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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;
n = 2940 rot/min;
iC= 1.14;
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
-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
=0.38
fn
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
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
1
1
=
=0.714
1.4
Zn1
Zn2
Z 1,2
3
cos
Z1
3
cos
Z2
3
cos
26
=27.781
cos 3 12
63
=67.317
cos3 12
0.75
0.75
cos 2 =0.25+
cos2 12=0.762
1.4
12
=1
=0.9
120
120
cos
1.4
=1.46 1.44
cos2 12
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=
Ra 0.4 m
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
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
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
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
b=2 mm
3.8 Teeth modulus
2 aW
2 56
cos =
cos 12=2.97 mmin
z1 z2
6326
m n=
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
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
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
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
MPa
1500
Hlim1,2, MPa
1500
MPa
550
Flim1,2, MPa
550
z1
26
z2
61
Profile roughness
Ra, m
1.6
Root roughness
Ra, m
3.2
SHmin
1.3
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:
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
xnmin2=-1.751
s an2
san1
1.41 mm
1.66 mm
10
s an min 2
0.80
mm
Kv = 1.10
KH = 1.39
KF = 1.39
KH = 1.46
KF = 1.46
Elastic factor
ZE = 189.8
Contact factor
ZH = 2.46
Z = 1.01
Form factor
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
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
N2=5
WNn2 =27.34331
mm
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
hct2= 0.77531
mm
scn2= 2.26800
mm
sct2= 2.26603
mm
hcn2= 0.78342
mm
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
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
, where
Load
scheme of the shafts in
the 2 planes: Horizontal
and vertical
o Input shaft
o Output
shaft
15
( )
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
{
{
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
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
aiIII 90
=
=0.6
aiII 150
18
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
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
20
RB
1744.4
=0.5
=545.125 N
Y
1.6
Bearing A
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
f p=1.16
V =1
X =0.4
Y =1.6
L=
60 n Lh
10 6
L=
Cr
31000
=
PA
2896.709
( ) (
3.33
paths. The oil drops are obtained by interaction between the lubricating
oil with the rotating parts: gears and rings.
Fig. 9.1
18
35
II
23
40
Fig.
10.1
Due to high rotations, it is used sealing system with rotational sleeve.
15
31
II
21
36
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
( 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
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
25