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FACULTY: PRODUCT DESIGN MECHATRONICS AND ENVIRONMENT

DEPARTMENT OF PRODUCT DESIGN AND ENVIRONMENT


COURSE: MACHINE ELEMENTS II

PROJECT THEME
Mechanical transmission consisted of:
-

electrical engine;
belt/chain transmission;
one step speed reducer with helical gear.
DESIGN INPUTS:
- Electrical engine power:

P = 15 kW;

- Electrical engine rotation:

n = 2940 rot/min;

- Ratio of the V-belt:

iC= 1.14;

- Ratio of the speed reducer:

ir =2.42;

- Life time:

Lh = 8500h.

Drawings
1. Assembly drawing of gear
2. Execution drawing of the input shaft
1. Preparation and determination of structural scheme, moments and rotation for
each shaft.
1.1 Structural scheme of the transmision and horizontal gear

1.2. On gears determination of torsion moments and revolution:


- driving shaft
15
6 P
6
Mtm=9.55 10 n =9.55 10 2940 =48724.48 N mm
1

-input shaft(I)
MtI=TI=MtmIc=48724.481.14=55545.90 Nmm
n 2940
nI= I c = 1.14 =2578.94 rot /min
-output shaft(II)
MtII=TII=MtIIr=55545.902.42 =134421.07 Nmm
nI 2578.94
nII= I r = 2.42 =1065.67 rot /min
2 Gear calculus
2.1. Gear predimensioning calculus
1. PROJECTING DATA
1.1Pinion revolution
nI=2578.94 rot/min
1.2Torsion moment of the pinion
1.3Gear ratio
U dat =2.42
1.4Minimum functioning time of the gear
Lh=850
0h

1.5Functioning condition of the gear


Drive mtors- electriv motors asynchronous
Driven machine- converter tape
2

1.6Tooth load cycles


Contact stress: pulse cycle
Bending stress: cycle pulse
1.7Number of load cycles of the tooth Flank at a complete rotation 1 for pinion
respectively 2 for driven wheel
1,2=1
1.8Reference rack profile
For inclined teeth n=20, han=1, cn=0.25,

=0.38

fn

2. CHOOSING STEEL, APPLIED TREATEMENTS AND LIMIT TENSION


2.1 Choosing thetwo wheels steel , treatements and obtained hardnesses
18CrNi20- cementation steel
r .1,2=880 .1180 MPa
02. 1,2 =635 Mpa
HRC60
2.2

Limit tensions at contact and at bending

Quality class MQ
H lim 1,2=1500 MPa
F lim 1,2 =550 MPa
3. Predimensioning calculus
3.1 Teeth number z1 of pinion respectively z2 of driven wheel
z 1max =

aw
2
2
cos =45
cos 12=25.74
mn udat +1
2.42+1

( )

z1=z1max=26
z 2=z 1 udat =26 2.42=62.92 =63
aw
=40 50 for gears
mn
=6 14 for gears
3.2

Real gearing ratio u

u=

z 2 63
= =2.42
z 1 26

u
2.42
= 1
=0 u
udat
2.42

||

u =0.03
3.3 CONTACT CALCULUS FACTORS
3.3.1 Elasticity factor of the wheels materials
zE=

1
2
1

1 1

+
E1
E2

2
2

10.3 2
10.32
3.14
+
2.06 105 2.06 102

=189.8 MPa

3.3.2 Contact zone factor


Z h =2.49 cos 2.49 cos 12=2.462
3.3.3Covering grade factor
Z=

1
1
=
=0.714

1.4

=1.4 for inclined teeth


3.3.4Teeth tilting factor
Z = cos = cos 12=0.989
3.4BENDING CALCULUS FACTORS
3.4.1 Teeth numbers of the equivalent wheels
Z n 1,2

Zn1

Zn2

Z 1,2
3

cos
Z1
3

cos
Z2
3

cos

26
=27.781
cos 3 12

63
=67.317
cos3 12

3.4.2 Form factors of the teeth


Y Fa 1,2=Y Fa 1,2 ( Z n 1,2 ; X n 1,2 )

Y Fa 1=Y Fa 1 ( 27.781 ; 0 )= 2.6


Y Fa 2=Y Fa 2 ( 67.371 ; 0 ) =2.27
3.4.4 Tension corection factors at teeth base
Y Sa 1,2=Y Sa( Z n 1,2 ; X n 1,2)
Y Sa 1=Y Sa ( 27.781; 0 )=1.6
Y Sa 2=Y Sa ( 67.371; 0 )=1.75
3.4.5 Covering grade factor
Y =0.25+

0.75
0.75
cos 2 =0.25+
cos2 12=0.762

1.4

3.4.6 Teeth tilting factor


Y =1

12
=1
=0.9
120
120

3.5LOAD CORECTIONS FACTORS


3.5.1 Functioning regime factor
K A =1.35
3.5.2 Dynamic factor
K =1.07
3.5.3 Uneven distribution factors of the load on teeth width for contact and for
bending
K H =1.5 for hardened steel
3.5.4 Uneven distribution factors of load in frontal plane for contact and for bending
K Ha =K Fa=

cos

1.4
=1.46 1.44
cos2 12

for inclined teeth

3.6 Admisible resistency


For contact respectively for bending
H lim Z
1500 1.15
Z L Z Z R Zw Z x=
1 1 1=1326.923 MPa
S Hmin
1.3
HP 1=
N1

Hlim Z N 2
1500 1.3
Z L Z Z R Z w Z x=
1 1 1=1500 MPa
S Hmin
1.3

HP 2=

HP=min ( HP 1 , HP 2) =1326.923 MPa


3.6.1 Predimensioning calculus factors
3.6.2 Lubrication factor
3.6.3 Speed factor
3.6.4 Roughness factor
Z L Z Z R =1.0

for rectified gears with

Ra 0.4 m

3.6.5 Materials couple factor


Z w =1.0
3.6.6 Size factor
Z x =1
3.6.7 Durability factors at contact for wheels
N L 1=60 n I Lh 1=60 2578.94 8500 1=1315.25 106
N L 2=60 n2 Lh 2 =60 1065.67 8500 1=543.49 106
Z N 1=1.0
Z N 2=1.03
3.6.8 Minimum safety coefficient for contact
S hmin =1.3
3.6.9 Admissible resistency for bending
FP 1=

Flim 1 Y ST Y N 1
550 2 1
Y 1 Y R1 Y X=
1 1 1=687.5 MPa
S Fmin
1.6

3.6.10 Predimensioning calculus factors


Bending tension corrections factor
Y ST =2
6

The relative sensitivity factor of stress concentrator for tooth foot for wheels
Y 1,2=1
The relative roughness factor for the conection from the tooth foot for wheels
Y R 1,2=1.0 for Ra 3.2
Size factor
Y X =1
Durability factors at bending for the wheels
Y N 1=1Y N 2 =1
Minimum safety corfficient for bending
S Fmin =1.6
3.7 DISTANCES BETWEEN AXES AT PREDIMENSIONING
3.7.1 Width coefficients
a=0.6
d=

u +1
2.42+1
a=
0.6=1.026
2
2

3.7.2 Distance between axes from the condition of resistency at contact

aWH = (u+ 1 ) 3

T 1 K A K v K H K H
2 a u

2
HP

( Z
3

Z H Z Z ) =( 2.42+1 ) 3

55545.90 1.35 1.07 1.5 1.44 3


(189.8 2.47 0.84 0.
2
2 0.6 2.42 1326.923

3.7.3 Distance between axes from the condition of resistancy at bending


aWF =

T 1 z 1 (u+1)
Y Y
3 55545.90 26 (2.42+1)
2.6 1
K A K v K F K F Y Y Fa Sa =
1.35 1.07 1.5 1.44 0.762 0.9
2 a cos
FP
2 0.6 cos 12
687

3.7.4 Adoptig the distance between the axes at predimensioning


aW =max ( a WH ; aWF )=max ( 59.06; 39.004 )=59.06
Adopted from STAS 6055 aW=56 mm
3.7.5 Preliminary wheels widths
b2= a a W =0.6 56=33.6 mm
b1=b2 + b=33.6+2=35.6 mm
7

b=2 mm
3.8 Teeth modulus
2 aW
2 56
cos =
cos 12=2.97 mmin
z1 z2
6326

m n=

mmin =2.0 for cemented steel


From STAS 822 it is adopted mn=3
d I ,II =

dI =

16 T I , II
at I , II

16 T I 3 16 55545.9
=
=24.18 mm=25
at I
20

Se adopta
d II =

d I =25 mm

16 T II 3 16 134421.07
=
=25.77 mm=26
at II
40

Se adopta

d II =26 mm

at I =15 .20 MPa=20 MPa


atII =35 .45 MPa=40 MPa
d I > 20 mm
d w 1=

2 aW
2 56
=
=32.74853801 mm
u+1 2.42+ 1

d w 2=

2 aW
2 56
u=
2.42=79.25146199 mm
u+1
2.42+1

2.2. Geometric dimensioning and calculus of gear


2.2.1 INPUTS
Parameter

Symbol

Value

Inputs
Power

P, kW

15

Lifetime

Lh, h

8500

Functioning factor

KA

1.35
8

Type of engine

Electric asincron

Load variation

Pulsatory

Rotation at pinion

n1, rot/min

2578.94

Gear ratio (imposed)

udat

2.42

Helical angle

Center distance

aw

71

Width factor

0.6

12

Materials
Steel treatment

Cemented steels
18 CrNi20

Type
Superficial hardness

HRC

60

Inside hardness

HB

350 450

Recommended limit contact stress

MPa

1500

Limit contact stress

Hlim1,2, MPa

1500

Recommended limit bending stress

MPa

550

Limit bending stress

Flim1,2, MPa

550

z1

26

z2

61

Profile roughness

Ra, m

1.6

Root roughness

Ra, m

3.2

For contact stress

SHmin

1.3

For bending stress

SFmin

1.6

Teeth numbers

Machining informations

Functioning conditions
Minimal safety coefficients

2.2.2 RESULTS
Parameter

Gear
Pinion

Wheel
9

GEAR PARAMETERS
Centre distance
Reference centre distance
Normal module
Frontal module
Helix angle
Helix angle on the base circle
Frontal pressure angle
Gearing
frontal
angle:
normal
Total addendum correction
coefficient, in normal plane

aw= 71
a= 88.94362
mn= 2
mt= 2.04468
= 12
b= 11.26652
t = 20.41031
wt = 19.15061
wn = 18.76717

mm
mm
mm
mm
grade
grade
grade
grade
grade

xsn= -0.27367

frontal
= 1.40
helical
= 1.41
overall
= 3.07
Speed on the pitch circle
v = 5.21
Precission
8
Lubricant viscosity
50= 120
Rough active profile
Ra = 0.40
-ness: fillet
Ra = 0.80
PINION AND WHEEL PARAMETERS
Addendum diameters
da1= 57.60872
mm
Deddendum diameters
df1= 48.64171
mm
Pitch diameters
d1= 53.16171
mm
Rolling circle diameters
dw1 = 52.74286
mm
Base circle diameters
db1= 49.82418
mm
Numbers of teeth
z1= 26
Width
b1= 45
mm
Normal addendum correction
xn1= 0.120000
coefficient
Contact
degree:

Frontal addendum correction


coefficient

Xt1= 0.11738

m/s
cSt
m
m
da2= 92.35829
mm
df2= 83.39128
mm
d2= 89.96597
mm
dw2 = 89.25714
mm
db2= 84.31784
mm
z2= 44
b2= 43
mm
xn2= -0.39367
Xt2= -0.38507

Minimum normal addendum


xnmin1= -0.626
correction coefficient

xnmin2=-1.751

Tooth width on the addendum


circle, on the normal plane

s an2

san1

1.41 mm

1.66 mm
10

Minimum tooth width on the s


an min 1
addendum circle, on the
0.80
normal plane
mm

s an min 2

0.80

mm

EQUIVALENT GEAR PARAMETERS


Numbers of teeth
zn1= 27.64
zn2=46.74
Pitch diameters
dn1 = 55.27146
dn2 = 93.53631
mm
mm
Base circle diameters
dbn1= 51.93818
dbn2= 87.89538
mm
mm
Addendum diameters
dan1= 59.71847
dan2= 95.92863
mm
mm
Centre distance
awn= 73.84272
mm
Contact degree
n = 1.73
Parameter
Gear
Contact
Bending
CALCULUS FACTORS
Application factor
KA= 1.35
Dynamic factor

Kv = 1.10

Face load factor

KH = 1.39

KF = 1.39

Transverse load factor

KH = 1.46

KF = 1.46

Elastic factor

ZE = 189.8

Contact factor

ZH = 2.46

Helix angle factor

Z = 1.01

Form factor

Stress correction factor for


bending stress

Y = 0.90
YFa1=2.57
YFa2=2.26
YSa1=1.71
YSa2=1.85

Lubricating factor

ZL= 1.01

Speed factor

Zv= 0.99

Roughness factor

ZR = 1.01

Sensitive factor
Lifetime factor
Minimal safety factor

ZN1 =1
ZN2 =1.05
SHmin=1.3

YR = 0.90
Y1 =0.998
Y2 =1.002
YN1 =1
YN2 =1
SFmin=1.6

STRESSES
Limit stress (choosen)
Permissible stress

Hlim1= 1500
MPa Flim1= 1500
MPa
Hlim2= 430
MPa Flim2= 430
MPa
HP1= 980.8 MPa
FP1= 1027.8 MPa
11

HP2= 483.8

MPa

H1= 1177 MPa


H2= 368.7
MPa

Actual stress

F1= 1177
F2= 394.6
MPa
a =0.6

Width
preliminary
coefficient
final

dimension

Ball diameter

MPa
MPa

arec =0.62

CONTROL ELEMENTS
Dimension over Teeth
No. of teeth for dimension N1=4
over teeth
Normal
teeth

FP2= 483.8

over WNn1 = 21.60478


mm

N2=5
WNn2 =27.34331
mm

or Dimension over Balls


dB =

Dimension over balls

mm

MB1 =
mm
Tooth width
Normal tooth width
scn1= 2.92837
mm
Frontal tooth width
sct1= 2.92066
mm
Height of the normal tooth hcn1= 1.69059
mm
width

MB2 =
mm

Height of the frontal tooth hct1= 1.68012


mm
width

hct2= 0.77531
mm

scn2= 2.26800
mm
sct2= 2.26603
mm
hcn2= 0.78342
mm

3. Gear forces calculus


3.1. Forces calculus
a) Tangential force
Ft 1=Ft 2=

2 T 1
2 55545.9
=
=3392.26 N
d w 1 32.74853801

b) Radial force
Fr 1=Fr 2=

Ft
3392.26
tan wn =
tan18.76717 =1178.401 N
cos
cos 12

c) Axial force
Fa 1 =F a 2=F t 1 tan =3392.26 tan12 =721.047 N
3.2. Sense of the forces
12

13

4. Shaft calculus
4.1 Choosing bearing for input and output shaft
d b 1=d 1 (3 7 )=255=20 mm
d b 2=d 2 ( 1 7 )=261=25 mm
Choosing bearings:
Table 4.2
Shaft Bearing
s
Interior
diamet
er

dimensions

Base radial load

Width

Exterio
r
diamet
er
D

Dynam
ic

mm
20

mm
42

mm
15

N
32900

II

25

52

16.25

36900

C1

Factors

e
0.3
7
0.3
7

Y
1.6
1.6

Symb
ol
Dynamic

C 90
N
962
0
957
0

C a 90 K
N
546
0
615
0

Bearing dimensions
Widt Wi
h
dth

Shaft
Fill Shaft
et
diamete
rad r
ius
da
db
R

Housing
Fillet
Housing
radius diameter

mm

mm mm

0.6

39.
5
48.
5

mm

mm

15

m
m
12

-4.6

m
m
0.6

15

13

-3.8

C0

N
1.56 2940 30204
0
A
1.56 3830 30205
0
A
Table4.2(continues)
Geometric
factors

The
effec
tive
cent
er
a

Facto Stati
r
c

m
m
22.
5
31

m
m
26
.5
32
.5

Da

Db

37
45.5

Weig
ht

Cage

Aa

Ab

mm m
m
0.4 1.
5
0.4 1.
9

G1

G2

Cg
kg

6.
2
9

6.
1
8

0.04
69
0.05
29

0.10
0.15

14

4.2 Checking input shafts at composed loads

Establishing the length of the shaft

l=b 1+2 a+ 2 x=45+2 4.6+2 5.4=65 mm

, where

x=5.4 mm the distance between the wheel and the


bearing

Load
scheme of the shafts in
the 2 planes: Horizontal
and vertical
o Input shaft

o Output
shaft

15

Determining the reactions in bearings for the two perpendicular planes


In horizontal plane:
d
l
l l
M A =0 F r 1 Fa 1 w 1 H B + =0
2
2
2 2

( )

d
l
65
32.75
F r 1 Fa 1 w 1 1178.401 721.047
2
2
2
2
H B=
=
=407.552 N
l
65
d
l
l l
M B =0 F r 1 + F a 1 w 1 H A + =0
2
2
2 2

( )

d
l
65
32.75
F r 1 + F a 1 w1 1178.401 +721.047
2
2
2
2
H A=
=
=770.848 N
l
65
Checking condition:
Y =0 H A F r 1+ H B=0 770.8481178.401 +407.552=0Condition accomplish
In vertical plane:
l
l l
M A =0 F t 1 V B + =0
2
2 2

( )

V B=

Ft1

l
2

F t 1 3392.26
=
=1696.13 N
2
2

l
l l
M B =0 F t 1 V A + =0
2
2 2

( )

V A=

Ft1
l

l
2

Ft 1 3392.26
=
=1696.13 N
2
2

Checking condition:
Y =0 V A F t 1 +V B =0 1696.133392.26+1696.13=0Condition accomplish

16

Determining the
reactions from the two
bearings

R A = H 2A +V 2A = 770.848 2+1696.132 =1863.07 N

RB = H 2B +V 2B= 407.5522 +1696.132=1744.40 N

Drawing the bending moments diagram in the two planes


In horizontal plane

{
{

x=0 M iA =0
M iA1=H A x
l
l
65
x= M i 1=H A =770.848 =25052.56 Nmm
2
2
2

M iB1 =H B x

x=0 M iB =0
l
l
65
x= M i 1=H B =407.552 =13245.44 Nmm
2
2
2

M iHmax =25052.56 Nmm

17

In vertical plane:

M iA1=V A x

{
{

x=0 M iA =0
l
l
65
x= M iB =V A =1696.13 =55124.22 Nmm
2
2
2

x=0 M iB =0
M iB1 =V B x
l
l
65
x= M i 1=V B =1696.13 =55124.22 Nmm
2
2
2
M iVmax =55124.22 Nmm
Determining the maximum total bending moment:
M imax= M 2iHmax + M 2iVmax = 25052.56 2+55124.222=60550.06 Nmm
Loads identifying:
Compression:
4 Fa1

c=

4 721.047
=1.46 MPa
252

Torsion:

t 1=

16 T 1
d

i=

2
I

3
I

16 55545.9
=18.11 MPa
253

Bending:

32 M imax
d

3
I

32 60550.06
=39.47 MPa
25 3

The equivalent stress:

e = ( i+ c ) +4 ( t ) = ( 39.47+1.46 ) + 4 ( 0.6 18.11 ) =46.34 MPa< aiIII


=

aiIII 90
=
=0.6
aiII 150
18

aiIII =90 MPa


aiII =150 MPa
5. Choosing and verifying the parallel key assembly between the driven
wheel and the output shaft.

Choosing the standardized dimensions for the parallel key:

From STAS 1004 for

d II =26 mm

we choose:

b=8 mm

h=7 mm

lc =

Length dimensioning:
4 T II
4 134421.07
=
=29.54 mm
d II h as
26 7 100

19

as =100 120 MPa=100 MPa


l=l c +b=29.54+8=37.54 mm
l STAS =40 mm
There are chosen 1 key

f=

A 8 x 7 x 40

STAS 1004

Shearing checking
2 T II 2 134421.07
=
=43.75 MPa< af =100 MPa
d II b l c 26 8 29.54

6. Choosing and verifying the bearing mounting of the input shaft

Verifying the bearing mounting


Choosing the bearings
It is chosen radial-axial bearing mounting with conical
roles with one row in X
X bearing mounting scheme

20

Verifying the bearing mounting for dynamic loading


capacity
- Suplimentar axial forces chosing
R
1863.07
F ' aA=0.5 A =0.5
=582.209 N
Y
1.6
F ' aB=0.5

RB
1744.4
=0.5
=545.125 N
Y
1.6

Establishing the total axial forces:


Fa + F ' aB > F' aA
Fa + F ' aB=721.047+545.125=1266.172 N > F ' aA=582.209 N
FatA =F' aA + ( F a + F ' aBF' aA ) =F a + F' aB =1266.172 N
FatB =F ' aB=545.125 N

Bearing A

Establishing the zone where the bearing load is found:

21

F atA 1266.172
=
=1.07> e=0.37
F rA 1178.401
-The bearing is found in the 2nd zone, where it cannot be neglected the
influence of the axial force on the equivalent dynamic load

The equivalent dynamic load


P A =f p ( VX F rA +Y F atA ) =1.16 ( 1 0.4 1178.401+1.6 1266.127 )=2896.709 N

f p=1.16
V =1

X =0.4
Y =1.6

L=

60 n Lh
10 6

The imposed durability of the bearing


60 2578.94 8500
=
=1315 millions of rotation
106

The necessary load capacity


p
3.33
Cr necesarA=P A L=2896.709 1315=25033 N <Cr catalog=31000 N
p=3.33for tapered roller bearings

L=

The provided durability of the bearing

Cr
31000
=
PA
2896.709

( ) (

3.33

=2679 millions of rotations

The running time of the bearing


10 L
106 1315
Lh =
=
=8498
60 n 60 2578.94
6

1. Choosing and justification of lubricating device


The lubricant used is the mineral oil.
It is chosen the lubrication by immersion the driven wheel is
immmersed in the oil bath and through gearing it lubricates the pinion.
There are formed oil drops that reach the rolling bodies and the rolling
22

paths. The oil drops are obtained by interaction between the lubricating
oil with the rotating parts: gears and rings.
Fig. 9.1

2. Choosing the sealing elements


d m <d rul
Table 10.1
d

18

35

II

23

40

It is chosen: Sealing ring A 1835 STAS 7950/2-72


A 2340 STAS 7950/2-72

Fig.
10.1
Due to high rotations, it is used sealing system with rotational sleeve.

10.1 Choosing the shaft ends


d a dm 3
Table 10.2
da

15

31

II

21

36

3. Design of the V-belt


Calculus power
P 15
Pc = = =16.66 kW
0.9
=0.85 0.95
23

Belts actuating wheel rotation


n1=2940 rpm
Belts driven wheel rotation
n2=2578.94 rpm
V-belt transmission ration
n
i c = 1 =1.14
n2
Type of the V-belt
It is chosen SPA belt
Driving wheel diameter
It is chosen D p 1=150 mm STAS 7192
Driven wheel diameter
D p 2 D P 1 i c =150 1.14=171 mm
It is chosen

D p 2=170 mm STAS 7192

Distance between axes


0.7 ( D p 1 + D p 2 ) A 2 ( D p 1 + D p 2 )
224 A 640

It is chosen A=250 mm
The angle between belts arms
D D p 1
=2 arcsin p 2
=4.6
2A
The rolling up angle of the belt on both wheels
1=180 =175.4
2=180 + =184.6
The length of the belt
L p=2 Asin

175.4

+
1 D p 1 + 2 D p 2 ) =2 250 sin
+
( 175.4 150+184.6 170 ) =1003.0
(
2 360
2
360

It is chosen

L p=1000 mm STAS 7192

Distance between axes (final)

L p
( 1 D p 1+ 2 D p 2) 1000
( 175.4 150+184.6 170 )
360
360
A=
=
=248.47 mm
1
175.4
2
sin
2 sin
2
2
Peripheral speed of the belt
D p 1 n1 150 2940
=
=
=23.09 m/s
60 1000
60000

24

c f =1.2 STAS 1163

The working coefficient


The length coefficient

c L =0.91 STAS 7192

The wrapping coefficient

c =0.99 STAS 1163

The nominal power transmitted by the belt


P0=3.17 STAS 1163
The belts number
c f Pc
1.2 16.66
z 0=
=
=7
c L c P0 0.91 0.99 3.17
The belts number coefficient

c z =0.95 STAS 1163

The final belts number


z
7
z= 0 =
=7.36
c z 0.95
It is chosen z=8
Frequency of belt bending

23.09
3
3
f =10 x =10 2
=46.18 Hz
Lp
1000
Peripheral transmitted force
P
16.66
F=103 c =103
=721.52 N

23.09

Stretching force of the belt


S a= (1.5 2 ) F=1.70 721.52=1226.584 N
Modifications of the distance between axes
X 0.03 L p X 42mm
Y 0.015 L p Y 21mm

25

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