Data #7:

Power of blender’s shaft P = 4.7kW

Rotation speed of blender’s shaft, n = 150 rpm
Working life: L = 6 (years)
Loading characteristic: T1 = T; t1 = 53; T2 = 0.8T; t2 = 47
Allowable transmission error: ± 5%
Operating conditions: one-direction working, light-impact loading, 2-shift operation (8
hours/shift), and 300 days/year.

1. Selection of the electrical motor:

a. Transmission efficiency:
- Transmission Efficiency: η=ηgear η fbelt η3bearing η coupling

In which: η gear: efficiency of gear drive

η fbelt: efficiency of flat belt drive

ηbearing : efficiency of bearing

ηcoupling : efficiency of coupling

− Select desired efficiencies:

η gear: 0.97
η fbelt :0.96
ηbearing :0.99
ηcoupling :1

Therefore, Transmission efficiency η=0.97∗0.96∗0.993∗1=0.9035

b. Load calculation:
Equivalent load:

√ ( ) ( )
2 2
T1 T2
∗t 1 + ∗t 2

√
2 2
T T 1 ∗53+ 0.8 ∗47
Ptd =P∗ =4.7∗ =4.28 kW
t 1 +t 2 53+47
P 4.28
Required power: Pct = td = =4.73 kW
η 0.9035
c. Preliminary rotation speed:
 - Given: Working shaft rotation speed: n w =¿ 150rpm
- Select u fbelt =2, u gear=2
- Whole system transmission ratio: u=ufbelt∗u gear=2∗2=4
- Rotation speed of the motor shaft: n preliminary =4∗150=600 rpm.
d. Motor selection:
- According to the calculation, select motor with P ≥ Pct and n dc ≈ n preliminary

- Therefore, select motor 132M2-6 with 960rpm and 5.5kW of power.

e. Distribute transmission ratio:
ndc 960
- Overall transmission ratio: u sys= = =6.4
nw 150
- Select u gear =3.2, we have transmission ratio of belt drive as:
u sys 6.4
u fbelt = = =2
u gear 3.2
f. Calculate load on each shaft:
P 4.7
- Load on blender shaft (shaft 3): P3= = =4.75 kW
ηcoupling ∗ηbearing 1∗0.99
- Load on speed reducer’s driven gear shaft (shaft 2):
P3 4.75
P2= = =4.8 kW
ηbearing 0.99
- Load on speed reducer’s driving gear shaft (shaft 1):
P2
P 1=
4.75
ηbearing∗¿η = =5 kW ¿
0.99∗0.97
gear

P1
Pmotor =
- Load on motor shaft: 5 →
ηbearing∗¿ η = =5.26 kW <5.5 kW ¿
belt
0.99∗0.96
Satisfied motor selection condition.
g. Torque and rotation speed on each shaft
ndc 960
- Rotation speed on shaft 1: n1 = = =480 rpm
u fbelt 2
ndc 960
- Rotation speed on shaft 2: n2 = = =300 rpm
u gear 3.2
6
9.55∗10 ∗Pdc 9.55∗106∗5.26
- Torque of motor shaft: T dc = = =52326.04 Nmm
ndc 960
6
9.55∗10 ∗P1 9.55∗106∗5
- Torque of shaft 1: T 1= = =99479.17 Nmm
n1 480
6
9.55∗10 ∗P2 9.55∗106∗4.8
- Torque of shaft 2: T 2= = =152800 Nmm
n2 300
 6
9.55∗10 ∗P3 9.55∗10 6∗4.7
- Torque of shaft 3: T 3= = =299233.33 Nmm
n3 150

h. Characteristic table

2. Design of Flat Belt drive

a. Specification:
- Power: 5,26 kW
- Transmission ratio: 2
- Rotation speed: 960 rpm
b. Select material:
- Select Rubber for belt material.
c. Diameter d1 and d2 of small pulley:
- d 1=( 1100|1300 )
P1
n1√
3
=( 1100|1300 ) 3

 Select diameter d1 as 200mm.

√
5.26
960
=193.92mm∨229.18 mm

- Rotation speed with respect to chosen d1:

π d 1 n π∗200∗960
v1 = = =10.05 m/ s
60000 60000
- Choose ξ=0.01, we have diameter d2 as:
d 2=u d 1 ( 1−ξ )=2∗200∗( 1−0.01 )=396 mm
 Select diameter d2 as 400mm
- Verify transmission ratio:
 ' d2 400
u= = =2.02
d 1 (1−ξ )
200(1−0.01)
'
u −u 2.02−2
- Error: Δ %= ∗100 %= ∗100 %=1 %<5 % → acceptable.
u 2
d. Center distance calculation:
- Condition of center distance: 15000 ≥ a ≥2 ( d 1 +d 2 ) →15000 ≥ a ≥1200
select preliminary minimum center distance as 1200mm
→
- Length of belt:
2
π (d 1 +d 2 ) ( d 2−d 1 ) π ( 200+400 ) ( 400−200 )
2
L=2 a+ + =2∗12000+ + =3350.81mm
2 4a 2 4∗1200
- Increase L by 100-400mm → select L=3650mm → non-standard
- Readjust a to 1400mm, we get L=3749.62mm. → select L=4000mm
e. Number of rotations in one second:
v 1 10.05∗10 4
- i= = =2.5125< [ i ] =5→ satisfied.
L 4
f. Contact angle α of belt and selection of belt thickness:
d 2−d 1 400−200
- α =π− =π− ≈ 3 rad∨171.86 °
a 1400
d
→ select δ=5 mm so that it satisfies 1 ≥ 40
δ
g. Correction Coefficients:
- C v =1−c v ( 0.01 v2 −1 )=1−0.04 ( 0.01∗10.052−1 )=0.999≈ 1

- C α =1−0.003 ( 180 °−α 1 )=1−0.003 ( 180°−171.86 )=0.98

- C o=1
- C r=0.9−0.2=0.7 based on work condition
d1
- Select [ σ t ] 0=2.25 MPa due to =40
δ
- ¿
1000 P1 1000∗5.26
- Width of belt: b= = =67.97 mm →select b = 71 and
δ v 1 [σ t ] 5∗10.05∗1.54
pulley width B = 80 by standard
h. Initial tension and circumferential force:
- F 0=[ σ 0 ] bδ =1.8∗71∗5=639 N
1000 P1 10000∗5.26
- F t= = =523.38 N
v1 10.05
 α1 171.86
- Shaft load: F r=2 F 0 sin =2∗639∗sin =1274.78 N
2 2
i. Specification table

3. Design of Bevel gear drive:

a. Specification:
- Power: 5 kW
- T = 99749.7 Nmm
- n = 480 rpm
- u = 3.2
b. Material
- 40CrNi steel, normalizing
- H B 1=300 , H B2=280 → s h=1.1 , s f =1.75
- Angular contact bearing is used → k H β =1.14
- ψ be =0.285
c. Calculation and verification of Contact stress:

- {σ 0 Hlim =2 HB 1+70=2∗300+ 70=670 MPa

1

σ 0 Hlim =2 HB 2+70=2∗280+70=630 MPa

2

2.4 2.4 9
- Theoretical load cycles: N H O =30 HB =30∗300 =0.026∗10
1

2.4 2.4 9
Similarly: N H O =30 HB =30∗280 =0.022∗10
2

( ) Ti 3
n
=60 c ∑
❑
- Equivalent load cycles: N H E1 t n
i=1 T max i i

¿ 60 c n1 Lh
[( ) ( ) ( ) ( )]
T 1 3 t2
T max
∗
t tot
+
T 2 3 t2
T max
∗
t tot
3
=60∗1∗n1∗6∗365∗24∗ 1 ∗
53
100
3
+0.8 ∗
[ ( )
47
100
=1 ( )]
With t tot =t 1+t 2=53+ 47=100 s
❑ 9
- Similarly, N H E =0.73∗10
2

- N HE > N HO for both gears, therefore K HL1=K H L =1 2

- Allowable contact stress:

0.9 × K 670∗0.9∗1
[ σ H ]1=σ 0 Hli m × s HL = 1.1 =548.18 MPa
1
h

Similarly: [ σ H ]2=515.45 MPa.

Therefore [ σ H ]2 is chosen for contact stress limit.
- Preliminary calculation of outer diameter d e : 1

√
T 1 K Hβ
d e 1=95 3 2 2
=83 mm
0.85 ( 1−0.5 ψ be ) ψ be u [ σ H ]
- Select Z1 p =20→ Z1 =1.6 Z 1 p=1.6∗20=32 → Select Z1 =32
- Z2 =u Z 1=32∗3.2=102.4 → Select Z2 =102
Z 2 102
- Actual transmission ratio: u ' = = =3.1875
Z 1 32
' ¿
- Error: Δ %=¿u −u∨ u ∗100 %=0.4 % → ¿ Acceptable
d 83
- m e modulus: me = e1 = =2.59 →Select me by standard as 3
Z 1 32
1 1
- Pitch angle: δ 1=arctan ' =arctan =17.42°
u 3.18
δ 2=90 °−δ 1=72.58 °
- Actual pitch diameter: d e 1=me . Z 1=3∗32=96 mm
d e 2=me . Z2 =3∗102=306 mm
 - Base diameter: d m 1=d e1 ( 1−0.5 ψ be ) =96 (1−0.5∗0.285)=82.32 mm
d m 2=d e2 ( 1−0.5 ψ be ) =306(1−0.5∗0.285)=262.4 mm

- Outer cone distance: Re =0.5 m e √ Z 21+ Z 22=0.5∗3∗ √322 +1022=160.35 mm

- Face width: b=Re∗ψ be =160.35∗0.285=45.7 mm
πd n
- Tangential velocity of gear 1: v1 = m 1 1 =2.06 m/s → Select accuracy class
60000
8, K HV =K FV =1.08
- Calculated contact stress:

√ 2. T 1 . K H . √u 2+1
√
2∗99749.7∗1.23∗√ 3.18 +1
2
σ H =Z M . Z H . Z ε . 2
≤[ σH ]= 2
=402.05 MPa< [ σ H ]
0.85 . d m 1 . b . u 0.85∗82.32 ∗45.7∗3.18
Requirement satisfied.
Where:
1/ 2
Z M =275 MP a for steel

ZH=
√ 2
sin 2α w
=1.76 , α w =20 °by default

Z ε=
4−ε α
3 √
=0.84 , ε α =1.9
K H =K HV∗K Hα∗K H β =1.08∗1∗1.14=1.23
d. Force calculation:
2T 1
- F t 1=F t 2= =2423.46 N
dm 1
- F r 1=F a 2=Ft 1 tan α cos δ 1=841.62 N
- F a 1=Fr 2=Ft 1 tan α sin δ 2=264.04 N

e. Calculation and verification of bending stress:

- Repeat the same procedure to find equivalent work cycle N FE, given by

60 c n1 Lh

2
[( ) ( ) ( ) ( )]
T1 6 t2
T max
9
∗
t tot
+
T 2 6 t2
T max
∗
t tot
, we get N 1FE=1.48∗109 and

N FE=0.93∗10 .
- As these two values are greater than 5∗106, K F L =K FL2=1 1

- {σ 0 Flim =1.8 H B 1=1.8∗300=540 MPa

1

σ 0 Flim =1.8 H B2 =1.8∗280=504 MPa

2

0.9× K FL 540∗0.9∗1
- [ σ F ]1 =σ 0 Flim × 1
sf
=
1.75
=277.71 MPa
0.9× K FL 504∗0.9∗1
- [ σ F ]2 =σ 0 Flim 2
×
sf
=
1.75
=259.2 MPa
 - Equivalent number of teeth on spur gear:
Z 32
Z v1 = 1 = =33.53
cos δ cos 17.42
Z1 102
Z v2 = = =340.71
cos δ 2 cos 72.58

- Y F Coefficients:
13.2
Y F 1=3.47+ =3.86
Zv 1
13.2
Y F 2=3.47+ =3.51
Zv 2

[ σ F ]1 277.71 [ σ F ]1 259.2
- = =71.95 and = =73.85
Y F1 3.86 Y F 1 3.51
→ Driving gear is weaker, therefore Y F 1 is selected for verification

- K F=K Fβ K FV K Fα =[ 1+1.5 ( 1−K Hβ ) ]∗1.08∗1=1.42

- mm=( 1−0.5 ψ be ) me (Select ψ be as 0.25) ¿ ( 1−0.5∗0.25 )∗3=2.625
- Calculated bending stress:
Y F . F t . K F 3.86∗2423.86∗1.42
σ F1= = =130.29 MPa< [ σ F ]=277.71 MPa →
0.85 . b . mm 0.85∗45.7∗2.625 1

Requirement satisfied.

f. Specification table:
4. Design of two shafts in speed reducer
a. Specification:
- Shaft 1:
o F t 1=2423.86 N o F t 2=0
o F a 1=264.04 N o F a 2=0
o F r 1=841.62 N o F r 2=1274.78 N
o T 1=99479.7 Nmm

b. Select material:

- Select both shafts’ material to be C45 steel with [ σ b ] =600 MPa and
[ σ −1 ]=260 MPa → [ σ ] =70 MPa
c. Calculate diameter and distances:
- Preliminary diameter of shaft: d=

select the diameter of shaft as 25mm

√
3

√
5 T 1 3 5∗99749.7
0.5 [ σ ]
=
0.5∗70
=24.24 mm→

- Distances on shaft:
o Distance from pulley to bearing surface of shaft 1: 20 mm
o Distance between two bearings of shaft 1: 15 mm
o Distance from second bearing to driving bevel gear: 17 mm
o With width of pulley, gear, and bearing included, the shaft can be
divided into 3 parts AC, AB, BD.
 Length of AC: l AB=20+ b pulley =20+71=91 mm ≈ 100 mm
 Length of AB: l AB=15+ b0=15+17=32 mm
 Length of BD:
l AB=17+ bdrivinggear +b 0=17+ 45.7+17=79.7 mm ≈ 80 mm

d. Force analysis on shaft 1

 -On YZ plane: ∑ F y =0 : R yA + R By =−Fr 1−Fr 2
∑ M C =0 :100 R yA +132 R yB=−219 F r 1−M a 1
→ R yA=−2630.69 N , RBy =514.29 N
- On XZ plane: ∑ F y =0 : R xA + R xB =F ❑t 1∑ M C =0 :100 R xA +132 R xB=219 Ft 1
yx x
→ R A =−6588.24 N , R B=9011.5 N
- Moment diagram of shaft:
- Equivalent moment at B:
M td =√ M xB2 + M By2 +0.75 T 2=√ 84088.632 +210823.22+ 0.75 ¿ 99749.72=261074.21 Nmm
- Equivalent moment at C:
M td =√ M C + M C +0.75 T =√ 127478 + 0 +0.75 ¿ 99749.7 =153990.72 Nmm
x2 y2 2 2 2 2

→ B is the critical section; therefore, diameter of shaft will be calculated with

respect to B.

-
√
Diameter at B: d B= 3
√
M td
0.1[σ ]
=
3 261074.21
0.1[70]
=33.41 mm

Increase 10% for keyhole: d B=33.41∗110 %=36.75 mm → select diameter at

B = 40mm
e. Select Bearing for shaft
Radial force on Bearing A: √ R xA2 + R Ay 2=√ 6588.242 +2630.692=7094.04 N
2 2
-
Radial force on Bearing B: √ RBx2 + R By2=√ 9011.52 +514.292=9026.16 N
2 2
-
- → Therefore, bearing calculation will be performed based on B, which means
Bearing selected for B will be applied to A.
- Select contact angle of bearing to be α =12 °, e coefficient is
e=1.5 tan α=1.5 tan12=0.32
- Auxiliary axial force components:
o S1=0.83 e Fr 1 =0.83∗0.32∗841.62=222.72 N
o S2=0.83 e Fr 2=0.83∗0.32∗1274.78=338.58 N
o Since S2 > S1and F a> S 2−S1, F a 1=S 1=222.72 N and
F a 2=F a+ S 1=264.04+222.72=486.76 N
F a 264.04
- = =0.313< e=0.32→ select X=1 and Y=0.
F r 1 841.62
- Select K σ =1.5 for machine with continuous services, K t =V =1
- Q=( XV F rB +Y F a 1 ) K σ K t =( 1∗1∗9026.16+ 0∗264.04 )∗1.5∗1=13539.4 N
60 n Lh 60∗480∗6∗365∗24
- L= 6
= 6
=1513.73 mil . rev .
10 10
10
- m 3
C tt =Q √ L=13539.4 √ 1513.73=121790.65 N
 Select Bearing 3205A for both bearing A and B.