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1.1Structural scheme
Figure 1
Engine
P=5.5 kw
n=705rot /min
P 5.5
M t =9 , 55⋅106 =9 , 55⋅106⋅ =74504 Nmm
n 705
Input shaft (I)
n 705
nI = = =598 rot /min
i c /l 1 , 18
M tI =M t⋅i c /l =74504⋅1 , 18=87915 Nmm
nI598
n II = = =150 rot /min
ir 4
M tII =M tI⋅ir =87915⋅4=351660 Nmm
2. PROJECT PARAMETERS
INPUT DATA
2.1 Pinion speed n1, rot/min
n1 = 598 rot/min
2.2 The torsion torque at the pinion of the gearing T1, Nmm
T1 =74504 Nmm
2.3 Gearing ratio udat
udat = 4
2.4 Minimum functioning time of the gearing Lh, hours
Lh = 8500 hours
2.5 Functioning conditions of the gearing
Driver machine: electrical engine
Driven machine: fans
Type of load: uniform
2.6 The loading cycles for the teeth
contact load : pulsatory cycle
bending load : pulsatory cycle
2.7 Number of load cycles of the tooth flank, at a full rotation 1 for the pinion, 2 for the
driven wheel
1,2 = 1
2.8 The reference rack profile
For inclined teeth
n = 200; h*an = 1,0; c*u = 0.25; *fn = 0.38
aw
=50
mn
∘
. β=6
We choose: z 1=20
We choose z 2=80
z 80
u= 2 = =4
z 1 20
u
|1− |≤Δu
u dat
0≤0. 03
√[π
ν 1 = ν2 =0,3
1− ν 21 1−ν 22
E1
+
E2 ]
E1 = E2 =2 , 06⋅105 MPa
Z E =189 , 8 √ MPa
4.3.2 The contact area factor zH
z H =2 , 49 √ cos β=2 , 49 √ cos6=2. 46
z 80
z n2 = 2 3 = 3 =81 .33
cos β cos 6
4.4.2 The displacement coefficient of the profile in the normal plane xn1,2
x n1,2 =0
k Fβ =1, 50
4.5.4 The uneven distribution factor of the frontal plane kH at contact and kF for
bending
εα
1. 4
k Hα =k Fα = ==1 . 404>1. 4
cos β cos2 62
4.6 The allowable resistances HP1,2 at contact and FP1,2 for bending [MPa]
Z L Z V Z R =1
N L1=60 n 1 L H χ 1=60⋅598⋅8500⋅1=3 .05⋅108
N L2=60n 2 LH χ 2=60⋅150⋅8500⋅1=7 . 65⋅107
z w =1. 0
z x =1
z N 1 =1 , 02
z N 2 =1 , 17
S H min =1,3
σ H lim z N 1 1500⋅1 , 02
σ HP1 = ZL ZV ZR ZW Z X = ⋅1⋅1⋅1=1176, 92 MPa
S H min 1. 3
σ HP =min (σ HP1 , σ HP 2 )
σ H lim z N 2 1500⋅1 , 17
σ HP2 = Z L ZV Z R Z W Z X = ⋅1⋅1⋅1=1350 MPa
S H min 1 .3
σ HP =min (1176 , 92;1350 )=1176 , 92
Y ST =2 . 0
Y δ 1,2=1
Y R 1,2 =1
Y x=1
Y N 1=1
Y N 2=1
S F min=1 . 5
σ F lim 1 Y ST Y N 1 450⋅2⋅1⋅1⋅1⋅1
σ FP1 = Y δ 1 Y R 1 Y x= =600 MPa
S F min 1,5
σ F lim2 Y ST Y N 2 450⋅2⋅1⋅1⋅1⋅1
σ FP2 = Y δ 2 Y R 2Y x = =600 MPa
S F min 1,5
¿( 4+1) 3
√
2⋅0 . 3⋅4⋅(1176 , 92)2
(189 . 8⋅2 . 47⋅0 . 84⋅0 .997 )2 =115, 38 mm
4.7.3 Distance between axis from the strength condition at bending awF, mm
T 1 z 1 (u+1)2 Y Y
a wF =
√
3
2 ψ a cos β
k a k v k Fβ k Fα Y ε Y β Fa Sa =
2
σ FP
¿
87915⋅20 ( 4 +1 )
√
3
2⋅0,3⋅cos 6°
Y Fa⋅Y Sa Y ⋅Y
1,1⋅1 ,35⋅1 , 404⋅1 , 45⋅0 ,76⋅0 , 95⋅0 , 007228=105 ,13 mm
Y ⋅Y
=max( Fa 1 Sa1 , Fa 2 Sa 2 )=0. 007228
σ FP σ FP1 σ FP2
4.7.4 Adopting the distance between the axis at predimensioning aw, mm
aw = max (awH,awF) = max (115,38;105,13) = 115,38 mm ;
We adopt from STAS 6055 the following aw = 112 mm.
4.7.5 The preliminary lengths of the wheels
b2 =ψ a aW =0. 3⋅112=33 , 6 mm
b1 =b 2 +Δb=3+33 ,6=36 , 6 mm
Δb=1...3; Δb=3
5. DIMENSIONING CALCULATION
INPUTS
Table 5.1
Inputs
Power P , kW 5.5
Lifetime Lh , ore 8500
Functioning factor KA 1,35
Type of engine Electric asynchronous
Type of load Pulasting stress
Rotation at pinion n1 , rot /min 545
Center distance a w , mm 112
Helical angle β , grade 6
Width factor ψa 0,3
Teeth number of pinion z1 20
Teeth number of wheel z2 80
Materials
Steel Carburized, hardened and temperated
Type 19MoCr11
Superficial hardness HRC 57
Inside hardness HB 260
Recomanded limit contact stress 770
MPa
Limit contact stress σ H lim 1,2 , MPa 1500
Recomanded limit bending stress MPa 1500
Limit bending stress σ F lim 1,2 ,MPa 450
Machining information
Profile roughness 1,6
Root roughness Ra , μm <3,2
Functioning conditions
Minimal safety coeficients
For contact stress S H min 1,3
For bending stress S F min 1,5
Gear
Parameter Pinion Wheel
GEAR PARAMETERS
Center distance a w =112mm
Reference center distance a=111.98848 mm
Normal module mn =2. 25 mm
Helix angle β=6°
Helix angle on base circle β b =11.2665 °
Frontal pressure angle α t =5 .63695 °
Gearing angle Frontal α wt =20 .1176 °
Normal α wn=20 .01600 °
Total addendum correction coefficient,
in normal plane x sn =0 . 00512
Contact degree Frontal ε α=1 , 61
Helical ε β =0 . 50
Total ε γ =2 .10
Speed on pitch circle v=1.42 m/s
Precission 8
Lubricant viscosity υ 50=270 cSt
Rougness Active profile Ra =1 .6 μm
Fillet (root) Ra =3 . 2 μm
PINION AND WHEEL PARAMETERS
Addendum diameters d a 1=51. 09786 mm d a 2=181 . 90213 mm
Dedendum diameters d f 1=40 . 97287 mm d f 2 =171. 77714 mm
Pitch diameters d 1 =45 . 24787 mm d 2 =178. 72910 mm
Rolling circle diameters d w 1 =45 . 25253 mm d w 2 =178.74747 mm
Base circle diameters d b 1=42. 49165 mm d b 2=167 . 842 mm
Numbers of teeth z 1=20 dinţi z 2=79 dinţi
Width b1 =48 mm b2 = 46 mm
.
Normal addendum correction coefficient x n1 =−0.300 x n2 =−0.29488
Frontal addendum correction coefficient x t1 =0 . 29836 x t2 =−0.29326
Minimum normal addendum correction coeffficient x n min1=−0.194 x n min 2=−3.718
Table 5.2 (part 2)
Figure. 6.1
2 T 1 2⋅87915
Ft 1 = = =3885 , 74 N
d w 1 45. 25
Ft 1 =F t2 =3885 , 74 N
6.2 Radial force Fr, N;
F t1 3885 ,74
Fr 1 = ⋅tg α wn= ⋅tg 20 .01=1422, 85 N
cos β cos6
Fr 2 =F r1 =1422 , 85 N
Figure. 6.2
F a1 =Ft 1⋅tg β=3885 , 74⋅tg6 °= 408 , 4 N
F a1 =F a2 =408 , 4 N
6.4 Choosing the sense of rotation and applying forces
7 CALCULUS OF THE SHAFTS
16⋅T II
d II =
√ √3
π⋅τ atII
=
3 16⋅351660
3 . 14⋅30
=39 , 08 mm≈40 mm
Figure. 7.2
C
Type d D B C T Cor a e Y Yo n
r
rot/m
- mm KN mm
in
Input
Shaft 30206-XL 30 62 16 14 17.25 52 48.5 13.7 0.37 1.6 0.88 7400
[H]
Fa1
Fr1
A B
RAH RBH
Figure 7.2
ΣM B =0
d
R AH (l 1 +l 2 )−F r 1 l 2−F a 1⋅ w1 =0
2
d 45 . 25
F r 1⋅l 2 + Fa 1⋅ w 1 1422. 85⋅42+408 . 4⋅
2 2
H B= = =821. 42 N
(l 1 +l 2 ) 84
H A =F r 1 −R AH =1422 . 85−821 . 42=601 . 45 N
Ft1
A B
RAV
RBV
l1
Figure 7.3
ΣM B =0
R AV (l 1 +l 2 )−F t 1⋅l 2 =0
F ⋅l 3885 . 74⋅42
V B= t 1 2 = =1942 . 88 N
l1 +l 2 84
V A=F t 1 −V B=3885 . 74−1942. 88=1942 . 86 N
7.4 Determining of the reactions in the 2 bearings
B
A
l1
Mih
Miv
Mt
Figure 7.4
7.5.2 Bending
32⋅ M
√ +M
iH 2 iV 2 32⋅√ ( 34499. 64 )2 +(81600. 96 )2
σi= = =28 .35 MPa
π⋅d 3f 1 3 , 14⋅( 40 . 97 )3
7.6 Equivalent stress
2
σ eq =√ σ 2 +4 ( α⋅τ ) ≤σ aiIII
2
σ eq =√(0. 31)2 +4 ( 0, 27⋅9 .88 ) =6. 46≤σ aiIII
4⋅F a1 4⋅408. 4
σ t ( c )= = =0 ,31 MPa
π⋅d 3 ,14⋅( 40 .97 )2
f 12
σ
α= aiIII =0 . 27 °
σ aiI σ aiIII =90 MPa σ aiI =330 MPa
8.DESIGN OF THE ASSEMBLE BETWEEN THE ENHECE AND THE
OUTPUT SHAFT
F rA1942. 88
F'aA=0,5 =607 .15 N
=0,5
Y 1,6
F 1942 .86
F'aB=0,5 rB =0,5 =607 ,14 N
Y 1,6
Bearing B
F aB 607 . 15
= =11.67
o C r 52
F aB 607 . 15
= =0. 312
F rB 1942 . 86
Equivalent dynamic load
Bearing durability
60 n I Lh 60⋅598⋅8500
L= 6
= =304 . 9 mil . rot .
10 106
Dynamic loading capacity
p 3
Cr nec B =P B √ L=2028 .214 √ 304 . 9=13649 .611 N
Bearing asured durability
p
Cr 52000 3
L=
( )(
PB
=
2028. 214 )
=432mil . rot .
The wheel is pun in oil bath and the pinion is lubricated by gearing. Because
of big rotations, the bearing are lubricated by mixing
12. CHOOSING AND VERIFYING THE SEALING DEVICES
dm1=drul1-(2..3)=30-2=28mm
dm2=drul2-(2...3)=35-3=32mm
There are chosen two sockets : A28x40 STAS 7950/2-72 and A33X
Table 12.1
Nr dm h D
I 28 10 50
II 32 10 52
Because of the high rotations it is chosen sealing device with rotational socket.
daI,II=dmI,II-(4...6)
da1=dm1-(4...6)=28-4=24mm
da2=dm2-(4...6)=32-4=28mm
Tabel 12.1
h b
Nr d a(mm) l
I 24 50 7 8
II 28 60 7 8
I. Preliminary
0.7 ∙(D p 1 + D p 2 )≤ A ≤2 ∙(D p 1 + D p 2)
0.7 ∙(150+183)≤ A ≤ 2∙(150+ 183)
233 ≤ A ≤ 2 ∙(666)
A=400 mm
II. Definitive
π
Lp− (β ∙ D + β ∙ D )
360 1 p 1 2 P 2
A=
β
2 ∙ sin 1
2
π
1400− (177.64 ∙ 150+182.36 ∙183)
360
A= =438.21mm
177.64
2 ∙ sin
2
It is chosen 19MOCr11 steel hardening and tempering to achieve the shaft and gear
wheel transmission because this steel has good resistance to bending and also has a high
resistance to fatigue.
Materials used for gears:
Steel
It is used great steel: steel with carbon0.4-0.6 %C and steel with 0.35-0.45%C low alloyed with
Mn, Cr, Cr-Mo, Cr-Ni etc. Steel non alloyed with Cr, Cr=Mo, Cr-Ni, with cyaniding.
Cast irons
Cast irons are used at gearing which has a easy working, change wheels which doesn’t function
every time.When it is asking a silent condition may be used normal iron ash.
Materials used for axels execution:
Generally the axel which don’ t have a heat treatment are made by normally steel carbon: OL 50,
OL 60, STAS 500-78
For axel which has a big lifting power we can use carbon steel of quality: OLC 35, OLC 45,
OLC 60, according to STAS 880-66.
In case of axel which have a strong load and are required small dimension are used steel alloyed
with crom, Cr-Ni or Cr-Mn.
Marerials used for producing the body.
Because of the stiffness the body is made by cast irons or by casting steel. Most of the bodies
are made by cast iron with average resistance Fc 200, Fc 250.
Be sure to use the electric motor asynchronous type having a power of 11 KW operating speeds
of 590 rot/min.
15. RULES OF SAFETY AT WORK
At work or in the operation of the gears you will need to take into account the
following provisions relating to rules of safety at work.