Impeller Assembly Technical Documentation and Design Analysis

Team 1

Easton Fray & Reece Armbrustmacher

Department of Mechanical Engineering, Kettering University

MECH 300: Computer Aided Engineering

Professor Paul Zang

December 16, 2021

File Locations:
Final impeller assembly file location:
U:/Mech_300_B/fray3513/Final Project/Parts

FEA:
U:/Mech_300_B/armb2470/Final Project/

Shaft_subassm
Shaft_Extension

U:/Mech_300_B/fray3513/Final Project/FEA

fray3513_Shaft_Load

Final Project Presentation & Report:

U:/Mech_300_B/fray3513/Final Project/Oral Presentation

Introduction:
In this project we were tasked with creating the CAD modeling for the Impeller
Assembly. Once we assembled the parts we then were tasked with creating FEA
analysis of the shaft assembly parts. These three parts were the shaft impeller, shaft
extension, and the shaft load. We were tasked with optimizing each part to meet the
target stress of 8,500 PSI that is derived from having a factor of safety of 4 which is
divided by the yield strength of rolled steel which was 34,000 PSI and to reduce the
weight. We showed this by running FEA analysis on each part with its original design.
Once we had a starting point we then started creating new designs that were optimized
to meet the requirements of Von-Mises stress and to reduce the weight. Below is the
constraint and load information that each part was analyzed for. We provided the before
optimization analysis and the after optimization analysis with a comparable summary
page and table. For the FEA loads each part will have a 20,000 in/lbf torque and a
10,000 lbf axial force acting on it. The shaft components need to have a factor of safety
of 4. This will also result in reducing the weight of each component.
Image: Constraint and Load Information of Shaft Impeller

Image: Constraint and Load Information of Shaft Extension

Image: Constraint and Load Information of Shaft Load
Rendered/Exploded Views:

Image: Isometric View of Complete Assembly

Image: Isometric Rendered View of Complete Assembly

Image: Isometric Rendered Assembly Exploded View

Assembly Drawing:

Component Drawings:
Image: Engineering Drawing of Bottom Housing

Image: Engineering Drawing of Top Housing

 Image: Engineering Drawing of Impeller

Image: Engineering Drawing of Shaft Extension Before Optimization

Image: Engineering Drawing of Shaft Extension After Optimization

Image: Engineering Drawing of Shaft Impeller Before Optimization

Image: Engineering Drawing of Shaft Impeller After Optimization

Image: Engineering Drawing of Shaft Load Before Optimization

Image: Engineering Drawing of Shaft Load Before Optimization
 FEA Analysis
Shaft Impeller:

Image: Shaft Impeller Constraint and Load Information

In order to run an FEA analysis on this part we used the following constraints. On the
right side of the pictured part the flange on the second lip is fixed. There are two forces
placed on this part. The axial force is placed on the edge of the spline as illustrated in
the image above with the red arrows. The axial force is the total load of 10,000 lbf
divided by the number of splines which is 10 in our case which is 1,000 lbf per spline.
The direction of these loads is facing down the center of the part toward the left end.
The torque force is the total load of 20,000 in/lbf divided by the 10 splines which is
2,000 in/lbf per spline. Which is then divided by the distance to the center which was
1.64 inches so the load per spline would be 1,219.51 lbf.
 Image: Before Optimization FEA Analysis

After running the FEA analysis on the shaft impeller part the results are pictured above.
In the original design the Current Max Von-Mises stress is at 29,919 PSI. The target
value is 8,500 PSI which we found by taking the yield strength divided by the factor of
safety which was 4. The current design is under-designed by 251%.

Image: First Design Change Adding Splines

The above image shows the first design change we had to this part. Instead of using the
keyway we used splines to make a more efficient design in connecting the shaft to the
impeller. We added 10 splines that use ISO 14-1982(E) for the dimensions that were
10X92X98.

Image: FEA Analysis on First Design Change

The image above is the FEA analysis for our first design change of adding the splines;
the current Max Von-Mises stress is 3,445.38 PSI. The target value is 8,500 PSI which
we found by taking the yield strength divided by the factor of safety which was 4. The
current design is over-designed by 59%.
 Image: Second Design Change of Adding Hole to Center of Part

The second design change we added is a hole that runs from the welded end of the part
into the splined portion. We did this in order to bring the max stress down to the target
stress that was assigned to us from the factor of safety of 4. The diameter of the hole is
3.447 inches and the depth is 10.5 inches so it does not interfere with the head slot on
the spline end of the part.
 Image: After Optimization FEA Analysis

The image above shows the final FEA analysis after the two design changes to
completely optimize the part. The target max stress for this part was 8,500 PSI and after
adding splines and the hole to the center of the part our final Max Von-Mises Stress is
8,566 PSI which is within 77% of the target value. We also can see the optimization in
the weight of the part. Before optimizing the part the weight was 26.84 kg and after the
two design changes it is now 12.7 kg. We were able to take off 47% of the weight which
was 14.14 kg to get to the required stress of the part with the material being rolled steel.
Shaft Extension:

Image: Shaft Extension Constraint and Load Information

In order to run an FEA analysis on this part we used the following constraints. On the
left side of the pictured part on the weld ring is fixed. There are two forces placed on this
part. The axial force is placed on the edge of the spline as illustrated in the image above
with the red arrows. The axial force is the total load of 10,000 lbf. The direction of these
loads is facing down the center of the part toward the right end. The torque force is the
total load of 20,000 in/lbf.
 Image: Shaft Extension FEA Analysis Before Optimization

After running the FEA analysis on the shaft extension part the results are pictured
above. In the original design the Current Max Von-Mises stress is at 2,619.56 PSI. The
target value is 8,500 PSI which we found by taking the yield strength divided by the
factor of safety which was 4. The current design is over-designed by 69%.
 Image: Shaft Extension FEA Analysis After Optimization

The image above shows the post optimization FEA analysis after the design change. To
optimize this part the thickness of the tube was changed to 0.12 inches. The target max
stress for this part was 8,500 PSI and after reducing the thickness of the tube wall our
final Max Von-Mises Stress is 8,504 PSI which is within 0.05% of the target value. We
also can see the optimization in the weight of the part. Before optimizing the part the
weight was 30.5 kg and after the design change it is now 9.27 kg. We were able to take
off 69% of the weight which was 21.23 kg to get to the required stress of the part with
the material being rolled steel.
In conclusion, the objective was to optimize the part to meet the target yield strength of
8,500 PSI and to reduce the weight. With the design change we were able to
accomplish these corrections. The weld area will be affected slightly but the part will still
be able to be assembled correctly.
Shaft Load:

Image: Shaft Load Constraint and Load Information

In order to run an FEA analysis on this part we used the following constraints. On the
right side of the pictured part on the weld ring is fixed. There are two forces placed on
this part. The load force is on the outside flat surfaces that are split. Those load forces
are 2,222 lbf on all 4 sides of the part. These load forces are all pointing directly
perpendicular to their surface towards the center of the part. There is also a load force
that is applied on the end of the part to the left side in the image. This force is 10,000 lbf
that is in the left direction of the part.
 Image: Shaft Load FEA Analysis Before Optimization

After running the FEA analysis on the shaft load part the results are pictured above. In
the original design the Current Max Von-Mises stress is at 1,939 PSI. The target value
is 8,500 PSI which we found by taking the yield strength divided by the factor of safety
which was 4. The current design is over-designed by 77%.

Image: Shaft Load FEA Analysis After Optimization

The image above shows the post optimization FEA analysis after the design change. To
optimize this part a hole was added in the center of the part that was 4.36 inches in
diameter. The target max stress for this part was 8,500 PSI and after adding the hole to
the center and finding the correct diameter our final Max Von-Mises Stress is 8,430 PSI
which is within 0.82% of the target value. We also can see the optimization in the weight
of the part. Before optimizing the part the weight was 25.5 kg and after the design
change it is now 8.35 kg. We were able to take off 69% of the weight which was 17.15
kg to get to the required stress of the part with the material being rolled steel.

Summary Table:
FEA Analysis Summaries
Initial Final
Initial FEA Max Final FEA Max Weight Weight Optimizati Optimization
Stress (PSI) Stress (PSI) (kg) (kg) on (kg) Percentage
Shaft
Impeller 29,919 8,566 26.84 12.7 14.14 47%
Shaft
Extension 2,619.56 8,504 30.5 9.27 21.23 69%
Shaft Load 1,939 8,430 25.5 8.35 17.15 67%

Conclusion:
After going through all of the parts we found that all of the parts needed to be optimized.
Starting with the shaft impeller, we had to change the key to a 10 spline shaft in order to reach
the required target design stress by distributing the load. We used ISO 14-1982(E) for the
dimensions of the splines. We also had to add a hole to the center of the part on the side that
will attach to the shaft extension. This hole was 10.5 inches long and had a diameter of 3.447
inches. By making these changes we were able to meet the stress requirements and reduce the
weight of the part. The next part we optimized was the shaft extension. For this part we had to
simply reduce the thickness of the tube wall from 0.375 down to 0.12 inches in order to meet the
stress requirements and reduce the weight. The objective was to optimize the part to meet
the target yield strength of 8,500 PSI and to reduce the weight. With the design change
we were able to accomplish these corrections. The weld area will be affected slightly but
the part will still be able to be assembled correctly and the change is still easy to
manufacture. The final part we optimized was the shaft load. In order to optimize this
part we added a hole that goes through the center of the entire part to reduce the stress
to the optimized value. The diameter of the hole was 4.36 inches. By making this
change we were able to meet the Von-Mises stress requirement derived from the yield
stress of rolled steel divided by the factor of safety.