Design and fabrication of a durability testing machine for spring seat of strut

Project Title

Design and fabrication of a durability testing machine for spring seat of strut

Project Area of Specialization Mechanical EngineeringProject Summary

we have to design a durbability testing machine for struts of toyota corolla, toyota yaris and suzuku Alto. the durability testing machine will test the integrity of the whole outer shell of struts. the design requirements are:

1) 2 samples need to be tested simultaneously 

2) each strut has to endure 200,000 cycles of  fatigue

3)  fatigue loading range from 3000N to 4500N 

4) size provision to be provided in machine design.

the project is only half funded by Agriautos. 

Project Objectives

our project will provide Agriauto industries with in-house capability of testing their struts. Agriautos is a major shock manufacturing factory and it sends its shock absorbers and struts abroad for durability testing. with the help from our machine, Agriautos will be able to test it's shock absorbers on site and will be able to simultaneously reduce expenses as well. 

Project Implementation Method

we are under the guidance of General manager technical Muhammad Kaleem of Agriautos Industries for the development of this machine. every week we hold a meeting in Agriautos Industries in regards to this project. 

project implementation:

research phase ---> 20 aug'20  to 20 sept'20

project paper for Agriautos--> 21sep'20 to 21oct'20

detailed designing-->22oct'20 to 1jan'21

ansys simulation--> 2jan'21to 20jan'21

exam break--> 21jan'21 to 20 feb'21

fabrication-->21feb'21 to 21 april'21

assembly--> 22april'21 to 22 may'21

assembly electrical--> 23may'21- 1july'21

testing--> 2july'21 to 4 Aug'21 

Benefits of the Project

shock absorbers are not being tested in pakistan because pakistan does not have this technology yet. thanks to the initiative of Agriauto industries, my group has the opportunity to provide in-house capability to Agriautos. due to our project, toyots struts will not be sent to Japan for testing rather they will be tested right here in karachi.  to sum up:

The concept and applications of this project are:

? Agriautos sends it's shock absorbers abroad for durability and testing. our aim is to provice indigenous capability.

? The outcome of this new facility will result in cost reductions for Agriautos.

? 'shock absorber will be 'ready to go' in a lot less time than before.

Technical Details of Final Deliverable

no. of samples that need to be tested simultaneously=2

fatigue loading range= 3000N to 4500N

spring stifffness of springs of all struts are provided by Agriautos.

the final design(approved) developed by our group is attached:

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Transportation Core Technology Internet of Things (IoT)Other TechnologiesSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	70000
beams	Equipment	12	1200	14400
ball bearing	Equipment	2	12000	24000
fulcrum bearing	Equipment	2	12000	24000
transport	Miscellaneous	1	7600	7600