Summer Internship Overview

Mykhailo Asaulov

m.asaulov@ncl.ac.uk

Design Unit

Mechanical and Systems Engineering

www.ncl.ac.uk/gears

Contents

• Bearing Test Rig:

– Transferring the CAD model / Engineering Drawings into the new DU BOM.

– Assisting technicians in assembly of the Bearing Test Rig.

– Organising ED / Datasheets / Calibration documents.

• Adaptor hand calculations for 91.5 Gear Test Rig:

– Required quantity and diameter of bolts essential to withstand the worst

case conditions.

– Axial load induced by helical gears. Conical effective clamp diameter.

– Maximum deflection of adaptor caused by the axial load.

• Validation of hand calculations by applying ANSYS simulation

software:

– Adaptor 3D model

– Adaptor 2D model

– Assembly 3D model

Bearing Test Rig:

• Improvements / Optimisations of assembly sequence.

• Checking all engineering drawings. Updating and modifying

them where it was required.

• Completing “Lubrication Circuit ASY” and designing

“Trimming Circuit ASY” by applying Tube & Pipe Design.

Lubrication Circuit

TrimmingCircuit

Bearing Test Rig:

• Understanding the difference between assembly of different components in

real life compare to CAD model virtual assembly.

• Learning how to use various equipment.

SKF InductionHeater

SKF Test Bearing

Torque multiplierRation 25:1Max 6000 Nm

Bearing Test Rig:

• Creating Multilevel BOM for engineering drawings folder to make it easy to

follow the assembly structure and in case of manufacturing process to know

exactly how many components are required for each sub assembly.

Adaptor hand calculations

for 91.5 Gear Test Rig:

Bolts Fitted in Large Clearance Holes:

• Initial conditions: max torque = 1500 Nm, friction = 0.125, S.F = 2.

• Results: 10 bolts of M12 with Preload = 36.2 kN or 12 bolts of M10 with

Preload = 30.1 kN.

Adaptor hand calculations

for 91.5 Gear Test Rig:

Cone Diameter:

• Result: 31 mm

Helical Gears:

• Result: Axial load on

Pinion = 27.7 kN

Maximum Deflection:

• Results:

– www.roymech.co.uk – y = 0.02226 mm

– ROARK’S Formulas – y = 0.02387 mm

Adaptor hand calculations

for 91.5 Gear Test Rig:SplineCoupling

27.7 kN

GearShaft

Adaptor

M12 Socket Head Cap Screw

Deflectiony [mm]

ANSYS Simulation

Adaptor 3D model

• Elements - Tetrahedron

• Results:

– Maximum deformation = 0.013886 mm

Elements Deformation [mm]

1775 0.011667

7980 0.012859

15681 0.013363

38424 0.013607

85953 0.013710

166054 0.013814

313970 0.013886

27.7 kN

FixedSupport( Ø Cone)

ANSYS Simulation

Adaptor 2D model

• Elements – Hex-Dominant

• Results:

– Maximum deformation = 0.013358 mm

Elements Deformation [mm]

123 0.012655

230 0.013014

516 0.013147

2043 0.013261

8085 0.013325

32416 0.013358

27.7 kN

FixedSupport( Ø Cone)

Assembly 3D model

• Elements - Tetrahedron

• Moment was applied along with others forces.

• Results:

– Maximum deformation = 0.013547 mm

ANSYS Simulation

Moment1500 Nm Fixed

Support

2x 27.7 kN

Bonded connections

Elements Deformation [mm]

7294 0.01245

206148 0.013417

280764 0.013516

369954 0.013547

Conclusion

• Bearing Test Rig:

– Fully transferred into DU BOM.

– Ready for commercial usage.

• Coupling Adaptor:

– 10 Bolts of M12

– Hand calculation – deformation = 0.02387 mm

– ANSYS 3D model = 0.013886 mm

– ANSYS 2D model = 0.013358 mm

– ANSYS ASY 3D model = 0.013547 mm

QUESTIONS?