Project Report

On

Stress Analysis on Shaft carrying Gear and

Pulley.
By
Mr. Harsh R. Bokil (BM 211)
Guide
Prof. N.R.Sukhalkar

Department of Mechanical Engineering

Marathwada Mitra Mandal’s
College of Engineering,
Karvenagar, Pune
[2023-24]
 Marathwada Mitra Mandal’s
College of Engineering,
Karvenagar, Pune

CERTIFICATE

This is to certify that Name of Students with Exam Seat No

have successfully completed the Project Stress Analysis on Shaft carrying Gear
and Pulley using ANSYS under my supervision, in partial fulfillment of Bachelor
of Engineering - Mechanical Engineering of Savitribai Phule Pune University.

Date:

Place:

Prof. A.G.Nimalkar External Examiner

Dr. V. R. Deulgaonkar Dr. V. N. Gohokar

HEAD Principal
Dept. of Mech. Engg. MMCOE, Pune
MMCOE, Pune
 ACKNOWLEDGEMENT

We take this opportunity here to thank all those who had helped us in making this project a
reality.

First of all, we express our deep gratitude to our project guide Prof. N.R.Sukhalkar for their
valuable support, help & guidance from time to time during the project work. We are also grateful
to our Head of Department, Dr. V. R. Deulgaonkar and Principal Dr. V. N. Gohokar for giving
us this opportunity to present this project report.
Last but not the least; we would like to thank our entire teaching staff who assisted us directly
or indirectly throughout the duration of this project.

Name of student: Harsh R. Bokil

Roll No: BM211

Exam Seat No.

ii
 ABSTRACT

In mechanical engineering, the integrity of rotating shafts carrying gears and pulleys is critical
for ensuring the reliability and safety of machinery. This study presents a comprehensive stress
analysis of a shaft subjected to the combined loads imposed by gears and pulleys. The analysis
considers the effects of bending, torsion, and shear stresses on the shaft, taking into account both
static and dynamic loading conditions. The analysis begins with the determination of the external
loads acting on the shaft, including the torque transmitted by the gears and the tension in the belt
connected to the pulley. The shaft geometry, material properties, and boundary conditions are
also defined. Finite Element Analysis (FEA) techniques are employed to simulate the complex
stress distribution along the length of the shaft under various operating conditions.

The results of the stress analysis reveal critical regions of the shaft where the stresses exceed the
allowable limits, indicating potential areas of failure. Sensitivity analyses are conducted to
investigate the effects of key parameters such as shaft diameter, material properties, and
operating conditions on the stress distribution and structural integrity of the shaft.Based on the
findings, recommendations are provided for optimizing the design parameters to enhance the
strength and durability of the shaft. These recommendations may include adjustments to the shaft
geometry, material selection, or operating conditions to minimize stress concentrations and
improve overall performance. The insights gained from this study contribute to the understanding
of the structural behavior of shafts carrying gears and pulleys and provide valuable guidance for
the design and optimization of rotating machinery systems in various industrial applications.

iii
 INDEX

CHAPTER NO. TITLE PAGE NO.

CERTIFICATE i

ACKNOWLEDGEMENT ii
ABSTRACT iii

INDEX iv

LIST OF FIGURES v

LIST OF TABLES vi

1 INTRODUCTION 1

2 LITERATURE REVIEW 7

3 OBJECTIVES 8

4 METHODOLOGY 9

5 MODELLING 10

6 SETUP 12

7 RESULT 13

8 CONCLUSION 15

9 REFERENCES 16

iv
 LIST OF FIGURES

Figure Title of Figure Page

No. No
1.3 Actual System of Shaft Carrying Gear & 4
Pulley
1.4 Diagram System of Shaft Carrying Gear 4
& Pulley
5.1 Geometry 10
5.2 Mesh 11
6.1 Boundary Conditions 12
7.2.1 Equivalent Stress 13
7.2.2 Total Deformation 14
7.2.3 Factor of Safety 14

v
 LIST OF TABLES

Table No Title of Table Page Number

5.2 Mesh Result 11
6.1.1 Boundary Conditions 12
7.1.1 Stress Table 13
7.1.2 Deformation Table 13

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Chapter 1
INTRODUCTION

1.1 Shaft:

A shaft is a mechanical component used to transmit rotary motion and torque

from one part of a machine to another. It typically serves as a support or axis for
rotating elements such as gears, pulleys, sprockets, and flywheels. Shafts are
essential components in various mechanical systems and are found in a wide
range of applications across industries such as automotive, aerospace,
manufacturing, and power generation.
In summary, shafts play a vital role in the functionality and performance of
various mechanical systems, serving as the backbone for transmitting motion and
torque between rotating components. Proper design, material selection, and
maintenance are essential for ensuring the reliability, efficiency, and longevity
of shafts in industrial applications.
1.2 Gear & Pulley:

Gears and pulleys are mechanical components used to transmit motion and power
between rotating shafts in machinery and mechanical systems. While they serve
similar functions of transferring rotational motion, they have distinct designs and
applications:
1.2.1 Gears:
Gears are toothed wheels that mesh with each other to transmit motion and
torque from one shaft to another. They are used to change the speed,
direction, and torque of rotational motion in machines.
Gears come in various types, including spur gears, helical gears, bevel
gears, worm gears, and planetary gears, each suited for specific
applications and operating conditions.
Gears are used in a wide range of applications, including automotive
transmissions, industrial machinery, power generation systems, and
robotics.

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Design Considerations: Factors such as tooth profile, pitch diameter,

module, pressure angle, and backlash are crucial in gear design to ensure
smooth operation, minimal noise, and efficient power transmission.
1.2.2 Pulleys:
Pulleys are wheels with a grooved rim designed to support and guide belts
or ropes. They transmit rotational motion and torque between shafts by
means of a flexible element such as a belt or rope.
Pulleys can be categorized into two main types:
- Driven Pulleys (or idlers): These pulleys are mounted on shafts and
rotate freely to guide and support the belt.
- Driving Pulleys (or drivers): These pulleys are connected to the power
source (e.g., motor) and transmit rotational motion to the belt, which in
turn drives the driven pulleys.
Pulleys are commonly used with belts made of materials such as rubber,
polyurethane, or metal, depending on the application requirements.
Pulleys are widely used in systems such as conveyor belts, power
transmission systems (e.g., in engines and generators), and lifting
equipment (e.g., cranes and elevators).
Pulley design involves considerations such as groove profile, diameter,
width, and alignment to ensure proper belt tracking, minimal slippage, and
efficient power transmission.
In summary, gears and pulleys are essential components in mechanical systems
for transmitting motion and power. While gears are primarily used for direct
mechanical power transmission with shafts in mesh, pulleys facilitate power
transmission through belts or ropes, offering flexibility in system design and
operation. Both gears and pulleys play crucial roles in a wide range of industrial
and commercial applications, contributing to the efficiency, reliability, and
functionality of machinery and equipment.

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1.3 Shaft carrying Gear and Pulley:

A shaft carrying both gears and pulleys serves as a pivotal component in various
mechanical systems where rotational motion and power transmission are
required. Here's an overview of the role and considerations for a shaft carrying
gears and pulleys:
1.3.1 Functionality:
The shaft acts as a central axis or support for both gears and pulleys,
facilitating the transmission of rotational motion and power between them.
Gears mounted on the shaft engage with mating gears on other shafts to
transmit torque and change rotational speed.
Pulleys mounted on the shaft guide and support belts or ropes, transferring
rotational motion and torque to connected machinery or components.
1.3.2 Load and Stress Analysis:
The shaft undergoes various types of loads, including torsional (from gears
transmitting torque), bending (due to radial loads from pulleys or
misalignment), and shear (from belt tensions).
Performing stress analysis on the shaft is crucial to ensure that it can
withstand the combined loads imposed by gears and pulleys without
failure.
Factors such as shaft diameter, material properties, loading conditions, and
boundary constraints are considered in the analysis to determine the shaft's
strength and durability.
1.3.3 Design Considerations:
Shaft diameter: Determined based on the torque requirements of the gears
and pulleys, considering factors such as safety margins and fatigue
resistance.
Material selection: Choose a material with suitable mechanical properties
(e.g., strength, hardness, and ductility) to withstand the loads and operating
conditions.
Shaft alignment: Proper alignment of gears and pulleys on the shaft is
essential to minimize wear, noise, and vibration and ensure efficient power
transmission.

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Fig1.3: Actual System of Shaft carrying Gear and Pulley

1.4 Working Principle:

The term shaft usually refers to a component of circular cross-section that rotates
and transmits power from a driving device, such as a motor or engine, through a
machine.

Fig 1.4: Diagram of Shaft carrying Gear and Pulley.

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1.5 Applications of Shaft carrying Gear and Pulley:

1.4.1 Automotive: Shafts carrying gears and pulleys are found in engine
timing systems, transmissions, and accessory drives.
1.4.2 Industrial machinery: They are used in conveyor systems,
machine tools, and manufacturing equipment for material handling and
power transmission.
1.4.3 Power generation: Shafts with gears and pulleys are utilized in
turbines, generators, and pumps for converting rotational motion into
electrical power or fluid flow.
In summary, a shaft carrying gears and pulleys plays a crucial role in transmitting
rotational motion and power in various mechanical systems. Proper design,
analysis, installation, and maintenance are essential to ensure the shaft's
reliability, efficiency, and longevity in operation.

1.6 Stress Analysis (FEA):

Stress analysis is a branch of engineering mechanics that involves the study of

how materials and structures respond to external loads or forces. The main goal
of stress analysis is to determine the internal stresses and deformations within a
structure under applied loads, and to assess whether the structure can withstand
these loads without failure. Here's an overview of stress analysis:
1.6.1 Types of Stress:
- Normal Stress: Normal stress acts perpendicular to the surface of a material and
can be either tensile (stretching) or compressive (squeezing).
- Shear Stress: Shear stress acts parallel to the surface of a material and tends to
cause adjacent layers of material to slide past each other.
- Von Mises Stress: A combined measure of both normal and shear stresses,
commonly used to evaluate yielding and failure in ductile materials.
1.6.2 Types of Loading:
- Static Loading: Loads that are applied slowly or held constant over time, such
as dead loads, live loads, and wind loads.
- Dynamic Loading: Loads that vary with time or are applied suddenly, such as
impact loads, vibration, or seismic loads.

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1.6.3 Applications:
- Stress analysis is used in a wide range of engineering disciplines and
applications, including structural engineering, mechanical engineering,
aerospace engineering, civil engineering, and materials science. It is applied in
the design, analysis, and optimization of structures, components, and systems to
ensure they meet safety, performance, and durability requirements.

Overall, stress analysis plays a crucial role in engineering design and ensures that
structures and components are designed to withstand expected loads and
operating conditions without failure. It helps engineers make informed decisions
about material selection, structural design, and safety considerations in various
engineering applications.

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Chapter 2
LITERATURE REVIEW

This paper's case analysis on replacing traditional steel drive shaft with titanium
alloys (Ti-6Al-7Nb). Because of its strong resistance and low weight. The shaft
model was developed in Pro-E and simulation was carried out by Appling
Boundary Condition as Fixed one end in ANSYS program and applies a torque at
3000rpm of shaft on the other end. From the analysis, MAX Stress and Equivalent
Stress parameters were obtained after Calculation Deformation. This shows that
the Titanium alloy (Ti-6Al-7Nb) is a better choice for a drive shaft due to its low
weight and Total deformation of steel and titanium alloy. The Simulation also
shows the two frequency modes.

(2) (PDF) Design and Analysis of Drive Shaft with a Critical Review of Advance
Composite Materials and the Root Causes of Shaft Failure. Available from:
https://www.researchgate.net/publication/342317433_Design_and_Analysis_of_
Drive_Shaft_with_a_Critical_Review_of_Advance_Composite_Materials_and_t
he_Root_Causes_of_Shaft_Failure [accessed Apr 17 2024].

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Chapter 3
OBJECTIVES
3.1 Objectives:
The objectives of shafts carrying gears and pulleys in mechanical systems
encompass various aspects related to their design, function, and performance.
Here are some key objectives:
3.2.1 Power Transmission: One of the primary objectives of shafts carrying
gears and pulleys is to transmit power from one rotating component to
another within a mechanical system.
3.2.2 Motion Conversion: Shafts, gears, and pulleys facilitate the conversion
of motion characteristics such as speed, direction, and type (rotational or
linear) between different components of a mechanical system.
3.2.3 Load Distribution: Another objective is to distribute loads and stresses
evenly across the shaft, gears, and pulleys to prevent premature failure due
to excessive stresses, fatigue, or wear
3.2.4 Torque Amplification or Reduction: Gears and pulleys mounted on
shafts can be designed to amplify or reduce torque depending on their
configuration and gear ratios.
3.2.5 Speed Regulation and Control: Shafts carrying gears and pulleys can
be used to regulate and control the speed of driven components within a
mechanical system.
3.2.6 Efficiency Optimization: Optimizing the design and configuration of
shafts, gears, and pulleys aims to maximize the efficiency of power
transmission within a mechanical system.

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Chapter 4
METHODOLOGY
4.1 Process Flowchart:

4.1.1 Geometry & Mesh:

 To create geometry according to given dimensions(shaft,pulley & gear).
 Also, validating a mesh for fast computation is necessary too.

4.1.2 Setup:
 Applying Boundary Conditions
 Selecting the required result
parameters.

4.1.3 Result & Solution:

 To check the results and plot the graph

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Chapter 5
MODELLING
5.1 Geometry:

Overall, the model consists of one rigid rotating cylindrical pulley on parallel
spinning shafts and connected by a belt span..

Fig 5.1: Geometry.

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5.2 Mesh:

The mesh used is a quadratic mesh for fast computation and better quality.

Domain Nodes Elements

All Domains 43703 19981

Table 5.2: Mesh Result

Fig 5.2: Mesh for shaft carrying gear and pulley.

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Chapter 6
SETUP

6.1 Setup:

6.1.1 Apply Boundary Conditions:

Here we select the condition type, compute from area and initialize and run
calculations.
Domain Boundaries
Remote Displacement Along the Shaft
Fixed Support Face of Gear
Moment 25 N mm along X-axis

Table 6.1.1 Boundary Conditions

Fig6.1: Boundary Conditions

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Chapter 7
RESULT
7.1 Result Table:
- Stress Table:

Case no Maximum(MPa) Minimum(MPa) Average(MPa)

Case 1 5.6573 e-006 0.26049 3.5353e-003

Table 7.1.1: Stress Table

- Deformation Table

Case no Maximum(mm) Minimum(mm) Average(mm)

Case 1 0 1.7897e-004 5.1486e-005

Table 7.1.2: Deformation Table

7.2 Result Analysis:

Fig 7.2.1: Equivalent Stress

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Fig 7.2.2: Total Deformation

Fig 7.2.3: Factor of Safety

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Chapter 8
CONCLUSION

In conclusion, the Ansys analysis of a shaft carrying gears and pulleys provides
valuable insights into the structural integrity, performance, and reliability of these
critical components within mechanical systems. Through advanced finite element
analysis (FEA) techniques, engineers can assess various aspects of the shaft-gear-
pulley system, including stress distribution, deformation, fatigue life, and mode of
failure, to ensure optimal design and operation.

The conclusion drawn from the Ansys analysis of a shaft carrying gears and pulleys
depends on the specific objectives and criteria set for the analysis. However, some
general conclusions that can be drawn include:
 Structural Integrity
 Fatigue Life Prediction
 Failure Mode Analysis

In summary, the Ansys analysis of a shaft carrying gears and pulleys offers
valuable insights and predictive capabilities that empower engineers to optimize
design, ensure structural integrity, and maximize the performance and reliability
of mechanical systems in diverse applications. By leveraging advanced simulation
tools and techniques, engineers can make informed decisions and drive continuous
improvement in product development and engineering design processes. A novel
analytical method for the FEA solution of a pair of rigid rotating pulleys mounted
on parallel compliant spinning shafts is developed. This is part of a belt drive
system where the pulleys are connected by a belt span having extensional and
torsional stiffness.

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Chapter 9
REFERENCES

9.1 https://www.researchgate.net/publication/290624131_Dynamics_of_belt-
pulley-shaft_systems

9.2 (PDF) Design and Analysis of Drive Shaft with a Critical Review of
Advance Composite Materials and the Root Causes of Shaft Failure.
Available from:
https://www.researchgate.net/publication/342317433_Design_and_Analysi
s_of_Drive_Shaft_with_a_Critical_Review_of_Advance_Composite_Mate
rials_and_the_Root_Causes_of_Shaft_Failure [accessed Apr 17 2024].

9.3 https://www.sciencedirect.com/topics/engineering/shaft-design

9.4 https://www.me.iitb.ac.in/~ramesh/courses/ME423/shafts.pdf

9.5 Mechanical Engineering Online Resources: Websites such as Mechanical

Engineering Portal (https://mechanical-engineering.in/) and Mechanical
Engineering Blog (https://mechanical-engg.com/)

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