John Deere India Private Ltd

Pune, India

John Deere India Private Ltd

Pune, India
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Goyal R.,John Deere India Private Ltd | El-Zein M.,The Innovation Company | Glinka G.,University of Waterloo
Welding in the World | Year: 2016

In the case of structural weldments, the procedure for estimating fatigue life requires information concerning geometry of the object, loads, and material. Detailed knowledge of stress fields in the critical regions of weldments is used to determine the fatigue life. The main theme of the research discussed in this paper is to provide details of the methodology which has been developed to determine the peak stress and associated non-linear through-thickness stress distribution at the critical weld toe crack plane by using only the geometry-dependent stress concentration factors along with appropriate unique reference stress calculated in an efficient manner, e.g., without modeling geometrical weld toe details. The peak stress at the weld toe can be subsequently used for estimating the fatigue crack initiation life. The non-linear through-thickness stress distribution and the weight function method can be used for the determination of stress intensity factors and for the analysis of subsequent fatigue crack growth. Accurate peak stress estimation requires 3D fine mesh finite element (FE) models, accounting for the micro-geometrical features, such as the weld toe angle and weld toe radius. Such models are computationally expensive and therefore impractical. On the other hand, stresses at the sharp weld corners obtained from 3D coarse FE meshes are inaccurate and cannot be used directly for fatigue life estimations. This paper describes a robust, sufficiently accurate, and efficient stress analysis method for fatigue life estimation of welded structures based on 3D FE coarse mesh models. Another objective is to establish a methodology which is capable of accounting for the actual variability of stress concentration factors at welds, welding defects such as misalignment, and incomplete penetration resulting from the manufacturing process. The methodology described in the paper has been validated by analyzing several weldments of varying geometrical and load configurations. The proposed methodology not only reduces conservative fatigue design of welded structures but also leads to significant savings concerning modeling and computation efforts. © 2016, International Institute of Welding.

Goyal R.,John Deere India Private Ltd | Glinka G.,University of Waterloo | Glinka G.,Aalto University
Welding in the World | Year: 2013

The effects of the lack of penetration flaw and misalignment on fatigue life of cruciform welded joints made of low-alloy steel were studied experimentally and theoretically. It was found that two locations of fatigue fracture were possible under cyclic tension loading, depending on the relative magnitude of the misalignment. In the absence of misalignment, all fatigue failures occurred as a result of fatigue growth of cracks emanating from the weld root. In the presence of misalignment, fatigue life depended on the fatigue growth of cracks growing from the weld toe. It has been shown that the entire fatigue life can be modeled as a fatigue growth of cracks starting either from the weld toe or the weld root. The initial crack size was selected as a small crack characteristic for a given material, i.e., being dependent only on the material. The weight function method was used to calculate the required stress intensity factors. © 2013 International Institute of Welding.

Vinodh S.,National Institute of Technology Tiruchirappalli | Gautham S.G.,Purdue University | Ramiya R. A.,John Deere India Private Ltd
Production Planning and Control | Year: 2011

The manufacturing organisations have been witnessing a key transition to lean manufacturing paradigm so as to eliminate waste. Concurrently, six sigma methodology has been widely used for reducing the defects. In order to attain the combined benefits of these two approaches, the amalgamated lean sigma framework has originated. Lean sigma framework proves drawbacks, such as lack of systematic and scientific management and feeble lean anchorage. In order to overcome these deficiencies, this article contributes a refined lean sigma framework, and its effectiveness has been test implemented in an Indian automotive valves manufacturing organisation. The implementation benefits are described in this article. © 2011 Taylor & Francis.

Maisenbacher S.,TU Munich | Yassine A.,American University of Beirut | El-Zein M.,Moline Technology Innovation Center | Goyal R.,John Deere India Private Ltd | Maurer M.,TU Munich
Gain Competitive Advantage by Managing Complexity - Proceedings of the 14th International Dependency and Structure Modelling Conference, DSM 2012 | Year: 2012

Changes in welding sequence have high effects on welding distortion and production time. As the effects on cycle time are simply due to the distance travelled by the Heat Source, the influences of welding sequence on distortion are still not clearly defined. The goal of this paper is to build a model of the entire welding process to get deeper insights on the physics of welding and especially on the influence of welding sequence on distortion. DSM and MDM models are used to map and analyse these correlations.

Malik M.,VJTI Mumbai | Kshirsagar S.,John Deere India Private Ltd | Barve S.,VJTI Mumbai
SAE Technical Papers | Year: 2012

Rollover Protective Structures (ROPSs) are used in off-highway vehicles to protect operator in case of accidents involving overturning of vehicle. The role of a ROPS is to absorb the energy of Rollover without violating the protected operator zone. The performance of a ROPS is determined by its ability to absorb energy under prescribed loading conditions. The performance depends upon design parameters, such as tube thicknesses, material grades, ROPS tube cross-sections, etc., that define the structure. In this paper, we describe a method that uses Design of Experiments (DOE) to determine the correlation between the performance of a ROPS for a small tractor and its critical design parameters. The correlation results are discussed for two types of loading conditions, namely "front push loading" and "side push loading". The correlation obtained is further used to identify the optimal design parameters for maximum energy absorption under constraints on allowable deflections. Copyright © 2012 SAE International.

Dhokey N.B.,College of Engineering, Pune | Raskar A.,College of Engineering, Pune | Hake A.R.,College of Engineering, Pune | Mohapatra G.,John Deere India Private Ltd
Tribology - Materials, Surfaces and Interfaces | Year: 2015

Wear by sand abrasion occurs in cutter blades of sugarcane cutting machine. The wear life of components used under sand abrasion conditions is governed by process parameters, properties of abrasive particles in the soil and material properties. In this article, the wear performance of conventionally and cryotreated specimens was tested in the soil containing 20% silica at different blade speeds such as 300, 400, 600 and 750 rev min−1 at the varied cutting times of 8, 16, 24 and 32h respectively using simulated test rig fixture of sugarcane cutting machine. In addition, treated specimens were characterised for the microstructural features, hardness and surface roughness. Microstructural study indicated fine structure of tempered martensite with addition of segregation of silicon and carbon spots in the cryotreated specimen. The surface roughness of cryotreated material was decreased by 50% with respect to conventionally treated one. The mass loss of cryotreated cutting blades was reduced by 28% over conventional treatment at 750rev min−1. The wornout surface and subsurface of conventionally treated specimens showed predominant dislodgment of wear particles. © 2015 Institute of Materials, Minerals and Mining and W. S. Maney & Son Ltd.

Sundaresan T.G.,John Deere India Private Ltd
SAE Technical Papers | Year: 2011

In the automobile industry finite element analysis is extensively used to simulate a structures response to external loads. Inadvertently the simulation typically captures the primary failure mode which is applicable when there is no redundancy - i.e. the structure being 100% complaint with the design. In spite of the advances in the manufacturing systems used in the automobile industry across the world it is observed that it is not possible to have zero redundancy products especially when it is a mass production and there are non-automated manufacturing phases. In the automobile industry the most prominent contributor to redundancy are manual welds. This paper is about incorporation of weld redundancy in the simulation for pre-identified critical welds using design of experiments. Copyright © 2011 SAE International.

Pingle A.,John Deere India Private Ltd | Reddy V.,John Deere India Private Ltd | Jog S.,John Deere India Private Ltd | Raj A.,John Deere India Private Ltd | Chiramana S.,John Deere India Private Ltd
SAE Technical Papers | Year: 2011

Weight reduction in construction equipment is sought to achieve energy conservation and also to comply with the vehicle safety and compliance regulations, managing the weight distribution across the rear and the front end of the equipment to achieve the optimum balancing. Of late the thrust on product weight has increased along with reduced time to market, leading to increased usage of structural optimization methods. This has been further supported by the availability of high performance computing at relatively low cost. VOC and CTQ tools provided the motivation and initial screening of the design variables. The structural optimization software provides an integrated platform for analysis as well as optimization of components. In this work, an optimization tool has been used for size and shape optimization of a construction equipment assembly and a commercial FEA package was used for verification and validation of the results. The overall purpose was to reduce the weight of an assembly through gauge optimization. For this purpose, structural weight was chosen as the objective function and structural responses such as stress was chosen as constraint. In addition to the global level optimization exercise, at the local level shape optimization was used to reduce peak stresses. In this case peak stress area was chosen as an objective function and the stress was reduced below the acceptable limit of the material, which was calculated by taking in to account the number of cycles of operation for each sub assembly. The main idea was utilizing factor of safety in optimization to make it a robust design. Significant reduction in design iterations as well as weight reduction was achieved by using the optimization framework Copyright © 2011 SAE International.

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