The Machine Design

2
2
0
0
0
0
8
8
K.M .A.D. B PAHATHKUM BURA
M EX4231
E
E
L
L
E
E
M
M
E
E
N
N
T
T
A
A
R
R
Y
Y

M
M
A
A
C
C
H
H
I
I
N
N
E
E
D
D
E
E
S
S
I
I
G
G
N
N
I
I
N
N
G
G

2

INTRODUCTION

The machine design is the creation of new and better machines and improving the
existing ones.
A new or better machine is one which is more economical in the overall cost of
production and operation. The process of designing is a long and time consuming one
.from the study of existing ideas, a new idea has to be conceived. The idea is then studied
keeping in mind its commercial success and given shape and form in the form of drawing.
In the preparation of these drawing, cares must be taken of the availability of resources in
money, in men and in materials required for the successful completion of the new idea into
an actual reality. In designing a machine component, it is necessary to have a good
knowledge of many subjects such as Mathematics, Engineering Mechanics, Strength of
Materials, Theory of Machines, Workshop Processes and Engineering Drawing

3
CONTENTS

Page no

Selection of motor 04
Designing of super Gear 06
Designing of V- belt Drives 16
Designing of Pulley 17
Designing of shaft 18
Designing of Bearing 31
Designing of Keys 42
Selection of the Oil seal 50
Selection of the Lubrication for Bearing 51
Selection of the Lubrication for Gear Box 51
Designing of the Clutch 51
Designing of the Universal Coupling 53
Designing of the Brake 54
Designing of Outer shaft 56
Designing of Bearing to Outer shaft 58
Designing of Bolts for Gear Box Housing 60
Drawings 62
Reference 63

4

DEFINED TECHNOLOGICAL PARAMETERS AND
INFORMATION

The maximum load including the weight of operator and the tare weight of the elevator to be lifted
is M metric tons

Effective diameter of the drum d m- 0.6 m

Drive torque at the drum end-T Nm

The friction couple (
f
T ) at the drum bearing 3% of T

Drum width(t) in then axial direction-1 m

Drum Density ( ) -7870 kg/
3
m

Mass of the rope can be comparatively neglected

V- belt drive ratio -3 to 5

Center distance between the pulleys -0.3 m to 0.5 m

Operation condition Heavy shock and 8 to 10 hours per day

power losses
As a percentages of the total
design power
Coupling 1.0
All Bearing 2.0
Belt Drive 1.5
Gear Train 4.0

Mass of lift 1.25 tones

Speed of lift (
Max
V
) = 1 m/s

Time of acceleration (t) = 3 s

5

SELECTION OF THE MOTOR

Force arrangement on the load

T
Mg

Acceleration according to graph of velocity& time

V
time
1
3

Acceleration (a) =
t
v
=
3
1

Lets Assume (g = 9.81
2
/ s m )

Therefore tension on the load

T=1.25
3
10 (9.81+1/3)
T=12679.125 N

Lifting force (F) =T
F=12679.125 N

Power of elevator

P
elevator
=12679.125 N 1 m/s
2

P
elevator
=12679.125 W

6

Torque of the drum (T
drum
)
T
drum
= o I
=M o
2
r
=
|
|
|
|
.
|
\
|

3
0
2 2 t
v
r h r t

= |
.
|
\
|
3
3333 . 3
4
t h r
T
drum
=222.5168

Power of the drum

= T
drum
e
P
drum
=741.7152 W

Total power for drum and elevator

= p
drum
+ p
elevator

Total power =13420.8402 W

power loss from couplings = 13420.8402 W
100
1

= 134.2084 W

power loss from all bearings =13420.8402 W
100
2

=268.4168 W

power loss from belt drives =13420.8402 W
100
5 . 1

=201.3126 W

power loss from gear train =13420.8402 W
100
4

=536.8336 W

Total power requirement due to the loses

P
total
= P
losses
+P
drum
+ p
elevator

P
total
=14561.6116 W
P
total
=14.5616 Kw

7
Therefore select suitable power motor from
manual

DESIGNING OF SUPER GEARS

Strength calculation of first gear pair

Speed of pinion = 290 r p m
Module = 6 mm
No of teeth (Z) = 20

Diameter of pinion = D
p
= Z.m = 120 mm

Torque of pinion
P = T e

T =
290 2
60 10 15
3

t

T = 493.9291 Nm
Tangential tooth load (F
T
) =
p
D
T 2

F
T
=
3
10 120
9291 . 493 2
N
F
T
= 8.2333
3
10 N

select service factor ( C
S
) = 1.8

F
t
= 8.2333
3
10 1.8 N
F
t
(Actual) =14817.96 N

Select material from chart

EN6, 6A
Y
o = 55 Kg/mm
2

Ut
o = 100 Kg/mm
2

E = 2.038 Kg/mm
2

Power = 15 Kw

Speed = 750 r p m

Model = D 200 L

8

For steady load & Ordinary cut gear

C
V
=
V + 3
3

Pitch line velocity (V) =
3
10 60
60
2 290

t

= 1.8221 m/s

C
V
=
8221 . 1 3
3
+

C
V
= 0.6221

For face width (b)

U
m
=
m
b
= 8
b = 48 mm

Lewis form factor Y = 0.154
20
912 . 0

= 0.1084

V O W
C = o o
=
V
ut
C
3
o

=
6
10 3
6221 . 0 81 . 9 100

W
o = 203.4267
6
10 N/m
2

From the Lewis equation

F
t
= y m b
W
t o
=
6 3 3
10 1084 . 0 10 6 10 48 4267 . 203

t
F
t
= 19951.6858 N
F
t
(Actual) F
t
(Theoretical)

Face width (b) = 4.8 cm

Velocity (V) =
3
10 60 2 290

t
= 109.3274 m/mts
= 1.8221 m/s

Tooth error action from chart
e = 0.0800 mm
e = 0.0080 cm

9
C =
P P
E E
1 1
008 . 0 111 . 0
+

=
6 6
10 038 . 2
1
10 038 . 2
1
008 . 0 111 . 0

C = 904.872 kg/cm

Dynamic tooth load

F
D
= F
T
+ F
I

F
T
=
p
D
T 2

=
81 . 9
10 2322 . 8
3
kg
F
D
= F
T
+
T
T
F bc V
F bc V
+ +
+
11 . 0
) ( 11 . 0

F
D
= 1580.9925 kg

Endurance stress (
C
o )
= 17.85 HB
= 17.85 370
= 6604.5 kg/cm
2

Static tooth load (F
S
)
F
S
= y m b
C
t o
= 1084 . 0 6 . 0 8 . 4 5 . 6604 t
F
S
= 6477.5621 kg
F
S
1.5 F
D
for shock load

Gear ratio (i) =
P
W
Z
Z
= 2.5

(No of teeth of wheel)
W
Z = 50

Q =
P W
W
Z Z
Z
+
2
-( for external gear )
Q = 1.4286

) 700 28 ( = BH
CS
o
) 700 370 28 ( =
CS
o
=
CS
o 9660 kg/cm
2

(
=
W P
CS
E E
K
1 1
4 . 1
sin
2
o o

K = 21.924
10

wear tooth load (
W
F )

W
F = bQK D
P

W
F = 924 . 21 4286 . 1 8 . 4 12

W
F = 1804.0608 kg
D W
F F

Strength calculation of second gear pair

Module = 8 mm

p
= Z.m = 192 mm

Torque of pinion
P = T e

T =
116 2
60 10 15
3

t

T = 1234.8228 Nm
T
) =
p
D
T 2

F
T
=
3
10 192
1234.8228 2
N
F
T
= 12.8627
3
10 N

S
) = 1.8
Selected material of gear, EN6, 6A

Diameter of pinion = 120 mm
No of teeth of pinion =20
Face width (b) =48 mm
Ratio of gear = 2.5

No of teeth of gear = 50
Diameter of gear = 300 mm

11

F
t
= 12.8627
3
10 1.8 N
F
t
(Actual) =23152.86 N


EN6, 6A
Y
o = 55 Kg/mm
2

Ut
o = 100 Kg/mm
2

E = 2.038 Kg/mm
2


C
V
=
V + 3
3

3
10
2
192
60
2 116

t

= 1.1662 m/s

C
V
=
1662 . 1 3
3
+

C
V
= 0.72

For face width (b)

U
m
=
m
b
= 8
b = 64 mm

24
912 . 0

= 0.116

V O W
C = o o
=
V
ut
C
3
o

=
6
10 3
72 . 0 81 . 9 100

W
o = 235.44
6
10 N/m
2


F
t
= y m b
W
t o
=
6 3 3
10 116 . 0 10 8 10 64 44 . 235

t
F
t
= 43929.6833N
F
t
(Actual) F
t
(Theoretical)

12

Velocity (V) =
3
10
2
192
2 116

t
= 69.9696 m/mts
= 1.1662 m/s

e = 0.0925 mm
e = 0.00925 cm

C =
P P
E E
1 1
00925 . 0 111 . 0
+

=
6 6
10 038 . 2
1
10 038 . 2
1
00925 . 0 111 . 0

C = 1046.2583 kg/cm

Dynamic tooth load

F
D
= F
T
+ F
I

F
T
=
p
D
T 2

=
81 . 9
10 12.8627
3
kg
F
D
= F
T
+
T
T
F bc V
F bc V
+ +
+
11 . 0
) ( 11 . 0

F
D
= 1940.2118 kg

Endurance stress (
C
o )
= 17.85 HB
= 17.85 370
= 6604.5 kg/cm
2

S
)
F
S
= y m b
C
t o
= 116 . 0 8 . 0 4 . 6 5 . 6604 t
F
S
= 12323.0374 kg
F
S
1.5 F
D
for shock load

Gear ratio (i) =
P
W
Z
Z
= 2

W
Z = 48

13
Q =
P W
W
Z Z
Z
+
2
Q = 1.3333

) 700 28 ( = BH
CS
o
) 700 370 28 ( =
CS
o
=
CS
o 9660 kg/cm
2

(
=
W P
CS
E E
K
1 1
3333 . 1
sin
2
o o

K = 23.4911

wear tooth load (
W
F )

W
F = bQK D
P

W
F = 4911 . 23 3333 . 1 4 . 6 2 . 19

W
F = 3848.9372 kg
D W
F F

Strength calculation of third gear pair

Module = 11 mm

p
= Z.m = 352 mm

Torque of pinion
P = T e

Selected material of gear, EN6, 6A

Ratio of gear = 2


14
T =
58 2
60 10 15
3

t

T = 2469.6457 Nm
T
) =
p
D
T 2

F
T
=
3
10 352
6457 . 469 2 2
N
F
T
= 14.0321
3
10 N

S
) = 1.8

F
t
= 14.0321
3
10 1.8 N
F
t
(Actual) =25257.78 N


EN23B
Y
o = 115 Kg/mm
2

Ut
o = 130 Kg/mm
2

E = 2.038 Kg/mm
2


C
V
=
V + 3
3

3
10
2
352
60
2 58

t

= 1.0689 m/s

C
V
=
0689 . 1 3
3
+

C
V
= 0.7373

For face width (b)

U
m
=
m
b
= 8
b = 88 mm

32
912 . 0

= 0.1255

V O W
C = o o
=
V
ut
C
3
o

15
=
6
10 3
7373 . 0 81 . 9 130

W
o = 313.4262
6
10 N/m
2


F
t
= y m b
W
t o
=
6 3 3
10 1255 . 0 10 11 10 88 4262 . 313

t
F
t
= 119620.1368 N
F
t
(Actual) F
t
(Theoretical)


Velocity (V) =
3
10
2
352
2 58

t
= 64.1387 m/mts
= 1.0689 m/s

e = 0.0925 mm
e = 0.00925 cm

C =
P P
E E
1 1
00925 . 0 111 . 0
+

=
6 6
10 038 . 2
1
10 038 . 2
1
00925 . 0 111 . 0

C = 1046.2583 kg/cm

Dynamic tooth load

F
D
= F
T
+ F
I

F
T
=
p
D
T 2

=
81 . 9
10 14.0321
3
kg
F
D
= F
T
+
T
T
F bc V
F bc V
+ +
+
11 . 0
) ( 11 . 0

F
D
= 2111.4634 kg

Endurance stress (
C
o )
= 17.85 HB
= 17.85 550
= 9817.5 kg/cm
2

S
)
F
S
= y m b
C
t o
16
= 1255 . 0 8 . 0 8 . 8 5 . 9817 t
F
S
= 37468.8070 kg
F
S
1.5 F
D
for shock load

Gear ratio (i) =
P
W
Z
Z
= 1.8125

W
Z = 58

Q =
P W
W
Z Z
Z
+
2
Q = 1.29

) 700 28 ( = BH
CS
o
) 700 550 28 ( =
CS
o
=
CS
o 14700 kg/cm
2

(
=
W P
CS
E E
K
1 1
29 . 1
sin
2
o o

K = 87.11

wear tooth load (
W
F )

W
F = bQK D
P

W
F = 11 . 87 29 . 1 8 . 8 2 . 35

W
F = 34808.3197 kg
D W
F F

Selected material of gear, EN23B

Ratio of gear = 1.8125


17

DESIGNING OF V-BELT DRIVES

Class of the V-belt should be selected, in the designing of V- belt therefore class can be selected
according to speed of faster shaft (rev/min) & design power (Kw) graph which given by
manufacture of belt drives

Class of the V- belt (750 rev/min & 15 Kw )
C- Class V-belt

( ) B A A C + =
2

Where A =
( )
8 4
d D L +
t

B =
( )
8
2
d D

C = center distance of drives
D = pitch diameter of larger pulley
d = pitch diameter of smaller pulley
L = pitch length of belt
Assume D = 500 mm, d = 200 mm
And L = 1950 mm (from table)

A =
( )
8
200 500
4
1950 +
t

A = 212.6106 mm

B =
( )
8
200 500
2

B = 11250 mm

C = 396.8801 mm / 0.3969 m

Service factor for heavy duty -1.2

Power correction factor for arc of contact

=
C
d D

=
8801 . 396
200 500

= 0.7559
Correction factor (from table) =0.88

Power correction factor for belt pitch length (from table)
= 0.87

Power per belt = 5.76 Kw

18

Additional power per belt for belt ratio (from table)
= 0.63
Power per belt = (5.76 + 0.63) Kw
= 6.39 Kw / belt

Accuracy to the correction factor
= 87 . 0 88 . 0
2 . 1
39 . 6
Kw
= 4.0768 Kw

No of belt Required =
belt power
Totalpower
/

=
0768 . 4
15
= 3.67

4 Belts Required
Wide of a belt = 22 mm

Wide of 4 belts = 88 mm

DESIGNING OF PULLEYS

Larger pulley

Width of large pulley = 108 mm
Diameter of large pulley = 500 mm

Width of smaller pulley = 108 mm
Diameter of smaller pulley = 200 mm

19

DESIGNING OF THE SHAFTS

Force arranging distance on the shafts

1 1 4 6 4 6 1 8 1 8 4

First shaft (Tangential force)

64 226
14817. 96 N
R 3 R 4
A B C

For vertical equilibrium
14817.96 N = R3+R4

Taking moment on the
290 R3 = 226 14817.96

R3 = 11547.78952 N
R4 = 3270.1705 N

Bending moments
On B
= 64 7895 . 11547 10
3

= -739.0585 Nm
2
1
20

Bending moment diagram
739.0585 N

Radial force

Force on F = F
r
= 14817.96 tan20
= 5393.2964 N

Limiting belt tension ratio for belt

2
1
T
T

|
1
e =
=
|
o

sin
e

Assume
= 0.4, | = 18
0

=
2
1
T
T
21.3945
T1 = 21.3945 T2

Power transmission of belt
P = (T1 - T2) V
T1 - T2 = 1975.7165

From equation 3 and 4
T1 = 2072.5915 N
T2 = 96.8749 N

T1 + T2 = 2169.4665 N
3
4
21
6 4 2 2 6
5 3 9 3 . 2 9 6 4 N
R 1
R 2
A B C D
1 1 4
T 1 + T 2

R1 + R2 +T1 + T2 = 5393.2964 N

Taking moment on G
290 R1 = 342420.5204 N
R1 = 1180.7604 N
R2 = 2043.0695 N

Bending moments
On E = -2169.4665 114 10
3

= -247.3192 Nm
On F = -461.7337 Nm

D A B C
24 7 .3 19 2 N
46 1 .7 33 7 N

Bending moment (M) =
2 1 2
) (M M +

2 2 2 2
) 733 . 461 ( ) 0585 . 739 ( ) 3192 . 247 ( 0 + +

M = 871.4387 Nm

Twisting moment (T) =
290 2
60 10 15
3

t

= 493.9291 Nm
22

Selection of material ( from table )
AISI number = 1018

Yt
o
= 373
6
10 N/m
2

Ut
o
= 442
6
10 N/m
2

Allowable shear stress of material
75 . 0 10 373 3 . 0
6
=
eq
t
=
eq
t 83925000 N/m
2

Allowable normal stress of material

eq
o
= 0.36 75 . 0 442 10
6

eq
o
= 119340000 N/m
2

values of
b
K &
t
K for heavy shocks

b
K = 2.5,
t
K = 2.0

| |
2
1
2 2
3
) ( ) (
16
T K M K
d
t b eq
+ =
t
t
d = 52.56 mm

( )
(
+ + =
2
1
2 2
3
) ( ) (
16
T K M K M K
d
t b b eq
t
o
d = 57.99 mm

d =58 mm

Diameter of shaft = 58 mm

Length of shaft = 488 mm

AISI number for material = 1018
23

Second shaft (Tangential force)

64 61
14817.96 N
R6
R7
H
I
J
K
23152.86 N
165

37970 N = R6+R7

Taking moment on the K
290 R6 = 226 14817.96 + 23152.86165

R6 = 24720.9684 N
R7 = 13249.8515 N

Bending moments
On I
= 1582.1419 Nm

On J
= 2186.2255 Nm


H
I J K
1 5 8 2 . 1 4 1 9 N
2 1 8 6 . 2 2 5 5 N

7
6
24

Radial force

Force on I = F
r
= 14817.96 tan20
= 5393.2964 N

Force on J = F
r
= 23152.86 tan20
= 8426.9519 N

6 4 6 1
5 3 9 3 . 2 9 6 4 N
R 5
R 8
H
I
J K
8 4 2 6 . 9 5 1 9 N
1 6 5

R5 + R8 = 13820.2483 N

Taking moment on K
290 R5 = -171562.086 N
R5 = -591.5934 N
R8= 14411.8417 N

Bending moments
On I = -591.5934 64 10
3

= -37.8619 Nm
On J = -402.9403 Nm

H I J K
591.5934 N
402.9403 N

25

2 1 2
) (M M +

2 2 2 2
) 9403 . 402 ( ) 2255 . 2186 ( ) 8619 . 37 ( ) 1419 . 1582 ( + +
M = 2223.0481 Nm

Twisting moment (T) = 1234.8228 Nm

AISI number = 1018

Yt
o
= 373
6
10 N/m
2

Ut
o
= 442
6
10 N/m
2

75 . 0 10 373 3 . 0
6
=
eq
t
=
eq
t 83925000 N/m
2


eq
o
= 0.36 75 . 0 442 10
6

eq
o
= 119340000 N/m
2

values of
b
K &
t
K for heavy shocks

b
K = 2.5,
t
K = 2.0

| |
2
1
2 2
3
) ( ) (
16
T K M K
d
t b eq
+ =
t
t
d = 71.73mm

( )
(
+ + =
2
1
2 2
3
) ( ) (
16
T K M K M K
d
t b b eq
t
o
d = 79.19 mm

d = 80 mm



26

Third shaft (Tangential force)

81
84
25257.78 N
R11
R12
L
M N
O
23152.86 N
125

48410.64 N = R11+R12

Taking moment on the O
290 R11 = 165 23152.86 + 25257.7884

R11 = 20489.2256 N
R12= 27921.4144 N

Bending moments
On M
= 2561.1532 Nm

On N
= 2345.3988 Nm


L M N O
1 5 8 2 . 1 4 1 9 N
2 1 8 6 . 2 2 5 5 N

7
6
27

Radial force

Force on M = F
r
= 23152.86 tan20
= 8426.9519 N

Force on N = F
r
= 25257.78 tan20
= 9193.0801 N

81
84
8426.9519 N
N
R10
M
N
O
L 125
R9

R9 + R10= -766.1282 N

Taking moment on K
290 R9= 618228.3351 N
R9 = 2131.8218 N
R10= -2897.95 N

Bending moments
On M = 266.4777 Nm

On N = -243.4278 Nm

28
L M
N O
266.4777 N
243.4278 N

2 1 2
) (M M +

2 2 2 2
) 4278 . 243 ( ) 3988 . 2345 ( ) 4777 . 266 ( ) 1532 . 2561 ( + +
M = 2574.9788 Nm


AISI number = 1045

Yt
o
= 532
6
10 N/m
2

Ut
o
= 626
6
10 N/m
2

75 . 0 10 532 3 . 0
6
=
eq
t
=
eq
t 119700000 N/m
2


eq
o
= 0.36 75 . 0 626 10
6

eq
o
= 169020000 N/m
2

values of
b
K &
t
K for heavy shocks

b
K = 2.5,
t
K = 2.0

| |
2
1
2 2
3
) ( ) (
16
T K M K
d
t b eq
+ =
t
t
d = 70.1516 mm
29

( )
(
+ + =
2
1
2 2
3
) ( ) (
16
T K M K M K
d
t b b eq
t
o
d = 75.97 mm

d =76 mm

Forth shaft (Tangential force)

48410.64 N = R13+R14

Taking moment on the R
290 R13 = 84 25257.78

R13 = 7316.0466 N
R14= 17941.7334 N



9
8
8 4
2 5 2 5 7 . 7 8 N
R 1 3
R 1 4
P
Q
R 2 0 6
30

Bending moments
On Q
= 1507.1056 Nm


P Q R
1 5 0 7 . 1 0 5 6 N

Radial force

Force on Q = F
r
= 25257.78 tan20
= 9193.0801 N
8 4
9 1 9 3 . 0 8 0 1 N R 1 6
Q R
P
2 0 6
R 1 5

R15 + R16= 9193.0801 N

Taking moment on R
290 R15= 772218.7284 N
R15 = 2662.8232 N
R16= -6530.2569 N
31

Bending moments
On Q = 548.5416 Nm

P Q R
5 4 8 . 5 4 1 6 N

2 1 2
) (M M +
=
2 2
) 1056 . 1507 ( ) 5416 . 548 ( +

M = 1603.8283 Nm


AISI number = 1045

Yt
o
= 532
6
10 N/m
2

Ut
o
= 626
6
10 N/m
2

75 . 0 10 532 3 . 0
6
=
eq
t
=
eq
t 119700000 N/m
2


eq
o
= 0.36 75 . 0 626 10
6

eq
o
= 169020000 N/m
2

32

values of
b
K &
t
K for heavy shocks

b
K = 2.5,
t
K = 2.0

| |
2
1
2 2
3
) ( ) (
16
T K M K
d
t b eq
+ =
t
t
d = 74.73 mm

( )
(
+ + =
2
1
2 2
3
) ( ) (
16
T K M K M K
d
t b b eq
t
o
d = 74.67 mm

d =75 mm

DESIGNING OF BEARING

Bearings of First shaft

(A- Side)

Actual radial bearing load

2 2
3 1 R R F
r
+ =

2 2
) 7895 . 11547 ( ) 7604 . 1180 ( + =
r
F

r
F
= 11607.9989 N



33

Equivalent static bearing load

a r
F Y F X P
0 0 0
+ =
(
a
F = 0, No static load)
Radial load factor for bearing (
0
X ) = 0.6

0
P
= 6964.7993 N

Basic static load rating (
0
C )

0
C =
0 0
p s
0
s = 1 for normal vibration conditions

0
C = 6964.7993 N

0 =
o
a
C
F
and e = 0.22 (according to manual)

X = 1, Y = 0

Equivalent dynamic load ( P )

a r
YF XF P + =
(
a
P = 11607.9989 N

Basic life time in million of revolutions (
10
L
)

10
L
=
6
10
2 10 365 60 290

10
L
= 127.02

P
C
= 5.19 (form table)

p
P
C
L
(
=
10
, (p = 3)

C = 60245.5143 N

Bearing model (Deep groove ball bearing) = 6312

Outer diameter (D) =130 mm

Inner diameter (d) = 60 mm

Wide (B) = 31 mm

34

(C- Side)


2 2
4 2 R R F
r
+ =

2 2
) 1705 . 3270 ( ) 0695 . 2043 ( + =
r
F

r
F
= 3855.9288 N


a r
F Y F X P
0 0 0
+ =
(
a
0
X ) = 0.6

0
P = 2313.5543 N

0
C )

0
C =
0 0
p s
0

0
C = 2313.5543 N

0 =
o
a
C
F

X = 1, Y = 0


a r
YF XF P + =
(
a
P = 3855.9238 N

10
L
)

10
L
=
6
10
2 10 365 60 290

10
L
= 127.02

P
C
= 5.19 (form table)

p
P
C
L
(
=
10 , (p = 3)

C = 20012.2425 N
35

Bearings of Second shaft

(H- Side)


2 2
6 5 R R F
r
+ =

2 2
) 5934 . 591 ( ) 9685 . 24720 ( + =
r
F

r
F
= 24728.0462 N


a r
F Y F X P
0 0 0
+ =
(
a
0
X ) = 0.6

0
P
= 14836.8277 N

0
C )

0
C =
0 0
p s
0

0
C = 14836.8277 N

0 =
o
a
C
F

X = 1, Y = 0




Wide (B) = 18 mm

36

a r
YF XF P + =
(
a
P = 24728.0462 N

10
L
)

10
L
=
6
10
2 10 365 60 116

10
L
= 50.808

P
C
= 3.91 (form table)

p
P
C
L
(
=
10 , (p = 3)

C = 96686.66 N

(K- Side)


2 2
8 7 R R F
r
+ =

2 2
) 8417 . 14411 ( ) 8515 . 13249 ( + =
r
F

r
F
= 19577.0209 N


a r
F Y F X P
0 0 0
+ =
(
a



Wide (B) = 39 mm

37

0
X ) = 0.6

0
P = 11746.2125 N

0
C )

0
C =
0 0
p s
0

0
C = 11746.2125 N

0 =
o
a
C
F

X = 1, Y = 0


a r
YF XF P + =
(
a
P = 19577.0209 N

10
L
)

10
L
=
6
10
2 10 365 60 116

10
L
= 50.808

P
C
= 3.91 (form table)

p
P
C
L
(
=
10
, (p = 3)

C = 76546.1517 N




Wide (B) = 39 mm

38

Bearings of third shaft

(L- Side)


2 2
11 9 R R F
r
+ =

2 2
) 2256 . 20489 ( ) 8218 . 2131 ( + =
r
F

r
F
= 20599.8308 N


a r
F Y F X P
0 0 0
+ =
(
a
0
X ) = 0.6

0
P = 12359.8985 N

0
C )

0
C =
0 0
p s
0

0
C = 12359.8985 N

0 =
o
a
C
F

X = 1, Y = 0


a r
YF XF P + =
(
a
P = 20599.8308 N

10
L
)

10
L
=
6
10
2 10 365 60 58

10
L
= 25.404

P
C
= 3.11 (form table)

p
P
C
L
(
=
10
, (p = 3)

C = 64065.4738 N

39

(O- Side)


2 2
12 10 R R F
r
+ =

2 2
) 95 . 2897 ( ) 4144 . 27921 ( + =
r
F

r
F
= 28071.3999 N


a r
F Y F X P
0 0 0
+ =
(
a

0
X ) = 0.6

0
P
= 16842.8399 N

0
C )

0
C =
0 0
p s
0

0
C = 16842.8399 N

0 =
o
a
C
F

X = 1, Y = 0


a r
YF XF P + =
(
a
P = 28071.3999 N




Wide (B) = 26 mm

40
10
L
)

10
L
=
6
10
2 10 365 60 58

10
L
= 25.404

P
C
= 3.11 (form table)

p
P
C
L
(
=
10
, (p = 3)

C = 87302.0539 N

Bearings of forth shaft

(P- Side)


2 2
15 13 R R F
r
+ =

2 2
) 8232 . 2662 ( ) 0466 . 7316 ( + =
r
F

r
F
= 7785.5742 N


a r
F Y F X P
0 0 0
+ =
(
a
0
X ) = 0.6

0
P = 4671.3445 N



Wide (B) = 39 mm

41

0
C )

0
C =
0 0
p s
0

0
C = 4671.3445 N

0 =
o
a
C
F

X = 1, Y = 0


a r
YF XF P + =
(
a
P = 7785.5742 N

10
L
)

10
L
=
6
10
2 10 365 60 32

10
L
= 14.016

P
C
= 2.52 (form table)

p
P
C
L
(
=
10 , (p = 3)

C = 19619.65 N

(R- Side)

In this side of axial act both axial and radial loads, therefore bearing should be
selected as accommodate for both loads. Spherical roller thrust bearing can be
used for these cases




Wide (B) = 13 mm

42


2 2
16 14 R R F
r
+ =

2 2
) 2569 . 6530 ( ) 7334 . 17941 ( + =
r
F

r
F
= 19093.1939 N

Actual axial bearing load

a
F
= 28884 N (from the clutch)


a r
F F P + = 7 . 2
0

0
P = 80435.6236 N

0
C )

0
C =
0 0
p s
0

0
C = 80435.6236 N


a r
F F P + = 2 . 1

P = 51795.8327 N

10
L
)

10
L
=
6
10
2 10 365 60 32

10
L
= 14.016

P
C
= 2.52 (form table)

p
P
C
L
(
=
10 , (p = 3)

C = 130525.4984 N

43

DESIGNING OF KEYS

Key for Larger pulley

F = T1 T2
=1975.7 N

Selected b and h according to diameter from the manual
Assume l

Allowable crushing stress of key

dhl
T
cr
4
= o

058 . 0 04 . 0 011 . 0
9291 . 493 4

=
cr
o

=
cr
o 77418354.24 N/m
2

Allowable shear stress of key

dhl
T
s
2
= t

058 . 0 04 . 0 011 . 0
9291 . 493 2

=
s
t

=
s
t 38709177.12 N/m
2

Bearing model (Spherical roller thrust bearing) = 29415E



Wide (H) = 51 mm

44

Select Material AISI 1045

Shear stress of Material

75 . 0 10 532 3 . 0
6
=
eq
t

2
/ 119700000 m N
eq
= t

s eq
t t

Key for first shaft (Pinion)

Assume l


dhl
T
cr
4
= o

058 . 0 04 . 0 011 . 0
9291 . 493 4

=
cr
o

=
cr
o 77418354.23 N/m
2


dhl
T
s
2
= t

058 . 0 04 . 0 011 . 0
9291 . 493 2

=
s
t

=
s
t 38709177.12 N/m
2

Material = AISI 1045

b = 18 mm

H = 11 mm

L = 40 mm
45



75 . 0 10 532 3 . 0
6
=
eq
t

2
/ 119700000 m N
eq
= t

s eq
t t

Key for second shaft (Gear)

Assume l


dhl
T
cr
4
= o

040 . 0 014 . 0 08 . 0
8228 . 1234 4

=
cr
o

=
cr
o 110252035.7 N/m
2


dhl
T
s
2
= t

040 . 0 014 . 0 08 . 0
8228 . 1234 2

=
s
t

=
s
t 55126017.86 N/m
2


b = 18 mm

H = 11 mm

L = 40 mm
46



75 . 0 10 532 3 . 0
6
=
eq
t

2
/ 119700000 m N
eq
= t

s eq
t t

Key for second shaft (Pinion)

Assume l


dhl
T
cr
4
= o

06 . 0 014 . 0 08 . 0
8228 . 1234 4

=
cr
o

=
cr
o 73501357.14 N/m
2


dhl
T
s
2
= t

06 . 0 014 . 0 08 . 0
8228 . 1234 2

=
s
t

=
s
t 36750678.57 N/m
2


b = 25 mm

H = 14 mm

L = 40 mm
47



75 . 0 10 532 3 . 0
6
=
eq
t

2
/ 119700000 m N
eq
= t

s eq
t t

Key for third shaft (Gear)

Assume l


dhl
T
cr
4
= o

06 . 0 011 . 0 076 . 0
6457 . 2469 4

=
cr
o

=
cr
o 196941443.4 N/m
2


dhl
T
s
2
= t

06 . 0 011 . 0 076 . 0
6457 . 2469 2

=
s
t

=
s
t 98470721.69 N/m
2


b = 25 mm

H = 14 mm

L = 60 mm
48



75 . 0 10 683 3 . 0
6
=
eq
t

2
/ 153675000 m N
eq
= t

s eq
t t

Key for third shaft (Pinion)

Assume l


dhl
T
cr
4
= o

06 . 0 011 . 0 076 . 0
6457 . 2469 4

=
cr
o

=
cr
o 196941443.4N/m
2


dhl
T
s
2
= t

06 . 0 011 . 0 076 . 0
6457 . 2469 2

=
s
t

=
s
t 98470721.69 N/m
2


b = 25 mm

H = 14 mm

L = 60 mm
49



75 . 0 10 683 3 . 0
6
=
eq
t

2
/ 153675000 m N
eq
= t

s eq
t t

Key for forth shaft (Gear)

Assume l


dhl
T
cr
4
= o

08 . 0 015 . 0 075 . 0
2328 . 4476 4

=
cr
o

=
cr
o 196941443.4 N/m
2


dhl
T
s
2
= t

08 . 0 015 . 0 075 . 0
2328 . 4476 2

=
s
t

=
s
t 98470721.69 N/m
2


b = 25 mm

H = 14 mm

L = 60 mm
50



75 . 0 10 683 3 . 0
6
=
eq
t

2
/ 153675000 m N
eq
= t

s eq
t t

Key for cultch

Assume l


dhl
T
cr
4
= o

075 . 0 014 . 0 075 . 0
2328 . 4476 4

=
cr
o

=
cr
o 236837714.3 N/m
2


dhl
T
s
2
= t

072 . 0 014 . 0 075 . 0
2328 . 4476 2

=
s
t

=
s
t 118418857.1 N/m
2


b = 22 mm

H = 14 mm

L = 80 mm
51


75 . 0 10 532 3 . 0
6
=
eq
t

2
/ 119700000 m N
eq
= t

s eq
t t

SELECTION OF THE OIL SEALS

Selected rubbing seals for the bearing .The action of rubbing seals depend on the
seal exerting a certain pressure, by virtue of its elasticity. At the seal/sealing
surface contact. the usefulness of the various seal designs and the sealing surface
quality required depend on the peripheral speed

SELECTION OF THE LUBRICATION FOR BEARINGS

Selected Greases lubrications for the bearing. Lubricating greases are thickened
mineral oil or synthetic fluid. The consistency of greases depends largely on the
type and quantity of the thickening agent used. When selecting a grease,
consistency, temperature rang and rust inhibiting properties are the most
important factors to be considered


b = 22 mm

H = 14 mm

L = 72mm
52

SELECTION OF THE LUBRICATION FOR GEAR BOX

Selected Oil lubrications for the gear box. Lubricating Oil is mineral oil or
synthetic fluid. Lubricating Oil can be reduced friction of the gear box by the way
increase the efficiency ,reduced wastages and temperate of gear box

DESIGNING OF THE CLUTCH

Select a cone clutch

(Cone clutch)

Transmit Torque = 4476.2328 N
Transmit Power = 15000 W
Speed = 32 rpm

Material of friction surface -( Powder metal )

n
P = 0. 3 N/ mm
2

= 0.4

Assume Diameter ( D ) = 500 mm
Radius = 250 mm

Torque of the clutch
b R p T
n
2
2 = t
b
2
) 250 ( 3 . 0 4 . 0 2 2328 . 4476 = t
b = 94.9886 mm
b = 95 mm

53
Normal force acting on contact surfaces
b R P W
n n
= t 2
= 44767.6953 N

Axial spring force necessary to engage the clutch
) cos (sin o o + =
n e
W W

=
e
W
28884 N =
a
F

Axial force for disengage the clutch
) sin cos ( o o =
n d
W W

d
W = 5711 N

1
r
= Outer radius of the friction surface

2
r
= Inner radius of the friction surface
b = Width of the friction surface

R
r r
=
+
2
2 1
,
500
2 1
= + r r

o sin
2 1
b r r =

According to 10 and 11 equation

~
1
r
263 mm,
~
2
r
238 mm

10
11

Material of friction surface is powder metal on
cast iron or steel

~
1
r
263 mm

~
2
r
238 mm

b = 95 mm
54

DESIGNING OF THE UNIVERSAL COUPLING

(Universal coupling)

Diameter of the shaft (d)

3
16
d T
s
= t
t

T = 2328 . 4476 Nm

Shear force (Material AISI 1045)
75 . 0 10 532 3 . 0
6
=
s
t
= 119700000
2
/ m N

d = 57.53 mm
d = 58 mm

Diameter of the pinion (d p )

d d T
s p
= t
t
2
4
2

p
d
= 20.342 mm

p
d
= 21 mm

Material -AISI 1045

d = 58 mm

p
d
= 21mm

55

DESIGNING OF THE BRAKE
Q2 Q1
P
0.325
0.3
0.125

(Shoe brake)

Select Shoe brake for the designing

Torque (T) = 4476.2328 Nm
Diameter of drum = 0.5 m

= 0.3 For Leather on metal braking lining

Spring force to set brake (S)

1 1 t N
F R = = Normal reaction and the braking force on the right hand side shoe

2 2 t N
F R = = corresponding values for the left hand side shoe

u u
u
2 sin 2
sin 4
1
+
=

1
= 0.32
Taking moment Q1
S 0.625 = ) 125 . 0 25 . 0 ( 3 . 0
1 1
+
t N
F R

Taking moment Q2
3 . 0 625 . 0
2 2 N t
R F S = +

According to I and II equations

2 t
F = 0.7143 S

1 t
F = 0.5555 S
Torque capacity of brake

2 1
2328 . 4476
t t
F F N + =
S = 14095.2215 N

Dimension of the spring coil
D = Mean diameter
d = Diameter of the spring wire
I
II
56

Wahls spring factor

C C
C
K
615 . 0
4 4
1 4
+
=
, (C =6)
K = 1.2525
The maximum spring force is 1.3 times the force required during braking,
therefore maximum spring force
695 . 18323 3 . 1 = = S W
s
N

Shear stress induced in spring (t )

2
6
8
10 525
d
C W K
s

=
t

d = 26 mm

D = C.d = 156 mm

Deflection of the spring

2
/ 80 mm KN G =

d G
n C W
s

=
3
8
o

o
= 122 mm

Total number of Coil
10 2 8 2
1
= + = + = n n
Free Length of the spring
o o 15 . 0
1
+ + = d n L
F

F
L = 401 mm

Width of the brake shoes (b)

b
P = bearing pressure on the material of shoes = 0.2 N/mm
2

Projected bearing area on shoe
) sin 2 ( u = r b A
b
,u = 35
0

= 287b

Normal force on the right hand side

1
1
1
t
N
F
R = = 26104.3502 N

Normal force on the left hand side

1
2
2
t
N
F
R = = 33560.7224 N

57
Bearing pressure on the material (
b
P )
0.5 =
b
N
A
R
2

b = 585 mm

Force required to be exerted by the release the brake
Taking moment about the fulcrum of the lever O

325 ) 125 250 ( ) 125 250 ( 375 250
2 2 1 1
+ + + =
N t t N
R F F R P
P = 8763 N

DESIGNING OF THE OUTER SHAFT

Forces from drum
5 2 5
R 1 8
T U S 5 2 5
R 1 7 ( M + m ) ( g + a )

Torque (T) = 4476.2328 Nm
7870
2
6 . 0
10 25 . 1
2
3
+ = + t m M
m M + = 35250.112 N

R17 + R18 = 35250.112 N

Taking moment on U
1050 R17 = 35250.112 N
R17 = 17625.056 N
R18 = 17625.056 N

Bending moments
On T = 9253.1544 Nm

58

S T U
9253.1544 N

Bending moment (M) = 9253.1544 Nm

M = 9253.1544 Nm

Twisting moment (T) =
32 2
60 10 15
3

t

= 4476.2328 Nm

AISI number = 1045

Yt
o
= 373
6
10 N/m
2

Ut
o
= 442
6
10 N/m
2

75 . 0 10 532 3 . 0
6
=
eq
t
=
eq
t 119700000 N/m
2


eq
o
= 0.36 75 . 0 626 10
6

eq
o
= 169020000N/m
2

values of
b
K &
t
K for heavy shocks

b
K = 2.5,
t
K = 2.0

| |
2
1
2 2
3
) ( ) (
16
T K M K
d
t b eq
+ =
t
t
d = 102 mm
59

( )
(
+ + =
2
1
2 2
3
) ( ) (
16
T K M K M K
d
t b b eq
t
o
d = 114 mm

d =114 mm

DESIGNING OF BEARING TO OUTER SHAFT

Actual radial and axial bearing loads

a
F
= 28884 N

r
F
(Max)= 17625.056 N


a r
F Y F X P
0 0 0
+ =

0
X ) = 0.6, (
0
Y ) = 0.5

0
P = 25017.0336 N


Total Length of shaft = 2477 mm

60

0
C )

0
C =
0 0
p s
0

0
C = 25017.0336 N

1546 . 1 =
o
a
C
F

X = 1, Y = 0


a r
YF XF P + =
(
a
P = 17625.056 N

10
L
)

10
L
=
6
10
2 10 365 60 32

10
L
= 14.016

P
C
= 2.52 (form table)

p
P
C
L
(
=
10 , (p = 3)

C = 44415.14 N

4 Supporters used to outer shaft

No of Bearings = 4

61

DESIGNING OF THE BOLT FOR GEAR BOX HOUSING

Assume 6 Bolts
Thicknesses of the housing = 60 mm
Material for Bolt Mild Steel

Direct shear stress Due to Axial force of clutch
= 28884/6 N

Direct shear stress Due to Tension force of clutch
= (T1 + T2)/6
= 2169.4665/6 N

6 6 5 5 4 4 3 3 2 2 1
l F l F l F l F l F l F Fe + + + + + =

a
F
1
= 2392 N

t
F
1
= 127N

Bending moments from forces
Direct shear stress Due to Axial force of clutch
= 28884 0.367 =10600.428 Nm
Direct shear stress Due to Tension force of clutch
= (T1 + T2) 0.259
= 561.9 Nm

Bearing model (Spherical roller thrust bearing) = 16024



Wide (B) = 19 mm

No of Bearings = 4

62
Maximum stress Due to Axial force of clutch
= ) 9706 . 0 2392 4814 2 2392 4814 (
2 2
+ +
= 7159 N

Maximum stress Due to Tension forces
= ) 9706 . 0 127 362 2 127 362 (
2 2
+ +
= 489 N

Total force = (7159 + 7489) N
= 7648 N

Minimum Diameter of bolt
D (min) =
t o
4 totalforce

= 13.186 mm

Standard Bolt M16 X 2, No of Bolts 6

63
DRAWINGS

ITEM NO ITEM QUANTITY
01 Gear box housing 01
02 Bottom plate of gear box 01
03 First shaft 01
04 Second shaft 01
05 Third shaft 01
06 Forth shaft 01
07 Deep groove ball
bearing(6312)
01
08 Deep groove ball
bearing(6012)
01
09 Deep groove ball
bearing(6316)
03
10 Deep groove ball
bearing(6216)
01
11 Deep groove ball
bearing(16015)
01
12 Spherical roller thrust
bearing(29415)
01
13 Bearing cover (6312) 01
18 Bearing cover (29415 01
19 Oil drain value and
indicator
01
20 Standard bolt (M8 x 1.25) 32
21 Standard bolt (M16 x 2) 06
22 First pinion 01
23 First gear 01
24 Second pinion 01
25 Second gear 01
26 Third pinion 01
27 Third gear 01
28 Keys 07
29 Washes 06
30
64

REFERENCE

TECO motor manual

Keys manual

Bearing manual

Gear and Shaft manual

V-belt manual

A Text book of Machine Design (R.S.Khurmi,J.K.Gupta)

The Machine Design

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The Machine Design

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2

= 0.3 For Leather on metal braking lining

Standard Bolt M16 X 2, No of Bolts 6

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