DESIGN OF THE CANTILEVER

SUPPORT FOR THE SPINDLE AND THE

PULLEY & BELT DRIVE SYSTEM OF
THE VERTICAL BALANCING
MACHINE
 Project Report (Mechanical Vibration): Complex Engineering Problem

Contents

Contents ................................................................................................................................. 2
1. Introduction ........................................................................................................................ 3
2. Methodology ...................................................................................................................... 4
2.1 Pulley Design ............................................................................................................... 4
2.2 Cantilever Beam Design For System Frequency Requirements .................................. 7
2.3 Cantilever Beam Design For Static Loading: ............................................................ 10
2.4 Cantilever Beam Design For Dynamic Loading:....................................................... 11
3. Design Summary.............................................................................................................. 15
References ............................................................................................................................ 16

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 Project Report (Mechanical Vibration): Complex Engineering Problem

1. Introduction
A vertical balancing machine is at the design stage such that the support for the spindle is in
the shape of cantilever beam which provide structural support to beam as shown in Figure 1:

Parameter Values

The spindle speed 800-1200 rpm

Motor rotational 1400 rpm

speed

Spindle Mass 7 kg

Disk Mass 5 kg

Unbalance mass on 0.5 mg-2 mg

the disk

Diameter of the disk 12 inches

Figure 1: Vertical balancing machine with Table 1: Operating parameters and specification of
cantilever beam support vertical balancing machine

The design of the cantilever support for the spindle and the pulley & belt drive system of the
vertical balancing machine is carried out based on the operating parameters and specifications
of vertical balancing machine (refer to Table 1) to achieve the following design objectives:

• Design the of the pulley and belt drive for the spindle operation
• Design the cantilever support such that the natural frequency of the system lies outside
the range of operating speed of the spindle.
• Design the cantilever support considering the fatigue failure for endurance strength.

In this regard, the section 1.2 outlines the design calculation for meeting the above-mentioned
design objectives. The design calculations are initiated with the design of the pulley and belt
drive system based on the motor and spindle operating parameters. This is followed by the
design of the cross section of the cantilever beam to meet the natural frequency requirement of
the system. The design of the cantilever beam is then finalized based on its stress analysis for
the static and dynamic loading. Finally, the final design summary is outlined in Section 1.3.

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 Project Report (Mechanical Vibration): Complex Engineering Problem

2. Methodology
The design calculation are aimed to meet design objectives in section 1 and are outlined in the
subsections 2.1-2.4.

2.1 Pulley Design

2.1.1 Assumptions:

The pulley design calculations are done based on the following assumptions:

• Based on the operating parameter of 1400 rpm speed of the motor, the electric motor used
in the pulley design calculation is 3.7kw single phase electric motor – 240 volt 5hp
1400rpm – high torque capacitor start/run motor [1] which is readily available in the
market.
• Critical operating scenarios are considered for the design of the pulley and belt drive
system of the vertical balancing machine to ensure that the system operation does not fail
under these extreme circumstances:
𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑑𝑟𝑖𝑣𝑖𝑛𝑔 𝑝𝑢𝑙𝑙𝑒𝑦 = 𝑁1 = 1400 𝑅𝑃𝑀

𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦 = 𝑁2 = 1200 𝑅𝑃𝑀

• The diameter of the driven pulley is taken as the standard pulley diameter as per its
availability in the market [reference]
𝐷1 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑑𝑟𝑖𝑣𝑖𝑛𝑔 𝑝𝑢𝑙𝑙𝑒𝑦 = 0.259 𝑚
• The material of both the small and large pulley is chosen as stainless steel due to its
modern usage [2] in pulley design owing to its high strength and durability
2.1.2 Design Calculations

The calculations for the design of pulley and belt drive system are carried as follows out based
on the assumptions mentioned in section 2.1.1 and the findings in [3]:

Diameter of Driven Pulley:

The diameter of the driven pulley (𝐷2 ) is calculated from the pulley ratio:

𝑁1 1400
𝑃𝑢𝑙𝑙𝑒𝑦 𝑟𝑎𝑡𝑖𝑜 = = = 1.1667
𝑁2 1200

Since,

𝐷2 𝑁1
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑟𝑎𝑡𝑖𝑜 = 𝑃𝑢𝑙𝑙𝑒𝑦 𝑟𝑎𝑡𝑖𝑜 = =
𝐷1 𝑁2

For 𝐷1 = Diameter of driving pulley = 0.259 m:

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 Project Report (Mechanical Vibration): Complex Engineering Problem

∴ 𝐷2 = 1.1667 × 𝐷1 = 1.1667 × 0.259 = 0.302 𝑚

Velocity of belt:

The velocity (𝑉) of the belt is then calculated as:

𝑁1
∴ 𝑉 = 𝜋 × 𝐷1 × = 18.98 𝑚/𝑠
60
Design Power:

The design power (𝑃) of the pulley and belt-drive system is calculated based on the rated power
of electric motor:

𝑅𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟(𝑘𝑊) × 𝐿𝑜𝑎𝑑 𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟

𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑜𝑤𝑒𝑟 =
𝐴𝑟𝑐 𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝐹𝑎𝑐𝑡𝑜𝑟 × 𝑆𝑚𝑎𝑙𝑙𝑒𝑟 𝑝𝑢𝑙𝑙𝑒𝑦 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟

Where,

𝑅𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 = 𝑖𝑛𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟 = 5𝐻𝑃 = 5.59275 𝑘𝑊

For normal loading,

𝐿𝑜𝑎𝑑 𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 = 1

For C = center to center distance between pulleys = 0.8m,

𝐷2 − 𝐷1 0.302 − 0.259
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 = 180 − × 60 = 180 − × 60 = 176.775
𝐶 0.8
For smaller pulley diameter, 𝐷1 = 0.259 𝑚,

𝑆𝑚𝑎𝑙𝑙𝑒𝑟 𝑝𝑢𝑙𝑙𝑒𝑦 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 = 0.7

5.59275 × 1
∴ 𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑜𝑤𝑒𝑟, 𝑃 = = 7.9896𝑘𝑊
1 × 0.7
Number of Piles:

For 𝐷1 = 0.259 and V = 18.98m/s,

∴ 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑖𝑙𝑒𝑠 = 5

Belt Selection:

𝐹𝑜𝑟 𝑉 > 16𝑚/𝑠 𝑎𝑛𝑑 𝑃 < 20𝑘𝑊,

∴ 𝑆𝑒𝑙𝑒𝑐𝑡𝑒𝑑 𝐵𝑒𝑙𝑡 𝑖𝑠 𝐷𝑢𝑛𝑙𝑜𝑝 𝐻𝑖 − 𝑠𝑝𝑒𝑒𝑑 878𝑔 𝐷𝑢𝑐𝑡 𝑏𝑒𝑙𝑡

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 Project Report (Mechanical Vibration): Complex Engineering Problem

Load Rating:

Using linear interpolation to calculate the load rating (𝐿𝑅) at the belt velocity of 18.98 m/s
from:

At V = 10m/s, LR = 0.0203 ,

18.98
∴ 𝐿𝑅 @ 18.98 𝑚/𝑠 = 0.0203 × = 0.04365
10
Belt Width:

The belt width (𝑏) is calculated for the pulley and belt drive system based on the load rating
and number of piles:

𝑝𝑜𝑤𝑒𝑟 7.989
∴ 𝑏(𝑚𝑚) = 𝑑𝑒𝑠𝑖𝑔𝑛 = = 36.64 𝑚𝑚 = 0.0366𝑚
𝑛𝑜 𝑜𝑓 𝑝𝑖𝑙𝑒𝑠 × 𝐿𝑜𝑎𝑑 𝑅𝑎𝑡𝑖𝑛𝑔 5 × 0.0436

However, b is taken as 0.076 mm because the standard belt width available is 0.076 m.

Pulley Width:

For belt width of up to 125mm and belt fitting tolerance of 13mm, the pulley width (𝑤) is
calculated as:

∴ 𝑤 = 𝑏 + 𝑏𝑒𝑙𝑡 𝑓𝑖𝑡𝑡𝑖𝑛𝑔 𝑡𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 = 0.076 + 0.013 = 0.089𝑚

Belt length:

Finally, the belt length (𝐿) is calculated based on the center to center distance between small
and large pulleys as well as the pulley diameters:

𝜋 (𝐷2 − 𝐷1 )2
∴ 𝐿 = 2𝐶 + (𝐷1 + 𝐷2 ) + × 𝑐 = 2.48𝑚
2 4
Mass of Pulleys

For the stainless-steel material,

𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑆𝑡𝑎𝑖𝑛𝑙𝑒𝑠𝑠 𝑆𝑡𝑒𝑒𝑙, 𝜌 = 7800
𝑚3

𝐷1 2
∴ 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑑𝑟𝑖𝑣𝑖𝑛𝑔 𝑝𝑢𝑙𝑙𝑒𝑦 = 𝑉1 = 𝜋 × × 𝑤 = 4.68 × 10−3
4

𝐷2 2
∴ 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦 = 𝑉2 = 𝜋 × 𝑤 = 6.37 ∗ 10−3
4
∴ 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑑𝑟𝑖𝑣𝑖𝑛𝑔 𝑝𝑢𝑙𝑙𝑒𝑦 = 𝜌 × 𝑉1 = 36 𝑘𝑔

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∴ 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦 = 𝜌 × 𝑉2 = 49 𝑘𝑔

Mass of Pulleys

The total mass of large pulley and spindle is then given as:

∴ 𝑇𝑜𝑡𝑎𝑙 𝑀𝑎𝑠𝑠 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑙𝑎𝑟𝑔𝑒 𝑝𝑢𝑙𝑙𝑒𝑦 + 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 = 7 𝑘𝑔 + 49 𝑘𝑔 = 58 𝑘𝑔

2.2 Cantilever Beam Design For System Frequency Requirements

2.2.1 Assumptions:

• The cantilever beam is a straight beam of rectangular cross section area that remains
constant throughout its length. The significant properties of the beam are assumed to be the
flexural stiffness (𝐸) and mass per unit length (𝑚 ̅ = 𝜌𝐴) that remain constant throughout
its length. These assumptions are taken to keep the design calculations straightforward
without running into unnecessary geometrical and material complexities.
• The spindle and large pulley are both modelled as an additional rigid mass (m1) attached
by fixed connection at the free end of the cantilever beam (refer to Figure 2 & Figure 3) for
the accurate development of the mathematical model of the system transverse vibration
response 𝑦(𝑥, 𝑡) which is a function of the position and time
• The cantilever beam is made of steel for initial analysis and, therefore, is subject to change
based on the result of the design calculations.

Figure 2: Diagram for force equilibrium analysis cantilever beam with additional attached mass (spindle and large pulley)

7 3: Diagram for force equilibrium analysis at the free end for additional attached mass (spindle and large
Figure
pulley)
 Project Report (Mechanical Vibration): Complex Engineering Problem

2.2.2 Design Calculations

Based on the above assumptions, the force equilibrium analysis of all the forces on the
differential element of the beam is carried out based on the findings in [4]:

The free vibration equation of motion for the system shown in Figure 2 is:

𝜕 4 𝑦(𝑥, 𝑡) 𝜕 4 𝑦(𝑥, 𝑡)
𝐸𝐼 + 𝑚
̅ =0
𝜕𝑥 4 𝜕𝑡 4
The method of separation of variables is used to obtain the following form of the solution of
the above equation thus indicating that the free-vibration of the cantilever beam has a specific
shape 𝜙(𝑥) along with a time dependent amplitude 𝑌(𝑡):

𝑦(𝑥, 𝑡) = 𝜙(𝑥)𝑌(𝑡)

Where,

𝑌̈(𝑡) + 𝜔2 𝑌(𝑡) = 0

𝜙 ′′′′ (𝑥) − 𝛽 4 𝜙(𝑥) = 0

in which,

𝜔 = 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦

𝛽 4 = 𝜔2 𝑚
̅ /𝐸𝐼

The solution of this fourth-order PDE requires four boundary conditions:

➔ Since the cantilever beam is fixed at one end so its two known boundary conditions are:

𝜙(𝑥) = 0
𝜙 ′ (𝑥) = 0

➔ The equilibrium analysis of the force and moment produced by the additional mass m1 with
a rotary mass moment of inertia (J1) attached to the free end of the cantilever beam results
in two more boundary condition:

𝑀(𝐿) = 𝐸𝐼𝜙 ′′ (𝐿) = −𝜔2 𝜙 ′ (𝐿)𝐽1

𝑉(𝐿) = 𝐸𝐼𝜙 ′′′ (𝐿) = −𝜔2 𝜙(𝐿)𝑚1

Using the four boundary conditions, the algebraic manipulation of the equations results in the
formulation of the following matrix:
𝜔2 𝐽1 𝜔2 𝐽1
𝛽2 (𝑐𝑜𝑠 𝛽𝐿 + 𝑐𝑜𝑠ℎ 𝛽𝐿) + 𝛽(𝑠𝑖𝑛 𝛽𝐿 + 𝑠𝑖𝑛ℎ 𝛽𝐿) 𝛽2 (𝑠𝑖𝑛 𝛽𝐿 − 𝑠𝑖𝑛ℎ 𝛽𝐿) − 𝛽(𝑐𝑜𝑠 𝛽𝐿 − 𝑐𝑜𝑠ℎ 𝛽𝐿) 𝐴
𝐸𝐼 𝐸𝐼 0
{ 1} = { }
𝜔 2
𝑚1 𝜔 2
𝑚1 𝐴1 0
3 3
[ 𝛽 (𝑠𝑖𝑛 𝛽𝐿 − 𝑠𝑖𝑛ℎ 𝛽𝐿) + 𝐸𝐼 (𝑐𝑜𝑠 𝛽𝐿 − 𝑐𝑜𝑠ℎ 𝛽𝐿) −𝛽 (𝑐𝑜𝑠 𝛽𝐿 + 𝑐𝑜𝑠ℎ 𝛽𝐿) + 𝐸𝐼 (𝑠𝑖𝑛 𝛽𝐿 − 𝑠𝑖𝑛ℎ 𝛽𝐿)]

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The determinant of the square matrix is equated to zero to formulate the frequency equation
which in turn is solved by numerical methods to obtain the first three non-dimensionalized
natural frequencies (𝜔𝑛∗ ) of the system as mentioned in Table 2:

Frequency Number 𝝎𝒏∗

1 1.557298

2 16.25009

3 50.89584
Table 2: First three non-dimensionalized natural frequencies of the system

Finally, the natural frequency of the system in Figure 2 is given as:

1/2
̅ 𝐿4
𝑚
𝜔𝑛 = (𝜔𝑛∗ )2 ( )
𝐸𝐼

Since, the natural frequency (𝜔𝑛 ) of the system increases with n, hence for the system natural
frequency to remain above the operating range of the spindle speed:

𝜔1 > 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑 = 1200 𝑟𝑝𝑚

2𝜋
∴ 𝜔1 > 1200 × 𝑟𝑎𝑑/𝑠
60
where, the first natural frequency of the system is:
1/2 1/2
̅ 𝐿4
𝑚 𝑚̅ 𝐿4
𝜔1 = (𝜔1∗ )2 ( ) = (1.557298) ( 2
)
𝐸𝐼 𝐸𝐼

Therefore, for the material of the beam chosen as steel:

𝑁 𝑘𝑔
𝐸 = 2.07 × 1011 , 𝜌 = 7880 ,
𝑚2 𝑚3
Taking the thickness of the mount plate as ℎ = 0.40 𝑚 (approximately):

𝐿 = 𝐶 − 𝐷𝑠𝑚𝑎𝑙𝑙 𝑝𝑢𝑙𝑙𝑒𝑦 − ℎ = 0.8 − 0.259 − 0.040 ≈ 0.5 𝑚

1/2
7880 × 𝐴 × 0.54
2
∴ 𝜔1 = (1.557298) ( )
2.07 × 1011 × 𝐼

Setting,
1/2
7880 × 𝐴 × 0.54
2
2𝜋
(1.557298) ( ) > 1200 × 𝑟𝑎𝑑/𝑠
2.07 × 1011 × 𝐼 60

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 Project Report (Mechanical Vibration): Complex Engineering Problem

𝐼
> 8.86 × 10−13 𝑚4 (1)
𝐴
For the rectangular cross-section of the beam, in Figure 4:

1 𝐼 ℎ2
𝐴 = 𝑏ℎ, 𝐼= 𝑏ℎ3 , = , ℎ>𝑏
12 𝐴 12
For the rectangular cross-section to satisfy the inequality (1):

Let,

𝐼
= 2.5 × 10−3 𝑚4
𝐴
𝐼 ℎ2
Therefore, from 𝐴 = 12,

𝐼
ℎ2 = × 12 = 2.5 × 10−3 × 12
𝐴
∴ ℎ = 0.173 𝑚

Taking 𝑏 = 0.05 𝑚 (b can have any value unless b < h),

∴ 𝐴 = 𝑏ℎ = 0.05 × 0.173 = 8.65 × 10−3 𝑚2

Figure 4: Rectangular cross-
1 section of the beam
∴𝐼= × (0.05) × (0.173)3 = 2.157 × 10−5 𝑚4
12
Therefore, the rectangular cross-section of the beam has the following dimensions based on the
above design calculations:

𝐿 = 0.5 𝑚

𝑏 = 0.05 𝑚, ℎ = 0.173 𝑚

2.3 Cantilever Beam Design For Static Loading:

2.3.1 Assumptions

• The cantilever beam is a straight beam of rectangular cross section area that remains
constant throughout its length. The significant properties of the beam are assumed to be the
flexural stiffness (𝐸) and mass per unit length (𝑚 ̅ = 𝜌𝐴) that remain constant throughout
its length. These assumptions are taken to keep the design calculations straightforward
without running into unnecessary geometrical and material complexities.
• The spindle and large pulley are both modelled as an additional rigid mass (m1) attached
by fixed connection at the free end of the cantilever beam (refer to Figure 2 & Figure 3) for
the accurate development of the mathematical model for the stress analysis.

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 Project Report (Mechanical Vibration): Complex Engineering Problem

• The cantilever beam is made of steel for initial analysis and, therefore, is subject to change
based on the result of the design calculations.
2.3.2 Design Calculations:

The maximum stress in the beam due to lead additional rigid mass (m1) is given as (Figure 5):

𝐹𝐿(ℎ/2)
𝜎𝑚𝑎𝑥 =
𝐼

Figure 5: Rectangular cross-

section of the beam

Where,

𝑃 = (𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑀𝑎𝑠𝑠 + 𝐿𝑎𝑟𝑔𝑒 𝑃𝑢𝑙𝑙𝑒𝑦 𝑀𝑎𝑠𝑠 + 𝐷𝑖𝑠𝑘 𝑀𝑎𝑠𝑠)𝑔 = (7 + 49 + 5) × 9.81 = 588.41 𝑁

𝐿 = 0.5 𝑚

ℎ = 0.173 𝑚

𝐼 = 2.157 × 10−5 𝑚4

598.41 × 0.5 × (0.173/2)

∴ 𝜎𝑚𝑎𝑥 = = 1.2 𝑀𝑃𝑎
2.157 × 10−5
Since, the yield stress for the steel beam is 𝜎𝑦 = 243 𝑀𝑃𝑎,

𝑆𝑦 243 𝑀𝑃𝑎
∴ 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = = ≈ 203
𝜎𝑚𝑎𝑥 1.2 𝑀𝑃𝑎

As the factor of safety is very high, so this verifies that the material and geometric dimensions
of the beam will allow it to withstand the static loading without failure.

2.4 Cantilever Beam Design For Dynamic Loading:

2.4.1 Assumptions

In order to ensure that the beam has endurance for maximum fatigue loading:

• Following operating scenarios are considered for critical loading:

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𝑈𝑛𝑏𝑎𝑙𝑎𝑛𝑐𝑒 𝑚𝑎𝑠𝑠, 𝑚 = 2 𝑚𝑔, 𝑟 = 𝑑𝑖𝑠𝑘 𝑟𝑎𝑑𝑖𝑢𝑠 = = 6 𝑖𝑛 = 0.1524 𝑚,
2
𝜔 = 1200 𝑟𝑝𝑚 = 125.66 𝑟𝑎𝑑/𝑠

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• The maximum unbalance force (causing harmonic excitation of the spindle system) acts on
the tip of the cantilever beam and the effect of the beam’s weight during dynamic loading
of the cantilever beam is appreciable.
• The cantilever beam is made of steel for initial analysis and, therefore, is subject to change
based on the result of the design calculations.
2.4.2 Design Calculations:

The spindle system for mathematical modelling is illustrated in the Figure 6:

Figure 6: Horizontal view of the spindle system

Where,

𝑀 = 𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 𝑖𝑛𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝑢𝑛𝑏𝑎𝑙𝑎𝑛𝑐𝑒𝑑 𝑚𝑎𝑠𝑠

𝑚 = 𝑢𝑛𝑏𝑎𝑙𝑎𝑛𝑐𝑒𝑑 𝑚𝑎𝑠𝑠

𝑟 = 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑡ℎ𝑒 𝐶. 𝐺 𝑜𝑓 𝑚 𝑓𝑟𝑜𝑚 𝑎𝑥𝑖𝑠 𝑜𝑓 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛

𝜔 = 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑡ℎ𝑒 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑦𝑠𝑡𝑒𝑚

The centrifugal force generated by unbalanced mass is expressed as

𝐹 = 𝑟𝑚𝜔2

The component perpendicular to axis of rotation (refer to Figure 1) of centrifugal force is

𝐹𝑥 = 𝐹𝑠𝑖𝑛(𝜔𝑡) = 𝑟𝑚𝜔2 𝑠𝑖𝑛(𝜔𝑡)

Based on D’Alembert’s principle of rotor kinematics, the linear differential equation of motion
of spindle for damping constant (c) and spring stiffness constant (k):

𝑀𝑥̈ + 𝑐𝑥̇ + 𝑘𝑥 = 𝐹𝑥

Hence, the spindle system is basically a second order linear time-invariant system with
harmonic forcing function that generates the greatest dynamic load as:

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 Project Report (Mechanical Vibration): Complex Engineering Problem

𝐹𝑥,𝑚𝑎𝑥 = 𝑟𝑚𝜔2 = (0.1524 𝑚)(2 × 10−3 𝑘𝑔)(125.66 𝑟𝑎𝑑/𝑠) = 4.81 𝑁

This means that the cantilever beam is loaded by a dynamic force (𝐹𝑥 ) at its tip such that the
magnitude of the force (𝐹𝑥 ) changes harmonically between −4.81 𝑁 and 4.81 𝑁:

For a steel beam,

𝑘𝑔
𝑑𝑒𝑛𝑠𝑖𝑡𝑦(𝜌) = 7880 , 𝑌𝑖𝑒𝑙𝑑 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ(𝑆𝑦 ) = 243 𝑀𝑃𝑎,
𝑚3
𝑈𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑇𝑒𝑛𝑠𝑖𝑙𝑟 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ(𝑆𝑢𝑡 ) = 310 𝑀𝑃𝑎,
𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐸𝑛𝑑𝑢𝑟𝑎𝑛𝑐𝑒 𝐿𝑖𝑚𝑖𝑡(𝑆𝑒 ) = 94 𝑀𝑃𝑎

The most critical point for fatigue failure (refer to Figure 6) is at the fixed end of the beam
because the bending moment & stress concentration factor is high at fixed end:

For this current dynamic loading scenario, the cyclic stress due to dynamic loading, mean stress
(𝜎𝑚 ) and stress amplitude (𝜎𝑎 ) of the cyclic stress cycle is given in Figure 7:

Figure 7: Fully reversed cyclic stress on the cantilever beam

Maximum Moments (𝑀𝑏±,𝑚𝑎𝑥 ) by Fx at tip of the beam are:

𝑀𝑏+,𝑚𝑎𝑥 = 4.81 × 0.50 = 2.405 𝑁𝑚

𝑀𝑏−,𝑚𝑎𝑥 = −4.81 × 0.50 = −2.405 𝑁𝑚

Therefore,

1 1
𝑀𝑏,𝑚 = (𝑀𝑏+,𝑚𝑎𝑥 + 𝑀𝑏−,𝑚𝑎𝑥 ) = (2.405 + (−2.405)) = 0 𝑁𝑚
2 2
1 1
𝑀𝑏,𝑎 = (𝑀𝑏+,𝑚𝑎𝑥 − 𝑀𝑏−,𝑚𝑎𝑥 ) = (2.405 − (−2.405)) = 2.405 𝑁𝑚
2 2
Hence, mean cyclic stress (𝜎𝑚 ) and stress amplitude (𝜎𝑎 ) are given as:

6𝑀𝑏,𝑚 6 × 0
𝜎𝑚 = = = 0 𝑀𝑃𝑎
𝑏ℎ2 𝑏ℎ2

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 Project Report (Mechanical Vibration): Complex Engineering Problem

6𝑀𝑏,𝑎 6 × 2.405
𝜎𝑎 = 2
= = 9.64 × 103 𝑀𝑃𝑎
𝑏ℎ (0.05) × (0.173)2

Using Goodman’s fatigue theory [ref machine design], the factor of safety (𝑓𝑠 ) is calculated as:

𝜎𝑚 𝜎𝑎 1 0 9.64 × 103 𝑀𝑃𝑎 1

+ = ⇒ + =
𝑆𝑢𝑡 𝑆𝑒 𝑓𝑠 310 𝑀𝑝𝑎 94 𝑀𝑃𝑎 𝑓𝑠

∴ 𝑓𝑠 = 9751

Hence, the high factor of safety (𝑓𝑠 = 9751) establishes the viability of the material and
geometrical properties of the cantilever beam.

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 Project Report (Mechanical Vibration): Complex Engineering Problem

3. Design Summary
The finalized design of the pulley belt-drive system and the cantilever beam is summarized in
Table 3 and Table 4, respectively:

Parameter Value/Quality
Pulley Design
Material for small & large pulley Stainless Steel
Diameter of driving (small) pulley 0.259 m
Diameter of driven (large) pulley 0.302 m
Pulley Width (driving and driven) 0.089 m
Mass of driving (small) pulley 36 kg
Mass of driven (large) pulley 49 kg
Center to Center distance between pulleys 0.8 m
Belt Design
Belt Type Dunlop Hi – speed 878g Duct belt
Belt Width 0.076 m
Belt Length 2.48 m
Table 3: Design summary of pulley and belt-drive system

Figure 5: Rectangular cross-

section of the beam

Parameter Value/Quality
material Steel
Length of the beam (𝐿) 0.5 𝑚
Area of cross-section (𝑏 × ℎ) 0.05 𝑚 × 0.173 𝑚
Table 4: Design summary of cantilever beam (refer to Figure 5)

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4. References
[1] G. 2018 Electrotech Drives - Electric Motors, Switchgear - Dungannon, Belfast,
Cookstown, Armagh. (2019). 3.7KW SINGLE PHASE ELECTRIC MOTOR – 240
VOLT 5HP 1400RPM – HIGH TORQUE CAPACITOR START/RUN.
[2] R. J. Fadler, L. A. Ahaus, and J. K. Leicht, "Two piece stamped steel pulley," ed:
Google Patents, 2009.
[3] S. Sankararaj. (2013). How to Design a Flat Belt Drive [Step-by-step Tutorial].
[4] B. Wang, Z. Wang, and X. Zuo, "Frequency Equation of Flexural Vibrating
Cantilever Beam Considering the Rotary Inertial Moment of an Attached Mass %J
Mathematical Problems in Engineering," vol. 2017, p. 5, 2017, Art. no. 1568019.

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