To: Dr.

PeterLaz

From: AlishaAlomia,MattMinuti,AriannaVierczhalek

Subject: ShaftandGearDesign

I.Purpose

Thepurposeofthisprojectwastodesignashaftthatcontainedgears,bearings,keysandpressfits.
Analysiswasusedforthefourdifferentcomponentstoensurethedesignwouldlast20yearsforfive
tenhourdaysaweek.Forthekeysandshaftssteelwasusedallowingustoassumetheendurancelimit
washalfoftheultimatestrengthensuringinfinitelife.Thelifegivenwastakenintoaccountfortheboth
thegearsandthebearingstoensuretheywouldlastatleastthespecifiedlife.Becauseweweregivenan
unexpectedoutagecostoffiftythousanddollarsperdaywewantedallofthepartstomeetasafety
factorofatleasttwo.

II.Analysis

IIA.GearRatio

Theanalysisbeganbydeterminingthetotalgearratioofthesystemandthenusingtheintermediate
ratiostoequaltheoverallgearratio(equation12.8).Fromthiswewereabletodeterminethenumber
ofteethineachofthegearsandpinions.Anarbitraryvaluewasusedforthediametricalpitch.These
valueswerethenusedtofindthediameterofthegears.Knowingthegeardiameterallowedustothen
findtheforceateachofthegears(equation1).

IIB.SingularityFunctions

Singularityfunctionswerethenusedtofindthereactionforcesateachofthebearingsaswellasthe
shearandmomentdiagrams.Themaximummomentwasdeterminedfromthediagram.Becausethe
shaftloadwasundersteadytorquewewereabletoassumethemaximummomentwasequivalenttothe
alternatingmoment,theminimummomentwasequivalenttothemeanmoment,themaximumtorquewas
equivalenttothemeantorqueandtheminimumtorquewasequivalenttothealternatingtorque.

IIC.ShaftAnalysis

Afterusingfreebodydiagramsandsingularityfunctionstodeterminethemomentsandreactionforces,
wewerethenabletodoshaftanalysis.Themainpurposeoftheshaftanalysiswastodeterminethe
1

diameteroftheshaftthatholdsuptothesafetyfactoroftwo.Wemadesuretochoosesteelasthe
materialsothattheshaftwouldhaveinfinitelife.Equation10.8wasusedtofindtheshaftdiameter.The
modifiedendurancelimitwasfoundusingknockdownfactorsandthealternatingandmeantorquesand
momentswerefoundinprevioussteps.The wasdeterminedfromtable1016usingar/dratioof K
t

.02.Knowing andq(table63)thefatigueconcentrationsofthekeyandinterferencefitintheshaft K
t

wereabletobedeterminedusingequation6.11b.Afterfindingthediameteroftheshaftalarger
diameterwasthenchosentoallowustofindbearingsthatwouldfitthediameter.

IID.BearingAnalysis

Thebearingswerechosenusingtheknownreactionforcesandthelifethatwasgiven.Thebearings
weredeterminedsothatthelifewouldbeatleastthegivenlife.Equation11.20cwasusedtodetermine
theloadthateachbearingwouldneedtowithstandusingareliabilityfactorthatwasbasedonninety
percentreliability(Table115).Afterdeterminingtheneededloadbearingswerechosenthathada
minimumloadoftheneededload.Oncethebearingswerechosenequation11.20awasusedto
determinethelife(L10).ToensurethecorrectbearingwaschosenL10wastobelargerthanthelife
thatwasgiven.

IIE.KeyAnalysis

Keyanalysiswasthenperformed.ThewidthofthekeywasfoundfromTable102usingtheknown
shaftdiameter.Thematerialsofthekeyswereastandardcoldrolledsteel.Thekeyswerechecked
againstbothshear(equation10.10)andbendingfailure(10.11).Vonmisesequivalentstresses
(equation5.7d)werecomputedtouseinequation6.18todeterminethelengthofthekey.The
endurancelimitwasfoundknowingthekeymaterialandapplyingtheknockdownfactors.After
determiningthekeylength,therealisedsafetyfactorandbearingstresssafetyfactorswerefound.Itwas
essentialthatthesafetyfactorswereatleasttwo.Ifnot,astrongermaterialhadtomechosentoensure
itmetthecriteriaofasafetyfactorofatleasttwo.

IIF.InterferenceFit
Theinterferencefitislocatedonthesecondshaftandusedforboththegearandtheidlerpinion.The
theassumedshaftmaterialwasnotadequatewentimplementingapressfitof.002.Thepressfitwas
foundbyusingtheruleofthousands.Theresultantsafetyfactorwasdeterminedusingequations
(10.14a,10.15a,10.16a).Toreachthesafetyfactorof2theshaftmaterialof1020steelwasreplaced
with1035steelthisimprovementresultedinanadequatesafetyfactor.Theassumeddiameterwas
chosentobeproportionallypracticalinrelationtothegear.

IIG.GearAnalysis

Thelastpartofthedesignprocedurewastodesignandanalyzethegears.Thegearsweretobe
designedusinga20degreepressureangleandfulldepthteethwithHPSTCloading.Knowingthis,table
129wasusedtodetermineJ(geometryfactors).Withanarbitrarypitchdiameterandknowngearratio,
thenumberofteethoneachpinionandgearwereabletobedetermined.Tobegintheanalysis,thepitch
velocity(equation2)hadtobefoundtofindthequalityofindexfromtable127.Afterfindingthe
qualityofindex,thedynamicfactorwasthenfoundfromfigure1222andequations12.17a,12.17b
and12.16us.Thetangentialforcewasfoundusingequation12.13a.Thebendingstresswasthen
determinedusingequation12.15us.Afterfindingthebendingstress,thecorrectedbendingfatigue
strengthwasthenfoundtodeterminethesafetyfactor.Thebendingfatiguestrengthwasfoundfrom
table1220andtheknockdownfactorsKt,KrandKlwereused.Thecorrectedbendingfatigue
strengthandbendingstresswerethencomparedtoeachothertofindthesafetyfactor.

Thesurfacefatiguewasfoundsimilarlytothebendingfatigue.Thesamestepsweretakenexcept
equation12.21wasusedtofindthesurfacestress.Thesurfacegeometryfactorwasfoundusing
equation3andtheelasticcoefficientwasfoundfromtable1218.Thestresswascomparedtothe
correctedsurfacestrengths(equation12.25,table1220)todeterminethesafetyfactor.

III.ProjectSummary
Theoverallprocessofofthisgeartrainprojectinvolvedhoursoftediouscalculationsandrecalculations
inordertomakesurethatallofthesafetyfactorswereinareasonablerange.Thestepsthatwere
takenseemedmostlogicalinthebeginning,butlaterrealizedthattheshaftsizeshouldhavebeen
computedafterthebearingsizeswerepicked.Thisisduetothefactthatthebearingsarethemost
expensivepartintheassembly.Thecourseofanalysistakenstillworkswithdeterminingtheshaft
diameterbeforethebearing,itjustisn'tthemostcostefficientdesign.Thisledtothebearinglifetobe
waybeyondtheneededlifecyclethatwasrequiredforthisproject.Besidesnotbeingthecheapest
design,itisthesafestwithallsafetyfactorsabove2withmostinthe56range.Thisensuresthatwith
thechosenmaterialthatthedesignshouldholdupforpastthe20yrdesignlife.Also,thevaluesthat
werecomputedforeachshaftwerecomparedagainsttheothershaftsanalysistomakesurethatthe
pitchvelocityandforcesonthegearalllineupwitheachother.Thefinaldesignpresentedmeetsall
requirements,butsomeofthepartschosenarenotstandardgearsizesorteeth.Besidessomeofthe
realworldapplicationissuesthatcouldarisefromthisdesign,itisanalyticallysound.Overall,the
projectshowedaglimpseatanactualmachinedesignproblemthatcouldbefacedwhenworkingasan
engineerandthechallengesthatcomewithit.

AppendixAEquations

+ m
v= (
N
3
N
2
)

(
N
4
N
3
)

(
N
5
N
4
)

(
N
6
N
5
)
=
N
2
N
6
(equation12.8)

F =
T
(d/2)
(equation1)

d =
{
32N
f

[ S
f

(K M ) + (K T )
f
a
2
4
3
fs
a
2
+
S
ut

(K M ) + (K T )
fm
m
2
4
3
fsm
m
2
]}

3
1

(equation10.8)

L
10
=
(
C
P
)

3
(equation11.20a)

L
p
= K
r (
C
P
)

3
(equation11.20c)

xy
=
F
A
shear
(equation10.10)

x
=
F
A
bearing
(equation10.11)

x
2
+
y
2

x y
+
xy
2
(equation5.7d)

N
f
=
S S
f ut
S + S a
ut
m
f
(equation6.18e)

(P ) V
t d
=
2
d(P ) n
d *
(equation2)

0 6(1 ) A = 5 + 5 B (equation12.17a)

B =
4
(12Q ) v
3
2
(equation12.17b)

K
v
=
(
A
A+

V
t
)

B
(equation12.16us)

W
t
=
Np
2p T
d
p
(equation12.13a)

K K K
b
=
FJ
W p
t d
Kv
K K a m
s
B I
(equation12.15us)

I =
(
2
sin()cos()
)
Ng
N +N p g
(equation3)
4

S S
f b
=
K
L
K K
T R
f b
(equation12.24a)

S S
f c
=
C C
T R
C C
L H
f c
(equation12.25)

(equation10.14a) p =
.5
( +v )+ ( v )
r
E
0
r +r
2
0
2
r r
2
0

2
0
r
E
i r r
2
i
2
r +r
2
i
2
i

(equation10.15a)
t
shaft
= p
r r
2
i
2
r +r
2
i
2

(equation10.16a)
t
hub
= p
r r
2
0
2
r +r
2
0
2

(K ) K
f
= 1 + q
t
1 (equation6.11b)

AppendixBFinalValuesforEachShaft
5

Shaft1(Alisha) Shaft2(Arianna) Shaft3(Matt)

ReactionForce1(lb) 80 120 80
ReactionForce2(lb) 40 120 40
GearForce1(lb) 120 120 120
GearForce2(lb) N/A 120 N/A
(rpm) 750 296 187.5
MaximumMoment
(lbin)
320 480 320
MinimumMoment
(lbin)
0 0 0
MaximumTorque=
MeanTorque(lbin)
150 380 600
MinimumTorque=
AlternatingTorque
(lbin)
0 0 0
ShaftDiameter(in) .85 2 1.125
RightBearing S90K MM311K 9306k
LeftBearing S90K MM311K 9306k
KeyWidth(in)

.187 N/A .25

Key
Length/Interference
Fit(in)
.242588 .002 .70
RealisedSafety
Factor
2 2.217 6.42
ShearSafetyFactor 2.8277 N/A 21.65
GearBendingStress
SafetyFactor
5.31748 5.23 5.84
GearShearStress 2.1 2.1 5.69
6

SafetyFactor

AppendixCReferences
7

Norton,RobertL.MachineDesign:AnIntegratedApproach.N.p.:n.p.,n.d.Print

"QuickLinks."TheTimkenCompany.N.p.,n.d.Web.12Mar.2014.

AppendixDCalculations
8

AppendixECADDrawings
9