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BACHULER THESIS ON MULTI-SPINDLE DRILL MACHINE 2005
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TABLE OF CONTENTS
ACKNOWLEDGEMENT.........................................................................................................................2
ABSTRACT...........................................................................................................................................3
1 INRTODUCTION.................................................................................................................................4
1.1 BACKGROUND OF THE PROBLEM...................................................................................................................5
1.2. STATEMENT OF THE PROBLEM......................................................................................................................6
1.3 OBJECTIVE OF THESIS........................................................................................................................................7
1.4. RESAERCH METHODOLOGIES AND DATA COLLECTION.........................................................................8
1.5 THE EXPECTED OUTCOME AND BENEFICIARIES OF THE THESIS........................................................10
1.6 SCOPE AND LIMITATION OF THE STUDY....................................................................................................11
2 LITERATURE REVIEW.....................................................................................................................12
2.1 CHARACTERISTICS OF DRILLING MACHINE..............................................................................................12
2.2 IMPORTANCE OF MULTI-SPINDLE DRILL MACHINE................................................................................13
2.3 MANUFACTURING.............................................................................................................................................13
2.4 LUBRICATION.....................................................................................................................................................14
2.5 CONSTRUCTION OF DRILL MACHINE..........................................................................................................14
3 DRILL MACHINE HEAD DESIGN......................................................................................................16

3.1 STATIONARY MULTISPINDLE HEADS..........................................................................................................16
3.2 KINEMATIC SYSTEM OF MULTISPINDLE VERTICAL DRILLING MACHINE........................................16
AND THEIR PRINCIPLE OF WORKING.................................................................................................................16
3.3 CUTTING DATA..................................................................................................................................................18
3.4 DRILL MOTOR SELECTION..............................................................................................................................22
3.5 CHAIN AND SPROCKET DESIGN....................................................................................................................22
3.6 GEAR DESIGN.....................................................................................................................................................31
3.7 BEARING SELECTION.......................................................................................................................................49
3.8 HOUSING DESIGN..............................................................................................................................................53
3.9 DESIGN OF DRILL COLUMN............................................................................................................................56
3.10 DESIGN OF COLUMN SLEEVE:......................................................................................................................58
3.11 RACK AND PINION DESIGN...........................................................................................................................59
3.12 JIG AND FIXTURE............................................................................................................................................64
3.13 MANUFACTURING CONSIDERATIONS.......................................................................................................65
3.14 COST ESTIMATION FOR THE DRILL MACHINE........................................................................................67
4 CONCLUSION AND RECOMMENDATION.........................................................................................68

4.1 CONCLUTION......................................................................................................................................................68
4.2 RECOMMENDATION.........................................................................................................................................69
APPENDIX..........................................................................................................................................70
REFERENCES AND SOURCES OF INFORMATION................................................................................79
AAIT Page 1 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

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ABSTRACT
Although there are different types of drilling machine, in this thesis vertical multi-spindle drilling
machine, manually operated, electric motor driven, with rack and pinion gear system is anticipated to
solve the problem of less production and time delay in Selam Technical and Vocational Collage and
also to increase production capacity and improve efficiency of productivity of Selam Technical and
Vocational Collage. Vertical multi- spindle drilling machine is used to drill holes on a bar of metal
which is used in the crop threshing machine. Mass production of the metal bar is needed because of
mass production of crop threshing machine. In one metal bar seven holes are needed. To drill these

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seven holes by using single spindle drilling machine is not completely appropriate. Using multi-
spindle drilling machine is more productive.
In this thesis main system of the machine i.e. rack and pinion gear and sprockets are designed and
optimized carefully and also its stress analysis will be performed. Other parts like chain, spindle, and
power source of the machine (electric motor), handle, jig and fixture (work piece holding part) will be
correctly analyzed. Also this thesis is deals with selection of best motor type, appropriate chain
selection, correct bearing selection and over all assembly of machine and geometry will be worked
carefully.
CHAPTER ONE
1 INRTODUCTION
Drilling is an operation of making a circular hole by removing a volume of metal from the job by
cutting tool called drill. A drill is a rotary end-cutting tool with one or more cutting lips and usually
one or more flutes for the passage of chips and the admission of cutting fluid. A drilling machine is a
machine tool designed for drilling holes in metals. It is one of the most important and versatile
machine tools in a workshop. Besides drilling round holes, many other operations can also be

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performed on the drilling machine such as counter-boring, countersinking, reaming, honing, lapping,
sanding etc. Because of the three-dimensional nature of these operations, chip movement and its
control are important considerations. Chip removal can be a significant problem (especially in drilling
and tapping) and can lead tool breakage.
Multiple- spindle drill machines are used for mass production, a great time saver where many pieces of
jobs having many holes are to be drilled. Multi-spindle head machines are used in mechanical industry
in order to increase the productivity of machining systems. The multi-spindle drilling machines are a
production type of machine. It is used to drill seven holes in a work piece simultaneously, in one
setting. The holes are drilled on number of work pieces with the same accuracy, so as to make
interchangeable. These machines have seven spindles driven by a single motor and all the spindles are
fed in to the work piece simultaneously. Feeding motions are obtained by raising the work table. The
center distance between the drill spindles adjusted at 90mm distance during design. In mass production
work drill jigs are used for guiding the drills in the work piece so as to achieve accurate results.
In today’s market the customer demands the product of right quality, right quantity, right cost, and at
right time. Therefore it is necessary to improve productivity as well as quality. One way to achieve this
is by using multi-spindle drilling head.
1.1 BACKGROUND OF THE PROBLEM
The current experiences of most local manufacturing industries have considerable problems in
connection with their product quality, delivery time and price. And this is due to high production cost,
high design and lead time, in efficiency in resource utilization, lack of efficient production planning
and scheduling, material handling problem, and etc. Moreover most of the local manufacturing
industries use the traditional job shop layout, where similar machines and labor with similar skills are
located together. The process or functional layout results in law machine utilization and high wastage
of time. The high cost of set-ups for small batches results in high manufacturing costs.

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However, in the existing current production system, small to medium batch production, which
generates a great deal of industrial output, has become dominant manufacturing activity in the world.
This domination comes into being for cop up with the various processing changes; low price short
delivery time, high quality level, minimum raw material price, etc. one and the best method to cope up
with the above changes in small to medium batch production is the use of appropriate production
process and machine equipment . From manufacturing point of view, this drill machine attempts to
decrease production cost by reducing production time and other tangible and intangible costs.
Thus to realize these advantage for the local industries, drilling machine is chosen as a research topics.
And Selam Technical and Vocational Collage is taken as a case since it is one of the early established
manufacturing factories, which is in great difficulty to coup up with the existing completion due to its
high production cost; delay delivery, low product quality level, etc. In this company we saw that
drilling many holes on the metal bars process takes place by using vertical single spindle drilling
machine. This single spindle machine drills one hole at one cycle and the needed holes on one bar of
metal are seven. To drill seven holes the operator cycles seven times the spindle this takes a lot of
production time. Also when mass production of metal bar is needed it takes much more production
time. Also there is no hole center distance accuracy between because of the holes are not drilled at the
same time. This reduces the company’s productivity and efficiency.
In this thesis we want to improve this process or solve this problem by designing vertical multi-spindle
drilling machine. Vertical multi-spindle drilling machine have seven spindles that arranged
horizontally in line and rotate at their position and the work piece holding table moves up and down by
using handle manually in order to fulfill drilling process. The multi-spindle drilling machine is used to
drill a number of holes in a job simultaneously and to produce the same pattern of holes in a number of
identical pieces in a mass production work. This machine has seven spindles and all the spindles
holding drills are fed into the work simultaneously. Therefore, the implication of drilling machine will
bring considerable changes to the stated problems of the factory.

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1.2. STATEMENT OF THE PROBLEM
The problem which this thesis is focus is found from company called Selam technical and vocational
collage (Selam children’s village) which is technical school and a place where income generating
activities are performed. In this company we saw that drilling many holes on the metal bars process
takes place by using vertical single spindle drilling machine. This single spindle machine drills one
hole at one cycle and the needed holes on one bar of metal are seven. To drill seven holes the operator
cycles seven times the spindle this takes a lot of production time. Also when mass production of metal
bar is needed it takes much more production time. This reduces the company’s productivity and
efficiency. In this thesis we want to improve this process or solve this problem by designing vertical
multi-spindle drilling machine. Vertical multi-spindle drilling machine have seven spindles that
arranged horizontally in line which are connected or welded each other so that they come down at the
same time and drills seven holes and return back by rack and pinion mechanism using handle
manually.

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1.3 OBJECTIVE OF THESIS
This thesis addresses the problem encountered by rice mill machine manufacturing industries with
respect to the productivity, effective use of time and quality by analyzing drill machine in drilling of
hole on the bar. By the end of this research the Selam vocational and technical college will have well
designed multi-spindle drill machine in cost effective, simple and manageable way.
General Objective
The main objective of this thesis is to improve vertical single spindle drilling machine in to vertical
multi-spindle drilling machine and perform the design aspect of the major parts of the machine.
Specific objectives are:
Specific objective of the thesis are:-
 To change single spindle drilling machine to multi-spindle drilling machine.
 To design drill machine that drills a number of holes in a job simultaneously and to
reproduce the same pattern of holes in a number of identical pieces in a mass production
work.
 To perform the design of different parts of the machine.
 To find the required power and to select an electric motor that matches the power needed.
 To perform stress analysis of the rack and pinion gear as well as the shaft.
 To design sprockets and select chain.
 To construct parts as well as assembly of the machine.
 Reducing the production time and to improve the manpower usage.
 To reduce the work fatigue of the operators.

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1.4. RESAERCH METHODOLOGIES AND DATA COLLECTION
Once the problem is identified and the proposed solution methodology hypothesized, the next logical
step would be to identfy research methodology, collect appropraite data, analyze it, develop a working
model, and provide a solution proposal. to do this the step is to define the research methods and collect
appropriate data, which address the problem. so the research followed the following steps: Literature
survey, Data collection and design.
1.4.1. Literature Review
To asses the advantage, design principles, and working procedure of multi-spindle drill machine, the
researcher surveyed literature from books, previous research works, policy and guidelines, consultant
firms, machinery suppliers, and World Wide Web. for this materials from Addis Ababa Institute of
Technology Library, Selam Technical and Vocational collage Libriary, Trade and Industry Library
and others.
Generally the following literature was compiled:
 Defination and classification of multi-spindle drill machine
 Introduction to multi-spindle drill machine and types of operation
 Finding of all the component of machine and their function.
 Present methods that most company used to drill multi-holes.
 Desing procedure and others

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1.4.2. Data Collection
The methods to be employed to achieve the objective of the thesis are divided into different parts:
As it is already described in the above sections this thesis is about design of vertical multi-spindle
drilling machine. In this thesis to accomplish the proposed ideas the first steps is searching of different
drilling machines to identify parts and the working principle of various drilling machines. After
exploring this data the next step is collecting diverse data concerning parts of the machine and design
procedure of those parts. This process of data collection will be accomplished by:-
 Information gathering from different machine and machine parts manufacturing company and
research centers.
 Information from different literature on this area.
 Information from internet
Mechanical Design of Components
Here different parts of the machine will be designed, optimization of parameters of the components
performed. Specially gear system and sprockets are carefully designed and tested because of main part
of the system. In this section design of the following parts will be done:-
A. Design of gear system, i.e. rack and pinion gear.
B. Design of sprockets
C. Selection of appropriate bearing, chain, and power source (electric motor).
D. Housing
E. Dimension of each parts and overall.
F. Material selection.

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Power supply unit
The other parts of this thesis is selection of an appropriate electric motor type, specifying power and
torque for proper and safe operation, since it is the power source of the machine.
Stress Analysis
After completing the material selection for the components, stress analysis will be performed.
Construction and assembly
Finally construction of different parts of the machine and the assembly will be done using Sold Work
or Catia V5 software.
1.4.3. Design
In this modern age of industrial compitition, a succesfull desingner needs more knowlegde and
understanding of fundamental sience and related engineering subjects.
A multi-spindle drill machine project moves to completion through a series of stages such
as :Inspection, preliminary evaluation of the economics and market, development of data neecessary
forfinal desing, economic evaluation, detailed engineering design and implementation.
Design is a creative activity, and as such can an engineering undertake one of the most rewardingand
satisfaying activities.It is the synthesis, the putting together, of ideas to achieve dessired purpose. The
designer with specific objective in mind, a need, and by developing and evaluating possible designs,
arrives ant what he considers the best way of achieving that objective.
1.5 THE EXPECTED OUTCOME AND BENEFICIARIES OF THE THESIS
The multi-spindle vertical drill machine designed in this thesis would result in:
1. increasing the productivity of the company

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2. time saving
3. precision of center distance between each holes
4. good finishing and accuracy of holes
5. mass production is very easy
At the end of this work, the following manufacturing industries and other bodies are beneficiaris:
 Selam Technical and Vocational Collage
 Akaki
 Engineering Coorporation
 AAIT Technology Workshop
1.6 SCOPE AND LIMITATION OF THE STUDY
The scope of this thesis is desighning of multi-spindle vertical drill machine for drilling seven holes
simoultaniously.
Specifically, full desing was done for drilling bar used in rice mill machine assembly manufactured at
Selam Technical And Vocational Collage .
Specification of drill machine is done with its detail drawing using AutoCAD 2007.
The economic analysis, cost analysis and design of machine was clearly set out.
During conducting this thesis the following constraints made difficulty for the researcher:
I. high financial constraint to asses all manufacturing industries in the countries and recommend
ways designing multi-holes drill machines.
II. slow cooperation of some visited industries to give information, which are important to desing
multi-spindle drill machine.

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CHAPTER TWO
2 LITERATURE REVIEW
A drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other
materials. Drilling machines use a drilling tool that has cutting edges at its point. This cutting tool is
held in the drill press by a chuck or Morse taper and is rotated and fed into the work at variable speeds.
Drilling machines may be used to perform other operations. They can perform countersinking, boring,
counter boring, spot facing, reaming, and tapping. Drill press operators must know how to set up the
work, set speed and feed, and provide for coolant to get an acceptable finished product. The size or
capacity of the drilling machine is usually determined by the largest piece of stock that can be center-
drilled. For instance, 15-inch drilling machines can center-drill a 30-inch-diameter piece of stock.
Other ways to determine the size of the drill press are by the largest hole that can be drilled, the
distance between the spindle and column, and the vertical distance between the worktable and spindle.
2.1 CHARACTERISTICS OF DRILLING MACHINE
All drilling machines have the following construction characteristics: a spindle, Sleeve or quill,
Column, head, worktable, and base.
 The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve. In most
drilling machines, the spindle is vertical and the work is supported on a horizontal table.
 The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel
to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting tool
is fed into the work: and when it is moved upward, the cutting tool is withdrawn from the
work.

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 Feed pressure applied to the sleeve by hand or power causes the revolving drill to cut its way
into the work a few thousandths of an inch per revolution
 The worktable is supported on an arm mounted to the column. The worktable can be adjusted
vertically to accommodate different heights of work. or it may be swung completely out of the
way. It may be tilted up to 90 in either direction, to allow for long pieces to be end or angled
drilled.
 The base of the drilling machine supports the entire machine and when bolted to the floor
provides for vibration-free operation and best machining accuracy. The top of the base is
similar to a worktable and maybe equipped with T-slots for mounting work too large for the
table.
2.2 IMPORTANCE OF MULTI-SPINDLE DRILL MACHINE
 By using multi-spindle drilling head productivity will increase. Because with the present
process one hole produces at a time requires 4 minutes for each component (because tool
change takes place for drilling 5mm hole (for M6x1 tap)). i.e. 12-15 parts are produced during
one hour, but by using multi-spindle drilling head cycle time approximately takes place 1
minutes. i.e. 55-60 parts may produce during one hour.
 Possibility of hole missing is eliminated, because six holes drilled at a time.
 The cost per piece is reduced. As seen in conclusion no.1 the production rate is approximately
double by using multi-spindle drilling head. The machine used for multi-spindle drilling head
is same (Radial drilling machine) which present uses to produce the part, so machine hour rate
remains unchanged.
2.3 MANUFACTURING
The Multi-spindle drilling head requires various components, the major components are gear box,
drilling spindle, gear shafts, main spindle gear, drive gears, idler gears etc. It requires various
machines to manufacture them like band saw machine for cutting operation, lathe machine for rough

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machining, drilling machine, surface grinding machine, cylindrical grinding machine, internal grinding
machine, slotting machine, milling machine, hobbling machine etc.
2.4 LUBRICATION
Lubrication is important because of the heat and friction generated by the moving parts. Follow the
manufacturers manual for proper lubrication methods. Clean each machine after use. Also remove
chips to avoid damage to moving parts. Wipe all spindles and sleeves free of grit to avoid damaging
the precision fit. Put a light coat of oil on all unpainted surfaces to prevent rust. Operate all machines
with care to avoid overworking the electric motor.
2.5 CONSTRUCTION OF DRILL MACHINE
In drilling machine the drill is rotated and fed along its axis of rotation in the stationary workpiece.
Different parts of a drilling machine are discussed below:
1) The head containing electric motor, sprocket and chain which transmit rotary motion to the drill
spindle at a number of speeds.
2) Spindle is made up of alloy steel. It rotates as well as moves up and down in a sleeve. A pinion
engages a rack fixed on the sleeve to provide vertical up and down motion of the spindle and
hence the drill so that the same can be fed in to the work piece or withdrawn from it while
drilling.
3) Drill chuck is held at the end of the drill spindle and in turn it holds the drill bit.
4) Adjustable work piece table is supported on the column of the drilling machine. It can be moved
vertically up and down. Tables are generally having slots so that the jig and fixture can be
securely held on it.
5) Base table is a heavy welding and it supports the drill press stricture. The base supports the
column, which in turn, supports the table, head etc.

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6) The column is a vertical round or box section which rests on the base and supports the head and
the table. The round column may have rack teeth cut on it so that the table can be raised or
lowered depending upon the work piece requirements.
Fig 1.1 construction of drill machine

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CHAPTER THREE
3 DRILL MACHINE HEAD DESIGN
3.1 STATIONARY MULTISPINDLE HEADS
It ensures efficient large scale production on production lines and special machines. Several spindles
per head ensure simultaneous processing of several drillings in one working cycle. Thus, machining
times are shortened and production yield is increased.
Transmission of power from a source, electric motor, through a machine to the drill is the major task
of this section. An efficient means of transmitting power is through rotary motion of a shaft that is
supported by bearings. Gears, chain sprockets are incorporated to provide for torque and speed
changes between shafts. Most shafts are cylindrical (solid and hollow), and include stepped diameters
with shoulders to accommodate the positioning and support of bearings, gears, etc. The design of a
system to transmit power requires attention to the design and selection of individual components
(gears, bearings, shaft, etc.).
3.2 KINEMATIC SYSTEM OF MULTISPINDLE VERTICAL DRILLING MACHINE
AND THEIR PRINCIPLE OF WORKING
Kinematic system in any machine tool is comprised of chain(s) of several mechanisms and gears to
enable transform and transmit motion(s) from the power source(s) to the cutting tool and the
workpiece for the desired machining action. The kinematic structure varies from machine tool to
machine tool requiring different type and number of tool-work motions. Even for the same type of
machine tool the designer may take different kinematic structure depending upon productivity, process
capability, durability, compactness, overall cost etc. targeted.

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The kinematic system enables the drilling machine the following essential works;
Cutting motion: The cutting motion in drilling machines is attained by rotating the drill at different
speeds (r.p.m.). Like center lathes, milling machines etc., drilling machines also need to have a
reasonably large number of spindle speeds to cover the useful ranges of work material, tool material,
drill diameter, machining and machine tool conditions. But, our machine has four spindle speeds
because it uses for single application only (8mm carbon steel plate).
Feed motion: In drilling machines, generally both the cutting motion and feed motion are imparted to
the drill. Like cutting velocity or speed, the feed (rate) also needs varying (within a range) depending
upon the tool-work materials and other conditions and requirements. This is not the case for our
machine the feed motion is by using the movement of the work table rather imparting it into the drill.
This is because of the kinematics difficulty to move the seven spindles together. The feed rate can be
varied manually by giving either slow or quicker motion to the work table by the working operator.
Tool work mounting: The taper shank drills are fitted into the taper hole of the spindle through taper
socket(s). Small straight shank drills are fitted through a drill chuck having taper shank. The
workpiece is kept rigidly fixed on the bed (of the table). Small jobs are generally held in vice and large
or odd shaped jobs are directly mounted on the bed by clamping tools using the T-slots made in the top
and side surfaces of the bed.
Design Sequence for Power Transmission
STEP1. Power and torque requirements: Power considerations should be addressed first, as this will
determine the overall sizing needs for the entire system. Any necessary speed or torque ratio from
input to output must be determined before addressing gear/pulley sizing.
Given datas
Workpiece material having Brinell hardnessn o , BHN =200, Hole diameter,d=12mm , center distance
of the holes, C=90 mm , number of holes 7, thickness of the plate, t=8 mm.

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3.3 CUTTING DATA
1. The cutting speed or surface speed (vc): the cutting speed for drilling is determined by the periphery
speed and can be calculated from the spindle speed (N). There are four spindle speeds for our drill
head and therefore four possible cutting speeds are calculated below.
( π x d ) N ( π x 0.012 ) 300 ( π x d ) N ( π x 0.012 ) 400

V c ,1= = , V c ,2= =
12 12 12 12
¿ 0.943 m/s=1.26 m/ s
( π x d ) N ( π x 0.012 ) 500 ( π x d ) N ( π x 0.012 ) 600

V c ,3= = ,V c , 4= =
12 12 12 12
¿ 1.57 m/s ¿ 1.885 m/s
Where d isthe tool diameter∧N is spind≤speed .
NOTE THAT: The optimum drill speed for a particular setup is affected by many factors, including
the following: Composition, hardness & thermal conductivity (k) of material , Depth of hole ,
Efficiency of cutting fluid , Type, condition and stiffness of drilling machine , Stiffness of, workpiece,
fixture and tooling (shorter is better) , Quality of holes desired , life of tool before regrind or
replacement.
2. The feed per revolution (ƒn): in mm/rev expresses the axial movement of the tool during one
revolution. The recommended feed for steel is 0.3 mm/rev.
3. The penetration rate or feed speed (vf): in mm/min is the feed of the tool in relation to the workpiece
expressed in length per unit of time. This is also known as the machine feed or table feed. The product
of feed per revolution and spindle speed gives the rate at which the drill penetrates the workpiece.
Vf,1 = ƒn× N = 0.3 mm/rev× 300 rev/min = 90 mm/min (1.5 mm/s),
Vf,2 = ƒn× N = 0.3 mm/rev× 400 rev/min = 120 mm/min (2 mm/s),
Vf,3 = ƒn× N = 0.3 mm/rev× 500 rev/min = 150 mm/min (2.5 mm/s) and
Vf,4 = ƒn× N=0.3 mm/rev× 600 rev/min= 180 mm/min (3 mm/s)

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4. Material removal rate (Q): The material removal rate in drilling is the volume of material removed
by the drill per unit time.
2
ᴨ d2 ᴨ(12 ) mm3
Q 1= × f × N= ×0.3 × 600=20357.52 mm3 /min ⁡( 339.3 )
4 4 s
ᴨd
2
ᴨ(122 ) mm
3
Q 2= × f × N= ×0.3 × 500=16964.6 mm3 /min ⁡(282.75 )
4 4 s
ᴨd
2
ᴨ(122) 3 mm
3
Q 3= × f × N= × 0.3× 400=13571.68 mm /min ⁡(226.2 )
4 4 s
2 2 3
ᴨd ᴨ(12 ) mm
Q 4= × f × N= ×0.3 × 300=10178.76 mm3 /min ⁡(169.6 )
4 4 s
5. Torque (m) in Nm is regard as the total drilling moment that the drill is subjected to during
machining. The feed, diameter and material are the main factors that affect the torque value. The
equation for torque of a drill of regular proportions whose c /d may be set equal to 0.18,
M =41.7 ×106 f n 0.8 d1.9 =41.7 × 106 0.00030.8 0.0121.9=14.2 Nm for steel .
Where c−chisel edge length, f n−feed per rev .
6. The feed force (ff): in N is usually the most important in drilling from a performance point of view.
This is the axial force acting on the drill as it penetrates the material. It needs to be considered in order
to ensure that the spindle power and strength is sufficient for the drilling operation.
The feed force is equal to the axial thrust force created during drilling application.
7. Estimating drilling thrust:
T =0.05 K d F f F t BW +0 .007 K d d 2 JW =0.05 ×24000 × 0.382×7.297 × 1.355× 1.3+0.007 ×24000 × 0.0122 ×
Where: T =axial thrust , F f =feed factor ( 0.382 ) , F T =thrust factor (7.297)
B=chiesel edge factor for thrust ( 1.355 ) , J =chiesel edge factor for thrust (0.030)
W =tool wear factor ( 1.3 ) , D=drill diameter

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The feed factor for drilling at feed of 0.3 is therefore 0.382 (table A-4)
The drill diameter factors at diameter of 12mm are determined by iteration (data from table A-5)
( 7.54 – 6.81 ) ( 12 – 11 )
FT= =7.297∧¿
12.5 – 11
( 94.28 – 74.9 )( 12 – 11 )
F M= =12.92
12.5 – 11
At c /d=0.18 the factors become A = 1.155, B = 1.355, J = 0.030 (table A-6)
The tool wear factor for normal drilling operation is therefore 1.3 (table A-3)
The work material factor for steel having Brinell hardness number is therefore 24,000 (table A-7)
8. Estimating machining power: Knowledge of the power required to perform machining operations is
useful when planning new machining operations, for optimizing existing machining operations, and to
develop specifications for new machine tools that are to be acquired.
The power required to cut a material is dependent upon the rate at which the material being cut and
upon an experimentally determined power constant (unit power or specific power consumption), Kp.
The power constant is the power required to cut a unit of material removal rate. The unit of power
constant is Kw/ (cm3/s) for metric unit; which is tabulated for different material see appendix A.
The power constant for steel material having Brinell hardness number (BHN) 200 is therefore 2.32
from table A-1.
The effect of rake angle usually can be disregarded. The rake angle for which most of the data in the
power constant tables are given is positive 14 degrees.
The machine tool transmits the power from the driving motor to the workpiece, where it is used to cut
the material. The effectiveness of the transmission is measured by the machine tool efficiency factor,
E. take the factor 0.9 for chain drive and gear mechanism for our assumption.

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Pc=KpCQW
Pc KpCQW
Pm= =
E E
Where : Pc= power at the cutting tool∈KW , P m= power at themotor ∈ KW
Kp= power constant ,Q=material removal rate ,
C=feed factor for power constant , W =tool wear factor ,
E=machine tool efficiency , V =cutting speed
0.30 mm
N=spindle speed ∈rpm, f =feed ra te for turning ,d =depth of cutC=1 for feed of , W =1.3 , E=0
rev
Pc=KpCQW =2.32 ×0.3393 ×1.3=1.0233 KW (for single spindle)
For seven spindles ; P c , 7=7 ×1.0233=7.16 KW
Pc 7.16
Power at themotor ; Pm= = =7.96 KW ≅ 8 KW =10.7 hp ≅ 11hp
E 0.9
The feed factor for power constant at feed of 0.3mm is therefore 1.00 (from table A-2)
Whenever possible the maximum power available on a machine tool should is used when heavy cuts
must be taken. Summarizing the values yet calculated:
60 P 60 ×8
P=8 KW , V . Rmin=2.333∧, V . Rmax=4.67 , T 1= = =254.65 N . m ( spindle torque ) max
2 2 ×300
60 P 60× 8
T 2= = =191 N . m ,
2 2 × 400
60 P 60× 8
T 3= = =152.8 N . m
2 2 × 500
60 P 60× 8
T 4= = =127.3 N .m(spindle torque)minimum
2 2× 600

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3.4 DRILL MOTOR SELECTION
The drilling operation can be very complex and require detailed planning for any type of application.
Several factors must be considered when selecting the motor for a drilling application. These include
hole size, drill bit type, Required bit speed and torque.
Specification of the motor: power=8 KW , Speed :1440 rpm , 3− phase electric motor
STEP TWO: Gear and sprocket specification. Necessary gear ratios and torque transmission issues can
now be addressed with selection of appropriate gears and sprocket.
3.5 CHAIN AND SPROCKET DESIGN
Fig 3.1 Pictures of components of chain
The chains are mostly used to transmit motion and power from one shaft to another, when the
centre distance between their shafts is short such as in bicycles, motor cycles, agricultural
machinery, conveyors, rolling mills, road rollers etc.
The chains may also be used for long center distance of up to 8 meters. The chains are used for
velocities up to 25 m/s and for power up to 110kw. In some cases, higher power transmission is
also possible.

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Fig.3.2 Sprockets and chains
ADVANTAGES OF CHAIN
 As no slip takes place during chain drive, hence perfect velocity ratio is obtained.
 Since the chins are made of metal, therefore they occupy less space in width than a belt or
rope drive.
 It may used for both long as well as short distances.
 It gives high transmission efficiency (up to 98%).
 It gives fewer loads on the shafts.
 It has the ability to transmit motion to several shafts by one chain only.
 It transmits more power than belts.
 It can be operated under adverse temperature and atmospheric conditions.
 It permits high speed ratio of 8 to 10 in one step.
DISADVANTAGES
 The production cost of chains is relatively high.
 The chain drive needs accurate mounting and careful maintenance, particularly lubrication
and slack adjustment.
 The chain drive has velocity fluctuations especially when unduly (excessively) stretched.
SELECTION OF THE TYPE OF CHAIN: BUSH ROLLER CHAIN.

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POWER TRANSMITTING CHAINS
These chains are used for transmission of power, when the distance between the centers of shaft is
short. These chains have provision for efficient lubrication. The power transmitting chains are of the
following three types.
1. Block or bush chain. These types of chain were used in the early stages of development in the
power transmission. It produces noise when approaching or leaving the teeth of the sprocket because
of rubbing between the teeth and the links.
2. Bush roller chain. A bush roller chain as shown in Fig. 21.7 consists of outer plates or pin link
plates, inner plates or roller link plates, pins, bushes and rollers. A pin passes through the bush which
is secured in the holes of the roller between the two sides of the chain. The rollers are free to rotate on
the bush which protects the sprocket wheel teeth against wear. The pins, bushes and rollers are made
of alloy steel.
Fig 3.3 Bush roller chain
A bush roller chain is extremely strong and simple in construction. It gives good service under severe
conditions. There is a little noise with this chain which is due to impact of the rollers on the sprocket
wheel teeth. This chain may be used where there is a little lubrication.
The roller chains are standardized and manufactured on the basis of pitch. These chains are available
in single-row or multi-row roller chains such as simple, duplex or triplex strands, as shown in Fig3.5.

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Fig 3.4 types of roller chain
3. Silent chain. A silent chain (also known as inverted tooth chain)
CHAIN DESIGN
We have one chain and 12 sprockets, and 7 gears for our mechanism; one chain for reduction of speed
and the gears for transmitting motion from the main spindle to the rest of each spindle. Four integrated
sprockets on the motor shaft, four integrated sprockets are on the top of the main spindle and on the
idler shaft and the gears on each spindle. This mechanism is easily understood by looking the drawing.
We are used gear system instead of either belt or chain mechanism because with the belt we can’t
transmit motion from the main spindle to each spindle as we need and to use the chain it is impossible
since the center distance specified is very short.
IDLER SPROCKETS: when the drive and the driven sprocket centers are fixed it may be desirable
to include idlers sprocket to take up slack in the chain. Idler sprockets should preferably be located
against the slack side of the chain with in the chain envelope-diverting the chain outwards.
1 speed reduction chain: the motor speed must be reduced at the drill to power the drilling operation
since motors have low torque. This can be accomplished by reducing the speed of the motor and
increasing the torque by using the speed reducing chain in the motion transmitting mechanism.

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Design Procedure of Chain Drive
Step 1: Determine the velocity ratio
Velocity ratio of chain drives
The velocity ratio of a chain drive is given by;
N1 T2
V . R= =
N2 T1
N 1=speed of rotation of smaller sprocket( motor sprocket )∈rpm
N 2=speed of rotation of larger sprocket∈rpm
T 1=number of teeth on the smaller sprocket ,∧¿
T 2=number of teeth on the larger sprocket .
We have four spindle speeds and therefore four VR are there.
The motor speed , N motor=1400 rpm , M inimum Spindle speed , Nmin=300 rpm , N 2=400 rpm , N 3=500 rpm
Maximum Spindle speed , Nmax=600rpm
1400 1400 1400

V . R 1= =4.667 say 5 , V . R 2= =3.5 , V . R 3= =2.8∧¿
300 400 500
V . R 4=1400/ 600=2.33 say 3
Step 2: Minimum no of teeth on the smaller sprocket
From Table A-9, we find that for the roller chain, the number of teeth on the smaller sprocket or pinion
(T1) for a velocity ratio of 5 and 3 is 21 and 25 respectively. Therefore, the minimum no. of teeth on
the motor sprocket becomes 25 teeth.
Step 3: No of teeth on the larger sprocket
The Number of teeth on the larger sprockets is therefore,

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T 2=T 1× 4.667=25 × 4.667=117 ,T 2 '=T 1 ×3.5=25× 3.5=88 , T 2 ' '=T 1 ×2.8=25× 2.8=70
T 2 ' ' ' =T 1 ’×2.333=25 ×2.333=59
Step 4: Design power
Design power = Rated power×Service factor
The service factor (KS) is the product of various factors, such as load factor (K1), lubrication factor (K2)
and rating factor (K3). The values of these factors are taken as follows:
Load factor = 1, for continuous load, Lubrication factor =1.5, for periodic lubrication
Rating factor = 1.5, for continuous service
Ks = 1× 1.5×1.5 = 2.25
Design power = rated power×service factor = 8×2.25 =18 KW
Step 5: No of strand of the chain
From Table A-12, we find that corresponding to a pinion speed of 1400 r.p.m. the power transmitted
for chain No. 12 is 18.15 kW per strand. Therefore, a chain No. 12 with single strand can be used to
transmit the required power (18KW).
Step 6: The chxcs of the roller chain
From Table A-11, we find that Pitch, p = 19.05 mm, roller diameter, d1 = 12.07mm (max), the width
of plates, b1 = 11.68mm (max), breaking load = 28.9KN for 12B ISO chain number.
Step 7: Pitch circle diameter and Pitch line velocity
The pitch circle diameter of the smaller sprocket, D1 = p csc ( 180

T1 ) =19.05csc (
25 )
180
=¿152mm

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Larger sprocket, D2 = p csc ( 180

T2 ) =19.05csc (
117 )
180
=¿709.5mm
D2’ = p csc ( T1802 ' )=19.05csc ( 180

88 )
=¿546.4mm
D2’’ = p csc ( T1802 ' ' )=19.05csc ( 180

70 )
=¿424.6mm
D2’’’ = p csc ( T1802 ' )=19.05csc ( 180

59 )
=¿357.9mm
Idler sprocket, Di = p csc ( 180

T2 ) =19.05csc (
21 )
180
=¿127.5
mm
152∗1400 m
Pitchline velocity of the smaller sprocket , V 1=D 1 N 1/60= =11.14
60 s
˚
Where D=pitch diameter of the sprocket ∧¿
P= pitch of the chain∈meters .
Step 8: Load on the chain becomes:
W =(rated power )/( pitchline velocity)=18 /11.14=1.615 KN
Step 9: Factor of safety
The following table shows the factor of safety for the bush roller and silent chains depending upon the
speed of the sprocket pinion in r.p.m. and pitch of the chains.
the load where the chaincan transmitt

Factor of safety =
load onthe chain
= WB/W = 28.9 / 1.615

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= 18¿ 13.2 ¿ 11.7is more safe ‼ (referring table A-10)
Step 10: Center distance
The centre distance is given by;
[ √( ) ( )]
2 2
p T 1+ T 2 T 1+T 2 T 1−T 2
x= K − + K− −8
4 2 2 2
The minimum centre distance between the smaller and larger sprockets should be 30 to 50 times the
pitch. Let us take it as 30 times the pitch.
∴ Centre distance between the sprockets, = 30 p = 30 × 19.05 = 572 mm, In order to accommodate
initial sag in the chain, the value of centre distance is reduced by 2 to 5 mm.
∴ Correct centre distance, x = 572 – 2 = 570 mm
The number of chain links may be obtained from the following expression, i.e.
[ ] [ ]
2 2
(T 1+T 2)max 2 x T 1−T 2 p 25+117 2∗570 25−117 19.05
K= + + = + + =138max
2 p 2 x 2 19.05 2 570
Step 11: The length of the chain
An open chain drive system connecting the two sprockets is shown in Fig. 3.4
The length of the chain (L) must be equal to the product of the number of chain links (K) and the pitch
of the chain (p). Mathematically, L = Kp
∴ Length of the chain, L = K.p = 138 × 19.05 = 2629 mm = 2.629 m
Angular contact of the chain on the sprockets:
First gear: The motor sprocket (25 teeth) directly connected to the spindle sprocket (having 117 teeth)
1=180 °−2sin −1 {T 2−T

2C
1
}=¿ 180°−2 sin {
2×570 }
117−25
−1
=¿ 170.8 °> 120° ¿ ¿
2=180 °+2 sin −1 {T 2−T

2C
1
}=180 °+2 sin {
2× 570 }
117−25
−1
=189.3 °>120 °

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Second gear: The motor sprocket (25 teeth) drives the spindle sprocket (88 teeth) through the idler
sprocket to tension the chain slack, look at the diagram.
2 1=180 °−2 sin

−1
{T 2−T
2C
1
}=¿ 180 °−2 sin {
2 ×570 }
88−25
−1
=¿ 173.7 ° ¿ ¿
2 2=180 ° +2 sin−1 { T 2−T

2C
1
}=180 ° +2sin {
2× 570 }
88−25
−1
=186.3 °
Let the no of teeth of the idler sprocket be 21 for second gear.
0.5 C 0.5 ×570

C 1=C 2= = =329 mm
cos 30 cos 30
The number of chain links shared between the motor and the spindle sprocket is:
{ [ ] } [ ]
2 2
(T 2 '+T 1) 2 C T 2−Ti p 88+21 2∗570 88−25 19.05
K 2=0.5 + + = + + =61
2 p 2 C 2 19.05 2 570
The length of chain shared between the motor sprocket and spindle sprocket is:
L 3=K 3. p=61 ×19.05=1162.7 mm=1.16 m
The length of chain shared between the motor, idler, and spindle sprocket is therefore:
'
d2 ' d 1 ' di
L=2629−1163=1466= 2 +b 1+b 2+ 1 + (+ ')
2 2 2
{ }
'
d2 ' d 1 ' di
b 1=L− 2 + b2+ 1 + (+')
2 2 2

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Let( +❑' )=120 ° , b 2=c 2 sin 37=329sin 37=198 mm ,
{ } { }
'
d2 ' d 1 ' di 546.4 152 127.5
b 1=L− 2 + b2+ 1 + (+') =1466− (0.25)+198+ (0.36)+ ( 0.67) =575.4 mm
2 2 2 2 2 2
575.4
b 1=c 1 sin❑=329 sin❑ ,=sin −1
329
PRINCIPAL DIMENSIONS OF TOOTH PROFILE
The standard profiles for the teeth of a sprocket are shown in Fig. 3.7. According to Indian Standards
(IS: 2403 – 1991), the principal dimensions of the tooth profile are as follows:
Top diameter (Da)
Da = D + 1.25p – d1……………..maximum
= 152 + 1.25×19.05 – 12.07 = 163.74 mm (motor sprocket)
= 709.5 + 1.25×19.05 – 12.07 = 721.24 mm (spindle larger sprocket)
Root diameter (Df); Df = D -2 ri
For motor sprocket;
Df = 152 - 2 ×7.67 = 136.66 mm ………….max
For spindle sprockets;
Df = 709.5 - 2 ×7.67 = 694.16 mm ………….max
Tooth width (bf1); bf1 = 0.93b1 when p≤ 12.7 mm
= 0.95b1 when p¿ 12.7 mm where b1 is the width of plates, which is 11.68mm.
For pitch of 19.05mm the tooth width becomes, bf1 = 0.95b1= 0.95×11.68=11.09 mm
Summary on sprocket and chain
Sprocket specification: main spindle sprocket pitch diameter, D2 = 709.5mm
Motor sprocket pitch diameter, D1 = 152mm
Main spindle sprocket outer diameter, Do = 721.24m
Motor sprocket outer diameter, Da = 163.74mm
Tangential force created on the sprocket, Fs = P/V = 8/11.14 = 0.718 KN

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Tangential component of force on the shaft:
189.3−180
Fs , T =0.718 ×cos ∅=0.718 ×cos ( )=0.715 KN
2
Radial component of force on the shaft:
189.3−180
Fs , R=0.718 × sin ∅=0.718 ×sin( )=0.0582 KN
2
Where ∅− Angule of contact of the chain on the sprocket
3.6 GEAR DESIGN
Advantages and Disadvantages of Gear Drives
The following are the advantages and disadvantages of the gear drive as compared to other drives, i.e.
belt, rope and chain drives:
Advantages
1. It transmits exact velocity ratio.
2. It may be used to transmit large power.
3. It may be used for small center distances of shafts.
4. It has high efficiency.
5. It has reliable service.
6. It has compact layout.
Disadvantages
1. Since the manufacture of gears requires special tools and equipment, therefore it is costlier than
other drives.
2. The error in cutting teeth may cause vibrations and noise during operation.
3. It requires suitable lubricant and reliable method of applying it, for the proper operation of gear
drives.

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Advantages of using parallel Helical Gears
1. Helical gears, used to transmit motion between parallel shafts.
2. The gradual engagement of the teeth and the smooth transfer of load from one tooth to
another that give helical gears the ability to transmit heavy loads at high speeds.
3. Helical gears can be used for the same applications as spur gears and, when so used, are not
as noisy, because of the more gradual engagement of the teeth during meshing.
4. Helical gears subject the shaft bearings to both radial and thrust loads. When the thrust
loads become high or are objectionable for other reasons, it may be desirable to use double
helical gears.
Design the seven helical gears: The power transmitted by the gears, P = 8KW and the speed of the
gears, N = 600,500, 400 and 300rpm.
Proportions for Helical Gears
Though the proportions for helical gears are not standardized, yet the following are recommended by
American Gear Manufacturer's Association (AGMA). Let module, m=4.5 mm/tooth
Pressure angle (in the plane of rotation),  = 150 to 250, let  = 200
Helix angle,  = 200 to 450, let  = 250
Addendum, a = 1m (maximum), let a = 1m =4.5
Dedendum, d = 1.25m (minimum), let d = 1.25m = 5.625 mm
Total depth, h = 2.25 m = 2.25 ×4.5 = 10.125mm
Clearance, c = 0.25 m = 0.25 ×4.5 = 0.9 mm
Thickness of the tooth bt = 1.5708m = 1.5708× 4.5=7.07 mm
Circular pitch, pc= m = 4.5 = 14.14 mm, Normal pitch, pn = pccos ❑ = 14.14 cos 25 = 12.8 mm
The Normal pressure angle, N = tan−1 ( tancos ) = tan−1 ( tan20 cos 25)=18.25 0
The minimum number of teeth on the pinion gear
The smallest tooth number TP of a helical-spur pinion that will run without interference with a gear
with the same number of teeth is,

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cos cos 25
T p=2 k 2
(1+ √1+3 sin 2)=2 ×1 2
(1+ √ 1+ 3 sin2 20)=12 teeth
3 sin 3 sin 20
The actual no of teeth on the gears
Center distance b/n the shafts, C , is 90 mm ,
( D P+ D G ) 2 D
C= = (Since the pitch diameter of the gears are equal)
2 2
C=D=90 mm
pit ch diameter ( D ) D 90 mm
Module= ,T = = =20 teeth>12teeth
n o of teeth ( T ) m mm
4.5
tooth
Face Width of Helical Gears
In order to have more than one pair of teeth in contact, the tooth displacement (i.e. the advancement of
one end of tooth over the other end) or overlap should be at least equal to the axial pitch, such that
Overlap = pc= b tan () …………….equation 1
The axial or end thrust is given by WA = WN sin () = WT tan () ………. equation 2
From equation (1), we see that as the helix angle increases, then the tooth overlap increases. But at the
same time, the end thrust as given by equation (2), also increases, which is undesirable. It is usually
recommended that the overlap should be 15 percent of the circular pitch.
1.15 p c 1.15 m
Overlap=b tan()=1.15 p c ∨b= = p c=m ,
( tan() ) tan( )
1.15 m 1.15× 4.5

b= = =35 mm
tan( ) tan ( 25 )
Let b = 40 mm
Where b = minimum face width and, m = module
Force analysis

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The normal tooth load (WN) has two components; one is tangential component (WT) and the other axial
component (WA).
We know that the maximum torque transmitted by the pinion,
T =60 P/(2 N p)=60 ×8 ×1000 /(2× 300)=254.7 N−m(max)
2T 2 ×254.7
Tangential toothload onthe pinion, W T = = =5.7 KN The axial∨end thrust is given by W A=W N sin
D 0.09
The normal tooth lo ad , W N=W A /sin( )=2.66/sin( 25)=6.29 KN
The radial tooth load , W R=W T tan=¿ 2.66 tan20=0.97 KN
Formative or Equivalent Number of Teeth for Helical Gears:
T E=T /cos 3=20 /cos 3(25)=27 teeth
Where T = actual number of teeth on a helical gear
Contact ratios: 1. The transverse contact ratio is the same as that of the spur gears. It shows the
number of teeth in contact in the plane of rotation, which is defined as the length of contract divided
by the base pitch. Mathematically
2 √ ⌊(r +a) −(r cos ❑) ⌋ −C sin❑ ( √ ⌊ 2 ( 45+ 3.6 ) −2 ( 45 cos 20 ) ⌋ – 90 sin 20 )

2 2 2 2
L
m c= = = =1.28 ,
pcos pcos (14.14 cos 20)
where , p c=m=× 4.5=14.14 mm
Where Z−length of contact ,r – Pitch radius , a – addendum , C – Center distance
Axial contact ratio: The helix angle introduces another ratio called the axial contact ratio mF, which is
defined as the quetient of face width b and the axial pitch pc
b b tan 40 tan 25
m F= = = =1.319
pc m 4.5
This ratio shuld at least be 1.15 and indicates the degree of helical overlaod in the mesh.
STRENGTH ANALYSIS OF POWER TRANSMITTING HELICAL GEARS (reference shigley
textbook)
In order to find the strength of helical gears, AGMA strength equation is used.

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GEAR MATERIAL SELECTION- NITRIDED THROUGH-HARDENED STEELS: are commonly
used for gears. They have superior tensile strength to cast iron. They need heat treatment to get a
surface hardness that will resist wear.
THE BENDING STRESS IS:
W T KoKvK sK HK B
Ϭ=
( bm t Y J )
Where K o−overload factor (1.25 ) , K v −dynamic factor ( 1.277 )
K s−¿ ( 1.0 ) , K H −load distribution factor (1.1254 )
K B−rim thickn ess factor ( 1.0 ), Y J ,Geometry factor for bending strength
m t−Transverse metric module , b−Face width
W T KoKv KsK H KB 1
Therefore , Ϭ= =5.7 × 1.25× 1.277 ×1.0 ×1.1254 × =237 MPa
bmt Y J 40× 4.5 ×0.24
THE FUNDAMENTAL EQUATION FOR PITTING RESISTANCE (CONTACT STRESS)
Ϭ c=Z E
√ W T KoKv KsK H ZR
d w 1 bZ I
Where Z E−elastic coefficient ( 191 √ MPa ) , Z R−surface condition factor ( 1.0 )
d w 1− pitch diameter of the pinion,
Z I−geometry factor for pitting resi stance(0.107)
Ϭ c=Z E √(W T K o K v K s K H Z R)/(d w 1bZ I )=191 √ (5.7 ×1.25 × 1.277× 1.0 ×1.1254 ×1.0)/( 90× 40 × 0.
THE EQUATION FOR THE ALLOWABLE BENDING STRESS IS:
StY N
Ϭ all=
(S F Y ѳ Y Z )
Where , St−allow able bending stress ,Y N−the stress cycle factor
S F−the AGMA factor of safety , Yѳ−thetemperature factor ,
Y Z−thereliability facto r
THE EQUATION FOR THE CONTACT STRESS Ϭc, all IS

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Sc Z N ZW
Ϭ c , all=
(S FY ѳY Z)
Where , S c−allowable contact stress , Z N −the stress cycle factor
Z W −the hardness ratio factor for pitting resistance
Sc -allowable contact stress
For 2.5% chrome (no aluminum) Grade 3 steel, Sc = 1488.24 Mpa (from table A-8)
ZW-the hardness ratio factor for pitting resistance
Z W =1.0 since both of the gears are equal
Safety Factor SF
The ANSI/AGMA standards 2001-D04 and 2101-D04 contain a safety factor SF guarding against
bending fatigue failure and safety factor SH guarding against pitting failure.
1. Safety factor guarding against bending fatigue failure
S F=Ϭ all /Ϭ =(S t Y N /(S F Y ѳ Y Z))/Ϭ =( 437.7)/237=1.8
2. Safety factor guarding against pitting failure
S H=Ϭ c , all /Ϭ c=( S c Z N Z W /(S F Y ѳ Y Z ))/Ϭ c=(1488.24)/984.7=1.5
Summary on the gear
Gear specification: module, m=4.5mm/tooth
Pitch diameter, dgear = 90 mm, Pressure angle (tangential),, 200, Helix angle,, 250
Face width, b, 40mm, T = 254.7 N.m (max), WT = 5.7 KN, WA = 2.66 KN, WR = 0.97 KN,
T = 6 KN, axial thrust on the spindle shaft.
Gear material: through hardened medium carbon steel
STEP 3: Shaft layout. The general layout of the shaft, including axial location of sprocket, gears and
bearings must now be specified.
1. Distance b/n the sprocket and the top bearing on the main spindle, Lo = 61 mm
2. Distance b/n the gear and the top bearing on the main spindle, Lo = 61 mm
3. Distance b/n the gear and the bottom bearing, Lo = 61mm

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4. How to transmit the torque from the gears to the shaft-through key.
5. How to hold gears and bearings in place-through retaining rings.
Fig 3.5 Side sectional view of the housing
Fig 3 .6 front sectional view of the housing
STEP 4: Force analysis. Once the gear and sprocket diameters are known and the axial locations of
the sprocket, gears and bearings are known, the free-body, shear force, and bending moment diagrams
for the shafts can be produced Forces at the bearings can be determined.
FREE BODY DIAGRAM
ON THE MAIN SPINDLE:

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X-Y plane
∑ M A = 0  RB, y×122 = WR×61−¿ Fs, r× 97

0.97 × 61 – 0.0582× 97
R B , y= =0.439 KN
122
∑ FY = 0  RA, y ¿ 0.97−0.0582−0.439=0.473 KN
∑ Fx = 0  RB, x = F A−WA=6 – 2.66=3.34 KN
X-Z plane
∑ M A= 0  RB, z×122 = WT ×61−Fs , T × 97
 RB, z = (5.7 ×61−0.715 ×97 ¿ /122 = 2.282 KN
∑ FY = 0  RA, Z = WT – RB, Z−Fs , T =5.7 – 2.282−0.715=¿ 2.7 KN
Bearing forces

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Thrust ball bearing:
Axial, RB, x = 3.34 KN,
Radial, RB = √ RB, z 2 + RB, y 2 = √ 2.2822+ 0.4392 ¿ 2.324 KN
Ball bearing:
Radial, RA = √ RA , z 2 + RA , y 2 = √ 2.72 +0.4732 ¿ 2.741 KN
SHEAR FORCE AND BENDING MOMENT EQUATION
FOR 0¿ X ≤ 97 FOR97< X ≤158 FOR158< X ≤ 219
X-Y Vy ¿ 0.0582 KN Vy = 0.531 KN, Vy = −0.4439 KN ,

PLANE
Mz = 0.0582 X N .m Mz = 0.531 X−45.88 N.m Mz =104.38−0.439 X N.m
X-Z Vz = 0.715 KN, Vz = 3.415 KN N, Vz =−2.285 KN ,

PLANE
My =0.715 X My = 3.415 X −261.9 My = −2.285 X +500
ON THE OTHER SPINDLES:

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X-Y plane
0.97 × 61
∑M A = 0  RB, y×122 = WR×61 , R B , y=
122
=0.485 KN
∑ FY = 0  RA, y ¿ 0.485−0.97=−0.485 KN
∑ Fx = 0  RB, x = F A+WA=6+2.66=8.66KN
X-Z plane
∑ M A= 0  RB, z×122 = WT ×61
 RB, z = (5.7 ×61 ¿ /122= 2.85 KN

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∑ FY = 0  RA, Z = WT – RB, Z−Fs , T =2.85−5.7=−2.85 KN
Bearing forces
Axial, RB, x = 8.66 KN,
Radial, RB = √ RB, z 2 + RB, y 2 = √ 2.852 +0.485 ¿ 2.89 KN
Ball bearing:
Radial, RA = √ RA , z 2 + RA , y 2 = √ 2.852 +0.4852 ¿ 2.89 KN
SHEAR FORCE AND BENDING MOMENT EQUATION
FOR 0¿ X ≤ 61 FOR61< X ≤ 122
X-Y Vy ¿−0.485 KN , Vy = 0.485 KN,
PLANE Mz = −0.485 X N . m Mz = 0.485 X −59.17 N.m
X-Z Vz = −2.85 KN, Vz = 2.85 KN N,
PLANE My = −2.85 X N . m My = 2.85 X −347.7 N.m
STEP 5: Shaft material selection. Since fatigue design depends so heavily on the material choice, it is
usually easier to make a reasonable material selection first, and then check for satisfactory results.
Cold drawn steel is selected having the following properties:
UNSI NO AISI NO PROCESSING SUT, MPA SY,MPA E, GPA BRINELL
HARDNESS
G10500 1050 CD 690 580 207 197

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STEP 6: 3.7 SPINDLE SHAFT DESIGN FOR STRESS (FATIGUE AND CONTACT) . Shear
force and bending moment diagrams are known, critical locations can be predicted, approximate stress
concentrations can be used, and estimates for shaft diameters can be determined.
MAIN SPINDLE SHAFT:
Critical point: to the right of gear center, where key groove is there.
Where high bending moment, stress concentration at keaway, and torque presents.
M = √ 352 +227.72 = 280 N.m, T = 254.65 N.m.
Assume the radius at the bottom of the keyway will be the standard, r/d = 0.02, r =0.02 d
From table A-13 first iteration estimates for stress concentration factors, K t = 2.2 and Kts = 3.0 for
quick, conservative first pass, assume Kf = Kt, Kf s = Kts.
Endurance limit modifying factors
It is unrealistic to expect the endurance limit of a mechanical or structural member to match the values
obtained in the laboratory. Some differences include
• Material: composition, basis of failure, variability
• Manufacturing: method, heat treatment, fretting corrosion, surface condition, stress concentration
• Environment: corrosion, temperature, stress state, relaxation times
• Design: size, shape, life, stress state, stress concentration, speed, fretting, galling
Marin12 identified factors that quantified the effects of surface condition (Ka), size (Kb), loading (Kc),
temperature (Kd), reliability (Ke) and miscellaneous items (Kf). A Marin equation is therefore written
as Se=0.5 KaKbKcKdKeKf S UT
Ka =aS UT b , a=4.51 MPA ¿ b=−0.265 for cold drawn surface
Ka =aS UT b=4.51× 690−0.265 =0.8
Kb = 1.51d −0.157 for 51< d ≤ 254 mm , let Kb = 0.9 check later when the diameter is known
Kc = 1 for bending loading
Kd =1 for low temperature
Ke = 0.814 for 99% reliability

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Kf = 1
Se=0.5 KaKbKcKdKeKf S UT =0.8 × 0.9 ×1.0 ×1.0 ×0.814 × 1.0 ×0.5 ×690=202.2 MPA
When the shaft is subjected to an axial load (F) in addition to torsion and bending loads then the stress
due to axial load must be added to the bending stress (σb).
Note: In general, for a solid shaft subjected to fluctuating torsional and bending load, along with an
axial load, the equations for equivalent twisting moment (Te) and equivalent bending moment (Me)
may be written as M = 280 N.m, T = 254.7 N.m.
√[ ]
2
Tm=Te=¿ Fd
1.6 × M + +(1.6 ×T )2
8
[ √[ ] ]
2
1 Fd Fd 2
Ma=Me= 1.6 × M + + 1.6 × M + +(1.6 ×T )
2 8 8
For first estimate of the small diameter, use the DE-Goodman criterion .This criterion is good for the
initial design, since it is simple and conservative. With Mm = Ta = 0, the DE-Goodman criterion
( √
)
−1
reduces to n= d 2 KfMa + [ ]
2
3
3 ( KfsTm )
16 Se SUT
Let d = 55mm
√[ ]
2
Tm=¿ 6000 ×0.055
1.6 ×280+ +(1.6× 254.7)2=636.8 Nm
8
[ √[ ] ]
2
1 6000 ×0.055 6000 ×0.055 2
Ma= 1.6 ×280+ + 1.6 ×280+ +(1.6× 254.7) =563.1 Nm
2 8 8
( √
) ( √ [ 3 ( 3× 636.8 ) ]
)
−1 −1
d 2 KfMa [ 3 ( KfsTm ) ]
3 2 3 2
×0.055 2× 2.2× 563.1
n= + = + =1.9 safe‼ !
16 Se SUT 16 202.2 690
Assume the radius at the bottom of the keyway will be the standard
r /d =0.02 ,r =0.02 d=0.02 ×55=1.1mm , from shigley text book we can find Kt =2.14 , q=0.65
Kf =1+0.65 ( 2.14−1 )=1.74 , Kts=3 , qs=0.9, Kfs=1+0.9 ( 3−1 ) =2.8
Ka¿ 0.8 , Kc = 1, Kd =1, Ke = 0.814, Kf = 1
Kb = 1.51d −0.157 for 51< d ≤ 254 mm , Kb = 1.5155−0.157 =¿0.808

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Se=0.5 KaKbKcKdKeKfS UT =0.8× 0.808 ×1.0 ×1.0 ×0.814 × 1.0 ×0.5 ×690=181.5 MPA
The fatigue factor of safety:
( √
) ( √ [ 3 ( 2.8× 636.8 ) ]
)
−1 −1
d 2 K f Ma [ 3 ( KfsTm ) ]
3 2 3 2
×0.055 2×1.74 ×563.1
nf = + ¿ + =2.1 safe‼ !
16 Se SUT 16 181.5 690
Yield factor of safety:
32 KfMa 32 × 490.8
Ϭ ’ a= = =30 MPA
d3 ×0.055 3
√(
Ϭ ’ m= 3
16 KfsTm 2
d
3
= 3
) √(
16 × 2.8× 575.4 2
× 0.055
3
=85.4 MPA
)
Sy 580
ny= = =5
(Ϭ ’ a+Ϭ ’ m) (30+ 85.4)
d4 55
d 4=55 mm , d 2=45 mm, d 3=1.2 × d 4=1.1 ×55=60 mm, d 5= = =45 mm
1.25 1.25
d 1=40 mm
ADJECENT SPINDLE SHAFT:
Critical point: to the right of gear center, where key groove is there.
Where high bending moment, stress concentration at keaway, and torque presents.
M = √ 29.62 +173.42 = 175.9 N.m, T = 254.7 N.m.
Assume the radius at the bottom of the keyway will be the standard, r/d = 0.02, r =0.02 d
From table first iteration estimates for stress concentration factors, Kt = 2.2 and Kts = 3.0 for quick,
conservative first pass, assume Kf = Kt, Kf s = Kts.
A Marin equation is Se=0.5 KaKbKcKdKeKf S UT
Ka =aS UT b , a=4.51 MPA ¿ b=−0.265 for cold drawn surface
Ka =aS UT b=4.51× 690−0.265 =0.8

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Kb = 1.51d −0.157 for 51< d ≤ 254 mm , let Kb = 0.9 check later when the diameter is known
Kc = 1, Kd =1,Ke = 0.814 for 99% reliability, Kf = 1
Se=0.5 KaKbKcKdKeKf S UT =0.8 × 0.9 ×1.0 ×1.0 ×0.814 × 1.0 ×0.5 ×690=202.2 MPA
Equivalent twisting moment (Te) and Equivalent bending moment (Me)
M = 175.9 N.m, T = 254.7 N.m.
√[ ]
2
Tm=Te=¿ Fd 2
1.6 × M + +(1.6 ×T )
8
[ √[ ] ]
2
1 Fd Fd
Ma=Me= 1.6 × M + + 1.6 × M + +(1.6 ×T )2
2 8 8
With Mm = Ta = 0, the DE-Goodman criterion reduces to
( √
)
−1
d 3 2 K f Ma [ 3 ( KfsTm ) ]
2
n= +
16 Se SUT
Let d = 55mm
√[ ]
2
Tm=¿ 8660 ×0.055
1.6 ×175.9+ +(1.6× 254.7)2=531.4 Nm
8
[ √[ ] ]
2
1 8660 ×0.055 8660 ×0.055 2
Ma= 1.6 ×175.9+ + 1.6 ×175.9+ +(1.6 × 254.7) = 436.2 Nm
2 8 8
( √
)
−1
d 2 K f Ma [ 3 ( KfsTm ) ]
3 2
n= +
16 Se SUT
( √ [ 3 ( 3× 531.4 ) ]
)
−1
3 2
×0.055 2× 2.2× 436.2
¿ + =2.4 safe‼ !
16 202.2 690
Assume the radius at the bottom of the keyway will be the standard
r /d =0.02 ,r =0.02 d=0.02 ×55=1.1mm , from shigley text book we can find Kt =2.14 , q=0.65
Kf =1+0.65 ( 2.14−1 )=1.74 , Kts=3 , qs=0.9, Kfs=1+0.9 ( 3−1 ) =2.8
Ka¿ 0.8 , Kc = 1, Kd =1, Ke = 0.814, Kf = 1
Kb = 1.51d −0.157 for 51< d ≤ 254 mm , Kb = 1.5155−0.157 =¿0.808
Se=0.5 KaKbKcKdKeKfS UT =0.8× 0.808 ×1.0 ×1.0 ×0.814 × 1.0 ×0.5 ×690=181.5 MPA

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The fatigue factor of safety:
( √
) ( √
)
−1 −1
d 2 K f Ma [ 3 ( KfsTm ) ] [ 3 ( 2.8 ×531.4 ) ]
3 2 3 2
×0.055 2×1.74 ×436.2
nf = + ¿ + =2.7 safe ‼!
16 Se SUT 16 181.5 690
Yield factor of safety:
32 KfMa 32 × 436.2
Ϭ ’ a= = =26.7 MPA
d3 ×0.0553
Ϭ ’ m= 3
√( 16 KfsTm 2
d
3
= 3
) √(
16 × 2.8× 531.4 2
× 0.055
3
=79 MPA
)
Sy 580
ny= = =5.5
(Ϭ ’ a+Ϭ ’ m) (26.7+ 79)
d4 55
d 4=55 mm , d 2=45 mm , d 3=1.2 × d 4=1.1 ×55=60 mm, d 5= = =45 mm
1.25 1.25
d 1=0
STEP 7: Shaft design for deflection. Since deflection analysis is dependent on the entire shaft
geometry, it is saved until this point. With all shaft geometry now estimated, the critical deflections at
the bearing and gear locations can be checked by analysis.
Typically, a deflection problem in a shaft will not cause catastrophic failure of the shaft, but will lead
to excess noise and vibration, and premature failure of the gears or bearings.
For adjacent spindles: deflection at the gear center

3
Wl
liner deflection ,Y C=
48 EI
4
d 4 (55)
W =√ WR +WT =√ 0.97 +5.7 =5.8 KN , I =
2 2 2 2 −7 4
= =4.5 ×10 m
64 64
Y C=5.8 ¿¿
2
Wl
ang ular deflection ,ѳ c= =5.8 ¿ ¿
16 EI

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3.7 BEARING SELECTION.
Specific bearings from a catalog may now be chosen to match the estimated shaft diameters. The
diameters can be adjusted slightly as necessary to match the catalog specifications.
Bearing forces
Axial, RB, x = 8.66 KN, Radial, RB ¿ 2.89 KN
Bearing selected: Single row 02-series angular contact ball bearing having the following geometric
properties.
Bore Outer Width Fillet Shoulder diameter Load rating, KN
diameter radius
ds dH
OD
C10 C0
45 mm 85 mm 19 mm 1.0 mm 52 mm 77 mm 35.8 21.2
V = 1 for outer ring stationary
Fa 8.66
= =3> e ¿ shiegly text for equivalent radial load factors , X 2=0.56
VFr 2.89
¿ Y 2=1.05
Fe = X2V Fr + Y2 Fa =0.56 ×1 ×2.89+1.05 × 8.66=10.7 KN
Application factor :=1.0
The equivalent radial load becomes: Fe=1×10.7=10.7 KN
The bearing life becomes : L 10=

60 nD ( )
60 LRnR C 10 a
Fe
=
10 6
60 ×300 10.7( )
35.8 3
=2080.8 hr .
Ball bearing: Radial, RA ¿ 2.89 KN =FD
Dimensions and Load Ratings for Single-Row 02-Series Deep-Groove Ball Bearing
Bore Outer Width Fillet Shoulder diameter Load rating, KN
diameter radius

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OD ds dH C10 C0
45 mm 85 mm 19 mm 1.0 mm 52 mm 77 mm 33.2 18.6
Figure 3.7
Shaft and housing shoulder diameters dS and
dH should be adequate to ensure good bearing
support.
( ) ( )
a 6 3
60 LRnR C 10 10 33.2
The bearing life becomes : L 10= = =84.2 Khr .
60 nD FD 60 ×300 2.89
STEP 8: Key and Retaining ring selection.
Key selection: Transmitted torque: T = 254.65 N.m
Bore diameter: dg=55 mm , ds=40 mm
Gear hub length: LG¿ 44 mm , Ls¿ 50 mm
For the gear: A square key having the following geometric properties is selected
Shaft diameter Key size Key depth
Over To (include) W H
3 1 12.7 mm 12.7 mm 6.35 mm

1( ) inch 2( ) inch
4 4
For the sprocket:
Shaft diameter Key size Key depth

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Over To (include) W H
3 3 9.5 mm 9.5 mm 4.8 mm

1( ) inch 1( ) inch
8 4
Key material: CD steel is selected
UNSI No AISI No Processing SUT SY
G10200 1020 CD 470 MPA 390 MPA
Fig 3.8 From the fig 3.8, the force at the surface of
the shaft is,
T 254.7
For the gear key : F= = =9.3 KN
R 27.5
T 254.7
For the sprocket key : F= = =9.3 KN
R 27.5
Ssy = 0.577Sy = (0.577) (390) = 225 MPA
Fn 9.3 ×3
l= = =13 mm
Ssy × t 225 ×9.5
For four integrated sprockets the length of the key becomes 4 ×13=52mm
Retaining ring selection:
Gear Thrust bearing
Nominal shaft diameter 55 mm 45 mm
Allowable axial thrust 3.7 KN 6 KN
At the bottom of the shaft there is hollow tapered hole for the installation of chuck and therefore
determine the maximum diameter of the hole the bottom tip of the shaft.
Using minimum factor of safety, nf =2 and

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Tmax+ Tmin
Tm=
2
254.7
¿ =127.4 N . m
2
{ ( )} { )}
1
(
1
√ [ 3 ( Tm ) ]
2 3
√ [ 3 (127.4 ) ]
2 3
SUT 690
di=do− 16 nf =45− 16 ×2 =45−14.8=30.2 mm
❑ ❑
3.8 HOUSING DESIGN
The housing design process must be both creative and practical. What provisions should be made to
mount the bearings accurately and to transmit the bearing loads safely through the case to the
structure. How will the various elements be assembled into the housing? How will the gears and
bearings be lubricated? What housing material should be used? Should the housing be a casting, a
weldment, or an assembly of machined parts? Are the main questions asked to lay the layout of the
housing?
The design process as outlined here implies that the design can progress in sequence: from the chain to
the shaft, to the bearings, to the gears and keys, and finally to the housing.
Material selection for housing: Grey cast iron
Since the cast iron is a brittle material, therefore, it cannot be used in those parts of machines which
are subjected to shocks. The properties of cast iron which make it a valuable material for engineering
purposes are its low cost, good casting characteristics, high compressive strength, wear resistance and
excellent machineability. The compressive strength of cast iron is much greater than the tensile
strength. A portion of the housing is used to analyze whether it fails or can resist the shear stress.

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Design for shear gives the following thickness:
Fn 8.7 ×3
t= = ≅ 7.3 mm
Ssy ×l 120 ×30
From the fig we can decide the total layout of the housing:
w
X =C+ rs+ +2 t+ allowance +d
2
X 2=2rg+2 t+ allowance
b=2 rs+2 t+ allowance
Y 1=Fb+Co+4 Cc+2 t+allowance , Y 2=C 2+2 t+ allowance
Z=7 Cs+2 t+ allowance
b
where , C−center distance the main spindle∧motor shaft (570 mm)
n
b
Co−the distance the sprocket ∧the top bearing( 43 mm)
n
b
C 2=the distance the top∧botto mbearing( 122mm)
n
b
Cs−thecenter distance the adjecent spindles ( 90 mm )
n
Cc−the half width of the chain (32.7 mm ) ,d −chainroller diameter( 12mm)
t−housing thickness(7.3 mm) ,w−the motor width (200 mm),
rs−sprocket radius(361 mm), rg−gear radius(45 mm)
Fb=bearing width(19 mm), Fs−spindle sprocket width ( 86.36 ) , H−spindle top net width (20 mm)

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w
X =C+ rs+ +2 t+ allowance+d=570+361+100+14.6+ 100+12+ 22=1180 mm
2
X 2=rg+ 2t +allowance=2× 45+ 45.4+14.6=150 mm
Y 1=Fb+Co+2 t+ Fs+ H + allowance=19+ 43+86.36+14.6+ 20+ 20=203 mm
Y 2=C 2+2 t+ allowance , Y =Y 1+Y 1
Y 1=Fb+Co+4 Cc+2 t+allowance=25+97+ ( 32.7 ×4 ) +14.6+20=287.3 mm
Y 2=C 2+2 t+ allowance=122+14.6+ 20=156.6 mm, Y =287.3+ 156.6=444 mm
Z=2 rs+2 t+ allowance=722+14.6+30=767 mm
Bolt selection: For fasting the different components of the drill machine together
Nominal size Fine threads
Pitch Tensile stress area
M5 0.5 mm 16.1 mm2
Bolt material: steel:
Grade Bolt size SUT Yield strength
4.6 M5 400 MPA 240 MPA
As 16.1
Check for shear of the bolt: n=0.577 SY × =0.577 ×240 ×
F 7
Sleeve bolt length: L=t housing+ t ( sleeve

2 )
=7.3+1.5 ≅ 9 mm
Bushing:
Bushing material: beryllium bronze. It is a copper base alloy containing about 97.75% copper and
2.25% beryllium. It has high yield point, high fatigue limit and excellent cold and hot corrosion
resistance. It is particularly suitable material for springs, heavy duty electrical switches, cams and
bushings. Since the wear resistance of beryllium copper is five times that of phosphor bronze,

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therefore, it may be used as a bearing metal in place of phosphor bronze. It has a film forming and a
soft lubricating property, which makes it more suitable as a bearing metal.
Internal diameter of the bushing: 45 mm
Nominal outer diameter: 65 mm
3.9 DESIGN OF DRILL COLUMN
The entire weight of the drill machine is supported by the column, which is the backbone of the drill
machine to support the weight. Note that the column supports not only the weight but also the axial
thrust force produced due to the machining operation. Therefore, the total force on the column is the
sum of the weight of the electric motor, the working table, the entire weight of the drill and the axial
force acting on the table.
Let W =1 KN where W −the entire weight of the drill machine
The axial thrust force as determined before , Fa=6 KN
Design the column for buckling and axial compressive stress.
Material selection: cold drawn steel
UNS No. AISI NO. SUT SY BHN
G10060 1006 330 280 95
Johnson column formula
Pcr
A
=Sy−(
Syl 2 1 l
) , ≤
2 k CE k k
l
()
1 , Referance shigley text book page 176
where Fcr−the critical tha makes thecolumn unstable ,

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l−the length of thecolumn
A−x sectional area
C−end condition constant (for ¿−¿ end ,C=1.2)
Fcr=Fn , let thelength of the column ,l =1.63 m¿ workshop drill measurement
For steel material E=207 GPA
l 4 l 1.63
= = =65.2
k d 0.025
()
l
k √
1= (
2❑2 CE
Sy
)= (
√2❑2 ×1.2 ×207
280
l
)=132.33> is J . B . Johnson columns .
k
Rearanging∧substitution of the values for factor of safety gives∧assume the
diameter of thecolumn t o be 100 mm
( ) ( )
2 2 2 2
d Syl Sy 0.05 280 ×1.63 280
n= − = − =9
4 CE❑ E
2
4 1.2× 207❑ 207
2
Check for fatigue loading
Ϭa Ϭm 1
Modified Goodman criteria: + =
Se SUT n
Fmax + Fmin Fmax−Fmin

Fmax=7 KN , Fmin=1 KN ,Ϭm= 2
=1.0186 MPA , Ϭa= =0.764 MPA ,
d d2
4 4
Ka=0.97 for cold drawn surface , Kb=0.733 for 51< d ≤ 254 ,
Kc=0.85 for axial loading , Kd=1 for at room tempratu ℜ ,
Ke=0.814 for 99 % reliability , Kf =1
Se=0.5 KaKbKcKdKeKfSUT =0.5 × 0.97 ×0.733 ×0.85 ×1 × 0.814 ×1 ×330=228.7 MPA

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SUT × Se 330 ×228.7

n= = =155
SUT ×Ϭa+ Se × Ϭm 330 ×0.764 +228.7 ×1.0186
3.10 DESIGN OF COLUMN SLEEVE: the purpose of the sleeve is to transfer the load from the
housing to the column. In this way a bolt is used to hinge the housing on the column. The bolt section
of the housing and the sleeve is subjected to a shear stress.
Material selection: steel
AISI NO. Processing SUT SY
1015 Hot rolling 340 MPA 190 MPA
Checking shear across the bolt center;
F S sy 0.577 SY Fn 7 ×3
τ= = = , but A s=2 π r o t , tmin= = =0.43 mm
As n n 0.577 SY ( 2 π r o) 0.577× 190 ( 2 π ×70 )
SY ( 2ro−100 ) 190 × ( 2×70−100 )

For bending: n= 2
= =¿
64 ro F 64 ×702 ×7
Let assume t=4 mm
3.11 RACK AND PINION DESIGN
For the operation to be performed the worktable must move up and down to get feed manually since
feed mechanism is accomplished by the movement of the table.

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A rack and pinion mechanism is used in the feed mechanism to accomplish the required work. So the
rack and pinion teeth must be checked for contact stress and bending stress.
A well designed mechanism such as the rack and pinion gears save effort and time.
The rack and pinion is used to convert between rotary and linear motion. Rack and pinion can convert
motion from rotary to linear or linear to rotary.
Fig 3.9 rack and pinion
Proportions for spur Gear system 200 full depth involute system.
Take module ; m=4 , Addendum ( a )=1 m=1 ×4=4 mm ,
Dedendum ( b ) =1.25 m=1.25× 4=5 mm , Workingdepth=2m=2 × 4=8 mm , Minimum total depth=2.25 m=9 mm
Tooth thickness=1.5708=1.5708 × 4=6.3 mm
Minimum clearance=0.25 m=0.25 × 4=1 mm
Fillet radius at root=0.4 m=0.4 × 4=1.6 mm
p=πm=4 π=12.566 mm , p=circular pitch
Face width ; F=4 p=4 ×12.566=50.26 mm
The smallest spur pinion that will operate with a rack without interference is:
2k 2
Np= 2
= 2 =17.1 ≅ 18
sin ❑ sin 20
The pitch diameter of the pinion: dp=mNp=4 ×18=72mm

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Force analysis
The normal tooth load (WN) has two components; one is tangential component (WT) and the other axial
component (WA).
Tangential toothload onthe pinion∧rack ,
WT =F a=6 KN ( axial thrust force created due ¿machining operation )
The normal tooth load , W N=W A/sin ()=2.66/sin(25)=6.29 KN
The radial tooth load , W R=W T tan=6 tan 20=2.2 KN
STRENGTH ANALYSIS OF PINION GEAR (reference shigley textbook)
In order to find the strength of helical gears, AGMA strength equation is used.
GEAR MATERIAL SELECTION- NITRIDED THROUGH-HARDENED STEELS: are commonly
used for gears. They have superior tensile strength to cast iron. They need heat treatment to get a
surface hardness that will resist wear.
THE BENDING STRESS IS:
W T KoKvK sK HK B
Ϭ=
( bmY J )
Where K o−overload factor (1.0 ) , K v −dynamic factor (1.277 )
K s−¿ ( 1.0 ) , K H −load distribution factor (1.1254 )
K B−rim thickness factor ( 1.0 ), Y J ,Geometry factor for bending strength
m−module , b−Face width
W T KoKv KsK H KB 1
Therefore , Ϭ= =6× 1.25 ×1.277 ×1.0 ×1.1254 × =225 MPa
bmY J 50 × 4 × 0.24
THE FUNDAMENTAL EQUATION FOR PITTING RESISTANCE (CONTACT STRESS)
Ϭ c=Z E
√ W T KoKv KsK H ZR
d w 1 bZ I

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Where Z E−elastic coefficien t ( 191 √ MPa ) , Z R−surface condition factor ( 1.0 )
d w 1 ; pitch diameter of the pinion(72 mm),
Z I−geometry factor for pitting resistance (0.107)
Ϭ c=Z E
√ W T KoKv KsK HZR
d w 1 bZ I
=191
√
6 ×1.25 ×1.277 ×1.0 ×1.1254 × 1.0
72 ×50 ×0.107
=1010.3 MPa
THE EQUATION FOR THE ALLOWABLE BENDING STRESS IS:
StY N
Ϭ al l=
(S F Y ѳ Y Z )
Where , St−allowable bending stress , Y N −the stress cycle factor
S F−the AGMA factor of safety , Yѳ−thetemperature factor ,
Y Z−thereliability factor
THE EQUATION FOR THE CONTACT STRESS Ϭc, all IS
Sc Z N ZW
Ϭ c , all=
(S FY ѳY Z)
Where , S c−allowable contact stress , Z N −the stress cycle ¿!
Z W −the hardness ratio factor for pitting resistance
Sc -allowable contact stress
For 2.5% chrome (no aluminum) Grade 3 steel, Sc = 1488.24 Mpa (from table A-8)
ZW-the hardness ratio factor for pitting resistance
Z W =1.0 since both of the gears are equal
Safety Factor SF
1. Safety factor guarding against bending fatigue failure
S F=Ϭ all /Ϭ =(S t Y N /(S F Y ѳ Y Z))/ Ϭ =(437.7)/225=1.9
2. Safety factor guarding against pitting failure
S H=Ϭ c , all /Ϭ c=( S c Z N Z W /(S F Y ѳ Y Z ))/Ϭ c=(1488.24)/1010.3=1.5

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Rack material:
AISI NO Processing SUT SY
1006 Hot rolling 300 MPA 170 MPA
Check the rack shaft for buckling and axial compressive stress
Buckling :
2
Pcr CE ❑
Euler column formula = , Referance shigley text book page 174
()
2
A l
k
where Pcr−the critical loadthat makes the column unstable ,
l−the length of thecolumn (150 mm)
A−x sectional area
C−end condition constant (for ¿−¿ end ,C=1.2)
Fcr=Fn
For steel material E=207 GPA
l 4l 0.6
= = =560
k d 0.00107
()
l
k
1= (
√
2❑2 CE
Sy
)= (
√
2❑2 ×1.2 ×207
170
l
)=170< is Euler columns .
k
2
CE❑ 2
=1.2 ×207 × ❑ 2 =7.8 ×106
()
2
l ( 560 )
k
Let the root diameter=50 mm
d=theroot diameter−the rac k toothtotal depth=50−9=41 mm

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(( ) )
2CE❑2
d
l 2
k 2 6
× 0.041 × 7.8× 10
n= = =1.7
4F 4 ×6000
Check for fatigue loading
Ϭa Ϭm 1
Modified Goodman criteria : + =
Se SUT n
Fmax + Fmin Fmax −F

Fmax=7 KN , Fmin=0.4 KN (asume the weight of the worktable), Ϭm= 2
=0.23 MPA , Ϭa= 2
d d
4 4
Ka=0.96 for hot rolled surface , Kb=0.83 for 2.79<d ≤51 ,
Kc=0.85 for axial loading , Kd=1 for at room temprature ,
Ke=0.814 for 99 % reliability , Kf =1
Se=0.5 KaKbKcKdKeKfSUT =0.5 × 0.96 ×0.83 ×0.85 ×1 × 0.814 ×1 ×300=82.7 MPA
SUT × Se 300× 82.7

n= = =314
SUT ×Ϭa+ Se × Ϭm 300 ×0.2+82.7 × 0.23
3.12 JIG AND FIXTURE
The jigs and fixtures are the economical ways to produce a component in mass. So jigs and fixtures are
used and serve as one of the most important facility of mass production system. These are special
work holding and tool guiding device. The quality of performance of a process largely influenced by
quality of jigs and fixtures used for this purpose. What makes a fixture unique is that each one is built
to fit a particular part or shape. The main purpose of a fixture is to locate and in the cases hold a work
piece during an operation. A jig differs from a fixture in the sense that it guides the tool to its correct
position or towards to its correct movements during an operation in addition to locating and supporting
work piece. Purpose and advantage of jigs and fixtures

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i. It reduces or sometimes eliminates the efforts of marking, measuring and setting of work
piece on a machine and maintains the accuracy of performance.
ii. The work piece and tool are relatively located at their exact positions before the operation
automatically within negligible time. So it reduces product cycle time.
iii. Variability of dimension in mass production is very low so manufacturing processes
supported by use of jigs and fixtures maintains a consistent quality.
iv. Due to low variability in dimension assembly operations becomes very easy, low rejection
due to less defective production is observed.
v. It reduces production cycle time so increases production capacity. Simultaneously working
by more than one tool on the same work piece is possible.
vi. The operating conditions like speed, feed rate and depth of cut can be set to higher values
due to rigidity of clamping of work piece by jigs and fixtures.
vii. Operators working become comfortable as his efforts in setting in work piece can be
eliminated.
viii. Semi-skilled operators can be assigned the work so it saves the cost of manpower also.
3.13 MANUFACTURING CONSIDERATIONS
Manufacturing processes: The knowledge of manufacturing processes is of great importance for a
design engineer. The following are the various manufacturing processes used in mechanical
engineering.
1. Primary shaping processes. The processes used for the preliminary shaping of the machine
components. The common operations used for this process are casting, forging, extruding, rolling,
drawing, bending, shearing, spinning, powder metal forming, squeezing, etc.
2. Machining processes. The processes used for giving final shape to the machine component,
according to planned dimensions. The common operations used for this process are turning, planning,
shaping, drilling, boring, reaming, sawing, broaching, milling, grinding, hobbing, etc.

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3. Surface finishing processes. The processes used to provide a good surface finish for the machine
component are known as surface finishing processes. The common operations used for this process are
polishing, buffing, honing, lapping, abrasive belt grinding, barrel tumbling, electroplating,
superfinishing, sheradizing, etc.
4. Joining processes. The processes used for joining machine components are known as joining
processes. The common operations used for this process are welding, riveting, soldering, brazing,
screw fastening, pressing, sintering, etc.
5. Processes effecting change in properties. These processes are used to impart certain specific
properties to the machine components so as to make them suitable for particular operations or uses.
Such processes are heat treatment, hot-working, cold-working and shot peening.
Most of the parts manufacturing processes are stated as the materials selected for the specific
components. To generalize a tabulated data is as follows;
Part name Part material Manufacturing method
Housing Grey cast iron Casting and Machining
Spindle shafts Carbon steel Forging and machining
Sprocket Carbon Steel Extrusion and hammering
Gear Carbon Steel Machining and through hardening
Drill column Carbon steel Machining and cold working

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3.14 COST ESTIMATION FOR THE DRILL MACHINE
Component Unit cost (birr per No of unit The total cost for the
unit) component (in birr)
Electric motor 9,200 1 9,200
Gear 200 7 1,400
Sprocket 300 12 3,600
Chain 1,600 1 1,600
Bearing 100 15 1,500
Drill bit 200 7 1,400
Jig and fixture 2,000 1 2,000
Cast iron bed 4,000 1 4,000
Spindle shafts 400 7 2,800
Oil pump 1,500 1 1,500
Drill column 500 1 500

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Oil pan 500 1 500
Housing 500 1 500
Contingency 4,000 −¿ 4,000
Total=34,500 birr
CHAPTER FOUR
4 CONCLUSION AND RECOMMENDATION
4.1 CONCLUTION
Multi-spindle drill machine is a type of drill machine which drills several holes at the same time or
spontaneously. It increase productivity, save time, and good surface finish and have good precision of
product. In this thesis mechanical design of machine, cost analysis, standard element selection,
manufacturing case, operation condition, assembly and disassembly and lubrication case of machine
are clearly stated or considered. Typically this machine is designed to improving and increasing
productivity of Selam Technical and Vocational Collage in the manufacturing of rice mill machine.
Also it enables the company to mass production within few working time with accurate hole center
distance in manufacturing metal bar used in rice mill machine. The machine equipped with electric
motor, gear, and sprockates with chain. The feed is given by means of rack and pinion mechanism
which is the table with work piece is pushed up and down by rotating handle.
This thesis not only includes the design of multi-spindle drill machine but also it includes the design of
jig and fixture to hold the work piece and fix it in position and to inhibit the vibration during drilling
time and to keep the drill beat from break down.

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4.2 RECOMMENDATION
During design multi-spindle drill machine, we faced to many problems in the manufacturing
company because of inappropriate drill machine.
So now we recommend
 To design automatic multi-spindle drill machine
 Adjustable: - adjusting the spindle in to needed hole diameter and needed distance between
hole center.
 Flexible in to different direction.
 Manufacturing a drill machine having different work function like turning , facing, etc

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APPENDIX
STRESS MODIFYING FACTORS FOR BENDING OF GEAR
Kv- dynamic factor
Dynamic factors are used to account for inaccuracies in the manufacture and meshing of gear teeth in
action. Transmission error is defined as the departure from uniform angular velocity of the gear pair.
Some of the effects that produce transmission error are:
 Inaccuracies produced in the generation of the tooth profile; these include errors in
 tooth spacing, profile lead, and run out
 Vibration of the tooth during meshing due to the tooth stiffness
 Magnitude of the pitch-line velocity
 Dynamic unbalance of the rotating members
 Wear and permanent deformation of contacting portions of the teeth
 Gear shaft misalignment and the linear and angular deflection of the shaft
 Tooth friction
In an attempt to account for these effects, AGMA has defined a set of quality numbers. These numbers
define the tolerances for gears of various sizes manufactured to a specified accuracy. Quality numbers
3 to 7 will include most commercial-quality gears. Quality numbers 8 to 12 are of precision quality.
The AGMA transmission accuracy level number Qv could be taken as the same as the quality number.
The following equations for the dynamic factor are based on these Qv numbers: let Qv = 5
B = 0.25 (12 – Qv)2/3 = 0.25 (12 – 5)2/3 = 0.915
A = 50+56(1−B) = 50+56 ( 1 – 0.915 ) =54.77

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N D 300∗0.09
V= = = 1.41m/s
60 60
B 0.915
A+ √ 200 V 54.77+ √ 200∗1.41
Kv = ⌊ ⌋ =⌊ ⌋ =1.277
A 54.77
Ks- size factor
The size factor reflects non-uniformity of material properties due to size. It depends upon
Tooth size, Diameter of part, Ratio of tooth size to diameter of part, Face width, Area of stress pattern,
Ratio of case depth to tooth size, Hardenability and heat treatment
Use Ks=1 for small gears
KH- load distribution factor
The load-distribution factor modified the stress equations to reflect nonuniform distribution of load
across the line of contact. The ideal is to locate the gear “midspan” between
two bearings at the zero slope place when the load is applied. However, this is not always possible.
The following procedure is applicable to
• Net face width to pinion pitch diameter ratio F/d ≤ 2
• Gear elements mounted between the bearings
• Face widths up to 40 in
• Contact, when loaded, across the full width of the narrowest member
The load-distribution factor under these conditions is currently given by the face load distribution
factor, Cmf, where KH = Cmf =1 + Cmc (Cpf Cpm + Cma Ce)
where Cmc = 1 for uncrowned teeth
Cpf = F/(10d) – 0.0375 + 0.0125F
F/(10d) = 1.575/(10*3.54) = 0.044¿ 0.05, therefore use F/(10d) = 0.05
Cpf = F/(10d) – 0.0375 + 0.0125F = 0.05 – 0.0375 + 0.0125*1.575 = 0.0322
Cpm = 1.1 for straddle-mounted pinion with S1/S≥0.175

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Table A-1. Power constants, Kp, for wrought steels, using sharp cutting tools
Material Brinell hardness no Kp ( SI metric units)
PLAIN CARBON STEELS
All plain carbon steels 80-100 1.72
100-120 1.80
120-140 1.88
140-160 2.02
160-180 2.13
180-200 2.24
200-220 2.32
220-240 2.43
240-260 2.51
260-280 2.59
280-300 2.73
300-320 2.81
320-340 2.89
340-360 3.11

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Table A-2. Feed factors, C, for power constants
Feed (mm) C Feed (mm) C
0.02 1.70 0.15 1.15
0.05 1.40 0.18 1.11
0.07 1.30 0.20 1.08
0.10 1.25 0.30 1.00
0.12 1.20 0.33 0.98
Table A-3 Tool wear factor, W
Type of operation W
For all operation with sharp cutting tools 1.00
Turning: finish turning (light cuts) 1.10
Normal rough and semi-finishing turning 1.30
Extra heavy-duty rough turning 1.30-1.60
Drilling: normal drilling 1.30
Drilling hard-to-machine materials and drilling with very dull drill 1.50

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Table A-4 Feed factor, Ff, for drilling
Feed(mm/rev) Ff
0.01 0.025
0.10 0.158
0.20 0.276
0.25 0.330
0.30 0.382
Table A-5 Drill diameter factors: FT for thrust; FM for torque
Drill diameter(mm) FT FM
1.60 1.46 2.33
4.00 3.03 12.12
8.00 5.28 42.22
11.00 6.81 74.90
12.50 7.54 94.28
14.50 8.49 123.10
16.00 9.19 147.0

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Table A-6 Chisel edge factors for torque and thrust
c/d Approx. Torque factor Thrust factor Thrust factor
w/d A B J
0.03 0.025 1.000 1.100 0.001
0.10 0.085 1.020 1.235 0.010
0.15 0.130 1.080 1.310 0.022
0.18 0.155 1.155 1.355 0.030
For drills of standard design, use c/d = 0.18
For split point drills, use c/d = 0.03
Table A-7 Work material factor, Kd, for drilling with a sharp drill
Work material Work material constant
Steel, 200Bhn 24,000
Cast iron, 150Bhn 14,000
Most aluminum alloys 7,000

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A-8 Contact-fatigue strength, Sc, at 107 cycles and 0.99 reliability for through hardened steel gears is
tabulated as follows. Source: ANSI/AGMA 2001-DO4.
Material Heat treatment Allowable contact stress number, Sc, MPa
designation
Grade 1 Grade 2 Grade 3
Steels Through hardened
Flame or induction hardened 1171.3 1309.1 _
Carburized & hardened 1205.75 1343.55 _
Nitrided(Through hardened steels) 1240.2 1550.25 1894.75
2.5% chrome( no Nitrided 1067.95 1185.08 1302.21
aluminum)
Nitralloy 135M Nitrided 1171.3 1260.87 1343.55
Nitralloy N Nitrided 1185.08 1295.32 1412.45
2.5% chrome (no Nitrided 1212.64 1350.44 1488.24
aluminum)
Table A-9 Minimum no of teeth on the smaller sprocket

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Table A-10 recommended factor of safety for bush roller and silent chains
Table A-11: According to Indian Standards (IS: 2403 —1991), the various characteristics such as
pitch, roller diameter, and width between inner plates, transverse pitch and breaking load for the roller
chains are given in the following table.
Table A-12 power rating (in KW) of simple roller chain

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Table A-13 first iteration estimates for stress concentration factors
BENDING TORSIONAL AXIAL
Shoulder fillet-sharp 2.7 2.2 3.0
(r/d = 0.02)
Sho0ulder fillet-well 1.7 1.5 1.9
rounded (r/d = 0.1)
End mill keyseat 2.2 3.0 -
(r/d=0.02)
Retaining ring 5.0 3.0 5.0
groove
Note that these factors are only for use when actual dimensions are not yet determined. Do not use
these once actual dimensions are available.
REFERENCES AND SOURCES OF INFORMATION
BOOKS AND PAPERS

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 BUDYNAS−NISBETT, Shigley’s Mechanical Engineering Design, Eighth Edition
 Machinery’s Handbook 28th Edition BY ERIK OBERG, FRANKLIN D. JONES,
 HOLBROOK L. HORTON, AND HENRY H. RYFFEL CHRISTOPHER J. MCCAULEY,
SENIOR EDITOR RICCARDO M. HEALD, ASSOCIATE EDITOR MUHAMMED IQBAL
HUSSAIN, ASSOCIATE EDITOR
 A text book of machine design, R.S. KHURMI and J.K. GUPTA, 2005.
 Introduction to basic manufacturing processes and workshop technology, RAJENDER SINGH.
 Machine Design by JINDAL U. C.
 Machine elements in mechanical design, ROBERT L. MOTT, RE, University of Dayton, fourth
edition.
 Machine design an integrated approach, ROBERT L. NORTON, third edition.
 Machinery's Handbook 28th Edition BY ERIK OBERG, FRANKLIN D. JONES,
HOLBROOK L. HORTON, AND HENRY H. RYFFEL, Industrial press.
 Machines and mechanisms applied kinematic analysis, by DAVID H. MYSZKA,
University of Dayton.
 Mechanical design, second edition, PETER R.N. CHILDS, BSc(Hons), Dphil,
CEng,FIMechE, MIED, ILTM, Mem ASME, University of sussex, UK.
WEBSITES
 www.ALIBABA.com
 www.GLOBALSPEC.com

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BACHULER THESIS ON MULTI-SPINDLE DRILL MACHINE 2005

3 DRILL MACHINE HEAD DESIGN......................................................................................................16

4 CONCLUSION AND RECOMMENDATION.........................................................................................68

REFERENCES AND SOURCES OF INFORMATION................................................................................79

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spindle drilling machine is more productive.

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and tapping) and can lead tool breakage.

is by using multi-spindle drilling head.

1.1 BACKGROUND OF THE PROBLEM

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same time. This reduces the company’s productivity and efficiency.

bring considerable changes to the stated problems of the factory.

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1.2. STATEMENT OF THE PROBLEM

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1.3 OBJECTIVE OF THESIS

Specific objectives are:

Specific objective of the thesis are:-

 To change single spindle drilling machine to multi-spindle drilling machine.

 To perform the design of different parts of the machine.

 To design sprockets and select chain.

 To construct parts as well as assembly of the machine.

 Reducing the production time and to improve the manpower usage.

 To reduce the work fatigue of the operators.

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1.4. RESAERCH METHODOLOGIES AND DATA COLLECTION

survey, Data collection and design.

1.4.1. Literature Review

Generally the following literature was compiled:

 Defination and classification of multi-spindle drill machine

 Introduction to multi-spindle drill machine and types of operation

 Finding of all the component of machine and their function.

 Present methods that most company used to drill multi-holes.

 Desing procedure and others

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1.4.2. Data Collection

 Information from different literature on this area.

 Information from internet

Mechanical Design of Components

A. Design of gear system, i.e. rack and pinion gear.

C. Selection of appropriate bearing, chain, and power source (electric motor).

E. Dimension of each parts and overall.

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Power supply unit

Construction and assembly

understanding of fundamental sience and related engineering subjects.

forfinal desing, economic evaluation, detailed engineering design and implementation.

1.5 THE EXPECTED OUTCOME AND BENEFICIARIES OF THE THESIS

1. increasing the productivity of the company

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3. precision of center distance between each holes

4. good finishing and accuracy of holes

5. mass production is very easy

 Selam Technical and Vocational Collage

 AAIT Technology Workshop

1.6 SCOPE AND LIMITATION OF THE STUDY

Selam Technical And Vocational Collage .

ways designing multi-holes drill machines.

multi-spindle drill machine.

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