ABE 330 Design of Machine Elements Design Of Shafts for Deflections

Problem Design an idler shaft for an underdrive mechanism in a tractor. The shaft is labeled SII in Fig. 1. Specifications Power transmitted, hp = 80 hp. Speed of shaft SII, Na2 = 600 rpm; Radius of gear G2 = 4 in. Radius of gear G3 = 3.5 in. The pressure angle is 20o. This means radial force = tan 20o * tangential force. G1 is a right-hand helical gear. (Verify that the axial force on G2 is in the negative x direction.) The helix angle is 15o. This means axial force = tan 15o * tangential force. Assume the indicated distances in Fig. 1 are between centers of gears or bearings. Distance between bearings B3 and B4 = 12 in; x3 and x5 minimum = 3.5 in. Maximum deflection slope at bearings B3 and B4 is 1o. Maximum deflection at gear G3 is 1/100 in. SI, SII, SIII are shafts. G1, G2, and G3 are helical gears. B1, B2, B6 are deep-groove ball bearings.

From SI engine B1 B2 B3 G2

G1 B5 G4 B6 SIII SII x3 G3 x4 y x5 x z B4 To load

Figure 1 Tractor underdrive gears, shafts and bearings.

Include in report 1. Free-body diagram of shaft SII. Calculate all forces and moments. a. Isometric (3-D) sketch. b. In x-y plane. Replace gears and bearings with forces and concentrated moments. Assume axial components of bearing forces B3y = B4y. c. In x-z plane. 2. Bending moment diagrams of shaft SII: a. In x-y plane. b. In x-z plane. 3. (Most important result) Sketch of shaft SII with its dimensions and positions of gears G2 and G3.
Sumali, Shaft Deflection Design

a. Pick x3 and x5 according to the specifications. b. Calculate the diameter so that the deflections are within specifications. Assume uniform diameter for the whole shaft. If all forces and moments in one plane are much higher than forces and moments in the other plane, use only the high-load plane for deflection calculations. c. Round up the diameter to the nearest bearing internal diameter in Hamrock Table 13.6. 4. Calculate the safety factor against yielding. a. Calculate the torsion in the shaft between G2 and G3. b. At G2, and G3, combine the bending moments vectorially, e.g. at G3, M 3 = M 3 y 2 + M 3 z 2 . c. Calculate the bending (normal) stress at G2, and G3. (If one bending moment is much higher than the other, don't worry about calculating the smaller bending stress). d. Calculate the torsional (shear) stress at G2 or G3 (same value). e. Use Mohr's circle formula to obtain the principal stresses at G2 or at G3, whichever has a higher bending moment. f. Calculate the von Mises equivalent stress e. Safety factor against yielding = yield strength/e. 5. Plot the deflections of the shaft as a function of x: a. In the x-y plane. b. In the x-z plane.

Sumali, Shaft Deflection Design

Possible Solution to the shaft deflection design problem Free-Body Diagram of shaft-gear assembly

F2y

x G3 y

Calculate tangential force F2y using torque-power-rpm relationship. Calculate vertical force F2z = F2y tan(pressure angle). Calculate axial force F2x = F2y tan(helix angle). Calculate the reaction forces using static equilibrium equations.

Sumali, Shaft Deflection Design

Sumali, Shaft Deflection Design

Sumali, Shaft Deflection Design

Sumali, Shaft Deflection Design

Sumali, Shaft Deflection Design

Sumali, Shaft Deflection Design

Sumali, Shaft Deflection Design

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%deflab.m %design of shaft based on deflection %sumali Feb 2000 clf; clear F2y=2101; F2z=765; F3y=2401; F3z=874; R2y=788; R2z=797; R3y=1088; R3z=842; F2x=563; F3x=643; R2=4; R3=3.5; M2=F2x*R2; M3=F3x*R3; dx=0.1; Imax=121; %Bending Moment in x-z plane for i=1:Imax; x(i)=(i-1)*dx; My(i)=-R3z*(x(i)); end for i=36:Imax; My(i)=My(i)+F3z*(x(i)-3.5)-M3;end for i=86:Imax; My(i)=My(i)+F2z*(x(i)-8.5)+M2;end plot(x,My); grid; title('Bending Moment in x-z plane'); xlabel('x (in)'); ylabel('M (lb.in)');

%Deflection in x-z plane C1=(-R3z/6*12^3+F3z/6*8.5^3-M3/2*8.5^2+F2z/6*3.5^3+M2/2*3.5^2)/12; for i=1:Imax; z(i)=R3z/6*(x(i))^3+C1*x(i); end for i=36:Imax; z(i)=z(i)-F3z/6*(x(i)-3.5)^3+M3/2*(x(i)-3.5)^2;end for i=86:Imax; z(i)=z(i)-F2z/6*(x(i)-8.5)^3-M2/2*(x(i)-8.5)^2;end

EI1=(R3z/6*3.5^3+C1*3.5)/(-0.01); E=30e6; I1=EI1/E; d1=2*(4*I1/pi)^0.25; %d turns out to be 1.4 in. Round it up to 40 mm to fit bearing d=40/25.4; I=pi/4*(d/2)^4; EI=E*I; z1=z/EI1; z=z/EI; figure plot(x,z,'-',x,z1,':'); legend('d=1.575in','d=1.40in'); grid; title('Deflection in x-z plane'); xlabel('x (in)'); ylabel('z (in)');

%Slope in x-z plane for i=1:Imax; thetay(i)=R3z/2*(x(i))^2+C1; end for i=36:Imax; thetay(i)=thetay(i)-F3z/2*(x(i)-3.5)^2+M3*(x(i)-3.5);end for i=86:Imax; thetay(i)=thetay(i)-F2z/2*(x(i)-8.5)^2-M2*(x(i)-8.5);end thetay=thetay/EI;

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figure plot(x,thetay*180/pi); grid; title('Slope in x-z plane'); xlabel('x (in)'); ylabel('Theta y (deg)'); %Bending Moment in x-y plane for i=1:Imax; Mz(i)=-R3y*(x(i)); end for i=36:Imax; Mz(i)=Mz(i)+F3y*(x(i)-3.5);end for i=86:Imax; Mz(i)=Mz(i)-F2y*(x(i)-8.5);end figure plot(x,Mz); grid; title('Bending Moment in x-y plane'); xlabel('x (in)'); ylabel('M (lb.in)');

%Deflection in x-y plane C1y=(-R3y/6*12^3+F3y/6*8.5^3-F2y/6*3.5^3)/12; for i=1:Imax; y(i)=R3y/6*(x(i))^3+C1y*x(i); end for i=36:Imax; y(i)=y(i)-F3y/6*(x(i)-3.5)^3;end for i=86:Imax; y(i)=y(i)+F2y/6*(x(i)-8.5)^3;end

EI2=(R3y/6*3.5^3+C1y*3.5)/(-0.01); E=30e6; I2=EI2/E; d2=2*(4*I2/pi)^0.25; %d turns out to be 1.026 in. So keep d=40 mm from the x-z plane calculation y=y/EI; figure plot(x,y); grid; title('Deflection in x-y plane'); xlabel('x (in)'); ylabel('y (in)');

%Slope in x-y plane for i=1:Imax; thetaz(i)=R3y/2*(x(i))^2+C1y; end for i=36:Imax; thetaz(i)=thetaz(i)-F3y/2*(x(i)-3.5)^2;end for i=86:Imax; thetaz(i)=thetaz(i)+F2y/2*(x(i)-8.5)^2;end thetaz=thetaz/EI; figure plot(x,thetaz*180/pi); grid; title('Slope in x-y plane'); xlabel('x (in)'); ylabel('Theta z (deg)');

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