International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 11 Issue: 11 | Nov 2024
p-ISSN: 2395-0072
www.irjet.net
Structural and Performance Analysis of Mild Steel vs. Hardened EN8D in Automotive Rigid Couplings Using ANSYS Milind Solanki1, Ronak Patel2 1Mechanical Design Engineer, B.E. Mechanical Engineering, Mumbai, Maharashtra, India
2Mechanical Design Engineer, B.E. Mechanical Engineering, Mumbai, Maharashtra, India
---------------------------------------------------------------------***--------------------------------------------------------------------2. Rigid Sleeve coupler: Abstract -This study investigates the design and performance evaluation of rigid couplings in automotive power transmission systems, focusing on a comparative analysis of Mild Steel and Automotive grade EN8D metal materials. Rigid couplings play a crucial role in ensuring efficient torque transmission and maintaining alignment between connected shafts. Finite Element Analysis (FEA) using ANSYS is employed to simulate and assess stress distribution, deformation, and fatigue resistance under varying load conditions. Key performance metrics such as torque capacity, wear resistance, and lifespan are evaluated. The results indicate that rigid couplings made from EN8D exhibit superior mechanical performance, including higher resistance to stress-induced deformation and enhanced durability in high-load scenarios. The study also explores the trade-offs in material selection, considering factors like cost, manufacturability, and application-specific requirements. This research provides a comprehensive framework for material selection in the design of rigid couplings, offering practical insights for improving the reliability and efficiency of automotive drivetrains.
A rigid sleeve coupler in the automotive industry is a mechanical device used to connect two shafts in a power transmission system, ensuring precise alignment and efficient torque transfer without allowing any relative motion between the shafts. It consists of a cylindrical sleeve that fits tightly over the ends of the shafts, creating a rigid and fixed connection. This type of coupler is commonly used in applications where maintaining strict alignment and structural integrity is critical to prevent misalignment-related failures and ensure optimal drivetrain performance. Key Features:
Key Words: Rigid couplings, FEA, torque, Durability, Lifespan, Wear Resistance, ANSYS.
Rigid sleeve couplings are critical components in mechanical systems, providing the necessary alignment and torque transmission between rotating shafts. Their design and material selection are crucial for optimizing performance, reliability, and durability in various applications. This study investigates two types of rigid sleeve couplings: one constructed from Mild Steel material and the other with EN8D through heat treatment and surface treatment processes. While the untreated MS material coupling offers advantages in terms of lightweight construction, it often falls short in terms of strength and resistance to wear. Conversely, the treated EN8D coupling, presents improved mechanical properties that can significantly extend service life and reduce maintenance needs. This introduction sets the stage for a comparative analysis of these two coupling types, aiming to provide insights into their respective advantages and limitations in real-world applications.
|
Rigid Connection: Maintains precise alignment between shafts, essential for systems requiring high accuracy.
●
Simple Design: Typically composed of a single sleeve, making it easy to manufacture and install.
●
Applications: Commonly used in automotive systems where flexibility is not needed, such as in precise power transmission setups like gearboxes or differentials.
2.1 MS material coupler
1. INTRODUCTION
© 2024, IRJET
●
Impact Factor value: 8.315
|
Parameter
Description
Material
Mild Steel
Tensile Strength
560 MPa
Yield Strength
460 MPa
Outside Diameter
64 mm
Total Length
61 mm
Motor Keyway Dimension
12 X 6 mm
Bore Length
35 mm
Motor Shaft Diameter
42 mm
Weight
1084.81 g
ISO 9001:2008 Certified Journal
|
Page 658