Design, Development, And Fabrication Of Tyre Lug Wrench.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

TO HAVE A NEW DESIGN ON THE EXISTING LUG WRENCH

Thesis submitted in accordance with the requirements of the National Technical

College University of Malaysia for the Bachelor Degree of Manufacturing

Engineering in Manufacturing Process

By

MOHD FAIZ BIN ABD RAHIM

Faculty of Manufacturing Engineering

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UTeM Library (Pind.1/2005)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972) * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau

BORANG PENGESAHAN STATUS TESIS*

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

JUDUL: TO HAVE A NEW DESIGN ON LUG WRENCH

SESI PENGAJIAN: 2/2006-2007

Saya _____________________________________________________________________

mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka.

2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan (√)

MOHD FAIZ BIN ABD. RAHIM

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FAKULTI KEJURUTERAAN PEMBUATAN

- TESIS SARJANA MUDA KEJURUTERAAN PEMBUATAN (PROSES PEMBUATAN): MOHD FAIZ BIN ABD. RAHIM

TAJUK: TO HAVE A NEW DESIGN ON LUG WRENCH.

Sukacita dimaklumkan bahawa tesis yang tersebut di atas bertajuk

“TO HAVE A NEW DESIGN ON LUG WRENCH” mohon dikelaskan sebagai terhad untuk tempoh lima (5) tahun dari tarikh surat ini memandangkan ia mempunyai nilai dan potensi untuk dikomersialkan di masa hadapan.

Sekian dimaklumkan. Terima kasih.

Karung Berkunci 1200, Ayer Keroh, 75450 Melaka Tel : 06-233 2421, Faks : 06 233 2414

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DECLARATION

I hereby, declare this thesis entitled “Design on a new Lug Wrench” is the results of my own research except as cited in the reference.

Signature :

Author’s Name : MOHD FAIZ BIN ABD RAHIM

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APPROVAL

This thesis submitted to the senate of UTeM and has been accepted as partial fulfillment

of the requirements for the degree of Bachelor of Manufacturing Engineering

(Manufacturing Process). The members of the supervisory committee are as follow:

……… Main Supervisor

(Official Stamp and Date)

……….. Co – Supervisor

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ABSTRACT

Most of the people in Malaysia have their own transportation to shift around. The

most popular one is totally, car. With the improved volume of cars on road each day, it

shows that that kind of transportation has becoming crucial and a must in Malaysia.

With a statistic like that, then the idea to improve the lug wrench comes about. The new

design of lug wrench has to be easy in usage, ergonomics, and can solve the common

problems for the available lug wrench in the market. The design has to be compact, so it

will answer the problem from the mostly nowadays lug wrench that is not very space

saver. Lug wrench which is used to loosen or tighten the lug nuts on car’s rim is

compulsory for every car’s owner in case of emergency. For that, some research and

findings has to be done about lug wrench and the cars rim composition. The idea on

having a reduced torque lug wrench based on the questionnaire provided. Most of car

owner has facing their main problem on lug nuts that are too tight to be loosened. So,

with a 3:1 ratio on its input/output rotation, it will at least reduce the torque three times

less theoretically. The epicylic gearing used is suitable in having such a compact design.

The prototype built will be used in trial to show its compatibility in all sizes of cars rim.

Methods such as Design for Manufactured (DFM) and Design for Assembly (DFA) are

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ABSTRAK

Di Malaysia, kebanyakan orang menggunakan kenderaan tertentu untuk bergerak

dari satu tempat ke satu tempat. Tetapi, yang paling mendapat perhatian rakyat Malaysia

ialah kereta. Dengan peningkatan jumlah kerata yang terdapat di jalan-jalan,

menunjukkan yang kereta telah menjadi salah satu pengangkutan yang terpenting. Dari

situlah lahirnya untuk mencipta sebuah pembuka nut tayar. Alat pembuka tayar tersebut

haruslah mudah dikendalikan, ergonomik, dan dapat menyelesaikan kebanyakan

masalah yang terdapat pada alat pembuka nut tayar sekarang. Rekabentuknya pula

mestilah kompak agar tidak menggunakan ruang yang banyak pada kenderaan.

Kegunaan utama alat pembuka nut tayar adalah untuk menggantikan tayar ketika

kecemasan. Dengan itu, kajian perlu dilakukan mengenai alat pembuka nut tayar sedia

ada termasuk komposisi tayar tersebut. Segala konsep-konsep yang telah dicadangkan

adalah berdasarkan borang soal selidik yang telah diberi. Berdasarkan borang tersebut

juga didapati masalah utama ketika membuka nut tayar adalah keaadaan nut yang terlalu

ketat. Dengan itu, dengan rekabentuk mekanisme yang dapat mengurangkan jumlah

putaran output secara nisbah 3:1 diharap dapat mengurangkan keseluruhan tenaga yang

diperlukan ketika membuka tayar. Mekanisme penting dalam menghasilkan alat

pembuka nut tayar ini adalah dengan penggunaan epicylic gear. Prototaip yang telah

dihasilkan akan digunakan untuk menguji kebolehsesuaian alat tersebut ke atas

kebanyakan saiz rim kereta. Kaedah-kaedah seperti Design for Manufactured (DFM)

dan Design for Assembly (DFA) digunakan untuk memastikan ianya boleh dihasilkan

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ACKNOWLEDGEMENTS

Several people have contributed to this attempt. The following individuals

provided valuable comments on earlier drafts of the work: Prof. Dr. Md. Dan B. Md.

Palil as my supervisor, Mr Yuhazri as my co-supervisor, Mr Khairul Anwar B. Rahman

as my second reader and others who have significantly help, whether directly or not, to

the publication of this thesis. Special thanks to all the technical staff from the

laboratories for their guidance such as Mr Nazri b Mokte from machine shop lab, Mr

Ashari from machine shop, Mr Hairmi from CAD/CAM lab and also Mr Hisyam from

machine shop. A very huge appreciation also would like to be given to all the academic

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DEDICATION

All of my dedication goes to,

My father, Abd Rahim B. Abd Rahman and my mother, Khairul Bariah Bt. Ishak

My brothers, Faizal, Fadly, Faizul, and Fikry,

My grandfather, Hj Ishak B. Hj Surin and my grandmother, Hjh Latifah Bt. Hj Rahman

Also to all my relatives and friends,

For;

All of your advices and supports,

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LIST OF FIGURES

NO. TITLE PAGE

2.1 Differences between bolt circle pattern 12

2.2 Basic dimension of a lug nut 16

2.3 Cross-shaped lug wrench 16

2.4 Foldable lug wrench 17

2.5 L shaped lug wench 17

2.6 (a)The ‘spring’ reaction with multiplier behave like a very stiff ‘spring’(b)

When multiplier achieve the maximum torque 29

2.7 Mechanism on Epicyclic gearing 30

2.8 Sample of rotation in Epicyclic gearing 31

3.1 Methodology Flow Chart 41

3.2 Questionnaire Form 38

3.8 Concept Development on holder design 50

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4.4 Input Carrier and Rods assembly 71

4.5 Gears applied 71

4.6 Housing and Internal Gear assembly (MIG welding) 72

4.7 Final Assembly 73

5.1 New Output Carrier 79

5.2 Applied force on existing Output Carrier 80

5.3 Applied force on new Output Carrier 80

5.4 New Input Carrier 81

5.5 Input Carrier with Gears 82

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LIST OF TABLES

NO. TITLE PAGE

2.1 Sample of lug nut sizes for car’s rim 15

3.1 Screening Method 47

3.2 Scoring method 48

3.3 Gear Selection 56

4.1 Components 59

4.2 Bill of Material 61

4.3 Final Components List 73

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LIST OF SYMBOLS

1. " inch

2. τ torque

3. π pie

4. θ angle

5. Σ sums

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LIST OF ABBREVIATIONS

1. mm millimeters

2. kg kilograms

3. in inch

4. PCD Pitch Circle Diameter

5. ft feet

6. lbs pound

7. N newton

8. m meter

9. Pa pascal

10. W weight

11. g gravity

12. E energy

13. r displacement length

14. F force

15. P power

` 16. T period

17. f frequency

18. rpm revolution per minute

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CHAPTER 1

INTRODUCTION

Having a car is a must nowadays. We need transport to travel from one place to

another. There are a lot to be considered so the car will run smoothly and achieved the

objective in going to the specified destination. Car maintenance, for example, is of the

major factor in keeping the life span of the car. In addition, the car owner has to know

the basic specification of their own vehicle. This include in having the basic knowledge about how to change the car’s tire.

To change car’s tire, it requires a very most minimum skill. Almost everyone can

do it. To change tire, we need a proper tool. In this situation, we use lug wrench. Most of

the cars today will be provided with their own lug wrench. There are several types of lug

wrench available in the market. The most common lug wrench is the Cross and the L

shape type. This is initially provided by the manufacturer when we buy a new car. All of

these lug wrenches is actually quite ergonomics but it also requires strength in using it.

Both types used the same method but the experts has said that it is better to use the cross

shape.

Although it is recommended by experts, the cross shape lug wrench still requires

a great strength to use it. So, from this problem, many manufacturers have come out

with several solutions. The most popular one is using the torque multiplier, but in very

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1.1 Objectives of Project

i. Study on the development of the lug wrench that is simple, easy to use, and available to be kept in average car’s boot

ii. To have a new design of the new lug wrench system and all the mechanism

involved

iii. To have a new design that are able to be commercialized

1.2 Problem Statement

Everyone will be facing the problem while changing their own car’s tire. This is

caused by the provided lug wrench by the manufacturer. It is designed to have the

simplest material and cost used. Because of that, it is not very suitable for lug wrench

when it comes to the simplest strength required in using it. Most of the provide lug

wrench will requires each person to use a great strength before the nuts can be loosen. It

is poorly effective when it comes to a weak person like a woman for example. A woman

is actually has a lower strength compared to man. It can be imagined the force required

to loosen up the nuts as most of the nuts are tighten by the impact wrench. As for

example, when the nuts is tighten using impact wrench for about 100 N.m, the energy

when we need to loosen it is not the same. It actually for at least two times energy

required when it comes to loosen it. This is because of the nuts itself has its own force

between the meshing thread. So, roughly, for a 100 N.m force when tightening the nuts,

it requires at least 200 N.m of energy to loosen it. The other factor that makes the nuts

are hard to loosen is the rust factor that actually will ended up with a loosen head of the nuts when we didn’t have enough force to loosen the nuts.

By all of the problems stated, it is very appropriate to have a new lug wrench that

requires a small energy but provide a great energy on the output. This will become

possible when we study on the torque multiplier and the mechanism of the Epicyclic

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1.3 Scope/Methodology

i. Literature review on the lug wrench available in the market nowadays

ii. Study on the suitable structure and the material involved on the available lug

wrench

iii. To have a new design on the system used whether it is manual, mechanical, or

automatic, or both

iv. To have a new design of lug wrench that easy to be kept in tool box

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CHAPTER 2

LITERATURE REVIEW

Conveniently enough, a lug wrench is a tool designed to loosen and tighten lug

nuts. Lug nuts are responsible for keeping tire rims attached to the axles, which means

they are usually kept very tight. Professional mechanics generally use pneumatic socket

wrenches to accomplish this feat, guaranteeing that the lug nuts won't work themselves

loose during normal driving. A lug wrench is designed to provide drivers with enough

leverage to loosen lug nuts during a roadside emergency.

There are two common lug wrench designs drivers may encounter. One is a

metal bar bent on the end nearest a socket wrench. The other common lug wrench

configuration resembles a cross, with various socket wrenches on each arm.

Both provide enough leverage for a driver to loosen lug nuts, but many experts

recommend the cross-shaped lug wrench for maximum leverage. The bent-arm lug

wrench features a pry bar on the opposite end, however, which can make removing hub

caps or other wheel covers much easier.

The lug wrench comes into play most often with a flat tire. The driver usually

removes the spare tire, car jack and lug wrench from the trunk in order to replace the

flat. Once the hubcap or wheel cover is pried off, the lug nuts are revealed.

The driver must loosen, but not remove, all of the lug nuts before jacking up the

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until the nut breaks loose. Once the lug nut becomes loose enough to turn by hand, the

driver repeats the process with the rest of the nuts. With a cross-shaped lug wrench, the

driver should be able to apply both upward and downward pressure on the left and right

arms. This additional torque is why many professionals prefer the cross-shaped lug

wrench.

Great care must be taken not to strip out the socket of a lug wrench. If the end of

a bent-arm lug wrench is not attached to the lug nut correctly, excessive force can

damage the nut or the socket. A lug wrench made from softer metals may be less

expensive than a drop-forged steel model, but it may not be able to handle the most

stubborn lug nuts. It is not uncommon for car owners to replace the factory-provided lug

wrench and car jack with higher quality tools from an auto supply store.

2.1 Definition of Lug Wrench

A wrench or spanner is a tool used to provide a mechanical advantage in

applying torque to turn bolts, nuts or other hard-to-turn items. In American English,

wrench is the standard term, while spanner refers to a specialized wrench with a series of

pins or tabs around the circumference. (These pins or tabs fit into the holes or notches

cut into the object to be turned.) In British English, spanner is the standard term. Hinged

tools, such as pliers or tongs, are not generally considered wrenches.

2.1.1 Common Wrenches

i. Open-end wrench or Open-ended spanner: a one-piece wrench with a U-shaped

opening that grips two opposite faces of the bolt or nut. This wrench is often

double ended, with a different sized opening at each end. The ends are

generally oriented at an angle of around 30 degrees to the longitudinal axis of

the handle. This allows a greater range of movement in enclosed spaces by

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ii. Box-end wrench, or Box spanner, or Ring spanner: a one-piece wrench with an

enclosed opening that grips the faces of the bolt or nut. The recess is generally

a six-point or twelve-point opening for use with nuts or bolt heads with a

hexagonal shape. The twelve-point fits onto the fastening at twice as many

angles, an advantage where swing is limited. Eight-point wrenches are also

made for square shaped nuts and bolt heads. Box-ends are also often

double-ended.

iii. Combination wrench or Combination spanner: a double-ended tool with one

end being like an open-end wrench or open-ended spanner, and the other end

being like a box-end wrench or ring spanner. Both ends generally fit the same

size bolt.

iv. Flare-nut wrench or Tube wrench: used for gripping the nuts on the ends of

tubes. The design is similar to a box–end wrench but with an opening to allow

the wrench to fit over the tube

v. Socket wrench: a hollow cylinder that fits over one end of a nut or bolt head—

may include a handle but usually used with various drive tools. It generally has

either a six–point or twelve–point recess, may be shallow or deep, and may

have a built-in universal joint. In addition, face driving sockets are available.

These are more durable still, and have the ability to drive a range of hexagonal

head sizes, with less risk of damaging the nut or bolt head than traditional

"corner" drivers. The drive handles generally used are:

a) A break–over (or hinged) handle.

b) A ratchet handle (contains a mechanism which allows the socket to be

turned without removing it from the nut or bolt).

c) A speed handle (sometimes called a crank handle).

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Sockets are often sold as a set containing a collection of sockets of various sizes

and associated drive tools; usually including, as a minimum, extensions, a ratchet driver,

and a universal joint. Sockets are also used with various power tools.

2.1.2 Specialized Wrenches

i. Spoke wrench or spoke key: a wrench with a clearance slot for a wire wheel

spoke such as a bicycle wheel and a drive head for the adjustment nipple nut.

ii. Tap wrench: a double–handled wrench for turning the square drive on taps

used in threading operations (cutting the female threads such as within a nut) or

a precision reamer.

iii. Die wrench: A double–handled wrench for turning the dies used in threading

operations (cutting the male threads such as on a bolt).

iv. Torque wrench: a socket wrench drive tool that measures the amount of

rotational force applied to the socket—this may be indicated visually with a rod

or dial or may simply slip when a set torque is exceeded. The torque wrench

would also be categorized as a measuring tool.

v. Drum wrench: a tool commonly used to open bungs on large 55 gallon drums.

vi. Lug wrench: a socket wrench used to turn lug nuts on automobile wheels.

vii. Plumber wrench: a tool to screw (rotate with force) various pipes during

plumbing.

viii. Tuning wrench: a socket wrench used to tune some stringed musical

instruments.

2.1.3 Lug Wrench

A lug wrench is a type of socket wrench used to turn lug nuts on an automobile

wheel. The form commonly found in car trunks is an L-shaped metal rod with a socket

wrench on the bent end and a prying tip on the other. The prying tip is mainly intended