30 Figure 2 Specimen of Sheet Metal which is Lap Joints
after RSW
2.3 Tensile Test
This method was suitable and simple to test the strength of the welded joint of sheet metal in terms of
the tensile strength of the joint before fail or tear apart. Tensile-shear test was used to determine the maximum
lap-shear force that can be achieved after the overlapping sheet metal joint together using RSW. A
total twenty specimens underwent the tensile-shear test to obtain the maximum load before break due to shear
force applied to weld area. The result is discussed in the next section.
3. RESULTS AND DISCUSSION
Table 2 shows the thickness of the specimen influences the maximum load, ultimate tensile stress and
modulus young. Referring to Table 2, the tensile shear strength increased significantly with the increase of
sheet thickness. Based on Table 2, it is showed that sheet 3.50mm-thickness value data requires further
investigation. Based on the previous study, the ultimate value tensile stress will increase when the thickness of
the welded sheet increases because the higher thickness will reach the breaking point much slower [2]. From the
observation, it was predicted that this happened due to insufficient growth of weld nugget at the specimen.
Insufficient growth of nugget may occur from insufficient current supply and also because insufficient
weld time. Table 2 Tensile test data for different thickness and
layer
Total Layer
Thickness [mm]
Max Load
[N] Ultimate
tensile Stress
[MPa] Modulus
Automatic Young’s
[MPa]
3 2.80
7641.98 109.17
15584.31 4
2.80 7414.09
105.92 17703.26
4 3.50
8436.01 96.41
11148.32 4
4.40 11904.55 108.22
13876.35
4. CONCLUSIONS
Based on the project, the strength of four welded sheet can be said have higher tensile strength compared
to the three layers. However, due to the result of sample 3.5mm thickness and 4 layer welded sheet, this research
requires further investigation. The mechanism of the strength of welded sheet
with same layer but different thickness has been tested by using tensile shear test method. The weld strength of
4.4mm-sheet thickness measure by tensile shear test were found to be relatively high compared to the
2.80mm-sheet thickness and 3.50mm-sheet thickness. The study discovered that the maximum peak load for
3.50mm-sheet thickness is higher compared to 2.80mm- sheet thickness which means 3.50mm-sheet thickness
was better than 2.80mm-sheet thickness. Even though, the less thickness of spot welded sheet would reduce the
car weight and reduce petrol consumption it would also reduce the rigidity of the car. Lower strength of spot
weld can lead into total destruction of manufacturing parts of car bodies. Therefore, the failure characteristics
and performance of the spot welds significantly affect the durability and safety design of the vehicles [3].
5. REFERENCES [1] Nielsan, C.V., Friis, K.S., Zhang, W, and N Bay,
“Three-Sheet Spot Welding of Advanced High- Strengh Steels,” Welding , vol.90, Journal, pp.32-
40, 2011. [2] Pouranvari, M. et al., 2011. “ Influence of Fusion
Zone Size and Failure Mode on Mechanical Performance of Dissimilar Resistance Spot Welds
of AISI low carbon steel and DP600 advanced hi strength steel,” Materials Design, vol.323, pp.
1390-1398,2011. [3] Ambroziak, A. Korzeniowski, M., “Using
Resistance Spot Welding for Joining Aluminium Elements in Automotive Industry,” Archives of
Civil and Mechanical Engineering, vol.101, pp.5-13, 2010
__________ © Centre for Advanced Research on Energy
Pneumatic gear shifter analysis
M.A. Abdullah
1,2,
, M.A. Mohd Ahyak
1
, M.A.I. Abd Hamid
1
, F.R. Ramli
1,2
, S.A. Shamsudin
1,2 1
Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia.
2
Centre for Advanced Research on Energy, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia.
Corresponding e-mail: mohdazmanutem.edu.my
Keywords: Pneumatic gear shifter; wireless gear shifter; gear shifter mechanism; gear lever. ABSTRACT - Conventional design of transmission
gear shifter is basically consists of mechanical linkage of gear lever attached on the side of motorcycle engine
with pivot directly connected to the gear shifting mechanism. Shifting up and down of gear positions are
performed by moving foot or toe upward and downward on the lever respectively. For disable rider rider
requires special need, shifting gear for manual transmission type of motorcycle with or without clutch
system is difficult. In this research, a pneumatic gear shifter is designed and tested. It consists of pneumatic
circuit with actuator, tanks and air compressor. The movement of gear lever is performed by the pneumatic
actuator. Pneumatic tanks are installed to achieve optimum pressure. It also controlled by wireless system
for convenient purpose and buttons installed at the handle. Simple experiment is performed to measure the
force for each gear position. 1. INTRODUCTION
The transmission of a light vehicle is determined by the number of force applied to the gearshift. Most
motorcycle gearshift assemblies in recent years have been fabricated with a foot pedal that is shifted
upwardly and downwardly by the bottom and top surfaces of the toe or foot. In transmission system,
conventionally, it has a mechanical linkage that connects the gear lever to the gear switching
mechanism. The mechanism for gear changing of the transmission still remains the same that is the reliance
towards the gear lever situated on the left leg of the rider [1]. The transmission system size, weight and type
are varied from one manufacturer to another. Nevertheless, its basic principle on how the system
works remain constant although it is produced by different manufacturers. For the simplest form of this
system, it will only contain a centrifugal clutch attached to the crankshaft and then redirected to the sprocket via
chain. As the engine speed increases, the clutch activates and propels the rear wheel [2][3]. A solenoid
gear shifter or an electric solenoid shifter is an invention that is equipped onto motorcycle or car for the gear
changing process [4]. Solenoid gear shifting mechanism uses magnet to move upwardly and downwardly [5].
This movement depends on the magnetic field that is produce by the magnet when power is supply through it.
In this research, a gear shifter test rig is designed and used to analyze the forces required for shifting up
and down in pneumatic gear shifter demo set.
2. METHODOLOGY
A gear shifter jig is developed to measure the forces required to shift the gear. Since the jig will be
used for the testing of a pneumatic actuator; it will be made from plywood with thickness of 15 mm. Figure 1
shows the design of the test rig. Figure 2 shows the pneumatic gear shifter demo set. The forces are
measured and recorded for analysis.
Figure 1 Gear shifter test rig design
3. RESULT AND DISCUSSION
Figure 3 to 6 show force in kg graph for the data of the 1
st
to 4
th
gear shifting blue,
= shift up from current gear, red,
■
= shift down from current gear. The average value of mass needed for engaging and
disengaging is around 6 kg and 4 kg respectively. The amount of force required to be exerted by the riders
depend on the speed of his leg; experiment result as tabulated in Table 1 shows the trend of force required
for shifting on a light vehicle which is Honda Wave 110. The engagement and disengagement of gear n mean
shifting from gear n-1 to gear n or from gear n+1 to gear n. From the table, it can be seen that based on all 20
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