EGA-214 Supplemental Assessment Design

Brief (2018-2019)

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Contents
Introduction................................................................................................................................1

Conceptual designs.....................................................................................................................1

Concept 1...............................................................................................................................1

Concept 2...............................................................................................................................2

Concept 3...............................................................................................................................2

Preferred Conceptual design......................................................................................................3

Stress analysis............................................................................................................................3

Engineering Drawings................................................................................................................4

Material and Manufacturing.......................................................................................................5

FMEA.........................................................................................................................................6

Conclusion..................................................................................................................................7

References..................................................................................................................................7

Table of Figures
Figure 1: Concept 1....................................................................................................................2
Figure 2: Concept 2....................................................................................................................3
Figure 3: Concept 3....................................................................................................................3
Figure 4: Shaft stress analysis....................................................................................................5
Figure 5: Joint stress analysis.....................................................................................................5
Figure 6: Shaft factor of safety...................................................................................................5
Figure 7: Joint factor of safety...................................................................................................5
Figure 8: SHaft engineering Drawing........................................................................................6
Figure 9: Joint Engineering drawing..........................................................................................6
Figure 10: Manufacturing selection...........................................................................................7

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Introduction
In this design, three concepts of the universal joint are mentioned and one design among three
is selected based on the simplicity, compactness, manufacturing constraints. All designs can
be made suitable for the given specified requirement. But to make this possible the design
may need more material added or removed. In this project, the design is selected such that the
design must withstand the load requirement and at the same time the design must be able to
perform its function below its endurance limit to achieve the desired life. The design
specifications are given below

 The universal joint must be connecting the input and output shaft of diameter 25.4mm
with a thickness of 1.6mm.
 The design must withstand the torque of 6Nm and an axial load of 20N.
 The design must be able to bend till 45o from the axis of rotation.
 The design must be light in weight and cost-effective.
 The design is limited to 200 in any direction.
 The design must be durable and ensure environmental safety.

Conceptual designs
Concept 1

Figure 1: Concept 1

In this design, both input and the output shaft is connected to a single part joint. Both the
shafts have to be drilled on its sides near to the joint. Same type and size holes are created in

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the output shaft but the axis of the holes are perpendicular to the axis of the holes in the input
shaft.

Concept 2

Figure 2: Concept 2

In this concept, the input and output shafts are connected to a spherical part as in the above
picture. The shafts are connected to a sphere with four extended rodes at its four sides. These
rodes are connected to the input and output shafts.

Concept 3

Figure 3: Concept 3

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The spherical part in the second is removed and the shaft is connected with a ‘C’ bracket to
connect the joint. The connector is a combination of two rodes connected perpendicular but
in the same plane.

Preferred Conceptual design

All the three concepts are capable of withstanding the load and will also have the designed
life cycle. But each design needs the different volume of material added or ejected to make it
best fit for the applications. Since more material increases the material cost, as well as
manufacturing cost the prior factor considered in the selection of the design is the size and
simplicity of the design. Assuming the same materials are using for all designs, and different
other parameters considered for the ranking of the concepts are shown below.

Criteria Weight % Concept 1 Concept 2 Concept 3

Material weight 50 3 1 2
Size 20 3 2 2
Manufacturing 30 3 2 3
Score 3 1.5 2.3
Rank 1 3 2

From the ranking analysis, concept 1 is selected for the universal joint.

Stress analysis
Stress analysis is performed in solidworks2018. Both shaft and the joint is analyzed and the
results are shown below. Both results show that the given material selection and the
dimensions of the shaft are capable of withstanding the loads.

Figure 5: Joint stress analysis

Figure 4: Shaft stress analysis

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The static stress analysis shows that the factor of safety obtained for the shaft is 2.7 and the
factor of safety for the joint connecting the shafts is 1.1.

Figure 6: Shaft factor of safety Figure 7: Joint factor of safety

Engineering Drawings

Figure 8: SHaft engineering Drawing

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 Figure 9: Joint Engineering drawing

Material and Manufacturing

The material selected for the universal joint is aluminum 1016 alloy. The material properties
are shown below.

Property Range of values

Density 2500-2900 Kg/M3
Price 2.4-2.6$/Kg
Yield stress 30-500MPa
Melting point 450-650C
Embodied energy 200MJ/Kg
CO2 Footprint 13Kg/Kg
Recycle Possible

The amount of CO2 released per year for the production of aluminum 1016 is 13Kg/Kg. The
total energy used to produce this material is 200MJ/Kg. The selection of material will be the
best fir where the weight is needed to be less. The strength to weight ratio of aluminum 1016
is very height compared to steel.

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 Figure 10: Manufacturing selection

The above figure shows the different manufacturing process used for making 3D hollow
aluminum or alloys. Four manufacturing process is suitable for the design and shaping of this
material provided a hollow category. All the four manufacturing process are marked based on
the relative equipment cost as well as relative tooling cost. Out of these manufacturing
process, the less cost is selected and is Sand casting process. This analysis is considered for a
single piece production. When it comes to batch production pressing and sintering
manufacturing method will be considered in the analysis.

FMEA
The importance of failure mode analysis is the make sure the future operations of the design
goes well. Performing this analysis will help to maintain the performance of the design in
time. It also helps to avoid the issues like breakage of the parts due to unexpected load.

Failure Effects of Possible Severity Probability Detection Net Mitigation

mode Failure causes of
failure
Over load Breakage Additiona 10 4 4 16 Ensure the
l load 0 effective load
before
operation
Transverse Bending Bending 7 4 5 14 Avoid any
loading more than 0 transverse
allowed loading during

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 operation
Loosening Transmission Improper 7 2 8 11 Take
of parts loss caring 2 appropriate
care before the
operation and
proper
maintenance

Conclusion
The analysis of the universal joint is performed with the help of the Solidworks software tool.
Suitable design is selected from the three concept design based on the size and weight of the
design. The less weight and size is selected and the material selected is aluminum 1016 alloy.
The stress developed in the design is less than yield and the factor of safety obtained is 2.2
for the shaft and 1.1 for the connecting part. Failure mode analysis is performed to forecast
the failure may take place due to several changes. Four different manufacturing process is
suitable for this design and the one among four is selected based on the relative tool and
equipment cost. The best manufacturing process suitable for a single piece of the universal
joint is sand casting.

References
 Lu, M. (2012). Computer-Aided Design Technology in the Application of Modelling
Design of Shaft Parts. Applied Mechanics and Materials, 246-247, pp.1255-1259.
 Bansal, R. (2015). A textbook of the strength of materials. New Delhi: Laxmi
Publications.