BASIC CALCULATIONS:

1.Design of Frame:

Frame design for safety FOR 25*25*3 L angle mild steel channel

b = 25 mm, d= 25 mm, t = 3 mm.

Consider the maximum load on the frame to be 20 kg.

Max. Bending moment = force*perpendicular distance

= 20*9.81*325

M = 63765 Nmm

We know,

M / I = σb / y

M  = Bending moment

I   = Moment of Inertia about axis of bending that is; Ixx

y  = Distance of the layer at which the bending stress is consider

(We take always the maximum value of y, that is, distance of extreme fiber
from N.A.)

E = Modulus of elasticity of beam material.

I = bd3 /12

= 25*25^3 / 12

I = 32552.08 mm4

σb = My / I

= 63765 *12.5 / 32552.08

σb = 24.48 N /mm2

The allowable shear stress for material is σallow = Syt / fos

Where Syt = yield stress = 210 MPa = 210 N/mm2

And fos is factor of safety = 2

So σallow= 210/2 = 105 MPa = 105 N/mm2

Comparing above we get,

σb < σallow i.e

24.48 < 105 N/mm 2

So design is safe.
Motor Specification:
Motor selection for wheels
Given
Diameter for wheel=300mm
Weight of wheel with assembly is =6kg
Torque required for one motor
Torque=force*radius of wheel
=6*9.81*150
=9564.75Nmm
=9.5 Nm
Therefore we are selecting motor with 9.5 torque.

By battery,

Voltage = 12V, Current = 5Amp, Speed = 60 RPM

We know that, P = V*I = 12*5 = 60W

P = 2*π*N*T/60

60 = 2*π*60*T/60

T = 9.5 Nm

 
SHAFT CALCULATION:
Material of shaft = M.S.

M σb
=¿ …………………….(1)
I Y
Bending moment=force*perpendicular distance

π 4
I= *d
64

Bending moment= force*perpendicular distance

=5*9.81*225

=11036.25Nmm
For diameter 20mm,

π 4
I= *d
64

π
= *204
64

=7853.98
 And ,Y =10

Therefore ,
σb = My / I

11036.25 σb
=¿
7853.98 7.5

σb=1.40*10

=14 N/mm2
The allowable shear stress for material is σallow = Syt / fos

Where Syt = yield stress = 210 MPa = 210 N/mm2

And fos is factor of safety = 2

So σallow= 210/2 = 105 MPa = 105 N/mm2

Comparing above we get,

σb < σallow i.e

14 < 105 N/mm 2

So design is safe.

  BEARING DIMENSION:

We select the deep groove ball bearing having dimensions as

d = 20mm, D = 52mm

Bearing Designation = 6304

Chain design
Used chain no. 06B
pitch -9.525mm
roller diameter,d1=6.35 mm
width, b1=5.72 mm
transverse pitch pt=54.85 mm
z1=18 z2=18 approximate
centre distance, a=40p
=40*9.525
=381mm
No of links,

Ln
2 2𝜋 𝑎

=98

Design of sprocket
Used chain no.06B
For Z=18
Pitch ,P=9.525
Width between inner plates , b1=5.72
Roller diameter, d1=6.35
Transverse pitch pt=10.24

1.pitch circle diameter

 D=p/sin(180/𝑧)

=
=54.85 mm

Top diameter (Da)

(Da)max=D+1.25p-d1
=54.85+1.25*9.525-6.35
=60.4 mm
Root diameter ,
Df=D-2r1
But roller seating radius (r1)

=3.33 mm
Df=D-2r1
=54.85-2*3.33
=48.19mm
Tooth flank radius (re)max=0.008d1(Z2+180)
=0.008*6.35 (182+180)
=25.6 mm
(re)min=0.12d1(Z+2)
=0.12*6.35 (18+2)
=15.24
Roller seating angle (ά)max=(120-90/Z)
=(120-90/18)
=115
(ά)min=(140-90/Z)=140-90/18
=135
Tooth height above the pitch polygon
(ha)max=0.625 p-0.5d1+0.8p/Z
=0.625*9.525-0.5*6.35+0.8*9.525/18
=3.2 mm
(ha)min=0.5(p-d1)
=0.5(9.525-6.35)
=1.58 mm
Tooth side radius (rx)=p
Tooth width bf1=0.95b1
=0.95*5.72
=5.434 mm
Tooth side relief (ba) =0.1p
=0.1*9.525
=0.9525 mm