Use a Finite Element Analysis package to detennine the maximum load on the system at failure and the factor of safety built into the product to the given set of parameters.

Scenario

You are employed in a company design department, your company has been asked to manufacture a gear box for a customer. It is essential that the key in the drive shaft acts as the failsafe ensuring that the key fails before any expensive damage is done to the drive or worm gears. Your job is to model up the gear box and experiment with differing key materials and sizes until a suitable combination can be found.

Assignment Outline
This assignment will require you apply knowledge gained from previous class exercises in order to solve a practical engineering design problem.

It will allow you to use some of the latest design techniques utilised throughout various manufacturing industries.

These include using models from suppliers E catalogues, using advanced assembly methods and analysis techniques using Solidworks.

Material selection of components and using Finite Element Analysis to calculate the failure load for the whole gearbox assembly.
Use the following guide notes to assist you to work through this design project.

Task 1
The assignment is to design a reduction gearbox from a given set of criteria then use Finite Element Analysis to determine it`s safe working load.

A successful assignment will:
• Design a solid model assembly of a reduction gearbox given the set criteria, use the guide notes below.
• Produce an orthographic assembly drawing with bill of material and sectioned I detailed views where appropriate.
• Selection of suitable material for the main drive shaft and keys give examples of typical engineering applications for the chosen material to back up your material choice.
• Apply appropriate tolerances to the shaft, bearings, worm gear and worm wheel.
• Write a method statement of how to assemble this product and identify the use of any equipment required.
• Produce an FEA report which includes data such as Fixture and Force Diagrams, Mesh Data, Von Mises Stress Diagrams, Displacement Data, In the Conclusion of the report state the force at which your Gearbox is likely to fail.

Task 2
• Use "advanced mates" to mesh and drive the gearbox components and animate the assembly to produce a realistic simulation of the working gearbox assembly.
• Use a Finite Element Analysis package to detennine the maximum load on the system at failure and the factor of safety built into the product to the given set of parameters.
• Submit the report to support your findings.

Task 2
• Produce a full set of orthographic drawings for the individual components.
• An assembly drawing with Bill of Material
• Apply interference fits (classification H7 / p6 ) to two shafts diameters and the bores on the worm and worm gear.
• Write a set of instructions for the method of assembly.

Task 3
• Use "advanced mates" to mesh and drive the gearbox components and animate the assembly to produce a realistic simulation of the working gearbox assembly.
• Use a Finite Element Analysis package to determine the maximum load on the system at failure and the factor or s:.:k-f::y built into the product to the given set of parameters.
• Submit the FEA report along set of engineering drawings to support your findings.

Task 4
• Redesign the Drive Key so the Factor of Safety equals one when a force of 2100 lbf is applied.

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