Assignment Cover Sheet

Student Details

1 0 4 9 8 8 5 0
Student Number
1 0 5 0 4 2 8 3
1 0 5 0 3 2 7 5
1 0 5 0 0 8 6 5

Palle Gedara Nilanka Keerthi Bandara

Family Name Given Name
Weerasekare Kalum Salinda
Rathnayakage Pradeep Dulan
Baduge Hiranya Janitha Sankalpa

Unit Details

Unit Title
Unit Code ENS5114 Advance Mechanical Design

Name of Lecturer Due Date

Dr Ferdinando Guzzomi 02/11/2020
Major Project – PDS
Topic of & Load Calculations Group or Tutorial (if
10
Assignment applicable)
Master of Engineering & Batchelor of Engineering in
Course Mechanical Campus
JO
I certify that the attached assignment is my own work and that any material drawn from other sources has
been acknowledged. This work has not previously been submitted for assessment in any other unit or course.
Copyright in assignments remains my property. I grant permission to the University to make copies of
assignments for assessment, review and/or record keeping purposes. I note that the University reserves the
right to check my assignment for plagiarism. Should the reproduction of all or part of an assignment be
required by the University for any purpose other than those mentioned above, appropriate authorisation
will be sought from me on the relevant form.

1
Table of Contents
1.0 Design Report ................................................................................................................................................... 4
1.1 Product Design Specifications. ............................................................................................................... 4
1.1.1 Customer Needs ..................................................................................................................................... 4
1.1.2 Performance under specified conditions ................................................................................................ 4
1.1.3 Standards and Specifications ................................................................................................................. 4
1.1.4 Sizes and Dimensions ............................................................................................................................ 4
1.1.5 Materials ................................................................................................................................................ 4
1.1.6 Performance, Quality and Reliability ..................................................................................................... 5
1.1.7 Cost ........................................................................................................................................................ 5
1.1.8 Ergonomics ............................................................................................................................................ 5
1.1.9 Safety ..................................................................................................................................................... 5
1.1.10 Aesthetic .............................................................................................................................................. 5
1.2 Evaluation of Concepts ................................................................................................................................. 6
1.2.1 Different Concepts ................................................................................................................................. 6
1.2.2 Locking fixtures for the gear shaft ......................................................................................................... 9
1.2.3 Linking Mechanism ............................................................................................................................. 10
1.3 Final conceptual designs ............................................................................................................................. 12
1.3 Materials and Manufacturing Details. ......................................................................................................... 13
2.0 Design Report ................................................................................................................................................. 15
2.1 Load Calculation ......................................................................................................................................... 15
2.2 Stress and fatigue calculations for life analysis .......................................................................................... 19
2.2.1 Calculation for threaded rod ................................................................................................................ 19
2.2.2 Design for nut ...................................................................................................................................... 24
2.2.3 Calculations for planetary gear system design ..................................................................................... 26
2.2.4 Calculations for Input motor shaft ....................................................................................................... 32
2.2.5 Calculation for Input shaft Bearing ...................................................................................................... 35
2.2.6 Calculation for Input shaft key way: .................................................................................................... 36
2.2.7 Calculation Planet gear pin stress ........................................................................................................ 37
2.2.9 Calculation of Diameter and Fatigue Life for Gearbox Housing-Truck Bed Mounting Shaft (Pin) ... 39
2.3 Finite Element Analysis of structural gearbox housing .............................................................................. 47
3.0 References ................................................................................................................................................... 53
4.0 set of manufacturing drawing ......................................................................................................................... 54

2
Figure 1 Planetary gear system Invalid source specified. ...................................................................................... 6
Figure 2: Two-stage compound helical gear train (Richard G.Budynas, 2011) .................................................... 7
Figure 3:Two-stage compound spur gear train (Richard G.Budynas, 2011) ......................................................... 8
Figure 4:Spur Gear (KHK Gears, n.d.) .................................................................................................................. 8
Figure 8 - Figure 5:Tapered Shaft (KYOUIKU, 2005) ........................................................................................ 10
Figure 10 - Figure 6:Worm gear (Black, Machinery lubrication, n.d.) ................................................................ 10
Figure 7:Circulating Ball Screw and Belt Drive: Image : New port(n.d.) ........................................................... 11
Figure 8:Lead Screw............................................................................................................................................. 12
Figure 9:Warm Screw ........................................................................................................................................... 12
Figure 10: Freebody diagram for the load calculation ........................................................................................ 15
Figure 11:Terminology of screw threads. Sharp vee threads shown for clarity; the crests and roots are actually
flattened or rounded during the forming operation ............................................................................................. 21
Figure 12:Thread selection for screw drive ........................................................................................................... 21
Figure 13:Acme or trapezoidal threads................................................................................................................. 22
Figure 14: Forces acting on the screw thread ....................................................................................................... 22
Figure 15:planetary FBD diagrams and Angular velocities ................................................................................... 27
Figure 16:Key way selection .................................................................................................................................. 36
Figure 17 Truck Bed-Gearbox Pin Assembly .......................................................................................................... 39
Figure 18:FBD of Bin Arm ...................................................................................................................................... 40
Figure 19:Actuator-Gearbox-Truckbed position and Freebody Diagram for actuator and gear box housing...... 41
Figure 20:Freebody Diagram for forces acting on Gearbox-Truck bed connecting shaft when unloading skip bin
.............................................................................................................................................................................. 41
Figure 21:Freebody Diagram for forces acting on Gearbox-Truck bed connecting shaft when loading skip bin . 43
Figure 22:Some of the Constraint applied to Gear Box Housing ........................................................................... 48
Figure 23:Moment applied with using tangential force of the Ring Gear ............................................................ 48
Figure 24:Pressure applied with using radial force of the Ring Gear .................................................................... 49
Figure 25:Error message due to large number of elements/nodes ...................................................................... 49
Figure 26:Final Mesh appearance ......................................................................................................................... 50
Figure 27:Total Deformation results of Gear Box Housing ................................................................................... 51
Figure 28 : Equivalent Stress (Von-Mises) results of Gear Box Housing................................................................ 52

3
1.0 Design Report

This design report is aimed to design a gearbox for operating a linear actuator which is used to load and
unload a skip bin of a truck safely. The actuator is operated by a nut driven power screw shaft where nut
is connected to the gearbox which is powered by a hydraulic motor to transfer adequate torque to the
actuator for retract and extend motions. In the complete design hydraulic motor and gearbox should be
designed as one single device which is mounted to most as a structural member.

1.1 Product Design Specifications.

1.1.1 Customer Needs

 Gear design
 Shaft design
 Fastener sizing
 Bearing selection
 Gear housing design
 Designing of nut driven threaded rod actuator
 Seals and clips

1.1.2 Performance under specified conditions

 Lift the bin from the truck bed and land it on the ground which is 900mm below. (the average
work done from the whole process is 8.83kJ)
 Increase the productivity by increasing the speed of the actuator under operating conditions.
 The actuator should lift the bin under a maximum combined weight of 1000kg.
 The operator should only operate the system as in the correct manner specified in the
engineering design.

1.1.3 Standards and Specifications

 A TB0036 hydraulic motor as the power source is used.
 Maximum oil pressure is 100 bar and maximum oil flow rate is 50L/min from the hydraulic
motor.
 Gearbox housing should act as a

1.1.4 Sizes and Dimensions

 Actuator length varies from 1m to 1.77m.
 The bin dimensions are (2.5m x 1.5m x 0.9m).
 Centre of gravity of the combined bin with the payload is 0.49m above from the truck bed.
 Truck bed is 0.9m above from the ground.

1.1.5 Materials
 Higher strength to avoid failures
4
 Lighter to increase the overall efficiency of the machine
 Good wear resistance and resistance to corrosion in various weather conditions.

1.1.6 Performance, Quality and Reliability

 Should be able to perform loading and unloading in a short time
 No maintenance below 10,000 hours.
 Maximise the reliability by reducing the downtime.
 Avoid noises and vibration during operation

1.1.7 Cost
 Lower manufacturing and assembly cost by using cost effective and materials.
 Lower maintenance cost

1.1.8 Ergonomics
 Should be easy to assemble and disassemble
 Should ensure easy access for any technical maintenance

1.1.9 Safety
 The actuator, shaft and gear box should work under safe conditions. (design the components
below the stress failure limits)
 Operate smoothly during loading and unloading by avoiding impacts.
 Avoid pinch points and sharp edges.
 Gear box housing should not be failed when it works as a structural member
 Entire mechanism should be fastened firmly to avoid failures

1.1.10 Aesthetic
 Final design should be present robust and reliable.

5
1.2 Evaluation of Concepts

1.2.1 Different Concepts

Gear Arrangement

Concept 01

Figure 1 Planetary gear system Invalid source specified.

A planetary gear layout was selected to achieve desired gear ratio and output as the conceptual design
one, it has three sets of gears with deferent degree of freedom. Spur gears are used for epicyclic gear
arrangement to avoid complexity of design and manufacturing.

Higher proportion of input energy can be transmitted due to high power distribution of the planetary
gear train compared to other parallel axis gear arrangements and A higher stability is also achieved
according to sharing of the weight to load ratio among epicyclic and sun gears. Increased mass and load
distribution are helped to reduce contact stresses due to larger contact of meshing surfaces and thus the
crack and wear resistance is increased of the gear teeth. Required high precision components and
assemblies is a disadvantage of this concept. Invalid source specified.

6
Concept 02
Figure 2 illustrate a simple two stage reduction compound gear arrangement using helical gears. The
inclination of teeth to the rotating axis is used to transmit energy from one shaft to another. The shafts
can be non-parallel or parallel. Helical gears are used high power and high-speed mechanisms due to
better meshing arrangement of teeth and thus the higher load transfer.
From the Figure 2, Using idlers 3 and 4 the input rotary motion is transmitted from input gear 2 to
output gear 5. Bearings are used to support the all shaft for generated transmission load along the
radial and axial direction due to helical gear meshing.
This configuration especially can result to improve stresses produced, on the smaller gears.

Figure 2: Two-stage compound helical gear train (Richard G.Budynas, 2011)

Concept 03
Figure 03 illustrates a simple planetary gear arrangement for the same gear system was used for concept
02. A spur gears setup is the most common to use to transmit the motion between two parallel shafts and
they do not generate the thrust force on the axial direction. As well as easy to manufacture with high
degree of precision.

7
Figure 3:Two-stage compound spur gear train (Richard G.Budynas, 2011)

Figure 4:Spur Gear (KHK Gears, n.d.)

Table 1 – Table 1:Evaluation of the gears

Spur Gears- Helical Gears- Planetary Gear Box-

Concept - 3 Concept - 2 Concept -1
Cost 5 3 2
Size 2 3 4
Efficiency 3 2 5
Maintenance 2 3 4
Noise & Vibration 1 3 5
Load Tolerance 1 4 4
14 18 24

Based on this evaluation, planetary gears are the gear system which best for this project.

8
1.2.2 Locking fixtures for the gear shaft

Table 2 – Table 2: Evaluation of the Locking Fixtures

Feather Key Spline Tapered Shaft Spring Washer

Cost of
Manufacturing 3 2 3 4
Easy to Assembly 4 3 2 1
Resistance to
Slippage 5 5 2 1
Reliability 4 4 2 1
Noise & Vibration 4 4 2 2
Torque Transferring 3 4 2 1
23 22 13 10

Based on this evaluation feather key is selected as locking fitures of the gear box assembly.

Figure 6 -: Spline (KYOUIKU, 2005)

Figure 7: Feather Key (KYOUIKU, 2005)

9
 Figure 8 - Figure 5:Tapered Shaft (KYOUIKU, 2005)

Figure 9:Spring Washer (KYOUIKU, 2005)

1.2.3 Linking Mechanism

Worm screw
Worm drives eliminate the backlash, the worm and the wheel need to be in perfect contact to each
other and which requires a sophisticated worm preloading system with high transversal stuffiness.
Higher torque capacity and self-locking capacity is an advantage over direct drives or belt drives.

Figure 10 - Figure 6:Worm gear (Black, Machinery lubrication, n.d.)

10
Lead Screw
advantages of lead screws include self-locking capability, low-noise motion, low initial costs, ease
of manufacture, and a wide choice of materials.
In order to eliminate play between the screw and the nut, the nut needs to be preloaded to the
screw.

Recirculating Ball Screw & Belt drive

Figure 7:Circulating Ball Screw and Belt Drive: Image : New port(n.d.)

Ball screws are not self-locking, which limits their use in vertical applications. Also, ball screws
generate more noise than lead screws due to the recirculating balls in the nut. And also, belt drives
provide a similar function to gearboxes, a toothed belt is used to transfer the power and motion. It
provides a low reduction ratio to improve torque and servo sensitivity and offer more design options
than gear boxes. Also belt drives are backlash free and require very little maintenance. However not
like direct gear contact there is no direct contact between pinions which cause to slippage during high
load transferring.

11
1.3 Final conceptual designs

Figure 8:Lead Screw

Figure 9:Warm Screw

12
Table 3 – Table 3: Evaluation of Conceptual Designs and linking mechanism

Concept 1-Lead Screw Concept-2: Warm Gear

Drive Drive
Cost of Manufacturing 5 2
Easy to Assembly 4 2
Friction losses 2 4
Precision 4 2
Noise & Vibration 4 3
Freedom to make gear box as a
structural member 5 2
Freedom to rotation motion of
actuator 5 3
Overall Power & Torque
transferring Efficiency 5 3
34 21

1.3 Materials and Manufacturing Details.

This section provides a detail description about manufacturing technics and material selection for each
and every component of the gearbox and linear actuator. Selection of the materials for a product should
be carried out based on desired properties such as yield strength, shear strength, fatigue strength,
tendency to withstand to buckling to make a reliable product. In addition to the mechanical properties,
cost of the material and easiness to manufacture are considered when product comes to commercial
level.

Gears

As this required good strength to increase the crack and wear resistance of the gear teeth, 4140 Nitride
grade two steel was selected as the material. All the gears are machined using milling and cutting to
achieve desired dimensional specifications and surface finish.

Power Screw

Power screw should have higher strength and resistance to corrosion. Therefore, stainless steel is the
ideal material for this application. This can be easily and cost effectively manufactured by machining.

The elastic strength of screw material in tension and compression is 200 MPa and in shear 120 MPa.

13
Screw Nut

The material for nut is phosphor-bronze for which the elastic limit may be taken as 100 MPa in tension,
90 MPa in compression and 80 MPa in shear

Gearbox Housing

Gearbox housing should have excellent vibration resistance, rigidity, light weight, compact, and enough
strength to support the impact forces while acting as a structural member. In order to meet this
requirement, grey cast iron is used as the material with galvanization to avoid rust. Gearbox housing is
manufactured by casting process the structure.

Gearbox Shafts

Gearbox shafts are subjected to heavy cyclic radial loads and thrust loads. Therefore, material should
have good fatigue strength, wear resistance, shear strength. for these desired properties, Hot roll steel is
selected. This can be manufactured by machining.

Actuator Housing

This component should have protected from higher loads and it should resist to vibration and weather
conditions. Further, structure should be lighter in weight. Therefore, most suitable material is
Aluminium. Manufacturing method for this type of housing component is casting.

Fasteners and Bearing

Fasteners and bearings are purchased based on industry accepted standard guild line to meet the desired
properties.

14
2.0 Analysis Report
2.1 Load Calculation

Free body diagram at a certain position, where angle of Bin arm is 𝜃 with the horizontal,

Figure 10: Freebody diagram for the load calculation

𝑙 ; 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑡ℎ𝑒 𝑡𝑟𝑢𝑐𝑘 𝑓𝑙𝑜𝑜𝑟 𝑎𝑛𝑑 𝑏𝑜𝑡𝑡𝑜𝑚 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑖𝑛

𝜃; angle of Bin arm
c; Actuator length
α; Angle between Bin arm and Actuator

Using Cosine Rule,

1.252 + 0.62 − 𝑐 2
cos 𝜃 =
2 × 1.25 × 0.6

1.9225 − 𝑐 2
cos 𝜃 =
1.5

1.9225 − 𝑐 2
𝑐 = √1.9225 − 1.5 × cos𝜃 θ = cos −1
1.5

15
Θ can be found with changing actuator length and Table 3 illustrate various Bin arm angle which were
calculated with changing Actuator length;

Table 4:Angle of the bin raising arm vs actuator length

Actuator Length(m) angle of Bin arm (𝜃 0 )

1 52.05
1.2 71.24
1.4 91.43
1.6 115.15
1.7 130.17
1.77 143.797

Using Sine Rule

sin 𝛼 sin 𝜃
=
1.25 𝑐
1.25 × sin 𝜃
sin 𝛼 =
𝑐
Equilibrium of bin Arm (AC)
Taking moment at point A

𝑚𝑔
M+ = 0; 𝑇𝑠𝑖𝑛 𝛼 × 0.6 − × 1.9 cos(180 − 𝜃) = 0
2

𝑚𝑔 × 1.9 cos(180 − 𝜃)
→𝑇=
2 × 𝑠𝑖𝑛 𝛼 × 0.6

𝑘𝑔𝑚
1000𝑘𝑔 × 9.81 × 1.9𝑚 cos(180 − 𝜃)
→𝑇= 𝑠2
1.25 × sin 𝜃
2× × 0.6
𝑐

𝑘𝑔𝑚
1000𝑘𝑔 × 9.81 × 1.9𝑚 cos(180 − 𝜃)
𝑇= 𝑠2
1.25 × sin 𝜃
2× × 0.6
√1.9225 − 1.5 × cos𝜃

16
 12426 × cos(180 − 𝜃) × √1.9225 − 1.5 × cos𝜃
𝑇=
sin 𝜃

Using above equation, force exerted by linear actuator on skip bin rains can be obtained for the
different length of the actuator and angles of the skip bin raising arm.
Table 5:Actuator Length vs Force exerted by actuator on bin raising arm

Actuator 𝜃(Deg) T(N) T(kN)

Length(m)
1 52.05 -9691.47 -9.69147
1.1 61.64 -7378.06 -7.37806
1.2 71.24 -5065.66 -5.06566
1.3 81.08 -2534.47 -2.53447
1.4 91.43 435.046 0.435046
1.5 102.61 4170.122 4.170122
1.6 115.15 9334.669 9.334669
1.7 130.17 17829.65 17.82965
1.77 143.80 30048.14 30.04814

17
Graph: 1 Axial force exerted by actuator on skip bin arm

Maximum tensile force and maximum compressive force delivered by actuator can be obtained from
this chart.
𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝐹𝑜𝑟𝑐𝑒 𝑚𝑎𝑥 = 30.048𝑘𝑁

𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑖𝑣𝑒 𝐹𝑜𝑟𝑐𝑒 𝑚𝑎𝑥 = 9.69𝑘𝑁

18
2.2 Stress and fatigue calculations for life analysis

2.2.1 Calculation for threaded rod

For the steel used take ultimate crushing stress as 310 MPa, yield stress in tension or compression as
200 MPa and that in shear as 120 MPa. Young's modulus for steel = 207 kN/mm2

Allowable minimum minor diameter (𝑑𝑐 ) for the threaded rod needs to be designed for the maximum
tensile stress (𝜎𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 )
Maximum axial Force on the threaded rod = 𝑇𝑚𝑎𝑥 = 30.048𝑘𝑁

𝑇𝑚𝑎𝑥 30.048𝑘𝑁
(𝜎𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 ) ≥ =
𝐴𝑐 𝑑2
𝜋×4

𝑠𝑦 310𝑀𝑃𝑎 30.048𝑘𝑁
= ≥
𝑛 3 𝑑𝑐 2
𝜋×
4
; where safety factor n=3
→ 𝑑𝑐 ≥ 19.24𝑚𝑚
→ 𝑑𝑐 = 19.24𝑚𝑚 -----------------------------------------------------------(1)

Allowable minimum minor diameter (𝑑𝑐 ) for the threaded rod needs to be designed such as stable in
bending deflection for the maximum axial forces,
Using J.B. Johnson (Parabolic) column formula;
Since both ends are pivoted
𝑆𝑦 = 310𝑀𝑃𝑎

𝐶=1
𝑃𝑐𝑟 = 9.69𝑘𝑁
𝜋
𝐼 × 𝑑4 𝑑𝑐2
𝑘=√ = 64 = √
𝐴 𝜋𝑑 2 16
4
𝐸 = 207𝐺𝑃𝑎
𝑙 is Assumed to be;
𝑙 = 920𝑚𝑚 = 0.92𝑚

𝑃𝑐𝑟 × 𝑛 𝑆𝑦 𝑙 2 1 𝑙 𝑙
= [𝑆𝑦 − ( ) ] ; ≤( )
𝐴𝑐 2𝜋 𝑘 𝐶𝐸 𝑘 𝑘 1

19
 2

9.69 × 103 𝑁 × 3 310 × 106 𝑃𝑎 0.92𝑚 1

= 310 × 106 𝑃𝑎 − ∙
𝑑 2 2𝜋 2 1 × 207 × 109 𝑃𝑎
𝜋 × 4𝑐 √ 𝑑𝑐
[ ( 16 ) ]
; where safety factor n=3
→ 𝑑𝑐 = 25.162𝑚𝑚 -----------------------------------------------------------(2)
Considering (1) and (2)
Allowable minimum minor diameter can be assumed (𝑑𝑐 ) = 25.5mm

Table 6:Basic dimensions for trapezoidal/Acme threads

(A_Textbook_of_Machine_Design_by_R_S_KHUR, page 630, Table 17.4. Basic dimensions for trapezoidal/Acme threads)

Therefor:
Major diameter d =32mm
Minor diameter dc= 25.5mm and pitch p= 6 Area of core= 511 mm2

One of the key targets of current design for manufacture is to reduce the number of fasteners.
However, there will always be a need for fasteners to facilitate disassembly for whatever purposes.

The major diameter d is the largest diameter of a screw thread. The minor (or root) diameter dr is the
smallest diameter of a screw thread. The pitch diameter dp is a theoretical diameter between the major
and minor diameters.
The lead l, not shown, is the distance the nut moves parallel to the screw axis when the nut is given
one turn. For a single thread, as in Fig.14 , the lead is the same as the pitch.

20
Figure 11:Terminology of screw threads. Sharp vee threads shown for clarity; the crests and roots are actually
flattened or rounded during the forming operation

Figure 12:Thread selection for screw drive

a). This thread results in maximum efficiency and minimum radial or bursting pressure on the nut. It is
difficult to cut with taps and dies. It is usually cut on a lathe with a single point tool and it can not be
easily compensated for wear
b). An acme thread may be cut by means of dies and hence it is more easily manufactured than square
thread
c). this kind of thread is used when large forces act along the screw axis in one direction only.

The material of screw is usually steel and the nut is made of cast iron, gun metal, phosphor bronze in
order to keep the wear to a minimum.

21
 Figure 13:Acme or trapezoidal
threads

Figure 14: Forces acting on the screw thread

p = Pitch of the screw

d = Mean diameter of the screw
α = Helix angle,
P = Effort applied at the circumference of the screw to lift the load,
W = Load to be lifted,
μ = Coefficient of friction, between the screw and nut = tan φ, where φ is the friction angle.

The coefficient of friction, with good lubrication and average workmanship, may be assumed between
0.10 and 0.15. The various values for coefficient of friction for steel screw and cast iron or bronze nut,
under different conditions are shown in the following table.
For Acme threads, 2 β = 29°,
2β = Angle of the Acme thread, and
β = Semi-angle of the thread.

Maximum load which needs to be raised 𝑊= 30.048kN

𝑝
Mean diameter 𝑑𝑚 of the screw= 𝑑 − 2 =32- 6/2= 29mm

22
Lead of the screw= 𝑙 = p= 6mm
𝐿𝑒𝑎𝑑 6
∴ tan 𝛼 = = =0.065857
𝜋𝑑𝑚 𝜋 × 29
𝜇 0.15 0.15
Virtual coefficient of friction=𝜇1 = tan 𝜑1 = cos 𝛽 = cos 14.5 = 0.9659 = 0.155

Torque required For raising the load, or for tightening a screw or bolt, this yields
𝑑𝑚 𝑑𝑚 𝑑𝑚 tan 𝛼 + tan 𝜑1
𝑇=𝑃 × = 𝑊 tan(𝛼 + 𝜑1 ) =𝑊 [ ]
2 2 2 1 − tan 𝛼 tan 𝜑1
Here: the effect of the lead angle has been neglected
29 0.06586 + 0.155
𝑇 = 30.048 × 103 × ×[ ]
2 1 −0.06586 × 0.155
𝑇 =93.57Nm
𝜇 = 0.155 > tan 𝛼 = 0.065857 → 𝑆𝑐𝑟𝑒𝑤 𝑖𝑠 𝑠𝑡𝑎𝑖𝑠𝑓𝑦 𝑡ℎ𝑒 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 𝑠𝑒𝑙𝑓 𝑙𝑜𝑐𝑘𝑖𝑛𝑔

Now Tensile stress due to axial load;

𝑑𝑐 = 25.5𝑚𝑚 ; 𝐴𝑐 = 511𝑚𝑚2
𝑊 30.048 × 103
𝜎𝑐 = = =58.8023
𝐴𝑐 511
Shear stress due to torque 𝑇;
16 𝑇 16 ×97220 N
𝜏= = = 29.86
𝜋 𝑑𝑐3 𝜋 × 25.53 𝑚𝑚2
Bending stress
Maximum principal stress (tensile or compressive)

1 40.81𝑁
𝜎𝑐(𝑚𝑎𝑥) = [18.963+ √18.9632 + 4 ∙ 29.862 ] =
2 𝑚𝑚2

𝜎
𝑒𝑐 200
The given value of 𝜎𝑐 is equal to 𝐹.𝑆., i.e. = 100 N/mm
2

maximum shear stress,

1 31.32919𝑁
𝜏𝑚𝑎𝑥 = [√18.9632 + 4 ∙ 29.862 ] =
2 𝑚𝑚2
𝑒 𝜏 120 40.81𝑁
The given value of 𝑆.𝐹. is equal to = .
2 𝑚𝑚2

Since these maximum stresses are within limits, therefore design of screw for spindle is safe.

23
2.2.2 Design for nut

Table 7: (A_Textbook_of_Machine_Design_by_R_S_KHUR, page 642 Coefficient of friction under different

conditions; Table 17.5)

Friction coefficeint was selected μ = 0.15

The following table shows some limiting values of bearing pressures.

Table 8: A_Textbook_of_Machine_Design_by_R_S_KHUR, page 646 ; Table 17.7. Limiting values of bearing

pressures.

Allowable shear stress for cast iron is 20 MPa and allowable bearing pressure between screw and nut is
12 N/mm2.

24
Equation from A_Textbook_of_Machine_Design_by_R_S_KHUR, page 645

Therefore, from the above expression, the height of nut or the length of thread engagement of the
screw and nut may be obtained
According to table 8 , Assuming uniform wear condition at the collar and allowable thread bearing
pressure of 5.8 N/mm2
𝑊 30.048 × 103 109.937𝑁𝑚𝑚2
5.8 = = =
𝜋𝑑 × 𝑡 × 𝑛 𝜋 × 29 × 6 × 𝑛 𝑛
2
109.937
𝑛= = 18.953 𝑠𝑎𝑦 19
5.8
Height of the nut;
h = n × p = 19 × 6 = 114mm

p 6
Thickness of the threads t = 2 = 2 = 3mm

Shear stress for nut;

𝑊
𝜏𝑛𝑢𝑡 =
𝜋𝑛𝑑0 𝑡
Equation from A_Textbook_of_Machine_Design_by_R_S_KHUR, page 645
where W = Axial load on the screw,
n = Number of threads in engagement,
dc = Core or root diameter of the screw,
do= Outside or major diameter of nut or screw, and
t = Thickness or width of thread.
∴
30.048 × 103 5.25𝑁
𝜏𝑛𝑢𝑡 = = = 5.25𝑀𝑝𝑎
6 𝑚𝑚2
𝜋 × 19 × 32 × 2

the shear stress in nut does not exceed 𝜏𝑛𝑢𝑡 Allowable shear stress for cast iron is 20 MPa
25
The coefficient of thread friction and collar friction may be assumed as 0.2 and 0.15 respectively

2.2.3 Calculations for planetary gear system design

Gear ratio
The gear box was selected with input torque 23.5Nm and output torque 93.57 Nm with 100% of
reliability of transfer efficiency.

Given power source for the gearbox is TB0036 hydraulic motor which provide an input torque
23.5Nm (208lbin) @ 915rpm.

𝑇𝑜𝑢𝑡 93.57
Gear box ratio= = =3.9817 say 4.0 reduction
𝑇𝑖𝑛 23.5

To obtain 3.98 gear reduction, an epicyclic gear system was selected

Ring gear will be fixed, Output shaft will be planet carrier and the Input shaft will be connected to the
sun gear
Calculation for number of gear teeth for sun, planet and ring gears.
𝑁𝑠 , 𝑁𝑟 , 𝑁𝑝 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑛 𝑠𝑢𝑛 𝑔𝑒𝑎𝑟, 𝑟𝑖𝑛𝑔 𝑔𝑒𝑎𝑟 𝑎𝑛𝑑 𝑝𝑙𝑎𝑛𝑒𝑡 𝑔𝑒𝑎𝑟𝑠 𝑎𝑐𝑐𝑜𝑟𝑑𝑖𝑛𝑔𝑙𝑦
𝑁𝑠 + 𝑁𝑟
Gear ratio =
𝑁𝑠
𝑁𝑠 + 𝑁𝑟
→4=
𝑁𝑠
→ 3𝑁𝑠 = 𝑁𝑟

Assume; 𝑁𝑠 = 24 𝑡𝑒𝑒𝑡ℎ
→ 𝑁𝑟 = 72 𝑡𝑒𝑒𝑡ℎ
𝑁𝑟 − 𝑁𝑠 72 − 24
𝑁𝑝 = = = 24 𝑡𝑒𝑒𝑡ℎ
2 2
Number of planet gears:
𝑁𝑠 + 𝑁𝑟
=𝑖; 𝑖 ∈ Ν
𝑛
24 + 72
= 32 → 𝑖 𝑖𝑠 𝑎𝑛 𝐼𝑛𝑡𝑒𝑔𝑒𝑟
3
→ 3 𝑝𝑙𝑎𝑛𝑒𝑡𝑎𝑟𝑦 𝑔𝑒𝑎𝑟𝑠 𝑤𝑖𝑙𝑙 𝑚𝑒𝑠𝑠
Free body diagram for planetary gear box:

26
Figure 15:planetary FBD diagrams and Angular velocities

Table 9: Angular velocitess of gears in RPM

Ns 24 24 24 24 24 24
Nr 72 72 72 72 72 72
Number of Planet
Gears 1 2 3 4 5 6
Np 24 24 24 24 24 24
Integer 96 48 32 24 19.2 16

Module(mm) 1 2 3 4 5 6
ds 0.024 0.048 0.072 0.096 0.120 0.144
dp 0.024 0.048 0.072 0.096 0.12 0.144

N Sun/ input rpm 932 932 932 932 932 932

N Planet 466 466 466 466 466 466
N output 233 233 233 233 233 233

Angular velocities of Gears

𝑁̇𝑠𝑢𝑛 = 𝑁̇𝑚𝑜𝑡𝑜𝑟 = 932𝑟𝑝𝑚

𝑅𝑠 0.06
𝑁̇𝑝𝑙𝑎𝑛𝑒𝑡 = − 𝑁̇𝑠𝑢𝑛 = − 932𝑟𝑝𝑚 = 466𝑟𝑝𝑚
2𝑅𝑝 2 × 0.06
𝑅𝑠 0.06
𝑁̇𝑜𝑢𝑡𝑝𝑢𝑡 = 𝑁̇𝑠𝑢𝑛 = 932𝑟𝑝𝑚 = 233𝑟𝑝𝑚
2(𝑅𝑠 + 𝑅𝑝 ) 2 × (0.06 + 0.06)

𝑁̇𝑟𝑖𝑛𝑔 = 0 𝑟𝑝𝑚 ∵ 𝑟𝑖𝑛𝑔 𝑔𝑒𝑎𝑟 𝑖𝑠 𝑓𝑖𝑥𝑒𝑑

Forces on gears:
Tangential force on sun and planet= 𝐹𝑡𝑠,𝑝

27
 𝑇𝑖𝑛 932
𝐹𝑡𝑠,𝑝 = = = 7766.667𝑁
2𝑅𝑠 2 × 0.024
𝐹𝑡𝑝,𝑟 = 𝐹𝑡𝑠,𝑝 = 7766.667𝑁

𝐹𝑐𝑎𝑟𝑒𝑒𝑟 = 𝐹𝑡𝑠,𝑝 + 𝐹𝑡𝑝,𝑟 = 2 × 7766.667𝑁 =15533.334N

Sizing and specifications of Gears:

The 24 teeth sun gear drives 24 teeth planet gear with a loading of 𝐹𝑡𝑠,𝑝 = 7766.667𝑁. The

Estimated gear sizing table

Table 10: Estimated gear sizing table for sun gear

paramete symbol unit

rs s s
Module m mm 1 2 3 4 5 6
Pitch
diameter d mm 0.024 0.048 0.072 0.096 0.12 0.144

Pitch line m/s 1.1711857 2.3423714 3.5135572 4.68474 5.85592 7.02711

2
velocity V 41 83 24 3 9 4
N 38833.333 19416.666 12944.444 9708.33 7766.66 6472.22
Load Ft 33 67 44 3 7 2
Dynamic 1.1919976 1.3839953 1.5759929 1.76799 1.95998 2.15198
Factor Kv 63 25 88 1 8 6
Face mm
width b 0.85516 0.24823 0.12563 0.07927 0.05625 0.04289
mm 0.0031415 0.0062831 0.0094247 0.01256 0.01570
pitch p 93 85 78 6 8 0.01885
Minimu
m Face mm
width 3p 0.00942 0.01885 0.02827 0.03770 0.04712 0.05655
Maximu
m face mm
width 5p 0.01571 0.03142 0.04712 0.06283 0.07854 0.09425

Sun gear AGMA bending stress

Bending stress of sun gear with Face width 𝑏 = 56.25𝑚𝑚
Permissible
stress Sy/4 163.75
Y 0.33056

𝜋𝑑𝑛 𝜋 × 0.012𝑚 × 932𝑟𝑝𝑚

𝑝𝑖𝑡𝑐ℎ 𝐿𝑖𝑛𝑒 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 𝑉 = = = 5.855929
60 60
28
 6.1 + 𝑉 6.1 + 5.855929
𝐷𝑦𝑎𝑛𝑎𝑚𝑖𝑐 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝐾𝑣 = = = 1.959988
6.1 6.1
𝐺𝑒𝑜𝑚𝑒𝑡𝑟𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝐽 = 0.31 Shigley ′ s mechanical design
𝐴𝑝𝑝𝑙𝑖𝑐𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝐾𝑎 = 1 ; 𝑈𝑛𝑖𝑓𝑜𝑟𝑚
𝑆𝑖𝑧𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝐾𝑠 = 1
𝑡𝑅
𝑅𝑖𝑚 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝐹𝑎𝑐𝑡𝑜𝑟 = 𝐾𝐵 = 1 ; 𝑚𝐵 = = 1.2, → 𝑡𝑅 = 1.2ℎ𝑡 = 1.2 × (2.25 × 5) = 13.5𝑚𝑚
ℎ𝑡
𝑤ℎ𝑒𝑟𝑒 ℎ𝑡 = 2.25 × 𝑚 = 2.25 × 5 = 11.25
𝑡 𝐹
𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 = 𝜎𝐵 = 𝐾𝑣 𝑏𝑚𝐽 𝐾𝑎 𝐾𝑠 𝐾𝐻 𝐾𝐵
7766.667𝑁
𝜎𝐵 = 1.959988 × 56.25𝑚𝑚×5𝑚𝑚×0.31 × 1 × 1 × 1 × 1 = 159.2035294𝑀𝑃𝑎

sun gear is manufactured by cutting or milling from

Nitride 4140 𝑔𝑟𝑎𝑑𝑒 2 𝑠𝑡𝑒𝑒𝑙 𝑤𝑖𝑡ℎ 𝑆𝑢𝑡 1020𝑀𝑃𝑎, 𝑆𝑦 = 655𝑀𝑃𝑎, 𝐻𝐵 = 302 𝑎𝑛𝑑 𝐸 = 200𝐺𝑃𝑎.
figure: Spur-gear geometry factors J. 𝐹𝑖𝑔𝑢𝑟𝑒 14.6 − 𝑆ℎ𝑖𝑔𝑙𝑒𝑦′ page 751
𝑇ℎ𝑒 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 = 𝑆𝑡 = (0.749 ∗ 300) + 110 = 334.7𝑀𝑃𝑎
𝑆𝑡𝑟𝑒𝑠𝑠 𝑐𝑦𝑐𝑙𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑌𝑁 = 1 ; 107 𝑐𝑦𝑐𝑙𝑒𝑠,
; 𝑓𝑖𝑔𝑢𝑟𝑒 14.14; 𝑆ℎ𝑖𝑔𝑙𝑒𝑦 ′ 𝑠 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛
𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑌𝑍 = 1, 99% 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦,
; 𝑡𝑎𝑏𝑙𝑒 14.10; 𝑆ℎ𝑖𝑔𝑙𝑒𝑦 ′ 𝑠 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛
𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑌𝜃 = 1, 𝑜𝑖𝑙 𝑡𝑒𝑚𝑝𝑒𝑟𝑡𝑢𝑟𝑒 ≤ 1200
; section 14.15 𝑆ℎ𝑖𝑔𝑙𝑒𝑦 ′ 𝑠 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛
𝑆𝑡 𝑌𝑁 334.7𝑀𝑃𝑎 × 1
𝐹𝑢𝑙𝑙𝑦 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ = = = 334.7𝑀𝑃𝑎
𝑌𝜃 𝑌𝑍 1×1
𝐹𝑢𝑙𝑙𝑦 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 334.7𝑀𝑃𝑎𝑀𝑃𝑎
𝑆𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑛𝐵𝐹 = = = 2.10
𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝜎𝐵 159.204𝑀𝑃𝑎𝑀𝑃𝑎
All bending stress calcualtions are shown in table 11.
Sun gear Planet Gears Ring Gears
St 334.7 334.7 334.7
Stress Cycle factor 𝑌𝑁 1 1 1
Reliability factor 𝑌𝑍 1 1 1
Temperature Factor 𝑌𝜃 1 1 1
Fully corrected bending
Strength 334.7 334.7 334.7
Safety factor 2.10 2.23 5.15

Table 11:Bending stress calculation results

29
Sun gear AGMA Contact stress
𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 𝑑𝑝 = 𝑚𝑁𝑠 =
𝜋𝑑𝑛 𝜋 × 0.12𝑚 × 932 𝑟𝑝𝑚
𝑃𝑖𝑡𝑐ℎ 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 𝑉 = = = 5.8559
60 60
6.1 + 𝑉
𝐷𝑦𝑎𝑛𝑎𝑚𝑖𝑐 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝐶𝑣 = 𝐾𝑣 = = 1.96
6.1

1 1
𝐸𝑙𝑎𝑠𝑡𝑖𝑐 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 𝐶𝑝 = = √ 𝑣
√ 1− 𝑣𝑝2 1− 𝑣𝑔2 1− 0.292 1 − 0.292
𝜋( 𝐸 + 𝐸 ) 𝜋 ( 300000 + 300000 )
𝑝 𝑔

𝐶𝑝 = 2283.214

cos 200 sin 200 1

𝐺𝑒𝑜𝑚𝑒𝑡𝑟𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝐼 = = 0.0803
2 1+1
sun/Planet Planet/Ring

1 3
Table:

Pressure angle 20
Sin 0.34202
Cos 0.939693
Table:

𝐶𝑣 𝐹𝑡 1.96 × 7766.667
𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑠𝑡𝑟𝑒𝑠𝑠 = 𝜎𝐻 = −𝐶𝑝 √ = −2283.2142√
𝑏𝑑𝑝 𝐼 0.05625 × 0.12 × 0.0803

𝜎𝐻 = −382.5323𝑀𝑃𝑎
𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ, 𝑆𝑐 = (2.41 ∗ 300) + 237 = 960𝑀𝑃𝑎,

𝑡𝑎𝑏𝑙𝑒 14.6 ; 𝑝𝑎𝑔𝑒 743 𝑆ℎ𝑖𝑔𝑙𝑒𝑦 ′ 𝑠 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛

𝑆𝑡𝑟𝑒𝑠𝑠 𝑐𝑦𝑐𝑙𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑍𝑁 = 1, 107 𝑐𝑦𝑐𝑙𝑒𝑠,

𝑓𝑖𝑔𝑢𝑟𝑒 14.6 ; 𝑝𝑎𝑔𝑒 743 𝑆ℎ𝑖𝑔𝑙𝑒𝑦 ′ 𝑠 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛

𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑌𝑍 = 1, 99% 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦,
; 𝑡𝑎𝑏𝑙𝑒 14.10; 𝑆ℎ𝑖𝑔𝑙𝑒𝑦 ′ 𝑠 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛
𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑌𝜃 = 1, 𝑜𝑖𝑙 𝑡𝑒𝑚𝑝𝑒𝑟𝑡𝑢𝑟𝑒 ≤ 1200
; section 14.15 𝑆ℎ𝑖𝑔𝑙𝑒𝑦 ′ 𝑠 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛

30
 𝐻𝑎𝑟𝑑𝑛𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑍𝑊 = 1

𝑠𝑒𝑐𝑡𝑖𝑜𝑛 14.11 ; 𝑝𝑎𝑔𝑒 743 𝑆ℎ𝑖𝑔𝑙𝑒𝑦 ′ 𝑠 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛

𝑆𝑐 𝑍𝑁 𝐶𝐻 960𝑀𝑃𝑎×1×1
Fully Corrected Contact Strength = = = 960 𝑀𝑃𝑎
𝑌𝜃 𝑌𝑍 1×1

𝐹𝑢𝑙𝑙𝑦 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 2 960𝑀𝑃𝑎, 2

𝑆𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑛𝐵𝐹 = ( ) = ( )
𝐶𝑜𝑛𝑡𝑎𝑐𝑡 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝜎𝐻 −382.5323𝑀𝑃𝑎
𝑛𝐵𝐹 = 6.3

Calculation results for Gear specifications are shown in Table 12.

Terminology
Units Sun Planet Ring
Number of Teeth 24 24 72
Module mm 5 5 5
Pitch diameter m 0.12 0.12 0.36
Pitch line velocity
(sun/planet) m/s 5.855928706 5.855928706
Pitch line velocity
(ring/planet) m/s 0 0
Dynamic
Factor(sun/planet) 1.959988313 1.959988313
Dynamic
Factor(ring/planet) 1 1
Face width m 0.05625 0.056245339 0.056245339
Pressure Angle degrees 20 20 20

Bending Stress
Application Factor Ka 1 1 1
Geometry Factor
Figure 14.6 in
(sun/planet) Jsp 0.34 0.34
Shigley's mechanical
Geometry Factor
design
(ring/planet) Jpr 0.36 0.425
Ks 1
mb=tr/ht ht =
KB 1 = 1.2 2.25m
ht 11.25mm
tr 13.5mm

Mpa 159.2035 150.3588 64.9814

31
 St 334.7 334.7 334.7
Stress Cycle factor Yn 1 1 1
Reliability factor Yz 1 1 1
Temperature Factor To 1 1 1
Fully corrected bending
Strength St*Yn/To*Yz 334.7 334.7 334.7
Safety factor 2.10 2.23 5.15

Contact Stress
Dynamic Factor(sun/planet) 1.959988313 1.959988313
Cv=Kv
Dynamic Factor(ring/planet) 1 1
Elastic Coefficient Cp 2283.214236 2283.214236 2283.214236
Geometry Factor (sun/planet) Isp 0.080348451 0.080348451
Geometry Factor (ring/planet) Ipr 0.120522677 0.241045354
Contact Stress (sun/planet) - -
Mpa 382.5322828 382.5322828
Contact Stress (ring/planet) -
Mpa -223.098023 91.07938651
Hardness Factor Ratio 1 1 1

Surface Contact Strength 960 960 960

Stress Cycle factor Zn 1 1 1
Relability factor Yz 1 1 1
Temperature Factor Yo 1 1 1
Fully corrected Contact
Strength 960 960 960
Safety Factor n 6.3 6.3 111.1

Table 12:Calculation results for Gear specifications

2.2.4 Calculations for Input motor shaft

Face width of sun gear =56.25mm

The input shaft is subjected to variable torsional loads of ±8𝑁𝑚 𝑓𝑟𝑜𝑚 ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑚𝑜𝑡𝑜𝑟
Pitch diameter of sun= 120mm
OD= 120+5=125mm
Base circle diameter= OD-(tr+ht) = 125-(13.5+11.25) = 100.25mm
Shaft diameter → 50mm which is less than 100.25mm
𝜋(𝐷2 − 𝑑2 )
𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠ℎ𝑎𝑓𝑡 ; 𝐴 =
4
𝜋(502 − 252 )
𝐴= =1472.621556 𝑚𝑚2
4
Moment of inertia.

32
 𝜋(𝐷4 − 𝑑 4 ) 𝜋(504 − 254 )
𝐼= = =287621.3977 𝑚𝑚4
64 64
Polar moment of inertia
𝜋(𝐷4 − 𝑑 4 ) 𝜋(504 − 254 )
𝐽= = =575242.7955𝑚𝑚4
32 32
𝑆UT = 1020𝑀𝑝, notch radius= 1mm, 𝑆𝑦 = 655𝑀Pa, 𝐻𝐵 = 300 and E=200GPa
The input shaft incorporates a hole boss for hydraulic motor input shaft of 25mm diameter with 8 x
7mm keyway and is supported by a single roller ball bearing located against a shoulder and retained by
circlip

𝐷 50
= =2
𝑑 25
𝑟 1
= = 0.04
𝑑 25
Stress concentration factors,
Bending stress concentration factor
𝑞 = 0.855 𝑓𝑜𝑟 1000𝑀𝑃𝑎 𝑎𝑛𝑑 1𝑚𝑚 notch 𝑟𝑎𝑑𝑖𝑢𝑠,
𝑓𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒 6 − 20 𝑝𝑎𝑔𝑒 303 𝑆ℎ𝑖𝑔𝑙𝑒𝑦’ mechanical design
𝐾𝑡𝐵 = 1.25
𝐾𝑓𝐵 ≅ 1 + 𝑞(𝐾𝑡𝐵 − 1) = 1 + 0.855 (1.25 − 1) = 1.2137

Torsional shear concentration

𝐾𝑡𝑆 = 1.2; 𝑞 = 0.9
𝐾𝑓𝑆 ≅ 1 + 0.9(1.2 − 1) = 1.18

Radial gear loading

2𝑇 2 × 23.5𝑁𝑚
𝐹𝑡 = = = 391.67𝑁
𝑑 0.12
𝐹𝑟 = 𝐹𝑡 tan ∅ = 391.67𝑁𝑚 × tan 200 = 142.56𝑁
Completely reversed bending moment
M = 𝐹𝑟 × 𝐿 = 142.56 𝑁 × 0.126𝑚 = 17.96𝑁𝑚
Stress concentration corrected bending amplitude and mean stresses

33
 𝑀𝑎 𝑦 (𝑀𝑚𝑎𝑥 − 𝑀𝑚𝑖𝑛 )𝑦
𝜎𝑎𝐵 = 𝐾𝑓𝐵 = 𝐾𝑓𝐵
𝐼 2𝐼
(17.96 − (−17.96))𝑁𝑚 × 25𝑚𝑚
𝜎𝑎𝐵 = 1.2137 = 1.895𝑀𝑃𝑎
2 ×287621.3977 𝑚𝑚4

𝑀𝑚 𝑦 (𝑀𝑚𝑎𝑥 + 𝑀𝑚𝑖𝑛 )𝑦
𝜎𝑚𝐵 = 𝐾𝑓𝐵 = 𝐾𝑓𝐵
𝐼 2𝐼
(17.96 + (−17.96))𝑁𝑚 × 25𝑚𝑚
𝜎𝑚𝐵 = 1.2137 = 0 𝑀𝑃𝑎
2 ×287621.3977 𝑚𝑚4
Variable Torsional loading; T= ±23.5𝑁𝑚
𝑇𝑎 𝑟 (𝑇𝑚𝑎𝑥 − 𝑇𝑚𝑖𝑛 )𝑦
𝜏𝑎𝑆 = 𝐾𝑓𝑆 = 𝐾𝑓𝑆
𝐽 2𝐽
(23.5 − (−23.5))𝑁𝑚 × 25𝑚𝑚
𝜏𝑎𝑆 = 1.18 = 1.2051𝑁𝑚
2 ×575242.7955𝑚𝑚4
(𝑇𝑚𝑎𝑥 + 𝑇𝑚𝑖𝑛 )𝑦
𝜏𝑚𝑆 = 𝐾𝑓𝑆 = 0 𝑁𝑚
2𝐽
Von Mises amplitude and mean stresses
1/2
𝜎𝑚𝐵 2
𝜎𝑎′ = {[𝜎𝑎𝐵 + 2
] + 3𝜏𝑎𝑆 }
0.85
1/2
0 2
𝜎𝑎′ = {[1.895𝑀𝑃𝑎 + ] + 3 × 1.20512 } =2.8192 Mpa
0.85
′
𝜎𝑚 = {[𝜎𝑚𝐵 + 𝜎𝑚𝐴 ]2 + 3𝜏𝑚 2 }1/2

Estimating fatigue strength

𝜎𝑎′ 2.8192 Mpa
𝐿𝑜𝑎𝑑 𝑙𝑖𝑛𝑒 = 𝑟 = ′
= = 2.8192, 𝑀𝑜𝑑𝑖𝑓𝑖𝑒𝑑 𝐺𝑜𝑜𝑑𝑚𝑎𝑛
𝜎𝑚 0 𝑀𝑝𝑎
Load line intersects with modified Goodman

2.8192 Mpa
=
1 0𝑀𝑃𝑎
1 − 1020𝑀𝑝𝑎
𝑆𝑓 =2.8192 Mpa

34
Estimating number of cycles to failure
𝐼𝑛𝑓𝑖𝑛𝑖𝑡𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑦𝑐𝑙𝑒𝑠 𝑁 = ∞
𝑎𝑠 𝑆𝑓 =2.8192 Mpa < 𝑆𝑒 = 249.5 MPa

2.2.5 Calculation for Input shaft Bearing

The input shaft is supported by one roller ball bearing at hydraulic motor end and by the planet gears at
the other end. The hydraulic motor rotates at 915rpm and applies a 23.5Nm torsional loading. Under
worst conditions were only one planet gear is in contact with the sun gear the input shaft is subjected to
a radial loading of 142.56𝑁 and the roller ball bearing is selected for these load conditions with an
internal bore of 50mm.
Bearing dynamic load rating
𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑡𝑖𝑜𝑛 = 𝑎𝑓 = 1.2( 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑔𝑒𝑎𝑟𝑖𝑛𝑔)

𝑎 = 3 (𝑏𝑎𝑙𝑙),
𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑙𝑖𝑡𝑦 𝑅 = 99%
𝐷𝑒𝑠𝑖𝑔𝑛 𝑙𝑖𝑓𝑒 = 𝐿𝐷 = 10 000ℎ , 𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑝𝑒𝑒𝑑 = 915𝑟𝑝𝑚

1
3
10 000ℎ × 915𝑟𝑝𝑚 × 60
106 𝑐𝑦𝑐𝑙𝑒𝑠
𝐶10 = 1.2 × 142.56 1
1 1.4
0.02 + 4.91 (ln 0.99)
( )
𝐶10 = 2380.78𝑁
=2.380 kN
35
SKF W 61 810 radial ball bearing, determine bearing life.
𝐶10 = 5.07𝑘𝑁, 𝐶0 = 5.5𝑘𝑁, 𝑂𝐷 = 65𝑚𝑚 , 𝐼𝐷 = 50𝑚𝑚, 𝑇 = 7𝑚𝑚
1/3
𝐿𝐷 × 915𝑟𝑝𝑚 × 60
106 𝑐𝑦𝑐𝑙𝑒𝑠
5070 = 1.3 × 142.56 ( )
1
0.02 + 4.91(ln 0.99)1/1.4

𝐿𝐷 = 75 959.48ℎ
2.2.6 Calculation for Input shaft key way:

Figure 16:Key way selection

The input shaft of hydraulic motor is 25mm diameter with an 8 × 7 × 32𝑚𝑚 keyway and must
transmit 23.5 Nm of torque to gearbox. The key shear strength is determined from the normal yield
strength, were the selected key steel yield strength is 𝑆𝑦 = 455𝑀𝑝𝑎, Lower than input shaft strength.

Shear failure occurs along the width and length of the key way,
Therefore,
𝐹 𝑇 2 × 23.5𝑁𝑚𝑚 × 1000
𝜏= = = = 7.344 𝑀𝑃𝑎
𝑡𝑙 𝑡𝑙 𝑑/2 8 × 32 × 25𝑚𝑚3
𝑆𝑠𝑦 𝑆𝑠𝑦 262.5𝑀𝑃𝑎
𝜏𝑎𝑙𝑙𝑜𝑤𝑒𝑑 = ;𝑛 = = = 35.745
𝑛 𝜏𝑎𝑙𝑙𝑜𝑤𝑒𝑑 7.344𝑀𝑃𝑎
Compression failure occurs using one half the contact face,
2𝐹 𝑇 4 × 23.5𝑁𝑚𝑚 × 1000
𝜎= = = = 16.786𝑀𝑃𝑎
𝑡𝑙 𝑡𝑙 𝑑/2 7 × 32 × 25𝑚𝑚3
𝑆𝑦 𝑆𝑠𝑦 455𝑀𝑃𝑎
𝜎𝑎𝑙𝑙𝑜𝑤𝑒𝑑 = ;𝑛 = = = 27.1059
𝑛 𝜎 16.786𝑀𝑃𝑎

36
2.2.7 Calculation Planet gear pin stress
The planet gears are connected to the cover by pins, pressed and welded into the cover. The pins are
subjected to shear stress and bending stress. The pins are machined manufactured from 1040 steel with
𝑆𝑈𝑇 = 590𝑀𝑝𝑎, 𝑆𝑦 = 374𝑀𝑃𝑎, 𝐻𝐵 = 225 and 𝐸 = 200𝐺𝑃𝑎. Worst case condition loadings for pin is
when only one planet gear is in contact with the sun and ring gear.

Shear stress;

8 × 391.67𝑁
=
𝜋 0.042 𝑚2
= 0.6234𝑀𝑃𝑎
𝑆𝑠𝑦 340
𝑛𝑠 = = = 545
𝜏 0.6234
Bending stress
𝜋 × 𝐷4
𝐼= = 1.2566 × 10−7 𝑚4
64
Bending moment → 𝑀 = 𝐹 ∙ 𝐿 = 142.56 × 0.037 = 5.27𝑁𝑚
𝐷 40 𝑟 1
Stress concentration Factor → 𝑑 = 30 = 1.3 ; 𝑑 = 30 = 0.03

Notch diameter 𝑟 = 1𝑚𝑚

𝑞 = 0.7; 𝐾𝑡𝐵 = 2.3
𝐾𝑓𝐵 = 1 + 𝑞(𝐾𝑡𝐵 − 1) = 1.91

Corrected bending stress

𝑀𝑎 𝑦 1.91 × 5.27 × 103 × 20
𝜎𝑎𝐵 = 𝐾𝑓𝐵 =
𝐼 1.2566 × 10−7
= 1.6𝑀𝑃𝑎
𝜎𝑚𝐵 = 0
𝑆𝑒′ = 0.5𝑆𝑢𝑡 = 0.5 × 590 = 295𝑀𝑃𝑎
i. Surface factor(machined)
𝑏
𝑘𝑎 = 𝑎 𝑆𝑢𝑡 = 4.51 × 590MP𝑎 −0.265 = 0.831

ii. Size factor. (40mm rotating shaft)

𝑘𝑏 = 1.24𝑑 −0.107 = 1.24 × 0.04−0.107 = 1.75
𝑤ℎ𝑒𝑟𝑒; 2.79𝑚𝑚 ≤ 𝑑 ≤ 51𝑚𝑚
iii. Loading factor (bending)

37
 𝑘𝑐 = 1

iv. Temperature factor. ( 200 𝑟𝑜𝑜𝑚 𝑡𝑒𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒)

𝑘𝑑 = 1

v. Reliability factor (99% confidence)

𝑘𝑒 = 0.814

Corrected endurance limit

𝑆𝑒 = 𝑘𝑎 𝑘𝑏 𝑘𝑐 𝑘𝑑 𝑘𝑒 𝑆𝑒′ = 0.831 × 1.75 × 1 × 1 × 0.814 × 295 = 349.2 𝑀𝑃𝑎

vi. Estimating number of cycles to failure;

𝜎𝑎 𝜎𝑚 1 𝜎𝑎 1.6
+ = → 𝑆𝑓 = = = 1.6𝑀𝑃𝑎
𝑠𝑓 𝑠𝑢𝑡 𝑛 1 𝜎𝑚 1
𝑛 − 𝑆𝑢𝑡 1−0
𝑆𝑓 < 𝑆𝑒

→Infinite number of cycles 𝑁 = ∞,

Bearing contact stress;

𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑡𝑖𝑜𝑛 = 𝑎𝑓 = 1.2( 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑔𝑒𝑎𝑟𝑖𝑛𝑔)

𝑎 = 3 (𝑏𝑎𝑙𝑙),
𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑙𝑖𝑡𝑦 𝑅 = 99%
𝐷𝑒𝑠𝑖𝑔𝑛 𝑙𝑖𝑓𝑒 = 𝐿𝐷 = 10 000ℎ , 𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑝𝑒𝑒𝑑 = 457.5𝑟𝑝𝑚

1
3
10 000ℎ × 457.5𝑟𝑝𝑚 × 60
142.56 106 𝑐𝑦𝑐𝑙𝑒𝑠
𝐶10 = 1.3 × 1
2
1 1.4
0.02 + 4.91 (ln 0.99)
( )
𝐶10 = 1.0235 𝑘𝑁

SKF W 61 810 radial ball bearing, determine bearing life.

𝐶10 = 1.43

38
 1/3
𝐿𝐷 × 457.5𝑟𝑝𝑚 × 60
142.56 106 𝑐𝑦𝑐𝑙𝑒𝑠
1.43 = 1.3 × ( )
2 1 1/1.4
0.02 + 4.91(ln 0.99)

𝐿𝐷 = 27 272.4 ℎ

2.2.9 Calculation of Diameter and Fatigue Life for Gearbox Housing-Truck Bed Mounting Shaft (Pin)

Figure 17 Truck Bed-Gearbox Pin Assembly

Calculation of Shaft Diameter to avoid failure

Material used for the shaft is 1040 steal and its properties are , Sut=590MPA, Sy=374MPA, HB= 225,
E=200 GPa

39
Figure 18:FBD of Bin Arm

Take angle of skip bin arm and truck bed as β1 & β2 when actuator is under compression and tension
respectively.
For compressive state of the skip bin actuator, calculate angle β1.

1000 sin β1 = 600 sin θ

3 sin(52.05)
β1 = sin-1( ) = 28.24 degree
5

Following figures provide free body diagram for force acting on centre shaft when bin is being unloaded
and unloaded from the truck bed.

Here neglect the changes in angel due to the distance from truck bed and actuator connecting plane to
the gear box housing.

40
Figure 19:Actuator-Gearbox-Truckbed position and Freebody Diagram for actuator and gear box housing

Figure 20:Freebody Diagram for forces acting on Gearbox-Truck bed connecting shaft when unloading skip bin

This shaft is under bending and torsion, therefore all the calculationsfor shaft is based on this
condition.

Considering horizontal stability of gear boxhousingh assembly,

Y1= sin β1 = 9.69 sin (28.24) = 4.59kN
X1 = 969 Cos (28.24) = 8.54kN

41
RA = RB = 2.3KN, Calculating vertical forecess acting on the shaft.

Torqe on shaft= 8.54 X 0.330 = 2.8182 KNm

Maximum bending moment at the xenrter of shaft.
Mmax = 2.3KN X 0.246 m = 0.5658 KNm

According to the maximum shear stress theory, equivalent twisiting moment Te,

Te,= √(M 2 + T 2 ) = √(0.56582 + 2.818222 ) = 2.875 KNm

Since the material is 1040 Steel,

Τut = 0.577 ×Sy
τ=0.577 × 374 = 340MPa

Taking a safety factor of 3,

τ= 340 MPa / 3= 113.33 MPa

16
𝑑 3 = 𝑇𝑒 𝑥 𝜏𝜋
16
𝑑 3 = 2.875 𝑥
113.33 𝑥 1000 𝜋
d= 50.55 mm //

According to the maximum normal stress theory, equivalent bending moment,

1
𝑀𝑒 = 2 ( 0.5658 + 2.875 ) = 1.7204 kNm

𝑆𝑢𝑡 590
Fore safety factor of 3, 𝜎𝑏 = = = 196.67𝑀𝑝𝑎
𝑛 3
𝜋
𝑀𝑒 = 𝑥 𝜎𝑏 𝑥 𝑑 3
32

42
 𝜋
1.7204 𝑘𝑁𝑚 = 𝑥 196.67𝑥 103 𝑥 𝑑 3
32

1
1.7204 𝑥 32 3
𝑑=( )
𝜋 196.67𝑥 103
d= 44.67mm

For Tensional stress state,

For tensile state of the skip bin actuator at tensile state, do load calculation for shaft.

1770 sin β1 = 600 sin (180-θ)

60 sin(36.03)
β1 = sin-1( ) = 11.5 degree
177

Y1= sin β1 = 30.048 sin (11.5) = 5.99 KN

X1 = 30.048 Cos (11.5) = 29.45 KN

Figure 21:Freebody Diagram for forces acting on Gearbox-Truck bed connecting shaft when loading skip bin

RA = RB = 3 KN, Calculating vertical forecess acting on the shafts

Torqe on shaft= 29.45 X 0.330 = 9.7152 KNm

Maximum bending moment at the cenrter of the shaft.
Mmax = 3kN X 0.246 m = 0.738 kNm

According to the maximum shear stress theory, equivalent twisiting moment Te,

Te,= √(𝑀2 + 𝑇 2 ) = √(0.7382 + 9.71522 ) = 9.743 kNm

43
 Since the material is 1040 Steel,
τ ut = 0.577 x Sy
τ ut =0.577 x 374 = 340MPa

Taking a safety factor of 3,

τ= 340 MPa / 3= 113.33 MPa

16
𝑑 3 = 𝑇𝑒 𝑥
𝜏𝜋
16
𝑑 3 = 9.743 𝑥
113.33 𝑥 1000 𝜋

1
16 3
𝑑 = (9.743 𝑥 )
113.33 𝑥 1000 𝜋
d= 75.94 mm //

According to the maximum normal stress theory, equivalent bending moment,

1
𝑀𝑒 = 2 ( 0.738 + 9.743 ) = 5.241 kNm
𝑆𝑢𝑡 590
Fore safety factor of 3, 𝜎𝑏 = = = 196.67𝑀𝑝𝑎
𝑛 3
𝜋
𝑀𝑒 = 𝑥 𝜎𝑏 𝑥 𝑑 3
32
𝜋
5.241 𝑘𝑁𝑚 = 32 𝑥 196.67𝑥 103 𝑥 𝑑 3
1
5.241 𝑥 32 3
𝑑 = (𝜋 196.67𝑥 103 )

d= 64.75mm//

44
Table 13:: Diameter value for worst case conditions based on maximum shear/normal stress theory

Diameter
Load Condition Calculation Criteria (mm) Suggested Diameter
Compression of
actuator Maximum shear stress Theory 50.55
Compression of Maximum normal stress
actuator Theory 44.67
Tension on Actuator Maximum shear stress Theory 75.94 76mm
Maximum normal stress
Tension on Actuator Theory 64.75

Based on this table, minimum required diameter for this shaft under prescribed conditions of the shaft
is 76mm.

Fatigue Life cycle Calculation

Since the shaft is under gone to cyclic load, fatigue can cause for a failure. In here fatigue calculation is
done for checking the cycle life of shaft for the above selected diameter.

Material used for the shaft is 1040 steal and its properties are, Sut=590MPA, Sy=374MPA, HB= 225,
E=200 GPa Ssy= 0577 Sy = 340MPa

Taking diameter of the shaft as 76mm.

Polar moment of inertia of the shaft

M max= 0.738 kNm

M min= 0.5658 KNm
𝜋𝑑4 𝜋764 ∗10−3∗ 4
𝑗= = = 3.28 x10-6 mm4
32 32

𝜋𝑑4 𝜋764 ∗10−3∗ 4

𝐼= = = 1.64 x10-6 mm4
64 64

Here kf=1

𝑀𝑦 (𝑀𝑚𝑎𝑥 −𝑀𝑚𝑖𝑛 )𝑦 = (0.738−0.5658) 𝑥 38 𝑥 10−3

𝜎𝑎 = 𝑘𝑓 = 1𝑥 = 2.0449 𝑀𝑃𝑎
𝐼 2𝐼 2 𝑥1.64 𝑥 10−6

𝑀𝑦 (0.738+0.5658)𝑥 38 𝑥 10−3 = 15.483 MPa

𝜎𝑚 = 𝑘𝑓 =1𝑥
𝐼 2 𝑥1.64 𝑥 10−6

Variable Torsional load τ, Here kf=1

T = - 2.8182 KNm & +9.7152kNm
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 𝑇𝑟 (𝜏𝑚𝑎𝑥 −𝜏𝑚𝑖𝑛 )𝑟 = (−2.8182−9.7152) 𝑥 38 𝑥 10−3
𝜏𝑎 = 𝑘𝑓 =1𝑥 = −72.602 𝑀𝑃𝑎
𝑗 2𝑗 2 𝑥1.64 𝑥 10−6

𝑇𝑟 (𝜏𝑚𝑎𝑥 −𝜏𝑚𝑖𝑛 )𝑟 (−2.8182+9.7152)𝑥 38 𝑥 10−3 = 39.952 MPa

𝜏𝑚 = 𝑘𝑓 = 1𝑥 =
𝑗 2𝑗 2 𝑥3.28 𝑥 10−6

Von misses amplitude and mean stress,

𝜎𝑎𝐴 2 1
𝜎𝑎′ = {[𝜎𝑎𝐵 + ] + 3𝜏𝑎2 }2
0.85
0 2 1
𝜎𝑎′ = {[2.0449 + 0.85] + 3 (−72.602)2 }2 = 125.77 Mpa

′
0 2 2 2
1
𝜎𝑚 = {[𝜎𝑚𝐵 + ] + 3𝜏𝑚 }
0.85

0 2 1
′
𝜎𝑚 = {[15.483 + 0.85] + 3 𝑥 39.9522 }2 = 70.91 Mpa

Estimating fatigue strength,

𝜎𝑎′
𝐿𝑜𝑎𝑑 𝐿𝑖𝑛𝑒 = 𝑟 = ′
𝜎𝑚

125.77 𝑀𝑃𝑎
𝑟= = 1.774 , modified Goodman
70.91 𝑀𝑃𝑎

Load line intersect with modified Goodman

𝜎𝑎 𝜎 1 𝜎𝑎 𝜎 1 𝜎𝑎
+ 𝑆𝑚 = 𝑛 => + 𝑆 𝑚 = 𝑛 , => 𝑆𝑓 = 1 𝜎𝑚 for failure,
𝑆𝑒 𝑈𝑇 𝑆𝑓 𝑈𝑇 −
𝑛 𝑆𝑈𝑇

2.0449
𝑆𝑓 = 1 15.483 = 2.1 MPa
−
1 590

Endurance limiting strength

Estimated endurance limit,
(𝐹𝑜𝑟 𝑆𝑈𝑇 ≤ 1400 𝑀𝑝𝑎), 𝑆𝑒′ = 0.5 𝑥𝑆𝑈𝑇 = 295 MPa
Fatigue Stress correction factors,
(i) Surface factor (machined)
𝑏
𝑘𝑎 = 𝑎 𝑆𝑢𝑡 = 4.51 x 590−0.265 = 0.832
(ii) Size factor (d= 76mm) for 51mm <d< 254mm
𝑘𝑏 = 1.51 𝑑 −0.157 = 1.51 x 76−0.157 = 0.765
(iii) Loading factor (torsion + bending),
Therefore 𝑘𝑐 = 1
(iv) Temperature factor (room temperature)

46
 𝑆𝑇
𝑘𝑑 = =1
𝑆𝑅𝑇
(v) Reliability factor (99% confidence)
𝑘𝑒 = 0.814
𝑆𝑒 = 𝑘𝑎 𝑘𝑏 𝑘𝑐 𝑘𝑑 𝑘𝑒 𝑆𝑒′ = 0.832 𝑥0.765 𝑥 1𝑥1𝑥0.814 x295 MPa = 152.84 MPa

Here Se > Sf , therefore shaft has an infinite cycle life when diameter is 76mm.

2.3 Finite Element Analysis of structural gearbox housing

FEA for Gear Box Housing

Finite Element Analysis was done to check the stability of the Gear box housing and to optimize the
final design to get more stable and rigid design. To perform the FEA, Ansys workbench was used and
Analysis was done with using following constraints.
 Cylindrical support was set to the pin connecting location at the bottom of the Gear Box Housing
and Figure 23 is illustrated the condition
 Set input shaft bearing load as 940N (Check Figure 23 for more details)
 Set output shaft bearing load as 4700N (Check Figure 23 for more details)
 Put 30kN Force on actuator connecting surface (Check Figure 23 for more details)
 Set ring gear tangential forces (7766N) as a moment (Check Figure 24 for more details)

47
  Set ring gear radial forces as pressure force (Check Figure 35 for more details)

Figure 22:Some of the Constraint applied to Gear Box Housing

Figure 23:Moment applied with using tangential force of the Ring Gear

48
Figure 24:Pressure applied with using radial force of the Ring Gear

It was difficult to set the correct mesh and fine-tuned it as student version of Ansys Mechanical only
allow 32 000 elements/nodes. It gives error message as illustrated in Figure 26 when the model was
solved.

Figure 25:Error message due to large number of elements/nodes

However, when the mesh size was set to a value higher than 35mm level, it gave some results. Table 14
shows the number of elements/nodes which was obtained when 35mm size elements were used and the
mesh result were exhibited in Figure 27.

Table 15:Number of elements and nodes obtain with the least Mesh sizes

Mesh
Object Name

State Solved

Statistics

Nodes 27525

Elements 15169

49
Figure 26:Final Mesh appearance

Figure 28 and Figure 29 shows the total deformation and equivalent von mises stress results. To
perform better analysis, need to buy better Ansys Mechanical software license and do a mesh
optimization.

50
Figure 27:Total Deformation results of Gear Box Housing

51
Figure 28 : Equivalent Stress (Von-Mises) results of Gear Box Housing

52
3.0 References
Black, A. (2001, JUN). machinerylubrication. Retrieved from www.machinerylubrication.com:
https://www.machinerylubrication.com/Read/1080/worm-gears
Budynas, R. & Nisbett, K. (2010). Shigley's mechanical engineering design (9th ed.).
Boston: McGrawHill.

Black, A. (n.d.). Machinery lubrication. Retrieved from The ins and outs of worm gears:
http://www.machinerylubrication.com/Read/1080/worm-gears
KHK Gears. (n.d.). Spur Gears. Retrieved from http://khkgears.net/product-category/spur-gears/
Khurmi, R. S., & Gupta, J. K. (2005). Machine design. multicolour edition
EURASIA PUBLISHING HOUSE (PVT.) LTD.
Kubota, M. (n.d.). khkgears. Retrieved from khkgears.ne.
KYOUIKU. (2005). Locking fixtures for gear shaft . Retrieved from https://www.kggear.co.jp/en:
https://www.kggear.co.jp/en/wp-content/themes/bizvektor-global-edition/pdf/2.7_Locking-
fixture-for-gear-shaft_TechnicalData_KGSTOCKGEARS.pdf
Nazzaro, J. (2013, APR 03). machinedesign. Retrieved from www.machinedesign.com:
https://www.machinedesign.com/motors-drives/article/21833641/the-benefits-of-gearboxes-
and-when-to-pick-integrated-gearmotors
newport. (n.d.). newport. Retrieved from www.newport.com: https://www.newport.com/n/stage-
components-considerations
Powers, K. (2000, OCT 01). machinedesign. Retrieved from www.machinedesign.com:
https://www.machinedesign.com/automation-iiot/article/21827133/keyless-devices-get-a-grip-
on-shafts
Powers, K. (2000, OCT 01). machinedesign. Retrieved from www.machinedesign.com:
https://www.machinedesign.com/automation-iiot/article/21827133/keyless-devices-get-a-grip-
on-shafts
Srivastava, A. (2017, JAN 30). thors. Retrieved from thors.com: https://thors.com/2017/01/30/spur-
gears-versus-helical-gears/

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4.0 set of manufacturing drawing

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