Bachuler Thesis On Multi-Spindle Drill Machine

BACHULER THESIS ON MULTI-SPINDLE DRILL MACHINE 2005 E.
TABLE OF CONTENTS

ABSTRACT
1 INRTODUCTION
1.1 BACKGROUND OF THE PROBLEM ................................................................................................................. 5
1.2. STATEMENT OF THE PROBLEM..................................................................................................................... 6
1.3 OBJECTIVE OF THESIS ...................................................................................................................................... 7
1.4. RESAERCH METHODOLOGIES AND DATA COLLECTION ....................................................................... 8
1.5 THE EXPECTED OUTCOME AND BENEFICIARIES OF THE THESIS ....................................................... 10
1.6 SCOPE AND LIMITATION OF THE STUDY .................................................................................................. 11
2 LITERATURE REVIEW
2.1 CHARACTERISTICS OF DRILLING MACHINE ............................................................................................ 12
2.2 IMPORTANCE OF MULTI-SPINDLE DRILL MACHINE .............................................................................. 13
2.3 MANUFACTURING ........................................................................................................................................... 13
2.4 LUBRICATION ................................................................................................................................................... 14
2.5 CONSTRUCTION OF DRILL MACHINE ......................................................................................................... 14
3 DRILL MACHINE HEAD DESIGN
3.1 STATIONARY MULTISPINDLE HEADS ........................................................................................................ 16
3.2 KINEMATIC SYSTEM OF MULTISPINDLE VERTICAL DRILLING MACHINE ....................................... 16
AND THEIR PRINCIPLE OF WORKING ............................................................................................................... 16
3.3 CUTTING DATA ................................................................................................................................................ 18
3.4 DRILL MOTOR SELECTION ............................................................................................................................ 22
3.5 CHAIN AND SPROCKET DESIGN ................................................................................................................... 22
3.6 GEAR DESIGN ................................................................................................................................................... 31
3.7 BEARING SELECTION ..................................................................................................................................... 49
3.8 HOUSING DESIGN ............................................................................................................................................ 53
3.9 DESIGN OF DRILL COLUMN .......................................................................................................................... 56
3.10 DESIGN OF COLUMN SLEEVE: .................................................................................................................... 58
3.11 RACK AND PINION DESIGN ......................................................................................................................... 59
3.12 JIG AND FIXTURE........................................................................................................................................... 64
3.13 MANUFACTURING CONSIDERATIONS ..................................................................................................... 65
3.14 COST ESTIMATION FOR THE DRILL MACHINE ....................................................................................... 67
4 CONCLUSION AND RECOMMENDATION
4.1 CONCLUTION .................................................................................................................................................... 68
4.2 RECOMMENDATION ....................................................................................................................................... 69
APPENDIX
REFERENCES AND SOURCES OF INFORMATION 
AAIT Page 1 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

BACHULER THESIS ON MULTI-SPINDLE DRILL MACHINE 2005 E.C

















ABSTRACT
Although there are different types of drilling machine, in this thesis vertical multi-spindle drilling
machine, manually operated, electric motor driven, with rack and pinion gear system is anticipated to
solve the problem of less production and time delay in Selam Technical and Vocational Collage and
also to increase production capacity and improve efficiency of productivity of Selam Technical and
Vocational Collage. Vertical multi- spindle drilling machine is used to drill holes on a bar of metal
which is used in the crop threshing machine. Mass production of the metal bar is needed because of
mass production of crop threshing machine. In one metal bar seven holes are needed. To drill these
seven holes by using single spindle drilling machine is not completely appropriate. Using multi-
spindle drilling machine is more productive.
In this thesis main system of the machine i.e. rack and pinion gear and sprockets are designed and
optimized carefully and also its stress analysis will be performed. Other parts like chain, spindle, and
power source of the machine (electric motor), handle, jig and fixture (work piece holding part) will be
correctly analyzed. Also this thesis is deals with selection of best motor type, appropriate chain
selection, correct bearing selection and over all assembly of machine and geometry will be worked
carefully.

CHAPTER ONE
1 INRTODUCTION
Drilling is an operation of making a circular hole by removing a volume of metal from the job by
cutting tool called drill. A drill is a rotary end-cutting tool with one or more cutting lips and usually
one or more flutes for the passage of chips and the admission of cutting fluid. A drilling machine is a
machine tool designed for drilling holes in metals. It is one of the most important and versatile
machine tools in a workshop. Besides drilling round holes, many other operations can also be
performed on the drilling machine such as counter-boring, countersinking, reaming, honing, lapping,
sanding etc. Because of the three-dimensional nature of these operations, chip movement and its
control are important considerations. Chip removal can be a significant problem (especially in drilling
and tapping) and can lead tool breakage.
Multiple- spindle drill machines are used for mass production, a great time saver where many pieces of
jobs having many holes are to be drilled. Multi-spindle head machines are used in mechanical industry
in order to increase the productivity of machining systems. The multi-spindle drilling machines are a
production type of machine. It is used to drill seven holes in a work piece simultaneously, in one
setting. The holes are drilled on number of work pieces with the same accuracy, so as to make
interchangeable. These machines have seven spindles driven by a single motor and all the spindles are
fed in to the work piece simultaneously. Feeding motions are obtained by raising the work table. The
center distance between the drill spindles adjusted at 90mm distance during design. In mass production
work drill jigs are used for guiding the drills in the work piece so as to achieve accurate results.
In today’s market the customer demands the product of right quality, right quantity, right cost, and at
right time. Therefore it is necessary to improve productivity as well as quality. One way to achieve this
is by using multi-spindle drilling head.

1.1 BACKGROUND OF THE PROBLEM
The current experiences of most local manufacturing industries have considerable problems in
connection with their product quality, delivery time and price. And this is due to high production cost,
high design and lead time, in efficiency in resource utilization, lack of efficient production planning
and scheduling, material handling problem, and etc. Moreover most of the local manufacturing
industries use the traditional job shop layout, where similar machines and labor with similar skills are
located together. The process or functional layout results in law machine utilization and high wastage
of time. The high cost of set-ups for small batches results in high manufacturing costs.
However, in the existing current production system, small to medium batch production, which
generates a great deal of industrial output, has become dominant manufacturing activity in the world.
This domination comes into being for cop up with the various processing changes; low price short
delivery time, high quality level, minimum raw material price, etc. one and the best method to cope up
with the above changes in small to medium batch production is the use of appropriate production
process and machine equipment . From manufacturing point of view, this drill machine attempts to
decrease production cost by reducing production time and other tangible and intangible costs.
Thus to realize these advantage for the local industries, drilling machine is chosen as a research topics.
And Selam Technical and Vocational Collage is taken as a case since it is one of the early established
manufacturing factories, which is in great difficulty to coup up with the existing completion due to its
high production cost; delay delivery, low product quality level, etc. In this company we saw that
drilling many holes on the metal bars process takes place by using vertical single spindle drilling
machine. This single spindle machine drills one hole at one cycle and the needed holes on one bar of
metal are seven. To drill seven holes the operator cycles seven times the spindle this takes a lot of
production time. Also when mass production of metal bar is needed it takes much more production
time. Also there is no hole center distance accuracy between because of the holes are not drilled at the
same time. This reduces the company’s productivity and efficiency.

In this thesis we want to improve this process or solve this problem by designing vertical multi-spindle
drilling machine. Vertical multi-spindle drilling machine have seven spindles that arranged
horizontally in line and rotate at their position and the work piece holding table moves up and down by
using handle manually in order to fulfill drilling process. The multi-spindle drilling machine is used to
drill a number of holes in a job simultaneously and to produce the same pattern of holes in a number of
identical pieces in a mass production work. This machine has seven spindles and all the spindles
holding drills are fed into the work simultaneously. Therefore, the implication of drilling machine will
bring considerable changes to the stated problems of the factory.
1.2. STATEMENT OF THE PROBLEM
The problem which this thesis is focus is found from company called selam technical and vocational
collage (Selam children’s village) which is technical school and a place where income generating
activities are performed. In this company we saw that drilling many holes on the metal bars process
takes place by using vertical single spindle drilling machine. This single spindle machine drills one
hole at one cycle and the needed holes on one bar of metal are seven. To drill seven holes the operator
cycles seven times the spindle this takes a lot of production time. Also when mass production of metal
bar is needed it takes much more production time. This reduces the company’s productivity and
efficiency. In this thesis we want to improve this process or solve this problem by designing vertical
multi-spindle drilling machine. Vertical multi-spindle drilling machine have seven spindles that
arranged horizontally in line which are connected or welded each other so that they come down at the
same time and drills seven holes and return back by rack and pinion mechanism using handle
manually.

1.3 OBJECTIVE OF THESIS
This thesis addresses the problem encountered by rice mill machine manufacturing industries with
repect to the productivity, effective use of time and quality by analyzing drill machine in drilling of
hole on the bar. By the end of this research the Selam vocational and technical college will have well
designed multi-spindle drill machine in cost effective, simple and manageable way.
General Objective
The main objective of this thesis is to improve vertical single spindle drilling machine in to vertical
multi-spindle drilling machine and perform the design aspect of the major parts of the machine.
Specific objectives are:
Specific objective of the thesis are:-
 To change single spindle drilling machine to multi-spindle drilling machine.
 To design drill machine that drills a number of holes in a job simultaneously and to
reproduce the same pattern of holes in a number of identical pieces in a mass production
work.
 To perform the design of different parts of the machine.
 To find the required power and to select an electric motor that matches the power needed.
 To perform stress analysis of the rack and pinion gear as well as the shaft.
 To design sprockets and select chain.
 To construct parts as well as assembly of the machine.
 Reducing the production time and to improve the manpower usage.
 To reduce the work fatigue of the operators.

1.4. RESAERCH METHODOLOGIES AND DATA COLLECTION
Once the problem is identified and the proposed solution methodology hypothesized, the next logical
step would be to identfy research methodology, collect appropraite data, analyze it, develop a working
model, and provide a solution proposal. to do this the step is to define the research methods and collect
appropriate data, which address the problem. so the research followed the following steps: Literature
survey, Data collection and design.
1.4.1. Literature Review
To asses the advantage, design principles, and working procedure of multi-spindle drill machine, the
researcher surveyed literature from books, previous research works, policy and guidelines, consultant
firms, machinery suppliers, and World Wide Web. for this materials from Addis Ababa Institute of
Technology Library, Selam Technical and Vocational collage Libriary, Trade and Industry Library
and others.
Generally the following literature was compiled:
 Defination and classification of multi-spindle drill machine
 Introduction to multi-spindle drill machine and types of operation
 Finding of all the component of machine and their function.
 Present methods that most company used to drill multi-holes.
 Desing procedure and others

1.4.2. Data Collection
The methods to be employed to achieve the objective of the thesis are divided into different parts:
As it is already described in the above sections this thesis is about design of vertical multi-spindle
drilling machine. In this thesis to accomplish the proposed ideas the first steps is searching of different
drilling machines to identify parts and the working principle of various drilling machines. After
exploring this data the next step is collecting diverse data concerning parts of the machine and design
procedure of those parts. This process of data collection will be accomplished by:-
 Information gathering from different machine and machine parts manufacturing company and
research centers.
 Information from different literature on this area.
 Information from internet
Mechanical Design of Components
Here different parts of the machine will be designed, optimization of parameters of the components
performed. Specially gear system and sprockets are carefully designed and tested because of main part
of the system. In this section design of the following parts will be done:-
A. Design of gear system, i.e. rack and pinion gear.
B. Design of sprockets
C. Selection of appropriate bearing, chain, and power source (electric motor).
D. Housing
E. Dimension of each parts and overall.
F. Material selection.

Power supply unit
The other parts of this thesis is selection of an appropriate electric motor type, specifying power and
torque for proper and safe operation, since it is the power source of the machine.
Stress Analysis
After completing the material selection for the components, stress analysis will be performed.
Construction and assembly
Finally construction of different parts of the machine and the assembly will be done using Sold Work
or Catia V5 software.
1.4.3. Design
In this modern age of industrial compitition, a succesfull desingner needs more knowlegde and
understanding of fundamental sience and related engineering subjects.
A multi-spindle drill machine project moves to completion through a series of stages such as
:Inspection, preliminary evaluation of the economics and market, development of data neecessary
forfinal desing, economic evaluation, detailed engineering design and implementation.
Design is a creative activity, and as such can an engineering undertake one of the most rewardingand
satisfaying activities.It is the synthesis, the putting together, of ideas to achieve dessired purpose. The
designer with specific objective in mind, a need, and by developing and evaluating possible designs,
arrives ant what he considers the best way of achieving that objective.
1.5 THE EXPECTED OUTCOME AND BENEFICIARIES OF THE THESIS
The multi-spindle vertical drill machine designed in this thesis would result in:
1. increasing the productivity of the company
2. time saving
3. precision of center distance between each holes
4. good finishing and accuracy of holes

5. mass production is very easy
At the end of this work, the following manufacturing industries and other bodies are beneficiaris:
 Selam Technical and Vocational Collage
 Akaki
 Engineering Coorporation
 AAIT Technology Workshop
1.6 SCOPE AND LIMITATION OF THE STUDY
The scope of this thesis is desighning of multi-spindle vertical drill machine for drilling seven holes
simoultaniously.
Specifically, full desing was done for drilling bar used in rice mill machine assembly manufactured at
Selam Technical And Vocational Collage .
Specification of drill machine is done with its detail drawing using AutoCAD 2007.
The economic analysis, cost analysis and design of machine was clearly set out.
During conducting this thesis the following constraints made difficulty for the researcher:
I. high financial constraint to asses all manufacturing industries in the countries and recommend
ways designing multi-holes drill machines.
II. slow cooperation of some visited industries to give information, which are important to desing
multi-spindle drill machine.

CHAPTER TWO
2 LITERATURE REVIEW
A drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other
materials. Drilling machines use a drilling tool that has cutting edges at its point. This cutting tool is
held in the drill press by a chuck or Morse taper and is rotated and fed into the work at variable speeds.
Drilling machines may be used to perform other operations. They can perform countersinking, boring,
counter boring, spot facing, reaming, and tapping. Drill press operators must know how to set up the
work, set speed and feed, and provide for coolant to get an acceptable finished product. The size or
capacity of the drilling machine is usually determined by the largest piece of stock that can be center-
drilled. For instance, 15-inch drilling machines can center-drill a 30-inch-diameter piece of stock.
Other ways to determine the size of the drill press are by the largest hole that can be drilled, the
distance between the spindle and column, and the vertical distance between the worktable and spindle.
2.1 CHARACTERISTICS OF DRILLING MACHINE
All drilling machines have the following construction characteristics: a spindle, Sleeve or quill,
Column, head, worktable, and base.
 The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve. In most
drilling machines, the spindle is vertical and the work is supported on a horizontal table.
 The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel
to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting tool
is fed into the work: and when it is moved upward, the cutting tool is withdrawn from the
work.
 Feed pressure applied to the sleeve by hand or power causes the revolving drill to cut its way
into the work a few thousandths of an inch per revolution

 The worktable is supported on an arm mounted to the column. The worktable can be adjusted
vertically to accommodate different heights of work. or it may be swung completely out of the
way. It may be tilted up to 90 in either direction, to allow for long pieces to be end or angled
drilled.
 The base of the drilling machine supports the entire machine and when bolted to the floor
provides for vibration-free operation and best machining accuracy. The top of the base is
similar to a worktable and maybe equipped with T-slots for mounting work too large for the
table.
2.2 IMPORTANCE OF MULTI-SPINDLE DRILL MACHINE
 By using multi-spindle drilling head productivity will increase. Because with the present
process one hole produces at a time requires 4 minutes for each component (because tool
change takes place for drilling 5mm hole (for M6x1 tap)). i.e. 12-15 parts are produced during
one hour, but by using multi-spindle drilling head cycle time approximately takes place 1
minutes. i.e. 55-60 parts may produce during one hour.
 Possibility of hole missing is eliminated, because six holes drilled at a time.
 The cost per piece is reduced. As seen in conclusion no.1 the production rate is approximately
double by using multi-spindle drilling head. The machine used for multi-spindle drilling head
is same (Radial drilling machine) which present uses to produce the part, so machine hour rate
remains unchanged.
2.3 MANUFACTURING
The Multi-spindle drilling head requires various components, the major components are gear box,
drilling spindle, gear shafts, main spindle gear, drive gears, idler gears etc. It requires various
machines to manufacture them like band saw machine for cutting operation, lathe machine for rough
machining, drilling machine, surface grinding machine, cylindrical grinding machine, internal grinding
machine, slotting machine, milling machine, hobbling machine etc.

2.4 LUBRICATION
Lubrication is important because of the heat and friction generated by the moving parts. Follow the
manufacturers manual for proper lubrication methods. Clean each machine after use. Also remove
chips to avoid damage to moving parts. Wipe all spindles and sleeves free of grit to avoid damaging
the precision fit. Put a light coat of oil on all unpainted surfaces to prevent rust. Operate all machines
with care to avoid overworking the electric motor.
2.5 CONSTRUCTION OF DRILL MACHINE
In drilling machine the drill is rotated and fed along its axis of rotation in the stationary workpiece.
Different parts of a drilling machine are discussed below:
1) The head containing electric motor, sprocket and chain which transmit rotary motion to the drill
spindle at a number of speeds.
2) Spindle is made up of alloy steel. It rotates as well as moves up and down in a sleeve. A pinion
engages a rack fixed on the sleeve to provide vertical up and down motion of the spindle and
hence the drill so that the same can be fed in to the work piece or withdrawn from it while
drilling.
3) Drill chuck is held at the end of the drill spindle and in turn it holds the drill bit.
4) Adjustable work piece table is supported on the column of the drilling machine. It can be moved
vertically up and down. Tables are generally having slots so that the jig and fixture can be
securely held on it.
5) Base table is a heavy welding and it supports the drill press stricture. The base supports the
column, which in turn, supports the table, head etc.
6) The column is a vertical round or box section which rests on the base and supports the head and
the table. The round column may have rack teeth cut on it so that the table can be raised or
lowered depending upon the work piece requirements.

Fig 1.1 construction of drill machine

CHAPTER THREE
3 DRILL MACHINE HEAD DESIGN
3.1 STATIONARY MULTISPINDLE HEADS
It ensures efficient large scale production on production lines and special machines. Several spindles
per head ensure simultaneous processing of several drillings in one working cycle. Thus, machining
times are shortened and production yield is increased.
Transmission of power from a source, electric motor, through a machine to the drill is the major task
of this section. An efficient means of transmitting power is through rotary motion of a shaft that is
supported by bearings. Gears, chain sprockets are incorporated to provide for torque and speed
changes between shafts. Most shafts are cylindrical (solid and hollow), and include stepped diameters
with shoulders to accommodate the positioning and support of bearings, gears, etc. The design of a
system to transmit power requires attention to the design and selection of individual components
(gears, bearings, shaft, etc.).
3.2 KINEMATIC SYSTEM OF MULTISPINDLE VERTICAL DRILLING MACHINE
AND THEIR PRINCIPLE OF WORKING
Kinematic system in any machine tool is comprised of chain(s) of several mechanisms and gears to
enable transform and transmit motion(s) from the power source(s) to the cutting tool and the
workpiece for the desired machining action. The kinematic structure varies from machine tool to
machine tool requiring different type and number of tool-work motions. Even for the same type of
machine tool the designer may take different kinematic structure depending upon productivity, process
capability, durability, compactness, overall cost etc. targeted.
The kinematic system enables the drilling machine the following essential works;

Cutting motion: The cutting motion in drilling machines is attained by rotating the drill at different
speeds (r.p.m.). Like center lathes, milling machines etc., drilling machines also need to have a
reasonably large number of spindle speeds to cover the useful ranges of work material, tool material,
drill diameter, machining and machine tool conditions. But, our machine has four spindle speeds
because it uses for single application only (8mm carbon steel plate).
Feed motion: In drilling machines, generally both the cutting motion and feed motion are imparted to
the drill. Like cutting velocity or speed, the feed (rate) also needs varying (within a range) depending
upon the tool-work materials and other conditions and requirements. This is not the case for our
machine the feed motion is by using the movement of the work table rather imparting it into the drill.
This is because of the kinematics difficulty to move the seven spindles together. The feed rate can be
varied manually by giving either slow or quicker motion to the work table by the working operator.
Tool work mounting: The taper shank drills are fitted into the taper hole of the spindle through taper
socket(s). Small straight shank drills are fitted through a drill chuck having taper shank. The
workpiece is kept rigidly fixed on the bed (of the table). Small jobs are generally held in vice and large
or odd shaped jobs are directly mounted on the bed by clamping tools using the T-slots made in the top
and side surfaces of the bed.
Design Sequence for Power Transmission
STEP1. Power and torque requirements: Power considerations should be addressed first, as this will
determine the overall sizing needs for the entire system. Any necessary speed or torque ratio from
input to output must be determined before addressing gear/pulley sizing.
Given datas
Workpiece material having Brinell hardness 𝑛𝑜, 𝐵𝐻𝑁 = 200, Hole diameter,𝑑 = 12𝑚𝑚, center
distance of the holes, 𝐶 = 90𝑚𝑚, number of holes 7, thickness of the plate, 𝑡 = 8𝑚𝑚.

3.3 CUTTING DATA
1. The cutting speed or surface speed (vc): the cutting speed for drilling is determined by the periphery
speed and can be calculated from the spindle speed (N). There are four spindle speeds for our drill
head and therefore four possible cutting speeds are calculated below.
𝜋𝑥𝑑 𝑁 𝜋 𝑥 0.012 300 𝜋𝑥𝑑 𝑁 𝜋 𝑥 0.012 400

𝑉𝑐, 1 = = , 𝑉𝑐, 2 = =
12 12 12 12
= 0.943 𝑚/𝑠 = 1.26 𝑚/𝑠
𝜋𝑥𝑑 𝑁 𝜋 𝑥 0.012 500 𝜋𝑥𝑑 𝑁 𝜋 𝑥 0.012 600

𝑉𝑐, 3 = = , 𝑉𝑐, 4 = =
12 12 12 12
= 1.57 𝑚/𝑠 = 1.885 𝑚/𝑠
𝑊𝑕𝑒𝑟𝑒 𝑑 𝑖𝑠 𝑡𝑕𝑒 𝑡𝑜𝑜𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑎𝑛𝑑 𝑁 𝑖𝑠 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑.
NOTE THAT: The optimum drill speed for a particular setup is affected by many factors, including
the following: Composition, hardness & thermal conductivity (k) of material , Depth of hole ,
Efficiency of cutting fluid , Type, condition and stiffness of drilling machine , Stiffness of, workpiece,
fixture and tooling (shorter is better) , Quality of holes desired , life of tool before regrind or
replacement.
2. The feed per revolution (ƒn): in mm/rev expresses the axial movement of the tool during one
revolution. The recommended feed for steel is 0.3 mm/rev.
3. The penetration rate or feed speed (vf): in mm/min is the feed of the tool in relation to the
workpiece expressed in length per unit of time. This is also known as the machine feed or table feed.
The product of feed per revolution and spindle speed gives the rate at which the drill penetrates the
workpiece.
Vf,1 = ƒn× N = 0.3 mm/rev× 300 rev/min = 90 mm/min (1.5 mm/s),
Vf,2 = ƒn× N = 0.3 mm/rev× 400 rev/min = 120 mm/min (2 mm/s),
Vf,3 = ƒn× N = 0.3 mm/rev× 500 rev/min = 150 mm/min (2.5 mm/s) and
Vf,4 = ƒn× N=0.3 mm/rev× 600 rev/min= 180 mm/min (3 mm/s)

4. Material removal rate (Q): The material removal rate in drilling is the volume of material removed
by the drill per unit time.
ᴨ𝑑 2 ᴨ(122 ) 𝑚𝑚3
𝑄1 = ×𝑓×𝑁 = × 0.3 × 600 = 20357.52 𝑚𝑚3 /min⁡
(339.3 )
4 4 𝑠
ᴨ𝑑 2 ᴨ(122 ) 3
𝑚𝑚3
𝑄2 = ×𝑓×𝑁 = × 0.3 × 500 = 16964.6 𝑚𝑚 /min⁡
(282.75 )
4 4 𝑠
ᴨ𝑑 2 ᴨ(122 ) 3
𝑚𝑚3
𝑄3 = ×𝑓×𝑁 = × 0.3 × 400 = 13571.68 𝑚𝑚 /min⁡
(226.2 )
4 4 𝑠
ᴨ𝑑2 ᴨ(122 ) 𝑚𝑚3

𝑄4 = ×𝑓×𝑁 = × 0.3 × 300 = 10178.76 𝑚𝑚3 /min⁡
(169.6 )
4 4 𝑠
5. Torque (m) in Nm is regard as the total drilling moment that the drill is subjected to during
machining. The feed, diameter and material are the main factors that affect the torque value. The
equation for torque of a drill of regular proportions whose 𝑐/𝑑 may be set equal to 0.18,
𝑀 = 41.7 × 106 𝑓𝑛0.8 𝑑1.9 = 41.7 × 106 0.00030.8 0.0121.9 = 14.2 𝑁𝑚 𝑓𝑜𝑟 𝑠𝑡𝑒𝑒𝑙.
𝑊𝑕𝑒𝑟𝑒 𝑐 − 𝑐𝑕𝑖𝑠𝑒𝑙 𝑒𝑑𝑔𝑒 𝑙𝑒𝑛𝑔𝑡𝑕, 𝑓𝑛 − 𝑓𝑒𝑒𝑑 𝑝𝑒𝑟 𝑟𝑒𝑣.
6. The feed force (ff): in N is usually the most important in drilling from a performance point of view.
This is the axial force acting on the drill as it penetrates the material. It needs to be considered in order
to ensure that the spindle power and strength is sufficient for the drilling operation.
The feed force is equal to the axial thrust force created during drilling application.
7. Estimating drilling thrust: 𝑇 = 0.05𝐾𝑑𝐹𝑓𝐹𝑡𝐵𝑊 + 0 .007𝐾𝑑𝑑2𝐽𝑊 = 0.05 × 24000 × 0.382 ×
7.297 × 1.355 × 1.3 + 0.007 × 24000 × 0.0122 × 0.03 × 1.3 = 6 𝐾𝑁
Where: 𝑇 = 𝑎𝑥𝑖𝑎𝑙 𝑡𝑕𝑟𝑢𝑠𝑡, 𝐹𝑓 = 𝑓𝑒𝑒𝑑 𝑓𝑎𝑐𝑡𝑜𝑟 0.382 , 𝐹𝑇 = 𝑡𝑕𝑟𝑢𝑠𝑡 𝑓𝑎𝑐𝑡𝑜𝑟 (7.297)
𝐵 = 𝑐𝑕𝑖𝑒𝑠𝑒𝑙 𝑒𝑑𝑔𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑡𝑕𝑟𝑢𝑠𝑡 1.355 , 𝐽 = 𝑐𝑕𝑖𝑒𝑠𝑒𝑙 𝑒𝑑𝑔𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑡𝑕𝑟𝑢𝑠𝑡(0.030)
𝑊 = 𝑡𝑜𝑜𝑙 𝑤𝑒𝑎𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 1.3 , 𝐷 = 𝑑𝑟𝑖𝑙𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

The feed factor for drilling at feed of 0.3 is therefore 0.382 (table A-4)
The drill diameter factors at diameter of 12mm are determined by iteration (data from table A-5)
7.54 – 6.81 12 – 11
𝐹𝑇 = = 7.297 𝑎𝑛𝑑
12.5 – 11
94.28 – 74.9 12 – 11
𝐹𝑀 = = 12.92
12.5 – 11
At 𝑐/𝑑 = 0.18 the factors become A = 1.155, B = 1.355, J = 0.030 (table A-6)
The tool wear factor for normal drilling operation is therefore 1.3 (table A-3)
The work material factor for steel having Brinell hardness number is therefore 24,000 (table A-7)
8. Estimating machining power: Knowledge of the power required to perform machining operations is
useful when planning new machining operations, for optimizing existing machining operations, and to
develop specifications for new machine tools that are to be acquired.
The power required to cut a material is dependent upon the rate at which the material being cut and
upon an experimentally determined power constant (unit power or specific power consumption), Kp.
The power constant is the power required to cut a unit of material removal rate. The unit of power
constant is Kw/ (cm3/s) for metric unit; which is tabulated for different material see appendix A.
The power constant for steel material having Brinell hardness number (BHN) 200 is therefore 2.32
from table A-1.
The effect of rake angle usually can be disregarded. The rake angle for which most of the data in the
power constant tables are given is positive 14 degrees.
The machine tool transmits the power from the driving motor to the workpiece, where it is used to cut
the material. The effectiveness of the transmission is measured by the machine tool efficiency factor,
E. take the factor 0.9 for chain drive and gear mechanism for our assumption.

𝑃𝑐 = 𝐾𝑝𝐶𝑄𝑊
𝑃𝑐 𝐾𝑝𝐶𝑄𝑊
𝑃𝑚 = =
𝐸 𝐸
𝑊𝑕𝑒𝑟𝑒: 𝑃𝑐 = 𝑝𝑜𝑤𝑒𝑟 𝑎𝑡 𝑡𝑕𝑒 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑡𝑜𝑜𝑙 𝑖𝑛 𝐾𝑊, 𝑃𝑚 = 𝑝𝑜𝑤𝑒𝑟 𝑎𝑡 𝑡𝑕𝑒 𝑚𝑜𝑡𝑜𝑟 𝑖𝑛 𝐾𝑊
𝐾𝑝 = 𝑝𝑜𝑤𝑒𝑟 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡, 𝑄 = 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑟𝑒𝑚𝑜𝑣𝑎𝑙 𝑟𝑎𝑡𝑒,
𝐶 = 𝑓𝑒𝑒𝑑 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡, 𝑊 = 𝑡𝑜𝑜𝑙 𝑤𝑒𝑎𝑟 𝑓𝑎𝑐𝑡𝑜𝑟,
𝐸 = 𝑚𝑎𝑐𝑕𝑖𝑛𝑒 𝑡𝑜𝑜𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 𝑉 = 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑
𝑁 = 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑 𝑖𝑛 𝑟𝑝𝑚, 𝑓 = 𝑓𝑒𝑒𝑑 𝑟𝑎𝑡𝑒 𝑓𝑜𝑟 𝑡𝑢𝑟𝑛𝑖𝑛𝑔,
0.30𝑚𝑚
𝑑 = 𝑑𝑒𝑝𝑡𝑕 𝑜𝑓 𝑐𝑢𝑡𝐶 = 1 𝑓𝑜𝑟 𝑓𝑒𝑒𝑑 𝑜𝑓 , 𝑊 = 1.3, 𝐸 = 0.9,
𝑟𝑒𝑣
𝑑 = 8𝑚𝑚,
𝑃𝑐 = 𝐾𝑝𝐶𝑄𝑊 = 2.32 × 0.3393 × 1.3 = 1.0233 KW (for single spindle)
𝐹𝑜𝑟 𝑠𝑒𝑣𝑒𝑛 𝑠𝑝𝑖𝑛𝑑𝑙𝑒𝑠; 𝑃𝑐, 7 = 7 × 1.0233 = 7.16 𝐾𝑊
𝑃𝑐 7.16
𝑃𝑜𝑤𝑒𝑟 𝑎𝑡 𝑡𝑕𝑒 𝑚𝑜𝑡𝑜𝑟; 𝑃𝑚 = = = 7.96 𝐾𝑊 ≅ 8 𝐾𝑊 = 10.7𝑕𝑝 ≅ 11𝑕𝑝
𝐸 0.9
The feed factor for power constant at feed of 0.3mm is therefore 1.00 (from table A-2)
Whenever possible the maximum power available on a machine tool should is used when heavy cuts
must be taken. Summarizing the values yet calculated:
60𝑃 60 × 8
𝑃 = 8 𝐾𝑊, 𝑉. 𝑅𝑚𝑖𝑛 = 2.333 𝑎𝑛𝑑, 𝑉. 𝑅𝑚𝑎𝑥 = 4.67, 𝑇1 = =
2  2  × 300
= 254.65 𝑁. 𝑚 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑡𝑜𝑟𝑞𝑢𝑒 𝑚𝑎𝑥𝑖𝑚𝑢𝑚

60𝑃 60 × 8
𝑇2 = = = 191 𝑁. 𝑚,
2  2  × 400
60𝑃 60 × 8
𝑇3 = = = 152.8 𝑁. 𝑚
2  2  × 500
60𝑃 60 × 8
𝑇4 = = = 127.3 𝑁. 𝑚 (𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑡𝑜𝑟𝑞𝑢𝑒) 𝑚𝑖𝑛𝑖𝑚𝑢𝑚
2 2 × 600
3.4 DRILL MOTOR SELECTION
The drilling operation can be very complex and require detailed planning for any type of application.
Several factors must be considered when selecting the motor for a drilling application. These include hole
size, drill bit type, Required bit speed and torque.
Specification of the motor: 𝑝𝑜𝑤𝑒𝑟 = 8 𝐾𝑊, 𝑆𝑝𝑒𝑒𝑑: 1440 𝑟𝑝𝑚, 3 − 𝑝𝑕𝑎𝑠𝑒 𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑚𝑜𝑡𝑜𝑟
STEP TWO: Gear and sprocket specification. Necessary gear ratios and torque transmission issues can
now be addressed with selection of appropriate gears and sprocket.
3.5 CHAIN AND SPROCKET DESIGN
Fig 3.1 Pictures of components of chain
The chains are mostly used to transmit motion and power from one shaft to another, when the centre
distance between their shafts is short such as in bicycles, motor cycles, agricultural machinery,
conveyors, rolling mills, road rollers etc.

The chains may also be used for long center distance of up to 8 meters. The chains are used for
velocities up to 25 m/s and for power up to 110kw. In some cases, higher power transmission is also
possible.
Fig.3.2 Sprockets and chains
ADVANTAGES OF CHAIN
 As no slip takes place during chain drive, hence perfect velocity ratio is obtained.
 Since the chins are made of metal, therefore they occupy less space in width than a belt or
rope drive.
 It may used for both long as well as short distances.
 It gives high transmission efficiency (up to 98%).
 It gives fewer loads on the shafts.
 It has the ability to transmit motion to several shafts by one chain only.
 It transmits more power than belts.
 It can be operated under adverse temperature and atmospheric conditions.
 It permits high speed ratio of 8 to 10 in one step.

DISADVANTAGES
 The production cost of chains is relatively high.
 The chain drive needs accurate mounting and careful maintenance, particularly lubrication and
slack adjustment.
 The chain drive has velocity fluctuations especially when unduly (excessively) stretched.
SELECTION OF THE TYPE OF CHAIN: BUSH ROLLER CHAIN.
POWER TRANSMITTING CHAINS
These chains are used for transmission of power, when the distance between the centers of shaft is short.
These chains have provision for efficient lubrication. The power transmitting chains are of the following
three types.
1. Block or bush chain. These types of chain were used in the early stages of development in the power
transmission. It produces noise when approaching or leaving the teeth of the sprocket because of rubbing
between the teeth and the links.
2. Bush roller chain. A bush roller chain as shown in Fig. 21.7 consists of outer plates or pin link plates,
inner plates or roller link plates, pins, bushes and rollers. A pin passes through the bush which is secured
in the holes of the roller between the two sides of the chain. The rollers are free to rotate on the bush
which protects the sprocket wheel teeth against wear. The pins, bushes and rollers are made of alloy steel.

Fig 3.3 Bush roller chain
A bush roller chain is extremely strong and simple in construction. It gives good service under severe
conditions. There is a little noise with this chain which is due to impact of the rollers on the sprocket
wheel teeth. This chain may be used where there is a little lubrication.
The roller chains are standardized and manufactured on the basis of pitch. These chains are available in
single-row or multi-row roller chains such as simple, duplex or triplex strands, as shown in Fig3.5.
Fig 3.4 types of roller chain
3. Silent chain. A silent chain (also known as inverted tooth chain)

CHAIN DESIGN
We have one chain and 12 sprockets, and 7 gears for our mechanism; one chain for reduction of speed
and the gears for transmitting motion from the main spindle to the rest of each spindle. Four integrated
sprockets on the motor shaft, four integrated sprockets are on the top of the main spindle and on the idler
shaft and the gears on each spindle. This mechanism is easily understood by looking the drawing. We are
used gear system instead of either belt or chain mechanism because with the belt we can’t transmit
motion from the main spindle to each spindle as we need and to use the chain it is impossible since the
center distance specified is very short.
IDLER SPROCKETS: when the drive and the driven sprocket centers are fixed it may be desirable to
include idlers sprocket to take up slack in the chain. Idler sprockets should preferably be located against
the slack side of the chain with in the chain envelope-diverting the chain outwards.
1 speed reduction chain: the motor speed must be reduced at the drill to power the drilling operation
since motors have low torque. This can be accomplished by reducing the speed of the motor and
increasing the torque by using the speed reducing chain in the motion transmitting mechanism.
Design Procedure of Chain Drive
Step 1: Determine the velocity ratio
Velocity ratio of chain drives
The velocity ratio of a chain drive is given by;
𝑁1 𝑇2
𝑉. 𝑅 = =
𝑁2 𝑇1
𝑁1 = 𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑠𝑚𝑎𝑙𝑙𝑒𝑟 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡 (𝑚𝑜𝑡𝑜𝑟 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡) 𝑖𝑛 𝑟𝑝𝑚

𝑁2 = 𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑙𝑎𝑟𝑔𝑒𝑟 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡 𝑖𝑛 𝑟𝑝𝑚
𝑇1 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡𝑕 𝑜𝑛 𝑡𝑕𝑒 𝑠𝑚𝑎𝑙𝑙𝑒𝑟 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡, 𝑎𝑛𝑑
𝑇2 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡𝑕 𝑜𝑛 𝑡𝑕𝑒 𝑙𝑎𝑟𝑔𝑒𝑟 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡.
We have four spindle speeds and therefore four VR are there.
𝑇𝑕𝑒 𝑚𝑜𝑡𝑜𝑟 𝑠𝑝𝑒𝑒𝑑, 𝑁𝑚𝑜𝑡𝑜𝑟 = 1400𝑟𝑝𝑚,
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑, 𝑁𝑚𝑖𝑛 = 300𝑟𝑝𝑚, 𝑁2 = 400𝑟𝑝𝑚, 𝑁3 = 500𝑟𝑝𝑚
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑, 𝑁𝑚𝑎𝑥 = 600𝑟𝑝𝑚
1400 1400 1400

𝑉. 𝑅1 = = 4.667 𝑠𝑎𝑦 5, 𝑉. 𝑅2 = = 3.5, 𝑉. 𝑅3 = = 2.8 𝑎𝑛𝑑
300 400 500
𝑉. 𝑅4 = 1400/600 = 2.33 𝑠𝑎𝑦 3
Step 2: Minimum no of teeth on the smaller sprocket
From Table A-9, we find that for the roller chain, the number of teeth on the smaller sprocket or pinion
(T1) for a velocity ratio of 5 and 3 is 21 and 25 respectively. Therefore, the minimum no. of teeth on the
motor sprocket becomes 25 teeth.
Step 3: No of teeth on the larger sprocket
The Number of teeth on the larger sprockets is therefore,
𝑇2 = 𝑇1 × 4.667 = 25 × 4.667 = 117, 𝑇2′ = 𝑇1 × 3.5 = 25 × 3.5 = 88, 𝑇2′′ = 𝑇1 ×
2.8 = 25 × 2.8 = 70 𝑇2′′′ = 𝑇1’ × 2.333 = 25 × 2.333 = 59

Step 4: Design power
Design power = Rated power× Service factor
The service factor (KS) is the product of various factors, such as load factor (K1), lubrication factor (K2)
and rating factor (K3). The values of these factors are taken as follows:
Load factor = 1, for continuous load, Lubrication factor =1.5, for periodic lubrication
Rating factor = 1.5, for continuous service
Ks = 1× 1.5×1.5 = 2.25
Design power = rated power×service factor = 8×2.25 =18 KW
Step 5: No of strand of the chain
From Table A-12, we find that corresponding to a pinion speed of 1400 r.p.m. the power transmitted for
chain No. 12 is 18.15 kW per strand. Therefore, a chain No. 12 with single strand can be used to transmit
the required power (18KW).
Step 6: The chxcs of the roller chain
From Table A-11, we find that Pitch, p = 19.05 mm, roller diameter, d1 = 12.07mm (max), the width of
plates, b1 = 11.68mm (max), breaking load = 28.9KN for 12B ISO chain number.
Step 7: Pitch circle diameter and Pitch line velocity
180 180
The pitch circle diameter of the smaller sprocket, D1 = p csc =19.05csc =152mm
T1 25
180 180
And the pitch circle diameter of the larger sprocket, D2 = p csc =19.05csc =709.5mm
T2 117
180 180
D2’ = p csc =19.05csc =357.9mm
T2′ 59

152 ∗ 1400 𝑚
𝑃𝑖𝑡𝑐𝑕 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑡𝑕𝑒 𝑠𝑚𝑎𝑙𝑙𝑒𝑟 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡, 𝑉1 =  𝐷1𝑁1/60 =  = 11.14
60 𝑠
𝑊𝑕𝑒𝑟𝑒 𝐷 = 𝑝𝑖𝑡𝑐𝑕 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡𝑕𝑒 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡 𝑎𝑛𝑑
𝑃 = 𝑝𝑖𝑡𝑐𝑕 𝑜𝑓 𝑡𝑕𝑒 𝑐𝑕𝑎𝑖𝑛 𝑖𝑛 𝑚𝑒𝑡𝑒𝑟𝑠.
Step 8: Load on the chain becomes:
𝑊 = (𝑟𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟)/(𝑝𝑖𝑡𝑐𝑕 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦) = 18/11.14 = 1.615𝐾𝑁
Step 9: Factor of safety
The following table shows the factor of safety for the bush roller and silent chains depending upon the
speed of the sprocket pinion in r.p.m. and pitch of the chains.
𝑡𝑕𝑒 𝑙𝑜𝑎𝑑 𝑤𝑕𝑒𝑟𝑒 𝑡𝑕𝑒 𝑐𝑕𝑎𝑖𝑛 𝑐𝑎𝑛 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡

𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 =
𝑙𝑜𝑎𝑑 𝑜𝑛 𝑡𝑕𝑒 𝑐𝑕𝑎𝑖𝑛
= WB/W = 28.9 / 1.615
= 18> 13.2 > 11.7 𝑖𝑡 𝑖𝑠 𝑚𝑜𝑟𝑒 𝑠𝑎𝑓𝑒‼ (referring table A-10)
Step 10: Center distance
The centre distance is given by;
2 2
𝑝 𝑇1 + 𝑇2 𝑇1 + 𝑇2 𝑇1 − 𝑇2
𝑥 = 𝐾− + 𝐾− −8
4 2 2 2
The minimum centre distance between the smaller and larger sprockets should be 30 to 50 times the
pitch. Let us take it as 30 times the pitch.
∴ Centre distance between the sprockets, = 30 p = 30 × 19.05 = 572 mm, In order to accommodate initial
sag in the chain, the value of centre distance is reduced by 2 to 5 mm.

∴ Correct centre distance, x = 572 – 2 = 570 mm
The number of chain links may be obtained from the following expression, i.e.
( 𝑇1 + 𝑇2)𝑚𝑎𝑥 2𝑥 𝑇1− 𝑇2 2 𝑝 25 + 117 2∗570 25− 117 2 19.05

𝐾 = + + = + + = 138 max
2 𝑝 2 𝑥 2 19.05 2 570
Step 11: The length of the chain
An open chain drive system connecting the two sprockets is shown in Fig. 3.4
The length of the chain (L) must be equal to the product of the number of chain links (K) and the pitch of
the chain (p). Mathematically, L = Kp
∴ Length of the chain, L = K.p = 138 × 19.05 = 2629 mm = 2.629 m
Angular contact of the chain on the sprockets:
𝑇2 − 𝑇1 117 − 25
1 = 180° − 2 sin−1 = 180° − 2 sin−1 = 170.8° > 120°
2𝐶 2 × 570
𝑇2 − 𝑇1 117 − 25
2 = 180° + 2 sin−1 = 180° + 2 sin−1 = 189.3° > 120°
2𝐶 2 × 570
PRINCIPAL DIMENSIONS OF TOOTH PROFILE
The standard profiles for the teeth of a sprocket are shown in Fig. 3.7. According to Indian Standards (IS:
2403 – 1991), the principal dimensions of the tooth profile are as follows:
Top diameter (Da)
Da = D + 1.25p – d1……………..maximum
= 152 + 1.25×19.05 – 12.07 = 163.74 mm (motor sprocket)
= 709.5 + 1.25×19.05 – 12.07 = 721.24 mm (spindle larger sprocket)
Root diameter (Df); Df = D -2 ri
For motor sprocket;
Df = 152 - 2 ×7.67 = 136.66 mm ………….max

For spindle sprockets;
Df = 709.5 - 2 ×7.67 = 694.16 mm ………….max
Tooth width (bf1); bf1 = 0.93b1 when p ≤ 12.7𝑚𝑚
= 0.95b1 when p > 12.7𝑚𝑚 where b1 is the width of plates, which is 11.68mm.
For pitch of 19.05mm the tooth width becomes, bf1 = 0.95b1= 0.95× 11.68 = 11.09𝑚𝑚
Summary on sprocket and chain
Sprocket specification: main spindle sprocket pitch diameter, D2 = 709.5mm
Motor sprocket pitch diameter, D1 = 152mm
Main spindle sprocket outer diameter, Do = 721.24m
Motor sprocket outer diameter, Da = 163.74mm
Tangential force created on the sprocket, Fs = P/V = 8/11.14 = 0.718 KN
Tangential component of force on the shaft:

189.3−180
𝐹𝑠, 𝑇 = 0.718 × 𝑐𝑜𝑠 ∅ = 0.718 × 𝑐𝑜𝑠( ) = 0.715 𝐾𝑁
2
Radial component of force on the shaft:

189.3−180
𝐹𝑠, 𝑅 = 0.718 × 𝑠𝑖𝑛 ∅ = 0.718 × 𝑠𝑖𝑛( ) = 0.0582 𝐾𝑁
2
Where ∅ − Angule of contact of the chain on the sprocket
3.6 GEAR DESIGN
Advantages and Disadvantages of Gear Drives
The following are the advantages and disadvantages of the gear drive as compared to other drives, i.e.
belt, rope and chain drives:

Advantages
1. It transmits exact velocity ratio.
2. It may be used to transmit large power.
3. It may be used for small center distances of shafts.
4. It has high efficiency.
5. It has reliable service.
6. It has compact layout.
Disadvantages
1. Since the manufacture of gears requires special tools and equipment, therefore it is costlier than
other drives.
2. The error in cutting teeth may cause vibrations and noise during operation.
3. It requires suitable lubricant and reliable method of applying it, for the proper operation of gear
drives.
Advantages of using parallel Helical Gears
1. Helical gears, used to transmit motion between parallel shafts.
2. The gradual engagement of the teeth and the smooth transfer of load from one tooth to
another that give helical gears the ability to transmit heavy loads at high speeds.
3. Helical gears can be used for the same applications as spur gears and, when so used, are not as
noisy, because of the more gradual engagement of the teeth during meshing.
4. Helical gears subject the shaft bearings to both radial and thrust loads. When the thrust loads
become high or are objectionable for other reasons, it may be desirable to use double helical
gears.
Design the seven helical gears: The power transmitted by the gears, P = 8KW and the speed of the gears,
N = 600,500, 400 and 300rpm.

Proportions for Helical Gears
Though the proportions for helical gears are not standardized, yet the following are recommended by
American Gear Manufacturer's Association (AGMA). Let module, 𝑚 = 4.5𝑚𝑚/𝑡𝑜𝑜𝑡𝑕
Pressure angle (in the plane of rotation),  = 150 to 250, let  = 200
Helix angle,  = 200 to 450, let  = 250
Addendum, a = 1m (maximum), let a = 1m =4.5
Dedendum, d = 1.25m (minimum), let d = 1.25m = 5.625 mm
Total depth, h = 2.25 m = 2.25 ×4.5 = 10.125mm
Clearance, c = 0.25 m = 0.25 ×4.5 = 0.9 mm
Thickness of the tooth bt = 1.5708m = 1.5708 × 4.5 = 7.07 𝑚𝑚
Circular pitch, pc= m = 4.5 = 14.14 mm, Normal pitch, pn = pccos  = 14.14 cos 25 = 12.8 mm
The Normal pressure angle, N = tan−1 (𝑡𝑎𝑛 𝑐𝑜𝑠) = tan−1 (𝑡𝑎𝑛20𝑐𝑜𝑠25) = 18.250
The minimum number of teeth on the pinion gear
The smallest tooth number TP of a helical-spur pinion that will run without interference with a gear with
the same number of teeth is,
𝑐𝑜𝑠 𝑐𝑜𝑠25
𝑇𝑝 = 2𝑘 (1 + 1 + 3𝑠𝑖𝑛2  ) = 2 × 1 (1 + 1 + 3𝑠𝑖𝑛2 20 ) = 12 𝑡𝑒𝑒𝑡𝑕
3𝑠𝑖𝑛 
2 3𝑠𝑖𝑛2 20
The actual no of teeth on the gears
Center distance b/n the shafts, 𝐶, 𝑖𝑠 90𝑚𝑚,
𝐷𝑃 + 𝐷𝐺 2𝐷
𝐶 = = (𝑆𝑖𝑛𝑐𝑒 𝑡𝑕𝑒 𝑝𝑖𝑡𝑐𝑕 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡𝑕𝑒 𝑔𝑒𝑎𝑟𝑠 𝑎𝑟𝑒 𝑒𝑞𝑢𝑎𝑙)
2 2
𝐶 = 𝐷 = 90𝑚𝑚
𝑝𝑖𝑡𝑐𝑕 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝐷 𝐷 90 𝑚𝑚
𝑀𝑜𝑑𝑢𝑙𝑒 = , 𝑇 = = = 20 𝑡𝑒𝑒𝑡𝑕 > 12 𝑡𝑒𝑒𝑡𝑕
𝑛𝑜 𝑜𝑓 𝑡𝑒𝑒𝑡𝑕 𝑇 𝑚 4.5 𝑚𝑚
𝑡𝑜𝑜𝑡 𝑕

Face Width of Helical Gears
In order to have more than one pair of teeth in contact, the tooth displacement (i.e. the advancement of
one end of tooth over the other end) or overlap should be at least equal to the axial pitch, such that
Overlap = pc= b tan () …………….equation 1
The axial or end thrust is given by WA = WN sin () = WT tan () ………. equation 2
From equation (1), we see that as the helix angle increases, then the tooth overlap increases. But at the
same time, the end thrust as given by equation (2), also increases, which is undesirable. It is usually
recommended that the overlap should be 15 percent of the circular pitch.
1.15𝑝𝑐 1.15𝑚
𝑂𝑣𝑒𝑟𝑙𝑎𝑝 = 𝑏 tan  = 1.15𝑝𝑐 𝑜𝑟 𝑏 = =  𝑝𝑐 = 𝑚,
𝑡𝑎𝑛  𝑡𝑎𝑛 
1.15𝑚 1.15 × 4.5

𝑏 = = = 35 𝑚𝑚
𝑡𝑎𝑛  𝑡𝑎𝑛 25
Let b = 40 mm
Where b = minimum face width and, m = module
Force analysis
The normal tooth load (WN) has two components; one is tangential component (WT) and the other axial
component (WA).
We know that the maximum torque transmitted by the pinion, 𝑇 = 60𝑃/ (2𝑁𝑝) = 60 × 8 ×
1000 / (2 × 300) = 254.7 𝑁 − 𝑚 (𝑚𝑎𝑥)
2𝑇 2 × 254.7
𝑇𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑡𝑜𝑜𝑡𝑕 𝑙𝑜𝑎𝑑 𝑜𝑛 𝑡𝑕𝑒 𝑝𝑖𝑛𝑖𝑜𝑛, 𝑊𝑇 = =
𝐷 0.09
= 5.7 𝐾𝑁 𝑇𝑕𝑒 𝑎𝑥𝑖𝑎𝑙 𝑜𝑟 𝑒𝑛𝑑 𝑡𝑕𝑟𝑢𝑠𝑡 𝑖𝑠 𝑔𝑖𝑣𝑒𝑛 𝑏𝑦 𝑊𝐴 = 𝑊𝑁 𝑠𝑖𝑛 () = 𝑊𝑇 𝑡𝑎𝑛 ()
= 5.7 𝑡𝑎𝑛 (25) = 2.66 𝐾𝑁

𝑇𝑕𝑒 𝑛𝑜𝑟𝑚𝑎𝑙 𝑡𝑜𝑜𝑡𝑕 𝑙𝑜𝑎𝑑, 𝑊𝑁 = 𝑊𝐴/ 𝑠𝑖𝑛 () = 2.66/ 𝑠𝑖𝑛 (25) = 6.29 𝐾𝑁
𝑇𝑕𝑒 𝑟𝑎𝑑𝑖𝑎𝑙 𝑡𝑜𝑜𝑡𝑕 𝑙𝑜𝑎𝑑, 𝑊𝑅 = 𝑊𝑇 𝑡𝑎𝑛 = = 2.66 𝑡𝑎𝑛20 = 0.97 𝐾𝑁
Formative or Equivalent Number of Teeth for Helical Gears:
𝑇𝐸 = 𝑇 /𝑐𝑜𝑠3 = 20 /𝑐𝑜𝑠3(25) = 27 𝑡𝑒𝑒𝑡𝑕
Where T = actual number of teeth on a helical gear
Contact ratios: 1. The transverse contact ratio is the same as that of the spur gears. It shows the number
of teeth in contact in the plane of rotation, which is defined as the length of contract divided by the base
pitch. 𝑀𝑎𝑡𝑕𝑒𝑚𝑎𝑡𝑖𝑐𝑎𝑙𝑙𝑦
𝐿 2 (𝑟+𝑎)2 −(𝑟 𝑐𝑜𝑠 )2 − 𝐶 𝑠𝑖𝑛  2 45+3.6 2 −2 45 𝑐𝑜𝑠 20 2 – 90 𝑠𝑖𝑛 20

𝑚𝑐 = 𝑝𝑐𝑜𝑠  = = = 1.28, 𝑤𝑕𝑒𝑟𝑒, 𝑝𝑐 =
𝑝𝑐𝑜𝑠  (14.14𝑐𝑜𝑠 20)
𝑚 =  × 4.5 = 14.14𝑚𝑚
Where 𝑍 − 𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡, 𝑟 – 𝑃𝑖𝑡𝑐𝑕 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑎 – 𝑎𝑑𝑑𝑒𝑛𝑑𝑢𝑚, 𝐶 – 𝐶𝑒𝑛𝑡𝑒𝑟 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒
Axial contact ratio: The helix angle introduces another ratio called the axial contact ratio mF, which is
defined as the quetient of face width b and the axial pitch pc
𝑏 𝑏 𝑡𝑎𝑛 40 𝑡𝑎𝑛25
𝑚𝐹 = = = = 1.319
𝑝𝑐 𝑚 4.5
This ratio shuld at least be 1.15 and indicates the degree of helical overlaod in the mesh.
STRENGTH ANALYSIS OF POWER TRANSMITTING HELICAL GEARS (reference shigley
textbook)
In order to find the strength of helical gears, AGMA strength equation is used.
GEAR MATERIAL SELECTION- NITRIDED THROUGH-HARDENED STEELS: are commonly used
for gears. They have superior tensile strength to cast iron. They need heat treatment to get a surface
hardness that will resist wear.

THE BENDING STRESS IS:
𝑊𝑇𝐾𝑜𝐾𝑣𝐾𝑠𝐾𝐻𝐾𝐵
Ϭ =
𝑏𝑚𝑡𝑌𝐽
Where𝐾𝑜 − 𝑜𝑣𝑒𝑟𝑙𝑜𝑎𝑑 𝑓𝑎𝑐𝑡𝑜𝑟 1.25 , 𝐾𝑣 − 𝑑𝑦𝑛𝑎𝑚𝑖𝑐 𝑓𝑎𝑐𝑡𝑜𝑟 1.277
𝐾𝑠 − 𝑠𝑖𝑧𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 1.0 , 𝐾𝐻 − 𝑙𝑜𝑎𝑑 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 1.1254
𝐾𝐵 − 𝑟𝑖𝑚 𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑓𝑎𝑐𝑡𝑜𝑟 1.0 , 𝑌𝐽, 𝐺𝑒𝑜𝑚𝑒𝑡𝑟𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡𝑕
𝑚𝑡 − 𝑇𝑟𝑎𝑛𝑠𝑣𝑒𝑟𝑠𝑒 𝑚𝑒𝑡𝑟𝑖𝑐 𝑚𝑜𝑑𝑢𝑙𝑒, 𝑏 − 𝐹𝑎𝑐𝑒 𝑤𝑖𝑑𝑡𝑕
𝑊𝑇𝐾𝑜𝐾𝑣𝐾𝑠𝐾𝐻𝐾𝐵 1
𝑇𝑕𝑒𝑟𝑒𝑓𝑜𝑟𝑒, Ϭ = = 5.7 × 1.25 × 1.277 × 1.0 × 1.1254 ×
𝑏𝑚𝑡𝑌𝐽 40 × 4.5 × 0.24
= 237 𝑀𝑃𝑎
THE FUNDAMENTAL EQUATION FOR PITTING RESISTANCE (CONTACT STRESS)
𝑊𝑇𝐾𝑜𝐾𝑣𝐾𝑠𝐾𝐻𝑍𝑅
Ϭ𝑐 = 𝑍𝐸
𝑑𝑤1𝑏𝑍𝐼
𝑊𝑕𝑒𝑟𝑒 𝑍𝐸 − 𝑒𝑙𝑎𝑠𝑡𝑖𝑐 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 191 𝑀𝑃𝑎 , 𝑍𝑅 − 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 1.0
𝑑𝑤1 − 𝑝𝑖𝑡𝑐𝑕 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡𝑕𝑒 𝑝𝑖𝑛𝑖𝑜𝑛,
𝑍𝐼 − 𝑔𝑒𝑜𝑚𝑒𝑡𝑟𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑝𝑖𝑡𝑡𝑖𝑛𝑔 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 (0.107)
Ϭ𝑐 = 𝑍𝐸 (𝑊𝑇𝐾𝑜𝐾𝑣𝐾𝑠𝐾𝐻𝑍𝑅)/(𝑑𝑤1𝑏𝑍𝐼)
= 191 (5.7 × 1.25 × 1.277 × 1.0 × 1.1254 × 1.0)/(90 × 40 × 0.107)
= 984.7 𝑀𝑃𝑎
THE EQUATION FOR THE ALLOWABLE BENDING STRESS IS:
𝑆𝑡𝑌𝑁
Ϭ𝑎𝑙𝑙 =
𝑆𝐹𝑌ѳ𝑌𝑍
𝑊𝑕𝑒𝑟𝑒, 𝑆𝑡 − 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠, 𝑌𝑁 − 𝑡𝑕𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑐𝑦𝑐𝑙𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
𝑆𝐹 − 𝑡𝑕𝑒 𝐴𝐺𝑀𝐴 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦, 𝑌ѳ − 𝑡𝑕𝑒 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑓𝑎𝑐𝑡𝑜𝑟,

𝑌𝑍 − 𝑡𝑕𝑒 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟
THE EQUATION FOR THE CONTACT STRESS Ϭc, all IS
𝑆𝑐𝑍𝑁𝑍𝑊
Ϭ𝑐, 𝑎𝑙𝑙 =
𝑊𝑕𝑒𝑟𝑒, 𝑆𝑐 − 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑠𝑡𝑟𝑒𝑠𝑠, 𝑍𝑁 − 𝑡𝑕𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑐𝑦𝑐𝑙𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
𝑍𝑊 − 𝑡𝑕𝑒 𝑕𝑎𝑟𝑑𝑛𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑝𝑖𝑡𝑡𝑖𝑛𝑔 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒
Sc -allowable contact stress
For 2.5% chrome (no aluminum) Grade 3 steel, Sc = 1488.24 Mpa (from table A-8)
ZW-the hardness ratio factor for pitting resistance
𝑍𝑊 = 1.0 𝑠𝑖𝑛𝑐𝑒 𝑏𝑜𝑡𝑕 𝑜𝑓 𝑡𝑕𝑒 𝑔𝑒𝑎𝑟𝑠 𝑎𝑟𝑒 𝑒𝑞𝑢𝑎𝑙
Safety Factor SF
The ANSI/AGMA standards 2001-D04 and 2101-D04 contain a safety factor SF guarding against
bending fatigue failure and safety factor SH guarding against pitting failure.
1. Safety factor guarding against bending fatigue failure
𝑺𝑭 = Ϭ𝑎𝑙𝑙 / Ϭ = (𝑆𝑡𝑌𝑁/ (𝑆𝐹𝑌ѳ𝑌𝑍)) / Ϭ = (437.7)/ 237 = 1.8
2. Safety factor guarding against pitting failure
𝑺𝑯 = Ϭ𝑐, 𝑎𝑙𝑙 / Ϭ𝑐 = (𝑆𝑐𝑍𝑁𝑍𝑊/ (𝑆𝐹𝑌ѳ𝑌𝑍)) / Ϭ𝑐 = (1488.24)/ 984.7 = 1.5
Summary on the gear
Gear specification: module, m=4.5mm/tooth
Pitch diameter, dgear = 90 mm, Pressure angle (tangential),, 200, Helix angle,, 250
Face width, b, 40mm, T = 254.7 N.m (max), WT = 5.7 KN, WA = 2.66 KN, WR = 0.97 KN,
T = 6 KN, axial thrust on the spindle shaft.
Gear material: through hardened medium carbon steel

STEP 3: Shaft layout. The general layout of the shaft, including axial location of sprocket, gears and
bearings must now be specified.
1. Distance b/n the sprocket and the top bearing on the main spindle, Lo = 61 mm
2. Distance b/n the gear and the top bearing on the main spindle, Lo = 61 mm
3. Distance b/n the gear and the bottom bearing, Lo = 61mm
4. How to transmit the torque from the gears to the shaft-through key.
5. How to hold gears and bearings in place-through retaining rings.
Fig 3.5 Side sectional view of the housing
Fig 3 .6 front sectional view of the housing

STEP 4: Force analysis. Once the gear and sprocket diameters are known and the axial locations of the
sprocket, gears and bearings are known, the free-body, shear force, and bending moment diagrams for the
shafts can be produced Forces at the bearings can be determined.
FREE BODY DIAGRAM
ON THE MAIN SPINDLE:
X-Y plane
𝑀A = 0  RB, y× 122 = WR × 61 − Fs, r× 97
0.97 × 61 – 0.0582 × 97
𝑅 𝐵, 𝑦 = = 0.439 𝐾𝑁
122

𝐹𝑌 = 0  RA, y = 0.97 − 0.0582 − 0.439 = 0.473 𝐾𝑁
𝐹𝑥 = 0  RB, x = F𝐴 − 𝑊𝐴 = 6 – 2.66 = 3.34 KN
X-Z plane
𝑀A= 0  RB, z× 122 = 𝑊𝑇 × 61 − Fs, T × 97
 RB, z = (5.7 × 61 − 0.715 × 97)/122 = 2.282 KN
𝐹𝑌 = 0  RA, Z = WT – RB, Z−Fs, 𝑇 = 5.7 – 2.282 − 0.715 = 2.7 KN
Bearing forces
Thrust ball bearing:
Axial, RB, x = 3.34 KN,
Radial, RB = RB, z 2 + RB, y 2 = 2.2822 + 0.4392 = 2.324 𝐾𝑁
Ball bearing:
Radial, RA = RA, z 2 + RA, y 2 = 2.72 + 0.4732 = 2.741 𝐾𝑁
SHEAR FORCE AND BENDING MOMENT EQUATION
FOR 0< 𝑋 ≤ 97 FOR 97 < 𝑋 ≤ 158 FOR 158 < 𝑋 ≤ 219
X-Y Vy = 0.0582 𝐾𝑁 Vy = 0.531 KN, Vy = −0.4439 𝐾𝑁,

PLANE
Mz = 0.0582𝑋 𝑁. 𝑚 Mz = 0.531 𝑋 − 45.88 N.m Mz =104.38−0.439𝑋N.m
X-Z Vz = 0.715 KN, Vz = 3.415 𝐾𝑁 N, Vz =−2.285 𝐾𝑁,

PLANE
My = 0.715 𝑋 My = 3.415𝑋 − 261.9 My = −2.285𝑋 + 500

ON THE OTHER SPINDLES:
X-Y plane
0.97 ×61
𝑀A = 0  RB, y× 122 = WR × 61 , 𝑅𝐵, 𝑦 = = 0.485 𝐾𝑁
122
𝐹𝑌 = 0  RA, y = 0.485 − 0.97 = −0.485 𝐾𝑁
𝐹𝑥 = 0  RB, x = F𝐴 + 𝑊𝐴 = 6 + 2.66 = 8.66 KN
X-Z plane

𝑀A= 0  RB, z× 122 = 𝑊𝑇 × 61
 RB, z = (5.7 × 61)/122 = 2.85 KN
𝐹𝑌 = 0  RA, Z = WT – RB, Z−Fs, 𝑇 = 2.85 − 5.7 = −2.85 𝐾𝑁
Bearing forces
Axial, RB, x = 8.66 KN,
Radial, RB = RB, z 2 + RB, y 2 = 2.852 + 0.485 = 2.89 𝐾𝑁
Ball bearing:
Radial, RA = RA, z 2 + RA, y 2 = 2.85 2 + 0.4852 = 2.89 𝐾𝑁
SHEAR FORCE AND BENDING MOMENT EQUATION
FOR 0< 𝑋 ≤ 61 FOR 61 < 𝑋 ≤ 122
X-Y Vy = −0.485 𝐾𝑁, Vy = 0.485 KN,
PLANE Mz = −0.485𝑋 𝑁. 𝑚 Mz = 0.485𝑋 − 59.17 N.m
X-Z Vz = −2.85 KN, Vz = 2.85 𝐾𝑁 N,
PLANE My = −2.85𝑋 𝑁. 𝑚 My = 2.85 𝑋 − 347.7 N.m
STEP 5: Shaft material selection. Since fatigue design depends so heavily on the material choice, it is
usually easier to make a reasonable material selection first, and then check for satisfactory results.

Cold drawn steel is selected having the following properties:
UNSI NO AISI NO PROCESSING SUT, MPA SY,MPA E, GPA BRINELL
HARDNESS
G10500 1050 CD 690 580 207 197
STEP 6: 3.7 SPINDLE SHAFT DESIGN FOR STRESS (FATIGUE AND CONTACT). Shear force
and bending moment diagrams are known, critical locations can be predicted, approximate stress
concentrations can be used, and estimates for shaft diameters can be determined.
MAIN SPINDLE SHAFT:
Critical point: to the right of gear center, where key groove is there.
Where high bending moment, stress concentration at keaway, and torque presents.
M = 352 + 227.72 = 280 N.m, T = 254.65 N.m.
Assume the radius at the bottom of the keyway will be the standard, r/d = 0.02, r =0.02 d
From table A-13 first iteration estimates for stress concentration factors, Kt = 2.2 and Kts = 3.0 for quick,
conservative first pass, assume Kf = Kt, Kf s = Kts.
Endurance limit modifying factors
It is unrealistic to expect the endurance limit of a mechanical or structural member to match the values
obtained in the laboratory. Some differences include
• Material: composition, basis of failure, variability
• Manufacturing: method, heat treatment, fretting corrosion, surface condition, stress concentration
• Environment: corrosion, temperature, stress state, relaxation times
• Design: size, shape, life, stress state, stress concentration, speed, fretting, galling

Marin12 identified factors that quantified the effects of surface condition (Ka), size (Kb), loading (Kc),
temperature (Kd), reliability (Ke) and miscellaneous items (Kf). A Marin equation is therefore written as
𝑆𝑒 = 0.5 𝐾𝑎𝐾𝑏𝐾𝑐𝐾𝑑𝐾𝑒𝐾𝑓 𝑆𝑈𝑇
Ka = 𝑎𝑆𝑈𝑇 𝑏 , 𝑎 = 4.51 𝑀𝑃𝐴 𝑎𝑛𝑑 𝑏 = −0.265 𝑓𝑜𝑟 𝑐𝑜𝑙𝑑 𝑑𝑟𝑎𝑤𝑛 𝑠𝑢𝑟𝑓𝑎𝑐𝑒
Ka = 𝑎𝑆𝑈𝑇 𝑏 = 4.51 × 690−0.265 = 0.8
Kb = 1.51𝑑 −0.157 𝑓𝑜𝑟 51 < 𝑑 ≤ 254 𝑚𝑚, let Kb = 0.9 check later when the diameter is known
Kc = 1 for bending loading
Kd =1 for low temperature
Ke = 0.814 for 99% reliability
Kf = 1
𝑆𝑒 = 0.5 𝐾𝑎𝐾𝑏𝐾𝑐𝐾𝑑𝐾𝑒𝐾𝑓 𝑆𝑈𝑇 = 0.8 × 0.9 × 1.0 × 1.0 × 0.814 × 1.0 × 0.5 × 690 = 202.2 𝑀𝑃𝐴
When the shaft is subjected to an axial load (F) in addition to torsion and bending loads then the stress
due to axial load must be added to the bending stress (σb).
Note: In general, for a solid shaft subjected to fluctuating torsional and bending load, along with an axial
load, the equations for equivalent twisting moment (Te) and equivalent bending moment (Me) may be
written as M = 280 N.m, T = 254.7 N.m.
𝐹𝑑 2
𝑇𝑚 = 𝑇𝑒 = 1.6 × 𝑀 + + (1.6 × 𝑇)2
8
1 𝐹𝑑 𝐹𝑑 2
𝑀𝑎 = 𝑀𝑒 = 1.6 × 𝑀 + + 1.6 × 𝑀 + + (1.6 × 𝑇)2
2 8 8
For first estimate of the small diameter, use the DE-Goodman criterion .This criterion is good for the
initial design, since it is simple and conservative. With Mm = Ta = 0, the DE-Goodman criterion reduces
−1
𝑑 3 2𝐾𝑓𝑀𝑎 3 𝐾𝑓𝑠𝑇𝑚 2
to 𝑛 = +
16 𝑆𝑒 𝑆𝑈𝑇

Let d = 55mm
6000 ×0.055 2
𝑇𝑚 = 1.6 × 280 + + (1.6 × 254.7)2 = 636.8 𝑁𝑚
8
1 6000 ×0.055 6000 ×0.055 2

𝑀𝑎 = 2 1.6 × 280 + + 1.6 × 280 + + (1.6 × 254.7)2 = 563.1 𝑁𝑚
8 8
−1 −1
𝑑3 2𝐾𝑓𝑀𝑎 3 𝐾𝑓𝑠𝑇𝑚 2  × 0.0553 2 × 2.2 × 563.1 3 3 × 636.8 2
𝑛 = + = +
16 𝑆𝑒 𝑆𝑈𝑇 16 202.2 690
= 1.9 𝑠𝑎𝑓𝑒‼!
Assume the radius at the bottom of the keyway will be the standard 𝑟/𝑑 = 0.02, 𝑟 = 0.02 𝑑 =
0.02 × 55 = 1.1𝑚𝑚, from shigley text book we can find 𝐾𝑡 = 2.14, 𝑞 = 0.65
𝐾𝑓 = 1 + 0.65 2.14 − 1 = 1.74, 𝐾𝑡𝑠 = 3, 𝑞𝑠 = 0.9, 𝐾𝑓𝑠 = 1 + 0.9 3 − 1 = 2.8
Ka= 0.8 , Kc = 1, Kd =1, Ke = 0.814, Kf = 1
Kb = 1.51𝑑 −0.157 𝑓𝑜𝑟 51 < 𝑑 ≤ 254 𝑚𝑚, Kb = 1.5155−0.157 =0.808
𝑆𝑒 = 0.5𝐾𝑎𝐾𝑏𝐾𝑐𝐾𝑑𝐾𝑒𝐾𝑓𝑆𝑈𝑇 = 0.8 × 0.808 × 1.0 × 1.0 × 0.814 × 1.0 × 0.5 × 690 = 181.5 𝑀𝑃𝐴
The fatigue factor of safety:

−1
𝑑 3 2K𝑓Ma 3 𝐾𝑓𝑠𝑇𝑚 2
𝑛𝑓 = +
16 Se 𝑆𝑈𝑇
−1
 × 0.0553 2 × 1.74 × 563.1 3 2.8 × 636.8 2
= + = 2.1 𝑠𝑎𝑓𝑒‼!
16 181.5 690
Yield factor of safety:
32𝐾𝑓𝑀𝑎 32 × 490.8
Ϭ’𝑎 = = = 30𝑀𝑃𝐴
𝑑 3  × 0.0553
2 2
16𝐾𝑓𝑠𝑇𝑚 16 × 2.8 × 575.4
Ϭ’𝑚 = 3 = 3 = 85.4𝑀𝑃𝐴
𝑑 3  × 0.0553

𝑆𝑦 580
𝑛𝑦 = = =5
(Ϭ’𝑎 + Ϭ’𝑚) (30 + 85.4)
𝑑4 55
𝑑4 = 55𝑚𝑚, 𝑑2 = 45 𝑚𝑚, 𝑑3 = 1.2 × 𝑑4 = 1.1 × 55 = 60 𝑚𝑚, 𝑑5 = 1.25 = 1.25 = 45𝑚𝑚
𝑑1 = 40 𝑚𝑚
ADJECENT SPINDLE SHAFT:
Critical point: to the right of gear center, where key groove is there.
Where high bending moment, stress concentration at keaway, and torque presents.
M = 29.62 + 173.42 = 175.9 N.m, T = 254.7 N.m.
Assume the radius at the bottom of the keyway will be the standard, r/d = 0.02, r =0.02 d
From table first iteration estimates for stress concentration factors, Kt = 2.2 and Kts = 3.0 for quick,
conservative first pass, assume Kf = Kt, Kf s = Kts.
A Marin equation is 𝑆𝑒 = 0.5 𝐾𝑎𝐾𝑏𝐾𝑐𝐾𝑑𝐾𝑒𝐾𝑓 𝑆𝑈𝑇
Ka = 𝑎𝑆𝑈𝑇 𝑏 , 𝑎 = 4.51 𝑀𝑃𝐴 𝑎𝑛𝑑 𝑏 = −0.265 𝑓𝑜𝑟 𝑐𝑜𝑙𝑑 𝑑𝑟𝑎𝑤𝑛 𝑠𝑢𝑟𝑓𝑎𝑐𝑒
Ka = 𝑎𝑆𝑈𝑇 𝑏 = 4.51 × 690−0.265 = 0.8
Kb = 1.51𝑑 −0.157 𝑓𝑜𝑟 51 < 𝑑 ≤ 254 𝑚𝑚, let Kb = 0.9 check later when the diameter is known
Kc = 1, Kd =1,Ke = 0.814 for 99% reliability, Kf = 1
𝑆𝑒 = 0.5 𝐾𝑎𝐾𝑏𝐾𝑐𝐾𝑑𝐾𝑒𝐾𝑓 𝑆𝑈𝑇 = 0.8 × 0.9 × 1.0 × 1.0 × 0.814 × 1.0 × 0.5 × 690 = 202.2 𝑀𝑃𝐴
Equivalent twisting moment (Te) and Equivalent bending moment (Me)
M = 175.9 N.m, T = 254.7 N.m.
𝐹𝑑 2
𝑇𝑚 = 𝑇𝑒 = 1.6 × 𝑀 + + (1.6 × 𝑇)2
8

1 𝐹𝑑 𝐹𝑑 2
𝑀𝑎 = 𝑀𝑒 = 1.6 × 𝑀 + + 1.6 × 𝑀 + + (1.6 × 𝑇)2
2 8 8
With Mm = Ta = 0, the DE-Goodman criterion reduces to

−1
𝑛 = +
16 Se 𝑆𝑈𝑇
Let d = 55mm
8660 ×0.055 2
𝑇𝑚 = 1.6 × 175.9 + + (1.6 × 254.7)2 = 531.4 𝑁𝑚
8
1 8660 ×0.055 8660 ×0.055 2

𝑀𝑎 = 2 1.6 × 175.9 + + 1.6 × 175.9 + + (1.6 × 254.7)2 = 436.2 𝑁𝑚
8 8
−1
𝑑3 2K𝑓Ma 3 𝐾𝑓𝑠𝑇𝑚 2
𝑛= +
16 Se 𝑆𝑈𝑇
−1
 × 0.0553 2 × 2.2 × 436.2 3 3 × 531.4 2
= + = 2.4 𝑠𝑎𝑓𝑒‼!
16 202.2 690
Assume the radius at the bottom of the keyway will be the standard 𝑟/𝑑 = 0.02, 𝑟 = 0.02 𝑑 =
0.02 × 55 = 1.1𝑚𝑚, from shigley text book we can find 𝐾𝑡 = 2.14, 𝑞 = 0.65
𝐾𝑓 = 1 + 0.65 2.14 − 1 = 1.74, 𝐾𝑡𝑠 = 3, 𝑞𝑠 = 0.9, 𝐾𝑓𝑠 = 1 + 0.9 3 − 1 = 2.8
Ka= 0.8 , Kc = 1, Kd =1, Ke = 0.814, Kf = 1
Kb = 1.51𝑑 −0.157 𝑓𝑜𝑟 51 < 𝑑 ≤ 254 𝑚𝑚, Kb = 1.5155−0.157 =0.808
𝑆𝑒 = 0.5𝐾𝑎𝐾𝑏𝐾𝑐𝐾𝑑𝐾𝑒𝐾𝑓𝑆𝑈𝑇 = 0.8 × 0.808 × 1.0 × 1.0 × 0.814 × 1.0 × 0.5 × 690 = 181.5 𝑀𝑃𝐴
The fatigue factor of safety:

−1
𝑛𝑓 = +
16 Se 𝑆𝑈𝑇
−1
 × 0.0553 2 × 1.74 × 436.2 3 2.8 × 531.4 2
= + = 2.7 𝑠𝑎𝑓𝑒‼!
16 181.5 690

Yield factor of safety:
32𝐾𝑓𝑀𝑎 32 × 436.2
Ϭ’𝑎 = = = 26.7𝑀𝑃𝐴
𝑑 3  × 0.0553
2 2
16𝐾𝑓𝑠𝑇𝑚 16 × 2.8 × 531.4
Ϭ’𝑚 = 3 = 3 = 79𝑀𝑃𝐴
𝑑 3  × 0.0553
𝑆𝑦 580
𝑛𝑦 = = = 5.5
(Ϭ’𝑎 + Ϭ’𝑚) (26.7 + 79)
𝑑4 55
𝑑4 = 55𝑚𝑚, 𝑑2 = 45 𝑚𝑚, 𝑑3 = 1.2 × 𝑑4 = 1.1 × 55 = 60𝑚𝑚, 𝑑5 = 1.25 = 1.25 = 45𝑚𝑚
𝑑1 = 0
STEP 7: Shaft design for deflection. Since deflection analysis is dependent on the entire shaft geometry,
it is saved until this point. With all shaft geometry now estimated, the critical deflections at the bearing
and gear locations can be checked by analysis.
Typically, a deflection problem in a shaft will not cause catastrophic failure of the shaft, but will lead to
excess noise and vibration, and premature failure of the gears or bearings.
For adjacent spindles: deflection at the gear center
𝑊𝑙 3
𝑙𝑖𝑛𝑒𝑟 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛, 𝑌𝐶 =
48𝐸𝐼
𝑑 4 (55)4
𝑊 = 𝑊𝑅 2 + 𝑊𝑇 2 = 0.972 + 5.72 = 5.8 𝐾𝑁, 𝐼 = = = 4.5 × 10−7 𝑚4
64 64
5.8(122)3
𝑌𝐶 = = 0.00234 𝑚𝑚 < 𝑡𝑕𝑒 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑣𝑎𝑙𝑢𝑒
48 × 207 × 4.5 × 10−7

𝑊𝑙 2 5.8(122)2
𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛, ѳ𝑐 = = = 0.00026 𝑟𝑎𝑑
16𝐸𝐼 16 × 207 × 4.5 × 10−7
< 𝑡𝑕𝑒 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑣𝑎𝑙𝑢𝑒
3.7 BEARING SELECTION.
Specific bearings from a catalog may now be chosen to match the estimated shaft diameters. The
diameters can be adjusted slightly as necessary to match the catalog specifications.
Bearing forces
Axial, RB, x = 8.66 KN, Radial, RB = 2.89 𝐾𝑁
Bearing selected: Single row 02-series angular contact ball bearing having the following geometric
properties.
Bore Outer Width Fillet Shoulder diameter Load rating, KN
diameter radius ds dH
OD C10 C0
45 mm 85 mm 19 mm 1.0 mm 52 mm 77 mm 35.8 21.2
From the table for machines for intermittent service where reliable operation is great importance, the
bearing life is 14000 hr.
𝐹𝑎 8.66
= = 0.408 𝑓𝑟𝑜𝑚 𝑠𝑕𝑖𝑒𝑔𝑙𝑦 𝑡𝑒𝑥𝑡 𝑓𝑜𝑟 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑟𝑎𝑑𝑖𝑎𝑙 𝑙𝑜𝑎𝑑 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑒 = 0.41
𝐶𝑜 21.2
V = 1 for outer ring stationary
𝐹𝑎 8.66
= = 3 > 𝑒 𝑓𝑟𝑜𝑚 𝑠𝑕𝑖𝑒𝑔𝑙𝑦 𝑡𝑒𝑥𝑡 𝑓𝑜𝑟 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑟𝑎𝑑𝑖𝑎𝑙 𝑙𝑜𝑎𝑑 𝑓𝑎𝑐𝑡𝑜𝑟𝑠, 𝑋2 = 0.56
𝑉𝐹𝑟 2.89
𝑎𝑛𝑑 𝑌2 = 1.05
Fe = X2V Fr + Y2 Fa =0.56 × 1 × 2.89 + 1.05 × 8.66 = 10.7 𝐾𝑁

𝐴𝑝𝑝𝑙𝑖𝑐𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟: = 1.0
The equivalent radial load becomes: 𝐹𝑒 = 1 × 10.7 = 10.7 𝐾𝑁
𝑎 3
60𝐿𝑅𝑛𝑅 𝐶10 106 35.8
𝑇𝑕𝑒 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑙𝑖𝑓𝑒 𝑏𝑒𝑐𝑜𝑚𝑒𝑠: 𝐿10 = =
60𝑛𝐷 𝐹𝑒 60 × 300 10.7
= 2080.8 𝑕𝑟.
Ball bearing: Radial, RA = 2.89 𝐾𝑁 = 𝐹𝐷
Dimensions and Load Ratings for Single-Row 02-Series Deep-Groove Ball Bearing
Bore Outer Width Fillet Shoulder diameter Load rating, KN
diameter radius ds dH
OD C10 C0
45 mm 85 mm 19 mm 1.0 mm 52 mm 77 mm 33.2 18.6
Figure 3.7
Shaft and housing shoulder diameters dS and
dH should be adequate to ensure good
bearing support.
𝑎 3
60𝐿𝑅𝑛𝑅 𝐶10 106 33.2
𝑇𝑕𝑒 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑙𝑖𝑓𝑒 𝑏𝑒𝑐𝑜𝑚𝑒𝑠: 𝐿10 = =
60𝑛𝐷 𝐹𝐷 60 × 300 2.89
= 84.2 𝐾𝑕𝑟.

STEP 8: Key and Retaining ring selection.
Key selection: Transmitted torque: T = 254.65 N.m
Bore diameter: 𝑑𝑔 = 55 𝑚𝑚, 𝑑𝑠 = 40 𝑚𝑚
Gear hub length: LG= 44 𝑚𝑚, Ls= 50 𝑚𝑚
For the gear: A square key having the following geometric properties is selected
Shaft diameter Key size Key depth
Over To (include) W H
3 1 12.7 mm 12.7 mm 6.35 mm

1(4) inch 2(4) inch
For the sprocket:
Shaft diameter Key size Key depth
Over To (include) W H
3 3 9.5 mm 9.5 mm 4.8 mm

1(8) inch 1(4) inch
Key material: CD steel is selected
UNSI No AISI No Processing SUT SY
G10200 1020 CD 470 MPA 390 MPA
Fig 3.8 From the fig 3.8, the force at the surface of
the shaft is,
𝑇 254.7
𝐹𝑜𝑟 𝑡𝑕𝑒 𝑔𝑒𝑎𝑟 𝑘𝑒𝑦: 𝐹 = =
𝑅 27.5
= 9.3 𝐾𝑁

𝑇 254.7 Ssy = 0.577Sy = (0.577) (390) = 225 MPA

𝐹𝑜𝑟 𝑡𝑕𝑒 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡 𝑘𝑒𝑦: 𝐹 = =
𝑅 27.5
= 9.3 𝐾𝑁
𝐹𝑛 9.3 × 3
𝑙 = = = 13 𝑚𝑚
𝑆𝑠𝑦 × 𝑡 225 × 9.5
For four integrated sprockets the length of the key becomes 4 × 13 = 52 𝑚𝑚
Retaining ring selection:
Gear Thrust bearing
Nominal shaft diameter 55 mm 45 mm
Allowable axial thrust 3.7 KN 6 KN
At the bottom of the shaft there is hollow tapered hole for the installation of chuck and therefore
determine the maximum diameter of the hole the bottom tip of the shaft.
Using minimum factor of safety, 𝑛𝑓 = 2 and
𝑇𝑚𝑎𝑥 + 𝑇𝑚𝑖𝑛
𝑇𝑚 =
2
254.7
= = 127.4 𝑁. 𝑚
2
1 1
3 𝑇𝑚 2 3 3 127.4 2 3
𝑆𝑈𝑇 690
𝑑𝑖 = 𝑑𝑜 − 16𝑛𝑓 = 45 − 16 × 2 = 45 − 14.8 = 30.2𝑚𝑚
 

3.8 HOUSING DESIGN
The housing design process must be both creative and practical. What provisions should be made to
mount the bearings accurately and to transmit the bearing loads safely through the case to the
structure. How will the various elements be assembled into the housing? How will the gears and
bearings be lubricated? What housing material should be used? Should the housing be a casting, a
weldment, or an assembly of machined parts? Are the main questions asked to lay the layout of the
housing.
The design process as outlined here implies that the design can progress in sequence: from the chain to
the shaft, to the bearings, to the gears and keys, and finally to the housing.
Material selection for housing: Grey cast iron
Since the cast iron is a brittle material, therefore, it cannot be used in those parts of machines which
are subjected to shocks. The properties of cast iron which make it a valuable material for engineering
purposes are its low cost, good casting characteristics, high compressive strength, wear resistance and
excellent machineability. The compressive strength of cast iron is much greater than the tensile
strength. A portion of the housing is used to analyze whether it fails or can resist the shear stress.

Design for shear gives the following thickness:
𝐹𝑛 8.7 × 3
𝑡 = = ≅ 7.3 𝑚𝑚
𝑆𝑠𝑦 × 𝑙 120 × 30
From the fig we can decide the total layout of the housing:
𝑤
𝑋 = 𝐶 + 𝑟𝑠 + + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 + 𝑑
2
𝑋2 = 2𝑟𝑔 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑏 = 2𝑟𝑠 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑌1 = 𝐹𝑏 + 𝐶𝑜 + 4𝐶𝑐 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒, 𝑌2 = 𝐶2 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑍 = 7𝐶𝑠 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑏
𝑤𝑕𝑒𝑟𝑒, 𝐶 − 𝑐𝑒𝑛𝑡𝑒𝑟 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑕𝑒 𝑚𝑎𝑖𝑛 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑎𝑛𝑑 𝑚𝑜𝑡𝑜𝑟 𝑠𝑕𝑎𝑓𝑡 (570 𝑚𝑚)
𝑛
𝑏
𝐶𝑜 − 𝑡𝑕𝑒 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑕𝑒 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡 𝑎𝑛𝑑 𝑡𝑕𝑒 𝑡𝑜𝑝 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 (43 𝑚𝑚)
𝑛
𝑏
𝐶2 = 𝑡𝑕𝑒 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑕𝑒 𝑡𝑜𝑝 𝑎𝑛𝑑 𝑏𝑜𝑡𝑡𝑜𝑚 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 (122 𝑚𝑚)
𝑛
𝑏
𝐶𝑠 − 𝑡𝑕𝑒 𝑐𝑒𝑛𝑡𝑒𝑟 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑕𝑒 𝑎𝑑𝑗𝑒𝑐𝑒𝑛𝑡 𝑠𝑝𝑖𝑛𝑑𝑙𝑒𝑠 90 𝑚𝑚
𝑛
𝐶𝑐 − 𝑡𝑕𝑒 𝑕𝑎𝑙𝑓 𝑤𝑖𝑑𝑡𝑕 𝑜𝑓 𝑡𝑕𝑒 𝑐𝑕𝑎𝑖𝑛 32.7 𝑚𝑚 , 𝑑 − 𝑐𝑕𝑎𝑖𝑛 𝑟𝑜𝑙𝑙𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(12 𝑚𝑚)
𝑡 − 𝑕𝑜𝑢𝑠𝑖𝑛𝑔 𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (7.3 𝑚𝑚), 𝑤 − 𝑡𝑕𝑒 𝑚𝑜𝑡𝑜𝑟 𝑤𝑖𝑑𝑡𝑕 (200 𝑚𝑚),
𝑟𝑠 − 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡 𝑟𝑎𝑑𝑖𝑢𝑠 (361 𝑚𝑚), 𝑟𝑔 − 𝑔𝑒𝑎𝑟 𝑟𝑎𝑑𝑖𝑢𝑠 (45 𝑚𝑚)
𝐹𝑏 = 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑤𝑖𝑑𝑡𝑕 (19 𝑚𝑚), 𝐹𝑠 − 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡 𝑤𝑖𝑑𝑡𝑕 86.36 ,
𝐻 − 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑡𝑜𝑝 𝑛𝑒𝑡 𝑤𝑖𝑑𝑡𝑕 (20 𝑚𝑚)
𝑤
𝑋 = 𝐶 + 𝑟𝑠 + + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 + 𝑑 = 570 + 361 + 100 + 14.6 + 100 + 12 + 22
2
= 1180 𝑚𝑚
𝑋2 = 𝑟𝑔 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 = 2 × 45 + 45.4 + 14.6 = 150 𝑚𝑚
𝑌1 = 𝐹𝑏 + 𝐶𝑜 + 2𝑡 + 𝐹𝑠 + 𝐻 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 = 19 + 43 + 86.36 + 14.6 + 20 + 20 = 203 𝑚𝑚

𝑌2 = 𝐶2 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒, 𝑌 = 𝑌1 + 𝑌1
𝑌1 = 𝐹𝑏 + 𝐶𝑜 + 4𝐶𝑐 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 = 25 + 97 + 32.7 × 4 + 14.6 + 20 = 287.3 𝑚𝑚
𝑌2 = 𝐶2 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 = 122 + 14.6 + 20 = 156.6 𝑚𝑚, 𝑌 = 287.3 + 156.6 = 444 𝑚𝑚
𝑍 = 2𝑟𝑠 + 2𝑡 + 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 = 722 + 14.6 + 30 = 767 𝑚𝑚
Bolt selection: For fasting the different components of the drill machine together
Nominal size Fine threads
Pitch Tensile stress area
𝑀5 0.5 mm 16.1 𝑚𝑚2
Bolt material: steel:
Grade Bolt size SUT Yield strength
4.6 M5 400 MPA 240 MPA
𝐴𝑠 16.1
Check for shear of the bolt: 𝑛 = 0.577𝑆𝑌 × = 0.577 × 240 ×
𝐹 7
𝑠𝑙𝑒𝑒𝑣𝑒
Sleeve bolt length: 𝐿 = 𝑡 𝑕𝑜𝑢𝑠𝑖𝑛𝑔 + 𝑡 = 7.3 + 1.5 ≅ 9𝑚𝑚
2
Bushing:
Bushing material: beryllium bronze. It is a copper base alloy containing about 97.75% copper and
2.25% beryllium. It has high yield point, high fatigue limit and excellent cold and hot corrosion
resistance. It is particularly suitable material for springs, heavy duty electrical switches, cams and
bushings. Since the wear resistance of beryllium copper is five times that of phosphor bronze,
therefore, it may be used as a bearing metal in place of phosphor bronze. It has a film forming and a
soft lubricating property, which makes it more suitable as a bearing metal.

Internal diameter of the bushing: 45 mm
Nominal outer diameter: 65 mm
3.9 DESIGN OF DRILL COLUMN
The entire weight of the drill machine is supported by the column, which is the backbone of the drill
machine to support the weight. Note that the column supports not only the weight but also the axial
thrust force produced due to the machining operation. Therefore, the total force on the column is the
sum of the weight of the electric motor, the working table, the entire weight of the drill and the axial
force acting on the table.
Let 𝑊 = 1𝐾𝑁 𝑤𝑕𝑒𝑟𝑒 𝑊 − 𝑡𝑕𝑒 𝑒𝑛𝑡𝑖𝑟𝑒 𝑤𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑑𝑟𝑖𝑙𝑙 𝑚𝑎𝑐𝑕𝑖𝑛𝑒
𝑇𝑕𝑒 𝑎𝑥𝑖𝑎𝑙 𝑡𝑕𝑟𝑢𝑠𝑡 𝑓𝑜𝑟𝑐𝑒 𝑎𝑠 𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑒𝑑 𝑏𝑒𝑓𝑜𝑟𝑒, 𝐹𝑎 = 6 𝐾𝑁
Design the column for buckling and axial compressive stress.
Material selection: cold drawn steel
UNS No. AISI NO. SUT SY BHN
G10060 1006 330 280 95
𝐽𝑜𝑕𝑛𝑠𝑜𝑛 𝑐𝑜𝑙𝑢𝑚𝑛 𝑓𝑜𝑟𝑚𝑢𝑙𝑎
𝑃𝑐𝑟 𝑆𝑦𝑙 2 1 𝑙 𝑙
= 𝑆𝑦 − ( ) , ≤ 1, 𝑅𝑒𝑓𝑒𝑟𝑎𝑛𝑐𝑒 𝑠𝑕𝑖𝑔𝑙𝑒𝑦 𝑡𝑒𝑥𝑡 𝑏𝑜𝑜𝑘 𝑝𝑎𝑔𝑒 176
𝐴 2𝑘 𝐶𝐸 𝑘 𝑘
𝑤𝑕𝑒𝑟𝑒 𝐹𝑐𝑟 − 𝑡𝑕𝑒 𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑡𝑕𝑎 𝑚𝑎𝑘𝑒𝑠 𝑡𝑕𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 𝑢𝑛𝑠𝑡𝑎𝑏𝑙𝑒,
𝑙 − 𝑡𝑕𝑒 𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑡𝑕𝑒 𝑐𝑜𝑙𝑢𝑚𝑛
𝐴 − 𝑥 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎

𝐶 − 𝑒𝑛𝑑 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡( 𝑓𝑜𝑟 𝑓𝑖𝑥𝑒𝑑 − 𝑓𝑖𝑥𝑒𝑑 𝑒𝑛𝑑, 𝐶 = 1.2)
𝐹𝑐𝑟 = 𝐹𝑛 , 𝑙𝑒𝑡 𝑡𝑕𝑒 𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑡𝑕𝑒 𝑐𝑜𝑙𝑢𝑚𝑛, 𝑙 = 1.63 𝑚 𝑓𝑟𝑜𝑚 𝑤𝑜𝑟𝑘𝑠𝑕𝑜𝑝 𝑑𝑟𝑖𝑙𝑙 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡
𝐹𝑜𝑟 𝑠𝑡𝑒𝑒𝑙 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝐸 = 207 𝐺𝑃𝐴
𝑙 4𝑙 1.63
= = = 65.2
𝑘 𝑑 0.025
𝑙 22 𝐶𝐸 22 × 1.2 × 207 𝑙

1= ( )= ( ) = 132.33 > it is J. B. Johnson columns.
𝑘 𝑆𝑦 280 𝑘
𝑅𝑒𝑎𝑟𝑎𝑛𝑔𝑖𝑛𝑔 𝑎𝑛𝑑 𝑠𝑢𝑏𝑠𝑡𝑖𝑡𝑢𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡𝑕𝑒 𝑣𝑎𝑙𝑢𝑒𝑠 𝑓𝑜𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 𝑔𝑖𝑣𝑒𝑠 𝑎𝑛𝑑 𝑎𝑠𝑠𝑢𝑚𝑒 𝑡𝑕𝑒
𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡𝑕𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 𝑡𝑜 𝑏𝑒 100𝑚𝑚
𝑑 2 𝑆𝑦𝑙 2 𝑆𝑦 0.052 280 × 1.632 280

𝑛= − = − =9
4 𝐶𝐸 2 𝐸 4 1.2 × 2072 207
Check for fatigue loading
Ϭ𝑎 Ϭ𝑚 1
Modified Goodman criteria: + 𝑆𝑈𝑇 = 𝑛
𝑆𝑒
𝐹𝑚𝑎𝑥 = 7 𝐾𝑁, 𝐹𝑚𝑖𝑛 = 1𝐾𝑁,
𝐹𝑚𝑎𝑥 + 𝐹𝑚𝑖𝑛 𝐹𝑚𝑎𝑥 − 𝐹𝑚𝑖𝑛

Ϭ𝑚 = 𝑑 2
= 1.0186 𝑀𝑃𝐴, Ϭ𝑎 = 𝑑 2
= 0.764 𝑀𝑃𝐴,
4 4
𝐾𝑎 = 0.97 𝑓𝑜𝑟 𝑐𝑜𝑙𝑑 𝑑𝑟𝑎𝑤𝑛 𝑠𝑢𝑟𝑓𝑎𝑐𝑒, 𝐾𝑏 = 0.733 𝑓𝑜𝑟 51 < 𝑑 ≤ 254,
𝐾𝑐 = 0.85 𝑓𝑜𝑟 𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝐾𝑑 = 1 𝑓𝑜𝑟 𝑎𝑡 𝑟𝑜𝑜𝑚 𝑡𝑒𝑚𝑝𝑟𝑎𝑡𝑢𝑟𝑒,
𝐾𝑒 = 0.814 𝑓𝑜𝑟 99% 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦, 𝐾𝑓 = 1
𝑆𝑒 = 0.5𝐾𝑎𝐾𝑏𝐾𝑐𝐾𝑑𝐾𝑒𝐾𝑓𝑆𝑈𝑇 = 0.5 × 0.97 × 0.733 × 0.85 × 1 × 0.814 × 1 × 330 = 228.7𝑀𝑃𝐴

𝑆𝑈𝑇 × 𝑆𝑒 330 × 228.7

𝑛= = = 155
𝑆𝑈𝑇 × Ϭ𝑎 + 𝑆𝑒 × Ϭ𝑚 330 × 0.764 + 228.7 × 1.0186
3.10 DESIGN OF COLUMN SLEEVE: the purpose of the sleeve is to transfer the load from the
housing to the column. In this way a bolt is used to hinge the housing on the column. The bolt section
of the housing and the sleeve is subjected to a shear stress.
Material selection: steel
AISI NO. Processing SUT SY
1015 Hot rolling 340 MPA 190 MPA
Checking shear across the bolt center;
𝐹 𝑆𝑠𝑦 0.577𝑆𝑌 𝐹𝑛 7×3

𝜏=𝐴 = = , 𝑏𝑢𝑡 𝐴𝑠 = 2𝜋𝑟𝑜 𝑡, 𝑡𝑚𝑖𝑛 = 0.577𝑆𝑌 = 0.577×190 = 0.43 𝑚𝑚
𝑠 𝑛 𝑛 2𝜋𝑟𝑜 2𝜋×70
𝑆𝑌 2𝑟𝑜 −100 190× 2×70−100

For bending: 𝑛 = = =
64𝑟𝑜 2 𝐹 64×70 2 ×7
Let assume 𝑡 = 4 𝑚𝑚

3.11 RACK AND PINION DESIGN
For the operation to be performed the worktable must move up and down to get feed manually since
feed mechanism is accomplished by the movement of the table.
A rack and pinion mechanism is used in the feed mechanism to accomplish the required work. So the
rack and pinion teeth must be checked for contact stress and bending stress.
A well designed mechanism such as the rack and pinion gears save effort and time.
The rack and pinion is used to convert between rotary and linear motion. Rack and pinion can convert
motion from rotary to linear or linear to rotary.
Fig 3.9 rack and pinion
Proportions for spur Gear system 200 full depth involute system.
𝑇𝑎𝑘𝑒 𝑚𝑜𝑑𝑢𝑙𝑒; 𝑚 = 4, 𝐴𝑑𝑑𝑒𝑛𝑑𝑢𝑚 𝑎 = 1𝑚 = 1 × 4 = 4 𝑚𝑚,
𝐷𝑒𝑑𝑒𝑛𝑑𝑢𝑚 𝑏 = 1.25𝑚 = 1.25 × 4 = 5 𝑚𝑚,
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑑𝑒𝑝𝑡𝑕 = 2𝑚 = 2 × 4 = 8 𝑚𝑚,
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑡𝑜𝑡𝑎𝑙 𝑑𝑒𝑝𝑡𝑕 = 2.25𝑚 = 9 𝑚𝑚

𝑇𝑜𝑜𝑡𝑕 𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 1.5708 = 1.5708 × 4 = 6.3 𝑚𝑚
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 0.25𝑚 = 0.25 × 4 = 1 𝑚𝑚
𝐹𝑖𝑙𝑙𝑒𝑡 𝑟𝑎𝑑𝑖𝑢𝑠 𝑎𝑡 𝑟𝑜𝑜𝑡 = 0.4𝑚 = 0.4 × 4 = 1.6 𝑚𝑚
𝑝 = 𝜋𝑚 = 4𝜋 = 12.566 𝑚𝑚, 𝑝 = 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑝𝑖𝑡𝑐𝑕
𝐹𝑎𝑐𝑒 𝑤𝑖𝑑𝑡𝑕; 𝐹 = 4𝑝 = 4 × 12.566 = 50.26𝑚𝑚
The smallest spur pinion that will operate with a rack without interference is:
2𝑘 2
𝑁𝑝 = = = 17.1 ≅ 18
sin2  sin2 20
The pitch diameter of the pinion: 𝑑𝑝 = 𝑚𝑁𝑝 = 4 × 18 = 72 𝑚𝑚
Force analysis
The normal tooth load (WN) has two components; one is tangential component (WT) and the other axial
component (WA).
𝑇𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑡𝑜𝑜𝑡𝑕 𝑙𝑜𝑎𝑑 𝑜𝑛 𝑡𝑕𝑒 𝑝𝑖𝑛𝑖𝑜𝑛 𝑎𝑛𝑑 𝑟𝑎𝑐𝑘,
𝑊𝑇 = 𝐹𝑎 = 6 𝐾𝑁 𝑎𝑥𝑖𝑎𝑙 𝑡𝑕𝑟𝑢𝑠𝑡 𝑓𝑜𝑟𝑐𝑒 𝑐𝑟𝑒𝑎𝑡𝑒𝑑 𝑑𝑢𝑒 𝑡𝑜 𝑚𝑎𝑐𝑕𝑖𝑛𝑖𝑛𝑔 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛
𝑇𝑕𝑒 𝑛𝑜𝑟𝑚𝑎𝑙 𝑡𝑜𝑜𝑡𝑕 𝑙𝑜𝑎𝑑, 𝑊𝑁 = 𝑊𝐴/ 𝑠𝑖𝑛 () = 2.66/ 𝑠𝑖𝑛 (25) = 6.29 𝐾𝑁
𝑇𝑕𝑒 𝑟𝑎𝑑𝑖𝑎𝑙 𝑡𝑜𝑜𝑡𝑕 𝑙𝑜𝑎𝑑, 𝑊𝑅 = 𝑊𝑇 𝑡𝑎𝑛 = 6 𝑡𝑎𝑛20 = 2.2 𝐾𝑁
STRENGTH ANALYSIS OF PINION GEAR (reference shigley textbook)
In order to find the strength of helical gears, AGMA strength equation is used.
GEAR MATERIAL SELECTION- NITRIDED THROUGH-HARDENED STEELS: are commonly
used for gears. They have superior tensile strength to cast iron. They need heat treatment to get a
surface hardness that will resist wear.

THE BENDING STRESS IS:
𝑊𝑇𝐾𝑜𝐾𝑣𝐾𝑠𝐾𝐻𝐾𝐵
Ϭ =
𝑏𝑚𝑌𝐽
Where𝐾𝑜 − 𝑜𝑣𝑒𝑟𝑙𝑜𝑎𝑑 𝑓𝑎𝑐𝑡𝑜𝑟 1.0 , 𝐾𝑣 − 𝑑𝑦𝑛𝑎𝑚𝑖𝑐 𝑓𝑎𝑐𝑡𝑜𝑟 1.277
𝐾𝑠 − 𝑠𝑖𝑧𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 1.0 , 𝐾𝐻 − 𝑙𝑜𝑎𝑑 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 1.1254
𝐾𝐵 − 𝑟𝑖𝑚 𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑓𝑎𝑐𝑡𝑜𝑟 1.0 , 𝑌𝐽, 𝐺𝑒𝑜𝑚𝑒𝑡𝑟𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡𝑕
𝑚 − 𝑚𝑜𝑑𝑢𝑙𝑒, 𝑏 − 𝐹𝑎𝑐𝑒 𝑤𝑖𝑑𝑡𝑕
𝑊𝑇𝐾𝑜𝐾𝑣𝐾𝑠𝐾𝐻𝐾𝐵 1
𝑇𝑕𝑒𝑟𝑒𝑓𝑜𝑟𝑒, Ϭ = = 6 × 1.25 × 1.277 × 1.0 × 1.1254 ×
𝑏𝑚𝑌𝐽 50 × 4 × 0.24
= 225 𝑀𝑃𝑎
THE FUNDAMENTAL EQUATION FOR PITTING RESISTANCE (CONTACT STRESS)
𝑊𝑇𝐾𝑜𝐾𝑣𝐾𝑠𝐾𝐻𝑍𝑅
Ϭ𝑐 = 𝑍𝐸
𝑑𝑤1𝑏𝑍𝐼
𝑊𝑕𝑒𝑟𝑒 𝑍𝐸 − 𝑒𝑙𝑎𝑠𝑡𝑖𝑐 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 191 𝑀𝑃𝑎 , 𝑍𝑅 − 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 1.0
𝑑𝑤1; 𝑝𝑖𝑡𝑐𝑕 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡𝑕𝑒 𝑝𝑖𝑛𝑖𝑜𝑛 (72 𝑚𝑚),
𝑍𝐼 − 𝑔𝑒𝑜𝑚𝑒𝑡𝑟𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑝𝑖𝑡𝑡𝑖𝑛𝑔 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 (0.107)
𝑊𝑇𝐾𝑜𝐾𝑣𝐾𝑠𝐾𝐻𝑍𝑅 6 × 1.25 × 1.277 × 1.0 × 1.1254 × 1.0

Ϭ𝑐 = 𝑍𝐸 = 191 = 1010.3 𝑀𝑃𝑎
𝑑𝑤1𝑏𝑍𝐼 72 × 50 × 0.107
THE EQUATION FOR THE ALLOWABLE BENDING STRESS IS:
𝑆𝑡𝑌𝑁
Ϭ𝑎𝑙𝑙 =
𝑊𝑕𝑒𝑟𝑒, 𝑆𝑡 − 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠, 𝑌𝑁 − 𝑡𝑕𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑐𝑦𝑐𝑙𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
𝑆𝐹 − 𝑡𝑕𝑒 𝐴𝐺𝑀𝐴 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦, 𝑌ѳ − 𝑡𝑕𝑒 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑓𝑎𝑐𝑡𝑜𝑟,
𝑌𝑍 − 𝑡𝑕𝑒 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟

THE EQUATION FOR THE CONTACT STRESS Ϭc, all IS
𝑆𝑐𝑍𝑁𝑍𝑊
Ϭ𝑐, 𝑎𝑙𝑙 =
𝑊𝑕𝑒𝑟𝑒, 𝑆𝑐 − 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑠𝑡𝑟𝑒𝑠𝑠, 𝑍𝑁 − 𝑡𝑕𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑐𝑦𝑐𝑙𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
𝑍𝑊 − 𝑡𝑕𝑒 𝑕𝑎𝑟𝑑𝑛𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑝𝑖𝑡𝑡𝑖𝑛𝑔 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒
Sc -allowable contact stress
For 2.5% chrome (no aluminum) Grade 3 steel, Sc = 1488.24 Mpa (from table A-8)
ZW-the hardness ratio factor for pitting resistance
𝑍𝑊 = 1.0 𝑠𝑖𝑛𝑐𝑒 𝑏𝑜𝑡𝑕 𝑜𝑓 𝑡𝑕𝑒 𝑔𝑒𝑎𝑟𝑠 𝑎𝑟𝑒 𝑒𝑞𝑢𝑎𝑙
Safety Factor SF
1. Safety factor guarding against bending fatigue failure
𝑺𝑭 = Ϭ𝑎𝑙𝑙 / Ϭ = (𝑆𝑡𝑌𝑁/ (𝑆𝐹𝑌ѳ𝑌𝑍)) / Ϭ = (437.7)/ 225 = 1.9
2. Safety factor guarding against pitting failure
𝑺𝑯 = Ϭ𝑐, 𝑎𝑙𝑙 / Ϭ𝑐 = (𝑆𝑐𝑍𝑁𝑍𝑊/ (𝑆𝐹𝑌ѳ𝑌𝑍)) / Ϭ𝑐 = (1488.24)/ 1010.3 = 1.5
Rack material:
AISI NO Processing SUT SY
1006 Hot rolling 300 MPA 170 MPA
Check the rack shaft for buckling and axial compressive stress
Buckling :
𝑃𝑐𝑟 𝐶𝐸 2
𝐸𝑢𝑙𝑒𝑟 𝑐𝑜𝑙𝑢𝑚𝑛 𝑓𝑜𝑟𝑚𝑢𝑙𝑎 = , 𝑅𝑒𝑓𝑒𝑟𝑎𝑛𝑐𝑒 𝑠𝑕𝑖𝑔𝑙𝑒𝑦 𝑡𝑒𝑥𝑡 𝑏𝑜𝑜𝑘 𝑝𝑎𝑔𝑒 174
𝐴 𝑙 2
𝑘
𝑤𝑕𝑒𝑟𝑒 𝑃𝑐𝑟 − 𝑡𝑕𝑒 𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑙𝑜𝑎𝑑𝑡𝑕𝑎𝑡 𝑚𝑎𝑘𝑒𝑠 𝑡𝑕𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 𝑢𝑛𝑠𝑡𝑎𝑏𝑙𝑒,
𝑙 − 𝑡𝑕𝑒 𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑡𝑕𝑒 𝑐𝑜𝑙𝑢𝑚𝑛(150𝑚𝑚)

𝐴 − 𝑥 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
𝐶 − 𝑒𝑛𝑑 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡( 𝑓𝑜𝑟 𝑓𝑖𝑥𝑒𝑑 − 𝑓𝑖𝑥𝑒𝑑 𝑒𝑛𝑑, 𝐶 = 1.2)
𝐹𝑐𝑟 = 𝐹𝑛
𝐹𝑜𝑟 𝑠𝑡𝑒𝑒𝑙 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝐸 = 207 𝐺𝑃𝐴
𝑙 4𝑙 0.6
= = = 560
𝑘 𝑑 0.00107
𝑙 22 𝐶𝐸 22 × 1.2 × 207 𝑙

1= ( )= ( ) = 170 < it is Euler columns.
𝑘 𝑆𝑦 170 𝑘
𝐶𝐸 2 2
= 1.2 × 207 × = 7.8 × 106
𝑙 2 560 2
𝑘
Let the root diameter = 50 mm
𝑑 = 𝑡𝑕𝑒 𝑟𝑜𝑜𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 − 𝑡𝑕𝑒 𝑟𝑎𝑐𝑘 𝑡𝑜𝑜𝑡𝑕 𝑡𝑜𝑡𝑎𝑙 𝑑𝑒𝑝𝑡𝑕 = 50 − 9 = 41𝑚𝑚
𝐶𝐸 2
𝑑 2 𝑙 2
𝑘
 × 0.0412 × 7.8 × 106
𝑛= = = 1.7
4𝐹 4 × 6000
Check for fatigue loading
Ϭ𝑎 Ϭ𝑚 1
𝑀𝑜𝑑𝑖𝑓𝑖𝑒𝑑 𝐺𝑜𝑜𝑑𝑚𝑎𝑛 𝑐𝑟𝑖𝑡𝑒𝑟𝑖𝑎: + =
𝑆𝑒 𝑆𝑈𝑇 𝑛
𝐹𝑚𝑎𝑥 = 7 𝐾𝑁, 𝐹𝑚𝑖𝑛 = 0.4 𝐾𝑁( 𝑎𝑠𝑢𝑚𝑒 𝑡𝑕𝑒 𝑤𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑤𝑜𝑟𝑘𝑡𝑎𝑏𝑙𝑒),
𝐹𝑚𝑎𝑥 + 𝐹𝑚𝑖𝑛 𝐹𝑚𝑎𝑥 − 𝐹𝑚𝑖𝑛

Ϭ𝑚 = 𝑑 2
= 0.23 𝑀𝑃𝐴, Ϭ𝑎 = 𝑑 2
= 0.2 𝑀𝑃𝐴,
4 4
𝐾𝑎 = 0.96 𝑓𝑜𝑟 𝑕𝑜𝑡 𝑟𝑜𝑙𝑙𝑒𝑑 𝑠𝑢𝑟𝑓𝑎𝑐𝑒, 𝐾𝑏 = 0.83 𝑓𝑜𝑟 2.79 < 𝑑 ≤ 51,

𝐾𝑐 = 0.85 𝑓𝑜𝑟 𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝐾𝑑 = 1 𝑓𝑜𝑟 𝑎𝑡 𝑟𝑜𝑜𝑚 𝑡𝑒𝑚𝑝𝑟𝑎𝑡𝑢𝑟𝑒,
𝐾𝑒 = 0.814 𝑓𝑜𝑟 99% 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦, 𝐾𝑓 = 1
𝑆𝑒 = 0.5𝐾𝑎𝐾𝑏𝐾𝑐𝐾𝑑𝐾𝑒𝐾𝑓𝑆𝑈𝑇 = 0.5 × 0.96 × 0.83 × 0.85 × 1 × 0.814 × 1 × 300 = 82.7 𝑀𝑃𝐴
𝑆𝑈𝑇 × 𝑆𝑒 300 × 82.7

𝑛= = = 314
𝑆𝑈𝑇 × Ϭ𝑎 + 𝑆𝑒 × Ϭ𝑚 300 × 0.2 + 82.7 × 0.23
3.12 JIG AND FIXTURE
The jigs and fixtures are the economical ways to produce a component in mass. So jigs and fixtures are
used and serve as one of the most important facility of mass production system. These are special
work holding and tool guiding device. The quality of performance of a process largely influenced by
quality of jigs and fixtures used for this purpose. What makes a fixture unique is that each one is built
to fit a particular part or shape. The main purpose of a fixture is to locate and in the cases hold a work
piece during an operation. A jig differs from a fixture in the sense that it guides the tool to its correct
position or towards to its correct movements during an operation in addition to locating and supporting
work piece. Purpose and advantage of jigs and fixtures
i. It reduces or sometimes eliminates the efforts of marking, measuring and setting of work
piece on a machine and maintains the accuracy of performance.
ii. The work piece and tool are relatively located at their exact positions before the operation
automatically within negligible time. So it reduces product cycle time.
iii. Variability of dimension in mass production is very low so manufacturing processes
supported by use of jigs and fixtures maintains a consistent quality.
iv. Due to low variability in dimension assembly operations becomes very easy, low rejection
due to less defective production is observed.
v. It reduces production cycle time so increases production capacity. Simultaneously working
by more than one tool on the same work piece is possible.

vi. The operating conditions like speed, feed rate and depth of cut can be set to higher values
due to rigidity of clamping of work piece by jigs and fixtures.
vii. Operators working become comfortable as his efforts in setting in work piece can be
eliminated.
viii. Semi-skilled operators can be assigned the work so it saves the cost of manpower also.
3.13 MANUFACTURING CONSIDERATIONS
Manufacturing processes: The knowledge of manufacturing processes is of great importance for a
design engineer. The following are the various manufacturing processes used in mechanical
engineering.
1. Primary shaping processes. The processes used for the preliminary shaping of the machine
components. The common operations used for this process are casting, forging, extruding, rolling,
drawing, bending, shearing, spinning, powder metal forming, squeezing, etc.
2. Machining processes. The processes used for giving final shape to the machine component,
according to planned dimensions. The common operations used for this process are turning, planning,
shaping, drilling, boring, reaming, sawing, broaching, milling, grinding, hobbing, etc.
3. Surface finishing processes. The processes used to provide a good surface finish for the machine
component are known as surface finishing processes. The common operations used for this process are
polishing, buffing, honing, lapping, abrasive belt grinding, barrel tumbling, electroplating,
superfinishing, sheradizing, etc.
4. Joining processes. The processes used for joining machine components are known as joining
processes. The common operations used for this process are welding, riveting, soldering, brazing,
screw fastening, pressing, sintering, etc.
5. Processes effecting change in properties. These processes are used to impart certain specific
properties to the machine components so as to make them suitable for particular operations or uses.
Such processes are heat treatment, hot-working, cold-working and shot peening.

Most of the parts manufacturing processes are stated as the materials selected for the specific
components. To generalize a tabulated data is as follows;
Part name Part material Manufacturing method
Housing Grey cast iron Casting and Machining
Spindle shafts Carbon steel Forging and machining
Sprocket Carbon Steel Extrusion and hammering
Gear Carbon Steel Machining and through hardening
Drill column Carbon steel Machining and cold working

3.14 COST ESTIMATION FOR THE DRILL MACHINE
Component Unit cost (birr per No of unit The total cost for the
unit) component (in birr)
Electric motor 9,200 1 9,200
Gear 200 7 1,400
Sprocket 300 12 3,600
Chain 1,600 1 1,600
Bearing 100 15 1,500
Drill bit 200 7 1,400
Jig and fixture 2,000 1 2,000
Cast iron bed 4,000 1 4,000
Spindle shafts 400 7 2,800
Oil pump 1,500 1 1,500
Drill column 500 1 500
Oil pan 500 1 500
Housing 500 1 500
Contingency 4,000 − 4,000
Total=34,500 birr

CHAPTER FOUR
4 CONCLUSION AND RECOMMENDATION
4.1 CONCLUTION
Multi-spindle drill machine is a type of drill machine which drills several holes at the same time or
spontaneously. It increase productivity, save time, and good surface finish and have good precision of
product. In this thesis mechanical design of machine, cost analysis, standard element selection,
manufacturing case, operation condition, assembly and disassembly and lubrication case of machine
are clearly stated or considered. Typically this machine is designed to improving and increasing
productivity of Selam Technical and Vocational Collage in the manufacturing of rice mill machine.
Also it enables the company to mass production within few working time with accurate hole center
distance in manufacturing metal bar used in rice mill machine. The machine equipped with electric
motor, gear, and sprocates with chain. The feed is given by means of rack and pinion mechanism
which is the table with work piece is pushed up and down by rotating handle.
This thesis not only includes the design of multi-spindle drill machine but also it includes the design of
jig and fixture to hold the work piece and fix it in position and to inhibit the vibration during drilling
time and to keep the drill beat from break down.

4.2 RECOMMENDATION
During design multi-spindle drill machine, we faced to many problems in the manufacturing
company because of inappropriate drill machine.
So now we recommend
 To design automatic multi-spindle drill machine
 Adjustable: - adjusting the spindle in to needed hole diameter and needed distance between
hole center.
 Flexible in to different direction.
 Manufacturing a drill machine having different work function like turning , facing, etc

APPENDIX
STRESS MODIFYING FACTORS FOR BENDING OF GEAR
Kv- dynamic factor
Dynamic factors are used to account for inaccuracies in the manufacture and meshing of gear teeth in
action. Transmission error is defined as the departure from uniform angular velocity of the gear pair.
Some of the effects that produce transmission error are:
 Inaccuracies produced in the generation of the tooth profile; these include errors in
 tooth spacing, profile lead, and run out
 Vibration of the tooth during meshing due to the tooth stiffness
 Magnitude of the pitch-line velocity
 Dynamic unbalance of the rotating members
 Wear and permanent deformation of contacting portions of the teeth
 Gear shaft misalignment and the linear and angular deflection of the shaft
 Tooth friction
In an attempt to account for these effects, AGMA has defined a set of quality numbers. These numbers
define the tolerances for gears of various sizes manufactured to a specified accuracy. Quality numbers
3 to 7 will include most commercial-quality gears. Quality numbers 8 to 12 are of precision quality.
The AGMA transmission accuracy level number Qv could be taken as the same as the quality number.
The following equations for the dynamic factor are based on these Qv numbers: let Qv = 5
B = 0.25 (12 – Qv)2/3 = 0.25 (12 – 5)2/3 = 0.915
A = 50 + 56 (1 − 𝐵) = 50 + 56 1 – 0.915 = 54.77
𝑁𝐷 300 ∗0.09

V= = = 1.41m/s
60 60
𝐵 0.915
𝐴 + 200𝑉 54.77 + 200∗1.41
Kv = = = 1.277
𝐴 54.77

Ks- size factor
The size factor reflects non-uniformity of material properties due to size. It depends upon
Tooth size, Diameter of part, Ratio of tooth size to diameter of part, Face width, Area of stress pattern,
Ratio of case depth to tooth size, Hardenability and heat treatment
Use Ks=1 for small gears
KH- load distribution factor
The load-distribution factor modified the stress equations to reflect nonuniform distribution of load
across the line of contact. The ideal is to locate the gear ―midspan‖ between
two bearings at the zero slope place when the load is applied. However, this is not always possible.
The following procedure is applicable to
• Net face width to pinion pitch diameter ratio F/d ≤ 2
• Gear elements mounted between the bearings
• Face widths up to 40 in
• Contact, when loaded, across the full width of the narrowest member
The load-distribution factor under these conditions is currently given by the face load distribution
factor, Cmf, where KH = Cmf =1 + Cmc (Cpf Cpm + Cma Ce)
where Cmc = 1 for uncrowned teeth
Cpf = F/(10d) – 0.0375 + 0.0125F
F/(10d) = 1.575/(10*3.54) = 0.044< 0.05, therefore use F/(10d) = 0.05
Cpf = F/(10d) – 0.0375 + 0.0125F = 0.05 – 0.0375 + 0.0125*1.575 = 0.0322
Cpm = 1.1 for straddle-mounted pinion with S1/S≥0.175

Table A-1. Power constants, Kp, for wrought steels, using sharp cutting tools
Material Brinell hardness no Kp ( SI metric units)
PLAIN CARBON STEELS
All plain carbon steels 80-100 1.72
100-120 1.80
120-140 1.88
140-160 2.02
160-180 2.13
180-200 2.24
200-220 2.32
220-240 2.43
240-260 2.51
260-280 2.59
280-300 2.73
300-320 2.81
320-340 2.89
340-360 3.11

Table A-2. Feed factors, C, for power constants
Feed (mm) C Feed (mm) C
0.02 1.70 0.15 1.15
0.05 1.40 0.18 1.11
0.07 1.30 0.20 1.08
0.10 1.25 0.30 1.00
0.12 1.20 0.33 0.98
Table A-3 Tool wear factor, W
Type of operation W
For all operation with sharp cutting tools 1.00
Turning: finish turning (light cuts) 1.10
Normal rough and semi-finishing turning 1.30
Extra heavy-duty rough turning 1.30-1.60
Drilling: normal drilling 1.30
Drilling hard-to-machine materials and drilling with very dull drill 1.50

Table A-4 Feed factor, Ff, for drilling
Feed(mm/rev) Ff
0.01 0.025
0.10 0.158
0.20 0.276
0.25 0.330
0.30 0.382
Table A-5 Drill diameter factors: FT for thrust; FM for torque
Drill diameter(mm) FT FM
1.60 1.46 2.33
4.00 3.03 12.12
8.00 5.28 42.22
11.00 6.81 74.90
12.50 7.54 94.28
14.50 8.49 123.10
16.00 9.19 147.0

Table A-6 Chisel edge factors for torque and thrust
c/d Approx. Torque factor Thrust factor Thrust factor
w/d A B J
0.03 0.025 1.000 1.100 0.001
0.10 0.085 1.020 1.235 0.010
0.15 0.130 1.080 1.310 0.022
0.18 0.155 1.155 1.355 0.030
For drills of standard design, use c/d = 0.18
For split point drills, use c/d = 0.03
Table A-7 Work material factor, Kd, for drilling with a sharp drill
Work material Work material constant
Steel, 200Bhn 24,000
Cast iron, 150Bhn 14,000
Most aluminum alloys 7,000

A-8 Contact-fatigue strength, Sc, at 107 cycles and 0.99 reliability for through hardened steel gears is
tabulated as follows. Source: ANSI/AGMA 2001-DO4.
Material Heat treatment Allowable contact stress number, Sc, MPa
designation
Grade 1 Grade 2 Grade 3
Steels Through hardened
Flame or induction hardened 1171.3 1309.1 _
Carburized & hardened 1205.75 1343.55 _
Nitrided(Through hardened steels) 1240.2 1550.25 1894.75
2.5% chrome( no Nitrided 1067.95 1185.08 1302.21
aluminum)
Nitralloy 135M Nitrided 1171.3 1260.87 1343.55
Nitralloy N Nitrided 1185.08 1295.32 1412.45
2.5% chrome (no Nitrided 1212.64 1350.44 1488.24
aluminum)

Table A-9 Minimum no of teeth on the smaller sprocket
Table A-10 recommended factor of safety for bush roller and silent chains
Table A-11: According to Indian Standards (IS: 2403 —1991), the various characteristics such as
pitch, roller diameter, and width between inner plates, transverse pitch and breaking load for the roller
chains are given in the following table.

Table A-12 power rating (in KW) of simple roller chain
Table A-13 first iteration estimates for stress concentration factors
BENDING TORSIONAL AXIAL
Shoulder fillet-sharp 2.7 2.2 3.0
(r/d = 0.02)
Sho0ulder fillet-well 1.7 1.5 1.9
rounded (r/d = 0.1)
End mill keyseat 2.2 3.0 -
(r/d=0.02)
Retaining ring 5.0 3.0 5.0
groove
Note that these factors are only for use when actual dimensions are not yet determined. Do not use
these once actual dimensions are available.

REFERENCES AND SOURCES OF INFORMATION
BOOKS AND PAPERS
 BUDYNAS−NISBETT, Shigley’s Mechanical Engineering Design, Eighth Edition
 Machinery’s Handbook 28th Edition BY ERIK OBERG, FRANKLIN D. JONES,
 HOLBROOK L. HORTON, AND HENRY H. RYFFEL CHRISTOPHER J. MCCAULEY,
SENIOR EDITOR RICCARDO M. HEALD, ASSOCIATE EDITOR MUHAMMED IQBAL
HUSSAIN, ASSOCIATE EDITOR
 A text book of machine design, R.S. KHURMI and J.K. GUPTA, 2005.
 Introduction to basic manufacturing processes and workshop technology, RAJENDER SINGH.
 Machine Design by JINDAL U. C.
 Machine elements in mechanical design, ROBERT L. MOTT, RE, University of Dayton, fourth
edition.
 Machine design an integrated approach, ROBERT L. NORTON, third edition.
 Machinery's Handbook 28th Edition BY ERIK OBERG, FRANKLIN D. JONES,
HOLBROOK L. HORTON, AND HENRY H. RYFFEL, Industrial press.
 Machines and mechanisms applied kinematic analysis, by DAVID H. MYSZKA,
University of Dayton.
 Mechanical design, second edition, PETER R.N. CHILDS, BSc(Hons), Dphil,
CEng,FIMechE, MIED, ILTM, Mem ASME, University of sussex, UK.
WEBSITES
 www.ALIBABA.com
 www.GLOBALSPEC.com

Bachuler Thesis On Multi-Spindle Drill Machine

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Bachuler Thesis On Multi-Spindle Drill Machine

Uploaded by

Copyright:

Available Formats

BACHULER THESIS ON MULTI-SPINDLE DRILL MACHINE 2005 E.

AAIT Page 1 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

AAIT Page 2 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

spindle drilling machine is more productive.

AAIT Page 3 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

and tapping) and can lead tool breakage.

is by using multi-spindle drilling head.

AAIT Page 4 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

1.1 BACKGROUND OF THE PROBLEM

same time. This reduces the company’s productivity and efficiency.

AAIT Page 5 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

bring considerable changes to the stated problems of the factory.

1.2. STATEMENT OF THE PROBLEM

AAIT Page 6 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

1.3 OBJECTIVE OF THESIS

Specific objectives are:

Specific objective of the thesis are:-

 To change single spindle drilling machine to multi-spindle drilling machine.

 To perform the design of different parts of the machine.

 To design sprockets and select chain.

 To construct parts as well as assembly of the machine.

 Reducing the production time and to improve the manpower usage.

 To reduce the work fatigue of the operators.

AAIT Page 7 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

1.4. RESAERCH METHODOLOGIES AND DATA COLLECTION

survey, Data collection and design.

1.4.1. Literature Review

Generally the following literature was compiled:

 Defination and classification of multi-spindle drill machine

 Introduction to multi-spindle drill machine and types of operation

 Finding of all the component of machine and their function.

 Present methods that most company used to drill multi-holes.

 Desing procedure and others

AAIT Page 8 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

1.4.2. Data Collection

 Information from different literature on this area.

 Information from internet

Mechanical Design of Components

A. Design of gear system, i.e. rack and pinion gear.

C. Selection of appropriate bearing, chain, and power source (electric motor).

E. Dimension of each parts and overall.

AAIT Page 9 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

Power supply unit

Construction and assembly

understanding of fundamental sience and related engineering subjects.

forfinal desing, economic evaluation, detailed engineering design and implementation.

1.5 THE EXPECTED OUTCOME AND BENEFICIARIES OF THE THESIS

1. increasing the productivity of the company

3. precision of center distance between each holes

4. good finishing and accuracy of holes

AAIT Page 10 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

5. mass production is very easy

 Selam Technical and Vocational Collage

 AAIT Technology Workshop

1.6 SCOPE AND LIMITATION OF THE STUDY

Selam Technical And Vocational Collage .

ways designing multi-holes drill machines.

multi-spindle drill machine.

AAIT Page 11 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

2.1 CHARACTERISTICS OF DRILLING MACHINE

Column, head, worktable, and base.

into the work a few thousandths of an inch per revolution

AAIT Page 12 SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING