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ME450 Project

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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