Design of wheel hub assembly of a single wheel application for a light commercial vehicle

Madhusudhan Reddy V J 1RV08ME046 Manjunath M M 1RV08ME050 Shridhar Patil 1RV08ME099

Internal Guide Associate Professor P R Venkatesh External Guide Deepak Sheelvanth Project manager, Meritor Commercial Vehicle Systems Pvt. Ltd.

Classification
Based on GVWR commercial vehicles are classified as follows 1. Light commercial vehicles (0-6.5 tonnes) 2. Medium commercial vehicle (6.5-11.8 tonnes) 3. Heavy commercial vehicle (11.8 tonnes onwards)

Light commercial vehicle

Light commercial vehicles (LCVs) are usually referred to goods and carriage vehicles with a light capacity that varies from one region to another. Ex: - Tata 407, Tata 709

Wheel Hub
Wheel hub is a rotary component which provides support to the wheel and assists in easy movement. It is the component upon which the wheel and brake mounts, it is fitted over the wheel bearings. A hub assembly contains the wheel bearing, fasteners, seal and the hub to mount the wheel. It may also contain the anti lock brake system, wheel speed sensor which makes them very expensive in some cases.

 The bearings over which the wheel hub is mounted is again over the axle. Single wheel application means the rear axle contains only a single wheel on its either side.

Problem definition
The GAWR for our application is 3.5 tonnes, with the GVWR being 5.7 tonnes. So, the load that single wheel on the rear side should bear is 1.75 tonnes. And the mass of the hub being 10.25 kg (cast hub)

Hubs can be classified into two types 1. Outboard mounted hub 2. Inboard mounted hub

 Hub for a single wheel application

 Hub for dual wheel application

 The loads acting on a vehicle are 1. Torsion stress due to driving and braking torque. 2. Shear stress due to the weight of the vehicle 3. Bending stress due to the weight of the vehicle 4. Tensile and compressive stress due to cornering forces. These above forces can be divided into vertical and horizontal forces.

Test fixtures
1. With the axle fixed

2. Fixture with wheel fixed

Bearings
As the hub is a rotatory component, we use rolling contact bearings. In rolling contact bearings, the contact between bearing surfaces is rolling instead of sliding as in case sliding contact bearings. Te advantage of a rolling contact bearings over a sliding contact bearing is that of a low starting friction. Due to this low friction offered by rolling contact bearings, these are also known as the antifriction bearings.

 Friction in bearings leads to heat, higher torque needed to overcome the friction, wear all of which ultimately leads to the deterioration in performance of the bearings. Anti-friction bearings overcome these effects. Nomenclature

 Anti-friction bearing types

Tapered roller bearings

Tapered roller bearings are uniquely designed to manage both thrust and radial loads on rotating shafts and in housings. The taper angles allow the bearing to handle a combination of radial and thrust loads. The steeper the cup angle, the greater the ability of the tapered roller bearing to handle thrust loads. These are extensively used in automobiles (to support the wheels); here they are used in pairs to accommodate the axial thrust from both directions, as well as radial loads.

Tapered roller bearings nomenclature

 Tapered roller bearings are further classfied into 1. Single row tapered bearings. 2. Dual row tapered bearings. 3. Multi row tapered bearings For our design we are considering single row tapered bearings, as they are enough to bear the load in our application. The point where the force line meets the axis is known as the bearing effective centre.

Free body diagram, shear force diagrams and bending moment diagrams.

Calculations
Reaction forces acting on the bearings
RA = F (z/y -1) RB = F (z/y)

Pressure acting on the bearings PA = RA / A PB = RB / A Moment arm = [ 0.7 (slr) + d ] Test load = moment/moment arm Moment = [ 0.7 (slr) + d ](S)(L)

 Slr = static loaded radius S = load acceleration factor L = load rating of the hub ( In this application the load rating being 1.75 tonnes ). d = load offset value.

DESIGN OF HUB

 We already know how important the bearings are, so the bearings have to carefully selected. The outboard bearing is X32211-Y32211 The inboard bearing is X3982-Y3920 ( bearing info from Timken)

Outboard and inboard bearing info

Dimensions D - Cup Outer Diameter d - Cone Bore B - Cone Width C - Cup Width T - Bearing Width a - Effective Center Location Outboard 100.000 mm 55.000 mm 25.000 mm 21.000 mm 26.750 mm 4.10 mm Inboard 112.713 mm 63.500 mm 30.048 mm 23.813 mm 30.163 mm 4.60 mm

Hub specifications
Hub with a inboard mounted drum. Mounting bolt circle dia = 203.2 mm Hole size = 18.9 mm Drum pilot dia = 162.85 mm Wheel pilot dia = 160.7 mm Oil seal dia = 114.3 mm Flange thickness = 16 mm Load line to inboard bearings effective centre = 30 mm

 Outboard bearing shoulder to drive shaft flange = 60.73 mm Density of the material= 7.1 E -6 kg/mm Poissons ratio = 0.25 Oil seal width = 24 mm Wheel offset = 107.5 mm Machining stock = 3.5 mm Bearing span = 92 mm

 Designed hub within the set weight limit 1. The basic cross section

2. The model cut section

 The volume of the designed model is 1388886.0830 mm

 The mass of the model is given by, Mass = Density * volume = ( 7.1 E-6 ) * (1388886.0830) = 10.13 Kg.

Further work
Analysis using PRO/ENGINEER MECHANICA