HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY

VIETNAM NATIONAL UNIVERSITY HO CHI MINH CITY

FACULTY OF MECHANICAL ENGINEERING

MACHINE ELEMENT
INDIVIDUAL ASSIGNMENT REPORT
Lecturer: Dr. Phạm Minh Tuấn

Full Name: Nguyễn Phúc Khang

Student ID: 2352485

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Contents
1. Project requirements ................................................................................................... 3
2. Electric motor selection and transmission ratio distribution ...................................... 3
2.1. Selecting efficiency of transmission systems: ....................................................... 3
2.2. Selecting transmission ratio: ................................................................................. 3
2.3. Power, speed and torque calculations .................................................................. 4
3. Design of bevel gear drive in speed reducer ................................................................ 5
3.1. Working life and allowable stress ......................................................................... 5
3.2. Geometric calculations ......................................................................................... 6
3.3. Kinematics and dynamics ..................................................................................... 7
3.4. Verification for contact stress ............................................................................... 7
4. Design of roller chain drive .......................................................................................... 8
4.1. Choosing number of sprocket teeth Z .................................................................. 8
4.2. Calculating pitch pc ............................................................................................... 8
4.3. Preliminary geometric calculations ...................................................................... 9
4.4. Kinematics and dynamics ................................................................................... 10
4.5. Verification .......................................................................................................... 10
4.6. Dimensions of sprockets: .................................................................................... 11
5. Design of shafts in speed reducer .............................................................................. 12
5.1. Shaft 1 ................................................................................................................. 12
5.2. Shaft 2 ................................................................................................................. 14
6. Selecting bearings for shafts ...................................................................................... 17
6.1. Pair 1 (shaft 1) ..................................................................................................... 17
6.2. Pair 2 (shaft 2) ..................................................................................................... 18

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 1. Project requirements

• Power of blender' shaft, P = 5 kw

• Rotation speed of blender' shaft, n = 130 rpm
• Working life: L = 3 years
• Allowable transmission error: ± 5%
• Operating conditions: one-direction working, light-impact loading, 2-shift operation
(8 hours/shift) and 300 days/year

2. Electric motor selection and transmission ratio distribution

2.1. Selecting efficiency of transmission systems:

gear = 0.97
chain = 0.95 bearing = 0.99 coupling = 1

 System efficiency:  sys =  gear chain  2bearing coupling

= 0.97  0.95  0.992  1 = 0.9

2.2. Selecting transmission ratio:

u gear = 3.6
, uchain = 2.04

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 2.3. Power, speed and torque calculations

PIII 5
Required power of motor: Prequired = = = 5.55
• 0.9 0.9 Kw
→ Selected motor:
Motor Power kW n (rpm)
DK 62-6 7 960
• Speed distribution for each shaft:
n1 = 960 rpm
n1 960
n2 = = = 266.67 rpm
u gear 3.6
n2 266.67
n3 = = = 130.72 rpm
uchain 2.04
n3 − nrequired 130.72 − 130
Rotational speed error: % =  100% =  100% = 0.55%
nrequired 130
• Calculating power for each shaft:
PI = 5 kW

PIII 5
PII = = = 5.32 kW
chain bearing 0.95  0.99

PII 5.32
PI = = = 5.54 kW
gear bearing 0.97  0.99

• Calculating torque:
PIII  9.55  106 5  9.55  106
TIII = = = 365284.58 Nmm
nIII 130.72
TIII 365284.58
TII = = = 179061.07 Nmm
uchain 2.04
TII 179061.07
TI = = = 49739.19 Nmm
ugear 3.6

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 Motor I II III
P 5.54 5.54 5.32 5.00
u 3.60 2.04
n 960.00 266.67 130.72
T 49739.19 179061.07 365284.58

3. Design of bevel gear drive in speed reducer

3.1. Working life and allowable stress

Selecting material hardness for drive and driven gear: HB1 = 250 , HB2 = 228
NHO1 = 30HB12.4 = 30  3302.4 = 33.23  106 Cycles
NHO2 = 30HB22.4 = 30  3202.4 = 30.87  106 Cycles
Assuming the gears would be changed twice in their lifetime, required gear life:
3
Lh = 2  8  300  = 7200 hours
2
Equivalent operating cycles (static loading):
NHE 1 = 60cnLh
= 60  1  960  7200 = 414.72  106 (Cycles)
NHE 2 = 60cnLh
= 60  1  266.67  7200 = 115.2  106 (Cycles)
 OH lim1 = 2HB1 + 70 = 2  330 + 70 = 730 MPa
 OH lim = 2HB2 + 70 = 2  320 + 70 = 710 MPa
2

Life factor:
33.23  106 30.87  106
KHL1 = 6 = 0.79 K = 6 = 0.8
141.72  106 115.2  106
HL2

0.9KHL1 0.9  0.79

[ H1 ] =  OH lim1  = 730  = 471.85 MPa
SH 1.1

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 0.9KHL2 0.9  0.8
[ H2 ] =  OH lim2  = 710  = 464.72 MPa
SH 1.1
For bevel gears, [ H ] = 1.15  min([ H1 ],[ H 2 ]) = 534.43 MPa

3.2. Geometric calculations

Select gear width factor  be = 0.285

 beu 0.285  3.6
Assuming angular contact bearing: = = 0.6
2 − be 2 − 0.285
→ KH = 1.23

Preliminary calculations of outer diameter:

T1 xK H
de1 = 95 3
0.85(1 − 0.5 be )2 beux[ H ]2
49739.19  1.23
= 95 3
0.85(1 − 0.5  0.285)2  0.285  3.6  242.512
= 111.62 mm
Select de1 = 100,u = 3.6 → Z1 p = 17

→ Z1 = 1.6 Z1 p = 1.6  17  27 , select Z1 = 25 → Z2 = Z1  u = 25  3.6 = 90

de1 100
Outer module: me = = = 4 mm
Z1 25

Actual outer diameter: de1 = me Z1 = 4  25 = 100

de2 = me Z2 = 4  90 = 360

Pitch diameters: dm1 = de1 (1 − 0.5 be ) = 100(1 − 0.5  0.285) = 85.75 mm

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dm2 = de2 (1 − 0.5 be ) = 360(1 − 0.5  0.285) = 308.7 mm

Outer cone distance: Re = 0.5me Z12 + Z22 = 0.5  4 252 + 902 = 186.82 mm

Face width: b = Re be = 186.82  0.285 = 53.24 mm

Pitch angles:

1  1 
 1 = arctan  = arctan  = 15.52
o

 
u  3.6
→  2 = 90 − 15.52 = 74.48
o o o

3.3. Kinematics and dynamics

 dm1n1   85.75  960

Tangential velocity: v1 = 4
= = 4.31 m/s
6 x10 6 x104
→ Accuracy class 8 → KHv = 1.1

Force calculations:

2T1 2  49739.19
Ft 1 = Ft 2 = = = 1160 N
d m1 85.75

Fr 1 = Fa2 = Ft 1 tan cos  1 = 1160  tan20o  cos15.52o = 406.81 N

Fr 2 = Fa1 = Ft 1 tan sin1 = 1160  tan20o  sin15.52o = 112.97 N

3.4. Verification for contact stress

Select ZM = 275 (MPa1/2 ) for steel gears

Selecting ZH = 1.76 based on helical angle and ratio between (x1 + x2 ) / (Z1 + Z2 )

Axial contact ratio:   = 0 (No helical angle)

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 4 −  4 − [1.88 − 3.2(1 / Z1 + 1 / Z2 )] 4 − [1.88 − 3.2(1 / 25 + 1 / 90)]
→ Z = = = = 0.87
3 3 3

Loading factor for contact stress: KH = KH KHv KH = 1  1.1  1.23 = 1.35

2T1K H (u2 + 1)
 H = Z M Z H Z
0.85dm2 1bu
2  49739.19  1.35  (3.62 + 1)
= 275  1.76  0.87 
0.85  85.752  53.24  3.6
= 526.77 MPa < [ H ] = 534.43 MPa

➔ Satisfactory

4. Design of roller chain drive

4.1. Choosing number of sprocket teeth Z

Z1 = 29 − 2u = 29 − 2  2.04 = 25

→ Z2 = Z1  u = 25  2.04 = 51

4.2. Calculating pitch pc

Selecting Z1 = 25 , → Z2 = Z1  u = 25  2.04 = 51

Dynamic load correction factor: Kr = 1.2

Center distance correction factor: Ka = 1

Orientation correction factor: K o = 1

Tension correction factor: Kdc = 1

Lubrication correction factor: Kb = 1.5

Operation shift correction factor: Klv = 1.12

→ Operation correction factor: K = 2.02

Z 01 25
Sprocket teeth coefficient factor: K z = = =1
Z1 25

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 n01 200
Rotation speed coefficient factor: K n = = = 0.75
n1 266.67

KK Z K nP1 2.02  0.75  5.32

Pt = = = 8.06 kW
Kx 1

From calculated values, select pitch pc = 25.4 mm

4.3. Preliminary geometric calculations

Selecting center distance: a = 40  pc = 40  25.4 = 1016 mm

Calculating number of linkages based on center distance:

2
2a Z + Z  Z − Z  p
X = + 1 2 + 2 1   c
pc 2  2  a
2
2  1016 25 + 51  51 − 25  25.4
= + +  
25.4 2  2  1016
= 118.43 → Select X = 118
Recalculating center distance with X = 118:

 Z1 + Z 2  Z1 + Z 2 
2
 Z 2 − Z1  
2

a = 0.25pc  X − + X−  − 8  
 2  2   2  
 
 25 + 51  25 + 51 
2
 51 − 25  
2

= 0.25  25.4  118 − +  118 −  − 8  

 2  2   2  
 
= 1010.53 mm
Selecting a = 1008 mm , a = 2.02  4.04 mm

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 4.4. Kinematics and dynamics

n1 Z1 pc 266.67  25  25.4
Average velovity: v = = = 2.82 m/s
6  104 6  104

Tension due to centrifugal force: Fv = qmv12 = 2.6  2.822 = 20.67 N

1000P1 1000  5.32

Tangential force: Ft = = = 1886.52 N
v1 2.82

Shaft load: Fr = KmFt = 1.15  1886.52 = 2169.5 N (Km = 1.15 because incline is < 40o)

Initial tension: Fo = K f aqmg = 6  1008  2.6  9.8 = 154.1 N

4.5. Verification

P1K 5.32  2.02

Verify pitch: pc = 25.4 mm  600 3 = 600 3 = 22.64 , where
Z1n1 [ p0 ]K x 25  266.67  30  1
[p0] = 30 MPa based on the table below

Safety factor:

Q
s=  [ s]
F1 + Fv + Fo
50000
=  8.9
1886.52 + 20.67 + 154.1
= 24.26  8.9
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[s] is selected based on rotational speed and pitch:

Impacts per second:

Z 1n1
i=  [i ]
15 X
25  266.67
=  [i ]
15  118
= 3.77  20
[i] is selected from the table below based on chain type and pc

4.6. Dimensions of sprockets:

Pitch diameters:

pc 25.4
d1 = = = 202.66 mm
 
sin sin
Z1 25

pc 25.4
d2 = = = 412.6 mm
 
sin sin
Z1 51

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Outer diameters:

da1  d1 + 0.7pc =202.66+0.7  25.4=220.44 mm

da2  d2 + 0.7pc =412.6+0.7  25.4=430.38 mm

5. Design of shafts in speed reducer

5.1. Shaft 1

Select C45 steel for shaft material → [ ] = 70 MPa

Free body diagram for shaft is as follow:

Point A connects to the motor, the bevel gear is mounted at point D.

Ft 1 = 1160 N , Fr 1 = 406.81 N

Ma1 = 0.5dm1  Fa1 =0.5  85.75  112.97=4847.59 N.mm

In Oyz plane:

{
 M = −50R
/B y
C
− Ma1 + 80Fr 1 = 0
{
−50RyC − 4847.59 + 80  406.81 = 0 RyB = 147.13 N
{ C
 F = −R
y
B
y + RyC − Fr 1 = 0 −RyB + RyC − 406.81 = 0 Ry = 553.94 N

In Oxz plane:

{
M /B = −50RxC + 80Ft 1 = 0
 {
−50RxC + 80  1160 = 0
 {
RxB = 696 N
F x = RxB − RxC + Ft 1 = 0 RxB − RxC + 1160 = 0 RxC = 1856 N

From the reaction forces above, the bending moment diagram can be drawn

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As well as the torque diagram:
13
From the diagrams, critical section is at C, the equivalent moment is:

Mtd = Mx2 + My2 + 0.75T 2 = 348002 + 7356.52y + 0.75  49739.192 = 55862.76 N.mm

Mtd 55862.76
Therefore the diamter at section C: d  3 =3 = 19.98 mm
0.1[ ] 0.1  70

➔ Select dC = 20mm

Draft of shaft structure:

Base on diameter d = 15mm, select feather key size of 6mmx6mmx18mm

5.2. Shaft 2

Select C45 steel for shaft material → [ ] = 70 MPa

Free body diagram for shaft is as follow:

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Point A is where the sprocket will be mounted, the bevel gear at point D.

Ft 2 = 1160 N , Fr 2 = 112.97 N

Fr 3 = 2169.5 N (radial force by chain sprocket)

Ma2 = 0.5dm2  Fa2 =0.5  308  406.81=62791.12 N.mm

In Oyz plane:

{
 M = −50R
/B y
C
+ Ma2 − 80Fr 2 = 0
{
−50RyC + 62791.12 + 80  112.97 = 0 RyB = 1188.04 N
{ C
 F = −R
y
B
y + RyC + Fr 2 = 0 −RyB + RyC + 112.97 = 0 Ry = 1075.07 N

In Oxz plane:

{
 M = −50F + 50R
/B r3
C
x + 80Ft 2 = 0
{
−50  2169.5 + 50RxC + 80  1160 = 0
 {
RxB = 3643 N
 F = −R + R + F
x
B
x
C
x t 2 + Fr 3 = 0 RxB − RxC + 1160 + 2169.5 = 0 RxC = 313.5 N

From the reaction forces above, the bending moment diagram can be drawn

15
Mtd /B = Mx2 + My2 + 0.75T 2 = 1080922y + 0.75  179061.072 = 189026.5 N.mm

Mtd /C = Mx2 + My2 + 0.75T 2 = 348002 + 594022 + 0.75  179061.072 = 169666.7 N.mm

From the calculations, critical section is at B.

Mtd 189026.5
Therefore the diamter at section B: d  3 =3 = 30 mm
0.1[ ] 0.1  70

➔ Select dB = 30mm

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Draft of shaft 2 structure:

Base on diamter d = 25mm, select feather key size of 10mmx8mmx22mm

6. Selecting bearings for shafts

6.1. Pair 1 (shaft 1)

Since there is no axial load, selecting single-row deep groove ball bearing with bore
diameter of 20mm for the shaft.

Radial force at section B:

FrB = RBx 2 + RBy 2 = 6962 + 147.132 = 711.38 N

Radial force at section C:

FrC = RCx 2 + RCy 2 = 18562 + 553.942 = 1937 N

➔ Calculating with FrC

Select K = Kt = V = 1

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No axial load → X = 1,Y = 0

Dynamic equivalent load:

Q = (XVFrC + YFa )K Kt = FrC = 1937 N

Work life in million revolutions (3 years):

60nLh 60  960  14400

L= = = 829.44
106 106
Calculated dynamic load factor:

Ctt = Qm L = 1937 3 829.44 = 18199 N

Given the calculated variables, select the 6304 ETN9 bearing from SKF:

6.2. Pair 2 (shaft 2)

Since there is no axial load, selecting single-row deep groove ball bearing with bore
diameter of 30mm for the shaft.

Radial force at section B:

FrB = RBx 2 + RBy 2 = 36432 + 1188.042 = 3831.83 N

Radial force at section C:

FrC = RCx 2 + RCy 2 = 313.52 + 1075.072 = 1119.84 N

Moving on using FrB

Select K = Kt = V = 1

No axial load → X = 1,Y = 0

Dynamic equivalent load:

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Q = (XVFrB + YFa )K Kt = FrB = 3831.83 N

Work life in million revolutions, assume the bearings are changed twice in their life time:

60nLh 60  960  7200

L= = = 414.72
106 106
Calculated dynamic load factor:

Ctt = Qm L = 3831.83 3 414.724 = 28757 N

Given the calculated variables, select the 6306-Z bearing:

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