BOSTON UNIVERSITY

ME 359 Final Project Report

Group #5
Alex Patow, ME 2015 John Griese, ME 2015 Michael Gonzalez, ME 2014 Abby Dutke, ME 2015

12/1/2013

ME359 Final Project Report

Description
The objective of this project is to design a manufacturable prototype gear box. The gear box is required to have a ratio of 1/240, and a minimum life of 25,000 hours. The input and output shafts are orthogonal and a maximum of 1.5 inches past the outer surface of the gearbox. The output shaft and its bearing must support an eccentric load of 50lbf, and have a maximum input shaft rotation speed of 240rpm. Alex Patow Spec Parts, CAD, CAD Drawings, Presentation and Report Michael Gonzalez Spec Parts, CAD Drawings, Tolerancing, Presentation and Report John Griese CAD, CAD Drawings, Tolerancing, Life Analysis, Presentation and Report Abby Dutke Spec Parts, CAD Drawings, Presentation and Report

Design Review
The final design of the project includes a 10 tooth spur gear, a 100 tooth spur gear, a 1 start worm, and a 24 tooth worm gear. The input shaft houses the worm, which is paired with the worm gear. The 10 tooth gear shares the same shaft as the worm gear and is paired with the 100 tooth spur gear. This gives us a gear ratio of 1/240 and the orientation of the worm and gears makes the input and output shafts perpendicular. The input and output shafts both protrude 1 inch (nominally) from the surface of the box. All bearings were specified to support a 50lbf eccentric load with a maximum speed of 240rpm with a lifetime of 25,000 hours under these most strenuous conditions.

Our gear box housing is made out of 304-Stainless Steel sheet metal which is 0.060 thick. There are two parts to the housing. One fits into the other and they are connected by self-clinching nuts. The holes will be drilled into the flat sheet metal pieces, which will then be bent in a set of presses to achieve the desired shapes. Page 1 of 10

ME359 Final Project Report

Ninput = # input teeth input = input torque input = input rotation speed
GR = gear ratio

Noutput = # output teeth output = output torque output = output rotation speed

Gear Speed Relation

v = velocity at gear tooth contact R = radius of gear = rotation speed DP= diametral pitch

F = force at gear tooth contact PD = pitch diameters N= number of teeth

Gear Torque Relation ( ) Page 2 of 10

ME359 Final Project Report ( ) ( ) ( ) ( Gear Trains without Shared Axles ( ( ) [( ) ) ] ( ) ( ) ) ( )

Gear Trains with Shared Axles

Tolerance Analyses
We encountered significant problems with SDP-SIs catalog, which led to discrepancies in tolerancing. When we measured some of the downloaded parts with Smart Dimension in SolidWorks they were different, about twice as large in certain cases, than the size stated on the website. The most intensive analysis was for the input shaft because it drives the dimensions in spacing the rest of the features. For the input shaft (shown below) we performed a detailed circuit analysis. This was not necessary for the rest of the components for which we did basic tolerance analysis.

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ME359 Final Project Report Input Shaft

Calculate distance from outer face to 2nd Shaft hole (J), J = - F.W. - O.S. + W.H + P.D.P Measurement Nominal (in) Upper + (in) Lower - (in) MAX MIN Flange Width (F.W.) 0.045 0.000 0.002 0.025 Outer Shaft (O.S.) 1.000 0.005 0.005 1.005 Worm Hole (W.H.) 1.730 0.005 0.005 1.735 Pitch Diameter Center (P.D.C.) 0.438 0.000 0.000 0.438 2nd Shaft Hole (J) 1.123 0.010 0.012 1.133 First Groove (G1) Measurement Outer Shaft (O.S.) Bearing Width (B.W.) First Groove (G1) O.S + B.W. = G1 Nominal (in) Upper + (in) Lower - (in) MAX 1.000 0.005 0.005 1.005 0.188 0 0.005 1.188 0.005 0.01

0.021 0.995 1.725 0.438 1.111

MIN 0.995 0.188 1.193 0.183 1.178

*The greyed cell indicated the critical dimension, i.e. the dimension which, the actual part cannot be greater or less that without a chance that the part will not fit.
Second Groove (G2) Measurement Flange Width (F.W.) Outer Box Lenth (O.B.L) Bearing Width (B.W.) Second Groove (G2) - B.L. + F.W. + O.B.L. + F.W. -B.L. = G2 Nominal (in) Upper + (in) Lower - (in) MAX 0.045 0.000 0.002 5.811 0.188 5.525 0.005 0 0.005 0.005 0.005 0.019

MIN 0.025 5.816 0.188 5.530 0.021 5.806 0.183 5.506

Bearings (from SDP-SI)

Measurement Bore Diameter Outer Diameter Bearing Width (B.W.) Flange Width (F.W.) Nominal (in) Upper + (in) 0.25 0.5 0.188 0.045 0 0 0 0 Lower - (in) MAX 0.002 0.003 0.005 0.002 MIN 0.25 0.5 0.188 0.025 0.248 0.497 0.183 0.021

Worm (from SDP-SI)

Measurement Groove Diameter Groove Width Nominal (in) Upper + (in) Lower - (in) MAX (in) MIN (in) 0.21 0.003 0 0.213 0.21 0.029 0.003 0 0.032 0.029

Retaining Rings (from McMaster-Carr)

Measurement Bore Diameter Face Width Overall Width Outside Diameter Hub Diameter Nominal (in) Upper + (in) Lower - (in) MAX (in) MIN (in) 0.25 0.0008 0 0.2508 0.25 0.625 0.875 0.583 0.375

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ME359 Final Project Report

P.D. 0.5

Second Shaft
Calculate Total Length Measurement Bearing Width (B.W.) Interior Width (I.W.) Total Length B.W. + I.W. + B.W. Nominal (in) Upper + (in) Lower - (in) MAX 0.281 0.000 0.005 2.000 0.000 0.010 2.562 0.000 0.020

MIN 0.281 2.000 2.562 0.276 1.990 2.542

Bearings (from SDP-SI)

Measurement Bore Outer Diameter Bearing Width (B.W.) Flange Width (F.W.) Nominal (in) Upper + (in) Lower - (in) MAX 0.1875 0.0000 0.0020 0.3125 0.0000 0.0030 0.125 0.000 0.005 0.023 0.000 0.002 MIN 0.1875 0.3125 0.125 0.023 0.1855 0.3095 0.120 0.021

Retaining Rings (from McMaster-Carr)

Measurement Groove Diameter Groove Width Nominal (in) Upper + (in) Lower - (in) MAX (in) MIN (in) 0.147 0.002 0.000 0.149 0.147 0.029 0.003 0.000 0.032 0.029

Worm Gear (from SDP-SI)

Measurement Bore Diameter Hub Diamter Hub Projection Length P.D. Nominal (in) Upper + (in) Lower - (in) MAX (in) MIN (in) 0.1869 0.0010 0.0000 0.1879 0.1869 0.625 0.3125 0.5625 1.000

10 Tooth Gear (from SDP-SI)

Measurement Bore Diameter P.D. O.D. Nominal (in) Upper + (in) Lower - (in) MAX (in) MIN (in) 0.1873 0.0005 0.0000 0.1878 0.1873 0.4167 0.5

Output Shaft
Calculate Total Length Measurement Bearing Width (B.W.) Interior Width (I.W.) Output Length (O.L.) B.W. + I.W. + B.W. + O.L Nominal (in) Upper + (in) Lower - (in) MAX MIN 0.281 0.000 0.005 0.281 2.000 0.000 0.010 2.000 1.000 0.005 0.005 1.005

0.276 1.990 0.995

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ME359 Final Project Report

Total Length 3.562 0.005 0.025 3.567 3.537

Bearings (from SDP-SI)

Measurement Bore Outer Diameter Bearing Width (B.W.) Flange Width (F.W.) Nominal (in) Upper + (in) Lower - (in) MAX 0.375 0.000 0.002 0.875 0.000 0.003 0.281 0.000 0.005 0.062 0.000 0.002 MIN 0.375 0.875 0.281 0.062 0.373 0.872 0.276 0.060

Retaining Rings (from McMaster-Carr)

Measurement Groove Diameter Groove Width Nominal (in) Upper + (in) Lower - (in) MAX (in) MIN (in) 0.303 0.003 0.000 0.306 0.303 0.039 0.003 0.000 0.042 0.039

100 Tooth Gear (from SDP-SI)

Measurement Bore Diameter P.D. Length Nominal (in) Upper + (in) Lower - (in) MAX (in) MIN (in) 0.3747 0.0005 0.0000 0.3752 0.3747 4.1667 4.1667 4.1667 0.787 0.787 0.787

Bearing Fits Shaft Tolerance Conditions: Normal Load Rotating in Direction of Load All Shafts are <.71 Tolerance Classification: J5 For All Shafts: Tolerance is +.0002, -.0001 Housing Tolerance: Conditions: Outer Ring Stationary Housing Not Split Axially Tolerance Classification: H6 For All Shafts: Tolerance is +0, -.0005

Component Life Analyses

Requirements 50lbf over hung load at output shaft Output shaft is 1.5 max Max speed of 240 rpm Life of 25,000 hours Page 6 of 10

ME359 Final Project Report Assumptions Assume no axial load, all load radially Wear on the gears should be negligible compared to wear on the bearings Weight of the shaft and shaft components is negligible compared to the 50lbf eccentric load

Force Analysis Where: P = dynamic load;

x = .6 (from tables);

Fr = 50lbf

Lifetime Analysis ( ) Where: m=3 (ball bearings); P=dynamic load; C=dynamic load rating; L10=life in millions of hours

Input shaft:

( ( ) )

All Gears with 0.375 Bore All bearings are rated for well over 50lbf static load and also well over the 30lbf dynamic load, including a 1.5x safety factor. Even adding that 50lbf load, the static load rating (273lbf) exceeds the minimum requirements for both the input and output shafts. We specified our bearings to the input rotational velocity. Any section between input and output will be rotating slower than the input velocity.

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ME359 Final Project Report

Work Estimate and Actual

Preliminary Work Estimate: Part/Assy Description Sprocket Shaft Body Assembly Arm 1 Arm 2 Arm Assembly 1 Arm Assembly 2 Responsible Engineer Alex Patow Mike Gonzalez John Griese Abby Dutke Alex Patow Mike Gonzalez John Griese Abby Dutke Model Time Completion Estimate [min] 45 45 30 60 30 30 45 45 Drawing Time Completion Estimate [min] 30 30 30 30 30 30 30 30

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ME359 Final Project Report

Actual Work Estimate Part/Assy Description Spec/Find PartsWorm & Worm Gear Spur Gears Bearings Retaining Rings Self-Clinching Nuts CADBox Input Shaft Output Shaft Assembly Modify Downloaded CAD Models CAD DrawingsWorm Worm Gear 10 Tooth Spur Gear 100 Tooth Spur Gear Box Pt 1 Box Pt 2 Input Shaft Output Shaft Assembly WrittenTolerancing Life Analysis Project Report Project Presentation Responsible Engineer \\\\\\\\\\\\\\\\\\\\\\\ Alex & Mike Alex & Mike Alex & Abby Alex & Abby Alex \\\\\\\\\\\\\\\\\\\\\\\ Alex Alex & John Alex & John Alex Alex \\\\\\\\\\\\\\\\\\\\\\\ Alex & Abby Alex & Abby Alex Alex Mike Mike Alex & John Alex & John Alex \\\\\\\\\\\\\\\\\\\\\\\ John & Mike John & Abby Abby & Mike & John & Alex Abby & Mike & John & Alex Completion Time Estimate [min] \\\\\\\\\\\\\\\\\\\\\\\ 60 60 20 15 5 \\\\\\\\\\\\\\\\\\\\\\\ 60 45 45 60 45 \\\\\\\\\\\\\\\\\\\\\\\ 30 30 20 20 30 30 40 40 45 \\\\\\\\\\\\\\\\\\\\\\\ 480 150 300 210

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ME359 Final Project Report

Bill of materials
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NUMBER 102 101 103 104 602 603 601 201 202 203 301 302 704 703 502 501 503 702 701 DESCRIPTION 24 TOOTH WORM 1 FLUTE START 10 TOOTH SPUR 100 TOOTH SPUR SECOND SHAFT OUTPUT SHAFT INPUT SHAFT INPUT SHAFT SECOND SHAFT OUTPUT SHAFT BOX PT. 1 BOX PT. 2 PEM NUT 6-32 MACHINE SIDE-MOUNT SIDE-MOUNT SIDE-MOUNT SHAFT PIN KEY VENDOR SDP-SI P/N: A 1B 6-N24024 SDP-SI P/N: A 1C55-N24 SDP-SI P/N: S1084Z-024A010 SDP-SI P/N: S1VS24-100F1524 SDP-SI P/N: A 7Y55-FS3118G SDP-SI P/N: A 7Y55-FS8737G SDP-SI P/N: A 7Y55-FS5025G MCMASTER-CARR P/N: 8984K823 MCMASTER-CARR P/N: 8984K823 MCMASTER-CARR P/N: 8984K823 MCMASTER-CARR P/N: 8983K62 MCMASTER-CARR P/N: 8983K62 PEM P/N: S-632-0 ZI--N MCMASTER-CARR P/N: 91735A142 MCMASTER-CARR P/N: 97431A280 MCMASTER-CARR P/N:97431A300 MCMASTER-CARR P/N:97431A320 MCMASTER-CARR P/N: 92373A106 MCMASTER-CARR P/N: 98535A130 MANUFACTURING PROCESSES DRILL QTY. 1 1 1 1 2 2 2 1 1 1 1 1 8 8 2 2 2 2 1

MILLING

TURNING/DRILL TURNING/MILLING TURNING/MILLING SHEET METAL SHEET METAL

MILLING

Drawings
(Attached)

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