Universiti Malaysia Perlis

ENT 345: Mechanical Components Design

GROUP PROJECT

PROJECT TITLE : CHAIN HOIST

No. Student Name Matrix number

1 AMINURASYID BIN NORIZAN 141113182

2 SABARRY BIN PAHIN 141113193

3 NOR NAZIMAN AZLYE BIN NORAMZIL 141113192

4 MOHAMAD AZLY BIN MHD AKHIR 111110653

LECTURER : DR. HAFTIRMAN

TEACHING ASSISTANT : MR. KHAIRUL FAIZI

DATE OF SUBMISSION : 17/12/2015

 ABSTRACT

What we have learnt in ENT345 Mechanical Component Design is to cover the basics
of machine design, including design process, engineering mechanics, failure prevention
under static and variable loading and characteristics of the principle types of mechanical
elements. Some of the mechanical elements that we had learned are shaft, screw, fastener and
joints, various types of gear, bearing and spring, clutches and also belt. And we got to practice
and get more understanding about this subject through mini project

ii
 TABLE OF CONTENTS

ABSTRACT ii
TABLE OF CONTENTS iii
LIST OF TABLES iv
LIST OF FIGURES v
1. INTRODUCTION 1
2. PLANNING 2
3. DESIGN ANALYSIS 3
3.0 Gear 3
3.1 Shaft 18
3.2 Bearing 27
3.3 Ratchet 30
3.4 Chain and Sprocket 35
3.5 Improved Product 38
3.6 Comparison 46
4. DISCUSSION 47
5. CONCLUSION AND RECOMMENDATION 48
6. REFERENCES 49
7. APPENDICES 50

iii
 LIST OF TABLES

Table 3.1: Gear properties for existing product 3

Table 3.2: Gear RPM for existing product 4
Table 3.3: Chain for existing product 37
Table 3.4: Gear properties for improved product 38
Table 3.5: Gear RPM for existing product 38
Table 3.6: Comparison between existing and improved product 46

iv
 LIST OF FIGURES
Figure 2.1: Gantt chart 2
Figure 3.1: Gear 4 teeth for existing product 4
Figure 3.2: Gear 19 teeth for existing product 4
Figure 3.3: Gear 5 teeth for existing product 11
Figure 3.4: Gear 19 teeth for existing product 11
Figure 3.5: Shaft drawing 18
Figure 3.6: x-y shaft plane for existing product 19
Figure 3.7: Calculated x-y shaft plane for existing product 21
Figure 3.8: Shear diagram x-y shaft plane for existing product 21
Figure 3.9: Moment diagram x-y shaft plane for existing product 21
Figure 3.10: x-z shaft plane for existing product 22
Figure 3.11: Calculated x-z shaft plane for existing product 24
Figure 3.12: Shear diagram x-z shaft plane for existing product 24
Figure 3.13: Moment diagram x-z shaft plane for existing product 24
Figure 3.14: Bearing drawing 27
Figure 3.15: x-y bearing plane for existing product 27
Figure 3.16: x-z bearing plane for existing product 28
Figure 3.17: Rachet Drawing 30
Figure 3.18: Pawl Drawing 30
Figure 3.19: Sprocket drawing 35
Figure 3.20: Gear 25 teeth drawing for improved product 39
Figure 7.1: Gear 5 teeth 50
Figure 7.2: Gear 4 teeth 50
Figure 7.3: Bearing 51
Figure 7.4: Gear 18 teeth 51
Figure 7.5: Gear 19 teeth 51
Figure 7.6: Ratchet 51
Figure 7.7: Spring 52
Figure 7.8: Gear 25 teeth 52
Figure 7.9: Shaft 53
Figure 7.10: Pawl 53
Figure 7.11: Sprocket 53
Figure 7.12: Exploded drawing 54
Figure 7.13: Fully assemble 54

v
 1. INTRODUCTION

The mini project of ENT 345 Mechanical Component Design is a project that has
open-ended solutions and will result in a product which satisfies design requirements .So, for
this mini project we had choose Chain Hoist Mechanism as our main product that we are
going to do some adjustment in this mini project. A Chain Hoist or can be called `differential
pulley` or `chain fall` is used to manually lift a very heavy object like car engines. It is
operated by pulling upon the slack section of a continuous chain that wrap around the pulleys.
The relative size of two connected pulleys determines the weight that can be lifted by hand.

There are three main objectives in this mini project. Firstly is to teach the student to
have a good technical communication skill. Secondly is to create a new design of product
which respect to the material, size, shape and functions that we use. Finally is to draw and
analyse the mechanism of mechanical component design by using CATIA V5 software. So,
we had chosen Chain Hoist as our product. Therefore, we had chosen few critical components
that become our project boundaries which are gears, bearing, and shaft.

1
 2. PLANNING

A Gantt chart was used as a management tool for our mini project. A Gantt chart is a
bar chart that illustrates the beginning and end dates of tasks in a project. It clearly visualizes
the structure of the project broken down into several elements.

Week
1 2 3 4 5 6 7 8 9 10 11 12 13
Activities
Grouping and
Brainstorming on idea for
Mini Project.

Research on Background

Calculation and Analysis

Draw in Catia V5 software

Compilation and Review

of Project

Figure 2.1: Gantt chart

2
 3. DESIGN ANALYSIS

3.0 Gear

Table 3.1: Gear properties for existing product

No of teeth , N 5 18 4 19
Face Width, F (mm) 10 10 30 20
Diametral Pitch , P (teeth/inch) 6
Circular Pitch, p (mm) 13.2994
Module , m (mm/tooth) 4.2333
Pressure Angle 20°
Pitch Diameter, d (mm) 21.167 76.200 16.933 80.433
Outside Diameter , OD (mm) 29.633 84.667 25.400 88.900
Addendum , a 0.167
Dedendum 0.208
Material Steel
Clearance, c 0.041

3
 Table 3.2: Gear RPM for existing product

Term Calculation
Symbol Formula
Pinion Gear
No of teeth (First gear) Z1 , Z2 - 5 18
No of teeth (Second gear) Z3 , Z4 - 4 19
RPM (Gear 1) (rpm) n1 - 50 -
Speed ratio (First stage) Z2
i1 ⁄Z 3.6
1
Speed ration (Second stage) Z4
i2 ⁄Z 4.75
3
Final speed ratio i i1 × i2 17.1
RPM (Gear 2 and 3) (rpm) n1
n2 ⁄i 13.889
1
RPM (Gear 4) (rpm) n1
n4 ⁄i 10.526
2

Figure 3.1: Gear 4 teeth for existing product Figure 3.2: Gear 19 teeth for existing product

4
Calculation for gear 4 and 19

Table A-20 :

Material = AISI HR 1020

Sut = 380 𝑀𝑃𝑎 𝐻𝐵 = 200

𝑆𝑦 = 210 𝑀𝑃𝑎 𝑛𝑑 = 1.5

𝑌𝑃 = 0.245

𝑌𝐺 = 0.314

dP = mNp = 4.233 (4) = 16.9332 mm

dG = mNG = 4.233 (19) = 80.4327 𝑚𝑚

πdP nP π(16.9332 × 10−3 )(50)

V= = = 0.04432 m⁄s
60 60
6.1 + 𝑉 6.1 + 0.04432
Kv = = = 1.0072
6.1 6.1
S′e = 0.5Sut = 0.5(380 MPa) = 190 MPa Sut ≤ 1400 MPa

Hot-rolled, a = 57.7 , b = -0.718

Surface factor, k a = aSut b = 57.7(380)−0.718 = 0.8107

𝑙 = 2.25𝑚 = 2.25(4.2333) = 8.4666 𝑚𝑚

3𝑌𝑚 3(0.245)(4.2333)
𝑥= = = 1.5557
2 2

𝑡 = √4𝑙𝑥 = √4(8.466)(1.5557) = 7.25𝑚𝑚

𝑑𝑒 = 0.808√𝐹𝑡 = 0.808√(30)(7.25) = 11.91 𝑚𝑚

𝑑
𝑒 −0.107 11.91
Size factor, k b = (7.62) = ( 7.62 )−0.107 = 0.9532 2.79 ≤ d ≤ 51 mm

5
kc = kd = ke = 1

𝐹𝑜𝑟 𝑜𝑛𝑒 𝑤𝑎𝑦 𝑏𝑒𝑛𝑑𝑖𝑛𝑔, 𝑘𝑓 = 1.66

Se = k a k b k c k d k e k f S′e

Se = (0.8107)(0.9532)(1)(1)(1)(1.66)(190) = 243.72 MPa

𝑟𝑓 = 0.30 𝑚 = 0.30(4.2333) = 1.269 𝑚𝑚

𝑟⁄ = 𝑟𝑓 = 1.269 = 0.1750
𝑑 𝑡 7.25

𝑘𝑡 = 1.68

Figure 6-20

Notch sensitivity, q = 0.86

𝑘𝑓 = 1 + 𝑞(𝑘𝑡 − 1) = 1 + 0.86(1.68 − 1) = 1.58

𝑆𝑒 243.72
𝜎𝑎𝑙𝑙 = 𝑘 = 1.58(1.5) = 102.83 𝑀𝑃𝑎
𝑓 𝑛𝑑

FYm𝜎𝑎𝑙𝑙 30(0.245)(4.2333)(102.83)
Wt = = = 3176.65 N
𝑘𝑣 1.0072

𝑊 𝑡 𝜋𝑑𝑛𝑝 𝜋3176.65(50)(16.933)
𝐻= = = 140.82 𝑘𝑊
60000 60000
K b = K o = Yθ = ZR = 1

From Table 14-2 : YP = 0.245 YG = 0.314

1 0.0535
K S = K = 0.8433(mF√Y) K S < 1 use 1
b

0.0535
(K s )P = 0.8433(4.2333(30)√0.245) = 1.0524 use 1
0.0535
(K s )G = 0.8433(4.2333(20)√0.314) = 1.036 use 1

6
Load distribution Factor, (K m )K H

(K H )K m = Cmf = 1 + Cmc (Cpf Cpm + Cma Ce )

Cmc = 1 , uncrowned teeth

Ce = 1 , all other condition

Cpm = 1 , straddle − mounted pinion

b
Cpf = − 0.0375 + (4.92 × 10−4 )b , 25 < b < 425mm
10d
30
Cpf = − 0.0375 + (4.92 × 10−4 )(30) = 0.1544
10(16.9332)

Cma = A + BF + CF 2

For open gearing condition at Table 14-9 :

A = 0.247 B = 0.0167 C = −0.765(10−4 )

b 30
F= = = 1.1811
25.4 25.4
Cma = 0.0247 + 0.0167(1.811) − 0.765(10−4 )(1.1811)2 = 0.2666

K H = 1 + 1[0.1544(1) + 0.2666(1)] = 1.421

Stress-Cycle Factor, YN and ZN

NG 19
Figure 14-4 : Life cycle = 108 Gear ratio, N(gear) = mG = = = 4.75
NP 4

(YN )P = 1.3558(N)−0.0178 = 1.3558(108 )−0.0178 = 0.977

−0.0178 8 −0.0178
(YN )G = 1.3558(N⁄mG ) = 1.3558 (10 ⁄4.75) = 1.0041

7
Bending strength geometry Factor, J(YJ )

Figure 14-6 : (YJ )P = 0.21 (YJ )G = 0.31

Reliability Factor, K R (YZ )

Reliability of gear 0.90

Table 14-10 : K R (YZ ) = 0.85 YZ = 0.85

Surface strength geometry, I(ZI )

cos ∅t sin ∅t mG
ZI = , external gear Spur gear MN = 1
2mN mG +1

cos 20 sin 20 4.75

ZI = ( ) = 0.1327
2(1) 4.75 + 1

The elastic coefficient, CP (ZE )

Pinion material = Steel

Table 14-8: ZE = 191√MPa

Hardened Steel at 200 Brinell

Strength, Grade 1 Steel, HBP = HBG = 200

AGMA Strength equation,

Allowable bending stress number through hardened steel

(St )P = (St )G = 0.533HB + 88.3MPa

Figure 14-2: (St )P = (St )G = 0.533(200) + 88.3MPa = 194.9MPa

8
Contact fatigue strength, Sc

(Sc )P = (Sc )G = 2.22HB + 200MPa

Figure 14-5: (Sc )P = (Sc )G = 2.22(200) + 200MPa = 644MPa

Stress cycle Factor, YN and ZN

Pitting resistance Stress-cycle Factor, ZN

Figure 14-15: ZN = 1.4488(N)−0.023

(ZN )P = 1.4488(N)−0.023 = 1.4488(108 )−0.023 = 0.948

−0.023 8 −0.023
(ZN )G = 1.4488(N⁄mG ) = 1.4488 (10 ⁄4.75) = 0.9830

Hardness ratio Factor, CH (ZW )

H 200
Figure 14-12: Calculated hardness ratio = HBP = 200 = 1 (ZW )CH = 1
BG

Pinion Tooth Bending

1 KH KB
(σ)P = [W t K o K v K s bm ] (Bending Stress)
t YJ
P

1.421(1) 1
(σ)P = 3176.65(1)(1.0072)(1) [ ][ ] = 170.48 MPa
0.21 30(4.233)

St YN 194.9 0.977
(SF )P = = [ ] = 1.30
σ Yθ YZ 170.48 1(0.85)

9
Gear Tooth Bending

1 KH KB
(σ)G = [W t K o K v K s bm ] (Bending Stress)
t YJ G

1.421(1) 1
(σ)G = 3176.65(1)(1.0072)(1) [ ][ ] = 115.49 MPa
0.31 20(4.233)

St YN 194.9 1.0041
(SF )G = = [ ] = 1.98
σ Yθ YZ 115.49 1(0.85)

Pinion Tooth Wear

KH Z R
(σC )P = ZE √W t K 0 K V K S d (Contact Stress)
wl b ZI

1.421 1
(σC )P = 191√3176.65(1)(1.0072)(1) [ ] = 1568.58 MPa
16.9332(30) 0.1327

S c ZN Zw 644 0.948(1)
(SH )P = = [ ] = 1.457
σc Yθ YZ 1568.58 1(0.85)

Gear Tooth Wear

1⁄ 1⁄
(Ks )G 2 1 2
(σC )G = [(K ] σC = [1] (1568.58) MPa = 1568.58 MPa
s )P

So ; (σC )G = (σC )P = 1568.58 MPa

S c ZN Zw 644 0.9830(1)
(SH )G = = [ ] = 1.4748
σc Yθ YZ 1568.58 1(0.85)

10
 Figure 3.3: Gear 5 teeth for existing product Figure 3.4: Gear 19 teeth for existing product

Calculation for gear 5 and 18

d = mN

dP = mNp = 4.233 (5) = 21.1665

dG = mNG = 4.233 (18) = 76.1994

πdP nP π(21.1665 × 10−3 )(30)

V= = = 0.03324 m⁄s
60 60
60H 60(2.3936)
Wt = = = 71.9917 N
πdP nP π(21.1665 × 10−3 )(30)

K b = K o = Yθ = ZR = 1

Qv = 6 (Quality Standard)
2⁄ 2⁄
B = 0.25(12 − Qv ) 3 = 0.25(12 − 6) 3 = 0.8255

A = 50 + 56(1 − B) = 50 + 56(1 − 0.8255) = 59.772

B 0.8255
A + √200V 59.772 + √200(0.03324)
Kv = [ ] =[ ] = 1.0354
A 59.772

11
From Table 14-2 : YP = 0.245 YG = 0.30
1 0.0535
K S = K = 0.8433(mF√Y) K S < 1 use 1
b

0.0535
(K s )P = 0.8433(4.2333(10)√0.245) = 0.9923 use 1
0.0535
(K s )G = 0.8433(4.2333(10)√0.309) = 0.9985 use 1

Load distribution Factor, (K m )K H

(K H )K m = Cmf = 1 + Cmc (Cpf Cpm + Cma Ce )

Cmc = 1 , uncrowned teeth

Ce = 1 , all other condition

Cpm = 1 , straddle − mounted pinion

b
Cpf = − 0.025 , b ≤ 25mm
10d
10
Cpf = − 0.025 = 0.0222
10(21.1665)

Cma = A + BF + CF 2

For open gearing condition at Table 14-9 :

A = 0.247 B = 0.0167 C = −0.765(10−4 )

b 10
F= = = 0.3937
25.4 25.4
Cma = 0.0247 + 0.0167(0.3937) − 0.765(10−4 )(0.3937)2 = 0.2536

K H = 1 + 1[0.0222(1) + 0.2536(1)] = 1.275

12
Stress-Cycle Factor, YN and ZN
NG 18
Figure 14-4 : Life cycle = 108 Gear ratio, N(gear) = mG = = = 3.6
NP 5

(YN )P = 1.3558(N)−0.0178 = 1.3558(108 )−0.0178 = 0.977

−0.0178 8 −0.0178
(YN )G = 1.3558(N⁄mG ) = 1.3558 (10 ⁄3.6) = 0.9767

Bending strength geometry Factor, J(YJ )

Figure 14-6 : (YJ )P = 0.21 (YJ )G = 0.29

Reliability Factor, K R (YZ )

Reliability of gear 0.90

Table 14-10 : K R (YZ ) = 0.85 YZ = 0.85

Surface strength geometry, I(ZI )

cos ∅t sin ∅t mG
ZI = , external gear Load sharing ration, Spur gear MN = 1
2mN mG +1

cos 20 sin 20 3.6

ZI = ( ) = 0.1257
2(1) 3.6 + 1

The elastic coefficient, CP (ZE )

Pinion material = Steel

Table 14-8: ZE = 191√MPa

Hardened Steel at 200 Brinell

Strength, Grade 1 Steel, HBP = HBG = 200

13
AGMA Strength equation,

Allowable bending stress number through hardened steel

(St )P = (St )G = 0.533HB + 88.3MPa

Figure 14-2: (St )P = (St )G = 0.533(200) + 88.3MPa = 194.9MPa

Contact fatigue strength, Sc

(Sc )P = (Sc )G = 2.22HB + 200MPa

Figure 14-5: (Sc )P = (Sc )G = 2.22(200) + 200MPa = 644MPa

Stress cycle Factor, YN and ZN

Pitting resistance Stress-cycle Factor, ZN

Figure 14-15: ZN = 1.4488(N)−0.023

(ZN )P = 1.4488(N)−0.023 = 1.4488(108 )−0.023 = 0.948

−0.023 8 −0.023
(ZN )G = 1.4488(N⁄mG ) = 1.4488 (10 ⁄3.6) = 0.9768

Hardness ratio Factor, CH (ZW )

H 200
Figure 14-12: Calculated hardness ratio = HBP = 200 = 1 (ZW )CH = 1
BG

Pinion Tooth Bending

1 KH KB
(σ)P = [W t K o K v K s bm ] (Bending Stress)
t YJ P

1.275(1) 1
(σ)P = 71.9917(1)(1.0354)(1) [ ][ ] = 10.691 MPa
0.21 10(4.233)

14
 St YN 194.9 0.977
(SF )P = = [ ] = 20.954
σ Yθ YZ 10.691 1(0.85)

Gear Tooth Bending

1 KH KB
(σ)G = [W t K o K v K s bm ] (Bending Stress)
t YJ
G

1.275(1) 1
(σ)G = 71.9917(1)(1.0354)(1) [ ][ ] = 7.7420 MPa
0.29 10(4.233)

St YN 194.9 0.977
(SF )G = = [ ] = 28.9357
σ Yθ YZ 7.7420 1(0.85)

Pinion Tooth Wear

KH Z R
(σC )P = ZE √W t K 0 K V K S d (Contact Stress)
wl b ZI

1.275 1
(σC )P = 191√71.9917(1)(1.0354)(1) [ ] = 359.843 MPa
21.16659(10) 0.1265

S c ZN Zw 644 0.948(1)
(SH )P = = [ ] = 1.9960
σc Yθ YZ 359.843 1(0.85)

Gear Tooth Wear

1⁄ 1⁄
(Ks )G 2 1 2
(σC )G = [(K ] σC = [1] (359.843) MPa = 359.843 MPa
s )P

So ; (σC )G = (σC )P = 359.843 MPa

S c ZN Zw 644 0.9768(1)
(SH )G = = [ ] = 2.0566
σc Yθ YZ 359.843 1(0.85)

15
Power and torque transmission

F1 = F2

T = Fr

rN5 = 14.816 mm , rN18 = 42.335 mm , rN4 = 12.7 mm , rN19 = 44.45 mm , rsp = 50 mm

T19 = Fr19 = (9.81 × 103 )(44.45 × 10−3 ) = 436.054 N. m

⇒ While F = (1000)(9.81) = 9.81 kN

T19 436.054 N. m
F19 = = = 9809.98 N
r19 44.45 × 10−3

T19 436.054 N. m
T4 = ∙ r4 = (12.7 × 10−3 ) = 124.586 N. m⁄2 = 62.293 N. m
r19 44.45 × 10−3

T4 62.293 N. m
F4 = = = 5191.08 N
r4 12.7 × 10−3

r4 12.7 × 10−3
T18 = ∙ T4 = (62.293 N. m) = 18.687 N. m⁄2 = 9.343 N. m
r18 42.335 × 10−3

T18 9.343 N. m
F18 = = = 220.70 N
r18 42.335 × 10−3

r18 42.335 × 10−3

T5 = ∙ T18 = (9.343 N. m) = 3.2699 N. m
r5 14.816 × 10−3

T5 3.2699 N. m
F5 = = = 220.70 N
r5 14.816 × 10−3

r5 14.816 × 10−3
Tsp = ∙ T5 = (3.2699 N. m) = 0.9689 N. m
rsp 50 × 10−3

Tsp 0.9689 N. m
Fsp = = = 19.372 N
rsp 50 × 10−3

Horsepower
LV
Hp =
33000
SYF 600
While L= DP
× 600 +V , V = 0.262 × Pd × RPM

16
Gear 5, 18

F = 10 mm (0.393701 in)

DP = 6 mm (0.23622 in)

S = (table one) − material steel = 35000

Table 14-2 , Y = 0.209

Pd = 21.167 mm (0.8333 in)

V = 0.262 × 0.8333 × 30 = 6.5497

35000(0.209)(0.393701) 600
L= × = 12060.048
0.23622 600 + 6.5497

12060.048(6.5497)
Hp = = 2.3936 W
33000

Gear 4, 19

F = 30 mm (1.1811 in)

DP = 6 mm (0.23622 in)

S = (table one) − material steel = 35000

Table 14-2 , Y = 0.245

Pd = 16.9332 mm (0.6667 in)

V = 0.262 × 0.6667 × 8.33 = 1.4550

35000(0.209)(1.1811) 600
L= × = 36486.52
0.23622 600 + 1.4550

36486.52(1.4550)
Hp = = 1.6087 W
33000

17
3.1 Shaft

Figure 3.5: Shaft drawing

∑ T = Fr = 0

∑ T = 9810 cos 20° (0.0444) + FF (0.025) + 19.372 cos 30° (0.05) = 0

FF = −16405.40 N

18
 y
𝑦 𝑦
𝑦 𝑅𝐶 𝑅𝐸
𝑅𝑂

B D G
O x
A 0.025 0.015 C 0.03 0.03 E 0.045

9810 cos 20° 9810 19.372 cos 30°

Figure 3.6: x-y shaft plane for existing product

∑M = 0

y y
+↺ ∑ Mo = −9218.38(0.025) + R C (0.04) − 9810(0.07) + R E (0.1) − 16.77(0.045) =
0
y y
R C (0.04) + R E (0.1) = 917.914 N ———①

y y
+↺ ∑ Mc = −R O (0.04) + 9218.38(0.015) − 9810(0.03) + R E (0.06) −
16.77(0.105) = 0

y y
R E (0.06) − R O (0.04) = 157.78 N

y y
R E = 2629.66 N + 0.6666R O ———②

19
 ∑F = 0

y y y
+↑ ∑ Fy = R O − 9218.38N + R C − 9810N + R E − 16.77N = 0

y y y
R O + R C + R E = 19045.15 N

y y y
R O = 19045.15 N − R C − R E ———③

∴ ③ into ②

y y y
R E = 2629.66 N + 0.6666(19045.15 N − R C − R E )

y y
R E = 9195.46N − 0.3999R C ———④

∴ ④ into ①

y y
R C (0.04) + (9195.46N − 0.3999R C )(0.1) = 917.914 N

y
R C = −16320N

y
∴ R C into ①

y
(−16320)(0.04) + R E (0.1) = 917.914 N

y
R E = 15707.14N

y y
∴ R C and R E into ③

y
R O = 19045.15 N − 16320 − 15707.14

y
R O = 19658.01N

20
 y
15707.14N
19658.01N

B C D G
O x
A 0.025 0.015 0.03 0.03 E 0.045

9218.38N 16320N 9810N 16.77N

Figure 3.7: Calculated x-y shaft plane for existing product

V(N)
19658.01
10439.63
+ 16.77
+
+ x
O
-
-
-5880.37

-15690.37

Figure 3.8: Shear diagram x-y shaft plane for existing product

M(N.m)

O x

Figure 3.9: Moment diagram x-y shaft plane for existing product

21
 z
9810 sin 20° 𝑅𝐸𝑧

0.025 0.015 0.06 0.01 F 0.035 G

O x
A B C E

𝑅𝑂𝑧 𝑅𝐶𝑧 16405.40 19.372 sin 30°

Figure 3.10: x-z shaft plane for existing product

+↺ ∑ Mo = 3355.21(0.025) − RzC (0.04) + RzE (0.1) − 16405.40(0.11) −

9.686(0.145) = 0

RzE (0.1) = RzC (0.04) + 1722.11 N ———①

+↺ ∑ Mc = RzO (0.04) − 3355.21(0.015) + RzE (0.06) − 16405.40(0.07) −

9.686(0.105) = 0

RzO (0.04) + RzE (0.06) = 1199.72 N ———②

+↑ ∑ Fz = −RzO + 3355.21N − RzC + RzE − 16405.40N − 9.686N = 0

RzO = RzE − RzC − 13059.87 N ———③

∴ ③ into ②

(RzE − RzC − 13059.87 N)(0.04) + RzE (0.06) = 1199.72 N

RzE = 17221.1 + 0.4RzC ———④

22
∴ ④ into ①

(17221.1 + 0.4RzC )(0.1) = RzC (0.04) + 1722.11 N

RzC = 0

∴ RzC into ①

RzE (0.1) = (0)(0.4) + 17221.1 N

RzE = 17221.1N

∴ RzC and RzE into ③

RzO = 17221.1N − 0 − 13059.87 N

RzO = 4161.23N

23
 z
3355.21N 17221.1N

0.025 0.075 0.01 F 0.035 G

O x
A B E

-4161.23N 16405.40N 9.68N

Figure 3.11: Calculated x-z shaft plane for existing product

V(N)
16415.08

+ 9.68
+ x
O
-
- -806.02

-4161.23

Figure 3.12: Shear diagram x-z shaft plane for existing product

M(N.m)

O x

Figure 3.13: Moment diagram x-z shaft plane for existing product

24
 MB = √(491.45)2 + (−104.03)2 = 502.33 N. m

T = 9810 cos 20° (0.0444) = 409.29 N. m

32M
σ=
πd3
32(502.33)
σ= π(0.015)3
= 1516.3 MPa while; ∅ shaft = 15 mm = 0.015 m

16T
τ=
πd3
16(409.29)
τ= = 617.62 Mpa
π(0.015)3

σx σx 2 2
σ1 , σ2 = ± √( ) + (τxy )
2 2

1516.3 1516.3 2
σ1 , σ2 = ± √( ) + (617.62)2 = 758 ± 977.87
2 2

σ1 = 1735.87 MPa σ2 = −219.87 MPa

σx 2 2
τmax = √( ) + (τxy )
2

1516.3 2
τmax = √( ) + (617.62)2 = 977.87 MPa
2

25
Endurance strength of the shaft

Table A-22 :

Material : 1214 Steel with Sut = 424 MPa

Diameter shaft = 15 mm = 0.015m

Table 6-2 :

Marine Surface modification factor

Hot-rolled, a = 57.7 , b = -0.718

S′e = 0.5Sut = 0.5(424 MPa) = 212 MPa Sut ≤ 1400 MPa

Surface factor, k a = aSut b = 57.7(424)−0.718 = 0.749

Size factor, k b = 1.24d−0.107 = 1.24(15)−0.107 = 0.9280 2.79 ≤ d ≤ 51 mm

Se = k a k b k c k d k e k f S′e kc = kd = ke = kf = 1

Se = (0.749)(0.9280)(1)(1)(1)(1)(212) = 147.35 MPa

26
3.2 Bearing

Figure 3.14: Bearing drawing

y
220.7 cos 20°

0.005 A 0.04 B
O x

𝑦 𝑦
𝑅𝑂 𝑅𝐵
Figure 3.15: x-y bearing plane for existing product

27
 𝑦
+↺ ∑ 𝑀𝑜 = 0 ; 207.39𝑁(0.005) − 𝑅𝐵 (0.045) = 0

𝑦
𝑅𝐵 = 23.043 𝑁

𝑦
+↑ ∑ 𝐹𝑦 = 0 ; − 𝑅𝑂 + 207.39𝑁 − 23.043𝑁 = 0

𝑦
𝑅𝑂 = 184.346 𝑁

z
𝑅𝐵𝑧
𝑅𝑂𝑧

0.005 A 0.04
O x
B

220.7 sin 20°

Figure 3.16: x-z bearing plane for existing product

+↺ ∑ 𝑀𝑜 = 0 ; −75.48𝑁(0.005) − 𝑅𝐵𝑧 (0.045) = 0

𝑅𝐵𝑧 = 8.386 𝑁

+↑ ∑ 𝐹𝑧 = 0 ; 𝑅𝑂𝑧 − 75.48𝑁 + 8.386𝑁 = 0

𝑅𝑂𝑧 = 67.09 𝑁

𝑦 2
𝑅𝐵 = √(𝑅𝐵 ) + (𝑅𝐵𝑧 )2 = √(23.04)2 + (8.38)2 = 24.51 𝑁

28
Table 11-4 :

Life = 20000 H

Application factor 1.2

𝐹𝐷 = (1.2)(24.51𝑁) = 29.419 𝑁

ℒ𝐷 𝑛𝐷 60 (20000)(8.33)(60)
𝑥𝐷 = = = 9.996 𝑁
ℒ𝑅 𝑛𝑅 60 106

1⁄
𝑎

𝑥𝐷
𝐶10 = 𝐹𝐷 1
1 𝑏
𝑥 + (𝜃 − 𝑥 ) [ln (
[ 0 0 𝑅𝐷 )] ]

1⁄
3
9.996
𝐶10 = 29.419 1 = 86.58 = 494.32 𝑁 (𝑐𝑜𝑛𝑠𝑖𝑑𝑒𝑟)
1 1.483
[0.02 + 4.439 [ln (0.975)] ]

Angular contact

Bore = 10 mm

OD = 30 mm

Width = 9 mm

Fillet radius = 0.6

Shoulder diameter - 𝑑𝑠 = 12.5 mm , 𝑑𝐻 = 27 mm

29
3.3 Ratchet

Figure 3.17: Rachet Drawing

Figure 3.18: Pawl Drawing

30
Material – AISI 1020 Steel (as-rolled condition)

Pitch = 6.28 mm

No. of teeth, N = 30

A = Bore = 15 mm

D = Outside diameter = 60 mm

Face width = 10 mm

G Total length = 15 mm

H Depth of teeth = 3.1

I Center distance = 61.23

J Mounting distance

Material : AISI 1020 Steel (as-rolled condition)

Design factor, 𝑛𝑑 = 2

Speed = 30 rpm

Diametral pitch = 3.14 mm

N = 30

OD = 50 mm

Face width = 10

h = Depth of teeth = 3.1 mm

31
Table A-20 :

Minimum tensile strength, 𝑆𝑢𝑡 = 380 MPa

Yield strength, 𝑆𝑦 = 210 MPa

𝑆𝑦 210
𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠, = = 105 𝑀𝑃𝑎
𝑛𝑑 2

𝑇𝑜𝑟𝑞𝑢𝑒, 𝑇 = 𝐹𝑟 = 16405.40 (0.03) = 492.16 𝑁. 𝑚

360
𝑅𝑜𝑜𝑡 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑒 = 𝐷𝑒𝑝𝑡ℎ 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ (ℎ) × tan (60 − )
𝑁

360
𝑒 = 3.1 × tan (60 − ) = 3.44 𝑚𝑚
30

𝑂𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 (𝐷) − (2. ℎ)

Tooth root radius (m), 𝑟𝑓 =
2000

60 − (2 × 3.1)
𝑟𝑓 = = 0.02999
2000

𝑅𝑜𝑡𝑎𝑡𝑖𝑛𝑔 𝑏𝑒𝑎𝑚 𝑒𝑛𝑑𝑢𝑟𝑎𝑛𝑐𝑒 𝑙𝑖𝑚𝑖𝑡, 𝑆′𝑒 = 0.5𝑆𝑢𝑡 , 𝑆𝑢𝑡 ≤ 1400 𝑀𝑃𝑎

𝑆 ′ 𝑒 = 0.5(380 𝑀𝑃𝑎) = 190 𝑀𝑃𝑎

𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑚𝑜𝑑𝑖𝑓𝑖𝑐𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑘𝑎 = 𝑎𝑆𝑢𝑡 𝑏

Table 6-2: Hot-rolled

a = 57.7 MPa , b = -0.718

𝑘𝑎 = 57.7(380)−0.718 = 0.8107

𝑆𝑖𝑧𝑒 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑘𝑏 = 1.24𝑑 −0.107 , 2.79 ≤ 𝑑 ≤ 51 𝑚𝑚

𝑘𝑏 = 1.24(50)−0.107 = 0.8158

𝑘𝑐 = 𝑘𝑑 = 𝑘𝑒 = 1

32
 𝜎𝑎 = 𝜎𝑚 = 𝜎⁄2

𝑆𝑎 𝑆𝑚
+ =1 (𝑆𝑖𝑛𝑐𝑒 𝑆𝑎 = 𝑆𝑚 𝑓𝑜𝑟 𝑜𝑛𝑒 𝑤𝑎𝑦 𝑏𝑒𝑛𝑑𝑖𝑛𝑔)
𝑆 ′ 𝑒 𝑆𝑢𝑡

𝑆 ′ 𝑒 𝑆𝑢𝑡
𝑆𝑎 = (𝑆𝑎 = 𝜎⁄2 , 𝑆 ′ 𝑒 = 0.55𝑆𝑢𝑡 )
𝑆 ′ 𝑒 + 𝑆𝑢𝑡

2𝑆′𝑒 𝑆𝑢𝑡 2𝑆′𝑒

𝜎 = = 1.33𝑆′𝑒
0.5𝑆𝑢𝑡 + 𝑆𝑢𝑡 0.5 + 1

′
1.33𝑆 𝑒
𝑘𝑓 = 𝜎⁄𝑆 ′ = = 1.33
𝑒 𝑆 ′𝑒

𝑀𝑎𝑟𝑖𝑛 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛, 𝑆𝑒 = k a k b k c k d k e k f S′e

𝑆𝑒 = 0.8107(0.8158)(1)(1)(1)(1.33)(1.90 𝑀𝑃𝑎) = 167.12 𝑀𝑃𝑎

𝑟𝑓 = 0.2999

Figure 6-20 : Notch sensivity chart for steel and UNS A92024-T

q = 0.6

𝑘𝑓 = 1 + 𝑞(𝑘𝑓 − 1)

𝑘𝑓 = 1 + (0.6)(1.33 − 1) = 1.198

𝑆𝑒 𝑆𝑒
𝜎𝑚𝑎𝑥 = 𝑘𝑓 𝜎𝑎𝑙𝑙 = ⇒ 𝜎𝑎𝑙𝑙 =
𝑛𝑑 𝑘𝑓 𝑛𝑑

167.12
𝜎𝑎𝑙𝑙 = = 69.74 𝑀𝑃𝑎 (𝑀𝑎𝑥 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠)
(1.198)(2)

33
Bending strength of ratchets

b∙e2 1 1
Allowable transmission forces, Fb = σall ∙ ∙h∙S
6 F

10 ∙ (3.44)2 1 1
Fb = (69.74 × 106 ) ∙ ∙ ∙ = 220.07 N
6 3.1 2

Ratchet’s allowable torque, T = Fb ∙ rf

T = (220.07) ∙ (0.02999) = 6.5999 N. m

34
3.4 Chain and Sprocket

Figure 3.19: Sprocket drawing

Table 17-19 :

Pitch, p = 76.70 mm (3 in)

Width = 47.63 mm (1.875 in)

Minimum tensile strength = 498 000 N

No. of teeth, N = 6

Npn 6(3)(50)
Velocity, V = (in) = = 75
12 12

πnp π(50)(3)
Vmax = γ = = 78.53
12 sin (N) 12 sin (180)
6

35
 γ 180
πnp cos (N) π(50)(3) cos ( 6 )
Vmin = γ = = 68.01
12 sin (N) 180
12 sin ( 6 )

Nominal power, H1 = 0.003N1.08 n0.9 p(3−0.07p) (kW)

H1 = 0.003(6)1.08 (50)0.9 (3)[3−0.07(3)] = 15.05

Selecting sprocket and chain

K s = 1.5 (service factor)

Design factor of 1.1

Evaluate K1 and K 2

K s ndHnom
Htable =
K1 K 2

Table 17-22 : Tooth correction factor (post extreme horsepower)

K1 = 0.52

Table 17-23 : Multiple – strand factor

K 2 = 1 , 1.7 , 2.5 , 3.3

1.5(1.1)(15.5)
H ′ table,1 = = 23.25
(1)(1)

Table 17-20 :

K1 K 2 Htab (1)(1)(61.8)
nfs = = = 2.658
K s Hnom 1.5(15.5)

1.5(1.1)(15.5)
H ′ table,2 = = 13.676
(1)(1.7)

36
Table 17-20 :

K1 K 2 Htab (1)(1.7)(61.8)
nfs = = = 4.51
K s Hnom 1.5(15.5)

1.5(1.1)(15.5)
H ′ table,3 = = 9.3
(1)(2.5)

Table 17-20 :

K1 K 2 Htab (1)(2.5)(61.8)
nfs = = = 6.64
K s Hnom 1.5(15.5)

1.5(1.1)(15.5)
H ′ table,4 = = 7.04
(1)(3.3)

Table 17-20 :

K1 K 2 Htab (1)(3.3)(61.8)
nfs = = = 8.77
K s Hnom 1.5(15.5)

Table 3.3: Chain for existing product

Strands K2 H′tab Chain no Htab nfs

1 1.0 23.25 240 61.8 2.658
2 1.7 13.676 240 28.9 2.11
3 2.5 9.3 240 5.52 0.5935
4 3.3 7.04 240 2.88 0.6131

Chain number 240 (AISI chain) is selected because the value of nfs is lower than the other
using Strand and Strand Factor, K 2 comparison.

37
3.5 Improved Product

Table 3.4: Gear properties for improved product

No of teeth , N 5 18 4 25
Face Width, F (mm) 10 10 30 20
Diametral Pitch , P (teeth/inch) 6
Circular Pitch, p (mm) 13.2994
Module , m (mm/tooth) 4.2333
Pressure Angle 20°
Pitch Diameter, d (mm) 21.167 76.200 16.933 105.833
Outside Diameter , OD (mm) 29.633 84.667 25.400 114.300
Addendum , a 0.167
Dedendum 0.208
Material Steel
Clearance, c 0.041

Table 3.5: Gear RPM for existing product

Term Calculation
Symbol Formula
Pinion Gear
No of teeth (First gear) Z1 , Z2 - 5 18
No of teeth (Second gear) Z3 , Z4 - 4 25
RPM (Gear 1) (rpm) n1 - 50 -
Speed ratio (First stage) Z2
i1 ⁄Z 3.6
1
Speed ration (Second stage) Z4
i2 ⁄Z 6.25
3
Final speed ratio i i1 × i2 22.5
RPM (Gear 2 and 3) (rpm) n1
n2 ⁄i 13.89
1
RPM (Gear 4) (rpm) n1
n4 ⁄i 8.00
2

38
 Figure 3.20: Gear 25 teeth drawing for improved product

Table A-20:

Material = AISI HR 1050

Sut = 620 𝑀𝑃𝑎 𝐻𝐵 = 200

𝑆𝑦 = 340 𝑀𝑃𝑎 𝑛𝑑 = 1.5

𝑌𝑃 = 0.245

𝑌𝐺 = 0.337

dP = mNp = 4.233 (4) = 16.9332 mm

dG = mNG = 4.233 (25) = 105.82 mm

πdP nP π(16.9332 × 10−3 )(50)

V= = = 0.04432 m⁄s
60 60
6.1 + 𝑉 6.1 + 0.04432
Kv = = = 1.0072
6.1 6.1

39
S′e = 0.5Sut = 0.5(620 MPa) = 310 MPa Sut ≤ 1400 MPa

Hot-rolled, a = 57.7 , b = -0.718

Surface factor, k a = aSut b = 57.7(620)−0.718 = 0.5704

𝑙 = 2.25𝑚 = 2.25(4.2333) = 9.5249 𝑚𝑚

3𝑌𝑚 3(0.245)(4.2333)
𝑥= = = 1.5557
2 2

𝑡 = √4𝑙𝑥 = √4(9.5249)(1.5557) = 7.819𝑚𝑚

𝑑𝑒 = 0.808√𝐹𝑡 = 0.808√(30)(7.819) = 12.375 𝑚𝑚

𝑑
𝑒 −0.107 12.375 −0.107
Size factor, k b = (7.62) =( ) = 0.9494 2.79 ≤ d ≤ 51 mm
7.62

kc = kd = ke = 1

𝐹𝑜𝑟 𝑜𝑛𝑒 𝑤𝑎𝑦 𝑏𝑒𝑛𝑑𝑖𝑛𝑔, 𝑘𝑓 = 1.66

Se = k a k b k c k d k e k f S′e

Se = (0.5704)(0.9494)(1)(1)(1)(1.66)(310) = 278.675 MPa

𝑟𝑓 = 0.30 𝑚 = 0.30(4.2333) = 1.269 𝑚𝑚

𝑟⁄ = 𝑟𝑓 = 1.269 = 0.1750
𝑑 𝑡 7.25

𝑘𝑡 = 1.68

40
Figure 6-20

Notch sensitivity, q = 0.86

𝑘𝑓 = 1 + 𝑞(𝑘𝑡 − 1) = 1 + 0.86(1.68 − 1) = 1.58

𝑆𝑒 278.675
𝜎𝑎𝑙𝑙 = 𝑘 = 1.58(1.5) = 117.83 𝑀𝑃𝑎
𝑓 𝑛𝑑

FYm𝜎𝑎𝑙𝑙 30(0.245)(4.2333)(117.83)
Wt = = = 3641.48 N
𝑘𝑣 1.0068

𝑊 𝑡 𝜋𝑑𝑛𝑝 𝜋(3641.48)(50)(16.933)
𝐻= = = 161.428 𝑘𝑊
60000 60000
K b = K o = Yθ = ZR = 1

From Table 14-2 : YP = 0.245 YG = 0.314

1 0.0535
K S = K = 0.8433(mF√Y) K S < 1 use 1
b

0.0535
(K s )P = 0.8433(4.2333(30)√0.245) = 1.0524 use 1
0.0535
(K s )G = 0.8433(4.2333(20)√0.337) = 1.0614 use 1

Load distribution Factor, (K m )K H

(K H )K m = Cmf = 1 + Cmc (Cpf Cpm + Cma Ce )

Cmc = 1 , uncrowned teeth

Ce = 1 , all other condition

Cpm = 1 , straddle − mounted pinion

b
Cpf = − 0.0375 + (4.92 × 10−4 )b , 25 < b < 425mm
10d
30
Cpf = − 0.0375 + (4.92 × 10−4 )(30) = 0.1544
10(16.9332)

Cma = A + BF + CF 2

41
For open gearing condition at Table 14-9 :

A = 0.247 B = 0.0167 C = −0.765(10−4 )

b 30
F= = = 1.1811
25.4 25.4
Cma = 0.0247 + 0.0167(1.811) − 0.765(10−4 )(1.1811)2 = 0.2666

K H = 1 + 1[0.1544(1) + 0.2666(1)] = 1.421

Stress-Cycle Factor, YN and ZN

NG 25
Figure 14-4 : Life cycle = 108 Gear ratio, N(gear) = mG = = = 6.25
NP 4

(YN )P = 1.3558(N)−0.0178 = 1.3558(108 )−0.0178 = 0.977

−0.0178 8 −0.0178
(YN )G = 1.3558(N⁄mG ) = 1.3558 (10 ⁄6.25) = 1.0091

Bending strength geometry Factor, J(YJ )

Figure 14-6 : (YJ )P = 0.21 (YJ )G = 0.33

Reliability Factor, K R (YZ )

Reliability of gear 0.90

Table 14-10 : K R (YZ ) = 0.85 YZ = 0.85

Surface strength geometry, I(ZI )

cos ∅t sin ∅t mG
ZI = , external gear Spur gear MN = 1
2mN mG +1

cos 20 sin 20 6.25

ZI = ( ) = 0.1385
2(1) 6.25 + 1

42
The elastic coefficient, CP (ZE )

Pinion material = Steel

Table 14-8: ZE = 191√MPa

Hardened Steel at 200 Brinell

Strength, Grade 1 Steel, HBP = HBG = 200

AGMA Strength equation,

Allowable bending stress number through hardened steel

(St )P = (St )G = 0.533HB + 88.3MPa

Figure 14-2: (St )P = (St )G = 0.533(200) + 88.3MPa = 194.9MPa

Contact fatigue strength, Sc

(Sc )P = (Sc )G = 2.22HB + 200MPa

Figure 14-5: (Sc )P = (Sc )G = 2.22(200) + 200MPa = 644MPa

Stress cycle Factor, YN and ZN

Pitting resistance Stress-cycle Factor, ZN

Figure 14-15: ZN = 1.4488(N)−0.023

(ZN )P = 1.4488(N)−0.023 = 1.4488(108 )−0.023 = 0.948

−0.023 8 −0.023
(ZN )G = 1.4488(N⁄mG ) = 1.4488 (10 ⁄6.25) = 0.9892

43
Hardness ratio Factor, CH (ZW )
H 200
Figure 14-12: Calculated hardness ratio = HBP = 200 = 1 (ZW )CH = 1
BG

Pinion Tooth Bending

1 KH KB
(σ)P = [W t K o K v K s bm ] (Bending Stress)
t YJ
P

1.421(1) 1
(σ)P = 3641.48(1)(1.0068)(1.052) [ ][ ] = 205.51 MPa
0.21 30(4.233)

St YN 194.9 0.977
(SF )P = = [ ] = 1.089
σ Yθ YZ 205.51 1(0.85)

Gear Tooth Bending

1 KH KB
(σ)G = [W t K o K v K s bm ] (Bending Stress)
t YJ G

1.421(1) 1
(σ)G = 3641.48(1)(1.0068)(1.052) [ ][ ] = 130.78 MPa
0.33 20(4.233)

St YN 194.9 1.0091
(SF )G = = [ ] = 1.76
σ Yθ YZ 130.78 1(0.85)

44
Pinion Tooth Wear

KH Z R
(σC )P = ZE √W t K 0 K V K S d (Contact Stress)
wl b ZI

1.421 1
(σC )P = 191√3641.48(1)(1.0068)(1.052) [ ] = 1686.5 MPa
16.9332(30) 0.1327

S c ZN Zw 644 0.948(1)
(SH )P = = [ ] = 1.4258
σc Yθ YZ 1686.5 1(0.85)

Gear Tooth Wear

1⁄ 1⁄
(K ) 2 1 2
(σC )G = [(Ks )G ] σC = [1] (1686.5) MPa = 1686.5 MPa
s P

So ; (σC )G = (σC )P = 1686.5 MPa

S c ZN Zw 644 0.9892(1)
(SH )G = = [ ] = 1.3818
σc Yθ YZ 1686.5 1(0.85)

45
3.6 Comparison

Table 3.6: Comparison between existing and improved product

Product
Existing Improved
Specification

Material AISI HR 1020 AISI HR 1050

No. of teeth 19 25

Pinion tooth bending stress (MPa) 170.48 2051.1

Pinion tooth bending safety factor 1.30 1.089

Gear tooth bending stress (MPa) 115.49 130.78

Gear tooth bending safety factor 1.98 1.76

Pinion tooth wear stress (MPa) 1568.58 1686.5

Pinion tooth wear safety factor 1.457 1.4258

Gear tooth wear stress (MPa) 1568.58 1686.5

Gear tooth wear safety factor 1.4748 1.3818

46
 4. DISCUSSION

From the mini project title that we had chosen which Chain Hoist is, we selected it
because we think it related so much with our syllabus in Mechanical Component Design
Subject. Based from our discussion with group members, we selected this title due to it
frequently in many syllabus in our subject such as failure for static loading, fatigue failure,
load and stress and etc. So by selected this title, we can easily refer to our textbook Shigley`s
Mechanical Engineering Design, Tenth Edition in SI Unit and from websites. Other that than,
we can privately discuss with our lecturer, Dr.Haftirman for uncertainty in our project during
lab session or even after classes.

For group discussion, we had decided to divide our job due to we have 4 members in
our group. So, we can easily do the calculation of critical components which we are already
selected during our discussion which is gears, bearing, chain, nut and shaft. From the existing
product that has been produced in the market nowadays, all the products are user-friendly but
from our project, we decide to do some modification that will be more user-friendly which
is by changing the number of teeth in gears. We are also selecting new material so that our
gears can last longer and will give a better result to the user compare to the existing one.

47
 5. CONCLUSION AND RECOMMENDATION

As a conclusion, from our mini project, we managed to redesign the existing Chain Hoist
using our own dimension and more user-friendly by using new materials that are stronger
and last longer compare to the current one. For the future, we hope our project can help the
user in saving their time, cost and so on. For our project conclusion we have include analysis
regarding the strength and factor of safety to prove that we have satisfies the engineering
specifications designated for a similar kind of product.

For recommendation, we design small and do not require minimum space for storing.
Lightweight and easy to carry to any place. Suitable for women to operating. Did not require
heavy power or energy to lifting the load. Maximum load for handle is 1-2 ton. Maximum
height for lifting is 10 ft. Materials that going to use is lightweight and user-friendly. Using
more number of teeth at gears so that we can minimize the power of the handler. Lastly,
creating a product that will last longer than the existing one.

48
 6. REFERENCES

1) Shingley J.E., Mischke C.R., Budynas R.G., (2011). Mechanical Engineering Design,
9th Edition, New York: McGraw-Hill.

2) Ugural, Ansel C. (2004). Mechanical Design: An Integrated Approach. Boston:

McGraw-Hill.

3) Harold A. Rothbart. (1996). Mechanical Design Handbook. New York: McGraw-

Hill.

4) Kelley, David S. (2005). CATIA for Design and Engineering, Version 5, Releases 14
& 15. Midland, Michigan: Schroff Development.

5) Cozzens, Richard. (2004). Catia V5 Workbook. Southern Utah University: Schroff

Development Corporation.

49
 7. APPENDICES

Figure 7.1: Gear 5 teeth

Figure 7.2: Gear 4 teeth

50
 Figure 7.3: Bearing Figure 7.4: Gear 18 teeth

Figure 7.5: Gear 19 teeth Figure 7.6: Ratchet

51
Figure 7.7: Spring

Figure 7.8: Gear 25 teeth

52
 Figure 7.9: Shaft

Figure 7.10: Pawl

Figure 7.11: Sprocket

53
54