PROJECT III ME 360:

Monster Truck Slipper Clutch Design

Jack Wise
Matt Murphy
Keith Grauer
Section 001
2 May 2014

2

Table of Contents:
Deliverable: Page #:
1. Safety Factors for Gears in Both Failure Modes 6
2. Coil and Wire Diameters of Spring 7
3. Observations 8
4. Key Parameters 3

3

Key Parameters:
Symbol Definition Value
F
spring
Force on spring 9.67 lbf
W
t
Force due to torque 4.05 lbf
K
v
Dynamic Factor 0.46
K
m
Load Distribution Factor 1.00
K
a
Application Factor 1.00
K
s
Size Factor 1.00
K
B
Rim Thickness Factor 1.00
K
I
Idler Factor 1.00
J Bending Strength Geometry Factor 0.3

b
Bending Stress 6010.4 psi
d
p
Diameter of Pinion 0.4375 in
D
g
Diameter of Gear 1.875 in
C
f
Surface Finish Factor 1.00
C
p
Elastic Coefficient 1966
I Surface Geometry Factor 0.0938

c
Surface Stress 72850.4 psi
K
L
Life Factor 1.1
K
T
Temperature Factor 1.00
K
R
Reliability Factor 1.00
S
fb
Bending Fatigue Strength
5.7 ksi (gear)
29 ksi (pinion)
S
fb
Corrected Bending Fatigue Strength
6.27 ksi (gear)
31.9 ksi (pinion)
N
b gear
Bending Factor of Safety for Gear 1.043
N
b pinion
Bending Factor of Safety for Pinion 5.307
C
L
Surface Life Factor 1.00
C
H
Hardness Ratio 1.00
S
fc
Surface Fatigue Strength
30 ksi (gear)
90 ksi (pinion)
S
fc
Corrected Surface Fatigue Strength
30 ksi (gear)
90 ksi (pinion)
N
c gear
Surface Factor of Safety for Gear 0.412
N
c pinion
Surface Factor of Safety for Pinion 1.235

shaft
Major Diameter of Threaded Shaft 0.19 in
y Deflection of Spring 0.0156 in
K Spring Stiffness 619 lb/in
Na Active Coils 2
G Modulus of Rigidity 11.5x10
6
psi
D Coil Diameter 0.255 in
d Wire Diameter 0.055 in


4

5

6

7


8

Observations:
As seen from the safety factor calculations, the gear will fail during use due to surface loading.
With a factor of safety of 0.412, the pinion teeth will most likely grind into it causing a lot of debris to
collect in the system and eventually the gear will fail. This is likely due to the company wanting their
parts to fail after a certain amount of time forcing the customer to either purchase a new truck entirely
or order replacement parts in order to continue using the toy. To raise the factor of safety of the gear
one of two methods could be implemented. The first would be to increase the width of the gear, this
would divide the stress components by a larger number making them smaller, but this would require the
gear to be at least 22.5 inches wide. This is definitely too wide and would require heavy modification of
the design of the truck and this is to only achieve a factor of safety of 1. This method is not very
practical. The other method would be to choose a gear of a different material. If it was a steel gear, like
the pinion, then it would also have a bending factor of safety of 5.307 and a surface factor of safety of
1.235, much more reliable. If the surface factor of safety was still too small for comfort, the width could
also be increased slightly to lower the bending and surface stresses, resulting in higher factors of safety.
The coil and wire diameters of the spring will allow it to clear the threads on the shaft by 0.010 and
provide a force of 43 N on the clutch plates when the nut is twisted a half turn.