Investigation of Materials For Shaft and

Department of Mechanical and Indutrial Engineering Technology
Project
DESIGN OF SUN GEAR AND SHAFT OF

A HAMONIC PLANETARY GEAR
By
B.R. Ngoyi Preston

(201103088)
A mini-project report submitted

in partial fulfilment of the requirements for the module
STRENGTH OF MATERIALS IV (TSH 441)
FOR THE DEGREE OF BACHELOR OF

MECHANICAL ENGINEERING TECHNOLOGY
Submitted to
Supervisor - Dr.Daramy Kallon
DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING

TECHNOLOGY
FACULTY OF ENGINEERING AND THE BUILT ENVIRONEMNT
UNIVERSITY OF JOHANNESBURG
Submitted: Thursday 14th May, 2014

Design of Sun Gear and Shaft of a Harmonic Planetary Gear – TSH441
Marking plan
Chapter Section Description Sum- Maximum

mark
Marks
1 I Abstract 5 15
II Introduction 5
III Problem formulation 5
2 I Approach 5 20
II Literature review 10
III Methodology 5
3 I Design 8 20
II Calculations 10
III Results 2
4 I Discussion (materials selection) 12 15
II List of assumptions 3
5 I Conclusion (Most cost effective material) 6 10
II Recommendations 4
References 6 10
Appendices 4
Report layout 4 10
Neatness 3
Presentation 3
Total Marks 100 100
Name: ………………………..……………Student No: ………………………. ………….
Signature: ..................................................Date: …………………………………………...
Page | 1
DECLARATION
I ……………………………………….. Hereby declare that this mini-project report is

wholly my own work and has not been submitted anywhere else for academic credit, either
by myself or another person.
I understand what plagiarism implies and declare that this report embodies my own ideas,
words, phrases, arguments, graphics, figures, results and organization except where reference
is explicitly made to another work.
I understand further that any unethical academic behaviour, which includes plagiarism, is
seen in a serious light by the University of Johannesburg and is punishable by disciplinary
action as stipulated by the university rules and regulations.
Name: ………………………..……………
Student No: ………………………..…….
Signature: ..................................................
Date: ………..............................................
Page | 2
ABSTRACT
This project dealt with the selection of materials for a harmonic planetary gear system. The
selected materials had to meet strength requirements while being cost effective. The input
shaft was modelled as a cantilever beam carrying the weight of the gears represented as a
point load. The selection of the shaft material was based on rigidity, or their ability to resist
lateral deflection. The analysis was done using Maccauley’s approach to beams and CAD
simulations.
An internet and book based research was conducted to gain knowledge of the materials
already in use for the shaft and sun gear of a planetary gear system. Following the research
phase three materials were selected for the sun and the shaft. Then analysis to determine the
slope and deflection was done using Maccauley’s approach to beams and CAD simulations
for the different materials selected.
The results from the research revealed that carbon steels and alloy steels are the most
common used materials for this type of application. Alloy steels were found to have greater
strength and rigidity than carbon steels which are more sensitive to impact loading. Nickel-
Chromium-Molybdenum AISI 8620 was selected for the shaft and Nickel-Chromium-
Molybdenum AISI 4320 for the gear. These alloy steels were found to have great rigidity,
strength and to be the most cost effective in terms of reliability.
Last an evaluation of the cost for each material was conducted and the results presented. It
was noted that the cost of the materials depended on the process they undergo.
Recommendations were made regarding further ways of selecting materials and future studies
on material processing which can enhance the properties of materials at low cost.
Page | 3
TABLE OF CONTENTS
DECLARATION ............................................................................................................................ 2
ABSTRACT .................................................................................................................................... 3
CHAPTER 1 ................................................................................................................................... 8
1.1. Project Background ..................................................................................................... 8
1.2. Problem Formulation................................................................................................... 8
1.2.1 Problem Statement ................................................................................................... 8
1.2.2 Scope of Project ....................................................................................................... 8
1.2.3 Limitations ............................................................................................................... 9
2.1 Approach ................................................................................................................... 10
2.2 Literature review ....................................................................................................... 10
2.2.1 The Sun Gear and Shaft of a Harmonic Planetary Gear ........................................ 11
2.2.2 Design and Application of the Sun Gear of a Harmonic Planetary Gear .............. 11
2.2.3 Fatigue and failure of the Sun Gear and Shaft of a Harmonic Planetary Gear ...... 12
2.2.4 Engineering Materials............................................................................................ 13
2.2.5 Engineering Materials Selection Procedure .......................................................... 14
---------------------------------------------------------------------------------------------- ................ 16
3.1 Introduction ............................................................................................................... 16
3.2 Design........................................................................................................................ 16
3.4 Results ....................................................................................................................... 18
---------------------------------------------------------------------------------------------- ................ 20
4.1 Introduction ............................................................................................................... 20
4.2 Discussions ................................................................................................................ 20
4.3 Assumptions .............................................................................................................. 22
---------------------------------------------------------------------------------------------- ................ 23
5.1 Introduction ............................................................................................................... 23
5.2 Conclusions ............................................................................................................... 23
5.3 Recommendations ..................................................................................................... 24
REFERENCES ............................................................................................................................. 25
Page | 4
LIST OF FIGURES
Figure 1: Planetary gear system, showing the sun gear, the planet and the ring gear. ............ 10
Figure 2: Design of a sun gear tooth ........................................................................................ 12
Figure 3: Fatigue breakage of tooth. ........................................................................................ 12
Figure 4: Workflow of the project ........................................................................................... 15
Figure 5: Drawing of the shaft and Gear ................................................................................. 16
Figure 6: Loading of the beam ................................................................................................. 17
Figure 7: CAD Displacement for AISI 4340 Figure 8: Displacement of AISI 8620 ........ 19
Figure 9: Deflection of AISI 1018 Figure 10: Right hand fixed cantilever ........................ 19
Figure 11: Materials price list by SRM.................................................................................... 26
Figure 12: Mechanical properties of Chromium Molybdenum steels ..................................... 26
Figure 13: Mechanical properties of Ni Cr Mo steels.............................................................. 27
Figure 14: Mechanical properties of carbon steels .................................................................. 27
LIST OF TABLES
Table 1: Slope and deflection calculations summary .............................................................. 18
Page | 5
NOMENCLATURE
M : Bending moment
E : Young’s modulus of elasticity
Θ : Slope
I : Second moment of area
Y : Deflection
Ni : Nickel
Cr : Chromium
Mo : Molybdenum
C : Carbon
AISI : Amercican Iron and Steel Institute
Page | 6
Page | 7
CHAPTER 1
----------------------------------------------------------------------------------------------------------------
1.1. Project Background
In the early development of gearbox, designers namely Dr F.W. Lanchester in England and
Henry Ford in America adopted a new approach to gear meshing known as Epicyclic or
planetary gear system. The system is so called due to the fact that its gear rotates around a
common axis which is compared to the rotation of the planet around the sun. Planetary gear
system is the heart of today’s cars automatic transmission. A transmission transfer heat
energy from the engine to mechanical energy on the wheels. An automatic transmission as
defined by the Society of Automotive Engineers in America as ‘a transmission in which gear
ratio changes are done automatically without manual assist’. However the use of such
transmissions was not considered because of their high fuel consumption during gear shift; it
was not until the year 1930 when engineers from General Motors led by Earl Thompson
added a hydraulic control system to the operation of automatic transmissions that they
became economically practical.
1.2. Problem Formulation

The main shaft of the first harmonic planetary gear carries the sun gear as shown in fig.1. It is
desired to select the most appropriate materials for the sun gear and shaft design.
1.2.1 Problem Statement

Car manufacturer emphasizes on light weight and strong components for their cars.
Reliability, cost effectiveness and strength are three major requirements that should meet the
design of the input shaft and sun gear. The designed should be guided by car manufacturing
regulations as well as the material selection process.
1.2.2 Scope of Project

 Analysis of beams
The input shaft and sun gear were converted into a cantilever beam model to
investigate the effect of a point load applied.
 Mechanics of fatigue
The life expectancy, fatigue strength limit of the shaft and gear sun under cyclic
loading was approximated using mechanics of fatigue theories for each material.
Page | 8
1.2.3 Limitations
 Transmission weight
Overweighting transmissions can impact the performance of the car, transmission
generally account for 17% of the total weight of a car. (Ref)
 Cost
Implies a material should be selected taking into account its cost. However cost versus
reliability relationship should be investigated before discarding a material for its price.
 Analysis can only be done for static conditions
The information provided only allow for static analysis of the shaft-sun gear system.
The extent to which fatigue can be analysed was limited because fatigue is due to
cyclic loading (e.g. Torque) encountered for example during rotation.
Page | 9
CHAPTER 2
Approach, Literature Review and Methodology
2.1 Approach
Choosing the most strong and cost effective material required a defined workflow to provide
an effective solution. In order to approach this problem, it was first defined and logical steps
to the solution were outlined. A material research based on engineering materials for
automotive applications was conducted and historical review of the materials investigated.
The transmission was then converted into a beam model to evaluate the effect of the force
acting on the transmission shaft, using CAD analysis and numerical beam calculations. The
results for the three materials were later compared based on their strength and cost and
recommendations made.
2.2 Literature review
A planetary gear system is made of a sun gear, a ring gear and two or more planet gears, all
remaining in constant mesh. The planet gears are mounted within the ring gear and they are
meshed to the sun gear which is mounted on the shaft.
The fact that the gears remain in mesh at all times, prevents gear clash when shifting ratios.
Depending on which part is held stationary and the driving part, different gear ratios can be
obtained.
Figure 1: Planetary gear system, showing the sun gear, the planet and the ring gear.
Page | 10
2.2.1 The Sun Gear and Shaft of a Harmonic Planetary Gear
The shaft is an important element of the planetary gear system. It transmits torque from the
engine to the gear set. The shaft of a planetary gear system like any other shaft used to
transmit power is subjected to torsion and bending. When designing this shaft more
consideration is given on strength and ability to withstand both steady and fluctuating loads.
The selection of the input shaft based on strength depends on the working stress of the
material, the torque, the bending load to be carried and other stress concentration points.
Selecting the shaft based on rigidity entails more criteria to be met in order to satisfy the
deflection requirement induced by the twisting moment and lateral stress. (Drotsky, 2010)
Vibration is an other important aspect of the design. Rotating shafts start to vibrate when the
rotational speed reaches the critical speed of the material. An increase in the diameter of the
shaft pushes away its critical speed reducing the tendency for vibration at low RPM.
The rules for designing the input shafts based on strength are:
 When subject to pure bending moment, the maximum bending stress is given by the
bending moment equation.
 When subjected to pure torsion, the maximum shear stress is obtained from the
torsion equation.
 When subjected to both bending and torsion, the theory for failures give two possible
approaches.
For the maximum shear stress theory:
For the maximum normal stress theory:
The sun gear is mounted on the shaft; it meshes with the planet gears.
2.2.2 Design and Application of the Sun Gear of a Harmonic Planetary Gear
The design of sun gear like any other gears are based on international gear standards such as
the American Gear Manufacturer Association (AGMA) and the international Organization for
Standardization (ISO). For impact load on a gear tooth can be analysed by modelling the
tooth as a cantilever beam subject to a point load at its tip as
Page | 11
Figure 2: Design of a sun gear tooth
The sun and planetary gear is used in most of the automatic transmission system. In
automatic transmission compound sun and planetary gear is used. These kinds of gear also
find application for converting reciprocal motion to the rotary motion in steam engines.
Another application of the sun and planetary gear is electric screw driver. You need to
achieve a moderate reduction ratio in a limited space. (suvo, 2010)
2.2.3 Fatigue and failure of the Sun Gear and Shaft of a Harmonic Planetary Gear
The sun gear is subjected to impact loads which

lead to crack initiation in the root of the gear.
Repetitive application of these loads, generally
bending loads, will cause rapid fatigue failure of
the gear. Stress concentration points on the gear
like notches, fillet help the propagation of cracks
leading to failure. The best way to prevent
fatigue breakage is to design the gear tooth so
that the resulting stresses from the loads fall
below the endurance limit of the material. Fig1.
Shows a fatigue breakage due to bending.
(ShIpley, 1967)
Figure 3: Fatigue breakage of tooth.

Picture from IITM
Fatigue failure of the input shaft of the planetary gear system is mainly due to two factors.
The fluctuating torsional load and the bending moment resulting from the gear load. When
designing for fatigue failure the resulting stress from these two loads should be below the
fatigue endurance limit of the shaft. (Drotsky, 2010)
Page | 12
2.2.4 Engineering Materials

The shaft and sun gear of a planetary system has to be able to withstand high torque and
bending moment. The Considerations taken for the pre-selection of the materials for this
particular design were that the shaft and sun gear should have:
1. Good strength
2. High stiffness
3. Low cost
4. Good wear resistance
5. Low notch sensitivity
Based on the above characteristics and common applications review, materials from the two
main kinds of steels, carbon steel and alloy steel, were proven to meet the requirements of
such applications. The materials pre-selected for this design for the shaft and gear were:
1. Medium carbon steel AISI 1018 (shaft and Gear)
AISI 1024 is a medium carbon steel with 0.19-0.25% Carbon. Hot rolled, it physical
properties are as follow: Tensile strength 510 Mpa (74 Psi), Yield strength 283 Mpa (41 Psi)
and percentage elongation of 20%. (del metals)
Medium carbon steels are strengthened by quenching and tempering because of their high
carbon content. AISI 1024 are used for a wide range of applications notably parts of
automobiles such are transmission shafts, gears, suspension...etc. it can be produced at a
relatively low cost (Smith, 1981, p. 104)
2. Nickel Chromium-Molybdenium steel AISI 4340 (Shaft and gear)
Alloy steels were developed to alleviate some of the disadvantages of carbon steel. Although
they cost more, they are economical for some applications. The chemical composition of
AISI 4340 is: Nickel (Ni 1.65-2%), Chromium (Cr 0.7-0.9%), molybdenium (Mo 0.2-0.3%),
manganese (Mn 0.6-0.8%), silicon (Si 0.15-0.3%), phosphorous (P 0.035%) and sulphur (S
0.04%). AISI 4340 presents high strength and toughness when heat treated. AISI 4340
mechanical properties are: Tensile strength 745 MPa (108 KPsi), yield strength 470 Mpa
(68,2 Kpsi), elastic modulus 190-210 Gpa and elongation 22%.
3. Nickel Chromium-Molybdenum steel AISI 8620 (Shaft)
Low alloy steels consisting of about 1.8% Ni, 0.5 to 0.8% Cr and 0.20% Mo. The 86xx series
have lower nickel content (0.55% lower) than the 43xx series. (Smith, 1981). Nickel in
combination with chromium produces low alloy steels with higher elastic limit, greater
hardenability, higher impact and fatigue resistance than plain carbon. 8620 is mostly used
shafts and axles. The mechanical properties of AISI8620 when annealed are:
Page | 13
Syt 385 Mpa – Sut 530 Mpa – E 190-210 Gpa.
4. Chromium-Molybdenum steel AISI 4320 (Gear)
AISI 4320 is made of 0.95% of Chromium, 0.88 Manganese, 0.2% Molybdenum and 0.4% of
carbon. The addition of chromium further increases the hardenability, strength and wear
ability of the plain carbon of the same concentration of carbon. However the addition of
chromium to low alloy steels tends to make them brittle under some conditions. They are
mostly used for aircraft parts, gears and pressure vessels. (Smith, 1981). The mechanical
properties are: Sut-560MPa – Syt-360MPa.
2.2.5 Engineering Materials Selection Procedure
Basic considerations for material selection were considered as factors that influences the
selection of the appropriate material.
1. Cost and availability
Cost, availability and mass were important factors to consider. Basic materials were given
more considerations against more sophisticated materials which often rare and expensive.
2. Strength
Ductile materials were preferred to brittle materials because brittle materials have lower
toughness and elongation. The materials selected were then classified according to their
strength (ultimate tensile strength, yield strength and Young’s modulus and toughness), this
are available in table 1. Guest and tresca failure theory was used to calculate the stresses
which would cause failure, the Factors of safeties were calculated based on the yield strength
in order to provide a safe design.
3. Fatigue
Fatigue failure is a function of surface finish, shaft with stress concentration points like
notches an keyways increases the likelihood of fatigue failure. Fatigue is induced by
repetitive or cyclic loading. Fatigue strength had to be taken into consideration because they
cause a material to fail at a stress much lower than the anticipated tensile strength. For steel
the fatigue strength is about half the tensile strength. (Drotsky, 2010, p. 12)
Page | 14
2.3 Methodology
The research phase gave guidance on where to start the project. It was vital because it
gave thorough understanding of the materials in play.
In order to analyse the effect of the gear load on the shaft it was necessary to convert it
into a proper beam model.
CAD simulations were an important tool because it revealed important aspects which
human cannot process.
Finally cost considerations were essential, as manufacturers try to keep their production
cost as low as possible. The cost should be justified with sound engineering facts.
Bellow is a snap chart of the methodology of this project
Research
materials common materials used from books, reviews, the
Convert internet and their application.
problem into
model A cantiliver with a point load was considered to
model the problem.
Numerical
calculations
Elongation and slope.
CAD
simulations
CAD simulations
Compare
results
Compare results
Cost,
availaibility
and weight
Cost, availaibility and weight assessment
assessment
Final selection Final selection
Figure 4: Workflow of the project
Page | 15
CHAPTER 3
Design of Sun Gear and Shaft
----------------------------------------------------------------------------------------------
3.1 Introduction
In this chapter the schematic of the design is shown with the independent parts and a
sectional assembly drawing. The steps toward the mathematical solutions clearly stated for
each materials and results of slope and deflection tabulated in a table. Last the calculated
results were compared to the computed CAD simulations.
3.2 Design
Figure 5: Drawing of the shaft and Gear
Page | 16
3.3 Calculations
25 KN
42 11
Figure 6: Loading of the beam
Bending moment, deflection and slope were calculated using Maccauley’s method.
Bending moment
Slope
Deflection y
Where:
M : Bending moment E : Young’s modulus of elasticity
Θ : Slope I : Second moment of area
Y : Deflection
From initial conditions we found A and B:
The equations for slope and deflection in terms of EI become:
And
For circular section:
The slope and deflection at the point of application of the applied load, x= 0.042 m.
And
Page | 17
AISI 8620
E = 210 Gpa
(Anticlockwise)
AISI 4340
E = 190 Gpa
(Anticlockwise)
AISI 1018
E = 205 Gpa
(Anticlockwise)
3.4 Results
E (Gpa) Slope (rad) Deflection (mm)
AISI 8620 210x109 0.000375 0.00275
AISI 4340 190x109 0.000415 0.00304
AISI 1018 205x109 0.000385 0.00282
Table 1: Slope and deflection calculations summary
Page | 18
Figure 7: CAD Displacement for AISI 4340 Figure 8: Displacement of AISI 8620
Figure 9: Deflection of AISI 1018 Figure 10: Right hand fixed cantilever
Page | 19
CHAPTER 4
Discussion of Results - Stress Analysis of the I.C. Engine Connecting Rod
----------------------------------------------------------------------------------------------
4.1 Introduction
In this chapter, the material selection for the gear and the shaft was discussed. The important
facts toward the selection of the material for the gear were stated and selection based on
them. For the shaft we discussed the factors affecting the slope and deflection and then drew
conclusions on a pre-selected material.
4.2 Discussions
4.2.1 Materials Selection for Sun Gear
Although carbon steel can withstand very high heat treatment temperature and be produced at
a low price. Carbon steel 1018 cannot be strengthened beyond 680 Mpa. (Smith, 1981). Plain
carbon particularly are known to have poor resistance to impact at low temperature. Because
they have a low resistance to corrosion, further coating needs to be applied on its surface to
prevent it from oxidizing. (del metals). Furthermore in order to account for its low strength,
the size of the gear have to be increased. Gears are subject to very high sudden impacts and a
worn gear quickly fail under fatigue; for these reason carbon steel is not the most favourable
materials in terms of reliability.
Chrome molybdenum alloy steel 4140 offers a great hardness, resistance to wear and strength
to the gear due to its chromium content while molybdenum tries to keep that hardness
constant at high temperature. (twigg, 1996, p. 283) AISI 4140 has more strength than AISI
1018 (khk gears, 2007). Unlike carbon steels, the chromium content in AISI 4140 increases
its corrosion resistivity and elasticity. (twigg, 1996). Cracks on a gear will quickly lead to its
failure under repetitive loading. Chromium and molybdenum can be oil quench, since oil
quench reduces temperature gradient and internal stress due to volume contraction and
expansion during quenching, distortion and cracking tendencies can be minimized.
Chromium-molybdenum AISI4140 meets most of the strength requirements of a gear.
However because of the process involve in producing alloy steels, these steels are more
expensive than carbon steels. (Smith, 1981)
Nickel-Chromium Molybdenum alloy steel AISI 4340 have the almost the same
characteristics as AISI 4140, with nickel dominant in the mixture (1.8%). Nickel improves
further the tensile strength and toughness of the steel. The hardness and corrosion resistance
are also increased. (twigg, 1996). This makes it a perfect material for heavy duty gearing
applications.
Based on the strength, size and cost requirements mentioned above. The selected material for
the gear was chromium-molybdenum AISI 4140. AISI 4140 and AISI 4340 have respectively
Page | 20
yield strength values of 212 Ksi (1462 Mpa.) and 243 Ksi (1675 MPa). (Smith, 1981). The
extra cost in Nickel-molybdenum would not be justified.
4.2.2 Materials Selection for Shaft
Unlike the selection process of the gear which was based on theoretical review, the material
selection of the shaft was based on the deflection and slope results obtained from the
calculations and CAD simulation.
Deflection and slope are both inversely proportional to the flexural rigidity of a material, hat
is the product of the elastic young’s modulus by the second moment of area of the section.
And since the Young’s modulus of elasticity of a material increases with its tensile strength,
the higher the elastic limit the lower the slope and deflection.
The second moment of area I is dependent on the shape and size of the material. Lager size
materials will have lower slope and deflection.
The materials for the shaft were:
1. Medium carbon steel AISI 1024

2. Nickel Chromium-Molybdenum steel AISI 4342
3. Nickel Chromium-Molybdenum steel AISI 8620
Below is a table of results from the calculations and CAD simulations.
E (Gpa) Slope (rad) Deflection Deflection

(mm) CAD (mm)
AISI 8620 210x109 0.000375 0.00275 0.00726
AISI 1018 190x109 0.000415 0.00304 0.01024
AISI 4340 205x109 0.000385 0.00282 0.01002
Analysing the calculations, results from AISI 1018 showed the highest slope and deflection
(0.000415 rad, 0.00304 mm). AISI 4340 had better rigidity with 0.000385 rad slope and
0.00282 mm deflection. AISI 8620 had the lowest deflection and slope when subjected to the
load.
The CAD simulations although they gave different values for deflection, they still follow the
same order as the calculated values. The change in results might be due to the shape factor of
the shaft. The change in shapes on the shaft was not considered when deriving the formulas,
most importantly in the calculation of the second moment of area. We considered a solid
Page | 21
shaft with even crossection. CAD however compute all the small parameters that human
cannot process.
Based on these results Nickel-Chromium Molybdenum was found to be the most resistive to
static loading and therefore selected.
4.3 Assumptions
1. For the calculations, it was assumed that the beam is a cantilever subject to pure static
loading.
2. The crossectional area of the shaft was even along the entire length.
3. The shaft can be modelled as a cantilever beam.
4. The shaft does not transmit any torque.
Page | 22
CHAPTER 5
Conclusions and Recommendations
----------------------------------------------------------------------------------------------
5.1 Introduction
Pre-selection of the material was done in the previous chapter considering the deflection and
slope of the materials. Here the cost aspect was introduced. For each material the price was
compared. Base on reasonable facts illustrated, the final selection of the materials for the
shaft and gear was done.
5.2 Conclusions
5.2.1 Most Cost Effected Material
The cost of steels depends on the manufacturing process of these. Carbon steels in
comparisons with alloy steels do not undergo rigorous processes. This makes them the most
available and cheaper materials in the market.
Most alloy steels have a density of about 7.89 g/cm3, it could safely be said that all the
materials will result in the same volume.
According to publications from the website https://www-s.nist.gov/srmors/pricerpt.cfm/
Chromium-Nickel-Molybdenum 150 g $335.00

Chromium-Molybdenum Steel 150 g $367.00
Carbon Steel (AISI 1018) 150 g $305.00
(National institute of standard and technology, 2011)
The prices per 150 g of these materials do not vary much relative to one another. CAD
simulation results estimate the mass of the total mass of the shaft to be 0.192 kg
Chromium-Nickel-Molybdenum 1920 g $4288.00 (gear 4320 and shaft 8620, 4342)

Chromium-Molybdenum Steel 4140 1920 g $4697.60 (gear)
Carbon Steel (AISI 1018) 1920 g $3904.00 (gear and shaft)
Carbon steel have the least price, however given its low resistance to impact. This does not
make it the most cost effective material in the long run.
Chromium-Molybdenum steel AISI 4140 is the most expensive of the three materials
however Chromium-Nickel Molybdenum have better properties and is slightly cheaper than
AISI 4140.
Page | 23
The final material selection is:
Shaft: Chromium Nickel Molybdenum AISI 8620
Gear: Chromium Nickel Molybdenum AISI 4340
5.3 Recommendations
Alloy steels have almost the same modulus of elasticity varying between 205-210 GPa. This
implies these materials will almost have the same deflection and slope when doing a static
analysis. Further studies considering the combined effect of torsion and bending would be
valuable for future academics intending to follow on this project.
The cost of materials as mentioned before depends on their processing method. To meet high
strength properties processes like heat treatment is required. Studies on new cheaper
processes approach which will result in the objectives should be considered.
Page | 24
REFERENCES
1 del metals. (n.d.). Retrieved May 09, 2015, from www.delmetals.com:

http://www.delmetals.com/fr/pdfs/D-Limits&Tolerances.pdf
2 Drotsky, J. (2010). Mechanical engineering design. Johannesburg: Juta.
3 khk gears. (2007, September 1). Gear technology. Retrieved April 5, 2015, from
http://www.khkgears.co.jp:
http://www.khkgears.co.jp/en/gear_technology/pdf/gearabc_b.pdf
4 National institute of standard and technology. (2011, may 5). Standard referemce
materials. Retrieved May 10, 2015, from https://www-s.nist.gov/srmors/pricerpt.cfm:
https://www-s.nist.gov/srmors/pricerpt.cfm
5 Smith, W. F. (1981). Structure and properties of engineering alloys. New York:
McGraw-Hill Book Company.
6 twigg, P. (1996). science for motor vehicles engineers. London: Arnold.
Page | 25
Appendices
Figure 11: Materials price list by SRM
Figure 12: Mechanical properties of Chromium Molybdenum steels
Page | 26
Figure 13: Mechanical properties of Ni Cr Mo steels
Figure 14: Mechanical properties of carbon steels
Page | 27

Investigation of Materials For Shaft and

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Investigation of Materials For Shaft and

Загружено:

Авторское право:

Доступные форматы

Department of Mechanical and Indutrial Engineering Technology

DESIGN OF SUN GEAR AND SHAFT OF

B.R. Ngoyi Preston

A mini-project report submitted

STRENGTH OF MATERIALS IV (TSH 441)

FOR THE DEGREE OF BACHELOR OF

Supervisor - Dr.Daramy Kallon

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING

Submitted: Thursday 14th May, 2014

Chapter Section Description Sum- Maximum

III Problem formulation 5

4 I Discussion (materials selection) 12 15

5 I Conclusion (Most cost effective material) 6 10

Total Marks 100 100

Name: ………………………..……………Student No: ………………………. ………….

Signature: ..................................................Date: …………………………………………...

I ……………………………………….. Hereby declare that this mini-project report is

Student No: ………………………..…….

Table 1: Slope and deflection calculations summary .............................................................. 18

1.2. Problem Formulation

1.2.1 Problem Statement

1.2.2 Scope of Project

2.2 Literature review

2.2.1 The Sun Gear and Shaft of a Harmonic Planetary Gear

For the maximum shear stress theory:

For the maximum normal stress theory:

Figure 2: Design of a sun gear tooth

The sun gear is subjected to impact loads which

Figure 3: Fatigue breakage of tooth.

2.2.4 Engineering Materials

1. Medium carbon steel AISI 1018 (shaft and Gear)

2. Nickel Chromium-Molybdenium steel AISI 4340 (Shaft and gear)

3. Nickel Chromium-Molybdenum steel AISI 8620 (Shaft)

Syt 385 Mpa – Sut 530 Mpa – E 190-210 Gpa.

4. Chromium-Molybdenum steel AISI 4320 (Gear)

2.2.5 Engineering Materials Selection Procedure

1. Cost and availability

Bellow is a snap chart of the methodology of this project

Final selection Final selection

Figure 4: Workflow of the project

Figure 5: Drawing of the shaft and Gear

Figure 6: Loading of the beam

From initial conditions we found A and B:

The equations for slope and deflection in terms of EI become:

For circular section:

E (Gpa) Slope (rad) Deflection (mm)

AISI 8620 210x109 0.000375 0.00275

AISI 4340 190x109 0.000415 0.00304

AISI 1018 205x109 0.000385 0.00282

Table 1: Slope and deflection calculations summary

4.2.2 Materials Selection for Shaft

1. Medium carbon steel AISI 1024

Below is a table of results from the calculations and CAD simulations.

E (Gpa) Slope (rad) Deflection Deflection

AISI 8620 210x109 0.000375 0.00275 0.00726

AISI 1018 190x109 0.000415 0.00304 0.01024

AISI 4340 205x109 0.000385 0.00282 0.01002

Chromium-Nickel-Molybdenum 150 g $335.00

Chromium-Nickel-Molybdenum 1920 g $4288.00 (gear 4320 and shaft 8620, 4342)

The final material selection is:

Shaft: Chromium Nickel Molybdenum AISI 8620

Gear: Chromium Nickel Molybdenum AISI 4340