GUICHARD Cyril
DESIGN REPORT
ACKNOWLEDGEMENT
We are thankful to Dr. Atef Fahim for his kind help and
guidance without which I could not have completed this
project.We are also thankful to our T.A, Mr. Albert Mazzawi for
his help.
ABSTRACT
INTRODUCTION Page 3
FUNCTIONNAL ANALYSIS Page 4
1./ Functional analysis Page 4
2./ Requirements concerning the system Page 4
OUR CONCEPTS Page 6
1./ Concept #1 Page 6
2./ Concept #2 Page 6
3./ Concept #3 Page 6
4./ Other Miscellaneous Page 8
5./ Decision analysis
WATTAGE REQUIRED FROM THE MOTOR Page 11
DESIGN OF GEAR BOX page 12
1./ Selection of type of gears page 12
2./ Selection of gear ratios page 13
3./ Design of gears page 14
4./ Design of gears to prevent failures page 17
(a)./ Bending strength page 18
(b)./ Pitting strength page 19
DESIGN OF SHAFT page20
(1)./ Solid shaft in bending and Torsion page 22
(2)./ Deflection of the shaft page 24
(3)./ Torsional deflection of the shaft page 25
(4)./ Selection of key for the shaft page 25
DESIGNING PARTS FOR EXPECTED LIFE page26
CONCLUSION page27
LITERATURE SEARCH Page 28
INTRODUCTION
We often see handicapped persons waiting to get some breath of air before
moving her manual wheelchair again.
Handicaped
Wheelchair
person
CF1
MF1
MF2
Electric
package
CF3
CF2
Power
Road
supply
We had to seek for what such a system needs to be. We found some
specifications that our assembly will have to follow :
F2 F3 F4 F5 F6 F7
F1 F2 F3 F4 F5 F1 F7
F2 F3 F4 F5 F6 F7
F3 F3 F5 F3 F7
F4 F5 F4 F7
F5 F5 F5
F6 F7
F1 4.76 5
F2 4.76 5
F3 19.05 20
F4 14.29 15
F5 28.57 30
F6 4.76 5
F7 23.81 25
OUR CONCEPTS
1./ Concept #1
2./ Concept #2
3./ Concept #3
So , our final winning concept is concept no. 1.It is all teh characteristics we
need.Though It may be not very light and easy to fix and remove but it has very
good reliability and long life.Also it is universally adaptable.
WATTAGE REQUIRED FROM THE MOTOR :
The most common pressure angles used for spur gears are
14.5,20,25.In general ,the 14.5 pressure angle is not used for
new designs( and has, in fact been withdrawn as an AGMA
standard tooth form) ; However it is still used for special designs
and for some replacement gears.Lower pressure angles have the
advantage of smoother and quiter tooth action because of large
profile contact ratio.In addition,lower loads are imposed on the
support bearings because of decreased radial load
component ;however,the tangential load components remains
unchanged with pressure angle.The problem of undercutting
associated with small numbers of pinion teeth is more severe
with lower pressure angles.Lower pressure angles gears also have
lower bending strength and surface durability ratings and operate
with higher sliding velocities( which contributes to their relatively
poor scoring and wear performance characteristics) than their
higher pressure angle counterparts.
Higher pressure angles have the advantage of better load-
carrying capacity,with respect to both strength and durability,and
lower sliding velocities( thus better scoring and wear
performance characteristics).In some cases,very high pressure
angles,28,30 and in few cases as highas 45 are employed.
We selected spur gear for for gear box.
2./ SELECTION OF GEAR REDUCTION RATIO
(1). In the first step of design of gears we try to determine the
desired reduction ratio and the input speed by the motor.We shall
denote this speed ( say p).We also determine the main function
of the gear, i.e, to transmit motion or power.
In our design cost and adaptibility were very important factors of
consideration so we have selected spur gears.As they are
cheaper and are most widely used gears.
We take the face width (F) of gears to be one third of the pitch
diameter of the gears (Dp).
i.e, Fd = F/Dp,
Here,
Tp is Pinion torque.
P is the wattage of motor in kw.
S2 is 1 for external gears and 1 for internal gears.
K is synthetic surface loading factor for RH.The value of K may be
selected from the table 11.1(attached).Thus in the above
calculation we calculate the Pitch diameter of the gear (Dp).
Now we have an empirical relation between the pitch diameter
and the center distance between the gears.
Dp = 2C/Mg + S2
Dg = Mg.Dp
Where,
C is the center distance between two gears.
Mg is the gear ratio i.e, N g / N p.
T = a.2tan n
The three most common types of gear tooth failure are tooth
breakage, surface pitting ,and scoring.
(a) Tooth breakage may be caused by an unexpected heavy
load imposed on the teeth .A more common type of
failure is due to bending fatigue, which results from the
large number of repetitions of load imposed on the tooth
as the gear rotates. A small value of the radius of the
fillet may accentuate the bending fatigue effects.
S = WtKoKvKsPKmKb/F J [3]
For proper design ,this bending stress must not exceed the design
stress value given by
S = Sat Yn/SfKtKr
Where :
Sat = the allowable bending stress(psi)
Yn= the stress cycle factor for bending strength
Sf = the factor of safety for bending strength
Kt = the temperature factor
Kr= the reliability factor
[3] Design of machine elements, M.F.Spoutts, T.E.Spoutts, Chap 10,Sec 10-22
Where :
Sc = Sac Zn Ch/Sh Kt Kr
Where:
Sac = the allowable contact stress for the material
Zn = the stress cycle factor for pitting resistance.
Ch = the hardness ratio factor for pitting resistance.
Sh = the safety factor for pitting.
Kt = the temperature factor.
Kr = the reliability factor.
[4] Design of machine elements, M.F.Spoutts, T.E.Spoutts, Chap 10,Sec 10-22
Design of Shaft
Shaft are classified in two broad categories :
(a) Machine shaft.
(b) Transmission shaft.
The machine shaft is used when motion has to be transferred
between two elements.The transmissoin is used where the power
has to be transmitted between two elements.In our case we have
both the machine shaft and transmission shaft in use.We have
three machine shaft and one transmission shaft in our drawing.
Let the Torque on the shaft from the motor be denoted by T.Now
the force developed by output surface i.e, tooth of gear will be,
Fg = T/R.P.M,
Taking moments about Rr .Now since the shaft has uniform weight
per foot of length so we can assume that total weight of shaft is
concentrated at the bottom of the shaft under consideration.
So,
L Lr _- Wg L/2 - Fg a = 0,
Lr L Rr
1./ Solid shaft in bending and torsion
Now we know the gear concentrated load and now we try to find
out the shear diagrams.
We know the reactions at Lr thus looking at the shaft we can
conclude that
VWG2 = VWG1 - Wg
VWG2 = (Fg a + Wg L/2)/ L L/2 223.2 Wg ,
Vr = VFG2
Thus, the final shear diagram will look somewhat like this :
Now we try to determine the required shaft diameter.We use the
method of maximum shear theory to size the shaft.We first
determine the equivalent torque Te.
Te = (Mm2 + T2)0.5,
Where :
Mm is the max bending moment.
T is the maximun torque acting on the shaft
Once the equivalent torque is known ,the shaft diameter d in is
computed from
d =1.72 (Te /s)1/3
1 = W1 L 3
/48 E I,
= 1 + 2
We must compare the two diameters and select the one which is
greater.
i= 2 Fs/Wk Ss
I = 2 Fs/ t Sc
Here, I = key thickness
Sc = allowable compressive stress.
We must check both the thickness and select one which is
greater.
DESIGNING PARTS FOR EXPECTED LIFE
N1 = 1000(Su/Sv)3log(Su/Se)
Having estimated the number of cycles we compute for the
exponent for the fatigue life equation.
The exponent for the fatigue llife equation is
2.55/log(Su/Se).
Thus,the factors needed for the fatigue life equation are
(Sv1/Svi), (Svi/Sv1)2.55/log(Su/Se) and i(Svi/Sv1) 2.55/log(Su/Se).
In these factors the value of Svi = Sv2,Sv3 and i = percent time
duration of a stress,its expressed as decimal.
Now we compute the part fatigue life in cycles.
Its given by
N = N1/1 + 2[ 1/( Sv1/Sv2)] 2.55/log(Su/Se) + 3[ 1/( Sv1/Sv2)]
2.55/log(Su/Se)
+ ----for each bending load.In this equation 1, 2
are percent time duration of a stress expressed as decimal.
[6] Standard handbook for Engg. Calculations, Tyler G.Hicks,section-3
CONCLUSION
The aim pf the project was to design a complete gear box
parametrically and it included a software programming part with
intraction with solid works.We have been able to work with solid
works and generate our design in it .But we have been unable to
write programms for that.There is a bright prospect for this
project and if completted it will be a great tool to work with .We
were also unable to include design of some parts like
,spring.diffrential,shifter.
LITERATURE SEARCH
We find some documentation at the following sources:
www.usedwheelchairs.com
www.syndesis.com
www.technical.manpower.com
www.patents.ibm.com
www.pms.com
www.shimano.com
www.dynamicmobility.co.nz
www.vesconite.com
www.selfube.com
www.invacare.com
www.motionnet.com
Guide du dessinateur industriel , A. CHEVALIER,
Hachette technique
Introduction to engineering design and graphics, G.
BEAKLEY & E. CHILTON
Design of machine elements M.F.Spotts.,T.E.shoup
Dudleys gear handbook:, Dennis P.Townsend