MECG1022 Design Project Re-

port

Design of XY Table with Power

Screws

Date: January 22, 2020

Name: Daniel Andrés Crespo Arízaga

Design Project No.: 2

Instructor: Profesor Carlos Gabriel Helguero

Mechanical Engineering Faculty

ESPOL
Contents

Contents 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Design criteria and assumptions . . . . . . . . . . . . . . . . . . . . . . . . . 3
Design procedures and descriptions with abridged derivations . . . . . . . . 4
Results and discussions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Conclusions and recommendations . . . . . . . . . . . . . . . . . . . . . . . 7
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Annexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calculation of the torque required in the longitudinal displacement motor. 9
Stress analysis applied on the longitudinal screw . . . . . . . . . . . . . 10
Combined stress on the screw body . . . . . . . . . . . . . . . . 11
Axial load and torsion failure in the screw core . . . . . . . . . . 12
Shear or bending failure on screw and nut fillets. . . . . . . . . . 12
Crushing failure on the flanks of the fillets . . . . . . . . . . . . 13
Buckling failure in the screw body . . . . . . . . . . . . . . . . . 14
Failure due to fatigue . . . . . . . . . . . . . . . . . . . . . . . . 15
Calculation of the torque required in the longitudinal displacement motor. 17
Stress analysis applied on the longitudinal screw . . . . . . . . . . . . . 18
Combined stress on the screw body . . . . . . . . . . . . . . . . 18
Axial load and torsion failure in the screw core . . . . . . . . . . 19
Shear or bending failure on screw and nut fillets. . . . . . . . . . 20
Crushing failure on the flanks of the fillets . . . . . . . . . . . . 21

2
 Buckling failure in the screw body . . . . . . . . . . . . . . . . . 21
Failure due to fatigue . . . . . . . . . . . . . . . . . . . . . . . . 22
Analysis for speed reduction from the motor. . . . . . . . . . . . . . . . 24
Calculation of the available motor speed and the required speed
on the screw . . . . . . . . . . . . . . . . . . . . . . . 24
V-band selection to supply power from the motor. . . . . . . . . 25
Bearing analysis, selection and lubrication. . . . . . . . . . . . . . . . . 27
Introduction
This project is based on the design of an XY table with power screws whose movement
is generated by step-by-step motors coupled to the screws through a speed reduction
system according to the requirements. The engines in turn will be computer controlled
by some control system that will not be detailed in this document.

An XY table is a fundamental part of many machines in the manufacturing and pro-

duction industry. They appear on manual lathes, manual milling machines, machining
centers, 3D printers, and on any other device that requires fine control of the move-
ment in two directions with reduced tolerance margins. Power screws are mechanical
elements that are used to move loads with the advantage that the movement is done
in a controlled way and we can find them in actuators, presses, production machines,
mechanical cats and many other applications. There are several classes, like ACME,
square and ball screws.

For this project, ACME threads will be used because they are relatively easier to ma-
chine, and the XY table requires the displacement of the thread/nut in both directions.
In addition, the loads are not high so friction is not a limiting factor (reason why a ball
screw was not chosen).

The screws shall rest on angular contact ball bearings arranged at the ends in order to
facilitate the rotation of the screw while supporting the axial and radial loads generated
during the operation of the XY table.

V-belts will be used for power transmission from engines to screws because the use of
belts is more economical and easier to maintain; In addition, the load requirements
detailed in the following section suggest the use of belts instead of gears. Refer to
Figure 1 of the annexes for a quick visualitation of the design scheme.

Design criteria and assumptions

• Two step engines will be used which will be selected from an available catalogue.

• The pitch angle of the motors shall be 0.9◦

• Two power screws shall be used; one for the direction X and one for the direction
Y

• The linear motion resolution shall be better than 12 µ m (0.0004724 in)

• The screws shall be mounted on bearings at each one of the ends.

• The working space range for the XY table is 18 "x18".

• The speed in the x or y direction does not exceed 10 mm / s.

 • The screws used are ACME type.

• There is an external load of 21.7 lb along the Y direction which has a displacement
height of 1.5" from the top level of the XY table

Design procedures and descriptions with abridged deriva-

tions
The design strategy consisted of the gradual calculation of the mechanical members
according to their dependence on other elements of the machine. With this in mind,
we started by carrying out the verifications of the design requirements requested which
was mentioned in part 2. All calculations need special treatment based on theory and
available equations, for this reason it is preferred in this section only to explain the
general procedure followed and finalize with a table that summarizes all the results
obtained for their discussion.

The pitch of the screw, its diameter and the resolution of the linear movement are
related. It was started by choosing a screw diameter that meets this initial requirement.

The resolution of linear motion should be better than 12 µ m=0.0003937 inches. The
resolution that can be achieved with a motor with a steep angle of 0.9◦ that moves
a 0.25-inch diameter screw is 0.00025 inches which we reach the requirement. With
this tentative diameter we go to table 5 of the Annexes to obtain the standard ACME
thread parameters which are the number of strings per inch=16, step p= 0.063 in, the
smaller diameter dr=0.188 in.

It is necessary to know the load requirements of the system and to calculate the torque
required to turn each screw. These calculations are detailed in the Annexes under
representative calculations.

With the required torques we can select the motor in the available catalogues. Part of
the catalogue with the selection of step-by-step motor is shown in the catalogue section
of the Annexes, Table 20. The selected motors were VRDM364 for the transverse screw
and VRDM366 for the longitudinal screw.

A static and dynamic analysis of the screws was then carried out to determine their
safety factors for their possible failure modes. These calculations are shown in Repre-
sentative calculations of Annexes.

With the information provided by the step by step manufacturer and the screw output
requirements (linear speed) the available motor speed and the speed required by the
screw were calculated. With these calculations, it was concluded that a speed reduction
was required and the use of one V-band per motor for this purpose was considered. The
band selection is detailed in Annexes.
With the above results of the forces on the sides of the belts and applying Newton’s Law
for static equilibrium, we proceed to calculate the axial loads acting on the bearings
whose calculations are detailed in the Annexes. The bearings were finally selected based
on the load requests present during the operation. The configuration of Figure 12 shall
be used for mounting the bearings

The tables below contain the most relevant results of the above analysis.

Type of analysis Results

Torque required 3.25lb · in
Torque of the selected motor 3.98lb · in
Code of the motor VRDM364
Nominal diameter of screw in
Safety factor against combined stress on 7.2
the screw body
Safety factor against axial load failure 4.2
and torsion in the screw core
Safety factor against shear or bending 35 screw
failure in screw and nut fillets 28 nut
Safety factor against crushing failure on 212
the sides of the fillets
Safety factor against buckling failure in 3.4
the screw body
Safety factor against fatigue failure 3.4
Band selected Section V A26
Safety factor of the belt 2.6
Bearing selected 7200 BECBP
 Tipo de análisis Resultado
Torque required 4.68lb · in
Torque of the selected motor 7.97 lb · in
Code of the motor VRDM366
Nominal diameter of screw in
Safety factor against combined stress on 3.7
the screw body
Safety factor against axial load failure 5.4
and torsion in the screw core
Safety factor against shear or bending 15.15 screw
failure in screw and nut fillets 12.35 nut
Safety factor against crushing failure on 95.1
the sides of the fillets
Safety factor against buckling failure in 1.46
the screw body
Safety factor against fatigue failure 1.5
Band selected Section V A26
Safety factor of the belt 2.6
Bearing selected 7200 BECBP

Results and discussions.

Tables 1 and 2 show the most important results of the calculations made. Table 1
presents the results for the mechanism of longitudinal movement while table 2 shows
the results of the transverse mechanism.

The proposed screw diameter for the longitudinal movement mechanism supports the
loading requirements as seen in the safety factors obtained. Similarly, the screw pro-
vided by the transverse movement meets the loading requirements as shown by its safety
factors in Table 2. Safety factors show very different amounts for different possible fail-
ure modes; This means that there will be regions that are more susceptible to failure
while others will feel the efforts with less intensity. This may be due to two factors, one
being the nature of the load and the other being the area supporting the load.

Fatigue tests showed the lowest safety factors. This was due to the fact that the
calculations were made under conservative conditions and considering the concentration
factors of stress in fatigue slightly high due to the limited information available. Safety
factors for fatigue were 3.4 and 1.5 for longitudinal and transverse screws respectively.
These factors are acceptable as long as the load conditions specified for the proper
functioning of the equipment are not exceeded. Allowing very high safety factors would
mean more investment and equipment that would not require regular maintenance,
which is a notable disadvantage.

The selected step motors were VRDM364 and VRDM366. Two different motors were
selected because only one of the screws requires a higher torque inlet and thus avoids
falling over-sizing the engine and making unnecessary expenses.
The rotation speed of the engines did not provide the desired controlled output and
a speed reduction system was used. The belt/pulley system was chosen because it is
more economical and easier to maintain in relation to gears that require additional
manufacturing processes. The safety factors of the bands are considered acceptable.
The loads on the bearings were calculated and the most critical load was chosen for the
analysis, that is, the loads on the bearing closest to the pulley. The analysis shown in
the annexes allowed us to choose the bearings needed to support the radial and axial
loads at the points of support. The code of the 4 selected bearings is 7200 BECBP.
The use of lubricant for low-speed systems is also proposed.

Conclusions and recommendations

We concluded that the XY table with power screws that was presented as a design pro-
posal in this research document does not fail under static load and also under dynamic
load.

It is also concluded that the requested requirements, including the resolution, the linear
feed speed of the trolleys and the longitudinal and transverse displacement, are fulfilled
within the acceptable design margins.

We recommend a more thorough study of the fasteners of the parts that make up the
assembly such as screws, retaining rings, wedges, etc since these are essential in the
proper functioning of the whole assembly.

It is recommended to use angular contact bearings because they provide an axial force
component that counteracts the loads that are directed parallel to the shaft of the power
screws.

It is recommended to avoid the use of push collars since these usually provide an ad-
ditional resistant torque component, which leads to the use of a motor with higher
capacity and more expensive.

It is recommended to keep the surfaces in sliding contact properly lubricated during the
operation of the machine. Keep the rails free of swarf and any other element capable
of obstructing their movements.
Bibliography
• Budynas, R. and Nisbett, J. (2008). Shigley’s mechanical engineering design. 8th
ed. Boston, [Mass.]: McGraw-Hill Higher Education.

• Norton, R. (2011). Machine design an integrated approach. 4th ed. Naucalpan

de Juarez: Pearson Education.

• Kalpakjian, S. and Schmid, S. (2008). Manufacturing, engineering and technology.

5th ed. Mexico: Pearson Education.

• Bazus.com. (2020). MF DRILL, XY table for drills. [online] Available at:

https://www.bazus.com/es/mesas-manuals/mf-drill-mesa-xy-taladros/ [Access 18
Jan. 2020].

• dipacmanta.com. (2020). DIPAC ACERO AISI 1018. [online] Available at:

http://www.dipacmanta.com/aisi-1018-transmision [Access 18 Jan. 2020].

• Skf.com. (2020). Rodamientos. [online] Available at: https://www.skf.com/binary/87-

121486/0901d19680416953-10000_2-ES—Rolling-bearings.pdf [Access 18 Jan. 2020].
Annexes

Representative calculations

Calculation of the torque required in the longitudinal displace-

ment motor.

In order to calculate the torque to be provided by the engine for moving the longitudinal
trolley, the effective load is first calculated for the case of a horizontal displacement of
the nut coupled to the trolley.

As shown in Figure 2, the force opposing the movement of the nut (all elements coupled
to it) is the friction force between the external surface of the nut and the contact surface
which is assumed to be well lubricated.

Table 3 shows the coefficients of friction for typical surfaces in contact with lubrication.
For our case, the corresponding coefficient of friction is µ =0.17; so that:

F =µ

Where F is the force that opposes the movement of the nut, µ is the coefficient of
friction between the nut and the sliding surface and W is the total load corresponding
to all elements coupled to the transverse sliding nut.

P =µ

P = 0.17 ∗ 95lb

P = 16.15lb

Axial load Fh in the Y direction shown in figure 3 has no effect on the longitudinal
screw. The diameter of the collar is dc= 0.5 in. As it is a simple string, the advance L
is equal to the step p=0.063 in. Diametral pitch is dp=0.219 in. The screw and nut are
lubricated with oil and both are steel, then from table 3 we have a µ =0.17. The sliding
friction on the thrust collar is obtained from Table 4 and is µ c =0.15. In addition, the
inertial load is considered to speed up the system.

We assume that we want to accelerate the initial load from 0 to 39.26 rad/s in 1 second
at boot so that α = 39.26 rad
s2
The total load inertia is:

J = Jr + Js + Jm

Where Jr, Js and Jm are the reflected inertia of the weight, the inertia of the power
screw and the engine inertia respectively.

2 1∗0.063 2
Jr = m np


2π
= 95 2π
= 0.0096lb2
0.219 2
Js = 12 mrp2 = 21 (1.15)


2
= 0.0069lb2

Jm = 0.034lb2 (tabla20)

Thus the total inertia is:

J = 0.051lb2

With this information, the torque needed to carry the load transversely is calculated:
P dp (µπdp +L cos α)
Tu = Tsu + Tc = 2 (µπ cos α−µL)
+ µc P d2c + Jα

16.15∗0.219 (0.17∗π∗0.219+0.063∗cos 29◦ ) 0.50

Tu = 2 (0.17∗π29◦ −0.17∗0.063)
+ 0.15 ∗ 16.15 ∗ 2
+ 0.051 ∗ 39.26

Tu = 3.25lb

The torque to move the load in the opposite direction is:

P dp (µπdp −L cos α)
Td = Tsd + Tc = 2 (µπ cos α+µL)
+ µc P d2c + Jα

16.15∗0.219 (0.17∗π∗0.219−0.063∗cos 29◦ ) 0.50

Tu = 2 (0.17∗π29◦ +0.17∗0.063)
+ 0.15 ∗ 16.15 ∗ 2
+ 0.051 ∗ 39.26

Td = 2.83lb

In Table 20 you will find the technical sheet of the selected engine which is a VRDM364
step motor that has a nominal torque of 0.45 Nm= 3.98 lb∗ in.

Stress analysis applied on the longitudinal screw

To design a power screw the following failure mode must be considered:

–Combined effort in the screw body.

-Failure by axial load and torsion in the screw core.

-Cutting or bending failure in the screw and nut fillets.

-Crushing fault in the flanks of the fillets -Buckling failure in the screw body

-Fatigue failure
Combined stress on the screw body

The shear force on the body τ , due to the torque Tu on the outside of the screw body,
is:
16Tu
τ= πd3r

16∗3.25
τ= π∗0.1883

τ = 2491.04 inlb2

Where Tu is the higher torque applied to the screw and dr is the root diameter of the
screw (table 5)
The nominal normal axial stress σ is:

4P
σ = − πd2
r

4∗16.15
σ = − π∗0.1882

σ = −581.8 inlb2
The bending force at the root of the σ b thread with a 0.38F supporting thread is:

σb = − πd6P
r nt p

6∗16.15
σb = − π∗0.188∗1∗0.063

σb = 2604.21 inlb2

Figure 5 shows the three-dimensional stresses to which a differential element is subjected

at the root of the screw, which are:
lb
σx = σb = 2604.21 in2
τxy = 0
lb
σy = 0 τyz = 2491.04 in2

σz = −581.8 inlb2 τzx = 0

Then applying distortion energy,

 12
σ = √12 (σx − σy )2 + (σy − σz )2 + (σz − σx )2 + 6 τxy
 2 2 2
+ τyz + τzx
1
σ = √12 (2604.21 − 0)2 + (0 − (−581.8))2 + (−581.8 − 2604.21 )2 + 6 (2491.042 ) 2


σ = 4709.31 inlb2
The safety factor of the screw body for static load if the screw material is AISI 1018
steel with Sy=34x103 (see table 21) is:
34×103
n= 4709.31

n ≈ 7.2

Axial load and torsion failure in the screw core

The screw core is subjected to axial loading and torsion. The traction/compression
stress area is:
 2
At = π4 dp +d
2
r

π 0.219+0.188 2


At = 4 2

At = 0.0325in2

The compression force is then:

σc = − APt
16.15 lb
σc = − 0.0325 in2

σc = −496.92 inlb2

The torque cutting effort is the same as previously calculated:

τ = 973.42 inlb2

Then using distortion energy

1
σ = (σc )2 + 3 (τ )2 2


 21
+ 3 (4709.31)2
 2
σ = (−496.92)

σ = 8171.90 inlb2

Then the safety factor of the screw is:

34×103
n= 8171.90

n ≈ 4.2

Shear or bending failure on screw and nut fillets.

The cutting area by scanning Ace for the rope of the screw is the area of the cylinder
of its smaller diameter dr:
As = πdr wi p

Where p is the step of the rope and wi is the factor that defines the percentage of the
step occupied by the metal in the smaller diameter. These factors appear in Table 6.

As = π ∗ 0.188 ∗ 0.77 ∗ 0.063

As = 0.0287in2

The shear force τ s for sweeping the rope is then determined with:
P
τs = As

16.15 lb
τs = 0.0287 in2

τs = 562.72 inlb2

Then applying distortion energy, we have:

1
σ = 3 (τs )2 2 = 1.732 ∗ τs inlb2


Sy 0.577y 0.577∗34×103
n= 1.732∗τs
= τs
= 562.72

n ≈ 35

Similarly, for the nut.

As = πdr wo p

As = π ∗ 0.188 ∗ 0.63 ∗ 0.063

As = 0.0234in2
P
τs = As

16.15 lb
τs = 0.0234 in2

τs = 690.17 inlb2
Sy 0.577y 0.577∗34×103
n= 1.732∗τs
= τs
= 690.17

n ≈ 28

Crushing failure on the flanks of the fillets

The σ B supporting or crushing force is, with a 0.38P supporting thread:

2∗0.38
σB = − πdp nt p
Where making nt =1
2∗0.38∗16.15
σB = − π∗0.219∗1∗0.063

σB = −283.17 inlb2
Where the safety factor, and considering Syc = Syt = 60kpsi

is:
60×103
n= 283.17

n ≈ 212

Buckling failure in the screw body

The screw is considered as a column with centered load as shown in Figure 6 We

calculate the area where the force, inertia and rotation radius is applied as follows:
πd2r
A= 4
.
π∗(0.188)2
A= 4

A = 0.0278 in2
πd4r
I= 64

π(0.188)4
I= 64

I = 6.13 × 10−5 in2

q
K = AI
q
−5
K = 6.13×10
0.0278

K = 0.046in

We calculate the ratio of slenderness and the ratio of critical slenderness:

l 20
k
= 0.046
= 425.9
  12   12
l 2π 2 CE 2π 2 ∗1.2∗30×106


k 1
= Sy
= 34×103
= 144.6

l l


Verify that k
≥ k 1
→ 425.9 ≥ 144.6 → Long column of Euler

The following equation is used:

Pcr Cπ 2 E
A
< 2 = σadm
( kl )
Where C is the condition factor of column ends. From Table 7 an end factor of C=1.2
is used considering both embedded ends.
Pcr P 4P 4∗16.15
σ= A
= A
= πd2r
= π(0.188)2
= 581.80 inlb2

Cπ 2 E 1.2∗π 2 ∗30×106
σadm = l 2
= (425.9)2
= 1958.9 inlb2
( )k

The safety factor that protects against buckling is then:

1958.9
n= 581.80

n = 3.4

Failure due to fatigue

Figure 5 shows the state of nominal stresses for points A and B. where:
lb
σx = σb = 2604.21 in2

σz = −581.8 inlb2
lb
τyz = 2491.04 in2

Alternating and mean stresses are:

σxmax −σxmin 2604.21−(−2604.21)
σxa = 2
= 2
= 2604.21 inlb2

σxm = 0

σza = 0
σzmax −σzmin −581.8−0
σzm = 2
= 2
= 290.9 inlb2

τyza = 0
τyzmax −τyzmin 2491.04−0
τyzm = 2
= 2
= 1245.52 inlb2

Due to the shortage of information, Figures 9 and 10 shall be used to approximate stress
concentration factors in Ktt (tension), Ktb (bending) and Kts (shear). Square thread is
assumed with a filet radius equal to half of the step so that these factors remain:

ktt = 3.5

ktb = 3.5

kts = 1.25

From Figure 11 is obtained the notch sensitivity for reverse bending qb= 0.7
From Figure 12 the sensitivity to the torsion notch is obtained qs = 0.9

The stress concentration factors for fatigue are then:

kf t = 3.5 assuming that q=1 for the most critical case

kf b = 1 + q (ktb − 1) = 1 + 0.7 ∗ (3.5 − 1) = 2.75

kf s = 1 + q (kts − 1) = 1 + 0.9 ∗ (1.25 − 1) = 1.23

We calculate Von Mises’ alternating and mean stresses including stress concentration
factors for fatigue:
1
σa = (kf b σxa )2 2


1
σa = (2.75 ∗ 2604.21)2 2


σa = 7161.6 inlb2
1
σm = (kf t σzm )2 + 3 (kf s τyzm )2 2


1
σm = (3.5 ∗ 290.9)2 + 3 (1.23 ∗ 1245.52)2 2


σm = 2842.11 inlb2

We determine the factors that modify the limit of fatigue resistance using the Marin
equation which is expressed as follows:

Se = ka kb kc kd ke kf Se

Surface factor, ka (cold-rolled or machined surface)

b −0.265
ka = aSut = 2.7 ∗ (75 × 103 ) = 0.86

Size factor kb

From table 9. kb = 0.879d−0.107

r = 1.05

Load factor kc

From table 10. kc = 1 (carga combinada)

Temperatura factor kd

kd = 1

Factor of reliability ke

For a reliability of 99% ke = 0.814 (table 11)

Factor of various effects

kf = 1

The fatigue resistance limit is calculated as 0.5Sut so that:

Se = 0.5 ∗ 75 × 103 = 37.5 × 103 psi

Thus, the corrected fatigue resistance limit is:

Se = 0.86 ∗ 1.05 ∗ 1 ∗ 0.814 ∗ 1 ∗ 37.5 × 103

Se = 27.6kpsi

Finally using Goodman’s criteria, we obtain the safety factor against fatigue in the
screw.
σa σm 1
Se
+ Sut
= nf

7161.6 2842.11 1
27600
+ 75000
= nf

nf = 3.4

Calculation of the torque required in the longitudinal displace-

ment motor.

Similarly, the torque to be provided by the motor to move the transversal trolley is cal-
culated. There is an additional force to the friction force and this is the force generated
by a tool placed on the table in the direction and whose magnitude is Fh = 21.7 lb

P = µ + Fh

P = µ + Fh

P = 0.17 ∗ 91 + 21.7

P = 37.17lb

Then considered a screw of the same dimensions and with the same friction factors we
have:
P dp (µπdp +L cos α)
Tu = Tsu + Tc = 2 (µπ cos α−µL)
+ µc P d2c + Jα

37.17∗0.219 (0.17∗π∗0.219+0.063∗cos 29◦ ) 0.50

Tu = 2 (0.17∗π29◦ −0.17∗0.063)
+ 0.15 ∗ 37.17 ∗ 2
+ 0.051 ∗ 39.26

Tu = 4.68lb

The torque to move the load in the opposite direction is:

 P dp (µπdp −L cos α)
Td = Tsd + Tc = 2 (µπ cos α+µL)
+ µc P d2c + Jα

37.17∗0.219 (0.17∗π∗0.219−0.063∗cos 29◦ ) 0.50

Tu = 2 (0.17∗π29◦ +0.17∗0.063)
+ 0.15 ∗ 37.17 ∗ 2
+ 0.051 ∗ 39.26

Td = 3.84lb

A VRDM366 motor is selected that has a nominal torque of 0.9 Nm =7.97 lb∗ in which
is more robust than the motor selected for the cross carriage.

Stress analysis applied on the longitudinal screw

Combined stress on the screw body

The shear force on the body τ , due to the torque Tu on the outside of the screw body,
is:
16Tu
τ= πd3r

16∗4.68
τ= π∗0.1883

τ = 3587.10 inlb2
The nominal normal axial stress σ is:

4P
σ = − πd2
r

4∗37.17
σ = − π∗0.1882

σ = −1339.02 inlb2
The bending force at the root of the σ b thread with a 0.38F supporting thread is:

σb = − πd6P
r nt p

6∗37.17
σb = − π∗0.188∗1∗0.063

σb = 5993.71 inlb2

Figure 5 shows the three-dimensional stresses to which a differential element is subjected

at the root of the screw, which are:
lb
σx = σb = 5993.71 in2
σz = −1339.02 inlb2

σy = 0 τxy = 0
 lb
τyz = 3587.10 in2
τzx = 0

Then applying distortion energy,

 12
σ = √12 (σx − σy )2 + (σy − σz )2 + (σz − σx )2 + 6 τxy
 2 2 2
+ τyz + τzx
1
σ = √12 (5993.71 − 0)2 + (0 − (−1339.02))2 + (−1339.02 − 5993.71)2 + 6 (3587.102 ) 2


σ = 9183.96 inlb2

With Sy =34x103 we have:

34×103
n= 9183.96

n = 3.7

Axial load and torsion failure in the screw core

The screw core is subjected to axial loading and torsion. The traction/compression
stress area is:
 2
At = π4 dp +d
2
r

π 0.219+0.188 2


At = 4 2

At = 0.0325in2

The compression force is then:

σc = − APt
37.17 lb
σc = − 0.0325 in2

σc = −1143.70 inlb2

The torque cutting effort is the same as previously calculated:

τ = 3587.10 inlb2

Then using distortion energy

1
σ = (σc )2 + 3 (τ )2 2


 21
+ 3 (3587.10 )2
 2
σ = (−1143.70)
σ = 6317.43 inlb2
Then the safety factor of the screw is:
34×103
n= 6317.43

n = 5.4

Shear or bending failure on screw and nut fillets.

The cutting area by scanning Ace for the rope of the screw is the area of the cylinder
of its smaller diameter dr:
As = πdr wi p
As = π ∗ 0.188 ∗ 0.77 ∗ 0.063
As = 0.0287in2
The shear force τ s for sweeping the rope is then determined with:
P
τs = As

37.17 lb
τs = 0.0287 in2

τs = 1295.12 inlb2
Then applying distortion energy, we have:
1
σ = 3 (τs )2 2 = 1.732 ∗ τs inlb2


Sy 0.577y 0.577∗34×103
n= 1.732∗τs
= τs
= 1295.12

n ≈ 15.15
Similarly, for the nut.
As = πdr wo p
As = π ∗ 0.188 ∗ 0.63 ∗ 0.063
As = 0.0234in2
P
τs = As

37.17 lb
τs = 0.0234 in2

τs = 1588.50 inlb2
Sy 0.577y 0.577∗34×103
n= 1.732∗τs
= τs
= 1588.50

n ≈ 12.35
Crushing failure on the flanks of the fillets

The σ B supporting or crushing force is, with a 0.38P supporting thread:

2∗0.38
σB = − πdp nt p

Where making nt =1
2∗0.38∗37.17
σB = − π∗0.219∗1∗0.063

σB = −651.75 inlb2
Where the safety factor, and considering Syc = Syt = 60kpsi

es:
60×103
n= 283.17

n ≈ 95.1

Buckling failure in the screw body

We calculate the area where the force, inertia and rotation radius are applied as follows:
πd2r
A= 4

π∗(0.188)2
A= 4

A = 0.0278 in2
πd4r
I= 64

π(0.188)4
I= 64

I = 6.13 × 10−5 in2

q
K = AI
q
−5
K = 6.13×10
0.0278

K = 0.046in

We calculate the ratio of slenderness and the ratio of critical slenderness:

l 20
k
= 0.046
= 425.9
  12   12
l 2π 2 CE 2π 2 ∗1.2∗30×106


k 1
= Sy
= 34×103
= 144.6
 l l


Verificamos que k
≥ k 1
→ 425.9 ≥ 144.6 → ColumnalargadeEuler

The following equation is used:

Pcr Cπ 2 E
A
< 2 = σadm
( kl )
With C=1.2 considering both embedded ends.
Pcr P 4P 4∗37.17
σ= A
= A
= πd2r
= π(0.188)2
= 1339.01 inlb2

Cπ 2 E 1.2∗π 2 ∗30×106
σadm = l 2
= (425.9)2
= 1958.9 inlb2
( )
k

The safety factor that protects against buckling is then:

1958.9
n= 1339.01

n = 1.46

Failure due to fatigue

Figure 5 shows the state of nominal stresses for points A and B. where:
lb
σx = σb = 5993.71 in2

σz = −1339.02 inlb2

τyz = 3587.10 inlb2

Alternating and mean stresses are:

σxmax −σxmin 5993.71−(−5993.71)
σxa = 2
= 2
= 5993.71 inlb2

σxm = 0

σza = 0
σzmax −σzmin −1339.02−0
σzm = 2
= 2
= −669.51 inlb2

τyza = 0
τyzmax −τyzmin 3587.10−0
τyzm = 2
= 2
= 1793.55 inlb2

Then:

ktt = 3.5

ktb = 3.5

kts = 1.25
The notch sensitivity for reverse bending qb = 0.7

The sensitivity to the torsion notch is obtained qs = 0.9

The stress concentration factors for fatigue are then:

kf t = 3.5 assuming that q=1 for the most critical case

kf b = 1 + q (ktb − 1) = 1 + 0.7 ∗ (3.5 − 1) = 2.75

kf s = 1 + q (kts − 1) = 1 + 0.9 ∗ (1.25 − 1) = 1.23

We calculate Von Mises’ alternating and mean stresses including stress concentration
factors for fatigue:
1
σa = (kf b σxa )2 2


1
σa = (2.75 ∗ 5993.71)2 2


σa = 16482.70 inlb2
1
σm = (kf t σzm )2 + 3 (kf s τyzm )2 2


1
σm = (3.5 ∗ 669.51)2 + 3 (1.23 ∗ 1793.55)2 2


σm = 4482.32 inlb2

We determine the factors that modify the limit of fatigue resistance using the Marin
equation which is expressed as follows:

Se = ka kb kc kd ke kf Se

The factors are the same as in the previous analysis. The fatigue resistance limit is
calculated as 0.5Sut so:

Se = 0.5 ∗ 75 × 103 = 37.5 × 103 psi

Thus, the corrected fatigue resistance limit is:

Se = 0.86 ∗ 1.05 ∗ 1 ∗ 0.814 ∗ 1 ∗ 37.5 × 103

Se = 27.6kpsi

Finally using Goodman’s criteria, we obtain the safety factor against fatigue in the
screw.
σa σm 1
Se
+ Sut
= nf

16482.70 4482.32 1
27600
+ 75000
= nf

nf = 1.5
Analysis for speed reduction from the motor.

As shown in Figure 1, a belt will be used for transmission from the engine to the screw
to achieve the desired speed. A belt is chosen instead of gears because they are cheaper
and the power requirement is not high.

Calculation of the available motor speed and the required speed on the screw

The speed of a step-by-step motor is calculated as follows:

n= α
360◦
· fs · 60 · min−1

Where n is in rpm, α is the step angle in degrees and fs is the frequency of the pulse
train.

From Table 20 we obtain the necessary data to calculate the rotation speed of the motor
shaft available as follows:

ω= 0.9
360◦
· 8.5 × 103 · 60 · min−1

ωdisp = 1275rpm = 133.52rad/s

To calculate the required speed, we start from the following equation that relates the
screw advance with its rotation.
θ x
2π
= L

Where is in radians, x is the linear displacement of the screw or nut corresponding to

the angular displacement and L is equal to the step for simple threads.

If we derive the above equation we have:

ω v
2π
= L

The required linear speed is 10 mm/s=0.3937 in/s. Then the angular speed required
to meet the requirement is:
v
ω = 2π · L

0.3937
ω = 2π · 0.063

ωnec = 39.26rad/s

With these results it is accepted that a speed reduction is necessary.

V-band selection to supply power from the motor.

The diameter of the engine pulley is calculated as follows:

We chose a pulley diameter at the screw inlet of 2 inches.

D = 2 in

ωt = ωnec = 39.26rad/s = 374.91rpm

ωm = ωdisp = 133.57rad/s = 1275rpm

 
d = ωωmp D = 133.57
39.26


2

d = 0.59in

The peripheral speed V of the band is given by

πDωm π×2×1275
V = 12
= 12
= 667.6f t/ min

The motor power is:

P = Tu ωm

P = 4.68lb · in · 133.52rad/s

P = 624.87 lb·in
s
≈ 0.1hp

From Table 1 for the range 1/4-10 hp, it is recommended to use a V-band of section A.
It is recommended that the distance between centers not exceed by 3 times the sum of
the diameter of the pulleys (Shigley, 2008) so that:
π(D+d) (D−d)2
Lp,aprox < 2C + 2
+ 4C

Con C = 3 (D + d)

Replacing values, we have

Lp,aprox < 19.67 in

From table 13 we choose L=26 in because it is the smallest available. Then our band
is an A26.

From table 3 we have Lc = 1.3

Lp = L + Lc = 26 + 1.3 = 27.3in

We now calculate the distance between centers


 q 2
C = 0.25 Lp − 2 (D + d) + Lp − π2 (D + d) − 2 (D − d)2
π

C = 11.59in

The angle of contact is

θd = ∅ = π − 2 sin−1 D−d


2C

θd = 3.02rad

Assuming slotted pulley f=0.5123 and calculate

exp (f ∅) = exp (0.5123 × 3.02) = 4.7

With V =667.6 ft/min we go to table 15 and interpolate to get the power tabulated,
Htab =0.47 hp

The angle of coverage in degrees is calculated

◦
180
∅ = 3.02rad πrad = 173.03◦

From Table 16 we get the contact angle correction factor, K1 but before we calculate:
D−d
C
= 0.121

Interpolating we have, K1 = 0.77

From table 17 with Lp=27.3 in we have K2 = 0.85

The permissible power is then calculated

Ha = K1 K2 Htab = 0.31hp

Assuming medium impact conditions we have a service factor with a normal torque,
then from Table 18 we have Ks =1.2

The efficiency of a V-band transmission is known to range from 70% to 96% (Shigley,
2008). Assuming an efficiency of 90% and a safety factor of 1.1 then the design power
is given by:

Hd = 0.9Hnom Ks nd = 0.12hp

The number of bands to be used is:

Hd
Nb ≥ Ha
= 0.4 → 1

The factor Kc =0.965 affecting the centrifugal force is then obtained and calculated as
follows:
V

2
Fc = Kc 1000 = 0.43lbf

Then delta F is calculated:

 H
63025 Nd
∆F = n d2
b
= 20.1lbf ; donde n = ωm

Now is possible to calculate the higher tension in the band

∆F exp(f ∅)
F1 = Fc + exp(f ∅)−1
= 25.96lbf

The lower tension is:

F2 = F1 − ∆F = 5.86lbf

And the safety factor of the band is:

Ha Nb
nf s = Hnom Ks
0.31·1
nf s = 0.1·1.2

nf s = 2.6

It should be noted that this result was obtained by resizing the conditions from the
beginning because the nominal power was almost three times lower than the lowest
permissible power of the tabulated data.

Bearing analysis, selection and lubrication.

There are several aspects to consider when selecting bearings. For this design we will
only consider the aspects of space availability to locate the bearings, the loads applied
and the type of lubrication.

For this section it is necessary to calculate the forces acting on the bearings. Figure
7 shows the diagram of the screw-free body by which the RA and RB reactions are
calculated as follows:
P
MA = 0

20 · Fp − 21.5 · RBz = 0

20 · (F1 + F2 ) − 21.5 · RBz = 0

20 · (25.96 + 5.86) − 21.5 · RBz = 0

RBz = 29.6 lb → Carga radial en B

P
Fz = 0

RAz + RBz − Fp = 0

RAz + 29.6 − (25.96 + 5.86) = 0

RAz = 2.22lb
P
Fy = 0

µ + Fh + RBy = 0

0.17 ∗ 91 + 21.7 − RBy = 0

RBy = 37.17lb → Carga axial en B

As can be seen from the results, the selection of bearings is based on those closest to
the pulleys. Calculations will be made on the basis of the most demanding bearing and
thus the remaining bearings can be selected based on the same or lower requirement
but which meet the other restrictions already mentioned.

A reliability factor equal to or greater than 0.95 is desired for the entire set √
of 4 bearings.
Assuming that bearings are equal then the individual reliability of each is 4 0.95 ≈ 0.99
. A life of 20kh is also desired

The dimensionless bearing design life is:

L 60LD nD
xD = L10
= 60LR nR

Where 60LR nR = 106 because the catalogues of the company SFK will be used. LD is
the desired life in hours and nD is the desired speed in rpm.
L 60·20000·374.91
xD = L10
= 106
= 449.89

As a first approximation, the initial annotation of table 19 is taken. We also assume F a /(V F r ) > e.

X2 = 0.56

Y2 = 2.30
Then with V = 1 we use the following equation:
Fe Y Fa 2.30 37.17
V Fr
=X+ V Fr
= 0.56 + 1 29.6
= 3.45

Fe = 3.45V Fr = 3.45 (1) 29.6 = 102.1lb = 0.454kN

The Weibull parameters are: x0 = 0.02, (– x0) = 4.439 y b = 1.483

An application factor of af =1.1 and a=3 (ball bearing) is considered appropriate then the following
equation remains:
  a1
xD
C10 = af FD 1
x0 +(θ−x0 )(1−RD ) b
  13
449.89
C10 = 1.1 · 0.454 1
0.02+4.439(1−0.99) 1.483

C10 = 6.35kN
Angular contact bearings shall be selected because the effect of the axial load needs to be supported.
Table 22 shows a section of one of the sheets in the SFK catalogue. With the entry of C10 we notice
that the minimum value is C10 =7.02 kN and C0 =3.35 kN with a diameter of less than 10 mm = 0.39
in which is greater than the diameter of the screw. This consideration must be taken into account
during the machining of the screw.

Then we calculate the following by converting the axial force to kN.

Fa 37.17(4.45)10−3
C0
= 3.35
= 0.0494

What according to table 19 and performing an interpolation of the data gives us a value of e=0.25.
Now Fa/[V Fr] =37.17/29.6=1.26, that is greater than 0.25. Again, in table 19 we find the value of
Y2 by interpolation which gives us Y2 =1.776.

With this data we recalculate the following:

Fe Y Fa 1.776
V Fr
=X+ V Fr
= 0.56 + 1
1.26 = 2.80

Fe = 3.45V Fr = 2.80 (1) 29.6 = 82.88lb = 0.37kN

0.37
C10 = 0.454
6.35 = 5.18kN

With this value we go back to table 22 from which we are again in the same row for
the selection of the bearing so the selection is successful.

The code for bearing selection is 7200 BECBP.

As for lubrication, since the operation is at low speeds, a low-viscose lubricant is re-
quired. Table 22 of SFK recommends the GWF lubricant whose type of base oil is
synthetic SHC/ether.
Free body diagrams and diagrams, tables, data figures, catalogues
and plans
Free body diagrams and diagrams

Fig. 1 Diagram of the XY table.

Fig. 2 Longitudinal screw and the loads applied on it.

Fig. 3 Transversal screw and applied loads on it.

 Fig. 4 Load diagram on the screw

Fig. 5 State of stress in the screw body.

 Fig. 6 Buckling consideration with screw-centric load

Fig. 7 Free body diagram to determine reactions in bearings

 Tables

Table 3 Friction coefficients f of threaded pairs

Table 4 Coefficients of friction on thrust collar

Table 5 Main dimensions of standard ACME strings.

Table 6 Area gauges for sweeping shear areas on ropes

 Table 7 Euler columns end condition constants

Table 8 Marin Surface Condition Factor Parameters

Table 9 Parameters of the size factor

 Table 10 Parameters of the load factor.

Table 11 Parameters of the reliability factor

Table 12 Band selection according to input power requirement

Table 13 Standard V-band inner circumferences

Table 14 Dimensions of length conversion.

Table 15 Standard V-band rated powers
Table 16 Contact angle correction factor K1 for flat band transmissions VV∗ and V
 Table 17 Belt length correction factor K2 ∗

Table 18 Suggested KS service factors for V-band transmissions

Table 19 Equivalent radial load factors for ball bearings

 Catalogs

Table 20 Berger Lahr Step-by-Step Motors Catalog Sheet | Schneider Electric.

Table 21 Dipac catalogue of steel shafts AISI 1018 and dimensions available
Table 22 SFK’s catalogue section for the selection of angular contact ball bearings.

Figures of data
Fig. 8 Curves to find the value of the stress concentration factor in tension and bending.

Curves to find the value of the stress concentration factor in torsion.

Fig. 10 Curves to find the value of the bending notch sensitivity.

Fig. 11 Curves to find the value of notch sensitivity in torsion.

 Fig. 12 Bearing assembly scheme used in the design

Fig. 13 Lubricants recommended by SFK for angular contact ball bearings.

PLANOS