A gear and shaft with nominal diameter of 1.5 in are to be assembled with a medium drive fit, as specified in Table 7–9. The gear has a hub, with an outside diameter of 2.5 in, and an overall length of 2 in. The shaft is made from AISI 1020 CD steel, and the gear is made from steel that has been through hardened to provide Su =100 kpsi and Sy = 85 kpsi.
(a) Specify dimensions with tolerances for the shaft and gear bore to achieve the desired fit.
(b) Determine the minimum and maximum pressures that could be experienced at the interface with the specified tolerances.
(c) Determine the worst-case static factors of safety guarding against yielding at assembly for the shaft and the gear based on the distortion energy failure theory.
(d) Determine the maximum torque that the joint should be expected to transmit without slipping, i.e., when the interference pressure is at a minimum for the specified tolerances.