Design of a one-stage parallel-shaft helical gear drive

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Reference no: EM133014333

MECH215 Mechanical Engineering Design - University of Wollongong

Design Project - Two-Stage Spur Gear Drive Design

This is a group project where you will collaborate in teams of three. Group allocations will occur during Week 5-6.

Scenario
You have developed a promising design of a one-stage parallel-shaft helical gear drive for the client. Now the client is requesting another design of gear drives with input and output shafts being concentric (on the same axis).

The client's design requirements to this new gearbox are as follows:

Design Arrangement, Decision, and Assumptions

You will work on this project with another two teammates (i.e., another two students in the class). To plan for the design, you three have had a team meeting, from which the following design decisions and assumptions have been made according to design experience and the user guides of the commercial mechanical components:

• The gear drive is to be a two-stage spur gear train.
• KHK spur gears and SKF rolling bearings are used.

Task 3.1: Identification of the design requirements (Group task)
• Summarise the design requirements of the given design task.

Task 3.2: Kinematic design of the gear reducer (Group task)
• Select the gears from KHK spur gear catalogue to meet the required speed ratio.
• Determine the remaining kinematic dimensions of the gear drive.

Task 3.3: Shaft layout (Individual task)
• Sketch out a schematic of the layout of the input shaft, (Student A), intermediate shaft (Student B), and output shaft (Student C), respectively. The layout should consider the arrangement for all essential shaft components such as the gears, bearings, retaining rings, pins or keys, seals, etc.

Task 3.4: Bearing selection (Individual task)
• Perform the force analysis for the input shaft, (Student A), intermediate shaft (Student B), and output shaft (Student C), respectively.

• Select suitable bearings from the SKF rolling bearing catalogue for the input shaft, (Student A), intermediate shaft (Student B), and output shaft (Student C) to meet the required duty and load conditions of the gear drive.

Task 3.5: Shaft sizing (Individual task)
• Determine the sizes of the input shaft, (Student A), intermediate shaft (Student B), and output shaft (Student C). All the detailed shaft arrangements such as keyways, shoulders, and relief grooves should be included. Check KHK and SKF user guides to design the fits of the input shaft for the pinion and the bearings, respectively. Provide your calculation for sizing such as the fits.

Task 3.6: Stress analysis of the shafts (Individual task)
• Analytical analysis: Calculate the von-Mises stresses and Factors of Safety for fatigue failure of the input shaft, (Student A), intermediate shaft (Student B), and output shaft (Student C), at the nominal torque, using the modified Goodman criteria for the critical section that you identified. For this analysis, you are required to use the basic theory as set out in Chapters 5 and 6 of the textbook. You are forbidden from using the approach given in Chapter 7 or other direct shaft analysis algorithms.
• Numerical analysis: Perform an FEA simulation of the input shaft, (Student A), intermediate shaft (Student B),
and output shaft (Student C).

Task 3.7: CAD of the gear drive (Group task)
• Produce the relevant part and assembly drawings and section views of the gearbox including, for example, shafts, gears, bearings, keys, seals, rings, bolts/screws, and housing. You are allowed to use the supplier provided CAD files of the proprietary items (e.g., KHK gears and SKF bearings).
• Produce an animation to demonstrate the interior structure of the gearbox.

Task 3.8: Motor selection (Group task)
• Search for three different commercial electric motors from different companies that are feasible to work with this gear drive. Justify your reason for the selection.

Task 3.1 to 3.6
• Refer to Design Projects 1 & 2 handouts to check what should be provided in these relevant tasks.

Task 3.7: CAD of the gear drive
• Prints of relevant part drawings. You DO NOT have to include the part drawings of the proprietary items that you downloaded from internet.
• Prints of the overall assembly drawings.
• Prints of the relevant section views.
• Animation of the exploded view of the gear drive in AVI file format. (Check the following webpage to learn how to do it:
Autodesk official website: About Presentations,
• You DO NOT have to upload the source files of the drawings, but they should be ready to provide when requested.

Task 3.8: Motor selection
• Three tables that summarise the company names, motor ID, and key technical specifications of the three identified motors.
• Explanation of why the selected motors are suitable for the gearbox.

Attachment:- Mechanical Engineering Design.rar

Reference no: EM133014333

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