ROBT 301: Mechanical Design

Project Report
Aikorkem Zhumabek Iliyas Assylgaly
School of Science and Technology School of Science and Technology
Robotics and Mechatronics Department Robotics and Mechatronics Department
Nazarbayev University Nazarbayev University
Astana, Kazakhstan 010000 Astana, Kazakhstan 010000
Email: [email protected] Email: [email protected]

Abstract—In this project, we will design a simplified Cardan regular operations. In addition, the material of the drive shift
shaft (Drive shaft) according to loads and power output such should be relatively cheap and easy to obtain while also
that it is safe in static and fatigue loadings. meeting the necessary standarts for safety. For this reason we
I. I NTRODUCTION chose AISI 1045 cold-rolled carbon steel from Appendix A of
Drive shaft is a mechanical component for transmitting Machine Design book.
torque and rotation, usually used to connect other components III. C ALCULATIONS
of a drive train that cannot be connected directly because of First we must obtain the value for the drive shaft from
distance or the need to allow for relative movement between ID, safety factor for the fatigue loading and length of the
them. As torque carriers, drive shafts are subject to torsion shaft. Values for the density, tensile yield strength and ultimate
and shear stress, equivalent to the difference between the input tensile strength were obtained from the Solidworks (Figure 2).
torque and the load. They must therefore be strong enough to The maximum torque that can be applied by the engine is 231
bear the stress, whilst avoiding too much additional weight as Nm as we established earlier and the torque which was tested
that would in turn increase their inertia. during static loading is 231 ∗ 3.3 = 762.3N m. The values for
To allow for variations in the alignment and distance the calculations are listed below:
between the driving and driven components, drive shafts
frequently incorporate one or more universal joints, jaw cou- ID = 60 mm
plings, or rag joints, and sometimes a splined joint or prismatic L = 2m
joint. (Wikipedia) ρ = 7850kg/m3
We will treat this problem as two-dimensional and the
stresses in an assembly (Universal Joint and Drive Shift) Sy = 530M P a
will be evaluated. Firtst, for this project we are looking at Sut = 625M pa
Toyota Camry XV40 with 2.5L 2AR-FE gasoline engine. T = 762.3N m
The car has 6 forward gear ratios and 1 backward gear N =4
ratio, with maximum gear ratio being 3.3, minimum 0.608
and reverse one with 4.148. The maximum torque is 231
Nm. Specifications can be found in the references. Then, we Here, ID - inner diameter, L = length of the tube, ρ -
examine a regular drive on a flat road with no load. Finally, density, Sy - tensile yield strength, Sut - ultimate tensile
conditions when the gear shifts between forward to backward strength, T - applied torque and N - safety factor.
will be considered. Below equations which we are going to use in order to find
In this project, we presume that the model is simplified, appropriate OD:
that it is pure torsional shaft. We also assume that weight is
going to distributed equally over its length. For this work, the (OD2 − ID2 )
shape of the drive shift is going to be cylindrical with inner m = ρπ L (1)
4
and outer radius with constant density. The visual illustration 4 4
π(OD − ID )
can be seen in the Figure 1. ”w” is the weight that is loaded to I= (2)
64
the shaft, ”L” is the length of the shaft, OD is outer diameter J
and ID is the inner diameter. I= (3)
2
II. D ESIGN REQIREMENTS (4)
It is quite obvious that the drive shaft should be as light These equations are taken from the Chapter 4 of the book. m
as possible while also avoiding fracturing and yielding under is the mass of the shaft, I - moment of inertia. Now we need
to find alternating moment. We have two reactionary forces R2 = m∗g / 2 ;
from both ends of the tube: R1 and R2. Since the weight is
distributed uniformly through the length of the shaft, R1 = Ma = m∗g ∗L / 8 ;
R2 = R = m 2 . Now, we are going to calculate maximum I = p i ∗ (ODˆ4−ID ˆ 4 ) / 6 4 ;
bending moment and miniumum bending moment: J = 2∗ I ;
M ∗L W ∗L
Mmax = = (5) s i g m a a x = Ma∗OD/ ( 2 ∗ I ) ;
4 8
M ∗L W ∗L tau mxy = T∗OD/ ( 2 ∗ J ) ;
Mmin = − =− . (6)
4 8
Mmax − Mmin W ∗L e q u a t i o n = Sy∗(1− s i g m a a x / Sy ) / tau mxy == N ;
Ma = = (7) S o l u t i o n = s o l v e ( e q u a t i o n , OD)
2 8
Mmax + Mmin From this we conclude that OD should be equal to 62.01mm
Mm = =0 (8)
2 in order to meet the neccessary safety standards for fatigue
Now we can calculate the alternating and the mean normal loading. For the next phase, we are going to determine the
stresses: safety factor for the static loadings with the values that we
obtained. First we need to write the equations for moment,
Mmax ∗ OD normal and shear stress:
σmax = (9)
2I
Mmax ∗ OD mgl
σmin = − (10) M= (18)
2I 8
σmax − σmin Ma OD M ∗ OD
σax = = (11) σ= (19)
2 2I 2I
σmax − σmin T ∗ OD
σmx = =0 (12) τ= (20)
2 2J
We also should not forget about the alternating and the mean The principal normal stresses, based on the book, are:
stresses:
T ∗ OD
r
σ σ
τmxy = (13) σ1 = + ( )2 + τ 2 (21)
2J 2 2
τaxy = 0 (14) σ2 = 0 (22)
r
Consequently, values for the alternating and the mean The σ σ
σ3 = + ( )2 + τ 2 (23)
von Mises effective stresses are: 2 2
The equation for the von Mises effective stress for the two-
σa0 = σax (15) dimensional case is:
σm = τmxy (16)
q
σ 0 = σ12 − σ1 σ2 + σ32 (24)
The equation for calculating the fatigue safety factor is:
Finally, the equation for the static safety factor usign
σa0 1 distortion-energy theory is determined as:
Nf = Sy (1 − ) 0 (17)
Sy σm Sy
Ns = (25)
By running the Matlab code below, we can use these σ0
calculations in order to find OD:
p0 = 7 8 5 0 ; %d e n s i t y
syms OD;
ID = 0 . 0 6 0 ;
L = 2;
g = 9.981;
T = 231∗3.3;
Sy = 5 3 0 ∗ 1 0 ˆ 6 ;
Sut = 625∗10ˆ6;
N = 4;

m = p0 ∗ p i ∗ (ODˆ2−ID ˆ 2 ) ∗ L / 4 ;
R1 = m∗ g / 2 ;