METU Mechanical Engineering Department ME 308 Machine Elements II Spring 2013 - Term Project Gearbox Design and Bearing

g Selection Ali Murat KAYIRAN Enes SALMAN Ferhat SALAM A-208 G-157 C-210 Due Date: 29/04/2013 mkayiran@metu.edu.tr salman@metu.edu.tr fsaglam@metu.edu.tr

Gun is one of the most critical parts of a battle tank (Figure 1). In order to hit the target successfully, the gun must be controlled in an accurate way. For this purpose, the guns of battle tanks can be controlled by means of linear actuators as shown in Figure 2. The linear motion of the actuator is used for changing the gun barrel angle of the battle tank. The gun elevation actuator is driven by an electric motor. In order to move the linear actuator with a desired speed and torque, a gearbox is used as shown in Figure 3. The purpose of the power transmission system is to transfer power from electric motor to the linear actuator of the battle tank gun. The transmission takes the electric motor output (torque at a certain angular velocity) and transfers it to the linear actuator at another angular velocity and torque. For power transmission helical and bevel gear sets are used. Figure 2 Electric motor and gearbox for linear actuator The gun angle is required to be changed between -10 and +20 degrees depending on terrain condition and location of target. The gun should be adjusted for shooting within one second. The barrel having 400 kg weight can be rotated around a hinged joint with a moment arm ratio of 20:1. It leads to approximately 0.1 m/s elevation speed of actuator rod. For this operation an electric motor with power output of about 5 kW is selected.

Figure 1 Gun of a battle tank

Figure 3 Linear actuator used for changing the gun angle

The gearbox:

Figure 4: Schematic view of the gearbox Gearbox Details The electric motor driving the gun rotates in +y direction for lifting the gun. The power from the electric motor is transmitted to the gearbox as shown in Figure 4 in which there is a helical and bevel gear set. The first stage is to be built up with a helical gear set and the second step is to be constructed as a bevel gear set. The operating conditions and the geometrical parameters are given in Table 1. The helical gears are cut using the cutters given in Figure 14-6&7 (Notes to be Used in Examinations). Helix angle is 20 for helical gears. The bevel gears are straight bevel gears with 20 pressure angle. The gear box dimensions given in the Table 4, are to be measured from housing and bearing centerlines. Tooth profiles are uncrowned. Design all the gears for the minimum standard module. Choose the minimum number of teeth to avoid interference and undercutting, and use the standard modules in general use from the table given in Notes to Be Used in Examination. Specify the smallest (e.g. inner diameter, outer diameter) bearings on the Shaft 1 and 3 in the gearbox. o For the bearings which support Shaft 3, use 303 series tapered roller bearing. o For Shaft 1, deep groove ball bearings are to be selected. Consider Bearing A as a floating bearing. Note that bearings run in uppermost region of normal operating conditions for a23. Take fz=1.1 & fd=1.3 for deep groove ball bearings and tapered roller bearings. Explain the mounting details (keys, retaining rings, grooves, shoulders, seals, etc) of bearings and gear on Shaft 1 by drawing sketches. Fill in the Table 2 & 3 with the specified manufacturing data. In your detailed design, consider the assembly steps. Prepare an animation video file to show the assembly. (3 points out of 100 /Bonus) Prepare an animation of the working gearbox. (3 points out of 100 /Bonus)

Table 1: Gearbox Specifications Data Set 1 3000 5.0 1*107 99 2.45-2.50 2.10-2.18 3 3 9 20 50 SAE40 1000 90 Grade 1 steel, through hardened, 360 HB Grade 1 steel, through hardened, 380 HB Data Set 2 Data Set 3 Data Set 4 Data Set 5 3100 3200 2900 2800 5.2 5.1 4.9 5.0 2*107 3*107 4*107 5*107 99 99 99 99 2.45-2.50 2.45-2.50 2.45-2.50 2.45-2.50 2.10-2.18 2.10-2.18 2.10-2.18 2.10-2.18 3 3 3 3 3 3 3 3 8 8 9 8 20 20 20 20 50 50 50 50 SAE40 SAE40 SAE40 SAE40 1000 1000 1000 1000 90 90 90 90 Grade 1 Grade 1 Grade 1 Grade 1 steel, steel, steel, steel, through through through through hardened, hardened, hardened, hardened, 360 HB 360 HB 360 HB 360 HB Grade 1 Grade 1 Grade 1 Grade 1 steel, steel, steel, steel, through through through through hardened, hardened, hardened, hardened, 380 HB 380 HB 380 HB 380 HB Data Set 6 3000 4.8 6*107 99 2.45-2.50 2.10-2.18 3 3 9 20 50 SAE40 1000 90 Grade 1 steel, through hardened, 360 HB Grade 1 steel, through hardened, 380 HB

Input shaft 1 speed(rpm) Input power (kW) Number of load cycles for helical pinion Reliability (%) Velocity ratio of the helical gear set Velocity ratio of the bevel gear set Bending Factor of Safety Wear Factor of Safety Quality number Diameter of Shaft 1 (mm) Operating temperature (oC) Oil type Required service life for bearings (hours) Reliability of the bearings (%) Material of helical gear

Material of bevel gear

Table 2: Helical Gear Set Manufacturing Data Pinion Gear Part name / Index Material Normal pressure angle, n Normal module, mn Helix angle, Outside diameter Face width, F Number of teeth

Table 3: Bevel Gear Set Manufacturing Data Pinion Gear Part name / Index Material Normal pressure angle, Module, m Outside diameter Face width, F Number of teeth

Table 4: Geometric parameters [mm] L1 L2 L3 L4 98 102 105 120