HCMC University of Technology

HCMC UNIVERSITY OF TECHNOLOGY - VNU HCM
FACULTY OF MECHANICAL ENGINEERING

DEVISION OF MACHINE DESIGN
DESIGN PROJECT
(ME3139)
Semester 2/Academic year 2023-2024
PROJECT #14
DESIGN OF A TRANMISSION SYSTEM FOR
INDUSTRIAL BLENDER
Data No: 9
Student: Tô Xuân Bình

Student ID: 2052885
Advisor: Assoc.Prof.Dr. Lê Thanh
Long
Ho Chi Minh City, .../2024

DESIGN PROJECT PROJECT #14 ADVISOR: ASSOC.PROF.DR. LÊ THANH LONG
DESIGN OF A TRANMISSION SYSTEM FOR INDUSTRIAL BLENDER HCMC UNIVERSITY OF TECHNOLOGY - VNU HCM
FACULTY OF MECHANICAL ENGINEERING
DEVISION OF MACHINE DESIGN
DESIGN PROJECT
THIẾT KẾ HỆ THỐNG DẪN ĐỘNG

THÙNG TRỘN
Phương án số: 9
DESIGN OF A TRANMISSION SYSTEM FOR

INDUSTRIAL BLENDER
Data No: 9
Student: Tô Xuân Bình

Student ID: 2052885
Advisor: Assoc.Prof.Dr. Lê Thanh Long
.../2024
Ho Chi Minh City, .../2024
TABLE OF CONTENTS:
2
Student: Tô Xuân Bình – Student ID: 2052885
TABLE OF CONTENTS....................................................................................................................................
INTRODUCTION...............................................................................................................................................
LIST OF FIGURES............................................................................................................................................
CHAPTER 2: SELECT PROPER ELECTRIC MOTOR AND DISTRIBUTE VELOCITY
RATIO FOR THE TRANSMISSION SYSTEM.............................................................................................
2.1 Select proper electric motor..................................................................................................................
2.2 Distribute velocity ratio........................................................................................................................
CHAPTER 3: DESIGN V-BELT.......................................................................................................................
CHAPTER 4: DESIGN TRANSMISSION IN GEAR BOX.........................................................................
4.1 Design bevel gear................................................................................................................................
4.2 Design helical gear..............................................................................................................................
4.3 Lubrication and oil immersion tests....................................................................................................
CHAPTER 5: SHAFT DESIGN......................................................................................................................
5.1 Design shaft I......................................................................................................................................
5.2 Design shaft II.....................................................................................................................................
5.3 Design shaft III....................................................................................................................................
CHAPTER 6: KEY TESTING........................................................................................................................
6.1 Shaft testing.........................................................................................................................................
6.2 Key testing..........................................................................................................................................
CHAPTER 7: DESIGN ROLLER BEARINGS AND COUPLINGS..........................................................
7.1 Shaft I..................................................................................................................................................
7.2 Shaft II.................................................................................................................................................
7.3 Shaft III...............................................................................................................................................
7.4 Design couplings.................................................................................................................................
CHAPTER 8: GEAR BOX DESIGN..............................................................................................................
8.1 Gearbox design...................................................................................................................................
8.2 Components details.............................................................................................................................
8.3 Choosing lubricating oil and mounting tolerances..............................................................................
CHAPTER 9: FITTING AND TOLERANCE...............................................................................................
9.1 Select manufacturing precision grade.................................................................................................
9.2 Select mounting type...........................................................................................................................
9.3 Fitting tolerance table of gear and key................................................................................................
REFERENCES..................................................................................................................................................
3
INTRODUCTION
Creating, advancing, and optimizing systems for mechanical power transfer consistently pose
fundamental challenges within the mechanical engineering realm. It is evident that a progressive
industry cannot thrive without a contemporary foundation in mechanical engineering.
Consequently, the task of designing and enhancing power transmission systems stands as a
pivotal aspect in the ongoing processes of industrialization and modernization within the country.
In our day-to-day experiences, encounters with power transmission systems are ubiquitous, and it
can be asserted that a gearbox plays an indispensable role in discussions regarding the
functionality of such systems.
The project on mechanical system design provides mechanical engineering students with the
opportunity to delve into and craft a gearbox. This, in turn, fortifies the knowledge acquired in
courses such as Material Strength, Machine Components, Technical Drawing, AutoCAD,
offering students a holistic understanding of the mechanical design process by involving the
creation of external transmissions, gears, shafts, roller bearings, etc.
I express sincere gratitude to Assoc.Prof.Dr. LÊ THANH LONG for providing substantial
assistance throughout the execution of this project. Given the constraints of limited knowledge,
errors become unavoidable, and I earnestly anticipate feedback from the professor to further
enhance my understanding.
Candidate executed
Tô Xuân Bình
4
LIST OF FIGURES
Figure 5.1: Shaft 1 Load Diagram..........................................................................................................

Figure 5.2: Preliminary drawing of shaft 1.............................................................................................
Figure 8.1: Shape and dimension of the visitor door..............................................................................
Figure 8.2: Shape and dimension of the dowel pin.................................................................................
Figure 8.3: Shape and dimension of the air vent button..........................................................................
Figure 8.4: Shape and dimension of the oil drain plug...........................................................................
Figure 8.5: Shape and dimension of the oil checkstick...........................................................................
Figure 8.6: Shape and dimension of the oil seal.....................................................................................
5
CHAPTER 2: SELECT PROPER ELECTRIC MOTOR AND DISTRIBUTE VELOCITY

RATIO FOR THE TRANSMISSION SYSTEM
2.1 Select proper electric motor
2.1.1 Select the system efficiency
Efficiency of helical gear: ηhelical gear =0.97
Efficiency of bevel gear: ηbevel gear =0.96
Efficiency of V-belt: ηV −belt =0.96
Efficiency of bearings: ηbearings =0.99
Efficiency of coupling: η coupling =0.99
4 4
η=ηcoupling∗ηV −belt ∗ηhelical gear∗ηbevel gear∗η bearings =0.99∗0.96∗0.97∗0.96∗0.99 =0.85
2.1.2 Calculate the required power
Due to the load variation with levels, we have:
√ ( )
n
Ti 2
∑ ∗t i
Ptd =P∗
1 T
n
∑ ti
√
≈ 6.1∗
12∗19+0.62∗14
19+14
=5.21(kW )
Peq 5.21
Pct = = =6.13 (kW )
η 0.86
2.1.3 Preliminary rotation speed
According to table 2.4 in [1], we choose
Preliminary transmission ratio of helical gear: uhelical gear=3
Preliminary transmission ratio of bevel gear: ubevel gear =3.3
Preliminary transmission ratio of V-belt: uV −belt =5
Preliminary transmission ratio of coupling: ucoupling =1
Preliminary transmission ratio of the system:
u sb=uV −belt ∗ubevel gear∗uhelical gear∗u coupling =5∗3.3∗3∗1=49.5
Preliminary rotation speed of motor shaft:
n sb =n∗usb =47∗49.5=2326.5(rpm)
2.1.4 Select motor
Choose an electric motor satisfying the conditions
6
{P dc ≥ P ct =6.13(kW )
ndc ≈ n sb=2326(rpm)
From table P1.3 in [1] select motor: 4A112M2Y3

Pdc (kW ) n dc (rpm) cosφ η% T max TK
T dn T dn
7.5 2922 0.88 87.5 2.2 2.0
2.2 Distribute velocity ratio

2.2.1 New transmission ratio of the system
ndc 2922
u sys= = ≈ 62.17
n 47
With:
uV −belt =5
uhelical gear=3
ubevel gear =4.1
ucoupling =1
2.2.2 Rotation speed on each shaft:
Shaft between V-belt drive and bevel gear is I.
Shaft between bevel gear and helical gear is II.
Shaft between helical gear and coupling is III.
Shaft between coupling and blender is IV (Working shaft).
n dc=2922( rpm)
n dc 2922
nI= = =584.4 (rpm)
uV −belt 5
nI 584.4
n II = = =142.53( rpm)
ubelvel gear 4.1
nII 142.53
n III = = =47.51(rpm)
n helical gear 3
n III 47.51
n IV = = =47.51(rpm)
u coupling 1
7
2.2.3 Power on each shaft

P IV =P=6.1(kW )
P IV 6.1
P III= = =6.22(kW )
ηbearings ∗ηcoupling 0.99∗0.99
P III 6.22
P II = = =6.48(kW )
ηbearings∗ηhelical gear 0.99∗0.97
PII 6.48
P I= = =6.82(kW )
ηbearings∗η bevel gear 0.99∗0.96
PI 4.42
Pdc = = =7.18(kW )
ηbearings∗η V −belt 0.99∗0.96
2.2.4 Torque on each shaft

6
9.55∗10 ∗Pdc 9.55∗106∗7.18
T dc = = =23466.46(N . mm)
ndc 2922
6
9.55∗10 ∗PI 9.55∗106∗6.82
T I= = =111449.35( N .mm)
nI 584.4
6
9.55∗10 ∗P II 9.55∗106∗6.48
T II = = =434182.28(N . mm)
n II 142.53
6
9.55∗10 ∗P III 9.55∗106∗6.22
T III = = =1250284.15 ( N .mm)
n III 47.51
6
9.55∗10 ∗P IV 9.55∗106∗6.1
T IV = = =1226162.91( N . mm)
n IV 47.51
Data table
Motor I II III Working shaft
P(kW) 7.81 6.82 6.48 6.22 6.1
u uV −belt =5 ubevel gear =4.1 uhelical gear=3 ucoupling =1
n(rpm) 2922 584.4 142.53 47.51 47.51
T(N.mm) 23466.46 111449.35 434182.28 1250284.15 1226162.91
8
CHAPTER 3: DESIGN V-BELT

3.0.1 Parameters
Specifications for designing a V-belt transmission.
Transmitter power: P = 7.81 kW
Transmission ratio uV −belt =5
Number of revolutions n1 = 2922 rpm
3.0.2 Belt transmission design calculations
According to the figure, choose belt type A
According to table 4.13 in [1] choose a small belt diameter according to the standard d1 =180mm
Belt velocity:
π × d 1 ×n 1 π × 180 ×2922
v= 4
= 4
=27.54 m/ s
6 ×10 6 ×10
Large belt wheel diameter
Choose ξ = 0,01
d 2=u V −belt ×d 1 ( 1−ξ )=5 ×180 ( 1−0 , 01 )=891 mm
According to table 4.21 in [1] select standard diameter, choose d2 = 900mm
d2 900
ut = = =5.05
d 1 (1−ξ ) 180 ×(1−0 , 01)
Deviation from the initial value
|ut −uV −belt| |5.05−5|
∆ u= ×100= ×100=1%
uV −belt 5
Preliminary selection of axis distance a = 1× d2 = 900 mm
Belt length by axis distance a
π ( d 2 +d 1 ) ( d2 −d 1 )2 π ( 900+180 ) ( 900−180 )2
l=2 a+ + =2∗900+ + =3640.46 mm
2 4a 2 4∗900
According to table 4.13 in [1] select the standard belt length L = 4000 mm
Test the number of laps in 1 second
v 27.54
i= = =6.885< 10→ accept
l 4
Recalculated a according to standard length L = 4000mm
λ=4000−0.5 π ( 900+180 )=2303.54
d 2−d 1 900−180
∆= = =360
2 2
9
λ+ √ λ2 −8 ∆2 2303.54+ √ 2303.54 2−8∗3602

According to formula 4.6 in [1]: a= = =1092.45 mm
4 4
According to formula 4.7 in [1], contact angel:
57 × ( d 2−d 1 ) 57 × ( 900−180 ) °
α 1=180− =180− =142.43 >α min =120°
a 1092.45
Determination of belt number: according to formula 4.16 in [1]
P1 K d 7.81 ×1 , 1
z= = =1.58
[ P0 ]C α C l C u C z 4 , 46 × 0 ,94 ×1.2 ×1 ,14 ×0 , 95
According to table 4.7 in [1], choose Kđ = 1,1
°
α 1=153 ⇒C α =0 , 94 (table 4.15∈[1])
l 4000
= =2.35 ⇒Cl =1.2¿
l 0 1700
u=5⇒ Cu=1, 14 ¿
v=27.54 m / s ; d 1=180 mm ⇒ [ P 0 ] =4 , 06 kW ¿
P1
7.81
[ P¿¿ 0]= =1.75 ≈ 2=¿ C z =0 , 95 ¿ ¿
4.46
⇒ Z=2
Belt pulley width, according to 4.17 and table 4.21 ¿ [1]
B=( z−1 ) t+ 2 e= ( 2−1 ) ×15+2 ×10=35 mm
Outer diameter of the pulleys:
d a 1=d 1+2 h0 =180+2 ×3.3=186.6 mm
d a 2=d 2+2 h 0=900+2 ×3.3=906.6 mm
Determination of the initial tension and the force acting on the shaft:
780 P1 K d 780 ×7.81 ×1.1
Acorrding to 4.19: F 0= + F v= + 80.22=209.18 N
v Cα z 27.64 ×0 , 94 ×2
With: F v =q m × v 2=0,105× 27.64 2=80.22 N (Table 4.22)
According to 4.21 ¿ [1] force acting on the shaft:
( )
α1
( )
°
142.43
F r=2 F 0 zsin =2 ×209.18 × 2× sin =792.15 N
2 2
10
CHAPTER 4: DESIGN TRANSMISSION IN GEAR BOX

4.1 Design bevel gear
4.1.1 Specification
Power: P1=6.82 kW
Torque: T =111449.35 N . mm
Number of revolutions: n1=584.4 rpm
Transmission ratio: u=4.1
Service life: 6 years
One-directional rotations, two shifts, low impact loading (187 days of working per year, 8 hours
per shift)
Load mode: T1 = T; t1 = 19s; T2 = 0.6T; t2 = 14s
4.1.2 Choose material
We choose the material for the pair of bevel gear as follows:

Small gear: steel C45 improved, annealing at HB 1=245 ; σ b =850 MPa ; σ ch 1=580 MPa
1
Big gear: steel C45 improved, annealing at HB 2=230 ; σ b =750 MPa ; σ ch 2=450 MPa
2
4.1.3 Determine allowable stress

Preliminary calculation of bending stress and allowable contact stress according to the formulas
6.1a and 6.1b ¿ [1] we have:
° °
σ Hlim × K HL σ Flim × K FL × K FC
[ σ H ]= SH
; [ σ F ]=
SF
;
Where: σ F lim ¿ , σ0
¿: respectively are bending stress and contact stress allowing base cycle, their
H lim ¿ 0 ¿
values are founded at table 6.2: σ ¿ ¿

S F , S H : respectively are safety coefficient when calculating bending and contacting searched in
table 6.2: S F=1 , 75 , S H =1 , 1
Therefore,
0
σ H lim 1=2 ×245+ 70=560 MPa
0
σ F lim 1=1.8 ×245=441 MPa
0
σ H lim 2=2 ×230+ 70=530 MPa
0
σ F lim 2=1.8 ×230=414 MPa
K Fc: coefficient affects the load, take K Fc=1 (Load is put on one side)
K HL , K FL: Age coefficient, determined by formula (6.3) and (6.4):
11
K HL=
√
mH N HO
N HE
; K FL =
m N FO
N FE √
F
Where:
m H , mF : the degree of the curve in each time contacting and bending with HB <350, take:
m H =6 , mF =6
N FO , N HO: the number of cycles changing stress when try bending and contacting.
6
N FO=4 ×10 (cycles) with all type of steel
{
7
2.4 N HO =1 , 6 ×10 (cycles)
N HO=30 H HB ⟹ 1
N HO =1 , 4 ×107 (cycles)
2
N HE , N FE : number of cycles changing stress

Because the system works in load mode changing at many degrees, according to the formula 6.7
and 6.8 ¿ [1], we have:
( ) ( )
3 mF
Ti Ti
N HE=60 c ∑ × ni ×t i ; N FE=60 c ∑ ×ni ×t i
T T
With c is the number of times they fit in a rotation of pulley, c=1 ; ni , t i : the number of cycles and
time in hour working in mode i
We have:
N HE 2=60 ×1 ×142.53 × ( 8× 2× 187 ×6 ) × 13 × ( 19

19+14
+0.63 ×
14
19+14 )
=10.2 ×107 > N HO 1
⇒ K HL1=K HL2=1
N FE 2=60 ×1 ×142.53 × ( 8 × 2× 187 ×6 ) × 16 × ( 19

19+ 14
+0.66 ×
14
19+14 )
=9.1 ×10 7> N HO 2
⇒ K FL1=K FL2=1
σ H lim ¿ × k 0
560 ×1 σ H lim ¿ ×k
0
530 ×1
So, [ σ H 1 ] = HL
= =509.09 ( MPa ) ; [ σ H 2 ]= HL
= =481.82 ( MPa ) ¿¿
SH 1,1 SH 1 ,1
With bevel gear due to formula 6.12 ¿ [1] we have
[ σ H ]=min ( [ σ H 1 ] , [ σ H 2 ])=481.82(MPa)
0 0
σ × K ×K 441× 1× 1 σ ×K ×K 414 × 1× 1
[ σ F 1 ] = F lim 1 S FC FL = 1 ,75 =252 ( MPa ) ; [ σ F 2 ]= F lim 2 S FC FL = 1 , 75 =236.5 ( MPa )
F F
Maximum allowable stress, due to formula 6.10 and 6.11 ¿ [1] we have:
[ σ H ]max =2 ,8 σ ch =2 , 8 × 450=1260 (MPa)
2
[ σ F 1 ]max =0 , 8 σ ch =0 , 8 ×580=464 (MPa)

1
12
[ σ F 2 ]max =0 , 8 σ ch =0 , 8 × 450=360 (MPa)

2
4.1.4 Determine the outer cone length.
According to formula 6.52a ¿ [1] we have:
√
T 1 ×k Hβ
Re =k R × √ u +1 × 3
2
2
(1−k be )× k be × u× [ σ H ]
Which:
k R=0 ,5 × k d : The coefficient depends on the gear material and tooth type, with straight tooth
1 1
bevel gear: K =100 ( MPa ) 3 =¿ k =0 , 5× 100=50 ( MPa )3
d R
u: Fast transmission ratio of the gear reducer, u = 5

T1: Torque on the driving shaft (T1=111449.35 N.mm)
Kbe: Ring width coefficient, take Kbe = 0.285
K Hβ : The coefficient accounts for the uneven load distribution across the rim width table 6.21
¿ [1] with:
K be ×u 0.285 ×5
= =0 ,8 , Because the shaft is mounted on a cylindrical bearing, we take
2−K be 2−0.285
K Hβ=1.13
 Re =50 × √ 4.12+1 × 3
√ 111449.35× 1.13
(1−0.285)× 0.285 ×4.1 × 481.822
=182.72mm
4.1.5 Determine matching parameters

The outer diameter of the driving bevel gear is determined according to formula 6.52b ¿ [1]:
√
T 1 × K Hβ 2 × Re 2× 182.72
d e 1=K d 3 = = =86.59 mm
(1−K be )× K be ×u × [ σ H ]
2
√u +1
2
√ 4.12 +1
Looking up table 6.22 ¿ [1], we have z 1 p=17 with HB<350=¿ z 1=1 , 6× z 1 p =1 ,6 × 17=27.2 teeth
Average diameter and average modulus of small bevel gear:
d m 1=( 1−0 , 5 × K be ) × d e1= ( 1−0 , 5 ×0,285 ) ×86.59=74.25 mm
d m 1 74.25
mtm= = =2.73 mm
z1 27.2
The outer ring module is determined according to formula 6.5 ¿ [1]:
mtm 2.73
mte= = =3.18 mm
1−0 ,5 K be 1−0 ,5 × 0.285
According to table 6.8 ¿ [1], take the standard mte=3 mm so:
13
mtm=mte × ( 1−0 ,5 × K be ) =3 × ( 1−0 , 5 ×0,285 )=2 , 6 mm

d m 1 74.25
z 1= = =28.56 take z 1=29 teeth
mtm 2.6
z 2=u1 × z 1=4.1 ×29=118.9 take z 2=119 teeth
z 2 119
So, the actual gear ratio: u1= = =4.1
z 1 29
Split taper angle:
δ 1=arctan
()
z1
z2
=arctan
29
119 ( )
=13.69
°
°
δ 2=90−13.69=76.31
The average diameter of the small bevel gear:
d m 1=z 1 ×mtm=29 ×2 , 6=75.4 mm
Outer taper length:
Re =0 , 5 ×mte × √ z 21 + z 22=0 , 5× 3.18 × √ 292 +1192=194.74 mm
4.1.6 Teeth testing for contact strength
√ 2 ×T 1 × K H × √ u +1
2
According to formula 6.33 ¿ [1], we have: σ H =Z M × Z H × Z ε × 2
≤[σ ¿¿ H ]¿
0 , 85 b d m 1 u
Where:
Z M : The coefficient refers to the mechanical properties of the gear, according to table 6.5 ¿ [1],
1
we have Z =274 MPa 3
M
z ε : The coefficient refers to the match of teeth, determined by the formula z ε = 4−ε a
3 √
with ε ais the horizontal coefficient of match, calculated by the formula:
ε a=1 , 88−3 , 2
( 1 1
)
+ × cos ( β )=1.74 with β=0
z 1 z2
 Z ε=
√ 4−1 , 74
3
=0 , 87
Z H : The coefficient considers the shape of the contact surface, according to table 6.12 we have
Z H =1 , 6
T 1: Torque on the conduction shaft T 1=111449.35 N . mm
14
K H : The coefficient of load when calculating about exposure, determined by the formula 6.61
¿ [1]
K H =K Hα × K Hβ × K HV
With:
K Hβ: The coefficient refers to the uneven distribution of the load across the tooth width
K Hβ=1 , 13
K Hα: The coefficient refers to the uneven concentration of load between the intake’s teeth K Hα =1
K HV : The coefficient takes into account the influence of dynamic loads, calculated using the
formula 6.63
v H × b × d m1
K HV =1+
2× T 1 × K Hβ × K Hα
√ d m 1 × ( u+1 ) π d m 1 n π ×85 , 8 ×1050

Which: v H =δ H × g 0 × v × ; with v= 3
= 3
=2.3 m/s
u 60× 10 60 ×10
Due to table 6.13, we choose precision grade is 8
δ H : coefficient about the matching error due to table 6.15 ¿ [1], we have δ H =0,006
g0: coefficient about the affection of pitch, take g0=56 due to table 6.16 ¿ [1]
 v H =δ H × g 0 × v ×
√ d m 1 × ( u+1 )
u
=0.006 ×56 ×2.3 ×
√
75.4 ×(4.1+1)
4.1
=7.48 mm
b=K be × R e =0,285 ×194.74=55.5 mm

v H × b × d m1 7.48 ×55.5 ×75.4
So we have K HV =1+ =1+ =1.12
2× T 1 × K Hβ × K Hα 2 ×111449.35× 1.13 ×1
 K H =K Hα × K Hβ × K HV =1 ×1.13 ×1.12=1.26

√ 2 ×T 1 × K H × √ u +1
√ 2× 111449.35× 1.26 × √ 4.1 +1
2 2
σ H =Z M × Z H × Z ε × 2
=274 × 1.6 ×0.87 × 2
=395.98 MPa
0 , 85 b d m 1 u 0.85 × 55.5× 75.4 × 4.1
Accurately determine the permissible contact stress

z v : The coefficient refers to the effect of the rotational velocity, with v=2.3 m/s => Z v =1
z R : Coefficient considering surface roughness, with Ra =1 ,25 0 , 63 ( μm) Z R=1
K xH : The coefficient considers the influence of gear size, with d a <700 mm => K xH =1
[ σ H ]=[ σ H ] sys × Z v × Z R × K xH =481 ,82 ×1 ×1 ×1=481 , 82 ( MPa )
15
We have: σ H < [ σ H ] so durable contact conditions are guaranteed.
4.1.7 Teeth test for overload strength

2 ×T 1 × K F × Y ε ×Y β ×Y F
According to formula 6.65 we have: σ F 1 =
0 , 85 ×b × mtm × d m 1
Which:
K F: The coefficient of load when calculating bending, calculated by the formula 6.71 ¿ [1]
K F=K Fα × K Fβ × K Fv
With K Fβ is a coefficient that takes into account the uneven set of loads on the width of the tooth
rim, according to table 6.21 ¿ [ 1 ] , we have K Fβ=1.92; K Fα is a coefficient that takes into account
the uneven concentration of load between the teeth K Fα=1, K Fv: is a coefficient that takes into
account the influence of dynamic loads, determined by the formula:
v F ×b × d m 1
K Fv =1+
2 ×T 1 × K Fβ × K Fα
With: v F =δ F × g 0 × v ×
δ F =0.016 ; g0 =56
√ d m 1 ×(u+1)
u
, according to table 6.15 and 6.16 ¿ [ 1 ] , we have
 v F =δ F × g 0 × v ×
√
d m 1 ×(u+1)
u
19.95 ×55.5 ×75.4
=0.016 ×56 ×2.3 ×
4.1 √
75.4 ×(4.1+1)
=19.95
 K Fv =1+ =1.2
2 ×111449.35 ×1.92 ×1
So K F=K Fα × K Fβ × K Fv =1× 1.92× 1.2=2.304
°
1 1
Y ε= = =0 , 57; Y β=1− β n =1− 0 =1
ε α 1.74 140 140
z1 29 z2 119
z v 1= = =29.85; z v 2= = =502.81
cos ⁡(σ 1 ) cos ⁡(13.69) cos ⁡(σ 2 ) cos ⁡(76.31)
Search in table 6.18 ¿ [1] => Y F 1=3 , 8 , Y F 2=3 , 6

2 ×111449.35 ×2.304 × 0 , 57 ×1 ×3 , 8
So σ F 1 = =120.28 MPa
0 , 85× 55.5 ×2 , 6 ×75.4
Y F1 3.8
σ F 2 =σ F 1 × =120.28 × =126.96 MPa
Y F2 3.6
So we can see that: { σ F 1 < [ σ F 1 ] =252 MPa

σ F 2 < [ σ F 2 ] =236.5 MPa
So the flexural strength of the pair of bevel gears is guaranteed

16
4.1.8 Teeth testing for overload strength
According to formula 6.48 ¿ [1] we have: σ Hmax =σ H × √ K qt ≤ [ σ H ] max

T max
With: σ H =395.98 MPa ; K qt = =2, 2
T
So that: σ Hmax =395.98 × √ 2 ,2=587.33 MPa < [ σ H ]max =1260 MPa
σ Fmax =σ F ×k qt ≤ [ σ F ] max
So that:
σ Fmax 1=σ F 1 × k qt =120.28× √ 2 ,2=178.4 MPa< [ σ F 1 ]max =464 MPa
σ Fmax 2=σ F 2 × k qt =126.96 × √ 2 ,2=192.76 MPa< [ σ F 2 ]max =360 MPa
Parameter table of bevel gears

Outer taper length Re =194.74 mm
Outer ring module mte=3.18 mm
Teeth width b w =55.5 mm
Gear ratio u1=4.1
Precision grade 8
The angle of inclination of the °
teeth 0
Number of teeth of the bevel z 1=29 , z 2=119
gears
Tooth height adjustment x 1=0 , x 2=0
coefficient
Outer divider diameter d e 1=mte × z 1=3.18 ×29=92.22 mm
d e 2=mte × z 2=3.18 ×119=378.42 mm
° °
Split taper angle δ 1=13.69 ; δ 2=76.31
Height of external teeth h e=2 h te mte + c with c=0.2 mte ; hte =cos β m with β m=20° ÷ 30 ° , select β m=
Height of the tip of the outer tooth h ae 1=( h te + x n1 cos β m ) mte with x n 1=0.33 ( table 6.20 ) ; β m =25° → hae 1=3.83
h ae 2=2 hte mte−hae 1=1.93 mm
Height of the root of the outer h fe 1=h e−hae 1=6 , 4−3.83=2.57 mm
tooth h fe 2=h e−hae 2=6 , 4−1.93=4.47 mm
Diameter of the top of the outer d ae 1=d e 1+2 h ae1 cos δ 1=99.66 mm
tooth d ae 2=d e 2+2 h ae2 cos δ 2=379.33 mm
17
4.2 Design helical gear

4.2.1 Specification
Power: P1=6.48 kW
Torque: T =434182.28 N . mm
Number of revolutions: n1=142.53rpm
Transmission ratio: u=3
Service life: 6 years
One-directional rotations, two shifts, low level load (187 days of working per year, 8 hours per
shift)
Load mode: T1 = T; t1 = 19s; T2 = 0.6T; t2 = 14s
We choose the material for the pair of helical gear:
Small gear: Steel C45 improved, annealing at HB=275 , having σ b =850 MPa; σ CH =580 MPa 1 1
Big gear: Steel C45 improved, annealing at HB=260 , having σ b =850 MPa; σ CH =580 MPa 2 2
4.2.3 Determine allowable stress

According to the formula 6.1a and 6.2a
σ H lim ¿ × k
0 σ F lim ¿ ×k
0
×k Fl
[ σ H ]= SH
Hl
; [ σ F ]=
SF
Fc
¿¿
Where: σ F lim ¿ , σ ¿: respectively are bending stress and contact stress allowing base cycle, their
0
H lim ¿ 0 ¿
values are founded at table 6.2 ¿ [1]: σ ¿ ¿

S F , S H : respectively are safety coefficient when calculating bending and contacting searched in
table 6.2 ¿ [1]: S F=1.75 , S H =1.1
Therefore,
0
σ H lim 1=2 ×275+ 70=550 MPa
0
σ F lim 1=1 ,8 × 275=513 MPa
0
σ H lim 2=2 ×255+ 70=580 MPa
0
σ F lim 2=1 , 8× 275=495 MPa
K Fc: coefficient affects the load, take K Fc=1 (Load is put on one side)
K HL , K FL: Age coefficient, determined by formula 6.3 and 6.4 ¿ [1]:
K HL=
√
mH N HO
N HE
; K FL =
m N FO
N FE √
F
Where:
18
m H , mF : the degree of the curve in each time contacting and bending with HB <350, take:
m H =6 , mF =6
N FO , N HO: the number of cycles changing stress when try bending and contacting
6
N FO=4 ×10 with all type of steel
{
6
2.4 N HO =23.4 ×10
N HO=30 H HB ⟹ 1
N HO =21.5 ×106
2
N HE , N FE : number of cycles changing stress

Because the system works in load mode changing at many degrees, according to the formula 6.7
and 6.8 ¿ [1], we have:
( )
3
N HE =60 c ∑
2
Ti
T
3
× ni × t I =60 × 1× 142.53× 17952× 1 ×
19
19+14
3
+0.6 ×
14
19+14 (
=102459594.7 > N HO ) 1
⇒ K HL1=K HL2=1
( ) × n ×t =60 ×1 ×142.35 ×17952 ×(1 × 19+14

mF
Ti 19 14
N FE =60 c ∑
6 6
i i + 0.6 × )=91430133.82> N HO2
2
T 19+14
⇒ K FL1=K FL2=1
σ H lim ¿ × K 0
550 ×1 σ H lim ¿ × k 580 ×1
0
So, [ σ H 1 ] = Hl
= =500 MPa ; [ σ H 2 ] = =Hl
=527.27 MPa ¿ ¿
SH 1,1 SH 1, 1
With helical gear due to formula 6.12 ¿ [1] we have:
[ σ H 1 ]+ [ σ H 2 ] 500+527.27
[ σ H ]= 2
=
2
=513.635 MPa ⟹ [ σ H ]< 1, 25 [ σ H 1 ]
0 0
σ F lim 1 × k Fc ×k Fl 513 ×1 ×1 σ F lim 2 × k Fc × k Fl 495 ×1 ×1
[σ F1]= SF
=
1, 75
=293 ,14 MPa ; [ σ F 2 ]=
SF
=
1 , 75
=282 , 86 MPa
Maximum allowable stress, due to formula 6.13 and 6.14 ¿ [ 1 ] , we have:

[ σ H ]max =2 ,8 σ ch =2 , 8 ×580=1624 MPa
2
[ σ F 1 ]max =0 , 8 σ ch =0 , 8 ×580=464 MPa

1
[ σ F 2 ]max =0.8 σ ch =0 , 8 ×580=464 MPa

2
4.2.4 Basic specification of the shaft

Determine basically the shaft distance due to formula 6.15a:
√
T 2 k Hβ
a w =k a × ( u2 +1 ) × 3 2
[ σH ] u2 ψ ba
Where:
19
k a: coefficient depended on the material of gear and type of tooth. Due to table 6.5, we have
1/ 3
k a=43 ( MPa )
T 2; Torque, T 2=434182.28 N . mm
[ σ H ]: Allowable contact stress, [ σ H ]=513,635 MPa

ψ ba=0.3 , due to table 6.6 ¿ [1]
k Hβ : coefficient about the unbalanced load distribution over the ring width when the load is in
contact.
According to table 6.7 ¿ [1] with ψ bd =0.5 ×ψ ba × ( u ±1 ) =0.5 ×0.3 × ( 3+1 )=0 , 6, we determine
k Hβ =1.03
√
Therefore: a w =43 × ( 3+1 ) × 3
434182.28 ×1.03
513,6352 ×3 ×0.3
=212.41 mmtake a w =213 mm
We have: b w 2=ψ ba × aw =0.3× 213=63.9 mm and b w 1=bw 2 +5=68.9 mm

4.2.5 Determine matching parameters
Due to formula 6.17 ¿ [1], we have:
m=( 0 ,01 ÷ 0 , 02 ) × aw =( 0 , 01÷ 0 , 02 ) ×213=2.13÷ 4.26 mm
Due to table 6.8 ¿ [1] choose standard module m=2.5 mm
Choose basically β=10 ° , we determine the number of tooth on small pulley:
cos ( β ) cos ⁡( 10)
z 1=2 ×a w × =2 ×213 × =41.95, take z 1=42 teeth
m × ( u+1 ) 2.5 ×(3+1)
z 2=u × z 1=3 × 42=126 teeth
z 2 126
Therefore, the real transmission ratio: u2= = =3
z 1 42
z1 + z2 42+ 126
c os ( β )=m× =2.5 × =0,9859 → β=9.628 °
2× a w 2 ×213
Due to formula 6.18 ¿ [1] we calculate again shaft distance:
z 1+ z 2 42+126
a w =m× =2.5× =213 mm
2× cos ( β ) 2 × 0.9859
tan α tan20
Matching angle: α tw =α t=arctan =arctan =20.26 ° wtih α =20 due to table 6.11
cos β cos 9.628
¿ [1]
4.2.6 Testing tooth for contact strength
Due to formula 6.33 ¿ [1], contact stress on working surface of tooth is:
20
σ H =Z M Z H Z ε
Where:
√ 2 T 2 K H ( u+1 )
2
b w u d w1
Z M : coefficient about mechanical properties of material, due to table 6.5 ¿ [1] we have
1
z M =274 MPa 3
Z H : coefficient about the contact shape, following 6.34 ¿ [1] we have
ZH=
√ 2cos βb
sin 2 α tw
Where:
β b: inclination angle of teeth on basis cylinder
Due to formula 6.35 ¿ [1], we have
tan β b =cos α t × tan β=cos 20.26 ° × tan 9.628° =0.16 → β b =9.09 °
Therefore,
ZH=
√ 2cos ⁡( 9.09)
sin ⁡(2 ×20.28)
=1.74
Z ε: coefficient about tooth matching, determined through formula 6.36c:

sin β sin 9.628°
We have ε β =b w × =63.9× =1.36> 1
πm 2.5 π
So we have Z ε=
√ √
1
εα
=
1
1.36
=0.86
[
While ε α = 1 , 88−3 , 2 ( z1 + z1 )] × cos β=[1.88−3.2( 421 + 1261 )] ×cos 9.628 °=1.75
1 2
Pitch diameter of small pulley:

aw 213
d w 1=2 × =2 × =106.5 mm
u+1 3+1
K H : load coefficient when calculating contact, determine through formula 6.39 ¿ [1]:
K H =K Hα × K Hβ × K HV
With:
K Hβ: coefficient about the unbalance distribution of load on the width of internal toothing,
searching in table 6.7 ¿ [ 1 ] , we have K Hβ=1.03
K HV : coefficient about the affection of flexible load in matching zone, due to formula 6.41 ¿ [1],
we have:
21
v H × bw ×d w 1
K HV =1+
2× T 1. × K Hβ × K Hα
Where:
v H =δ H × g 0 × v ×
√ d w1 ( u+1 )
u
δ H : coefficient about the matching error due to table 6.15 ¿ [1], we have δ H =0.002
g0: coefficient about the affection of pitch, take g0=73 due to table 6.16 ¿ [1]
π d w 1 n1 π ×106.5 ×142.53
v : pitch velocity v= = =0.79 m/ s
60000 60000
Due to table 6.13 ¿ [1], we choose the degree of accuracy is 9 => K Hα : The coefficient refers to
the uneven distribution of the load between the pairs of teeth at the same time, choose K Hα =1.13
v H =0.002 ×73 × 0.79×

√ 106.5 × ( 3+ 1 )
3
=1.37
1.37 ×63.9 ×106.5

So: K HV =1+ =1
2× 434182.28 ×1.03 × 1.13
K H =1.13 ×1.03 ×1=1.16
Substituting values to the formula we have:
σ H =274 ×1.74 × 0.86 ×

√ 2 × 434182.28 ×1.1639 × ( 3+1 )
63.9× 3 ×106.52
=558.14 MPa
Determine exactly the contact stress:

With: v< 5 m/ s ⟹ z V =1
Ra =0 , 63÷ 1 , 25 μm z R=1
d a <700 ( mm ) K XH =1
Due to 6.1 and 6.1a ¿ [ 1 ] , we have:
[ σ H ]=[ σ H ] sys × z v × z R × K XH =572 ,7 ×1 ×1 ×1=572 ,7 MPa
Because of σ H =558.14 MPa < [ σ H ]=572 , 7 MPa then condition for contact stress is secured. To
calculate simply, choose b w =64 mm
4.2.7 Testing tooth about bending strength
2 ×T 2 × K F × Y ε ×Y β ×Y F 1
Due to formula 6.43 ¿ [1], we have: σ F 1 =
bw ×d w 1 × m
Where:
T 2=434182.28 : bending momentum on driving gear, N.mm
m=3 : module
22
b w: width of pitch b w =64 mm

d w 1=106.5 : pitch diameter of driving gear, mm
1 1
Y ε= = =0 , 57 coefficient about the tooth matching (with ε α =1 ,75 )
ε α 1, 75
1−β ° 9.628
Y β= =1− =0.93: coefficient about the inclination
140 140
Y Fi: Coefficient about type of tooth on gear 1 and 2
{
z1 42
z v1= 3
= 3
=43.83
cos β 0,9859
z 126
z v 2= 23 = 3
=131.48
cos β 0,9859
So due to table 6.18 with coefficient of correction x 1=x 2=0

We have: Y F 1=3.7 ; Y F 2=3.6
K F: load coefficient when calculating bending.
K F=K F α × K Fβ × K Fv
K F α =1.37 due to table 6.14
K Fβ=1.08 due to table 6.7
v F ×b w × d w 1
K FV =1+
2× T 2 × K Fβ × K Fα
When v F =δ F × g 0 × v ×
√ aw
u
Due to table 6.15 and table 6.16 ¿ [1], we have:
δ F =0.006
g0=73
⟹ v F=0.006 ×73 ×0.79 ×

√ 213
3
=2.92
2.92× 64 ×106.5
⟹ K FV =1+ =1.02
2 × 434182.28 ×1.08 ×1.37
⟹ K F =1.37 ×1.08 × 1.02=1 ,51
2 ×434182.28 × 1.51× 0.57 ×0.93 ×3.7
⟹ σ F 1= =125.77 MPa
64 ×106.5 ×3
Y F2 3.6
We have: σ F 2 =σ F 1 × =125.77 × =122.37 MPa
Y F1 3.7
23
Seeing that: {σ F 1 < [ σ F 1 ] =293.14

σ F 2 < [ σ F 2 ]=282.86
Bending stress condition is secured.

4.2.8 Testing overload endurance
According to 6.48 ¿ [1]we have: σ Hmax =σ H × √ K qt ≤ [ σ H ] max
T max
With: σ H =558.14 ( MPa ) ; K qt = =2.2
T
So that:
σ Hmax =558.14 × √ 2.2=827.86 MPa< [ σ H ]max =1624 MPa
σ Fmax =σ F × K qt ≤ [ σ F ]max
So that:
σ Fmax 1=σ F 1 × k qt =125.77 × √ 2 ,2=186.55 MPa < [ σ F 1 ] max =464 MPa
σ Fmax 2=σ F 2 × k qt =122.37 × √ 2 ,2=181.5 MPa< [ σ F 2 ]max =464 MPa

Parameter table of helical gears
Shaft distance a w =213 mm
Module m=3 mm
{
Ring width bw 1=63.9 mm
bw 2=68.9 mm
Speed ratio u=3

Angle of tooth β=9.628 °
Number of tooth z 1=42 ; z 2=126
Coefficient of correction x 1−x 2=0 mm
Accurate levels 9
Pitch diameter m z1 3× 42
d 1= = =127.8 mm
cosβ 0.9859
m z2 3 ×126
d 2= = =383.4 mm
cosβ 0.9859
Addendum diameter d a 1=d 1+2 × m=127.8+2× 3=133.8 mm
d a 2=d 2+2 × m=383.4+2 ×3=389.4 mm
Dedendum diameter d f 1=d a 1−3 × m=105 , 4−3 ×3=124.8 mm
24
d f 2=d a 2−3 × m=389.4−3 ×3=380.4 mm
4.3 Lubrication and oil immersion tests

Conditions for oil-bath lubrication in bevel-helical gear reducers:
Bevel gears need to be immersed to the entire width of the large gear h in oil
Helical gears need to be immersed to the full tooth height hr and at least 10mm.
1
The highest level of oil is not exceeded R gear 4.
3
The distance between the highest and lowest oil levels: h max−h min=10 ÷ 15 mm
4.3.1 Consider the driven bevel gear
The lowest height of the driven bevel gear that needs to be immersed in oil is:
h2 min =2.25 m=2.25 ×3=6.75 mm<10 mm
1 1 1 1
H 1= d ae 2−10−15= ×379.33−10−15=164.665> d a3 = ×379.33=126.44 mm
2 2 3 3
4.3.2 Consider the driven helical gear
The lowest height of the driven helical gear that needs to be immersed in oil is:
h 4 min =2.25 m=2.25 ×3=6.75 mm<10 mm
1 1 1 1
H 2= d a 4−10−15= ×389.4−10−15=169.7> d a 4 = ×389.4=129.8 mm
2 2 3 3
Due to this, the transmission satisfies lubrication conditions.
25
CHAPTER 5: SHAFT DESIGN
5.1 Design shaft I
5.1.1 Parameters
Torque: T 1=111449.35 N . mm
Number of revolutions: n1=584.4 rpm

Tooth rim width: b w =55.5 mm
Choose steel C45 improved. Parameters:
Durable limit: σ b=600 MPa
Melting limit: σ ch=340 MPa
Permissible torsional stress: [ τ ]=15 ÷ 30 MPa choose [ τ 1 ] =15 MPa
5.1.3 Preliminary selection of diameter
Preliminary calculated diameter:
d 1=
√
3 T1
√
0 , 2× [ τ ]
=
3 111449.35
0 ,2 ×15
=33.37 mm choose standard d 1=35 mm (Table 10.2 ¿ [1])
5.1.4 Roller bearing width

According to table 10.2 ¿ [1], we choose b 1=21 mm
5.1.5 Shaft size outline calculation
l 11= ( 2, 5 ÷ 3 ) d 1=87.5 ÷105 , choose l 11=100 mm
l 13=l 11 +k 1+ k 2+ l m 13+0 , 5 ¿
With
k 1=8 ÷15 ; choose k 1 =15: The distance between the rotating details
k 2=5÷ 15 ; choose k 2=15: Distance from the bearing to the inner wall of the box
l m 13=( 1 , 2÷ 1 , 4 ) d 1=42÷ 49 ; choose l m 13=48 mm : bevel gear mayo length
Choose l 13=162 mm
l 12=−l c 12=−[0 , 5 ( l m12 +b 1) + k 3 +hn ]=−[0 , 5 ( 50+21 ) +15+15]=−65.3 mm
k 3=10 ÷20 ; choose k 3 =15: Distance from the bearing to the bearing hub
h n=15 ÷20 ; choose hn =15: Height of the bearing hub and screw head
l m 12=( 1 ,2 ÷ 1 ,5 ) d 1=42÷ 52.5 ; choose l m 12=50 mm : belt mayo length
Choose l 12=66 mm
26
5.1.6 Force acting on the shaft

Force from driving bevel gear:
2T 1 2 ×111449.35
F t 1= = =3002 N
d m1 74.25
F r 1=F t 1 tan α cos δ 1=3002 × tan 20 °. cos 13.69 °=1061.6 N
F a 1=Ft 1 tan α sin δ 1=3002× tan 20 ° sin 13.69° =258.6 N
Force from belt:
F r=2 F 0 zsin ( )
α1
2
=2 ×209.18 × 2× sin
2 (
142.43°
)
=792.15 N
F a 1 × d m 1 258.6 ×74.25
M A 1= = =9600.525 N . mm
2 2
5.1.7 Determination of shaft diameter
Total bending moment at cross sections:
M A 1= √ M 2rx + M 2ry =√ 02 +0 2=0 N .mm
M B 1= √ M 2rx + M 2ry = √ 56219.12 +1861242 =194429.24 N . mm
M C 1=√ M rx + M ry =√ 52281.9 + 0 =52281.9 N .mm

2 2 2 2
M D 1=√ M 2rx + M 2ry =√ 02+ 02=0 N . mm

Equivalent moment at cross sections:
M tA 1=√ M 2A 1 +0 , 75T 21=√ 02 +0 , 75 ×111449.352=96517.97 N . mm
M tB 1=√ M B 1+ 0 ,75 T 1=√ 194429.24 +0 ,75 ×111449.35 =217067.84 N .mm

2 2 2 2
M tC1 =√ M 2C 1 +0 , 75 T 21= √ 52281.92 +0 , 75 ×111449.352=109768.46 N . mm
M tD 1=√ M 2D 1 +0 , 75 T 21= √ 0 2+ 0 ,75 ×111449.35 2=96517.97 N . mm

Diameter of shaft segments
d A1=
√
3
0,1[σ]
=
√
M tA 1 3 96517.97
0 , 1 ×50
=29 , 1 mm Choose d A 1 =30 mm
d B 1=
√
3
0,1[σ]
=
√
M tB 1 3 217067.84
0 ,1 ×50
=35.14 mm Choose d B 1=40 mm
d C 1=
√
3
√
M tC 1 3 109768.46
0 ,1 [ σ ]
=
0 ,1 ×50
=28 mm Choose d C 1=30 mm
d D 1=
√
3
√
M tD 1 3 96517.97
0 ,1 [ σ ]
=
0 ,1 ×50
=29 , 1mm Choose d D 1=30 mm
27
Radial force at the bearing

X B 1=4863.24 N ; Y B 1=2146.61 N
X C 1=1861.24 N ; Y C1 =1877.16 N
28
Figure 5.1: Shaft 1 Load Diagram
Figure 5.2: Preliminary drawing of shaft 1
29
5.2 Design shaft II

5.2.1 Parameters
Torque: T 2=434182.28 N . mm
Number of revolutions: n2 =142.53 rpm

Choose steel C45 improved. Parameters:
Durable limit: σ b=600 MPa
Melting limit: σ ch=340 MPa
Permissible torsional stress: [ τ ]=15 ÷ 30 MPa choose [ τ 1 ] =15 MPa
5.2.3 Preliminary selection of diameter
Preliminary calculated diameter:
d 2=
√
3 T2
√
0 , 2× [ τ ]
=
3 434182.28
0 , 2 ×15
=52.5 mm choose standard d 2=55 mm (Table 10.2 ¿ [1])
5.2.4 Roller bearing width

According to table 10.2 ¿ [1], we choose b 2=29 mm
5.2.5 Shaft size outline calculation
l 22=0 , 5 ( l m 22+b 2 ) +k 1 +k 2=0 ,5 ( 70+ 29 ) +15+15=79 , 5 mm
choose l 22=80 mm
l 23=l 22+ 0 ,5 ¿
Choose l 23=137 mm
l 21=l m 22+l m 23 +b 2+3 k 1+ 2k 2=70+70+29+ 45+30=244 mm
Choose l 21=244 mm
With:
k 1=8 ÷15 ; choose k 1 =15: The distance between the rotating details
k 2=5÷ 15 ; choose k 2=15: Distance from the bearing to the inner wall of the box
l m 22=( 1 ,2 ÷ 1 ,5 ) d 2=66 ÷82.5 ; choose l m 22=70 mm : helical gear mayo length
l m 23=( 1 , 2÷ 1 , 4 ) d 2=66÷ 77 ; choose l m 23=70 mm : bevel gear mayo length

5.2.6 Force applied to the shaft.
The force applied from the driving bevel gear:

30
F t 2=F t 1=3002 N
F a 2=F r 1=1061.6 N
F r 2=F a 1=258.6 N
Fa 2 d m 2 1061.6 × 304.425
M 2= = =161588.79 N . mm
2 2
The force applied from the driving helical gear:
2T 2 2× 434182.28 Ft 3 tan α tw 6794.71 × tan 20.26 °
F t 3= = =6794.71 N F r 3= = =2543.88 N
dw 3 127.8 cos β cos 9.628 °
F a 3=F t 3 tan β=6794.71 × tan 9.628° =1152.65 N
F a3 d m 3 1152.65×127.8
M 3= = =73654.34 N . mm
2 2
5.2.7 Determination of shaft diameter:

M A 2= √ M 2rx + M 2ry =0 N . mm
M B 2= √ M 2rx + M 2ry= √ 228927.14 2+ 485435.22=536707.53 N . mm
M C 2=√ M 2rx + M 2ry =√ 203602.42 +454910.86 2=498395.25 N . mm
M D 2=√ M 2rx + M 2ry =0
Equivalent moment at cross sections

M tdA 2=√ M 2A 2+ 0 ,75 T 2A 2= √ 0 2+0.75 × 434182.282=376012.88 N . mm
M tdB2 =√ M 2B 2+ 0 ,75 T 2B 2= √ 536707.532 +0 , 75 × 434182.282=655317.22 N .mm
M tdC 2= √ M 2C 2 +0 , 75T 2C 2=√ 498395.25 2+ 0 ,75 × 434182.282=624326.45 N . mm
M tdD 2=√ M 2D 2 +0 , 75 T 2D 2=√ 02 +0.75 × 434182.282=376012.88 N . mm
d A 2=
√
3
0,1[σ]
=
√
M tA 2 3 376012.88
0 , 1× 50
=42.21mm Choose d A 2=45 mm
d B 2=
√
3
0,1[σ]
=
√
M tB 2 3 655317.22
0 , 1× 50
31
d C 2=
√
3
√
M tC 2 3 624326.45
0 ,1 [ σ ]
=
0 ,1 ×50
=49.98 mm Choose d C 2=50 mm
d D 2=
√
3
√
M tD 2 3 376012.88
0 ,1 [ σ ]
=
0 ,1 ×50
=42.21 mm Choose d D 2=45 mm

X A 2=6067.94 N N ; Y A 2=1940.91 N
X D 2=3728.77 N ; Y D 2=344.37 N
32
33
5.3 Design shaft III

5.3.1 Parameters
Torque: T 3=250284.15 N . mm
Number of revolutions: n3 =47.51 rpm
Choose steel C45 improved. With parameters:

Durable limits: σ b=600 MPa
Melting limits: σ ch=340 MPa
Allowable torsional stress: [ τ ]=15 ÷ 30 MPa choose [ τ 3 ]=30
5.3.3 Preliminary selection of diameter:
Preliminary calculation diameter: d 3= 3

√ T3
0,2[τ]
=
√3 1250284.15
0 , 2× 30
=59.29 mm
Choose d 3=60 mm according to standard (Table 10.2 ¿ [1])

5.3.4 Roller bearing width:
According to table 10.2 in [1] choose b 3=31 mm

5.3.5 Shaft size outline calculation:
l 31=l 21=244 mm
l 33=l 31−l 22=244−80=164 mm
l 32=−l c 32=−[ 0 , 5× ( l m 32+ b3 ) +k 3 + hn ]=−( 0 ,5 ( 100+31 ) +15+15 )=−95 ,5 mm
Choose l 32=96 mm
With:
k 3=10 ÷20 ; choose k 3 =15: Distance from the bearing to the bearing hub
h n=15 ÷20 ; choose hn =15: Height of bearing hub and screw head
l m 32=( 1 , 4 ÷ 2 ,5 ) d 3=84 ÷ 150 mm ; choose l m 32=100 mm : coupling length
5.3.6 Force applied on the shaft
Force applied from the driven helical gear

F t 4 =Ft 3=6794.71 N
F r 4 =F r 3 =2543.88 N
34
F a 4=F a 3=1152.65 N
F a 4 d m 4 1152.65× 383.4
M a4= = =220963.005 N . mm
2 2
Force applied from the coupling
2 T3 2×1250284.15
F nt =0 , 2. Ft =0 , 2. =0 ,2. =2500.57 N
Dt 200
5.3.7 Determination of shaft diameter:

M A 3= √ M 2rx + M 2ry =0 N . mm
M B 3 =√ M 2rx + M 2ry= √ 209232.82 + 444060.82=490885.28 N . mm
M C 3=√ M 2rx + M 2ry =√ 02 +2400532=240053 N . mm
M D 3=√ M 2rx + M 2ry =0 N .mm
Equivalent moment at cross sections

M tA 3=√ M 2A 3 +0 , 75 T 2A 3=√ 02 +0.75 ×250284.152 =216752.43 N . mm
M tB 3=√ M B 3 +0 , 75 T 3= √ 490885.28 +0.75 ×250284.15 =536609.7 N . mm

2 2 2 2
M tC3 =√ M C 3 +0 , 75 T 3 =√ 240053 + 0 ,75 × 250284.15 =323430.15 N . mm

2 2 2 2
M tD 3=√ M 2D 3 +0 ,75 T 2D 3 =√ 02+ 0.75 ×250284.152=216752.43 N . mm
d A3=
√
3
0,1[σ]
=
√
M tA 3 3 216752.43
0 , 1 ×50
=35.13 mm Choose d A 3 =40 mm
d B 3=
√
3
0,1[σ]
=
√
M tB 3 3 536609.7
0 ,1 ×50
d C 3=
√
3
√
M tC 3 3 323430.15
0 , 1[ σ ]
=
0 ,1 ×50
=40.14 mm Choose d C 3=45 mm
d D 3=
√
3
√
M tD 3 3 216752.43
0 ,1 [ σ ]
=
0 ,1 ×50
=35.13 mm Choose d D 3=40 mm

X A 3=5550.76 N ; Y A 3=2615.41 N
35
X C 3 =1256.62 N ; Y C 3=71.53 N
36

CHAPTER 6: KEY TESTING
37
6.1 Shaft testing

6.1.1 Test for fatigue strength
s σj . s τj
s j= ≥[s]
√s 2
σj
2
+ s τj
Chọn [ s ] =3: permissible safety factor, such as no need to check the stiffness of the shaft
Which:
σ −1
sσj =
K σdj σ aj +ψ σ σ mj
τ−1
sτj =
K τdj τ aj +ψ τ τ mj
With:
+ Permissible bending fatigue limit of carbon steel:
σ −1=0,436 × σ b=0,436 ×600=261.6 MPa
+ Torsional fatigue limit:

τ −1=0 , 58 ×σ −1=0 , 58× 261 ,6=151.75 MPa
+ For the axis of rotation, the bending stress varies with symmetrical cycles
σ mj=0
Mj
σ aj =σ maxj =
Wj
+ Which:
M j =√ M 2xj + M 2yj
W j: Bending resistance moment, calculated in table 10.6 in [1]
+ 1-way rotary drive:

τ maxj Tj
τ mj=τ aj = =
2 2W0 j
With:
τ j: torque at cross section j
W 0 j: torsional resistance torque, in table 10.6 in [1]
+ Coefficient of influence of average value on fatigue strength, table 10.7 in [1]

38
ψ σ =0 , 05 ; ψ τ =0
Kσ Kτ
+ K x −1 + K x −1
+ Coefficient: εσ ετ
K σdj = ; K τdj=
Ky Ky
With:
K x =1 ,06 : The stress concentration coefficient due to the surface state is turned with
roughness Ra =2 ,5 ÷ 0 , 63 Durable limit application.
K y =2: The shaft surface is enhanced by carbon impregnation.
K σ =1 , 76 ; K τ =1, 54 : Shaft with a key groove cut with a finger milling cutter
ε σ ; ε τ : Check in table 10.10 in [1]
Shaft Detail’s b × h× t 1 W j W oj εσ ετ σ aj τ a=τ m sσ sτ s

location face
Shaft 1 A1(35) 10 ×8 ×52923,5 7132,8 0,87 0,8 4,98 9,9 50.4 15, 14,7
4
B1,C1(40) x 6283,2 12566, 0,85 0,78 30,5/ 5,6 8,05/ 26, 7,7/
4 14,9 16,5 47 14
D1(35) 10 ×8 ×52923,5 7132,8 0,87 0,8 0 9,9 x 15, x
4
Shaft 2 A2,D2(40) x 6283,2 12566, 0,85 0,78 0 0 x x x
4
B2(50) 14 × 9 ×5 9222,3
,5 21494, 0,81 0,76 53,2 10,5 4,4 13, 4,2
1 8
C2(55) 16 ×10 × 6
12142,9 28476, 0,79 0,75 47,8 7,9 4,78 18, 4,62
8 05
Shaft 3 A3,C3(65) x 26961,3 53922, 0,78 0,73 0/9,4 0/ X/ X/ X/
5 12,7 24,04 11 10
B3(75) 20 ×12 ×7 ,5
32304,9 73722, 0,74 0,72 19,23 9,3 11,15 14, 8,92
5 85
D3(63) 18 ×11×7
18276,3 42824, 0,78 0,73 0 16 X 8,7 X
6
39
Thus, the shafts satisfy the shaft fatigue conditions.

6.1.2 Test for static durability
σ td =√ σ 2 +3 τ 2 ≤ [ σ ]
Which:
M max
σ= 3
0 ,1 d
T max
τ= 3
0 ,2 d
[ σ ]=0 , 8 [ σ ch ]=0 ,8 × 340=272 MPa
Shaft σ τ σ td
I 29,9 11,1 35,55
II 46,44 18,12 56,05
III 24,5 24,95 49,68
Thus, the shafts satisfy the condition of static stability of the shaft.
6.2 Key testing
Key parameters are selected according to the table 9.1
Stamping durability conditions:
2T
σ d= ≤ [ σ d ]=150 MPa
d l t (h−t 1)
Shear durability conditions:

2T
τ c= ≤ [ τ c ] =60 MPa
d lt b
With:
T: Torque
d: Shaft diameter at the place where the key is used
b x h x t1: basic diameter of the key
l t =(0 , 8 ÷ 0 , 9)l m: length of the key
Shaft Diameter b × h× t 1 lt σd τc
35(A1) 10 ×8 ×5 40 67,43 20,23
I
35(D1) 10 ×8 ×5 50 53,94 16,18
40
50(B2) 14 × 9 ×5 , 5 54 95,88 23,97

II
55(C2) 16 ×10 × 6 64 64,35 16,09
75(B3) 20 ×12 ×7 , 5 59 137,65 30,97
III
63(D3) 18 ×11×7 80 135,96 30,21
So, the keys satisfied the conditions of stamping strength and shear strength
41
CHAPTER 7: DESIGN ROLLER BEARINGS AND COUPLINGS

7.1 Shaft I
7.1.1 Parameters
Inner diameter: d 1=35 mm
Rotation speed: n1=584.4 rpm
One-way rotation, 2 shift working, light impact load.
7.1.2 Force on roller bearing
Radial force at the roller bearing
X B 1=4863.24 N ; Y B 1=2146.61 N
X C 1=1861.24 N ; Y C1 =1877.16 N
F rB1 =√ X 2B 1 +Y 2B 1=√ 4863.24 2+2146.612 =5315.92 N
F rC1= √ X 2C 1+Y 2C 1= √ 1861.24 2+ 1877.162=2643.47 N

Fa1 258.6
= =0.049<0.3
F rB 1 5315.92
→Choose deep grove ball bearing.
Preliminary selection of roller bearings:

Symbols d, mm D, mm B, mm C, kN C0, kN
SKF
35 100 25 55.3 31
6407N
7.1.3 Test the load capacity of the bearing
Consider the ratio (V=1 due to rotation of the inner ring)

Fa1 258.6
= =0,0487
V F rB 1 1 ×5315.92
Fa1 258.6
= =0.098
V F rC 1 1 ×2643.47
Fa1 258.6
= =0.008
C o 31× 103
Based on the table 11.4 in [1], we choose e=0 , 19 , X 0= X 1=1 ; Y 0=Y 1=0
42
F r=max { F rB 1 ; F rC 1 }=max {5315.92 ; 2643.47 }=5315.92 N
Q=( XV F r +Y F a ) k t k d=( 1 ×1 ×5315.92+0 × 258.6 ) ×1 ×1=5315.92 N
Calculate dynamic loading capacity:
C d=Q √ L
m
Where:
Working hours of deep grove ball bearing: Lh=17952 h
Lh nI 60 17952× 584.4 ×60
Working time in million cycles: L= 6
= 6
=629.47million revolutions
10 10
m=3 (ball bearing)
K t =1: Temperature influence coefficient
K đ =1: Impact coefficient of load characteristics (light impact, short-term overload, see
table 11.3)
→ Cd =Q √ L=5315.92× √ 629.47=45558.57 N <C=65.3 kN (satisfied)
m 3
7.1.4 Calculate static load capacity:
Q0= X 0 F r +Y 0 F a
Based on the table 11.6 in [1], we choose X 0=0 , 6 ; Y 0=0 , 5
Q0=0 ,6 × 5315.92+0 , 5× 258.6=3318.852 N < F rB 1
Q0=F rB 1=5315.92 N <C 0=31 kN (satisfied)
7.2 Shaft II
7.2.1 Parameters
Rotation speed: n2 =142.53 rpm
43
X A 2=6067.94 N ; Y A 2 =1940.91 N
X D 2=3728.77 N ; Y D 2=344.37 N
F rA 2=√ X 2A 2 +Y 2A 2=√ 6067.942 +1940.912=6370.79 N
F rD 2=√ X 2C 1+ Y 2C 1=√ 3728.772 +344.372=3744.64 N

F a F a 2−F a 1 1061.6−258.6 803
= = = =0.21<0 , 3
F rD 2 F rD 2 3744.64 3744.64
→Choose deep grove ball bearing.

Symbols d, mm D, mm B, mm C, kN C0, kN
SKF
55 140 33 99.5 62
6411N

Fa 803
= =0.126
V F rA 2 1 ×6370.79
Fa 803
= =0.214
V F rD 2 1 ×3744.64
Fa 803
= =0.0129
Co 62 ×103
Based on the table 11.4 in [1], we choose e=0 , 19 , X 0= X 1=1 ; Y 0=Y 1=0
F r=max { F rA 2 ; FrD 2 } =max { 6370.79 ; 3744.64 }=6370.79 N
Q=( XV F r +Y F a ) k t k d=( 1 ×1 ×6370.79+ 0× 803 ) ×1 ×1=6370.79 N
C d=Q √ L
m
Where:
Lh n2 60 17952 ×584.4 × 60
= 6
10 10
44
m=3 (ball bearing)
table 11.3)
→ Cd =Q √ L=6370.79× √ 153.52=34112.61 N <C=62 kN (satisfied)
m 3
7.3 Shaft III
7.3.1 Parameters
Rotation speed: n3 =47.51 rpm
X A 3=5550.76 N ; Y A 3=2615.41 N
X C 3 =1256.62 N ; Y C 3=71.53 N
F rA 3=√ X 2A 3 +Y 2A 3=√ 5550.762 +2615.412=6136.07 N
F rC3 =√ X 2C 3+ Y 2C 3=√ 1256.622+71.53 2=1258.65 N

Symbols d, mm D, mm B, mm α ,° C, kN C0, kN
SKF
60 120 29.75 15 125 160
32212
e=1 , 5 tan α =0 , 4
Axial force at A3:

∑ F aA 3=F sC 3−F at 3=0 , 83 e FrC 3−F at 3=0 ,83 × 0 , 4 ×1258.65−1152.65=−734.78 N
F sA 3=0 , 83 e F rA 3=0 , 83× 0 , 4 × 6136.07=2037.17 N
Because ∑ F aA 3 < F sA 3 so F aA 3=F sA 3=2037.17 N

Axial force at C3:
∑ F aC 3=F sA 3 + F at 3=2037.17+ 1152.65=3189.85 N
45
F sC 3=0 , 83 e F rC3 =0.83 ×0.4 × 1258.65=417.87 N
Because ∑ F aC 3 > F sC3 so ∑ F aC 3=F sC 3=3189.85 N

F aA 3 2037.17
= =0,332<e
V . F rA 3 1 ×6136.07
Check in table 11.4 in [1], we have: X =1 ,Y =0

F aC3 3189.85
= =2.53>e
V . F rC3 1× 1258.65
Check in table 11.4 in [1], we have: X =0 , 4 ; Y =0 , 4 cot α=1.49

Conventional load on the bearing:
Q A 3 =( XV FrA 3 +YF aA 3 ) K t K đ =( 1 ×1 ×6136.07 +0 ×2037.17 ) ×1 ×1=6136.07 N
QC 3=( XV F rC 3+Y F aC 3 ) K t K đ =( 0.4 × 1× 1258.65+1.49× 3189.85 ) ×1 ×1=5256.34 N
With:
table 11.3 in [1])
QC 3 <Q A 3 so we calculate the bearing according to the parameter at A3

Lh n3 60 17952 × 47.51× 60
= 6
10 10

10
m 3
C d=Q A 3 √ L=6136.07 × √ 51.17=19979.97 N <C=125 kN
10
Which m= (tapper ball bearing)
3
So the selected bearing satisfied dynamic loading capacity.
7.3.4 Calculate static load capacity
For tapper ball bearing according to table 11.6 in [1] we have
46
X 0=0 , 5 ;Y 0=0 , 22 cot α =0 , 82
Q0= X 0 F rC 3 +Y 0 F aC 3=0 , 5 ×1258.65+ 0.82× 3189.85=3245.002 N < F rA 3
So Q0=F rA 3=6136.07 N <C0 =160 kN

So the selected bearing satisfied static load capacity.
7.4 Design coupling
Torque moment at shaft 3: T 3=1250284.15 N .mm

Looking up table 16.10a in [2], we have the following axial parameters:
d D dm L l d1 D0 Z n max B B1 l1 D3 l2
63 260 140 110 200 8 2300 8 70 48 48 48
Table 16.10b in [2]
dc d1 D2 l l1 l2 l3 h
24 M16 32 95 52 24 44 2
Stamping Strength Test
2 kT
σ d= ≤ [σ d]
Z D0 d c l 3
With:
[ σ d ]=4 MPa: Permissible stamping stress of rubber rings
k =1 ,2 : Working mode coefficient (16.1 in[2])
2 ×1.2 ×1250284.15
σ d= =1.776 MPa ≤ [ σ d ] =4 MPa
8 ×200 × 24 × 44
So the shaft is durable
Key strength test
24
1.2 ×1250284.15 ×(52+ )
kT l 0 2
σ u= 3
= 3
=43.41 MPa ≤ [ σ u ] =80 MPa
0 ,1 d c D0 Z 0 ,1 ×24 × 200 ×8
So the key durable condition is satisfied
47
CHAPTER 8: GEAR BOX DESIGN
8.1 Gearbox design
The gear box housing is responsible for ensuring the relative position between the details
and parts of the machine, receiving loads transmitted by the components installed on the
housing, containing lubricating oil and protecting the components from dust.
The material used to make the box is gray cast iron: GX15-32
Choose the mounting surface between the box lid and the box body that passes through
the centerline of the shafts to make it easier and more convenient to install the details. The
mating surface is parallel to the base surface.
The casting gearbox reducer has the following basic parameters:
Name Parameters
Distance shaft 2-3 a=221 mm
δ=0 , 03 a+ 3=9 , 63 mm
Thickness:
choose δ=10 mm
Gearbox body,  δ 1=0 , 9 δ=9 mm
Gearbox cap, 1 choose δ 1=9 mm
Ribbed stiffener:
Thickness, e e=( 0 , 8 ÷ 1 ) δ=10 mm
Height, h h<5 δ=50 mm choose h=48 mm
Diameters:
Base screw, d1 d 1=20 mm >0 , 04 a+10=18 , 84
Drive edge screw, d2 d 2= ( 0 ,7 ÷ 0 , 8 ) d 1=16 mm
Cap and body flange screw, d3 d 3= ( 0 ,8 ÷ 0 , 9 ) d 2=14 mm
Bearing cover screw, d4 d 4 =( 0 , 6 ÷ 0 ,7 ) d 2=10 mm
d 5= ( 0 ,5 ÷ 0 , 6 ) d 2=8 mm
Screw to connect the oil visitor door
cover, d5
Flange connecting cap and body:
Box body flange thickness, S3 S3= (1 , 4 ÷1 , 8 ) d 3=25 mm
Box cap flange thickness, S4 S4 =( 0 , 9 ÷ 1 ) S3 =25mm
Width of box cap and body flanges, K 3 ≈ K 2−( 3 ÷ 5 )=¿48mm
K3
Plane bearing size: Determine by bearing hub size
Outer diameter and screw hole center, K 2=E 2+ R 2+ ( 3÷ 5 ) =¿51mm
D 3, D 2 E2 ≈ 1 ,6 d2 =25 ,6 mm
Width of bolt face next to bearing: K2 R2 ≈ 1, 3 d 2=20 , 8 mm
Center of bolt hole next to bearing: E2
and C ( k is the distance from the bolt
center to the edge of the bearing)
Box base:
Thickness without convex parts: S1 S1 ≈ ( 1, 3 ÷ 1, 5 ) d 1=30 mm
48
K 1 ≈ 3 d 1=60 mm
Box base width, K1 and q q=90 mm ≥ K 1 +2 δ=80 mm
Gaps between details:
Between the gear and the wall in the ∆=10 mm ≥ ( 1÷ 1 , 2 ) δ=(10 ÷12)
box ∆ 1=40 mm ≥ ( 3 ÷ 5 ) δ=(30 ÷ 50)
Between the top of the large gear and ∆ 2=10 mm ≥ δ=10
the bottom of the box
Between the sides of the gears
together.
L+B 614+ 327
Number of base bolt Z Z= = ≈4
200 ÷ 300 250
 Plane bearing size
Outer diameter and center of the screw hole D3, D2 choose according to 18.2
Shaft D (mm) D2 (mm) D3 (mm) D4 (mm) h d4 Z
I 110 130 160 100 12 M10 6
II 110 130 160 100 12 M10 6
III 120 140 170 115 14 M10 6
8.2 Component details

8.2.1 Visitor door
Figure 8.1: Shape and dimension of the visitor door
A B A1 B1 C C1 K R Screw Number
100 75 150 100 125 - 87 12 M 8× 22 4
8.2.2 Dowel pin
49
Fig 8.2: Shape and dimension of the dowel pin

Choose cone dowel pin d ×c ×l=6 × 1× 50 mm
8.2.3 Vent button
Figure 8.3: Shape and dimension of the air vent button

A B C D E G H I K L
M 27× 2 15 30 15 45 36 32 6 4 10
M N O P Q R S
8 22 6 32 18 36 32
8.2.4 Oil drain plug
Figure 8.4: Shape and dimension of the oil drain plug

d b m f L c q D S D0
M 20 15 9 3 28 2,5 17,8 30 22 25,4
8.2.5 Oil check stick
50
When working, gears are immersed in oil according to lubrication conditions. To check
the oil level height in the box, we use an oil check stick. The size of the oil check stick is
shown in the picture:
Figure 8.5: Shape and dimension of the oil checkstick

8.2.6 Oil seal
The ring consists of many triangular cross-section grooves with an apex angle of 60
degrees. The distance between the peaks is 3 mm. The ring is about ( 0.5 ÷ 1 ) mm from the
inside edge of the box wall. The gap between the shell and the outside of the threaded ring
is 0,4 mm.
Figure 8.6: Shape and dimension of the oil seal
8.2.7 Dust seal

51
In addition to eliminating stains from the operating surface, the anti-dust closed loop also
stops oil leaks from occurring within the box.
8.3 Choosing lubricating oil and mounting tolerances

Lubricating gear reducer:
Choosing a viscosity depends on the velocity of the gear material, according to table
18.11 with a rev velocity of 1 – 2.5 m/s, the gear material is improved C45 steel, the
viscosity of the oil at 50°C is 186
Look up table 18.13 in [2] we use lubricating oil AK-15
52
CHAPTER 9: FITTING AND TOLERANCE

9.1 Select manufacturing precision grade
For gears: pair of bevel gear is 7, pair of helical gear is 9
For shafts, key and key grooves select the correct grade as 7
For the holes the correct grade is 6
9.2 Select mounting type
For the key and gear select the mounting type H7/k6
For the inner diameters select the mounting type k6
For the outer diameters select the mounting type H7
9.3 Fitting tolerance table of gear and key
Detail Dimension Joints es (μm) ei(μm) ES(μm) EI (μm) Largest Largest
redundancy clearance
(μm) (μm)
Gear
Driving ∅ 35 H7 +18 +2 +25 0 18 23
bevel k6
gear
Driven ∅ 55 H7 +18 +2 +25 0 18 23
bevel k6
gear
Driving ∅ 60 H7 +25 0 +30 0 25 30
helical k6
gear
Driven ∅ 75 H7 +25 0 +30 0 25 30
helical k6
gear
Outer diameter of bearing
Shaft I ∅ 100 H7 +25 +3 +35 0 25 32
Shaft II ∅ 140 H7 +25 +3 +35 0 25 32
Shaft III ∅ 120 H7 +25 +3 +35 0 25 32
Inner diameter of bearing
Shaft I ∅ 40 k6 +18 +2 +25 0 18 23
Shaft II ∅ 40 k6 +15 +2 +21 0 15 19
Shaft III ∅ 65 k6 +21 +2 +30 0 21 28
Key
Key Limited deviation of the key groove width Deviation from the depth of the key groove
diameter On shaft On bushing On shaft On bushing
s P9 D10 Js9 Js9
10 ×8 ×5 -15 +98 ±18 ±18
53
-51 +40
14 × 9 ×5 , 5 -18 +120 ± 21 ,5 ± 21 ,5
-61 +50
16 ×10 × 6 -18 +120 ± 21 ,5 ± 21 ,5
-16 +50
18 ×11×7 -22 +149 ± 21 ,5 ± 21 ,5
-74 +65
20 ×12 ×7 , 5 -22 +149 ± 26 ± 26
-74 +65
54
REFERENCES
[1] TÍNH TOÁN THIẾT KẾ HỆ DẪN ĐỘNG CƠ KHÍ (Tập một) – Trịnh Chất, Lê Văn
Uyển
[2] TÍNH TOÁN THIẾT KẾ HỆ DẪN ĐỘNG CƠ KHÍ (Tập hai) – Trịnh Chất, Lê Văn
Uyển
55

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HCMC UNIVERSITY OF TECHNOLOGY - VNU HCM

FACULTY OF MECHANICAL ENGINEERING

Student: Tô Xuân Bình

Ho Chi Minh City, .../2024

THIẾT KẾ HỆ THỐNG DẪN ĐỘNG

DESIGN OF A TRANMISSION SYSTEM FOR

Student: Tô Xuân Bình

Ho Chi Minh City, .../2024

Figure 5.1: Shaft 1 Load Diagram..........................................................................................................

CHAPTER 2: SELECT PROPER ELECTRIC MOTOR AND DISTRIBUTE VELOCITY

From table P1.3 in [1] select motor: 4A112M2Y3

2.2 Distribute velocity ratio

2.2.3 Power on each shaft

2.2.4 Torque on each shaft

CHAPTER 3: DESIGN V-BELT

λ+ √ λ2 −8 ∆2 2303.54+ √ 2303.54 2−8∗3602

CHAPTER 4: DESIGN TRANSMISSION IN GEAR BOX

We choose the material for the pair of bevel gear as follows:

4.1.3 Determine allowable stress

values are founded at table 6.2: σ ¿ ¿

N HE , N FE : number of cycles changing stress

N HE 2=60 ×1 ×142.53 × ( 8× 2× 187 ×6 ) × 13 × ( 19

N FE 2=60 ×1 ×142.53 × ( 8 × 2× 187 ×6 ) × 16 × ( 19

[ σ F 1 ]max =0 , 8 σ ch =0 , 8 ×580=464 (MPa)

[ σ F 2 ]max =0 , 8 σ ch =0 , 8 × 450=360 (MPa)

4.1.4 Determine the outer cone length.

According to formula 6.52a ¿ [1] we have:

u: Fast transmission ratio of the gear reducer, u = 5

4.1.5 Determine matching parameters

mtm=mte × ( 1−0 ,5 × K be ) =3 × ( 1−0 , 5 ×0,285 )=2 , 6 mm

T 1: Torque on the conduction shaft T 1=111449.35 N . mm

√ d m 1 × ( u+1 ) π d m 1 n π ×85 , 8 ×1050

b=K be × R e =0,285 ×194.74=55.5 mm

Accurately determine the permissible contact stress

z R : Coefficient considering surface roughness, with Ra =1 ,25 0 , 63 ( μm) Z R=1

[ σ H ]=[ σ H ] sys × Z v × Z R × K xH =481 ,82 ×1 ×1 ×1=481 , 82 ( MPa )

We have: σ H < [ σ H ] so durable contact conditions are guaranteed.

4.1.7 Teeth test for overload strength

Search in table 6.18 ¿ [1] => Y F 1=3 , 8 , Y F 2=3 , 6

So we can see that: { σ F 1 < [ σ F 1 ] =252 MPa

So the flexural strength of the pair of bevel gears is guaranteed

4.1.8 Teeth testing for overload strength

According to formula 6.48 ¿ [1] we have: σ Hmax =σ H × √ K qt ≤ [ σ H ] max

So that: σ Hmax =395.98 × √ 2 ,2=587.33 MPa < [ σ H ]max =1260 MPa

σ Fmax 2=σ F 2 × k qt =126.96 × √ 2 ,2=192.76 MPa< [ σ F 2 ]max =360 MPa

Parameter table of bevel gears

4.2 Design helical gear

4.2.3 Determine allowable stress

values are founded at table 6.2 ¿ [1]: σ ¿ ¿

N HE , N FE : number of cycles changing stress

( ) × n ×t =60 ×1 ×142.35 ×17952 ×(1 × 19+14

Maximum allowable stress, due to formula 6.13 and 6.14 ¿ [ 1 ] , we have:

[ σ F 1 ]max =0 , 8 σ ch =0 , 8 ×580=464 MPa

[ σ F 2 ]max =0.8 σ ch =0 , 8 ×580=464 MPa

4.2.4 Basic specification of the shaft

[ σ H ]: Allowable contact stress, [ σ H ]=513,635 MPa

We have: b w 2=ψ ba × aw =0.3× 213=63.9 mm and b w 1=bw 2 +5=68.9 mm

Z ε: coefficient about tooth matching, determined through formula 6.36c:

Pitch diameter of small pulley:

v H =0.002 ×73 × 0.79×

1.37 ×63.9 ×106.5

σ H =274 ×1.74 × 0.86 ×