Bao Dang Thai 2022 11 28

VIETNAM NATIONAL UNIVERSITY, HO CHI MINH CITY
UNIVERSITY OF TECHNOLOGY
FACULTY OF MECHANICAL ENGINEERING
DESIGN OF A TRANSMISSION SYSTEM FOR INDUSTRIAL BLENDER
(ME2011 / ME3139)
Semester 1/Academic year 2022-2023
Student: Dang Thai Bao Student ID: 2052869
Advisor: Dr. Nguyen Vu Thinh Signature: ..................................
Completion day: Defense day: ..............................
1
CHAPTER I: MOTOR SELECTION AND TRANSMISSION RATIO.....8
1.1 General efficiency of the system.........................................................8
1.2 Motor selection and transmission ratio..............................................9
1.3 Transmission ratio of system:.............................................................9
1.4 Parameters of transmission system:.................................................10
CHAPTER II: DESIGN AND TESTING BELT CONVEYOR.................12
2.1 Initial information.............................................................................12
2.2 Calculation and choose belt for the system......................................12
CHAPTER III: DESIGN AND TESTING GEAR.......................................17
I. Fast stage helical gear..........................................................................18
II. Slow stage spur gear...........................................................................27
CHAPTER IV: DESIGN OF SHAFT...........................................................37
I. Choosing material................................................................................37
II. Preliminary design diameter and length of shaft.............................37
III. Determine force on shaft...................................................................38
IV. Key design..........................................................................................43
V. Testing the shaft on the fatigue durability........................................45
VI. Testing shafts on static durability....................................................48
VII. Coupling...........................................................................................48
CHAPTER V: BEARING DESIGN..............................................................50
 Shaft II..................................................................................................50
 Shaft III................................................................................................51
 Shaft IV................................................................................................53
CHAPTER VI: DESIGN GEARBOX, LUBRICATION AND FEATURE
ADJUSTMENT..............................................................................................56
I. Design gearbox.....................................................................................56
1. Structure of die-cast reducer box.....................................................56
2. Details related to the box structure..................................................57
Design Project (ME3139) – HK221 2

Student: Dang Thai Bao – ID: 2052869
II. Mounting Tolerance...........................................................................61
III. Lubrication........................................................................................62
Chapter VII: Reference.................................................................................63

PROJECT #12
DESIGN OF A TRANSMISSION SYSTEM FOR BELT

CONVEYOR
Data No: 4
 System components:
1. Electric motor
2. V-belt drive
3. Dual-stage gear reducer
4. Flexible shaft coupling
5. Belt conveyor
 Given parameters:
Tangential force on conveyor chain, F=5300( N )
Tangential velocity on conveyor chain, v=1.78(m/s )
Diameter of drive conveyor pulley: D=330 (mm)
Service life: L=5 ( years)
Number of working days per year: 329 days

Number of shifts per working day: 1
Loading characteristic: T1 = T; t1 = 28 (s); T2 = 0.3T; t2 = 48 (s)
 Operating conditions: one-direction working, light-impact loading, 8-hour shift
 Contents of the project report:

1. Select proper electric motor and distribute velocity ratio for the transmission system.
2. Design machine elements:
a. Design uncovered drives (belt, chain or gear).
b. Design covered drives (gears, worm, worm wheel).
c. Draw diagram of forces applied on drives and calculate the values of forces.
d. Design shafts and keys.
e. Select bearings and shaft coupling.
f. Select housing of the speed reducer, bolts/screws and other parts.
3. Select assembly fits and tolerances.
4. References.

Chapter 1: Motor selection and transmission ratio
CHAPTER I: MOTOR SELECTION AND

TRANSMISSION RATIO
 Maximum power at the output shaft respectively:
Fv 5300 ×1.78
Pconv = = =9.434(kW )(1)
1000 1000
 Equivalent load:
√ ( )
Ti 2
∑ T
×t i
n
Peq =P× (2)
∑ ti
n
√ ( ) ( )
T1 2 T2 2
× t 1+ ×t 2
T T
¿P×
t 1+t 2
√ ( ) ( )
2 2
T 0.3 T
× 28+ × 48
T T
¿ 9.434 ×
28+48
¿ 6.152(kW )
1.1 General efficiency of the system

According to the table 3.3, we can choose system efficiency:
The system efficiency:
2 4
η sys=ηbelt × ηg ×η cp × ηrb (4 )
2 4
¿ 0.95 ×0.96 × 0.98× 0.99
= 0.824
Where as:
η s: general effecicency of system
η g: general effecicency of helical gear
ηcp : general effecicency of coupling
ηb : general effecicency of rolling-bearing
6
ηbelt : general effecicency of V-belt
 Power requirement for motor:
P eq 6.152
Prq = = =7.466( kW )(3)
ƞs 0.824
1.2 Motor selection and transmission ratio

From the provided table of page 17 [V]. We choose motors as to satisfy the
condition:
{ Prq ≥ P motor=7.466
n ’ ≈ nmotor
According to the table we choose the 2SIE 132M4 motor because it satify the
condition that we mention above
1.3 Transmission ratio of system:

6000× v 60000× 1.78
n convenyor=¿ = = 103.02 (rpm)
π ×d π × 330
+ General system tranmission ratio u sys is:
n motor
u sys= ubelt ×u gb= ubelt ×u 12 ×u34 =
nconvenyor
Where:
ubelt : Tranmission ratio of V-belt drive
u gr: Tranmission ratio of dual-stage gear reducer
According to the table 3.2 [ I ] in oder to choose the tranmission ratio of the
drives. We preliminary choose tranmission ratio of V-belt drive first ubelt = 2.24
for the 2SIE 132M49
Power Motor Rotation System speed V-Belt drive Dual stage

speed ηmt , speed ratio ( gear box (u gb ¿
P, kW ratio
(rpm)

(u sys ¿
2SIE
7.5 1460 14.17 2.24 6.326
132M4
Distribution dual stage gear box tranmission: After we calculated and get the
result is u gb= 6.326. We will base on a standard table 3.1 [ I ] and get u gb=6 and
u12=2.54 ,u34 = 2.36
Then we will recaculated ubelt :
u sys 14.17
ubelt = = ≈ 2.364
u12 ×u 34 2.54 ×2.36
1.4 Parameters of transmission system:

 Working power on each shaft:
Pconv =6.152( kW )(8)
P conv 6.152
P IV = = =6.341(kW )
ηrb ×ηcp 0.99 × 0.98
P IV 6.341
P III= = =6.672(kW )
η g × ηrb 0.96 × 0.99
P III 6.672
P II = = =7.02(kW )
η g × ηrb 0.96 × 0.99
PII 7.02
Pmotor = = =7.389(kW )
ηbelt 0.95
 Rotational speed on speed shaft:
n motor=1460( rpm)
n motor 1460
n II = = =617.597(rpm)(9)
ub 2.364
n II 617.597
n III = = =243.148(rpm)
u 12 2.54

nIII 243.148
n IV = = =103.029(rpm)
u34 2.36
n IV 103.029
n conv= = =103.029(rpm)
ucp 1
 Torque on each shaft:

6 PI 6 7.389
T motor =T I =9.55 ×10 × =9.55 ×10 × =48332.158 ( Nmm ) (10)
n1 1460
6 PII 6 7.02
T II =9.55 ×10 × =9.55 ×10 × =108551.369(Nmm)
n II 617.597
6 P III 6 6.672
T III =9.55 ×10 × =9.55 ×10 × =262052.742( Nmm)
nIII 243.148
6 P IV 6 6.341
T IV =9.55 ×10 × =9.55 ×10 × =587762.184( Nmm)
nIV 103.029
6 Pconv 6 6.152
T conv =9.55 ×10 × =9.55× 10 × =570243.329(Nmm)
n conv 103.029

Chapter 2: Design and testing belt conveyor
CHAPTER II: DESIGN AND TESTING BELT

CONVEYOR
2.1 Initial information
Motor
Power 7.5
(kw)
Revolution 1460
(rpm)
2.2 Calculation and chose belt for the system

1. Choose type of V-belt base on the graph
 Base on the P1 and n1 we have in the table 4.13 [ I ], B-type belt is selected
We have the detail of the B-type belt as follows:
Type bp bo h yo A L T1 d 1 (mm)
(mm) (mm) (mm) (mm) (mm2 ) (mm) (Nm)

B 14 17 10.5 4 138 800÷ 6300 40÷ 190 140÷ 280
2. Diameter of small pulleys

d 1= 1,2d min = 1,2 ×140 = 168 (mm) -> Select d 1= 200(mm) (11)
3.Peripheral velocity of belt

π∗d belt ∗nbelt π × 200× 1460
v belt= => v I = = 15.289 (m/s) (12)
6∗10
4
6∗10 4
With the v I we calculation, It satisfy the conditon: v I ≤ [ v ], with [ v ]= 25m/s

4. Select relative slip coefficient
 Select ξ= 0.01 and u = 2.364, we have
d 2= u× d 1 × (1 - ξ) (13)
= 2.364× 200×(1-0.02)
Design Project (ME3139) – HK221

Student: Dang Thai Bao – ID: 2052869 10
Chapter 2: Design and testing belt convenyor
= 463.344 (mm)
Where:
 d 1 and d 2 are the diameters of driving and driven pulleys (mm)
 ξ = 0,01 ÷ 0,02 is the relativie slip coefficient of the belt drive, dependant
on loading
By standard as same as d 1, choose d 2 = 450 mm
 Real transmission ratio of B-belt:
d2 450
u= = = 2.296 (14)
d 1 ×(1−ξ) 200×(1−0.02)
->Error compare to the value u we choose earlier:
∆ u= |2.296−2.364
2.364 |×100%= 2.88% ≤ 3% (15)
5. Center distance:
 We calculate the range of a according to the following formula:
2(d 1+d 2) ≥ a ≥ 0.55(d 1+d 2) + h (16)
2(200+450) ≥ a ≥ 0.55(200+450) +10.5
1300 ≥ a ≥ 368
u 1 2 3 4 5 6
a= …d 2 1.5 1.2 1 0.95 0.9 0.85
-> Initial selection: a theory = 1.2d 2 = 540mm (for u¿2) => Satisfy condition (17)
6. Calculate the length of belt

π (d 1+ d 2) (d 2−d 1)2
L = 2a + + (18)
2 4a
π (200+450) ( 450−200)2
= 2*540+ +
2 4∗540
= 2129.953 mm
+ Note: Standard of L (mm): 400, 450, 500, 560, 630, 710, 800, 900, 1000,
1120, 1250, 1400, 1600, 1800, 2000, 2240, 2500, 2800, 3150, 3550, 4000,
5000, 5600, 6300, 7100, 8000, 9000, 10000, 11200, 12500, 14000, 16000,
18000
By standard, choose L=2500 mm = 2.5 m

We testing the revolution of belt per second base on the L we choose:

v 15.289
i= = = 6.12 ( s−1 ) < [I]= 10 ( s−1 ) (19)
L 2.5
 Recaculate center distance:

k + √ k +8 ∆ 1478.982+ √ 1478.982 +8∗125
2 2 2 2
a= = = 749.909 (mm) (20)
4 4
=> Satisfy with the condition ( 1000 ≥ a ≥ 285.5)

Within:
(d ¿ ¿ 1+ d 2) π (200+450)
 k=L-π ¿ = 2500 - = 1478.982 (21)
2 2
(d ¿ ¿ 2−d 1) ( 450−200)
 ∆= ¿= = 125 (22)
2 2
7. Calculate the wrap angle

d 2−d 1 450−200
α 1= 180 - 57* = 180 - 57× = 160.997° (≥ 120° ¿ (23)
a 749.909
=> α 1= 2.809 (rad)
8. Correction factors
 Contact angle correction factor:
C α = 1,24(1-e−α 1 /110
¿=¿1,24(1-e−160.997 / 110 ¿= 0.953
 Velocity correction factor:

C v = 1-0.05(0.0.1 v 2-1) = 1-0.05(0.01*15.2892-1) = 0.933
 Transmission ratio correction factor: C u= 1.12 because u= 2.364 ≈ u= 1.8

base on table 4.7 [ III ]
 Belt length correction factor: C L=

√ √
6 L
L0
=
6 2500
2240
= 1.018
+ Note: B type ( L0= 2240mm) base on the standard of table 4.8 [ III ]
 Number of belt correction factor (initial selection): C z = 0.95 where we
P1 ×C 7.389
calculate z= = = 1.43 then we select C z base on table 4.8 [ III
[ P0 ]× K d 5.133
]
 Operation correction factor: C r= 0.8 because it light-impact loading then
we select base on talbe 4.7 [ III ]
 C= C α ×C v ×C u × C L ×C z ×C r = 0.953×0.933×1.12×1.018×0.95×0.8 = 0.77

9. Number of belt calculation

We have a table showing the allowable useful power [ P0] according to table
4.8 [ III ]
 According to the table, we interpolate and get P0= 5.133 and L0=2240mm
with d 1= 200 and v= 15.289 m/s
 Number of belt:
1000 P1 P1 P1 C 7.5 × 0.77
z ≥ = = = = 1.023-> Select z= 2 (29)
[σ t ]vA [ P1 ] [ P0 ] K d 5.133× 1.1
Where K d = 1,1 in table 4.7 [ I ]

10. Force calculation
+ Maximum tension force:
780 Pmotor K d 780× 7.5 ×1.1

F 0= + F v= + 70.126= 290.95 (N)
v1 C α z 15.289× 0.953× 2
Where: F v = q m v 2= 0.3×5.2892 = 70.126

*Note: q m= 0.3 in table 4.22 [ I ]
+ Circumferential force:
1000 Pmotor 1000× 7.5

F t= = = 490.549 (N) (31)
v1 15.289
+Shaft load:
α1 160.997
F r= 2 zF 0sin =2×2×290.95 ×sin =1147.834(N) (33)
2 2
+ Maximum belt stress (Mpa):
1000 P1 Ft 2 y0
σ max = × + ρ v 2 ×10−6 + ×E (36)
vA 2A d1
1000∗7.5 490.549 2∗4
= × +1000×15.2892 ×10−6+ ×100
15.289∗138∗2 2× 138× 2 200
= 5.813 Mpa
Where:

ρ is density of belt (kg/m3 )
*Note: Base on a TCVN, dual speed gearbox density= 1000

v is peripheral velocity (m/s)
E is belt modulus of elasticity = 100 MPa
11. Life time service:
Lh= ¿ ¿ = ¿ ¿= 7492.963 (hours) (37)
Where as :
σ r is the limit fatigue stress of belt (MPa) (σ r = 9: V-belt)
V-belt: m= 8
12. V-Belt specification
Parameter Value
Belt type V-belt

Symbol B
Number of belt, z 2
Center distance, a (mm) 749.909
Wrap angle, α 1 (degree) 160.997
Belt length, L (mm) 2500
Error of transmission ratio 2.8%
Drive pulley diameter, d 1(mm) 200
Driven pulley diameter, d 2(mm) 450
Maximum tension force, F 0(N) 414
Force on input, F 1(N) 659.275
Force on output, F 2(N) 168.726
Resultant axle load, F r(N) 1633.282
Maximum shear stress, σ max(MPa) 6.045
Lifespan of belt, Lh (hours) 5478.803

Chapter 3: Design and testing gear
CHAPTER III: DESIGN AND TESTING GEAR

 Specifications
- Service life L: 5 years
- Number of working days per year: 329
- Number of shifts per working day: 1
- Operating conditions: one-direction working, light-impact loading, 8-hour
shift
 Fast stage helical gear:
Power P, kW 7.02
Transmission ratio u 2.54
Rotational speed of the driving gear n2 , rpm 617.597
Rotational speed of the driven gear n3 , rpm 243.148
Torque on the driving gear’s shaft T II , Nmm 108551.369
Torque on the driven gear’s shaft T III , Nmm 262052.742
 Slow stage spur gear:

Power P, kW 6.672
Transmission ratio u 2.36
Rotational speed of the driving gear n3 , rpm 243.148
Rotational speed of the driven gear n 4, rpm 103.029
Torque on the driving gear’s shaft T III , Nmm 262052.742
Torque on the driven gear’s shaft T IV , Nmm 587762.184

I. Fast stage helical gear

1. Choosing material:
Because there is not special require for the gear so we choose the gear base on
standard of the table 6.1 [ I ]. According from the table we choose the material
and the hardness of both gear but the hardness of driven gear is smaller than the
drive gear 10 to 15 unit [ H 1 ≥ H 2 + (10÷ 15)HB]
Material Heat treament Hardness σ 0 Flim σ hb σ melt

(MPa)
Drive C45 Improving 250 1.8 HB 850 580

gear quenching
Driven C45 Improving 235 1.8 HB 750 450
gear quenching
2.Theoretical operating cycles

N H 01= 30 HB 12.4= 30×250 2.4= 1.701×10 7 (cycles) (38)
N H 02= 30 HB 22.4 = 30×235 2.4= 1.471×10 7 (cycles) (39)
N F 01= N F 02= 5×10 6 (cycles) (40)

3. Determine allowable stress
+ Contact stress:
 Equivalent operating cycles:
N HE 1= 60c∑ (T i /T max )3 ni t i (41)
T 1 3 t1 T t
= 60×c× n1 ¿ Lh ×[ ( ¿ ¿ × + ( 2 ¿ ¿3 × 2 ]
T tp T tp
3 28
= 60×1×617.597×13160*[ (1 ¿ ¿ × +(
28+ 48
48
0.3 ¿ ¿3 × ]
28+48
≈ 1.879 ×10 8(cycles)
Where:
Lh: gear life ( hours) ( Lh= 329 x 5 x 8= 13160 )
c: number of gear contact to each other= 1

N HE 1 1.879× 108
 Similarly: N HE 2= = ≈ 7.398×10 7(cycles)
u12 2.54
+ Bending stress:
We have formula: N FE 1= 60c∑ (T i /T max )m ni t i with mF = 6 when HB≤ 350
F
 N FE 1 = 60c∑ (T i /T max )m ni t i F
(41)
T 1 3 t1 T 2 3 t2
= 60×c× n1 × L h ×[ ( ¿¿ × + ( ¿¿ × ]
T tp T tp
6 28 6 48
= 60×1×617.597×13160×[ (1 ¿ ¿ × + (0.3 ¿ ¿ × ]
28+ 48 28+48
≈ 1.799 ×10 9(cycles)
N FE 1 1.799× 109
 Similarly: N FE 2= = ≈ 7.083×10 8(cycles)
u 12 2.54
Because N HE 1> N H 01; N HE 2> N H 02; N FE 1> N F 01; N FE 2> N F 02 according to the
formula
Life factor: K HL =
√
mH NH0
N HE
; K FL =
√
mF N F0
N FE
(*Note: In case K HL < 1, select K HL= 1. Same with K FL)

 We have denominator is always bigger than numerator so the result is
always smaller than 1. Therefore, we choose K HL1= K HL2= K FL1= K FL2=1
 Fatigue limits for contact stresses :
{σ 0 Hlim1=2 HB1 +70=2× 250+70=570( Mpa)

σ 0 Hlim2=2 HB 2+70=2× 235+70=540( Mpa)
(42)
 Fatigue limits for bending stresses :
{σ 0 Flim 1=1.8 HB1 =1.8× 250=450( Mpa)

σ 0 Flim 2=1.8 HB2 =1.8× 235=423( Mpa)
(43)
 Allowable contact stress:

{
0.9 K HL1 0.9 ×1
[σ H 1]=σ 0 Hlim 1 =570 × ≈ 466.364 (MPa)
sH 1 1.1
(44)
0.9 K HL2 0.9 ×1
[σ H 2 ]=σ 0 Hlim 2 =540 × ≈ 441.818(MPa)
sH 2 1.1
 With inclined cylindrical gear transmission:

[σ H ]= √ 0.5 ×([σ H 1] ¿¿ 2+[σ H 2] 2¿)¿ ¿=√ 0.5 ×(466.364 ¿ ¿2+ 441.8182) ¿ ≈ 454.257
(45)
* Condition:
[σ Hmin ]≤[σ H ]≤ 1.25[σ Hmin ] (46)
441.818 ≤ 454.257 ≤ 552.273 -> Satisfactory
 Allowable bending stress:
{
0.9 K FL1 0.9∗1
[σ F 1 ]=σ 0 Flim 1 =450× =231.429(Mpa)
sF1 1.75
(47)
0.9 K FL2 0.9∗1
[σ F 2 ]=σ 0 Flim 2 =423× =217.543(Mpa )
sF2 1.75
*Note: With s F and s H is choose base on table 5.3 [ III ]

4. Allowable stress when overload
 We have contact stress when overload is :
[σ H ]max= 2.8σ melt (48)
Therefor:
[σ H 1 ]max= 2.8σ melt 1= 2.8×580 = 1624 MPa
[σ H 2 ]max= 2.8σ melt 2= 2.8×450 = 1260 MPa
 We have bending stress when overload is :

[σ H ]max = 0.8σ melt (49)
Therefor:
[σ F 1 ]max = 0.8σ melt 1= 0.8×580 = 464 MPa
[σ F 2 ]max = 0.8σ melt 2= 0.8×450 = 360 MPa

5. Calculate for inclined cylindrical gear transmission

Because the gears are placed unequal distance on the shaft we chooseψ ba base on
table 5.1 [ III ]. Then we select ψ ba= 0.3
u+1 2.54+1
=> ψ bd =ψ ba = 0.3× ≈ 0.53
2 2
 Base on table 5.5 [ III ] we have formula to calculate ψ bd . Because it have
unequal distance to bearings:
K H β = 1 + 0.275ψ bd = 1 + 0.1×0.53≈ 1.053 (51)

5.1 Center distance
a w 1 ≥ 43(u+1) 3
√ K H β ×T 1
2
ψ ba [ σ H 1 ] u
(52)
≥ 43(2.54+1) 3
√ 1.146 × 108551.369
2
0.3× 454.257 ×2.54
= 140.78 (mm)
-> Select a w 1= 160 mm
5.2 Gear module
mn= (0.01÷0.02)a w= (0.01÷0.02)×160= 1.6 ÷ 3.2(mm) (53)
-> Select mn= 2
5.3 Condition of helical angle ( 30° ≤ β ≤ 40° )

2 aw cos β min 2 aw cos β max
≥ Z1 ≥ (54)
mn (u +1) mn (u+ 1)
2× 160× cos 30 ° 2× 160× cos 40 °

≥ Z1 ≥
2 ×(2.54+1) 2×(2.54+ 1)
39.142 ≥ Z1 ≥ 34.623
+ Select Z1 = 38 then we calculate Z2 = u Z1 = 2.54×36 = 96.52

=> We select Z2 = 97
Z 2 97
Then we have actual tranmission ratio for fast stage is u12= = = 2.55
Z 1 38
Z 1 mn (u+ 1) 38× 2×(2.54 +1)

+ Helical angle: β= arccos[ ]= arccos[ ]= 32.781°
2 aw 2 ×160
(55)
5.4 Diameters of circles
 Diameters of pitch circle d

m Z1 2∗38
d 1= = = 90 (mm)
cos β cos(32.781)
(57)
m Z2 2∗97
d 2= = = 230 (mm)
cos β cos(32.781)
 Diameter of addendum circlesd a
d a 1=d 1+2 mn=90
d a 2=d 2+2 mn=230+ 2× 2=234 (mm)
 Diameter of dedendum circle d d (59)
d d 1=d 1−2.5 m n=90−2.5 ×2=85 ¿)
d d 2=d 2−2.5 mn=230−2.5 ×2=225¿ )
5.6 Face width
+ b w 2= ψ baa= 0.3*160= 48(mm) (60)

bw 1 b
+ = 1.07( page 103−[I ] ) => w 1 =1.07 => b w1 = 51.36 (mm)
bw 2 48
5.7 Tangential velocity
π d 1 n1 π × 90× 617.597
v= 4 = 4
=2.91(m/ s) (61)
6 ×10 6 ×10
-> Select accurate class 9 according to table 6.3 [ IV ]
5.8 Select dynamic load factors
Base on the tangential velocity v = 2.91 (m/s) and accurate class 9 we use the
table 6.5 [ V], 6.11 [V], 6.7 [V]
=> According to the table, we interpolate and have: K HV =1.06, K FV = 1.13 and
K H α= 1.13, K F α = 1.37 and K Hβ= 1.053, K Fβ= 1.15

5.9 Verification of contact stress
σ H=
d1 √
Z M Z H Z ε 2 T 1 K H (u ± 1)
bw u
(64)
=
275×
√ 2 cos(32.781)
sin (2× arctg( tg(20)/cos (32.781)))
90
×
1
1.482 √ √ 2 ×108551.369 ×(1.06 ×1.053 ×1.13)×(2.54 +
2.54 × 48
= 339.86 (Mpa)
 Where:
Z M = 275 (MPa) for steel gears
Z H factor on contact surface:

√ 2 cosβ α
sin 2 α w
; tw= arctg(tg(α nw)/cos( β ))
Z ε gear contact coincidence:

√ 1
εα
1 1 1 1
=> ε α = [ 1.88-3.2( Z + Z ) ]cos β = [ 1.88-3.2( + ) ]cos(32.781)= 1.482
1 2 38 97
K H load factor on contact: K Hα K Hβ K Hv
b w: belt width = b w 2 (66)
 Recalculate bending stress:

K HL Z R Z V K l K xH
[σ ¿¿ H ]¿= σ 0 Hlim (67)
sh
Where:
 Z R: Factor of surface toughness= 0.95
 ZV : Factor that effect the tangential velocity
*When v ≤ 5 then ZV = 1 (68)
 K l : Factor that effect the lubrication
 K xH : Factor that determine the size of tooth:
√ 10 10 √
K xH = 1.05− d 4 = 1.05− 904 = 1.02 (69)
0.95 ×1 ×1 ×1.02
=> [σ ¿¿ H ]¿=454.257× = 400.159
1.1

=> σ H = 357.06 ¿ [σ ¿¿ H ]=400.159¿ it satisfy the condition
5.10 Verification of bending stress
 Allowable bending stress

K FL Y R Y x Y δ K FC
[σ ¿¿ F ]¿ = σ 0 Hlim (70)
sF
Where:
K FC= 1 because it has one-direction working
Y R= 1 when it milling and grinding teeth of gear
Y x is factor of size = 1.05 - 0.005m= 1.05-0.005×2= 1.04
Y δ is a gear material sensitivity to stress concentration:
Y δ = 1.082 - 0.1721lg(m) =1.082 - 0.1721×lg(2)= 1.03 (71)
=> ¿
 Calculate Y F 1 and Y F 2 base on the formula with x is profile shift factor

which equal to 0 because helical don’t need to adjust distance to make sure
the center distance is fit instead it change the angle of gear tooth to do it.
13.2 27.9 x
Y F= 3.47 +
z v - z v + 0.092 x (72)
2
13.2
Y F 1= 3.47 + = 3.677 (73)
63.66
13.2
Y F 2= 3.47 + = 3.551
162.69
d
Where z v = 2
mn cos β
90
 zv 1 = 2 = 63.66
2∗cos (32.781)

230
 zv 2 = 2 = 162.69
2∗cos (32.781)
Recalculate the bending stress of gear tooth:

Y F1 Ft K F Y ε Y β
σ F1= (75)
bw m
108551.369
3.677× 2× ×1.78 ×0.675 ×0.765
= 2
2.54 × 48 ×90
= 33.435 MPa
Y F2 3.551
σ F 2 =σ F 1 × = 33.435 × = 32.289 MPa
Y F1 3.677
W
Where:
 K F=K Fα K Fβ K Fv = 1.37×1.15 ×1.13≈ 1.78 (76)
1 1
 Y ε= ε = = 0.675 : Coefficient taking into account the effect of
α 1.482
horizontal matching
β 32.781
 Y β= 1 - = 1- = 0.765: Factor taking into account the influence of
140 140
tooth inclination angle on flexural strength
 ¿ => Satisfy the condition
=> Therefor, bending stress is satisfy

6. Helical gear specification
Parameter Value
Center distance a , mm 160
Normal module m n, mm 2
Face width b w, mm b 2=48 mm ; b1 =51.36 mm
Transmission ratio 2.57
Helix angle β , degree 32.781 °
Number of teeth Z1 =¿38 Z2 =¿97
Profile shift coefficient x x 1=0 x 2=0
Diameter of pitch circle d , mm 90 230
Diameter of addendum circle d a , mm 94 234
Diameter of dedendum circle d d , mm 85 225
Pressure angle α nw , degree 20 °
Profile angle α tw , degree 23.408°

II. Slow stage spur gear

1. Choosing material:
Because there is not special require for the gear so we choose the gear base on
standard of the table 6.1 [ I ]. According from the table we choose the material
and the hardness of both gear but the hardness of driven gear is smaller than the
drive gear 10 to 15 unit [ H 1 ≥ H 2 + (10÷ 15)HB]
Material Heat treament Hardness σ 0 Flim σ hb σ melt

(MPa)
Drive C45 Improving 250 1.8 HB 850 580

gear quenching
Driven C45 Improving 235 1.8 HB 750 450
gear quenching
2.Theoretical operating cycles

N H 01= 30 HB 12.4= 30×250 2.4= 1.701×10 7 (cycles) (38)
N H 02= 30 HB 22.4 = 30×235 2.4= 1.471×10 7 (cycles) (39)
N F 01= N F 02= 5×10 6 (cycles) (40)

3. Determine allowable stress
+ Contact stress:
 Equivalent operating cycles:
N HE 1= 60c∑ (T i /T max )3 ni t i (41)
T 1 3 t1 T t
= 60×c× n3 ¿ Lh ×[ ( ¿ ¿ × + ( 2 ¿ ¿3 × 2 ]
T tp T tp
3 28
= 60×1×243.148 ×13160*[ (1 ¿ ¿ × +(
28+ 48
48
0.3 ¿ ¿3 ]
28+ 48
≈ 7.401 ×10 7(cycles)
Where:
Lh: gear life ( hours) ( Lh= 329 x 5 x 8= 13160 )
c: number of gear contact to each other= 1

N HE 1 7.401×10 7
 Similarly: N HE 2= = ≈ 3.136×10 7(cycles)
u34 2.36
+ Bending stress:
We have formula: N FE 1= 60c∑ (T i /T max )m ni t i with mF = 6 when HB≤ 350
F
 N FE 1 = 60c∑ (T i /T max )m ni t i F
(41)
T 1 3 t1 T 2 3 t2
= 60×c× n3 × Lh ×[ ( ¿¿ × + ( ¿¿ × ]
T tp T tp
6 28 6 48
= 60×1×243.148 ×13160×[ (1 ¿ ¿ × + (0.3 ¿ ¿ × ]
28+ 48 28+48
≈ 7.082 ×10 7(cycles)
N FE 1 7.082 ×107
 Similarly: N FE 2= = ≈ 3×10 7(cycles)
u 12 2.36
Because N HE 1> N H 01; N HE 2> N H 02; N FE 1> N F 01; N FE 2> N F 02 according to the
formula
Life factor: K HL =
√
mH NH0
N HE
; K FL =
√
mF N F0
N FE
(*Note: In case K HL < 1, select K HL= 1. Same with K FL)

 We have denominator is always bigger than numerator so the result is
always smaller than 1. Therefore, we choose K HL1= K HL2= K FL1= K FL2=1
 Fatigue limits for contact stresses :
{σ 0 Hlim1=2 HB1 +70=2× 250+70=570( Mpa)

σ 0 Hlim2=2 HB 2+70=2× 235+70=540( Mpa)
(42)
 Fatigue limits for bending stresses :
{σ 0 Flim 1=1.8 HB1 =1.8× 250=450( Mpa)

σ 0 Flim 2=1.8 HB2 =1.8× 235=423( Mpa)
(43)
 Allowable contact stress:

{
0.9 K HL1 0.9 ×1
[σ H 1]=σ 0 Hlim 1 =570 × ≈ 466.364 (MPa)
sH 1 1.1
(44)
0.9 K HL2 0.9 ×1
[σ H 2 ]=σ 0 Hlim 2 =540 × ≈ 441.818(MPa)
sH 2 1.1
+ Allowable contact stress for calculation:

[σ H ] = min([σ H 1 ],[σ H 2 ])= 441.818( Mpa )
 Allowable bending stress:
{
0.9 K FL1 0.9× 1
[σ F 1 ]=σ 0 Flim 1 =450× =231.429( Mpa)
sF1 1.75
(47)
0.9 K FL2 0.9× 1
[σ F 2 ]=σ 0 Flim 2 =423× =217.543( Mpa)
sF2 1.75
*Note: With s F and s H is choose base on table 5.3 [ III ]

4. Calculate for spur gear transmission
Because the gears are placed equal distance on the shaft we chooseψ ba base
on table 5.1 [ III ]. Then we select ψ ba= 0.4
u+1 2.36+1
ψ bd =ψ ba = 0.4 × =¿ 0.672
2 2
 Base on table 5.5 [ III ] we have formula to calculate ψ bd . Because it have

unequal distance to bearings:
K H β = 1 + 0.0373ψ bd = 1 + 0.0373×0.672≈ 1.025
4.1 Center distance
a w ≥ 50(u+1) 3
√ K H β ×T 1
ψ ba [σ H 1 ]2 u
(79)
≥ 50(2.36+1) 3
√ 1.025× 262052.742
0.4 ×441.818 2 ×2.36
= 190.48 (mm)
-> Select a w= 195 mm
4.2 Gear module
mn= (0.01÷0.02)a w= (0.01÷0.02)×195= 1.95÷3.9(mm) (80)

-> Select mn= 2.5 mm
4.3 Total number of teeth
2 aw 2× 195
Z3 = = = 46.42
m(u2+ 1) 2.5(2.36+1)
 Select Z3 = 46 then calculate Z 4=u2 Z 3

= 2.36× 46 = 108.56
=> Select Z 4= 109

4.4 Recaculate tranmission ratio and center distance
Z 2 109
+u34 = = = 2.37
Z 1 46
m(Z 3 + Z 4) 2.5(46 +109)

+ a w= = = 193.75
2 2
4.5 Calculate profile shift factor
Because the center distance we calculate is a w= 193.75mm we want to profile

shift it to prevent root cutting phenomenon and increase contact strength,
flexural strength so we profile shift it to a w= 195mm
Base on the formula 6.22 [ I ]:
aw 195
y= - 0.5( Z3 + Z 4)= - 0.5( 46 + 109)= 0.5
m 2.5
1000 y 1000× 0.5
 Follow formula 6.23 [ I ] : ky= Zt = 155
= 3.226
 Base on the table 6.10a [ I ] we have : k x = 0.077

k x Z t 0.077 ×155
 Using the formula (6.24) [ I ]: ∆ y = = = 0.012
1000 1000
 Using the formula (6.25) [ I ]: x t = y + ∆ y = 0.5 + 0.012= 0.512

 Using the formula (6.26) [ I ]:
( Z 4−Z 3) y (109−46) 0.5
x 1= 0.5[ x t - ]= 0.5[0.512 - ]= 0.154
Zt 155
x 2= x t - x 1= 0.512 - 0.154= 0.358
Using the formula (6.27) [ I ] angle contact:

mCosα 2.5 ×cos 20
cosα tw= Zt × 2 a = 155 × = 0.933
w 2×195
=> α tw= 20.98 °
4.6 Diameters of circles
 Diameters of pitch circle, d

d 3= m Z 1= 2.5*46= 115 (mm) (83)

d 4 = m Z 2= 2.5*109= 272.5(mm)
=> we select d 4 = 273 (mm)

 Working pitch diameter
2 y d3 2 ×0.5 ×115
d w =d 3+ =115+ =115.742 mm
3
Z 3+ Z 4 46+109
2 y d4 2× 0.5 ×273
d w =d 4 + =273+ =274.76 mm
4
Z3+ Z4 46+109
 Diameter of addendum circles,d a (84)
d a 3=d 3+ 2mn=11
.
d a 4 =d 4 + 2mn=273+ 2× 2.5=278(mm)
 Diameter of dedendum circle, d d (85)
d d 3=d 3−2.5 m n=115−2.5 ×2.5=108.75¿ )
=> we select d d 3= 109 (mm)

d d 4=d 4−2.5 mn=273−2.5 ×2.5=266.75 ¿) (86)
=> we select d d 4= 267 (mm)

 Base diameter, d b
d b =d 3 cos α =115 cos 20 °=108.06 mm

3
=> we select d b 3 = 108 (mm)

d b =d 4 cos α=273cos 20° =256.54 mm
4
=> we select d b 4 = 257 (mm)
4.7 Face width
b w 2= ψ baa= 0.4×195= 78 (mm) (87)

bw 1 b
= 1.06 => w 1 =1.06 => b w1 = 82.68 (mm) (88)
bw 2 78
=> We select b w1 = 83 (mm)
4.8 Tangential velocity
π d III n III π ×112.5 × 243.148

v= = =1.432(m/s) (89)
6∗10
4
6 ×104
-> Select accurate class 9 according to table 6.3 [ IV ]
4.9 Select dynamic load factors
Base on the tangential velocity v = 1.464 (m/s) and accurate class 9 we use the
table 6.5 [ V], 6.11 [V], 6.7 [V]
=> According to the table, we interpolate and have: K HV =1.03, K FV = 1.06 and
K H α = 1.13, K F α = 1.37 and K Hβ= 1.01, K Fβ= 1.01
4.10 Verification of contact stress
σH =
dw 1 √
Z M Z H Z ε 2 T III K H (u ± 1)
bw u
(92)
=
275×
√ 2
sin(2× 20.98)
115
×
4−1.78
3 √ √ 2 ×262052.742×(1.13 ×1.01 ×1.03)(2.36+1)
2.36 ×78
= 377.29 (Mpa)
Where:
Z M = 275 (MPa) for steel gears
Z H factor on contact surface:

√ 2
sin 2 α w
;
Z ε gear contact coincidence:

√ 4−ε α
3
base on (6.38b) [ I ]
1 1 1 1
=> ε α = [ 1.88-3.2( Z + Z ) ] = [ 1.88-3.2( + ) ]= 1.78 (93)
1 2 46 109

K H load factor on contact: K Hα K Hβ K Hv
 Recalculate bending stress:

K HL Z R Z V K l K xH
[σ ¿¿ H ]¿= σ 0 Hlim (94)
sh
Where:
 Z R: Factor of surface toughness= 0.95
 ZV : Factor that effect the tangential velocity
*When v ≤ 5 then ZV = 1 (95)
 K l : Factor that effect the lubrication = 1
 K xH : Factor that determine the size of tooth:
√ 10 10 √
K xH = 1.05− d 4 = 1.05− 1154 = 1.019 (96)
0.95 ×1 ×1 ×1.019
=> [σ ¿¿ H ]¿= 441.818 × = 388.819
1.1
=> σ H = 377.29 < [σ ¿¿ H ]=388.819¿
4.11 Verification of bending stress
 Allowable bending stress

K FL Y R Y x Y δ K FC
[σ ¿¿ F ]¿ = σ 0 Flim (97)
sF
Where:
K FC= 1 because it have one-direction working
Y R= 1 when it milling and grinding teeth of gear
Y x is factor of size = 1.05 - 0.005m= 1.05-0.005*2.5= 1.038
Y δ is a gear material sensitivity to stress concentration:
+ Y δ = 1.082 - 0.1721lg(m) =1.082 - 0.1721lg(2.5)= 1.014 (98)

=> ¿
 Calculate Y F 1 and Y F 2 base on the formula:
13.2 27.9 x
Y F 1= 3.47 +
Z v1 - Z v 1 + 0.092 x
2

13.2 27.9× 0.512

= 3.47 + - + 0.092× 0.5122 = 3.47
46 46
13.2 27.9 x
Y F 2= 3.47 +
Z v2 - Z v 1 + 0.092 x
2
13.2 27.9× 0.512

= 3.47 + - + 0.092× 0.5122 = 3.48
109 109
d
+ Where z v = 2
mn cos β
115
 zv 1 = 2 = 46
2.5× cos (0)
272.5
 zv 2 = 2 = 109
2.5× cos (0)
 Recalculate the bending stress of gear tooth:

Y F1 Ft K F Y ε Y β
σ F1= (75)
bw m
262052.742
3.526× 2× × 1.78 ×1× 0.562
= 2
2.54 ×78 × 115
= 40.569 MPa
Y F2 3.48
σ F 2 =σ F 1 × = 40.569 × = 40.686MPa
Y F1 3.47
W
Where:
 K F=K Fα K Fβ K Fv = 1.37×1.15 ×1.13≈ 1.78 (76)
1 1
 Y ε= ε = = 0.562 : Coefficient taking into account the effect of
α 1.78
horizontal matching
 Y β= 1 Factor taking into account the influence of tooth inclination angle on
flexural strength
 ¿ => Satisfy the condition

=> Therefor, bending stress is satisfy

5. Spur specification
Parameter Value
Center distance a , mm 195
Normal module mn, mm 2.5
Face width b w, mm b w 2=78 mm ; bw 1=83 mm
Transmission ratio 2.37
Number of teeth Z1 =¿ 46 Z2 =¿ 109
Profile shift coefficient x x 1=¿0.154 x 2=0 .358
Diameter of pitch circle d , mm 115 273
Diameter of addendum circle 120 278

mm
Diameter of dedendum circle 108.75 267

mm
Pressure angle α nw, degree 20 °
Contact angle α t w , degree 20.98 °


 Recalculate the tranmission system:
 Rotational speed on speed shaft:
n motor=1460( rpm)
n motor 1460
n II = = =635.888(rpm)(9)
ub 2.296
n II 635.888
n III = = =247.427(rpm)
u 12 2.57
nIII 247.427
n IV = = =104.399(rpm)
u34 2.37
n IV 104.399
n conv= = =104.399(rpm)
ucp 1
 Torque on each shaft:
6 PI 6 7.389
T motor =T I =9.55 ×10 × =9.55 ×10 × =48332.158 ( Nmm ) (10)
n1 1460
PII 7.02
T II =9.55 ×106 × =9.55 ×106 × =105428.944(Nmm)
n II 635.888
P III 6.672
T III =9.55 ×10 6 × =9.55 ×106 × =257520.804 ( Nmm)
nIII 247.427
6 P IV 6 6.341
T IV =9.55 ×10 × =9.55 ×10 × =580049.138( Nmm)
nIV 104.399
6 Pconv 6 6.152
T conv =9.55 ×10 × =9.55× 10 × =562760.179(Nmm)
n conv 104.399

After we have recalculate the tranmission ratio and torque. We receive the
following table of parameters of the transmission system:
Shaft
Motor II III IV Conveyor
Parameters
Power P 7.389 7.02 6.672 6.341 6.152
(kW)
Transmission ratio 2.296 2.57 2.38 1

u
Rotational speed 1460 635.888 247.427 104.399 104.399
(n, rpm)
Torque T 48332.158 105428.944 257520.804 580049.138 562760.179
(Nmm)
=> ∆ nconv = | n |
nconv −n
|
∗100=
104.399−103.029
103.029 |
∗100=1.33 % <2 %

Chapter 4: Design of shaft
CHAPTER IV: DESIGN OF SHAFT

I. Choosing material
Material that commonly using in desgin, manufacture in gearbox is C45 steel
normalization. We know σ b= 600(MPa), [τ ]= 20÷ 25MPa. We choose [τ ]= 25
with Shaft II and IV and [τ ]= 15MPa with shaft III
II. Preliminary design diameter and length of shaft
d≥
√
3 5T
[τ ]
 d2 ≥
√ √
3 T2
[τ ]
=
3 5∗105428.944
25
= 27.627mm
 d3 ≥ 3
√ √ 5T 3 3 5∗257520.804
[τ ]
=
15
= 44.113 mm
 d4 ≥
√ √
3 5T4
=
3 5∗580049.138
[τ ]
= 48.77 mm
25
 We choose preliminary diameter for each shaft base on standard:

d 2= 30 ; d 3= 45 ; d 4 = 55
Base on the diameter we have calculated above and by using the table 10.2 [ I ]
we have diameter for bearing:
b 01 =¿ 19 ; b 02= 25 ; b 03= 29
 Determine the preliminary length

l m 22= (1.4…2.5) × 30= (42…75) -> Choose l m 22= 50
l m 23= (1.2…1.5)×30= (36…45) -> Choose l m 23= 42
l m 32= (1.2…1.5) × 45= (54…67.5) -> Choose l m 32= 56
l m 42= l m 43 = (1.2…1.5) × 55= (66…82.5) -> Choose l m 42= 80
 Shaft II
+ lc 22= 0.5(lm 22 + b 01) + k 3 + k n= 0.5(50 + 19) + 10 + 15= 59.5
=> Select l c 22=60
+ l23= 0.5(l m 32 + b 02) + k 1 + k 2= 0.5(56 + 25) + 12 + 10= 62.5
=> Select l 23= 63

+ l24 = 2l 33 - l 23= 2×146 - 63= 229
 Shaft III
+ l 23= l 32= 63
+ l33= l 32 + 0.5(l m 33 + l m 32) + k 1 + k 2= 63 + 0.5(66 + 56) + 12 + 10= 146
=> l m 33= (1.2…1.5)×45= (54…67.5)= 66
+ l 34= l 24 = 229
+ l31= 2×146= 292
 Shaft IV
+ l42= l 33= 146
+ l21= l 31= l 41= 292
+ lc 43= 0.5(l m 43 + b 03) + k 3 + k n= 0.5(80 + 29) + 10 + 15= 79.5
=> Select l c 43= 80
III. Determine force on shaft
a. Draw axis diagrams, rotating detail diagrams and forces from
rotating parts acting on the shaft
+ Calculate the circular force, axial force, radial force:
T1 105428.944
2× 2×
 Tangential force: F t 1= F t 2= 2 = 2 = 1171.433 N
d1 90
2× T 2 2× 257520.804
F t 3= = = 4578.148 N
d2 112.5
 Axial force : F a 1= F a 2= F t 1tan β = 1171.43×tan(32.781)= 754.385 N

tan α tw tan20
 Radial force: F r 1= F r 2= F t 1 × = 1171.43 × = 507.128 N
cosβ cos 32.781
F r 3= F t 3 × tan α tw= 4578.15× tan ¿0.91)= 1749.141 N
+ Force on belt: F r= 1147.834 (N)

2T 1 2× 565131.155
+ Force on coupling: F r= 0.2 F t= 0.2× = 0.2× = 1738.865 N
Dt 130

b. Calculate the reactions on shaft in the zOy and zOx . planes:

 Shaft II
Moment cause by axial force:
d1 90
M 1= F a 1 × = 754.385× = 33947.325 (Nmm)
2 2
 On yOz plane: At B
{ F rA + F rD+ F rC =F rB + F ℜ {
FrA AB+ F rD BD + F rC BC + M 1C =M 1 D + F ℜ BE F =747.932( N )
⇒ ℜ
F rB=−881.51( N)
 On xOz plane: At B

{ FtA + F tE=F tC + F tD {
FtE BE =FtC BC+ F tD BD F tE=1171.433( N )
⇒
F tB=1171.433( N )

 Shaft III
Moment cause by axial force:
d1 230
M 2= F a 1 × = 754.39× = 86754.85 (Nmm)
2 2
 On yOz plane: At A
{ F rB+ F rD =F rA + F ℜ + FrC {
FrB AB + F rD AD + M 1 B=M 1 D + F rC AC + F ℜ AE F =−367.443( N )
⇒ ℜ
RrA =−367.443(N )
 On xOz plane: At A
{ F tB+ F tD + FtC =F tE + FtA

⇒
{
FtB AB + F tD AD + FtC AC=F tE AE F tE =3460.507(N )
F tA =3460.507(N )


 Shaft IV
 On yOz plane: At B
{ FrB AB=FrC AC
F rA + F rC =F rB {
F =874.571( N )
⇒ rC
R rA =874.571(N )
 On xOz plane: At A
{ FtB AB =FtC AC+ F tD AD

F tA + F tC + F tD=F tB {
F =79.763( N )
⇒ tC
F tA =2759.52(N )

c. Determine diameter on each shaft:

We have the formula to determine the diameter base on moment we have
calculated above:
+ Equivalent moment:
M eqj= √M 2
xj
2 2
+ M yj +0.75 T j (Nmm)
+ Shaft diameter:
dj ≥3
√ M eqj
0.1[σ ]
(mm)
Where [σ ] is the allowable stress of steel to make shaft. With σ b= 600MPa base
on the table 10.5 [ I ] we choose σ 1= 63, σ 2= 63, σ 3= 50
 By using the formula we have mention above we result moment equivalent
on each shaft:
+ Shaft II
M eq 22= 91304.14 (Nmm) M eq 24 = 115053.68 (Nmm)
M eq 20 = 104859.03 (Nmm) M eq 21 = 0
M eq 23 = 143582.32 (Nmm)
+ Shaft III
M eq 30 = 111509.77 (Nmm) M eq 34 = 260045.49 (Nmm)
M eq 32= 260045.49 (Nmm) M eq 31= 111509.77 (Nmm)
M eq 33 = 482962.37 (Nmm)
+ Shaft IV
M eq 40 = 0 M eq 41 = 522823.213 (Nmm)
M eq 42 = 658101.726 (Nmm) M eq 43 = 504453.696 (Nmm)
 Result of diamter on each part of the shaft:

+ Shaft II
d 22 ≥ 24.38 (mm) d 24 ≥ 26.33 (mm)
d 20 ≥ 25.53 (mm) d 21= 0
d 23 ≥ 28.35 (mm)

+ Shaft III
d 30 ≥ 26.06 (mm) d 34 ≥ 34.55 (mm)
d 32 ≥ 34.55 (mm) d 30 ≥ 26.06 (mm)
d 33 ≥ 42.48 (mm)
+ Shaft IV
d 40 ≥ 0 d 41 ≥ 47.11 (mm)
d 42 ≥ 50.86 (mm) d 43 ≥ 46.55 (mm)
Base on the diameter we have calculated above to make sure it guarantee accuracy,
machinability and assembly request we choose diameter shaft like below:
+ Shaft II
d 22 = 25 (mm) d 24 = 34 (mm)
d 20 = 30 (mm) d 21= 30 (mm)
d 23 = 34 (mm)
+ Shaft III
d 30= 45 (mm) d 34 = 50 (mm)
d 32= 50 (mm) d 31= 45 (mm)
d 33= 55 (mm)
+ Shaft IV
d 40 = 55 (mm) d 41 = 55 (mm)
d 42 = 60 (mm) d 43 = 50 (mm)

IV. Key design

Base on the diameter we have calculated before, we choose and test feather
key. Select C45 material for feather key, allowable cut stress [τ C ¿=40 … 60 MPa
because of light impact loading therefore stress reduce 1/3, we select [
τ C ¿=60 MPa.
Allowable Stamp stress, we select [σ d ¿=100 MPa light impact loading base
for shaft II and IV and select [σ d ¿=40 MPa light impact loading for shaft II
base on table 9.5 [ I ]Base on table 9.1 [ I ] we select key for each section on
each shaft:
Section Diameter Size of key
b(mm) h(mm) t1 t2
22 25 8 7 4 2.8
23 34 10 8 5 3.3
24 34 10 8 5 3.3
32 50 16 10 6 4.3
33 55 16 10 6 4.3
34 50 16 10 6 4.3
42 60 18 11 7 4.4
43 50 16 10 6 4.3
After select the key we need to test it to see it satisfactory the condition by using the
formula:
2T
 σ d= [d ×l h−t ] ≤[σ d ] ( Formula 9.1 [ I ] )
t( 1)
2T
 τ c= ≤[τ c ] ( Formula 9.2 [ I ] )
(d lt b)
Where:
+ d (mm) is shaft diameter + [σ d ] (Mpa) is allowable stamping
stress
+ T (Nmm) is torque
+ [τ c ¿ (Mpa) is allowable shear stress
+l t , b, h, t 1 is a size of a key we have
select base on table 9.1 [ I ]


 Compute table
Shaft Section d lm lt σd τc T
II 22 25 50 45 62.476 23.428 105428.944

II 23 34 42 37.8 27.344 7.383 52714.472
II 24 34 42 37.8 27.344 7.383 52714.472
III 32 50 56 50.4 25.547 6.386 128760.402
III 33 55 66 59.4 39.412 9.853 257520.804
III 34 50 56 50.4 25.547 6.386 128760.402
IV 42 60 80 72 67.418 14.982 582492.954
IV 43 50 80 72 80.902 20.225 582492.954
=> Satisfactory the condition so we can select the key

V. Testing the shaft on the fatigue durability
Structure of shaft need to satisfie fatigue durability if safty factor at dangerous
sections satisfie following condition:
s τj
 s j=sσj × ≥[s ] (Formula 10.19 [ I ])
√s 2
σj
2
+ sτj
Where:
+ [ s ] =1.5 … 2.5 is safety factor
+ s2σj ∧s2τj following safety factor of perpendicular stress and tangential stress:
σ −1
 sσj = (Formula 10.20 [ I ])
K σdj σ aj +ψ σ σ mj
τ−1
 sτj = (Formula 10.21 [ I ])
K τdj τ aj +ψ τ τ mj
We have:
+ σ −1∧τ −1 – fatigue limit of bending stress and twisting stress with symmetry
cycles we can choose σ −1=0,436 σ b∧τ−1 ≈ 0,58 σ −1
=> We have choose material C45 steel ¿ ¿)

{ σ−1=0,436× 600=261.6 MPa

τ −1 =0,58× 261.6=151.73 MPa
+ σ aj , σ mj , τ aj , τ mj Average amplitude and value of perpendicular stress and

tangential stress at section j:
σ maxj −σ minj
 σ aj =
2
σ maxj +σ minj
 σ mj=
2
For the axis of rotation, the torsional stress varies with the period of
symmetry, so:
Mj
 σ mj =0 ; σ aj =σ maxj = (Formula 10.22 [ I ])
Wj
*Note: M j =√ M 2yj + M 2xj

Because the shaft rotates in one direction, the torsional stress changes with the
circuit period
τ maxj T
 τ mj =τ aj = = j (Formula 10.23 [ I ])
2 2 W oj
With W j∧W 0 j is the bending moment and the torsion moment is determine
base on table 10.6 [ I ]:
2
π d 3j b t 1 ( d j−t 1 )
 W j= −
32 2d j
3 2
π d j b t 1 ( d j−t 1 )
 W oj = −
16 2dj
*Note: ψ σ =0.05; ψ τ =0 - Effect factor of average stress value on fatigue strength

select base on table 10.7 [ I ]
Shaft Dangerous M(Nmm) W Wo σa T(Nmm) τm
section
II 23 138031.8 3240.28 7098.94 42.59 52714.472 3.71
8
III 33 435422.8 14238.41 30572.2 30.58 257520.80 4.21
8 4 4
IV 42 422639.7 18256.3 39462.0 23.15 582492.95 7.38

4 5 4

 K σdj and K τdj coefficient determined by the formula:

Kσ
+ K x −1
+ εσ ( Formula 10.25 [ I ] )
K σdj =
Ky
Kτ
+ K x −1
+ ετ ( Formula 10.26 [ I ] )
K τdj =
Ky
Where:
+ K x: Stress concentration coefficient due to surface state, using table 10.8 [ I ]
we have K x= 1.06
+ K y : Stress coefficient for shaft surface, using current quenching method we
have K y = 1.7
+ ε σ and ε τ Dimensional factor takes into account the influence of shaft cross-
sectional dimensions on fatigue limit, values given in table 10.10 [ I ]
+ K σ and K τ : Actual stress concentration coefficients in bending and torsion,
their values depend on the type of stress concentration factors according to the
tables 10.11 [ I ], 10.12 [ I ], 10.13 [ I ]
Shaft Shaft Kσ Kτ
εσ ετ
II 23 2.06 1.64
III 33 2.52 2.03
IV 42 2.52 2.03
With the data we have calculated, we have:

Shaft Section K σd sσ K τd sτ S [S]
II 23 1.25 4.91 1 38.95 4.87
III 33 1.52 5.64 1.23 28.16 5.53 1.5…2.5
IV 42 1.52 7.43 1.23 16.71 6.79

=> It satisfy condition S > [S] for each shaft

VI. Testing shafts on static durability
To prevent the possibility of excessive plastic deformation or damage due to
sudden loading (such as when opening the machine), it is necessary to conduct
a shaft test for static strength. We have formula 10.27 [ I ]
σ eq= √ σ + 3 τ ≤ [σ ]
2 2
Where:
M max
+ σ= 3 ( Formula 10.28 [ I ] )
0.1 d
T max
+ τ= ( Formula 10.29 [ I ] )
0.2d 3
+ ¿ ]≈ 0.8 σ melt ≈ 0.8× 340≈ 272 ( MPa )
Shaft Section σ τ σ eq
II 23 35.12 6.71 36.99

III 33 26.11 7.74 29.35
IV 42 19.56 13.48 30.46
=> Satisfy the condition so the shaft can handle the force when starting the
machine without plastic deformation or damage to shaft causing it to break.
VII. Coupling
We choose elastic shaft coupling because using elastic shaft coupling has the
advantages of simple structure, easy manufacture and replacement, and reliable
workability.
Using table 16.10a [ II ] we have basic dimensions of elastic shaft coupling
base on T= 582492.954 Nmm, we have:
d D dm L l d1 D0 z n max B B1 l1 D3 l2
50 210 95 175 110 90 160 8 2850 6 70 40 36 40
Using table 16.10b [ II ] we have detail of elastic ring:

dc d1 D2 l l1 l2 l3 h
18 M12 25 80 42 20 36 2

 Stamping strength condition of elastic ring:

2 kT
σ d= ≤ σ
Z D0 d c l 3 [ d] (Formula page 69-[ II ])
With:
k - working coefficient, using table 16.1 [ II ] we have k= 1.5
[σ d]= 4MPa with rubber ring
2× 1.5× 582492.954
=> σ d= = 2.11 ≤ [σ d]= 4
8× 160× 18 ×36
=> The elastic ring satisfies the stamping strength condition

 Strength condition of pin
kT l 0
σ u= 3 ≤ [σ u]
0.1 d c D 0 Z
With:
l2 20
l 0= l 1 + = 42 + = 52
2 2
[σ u]= 80MPa- Allowable stress of pin

1.2×582492.954 × 52
=> σ u= =¿ 48.69MPa ≤ [σ u]= 80MPa
0.1 ×183 ×160 ×8
=> Pin is satisfies the strength condition of pin

Chapter 5: Bearing desin
CHAPTER V: BEARING DESIGN

We have working hours is L= 13160 hours
 Shaft II
a. Choosing type of bearing
Rotation speed: n2 =635.888 rpm
 Radial force on bearing at B section
F rB=√ F Bx + F By =√ 881.51 + 1171.433 =1466.05 N
2 2 2 2
 Radial force on the bearing at B section:

F ℜ=√ F Ex + F Ey = √747.932 +1171.433 =1389.84 N
2 2 2 2
 Axial force: ∑ F a=0 N

Because F ℜ< F rB so we choose F rB to use to calculate
=> Because F a= 0 so we choose
So that we choose deep groove ball bearing. We select 106 deep groove ball
bearing base on table P2.7 [ I ]
d D B C Co
30 55 13 10.4 7.02
b. Choosing exact level of bearing

Choosing exact level is very important because it depending on the purpose
when we design machine like standards for radial run-out, axial run-out of the
shaft, … In gearbox, we commonly use bearing with exact level equal to 0 base
on page 213- [ I ]
c. Check the load capacity of the bearing
The bearing capacity of the drive is calculated by the formula 11.1 [ I ]:
C¿ Q m√ L
Where:
+ Q - Conventional dynamic load, kN
+ L - Life in million revolutions
60 LhE n 60 × 1645× 1460
L= 6
= =144.102million rev
10 106

Chapter 5: Bearing design
*Note LhE= K HE Lh = 0.125*13160= 1645 ( Where K HE is select base on table 6.4

[I])
+ m - degree of curve with m= 3 for ball bearing and m= 10/3 for cylindrical
roller
+ Determine conventional dynamic load base on formula 11.3 [ I ]
Q=( XV F r +Y F a ) K t K d
+ F r and F a radial load and axial load

+ Kt: Temperature coefficient, Kt=1
+ Kd: Load condition coefficient, Kd=1.2 base on table 11.3 [ I ]
+ V: Coefficient refers to which revolution, V= 1
+ X: Radial load factor
+ Y: axial load factor
Because F a= 0 so base on the table 11.4 we have X= 1 and Y= 0
{Q B =( XV Fr + Y F a ) K t K d =(1 ×1 ×1466.05+0 × 0)× 1×1.2=1759.26 N

Q E =( XV Fr + Y F a ) K t K d =(1 ×1 ×1389.84 +0 ×0) ×1× 1.2=1667.808 N
Because QB > Q E so we calculate according to the parameter at B

C B=Q B √ L= 1759.26 √3 144.102= 9.22 kN < C= 10.4kN
m
d. Life service of bearing

Lh =
10 6 C m
60 n Q ( )
=
10 6 10400 3
60 ×635.888 1759.26 (
=5 414.75 hours )
e. Static load test
Q 0 B =X O F r +Y o F a ( Formula 11.6 [ I ] )
Following 11.6 [ I ], => X0=0.6; Y0=0.5
QOB=0 .879 kN <C0 = 7.02
=> Satisfactory
 Shaft III
Rotation speed: n3 =247.427 rpm
F r A =√ F A x + F A y =√ 367.443 +3460.507 =3 479.96 N
2 2 2 2


F ℜ=√ F Ex + F Ey = √367.443 +3460.507 =3 479.96 N
2 2 2 2

For the middle shaft of gearbox we choose cylindrical roller bearing. We select
2109 cylindrical roller bearing table P2.8 [ I ]
d D B C Co
45 76 16 19.1 13.4

on page 213- [ I ]
C d=Q m√ L
Where:
60 LhE n 60 × 1645× 247.427
L= 6
= =24.421 million rev
10 106
*Note LhE= K HE Lh = 0.125*13160= 1645 (Where K HE is select base on table 6.4
[I])
roller
Where K HE is select base on table 6.4 [ I ]



{
Q A=( XV F r +Y F a ) K t K d=(1 ×1 ×3 479.96+ 0× 0)× 1× 1.2=4 175.952 N
Q E=( XV F r +Y F a ) K t K d=(1× 1× 3 479.96+0 × 0) ×1 ×1.2=4 175.952 N
Because QB = Q E so we calculate either to calculate so we choose to calculate

the parameter at A
10
C A=Q A √ L= 4 175.952 3 24.421 = 10.89 kN < C= 19.1kN
m
√
=> Because there no other else cylindrical roller bearing so we choose this one
( ) ( ) =10698.62 hours
6 m 6 10
10 C 10 19100
Lh = = 3
60 n Q 60 ×247.427 4 175.952
e. Static load test

Q0 B =X O F r +Y o F a ( Formula 11.6 [ I ] )
Following 11.6 [ I ], => X0=0.5; Y0=0.22cotgα ( α =0)
QOB=1.7 kN <C 0= 13.4
=> Satisfactory
 Shaft IV
Rotation speed: n 4=103.961 rpm
F r A =√ F A x + F A y =√ 874.571 +2759.52 =2894.793 N
2 2 2 2

F r C =√ FC2 x + F 2C y = √874.5712 +79.7632=878.2 N

Because F r C < Fr A so we choose F r A to use to calculate
=> Because F a= 0 so we choose
So that we choose deep groove ball bearing. We select 1000911 deep groove
ball bearing base on reference [ II ]

d D B C Co
55 80 13 12.3 10.2

on page 213- [ I ]
C¿ Q m√ L
Where:
60 LhE n 60 × 1645× 103.961
L= 6
= 6
=10.26 million rev
10 10
*Note LhE = K HE Lh = 0.125*13160= 1645 ( Where K HE is select base on table 6.4
[I])
roller

{Q A=( XV F r +Y F a ) K t K d=(1 ×1 ×2894.793+0 × 0)×1 ×1.2=3473.75 N

QC =( XV F r +Y F a ) K t K d =(1× 1× 878.2+ 0 ×0)× 1× 1.2=1053.84 N

Because Q A > Q C so we calculate according to the parameter at A

C A=Q A √ L= 3473.75 √3 10.26 = 7.55 kN < C= 12.3kN
m

Lh = ( )
10 6 C m
60 n Q
=
10 6
(
12300 3
60 ×103.961 3473.75 )
=7117.016 hours
e. Static load test

Q 0 B =X O F r +Y o F a ( Formula 11.6 [ I ] )
Following table 11.6 [ I ], => X0=0.6; Y0=0.5
QO C =2.08 kN <C 0= 10.2
=> Satisfactory

Chapter
CHAPTER VI: DESIGN GEARBOX, LUBRICATION AND

FEATURE ADJUSTMENT
I. Design gearbox
1. Structure of die-cast reducer box
Molded reducer housings can come in many different forms, but they all have
one thing in common is to ensure the relative position between the parts and
machine parts, receive the load transmitted by the parts mounted on the
housing, containing lubricating oil, protecting the machine parts from dust. The
basic criteria of the reducer are small volume and high rigidity.
We choose material is gray cast iron GX15-32
The reducer includes: box wall, brace or tendon, flange, bearing, ...
The mounting surface between the cover and the body is shaved or ground for a
tight fit a thin layer of paint or special paint.
Select the surface to join the lid and body: parallel to the base. The bottom face
towards the oil drain hole with a slope of about 20 and right at the oil drain
hole down.
Name Formula
Thickness: Gearbox body, δ δ = 0.03a + 3= 9 mm
Gearbox lid, δ 1 δ 1= 0.9δ = 8 mm
Strong tension: Thickness, e e= (0.8÷ 1¿ δ = (7.2÷ 9) => e= 8 mm

Height, h h < 58
Slope About 2 °
Diameter:
Background bolts, d 1 d 1> 0.04a + 10= 18
Drive side bolts, d 2 d 2= (0.7÷ 0.8)d 1= (12.6÷ 14.4)= 14 mm
Cover and body flange joint bolts, d 3 d 3= (0.8÷ 0.9)d 2= (11.2÷ 12.6)= 12 mm
Drive cover mounting screw, d 4 d 4 = (0.6÷ 0.7)d 2= (8.4÷ 9.8)= 10 mm

Door cover screw, d 5 d 5= (0.5÷ 0.6)d 2= ( 7÷ 8.4)= 8 mm
Cover and body face:

Thickness of body, S3 S3= (1.4÷ 1.8)d 3= (16.8÷ 21.6)= 22 mm

Chapter 6: Design gearbox,lubrication and feature adjustment
Thickness of lid, S4 S4 = (0.9÷ 1) S3= (19.8÷ 22)= 22 mm
Cap and body flange width, K 3 K 3 ≈ K 2 - (3÷ 5)= 40 mm
Pillow size
Outside diameter and center of screw Determine base on drive cover
hole: D2, D 3
Bearing side bolt joint width, K 2 K 2= E2 + R2 + (3÷ 5) = 43 mm
Bearing side bolt center, E2 and C
E2 = 1.6d 2= 22 and R2= 1.3d 2= 18 mm
C ≈ D3/2 but to make sure it have to satisfy

condition k ≥ 1.2d 2= 16.8 mm
Height h Determine base on structure
Box base
Thickness: Without bulge, S1 S1 ≈ ¿1.3÷ 1.5)d 1= (23.4÷ 27)= 27 mm
With bulge, D d , S1 and S2 S1= ¿1.4÷ 1.7)d 1= ¿)= 27 mm
S2= ¿1÷ 1.1)d 1= (18÷ 19.8)= 20 mm
Width of box base, K 1 and q K 1= 3d 1= 54 mm
q ≥ K 1+ 2δ = 72 mm
Gaps between details
Between gear and box wall ∆ ≥(1 ÷ 1.2)δ = (9÷ 10.8)= 10 mm
Between the large gear and the ∆ 1 ≥(3 ÷ 5) δ = (27÷ 45)= 28 mm

bottom of the box
∆ ≥ δ= 9
Between the gear side faces together
Number of screw Z Z= (L+B)/(200÷ 300)= 6
2. Details related to the box structure
a. Dowel pins
The joint between the cap and the body is in the plane containing the
centerlines of the axes. Cylindrical hole (diameter D) mounted on the lid and
machined body at the same time. To secure the position relative of lid and body
before and after machining and assembly, using 2 pins locate. Thanks to the
locating pin, when tightening the bolt does not deform the outer ring of the
bearing (due to relative position deviation of the lid and body), thus eliminating
one of the causes drive to fail.
 We use a conical locator with the following parameters base on table 18-4b
[ II ]
d c l
6 1 20 ÷ 110
b. Drive cover
+ Shield the bearing from dust from the outside.

+ Made of GX15-32 material.
+ Structure of the drive covers in the reducer, table 18.2 [ II ]:
Shaft D D2 D3 D4 h d4 z
II 55 70 85 48 8 M6 4
III 76 90 115 65 10 M8 6
IV 80 100 125 75 10 M8 6
c. Door visist
To check, observe the machine parts in the box when assembling and to pour
oil inside box, on the top of the box there is a door to visit. The entrance door is
covered with a lid. On the lid there is an additional installation vent button. The
size of the door is selected according to table 18-5 [ II ] as follows:
A B A1 B1 C C1 K r Screw amount
100 75 150 100 125 80 87 12 M8 x 22 4

d. Vent plug
- When working, the temperature in the box increases. To reduce pressure and
side air conditioner inside and outside the mailbox, the user uses the node
information. The information cap is mounted on the cover door visits.
- Dimensions of the button vent ( see table 18-6 [ II ] ):
A B C D E G H I K L M N O P Q R S
M27x2 15 30 15 45 36 32 6 4 10 8 22 6 32 18 36 32
e. Oil drain plug.
After a period of work, the lubricating oil contained in the box is dirty (due to
dust and particles grinding) or degraded, so a new oil change is required. To
remove the old oil, there is a hole in the bottom of the can remove oil. At work,
the hole is sealed with an oil drain plug.
Structure and dimensions of oil drain plug in table 18-8 [ II ] (oil drain plug
pillar) as follows:
d b m f L c q D S D0
M16x1.5 12 8 3 23 2 13.8 26 17 19.6
f. Oil level stick
To check the oil level in the box, use the dipstick
g. The screw separates the cover and reducer body
Has the effect of separating the cover and body of the reducer, M8x30 screw
h. Hook ring
Used to move the gear box easily.
Thread d1 d2 d3 d4 d5 h h1 h2 l≥ f b c x r r1 r2

d
M12 54 30 12 30 17 26 10 7 25 2 14 1.8 3. 2 5 6
5
i. Summary of bolts
Base bolt: d 1= 18
Bearing side bolt: d 2= 14
Bolts connecting the cap flange and body: d 3= 12
Screw for socket cover: d 4 = 10
Visitor cover assembly screw: d 5= 8
II. Mounting Tolerance

a. Bearing tolerance
Bearing inner ring is under the cyclic load. We choose to assemble transition
fit to prevent the bearing from running across the surface of shaft. So we
choose k6 for the bearing so it have interference so make the bearing evenly
worn.
Bearing outer ring is not under the cyclic load. We choose to assemble
transition fit so the bearing can move across shaft so we can easily assemble it.
So we choose H7
b. Gear assembly on shaft
Gear mounted on bearing on the shaft with light impact and one-direction
working so we choose assemble H7/k6
c. Assembling the bearing cover
For easy to assemble and disassemble we choose H7/e8
d. Oil seal on the shaft
For easy to assemble and disassemble we choose H7/ J s 6
e. Locating pin
For easy to assemble, disassemble and the concentric we choose P7/h6
f. Assembling the key
For the key we choose J s 9/h8 for bearing assembly, and P9/h8 for shaft
assembly

Size limit deviation by height is h11

Size limit deviation by length is h14
g. Assembly of coupling
For the coupling we choose H7/h6
h. Mounting tolerance table
Base on the reference [ II ] and [ VI ] we have the table below
Gear of Diameter Assembly ES EI es ei
shaft
(mm) ( μm) ( μm) ( μm) ( μm)
II 34 H7/k6 +25 0 +18 +2
III 50 H7/k6 +25 0 +18 +2
III 55 H7/k6 +30 0 +21 +2
IV 60 H7/k6 +30 0 +21 +2
Shaft D Bearing
ES EI es ei
( μm¿ ( μm) ( μm) ( μm)
II 55 H7 +30 0 0 -19
III 76 H7 +30 0 0 -19
IV 80 H7 +30 0 0 -19
II 30 k6 +25 0 +18 +2
III 45 k6 +25 0 +18 +2
IV 55 k6 +30 0 +21 +2
III. Lubrication
In order to reduce power loss due to friction, reduce tooth wear, ensure good
heat dissipation and prevent rusting, it is necessary to continuously lubricate
the transmissions in the reducer.

Lubrication method in the reducer: we use oil immersion lubrication. The

minimum oil level is chosen so that the oil fills the tooth root of the quick-feed
gear and the highest level is not more than 1/6 of the quick-feed gear's diameter
from the top of the tooth upwards.
Gearbox lubricating oil: First of all, we need to choose the viscosity of the oil
to lubricate the gear box. According to table 18.11 [ II ], with the working
characteristic of light impact, the maximum lap velocity v1 = 2.91m/s, [σ b ]max=
80
850 MPa, choose oil viscosity
11
From the table 18.13 [ II ], we select industrial oil 50

For bearing we lubricate with grease periodically

Chapter 7: Reference
Chapter VII: Reference

[ I ] Trịnh chất - Lê Văn Tuyển: Tính toán thiết kế hệ thống dẫn động cơ khí -
Tập 1, Nhà xuất bản giáo dục 2003
[ II ] Trịnh chất - Lê Văn Tuyển: Tính toán thiết kế hệ thống dẫn động cơ khí -
tập 2, Nhà xuất bản giáo dục 2003
[ III ] Nguyễn Hữu Lộc: Thiết kế máy và Chi tiết máy (Machine Design and
Machine elements)
[ IV ] Nguyễn Hữu Lộc, Giáo trình cơ sở thiết kế máy, NXB Đại học Quốc gia
TP Hồ Chí Minh, 2019
[ V ] Cantoni Motor: General purpose 3-phase induction motors
[ VI ] Ninh Đức Tốn- Dung sai và lắp ghép, Nhà xuất bản giáo dục 2016
[ VII ] Industrial shaft seal SKF

Chapter 7: Reference



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VIETNAM NATIONAL UNIVERSITY, HO CHI MINH CITY

Student: Dang Thai Bao Student ID: 2052869

Advisor: Dr. Nguyen Vu Thinh Signature: ..................................

Completion day: Defense day: ..............................

Design Project (ME3139) – HK221 2

Design Project (ME3139) – HK221 3

DESIGN OF A TRANSMISSION SYSTEM FOR BELT

3. Dual-stage gear reducer

4. Flexible shaft coupling

Tangential velocity on conveyor chain, v=1.78(m/s )

Diameter of drive conveyor pulley: D=330 (mm)

Service life: L=5 ( years)

Number of working days per year: 329 days

Loading characteristic: T1 = T; t1 = 28 (s); T2 = 0.3T; t2 = 48 (s)

 Operating conditions: one-direction working, light-impact loading, 8-hour shift

 Contents of the project report:

2. Design machine elements:

a. Design uncovered drives (belt, chain or gear).

b. Design covered drives (gears, worm, worm wheel).

d. Design shafts and keys.

e. Select bearings and shaft coupling.

f. Select housing of the speed reducer, bolts/screws and other parts.

3. Select assembly fits and tolerances.

Design Project (ME3139) – HK221 5

CHAPTER I: MOTOR SELECTION AND

1.1 General efficiency of the system

η s: general effecicency of system

η g: general effecicency of helical gear

ηcp : general effecicency of coupling

ηb : general effecicency of rolling-bearing

ηbelt : general effecicency of V-belt

 Power requirement for motor:

1.2 Motor selection and transmission ratio

1.3 Transmission ratio of system:

+ General system tranmission ratio u sys is:

ubelt : Tranmission ratio of V-belt drive

u gr: Tranmission ratio of dual-stage gear reducer

Power Motor Rotation System speed V-Belt drive Dual stage

Design Project (ME3139) – HK221 7

Then we will recaculated ubelt :

1.4 Parameters of transmission system:

Pconv =6.152( kW )(8)

 Rotational speed on speed shaft:

Design Project (ME3139) – HK221 8

 Torque on each shaft:

Design Project (ME3139) – HK221 9

CHAPTER II: DESIGN AND TESTING BELT

2.2 Calculation and chose belt for the system

(mm) (mm) (mm) (mm) (mm2 ) (mm) (Nm)

2. Diameter of small pulleys

3.Peripheral velocity of belt

With the v I we calculation, It satisfy the conditon: v I ≤ [ v ], with [ v ]= 25m/s

Design Project (ME3139) – HK221

->Error compare to the value u we choose earlier:

a= …d 2 1.5 1.2 1 0.95 0.9 0.85

6. Calculate the length of belt

Design Project (ME3139) – HK221 11

We testing the revolution of belt per second base on the L we choose:

 Recaculate center distance:

=> Satisfy with the condition ( 1000 ≥ a ≥ 285.5)

7. Calculate the wrap angle

 Velocity correction factor: