Journal of Reliability and Statistical Studies; ISSN (Print): 0974- 0!4" (#nline):!!!9-$%%% &ol' $" Issue ! (!0(!

): $9-7%

AUTOMOTIVE TRANSMISSION SYSTEM DESIGN BASED ON RELIABILITY PARAMETERS

(" !

Douzi Imran Khan1, Se o Vir!anen" an# A$K Verma% Reliability )n*ineerin* and +aintenance" ,-," ,a./ere" 0inland' 1 Reliability )n*ineerin*" Stord23au*esund -ni4ersity" Nor5ay' ) +ail: i.ran67an7(78*.ail'co. (Recei4ed June ($" !0(!)

A&'!ra(!
0ailure of any co./onent or /roduct or syste. before its ti.e /eriod is al5ays unacce/table and 7ence in t7e en*ineerin* desi*n t7e safety and reliability of any syste. is in4ariably t7e /rinci/al tec7nical ob9ecti4e' ,7e le4el of desi*n" control and .anufacturin* of auto.obiles trans.ission syste. 7as al5ays been critical in ter.s of reliability and safety' ,7is /a/er describes t7e 5or6 done by t7e :ut7or(s) for t7e reliability based desi*n of auto.obiles trans.ission syste. based on its failure criteria at subsyste. and syste. le4el in order to i./ro4e t7e reliability of 57ole trans.ission syste. and 7encefort7 t7e safety and it 7as also s7o5n 5it7 t7e results t7at 57ile desi*nin* suc7 syste. based on reliability /ara.eters" t7e reliability 7as al5ays i./ro4ed 5it7 t7e i./ro4ed factor of safety 4alues'

Ke) *or#'+ :uto.oti4e ,rans.ission Syste." Reliability" Safety" 0actor of Safety" 0ailure
:nalysis'

1$ In!ro#u(!ion
,7e trans.ission syste. of t7e 4e7icle is an elaborate asse.bly of *ears" s7afts" bearin*s and ot7er /arts t7at transfers selected a.ount of /o5er to t7e 4e7icles 57eels ;(<' ,7e trans.ission enables t7e 4e7icle to accelerate for5ard or bac65ard or to .aintain 7i*7 cruisin* s/eeds-all 57ile t7e en*ine o/erates at efficient s/eeds and 5it7in safety li.its' In t7e de4elo/.ent of cars" trans.ission e4olution 4eered t7e 4e7icle to5ards co.fort and con4enience' ,7e researc7 5or6 /resented in t7is /a/er" to desi*n auto.oti4e trans.ission syste. based on reliability /ara.eters is t7e ad4anced and co./letely ne5 .et7odolo*y de4elo/ed by considerin* t7e 5or6 done by S'S Rao and + ,9andra ;!<' In t7is 5or6 t7e follo5in* .ain co./onents for .odelin* and reliability based desi*n of t7e trans.ission syste. at syste. le4el" considerin* t7e .ain failures t7at could occur 5it7 t7eir res/ecti4e co./onents ;1" 4< is done' () =ear Pairs' !) S7afts and 1) >earin*s'

%0

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

1$1 Gear, air'

In t7e trans.ission syste. case" t7e failure of t7e *ear train is c7aracteri@ed by eit7er of t7e t5o .odes of failure ;$" %<' () >endin* and !) Surface 5ear' ,7e layout" s/eeds and t7e interconnection of t7e 4arious *ear /airs of t7e *ear train are considered to be 6no5n' ,7e /o5er trans.itted by all t7e *ear /airs is assu.ed to be t7e sa.e' ,7e desi*n /ara.eters are t7e face 5idt7s of t7e *ear /airs for 4ariable data'

1$" Sha-!'
,7e t7ree s7afts as .entioned belo5 in t7e trans.ission syste. is considered for desi*nin*' () In/ut s7aft (clutc7 s7aft) !) Aay s7aft (counter s7aft) 1) #ut/ut s7aft (.ain s7aft) ,7e trans.ission s7afts are sub9ect to co.bined bendin* and torsion' It 5ould see. reasonable to use .aBi.u. s7ear stress for t7e case of ductile co./onents under co.bined stress' So for t7e case of a rotatin* s7aft" it can be desi*ned 5it7 res/ect to failure .ode of 0ati*ue failure due to its .aBi.u. s7aft dia.eter'

1$% Bearin.'
,7ere are fi4e bearin*s 57ic7 7as been considered for desi*n () In/ut s7aft bearin*' !) Aay s7aft front bearin*' 1) Aay s7aft rear bearin*' 4) +ain s7aft front bearin*' $) +ain s7aft rear bearin*' :ll bearin* are cylindrical roller bearin*s' ,7e roller bearin*s 7a4e a 7i*7er radial load ca/acity co./ared to ball bearin*s' 0urt7er.ore" .ost .odern auto.obile trans.ission syste.s use /lain or ta/ered roller bearin*s to su//ort t7e s7afts' In calculatin* t7e forces actin* on t7e bearin*s" t7e bearin*s are .odeled as si./le su//orts for t7e s7aft' ,7e desi*n /ara.eter is t7e len*t7 of t7e roller bearin*'

"$ /ormu0a!ion o- Au!oma!i( Tran'mi''ion S)'!em De'i.n

?esi*n of t7e auto.oti4e trans.ission syste. in4ol4es t7e Reliability based desi*n of *ear-/airs" s7afts and bearin*s ta6in* t7e /ara.eters i'e'" face 5idt7 of *ears" dia.eter of s7afts and len*t7 of roller of bearin*s 5it7 res/ect to t7e 4ariable factor of

:uto.oti4e ,rans.ission Syste. ?esi*n C

%(

safety 4alues' ,7e .et7odolo*y and t7e necessary /rocedural fra.e 5or6 to do t7e safe desi*n of t7e trans.ission syste. is analy@ed and deri4ed by :ut7or(s) and is 4erified and i./le.ented in collaboration 5it7 II, >o.bay and =eneral +otors" >an*alore' ,7e conce/ts belo5 eB/lain t7e strate*y for safe desi*n of t7e trans.ission syste. considerin* reliability /ara.eters" in order to i./ro4e t7e reliability of t7e 57ole syste. and as 5ell as at co./onent le4el (refer ://endiB : for understandin*)

"$1 Re0ia&i0i!) Ba'e# De'i.n o- Gear, air' 1a0(u0a!in. -a(e 2i#!h o- .ear
(' Dalculate ,an*ential Aoad 0t

Ft =

P Kt K w Vp

(1)

E7ere P F Po5er" 3P Gt F Aoad 0actor G5 F Eear 0actor &/ F Pitc7 line &elocity .2sec!

Ben#in. 1ri!eria+
!' Dalculate bea. stren*t7 0b

Fb = S0 'Cv 'b'Y 'mn

1' Dalculate 0ace 5idt7 b by eHuatin* 0b I 0t

(!)

Sur-a(e 2ear (ri!eria

4' Dalculate ?yna.ic load 0d

Fd = Ft +

!Wp (C'e'b'cos ! + Ft ) !Wp + C'e'b'cos ! + Ft

(1)

$' Dalculate Eear Stren*t7 05

Fw =

mn 'Tp 'b'K 'Q cos !

(4)

%' Dalculate 0ace 5idt7 b by eHuatin* 05 I 0d ,a6e .aBi.u. 4alue of face 5idt7 to .a6e *ear safe bot7 fro. bendin* and surface 5ear'

%!

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

S!e ' -or (a0(u0a!in. Re0ia&i0i!) o- a .ear

,a6e face 5idt7 as calculated abo4e' Surface criteria: Dalculate .ean 4alue of ,an*ential load

Ft

Ft =

P Kt K w Vp

($)

Dalculate standard de4iation of ,an*ential load

F = Ft + +
t

! p

! Kt

! Kw

! vp

( !

(%)

>endin* criteria: Dalculate .ean 4alue of >ea. Stren*t7

Fb
(7)

F b = S0 'Cv 'b'Y 'mn

Dalculate standard de4iation of >ea. stren*t7

F
! mn

F = Fb ( + + + +
b

! S0

! Cv

! b

! yJ

( !

( )

Dalculate reliability indeB K

Fb Ft

F ! +F !
b t

(9)

Dalculate Reliability" usin* Nor.al standard RI L(K) Surface 5ear criteria: Dalculate .ean 4alue of ?yna.ic load

Fd

:uto.oti4e ,rans.ission Syste. ?esi*n C

%1

Fd = F t +

!W p (C'e'b'cos ! + Ft ) !W p + C'e'b'cos ! + F t
((0)

Dalculate standard de4iation of ?yna.ic load

F = ( +
d

! Ft

! X$

( !

((() Dalculate .ean 4alue of 5ear stren*t7

Fw

Fw =

mn 'T p 'b'K 'Q cos !

((!)

Dalculate standard de4iation of 5ear stren*t7

F = Fw
w

! mn

+ + + + 1 tan

! b

! k

! Q

) '

( !

((1)

Dalculate reliability indeB K

Fw Fd

F ! +F !
w d

((4)

Dalculate Reliability" usin* Nor.al standard table RI L(K)

"$" Re0ia&i0i!) Ba'e# De'i.n o- Sha-!'

,7e loadin* on ,rans.ission S7aft is t7e ,orHue (,) and >endin* (+)' ,7ey /roduce s7ear stress and bendin* stress res/ecti4ely in it' ,7e s7ear and bendin* stress are

sshr =
sb =

(%T (?ue to torsion) d 1

(?ue to bendin* .o.ent)

(($)

1! M d 1

((%)

%4

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

E7ere"

sshr IS7ear stress (N2..!)

SbI bendin* stress (N2..!) dI dia.eter of s7aft (..) ,ItorsionI

%0 P M kl M k w M(01 (N-..) !N input

Gl Iload factor G5 I5ear factor +I bendin* .o.ent (in N-..) 57ic7 can be obtain fro. a >endin* +o.ent ?ia*ra. (>+?) of t7e s7aft' PI /o5er (E)

/a!i.ue /ai0ure #ue !o ma3imum 'hear '!re'' !heor)

In case of co.bined bendin* and torsion of circular s7afts" t7e .aBi.u. s7ear t7eory 5it7 Sodarber*Ns a//roac7 of fati*ue failure yields induced s7ear stress as

sshr =

S S (%T M O; M m + y M K f M M v <! + ;Tw + yshr M K f M Tv <! P 1 d Se Seshr

((7)

,7e .a9ority of Rotatin* s7afts carry a steady torHue and loads re.ain fiBed in s/ace in bot7 direction and .a*nitude' ,7us durin* eac7 re4olution e4ery fiber on t7e surface of t7e s7aft under*oes a co./lete re4ersal of stress due to bendin* .o.ent' ,7erefore for t7e usual case 57en +.I0" +4I+" ,.I," ,4I0" t7e abo4e eHuation 5ill beco.e as

sshr =

Sy (% M ; M K f M M <! +T ! 1 d Se

(( )

Mean Va0ue an# S!an#ar# De4ia!ion

+ean and Standard ?e4iation of induced s7ear stress is calculated usin* first order ,aylorNs Series eB/ansion" so

sshr =

(% d

M ; 1

! Sy M K f M M <! + T Se

((9)

Standard de4iation is calculated in t7e follo5in* 5ay

:uto.oti4e ,rans.ission Syste. ?esi*n C

%$

Me =

Sy MK f MM Se
y f e

M = M e ( S ! + K ! + M ! + S ! )
e

Te = M e ! + T !

T =
e

M e! Me +T
! !

M M e ! +

T! Me +T
! !

M M e !

T =
e

T
Te

sshr =

(% d
1

M Te

sshr = sshr Te ! + 9 d !
"$% Re0ia&i0i!) Ba'e# De'i.n o- Bearin.'+
,7e induced stress in a roller bearin*" deri4ed fro. t7e contact stress bet5een t5o cylinders" can be eB/ressed as

sbe"r = !99'(($
E7ere" PoI radial load (N) lr I len*t7 of roller (..) drI dia.eter of roller (..) +ean &alue and Standard ?e4iation:

P! lr d r

(!0)

+ean and Standard ?e4iation of induced contact stress is calculated usin* first order ,aylorNs series eB/ansion" so

sbe"r = !99'(($

P! lr d r

(!()

%%

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

s
%$ Re'u0!'

be"r

= sbe"r 0'!$( P! ! + lr ! + dr ! )

(!!)

,7e results are obtained usin* t7e /rocedure .entioned abo4e for t7e 4ariable data sa./les collected fro. 3industan +otors and =eneral +otors'

Gear, air' Re'u0!'+ 0or =ear-/airs face 5idt7 is calculated considerin* bendin* or
surface 5ear only and considerin* bot7 bendin* and surface 5ear' ,o .a6e *ear /air safe bot7 fro. bendin* and surface 5ear t7e .aBi.u. 4alue of face 5idt7 is used for desi*nin* obtained fro. t7e 4arious data sa./les 5it7 4ariable coefficient of factor of safety' Results s7o5 t7at t7e reliability of *ear-/air syste. at factor of safety ('0 is 0'(!$ 57ic7 is 4ery-4ery less and fro. t7e /robabilistic /oint of 4ie5 t7e c7ance of syste. failure is eBtre.ely 7i*7' 0urt7er if factor of safety is increased fro. ( to !'0 t7e reliability increases considerably 0'979 ' :lso if factor of safety is increased to !'! t7e reliability increases to 0'99(9 57ic7 s7o5s t7at t7e desi*n is co./letely safe'

/i.$1+ Re0ia&i0i!) o- Gear air ')'!em V' -a(!or o- 'a-e!)

,7e face 5idt7 4alues calculated at different 4alues of factor of safety is considered" 57ere bot7 t7e bendin* and surface 5ear criteria is considered and t7e *ra/7 s7o5s t7at

:uto.oti4e ,rans.ission Syste. ?esi*n C

%7

t7e reliability increases as t7e 4alue of face 5idt7 of *ear increases' It is to be /resu.ed t7at to .a6e t7e *ear train desi*n safe fro. bot7 failures" t7e 7i*7er face 5idt7 4alues 7as to be considered'

/i.$"+ Re0ia&i0i!) o- Gear air ')'!em V' -a(e 2i#!h o- .ear

Sha-!' Re'u0!'+
0or s7afts dia.eter is calculated considerin* fati*ue failure 5it7 .aBi.u. s7ear stress t7eory'

/i.$%+ Re0ia&i0i!) o- 'ha-! ')'!em V' -a(!or o- 'a-e!)

0or t7e s7afts t7e result s7o5s t7at at factor of safety (" t7e reliability is 4ery4ery less 57ic7 is 0'(!$ and fro. /robabilistic /oint of 4ie5 t7ere is eBtre.e c7ance of

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

failure and totally unacce/table desi*n' #n t7e ot7er 7and at factor of safety ('% t7e reliability is 0'9 $9 57ic7 is Huite acce/table and it s7o5s t7at t7e desi*n is safe'

Bearin. Re'u0!'
0or bearin*s len*t7 of t7e roller of bearin*s is calculated considerin* contact stress de4elo/ed bet5een t5o cylinders'

/i.$5+ Re0ia&i0i!) o- &earin. ')'!em V' -a(!or o- 'a-e!)

In t7e abo4e fi* t7e reliability of s7aft syste. is ta6en on y-aBis and factor of safety is ta6en on B-aBis' 0ro. t7e *ra/7 5e can clearly see t7at for t7e bearin* syste. to *et Reliability .ore t7an 9 Q" factor of safety s7ould be *reater t7an ('4 (0'9 %9) and 7ence t7e desi*n 5ill be safe'

5$ Re'u0!'
,7e desi*n of t7e of t7e :uto.oti4e ,rans.ission Syste. s7o5s t7at reliability of *ear /air syste." s7aft syste. and bearin* syste. at factor of safety ('0 is 4ery less and 7ence t7ere is a *reat ris6 of failure' 0or *ear /airs face 5idt7 is calculated considerin* bendin* or surface 5ear only and considerin* bot7 bendin* and surface 5ear' ,7e reliability of *ear /airs at factor of safety ! is 0'9 57ic7 is acce/table accordin* to t7e .anufacturin* ter.s of =eneral +otors' ,7is s7o5s t7at to .a6e *ear /air syste. reliable factor of safety s7ould be 6e/t *reater t7an !' Si.ilar to *ear /airs for t7e s7afts" t7e dia.eter of s7afts is calculated considerin* fati*ue failure 5it7 .aBi.u. s7ear stress t7eory and to .a6e t7e safe desi*n of s7aft syste. (i'e'" reliability *reater t7an 9 Q) t7e factor of safety 4alue s7ould be *reater t7an ('% and si.ilarly for bearin*s syste. len*t7 of roller bearin* is calculated considerin* contact stress de4elo/ed bet5een t5o cylinders and to desi*n t7e bearin* syste. safely t7e

:uto.oti4e ,rans.ission Syste. ?esi*n C

%9

factor of safety 4alue for bearin* syste. s7ould be *reater t7an ('4' :s all t7ese co./onents are connected in series and to .a6e t7e safe desi*n of entire syste. t7e factor of safety s7ould be 6e/t .ore t7an !'$ for all *ear /airs" s7afts and bearin*s'

Re-eren(e'
((99!)' : study on auto.atic trans.ission controlR Aondon' :*ar5al" 3' (!004)' ?octoral ,7esis (Reliability >ased ?esi*n #/ti.i@ation)" -ni4ersity of Notre ?a.e' 1' Druse" ,':' ((997)' Reliability-based +ec7anical ?esi*n" DRD Press; 3ar2?s6t edition' 4' 3e S' ?' and Een >' D' (!00$)' Reliability Sensiti4ity of :uto.obiles Do./onents S5itc7 :rbitrary ?istribution Para.eters" Journal of :uto.obile )n*ineerin*" !(9" /' (%$-( !' $' Rao" S'S' and ,9andra" +' ((994)' Reliability based desi*n of :uto.oti4e ,rans.ission Syste." Journal of Reliability )n*ineerin* T Syste. Safety" 4%(!)' %' Sun" U' and 3ebbale" G' (!00$)' D7allen*es and #//ortunities in :uto.oti4e ,rans.ission Dontrol" :.erican Dontrol Donference" June -(0" !00$' 7' ,ani" +'" Va.ada" G'" Vos7ida" 3'" 3ayafune" G'" 3atta" G' and Vos7ida" S' ' Een" >' and U7an* V' +' (!001)' Practical Reliability >ased ?esi*n of =ear Pairs" Journal of +ec7anis. and +ac7ine ,7eory" 1 " /' (1%1-(170' 9' Vi.in" U' and Wiaolin*" A' (!00!)' Reliability-based desi*n of auto.obile co./onents' Proceedin*s of t7e Institution of +ec7anical )n*ineers Part ?Journal of :uto.obile )n*ineerin*" !(% (?%)" /' 4$$F47( (0' U7an*" V'+' (!00 )' Reliability >ased ?esi*n for :uto.obiles in D7ina" 0ront' +ec7' )n*' D7ina" 1(4)" /' 1%9F17%' ((' U7an*" V'+' and' Aiu" W'A (!00!)' Reliability based desi*n of s/ur *ears" Proceedin*s of t7e Institution of +ec7anical )n*ineers Part D" Journal of +ec7anical )n*ineerin* Science" !(% (D!)" /' (79F( !' (' !'

70

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

en#i3 A

Re0ia&i0i!) Ba'e# De'i.n an# (a0(u0a!ion o- Re0ia&i0i!) o- an Au!oma!i( Tran'mi''ion S)'!em$

,7e initial data a4ailable for t7e fi4e s/eed .anual trans.ission syste. (3industan +otors" ( 00 ISU +P0I) is *i4en belo5 )N=IN): ,y/e 0uel +aB /o5er (P): ,R:NS+ISSI#N SVS,)+: =ear >oB: =ear Ratio: $ s/eed o4erdri4e *ear boB Gear (st !nd 1rd 4
t7

+P0I 5it7 4 cylinder #3D Petrol 743P at $000r/.

Gear Ra!io 1'717 : ( ('9%1 : ( ('1%4 : ( ('000 : ( 0'77% : ( 1'40! : (

$t7 Pri.ary Reduction ratio: =):RS: ,y/e +aterial : +aB' :llo5able >endin* stress : :llo5able Surface Eear Stress : Voun*Ns +odulus : ?efor.ation factor : )rror in /rofile: Aoad 0actor Aubrication factor: (' : ( Re4erse

standard !00 in4olute S:) (04$ 7eat treated (carbon steel) Sb I !4$'!4 N2 ..! S5 I (7(7'7$ N2..! ) I !'(09($ M (0$ N2 ..! D I (!100 e I 0'!$ Gl I ('!$ G5 I ('($

:uto.oti4e ,rans.ission Syste. ?esi*n C

7(

Num&er o- !ee!h on Gear Pair'

Gear Pair

Num&er o- Tee!h

Tran'mi''ion Ra!io

(st s/eed *ear /air

,( I !$" ,! I 4$

(' 00 : (

!nd s/eed *ear /air

,$ I !1" ,(( I 47

1'%7 : (

1rd s/eed *ear /air

,4 I 14" ,(0 I 1%

('90% : (

4t7 s/eed *ear /air

,1 I 40"

,9 I 10

('1$0 : (

$t7 s/eed *ear /air

,1 I 49"

,9I !(

0'77( : (

Re4erse S/eed

,%I($" , I($" ,(!I!

1'1%0 : (

+odule: 3eliB an*le: Denter distance: S3:0,S: +aterial Vield Stren*t7 (Sy) S7ear Vield Stren*t7 (Sy-s7r) -lti.ate Stren*t7 (Sut) )ndurance Ai.it (Se) 0ati*ue Stress concentration factor (Gf) >):RIN=S: ,y/e Roller dia.eter (dr) (for eac7 bearin*)

.n I .t I1.. X I (%'$0 : I (09'$..

D$$Nn("for*ed:7ardened and te./ered 4%0 N2..! yield stren*t72! I !10 N2..! 77$ N2..! 0'4% Sut N2..! ('$ Dylindrical roller bearin* (0..

7!

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

+aBi.u. allo5able stren*t7 (Sa)

1411'$ N2..!

Y/ I 0'(" Y65I0'011" Y.I0'00$" Y5I0'00$" YNI0'(" YbI0'00$" YsoI0'(" YS5I0'(" Y)I0'$" YSyI0'(" YSutI0'(" Y6fI0'0(" YAZs7aftI0'00$" YdZs7aftI0'00$" YdZ*earI0'00$" YSaI0'(" YdrZbearin*I0'00$" YlrZbearin*I0'00$

1a0(u0a!ion o- -a(e 2i#!h an# Re0ia&i0i!) E'!ima!ion o- Gear, air'

,7is in4ol4es t7e desi*nin* of *ear /airs and its reliability' ,o find out t7e reliability of t7e *ear /airs" t7e face 5idt7 of *ear /airs is calculated considerin* t7e bendin* or surface 5ear' ,o .a6e *ear /air desi*n safe fro. bot7 bendin* and surface 5ear t7e .aBi.u. 4alue of face 5idt7 is used' ,7e reliability of *ear /air syste. at different 4alues of factor of safety and face 5idt7 of *ear is found out and t7e *ra/7 7as been /lotted usin* t7ose 4alues' ,7e Reliability >ased ?esi*n of =ear /airs of :uto.atic ,rans.ission Syste. 7as done 5it7 an intention to obtain .ore t7an 9 Q Reliability of t7e *ear-/air syste. and to obtain t7e sa.e 5e obser4ed t7at t7e factor of safety s7ould be atleast !'0 ,o obtain t7is results t7e face 5idt7 of t7e *ear /airs is calculated considerin* bendin* and surface 5ear criteria and considerin* bendin* or surface 5ear criteria only and t7e *ra/7s for t7is t5o conditions 7as been /lotted for different 4alues of face 5idt7 and factor of safety obtained fro. t7e calculations by calculatin* t7e Reliability &alues for all 4alues' 0ro. t7e data *i4en 5e 5ill no5 /roceed to calculate t7e face 5idt7 and t7e reliability of a *ear syste.' E7ile desi*nin*" for .a6in* *ear safe fro. bendin*" t7e bea. stren*t7 (0b) .ust be *reater t7an tan*ential load (0t) ' i'e'" (0b [0t) and 0ro. surface 5ear" 5ear stren*t7 (05) .ust be *reater t7an dyna.ic load (0d) ' i'e'" (05[0d) 1a0(u0a!in. -a(e 2i#!h o- a .ear (' Dalculate ,an*ential Aoad 0t !' >endin* criteria: Dalculate >ea. Stren*t7 0b Dalculate 0ace 5idt7 b by eHuatin* 0b I 0t 1' Surface 5ear criteria: Dalculate ?yna.ic load 0d Dalculate Eear Stren*t7 05 Dalculate 0ace 5idt7 b by eHuatin* 05 I 0d ,a6e .aBi.u. 4alue of 0ace 5idt7 to .a6e *ear safe bot7 fro. >endin* and 5ear'

:uto.oti4e ,rans.ission Syste. ?esi*n C

71

1a0(u0a!in. Re0ia&i0i!) o- a .ear ,a6e face 5idt7 as calculated abo4e' Dalculate .ean 4alue of ,an*ential load Ft Dalculate standard de4iation of ,an*ential load

>endin* criteria: Dalculate .ean 4alue of >ea. Stren*t7 Fb Dalculate standard de4iation of >ea. stren*t7 Fb Dalculate reliability indeB K Dalculate Reliability" usin* Nor.al standard table RI L(K) Surface 5ear criteria: Dalculate .ean 4alue of ?yna.ic load Fd Dalculate standard de4iation of ?yna.ic load Fd Dalculate .ean 4alue of 5ear stren*t7 Fw Dalculate standard de4iation of 5ear stren*t7

Fw

Dalculate reliability indeB K Dalculate Reliability" usin* Nor.al standard table RI L (K) :s 5e 6no5 t7at t7e :uto.atic ,rans.ission Syste. is a co.bination of =ear-/airs" S7afts" bearin*s and ot7er s.all /arts 5e 5ill furt7er .o4e to loo6 a7ead for t7e Reliability based desi*n of s7afts and bearin*s to co./lete t7e desi*n of total :uto.atic ,rans.ission Syste.' No5 for t7e Reliability based desi*n of s7afts t7e dia.eter of a s7aft is calculated at different 4alues of factor of safety and t7e *ra/7 7as been /lotted' Si.ilarly t7e Reliability based desi*n of bearin*s 7as been done in 57ic7 t7e len*t7 of t7e roller bearin* is calculated for different 4alues of factor of safety'

1a0(u0a!ion o- Sha-! #iame!er an# Re0ia&i0i!) E'!ima!ion o- Sha-!'

E7ile desi*nin*" to .a6e s7aft safe fro. fati*ue failure t7e yield s7ear stress(Sy-s7r) .ust be *reater t7an t7e induced s7ear stress (Ss7r) as obtained fro. t7e .aBi.u. s7ear stress t7eory i'e" Sy-s7r [ Ss7r

74

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

1a0(u0a!in. #iame!er o- a 'ha-!

(' Dalculate .aBi.u. bendin* .o.ent (+) on t7e s7aft usin* >endin* .o.ent dia*ra. (>+?) tec7niHue' !' 1' 4' $' Dalculate .aBi.u. ,orHue (,) a//lied on s7aft' Dalculate endurance li.it (Se)" usin* Se I0'4% Sut Dalculate induced s7ear stress (Ss7r) usin* t7e eHuation *i4en in for.ulae list' Dalculate desi*n s7ear stren*t7 of .aterial of s7aft by di4idin* s7ear yield stren*t7 by 0actor of Safety (0S)' Sd-s7r I Sy-s7r 20S %' Dalculate dia.eter of s7aft by eHuatin* induced s7ear stress and desi*n s7ear stren*t7 of .aterial of s7aft i'e" Sd-s7r I Ss7r

1a0(u0a!in. Re0ia&i0i!) o- a 'ha-!

(' !' 1' 4' $' ,a6e dia.eter as calculated abo4e in ste/ %' Dalculate .ean 4alue of induced s7ear stress Ss7r fro. for.ulae list' Dalculate standard de4iation of induced s7ear stress

be"r

Dalculate .ean 4alue of s7ear yield stren*t7 S y shr of .aterial of s7aft Dalculate Standard de4iation of s7ear yield stren*t7 usin*

S
%' 7'

y shr

= S y shr M S y

Dalculate Reliability indeB K usin*

S y shr S shr

!
y shr

+ S shr !

Dalculate Reliability" usin* Nor.al Standard table RI L(K) stren*t7 of .aterial of s7aft i'e" Sd-s7r I Ss7r In t7e ,rans.ission Syste. t7ere are different s7afts called in/ut s7aft" lay s7aft and .ain s7aft and if any one failure of t7is s7aft 5ill cause t7e failure of t7e 57ole ,rans.ission Syste. and 7ence t7is s7afts s7ould be arran*ed in a series'
Input shaft Lay shaft Main shaft

/i.$6+ Re0ia&i0i!) B0o(7 #ia.ram o- Sha-! ')'!em

Reliability of t7is s7aft syste. is *i4en as Rs7aft-systI Rin/ut-s7aft M Rlay-s7aft M R.ain-s7aft

:uto.oti4e ,rans.ission Syste. ?esi*n C

7$

1a0(u0a!ion o- 0en.!h o- ro00er &earin. an# Re0ia&i0i!) E'!ima!ion oBearin.'

E7ile desi*nin* of bearin*" .aBi.u. allo5able stren*t7 (Sa) .ust be *reater t7an t7e induced contact stress (s) i'e'" Sa [s

1a0(u0a!in. o- 0en.!h o- ro00er o- a &earin.

(' Dalculate radial load (Po) actin* on t7e bearin* usin* eHuations of eHuilibriu. of forces and .o.ents on it' !' 1' Dalculate induced contact stress(s) on t7e bearin* usin* for.ulae list' Dalculate desi*n stren*t7 (Sd)of .aterial of roller of bearin* by di4idin* .aBi.u. allo5able stren*t7 (Sa) of roller of .aterial by 0actor of safety SdI Sa 20S 5$ Dalculate len*t7 of roller (lr) of bearin* by eHuatin* induced stress and desi*n stren*t7 of .aterial of roller of bearin* SdIs

1a0(u0a!in. o- Re0ia&i0i!) o- &earin.

(' !' 1' 4' $' ,a6e len*t7 of roller as calculated abo4e in ste/ 4' Dalculate .ean 4alue of induced contact stress s usin* for.ulae list' Dalculate standard de4iation of induced contact stress \s Dalculate .ean 4alue of .aBi.u. allo5able stren*t7 of .aterial of roller of bearin*' Dalculate standard de4iation of .aBi.u. allo5able stren*t7 of .aterial of roller of bearin* usin* %' 7'

S = S" M S
"

"

Dalculate Reliability indeB K" usin*

S" s
! ! S +S
"

Dalculate Reliability" usin* Nor.al standard table RI L(K)

In t7e ,rans.ission Syste. t7ere are fi4e different bearin* and if any of t7e bearin* i'e'" in/ut-s7aft bearin*" lay-s7aft bearin*" lay-s7aft front bearin*" lay-s7aft rear bearin*" .ain-s7aft front bearin* or .ain s7aft rear bearin* fails" t7e total syste. 5ill *et failed' So all t7e fi4e bearin*s .ust be connected in series" 57ile .a6in* t7e reliability bloc6 dia*ra. for bearin* syste.'
In/ut s7aft bearin* Aay s7aft front bearin* # +ain s7aft front bearin* # Aay s7aft rear bearin*

#
+ain s7aft rear bearin*

7%

Journal of Reliability and Statistical Studies" ?ece.ber !0(!" &ol' $ (!)

# # # /i.$8+ Re0ia&i0i!) B0o(7 Dia.ram o- &earin. ')'!em$

Reliability of t7is >earin* syste. is *i4en as R(bear-syst)I Rin/uts7aft-bear MRin/uts7aft-front-bear MR.ains7aft-front-bear MR.ains7aft-rear-bear

MRlays7aft-rear-bear

Re0ia&i0i!) e'!ima!ion o- Au!oma!i( Tran'mi''ion S)'!em

Reliability bloc6 dia*ra. for t7e ,rans.ission syste. 5ill be as follo5s
Gear-pair System Shaft System Bearing System

/i.$9+ Re0ia&i0i!) B0o(7 Dia.ram o- Au!oma!i( Tran'mi''ion S)'!em

Reliability of t7is syste. is *i4en as ;R,rans-systI R*ear/air-syst M Rs7aft-syst M Rbearin*-syst<