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Related Concept Videos

Transmission Shafts: Problem Solving01:09

Transmission Shafts: Problem Solving

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Designing a solid shaft that transmits power from a motor to a machine tool involves a series of calculations to ensure the shaft can withstand the stresses applied by bending moments and torques. First, calculate the torque exerted on the gear, considering the power transmitted by the shaft and its rotational speed. Following this, compute the tangential forces acting on the gears, which directly relate to the torque and the gear radius.
Next, use bending moment diagrams for the shaft to...
267
Design of Transmission Shafts - Stress Analysis01:15

Design of Transmission Shafts - Stress Analysis

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Designing a transmission shaft requires a thorough understanding of the stresses induced by bending moments and torques, especially in systems where power is transferred through gears. These forces create force-couple systems at the centers of the shaft's cross-sections, leading to both transverse and torsional loading. Although shearing stresses from transverse loads are typically smaller than those from torques and are often overlooked, the significant normal stresses from these loads...
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Design of Transmission Shafts01:16

Design of Transmission Shafts

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The design of a transmission shaft is governed by two primary specifications: the power it transmits and its rotational speed. These parameters guide the selection of the shaft's material and cross-sectional dimensions, ensuring that the material's maximum shearing stress remains within the elastic limit while transmitting the desired power at the given speed. The system's power is intrinsically linked to the applied torque. The torque applied to the shaft can be calculated by...
393
Deformation in a Circular Shaft01:10

Deformation in a Circular Shaft

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One of the distinctive characteristics of circular shafts is their ability to maintain their cross-sectional integrity under torsion. In other words, each cross-section continues to exist as a flat, unaltered entity, simply rotating like a solid, rigid slab. To understand the distribution of shearing stress within such a shaft, consider a cylindrical section inside this circular shaft. This section has a length of L and a radius of R, with one end fixed. The radius of the cylindrical section is...
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Plastic Deformation in Circular Shafts01:20

Plastic Deformation in Circular Shafts

211
When materials are subjected to forces that surpass their yield strength, they undergo a process known as plastic deformation. This results in a permanent alteration or strain in their structure. This concept can be specifically applied to circular shafts, where the deformation leads to a change in its shape. The precise evaluation of this plastic deformation requires understanding the stress distribution within the circular shaft, which is achieved by calculating the maximum shearing stress in...
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Screw: Problem Solving01:21

Screw: Problem Solving

441
In mechanical engineering, the interaction between a threaded screw shaft and a plate gear involves analyzing the resisting torque on the plate gear that can be overpowered when a specific torsional moment is applied to the shaft. To better comprehend this concept, consider a generic situation with a threaded screw shaft with a given mean radius and lead and a plate gear with a specified mean radius. The coefficient of static friction between the screw and gear is also provided.
To evaluate the...
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Direct Energy Deposition Parametric Simulation Investigation in Gear Repair Applications.

Nuno Miguel Ferreira1,2, Maria Vila Pouca1,2, Carlos Fernandes1,2

  • 1DEMec-Department of Mechanical Engineering, Faculty of Engineering, University of Porto (FEUP), Rua Dr. Roberto Frias, 4200-465 Porto, Portugal.

Materials (Basel, Switzerland)
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PubMed
Summary

This study validates a numerical model for predicting stresses and distortions in additive manufacturing using directed energy deposition (DED). The validated model aids in analyzing gear repair and fatigue life by accounting for residual stresses.

Keywords:
DEDfinite element methodgear repairmetal additive manufacturing

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Area of Science:

  • Materials Science and Engineering
  • Mechanical Engineering
  • Computational Science

Background:

  • Additive manufacturing (AM) offers advantages but can induce residual stresses and distortions.
  • Numerical simulations are crucial for predicting these effects in AM processes.
  • Directed Energy Deposition (DED) is an AM technique used for part repair and manufacturing.

Purpose of the Study:

  • To predict residual stresses and distortions during the gear repair process using DED.
  • To validate a numerical simulation model against experimental data.
  • To investigate the influence of DED process parameters on part integrity.

Main Methods:

  • Validated a numerical model using the National Institute of Standards and Technology (NIST) benchmark bridge model.
  • Performed a parametric study on DED process parameters.
  • Integrated residual stress effects into gear loading stress calculations for fatigue analysis.

Main Results:

  • Numerical model validation showed good agreement with experimental results from the NIST benchmark.
  • Parametric study generally aligned with theoretical expectations, clarifying the impact of certain DED parameters.
  • The model successfully incorporated residual stress effects into gear loading stress analysis.

Conclusions:

  • The validated numerical model provides reliable predictions for DED processes, including gear repair.
  • Understanding the influence of DED parameters is essential for optimizing part quality and performance.
  • The simulation approach aids in crucial fatigue life assessments by considering residual stresses.