ELIMINATION OF BRAKE ASSEMBLY FAILURE AT CUSTOMER END

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ABOUT THE ORGANISATION

Established in 1981, Automotive Axles Limited (AAL) is a joint venture of Kalyani Group and
Meritor Inc., USA. With manufacturing facilities located at Mysore (Karnataka), the company is
currently the largest independent manufacturer of Rear Drive Axle Assemblies in India. The
company has also expanded its footprints in North India with its plants at Pantnagar and Jamshedpur.

Over the past 30 years, it has successfully been manufacturing reliable & long-life Medium & Heavy
duty Drive axles, Front Steer axles, Non-Drive axles, Axles for Defence & Off-Highway applications
and Drum & Disc Brakes. Recently it has forayed into manufacturing of Light duty Drive axles.

Established

April 21, 1981

i. Meritor

35.52%

ii. Kalyani

35.52%

iii. Public

28.96%

Land Size

202,343.5 Sqm

Location

Mysore, India

Total Employees

2000+

Manufacturing

Equity Share

Plants

Mysore, Pantnagar, Jamshedpur

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Over the years, AAL has developed an impressive domestic OEM clientele that includes Ashok Leyland, Tata
Motors, Asia Motor Works, Daimler India, Volvo India, SML Isuzu Ltd., Volvo Eicher Commercial Vehicles,
Vehicle Factory-Jabalpur, BEML, MAN Trucks Pvt. Ltd., Mahindra Trucks & Buses, CAT, Escorts, TIL and
Sonalika. AAL also exports axle parts to USA, France, Italy, China, Brazil and Australia.

VISION:
To be a world class quality manufacturer of axles, providing innovative solutions to customer at
competitive price that enhance mobility, safety & environment and retain leadership.

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ABSTRACT
Brake adaptor or brake flange is a plate on which brake assembly is mount. These flanges are
welded on the axle housing or the spindle. Most spindles have these welded on at the factory with
specialized jigs and higher precision welding equipment that what even experienced do-it-yourselves
have.
The flange needs to be welded on concentric and square. Square meaning the flange must be a
true 90 degrees from the spindle and concentric meaning the gap around the spindle must be the same
360 degrees around. If not, the brakes will not wear evenly and will cause reduced braking
performance. If not at the right depth the brakes will not be as effective and again, wear unevenly. If
the flange is not welded square to the spindle then there are the chances for un-machined surface to
appear on flange during flange turning process due to improper orientation.
The uneven surface formed will have an effect on bake assembly mounting failure. The uneven
surface leads to uneven distribution of load over the flange. This may gradually lead to brake failure
due to varying cyclic loads.
Our aim is to find out root cause for the error causing the orientation problem. Since the
manufacturing process responsible for creating the problem is unknown. We have to find out the
process responsible for the error. Hence six sigma technique is used to analyse the problem and to find
out a solution to eliminate the unclear surface on the brake flange.

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CHAPTER 1
INTRODUCTION
1.1 AXLE
An axle is a central shaft for a rotating wheel or gear. On wheeled vehicles, the axle
may be fixed to the wheels, rotating with them, or fixed to the vehicle, with the wheels
rotating around the axle. In the former case, bearings or bushings are provided at the
mounting points where the axle is supported. In the latter case, a bearing or bushing sits
inside a central hole in the wheel to allow the wheel or gear to rotate around the axle.
Sometimes, especially on bicycles, the latter type axle is referred to as a spindle.
On cars and trucks, several senses of the word "axle" occur in casual usage, referring
to the shaft itself, its housing, or simply any transverse pair of wheels. Strictly speaking, a
shaft which rotates with the wheel, being either bolted or splinted in fixed relation to it,
is called an "axle" or "axle shaft". However, in looser usage an entire assembly including
the surrounding "axle housing" (typically a casting) is also called an "axle".

Fig 1.1: MS08-120 Single Reduction Hypoid Solo Drive Axle.

In rear wheel drive cars and trucks, the engine turns a drive shaft (also called a
propeller shaft or tail shaft) which transmits rotational force to a drive axle at the rear of the
vehicle. The drive axle may be a live axle, but modern rear wheel drive automobiles
generally use a split axle with a differential. In this case, one half-axle or half-shaft connects
the differential with left rear wheel, and second one does the same with the right rear wheel;
thus the two half axles and the differential constitute\ the rear axle.
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1.2 TYPES OF AXLES

1.2.1

BASED ON STRUCTURAL FEATURES

STRAIGHT AXLE:

A straight axle is a single rigid shaft connecting a wheel on the left side of the vehicle
to a

wheel on the right side. The axis of rotation fixed by the axle is common to both

wheels. Such a design can keep the wheel positions steady under heavy stress, and can
therefore support heavy loads. Straight axles are used on trains (that is locomotives and
railway wagons), for the rear axles of commercial trucks, and on heavy duty offroad vehicles. The axle can optionally be protected and further reinforced by enclosing the
length of the axle in housing.

SPLINT AXLE:

In split-axle designs, the wheel on each side is attached to a separate shaft. Modern
passenger cars have split drive axles. In some designs, this allows independent suspension of
the left and right wheels, and therefore a smoother ride. Even when the suspension is not
independent, split axles permit the use of a differential, allowing the left and right drive
wheels to be driven at different speeds as the automobile turns, improving traction and
extending tire life.

TANDEM AXLE:

A tandem axle is a group of two or more axles situated close together. Truck designs will
use such a configuration to provide a greater weight capacity than a single axle. Semi
trailers usually have a tandem axle at the rear.

1.2.2

BASED ON THE WORKING

DRIVE AXLE:

An axle that is driven by the engine or prime mover is called a drive axle.
Modern front wheel drive cars typically combine the transmission (i.e. gearbox and
differential) and front axle into a single unit called a transaxle. The drive axle is a split axle
with a differential and universal joints between the two half axles. Each half axle connects to
the wheel by use of a constant velocity (CV) joint which allows the wheel assembly to move
freely vertically as well as to pivot when making turns.
In rear wheel drive cars and trucks, the engine turns a driveshaft (also called a propeller shaft
or tail shaft) which transmits rotational force to a drive axle at the rear of the vehicle. The
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drive axle may be a live axle, but modern rear wheel drive automobiles generally use a split
axle with a differential. In this case, one half- axle or half-shaft connects the differential
with the left rear wheel, and second one does the same with the right rear wheel; thus the two
half-axles and the differential constitute the rear axle.
Some simple vehicle designs, such as leisure go-karts, may have a single driven wheel where
the drive axle is a split axle with only one of the two shafts driven by the engine, or else have
both wheels connected to one shaft without a differential (kart racing). However, other gokarts have two rear drive wheels too.

Fig2.1: Drive Axle

DEAD AXLE(LAZY AXLE) :

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A dead axle, also called lazy axle, is not part of the drive train but is instead freerotating. The rear axle of a front-wheel drive car is usually a dead axle. Many trucks and
trailers use dead axles for strictly load-bearing purposes. A dead axle located immediately in
front of a drive axle is called a pusher axle. A tag axle is a dead axle situated behind a drive
axle. Dead axles are also found on semitrailers, farm equipment, and certain heavy
construction machinery serving the same function. On some vehicles (such as motor

coaches), the tag axle may be steerable. In some designs the wheels on a lazy axle only come
into contact with ground when the load is significant, thus saving unnecessary tire we

LIFT AXLE:

Some dump trucks and trailers may be configured with a lift axle (also known as airlift
axle or drop axle), which may be mechanically raised or lowered. The axle is lowered to
increase the weight capacity, or to distribute the weight of the cargo over more wheels, for
example to cross a weight restricted bridge. When not needed, the axle is lifted off the ground
to save wear on the tires and axle, and to increase traction in the remaining wheels. Lifting an
axle also alleviates lateral scrubbing of the additional axle in very tight turns, allowing the
vehicle to turn more readily. In some situations removal of pressure from the additional axle
is necessary for the vehicle to complete a turn at all.

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Fig2.2:
Lift Axle

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CHAPTER 2
LITERATURE REVIEW
A literature review is much more than a list of separate reviews of articles and books. They are
common and very important in the sciences. A literature review is a critical, analytical summary and
synthesis of the current knowledge of a topic. It should compare and relate different theories,
findings, and so on, rather than just summarize them individually. It should also have a particular
focus or theme to organize the review. It does not have to be an exhaustive account of everything
published on the topic. But it should discuss all the more significant academic literature important
for that focus.

2.1 Base Papers:

Review Paper-1:
Sawita D. Dongre1, Prof. U. D. Gulhane2, Harshal C. Kuttarmare3,
Authors: M.Tech 3rd sem student1. Professor of Mechanical Department2. Assistant Professor of Mechanical
Department3, S.S.P.A.C.E Wardha1. B.D.C.O.E. Sevagram2. D.M.I.E.T.R. Wardha3.
Title:
Chassis

Design and Finite Element Analysis of JIGS and Fixtures for Manufacturing of
Bracket.

Publication: International Journal of Research in Advent Technology, Vol.2, No.2, February 2014
E-ISSN: 2321-9637.
Description: This project is about the design and analysis of Jigs and fixture which is used in the
manufacturing of chassis bracket of Bajaj car RE60 (passenger car).The purpose of the
jigs is to provide strength, holding, accuracy and interchangeability in the
manufacturing of product. By performing analysis on jigs and fixtures we find out
stress acting on jigs and fixtures and bracket. The jigs and fixtures are the economical
ways to produce a component in mass. So jigs and fixtures are used and serve as one of
the most important facility of mass production system. These are special work holding
and tool guiding device. What makes a fixture unique is that each one is built to fit a
particular part or shape. The main purpose of a fixture is to locate and in the cases hold
a work piece during an operation. A jig differs from a fixture in the sense that it guides
the tool to its correct position or towards its correct movement during an operation in
addition to locating and supporting the work piece. So in this project we will design
jigs and fixtures while manufacturing of chassis bracket and analyzing stress and strain
developed in jigs and fixtures and chassis bracket. In this we will minimize the
different problem of breakage of jigs and fixtures.

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Review Paper-2:
Authors:
Title:

G. Rajesh Babu and N. Amar Nageswara Rao Mechanical Engineering Department,

Nimra College of Engineering & Technology, Ibrahimpatnam, Vijayawada

STATIC AND MODAL ANALYSIS OF REAR AXLE HOUSING OF A TRUCK.

Publication: International Journal of Mathematical Sciences, Technology and Humanities 7 (2011) 69

76
Description: Axle housing is one of the significant components that lead to great performance of the
vehicle. It may be available in one-piece or has spilt type construction that is also known
as banjo type construction. Axle housings are usually comprised of double lip seals and
over size bearings. This results in more capacity and enhanced surface area contact over
axle. Both the front and rear openings have centre housing. Differential carrier closes the
front opening. On the other hand, spherical cover plate is used for closing the rear. This
paper analysis the static and modal analysis of the rear axle housing. The geometry of
axel housing is created in Pro-E-4.0 software as per the drawing. Then the model is
imported to develop a mesh by using HyperMesh-10, through IGES format and then solid
elements were created for axel housing. A converged mesh is generated and the meshed
component is exported to Ansys-11 to evaluate the product strength and ability to
withstand against all forces and vibrations .Finally the stresses, deflections and natural
frequencies of the cast iron and mild steel models are carried out and compared.

Review Paper-3:

Authors:
Title:

Roger G. Schroeder a,*, Kevin Linderman a,1, Charles Liedtke b,2, Adrian S. Choo c,3,a
a
Curtis L. Carlson School of Management, University of Minnesota, USA
b
Strategic Improvement Systems, LLC Excelsior, MN, USA
c
Lally School of Management and Technology, Rensselaer Polytechnic Institute, USA
SIX SIGMA: DEFINITION AND UNDERLYING THEORY

Publication: Journal of Operations Management 26 (2008) 536554

Description:

Six Sigma has been gaining momentum in industry; however, academics have
conducted little research on this emerging phenomenon. Understanding Six Sigma first
requires providing a conceptual definition and identifying an underlying theory. In this
paper we use the grounded theory approach and the scant literature available to propose
an initial definition and theory of Six Sigma. Our research argues that although the tools
and techniques in Six Sigma are strikingly similar to prior approaches to quality
management, it provides an organizational structure not previously seen. This emergent
structure for quality management helps organizations more rigorously control process
improvement activities, while at the same time creating a context that enables problem
exploration between disparate organizational members. Although Six Sigma provides

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benefits over prior approaches to quality management, it also creates new challenges for
researchers and practitioners.

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CHAPTER 3
NEED OR SCOPE OF PROJECT
The following are some of the factors which improves the performance and reduces the cycle time of
the manufacturing process carried out.
1. The main reason for break assembly mounting failure is the un-machined surface left out on the
brake flange. The brake flanges with unclear surfaces are not accepted by the customers. Hence
the main aim of the project is to eliminate the un-machined surface.
2. Straightening and load testing of the axle is done to remove the run-out, centre shift and face
height defects. So, these defects can be eliminated at the stage in which they are generated.
3. If these defects are eliminated at respective stages then the energy required to drive the
hydraulic press straightening system will be reduced.
4. The amount of material removed during the flange turning can be further reduced if there is no
error in the orientation of the flange.
5. It reduces the chance of rework to be done if there is no unclear surface.
6. The defect causing manufacturing process can be replaced or altered or repaired.
7. Proper clamping and fixtures can be provided in the manufacturing process if necessary

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CHAPTER 4
INTRODUCTION TO SIX SIGMA [6]:
Six Sigma seeks to improve the quality of the output of a process by identifying and removing
the causes of defects and minimizing variability in manufacturing and business processes. It uses a set
of quality management methods, mainly empirical, statistical methods, and creates a special
infrastructure of people within the organization, who are experts in these methods. Each Six Sigma
project carried out within an organization follows a dened sequence of steps and has specic value
targets, for example: reduce process cycle time, reduce pollution, reduce costs, increase customer
satisfaction, and increase prots.
Methodologies
Six Sigma projects follow two project methodologies inspired by Deming's Plan-Do-Check-Act
Cycle.
These methodologies, composed of ve phases each, bear the acronyms DMAIC and DMADV.

DMAIC is used for projects aimed at improving an existing business process.

DMADV is used for projects aimed at creating new product or process designs.

Methodology
The six sigma technique used to resolve the problem is DMAIC. i.e. Define Measure Analyse Improve
and Control

DMAIC
The DMAIC project methodology has ve phases:
The ve steps of DMAIC
Dene the system, the voice of the customer and their requirements, and the project goals,

specically.
Measure key aspects of the current process and collect relevant data; calculate the 'as-is

Process Capability.
Analyse the data to investigate and verify cause-and eect relationships. Determine what the
relationships are, and attempt to ensure that all factors have been considered. Seek out root
cause of the defect under investigation.

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Improve or optimize the current process based upon data analysis using techniques such as
design of experiments, pokayoke or mistake proong, and standard work to create a new, future

state process. Set up pilot runs to establish process capability.

Control the future state process to ensure that any deviations from the target are corrected
before they result in defects. Implement control systems such as statistical process control,
production boards, visual workplaces, and continuously monitor the process.

Any organisations main initiative is to improve the current Process and thereby enhancing the
production rate.
There are two methods in Process improvements.

Problem Solving [Defect Reduction].

Process optimisation [Cost and Cycle time Reduction].

Selection of improvement projects

For each improvement projects identified we have to do the following

Categorize whether the problem is generic or specific.

Departmental/ Functional level projects are called Generic problems. Process level projects are
called specific defects or specific problems. The specific problems are technically clear.
Identify the category of specific problem

2
UNKNOWN

KNOWN
Cause known
SOLUTION
Solution unknown

4
Cause unknown
Solution unknown

Cause known
Solution known

Cause unknown
Solution known

KNOWN
UNKNOWN

CAUSE
For type 1, 2 & 3
problem, we have to

do only improve & control.

For type 4 problem, entire DMAIC is applicable

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Fig: Category identification for Specific problem

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PROCESS OBSERVATION

FIG: PROCESS OBSERVATION FLOW CHART

Some of the main processes to be observed is as follows
1. Tack welding
2. Seam welding
3. Bore and Face housing banjo
4. Ring and cover welding
5. Swaging
6. Friction weld spindles to housing
7. Tack and full weld brake flanges
8. Cooling
9. Straightening and Load testing
10. Grinding bearing dia
11. Curl turn and flange turnig

KEY WORDS
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HOUSING
SPINDLE
BRAKE FLANGE
RUN OUT
FACE HEIGHT

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