ME 322 Project (W15)

Due:

Thursday April 2nd, 2015 at 12:30 PM

Please hand it in to the class representatives.

Marks Available:

10 (4 demerit points for late submissions and each day of delay)

Report Format:

The first page of your report should be a title page with your name and ID
number. The report does not need to have sections for abstract,
introduction, conclusions, table of contents, etc. but can simply identify
each specific task by number and a brief title and give the requested
information. Also, please simply staple your report in the top left corner.
Do not use covers, folders or binders.
The report has to be neat with legible writing and submitted on letter
size paper.

Project:

The shaft shown in the figure below is supported by two deep grove ball bearings and is to be
designed for sufficient static strength and fatigue durability. The shaft is a part of a large power
transmission system supplying the power of 48hp. Power is supplied to the pulley P by means
of a flat belt and transmitted through the shaft to the bevel gear G. The belt forces F1 and F2
are perpendicular to the picture plane with the tight side being F1 and the slack side being F2.
There are three load components applied to the gear G: Ft - tangential force (normal to the
picture plane), Fr - radial force (normal to the shaft axis), Fa - axial force (paralleled to the shaft
axis).
The shaft is made of machined AISI 1060 steel with tensile properties of Sut=140 kpsi (ultimate
tensile strength) and Sy = 97 kpsi (yield strength). The following information has also been
established:

Speed of the shaft:

Pitch diameter of the gear:
Diameter of the pulley:
Weight of the gear:
Weight of the pulley:
The ratio of the belt tension forces:
The ratios of the gear forces:
The shaft diameters:
The shaft fillet radius:

n=900 rpm constant

DG=10 in
DP=10 in
WG=30 lb
WP=30 lb
F1/F2 =2.5
Fr/Ft=5/14 and Ft/Fa = 14/8
1D, 1.5D, and 2D (D =1.45 in)
r = 0.04 in

1. Show the free body diagram, determine all forces acting on the shaft, determine and
draw diagrams of all internal loads.
2. Determine the maximum equivalent von Mises stress in the shaft and verify its safety
from a static yielding point of view.
3. Find the minimum power level at which plastic yielding in the shaft will commence.
4. Estimate the fatigue life of the shaft. Use the Goodman approach.
5. Design the shaft for infinite life by changing diameters with minimum fatigue factor of
safety of 2.5.
Note:
You must submit proof of your iteration process, whether it is a detailed spread sheet,
hand calculations, or computer code.
Make reasonable assumptions, if needed, and state your assumptions in your solution.