Use a Finite Element Analysis package to determine the maximum load on the system at failure and the factor of safety incorporated into the product based on the specified parameters.

Scenario:

You are part of a design team in a company tasked with manufacturing a gear box for a customer. The critical requirement is that the key in the drive shaft must act as a failsafe, ensuring that the key fails before any costly damage occurs to the drive or worm gears. Your role involves modeling the gear box and experimenting with different key materials and sizes to identify a suitable combination.

Assignment Outline:

This assignment leverages knowledge from previous class exercises to solve an engineering design problem, applying advanced design techniques used across manufacturing industries. Key tasks include using models from supplier e-catalogs, employing advanced assembly methods, and conducting analysis using Solidworks.

Task 1:

Design a reduction gearbox based on specified criteria and use Finite Element Analysis to determine its safe working load. A successful assignment will involve:

• Creating a solid model assembly of the reduction gearbox as per criteria.
• Generating an orthographic assembly drawing with a bill of materials and detailed views where necessary.
• Selecting appropriate material for the main drive shaft and keys, supporting the choice with examples of typical engineering applications.
• Applying suitable tolerances to shafts, bearings, worm gear, and worm wheel.
• Writing an assembly method statement and identifying required equipment.
• Producing an FEA report including Fixture and Force Diagrams, Mesh Data, Von Mises Stress Diagrams, Displacement Data, and concluding with the expected failure force of the gearbox.

Task 2:

• Using "advanced mates" to mesh and animate the gearbox components for a realistic simulation.
• Conducting Finite Element Analysis to determine the maximum load at system failure and the product`s factor of safety based on given parameters.
• Submitting a comprehensive report to substantiate findings.

Task 3:

• Developing full orthographic drawings for individual components and an assembly drawing with a Bill of Materials.
• Applying interference fits (classification H7 / p6) to shafts and bores on the worm and worm gear.
• Creating assembly instructions.

Task 4:

• Redesigning the Drive Key to achieve a Factor of Safety of one when subjected to a force of 2100 lbf.