ME450 Project

Gearbox Analysis

ME450 Finite Element Analysis Fall Semester, 2007 Prof: Dr. K. Nematollahi Team Members

Aaron Huesman Jae Shin Kelly McCormick

12-10-2007

Objective
Perform structural analysis of two competing designs of a machined aluminum gearbox casing.

Applicable Theory
{F} = [T][K][T]-1{U}

Introduction

Two competing designs Webbed Non-webbed Previous choice based on ease of machining Performing structural analysis to confirm choice

Non-Webbed

Webbed

Unigraphics Model

Forces

Ansys Model Details

Model reduced to simplest form

One

half of casing used (symmetry) Gears removed Bearings simulated

Aluminum alloy material for case Brass material for bearing volumes

Ansys Model
Substitute Bearing Volumes

Solid Cylinders Simulate Bearings

Boundary Conditions

Boundary Conditions Cont

Element Type
Utilized ten-node SOLID92 tetrahedral elements Ideal for complicated solids with curved boundaries

Meshing

Automatic meshing option

Analysis

Deformation study Von-Mises Stress study

Consistent boundary conditions and forces applied.

Deformation Distribution
Non-Webbed Webbed

Max: 5.17E-4 in.

Max: 5.00E-4 in.

Stress Distribution
Non-Webbed Webbed

Max: 4633.8 psi

Max: 3497.4 psi

Results

Non-Webbed

Webbed

%Change

1. Max Deformation = 0.00051749 in 2. Max Stress = 4633.8 PSI 3. Mass = 0.854 lbm

1. Max Deformation = 0.00050028 in 2. Max Stress = 3497.4 PSI 3. Mass = 0.878 lbm

1. Max Deformation = -3.3% 2. Max Stress = -24.5% 3. Mass = +2.7%

Impact Statement

1.

2.

3.

Reduced chance of a failure Reduces potential waste of material Reduces potential environmental contamination Reduces potential injuries (Robust design)

Conclusion

Webbed design is superior.

Less stress Less deformation Easier machining Minimal change in weight

1.
2. 3.

4.

Bibliography
[1] Moaveni, Saeed. Finite Element Analysis Theory and Application with Ansys 3rd Addition, Pearson Education, Inc., Pearson Prentice Hall, Upper Saddle River, NJ 07458, 2008.

Questions