AUTOMOTIVE

STEERING WHEEL

K.BHAVANA
MFD14I005
INTRODUCTION
• The steering wheel is the critical interface between driver and car.

• Steering wheels are used in most modern land vehicles, including all mass-
production automobiles, as well as buses, light and heavy trucks, and tractors.

• The steering wheel is the part of the steering system that is manipulated by the
driver; the rest of the steering system responds to such driver inputs`.

• The steering wheel cover is made up of polyurethane foam formed by reaction

injection moulding.
 Manufacturing process
• The process begins with making the internal support structure, made up of either
aluminium or magnesium alloys(strong and light weight ).

• The aluminium or magnesium in liquid form(700C) is injected into armature

shaped hold from where it is injected into the mould in the die casting
machine(~40MPa pressure)

• After solidification ,the support structure is removed from the mould by a robot
arm and is placed on a holder for further cooling.

Internal support structure is kept on holders for cooling Internal support structure
Manufacturing process
• Excess material is removed by the trimming operation , by the trimming die in
one stroke.
• Then rivets are inserted by a robotic arm, for the horn assembly operation in the
later stage.
• Then Laser engraving of a number (~20W)takes place for quality tracking.
 Manufacturing process
• In the next operation, the mould is coated with release agent to prevent sticking

• The internal support structure is placed into the mould, and polyurethane foam is
formed around the internal support structure by chemical reaction of toluene
diisocyanate (TDI)& polyols(chemicals that contain that contain multiple alcohol
groups (OH) in the mould cavity,when they are injected inside the cavity.
• low processing temperatures of 35°C, low internal moulding pressures between
3 and 10 bar are advantages of this process.
• suitable additives(UV screener called hydroxybenzotriazole is added to reduce
damage from heat, light, atmospheric contaminants, and chlorine).

• Various antioxidants are available such as monomeric and polymeric hindered

phenols are also added to prevent oxidation reactions. Colorants may be added
to change their aesthetic appearance.
the foam formed expands around the internal support structure in the mould.

Thermoset
elastomer(
PUR
foam)
Manufacturing process
• Excess polyurethane foam(thermoset-elastomer) is trimmed.

• Then buttons which control operation are pre assembled manually into finishers,
which are injection moulded from ABS plastic and coated with metallic
paint(~5um)
• The electrical unit is connected with the assembly and installed on steering
wheel. Springs are inserted into the assembly for functioning of airbag module,
to enable in and out movement during horn sounding, onto which the horn plate
will get installed.
Manufacturing process
• Back cover made up of plastic resin(which is made by injection moulding) is
assembled and the final steering wheel is obtained.
• Magnesium alloys are mixtures of magnesium with other metals
often aluminum, zinc, manganese, silicon, copper.

• Melting point: 650 °C

• Density: 1.8 g/cm³
• Tensile strength: 380Mpa (32 ksi)
Yield strength: 305 MPa (19 ksi)
• Young's modulus is 42 Gpa
• Cast magnesium alloys are used for many components of modern automobiles have
been used in some high-performance vehicles with corrosion resistance.
• Acrylonitrile butadiene styrene (ABS) (chemical formula (C8H8)x·​(C4H6)y·​(C3H3N)z)
is a common thermoplastic polymer
• . For the majority of applications, ABS can be used between −20 and 80 °C (−4 and
176 °F) as its mechanical properties vary with temperature

• Density:1.06g/cm3
• its glass transition temperature is approximately 105 °C.
Aluminium alloys are alloys in which aluminium (Al) is the
predominant metal. The typical alloying elements
are copper, magnesium, manganese, silicon, tin and zinc.
• Steering Wheels have been cast from A356.0 aluminium
• Melting point:670C
• Density: 2.75 g/cm³
• Tensile strength: 600 MPa (32 ksi)
Yield strength: 550 MPa (19 ksi)
• Young's modulus is 42 Gpa
• Cast magnesium alloys are used for many components of modern
automobiles have been used in some high-performance vehicles
with corrosion resistance.
PRICE

S. COMPO MATER PROCESS COST DIMEN weight TOTAL

NO NENT IAL SIONS COST
1 Internal
support
aluminiu
m
Die casting Rs
450/kg
ꬾ0.36 0.71kg Rs 310

structure m /piece
1 Internal
support
magnesiu Die casting
m
Rs
470/kg
ꬾ0.36 0.71kg Rs 329

structure m /piece
2 rivets aluminiu Cold Rs 4*5 mm 20g Rs 24
m forging,hot 6/piece
dip
galvanising
3 Back ABS Injection Rs50 to .18*.18*. rs80
cover molding 100/pie 05 m
ce
 Rs. 1,525.00 Rs. 6025.00

Companies Magnesium/magnesium alloy

producers
Rane TRW Steering Systems Pvt Ltd • Alliance magnesium
• Advanced Magnesium Alloys
PU Steering Wheels Corporation (AMACOR).

Mando automotive pvt limited • Aluminium/aluminium alloy

manufacturers
Shah automobiles • HINDALCO
• NALCO