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Assignment Task :
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 are able to run for 5,000 hours under the occurring loading conditions (assuming an average speed of travel of 60km/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 on Slide 11 in Lecture 3). 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.
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