02-07-2014, 10:06 AM
ANALYSIS OF UNIVERSAL COUPLING UNDER DIFFERENT TORQUE CONDITION
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Abstract
The power produced from an engine of automobile can be transferred to the drive wheel by power transmission system. Each automobile has different power transmission system constructive features depend on the vehicle’s driveline concept.(H.Bayrakceken et al., 2006) To transmit the driving torque from the engine or gear unit to the wheels, most of passenger car and light vehicle driven by combustion engine has at least two driveshaft as a basic requirement (Amborn, P. 1995). During operation, torsional stress and bending stress was experienced by driveshaft due to the weight of the car or misalignment of journal bearing (Asi, 2006). In order to meet the requirements of one of the most highly stressed components in automotive assembly, a failure investigation must be conducted. Finite element method was used as stress analysis to determine the stress conditions at the failed section. Nearly all of driveshaft are metal shafts or metal tubes that has special joint at each end called universal joint (Birch and Rockwood2005). Power transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some common reasons for the failures may be manufacturing and design faults, maintenance faults, raw material faults, material processing faults as well as the user originated faults. In this study, fracture analysis of a universal joint yoke and a drive shaft of an automobile power transmission system are carried out. Spectroscopic analyses, metallographic analyses and hardness measurements are carried out for each part. For the determination of stress conditions at the failed section, stress analysis is also carried out by the finite element method. The common failure types in automobiles and revealed that the failures in the transmission system elements cover 1/4 of all the automobile failures. Some common reasons for the failures may be manufacturing and design faults, maintenance faults, raw material faults as well as the user originated faults. This paper presents FEM analysis of universal coupling with the help of ANSYS for different torque or load condition and it verify by manual calculation.
INTRODUCTION
In day-to-day life every aspect is influenced by the work of engineer. The equipments we use, the food we eat, and the vehicles we travel in and many more all are developed with the assistance of design engineering. Traditional design has been done by simple calculation. But with increase in product performance and reliability it is difficult to follow the traditional iterative design procedures. As product performance becomes more important and as designs becomes more complex the simple method have becomes inadequate. To understand the growth and its implication for design, it is necessary to look at how design solutions are implemented. To satisfy the market needs it is necessary to provide a computational capacity along with the creativity of the human being. By adding computer technology to the armory of the designer, the best qualities of the designer can be linked with the best qualities of the computer. Most engineering designs are too complex for traditional approach. For example a structure may have spatially dependent material properties if different materials are used; the geometry may be irregular in some sense or the boundary condition may be complex. In all these examples no solution functions exist and so solutions can be achieved only by resorting to an approximate numerical method. A widely used numerical method for solving structural problems in both industry and academia is “FINITE ELEMENT METHOD”.
UNIVERSAL JOINT
An automotive drivetrain is an assembly of one or more driveshaft, universal joint, and slip joint that forms the connection between the transmission and the drive axle. The function of drivetrain is that it allows the driver to control the power flow, speed and multiple the engine’s torque
PROBLEM STATEMENT
Drive shafts are one of the most important components in
vehicles. It generally subjected to torsional Stress and bending
stress due to weights of components. Thus, these rotating
components are susceptible to fatigue by the nature of their
operation. Common sign of driveshaft failure is vibration or
shudder during operation. Driveshaft mainly involves in
steering operation of vehicle. Drivers will lose control of their
vehicle if the drive shafts broke during high speed cornering.
Because of this human life can be in great danger if we don’t
know when, where and how the drive shaft will failed. It is
very important to know the accurate prediction for the drive
shaft to fail.
FINITE ELEMENT ANALYSIS
The trend in engine industry today is toward a shorter product
development cycle and faster time-to-market, with increased
emphasis on up-front analysis to design, develop, and
optimize a reliable and durable product. Electronic
prototyping, instead of hardware prototyping, in the initial
design stage can substantially reduce development costs.
The trend in structural analysis today is to perform system
analysis instead of component analysis. The advent of faster
computers and robust FEA software allows Design engineers
to build larger, more refined and complex models resulting in
timely, cost-effective, accurate, and informative solutions to
customer problems
CONCLUSION
The results were obtained are quite favorable which was expected. This result focus the relationship between the manufacturing cost and joint angle performance measures of an automotive universal joint, The results illustrate that an increase in the drivable joint angle requires a corresponding increase in manufacturing cost. However, for both the flange and weld yoke, a substantial reduction in manufacturing cost may be realized by restricting the joint angle to less than 30°. that the manufacturing cost of the flange and weld yokes may be decreased by 4.5% and 4.0%, respectively, while simultaneously increasing the joint angle by 34° and 38°.
[attachment=65539]
Abstract
The power produced from an engine of automobile can be transferred to the drive wheel by power transmission system. Each automobile has different power transmission system constructive features depend on the vehicle’s driveline concept.(H.Bayrakceken et al., 2006) To transmit the driving torque from the engine or gear unit to the wheels, most of passenger car and light vehicle driven by combustion engine has at least two driveshaft as a basic requirement (Amborn, P. 1995). During operation, torsional stress and bending stress was experienced by driveshaft due to the weight of the car or misalignment of journal bearing (Asi, 2006). In order to meet the requirements of one of the most highly stressed components in automotive assembly, a failure investigation must be conducted. Finite element method was used as stress analysis to determine the stress conditions at the failed section. Nearly all of driveshaft are metal shafts or metal tubes that has special joint at each end called universal joint (Birch and Rockwood2005). Power transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some common reasons for the failures may be manufacturing and design faults, maintenance faults, raw material faults, material processing faults as well as the user originated faults. In this study, fracture analysis of a universal joint yoke and a drive shaft of an automobile power transmission system are carried out. Spectroscopic analyses, metallographic analyses and hardness measurements are carried out for each part. For the determination of stress conditions at the failed section, stress analysis is also carried out by the finite element method. The common failure types in automobiles and revealed that the failures in the transmission system elements cover 1/4 of all the automobile failures. Some common reasons for the failures may be manufacturing and design faults, maintenance faults, raw material faults as well as the user originated faults. This paper presents FEM analysis of universal coupling with the help of ANSYS for different torque or load condition and it verify by manual calculation.
INTRODUCTION
In day-to-day life every aspect is influenced by the work of engineer. The equipments we use, the food we eat, and the vehicles we travel in and many more all are developed with the assistance of design engineering. Traditional design has been done by simple calculation. But with increase in product performance and reliability it is difficult to follow the traditional iterative design procedures. As product performance becomes more important and as designs becomes more complex the simple method have becomes inadequate. To understand the growth and its implication for design, it is necessary to look at how design solutions are implemented. To satisfy the market needs it is necessary to provide a computational capacity along with the creativity of the human being. By adding computer technology to the armory of the designer, the best qualities of the designer can be linked with the best qualities of the computer. Most engineering designs are too complex for traditional approach. For example a structure may have spatially dependent material properties if different materials are used; the geometry may be irregular in some sense or the boundary condition may be complex. In all these examples no solution functions exist and so solutions can be achieved only by resorting to an approximate numerical method. A widely used numerical method for solving structural problems in both industry and academia is “FINITE ELEMENT METHOD”.
UNIVERSAL JOINT
An automotive drivetrain is an assembly of one or more driveshaft, universal joint, and slip joint that forms the connection between the transmission and the drive axle. The function of drivetrain is that it allows the driver to control the power flow, speed and multiple the engine’s torque
PROBLEM STATEMENT
Drive shafts are one of the most important components in
vehicles. It generally subjected to torsional Stress and bending
stress due to weights of components. Thus, these rotating
components are susceptible to fatigue by the nature of their
operation. Common sign of driveshaft failure is vibration or
shudder during operation. Driveshaft mainly involves in
steering operation of vehicle. Drivers will lose control of their
vehicle if the drive shafts broke during high speed cornering.
Because of this human life can be in great danger if we don’t
know when, where and how the drive shaft will failed. It is
very important to know the accurate prediction for the drive
shaft to fail.
FINITE ELEMENT ANALYSIS
The trend in engine industry today is toward a shorter product
development cycle and faster time-to-market, with increased
emphasis on up-front analysis to design, develop, and
optimize a reliable and durable product. Electronic
prototyping, instead of hardware prototyping, in the initial
design stage can substantially reduce development costs.
The trend in structural analysis today is to perform system
analysis instead of component analysis. The advent of faster
computers and robust FEA software allows Design engineers
to build larger, more refined and complex models resulting in
timely, cost-effective, accurate, and informative solutions to
customer problems
CONCLUSION
The results were obtained are quite favorable which was expected. This result focus the relationship between the manufacturing cost and joint angle performance measures of an automotive universal joint, The results illustrate that an increase in the drivable joint angle requires a corresponding increase in manufacturing cost. However, for both the flange and weld yoke, a substantial reduction in manufacturing cost may be realized by restricting the joint angle to less than 30°. that the manufacturing cost of the flange and weld yokes may be decreased by 4.5% and 4.0%, respectively, while simultaneously increasing the joint angle by 34° and 38°.