Power Transmission Mechanism: Spring and Gear System

The present design deals with the power transmission mechanism using spring and gear system. The article discusses the design, manufacturing, and finite element analysis of the assembly. Materials used and deflection analysis are also discussed. The article also includes a literature review and references.

Table of Contents
Introduction................................................................................................................................2
Spring.........................................................................................................................................2
Gear............................................................................................................................................3
Top view.....................................................................................................................................4
Front view..................................................................................................................................4
2D view......................................................................................................................................5
Motion of the power transmission assembly..............................................................................5
Literature review........................................................................................................................6
Deflection analysis.....................................................................................................................7
Manufacturing of the parts.........................................................................................................8
Finite element analysis...............................................................................................................8
Materials.....................................................................................................................................9
Results......................................................................................................................................10
References................................................................................................................................10
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Introduction
Present design deals with the power transmission from one place to another. There are
different mechanisms by which one can transmit the power, liker gear system, crank chain
mechanism, spring etc.
Spring
A spring is an elastic body, whose expand in size when load applied and regain its original
shape when removed. It absorbs automobile vibrations, shocks and loads by springing action
and to some extend by damping functions. It absorbs energy in the form of potential energy.
Springs capacity to absorb and store more strain energy makes the suspension system more
comfortable. Leaf spring is the simplest form of spring used in the suspension system of
vehicle. These springs are also known as flat, laminated or carriage spring. Most widely used
leaf spring type is semi-elliptic in heavy and light automobile vehicles. The multi leaf spring
comprises of various steps called blades while mono leaf spring is of only one step. Number
of steps increases the spring absorbing capability. For heavy vehicles multi leaf spring are
used while light vehicle mono leaf spring can be used.
Springs initially given a camber so they will have a tendency to bend under loading
condition. The leaf spring works under two hypothesis uniform strength and uniform width.
The master leaf spring is the longest and has eyes at its end while remaining steps of spring
are called graduated leaves.
Gear
A gear transmits power from one shaft to another. It is a rotating machine which has teeth on
its periphery. Teeth on meshing gears should have the same shaper for proper transmission of
motion or power. At least two gears are required for transfer of motion from one shaft to
another, more than two gears produces a gear train which has wide amount of applications in
the automobile industry. If one gear is smaller it will rotate faster compared to the larger gear.
One gear is termed as driver gear while second gear is termed as driven gear.
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Figure below shows the power transmission mechanism.
Above figure illustrates the type of motion transmission. In this mechanism two axial has
been used to hold the power transmission plate in their respective positions. While two
connecting plates has been utilized to connect them with the connecting angle with the help
of connecting shaft.
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Top view
Above figure shows the top view of the power mechanism generated in the present work.
Front view
Above figure shows the front view of the power transmission mechanism produced in the
present work. From the front view one can easily visualise all the parts of the power
transmission mechanism.
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2D view
(a) (b)
(c) (d)
Above figures shows the 2D view of the different parts of the power transmission system.
Figure 1-a represents the connecting angle while figure 1-b represents the connecting shaft
and connecting angle together. Figure 1-c represents the connecting plate and power
transmission plate together while figure 1-d represents the top portion of the assembly which
includes axial holder, power transmission plate and connecting plate.
Motion of the power transmission assembly
Below figure shows the right view of the power transmission assembly. In this assembly axial
holder will remain on their while all other parts will rotate at an angle. The bottom power
transmission plate will rotate on their axis; due to the motion of power transmission plate
bottom connecting plate will also rotate, same will happen with the upper part of the body
which will also rotate. This full rotation will give a rotatory motion to the assembly. This
rotatory motion either is circular or spherical shape which will depends upon the angle
developed. This type of motion can be applied to the applications where rotation of any
device at any angle is required.
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Literature review
Shokrieh and Rezaei (2003) conducted optimization of spring while Pateriya and Khan
(2015) studied dynamic characteristics. Different materials have been used considering
similar boundary condition for finding the best suitable material. Pozhilarasu and Pillai
(2013) analysed conventional steel and composite material. They also utilized GFRP (glass
fibre reinforced polymer) in their analysis. Aishwarya et al (2014) conducted vibration
analysis of assembly made of composite material.
Kumar et al (2014) conducted optimization analysis of material for large weight vehicles.
They used ANSYS to conduct their study and compared their results between composite
material and conventional material. Anuraag and Sivaram (2012) targeted their analysis
towards shock analysis and dynamic analysis of spring made of composite materials having
different layers. They modelled their leaf spring using Unigraphics software NX7.5. They
sued ANSYS to analyse their study. They have done static, dynamic and shock analysis. For
analysing the results they have used five layered and two layered composite leaf spring. They
noticed maximum displacement in the two layered leaf spring compared to five layered
101.5mm to 83.23mm. They found more compressive stress in case of vehicles with more
layers compared to vehicles with fewer layers. They found that shock first increases than
decreases for fewer layers vehicle, and also concluded that shock increases with increment in
the time. While for vehicles having larger layers deflection first decreases than increases with
increment in the time.
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Mahdi et al (2006) and Kumar & Teja (2012) analysed the suspension system of the vehicles
having elliptic spring. They conducted different sets of experimentation to analysed the
behaviour of spring, they also conducted the numerical analysis for same sets of variable and
compared them, found that results matches well with the experimental results. They
determined that design of experiments helps in achieving the best results. Amrute et al (2013)
and AI-Qureshi (2001) conducted study on composite material leaf spring. They considered a
composite spring and analysed its behaviour under different sets of parameters. Rupesh et al
(2015) and Zhang et al (2014) conducted Analysis on Performance of Leaf Spring Rotary
Engine. They simulated a leaf spring rotary engine which was different on the basis of rotor
structure.
Durus et al (2015) conducted fatigue life prediction of z type leaf spring and new approach to
verification method. They studied the different loading condition. They conducted the results
when fracture reached and to take process effect they framed an S-N curve. A finite element
tool has also been used by them to perform the study and they found that FE tool generates
the good results. Fuentes et al (2009) conducted premature fracture in automobile leaf springs
which has been used in Venezuelan buses. They conducted failure analysis and fracture
analysis on the Venezuelan bus. They also conducted Chemical analysis, macroscopic
inspection, metallographic analysis and hardness test.
Deflection analysis
Load required to create a unit deflection is called spring stiffness.
F=kδ
Stiffness of the spring is in Newton/meter (N/m)
Load in Newton
Deflection in meter
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Manufacturing of the parts
Below a flow layout of the manufacturing of the parts to be created, first the raw materials
will be selected after that cutting of the material will be done as per the required shape or
size, than different test and operations will be performed on the material as per the
requirements.
Raw material
Shearing/Cutting process
Drilling
Eye rolling of main blade
Hardening
Tempring
Hardness testing
Fitting
Painting
labelling
Inspection
Stock ready for supply
Finite element analysis
Finite element analysis of the above assembly can be done to analyse the regions whwre
maximum amount of deflection and stress are generating. FEM is a great tool as it helps in
understanding the model developed accurately before going for actual production.
This can be done with the help of software available in the market like Abaqus or ANSYS.
Geometry created in the Autodesk inventor can be imported in these tools for further
analysis.
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Materials
Two different materials have been considered in the present study. Conventional steel and E-
glass/Epoxy has been used as an alternative material. Weight reduction by using
E-glass/Epoxy can also be studied in the present work.
Mechanical properties and composition of conventional steel (EN47 steel) have been shown
in table 1 and 2. While E-glass/Epoxy mechanical properties are represented in table 3.
Table 1 Steel (EN47) mechanical properties
Properties Value
Young’s modulus E 2.1E11 Pascal
Poisson ratio 0.266
Ultimate strength 1.272E9
Pascal
Yield strength 1.158E9
Pascal
Material density 7860 Kg/m3
Table 2 Chemical composition of steel (EN47)
Material Amount (%)
C 0.45-0.55
Si 0.50
Mn 0.50-0.80
S 0.05
P 0.05
Cr 0.80-1.20
V 0.15
Table 3 E-glass/Epoxy material properties
Properties Value
Elasticity modulus 85E12 Pascal
Poisson ratio 0.23
Ultimate strength 9 E8 Pascal
Yield strength 1470 Pascal
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Material Density 2160 Kg/m3
Results
From the tables above it can be noticed that the density of the e-glass material is very less
compared to the conventional steel material. If we compare the same geometry for two
different materials considered in the study, this will give that the power transmission
assembly made of E-glass material weight less compared to the power transmission assembly
made of conventional steel.
References
Aishwarya A.L., Kumar, A. E. & Murthy, B.V., (2014), Free vibration analysis of composite
leaf springs, International Journal of Research in Mechanical Engineering &
Technology, 4(1), 95-97.
Ai-Qureshi, H.A., (2001), Automobile Leaf Spring from Composite Materials, Journal of
Materials Processing Technology, 118(1-3), 58-61.
Amrute A. V., Karlus E. N. & Rathore R. K., (2013), Design and Assessment of Multi Leaf
Spring, International Journal of Research in Aeronautical and Mechanical
Engineering, 1(7), 115-124.
Durus M., Kirkayak L., Ceyhan A. & Kozan K, (2015), Fatigue Life Prediction of Z type
Leaf Spring and new approach to verification method, Procedia Engineering, 101,
143-150.
Fuentes, J.J., Aguilar, H.J., Rodrı´guez J.A. & Herrera, E.J., (2009), Premature Fracture in
Automobile Leaf Springs which has been used in Venezuelan Buses, Engineering
Failure Analysis, 16(2), 648-655.
Kalwaghe R. N. & Sontakke K. R., (2015), Design and Analysis of Composite Leaf Spring
by using FEA and ANSYS, International Journal of Scientific Engineering and
Research, 3(5), 74-77.
Kumar A. T. N. V., Rao E. V. & Krishna G. S. V., (2014), Design and Material Optimization
of Heavy Vehicle Leaf Spring, International Journal of Research in Mechanical
Engineering & Technology, 4(1), 80-88.
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Kumar S. Y. N. V. & Teja M. V., (2012), Design and Analysis of Composite Leaf Spring,
International Journal of Mechanical and Industrial Engineering, 2(1), 97-100.
Mahdi E., Alkoles O.M.S., Hamouda A.M.S., Sahari B.B., Yonus R., & Goudah G., (2006),
Light composite elliptic springs for vehicle suspension, Composite Structures, 75(1-
4), 24–28.
Patnaik M., Yadav N. & Dewangan R., (2012), Study of a Parabolic Leaf Spring by Finite
Element Method & Design of Experiments, International Journal of Modern
Engineering Research, 2(4), 1920-1922.
Pateriya, A, & Khan, M., (2015), Structural and thermal analysis of spring loaded safety
valve using FEM, International Journal of Mechanical Engineering and Robotics
Research, 4(1), 430-434.
Pozhilarasu V. & Pillai, T. P., (2013), Performance analysis of steel leaf spring with
composite leaf spring and fabrication of composite leaf spring, International Journal
of Engineering Research and Science & Technology, 2(3), 102-109.
Saianuraag K. A. & Sivaram B. V., (2012), Comparison of Static, Dynamic & Shock
Analysis for Two & Five Layered Composite Leaf Spring, Journal of Engineering
Research and Applications, 2(5), 692-697.
Saini P., Goel A., & Kumar D., (2013), Design and analysis of composite leaf spring for light
vehicles, International Journal of Innovative Research in Science, Engineering and
Technology, 2(5), 1-10.
Shokrieh, M. M. & Rezaei, D., (2003), Analysis and optimization of a composite leaf spring,
Composite Structures, 60, 317–325.
Zhang Y., Zou Z-X, Yuan C-H & Wang D-J, (2014), Analysis on Performance of Leaf
Spring Rotary Engine, Energy Procedia, 61, 984-989.
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