The intern worked on two main projects: the Bearing Test Rig and calculations for an adaptor for the 91.5 Gear Test Rig. For the Bearing Test Rig, the intern transferred engineering drawings to a BOM, assisted with assembly, and organized documentation. Calculations and ANSYS simulations were performed for bolt sizing, axial load calculations, and deformation analysis of the adaptor for the 91.5 Gear Test Rig. Results from hand calculations and ANSYS models showed maximum deflection values between 0.01-0.02mm, validating the design of the adaptor.

1. Summer Internship Overview
Mykhailo Asaulov
m.asaulov@ncl.ac.uk
Design Unit
Mechanical and Systems Engineering
www.ncl.ac.uk/gears

2. Contents
• Bearing Test Rig:
– Transferring the CAD model / Engineering Drawings into the new DU BOM.
– Assisting technicians in assembly of the Bearing Test Rig.
– Organising ED / Datasheets / Calibration documents.
• Adaptor hand calculations for 91.5 Gear Test Rig:
– Required quantity and diameter of bolts essential to withstand the worst
case conditions.
– Axial load induced by helical gears. Conical effective clamp diameter.
– Maximum deflection of adaptor caused by the axial load.
• Validation of hand calculations by applying ANSYS simulation
software:
– Adaptor 3D model
– Adaptor 2D model
– Assembly 3D model

3. Bearing Test Rig:
• Improvements / Optimisations of assembly sequence.
• Checking all engineering drawings. Updating and modifying
them where it was required.
• Completing “Lubrication Circuit ASY” and designing
“Trimming Circuit ASY” by applying Tube & Pipe Design.
Lubrication
Circuit
Trimming
Circuit

4. Bearing Test Rig:
• Understanding the difference between assembly of different components in
real life compare to CAD model virtual assembly.
• Learning how to use various equipment.
SKF Induction
Heater
SKF Test Bearing
Torque multiplier
Ration 25:1
Max 6000 Nm

5. Bearing Test Rig:
• Creating Multilevel BOM for engineering drawings folder to make it easy to
follow the assembly structure and in case of manufacturing process to know
exactly how many components are required for each sub assembly.

6. Adaptor hand calculations
for 91.5 Gear Test Rig:
Bolts Fitted in Large Clearance Holes:
• Initial conditions: max torque = 1500 Nm, friction = 0.125, S.F = 2.
• Results: 10 bolts of M12 with Preload = 36.2 kN or 12 bolts of M10 with
Preload = 30.1 kN.

7. Adaptor hand calculations
for 91.5 Gear Test Rig:
Cone Diameter:
• Result: 31 mm
Helical Gears:
• Result: Axial load on
Pinion = 27.7 kN

8. Maximum Deflection:
• Results:
– www.roymech.co.uk – y = 0.02226 mm
– ROARK’S Formulas – y = 0.02387 mm
Adaptor hand calculations
for 91.5 Gear Test Rig:
Spline
Coupling
27.7 kN
Gear
Shaft
Adaptor
M12 Socket
Head Cap Screw
Deflection
y [mm]

9. ANSYS Simulation
Adaptor 3D model
• Elements - Tetrahedron
• Results:
– Maximum deformation = 0.013886 mm
Elements Deformation [mm]
1775 0.011667
7980 0.012859
15681 0.013363
38424 0.013607
85953 0.013710
166054 0.013814
313970 0.013886
27.7 kN
Fixed
Support
( Ø Cone)

10. ANSYS Simulation
Adaptor 2D model
• Elements – Hex-Dominant
• Results:
– Maximum deformation = 0.013358 mm
Elements Deformation [mm]
123 0.012655
230 0.013014
516 0.013147
2043 0.013261
8085 0.013325
32416 0.013358
27.7 kN
Fixed
Support
( Ø Cone)

11. Assembly 3D model
• Elements - Tetrahedron
• Moment was applied along with others forces.
• Results:
– Maximum deformation = 0.013547 mm
ANSYS Simulation
Moment
1500 Nm Fixed
Support
2x 27.7 kN
Bonded
connections
Elements Deformation [mm]
7294 0.01245
206148 0.013417
280764 0.013516
369954 0.013547

12. Conclusion
• Bearing Test Rig:
– Fully transferred into DU BOM.
– Ready for commercial usage.
• Coupling Adaptor:
– 10 Bolts of M12
– Hand calculation – deformation = 0.02387 mm
– ANSYS 3D model = 0.013886 mm
– ANSYS 2D model = 0.013358 mm
– ANSYS ASY 3D model = 0.013547 mm

13. QUESTIONS?