NAME

: ADITYA AVINASH JOSHI

STUDENT ID # : 200059052
COURSE : MECHANICAL DESIGN ENGINEERING (MAE 589 005)
PROBLEM : FLUID COUPLING PERFORMANCE DYNAMOMETER

PROBLEM STATEMENT
Shown below is a dynamometer set-up used to test the performance of uid coupling. An engine or
motor provides power to the coupling that in turn delivers its output to a gear reduction unit that drives
some dissipative load operating at constant speed. (The gear reduction unit is inserted between the
coupling and the load to insure that the coupling will operate at speeds where its eciencies are
acceptable.)A problem has arisen in the gear reduction unit. The sleeve bearings supporting the gear
shafts at 1 and 2 are becoming noisy and need to be replaced. It is proposed to do this with antifriction
bearings to increase their life and reduce losses. Your task is to determine reasonable loads to be used
to select the replacement bearings at locations 1 and 2 on both shafts using a measured severe set of
operating conditions. (Do not specify the bearing replacements). As a side issue how can the
measurements be used to determine the eciency of the coupling under test conditions.

Figure 1: FLUID COUPLING PERFORMANCE DYNAMOMETER

TEST OPERATING CONDITIONS

Results obtained during typical operation test are given as follows:
Input speed to fluid coupling

: 2000 rpm

Output speed from transmission

: 2000 rpm

Force required at point P

: 787.5 lbf

PROBLEM DEFINATION
We need to find net reaction force on just two bearing at location (1) and (2) as shafts on which gears D
& E and G and F & G are mounted would insert forces of same magnitude on shafts due to symmetry
and there would be no net reaction on bearing holding gears C and H due to symmetry.
Also in order use the proposed dynamometer for measurement of efficiency of fluid coupling we need
to determine relation between force that must be P in order to stop gear box from rotating and the
input torque to gear box. Once we know this relation we can measure Power output of fluid of coupling
by simply measuring force at P and knowing the output power of the engine (which is input power of the
coupling).

ASSUMPTIONS

Efficiency of gear box is assumed to be 100 %. Thus net power loss inside the gearbox is zero.
Power at gear C is equally distributed between gears D and F.
Gears inside the gear box are spur gears and pressure angle is 14.5o

ANALYSIS MODEL
As seen in following diagram, the driving torque of engine is in clockwise direction. Thus reaction
torque on coupling at B would be in anti-clockwise direction as shown in figure. Obviously the resulting
torque on shaft BC would be in clockwise direction. Gear C would possess torque in anti-clockwise
direction and it would transfer torque to gears D and F in clockwise direction. Thus resulting torque on
shaft holding gears D and F would be in anti-clockwise direction. As D and E are driven gears and E and
G are driving gears, torque received by gears D and F would be transmitted to output shaft through
gears E and G. Thus resulting torque on gears E and G would be in anti-clockwise direction and resulting
reaction torque on shaft holding gears E and G would be in clockwise direction. Also net torque on gear
H would be in clockwise direction and net torque on output shaft would be in anti-clockwise direction.

Figure 2: Torque Balance

TC, TD, TE, TF, TG, Tout = Torque on shafts where gears C, D, E, F, G and H are attached (lbf-in)
C, D, E, F, G, H = Angular speeds of gears C, D, E, F, G and H (rpm)
Fcd, Fcf = Force exerted by gear C on gears D and F (lbf)
Fcd, Fcf = Force exerted by gear C on gears D and F (lbf)
Fcd, Fcf = Corresponding reaction forces exerted by gears D and F on shafts (lbf)
Fhe, Fhg = Corresponding reaction forces exerted by gears E and G on shafts (lbf)
Fcdt, Fcft, Fhet, Fhgt = Tangential components of corresponding forces (lbf)
Fcda, Fcfa, Fhea, Fhga = Axial components of corresponding forces (lbf)
Fcdt, Fcft, Fhet, Fhgt = Reaction force due to tangential components of corresponding forces (lbf)
Fcda, Fcfa, Fhea, Fhga = Reaction force due to axial components of corresponding forces (lbf)
X1, X2 = Net horizontal reactions on bearing at locations 1 and 2 (lbf)
Y1, Y2 = Net vertical reactions on bearing at locations 1 and 2 (lbf)

Tinput = Input torque (lbf-in)

TB = torque at output of coupling (lbf-in)
input = Input speed (rpm)
B = C = Speed of gear C (rpm)
MATHEMATICAL MANIPULATIONS
With an assumption that power is equally distributed by gear C to gears D and F

TD D= TF f = (Tc /2) x c
TD = TF = (Tc x c)/ (2 x D ) = (Tc x c)/ (2 x F ) .. (Since D = F due to same gear ratio)
But,

TD = Fcd x cos (Pressure Angle) x Radius of gear D

.. (1)

TF = Fcf x cos (Pressure Angle) x Radius of gear F

Thus it can be concluded that,

Fcd = Fcf

. (Since radius and pressure angle of both gears is same)

Thus net reaction force on gear C is zero.

Net axial force on gear D

Fcda =Fcd

x sin (Pressure Angle)

Net Tangential force on gear D

Fcdt =Fcd

x cos (Pressure Angle) = TD / Radius of gear D

Fcd = Fcdt / cos (Pressure Angle) = TD /[ Radius of gear D x cos (Pressure Angle) ]
Fcda =Fcd

x sin (Pressure Angle) = [TD x cos (Pressure Angle) ]/[ Radius of gear D x cos (Pressure Angle) ]

Fcda = [TD x tan (Pressure Angle)] / Radius of gear D

Similarly,

Fcft = TF / Radius of gear F

Fcfa = [TF x tan (Pressure Angle)] / Radius of gear F

Consider following free body diagram:

Using similar analysis as done previously it can be proved that there is no net reaction force of gear H
and net reaction forces on gear E and G can be evaluated as:

Fhet = TE / Radius of gear E

Fhea = [TE x tan (Pressure Angle)] / Radius of gear E
Fhgt = TG / Radius of gear G
Fhga = [TG x tan (Pressure Angle)] / Radius of gear G
Also it can from equilibrium point of view

TG = TF and TE = TD

Thus,

TG = TF = TE = TD = (Tc x c)/ (2 x D ) = (Tc x c)/ (2 x F )

And also Tc = - TB = TInput

TG = TF = TE = TD = (Tinput x c)/ (2 x D )
Also, c /D = (No of teeth on gear C / No of teeth on gear D)
Thus, c /D = (36/20)

TG = TF = TE = TD = (Tinput) x (36/40)
And total power received by the output shaft is addition of power received from gears E & G.

TG G + TE E = Tout x H
Tout x H = 2 x TG G = 2 x TE E
Tout x H = 2 x (Tinput) x (36/40) x G = 2 x (Tinput) x (36/40) x E
Tout = (Tinput) x (72/40) x (G / H) = (Tinput) x (72/40) x (E / H)
Also, E /H = (No of teeth on gear H / No of teeth on gear E)
Thus, E /H = 40/16

Tout = (Tinput) x (72/40) x (40 / 16)

Tout = 4.5 x Tinput (Its direction would be opposite to that of input torque)
Thus,
Gear ratio (G) = 4.5
Also it can be observed that both input and output shaft rotates in same direction.
Thus resisting torque can be evaluated as,

TR = Tout - Tinput = Tinput x (G-1)

TR = 3.5 x Tinput (Its direction would be same as that of input torque)

With our assumption we dont need to evaluate net bending and twisting moment in this problem.
Horizontal and vertical force diagram are shown in following figure.

Figure 3: Horizontal and Vertical Force diagram

From horizontal force diagram

Fx = 0

X1 + X2 + Fcdt - Fhet = 0

(1)

1 = 0

Fcdt x 4 - Fhet x 9 + X2 x 13 = 0

(2)

Solving (1) and (2) simultaneously X1 and X2 can be obtained

From vertical force diagram
Fy = 0

Y1 + Y2 - Fcda - Fhea = 0

(3)

 1 = 0

- Fcda x 4 - Fhea x 9 + Y2 x 13 = 0

(4)

Solving (3) and (4) simultaneously Y1 and Y2 can be obtained

NUMERICAL COMPUTATION
TR = 3.5 x Tinput
But, TR

= Force at P x 16

Tinput = TR / 3.5 = (Force at P x 16 ) / 3.5

Thus for given operating conditions,

Tinput = (787.5 x 16) / 3.5 = 3600 lbf-in

Toutput = 4.5 x Tinput = 16200 lbf-in
P = Tinput x C = Toutputx H
Under operating conditions,

H = 400 rpm
Thus,

C = 1800 rpm
P = 6480000 lbf-in / min =
Now, We need to solve equations 1,2,3 and 4.

Fcdt = TD / Radius of gear D

Fhet = TE / Radius of gear E
Where, TD = TE = (Tinput) x (36/40) = 3600 x (36/40) = 3240 lbf-in

Fcdt = TD / Radius of gear D = 3240 / 4.5 = 720 lbf

Fhet = TE / Radius of gear E = 3240 / 2 = 1620 lbf

Fcda= [TD x tan (pressure angle)]/ Radius of gear D = Fcdt x tan (pressure angle) = 186.20 lbf
Fhea= [TE x tan (pressure angle)]/ Radius of gear E = Fhet x tan (pressure angle) = 418.96 lbf
Thus solving equations (1) and (2) simultaneously,
X1 = 0 lbf
X2 = 900 lbf
Solving equations (3) and (4) simultaneously,
Y1 = 257.81 lbf
Y2 = 347.34 lbf
Thus total radial loading on bearing at location (1) & (2):

B1 = (12 + 12 )1/2 = 257.81 lbf

B2 = (22 + 22 )1/2 = 964.70 lbf
Efficiency of fluid coupling = 1 slip = C / input = 1800/2000 = 90%
In general efficiency can be evaluated knowing the value of input by measuring H (which is output
speed) and knowing the fact that gear ratio is 4.5 which means that C = 4.5 x H
Thus general formula for efficiency of proposed fluid coupling is given as:
Efficiency of fluid coupling = 4.5 x H / input
Where H is measured output speed and input is known

RECOMMENDATIONS

Bearings at locations (1) and (2) must be selected to withstand radial load of approximately 260
lbf and 970 lbf.
Efficiency of fluid coupling can be determined using following relation by measuring the output
speed and knowing the input speed.
Efficiency of fluid coupling = 4.5 x H / input
where H is measured output speed and input is engine speed.