Trường Đại Học Bách Khoa

Vietnam National University
HO CHI MINH UNIVERSITY OF TECHNOLOGY
DESIGN PROJECT
Name: HOANG NGOC ANH DUY
Student’s ID: 1952611
Instructor: PhD Lê Thanh Long
SEMESTER 202 , 2021
1
DESIGN PROJECT - 2021 Instructor: Le Thanh Long
TOPIC
Topic 15: CONVEYOR DRIVE SYSTEM DESIGN
Option: 15
Conveyor drive system include:

1) Asynchronous 3 Phase Electric Motor
2) Ladder Belt Transmitter
3) 2-stages cylindrical bevel gear speed reducer
4) Elastic shaft connection
5) Conveyor belt
 One-way rotation, light impact load, 1 8-hour shift
Given data:
- Ring force on conveyor belt F: 5300 N
- Conveyor speed v: 1.6 m/s
- Cable drum diameter D: 250 mm
- Service time L: 5 years
- Number of working days in a year Kng: 290 days
- Number of shifts for the day: 1
- t1: 29 sec
- t2: 16 sec
- T1: T
- T2: 0.8T
Hoang Ngoc Anh Duy – 1952611 1

PREFACE
Our country is on the way of development, so science and technology play an important role
in the process of industrialization and modernization of the country. The application of science and
technology is increase labor productivity, replace labor force of workers in the most effective way,
ensure the safety of workers during work. To create a good foundation for the development step In
the future, we need to invest, research, educate, develop science and technology one by one seriously
from within the university.
The Machine Detail course project is a subject that helps students in Machine Building take steps.
Toddling, get acquainted with the design work that every mechanical engineer will attach his or her
life to go there. Studying well in this subject will help students envision future jobs, through That has
a more correct view of the learning path and at the same time increases enthusiasm, love profession
for each student. Not only that, the process of implementing the project will be a real challenge for
them with skills that students have learned from previous years such as mechanical drawing, user
skills software: Autocad, Autocad Mechanical, Autodesk Inventor… along with the knowledge in
Foundation subjects: Machine Principles, Machine Details, Tolerances and Measuring Techniques…
Since this is the first technical design we've done, it's bound to happen shortcomings and mistakes. I
look forward to receiving honest feedback from the teachers. I'm sorry
Sincere thanks.

CONTENTS
1) Select electric motors and distribute transmission ratios..........................................................................4
1.1) Select electric motors..........................................................................................................................4
1.2) Feature table......................................................................................................................................5
2) Design of ladder belt transmission............................................................................................................7
3) Design of the transmission in the reducer...............................................................................................10
3.1) Calculation and design of cylindrical bevel gear transmission.........................................................10
3.2) Calculation and design of bevel gear transmission..........................................................................13
3.3) Check lubrication and oil immersion..............................................................................................16
4) Shaft design.............................................................................................................................................18
4.1) Shaft I...............................................................................................................................................18
4.2) Shaft II.............................................................................................................................................24
4.3) Shaft III...........................................................................................................................................27
4.4) Shaft test..........................................................................................................................................30
5) Select the bearing and connect the shaft:...............................................................................................33
5.1) Input shaft 1:....................................................................................................................................33
5.2) Intermediate shaft 2.........................................................................................................................35
5.3) Output shaft 3:.................................................................................................................................36
5.4) Select elastic ring shaft connection:.................................................................................................37
6) Box design and additional details...........................................................................................................39
6.1) Shaft bearing size.............................................................................................................................39
6.2) Ingredient details.............................................................................................................................40
7) Selection of lubricating oil and mounting tolerances...............................................................................41
7.1) Gearbox lubricating oil:......................................................................................................................42
7.2) Mounting Tolerance..........................................................................................................................43
References...................................................................................................................................................44

1.1) DETERMINE THE ENGINE
1.1.1) Determine the efficiency of the system
ŋk= 0.99; ŋol= 0.99; ŋbrc= 0.97; ŋbrn= 0.97; ŋđ= 0.96
ŋtotal= ŋk* ŋol3 *ŋbrc* ŋbrt *ŋx = 0.87
1.1.2) Calculate power needed
Fv 5300∗1.6
Plv = 1000 = 1000
= 8.58 kW
√
i
Ti 2
∑ ( T ) ti
√
2
Ptt = Ptd = P 1
= 8.58 1∗29+0.8 ∗16 = 8.012 kW
i 29+ 16
∑ ti
1
P tt 8.012
Power needed: Pct = = 0.87 = 9.21 kW
ŋ
1.1.3) Determine preliminary rotation number of the engine
60∗1000∗V 60∗1000∗1.6
nlv= πD
= π∗250
= 37.18 rpm
uch = uh*uđ = 15*4 = 60

nsb = nlv*uch = 37.18*60 = 2230.8rpm
1.1.4) Choose electric engine
{
dc
P ≥ P =9.21 kW
Engine: n dc≈ n =2230.8
sb
ct
rpm
I choose: 4A132M2Y3 n dc=2907 rpm

dc
{ P =11.0 kW
1.2) TRANSMISSION RATIO DISTRIBUTION

n dc 2907
uch = n =¿ 37.18 = 76.105
lv
choose uđ = 4
uch 76.105
uh = u = 4 = 19
đ
Follow 3.21
U1 = 5 => U2 = 3.8
1.3) SPECIAL VALUES TABLE
1.3.1) Calculate power in shafts
Pmax 8.4
P3 = ŋ = 0.99 = 8.49 kW
kn
P3 8.49
P2 = ŋ ∗ŋ = 0.97∗0.99 = 8.84 kW
ol brn
P2 8.84
P1 = ŋ ∗ŋ = 0.97∗0.99 = 9.2 kW
ol brc
P2 9.2
Pdc = ŋ ∗ŋ = 0.99∗0.96 = 9.7 kW
ol đ
1.3.2) Calculate rotation speed of shafts
ndc 2907
n1 = u = 4 = 725.5 rpm
đ
n1 725.5
n2 = u = 5
= 145.1 rpm
brc
n2 145.1
n3 = u = 3.8 = 38.18 rpm
brn
1.3.3) Calculate torque in shafts

6
9.55∗10 ∗Pdc 6
9.55∗10 ∗9.6
Tdc = = = 32457.52 Nmm
n dc 2907
6
9.55∗10 ∗P1 9.55∗10 6∗9.2
T1 = = = 64915.03 Nmm
n1 725.5
9.55∗10 6∗P2 9.55∗10 6∗8.84
T2 = = = 215131.98 Nmm
n2 145.1
6
9.55∗10 ∗P3 9.55∗10 6∗8.49
T3 = = = 683665.37 Nmm
n3 38.18
9.55∗10 6∗P 9.55∗10 6∗8.4

Ttải = nct
= = 719590.12 Nmm
38.197
Engine 1 2 3 Tải
Power (kW) 9.6 9.2 8.84 8.49 8.4
Ratio trans u 4 5 3.8 1
Speed (rpm) 2907 725.5 145.1 38.18 38.18

Torque (Nmm)32457.52 64915.03 215131.98 683665.37 719590.12
2) TRAPEZOIDAL BELT TRANSMITTER DESIGN
Power: P = 9.88
Transmittion ratio: u = 4
Speed ndc = 2907 rpm
2.1) Calculation
According to the picture, we choose type B

According to table 4.13, I choose small pulley follow the standard
d1 = 140 mm bp=14(mm); bo=17(mm); h=10,5(mm); yo=4(mm); A=138(mm2)
Speed of belt:
π d 1 n1 π ×140 ×2907
v= 4
= 4 = 21.31 m/s
6. 10 6. 10

Diameter of big pulley

Choose ξ = 0.02
d 2=u 1 × d1 ( 1−ξ )=2×140 ( 1−0.02 )=411.6 mm
According to table 4.26, I choose d2 = 450mm
Actual transmission ratio
d2 4 50
utt = = =¿ 2.04
d1 (1−ξ) 140(1−0.02)
Error:
|utt−u 1| |2.04−2|
∆ u= ×100= ×100=3.28 %< 4 % accepted
u1 2
Choose length of shaft a = 0.95d2 = 532mm

Length of belt
π ( d 2+ d 1 ) ( d 2−d 1) 2 π (560+ 140 ) ( 560−140 )
2
L=2 a+ + = 2 532+ + =2 329.35 mm

2 4a 2 4 336
According to table 4.13 choose length of belt follow standard L = 2500 mm

Test number of revolution in 1 sec
v 21,3
i= = =8,51 s−1 < 10, accepted
L 2,5
Calculate a with L = 2500
a=
√
2 L−π (d 1+ d 2)+ [2 L−π ( d 2+ d 1) ] −8(d 2−d 1) 2× 1 400−π ( 140+280 ) + √[2 ×1400−π ( 280+140 ) ]2 −8(280
2
=
2
8 8
Belt contact
d 2−d 1 5 60−140
α 1=1800−570 =180 0−570 =158.04 0=2,42 rad
a 363.39
Coefficient considering the effect of the belt contact

C α =1,24 ( 1−e )=1,24 (1−e−158.04 /110)=0.95
−α1 /110

According to table 4.17 coefficients affect the transmission ratio

C u=1.13
The coefficient considering the effect of load Cr = 0.7

The coefficient considering the effect of belt length CL = 0.95 (*4.16)
According to table 4.19, choose [P0] = 5kW when d1 = 140mm; v=21.3m/s; Type B
The coefficient considering the effect of Cz = 0.95 (*4.18)

The coefficient of dynamic load Kđ = 1,3 (*4.7)
P1 Kđ 9,8 8 ×1,3
Z = P C C C C = 5 × 0,95× 1,13× 0.95 ×0,95 = 2.65
[ 0] α u L z
Choose z = 3 => Cz = 0.95
Belt width
B = ( z−1 ) t+2 e=( 3−1 ) × 19+2× 12,5 = 63mm
Outer diameter
d n 1=d1 +2 h0 =140+2× 4,2=148,4 mm
d n 2=d2 +2 h0 =560+2× 4,2=568,4 mm
Tension for each belt

P1 Kđ 2 9,88.1,3 2
F 0=780 +q m v =780 + 0,178.21,3 =250 N
v Cα z 21,3.0,95 .3
Force on the shaft

α1 158.04 °
F=2 F 0 z sin =2 ×2 45.79 ×3 × sin =¿ 1447.74 N ¿
2 2
Special value table
Name Sign Value
Type B
Small belt diameter d1 140 mm
Large belt diameter d2 560 mm

Belt width b 63 mm
Belt length L 2500 mm
Shaft distance a 5 65.2mm
Belt contact 1 2.42 rad

Initial tension F0 250 N N
Force on the shaft F 1447.74 N
Number of belt z 3

3) Design the transmitter in the gearbox
3.1) Calculation and design of bevel gear transmitter

3.1.1) Initial values
T 1=121114,5 Nmm.
u1=5
n1 =725,5 rpm
P1=9,2 kW
3.1.2) Choose the material for the Driving gear and driven gear.
Choosing steel 45 is tempered. According to table 6.1 for driving gear, we choose the
average solidity of HB1 =285,, For the driven gear, we choose the average solidity
HB2=275, this material has good trawling ability.
NHO1=30HB12,4=30.2852,4=2,34.107cycles
NHO2=30HB22,4=30.2752,4=2,14.107cycles
NF01=NF02= 5.106 cycles
According to table 6.2, the limit of contact fatigue and bending of gears is determined as
σ 0H lim = 2HB+70,
σ H lim1 =2.285+70=640Mpa
σ 0H lim 2 =2.250+70=620Mpa
σ 0F lim =1,8HB,
σ 0F lim 1 =1,8.285=513Mpa
σ 0F lim 2 = 1,8.275=495Mpa
Contact stress
σ 0 H lim ¿.1
[ σ H ]= SF
K HL ¿
Tempered process S H =1,1:

640.1
[σ H1]= 1,1 = 581,82 MPa
620.1
[σ H2]= 1,1 = 563,64 MPa
[σ H]sb=min{[σ H1], [σ H2]) =563,64 Mpa

σ 0 Flim
Allowable bending stress: [σ F]= sF
KFL
S F=1,75 :
513
[σ F1]= 1,75 .1,1=322,46 Mpa
495
[σ F2]= 1,75 .1,1=311,14 Mpa
3.1.3) Basic value
Choose gear width coefficient ψ be =0,285
ψ be .u
=0,66
2−ψ be
Choose K Hβ=1,13 ; K Fβ=1,25 (*6.21)
Outer effective diameter:
d e 1=100.
Outer taper length

√
3 T 1 . K Hβ
2
(1−ψ be )ψ be . u[σ H ]
=100. 3
√ 121114,5.1,13
(1−0,285).0,285 .5.433,6 3 2
=89,4 mm
Re =K R . √ u +1 .
2
3.1.4) Matching parameters

√3 T 1 . K Hβ
(1−ψ be )ψ be . u[σ H ]
2
=50. √5 +1 . 3
2
√ 121114,5.1,13
(1−0,285).0,285 .5 .433,63
2
=228 mm
(*6.22): choose z1p=17

z1=1,6.z1p=27,2
Averaged diameter d m 1=( 1−0,5 ψ be ) . d e1 =76,7 mm
m1 76,7 d
Averaged modun mtm= z = 27,2 =2,82 mm
1
tm m2,82
Modun: mte= 1−0,5ψ = 1−0,5.0,285 =3,28 => choose mte=3
be
te m 3
Re-calculate: mtm= 1−0,5 ψ = 1−0,5.0,285 =3,5
be
m1d76,7
Re-calculate: z 1= m = 3,5 =21,9=¿ c hoose z 1=22
tm
Re-calculate: d m 1=mtm . z 1=3,5.22=77 mm ;d m 2=mtm . z 2=¿ 110.3,5=385mm

z 2=u z 1=5.22=110
−1 1 ο z ο ο
Split taper angle: δ 1=tan z =11,3 ; δ 2=90 −δ 1=78,7
2
Gear rim width: b=Re ψ be =228.0,285=65mm

Ring diameter: de1=mte.z1=3.22=66mm; de2=mtez2=3.110=330mm

Outer tooth head height: h ae 1=mte=3; hae 2=2 mte−hae 1=3
Outer tooth peak diameter: d ae 1=d e 1+2 h ae 1 cos δ1=72 mm ; d ae 2=331mm
3.1.5) Gear ring speed:
π d m 1 n1 π .725,5 .77
v= = 60000 =2,92 m/s
60000
3.1.6) Dynamic load coefficient
vH b dm1 9,43.65 .77
K Hv =1+ =1+ =1,17
2 T 1 K Hβ K Hα 2.121114,5 .1,13 .1
(*6.13) we choose the exact level of the transmitter is 8. δ H is the value that takes into
account the effect of the misalignment error, according to table 6.15 with the straight
tooth shape, then δ H =0,006. g0 is the factor that takes into account the effect of tooth
pitch deviation, according to table 6.16 with the smooth working accuracy class of 8
strokes. g0 =56. So:
K Hα= 1
v H =δ H g0 v
√ d m 1 ( u+1 )
u
=0,006.56 .2,92
√
77(5+1)
5
=9,43 m/s
 K H =K Hα K Hβ K Hv=1.1,17.1,13=1,9
3.1.7) Calculation and testing of contact stress values:
√ 2.T 1 . K H . √ u +1
√ 2.121114,5 .1,9 √( 5 + 1)
2 2
σ H =Z H . Z M . Z ε 2
=1,76.274 .0,87 2
=¿ 502,2MPa
0,85. b .d m 1 .u 0,85.65 .77 .5
Z M =274 Mpa 1/2
( *6.5)
Z H = 1,76
Z ε= √ (4−ε α )/ 3=0,87
[
ε α = 1,88−3,2
( 1 1
+
z1 z2 )]
=1,7
(*6.1): [ σ H ]=[ σ H ]sb z v z R K xH =0,95.0,95.1 .563,64=508,7MPa

z v =0,85 v 0,1=0,85. 2,920,1=0,95 z R : The coefficient taking into account surface roughness,
with Rα =2,5÷ 1,25 μm choose z α =0,95
K xH : The coefficient taking into account the effect of gear size, with d α <700 mm
¿> K xH =1
2
σH
Re-calculate b=ψ be Re ( ) =¿63,33mm
[σ H ]
3.1.8) Bending strength test

Tooth form coefficient YF

Driving gear: YF1= 3,85
Driven gear: YF2= 3,6
Comparative characteristics of gear strength (bending strength):
[σ F 1 ] 322,46
Driving gear: Y = 3,85 =83,75
F1
[ σ F2] 311,14
Driven gear: Y = 3,6 =86,427
F2
We test the bending strength according to the lower strength guide wheel
The bending stress is calculated according to the formula:
2T K F Y ε Y β Y F 1 2.121114,5.1,6 .1 .3,85
σ F 1= = 0,85.77 .65 .3,5 =100,21MPa≤ 322,46Mpa
0,85 d m 1 . b . mtm
K F=K Fβ K Fα K Fv =1,25.1 .1,41=1,6
vF b dm1 25,15.65.77
K Fv =1+ =1+ =1,41
2 T K Fβ K Fα 2.121114,5 .1,25.1
v F =δ F g0 v
√ dm 1 ( u+1 )
u √
=0,016.56 .2,92
77(5+1)
5
=25,15 m/s
Accepted
3.2. Calculation and design of helical gear transmission.

3.2.1) Initial parameters
T 2=581819,4 Nmm.
u2=3,8
n2 =145,1 rpm
P2=8,84
3.2.2) Choose the material for the Driving gear and driven gear.
Choosing steel 45 is tempered. According to table 6.1 for driving gear, we choose the
average solidity of HB1 =285,, For the driven gear, we choose the average solidity
HB2=275, this material has good trawling ability.
Number of basic duty cycles:
NHO1=30HB12,4=30.2852,4=2,34.107cycles
NHO2=30HB22,4=30.2752,4=2,14.107cycles
NF01=NF02= 5.106 cycles

(* 6.2), Gears bending and contact fatigue limits are determined:

σ 0H lim = 2HB+70,
σ H lim1 =2.285+70=640Mpa
σ 0H lim 2 =2.250+70=620Mpa
σ 0F lim =1,8HB,
σ 0F lim 1 =1,8.285=513Mpa
σ 0F lim 2 = 1,8.275=495Mpa
Preliminary allowable contact stress
σ 0 H lim ¿.1
[ σ H ]= SF
K HL ¿
Tempered process S H =1,1:

640.1
[σ H1]= 1,1 = 581,82 MPa
620.1
[σ H2]= 1,1 = 563,64 MPa
Preliminary allowable contact stress
1 1
( [ σ H 1 ] + [ σ H 2 ] )= ( 581,82+563,64 ) =572,73
[σ H ]sb =
2 2
σ 0 Flim
Allowable bending stress: [σ F]= sF KFL Choose S F=1,75 ,
513
[σ F1]= 1,75 .1,1=322,46 Mpa
495
[σ F2]= 1,75 .1,1=311,14 MPa
3.2.3) Basic parameters of the transmitter
According to table 6.6 because the gear is asymmetrical in the shaft, choose ψ ba=0,3
according to the standard, then:
ψ ba .(u+1)
ψ bd= =0,72
2
(*6.7), choose KHβ=1,05; KFβ=1,12
Gear pair material dependence factor: K a =43( MPa)1 /3
Gear transmission shaft distance
√ √
T 2 K Hβ 581819,4.1,05
a w =K a ( u2 +1 ) 3 2
=43 ( 3,8+1 ) 3 2
=243,1 mm
ψ ba [ σ H ] u2 0,3. 572,73 .3,8
Choose: aw= 250 mm
Modun

m=(0,01÷0,02) aw= 2,5÷ 5mm

Choose mn=3 mm
3.2.4) Matching parameters
From 20° ≥ β ≥8°
2 aw cos 20 ° 2 aw cos 8 ° 2.250 . cos 20 ° ( 2.250 . cos 8 ° )
 ≤ z1 ≤ ≤¿ ≤ z1 ≤
m ( u± 1 ) m ( u ±1 ) 3 (3,8+ 1 ) 3 ( 3,8+ 1 )
32,63 ≤ z 1 ≤34,38
Choose z1=33
=> z2=z1.u2=33.3,8=125,4
Choose z2=125
Tooth tilt angle:
−1 ( z 1+ z 2 ) −1 33+125
β=cos m =cos 3 =18,6 °
2 aw 250.2
2 z
125
Ratio: u2= z = 33 =3,8
1
Re-calculate:
m( z1 + z 2) 3(125+33)
a w= = =250
2cos β 2 cos 18,6 °
Using non-aligned teeth x 1=x 2=0
−1 tan α −1 tan 20 °
Matching angle: α tw =αt =tan cos β =tan cos 18,6 ° =21 °
Ring diameter:
m z1
d 1= =104,45 mm
cos β
m z2
d 2= =395,67 mm
cos β
Diameter of top ring:
da1= d1+2m=104,45+2.3=110,45mm
da2= d2+2m=448+2.3=401,67mm
3.2.5) Gear ring speed:
π d 1 nII π .104,45.145,1
v= = =¿ 0,79 m/s
60000 60000
According to table 6.13, we choose the correct level 9, vgh=4 m/s
3.2.6) Dynamic load factor according to P2.3 we choose:
K HV =1,01 ; K Fv =1,04

3.2.7) Load factor unevenly distributed between gears, table 6.14:

K Hα =1,13; K Fα =1,37
3.2.8) Calculation and testing of contact stress values:
σ H=
dw 1
Z M =274 ( *6.5)
√
bw .u
=
104,17 √
Z H . Z M . Zε 2 T K H (u+1) 1,69.274 .0,77 2. 581819,4.1,2.(3,8+1)
75.3,8
=524,9MPa
ZH=
√ 2cos βb
sin 2α t
−1
= 1,69
−1
β b=tan cos α t tan β=tan cos 21° tan18,6 °=17,44 °
Z ε= √ 1/ε α =0,77
[
ε α = 1,88−3,2
( z1 + z1 )] ×cos β =1,67
1 2
2 aw
d w 1= =104,17 mm
( u+1 )
b w =a w ψ ba=75 mm
K H =K HV K Hα K Hβ =¿1,01.1,13.1,05=1,2
(*6.1)
[ σ H ]=[ σ H ]sb z v z R K xH =1.1.0,95 .572,73=544,1 MPa>σ H =524,9 MPa
z v =1: Ring speed influence factor
z R =0,95 : Surface roughness factor
K xH =1 : Factor taking into account the effect of gear size
Recalculate the rim width
2
σH
b w =ψ ba aw ( ) =70mm
[σ H ]
3.2.9) Bending strength test
Hệ số dạng răng YF:
z1 33 z2 125
zv1= 3 = 3 = 34,81 ; zv2= 3 = 3 =131,89
cosβ cos 18,6 ° cosβ cos 18,6 °
Driving gear: YF1= 3,7
Driven gear: YF2= 3,6
Comparative characteristics of gear strength (bending strength):
[σ F 1 ] 581,82
Driving gear: Y = 3,7 =157,25
F1

[ σ F2] 563,64
Driven gear: Y = 3,6 =156,57
F2
We test the flexural strength in the lead wheel with lower strength
The bending stress is calculated according to the formula:
2 T K F Y ε Y β Y F 1 2.581819,4 .1,6 .0,6 .0,87 .3,7
σ F1= = =153,42MPa≤ 157,25Mpa
dw 1bw m 75.104,17 .3
K F=K Fβ K Fα K Fv =1,37.1,04 .1,12=1,6
1 1
Y ε= = =0,6
ε α 1,67
β 18,6 °
Y β=1− =1− =0,87Accepted
140 ° 140 °
Parameters Bevel gear Helical gear

Torque (Nmm) 121114,5 581819,4
Ratio 5 3.8
Speed rpm 725,5 145,1
Shaft distance(mm) 250
Modun(mm) 3 3
z1
22 33
z2
110 125
δ 1=11,3o ;
Tooth tilt angle 18,6o
δ 2=78,7 o
66 104,45
Ring diameter(mm)
330 395,67
Width(mm) 63,33 70

65
Speed(m/s) 2,92 0,79
3.3. Check lubrication and oil immersion

Conditions of oil-immersed lubrication in conical-cylindrical reducers:
The bevel gear needs to be immersed in the full width of the large gear h in oil
The helical spur gear should be fully immersed in the tooth height hr and at least 10mm.
1
The highest level of oil does not exceed 3 R gear 4.
Distance between highest and lowest oil level: h max−h min=10÷ 15 mm
3.3.9) Driven bevel gear
The minimum height of the driven bevel gear that needs to be immersed in oil is
h2 min =2,25 m=2,25.3=6,75<10 mm
1 1 1 1
H 1= d ae 2−10−15= .331−10−15=140,5> d a 4= .401,67=134 mm
2 2 3 3
3.3.10) Driven helical gear
The minimum height of the driven cylindrical gear to be immersed in the oil is
h 4 min =2,25 m=2,25.3=6,75< 10 mm
1 1 1 1
H 2= d a 4−10−15= .401,67−10−15=175,84> d a 4= .401,67=134 mm
2 2 3 3

Therefore, the transmission is satisfied with the lubrication condition

4) SHAFT DESIGN
4.1) SHAFT I
4.1.1) Initial parameters:
T 1=121114,5 Nmm
n1 =725,5rpm
b w =63,33 mm
4.1.2) Choosing material:
Material selection is normalized C45 steel. Parameters:
σ b=600 MPa
σ ch=340 MPa
Allowable torsional stress: [ τ ]=15 ÷ 30 MPa choose [ τ 1 ] =15
4.1.3) Preliminary selection of diameter::
Preliminary calculated diameter:
d 1=
√
T1
3
0,2 [ τ ]
=
√3 121114,5
0,2.15
Choose d 1=50 mm (*10.2)
=34,3 mm
4.1.4) Bearing width:

Choose b 1=27 mm (*10.2)
4.1.5) Calculation of the outline size of the shaft:
l 11=( 2,5 ÷3 ) d 1=125 ÷ 150 choose l 11 =125 mm
l 13=l 11+ k 1 +k 2 +l m 13+ 0,5 ¿
We have:
k 1=8 ÷15 ; choose k 1=10 : Distance between rotating parts
k 2=5 ÷15 ; choose k 2=10 : Distance from the end of the drive to the inner wall of the box
l m 13=( 1,2 ÷1,4 ) d 1=60 ÷70 ; choose l m 13=70 mm : bevel gear hub length
Choose l 13 =200 mm
l 12 =−l c 12 =−¿
k 3=10 ÷20 ; choose k 3 =15: Distance from bearing face to bearing cover
h n=15 ÷20 ; choose hn=15 : Height of bearing cover and bolt head
l m 12=( 1,2÷ 1,5 ) d 1=60 ÷ 75 ; choose l m 12=60 mm : belt hub length
Choose l 12=−75 mm
4.1.6) Force acting on the shaft
Force exerted by bevel gear

2T 1 2.121114,5
F t 1= = =3145,83 N =F t 2
dm 1 77
F r 1=F t 1 tan α cos δ1=3145,83. tan 20 ° cos 11,3° =1122,8 N =F a 2
F a 1=Ft 1 tan α sin δ 1=3145,83. tan 20° sin 11,3 °=224,36 N=F r 2
Force exerted by the pulley:
α1 144,12 °
F r=2 F 0 z sin =2× 250× 3 ×sin =¿ 1427,1 N ¿
2 2
F a 1 d m 1 224,36.77
M 1= = =8637,86 Nmm
2 2
4.1.7) Determination of shaft diameter:
Total bending moment at the sections:
M A 1= √ M 2rx + M 2ry =√ 8637,862 +0 2=8637,86 Nmm
M B 1= √ M rx + M ry =√ 244575,11 + 84210 =258666,4 Nmm
2 2 2 2
M C 1=√ M 2rx + M 2ry =√107032,5 2+0 2=107032,5 Nmm

M D 1=√ M rx + M ry =0
2 2
Equivalent moment at the cross-sections

M tA 1=√ M A 1 +0,75 T 2= √8637,86 + 0,75.121114,5 =105243,3 Nmm
2 2 2 2
M tB 1=√ M 2B 1+ 0,75T 22= √ 258666,4 2+ 0,75.121114,52=279123,36 Nmm

M tC 1 =√ M C 1 +0,75 T 2 =√107032,5 +0,75.121114,5 =149858,26 Nmm
2 2 2 2
M tD 1=√ M 2D 1 +0,75 T 22=√ 0+0,75.121114,52=104888,23 Nmm

Diameter of shaft segments
d A1=
√
3
√
M tA 1 3 105243,3
0,1 [ σ ]
=
0,1.63
=25,6 mm choose d A 1 =35 mm
d B 1=
√
3
√
M tB 1 3 279123,36
0,1 [ σ ]
=
0,1.63
=35,38mm choose d B 1=40 mm
d C 1=
√
3
√
M tC 1 3 149858,26
0,1 [ σ ]
=
0,1.63
=28,76 mm choose d C 1=40 mm
d D 1=
√
3
√
M tD 1 3 104888,23
0,1 [ σ ]
=
0,1.63
4.1.8) Radial force at bearing
=25,5 mm choose d D 1=35 mm
X 1 =1796,48 N ; Y 1=4246,17 N
X 2 =673,68 N ; Y 2=326,76 N

Diagram of shaft I

4.2. Shaft II
T 2=581819,4 Nmm
n2 =145,1rpm
4.2.2) Choosing materials:
σ b=600 MPa
σ ch=340 MPa
Permissible torsional stress: [ τ ]=15 ÷ 30 MPa choose [ τ 2 ] =20
4.2.3) Preliminary selection of diameter:
Preliminary calculated diameter: d 2=
Choose d 2=55 mm (*10.2)

√
3 T2
√
0,2 [ τ ]
=
3 581819,4
0,2.20
=52,6 mm

(*10.2) choose b 2=29 mm
4.2.5) Calculation of outline size of shaft:
l 22=0,5 ( l m 22+ b2 ) +k 1 + k 2=0,5 ( 70+29 ) +10+10=69,5
choose l 22=70 mm
l 23 =l 22+ 0,5 ¿
Choose l 23 =120 mm
l 21 =l m 22+l m 23 +b 2+3 k 1+ 2k 2=66+70+29+ 30+20=215 mm
Choose l 21 =215 mm
Với:
k 1=8 ÷15 ; choose k 1=10 : Distance between rotating parts
k 2=5 ÷15 ; choose k 2=10 : Distance from the end of the drive to the inner wall of the box
l m 22=( 1,2÷ 1,4 ) d2 =66 ÷77 ; choose l m 22=70 mm : bevel gear hub length
l m 23=( 1,2 ÷1,5 ) d 2=66÷ 82,5 ; choose l m 23=66 mm : helical gear hub length
Force acting from the driven bevel gear
F t 2=F t 1=3145,83 N
F a 2=Fr 1=1122,8 N
F r 2=F a 1=224,36 N
Force from the guide gear:

2T 2 cos β 2.581819,4 cos 18,6 ° Ft 3 tan α tw 10587. tan 21 °

F t 3= = =10587 N F r 3= = =4288 N
dw 3 104,17 cos β cos 18,6 °
F a 3=F t 3 tan β=10587. tan 18,6° =3563 N
Fa 3 d m3 3563.104,47
M 3= = =186113,3 Nmm
2 2
Fa 2 d m 2 1122,8.385
M 2= = =216139 Nmm
2 2
4.2.7) Determine shaft diameter:
M A 2= √ M rx + M ry =0 Nmm
2 2
M B 2= √ M 2rx + M 2ry = √ 728069,262 +1954942 =753858,6 Nmm

M C 2=√ M rx + M ry =√ 532660,31 +120732,54 =546171,5 Nmm
2 2 2 2
M D 2=√ M 2rx + M 2ry =0

M tA 2=√ M 2A 2 +0,75 T 2A 2=0
M tB 2=√ M B 2 +0,75 T 3= √ 753858,6 +0,75.581819,4 =906746 Nmm
2 2 2 2
M tC2 =√ M 2C 2 +0,75 T 32=√ 546171.52+ 0,75.581819,42=743094 Nmm

M tD 2=√ M D 2 +0,75 T D 2 =0
2 2
d A2=
√
3 M tA 2
0,1 [ σ ]
=0 mm choose d A 2 =50 mm
d B 2=
√
3
0,1 [ σ ]√
M tB 2 3 906746
=
0,1.63
=52,4 mm choose d B 2=55 mm
d C 2=
√
3
0,1 [ σ ]√
M tC 2 3 743094
=
0,1.63
=49 mm choose d C 2=50 mm
d D 2=
√
3 M tD 2
0,1 [ σ ]
=0 mm
4.2.8) Radial force at the bearing

choose d D 2=50 mm
X 3 =1270,87 N ; Y 3 =3331,8 N
X 4=2792,77 N ; Y 4 =10401,03 N


Diagram of shaft II
4.3. Shaft III

T 3=2123612 Nmm
n3 =38,18rpm
4.3.2) Choosing mateials:
σ b=600 MPa
σ ch=340 MPa
Permissible torsional stress:[ τ ]=15 ÷ 30 MPa choose [ τ 3 ] =30
4.3.3) Preliminary selection of diameter:
Preliminary calculated diameter: d 3=
Choose d 3=75 mm (*10.2)

√
3 T3
√
0,2 [ τ ]
=
3 2123612
0,2.30
=70,7 mm

(*10.2) choose b 3=37 mm
4.3.5) Calculation of the outline of the shaft size:
l 31 =l 21=215 mm
l 33 =l 31−l 22=215−70=145 mm
l 32 =−l c 32 =−( 0,5 ( l m 32+ b3 ) + k 3+ hn ) =−( 0,5 ( 105+37 ) +15+15 )=−101 mm
Choose l32 =−105 mm
We have
k 3=10 ÷20 ; chọn k 3=15: Distance from bearing face to bearing cover
h n=15 ÷20 ; chọn h n=15: Height of bearing cover and bolt head
l m 32=( 1,4 ÷ 2,5 ) d 3=105 ÷187,5 mm ;choose l m 32=105 mm : length of elastic shaft coupling half
thread
Force acting from the driven bevel gear
F t 4 =Ft 3=10587 N
F r 4 =F r 3 =4288 N
F a 4=F a 3=3563 N
Force acting from the elastic shaft
2T 3 2.2123612
F nt =0,2 F t=0,2 =0,2 =3267 N
Dt 260
F a 4 d m 4 3563.395,67
M 4= = =704886 Nmm
2 2
4.3.7) Determine shaft diameter:


M A 3= √ M 2rx + M 2ry =0 Nmm
M B 3 =√ M rx + M ry= √ 862507,3 +202433,5 =885945 Nmm
2 2 2 2
M C 3=√ M 2rx + M 2ry =√ 3430352+ 02=343035 Nmm

M D 3=√ M 2rx + M 2ry =0
M tA 3=√ M 2A 3 +0,75 T 2A 3=0
M tB 3=√ M 2B 3 +0,75 T 23 =√ 8859452+ 0,75.21236122 =2041370,6 Nmm
M tC 3 =√ M C 3 +0,75 T 3=√ 343035 + 0,75.2123612 =1870820.4 Nmm
2 2 2 2
M tD 3=√ M 2D 3 +0,75 T 2D 3=√ 0,75.2123612 2=1839102

d A3=
√
3 M tA 3
0,1 [ σ ]
=0 mm choose d A 1 =70 mm
d B 3=
√
3
0,1 [ σ ]√
M tB 3 3 2041370,6
=
0,1.63
=68,68 mm choose d B 1=75 mm
d C 3=
√
3
0,1 [ σ ]√
M tC 3 3 1870820.4
=
0,1.63
=66,71 mm choose d C 1=70 mm
d D 3=
√
3
0,1 [ σ ]√
M tD 3 3 1839102
=
0,1.63
=66,34 mm
4.3.8) Radial force at the bearing

choose d D 1=75 mm
X 5 =2891,91 N ; Y 5=5216,25 N
X 6 =1369,09 N ; Y 6 =8637,75 N

Diagram of shaft III

4.4. Shaft test

4.4.1) Fatigue test.
s σj . s τj
s j= ≥ [s]
√s2
σj + s τj
2
Choose [ s ] =3: allowable factor of safety, so there is no need to check the stiffness of the shaft
We have:
σ −1
sσj =
K σdj σ aj +ψ σ σ mj
τ−1
sτj =
K τdj τ aj +ψ τ τ mj
+ Allowable bending fatigue limit of Carbon Steel:

σ −1=0,436 σ b=0,436.600=261,6 MPa
+ Torsion fatigue limit:
τ −1=0,58 σ −1=0,58.261,6=151,75 MPa
+ For the rotation shaft, the bending stress varies with the period of symmetry
σ mj =0
Mj
σ aj =σ maxj=
Wj
M j =√ M 2xj + M 2yj
W j: Bending resistance moment, (*10.6)
+ One-way rotary drive system:
τ maxj Tj
τ mj=τ aj = =
2 2W0 j
With:
τ j: the torque at the cross section j
W 0 j: the torque resistance, (*10.6)
+ The coefficient of influence of the average value on the fatigue strength, (*10.7)
ψ σ =0,05 ; ψ τ =0
Kσ Kτ
+ K x −1 + K x −1
+ Coefficient: εσ ετ
K σdj = ; K τdj =
Ky Ky
Với:

K x =1,06: stress concentration factor due to surface state turned with roughness
Ra =2,5÷ 0,63 ultimate strength
K y =2: The shaft surface is strengthened by carbon impregnating
K σ =1,76 ; K τ =1,54 : Keyway shafts cut with end mills
ε σ ; ε τ : (*10.10)
Shaf Wj W0 j εσ ετ σa τ a=τ m sσ sτ
Position Key s
t
2923,5 7132,7 0,86 0,79
A1(35) 10 ×8 ×5 2,95 8,49 84,67 17,9 17,5
3 7 5 5
B1,C1(40 37,6/2 6,7/1 6,4/10,
I x 4209,2 8418,5 0,87 0,79 7,2 21,1
) 1 2 4
2923,5 7132,7
D1(35) 10 ×8 ×5 0 x x
3 7
A2,D2(50
x 0 0 x x x
)
II
B2(55) 16 ×10 ×12143
6 28477 0,79 0,75 62 13,2 3,7 11,7 3,5
C2(50) 9222,6
14 × 9 ×5,5 21494 0,81 0,76 59,2 27 3,9 5,4 3,2
A3,C3(70 0/15, x/ x/
x 33674 67348 0,76 0,73 0/10,2 8,2
) 8 21,5 8,9
29402,
III B3(75) 20 ×18 ×11 70820 0,75 0,72 30,13 15 7,2 9,2 5,67
5
73722,
D3(75) 32305
20 ×12 ×7,5 0,75 0,72 0 14,4 x 5,3 x
5
Thus, the shafts satisfy the fatigue strength condition of the shaft.
4.4.2) Static strength test
σ td =√ σ +3 τ ≤ [ σ ]
2 2
We have
M max
σ= ;
0,1 d3
T max
τ= 3
0,2d

[ σ ]=0,8 [ σ ch ] =0,8.340=272 MPa
Shaft σ τ σ td
I 40,42 14,12 47,24
II 45,3 23,3 60,7
III 48,4 31 72,3
Thus the shafts satisfy the condition of the shaft's static stability
4.4.3) Shaft key test
(*9.1)
Stamping strength condition:
2T
σ d= ≤ [ σ d ]=150 MPa
d l t (h−t 1)
Shear strength condition:
2T
τ c= ≤ [ τ c ] =60 MPa
d lt b
T: torque
d: Shaft diameter at the place of use of the key
b x h x t1: basic size of key
l t =(0,8 ÷ 0,9)l m : key length
Shaft Diameter b × h× t 1 lt σd τc
35(A1) 10 ×8 ×5 36 64,08 19,22
I
35(D1) 10 ×8 ×5 32 72,09 21,63
55(B2) 16 ×10 × 6 56 94,45 23,61
II
50(C2) 14 × 9 ×5,5 63 105,54 23
75(B3) 20 ×18 ×11 63 128,4 45
III
75(D3) 20 ×12 ×7,5 90 139,83 31,46
So the keys satisfy the conditions of stamping strength and shear strength
5) Select bearing and connecting shaft:

5.1) Input shaft I:
d 1=40 mm

n1 =725,5rpm
One-way rotation, 3 shifts, light impact load
5.1.2) Design:
a) Bearing force
Shaft I is the input shaft, working at high rotational speed, has bevel gears, so it is preferable to
use tapered roller bearings.
Radial force at the bearing:
X 1 =1796,48 N ; Y 1=4246,17 N
X 2 =673,68 N ; Y 2=326,76 N
F rB1 =√ X 21+ Y 21=√ 1796,482+ 4246,172=4610,56 N
F rC1= √ X 2+Y 2=√ 673,68+326,76 =748,74 N
2 2 2
b) Preliminary selection of bearing:
Sign d, mm D, mm B, mm T, mm r, mm α C, kN C0, kN
7508 40 80 23 24,75 2,0 14,25 53,90 44,80
5.1.3) Check the load capacity of the bearing

e=1,5 tan α=0,38
Axial force at B1
∑ F aB 1=F sC 1−F at 1=0,83 e F rC 1−Fat 1=0,83.0,38 .748,74−224,36=12,38 N
F sB 1=0,83 e F rB 1=0,83.0,38 .4610,56=1457,81 N
∑ F aB 1 < F sB 1 nên F aB 1=F sB 1=1457,81 N
Axial force at C1
∑ F aC 1=F sB 1+ F at 1=0,83 e FrB 1 + F at 1=0,83.0,38 .4610,56+224,36=1682,17 N
F sC 1=236,15 N
∑ F aC 1> F sC1 nên ∑ F aC 1=F sC 1=1682,17 N
(V=1 due to the rotation of the inner ring)
FaB 1 1457,81
= =0,316< e
V . F rB 1 1.4610,56
(*11.4), we have: X =1 ,Y =0
FaC 1 1682,17
= =2,25>e
V . F rC1 748,74
(*11.4), we have: X =0,4 ;Y =0,4 cot α =1,57
Conventional load on rolling bearing
Q B 1=( XV FrB 1 +YF aB1 ) K t K đ =( 1.1.4610,56+0 ) .1 .1=4610,56 N
QC 1=( XV F rC1 +Y F aC1 ) K t K đ =( 0,4.1748,74+1,57.1682,17 ) .1.1=3340,5 N

K t =1: Temperature influence coefficient

K đ =1: Effect factor of load characteristics (light impact, short-term overload, (*11.3))
QB 1>QC 1 so we calculate the bearing according to the parameter at B1
Working time of tapered roller bearing: Lh=50000 h
60 n Lh 60.725,25 .50000
Working time in million cycles: L= = =2175,75
106 106
Dynamic loading capacity:
10
m 3
C m=Q B 1 √ L=4610,56. √2175,75=46,2 kN <C=53,90 kN
10
m= due to the use of tapered bearing
3
Thus, the selected bearing ensures the load capacity.
5.1.4) Static load capacity test:
(*11.6)
X 0=0,5 ;Y 0=0,22 cot α =0,87
(* 11.19):
Q0= X 0 F rB 1 +Y 0 F aB 1=0,5.4610,56+ 0,87.1457,81=3573,6 N < F rB1
So Q0=F rB 1=4610,56 N < C0=44800 N
So the chosen bearing ensures the static load capacity
5.2. Intermediate shaft II
5.2.1) Initial paramaters
d 2=50 mm
n1 =145,1rpm
5.2.2) Design:
a) Force on bearing
Axis II has bevel gears and inclined cylindrical gears, so it is preferable to use tapered roller
bearings.
F rD 2=√ X 23 +Y 23= √1270,872 +3331,82=3565,95 N
F rA 2=√ X 4 +Y 4= √2792,77 +10401,03 =10769,45 N
2 2 2 2
b) Preliminary choice of bearings:
7610 50 110 40 42,25 3 11,17 122 108
5.2.3) Test
e=1,5 tan α=0,29
Axial force at A2

F at 2=F a 3−F a 2=3563−1122,8=2440,2 N

∑ F aA 2=F sD 2 + F at 2=0,83 e F rD 2 + F at 2=0,83.0,29 .3565,95+2440,2=3316,85 N
F sA 2=0,83 e F rA 2=0,83.0,29.10769,45=2647,55 N
∑ F aA 2 > F sA 2 so F aA 2=F sA 2=3316,85 N
Axial force at D2
∑ F aD 2=F sA 2−F at 2 =2647,55−2440,2=207,35 N
F sD 2=858,32 N
∑ F aD 2 < F sD 2 so F aD 2=F sD 2=858,32 N
Considering the ratio (V=1 due to the rotation of the inner ring)
FaA 2 3316,85
= =0,3> e
V . F rA 2 1.10769,45
(*11.4), we have: X =0,4 ; Y =0,4 cot α =2
FaD 2 858,32
= =0,24 <e
V . F rD 2 1.3565,95
(*11.4), we have: X =1 ,Y =0
Conventional load on the bearing
Q A 2 =( XV F rA 2 +YF aA 2 ) K t K đ =( 0,4.1 .10769,45+ 2.3316,85 ) .1 .1=10941,5 N
Q D 2=( XV F rD 2+Y F aD 2 ) K t K đ =( 1.1.3565,95+ 0 ) .1 .1=3565,95 N

Q A 2 >Q D 2 so we calculate the drive according to the parameter at A2
60 n Lh 60.725,25 .50000
Working time in million cycles: L= = =2175,75
106 106
Dynamic load capacity:
10
m 3
C m=Q A 2 √ L=10941,5. √ 2175,75=109,7 kN <C=122 kN
10
m= due to using tapered bearing
3
The chosen bearing ensures the load capacity
5.2.4) Static load capacity test
(*11.6)
X 0=0,5 ;Y 0=0,22 cot α =1,11
(*11.19):
Q0= X 0 F rA 2 +Y 0 FaA 2=0,5.10769,45+1,11.3316,85=9080,2 N < F rA 2
So Q0=F rB 1=10769,45 N <C 0=108 kN
So the selected bearing ensures the static load capacity..
5.3. Output shaft 3:

d 1=70 mm
n1 =38,18rpm
5.3.2) Design:
a) Force at the bearing
Because the shaft is long, we choose a tapered roller bearing
F rA 3=√ X 25 +Y 25= √ 2891,912 +5216,252=5964,26 N
F rC3 =√ X 6 +Y 6= √ 1369,09 +8637,75 =8745,57 N
2 2 2 2
b) Preliminary choice of bearings:
7314 70 150 35 38 3,5 11,67 168 137
5.3.3) Check the load capacity of the bearing

e=1,5 tan α=0,31
Axial force at B1
∑ F aA 3=F sC 3−F at 3=0,83 e FrC 3 + F a 4=0,83.0,31.8745,57−3563=−1314,1 N
F sA 3=0,83 e F rA 3 =0,83.0,31.5964,26=1533,7 N
∑ F aA 3 ; F sA 3 so F aA 3=F sA 3=1314,1+1533,7=2847,8 N
Axial force at C1
∑ F aC 3=F sA 3 + F at 3=0,83 e F rA 3 + F a 4=1533,7+ 3563=5096,7 N
F sC 3=2248,9 N
∑ F aC 3 > F sC3 so ∑ F aC 3=F sC 3=5096,7 N
Considering the ratio (V=1 due to the rotation of the inner ring)
FaA 3 2847,8
= =0,48>e
V . F rA 3 1.5964,26
(*11.4), we have: X =0,4 ; Y =0,4 cot α =1,94
FaC 3 5096,7
= =0,58> e
V . F rC3 1.8745,57
(*11.4), we have: X =0,4 ; Y =0,4 cot α =1,94
Conventional load on rolling bearing
Q A 3 =( XV F rA 3 +YF aA 3 ) K t K đ =( 0,4.1 .5964,26+1,94.2847,8 ) .1.1=7901 N
QC 3=( XV F rC3 +Y F aC 3) K t K đ =( 0,4.1.8745,57+ 1,94.5096,7 ) .1 .1=13368,7 N


QC 3 >Q A 3 so we calculate the drive according to the parameter at C3

60 n Lh 60.725,25 .50000
Working time in million cycles: L= 6
= =2175,75
10 106
Dynamic load capacity:
10
m 3
C m=QC 3 √ L=13368,7. √2175,75=134 kN <C=168 kN
10
m= due to using tapered bearing
3
The chosen bearing ensures the load capacity
5.3.4) Static load capacity test:
(*11.6) we have
X 0=0,5 ; Y 0=0,22 cot α =1,065
(* 11.19):
Q0= X 0 F rC 3 +Y 0 F aC 3=0,5.8745,57+1,065.5096,7=9801,5 N > F rC3
so Q0=9801,5 N <C 0=137000 N
So the selected bearing ensures the static load capacity..
5.4. Select elastic ring shaft connection:

Torque at 3 : T 3=2123612 Nmm
(*16.10a) we have the following shaft connection parameters:
T d D dm L l d1 D0 Z n max B B1 l1 D3 l2
2000 80 260 160 170 140 200 8 2300 8 70 48 48 48
(*16.10b)
dc d1 D2 l l1 l2 l3 h
24 M16 32 95 52 24 44 2
Stamping strength test

2 kT
σ d= ≤ [ σ d]
Z D0 d c l 3
[ σ d ]=4 MPa: Allowable stamping stress of rubber ring
k =1,2 : Working mode factor (16.1)
2.1,2 .2123612
σ d= =3,02 MPa ≤ [ σ d ]=4 MPa
8.200.24 .44
So the shaft can satisfy the stamping strength

Latch strength test

24
1,2.2123612.(52+ )
kT l 0 2
σ u= = =73,74 MPa ≤ [ σ u ] =80 MPa
0,1 d3c D0 Z 0,1.243 .200.8
So the latch satisfy the strength
6) Design box and extra elements

The reducer housing is responsible for ensuring the relative position between the details and
parts of the machine, receiving the load transmitted by the components mounted on the
housing, containing the lubricating oil and protecting the details from dust.
The material of the box is gray cast iron, GX15-32
Select the mounting surface between the box cover and the box body that passes through the
center lines of the shafts to make mounting parts more convenient and easier. The joint
surface is parallel to the base surface.
The bottom of the box is inclined at an angle from 10 to the oil drain hole to make it easier
to remove the oil: the lubricating oil is replaced cleanly, increasing the working quality of
the reducer.
The cast reducer has the following basic parameters:

Name Parameters
a=250 mm
Shaft distance 2-3
δ =0,03 a+ 3=10,5 mm
Thickness:
choose δ=10 mm
Box body,  δ 1=0,9 δ =9,45 mm choose
Lid, 1 δ 1=10 mm
Tendons increase stiffness:
Thickness, e e=( 0,8 ÷ 1 ) δ=9 mm
Height, h h<5 δ=50 mm choose h=40 mm
About 2 °
Slope
Diameter:
Base Bolt, d1 d 1=24 mm>0,04 a+10=20
Bearing side bolt, d2 d 2=( 0,7÷ 0,8 ) d 1=18 mm
d 3= ( 0,8÷ 0,9 ) d 2=16 mm
Cover and body flange joint bolts,d3
d 4 =( 0,6 ÷ 0,7 ) d 2=12 mm
Drive cover mounting screw, d4
d 5= ( 0,5÷ 0,6 ) d 2=10 mm
Oil filler door cover screw, d5
Flange for cap and body:
Body flange thickness, S3 S3= (1,4 ÷1,8 ) d 3=28mm
Box cover flange thickness, S4 S4 =( 0,9 ÷ 1 ) S3=26 mm
Width of box cover flange and body, K3 K 3 ≈ K 2−( 3 ÷ 5 )=¿46mm
Shaft bearing size: Set according to the size of the drive
Outer diameter and center of screw hole, cover
D3 , D 2 K 2=E 2+ R 2+ (3 ÷ 5 )=¿56mm
Width of bolt joint face of bearing edge: E2 ≈ 1,6 d 2=28,8 mm
R2 ≈ 1,3 d2 =23,4 mm
K2
Bearing edge bolt hole center: E2 and C (
k is the distance from the center of the
bolt to the edge of the hole )
Box base: S1 ≈ (1,3 ÷ 1,5 ) d 1=36 mm
Thickness without protrusion S1 K 1 ≈ 3 d1 =72mm
Width of box base, K1 và q q=95 mm ≥ K 1+ 2 δ=93 mm
Gaps between details:
Between the gear and the inner wall of ∆=10 mm ≥ (1 ÷ 1,2 ) δ=(10 ÷12)
the box ∆ 1=40 mm ≥ ( 3 ÷5 ) δ =(30 ÷50)
Between the top of the big gear and the ∆ 2=10 mm ≥ δ=10
bottom of the box
Between the side faces of the gears
together.

L+B 847+350
Number of foundation bolts Z Z= = ≈4
200 ÷ 300 300
6.1) Plane bearing size

Outer diameter and screw hole center D3, D2 selected according to table 18.2
Shaft D (mm) D2 (mm) D3 (mm) D4 (mm) h d4 Z
I 80 100 135 75 10 M8 4
II 110 130 160 100 12 M10 6
III 140 160 190 125 14 M10 6
6.2) Component details

6.2.1) Ring bolt
Thread d 1 d 2 d 3 d 4 d5 h h1 h2 Liftable weight a
M16 63 35 14 35 22 30 12 8 550
6.2.2) Positioning pin

Chọn chốt định vị hình côn: d ×c ×l=6 × 1× 50 mm
6.2.3) Inspection door
A B A1 B1 C C1 K R Screw Quant
100 75 150 100 125 - 87 12 M 8× 22 4
6.2.4) Vent button

A B C D E G H I K L
M 27 × 2 15 30 15 45 36 32 6 4 10
M N O P Q R S
8 22 6 32 18 36 32
6.2.5) Oil drain plug
d b m f L c q D S D0
M 20 × 2 15 9 3 28 2,5 17,,8 30 22 25,4
6.2.6) Oil indicator eye
Size of glasses D D1 l h
20 55 40 10 6

7. Choosing lubricating oil and mounting tolerances

7.1) Gearbox lubricating oil:
Choose the viscosity depends on the speed of the gear material, look up according to the
table 18.11.
With a ring speed of 1-2.5 m/s, the material for making the geat is improved C45 steel, the
viscosity of the oil at 50°C is 186
Looking at 18.13, I use AK-15 lubricating oil
7.2) Mounting tolerance
7.2.1) Choose degree of accuracy:
For gears: fast feeder is 8, slow gear is 9
For shaft, key and keyway select the correct grade 7
For grade holes exactly 6
For deviations of parallelism, orthogonality, inclination, and inversion, it is 6; straightness,
flatness is 7; concentricity, symmetry, intersection, radial reversal, cylinder, roundness and
longitudinal profile are 6.
7.2.2) Choose mounting type:
For key and gear choose mounting type H7/k6
For inner ring choose mounting type k6
For outer ring choose mounting type H7
Gear and key mounting tolerance table
Elements Size Joint es (μm) ei(μm) ES(μm ) EI (μm ) Largest Largest

excess clearance
(μm) ( μm)
Gear
Drive bevel ∅ 30 H7 +15 +2 +2 -11 26 0
gear k6
Driven bevel ∅ 55 H7 +21 +2 +4 -15 36 2
gear k6
Drive spur ∅ 50 H7 +21 +2 +4 -15 36 2
gear k6
Driven spur ∅ 75 H7 +21 +2 +4 -15 36 2
gear k6
Outer ring of bearing
Shaft I ∅ 72 H7 +21 +2 +30 0 21 28
k6
Shaft II ∅ 110 H7 +25 +3 +35 0 25 32
k6
Shaft III ∅ 150 H7 +28 +3 +40 0 28 37
k6
Inner ring of bearing

Shaft I ∅ 35 H7 +18 +2 +25 0 18 23

k6
Shaft II ∅ 30 H7 +15 +2 +21 0 15 19
k6
Shaft II ∅ 70 H7 +21 +2 +30 0 21 28
k6
Key
Size of key Limit deviation of keyway width Limit deviation of keyway depth
Shaft Piston ring groove Shaft Piston ring groove
P9 D10 Js9 Js9
8 ×7 × 4 -15 +98 ± 15 ± 12,5
-51 +40
16 ×10 × 6 -18 +120 ± 15 ± 15
-16 +50
14 × 9 ×5,5 -18 +120 ± 15 ± 15
-61 +50
20 ×18 ×11 -22 +149 ± 21,5 ± 18
-74 +65
20 ×12 ×7,5 -22 +149 ± 18 ± 15
-74 +65
8 ×7 × 4 -15 +98 ± 15 ± 12,5
-51 +40
REFERENCES
[1]. TÍNH TOÁN THIẾT KẾ HỆ DẪN ĐỘNG CƠ KHÍ (Tập một, Tập hai) – Trịnh Chất,
Lê Văn Uyển.
[2]. CƠ SỞ THIẾT KẾ MÁY – Nguyễn Hữu Lộc.
[3]. VẼ KỸ THUẬT CƠ KHÍ – Lê Khánh Điền.
[4]. KỸ THUẬT ĐO Tập một DUNG SAI LẮP GHÉP VÀ TIÊU CHUẨN HÓA –
TS.Nguyễn Trọng Hùng, PGS.TS. Ninh Đức Tôn
[5]. BÁO CÁO ĐỒ ÁN THIẾT KẾ MÁY – Thân Trọng Khánh Đạt và Nguyễn Vũ Cường

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Vietnam National University

HO CHI MINH UNIVERSITY OF TECHNOLOGY

Name: HOANG NGOC ANH DUY

Student’s ID: 1952611

Instructor: PhD Lê Thanh Long

SEMESTER 202 , 2021

Conveyor drive system include:

Hoang Ngoc Anh Duy – 1952611 1

Hoang Ngoc Anh Duy – 1952611 2

Hoang Ngoc Anh Duy – 1952611 3

1.1) DETERMINE THE ENGINE

1.1.1) Determine the efficiency of the system

1.1.2) Calculate power needed

1.1.3) Determine preliminary rotation number of the engine

uch = uh*uđ = 15*4 = 60

1.1.4) Choose electric engine

I choose: 4A132M2Y3 n dc=2907 rpm

1.2) TRANSMISSION RATIO DISTRIBUTION

Hoang Ngoc Anh Duy – 1952611 4

1.3) SPECIAL VALUES TABLE

1.3.1) Calculate power in shafts

1.3.2) Calculate rotation speed of shafts

1.3.3) Calculate torque in shafts

Hoang Ngoc Anh Duy – 1952611 5

9.55∗10 6∗P 9.55∗10 6∗8.4

Speed (rpm) 2907 725.5 145.1 38.18 38.18

2) TRAPEZOIDAL BELT TRANSMITTER DESIGN

According to the picture, we choose type B

Hoang Ngoc Anh Duy – 1952611 6

Diameter of big pulley

Choose length of shaft a = 0.95d2 = 532mm

L=2 a+ + = 2 532+ + =2 329.35 mm

According to table 4.13 choose length of belt follow standard L = 2500 mm

Calculate a with L = 2500

Coefficient considering the effect of the belt contact

Hoang Ngoc Anh Duy – 1952611 7

According to table 4.17 coefficients affect the transmission ratio

The coefficient considering the effect of load Cr = 0.7

The coefficient considering the effect of Cz = 0.95 (*4.18)

Choose z = 3 => Cz = 0.95

Tension for each belt

Force on the shaft

Special value table

Name Sign Value

Hoang Ngoc Anh Duy – 1952611 8

Belt contact 1 2.42 rad

Force on the shaft F 1447.74 N

Hoang Ngoc Anh Duy – 1952611 9

3) Design the transmitter in the gearbox

3.1) Calculation and design of bevel gear transmitter

Tempered process S H =1,1:

[σ H]sb=min{[σ H1], [σ H2]) =563,64 Mpa

Hoang Ngoc Anh Duy – 1952611 10

Outer taper length

3.1.4) Matching parameters

(*6.22): choose z1p=17

Re-calculate: d m 1=mtm . z 1=3,5.22=77 mm ;d m 2=mtm . z 2=¿ 110.3,5=385mm

Gear rim width: b=Re ψ be =228.0,285=65mm

Hoang Ngoc Anh Duy – 1952611 11

Ring diameter: de1=mte.z1=3.22=66mm; de2=mtez2=3.110=330mm

(*6.1): [ σ H ]=[ σ H ]sb z v z R K xH =0,95.0,95.1 .563,64=508,7MPa

Hoang Ngoc Anh Duy – 1952611 12

Tooth form coefficient YF

uch = uhuđ = 154 = 60