MEE3003: Design Axle Of The Train - Engineering Assignment Help

Assignment Task

Outline:

You task is to design the axle of a train and select suitable bearings and relevant dimensions of the relevant mechanical elements. Please find the image with the central forces acting on the axle at the end of this document. You are required to choose relevant design parameters appropriately, using relevant formula.

You are to submit, as ONE pdf through Canvas:

• Your calculations, by hand on paper (scans are preferred, photos will be acceptable – make sure the pictures are all clear and readable, as we cannot mark what we cannot read). Indicate the numbers of all tables, figures, etc. from the textbook you used to acquire values wherever applicable.
• An engineering drawing of your final shaft design following AS1100 – this must be created by hand; choose a suitable scaling factor so that the shaft fits on an A4 or A3 sheet (depending on your preference) you are not obliged to use a ruler, though it is recommended, all measures need to be clearly readable; the thicknesses of lines as thick or thin need to be clearly discernible. No title block is required for the drawing.
• A brief textual description of your engineering design rational (about half a page) – this must be typed with word or similar software tools. Here, you should concisely describe your design progress. You may use the following questions as guidelines: How did you start? What approach did you take? What decisions did you make and how did you select relevant parameters? What changes (if applicable) were necessary to these later? Please provide justifications and explain your reasoning.

Task description and points distribution:

For the train axle, you are to design the shaft, select suitable bearings and determine appropriate dimensions for disk brakes mounted onto the shaft. For this, you must calculate and/or determine the following:

• The loads and stresses in the axle to determine the minimal required diameter in the critically loaded section(s) of the shaft – draw a Free-Body Diagram (FBD) for all shear forces, bending moments and torsion occurring; the FBD must be part of your submission.
• The selection of suitable ball or roller bearings that is able to run for 5,000 hours under the occurring loading conditions (assuming an average speed of travel of 60 km/h travel of the train). Bearings should be selected from the textbook or, but only if no suitable bearing for your constellation is available in the textbook, an (online) catalogues of relevant suppliers (please provide reference/link).
• You do not need to design the brake rotor in all detail, but you are to determine a suitable major diameter and contact diameter (average) for the pads.
• Beyond this, you must ensure deflections in the shaft at the critical diameter(s) not to become too great (see recommendations on this in Shaft Lecture). Also show that the shaft will not fatigue under the given conditions with appropriate reliability. You may make reasonable simplifications (FS and brake force for instance may be neglected for fatigue life).
• The technical drawing of the shaft should visualise separate shoulders for each set of machine elements mounted onto it and must follow AS1100.
• Explain all choices for diameters, sizes, etc. and your overall approach briefly as outlines above. (3.5 points)

Note:

• F_BS is the resulting brake force from FN – select suitable materials for brake pad and brake rotor and coefficient of friction resulting from this pairing.
• F_S is the force acting on the wheel in motion that acts against the resulting brake force.
• F_L refers to the radial bearing reaction forces, assume an additional axial force component of 20% of the radial forces (which occurs when cornering, for instance).

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