SHAFT DESIGN WITH HELICAL GEAR, BEBEL GEAR, AND TWO

SUPPORTING BEARINGS

Virna V. Rodríguez
Aisha M. Nieves
Emmanuel Rosa
Wilfredo Mercado
Mechanical Engineering Department, University of Puerto Rico
Dr. Pablo Caceres

Abstract: A detailed analysis was performed in order to complete a shaft design with a
helical gear, bevel gear, two supporting bearings and a section change. The unknown
forces were calculated by sums of forces and moments, which were further used to
determine the shear stresses, bending moments and principal stresses. Taking into
consideration the actual uses of the shaft, an appropriate material was assumed to
calculate a diameter using material indices. The characteristics in consideration were a
stiff, strong, and light material. Calculations for acting plane and principal stresses,
fracture toughness, along with material selection properties agreed with the selection of
a low carbon steel (AISI 1025) as the best material for the shaft.

Introduction A shaft design will be completed in which the team will determine the
combined loads that are acting on the component, the maximum stresses and the stresses
with stress concentrators. A material selection and a fatigue analysis due to fluctuating
loads will be done in order to find the radius of the shaft. The team will research among
existing devices which work with such components, incorporating the helical gear, bevel
gear and the supporting bearings. Transmission shafts that transmit torque from one
location to another, such as the Caterpillar tractor transmission is an application for the
shaft design. Therefore, the analysis will help in the design of an efficient component
that might be used in real life.

Schematic:
 The analysis begins by noticing the forces acting on the shaft, and performing a series of
calculations to determine the unknowns.

Analysis of forces acting on the shaft

Assumptions:
1) Thrust load at bearing A.
2) Both gears will have forces acting on the three directions.
3) Bearing C will not have any forces acting on the ‘x’ direction
4) Uniform diameter throughout the shaft
5) Torque input magnitude at point D equal to torque output at point B

Given:
 First gear located on Point D:
a. Fx=2.57 KN
b. Fy=2.57 KN
c. Fz=10.0 kN

Torque at point D (Input)

 T  Fz rb
 d   0.375 
rb        0.1875m
2  2  d  0.375m
Fz  10kN
T  Fz rb  (10 kN ) * (0.1875m)
T  1.875kN  m

Therefore;

Tinput=Toutput

Ti  To  1.875kN  m  rg Fy
rg  250mm  0.250m

Ti  1.875kN  m 
FBy     7.5kN
rg  0.250m 

With this value we can proceed to calculate the force in the ‘z’ and ‘x’ direction at point
B.

FBx  (0.2625) FBy  (0.2625) * (7.5kN )  1.96875kN

FBz  (0.3675) * ( FBy )  (0.3675) * (7.5kN )  2.75625kN

Forces and Momentum on the different sections of the shaft:

F x  0;
 FAx  FBx  FDx  0
 FAx  1.96875  2.57  0
FAx  4.53kN

F y  0;
FAy  FBy  FCy  FDy  0
FAy  7.5  FCy  2.57  0
FAy  FCy  4.93

F z  0;
FAz  FBz  FCz  FDz  0
FAz  2.75625  FCz  10  0
FAz  7.24375  FCz
  We calculated the Momentum in point A, in the ‘y’ direction, to find the
Force acting on point C in the ‘z’ direction. By obtaining this we will be able
to calculate the Force acting on point A in the ‘z’ direction.

M Ay 0

FBz (0.5m)  FCz (0.9m)  FDz (1.25m)  0

 (2.75625kN ) * (0.5m)  FCz (0.9m)   (10 KN ) * (1.25m)  0

FCz (0.9m)   ( 2.75625kN ) * (0.5m)   (10 KN ) * (1.25m)

FCz  12.357639kN

Therefore;
FAz  7.24375  FCz
FAz  7.24375  12.357639
FAz  5.113889 kN
 We calculated the Momentum in point A, in the ‘z’ direction, to find the
Force acting on point C in the ‘y’ direction. By obtaining this we will be able
to calculate the Force acting on point A in the ‘y’ direction.

M Az 0

FBy (0.5m)  FCy (0.9m)  FDy (1.25m)  0

 (7.5kN ) * (0.5m)  FCy (0.9m)   (2.57kN ) * (1.25m)  0

FCy (0.9m)   (7.5kN ) * (0.5m)   (2.57kN ) * (1.25m)

FCy  0.59722kN

Therefore;
FAy  FCy  4.93
FAy  4.93  ( 0.59722)
FAy  4.332kN

As part of the analysis for the shaft chosen, it includes the search for the different
forces exerted in the bearings. Also, how these forces act on the shaft. By finding these
different forces and developing the Shear and Moment Diagrams we are able to find out
which are the critical points.

Fay Fby Fcy Fy

V 3.168
0 2.57

-4.332

M 0

.8988
-2.166
Z

X Faz Fbz Fcz Fz

10

V 0

-2.3576
-5.113

M 0

-2.5569

-3.5
 Critical Section:

At Point B:
M y
 x  z =-120.575MPa
I

With Stress concentration:

σs.c= Kfbσnom= -233.314MPa

At Point C:

Mzy
x  = -165.049 MPa
I

Therefore the critical Section will be at point B

 0.032
I  6.36 *10 7
4

M Fcy r
 MFcy   11 .265MPa
I
M Fy r
 MFy   90.895MPa
I
FBx
 FBx   0.696 MPa
A
F
 Fx  x  0.909 MPa
A

16T
T   44.210 MPa
d 3
4 FBz
 FBz   1.3MPa
3A
4 FCz
 FCz   5.827 MPa
3A
4 Fz
 Fz   4.715MPa
3A
 total   FBx   Fx   MFcy   MFy  103.765

 max   FBz   FCz   Fz   T  41.798MPa

Principal Stresses
 x  yx  zx    103.765 41.798 0
   41.798
 xy  y  zy    0 0
 xz  yz  z   0 0 0
 

 1  14.7366MPa
 2  0MPa
 3  118.501MPa

Stresses
 r 4  *  0.03m  4
I    6.36e  7 m 4
4 4
M Fcy y
x   11 .265MPa
I
M Fy r
 Mfy   90.895MPa
I
F
 Fbx  Bx  0.696MPa
A
Fx
 Fx   0.909MPa
A
4V 4 *  2.57kN  kN
 xy    436.296750663 2
3 A 3 *  *  0.05m  2
m

For the ‘zx’ plane the critical zone occurs at point c: Moment in ‘y’

Vmax=10kN
Mmax=-3.5kN*m

r 4  * (0.05m) 2
I    4.90873852 x10 6 m 4
4 4
M y y   3.5kN  m  *  0.05m  kN
x   6 4
 35650.7072526 2
I 4.90873852 x10 m m
4V 4 * 10kN  kN
 xz    1697.65272631 2
3 A 3 *  *  0.05m  2
m

There are two shear stresses caused by Torsion. They are the following:

Tr (0.6425kN * m)(0.05m)
 xy    3272.22562997kN / m 2
r 4
 (0.05) 4

2 2

Tr 1.875kN * m(0.05)m
 xy    9549.29658551kN / m 2
r
4
 (0.05) 4

2 2

The total stresses are the following:

Normal stresses for ‘zx’ and ‘yx’ are:

 total  -43831.2713275 kPa

The shear stresses for ‘yx’ plane and due to the torsion acting on critical sections B and
C:
τtotal= 436.296750663-3272.22562997-9549.29658551= -12385.2254648 kPa

Invariants

I1   x   y   z  43831.2713275kPa

I 2   x y   y z   x z   xy
2
  xz2   yz
2

I 2     43831.2713275 *  0     0 *  0       43831.2713275 *  0  
   12385.2254648  (1697.65) 2   0   156275825.336kPa
2 2

I 3   x y  z  2 xy xz yz   x yz
2
  y xz
2
  z xy
2

I 3   (43831.2713275) * (0) * (0)   2 *   12385.2254648 * 1697.65272631 *  0  

    43831.2713275 *  0      0  *   1697.65272631     0  * 12385.2254648 

I3  0

We substitute in the following equation to find the principal stresses acting in the shaft.

 3  I 1 2  I 2  I 3  0
 3    43831.27132752 * ( 2 )  (156275825.336) * ( )  (0)  0
kN
 1  3314.72128739 2
m
kN
2  0 2
m
kN
 3  47145.9926149 2
m
Corrected Stresses with Stress Concentrators

Fatigue Analysis

Material Selection:

In order to select our material, we determined that the shaft should be stiff. It
should be able to hold a large amount of force to prevent it from bending and it should
have a small angle of twist. If it has a big deflection, the gears could separate from each
other, causing them to not function properly or to wear off. This would also cause failure
of the bearings. In order to achieve these criteria, the following calculations were
performed.

For the bending forces:

F  ( stiffness ) max
r 2
I 
4
m  r 2 L

N 2 EI
F  max
L2

N 2 E
r 4

F 4  max
L2

N 3 Er 4
F  max
4 L2

4 FL2
r2 
N 3 E max

4 FL2
m  
N 3 E max

 4 FL2   
m     1/ 2 
 N 3 max   E 

 4 FL2   
m     1/ 2 
 N 2 max   E 

 4   
m  2 L   1/ 2 
 N max  E 
 For angle of twist:

TR 2T
   3
J r
m  r L
2

r 4
J 
2

F
 
N

F 2T
 3
N r

  2TN  2 / 3    
m  L   2 / 3 
      F 

After obtaining these results, we went to the tables (“Young’s modulus of

elasticity vs Density” and “Strength vs Density”) to maximize the followings
E 
1/ 2  F 2 / 3 
relationships:   for bending forces, and   for the angle. Because  F is a
     
 y   y 2 / 3 
function of:  y   F   , we maximize  .
2 
   

The following diagram was used to determine the materials applicable to the shaft design:
From the table, we obtained certain materials that could be use for the shaft.

Strenght Angle of twist

 Al2O3  CFRP
 SiC  Ti alloys
 Composites  Mg alloys
 Glass  Al alloys
 Al alloys  Al2o3
 CFRP  SiC
 Steels  Steels

As we can observe, some of these material can be discarded such as glass and
ceramics because of their tendency to fail due to the appearance of cracks. After
analyzing these facts, we determine that Al and steels are good candidates for the shaft,
but aluminum was discarded because it can be seen in the fatigue diagram that aluminum
will always fail after certain number of cycles, while steel supports higher stresses
fluctuations before failing. Research was performed and it was founded that low carbon
steel has the specifications desired for a shaft design.
An analysis between several low carbon steels was done.

Material E  y  E 1/ 2   y 2 / 3 
   
     
AISI 1010 Steel 205GPa 7.87g/cc 305 GPa 57.53 5757.38
AISI 1015 Steel 205GPa 7.87g/cc 300 GPa 57.53 5694.28
AISI 1022 Steel 205GPa 7.85g/cc 300 GPa 57.61 5702.98
AISI 1025 Steel 200GPa 7.85g/cc 310 GPa 56.91 5829.02

After comparing various types of carbon steels we have selected AISI 1025 which is a
low-carbon steel. This material will be machined to achieve the desired shape.

AISI 1025 Steel

Physical Properties Metric English Comments

Density 7.858 g/cc 0.284 lb/in³ Chemical composition of 0.23% C, 0.635%

Mn, 0.11% Si, annealed at 925°C

Mechanical Properties

Hardness, Brinell 111 111

Hardness, Knoop 129 129 Converted from Brinell hardness.
Hardness, Rockwell B 64 64 Converted from Brinell hardness.
Hardness, Vickers 115 115 Converted from Brinell hardness.
Tensile Strength, Ultimate 380 MPa 55100 psi
Tensile Strength, Yield 310 MPa 45000 psi
Elongation at Break 15 % 15 %
Reduction of Area 35 % 35 %
Modulus of Elasticity 200 GPa 29000 ksi Typical for steel
Bulk Modulus 140 GPa 20300 ksi Typical for steel.
Poisson's Ratio 0.29 0.29 Typical For Steel
Shear Modulus 80 GPa 11600 ksi Typical for steel.
Stress concentrations:
Section y-x: Critical Point B

Using the following diagrams:

r/d = 1.8/60= 0.03

D/d = 90/60 = 1.5

Kt,bending = 2.35
Kt,shear = 1.9
Kt, axial = 2.7

Sut steel = 900 MPa

a  0.118in 0.5
kf  1  q (kt  1)
1 1
q   0.693
a 0 .118
1 1
r 0.07

Kf (bending) = 1.94
Kf (shear) = 1.62
Kf (axial) = 2.18

From Materials selection Sut= 900MPa:

Se’ = 0.5Sut = 0.5 (900) = 450MPa

Se corrected:
Ksurf=0.93
Ksize:
A95= 0.0766d^2 = 0.0766 (0.06)^2 = 2.758e-4 m2
d equivalent =
A95 / 0.0766  0.06m

Ksize = 1.189(d)^*-0.097 = 0.8

Se= (0.93)(0.897)(0.8)(1.5621)= 300.3156 Mpa

Corrected stresses :

σs.c= (0.696 MPa) (2.18) + (0.909) (2.18) + (11.265) (1.94) + (90.895) (1.94)
= -201.6893MPa
τs.c = (1.62)(-44.20) + 1.3 + 5.827 – 4.715 = 234.55 MPa
 VM   total  3 total
2 2
 (201.6) 2  3(69.21) 2  234.55MPa
nf= Se/σVM= 300.3156/234.55 = 1.3
Conclusion
A complete analysis of the forces acting on the shaft, the calculation of the maximum
stresses acting with stress concentrators and a fatigue analysis was done. Low carbon
steel AISI 1025 has been selected as the proper material that agrees with the material
selection analysis drawn. The material selected is stiff, holds a considerably high static
force, has a small twist angle, and supports considerably high load fluctuation. A diameter
of 60mm has been selected for the shaft taking into consideration the material selected
along with the loads acting on it. A safety factor was computed using Goodman theory in
a fatigue analysis. The fatigue analysis was done for infinite life. These calculations
corroborated the safe operation of the shaft we designed.

References:

http://www.matweb.com/index.asp?ckck=1

http://academic.uprm.edu/pcaceres/

http://www.google.com