Đồ án thiết kế HGT phân đôi cấp nhanh

HO CHI MINH CITY UNIVERSITY OF
TECHNOLOGY
DEPARTMENT OF MACHINE DESIGN
DESIGN PROJECT REPORT

TOPIC :12
OPTION:19
Instructor:
Class:
Student:
Ho Chi Minh City, June, 2020

HCMUT Design project
TRƯỜNG ĐẠI HỌC BÁCH KHOA TP. HCM

KHOA CƠ KHÍ
BỘ MÔN THIẾT KẾ MÁY
ĐỒ ÁN THIẾT KẾ
(ME2011)
Học kỳ II / Năm học
Sinh viên thực hiện : ......................................................... MSSV: ..........................................
Người hướng dẫn : ......................................................... Ký tên: ..........................................
Ngày hoàn thành : ......................................................... Ngày bảo vệ: ................................
ĐỀ TÀI
Đề số 12: THIẾT KẾ HỆ THỐNG DẪN ĐỘNG THÙNG TRỘN
Phương án số:
1 2 3 4 5 T
T1
T2
t2 t
Sơ đồ t ải tr ọng
Hệ thống dẫn động thùng trộn gồm: 1-Động cơ điện 3 pha không đồng bộ; 2- Bộ truyền đai
thang; 3- Hộp giảm tốc bánh răng trụ hai cấp phân đôi; 4- Nối trục đàn hồi; 5- Băng tải. (Quay
một chiều, tải va đập nhẹ, 1 ca làm việc 8 giờ)
BẢNG SỐ LIỆU ĐỀ 12
Phương án 1 2 3 4 5 6 7 8 9 10
Lực vòng trên băng tải F, N 7200 6300 4800 7100 6600 6400 4400 5500 6100 7700
Vận tốc băng tải v, m/s 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7
2
Instructor: Student:
Đường kính tang dẫn, D(mm) 650 500 350 350 250 600 450 300 550 550
Thời gian phục vụ L, năm 4 4 5 5 6 6 7 7 8 8
Số ngày làm/năm Kng , ngày 310 340 300 190 280 250 270 280 310 210
Số ca làm trong ngày, ca 2 3 2 3 2 3 2 3 2 3
t1, giây 19 26 25 30 21 25 25 22 27 26
t2, giây 23 23 15 12 24 13 17 19 14 16
T1 T T T T T T T T T T
T2 0,7T 0,6T 0,9T 0,8T 0,6T 0,8T 0,7T 0,8T 0,7T 0,9T
Đề số 12 – Trang 1/2
Phương án 11 12 13 14 15 16 17 18 19 20
Lực vòng trên băng tải F, N 6700 5600 5400 6800 7300 7000 5800 6300 5700 6400
Vận tốc băng tải v, m/s 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7
Đường kính tang dẫn, D(mm) 650 500 350 350 250 600 450 300 550 550
Thời gian phục vụ L, năm 4 4 5 5 6 6 7 7 8 8
Số ngày làm/năm Kng , ngày 200 220 210 190 300 320 310 330 200 180
Số ca làm trong ngày, ca 2 3 2 3 2 3 2 3 2 3
t1, giây 19 26 25 30 21 25 25 22 27 26
t2, giây 23 23 15 12 24 13 17 19 14 16
T1 T T T T T T T T T T
T2 0,7T 0,6T 0,9T 0,8T 0,6T 0,8T 0,7T 0,8T 0,7T 0,9T
YÊU CẦU
• 01 thuyết minh.
• 01 bản vẽ lắp A0 ; 01 bản vẽ chi tiết.
NỘI DUNG THUYẾT MINH

1. Xác định công suất động cơ và phân bố tỉ số truyền cho hệ thống truyền cho hệ
thống truyền động.
2. Tính toán thiết kế các chi tiết máy:
a. Tính toán các bộ truyền hở (đai, xích hoặc bánh răng).
b. Tính các bộ truyền trong hộp giảm tốc (bánh răng, trục vít).
c. Vẽ sơ đồ lực tác dụng lên các bộ truyền và tính giá trị các lực.
d. Tính toán thiết kế trục và then.
e. Chọn ổ lăn và nối trục.
f. Chọn thân máy, bu-lông và các chi tiết phụ khác.
3
3. Chọn dung sai lắp ghép.

4. Tài liệu tham khảo.
Content for Report

CHAPTER 1: SELECT MOTOR AND TRANSMISSION RATIO..................................6
I. SELECT AN ELECTRIC MOTOR.....................................................................6
II. RECALCULATE TRANSMISSION RATIO DISTTRIBUTION.....................8
III.OTHER PARAMETERS.......................................................................................8
CHAPTER 2: DESIGNING BELT DRIVE.....................................................................10
I. DESIGN DATA....................................................................................................10
II. DESIGN PROCESS OF V-BELT DRIVE.........................................................10
PARAMETER OF BELT DRIVE............................................................................14
CHAPTER 3: DESIGNING GEARS TRANSMISSION.................................................15
I. DESIGN PROCESS.............................................................................................15
II. Calculation for spur gear drive (low level):.......................................................17
III. Calculation for helical spur gear drive (high level):..........................................21
V. CHECKING OIL LUBRICATION CONDITIONS.........................................29
CHAPTER 4: DESIGNING SHAFTS AND KEYS........................................................30
I. INITIAL PARAMETERS...................................................................................30
II. DESIGN PROCESS.............................................................................................32
III. SELECTING KEY..............................................................................................41
IV. CHEKING SHAFT FATIGUE STRENGTH...................................................42
CHAPTER 5: SELECTING COUPLING........................................................................46
I. INITIAL PARAMETERS...................................................................................46
II. DESIGN PROCESS.............................................................................................46
III. STRENGTH CHECK.........................................................................................46
CHAPTER 6: SELECTING BEARINGS........................................................................47
I. Shaft I.................................................................................................................... 47
II. Shaft II..................................................................................................................48
4
III. Shaft III................................................................................................................49

CHAPTER 7: DESIGNING GEAR BOX COVER AND EXTRA DETAILS................52
I. DESIGNING THE GEAR BOX COVER..........................................................52
II. LUBRICATING THE GEAR BOX...................................................................54
III. EXTRA DETAILS...............................................................................................54
CHAPTER 8: TOLERANCE ASSEMBLY.....................................................................58
REFERENCES................................................................................................................60
5
CHAPTER 1: SELECT MOTOR AND TRANSMISSION RATIO

I. SELECT AN ELECTRIC MOTOR
The maximum power of working element: [1]
Fv 5700 1.6
Plv    9.12kW
1000 1000
where: F: force on conveyer, F = 5700 N
v: velocity, v = 1.6 m/s
The average power of the working element:
Based on the given Load diagram to determine the average power of the working
element:
2 2
 T1   T2 
  t1    t2
Pt
n 2
Ptd  i i i
 Plv T  T 
t t1  t2
n
i i
12 (27)  0.7 2 (14)

 9.12  8.288 kW
27  14
where: Plv : The maximum power of the working element, Plv =9.12 kW
T 1: period of heavy loading,T 1=T
T 2: period of light loading,T 2=0.7 T
T: 1 working period
t 1: time of period T 1, t 1=27 s
t 2: time of period T 1, t 2=14 s
Efficiency of the system:
Based on the given diagram below that consist of: 1 chain drive, 1 coupling, 1 pair of
spur gear, 1 pair of helical gear 4 pair of bearings, so the total efficiency of the system:
6
Ƞ=Ƞ coupling Ƞ b Ƞ spurgear Ƞ helicalgear Ƞ 4bearing [1]

where: Ƞ coupling =0.98: Efficiency of coupling, choose flexible coupling as it is simple,
cheap and widely used
Ƞ b=0.95 : Efficiency of belt drive
Ƞ spurgear =0.97 : Efficiency of spur gear
Ƞ helicalgear=0.97 : Efficiency of helical gear
Ƞ ol =0.99: Efficiency of roller bearing
 Ƞ=0.95(0.98)( 0.97)(0.97)(0.994 )=0.841
Required power of the motor:
Ptd 8.288
Pct = = ≈ 9.855 kW
Ƞ 0.841
Use Ptd instead of Plv to avoid surplus power from the chosen motor, however the motor
could be overload periodically, this can be re-check later.
Number of revolutions of the working element:
60000v 60000(1.6)
nlv    55.56 rpm
D 550
where: v: Speed of the working element, v=1.2 m/s
D: Diameter of driving sprocket of working element, D=400 mm
Transmission speed ratio:
uch  uh ub 1 6(3)  48 [1]
where: uh : Transmission ratio of gearbox, choose uh = 16

u spurgear: Transmission ratio of spur gear, choose u spurgear = 2.42
ub : Transmission ratio of belt drive , choose ub =3
The transmission ratio for 2 level reduction gear-box is suggested between 8 to 40,
choose 16 so that it will be suitable for the motor that is going to be chosen. For ratio of
each pair of gear, based on table 3.5.
nsb  nlv uch  55.56(48)  2666.9rev / min
Choose motor according to table appendix 3, page 737 [1]

Requirement: P ≥ Pmotor ; n ≈ nmotor
7
I choose the motor base on the catalogue of VIHEM company
Power (kW) Rotational speed

Type Mmax/Mdd
(rpm)
KW HP
3K132M2 7.5 10 2930 2.2
3K160S2 11 15 2840 3.0
3K160M2 15 20 2940 3.1
3K160L2 18.5 25 2940 2.2

I choose motor which has type 3K160S2, 11KW and 2840 rotational speed.
II.RECALCULATE TRANSMISSION RATIO DISTTRIBUTION
n 2840
uch  dc   51.12 uh
nlv 55.56 => I choose = 16
uhelicalspurgear  6.35=u1 uspurgear  2.5  u2
Based on table 3.5: ;
uh  6.35(2.5)  15.875
|16  15.875 |
   0.78%
Error: 16 [1]
uch 51.12
ub    3.2
uh 15.875
III. OTHER PARAMETERS
Average power on shafts: [1]
P=9.12 kW
Plv 9.12
P 3= = =9.4 kW
ƞbearing ƞ coupling 0.99(0.98)
P3 9.4
P 2= = =9,789 kW
ƞbearing ƞ spurgear 0.99( 0.97)
P2 9.789
P 1= = =10.194 kW
ƞbearing ƞhelicalgear 0.99( 0.97)
P1 10.194
Pmotor = = =10.84 kW
ƞb ƞbearing 0.95(0.99)
8
Shaft rotational speed:

n đ c 2840
n1 = = ≈ 887.5 rev /min
ub 3.2
n 1 887.5
n2 = = ≈139.76 rev /min
u 1 6.35
n 2 139.76
n3 = = ≈55.9 rev /min
u2 2.5
Torque on shafts: [1]
6 P1 6 10.194
T 1=9.55(10 )( )=9.55 (10 )( )≈ 109.693 Nm
n1 887.5
P2 9.789
T 2=9.55 ×106 ( )=9.55(106 )( )≈ 668.9 Nm
n2 139.76
6 P3 6 9.4
T 3=9.55(10 )( )=9.55(10 )( )≈ 1605.9 Nm
n3 55.9
P dc 10.84
T dc =9.55(106 )( )=9.55(106 )( ) ≈ 36.451 Nm
ndc 2840
6 Pct 6 9.12
T ct =9.55(10 )( )=9.55(10 )( ) ≈ 1588.068 Nm
n ct 55.9
Table of properties: (using average power and average torque)

Shaft IV
Motor I II III
Data (Working)
Power - P (kW) 10.84 10.194 9.789 9.4 9.12
Transmission
3.2 6.35 2.5 1
ratio - u
Rotational speed
2840 887.5 139.76 55.9 55.9
- n (rpm)
Torque - T (Nm) 36.451 109.693 668.9 1605.9 1588.068
9
CHAPTER 2: DESIGNING BELT DRIVE

I. DESIGN DATA
Power of the chain drive: P = 10.84 kW
Transmission ratio: u= 3.2
Rotational speed of driving pulley: n1= 2840 rpm
Torque: T = 36.451 Nm
One-directional rotation, a 8-hour shift, low level load.
II. DESIGN PROCESS OF V-BELT DRIVE [1]
1. Select the belt type B
Type bp b0 h Length y0 A of T1 d1 min

(mm) (mm) (mm) (mm) (mm2) belt (N.m) (mm)
(mm)
B 14 17 10.5 4 138 800  6300 40  190 125
2. Select the diameter of smaller pulley
d1 = 1.2 dmin = 1.2 (235) = 150 mm
Basing on the standard, d1  160,   0.01

π d 1 n 1 π (160)(2840)
3. Belt’s velocity: v1 = = =23.8 m/ s
60000 60000
d 1 is acceptable (because v1 ≤ v max =25 m/s)
Select slip ratio ξ = 0.01 and diameter of larger pulley:
 d 2=u d 1 ( 1−ξ )=3.2 ( 160 ) ( 1−0.01 )=506.9 mm
 d2 = 500 (follow the standard)
d2 500
4. The exactly transmission ratio: u = = =¿3.16
d 1 ( 1−ξ ) 160 ( 1−0.01 )
3.2−3.16
( 100 %=1.25 % <3 % ¿ => satisfies
3.2
Calculating the distance (a) and length (L) of shaft
U 1 2 3 4 5 ≥6
A 1.5d 2 1.2d 2 d2 0.95d 2 0.9d 2 0.85d 2
Or : 2(d1  d 2 )  a  0.55(d1  d 2 )  10.5

2(160  500)  a  0.55(160  500)  10.5
1320  a  373.5
10
 Select a = 560
π (d 1+ d 2) (d 2−d 1)2
5. Length : L = 2a + +
2 4a
π (160+560) (560−160)2
= 2(560) + + = 2322.4 mm
2 4 (560)
 L = 2500 mm (follow the standard) =2.5 m
6. Calculating exactly:
π (d 1+ d 2) π (500+160)
K =L- = 2500 - = 1463.3 mm
2 2
d 2−d 1 500−160
Δ= = = 170 mm
2 2
2 2
k + √ k 2−8 Δ2 1463.3+ √1463.3 −8(170)
a= = = 711.34 mm
4 4
 Satisfies the condition
7. Round per second i:
v1 −1 23.8
i= ≤ [ i ][ i ]=10 s for V belt i= =9.52 ≤10 (Satisfied )
L 2.5
8. Wrap angle:
d 2−d 1 500−160 '
 α 1=180 °− ×57=180 °− ×57 °=152 ° 45 =2.66 rad
a 711.34
9. The number of belt:
P1 10.84
z≥ = = 3.17
[ P 0 ] C v C α C u C L C Z C r 4.84 (0.93)(1.14)(1.018)(1)(0.85)(0.77)
 z=4
Where:
Velocity factor:C v =1−0.05 ( 0.01 v 2−1 )
= 1 – 0.05 [0.01 (23.8 ¿ ¿2 – 1]
= 0.77
−α1
(
Correction factor for contact angle: C =1.24 1−e 110 =0.93
α
)
Correction factor relating to transmission ratio C u: u = 3.2
=> C u=1.14
L 2500
Correction factor relating to the length of belt:C L =
√ √
6
L0
= 6
2240
= 1.018
Correction factor relating to uneven distribution of the load between the belts: C Z = 1
Load correction factor:C r=0.85
11
Because z =4
 C Z = 0.9
10. The width of belt and outer diameters:
We have: f  12.5, e  19, b  4.2
The width of V-belt: B  ( z  1)e  2 f  3(19)  2(12.5)  82mm
The outer diameter of smaller pulley: d a1  d1  2b  160  2(4.2)  168.4
The outer diameter of larger pulley: d a 2  d 2  2b  500  2(4.2)  508.4

11. Forces acting upon the shafts:
Initial force can be determined by formula:
F 0=zA σ 0=4 ×138 ×1.5=828 N
Where:  0  1.5Mpa, A  138 ( V-belt)

Force exerted on the shaft:
1 152.76
Fr  2 F0 sin( )  2(828)(sin( ))  1609.4 N
2 2
Tangential force:
1000 P1 1000(10.84)
Ft    455.46
v1 23.8
Coefficient of friction
  2.66rad
1 2 F0  Ft 1 2(828)  455.46
f ln( ) ln( )  0.21
 2 F0  Ft 2.66 2(828)  455.46
The smallest coefficient of friction holding the belt drive do not slip off: Assume that
  38

f min  f ' sin( )  0.21sin(19)  0.068
2
Tight-side tension F1
Ft 455.46
F1  F0   828   1055.73N
2 2
Slack-side tension F2
Ft 455.46
F2  F0   828   600.27 N
2 2
12
12. Calculation of Allowable stress  max

 v   v12106  1200(23.82 )(106 )  0.68Mpa
Where:   1200kg / m is specific weight of belt

3
F0 828
0    1.5Mpa
Az 138(4)
Ft 455.46
t    0.825Mpa
Az 138(4)
2 y0 E 2(4)(100)
 u1    5Mpa
d1 160
Where: E  100 N / m is elastic modulus

2
Thus  max   1   u1   v   0  0.5 t   v   u1

 max  1.5  0.5(0.825)  5  0.68  7.59 Mpa  10 Mpa
 Satisfied the condition
13. Calculate the service life for V belt drive by following section
σr m
( ) ×107
σ max
Lh = , hours
2× 3600× i
Where:σ r is the fatigue limit of belt (with the rubber belt with buffet, we choose
σ r=9 Mpa ).
m=8(V-belt)
9 8 7
) ×10
(
Then, service life of belt drive: 7.59
Lh = ≈ 570.212hours
2 ( 3600 ) (9.52)
13
PARAMETER OF BELT DRIVE

Parameter Value
Type of belt B
A (mm2) 138
Number of belts 4
Material Rubber
Center Distance a, mm 560
Belt Length B, mm 82
Wrap Angle α , degree 152.45 °
Number Of Revolution In A Second i, 1/s 9.52
Driving Pulley Diameter d 1, mm 160
Driven Pulley Diameter d 2, mm 500
Maximum Stress σ max, MPa 7.59
Initial Tension F 0, N 828
Force Acting On Shaft F r, N 1609.4
Tangential tension Ft, N 455.46
Tight-side tension F1, N 1055.73
Slack-side tension F2, N 600.27
Life Service Lh, hours 570.212
14
CHAPTER 3: DESIGNING GEARS TRANSMISSION

I. DESIGN PROCESS
Choosing the material for all gears:
According to table 6.1 p.92[1], without any specific requirement, choose widely used
material type I material (HB ≤ 350), to facilitate the gear’s teeth cutting procedure, make
it more accurate, lessen the need for stronger material for shafts, but also provide high
allowable stress; H 1 ≥ H 2 + (10 … 15)HB so as to reduce the friction between gears :
For the driving gear we choose steel 45 quenched with rigidity H 1=250 HB ; ultimate
strength σ b = 850 MPa; yield limit σ ch = 580 MPa
For the driven gear we choose steel 45 quenched with rigidity H 2=230 HB ; ultimate
strength σ b = 750 MPa; yield limit σ ch = 450 MPa
Calculating the allowable stress for gears [1]
σ 0 Hlim =2 HB +70 MPa; S H =1.1
σ 0 Hlim1=2 H 1 +70 MPa=2(250)+70=570 MPa
σ 0 Hlim2=2 H 2 +70 MPa=2(230)+70=530 MPa
σ 0 Flim=1.8 HB ; S F=1.75
σ 0 Flim 1=1.8 H 1=1.8( 250)=450 MPa
σ 0 Flim 2=1.8 H 2=1.8(235)=414 MPa
Numbers of stress-changing cycles: [1]
N HO1  30 H12.4  30(2502.4 )  1.71(107 )revolutions
N HO 2  30 H 2 2.4  30(2302.4 )  1.397(107 ) revolutions
N FO1  N FO 2  5(106 ) revolutions
Numbers of corresponding stress-changing cycles (based on the load diagram):

Ti 3
N HE  60c ( ) ni ti
Tmax [1]
 T 3 27  0.7 T  14 
3
N HE1  60(1)      (887.5)(25600)

 T  27  14  T  27  14  [1]
 10.57(108 )revolutions

 T 3 27  0.7  T  14 
3
N HE 2  60(1)      (197.22)(25600)
 T  27  14  T  27  14  [1]

15
Ti 6
N FE  60c ( ) ni ti
Tmax
 T 6 27  0.7  T  14 
6
N FE1  60(1)      (25600)887.5

 T  27  14  T  27  14 
 T 6 27  0.7  T  14 
6
N FE 2  60(1)      (197.22)25600
  T  27  14  T  27  14 
with: c is the amount of times the two gears mesh per revolution. There is one time they
mesh, so c = 1;
Lh=8 ( 200 )( 2 ) ( 8 )=25600 h is the total working time of each gear:
Because N HE 1> N HO 1; N HE 2> N HO 2; N FE 1> N FO 1; N FE 2> N FO 2
Choose coefficients of longevity: K HL1=K HL2=K FL1=K FL2=1
Calculate the allowable tangential stress [1]
0.9 0 Hlim1 K HL1 0.9(570)(1)
  H1     466.36 MPa
sH 1.1
0.9 0 Hlim 2 K HL 2 530(0.9)
H2    433.63 MPa
sH 1.1
Helical spur gear: [1]
  H   0.45(  H 1     H 2  )  0.45(466.36  433.63)  405Mpa
1.25[ H ]min  1.25[ H 2 ]=1.25(433.63)=542.04 MPa 1.25
 Condition : 433.63  405  542.04 1.25 (no satisfies)

   H     H  min    H  2  433.63MPa
Spur gear: N HE > N HO =¿ K HL=1
  H     H  min    H  2  433.63MPa
Calculate the allowable bending stress:
 0 F lim1 450
  F1   K FL1K FC  (1)(1)  257.14 MPa
sF 1.75 [1]
 0 F lim 2 414
F2  K FL 2 K FC  11  236.57 MPa
sF 1.75 [1]
with: K FC = 1 for 1 directional rotation (coefficient of direction)
16
Calculate the allowable stress when overload:

  Hmax   2.8 ch 2  2.8(450)  1 260 MPa [1]
  F1max   0.8 ch1  0.8(580)  464 MPa [1]
  F 2max   0.8 ch 2  0.8(450)  360 MPa [1]
II.Calculation for spur gear drive (low level):
Parameters acquired for designing the helical spur gear:
Power: P2 = 9.789 kW
Transmission ratio of spur gear: u2= 2.5
Rotational speed of driving gear: n2 = 139.76 rpm
Torque: T2 = 668.9 Nm
Selecting the coefficient of the tooth width:
According to table 6.6 [1] choose: ψ ba=0.4 (the two gears are symmetrical to the axis and
H 1 , H 2 <350 HB)
ψ bd =0.5ψ ba ( u+1 )=0.5(0.4) ( 2.5+1 )=0.7
According to table 6.7 [1], given that the gears are presented in figure 3, choose:
K Hβ=1.05 and K Fβ =1.09
Select the initial center distance of the axes:
T1 K H 
aw  500  u  1 3
 ba [ H ]2 u
[1]
668.9(1.05)
 500  2.5  1 3 = 271.52 mm
0.4(433.632 )(2.5)
Based on standard, choose a w =280 mm, which satisfy the condition: closet to the
calculated a w
Gear module:
Module
m   0.01  0.02  aw   0.01  0.02  280  2.8  5.6 mm
[1]
Based on suggestion of row 1, I choose m = 4 mm
Gear teeth:
2aw 2(280)
Z1  Z 2    140
Sum of No. of teeth : m 4
17
Z1  Z 2 140
Z1    40
Number of teeth of driving gear: u 1 2.5  1
Driven gear teeth:

z2 1 40  40  100 teeth [1]
Transmission ratio in reality:
z 100
um  2   2.5
z1 40
Relative error of transmission ratio:

| 2.5  2.5 |
u  = 0% (satisfied)
2.5 [1]
Width of driven gear:
bw 2   ba aw  0.4(280)  112 mm [1]
Choose width for driven gear larger than driving gear from (4-5) mm for better meshing:
bw1  bw 2  5  112  5  117mm
Geometry parameters of the gears:
Pitch circle diameter:
d1  z1m  4(40)  160 mm [1]
d 2  z1m  4(100)  400 mm [1]
Crest circle diameter of driving gear:
d a1  d1  2m  160  8  168 mm [1]
d a 2  d 2  2m  400  8  408 mm
Reference diameter:
d w1  d1 [1]
d w2  d2
Root diameter:
d f 1  d1  2.5m 1 60  2.5(4) 1 50 mm
[1]
d f 2  d 2  2.5m  400  2.5(4)  390 mm
Center distance:
18
( z2  z1 )m 4(100  40)
aw    280mm
2 2 [1]
Driving gear speed:
 d w1n2  (160)(139.76)
v   1.17 m / s
60000 60000 [1]
According to table 6.3 [1], given that v = 1.17 m/s, choose the degree of accuracy is 9,
choose the undistributed load coefficient K Hv= 1.06935; K Fv= 1.129.
Forces acting upon spur gear:
2T 2(668.9)(103 )
Ft1  Ft 2    8361.25 N
Tangential force: d w1 160
Tangential force: Fr1  8361.25 tan 20  3043.25 N  Fr 2

Ft1 8361.25
Fn1    8897.9 N  Fn 2
Normal Force: cos aw cos(20)
Calculate contact stress [1]

The calculated tangential stress:
Z M Z H Z Ft1 K H  u  1
H   [ H ]
1 d w1bw u
190(2.5)(0.863) 8361.25(1.269)  2.5  1
  373.22 MPa
1 160(112)(2.5)
Where: Z H : coefficient of contact area
4 4
ZH    2.5
sin 2 tw sin  2  20 
tan  nw tan 20

 tw  tan 1 ( )  tan 1 ( )  20
cos  cos 0
4  
Zε Z   0.863
: contact length coefficient: = 3
1 1
   [1.88  3.2(  )]cos
Where: z1 z2
1 1
   [1.88  3.2(  )]cos0=1.768
40 100
19
1
Z M  190 MPa 2 : given that the gears are made by steel
K H : coefficient of static load:

K H  K H  K Hv K H  1.05(1.06935)(1.13)  1.269
where: K H  1 .13 is undistributed load coefficient, chosen above
Calculating precisely the allowable contacting stress:

  H     H  min Z R ZV K xH Kl  433.63(1)(0.863)(1)(1.017)  380.6 MPa
Where:
Z R=1 is the coefficient of surface roughness (lowest roughness surface is chosen for
higher performance).
ZV : the coefficient affecting the gear’s velocity, when HB ≤ 350
ZV  0.85  v 0.1  0.85  1.17 0.1  0.863
d 160
K xH  1.05  4
 1.05  4  1.017
10 10 : the coefficient impacting on the dimension of the
gear’s teeth
Efficiency of safety: S H  1.1

 H  373.22 MPa    H   380.6 MPa
 The gears satisfy the contact stress test

Use the recalculated parameters in the properties table of helical gear for the
calculations below:
Determine the bending stress for driving gear (it has lower bending stress)
Ft K F YF 1
 F1 
bw m
[1]
 3.8(8361.25)(1.23) /  112(4)   87.23MPa
where: K F=K Fβ K Fα K Fv =1.09 ×1.129 ×1=1.23is coefficient of load affected bending (the
other parameters are chosen and calculated above)
1
Y ε= =1/1.768=0.56 is the coefficient of meshing
εα
YF 1  3.8
Calculating precisely the allowable bending stress for both gears:
20
K HLYRYX Y K FC
  F    OF lim
  F1     F 1  YRYx K FCY  257.14(1)(1.03)(0.98)  259.6 MPa
SF
  F 2     F 2  YRYX K FCY  236.57 (1)(1.03)(1)(0.98)  238.8 MPa
where:
YR  1 is coefficient of surface roughness (use gears had been through grinding process)
Y  1.082  0.172lg  m   1.082  0.172lg  4   0.98

is coefficient of sensitivity to load
Yx  1.05  0.005m  1.05  0.005(4)  1.03 is coefficient of gear size affected to bending
stress.
K FC  1 (1-way rotation)
The coefficient of teeth type following to experimental formula:

13.2 27.9 x
YF  3.47    0.0092 x 2
zv zv
Where:
Coefficient of correction : x1  0, x2  0
The corresponding teeth of spur gear:
z1 40
zv1    40 teeth
cos  cos3 (0)
3
z2 100
zv 2    100 teeth
cos  cos3 (0)
3
13.2
YF 1  3.47   3.8
40
13.2
YF 2  3.47   3.602
100
Comparison of bending stresses of two gears:
[ F 1 ] 259.6
  68.32
YF 1 3.8
[ F 2 ] 238.8
  66.3
YF 2 3.602
Checking the bending stress:
 F 1  87.23Mpa    F 1   259.6 MPa
 Satisfy the bending stress test
21
III. Calculation for helical spur gear drive (high level):

Parameters acquired for designing the helical spur gear:
Power: P = 10.194 kW
Transmission ratio of helical spur gear: u1= 6.35
Rotational speed of driving gear: n1= 887.5 rpm
Torque: T1 = 109.683 Nm => T= 54.85 Nm
Selecting the coefficient of the tooth width:
According to table 6.6 [1]
choose: ψ ba=0.25 (the two gears are unsymmetrical tothe axis and H 1 , H 2 <350 HB)
And ψ bd =0.5ψ ba ( u+1 )=0.5(0.25) ( 6.35+1 ) =0.91875
According to table 6.4 [1] , choose: K Hβ=1.072 and K Fβ=1.134
Select the initial center distance of the axes:
T1 K H 
aw  430  u  1 3
 ba [ H ]2 u
[1]
54.85(1.072)
 430  6.35  1 3 = 183.89mm
0.25(433.632 )(6.35)
Based on standard, choose a w =200 mm, which satisfy the condition: closet to the
calculated a w
Gear module:
Module
m   0.01  0.02  aw   0.01  0.02  160  2  4 mm
[1]
Based on suggestion of row 1, I choose m = 2.5 mm
Gear Teeth
Driving gear teeth:
From the condition 80 ≤ β ≤ 200 for helical spur gear
2aw cos(40) 2 cos(30) 2(200) cos(40) 2(200) cos(30)
 z1    z1 
m  u  1 m   u  1 2.5  6.53  1 2.5   6.35  1
 18.85 teech> z1 >¿ 16.68 teeth => Select z 1=18

Driven gear teeth:
z2  z1u  21 6.35  133.35 teeth => Select z 2=114 teeth [1]
Transmission ratio in reality:
22
z 134
um  2   6.33
z1 21
Relative error of transmission ratio:
| 6.33  6.35 |
u   0.31% < 2% (satisfied)
6.35
Teeth helical angle:
 m  z1  z2   1 3  18  114 
 
  cos 1    cos    34.4
0
 2 aw   2(200)  [1]
 Satisfies the condition of helical angle: 30    40

0 0
Determine helical spur gear dimensions

Width of driven gear:
bw 2   ba aw  0.25(200)  50 mm
[1]
Choose width for driven gear larger than driving gear from (4-5) mm for better meshing:
bw1  bw 2  5  50  5  55mm
Geometry parameters of the gears

Pitch circle diameter:
z1m 18(2.5)
d1    54.54 mm
cos  cos(34.40 )
z2 m 114(2.5)
d2    345.41 mm
cos  cos(34.40 )
Addendum diameter of driving gear:
d a1  d1  2m  54.54  5  59.54 mm
d a 2  d 2  2m  345.41  5  350.41mm
Reference diameter:
d w1  d1
d w2  d2
Root diameter:
d f 1  d1  2.5m  54.54  2.52  48.29 mm
d f 2  d 2  2.5m  345.41  2.52  339.16 mm
Center distance:
23
( z2  z1 )m 2.5(114  18)
aw    200 mm
cos  2 cos(34.40 )
Driving gear speed:
 d w1n1  (54.54)(887.5)
v   2.53 m / s
60000 60000
According to table 6.6, [1], given that v = 2.52 m/s, choose the degree of accuracy is 9,
choose the undistributed load coefficient K Hv= 1.0544; K Fv= 1.11.
Forces acting upon helical spur gear: [1]
2T 2(54846.6)
Ft    2011.24 N
Tangential force: d w1 54.54
Ft1 (tan aw ) 2011.24 tan(20)

Fr1    887.2 N
Radial force: cos  cos(34.4)
Axial Force: Fa  2011.24 tan(34.4)  1377.12 N

Calculate contact stress
The calculated tangential stress:
Z M Z H Z 2T1 K H  u  1
H   [ H ]
d1 bw u
190(2.11)(0.85) 2(54846.6)(1.072)(1.0544)  6.35  1
  334.74 MPa
54.54 50  6.35
where: Z H : coefficient of contact area
4 cos  4cos34.4
ZH    2.11
sin 2 tw sin  2  23.8 
tan  nw tan 20

 tw  tan 1 ( )  tan 1 ( )  23.8
cos  cos 34.4
1
Zε Z   0.85

: contact length coefficient: =
1 1
   [1.88  3.2(  )]cos
where: z1 z2
1 1
   [1.88  3.2(  )]cos(34.4)=1.38
18 114
1
Z M  190 MPa 2 : given that the gears are made by steel
24
K H : coefficient of static load:

K H  K H  K Hv K H   1.072 1.0544  1.13  1.28
where: K H  1 .13 is undistributed load coefficient, chosen above

Calculating precisely the allowable contacting stress:
  H     H  Z R ZV K xH Kl  433.63(1)(0.933)(1)(1.022)  413.48 MPa
Where:
Z R=1 is the coefficient of surface roughness (lowest roughness surface is chosen for
higher performance )
ZV  0.94 : the coefficient affecting the gear’s velocity, when HB ≤ 350
ZV  0.85  v 0.1  0.85  2.530.1  0.933
d 54.54
K xH  1.05  4
 1.05   1.022
10 104 : the coefficient impacting on the dimension of
the gear’s teeth
Efficiency of safety: S H  1.1

 H  334.74 MPa    H   413.48 MPa
 The gears satisfy the contact stress test
Use the recalculated parameters in the properties table of helical gear for the
calculations below:
Determine the bending stress for driving gear (it has lower bending stress)
Ft K F Y Y YF 1
 F1 
bw m
[1]
 3.88(2011.24)(1.26)(0.72)(0.982) /  50(2.5)   55.62MPa
where: K F=K Fβ K Fα K Fv =1.134 × 1.11× 1=1.26 is coefficient of load affected bending (the
other parameters are chosen and calculated above)
1
Y ε= =1/1.38=0.72 is the coefficient of meshing
εα
bw sin  50sin 34.4
    3.6
m 2.5
  34.4  0.6rad
  3.6(0.6)
Y  1   1  0.982
120 120 is the coefficient of teeth incline
25
YF 1  3.88
Calculating precisely the allowable bending stress for both gears:

K HLYRYX Y K FC
  F    OF lim
  F1     F 1  YRYx K FCY  257.14(1)(1.0375)(1.014)  270.52 MPa
SF
[1]
  F 2     F 2  YRYX K FCY  236.57 (1)(1.0375)(1.014)  248.8 MPa [1]
where:
YR  1 is coefficient of surface roughness (use gears had been through grinding process)
Y  1.082  0.172lg  m   1.082  0.172lg  2.5   1.014

is coefficient of sensitivity to load
Yx  1.05  0.005m  1.05  0.005(2.5)  1.0375 is coefficient of gear size affected to bending
stress.
The coefficient of teeth type following to experimental formula:
13.2 27.9 x
YF  3.47    0.0092 x 2
zv zv
Where:
Coefficient of correction : x1  0, x2  0
The corresponding teeth of gear:
z1 18
zv1    32.04teeth
cos  cos (34.4)
3 3
z2 114
zv 2    202.94teeth
cos  cos (34.4)
3 3
13.2
YF 1  3.47   3.88
32.04
13.2
YF 2  3.47   3.54
202.94
Comparison of bending stresses of two gears:
[ F 1 ] 270.52
  69.72
YF 1 3.88
[ F 2 ] 248.8
  70.28
YF 2 3.54
Checking the bending stress:
 F 1  55.62 Mpa    F 1   270.52MPa
26
 Satisfy the bending stress test
IV. GEAR DRIVE PARAMETERS

1. Helical gear drive properties table:
Helical gear
Geometry parameters Driving gear Driven gear
drive
Center distance: a (mm) 200 - -
Torque: T (Nm) (each gear) 54.85
Transmission ratio: u 6.35 - -
n (rpm) 887.5
Module: m (mm) 2.5 - -
Teeth number: z (teeth) - 18 114
Teeth angle: β (°) 34.4 - -
Pitch circle diameter: d (mm) - 54.54 345.41
Addendum diameter: d a (mm) - 59.54 350.41
Root diameter: d f (mm) - 48.29 339.16
Gear width: b (mm) - 55 50
Speed: v (m/s) 2.53 - -
27
Material Steel C45
Tangential Force(N) 2011.24
Radial Force (N) 887.2
Axial Force(N) 1377.12
Allowable Calculated
Testing Comment
Value Value
Contact Stress  H (Mpa) 334.72 413.18 Satisfies
Bending Stress  F 1 (Mpa) 55.62 270.52 Satisfies
Bending Stress  F 2 (Mpa) 248.8
2. Spur gear drive properties table:

Spur gear
Geometry parameters Driving gear Driven gear
drive
Center distance: a (mm) 280 - -
Torque: T (Nm) 668.9
Transmission ratio: u 2.5 - -
n (rpm) 139.76
Module: m (mm) 4 - -
Teeth number: z (teeth) - 40 100
Pitch circle diameter: d (mm) - 160 400
Addendum diameter: d a (mm) - 168 408
Root diameter: d f (mm) - 150 390
Gear width: b (mm) - 117 112
Speed: v (m/s) 1.17 - -
Material Steel C45
28
Tangential Force(N) 8361.25
Radial Force (N) 3043.25
Normal Force(N) 8897.9
Allowable Calculated
Testing Comment
Value Value
Contact Stress  H (Mpa) 373.22.9 380.6 Satisfies
Bending Stress  F 1 (Mpa) 87.23 259.6 Satisfies
Bending Stress  F 2 (Mpa) 238.8
V. CHECKING OIL LUBRICATION CONDITIONS

The conditions applied for lubricating a two-stage gearbox: [1]
The lowest oil level floods ( (0.75  2) the height h2 (h2  2.25m) of gear 2 ( at least 10mm).
The distance between the lowest and highest oil level hmax  hmin  10...15mm .
1
The highest oil level do not allow to exceed 3 the radius of gear 4 (d a 4 / 6)
1 1
H  d a 2  h2  (10...15)  d a 4 h  10mm
In total, inequality is : 2 3 if 2
1 1
H  d a 2  10  (10...15)  d a 4 h  10mm
2 3 if 2
With the gearbox under my practice, h2  2.25(2.5)  5.625  10mm

1 1
H (350.41)  10  (10...15)  (408)
2 3
150.21  136
 Satisfied the condition
29
30
CHAPTER 4: DESIGNING SHAFTS AND KEYS

I. INITIAL PARAMETERS
Choose shaft material: steel C45 standard quenched as it is suggested for gear boxes with
average load [1]. The other properties of this material [1]):
Hardness: 250 HB
Ultimate stress σ b=850 MPa
Yield stress σ ch=580 MPa
Torque on 1st shaft of gear box: T 1=109.693 Nm
Torque on 2nd shaft of gear box: T 2=668.9 Nm
Torque on 3rd shaft of gear box: T 3=1605.9 Nm
1. Preliminary selection of shaft diameters:
Calculate initial diameters of shaft I:
16T1 16(109.693)
d1  10 3  10 3  28.2 mm d 1=40 mm
   1  25
=> Choose [2]
where: [τ 1 ] is the allowable tangential stress, it is suggested to choose [τ 1 ]=15 … 30 MPa
[1], choose [τ 1 ]=25 for input shaft of gear box
T 1= 109.693 Nm is the torque applied on shaft I
Calculate initial diameters of shaft II
T2 16(668.9)
d 2  10 3  10 3  61.01 mm d 2=63 mm
  2  15
=> Choose [2]
where: [ τ 2 ] is the allowable tangential stress, it is suggested to choose [τ 2 ]=15 … 30 MPa
[1], choose [τ 2 ]=15 for the middle shaft of gear box because has medium torque applied
on it compare to input and output shaft.
T 2= 668.9 Nm is the torque applied on shaft II
Calculate initial diameters of shaft III
16T2 16(1605.9)
d3  10 3  10 3  74.23mm d 3=80 mm
 3  20
=> Choose [2]
where: [ τ 2 ] is the allowable tangential stress, it is suggested to choose [τ 2 ]=15 … 30 MPa
[1], choose [τ 2 ]=20 for output shaft of gear box because has higher torque applied on it
compare to input shaft.
T 3= 1605.9 Nm is the torque applied on shaft III.
2. Determine shaft’s length:
Choose the diameters based on the standard diameter of bearings.
31
All the parameters are suggested to be chosen within a range, choose the minimum values
that satisfy the clearance between elements, both to reduce the cost of material making
the gear box and maintaining the proper working of it.
Important dimensions of shafts:
Mayer length of belt: l 1=( 1.2 ÷1.5 ) d 1=( 48 ÷60 ) mm [2]
Choose l 1=60
Mayer length of coupling: l 3=( 1.2 ÷1.5 ) d 3 =( 96 ÷120 ) mm
Choose l 3=115
Mayer length of Gears:
d ( shaft II )=d 2+2 t=63+2 ( 4.6 )=72.2 mm
d 3 ( shaft II )=d+3.2 r =72.2+3.2 ( 3.5 ) =83.4 mm
Choose d 3 ( shaft II )=85
d ( shaft III ) =d 3 +2t=80+2 ( 5.6 )=91.2 mm
d 3 ( shaftII )  d  3.2r  91.2  3.2(3.5)  102.4mm
Choose d 3 ( shaft II )=105

l m 22=( 1 ÷1.5 ) d 3 ( shaft II )=( 1 ÷1.5 ) 85=( 85 ÷ 127.5 ) ≥ b w2 50 mm
Choose l m 22=85 mm=l m 24 ¿ l m 13
l m 32=l m 24=( 1 ÷ 1.5 ) d3 ( shaft III )=( 1÷ 1.5 ) 105=( 105 ÷ 157.5 ) ≥ b w 3=117 mm
Choose l m 32=117 mm=lm 23
Calculate parameters for shaft II:
L1  L4  0.5(lm 22  w)  e1  0.5(85  55)  10  80mm [2]
w  (50  90)  w2  55
L2  L3  0.5(lm 22  lm 23 )  e2  0.5(85  117)  10  111mm
L1  L2  191
L  2( L1  L2 )  382
Calculate parameters for shaft III:

L1ch  L2ch  L1  L2  191 [2]
2 L1ch  L  382
L1ch  L2 ch  L3ch  382  f  492( f  110)
=>w 3  100
32
Calculate parameters for shaft I:

L2 nh  L4 nh  L1  80 [2]
L1nh  2 L2  2(111)  222
L3nh  f  65
=>w1  50
II.DESIGN PROCESS
1. Shaft I:
T1  109.693 Nm
Force acting on shaft by belt:

Fr  Fy12  1609.4 N
Forces acting on shaft by gear:

Ft1  Fx13  Fx14  2011.24 N
Fr1  Fy13  Fy14  887.2 N
Fa1  Fz13  Fz14  1377.12 N
Reaction Forces acting on shaft:

Moment caused by axial force:
d1 54.54
M a 1=M a 2=F a 1 =1377.12× =37.554 Nm [2]
2 2
Moment equation in YOZ plane at O:
M o  Fy12l12 Fy13l13  Fy14l14  Fy11l11  Fz13r1  Fz14 r1  0
Fy11  [1609.4(65)  887.2(80)  887.2(302)]  382  1161.05 N
Force equation on y axis:

  F1 y  Fy12  Fy10  Fy13  Fy14  Fy11  0
Fy10  1609.4  887.2  887.2  1161.05  996.05 N
In XOZ plane, forces are symmetrical:

Fx10  Fx11  Fx13  Fx14  2011.24 N
33
The other moments are calculated and presented in the diagram on the next page:
34
Equivalent moment:
M tdj  M xj 2  M yj 2  0.75T j 2
[2]
Moment My: Moment Mx: Torque T:
M y10  0 M x10  0 T10  109.693 Nm
M y11  0 M x11  104.611Nm T11  109.693 Nm
M y12  160.9 Nm M x12  191.233 Nm T12  109.693 Nm
M y13  160.9 Nm M x13  130.438 Nm T13  54.85 Nm
M y14  0 M x14  0 T14  0
 M td 10  0  0  0.75(109.693)  94.997 Nm
2
 M td 11  104.611  0.75(109.693)  141.308 Nm

2 2
 M td 12  160.9  191.233  0.75(109.693)  267.363 Nm

2 2 2
 M td 13  160.9  130.438  0.75(54.85)  212.506 Nm

2 2 2
 M td 14  0
Select shaft sections:
Because [ ]  61
32(94.997)(103 )
d10  3  25.13 mm
61 (Belt section) [2]
32(141.308)(103 )
d11  3  28.68 mm
61 (Bearing section)
32(267.363)(103 )
d12  3  35.48 mm
61 (Gear section)
32(212.506)(103 )
d13  3  32.86 mm
d14  0 (Bearing section)
Select diameters of shaft section: d10  34, d11  d14  40

Gear would be machined directly onto shaft I
 I select type of pinion shaft for shaft I.
35
2. Shaft II:
T2  668.9 Nm  T  334.45Nm
Forces acting on shaft by driven gear(gear 2,4):

Ft1  Fx 22  Fx 24  2011.24 N
Fr1  Fy 22  Fy 24  887.2 N
Fa1  Fz 22  Fz 24  1377.12 N
Forces acting on shaft by driving gear (gear 3):

Ft 2  Fx 23  8361.25 N
Fr 2  Fy 23  3043.25 N
Fa 2  0 N

Moment caused by axial force:
d2 345.41
M a 2=F a 2 =1377.12× =237849.3 Nmm=237.85 Nm
2 2
M o   Fy 22l22 Fy 23l23  Fy 24l24  Fz 22 r22  Fz 24 r24  Fy 21l21  0
Fy 21  [-887.2(80)  3043.25(191)  887.2(302)]  382  634.43

  F2y  Fy 20  Fy 22  Fy 23  Fy 24  Fy 21  0
Fy 20  887.2  3043.25  887.2  634.43  634.43 N
Moment equation in XOZ plane at O:

M o  Fx 22l22 Fx 23l23  Fx 24l24  Fx 21l21  0
Fx 21  [2011.24(80)  8361.25(191)  2011.24(302)]  382  6191.87 N
Because forces on X direction are symmetrical:

Fx 20  Fx 21  6191.87 N
36
37
Equivalent moment:
M tdj  M xj 2  M yj 2  0.75T j 2

M y 20  0 M x 20  0 T20  0 Nm
M y 21  495.35 Nm M x 21  288.603Nm T21  334.45 Nm
M y 22  959.4 Nm M x 22  457.503 Nm T22  668.9 Nm
M y 23  495.35 Nm M x 23  288.603 Nm T23  334.45 Nm
M y 24  0 M x 24  0 T24  0
M td 20  0 Nm
M td 21  495.352  288.6032  0.75(334.45) 2  642.304 Nm
M td 22  959.42  457.5032  0.75(668.9) 2  1210.506 Nm
M td 23  M td 21  642.304 Nm
M td 24  0

[ ]  54
d 20  0 mm (Bearing section)
32(642.304)(103 )
d 21  3  49.5 mm
32(1210.506)(103 )
d 22  3  61.12 mm
d 23  d 21  49.5 mm (Gearing section)
d 24  0 (Bearing section)
Select diameters of shaft section : d 20  d 24  55, d 21  d 23  63, d 22  70
38
3. Shaft III:
T3  1605.9 Nm
Forces acting on shaft by driven gear

Ft 3  Fx 23  Fx 32  8361.25 N
Fr 3  Fy 23  Fy 32  3043.25 N
Fa 2  Fa 3  0 N
Forces acting on shaft by coupling: d=80mm => Do  235 [2]

2T3 (103 )
Fx 33  (0.2  0.3)  (2733.45  4100.2) N
235
 Fx 33  2734 N
M o   Fy 32l32 Fy 31l31  0
Fy 31  [3043.25(191)]  382  1521.63N


Because forces on Y axis are symmetrical:
Fy 30  Fy 31  1531.63 N
Moment equation in XOZ plane at O:

M o   Fx 32l32 Fx 31l31  Fx 33l33  0
 Fx 31  [8361.25(191)  2734(492)]  382  659.348 N

  F3x   Fx 30  Fx 32  Fx 31  Fx 33  0
 Fx 30  8361.25  659.348  2734  4967.9 N
39
40
Equivalent moment:
M tdj  M xj 2  M yj 2  0.75T j 2

M y 30  0 M x 30  0 T30  0 Nm
M y 31  948.87 Nm M x 31  290.63Nm T31  1605.9 Nm
M y 32  300.74 Nm M x 32  0 Nm T32  1605.9 Nm
M y 33  0 Nm M x 33  0 Nm T33  1605.9 Nm
 M td 30  0 Nm
 M td 31  948.87  290.63  0.75(1605.9)  1708.51Nm
2 2 2
 M td 32  300.74  0.75(1605.9)  1422.895 Nm

2 2
 M td 33  0.75(1605.9)  1390.75 Nm
2

[ ]  52
d30  0 mm (Bearing section)
32(1708.51)(103 )
d 31  3  69.43 mm
32(1422.895)(103 )
d 32  3  65.3 mm
52 (bearing section)
32(1390.75)(103 )
d 33  3  65mm
52 (coupling)
Select diameters of shaft section: d 30  d32  80, d31  85, d33  75
41
III. SELECTING KEY

Choose flat key (rectangular spunk key) as it is simple and widely used.
l  1.5d
l  (5  10)  lma
Testing the key’s stress and shear strength:

Use keys that has booth smallest l t 1 and d because those sections have the largest stress,
the results in table 4.1 are from, and must satisfy the 2 equations below:
2(103 )T
d     d   100 MPa
dl1t2 [1]
2(103 )T
c     c   (20  30) MPa
dl1b [1]
where:σ d , τ d are calculated stamp stress and shear stress (MPa)
T is torque on shafts (Nmm)
d is shaft diameter at the analyzing section (mm)
l1 is key length at the analyzing section (mm)
h is key height at the analyzing section (mm)
Table: Parameters of keys and strength check table
Section d bxh t2 T(Nm) σd τc

10 34 10x8 3.3 109.693 48.88 16.13
12 42 12x8 3.3 109.693 25.12 8.5
21 63 18x11 4.4 334.45 38.9 9.5

22 70 20x12 4.9 668.9 43.34 10.62
31 85 22x14 5.4 1605.9 79.52 19.5
33 75 20x12 4.9 1605.9 97.11 23.8
42
Table:
l
l1
50 40
63 51
80 62
110 90
110 88
110 90
Lowest values of key are chosen for each shaft (Parts in bold above)
 Recalculate: σ d < [ σ d ] =100 MPa
τ c ≤ [ τ c ] =(20 ….30) MPa
 All the keys satisfy the strength test
IV. CHEKING SHAFT FATIGUE STRENGTH
Shaft’s diameters chosen by using moment formula in section III have not been through
some condition analyses referring to fatigue stress such as period of stress changing, the
concentrated stress, size coefficient, surface quality… That is why strength checking
using the formula below is needed.
s j s j
sj    s
s j 2  s j 2
[1]
where:   is the allowable safety coefficient, choose 3 so that rechecking the shaft
s
hardness is not needed.
s j , s j
: Safety coefficient for bending and torsional stress, determined by the following
formula:
 1
s j 
K  a
   m
 
43
 1
s j 
K
K dj aj  a   m
 
with:  1  0.436 b  0.436(850)  370 MPa is ultimate bending stress corresponding to

each symmetrical cycle for carbon steel.
 1  0.25 b  0.25(850)  212.5MPa is ultimate torsional stress corresponding to each
symmetrical cycle.
where: σ b=850 MPa is the ultimate stress of the C45 steel.
Due to the spinning of shaft so bending stress changes according to the symmetric cycle:
103 M j
σ aj  σ maxj  ;σ mj  0
Wj
[1]
Mj M j  M xj 2  M yj 2
where: is the total bending moment, with:
Wj
is the bending resistance moment for shaft with 1key hole
 d j 3 bt1  d j  t1 
2
Wj  
32 2d j
[1]
with: t1 is key hole depth at shaft section j

b is key width at shaft section j
d j is shaft diameter at section j
Torsional stress changes periodically to working cycle when shaft rotates 1 way:
 maxj 103 T j
 mj   aj  
2 2Woj
where: T j is torque at section j

Woj
resistance torque for shaft with 1 key hole
 d j 3 bt1  d j  t1 
2
Woj  
16 2d j
[1]
with: t1 is key hole depth at shaft section j

b is key width at shaft section j
d j is shaft diameter at section j
44
   0.1;   0.05 are coefficients of affection of average stress to fatigue strength given
σ b=850 MPa. [1]
K σdj ; K τdj are coefficients that are calculated and presented in table 10.9
K  2.05
K  1.9
  1.5
ε σ , ε τ are size coefficient, chosen in table10.10
45
Table 10.4: Parameters for strength check 1
Dimensions ε σ ετ
d 10=34 0.88 0.81
d 12=42 0.84 0.78
d 21=63 0.78 0.74
d 22=70 0.78 0.74
d 31=85 0.73 0.72
d 33=75 0.75 0.73
Table 1:
Section Shaft bxh t1 Wj W oj

diameters
10 34 10x8 5 3240.3 7098.94
12 42 12x8 5 6295.72 13569.3
21 63 18x11 7 21412.31 45960.6
22 70 20x12 7.5 29488.7 63162.6
31 85 22x14 9 53564.24 113855.82
33 75 20x12 7.5 36861.23 78278.7
Table 2: Final parameters
Section d Sσ Sτ σa τa s M(Nm)
10 34 - 17.03 0 7.73 - 0
46
12 42 6 31.42 39.7 4.04 5.89 249.917

21 63 7.9 33.14 26.77 3.64 7.68 573.291
22 70 5.86 22.76 36.04 5.3 5.7 1062.9
31 85 10.67 16.7 18.53 7.05 8.9 992.38
33 75 - 11.6 0 10.26 - 0
All safety factors calculated in table 4.6 are greater than the allowable safety factor [ s ] =2
(which is the middle chosen from the range suggested in [1]).
 The shafts satisfy fatigue condition.
47
CHAPTER 5: SELECTING COUPLING

I. INITIAL PARAMETERS
Torque on motor shaft: T 3 = 1605.9 Nm
Choose flexible coupling as it is widely used, simple, light and cheap, can reduce
resonance, impacts when the load cycle changes.
The material for manufacturing is quenched C45 steel.
II.DESIGN PROCESS
Table: The coupling parameters
d Do dm l1 l2 c dc Z do lo lc Nut
13
70 190 30 55 2..8 24 10 45 44 52 M16
5
Checking the bearing strength of elastic ring:

2kT (103 ) 2(1.45)(1605.9)(103 )
d    2.3 MPa    d   3 MPa
ZD0 d clo 10(190)(24)(44) [1]
Where:
[ σ D ]=3 MPa is allowable bending stress of the elastic ring, chosen based on suggestion in
p.69[1]
k = 1.45 is the middle value chosen from the range in [1], given that our system is the
belt conveyer.
 The elastic ring satisfies the strength test
III. STRENGTH CHECK
Checking the strength:
32kTlc (103 ) 32(1.45)(1605.9)(52)(103 )
F    46.96 MPa    F   70 MPa
 d c 3 D0 Z  (243 )(190)(10) [1]
with: Z , D0 , d c,l 3 ,T are parameters in table 5.1
[ σ F ]=70 MPa is allowable bending stress of the key, chosen based on suggestion in [1]
 The coupling’s key satisfies the strength test
48
CHAPTER 6: SELECTING BEARINGS

I. Shaft I
Shaft diameter at bearing: d 11 =d 14=40 mm
Number of revolution : n1 =887.5 rpm
Working life: We choose a suitable bearing’s service life due to the working time of
gearbox is too large
I select 2-year working life bearings.
Lh  2(200)(2)(8)  6400 [1]
Because the axial forces F a ( F z 13 F z 14 ) automatically cancel each other, I select single-row
ball bearings having below parameter:
Symbol Size d(mm) D(mm) B(mm) r(mm) C(kN) Co(kN)

ligh
208 40 80 18 2 25.6 18.1
t
Reaction forces at bearings:
Radial load acting on Bearing 0: [1]
FR 0  F 2 x10  F 2 y10  2011.242  996.052  2244.37 N
Radial load acting on Bearing 1:

FR1  F 2 x11  F 2 y11  2011.242  1161.052  2322.31N
Because FR 0  FR1 , We choose bearings basing on bearing 1.

Testing the dynamic load of ball bearings
Conventional dynamic load: Q=( XV F r +Y F a ) k t k σ [1]
with: F a=0=¿ X =1, Y =0
V is coefficient of which ring rotate (V =1 when inner ring rotates)
k t is coefficient of temperature k t=1 when temperature θ<100 °
k σ is coefficient of load specificity, k d=1.1(chosen from table [1] for light impact load)
Q  2322.31(1.1)  2554.5
Equivalent dynamic load: [1]
 Qi m Li 3 3 1 (27)  0.7 (14)
3 3
QE  m  2554.5 ( )  2347.1N
 Li 27  14
Testing dynamic load capability: C tt =Q m√ L
49
m is grade of the bending line, m = 3 for ball bearing

L is longevity (million round)
60nLh 60(887.5)(6400)
L   340.8
106 106
[1]
with: Lh=6400 h is longevity of bearing in hours
Ctt  2347.13 340.8  16.4kN  C  25.6kN
Bearings satisfy the dynamic load conditions.
Testing static load capability: Q=( XV F r +Y F a ) k t k σ
With: F a=0=¿ X =1, Y =0
Qo  X o FR  0.6(2322.31)  1393.4
Because Qo  FR , select Qo  Fr  2.322kN  Co  18.1

 Bearings satisfy the static load conditions
II.Shaft II
Shaft diameter at bearing: d 20=d24 =55 mm
Lh  2(200)(2)(8)  6400
Because the axial forces F a ( F z 13 F z 14 ) automatically cancel each other, I select short
cylindrical roller bearings having below parameter:
Symbol Size d(mm) D(mm) B(mm) r(mm) C(kN) Co(kN)

ligh
2211 55 100 21 2.5 43.7 32.9
t
FR 0  F 2 x 20  F 2 y 20  6191.87 2  634.432  6224.3N

FR1  FR 0  6224.3 N

Conventional dynamic load: Q=( XV F r +Y F a ) k t k σ
50
with: F a=0=¿ X =1, Y =0

Q  6224.3(1.1)  6846.7
Equivalent dynamic load:
10 10
10
 Qi m Li 3
10
1 3 (27)  0.7 3 (14)
QE  m  2554.5 (3
)  6311.8 N
 Li 27  14
Testing dynamic load capability: C tt =Q m√ L

10
m is grade of the bending line, m = for cylindrical roller bearing
3
L is longevity (mil round)
60nLh 60(139.76)(6400)
L   53.7
106 106
with: Lh=6400 h is longevity of bearings in hours
10
Ctt  6311.8 3 53.7  20.851kN  C  43.7 kN

With: F a=0=¿ X =1, Y =0
Qo  X o FR  0.6(6224.3)  3734.6
Because Qo  FR , select Qo  Fr  6.224kN  Co  32.9

III. Shaft III
Shaft diameter at bearing: d 30=d32=80 mm
 Lh  2(200)(2)(8)  6400
Because the axial forces F a ( F z 13 F z 14 ) automatically cancel each other, I select single-row
ball bearings having below parameter:
51
C(kN
Symbol Size d(mm) D(mm) B(mm) r(mm) Co(kN)
)
116 Extremely light 80 125 22 2 37.4 31.9
FR 0  F 2 x 30  F 2 y 30  4967.92  1521.632  5195.7 N

FR1  Fx 312  Fy 312  659.3482  1521.632  1658.34 N

Conventional dynamic load: Q=( XV F r +Y F a ) k t k σ
with: F a=0=¿ X =1, Y =0
Q  5195.7(1.1)  5715.27 N
Equivalent dynamic load:
 Qi m Li 103 13 (27)  0.73 (14)
QE  m  5715.273 ( )  5251.22 N
 Li 27  14
Testing dynamic load capability: C d=Q m√ L

m is grade of the bending line, m =3 for ball bearing
L is longevity (mil round)
60nLh 60(55.9)(6400)
L   21.47
106 106
with: Lh=6400 h is longevity of bearings in hours
Ctt  5251.22 3 21.47  14.595kN  C  37.4kN
With: F a=0=¿ X =1, Y =0
Qo  X o FR  0.6(5195.7)  3117.42
Because Qo  FR , select Qo  Fr  3.117 kN  Co  31.9kN
52
Table: Chosen bearings
Shaft Symbol d(mm) D(mm) B(mm) C(kN) Co(kN)

1 208 40 80 18 25.6 18.1
2 2211 55 100 21 43.7 32.9
3 116 80 125 22 37.4 31.9
53
CHAPTER 7: DESIGNING GEAR BOX COVER AND EXTRA

DETAILS
I. DESIGNING THE GEAR BOX COVER
Use the material to make the cover is gray cast iron GX15 as it is mostly used, the gear
box is made by casting as the method can provide great hardness and light weight.
The parameters for the gear box cover are chosen based on table in [2]
Table: Parameters of gear box cover
The thickness of Gear box body:   0.025(280)  3  10  6mm

The thickness of gear box cover: 1  0.02(280)  3  8.6 , choose 1=9 mm
The thickness of gear harness

 3  (0.8...1)  10mm
plate’s box cover:
The length of Hardness plate:

¿( 0.9 …1)=( 9 …10) mm
inside:
¿ 0.5 δ =5 mm
outside h:
h g=5 δ =50 mm
height of plate:
Diameters:
Based bolt, d 1 d 1=( 0.03 … .0 .036 ) 280+12=(20.4 … 22)mm
 Choose d 1=22 mm
d 2=(0.7 … 0.75)d 1=(15.4 …16.5)mm
Bearing side bolt,d 2  Choose d 2=16 mm
d 3=(0.5 … 0.6) d 1=(11 …13.2) mm
Body-cover-assembly bolt,d 3  Choose d 3=12 mm
d 4 =10 mm
Screw for cover assembly,d 4 d 5=8 mm
Screw for lid,d 5 d 01=24 mm
The diameters of bolt hole: d 02=17 mm
d 03=13 mm
d 04=11 mm
54
The thickness of the flange:

Thickness of body’s flange, s2 s2=( 1.5 ÷ 1.8 ) δ =( 15÷ 18 )
 Choose S2=18
Thickness of cover’s flange, s1 s1=(1.5 ÷1.75) 1=(13.5 ÷ 15.75)
 Choose S1=16
Widths: S1=K 1 +1.5 δ =52+15=67 mm
S2=K 2+1.5 δ =40+15=55 mm
S3=K 3+1.5 δ=33+ 15=48 mm
S4 =K 4 +1.5 δ=28+ 15=43 mm
Thickness of bottom’s flange q=2.35 δ=23.5
The bearing seat areas:
Tightening bolt position at flanges: C 1=27 mm

C 2=21 mm
C 3=18 mm
C 4=15 mm
Gap between elements:

Between gears and gear box inner c 1=( 1 … 1.2 ) δ=10 mm
wall
Number of based bolt Z Use z=4 bolts
The space between the gearbox

body’s bottom and outer face of Y ≥ 4 c 1 ≈ 4.8 δ =48 mm
gears
The thickness of gearbox cover and H ≥ 2( s + s )=68 mm

1 1 2
bottom at the position of bearings
55
II. LUBRICATING THE GEAR BOX

Apply the method of soaking the gear box’s inner elements in oil, as it is common and
suitable for gears with speed lower than 12 m/s.
III. EXTRA DETAILS [2]
1. Oil barriers
Do not allow oil to contact with details
2. Dowel pins
To ensure the location between Top and Front part and after machining and assembly, we
two dowel pins. The function is when tightening bolts, it helps avoid outer deformation
of bearing
d c =( 0.7 … 0.8 ) d 3=8 , l=50
3. Observation cap
56
Information of observation in [1]
A B A1 B1 C K R Bolt Number
150 100 190 140 175 120 12 M8x22 4
4. Vent plug
Parameter of vent plug in [1]
A B C D E G H J l K L M N O Q P R
M27x2 15 30 15 45 36 32 6 4 10 8 22 6 32 18 36 32
5. Oil drain plug
d1 D D1 L l b s t d2 D2 D2
M20x1.
30 25.4 30 15 4 22 2.5 20 32 3
5
6. Oil level indicator
57
d d1 d2 D D1 L1 l l1 b
M12x1.2
5 6 18 12 30 12 6 3
5
7. Ring bolt
d d1 d2 d3 d4 b h h1 l l1 r1 d5 l2
M12 54 30 12 30 14 18 10 25 >19 6 17 26
8. Roller bearing cover

Roller bearing cover made of gray cast iron GX15
58
Shaft D D1 D2 D3 d d1 n H b
I 75 90 110 64 9 15 4 12 4
II 100 110 130 80 9 15 6 12 4
III 120 140 170 110 11 18 6 15 5
9. Bushing
Thickness: δ =8 mm , made by gray cast iron
10. Seal Ring
a. Inside
d d1 B r S b l
55 52 2.2 0.2 2 5.4 6
b. Outside
d d1 B r S b l
60 68 1.9 0.2 1.7 5.8 16
59
CHAPTER 8: TOLERANCE ASSEMBLY

1. Tolerances of gear assembly [2]
Lower limit(  m
Upper limit(  m )
Joint ) Nmax Smax
ES es EI ei
∅ 42 H 7 /k 6 25 18 0 2 18 23
∅ 63 H 7 /k 6 30 21 0 2 21 28
∅ 70 H 7 /k 6 30 21 0 2 21 28
∅ 85 H 7 /k 6 30 25 0 3 25 32
2. Tolerances of bearing:
Lower limit(  m
Upper limit(  m )
Joint )
ES es EI ei
∅ 40 k 6 - 18 - 2
∅ 55 k 6 - 21 - 2
∅ 80 k 6 - 25 - 3
∅ 80 H 7 30 - 0 -
∅ 90 H 7 35 - 0 -
∅ 125 H 7 40 - 0 -
3. Tolerances of key
Width deviation of key Keyway depth

Section Shaft bush Shaft’s Bush’s
deviatio deviation
H9 D10 n t1 t2
0.120
10 x 8 0.036 0.2 0.2
0.050
0.120
12 x 8 0.043 0.2 0.2
0.050
0.120
18 x 11 0.043 0.2 0.2
0.050
20 x 12 0.052 0.149 0.2 0.2
60
0.065
0.149
22x14 0.052 0.2 0.2
0.065
0.149
20x12 0.052 0.2 0.2
0.065
1.
61
REFERENCES
[1] Nguyễn Hữu Lộc. Cơ sở Thiết Kế Máy. 2018
[2] Nguyễn Hữu Lộc .Thiết kế chi tiết và Chi tiết máy.2020
62
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HO CHI MINH CITY UNIVERSITY OF

DESIGN PROJECT REPORT

Ho Chi Minh City, June, 2020

TRƯỜNG ĐẠI HỌC BÁCH KHOA TP. HCM

NỘI DUNG THUYẾT MINH

3. Chọn dung sai lắp ghép.

Content for Report

III. Shaft III................................................................................................................49

CHAPTER 1: SELECT MOTOR AND TRANSMISSION RATIO

12 (27)  0.7 2 (14)

Ƞ=Ƞ coupling Ƞ b Ƞ spurgear Ƞ helicalgear Ƞ 4bearing [1]

where: uh : Transmission ratio of gearbox, choose uh = 16

Choose motor according to table appendix 3, page 737 [1]

I choose the motor base on the catalogue of VIHEM company

Power (kW) Rotational speed

3K160S2 11 15 2840 3.0

3K160M2 15 20 2940 3.1

3K160L2 18.5 25 2940 2.2

Shaft rotational speed:

Table of properties: (using average power and average torque)

CHAPTER 2: DESIGNING BELT DRIVE

Type bp b0 h Length y0 A of T1 d1 min

Basing on the standard, d1  160,   0.01

Or : 2(d1  d 2 )  a  0.55(d1  d 2 )  10.5

The outer diameter of smaller pulley: d a1  d1  2b  160  2(4.2)  168.4

The outer diameter of larger pulley: d a 2  d 2  2b  500  2(4.2)  508.4

Where:  0  1.5Mpa, A  138 ( V-belt)

12. Calculation of Allowable stress  max

Where:   1200kg / m is specific weight of belt

Where: E  100 N / m is elastic modulus

Thus  max   1   u1   v   0  0.5 t   v   u1

PARAMETER OF BELT DRIVE

CHAPTER 3: DESIGNING GEARS TRANSMISSION

N HO 2  30 H 2 2.4  30(2302.4 )  1.397(107 ) revolutions

N FO1  N FO 2  5(106 ) revolutions

Numbers of corresponding stress-changing cycles (based on the load diagram):

N HE1  60(1)      (887.5)(25600)

N FE1  60(1)      (25600)887.5

 Condition : 433.63  405  542.04 1.25 (no satisfies)

Calculate the allowable stress when overload:

Driven gear teeth:

Relative error of transmission ratio:

Tangential force: Fr1  8361.25 tan 20  3043.25 N  Fr 2

Calculate contact stress [1]

tan  nw tan 20

K H : coefficient of static load:

where: K H  1 .13 is undistributed load coefficient, chosen above

Calculating precisely the allowable contacting stress:

ZV  0.85  v 0.1  0.85  1.17 0.1  0.863

Efficiency of safety: S H  1.1

 The gears satisfy the contact stress test

Calculating precisely the allowable bending stress for both gears:

Y  1.082  0.172lg  m   1.082  0.172lg  4   0.98

The coefficient of teeth type following to experimental formula:

III. Calculation for helical spur gear drive (high level):

 18.85 teech> z1 >¿ 16.68 teeth => Select z 1=18

 Satisfies the condition of helical angle: 30    40

Determine helical spur gear dimensions

Geometry parameters of the gears

d f 2  d 2  2.5m  345.41  2.52  339.16 mm

Ft1 (tan aw ) 2011.24 tan(20)

Axial Force: Fa  2011.24 tan(34.4)  1377.12 N

tan  nw tan 20

K H : coefficient of static load: