pre-stressing, achieved by a difference in radius of curvature, is known as nipping.\r\n\r\nApplication of Leaf Spring :\u00a0\r\n\r\n \tMainly in automobiles suspension systems.\r\n\r\nAdvantages of Leaf Spring :\r\n\r\n \tIt can carry lateral loads.\r\n \tIt provides braking torque.\r\n \tIt takes driving torque and withstand the shocks provided by the vehicles.\r\n\r\n5. Disc Springs or Belleville springs\r\n\r\n \tA Belleville spring consists of a coned disk, as shown in the above figure.\r\n \tIt is called Belleville spring because it was invented by Julian Belleville, who patented its design in France in 1867.\r\n \tBelleville spring has a typical load-deflection characteristic, as shown in the above figure.\r\n \tThe variation of (h\/t) ratio provides a wide variety of load-deflection curves.\r\n \tBelleville springs are used in plate clutches and brakes, relief valves, and a wide variety of bolted connections.\r\n\r\ndisc or Belleville spring\r\n\r\nBelleville spring offers the following advantages:\r\n\r\nAdvantages of Belleville springs are as follows :\u00a0\r\n\r\n1. It is simple in construction and easy to manufacture.\r\n2. It is a compact spring unit.\r\n3. It is especially useful where a very large force is desired for small deflection of spring.\r\n4. It provides a wide range of spring constants making it versatile.\r\n5. It can provide any linear or non-linear load-deflection characteristic.\r\n6. The individual coned disks of a particular size and thickness can be stacked in series, parallel or series-parallel combinations, as shown in\r\nFigure. These combinations provide a variety of spring constants without changing the design.\r\n7. When two Belleville springs are arranged in series, double deflection is obtained for the same force. On the other hand, when two Belleville springs are in parallel, almost double force is obtained for a given deflection.\r\n\r\ndisc or Belleville spring combination\r\n6. Special Purpose Springs :\u00a0\r\nThese springs are all together made of different materials such as air and water.\r\n\r\n\r\n\r\nSpring Materials\r\nThe material of the spring should have high fatigue strength, high ductility, high resilience and it should be creep-resistant.\r\n\r\nSelection of material for the spring wire depends upon the following factors:\r\n1. The load acting on the spring\r\n2. The range of stress through which the spring operates\r\n3. The limitations on mass and volume of spring\r\n4. The expected fatigue life\r\n5. The environmental conditions in which the spring will operate such as temperature and corrosive atmosphere\r\n6. The severity of deformation encountered while making the spring\r\n\r\nThe mainly used material for manufacturing the springs are as follows:\r\n1. Hard drawn high carbon steel\r\n2. Oil tempered high carbon steel\r\n3. Stainless steel\r\n4. Copper or nickel-based alloys\r\n5. Phosphor bronze\r\n6. Monel\r\n7. Titanium\r\n8. Chrome vanadium\r\n9. Chrome silicon\r\n\r\nCharacteristics of some typical materials are explained below\r\n\r\n1. Hard-drawn wire: This is cold drawn, cheapest spring steel. Normally used for low stress and static load. The material is not suitable at subzero temperatures or at temperatures above 120\u2070 C.\r\n\r\n2. Oil-tempered wire: It is a cold drawn, quenched, tempered, and general-purpose spring steel. However, it is not suitable for fatigue or sudden loads, at subzero temperatures, and at temperatures above 180\u2070 C. When we go for highly stressed conditions then alloy steels are useful.\r\n\r\n3. Chrome Vanadium: This alloy spring steel is used for high-stress conditions and at high temperature, up to 220\u2070 C. It is good for fatigue resistance and long endurance for shock and impact loads.\r\n\r\n4. Chrome Silicon: This material can be used for highly stressed springs. It offers excellent service for long life, shock loading, and for temperature up to 250\u2070 C.\r\n\r\n5. Music wire: This spring material is most widely used for small springs. It is the toughest and has the highest tensile strength and can withstand repeated loading at high stresses. However, it cannot be used at subzero temperatures or at temperatures above 120\u2070 C. Normally when we talk about springs we will find that the music wire is a common choice for springs.\r\n\r\n6. Stainless steel: Widely used alloy spring materials.\r\n\r\n7. Phosphor Bronze \/ Spring Brass: It has good corrosion resistance and electrical conductivity. That is the reason it is commonly used for contacts in electrical switches. Spring brass can be used at subzero temperatures.\r\n\r\n\r\n\r\nSpring Design\u00a0\r\nTerminology of Helical Springs\r\nspring Design\r\n\r\nThe main dimensions of a helical spring subjected compressive force are as follows:\r\n\r\nd = wire diameter of spring\r\nDi = inside diameter of the spring coil\r\nDo = outside diameter of the spring coil\r\nD = mean coil diameter\r\nTherefore,\r\nD= ( Di + Do ) \/ 2\u00a0\r\n\r\n1. Spring index (C): \r\nThe spring index is defined as the ratio of mean coil diameter to wire diameter. It is denoted by letter C.\r\nC = D\/d\r\n\r\n\r\n \tThe spring index indicates the relative sharpness of the curvature of the coil.\r\n \tA low index means high sharpness of curvature.\r\n \tWhen the spring index is low (C &lt; 3), the actual stresses in the wire are excessive due to the curvature effect.\r\n \tSuch a spring is difficult to manufacture and special care in coiling is required to avoid cracking in some wires.\r\n \tWhen the spring index is high (C &gt; 15), it results in a large variation in coil diameter.\r\n \tSuch a spring is prone to buckling and also tangles easily during handling.\r\n \tSpring index from 4 to 12 is considered better from manufacturing considerations. Therefore, in practical applications, the spring index usually varies from 4 to 12.\r\n \tHowever, the spring index in the range of 6 to 9 is still preferred particularly for close tolerance springs and those subjected to cyclic loading.\r\n\r\ncompression spring nomenclature\r\n2. Solid length: \r\n\r\n \tWhen the compression spring is compressed until the coils come in contact with each other, then the spring is said to be solid.\r\n \tThe solid length of a spring is the product of the total number of coils and the diameter of the wire.\r\n\r\nMathematically, Solid length of the spring formula,\r\nLs = n' * d\r\nwhere,\r\n\r\nn' = Total number of coils, and\r\nd = Diameter of the wire.\r\n3. Free length: \r\nThe free length of a compression spring is the length of the spring in the free or unloaded condition.\r\n\r\nIt is equal to the solid length plus the maximum deflection or compression of the spring and the clearance between the adjacent coils (when fully compressed).\r\n\r\nMathematically, Free length of the spring formula,\r\nLf= Solid length + Maximum compression + Clearance between adjacent coils\r\nLf = n'd + \u03b4max + 0.15 \u03b4max\u00a0\r\n\r\n4. Spring Rate OR Spring Stiffness : \r\nThe spring rate (or stiffness or spring constant) is defined as the load required per unit deflection of the spring.\r\n\r\nMathematically, Spring rate formula,\r\nk = W \/ \u03b4\r\nwhere W = Load, and\r\n\u03b4 = Deflection of the spring\r\n5. Pitch: \r\nIt is defined as the axial distance between adjacent coils in an uncompressed state.\r\n\r\nMathematically, spring pitch formula\u00a0\r\np= Lf \/ ( n'- 1 )\r\n\r\nBuckling of Compression Springs\r\nIt has been found experimentally that when the free length of the spring (LF) is more than four times the mean or pitch diameter (D), then the spring behaves like a column and may fail by buckling at a comparatively low load as shown in the below figure.\r\n\r\nbuckling of compression springs\r\n\r\nThe critical axial load (Wcr) that causes buckling may be calculated by using the following relation, i.e.\r\nWcr = k \u00d7 KB \u00d7 LF\r\nwhere \r\n\r\nk = spring rate or stiffness of the spring = W\/\u03b4,\r\nLF = Free length of the spring, and\r\nKB = Buckling factor depending upon the ratio LF \/ D.\r\n\r\nHow to prevent buckling?\r\n\r\n \tFree length (LF) should be less than 4 times the coil diameter (D) to avoid buckling.\r\n \tMaterial should be selected having higher stiffness.\r\n \tIt order to avoid the buckling of spring, it is either mounted on a central rod or located on a tube.\r\n \tWhen the spring is located on a tube, the clearance between the tube walls and the spring should be kept as small as possible, but it must be sufficient to allow for an increase in spring diameter during compression.\r\n\r\nSurge in Springs\r\n\r\n \tWhen one end of a helical spring is resting on a rigid support and the other end is loaded suddenly, then all the coils of the spring will not suddenly deflect equally, because some time is required for the propagation of stress along the spring wire.\r\n \tA little consideration will show that in the beginning, the end coils of the spring in contact with the applied load take up the whole of the deflection, and then it transmits a large part of its deflection to the adjacent coils.\r\n \tIn this way, a wave of compression propagates through the coils to the supported end from where it is reflected to the deflected end.\r\n \tThis phenomenon can also be observed in a closed water body where a disturbance moves toward the wall and then again returns back to the starting of the disturbance.\r\n \tThis wave of compression travels along the spring indefinitely\r\n \tIf the applied load is of fluctuating type and if the time interval between the load applications is equal to the time required for the wave to travel from one end to the other end, then resonance will occur.\r\n \tThis results in very large deflections of the coils and correspondingly very high stresses.\r\n \tUnder these conditions, it is just possible that the spring may fail. This phenomenon is called surge.\r\n\r\nHow to prevent surging?\r\n\r\nThe surge in springs may be eliminated by using the following methods :\r\n\r\n1. By using friction dampers on the center coils so that the wave propagation dies out.\r\n2. By using springs of high natural frequency (the operational frequency of the spring should be at least 15-20 times less than its fundamental frequency).\r\n3. By using springs having a pitch of the coils near the ends different than at the center to have different natural frequencies.\r\n\r\n\r\n\r\nAdvantages Of Springs :\r\nAdvantages of Springs are explained below :\u00a0\r\n\r\n \tNormally Springs are maintenance-free\u00a0\r\n \tSprings are available in large variety and shapes hence application area is large.\u00a0\r\n \tSpring can minimize machine vibration. Springs can eliminate the undesirable effects of vibrations.\u00a0\r\n \tSprings are easy to manufacture.\r\n \tSprings are highly reliable.\r\n \tMostly we use spring to avoid vibration because the sudden vibrations in a car may affect the human and it causes vomiting \r\n \tIt helps in storing energy as in the case of watches and toys.\r\n\r\nDisadvantages Of Springs :\r\n\r\n \tIf the deflection of the spring exceeds some critical value than the spring will buckle.\u00a0\r\n \tIt is difficult to replace the spring.\r\n \tOnes the spring is damaged it is difficult to repair.\r\n\r\nApplication Of Springs :\u00a0\r\nThe following are some applications of springs.\r\n\r\n \tTo absorb or control energy in automobiles suspension springs, vibration. dampers, railway buffers.\r\n \tTo apply forces in brakes, clutches, valves of IC engines.\r\n \tTo store the energy in watches and toys.\r\n \tTo measure forces in spring balances, gauges.\r\n \tTo provide clamping force in toolings like jigs and fixtures, etc.\r\n \tTo control motion by maintaining contact between two elements, as in the case of cam and follower, etc.\r\n \tTo exert a force, as in spring-loaded safety valve\r\n \tTo support moving masses or to isolate\u00a0vibration.\r\n \tTension springs are used in Industrial Robots, door locks.\r\n \tTorsion springs are used in clothes pins, garage doors\u00a0","headline":"Springs &#8211; Types, Diagram, Design, Material, Advantages, Application","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2020-05-13","mainEntityOfPage":"False","dateModified":"May 13, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/05\/Conical-spring-and-Volute-casing-266x300.jpg","height":300,"width":266},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <nav class="pagination-wrapper" aria-label="article pagination"> <a class="prev page-numbers" href="?page_num=8">&laquo; PREV</a> <a class="page-numbers" href="?page_num=1"><span class="screen-reader-text">Page </span>1</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=7"><span class="screen-reader-text">Page </span>7</a> <a class="page-numbers" href="?page_num=8"><span class="screen-reader-text">Page </span>8</a> <span aria-current="page" class="page-numbers current"><span class="screen-reader-text">Page </span>9</span> <a class="page-numbers" href="?page_num=10"><span class="screen-reader-text">Page </span>10</a> <a class="page-numbers" href="?page_num=11"><span class="screen-reader-text">Page </span>11</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=338"><span class="screen-reader-text">Page </span>338</a> <a class="next page-numbers" href="?page_num=10">NEXT &raquo;</a></nav></section></main><aside id="secondary" class="widget-area"><div class="about-wrapper"><h2 class="widget-title" style="background: #d693c6; color: #ff392e">About Us</h2><div class="about-image" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/03/Sachin-Thorat-300x300-min.png')"></div><p class="about-copy">LearnMech.Com is a Mechanical Project-oriented platform run by Sachin Thorat who is a B-Tech Graduate in Mechanical Engineering. 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