Faculty of Engineering – Cairo University

Mechanical Design and Production Engineering

Two-Semester System – 3rd Year
MDP 303: Machine Design II – Fall 2019

CVT Project

Submitted to
Prof.: Hesham Hegazi
T.A: Mohammed Hussein
T.A: Mostafa Rashad

Prepared by Group 2

Mahmoud Ahmed EL-Sayed

Mahmoud Mohamed Tawhid
Anton Tamer Shafique
Ayman Hisham Mahmoud

December 27th, 2019

Givens:

𝑃𝑚𝑎𝑥 = 5 𝐾𝑊 @ 𝑛 = 8000 𝑟𝑝𝑚 & @ 𝑖 = 2

𝑇𝑚𝑎𝑥 = 7.5 𝑁. 𝑀 @ 𝑛 = 6500 𝑟𝑝𝑚
𝑃𝑚𝑖𝑛 = ? ? @ 𝑛 = 2000 𝑟𝑝𝑚 & @ 𝑖 = 4

V-Belt Design
𝑛1 8000
𝐻 = 5𝐾𝑊, 𝑖=2= =
𝑛2 4000

1- Choosing belt section SPA taking 𝑑 = 112𝑚𝑚 (𝑑𝑝𝑢𝑙𝑙𝑦 from standard section SPA)
60𝑉 60𝑉
2- 𝑑 = , 112 ∗ 10−3 = 𝜋∗8000, 𝑉 = 46.91 𝑚/𝑠 > 40
𝜋𝑛

it’s big cause of high rpm n=8000 and it doesn’t reach this 8000 instantaneously so it’s
acceptable
3- 𝐷 = 𝑑 ∗ 𝑖 = 112 ∗ 2 = 224 𝑚𝑚 ( 𝐷𝑝𝑢𝑙𝑙𝑦 from standard section SPA )
4- 𝐹. 𝑠 = 1.1 Mutiny Cylinder 8-10 hr.
𝐻𝑑𝑒𝑠 = 𝐻 ∗ 𝐹. 𝑠 = 5 ∗ 1.1 = 5.5 𝐾𝑊
5- Choosing Center Distance C=600 𝐷 < 𝐶 < 3(𝐷 + 𝑑 ) 224 < 600 < 1008
𝐷−𝑑 224−112
6- 𝜃𝑠 = 𝜋 − ( )=𝜋−( ) = 2.955 𝑟𝑎𝑑
𝐶 600
𝜋 (𝐷−𝑑)2 𝜋 (224−112) 2
7- Belt length (L) =2𝐶 + 2 (𝐷 + 𝑑 ) + = 2 ∗ 600 + 2 (224 + 112) +
4𝐶 4∗600

𝐿 = 1733 𝑚𝑚
8- From Table for SPA section 𝐿 = 1700 𝑚𝑚
9- 𝐿𝑚 = 𝐿 − 𝐿𝑜 = 1700 − 18 = 1682 𝑚𝑚 (𝐿0 for SPA section = 18 mm)
10- For section SPA 𝐾1 = 0.64 , 𝐾2 = 20 , 𝐾3 = 0.75 , 𝐷𝑒 = 𝑑 ∗ 𝐾𝑒 = 112 ∗ 1.13 =
126.56 𝑚𝑚 < 𝑚𝑎𝑥 ( 𝐾𝑒 = 1.16 𝑓𝑜𝑟 𝑖 = 2 )
𝐾 20
11- 𝐻𝑟𝑎𝑡 = [𝐾1 ∗ 𝑉 −.09 − 𝐷2 − 𝐾3 ∗ 10−4 𝑉 2 ] ∗ 𝑉 = [. 64 ∗ 46.91−.09 − 126.56 − .75 ∗
𝑒

10−4 46.912 ] ∗ 46.91 = 6.078 𝐾𝑊

12- 𝐾𝐴 = 0.97 @ 𝜃𝑠 = 2.955 𝑟𝑎𝑑 = 169.5° , 𝐾𝐿 = 0.94 @ 𝐿𝑚 = 1682 𝑚𝑚

𝐻𝑑𝑒𝑠 5.5
13- 𝑁 = 𝐾 = .97∗.94∗6.078 = .99 ≅ 1
𝐿 ∗𝐾𝐴 ∗𝐻𝑟𝑎𝑡
 𝜋 (𝐷−𝑑)2
14- 𝐿 = 2𝐶 ′ + 2 (𝐷 + 𝑑 ) + , 𝐶 ′ = 584 𝑚𝑚
4𝐶 ′

From tables we choose belt from

section SPA but with special case 𝜶 = 𝟐𝟒
cause of the application of CVT

All of that was for end condition

For Start Condition:
𝑃 = ? ? @ 𝑛 = 2000 𝑟𝑝𝑚 & @ 𝑖 = 4
It’s obligatory that L=1700 mm & C=584 mm from end condition and same section type SPA
and number of belts is one.
Cause it is continuous variable pulley, we can choose diameters of pulley not in standard tables.
𝜋 (𝐷 − 𝑑 )2
𝐿 = 2𝐶 + (𝐷 + 𝑑 ) +
2 4𝐶
𝜋 (4𝑑 − 𝑑 )2
1700 = 2 ∗ 584 + (4𝑑 + 𝑑 ) + , 𝑑2 = 65 𝑚𝑚 , 𝐷2 = 263 𝑚𝑚
2 4 ∗ 584
𝐷2
𝑖= = 4.046
𝑑2
Because of at much lower rpm 𝑛1 = 2000 & 𝑛2 = 500 and lower power 𝑃𝑚𝑖𝑛 then it would be
safer than end condition. (We check it using MITCALC)

Results

𝐿 = 1700 𝑚𝑚 , 𝐶 = 584 𝑚𝑚 , 𝐵𝑒𝑙𝑡 𝑆𝑃𝐴 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 , 𝑜𝑛𝑙𝑦 𝑜𝑛𝑒 𝑏𝑒𝑙𝑡

Condition Input Pulley Output Pulley Reduction Ratio

At Start 𝑑 = 65 𝑚𝑚 𝐷 = 263 𝑚𝑚 𝑖 = 4.046
At Max Power 𝑑 = 112 𝑚𝑚 𝐷 = 224 𝑚𝑚 𝑖=2
Centrifugal Clutch

At the maximum position, masses exert maximum forces.

-At this position: 𝑛 = 8000 𝑟𝑝𝑚

•∆𝐹 = 107 𝑁
𝐹𝑐 = 𝑚𝜔2 𝑟
but
2𝜋∗8000
•𝜔 = = 837.758 𝑟𝑎𝑑/𝑠𝑒𝑐
60
𝑑𝑝2 −𝑑𝑝1 112−65
•𝑣𝑖𝑟𝑡𝑖𝑐𝑎𝑙 𝑚𝑜𝑣𝑖𝑛𝑔 = = = 23.5 𝑚𝑚
2 2

•ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑚𝑜𝑣𝑖𝑛𝑔 = 𝑥 = 23.5 ∗ 𝑡𝑎𝑛12𝑜 = 5 𝑚𝑚

-drawing arc that connect the two points:
∆𝐹 ∗ 𝑠𝑖𝑛𝛽
= 𝐹𝑐 ∗ 𝑠𝑖𝑛𝜃
𝜇
•For 𝜇 = 0.3 "𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑅𝑢𝑏𝑏𝑒𝑟 𝑎𝑛𝑑 𝑆𝑡𝑒𝑒𝑙"
107 ∗ 𝑠𝑖𝑛12
= 𝐹𝑐 ∗ sin (7)
0.3
∴ 𝐹𝑐 = 608.5 𝑁
𝑑𝑝2 112
•𝑟 = = = 56 𝑚𝑚
2 2

∴ 608.5 = 𝑚 ∗ (837.758)2 ∗ 56 ∗ 10−3

∴ 𝑚 = 0.0152 𝐾𝑔 = 15.2 𝑔𝑚
•Normally there are 6 elements
15.2
∴ 𝑚𝑒𝑎𝑐ℎ = = 2.5 𝑔𝑚
6
Shaft Calculation

Input Shaft
❖ Max distance between two sheaves = Belt width = 12 mm.
❖ Distance between first sheave and casing = width of sheave
= 20 mm.
❖ Distance after second sheave for the lock nut = 20 mm.
• This drawing is for maximum condition at maximum Power.
• For (max. torque = 7.5 Nm.) at (n = 6500 rpm) we don’t know the
pulley diameter so we will work on 𝑑𝑝 = 112 𝑚𝑚 at end condition
(𝑃𝑚𝑎𝑥 ) which will have lower torque but we will compensate it in
the factor of safety.
𝑃 5000
• 𝑃𝑚𝑎𝑥 = 5 𝐾𝑊 , 𝑛 = 8000 𝑟𝑝𝑚 , so 𝑇 = 2𝜋∗𝑛 = 2𝜋∗8000 =
60 60
5.9 𝑁. 𝑚
• From MITCALC:
𝐹1 𝑑𝑝
= 1.45 , 𝑇 = (𝐹1 − 𝐹2 ) ∗
𝐹2 2

∴ 𝐹1 = 345 𝑁 , 𝐹2 = 238 𝑁 , 𝐹𝑟 = 𝐹1 + 𝐹2 = 583 𝑁

- Note: 𝐹𝑟 : Total force on shaft due to belt tension (causes
Bending).
• For F.S = 3 , 𝑇 = 17.7 𝑁. 𝑚 , 𝐹1 = 1035 𝑁 , 𝐹2 = 714 𝑁
, 𝐹𝑟 = 1749 𝑁
• 𝐹𝑟 is divided into two equal forces each affects one sheave.
• Calculating Moment and Torque on shaft: 𝑀 = 80.45 𝑁. 𝑚 ,
𝑇 = 17.7 𝑁. 𝑚
• Assuming:
1. 𝐾𝑡 = 𝐾𝑚 = 1.5
2. Material: 1040 Normalized. 𝑆𝑢 = 590 𝑀𝑃𝑎 , 𝑆𝑦 = 370 𝑀𝑃𝑎 , 𝑆𝑒′ = 0.5 ∗ 𝑆𝑢 =
295 𝑀𝑃𝑎

3 32 𝐾𝑚∗𝑀 2 𝐾𝑡 ∗𝑇 2
• 𝑑 = √ 𝜋 √( ) (𝑆 ) = 16.17 𝑚𝑚 ≅ 20 𝑚𝑚
𝑆𝑒′ 𝑦

• For the output shaft, the same Material and Moment as input shaft 𝑀 = 80.45 𝑁. 𝑚 and for
𝑖=2
∴ 𝑇 = 2 ∗ 17.7 = 35.4 𝑁. 𝑚

3 32 𝐾𝑚∗𝑀 2 𝐾𝑡 ∗𝑇 2
• 𝑑 = √ √( ) ( ) = 16.4 𝑚𝑚 ≅ 20 𝑚𝑚
𝜋 𝑆𝑒′ 𝑆𝑦

Spring

𝑑𝑝1 −𝑑𝑝2 263−224

•𝑣𝑖𝑟𝑡𝑖𝑐𝑎𝑙 𝑚𝑜𝑣𝑖𝑛𝑔 = = = 19.5 𝑚𝑚
2 2

•ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑚𝑜𝑣𝑖𝑛𝑔 = 𝑥 = 19.5 ∗ 𝑡𝑎𝑛12𝑜 = 5.96 𝑚𝑚

❖ 𝐹1 : 𝑖𝑠 𝑡ℎ𝑒 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑡𝑖𝑔ℎ𝑡𝑒𝑛𝑖𝑛𝑔 𝑒𝑥𝑒𝑟𝑡𝑒𝑑 𝑤ℎ𝑒𝑛 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑖𝑛𝑔 𝑡ℎ𝑒 𝑐𝑙𝑢𝑐ℎ.
❖ 𝐿1 : 𝑖𝑠 𝑡ℎ𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 𝑙𝑒𝑛𝑔𝑡ℎ 𝑎𝑡 𝐹1 .
❖ 𝐹2 : 𝑖𝑠 𝑡ℎ𝑒 𝑓𝑖𝑛𝑎𝑙 𝑡𝑖𝑔ℎ𝑡𝑒𝑛𝑖𝑛𝑔 𝑒𝑥𝑒𝑟𝑡𝑒𝑑 𝑎𝑡 𝑚𝑎𝑥. 𝐹𝑜𝑟𝑐𝑒.
❖ 𝐿2 : 𝑖𝑠 𝑡ℎ𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 𝑙𝑒𝑛𝑔𝑡ℎ 𝑎𝑡 𝐹2 .

•𝐿1 = 𝐿2 + ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑚𝑜𝑣𝑖𝑛𝑔

•𝐿1 = 𝐿2 + 5.96
•𝐹2 = 𝐹1 + 𝐹𝑠ℎ𝑒𝑎𝑣𝑒
∆𝐹∗sin(𝛽)
•𝐹𝑠ℎ𝑒𝑎𝑣𝑒 ∗ cos(𝛽 ) = 𝜇

107∗sin(12)
•𝐹𝑠ℎ𝑒𝑒𝑣𝑒 = = 75 𝑁
0.3∗cos(12)

Using MITCALC:
Choosing parameters as follow:
𝐹1 = 50 𝑁 , 𝐹2 = 125 𝑁 , 𝐿1 = 50 𝑚𝑚 , 𝐿2 = 56 𝑚𝑚 , 𝐿0 = 115 𝑚𝑚 , 𝑛 = 6
Material: Chrome-Silicon alloy steel wire EN 10270-2 FDSicr
𝑑𝑤𝑖𝑟𝑒 = 6 𝑚𝑚 , 𝐷𝑖 = 38 𝑚𝑚 , 𝐷𝑜 = 50 𝑚𝑚

It is safe.
MITCALC Calculations:

Belt at end condition:

Belt at start condition:
d
Spring: