Axle Design
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Transcript of Axle Design
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All the information /data in this presentation are the property of Merritt Innovative Solutions India Pvt. Ltd.and cannot be used or reproduced without the written consent from the company. S t r a t e g i c P a r t n e r s h i p
Construction Equipments
Mining Equipments
Farm Equipments
Industrial Engineering
Software Training
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DESIGN OF AXLE FOR RIGID DUMP TRUCKS
AN OVERVIEWAbove 40 Ton Class
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Content
• Snap Shot of Axel and Layout
• Overview of Axel Design
• Axel Specification
• Design Process
– Design Calculations
– Design of Components
• Example – Design of Axel Shaft
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Snap Shot of Axel and Layout
RIGID DUMP TRUCK REAR AXLE
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POWRTRAIN LAYOUT
Snap Shot of Axel and Layout
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POWRTRAIN LAYOUT
Snap Shot of Axel and Layout
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POWRTRAIN LAYOUT
Snap Shot of Axel and Layout
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REAR VIEW
FRONT VIEW
Snap Shot of Axel and Layout
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Manufacturing Drawings
Design Verification and Validation
Geometric Modeling of Axel
Axel Specification
Axel Type Load CapacityTorque
CapacityReduction
RatiosDifferential
SpecsBrake specs
Rim & Tire Specs
Wheel Tread
Axel Component Design
Differential Bevel Gears Planetary Gears Bearings Brakes Center Housing Axel Shafts
Torque Calculation
Prime-mover torque Slip torque from GVW
Vehicle Parameters
Engine Power Engine Torque Transmission Gear Ratio Tire Size
Overview of Axel Design
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• Full-Floating Planetary AxelAxel Type
• Max Load • Max Torque
Axel Capacity
• Bevel Ratio • Final Drive Ratio• Total Ratio
Reduction Ratios
• Spiral Bevel Gear and Straight Bevel Gear Differential
Specification
• Oil Cooled Wet-multiple disk typeBrake Specification
• Rim Size• Tire Size• Wheel Tread
Tire Specification
Axel Specification
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Following Vehicle Parameters considered
– Engine output power
– Engine output torque
– Transmission Gear Ratio• First Gear - For gradability
determination
• Top Gear – For top speed determination
– Selection of tire size
Design Process
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• Torque Calculation
Input torque to axel is determined by calculating Prime-mover torque and Slip torque due to GVW, smaller of the both is considered as input torque to axel
Prime-mover torque
Slip Torque due to GVW
Design Process
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• Design of Differential
– Type :
• Plug-in differential, conventional type
• Spiral and Straight Bevel Gears
Design Process
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DIFFERENTIAL ASSEMBLY
Design Process
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• Design of Bevel Gears
– Design methodology published by American Gear Manufacturing Association (AGMA)
– Gear teeth primarily designed for two factors• Resistance to pitting caused by contact stresses
• Bending strength capacity based on cantilever beam theory
– Material processing:• Heat treatment
– Convert weaker grain structures to stronger ones
• Tempering
– Relieve brittleness and internal strains prior to machining
• Carburization
– Adds high hardness and strength at surface and toughens core to withstand impact stress
Design Process
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• Design of Bevel Gears
• Torque application to a bevel gear induces tangential, radial, and separating loads assumed to act as point loads applied at the mid-point of the gear tooth
• Reaction loads are a result of the tapered roller bearings that support the gear shaft and counteract the gear loads
• Loads are primarily a function of torque, pitch diameter, pitch angle, pressure angle, and face width
• Loads and bending moments are calculated based on a vectoral combination of two planes
Design Process
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• Deign of Planetary Gears– Calculation of final drive ratio, No. of teeth, pressure angle, contact
ratio, tip diameter, tip width, root diameter, radial clearance, inspection parameters
– Calculation of gear bending and contact strengths
Design Process
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• Bearing Life Calculation
– L10 Bearing life
– Speed and Load on Axel
– Duty cycle of usage
Design Process
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• Design of Brake System
– Type : Wet-Multiple Disk Brakes
– Features :
• Effective cooling due to higher heat transfer rate
• Self adjustable disks
• Sealed – Free from dust & contamination
• Oil Cooled
• Retarder
Design Process
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• Design of Brake System– Calculation of brake capacity
• Actual capacity
• As per SAE Standard
• As per ISO 3450
Basis of calculation
» Load on Axel – GVW
» Wheel Base
» Center of Gravity
» Gradability
» Loaded Radius
Design Process
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• Design of Brake System
– Sizing of Brake
• Determining disk diameter
• Co-efficient of friction between disks
• Actuation pressure
• Disk area
• No. of disks
• FOS
Design Process
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• Design of Central Housing
– Features :• 3 piece construction
• Steel casting
• Ease of manufacturing
Design Process
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• Design of Axel Shaft
– Full floating axel shaft, no load on axel shaft
– Only torsional load
– Stress is calculated for
• Shear stress at body
• Compressive & shear Stress at spline
– Stress at bolted joints is calculated considering,
• Tensile stress developed due to clamping force
• External applied load
Design Process
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Merritt Innovative Solutions India Private Limited
# 131/2, 1st Floor, West Of Chord Rd, 11th
Cross, 2nd Stage, Mahalakshmipuram,
Bangalore-86.
+91 80 23196515 / 516