Group Project

A speed reducer is to be designed for a Power Transmission System used in a small equipment.
According to the lay-out given below, the pulley M is the driver pulley and it transmits X% of
power to the gear D and the remainder to the gear G. The pulley M rotates counterclockwise and
it is connected to an electric motor (EM) of known RPM and power. The Gear G drives a blower
(BL) through the gear BL.
Data:
G is a gear with a diameter of dG mm.
D is a gear with a diameter of dD mm
M is a pulley with a diameter of about dM mm
A and J are the positions of the bearings bA and bJ respectively.
The gears G and D and the pulley M are connected to the shaft via keys k1, k2 and k3
respectively.
The distances (constraints) given by the design are: AD, AG, AJ and AM

x
z
 Additional Data:
The dimensions are given in mm (drawing not at scale).
The system should be designed for an operational life of 1250days with daily operation of 8h.
All accessories (bearing, sheave, gear) MUST be located by a change in the shaft diameter
(shoulder).
At bearing positions and at positions with no stress concentration, use the same stress
concentration factor of the nearest shoulder.
All the selected materials must be steel.
For pulley selection use.. https://www.fptgroup.com/dss/docs/682_03_Fenner_Friction_Belts.pdf
For bearing selection use… (https://www.skf.com/au/products/rolling-bearings/ball-
bearings/deep-groove-ball-bearings) with a reliability of 99.2%
Pulley M – Pulley/EM System
1. Speed ratio of RPM pulley EM/RPM pulley M should be near to the value of N3.
2. Distance from the center of the pulley M to the center of the pulley in the EM should not exceed
600mm.
Blower (BL) – Gear G System
3. Speed ratio of RPM gear G/RPM gear BL is N1
4. Type of electric motor (EM), AC star delta and it operates 8 hours a day
5. Consider spur gears with pressure angle 20 degrees and a reliability of 99.9%
Gear D – Exit Gear System
6. Speed ratio of gear D/Exit gear is N2

Group 1 2 3 4 5 6 7 8 9 10 11 12
Power EM 28 26 24 22 20 20 22 24 26 28 18 18
(kW)
RPM 1400 1500 1600 1700 1800 1750 1650 1550 1450 1500 1750 1500
(EM)
X(fraction) 0.6 0.5 0.4 0.45 0.55 0.65 0.5 0.6 0.7 0.7 0.65 0.4
N1 1.8 1.6 1.5 1.7 1.5 1.6 1.7 1.4 1.5 1.6 1.7 1.4
N2 1.25 1.3 1.3 1.2 1.25 1.2 1.3 1.2 1.3 1.4 1.5 1.5
N3 1.3 1.2 1.3 1.2 1.4 1.4 1.2 1.4 1.3 1.4 1.2 1.1
AD(mm) 70 80 80 70 75 80 60 70 70 60 75 75
AG(mm) 150 150 140 140 150 140 130 130 140 140 140 130
AJ(mm) 200 210 210 200 200 200 190 190 210 200 210 200
AM(mm) 250 250 250 250 250 250 250 250 250 250 250 250
dG (mm) 180 180 160 170 160 160 150 150 140 160 140 150
dD (mm) 120 120 130 125 120 120 110 120 120 130 130 130
dM (mm) 280 280 280 280 280 280 280 280 280 280 280 280
 Format of the Design Drawing

Drawing Sheet : Size A4

Required: For the gear, shaft and V-belt
1. Representation of all the details with one, two or three main views.
2. Part drawings for each and every component.
3. Assembly or sub assembly drawing as necessary.
4. A sketch of application set up.
5. Tables for Selected and design components as necessary
6. Problem data, Material data, System specifications, Machining or manufacturing details etc.

Format of the Design Report

(To be included in the First Page)
1. Students Name (include two surnames)
2. Date and Group Number
3. Table of Data Given
4. Table of Assumed Data: (Stress Concentration D/d, r/d, Face width of components, Safety
Factor, Material Specification)

Design Calculations
Where ever possible please provide sketches, figures as necessary to illustrate various parameters
used in your calculation
(a) Power, Torque calculations using given data and considering losses through the
transmission
(b) Design of V-belt drive (one drive) : Centre distance, speed ratios, Pulley diameters,
length of belts, standard nominal length, selection of belt section type, number of belts
required, and check for service level.
(c) Design of the gear: Centre distance, speed ratios, diameters of pinion and gear, material
selection from through hardened steels, selection of module, contact stresses, and
bending stresses, selection of face width of the pinion. Assume a safety factor of 1.15 for
contact stresses and equal hardness for the pinion and gear. Determine the safety
factor for bending stresses.
(d) Design of the line shaft: Diameter of line shaft using ASME elliptical, power through
each drive, Belt tensions, Torque at pulley and gear, Torque diagram, Force diagram
through each drive, Force due to self weight of pulley and belt tension, Components in
horizontal and vertical directions, Bending moment diagram for vertical and horizontal
directions, Maximum bending moment and resultant maximum bending moment,
Maximum combined stresses(torsion and bending). Check the diameter of the shaft for
deflections and slopes at the gears, pulleys and bearing positions. If the calculation of the
critical speed is required estimate the masses of pulley and gear on the line shaft,
(e) Selection of the Bearings: Use deep groove bearings, assume an axial load of 20% the
radial load for bearing selection. Use metric units.
(f) Design of key and key ways: Keys for motor shaft, Line shat and machine shafts. Key
section, Type, Cross section and length, Check for failures.
 Results
Results should be presented in tabulated form. Write down all the equations used for your
findings.
Draw the FBD ( the direction of the force given by the arrow in the diagram and the magnitude
given by a number in the diagram).
Draw the shear force diagram with the values (numbers) for each of the sections.
Draw the bending moment diagram with values (numbers) at each relevant point in the shaft.
Draw the resulting bending moment diagram with values (numbers) at each relevant point in the
shaft.
Draw the torque diagram with values (numbers) at each relevant section of the shaft.
Write a complete material specification for the shaft.
Assume a Safety Factor
For shoulders, assume a r/d between 0.04-0.06 at low loading sections and r/d between 0.07-0.1
at high loading areas in the shaft. Assume a D/d and calculate the static stress concentration for
bending and torsion for every shoulder in the shaft.
ofFor
the the first
stress iterationfactor.
concentration use static
Hence,stress concentrators,
the stress assume
concentration factor needsatoD/d (or H/d) and r/d and calculate
be deter-
the stress concentrator for bending and torsion (do not use the graphs)
mined for every individual type of geometric discontinuity (grooves, notches, change of cross(D=H=d+2t)
section, etc.) and for each di↵erent type of stresses (axial, bending, torsion, transverse shear).

equations:
uations: F Mb T
Fax = 4 ⇡d2 =) M b =b
32 3 =) ⌧t =
⇡d⌧ = 16 T ⇡d3
16
ax = 4 2
=) b = 32 3 =) t 3
⇡d
The static stress concentration factors for⇡dthese types of discontinuities
⇡d are given by (after
e static Petersen)
stress concentration
the equation: factors for these types of discontinuities are given by (after
tersen) the equation: 1
Kt = 1 + q
r 2 ⌧max,tor
r z d
= 2B1 dr =)
max,b
Kt = 1 + q A Krtt,b + 1 +K2t,tor
d = +C t D
nom,b ⌧ nom,tor
r r r 2 r z d
where A,where
B, C the A t indicates
andsubscript t +
z are constants 2B
given
that in 1
the+ 2
table
d the stress + C
below:
d concentration
t factor
D has been obtained for static
ere A, B, C and loading by either a theoretical
z are constants given in thecalculation
table using principles of finite element analysis or determined
below:
experimentally under laboratory conditions and static loading, the subscripts b and tor refer to
Groove Shoulder Fillet
the stress types of bending and torsion loading. The nominal stresses are therefore reference
stresses that need to be properly defined for each of the discontinuity types. In general, nominal
Groove bending torsion
tension Shoulderbending
tension Fillet torsion
net stresses are used that is they are obtained using the net cross section. So for the above
example the nominal stress for bending and torsion are:
tensionA bending
0.22 0.2
torsion 0.7 tension 0.62 bending0.62 torsion3.4
32M 16T
nom,b = =) ⌧ nom,tor =
⇡d3 ⇡d3
B 1.37 diameter
2.75 10.3 3.5 5.8
A 0.22 0.2
where d is the 0.7 0.62 between
d = D 2t measured 0.62 3.4 19
the roots of the groove.
Inglis
C (1913 -C.E. Inglis,- “Stresses -in a Plate Due- to the Presence
0.2 of Cracks and
1 Sharp Corners,”
B 1.37 2.75
Transactions 10.3 of Naval3.5
of the Institution Architects, Vol. 5.8 19pp. 219–230.) carried
55, London, 1913,
out zthe first- mathematical
- treatment
- of stress concentration
- factors
3 in an elliptical
2 hole on an
C infinite
- wide -plate. The ellipse
- of long axis
- (2a) and short
0.2 axis (2b) was1subjected to a tensile
stress in the direction perpendicular to the long axis.
2
z - radius of-curvature at- the tip of the ellipse
The - 3 as ⇢ = b and
was calculated 2 the maximum stress
" ✓ ◆ 12 # a
a
at the tip was calculated at max = 1 + 2 axial .
⇢
✓ ◆ 12 ✓ ◆ 12
a a
For very sharp or flatten ellipses, then a ⇢!1+2 =2 . In the case of circular
⇢ ⇢
holes, a = ⇢ ! max = 3 axial .
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