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2 / 1 2 2
max
] 48 ) 8 [(
4
T Fd M
d
+ +
=102 MPa
2 / 1 2 2
3 max
] 64 ) 8 [(
2
T Fd M
d
+ +
= 58.4 MPa
o Factors of Safety-
max
y
S
n
= 3.9
max
2
y
S
n
= 3.4
Fatigue Life
o Infinite Life- 2000RPM (Average operating speed)=33.3 cycles/second
5 year life @ 1 hour operating time (2 hr per week)-approximately
1,908,000 seconds of use
33.3*1,908,000=6.4E7 cycles to failure for infinite life
o The endurance strength can be calculated using the stress concentration
factors from the keyway (197 MPa)
o
F
=S
ut
+345MPa= 970 MPa
o
) 2 log(
) / ' log(
e
e F
N
S
b
=-0.109915548
o
b
ut
F
S
f ) 10 2 (
'
3
=.673
o
e
ut
S
S f
a
2
) (
=900 MPa
o Loads are based on typical operating conditions, not max conditions
Moment-Based on cantilevered distance from bearing and radial load
exerted on shaft from the miter gear (2.1 N-m)
Force- Based on axial load exerted on shaft from miter gear (156.12
N)
Torque- Exerted by the operating torque of the motor, through a gear
ratio of 2:1 (2.82 N-m)
o
2 / 1 2 2
3
] 48 ) 8 [(
4
T Fd M
d
a
+ +
= 39.4 MPa
o
b
a
a
N
1
,
_
= 2.25E12 cycles to failure
Shaft 2 (Diameter=1/2)
Material: 1045 Steel, Yield Strength= 530 MPa, Ultimate Strength= 625MPa
Max Stress
o The shaft is keyed for a 1/8 key, thus the actual yield strength can be equated
to the materials yield strength (Keyed Yield Strength=398 MPa)
o Loading is comprised of three components
Moment-Based on the axle length between bearings and radial load
exerted on shaft from the miter gear (4.28 N-m)
Force- Based on axial load exerted on shaft from miter gear (156.12
N)
Torque- Exerted by the stall torque of the motor, through a gear ratio
of 2:1 (9.64 N-m)
o Stress Calculation-
2 / 1 2 2
max
] 48 ) 8 [(
4
T Fd M
d
+ +
= 47.2 MPa
2 / 1 2 2
3 max
] 64 ) 8 [(
2
T Fd M
d
+ +
= 26.5 MPa
o Factors of Safety-
max
y
S
n
= 8.4
max
2
y
S
n
= 7.5
Fatigue Life
o Infinite Life- 1000RPM=16.67 cycles/second
5 year life @ 1 hour operating time (2 hr per week)-approximately
1,908,000 seconds of use
16.67*1,908,000=3.2E7 cycles to failure for infinite life
o The endurance strength can be calculated using the stress concentration
factors from the keyway (197 MPa)
o
F
=S
ut
+345MPa= 970 MPa
o
) 2 log(
) / ' log(
e
e F
N
S
b
=-0.109915548
o
b
ut
F
S
f ) 10 2 (
'
3
=.673
o
e
ut
S
S f
a
2
) (
=900 MPa
o Loads are based on typical operating conditions, not max conditions
Moment-Based on the axle length between bearings and radial load
exerted on shaft from the miter gear (4.28 N-m)
Force- Based on axial load exerted on shaft from miter gear (156.12
N)
Torque- Exerted by the operating torque of the motor, through a gear
ratio of 2:1 (2.82 N-m)
o
2 / 1 2 2
3
] 48 ) 8 [(
4
T Fd M
d
a
+ +
= 25.6 MPa
o
b
a
a
N
1
,
_
= 1.15E14 cycles to failure
Shaft 3 (Diameter=3/4)
Material: 1045 Steel, Yield Strength= 530 MPa, Ultimate Strength= 625MPa
Max Stress
o The shaft is keyed for a 3/16 key, thus the actual yield strength can be
equated to the materials yield strength (Keyed Yield Strength=398 MPa)
o Loading is comprised of three components
Moment-Based on the axle length between bearings and the force
exerted by the weight of the system (21.53 N-m)
Force- Based on axial load exerted on the shaft from turning forces
(235.44 N)
Torque- Exerted by the stall torque of the motor, through a gear ratio
of 8:1 (38.56 N-m)
o Stress Calculation-
2 / 1 2 2
max
] 48 ) 8 [(
4
T Fd M
d
+ +
= 59.0 MPa
2 / 1 2 2
3 max
] 64 ) 8 [(
2
T Fd M
d
+ +
= 32.7 MPa
o Factors of Safety-
max
y
S
n
= 6.7
max
2
y
S
n
= 6.1
Fatigue Life
o Infinite Life- 500RPM=8.34 cycles/second
5 year life @ 1 hour operating time (2 hr per week)-apprx 1,908,000
seconds of use
8.34*1,908,000=1.6E7 cycles to failure for infinite life
o The endurance strength can be calculated using the stress concentration
factors from the keyway (197 MPa)
o
F
=S
ut
+345MPa= 970 MPa
o
) 2 log(
) / ' log(
e
e F
N
S
b
=-0.109915548
o
b
ut
F
S
f ) 10 2 (
'
3
=.673
o
e
ut
S
S f
a
2
) (
=900 MPa
o Loads are based on typical operating conditions, not max conditions
Moment-Based on the axle length between bearings and the force
exerted by the weight of the system (21.53 N-m)
Force- Based on axial load exerted on the shaft from turning forces
(235.4 N)
Torque- Exerted by the operating torque of the motor, through a gear
ratio of 8:1 (11.28 N-m)
o
2 / 1 2 2
3
] 48 ) 8 [(
4
T Fd M
d
a
+ +
= 35.6 MPa
o
b
a
a
N
1
,
_
= 5.7E12 cycles to failure
Steering Shaft (Diameter=1/4)
Material: 303 Stainless Steel, Yield Strength= 240 MPa, Ultimate Strength= 620 MPa
Max Stress
o Loading is based on torque alone (0.745 N-m)
o Stress Calculation-
2 / 1 2 2
max
] 48 ) 8 [(
4
T Fd M
d
+ +
= 25.7 MPa
2 / 1 2 2
3 max
] 64 ) 8 [(
2
T Fd M
d
+ +
= 14.8 MPa
o Factors of Safety-
max
y
S
n
= 9.4
max
2
y
S
n
= 8.1
Fatigue Life
o
F
=S
ut
+345MPa=965E6 MPa
o
) 2 log(
) / ' log(
e
e F
N
S
b
=-0.07772
o
b
ut
F
S
f ) 10 2 (
'
3
=.862
o
e
ut
S
S f
a
2
) (
=914 MPa
o Load is comprised of torque alone (.745 N-m)
o
2 / 1 2 2
3
] 48 ) 8 [(
4
T Fd M
d
a
+ +
= 25.7 MPa
o
b
a
a
N
1
,
_
= 9.3E19 cycles to failure
Spur Gears (Calculated using ANSI standards)
Driving Spur
Material- Carbon Steel, Yield Strength=76900 psi, Modulus of Elasticity=30E6
psi, Poissons Ratio=.29, Brunell Hardness 179
Max Bending Stress
o
V
H
W
t
33000
= 306.8 lbf
o K
o
= 1.25 - Overload Factor, based on light shocks encountered
o K
v
= 1.15 - Dynamic Factor, based on quality and velocity of gears
o K
s
= 1 - Size Factor
o P
d
= .833 Pitch diameter
o F= .25 face width
o K
m
= 1.20 Load-Distribution factor, based on geometry
o K
B
= 1 Rim Thickness factor, based on geometry
o J= .325- Geometry factor, based on number of teeth of gears
o
J
K K
F
P
K K K W
B m d
s v o
t
=5357.1 psi
o
max
y
S
n = 9.0
Endurance Stress
o
2 / 1
2
2
)
1
1
(
1
1
1
1
1
1
]
1
G
G
p
p
p
E
v
E
v
C
=2284.7 lbf/in
2
o C
f
=1
o I=0.08- Geometry Factor
o
2 / 1
) (
I
C
F P
K
K K W C
f
d
m
s o
t
p
=56972.4 psi
o Sc= 180000 psi- Repeatedly applied contact strength @ 10
7
cycles,
material property
o Z
n
=.59 - Stress cycle life factor, based on hardness and number of cycles
o C
H
=1 -Hardness ratio factor
o K
T
= 1- Temperature factor
o K
R
= 1 Reliability factor
o
) /(
R T H N c
H
K K C Z S
S =1.9
o Comparable factor of safety= S
H
2
=3.5
Driven Spur
Material- Carbon Steel, Yield Strength=76900 psi, Modulus of Elasticity=30E6
psi, Poissons Ratio=.29, Brunell Hardness 179
Max Bending Stress
o
V
H
W
t
33000
= 306.7 lbf
o K
o
= 1.25 - Overload Factor, based on light shocks encountered
o K
v
= 1.15 - Dynamic Factor, based on quality and velocity of gears
o K
s
= 1 - Size Factor
o P
d
= 1.667 Pitch diameter
o F= .25 face width
o K
m
= 1.19 Load-Distribution factor, based on geometry
o K
B
= 1 Rim Thickness factor, based on geometry
o J= .389- Geometry factor, based on number of teeth of gears
o
J
K K
F
P
K K K W
B m d
s v o
t
=9011.0 psi
o
max
y
S
n = 5.4
Endurance Stress
o
2 / 1
2
2
)
1
1
(
1
1
1
1
1
1
]
1
G
G
p
p
p
E
v
E
v
C
=2284.7 lbf/in
2
o C
f
=1
o I=0.08- Geometry Factor
o
2 / 1
) (
I
C
F P
K
K K W C
f
d
m
s o
t
p
= 40010.7 psi
o Sc= 180000 psi- Repeatedly applied contact strength @ 10
7
cycles,
material property
o Z
n
=.60 - Stress cycle life factor, based on hardness and number of cycles
o C
H
=1 -Hardness ratio factor
o K
T
= 1- Temperature factor
o K
R
= 1 Reliability factor
o
) /(
R T H N c
H
K K C Z S
S = 2.70
o Comparable factor of safety= S
H
2
=7.2
Ring/Pinion Gears (Calculated using ANSI standards)
Steering Spur
Material- 2024-T4 Aluminum, Yield Strength=47000 psi, Modulus of
Elasticity=10.4E6 psi, Poissons Ratio=.333
Max Bending Stress
o
V
H
W
t
33000
= 39.3 lbf
o K
o
= 1.25 - Overload Factor, based on light shocks encountered
o K
v
= 1.10 - Dynamic Factor, based on quality and velocity of gears
o K
s
= 1 - Size Factor
o P
d
= .4375 Pitch diameter
o F= .125 face width
o K
m
= 1.20 Load-Distribution factor, based on geometry
o K
B
= 1 Rim Thickness factor, based on geometry
o J= .24- Geometry factor, based on number of teeth of gears
o
J
K K
F
P
K K K W
B m d
s v o
t
=951.8 psi
o
max
y
S
n = 44.1
Steering Ring
Material- 2024-T4 Aluminum, Yield Strength=47000 psi, Modulus of
Elasticity=10.4E6 psi, Poissons Ratio=.333
Max Bending Stress
o
V
H
W
t
33000
= 39.3 lbf
o K
o
= 1.25 - Overload Factor, based on light shocks encountered
o K
v
= 1.10 - Dynamic Factor, based on quality and velocity of gears
o K
s
= 1 - Size Factor
o P
d
= 3.125 Pitch diameter
o F= .125 face width
o K
m
= 1.8 Load-Distribution factor, based on geometry
o K
B
= 1 Rim Thickness factor, based on geometry
o J= .4- Geometry factor, based on number of teeth of gears
o
J
K K
F
P
K K K W
B m d
s v o
t
= 3996.0 psi
o
max
y
S
n = 10.5
Miter Gears (Calculated using ANSI standards)
Both Miters (At max torque)
Material- Medium Carbon Steel, Yield Strength=76900 psi
Max Bending Stress
o P
d
= 1.25 Pitch diameter
o
o
d
t
P
T
W
2
= 84.7 lbf
o K
o
= 1.25 - Overload Factor, based on light shocks encountered
o K
v
= 1 - Dynamic Factor, based on quality and velocity of gears
o K
s
= .5 - Size Factor
o F= .27 face width
o K
m
= 1.10 Load-Distribution factor, based on geometry
o J= 0.175- Geometry factor, based on number of teeth of gears
o K
x
= 1, Lengthwise curvature factor
o
J K
K K
K K P
F
W
x
m s
v o d
t
=14922.2 psi
o
max
y
S
n = 5.15
Both Miters (At max speed)
Material- Medium Carbon Steel, Yield Strength=76900 psi
Max Bending Stress
o P
d
= 1.25 Pitch diameter
o
o
d
t
P
T
W
2
= 4 lbf
o K
o
= 1.25 - Overload Factor, based on light shocks encountered
o K
v
= 1.28 - Dynamic Factor, based on quality and velocity of gears
o K
s
= .5 - Size Factor
o F= .27 face width
o K
m
= 1.10 Load-Distribution factor, based on geometry
o J= 0.175- Geometry factor, based on number of teeth of gears
o K
x
= 1, Lengthwise curvature factor
o
J K
K K
K K P
F
W
x
m s
v o d
t
=901.6 psi
o
max
y
S
n = 85.3
Forces
o Knowing max torque on miter (9.63 N-m), we can find the max tangential
force by dividing by half the pitch diameter=> F
tan
=606.6 N
o = 20 degress -pressure angle
o d= 45 degrees
o
cos
tan
F
F
n
=645.5 N
o
sin
1
n
F
F =220.8 N
o d F F F
radial axial
sin
1
=156.1 N
Retaining Rings
On 3/8 shaft
o Ring can withstand 542.7 N of axial force
o Miter gear provides axial load= 156.1 N
o Factor of safety= 3.48
On 1/2 shaft
o Ring can withstand 542.7 N of axial force
o Miter gear provides axial load= 156.1 N
o Factor of safety= 3.48
On 3/4 shaft
o Ring can withstand 631.6 N of axial force
o Axial load is from turning
Assume wheel instantaneously turns 90 degrees, the max force that
can be applied axially would be equivalent to the frictional force
W F F
friction axial =235.4 N (assuming =.6)
o Factor of safety= 2.68
Mechanical Brake
Max Temperature
Assuming all kinetic energy is converted directly into heat energy,
T C m v m
v plate veh veh
2
2 / 1
Assume emergency brake will not be used continuously, but rather for one cycle
during the emergency
Assume initial temperature of 23 Celcius
Solving the above equation for T
final
we find it to be 38.9 Celcius
Heat Dissipation
Assuming Free Convection, the time required for heat dissipation can be
calculated
Utilizing the properties of air at room temperature, the Rayleigh number, Nusselt
number, and convection heat transfer coefficient can be calculated
Using this information the heat transfer rate is determined
q
E
t
gives the time to dissipate the heat (4.8 minutes)
This resultant was later verified by the manufacturer of the brake
Keys
On 3/8 Shaft
Key is High carbon steel, Yield Strength 427 MPa, 3/32 square
Knowing the diameter of and torque on the shaft, the shear force on the key can
be calculated (2024.1 N)
Assuming a factor of safety of 4, the required length of the key is calculated
(.63)
On 1/2 Shaft
Key is High carbon steel, Yield Strength 427 MPa, 1/8 square
Knowing the diameter of and torque on the shaft, the shear force on the key can
be calculated (1518.1 N)
Assuming a factor of safety of 4, the required length of the key is calculated
(.35)
On 3/4 Shaft
Key is High carbon steel, Yield Strength 427 MPa, 3/16 square
Knowing the diameter of and torque on the shaft, the shear force on the key can
be calculated (4048.3 N)
Assuming a factor of safety of 4, the required length of the key is calculated
(.63)
Keyways
Keyway analysis was done using Cosmos FEA software
By utilizing shaft diameters and torques, forces on keyway surfaces were
calculated and input into the program
Factor of Safety
o Driving Miter=16
o Driven Miter=15
o Driving Pulley=3.4
o Driven Pulley=8.4
o Driven Spur=8.1
o Wheel=1.8, but in reality, failure would result in the slip of a pressed
insert, rather than physical failure of the wheel
Set Screws
To connect spur gear to 5/16 drive motor shaft
By choosing a screw size and quantity (2- #8s), the maximum force at the shaft
surface can be calculated (3425.1 N)
The torque and diameter of the shaft is used to determine the actual force seen at
this shaft surface (1214.5 N)
By comparing these two values the factor of safety is determined (2.82)
To connect spur gear to 8mm steering motor shaft
By choosing a screw size and quantity (2-#6s), the maximum force at the shaft
surface can be calculated (2224.1 N)
The torque and diameter of the shaft is used to determine the actual force seen at
this shaft surface (234.6 N)
By comparing these two values the factor of safety is determined (9.5)
Timing Belt and Pulleys
Utilizing MITCalc simulation software and inputting various parameters
including distance between centers, power applied to belt, operating
speeds, and other operating conditions a belt type and specific model was
selected
From this the 5M Powergrip GT2 belt was chosen and matched with
pulleys of 18 and 72 teeth
The selection of these parts was also verified with an engineer at the
supplier sdp-si.com
Bearings
C
10
= Catalog Load Rating (lb
f
)
L
R
= Rating Life (hrs)
n
R
= Rating Speed (RPM)
F
D
= Desired Radial Load (lb
f
)
L
D
= Desired Life (hrs)
n
D
= Desired Speed (RPM)
F
R
= Radial Force (lb
f
)
F
A
= Axial Force (lb
f
)
F
e
= Equivalent Radial Load (lb
f
)
C
0
= Static Load Rating (lb
f
)
X
2
= Factor dependent on bearing geometry
Y
2
= Factor dependent on bearing geometry
V = Rotation Factor
a = 3 (ball bearing)
e = abscissa
Lower Drive Bearing
C10 (lbs) 1171 Upper Drive Bearing Center Bearing
LR * nR 1.0E+06 C10 (lbs) 1187 C10 (lbs) 691
FD (lbs) 44.125 LR * nR 1.0E+06 LR * nR 1.0E+06
nD (RPM) 5.0E+02 Fe (lbs) 84.6 Fe (lbs) 70.6
a 3 nD (RPM) 2000 nD (RPM) 4000
A R e
D
R R
a
D
D
F Y VF X F
n
n L
F
C
L
2 2
10
*
+
,
_
,
_