UDLAP

Section 1
165577 Alberto Garcia Sanchez
Artifact Research Paper

Abstract
The objective of this work was to learn how to design and analyzed a mechanism that had the parts that
were previously learned in class in order to calculate its parameters. The fatigue failure on the shaft was
examined. As for the bearing's life will be evaluated as part of the analysis. The software of SolidWorks
was utilized for the mechanism's design and simulation. At last, the issues will be address logically and as
well as involving the SolidWorks for the analysis of each part of the mechanism.

KEY WORDS: GEARS DESIGN, SHAFT DESIGN, BEARINGS, SOLIDWORKS

Introduction
1.1 Gears
Now days modern mechanisms use gears in order to move the systems and transmit motion
and power, that’s why its very important to know the functions of this a how to design one with
the right specifications and parameters. With out he proper research on how to design a gear will
only lead to failure. Gear is the rotating machine element that can transmit the power, motion and
torque. The spur gear is the simplest type of gear having teeth projecting radially. Generally, the
effi-ciency of gear is nearly 98%.[1]

In any form of the gear mechanism, the tooth of the driving gear pushes the tooth of the meshing
driven gear for transmitting the required force. So, it is obvious that the tooth encounters the
maximum stress while meshing or transmitting, which intern will result in tooth failure. Upon
observations, it is found that the bending stress and the contact stress are the two main causes of
failure of spur gear at the surface of the tooth.[2]

FIGURE 1 illustrates the basic terminology of the spur gear. In 1892, Wilfred Lewis formulated
an equation called Lewis bending equation to determine the tooth stress of the gear teeth by
considering the tooth profile. It is one of the oldest and significant design equations to consider
for the design of gear, especially for spur gears.[2]

The module m is the ratio of the pitch diameter to the number of teeth. The customary unit of
length used is the millimeter. The module is the index of tooth size in SI. The diametral pitch P is
the ratio of the number of teeth on the gear to the pitch diameter.[3] Thus, it is the reciprocal of
the module. Since diametral pitch is used only with U.S. units, it is expressed as teeth per inch.
The addendum a is the radial distance between the top land and the pitch circle. The dedendum b
is the radial distance from the bottom land to the pitch circle. The whole depth ht is the sum of
the addendum and the dedendum. The clearance circle is a circle that is tangent to the addendum
circle of the mating gear.[3]

FIGURE 1 [3]

In the past, most of the research has been focused on design procedure of spur gear. Good spur gear
design offers better contact ratio. Enhanced tooth profile results in higher contact ratio which provides
better transfer of power.[4]

High contact ratio (HCR) spur gears can give smooth meshing in operation while being smaller
and lighter. The HCR gear has a contact ratio of at least 2 or more, which means that it has at
least two or more tooth pairs in contact during the meshing cycle to share the load. Gears with an
involute curve as the tooth profile are widely used in the industry. Using this gear type
necessitates teeth with a lower pressure angle, finer pitch, or extended addendum.[5]

In theory, the rotation of the output gear is a function of the input rotation and the transmission
ratio causing a constant rotation to be obtained at the output, however, this does not happen as
the gears fail and cause a non-uniform angular motion transmittance. [7]

1.2 Shafts
Moving to the shafts, a shaft is a rotating member, usually of circular cross-section for
transmitting power. It is supported by bearings and supports two flywheels. It is subjected to
torsion and bending in combination. Generally, shafts are not of uniform diameter but are
stepped, keyways, sharp corners etc. [8].

Bending, torsion, and axial stresses may be present in both midrange and alternating
components. Axial loads are usually comparatively very small at critical locations where bending
and torsion dominate, for a rotating shaft with constant bending and torsion, the bending stresses
completely reversed and the torsion is steady. [9]

For shafts, where the deflections may be sought at a number of different points, integration using
either singularity functions or numerical integration is practical. In a stepped shaft, the cross
sectional properties change along the shaft at each step, increasing the complexity of integration,
since both M and I vary. Fortunately, only the gross geometric dimensions need to be included,
as the local factors such as fillets, grooves, and keyways do not have much impact on
deflection.[9]

The shafts are subjected to combined bending and torsional loads. The design model parameters
are considered as random variables characterized by mean values and coefficients of variation
(covs).[10]

The most problematic design situation is dynamic where machine and structural members are subjected to
fatigue loading. About 80% to 90% of the failures of machine and structural members result from
fatigue.[12][13]
Applying experimentally generated fatigue data to shaftIng desippn Is certainly not a new
approach. Ilowevcr, rarely sloes the shall designer hare the appropriate fatigue data at his finger
tips which matches his application.[11]

1.3 Bearings
Then we have the bearings that are also known as rolling-contact bearing, antifriction
bearing, and rolling bearing are all used to describe that class of bearing in which the main load
is transferred through elements in rolling contact rather than in sliding contact. In a rolling
bearing the starting friction is about twice the running friction, but still it is negligible in
comparison with the starting friction of a sleeve bearing. Load, speed, and the operating viscosity
of the lubricant do affect the frictional characteristics of a rolling bearing.[3] The running friction
could present degradation in it’s surface originated spalling has been recognized as one of the
main modes of failure for rolling contact fatigue (RCF) of bearings. [18 ]

As a rotating component, journal bearing is widely used in internal combustion engine. Its
quality directly affects the power and economy of generator. With the development of internal
combustion engine towards heavy load and high speed, the performance requirements of journal
bearing are increasing.[14]

FIGURE 2: Nomenclature of a ball bearing. [3]

Looking at FIGURE 2 it is show all the parts necessary to design a ball bearing. All these
bearings may be obtained with shields on one or both sides. The shields are not a complete
closure but do offer a measure of protection against dirt. A variety of bearings are manufactured
with seals on one or both sides.[3]

It is very important to ensure that the journal bearing can be fully lubricated and reduce friction
and wear under extreme working conditions, both for improving the service life of internal
combustion engine and reducing fuel consumption rate.[15]

The traditional design method of bearing is mainly based on the manual design process which
invites numerous calculations. The small change in shape or size of assembly component will
cause massive chain reaction like revision of blueprint because of many interrelated design
issues. [6] In a more modern way, the use of a software that derived for determining the motion
of the ball and sliding friction in a high-speed, angular-contact ball bearing under thrust load in
terms of the inertia effects on the ball and the frictional resistances resulting from interfacial slip
at the contact areas. [20]

In order to reduce energy consumption and reduce friction and wear, wear-resistant materials,
lubricants and other factors have been widely studied by researchers. Previous studies have
shown that machining appropriate texture modeling on the structure surface can obviously
enhance the surface tribological properties of friction pairs, reduce energy consumption and
prolong service life. [16-17]

1.4 SolidWorks
SolidWorks is a three-dimensional parametric solid modeling software developed based on
windows. Any programming language supporting OLE (Object Linking and Embedding) and
COM (Component Object Model) can be used as development tools of SolidWorks, such as
Visual Basic (VB), Visual Basic Application (VBA), VC + +, C# etc. VBA is the simple tool for
secondary development as it manages the secondary development during recording and editing
macro [6] The SOLIDWORKS® program was among the first solid modeling programs to be
written exclusively for the Microsoft Windows environment. Since its initial release in 1995, it
has been adopted by thousands of companies worldwide. [19]
The objective of this research paper is going to be the right analysis of a mechanism that has
gears. As for shaft it is going to be analyze the maximum torque that can be transmitted and with
SolidWorks simulate the stress and torsion that the shaft can have. And finally for the bearing the
analysis will consist of determine the bearing life. For the design and creation of the mechanism
the software of Solid works will be used. Finally, the problems are going to be solve analytically
and as well as using the SolidWorks for the simulations.

Methods
• Formulate
2.1 Gears
For the gears analysis it necessary to calibrate the values of RPM (revolutions per minute). When
two gears are in mesh, its necessary to assign the pitch radios as r1and r2, as well as the angular
velocities as 𝜔1 𝑎𝑛𝑑 𝜔2 . so knowing this the pitch velocity is going to be:
(1)
𝑉 = |𝑟1 𝜔1 | = |𝑟2 𝜔2 |
Therefore the relationship between the radii on the angular velocity is
(2)
𝜔 𝑟
|𝜔1| = 𝑟2
2 1

Then we also have:

(3)
𝑁
𝑃=
𝑑
(4)
𝑑
𝑚=𝑁

(5)

𝜋𝑑
𝑃= = 𝜋𝑚
𝑁
(6)
𝑝𝑃 = 𝜋
P= diametral pitch, teeth per inch
N=number of teeth
d=pitch diameter, in
m=module, mm
d=pitch diameter, mm
p=circular pitch

2.2 Shaft
For the right design of the shaft we can calculate the maximum torque that can be transmitted to
a steel shaft. For this we will need:
(7)
𝜋𝑟 4 𝜋𝑑 4
𝐽= =
2 32
(8)
𝑇𝑟
𝜏𝑀𝐴𝑋 =
𝐽

2.3 Bearing
Finally for the bearing I wanted to calculate the desire life which can be obtained from the next
formula.
(10)
6
𝐿10 = 𝐿𝑅 = 𝑙𝑅 𝑛𝑅 60 = 10

So the rating life is going to be

(11)
1
𝐿𝐷 1/𝑎 𝐿𝐷 𝑛𝐷 60 𝑎
𝐶10 = 𝐹𝑅 = 𝐹𝑑 ( ) = 𝐹𝐷 ( )
𝐿𝑅 𝐿𝑅 𝑛𝑅 60
 • Apply resources

FIGURE 3
In figure 3 we are able to see how the gears of 64 tooth and 22 tooth were mesh in to one another
in order to the obtain the analysis wanted.

FIGURE 4:
In this figure it show the simulation of the angular velocity how the gears are moving with a
velocity of entry of 1800 rpm.
FIGURE 5
In this figure we are able to see how I isolates this shaft in order to do the analysis of the stress
concentration. First, I needed to create the study and select the material of the shaft.

FIGURE 6
In this figure I show how the study of the stress and strain was simulated in the software. As it is
visible in the figure the stress is going more to were the gears go. Never the less it can also be
show what the yield strength was.

FIGURE 7
Results and discussion
Going back to the methods where I explained hoe each formula going to be needed in order to
solve the problems.
• Develop solutions
Solving for the gears we know that an 22 tooth gear is mesh with a 64 tooth gear and the
diametral pitch offset is 2 teeth per inch. We have that with equation 3:

22
𝑃= 𝑓𝑜𝑟 𝑁1 = 11𝑖𝑛
2
64
𝑃= 𝑓𝑜𝑟 𝑁2 = 32𝑖𝑛
2
As for the velocity of the gear 2 that is moving thanks to gear 1

For the shaft I wanted to calculate the maximum torque that could be transmitted through a 20
mm diameter solid steel shaft, that could not exceed a shear stress of 60 mpa.
𝜋(0.02)4
𝐽= = 1.57𝑥10−8
32
And solving from (8) and clearing T we have
𝜏𝑚𝑎𝑥𝐽 6𝑋107 𝑃𝑎 ∗ 1.57𝑥10−8
𝑇= =
𝑟 0.01𝑚
𝑇 = 94.2 𝑁. 𝑚

For the bearing load life I’m considering SKF, which rates its bearings for 1 million revolutions.
And if I desired to have a life of 4000 h at 1800 rev/min with a load of 500 lbf with a reliability
of 90 percent.
Using equation (11) that comes from the equation (10) we obtain:
1
𝐿𝐷 𝑛𝐷 60 𝑎
𝐶10 = 𝐹𝐷 ( )
𝐿𝑅 𝑛𝑅 60
So
1/3
(4000)(1800)(60)
𝐶10 = 500 ( )
106

𝐶10 = 3779.76 𝑙𝑏𝑓

Conclusion
In conclusion to sum up everything that has being stated in this research paper, the design of a
mechanism that has an shaft, bearing and gears is not an easy task, it requires a lot of reading
through articles as well as compering them. The right use of the software Solidworks was
indispensable for the analysis an simulations of the mechanism.

Taking a look at the methos were I show how it could be simulated as well as obtained
analytically. I was able to obtain the torque of the shaft that is from the second gear. Then I
calculated the bearing load life. Finally, I calculated the velocity of the gears as well as the
diametral pitch.
References
[1] Hamrock, B. J., Schmid, S. R., & Jacobson, B. O. (2004). Fundamentals of machine
elements. McGraw-Hill Higher Education.
[2] ] E. Jayakiran Reddya, V. Pandu Rangadub, Development of knowledge based parametric
CAD modeling system for spur gear. An approach, Alexandria Eng. J. 57 (4) (2018) 3139–3149.
[3] Richard G. and J. Keith (2012). Shigley’s Mechanical Engineering Design (9th ed.).
McGraw-Hill.
[4] Wang, H., & Wang, H. P. (1994). Optimal engineering design of spur gear sets. Mechanism
and machine theory, 29(7), 1071-1080.
[5] Ahmed W. Hussein, Mohammad Q. Abdullah, High-contact ratio spur gears with conformal
contact and reduced sliding, Results in Engineering, Volume 14, 2022, 100412, ISSN 2590-
1230,
[6] Jayakiran Reddy, E., Sridhar, C.N.V., Pandu Rangadu, V. (2016). Research and Development
of Knowledge Based Intelligent Design System for Bearings Library Construction Using
SolidWorks API. In: Berretti, S., Thampi, S., Dasgupta, S. (eds) Intelligent Systems
Technologies and Applications. Advances in Intelligent Systems and Computing, vol 385.
Springer, Cham.
[7] Mark, W. D. (1978). Analysis of the vibratory excitation of gear systems: Basic theory.
Journal of the Acoustical Society of America
[8] Gujar, R. A., & Bhaskar, S. V. (2013). Shaft design under fatigue loading by using modified
goodman method. International Journal of Engineering Research and Applications, 3(4), 1061-
1066.
[9] Gujaran, S., & Gholap, S. (2014). Fatigue analysis of drive shaft. International journal of
research in aeronautical and mechanical engineering, 2(10), 22-28.
[10] Osakue, E., Anetor, L., & Odetunde, C. (2015). Fatigue shaft design verification for bending
and torsion. International Journal of Engineering Innovation Research, 4.
[11] Loewenthal, S. H. (1978, January). Proposed design procedure for transmission shafting
under fatigue loading. In Ann. Meeting of the Natl. Conf. on Power Transmission (No. NASA-
TM-78927).
[12] Kravchenko, P. YE., Fatigue Resistance, Pergamon, New York, 1964.
[13] Sachs, N., Root Cause Failure Verification –Interpretation of Fatigue Failures,Reliability
Magazine, 1999, August.

[14] Tao Nie, Kun Yang, Lei Zhou, Xin Wu, Yin Wang, CFD analysis of load capacity of
journal bearing with surface texture, Energy Reports, Volume 8, Supplement 7, 2022,Pages 327-
334, ISSN 2352-4847
[15] Zhaoding, H. (2018). Study on the Lubrication Performance of Surface Textured Journal
Bearing.

[16] Etsion I, Halperin G, Brizmer V, et al. Experimental investigation of laser surface textured
parallel thrust bearings. Tribol Lett 2004;17(2):295–300

[17] Segu Dawit Zenebe, Choi Si Geun, et al. The effect of multi-scale laser textured surface on
lubrication regime. Appl Surf Sci 2013;(270):58–63

[18] Sadeghi, F., Jalalahmadi, B., Slack, T. S., Raje, N., & Arakere, N. K. (2009). A review of
rolling contact fatigue.

[19] HOWARD, W.; MUSTO, J. Solid modeling using SolidWorks 2017. New York: McGraw-
Hill Education, 2017.

[20] JONES, A. B. Ball motion and sliding friction in ball bearings. Journal of Basic
Engineering, 1959, vol. 81, no 1, p. 1-12.