University of Bolton

Study World Lanka Campus

BEng (Hons) in Mechanical Engineering

Module Detail

Module Code and Name : AME5005

Automotive / Mechanical Design

Marking Tutor : Mr. Asanka

Assignment Number :1

Student Details

Student Name : M.G.G.A. Hasantha

Bolton ID : 1807892

Title of the Assignment : Design Proposal (Fatigue assessment rig)

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Preface Page

The following document is regarding design and development of a test machine

which can make repeated displacement of backrest so as to simulate person sitting on
chair. Literature review regarding existing mechanisms, conclusion, concept evaluation
and logically finalizing appropriate concept to required task will be discussed. Then
relevant calculations, CAD model designing and stress analysis will be shown and
explained.

First chapter explain about project scope, Aim and the Objectives of their project.

Chapter two discuss details found in research papers and industrially available test
rigs.

Third chapter discuss about 3 different concepts and determination of best ourt of
that using weight matrix method. And furthermore 3d model and ansys stress analysis
simulations will be explained in this section

Chapter four is about control systems, selections, and design and component
sections.

Final chapter concludes design details and bill of materials required to design the
machine.

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ACKNOWLEDGMENT

This page dedicated to acknowledge helping hands extended to me during the

my research study about the design proposal of a mechanism that can close the

repeated displacement of the backrest of a chair, to the submitted to the

University of Bolton, UK. As the assignment of the Automotive / Mechanical

Design (AME5005).

First and foremost, Mr.Asanka, and Study World Lanka campus who has

supervised this thesis. He enlightened me on theoretical background of research

methodology and source of encouragement in completing this period of research

study was carried out by me. Mrs. Janani Thilakarathne and Mr. Ajith Fernando

was the academic head and course coordinator of Study World Lanka campus

respectively. Without their guidance I would not able to complete this thesis in

the given line.

Finally, I wish to acknowledgment all the staff of the Study World Lanka campus

and my colleagues who follows the degree program with me for their heartiest

support

Thank You,

M.G.G.A. Hasantha

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 TABLE OF CONTENTS

1 Chapter1: Introduction .................................................................................................................... 1

1.1 Aim ......................................................................................................................................... 1

1.2 Objectives ............................................................................................................................... 1

2 Chapter2: Literature Review ........................................................................................................... 2

2.1 Research .................................................................................................................................. 2

2.2 Commercial Products .............................................................................................................. 3

3 Chapter3: Proposed Design............................................................................................................. 5

3.1 Design concept 1 ..................................................................................................................... 5

3.2 Design Concept 2 .................................................................................................................... 6

3.3 Design Concept 3 .................................................................................................................... 7

3.4 Concept Evaluation Process .................................................................................................... 8

3.5 3D Model Design .................................................................................................................... 9

3.6 2D Drawings ......................................................................................................................... 19

3.7 FEA Analysis ........................................................................................................................ 24

3.8 Material Selection ................................................................................................................. 27

3.9 bill of material ....................................................................................................................... 29

4 Control System Design ................................................................................................................. 32

4.1 Actuator Selection ................................................................................................................. 32

4.2 Control Circuit design ........................................................................................................... 34

4.3 Hardware Part Selection........................................................................................................ 34

5 Conclusion .................................................................................................................................... 35
6 REFERENCES LIST .................................................................................................................... 36

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 LIST OF TABLES

Table 1: Evaluation Matrix ...................................................................................................................... 8

Table 2: part List.................................................................................................................................... 18
Table 3:Bill of Materials ........................................................................................................................ 29

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 1 CHAPTER1: INTRODUCTION

In this report seat fatigue tester will be developed .existing mechanism related to seat
fatigue testing machines will be analyzed and 3 concepts will be finalized which would
satisfy our design requirement. Best concept will be analytically select and solid model
will be generated for that particular concept. During solid model development different
engineering components will be considered which is usually available in the market
place. Different materials will be considered and especial consideration will be gone for
the cost of it. Failure behavior will be considered under different failure theories using
ansys software. Finally all the relevant pneumatic calculations will be done and part list
and relevant bill of materials will be generated. Total product designing approach will
be covered under this report.

1.1 AIM
Design a mechanism that can cause the repeated displacement of the backrest of a
chair so as to simulate a person sitting on the chair and resting their back on the
backrest. Method need to be developed to constrain the chair in a way that only allows
the backrest to flex while the pressure (force of 267N) is being applied. Force must be
able to apply cyclically and should be able to operate it for a predetermined number of
cycles. And also there must be a method to count the number of cycles which the force
being applied.

1.2 OBJECTIVES
 Study about existing mechanisms
 Identify different concepts which can be used to achieve require results
 Find the best concept using logical arguments
 Design and develop solid models for that concept
 Design contro system
 Material selection and improve knowledge regarding industrially use materials.
 Stress analysis to find out how selected materials behavior under given forces.

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2 CHAPTER2: LITERATURE REVIEW

When study about existing mechanism it’s realized that this methodology is used
for measuring fatigue failure of the chairs. This mechanism is so popular among seat
manufacturing companies in order to develop better products which have higher
strength and durability.
Fatigue analysis for chair can be considered as one of the most important type of
analysis which needed to carry out by chair manufacture. Because people use this in
day to day life and apply force to back rest repeatedly.
Below explain commercially available fatigue test rigs and usage of it.in the next
chapter concept evaluation will be done using the knowledge gain through referring
research papers and documents.

2.1 RESEARCH
During the years of 1978-79 many research start regarding conducting a test for
intensive use chairs such as office chairs. This results to define new standards such as
FNEW83-269 so that designers get a scope to design their mechanism. Its main aim
was to make the products life time longer. In order to do that engineers had to make
design and develop mechanisms such a way that it give operator to evaluate about new
fasters strength, new material suitability and come to conclusion about which is most
suitable for their product. Later on those evaluated results can be used on mathematical
models in order to make the product much more productive.
Research papers strongly emphasize the facts engineers and designers consider
when developing mechanism. Most importantly it should be cheap and user friendly
even non-technical person can operate it and ability to maintain with low cost. But
while satisfying above facts it is really difficult to make the mechanism which has
higher degree of freedom.
Many researches analyze most important test types evaluate on the seats and they
realize seat fatigue test, seat strength test and seat arm rest test play a major role among
rest of the test methods.

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 Seat fatigue failure is the most commonly encounter failure of the seats. Due to that
reason fatigue failure test and design fatigue failure test rig play a crucial role.
Above figure illustrate the fatigue testing machine used to test fatigue life of a sofa.
When designing a fatigue test rig there are things we need to consider such as where the
chair is capable of performing the intending functions without any failure so that it
won’t cause any users injuries and whether chair is capable of fulfilling test stands
given by the government.

2.2 COMMERCIAL PRODUCTS

In the industry there are many fatigue test rigs available and they are capable of
operating for different type of chairs. Most importantly they control by programming
logic circuits such a way that even user can see what kind of load applying and how
many number of iterations have already been completed. Below figure illustrate the
fatigue testing machine use in automotive industry.

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 Below figure illustrate the fatigue test machine use to test a medical chair use for
disable persons.in this method number of cycles and evaluation performances are
different than previous scenarios.
Likewise depending on the environment seat being used some testing conditions
change and mechanisms have developed such a way that it can simulate any test
conditions available and even they have given a opportunity to select different
configurations so that user can easily operate the machine though he/she doesn’t have
enough knowledge about the process need to carried out.

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 3 CHAPTER3: PROPOSED DESIGN

Three different concepts will be developed using the knowledge gain through referring
documents and research papers in order to have a proper final product. Most suitable
one will choose logically and it will carry out to solid model generating stage.

3.1 DESIGN CONCEPT 1

Concept one will be discussed in this section and it’s schematically illustrate in the
below figure.1st we need to place the seat on the test rig and then as can be seen in the
figure two belts will be used to apply force to seat and backrest simultaneously. Force
will be generated using pneumatic cylinders which are attached to other ends of the
belts.in order to give the required tension for the belts, ratchets will be used and all the
pneumatic cylinders will be rigidly mount to a structure. Lower seat belt will tension 1st
in order to simulate person sitting on the chair and then the back rest belt will apply
force in order to simulate person applying force on the back rest.

Figure 1concept 1

Depending on the force required different types of pneumatic cylinders can be

chosen and number of cycles will be count using plc program. Uniform force will be
apply during the test and force will be applied in the middle plane of the chair in the
required height.
We set the belts such a way that load apply by test machine will cause to act force
perpendicular the force acting point on the surface. Test will be start using particular
force value and then keep increase until failure occurs or until desired performance
level achieved.

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 3.2 DESIGN CONCEPT 2

2nd concept developed using belt mechanism and heavy weight. Below figure
illustrate the mechanism use for the concept. Seat mounted to the structure using belts
as illustrated, then force applied to the seat back rest using pneumatic cylinder using a
belt. Heavy weigh represent person sitting on chair while repeated force apply through
the attached belt.in order to get the required tension ratchet is used.
User can manually adjust the force apply to the back rest by changing force acting
through pneumatic cylinder. Then number of iteration as well as number of increments
will be given manually. Process will be carried out until certain performance limit
exceed or until standard requirements satisfy. Normal force apply to the seat can be
changed using weights and it needed to do manually before the test starts. Failure
analysis as well as the fatigue strength can be measured using this device

Figure 2 concept 2

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 3.3 DESIGN CONCEPT 3

3rd concept uses totally different mechanism than used before.4 pillar structure is
used and chair is mounted to the floor using clamps. Then force exert on the seat back
rest using the pneumatic cylinder than belt attached to it.as previous methods did this
method uses ratchet as belt tensioner.
In order to simulate person sitting on the chair this mechanism uses a method using
elastic bands which have enough elastic modulus to remain its elastic region even
during full range of applying force by pneumatic cylinder. And those elastic bands
attached to rest arm by either side. Logic behind this concept is counteracting the
moment generated by pneumatic force using the elastic bands so that lower part of the
chair remain same during the whole operation.

Figure 3 concept 3

Just like previous methods this method also can be used to give different force
values as well as using this mechanism different failure modes as well as fatigue
strength can be measure for a given number of iterations.

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 3.4 CONCEPT EVALUATION PROCESS
Concept evaluation can be done in several ways but in this scenario weigh matrix
method is used in order to find the best suitable cost effective method to achieve
mentioned requirements. Weight values will be given from -5 to +5 range and best
represent the +5 and worse case represent the -5.
Highest weight value earned concept will be carried out to next stage to develop
solid models and to do ansys simulations.

Force apply Adaptability Safety Achieving Cost of the Easy

method of different Expected machine Maintenance
suitability chairs failure
Concept 1 +4 +4 +2 +5 +2 +4
Concept 2 +1 -1 +2 -3 +2 +4
Concept 3 +3 0 -2 +3 +4 +3
Table 1: Evaluation Matrix

As u can observed in the above matrix concept one get the highest value and
become the concept which needed to develop solid works models. Due to it uses two
pneumatic cylinders it cost is bit much higher than other concept and that cause to get
lower marks in weight matrix for costing. Electromagnetic systems can be implemented
but initial as well as maintenance cost is too much for the industry like seat
manufacturing. But when compare to other advantages it gives selecting that concept
become the best option to achieve the required targets.2nd concept use constant load on
seat. Due to that when pneumatic force increases seat lower part tend to lift and try to
bend over the seat back rest to seat connecting line. And next comes the 3rd concept.
It’s most important feature is the rubber bands uses to counter act the bending moments
of the seats. When consider about 3rd concept , It’s main importance is using elastic
material to make the it tends to make force on the arms rest and that causes arm rest to
have unnecessary forces which might not apply even in 24 hours using business
company.
Due to all those results we concluded, design solid model carried out for the
concept 1.

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3.5 3D MODEL DESIGN

Figure 4 test machine preview 1

Figure 5 test machine preview 2

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Figure 6side view of the machine

Figure 7 test machine front view

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 Figure 9 test machine rear view

Figure 8 seat lower part holding mechanism

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 Figure 10 seat back rest pressing mechanism

Figure 11 ratchet belt to chassis holding mechanism 1

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 Figure 12 ratchet use as belt tensioner

Figure 13 lower seat holder tension using ratchet belt

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 Figure 14 ratchets attach to pneumatic cylinders

Figure 15 pneumatic cylinder to holding mounts attachments

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Figure 16 pneumatic holding mounts to chassis attachment

Figure 17 chassis end holders

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Figure 18 HFS standard type industrial aluminum extrusion profile with rubber beading

Figure 19 rear roller holding mechanism of ratchet belt

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Commonly available industrial components used while designing above mechanism
and refer several documents before finalizing components in order to make the product
more industrially suitable. Other than ratchet, belt, standard extruded aluminum column
and pneumatic cylinders rest of the parts design to fit this especial mechanism. Below
illustrate all the parts used while designing the mechanism.

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part name Quantity
pan cross head M5 6
hexagonal flange nut M8 8
seat holder 4
seat presser holding bars 2
seat presser belt attachment bars 2
dee shackle 2
pad eye 6
ratchet belts 2
floor 1
clamp 14
bush 3
bush holders 12 mm diameter shaft 3
heavy hex flange screw M6 42
vertical seat presser 1
horizontal seat presser 1
ratchet 2
pneumatic to belt attaches 2
pneumatic actuator holders 4
pneumatic structure pillars 4
hexagonal nut M20 8
pneumatic cylinders 2
pneumatic cylinder to structure attachment 4
heavy hex flange nut M6 42
crossbar upper 1
crossbar middle 1
crossbar lower 1
structure vertical pillars 2
end connectors 10
rubber beading 4
lower bush clamp to structure mount 1
middle bush clamp to structure mount 1
Allan bolt M10 80
hex lock nut M10 80
Table 2: part List

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3.6 2D DRAWINGS

Figure 20end connector

Figure 21 structure vertical pillar

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Figure 22 rubber beading

Figure 23 roller holder new

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 Figure 24 pad eye

Figure 25actuator holder

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 Figure 26roller upper

Figure 27 pneumatic to belt attacher

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 Figure 28 seat back pad

Figure 29 seat vertical presser

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 3.7 FEA ANALYSIS

Other industrially available components strength considered while selecting them.so all we
need to do is consider strength of the structure in order to analyze the failure method and
to select suitable material.
Mesh generated in order to find the stresses in the structure.

Figure 30mesh 1

Figure 31mesh 2

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Below figure illustrate the total deformation of the structure

Figure 32total deformation

Below figure illustrate the von misses stress analysis of the structure and it’s very close to
zero and far away from the yield stress value.so no failure will be occur.

Figure 33 von misses stress

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Below figure illustrate how safety factor varies within the structure.

Figure 34 safety factor variation

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 3.8 MATERIAL SELECTION

When analyzing materials use for commercial products, mainly two types of
materials start to play a major role due to its low cost and other important mechanical
properties it has. One of those material is aluminum and the other one is structural steel.
Below figures illustrate the mechanical properties of the materials we choose.

Figure 35 aluminum properties

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 Figure 36structural steel properties

When compare with the stress analysis results and the cost of the materials in the
market place for our structure, aluminum was selected due to perfect surface finish with
the mechanical properties it has such as medium strength and excellent anodizing
properties.as can be seen in the figure above normally 6060, 6063 and 6082 aluminum
available with tensile strengths in the range 190 to 310 MPa and also 2014A, 7020 and
7075 aluminum materials available with high tensile strengths ranging from 470 to 570
MPa.
Aluminum 7075 considered as aircraft grade materials and cost is so higher. But
for our application 6063 mechanical properties sufficient.
For mounting brackets mild steel 1020 was selected and the shaft of the roller also
design by using mild steel 1020.floor design using structural steel in order to withstand
falling of different objects when user operate the machine.

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 3.9 BILL OF MATERIAL

Bom part unit of

level number part name quantity measure procurement description
300-000-
1 001 test machine 1 each assembly
300-100-XXX
part numbers
300-100- pneumatic belong to this
2 001 cylinder holders 2 each subassembly subassembly
cutting and
straight turning
300-100- pneumatic will be done in
3 002 structure pillar 2 each manufacture lathe
300-100- hexagonal nut
3 003 M20 4 each purchase
300-100- pneumatic
3 004 cylinders 1 each purchase
milling and
cutting
300-100- pneumatic operations will
3 005 actuator holder 2 each manufacturer be used
pneumatic
cylinder
300-100- structure
3 006 attachment 4 each manufacturer cnc milling
300-100- heavy hexagonal
3 007 nut M6 10 each purchase
300-100-
3 008 clamps 4 each purchase
300-200-XXX
part numbers
300-200- belong to this
2 001 ratchet assembly 2 each subassembly subassembly
300-200-
3 002 ratchet belts 1 each purchase
300-200- pneumatic to
3 003 belt attacher 1 each manufacture cnc milling
300-200-
3 004 ratchet 1 each purchase
300-200-
3 005 deshakle 1 each purchase
300-300-XXX
300-300- part numbers
2 001 roller assembly 3 each subassembly belong to this
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 subassembly
bush
300-300- holder10mm
3 002 diameter shaft 1 each purchase
300-300-
3 003 bush 1 each purchase
300-300-
3 004 clamps 2 each purchase
300-300- heavy hexagonal
3 005 nut M6 6 each purchase
300-400-XXX
part numbers
300-400- belong to this
2 001 roller holder 1 each subassembly subassembly
low bush to
300-400- clamp to
3 002 structure mount 1 each manufacture cnc milling
middle bush to
300-400- clamp to
3 003 structure mount 1 each manufacture cnc milling
300-500-XXX
part numbers
300-500- belong to this
2 001 structure 1 each subassembly subassembly
depending on
the dimensions
300-500- structure vertical length will be
3 002 pillar 2 each purchase selected
300-400-
3 003 crossbar lower 1 each purchase
300-500-
3 003 crossbar upper 1 each purchase
300-500-
3 004 crossbar middle 1 each purchase
300-400-
3 004 end connectors 10 each purchase
300-500-
3 005 Allan boltM10 80 each purchase
300-500- hex lock nut
3 006 M10 50 each purchase
300-600-
2 001 floor 1 each subassembly manufacture
300-700-XXX
part numbers
300-700- horizontal belong to this
2 001 pressure applier 2 each subassembly subassembly
300-700- pan cross head
3 002 M5 3 each purchase
3 300-700- hexagonal 4 each purchase

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 003 flange nut M8
external
300-700- grooving and
3 004 seat holder pillar 2 each manufacturer cutting
300-700-
3 005 pad eye 3 each purchase
300-700- seat dummy
3 006 holding box bar 1 each manufacture
300-700- seat belt attach
3 007 box bar 1 each manufacture
300-800- seat vertical
3 001 presser 1 each manufacture
300-700- seat horizontal
3 009 presser 1 each manufacture
Table 3:Bill of Materials

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 4 CONTROL SYSTEM DESIGN

4.1 ACTUATOR SELECTION

System parameters would limit the selection of the actuator. Force of the
application is a major factor in terms of actuator selection. The force should be applied
in a certain direction with the suitable force variation and therefore the controllability of
the actuation process is vital.
Pneumatic actuators would be selected by the available products in the market and
since the force required for the backrest is 267N and the holding force is 10 3 the
actuators should be selected accordingly. According to the available products most of
the pneumatic actuators which can apply the required force range works in a pressure
range from 0.1Pa to 5Pa. By assuming that the maximum working pressure is 5bar and
the minimum working pressure is 0.1bar the following calculations will determine the
bore diameter of the suitable pneumatic cylinder.
Calculate bore diameter for maximum pressure;

Calculate bore diameter for minimum working pressure;

26 mm to 184 mm is the acceptable range for the bore diameter of the pneumatic
actuator.

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Figure 4. 1 : Pneumatic Control Circuit

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 4.2 CONTROL CIRCUIT DESIGN

System is expected to be controlled according to the following sequence of control

options.
1. Start the machine
2. Insert number of cycles to apply the force to the backrest
3. Complete the number of cycles
4. Check whether the number of cycles is finished or not
5. If the number of cycles performed is less than the predetermined number of
cycles failure has occurred
6. Use the sensor feedback to identify failure and output the number of cycles
taken for failure

4.3 HARDWARE PART SELECTION

The following hardware parts are used to develop the above shown pneumatic
system.
 Air Compressor
 Pressure Control Valve with manometer
 Two 3/2-way valve, electrically Operated
 One 4/2-way valves, electrically operated
 One double acting cylinder
 One single acting cylinder

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 5 CONCLUSION
Report discussed about designing a mechanism that can cause the repeated
displacement of the backrest of a chair so as to simulate a person sitting on the chair.
Studying all the existing mechanisms and choosing most appropriate 3 concepts which
include modifications to existing mechanisms discussed in the report.
Analytical calculation was used to justify most suitable concept among those 3.
Solid works model was generated to implement the concept and ansys simulation was
carried out to test stress analysis of the test rig for different materials. Cost
consideration and the results from ansys simulation helped to finalize the appropriate
material for the test rig.
Bill of material was generated for developed 3d model and pneumatic actuation
related calculations completed with the logic included.
Task of designing fatigue test machine to check the fatigue failure of back rest was
achieved.

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6 REFERENCES LIST

1. Elementcom. 2019. Element. [Online]. [28 February 2019]. Available from:

https://www.element.com/nucleus/2016/12/14/13/37/fatigue-testing-in-the-
automotive-industry
2. Elementcom. 2019. Element. [Online]. [28 February 2019]. Available from:
https://www.element.com/nucleus/2016/12/14/13/37/fatigue-testing-in-the-
automotive-industry
3. Elementcom. 2019. Element. [Online]. [28 February 2019]. Available from:
https://www.element.com/nucleus/2016/12/14/13/37/fatigue-testing-in-the-
automotive-industry
4. Elementcom. 2019. Element. [Online]. [28 February 2019]. Available from:
https://www.element.com/nucleus/2016/12/14/13/37/fatigue-testing-in-the-
automotive-industry

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