Unit– 5 Design of Axles (Marks 14)

TOPICS AND SUBTOPICS:

5.1 Function of front axle. Material with justification and Design of front axle.
5.2 Function of rear axle, Material for rear axle with justification and Design of full floating
rear axle.
Front Axle

Theory- It takes the weight of the front portion of the automobile. It gives steering facility
and absorbs shocks. The weight of the front part of the vehicle is transmitted to the road
surface through front wheels by the front axle of a vehicle. It also houses the mechanism for
steering the vehicle to absorb shocks due to road surface variations.

Axle beams are made by drop forging of steel having 0.4% carbon or 1-3% nickel steel. The
front axle beam is formed into l-section in the centre portion. The ends are made into either
circular or elliptical. l-section construction carries bending loads caused by the load of
the vehicle and torque by braking of wheels. The centre portion of the front axle is provided a
downward sweep to maintain the chassis height low.

Design Procedure-

Front axles are subjected to both bending and shear stresses. In static condition, the axle may
be considered as a beam supported vertically upward at the ends, i.e. at the centre of the
wheels and loaded vertically downward at the centre of the spring pads. The vertical bending
moment thus caused is zero at the point of support and rises linearly to a maximum at the
point of loading and then remains constant.
IF, W = load on one wheel (N)
l = distance between the centre of wheel and spring pad, (mm)
Then Maximum bending moment M = Wl (N-mm).
The I-section is used for portion where bending moment predominates and is gradually
changed to circular, oval or rectangular section at the steering head.
The I-section is designed using following equations:
The maximum bending is given by the relation,
𝑀 σb
=
𝐼 𝑌
Where M = the maximum bending moment (N-mm).
σb= allowable bending stress for the material (N/mm 2)
Y = the maximum distance of fibre from the neutral axis – NA
= d/2 (mm)
And I = the moment of inertia of I-section about neutral axis – NA
= (bd3 – ch3) / 12 (mm4)
Where d = the overall depth of I-section
b = width of flange (mm)
t = thickness of web (mm)
w = Flange thickness
c=b–t
h = d – 2w
Generally, d = 6t; b = 4.25t; and w = 2.5t.
The resistance to motion causes torque in the front axle (breaking torque) and its magnitude
is given by

T = µ W R (N-mm)

Where R = the road wheel radius (mm)

µ = coefficient of adhesion between road and tyre

= 0.6 for dry, hard road surface (the maximum value for µ )

The breaking torque is lower for the section lying between spring pads. This torque is
maximum at steering head (at end). Thus I–section is used for portion where bending moment
predominates and is gradually changed to circular, oval or rectangular section at the steering
head.

For circular or oval section, the maximum torsion is given by the relation,

𝑇 𝜏
=
𝐽 𝑟
Where T = the maximum torque in the plane of section (N-mm)

𝜏= allowable shear stress in the material (N/mm2)

r = the distance from neutral axis to the outermost fibre of the axle

= d/2 (mm)

d = diameter of circular section

the major axis for oval section,

J = polar moment of inertia of the section

= 𝑑 for circular section

= 𝑑 𝑏 for oval section with minor axis b.

Example: Design a suitable I-Section for the front axle assuming following data:
Total weight of the car = 14 X 103 N, Load taken by front axle = 6.5 X 103 N, Wheel Track =
1400mm, Distance between centre of spring pads = 700 mm. Width of flange and thickness
are 0.6 and 0.2 of overall depth of the section, Thickness of the web = 0.25 of width of the
flange, Safe working stress = 90 N/MM2.

Given: Total weight of the car = 14 X 103 N,

Load taken by front axle = 6.5 X 103 N,
Wheel Track = 1400mm,
Distance between centre of spring pads = 700 mm.
b = 0.6d,
w = 0.2 d,
t = 0.25 b,
= 0.25 X 0.6d = 0.16d.
σb= 90 N/mm2
Solution: let l = distance between the centre of wheel and spring pad
= (1400 - 700) / 2
= 350 mm.
Let W = load on one wheel
= (6.5 X 103) / 2
= 3.25 X 103 N.
Bending moment M = Wl
= 3.25 X 103 X 350
 = 11.375 X 105 N-mm.
( – )
Now moment of inertia I =

= [ 0.6𝑑 𝑋 𝑑 – 0.45𝑑 𝑋 0.6𝑑 ] ------- (c = b – t & h = d – 2w)

= 0.0419 𝑑

Now, =
11.375 X 105 90
=
0.0419 𝑑 𝑑/2
d =53.4 mm.
The dimensions of I-section are as follows:
Width of flange b = 0.6d, = 0.6 X 53.4 = 32.04 mm
Thickness of flange w = 0.2d, = 0.2 X 53.4 = 10.68 mm
Thickness of web t = 0.25 b = 0.15d = 0.15 X 53.4 = 8.01 mm
Rear Axle

In between the differential and the driving wheels is the rear axle to transmit power
from the differential to the driving wheels. It is clear from the construction of the
differential, that the rear axle is not a single piece, but it is in two halves connected by
the differential, one part is known as the half shaft.
The inner end of the half shaft is connected to the sun gear of the differential and the
outer end of the driving wheel. In rear wheel drive vehicles, the rear wheels are the
driving wheels. Whereas, in front wheel drive vehicles, the front wheels are the
driving wheels. Almost all rear axles on modern passenger cars are live axles, that is,
they revolve with the wheels.

Types of Rear axles

Depending upon the methods of supporting the rear axles and mounting the rear
wheels, the rear axles are of the three types.
1. Semi-floating axle
2. Full floating axle
3. Three quarter floating axle
 Three quarter Floating

Design Procedure

1 Torque Produced by Engine (Te)

2πNT
P=
60
Where P= Engine Power, watt

N= Engine RPM
2 Torque Transmitted by rear axle shaft (TRA)

TRA= Te× 𝐺 × 𝐺

Where G1= Maximum gear ratio in gear box

G2= Final Gear reduction in differential

Diameter d of axle can be calculated using equation

𝜋
𝑇 = ×𝜏×𝑑
16
Where τ = Permissible shear stress for axle material

Example- Design the fully floating axle shaft with following data

Engine Power= 10 kW at 300 rpm, Gear box ratio=4:1, 2.4:1, 1.5:1, 1:1

Differential reduction= 6:1, Shear stress for axle material = 70 N/mm2

Solution- P= 10 kW= 10× 10 W, N=300 rpm

G1= Maximum gear ratio in gear box= 4
G2= Final Gear reduction in differential= 6
1 Torque Produced by Engine (Te)

2πNT
P=
60
× ×
10× 10 =

∴ 𝑇 = 318.471 𝑁𝑚

𝑇 = 318.471 × 10 𝑁𝑚𝑚

2 Torque Transmitted by rear axle shaft (TRA)

TRA= Te× 𝐺 × 𝐺

𝑇 = 318.471 × 10 × 4 × 6

𝑇 = 763.304 × 10 𝑁𝑚𝑚

Diameter d of axle can be calculated using equation

𝜋
𝑇 = ×𝜏×𝑑
16
𝜋
763.304 × 10 = × 70 × 𝑑
16
∴ 𝑑 = 82.24 𝑚𝑚 ≈ 83 𝑚𝑚
 Diameter of rear axle shaft= 83mm

3.
Descri
be the
diameter of rear axle shaft for fully floating type with following data-
Engine Power = 60 kW at 3000 rpm
Gear Box Ratio = 4.5:1, 2.5:1, 1.6:1, 1:1 ;
Differential reduction = 5:1
fs for shaft = 70 N/mm2

Answer: P = 60 kW = 60X 103 W

N = 3000 rpm,
Max gear ratio, G1 = 4.5 : 1,
Differential reduction, Gd = 5:1
Now the Torque transmitted by the engine Te :

= 190.98 Nm
= 190.98 X 103 Nmm
Now Torque transmitted by rear shaft Tra :
Tra = Te X G1 X Gd
∴ Tra = 190.98 X 103 X 4.5 X 5
∴ Tra = 4297.05 X 103 Nmm
Let
d = diameter of rear axle

∴ d3 = 312638.51
∴ d = 67.87 mm Say 68 mm