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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. - PowerPoint PPT Presentation
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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
Solid Cylinders Simulate Bearings
Substitute
Bearing Volumes
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
1. Max Deformation
= 0.00051749 in
2. Max Stress
= 4633.8 PSI
3. Mass
= 0.854 lbm
Webbed1. Max
Deformation
= 0.00050028 in
2. Max Stress
= 3497.4 PSI
3. Mass
= 0.878 lbm
%Change1. Max
Deformation
= -3.3%
2. Max Stress
= -24.5%
3. Mass
= +2.7%
Impact Statement
Reduced chance of a failure1. Reduces potential waste of material2. Reduces potential environmental
contamination3. Reduces potential injuries (Robust
design)
Conclusion
Webbed design is superior.
1. Less stress2. Less deformation3. Easier machining4. Minimal change in weight
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