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Structural Analysis of Competing Aluminum Gearbox Designs Using Finite Element Method

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This project analyzes two designs of a machined aluminum gearbox casing: a webbed and a non-webbed design. The aim is to validate the choice made based on ease of machining through structural analysis. Utilizing ANSYS for finite element analysis, the models are simplified, considering symmetry and simulating bearings using solid cylinders. Key findings indicate that the webbed design demonstrates significantly less stress and deformation compared to the non-webbed variant, resulting in a more robust design with minimal changes in weight.

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Structural Analysis of Competing Aluminum Gearbox Designs Using Finite Element Method

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  1. ME450 Project

  2. Gearbox Analysis • ME450 Finite Element Analysis • Fall Semester, 2007 • Prof: Dr. K. Nematollahi • Team Members • Aaron Huesman • Jae Shin • Kelly McCormick 12-10-2007

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

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

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

  6. Non-Webbed

  7. Webbed

  8. Unigraphics Model

  9. Forces

  10. 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

  11. Ansys Model Substitute Bearing Volumes Solid Cylinders Simulate Bearings

  12. Boundary Conditions

  13. Boundary Conditions Cont…

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

  15. Meshing • Automatic meshing option

  16. Analysis • Deformation study • Von-Mises Stress study Consistent boundary conditions and forces applied.

  17. Deformation Distribution Non-Webbed Webbed Max: 5.17E-4 in. Max: 5.00E-4 in.

  18. Stress Distribution Non-Webbed Webbed Max: 4633.8 psi Max: 3497.4 psi

  19. Results • Non-Webbed 1. Max Deformation = 0.00051749 in 2. Max Stress = 4633.8 PSI 3. Mass = 0.854 lbm • Webbed 1. Max Deformation = 0.00050028 in 2. Max Stress = 3497.4 PSI 3. Mass = 0.878 lbm • %Change 1. Max Deformation = -3.3% 2. Max Stress = -24.5% 3. Mass = +2.7%

  20. Impact Statement • Reduced chance of a failure • Reduces potential waste of material • Reduces potential environmental contamination • Reduces potential injuries (Robust design)

  21. Conclusion • Webbed design is superior. • Less stress • Less deformation • Easier machining • Minimal change in weight

  22. 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.

  23. Questions

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