Machine Component Design Project

Agenda
Overview Design Objectives Process Flowchart Data Analysis Material Selection Design Proposal

Overview
Our design labor consist in the design process of a V-belt speed reduction shaft for a given mechanism with fixed forces and torque. The model consist of two rotating pulleys with different diameters connected to a shaft linkage.

Shaft Design
Defining Problem Design objectives

Static Analysis
Defining forces and reaction Shear and momentum diagrams Critical Point

Stress analysis
Safety factor selection Material Selection Information research Solve for optimal Diameter

Design Proposal

Design Objectives
Construct a shaft with a safety diameter that can handle the forces created by the rotating belt tension Choose a material that is both reliable and economic viable Build a design that can be easily manufactured Accomplish with all the standards of good engineering practice

Static Analysis
The forces in the space are divided in to two different plane components, plane XY, and plane XZ The analysis will be consider at the surface point in the shaft critical point. Gravitational forces are neglected

Static Analysis

Pulley B

Pulley D

Static Analysis

Point C

Point A

Static Analysis
2552.18 N 2262.36 N

371.147 N Forces in Plane XZ 3580.43 N

4443.367 N

374.31 N

1640.49 N Forces in Plane YZ

2314.259 N

Static Analysis

Shear through the shaft in the plane XZ

Shear through the shaft in the plane YZ

Static Analysis

Momentum through the shaft in the plane XZ

Momentum through the shaft in the plane YZ

Static Analysis
160 140 120 100 80 Momentum 60 40

136.59 N-m Critical Point

20 0
0 50 100 Axis Title 150 200 250

Static Analysis
0

0
-50 Torque (N-m) -100 -150 -200 -250

50

100

150

200

250

254.5 N-m -300 Shaft Length (m)

Data Analysis
We selected a Safety factor of 2.5 because it is a dynamic system that will be under cyclic stresses. We assumed the step on the shaft between pulley b and bearing C to have a diameter of 40 mm.

point B stress Analysis: d1

Sigma Bending

Shear Stress

point C stress Analysis: d2

Sigma Bending

Shear Stress

Material Selection

The material selection process is reduce and analysis is reduced to steel materials. This due the reliability and value of this well known and very often used material. Ceramics, polymers, composites and other metals where unconsidered because the superiority of steel alloys, the availability and value in the industry

Material Selection
Three specific Steel alloy are considered :
: Low carbon steel use in many application because ins malleable, ductile and cheap, but it cannot be heat treated. : Medium carbon have a good balance between yield strength and ductility. : High carbon steel have a high hardness and yield point but it have a low ductility.

Material Selection
Properties of the considered materials

Property Elastic modulus (Gpa) Poison Ratio Yiel Strenght (Mpa) Elongation to fracture Hardness @ T=25

High Carbon Steel 1055 Low carbon Steel 1010 Medium Carbon Steel 1045 190 190 190 0.3 0.3 0.3 560 305 505 10% 20% 12% 197 105 170

Diameter Calculation
Using the DET theory:

Using the MSS theory:

Diameter calculations
Point C :

Diameter calculations
Point B :

Value found by Iteration In Excel

Stress Concentration

Diameter - Stress Concentration

Slope and deflection

Slope in Plane XZ

Deflection Plane XZ

Slope and deflection

Slope in Plane YZ

Deflection Plane YZ

Questions ?

Resources

MD Solids 3.5 software. www.mdsolids.com http://www.efunda.com/materials/alloys/carbon_steels/list_ca rbon.cfm?m=ais&Page_Title=AISI%2010xx&ID_Low=AISI_1 0 http://www.efunda.com/materials/alloys/alloy_home/steels.cf m http://www.metalsupplies.com/mild-steel-rounds.html