MA3001: Design Project

Sugarcane Extraction Machine Report

Group Members: Chow Wanxuan (U1221961F)

Danielle Milne (N1403295G)
Chanisara Netsuwan (N1402460F)

Tutorial Group: MA4, Group 7

Table of Contents
1.0 Introduction ................................................................................................................ 3
2.0 Motor........................................................................................................................... 3
3.0 Gear Reduction Box .................................................................................................... 3
3.1 Finding the gear pairs in gear reduction box ......................................................................3
4.0 Chain Drive ................................................................................................................. 4
4.1 Finding the chain drive ......................................................................................................5
5.0 Shaft Design ................................................................................................................ 6
5.1 Shaft bearings ..................................................................................................................12
6.0 Rollers ....................................................................................................................... 15
6.1 Force needed to crush sugarcane......................................................................................15
6.2 Force Analysis of Roller 1 ................................................................................................16
6.3 Shaft Design of Roller 1....................................................................................................18
6.4 Roller Bearing Forces ......................................................................................................19
7.0 Assembly Drawings ................................................................................................... 20
Appendix A .......................................................................................................................... 25
Appendix B .......................................................................................................................... 25
1.0 Introduction
This report is about designing a sugarcane machine’s power transmission drive using a 0.55 kW AC motor operating
approximately 1420 rpm and with the desired speed of the roller about 55 rpm.

2.0 Motor
The motor selected is an AEEB motor, which is a three-phase squirrel cage induction motor. This motor is from
TECO Company’s catalogue for AEEB motors. From the catalogue, at 0.55 kW, the full load of the motor is 1405
rpm, which is within the range of the speed (1420 rpm ± 5%). As for the size of the motor, the dimensions of the
motor are found at Appendix A.

3.0 Gear Reduction Box

Due to the motor’s speed at 1405 rpm is very much larger than the desired speed of the roller at 55 rpm, gear
reduction box is required to reduce the input speed to a much lower value. The gear reduction box uses two gear
pairs that help to reduce the speed from 1405 rpm to 133.81 rpm. The workings are shown below.

3.1 Finding the gear pairs in gear reduction box

The purpose of gear reduction is to reduce the speed of 1405 rpm to about 100 rpm.
M eff , output torque = T= P/ω
=550/(2×1405×π÷60)
= 3.7381 Nm
Since the application is of normal importance, s B = 1.5 and with moderate shock loading and drive, f B = 1.75,
M tab = M eff ×s B × fB = 3.7381 ×1.5×1.75
= 9.8126 Nm ≈ 10 Nm
Using load diagram Z-056, with M tab = 10 Nm,
Module, m = 1, min teeth = 50, max teeth = 120
1st trial: m = 1, N P = 50, N G = 120
a) Check for interference: From Table 3 in Gear notes, there is no inference.
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑁𝑁
b) Check for output speed: = 𝑁𝑁𝐺𝐺
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑃𝑃
1405 120
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 50
output speed = 585.42 rpm
If N G is lower than 120, the output speed will be more than 585.42 rpm, thus one pair of gears is not possible,
use gear train to reduce speed as low as possible.
c) Check tip to tip dimensions:
Outside diameter of N G = 122 mm (from Z-104)
With clearance of 3 mm at each side,
Z direction = 122 + 2(3)
= 128 mm < 750 mm
Outside diameter of N P = 52 mm (from Z-104)
Y direction = center distance + R OP + R OG + 2(3) = 0.5m(N P + N G ) + 0.5(52) + 0.5(122) + 6
= (0.5)(1.0)(50+120) + 93
= 178 mm < 520 mm
To find the 2nd gear pair:
M eff , output torque = T= P/ω
=550/(2×585.42×π÷60)
= 8.97153 Nm
M tab = M eff ×s B × fB = 8.97153 ×1.5×1.75
= 23.55026 Nm ≈ 23.6 Nm
Using load diagram Z-056, with M tab = 23.6 Nm,
Select module, m = 1, min teeth = 115, max teeth = 120
2nd trial: m = 1, N P = 115, N G = 120
a) Check for output speed:
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑁𝑁𝐺𝐺
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑁𝑁𝑃𝑃
585.42 120
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 115
 Output speed = 561.0275 rpm
Since the new output speed is not close to 100 rpm, select a larger value of module.
Select m = 1.25, min teeth = 60, max teeth = 70
3rd trial: m = 1.25, N P = 60, N G = 70
a) Check for output speed:
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑁𝑁𝐺𝐺
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑁𝑁𝑃𝑃
585.42 70
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 60
Output speed = 501.79 rpm
Since the new output speed is not close to 100 rpm, select a larger value of module.
Select m = 1.5, min teeth = 32, max teeth = 70
4th trial: m = 1.5, N P = 32, N G = 70
a) Check for output speed:
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑁𝑁𝐺𝐺
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑁𝑁𝑃𝑃
585.42 70
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 32
Output speed = 267.62 rpm
Since the new output speed is not close to 100 rpm, select a larger value of module.
Select m = 2.0, min teeth = 13, max teeth = 70
5th trial: m = 2.0, N P = 13, N G = 70
a) Check for output speed:
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑁𝑁𝐺𝐺
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑁𝑁𝑃𝑃
585.42 70
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 13
Output speed = 108.72 rpm
b) Since the output speed is close to 100 rpm, now check for interference:
From Table 3 in Gear notes, the maximum number of gear teeth is 16 when N P = 13. Since N G = 70,
there is interference.
Select a different value of N P such that there is no interference.
6th trial: m = 2.0, N P = 16, N G = 70
a) Check for output speed:
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑁𝑁𝐺𝐺
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑁𝑁𝑃𝑃
585.42 70
=
𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 16
Output speed = 133.81 rpm
b) Check tip to tip dimensions:
Outside diameter of N G = 144 mm (from Z-108)
With clearance of 3 mm at each side,
Z direction = 144 + 2(3)
= 150 mm < 750 mm
Outside diameter of N P = 36 mm (from Z-108)
Y direction = center distance + R OP + R OG + 2(3)
= 0.5m(N P + N G ) + 0.5(36) + 0.5(144) + 6
= (0.5)(2.0)(16+70) + 96
= 182 mm < 520 mm
For gear train: 1st pair: m = 1.0, N P = 50, N G = 120
2nd pair: m = 2.0, N P = 16, N G = 70

4.0 Chain Drive

Chain drives are selected because they are more compact, powerful and efficient than belt drives. Furthermore, chain
drives do not deteriorate with age, heat or oil and grease. The workings are shown below.
4.1 Finding the chain drive
Service factor = 1.3, using one strand and desired roller speed is 55 rpm
Design power per strand = (transmitted power × service power)/ no. of stand
= (0.55×1.3)/1.0
= 0.715 kW/strand
Since the speed of the driver is 133.81 rpm, which is more than 100 rpm, value of N 1 has to be at least 17 for a
smooth drive.
Let N 1 = 17, From Table B-4 from Appendix B, select no. 35 chain.
a) Find speed ratio:
𝑛𝑛1 133.81
=
𝑛𝑛2 55
= 2.4329
b) Find N 2 :
𝑛𝑛1 𝑁𝑁2
=
𝑛𝑛2 𝑁𝑁1
𝑛𝑛1
𝑁𝑁2 = 𝑁𝑁1 � �
𝑛𝑛2
= 17(2.4329)
= 41.3593 ≈42
From the catalogue, N 2 = 42 does not exist for chain no. 35. Hence use higher chain no. with N 1 = 17.
Select no. 40 chain and N 1 = 17 and speed ratio is 2.4329. From the catalogue for chain no. 40, N 2 = 42 exists.
Now check the actual speed of the roller:
𝑁𝑁1
𝑛𝑛2 = 𝑛𝑛1 � �
𝑁𝑁2
= 133.81(17/42)
= 54.17 rpm ≈ 55 rpm
Pitch of the no. 40 chain = 12.70 mm, N 1 = 17, with pitch diameter of 69.12mm and N 2 = 42, with pitch
diameter of 169.95 mm. The chain system uses type A lubricant.
Assuming no power loss, P = T 1 ω 1 = T 2 ω 2 ,
P = T1 ω1
550 = T 1 (2π(133.81)/60)
T 1 = 39.25 Nm
P = T2 ω2
550 = T 2 (2π(54.17)/60)
T 2 = 96.956 Nm
5.0 Shaft Design
Properties/ Assumptions:

Material:
AISI 1137 CD
S u = 676 MPa
S y = 565 MPa
(Appendix 3)

Polished:
S n = 350 MPa
(Fig 5-8)

Reliability:
99 %  C R = 0.81
(Table 5-1)

Size Factor:
Assume shaft diameter is
approximately 22 mm
D = 22 mm  C S = 0.89

Sn’ = Sn CS CR
S n ’ = (350 MPa) x (0.89) x (0.81)
S n ’ = 252.315 MPa

Factor of Safety:
N=3

Shaft 1
Forces Calculations:

𝑇𝑇 = 3.7381 𝑁𝑁𝑁𝑁 *
𝐷𝐷 = 50 𝑚𝑚𝑚𝑚 = 0.050 𝑚𝑚*

*found in gear calculations

𝑇𝑇
𝑊𝑊𝑇𝑇 =
𝐷𝐷⁄2
3.7381 𝑁𝑁𝑁𝑁
=
0.05⁄2 𝑚𝑚
= 149.524 𝑁𝑁

𝑊𝑊𝑟𝑟 = 𝑊𝑊𝑇𝑇 tan 𝛷𝛷

= (149.524) tan 20°
= 54.422 𝑁𝑁
Forces on Gear A
𝐹𝐹𝐴𝐴𝐴𝐴 = 54.422 𝑁𝑁
𝐹𝐹𝐴𝐴𝐴𝐴 = 149.524 𝑁𝑁
Proposed layout: Bearing mounting: press fit
Sharp fillet: r 1 , r 4 Gears: press fit
Well-rounded fillet: r 2 , r 3
X-Z direction X-Y direction
Take the moment about Bearing 1 Take the moment about Bearing 1
𝛴𝛴𝑀𝑀𝐵𝐵1 = 𝐹𝐹𝐴𝐴𝐴𝐴 (0.050) − 𝐵𝐵2𝑧𝑧 (0.100) = 0 𝛴𝛴𝑀𝑀𝐵𝐵1 = 𝐹𝐹𝐴𝐴𝐴𝐴 (0.050) − 𝐵𝐵2𝑦𝑦 (0.100) = 0

Force on Bearing 2 (z-direction) Force on Bearing 2 (y-direction)

𝐹𝐹𝐴𝐴𝐴𝐴 (0.050) 𝐹𝐹𝐴𝐴𝐴𝐴 (0.050)
𝐵𝐵2𝑧𝑧 = 𝐵𝐵2𝑦𝑦 =
0.100 0.100
(54.422 )(0.050) (149.524 )(0.050)
= =
(0.100) (0.100)
= 27.211 𝑁𝑁 = 74.762 𝑁𝑁

Sum of forces in the z-direction Sum of forces in the y-direction

𝛴𝛴𝐹𝐹𝑧𝑧 = −𝐵𝐵1𝑧𝑧 + 𝐹𝐹𝐴𝐴𝐴𝐴 − 𝐵𝐵2𝑧𝑧 = 0 𝛴𝛴𝐹𝐹𝑦𝑦 = −𝐵𝐵1𝑦𝑦+ 𝐹𝐹𝐴𝐴𝐴𝐴 − 𝐵𝐵2𝑦𝑦 = 0

Force on Bearing 1 (z-direction) Force on Bearing 1 (y-direction)

𝐵𝐵1𝑧𝑧 = 𝐹𝐹𝐴𝐴 − 𝐵𝐵2𝑧𝑧 𝐵𝐵1𝑦𝑦 = 𝐹𝐹𝐴𝐴𝐴𝐴 − 𝐵𝐵2𝑦𝑦
= 54.422 − 27.211 = 149.524 − 74.762
= 27.211 𝑁𝑁 = 74.762 𝑁𝑁
Bending moment Bending moment
𝑀𝑀 = −(27.211 𝑁𝑁)(0.050 𝑚𝑚) 𝑀𝑀 = −(74.762 𝑁𝑁)(0.050 𝑚𝑚)
= −1.361 𝑁𝑁𝑁𝑁 = −3.73 𝑁𝑁𝑁𝑁

Resultant Moment
𝑀𝑀1 = �𝑀𝑀1𝑧𝑧 2 + 𝑀𝑀1𝑦𝑦 2 = √0 + 0 = 0

𝑀𝑀𝐴𝐴 = �𝑀𝑀𝐴𝐴𝐴𝐴 2 + 𝑀𝑀𝐴𝐴𝐴𝐴 2 = �(−1.362)2 + (−3.7381)2 = 3.978 𝑁𝑁𝑁𝑁

𝑀𝑀2 = �𝑀𝑀2𝑧𝑧 2 + 𝑀𝑀2𝑦𝑦 2 = 0

Shaft 2
Forces Calculations:

𝜂𝜂 = 585.42 𝑟𝑟𝑟𝑟𝑟𝑟*
𝑃𝑃 = 550 𝑊𝑊

*found in gear calculations

𝜔𝜔 = 𝜂𝜂(2𝜋𝜋⁄60)
= (585.42)(2𝜋𝜋⁄60)
= 61.305 𝑟𝑟𝑟𝑟𝑟𝑟/𝑠𝑠

𝑃𝑃 550 𝑊𝑊
𝑇𝑇 = =
𝜔𝜔 61.305 𝑟𝑟𝑟𝑟𝑟𝑟⁄𝑠𝑠 Proposed layout: Bearing mounting: press fit
= 8.971 𝑁𝑁𝑁𝑁 Sharp fillet: r 3 , r 5 Gears: press fit
Well-rounded fillet: r 1 , r 2 , r 4

Calculating forces on Gear B Forces on Gear C

𝑇𝑇 𝐹𝐹𝐶𝐶𝐶𝐶 = 54.422 𝑁𝑁
𝑊𝑊𝑇𝑇 =
𝐷𝐷⁄2 𝐹𝐹𝐶𝐶𝐶𝐶 = 149.524 𝑁𝑁
8.971 𝑁𝑁𝑁𝑁 Same as the forces on Gear A since
= they are paired
0.032⁄2 𝑚𝑚
= 560.6875 𝑁𝑁

𝑊𝑊𝑟𝑟 = 𝑊𝑊𝑇𝑇 tan 𝛷𝛷

= (560.6875) tan 20°
= 204.0736 𝑁𝑁

Forces on Gear B
𝐹𝐹𝐵𝐵𝐵𝐵 = 204.0736 𝑁𝑁
𝐹𝐹𝐵𝐵𝐵𝐵 = 560.6875 𝑁𝑁
X-Z direction X-Y direction
Take the moment about Bearing 3 Take the moment about Bearing 3
𝛴𝛴𝑀𝑀𝐵𝐵3 = −𝐹𝐹𝐵𝐵𝐵𝐵 (0.060) − 𝐹𝐹𝐶𝐶𝐶𝐶 (0.080) + 𝐵𝐵4𝑧𝑧 (0.140) 𝛴𝛴𝑀𝑀𝐵𝐵3 = −𝐹𝐹𝐵𝐵𝐵𝐵 (0.060) − 𝐹𝐹𝐶𝐶𝐶𝐶 (0.080) + 𝐵𝐵4𝑦𝑦 (0.140)
= 0 = 0

Force on Bearing 4 (z-direction) Force on Bearing 4 (y-direction)

𝐹𝐹𝐵𝐵𝐵𝐵 (0.060) + 𝐹𝐹𝐶𝐶𝐶𝐶 (0.080) 𝐹𝐹𝐵𝐵𝐵𝐵 (0.060) + 𝐹𝐹𝐶𝐶𝐶𝐶 (0.080)
𝐵𝐵4𝑧𝑧 = 𝐵𝐵4𝑦𝑦 =
0.140 0.140
(204.0736)(0.060) + (54.422)(0.080) (560.6875)(0.060) + (149.524)(0.080)
= =
(0.140) (0.140)
= 118.558 𝑁𝑁 = 325.74 𝑁𝑁
Sum of forces in the z-direction Sum of forces in the y-direction
𝛴𝛴𝐹𝐹𝑧𝑧 = 𝐹𝐹𝐵𝐵𝐵𝐵 − 𝐵𝐵3𝑧𝑧 − 𝐹𝐹𝐶𝐶𝐶𝐶 + 𝐵𝐵4𝑧𝑧 = 0 𝛴𝛴𝐹𝐹𝑦𝑦 = 𝐹𝐹𝐵𝐵𝐵𝐵 − 𝐵𝐵3𝑦𝑦 − 𝐹𝐹𝐶𝐶𝐶𝐶 + 𝐵𝐵4𝑦𝑦 = 0

Force on Bearing 3 (z-direction) Force on Bearing 3 (y-direction)

𝐵𝐵3𝑧𝑧 = 𝐹𝐹𝐵𝐵𝐵𝐵 − 𝐹𝐹𝐶𝐶𝐶𝐶 + 𝐵𝐵4𝑧𝑧 𝐵𝐵3𝑦𝑦 = 𝐹𝐹𝐵𝐵𝐵𝐵 − 𝐹𝐹𝐶𝐶𝐶𝐶 + 𝐵𝐵4𝑦𝑦
= 204.0736 − 54.422 + 118.558 = 560.6875 − 149.524 + 325.74
= 268.21 𝑁𝑁 = 736.900 𝑁𝑁
Bending Moment Bending Moment
𝑀𝑀3𝑧𝑧 = (204.07 𝑁𝑁)(0.060 𝑚𝑚) = 12.24 𝑁𝑁𝑁𝑁 𝑀𝑀3𝑧𝑧 = (560.07 𝑁𝑁)(0.060 𝑚𝑚) = 33.64 𝑁𝑁𝑁𝑁
𝑀𝑀𝐶𝐶𝐶𝐶 = 12.24 − (64.13)(0.080) = 7.11 𝑁𝑁𝑁𝑁 𝑀𝑀𝐶𝐶𝐶𝐶 = 33.64 − (176.2125)(0.080) = 19.54 𝑁𝑁𝑁𝑁

Resultant Moment

𝑀𝑀𝐵𝐵 = �𝑀𝑀𝐵𝐵𝐵𝐵 2 + 𝑀𝑀𝐵𝐵𝐵𝐵 2 = √0 + 0 = 0

𝑀𝑀3 = �𝑀𝑀3𝑧𝑧 2 + 𝑀𝑀3𝑦𝑦 2 = �12.242 + 33.642 = 35.798 𝑁𝑁𝑁𝑁

𝑀𝑀𝐶𝐶 = �𝑀𝑀𝐶𝐶𝐶𝐶 2 + 𝑀𝑀𝐶𝐶𝐶𝐶 2 = �7.112 + 19.542 = 20.793 𝑁𝑁𝑁𝑁

𝑀𝑀4 = �𝑀𝑀4𝑧𝑧 2 + 𝑀𝑀4𝑦𝑦 2 = 0

Shaft 3
Forces Calculations:

Forces Calculations:
𝜂𝜂 = 133.81 𝑟𝑟𝑟𝑟𝑟𝑟*
𝑃𝑃 = 550 𝑊𝑊
*found in gear calculations

𝜔𝜔 = 𝜂𝜂(2𝜋𝜋⁄60)
= (133.81)(2𝜋𝜋⁄60)
= 14.01 𝑟𝑟𝑟𝑟𝑟𝑟/𝑠𝑠

𝑃𝑃 550 𝑊𝑊
𝑇𝑇 = =
𝜔𝜔 14.01 𝑟𝑟𝑟𝑟𝑟𝑟⁄𝑠𝑠
= 39.25 𝑁𝑁𝑁𝑁
Proposed layout: Bearing mounting: press fit
Sharp fillet: r 3 , r 5 Gears: press fit
Well-rounded fillet: r 1 , r 2 , r 4

Calculating forces on Chain Forces on Gear D

Sprocket 𝐹𝐹𝐷𝐷𝐷𝐷 = 204.0736 𝑁𝑁*
𝑇𝑇
𝐹𝐹𝐹𝐹𝐹𝐹 = 𝐹𝐹𝐷𝐷𝐷𝐷 = 560.6875 𝑁𝑁*
𝐷𝐷⁄2
39.25 𝑁𝑁𝑁𝑁 *Same as those on Gear B since they
= are pairs
0.06912⁄2 𝑚𝑚
= 1135.7 𝑁𝑁
Resultant Moment

𝑀𝑀𝐹𝐹 = �𝑀𝑀𝐹𝐹𝐹𝐹 2 + 𝑀𝑀𝐹𝐹𝐹𝐹 2 = √0 + 0 = 0

𝑀𝑀5 = �𝑀𝑀5𝑧𝑧 2 + 𝑀𝑀5𝑦𝑦 2 = �56.7852 + 02 = 56.785 𝑁𝑁𝑁𝑁

𝑀𝑀𝐷𝐷 = �𝑀𝑀𝐷𝐷𝐷𝐷 2 + 𝑀𝑀𝐷𝐷𝐷𝐷 2 = �33.49452 + 14.0172 = 36.309 𝑁𝑁𝑁𝑁

𝑀𝑀6 = �𝑀𝑀6𝑧𝑧 2 + 𝑀𝑀6𝑦𝑦 2 = 0

X-Z direction X-Y direction

Take the moment about Bearing 5 Take the moment about Bearing 5
𝛴𝛴𝑀𝑀𝐵𝐵5 = −𝐹𝐹𝐹𝐹𝐹𝐹 (0.050) − 𝐹𝐹𝐷𝐷𝐷𝐷 (0.050) + 𝐵𝐵6𝑧𝑧 (0.100) 𝛴𝛴𝑀𝑀𝐵𝐵5 = −𝐹𝐹𝐷𝐷𝐷𝐷 (0.050) + 𝐵𝐵6𝑦𝑦 (0.100) = 0
= 0
Force on Bearing 6 (y-direction)
Force on Bearing 6 (z-direction) 𝐹𝐹𝐷𝐷𝐷𝐷 (0.050)
𝐹𝐹𝐹𝐹𝐹𝐹 (0.050) + 𝐹𝐹𝐷𝐷𝐷𝐷 (0.050) 𝐵𝐵6𝑦𝑦 =
𝐵𝐵6𝑧𝑧 = 0.100
0.100 (560.6875)(0.050)
(1135.7)(0.050) + (204.0736)(0.050) =
= (0.100)
(0.100)
= 280.3438 𝑁𝑁
= 669.88698 𝑁𝑁
Sum of forces in the y-direction
Sum of forces in the z-direction 𝛴𝛴𝐹𝐹𝑦𝑦 = 𝐵𝐵5𝑦𝑦 − 𝐹𝐹𝐷𝐷𝐷𝐷 + 𝐵𝐵6𝑦𝑦 = 0
𝛴𝛴𝐹𝐹𝑧𝑧 = 𝐹𝐹𝐹𝐹𝐹𝐹 − 𝐵𝐵5𝑧𝑧 − 𝐹𝐹𝐷𝐷𝐷𝐷 + 𝐵𝐵6𝑧𝑧 = 0
Force on Bearing 5 (y-direction)
Force on Bearing 5 (z-direction) 𝐵𝐵5𝑦𝑦 = 𝐹𝐹𝐷𝐷𝐷𝐷 − 𝐵𝐵6𝑦𝑦
𝐵𝐵5𝑧𝑧 = 𝐹𝐹𝐹𝐹𝐹𝐹 − 𝐹𝐹𝐷𝐷𝐷𝐷 + 𝐵𝐵6𝑧𝑧
= 560.6875 − 280.3438
= 1135.7 − 204.0736 + 669.8868
= 280.3438 𝑁𝑁
= 1601.5132 𝑁𝑁
Bending Moment
Bending Moment
𝑀𝑀𝐷𝐷𝐷𝐷 = (280.34 𝑁𝑁)(0.050 𝑚𝑚) = 14.017 𝑁𝑁𝑁𝑁
𝑀𝑀5𝑧𝑧 = (1135.7 𝑁𝑁)(0.050 𝑚𝑚) = 56.785 𝑁𝑁𝑁𝑁
𝑀𝑀𝐷𝐷𝐷𝐷 = 56.785 − (465.82)(0.050) = 33.4945 𝑁𝑁𝑁𝑁

Filling in shaft diameter equation

1⁄3
2
32𝑁𝑁 𝐾𝐾𝑓𝑓𝑓𝑓 𝑀𝑀 2 3 𝑇𝑇
𝐷𝐷 = � �� � + � � �
𝜋𝜋 𝑠𝑠′𝑛𝑛 4 𝑠𝑠𝑦𝑦

Shaft 1
Location Component Layout Kfb M (Nm) T (Nm) Min. Diameter (mm)
Left Bearing 1 - - - - -
Bearing 1 Bearing/ Press Fit 1 0 3.7381 5.33247
Right Bearing 1 Sharp fillet 2.5 0 3.7381 5.33247
Left Gear A Well-rounded fillet 1.5 1.6572 3.7381 9.03622
Gear A Gear/ Press Fit 1 1.6572 3.7381 7.96184
Right Gear A Retaining Ring 3 1.6572 3.7381 11.32401
Left Bearing 2 Sharp fillet 2.5 0 3.7381 5.33247
Bearing 2 Bearing/ Press Fit 1 0 3.7381 5.33247
Right Bearing 2 - - - - -

Shaft 2
Location Component Layout Kfb M (Nm) T (Nm) Min. Diameter (mm)
Left Gear B Retaining Ring 3 0 0 0
Gear B Gear/ Press Fit 1 0 8.971 7.13934
Right Gear B Well-rounded fillet 1.5 0 8.971 7.13934
Left Bearing 3 Well-rounded fillet 1.5 35.798 8.971 18.67045
Bearing 3 Bearing/ Press Fit 1 35.798 8.971 16.32074
Right Bearing 3 Sharp Fillet 2.5 35.798 8.971 22.12887
Left Gear C Well-rounded fillet 1.5 20.793 8.971 15.59375
Gear C Gear/ Press Fit 1 20.793 8.971 13.64841
Right Gear C Retaining Ring 3 20.793 8.971 19.62421
Left Bearing 4 Sharp Fillet 2.5 0 8.971 7.13934
Bearing 4 Bearing/ Press Fit 1 0 8.971 7.13934
Right Bearing 4 - - 0 8.971 -

Shaft 3
Location Component Layout Kfb M (Nm) T (Nm) Min. Diameter (mm)
Left Chain Sprocket A Retaining Ring 3 0 0 0
Chain Sprocket A Chain/ Press Fit 1 0 39.25 11.67682
Right Chain Sprocket A Well-rounded fillet 1.5 0 39.25 11.67682
Left Bearing 5 Well-rounded fillet 1.5 56.785 39.25 21.84873
Bearing 5 Bearing/ Press Fit 1 56.785 39.25 19.17818
Right Bearing 5 Sharp fillet 2.5 56.785 39.25 25.83975
Left Gear D Retaining Ring 3 36.309 39.25 23.67945
Gear D Gear/ Press Fit 1 36.309 39.25 16.71907
Right Gear D Well-rounded fillet 1.5 36.309 39.25 18.92714
Left Bearing 6 Sharp fillet 2.5 0 39.25 11.67682
Bearing 6 Bearing/ Press Fit 1 0 39.25 11.67682
Right Bearing 6 - - 0 - -

5.1 Shaft bearings

Bearing 1
R 1,z = 74.762N
R 1,y = 27.211N

F r,1 = √((R 1.z )2+(R 1,y )2)

= 79.56N

F a,1 =0N as no applied axial load

P d,1 = XVF r + YF a (There is no axial load and so no X or Y)

P d,1 =VF r (Assuming V=1 for rotating of inner race of bearing)
P d,1 = (1)(79.56N)
P d,1 =79.56N

From table 14-4 of the notes the Sugar cane will be used in an 8-hour service working day and will not always
be fully utilized therefore it will have a life of L 10,h = 15000 hours
η 1 =Input speed = 1405rpm
k=3 for ball bearings

C 1 =P d,1 (L d /106)1/k
C 1 =79.56((15000x1405x60)/106)1/3
C 1 =0.86kN

From table 14A, for C=0.86kN: Bearing no. 6000 is selected with C=4.75kN (greater than C 1 so can be used)

Bearing 2
R 2,z = R 1,z
R 2,y = R 1,y

Therefore, C 1 =C 2 as they have the same speed and so the same bearing will be used, no. 6000

Bearing 3
R 3,z = 268.21N
R 3,y = 736.900N

F r,3 = √((R 3.z )2+(R 3,y )2)

= 784.19N

F a,3 =0N as no applied axial load

P d,3 = XVF r + YF a (There is no axial load and so no X or Y)

P d,3 =VF r,3 (Assuming V=1 for rotating of inner race of bearing)
P d,3 = (1)(784.19N)
P d,3 =784.19N

L 10,h = 15000 hours

η 3 = η B = 585.42rpm
k=3 for ball bearings

C 3 =P d,3 (L d /106)1/k
C 3 =784.19((15000x585.42x60)/106)1/3
C 3 =6.3kN

From table 14A, for C=6.3kN: Bearing no. 6202 is selected with C=8.06kN (greater than C 3 so can be used)

Bearing 4
R 4,z = 118.5584N
R 4,y = 325.74N

F r,4 = √((R 4.z )2+(R 4,y )2)

= 346.64N

F a,4 =0N as no applied axial load

P d,4 = XVF r + YF a (There is no axial load and so no X or Y)

P d,4 =VF r,4 (Assuming V=1 for rotating of inner race of bearing)
P d,4 = (1)(346.64N)
P d,4 =346.64N

L 10,h = 15000 hours

η 4 = η B = 585.42rpm
k=3 for ball bearings

C 4 =P d,4 (L d /106)1/k
C 4 =346.64((15000x585.42x60)/106)1/3
C 4 =2.8kN

From table 14A, for C=2.8kN: Bearing no. 6000 is selected with C=4.75kN (greater than C 4 so can be used)

Bearing 5
R 5,z = 1601.51N
R 5,y = 280.34N

F r,5 = √((R 5.z )2+(R 5,y )2)

= 1625.87N

F a,5 =0N as no applied axial load

P d,5 = XVF r + YF a (There is no axial load and so no X or Y)

P d,5 =VF r,5 (Assuming V=1 for rotating of inner race of bearing)
P d,5 = (1)(1625.87N)
P d,5 =1625.87N

L 10,h = 15000 hours

η 5 = Output Speed= 133.81rpm

k=3 for ball bearings

C 5 =P d,5 (L d /106)1/k
C 5 =1625.87((15000x133.81x60)/106)1/3
C 5 =8.029kN

From table 14A, for C=8.029kN: Bearing no. 6202 is selected with C=8.06kN (greater than C 5 so can be used)

Bearing 6
R 6,z = 669.87N
R 6,y = 280.34N

F r,6 = √((R 6.z )2+(R 6,y )2)

= 726.18N

F a,6 =0N as no applied axial load

P d,6 = XVF r + YF a (There is no axial load and so no X or Y)

P d,6 =VF r,6 (Assuming V=1 for rotating of inner race of bearing)
P d,6 = (1)(726.18N)
P d,6 =726.18N

L 10,h = 15000 hours

η 6 = Output Speed= 133.81rpm

k=3 for ball bearings

C 6 =P d,6 (L d /106)1/k
C 6 =726.18((15000x133.81x60)/106)1/3
C 6 =3.6kN

Bearing no. 6000 is selected with C=4.75kN (greater than C 6 so can be used)
 Figure 1: Shaft 1’s dimension

Figure 2: Shaft 2’s dimension

Figure 3: Shaft 3’s dimension

6.0 Rollers
There are two rollers in the sugarcane machine to crush the sugarcane. Each roller consists of one large roller
(diameter = 100mm) and a small roller (diameter = 90mm)

6.1 Force needed to crush sugarcane

Assume tensile strength of sugarcane = 70MPa. Diameter of sugarcane ranges from 2.5 to 7.5 cm, hence
average diameter of sugarcane = (25 + 75)/2 = 50mm.
Assume that the distance between the small rollers is 20mm,
𝜀𝜀𝑠𝑠 = 50 − 20
= 30 mm
= 0.03 m
Assume sugarcane in contact of roller at 30° of roller circumference and diameter of small roller is 90mm,
Length of contact = (30°/360) (2π) (45×10-3)
= 0.02356 m
= 23.56 mm
Thickness of sugarcane changed from 50mm to 20mm after being compressed by small rollers. This means the
width of sugarcane increases. Assume the new width of sugarcane is 70mm.
New area = 70×23.56
= 1649.2 mm2
= 1.6492 × 10-3 m2
σ = E 𝜀𝜀𝑠𝑠
= (70×106) (0.03)
= 2100000 Pa
σ = F/A
2100000 = F / (1.6492 × 10-3)
F = 3463.32 N (force to crush sugarcane using small rollers)
After being crushed by small rollers, the sugarcane is being pushed into the large rollers. Assume that the
distance between the large rollers is 10mm,
𝜀𝜀𝑠𝑠 = 20 − 10
 = 10 mm
= 0.01 m
Assume sugarcane in contact of roller at 30° of roller circumference and diameter of large roller is 100mm,
Length of contact = (30°/360) (2π) (50×10-3)
= 0.02618 m
= 26.18 mm
Thickness of sugarcane changed from 20mm to 10mm after being compressed by large rollers. This means the
width of sugarcane increases. Assume the new width of sugarcane is 80mm.
New area = (0.02618) × 0.080
= 2.0944 × 10-3 m2
σ = E 𝜀𝜀𝑠𝑠
= (70×106) (0.01)
= 700000 Pa
σ = F/A
700000 = F / (2.0944 × 10-3)
F = 1466.08 N (force to crush sugarcane using large rollers)

6.2 Force Analysis of Roller 1

Roller 1 is the one connected to chain sprocket.

Figure 4: Diagram of roller 1

Figure 5: Free body diagram of roller 1

Assume the position of the forces of the rollers is acting at the center of the rollers.
For the z-x axis:

Figure 6: FBD, shear force diagram and

bending moment diagram of roller 1 in z-x
axis

Forces acting on roller 1:

Chain sprocket, F cs , T 1 = (F 1 – F 2 ) D 1 /2
9.25052 = (F 1 – 0) (0.06912)/2
F cs = F 1 = 1135.72 N
Force of large roller, F LR = T 2 / r LR
= 96.956 / 0.050
= 1939.12 N
(2F LR ˃ 1466.08 N, force needed to crush sugarcane)
Force of small roller, F SR = T 2 / r SR
= 96.956 / 0.045
= 2154.58N
(2F SR ˃ 3463.32 N, force needed to crush sugarcane)
Gear to transmit torque from roller 1 to roller 2, module = 2.0 mm, N = 55.
Diameter of gear, D = mN
= (2.0 ×10-3)(55)
= 0.11 m
W t1 = 2T 2 / D
= 2(96.956)/0.11
= 1762.84 N
W r1 = W t1 tan ɸ
= 1762.84 tan 20°
= 641.62 N
Taking moments about bearing 1,
ƩM 1 = 0,
F cs (40) + F LR (85) + F SR (235) = F 2z (320) + W r1 (360)
(1135.72)(40) + (1939.12)(85) + (2154.58)(235) = F 2z (320) + (641.62)(360)
F 2z = 1517.49 N
ƩF z = 0,
F CS + F 1z + F 2z + W r1 = F LR + F SR
1135.72 + F 1z + 1517.47 + 641.62 = 1939.12 + 2154.58
F 1z = 798.89 N

For the y-x axis:

Figure 7: FBD, shear force diagram and bending moment diagram of roller 1 in y-x axis
Forces acting on roller 1:
W t1 = 1762.84 N
Taking moments about bearing 1,
ƩM 1 = 0,
F 2y (320) = W t1 (360)
F 2y (320) = (1762.84)(360)
F 2y = 1983.20 N

ƩF y = 0,
F 1y + F 2y = W t1
F 1y + 1983.20 = 1762.84
F 1y = -220.36 (force acting downwards)
Resultant moments:
M cs = 0 Nm
M 1 = 45.43 Nm
M LR = 209.87 Nm
M SR = 209.19 Nm
M 2 = 75.05 Nm
M G1 = 0 Nm
 6.3 Shaft Design of Roller 1
For Roller 1 shaft:
Proposed layouts: well-rounded fillets at r 1 , r 2 , r 3 , r 4 , r 5 , r 6 , r 7 , r 8
Bearing mounting: press fit
Assume N = 3, reliability of 99% and use C s = 0.90 as initial value (assume diameter less than 20 mm).
Shaft is made of AISI 1137 cold drawn, polished. From notes, s y = 565 MPa, s u = 676 MPa. Using value of s u ,
from Figure 5-8 in the notes, s n = 350 MPa.
From Table 5-1, C R = 0.81.
s n ’ = (350)(0.90)(0.81)
= 255.15 MPa
Shown below is the calculation of the roller shaft diameter.
Location Component/layout Kfb M (Nm) T (Nm) Diameter (mm)
Left of chain sprocket retaining ring groove 3 0 0 0
Chain sprocket chain sprocket 1 0 96.956 16.56
right of chain sprocket well rounded 1.5 0 96.956 16.56
left of bearing 1 well rounded 1.5 45.43 96.956 21.12
bearing 1 press fit 1 45.43 96.956 19.25
right of bearing 1 well rounded 1.5 45.43 96.956 21.12
Left of big roller well rounded 1.5 205.81 96.956 33.51
Right of small roller well rounded 1.5 197.97 96.956 33.09
left of bearing 2 well rounded 1.5 30.36 96.956 19.26
bearing 2 press fit 1 30.36 96.956 18.01
right of bearing 2 well rounded 1.5 30.36 96.956 19.26
left of gear well rounded 1.5 0 96.956 16.56
gear press fit 1 0 96.956 16.56
right of gear retaining ring groove 3 0 0 0

Some parts of the shaft diameter is more than 20mm, hence need to iterate.
Assuming diameter is less than 37.5 mm. And new value of C s = 0.84 (from Figure 5-9 in notes). New value
of s n ’ = (350)(0.84)(0.81)
= 238.14 MPa
Shown below is the calculation of the new roller shaft diameter.
Location Component/layout Kfb M (Nm) T (Nm) Diameter (mm)
Left of chain sprocket retaining ring groove 3 0 0 0
Chain sprocket chain sprocket 1 0 96.956 16.56
right of chain sprocket well rounded 1.5 0 96.956 16.56
left of bearing 1 well rounded 1.5 45.43 96.956 21.44
bearing 1 press fit 1 45.43 96.956 19.48
right of bearing 1 well rounded 1.5 45.43 96.956 21.44
Left of big roller well rounded 1.5 205.81 96.956 34.16
Right of small roller well rounded 1.5 197.97 96.956 33.73
left of bearing 2 well rounded 1.5 30.36 96.956 19.49
bearing 2 press fit 1 30.36 96.956 18.15
right of bearing 2 well rounded 1.5 30.36 96.956 19.49
left of gear well rounded 1.5 0 96.956 16.56
gear gear 1 0 96.956 16.56
right of gear retaining ring groove 3 0 0 0
All parts of the roller shaft diameter met the requirement, hence above table is the minimum diameter of the
roller shaft 1.

6.4 Roller Bearing Forces

For roller 1:
R 1,z = 798.89N
R 1,y =-220.36N

F r,1 = √((R 1.z )2+(R 1,y )2)

= 828.72N

F a,1 =0N as no applied axial load

P d,1 = XVF r + YF a (There is no axial load and so no X or Y)

P d,1 =VF r (Assuming V=1 for rotating of inner race of bearing)
P d,1 = (1)(828.72N)
P d,1 =828.72N

From table 14-4 of the notes the Sugar cane will be used in an 8-hour service working day and will not always
be fully utilized therefore it will have a life of L 10,h = 15000 hours

η 1 =Speed of roller = 54.1rpm

k=3 for ball bearings

C 1 =P d,1 (L d /106)1/k
C 1 =828.72((15000x54.12x60)/106)1/3
C 1 =3.0kN

From table 14A, for C=3kN: Bearing no. 6000 is selected with C=4.75kN (greater than C 1 so can be used)

R 2,z =1517.49N
R 2,y =1983.20N

F r,2 = √((R 2.z )2+(R 2,y )2)

F r,2 =2494.32N

F a,2 =0N as no applied axial load

P d,2 = XVF r + YF a (There is no axial load and so no X or Y)

P d,2 =VF r (Assuming V=1 for rotating of inner race of bearing)
P d,2 = (1)(2494.32N)
P d,2 =2494.32N

η 2 =Speed of roller = 54.1rpm

k=3 for ball bearings

C 2 =P d,2 (L d /106)1/k
C 2 =2494.32((15000x54.12x60)/106)1/3
C 2 =9.11kN

From table 14A, for C=9.11kN: Bearing no. 6004 is selected with C=9.95kN (greater than C 2 so can be used)
7.0 Assembly Drawings
Appendix A
Below is the figure showing the dimensions of the motor selected (the row which arrow is pointed to).

Appendix B
Force analysis of roller 2
 Figure 8: Diagram of roller 2

Figure 9: Free body diagram of roller 2

Assume the position of the forces of the rollers is acting at the center of the rollers.

Figure 11: FBD, shear force diagram and

bending moment diagram of roller 2 in
y-x axis

Figure 10: FBD, shear force diagram and

bending moment diagram of roller 2 in z-x
axis
For the z-x axis:
Forces acting on roller 2:
Force of large roller, F LR = 1939.12 N
Force of small roller, F SR = 2154.58 N
Gear to receives torque from roller 1 to roller 2, module = 2.0 mm, N = 55.
Diameter of gear, D = mN = (2.0 ×10-3)(55)
= 0.11 m
W t2 = 2T 2 / D = 2(96.956)/0.11
= 1762.84 N
W r2 = W t2 tan ɸ = 1762.84 tan 20°
= 641.62 N
Taking moments about bearing 4,
ƩM 4 = 0,
F LR (85) + F SR (235) = F 3z (320) + W r2 (360)
(1939.12)(85) + (2154.58)(235) = F 3z (320) + (641.62)(360)
F 3z = 1375.53 N
ƩF z = 0,
F 4z + F 3z + W r2 = F LR + F SR
F 4z + 1375.53 + 641.62 = 1939.12 + 2154.58
F 4z = 2076.55 N
For the y-x axis:
Forces acting on roller 2: W t2 = 1762.84 N
Taking moments about bearing 4,
 ƩM 4 = 0,
F 3y (320) = W t2 (360)
F 3y (320) = (1762.84)(360)
F 3y = 1983.20 N
ƩF y = 0,
F 4y + F 3y = W t2
F 4y + 1983.20 = 1762.84
F 4y = -220.36 (force acting upwards)
Resultant moments:
M 4 = 0 Nm
M LR = 176.51 Nm
M SR = 197.12 Nm
M 3 = 74.86 Nm
M G2 = 0 Nm

Shaft Design of Roller 2

For Roller 2 shaft: Proposed layouts: well-rounded fillets at r 1 , r 2 , r 3 , r 4 , r 5 , r 6 , r 7 .
Bearing mounting: press fit
Using the same method of calculating the roller 1 shaft diameter shown in section 6.3, below is the table of roller 2
shaft diameter values.
Location Component/layout Kfb M (Nm) T (Nm) Diameter (mm)
left of bearing 4 well rounded 1.5 0 0 0
bearing 4 press fit 1 0 96.956 16.56
right of bearing 4 well rounded 1.5 0 96.956 16.56
Left of big roller well rounded 1.5 176.51 96.956 31.87
Right of small roller well rounded 1.5 197.12 96.956 28.96
left of bearing 3 well rounded 1.5 74.86 96.956 24.29
bearing 3 press fit 1 74.86 96.956 24.29
right of bearing 3 well rounded 1.5 74.86 96.956 24.29
left of gear well rounded 1.5 0 96.956 16.56
gear press fit 1 0 96.956 16.56
right of gear retaining ring groove 3 0 0 0
Some parts of the shaft diameter is more than 20mm, hence need to iterate. Using the same method shown in section
6.3 for iteration, below is the table of new value of roller shaft 2 diameter.
Location Component/layout Kfb M (Nm) T (Nm) Diameter (mm)
left of bearing 4 well rounded 1.5 0 0 0
bearing 4 press fit 1 0 96.956 16.56
right of bearing 4 well rounded 1.5 0 96.956 16.56
Left of big roller well rounded 1.5 176.51 96.956 32.48
Right of small roller well rounded 1.5 197.12 96.956 33.68
left of bearing 3 well rounded 1.5 74.86 96.956 24.72
bearing 3 press fit 1 74.86 96.956 21.98
right of bearing 3 well rounded 1.5 74.86 96.956 24.72
left of gear well rounded 1.5 0 96.956 16.56
gear gear 1 0 96.956 16.56
right of gear retaining ring groove 3 0 0 0

All parts of the roller shaft diameter met the requirement, hence above table is the minimum diameter of the roller
shaft 2.

Roller Bearing Forces for Roller 2:

R 4,z = 2076.55N, R 4,y =-220.36N
F r,4 = √((R 4.z )2+(R 4,y )2), F r,4 = 2088.21N
F a,4 =0N as no applied axial load
P d,4 = XVF r + YF a (There is no axial load and so no X or Y)
P d,4 =VF r (Assuming V=1 for rotating of inner race of bearing)
P d,4 = (1)(2088.21N) =2088.21N

From table 14-4 of the notes the Sugar cane will be used in an 8-hour service working day and will not always be
fully utilized therefore it will have a life of L 10,h = 15000 hours
η 4 =Speed of roller = 54.1rpm
k=3 for ball bearings

C 4 =P d,4 (L d /106)1/k
C 4 =2088.21((15000x54.12x60)/106)1/3
C 4 =7.6kN

From table 14A, for C=7.6kN: Bearing no. 6202 is selected with C=8.06kN (> than C 4 so can be used)
R 3,z =1375.53N, R 3,y =1983.20N
F r,3 = √((R 2.z )2+(R 2,y )2), F r,3 =2413.54N
F a,3 =0N as no applied axial load
P d,3 = XVF r + YF a (There is no axial load and so no X or Y)
P d,3 =VF r (Assuming V=1 for rotating of inner race of bearing)
P d,3 = (1)(2413.54N) =2413.54N

η 3 =Speed of roller = 54.1rpm

k=3 for ball bearings

C 3 =P d,3 (L d /106)1/k
C 3 =2413.54((15000x54.12x60)/106)1/3
C 3 =8.81kN

From table 14A, for C=8.81kN: Bearing no. 6004 is selected with C=9.95kN (greater than C 3 so can be used)
Therefore, Bearing no. 6004 is used for the rollers as it can be used for all as it has the highest value of C.