ARID ZONE JOURNAL OF ENGINEERING, TECHNOLOGY & ENVIRONMENT AZOJETE June 2023. Vol. 19(2):247-256 Published by the Faculty of Engineering, University of Maiduguri, Maiduguri, Nigeria. Print ISSN: 1596-2490, Electronic ISSN: 2545-5818 www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 247 ORIGINAL RESEARCH ARTICLE DEVELOPMENT OF A MANUALLY OPERATED SLEEVE PULLER KIT FOR RECIPROCATING TYPE ENGINE M. A. Abba-Aji, M. Shuwa and V. M. Dagala Department of Mechanical Engineering, University of Maiduguri, P.M .B 1069, Maiduguri, Nigeria. *Corresponding author’s email address: birma4real2004@yahoo.com 1.0 Introduction Sleeve puller is bond to removal of piston liners of various kinds, particularly, to apparatus for removing the piston liners of internal combustion engines. During the active life of various engines, the pistons are constantly reciprocating up and down the cylinder and eventually the cylinder liner becomes scored, out of round, or so worn that compression is adversely affected and therefore, it becomes necessary to remove the cylinder liner and either replace the liner and the rings of the piston or grind and lap the bore of the cylinder liner and place oversized rings on the piston (Sarvana, 2017). In the past, many researchers made some efforts to provide tools for removing sleeves of various kinds from internal combustion engines. However, in most of these prior art structures, it has been necessary to remove the piston before the mechanism for removing the cylinder could be attached (Krishnamoorthi et al., 2017). Due to space limitations, in most cases it has been necessary to remove the crank shaft from the engine before the piston could be removed. Therefore, the entire mechanism has to be disassembled before removing the cylinder liners (Krishnamoorthi et al., 2017). ARTICLE INFORMATION ABSTRACT This work describes design and construction of manually operated sleeve puller kit for removal of piston liners. Piston cylinder sleeves which are firmly fixed in the engine block of many reciprocating engines are normally removed for the purpose of repairs, maintenance and replacement, and is difficult to remove by hammering; hence the need for a puller. To demonstrate the workability of the design, a cylinder sleeve of 100KvA generator was constructed. The components for the device were: frame, screw and base, constructed from grey cast iron, unalloyed free cutting steel and copper alloy materials respectively. The components were constructed using cutting, drilling, rolling and arc welding machine operations. The sleeve puller was tested on a 100KvA parkins generator. The cost of producing the device was N9, 150:00, which was effective compared to similar devices in the market that cost within the range of N15, 000 to N20, 000. From the performance test results obtained, the maximum torque to raise the required load was determined to be 452.898 × 103 N-mm and shear stress of the screw as 23.697MPa which was less than the strength of free cutting steel (56MPa). Buckling criterion was 371.09KN>75KN, transverse shear at the root and body area of the screw are 8.768<19MPa and 10.484MPa<56MPa. A piston sleeve puller was successfully developed. A hydraulic or electrically operated can further be investigate. © 2023 Faculty of Engineering, University of Maiduguri, Nigeria. All rights reserved. Submitted 2 December, 2022 Revised 6 March, 2023 Accepted 6 March, 2023 Keywords: Shear Stress Torque Grey-Cast Iron Screw Sleeves http://www.azojete.com.ng/ mailto:birma4real2004@yahoo.com mailto:williamolosunde@uniuyo.edu.ng Arid Zone Journal of Engineering, Technology and Environment, June, 2023; Vol. 19(2):247-256. ISSN 1596-2490; e-ISSN 2545-5818; www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 248 The present research concentrates on the design and construction of a cost effective sleeve puller kit, for removable of internal combustion engine cylinder sleeves or liners for the purpose of repairs and maintenance. The work is limited to a sleeves diameter of 100mm to 150mm. 2. Methodology 2.1 Materials selection and design of machine components The device comprises of three components; the frame, screw and the base. FRAME: the material selected for the frame was FG200 (Graphite flakes Grey-Cast Iron with tensile strength of 200N/mm) which is in agreement with the work of Sarvana, (2017). The material has precipitate of carbon as ‘graphite flakes which is soft in nature, and improves ability to resist compression load. SCREW: the material for the screw was ‘Unalloyed Free Cutting Steel’ with composition of 0.25% carbon, 1.2% manganese, 0.14% sulphur. It has tensile strength of 56N/mm2 with 10% elongation. Sulphur gives resistance to wear and 0.25% carbon gives it sufficient strength to compensate weakness in roots also easy in cutting due to manganese, this is in line with the work of Anand et al. (2015). BASE: to ease replacement due to wear, either screw or the base material has to be soft, as screw is costlier than the base, phosphor bronze is the ideal material for the base, which is a copper alloy having 0.2% of phosphor which increase tensile strength. Ultimate tensile strength for this according to Khurmi and Gupta, (2012) is 19MPa, coefficient of friction is 0.1, with bearing pressure of 10MPa. 2.2 Methods 2.2.1 Design Analysis The following considerations were made during the design: a. The form and shape of the device is produced in a simplified manner. b. The stresses and load bearing capacity. c. The device efficiency, economy and availability of materials d. The safety and durability of the device to be produced e. Single thread screw was assumed for the design. f. the screw is considered to be long coulomb 2.2.1 Screw Design: According to Khurmi and Gupta (2012), for unalloyed cutting steel, assuming Core Diameter = dc, Length = L = 360mm, syc = syt = Yield Strength = 1193.5 MPa Compressive Strength (σc) is given as: 𝜎𝑐 = 1193.5 5 ⁄ = 238.7𝑀𝑃𝑎 𝜎 = 𝑊 𝜋 4 ⁄ × (𝑑𝑐 2) (1) file:///C:/user/Downloads/azojete143/www.azojete.com.ng mailto:williamolosunde@uniuyo.edu.ng Abba-Aji et al: Development of a Manually Operated Sleeve Puller Kit for Reciprocating Type Engine. AZOJETE, 19(2):247-256. ISSN 1596- 2490; e-ISSN 2545-5818, www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 249 238.7 = 75000 𝜋 4 ⁄ × (𝑑𝑐 2) 𝑑𝑐 = 20𝑚𝑚 Let d = Nominal Diameter corresponding to the cylinder bore diameter, p = Pitch, dr = Root Diameter, dm = Mean Diameter, l = Lead Screw, FOS = Factor of Safety: d = 55mm, p = 9mm, According to Khurmi and Gupta (2012), dr = 55 – 9 = 46mm>30mm and 𝑑𝑚 = 𝑑 − 0.5𝑝 = 55 − 4.5 = 50.5𝑚𝑚 Assuming screw has single start threads l = p = 9mm According to Khurmi and Gupta (2012), helix angle is obtained using the relation: 𝑡𝑎𝑛 ∝ = 𝑙 𝜋 × 𝑑𝑚 ⁄ (𝑟𝑎𝑑) (2) = 9 𝜋 × 50.5 ⁄ , ∝ = 3.2460 𝑟𝑎𝑑 Coefficient of friction between screw and base, μ = o.1, considering bad lubricating conditions, assume μ = 0.18, according to Khurmi and Gupta (2012), the thread angle Ø is obtained from the relation: 𝑡𝑎𝑛∅ = 𝜇 = 0.18 ∅ = 10.2039 > 3.0346 Torque required to raise the load according to Khurmi and Gupta (2012) is calculated as: 𝑇 = 𝑊 ( 𝑑𝑚 2⁄ ) tan ∅ + 𝛼 (𝑁𝑚𝑚) (3) = 75 × 103 × (50.5 2⁄ ) tan 10.2039 + 3.246 𝑇 = 452.898 × 103𝑁𝑚𝑚 According to Khurmi and Gupta (2012), number of cross section of screw is subjected to addition of frame friction torque and base torque. 𝜏𝑡𝑒𝑛 = 16𝑇 𝜋 × 𝑑𝑟 3⁄ (𝑀𝑃𝑎) (4) = 16 × 452.898 𝜋 × 463⁄ 𝜏𝑡𝑒𝑛 = 23.697𝑀𝑃𝑎 𝜏𝑝𝑒𝑟𝑚 = 56𝑀𝑃𝑎 > 23.69𝑀𝑃𝑎 http://www.azojete.com.ng/ mailto:williamolosunde@uniuyo.edu.ng Arid Zone Journal of Engineering, Technology and Environment, June, 2023; Vol. 19(2):247-256. ISSN 1596-2490; e-ISSN 2545-5818; www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 250 The maximum tensile strength of free cutting steel (56MPa) is greater than the tensional shear stress of the screw. Therefore, according to Khurmi and Gupta (2012), the screw is safe in tensional shear stress. According to Khurmi and Gupta (2012), using buckling criterion, when load was raised, the screw acted as coulomb, and there were chances of buckling or crushing, therefore, it must be decided whether the coulomb was long or short. Since one end of the screw was fixed and other was free, the end fixity coefficient was 0.52, and the Young modulus 207, 000MPa. Border line between short and long coulomb was; 𝑠𝑦𝑡 2⁄ = 𝜂 × 𝜋2 × 𝐸 1 𝑘⁄ 2⁄ (5) 560 2⁄ = 0.25 × 𝜋2 × 2007000 1 𝑘⁄ 2⁄ 1 𝑘⁄ = 42.709 The length of the screw has to be greater than the length of the cylinder (360mm) in order to remove the liner, therefore, as reported by Khurmi and Gupta (2012), the length of screw considered is 550mm 𝐾 = √𝐼 𝐴 ⁄ (𝑚𝑚) (6) I = Inertia, K = Radius of gyration, A = Cross sectional area 𝐼 = 𝜋 4⁄ × 𝑑𝑟 4 𝑚𝑚4 (7) = 219.786 × 103𝑚𝑚4 𝐴 = 1661.9925𝑚𝑚2 𝐾 = 11.5 𝑚𝑚 According to Khurmi and Gupta (2012), 𝑆𝑙𝑒𝑛𝑒𝑟𝑑𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜 𝑙 𝐾⁄ = 550 11.5⁄ Slenderness ratio is more than critical slenderness ratio, therefore, screw is considered as long coulomb, hence using Euler’s formula; 𝑃𝑐𝑟 = 𝜋2 × 𝐸 × 𝐼 (1 𝑘⁄ )2 ⁄ (𝐾𝑁) (8) = 0.25 × 207000 × 𝜋2 × 1661.9025 47.8262⁄ = 371.09 > 75𝐾𝑁 file:///C:/user/Downloads/azojete143/www.azojete.com.ng mailto:williamolosunde@uniuyo.edu.ng Abba-Aji et al: Development of a Manually Operated Sleeve Puller Kit for Reciprocating Type Engine. AZOJETE, 19(2):247-256. ISSN 1596- 2490; e-ISSN 2545-5818, www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 251 2.2.2 Base Design: According to Khurmi and Gupta (2012), the permissible bearing pressure between steel screw and bronze base is 10MPa, number of threads required Given: pb = bearing pressure (MPa) W = load applied (N) Z = required number of threads 𝑃𝑏 = 𝑊 𝜋 4(𝑑2 − 𝑑𝑟 2) × 𝑧 (𝑀𝑃𝑎)⁄⁄ (9) 10 = 75 × 103 𝜋 4(552 − 462) × 𝑧⁄⁄ Where 𝑧 = 10.50 ≈ 11 𝐻 = 𝑍 × 𝑃 = 11 × 9 𝐻 = 100𝑚𝑚 Transverse shear stress at root of threads is given as; 𝜏 = 𝑊 𝜋 × 𝑑𝑟 × 𝑡 × 𝑍⁄ (𝑀𝑃𝑎) (10) where: W = Axial load on the screw (N) T = Torque (N.m) dr = root diameter of the screw (m) Z = number of engaged threads 𝜏 = 75 × 103 𝜋 × 55 × 4.5 × 11⁄ 𝜏 = 8.768𝑀𝑃𝑎 < 19𝑀𝑃𝑎 The ultimate tensile strength (19MPa) is greater than the transverse shear stress at root of threads, therefore, base is safe in transverse shear at the root (Khurmi and Gupta, 2012). Transverse shear stress at threads in screw is given by; 𝜏 = 𝑊 𝜋 × 𝑑 × 𝑡 × 𝑍⁄ (𝑀𝑃𝑎) (11) 𝜏 = 75 × 103 𝜋 × 46 × 4.5 × 11⁄ = 10.48𝑀𝑃𝑎 < 56𝑀𝑃𝑎 The tensile strength of free cutting steel (56MPa) is greater than the transverse shear stress at threads in the screw, making it safe in transverse shear stress at screw (Khurmi and Gupta, 2012). 𝜎𝑡 = 𝑊 𝜋 4⁄ × 𝐷𝑜 2 − 𝐷𝑖 2⁄ (12) where Di and Do are the inner and outer diameter respectively, http://www.azojete.com.ng/ mailto:williamolosunde@uniuyo.edu.ng Arid Zone Journal of Engineering, Technology and Environment, June, 2023; Vol. 19(2):247-256. ISSN 1596-2490; e-ISSN 2545-5818; www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 252 112 = 75 × 103 𝜋 4⁄ × 𝐷𝑜 2 − 552⁄ 𝐷𝑜 = 65𝑚𝑚 By empirical relations 𝐷𝑜 ′ = 1.3 × 𝐷𝑜 = 1.3 × 65 = 85𝑚𝑚 The width of coulomb, considering shear failure, 𝜏 = 𝑊 𝜋 × 𝐷𝑜 × 𝑇⁄ (13) 19 = 75 × 103 𝜋 × 65 × 𝑇⁄ 𝑇 = 20𝑚𝑚 2.2.3 Component construction and assembly The construction of three main parts of the device; frame, screw and base are described. Frame: a 5mm thick U-channel cast iron was used in the construction. Hacksaw was used for cutting and drilling machine was used to drill the hall, which was threaded using tap and wrench to accommodate the screw. The pieces were joint using electric arc welding (Figure 1). Figure1: Sleeve puller frame Screw: threads were produced using cutting and rolling operations. The shank of the blank design for cut threading was full-sized from the fillet under the head to the end of the bolt. Measuring tape was used to measure the required size, and hack saw was used for cutting. The bolt blank was mounted on a lathe machine in order to produce the thread (Figure 2). file:///C:/user/Downloads/azojete143/www.azojete.com.ng mailto:williamolosunde@uniuyo.edu.ng Abba-Aji et al: Development of a Manually Operated Sleeve Puller Kit for Reciprocating Type Engine. AZOJETE, 19(2):247-256. ISSN 1596- 2490; e-ISSN 2545-5818, www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 253 Figure 2: The Screw Base: the base was made at the machine shop by using the cylinder sleeve measurements. The most important measurement was the outside diameter, it must be as close as possible to the block size and tight fit (Figure 3). The required hole was drilled at the centre of the base using a drilling machine and then threaded using tap and wrench (Khurmi and Gupta, 2012). Figure 3 Assembled sleeve puller (Isometric view) The efficiency of the device was calculated using the relation 𝜂 = 𝑤𝑜𝑟𝑘 𝑖𝑛𝑝𝑢𝑡 𝑤𝑜𝑟𝑘 𝑜𝑢𝑡𝑝𝑢𝑡⁄ × 100 (14) 𝑤ℎ𝑒𝑟𝑒; 𝑤𝑜𝑟𝑘 𝑖𝑛𝑝𝑢𝑡 = 𝑒𝑓𝑓𝑜𝑟𝑡 × 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑚𝑜𝑣𝑒𝑑 𝑤𝑜𝑟𝑘 𝑜𝑢𝑡 𝑝𝑢𝑡 = 𝑙𝑜𝑎𝑑 × 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑚𝑜𝑣𝑒𝑑 (Mohammed, 2021) 3.1 Bills of Engineering Measurements and Evaluation The production cost is evaluated based on market prices of materials, the overhead and labour cost which is presented under section 3.1.1. 3.1.1 Analysis of Bill of Engineering Measurements The material cost depends on the market prices, given in Table 1, as MC = N 6, 100.00 http://www.azojete.com.ng/ mailto:williamolosunde@uniuyo.edu.ng Arid Zone Journal of Engineering, Technology and Environment, June, 2023; Vol. 19(2):247-256. ISSN 1596-2490; e-ISSN 2545-5818; www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 254 Table 1: Prices of materials S/No Material Size Amount (N) 1 Flat bar 750 x 100 x 10 2, 500.00 2 Blank bolt 600 x 30 2, 000.00 3 Flat plate 200 x 200 x 15 1, 000.00 4 Electrode Gauge 12 6, 000.00 5 Total 6, 100.00 Direct labour cost was assumed to be 40% of the material cost from table 1, that is, 𝐷𝐿𝐶 = 40 100⁄ × 6100 = 𝑁 2440.00 Overhead cost was assumed to be 10% of the material cost; 𝑂𝐻𝐶 = 10 100⁄ × 6100 = 𝑁 6100.00 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝐶𝑜𝑠𝑡 𝐶𝑃 = 610 + 2440 + 6100 = 𝑁 9150.00 From the market survey conducted so far, the price of similar device ranges from N15, 000 to N20, 000. This indicates the cost effectiveness of the present device. 3. Results and Discussion The shear stresses and the buckling in screw were determined from the performance test carried out and compared with the maximum as shown in Table 2. Table 2: Performance Test Evaluation Tensional shear stress (MPa) The screw in Buckling (KN) Transverse shear stress at root (MPa) Transverse shear area on the screw (MPa) 23.69 75 8.769 10.488 Maximum Tensional shear stress (MPa) Maximum buckling in screw (KN) Maximum Transverse shear stress at root (MPa) Maximum Transverse shear area on the screw (MPa) 56 371.09 19 56 The performance test was carried out where iron sleeves provided a wear resistant surface for the piston rings supported by surrounding block. The iron sleeves have the same coefficient of expansion as the block, about 0.0015 to 0.002 of interference to be removed. The sleeve puller was firmly fixed on engine block and removal was successful, as shown in Figure 4. file:///C:/user/Downloads/azojete143/www.azojete.com.ng mailto:williamolosunde@uniuyo.edu.ng Abba-Aji et al: Development of a Manually Operated Sleeve Puller Kit for Reciprocating Type Engine. AZOJETE, 19(2):247-256. ISSN 1596- 2490; e-ISSN 2545-5818, www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 255 Figure 4: A Piston removal using sleeve puller The frame was placed at the top of the engine block to provide the necessary support to remove sleeves. A threaded rod (screw) was inserted through the centre of the frame at the top where a nut was attached (Figure 1). The sleeve was removed manually. A flange (the base) was attached to the sleeve at the bottom of the threaded rod (screw). When the rod was turned in clockwise direction, the sleeve was then removed successfully. The torque required to raise the load was calculated using equation 3 as 452.898 x 103 N-mm and the shear stresses experienced by the screw and the base were calculated as the tensional shear stress of the screw as presented in Table 1, was 56MPa>23.69MPa , hence the screw was safe in tensional shear stress. The buckling criterion was 371.09KN>75KN, hence the screw was safe in buckling. The transverse shear stress at the root of threads in base was 8.768MPa<19MPa, making the base safe in transverse shear stress at root. The transverse shear area on screw body was safe in transverse shear stress at screw. Conclusion The sleeve puller was successfully constructed, using the specified design considerations, from locally sourced materials. The sleeve puller was tested on a 100kva parkins generator. The performance test was carried out where iron sleeves provided a wear-resistant surface for the piston rings, which were supported by surrounding block. The iron sleeves have the same coefficient of expansion as the block, so typically required about 0.0015 to 0.002 of interference to be removed. The sleeve puller was firmly fixed on engine block and removal was carried out successfully. The sleeve puller is an easy way of removing piston sleeves. The cost of the device, N9, 150:00, was effective when compared to similar devices in the market that range from N15, 000 to N20, 000 according to survey. It can be modified hydraulically or electrically to reduce effort applied on pulling. It can also be modified to serve dual purposes as a puller and presser. References Anand Kumar, M., Prasad Rao, AA. and Narayana Rao, H. 2015. Design Analysis of Dry Cylinder Liners used in Diesel Engines. International Journal of Science Engineering and Advance Technology, 9(3): 518-526. http://www.azojete.com.ng/ mailto:williamolosunde@uniuyo.edu.ng Arid Zone Journal of Engineering, Technology and Environment, June, 2023; Vol. 19(2):247-256. ISSN 1596-2490; e-ISSN 2545-5818; www.azojete.com.ng Corresponding author’s e-mail address: birma4real2004@yahoo.com 256 Khurmi, RS. and Gupta, JK. 2012. A Textbook of Machine Design. Eirasia Publishing House (PVT) Ltd. New Delhi. Krishnamoorthi, T., Prem Kumar, K., Velliyagiri, J., Vengatesh, J. and Murugesane G. 2017. Removal of Dry Type Liner from the Engine Block by using Hydraulic Operation. International Journal of Engineering Research and Technology, 7(5): 39-46. Mohammed, LK. 2021, Design, Construction and performance evaluation of hydraulic cylinder liner puller. International Journal of Information, Engineering and Technology, 11(4): 105-109 Sarvana Kumar, A. 2017. Design and Fabrication of Hydraulic Cylinder Liner Puller. International Journal of Mechanical Engineering Technology, 8(8): 1601-1607 file:///C:/user/Downloads/azojete143/www.azojete.com.ng mailto:williamolosunde@uniuyo.edu.ng