Department of Mechanical Engineering

Program: BSc Mechanical Engineering Course: Machine Design & CAD-I

Assignment: Problem Based Learning Session: 2018, 4th semester
Submission Date: 01/05/2020 Maximum Marks: 20
Instructions:
i. Submit PBL on Turnitin (Class ID and Enrollment key will be communicated separately)

Problem statement:

A gear reduction unit uses the countershaft shown in the figure. Gear A receives power from
another gear with the transmitted force FA applied at the 20° pressure angle as shown. The power
is transmitted through the shaft and delivered through gear B through a transmitted force FB at the
pressure angle shown. The material is AISI 1018 cold-drawn steel. The gears seat against the
shoulders and have hubs with setscrews to lock them in place. The effective centers of the gears
for force transmission are shown. The keyseats are cut with standard endmills (Assuming r / d =
0.02 for typical end-milled keyway cutter) . The bearings are press-fit against the shoulders.
(a) Determine the force FB, assuming the shaft is running at a constant speed.
(b) Find the bearing reaction forces, assuming the bearings act as simple supports.
(c) Draw shear-force and bending-moment diagrams for the shaft. (use MS Excel)
(d) At the point of maximum bending moment, determine the bending stress and the torsional
shear stress.
(e) Determine the minimum fatigue factor of safety using the DE-Gerber failure criterion.
(f) Sketch a general shaft layout on SolidWorks
 Figure: All fillets are of 2 mm. Dimensions in mm

Hint:
1. Critical locations
• keyway at A
• shoulder to the left of C
• shoulder to the right of C
2. Use table from Shigley for Stress concentration factors, Material properties
3. Take into consideration only the size and surface correction factor for defining the
endurance limit
4. Gear type: Spur gear
5. Assume dimensions (If missing)
6. 𝑋 = 4 ∗ 𝑅𝑒𝑔𝑖𝑠𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑛𝑢𝑚𝑏𝑒𝑟(𝑓𝑜𝑟 1𝑠𝑡 100 𝑟𝑒𝑔𝑖𝑠𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑛𝑢𝑚𝑏𝑒𝑟)
7. 𝑋 = 1.5 ∗ 𝑅𝑒𝑔𝑖𝑠𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑛𝑢𝑚𝑏𝑒𝑟(𝑓𝑜𝑟 𝑟𝑒𝑔𝑖𝑠𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑛𝑢𝑚𝑏𝑒𝑟 > 100)