MEGR 3221-001 Machine Design Spring 2014 Project Description Engineering Analysis of a Parallel Shaft Speed Reducer Pictured

below is a Dayton 4Z860 parallel shaft speed reducer with 17.5:1 speed reduction. It is rated for input from a 3/4 HP motor running at 1725 rpm. This provides an output speed of 100 rpm with a maximum output torque of 454 in-lbs. In addition the shaft must support a perpendicular overhanging load of up to 773 lbs. applied 3/4 inch from the oil seal of the output shaft. The input shaft is assumed to be mounted co-axially with the driving motor, so no external lateral loads will be present. The goal of this project is to do a complete engineering analysis of this product to verify the load and life capability of the shafts, gears, and bearings. The project will be completed in phases throughout the semester.

Item Type Shaft Orientation Duty Input RPM Nominal Output RPM Overhung Load (Lb.) Nominal Ratio Max. Input HP Max. Torque (In.-Lbs.) Output Torque @ 1/4 HP (In.-Lb.) Output Torque @ 1/3 HP (In.-Lb.) Output Torque @ 1/2 HP (In.-Lb.) Output Torque @ 3/4 HP (In.-Lb.) Number of Stages Rotation Lubrication Oil Seal Bearings Pinion Gearing Finish Output Shaft Dia. (In.) Output Shaft Height (In.)

Speed Reducer Indirect Drive Parallel Standard 1725 100 773 17.5:1 3/4 454 151 201 302 454 1 Forward/Reverse Kluber Food Grade Double Lip Ball Hardened Steel Helical and Spur Powdered Epoxy Paint 1 4.88

Project Breakdown (100 pts total)

1. Load analysis (25 points) Due Feb. 13, 2014 Create free body diagrams of all of the shafts (with gears in place) in both the horizontal and vertical planes. Use the manufacturers maximum load/torque ratings as inputs and compute the reaction loads on each shaft at the bearing locations, and at each gear mesh point. Use the dimensional layout and shaft dimensions supplied to determine the intersection points of all of the gears, and the resulting force directions. Note that the manufacturer allows an overhanging load normal to the shaft axis of up to 773 lbs on the output shaft at a point 1 inch outboard from the oil seal, but does not specify the direction of the load. Create your free body diagrams for this load in its worst case orientation, and justify the selected orientation. Consider how the loads will change if the direction of input torque is reversed, and choose the worst case for analysis. Deliverables: a. Report describing the loading cases selected for analysis, with justification b. Free body diagrams for all shafts in horizontal and vertical planes c. Summary table showing all bearing loads and gear tooth loads

2. Shaft calculations (35 points) Due Mar. 25, 2014 For each shaft, input shaft, countershaft, and output shaft, draw the shear and bending moment diagrams in both the horizontal and vertical planes. Use the shaft dimensions supplied, and the forces from the solutions provided for Part 1. Determine the critical section or sections to be analyzed for each shaft, taking into consideration any stress concentrations. Determine the range of stresses at each critical location as the device operates under full load. We do not know the material alloy or heat treatment used for these shafts, and therefore do not know the strength properties. Select a steel alloy for each shaft that will result in infinite fatigue life with a factor of safety of at least 2. Make reasonable assumptions needed to complete the analysis. Deliverables: a. Report on stress analysis for each shaft, with shear and bending moment diagrams if the horizontal and vertical planes and identifying the stresses acting on the critical sections. b. Material selection report for each shaft with accompanying fatigue life calculations, identifying any assumptions used in the analysis. 3. Bearing life (15 points) Due Apr. 10, 2014 Each of the shafts is supported by a two ball bearings. The bearing model numbers are provided in the dimensional drawings below. Consult the tables in the text for the basic static and dynamic load ratings for each bearing. Determine the expected life of the bearing based on the loads computed in Section 1. Make any reasonable assumptions required to complete the analysis. Deliverables: a. Analysis of bearing life for all bearings. 4. Gear calculations (25 points) Due Apr. 24, 2014 Analyze the pinion gears in each gearset using the tooth forces obtained from Part 1. The manufacturer states that the steel gears have been induction hardened, but does not provide a specific hardness. Assume that the steel pinions have been hardened to 500 Bhn, and find the required face width for each pinion to provide infinite life with a Factor of Safety of at least 1.4, based on both a Tooth Bending Analysis and a Surface Fatigue Analysis. Make any reasonable assumptions required to complete the analysis. Deliverables: a. Report on pinion gear tooth analysis, identifying any assumptions used in the analysis.

Output shaft

Countershaft Cover Input Shaft

Support for output shaft bearing

Support for countershaft bearing

Fig. 1. Speed reducer interior

Housing

Output gear

Input gear on countershaft

Output pinion on countershaft

Fig. 2. Speed reducer interior showing cover with countershaft and output shaft

Input helical gear

Input helical pinion integral with input shaft

Output pinion integral with countershaft Output gear

Fig. 3. Speed reducer interior from bottom showing input shaft pinion

Countershaft

Input shaft helical gear

Output shaft front bearing support

Output shaft

Fig. 4. Speed reducer interior from bottom with output shaft removed

Countershaft front bearing support

Input shaft helical gear Countershaft

Output shaft

Fig. 5. Speed reducer interior with countershaft and output shaft removed

Output shaft

Countershaft

Input shaft helical pinion

Fig. 6. Speed reducer cover with shafts

Cover

Input shaft retainer

Input shaft

Fig. 7. Input shaft assembly showing cover and retainer

Countershaft front bearing

Input gear meshes with input shaft pinion

Output pinion meshes with output shaft gear

Countershaft rear bearing

Fig. 8. Countershaft

Output shaft front bearing

Output shaft gear

Output shaft rear bearing

Fig. 10. Output shaft

Input shaft front bearing

Input shaft rear bearing

Input shaft helical pinion

Fig. 11. Input shaft

Input Shaft dimensions (not to scale, all dimensions in inches):

5.95 4.07 4.00 3.44 2.95 2.87 2.18 2.05 1.65 1.55 1.40 1.20 Keyway - .125W X .063 D

0.677 DIA 0.980 DIA 0.985 DIA Centerline of 205 BRG

0.750 DIA 0.788 DIA Centerline of 204 BRG All fillets 0.01 Radius 1.160 DIA

0.655 DIA

Countershaft Dimensions (Not to scale all dimensions in inches)

4.16 3.49 3.28 3.18 1.88 0.45 0.36 0.23 4.40

0.67 DIA

0.81 DIA 0.65 DIA

0.67 DIA Centerline of 203 BRG Centerline of Input Gear Keyway: 0.19W X 0.09D X 0.75L

Centerline of 203 BRG All fillets 0.01 Radius

Output pinion integral to shaft

Output Shaft Dimensions (Not to scale all dimensions in inches)

6.60 6.38 6.15 5.40 4.25 2.88 2.63 2.40 2.25 1.30 4.75

0.67 DIA 1.00 DIA Location of 773 lb. overhanging load Keyway: 0.25W X 0.19D All fillets 0.01 Radius Centerline of L06 BRG 1.37 DIA 1.18 DIA Centerline of output gear 0.82 DIA 0.98 DIA Centerline of 203 BRG Keyway: 0.25W X 0.19D X 0.75L

Shaft Layout - looking from input end towards output (Not to scale, all dimensions in inches)
O: I: C: Centerline of output shaft Centerline of input shaft Centerline of countershaft

= 1.383" = 2.219" = 1.857"

OCI = 38.4 OIC = 85.1 COI = 56.5
Output Gear

X O Output Pinion

Input Pinion Input Gear

Output Shaft

Countershaft

Input Shaft

Gear specifications:
Input Pair Input pinion:

16 teeth Pitch diameter = 0.571 inches Diametral pitch = 28 Pressure angle = 20 Helix angle = 11 88 teeth Pitch diameter = 3.143 Diametral pitch = 28 Pressure angle = 20 Helix angle = 11 Face width = 0.63

Input gear:

Output pair Output pinion: 17 teeth Pitch diameter = 1.063 Diametral pitch = 16 Pressure angle = 20 Output gear: 54 teeth Pitch diameter = 3.375 Diametral pitch = 16 Pressure angle = 20 Face width = 1.00