1

Part 01: CALCULATION OF WORKING SHAFT POWER AND SPEED

I. Calculation of load screws
1. Overview
2. For input parameters
3. Nature:
- Load screw productivity according to the formula:
2
πD
Q=60 S . n. ρ . . c
4

Where:
S: step screw, S = K. D.
D(m): loading screw diameter.
K: The coefficient depends on the screw step and the screw, under normal conditions take K = 1
n(v/ph): Number of screw revolutions, from CT 12.1 we have:
4Q
n= 3
60 π . D . ρ . . c

ρ: Density of material, according to table 2.1

ψ: Fill coefficient, look up table 2.2
c: The coefficient depends on the angle of inclination (λ) of the load screw, according to table 2.3

Table 2.1: Density () of some bulk materials commonly used for loading screws
STT Material Density (-ton/)m3 Notes
1 Cement 0.96 1.6÷
2 Sand 1.9÷2.05
3 Smooth stone 1.5 1.8÷
4 Gypsum 1.25÷1.5
5 Slag ash 0.9÷1
6 Salt 1.12÷ 1.28
Since the material is sand, we choose density  = 1.98

Table 2.2: Fill factor

2
 STT Type of material ψ Notes
1 Heavy, abrasive materials 0,125 Sand, stones
2 Heavy materials, little grinding 0,25 Salt, cement, fertilizer, ...
3 Lightweight, low-wear materials 0,32 Flour, sleeping cups, ...
4 Lightweight, non-abrasive 0,40 Ash, slag
material
We choose the fill factor  = 0.125
Table 2.3: Coefficient depends on loading screw tilt angle c

Load screw tilt angle,  0 5 10 15 20

(degrees)
𝑐 1 0,9 0,8 0,7 0,65
We choose a coefficient that depends on the angle of inclination of the loading screw c = 0.8
From this we calculate the number of screw revolutions:
4 × 45
n= 3
=147 ,18(vòng / phút)
60 × π × 0.32 × 1×1.98 × 0.125 ×0.8

- The power of the load screw according to the formula:

Q QL
P= ( L.+ H ) = (+ sin)
367 367

Table 2.4: Dynamic resistance coefficient of materials

Transport materials ω
Dry, non-abrasive (powder, sleeping cup, fly ash, coal dust ...) 1,2
Moist, non-abrasive (moist malt, cottonse) 1,5
Semi-abrasive (bucket, lump coal, table salt) 2,5
Abrasives (crushed stone, sand, cement) 3,2
Strong and sticky abrasives (ash, mold soil, quicklime, sulfur) 4,0
We choose the coefficient of motion resistance of the material  = 3.2
From there, we calculate the capacity of the load screw:
45 × 10
P= ׿
367

- Output parameters
1. Power on load screw: P=4.14(kW)
3
 2. Number of revolutions on the screw: n = 147.18 (rpm)
Part 02: SELECTION OF GEAR RATIO DISTRIBUTION MOTOR
1. Choosing an electric motor
- With the working shaft power and speed specified in part 1, namely:
Pt = 4.14 (kW) and n = 147.18 (rpm).
- Drive performance of the system:
h = ηnt × ηol3 × ηbr × ηd =1×0.993×0.98×0.96 = 0.91
Where: ηnt – axial connection performance;
ηol – performance of 1 pair of roller bearings;
ηbr – efficiency of 1 pair of gears;
ηx – Belt set performance
- Power required on the motor shaft:
Pct = Plv/ h = 4.14/0.91 = 4.55 (kW)
- Select preliminary TST: look up table 2.4 page 21 [1] Mechanical drive.
u sb=ud ×u h=¿3÷ 5) ׿ 3÷ 5) = ¿9÷ 25)

Where: ud – belt gear ratio;

uh – gear ratio of the box

- Engine preliminary revolutions:

n sb =nct ×usb =147 ,18 ×(9 ÷ 25)=(1324 , 62÷ 3679 , 5)(vòng / phút )

Select the number of synchronous revolutions of the motor NDB = 1500 (rpm)
- Choosing an electric motor must satisfy the following conditions:
{ = Pđc ≥ Pct 4.55 (kW) ; (rpm) }n sb ≈ n đb=1500
- Select the engine according to the document [1], look up table P1.3 page 236 Mechanical drive.
Choose a motor M2QA132S4A have: nđc = 1425 (rpm) and Pđc = 5.5 (kW)
Engine parameter sheet:

Engine type Power, kW Rotational Shaft diameter, Mass Overload

speed, v/ph Mm Kg factor
Tk/Tdn

4
 M2QA132S4A 5,5 1425 38 60 2,3
2. Gear ratio distribution
- General TST of the system ut according to formula (3.23) page 48[1]:
nđc 1425
ut = = =9 , 68
nlv 147 , 18

- Select the TST of the gearbox according to table 2.4 page 21 [1] and the standard gear ratio
range:
Ubr = 4.0
- Gear ratio of external transmission:
u t 9 , 68
ud = ≡ =2 , 42
ubr 4

- Check the allowable gear ratio error:

|ut −u| |9 , 68 - ( 4 x 2,42 )|

∆ u = = = 0% < 4% (eligible)
ut 9 ,68

Calculation of parameters on the axis

- Calculation of power on the axes:
Axis 2:
Plv 4 ,14
P 2= = =4 , 18( kW )
ηol ×η nt 0.99 ×1

Axis 1:
P2 4 , 18
P 1= = =4 ,31(kW )
ηol ×η br 0.99 × 0.98

P1 4 ,31
Motor shaft: Pđc = = =4 , 53(kW )
ηol × ηđ 0.99× 0 , 96

- Calculate the number of revolutions on the axes:

Axis 1:
n đc 1425
n1 = = =588 , 84(vòng / phút)
u d 2 , 42

5
 Axis 2:
n 1 588 , 84
n2 = = =147 ,2(vòng / phút)
u br 4

Working shaft:
nlv =n 2=147 , 2(vòng / phút )

- Momem twisted on the shaft:

Axis 2:
6 P2 6 4 , 18
T 2=9 , 55.10 × =9 ,55.10 × =271189 (N . mm)
n2 147 , 2

Axis 1:
6 P1 6 4 ,31
T 1=9 , 55.10 × =9 ,55.10 × =69901(N . mm)
n1 588 , 84

Motor shaft:
6 Pđc 6 4 , 53
T đc =9 ,55.10 × =9 , 55.10 × =30359(N . mm)
nđc 1425

Working shaft:
6 Plv 6 4 ,14
T ct =9 , 55.10 × =9 , 55.10 × =268593 ( N .mm)
nlv 147 ,2

3. Parameter sheet
Axle Axis of work
Engine Axis 1 Axis 2
Parameter (working shaft)
Power P, kW Pđc =4 ,53 P1=4 , 31 P2=4 , 18 Plv =4 ,14

Gear ratio ud =2 , 42 ubr =4 ,0 ukn =1 , 0

Revolutions n, vg/ph n đc=1425 n1=588 ,84 n2 =147 ,2 nlv =147 , 2

Torque T, N.mm T đc =30359 T 1=69901 T 2=271189 T ct =268592

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 Part 03: CALCULATION OF BELT TRANSMISSION
1. Input parameters
- Power on the conductive shaft: P1=4 , 53(kW )

- Rotational speed on the conductive shaft:= (rpm), n1 1425

- TST for belt transmission: udd = 2.42
2. Choosing a belt type and belt cross section
- With and = (rpm), P1=4 , 53(kW )n1 1425
We choose belt A (normal belt) with t = 15; h0= 1.3; e = 10
3. Choose a diameter of 2 belt wheels
- Based on table 4.13 we choose the standard small belt diameter =120 (mm)d 1
- Belt velocity:
π × d 1 × n1 π ×120 × 1425
v= =
6 ×10
4 = 60000
8.95(m/s) < 25(m/s)

- The large belt wheel diameter is:

Since this is a ladder range, choose = 0.02ξ
d 2=2 , 42 × d 1(1-)= 2.42 x 120 x (1 - 0.02)= 284.592 (mm)ξ

Based on table 4.21 select the standard diameter:

select = 280 (mm)d 2
- Recalculate TST:
d2 280
u'
d 1 (1−ξ )
= 120(1−0 ,02)
= = 2.38

Inferred :
2 , 42−2, 38
∆ ud = 100% =¿ u−u' ∨ ¿ × × 100 %=1 ,65 % < 4 % ¿
u 2 , 42

7
4. Axis spacing
- According to table 4.14 preliminary selection of axis spacing a:
select A = = 280 mmd 2
- Ladder length:
2
(d ¿ ¿ 1+d 2) (d 2−d 1 )
= 2a + + Lmin π ¿
2 4 ×a
2
π (280+120) (280−120)
=2280++=1211.18(mm)×
2 4 ×280
select L=1220(mm)
- Check the number of laps in 1s:
v 8 ,95
i = = = 7,34 (/s) < 10 (/s) => thỏa
L 1 ,22

5. Accurate calculation of axis spacing:

- With standard length L = 1220 (mm)
a = 2 L−π (d ¿ ¿ 1+d 2 )+ √ ¿¿ ¿ ¿
= 2 ×1220−π (120+280)+ √ ¿¿ ¿
= 477.64 (mm)
- Hugging angle and condition of α 1 α 1: >120(degree)α 1
(d 2−d 1) - 570 160.91 (280−120) 120
α 1 = 1800 – 570 = 180 0 0> 0
a 477 , 64

6. Calculate the number of belts:

- The belt number is determined by the formula:
P1 × K đ
z=
[ P0 ]×C α ×C L ×C u ×C z

Power on the shaft: = 4.53 (kW) P1

Permissible power = 1.77 (kW) P0

Value of dynamic load factor Kd : According to table (4.7)

Kđ = 1.1+0.1 = 1.2 (working 2 shifts)
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 Coefficient of influence of belt hugging angle with = 160.91α 10 : According to table (4.15)
C α = 0.95

Influence factor of belt length with L/L0 = 1: According to table (4.16)

CL=1
Influence factor of gear ratio with u = 2.38: According to table (4.17)
Cu = 1.135
Influence system of uneven distribution of load for belts: According to table (4.18)
With /= 4.53/1.77 = 2.56 hence C P1 [ P0 ]z = 0.95
Z-belt number:
4 ,53 ×1 , 2
z =
1, 77 × 0 ,95 × 1,135× 1× 0 , 95
= 2.98
Choose z = 3
7. Belt wheel width
- Based on table 4.21[1], belt B we choose =1.3 ,t=15, e=10h 0
Bracket width: B=(z-1)t+2e=(3-1)15+210=50(mm)××
8. Outer diameter of belt wheel:
- Small belt wheel outer diameter:
d a 1=+2 =120+21.3=122.6 (mm)d 1 h0 ×

- Large belt wheel outer diameter:

d a 2=+2 =280+21,3 =282,6 (mm)d 2 h0 ×

9. Determine the initial tension and the force acting on the shaft:
- The tension on 1 belt is determined by the formula:
780× P1 × K đ
F 0= + Fv
v × Cα × z

Tr That bee:

The tension is generated by the centrifugal force, where = 0.105 (kg/m) because of belt cross
section B:q m
F v ==0,105 = 8,41 (N)q m × v 2 ×8 , 952

Suy ra
9
 780× 4 ,53 ×1 , 2
F 0= + 8.41 = 174.64 (N) 175 (N) ≈
8 , 95× 0 , 95 ×3

- Force applied to the axis:

α1 160 , 91
F r=2sin() = 2sin() = 1035(N)× F 0 × z × ×175 × 3×
2 2

10. Summary of belt transmission parameters:

Parameter Symbols Value

Belt type A 81

Small belt wheel diameter D1(mm) 120

Large belt wheel line D2 (mm) 280

Actual gear ratio u 2,42

Belt wheel width Bđ(mm) 50

Belt number z 3

Axis spacing A (mm) 477,64

Belt length L(mm) 1220

Force applied to the shaft F0(N) 175

Ring force acting on the belt wheel Fr(N) 1035

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 Part 04: STRAIGHT PILLAR GEAR TRANSMISSION

Axle Axis of work

Engine Axis 1 Axis 2
Parameter (working shaft)
Power P, kW Pct =4 , 53 P1=4 , 31 P2=4 , 18 Plv =4 ,14

Gear ratio ud =2 , 42 ubr =4 ,0 ukn =1,0

Revolutions n, vg/ph n đc=1425 n1=588 ,84 n2 =147 ,2 nlv =147 , 2

Torque T, N.mm T đc =30359 T 1=69901 T 2=271189 T ct =268592

1. Input parameters
- Power on led gear shaft: P1=P1=4 , 31(Kw)
- Gear shaft rotation speed:n1=n1=588 , 84 (vg/min)
- Transmission ratio: u=ubr = 4
- Torque on the led gear shaft: T 1=T 1 =69901( N . mm)
- Working time Lh: 5 years (300 days/year, 2 shifts/day, 6 hours/shift)
2. Choosing gear material:
According to table 6.1[1]select:

Heat Durable limits Flow limits Hardness

Material
treatment σ b(MPa) σ ch (MPa) HB

BR led Steel C45 I improve 850 580 241... 285

BR is led Steel C45 I improve 750 450 192... 240

3. Determination of permissible stress

- According to table 6.2 with C45 steel, I improved to reach solid HB 180...350;
o
σ Hlim = 2HB + 70 (MPa) SH = 1.1
o
σ Flim = 1.8HB (MPa) SF = 1.75

- Select led gear stiffness: HB1=250HB

- Select conductive gear stiffness: HB2=195HB
We have :

11
 o
σ Hlim1 = 2250 + 70 = 570 (MPa)×
o
σ Flim 1 = 1.8250 = 450 (MPa)×
o
σ Hlim2 = 2195 + 70 = 460 (MPa)×
o
σ Flim 2 = 1.8195 = 351 (MPa)×

H 2HB, 4
Theo (6.5) GRAPES = 30 therefore:
NH01 = 30250×2.4 = 1.71.107
NH02 = 30195×2.4 = 0.94.107
Total gear working hours: = t Σ 623005 = 18000 hours×× ×
- According to 6.6[1], since the payload transmitter remains constant:
N HE 1 = = 60cn = 60118000 = 63.6 N FE 1 t Σ ×× 588 ,84 ××107

N HE 1 > N HO 1 do đó K HL1=1

Inferred N HE 2 > N HO 2 do đó K HL2=1

Thus according to (6.1a) preliminarily determined:

[ = /σ H ¿ σ oHlim × K HL SH
1
[ = 570 = 518.18 (MPa)σ H 1 ¿ ×
1,1
1
[ = 460 x = 418.18 (MPa)σ H 2 ¿
1 ,1

 Select [ = 418.18 (MPa)σ H ¿

According to 6.6[1], since the payload transmitter remains constant:
N HE 1 = = 60cn = 60118000 = 63.6 N FE 1 t Σ ×× 588 ,84 ××107

N FE 1 > N FO=4.106 do đó K FL1 =1

Inferred N FE 2 > N FO do đó K FL1=1

Theo (6.2a), since the transmitter rotates 1 way thus K FC =1

[ = / SFσ F ¿ σ oFlim × K FC × K FL
1
[ = 450 = 257.14 (MPa)σ F 1 ¿ ×
1 ,75
1
[ = 351 = 200.57 (MPa)σ F 2 ¿ ×
1 ,75
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Permissible overload stresses are calculated using formulas (6.13) and (6.14):
[ σ H 1 ]max=2, 8 σ ch 1=2 , 8× 580=1624 ( MPa )
[σ H 2 ] max=¿ 2.8 2.8450 1260 (MPa)σ ch2=×=¿

[σ F 1 ]max 0.6 0.6580 348(MPa)¿ σ ch1=×=¿

[σ F 2 ]max 0.6 0.6450 270 (MPa)¿ σ ch2=×=¿

4. Preliminary determination of axis spacing

a w =K a × ( u+1 )
√
3 T 1 K Hβ
2
[σ ¿¿ H ] uψ ba √
¿ = 49 ,5 × ( 4+1 ) 3
69901× 1 ,06
418 ,18 2 × 4 × 0 , 4
=158.9(mm)

Select a w =160 (mm)

Where:
Ka = £ 49.5 6.5 [1] p. 96 types of straight teeth
u : gear ratio of the transmitter being calculated, u = 4
T 1=69901 ¿N.mm)

According to table 6.6 ([1] p. 97) select Ψ ba=0 , 4

According to formula 6.16 ([1] p. 97:
Ψ bd =0 , 53Ψ ba ( u+1 ) =0 , 53× 0 , 4 × ( 4+ 1 )=1 , 06

Look up table 6.7 ([1] p. 98): K Hβ=1 , 06

5. Determination of matching parameters
According to formula 6.17 ([1] p. 97):
m=( 0 ,01 ÷ 0 , 02 ) × aw =( 0 , 01÷ 0 , 02 ) ×160=(1 , 60÷ 3 , 00)

According to table 6.8[1] select module m = 1.6 mm

6. Determination of the number of teeth and angle of inclination
- Straight gear, β=0 a=¿20o
- Number of teeth Z1 according to the formula (6.19)[1]
2 aw 2 ×160
z 1= = = 40 teeth
m(u+1) 1 ,6 ×(4+1)

Choose z 1=38 răng

z2 = u ×z1 = 4 3 8 = 1 5 2 t e e t h ×

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 Choose z 2=150 răng
z t =z1 + z 2=38+150=188 tooth

- Recalculate axis spacing by formula (6.21)

m× z t 1 , 6 ×188
a w =¿ = 150 =
2 2

z2 150
- Actual gear ratio: ut = =
z1 38
= 3.95

|ut −u| |3 , 95−4|

- Gear ratio error: 100% 100% = 1.25% <4% Δu= ×= ×
u 4
(Eligible)
7. Determine the angle of fit:
- Góc ăn khớp :
(z ¿ ¿ 1× z 2)×m ×cos 20 °
cos atw =¿ ¿
aw ×2

Suy ra : atw =¿ 20o

8. Formulated Contact Strength Test (6.33)σ H

According to formula 6.33 ([1] p. 105) contact stresses appear on the face surface of the transmitter:

σ H =Z M Z H Z ε
√ 2 T 1 K H ( u+1 )
b w u d2w1

Where:
- According to table 6.5 ([1] p. 96): Z M =274 Mpa

- Look up table 6.12 ([1] p. 106): ZH √

2 ×1
= = sin ( 2 ×20 ) = 1.76

- Rim width: b w =Ψ ba . aw =150 × 0 , 4=60 (mm)

- Z ε : Hệ số kể đến sự trùng khớprăng
- According to 6.38b ([1] p. 105)

[
ε α = 1 , 88−3 , 2.
( Z1 + Z1 )] ×cos β=[ 1 ,88−3 , 2× ( 381 + 1501 )]× cos ( 0 )=1 ,77
1 2

14
 Z ε=
√ 1
εα
= 0.75

- K H Load factor when calculating exposure using formula 6.39 ([1] p. 106)
KH = KHβ.KH.Kα Hυ
Where:
KHβ : The coefficient refers to the uneven distribution of the load across the width of the
tooth rim.
Choose KHβ = 1.06
KHα : The coefficient refers to the uneven distribution of the load of the teeth at the same
time
of gears. Select KHα = 1.09
- Small wheel ring diameter, recipe 5.16 page 117 [3]
2 aw 2× 150
d w 1= = =60
u+1 4 +1
- Gear rev velocity, formula 6.40[1]
π . d w1 n1 3 , 14 × 60 ×588 , 84
v= = = 1.87 (m/s)
60000 60000
- For straight gears look up table 6.14/page 107 KHα =1.009.
- According to formula 6.14/page 107.
v H ×b w × d w1
K Hv =1+
2 ×T 1 × K Hβ × K Hα

v H =δ H . g0 . v .
√ aw
u √
= (m/s)0,006 ×56 × 1 ,87 × 150 =3 , 86
4

δH = 0.006 : The constant refers to the effect of matching errors in table 6.15/page 107.
= 56 : The constant refers to the effect of gear step deviations 1 and 2 on table 6.16/107. g0
3 , 86 ×60 ×60
K Hv =1+ =1 , 08
2 ×69901 ×1 , 06 ×1 , 09

Inferred: KH = KHβ.KHα.KHv = 1,061,091.08 = 1,25××

Inferred: σ H =Z M Z H Z ε
√ 2 T 1 K H ( u+1 )
bw u d 2
w1
=274 × 1 ,76 × 0 ,75 ×
√ 2 ×69901 ×1 , 25×(4+1)
60 × 4 × 602

15
 = 360,52 (MPa)
9. Recalculate the permissible contact stress [ σ H ]
According to section 6.2 when calculating the values ; and z v z R K xH
[ σ H ]=[ σ H ] Z v Z R K xH =418 , 18 ×1 ×0 , 95 ×1=397 , 27 ¿)
Where
ZV coefficient refers to the effect of rev velocity. For v = (m/s) < 5 (m/s):1 , 85
Z v =¿ 1
Z R = 0.95 (with a kinematic accuracy level of 8, select the correct level of contact level of 7, then it
is necessary to process to roughness) Ra =2 ,5 ÷ 1 ,25 μm
K xH = 1 ()d a <700 mm

Thus, the condition of contact durability is satisfiedσ H =360 , 52 MPa<397 , 27 MPa= [ σ H ]

[σ ¿¿ H ]−σ H
¿
397 , 27−360 , 52
[σ ¿¿ H ].100 %= . 100 %=9 , 25 %< 10 %( thỏa)¿
397 ,27
10. Dental test for flexural strength
According to formulas 6.43, 6.44 ([1] p. 108):
2 T 1 K F Y ε Y β Y F 1 2× 69901× 1 , 41× 0 , 56× 1× 3 , 92
σ F1= = =74 , 38 MPa
bw . dw 1 . m 60× 60 ×1 , 6
σ F 1 . Y F 2 74 ,38 ×3 , 63
σ F2= = =68 , 88 MPa
Y F1 3 , 92

Where:
- T1 = 69901 Nmm
- According to table 6.7 ([1] p. 98): ; K Fβ=1 , 14
- According to formula 6.47 ([1] p. 109):

v F =δ F . g0 . v .
√ aw
u
=0,016 × 56× 1 ,87 ×
√150
4
=10 , 3 m/s

Where:
+ (Table 6.15[1] p. 107) δ F =0,016
+ (table 6.16[1] p. 107) g0=56
- According to formula 6.46 ([1] p. 109):
16
 v F .b w . d w 1 10 ,3 × 60× 60
K Fv =1+ =1+ =1 ,24
2 T 1 K Fβ K Fα 2× 69901 ×1 ,14 ×1
K F=K Fβ . K Fα . K Fv=1, 14 × 1×1 , 24=1 , 41

1 1
- With ε α =1 ,78 , Y ε = ε = 1, 78 =0 , 56
α

- With straight teeth β=0 , Y β=1

- Equivalent number of teeth.
Z1 38
Z v 1= 3
= 3
=38
cos β (cos 0 °)
Z2 150
Z v 2= 3
= 3
=150
cos β (cos 0 °)

- According to table 6.18 ([1] p. 109): Y F 1=3 , 92; Y F 2=3 , 63

11. Recalculation of bending stress allows:
According to (6.2) and (6.2a):
[ σ F 1 ] =[ σ F 1 ] . Y R .Y S . K xF =257 , 14 ×1 ×1 , 06 ×1=269 ,31 MPa
[ σ F 2 ]=[ σ F 2 ] .Y R .Y S . K xF =200 , 57 ×1 ×1 , 06 ×1=210 , 06 Mpa
Where
da < 400 (mm) nên KxF = 1
Ys = 1.08 – 0.0695ln(m) = 1.08 – 0.0695ln(1.6) = 1.06××
YR: Coefficient affecting the amount of root roughness, normally YR = 1
By:
σ F 1 =74 , 38 MPa < [ σ F 1 ]=269 , 31 MPa

σ F 2 =68 , 88 MPa < [ σ F 2 ]=210 , 06 MPa

 So satisfying the condition of bending strength.

12. Dental testing of the loading process
- According to the formulas (6.48) and (6.49) Kqt = 1
σ Hmax = = 360.521 = 360.52 MPa < σ H × √ Kqt × [ σ H ]max (Meets durable conditions)

σ F 1 max = Kσ F 1 ×qt = 74.38 = 74.38 MPa < ×1 [ σ F 1 ] max (Meets durable conditions)

σ F 2 max = Kσ F 2 ×qt = 68.88 = 68.88 MPa < ×1 [ σ F 2 ] max (Meets durable conditions)

17
13. Other parameters of gears
- Dividing ring diameter:
m. z 1 1 , 6 x 38
d w 1=¿ d1===60(mm)
cos β cos 0°
m. z 2 1 , 6 ×150
d w 2=¿ d2===240(mm)
cos β cos 0°

- Diameter of the top of the tooth:

DA1=D1+2M=60+21.6=64(mm)×
DA2=D2+2M=240+21.6=243.2(mm)×
- Bottom diameter:
DF1 = D1 – 2.5m = 60 - 2.51.6 = 56 (mm)×
DF2 = D2 – 2.5m = 240 - 2.51.6 = 236 (mm)×
- Force applied to the axis:
2T 2.69901
Ring force: F t= d = =2299 ,38 ( N )
w1 60

Ft 1 . tanαt 2299 ,38 . tan20 °

Centripetal Force: F r= = =836 ,9 (N )
cos β cos 0 °

Axial force: F a 1=Ft 1 . tanβ=2299 ,38 . tan 0 °=0( N )

18
14. Summary of gear transmission parameters

Parameter Symbols Value Unit

Axis spacing Aw 150 (mm)

Module/module mn or m 1,6 (mm)

Gear ratio Ut 4

Tooth rim width bw 60 (mm)

Tilt angle (BTRT none) β 0 (degrees)

Matching angle α tw 20 (degrees)

Number of led gear teeth Z1 38 (teeth)

Number of gear teeth led Z2 150 (teeth)

Guide wheel roller ring diameter dw1 60 (mm)

Led wheel ring diameter DW2 240 (mm)

Gear top ring diameter DA1 64 (mm)

The diameter of the wheel top ring is led DA2 243,2 (mm)

Conductor bottom ring diameter df1 56 (mm)

The diameter of the bottom ring is led DF2 236 (mm)

Contact stress on the tooth surface 𝜎𝐻 360,52 (MPa)

Matching force

Ring force Ft 2299,38 (N)

Centripetal force Fr 836,9 (N)

Axial force (BTRT absent) Ago 0 (N)

19
 Part 05: SHAFT COUPLING
1. Input parameters
- Shaft Torque 1 T 1=69001(N . mm)
- Shaft Torque 2 T 2=271189 (N .mm)
2. Choosing an elastic shaft coupling
Select coupling size

Based on the following calculated torque:

T =k ×T ≤[T ]
Where:
- Working safety factor k: look at table 9.1[8] k =1 ,5 ÷ 2
Choose k = 1.5
- Nominal torque T =T 2=271189 ( N . mm )=271,189 ( N .m)

T t=1 , 5 ×271,189=406,797 (N . m)

Looking at table 9.10a[8] we have the basic parameters of elastic ring shaft connections:

Table 5.1 Basic parameters of axial coupling

Wit
d D dm L l d1 D0 nmax B B1 l1 D3 l2
h

45 170 95 80 130 8 3600 5 70

Table 5.1 and 5.2 Basic parameters of elastic ring shaft connection

Looking up Table 9.10[b] we have the basic parameters of elastic ring shaft connections:

Table 5.2 Basic parameters of shaft coupling

dc dl D2 l l1 l2 l3 h

14 M10 20 62 34 15 28 1.5

Stamping strength conditions of elastic rings:

2 kT 2× 1 ,5 ×271189
σ d= = =2 ≤ [ σ d ] =3(MPa)
Z D0 d c l 3 8 ×130 ×14 × 28

20
 With is the rubber ring stamping stress[ σ d ] =2 ÷ 4 ( MPa )

Fastener strength conditions:

kT l 0 1 ,5 ×271189 ×41 , 5
σ u= 3
= 3
=59 , 16 ≤ [ σ u ]=70(MPa)
0 ,1. d . D 0 . Z
c 0.1× 14 ×130 ×8

l 15
With l 0=l 1 + 2 =34 + =41 ,5 ( mm ) và [ σ u ]=60 ÷ 80(MPa)
2 2

3.Analysis of the applied force of the coupling:

- Coupling ring force:
2 T t 2× 271189
F tkn= = =4172 ,28 ( N)
D 130
- The force due to axial connection exists heterogeneously:
F rnt =( 0 , 1÷ 0 , 3 ) × F t=0 ,2 × 4172 ,28=835 ( N )

21
 Part 06: CALCULATION OF SHAFT DESIGN

Axle Axis of work

Engine Axis 1 Axis 2
Parameter (working shaft)
Power P, kW Pct =4 , 53 P1=4 , 31 P2=4 , 18 Plv =4 ,14

Gear ratio ud =2 , 42 ubr =4 ,0 ukn =1,0

Revolutions n, vg/ph n đc=1425 n1=588 ,84 n2 =147 ,2 nlv =147 , 2

Torque T, N.mm T đc =30359 T 1=69901 T 2=271189 T ct =268592

1. Choosing the material for making the shaft:

Table 6.1/page 92
Material Heat treatment Hardness
Durable limits Flow limits
σ b ( MPa) σ ch (MPa)
Steel C45 Normalization 170-217 600 340

2. Calculate the shaft design according to durable conditions, select the key:
Force applied from the transmission :

22
3. The force acting on the gear transmission:
F t=F t 1=F t 2 =2299 ,38 ( N )

F r=F r 1=F r 2=836 , 9 ( N )

F a=0(N )

- The force exerted by the belt wheel on the shaft:

F rx=F r ×sin ( 30 )=517 , 5(N )

F ry=F r × cos ( 30 )=896 ,34 (N )

4. Preliminary calculation of shaft diameter

According to the formula 10.9[1]: , k = 1; 2:d k =

√
3 Tk
0.2 ×[τ ]k

With (the input shaft of the gearbox) we getT 1=69001 ( N . mm ) và [ τ ] =15

23
 d 1=28 , 44(mm) => select d 1=30 (mm)

With (the output shaft of the gearbox) we get:T 2=271189 ( N . mm ) và [ τ ] =30

d 2=35 , 62 ( mm ) => select d 2=40(mm)

For the preliminary shaft diameter, look at table 10.2[1] to determine the roller bearing width b 0

B01=19(mm)

B02 = 23(mm)
 The distance between the support pillows and the load setpoint

Looking up table 10.3[1] we determine:

k 1=12 is the distance from the inner button face of the rotating part to the inner wall of the box

k 2=10 is the distance from the face of the drive node to the inner wall of the box

k 3=15 is the distance from the button face of the rotating part to the drive cover

h n=18 is the height of the bearing cover and bolt

Mayo lengths:

l m 12=( 1.2÷ 1.5 ) × d 1=( 1 ,2 ÷ 1 ,5 ) ×30=36 ÷ 45 => select l m 12=45 (mm)

l m 13=( 1.2 ÷1.5 ) × d 1=( 1 ,2 ÷ 1.5 ) ×30=36 ÷ 45 => select l m 13=40 (mm)

l m 22=( 1.4 ÷ 2.5 ) ×d 2= (1 , 4 ÷2 , 5 ) × 40=56 ÷ 100 => select l m 22=67( mm)

l m 23=( 1.2 ÷1.5 ) × d 2=( 1 ,2 ÷ 1 ,5 ) × 40=48 ÷ 60 => select l m 23=54 (mm)

Looking up table 10.4[1] we get:

- Axis 1:

l 12=l c12=0.5× ( l m 12+ b01 ) +k 3 +h n=0 , 5× ( 45+ 19 )+ 15+18=65 (mm)

l 13=0.5 × ( l m 13 +b 01) + k 1 +k 2=0 ,5 × ( 40+19 ) +12+10=51 ,5( mm)

l 11=2× l13=2×51 , 5=103 (mm)

- Axis 2:

l 22=l c 22=0.5× ( l m 22+ b02 ) +k 3 +h n=0 , 5 × ( 67+23 )+ 15+18=78 (mm)

l 23=l 13=51 ,5 (mm)

24
 l 21=l 11=103 (mm)

Force applied on axis 1:

Consider the Oyz plane:

- ∑ M B=¿ F ry ×65+ F r 1 ×51 ,5−R Dy ×103=0 ¿

896 , 34 × 65+836 , 9 ×51 , 5−R Dy × 103=0=¿ R Dy =984 , 1(N )
- ∑ F Y =¿ F ry−R By −F r 1+ R Dy =0¿

 896 , 34−R By−836 , 9+984 ,1=0=¿ R By =1043 ,54 (N )

Considering the Oxz plane:

- ∑ M B=¿−F rx ×65+ F t 1 ×51 , 5−R Dx ×103=0 ¿

 −517 , 5 ×65+2299 , 38 ×51 , 5−R Dx ×103=0=¿ R Dx=823 ,11(N )
- ∑ F x =¿−Frx + RBx −F t 1 + R Dx=0 ¿

 −517 , 5+ R Bx−2299 ,38+ 823 ,11=0=¿ RBx =1993 , 77(N )

Axial link release diagram 1

25
Calculate the torque at hazardous cross sections according to formulas 10.15 and 10.16:

Mj=√ M 2xj + M 2yj ; M tđj= √ M 2j +0.75 ×T 2j

M A =0 ( N . mm )=¿ M tdA =59756 , 62(N . mm)

M B =67275 , 21 ( N . mm )=¿ M tdB =89982 , 26(N . mm)

M C =66072 , 11 ( N .mm )=¿ M tdC =89086 , 35(N . mm)

Calculate the shaft diameter at the cross section according to the formula 10.17:

d j=
√
3 M tđj
0.1 ×[σ ]
Look up table 10.5 we have [σ ¿=63
d A =21 ,17=¿ chọn d A =22(mm) belt mounting position
d B=24 ,26=¿ chọn d B=d D=25 (mm) Roller bearing mounting location
d C =24 , 18=¿ chọn dC =30(mm) gear mounting location
Force applied on axis 2:

26
Consider the Oyz plane:

- ∑ M A =¿−F r 2 × 51 ,5+ RCy × 103=0 ¿

−836 , 9 ×51 , 5+ RCy ×103=0=¿ R Cy=418 , 45(N )
- ∑ F Y =−R Ay +¿ F r 2−R Cy=0 ¿

 −R Ay +836 , 9−418 , 45=0=¿ R Ay=418 , 45(N )

Considering the Oxz plane:

- ∑ M A =¿−Ft 2 ×51 , 5−R Cx × 103+ Frnt ×181=0 ¿

 −2299 , 38 ×51 ,5−RCx ×103+835 × 181=0=¿ RCx=317 ,64 (N )
- ∑ F x =¿ F t 2+ R Cx−R Ax −F rnt =0 ¿

 −R Ax +2299 ,38+ 317 , 64−835=0=¿ R Ax =1782 , 02(N )

Axial link release diagram 2

27
Calculate the torque at hazardous cross sections according to formulas 10.15 and 10.16:
Mj=√ M xj + M yj ; M tđj= √ M j +0.75 ×T j
2 2 2 2

M C =65130 ( N . mm )=¿ M tdC =243727 , 68( N . mm)

M B =94270 , 27 ( N .mm )=¿ M tdB =253077 , 36(N . mm)

M D =0 ( N . mm )=¿ M tdD =234864 ,36 (N . mm)

Calculate the shaft diameter at the cross section according to the formula 10.17:

d j=
√
3 M tđj
0.1 ×[σ ]
Look up table 10.5 [ σ ]=50
d C =36 ,53=¿ chọn d C =d A=40(mm) Roller bearing mounting location
d B=36 , 99=¿ chọn d B =45 (mm) gear mounting location
d D=36 ,08=¿ chọn d D=38 (mm) coupling mounting location

Durability testing
+ Fatigue test:

C45 steel I usually have :

σ b = 600 Mpa

28
 σ −1=0 , 436 . σ b =0 , 436 . 600=261 , 6 Mpa
τ τ =0 , 58. σ −1=0 ,58 . 261 ,6=151 ,73 Mpa
-1

ψ σ =0 , 05 ; ψ τ =0
- According to table 10.7 documents [1]:
- According to formula 10.19[1] p. 195:

The newly designed shaft structure ensures fatigue resistance if the safety factor at hazardous sections satisfies
the following conditions, according to formula 10.19[1] test:

sj = ./ [s] sσ s τ √ s σ + s τ ≥
2 2
j j j j

Where:

[S] = 1.5... 2.5 is the permissible safety factor, We choose [s] = 2.5

Sσj : The safety factor considers the stress alone. According to the formula 10.20 documents [1]:

σ −1
Sσj =
K σ dj . σ aj +ψ σ . σ mj

Sτj : The safety factor considers only the continuing stress at section j. According to formula 10.21
documents [1]:

τ−1
Sτj =
K τ dj . τ aj +ψ τ . τ mj
ạ

The axes of the gearbox are all rotating, the further stress varies with symmetrical cycles. Hence according to
the formula 10.22 document [1]:

Mj
σ mj=0 ; σ aj =σ max j =
ƯW j
Since the I axis rotates 1 way, the torsional stress varies with arterial cycling. Thus according to formula 10.23
documents [1]:

τ max j Tj
τ mj=τ aj = =
2 2 . W oj

29
where Wj and Woj are the bending resistance moment and torsion resistance moment at the j cross section of
the shaft, defined according to table 10.6
Choose to assemble the roller bearing installed on the shaft in the k6 style, install the belt wheel, gear in the k6
style combined with the key mounting.

πd 3j b . t 1 .( d j −t 1 )2
W j= −
32 2. d j

πd 3j b . t 1 .( d j−t 1 )2
W oj = −
16 2d j
Circular cross section shaft:
3
π dj
W j=
32
3
π dj
W oj =
16

d BBh t1 wj Woj
Axle Cross
section
d12 22 6x6 3,5 882,02 1927,38

d10 25 1533,98 3067,96

d13 30 8x7 4 2290,19 4940,9

d23 45 14x9 5,5 7611,3 16557,47

d21 40 6283,19 12566,37

d22 38 10x8 5 4670,6 10057,64

30
In combination with table 9.1[1] page 173, we have the following parameter table:

- According to formulas 10.25 and 10.26 documents [1]:

( )
Kσ
+ K x −1
εσ
K σ dj =
Ky

( )
Kτ
+ K x−1
ετ
K τ dj =
Ky

Because of the machined shafts on the lathe. At hazardous sections required to set Out = 2.5... 0.63 . μm
According to table 10.8 documents [1] the stress concentration coefficient due to the surface state kx = 1.06.
Do not use surface increase methods, so ky = 1

Using a finger milling knife to process key grooves, from table 10.12 documents [1] we have: ,
K σ =1 ,76
K τ =1, 54

Using the interpolation method we calculate the exact values and according to table 10.10[1] page 198:
εσ ετ

Axis I Axis II

d12 = 22 ε σ 12 = 0.912 d22 = 38 ε σ 22 = 0.856

d13 = 30 ε σ 13 = 0.88 d23 = 45 ε σ 23 = 0.83

d12 = 22 ε τ 12 = 0.874 d22 = 38 ε τ 22 = 0.786

d13 = 30 ε τ 13 = 0.81 d23 = 45 ε τ 23 = 0.77

31
 Mj
 σ aj = W
j

M 12 M 22
σ a12 = = MPa ; 0 σ a22 = = MPa 0
W 12 W 22

M 10 67275 , 21 M 21 65130
σ a10 = = MPa; =43 , 86 σ a21 = = = 10,37 MPa
W 10 1533 , 98 W 21 6283 , 19

M 13 66072 ,11 M 23 94270 , 27

σ a13 = = = 28,85 MPa ; σ a23 = = = 12,39 MPa
W 13 2290 ,19 W 23 7611,3

Tj
 τ aj = 2.W
oj

T 12 69001 T 22 271198
τ a12 = = = 17,9 MPa ; τ a22 = = = 13,48 MPa
2.W o 12 2. 1927 , 38 2.W o 22 2.10057 , 64

T 10 69001 T 21 271198
τ a10 = = = 11,25 MPa ; τ a21 = = = 10,79 MPa
2.W o 10 2. 3067 , 96 2.W o 21 2.12566 , 37

T 13 69001 T 23 271198
τ a13 = = = 6,98 MPa ; τ a23 = = = 8,19 MPa
2.W o 13 2. 4940 , 9 2.W o 23 2.16557 , 47

The result after calculating the safety factor for the cross sections of 2 axes:

32
  So the cross section ensures safety in terms of fatigue strength.

+ Shaft testing for static durability:

- According to formula 10.27 [1] p. 200:

σ td = √ σ 2 +3. τ 2 ≤[σ ]
Where:

M max
σ= (10.28) 3
(0 , 1. d )

T max
τ= (10.29) 3
(0 , 2. d )

[σ ] = 0,8. (10.30)σ ch

With and : maximum torque and maximum torque at dangerous cross section at overload, N.mm; : yield limit
of shaft material, MPa. M max T max σ ch

[σ ] = 0,8. = 0,8.340 = 272 MPaσ ch

33
Parameter sheet:

Cross d M max T max σ τ σ E.g.

section
12 22 0 69001 0 32,4 56,12
10 25 67275,21 69001 43,06 22,08 57,59
13 30 66072,11 69001 24,47 12,78 33
23 45 94270 , 27 271198 10,35 14,88 27,77
21 40 65130 271198 10,18 21,19 38,09
22 38 0 271198 0 24,71 42,8

From the parameter table, we see all the dangerous sections with σ td ≤[σ ]

 So all of the above sections ensure safety in terms of static durability.

+ Durability test of then:

σd
- With the key joint solution sections, we conduct joint tests for stamping strength and shear

τc
strength
- According to formulas 9.1 and 9.2 documents [1]:

2T
σ d= ≤[ σ d ]
d . l t ( h−t 1 )

2T
τ c= ≤[τc ]
d .l t . b
With lt = 0.9.lm

34
Table of test calculation results for sections:
d (mm) lt (mm) b×h t1 T(Nmm) σ d (Mpa) τ c (Mpa)
22 40,5 6x6 3,5 69001 61,95 25,81
30 36 8x7 4 69001 42,59 15,97
38 60,3 10x8 5 271198 78,9 23,67
45 48,6 14x9 5,5 271198 70,86 17,71

-
According to Table 9.5 documents [1] with static load, light impact, fixed mounting form:

σ d ] = 150 (MPa)
[

[τc]=(60/3. .90/3)=20. .30 (Mpa) 40 60 MPa Select ÷[τc]=(60/3. .90/3)=20. .30 (Mpa) 50 MPa
 So the key joints ensure stamping strength and cutting strength.

35