Design

(1) Inner Body Poisson Radial Displacement
(2) Thermal Radial Mismatch

(3) Outer Body Radial Displacement Caused by Rotation

(4) Inner Body Radial Displacement Caused by Rotation

(5) Interface Pressure as a result of Diametrical Interference

For the Outer Body Subjected to Internal Pressure, Axial Force, Torque, and Rotation.
(6) Radial Displacement of the inner Surface Caused by Internal Pressure.

(7) Radial Stress Caused by internal Pressure

(8) Circumferential Stress Caused by Axial Force

(9) Axial Stress Caused by Torque

(10) Shear Stress Caused by Torque

(11) Circumferential Centrifugal Stress at the Inner Surface

(12) Von Mises Stress at the Inner Surface

For the Inner Body Subjected to External PRessure , Axial Force, torque and Rotation
(13) The Radial Stress Caused by Internal Pressure

(14) Radial Stress Caused by Internal Pressure

(15) Circumferential Stress Caused by Internal Pressure

(16) Axial Stress Caused by Axial Force

(17) Shear Stress Caused by Axial Force

(18) Circumferential Centrifugal Stress at the outer Surface

(19) Von Mises Stress at the outer Surface

Ideal Case

Worst Case for Loose Fit:
Joint may not be able to transmit desired force or torque

Worst Case for Tight Fit:
Yield stress may be exceeded and outer body may rupture

Reference:
Slocum, A.H.Precision Machine Design, 1995, Society of Manufacturing Engineers,
Dearborn Published by Prentice Hall, 1992.i

When a ball bearing is used, it is not used alone. It is likely to be used on a shaft or in a
housing bore by an Interference Fit. The Interference Fit is described as a value of tightness
between the shaft and bearing bore or the housing bore and bearing outside diameter. The
three main types of interference fits are distinguished as Loose Fit, Light Interference Fit and
Interference Fit.
As subject of the Fit, the purpose is to prevent creeping. Once creeping occurs, the
temperature will be abnormally generated by the slipping abrasion. Creeping is associated with
the slipping between fitted surfaces. It will be a cause of premature life failure or that the
abrasion particles will enter the bearing and cause it to become noisy and eventually burn up.
Typically a large interference fit prevents creeping, but it is necessary to select the
interference fit by giving attention to the reduction of radial clearance (negative clearance),
the temperature distribution during the bearing operation (the change of the interference fit
by temperature) and the influence to the raceways.
More details about what interference fits are, how creeping works, and how interference fits
and creeping are related are provided below.
The following formula sets up a standard to calculate how much radial clearance is reduced
when a bearing is pressed onto a shaft or into a housing.

Interference fit of the inner ring to the shaft
The sketches drawn in solid lines and dotted lines are the bearing prior to a fit, and the bearing after
a fit, respectively. When press fitted with an interference " i ", the inner ring groove diameter d2
increases by an amount . This is also equal to the decrease in radial clearance.
Press fits of the inner ring to the shaft :

Figure10-1
d : nominal bore diameter,
nominal outside diameter of the shaft
d1
: Shaft bore
(In the case of solid shafts
(d/d1)
2
+ 1
= 1 )
(d/d1)
2
- 1
d2 : Inner ring groove diameter
i : Interference (i/2 in radial direction)
Eb
:
Young's modulus of inner ring (Outer Ring)
Es : Young's modulus of shaft
mb : Poisson's ratio of inner ring (outer ring)
ms : Poisson's ratio of shaft
=
2i (d2/d)
{ (d2/d)
2
- 1 }

(d2/d)
2
+ 1
+
1

+
Eb

(d/d1)
2
+ 1
-
1
(d2/d)
2
- 1 mb Es (d/d1)
2
- 1 ms
Interference fit of the outer ring to the housing
The sketches drawn in solid lines and dotted lines are the bearing prior to a fit, and the bearing after
a fit, respectively. When it is press fitted with an interference " I ", the outer ring groove diameter D1
decreases by an amount . This amount is also equal to the decrease in radial clearance.
Press fits of the outer ring to the housing :

Figure10-2
D : nominal outside diameter of outer ring, nominal housing bore
D1
:
Outer ring groove diameter
D2 : Housing outer diameter
I : Interference (I/2 in radial direction)
Eh
:
Young's modulus of housing
mh : Poisson's ratio of housing
=
2I (D/D1)
{ (D/D1)
2
- 1 }

(D/D1)
2
+ 1
-
1

+
Eb

(D2/D)
2
+ 1
+
1
(D/D1)
2
- 1 mb Eh (D2/D)
2
- 1 mh
Securing with glue
When the bearing is fitted to the shaft and housing by glue without interference, it is necessary to
select the proper clearance to enhance the effectiveness of the glue. It is recommended to consult
with the glue manufacturer because the proper clearance depends on the type of glue. Please be
aware that the roundness of the ring raceways could worsen because of the curing stress of the glue.
Back to top
Referred from JIS B 0401-1
Deviation of holes for common fits
(unit : m)
Dimensional
division
(mm)
G H JS K M N P
Over Incl. G7 H5 H6 H7 JS5 JS6 JS7 K5 K6 K7 M5 M6 M7 N6 N7 P7
- 3
+12
+2
+4
0
+6
0
+10
0
2 3 5
0
-4
0
-6
0
-10
-2
-6
-2
-8
-2
-12
-4
-10
-4
-14
-6
-16
3 6
+16
+4
+5
0
+8
0
+12
0
2.5 4 6
0
-5
+2
-6
+3
-9
-3
-8
-1
-9
0
-12
-5
-13
-4
-16
-8
-20
6 10
+20
+5
+6
0
+9
0
+15
0
3 4.5 7.5
+1
-5
+2
-7
+5
-10
-4
-10
-3
-12
0
-15
-7
-16
-4
-19
-9
-24
10 18
+24
+6
+8
0
+11
0
+18
0
4 5.5 9
+2
-6
+2
-9
+6
-12
-4
-12
-4
-15
0
-18
-9
-20
-5
-23
-11
-29
18 30
+28
+7
+9
0
+13
0
+21
0
4.5 6.5 10.5
+1
-8
+2
-11
+6
-15
-5
-14
-4
-17
0
-21
-11
-24
-7
-28
-14
-35
Deviation of shafts for common fits
(unit : m)
Dimension
division
(mm)
f g h js k m n p r
Over Incl. f6 g5 g6 h4 h5 h6 js4 js5 js6 k4 k5 k6 m5 m6 n6 p6 r6
- 3
-6
-12
-2
-6
-2
-8
0
-3
0
-4
0
-6
1.5 2 3
+3
0
+4
0
+6
0
+6
+2
+8
+2
+10
+4
+12
+6
+16
+10
3 6
-10
-18
-4
-9
-4
-12
0
-4
0
-5
0
-8
2 2.5 4
+5
+1
+6
+1
+9
+1
+9
+4
+12
+4
+16
+8
+20
+12
+23
+15
6 10
-13
-22
-5
-11
-5
-14
0
-4
0
-6
0
-9
2 3 4.5
+5
+1
+7
+1
+10
+1
+12
+6
+15
+6
+19
+10
+24
+15
+28
+19
Referred from JIS B 1566
Fits of inner ring in radial bearings
*1

Bearing
grade
Rotating inner ring load or indeterminate direction
load
Stationary inner ring
load
Tolerance zone class of shaft
*2

0, 6 grades r6 p6 n6
m6
m5
k6
k5
js6
js5
h5
h6
h5
g6
g5
f6
5 grades - - - m5 k4 js4 h4 h5 - -
fits interference fit intermediate fit clearance fit
Fits of outer ring in radial bearings
*3

Bearing
grade
Stationary outer ring
load
Indeterminate direction load or rotating outer ring
load
Tolerance zone class of hole
*2

0, 6 grades G7
H7
H6
JS7
JS6
-
JS7
JS6
K7
K6
M7
M6
N7
N6
P7
5 grades - H5 JS5 K5 - K5 M5 - -
fits interference fit intermediate fit clearance fit
*1 tolerance of bearing bore is based on JIS B 1514-1.
*2 symbol of tolerance zone class is based on JIS B0401.
*3 Tolerance of outer diameter of bearings is based on JIS B1514-1.
More Information About Interference Fits and Creeping
What Is Interference Fit?
If you're not completely familiar with the idea of fit as it relates to a bearing, here is a brief primer to
clarify matters. Essentially, the fit in a ball bearing assembly refers to how much "play" or "give" there
is between the parts of the bearing. Specifically, this is the fit between the shaft and bearing bore or
bearing and housing bore. This space between the two parts is known as clearance, and a fitting
where there is clearance between the parts is known as a clearance fit. In the case of an interference
fit, sometimes known as a press fit, the two parts are pressed together so that there is a minimum of
give between the two parts of the bearing assembly; in fact, the two parts are overlapping and
"interfering" with one another. This occurs typically when one part is slightly larger than the part it is
supposed to fit into. Once the two parts are joined, they deform to accommodate the lack of space
and are effectively fused together as one.
How Is the Fit in an Interference Fit Created?
The fit can be created in one of two ways. The first is force, where a hydraulic press or similar
pressure-applying device simply forces the oversized part into the other, compelling the parts to
conform under the pressure. A less violent method is through thermal expansion. The part to be
inserted is cooled, causing it to contract, then it is inserted into the other part. When the metal heats
up and expands, the proper fit is created. The level of interference between the two parts determines
whether or not the bearing has a loose fit, a light interference fit, or an interference fit. The
interference fit is the tightest fit. NMB engineers can calculate the allowance which will produce these
different kinds of fits for different sizes and construction types of ball bearing assemblies. The
allowance is a planned deviation from the nominal, expected size of the part and the actual size of
the part.
What Is Creeping?
Creeping is the tendency of metals to move or permanently deform as a response to the constant
stresses placed upon them. Ball bearing assemblies are particularly vulnerable to creep as they are
often consistently subject to pressures and high temperatures for extended periods of time. As you
may imagine, creep can destroy the integrity of the ball bearing assembly, which can result in a
failure of the application that is making use of the ball bearings. Interference fit can defend against
creeping, and this is a large part of what makes this kind of fit desirable.
Definitions
Rotating inner ring load :
the line of action of the load is rotating in relation to the inner ring of the bearing
Stationary inner ring load :
the line of action of the load does not rotate in relation to the inner ring of the bearing
Stationary outer ring load :
the line of action of the load does not rotate in relation to the outer ring of the bearing
Rotating outer ring load :
the line of action of the load is rotating in relation to the outer ring of the bearing
Indeterminate direction load :
the direction of the load cannot be determined.
http://tribology-abc.com/calculators/e3_8.htm
http://engineersedge.com/calculators/machine-design/press-fit/press-fit-
calculator.htm
2-(nmbtc.com)
snipping tool pic 1

CALCULATIONS AND ANALYSIS

See Stress Calculation Spreadsheet for sources of equations,
sources of constants and material properties, and additional
calculations

Impact Analysis

Direct wheel impact at max speed
By using the deflection equation,
EI
Fl
s
192
3
= (based upon two fully constrained rod ends),
solving for F, and using a basic kinematic equation ( ) ( 2
2 2
s a v v
o f
A = = ) to solve for s in
terms of F, the force of impact can be determined (227505 N)
Utilizing shaft stress equations shown below the stress can be determined (400 MPa)
When comparing this to the shafts yield strength, a factor of safety of 1.33 is calculated

Direct pulley impact at max speed
Utilizing this same force and finding the stress on the shaft due to bending.
I
Mc
= o =8510
MPa
This means the shaft will permanently bend due to the moment applied on it
The way to avoid this catastrophic failure is to ensure the chassis protects these open gears
by extending past its edges or enclosing it completely. While this may not completely ensure
the modules safety, it will fix nearly every probable scenario.

Shaft Stress Calculations

Shaft 1 (Diameter=3/8)
- Material: 1045 Steel, Yield Strength (S
y
)= 530 MPa, Ultimate Strength= 625MPa
- Max Stress
o The shaft is keyed for a 3/32 key, thus a close approximation for the actual yield
strength is the materials yield strength (Keyed Yield Strength=398 MPa)
o Loading is comprised of three components
Moment-Based on cantilevered distance from bearing and radial load exerted
on shaft from the miter gear (2.1 N-m)
Force- Based on axial load exerted on shaft from miter gear (156.12 N)
Torque- Exerted by the stall torque of the motor, through a gear ratio of 2:1
(9.64 N-m)
o Stress Calculation-

2 / 1 2 2
max
] 48 ) 8 [(
4
T Fd M
d
+ +
H
= o =102 MPa

2 / 1 2 2
3 max
] 64 ) 8 [(
2
T Fd M
d
+ +
H
= t = 58.4 MPa
o Factors of Safety-

max
o
y
S
n = = 3.9

max
2t
y
S
n = = 3.4
- Fatigue Life
o Infinite Life- 2000RPM (Average operating speed)=33.3 cycles/second
5 year life @ 1 hour operating time (2 hr per week)-approximately 1,908,000
seconds of use
33.3*1,908,000=6.4E7 cycles to failure for infinite life
o The endurance strength can be calculated using the stress concentration factors from
the keyway (197 MPa)
o o
F
=S
ut
+345MPa= 970 MPa
o
) 2 log(
) / ' log(
e
e F
N
S
b
o
= =-0.109915548
o
b
ut
F
S
f ) 10 2 (
'
3
=
o
=.673
o
e
ut
S
S f
a
2
) (
= =900 MPa
o Loads are based on typical operating conditions, not max conditions
Moment-Based on cantilevered distance from bearing and radial load exerted
on shaft from the miter gear (2.1 N-m)
Torque- Exerted by the operating torque of the motor, through a gear ratio of
2:1 (2.82 N-m)
o
2 / 1 2 2
3
] 48 ) 8 [(
4
T Fd M
d
a
+ +
H
= o = 39.4 MPa
o
b
a
a
N
1
|
.
|
\
|
=
o
= 2.25E12 cycles to failure

- Material: 1045 Steel, Yield Strength= 530 MPa, Ultimate Strength= 625MPa
- Max Stress
o The shaft is keyed for a 1/8 key, thus the actual yield strength can be equated to the
materials yield strength (Keyed Yield Strength=398 MPa)
Moment-Based on the axle length between bearings and radial load exerted on
shaft from the miter gear (4.28 N-m)
(9.64 N-m)

2 / 1 2 2
max
] 48 ) 8 [(
4
T Fd M
d
+ +
H
= o
= 47.2 MPa

2 / 1 2 2
3 max
] 64 ) 8 [(
2
T Fd M
d
+ +
H
= t = 26.5 MPa

max
o
y
S
n = = 8.4

max
2t
y
S
n = = 7.5
- Fatigue Life
o Infinite Life- 1000RPM=16.67 cycles/second
5 year life @ 1 hour operating time (2 hr per week)-approximately 1,908,000
seconds of use
o o
F
=S
ut
+345MPa= 970 MPa
o
) 2 log(
) / ' log(
e
e F
N
S
b
o
= =-0.109915548
o
b
ut
F
S
f ) 10 2 (
'
3
=
o
=.673
o
e
ut
S
S f
a
2
) (
= =900 MPa
Moment-Based on the axle length between bearings and radial load exerted on
shaft from the miter gear (4.28 N-m)
2:1 (2.82 N-m)
o
2 / 1 2 2
3
] 48 ) 8 [(
4
T Fd M
d
a
+ +
H
= o = 25.6 MPa
o
b
a
a
N
1
|
.
|
\
|
=
o

- Material: 1045 Steel, Yield Strength= 530 MPa, Ultimate Strength= 625MPa
- Max Stress
o The shaft is keyed for a 3/16 key, thus the actual yield strength can be equated to the
materials yield strength (Keyed Yield Strength=398 MPa)
Moment-Based on the axle length between bearings and the force exerted by
the weight of the system (21.53 N-m)
Force- Based on axial load exerted on the shaft from turning forces (235.44 N)
(38.56 N-m)

2 / 1 2 2
max
] 48 ) 8 [(
4
T Fd M
d
+ +
H
= o = 59.0 MPa

2 / 1 2 2
3 max
] 64 ) 8 [(
2
T Fd M
d
+ +
H
= t = 32.7 MPa

max
o
y
S
n = = 6.7

max
2t
y
S
n = = 6.1
- Fatigue Life
o Infinite Life- 500RPM=8.34 cycles/second
5 year life @ 1 hour operating time (2 hr per week)-apprx 1,908,000 seconds of
use
o o
F
=S
ut
+345MPa= 970 MPa
o
) 2 log(
) / ' log(
e
e F
N
S
b
o
= =-0.109915548
o
b
ut
F
S
f ) 10 2 (
'
3
=
o
=.673
o
e
ut
S
S f
a
2
) (
= =900 MPa
Moment-Based on the axle length between bearings and the force exerted by
the weight of the system (21.53 N-m)
Force- Based on axial load exerted on the shaft from turning forces (235.4 N)
8:1 (11.28 N-m)
o
2 / 1 2 2
3
] 48 ) 8 [(
4
T Fd M
d
a
+ +
H
= o = 35.6 MPa
o
b
a
a
N
1
|
.
|
\
|
=
o
Steering Shaft (Diameter=1/4)
- Material: 303 Stainless Steel, Yield Strength= 240 MPa, Ultimate Strength= 620 MPa
- Max Stress
o Loading is based on torque alone (0.745 N-m)

2 / 1 2 2
max
] 48 ) 8 [(
4
T Fd M
d
+ +
H
= o = 25.7 MPa

2 / 1 2 2
3 max
] 64 ) 8 [(
2
T Fd M
d
+ +
H
= t = 14.8 MPa

max
o
y
S
n = = 9.4

max
2t
y
S
n = = 8.1
- Fatigue Life
o o
F
=S
ut
+345MPa=965E6 MPa
o
) 2 log(
) / ' log(
e
e F
N
S
b
o
= =-0.07772
o
b
ut
F
S
f ) 10 2 (
'
3
=
o
=.862
o
e
ut
S
S f
a
2
) (
= =914 MPa
o Load is comprised of torque alone (.745 N-m)
o
2 / 1 2 2
3
] 48 ) 8 [(
4
T Fd M
d
a
+ +
H
= o = 25.7 MPa
o
b
a
a
N
1
|
.
|
\
|
=
o
Spur Gears (Calculated using ANSI standards)

Driving Spur
Material- Carbon Steel, Yield Strength=76900 psi, Modulus of Elasticity=30E6 psi, Poissons
Ratio=.29, Brunell Hardness 179
Max Bending Stress
o
V
H
W
t

=
33000
= 306.8 lbf
o K
o
= 1.25 - Overload Factor, based on light shocks encountered
o K
v
= 1.15 - Dynamic Factor, based on quality and velocity of gears
o K
s
= 1 - Size Factor
o P
d
= .833 Pitch diameter
o F= .25 face width
o K
m
= 1.20 Load-Distribution factor, based on geometry
o K
B
= 1 Rim Thickness factor, based on geometry
o J= .325- Geometry factor, based on number of teeth of gears
o
J
K K
F
P
K K K W
B m d
s v o
t
= o =5357.1 psi
o
max
o
y
S
n = = 9.0
Endurance Stress
o
2 / 1
2
2
)
1
1
(
1
(
(
(
(
(
=
G
G
p
p
p
E
v
E
v
C
t
=2284.7 lbf/in
2

o C
f
=1
o I=0.08- Geometry Factor
o
2 / 1
) (
I
C
F P
K
K K W C
f
d
m
s o
t
p
= o =56972.4 psi
o Sc= 180000 psi- Repeatedly applied contact strength @ 10
7
cycles, material property
o Z
n
=.59 - Stress cycle life factor, based on hardness and number of cycles
o C
H
=1 -Hardness ratio factor
o K
T
= 1- Temperature factor
o K
R
= 1 Reliability factor
o
o
) /(
R T H N c
H
K K C Z S
S = =1.9
o Comparable factor of safety= S
H
2
=3.5

Driven Spur
Material- Carbon Steel, Yield Strength=76900 psi, Modulus of Elasticity=30E6 psi, Poissons
Ratio=.29, Brunell Hardness 179
Max Bending Stress
o
V
H
W
t

=
33000
= 306.7 lbf
o K
o
o K
v
o K
s
= 1 - Size Factor
o P
d
= 1.667 Pitch diameter
o F= .25 face width
o K
m
o K
B
o
J
K K
F
P
K K K W
B m d
s v o
t
= o =9011.0 psi
o
max
o
y
S
n = = 5.4
Endurance Stress
o
2 / 1
2
2
)
1
1
(
1
(
(
(
(
(
=
G
G
p
p
p
E
v
E
v
C
t
=2284.7 lbf/in
2

o C
f
=1
o I=0.08- Geometry Factor
o
2 / 1
) (
I
C
F P
K
K K W C
f
d
m
s o
t
p
= o = 40010.7 psi
o Sc= 180000 psi- Repeatedly applied contact strength @ 10
7
cycles, material property
o Z
n
=.60 - Stress cycle life factor, based on hardness and number of cycles
o C
H
=1 -Hardness ratio factor
o K
T
= 1- Temperature factor
o K
R
= 1 Reliability factor
o
o
) /(
R T H N c
H
K K C Z S
S = = 2.70
o Comparable factor of safety= S
H
2
=7.2

Ring/Pinion Gears (Calculated using ANSI standards)

Steering Spur
Material- 2024-T4 Aluminum, Yield Strength=47000 psi, Modulus of Elasticity=10.4E6 psi,
Poissons Ratio=.333
Max Bending Stress
o
V
H
W
t

=
33000
= 39.3 lbf
o K
o
o K
v
o K
s
= 1 - Size Factor
o P
d
= .4375 Pitch diameter
o F= .125 face width
o K
m
o K
B
o
J
K K
F
P
K K K W
B m d
s v o
t
= o =951.8 psi
o
max
o
y
S
n = = 44.1

Steering Ring
Material- 2024-T4 Aluminum, Yield Strength=47000 psi, Modulus of Elasticity=10.4E6 psi,
Poissons Ratio=.333
Max Bending Stress
o
V
H
W
t

=
33000
= 39.3 lbf
o K
o
o K
v
o K
s
= 1 - Size Factor
o P
d
o F= .125 face width
o K
m
o K
B
o
J
K K
F
P
K K K W
B m d
s v o
t
= o = 3996.0 psi
o
max
o
y
S
n = = 10.5
Miter Gears (Calculated using ANSI standards)

Both Miters (At max torque)
Material- Medium Carbon Steel, Yield Strength=76900 psi
Max Bending Stress
o P
d
o
o
d
t
P
T
W

=
2
= 84.7 lbf
o K
o
o K
v
= 1 - Dynamic Factor, based on quality and velocity of gears
o K
s
= .5 - Size Factor
o F= .27 face width
o K
m
o J= 0.175- Geometry factor, based on number of teeth of gears
o K
x
= 1, Lengthwise curvature factor
o
J K
K K
K K P
F
W
x
m s
v o d
t
= o =14922.2 psi
o
max
o
y
S
n = = 5.15
Both Miters (At max speed)
Material- Medium Carbon Steel, Yield Strength=76900 psi
Max Bending Stress
o P
d
o
o
d
t
P
T
W

=
2
= 4 lbf
o K
o
o K
v
o K
s
= .5 - Size Factor
o F= .27 face width
o K
m
o J= 0.175- Geometry factor, based on number of teeth of gears
o K
x
= 1, Lengthwise curvature factor
o
J K
K K
K K P
F
W
x
m s
v o d
t
= o =901.6 psi
o
max
o
y
S
n = = 85.3

Forces
o Knowing max torque on miter (9.63 N-m), we can find the max tangential force by
dividing by half the pitch diameter=> F
tan
=606.6 N
o o= 20 degress -pressure angle
o d= 45 degrees
o
o cos
tan
F
F
n
= =645.5 N
o
o sin
1
n
F
F = =220.8 N
o d F F F
radial axial
sin
1
= = =156.1 N

Retaining Rings

On 3/8 shaft
o Ring can withstand 542.7 N of axial force
o Miter gear provides axial load= 156.1 N
o Factor of safety= 3.48
On 1/2 shaft
o Miter gear provides axial load= 156.1 N
On 3/4 shaft
o Axial load is from turning
Assume wheel instantaneously turns 90 degrees, the max force that can be
applied axially would be equivalent to the frictional force
= = W F F
friction axial
=235.4 N (assuming =.6)

Mechanical Brake

Max Temperature
Assuming all kinetic energy is converted directly into heat energy,
T C m v m
v plate veh veh
A =
2
2 / 1
Assume emergency brake will not be used continuously, but rather for one cycle during the
emergency
Assume initial temperature of 23 Celcius
Solving the above equation for T
final
we find it to be 38.9 Celcius

Heat Dissipation
Assuming Free Convection, the time required for heat dissipation can be calculated
Utilizing the properties of air at room temperature, the Rayleigh number, Nusselt number,
and convection heat transfer coefficient can be calculated
Using this information the heat transfer rate is determined

q
E
t
A
= A gives the time to dissipate the heat (4.8 minutes)
This resultant was later verified by the manufacturer of the brake

Keys

On 3/8 Shaft
Key is High carbon steel, Yield Strength 427 MPa, 3/32 square
Knowing the diameter of and torque on the shaft, the shear force on the key can be
calculated (2024.1 N)
Assuming a factor of safety of 4, the required length of the key is calculated (.63)

On 1/2 Shaft
On 3/4 Shaft

Keyways

- Keyway analysis was done using Cosmos FEA software
- By utilizing shaft diameters and torques, forces on keyway surfaces were calculated and
input into the program
- Factor of Safety
o Driving Miter=16
o Driven Miter=15
o Driving Pulley=3.4
o Driven Pulley=8.4
o Driven Spur=8.1
o Wheel=1.8, but in reality, failure would result in the slip of a pressed insert, rather
than physical failure of the wheel
Set Screws

To connect spur gear to 5/16 drive motor shaft
By choosing a screw size and quantity (2- #8s), the maximum force at the shaft surface can
be calculated (3425.1 N)
The torque and diameter of the shaft is used to determine the actual force seen at this shaft
surface (1214.5 N)
By comparing these two values the factor of safety is determined (2.82)

To connect spur gear to 8mm steering motor shaft
By choosing a screw size and quantity (2-#6s), the maximum force at the shaft surface can
be calculated (2224.1 N)
The torque and diameter of the shaft is used to determine the actual force seen at this shaft
surface (234.6 N)
By comparing these two values the factor of safety is determined (9.5)

Timing Belt and Pulleys
- Utilizing MITCalc simulation software and inputting various parameters including
distance between centers, power applied to belt, operating speeds, and other
operating conditions a belt type and specific model was selected
- From this the 5M Powergrip GT2 belt was chosen and matched with pulleys of 18
and 72 teeth
- The selection of these parts was also verified with an engineer at the supplier sdp-
si.com

Bearings

C
10
= Catalog Load Rating (lb
f
)
L
R
= Rating Life (hrs)
n
R
= Rating Speed (RPM)
F
D
= Desired Radial Load (lb
f
)
L
D
= Desired Life (hrs)
n
D
= Desired Speed (RPM)
F
R
= Radial Force (lb
f
)
F
A
= Axial Force (lb
f
)
F
e
= Equivalent Radial Load (lb
f
)
C
0
= Static Load Rating (lb
f
)
X
2
= Factor dependent on bearing geometry
Y
2
= Factor dependent on bearing geometry
V = Rotation Factor
a = 3 (ball bearing)
e = abscissa

Lower Drive Bearing
C
10
(lbs) 1171 Upper Drive Bearing Center Bearing
L
R
* n
R
1.0E+06 C
10
(lbs) 1187 C
10
(lbs) 691
F
D
(lbs) 44.125 L
R
* n
R
1.0E+06 L
R
* n
R
1.0E+06
n
D
(RPM) 5.0E+02 F
e
(lbs) 84.6 F
e
(lbs) 70.6
a 3 n
D
(RPM) 2000 n
D
(RPM) 4000
L
D
(hrs) 3.74E+07 F
A
(lbs) 35.1 F
A
(lbs) 35.1
L
D
(years) 4267 F
R
(lbs) 35.1 F
R
(lbs) 35.1
a 3 a 3
Steering Bearing V 1 V 1
C
10
(lbs) 300 e 0.24 e 0.3
L
R
* n
R
1.0E+06 X
2
0.56 X
2
0.56
F
D
(lbs) 10 Y
2
1.85 Y
2
1.45
n
D
(RPM) 340 L
D
(hrs) 1.38E+06 L
D
(hrs) 2.34E+05
a 3 L
D
(years) 158 L
D
(years) 27
A R e
D
R R
a
D
D
F Y VF X F
n
n L
F
C
L
2 2
10
*
+ =
|
|
.
|
\
|
|
|
.
|
\
|
=
L
D
(hrs) 7.94E+07
L
D
(years) 9065

Screws

Bolts connecting Yoke to Turntable

Bolt type: 4 * 10-32 (SAE)

Torque applied to the turntable

T= 2.38 N-m

Converted ASTM

T = 21 lb-in

Resultant load on each bolt

lb
in
in lb
r
T
V 108 . 8
59 . 2
1
* 21 = = =
in lb T M = = 21

Primary Shear Load per Bolt is

lb
n
V
F 027 . 2
4
108 . 8
' = = =
Since the secondary shear Forces are equal we have

lb
r
M
r
Mr
F 027 . 2
59 . 2 * 4
21
4 4
' '
2
= = = =

The resultant force is

lb F
r
867 . 2 =

F
r
= F
a
= F
b
= F
c
= F
d
= 2.867lb

Maximum Shear Stress

A
s
= 0.155

psi
A
F
s
r
497 . 18
155 .
867 . 2
= = = t

Bolts connecting Brake to Brake plate

Bolt type: 4 * 8-32 (SAE)

Torque applied to the turntable

T = 15 lb-in

Resultant load on each bolt

lb
in
in lb
r
T
V 33 . 13
125 . 1
1
* 15 = = =
in lb T M = = 15

Primary Shear Load per Bolt is

lb
n
V
F 33 . 3
4
33 . 13
' = = =
Since the secondary shear Forces are equal we have

lb
r
M
r
Mr
F 33 . 3
125 . 1 * 4
15
4 4
' '
2
= = = =

The resultant force is

lb F
r
714 . 4 =

F
r
= F
a
= F
b
= F
c
= F
d
= 4.714 lb

Maximum Shear Stress

A
s
= .0992

psi
A
F
s
r
9 . 28
0992 .
867 . 2
= = = t

Yoke

- Yoke stress analysis was done using Cosmos FEA software
- Loading
o Weight vertically loads lower bearing holes (196.2 N each)
o Turning force loads inside wall (158.3 N)
o Driven Miter axial force loads inside wall (156 N)
o Driven Miter radial force loads upper bearing holes
o Driving Miter axial force loads upward on top plate
- Minimum factor of safety= 20
Brake Plate

- Brake plate stress analysis was done using Cosmos FEA software
- Loading
o Outside edge was fixed, as it is welded to the motor mount assembly
o Each brake mounting hole was loaded with a force corresponding to the brakes
torque output and the holes distance from center
- Minimum factor of safety= 200

Turntable

- Capable of withstanding 750 lbs, or 340 kg
- Actual weight is about 40 kg per module
- Factor of Safety= 8.5

Figure X: Shaft Stress and Fatigue Strength Calculations

Figure X: Drive Motor Spur Gear Stress Calculation

Figure X: Miter Gear Stress and Force Calculation

Figure X: Retaining Ring Calculations Figure X: Impact Calculations

Figure X: Brake Temperature and Heat Dissipation Calculations

Figure X: Key and Set Screw Analysis

Figure X: Timing Belt and Pulley Analysis

Figure X: Driven Miter Gear Keyway Analysis

Figure X: Driving Miter Gear Keyway Analysis

Figure X: Driven Pulley Keyway Analysis

Figure X: Driving Pulley Keyway Analysis (Representation)

Figure X: Driven Spur Gear Keyway Analysis

Figure X: Wheel Keyway Analysis (Representation)
Note: Actual wheel utilizes press fit keyway insert, thus failure during stall will result in slip of this
insert, rather than the physical failure of a mechanical part

Figure X: Yoke Displacement

Design

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(1) Inner Body Poisson Radial Displacement

(2) Thermal Radial Mismatch

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