Faculty of Engineering – Cairo University

Mechanical Design and Production Engineering

Two-Semester System – 3rd Year
MDP 303: Machine Design II – Fall 2019

Two Stages (Bevel-Helical) Gear Box

Submitted to
Prof.: Hesham Hegazi
T.A: Mohammed Hussein
T.A: Mostafa Rashad

Prepared by Group 2

Mahmoud Ahmed EL-Sayed

Yousef Gamal Hassan
Ayman Hisham Mahmoud

March 16th, 2020

Page | 2
Table of Contents

1. Preliminary Design for Bevel Gear

Set ...............................................................................
................... 4
1.1 Bevel
Pinion.............................................................................
...................................................... 4
1.2 Bevel
Gear ..............................................................................
....................................................... 5
2. Detailed Design for Bevel Gear
Set ...............................................................................
........................ 5
2.1 Bevel
Pinion.............................................................................
...................................................... 5
2.1.1 For Bending
Failure ...........................................................................
.................................... 5
2.1.2 For Surface
Failure ...........................................................................
..................................... 6
3. Preliminary Design for Helical Gear
Set ...............................................................................
................. 6
3.1 Helical
Pinion.............................................................................
.................................................... 6
3.1 Helical
Gear ..............................................................................
..................................................... 7
4. Detailed Design for Helical Gear
Set ...............................................................................
...................... 7
4.1 Helical
Pinion.............................................................................
.................................................... 7
4.1.1 For Bending
Failure ...........................................................................
.................................... 7
4.1.2 For Surface
Failure ...........................................................................
..................................... 8
5. Shaft
Calculations.......................................................................
........................................................... 9
5.1 Input
Shaft..............................................................................
....................................................... 9
5.2 Intermediate
Shaft .............................................................................
......................................... 10
5.3 Output
Shaft..............................................................................
.................................................. 11
6. Bearing
Selection .........................................................................
....................................................... 12
 6.1 For Input
Shaft .............................................................................
............................................... 12
6.2 For Intermediate
Shaft .............................................................................
................................... 13
6.3 For Output
Shaft .............................................................................
............................................ 14
7. Casing Analysis & Parts Construction
Drawings...........................................................................
....... 15

Page | 3
1. Preliminary Design for Bevel Gear Set

1.1 Bevel Pinion

P = 15 KW, 𝑛𝑖𝑛𝑝𝑢𝑡 = 1000 𝑟𝑝𝑚 , Reduction Ration = 2.5

From Graph Page 201

For P = 15 KW. N =16. 𝑛𝑖𝑛𝑝𝑢𝑡 = 1000 𝑟𝑝𝑚 ∅ = 20°

Get m = 4.5 mm
2𝑅
𝑚= 𝑅𝑃𝑖𝑛𝑖𝑜𝑛 = 36𝑚𝑚
𝑁

1 1
𝑡𝑎𝑛𝛾 = = 𝛾 = 21.8°
Reduction Ration 2.5
𝐷𝑎𝑣𝑔 = 𝐷𝑃𝑖𝑛𝑖𝑜𝑛 − 𝐹𝑆𝑖𝑛𝛾 = (72 − 35 ∗ 𝑆𝑖𝑛21.8) = 59 𝑚𝑚 𝑅𝑎𝑣𝑔 = 29.5 𝑚𝑚

𝐻 4 ∗ 15 ∗ 103
𝑊𝑡 = = = 15915.5 𝑁
𝜔𝑅 2𝜋 ∗ 1000 ∗ 36 ∗ 10−3
60
3
𝐾𝑣 = = 0.4926
3 + (𝜔𝑅𝑎𝑣𝑔 )

From Graph P.203

For 𝑁𝑃 = 16 a=m b = 1.25 m ∅ = 20° get Y = 0.2761
𝑅𝑃𝑖𝑛𝑖𝑜𝑛 36 𝐴𝑜
𝐴𝑜 = = = 96.939 𝑚𝑚 = 32.3 𝑚𝑚
𝑆𝑖𝑛𝛾 𝑆𝑖𝑛21.8 3
𝐴𝑜 𝐴𝑜
10 ∗ 4.5 > 𝐹= = 32.3 𝑚𝑚 ≅ 35 𝑚𝑚
3 3
𝑊𝑡 19422.38
𝜎𝑏 = = = 906.7 𝑀𝑃𝑎
𝐾𝑣 ∗ 𝐹 ∗ 𝑚 ∗ 𝑌 0.4926 ∗ 35 ∗ 4.5 ∗ 10−6 ∗ 0.2761
From Page 92
Select Alloy Steel HB 402-461 𝑆𝑢𝑡 = 1310 𝑀𝑃𝑎 𝑆𝑦 = 1170 𝑀𝑃𝑎
𝑆𝑦
𝐹. 𝑆 = = 1.29
𝜎𝑏

Page | 4
 1.2 Bevel Gear

Reduction Ration = 2.5 𝑅𝐺𝑒𝑎𝑟 = 2.5 ∗ 36 = 90𝑚𝑚 𝑁𝐺 = 2.5

∗ 𝑁𝑃 = 40
𝑛𝑖𝑛𝑝𝑢𝑡 1000
m = 4.5 mm 𝐹 = 35 𝑚𝑚 𝑛2 = = = 400 𝑟𝑝𝑚
2.5 2.5

2. Detailed Design for Bevel Gear Set

2.1 Bevel Pinion

2.1.1 For Bending Failure

From Page 196 table 9 for Automobile transmission Q = 10

2𝜋
From Page 206 Fig.11 for 𝑣= ∗ 1000 ∗ 36 ∗ 10−3 = 3.77 𝑚/𝑠 Q
= 10 𝐾𝑣 = 0.92
60

m = 4.5 mm 𝐹 = 35 𝑚𝑚
From Page 244 Fig.12 for 𝑁𝑃 = 16 𝑁𝐺 = 40 get J = 0.23
𝐻 15 ∗ 103
𝑊𝑡 = = = 3978.78 𝑁
𝑉 3.77
From Page 207 Fig.12 𝑆𝑢𝑡 = 1.3 𝐺𝑃𝑎 𝐾𝑎 = 0.64
From Table 13 m = 4.5 𝐾𝑏 = 0.92
From Table 14 Reliability = 0.99 𝐾𝑐 = 0.92
For 𝑆𝑢𝑡 < 1.4 𝐺𝑃𝑎 𝐾𝑓 = 1.33 𝑆𝑒 , = 0.5 ∗ 𝑆𝑢𝑡 = 655 𝑀𝑃𝑎

From Page 208 Table 16 Moderate shocks multiply cylinder 𝐾𝑜 = 1.5

From Page 245 one gear saddle mounted and the other is overhang 𝐾𝑚 = 1.2
𝑊𝑡 3978.78
𝜎𝑐 = = = 119.37 𝑀𝑃𝑎
𝐾𝑣 ∗ 𝐹 ∗ 𝑚 ∗ 𝐽 0.92 ∗ 35 ∗ 4.5 ∗ 10−6 ∗ 0.23
𝑆𝑒 = 𝐾𝑎 𝐾𝑏 𝐾𝑐 𝐾𝑓 𝑆𝑒 , = 417.527 𝑀𝑃𝑎
𝑆 𝑛𝐺
𝑛𝐺 = 𝜎𝑒 = 3.5 𝑛=𝐾 = 2.12 > 2 𝐶ℎ𝑒𝑐𝑘𝑒𝑑
𝑐 𝑜 ∗𝐾𝑚

Page | 5
 2.1.2 For Surface Failure

From Page 245 table 5 Steel on Steel 𝐶𝑃 = 2800 ∗ 0.083 = 232.52 𝑀𝑃𝑎
From Page 246 Fig.14 for 𝑁𝑃 = 16 𝑁𝐺 = 40 𝐼 = 0.074 𝑊𝑡 = 3978.78 𝑁
From Page 210 for 104 𝑐𝑦𝑐𝑙𝑒 𝐶𝐿 = 1.5 for reliability = 0.99 𝐶𝑅 = 0.8 𝐶𝑡 = 𝐶𝐻 = 1
𝑆𝐶 = 2.76 𝐻𝐵 − 70 = 2.76 ∗ 402 − 70 = 1039.52 𝑀𝑃𝑎

𝑊𝑡 3978.78
𝜎ℎ = 𝐶𝑃 √ = 193 ∗ √ = 1119.76 𝑀𝑃𝑎
𝐶𝑣 ∗ 𝐹 ∗ 𝑑𝑝 ∗ 𝐼 0.92 ∗ 35 ∗ 2 ∗ 36 ∗ 0.074

𝐶𝐿 ∗ 𝐶𝐻 1.5 ∗ 1
𝑆𝐻 = 𝑆𝐶 = ∗ 1039.52 = 1949.1 𝑀𝑃𝑎
𝐶𝑡 ∗ 𝐶𝑅 1 ∗ 0.8

𝑆 2 1949.1 2
(𝜎𝐻 ) (1119.76)
ℎ
𝑛= = = 1.836 > 1 𝐶ℎ𝑒𝑐𝑘𝑒𝑑
𝐾𝑜 ∗ 𝐾𝑚 1.5 ∗ 1.2

3. Preliminary Design for Helical Gear Set

3.1 Helical Pinion

Power = 15 KW n= 400 RPM reduction ratio =4

Assume 𝜑=20 ° ∅𝑛 =20°
From graph Page 201 𝑚𝑛 = 4 𝑚𝑚
𝑁𝑝 = 20 𝐷𝑝 = 𝑚𝑛 ∗ 𝑁𝑃 = 4 ∗ 20 = 80𝑚𝑚
𝐻 4 ∗ 15 ∗ 103
𝑊𝑡 = = = 35809.8 𝑁
𝜔∗𝑅 2𝜋 −3
60 ∗ 400 ∗ 40 ∗ 10
3
𝑘𝑣 = = 0.6416
3+𝑣
𝐶ℎ𝑒𝑐𝑘 ∶ 𝐹 ≥ 2𝑃𝑥
𝜋𝑚
𝑛 𝑃 13.317
𝑃𝑡 = 𝜋𝑚𝑡 = 𝐶𝑜𝑠𝜑 𝑡𝑎𝑘𝑒 𝜑 = 20° 𝑃𝑡 = 13.37 𝑃𝑥 = tan𝑡𝜑 = =
36.74
tan 20

𝐹 = 6𝜋𝑚 = 6 ∗ 𝜋 ∗ 4 ≅ 75𝑚𝑚

Page | 6
From table in page 203 for 𝑁 = 20 𝑎 = 𝑚 𝑏 = 1.25𝑚 𝜑 = 20° 𝑌 =
0.30769
𝑊𝑡 35809.8
𝜎= = = 604.64 𝑀𝑃𝑎
𝑘𝑣 ∗ 𝐹 ∗ 𝑚𝑛 𝑌 . 67173 ∗ 65 ∗ 3.5 ∗ 10−6 ∗ .30769
Material alloy steel HB 402-461 𝑆𝑢𝑙𝑡 = 1310 𝑀𝑃𝑎 𝑆𝑦 = 1170 𝑀𝑃𝑎
𝑆𝑦
𝐹. 𝑆 = = 1.935
𝜎𝑏

3.1 Helical Gear

Reduction Ration = 4 𝑅𝐺𝑒𝑎𝑟 = 160 𝑚𝑚 𝑁𝐺 = 4 ∗ 𝑁𝑃 = 80

𝑛1 400
𝑚𝑛 = 4 mm 𝐹 = 75 𝑚𝑚 𝑛2 = = = 100 𝑟𝑝𝑚
4 4

𝐶𝑒𝑛𝑡𝑒𝑟 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 𝑅𝐺𝑒𝑎𝑟 + 𝑅𝑃𝑖𝑛𝑖𝑜𝑛 = 200 𝑚𝑚

4. Detailed Design for Helical Gear Set

4.1 Helical Pinion

4.1.1 For Bending Failure

78
𝐾𝑣 = √ = .9
78 + √200𝑣
𝑛 𝑚
𝐹 = 75 𝑚𝑚 𝑚 = 𝐶𝑜𝑠𝜑 = 4.256 𝑚𝑚

From Page 237 ∅𝑛 = 20 𝜑𝑛 = 20 𝑁𝑃𝑖𝑛𝑖𝑜𝑛 = 20 𝑁𝐺𝑒𝑎𝑟 = 80 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠

𝑛𝑒𝑎𝑟 𝑡𝑜 𝑁 = 75
So, Correction Factor = 1
𝑃
𝑊𝑡 = = 8952.46 𝑁
𝜔∗𝑅
Form tables and graphs:
𝐾𝑎 = .64 𝐾𝑏 = .94 𝐾𝑐 = .814 𝐾𝑓 = 1.33

𝑆𝑒 = 422 𝑀𝑝𝑎

Page | 7
 𝑊𝑡 8952.46
𝜎𝑏 = 𝑘 = .9∗75∗4.296∗.44 = 70.82 𝑀𝑝𝑎
𝑣 ∗𝑓∗𝑚∗𝐽

𝑆𝑒
𝑛𝐺 = = 5.958
𝜎𝑏
𝑘𝑎 = 1.5 𝑘𝑚 = 1.3
𝑛𝐺
𝑛= = 3 > 2 𝐶ℎ𝑒𝑐𝑘𝑒𝑑
𝑘𝑎 ∗ 𝑘𝑚

4.1.2 For Surface Failure

𝐶𝑝 = 191𝑀𝑝𝑎 𝐶𝐿 = 1.5 𝐶𝑅 = .84 𝑐ℎ = 1 𝑐𝑡 = 1

𝑊𝑡 8952.46
𝜎ℎ = 𝑐𝑝 √ = 191 ∗ √ = 741.5 𝑀𝑃𝑎
𝑐𝑣 ∗ 𝑓 ∗ 𝐷𝑝 ∗ 𝐼 . 6785 ∗ 65 ∗ 2 ∗ 35 ∗ .116

𝑆𝑐 = 2.76 ∗ 𝐻𝐵 − 70 = 1039𝑀𝑃𝑎
𝑐𝑙 ∗ 𝑐ℎ 1 ∗ 1.5
𝑆ℎ = ∗ 𝑆𝑐 = ∗ 1039 = 1949.1𝑀𝑃𝑎
𝑐𝑡 ∗ 𝑐𝑅 1 ∗ .8

𝑠𝐻 2 1 1949.1 2 1
𝑛=( ) ∗ =( ) ∗ = 3.543 > 1 𝐶ℎ𝑒𝑐𝑘𝑒𝑑
𝜎ℎ 𝑘𝑎 ∗ 𝑘𝑚 741.5 1.5 ∗ 1.3

Page | 8
5. Shaft Calculations

5.1 Input Shaft

𝑊𝑡 = 15915.5 𝑁
𝑊𝑟 = 𝑊𝑡 𝑡𝑎𝑛𝜑𝑐𝑜𝑠𝛾 = 5378.45 𝑁
As 𝜑 = 20° 𝑎𝑛𝑑 𝛾 = 21.8°
𝑊𝑎 = 𝑊𝑡 𝑡𝑎𝑛𝜑𝑠𝑖𝑛𝛾 = 2151.24 𝑁
𝑇 = 𝑊𝑡 ∗ 𝑅𝑃𝑖𝑛𝑖𝑜𝑛 = 573 𝑁. 𝑚
𝑀𝑡𝑜𝑡𝑎𝑙 = 756 𝑁. 𝑚
Select Material for shaft:
1095 Normalized 𝑆𝑢𝑡 = 1013.5 𝑀𝑃𝑎 𝑆𝑦 = 500 𝑀𝑃𝑎

𝑆𝑒 , = 0.5 ∗ 𝑆𝑢𝑡 = 506.75 𝑀𝑃𝑎 𝑎𝑠𝑠𝑢𝑚𝑒 𝐾𝑚 = 𝐾𝑡 = 1.5

2
3
32 𝐾𝑚 𝑀 2 𝐾𝑇
𝑑=√ √( , ) + ( 𝑡 ) = 35 𝑚𝑚
𝜋 𝑆𝑒 𝑆𝑦

11936.6 2 4033.83 2
𝑅 𝑟𝑎𝑑𝑖𝑎𝑙 = √( ) +( ) = 3150 𝑁
𝑓𝑜𝑟 𝑙𝑒𝑓𝑡 4 4
𝑏𝑒𝑎𝑟𝑖𝑛𝑔

27852.12 2 9412.28 2
𝑅 𝑟𝑎𝑑𝑖𝑎𝑙 = √ ( ) + ( ) = 7350 𝑁
𝑓𝑜𝑟 𝑡ℎ𝑒 𝑜𝑡ℎ𝑒𝑟 4 4
𝑏𝑒𝑎𝑟𝑖𝑛𝑔

2151.24
𝐴𝑥𝑖𝑎𝑙 𝐿𝑜𝑎𝑑 𝑜𝑛 𝑏𝑜𝑡ℎ 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠 = = 537.81 𝑁
4
*The pinion rotates C.W making gear rotates C.C.W, which generates axial force on
pinion
shaft.

Page | 9
 5.2 Intermediate Shaft

𝑇 = 𝑊𝑡 ∗ 𝑅 = 35809.84 ∗ 40 ∗ 10−3 = 1432.4 𝑁. 𝑚

𝑀𝑡𝑜𝑡𝑎𝑙 = 1387.3 𝑁. 𝑚
Select Material for shaft:
1095 Normalized 𝑆𝑢𝑡 = 1013.5 𝑀𝑃𝑎 𝑆𝑦 = 500 𝑀𝑃𝑎

𝑆𝑒 , = 0.5 ∗ 𝑆𝑢𝑡 = 506.75 𝑀𝑃𝑎 𝑎𝑠𝑠𝑢𝑚𝑒 𝐾𝑚 = 𝐾𝑡 = 1.5

2
32 𝐾𝑚 𝑀 2
3
𝐾𝑡 𝑇
𝑑 = √ √( , ) + ( ) = 39.2𝑚𝑚 ≅ 40𝑚𝑚
𝜋 𝑆𝑒 𝑆𝑦

17370.2 2 14634.68 2
𝑅 𝑟𝑎𝑑𝑖𝑎𝑙 √
= ( ) +( ) = 5678.34 𝑁
𝑓𝑜𝑟 𝑙𝑒𝑓𝑡 4 4
𝑏𝑒𝑎𝑟𝑖𝑛𝑔

12415.5 2 23326.35 2
𝑅 𝑟𝑎𝑑𝑖𝑎𝑙 √
= ( ) +( ) = 6606.16 𝑁
𝑓𝑜𝑟 𝑡ℎ𝑒 𝑜𝑡ℎ𝑒𝑟 4 4
𝑏𝑒𝑎𝑟𝑖𝑛𝑔

Page | 10
 5.3 Output Shaft

𝑊𝑡 = 35809.84 𝑁
𝑊𝑡
𝑊= = 40553.72 𝑁
𝐶𝑜𝑠𝜓𝐶𝑜𝑠𝜑𝑛
𝜓 = 𝜑𝑛 = 20°
𝑊𝑎 = 𝑊𝑡 ∗ tan 𝜓 = 13033.71 𝑁

𝑤 = √𝑊𝑡 2 + 𝑊𝑟 2 + 𝑊𝑎 2

𝑊𝑟 = 13870.182 𝑁
𝑇 = 𝑊𝑡 ∗ 𝑅𝐺𝑒𝑎𝑟 = 5729.5 𝑁. 𝑚
𝑀𝑡𝑜𝑡𝑎𝑙 = 1008 𝑁. 𝑚
Select Material for shaft:
1095 Normalized 𝑆𝑢𝑡 = 1013.5 𝑀𝑃𝑎 𝑆𝑦 = 500 𝑀𝑃𝑎

𝑆𝑒 , = 0.5 ∗ 𝑆𝑢𝑡 = 506.75 𝑀𝑃𝑎 𝑎𝑠𝑠𝑢𝑚𝑒 𝐾𝑚 = 𝐾𝑡 = 1.5

2
3
32 𝐾𝑚 𝑀 2 𝐾𝑇
𝑑=√ √( , ) + ( 𝑡 ) = 55 𝑚𝑚
𝜋 𝑆𝑒 𝑆𝑦

17904.9 2 6935 2
𝑅 𝑟𝑎𝑑𝑖𝑎𝑙 =𝑅 𝑟𝑎𝑑𝑖𝑎𝑙 = √( ) +( )
𝑓𝑜𝑟 𝑙𝑒𝑓𝑡 𝑓𝑜𝑟 𝑅𝑖𝑔ℎ𝑡 4 4
𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑏𝑒𝑎𝑟𝑖𝑛𝑔

= 4800 𝑁

13033.71
𝐴𝑥𝑖𝑎𝑙 𝐿𝑜𝑎𝑑 𝑜𝑛 𝑏𝑜𝑡ℎ 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠 = = 3258.42 𝑁
4
*The pinion rotates C.C.W and that makes the gear rotates C.W which generates axial
force on
gear shaft.

Page | 11
6. Bearing Selection

6.1 For Input Shaft

Select bearings for shaft diameter=35mm

From SKF tables for taper bearing
Bearing A (left bearing) Bearing B (right
bearing)
Name: 30207 (3DB) Name: 32011 (3ce)
d=35mm d=35mm
D=72mm D=8mm
t=18.25mm t=32.75mm
c=63.2KN c=117KN
Y=1.6 Y=1.1
e=.37 e=.54
𝐹𝑟 = 3150𝑁 𝐹𝑟 = 7350𝑁

𝐾𝑎 = 537.81𝑁 to left
𝐹𝑟𝐴 𝐹𝑟𝐵
From P682 Case a <
𝑌𝐴 𝑌𝐵

𝐹𝑎𝐴 = 𝐹𝑎𝐵 + 𝑘𝑎 = 3340.9 + 537.81 = 3878.7𝑁 .

5𝐹𝑟𝐵 . 5 ∗ 7350
𝐹𝑎𝐵 = =
= 3340.9𝑁
𝑌𝑎
1.5
From P680 matched bearing
Face to face
𝐹𝑎𝐴 3878.7 𝐹𝑎𝐵
4858.13
= = 1.23 =
= 1.01
𝐹𝑟𝐴 3150 𝐹𝑟𝐵
4800

𝐹𝑎𝐴 𝐹𝑎𝐵
>𝑒
<𝑒

𝐹𝑟𝐴 𝐹𝑟𝐵
𝑃𝑎 =. 67𝐹𝑟 + 𝑦 ∗ 𝐹𝑎 = .67 ∗ 3150 + 1.6 ∗ 3878.7 𝑃𝑎 = 𝐹𝑟 + 𝑦 ∗ 𝐹𝑎
= 7350 + 1.1 ∗ 3340.9
= 3685.5𝑁
= 10690𝑁

60 ∗ 𝐿 ∗ 𝑛 3
𝐶 = 𝑃 ∗ 𝑆𝐹( )10
106
L=10000 for gear driven 10000-hour SF=1.3
60∗10000∗100 3
60∗10000∗100 3
𝐶𝐴 = 1.3 ∗ 3685 ∗ ( )10 =40.393 KN 𝐶𝐵 = 1.3 ∗ 10690 ∗ (
)10 =116.3KN
106 106
𝐶𝐴 < 𝐶𝐴,𝑡𝑎𝑏𝑙𝑒 𝐶𝐵 <
𝐶𝐵,𝑡𝑎𝑏𝑙𝑒
Page | 12
 6.2 For Intermediate Shaft

Select bearings for shaft diameter=40mm

From SKF tables for taper bearing
Bearing A (left bearing) Bearing B (right bearing)
Name: 30208 (3DB) Name: 32208 (3DC)
d=40mm d=40mm
D=80m D=80mm
t=19.75mm t=24.75mm
c=75.8KN c=91.6KN
Y=1.6 Y=1.6
e=.37 e=.37
𝐹𝑟 = 5678.34𝑁 𝐹𝑟 = 6606.16𝑁

𝐾𝑎 = 1913.81𝑁 TO right
𝐹𝐴 𝐹 𝐹 𝐹𝑟𝐴
From P682 Case b < 𝑌𝐵 𝑘𝑎 ≥ .5( 𝑌𝑟𝐵 − )
𝑌𝐴 𝐵 𝐵 𝑌𝐴

. 5𝐹𝑟𝐴 . 5 ∗ 5678.34 𝐹𝑎𝐵 = 𝐹𝑎𝐴 + 𝑘𝑎 = 1774.5

+ 1913.8 = 3688.28𝑁
𝐹𝑎𝐴 = = = 1774.5𝑁
𝑌𝐴 1.6
From P680 matched bearing
Face to face
𝐹𝑎𝐴 1774.5 𝐹𝑎𝐵
4858.13
= = .31 =
= 1.01
𝐹𝑟𝐴 5678.34 𝐹𝑟𝐵
4800
𝐹𝑎𝐴
𝐹𝑎𝐵
≤𝑒
>𝑒
𝐹𝑟𝐴
𝐹𝑟𝐵
𝑃𝑎 = 𝐹𝑟 + 𝑦 ∗ 𝐹𝑎 = 5678.34 + 1.6 ∗ 1774.5 𝑃𝑎 =. 67 ∗ 𝐹𝑟 + 𝑦
∗ 𝐹𝑎
= 8517.5𝑁
= .67 ∗ 6606.2 + 1.6 ∗ 3688.3
=
10327.4𝑁

60 ∗ 𝐿 ∗ 𝑛 3
𝐶 = 𝑃 ∗ 𝑆𝐹( )10
106
L=10000 for gear driven 10000-hour SF=1.3
60∗10000∗100 3
60∗10000∗100 3
𝐶𝐴 = 1.3 ∗ 8517.54 ∗ ( )10 =68.8KN 𝐶𝐵 = 1.3 ∗ 10327.4 ∗ (
)10 =83.4KN
106
106
𝐶𝐴 < 𝐶𝐴,𝑡𝑎𝑏𝑙𝑒 𝐶𝐵 <
𝐶𝐵,𝑡𝑎𝑏𝑙𝑒
Page | 13
 6.3 For Output Shaft

Select bearings for shaft diameter=55mm

From SKF tables for taper bearing
Bearing A (right bearing) Bearing B (left bearing)
Name: 32011X (3cc) Name: 32011 (3ce)
d=55mm d=55mm
D=90m D=90mm
t=23mm t=27mm
c=99.4KN c=111KN
Y=1.5 Y=1.9
e=.4 e=.31
𝐹𝑟 = 4800𝑁 𝐹𝑟 = 4800𝑁

𝐾𝑎 = 3258.63𝑁 to left
𝐹𝐴 𝐹
From P682 Case a ≥ 𝑌𝐵
𝑌𝐴 𝐵

. 5𝐹𝑟𝐴 . 5 ∗ 4800 𝐹𝑎𝐵 = 𝐹𝑎𝐴 + 𝑘𝑎 = 1600

+ 3258.63 = 4858.63𝑁
𝐹𝑎𝐴 = = = 1600𝑁
𝑌𝐴 1.5
From P680 matched bearing
Face to face
𝐹𝑎𝐴 1600 𝐹𝑎𝐵
4858.13
= = .33 =
= 1.01
𝐹𝑟𝐴 4800 𝐹𝑟𝐵
4800
𝐹𝑎𝐴
𝐹𝑎𝐵
≤𝑒
>𝑒
𝐹𝑟𝐴
𝐹𝑟𝐵
𝑃𝑎 = 𝐹𝑟 + 𝑦 ∗ 𝐹𝑎 = 4800 + 1.9 ∗ 1600 = 7840𝑁 𝑃𝑎 =. 67 ∗ 𝐹𝑟 + 𝑦 ∗
𝐹𝑎
= .67
∗ 4800 + 1.9 ∗ 4858.63
=
12447.7𝑁

60 ∗ 𝐿 ∗ 𝑛 3
𝐶 = 𝑃 ∗ 𝑆𝐹( )10
106
L=10000 for gear driven 10000-hour SF=1.3
60∗10000∗100 3
60∗10000∗100 3
𝐶𝐴 = 1.3 ∗ 7840 ∗ ( )10 =63.34KN 𝐶𝐵 = 1.3 ∗ 12447.4 ∗ (
)10 =100.6KN
106
106
𝐶𝐴 < 𝐶𝐴,𝑡𝑎𝑏𝑙𝑒 𝐶𝐵 <
𝐶𝐵,𝑡𝑎𝑏𝑙𝑒
Page | 14
7. Casing Analysis, Parts W.D & Construction Drawing

Page | 15
Page | 16
 2.50 A

25

134.50
-0.01
35 -0.02

35

60
3

SECTION A-A A
SCALE 1 : 2
-0.16
30 -0.37

scale 1:2

ITEM NO. PART NUMBER material

QTY.
1 input shaft 1040 NORMALIZED
1

SOLIDWORKS Educational Product. For Instructional Use Only.

+0.12
6 0
5

A A
+0.18
R17.50 0
63.62

gear
spicifications
Module
4.5
Number Of teeth
16
pitch Diameter
72mm
SECTION A-A Root Diameter
60.75mm
SCALE 1 : 1 Head Diameter
81mm
Pressure Angle
20

scale 1:1
ITEM NO. PART NUMBER material
QTY.
1 bevel pinion steel
1

SOLIDWORKS Educational Product. For Instructional Use Only.

 40 25

+0.03

40 +0.02
-0.01
50 -0.11

A
A

18.75 117
23.75
4

SECTION A-A

ITEM NO. PART NUMBER material

QTY.
1 intermedit shaft 1040
NORMALIZED 1

SOLIDWORKS Educational Product. For Instructional Use Only.

 N5

A A

40

gear
spicification
173.42

MODULE
4.5
Number Of teeth
40
pitch Diameter
180mm
ROOT Diameter
168.75mm
Head Diameter
189mm
Pressure Angle
20

SECTION A-A
SCALE 1 : 2

scale 1:2
ITEM NO. PART NUMBER material
QTY.
1 bevel gear steel
1

SOLIDWORKS Educational Product. For Instructional Use Only.

 +0.02
8 0

N6

A A

75
+0.01
45 0

GEAR
SPICIFICATION
SECTION A-A
Module
4
Number Of teeth
20
pitch Diameter
80mm
Root Diameter
70mm
Head Diameter
88mm
Pressure Angle
20
helical angle
20

scale 1:2
ITEM NO. PART NUMBER MATERIAL
QTY.
1 helical pinion Alloy Steel HB
402 1

SOLIDWORKS Educational Product. For Instructional Use Only.

 52 53 83

-0.03

65 -0.10
55
-0.01
40 -0.02

A
A
4

-0.01

51 -0.03

SECTION A-A
SCALE 1 : 2

scale 1:2
ITEM NO. PART NUMBER material
QTY.
1 output shaft 1040
NORMALIZED 1

SOLIDWORKS Educational Product. For Instructional Use Only.

 175 +0.9
+0. 4
31

A A
H6 +0.02
R32.50 0

.16
+0 .11
+0
270

75

Gear
spicification

Module
4
Number Of teeth
80
pitch Diameter
160mm
SECTION A-A ROOT Diameter
150mm
Head Diameter
168mm
Pressure Angle
20

ITEM NO. PART NUMBER

material QTY.
1 helical gear
Alloy Steel 1

SOLIDWORKS Educational Product. For Instructional Use Only.

 32 2
12
TEAM 2
37

23 21
Ayman Hisham
Mahomoud Ahmed
Yousef Gamal 5
SCALE 7:20
31

E
20 E

16

33
24

25
34

28

35

22

15 588 17 27 18

DETAIL Thread
SCALE 1 : 1

1
36 Thread
DETAIL Lock Nut & Washer
SCALE 1 : 1

H7
H
55 j6 H 26

Key Connection P. NO
DESIGNITION MATERIAL NO.OF
165

H7 H7
1 Lower Casing A380 1
Lock Nut & Washer
H7

50
k6 65 k6
35 k6

2 bevel pinion ALLOY STEEL 1

3 98541A146 1

4 input shaft 1095 NORMALIZED 1

5 bearing 33207 1

6 bearing 30207 1

Spring Oil Seal

H7

7 key 2 1
40
j6
8 intermedit shaft 1095 NORMALIZED 1

13
9 key 1 1

30 19 8 11 9 10 key 4
1
7 14 10
SECTION E-E 29
11 helical pinion ALLOY STEEL 1

12 bevel gear ALLOY STEEL 1

13 spacer 3 AL 3

14 bearing 32208 1

15 bearing 30208 1

16 output shaft 1095 NORMALIZED 1

17 spacer 4 AL 2

18 bearing 30211 1

19 bearing 32011x 1
DETAIL Spring Oil Seal
20 helical gear ALLOY STEEL 1
SCALE 1 : 1
21 Upper Casing A380 1

22 ISO 8676 - M24x2.0 x 40-S 1

40.00

23 ISO 10511-M10-C 15

24 Oil Cap 1

25 Oil level measuring Glass 1

26 Casing Cap 2

27 Casing Cover 2 1

28 Caing Cover 3 1

29 Spring Oil Seal 2 1

DETAIL Key Connection
30 key 3 1
SCALE 1 : 1
31 spacer 1 AL 1

32 spacer 2 AL 1

33 lock washer 1

34 DIN 1804 - M30x1.5 - S 1

SECTION H-H 35 Caing Cover 1

1
SOLIDWORKS Educational Product. For Instructional Use Only.
36 Spring Oil Seal #25 1

37 Quality Glass 1