1. ME 635 Modeling and Simulation Modeling and Simulation of Speed Reducer assembly - Hirak Patel

2. Agenda  Project outline  Problem definition  Selection of gear  Primary calculation  Modeling and simulation Modeling in Pro-E  Static load Analysis  Dynamic load Analysis Simulink Analysis  Discrete event simulation

4.  A single stage speed reducer is considered to demonstrate the complete design and manufacturing methodology  Our problem is to design and manufacture speed-reducer for following application: Input Speed(n1) =1750rpm Approximate Output speed(n2) = 450rpm Power to be Transmitted(P hp ) = 3.5hp Problem definition

5. Selection of Gear  Based on specifications Diametral pitch= 10 Pressure angle(φ)= 20 No. of teeth on pinion= 18

6. Primary calculations  Calculations Diameter of pinion = 1.8 No of teeth on the gear= 72 Diameter of Gear = 7.2 Diameter of shaft= 0.31 in. Exact output speed= 437.5 rpm Tangential load (F t )= 140.056 lb. Radial load (F r )= 50.97lb. Pitch line Velocity = 824.668 fpm

7. Modeling and simulation  Static Analysis Design Inputs  Pitch Diameter D p = 1.800 in.  Base diameter D b = 1.691 in.  Root Diameter D r = 1.556 in.  Outer Diameter D o = 2.000 in.

8. Modeling and simulation  Static Analysis (cont.) Material selection( AISI 1020 Steel)  Mechanical Properties of the material  Brinell Hardness no. 240  Modulus of Elasticity 29E06 psi  Tensile Strength, Yield 42700 psi  Poisson’s Ratio 0.29

9. Modeling and simulation  Static Analysis (cont.) Design in Pro-e

10. Modeling and simulation  Static Analysis (cont.) Assumption for Analysis  Only one tooth is considered for analysis of penion  Maximum intensity of the bending load is at the edge of the face of the tooth  Only Tangential component of total load is considered  Design based on Bending strength of the gear teeth

11. Modeling and simulation  Static Analysis (cont.) Single tooth

12. Modeling and simulation  Static Analysis (cont.) 3D-Model in Pro-Mechanica with constrains and meshing

13. Modeling and simulation  Static Analysis (cont.) Results ( Von mises Stress )

14. Modeling and simulation  Static Analysis (cont.) Results (deflation)

15. Modeling and simulation  Static Analysis (cont.) 2D model verification

16. Modeling and simulation  Static Analysis (cont.) 2D model verification

17. Modeling and simulation  Static Analysis (cont.) 2D model verification

18. Modeling and simulation Dynamic Analysis  Assumptions:-  Manufacturing errors are neglected  Transmission errors are neglected  Frictional effects at contact zone is neglected  Geometrical errors of tooth profile are neglected

19. Modeling and simulation  Dynamic Analysis (cont.)  Dynamic model

20. Modeling and simulation  Dynamic Analysis (cont.)  Dynamic model

21. Modeling and simulation  Dynamic Analysis(cont.)  Dynamic Deflation

22. Modeling and simulation  Dynamic Analysis(cont.)  Von Mises Stress

23. Modeling and simulation  Dynamic Analysis(cont.)  Contact stress

24. Modeling and simulation  Simulink Model  Freebody Diagram

25. Modeling and simulation  Simulink Model

26. Modeling and simulation  Simulink Model  Result

27. Manufacturing Simulation  To manufacture the designed Speed Reducer A manufacturing floor is designed with specific 1. Machine tools needed 2. Inventory levels 3. No.of Labors 4. Material handling equipments

28. Discrete event simulation  Simulation of a Manufacturing cell  Initial Model

29. Manufacturing Cell:- - Second Modification