Gear Box Design

Project presentation ME 423: Machine Design

Overview
A machine consists of a power source and a power transmission system, which provides controlled application of the power. Transmission is an assembly of parts including the speedchanging gears and the propeller shaft by which the power is transmitted from an engine to a live axle. Often transmission refers simply to the gearbox that uses gears and gear trains to provide speed and torque conversions from a rotating power source to another device.

Objective
To build a gearbox for a electric run motor car:
Minimize travel time required for a run on a straight route Minimize the cost of the gearbox Minimize the weight of the gearbox Maximize the performance and durability Maintain aesthetic design

Design Steps
Geometry of gears
Type of gear, module, no. of teeth, etc. Using C++ code and ANSYS

Design of shafts and bearings

Using force calculations

Design of Casing
As per final gear design and ANSYS

CAD
Dimensions of gears:
First Pinion = 20* mm and Module = 2 First Gear = 18 mm and Module = 2 Second Pinion = 24* mm and Module 2.5 Second Gear = 22 mm and Module 2.5

Dimensions of Shafts:
(for relaxed condition of only max torque=60Nm) OD 25mm shafts (for a conservative design: FOS=3 and max torque=60Nm) OD 36mm shafts

CAD
Dimensions of bearings:
ID=35 OD=62 T=18 wt=224 gm ID=25 OD=52 T=19.25 wt=187 gm ID=35 OD=62 T=21 wt=263 gm

Outer Shaft

tapered roller (single row)

32007 X/Q (From SKF)

Intermedia te Shaft
Input shaft

tapered roller (single row)

tapered roller (single row)

32205 BJ2/Q (From SKF)

32007X (From SKF)

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Code
For design of gears, Shigleys Mechanical Engineering Design was referred to Design analysis was carried out for both spur gears and helical gears

Allowable Bending Stress

Bending Stress Number

Stress Cycle Factor

Reliability Factor
For a reliability of 95%, the following equation was used:

Other Factors
Temperature factor = 1 for temperatures less than 120o C Factor of safety is taken to be 1

Output

Shaft Design
3 types of shaft
Connected to motor on which pinion is attached Intermediate Connected to wheel drive

Steps:
Calculated radial, axial and tangential forces from helical gear design provided for both interfaces of gear and pinion. Used maximum torque of 60Nm that motor can provide for calculation (though in steady state the torque will be less) Accordingly calculated axial and radial forces on shaft

Shaft design (continued)

Plotted moment diagram and torque diagram and found critical point on shaft Material used was SAE 4340, got max here. Used factor of 0.75 as the location was gear location. Used FOS of 3 to get new max as max/FOS Now used this value to get lower bound on OD of shaft Repeated the procedure for all the 3 shafts

Design of Bearings
To account for axial forces, used Tapper Roller Bearing Because, they can take large axial forces (i.e., they are good thrust bearings) as well as being able to sustain large radial forces. Commonly used for moderate speed, heavy duty applications where durability is required. We can also use Deep Groove Ball Bearings(calculations for this are provided, if we want to use ball bearings), But Its life is limited and does not fulfill our requirement .

Taper Bearing Design Steps

Given: Fa, Fr, Shaft diameter(OD) (for all three shafts) L= millions of revolutions (50,000 Km) L10>L (~170 millions of revolution) (for D=22 in for tyre) Also Our bearing should be of light weight Used a catalog available online (reference is given) Choose bearing(initially of minimum weight available) Calculate L10 for that bearing (SAE 50-oil is used for calculation) Check for L10>L. If L10<L, take next light weight bearing. Similar analysis for all three shafts. m1= 0.224kg(32007 X/Q) (L10=~220 millions of revolution) M2=0.190kg(32205 Q)(L10=~310 mr) M3=0.520kg(30307 RJ2/Q)(L10=~700mr)

Ball Bearing calculations

For the Shaft Connected to motor on which pinion is attached SKF bearing no. 6307 Fa=4112N, Fr=4825.25N, Shaft Speed= 5500rpm C0=17600N, C=26000N, Limiting Speed (SL)=8000rpm Fa/C0= 0.2336 From Page 4.4, DDB: closest to 0.2336 Fa/C0 -> 0.25 As Fa/Fr >e -> X=0.56, Y=1.2 P=XFr+YFa= 7636.54N L10= (C/P)^3 = 40 million revolutions < L (~ 170 mr) , hence not ok Also its weight is higher(0.46kg) than taper roller bearing (0.22kg) for the shaft connected to the motor. Hence working with Taper Roller Bearing is much better.

References
http://www.skf.com/skf/productcatalogue/jsp/calculation/calc ulationIndex.jsp http://www.irusa.com.br/catalogos/timken/usa_chap_1.pdf

ANSYS
Purpose:
ANSYS was used to
confirm the output of C++ code Ansys Analysis decrease the weight of gears design casing decrease weight of casing confirm shaft calculations

Optimization of weight of Gears

Initially used conventional arms for both gears as taught in the course
But these arms were heavy So, thought of using other profiles than arms

Used circular patterns to remove the material

Did static structural analysis in Ansys Iterative process of removing material and simulating it Maximum material was removed keeping FOS > 3

Gear 1 (FOS)

Gear 1 (Total Deformation)

Gear 1 (Von-Mises Equivalent Stress)

Gear 2 (FOS)

Gear 1 (Total Deformation)

Gear 1 (Von-Mises Equivalent Stress)

Casing
Initially used MS casing
but too heavy (from solidworks CAD model) used Al for casing

Initially made casing with 15 mm thickness (starting guess)

Did Ansys analysis for it and found out it is overdesigned Then designed the casing with 10 mm thickness This design was also overdesigned at some places Then designed a casing with thickness 5 mm at some places and 10 mm at other, using Ansys analysis to minimize the weight

FOS (min value = 3.9)

Total Deformation (max value = 12 microns)

References
Motor Specification: http://agnimotors.com/95_Series_Performance_Graphs.pdf