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Design Project of Shaft PDF
Design Project of Shaft PDF
INTRODUCTION
Project Objective
It was required to design a hub assembly and
halfshafts for the Formula 1 car of mass about
640 kg, maximum speed of 300 km/hr and
average speed of 150km/hr.
The assembly must give stability during rotation
of the wheels. The weight and the dimension of
the hub must be as small as possible because of
the unsprung weight which further reduces the
rotational mass. The half-shafts should not fail
under stress.
RB7 F1 is the official car from World Champions Red Bull for the 2011 season of
Formula 1. We have considered this vehicle as a reference for this Design Project
as it is one of the fastest and most technologically matured vehicle in the racing
scenario.
Half - Shafts
A half - shaft is an axle on a front wheel
drive vehicle connecting the transmission to
the driven wheels.
The rear wheel driven Formula 1 vehicle
being observed for the project uses half shafts
in rear, as the differential is rigidly mounted
and an independent rear suspension is used.
Design Consideration
Half shafts are designed as
a hollow metal tube to reduce weight.
CV joint at either end, allowing the driven wheels
to maintain constant velocity .
Splines to transmit power between differential, CV
joints, shaft and wheel hub.
the suspension travels during driving.
fatigues due to high speed rotation.
Wheel-Hub
A hub assembly contains the wheel bearing,
and the hub to mount the wheel to vehicle.
It is located between the brake rotors and axle.
Design Consideration
The bolt pattern is determined by the number
of bolts on the wheel hub.
Selection of material strong enough to take the
weight of the car.
Wheel bearings in the hub depending on ID
and OD of spindle coming out of hub.
Type of lug nuts or bolts.
LITERATURE
REVIEW
2006
The author says that numerical investigation of wheel dynamics impact and
cornering fatigue performance is essential to shorten design time , enhance
mechanism performance and lower development costs. The desertion
focused on two objectives:
i) Finite element models of a dynamic impact test on wheel and tire
assembly were developed which considered the material in homogeneity
of wheels. Comparison of numerical predictions with experimental
measurements of wheel impact indicated 20% reduction of initial striker
kinetic energy provide an effective method for simplifying modeling.
ii) numerical prediction of wheel cornering fatigue testing was considered.
It proceeded in two methods, first was static stress analysis with bending
direction applied to the hub. Second was dynamic stress analysis with
application of a rotating bending moment applied to hub.
PRELIMINARY
PRODUCT DESIGN
Isometric View
L
Do
Di
T
J
G
Length of shaft
Outer diameter of shaft
Internal diameter of shaft
Maximum Torque applied by
differential on shaft
Maximum Normal Stress on shaft
Maximum Sheer Stress on shaft
Polar Moment of Inertia of shaft
Modulus of Rigidity
Wheel Hub
S
W
P
Number of Bolts
Bolt Circle Diameter or
Pitch Circle Diameter
Flange diameter is measured
between opposite holes
Spoke hole diameter
Width centre to flange
Load capacity is the amount of
weight a wheel will carry
THEORETICAL
DESIGN
Half - Shaft
GIVEN :
280 N-m
=
1.833
=
2.15
Material selection:
The material chosen for the design of Half shaft is ion nitrided titanium
alloy.
The titanium and titanium alloys have unique corrosion, nonmagnetic
and
strength to-weight ratio properties.
Mechanical properties of nitride titanium alloys are as follows:
Yield stress
=
1.24105631 109 Pascal
Maximum Sheer Stress
=
0.62052815 109 Pascal
= 22882.115
do = 28.39 mm
Or, do = 29 mm.
Therefore, di = 29/5
di = 5.66 mm.
From the design calculation we find that the required external and internal
diameter of the half shaft as per the specified engine parameters and given
conditions is 29 mm and 5.6 mm.
Wheel-Hub Assembly
Tires and rims selection:
The tires selected were of 13 diameter. The diameter was selected as
such that floor of the formula car does not touch the ground. At the same
time a low ride height would give an aerodynamic as well as low Centerof-gravity advantage.
Number of bolts is taken 4 as it is a standard for 13 wheels.
Pitch Circle Diameter(P.C.D.) is fixed at 100 mm as it is a standard for
13 wheels.
Spoke Hole Diameter(S) is taken as M12 as it is a standard for 13
wheels.
Material : Ti6Al4V - titanium alloy is the most widely used .
Brake Calculation
:-
Velocity of Vehicle
Frictional force will be acting on it
Stopping distance
=
=
=
vo
F
d
Friction force of the road must do enough work on the car to reduce its kinetic
energy to zero .
To reduce the kinetic energy to zero
Workfriction = mgd = 0.5mv02
d= vo2/2g
Velocity of our vehicle
Friction of road
d
=
=
=
150 km/hr
0.90
98.31 m
vo2
= u2 + 2ad
=
=
0.2595 m
365.35 N-m
Torque on disc:Tdisc
Ffriction*reffective
=
=
25647.012 / 9
2849.67N
Ffriction/
= 2849.67/0.5 = 5699.34 N
SOFTWARE
ANALYSIS
Factor of Safety = 2
Safe Design
DETAILED PRODUCT
DESIGN
Half - Shaft
Material = ion nitride titanium alloy
Yield stress
= 1.241 x 109 Pascal
Max. Shear stress
= 0.62 x 109 Pascal
Engine characteristics
N = 1400 rpm
T = 280 N-m.
First gear ratio
= 2.833
Final drive ratio
= 2.15
Shock torque
= 2758.665 N-m.
K, d0/di
=5
External dia.
= 29 mm.
Internal dia.
= 5.6 mm
Wheel hub
Tyre dia.
No. of bolts
Pitch circle dia.
Spoke hole dia .
Material
Stopping distance
Velocity of vehicle
Acceleration of vehicle
Force on each wheel
Torque on tyre (R-13)
Diameter of disc
Effective radius
Clamping force
Width of flange
= 13
=4
= 100mm.
= M12
= Ti6Al4V titanium alloy
= 98.31 m.
= 150 Km/hr.
= 8.8 m/s2.
= 1408 N.
= 388.75 N-m.
= 200 mm.
= 90 mm.
= 8638.86 N.
= 10 mm.
conclusion
Wheel Hub has been designed for a formula 1 car of mass about 640 kg,
maximum speed of 300 km/hr and average speed of 150 km/hr.
The weight and dimension of the hub is such that it reduces the rotational
mass.
The design project enabled us to understand the various forces that act on a
half shaft and wheel hub, while the Formula 1 race car is in running
condition.
The calculated parameters help us to design half - shaft and wheel hub
such.
The design project helped to better under the uses of software in real
scenario.
10
B Literature review
Develop preliminary
C product design
D Theoretical Design
E CAD modelling
F Software analysis
G Optimization of design
Develop detailed product
H design
Final Presentation
I Compilation
***Please note that the weeks mentioned above doesnot contain the CAT weeks.
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