SHAFT DESIGN WITH HELICAL GEAR, BEBEL GEAR, AND TWO

SUPPORTING BEARINGS
Virna V. Rodrguez
Aisha M. Nieves
Emmanuel Rosa
Wilfredo Mercado
Mechanical Engineering Department, niversit! of "uerto Rico
Dr. "a#lo $aceres
Abstract% A detailed analysis was performed in order to complete a shaft design with a
helical gear, bevel gear, two supporting bearings and a section change. The unknown
forces were calculated by sums of forces and moments, which were further used to
determine the shear stresses, bending moments and principal stresses. Taking into
consideration the actual uses of the shaft, an appropriate material was assumed to
calculate a diameter using material indices. The characteristics in consideration were a
stiff, strong, and light material. Calculations for acting plane and principal stresses,
fracture toughness, along with material selection properties agreed with the selection of
a low carbon steel (AISI !"#$ as the best material for the shaft.
Introduction A shaft design &ill #e completed in &hich the team &ill determine the
com#ined loads that are acting on the component, the ma'imum stresses and the stresses
&ith stress concentrators. A material selection and a fatigue anal!sis due to fluctuating
loads &ill #e done in order to find the radius of the shaft. (he team &ill research among
e'isting devices &hich &or) &ith such components, incorporating the helical gear, #evel
gear and the supporting #earings. (ransmission shafts that transmit tor*ue from one
location to another, such as the $aterpillar tractor transmission is an application for the
shaft design. (herefore, the anal!sis &ill help in the design of an efficient component
that might #e used in real life.
Sc!"atic#
(he anal!sis #egins #! noticing the forces acting on the shaft, and performing a series of
calculations to determine the un)no&ns.
Ana$%sis o& &orc!s actin' on t! sa&t
Assumptions%
+, (hrust load at #earing A.
-, .oth gears &ill have forces acting on the three directions.
/, .earing $ &ill not have an! forces acting on the 0'1 direction
2, niform diameter throughout the shaft
3, (or*ue input magnitude at point D e*ual to tor*ue output at point .
4iven%
5irst gear located on "oint D%
a. 5'6-.37 8N
#. 5!6-.37 8N
c. 5z6+9.9 )N
Tor(u! at )oint D *In)ut+
m k% T
m k% r & T
m
d
r
r & T
b '
b
b '



,
_

,
_

:73 . +
, +:73 . 9 ; < , +9 ;
+:73 . 9
-
/73 . 9
-
k% &
m d
'
+9
/73 . 9

(herefore=
(input6(output
k%
m
m k%
r
T
&
m mm r
& r m k% T T
g
i
(y
g
y g o i
3 . 7
-39 . 9
:73 . +
-39 . 9 -39
:73 . +

,
_

With this value &e can proceed to calculate the force in the 0z1 and 0'1 direction at point
..
k% k% & &
k% k% & &
(y ('
(y ()
73>-3 . - , 3 . 7 ; < , />73 . 9 ; , ; < , />73 . 9 ;
?>:73 . + , 3 . 7 ; < , ->-3 . 9 ; , ->-3 . 9 ;


5orces and Momentum on the different sections of the shaft%
k% &
&
& & &
&
A)
A)
*) () A)
)
3/ . 2
9 37 . - ?>:73 . +
9
= 9

+ +
+ +

?/ . 2
9 37 . - 3 . 7
9
= 9
+
+ +
+ +

Cy Ay
Cy Ay
*y Cy (y Ay
y
& &
& &
& & & &
&
C' A'
C' A'
*' C' (' A'
'
& &
& &
& & & &
&

+ +
+ +

-2/73 . 7
9 +9 73>-3 . -
9
= 9
We calculated the Momentum in point A, in the 0!1 direction, to find the
5orce acting on point $ in the 0z1 direction. .! o#taining this &e &ill #e a#le
to calculate the 5orce acting on point A in the 0z1 direction.
[ ] [ ]
[ ] [ ]
k% &
m +% m k% m &
m +% m & m k%
m & m & m &
,
C'
C'
C'
*' C' ('
Ay
/37>/? . +-
, -3 . + ; < , +9 ; , 3 . 9 ; < , 73>-3 . - ; , ? . 9 ;
9 , -3 . + ; < , +9 ; , ? . 9 ; , 3 . 9 ; < , 73>-3 . - ;
9 , -3 . + ; , ? . 9 ; , 3 . 9 ;
9

+
+
+

(herefore=
k% &
&
& &
A'
A'
C' A'
++/::? . 3
/37>/? . +- -2/73 . 7
-2/73 . 7



We calculated the Momentum in point A, in the 0z1 direction, to find the
5orce acting on point $ in the 0!1 direction. .! o#taining this &e &ill #e a#le
to calculate the 5orce acting on point A in the 0!1 direction.
[ ] [ ]
[ ] [ ]
k% &
m k% m k% m &
m k% m & m k%
m & m & m &
,
Cy
Cy
Cy
*y Cy (y
A'
3?7-- . 9
, -3 . + ; < , 37 . - ; , 3 . 9 ; < , 3 . 7 ; , ? . 9 ;
9 , -3 . + ; < , 37 . - ; , ? . 9 ; , 3 . 9 ; < , 3 . 7 ;
9 , -3 . + ; , ? . 9 ; , 3 . 9 ;
9

+
+
+

(herefore=
k% &
&
& &
Ay
Ay
Cy Ay
//- . 2
, 3?7-- . 9 ; ?/ . 2
?/ . 2


+
As part of the anal!sis for the shaft chosen, it includes the search for the different
forces e'erted in the #earings. Also, ho& these forces act on the shaft. .! finding these
different forces and developing the @hear and Moment Diagrams &e are a#le to find out
&hich are the critical points.
!

'
5a! 5#! 5c! 5!
V /.+>:
9 -.37
A2.//-
M 9

.:?::
A-.+>>
B
C 5az 5#z 5cz 5z
+9
V 9

A-./37>
A3.++/

M 9
A-.33>?
A/.3
Critica$ S!ction#
At "oint .%
I
y ,
'
)
6A+-9.373M"a
With @tress concentration%
Ds.c6 8f#Dnom6 A-//./+2M"a
At "oint $%
I
y ,
'
)
6 A+>3.92? M"a
(herefore the critical @ection &ill #e at point .
,-a
A
&
,-a
A
&
,-a
A
&
,-a
d
T
,-a
A
&
,-a
A
&
,-a
I
r ,
,-a
I
r ,
I
'
&'
C'
&C'
('
&('
T
)
&)
()
&()
&y
,&y
&cy
,&cy
7+3 . 2
/
2
:-7 . 3
/
2
/ . +
/
2
-+9 . 22
+>
?9? . 9
>?> . 9
:?3 . ?9
->3 . ++
+9 < /> . >
2
9/ . 9
/
7
-

,-a
T &' &C' &('
,&y ,&cy &) &() total
7?: . 2+
7>3 . +9/
ma'
+ + +
+ + +


Princi)a$ Str!ss!s
,-a
,-a
,-a
' y' )'
'y y )y
') y) )
39+ . ++:
9
7/>> . +2
9 9 9
9 9 7?: . 2+
9 7?: . 2+ 7>3 . +9/
/
-
+

1
1
1
]
1

1
1
1
]
1

@tresses
( )
( )
( )
- -
2
2 2
-?>739>>/ . 2/>
93 . 9 < < /
37 . - < 2
/
2
?9? . 9
>?> . 9
:?3 . ?9
->3 . ++
7 /> . >
2
9/ . 9 <
2
m
k%
m
k%
A
.
,-a
A
&)
,-a
A
&
,-a
I
r ,
,-a
I
y ,
m e
m r
I
)y
&)
()
&b)
&y
,fy
&cy
)

5or the 0z'1 plane the critical zone occurs at point c% Moment in 0!1
Vma'6+9)N
Mma'6A/.3)N<m
( ) ( )
( )
( )
- -
- 2 >
2 >
- 2
>3-7->/+ . +>?7
93 . 9 < < /
+9 < 2
/
2
797-3-> . /3>39
+9 ?9:7/:3- . 2
93 . 9 < 3 . /
+9 ?9:7/:3- . 2
2
, 93 . 9 ; <
2
m
k%
m
k%
A
.
m
k%
m )
m m k%
I
y ,
m )
m r
I
)'
y
)

(here are t&o shear stresses caused #! (orsion. (he! are the follo&ing%
-
2 2
E --3>-??7 . /-7-
-
, 93 . 9 ;
, 93 . 9 ,; < >2-3 . 9 ;
-
m k%
m m k%
r
Tr
)y

(he total stresses are the follo&ing%
Normal stresses for 0z'1 and 0!'1 are%
-
2 2
E -?>3:33+ . ?32?
-
, 93 . 9 ;
, 93 . 9 ; < :73 . +
-
m k%
m m k%
r
Tr
)y

total

A2/:/+.-7+/-73 )"a
(he shear stresses for 0!'1 plane and due to the torsion acting on critical sections . and
$%
Ftotal6 2/>.-?>739>>/A/-7-.--3>-??7A?32?.-?>3:33+6 A+-/:3.--32>2: )"a
Gnvariants
k-a I
' y )
-7+/-73 . 2/:/+
+
+ +
( ) ( ) [ ] ( ) ( ) [ ] ( ) ( ) [ ]
( ) ( ) k-a
I
I
y' )' )y ' ) ' y y )
//> . +3>-73:-3 9 , >3 . +>?7 ; --32>2: . +-/:3
9 < -7+/-73 . 2/:/+ 9 < 9 9 < -7+/-73 . 2/:/+
- - -
-
- - -
-

+ +
+ +
[ ] ( ) ( ) ( ) [ ]
( ) ( ) [ ] ( ) ( ) [ ] ( ) ( ) [ ]
9
--32>2: . +-/:3 < 9 >3-7->/+ . +>?7 < 9 9 < -7+/-73 . 2/:/+
9 < >3-7->/+ . +>?7 < --32>2: . +-/:3 < - , 9 ; < , 9 ; < , -7+/-73 . 2/:/+ ;
-
/
/
- - -
/

+
I
I
I
)y ' )' y y' ) y' )' )y ' y )

We su#stitute in the follo&ing e*uation to find the principal stresses acting in the shaft.
( )
-
/
-
-
-
+
- /
/ -
-
+
/
??->+2? . 27+23
9
7-+-:7/? . //+2
9 , 9 ; , ; < , //> . +3>-73:-3 ; , ; < -7+/-73- . 2/:/+
9
m
k%
m
k%
m
k%
I I I

+ +
+ +

Corr!ct!d Str!ss!s ,it Str!ss Conc!ntrators
Fati'u! Ana$%sis
-at!ria$ S!$!ction#
Gn order to select our material, &e determined that the shaft should #e stiff. Gt
should #e a#le to hold a large amount of force to prevent it from #ending and it should
have a small angle of t&ist. Gf it has a #ig deflection, the gears could separate from each
other, causing them to not function properl! or to &ear off. (his &ould also cause failure
of the #earings. Gn order to achieve these criteria, the follo&ing calculations &ere
performed.
5or the #ending forces%
( )
1
]
1

1
]
1

1
]
1

1
1
]
1

1
]
1

1
1
]
1

- E +
ma'
- E +
ma'
-
-
- E +
ma'
/
-
ma'
/
-
ma'
/
-
-
ma'
-
2 /
ma'
-
2
-
ma'
-
-
-
-
ma'
2
-
2
2
2
2
2
2
2
, ;
/ %
0 m
/ %
&0
m
/ %
&0
m
/ %
&0
m
/ %
&0
r
0
/r %
&
0
r
/ %
&
0
/I %
&
0 r m
r
I
stiffness &

5or angle of t&ist%

1
]
1

1
1
]
1

,
_

/ E -
/ E -
/
2
-
/
-
-
-
-
&
&
&
T%
0 m
r
T
%
%
r
1
0 r m
r
T
1
T2

After o#taining these results, &e &ent to the ta#les ;HIoung1s modulus of
elasticit! vs Densit!J and H@trength vs Densit!J, to ma'imize the follo&ings
relationships%
1
]
1

- E +
/
for #ending forces, and 1
]
1

/ E -
&
for the angle. .ecause
&
is a
function of%

,
_

-
y
& y


, &e ma'imize
1
1
]
1

/ E -
y
.
(he follo&ing diagram &as used to determine the materials applica#le to the shaft design%
5rom the ta#le, &e o#tained certain materials that could #e use for the shaft.
Str!n't An'$! o& t,ist
Al-K/ $5R"
@i$ (i allo!s
$omposites Mg allo!s
4lass Al allo!s
Al allo!s Al-o/
$5R" @i$
@teels @teels
As &e can o#serve, some of these material can #e discarded such as glass and
ceramics #ecause of their tendenc! to fail due to the appearance of crac)s. After
anal!zing these facts, &e determine that Al and steels are good candidates for the shaft,
#ut aluminum &as discarded #ecause it can #e seen in the fatigue diagram that aluminum
&ill al&a!s fail after certain num#er of c!cles, &hile steel supports higher stresses
fluctuations #efore failing. Research &as performed and it &as founded that lo& car#on
steel has the specifications desired for a shaft design.
An anal!sis #et&een several lo& car#on steels &as done.
-at!ria$ /

y

1
]
1

- E +
/
1
1
]
1

/ E -
y
AG@G +9+9 @teel -934"a 7.:7gEcc /93 4"a 37.3/ 3737./:
AG@G +9+3 @teel -934"a 7.:7gEcc /99 4"a 37.3/ ./01.23
AG@G +9-- @teel -934"a 7.:3gEcc /99 4"a 37.>+ 379-.?:
AISI 452. St!!$ 255GPa 673.'8cc 945 GPa ./704 .320752
After comparing various t!pes of car#on steels &e have selected AG@G +9-3 &hich is a
lo&Acar#on steel. (his material &ill #e machined to achieve the desired shape.
AISI 452. St!!$
Physical Properties Metric English Comments
Density 7.858 g/cc 0.284 lb/in Chemical composition of 0.23% C, 0.35%
!n, 0.""% #i, anneale$ at %25&C
Mechanical Properties
'a($ness, )(inell """ """
'a($ness, *noop "2% "2% Con+e(te$ f(om )(inell ha($ness.
'a($ness, ,oc-.ell ) 4 4 Con+e(te$ f(om )(inell ha($ness.
'a($ness, /ic-e(s ""5 ""5 Con+e(te$ f(om )(inell ha($ness.
0ensile #t(ength, 1ltimate 380 !2a 55"00 psi
0ensile #t(ength, 3iel$ 3"0 !2a 45000 psi
4longation at )(ea- "5 % "5 %
,e$5ction of 6(ea 35 % 35 %
!o$5l5s of 4lasticity 200 72a 2%000 -si 0ypical fo( steel
)5l- !o$5l5s "40 72a 20300 -si 0ypical fo( steel.
2oisson8s ,atio 0.2% 0.2% 0ypical 9o( #teel
#hea( !o$5l5s 80 72a ""00 -si 0ypical fo( steel.
Str!ss conc!ntrations%
@ection !A'% $ritical "oint .
sing the follo&ing diagrams%
rEd 6 +.:E>96 9.9/
DEd 6 ?9E>9 6 +.3
8t,#ending 6 -./3
8t,shear 6 +.?
8t, a'ial 6 -.7
@ut steel 6 ?99 M"a
>?/ . 9
97 . 9
++: . 9
+
+
+
+
, + ; +
++: . 9
3 . 9

r
a
3
kt 3 kf
in a
8f ;#ending, 6 +.?2
8f ;shear, 6 +.>-
8f ;a'ial, 6 -.+:
5rom Materials selection @ut6 ?99M"a%
@e1 6 9.3@ut 6 9.3 ;?99, 6 239M"a
@e corrected%
8surf69.?/
8size%
A?36 9.97>>dL- 6 9.97>> ;9.9>,L- 6 -.73:eA2 m
-
d e*uivalent 6

m A 9> . 9 97>> . 9 E ?3
8size 6 +.+:?;d,L<A9.9?7 6 9.:
@e6 ;9.?/,;9.:?7,;9.:,;+.3>-+,6 /99./+3> Mpa
$orrected stresses %
Ds.c6 ;9.>?> M"a, ;-.+:, M ;9.?9?, ;-.+:, M ;++.->3, ;+.?2, M ;?9.:?3, ;+.?2,
6 A-9+.>:?/M"a
Fs.c 6 ;+.>-,;A22.-9, M +./ M 3.:-7 N 2.7+3 6 -/2.33 M"a
,-a
total total .,
33 . -/2 , -+ . >? ; / , > . -9+ ; /
- - - -
+ +
nf6 @eEDVM6 /99./+3>E-/2.33 6 +./
Conc$usion
A complete anal!sis of the forces acting on the shaft, the calculation of the ma'imum
stresses acting &ith stress concentrators and a fatigue anal!sis &as done. Oo& car#on
steel AG@G +9-3 has #een selected as the proper material that agrees &ith the material
selection anal!sis dra&n. (he material selected is stiff, holds a considera#l! high static
force, has a small t&ist angle, and supports considera#l! high load fluctuation. A diameter
of >9mm has #een selected for the shaft ta)ing into consideration the material selected
along &ith the loads acting on it. A safet! factor &as computed using 4oodman theor! in
a fatigue anal!sis. (he fatigue anal!sis &as done for infinite life. (hese calculations
corro#orated the safe operation of the shaft &e designed.
R!&!r!nc!s#
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