HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING

Department of Machine Design


MACHINE ELEMENTS
(ME2007)
Semester 2/Academic year 2021-2022
PROJECT #4
DESIGN OF A TRANSMISSION SYSTEM FOR BLENDER

Name: Đoàn Nhật Vinh

Student ID: 2053587
Data Number: 9

Ho Chi Minh City – 2022

1
System components:
1. Electric motor 2. V-belt drive
3. Dual-stage gear reducer 4. Flexible shaft coupling
5. Blender
Given parameters:
Power of blender' shaft, P = 3.6 (kW) = Pmax
Rotation speed of blender' shaft, n = 72 (rpm)
Service life: L = 8 (years)
Number of working days per year: 184 (days)
Number of shifts per working day: 1 (shift)
Loading characteristic: T1 = T; t1 = 54 (s) ; T2 = 0.3T; t2 = 35 (s) : T3 = 0.4T;
t3 = 29 (s)
Operating conditions: one-direction working, light-impact loading, 8-hour shift.

2
 Table of Contents
1. Select electric motor and distribute transmission ratio for the system 4

Reference:
Cơ Sở Thiết Kế Máy - Nguyễn Hữu Lộc [1]

3
 PART 1: Select electric motor and distribute
transmission ratio for the system
I. Select electric motor
1. Transmission efficiency
Select the transmission efficiency for each component using Table [3.3]
2 4
η=ηđ nbr 1 ηbr 2 η kn ηol

ηđ =0.95 : Flat belt transmission efficiency

ηbr 1 =0.97 : Helical gear transmission efficiency

ηbr 2 =0.97 : Spur gear transmission efficiency

η kn=0.98 : Flexible shaft coupling efficiency

η ol =0.995 : Bearing efficiency

⟹ η=ηđ ηbr ηkn η3ol=0.95× 0.972 ×0.97 × 0.98× 0.9954 =0.833

2. Equivalent power

√ ( ) ( ) ( )
T1 T2 T3
t1 + t2 + t
T T T 3
Ptđ =Pmax
t 1 +t 2+t 3

¿ 3.6
√ ( 1 )∗54+ ( 0.3 )∗35+ ( 0.4 )∗29
54 +35+29
=2.891( kW )

3. Required motor power

Ptđ 2.891
Pct = = =3.47(kW )
η 0.833

4. Select the electric motor

From the table “SGA electric motor (CMG Company, Australia)”, we choose
the motor with P = 4 (kW) in order to satisfy the following condition: Pmotor ≥ Pct

Model Motor System Dual-stage Fast-stage Slow-stage V-belt drive

rotational speed ratio speed reducer gear gear transmission
speed (usys) transmission transmission transmission ratio (uđ)
(nmotor) ratio (ubr) ratio (u12) ratio (u34)
112 M 2895 40.2 10 3.55 2.817 4.02

4
112 M 1440 20 10 3.55 2.817 2
132 MA 965 13.4 10 3.55 2.817 1.34

160 MA 720 10 10 3.55 2.817 1

⟹ We choose the electric motor 112 M

II. Establish the feature table
1. Power
P 3.6
P III= = =3.69( kW )
ηol ηkn 0.995∗0.98

P III 3.69
P II = = =3.82(kW )
ηol ηbr 2 0.995∗0.97

PII 3.82
P I= 2
= 2
=4.08(kW )
ηol n br 1 0.995∗0.97

PI 4.08
Pmotor = = =4.32(kW )
ηol ηđ 0.995∗0.95

2. Rotation speed
nmotor 1440
nI= = =720 (rpm)
uđ 2
nI 720
n II = = =203(rpm)
u12 3.55
nII 203
n III = = =72(rpm)
u 34 2.817

3. Torque
6
9.55∗10 ∗Pmotor 9.55∗106∗4.32
T motor = = =28650( N . mm)
nmotor 1440
6
9.55∗10 ∗PI 9.55∗106∗4.08
TI= = =54117(N . mm)
nI 720
6
9.55∗10 ∗PII 9.55∗106∗3.82
T II = = =179709.4(N . mm)
n II 203

5
 6
9.55∗10 ∗P III 9.55∗10 6∗3.69
T III = = =489438(N . mm)
n III 72

4. Feature table
Specification/Shaft Electric Shaft I Shaft II Shaft III
motor
Power (kW) 4.32 4.08 3.82 3.69
Transmission ratio 2 3.55 2.817
Torque (N.mm) 28650 54117 179709.4 489438
Rotation speed 1440 720 203 72
(rpm)

PART 2: Design of the flat-belt drive

1. Select the V-belt properties from PI, nI, and uđ.

6
 According to Table 4.5 and Figure 4.2, with P motor = 4.32 (kW), nmotor = 1440
(rpm), and uđ = 2 we can select the V-belt with the following properties

Belt Symbol bp bo h yo A Length T1 d1min

type
(mm) (mm) (mm) (mm) (mm2) (mm) (N.m) (mm)
V-Belt A 11 13 8 2.8 81 560 ÷4000 11÷70 90 (75)

2. Diameter of small pulley

d 1=1.2 d min =1.2∗90=108( mm)

→ Select d1 = 140 (mm)

3. Peripheral velocity of belt
π ∙ d1 ∙ nmotor π ∙ 112∙ 1440
v1 = 4
= =10.55 (m/s) ≤ [ v ] =25 (m/s)
6 ∙10 6∙ 10 4

4. Suppose we select ξ = 0,01. Diameter of big pulley

d 2=u đ d 1 ( 1−ξ )=2∗140 (1−0.01 )=277.2(mm)

→ Select d2 = 280 (mm)

Actual transmission ratio:
d2 280
uđ = = =2.02
d 1 (1−ξ) 140 (1−0.01)

|2.02−2|
Error: ∆ u= ∗100 %=1 % <3 %
2

→ Acceptable
5. Preliminary center distance
2(d ¿ ¿ 1+d 2 )≥ a ≥ 0.55 ( d 1+ d 2 ) +h ¿

⇔ 2∗( 140+280 ) ≥ a ≥ 0.55 ( 140+280 )+ 8

⇔ 840 ≥a ≥ 239

→ Select asb = 1.2d2 = 336 when uđ = 2 (mm)

6. Belt length

7
 2
π ( d 2 +d 1 ) ( d 2−d 1 )
L=2 a sb+ +
2 4 a sb
2
π ( 280+140 ) (280−140)
→ L=2∗336+ +
2 4∗336

→ L=1346.32 ( mm )
⟹ Select L = 1400 (mm)

7. Exact center distance:

k + √ k 2−8 ∆2
a=
4
π (d 1 +d 2) d −d
With ¿ L− ; ∆= 2 1
2 2

740.26+ √ 740.26 2−8∗702

→ a=
4

→ 840 ≥ a=363.4 ≥239

⟹ Acceptable
8. Revolution of belt per second
v 1 10.55
i= = =7.53 ( s−1 ) < [ i ] =10 ( s−1 ) → Satisfy
L 1.4

9. Contact angle of small pulley

d 2−d 1 280−140 o
α 1=180−57 =180−57 =158.04 =2.76( rad)
a 363.4

10. Correction factors

Contact angle correction factor:
C α =1.24 ( 1−e )=1.24 ( 1−e−158.04 /110 )=0.945
−α1 /110

Velocity correction factor:

C v =1−0.05 ( 0.01 v 2−1 )=1−0.05 ( 0.01∗10.552 −1 )=0.99

Transmission ratio correction factor :

C u=1.12(Table 4.7)

Belt length correction factor:

8
 √ √
C L= 6
L 6 1400
L0
=
1700
=0.97

Number of belt correction factor (preliminary selection):

C z =1

Operation correction factor:

C r=0.85 (one shift, light-impact loading)

⇒ C=C α C v C u C L C z C r =0.945∗0.99∗1.12∗0.97∗1∗0.85=0.864
11. Select [P0] = 1.82 (kW) for type A V-belt, d1 = 112 and v1 = 8.44 (m/s)
12. Number of belts:
P1 4.32
z≥ = =2.3
[ P 0 ]∗C 2.18∗0.864

⇒ Select z = 3
14. Initial tension
F 0=zA [ σ 0 ]=3∗81∗1=243(N )

15. Shaft load

F r=2 F 0 sin ( ) α1
2
=2∗243∗sin
158.04
2 (
=477.1( N ) )
16. Circumferential force
1000 P1 1000∗4.32
F t= = =409.5(N)
v1 10.55

17. Minimum friction force based on the condition to prevent belt slip
Ft (e +1 )
f 'α
F0≥
2 ( e −1 )
f 'α

1
⇔ f ' min = ln
α (
2 F 0+ F t
=)
2 F0 −Ft 2.76
1
ln (
2∗243+ 409.5
2∗243−409.5
=0.89 )
f
( 2γ )=0.89∗sin (20 )=0.304
'
f= ' o
With sin ⁡( ) ⇒ min
γ f =f ∗sin
min
2

18. Maximum belt stress

F 0 / z F t /z 2 −6 2 y 0
σ max= + + ρ v ∗10 + E
A 2A d1
9
 243/3 409.5/3 2 −6 2∗2.8
→ σ max= 81 + 2∗81 +1200∗10.55 ∗10 + 140 ∗100

→ σ max=5.98 ( MPa ) ≤ [ σ ] k =10( MPa)

where: Belt density ρ = 1200 kg/m3
Belt modulus of elasticity E = 100 Mpa
19. Service life of belt

( )
m
σr
( )
8
∗10
79 7
∗10
σ max 5.98
L h= = =4855 (hours)
2∗3600∗i 2∗3600∗7.53

where: σr = 9: the limit fatigue stress of V-belt

m = 8 for V-belt
20. Summary Table
Specification Value
Belt type Type A V-belt
Area (A) 81 (mm2)
Number of belts (z) 3 (belts)
Center distance (a) 363.4 (mm)
Belt length (L) 1400 (mm)
Contact angle of small pulley 158.04
o

Belt width 11 (mm)

Revolution of belt per second (i) 7.53 (s-1)
Small pulley diameter (d1) 140 (mm)
Big pulley diameter (d2) 280 (mm)
Maximum belt stress (σ max ¿ 5.98 (MPa)
Initial tension (F0) 243 (N)
Shaft load (Fr) 477.1 (N)
Tension on the tight side (F1) 481.55 (N)
Tension on the slack side (F2) 4.45 (N)
10
 Service life of belt 4855 (hours)

PART 3: Design of the gear drive in speed reducer

A. Fast-stage gear
Input data: u12=3.55 , T I =54117(kW ), n I =720( rpm)
1. Select material: With PI = 4.08 (kW) we can select the following material:
C45 soft hardening steel: 180 ÷ 350 HB
Select: H1 = 245 HB, H2 = 225 HB
2. Theoretical operating cycles
N HO 1=30 H 12.4=30∗2452.4 =1.626∗107 (cycles)
2.4 2.4 7
N HO 2=30 H 2 =30∗225 =1.325∗10 (cycles)
6
N FO 1=N FO 2 =5∗10 ( cycles)

Equivalent operating cycles:

N HE 1=60 c ∑
( )Ti 3
nt
T max i i

[( ) ( ) ( ) ]
3 3 3
T 0.3 T 0.4 T
∗54 ∗35 ∗29
T T T
¿ 60∗1∗720∗11776 + +
118 118 118
7
¿ 24.488∗10 (cycles)

Where: Lh = L*184*8 = 8*184*8 = 11776 (hours)

N HE 1 24.488∗107
N HE 2= = =6.898∗107 ( cycles)
u12 3.55

( )
mF
Ti
N FE 1=60 c ∑ ni t i ;with mF =6 ( HB ≤ 350 )
T max

[( ) ( ) ( ) ]
6 6 6
T 0.3 T 0.4 T
∗54 ∗35 ∗29
T T T
¿ 60∗1∗720∗11776 + +
118 118 118
7
¿ 23.34∗10 (cycles)

11
 N FE 1 23.34∗107 7
N FE 2= = =6.5746∗10 (cycles)
u12 3.55

Because NHE1 > NHO1; NHE2 > NHO2; NFE1 > NF01; NFE2 > NFO2
⇒ KHL1 = KHL2 = KFL1= KFL2 =1
Fatigue limits for contact stresses: (Table 5.3)
σ 0 Hlim 1=2 H B 1+70=2∗245+ 70=560 ( MPa )

σ 0 Hlim 2=2 H B 2+70=2∗225+70=520 ( MPa )

Fatigue limits for bending stresses:

σ 0 Flim1=1.8 H B 1=1.8∗245=441 ( MPa )

σ 0 Flim2=1.8 H B 2=1.8∗225=405 ( MPa )

Allowable contact stress:

0.9 K HL1 560∗0.9∗1
[ σ H 1 ]=σ 0 Hlim 1 sH 1
=
1.1
=458.18 ( MPa )

0.9 K HL2 520∗0.9∗1

[ σ H 2 ]=σ 0 Hlim 2 sH 2
=
1.1
=425.45 ( MPa )

Allowable bending stress:

0.9 K FL1 441∗0.9∗1
[ σ F 1 ] =σ 0 Flim1 sF 1
=
1.75
=226.8 ( MPa )

0.9 K FL2 405∗0.9∗1

[ σ F 2 ] =σ 0 Flim2 sF 2
=
1.75
=208.286 ( MPa )

3. Allowable contact stress for calculation

[ σ H ]= √0.5( [ σ H1 ] + [ σ H 2 ] )=442.12( MPa)

2 2

4. Driving gear are placed symmetrically on the shaft, we select ψ ba=0.315

ψ ba(u 12+1) 0.315∗( 3.55+ 1)
⇒ ψ bđ = = =0.717
2 2

⇒ Base on Table 5.5, K Hβ=1.027

12
⇒ Select K Fβ=1.03
5. Center distance:

√
TI
3 K
2 Hβ
a w =43 ( u 12 ±1 ) 2
ψ ba [ σ H ] u12

¿ 43∗( 3.55+1 )∗3

√ 27058.5∗1.027
2
0.315∗442.12 ∗3.55

= 98.4 (mm)
⇒ Select aw = 160 (mm)
5. Select module
With HB1, HB2 ≤ 350HB, we have
mn = (0.01 ÷ 0.02)aw = 1.6 ÷ 3.2
⇒ Select mn = 2.5
6. Number of teeth

13
 0 mn z 1(u12 +1) 0
cos 30 ≥ ≥ cos 4 0
2 aw

2 aw cos 300 2 a w cos 4 00

→ ≥ z1 ≥
mn (u12 +1) mn (u12 +1)

→24.36 ≥ z1 ≥ 21.55
⇒ Select z1 = 22 (teeth)
⇒ z2 = u12 z1 = 3.55*22 = 78.1 ⇒ z2 = 78 (teeth)
7. Helical angle: β=arccos ⁡¿] = 38.550
8. Actual velocity ratio:
z 2 78
u12= = =3.545
z 1 22

|3.545−3.55|
∆ u 12= ∗100 %=0.14 %<2 %
3.55

⇒ Acceptable
9. Dimension table
Dimension Formula Value
Ring diameter Driving gear d1 = mnz1 / cos β 70.32 (mm)
Driven gear d2 = mnz2 / cos β 249.34 (mm)
Top ring diameter Driving gear da1 = d1 + 2mn 75.32 (mm)
Driven gear da2 = d2 + 2mn 254.34 (mm)
Bottom ring Driving gear df1 = d1 – 2.5mn 64.07 (mm)
diameter
Driven gear df2 = d2 – 2.5mn 243.09 (mm)
Rim width Driving gear Table page 103 55 (mm)
[1]
Driven gear b2 = ψ baaw 50 (mm)

10. Tangential velocity:

π d 1 nI π∗70.32∗720
v1 = 4
= =2.65 ¿
6∗10 6∗10 4

14
⇒ Select accuracy class 9
10. Force calculation:
TI
2∗cos β
2
F t 1=F t 2=
mn z 1

54117∗cos 38.550
¿
2.55∗22
¿ 754.42 ( N )
F t 1 tan α nw 754.42∗tan 200 ⁡
F r 1=F r 2= = =351.1 ( N )
cosβ cos 38.550
F a 1=F a2 =F t 1∗tan ( β )

¿ 754.42∗tan ( 38.55 )=601.17 ( N )

0

11. Dynamic load factor:

15
Select K HV =1.02∧K FV =1.04
12. Verification of contact stress:

Select K Hα =1.13, K Fα =1 (Because accuracy class ≥ 9)

[
ε α = 1.88−3.4
( Z1 + Z1 )] cosβ=[ 1.88−3.4 ( 221 + 781 )] cos 38.55
1 2
0

ε α =1.315

16
 √
TI
2 K ( u +1 )
ZM ZH Z ε 2 H 12
σ H=
dw 1 bw u12

√ √ √
0
4 cos 38.55 1
190∗ ∗
sin ( 2∗20 ) 1.315 54117∗1.02∗1.027∗1.13∗(3.55+1)
¿
70.32 50∗3.55

= 209.47 (MPa) < [σ ¿¿ H ]=442.12 ¿(MPa) ⇒ Satisfy

13. Geometry factors:
13.2 13.2
Y F 1=3.47+ =3.47+ =¿
zv 1 45.99 3.76

13.2 13.2
Y F 2=3.47+ =3.47+ =¿ 3.55
zv 2 163.067

[σ F 1 ] 226.8
= =60.32
Y F1 3.76
[σ F 2 ] 208.286
= =58.67
Y F2 3.55

⇒ Gear 2 is selected to verify the bending stress.

14. Verification of bending stress:

σ F2=
Y F2 KF Ft Y ε Y β
=
3.59∗1∗1.04∗1.03∗754.42∗1
1.315
∗ 1− (
38.55
140 )
b w mn 50∗2.5

¿ 12.79 (MPa) <[σ F 1 ] = 226.8 (MPa) ⇒ Satisfy

15. Summary Table

Theoretical calculation
Specification Value Specification Value
Material C45 Helical angle (degree) 38.55
Center distance aw (mm) 160 Ring diameter:
Driving gear d1 (mm) 70.32
Driven gear d2 (mm) 249.34
Module m 2.5 Top ring diameter:
Driving gear da1 (mm) 75.32

17
 Driven gear da2 (mm) 254.34
Type of gear Helical Bottom ring diameter:
gear
Driving gear df1 (mm) 64.07
Driven gear df2 (mm) 243.09
Rim width: Torque T1 (N.mm) 54117
Driving gear b1 (mm) 55
Driven gear b2 (mm) 50
Number of teeth: Tangential velocity 2.65
(m/s)
Driving gear z1 (teeth) 27
Driven gear z2 (teeth) 36
Radial force Fr (N) 351.1
Tangential force Ft (N) 754.42
Axial force Fa (N) 601.17

Verification
Specification Allowable Calculated value Comment
value
Contact stressσ H (MPa) 442.12 209.47 Satisfy
Bending stress σ F 1 ( MPa) 226.8 11.63 Satisfy
σ F 2 (MPa) 208.286 12.79 Satisfy

B.Slow-stage gear
Input data: u34 =2.817, T II =179709.4( kW ), n II=203(rpm)
1. Select material: With PII = 3.82 (kW) we can select the following material:
C45 soft hardening steel: 180 ÷ 350 HB
Select: H3 = 245 HB, H4 = 225 HB
2. Theoretical operating cycles
2.4 2.4 7
N HO 3=30 H 3 =30∗245 =1.626∗10 (cycles)

18
 2.4 2.4 7
N HO 4=30 H 4 =30∗225 =1.325∗10 (cycles)

N FO 3=N FO 4=5∗106 (cycles)

Equivalent operating cycles:

N HE 3=60 c ∑ ( ) Ti 3
nt
T max i i

[ () ( ) ( ) ]
3 3 3
T 0.3 T 0.4 T
∗54 ∗35 ∗29
T T T
¿ 60∗1∗720∗11776 + +
118 118 118

¿ 24.488∗107 (cycles)

Where: Lh = L*184*8 = 8*184*8 = 11776 (hours)

N HE 4 24.488∗10 7 7
N HE 4= = =8.69∗10 (cycles)
u34 2.817

( )
mF
Ti
N FE 3=60 c ∑ ni t i ;with mF =6 ( HB ≤ 350 )
T max

[( ) ( ) ( ) ]
6 6 6
T 0.3 T 0.4 T
∗54 ∗35 ∗29
T T T
¿ 60∗1∗720∗11776 + +
118 118 118

¿ 23.34∗107 (cycles)
N FE 4 23.34∗10 7 7
N FE 4= = =8.285∗10 (cycles)
u34 2.817

Because NHE1 > NHO1; NHE2 > NHO2; NFE1 > NF01; NFE2 > NFO2
⇒ KHL1 = KHL2 = KFL1= KFL2 =1
Fatigue limits for contact stresses: (Table 5.3)
σ 0 Hlim 3 =2 H B3+ 70=2∗245+70=560 ( MPa )

σ 0 Hlim 4=2 H B 4+ 70=2∗225+70=520 ( MPa )

Fatigue limits for bending stresses:

σ 0 Flim3=1.8 H B 3=1.8∗245=441 ( MPa )

σ 0 Flim4 =1.8 H B4 =1.8∗225=405 ( MPa )

Allowable contact stress:

19
 0.9 K HL3 560∗0.9∗1
[ σ H 3 ]=σ 0 Hlim 3 sH 3
=
1.1
=458.18 ( MPa )

0.9 K HL 4 520∗0.9∗1
[ σ H 4 ]=σ 0 Hlim4 sH 4
=
1.1
=425.45 ( MPa )

Allowable bending stress:

0.9 K FL 3 441∗0.9∗1
[ σ F 3 ]=σ 0 Flim3 sF 3
=
1.75
=226.8 ( MPa )

0.9 K FL 4 405∗0.9∗1
[ σ F 4 ]=σ 0 Flim 4 sF 4
=
1.75
=208.286 ( MPa )

3. Allowable contact stress for calculation

[ σ H ]=min ⁡([ σ H 3 ] , [ σ H 4 ])=425.45(MPa)
4. Face width factor: ψ ba 34=K∗ψ ba12=1.6∗0.315=0.504
⇒ Select ψ ba 34= 0.5 base on standard
ψ ba(u 34+ 1) 0.5∗(2.817+1)
⇒ ψ bđ = = =0.95425
2 2

⇒ Base on Table 5.5 [1], K Hβ=1.0 1865

⇒ Select K Fβ=1.08
5. Center distance:

√
T II K Hβ
a w ≥ 50 ( u34 ±1 ) 3 2
ψ ba [ σ H ] u34

¿ 50∗( 2.817+1 )∗ 3
√ 179709.4∗1.01865
0.5∗425.452∗2.817
20
= 170.9 (mm)
⇒ Select aw = 200 (mm)
5. Select module
With HB1, HB2 ≤ 350HB, we have
m = (0.01 ÷ 0.02)aw = 2 ÷ 4
⇒ Select m= 2
6. Number of teeth
2 aw
z 3 + z 4= =200
m
z 3+ z 4 200
z 3= = =52.4
u34 +1 2.817 +1

⇒ Select z3 = 52 (teeth)
⇒ z4 = 200- z3 = 148 (teeth)
7. Actual center distance:
m( z3 + z 4 )
a w= =200 (mm)
2

8. Actual velocity ratio:

z 4 148
u34 = = =2.846
z 3 52

|2.846−2.817|
∆ u 34= ∗100 %=1.03 %< 2%
2.817

⇒ Acceptable
9. Dimension table
Dimension Formula Value
Ring diameter Driving gear d3 = mz3 / cos β 104 (mm)
Driven gear d4 = mz4 / cos β 296 (mm)
Top ring diameter Driving gear da3 = d3 + 2m 108 (mm)
Driven gear da4 = d4 + 2m 300 (mm)
Bottom ring Driving gear df3 = d3 – 2.5m 99 (mm)

21
 diameter Driven gear df4 = d4 – 2.5m 291 (mm)
Rim width Driving gear Table page 103 105 (mm)
[1]
Driven gear b4 = ψ baaw 100 (mm)

10. Tangential velocity:

π d 3 nII π∗104∗203
v 2= 4
= 4
=1.105¿
6∗10 6∗10

⇒ Select accuracy class 9

10. Force calculation:
2T II
F t 1=F t 2=
d1

2∗179709.4
¿
104
¿ 3455.95 ( N )
0
F r 1=F r 2=F t 1∗tan ( α w )=3455.95∗tan 20 =1257.86 ( N )

11. Dynamic load factor:

22
Select K HV =1.06∧K FV =1.11
12. Verification of contact stress:

Select K Hα =1.13, K Fα =1 (Because accuracy class ≥ 9)

[
ε α = 1.88−3.4
( Z1 + Z1 )] cosβ=[ 1.88−3.4 ( 341 + 1211 )] cos 14.8
1 2
0

ε α =1.75

σ H=
d w3 √
Z M Z H Z ε 2 T II K H ( u34 +1 )
b w u34

23
¿
190∗
√ (
4
sin 2∗20
104
√)
∗
4−1.75
3
√ 2∗179709.4∗1.06∗1.0 1865∗1.13∗(2.817+1)
100∗2.817

= 319.11 (MPa) < [σ ¿¿ H ]=425.45 ¿(MPa) ⇒ Satisfy

13. Geometry factors:
13.2 13.2
Y F 3=3.47+ =3.47+ =3.72
z1 52

13.2 13.2
Y F 4 =3.47+ =3.47+ =¿ 3.56
z2 148

[σ F 3 ] 226.8
= =60.97
Y F3 3.72
[σ F 4 ] 208.286
= =58.51
Y F4 3.56

⇒ Gear 4 is selected to verify the bending stress.

14. Verification of bending stress:
Y F 4 K F F t 3.56∗1∗1.11∗1.02∗3455.95
σ F 4= =
bw m 100∗2

¿ 69.65 (MPa) <[σ F 1 ] = 208.286 (MPa) ⇒ Satisfy

15. Summary Table

Theoretical calculation
Specification Value Specification Value
Material C45 Helical angle (degree) 0
Center distance aw 200 Ring diameter:
(mm)
Driving gear d1 (mm) 104
Driven gear d2 (mm) 296
Module m 2 Top ring diameter:
Driving gear da1 (mm) 108
Driven gear da2 (mm) 300
Type of gear Spur gear Bottom ring diameter:

24
 Driving gear df1 (mm) 99
Driven gear df2 (mm) 291
Rim width: Torque T1 (N.mm) 179709.4

Driving gear b1 (mm) 105

Driven gear b2 (mm) 100
Number of teeth: Tangential velocity 1.105
(m/s)
Driving gear z1 (teeth) 52
Driven gear z2 (teeth) 148
Radial force Fr (N) 1257.86

Tangential force Ft (N) 3455.95

Axial force Fa (N) 0

Verification
Specification Allowable Calculated value Comment
value
Contact stressσ H (MPa) 425.45 319.11 Satisfactory
Bending σ F 1 (MPa) 226.8 69.31 Satisfactory
stress σ F 2 (MPa) 69.65
208.286 Satisfactory

C.Lubrication
To avoid power loss due to oil stirring, power loss due to temperature rise and
oil oxidation we use oil immersion lubrication when the rpm of oil-soaked parts
≤ 15𝑚/𝑠 for gears.
Lubrication condition:
Lowest oil level of fast-stage gear must satisfy the following conditions:
+ h m=(2.25 m … 4 m)≥ 10 mm
+ h max – hmin =10 … 15 mm
1
+ h m2 ≤ 6 d a 4

25
From there, the lubrication condition must satisfy the following inequality:
1 1
H = 2 d a 2−10−( 10 … 15 ) ≥ 3 d a 4 (because hm = 2.5*2.5 =6.25 <10)

1 1
⇒ H = 2 ∗255.06−10−( 10 … 15 )=107.53 … 102.53 ≥ 3 ∗300=100

⇒ The speed reducer satisfy the lubrication condition

PART 4: Design of two shafts in speed reducer

I. Shaft design
1. Select material:
Base on Table 8.1 [1], we can select:
SHAFT 1 & 3:
C45 normalized, [ τ ]=25 (MPa), σ b=600( MPa)
SHAFT 2:
C45 normalized, [ τ ]=15 (MPa), σ b=600( MPa)
2. Preliminary estimate diameter of shaft

d I=
√ √
3 16 T I 3 16∗54117
π [τ ]
=
25 π
=22.26 ( mm )

d II =
√ √
3 16 T II 3 16∗179709.4
π [τ ]
=
25 π
=33.2 ( mm )

d III =
√ √3 16 T III 3 16∗489438
π [τ]
=
15 π
=54.98 ( mm )

⇒ Base on standard, we have:

Shaft 1: d I =25 ( mm )
Shaft 2: d II =34 ( mm )
Shaft 3: d III=55 ( mm )
3. Shaft specification: According to Table 8.2 [1], we have

Specification Shaft 1 Shaft 2 Shaft 3

26
 d1 25 (mm) 34 (mm) 55 (mm)
l1 34 (mm) 42 (mm) 63 (mm)
d 35 (mm) 45 (mm) 65 (mm)
l2 50 (mm) 63 (mm) 100 (mm)
d3 40 (mm) 52 (mm) 75 (mm)
l3
d4 35 (mm) 45 (mm) 65 (mm)
l4

With:
Shaft 1: l1 = 1.3d1 Shaft 2: l2 = 1.2d2 Shaft 3: l3 = 1.1d3
d = d1 + 2t
4. Preliminary estimate distance between two bearings
Shaft 1:
l mo 1=( 1 … 1.5 ) d3 =40 ÷ 60, withl mo 1 ≥ b1 =55

⇒ Select lmo 1=60 (mm)

e 1=12 (mm)

e 2=0.8 δ=0.8∗( 0.025 a w + 3 )=0.8∗( 0.025∗160+3 ) =5.6(mm)

w=40(mm) (Table 8.3 [1])

L1=0.5 l mo 1 +0.5 w+ e1=62 (mm)

'
L2=0.5 l mo 1 +l mo 2+ e1 +e 2+ 0.5 w=¿

L3=f

4.

27
According to Table 10.2, dI = 35 (mm) ⇒ b0 = 21 (mm)
dII = 50 (mm) ⇒ b0 = 27 (mm)

Figure 1. Dimension diagram of 1-stage bevel gear reducer

Table 3
From Table 3, select: k1 = 13, k2 = 13, k3 = 11, hn = 15

28
 Table 4
Using the formula from Table 4, we can calculate the dimensions of 2 shafts as
follow:
SHAFT 1:
lm12 = (1.2 ÷ 1.5)dI = 42 ÷ 52.5 (mm) ⇒ select lm12 = 45 (mm)
lm13 = (1.2 ÷ 1.4)dI = 42 ÷ 49 (mm) ⇒ select lm13 = 48 (mm
l 11=2.5 d I =2.5∗35=87.5(mm)

l 12=−l c 12=0.5(l m 12+ b0 )+ k 3 +¿hn

= 0.5 * (45 + 21) + 11 + 15

= 59 (mm)
l 13=l 11 + k 1 +k 2 +l m 13 + 0.5¿ ¿ )

= 87.5 + 13 +13 + 48 + 0.5(21-59.9355*cos140)

= 142.92 (mm)
SHAFT 2:
lm22 = (1.2 ÷ 1.5)dII = 60 ÷ 75 (mm) ⇒ select lm22 = 65 (mm)
lm23 = (1.2 ÷ 1.4)dII = 60 ÷ 70 (mm) ⇒ select lm22 = 63 (mm)
lm24 = (1.4 ÷ 2.5)dII = 70 ÷ 125 (mm) ⇒ select lm24 = 95 (mm)
l22 = 0.5(lm22 + b0) + k1 + k2
= 0.5*(65+27) +13+13
= 72 (mm)
l23 = l22 + 0.5(lm22 + b13cosδ 2) + k1
= 72 + 0.5 (65 +59.9355 * cos760) + 13
= 124.75 (mm)
l21 = lm22 + lm23 + b0 + 3k1 + 2k2
29
= 65 + 63 +27 + 3*13 + 2*13
= 220 (mm)
lc24 = 0.5(lm24 + b0) + k3 + hn
= 0.5(95 + 27) + 11 + 15
= 87 (mm)
4. Calculate reaction forces and draw diagrams of bending moments and torque
on shaft.
SHAFT 1:

SHAFT 1

SHAFT 1 FORCE ANALYSIS

30
 F a 1∗d m 1 271.12∗87.465
M 1= = =11900.4879( N .mm)
2 2

∑ F x=0⇒ −R Bx + RCx =3079.06 [1]

∑ M y / A =0 ⇒−59 RBx +146.5 R Cx=3079.06∗201.92 [2]
From [1] and [2]
⇒ RBx =1950.2 (N); RCx = 5029.25(N)

∑ F y=0⇒ R By−R Cy=−370.7 [3]

∑ M x/ A=0⇒ 59 R By −146.5 R Cy=11900.4879−1087.4∗201.92 [4]
From [3] and [4]
⇒ RBy =1752.68 (N); RCy = 2123.38 (N)

31
 BENDING MOMENTS AND TORQUE DIAGRAM OF SHAFT I

Equivalent moment at each section:

32
MA = √ M 2xA + M 2yA + 0.75T 21
¿ √ 0+0+ 0.75∗134655
2

= 116614.6507 (N.mm)

MB = √ M 2xB + M 2yB +0.75 T 21

¿ √ 42285.32 +02 +0.75∗1346552
¿ 124044.4411( N .mm)

MC = √ M 2xC + M 2yC + 0.75T 21

¿ √ 48363.22 +170641.51 + 0.75∗134655
2 2 2

¿ 212265.1708(N . mm)

MD = √ M 2xD + M 2yD +0.75 T 21

= √ 11900.492+ 02 +0.75∗1346552
¿ 117220.2987(N . mm)

Shaft diameter at section A:

dA≥
√
3 MA
0.1 [ σ ] √
=
3 116614.6507
0.1∗70
=25.54 (mm)

Select dA = 28 (mm) based on standard

Shaft diameter at section B:

d B≥
√
3 MB
0.1 [ σ ] √
=
3 124044.4411
0.1∗70
=26.1(mm)

⇒ Select dB = 35 (mm) based on standard

Shaft diameter at section C:

33
dC ≥
√
3 MC
√
0.1 [ σ ]
=3
212265.1708
0.1∗70
=31.2(mm)

⇒ Select dC = 35 (mm) based on standard

Shaft diameter at section D:

dD≥
√
3 MD
√
0.1 [ σ ]
=
3 117220.2987
0.1∗70
=25.6(mm)

⇒ Select dD = 28 (mm) based on standard

SHAFT 2:

Fa 2∗d m 2 1087.4∗349.86
M 2= = =190218.882( N . mm)
2 2

Table 5
With TII = 509.015 (N.m) ⇒ Based on Table 5, select d=56 (mm) , D= 170
(mm), dm = 95 (mm), d1 = 95 (mm), D0 = 130 (mm)
( 0.2÷ 0.3 )∗2T II
Fcoupling =
D0

34
 ( 0.2÷ 0.3 )∗2∗509015
¿
130
¿ ( 1566.2÷ 2349.3 ) (N )

⇒ Fcoupling = 2349.3 (N)

∑ F x=0⇒ R Ax −RCx =3079.06−2349.3 [5]

∑ M y / A =0 ⇒−220 RCx=3079.06∗124.75−2349.3∗307 [6]
From [5] and [6]
⇒ RAx =2262.13 (N); RCx = 1532.37(N)

∑ F y=0⇒ −R Ay + RCy =271.12 [7]

∑ M x/ A=0⇒ 220 R Cy=190218.882+271.12∗124.75 [8]
From [7] and [8]
⇒ RAy =747.25 (N); RCy = 1018.37 (N)

35
 BENDING MOMENTS AND TORQUE DIAGRAM OF SHAFT II

Equivalent moment at each section:

MA = √ M 2xA + M 2yA + 0.75T 2II
¿ √ 0+0+ 0.75∗0
2

= 0 (N.mm)

36
MB = √ M 2xB + M 2yB +0.75 T 2II
¿ √ 96999.61 + 282201.26 + 0.75∗509015
2 2 2

¿ 532323.8471( N .mm)

MC = √ M 2xC + M 2yC + 0.75T 21

¿ √ 02 +204389.12+ 0.75∗5090152
¿ 485898.2474 (N . mm)

MD = √ M 2xD + M 2yD +0.75 T 21

= √ 02 +02 +0.75∗5090152
¿ 440819.9209( N . mm)

Shaft diameter at section A:

dA≥
√
3 MA
0.1 [ σ ] √
=3
0
0.1∗60
=0 (mm)

Select dA = 45 (mm) based on standard

Shaft diameter at section B:

d B≥
√
3 MB
0.1 [ σ ] √
=3
532323.8471
0.1∗60
=44.6(mm)

⇒ Select dB = 50 (mm) based on standard

Shaft diameter at section C:

dC ≥
√
3 MC
0.1 [ σ ] √
=
3 485898.2474
0.1∗60
=43.26(mm)

⇒ Select dC = 45 (mm) based on standard

37
Shaft diameter at section D:

dD≥
√
3 MD
√
0.1 [ σ ]
=
3 440819.9209
0.1∗60
=41.88(mm)

⇒ Select dD = 45 (mm) based on standard

II. Verification based on safety factor

SHAFT 1:
Based on moment diagrams, section at C is the most critical position on the
shaft.

At section C, select a feather key with:

Section d b h t t1
C 30 8 7 4 2.8

Magnitude and mean values of bending stress:

38
 M
σ a= =
√ M x + M y = √ 48363.22 + 170641.51 =67.26 ( MPa )
2 2 2 2

W π d 3C bt ( dC −t ) 3
π∗30 8∗4 (30−4 )
− −
32 2 dC 32 2∗30

σ m=0

Magnitude and mean values of torsion stress (for one-way rotation):

T T 134655
τ a=τ m= = =

( ) ( )
2W 0 πd
3
bt ( d C −t ) π∗30 8∗4 ( 30−4 )
3
2 C
− 2 −
16 2 dC 16 2∗30

= 12.73 (MPa)
Fatigue limits of material:
σ −1=( 0.4 ÷ 0.5 ) σ b=400 ÷ 500 ( MPa )

τ −1=( 0.22 ÷ 0.25 ) σ b=220 ÷ 250(MPa)

Select σ −1=450 ( MPa ) ; τ −1=240( MPa)

⇒ Because there is a keyseat at section C, select K σ =2.3 and K τ =2.2

⇒ Because dC = 32, select ε σ =0.88 and ε τ =0.81

39
Because shaft’s surface was hardened using high frequency quenching,
K σ >1.5. Select β=2

Because σ b=1000, select ψ σ =0.1 and ψ τ =0.05

Safety factors regarding to bending and torsion stresses:

σ −1 450
sσ = = =5.12
Kσσa 2.3∗67.26
+ψ σ σ m +0.1∗0
εσ β 0.88∗2

τ−1 240
sτ = = =13.39
K τ τa 2.2∗12.73
+ψ τ τ m + 0.05∗12.73
ετ β 0.81∗2

sσ∗s τ 5.12∗13.39
s= = =4.8 ≥ [ s ] =1.5
√s τ
2
+ sσ
2
√5.122 +13.392
⇒ Satisfy
SHAFT 2:
Based on moment diagrams, section at B is the most critical position on the
shaft.
At section B, select a feather key with:
Section d b h t t1
40
 B 50 14 9 5.5 3.8

Magnitude and mean values of bending stress:

M
σ a= =
√ Mx+M y
2

=
√
2 2
96999.61 + 282201.26
2
=24.38 ( MPa )
W π d 3B bt ( d b−t ) π∗50 3 14∗5.5 ( 50−5.5 )
− −
32 2 dB 32 2∗50

σ m=0

Magnitude and mean values of torsion stress (for one-way rotation):

T T 509015
τ a=τ m= = =

( ) 16 − 2∗48 )
(
2W 0 πd
3
bt ( d B−t ) π∗48 14∗5.5 ( 48−5.5 )
3
2 B
− 2
16 2 dB

= 10.38 (MPa)
Fatigue limits of material:
σ −1=( 0.4 ÷ 0.5 ) σ b=400 ÷ 500 ( MPa )

τ −1=( 0.22 ÷ 0.25 ) σ b=220 ÷ 250(MPa)

Select σ −1=450 ( MPa ) ; τ −1=240( MPa)

⇒ Because there is a keyseat at section C, select K σ =2.3 and K τ =2.2

⇒ Because dB = 50, select ε σ =0.84 and ε τ =0.78
Because shaft’s surface was hardened using high frequency quenching,
K σ >1.5. Select β=2

Because σ b=1000, select ψ σ =0.1 and ψ τ =0.05

Safety factors regarding to bending and torsion stresses:

σ −1 450
sσ = = =13.48
Kσσa 2.3∗24.38
+ψ σ σ m + 0.1∗0
εσ β 0.84∗2

41
 τ−1 240
sτ = = =15.83
K τ τa 2.2∗10.38
+ψ τ τ m +10.38∗0.05
ετ β 0.78∗2

sσ∗s τ 13.48∗15.83
s= = =10.26 ≥ [ s ] =1.5
√s τ
2
+ sσ 2
√13.482 +15.832
⇒ Satisfy

PART 5: Select bearings for two shafts in speed

reducer
SHAFT 1:
As calculated above:
RBx =1950.2 (N); RCx = 5029.25(N)
RBy =1752.68 (N); RCy = 2123.38 (N)
Fa = 271.12 (N)
Radial force on the bearing at B section:
F rB=√ RBx + RBy =√ 1950.2 + 1752.68 =2622.05(N )
2 2 2 2

Radial force on the bearing at C section:

F rC =√ R 2Cx+ R2Cy= √5029.252 +2123.382=5459.13( N ).

Because tapered roller bearing is used along with dC = dB = 30 (mm), therefore

we preliminary select bearing with:
Serie d D D1 d1 B C1 T R r1 α C C0
s
mm mm mm mm mm mm mm m mm (o) kN kN
m
7606 30 72 55.5 50 27 23 28.75 2 0.8 12 61. 51
3

e = 1.5tgα1.5tg12o = 0.3188
SB = 0.83eFrB = 0.83 * 0.3188 * 2622.05 = 693.8(N)
SC = 0.83eFrC = 0.83 * 0.3188 * 5459.13= 1444.5 (N)

42
With SB < SC and Fa < SC – SB
⇒ FaB = SC - Fa = 1444.5 – 271.12 =1173.38 (N);
⇒ FaC = SC = 1444.5 (N)
⇒ Select bearing at C to calculate.
Select K σ , K t and V =1

F aC 1444.5
= =0.26<e=0.3188
V F rC 1∗5459.13

⇒ X = 1; Y = 0
Dynamic equivalent bearing load:
Q = (XVFrC + YFaC) K σ K t = (1*1*5459.13+0∗1444.5)*1*1
= 5459.13 (N)
Working live in million revolutions:

43
 60 Lh n 60∗24000∗400
L= 6
= =576 (million revolution)
10 106

Dynamic equivalent force:

10
m 3
C tt =Q √ L=5459.13 √576=36749.4 ( N ) =36.75(kN )
Ctt < C = 61.3 (kN)
⇒ The selected bearing satisfy the condition.

SHAFT 2:
As calculated above:
RAx =2262.13 (N); RCx = 1532.37(N)
RAy =747.25 (N); RCy = 1018.37 (N)
Fa = 1087.4 (N)
Radial force on the bearing at A section:
F rA=√ R2Ax + R 2Ay=√ 2262.132 +747.252=2382.35(N )

Radial force on the bearing at C section:

F rC =√ R Cx+ RCy= √1532.37 +1018.37 =1839.9(N) .
2 2 2 2

Because tapered roller bearing is used along with dA = dC = 45 (mm), therefore

we preliminary select bearing with:

Series d D D1 d1 B C1 T R r1 α C C0
mm mm mm mm mm mm mm mm mm (o) kN kN
7209 45 85 70 64.8 19 16 20.75 2 0.8 15.3 42.7 33.4
3

e = 1.5tgα1.5tg15.33o = 0.411
SA = 0.83eFrA = 0.83 * 0.411 * 2382.35 = 812.7(N)
SC = 0.83eFrC = 0.83 * 0.411 * 1839.9 = 627.65 (N)
With SA > SC and Fa > 0
44
⇒ FaA = SA = 812.7 (N);
⇒ FaC = SA + Fa =812.7+1087.4 = 1900.1 (N)
⇒ Select bearing at C to calculate.
Select K σ , K t and V =1

F aC 1900.1
= =1.03>e=0.411
V F rC 1∗1839.9

⇒ X = 0.4; Y = 0.4cot15.330 = 1.46

Dynamic equivalent bearing load:
Q = (XVFrC + YFaC) K σ K t = (0.4*1*1839.9+1.46∗1900.1)*1*1
= 3510.106 (N)
Working live in million revolutions:
60 Lh n 60∗24000∗100
L= 6
= =144( million revolution)
10 10 6

45
Dynamic equivalent force:
10
m 3
C tt =Q √ L=3510.106 √ 144=15589.4 ( N )=15.6(kN )
Ctt < C = 42.7 (kN)
⇒ The selected bearing satisfy the condition.

46