MECHANICAL AND AEROSPACE

ENGINEERING

MA3001 MACHINE ELEMENT DESIGN

SUGARCANE EXTRACTION MACHINE

FINAL REPORT

1
Content Page :

Summary Account of Group Project

Report Introduction

1. Motor selection

2. Belt Drive Selection

2.1 Belt Drive Design Calculations

2.2 Belt Drive Pulley & Bushing Specifications
2.3 Belt Drive Force Analysis
2.4 Belt Drive Load Analysis

3. Chain Drive 1 Selection

3.1 Chain Drive 1 Design Calculations

3.2 Chain Drive 1 ACD & Chain Length Calculation
3.3 Chain Drive 1 Force Analysis
3.4 Chain Drive 1 Pulley Specifications
3.5 Chain Drive 1 Load Analysis

4. Chain Drive 2 Selection

4.1 Chain Drive 2 Design Calculations

4.2 Chain Drive 2 Force Analysis
4.3 Chain Drive 2 ACD & Chain Length Calculations
4.4 Chain Drive 2 Pulley Specifications
4.5 Chain Drive 2 Load Analysis

5. Spur Gear Selection

5.1 Spur Gear Design Process

5.2 Selected Spur Gear Specifications
5.3 Spur Gear Force Analysis

6. Shaft Design

6.1 Selected Shaft Material

6.2 Summarised Essential Shaft Mounted Machine Element Specifications
6.3 Force & Moment Analysis of Roller 1
6.4 Roller Diameter Calculations
6.5 Shaft 1 & 2 Calculations

7. Bearing

7.1 Bearing Selection

2
8. Key Design

8.1 Key 1
8.2 Key 2
8.3 Key 3
8.4 Key 4
8.5 Key 5
8.6 Key 6
8.7 Key 7
8.8 Key 8

9. Mechanical Assembly

9.1 BOM List

10. Appendix (Insert part catalogues and graphs here)

a. Appendix A (AC motor)

b. Appendix B (Belt drive and sheave)
c. Appendix C (Chain drive and sprockets)
d. Appendix D (Spur gears)
e. Appendix E (Shafts)
f. Appendix F (Bearings)
g. Appendix G (Keys)
h. Appendix H (Components)

3
Report Introduction

Given the requirements of a centrifugal force of 4150N acting on the rollers, and a roller
output rpm of 66rpm, our group’s aim is to design an efficient and reliable sugar cane
machine to our utmost capabilities.

Above is our group’s concept design sketch prior to doing up the CAD drawing for machine
assembly. The conceptual design sketch has been sketched roughly to scale with each box
representing 50mm. For the design process, we designed our machine by piecing the
necessary critical components, and finally designing a frame around the machine
components.

4
The concept design sketch has assisted us a lot in deciding on required subsidiary
components and dimensions, and also guided us on how we should mount and place the
components within the machine. In the later stages of designing the machine components
such as the shaft lengths, this scale diagram will prove to come in very handy for our group
to figure out the lengths that we require in our shaft design.

Explanation of Machine Layout Design Rationale :

For the main layout and design, we have conceptualised a main machine structure of power
transmission and speed reduction assembly on one side of the machine, while the other side
consists of the rollers for sugar cane juicing operation, and also houses the selected motor
to provide a counter-balance weight for the machine. The strength of having such a design
is, performing preventive and corrective maintenance of this machine will be efficient since
all the various different systems are compartmentalised. Also, contamination of the cleaner
parts of the machine which will have to come into contact with the sugar cane being crushed
for consumption purposes is greatly minimised. This is due to most components that have to
be oiled and serviced regularly, which are “dirtier”, are segregated from the “cleaner” side.

Explanation of Machine Component Operation Process :

Regarding the drive arrangement of our sugar cane machine design, the belt-drive will
connect from the motor output shaft first. The belt-drive system will then connect to the first
stage chain drive through a common shaft connecting the pulley of the belt-drive, and the
sprocket of the chain-drive. Thus, having such an arrangement will help us minimise
vibrations from the output of the motor, which might potentially lead to a loss of power
transmission and lowered efficiency in our sugar cane machine.

5
The first stage chain drive will then transmit the power to the second stage chain drive,
which will help to reduce the speed further, in order to achieve a targeted output speed of
66rpm at the rollers.

Based on NParks provided data on the plant species Saccharum Officinarum, also known as
Sugarcane, the average estimated stem diameter is about 20-45mm. Going by this data, our
group has decided to come up with two roller sizes for our machine, with two gap choices of
10mm and 20mm for the sugar cane juice vendor.

Calculation & Tabulation of Design Forces & Design Parameters Based On Given
Specifications :

For our coefficient of friction that we had used in our calculation in the tangential roller force,
when the sugar cane is crushed by the metal rollers, we will use a coefficient of friction of
wood against metal of 0.2. We have approximated the sugar-cane as wood, since both
materials are organic plant compounds. We have obtained our coefficient of friction from the
link below :

https://www.emachineshop.com/coefficient-of-friction/

Parameter Value Remarks

Provided Centripetal Force 4150N Provided requirement

on Roller

Targeted Roller RPM 66rpm within 5% range Provided requirement

Rated Motor Output Speed 1250-1550 rpm Provided requirement

Range

Calculated tangential roller 4150 x 0.2 = 830N Calculated based on given

tangential force requirement

Calculated roller torque 830 x [(110 x 10^-3)/2] = Calculated based on given

(individual) 45.65Nm requirement

Calculated total roller torque 45.65 x 2 = 91.3Nm Calculated based on given

requirement

Calculated juicing power 91.3 x [66 x (2pi / 60) = Calculated based on given
0.631kW requirement

Calculated rated motor 1.6 x 0.631 = 1.0096kW Calculated based on given

power requirement

6
1. Motor Selection :

Motor requirements :

1. AC 230V
2. 50Hz
3. Single-phase electric motor
4. At least 160% of the juicing/machine power at a
5. Rated speed range of 1250 to 1550 rpm and then utilise the selected motor
speed

Given a specified centrifugal force (Fc) of 4150N (4.15kN), and roller speed of
66rpm, the motor that we have selected based on XX catalogue from XX
manufacturer is, model XX. (Remark : to consider, the tangential force (Ft))

Based on TCC’s manufacturer catalogue, we have selected a starter motor model of

TCC 90S-4. Technical data of the starter motor obtained from the parts catalogue are
listed below :

Power Current Speed Efficiency Power Rated Motor Weight

(kW) (A) (r/min) (%) Factor Torque (KG)

1.1 7.24 1410 71 0.93 7.45 13.8

1.1 Motor Installation & Dimensions :

Based on TEC’s electric motor catalogue, some of the crucial dimensions of model
TCC 90S-4 single-phase electric motor, that are major considerations for the design
of our sugar cane machine is provided as such :

Frame Spindle Overall Overall

Size Dimension Height Length

90S 24 150 335

Based on TEC’s manufacturer catalogue, the motor spindle will have a mounting
diameter of 24mm for motor model TCC-90S. Thus, the dimension of the spindle will
decide the bore dimension of the belt pulley, which is directly powered by the TCC
90S-4 motor.

7
2. Belt Drive Design :

Selected speed ratio : 1 to 3 for belt drive

Selected belt-drive service factor : 1.1
Belt type chosen : SPZ
Calculated belt speed : 10.336m/s
Belt mass per length : 0.07 kg/m^3 = M

Effective coefficient of friction from SPZ belt-type (based on Table A-8) :

Belt diameter less than 80 : coefficient. = 0.45
Belt diameter more than 80 : coefficient. = 0.40 <- selected effective
coefficient based on driver pulley diameter of 140mm.

The type of belt that we are using in our design will be a V-belt. V-belts are selected
for their ability to not be affected by the occurrence of slippage in the system, which
is a necessary design requirement in the sugar-cane juicing machine. If the running
gear systems experience some form of interruption during the juicing process, the
V-belt will largely remain unaffected by minor interruption, due to its characteristic of
being able to endure slippage in the system.

Based on the given constraints of the sugar cane machine, we initially estimated a
tentative centre distance value of 500mm (TCD), thus the actual centre distance that
we calculated is 510mm. Based on our juicing power of 0.631 kW, and a given
service factor of 1.1 for the belt, we calculated a design power of 0.694kW.

From the estimated centre distance, we obtained a driven speed of 493.5rpm for the
driven pulley. From Table A1, we also selected a V-belt of SPZ 1900. The calculated
actual belt speed is 10.336m/s.

2.1 Belt Drive Design - Calculation Formulas for Belt Selection :

Chosen factor of safety (with justification) : 1.1

Speed Ratio of belt drive = 3.0

Belt Drive

Design Power = 0.631kW × Safety Factor

= 0.631kW × 1.1
= 0.639kW

Assuming no power loss, from Table A-3, design power 0.639kW and 1410 rpm of
faster shaft gives SPZ belt cross section.

Select 𝑣𝑏 = 10m/s (between 5 and 33m/s)

8
To avoid the excessive generation of stress and vibration, we first determine an
estimated belt speed of 10m/s that is within the range of 5m/s to 33m/s. The belt
speed will then be used to calculate the diameters and cross section used.

𝑣𝑏 = 𝑟1𝑤1 = (𝐷1𝑤1)/2

𝐷1 = 2𝑣𝑏/𝑤1 = 2(10)/(2π×1410/60) = 0.135mm

From Table A-4 for SPZ belt, select a closest standard diameter; 𝐷1 = 140mm =
0.14m

Check belt speed, 𝑣𝑏 = 𝑟1𝑤1 = 0.14/2 × (2π×1410/60)

≈ 10.336m/s (between 5 and 33m/s)

Once the closest standard driver diameter has been chosen, we can find out the
actual belt speed and determine the driven diameter for the belt drive.

η1𝑏 𝐷2
Select Speed Ratio (SR) = 3 = η2𝑏
= 𝐷1

𝐷2 = 3 × 140mm = 420mm

From Table A-4 for SPZ belt, select a closest standard diameter; 𝐷2 = 400mm = 0.4m

𝐷2 400
Actual Speed Ratio (ASR) = 𝐷1
= 140
≈ 2.857 ( < 3.0 to avoid slippage)

Using recommended Centre Distance: 𝐷2 < C < 3(𝐷2+𝐷1) = 400mm < C < 1620mm

Select Tentative Centre Distance (TCD) = 500mm

To minimise the area or space of the belt drive, we select a tentative centre distance
of 500mm for the rest of the calculations.

2
(𝐷2 − 𝐷1)
Tentative Belt Length (TBL) = 2 × TCD + 1.57(𝐷2+𝐷1) + 4 × 𝑇𝐶𝐷
2
(400 − 140)
= 2 x 500 + 1.57(400+140) + 4 × 500
= 1881.6mm

From Table A-1, select closest standard belt length, L = 1900mm

B = 4L - 6.28(400+140)
= 4208.8mm

9
 2 2
𝐵+ 𝐵 − 32(𝐷2 − 𝐷1)
Actual Centre Distance (ACD) = 16
2 2
4208.8 + 4208.8 − 32(400 − 140)
= 16
≈ 509.515mm
≈ 510mm

◦ −1 400 − 140
θ1 = 180 - 2𝑠𝑖𝑛 [ 2(510)
]
◦
≈ 150. 464

150.464 − 145
Determine Angle of Contact Correction Factor ( 𝐶θ) from Table A-5: 𝐶θ − 0.91
=
151 − 145
0.93 − 0.91
𝐶θ ≈ 0.928

Determine Belt Length Correction Factor (𝐶𝐿) from Table A-6:

𝐶𝐿 = 1.03

Determine Rated Power (RP) from Table A-7a, for 𝐷1 = 140mm and Speed Ratio =
2.857:
𝑃𝑜𝑤𝑒𝑟 − 3 .74 3.77 − 3.74
(1) Power under 1200 rpm @ Speed Ratio = 2.857; 2.857 − 1.5
= 3 − 1.5
Power ≈ 3.767kW

𝑃𝑜𝑤𝑒𝑟 − 4.78 4.83 − 4.78

(2) Power under 1600 rpm @ Speed Ratio = 2.857; 2.857 − 1.5
= 3 − 1.5
Power ≈ 4.825kW

Using (1) & (2), 𝐷1 = 140mm, 1410 rpm @Speed Ratio = 2.857:
1410 − 1200 1600 − 1200
𝑅𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 − 3.767
= 4.825 − 3.767

Rated Power ≈ 4.322kW per belt

Corrected Rated Power (CRP) = 𝐶θ 𝐶𝐿 RP

= 0.928 × 1.03 × 4.322
≈ 4.131kW

𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑜𝑤𝑒𝑟
No of belts = 𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝑅𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟
0.639
= 4.131
≈ 0.155
≈ 1 belt

10
2.2 Belt Drive Pulley & Bushing Specifications :

Based on Uni-Drive Transmission Equipment part catalogue and also the selected
belt of SPZ 1700, our driver taper-lock pulley has a diameter of 140mm, while our
driven taper-lock pulley has a diameter of 400mm.

For the 140mm driver pulley, the bushing number is 1610. The bore diameter is
24mm, based on the motor spindle dimension from the selected motor. For the
400mm driven pulley, the bushing number is 2012.

Driver Pulley 140mm :

Total length : 25mm

Driver Pulley Bushing 1610 :

Bore diameter : 24mm
Keyway width : 8mm
Keyway depth at centre : 3.3mm
Dia. at large end of taper : 57mm

Driven Pulley 400mm :

Total length : 32mm

Driven Pulley Bushing 2012 :

Bore diameter : 30mm
Keyway width : 8mm
Dia. at large end of taper : 57mm

2.3 Belt Drive Force Analysis

−1 𝐷2−𝐷1
𝑎 = 𝑠𝑖𝑛 ( 2𝐶
)
−1 400−140
= 𝑠𝑖𝑛 ( 2 × 510 )
◦
≈ 14. 768

P = 𝑇1𝑤1 = 𝑇2𝑤2

2π
𝑤1 = 1410 x 60
≈ 147.655 rad/s

0.631𝑘𝑊
𝑇1 = 147.655 𝑟𝑎𝑑/𝑠
≈ 4.273 Nm

m = belt mass per unit length

= 0.070kg

11
 𝑣𝑏 = 10.336m/s

2 2
𝐹𝑐 = m𝑣𝑏 = 0.070 x 10. 336
≈ 7.478N

◦ −1 400−140
θ1 = 180 − 2𝑠𝑖𝑛 ( 2 × 510
)
◦
= 150. 464
= 2.626 rad

◦
Table A-8, SPZ for 𝐷𝑚=𝐷1=140mm which is >80mm. Then groove 2β = 38 and
effective coefficient of friction fe=0.4

f/sinβ = fe = 0.4

f ≈ 0.13

θ1𝑓/𝑠𝑖𝑛β
γ = 𝑒
(2.626)(0.13)/𝑠𝑖𝑛19
=𝑒
≈ 2.859

γ 𝑇
𝐹1 = 𝐹𝑐 + 2( γ −1 )( 𝐷1 )
1
2.859 4.273
= 7.478 + 2( 2.859 −1
)( 0.14
)
≈ 101.357N

𝑇
For one belt, 𝐹2 = 𝐹1 - 2( 𝐷1 )
1
4.273
= 101.357 - 2( 0.14
)
≈ 40.314N

𝑃 0.631𝑘𝑊
𝑇2 = 𝑤2
= 2π
493.5 × 60

≈ 12.210Nm

Assuming parallel tension, driver shaft forces: 𝐹𝑠 = 𝐹1 + 𝐹2 = 141.671N

2.4 Belt Drive Load Analysis :

Load of 140mm Driver Pulley : 1.2kg

Load of 400mm Driven Pulley : 6kg
Belt mass per length : 0.07kg / m
Load of SPZ 1900 Belt : 0.07 x 1.7 = 0.119kg = 119g
Total load of belt drive assembly : 1.2 + 6 + 0.133 = 7.319kg = 71.8N

12
Belt Drive

3. Chain Drive 1 (No.40)

Specified speed ratio : 1 to 7 for chain drive

Specified chain-drive service factor : 1.3

We have selected a chosen service factor of 1.3, based on the load classification of
moderate shock for the food industry.

3.1 Chain Drive 1 Design - Calculation Formulas for Chain Drive Selection :

Chain Drive 1

0.631 × 1.3
Design Power = 1
= 0.8203kW per strand

η1𝑏
2.857 = η2𝑏
, η2𝑏 ≈ 493.5rpm = Input speed of Chain Drive 1

Assuming no power loss, from Table B-4 (No.40), 17 teeth, design power 0.8203kW
493.5 − 400 500 − 400
and 493.5rpm of smaller sprocket: 𝑃𝑜𝑤𝑒𝑟 − 2.14
= 2.61 − 2.14

Power ≈ 2.58kW (>0.8203kW)

Select N0.40, 𝑁1 = 17 teeth for smooth operation

13
We initially found out that No.35 was able to produce power that fulfils the
requirement (>0.8203kW) as well. However, based on the speed ratio that we had
derived later for both the chain drives, the second chain drive will eventually be
No.40. Thus, both chain drives will be standardised to No.40; making the
replacement simpler and also preventing the user of the sugar cane machine from
mixing up the parts when performing servicing. The number of teeth for both the
driver sprockets was also set to 17 for smooth operation.

Set Driven Speed at 175rpm

η1𝐶 493.5 𝑁2
Speed Ratio (SR) = η2𝐶
= 175
= 2.82 = 𝑁1

𝑁2 = 2.82 × 𝑁1
= 2.82 × 17
= 47.94 teeth
≈ 48 teeth (ANSI Standard Sprocket No.40 Single Strand BP)

The number of teeth for the driven sprocket was rounded up to 48 based on the
catalogue and for the actual speed ratio to be as close to the original speed ratio
calculated.
𝑁2 48 η1𝐶 493.5
Actual Speed Ratio (ASR) = 𝑁1
= 17
= η2𝐶
= η2𝐶

Actual Driven Speed based on ASR ( η2𝐶) ≈ 175 rpm

From Table B-1 (No.40); p = 12.7mm

◦
𝐷1 = p/sin(180 /𝑁1)
◦
= 12.7/sin(180 /17)
≈ 69.116mm

◦
𝐷2 = p/sin(180 /𝑁2)
◦
= 12.7/sin(180 /48)
≈ 194.18mm

Using recommended Centre Distance: 𝐷2 < C < 3(𝐷2+𝐷1) = 194.18mm < C <
789.888mm

Select Tentative Centre Distance (TCD) = 545mm

= 545/12.7
≈ 42.913 pitches

2
𝑁2+𝑁1 (𝑁2 − 𝑁1)
Tentative Chain Length (TCL) = 2 × TCD + 2
+ 2
4π (𝑇𝐶𝐷)

14
 2
48+17 (48 −17)
= 2 × 42.913 + 2
+ 2
4π (42.913)
≈ 118.893 pitches

Select closest standard chain length, L = 120 pitches

The chain length was rounded up to 102 pitches to avoid using an offset link which in
turn wears faster than straight links.

⎧ 2 2
⎫
⎪ 𝑁 +𝑁 1 ⎡ (𝑁2 + 𝑁1) ⎤ 8(𝑁2 − 𝑁1) ⎪
Actual Centre Distance (ACD) = 𝐿 − 22 1 +
4 ⎢𝐿 − 2 ⎥ − 2
⎨ ⎣ ⎦ 4π ⎬
⎪ ⎪
⎩ ⎭
⎧ 2 2 ⎫
1 48 + 17 ⎡120 − (48 + 17) ⎤ 8(48 −17)
= 4 120 − 2 + ⎢ 2 ⎥ − 2
⎨ ⎣ ⎦ 4π ⎬
⎩ ⎭
≈ 43.470 pitches
= 43.470 × 12.7
≈ 552.069 mm

3.2 Chain Drive 1 Actual Centre Distance Design & Chain Length Calculation

Chain Drive 2’s actual centre distance is largely constrained by the height of the table
surface of the sugar cane machine for the machine operator. Based on a targeted
table height of 0.6 - 0.7m total, a clearance height of approximately 0.2m from the
rollers, and also Chain 1’s actual centre distance, we have obtained an approximate
actual centre distance of 546.037 mm.

Thus, the total chain length is (120 pitches x 0.01270) = 1.524m.

3.3 Chain Drive 1 Force Analysis

P = 𝑇1𝑤1 = 𝑇2𝑤2

𝑃 0.631𝑘𝑊
𝑇1 = 𝑤1
= 2π
493.5 × 60

≈ 12.210Nm

Based on the catalogue:

𝐷𝑝1 = 17 teeth, 69.12mm
𝐷𝑝2 = 48 teeth, 194.18mm

Since 𝐹2 = 0 for chain drives,

𝑇1 = (𝐹1)𝐷1/2 = 12.210
𝐹1 = 12.210 ÷ 0.06912/2
≈ 353.299N

15
3.4 Chain Drive 1. Pulley Specifications (based on ANSI standard sprocket for
No.40) :

Driver Sprocket :

No. of Teeth : 17
Outer Diameter : 75mm
Pitch Diameter : 69.12mm
Bore Diameter : 12.5-32mm
Hub Diameter : 54mm
Hub Length : 22mm
Weight : 0.46kg

Driven Sprocket:

No. of Teeth : 48
Outer Diameter : 201mm
Pitch Diameter : 194.18mm
Bore Diameter : 18-48mm
Hub Diameter : 73mm
Hub length : 32mm
Weight : 2.3kg

3.5 Chain Drive 1 Load Analysis

Load of 57mm Driver Pulley : 0.46kg

Load of 142mm Driven Pulley : 2.3kg
Load of Chain Per Metre (Approximate Weight) : 0.64kg / metre
Total Chain Length : 1.524m.
Total Load of Chain : 1.524 x 0.64 = 0.9856kg

Total load of Chain Drive 1 Assembly : 3.7456kg / 36.746N

16
Chain Drive 1

Chain Drive 2

17
4. Chain Drive 2 (No.40)

Specified speed ratio : 1 to 7 for chain drive

Specified chain-drive service factor : 1.3

4.1 Chain Drive 2 Design - Calculation Formulas for Chain Drive Selection :

Chain Drive 2

0.631 × 1.3
Design Power = 1
= 0.8203kW per strand

Assuming no power loss, from Table B-4 (No.40), 17 teeth, design power 0.8203kW
175 − 100 200 − 100
and 175 rpm of smaller sprocket: 𝑃𝑜𝑤𝑒𝑟 − 0.61
= 1.15 − 0.61

Power ≈ 1.015kW (>0.8203kW)

Select N0.40, 𝑁1 = 17 teeth for smooth operation

Set Driven Speed at 66rpm

η1𝐶 175 𝑁2
Speed Ratio (SR) = η2𝐶
= 66
= 2.652 = 𝑁1

𝑁2 = 2.652 × 𝑁1
= 2.652 × 17
= 45.084 teeth
≈ 45 teeth (ANSI Standard Sprocket No.40 Single Strand BP)

The number of teeth for the driven sprocket was rounded down to 45 based on the
catalogue and for the actual speed ratio to be as close to the original speed ratio
calculated.

𝑁2 45 η1𝐶 175
Actual Speed Ratio (ASR) = 𝑁1
= 17
= η2𝐶
= η2𝐶

Actual Driven Speed based on ASR ( η2𝐶) ≈ 66.111rpm

From Table B-1 (No.40); p = 12.7mm

◦
𝐷1 = p/sin(180 /𝑁1)
◦
= 12.7/sin(180 /17)
≈ 69.116mm

18
 ◦
𝐷2 = p/sin(180 /𝑁2)
◦
= 12.7/sin(180 /45)
≈ 182.062mm

Using recommended Centre Distance: 𝐷2 < C < 3(𝐷2+𝐷1) = 182.062mm < C <
753.534mm

Select Tentative Centre Distance (TCD) = 195mm

= 195/12.7
≈ 15.354 pitches

2
𝑁2+𝑁1 (𝑁2 − 𝑁1)
Tentative Chain Length (TCL) = 2 × TCD + 2
+ 2
4π (𝑇𝐶𝐷)
2
45+17 (45 −17)
= 2 × 15.354 + 2
+ 2
4π (15.354)
≈ 63.001 pitches

Select closest standard chain length, L = 64 pitches

With regards to the chain length, we had 2 choices, which were 56 and 58 pitches
based on the catalogue. 56 pitches was ultimately selected because firstly, if the
pitch length is an even number, we can avoid using an offset link which will wear
faster as compared to straight links. Secondly, the actual centre distance calculated
later will be smaller, thus making the whole assembly more compact.

Actual Centre Distance (ACD) =

⎧ 2 2
⎫
1 ⎪ 𝑁2 + 𝑁1 ⎡ (𝑁2 + 𝑁1) ⎤ 8(𝑁2 − 𝑁1) ⎪
4
𝐿 − 2
+ ⎢𝐿 − 2 ⎥ − 2
⎨ ⎣ ⎦ 4π ⎬
⎪ ⎪
⎩ ⎭
=
⎧ 2 2 ⎫
1 45 + 17 ⎡64 − (45 + 17) ⎤ 8(45 −17)
4
64 − 2
+ ⎢ 2 ⎥ − 2
⎨ ⎣ ⎦ 4π ⎬
⎩ ⎭
≈ 15.875 pitches
= 15.875 × 12.7
≈ 201.613 mm

4.2 Chain Drive 2 Force Analysis

P = 𝑇1𝑤1 = 𝑇2𝑤2

𝑃 0.631𝑘𝑊
𝑇1 = 𝑤1
= 2π
175 × 60

≈ 34.432Nm

19
 Based on the catalogue:
𝐷𝑝1 = 17 teeth, 69.12mm
𝐷𝑝2 = 45 teeth, 182.06mm

Since 𝐹2 = 0 for chain drives,

𝑇1 = (𝐹1)𝐷1/2 = 34.432
𝐹1 = 34.432÷ 0.06912/2
≈ 996.296N

4.3 Chain Drive 2 Actual Centre Distance Design & Chain Length Calculation

Chain Drive 1’s actual centre distance design is based on a few parameters. Firstly,
we have the total machine height constraint to work with. Secondly, we have our own
target of achieving an actual centre distance that is as short as possible, so that we
can achieve a lighter chain drive assembly, and reduce overall unnecessary loading
on our shafts and maximise the service life of the sugar cane machine.

Based on the height limit given of 1400mm, and working our way backwards, we
have come up with an approximate actual centre distance of 184.42 mm. This centre
distance will in turn affect the centre distance of Chain Drive 2.

4.4 Chain Drive 2. Pulley Specifications (based on ANSI standard sprocket for
No.40) :

Driver Sprocket :

No. of Teeth : 17
Outer Diameter : 75mm
Pitch Diameter : 69.12mm
Bore Diameter : 12.5-32mm
Weight : 0.46kg

Driven Sprocket:

No. of Teeth : 45
Outer Diameter : 189mm
Pitch Diameter : 182.06mm
Bore Diameter : 18-48mm
Weight : 2.1kg

4.5 Chain Drive 2 (No.40) Load Analysis

Load of 57mm Driver Pulley : 0.46kg

Load of 142mm Driven Pulley : 2.3kg
Load of Chain Per Metre (Approximate Weight) : 0.64kg / metre
Chain length = 60 pitches = 60 x 12.7 = 762mm = 0.762m

20
 Total Load of Chain : 0.64 x 0.762 = 0.488kg
Total load of Chain Drive 1 Assembly : 0.488 + 0.46 + 2.3 = 3.248kg = 31.86N

5. Spur Gears

Based on NParks provided data on the plant species Saccharum Officinarum, also
known as Sugarcane, the average estimated stem diameter is about 20-45mm.
Based on this information, we have decided to go with a minimum gap of 10mm
between our two rollers, and select the spur gear based on the minimum gap that we
require and the required roller diameter.

Roller radius : 110/2 = 55mm

Gap : 10mm
Required spur gear centre to centre distance : 55 + 55 + 10 = 120mm

If both gears are identical gears and only two gears are used, both spur gears will
have a required pitch diameter of 120mm.

5.1 Spur Gear Design & Selection Process - Calculation Formulas

Based on the pitch diameter requirement of da = 120mm, being able to withstand a

minimum total roller torque of 91.3Nm, and a minimum teeth of 17 teeth, and also a
length consideration that is not too long, we have narrowed down the Spur Gear
selection list on the NOZAG catalogue to the following options to choose from :

1. Module 2.0, SG 2060 with 60 teeth, heat treated, bore = 16mm

2. Module 2.5, SG 2548 with 48 teeth, heat treated, bore = 20mm
3. Module 3.0, SG 3040 with 40 teeth, heat treated, bore = 25mm
4. Module 4.0, SG 4030 with 30 teeth, heat treated, bore = 30mm

Ultimately, considering the restriction of having a spur gear length that cannot be too
long due to our roller shaft design restriction, our group has decided to go with
Module 2.0 spur gear, model 2060 for our project.

Module Model No. No. of Teeth Treatment Bore Dia. Spur Gear
(mm) Length

2.0 2060 60 Heat-treated 16 31

5.2 Selected Spur Gear Specifications

Selected module : 2.0

Bore diameter : 16mm
Total length : 31mm
Number of teeth : 60

21
 Pitch diameter : 120mm
Outside diameter : 124mm

5.3 Spur Gear Force Analysis

Calculation Assumption : assume constant roller torque

1. Obtain the tangential load acting on spur gear :

Roller torque = 45.65Nm

Spur gear radius = 0.06m (60mm)

Tangential load = Torque / Radius = 45.65 / 0.06 = 760.83N

2. Find the radial load :

Radial load = Tangential load x tan(20deg) = 760.83 x (tan20) = 276.919N

22
6. Shaft Design

Our shaft & roller assembly is as follows :

1. Shaft 1 (Uniform diameter shaft) : transmits torque from belt pulley driven
sheave to chain drive 1 driver pulley
2. Shaft 2 (Uniform diameter shaft) : transmits torque from chain drive 1 driven
pulley to chain drive 2 driver pulley
3. Roller 1 : transmits torque from chain drive 2 driven pulley to the rollers
4. Roller 2 : transmits torque using the spur gears from roller 1 to roller 2

We shall only be performing in-depth calculation and analysis for our most
complicated shaft of this system due to the limitations of the report length, which is
Roller 1, a shaft of varying diameter. Roller 2 will be identical to Roller 1, apart from
the lack of a section to mount the chain drive in Roller 1, which Roller 2 does not
require.

To calculate the forces, we will require the lengths of the shaft to be dimensioned
first. Based on the widths of the spur gear and chain driven sprocket, and giving a
length of 70mm to both the 110mm roller and 100mm roller, we have managed to
identify the lengths that we require for each portion of the varying diameter shaft. All
this information has been summarised in a table below.

For the load contributions from the other mounted components such as the chain
drive, they will all be treated as insignificant loads based on the load analysis that we
have performed in the earlier sections of the report, since all of them are less than
20% of the largest force acting upon the roller shaft, after performing load analysis at
the end segment of the major components in the earlier segments of the report.

Below is a sketch of our group’s shaft design work during the conceptualisation and
ideation process (drawing not to scale) :

23
 6.1 Selected Shaft Material

For the material of our shaft, we have selected a shaft metal of high-carbon alloy
steel with a material designation number of 4150, which also consists of chromium,
manganese and molybdenum. We have selected this material for its superb qualities
in terms of strength and hardness. The condition that we require is OQT 400.

This material will provide us with a good tensile strength of 2070 MPa, and a yield
strength of 1710 MPa. The material also ranks highly on the Brinell hardness scale,
with a rating of 578 HB.

We have also selected a value of N = 2 for our design factor, as we predict that the
sugar cane roller shaft will run relatively smoothly during operation.

The modified endurance strength will be calculated with the following formula :

Sn’ = Sn x Cs x Cr = (1035 MPa)(0.81)(0.78) = 653.913 MPa

Parameter Value Reasoning for obtained

value

Yield Strength (Sy) 1710 MPa Material property

Tensile Strength (Su) 2070 MPa Material property

Endurance Strength 1035 MPa Polished shaft, Sn is half the

(Sn) value of Su

Reliability Factor (Cr) 0.81 0.99 desired reliability

Size Correction 0.78 Assumed average shaft

Factor (Cs) diameter of close to 75mm

Modified Endurance 653.913 MPa Obtained from formula

Strength (Sn’) calculation

Design Factor 2 Selected from relatively

smooth application during
operation

6.2 Summarised Essential Shaft Mounted Machine Element Specifications

A summary table of the important dimensions that we require for the length and
diameter design, of our varying diameter shaft :

Shaft Component Specified Selected Component Additional

Name component final bore Width (mm) Information
bore diameter

24
 diameter / (mm)
Bore range
(mm)

Shaft 1 Belt Driven 14-38 30 32 Keyway

Sheave Width : 8mm
(400mm)

Chain Drive 12.5-32 30 22 -

1 Driver
Sprocket (17
Teeth)

Shaft 1 30 30 16 -
Model 6206
Bearings

Shaft 2 Chain Drive 18-48 30 32 -

1 Driven
Sprocket (48
Teeth)

Chain Drive 12.5-32 30 22 -

2 Driver
Sprocket (17
Teeth)

Shaft 2 30 30 16 -
Model 6206
Bearings

Roller 1 Chain Drive 18-48 30 32 -

2 Driven
Sprocket (45
Teeth)

Roller 1 40 40 15 -
Model 6008
Bearings

Spur Gears 16 16 31 -

Roller 2 Roller 2 40 40 15 -
Model 6008
Bearings

Spur Gears 16 16 31 -

6.3 Force & Moment Analysis of Roller 1

The force analysis of Shaft 3 will be divided into two different planes, in the vertical
direction (defined as ZX-plane), and the horizontal direction (defined as YX-plane).
This is due to the spur gear having a radial and tangential load, and the roller also
having a centripetal and tangential load.

25
For our force analysis, we shall assume that the force of 4150N will act upon the
centre of the 110mm diameter roller. We will also assume that the forces on the chain
drive have an angle alpha so small that the forces will be assumed to be parallel.

Calculated Forces :

Shaft Section / ZX-Axis (N) YX-Axis (N) Resultant Force

Mounted
Component

Chain Drive 2 996.296 0 -

Driven Pulley

Point B Bearing 1731 1164.83N 2086.43

Reaction Force

110mm Roller 4150 830 -

Point D Bearing 1700 426 1752.563

Reaction Force

Spur Gear 276.919 760.83 -

Calculated Resultant Moment :

Shaft Section / ZX-Axis (Nm) YX-Axis (Nm) Resultant Moment

Mounted
Component

Chain Drive 2 - - -
Driven Pulley

Bearing 1 -9.83 27 28.734

110mm Roller 171.93 23.5 174

Bearing 2 23.654 0 23.654

Spur Gear - - -

6.4 Roller Diameter Calculations

For the finalised diameter design of the shaft, based on the provided bore diameters
available from the belt drive bushing and the chain drive bore diameter range, we
have decided on a constant diameter of 30mm to mount all of our chain and belt
driver and driven pulleys. This means that shafts 1 & 2 will be uniform diameter
shafts of 30mm. For the varying shafts, which are rollers 1 & 2, we will use the ASME
practical shaft design equation to check and confirm if our selected final diameter is
able to be used in our machine.

26
 For the rest of the diameters on the shaft, we have finalised a diameter based on the
design principle of having a step-up to the largest centre diameter of the crushing
rollers of 110mm and 100mm, for the large and small rollers respectively.

1
3

32𝑁 𝐾𝑓𝑏𝑀 2 3 𝑇 2
Using the ASME shaft design equation : D = [ π
( 𝑠𝑛'
) + 4
(𝑠 ) ]
γ

ASME Shaft Design Calculations For Roller 1 :

Note : Force diagrams for Roller 1 can be found in Appendix E2.3

Shaft Feature 𝐾𝑓𝑏 Resultant Torque Calculate Selected Final Final

Section Moment (Nm) d Dia. Min. Dia. Dia. Column
(Nm) (mm) (mm) (mm) length
(mm)

Chain Well-Ro 1.5 0 45.65 0.73 0.73 30 32+5

drive 2 unded
driven Fillet
pulley
Retaini 3.0
ng Ring

Profile 2.0
Key

Deep-Gr Sharp 2.5 28.734 45.65 9.827 9.827 40 30

oove Fillet
Ball
Bearing Press-F 1.0
it Ball
Bearing

Bearing Sharp 2.5 - 45.65 - - 50 10

shoulder Fillet

Shaft 1.0 -

110mm Sharp 2.5 174 45.65 2.38 2.38 110 70

roller Fillet

Shaft 1.0 1.76

100mm Sharp 2.5 - 45.65 100 - 100 70

roller Fillet

Shaft 1.0 100

Bearing Sharp 2.5 - 45.65 - - 50 10

shoulder Fillet

Shaft 1.0 -

27
 Deep-Gr Sharp 2.5 23.654 45.65 0.328 0.328 40 30
oove Fillet
Ball
Bearing Press-F 1.0 0.241
it Ball
Bearing

Spur Sharp 2.5 0 45.65 0.73 0.73 16 31+5

gear Fillet

Retaini 3.0
ng Ring

Profile 2.0
Key

Well-Ro 1.5
unded
Fillet

ASME Shaft Design Calculations For Roller 2 :

Note : Force diagrams for Roller 2 can be found in Appendix E2.4

Shaft Feature 𝐾𝑓𝑏 Resultan Torque Calculat Selected Final Final

Section t (Nm) ed Dia. Min. Dia. Dia. Column
Moment (mm) (mm) (mm) length
(Nm) (mm)

Deep-Gr Sharp 2.5 0 45.65 0.73 0.73 40 30

oove Fillet
Ball
Bearing Press-Fi 1.0
t Ball
Bearing

Bearing Sharp 2.5 - 45.65 - - 50 10

shoulder Fillet

Shaft 1.0 -

110mm Sharp 2.5 160.55 45.65 2.32 2.32 110 70

roller Fillet

Shaft 1.0 1.71

100mm Sharp 2.5 - 45.65 100 - 100 70

roller Fillet

Shaft 1.0 100

Bearing Sharp 2.5 - 45.65 - - 50 10

shoulder Fillet

28
 Shaft 1.0 -

Deep-Gr Sharp 2.5 28.7 45.65 1.32 1.32 40 30

oove Fillet
Ball
Bearing Press-Fi 1.0 1.00
t Ball
Bearing

Spur Sharp 2.5 0 45.65 0.73 0.73 16 31+5

gear Fillet

Retainin 3.0
g Ring

Profile 2.0
Key

Well-Ro 1.5
unded
Fillet

Roller 1

Roller 2

29
6.5 Shaft 1 & 2 Calculations

1
3
32𝑁 𝑀 2 𝑇 2
Using the basic shaft equation: D = [ π
( 𝑠γ
) + (𝑠 ) ]
γ

At shaft 1, N=2, Maximum moment (M) = 17.655Nm, T=12.210Nm,

Min diameter for shaft 1 ≈ 0.635mm

At shaft 2, N=2, Maximum moment (M) = 99.63Nm, T=34.432Nm

Min diameter for shaft 2 ≈ 1.079mm

Shaft 1

Shaft 2

30
 7. Bearing Design

Due to the scenario of rotating power transmission and the application of v-belt and
chain drives, the bearings will only experience radial loads. Thus, all of the ball
bearings that we have selected will be Deep-Groove ball bearings that will have to be
press-fit onto shafts.

1. Bearing selection procedure selected : Dynamic Load Carrying Capacity (C)

Taking into consideration the busiest hours of the sugarcane stall resulting in
continuous operation of the sugar cane machine, our group will utilise the dynamic
load carrying capacity design procedure for bearing selection.

2. Bearing life

L10 = L10hr x rpm x 60

RPM output :
Shaft 1 : 493.5 rpm
Shaft 2 : 175 rpm
Roller 1 & 2 : 66.111rpm
K factor = 3 (Ball bearing)
1
𝐿10 𝐾
Basic dynamic load formula C = 𝑃𝑑( 6 )
10

Considering the situation of a machine used in an 8-hour service working day based
on stall operation hours, and also a machine which is not always fully utilised since
the stall will see certain downtimes during non-peak hours, we have selected a
recommended bearing life rating of 20 x 10^3 hours at the upper limit of the life rating
to work with.

3. Calculated basic dynamic load rating :

Roller 1 :
Bearing design load (Pd) : 1731N (↑) at Bearing 1 & 1700N (↑) at Bearing 2

Bearing 1 : C = 7.437kN
Bearing 2 : C = 7.3kN

Roller 2 :
Bearing design load (Pd) : 1599.919N (↓) at Bearing 1 & 2827N (↓) at Bearing
2

Bearing 1: C = 6.875kN
Bearing 2 : C = 12.147kN

Shaft 1 :

31
 Bearing design load (Pd) : 523.8N (↑) at Bearing 1 & 735.428N (↓) at Bearing
2, Ld = 592.2 x 10^6

Bearing 1: C = 4.39kN
Bearing 2 : C = 6.17kN

Shaft 2 :
Bearing design load (Pd) : 2317.609N (↑) at Bearing 1 & 967.323N (↓) at
Bearing 2, Ld = 210 x 10^6

Bearing 1: C = 13.77kN
Bearing 2 : C = 5.74kN

7.1 Bearing Selection

Based on the calculated dynamic load ratings, and based on the required bore
diameters of the bearing, we have decided to go with a bearing model of 6008 for the
rollers, and a bearing model of 6206 for the 30mm diameter uniform shafts.

Bearings for Rollers 1 & 2 :

Static / dynamic load rating : maximum C of 7.437 kN

Selected Bearing Number : 6008 (Dynamic load rating : 16.8kN)

Bearing specifications :

Bearing bore : 40mm

Outside diameter : 68mm
Bearing width : 15mm
Minimum shaft shoulder diameter : 45mm

Bearings for Shafts 1 & 2 :

Static / dynamic load rating : maximum C of 13.77 kN

Selected Bearing Number : 6206 (Dynamic load rating : 19.5kN)

Bearing specifications :

Bearing bore : 30mm

Outside diameter : 62mm
Bearing width : 16mm
Minimum shaft shoulder diameter : 35mm

32
8. Key Design

The designed key is to be kept within the width of the hub of all the pulleys and
gears. The key will be machined from SAE 1020 cold-drawn steel, which is the
softest metal compared to the alloy-steel shaft and its mounted components, this is to
protect the shaft and the components in the event of mechanical failure. We chose a
condition of cold-drawn steel rather than hot-rolled steel, due to the property of lower
ductility in cold-drawn steel, which is more desired in shaft keys.

Selected metal : SAE 1020 cold-drawn steel

Yield Strength : 352MPa
Ductility (percent elongation in 2 inches) : 15

For our keys, we will be using rectangular keys in the design. The length that we
designed will be 80% of the component hub length, with the dimension rounded up to
the nearest whole number. We will verify the length that we have designed with the
calculated minimum key length value.

8.1 Key 1 : Motor Spindle - Belt Drive Sheave Profile Key

Shaft Diameter : 24mm

Key width : 8mm
Key height : 7mm
Belt drive 140mm sheave length : 25mm
Minimum calculated key length : 1mm

Final key length : 20mm

8.2 Key 2 : Belt Driven Sheave - Shaft 1

Shaft Diameter for belt driven sheave : 30mm

Groove width : 8mm
Key height : 7mm
Belt drive 400mm sheave length : 32mm
Minimum calculated key length : 1.321mm

Final key length : 26mm

8.3 Key 3 : Shaft 1 - Chain 1 Driver

Shaft Diameter for driver chain : 30mm

Groove width : 8mm
Key height : 7mm
Chain 1 driver length : 22mm
Minimum calculated key length : 1.321mm

Final key length : 18mm

33
8.4 Key 4 : Chain 1 Driven - Shaft 2

Shaft Diameter for driven chain : 30mm

Groove width : 8mm
Key height : 7mm
Chain 1 driven sprocket length : 32mm
Minimum calculated key length : 3.726mm

Final key length : 26mm

8.5 Key 5 : Shaft 2 - Chain 2 Driver

Shaft Diameter for driver sprocket : 30mm

Groove width : 8mm
Key height : 7mm
Chain 2 driver sprocket length : 22mm
Minimum calculated key length : 3.726mm

Final key length : 18mm

8.6 Key 6 : Chain 2 Driven - Roller 1

Shaft Diameter for driven sprocket : 30mm

Groove width : 8mm
Key height : 7mm
Chain 2 driven sprocket length : 32mm
Minimum calculated key length : 3.726mm

Final key length : 26mm

8.7 Key 7 : Roller 1 - Spur Gear 1

Shaft Diameter for spur gear : 16mm

Groove width : 5mm
Key height : 5mm
Spur gear length : 31mm
Minimum calculated key length : 12.9mm

Final key length : 25mm

8.8 Key 8 : Spur Gear 2 - Roller 2

Shaft Diameter for spur gear : 16mm

Groove width : 5mm
Key height : 5mm
Spur gear length : 31mm
Minimum calculated key length : 12.9mm
Final key length : 25mm

34
 9. Mechanical Assembly

Assembled machine 3D views and close-up views with drive and gear housings set to
wireframe view :

35
36
Assembled CAD View :

Critical Designed Dimensions :

37
 9.1 BOM List

Enlarged BOM LIst

38
Appendix E2.1 (Shaft 1 diagrams)

39
Appendix E2.2 (Shaft 2 diagrams)

40
Appendix E2.3 (Roller shaft 1 diagram)

41
42
43
Appendix E2.4 (Roller shaft 2 diagram & ASME design equation table)

44
45
46
Appendix H (Component Cad Diagrams)

V-Belt Drive

47
Chain Drive 1

48
Chain Drive 2

49
Motor

Belt Drive

50
Chain Drive 1

Chain Drive 2

51
Shaft 1

Shaft 2

Roller 1

52
Roller 2

53