VIETNAM NATIONAL UNIVERSITY – HCM CITY

HO CHI MINH UNIVERSITY OF TECHNOLY



PROJECTS
SUBJECT: MACHINE ELEMENTS

INSTRUCTOR: PH. D PHAN ĐÌNH HUẤN

STUDENT: ĐỖ MINH HUY

ID student : 1952715
CLASS: CCO1
HCM UNIVERSITY OF TECHNOLOGY
FACULTY OF MECHANICAL ENGINEERING
DEPARTMENT OF MACHINE DESIGN

MACHINE ELEMENT PROJECT TOPIC 2

DESIGNING A MECHANICAL TRANSMISSION SYSTEM
FOR A BELT CONVEYOR

Load Diagram
Mechanical system
1- Electric motor; 2- Coupling; 3- Gearbox; 4- Rolling chain drive; 5-
Belt conveyor. Rotational direction is shown in above scheme.
Design Parameters
Tangential force, F (N): 6000
Belt velocity, v (m/s): 2,25
Pulley diameter, D (mm): 300
Service life, L (year): 4
One-directional rotation, two shifts, low level load.
(300 days of working per year, 8 hours per shift)
Load mode: t1= 15 ; t2= 48; T1= T; T2= 0,6T

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Error of speed ratio ≤ ±5%

REQUIREMENTS
Chapter 1: Selecting electric motor and speed ratio distribution
Chapter 2: Designing rolling chain drive
Chapter 3: Designing helical gear transmission
Chapter 4: Designing shafts
Chapter 5: Designing bearings

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Chapter 1: Selecting electric motor and speed ratio distribution
1.1 General efficiency of transmission system
We determine the efficiency of the components in the system according to Table 3.3:
The efficiency of coupling: 𝜂𝑐𝑜𝑢𝑝𝑙𝑖𝑛𝑔 = 0.98
The efficiency of chain drives: 𝜂𝑐ℎ𝑎𝑖𝑛 drive = 0.93
The efficiency of spur gear: 𝜂𝑔𝑒𝑎𝑟 = 0.97
The efficiency of rolling-contact bearings: 𝜂𝑟𝑜𝑙𝑙𝑖𝑛𝑔-contact bearnings = 0.99
The general efficiency of transmission system:

𝜂𝑔𝑒𝑛𝑒𝑟𝑎𝑙 = 𝜂spur gear × 𝜂𝑐ℎ𝑎𝑖𝑛 drive × 𝜂𝑐𝑜𝑢𝑝𝑙𝑖𝑛𝑔 × = 0.97 x 0.93 x 0.98 x 0.993 =
0.8578

1.2 Required power of motor

Working power of a load chain:

Required power of motor:

=>

1.3 Determine the number of preliminary revolutions

The number of impeller revolutions is:

Select transmission ratio ( based on Table 3.2 page 88/ Cơ sở thiết kế máy-
Nguyễn Hữu Lộc)
Gear box ugear box= 3,5
Chain drives uchain drives=2
Coupling ucouling=1
General transmission ratio

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Preliminary revolutions of the engine:

Based on table P1.3/page 237 ‘ Tính toán Thiết Kế Hệ Thống Dẫn Động Cơ
Khí Tập Một’ của ‘Trịnh Chất- Lê Văn Uyển’, we select motor 4A160S4Y3
with P=15,0 kW and a rotational speed of 1460 rpm
1.4 Transmission ratio distribution
Determine the transmission ratio of system

Select the transmission ratio of gear box: ugear box =3,5

Select the transmission ratio of coupling: ucoupling=1

Transmission ratio:
1.5 Parameters of transmission system
Power P on shafts:
Pmotor=11,2653 kW

Rotation speed on shafts:

Torque on shafts

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We have the following table of parameters of the transmission system:

Parameters Shafts

Motor 1 2 3

Power, P, kW 12,8742 12,8742 12.2356 11.2653

Rotational ratio, 1 3,5 2,8968

u

Rotational speed, 1460 1460 417,1439 144,0013

n, rpm

Torque, T, Nm 84211,376 84211,3767 280119,7863 747101,6928

7

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Chapter 2: Designing rolling chain drive
1. Select roller chain
Power on chain drive, P, kW 12,2356

Rotational speed of drive chain, n1, 144,0013

rpm

Transmission ratio, u 2.8968

Torque on drive sprocket, T, Nmm 280119,7863

2. The number of teeth of the driving sprocket:

3. The number of teeth of the driven sprocket:

Recalculate transmission ratio

4. Calculation coefficient
Dynamic load correction factor: Kr = 1,3
Chain length correction factor: Ka = 1; by preselecting a=(30 ÷ 50) pc
Orientation correction factor: K0 = 1; because the inclination angle ≤ 600
Tension correction factor: Kdc = 1
Lubrication correction factor: Kb = 1,5; because using drip lubrication
Operation shift correction factor: Klv= 1.12; due to 2-shift operation
with all the coefficients selected above, we get the operation correction factor:

Sprocket teeth coefficient factor:

Rotation speed coefficient factor:

Correction factor of the number of strands, due to 1 strand chain

𝐾𝑥 = 1

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5. Calculated transmitting power based on formula:

Based on Table 5.4, n01= 200rpm, we choose chain pitch pc=44,45 mm

6. Check the limit rotational speed of chain pitch

Acorrding to Table 5.3, the limit rotational speed of chain pitch 44,45
(mm) is [n]=400 rpm , satisfied condition n<[n].
7. Average velocity:

Tangential force:
8. Chain pitch pc can also be calculated directly or vertified by:

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Where [p0]= 26 (MPa) corresponding to pc= 44,45mm and n01= 200 rpm

9. Select initial center distance:

The number of links is determined by the formula:

=> We select X=127

The chain drive:
Calculate accurate center distance:

Select a= 1560 mm after subtracting (0,002:0,004)a

10. Verify the number of impacts per second:

According to Table, we choose [i] = 12 as pc= 44,45 mm

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 Verify the safety factor:

[s] based on table 5.10 book” Trinh Chat- Le Van Uyen with pc==44,45mm
Where Q: Ultimate tensile force (N) =172,4 KN = 172400 N

Fv: Tesion due to centrifugal force (N)= qm.v2=7,5.2,252=37,9688 (N)

F0: Initial tension = Weight of slack side (N)= K f.a.qm.g
=6.1,697.7,5.9,81=749,14 N
11. Force acting on the shaft:

Km= 1,15 cofficient of mass chain when chain is vertical

Ft= 4986,7949(N) - usefulring force
12. Dimensions of sprockets:
Pitch diameter of sprockets

Outer diameter

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Chapter 3: Designing helical gear transmission
3.1 Input data
Power P1= 12,8742 kW and Torque T 1= 84211,3767 Nmm
Speed ratio 3,5
The number of revolutions on driving gear: n1=1460 rpm
The number of revolutions on driven gear: n2 = 417,1439 rpm
Total working time:
One-way rotation, two work shifts (1 year working 300 days, 1 shift working 8
hours)
3.2 Calculation and design
1. Choose gear material, we select C45 steel with heat treatment method being
structural improvement.

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Hardness of driving gear HB 1=250
For driven gear, we choose hardness according to H 1 ≥ H 2 +(10 ÷ 15) HB so
HB 2=235

Allowable stress:

a. Contact stress:

Allowable contact stress

Equivalent number of cycles:

Since each tooth revolution only engages once, c = 1

3. Number of cirles to the inflection of the fatigue curve:

Due to N HE 1> N HO 1 ; N HE 2 > N HO 2 ; N FE 1 > N FO 1 ; N FE 2 > N FO 2 so life coefficient

K HL1=K HL2=K FL1=K FL2=1

4. Acorrdiang to given table above (table 6.13)

Fatigue limits for contact stresses: σ OHlim=2 HB+70
σ OHlim 1=2× 250+70=570 MPa
σ OHlim2=2 ×235+70=540 MPa
Fatigue limits for bending stresses: σ OFlim=1.8 HB
σ OFlim 1=1.8 ×250=450 MPa

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σ OFlim 1=1.8 ×235=423 MPa

5. Allowable contact stress [ σ H ]

σ OHlim × 0.9
[ σ H ]= sH
× K HL

Where s H =1.1 (following table 6.13)

σ OHlim1 ×0.9 570× 0.9
[ σ H 1 ]= sH
× K HL1=
1.1
× 1=466.4 MPa

σ OHlim2 ×0.9 540× 0.9

[ σ H 2 ]= sH
× K HL2=
1.1
× 1=441.8 MPa

Miminum allowable contact stress [ σ H ]min =[ σ H 2 ]=441.8 MPa

6. Allowable bending stress [ σ F ]

σ OFlim
[ σ F ]= sF
× K FL

Choose s F=1.75 (following table 6.13)

σ OFlim 1 450
[σ F1]= sF
× K FL1=
1.75
×1=257.1 MPa

σ OFlim 2 423
[ σ F2] = sF
× K FL2=
1.75
×1=241.7 MPa

Lubrication system of helical gear reducer is good, so we calculate and

design based on allowable contact stress [ σ H ]
7. Following table below, due to symmetrically between bearings and
H 1 , H 2 <350 HB so we choose ψ ba =0.3 ÷ 0.5, according to the standard value, we
select ψ ba=0.4

The standard value of factor:

ψ ba : 0.1; 0.125 ; 0.16 ; 0.2 ; 0.25 ; 0.315 ; 0.4 ; 0.5 ; 0.63 ; …

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 ψ ba (uh +1) 0.4 (5+1)
Currently, ψ bd = = =1.2
2 2
Based on table below, we choose K Hβ=1.05 and K Fβ=1.10

8. Center distance a

According to the standard value, we select aw= 160mm

9. Modulus m
With H 1 , H 2 ≤350 HB so
Following the standard value, we choose m= 3 mm
11. From condition of angle β : 20° ≥ β ≥ 8°
2 aw cos 8° 2a w cos 20°
So: ≥ z 1 ≥
mn ( uh +1 ) mn ( uh +1 )

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Inclined angle:

Face width of gear:

12. Re-calculating speed ratio after choosing number of teeth

Check the actual gear ratio:

13. Geometry parameters of gear

Pitch diameter:

Top diameter:

Root diameter:

14. Prepheral speed v and select the grade of accuracy

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15. Following table below, we choose the grade of accuracy being 9 with
limited peripheral velocity v gh=6 m/s

16. According to table below, we select:

K Hv =1.11∧K Fv =1.22

III. Check strength

18. Check contact strength:
- Determine accurate allowable contact stress:
K HL Z R Z V K L K xH
[ σ H ]=σ OHlim sH
Where,
ZR = 0.95 : Roughness coefficient of tooth surface
Zv=0,966 : factor considering the influence of peripheral velocity
0.1 0.1
ZV =0.85 v =0.85 × 4.21 =0.98 due ¿ HB ≤350

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K L=1 : factor considering the influence of lubrication
K xH : factor considering the influence of tooth size

- Contact stress

Where:
Z H =1.7 : factor considering the shape of the contact surface

With

: factor considering the effect of total contact lenght

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 1 /2
Z M =275 MPa

: elasticity factor that considering gear material properties (steel)

KH=1,285: contact stress load ratio

So

19. Check bending strength:

Determine accurate allowable bending stress:
K FL Y R Y x Y δ K FC
[ σ F ]=σ OFlim sF
Where:
K FC =1 : factor considering the effect of two-way rotation on fatigue strength,
one-way rotation so K FC =1
Y R=1 : factor considering the influence of surface roughness
Y x =1 : size factor, choose Y x =1 when through and nitriding

Y δ =1.0036 : Gear material sensitivity coefficient leads to load convergence

K FL1 Y R Y x Y δ K FC 1× 1× 1× 1.0036× 1
[ σ F 1 ] =σ OFlim 1 sF
=450
1.75
=258.069 MPa

K FL2 Y R Y x Y δ K FC 1× 1× 1× 1.0036 ×1
[ σ F 2 ] =σ OFlim 2 sF
=423
1.75
=242.584 MPa

- Teeth z v

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- Factor Y F
When modification factor is zero (x ¿ ¿ 1=x 1=0)¿ non correction

- The comparative bending strength according to the ratio [ σ F ] /Y F

[σ F 1 ] [ σ F2]
We have Y < Y , so we will calculate according to Driving gear
F1 F2

- Bending stress at dangerous section:

20. Gear parameters

Parameters Helical gear box

Center distance a w, mm 160

Torque, T 1 Nmm 84211,3767

Speed ratio, uh 3,5

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Number of ration n, rpm 1460

Modules m, mm 3

Number of teeth: z 1 23
z2 81

Teeth angle, ° 18,838

Pitch diameter, mm: d 1 70,77

d2 249,23

Adendum diameter, mm: d a 1 76,77

da2 255,23

Gear width b w,mm 70

Gear velocity v, m/s 5,41

Chapter 4: Designing shafts

4.1 Select the material
We select the material for making the shaft is steel C45 with the following data:
- Limit Durability
- Allowable bending stress [ σ ]=70 MPa
- Allowable torsion stress [ τ ]=20 MPa
4.2 Design layout of shafts for strength

Shaft I: d 1=
√
3 5T 1
[τ]
=20.85 so we choose d 1=21 as standard

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Shaft II: d 2=
√
3 5T 2
[τ ]
=35.19 so we choose d 2=35 as standard

- Peripheral force:
2T 1 2×36290
F t 1=F t 2= = =870.994 N
d1 83.33
- Axial force:
°
F a 1=F a2 =F t 1 tgβ =870.994 ×tg 16.26 =254.037 N
- Radial force:
F t 1 tg α nw 870.994 ×tg 20°
F r 1=F r 2= = =330.22 N
cosβ cos 16.26°

4.3 Design the shafts construction

Shaft I: l=l 1 +2 x+ w=81

According to the table below based on the T I =36.29 Nm, we choose
e=60 mm , u=50 mm , f =55 mm , w=40mm , x=10 mm
Shaft II: l=l 2 +2 x+ w=105
According to the table below based on the T II =174.275 Nm , we choose
e=100 mm , u=70 mm , f =80 mm , w=50 mm , x=10 mm

4.4 Forces acting on each shaft

Shaft I:

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On Oyz plane, we solve the moment equation at point D:
∑ M D=0↔ R By .81−F r 1 .40 .5+ M Fa 1=0
254.037 × 83.33
330.22× 40.5−
2
→ R By = =34.43 N (↑)
81
Then evaluate the force equaition on shaft
∑ F y=0↔−R By−F r 1−F Dy =0
→ R Dy =F r 1 −RBy =330.22−34.43=295.78(↑)
On Oxz plane, we solve the moment equation at point D:
∑ M D=0↔−F coupling . ( 81+55 ) + R Bx .81−F t 1 .40 .5=0
F t 1 .40 .5−F coupling . ( 81+55 )
→ R Bx = =−917.78(↓)
81
Then evaluate the force equation on shaft:

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∑ F y=0↔ F coupling−RBx + Ft 1−R Dx=0
→ R Dx =F coupling + F t 1−R Bx=2594.774 N (↑)
The force coupling applied on shaft we calculated by formula:
2. T
F coupling = =806 N , which D0 we choose in table 16.10a[3]
D0
Shaft II:

On Oyz plane, we solve the moment equation at point A:

∑ M A =0 ↔−RCy .135−Fr 2 .52.5+ F chain .235+ M Fa2 =0
F chain .215−F r 2 .52 .5+ M Fa 2
→ R Cy= =10492(↑)
105
Then evaluate the force equation on shaft:
∑ F y=0↔−R Ay −F r 2 −FCy + F chain =0
→ R Ay=F chain −F r 2 −RCy =−6454 N (↓)

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On Oxz, we solve the moment equation at point A:
∑ M D=0↔−RCx .105−F t 2 .52 .5=0
−Ft 2 .52 .5
→ R Cx= =−2190 N (↓)
105
Then evaluate the force equation on shaft:
∑ F y =0↔−RCx−F t 2−R Ax=0
→ R Ax =−Ft 2−RCx =−2190 N (↓)
According to the diagram, we calculate the total and equivalent moment at
dangerous section with this formula:
Total moment: M j =√ M 2jx + M 2jy , Equivalent moment: M td =√ M 2j + 0.75 T 2j

Then we specify diameters of each cross-section with formula: d ≥

√
3 M td
0.1 [ σ ]
Here are the results: d A 1 =25 mm , dC 1 =45 mm , d B 2=60 mm ,d D 2=40 mm
However, we will focus cross-section that assembling key on which are A1, C1,
B2, D2
4.5 Checking the fatigue strength
Shafts have been designed recently are testing fatigue strength due to these
formulas below:
c . sτ
s= ≥[ s]
√ s σ 2+ s τ 2
Within, [s ] – allowable safety factor in [1.5;2.5], therefore we can use 1.5, if [s ],
we do not need to test the shaft’s hardness
sσ , s τ safety factors belong to bending stress and torsional stress, evaluated
by these formulas:
σ −1
sσ =
K σ . σa
+ψ σ . σ m
εσ
τ−1
sτ =
K τ . τa
+ψ τ . τ m
ετ
The shaft rotates so the bending stress fluctuates based on symmetric cycle:
M
σ a=σ max= , σ =0
W m
W – Bending resistance moment

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Torsional stress chanes according to dynamic pulse cycle:
τ max T
τ a=τ m= =
2 2W0
W 0 – Torsional resistance moment
Each shafts have 2 keys either so W, W 0 can calculate by:
3 2
π d bt(d−t)
W= −
32 d
3 2
π d bt(d−t )
W0= −
16 d
At these sections have concentration of keyway on stress, so form table 10.8[2]
we choose K σ =2.05 , K τ =1.9
We choose ψ σ =0.05 , ψ τ =0 based on figure 2.9 [ 2 ].
(ε σ , ε τin table 10.3[2])
We conclude that all the safety factors are greater than []¿(2.5÷ 3), so we are not
necessary to reinforce the hardness of the shaft
4.5 Checking key/keyway
We choose the material of the key is steel, the type of assembly is fix and the
load with slight oscillation
2T
Bending condition: σ d= d l (h−t ) ≤ [ σ d ]=150 MPa
t 1

2T
Torque condition: τ c = d bl ≤ [ τ c ]=90 MPa
t

In conclusion, all keys and keyways are satisfied testing condition

Chapter 5: Designing bearings

5.1 Design and select bearing on shaft I
Table 6.1 Load acting on bearing
The total force at bearing A: F tA=F Ax .2+ F Ay .2=3642.5 N
The total force at bearing B: F tB=F Bx .2+ F By .2=1985.2 N
Form the table above, the axial force F a is not small compared to the radial

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 F r ∧F a
force Fr
=0.22< 0.3. Therefore, we select the single line angular contact ball

bearing. We preliminary select bearing based on the diameter of the shaft and
from table P2.12[3].
Table 6.2 Specifications of bearing 307

ID d, mm D, mm B, mm R, mm C, kN C0, kN

307 35 80 21 2.5 26.2 17.9

Bearing at A is exerted more load than bearing at B, so we calculate the strength

of bearing based on bearing at A
Calculation of dynamic load:
We have ratio
Fa 804
= =0.045
C0 17.9 ×103
According to table 11.4 [3], we choose e=0.26
For bearing with inner ring rotate, V=1
Fa
Therefore, V F =0.22< e=0.26
r

According to table 11.4[1], we select X=1, Y=0

Maximum load bearing is exerted
Q= X F r +Y F a . K t . K d =4735.2 N
Where, factor of temperature K t =1for = 1050
Factor of characteristic of load K d =1.3 for speed reducer, according to table
11.3[3].
60 L h n dc 60∗24960∗193
L= 6 = 6 =289.04 million revolutions
10 10
Calculated dynamic load capability:
10
C = QEm√ L = 4735.2* 3√ 92.3 = 25916.1 N < C = 26200N
Real life expectancy:
L = ¿ = 169.4million revolutions
6
10 L
Lh = 60 n = 20664 hours
II

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5.2 Design and select bearing on shaft II
Table 5.3 Load acting on bearing
The total force at bearing A: F tA =F Ax .2+ F Ay .2=2233.6 N
The total force at bearing B: F tB=F Bx .2+ F By .2=10717.8 N
Form the table above, the axial force F a is not small compared to the radial
F r ∧F a
force Fr
=0.075<0.3. Therefore, we select the single line angular contact ball

bearing. We preliminary select bearing based on the diameter of the shaft and
from table P2.12[3].
Table 5.4 Specifications of bearing 410

ID d, mm D, mm B, mm R, mm C, kN C0, kN

410 50 90 20 2 68.5 53

Bearing at A is exerted more load than bearing at B, so we calculate the strength

of bearing based on bearing at A
Calculation of dynamic load:
We have ratio
Fa
=0.015
C0
According to table 11.4 [3], we choose e=0.19
For bearing with inner ring rotate, V=1
Fa
Therefore, V F =0.015< e=0.19
r

According to table 11.4[1], we select X=1, Y=0

Maximum load bearing is exerted
Q= X F r +Y F a . K t . K d =13933.1 N
Where, factor of temperature K t =1for = 1050
Factor of characteristic of load K d =1.3 for speed reducer, according to table
11.3[3].
60 L h n dc 60∗24960∗193
L= = =75.2 million revolutions
10 6
106
Calculated dynamic load capability:
C = QEm√ L = 58811.7N < C = 68500N

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Real life expectancy:
L = ¿ = ¿ = 3320.857million revolutions
106 L 106∗3320.857
Lh = 60 n = = 1035429 hours
II 60∗53.44

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