Group 92 Project Report

Savitribai Phule Pune University, Pune 2015 Course
A Project Report on
DESIGN AND
MANUFACTURING OF
PNEUMATIC BUMPER FOR
SUDDEN IMPACT
REDUCTION IN FOUR-
WHEELER
By
MR. NISHANT SANJAY DESHPANDE. B150360876
MR. VAIBHAV SANJAY GAIKWAD. B150360903
MR. NIKHIL PANDIT GAVANDE. B150360909
MR. ATHARVA YOUVARAJ PATIL. B150361061
Guide
Prof. G. C. Pude
Department of Mechanical Engineering

Sinhgad Technical Education Society’s
Smt. Kashibai Navale College of
Engineering [2021-22]
Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)
1
Sinhgad Technical Education Society’s

Smt. Kashibai Navale College of Engineering
CERTIFICATE
This is to certify that,
MR. NISHANT SANJAY DESHPANDE. B150360876
MR. VAIBHAV SANJAY GAIKWAD. B150360903
MR. NIKHIL PANDIT GAVANDE. B150360909
MR. ATHARVA YOUVARAJ PATIL. B150361061

have successfully completed the Project Stage – I entitled “Design and
Manufacturing of Pneumatic Bumper for sudden impact reduction in four-
wheeler” under my supervision, in the partial fulfilment of Bachelor of
Engineering-Mechanical Engineering of Savitribai Phule Pune University.
Date: -
Place: - Pune Seal
Prof. G. C. Pude Prof. ……………….

Guide External Examiner
Prof. T. S. Sargar Dr. A.V. Deshpande

Head of Department Principal
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ACKNOWLEDGEMENT
I take this opportunity to thank all those who have contributed in successful completion
of this Project work. I would like to express my sincere thanks to my guide Prof. G. C.
Pude who have encouraged me to work on this topic and provided valuable
guidance wherever required. I also extend my gratitude to Prof. T. S. Sargar (H.O.D
Mechanical Department) who has provided facilities to explore the subject with more
enthusiasm.
I express my immense pleasure and thankfulness to all the teachers and staff of the
Department of Mechanical Engineering of Smt. Kashibai Navale College of
Engineering for their co-operation and support.
Mr. NISHANT SANJAY DESHPANDE Sign.……………….

Mr. VAIBHAV SANJAY GAIKWAD Sign.……………….
Mr. NIKHIL PANDIT GAVANDE. Sign.……………….
Mr. ATHARVA YOUVARAJ PATIL Sign.……………….
3
Contents
Topic No. Name of Topic Page No.

1 Introduction 11
1.1 Motive 13
1.2 Problem Statement 13
1.3 Objective 14
1.4 Scope 14
1.5 Methodology 15
2 Literature Review 16
2.1 Review of Papers 17
2.2 Observation from literature review 22
3 Design of Proposed work 23
3.1 Catia Software 23
3.2 Catia Design 26
3.2.1 Modelling 26
3.2.2 Drafting 27
3.2.3 3D Parts of the model 27
4 Construction and working 30
4.1 Frame 30
4.2 Single Acting Cylinder 30
4

4.3 Pneumatic Pipe Fittings 31
3/2 Solenoid Valve 31
4.4 Pneumatic Connectors 32
4.6 Ultrasonic Sensor 32
4.7 Pedstal Bearing 33
4.8 Shaft 33
4.9 12 Volt Battery 34
4.10 Wiper Motor 35
5 Design 37
5.1Design Calculation 37
5.2 System Design 37
5.3 Mechanical Design 37
5.4 Design Parts 37
5.4.1 Motor Selection 38
5.4.2 Design of belt drive 39
5.4.3 Shaft Design 41
5.4.4 Bearing Selection 42
5.4.5 Design Pneumatic Cylinder 43
6 Finite Element Analysis 46
6.2 Geometry 49
6.3 Material Properties 49
5
6.4 Meshing 49
6.5 Static Structural Analyse 50
6.5.1 Boundary Condition 50
6.6 Results and Plots 51
7 Fabrication 53
7.2 Frame 53
7.3 Arduino Circuit Board 53
7.4 Process Sheet 54
7.4.1 Cutting 54
7.4.2 Welding 54
7.4.3 Drilling 55
Outcomes and Cost Estimation 56
8 Advantages and Application 59
Conclusion 60
Monthly Activity Sheet 61
Reference 62
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LIST OF FIGURES: -
Sr No. List of Figures Page No.

1.1 Methodology 15
3.1 Cad Model 25
3.2 Frame 27
3.3 Solenoid DC Valve 27
3.4 Pneumatic Cylinder 28
3.5 Bumper 29
4.1 Single Acting Cylinder 30
4.2 Pneumatic Hoses & fitting 31
4.3 3/2 Direction Control Valve 31
4.4 Hose Collector 32
4.5 Ultrasonic Sensor 32
4.6 Pedstal Bearing 33
4.7 12 Volt Battery 34
4.8 Wiper Motor 35
4.1 Concept of automobile bumper 36
5.1 Analysis System 47
5.2 Results and Plots 51
6.1 Frame 53
6.2 Arduino Circuit 53
6.3 Cutting 54
6.4 Welding 54
6.5 Drilling 55
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LIST OF TABLES AND GRAPHS: -

Table No 7.1 Cost Estimation Page No. - 35
Table No 8.1 Monthly Activity Sheet Page No. - 61
8
NOMENCLATURE
Sr.
Symbol Nomenclature Page no.
No.
1 m Total Mass 25
2 FS Factor of Safety 25
3 E Young’s Modulus 25
4 S_yt Yield Strength 25
5 W Total Load 25
6 σ_c Compressive Stress 25
7 α Helix Angle 26
8 Ø Friction Angle 26
9 µ Coefficient of Friction 27
10 K Radios of Gyration 27
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ABSTRACT
This project is related with the use of pneumatic system installed on the bumper
of car to reduce the impact during the time of collision India has the large
number of vehicles running on roads. Every day 405 deaths and 1290 injuries
from 1274 accidents are reported in India. Though there are different causes for
these accidents but proper technology to reduce the damage during accident are
currently not in use. We are introducing our project “automatic Pneumatic
bumper”, which is fully equipped by IR sensors circuit and Pneumatic bumper
activation circuit. With use of these components a bumper with ability to stand
the impact up to a certain limit is developed and which results in increase of the
safety of passengers seating inside the vehicle equipped with this technology.
To achieve this system, modify- cation goal, design of “Automatic Pneumatic
Bumper system” is a good solution to bridge the gates between institution and
industries and able to understand the difficulties in maintaining the tolerances
and also quality. Keywords: Automatic, Bumper system, Electro-pneumatic
system.
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CHAPTER 1
1. INTRODUCTION
The Car accidents are happening every day. Most drivers are convinced that
they can avoid such troublesome situations. However, the statistics shows that
ten thousand dead and hundreds of thousands of million wounded each year.
Hence, improvement in the safety of automobiles is prerequisite to decrease the
numbers of accidents. Automobile bumper is a structural component of an
automobile vehicle which contributes to vehicle crash worthiness or occupant
protection during front or rear collisions. The bumper system also protects the
hood, trunk, fuel, exhaust and cooling system as well as safety related
equipment. Bumper beams are usually made of steel, aluminium, plastic, or
composite material. Bumper beams are also the backbone of the energy
absorbing systems located at both front and rear on automobiles. This energy
absorbs er which looks like shock absorber, functions as a connecting member
between a bumper and front cross member for the purpose of damping load and
the shock load during a low-speed collision between the motor vehicle and an
obstacle. Under the bumper impact situation these energy absorbers are loaded
in compression or tension as well as the bumper moves from a designed outer
position toward the vehicle body and are operative to absorb the energy of the
impact. After impact, these energy absorbers recover at various rates to return
associated with bumper assembly toward its original pre-impact position.
In case of accident occurs, there is no any provision to minimize the damages

of vehicles. In currently used vehicles generally bumpers used are of rigid
types. These bumpers have specific capacity and when the range of the
accidental force is very high then the bumpers are fails and these forces
transferred towards the passengers. So, this system never reduces the damage of
both vehicle and passed- Gers that much amount. We have introduced our
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project “Automatic Pneumatic bumper for four-wheeler”, which is fully

equipped by IR sensors circuit and Pneu- matic bumper activation circuit. it is a
genuine project which is fully equipped and designed for automobile vehicles.
this forms an integral part of best quality safety. Pneumatics form an attractive
medium for low-cost automobile automation. The main advantages of all
pneumatic systems are economy and simplicity.
We have introduced our project “automatic Pneumatic bumper”, which is fully

equipped by IR sensors circuit and Pneumatic bumper activation circuit. it is a
genuine project which is fully equipped and designed for automobile vehicles.
this forms an integral part of best quality. This product underwent strenuous
test in our automobile vehicles and it is good. Need for automation: automation
can be achieved through computers, hydraulics, Pneumatic, robotics, etc., of
these sources, Pneumatic form an attractive medium for low-cost automation.
the main advantages of all Pneumatic systems are economy and simplicity.
Automation plays an important role in mass production of the product; the
machining operations decide the sequence of machining. The machines
designed for producing a particular product are called transfer machines. The
components must be moved automatically from the bins to various machines
sequentially and the final component can be placed separately for packaging.
materials can also be repeatedly transferred from the moving conveyors to the
work place and vice versa. Nowadays almost all the manufacturing process is
being atomized in order to deliver the products at a faster rate. the
manufacturing operation is being automatized for the following reasons.
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1.1 MOTIVE:
India has the large number of vehicles running on roads. Every day 405
deaths and 1290 injuries from 1274 accidents are reported in India. Many of us
though small, has experienced road accident in our life. One of these
experiences got us thinking that there are no provisions to minimize the damage
of vehicles and passenger. Though there are different causes for these accidents
but there are no proper technology to reduce the impact during accident. So
today implementation of proper pneumatic bumper system to reduce the damage is
must for every vehicle. To achieve this system modification goal, design and
implementation of “Automatic Pneumatic Bumper system” is necessary. This
work is a good solution to bridge the gates between institution and industries and
be able to understand the difficulties in maintaining the tolerances and also
quality.
1.2 PROBLEM STATEMENT:

In currently used vehicles, bumpers used are of rigid types. These bumpers
have specific capacity and when the range of the accidental force increases then
these bumpers are of no help and so these forces are transferred towards the
passengers causing them severe injuries. Currently used bumpers can’t reduce
the damage of both vehicles and passengers. So, to reduce the damage to car and
increase passenger safety design of Automatic Pneumatic Bumpers is necessary.
The statement of project is “design and fabrication of automatic pneumatic
bumper system for four- wheeler.” for the safety application in automobile as
per requirements for vehicle performance.
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1.3 OBJECTIVES:
To overcome these unwanted accidental effects during automobile crash, we
have to design the Automatic Pneumatic Bumpers system which have
following objectives,
• 1) To improve the pre-crash safety.
• 2) To avoid the percentage of passenger injury by using external vehicle

safety.
• 3) To reduce the requirement of internal safety devices like air bags.
• 4) To increase the sureness of impact absorption application while

vehicle accident.
• 5) To reduce the response time of safety with bumper system.
1.4 SCOPE:
There is lot of scope for future development in vehicle. The technology of
pneumatics has gained tremendous importance in the field of workplace
rationalization and automation. vehicle producers are moving towards
increasing safety because customers are demanding for the same. Our project
will help in providing safety in case if accident happens which will help them
increase their sales. As there is large amount of development still to happen in the
field of safety, our project can contribute in small amount in this development and
help vehicles to be safer for consumers. After studying all the parameter and
considering the application and requirements of system project scope is to make
a system pre-crash safety passenger injury in automobile.
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1.4 METHODOLOGY
Study of topic with various Research Papers
3D Model and drafting with the help of CATIA software
Theoretical Design and Calculations
Material Selection with desired parameters
Analysis of the model with the ANSYS software
Fabrication of Two Wheel Fork Lift Drive
Practically Running and Testing
Inspect Errors and Rework
Finalized
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CHAPTER 2
2. LITERATURE SURVEY
2.1 Review of Papers

[1] Ahmad Syuhri, done the work on, Design and Modeling of Hydraulic
Crash Damper in a Racing Electric Vehicle, according to his work, racing vehicle
has greater risk of injury and vehicle damage than any others urban vehicle, this
paper presents the design, modeling and performance study of crash damper in
a racing electric vehicle. Using lumped parameter model (LPM) as analytical
approach, the de- elopement model of hydraulic crash damper is used to absorb
or to dissipate the kinetic energy on frontal crash. The mathematical model
between initial model and development model is derived to obtain responses of
both vehicle and occupant. Plot 3D surface from numerical simulation is used
to obtain optimum value of development model., occupant deceleration and
vehicle deformation in the range of 25% to 28.1% than initial model.
Considering the minimum deceleration of vehicle-occupant and deformation of
vehicle, the minimum slope or optimum value of damper valve diameter is
obtained at 3.5x10-3 m. The percentage energy absorbed in that diameter is in
the range of 88.03% to 64.7% parallel with increasing of velocity from 20 km/h
to 100 km/h. The time response of vehicle-occupant deceleration and
deformation vehicle also compared between IM and DM. The results are shown
that DM has better response and has ability to dissipate 72.9% crash energy than
IM in impact velocity of 65 km/h. The declining effect in the percentage of
energy absorbed as increasing impact velocity can be a further study since there
is lack of energy absorbed in a high range velocity.
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[2]. Balamurugan & Dr. M. Sekar, done the work on, Design of Shock Absorber for
Car Front Bumper, according to his work, Automotive designs with economy, safety
and aesthetics have been a great challenge to design engineers. Automobile bumper
subsystem is the front and rear structure of the vehicle that has the purpose of energy
absorption during low velocity impact. Bumpers are structural components installed to
reduce physical damage to the front and rear ends of a light/ heavy motor vehicle from
low-speed collisions. The bumper should support the mechanical components and the
body. It must also withstand dynamic loads without undue deflection. This Project
deals with the idea of Hydraulic shock absorber using bumper in the front overhang of
the four-wheeler, which reduces the loss and deformation of the vehicle during the
accident. It includes Hydraulic fluids and shock absorber spring as an active
component in the Impact reducing system. This Project model built using the CATIA
V5 R20Software
Vehicle collisions are occurred in different possible modes. It may be head on

collision, rear end collision, and side collision and roll overs. Of these modes, head-on
collision is mostly occurred one and causes severe damage to both vehicle and
passengers. We cannot totally avoid these types of vehicle collisions. Instead of
preventing these accidents which is not possible, collision effects can be reduced by
providing Bumpers in the front side of vehicles. Thus, in this project, effects of
collision are much reduced by implementing the several units of Hydraulic Shock
Absorber with spring in bumper of vehicles. The spring due to designed with stand 5
km/hr. and remaining fluid action. Thus, the development of smart materials will be an
essential task in many fields such as energy, transportation, safety engineering and
military technologies.
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[3] Prof. M. B. Bankar, Prof. S. K. Pawar, Prof. R. V. Lalge, done the work on,
Design and Development of Automatic Pneumatic Bumper System, according to his
work, India is the largest country in the use of various types of vehicles. As the
available resources to run these vehicles like quality of roads, and unavailability of new
technologies in vehicles are causes for accidents. Though there are different causes for
these accidents but proper technology of braking system and technology to reduce the
damage during accident are mainly effects on the accident rates. So today
implementation of proper braking system to prevent the accidents and pneumatic
bumper system to reduce the damage is must for vehicles. To achieve this system
modification goal, design this “Automatic Pneumatic Bumper system”. the work is a
good solution to bridge the gates between institution and industries and able to
understand the difficulties in maintaining the tolerances and also quality.
This project work has provided us an excellent opportunity and experience, to use our
limited knowledge. They gained a lot of practical knowledge regarding, planning,
purchasing, assembling and machining while doing this project work. They feel that
the project work is a good solution to bridge the gates between institution and
industries. They are able to understand the difficulties in maintaining the tolerances
and also quality. They have done to our ability and skill making maximum use of
available facilities. There is lot of scope for future development in vehicle. The
technology of pneumatics has gained tremendous importance in the field of workplace
rationalization and automation from old-fashioned timber works and coal mines to
modern machine shops and space robots. It is therefore important that- technicians and
engineers should have a good knowledge of pneumatic system, air operated valves and
accessories. The aim is to design and develop a control system- based an intelligent
electronically controlled automotive bumper activation system is called “Automatic
Bumper System for Four Wheelers”. This system is consisting of IR transmitter and
Receiver circuit, Control Unit, Pneumatic bumper system. Their sensor is used to
detect the obstacle. There is any obstacle closer to the vehicle (within 4 feet) the
control signal is given to the bumper activation system.
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[4] G.V.R. Seshagiri Rao, Vadnala Priyanka, V V S H Prasad, done the work on,
Design and Analysis of Automobile Bumper, according to his work, an automobile’s
bumper is the front-most or rear-most part, ostensibly designed to allow the car to
sustain an impact without damage to the vehicle’s safety systems. They are not capable
of reducing injury to vehicle occupants in high-speed impacts, but are increasingly
being designed to mitigate injury to pedestrians struck by cars. The automobile bumper
weight is reduced by the utilization of composite and high- strength gilded sheet of a
skinny material. Once the motor vehicle is hit from the front or behind, the bumper
beam collapses. The impact force is transmitted to the left and right front frames on
the bumper beam and bumper stays. The impact energy created throughout the crash
is absorbed by plastic deformation on the bumper beam and bumper stays that square
measure the specified elements of bumper For characteristic the foremost effective
material, varied analysis like static analysis, impact or crash analysis, dynamic and
modal analysis area unit required the target of the work is to counsel the foremost
effective material for bumper that is ready to ensure rider safety, with high strength to
weight quantitative relation through the static and dynamic analysis.
Modeling of an automobile bumper is completed mistreatment 3D modeling software

system Catia. Impact analysis is completed on the automobile bumper for various
speeds. The analysis is additionally automobilities on the car bumper for various
materials plastic, Polyetherimide, S2 glass and fiber composites. Now a days the fabric
used for automobile bumper is steel. Steel is substitution with plastic, Polyetherimide,
S2 glass and fiber composite. The density of plastic, Polyetherimide- ide, S2 glass and
fiber composes is a smaller amount than that of steel. By observing the Impact Analysis
results like Stress, Displacement and strain values. By compar- ing original modal and
existing modal these results of ABS Plastic, Polyetherimide, S2 glass and glass fiber
composites, the stress values are less for S2glass than ABS Plastic, Polyetherimide and
Glass fiber composite. S2glass is better Material. Glass fiber Deformation less than
other materials.
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[5] Raj Kumar G, Balasubramaniyam S, Senthil Kumar M, Vijayanandh R, Raj

Kumar R, Varun S., done the work on, Crash Analysis on the Automotive Vehicle
Bumper, according to his work, in this article deals the crash investigation of Bumper
for different materials using ANSYS Workbench. Bumper is a vital parameter which is
used as safety protection for passengers from accidents by means of impact energy
absorption from collision environment. The ultimate focus of this work is material
optimization for Bumper by performing impact analysis with the help of ANSYS. The
entire analysis process comprises of two stages, which are conceptual design of
Bumper and preparation of Bumper for numerical analysis. The optimization of this
work is based on structural parametric results, in which total deformation, equivalent
stress induced are primarily involved. The reference component’s modeling process is
completed by means of CATIA, and then the impact analysis is carried by ANSYS
Workbench 16.2, in which the materials used for bumper are Steel and Glass fiber-
based composite with the constant boundary conditions [speed = 13.3 m sec-1].
Finally suitable material is finalized for car bumper.
The standard formulae are contributed towards the attainment of conceptual design of
bumper. Literature survey about bumpers have provided the details of mechanical
properties of short-listed materials and then details are supported for successful
completion of numerical simulation. From the previous works, it is understood that
composite bumper is 53.8% lesser than steel bumper with high load withstanding
capability and also in the cost perspective composite bumper is 80% less than steel
bumper. The conceptual design and numerical simulation of bumper have been
successfully completed with the help of CATIA and ANSYS Workbench respectively,
in which 64 % of factor of safety is increased in Glass fiber-based composite compared
with Steel. Finally, it is understood that, Glass fiber-based composite is more
comfortable for automotives bumper.
20
[6] A.T. Beyenea, E.G. Korichob, G. Belingardib, B. Martoranac, done the work
on, Design and manufacturing issues in the development of lightweight solution for a
vehicle frontal bumper, according to his work, Automobile bumper sub system is the
frontal and rear structure of the vehicle that has the purpose of energy absorption
during low velocity impact. The main component of this subsystem is the transverse
bumper beam, generally made by steel. Design of vehicle subsystem for lightweight
and for safety seems to lead the designer toward opposite directions. Quite interesting
solutions can be obtained with the use of composite materials. This paper is analyzing
some possible alternative solutions for the particular case of the front and rear bumper.
The design of the transverse beam of a front or rear vehicle bumper can be done using
composite materials instead of steel. This leads to an effective decrement of the vehicle
weight without affecting the structural safety performance.
The design of the composite solution needs a choice of material and production
technology, as these two aspects are deeply influencing each other. Two solutions that
are under development as part of a cooperative research between Polytechnic di Torino
and FIAT Research Centre have been presented and discussed. Advantages and
disadvantages of the pultrusion and die forming technologies have been discussed, as
they lead to completely different structural solutions. As composite materials have
completely different failure behavior than the conventional metallic materials, the
direct adoption of the traditional metallic energy absorbing geometry may lead to a
catastrophic failure and yield higher peak loads. To prevent such a catastrophic failure
for the case of pultrusion solution, since it is limited to a constant cross section, it is taken
advantage from the pseudo-ductile characteristics, that arise from material fragmentation
and large changes in the tubes cross-sectional geometry during deformation. Further
design optimization has been utilized for choosing the beam end profile and curvature.
For the case of die forming solution, besides assess- ing the advantage of beam- crash
box integration into one single part to prevent joining related problems, the possibility
of having variable section along the length of the structure is also utilized to integrate
structurally the two parts and to get progressive failure.
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2.2 OBSERVATIONS FROM LITERATURE REVIEW:
Design and Modeling of Hydraulic Crash Damper in a Racing Electric Vehicle.

According to his work, since racing vehicle has greater risk of injury and vehicle
damage than any others urban vehicle, this paper presents the design, modeling and
performance study of crash damper in a racing electric vehicle. Using lumped
parameter model (LPM) as analytical approach, the development model of hydraulic
crash damper is used to absorb or to dissipate the kinetic energy on frontal crash. [1]
Design of Shock Absorber for Car Front Bumper. This Project deals with the idea of
Hydraulic shock absorber using bumper in the front overhang of the four- wheeler,
which reduces the loss and deformation of the vehicle during the accident. It includes
Hydraulic fluids and shock absorber spring as an active component in the Impact
reducing system. [2] Design and Development of Automatic Pneumatic Bumper
System. This paper presents implementation of proper braking system to prevent the
accidents and pneumatic bumper system to reduce the damage is must for vehicles. To
achieve this system modification goal, design this “Automatic Pneumatic Bumper
system”.[3]
Design and Analysis of Automobile Bumper. According to his work, the auto-
mobile bumper weight is reduced by the utilization of composite and high- strength
gilded sheet of a skinny material. The material, varied analysis like static analysis,
impact or crash analysis, dynamic and modal analysis area unit required the target of
the work is to counsel the foremost effective material for bumper that is ready to
ensure rider safety, with high strength to weight quantitative relation through the static
and dynamic analysis. [4] Crash Analysis on the Automotive Vehicle Bumper. In this
article deals the crash investigation of Bumper for different materials using ANSYS
Workbench. Bumper is a vital parameter which is used as safety protection for
passengers from accidents by means of impact energy absorption from collision
environment. The ultimate focus of this work is material optimization for Bumper by
performing impact analysis with the help of ANSYS. [5]
22
CHAPTER 3
3. DESIGN OF PROPOSED WORK
3.1 CATIA SOFTWARE

Computer-aided design (CAD) is the use of computers to aid in the creation,
modification, analysis, or optimization of a design. CAD software is used to
increase the productivity of the designer, improve the quality of design, improve
communications through documentation, and to create a database for
manufacturing. CAD output is often in the form of electronic files for print,
machining, or other manufacturing operations.
CAD is mainly used for detailed engineering of 3D models or 2D drawings of
physical components, but it is also used throughout the engineering process from
conceptual design and layout of products, through strength and dynamic analysis of
assemblies to definition of manufacturing methods of components. It can also be
used to design objects such as jewelry, furniture, appliances, etc. Furthermore, many
CAD applications now offer advanced rendering and animation capabilities so
engineers can better visualize their product designs. It is a type of virtual
construction engineering simulation incorporating time or schedule related
information for project management. CAD is used as follows:
1) To produce detailed engineering designs through 3-D and 2-D

drawings of the physical components of manufactured products.
2) To create conceptual design, product layout, strength and dynamic
analysis of assembly and the manufacturing processes themselves.
3) To prepare environmental impact reports, in which computer-aided
designs are used in photographs to produce a rendering of the
appearance when the new structures are built.
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CAD systems exist today for all of the major computer platforms, including
Windows, Linux, Unix and Mac-os. View manipulation can be accomplished with a
space mouse (or space ball). Some systems allow stereoscopic glasses for viewing
3-D models. In our olden days, designers and draughts men were struggling to
produce and submit engineering drawings in their scheduled times. It was mainly
due to tremendous efforts they had taken to produce both new drawings and
edited/updated drawings. Every line, shapes, measurements, scaling of the drawings
- all made them headache to the design / drafting field. All these difficulties and
pressures over-ridden by Computer Aided Design Drafting CAD) technology.
A layout represents a drawing sheet. It typically contains a border, title
block, dimensions, general notes, and one or more views of the model displayed in
layout viewports. Layout viewports are areas, similar to picture frames or windows,
through which you can see your model. You scale the views in viewports by
zooming in or out. Manual drafting requires meticulous accuracy in drawing line-
types, line-weights, text, dimensions, and more. Standards must be established in
the beginning and applied consistently. With CAD, you can ensure conformity to
industry or company standards by creating styles that you can apply consistently.
You can create styles for text, dimensions, and line-types.
Fig. 3.1 shows the 3D model of the project, which helps in understanding the
concept, layout for designing and manufacturing. This 3D model is done on CATIA
software.
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Fig. 3.1 CAD 3D Model
3.2 CATIA DESIGN

3.2.1 MODELING
It’s an excellent tool for companies to come up with designs, do a comprehensive
analysis, and manufacture new products which can be helpful in product
development. This modelling software is most convenient for the designing the
project. Where we use various features of this software and form a model.
CATIA can be beneficial to OEMs and manufacturers from various industries since
they can utilize this tool in ensuring quicker analysis, design, and creation of new
products. The revolutionary software integrates different approaches in the design
and development of products, allowing for various disciplines to use their current
tools in different stages of product development, hence, making CATIA handy for
systems architects, engineers, and industrial designers. CATIA offers a productive
3D design environment that allows stakeholders and designers to work together on
product modelling and sharing their product designs. The latest version of the
platform provides a plethora of tools for analysis and design. It allows for the
simulation of objects using a 3D digital mock-up.
25
3.2.2 DRAFTING
This software contains advance features which helps in creating a model. CATIA
software also use for the drafting of 3D parts. In the 3D drafting we can create the
orthographic views of isometric view.
The 3D CAD system CATIA V5 was introduced in 1999 by Dassault Systems.
Replacing CATIA V4, it represented a completely new design tool showing
fundamental differences to its predecessor.
3.2.3 3D PARTS OF MODEL
Fig. 3.2 Frame
The above fig. 3.2 the frame is of MS material. The frame of our machine is basically
used to support the pneumatic components mounted on it. That is Piston cylinder,
d.c.v, flow control valve, switches are mounted on frame.
26
Fig. 3.3 Solenoid DC Valve
This pilot valve is a small direct operated 3/2-way valve. The pilot valve delivers
compressed air to a small air cylinder inside the valve. The compressed air in this
cylinder pushes against the piston and actuates the solenoid to switch the valve. This
way, a relatively small solenoid can be used to switch the valve.
27
Fig. 3.4 Pneumatic Cylinder
The above fig. 3.4 Pneumatic cylinders are used where large forces and precise
movement required. Cylinders are linear actuators which convert fluid power into
mechanical power. For this reason, they are constructed of strong materials such as
steel and designed to withstand large forces.
28
Fig. 3.5 Bumper

The Above fig. 3.5 shows the bumper. This prevents vehicle damage and ensures the
safety of the inmates. This system only actuated when the vehicle speed is above 30-
40 km/hr. This vehicle speed sensed by the ultrasonic sensor and monitored
continuously, this signal given to the control unit, and it actuates the pneumatic
bumper system accordingly
29
CHAPTER 4
4. CONSTRUCTION AND WORKING

It consists of mainly;
4.1 FRAME:
The frame is of MS material. The frame of our machine is basically used to

support the pneumatic components mounted on it. That is Piston cylinder, d.c.v,
flow control valve, switches are mounted on frame.
4.2 SINGLE ACTING CYLINDERS:
Pneumatic cylinders are used where large forces and precise movement re-
quired. Cylinders are linear actuators which convert fluid power into mechanical
power. For this reason, they are constructed of strong materials such as steel and
designed to withstand large forces.
Figure 4.1: Single acting cylinder
30
4.3 PNEUMATIC PIPE FITTINGS:
Pneumatic tubing is also available in a number of other materials both with and
without reinforcement for use in standard applications. SMC fittings incorporate a
positive tube seal while the fitting is under pressure which allows polyurethane tubing to
be used. This can be used for connection of pneumatic system with total drill assemble.
Figure 4.2: pneumatic hoses and fittings
4.4 3/2 SOLENOID VALVE:
This pilot valve is a small direct operated 3/2-way valve. The pilot valve delivers
compressed air to a small air cylinder inside the valve. The compressed air in this cylinder
pushes against the piston and actuates the solenoid to switch the valve. This way, a
relatively small solenoid can be used to switch the valve.
Figure 4.3 3/2 Solenoid Valve
31
4.5 PNEUMATIC CONNECTORS, REDUCER AND

HOSECOLLECTOR:
In our pneumatic system there are two types of connectors used; one is
the hose connector and the other is the reducer.
Figure 4.4: hose collector
4.6 ULTRASONIC SENSOR:

An ultrasonic sensor is an instrument that measures the distance to an object using
ultrasonic sound waves. An ultrasonic sensor uses a transducer to send and receive
ultrasonic pulses that relay back information about an object's proximity. Ultrasonic
sensors are used primarily as proximity sensors. They can be found in automobile
self-parking technology and anti-collision safety systems.
Figure No. 4.5 Ultrasonic Sensor
32
4.7 PEDESTAL BEARINGS:
This type of bearing consists of i) a cast iron pedestal, ii) gun metal, or
brass bush split into two halves called “brasses”, and iii) a cast iron cap and two
mild steel bolts. The detailed drawing of a pedestal bearing is shown in image
below. The rotation of the bush inside the bearing housing is arrested by a snug
at the bottom of the lower brass. The cap is tightened on the pedestal block by
means of bolts and nuts. The detailed part drawings of another Plummer block
with slightly different dimensions are also shown in image below.
Figure 4.6: pedestal bearing
4.8 SHAFT:
Shaft is a common and important machine element. It is a rotating member,

in general, has a circular cross-section and is used to transmit power. The shaft
may be hollow or solid. The shaft is supported on bearings and it rotates a set of
gears or pulleys for the purpose of power transmission.
33
4.9 12 VOLT BATTERY:

An electric battery is a device consisting of one or more electrochemical
cells that convert stored chemical energy into electrical energy. Each cell
contains a positive terminal, or cathode, and a negative terminal, or anode.
Electrolytes allow ions to move between the electrodes and terminals, which
allows current to flow out of the battery to perform work.
Figure 4.7: 12 Volt Battery
34
4.10 WIPER MOTOR:

Windshield wipers are powered by a small electric motor, usually mounted on
the firewall or under the cowl (the area under the windshield’s base). The motor
activates linkage that moves the wiper arms back and forth. On vehicles with a
rear window wiper, a separate motor powers the one in the rear. Signs that a wiper
motor is about to fail include slow or intermittent operation, wipers that will
operate at only one speed, or arms that stop in the middle of the windshield when
turned off. If your wipers don’t work, the fault could also lie with other parts of
the wiper system. In the winter, for example, trying to use the wipers when the
blades are stuck to the windshield because of ice or snow can blow the fuse for the
motor or trip a circuit breaker. Other possible causes are the interior switch that
controls the wipers failing, wires in the system being damaged, or the linkage that
pushes and pulls the wiper arms breaking. Moving parts in the linkage may also be
stuck from corrosion and/or gunk and need lubrication.
Figure 4.8: Wiper Motor
35
WORKING
As this system is used at the time of emergency during work. In normal
travelling of vehicle this system is off and it never impact on the normal
working. When any obstacle, humans, animals or vehicle is coming in front of the
vehicle then the installed infrared sensor senses that obstacle. The range of
distance between the vehicle and obstacle is variable. This range is varied
according to the density of vehicles or humans on road. The received signal by
IR sensor is provided to the control unit. This control unit operates the relay
according to the input signal. The relay operated by solenoid valve control unit
the pneumatic power supply given to the cylinder so the working of bumper is
protecting the vehicle from impact. During impact IR Sensor on the Solenoid
control valve opens port going towards the bumper system. This pneumatic force
used to forward motion of the bumper. By receiving the impact of accidental
force bumper try to deflects. The flexible nature of the bumper able to sustain
the force and so the impact of this force on vehicle is reduces.
Figure 4.1: Concept of Automatic Bumper.
36
CHAPTER 5
5.0 DESIGN AND FINITE ELEMENT ANALYSIS
5.1 DESIGN CALCULATION
Design consists of application of scientific principles, technical

information and imagination for development of new or improvised machine or
mechanism to perform a specific function with maximum economy and
efficiency. Hence a careful design approach has to be adopted. The total design
work has been split up into two parts;
5.2 SYSTEM DESIGN
System design mainly concerns with various physical constrains, deciding

basic working principle, space requirements, arrangements of various
components etc. Following parameters are looked upon in system design.
Selection of system based on physical constraints. The mechanical design has
direct norms with the system design hence system is designed such that
distinctions and dimensions thus obtained in mechanical design can be well
fitted in to it. Arrangement of various components made simple to utilize every
possible space. Ease of maintenance and servicing achieved by means of
simplified layout that enables quick decision assembly of components Scope of
future improvement.
5.3 MECHANICAL DESIGN
In mechanical design the components are listed down and stored on the
basis of their procurement in two categories,
37
5.4 DESIGN PARTS & PARTS TO BE PURCHASED.
For designed parts detailed design is done and dimensions

there obtained are compared to next dimensions which are already available in
market. This simplifies the assembly as well as the post production and
maintenance work. The various tolerances on work are specified.
The process charts are prepared and passed to manufacturing
stage. The parts to be purchased directly are selected from various catalogues
and are specified so as to have case of procurement in mechanical designed at
the first stage selection of appropriate material for the part to be designed for
specific application is done. This selection is based on standard catalogues or
data books;
E.g.: - (PSG DESIGN DATA
BOOKS) (SKF BEARING
CATALOGUE) etc.
5.4.1 MOTOR SELECTION:
Thus, selecting a motor of the following specifications
• Single phase AC motor
• Power = 1/15hp=50 watt
• Speed= 60 rpm
38
MOTOR TORQUE
Power is transmitted from the motor shaft to the input shaft by means of an open
belt drive,
Motor pulley diameter = 20 mm
IP shaft pulley diameter = 60
mm Reduction ratio = 3
IP shaft speed = 60/3 = 20 rpm
Torque at IP rear shaft = 3 x 7.96= 23.88 Nm
5.4.2 DESIGN OF BELT DRIVE:

Motor pulley diameter d =
20 mm IP shaft pulley diameter
D = 60 mm Coefficient of
friction = 0.23
Let,
d= diameter of rope = 5 mm
Mass of belt per unit length is
given by; ρ = density of belt
material = 950kg/m3 m= 0.0285
kg/m
Velocity of rope is given by;

V=dn/ (60 X 1000)
V= (x 5 x 60)/ (60 X 1000)
V=0.078 m/s Linear velocity to find out tension in the belt
is; P= (F1-F2) V/ (1000)
50 X 10-3 = ((F1-F2) X 0.078)/ (1000)
F1-F2 = 636.619 N ————- (1)
39
Center distance between two pullies of motor pullies output

C=200mm
α = sin − 1(D − d)/(2C)
α = sin − 1((60 − 20))/(2X200)
α = 5.7390(InDegrees)
α = 5.739X(/180)
α =
0.10c(InRadia
ns)
θ =
Angleoflapofbe
lt.
θ = –2
θ= – [2 X 0.10]
θ = 2.94c(In Radians)
θ = 168.54O(In Degrees)
Now (F1)/(F2) = e ()/sin
(F1)/(F2) = e
(
(0.23x2.94))/sin19
(F1)/(F2) = 7.97
F1= 7.97 F2 ————————————————-(2)
Put Eq. (2) in Eq.
(1) F1- F2 =
636.619
7.97 F2 - F2 = 636.619
6.972
F2 = 636.619
F2 = 91.3 N
40
Put in Eq.
(3)
F1 =
727.69 N
Centrifugal force in belt is given
by,
Fc = mV2
=0.0285 X
(0.078)2
Fc = 1.73 N
5.4.3. SHAFT DESIGN:

To find diameter of shaft by ASME code
For commercial steel shaft, Actual shear stressτact = 55N/mm2
T = P/16 x τact xd3
𝟏𝟔𝐱𝐓
Þτact=
P𝐱𝐝𝟑
16 x 55
7.763 =
P x d3
d3=737.089
d=9.033mm
select d=20mm
5.4.4 BEARING SELECTION:
41
As shaft dia. – is 20mm so we have selection a pedestal bearing having shaft

outer dia. – 20mm.
5.4.5 DESIGN OF PNEUMATIC CYLINDER:
NOTE: if we increase the pressure of air as per formula

pressure is directly proportional to the force.
If , P F
Clavarino’s equation for closed end cylinder at both ends. For ductile
material use to determine the thickness of cylinder.
Let,
Material of the cylinder is Aluminium.
σt + ( 1 - 2µ ) P
t 1
σt – ( 1 + µ) P
Sut =Ultimate tensile strength = 200N/mm2
µ = Poisson’s Ratio for the cylinder material

=0.29 (std-) di = Inner diameter of cylinder
=25mm
Consider,
Double acting cylinder Ø25X 50 (Diameter

X Stroke) ri =12.5mm
By assuming pressure in working cylinder is, P = 3 bar =0.3
N/mm2 So according to Clavarino’s equation,
42
For closed end cylinder at both ends to determine the thickness of cylinder.
Assume,
p = 3 bar = 0.3
N/mm2 µ = 0.29
ri = 12.5mm.
σt + ( 1 - 2µ ) P
t= ri 1
σt – ( 1 + µ) P
200 + 0.3 [1 – (2 x 0.29)]

t = 12.5 x 1
200 – 0.3 (1 + 0.29)
200.784
t = 12.5 x 1
199.808
t = 0.03049 mm.
43
By considering Factor of safety
FOS =1.5 t=1.5 x0.03049 mm.
=0.0457mm.
Available thickness, t = 0.25mm
Piston dia- = 25mm
Stroke dia- = 50mm
Piston rod dia- =
10mm. Let,
A= Force area of cross-section of piston.

𝝅
A= (D2) mm2
𝟒
𝝅
A= (252) mm2
𝟒
A= 490.87 mm2
APR = Force area of cross-section of piston on road side

𝝅
APR= (D2 – d2) mm2
𝟒
𝝅
APR= (252 – 102) mm2
𝟒
required to complete stroke is 2 second.
𝑳
Linear velocity of piston V=
𝒕
50
=
2
= 25 mm/se
44
Piston force acting during forward stroke.
Fa= P X
𝝅
(D2)
𝟒
= 0.1 X 490.87
Fa = 49.087 N.
Piston force acting during return stroke.
FR= P X
𝝅
(D2 – d2)
𝟒
= 0.1 X 412.33
FR = 41.233 N.
45
5.5 FINITE ELEMENT ANALYSIS
INTRODUCTION
The finite element method (FEM), is a numerical method for solving problems
of engineering and mathematical physics. Typical problem areas of
interest include structural analysis, heat transfer, fluid flow, mass
transport, and electromagnetic potential. The analytical solution of these
problems generally require the solution to boundary value problems for partial
differential equations. The finite element method formulation of the problem
results in a system of algebraic equations. The method yields approximate
values of the unknowns at discrete number of points over the domain. To solve
the problem, it subdivides a large problem into smaller, simpler parts that are
called finite elements.
FEM is best understood from its practical application, known as finite
element analysis (FEA). FEA is applied in engineering as computational tool
for performing engineering analysis. It includes the use of mesh generation
techniques for dividing a complex problem into small elements, as well as the
use of software program coded with FEM algorithm. In applying FEA, the
complex problem is usually a physical system with the underlying physics such
as the Euler-Bernoulli beam equation, the heat equation, or the Navier-Stokes
equations expressed in either PDE or integral equations, while the divided small
elements of the complex problem represent different areas in the physical
system.
In present research for analysis ANSYS (Analysis System) software is used.
Basically, its present FEM method to solve any problem. Following are the steps:
1. Geometry
2. Discretization (Meshing)
3. Boundary condition
4. Solve (Solution)
46
Fig.5.2 Project Schematic (Toolbox)
Fig. 5.3 Analysis System
47
Fig. 5.4 Steps

Step 1: Details of material is deciding Mainly copper, steel, grey cast iron,
composite material, fluid domain material is defined in engineering data.
(ANSYS default material is structural steel.)
Step 2: Import of geometry created in any CAD software as CATIA, PRO E,
SOLIDWORK, INVENTOR etc. in geometry section. If any correction is to
be made it can be created in geometry section in Design modeler or space
claim.
Step 3: In model section after import of component
• Material is assigned to component as per existing material
• Connection is checked in contact region i.e., bonded,
frictionless, frictional, no separation etc. for multi body
components.
• Meshing or discretization is performed i.e., to break
components in small pieces (elements) as per size such that
preferably tetra mesh and hexahedral mesh for 3D geometry
and for 2 D quad or trio are generally preferred.
Step 4: Boundary condition are applied as per analysis namely in fixed
48
support,
Step 5: Now problem is well defined and solve option is selected to obtain
the solution in the form of equivalent stress, strain, energy, reaction force
etc.
5.5.1 GEOMETRY
Generally, the geometry is created in any CAD software and then imported
into this software for analysis purposes. So, this Geometry part is first
created in CATIA modeling software and then imported into this software
for finite element analysis.
5.5.2 MATERIAL PROPERTIES

As per the procedure analysis in the Ansys software, the next step after
importing the component is the material selection. The chosen material
for the analysis part is structural steel. Mainly copper, steel, grey cast
iron, composite material, and fluid domain material defined in
engineering data. The default material in ANSYS software is structural
steel.
5.5.3 MESH
ANSYS Meshing is a general-purpose, intelligent, automated high-
performance product. It produces the most appropriate mesh for accurate,
efficient multi physics solutions. A mesh well suited for a specific analysis
can be generated with a single mouse click for all parts in a model. Full
controls over the options used to generate the mesh are available for the
expert user who wants to fine-tune it. The power of parallel processing is
49
automatically used to reduce the time you have to wait for mesh generation.
Creating the most appropriate mesh is the foundation of engineering
simulations. For a quick analysis or for the new and infrequent user, a usable
mesh can be created with one click of the mouse. ANSYS Meshing chooses
the most appropriate options based on the analysis type and the geometry of
the model. Especially convenient is the ability of ANSYS Meshing to
automatically take advantage of the available cores in the computer to use
parallel processing and thus significantly reduce the time to create a mesh.
Parallel meshing is available without any additional cost or license
requirements.
5.6 STATIC STRUCTURAL ANALYSIS
5.6.1 BOUNDARY CONDITIONS:

A boundary condition for the model is the setting of a known value for a
displacement or an associated load. For a particular node you can set either
the load or the displacement but not both. The main types of loading
available in FEA include force, pressure and temperature. These can be
applied to points, surfaces, edges, nodes and elements or remotely offset
from a feature. The way that the model is constrained can significantly affect
the results and requires special consideration. Over or under constrained
models can give stress that is so inaccurate that it is worthless to the
engineer. In an ideal world we could have massive assemblies of
components all connected to each other with contact elements but this is
beyond the budget and resource of most people. We can however, use the
computing hardware we have available to its full potential and this means
understanding how to apply realistic boundary condition
50
5.6 RESULTS AND PLOTS:
In the Static Structural Analysis, the total deformation is observed to be

0.00081074 mm. The above Fig. 5.6 shows the total deformation occurs in the
bumper. If observed the figure carefully then it realizes that as per the graph
reading and the illustration of the stress the total deformation is occurs at the end
part of the bumper
51
CHAPTER 6
6. FABRICATION, OUTCOMES AND COST ESTIMATION

6.1 FABRICATION
Fabrication is the creation of metal structures by cutting, assembling, and bending
processes. It is a process involving the creation of machines, parts, and structures
from various raw materials.
The required Fabrication processes are cutting, Grinding, Drilling, Welding,
Punching were identified and implemented as per design requirement. Grinding
machine was used for cutting of all the parts like the angle, Sheetmetal etc. Metal
Arc welding is a fusion welding process used to join metals. An electric arc from
an DC power supply creates an intense heat of around 6500°F which melts the
metal at the join between two works
6.2. FRAME
The vertical frame in the structure has combination of square hollow pipes. These
pipes are going to be welded with the help of metal arc welding process. In the
fabrication of this vertical frame use cutting, welding, grinding operations
respectively. On the upper side of this vertical frame one DC motor is mounted for
the operation of forks.
Fig. 6.1Frame
52
6.3. ARDUINO CIRCUIT BOARD

Arduino consists of both a physical programmable circuit board (often
referred to as a microcontroller) and a piece of software, or IDE (Integrated
Development Environment) that runs on your computer, used to write and
upload computer code to the physical board. Additionally, the Arduino IDE
uses a simplified version of C++, making it easier to learn to program.
Finally, Arduino provides a standard form factor that breaks out the functions
of the micro-controller into a more accessible.
Fig. 6.2 Arduino Circuit Board
53
6.4 PROCESS SHEET
6.4.1 CUTTING
Cutting is the separation or opening of a physical object, into two or more
portions, through the application of an acutely directed force. Implements
commonly used for cutting are the knife and saw. In the medicine and science
branches use the scalpel and microtome.
Fig. 6.3 Cutting

6.4.2 WELDING
Welding is a fabrication or sculptural process that joins materials by using high

heat to melt the parts together and allowing them to cool causing fusion. An
electric arc from an DC power supply creates an intense heat of around 6500°F
which melts the metal at the join between two work pieces is used for joining parts
Fig. 6.4 Welding
54
6.4.3 DRILLING
Drilling is a cutting process that uses a drill bit to cut a hole of circular
cross-section in solid materials. The drill bit is usually a rotary cutting tool,
often multi-point. The bit is pressed against the workpiece and rotated at
rates from hundreds to thousands of revolutions per minute.
Fig. 6.5 Drilling
55
6.5 OUTCOMES AND COST ESTIMATION

PROPOSED OUTCOME
• This Auto Pneumatic Bumper System preferably use for All vehicle like
hatchbacks.
• The main function of this project is to reduce the vehicle

damage and to reduce impact to the passengers
• This project is based on automation so, helps in eliminating

human errors.
COST ESTIMATION
Cost estimation may be defined as the process of forecasting the
expenses that must be incurred to manufacture a product.
PURPOSE OF COST ESTIMATION:
1. To determine the selling price of a product for a quotation or
contract so as to ensure a reasonable profit to the company.
2. Check the quotation supplied by vendors.
3. Determine the most economical process or material to

manufacture the product.
4. To determine standards of production performance that may be
used to control the cost.
TYPES OF COST ESTIMATION:
1. Material cost 2. Machining cost
56
MATERIAL COST ESTIMATION

Material cost estimation gives the total amount required to collect the raw
material which has to be processed or fabricated to desired size and
functioning of the components.
These materials are divided into two categories.
1. Material for fabrication:
In this the material in obtained in raw condition and is
manufactured or processed to finished size for proper
functioning of the component.
2. Standard purchased parts:
This includes the parts which was readily available in the
market like Allen screws etc. A list is forecast by the estimation
stating the quality, size and standard parts, the weight of raw
material and cost per kg. For the fabricated parts.
MACHINING COST ESTIMATION
This cost estimation is an attempt to forecast the total expenses that may
include manufacturing apart from material cost. Cost estimation of
manufactured parts can be considered as judgment on and after careful
consideration which includes labor, material and factory services required
to produce the required part.
PROCEDURE FOR CALCULATION OF MATERIAL COST:

The general procedure for calculation of material cost estimation
is after designing a project
1. A bill of material is prepared which is divided into two categories.
a. Fabricated components
b. Standard purchased components
2. The rates of all standard items are taken and added up.
3. Cost of raw material purchased taken and added up.
57
Sr.
Component No. Cost
No.
1. Pneumatic Cylinder 2 1350
2. 5/2 Solenoid Valve 1 1300
3. Arduino Uno 1 950
4. Wiper Motors 1 1100
5. Humper Wire 10 350
6. Battery (12 Volt) 1 500
7. Wheels 4 325/piece
Total Rs. 11500
Table 6.1 Cost Estimation
58
7. ADVANTAGES AND APPLICATIONS

7.1 ADVANTAGES: -
1) Simple construction of the prototype vehicle.

2) It provides safety to passengers in the vehicle as well as to the vehicle
body.
3) It reduces accident intensity and impact.
4) This system increases the response time of vehicle by keeping safe distance
between two vehicles.
5) The design also increases the crashing distance by providing extra space
due to extension of the bumper, decreasing the chances of injuries to commuters.
7.2 APPLICATIONS: -
1) This system may be applicable in all types of light vehicles like cars.
2) This system also successfully installed in the heavy vehicles like buses,
trucks, trailers, etc.
59
CONCLUSION
The main goal of this project's design and production was to limit the number of
road accidents, therefore ensuring the safety of the passengers. With the help of
the pneumatic bumper, our concept also decreases the damage caused to the car
after a collision. Our work not only has strong feasibility and great reliability, but
it is also cost effective, compensating for the drawbacks of other presently
available systems. Our work on this project has given us a lot of experience in
terms of planning and applying our practical and theoretical skills. We are pleased
that we were able to complete the work in the allotted period. The prototype we
developed and built is operating in good conditions and achieving all of the goals
we set out to accomplished.
60
MONTHLY ACTIVITY SHEET
Months 2021-2022
September
Sr.
November
December
February
October
January
Activity
August
March
April
May
No.
Search and Selection

1 Of Topic
Finalize the Project

2 Topic
3 Literature Review
CAD Modelling
4
3D Drafting
5
Sample Calculations
6
Material and
7 Components Selection
Analysis through
8 ANSYS
Buying Standard
9
Components
Fabrication
10
Inspection and
11
Rework
Final Report
12
61
REFERANCES
[1] Ahmad Syuhri, Design and Modeling of Hydraulic Crash Damper in a Racing
Electric Vehicle, International Journal of Mechanical & Mechatronics Engineering
IJMME-IJENS Vol:16 No:03,pp.166-172.
[2] R. Balamurugan & Dr. M. Sekar, Design of Shock Absorber for Car Front
Bumper, IJSTE - International Journal of Science Technology & Engineering |
Volume 3 | Issue 09 | March 2017,pp.166-169.
[3] Prof. M. B. Bankar, Prof. S. K. Pawar, Prof. R. V. Lalge, Design And

Development Of Automatic Pneumatic Bumper System, Journal Of Information,
Knowledge And Research In Mechanical Engineering, NOV 16 TO OCT 17 ,2017,
VOLUME –04, ISSUE – 02,pp.820-825.
[4] G.V.R.Seshagiri Rao, Vadnala Priyanka, V V S H Prasad, Design and Analysis

of Automobile Bumper, International Journal of Innovative Technology and
Exploring Engineering (IJITEE) ISSN: 2278-3075, Volume-9 Issue-1, November
2019.pp.512-516.
[5] Raj Kumar G, Balasubramaniyam S, Senthil Kumar M, Vijayanandh R, Raj

Kumar R, Varun S., Crash Analysis on the Automotive Vehicle Bumper,
International Journal of Engineering and Advanced Technology (IJEAT) ISSN:
2249 – 8958, Volume-8, Issue-6S3, September 2019. pp.1602-1607.
[6] A.T. Beyenea, E.G. Korichob, G. Belingardib, B. Martoranac, Design and

manufacturing issues in the development of lightweight solution for a vehicle frontal
bumper, International Symposium on Dynamic Response and Failure of Composite
Materials, ScienceDirect Procedia Engineering 88 (2014) 77 – 84.
[7] Joseph E. Shigley, Mechanical engineering design, sixth edition, Tata Megraw
hill, 2005.
62
[8] Khurmi R. S., Gupta J. k., A textbook of machine design, first edition, S. chand
publication, 1979.
[9] Ballany P. L., Theory of machine elements, Twenty forth edition, Khanna
companies, 2005.
[10] Bhandari V. B., Design of machine elements, eighteenth edition, MC graw-
hillCompanies, 2003.
[11] PSG collage of technology, Coimbatore design data, first edition
KalaikaikathirAchchangam, 2003.
[12] Workshop Technology,Volume-1,2, Hajara Chaudhari.
REFERANCES URLS
https://www.researchgate.net/publication/311439307_Design_and_Modeling_of_H
ydraulic_Crash_Damper_in_a_Racing_Electric_Vehicle/link/585c896b08ae8fce48
fad3c5/download
http://www.ijste.org/articles/IJSTEV3I9076.pdf
http://www.ejournal.aessangli.in/ASEEJournals/MECH123.pdf
https://www.ijitee.org/wp-content/uploads/papers/v9i1/G5615058719.pdf
https://www.ijeat.org/wp-content/uploads/papers/v8i6S3/F12960986S319.pdf
https://pdf.sciencedirectassets.com/278653/1-s2.0-S1877705814X00251/1-s2.0-
S1877705814021900/main.pdf
63

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Savitribai Phule Pune University, Pune 2015 Course

Department of Mechanical Engineering

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

Sinhgad Technical Education Society’s

MR. VAIBHAV SANJAY GAIKWAD. B150360903

MR. NIKHIL PANDIT GAVANDE. B150360909

MR. ATHARVA YOUVARAJ PATIL. B150361061

Prof. G. C. Pude Prof. ……………….

Prof. T. S. Sargar Dr. A.V. Deshpande

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

Mr. NISHANT SANJAY DESHPANDE Sign.……………….

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

Topic No. Name of Topic Page No.

1.2 Problem Statement 13

2.1 Review of Papers 17

2.2 Observation from literature review 22

3 Design of Proposed work 23

3.1 Catia Software 23

3.2 Catia Design 26

3.2.3 3D Parts of the model 27

4 Construction and working 30

4.2 Single Acting Cylinder 30

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

Topic No. Name of Topic Page No.

3/2 Solenoid Valve 31

4.4 Pneumatic Connectors 32

4.6 Ultrasonic Sensor 32

4.7 Pedstal Bearing 33

4.9 12 Volt Battery 34

4.10 Wiper Motor 35

5.2 System Design 37

5.3 Mechanical Design 37

5.4 Design Parts 37

5.4.1 Motor Selection 38

5.4.2 Design of belt drive 39

5.4.3 Shaft Design 41

5.4.4 Bearing Selection 42

5.4.5 Design Pneumatic Cylinder 43

6 Finite Element Analysis 46

6.3 Material Properties 49

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

Topic No. Name of Topic Page No.

6.5 Static Structural Analyse 50

6.5.1 Boundary Condition 50

6.6 Results and Plots 51

7.3 Arduino Circuit Board 53

7.4 Process Sheet 54

Outcomes and Cost Estimation 56

8 Advantages and Application 59

Monthly Activity Sheet 61

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

Sr No. List of Figures Page No.

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

LIST OF TABLES AND GRAPHS: -

Table No 8.1 Monthly Activity Sheet Page No. - 61

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

In case of accident occurs, there is no any provision to minimize the damages

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

project “Automatic Pneumatic bumper for four-wheeler”, which is fully

We have introduced our project “automatic Pneumatic bumper”, which is fully

Smt. Kashibai Navale College of Engineering, BE (Mechanical Engineering)

1.2 PROBLEM STATEMENT: