Project #14 Design of A Tranmission System For Industrial Blender

HCMC UNIVERSITY OF TECHNOLOGY - VNU HCM
FACULTY OF MECHANICAL ENGINEERING

DEVISION OF MACHINE DESIGN
DESIGN PROJECT
(ME3139)
Semester 2/Academic year 2023-2024
PROJECT #14
DESIGN OF A TRANMISSION SYSTEM FOR
INDUSTRIAL BLENDER
Data No: 9
Student: Tô Xuân Bình

Student ID: 2052885
Advisor: Assoc.Prof.Dr. Lê Thanh Long
Ho Chi Minh City, .../2024

DESIGN OF A TRANMISSION SYSTEM FOR INDUSTRIAL BLENDER HCMC UNIVERSITY OF TECHNOLOGY - VNU HCM
FACULTY OF MECHANICAL ENGINEERING
DEVISION OF MACHINE DESIGN
DESIGN PROJECT
THIẾT KẾ HỆ THỐNG DẪN ĐỘNG

THÙNG TRỘN
Phương án số: 9
DESIGN OF A TRANMISSION SYSTEM FOR

INDUSTRIAL BLENDER
Data No: 9
Student: Tô Xuân Bình

Student ID: 2052885
Advisor: Assoc.Prof.Dr. Lê Thanh Long
.../2024
Ho Chi Minh City, .../2024

INTRODUCTION
Creating, advancing, and optimizing systems for mechanical power transfer consistently pose
fundamental challenges within the mechanical engineering realm. It is evident that a progressive
industry cannot thrive without a contemporary foundation in mechanical engineering.
Consequently, the task of designing and enhancing power transmission systems stands as a
pivotal aspect in the ongoing processes of industrialization and modernization within the country.
In our day-to-day experiences, encounters with power transmission systems are ubiquitous, and it
can be asserted that a gearbox plays an indispensable role in discussions regarding the
functionality of such systems.
The project on mechanical system design provides mechanical engineering students with the
opportunity to delve into and craft a gearbox. This, in turn, fortifies the knowledge acquired in
courses such as Material Strength, Machine Components, Technical Drawing, AutoCAD,
offering students a holistic understanding of the mechanical design process by involving the
creation of external transmissions, gears, shafts, roller bearings, etc.
I express sincere gratitude to Assoc.Prof.Dr. LÊ THANH LONG for providing substantial
assistance throughout the execution of this project. Given the constraints of limited knowledge,
errors become unavoidable, and I earnestly anticipate feedback from the professor to further
enhance my understanding.
Candidate executed
Tô Xuân Bình
5
TABLE OF CONTENTS
INTRODUCTION...............................................................................................................................................
TABLE OF CONTENTS....................................................................................................................................
LIST OF FIGURES............................................................................................................................................
LIST OF TABLES..............................................................................................................................................
CHAPTER 1: SELECT PROPER ELECTRIC MOTOR AND DISTRIBUTE VELOCITY
RATIO FOR THE TRANSMISSION SYSTEM...........................................................................................
1.1 Select proper electric motor................................................................................................................
1.2 Distribute velocity ratio......................................................................................................................
CHAPTER 2: DESIGN V-BELT.....................................................................................................................
CHAPTER 3: DESIGN TRANSMISSION IN GEAR BOX.........................................................................
3.1 Design bevel gear................................................................................................................................
3.2 Design helical gear..............................................................................................................................
3.3 Lubrication and oil immersion tests....................................................................................................
CHAPTER 4: SHAFT DESIGN......................................................................................................................
4.1 Design shaft I......................................................................................................................................
4.2 Design shaft II.....................................................................................................................................
4.3 Design shaft III....................................................................................................................................
CHAPTER 5: KEY TESTING........................................................................................................................
5.1 Shaft testing.........................................................................................................................................
5.2 Key testing..........................................................................................................................................
CHAPTER 6: DESIGN ROLLER BEARINGS AND COUPLINGS..........................................................
6.1 Shaft I..................................................................................................................................................
6.2 Shaft II.................................................................................................................................................
6.3 Shaft III...............................................................................................................................................
6.4 Design couplings.................................................................................................................................
CHAPTER 7: GEAR BOX DESIGN..............................................................................................................
7.1 Gearbox design...................................................................................................................................
7.2 Components details.............................................................................................................................
7.3 Choosing lubricating oil and mounting tolerances..............................................................................
CHAPTER 8: FITTING AND TOLERANCE...............................................................................................
8.1 Select manufacturing precision grade.................................................................................................
8.2 Select mounting type...........................................................................................................................
6
8.3 Fitting tolerance table of gear and key................................................................................................
REFERENCES.............................................................................................................................59
7
LIST OF FIGURES
Figure 4.1: Moment diagram of shaft I..........................................................................................34
Figure 4.2: Moment diagram of shaft II........................................................................................38
Figure 4.3: Moment diagram of shaft III.......................................................................................41
Figure 7.1: Shape and dimension of the visitor door.....................................................................54
Figure 7.2: Shape and dimension of the dowel pin........................................................................54
Figure 7.3: Shape and dimension of the air vent button................................................................55
Figure 7.4: Shape and dimension of the oil drain plug..................................................................55
Figure 7.5: Oil check stick.............................................................................................................56
Figure 7.6: Oil seal.........................................................................................................................56
8
LIST OF TABLES
Table 1.1: Motor specifications.....................................................................................................11
Table 1.2 Transmission ratio calculations......................................................................................12
Table 3.1: Bevel gears specifications............................................................................................22
Table 3.2: Helical gears specifications..........................................................................................29
Table 5.1: Key dimension on each shaft........................................................................................43
Table 5.2: Key safety coefficients on each shaft...........................................................................44
Table 5.3: Static durability on each shaft......................................................................................44
Table 5.3: Key testing on each shaft..............................................................................................45
Table 6.1: Bearings specifications on shaft I.................................................................................46
Table 6.2: Bearings specifications on shaft II................................................................................48
Table 6.3: Bearings specifications on shaft III..............................................................................49
Table 6.1: The basic dimensions of the torsion spring coupling...................................................50
Table 6.2: The fundamental dimensions of the torsion spring......................................................50
Table 7.1: Gear box specifications................................................................................................53
Table 7.2: Plane bearings size........................................................................................................54
Table 7.3: Visitor door specifications............................................................................................54
Table 7.4: Vent button specifications............................................................................................55
Table 7.5: Oil drain plug specifications.........................................................................................55
Table 8.1: Table of fitting tolerances of gears and keys ...............................................................58
9
RATIO FOR THE TRANSMISSION SYSTEM
1.1 Select proper electric motor
1.1.1 Select the system efficiency
Efficiency of helical gear: ηhelical gear =0.97
Efficiency of bevel gear: ηbevel gear =0.96
Efficiency of V-belt: ηV −belt =0.96
Efficiency of bearings: ηbearings =0.99
Efficiency of coupling: η coupling =0.99
4 4
η=ηcoupling∗ηV −belt ∗ηhelical gear∗ηbevel gear∗η bearings =0.99∗0.96∗0.97∗0.96∗0.99 =0.85
1.1.2 Calculate the required power
Due to the load variation with levels, we have:
√ ( )
n
Ti 2
∑ ∗t i
Ptd =P∗ 1 T
n
∑ ti
√
≈ 6.1∗
12∗19+0.62∗14
19+14
=5.21(kW )
Peq 5.21
Pct = = =6.13 (kW )
η 0.86
1.1.3 Preliminary rotation speed
According to table 2.4 [1], we choose
Preliminary transmission ratio of helical gear: uhelical gear=3
Preliminary transmission ratio of bevel gear: ubevel gear =3.3
Preliminary transmission ratio of V-belt: uV −belt =5
Preliminary transmission ratio of coupling: ucoupling =1
Preliminary transmission ratio of the system:
u sb=uV −belt ∗ubevel gear∗uhelical gear∗u coupling =5∗3.3∗3∗1=49.5
Preliminary rotation speed of motor shaft:
n sb =n∗usb =47∗49.5=2326.5(rpm)
1.1.4 Select motor
Choose an electric motor satisfying the conditions
10
{P dc ≥ P ct =6.13(kW )
ndc ≈ n sb=2326(rpm)
From table P1.3 [1] select motor: 4A112M2Y3
Table 1.1: Motor specifications

T max TK
Pdc (kW ) n dc (rpm) cosφ η%
T dn T dn
7.5 2922 0.88 87.5 2.2 2.0
1.2 Distribute velocity ratio

1.2.1 New transmission ratio of the system
ndc 2922
u sys= = ≈ 62.17
n 47
With:
uV −belt =5
uhelical gear=3
ubevel gear =4.1
ucoupling =1
1.2.2 Rotation speed on each shaft:
Shaft between V-belt drive and bevel gear is I.
Shaft between bevel gear and helical gear is II.
Shaft between helical gear and coupling is III.
Shaft between coupling and blender is IV (Working shaft).
n dc=2922( rpm)
n dc 2922
nI= = =584.4 (rpm)
uV −belt 5
nI 584.4
n II = = =142.53( rpm)
ubelvel gear 4.1
nII 142.53
n III = = =47.51(rpm)
n helical gear 3
n III 47.51
n IV = = =47.51(rpm)
u coupling 1
1.2.3 Power on each shaft
P IV =P=6.1(kW )
11
P IV 6.1
P III= = =6.22(kW )
ηbearings ∗ηcoupling 0.99∗0.99
P III 6.22
P II = = =6.48(kW )
ηbearings∗ηhelical gear 0.99∗0.97
PII 6.48
P I= = =6.82(kW )
ηbearings∗η bevel gear 0.99∗0.96
PI 4.42
Pdc = = =7.18(kW )
ηbearings∗η V −belt 0.99∗0.96
1.2.4 Torque on each shaft
6
9.55∗10 ∗Pdc 9.55∗106∗7.18
T dc = = =23466.46(N . mm)
ndc 2922
6
9.55∗10 ∗PI 9.55∗106∗6.82
T I= = =111449.35( N .mm)
nI 584.4
6
9.55∗10 ∗P II 9.55∗106∗6.48
T II = = =434182.28(N . mm)
n II 142.53
6
9.55∗10 ∗P III 9.55∗106∗6.22
T III = = =1250284.15 ( N .mm)
n III 47.51
6
9.55∗10 ∗P IV 9.55∗106∗6.1
T IV = = =1226162.91( N . mm)
n IV 47.51
Table 1.2: Transmission ratio calculations
Motor I II III Working shaft
P(kW) 7.81 6.82 6.48 6.22 6.1
u uV −belt =5 ubevel gear =4.1 uhelical gear=3 ucoupling =1
n(rpm) 2922 584.4 142.53 47.51 47.51
T(N.mm) 23466.46 111449.35 434182.28 1250284.15 1226162.91
12
CHAPTER 2: DESIGN V-BELT
2.0.1 Parameters
Specifications for designing a V-belt transmission.
Transmitter power: P = 7.81 kW
Transmission ratio uV −belt =5
Number of revolutions n1 = 2922 rpm
2.0.2 Belt transmission design calculations
According to the figure, choose belt type A
According to table 4.13 [1] choose a small belt diameter according to the standard d1 =180mm
Belt velocity:
π × d 1 ×n 1 π × 180 ×2922
v= 4
= 4
=27.54 m/ s
6 ×10 6 ×10
Large belt wheel diameter
Choose ξ = 0,01
d 2=u V −belt ×d 1 ( 1−ξ )=5 ×180 ( 1−0 , 01 )=891 mm
According to table 4.21 [1] select standard diameter, choose d2 = 900mm
d2 900
ut = = =5.05
d 1 (1−ξ ) 180 ×(1−0 , 01)
Deviation from the initial value
|ut −uV −belt| |5.05−5|

∆ u= ×100= ×100=1%
uV −belt 5
Preliminary selection of axis distance a = 1× d2 = 900 mm
Belt length by axis distance a
π ( d 2 +d 1 ) ( d2 −d 1 )2 π ( 900+180 ) ( 900−180 )2
l=2 a+ + =2∗900+ + =3640.46 mm
2 4a 2 4∗900
According to table 4.13 [1] select the standard belt length L = 4000 mm
Test the number of laps in 1 second
13
v 27.54
i= = =6.885< 10→ accept
l 4
Recalculated a according to standard length L = 4000mm
λ=4000−0.5 π ( 900+180 )=2303.54
d 2−d 1 900−180
∆= = =360
2 2
λ+ √ λ2 −8 ∆2 2303.54+ √ 2303.54 2−8∗3602

According to formula 4.6 [1]: a= = =1092.45 mm
4 4
According to formula 4.7 [1], contact angel:
57 × ( d 2−d 1 ) 57 × ( 900−180 ) °
α 1=180− =180− =142.43 >α min =120°
a 1092.45
Determination of belt number: according to formula 4.16 in [1]
P1 K d 7.81 ×1 , 1
z= = =1.58
[ P0 ]C α C l C u C z 4 , 46 × 0 ,94 ×1.2 ×1 ,14 ×0 , 95
According to table 4.7 [1], choose Kđ = 1,1

°
α 1=153 ⇒C α =0 , 94 (table 4.15 [1])
l 4000
= =2.35 ⇒Cl =1.2(table 4.16 [1])
l 0 1700
u=5⇒ Cu=1, 14 ¿
v=27.54 m / s ; d 1=180 mm ⇒ [ P 0 ] =4 , 06 kW (table 4.19[1])
P1
7.81
[ P¿¿ 0]= =1.75 ≈ 2=¿ C z =0 , 95(table 4.18[1])¿
4.46
⇒ Z=2
Belt pulley width, according to 4.17 and table 4.21 [1]
B=( z−1 ) t+ 2 e= ( 2−1 ) ×15+2 ×10=35 mm
Outer diameter of the pulleys:
d a 1=d 1+2 h0 =180+2 ×3.3=186.6 mm
14
d a 2=d 2+2 h 0=900+2 ×3.3=906.6 mm
Determination of the initial tension and the force acting on the shaft:
780 P1 K d 780 ×7.81 ×1.1

According to 4.19 [1]: F 0= + F v= + 80.22=209.18 N
v Cα z 27.64 ×0 , 94 ×2
With: F v =q m × v 2=0,105× 27.64 2=80.22 N (Table 4.22)
According to 4.21 [1] force acting on the shaft:
15
( )
α1
( )
°
142.43
F r=2 F 0 zsin =2 ×209.18 × 2× sin =792CHAPTER 3: DESIGN
2 2
TRANSMISSION IN GEAR BOX
3.1 Design bevel gear
3.1.1 Specification
Power: P1=6.82 kW
Torque: T =111449.35 N . mm
Number of revolutions: n1=584.4 rpm
Transmission ratio: u=4.1
Service life: 6 years
One-directional rotations, two shifts, low impact loading (187 days of working per year, 8 hours
per shift)
Load mode: T1 = T; t1 = 19s; T2 = 0.6T; t2 = 14s
3.1.2 Choose material
We choose the material for the pair of bevel gear as follows:

Small gear: steel C45 improved, annealing at HB 1=245 ; σ b =850 MPa ; σ ch 1=580 MPa
1
Big gear: steel C45 improved, annealing at HB 2=230 ; σ b =750 MPa ; σ ch 2=450 MPa
2
3.1.3 Determine allowable stress

Preliminary calculation of bending stress and allowable contact stress according to the formulas
6.1a and 6.1b [1] we have:
° °
σ ×K σ ×K × K
[ σ H ]= HlimS HL ; [ σ F ]= Flim S FL FC ;
H F
Where: σ F lim ¿ , σ
0
¿: respectively are bending stress and contact stress allowing base cycle, their
H lim ¿ 0 ¿
values are founded at table 6.2: σ ¿ ¿

S F , S H : respectively are safety coefficient when calculating bending and contacting searched in
table 6.2: S F=1 , 75 , S H =1 , 1
Therefore,
0
σ H lim 1=2 ×245+ 70=560 MPa
0
σ F lim 1=1.8 ×245=441 MPa
0
σ H lim 2=2 ×230+ 70=530 MPa
0
σ F lim 2=1.8 ×230=414 MPa
16
K Fc: coefficient affects the load, take K Fc=1 (Load is put on one side)
K HL , K FL: Age coefficient, determined by formula (6.3) and (6.4) [1]:
17
CHAPTER 3: DESIGN TRANSMISSION IN GEAR BOX
K HL=
mH
√ N HO
N HE
; K FL =
m N FO
N FE √
F
Where:
m H , mF : the degree of the curve in each time contacting and bending with HB <350, take:
m H =6 , mF =6
N FO , N HO: the number of cycles changing stress when try bending and contacting.
6
N FO=4 ×10 (cycles) with all type of steel
{
7
2.4 N HO =1 , 6 ×10 (cycles)
N HO=30 H HB ⟹ 1
N HO =1 , 4 ×107 (cycles)
2
N HE , N FE : number of cycles changing stress

Because the system works in load mode changing at many degrees, according to the formula 6.7
and 6.8 [1], we have:
( ) ( )
3 mF
Ti Ti
N HE=60 c ∑ × ni ×t i ; N FE=60 c ∑ ×ni ×t i
T T
With c is the number of times they fit in a rotation of pulley, c=1 ; ni , t i : the number of cycles and
time in hour working in mode i
We have:
N HE 2=60 ×1 ×142.53 × ( 8× 2× 187 ×6 ) × 1 × ( 3 19

19+14
3
+0.6 ×
14
19+14 ) 7
=10.2 ×10 > N HO 1
⇒ K HL1=K HL2=1
N FE 2=60 ×1 ×142.53 × ( 8 × 2× 187 ×6 ) × 16 × ( 19

19+ 14
+0.66 ×
14
19+14 )
=9.1 ×10 7> N HO 2
⇒ K FL1=K FL2=1
σ H lim ¿ × k 0
560 ×1 σ H lim ¿ ×k
0
530 ×1
So, [ σ H 1 ] = HL
= =509.09 ( MPa ) ; [ σ H 2 ]= HL
= =481.82 ( MPa ) ¿¿
SH 1,1 SH 1 ,1
With bevel gear due to formula 6.12 [1], we have
[ σ H ]=min ( [ σ H 1 ] , [ σ H 2 ])=481.82(MPa)
0 0
σ F lim 1 × K FC × K FL 441× 1× 1 σ F lim 2 × K FC × K FL 414 × 1× 1
[σ F1]= SF
=
1 ,75
=252 ( MPa ) ; [ σ F 2 ]=
SF
=
1 , 75
=236.5 ( MPa )
Maximum allowable stress, due to formula 6.10 and 6.11 [1], we have:
[ σ H ]max =2 ,8 σ ch =2 , 8 × 450=1260 (MPa)
2
[ σ F 1 ]max =0 , 8 σ ch =0 , 8 ×580=464 (MPa)

1
17
[ σ F 2 ]max =0 , 8 σ ch =0 , 8 × 450=360 (MPa)

2
3.1.4 Determine the outer cone length.

According to formula 6.52a [1], we have:
√
T 1 ×k Hβ
Re =k R × √ u +1 × 3
2
2
(1−k be )× k be × u× [ σ H ]
Which:
k R=0 ,5 × k d : The coefficient depends on the gear material and tooth type, with straight tooth
1 1
bevel gear: K =100 ( MPa ) 3 =¿ k =0 , 5× 100=50 ( MPa )3
d R
u: Fast transmission ratio of the gear reducer, u = 5

T1: Torque on the driving shaft (T1=111449.35 N.mm)
Kbe: Ring width coefficient, take Kbe = 0.285
K Hβ : The coefficient accounts for the uneven load distribution across the rim width table 6.21 [1]
with:
K be ×u 0.285 ×5
= =0 ,8 , Because the shaft is mounted on a cylindrical bearing, we take
2−K be 2−0.285
K Hβ=1.13
 Re =50 × √ 4.12+1 × 3
√ 111449.35× 1.13
(1−0.285)× 0.285 ×4.1 × 481.822
=182.72mm
3.1.5 Determine matching parameters

The outer diameter of the driving bevel gear is determined according to formula 6.52b [1]:
√
T 1 × K Hβ 2 × Re 2× 182.72
d e 1=K d 3 = = =86.59 mm
(1−K be )× K be ×u × [ σ H ]
2
√u +1
2
√ 4.12 +1
Looking up table 6.22 [1], we have z 1 p=17 with HB<350=¿ z 1=1 , 6× z 1 p =1 ,6 × 17=27.2 teeth
Average diameter and average modulus of small bevel gear:
d m 1=( 1−0 , 5 × K be ) × d e1= ( 1−0 , 5 ×0,285 ) ×86.59=74.25 mm
d m 1 74.25
mtm= = =2.73 mm
z1 27.2
The outer ring module is determined according to formula 6.5 [1]:
mtm 2.73
mte= = =3.18 mm
1−0 ,5 K be 1−0 ,5 × 0.285
According to table 6.8 [1], take the standard mte=3 mm so:
mtm=mte × ( 1−0 ,5 × K be ) =3 × ( 1−0 , 5 ×0,285 )=2 , 6 mm
18
d m 1 74.25
z 1= = =28.56 take z 1=29 teeth
mtm 2.6
z 2=u1 × z 1=4.1 ×29=118.9 take z 2=119 teeth
z 2 119
So, the actual gear ratio: u1= = =4.1
z 1 29
Split taper angle:
δ 1=arctan
()
z1
z2
=arctan
29
119 ( )
=13.69
°
°
δ 2=90−13.69=76.31
The average diameter of the small bevel gear:
d m 1=z 1 ×mtm=29 ×2 , 6=75.4 mm
Outer taper length:
Re =0 , 5 ×mte × √ z 21 + z 22=0 , 5× 3.18 × √ 292 +1192=194.74 mm
3.1.6 Teeth testing for contact strength
√ 2 ×T 1 × K H × √ u +1
2
According to formula 6.33 [1], we have: σ H =Z M × Z H × Z ε × 2
≤[σ ¿¿ H ]¿
0 , 85 b d m 1 u
Where:
Z M : The coefficient refers to the mechanical properties of the gear, according to table 6.5 [1], we
1
have Z =274 MPa 3
M
z ε : The coefficient refers to the match of teeth, determined by the formula z ε = 4−ε a
3 √
with ε ais the horizontal coefficient of match, calculated by the formula:
ε a=1 , 88−3 , 2
( z1 + z1 ) × cos ( β )=1.74 with β=0
1 2
 Z ε=
√ 4−1 , 74
3
=0 , 87
Z H : The coefficient considers the shape of the contact surface, according to table 6.12 [1] we
have Z H =1 , 6
T 1: Torque on the conduction shaft T 1=111449.35 N . mm
K H : The coefficient of load when calculating about exposure, determined by the formula 6.61 [1]
K H =K Hα × K Hβ × K HV
With:
19
K Hβ: The coefficient refers to the uneven distribution of the load across the tooth width
K Hβ=1 , 13
K Hα: The coefficient refers to the uneven concentration of load between the intake’s teeth K Hα =1
K HV : The coefficient takes into account the influence of dynamic loads, calculated using the
formula 6.63 [1]
v H × b × d m1
K HV =1+
2× T 1 × K Hβ × K Hα
√ d m 1 × ( u+1 ) π d m 1 n π ×85 , 8 ×1050

Which: v H =δ H × g 0 × v × ; with v= 3
= 3
=2.3 m/s
u 60× 10 60 ×10
Due to table 6.13, we choose precision grade is 8
δ H : coefficient about the matching error due to table 6.15 [1], we have δ H =0,006
g0: coefficient about the affection of pitch, take g0=56 due to table 6.16 [1]
 v H =δ H × g 0 × v ×
√ d m 1 × ( u+1 )
b=K be × R e =0,285 ×194.74=55.5 mm

u
=0.006 ×56 ×2.3 ×
√
75.4 ×(4.1+1)
4.1
=7.48 mm
v H × b × d m1 7.48 ×55.5 ×75.4

So we have K HV =1+ =1+ =1.12
2× T 1 × K Hβ × K Hα 2 ×111449.35× 1.13 ×1
 K H =K Hα × K Hβ × K HV =1 ×1.13 ×1.12=1.26

√ 2 ×T 1 × K H × √ u +1
√ 2× 111449.35× 1.26 × √ 4.1 +1
2 2
σ H =Z M × Z H × Z ε × 2
=274 × 1.6 ×0.87 × 2
=395.98 MPa
0 , 85 b d m 1 u 0.85 × 55.5× 75.4 × 4.1
Accurately determine the permissible contact stress
z v : The coefficient refers to the effect of the rotational velocity, with v=2.3 m/s => Z v =1
z R : Coefficient considering surface roughness, with Ra =1 ,25 0 , 63 ( μm) Z R=1
K xH : The coefficient considers the influence of gear size, with d a <700 mm => K xH =1
[ σ H ]=[ σ H ] sys × Z v × Z R × K xH =481 ,82 ×1 ×1 ×1=481 , 82 ( MPa )

We have: σ H < [ σ H ] so durable contact conditions are guaranteed.
3.1.7 Teeth test for overload strength
2 ×T 1 × K F × Y ε ×Y β ×Y F
According to formula 6.65 [1] we have: σ F 1 =
0 , 85 ×b × mtm × d m 1
Which:
K F: The coefficient of load when calculating bending, calculated by the formula 6.71 [1]
20
K F=K Fα × K Fβ × K Fv
With K Fβ is a coefficient that takes into account the uneven set of loads on the width of the tooth
rim, according to table 6.21 [ 1 ] , we have K Fβ=1.92; K Fα is a coefficient that takes into account
the uneven concentration of load between the teeth K Fα=1, K Fv: is a coefficient that takes into
account the influence of dynamic loads, determined by the formula:
v F ×b × d m 1
K Fv =1+
2 ×T 1 × K Fβ × K Fα
With: v F =δ F × g 0 × v ×
δ F =0.016 ; g0 =56
√ d m 1 ×(u+1)
u
, according to table 6.15 and 6.16 [ 1 ] , we have
u
19.95 ×55.5 ×75.4
√
d m 1 ×(u+1)
 v F =δ F × g 0 × v × =0.016 ×56 ×2.3 ×
75.4 ×(4.1+1)
4.1 √=19.95
 K Fv =1+ =1.2
2 ×111449.35 ×1.92 ×1
So K F=K Fα × K Fβ × K Fv =1× 1.92× 1.2=2.304
°
1 1
Y ε= = =0 , 57; Y β=1− β n =1− 0 =1
ε α 1.74 140 140
z1 29 z2 119
z v 1= = =29.85; z v 2= = =502.81
cos ⁡(σ 1 ) cos ⁡(13.69) cos ⁡(σ 2 ) cos ⁡(76.31)
Search in table 6.18 [1] => Y F 1=3 , 8 , Y F 2=3 , 6
2 ×111449.35 ×2.304 × 0 , 57 ×1 ×3 , 8
So σ F 1 = =120.28 MPa
0 , 85× 55.5 ×2 , 6 ×75.4
Y F1 3.8
σ F 2 =σ F 1 × =120.28 × =126.96 MPa
Y F2 3.6
So we can see that: { σ F 1 < [ σ F 1 ] =252 MPa

σ F 2 < [ σ F 2 ] =236.5 MPa
So the flexural strength of the pair of bevel gears is guaranteed

3.1.8 Teeth testing for overload strength
According to formula 6.48 [1] we have: σ Hmax =σ H × √ K qt ≤ [ σ H ] max
T max
With: σ H =395.98 MPa ; K qt = =2, 2
T
So that: σ Hmax =395.98 × √ 2 ,2=587.33 MPa < [ σ H ]max =1260 MPa
σ Fmax =σ F ×k qt ≤ [ σ F ] max
So that:
21
σ Fmax 1=σ F 1 × k qt =120.28× √ 2 ,2=178.4 MPa< [ σ F 1 ]max =464 MPa
σ Fmax 2=σ F 2 × k qt =126.96 × √ 2 ,2=192.76 MPa< [ σ F 2 ]max =360 MPa
22
Table 3.1: Bevel gears specifications

Outer taper length Re =194.74 mm
Outer ring module mte=3.18 mm
Teeth width b w =55.5 mm
Gear ratio u1=4.1
Precision grade 8
The angle of inclination of the °
teeth 0
Number of teeth of the bevel z 1=29 , z 2=119

gears
Tooth height adjustment x 1=0 , x 2=0
coefficient
Outer divider diameter d e 1=mte × z 1=3.18 ×29=92.22 mm
d e 2=mte × z 2=3.18 ×119=378.42 mm
° °
Split taper angle δ 1=13.69 ; δ 2=76.31
Height of external teeth h e=2 h te mte + c with c=0.2 mte ; hte =cos β m with β m=20° ÷ 30 ° , select β m=
Height of the tip of the outer tooth h ae 1=( h te + x n1 cos β m ) mte with x n 1=0.33 ( table 6.20 ) ; β m =25° → hae 1=3.83
h ae 2=2 hte mte−hae 1=1.93 mm
Height of the root of the outer h fe 1=h e−hae 1=6 , 4−3.83=2.57 mm
tooth
h fe 2=h e−hae 2=6 , 4−1.93=4.47 mm
Diameter of the top of the outer d ae 1=d e 1+2 h ae1 cos δ 1=99.66 mm
tooth
d ae 2=d e 2+2 h ae2 cos δ 2=379.33 mm
23
3.2 Design helical gear

3.2.1 Specification
Power: P1=6.48 kW
Torque: T =434182.28 N . mm
Number of revolutions: n1=142.53rpm
Transmission ratio: u=3
Service life: 6 years
One-directional rotations, two shifts, low level load (187 days of working per year, 8 hours per
shift)
Load mode: T1 = T; t1 = 19s; T2 = 0.6T; t2 = 14s
We choose the material for the pair of helical gear:
Small gear: Steel C45 improved, annealing at HB=275 , having σ b =850 MPa; σ CH =580 MPa 1 1
Big gear: Steel C45 improved, annealing at HB=260 , having σ b =850 MPa; σ CH =580 MPa 2 2
3.2.3 Determine allowable stress

According to the formula 6.1a and 6.2a
σ H lim ¿ × k
0 σ F lim ¿ ×k
0
×k Fl
[ σ H ]= SH
Hl
; [ σ F ]=
SF
Fc
¿¿
Where: σ F lim ¿ , σ ¿: respectively are bending stress and contact stress allowing base cycle, their
0
H lim ¿ 0 ¿
values are founded at table 6.2 ¿ [1]: σ ¿ ¿

S F , S H : respectively are safety coefficient when calculating bending and contacting searched in
table 6.2 ¿ [1]: S F=1.75 , S H =1.1
Therefore,
0
σ H lim 1=2 ×275+ 70=550 MPa
0
σ F lim 1=1 ,8 × 275=513 MPa
0
σ H lim 2=2 ×255+ 70=580 MPa
0
σ F lim 2=1 , 8× 275=495 MPa
K Fc: coefficient affects the load, take K Fc=1 (Load is put on one side)
K HL , K FL: Age coefficient, determined by formula 6.3 and 6.4 ¿ [1]:
K HL=
√
mH N HO
N HE
; K FL =
m N FO
N FE √
F
Where:
24
m H , mF : the degree of the curve in each time contacting and bending with HB <350, take:
m H =6 , mF =6
N FO , N HO: the number of cycles changing stress when try bending and contacting
6
N FO=4 ×10 with all type of steel
{
6
2.4 N HO =23.4 ×10
N HO=30 H HB ⟹ 1
N HO =21.5 ×106
2
N HE , N FE : number of cycles changing stress

Because the system works in load mode changing at many degrees, according to the formula 6.7
and 6.8 [1], we have:
( )
3
N HE =60 c ∑
2
Ti
T
3
× ni × t I =60 × 1× 142.53× 17952× 1 ×
19
19+14
3
+0.6 ×
14
19+14 (
=102459594.7 > N HO ) 1
⇒ K HL1=K HL2=1
( ) × n ×t =60 ×1 ×142.35 ×17952 ×(1 × 19+14

mF
Ti 19 14
N FE =60 c ∑
6 6
i i + 0.6 × )=91430133.82> N HO2
2
T 19+14
⇒ K FL1=K FL2=1
σ H lim ¿ × K 0
550 ×1 σ H lim ¿ × k 580 ×1
0
So, [ σ H 1 ] = Hl
= =500 MPa ; [ σ H 2 ] = =Hl
=527.27 MPa ¿ ¿
SH 1,1 SH 1, 1
With helical gear due to formula 6.12 [1] we have:
[ σ H 1 ]+ [ σ H 2 ] 500+527.27
[ σ H ]= 2
=
2
=513.635 MPa ⟹ [ σ H ]< 1, 25 [ σ H 1 ]
0 0
σ × k ×k 513 ×1 ×1 σ ×k ×k 495 ×1 ×1
[ σ F 1 ] = F lim 1 S Fc Fl = 1, 75 =293 ,14 MPa ; [ σ F 2 ]= F lim 2 S Fc Fl = 1 , 75 =282 , 86 MPa
F F
Maximum allowable stress, due to formula 6.13 and 6.14 [ 1 ] , we have:

[ σ H ]max =2 ,8 σ ch =2 , 8 ×580=1624 MPa
2
[ σ F 1 ]max =0 , 8 σ ch =0 , 8 ×580=464 MPa

1
[ σ F 2 ]max =0.8 σ ch =0 , 8 ×580=464 MPa

2
3.2.4 Basic specification of the shaft

Determine basically the shaft distance due to formula 6.15a [1]:
√
T 2 k Hβ
a w =k a × ( u2 +1 ) × 3 2
[ σH ] u2 ψ ba
Where:
25
k a: coefficient depended on the material of gear and type of tooth. Due to table 6.5 [1], we have
1/ 3
k a=43 ( MPa )
T 2; Torque, T 2=434182.28 N . mm
[ σ H ]: Allowable contact stress, [ σ H ]=513,635 MPa

ψ ba=0.3 , due to table 6.6 [1]
k Hβ : coefficient about the unbalanced load distribution over the ring width when the load is in
contact.
According to table 6.7 [1] with ψ bd =0.5 ×ψ ba × ( u ±1 ) =0.5 ×0.3 × ( 3+1 )=0 , 6, we determine
k Hβ =1.03
√
Therefore: a w =43 × ( 3+1 ) × 3
434182.28 ×1.03
513,6352 ×3 ×0.3
=212.41 mmtake a w =213 mm
We have: b w 2=ψ ba × aw =0.3× 213=63.9 mm and b w 1=bw 2 +5=68.9 mm

3.2.5 Determine matching parameters
Due to formula 6.17 [1], we have:
m=( 0 ,01 ÷ 0 , 02 ) × aw =( 0 , 01÷ 0 , 02 ) ×213=2.13÷ 4.26 mm
Due to table 6.8 [1] choose standard module m=2.5 mm
Choose basically β=10 ° , we determine the number of tooth on small pulley:
cos ( β ) cos ⁡( 10)
z 1=2 ×a w × =2 ×213 × =41.95, take z 1=42 teeth
m × ( u+1 ) 2.5 ×(3+1)
z 2=u × z 1=3 × 42=126 teeth
z 2 126
Therefore, the real transmission ratio: u2= = =3
z 1 42
z1 + z2 42+ 126
c os ( β )=m× =2.5 × =0,9859 → β=9.628 °
2× a w 2 ×213
Due to formula 6.18 [1] we calculate again shaft distance:
z 1+ z 2 42+126
a w =m× =2.5× =213 mm
2× cos ( β ) 2 × 0.9859
tan α tan20
Matching angle: α tw =α t=arctan =arctan =20.26 ° wtih α =20 due to table 6.11
cos β cos 9.628
[1]
3.2.6 Testing tooth for contact strength
Due to formula 6.33 [1], contact stress on working surface of tooth is:
26
σ H =Z M Z H Z ε
Where:
√ 2 T 2 K H ( u+1 )
b w u d2w1
Z M : coefficient about mechanical properties of material, due to table 6.5 [1] we have
1
z M =274 MPa 3
Z H : coefficient about the contact shape, following 6.34 [1] we have
ZH=
√ 2cos βb
sin 2 α tw
Where:
β b: inclination angle of teeth on basis cylinder
Due to formula 6.35 [1], we have
tan β b =cos α t × tan β=cos 20.26 ° × tan 9.628° =0.16 → β b =9.09 °
Therefore,
ZH=
√ 2cos ⁡( 9.09)
sin ⁡(2 ×20.28)
=1.74
Z ε: coefficient about tooth matching, determined through formula 6.36c [1]:

sin β sin 9.628°
We have ε β =b w × =63.9× =1.36> 1
πm 2.5 π
So we have Z ε=
√ √
1
εα
=
1
1.36
=0.86
[
While ε α = 1 , 88−3 , 2 ( z1 + z1 )] × cos β=[1.88−3.2( 421 + 1261 )] ×cos 9.628 °=1.75
1 2
Pitch diameter of small pulley:

aw 213
d w 1=2 × =2 × =106.5 mm
u+1 3+1
K H : load coefficient when calculating contact, determine through formula 6.39 [1]:
K H =K Hα × K Hβ × K HV
With:
K Hβ: coefficient about the unbalance distribution of load on the width of internal toothing,
searching in table 6.7 [ 1 ] , we have K Hβ=1.03
K HV : coefficient about the affection of flexible load in matching zone, due to formula 6.41 [1],
we have:
27
v H × bw ×d w 1
K HV =1+
2× T 1. × K Hβ × K Hα
Where:
v H =δ H × g 0 × v ×
√ d w1 ( u+1 )
u
δ H : coefficient about the matching error due to table 6.15 [1], we have δ H =0.002
g0: coefficient about the affection of pitch, take g0=73 due to table 6.16 [1]
π d w 1 n1 π ×106.5 ×142.53
v : pitch velocity v= = =0.79 m/ s
60000 60000
Due to table 6.13 [1], we choose the degree of accuracy is 9 => K Hα : The coefficient refers to the
uneven distribution of the load between the pairs of teeth at the same time, choose K Hα =1.13
v H =0.002 ×73 × 0.79×

√ 106.5 × ( 3+ 1 )
3
=1.37
1.37 ×63.9 ×106.5

So: K HV =1+ =1
2× 434182.28 ×1.03 × 1.13
K H =1.13 ×1.03 ×1=1.16
Substituting values to the formula we have:
σ H =274 ×1.74 × 0.86 ×

√ 2 × 434182.28 ×1.1639 × ( 3+1 )
63.9× 3 ×106.52
=558.14 MPa
Determine exactly the contact stress:

With: v< 5 m/ s ⟹ z V =1
Ra =0 , 63÷ 1 , 25 μm z R=1
d a <700 ( mm ) K XH =1
Due to 6.1 and 6.1a [ 1 ] , we have:
[ σ H ]=[ σ H ] sys × z v × z R × K XH =572 ,7 ×1 ×1 ×1=572 ,7 MPa
Because of σ H =558.14 MPa < [ σ H ]=572 , 7 MPa then condition for contact stress is secured. To
calculate simply, choose b w =64 mm
3.2.7 Testing tooth about bending strength
2 ×T 2 × K F × Y ε ×Y β ×Y F 1
Due to formula 6.43 [1], we have: σ F 1 =
bw ×d w 1 × m
Where:
T 2=434182.28 : bending momentum on driving gear, N.mm
m=3 : module
28
b w: width of pitch b w =64 mm

d w 1=106.5 : pitch diameter of driving gear, mm
1 1
Y ε= = =0 , 57 coefficient about the tooth matching (with ε α =1 ,75 )
ε α 1, 75
1−β ° 9.628
Y β= =1− =0.93: coefficient about the inclination
140 140
Y Fi: Coefficient about type of tooth on gear 1 and 2
{
z1 42
z v1= 3
= 3
=43.83
cos β 0,9859
z 126
z v 2= 23 = 3
=131.48
cos β 0,9859
So due to table 6.18 [1] with coefficient of correction x 1=x 2=0

We have: Y F 1=3.7 ; Y F 2=3.6
K F: load coefficient when calculating bending.
K F=K F α × K Fβ × K Fv
K F α =1.37 due to table 6.14 [1]
K Fβ=1.08 due to table 6.7 [1]
v F ×b w × d w 1
K FV =1+
2× T 2 × K Fβ × K Fα
When v F =δ F × g 0 × v ×
√ aw
u
Due to table 6.15 and table 6.16 [1], we have:
δ F =0.006
g0=73
⟹ v F=0.006 ×73 ×0.79 ×

√ 213
3
=2.92
2.92× 64 ×106.5
⟹ K FV =1+ =1.02
2 × 434182.28 ×1.08 ×1.37
⟹ K F =1.37 ×1.08 × 1.02=1 ,51
2 ×434182.28 × 1.51× 0.57 ×0.93 ×3.7
⟹ σ F 1= =125.77 MPa
64 ×106.5 ×3
Y F2 3.6
We have: σ F 2 =σ F 1 × =125.77 × =122.37 MPa
Y F1 3.7
29
Seeing that: {σ F 1 < [ σ F 1 ] =293.14

σ F 2 < [ σ F 2 ]=282.86
Bending stress condition is secured.

3.2.8 Testing overload endurance
According to 6.48 ¿ [1]we have: σ Hmax =σ H × √ K qt ≤ [ σ H ] max
T max
With: σ H =558.14 ( MPa ) ; K qt = =2.2
T
So that:
σ Hmax =558.14 × √ 2.2=827.86 MPa< [ σ H ]max =1624 MPa
σ Fmax =σ F × K qt ≤ [ σ F ]max
So that:
σ Fmax 1=σ F 1 × k qt =125.77 × √ 2 ,2=186.55 MPa < [ σ F 1 ] max =464 MPa
σ Fmax 2=σ F 2 × k qt =122.37 × √ 2 ,2=181.5 MPa< [ σ F 2 ]max =464 MPa
Shaft distance a w =213 mm

Module m=3 mm
Ring width {bw 1=63.9 mm

bw 2=68.9 mm
Speed ratio u=3
Angle of tooth β=9.628 °
Number of tooth z 1=42 ; z 2=126
Coefficient of correction x 1−x 2=0 mm
Accurate levels 9
m z1 3× 42
d 1= = =127.8 mm
cosβ 0.9859
Pitch diameter
m z2 3 ×126
d 2= = =383.4 mm
cosβ 0.9859
d a 1=d 1+2 × m=127.8+2× 3=133.8 mm
Addendum diameter
d a 2=d 2+2 × m=383.4+2 ×3=389.4 mm
d f 1=d a 1−3 × m=105 , 4−3 ×3=124.8 mm
Dedendum diameter
d f 2=d a 2−3 × m=389.4−3 ×3=380.4 mm
Table 3.2: Helical gears specifications
3.3 Lubrication and oil immersion tests
30
Conditions for oil-bath lubrication in bevel-helical gear reducers:

Bevel gears need to be immersed to the entire width of the large gear h in oil
Helical gears need to be immersed to the full tooth height hr and at least 10mm.
1
The highest level of oil is not exceeded R gear 4.
3
The distance between the highest and lowest oil levels: h max−h min=10 ÷ 15 mm
3.3.1 Consider the driven bevel gear
The lowest height of the driven bevel gear that needs to be immersed in oil is:
h2 min =2.25 m=2.25 ×3=6.75 mm<10 mm
1 1 1 1
H 1= d ae 2−10−15= ×379.33−10−15=164.665> d a3 = ×379.33=126.44 mm
2 2 3 3
3.3.2 Consider the driven helical gear
The lowest height of the driven helical gear that needs to be immersed in oil is:
h 4 min =2.25 m=2.25 ×3=6.75 mm<10 mm
1 1 1 1
H 2= d a 4−10−15= ×389.4−10−15=169.7> d a 4 = ×389.4=129.8 mm
2 2 3 3
Due to this, the transmission satisfies lubrication conditions.
31
CHAPTER 4: SHAFT DESIGN
4.1 Design shaft I
4.1.1 Parameters
Torque: T 1=111449.35 N . mm
Number of revolutions: n1=584.4 rpm

Tooth rim width: b w =55.5 mm
Choose steel C45 improved. Parameters:
Durable limit: σ b=600 MPa
Melting limit: σ ch=340 MPa
Permissible torsional stress: [ τ ]=15 ÷ 30 MPa choose [ τ 1 ] =15 MPa
4.1.3 Preliminary selection of diameter
Preliminary calculated diameter:
d 1=
√
3 T1
√
0 , 2× [ τ ]
=
3 111449.35
0 ,2 ×15
=33.37 mm choose standard d 1=35 mm (Table 10.2 ¿ [1])
4.1.4 Roller bearing width

According to table 10.2 ¿ [1], we choose b 1=21 mm
4.1.5 Shaft size outline calculation
l 11= ( 2, 5 ÷ 3 ) d 1=87.5 ÷105 , choose l 11=100 mm
l 13=l 11 +k 1+ k 2+ l m 13+0 , 5 ¿
With
k 1=8 ÷15 ; choose k 1 =15: The distance between the rotating details
k 2=5÷ 15 ; choose k 2=15: Distance from the bearing to the inner wall of the box
l m 13=( 1 , 2÷ 1 , 4 ) d 1=42÷ 49 ; choose l m 13=48 mm : bevel gear mayo length
Choose l 13=162 mm
l 12=−l c 12=−[0 , 5 ( l m12 +b 1) + k 3 +hn ]=−[0 , 5 ( 50+21 ) +15+15]=−65.3 mm
k 3=10 ÷20 ; choose k 3 =15: Distance from the bearing to the bearing hub
h n=15 ÷20 ; choose hn =15: Height of the bearing hub and screw head
l m 12=( 1 ,2 ÷ 1 ,5 ) d 1=42÷ 52.5 ; choose l m 12=50 mm : belt mayo length
Choose l 12=66 mm
31
4.1.6 Force acting on the shaft

Force from driving bevel gear:
2T 1 2 ×111449.35
F t 1= = =3002 N
d m1 74.25
F r 1=F t 1 tan α cos δ 1=3002 × tan 20 °. cos 13.69 °=1061.6 N
F a 1=Ft 1 tan α sin δ 1=3002× tan 20 ° sin 13.69° =258.6 N
Force from belt:
α1
( ) ( )
°
142.43
F r=2 F 0 zsin =2 ×209.18 × 2× sin =792.15 N
2 2
F a 1 × d m 1 258.6 ×74.25
M A 1= = =9600.525 N . mm
2 2
4.1.7 Determination of shaft diameter
Total bending moment at cross sections:
M A 1= √ M 2rx + M 2ry =√ 02 +0 2=0 N .mm
M B 1= √ M 2rx + M 2ry = √ 56219.12 +1861242 =194429.24 N . mm
M C 1=√ M 2rx + M 2ry =√ 52281.9 2+ 02=52281.9 N .mm
M D 1=√ M 2rx + M 2ry =√ 02+ 02=0 N . mm

Equivalent moment at cross sections:
M tA 1=√ M 2A 1 +0 , 75T 21=√ 02 +0 , 75 ×111449.352=96517.97 N . mm
M tB 1=√ M 2B 1+ 0 ,75 T 21=√ 194429.242 +0 ,75 ×111449.352=217067.84 N .mm
M tC 1 =√ M 2C 1 +0 , 75 T 21= √ 52281.92 +0 , 75 ×111449.352=109768.46 N . mm
M tD 1=√ M 2D 1 +0 , 75 T 21= √ 0 2+ 0 ,75 ×111449.35 2=96517.97 N . mm

Diameter of shaft segments
d A1=
√
3
0,1[σ]
=
√
M tA 1 3 96517.97
0 , 1 ×50
=29 , 1 mm Choose d A 1 =30 mm
d B 1=
√
3
0,1[σ]
=
√
M tB 1 3 217067.84
0 ,1 ×50
=35.14 mm Choose d B 1=40 mm
d C 1=
√
3
√
M tC 1 3 109768.46
0 ,1 [ σ ]
=
0 ,1 ×50
=28 mm Choose d C 1=30 mm
d D 1=
√
3
√
M tD 1 3 96517.97
0 ,1 [ σ ]
=
0 ,1 ×50
=29 , 1mm Choose d D 1=30 mm
32
Radial force at the bearing

X B 1=4863.24 N ; Y B 1=2146.61 N
X C 1=1861.24 N ; Y C1 =1877.16 N
33
Figure 4.1: Moment diagram of shaft I
34
4.2 Design shaft II

4.2.1 Parameters
Torque: T 2=434182.28 N . mm
Number of revolutions: n2 =142.53 rpm

Choose steel C45 improved. Parameters:
Durable limit: σ b=600 MPa
Melting limit: σ ch=340 MPa
Permissible torsional stress: [ τ ]=15 ÷ 30 MPa choose [ τ 1 ] =15 MPa
4.2.3 Preliminary selection of diameter
Preliminary calculated diameter:
d 2=
√
3 T2
√
0 , 2× [ τ ]
=
3 434182.28
0 , 2 ×15
=52.5 mm choose standard d 2=55 mm (Table 10.2 [1])
4.2.4 Roller bearing width

According to table 10.2 [1], we choose b 2=29 mm
4.2.5 Shaft size outline calculation
l 22=0 , 5 ( l m 22+b 2 ) +k 1 +k 2=0 ,5 ( 70+ 29 ) +15+15=79 , 5 mm
choose l 22=80 mm
l 23=l 22+ 0 ,5 ¿
Choose l 23=137 mm
l 21=l m 22+l m 23 +b 2+3 k 1+ 2k 2=70+70+29+ 45+30=244 mm
Choose l 21=244 mm
With:
k 1=8 ÷15 ; choose k 1 =15: The distance between the rotating details
k 2=5÷ 15 ; choose k 2=15: Distance from the bearing to the inner wall of the box
l m 22=( 1 ,2 ÷ 1 ,5 ) d 2=66 ÷82.5 ; choose l m 22=70 mm : helical gear mayo length
l m 23=( 1 , 2÷ 1 , 4 ) d 2=66÷ 77 ; choose l m 23=70 mm : bevel gear mayo length

4.2.6 Force applied to the shaft.
The force applied from the driving bevel gear:
35
F t 2=F t 1=3002 N
F a 2=F r 1=1061.6 N
F r 2=F a 1=258.6 N
Fa 2 d m 2 1061.6 × 304.425
M 2= = =161588.79 N . mm
2 2
The force applied from the driving helical gear:
2T 2 2× 434182.28 Ft 3 tan α tw 6794.71 × tan 20.26 °
F t 3= = =6794.71 N F r 3= = =2543.88 N
dw 3 127.8 cos β cos 9.628 °
F a 3=F t 3 tan β=6794.71 × tan 9.628° =1152.65 N
F a3 d m 3 1152.65×127.8
M 3= = =73654.34 N . mm
2 2
4.2.7 Determination of shaft diameter:
M A 2= √ M 2rx + M 2ry =0 N . mm
M B 2= √ M 2rx + M 2ry= √ 228927.14 2+ 485435.22=536707.53 N . mm
M C 2=√ M 2rx + M 2ry =√ 203602.42 +454910.86 2=498395.25 N . mm
M D 2=√ M 2rx + M 2ry =0
Equivalent moment at cross sections
M tdA 2=√ M 2A 2+ 0 ,75 T 2A 2= √ 0 2+0.75 × 434182.282=376012.88 N . mm
M tdB2 =√ M 2B 2+ 0 ,75 T 2B 2= √ 536707.532 +0 , 75 × 434182.282=655317.22 N .mm
M tdC 2= √ M 2C 2 +0 , 75T 2C 2=√ 498395.25 2+ 0 ,75 × 434182.282=624326.45 N . mm
M tdD 2=√ M 2D 2 +0 , 75 T 2D 2=√ 02 +0.75 × 434182.282=376012.88 N . mm
d A 2=
√
3
0,1[σ]
=
√
M tA 2 3 376012.88
0 , 1× 50
=42.21mm Choose d A 2=45 mm
d B 2=
√
3
0,1[σ]
=
√
M tB 2 3 655317.22
0 , 1× 50
36
d C 2=
√
3
√
M tC 2 3 624326.45
0 ,1 [ σ ]
=
0 ,1 ×50
=49.98 mm Choose d C 2=50 mm
d D 2=
√
3
√
M tD 2 3 376012.88
0 ,1 [ σ ]
=
0 ,1 ×50
=42.21 mm Choose d D 2=45 mm
X A 2=6067.94 N N ; Y A 2=1940.91 N
X D 2=3728.77 N ; Y D 2=344.37 N
37
Figure 4.2: Moment diagram of shaft II
38
4.3 Design shaft III

4.3.1 Parameters
Torque: T 3=250284.15 N . mm
Number of revolutions: n3 =47.51 rpm
Choose steel C45 improved. With parameters:
Durable limits: σ b=600 MPa
Melting limits: σ ch=340 MPa
Allowable torsional stress: [ τ ]=15 ÷ 30 MPa choose [ τ 3 ] =30
4.3.3 Preliminary selection of diameter:
Preliminary calculation diameter: d 3= 3

√ T3
0,2[τ]
=
√3 1250284.15
0 , 2× 30
=59.29 mm
Choose d 3=60 mm according to standard (Table 10.2 [1])

4.3.4 Roller bearing width:
According to table 10.2 in [1] choose b 3=31 mm
4.3.5 Shaft size outline calculation:
l 31=l 21=244 mm
l 33=l 31−l 22=244−80=164 mm
l 32=−l c 32=−[ 0 , 5× ( l m 32+ b3 ) +k 3 + hn ]=−( 0 ,5 ( 100+31 ) +15+15 )=−95 ,5 mm
Choose l 32=96 mm
With:
k 3=10 ÷20 ; choose k 3 =15: Distance from the bearing to the bearing hub
h n=15 ÷20 ; choose hn =15: Height of bearing hub and screw head
l m 32=( 1 , 4 ÷ 2 ,5 ) d 3=84 ÷ 150 mm ; choose l m 32=100 mm : coupling length
4.3.6 Force applied on the shaft
Force applied from the driven helical gear
F t 4 =Ft 3=6794.71 N
F r 4 =F r 3 =2543.88 N
F a 4=F a 3=1152.65 N
F a 4 d m 4 1152.65× 383.4
M a4= = =220963.005 N . mm
2 2
39
Force applied from the coupling

2 T3 2×1250284.15
F nt =0 , 2. Ft =0 , 2. =0 ,2. =2500.57 N
Dt 200
4.3.7 Determination of shaft diameter:
M A 3= √ M 2rx + M 2ry =0 N . mm
M B 3 =√ M 2rx + M 2ry= √ 209232.82 + 444060.82=490885.28 N . mm
M C 3=√ M 2rx + M 2ry =√ 02 +2400532=240053 N . mm
M D 3=√ M 2rx + M 2ry =0 N .mm

Equivalent moment at cross sections
M tA 3=√ M 2A 3 +0 , 75 T 2A 3=√ 02 +0.75 ×250284.152 =216752.43 N . mm
M tB 3=√ M 2B 3 +0 , 75 T 23= √ 490885.282 +0.75 ×250284.152=536609.7 N . mm
M tC 3 =√ M 2C 3 +0 , 75 T 23 =√ 2400532+ 0 ,75 × 250284.152=323430.15 N . mm
M tD 3=√ M 2D 3 +0 ,75 T 2D 3 =√ 02+ 0.75 ×250284.152=216752.43 N . mm

d A3=
√
3
0,1[σ]
=
√
M tA 3 3 216752.43
0 , 1 ×50
=35.13 mm Choose d A 3 =40 mm
d B 3=
√
3
0,1[σ]
=
√
M tB 3 3 536609.7
0 ,1 ×50
d C 3=
√
3
√
M tC 3 3 323430.15
0 , 1[ σ ]
=
0 ,1 ×50
=40.14 mm Choose d C 3=45 mm
d D 3=
√
3
√
M tD 3 3 216752.43
0 ,1 [ σ ]
=
0 ,1 ×50
=35.13 mm Choose d D 3=40 mm

X A 3=5550.76 N ; Y A 3=2615.41 N
X C 3 =1256.62 N ; Y C 3=71.53 N
40
Figure 4.3: Moment diagram of shaft III
41
CHAPTER 5: KEY TESTING
5.1 Shaft testing
5.1.1 Test for fatigue strength
s σj . s τj
s j= ≥[s]
√s 2
σj
2
+ s τj
Chọn [ s ] =3 : permissible safety factor, such as no need to check the stiffness of the shaft
Which:
σ −1
sσj =
K σdj σ aj +ψ σ σ mj
τ−1
sτj =
K τdj τ aj +ψ τ τ mj
With:
+ Permissible bending fatigue limit of carbon steel:
σ −1=0,436 × σ b=0,436 ×600=261.6 MPa
+ Torsional fatigue limit:
τ −1=0 , 58 ×σ −1=0 , 58× 261 ,6=151.75 MPa
+ For the axis of rotation, the bending stress varies with symmetrical cycles
σ mj=0
Mj
σ aj =σ maxj =
Wj
+ Which:
M j =√ M 2xj + M 2yj
W j: Bending resistance moment, calculated in table 10.6 [1]
+ 1-way rotary drive:
τ maxj Tj
τ mj=τ aj = =
2 2W0 j
With:
τ j: torque at cross section j
W 0 j: torsional resistance torque, in table 10.6 [1]
+ Coefficient of influence of average value on fatigue strength, table 10.7 [1]
42
Kσ Kτ
+ K x −1 + K x −1
ψ σ =0 , 05 ; ψ τ =0+Coefficient: εσ ετ
K σdj = ; K τdj=
Ky Ky
With:
K x =1 ,06 : The stress concentration coefficient due to the surface state is turned with roughness
Ra =2 ,5 ÷ 0 , 63 Durable limit application.
K y =2: The shaft surface is enhanced by carbon impregnation.
K σ =1 , 76 ; K τ =1, 54 : Shaft with a key groove cut with a finger milling cutter
ε σ ; ε τ : Check in table 10.10 [1]
Table 5.1: Key dimension on each shaft
Detail’s Diamete W j (mm)3 W 0 j (mm)3
b h t1
section r
A1 30 10 8 5 1609.05 4259.77
B1 40 12 x x 4445.68 10728.87
C1 30 10 x x 1609.05 4259.77
D1 30 x x x 1609.05 4259.77
A2 45 14 9 5.5 6276.41 15222.59
B2 50 x x x 9222.26 21494.11
C2 55 16 10 6 12142.99 28476.82
D2 45 14 9 5.5 6276.41 15222.59
A3 40 12 8 5 4445.68 10728.87
B3 50 14 9 5.5 9222.26 21494.11
C3 45 x x x 6276.41 15222.59
D3 40 12 8 5 4445.68 10728.87
43
Table 5.2: Key safety coefficients on each shaft
Detail’s K σ /ε σ K τ /ε τ
d(mm) K σd K τd Sσ Sτ S
section keyway fit keyway fit
A1 30 2.070588 2.06 1.97436 1.64 1.06529 1.01718 x 10.8536 x
B1 40 2.17284 2.06 2.02632 1.64 1.11642 1.04316 7.24838 24.2128 6.94391
C1 30 2.070588 2.06 1.97436 1.64 1.06529 1.01718 18.4038 12.7136 10.4603
D1 30 2.070588 2.06 1.97436 1.64 1.06529 1.01718 x 10.8536 x
A2 45 2.227848 2.52 2.05333 2.03 1.14392 1.05667 x 9.75523 x
B2 50 2.25641 2.52 2.08108 2.03 1.15821 1.07054 2.85496 10.7612 2.7595
C2 55 2.227848 2.52 2.05333 2.03 1.14392 1.05667 2.69332 8.50313 2.5676
D2 45 2.227848 2.52 2.05333 2.03 1.14392 1.05667 x 9.75523 x
A3 40 2.410959 2.52 2.16901 2.03 1.23548 1.11451 x 9.8692 x
B3 50 2.478873 2.52 2.16901 2.03 1.26944 1.11451 10.6966 11.0869 7.69792
C3 45 2.410959 2.52 2.16901 2.03 1.23548 1.11451 x 9.8692 x
D3 40 2.410959 2.52 2.16901 2.03 1.23548 1.11451 x 9.25647 x
Thus, the shafts satisfy the shaft fatigue conditions.

5.1.2 Test for static durability
σ td =√ σ 2 +3 τ 2 ≤ [ σ ]
Which:
M max
σ= 3
0 ,1 d
T max
τ= 3
0 ,2 d
[ σ ]=0 , 8 [ σ ch ]=0 ,8 × 340=272 MPa
Table 5.3: Static durability on each shaft
Shaft σ τ σ td
I 29,9 11,1 35,55
II 46,44 18,12 56,05
III 24,5 24,95 49,68
Thus, the shafts satisfy the condition of static stability of the shaft.
5.2 Key testing
Key parameters are selected according to the table 9.1
Stamping durability conditions:
44
2T
σ d= ≤ [ σ d ]=150 MPa
d l t (h−t 1)
Shear durability conditions:
2T
τ c= ≤ [ τ c ] =60 MPa
d lt b
With:
T: Torque
d: Shaft diameter at the place where the key is used
b x h x t1: basic diameter of the key
l t =(0 , 8 ÷ 0 , 9)l m: length of the key
Table 5.3: Key testing on each shaft
Shaft Diameter b × h× t 1 lt σ d ( MPa) τ c (MPa)
30(A1) 10 ×8 ×5 40 67,43 20,23
I
30(D1) 10 ×8 ×5 50 53,94 16,18
45(B2) 14 × 9 ×5 , 5 54 95,88 23,97
II
45(C2) 16 ×10 × 6 64 64,35 16,09
40(B3) 20 ×12 ×7 , 5 59 137,65 30,97
III
40(D3) 18 ×11×7 80 135,96 30,21
So, the keys satisfied the conditions of stamping strength and shear strength.
45
CHAPTER 6: DESIGN ROLLER BEARINGS AND COUPLINGS
6.1 Shaft I
6.1.1 Parameters
Inner diameter: d 1=35 mm
Rotation speed: n1=584.4 rpm
One-way rotation, 2 shift working, light impact load.
6.1.2 Force on roller bearing
Radial force at the roller bearing
X B 1=4863.24 N ; Y B 1=2146.61 N
X C 1=1861.24 N ; Y C1 =1877.16 N
F rB1 =√ X B 1 +Y B 1=√ 4863.24 +2146.61 =5315.92 N

2 2 2 2
F rC1= √ X C 1+Y C 1= √ 1861.24 + 1877.16 =2643.47 N

2 2 2 2
Fa1 258.6
= =0.049<0.3
F rB 1 5315.92
→Choose deep grove ball bearing.
Table 6.1: Bearings specifications on shaft I
Symbols d, mm D, mm B, mm C, kN C0, kN
SKF
35 100 25 55.3 31
6407N
6.1.3 Test the load capacity of the bearing
Consider the ratio (V=1 due to rotation of the inner ring)
Fa1 258.6
= =0,0487
V F rB 1 1 ×5315.92
Fa1 258.6
= =0.098
V F rC 1 1 ×2643.47
Fa1 258.6
= =0.008
C o 31× 103
Based on the table 11.4 [1], we choose e=0 , 19 , X 0= X 1=1 ; Y 0=Y 1=0
F r=max { F rB 1 ; F rC 1 }=max {5315.92 ; 2643.47 }=5315.92 N
Q=( XV F r +Y F a ) k t k d=( 1 ×1 ×5315.92+0 × 258.6 ) ×1 ×1=5315.92 N
Calculate dynamic loading capacity:
46
C d=Q √ L
m
Where:
Working hours of deep grove ball bearing: Lh=17952 h
Lh nI 60 17952× 584.4 ×60
Working time in million cycles: L= 6
= 6
=629.47million revolutions
10 10
m=3 (ball bearing)
K t =1: Temperature influence coefficient

K đ =1: Impact coefficient of load characteristics (light impact, short-term overload, see table
11.3)
→ Cd =Q √ L=5315.92× √ 629.47=45558.57 N <C=65.3 kN (satisfied)
m 3
6.1.4 Calculate static load capacity:
Q0= X 0 F r +Y 0 F a
Based on the table 11.6 in [1], we choose X 0=0 , 6 ; Y 0=0 , 5
Q0=0 ,6 × 5315.92+0 , 5× 258.6=3318.852 N < F rB 1
Q0=F rB 1=5315.92 N <C 0=31 kN (satisfied)
6.2 Shaft II
6.2.1 Parameters
Rotation speed: n2 =142.53 rpm
X A 2=6067.94 N ; Y A 2 =1940.91 N
X D 2=3728.77 N ; Y D 2=344.37 N
F rA 2=√ X 2A 2 +Y 2A 2=√ 6067.942 +1940.912=6370.79 N
F rD 2=√ X 2C 1+ Y 2C 1=√ 3728.772 +344.372=3744.64 N

F a F a 2−F a 1 1061.6−258.6 803
= = = =0.21<0 , 3
F rD 2 F rD 2 3744.64 3744.64
47
→Choose deep grove ball bearing.
Table 6.2: Bearings specifications on shaft II

Symbols d, mm D, mm B, mm C, kN C0, kN
SKF
55 140 33 99.5 62
6411N
Fa 803
= =0.126
V F rA 2 1 ×6370.79
Fa 803
= =0.214
V F rD 2 1 ×3744.64
Fa 803
= =0.0129
Co 62 ×103
Based on the table 11.4 [1], we choose e=0 , 19 , X 0= X 1=1 ; Y 0=Y 1=0
F r=max { F rA 2 ; FrD 2 } =max { 6370.79 ; 3744.64 }=6370.79 N
Q=( XV F r +Y F a ) k t k d=( 1 ×1 ×6370.79+ 0× 803 ) ×1 ×1=6370.79 N
C d=Q √ L
m
Where:
Lh n2 60 17952 ×584.4 × 60
= 6
10 10
m=3 (ball bearing)

K đ =1: Impact coefficient of load characteristics (light impact, short-term overload, see table
11.3)
→ Cd =Q √ L=6370.79× √ 153.52=34112.61 N <C=62 kN (satisfied)
m 3
6.3 Shaft III
6.3.1 Parameters
48
Rotation speed: n3 =47.51 rpm
X A 3=5550.76 N ; Y A 3=2615.41 N
X C 3 =1256.62 N ; Y C 3=71.53 N
F rA 3=√ X 2A 3 +Y 2A 3=√ 5550.762 +2615.412=6136.07 N
F rC3 =√ X 2C 3+ Y 2C 3=√ 1256.622+71.53 2=1258.65 N

Table 6.3: Bearings specifications on shaft III
Symbols d, mm D, mm B, mm α ,° C, kN C0, kN
SKF
60 120 29.75 15 125 160
32212
e=1 , 5 tan α =0 , 4
Axial force at A3:
∑ F aA 3=F sC 3−F at 3=0 , 83 e FrC 3−F at 3=0 ,83 × 0 , 4 ×1258.65−1152.65=−734.78 N
F sA 3=0 , 83 e F rA 3=0 , 83× 0 , 4 × 6136.07=2037.17 N
Because ∑ F aA 3 < F sA 3 so F aA 3=F sA 3=2037.17 N

Axial force at C3:
∑ F aC 3=F sA 3 + F at 3=2037.17+ 1152.65=3189.85 N
F sC 3=0 , 83 e F rC3 =0.83 ×0.4 × 1258.65=417.87 N
Because ∑ F aC 3 > F sC3 so ∑ F aC 3=F sC 3=3189.85 N

F aA 3 2037.17
= =0,332<e
V . F rA 3 1 ×6136.07
Check in table 11.4 [1], we have: X =1 ,Y =0
F aC3 3189.85
= =2.53>e
V . F rC3 1× 1258.65
Check in table 11.4 [1], we have: X =0 , 4 ; Y =0 , 4 cot α=1.49
Conventional load on the bearing:
Q A 3 =( XV FrA 3 +YF aA 3 ) K t K đ =( 1 ×1 ×6136.07 +0 ×2037.17 ) ×1 ×1=6136.07 N
QC 3=( XV F rC 3+Y F aC 3 ) K t K đ =( 0.4 × 1× 1258.65+1.49× 3189.85 ) ×1 ×1=5256.34 N
49
With:
K đ =1: Impact coefficient of load characteristics (light impact, short-term overload, see table 11.3
in [1])
QC 3 <Q A 3 so we calculate the bearing according to the parameter at A3
Lh n3 60 17952 × 47.51× 60
= 6
10 10

10
m 3
C d=Q A 3 √ L=6136.07 × √ 51.17=19979.97 N <C=125 kN
10
Which m= (tapper ball bearing)
3
So the selected bearing satisfied dynamic loading capacity.
6.3.4 Calculate static load capacity
For tapper ball bearing according to table 11.6 [1] we have

X 0=0 , 5 ;Y 0=0 , 22 cot α =0 , 82
Q0= X 0 F rC 3 +Y 0 F aC 3=0 , 5 ×1258.65+ 0.82× 3189.85=3245.002 N < F rA 3
So Q0=F rA 3=6136.07 N <C0 =160 kN
So the selected bearing satisfied static load capacity.
6.4 Design coupling
Torque moment at shaft 3: T 3=1250284.15 N .mm

Looking up table 16.10a and 16.10b [2], we have the following axial parameters:
Table 6.1: The basic dimensions of the torsion spring coupling
d D dm L l d1 D0 Z n max B B1 l1 D3 l2
63 210 120 175 140 110 160 8 2850 6 70 40 36 40
Table 6.2: The fundamental dimensions of the torsion spring
dc d1 D2 l l1 l2 l3 h
18 M12 25 80 42 20 36 2
Stamping Strength Test
2 kT
σ d= ≤ [σ d]
Z D0 d c l 3
With:
50
[ σ d ]=4 MPa: Permissible stamping stress of rubber rings
k =1 ,2 : Working mode coefficient (16.1 in[2])
2 ×1.2 ×1250284.15
σ d= =1.776 MPa ≤ [ σ d ] =4 MPa
8 ×200 × 24 × 44
So the shaft is durable
Key strength test
24
1.2 ×1250284.15 ×(52+ )
kT l 0 2
σ u= 3
= 3
=43.41 MPa ≤ [ σ u ] =80 MPa
0 ,1 d c D0 Z 0 ,1 ×24 × 200 ×8
So the key durable condition is satisfied
51
CHAPTER 7: GEAR BOX DESIGN
7.1 Gearbox design
The gear box housing is responsible for ensuring the relative position between the details and
parts of the machine, receiving loads transmitted by the components installed on the housing,
containing lubricating oil and protecting the components from dust.
The material used to make the box is gray cast iron: GX15-32
Choose the mounting surface between the box lid and the box body that passes through the
centerline of the shafts to make it easier and more convenient to install the details. The mating
surface is parallel to the base surface.
The casting gearbox reducer has the following basic parameters:
52
Table 7.1: Gear box specifications
Name Parameters
a=221 mm
Distance shaft 2-3
δ=0 , 03 a+ 3=9 , 63 mm
Thickness:
choose δ=10 mm
Gearbox body,  δ 1=0 , 9 δ=9 mm
Gearbox cap, 1 choose δ 1=9 mm
Ribbed stiffener:
Thickness, e e=( 0 , 8 ÷ 1 ) δ=10 mm
Height, h h<5 δ=50 mm choose h=48 mm
Diameters:
Base screw, d1 d 1=20 mm >0 , 04 a+10=18 , 84
Drive edge screw, d2 d 2= ( 0 ,7 ÷ 0 , 8 ) d 1=16 mm
Cap and body flange screw, d3 d 3= ( 0 ,8 ÷ 0 , 9 ) d 2=14 mm
Bearing cover screw, d4 d 4 =( 0 , 6 ÷ 0 ,7 ) d 2=10 mm
Screw to connect the oil visitor door d 5= ( 0 ,5 ÷ 0 , 6 ) d 2=8 mm
cover, d5
Flange connecting cap and body:
Box body flange thickness, S3 S3= (1 , 4 ÷1 , 8 ) d 3=25 mm
Box cap flange thickness, S4 S4 =( 0 , 9 ÷ 1 ) S3 =25mm
Width of box cap and body flanges, K3 K 3 ≈ K 2−( 3 ÷ 5 )=¿48mm
Plane bearing size: Determine by bearing hub size
Outer diameter and screw hole center, D3, K 2=E 2+ R 2+ ( 3÷ 5 ) =¿51mm
D2 E2 ≈ 1 ,6 d2 =25 ,6 mm
Width of bolt face next to bearing: K2 R2 ≈ 1, 3 d 2=20 , 8 mm
Center of bolt hole next to bearing: E2
and C ( k is the distance from the bolt
center to the edge of the bearing)
Box base: S1 ≈ ( 1, 3 ÷ 1, 5 ) d 1=30 mm

Thickness without convex parts: S1
K 1 ≈ 3 d 1=60 mm
Box base width, K1 and q
q=90 mm ≥ K 1 +2 δ=80 mm
Gaps between details:
Between the gear and the wall in the box ∆=10 mm ≥ ( 1÷ 1 , 2 ) δ=(10 ÷12)
Between the top of the large gear and the ∆ 1=40 mm ≥ ( 3 ÷ 5 ) δ=(30 ÷ 50)
bottom of the box ∆ 2=10 mm ≥ δ=10
Between the sides of the gears together.
L+B 614+ 327
Number of base bolt Z Z= = ≈4
200 ÷ 300 250
53
Plane bearings size

Outer diameter and center of the screw hole D3, D2 choose according to 18.2 [2]
Table 7.2: Plane bearings size
Shaft D (mm) D2 (mm) D3 (mm) D4 (mm) h d4 Z
I 110 130 160 100 12 M10 6
II 110 130 160 100 12 M10 6
III 120 140 170 115 14 M10 6
7.2 Component details

7.2.1 Visitor door
Figure 7.1: Shape and dimension of the visitor door

Table 7.3: Visitor door specifications
A B A1 B1 C C1 K R Screw Number
100 75 150 100 125 - 87 12 M 8× 22 4
7.2.2 Dowel pin
Figure 7.2: Shape and dimension of the dowel pin
54
Choose cone dowel pin d ×c ×l=6 × 1× 50 mm
7.2.3 Vent button
Figure 7.3: Shape and dimension of the air vent button

Table 7.4: Vent button specifications
A B C D E G H I K L
M 27× 2 15 30 15 45 36 32 6 4 10
M N O P Q R S
8 22 6 32 18 36 32
7.2.4 Oil drain plug:
Figure 7.4: Shape and dimension of the oil drain plug

Table 7.5: Oil drain plug specifications
d b m f L c q D S D0
M 20 15 9 3 28 2,5 17,8 30 22 25,4
7.2.5 Oil check stick
55
When working, gears are immersed in oil according to lubrication conditions. To check the oil
level height in the box, we use an oil check stick. The size of the oil check stick is shown in the
figure:
Figure 7.5: Oil check stick

7.2.6 Oil seal
The ring consists of many triangular cross-section grooves with an apex angle of 60 degrees. The
distance between the peaks is 3 mm. The ring is about ( 0.5 ÷ 1 ) mm from the inside edge of the
box wall. The gap between the shell and the outside of the threaded ring is 0,4 mm.
Figure 7.6: Oil seal
7.2.7 Dust seal
In addition to eliminating stains from the operating surface, the anti-dust closed loop also stops
oil leaks from occurring within the box.
7.3 Choosing lubricating oil and mounting tolerances

Choosing a viscosity depends on the velocity of the gear material, according to table 18.11 [2]
with a rev velocity of 1 – 2.5 m/s, the gear material is improved C45 steel, the viscosity of the oil
at 50°C is 186
According to table 18.13 [2] we use lubricating oil AK-15
56
CHAPTER 8: FITTING AND TOLERANCE
8.1 Select manufacturing precision grade
For gears: pair of bevel gear is 7, pair of helical gear is 9
For shafts, key and key grooves select the correct grade as 7
For the holes the correct grade is 6
8.2 Select mounting type
For the key and gear select the mounting type H7/k6
For the inner diameters select the mounting type k6
For the outer diameters select the mounting type H7
8.3 Fitting tolerance table of gear and key
57
CHAPTER 8: FITTING AND TOLERANCE
Table 8.1: Table of fitting tolerances of gears and keys

Detail Dimension Joints es (μm) ei(μm) ES(μm) EI (μm) Largest Largest
redundancy clearance
(μm) (μm)
Gear
Driving ∅ 35 H7 +18 +2 +25 0 18 23
bevel k6
gear
Driven ∅ 55 H7 +18 +2 +25 0 18 23
bevel k6
gear
Driving ∅ 60 H7 +25 0 +30 0 25 30
helical k6
gear
Driven ∅ 75 H7 +25 0 +30 0 25 30
helical k6
gear
Outer diameter of bearing
Shaft I ∅ 100 H7 +25 +3 +35 0 25 32
Shaft II ∅ 140 H7 +25 +3 +35 0 25 32
Shaft III ∅ 120 H7 +25 +3 +35 0 25 32
Inner diameter of bearing
Shaft I ∅ 40 k6 +18 +2 +25 0 18 23
Shaft II ∅ 40 k6 +15 +2 +21 0 15 19
Shaft III ∅ 65 k6 +21 +2 +30 0 21 28
Key
Key Limited deviation of the key groove width Deviation from the depth of the key groove
diameters On shaft On bushing On shaft On bushing
P9 D10 Js9 Js9
10 ×8 ×5 -15 +98 ±18 ±18
-51 +40
14 × 9 ×5 , 5 -18 +120 ± 21 ,5 ± 21 ,5
-61 +50
16 ×10 × 6 -18 +120 ± 21 ,5 ± 21 ,5
-16 +50
18 ×11×7 -22 +149 ± 21 ,5 ± 21 ,5
-74 +65
20 ×12 ×7 , 5 -22 +149 ± 26 ± 26
-74 +65
58
REFERENCES
[1] TÍNH TOÁN THIẾT KẾ HỆ DẪN ĐỘNG CƠ KHÍ (Tập một) – Trịnh Chất, Lê Văn Uyển
[2] TÍNH TOÁN THIẾT KẾ HỆ DẪN ĐỘNG CƠ KHÍ (Tập hai) – Trịnh Chất, Lê Văn Uyển
59

Project #14 Design of A Tranmission System For Industrial Blender

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HCMC UNIVERSITY OF TECHNOLOGY - VNU HCM

FACULTY OF MECHANICAL ENGINEERING

Student: Tô Xuân Bình

Ho Chi Minh City, .../2024

THIẾT KẾ HỆ THỐNG DẪN ĐỘNG

DESIGN OF A TRANMISSION SYSTEM FOR

Student: Tô Xuân Bình

Ho Chi Minh City, .../2024

Table 1.1: Motor specifications

1.2 Distribute velocity ratio

Transmitter power: P = 7.81 kW

Transmission ratio uV −belt =5

Number of revolutions n1 = 2922 rpm

2.0.2 Belt transmission design calculations

According to the figure, choose belt type A

Large belt wheel diameter

d 2=u V −belt ×d 1 ( 1−ξ )=5 ×180 ( 1−0 , 01 )=891 mm

According to table 4.21 [1] select standard diameter, choose d2 = 900mm

Deviation from the initial value

|ut −uV −belt| |5.05−5|

Preliminary selection of axis distance a = 1× d2 = 900 mm

Belt length by axis distance a

Test the number of laps in 1 second

Recalculated a according to standard length L = 4000mm

λ=4000−0.5 π ( 900+180 )=2303.54

λ+ √ λ2 −8 ∆2 2303.54+ √ 2303.54 2−8∗3602

According to formula 4.7 [1], contact angel:

Determination of belt number: according to formula 4.16 in [1]

According to table 4.7 [1], choose Kđ = 1,1

v=27.54 m / s ; d 1=180 mm ⇒ [ P 0 ] =4 , 06 kW (table 4.19[1])

Belt pulley width, according to 4.17 and table 4.21 [1]

B=( z−1 ) t+ 2 e= ( 2−1 ) ×15+2 ×10=35 mm

Outer diameter of the pulleys:

d a 1=d 1+2 h0 =180+2 ×3.3=186.6 mm

780 P1 K d 780 ×7.81 ×1.1

With: F v =q m × v 2=0,105× 27.64 2=80.22 N (Table 4.22)

According to 4.21 [1] force acting on the shaft:

3.1 Design bevel gear

We choose the material for the pair of bevel gear as follows:

3.1.3 Determine allowable stress

values are founded at table 6.2: σ ¿ ¿

N HE , N FE : number of cycles changing stress

N HE 2=60 ×1 ×142.53 × ( 8× 2× 187 ×6 ) × 1 × ( 3 19

N FE 2=60 ×1 ×142.53 × ( 8 × 2× 187 ×6 ) × 16 × ( 19

[ σ F 1 ]max =0 , 8 σ ch =0 , 8 ×580=464 (MPa)

[ σ F 2 ]max =0 , 8 σ ch =0 , 8 × 450=360 (MPa)

3.1.4 Determine the outer cone length.

u: Fast transmission ratio of the gear reducer, u = 5

3.1.5 Determine matching parameters

√ d m 1 × ( u+1 ) π d m 1 n π ×85 , 8 ×1050

b=K be × R e =0,285 ×194.74=55.5 mm

v H × b × d m1 7.48 ×55.5 ×75.4

[ σ H ]=[ σ H ] sys × Z v × Z R × K xH =481 ,82 ×1 ×1 ×1=481 , 82 ( MPa )

So we can see that: { σ F 1 < [ σ F 1 ] =252 MPa

So the flexural strength of the pair of bevel gears is guaranteed

σ Fmax 1=σ F 1 × k qt =120.28× √ 2 ,2=178.4 MPa< [ σ F 1 ]max =464 MPa

σ Fmax 2=σ F 2 × k qt =126.96 × √ 2 ,2=192.76 MPa< [ σ F 2 ]max =360 MPa

Table 3.1: Bevel gears specifications

Number of teeth of the bevel z 1=29 , z 2=119

3.2 Design helical gear

3.2.3 Determine allowable stress

values are founded at table 6.2 ¿ [1]: σ ¿ ¿