The Design of a Dough Roller Machine

Presented to
The School of Mechanical and Manufacturing Engineering
Mapúa University

In Partial Fulfilment of the

Requirements of ME151P-2 – Machine Design 2 for
the Degree of Bachelor of Science in Mechanical Engineering

Submitted by:

BEREZO, Florence Steven – 2018110418

CRISOLOGO, Cyril John – 2016142106

MACABALO, Rovic R. – 2016141827

MANAHAN, Aaron James C. – 2018103429

TAN, Sean P. – 2016131138

TOLENTINO, Andrew Joseph C. – 2018102555

 Table of Contents

Introduction .......................................................................................................................... 1
Statement of the Problem ....................................................................................................... 1
Significance of the Design ....................................................................................................... 2
Scope and Limitation ............................................................................................................. 2
Design Methodology............................................................................................................... 3
Description of Machine ........................................................................................................ 13
Description of Machine Utility .............................................................................................. 13
Design Considerations.......................................................................................................... 14
Social Factors ...................................................................................................................... 14
Global and Cultural Sensitivity and Awareness ..................................................................... 14
Related Designs ................................................................................................................... 15
Design Calculations.............................................................................................................. 18
Results and Discussion ......................................................................................................... 29
Conclusion and Recommendation ......................................................................................... 31
Introduction

Statement of the Problem

Even expert bakers fail at rolling out dough, which appears to be one of the most basic

tasks in a bakery. It's a time-consuming procedure; merely rolling dough may take up to 25

minutes, which adds up to a significant amount of time in the production process. The dough

sticking to the counter and the rolling pin are common issues. When the dough is too thin, too

thick, or uneven, air pockets form inside the dough, preventing the dough from developing

adequate gluten. The outcome is a firm and soft dough when done correctly. A dough roller's

advantages include uniformity, increased productivity, crisper crust, the ability to make various

types of dough, uniform baking outcomes, and time savings. With the use of gears, pulleys,

and a motor, the design aims to roll dough effectively. In addition, as compared to manually

rolling the dough, it saves time.

Objectives of the Design

● The design aims to be straightforward where regular people can operate without

problems.

● To help other people to understand what the machine is for and how it is being used in

the industry.

● To give additional safety features that will help the operator of the machine to be safer.

● To allow convenience in maintenance.

● To aid in making dough more efficiently and faster than the traditional dough roller.

● To apply theoretical calculations about machine design in the design application.

1
Significance of the Design
● The compact nature of the design allows it to be used for smaller scale operation

● The simplicity of the design allows it to be cheaper compared to its other variants

● The inclusion of a motor in the design allows the used to have more control over the

dough rolling

● The design allows an easier maintenance due to its uncomplicated nature

Scope and Limitation

● This design paper focuses on the design of an open belt drive including the theoretical

calculations of it

● This design paper focuses on the design of a spur gear system which includes obtaining

the specifications of the gear by means of calculation

● This design paper focuses on the design of a dough roller machine in consideration of

the following:

1. Health, Safety, and Welfare Factors

2. Social Factors

3. Global and Cultural Sensitivity and Awareness

2
Design Methodology

Figure 1: Isometric Left Side View of the Dough Roller Machine

3
Figure 2: Isometric Right-Side View of the Dough Roller Machine

4
Figure 3: Exploded View of the Dough Roller Machine

5
Figure 4: Isometric View of the Spur Gears

6
Figure 5: Isometric View of the Open Belt Drive System

7
Figure 6: Orthographic View of the Spur Gear with Dimensions

8
Figure 7: Orthographic View of the Belt Drive with Dimensions

9
Figure 8: Right Side View of the Machine with Dimensions

10
Figure 9: Front View of the Machine with Dimensions

11
Figure 10: Top View of the Machine with Dimensions

12
Description of Machine
A dough roller is a machine that rolls out pieces of dough to a desired thickness. The

resulting sheets are smooth, uniform and completed in a few minutes, a much shorter

turnaround than rolling by hand. It can press any kind of dough. Most commonly, they are used

for pizza crusts, flatbreads, pie crusts, pastry dough and cake fondant that is needed in large

quantities.

Description of Machine Utility

The machine starts off with two rolling cylinders or rollers, each attached to a shaft

where one is connected to a pulley. This pulley is connected to a flat belt drive mechanism

where it transforms the energy from the flat belt into rolling motion for the rollers. The rolling

motion is shared between the two rollers by means of two spur gears.

The machine performs by means of a pair of rigid rolls, of the same diameter or of

different diameters, with rotation motion. These pull the dough piece between them, bringing

it at a thickness given by the distance between them, in the form of a sheet.

13
Design Considerations
Health, Safety, and Welfare

● All materials that are in contact with the dough are safe for food use

● The Belt, Pulley and gears are covered with physical barrier for the operator’s safety

● The design is considered the ease of maintenance due to less moving parts

● The power source is isolated from the working area

Social Factors
● Design considered the average height of Filipino people

● Easy access to the components is provided

● The design was made to be understood easily without too much technical knowledge

● The dimensions for the parts considered the readily available part sizes in the

Philippine market

● The cost is considered if ever the design is manufactured

Global and Cultural Sensitivity and Awareness

● The design helps other people to understand what the machine is for and how it is

being used in the industry.

● Simplicity. The design aims to give people exact ideas on what the machine is.

● Easy to use. The design helps the user (especially the unfamiliar ones) to operate the

machine conveniently.

● General. The machine is designed globally the same with other machines similarly

with its certain function for better understanding on where it is used.

● The design of the machine has the same purpose as the normal/plain dough roller

machine.

14
Related Designs
Anetsberger, Frank. Patent No. 2,275,714, dated Sept. 25, 1941

15
Buechek, John. “Dough Sheeter” Patent No. 2,456,371, dated December 14, 1948

16
Baker's Craft Merchandising, “Heavy Duty Dough Roller Machine”

17
Design Calculations
Belt Parameters

Belt Thickness 5 mm

Belt Width 35 mm

Pulley Width 50 mm

Rotational Speed of the Driver Pulley, 𝑁1 60 RPM

Rotational Speed of the Driven Pulley, 𝑁2 30 RPM

Diameter of Driven Pulley, 𝐷2 140 mm

Diameter of Driver Pulley, 𝐷1 71 mm

Velocity of the belt, 𝑉𝑏 0.2231 m/s

Velocity Ratio, 𝑉𝑏𝑅 2:1

Center Distance, c 280 mm

Length of the Belt 895.6889 mm

Number of Belt/s 1

Angle of Contact in Driver pulley, 𝜃 2.8945 rad

Angle of Contact in Driven pulley, 𝜃1 3.3886 rad

18
For Driver Pulley:

𝑘𝑔
𝑃𝑢𝑙𝑙𝑒𝑦 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 𝐶𝑎𝑠𝑡 𝑖𝑟𝑜𝑛, 𝑠𝑡𝑒𝑒𝑙 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑐𝑎𝑠𝑡 𝑖𝑟𝑜𝑛, 𝑠𝑡𝑒𝑒𝑙 = 𝜌𝑝𝑢𝑙𝑙𝑒𝑦 = 7200
𝑚3

𝑁2 𝐷1 30 𝑅𝑃𝑀 𝐷1
= ; = ; 𝐷1 = 70 𝑚𝑚
𝑁1 𝐷2 60 𝑅𝑃𝑀 140 𝑚𝑚

If the width of the belt is known, then the width of the pulley or face of the pulley is taken

25% greater than the width of the belt.

𝐶𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑖𝑛𝑔 𝑎 𝑏𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 35 𝑚𝑚,

𝑏 = 35 𝑚𝑚, & 𝑡 = 5 𝑚𝑚 (𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡𝑠)

𝐵 = 1.25𝑏 = 1.25(35)

𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑃𝑢𝑙𝑙𝑒𝑦 = 43.75

𝐷 71 𝑚𝑚
𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑟𝑖𝑣𝑒𝑟 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑡= + 3𝑚𝑚 = + 3𝑚𝑚 = 3.355 𝑚𝑚
200 200

Standard thickness of pulley rim: 5 mm 𝐼𝑛𝑠𝑖𝑑𝑒 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑟 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑟 = 𝑅 − 𝑡 =

35.5 𝑚𝑚 − 5 𝑚𝑚 = 30.5 𝑚𝑚

𝐼𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑟 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑑 = 2𝑟 = 2(30.5 𝑚𝑚) = 61 𝑚𝑚

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐷𝑟𝑖𝑣𝑒𝑟 𝑃𝑢𝑙𝑙𝑒𝑦

19
 𝜋 2 𝜋
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦, 𝐴= (𝐷 − 𝑑 2 ) = ((71 𝑚𝑚)2 − (61 𝑚𝑚)2 ) = 1036.7256 𝑚𝑚2
4 4

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑉 = 𝐴𝐵 = 1036.7256 𝑚𝑚2 𝑥 50 𝑚𝑚 = 51,836.2788 𝑚𝑚3

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦,

3
𝑘𝑔 3
1𝑚
𝑚 = 𝜌𝑝𝑢𝑙𝑙𝑒𝑦 𝑥 𝑉 = 7200 3 𝑥 51,836.2788 𝑚𝑚 𝑥 ( )
𝑚 1000 𝑚𝑚

= 0.3732 𝑘𝑔

𝑚
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑊𝑝 = 𝑚𝑔 = 0.3732 𝑘𝑔 𝑥 9.81
𝑠2

𝑾𝒑 = 𝟑. 𝟔𝟔𝟏𝟑 𝑵

Center Distance between the two pulleys is twice the diameter of the larger pulley

𝑐 = 2𝐷2 = 2(140 𝑚𝑚) = 280 𝑚𝑚

𝜋 (𝐷2 − 𝐷1 )2 𝜋 (140 − 71)2

𝐿 = (𝐷2 + 𝐷1 ) + 2𝑐 + = (140 + 71) + 2(280) +
2 4𝑐 2 4(280)

𝐿 = 895.6889 𝑚𝑚

𝜋
𝜃 = (180 + 2𝛼) 𝑟𝑎𝑑
180

𝐷2 − 𝐷1 140 − 71
𝛼 = 𝑎𝑟𝑐𝑠𝑖𝑛 ( ) = 𝑎𝑟𝑐𝑠𝑖𝑛( ) = 7.0776
2𝑐 2(280)

𝜋
𝜃 = (180 − 2(7.0776)) 𝑟𝑎𝑑 = 2.8945 𝑟𝑎𝑑
180

𝜋
𝜃1 = (180 + 2(7.0776)) 𝑟𝑎𝑑 = 3.3886 𝑟𝑎𝑑
180

20
For Driven Pulley:

𝑃𝑢𝑙𝑙𝑒𝑦 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 𝐶𝑎𝑠𝑡 𝑖𝑟𝑜𝑛, 𝑠𝑡𝑒𝑒𝑙

𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑐𝑎𝑠𝑡 𝑖𝑟𝑜𝑛, 𝑠𝑡𝑒𝑒𝑙 = 𝜌𝑝𝑢𝑙𝑙𝑒𝑦 = 7200
𝑚3

𝐷2 = 140 𝑚𝑚

If the width of the belt is known, then the width of the pulley or face of the pulley is taken

25% greater than the width of the belt.

𝐶𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑖𝑛𝑔 𝑎 𝑏𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 35 𝑚𝑚,

𝑏 = 35 𝑚𝑚, & 𝑡 = 5 𝑚𝑚 (𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡𝑠)

𝐵 = 1.25𝑏 = 1.25(35)

𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑃𝑢𝑙𝑙𝑒𝑦 = 43.75

𝐷 140 𝑚𝑚
𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑟𝑖𝑣𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦 𝑟𝑖𝑚, 𝑡= + 3𝑚𝑚 = + 3𝑚𝑚 = 3.7 𝑚𝑚
200 200

Standard thickness of pulley rim: 5 mm

𝐼𝑛𝑠𝑖𝑑𝑒 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑟 = 𝑅 − 𝑡 = 70 𝑚𝑚 − 5 𝑚𝑚 = 65 𝑚𝑚

𝐼𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑑 = 2𝑟 = 2(65 𝑚𝑚) = 130 𝑚𝑚

21
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐷𝑟𝑖𝑣𝑒𝑛 𝑃𝑢𝑙𝑙𝑒𝑦

𝜋 2 𝜋
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦, 𝐴= (𝐷 − 𝑑2 ) = ((140 𝑚𝑚)2 − (130 𝑚𝑚)2 ) = 2120.5750 𝑚𝑚2
4 4

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑉 = 𝐴𝐵 = 2120.5750 𝑚𝑚2 𝑥 50 𝑚𝑚 = 106,028.7521 𝑚𝑚3

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦,

3
𝑘𝑔 3
1𝑚
𝑚 = 𝜌𝑝𝑢𝑙𝑙𝑒𝑦 𝑥 𝑉 = 7200 3 𝑥 106,028.7521 𝑚𝑚 𝑥 ( ) = 0.76 𝑘𝑔
𝑚 1000 𝑚𝑚

𝑚
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦, 𝑊𝑝 = 𝑚𝑔 = 0.76 𝑘𝑔 𝑥 9.81
𝑠2

𝑾𝒑 = 𝟕. 𝟒𝟖𝟗𝟎 𝑵

22
For Belt Design:

𝜋𝐷1 𝑁1 𝜋(0.071)(60 𝑅𝑃𝑀) 𝑚

𝑉𝑏 = = = 0.2231
60 60 𝑠

23
𝑻𝑬𝑵𝑺𝑰𝑶𝑵𝑺 𝑶𝑵 𝑩𝑬𝑳𝑻𝑺

𝑇𝑒𝑛𝑠𝑖𝑜𝑛 𝑎𝑡 𝑡𝑖𝑔ℎ𝑡 𝑠𝑖𝑑𝑒, 𝐹1

𝑇𝑒𝑛𝑠𝑖𝑜𝑛 𝑎𝑡 𝑠𝑙𝑎𝑐𝑘 𝑠𝑖𝑑𝑒, 𝐹2

𝑚
𝐶𝑒𝑛𝑡𝑟𝑖𝑓𝑢𝑔𝑎𝑙 𝑇𝑒𝑛𝑠𝑖𝑜𝑛, 𝐹𝑐 = 0 (𝑎𝑡 𝑙𝑜𝑤𝑒𝑟 𝑏𝑒𝑙𝑡 𝑠𝑝𝑒𝑒𝑑𝑠 , 𝑙𝑒𝑠𝑠 𝑡ℎ𝑎𝑛 10 )
𝑠

𝐷2−𝐷1 140−71
sinα = =
2𝐶 2(280)

α = 7.0776°

𝜃 = 180° - 2α = 180° - (2 x 7.0776°) = 2.8945 rad

𝐹𝑟𝑜𝑚 𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑠:

𝑅𝑎𝑡𝑖𝑜 𝑜𝑓 𝐷𝑟𝑖𝑣𝑖𝑛𝑔 𝑡𝑒𝑛𝑠𝑖𝑜𝑛 𝑓𝑜𝑟 𝐹𝑙𝑎𝑡 𝐵𝑒𝑙𝑡 𝐷𝑟𝑖𝑣𝑒,

𝐹1
= 𝑒𝑓𝜃 ; 𝑤ℎ𝑒𝑟𝑒 𝑓 = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦 𝑎𝑛𝑑 𝑏𝑒𝑙𝑡,
𝐹2

𝜃 = 𝑎𝑛𝑔𝑙𝑒 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦 𝑎𝑛𝑑 𝑏𝑒𝑙𝑡 𝑖𝑛 𝑟𝑎𝑑𝑖𝑎𝑛𝑠

𝐹1
= 𝑒𝑓𝜃 = 𝑒(0.30)(2.8945) = 2.3830 𝑟𝑎𝑑𝑖𝑎𝑛𝑠 → 𝐹1 = 2.3830𝐹2 (𝑒𝑞. 1)
𝐹2

𝐶𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑖𝑛𝑔 𝑎 𝑏𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 35 𝑚𝑚,

𝑏 = 35 𝑚𝑚, & 𝑡 = 5 𝑚𝑚 (𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡𝑠)

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐵𝑒𝑙𝑡, 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑏𝑒𝑙𝑡, 𝐴 = 𝑏𝑡 = 35 𝑚𝑚 𝑥 5 𝑚𝑚 = 175 𝑚𝑚2

2
1𝑚
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑏𝑒𝑙𝑡, 𝑉 = 𝐴𝐿 = 175 𝑚𝑚2 𝑥 ( ) (0.8957 𝑚) = 0.0001567 𝑚3
1000 𝑚𝑚

24
 𝑘𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑏𝑒𝑙𝑡, 𝑚 = 𝜌𝑏𝑒𝑙𝑡 𝑥 𝑉 = 1140 𝑥 0.0001567 𝑚3 = 0.1787 𝑘𝑔
𝑚3

𝑚
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑏𝑒𝑙𝑡, 𝑊𝑏 = 𝑚𝑔 = 0.1787 𝑘𝑔 𝑥 9.81
𝑠2

𝑾𝒃 = 𝟏. 𝟕𝟓𝟑𝟎 𝑵

𝐴𝑝𝑝𝑙𝑖𝑒𝑑 𝐹𝑜𝑟𝑐𝑒 𝑜𝑛 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡, 𝐹 = 𝑊𝑏 + 𝑊𝑝 = 1.7530 𝑁 + 7.4890 𝑁 = 9.2420 𝑁

𝑆𝑜𝑙𝑣𝑖𝑛𝑔 𝑓𝑜𝑟 𝑃𝑜𝑤𝑒𝑟 𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑,

2𝜋 𝑟𝑎𝑑 2𝜋 𝑟𝑎𝑑 𝑟𝑒𝑣

𝑥 𝑁𝑑𝑟𝑖𝑣𝑒𝑟 𝑥 𝑇 𝑥 60 𝑚𝑖𝑛 𝑥 9.2420 𝑁 𝑥 0.070 𝑚
𝑃= 𝑟𝑒𝑣 = 𝑟𝑒𝑣 = 𝟒. 𝟎𝟔𝟒𝟖 𝑾
60𝑠𝑒𝑐 60𝑠𝑒𝑐
1 𝑚𝑖𝑛 1 𝑚𝑖𝑛

𝑃 = 𝑇𝜔

4.0648 𝑊 = (𝐹1 − 𝐹2 )𝑣

𝑚
𝑣 = 0.2231
𝑠

𝑚
4.0648 𝑊 = (𝐹1 − 𝐹2 ) (0.2231 ) (𝑒𝑞. 2)
𝑠

𝑆𝑢𝑏𝑠𝑡𝑖𝑡𝑢𝑡𝑖𝑛𝑔 𝑒𝑞. 1 𝑡𝑜 𝑒𝑞. 2

𝐹1 = 2.3830𝐹2 (𝑒𝑞. 1)

𝑚
4.0648 𝑊 = (𝐹1 − 𝐹2 ) (0.2231 ) (𝑒𝑞. 2)
𝑠

𝑚
4.0648 𝑊 = (2.3830𝐹2 − 𝐹2 ) (0.2231 )
𝑠

𝑭𝟐 = 𝟏𝟑. 𝟏𝟕𝟒𝟎 𝑵 (𝒕𝒆𝒏𝒔𝒊𝒐𝒏 𝒂𝒕 𝒔𝒍𝒂𝒄𝒌 𝒔𝒊𝒅𝒆)

𝐹1 = 2.3830(13.1740 𝑁)

𝑭𝟏 = 𝟑𝟏. 𝟑𝟗𝟑𝟔 𝑵 (𝒕𝒆𝒏𝒔𝒊𝒐𝒏 𝒂𝒕 𝒕𝒊𝒈𝒉𝒕 𝒔𝒊𝒅𝒆)

25
 𝐹1
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑡𝑟𝑒𝑠𝑠, 𝜎=
𝑏𝑡

𝐹1 31.3936 𝑁
𝜎= = = 𝟎. 𝟏𝟕𝟗𝟒 𝑴𝑷𝒂
𝑏𝑡 (35 𝑚𝑚)(5 𝑚𝑚)

𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝐿𝑜𝑎𝑑 𝑜𝑛 𝑡ℎ𝑒 𝑆ℎ𝑎𝑓𝑡, 𝐹𝐵

𝑭𝑩 = (𝑭𝟏 + 𝑭𝟐 )𝒄𝒐𝒔(𝜶)

𝑭𝑩 = (𝟑𝟏. 𝟑𝟗𝟑𝟔 + 𝟏𝟑. 𝟏𝟕𝟒𝟎) 𝒄𝒐𝒔(𝟕. 𝟎𝟕𝟕𝟔)

𝑭𝑩 = 𝟒𝟒. 𝟐𝟐𝟖𝟎 𝑵

26
For the Spur Gears:

SSA2-80 SSA Steel Hub less Spur Gears are used. The following values are given:

1. Module

2. Number of Teeth

3. Pitch Diameter

4. Bore Diameter

5. Pressure Angle

Description Formula Answer

Module 2

Number of Teeth 80

Pitch Diameter 6.299 inches or 160 mm

Bore Diameter 0.7087 inches or 18 mm

Pressure Angle 20°

Diametral Pitch (# of Teeth/PD) 12.7

Dedendum (1.157/DP) 0.0911 inches

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 Addendum (1/DP) 0.0787 inches

Circular Pitch (3.1416/DP) 0.2474 inches

Whole Depth A+D 0.1698 inches

Working Depth 2/DP 0.1575 inches

Circular Thickness 1.57/DP 0.1236 inches

Outside Diameter PD+2A 6.4564 inches

Root Diameter PD-2D 6.1168 inches

Face Width 3CP 0.7422 inches

Base Circle PD cos PA 5.9191 inches

28
Results and Discussion

For the design of Driven pulley, the material selected was cast iron steel while its

diameter and rotational speed is set to be 140 mm and 30 RPM respectively. The width of the

driven pulley is 150 mm. Using the standard thickness of 5 mm, the thickness of the driven

pulley rim, inside radius of driven pulley and inside diameter of driven pulley were determined

to be 3.7 mm, 65 mm and 130 mm respectively. The area (2120.5750 mm 2) and the volume

(106,028.7521 mm3) were used to calculate the mass, which is 0.76 kg and the weight of the

driven pulley which is 7.489 N.

For the design of driver pulley, the material selected was also cast-iron steel while its

rotational speed is set to be 60 RPM. Using the ratio between the diameter of the driver and

driven pulley to its respective rotational speed, the diameter of the driver pulley was determined

to be 70 mm. The width of the driver pulley is 50 mm. Based on the standard thickness of 5

mm, the Thickness of the driver pulley rim, inside radius of driver pulley and Inside diameter

of the driver pulley were determined to be 3.355 mm, 30.5 mm, and 61 mm respectively. The

area (1036.7256 mm2) and the volume (51,836.2788 mm3) were used to calculate the mass,

which is 0.3732 kg and the weight of the driven pulley which is 3.6613 N.

For the design of the belt, the selected type of the belt is a flat belt, and the material

selected for the belt was rubber with a friction factor of 0.30. The length of the belt was set to

be 895.6889 mm. By considering a belt width of 35 mm and a belt thickness of 5 mm, the area

of the belt was determined to be 175 mm2. The mass and weight of the belt is 0.1787 kg and

1.7530 N respectively.

For the shaft calculation, the velocity ratio is 2 and the power transmitted in the design

is 4.0648 W. The tension at the tight and slack side were calculated to be 31.3936 N and

29
13.1740 N respectively. The maximum stress computed was 0.1794. Lastly, The Bending Load

on the shaft was determined to be 44.2280 N.

For the design of the spur gear, predetermined values of module, number of teeth, pitch

diameter, bore diameter, and pressure angle are given. This is used to compute for the following

values such as diametral pitch (12.7), dedendum (0.0911 inches), addendum (0.0787 inches),

circular pitch (0.2474 inches), whole depth (0.1698 inches), working depth (0.1575 inches),

circular thickness (0.1236 inches), outside diameter (6.4564 inches), root diameter (6.1168

inches), face width (0.7422 inches), and base circle (5.9191 inches). The formulas used in

obtaining these values are found in the provided reading material for this course and the

learnings obtained from the subject “Machine Elements”.

30
Conclusion and Recommendation
After the rendering of the design, the group was able to understand the concepts of a

belt drive and spur gear system. The group was able to design a machine with a straightforward

system that regular people can understand. The group was also able to design a machine that

considers the convenience of the user. The group was successful in incorporating the theoretical

calculations learned in the subject in the design of the machine. With this, the machine can

have higher reliability. The group recommends that the machine can be improved by

incorporating automation to further increase its reliability and feasibility.

31