Machine Elements: Ho Chi Minh City University of Technology

HO CHI MINH CITY UNIVERSITY OF
TECHNOLOGY
The Faculty of Mechanical Engineering
Machine Design Project
MACHINE ELEMENTS
Lecturer: ASSOC. PROF. PHAN ĐINH HUAN

Student: Liêu Quốc Huy
Student ID: 1752226
Class: CC01
Project: 01 – Design driving conveyor chain system
Plan: 08
Machine design project Plan 1- Solution 08 ASSOC. PROF. PHAN ĐINH HUAN
TABLE OF CONTENT
Chapter 1: Design the conveyor chain system……………………………….3
Chapter 2: Design the V-belt drive…………………………………………….7
Chapter 3: Design the spur gear………………………………………………12
Chapter 4: Design two shafts in the gear reducer…………………………...22
- Shaft 1………………………………………………………………….23
- Shaft 2………………………………………………………………... .31
Chapter 5: Design two pairs of roller bearing in the gear reducer……… …41
- Design the roller bearing on the shaft 1…………………………... .41
- Design the roller bearing on the shaft 2……………………………. 42
References………………………………………………………………………. 45
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The driving conveyor chain system includes:
1. Electric motor
2. V-belt drive
3. Reduction cylindrical gear
4. Flexible coupling
5. Conveyor chain
Design data: plan 08
- Turning force on conveyor chain, F (N): 4500
- Conveyor chain speed, v (m/s) :3.25
- The number of teeth on driving sprocket on conveyor chain, z (teeth) :15
- Pitch of chain, p (mm): 100
- Service life, L (year): 5
- Rotating in one direction, 2 work shifts, light impact load
(300 days/ year, 8h/ work shift)
Load: T1 = T ; t1, (giây) = 12
T2 = 0.6T ; t2, (giây) = 60
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The error of rotation compares to requirements: ≤ ±3%

Requirements
 Chapter 1: Select electric motor and distribute transmission ratio
 Chapter 2: Design V-belt drive
 Chapter 3: Design spur gear
 Chapter 4: Design two shafts in the gear reducer
 Chapter 5: Design two pairs of roller bearing in the gear reducer
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Chapter 1: Select electric motor & Distribute

transmission ratio
1.Selecting electric motor
2
System efficiency: 𝜂 = 𝜂𝑘𝑛 ∗ 𝜂𝑏𝑟 ∗ 𝜂𝑑 ∗ 𝜂𝑜𝑙
From Table 3.3 in [I], we have:
𝜂𝑘𝑛 = 1 : Coupling efficiency
𝜂𝑏𝑟 = 0.97 : Spur gear drive efficiency
𝜂𝑑 = 0.95 : Belt drive efficiency
𝜂𝑜𝑙 = 0.99 : Roller bearings efficiency
2
 𝜂 = 𝜂𝑘𝑛 ∗ 𝜂𝑏𝑟 ∗ 𝜂𝑑 ∗ 𝜂𝑜𝑙 = 1 ∗ 0.97 ∗ 0.95 ∗ 0.992 ≈ 0.903
 The maximum power on the shaft of conveyor chain:
𝐹𝑡 ∗ 𝑣 4500 ∗ 3.25 117
𝑃𝑚𝑎𝑥 = = = = 14.625 (𝑘𝑊)
1000 1000 8
 The equivalent power on the shaft of conveyor chain:
𝑇
∑𝑛𝑖 𝑃𝑖2 𝑡𝑖 ∑𝑛𝑖( 𝑖 )2 𝑡𝑖 12 ∗ 12 + 0.62 ∗ 60
𝑃𝑡𝑑 = √ = 𝑃𝑚𝑎𝑥 ∗ √ 𝑇 = 14.625 ∗ √
∑𝑛𝑖 𝑡𝑖 ∑𝑛𝑖 𝑡𝑖 12 + 60
39√105
= ≈ 9.99 (𝑘𝑊)
40
 The required power on the motor’s shaft:
𝑃𝑡𝑑 9.99
𝑃𝑐𝑡 = = ≈ 11.063 (𝑘𝑊)
𝜂 0.903
 The rotating speed on the shaft of the conveyor chain:
60000 ∗ 𝑣 60000 ∗ 3.25
𝑛𝑙𝑣 = = = 130 𝑟𝑝𝑚
𝑧∗𝑝 15 ∗ 100
 Transmission ratio of the system: 𝑢 = 𝑢𝑑 ∗ 𝑢𝑏𝑟
Selecting transmission ratio of the drive based on the table 3.2 in [I]:
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𝑢𝑑 = 3 : Transmission ratio of the V-belt drive

𝑢𝑏𝑟 = 3 : Transmission ratio of the spur gear drive
 𝑢 = 𝑢𝑑 ∗ 𝑢𝑏𝑟 = 3 ∗ 3 = 9
 The predicted rotating speed of the electric motor
𝑛𝑠𝑏 = 𝑛𝑙𝑣 ∗ 𝑢 = 130 ∗ 9 = 1170 𝑟𝑝𝑚
According to required power on the motor’s shaft 𝑷𝒄𝒕 = 𝟏𝟏. 𝟎𝟔𝟑 𝒌𝑾 and
the rotating speed of the electric motor 𝒏𝒔𝒃 = 𝟏𝟏𝟕𝟎 𝒓𝒑𝒎
 We choose the three-phase asynchronous motor model AESV2E with
P = 17.3 kW and n= 1175 rpm made by TECO Electric and Machinery
2.Distribute the transmission ratio
 The transmission system ratio:
𝑛𝑑𝑐 1175
𝑢 = 𝑢𝑑 ∗ 𝑢𝑏𝑟 = = ≈ 9.04
𝑛𝑙𝑣 130
𝑢 9.04
We choose: 𝑢𝑑 = 3⟹ 𝑢𝑏𝑟 = = = 3.013
𝑢𝑑 3
 The power on the shafts:

𝑃𝐼𝐼 = 𝑃𝑚𝑎𝑥 = 14.625 (𝑘𝑊)
𝑃𝐼𝐼 14.625
𝑃𝐼 = = ≈ 15.23 (𝑘𝑊)
𝜂𝑜𝑙 ∗ 𝜂𝑏𝑟 0.99 ∗ 0.97
𝑃𝐼 15.23
𝑃𝑑𝑐 = = ≈ 16.19 (𝑘𝑊)
𝜂𝑜𝑙 ∗ 𝜂𝑑 0.99 ∗ 0.95
 The rotating speed on the shafts:
𝑛𝑑𝑐 1175
𝑛𝐼 = = ≈ 391.67 𝑟𝑝𝑚
𝑢𝑑 3
𝑛𝐼 391.67
𝑛𝐼𝐼 = = ≈ 130.557 𝑟𝑝𝑚
𝑢𝑏𝑟 3
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 The torque on the shafts:

𝑃𝑑𝑐 16.19
𝑇𝑑𝑐 = 9.55 ∗ 106 ∗ = 9.55 ∗ 106 ∗ ≈ 131587 (𝑁𝑚𝑚)
𝑛𝑑𝑐 1175
𝑃𝐼 15.23
𝑇𝐼 = 9.55 ∗ 106 ∗ = 9.55 ∗ 106 ∗ ≈ 371350 (𝑁𝑚𝑚)
𝑛𝐼 391.67
𝑃𝐼𝐼 14.625
𝑇2 = 9.55 ∗ 106 ∗ = 9.55 ∗ 106 ∗ ≈ 1069791 (𝑁𝑚𝑚)
𝑛𝐼𝐼 130.557
 The estimated data table:
Shaft Motor I II
Power P(kW) 16.19 15.23 14.625

The transmission rate u 3 3.013
The number of. revolutions n (rev./minute) 1175 391.67 130.557
The torque T (Nmm) 131587 371350 1069791
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Chapter 2: Design the V-belt

1. The initial calculated data:
The power of motor, 𝑃𝑑𝑐 = 16.19 𝑘𝑊
Transmission ratio 𝑢𝑑 = 3
The number of revolutions n = 1175 (rev./minute)
The torque T = 131587 N.mm
2. Calculating the designed data:
- Select the type of belt
According to initial calculated data,𝑷𝒅𝒄 = 𝟏𝟔. 𝟏𝟗 𝒌𝑾, n = 1175
(rev./minute), and the picture 4.22 in reference [I]
 We choose the C belt with the data looked up in the table 4.3 in reference [I]:
b𝑞 = 19 𝑚𝑚, b𝑜 = 22 𝑚𝑚, h = 13.5 𝑚𝑚, y𝑜 = 4.8𝑚𝑚, A = 230 𝑚𝑚2,
L = 1800 ÷ 108600 mm, T1 = 110 ÷ 550 N. m, d𝑚𝑖𝑛 = 250 ÷ 400 mm
- The driving gear diameter 𝑑1 :
d1 = 1.2 ∗ dmin = 1.2 ∗ 250 = 300 mm
According to basic standard, selecting 𝐝𝟏 = 𝟑𝟏𝟓 𝐦𝐦
- The speed of driving gear:
π∗d1 ∗n 𝜋∗315∗1175
v1 = = ≈ 19.38 (𝑚⁄𝑠 ) < [𝑣] = 25 (𝑚⁄𝑠 )
60000 60000
 d1 = 315 mm
- The speed of driven gear 𝑑2 :
Due to light impact load, I select the relative slip coefficient  0.01
d2 = 𝑢𝑑 ∗ d1 ∗ (1 − ξ ) = 3 ∗ 315 ∗ (1 − 0.01) = 935.55 mm
According to the basic standard, I choose 𝐝𝟐 = 𝟗𝟎𝟎 𝒎𝒎
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- Calculating precisely 𝑢𝑑 :
d2 900
𝑢𝑑 = = = 2.886
d1 ∗ (1 − ξ) 315 ∗ (1 − 0.01)
Comparing the error to the initial data, it is acceptable.
- Select the preliminary distance of shaft follows the condition:
2 ∗ (𝑑1 + 𝑑2 ) ≥ 𝑎 ≥ 0.55 ∗ (𝑑1 + 𝑑2 ) + ℎ
↔ 2 ∗ (315 + 900) ≥ 𝑎 ≥ 0.55 ∗ (315 + 900) + 13.5
↔ 2430 ≥ 𝑎 ≥ 681.75
 Choose 𝒂 = 𝟏. 𝟐 ∗ 𝒅𝟐 = 𝟏𝟎𝟖𝟎 𝒎𝒎
- The belt length:
(𝑑2 − 𝑑1 )2
𝐿 =2∗𝑎++
4∗𝑎
𝜋 ∗ (315 + 900) (900 − 315)2
= 2 ∗ 1080 + + ≈ 4148 𝑚𝑚
2 4 ∗ 1080
According to the basic standard, selecting L = 4000 mm
- Calculating precisely the distance of shaft a:
𝑘 + √𝑘 2 + 8 ∗ ∆2
𝑎=
4
𝜋 ∗ (𝑑1 + 𝑑2 ) 𝜋 ∗ (315 + 900)
𝑘=𝐿− = 4000 − ≈ 2091.5
2 2
(𝑑2 − 𝑑1 ) 900 − 315
∆= = = 292.5
2 2
𝑘+√𝑘 2 +8∗∆2 2091.5+√2091.52 +8∗292.52
 𝑎= = ≈ 1085.2 𝑚𝑚
4 4
Compare the value 𝐚 to the condition: 𝟐𝟒𝟑𝟎 ≥ 𝐚 ≥ 𝟔𝟖𝟏. 𝟕𝟓

 The value of 𝑎 is acceptable.
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- The covered angle of the belt:
(𝑑2 − 𝑑1 ) (900 − 315)

𝑎1 = 180 − 57 ∗ = 180 − 57 ∗ = 149.3 > 𝑎𝑚𝑖𝑛 = 120
𝑎 1085.2
 𝑇ℎ𝑒 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝛼1 , 𝑑1 𝑎𝑛𝑑 𝑑2 𝑎𝑟𝑒 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒.
- The number of revolutions of belt per second:
𝑣1 19.38
𝑖= = = (𝑠 −1 ) = 4.845 (𝑠 −1 ) < [𝑖] = 10 (𝑠 −1 )
𝐿 4
- The number of belt cables:
𝑃𝑑𝑐
𝑧=
[𝑃𝑜 ] ∗ 𝐶𝑎 ∗ 𝐶𝑢 ∗ 𝐶𝐿 ∗ 𝐶𝑧 ∗ 𝐶𝑟 ∗ 𝐶𝑣
Where:
𝑃𝑑𝑐 = 16.19 𝑘𝑊
[𝑃0 ] = 12 𝑘𝑊, 𝑤𝑖𝑡ℎ 𝐿𝑜 = 2240 𝑚𝑚, 𝑣1 = 19.38 𝑚/𝑠, 𝑑1 = 315 𝑚𝑚 (graph 4.21
in reference [I])
The impact coefficient of the angle covering the belt:
𝛼1 149.3
𝐶𝛼 = 1.24 ∗ (1 − 𝑒 −110 ) = 1.24 ∗ (1 − 𝑒 − 110 ) ≈ 0.921
The impact coefficient of the transmission rate u: according to the Table 4.9 in
reference [I]: 𝐶𝑢 = 1.14
The impact coefficient of the length L:
𝐿
6 6 4000
𝐶𝐿 = √ = √ ≈ 1.1
𝐿0 2240
The impact coefficient of the uneven load distribution on the belt cables:
Because we don’t know the exact number of cables, so we preliminary choose
𝐶𝑧 = 0.9
The impact coefficient of load mode: due to light impact load, selecting
𝐶𝑟 = 0.7
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The impact coefficient of velocity:

𝐶𝑣 = 1 − 0.05 ∗ (0.01 ∗ 𝑣1 2 − 1) = 1 − 0.05 ∗ (0.01 ∗ 19.382 − 1) ≈ 0.862
We have:
𝑃𝑑𝑐
𝑧 ≥ [𝑃
𝑜 ]∗𝐶𝑎 ∗𝐶𝑢 ∗𝐶𝐿 ∗𝐶𝑧 ∗𝐶𝑟 ∗𝐶𝑣
16.19
 𝑧≥ ≈ 2.2
12∗0.921∗1.14∗1.1∗0.9∗0.7∗0.862
 Selecting z = 5 belts
- The width and the outer diameter of the belt gears:
 The width of the belt gears:
𝐵 = (𝑧 − 1) ∗ 𝑒 + 2 ∗ 𝑓 ; with z = 5
Based on the table 4.4 in the reference [I]: e = 25.5; f = 17
 𝐵 = (𝑧 − 1) ∗ 𝑒 + 2 ∗ 𝑓 = (5 − 1) ∗ 25.5 + 2 ∗ 17 = 136 𝑚𝑚
 The outer diameter of the belt gears: (ℎ𝑜 = 5.7 𝑚𝑚)
𝑑𝑎 = 𝑑1 + 2 ∗ ℎ𝑜 = 315 + 2 ∗ 5.7 = 326.4 𝑚𝑚
 𝑑𝑎 = 326.4 𝑚𝑚
- The force acts on the shafts:
 The initial belt tension:
𝐹𝑜 = 𝜎𝑜 ∗ 𝑧 ∗ 𝐴 = 1.5 ∗ 5 ∗ 230 = 1725 𝑁 ( V-belt ⇒ 𝜎𝑜 = 1.5 𝑀𝑃𝑎)
 𝐹𝑜 = 1725 𝑁
The force acts on the shafts and the bearing:
𝛼1 149.3
𝐹𝑟 = 2 ∗ 𝐹𝑜 ∗ sin ( ) = 2 ∗ 1725 ∗ sin ( ) ≈ 3327 𝑁
2 2
 𝐹𝑟 = 3327 𝑁
- The maximum stress coefficient on the belt cables and the longevity of the
belt:
 The tension on each cable:
𝐹0 1725
= = 345 𝑁
𝑧 5
10 | P a g e
 The useful gear force

1000 ∗ 𝑃𝑑𝑐 16.19
𝐹𝑡 = = 1000 ∗ ≈ 835.4 𝑁
𝑣1 19.38
 The useful gear force on each cable:
𝐹𝑡 672
= ≈ 167.08 𝑁
𝑧 5
 The maximum stress coefficient on the belt cables:
𝜎𝑚𝑎𝑥 = 𝜎1 + 𝜎𝑣 + 𝜎𝑢1 = 𝜎0 + 0.5 ∗ 𝜎𝑡 + 𝜎𝑣 + 𝜎𝑢1
𝐹0 𝐹𝑡 2∗𝑦0
= + 0.5 ∗ + 𝜌 ∗ 𝑣1 2 ∗ 10−6 + ∗𝐸
𝑧∗𝐴 𝑧∗𝐴 𝑑1
345 167.08 100

= + 0.5 ∗ + 1200 ∗ 19.382 ∗ 10−6 + 2 ∗ 4.8 ∗
230 230 315
≈ 5.36 𝑀𝑃𝑎
 The belt’s longevity:
𝜎 9 8
( 𝑟 )𝑚 ∗ 107 ( ) ∗ 107
𝜎𝑚𝑎𝑥
𝐿ℎ = = 5.36 ≈ 18113.212 (ℎ𝑜𝑢𝑟𝑠)
2 ∗ 3600 ∗ 𝑖 2 ∗ 3600 ∗ 4.845
(Because of V-belt, 𝜎𝑟 = 9 𝑀𝑃𝑎 𝑎𝑛𝑑 𝑚 = 8 )
- The data of the V-belt drive table:
P1 (kW) n (rev./m) 𝐹0 (N) 𝐹𝑟 (N)   (o ) u
16.19 1175 1725 3327 149.3 2.886
z d1 d2 a (mm) L (mm) B (mm)
5 315 900 1080 4000 136
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Chapter 3: Design the spur gear

1. The initial calculated data:
The power of transmission 𝑃1 = 15.23 𝑘𝑊
Torque 𝑇1 = 371350
Transmission rate u = 3.013
The number of revolutions of the driving gear: 𝑛1 = 391.67𝑟𝑝𝑚
The number of revolutions of the driven gear: 𝑛2 = 130.557 𝑟𝑝𝑚
Working hour: 𝐿ℎ = 5 ∗ 300 ∗ 8 ∗ 2 = 24000 ℎ
Rotating in one direction, 2 work shifts, light impact load
2. Calculating the designed data:
- Selecting the appropriate materials:
Based on Table 6.13 in reference [I]:
 The driving gear: choose steel C45 which was quenched with rigidity 𝐻1 ≈
250𝐻𝐵; ultimate strength 𝜎𝑏 = 850 𝑀𝑃𝑎; yield limit 𝜎𝑐ℎ = 580 𝑀𝑃𝑎 ( Table 6.1
in the reference [II])
 The driven gear: choose steel C45 which was quenched with rigidity 𝐻2
relating to 𝐻1 ≥ 𝐻2 + (10 ÷ 15)𝐻𝐵, so the magnitude of 𝐻2 ≈ 235 𝐻𝐵;
ultimate strength 𝜎𝑏 = 750 𝑀𝑃𝑎; yield limit 𝜎𝑐ℎ = 450 𝑀𝑃𝑎
- The acceptable stress:
a. The tangential stress:
 The limit of fatigued contacting corresponds to the basic cycle 𝜎0𝐻𝑙𝑖𝑚 :
According to Table 6.13 in reference [I], we have:𝜎0𝐻𝑙𝑖𝑚 = 2 ∗ 𝐻𝐵 + 70 𝑀𝑃𝑎
𝜎0𝐻𝑙𝑖𝑚1 = 2 ∗ 𝐻1 + 70 𝑀𝑃𝑎 = 2 ∗ 250 + 70 = 570 𝑀𝑃𝑎
𝜎0𝐻𝑙𝑖𝑚2 = 2 ∗ 𝐻2 + 70 𝑀𝑃𝑎 = 2 ∗ 235 + 70 = 540 𝑀𝑃𝑎
 The number of working basic cycle: 𝑁𝐻𝑂 = 30 ∗ 𝐻𝐵2.4
𝑁𝐻𝑂1 = 30 ∗ 𝐻1 2.4 = 30 ∗ 2502.4 = 0.17 ∗ 108 𝑐𝑦𝑐𝑙𝑒𝑠
𝑁𝐻𝑂2 = 30 ∗ 𝐻2 2.4 = 30 ∗ 2352.4 = 0.147 ∗ 108 𝑐𝑦𝑐𝑙𝑒𝑠
12 | P a g e
 The number of equivalent working cycles: due to the transmission system

works with different level of loads
𝑇𝑖
𝑁𝐻𝐸 = 60𝑐 ∑( )3 ∗ 𝑛𝑖 ∗ 𝑡𝑖
𝑇𝑚𝑎𝑥
With c: the amount of times the two gears mesh per revolution. There are
once times they mesh, so c = 1
𝑇 3 60 0.6 ∗ 𝑇 3 12
𝑁𝐻𝐸1 = 60 ∗ 1 ∗ 391.67 ∗ [( ) ∗ +( ) ∗ ] ∗ 24000
𝑇 72 𝑇 72
= 4.903 ∗ 108 𝑐𝑦𝑐𝑙𝑒𝑠
𝑇 3 60 0.6 ∗ 𝑇 3 12
𝑁𝐻𝐸2 = 60 ∗ 1 ∗ 182.5 ∗ [( ) ∗ +( ) ∗ ] ∗ 24000
𝑇 72 𝑇 72
= 2.285 ∗ 108 𝑐𝑦𝑐𝑙𝑒𝑠
Because 𝑁𝐻𝐸 > 𝑁𝐻𝑂 so 𝐾𝐻𝐿1 = 𝐾𝐻𝐿2 = 1
𝑁𝐻𝑂
With 𝐾𝐻𝐿 : the coefficient of longevity; 𝐾𝐾𝐿 = 𝑚𝑓 √
𝑁𝐻𝐸
 The safety factor 𝑠𝐻 : according to Table 6.13 in the reference [I]: 𝑠𝐻 = 1.1
 The allowable tangential stress:
0.9𝐻𝐾𝐻𝐿
[𝜎𝐻 ] = 𝜎0𝐻𝑙𝑖𝑚
𝑠𝐻
0.9𝐻𝐾𝐻𝐿1 0.9 ∗ 1
[𝜎𝐻1 ] = 𝜎0𝐻𝑙𝑖𝑚1 = 570 ∗ = 466.36 𝑀𝑃𝑎
𝑠𝐻 1.1
0.9𝐻𝐾𝐻𝐿2 0.9 ∗ 1
[𝜎𝐻2 ] = 𝜎0𝐻𝑙𝑖𝑚2 = 540 ∗ = 441.82 𝑀𝑃𝑎
𝑠𝐻 1.1
b. The bending stress:
 The limit of fatigued bending 𝜎0𝐹𝑙𝑖𝑚 , corresponding to the number of basic
cycles 𝑁𝐹𝑂 which are depended on the rigidity of the surface and heat
treatment method.
According to the Table 6.13 in reference [I], we have: 𝜎0𝐹𝑙𝑖𝑚 = 1.8 ∗ 𝐻𝐵
𝜎0𝐹𝑙𝑖𝑚1 = 1.8 ∗ 𝐻1 = 1.8 ∗ 250 = 450 𝑀𝑃𝑎
13 | P a g e
𝜎0𝐹𝑙𝑖𝑚2 = 1.8 ∗ 𝐻2 = 1.8 ∗ 235 = 423 𝑀𝑃𝑎

 Safety factor 𝑠𝐹 , according to the Table 6.13 in reference [I]:
we have 𝑠𝐹 = 1.75
𝑇
 The number of equivalent periods: 𝑁𝐹𝐸 = 60𝑐 ∑( 𝑖 )6 ∗ 𝑛𝑖 ∗ 𝑡𝑖
𝑇𝑚𝑎𝑥
Because there are once times the two gears mech in per revolution, so c =1
𝑇 6 60 0.6∗𝑇 6 12
𝑁𝐹𝐸1 = 60 ∗ 1 ∗ 391.67 ∗ [( ) ∗ + (
𝑇 72 𝑇
) ∗ 72] ∗ 24000 = 7.74 ∗ 108
𝑇 6 60 0.6∗𝑇 6 12
𝑁𝐹𝐸1 = 60 ∗ 1 ∗ 130.557 ∗ [( ) ∗ + (
𝑇 72 𝑇
) ∗ 72] ∗ 24000 = 2.21 ∗ 108
 The number of basic cycles is 𝑁𝐹𝑂 = 5 ∗ 106 to all type of steel

Because 𝑁𝐹𝐸 > 𝑁𝐹𝑂 , so 𝐾𝐹𝐿1 = 𝐹𝐹𝐿2 = 1
𝑁𝐹𝑂
𝐾𝐹𝐿 : the coefficient of longevity 𝐾𝐹𝐿 = 𝑚𝑓 √
𝑁𝐹𝐸
 The fatigued coefficient when rotating in two direction: 𝐾𝐹𝐶 = 1 when rotating
in only one direction
𝜎 ∗𝐾
 The bending stress: [𝜎𝐹 ] = 𝑂𝐹𝑙𝑖𝑚 𝐹𝐶 ∗ 𝐾𝐾𝐿
𝑠𝐹
𝜎𝑂𝐹𝑙𝑖𝑚1 ∗ 𝐾𝐹𝐶 450 ∗ 1

[𝜎𝐹1 ] = ∗ 𝐾𝐾𝐿1 = ∗ 1 = 257.14 𝑀𝑃𝑎
𝑠𝐹 1.75
𝜎𝑂𝐹𝑙𝑖𝑚2 ∗ 𝐾𝐹𝐶 423 ∗ 1
[𝜎𝐹2 ] = ∗ 𝐾𝐾𝐿2 = ∗ 1 = 241.7 𝑀𝑃𝑎
𝑠𝐹 1.75
Because of the closed-loop systems (speed-reducer) which is lubricated well
so we calculate and design the machine follow the durability to avoid tooth
surface fatigue
- Selecting allowable contacting stress [𝜎𝐻 ] following the formula:
[𝜎𝐻 ] = √0.5 ∗ ([𝜎𝐻1 ]2 + [𝜎𝐻2 ]2 )
[𝜎𝐻 ] = √0.5 ∗ (466.362 + 441.822 ) = 454.26 𝑀𝑃𝑎

Satisfy the condition: [𝜎𝐻 ]𝑚𝑖𝑛 ≤ [𝜎𝐻 ] ≤ 1.25 ∗ [𝜎𝐻 ]𝑚𝑖𝑛
14 | P a g e
- Selecting the coefficient of the wide toothing based on the standard:

According to the Table 6.15 in the reference [I], we have: 𝜓𝑏𝑎 = 0.3 (the two
gears are symmetrical to the axis and 𝐻1 , 𝐻2 < 350 𝐻𝐵)
𝜓𝑏𝑎 ∗(𝑢+1) 0.3∗(3.013+1)
We have: 𝜓𝑏𝑑 = = = 0.60195
2 2
According to the Table 6.4 in the reference [I]:

 𝐾𝐻𝛽 = 1.01 and 𝐾𝐹𝛽 = 1.02
- Calculating the gears data:
 Center distance:
3 𝑇1 ∗ 𝐾𝐻𝛽
𝑎𝑤 = 43 ∗ (𝑢 + 1) ∗ √
𝜓𝑏𝑎 ∗ [𝜎𝐻 ]2 ∗ 𝑢
3 371350 ∗ 1.01
= 43 ∗ (3.013 + 1) ∗ √
0.3 ∗ 454.262 ∗ 3.013
= 217.8 𝑚𝑚
According to the basic standard, we choose 𝒂𝒘 = 𝟐𝟓𝟎 𝒎𝒎
 The module of the gears m:
𝑚 = (0.01 + 0.02) ∗ 𝑎𝑤 = (0.01 + 0.02) ∗ 250 = 2.5 ÷ 5 𝑚𝑚
According to the basic standard, we choose: m = 3 mm
 The number of teeth on the gears:
2∗𝑎𝑤 ∗cos 𝛽 2∗250∗cos 𝛽
Driving gear: 𝑧1 = =
𝑚𝑛 ∗(𝑢+1) 3∗(3.013+1)
Because 80 < 𝛽 < 200 → 39.027 < 𝑧1 < 41.127

 Selecting 𝒛𝟏 = 𝟒𝟎 𝒕𝒆𝒆𝒕𝒉
Driven gear: 𝑧2 = 𝑢 ∗ 𝑧1 = 3.013 ∗ 24 = 120.52
 Selecting 𝒛𝟐 = 𝟏𝟐𝟏 𝒕𝒆𝒆𝒕𝒉
𝑚∗(𝑧1 +𝑧2 ) 3∗(40+121)
 The angle of incline: 𝛽 = cos −1 ( ) = cos −1 ( ) = 14.9840
2∗𝑎𝑤 2∗250
 The gear tooth width: 𝑏𝑤 = 𝜓𝑏𝑎 ∗ 𝑎𝑤 = 0.3 ∗ 250 = 75 𝑚𝑚
𝑧 121
 Calculating precisely the transmission ratio: 𝑢 = 2 = = 3.025
𝑧1 40
15 | P a g e
The transmission ratio in reality: 𝑢𝑡𝑡 = 𝑢𝑑 ∗ 𝑢𝑏𝑟 = 2.886 ∗ 3.025 = 8.73

The transmission ratio error:
|𝑢𝑡𝑡 − 𝑢|
∆𝑢 = ∗ 100
𝑢
|8.73 − 9|
= ∗ 100 = 3% < [∆𝑢] = 5% ( 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒)
9
 The reference diameter:
𝑧 ∗𝑚 40∗3
Driving gear: 𝑑1 = 1 = = 124.22 𝑚𝑚
cos 𝛽 cos 14.984 0
𝑧2 ∗𝑚 121∗3
Driven gear: 𝑑2 = = ≈ 376 𝑚𝑚
cos 𝛽 cos 14.984 0
 The tip diameter:
Driving gear: 𝑑𝑎1 = 𝑑1 + 2 ∗ 𝑚 = 124.22 + 2 ∗ 3 = 130.22 𝑚𝑚
Driven gear: 𝑑𝑎2 = 𝑑2 + 2 ∗ 𝑚 = 376 + 2 ∗ 3 = 382 𝑚𝑚
- The gear speed:
𝜋∗𝑑1 ∗𝑛1 𝜋∗130.22∗391.67
𝑣= = = 2.67 𝑚/𝑠
60000 60000
According to the Table 6.3 in reference [I], we select the degree of accuracy is
9 and the limit gear speed is 𝑣𝑔ℎ = 6𝑚/𝑠
- The coefficient of dynamic loading and the coefficient of unevenly distributed
between gear teeth
The coefficient of dynamic loading:
According to the Table 6.6 in reference [I], we have:
𝐾𝐻𝑣 = 1.1 𝑎𝑛𝑑 𝐾𝐹𝑣 = 1.22
The coefficient of unevenly distributed between gear teeth:
According to the Table 6.11 in reference [I], we have 𝐾𝐻𝛼 = 1.13
4+(𝜀𝛼 −1)∗(𝑛𝑐𝑥 −5)
The coefficient 𝐾𝐹𝛼 = 1.13 is determined as: 𝐾𝐹𝛼 =
4𝜀𝛼
Where: 𝑛𝑐𝑥 is the degree of accuracy, 𝑛𝑐𝑥 ≥ 9 so 𝐾𝐹𝛼 = 1

- Checking the precision of stresses:
a. Checking the precision of the contacting stress:
 Calculating precisely the allowable contacting stress:
16 | P a g e
𝐾𝐻𝐿 ∗ 𝑍𝑅 ∗ 𝑍𝑉 ∗ 𝐾𝑙 ∗ 𝐾𝑥𝐻
[𝜎𝐻 ] = 𝜎0𝐻𝑙𝑖𝑚 ∗
𝑠𝐻
𝑊ℎ𝑒𝑟𝑒:
The coefficient impacting on the surface roughness 𝑍𝑅 :
select 𝑍𝑅 = 0.95
The coefficient impacting on the gear’s velocity 𝑍𝑉 :
Because 𝐻𝐵 ≤ 350, so 𝑍𝑉 = 0.85 ∗ 𝑣 0.1 = 0.85 ∗ 2.670.1 ≈ 0.94
The coefficient impacting on the lubricant condition 𝐾𝑙 : 𝐾𝑙 = 1
The coefficient impacting on the dimension of the gear’s teeth 𝐾𝑥𝐻 :
𝑑1 124.22
𝐾𝑥𝐻 = √1.05 − = √1.05 − ≈ 1.02
104 104
We have:
[𝜎𝐻1 ] = 𝜎0𝐻𝑙𝑖𝑚1 ∗
𝑠𝐻
1 ∗ 0.95 ∗ 0.94 ∗ 1 ∗ 1.02
= 570 ∗ ≈ 472 𝑀𝑃𝑎
1.1
[𝜎𝐻2 ] = 𝜎0𝐻𝑙𝑖𝑚2 ∗
𝑠𝐻
1 ∗ 0.95 ∗ 0.94 ∗ 1 ∗ 1.02
= 540 ∗ ≈ 447.15 𝑀𝑃𝑎
1.1
[𝜎𝐻 ] = √0.5 ∗ ([𝜎𝐻1 ]2 + [𝜎𝐻1 ]2 ) = √0.5 ∗ (4722 + 447.152 ) ≈ 460 𝑀𝑃𝑎
 The contact stress in gear teeth:
𝑍𝑀 ∗ 𝑍𝐻 ∗ 𝑍𝜀 2 ∗ 𝑇1 ∗ 𝐾𝐻 ∗ (𝑢 + 1)
𝜎𝐻 = ∗√
𝑑𝑤𝑙 𝑏𝑤 ∗ 𝑢
Where:
The coefficient impact on the shape of the contact surface 𝑍𝐻 :
17 | P a g e
2 cos 𝛽
𝑍𝐻 = √
sin(2𝛼𝑡𝑤 )
With 𝛼𝑡𝑤 is the synchronized angle in horizontal surface:

tan 𝛼𝑛𝑤 tan 20
𝛼𝑡𝑤 = tan−1 ( ) = tan−1 ( 0
) = 20.650
cos 𝛽 cos 14.984
2 cos 14.984 0
 𝑍𝐻 = √ = 1.71
sin(2∗20.65)
The coefficient determines the total contact length 𝑍𝜀 :
1
𝑍𝜀 = √
𝜀𝛼
1 1
With 𝜀𝛼 = [1.88 − 3.2 ∗ ( + )] ∗ cos 𝛽
𝑧1 𝑧2
1 1
𝜀𝛼 = [1.88 − 3.2 ∗ ( + )] ∗ cos 14.9840 ≈ 1.713
40 121
1 1
 𝑍𝜀 = √ =√ ≈ 0.764
𝜀𝛼 1.713
The coefficient of the mechanical properties of materials 𝑍𝑀 : Because
the pair of materials are made of steel so 𝑍𝑀 = 275 𝑀𝑃𝑎
The coefficient of load to the contact stress 𝐾𝐻 :
𝐾𝐻 = 𝐾𝐻𝛽 ∗ 𝐾𝐻𝑣 ∗ 𝐾𝐻𝛼 = 1.01 ∗ 1.1 ∗ 1.13 = 1.225
We have:
275 ∗ 1.71 ∗ 0.764 2 ∗ 371350 ∗ 1.225 ∗ (3.013 + 1)

𝜎𝐻 = ∗√ = 367.63 𝑀𝑃𝑎
124.22 75 ∗ 3.013
Compare the value of σH 𝑡𝑜 [σH ], σH = 367.63 MPa < [σH ] = 463 MPa so, the
gears are rough enough to mech
18 | P a g e
b. Checking the precision of bending stress:

 Calculating precisely the allowable bending stress
𝐾𝐹𝐿 ∗ 𝑌𝑅 ∗ 𝑌𝑥 ∗ 𝑌𝛿 ∗ 𝐾𝐹𝐶
[𝜎𝐹 ] = 𝜎0𝐹𝑙𝑖𝑚 ∗
𝑠𝐹
Where:
The coefficient impacts on the roughness 𝑌𝑅 : select 𝑌𝑅 = 1 when
grinding and milling gear
The coefficient of dimension 𝑌𝑥 : select 𝑌𝑥 = 1 when annealing the
surface
The sensitive coefficient of the gear’s material to the center point load
𝑌𝛿 : select 𝑌𝛿 = 1.0036
We have:
[𝜎𝐹1 ] = 𝜎0𝐹𝑙𝑖𝑚1 ∗
𝑠𝐹
1 ∗ 1 ∗ 1 ∗ 1.0036 ∗ 1
= 450 ∗ = 258.069 𝑀𝑃𝑎
1.75
[𝜎𝐹2 ] = 𝜎0𝐹𝑙𝑖𝑚2 ∗
𝑠𝐹
1 ∗ 1 ∗ 1 ∗ 1.0036 ∗ 1
= 423 ∗ = 242.584𝑀𝑃𝑎
1.75
 The number of equivalent teeth:
𝑧1 40
𝑍𝑣1 = = ≈ 45 𝑡𝑒𝑒𝑡ℎ
𝑐𝑜𝑠 3 𝛽 𝑐𝑜𝑠 3 14.9840
𝑧2 121
𝑍𝑣2 = = ≈ 135 𝑡𝑒𝑒𝑡ℎ
𝑐𝑜𝑠 3 𝛽 𝑐𝑜𝑠 3 14.9840
 The bending stress at the unsafe section:
𝑌𝐹 ∗ 𝐹𝑡 ∗ 𝐾𝐹 ∗ 𝑌𝜀 ∗ 𝑌𝛽
𝜎𝐹 =
𝑏𝑤 ∗ 𝑚𝑛
Where:
The load coefficient to calculate the bending stress 𝐾𝐹 :
19 | P a g e
𝐾𝐹 = 𝐾𝐹𝛼 ∗ 𝐾𝐹𝛽 ∗ 𝐾𝐹𝑣 = 1.02 ∗ 1.22 ∗ 1 = 1.2444

The tooth coefficient according to the equivalent teeth:
13.2 27.9 ∗ 𝑥
𝑌𝐹 = 3.47 + − + 0.092 ∗ 𝑥 2
𝑧𝑣 𝑧𝑣
We have: x = 0 (because we do not move the gear)
13.2 13.2
𝑌𝐹1 = 3.47 + = 3.47 + = 3.763
𝑧𝑣1 45
13.2 13.2
𝑌𝐹2 = 3.47 + = 3.47 + = 3.567
𝑧𝑣2 135
The coefficient impacts on matching in horizon 𝑌𝜀 :
1 1
𝑌𝜀 = = = 0.584
𝜀𝛼 1.713
The incline angle of teeth coefficient impacts on the yield 𝑌𝛽 :
𝛽
𝑌𝛽 = 1 − 𝜀𝛽 ∗
120
sin 𝛽 sin 14.984
With 𝜀𝛽 = 𝑏𝑤 ∗ = 75 ∗ = 2.057
𝜋∗𝑚𝑛 𝜋∗3
𝛽 14.984
𝑌𝛽 = 1 − 𝜀𝛽 ∗ = 1 − 2.057 ∗ = 0.743
120 120
The force on the driven gear:
2 ∗ 𝑇2 2 ∗ 371350
𝐹𝑡 = = = 5690 𝑁
𝑑2 124.22
Make a ratio:
[𝜎𝐹1 ] 258.069
= = 69
𝑌𝐹1 3.763
[𝜎𝐹2 ] 242.584
= = 68
𝑌𝐹2 3.567
[𝜎𝐹1 ] [𝜎𝐹2 ]
Because > so, we base on the driven gear to calculate
𝑌𝐹1 𝑌𝐹2
We get the bending stress at unsafe section:
20 | P a g e
𝑌𝐹2 ∗ 𝐹𝑡 ∗ 𝐾𝐹 ∗ 𝑌𝜀 ∗ 𝑌𝛽
𝜎𝐹2 =
𝑏𝑤 ∗ 𝑚𝑛
3.567 ∗ 5690 ∗ 1.2444 ∗ 0.584 ∗ 0.743
= = 48.71 𝑀𝑃𝑎
75 ∗ 3
Because 𝜎𝐹2 = 48.61 𝑀𝑃𝑎 < [𝜎𝐹2 ] = 242.584 𝑀𝑃𝑎 so, the gears are yielded
enough.
- The transmission system data:
Center distance 𝑎𝑤 = 250 𝑚𝑚
Normal module 𝑚 = 3 𝑚𝑚
The width of toothing 𝑏𝑤 = 75 𝑚𝑚
The number of teeth 𝑧1 = 20 𝑧2 = 121
Incline angle 𝛽 = 14.9840
The coefficient of movement 𝑥1 = 0 𝑥2 = 0
The reference diameter 𝑑1 = 124.22 𝑚𝑚 𝑑2 = 376 𝑚𝑚
The tip diameter 𝑑𝑎1 = 130.22 𝑚𝑚 𝑑𝑎2 = 382𝑚𝑚
The root diameter 𝑑𝑓 : 𝑑𝑓 = 𝑑 − (2.5 − 2 ∗ 𝑥) ∗ 𝑚
𝑑𝑓1 = 𝑑1 − 2.5 ∗ 𝑚; (𝑥1 = 0)
𝑑𝑓2 = 𝑑2 − 2.5 ∗ 𝑚; (𝑥2 = 0)
 𝑑𝑓1 = 𝑑1 − 2.5 ∗ 3 = 118.22 𝑚𝑚
𝑑𝑓2 = 𝑑2 − 2.5 ∗ 3 = 370 𝑚𝑚
- The forces applying on the transmission system:
 The gear force 𝐹𝑡 :
2𝑇1 2 ∗ 371350
𝐹𝑡1 = 𝐹𝑡2 = = = 5979 𝑁
𝑑1 124.22
 The axial force 𝐹𝑎 :
𝐹𝑎1 = 𝐹𝑎2 = 𝐹𝑡1 ∗ tan 𝛽 = 5979 ∗ tan 14.9840 = 1600 𝑁
21 | P a g e
 The centripetal force 𝐹𝑟 :

𝐹𝑡1 ∗ tan 𝛼𝑛𝑤 5979 ∗ tan 20
𝐹𝑟1 = 𝐹𝑟2 = = ≈ 2253 𝑁
cos 𝛽 cos 14.984
22 | P a g e
Chapter 4: Design two shafts in the gear reducer

The calculated data:
Shaft Motor I II
Power P(kW) 16.19 15.23 14.625

The transmission rate u 3 3.013
The number of. revolutions n (rev./minute) 1175 391.67 130.557
The torque T (Nmm) 131587 371350 1069791
The length of the two shafts diagram:
Shaft 1
Shaft 2
23 | P a g e
The force analysis diagram applies on two shafts:
Shaft 1
Shaft 2
1. The shaft 1:
- Selecting the appropriate material:
Choose steel C45 with 𝜎𝑏 = 600 𝑀𝑃𝑎, [𝜎𝐹 ]−1 = 50 𝑀𝑃𝑎, [𝜏] = 20 ÷ 25 𝑀𝑃𝑎
- Selecting the dimensions of the axis:
24 | P a g e
- Free body diagram on the shaft:

Oy
Ox
Where:
𝑇1 = 371350 𝑁𝑚𝑚, 𝐹𝑟 = 3327 𝑁, 𝐹𝑡1 = 5979 𝑁, 𝐹𝑟1 = 2253 𝑁
𝑑1 124.22
𝐹𝑎1 = 1600 𝑁, 𝑀𝑎1 = 𝐹𝑎1 ∗ = 1600 ∗ = 99376 𝑁𝑚𝑚
2 2
- Calculating the reactions of all the supports:

 In the Oy axis:
𝑀/𝐵 = 0 ⇔ 𝑅𝐴𝑦 ∗ 143 − 𝐹𝑟1 ∗ 71.5 − 𝑀𝑎1 + 𝐹𝑟 ∗ 78 = 0
𝐹𝑟1 ∗ 71.5 − 𝐹𝑟 ∗ 78 2253 ∗ 71.5 − 3391.13 ∗ 78
⇔ 𝑅𝐴𝑦 = = = −723.21 𝑁
143 143
𝑅𝐴𝑦 + 𝑅𝐵𝑦 = 𝐹𝑟1 + 𝐹𝑟 ⇔ 𝑅𝐵𝑦 = 𝐹𝑟1 + 𝐹𝑟 − 𝑅𝐴𝑦 = 6303.21 𝑁
 In the Ox axis:
𝑀/𝐵 = 0 ⇔ 𝑅𝐴𝑥 ∗ 143 − 𝐹𝑡1 ∗ 71.5 = 0
𝐹𝑡1 ∗ 71.5 5679 ∗ 71.5
⇔ 𝑅𝐴𝑥 = = = 2839.5 𝑁
143 143
𝑅𝐵𝑥 = 𝐹𝑡1 − 𝑅𝐴𝑥 = 5679 − 2839.5 = 2839.5 𝑁
25 | P a g e
- The internal force diagrams:
Bending moment 𝑀𝑥
259506
151085.515
51710
Bending moment 𝑀𝑦
203024
The torque T
371350
26 | P a g e
- The moment at the unsafe section:

The unsafe section at the support B
𝑀 = √𝑀𝑥 2 + 𝑀𝑦 2 + 0.75 ∗ 𝑇 2
= √2595062 + 2030242 + 0.75 ∗ 3713502 ≈ 460421.25 𝑁𝑚𝑚

- Diameter at the unsafe section
 I notate that the unsafe section is section 1-3, with 1 is the shaft 1 and 3 is the
section number counting from the left to right.
3 𝑀 3 460421.25
𝑑13 ≥ √ =√ = 45.16 𝑚𝑚
0.1 ∗ [𝜎𝐹 ]−1 0.1 ∗ 50
Having a roller bearing at the unsafe section.

According to the basic standard, selecting 𝒅𝟏𝟑 = 𝟓𝟎 𝒎𝒎
We choose the diameter at the section 1-1, 1-2 and 1-4:
𝒅𝟏𝟏 = 𝟓𝟎 𝒎𝒎, 𝒅𝟏𝟐 = 𝟓𝟓 𝒎𝒎, 𝒅𝟏𝟒 = 𝟒𝟓 𝒎𝒎
 Checking the diameter at the section 1-2:
𝑀 = √𝑀𝑥 2 + 𝑀𝑦 2 + 0.75 ∗ 𝑇 2
= √517102 + 2030242 + 0.75 ∗ 3713502 ≈ 383821𝑁𝑚𝑚
3 𝑀 3 383821
𝑑12 ≥√ =√ = 42.5 𝑚𝑚 < 55 𝑚𝑚
0.1 ∗ [𝜎𝐹 ]−1 0.1 ∗ 50
So, the value of 𝑑12 is acceptable.

- Calculating to select the suitable bolt:
 Selecting the material of the bolt is steel C45, which has:
The allowable shear stress [𝜏𝐶 ] = 60 𝑀𝑃𝑎
The allowable normal stress [𝜎𝑑 ] = 100 𝑀𝑃𝑎
27 | P a g e
 Putting the bolt at the position of the gear

According to TCVN 2261-77 in the Table 9.1a in reference [II]
𝑑12 = 55 𝑚𝑚, 𝑏 = 16 𝑚𝑚, ℎ = 10 𝑚𝑚
𝑡1 = 6 𝑚𝑚, 𝑡2 = 4.3 𝑚𝑚, 𝑙 = 56 𝑚𝑚
The working length of the circular bolt
𝑙1 = 𝑙 − 𝑏 = 56 − 16 = 40 𝑚𝑚
 Checking the precision of the shear stress
2 ∗ 𝑇1 2 ∗ 371350
𝜏𝑐 = = = 21.1 𝑀𝑃𝑎 < [𝜏𝐶 ] = 60 𝑀𝑃𝑎
𝑑12 ∗ 𝑙1 ∗ 𝑏 55 ∗ 40 ∗ 16
 Checking the precision of the normal stress
2 ∗ 𝑇1 2 ∗ 371350
𝜎𝑑 = = = 84.4 𝑀𝑃𝑎 < [𝜎𝑑 ] = 100 𝑀𝑃𝑎
𝑑12 ∗ 𝑙1 ∗ (ℎ − 𝑡1 ) 55 ∗ 40 ∗ (10 − 6)
 Selecting to place a bolt at the position of the gear
𝑑14 = 45 𝑚𝑚, 𝑏 = 14 𝑚𝑚, ℎ = 9 𝑚𝑚
𝑡1 = 5.5 𝑚𝑚, 𝑡2 = 3.8 𝑚𝑚, 𝑙 = 56 𝑚𝑚
The working length of the both circular and square bolt:
𝑏 14
𝑙1 = 𝑙 − = 56 − = 59 𝑚𝑚
2 2
 Checking the precision of the shear stress
2 ∗ 𝑇1 2 ∗ 371350
𝜏𝑐 = = = 24.06 𝑀𝑃𝑎 < [𝜏𝐶 ] = 60 𝑀𝑃𝑎
𝑑14 ∗ 𝑙1 ∗ 𝑏 45 ∗ 49 ∗ 14
 Checking the precision of the normal stress
2 ∗ 𝑇1 2 ∗ 371350
𝜎𝑑 = = = 96.24 𝑀𝑃𝑎 < [𝜎𝑑 ] = 100 𝑀𝑃𝑎
𝑑14 ∗ 𝑙1 ∗ (ℎ − 𝑡1 ) 45 ∗ 49 ∗ (9 − 5.5)
28 | P a g e
 Checking the precision of the shaft according to the fatigue

Section 1-2:
* The safety coefficient of fatigue impacts on the normal stress ( change based
on the symmetrical cycle)
𝜎−1
𝑠𝜎 =
𝐾𝜎 ∗ 𝜎𝑎
+ 𝜓𝜎 ∗ 𝜎𝑚
𝜀𝜎 ∗ 𝛽
Where:
𝜎−1 : The fatigue of material 𝜎−1 = 0.5 ∗ 𝜎𝑏 = 0.5 ∗ 600 = 300 𝑀𝑃𝑎
The coefficient of total stress impacts on the fatigue 𝐾𝜎 :
This is a keyway shaft, based on the Table 10.8 in reference [I],
we get 𝐾𝜎 = 1.75
The coefficient of dimension 𝜀𝜎 : according to the Table 10.3 in reference [I],
we have 𝜀𝜎 = 0.81
The coefficient of improvement the ultimate on the surface 𝛽 : according to
the Picture 2.7 in reference [I], we have 𝛽 = 0.8
The coefficient of the average stress impacts on the fatigue 𝜓𝜎 :
According to the Picture 2.9 in reference [I], we have 𝜓𝜎 = 0.05
𝑀12
The maximum normal stress 𝜎𝑚𝑎𝑥 =
𝑊𝑥12
The section modulus moment 𝑊𝑥12

𝜋 ∗ 𝑑12 3 𝑏 ∗ 𝑡1 ∗ (𝑑12 − 𝑡1 )2
𝑊𝑥12 = −
32 2 ∗ 𝑑12
𝜋 ∗ 553 16 ∗ 6 ∗ (55 − 6)2
= − = 16333 𝑚𝑚3
32 2 ∗ 55
The total bending moment 𝑀 = √𝑀𝑥 2 + 𝑀𝑦 2
= √99375.5152 + 2030242 = 226040.4 𝑁𝑚𝑚
29 | P a g e
𝑀12 226040.4
𝜎𝑚𝑎𝑥 = = = 13.84 𝑀𝑃𝑎
𝑊𝑥12 16333
The average normal stress 𝜎𝑚 = 0
The amplitude normal stress 𝜎𝑎 = 𝜎𝑚𝑎𝑥 = 13.84 𝑀𝑃𝑎
𝜎−1 300
⟹ 𝑠𝜎 = = = 8.03
𝐾𝜎 ∗ 𝜎𝑎 1.75 ∗ 13.84
𝜀𝜎 ∗ 𝛽 0.81 ∗ 0.8
* The safety coefficient of fatigue impacts on the tangential stress (change based
on the dynamically positive cycle)
𝜏−1
𝑠𝜏 =
𝐾𝜏 ∗ 𝜎𝑎
+ 𝜓𝜏 ∗ 𝜏𝑚
𝜀𝜏 ∗ 𝛽
Where:
𝜏−1 : The fatigue of material 𝜏−1 = 0.25 ∗ 𝜎𝑏 = 0.25 ∗ 600 = 150 𝑀𝑃𝑎
The coefficient of total stress impacts on the fatigue 𝐾𝜏 :
we get 𝐾𝜏 = 1.5
The coefficient of dimension 𝜀𝜏 : according to the Table 10.3 in reference [I],
we have 𝜀𝜏 = 0.76
the Table 10.4 in reference [I], we have 𝛽 = 0.8
The coefficient of the average stress impacts on the fatigue 𝜓𝜏 :
According to the picture 2.9 in reference [I], we have 𝜓𝜏 = 0
𝑇12
The maximum normal stress 𝜏𝑚𝑎𝑥 =
𝑊012

𝜋 ∗ 𝑑12 3 𝑏 ∗ 𝑡1 ∗ (𝑑12 − 𝑡1 )2
𝑊012 = −
16 2 ∗ 𝑑12
𝜋 ∗ 553 16 ∗ 6 ∗ (55 − 6)2
= − = 30572 𝑚𝑚3
16 2 ∗ 55
The total bending moment 𝑇 = 371350 𝑁𝑚𝑚
30 | P a g e
𝑇12 371350
𝜏𝑚𝑎𝑥 = = = 12.1 𝑀𝑃𝑎
𝑊012 30672
𝜏 12.1
The average tangential stress 𝜏𝑚 = 𝑚𝑎𝑥 = = 6.05 𝑀𝑃𝑎
2 2
𝜏𝑚𝑎𝑥 12.1
The amplitude tangential stress 𝜏𝑎 = = = 6.05 𝑀𝑃𝑎
2 2
𝜏−1 150
⟹ 𝑠𝜏 = = = 12.69
𝐾𝜏 ∗ 𝜏𝑎 1.5 ∗ 6.05
𝜀𝜏 ∗ 𝛽 0.76 ∗ 0.8
The safety coefficient:
𝑠𝜎 ∗ 𝑠𝜏 5.45 ∗ 12.69
𝑠= = = 5.007 > [𝑠] = 1.5 … 2.5
√𝑠𝜎 2 + 𝑠𝜏 2 √5.452 + 12.692
 At the rest sections:
Section M T 𝐾𝜎 𝜎𝑚𝑎𝑥 𝐾𝜏 𝜏𝑚𝑎𝑥 𝑠𝜎 𝑠𝜏 𝑠
1-1 0 0 1 0 1 0 - - -
1-2 198878.77 199242 1.75 18.34 1.5 9.831 5.45 12.69 5.007
1-3 365333.845 199242 1 40.84 1 11.135 2.82 11.2 2.734
1-4 0 199242 1.75 0 1.5 - - - -
 The section of shaft 1:
31 | P a g e
 The structure of shaft 1:

45
40
45
48
2. The shaft 2:
- Selecting the appropriate material:
Choose steel C45 with 𝜎𝑏 = 600 𝑀𝑃𝑎, [𝜎𝐹 ]−1 = 50 𝑀𝑃𝑎, [𝜏] = 20 ÷ 25 𝑀𝑃𝑎
- Selecting the dimensions of the axis:
32 | P a g e
- Free body diagram on the shaft:

Oy
Ox
Where:
𝑇2 = 765308 𝑁𝑚𝑚, 𝐹𝑟 = 3391.13 𝑁, 𝐹𝑡2 = 5280 𝑁, 𝐹𝑟2 = 2014.47𝑁
𝑑2 424.5
𝐹𝑎2 = 1659.713 𝑁, 𝑀𝑎2 = 𝐹𝑎2 ∗ = 1659.713 ∗ = 352274.1 𝑁𝑚𝑚
2 2
 Supposed to select the flexible coupling. The working part is the chain so
based on the Table 14.1 in reference [I], we choose K = 1.5
 The estimated torque :
𝑇𝑡 = 𝐾 ∗ 𝑇2 = 1.5 ∗ 765308 = 1147962 𝑁𝑚𝑚 = 1147.962 𝑁𝑚
According to the Table 16-10a in the reference [VI], select the flexible coupling
with [T] = 2000 Nm, 𝐷𝑜 = 200 𝑚𝑚
2∗𝑇2 2∗765308
 The ring force at the end 𝐹𝑡𝑘 = = = 7653.08 𝑁
𝐷0 200
 The force caused by the coupling applies on the shaft:
𝐹𝑘 = (0.2 ÷ 0.3) ∗ 𝐹𝑡𝑘 = 0.25 ∗ 7653.08 = 1913.27 𝑁
The direction of 𝐹𝑘 opposite the direction of ring force on the gear
- Calculating the reactions of all the supports:
 In the Oy axis:
𝑀/𝐵 = 0 ⇔ 𝑅𝐴𝑦 ∗ 143 + 𝐹𝑟2 ∗ 71.5 − 𝑀𝑎2 = 0
𝑀𝑎2 − 𝐹𝑟1 ∗ 71.5 352274.1 − 2014.47 ∗ 71.5
⇔ 𝑅𝐴𝑦 = = = 1456.22 𝑁
143 143
𝑅𝐴𝑦 + 𝑅𝐵𝑦 + 𝐹𝑟2 = 0 ⇔ 𝑅𝐵𝑦 = −𝐹𝑟2 − 𝑅𝐴𝑦 = −3470.69 𝑁
33 | P a g e
 In the Ox axis:
𝑀/𝐵 = 0 ⇔ 𝑅𝐴𝑥 ∗ 143 + 𝐹𝑟2 ∗ 71.5 = 𝐹𝑘 ∗ 231
𝐹𝑘 ∗ 231 − 𝐹𝑡2 ∗ 71.5
⇔ 𝑅𝐴𝑥 =
143
1913.27 ∗ 231 − 5280 ∗ 71.5
⇔ 𝑅𝐴𝑥 = = 450.67 𝑁
143
𝑅𝐵𝑥 = 𝐹𝑘 − 𝐹𝑡2 − 𝑅𝐴𝑥 = 1913.27 − 5280 − 450.67 = −3817.4 𝑁
34 | P a g e
- The internal force diagrams:
Bending moment 𝑀𝑥
248151.37
104119.7
3
Bending moment 𝑀𝑦
272943.66
168367.7
6
The torque T
765308
35 | P a g e
- The moment at the unsafe section:

The unsafe section at the position of the spur gear
𝑀 = √𝑀𝑥 2 + 𝑀𝑦 2 + 0.75 ∗ 𝑇 2
= √352274.12 + 272943.662 + 0.75 ∗ 7653082 ≈ 798666.1 𝑁𝑚𝑚

- Diameter at the unsafe section:
 I notate that the unsafe section is section 2-2, with 2 is the shaft 2 and 2 is the
section number counting from the left to right.
3 𝑀 3 798666.1
𝑑22 ≥ √ =√ = 54.26 𝑚𝑚
0.1 ∗ [𝜎𝐹 ]−1 0.1 ∗ 50
Having a roller bearing at the unsafe section, so increase 5%

⟹ 𝑑22 ≥ 56.973 𝑚𝑚
According to the basic standard, selecting 𝒅𝟐𝟐 = 𝟔𝟎 𝒎𝒎
We choose the diameter at the section 2-1, 2-3 and 2-4:
𝒅𝟐𝟏 = 𝟓𝟐 𝒎𝒎, 𝒅𝟐𝟑 = 𝒅𝟐𝟒 = 𝟓𝟓 𝒎𝒎
 Checking the diameter at the section 2-2:
𝑀 = √𝑀𝑥 2 + 𝑀𝑦 2 + 0.75 ∗ 𝑇 2
= √168367.72 + 0.75 ∗ 7653082 ≈ 683827 𝑁𝑚𝑚
3 𝑀 3 683827
𝑑22 ≥ √ =√ = 51.52 𝑚𝑚 < 60 𝑚𝑚
0.1 ∗ [𝜎𝐹 ]−1 0.1 ∗ 50
So, the value of 𝑑22 is acceptable.

- Calculating to select the suitable bolt
 Selecting the material of the bolt is steel C45, which has:
The allowable shear stress [𝜏𝐶 ] = 60 𝑀𝑃𝑎
The allowable normal stress [𝜎𝑑 ] = 100 𝑀𝑃𝑎
36 | P a g e
 Selecting the two ends square bolt to place at the position of the gear:
𝑑22 = 60 𝑚𝑚, 𝑏 = 18 𝑚𝑚, ℎ = 11 𝑚𝑚
𝑡1 = 7 𝑚𝑚, 𝑡2 = 4.4 𝑚𝑚, 𝑙 = 70 𝑚𝑚
The working length of the square bolt
𝑙1 = 𝑙 = 70 𝑚𝑚
 Checking the precision of the shear stress:
2 ∗ 𝑇2 2 ∗ 765308
𝜏𝑐 = = = 20.246 𝑀𝑃𝑎 < [𝜏𝐶 ] = 60 𝑀𝑃𝑎
𝑑22 ∗ 𝑙1 ∗ 𝑏 60 ∗ 70 ∗ 18
 Checking the precision of the normal stress:
2 ∗ 𝑇2 2 ∗ 765308
𝜎𝑑 = = = 91.108 𝑀𝑃𝑎 < [𝜎𝑑 ] = 100 𝑀𝑃𝑎
𝑑22 ∗ 𝑙1 ∗ (ℎ − 𝑡1 ) 60 ∗ 70 ∗ (11 − 7)
 Selecting the two ends square bolt to place at the position of the gear:
𝑑21 = 52 𝑚𝑚, 𝑏 = 16 𝑚𝑚, ℎ = 10 𝑚𝑚
𝑡1 = 6 𝑚𝑚, 𝑡2 = 4.3 𝑚𝑚, 𝑙 = 70 𝑚𝑚
The working length of the square bolt:
𝑙1 = 𝑙 = 70 𝑚𝑚
 Checking the precision of the shear stress:
2 ∗ 𝑇2 2 ∗ 765308
𝜏𝑐 = = = 26.28 𝑀𝑃𝑎 < [𝜏𝐶 ] = 60 𝑀𝑃𝑎
𝑑21 ∗ 𝑙1 ∗ 𝑏 52 ∗ 70 ∗ 16
 Checking the precision of the normal stress:
2 ∗ 𝑇2 2 ∗ 765308
𝜎𝑑 = = = 105.124 𝑀𝑃𝑎 > [𝜎𝑑 ] = 100 𝑀𝑃𝑎
𝑑21 ∗ 𝑙1 ∗ (ℎ − 𝑡1 ) 52 ∗ 70 ∗ (10 − 6)
Choose the bolts again by putting them to form an angle of 1800 at the position of
coupling. At that moment, we consider they are just one bolt loaded 0.5𝑇
37 | P a g e
2 ∗ 0.75 ∗ 𝑇2 2 ∗ 0.75 ∗ 765308

𝜎𝑑 = = = 78.843 𝑀𝑃𝑎 < [𝜎𝑑 ] = 100 𝑀𝑃𝑎
𝑑21 ∗ 𝑙1 ∗ (ℎ − 𝑡1 ) 52 ∗ 70 ∗ (10 − 6)
 Checking the precision of the shaft according to the fatigue:
Section 2-3:
* The safety coefficient of fatigue impacts on the normal stress (change based on
the symmetrical cycle)
𝜎−1
𝑠𝜎 =
𝐾𝜎 ∗ 𝜎𝑎
𝜀𝜎 ∗ 𝛽
Where:
𝜎−1 : The fatigue of material 𝜎−1 = 0.5 ∗ 𝜎𝑏 = 0.5 ∗ 600 = 300 𝑀𝑃𝑎
The coefficient of total stress impacts on the fatigue 𝐾𝜎 :
we get 𝐾𝜎 = 1.75
The coefficient of dimension 𝜀𝜎 : according to the Table 10.3 in reference [I],
we have 𝜀𝜎 = 0.81
the Picture 2.7 in reference [I], we have 𝛽 = 0.8
The coefficient of the average stress impacts on the fatigue 𝜓𝜎 :
According to the Picture 2.9 in reference [I], we have 𝜓𝜎 = 0.05
𝑀12
The maximum normal stress 𝜎𝑚𝑎𝑥 =
𝑊𝑥12

𝜋 ∗ 𝑑23 3 𝑏 ∗ 𝑡1 ∗ (𝑑12 − 𝑡1 )2
𝑊𝑥23 = −
32 2 ∗ 𝑑12
𝜋 ∗ 553 16 ∗ 6 ∗ (55 − 6)2
= − = 14238.41 𝑚𝑚3
32 2 ∗ 55
38 | P a g e
The total bending moment 𝑀 = √𝑀𝑥 2 + 𝑀𝑦 2
= √352274.12 + 272943.662 = 445640.3 𝑁𝑚𝑚

𝑀23 445640.3
𝜎𝑚𝑎𝑥 = = = 31.3 𝑀𝑃𝑎
𝑊𝑥23 14238.31
The average normal stress 𝜎𝑚 = 0
The amplitude normal stress 𝜎𝑎 = 𝜎𝑚𝑎𝑥 = 31.3 𝑀𝑃𝑎
𝜎−1 300
⟹ 𝑠𝜎 = = = 3.55
𝐾𝜎 ∗ 𝜎𝑎 1.75 ∗ 31.3
𝜀𝜎 ∗ 𝛽 0.81 ∗ 0.8
* The safety coefficient of fatigue impacts on the tangential stress (change based
on the dynamically positive cycle)
𝜏−1
𝑠𝜏 =
𝐾𝜏 ∗ 𝜎𝑎
𝜀𝜏 ∗ 𝛽
Where:
𝜏−1 : The fatigue of material 𝜏−1 = 0.25 ∗ 𝜎𝑏 = 0.5 ∗ 600 = 150 𝑀𝑃𝑎
The coefficient of total stress impacts on the fatigue 𝐾𝜏 :
we get 𝐾𝜏 = 1.5
The coefficient of dimension 𝜀𝜏 : according to the Table 10.3 in reference [I],
we have 𝜀𝜏 = 0.76
the Table 10.4 in reference [I], we have 𝛽 = 0.8
The coefficient of the average stress impacts on the fatigue 𝜓𝜏 :
According to the picture 2.9 in reference [I], we have 𝜓𝜏 = 0
𝑇23
The maximum normal stress 𝜏𝑚𝑎𝑥 =
𝑊023
39 | P a g e
The section modulus moment 𝑊023

𝜋 ∗ 𝑑23 3 𝑏 ∗ 𝑡1 ∗ (𝑑23 − 𝑡1 )2
𝑊023 = −
16 2 ∗ 𝑑23
𝜋 ∗ 553 16 ∗ 6 ∗ (55 − 6)2
= − = 30572.24 𝑚𝑚3
16 2 ∗ 55
The total bending moment 𝑇 = 765308 𝑁𝑚𝑚
𝑇23 765308
𝜏𝑚𝑎𝑥 = = = 25.03 𝑀𝑃𝑎
𝑊023 30572.24
The average tangential stress 𝜏𝑚 = = = 12.515 𝑀𝑃𝑎
2 2
The amplitude tangential stress 𝜏𝑎 = = = 12.515 𝑀𝑃𝑎
2 2
𝜏−1 150
⟹ 𝑠𝜏 = = = 4.85
𝐾𝜏 ∗ 𝜏𝑎 1.5 ∗ 12.515
𝜀𝜏 ∗ 𝛽 0.76 ∗ 0.8
The safety coefficient:
𝑠𝜎 ∗ 𝑠𝜏 3.55 ∗ 4.85
𝑠= = = 2.865 > [𝑠] = 1.5 … 2.5
√𝑠𝜎 2 + 𝑠𝜏 2 √3.552 + 4.852
 At the rest sections:
Section M T 𝐾𝜎 𝜎𝑚𝑎𝑥 𝐾𝜏 𝜏𝑚𝑎𝑥 𝑠𝜎 𝑠𝜏 𝑠
2-1 0 765308 - - - - - - -
2-2 168367.7 765308 1 7.94 1 18.045 24.48 10.108 9.34
2-3 445640.3 765308 1.75 31.3 1.5 25.03 3.55 4.85 2.865
2-4 0 0 - - - - - - -
40 | P a g e
 The sections of the shaft 2:
 The structure of shaft 2:

52
60
18
55
55
16
41 | P a g e
Chapter 5: Design two pair of roller bearing in

the gear reducer
1. Design the roller bearing on the shaft 1:
- The centripetal force 𝐹𝑟 :
 The centripetal force applies on the roller bearing A:
𝐹𝑟𝐴 = 𝑅𝐴 = √𝑅𝐴𝑥 2 + 𝑅𝐴𝑦 2 = √2839,52 + 723,212 = 2930,15 𝑀𝑃𝑎
 The centripetal force applies on the roller bearing B:
𝐹𝑟𝐵 = 𝑅𝐵 = √𝑅𝐵𝑥 2 + 𝑅𝐵𝑦 2 = √2839,52 + 6303,212 = 6913,26 𝑀𝑃𝑎
- The axial force applies on the bearing A:

𝐹 1600
 Make a ratio 𝑎1 = = 0.546 > 0.3
𝐹𝑟𝐴 2930,15
⟹ Selecting the angular contact roller bearing.

The internal diameter d = 50 mm. According to the Table P2.12 in reference
[II], we choose the roller bearing medium size number 46309 with
𝐶 = 56,03 𝑘𝑁 𝑎𝑛𝑑 𝐶0 = 44,8 𝑘𝑁
- Calculating and checking the loading ability of roller bearing:
We calculate and experience only for the roller bearing A because it carries
heavier load.
𝐹𝑎1 1600
 Make a ratio = = 0.036. According to the Table 11.4 in reference [II],
𝐶0 44800
𝑒 ≈ 0.036. Due to the rotation of the internal gear, V = 1
𝐹 1600
Make a ratio 𝑎1 = ≈ 0,546 > 𝑒 ≈ 0.036
𝑉∗𝐹𝑟𝐴 2930,15
According to the Table 11.4 [1], we get X = 0.45; Y = 1.504
- According to the Table 11.3 in reference [II], the conventionary load:
𝑄 = (𝑋 ∗ 𝑉 ∗ 𝐹𝑟𝐴 + 𝑌 ∗ 𝐹𝑎1 ) ∗ 𝑘𝑡 ∗ 𝑘𝑑
Where:
𝑘𝑡 = 1
According to the Table 11.3 in reference [I], 𝑘𝑑 = 1.3
42 | P a g e
⟹ 𝑄 = (𝑋 ∗ 𝑉 ∗ 𝐹𝑟𝐴 + 𝑌 ∗ 𝐹𝑎1 ) ∗ 𝑘𝑡 ∗ 𝑘𝑑
= (0.45 ∗ 1 ∗ 2930,15 + 1.504 ∗ 1600) ∗ 1 ∗ 1.3
= 4842.6 𝑁 = 4.8426 𝑘𝑁
- The longevity of the roller bearing:
The unit of L is million revolutions
60 ∗ 𝑛1 ∗ 𝐿ℎ 60 ∗ 391,67 ∗ 24000
𝐿= = = 564 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠
106 106
Because the longevity of roller bearing 𝐿 is too large, so we divide L by 3
⇒ 𝐿 = 188 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠
- The coefficient of dynamic load ability:
𝑚
𝐶𝑑 = 𝑄 ∗ √𝐿, 𝑤𝑖𝑡ℎ 𝑚 = 3 ( 𝑟𝑜𝑙𝑙𝑒𝑟 𝑏𝑒𝑎𝑟𝑖𝑛𝑔)
3
⇒ 𝐶𝑑 = 4.8426 ∗ √188 = 27,74 𝑘𝑁 < [𝐶] = 56,03𝑘𝑁
- Recalculating the longevity of the roller bearing when 𝐶𝑑 = 56,03 𝑘𝑁
𝑚
𝐶𝑑 = 𝑄 ∗ √𝐿 , 𝑤𝑖𝑡ℎ 𝑚 = 3 ( 𝑟𝑜𝑙𝑙𝑒𝑟 𝑏𝑒𝑎𝑟𝑖𝑛𝑔)
⟺ 𝐿 = 1548,91 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠
- According to the appendix P2.12 in reference [II], we get the detail information
about the roller bearing number 46309
Bearing
d, mm D, mm b, mm r, mm 𝑟1 , mm 𝐶, 𝑘𝑁 𝐶𝑜 , 𝑘𝑁
number
46310 50 110 27 3 1.5 56.03 44.8
2. Design the roller bearing on the shaft 2

- The centripetal force 𝐹𝑟 :
 The centripetal force applies on the roller bearing A:
𝐹𝑟𝐴 = 𝑅𝐴 = √𝑅𝐴𝑥 2 + 𝑅𝐴𝑦 2 = √450.672 + 1457.222 = 1525.3 𝑁
43 | P a g e
 The centripetal force applies on the roller bearing B:
𝐹𝑟𝐵 = 𝑅𝐵 = √𝑅𝐵𝑥 2 + 𝑅𝐵𝑦 2 = √3817.42 + 3470.692 = 5150.3
- The axial force applies on the bearing B:

𝐹𝑎2 1659.713
 Make a ratio = = 0.32 > 0.3
𝐹𝑟𝐵 5150.3
⟹ Selecting the angular contact roller bearing.

The internal diameter d = 55 mm. According to the Table P2.12 in reference
[II], we choose the roller bearing especially small size number 46211 with
𝐶 = 39.4 𝑘𝑁 𝑎𝑛𝑑 𝐶0 = 32.1 𝑘𝑁
- Calculating and checking the loading ability of roller bearing:
We calculate and experience only for the roller bearing B because it carries
heavier load.
𝐹𝑎2 1659.713
 Make a ratio = ≈ 0.052. According to the Table 11.4 in reference
𝐶0 32100
[II], 𝑒 ≈ 0.365. Due to the rotation of the internal gear, V = 1
𝐹𝑎2 1659.713
Make a ratio = ≈ 0.32 < 𝑒 ≈ 0.365
𝑉∗𝐹𝑟𝐵 5150.3
According to the Table 11.4 [1], we get X = 1; Y = 0
- According to the Table 11.3 in reference [II], the conventionary load:
𝑄 = (𝑋 ∗ 𝑉 ∗ 𝐹𝑟𝐴 + 𝑌 ∗ 𝐹𝑎1 ) ∗ 𝑘𝑡 ∗ 𝑘𝑑
Where:
𝑘𝑡 = 1
According to the Table 11.3 in reference [I], 𝑘𝑑 = 1.3
⟹ 𝑄 = (𝑋 ∗ 𝑉 ∗ 𝐹𝑟𝐴 + 𝑌 ∗ 𝐹𝑎1 ) ∗ 𝑘𝑡 ∗ 𝑘𝑑
= (1 ∗ 1 ∗ 2771.17 + 0 ∗ 1659.713) ∗ 1 ∗ 1.3
= 3602.521 𝑁 = 3.602521 𝑘𝑁
- The longevity of the roller bearing:
The unit of L is million revolutions
44 | P a g e
60 ∗ 𝑛1 ∗ 𝐿ℎ 60 ∗ 391,67 ∗ 24000
𝐿= = = 262.8 𝑚𝑖𝑙𝑖𝑜𝑛 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠
106 106
- The coefficient of dynamic load ability:
𝑚
𝐶𝑑 = 𝑄 ∗ √𝐿, 𝑤𝑖𝑡ℎ 𝑚 = 3 ( 𝑟𝑜𝑙𝑙𝑒𝑟 𝑏𝑒𝑎𝑟𝑖𝑛𝑔)
3
⇒ 𝐶𝑑 = 3.602521 ∗ √262.8 = 23.07 𝑘𝑁 < [𝐶] = 39.4 𝑘𝑁
- Recalculating the longevity of the roller bearing when 𝐶𝑑 = 39.4 𝑘𝑁
𝑚
𝐶𝑑 = 𝑄 ∗ √𝐿 , 𝑤𝑖𝑡ℎ 𝑚 = 3 ( 𝑟𝑜𝑙𝑙𝑒𝑟 𝑏𝑒𝑎𝑟𝑖𝑛𝑔)
⟺ 𝐿 = 1308.2 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠
- According to the appendix P2.12 in reference [II], we get the detail information
about the roller bearing number 36211
Bearing
d, mm D, mm b, mm r, mm 𝑟1 , mm 𝐶, 𝑘𝑁 𝐶𝑜 , 𝑘𝑁
number
36211 55 100 21 2.5 1.2 39.4 34.9
45 | P a g e
REFERENCES
[I] Cơ sở thiết kế máy, Nguyễn Hữu Lộc, NXB ĐHQG TP.HCM
[II] Tính toán thiết kế hệ dẫn động cơ khí – Tập 1, Trịnh Chất – Lê Văn Uyển,
NXB GD
[III] Catalogue động cơ điện 3 pha không đồng bộ, Công ty chế tạo máy điện Việt
Nam – Hungary
[IV] Bài tập Chi tiết máy, Nguyễn Hữu Lộc, NXB ĐHQG TP.HCM
[V] Thông số nối trục đàn hồi Flexitech
[VI] Tính toán thiết kế hệ dẫn động cơ khí – Tập 2, Trịnh Chất – Lê Văn Uyển,
NXB GD
46 | P a g e

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HO CHI MINH CITY UNIVERSITY OF

Machine Design Project

Lecturer: ASSOC. PROF. PHAN ĐINH HUAN

Chapter 2: Design the V-belt drive…………………………………………….7

Chapter 3: Design the spur gear………………………………………………12

Chapter 4: Design two shafts in the gear reducer…………………………...22

- Shaft 2………………………………………………………………... .31

- Design the roller bearing on the shaft 1…………………………... .41

- Design the roller bearing on the shaft 2……………………………. 42

The driving conveyor chain system includes:

The error of rotation compares to requirements: ≤ ±3%

Chapter 1: Select electric motor & Distribute

𝑢𝑑 = 3 : Transmission ratio of the V-belt drive

 The power on the shafts:

 The torque on the shafts:

Power P(kW) 16.19 15.23 14.625

The torque T (Nmm) 131587 371350 1069791

Chapter 2: Design the V-belt

Compare the value 𝐚 to the condition: 𝟐𝟒𝟑𝟎 ≥ 𝐚 ≥ 𝟔𝟖𝟏. 𝟕𝟓

- The covered angle of the belt:

(𝑑2 − 𝑑1 ) (900 − 315)

The impact coefficient of velocity:

 The useful gear force

345 167.08 100

16.19 1175 1725 3327 149.3 2.886

z d1 d2 a (mm) L (mm) B (mm)

5 315 900 1080 4000 136

Chapter 3: Design the spur gear

 The number of equivalent working cycles: due to the transmission system

𝜎0𝐹𝑙𝑖𝑚2 = 1.8 ∗ 𝐻2 = 1.8 ∗ 235 = 423 𝑀𝑃𝑎

 The number of basic cycles is 𝑁𝐹𝑂 = 5 ∗ 106 to all type of steel

𝜎𝑂𝐹𝑙𝑖𝑚1 ∗ 𝐾𝐹𝐶 450 ∗ 1

[𝜎𝐻 ] = √0.5 ∗ ([𝜎𝐻1 ]2 + [𝜎𝐻2 ]2 )

[𝜎𝐻 ] = √0.5 ∗ (466.362 + 441.822 ) = 454.26 𝑀𝑃𝑎

- Selecting the coefficient of the wide toothing based on the standard:

According to the Table 6.4 in the reference [I]:

Because 80 < 𝛽 < 200 → 39.027 < 𝑧1 < 41.127

The transmission ratio in reality: 𝑢𝑡𝑡 = 𝑢𝑑 ∗ 𝑢𝑏𝑟 = 2.886 ∗ 3.025 = 8.73

Where: 𝑛𝑐𝑥 is the degree of accuracy, 𝑛𝑐𝑥 ≥ 9 so 𝐾𝐹𝛼 = 1

With 𝛼𝑡𝑤 is the synchronized angle in horizontal surface:

275 ∗ 1.71 ∗ 0.764 2 ∗ 371350 ∗ 1.225 ∗ (3.013 + 1)

b. Checking the precision of bending stress:

𝐾𝐹 = 𝐾𝐹𝛼 ∗ 𝐾𝐹𝛽 ∗ 𝐾𝐹𝑣 = 1.02 ∗ 1.22 ∗ 1 = 1.2444

We get the bending stress at unsafe section:

 The centripetal force 𝐹𝑟 :

Chapter 4: Design two shafts in the gear reducer

Power P(kW) 16.19 15.23 14.625

The torque T (Nmm) 131587 371350 1069791

The length of the two shafts diagram:

The force analysis diagram applies on two shafts:

- Free body diagram on the shaft:

- Calculating the reactions of all the supports:

- The internal force diagrams:

- The moment at the unsafe section:

= √2595062 + 2030242 + 0.75 ∗ 3713502 ≈ 460421.25 𝑁𝑚𝑚

Having a roller bearing at the unsafe section.

= √517102 + 2030242 + 0.75 ∗ 3713502 ≈ 383821𝑁𝑚𝑚

So, the value of 𝑑12 is acceptable.

 Putting the bolt at the position of the gear

 Checking the precision of the shaft according to the fatigue

The section modulus moment 𝑊𝑥12

The total bending moment 𝑀 = √𝑀𝑥 2 + 𝑀𝑦 2

= √99375.5152 + 2030242 = 226040.4 𝑁𝑚𝑚