02SXJJM – Fundamentals of Machine Design – A.Y.

2023/2024

Homework projet rules

During the course it is mandatory to complete a Homework project, that will be assigned to
groups of 3 students. Up to November 24th you can register your group in the online
Spreadsheet available at the following link:

https://docs.google.com/spreadsheets/d/1IVxn8lTE-
JhheZVp9LNvYxbZp1I8Q8ycVeg_4xaj7FI/edit?usp=sharing

For those of you who will not be able (for any reason) to find the other two people, you will
be assigned automatically to other groups that will have not been able to find all the three
elements.

To access the final examination the Homework Project must be completed in all its parts
and submitted no later than 19th of January 2024.Students who already attended the course
in previous years and got a mark for their project do not need to do the homework project
again, but they can if they want to achieve a higher score. However, in case the score of the
new Project is lower than the previous one, it cannot be declined.

Each group must submit the technical report in .pdf format on “Portale della didattica/
Fundamentals of machine design/Elaborati(Homework)” section. Each group must submit
only one file with name Group_Nr_XX_Surname1_Surname_2_Surname_3.pdf. No
other file other than the technical report will be taken into account (Spreadsheet, matfile,
etc.)

Shortly after the submission deadline you will be notified about the acceptance of the
uploaded material. If the uploaded files are missing of some relevant parts, you will not
be able to access the examination until a revised version is uploaded. The maximum
possible score for the new revised version will be 0.

For all accepted works the final mark after the evaluation of the technical report will be in
the range C = +3/-3.
Works with score C<0 can be delivered again one week before the next useful written
examination date, but the maximum score for the second revision will be C=0.

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Technical report for the verification of gearbox components

The subject of the technical report is the verification of the components of the mechanical gearbox represented
in Figure 1.

Figure 1. Gearbox assembly drawing

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Tin, nin
y
x
IN
z L1
A C E

L3

L2

F
B D L4 f = 80 mm
FOUT,a FOUT,r
OUT
Figure 2. Gearbox functional scheme

A1: gearbox input shaft; it receives power from the motor with the key L1.
A2: intermediate shaft; it receives power from shaft A1 by means of gear G2 and transmits power to shaft A3
with gear G3.
A3: output shaft of the gearbox; it receives power from shaft A2 by means of gear G4 and transmits power to
the user with the key L4.
G1-G4: helical gears (Helix orientations are given in Figure 1).
L1: key on the input shaft A1; it receives the power from the motor.
L2: key that connects shaft A2 with gear G2.
L3: key that connects shaft A3 with gear G4.
L4: key on the output shaft A3; it transmits the power to the end user.
FOUT,r - FOUT,a: external forces applied to the shaft A2 by the end user.

Consider:
- The forces FOUT,r and FOUT,a are applied at distance f = 80 mm from the midplane of the matched bearing unit
in support F
- The values of the forces must be calculated as a function of the torque on shaft A3, as:

𝑇𝐴3
𝐹𝑂𝑈𝑇,𝑟 = 𝑁 𝐹𝑂𝑈𝑇,𝑎 = 0.25 ∙ 𝐹𝑂𝑈𝑇,𝑟 𝑁
0.25
With TA3 expressed in Nm
Remember to consider the orientation of the forces with respect to the global reference frame x-y-z shown in
Figure 2.

Bearings:
A: NU 206 ECP; B: 30206 X/DF matched unit in face-to-face arrangement
C: 2x NU 209 ECP; D: 32011 X/DF matched unit in face-to-face arrangement
E: NU 2210 ECP; F: 32011 X/DF matched unit in face-to-face arrangement

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

The gear G1 is machined from the same piece of shaft A1 as well as gear G3 on shaft A2.
Gear G4 is keyed with L3 on shaft A3. Shafts A1 and A3 are supported by means of a cylindrical roller bearing
on one side and a matched unit of tapered roller bearings on the other. Shaft A2 is supported by means of a
pair of single-row cylindrical roller bearings on one side and a matched unit of tapered roller bearings on the
other.

V4
V3

V1 V2

13,75

a=79 mm b=70.5 mm c=59.25 mm

Figure 3. Shaft A2 and related components

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

General roughness: 1.6 m

Figure 4. Shaft A2 technical drawing

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Data for static and fatigue analysis on shaft A2 and gear G1

A motor, rotating at an angular speed of nin rpm, provides a power Pin kW to the input shaft A1 of the
gearbox (see Annex 1 for input data and Figure 2 for the direction of rotation). The power is transmitted to
shaft A2 through the meshing helical gears G1 and G2, and to the output shaft A3 by the meshing helical
gears G3 and G4.
The intermediate shaft A2 (Figure 3) is made with a 16MnCr5 hardened and tempered steel (σ u=1060 MPa,
σy=930 MPa, σD-1=700 MPa), is supported on one side by a pair of cylindrical roller bearings of the type NU
209 ECP (from SKF) and a matched unit of tapered roller bearings of the type 32011 X/DF (from SKF) in a
face to face arrangement.
The helical gears have the following characteristics:

G1 G2 G3 G4
normal module, 𝑚𝑛 (mm) 3 3 4 4
number of teeth, 𝑧 16 48 21 63
helix angle, 𝜓 15° 15° 15° 15°
normal pressure angle, 𝜙𝑛 20° 20° 20° 20°
transmission accuracy level, 𝑄𝑣 8 8 8 8
tooth face width (mm) 45 45 56 56
Ultimate strength (MPa) 1060 1060 1060 1060
Yield strength (MPa) 930 930 930 930
Surface Hardness (HB) 700 700 700 700

Part 1
➢ Static verification and Fatigue analysis for infinite life for shaft A2 in the sections shown in Figure 3
o 𝐕𝟏 in the mid-section of gear G3;
o 𝐕𝟐 in the shoulder given by G3 of shaft A2;
o 𝐕𝟑 in the shoulder used to axially constrain the gear G2;
o 𝐕𝟒 in the mid-section of gear G2 whereby the shaft features a keyseat.
considering the stress concentration and intensification factors where necessary.
➢ Bending and contact stress verification for gear G3 for an endurance of 108 cycles and a reliability of
99% (based on AGMA D2001-D04). Assume the following conditions:
o for the commercial enclosed units, a continuous working condition without overloads and
uniform power source, with an operating temperature of 60 °C
o a surface condition factor 𝑍𝑅 = 1
o for the load distribution factor 𝐾𝐻 , the coefficient 𝐶𝑒 = 1 and uncrowned teeth
o for the stress cycle factors 𝑌𝑁 and 𝑍𝑁 , the models 𝑌𝑁 = 1,3558 ∙ 𝑁 −0,0178 and 𝑍𝑁 = 1,4488 ∙
𝑁 −0,023.

Part 2
➢ Evaluate according to the SKF method the expected life of all bearings installed in the gearbox (A, B,
C, D, E and F) both in millions of cycles and operating hours. For the analysis let’s assume:
o Constant input power and rotational speed
o Constant operating temperature, T=60°C
o Normal cleanliness level
o Reliability 90%
o Choose the lubricant viscosity grade to ensure a value of the viscosity ratio κ as close as
possible to 1 on the bearings of the output shaft A3. Then use the selected lubricant to
perform the calculations on the bearings mounted on the other two shafts (A1 and A2).
➢ Evaluate for each bearing the static safety factor and the minimum load.

Perform the verifications following the list of calculations reported in the schemes below, which represents a
complete outline for the solution as well as a suggestion to write the technical report.
Remember to provide the numerical values of all your calculations adding to your report a finale table
like the submission table provided at the end of this document.

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

SCHEME FOR THE TECHNICAL REPORT: STATIC VERIFICATION

02SXJJM Fundamentals of Machine Design
Team n.
date ...............
sheet n. ...../.....

Shaft A1: External forces Shaft A2: External forces Shaft A3: External forces
𝐹𝑡12 = ⋯ N 𝐹𝑡34 = ⋯ N
𝐹𝑡21 = ⋯ N 𝐹𝑟12 = ⋯ N
𝐹𝑟34 = ⋯ N
{ 𝑟21 = ⋯ N
𝐹 𝐹𝑎12 = ⋯ N
𝐹𝑎34 = ⋯ N
𝐹𝑎21 = ⋯ N 𝐹𝑡43 = ⋯ N
𝐹𝑂𝑈𝑇,𝑟 = ⋯ N
𝐹𝑟43 = ⋯ N
{𝐹𝑂𝑈𝑇,𝑎 = ⋯ N
{𝐹𝑎43 = ⋯ N
Notes:
Assume a gear efficiency equal to 1.
Shaft A1: Reaction forces
x 𝑅𝑥𝐴 = ⋯ N
z {
𝑅𝑥𝐵 = ⋯ N
y
𝑅𝑦𝐴 = ⋯ N
{
𝑅𝑦𝐵 = ⋯ N
Shaft A2: Reaction forces

x 𝑅𝑥𝐶 = ⋯ N
{
z 𝑅𝑥𝐷 = ⋯ N
y
𝑅𝑦𝐶 = ⋯ N
{
𝑅𝑦𝐷 = ⋯ N

Shaft A3: Reaction forces

x 𝑅𝑥𝐸 = ⋯ N
{
z 𝑅𝑥𝐹 = ⋯ N
y
𝑅𝑦𝐸 = ⋯ N
{
𝑅𝑦𝐹 = ⋯ N

Notes:
o For the pair of roller bearings on shaft A2 (support C), consider a single application point in the
midplane section of the unit. For the matched units of tapered roller bearings in face-to-face
configuration, consider a single application point in the midplane section of the unit.
o Forces from the gears of the system can be considered applied on the midplane section of gears.

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Shaft A1: Axial reaction Shaft A2: Axial reaction Shaft A3: Axial reaction
forces forces forces

𝑅𝑧𝐴 = ⋯ N 𝑅𝑧𝐶 = ⋯ N 𝑅𝑧𝐶 = ⋯ N

{ { {
𝑅𝑧𝐵 = ⋯ N 𝑅𝑧𝐷 = ⋯ N 𝑅𝑧𝐷 = ⋯ N

Notes:
o For each shaft, identify the bearing acting as the roller support and the bearing behaving as the pinned
support.

Shaft A2 Internal loads

𝑁(𝑧) = ⋯ N
Calculate and plot the internal loads and the total bending 𝑀𝑥 (𝑧) = ⋯ Nm
moment 𝑀𝐵 (𝑧) = √𝑀𝑥2 + 𝑀𝑦2 in the intermediate shaft A2
𝑀𝑦 (𝑧) = ⋯ Nm
and plot their trends.
𝑀𝐵 (𝑧) = ⋯ Nm
{ 𝑀𝑡 (𝑧) = ⋯ Nm
Stress in the shaft A2: single components
Calculate and plot the trend of the stresses due to the 𝜎 𝑁 (𝑧) = ⋯ MPa
normal load 𝜎 𝑁 (𝑧), to the bending moment 𝜎 𝑀𝐵 (𝑧) and to
the torsional moment 𝜏 𝑀𝑡 (𝑧).
{𝜎 𝑀𝐵 (𝑧) = ⋯ MPa
𝜏 𝑀𝑡 (𝑧) = ⋯ MPa
Stress on the shaft A2: equivalent stress

Calculate and plot the trend of the resulting normal stress

𝜎 𝑡𝑜𝑡 (𝑧) and equivalent stress 𝜎𝑖𝑑 (𝑧). For the evaluation of 𝜎 𝑡𝑜𝑡 (𝑧) = ⋯ MPa
the equivalent stress, consider the Von Mises criterion and {
suppose that the material fails for full yielding. 𝜎𝑖𝑑 (𝑧) = ⋯ MPa

Static safety factor on the shaft A2

𝑆𝐹𝑉1 = ⋯
Calculate the static safety factors for the four cross 𝑆𝐹𝑉2 = ⋯
sections of the shaft represented in Figure 2. Identify the 𝑆𝐹𝑉3 = ⋯
most critical section and evaluate the minimum safety 𝑆𝐹𝑉4 = ⋯
factor of the shaft 𝑆𝐹𝑠,𝑚𝑖𝑛 .

{𝑆𝐹𝑠,𝑚𝑖𝑛 = ⋯
Notes:

o For pinion G3, which is directly machined from the same piece of the shaft, consider a shaft diameter
equal to the diameter of the gear dedendum circle.

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

SCHEME FOR THE TECHNICAL REPORT: FATIGUE VERIFICATION

02SXJJM Fundamentals of Machine Design
Team n.
date ...............
sheet n. ...../.....

Evaluation of the fatigue stress on Shaft A2

Evaluate, if present, the mean and alternate stress For each section V1, V2, V3 and V4:
𝑁
components due to the normal load, 𝜎𝑚 e 𝜎𝑎𝑁 , mean and
𝑁
alternate stress components due to the bending moment,
𝑀 𝑀
𝜎𝑚 = ⋯ MPa 𝜎𝑎𝑁 = ⋯ MPa
𝜎𝑚 𝐵 e 𝜎𝑎 𝐵 , and the mean and alternate stress components 𝑀 𝑀
𝑀 𝑀
due to the torsion moment, 𝜏𝑚𝑡 e 𝜏𝑎 𝑡 in the sections V1, V2,
{𝜎𝑚 𝐵 = ⋯ MPa 𝜎𝑎 𝐵 = ⋯ MPa
𝑀 𝑀
V3 and V4. 𝜏𝑚𝑡 = ⋯ MPa 𝜏𝑎 𝑡 = ⋯ MPa
Stress concentration factors
𝑞=⋯
𝐾𝑡,𝑁 = ⋯
Starting from the notch sensitivity 𝑞 (evaluated as a function 𝐾𝑓,𝑁 = ⋯
of the notch radius) and the geometric stress raiser notch 𝐾𝑡,𝐵 = ⋯
factor 𝐾𝑡 , evaluate the fatigue stress intensification factor
𝐾𝑓 for sections V1, V2, V3 and V4. 𝐾𝑓,𝐵 = ⋯
𝐾𝑡,𝑇 = ⋯
{ 𝐾𝑓,𝑇 = ⋯
Fatigue limit correction factors
Considering the working condition and the shaft geometry, 𝐶𝑆 = ⋯
evaluate from the corresponding diagrams the scale effect
factor 𝐶𝑆 , and the surface finish effect factor 𝐶𝐹 for sections
{
V1, V2, V3 and V4. 𝐶𝐹 = ⋯

Fatigue limit correction for the component and Haigh diagram

Considering the working condition and the shaft geometry,
𝑐
evaluate the fatigue limit of the component 𝜎𝐷−1 and plot 𝑐
for each section the Haigh diagram for infinite life with all
𝜎𝐷−1 = ⋯ MPa
the relevant information.
Fatigue safety factor
Considering the fatigue working condition and the shaft
geometry, calculate the coordinates of the working point P
𝜎𝑎,𝑒𝑞 = ⋯ MPa
{
on the Haigh diagram and evaluate the fatigue safety factor 𝜎𝑚,𝑒𝑞 = ⋯ MPa
for infinite life, 𝑆𝐹𝑓 . Choose the most appropriate definition
of the safety factor according to the specific characteristics 𝑆𝐹𝑓 = ⋯
of the application.

Reminder:
• Repeat the same procedure for sections V1, V2, V3 and V4.
• Use the diagrams in the following pages for the evaluation of the coefficients.
• Use the Shigley Method to calculate the alternate and average equivalent stress components of the
working point.
• For pinion G3, which is directly machined from the same piece of the shaft, consider a shaft diameter
equal to the diameter of the gear dedendum circle.
• For each section, it is requested to draw the Haigh diagram and identify the position of the
working point!

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Geometrical stress concentration factors Kt

Bending Torsion
Kf for the keyseat 1.6 2.0
Kf for machined pinion on shaft 1.2 1.5

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Size Effect Cs

Surface finish effect

Notch sensitivity q

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

SCHEME FOR THE TECHNICAL REPORT: GEAR TOOTH VERIFICATION

02SXJJM Fundamentals of Machine Design
Team n.
date ...............
sheet n. ...../.....

Maximum tooth gear bending stress equation for fatigue

1
𝜎max,𝐹𝑎𝑡𝑖𝑔𝑢𝑒 = 𝐹𝑡 𝐾0 𝐾𝐵 𝐾𝑣 𝐾𝐻 𝐾𝑠
𝑏∙𝑚𝑡 𝑌𝐽
Notes:
Express the face width b and the transverse modulus mt in mm

Face width 𝑏

𝑏 = min[𝑏𝐆 , 𝑏𝐏 ]

Where G is the gear and P is the pinion of the couple

Overload factor 𝐾0

𝐾0 = ⋯

Rim-thickness factor 𝐾𝐵

𝐾𝐵 = ⋯

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Dynamic factor 𝐾𝑣

𝐾𝑣 = . ..

where 𝑄𝑣 is the
transmission
accuracy-level
number and Vt is the
peripheral linear
speed of the coupling
expressed in ft/min

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Load distribution factor 𝐾𝐻

𝐾𝐻 = 1 + 𝐶𝑚𝑐 (𝐶𝑝𝑓 𝐶𝑝𝑚 + 𝐶𝑚𝑎 𝐶𝑒 ), where 𝐶𝑒 = 1.
ATTENTION:
Diagrams are provided here with a tooth width b (F in the plots) expressed in inches

1 for uncrowned teeth

𝐶𝑚𝑐 = {
0,8 for crowned teeth

where 𝑑 is the pitch circle diameter, 𝑏 is the face width.

1 𝑆1⁄𝑆 < 0,175

𝐶𝑝𝑚 = {
1,1 𝑆1⁄𝑆 ≥ 0,175 𝑜𝑟 𝑐𝑎𝑛𝑡𝑖𝑙𝑒𝑣𝑒𝑟 𝑠ℎ𝑎𝑓𝑡

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Size factor 𝐾𝑠

0,0535
𝐾𝑠 = 0,843(𝑏 ∙ 𝑚𝑡 √𝑌)

Express b and mt in mm

For helical gears

𝑧
𝑧′ =
𝑐𝑜𝑠 3 𝜓

Bending strength geometry factor 𝑌𝐽 = 𝐽′ ∙ 𝐽′′

𝐽′

𝐽′′

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Bending safety factor

𝜎𝐹𝑃 𝑌𝑁
𝑆𝐹 = 𝜎
max,𝐹𝑎𝑡𝑖𝑔𝑢𝑒 𝑌𝜃 𝑌𝑍

Bending fatigue strength 𝜎𝐹𝑃 (Sf,lim) = 860 MPa

Stress cycle life factor 𝑌𝑁

𝑌𝑁 =
⋯

Temperature factor 𝑌𝜃
𝑌𝜃 = 1, for temperature up to 120 °C
Reliability factor 𝑌𝑍

𝑌𝑍 = ⋯

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Maximum gear contact (pitting resistance) stress equation in fatigue

𝐾 𝑍𝑅
𝜎max,𝑝𝑖𝑡𝑡𝑖𝑛𝑔 = 𝑍𝐸 √𝐹𝑡 𝐾0 𝐾𝑣 𝐾𝑠 ∙ 𝑏∙𝑑𝐻 ∙
𝑷 𝑍𝐼

Elastic coefficient 𝑍𝐸

𝑍𝐸 = √MPa

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Surface strength geometry 𝑍𝐼

𝑟𝑏𝐏 = 𝑟𝐏 cos[𝜙𝑡 ]
{ ,
𝑟𝑏𝐆 = 𝑟𝐆 cos[𝜙𝑡 ]

where 𝑟𝐏 e 𝑟𝐆 are the pitch radii of the pinion P (the smaller gear) and the mating gear G
respectively while 𝑟𝑏 𝐏 e 𝑟𝑏 𝐆 are the base radii of P and G. 𝜙𝑡 is the transverse pressure
angle.

𝑍𝐴 = min [√(𝑟𝐏 + 𝑎)2 − 𝑟𝑏2𝐏 , (𝑟𝐏 + 𝑟𝐆 )sen[𝜙𝑡 ]]

𝑝𝑛 cos[𝜙𝑛 ]
⟹ 𝑚𝑁 = ,
0,95∙𝑍
𝑍𝐵 = min [√(𝑟𝐆 + 𝑎)2 − 𝑟𝑏2𝐆 , (𝑟𝐏 + 𝑟𝐆 )sen[𝜙𝑡 ]]

{ 𝑍 = 𝑍𝐴 + 𝑍𝐵 − (𝑟𝐏 + 𝑟𝐆 )sen[𝜙𝑡 ]

Where
• 𝑚𝑁 is the load sharing ratio,
• 𝑝𝑛 = 𝜋 ∙ 𝑚𝑛 is the normal pitch (with 𝑚𝑛 the normal module),
• 𝑎 = 𝑚𝑛 is the addendum,
• 𝜙𝑛 is the normal pressure angle,
tan[𝜙 ]
• 𝜙𝑡 is the transverse pressure angle with tan[𝜙𝑡 ] = cos[𝜓]𝑛 .

cos[𝜙𝑡 ]sen[𝜙𝑡 ] 𝑚𝐺
∙ external meshing
2𝑚𝑁 𝑚𝐺 + 1
𝑍𝐼 =
cos[𝜙𝑡 ]sen[𝜙𝑡 ] 𝑚𝐺
∙ internal meshing
{ 2𝑚𝑁 𝑚𝐺 − 1

where 𝑚𝐺 = 𝑛𝐏 ⁄𝑛𝐆 = 𝑑𝐆 ⁄𝑑𝐏 is the gear ratio.

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Wear safety factor (Hertzian contact)

𝜎𝐻𝑃 𝑍𝑁 𝑍𝑊
𝑆𝐻 = 𝜎
max,𝑝𝑖𝑡𝑡𝑖𝑛𝑔 𝑌𝜃 𝑌𝑍

Contact strength 𝜎𝐻𝑃 (Sc) = 1470 MPa

Stress cycle life factor 𝑍𝑁

𝑍𝑁
=⋯

Hardness-ratio factor 𝑍𝑊 (CH)

0 𝐻𝐵𝐏 ⁄𝐻𝐵𝐆 < 1,2

′
𝐴 = {8,98 ∙ 10−3 (𝐻𝐵𝐏 ⁄𝐻𝐵𝐆 ) −3
− 8,29 ∙ 10 1,2 ≤ 𝐻𝐵𝐏 ⁄𝐻𝐵𝐆 ≤ 1,7,
0,00698 𝐻𝐵𝐏 ⁄𝐻𝐵𝐆 > 1,7

where 𝐻𝐵𝐏 e 𝐻𝐵𝐆 are the Brinell hardness of P and G.

𝑍𝑊 = 1 + 𝐴′ (𝑚𝐺 − 1)

where 𝑚𝐺 = 𝑛𝐏 ⁄𝑛𝐆 = 𝑑𝐆 ⁄𝑑𝐏 is the gear ratio.

Temperature coefficient 𝑌𝜃
𝑌𝜃 = 1 for temperature lower than 120 °C
Reliability factor 𝑌𝑍

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

SCHEME FOR THE TECHNICAL REPORT: BEARINGS LIFE INVESTIGATION

Team n. 02SXJJM Fundamentals of Machine Design
date ...............
sheet n. ...../.....

Static analysis
• Verify each bearing under investigation for the minimum load.
• Provide the Safety Factor (SF) for the static bearing load.

Fatigue analysis: Bearing life estimation

Bearing life analysis (millions of cycles)

𝐶 𝑝
𝐿10𝑚 = 𝑎1 𝑎𝑆𝐾𝐹 ( )
𝑃

Bearing life in operating hours

106
𝐿10𝑚ℎ = 𝐿
60 ∙ 𝑛 10𝑚
Evaluation of the contamination
Values for 𝜂𝑐 are given for several levels of contamination
Evaluation of the viscosity ratio
𝜈
𝜅=𝜈 ,
1
with:
• 𝜈 lubricant viscosity at the given operating temperature
• 𝜈1 minimum required lubricant viscosity for the given working conditions

Remember to select the lubricant viscosity grade with the goal to ensure a value of
the viscosity ratio κ as close as possible to 1 on the bearings of the output shaft A3 for the
given operating temperature of 60°C.
Evaluation of the minimum required lubricant viscosity
Values for 𝜈1 are given as a function of 𝑑𝑚 and of the shaft rotational speed 𝑛
Evaluation of the lubricant viscosity at a given operating temperature
Values for 𝜈 are given as a function of 𝜈1 and of the operating temperature 𝑇
Evaluation of the coefficient aSKF
𝑃
Values for 𝑎𝑆𝐾𝐹 are given as function of 𝜂𝑐 𝑃𝑢 and 𝜅 for radial roller bearings where 𝜂𝑐 is
the contamination factor, 𝑃𝑢 is the ultimate fatigue load (catalogue) and 𝑘 is the viscosity
ratio.

Reminder:
- Use the uploaded SKF catalogue to find relevant tables and diagrams and for the
equivalent load definitions.
- Repeat the verification for all bearings in the gearbox (A, B, C, D, E and F).
TIPS:
- For the pair of roller bearings mounted on shaft A2 (support C), consider that
the total load is equally split between the two roller bearings in the unit.
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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

Annex 1: Group input data for gearbox analysis

Group No. Input Power Pin (kW) Input speed nin (rpm)
1 29,5 1000
2 34,5 1500
3 25,5 1250
4 20 750
5 31,5 1500
6 29 1250
7 36 1500
8 27 1250
9 19,5 750
10 30 1500
11 29,5 1250
12 21 750
13 22 750
14 26 1250
15 33 1500
16 24,5 1000
17 30 1250
18 21,5 750
19 25,5 1000
20 26,5 1000
21 35,5 1500
22 25 1000
23 28 1000
24 18,5 750
25 20,5 750
26 34 1500
27 30,5 1500
28 25 1250
29 32 1500
30 28,5 1000
31 19 750
32 26 1000
33 29 1000
34 27 1000
35 28 1250

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

SUBMISSION TABLE FOR KEY CALCULATION RESULTS

In your final report, it is MANDATORY to include tables like the submission tables
below filled with the required results.

UNIT OF
VALUE
MEASUREMENT
SHAFT ANALYSIS
Rx,C N
Ry,C N
Rx,D N
Ry,D N
Rz,C N
Rz,D N
Mx(z=V1) Nm
Mx(z=V2) Nm
Mx(z=V3) Nm
Mx(z=V4) Nm
My(z=V1) Nm
My(z=V2) Nm
My(z=V3) Nm
My(z=V4) Nm
N(z=V1) N
N(z=V2) N
N(z=V3) N
N(z=V4) N
Mbtot,max Nm
Mttot,max Nm
SF (static) -
σa,b nom (z=m.c.s.) MPa
σm,b nom (z=m.c.s.) MPa
σa,N nom (z=m.c.s.) MPa
σm,N nom (z=m.c.s.) MPa
τa,t nom (z=m.c.s.) MPa
τm,t nom (z=m.c.s.) MPa
Kf,b
σa,b eff (z=m.c.s.) MPa
σm,b eff (z=m.c.s.) MPa
Kf,N
σa,N eff (z=m.c.s.) MPa
σm,N eff (z=m.c.s.) MPa
Kf,T
τa,t eff (z=m.c.s.) MPa
τm,t eff (z=m.c.s.) MPa
σa,eqvP (z=m.c.s.) MPa
σm,eqvP (z=m.c.s.) MPa
SFf (fatigue) -
• M.c.s. Most critical section

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

UNIT OF
VALUE
MEASUREMENT
GEAR ANALYSIS - BENDING
𝐹𝑡
MPa
𝑏 ∙ 𝑚𝑡 ∙ 𝑌𝐽
𝜎max,𝐹𝑎𝑡𝑖𝑔𝑢𝑒 MPa
𝑆𝐹 -
GEAR ANALYSIS - PITTING

𝐹𝑡 1
𝑍𝐸 √ ∙ 𝑀𝑃𝑎
𝑏 ∙ 𝑑𝑷 𝑍𝐼
𝜎max,𝑝𝑖𝑡𝑡𝑖𝑛𝑔 MPa
𝑆𝐻 -

UNIT OF
VALUE
MEASUREMENT
BEARING ANALYSIS: LOAD CALCULATION
Fr,A kN
Fa,A kN
Fr,B kN
Fa,B kN
PA kN
PB kN
Fr,C kN
Fa,C kN
Fr,D kN
Fa,D kN
PC kN
PD kN
Fr,E kN
Fa,E kN
Fr,F kN
Fa,F kN
PE kN
PF kN

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02SXJJM – Fundamentals of Machine Design – A.Y. 2023/2024

UNIT OF
VALUE
MEASUREMENT
BEARING ANALYSIS: CORRECTED RATING LIFE
ISO VG of the selected oil mm2/s
askf,A -
askf,B -
askf,C -
askf,D -
askf,E -
askf,F -
𝐿10𝑚ℎ,𝐴 Hours
𝐿10𝑚ℎ,𝐵 Hours
𝐿10𝑚ℎ,𝐶 Hours
𝐿10𝑚ℎ,𝐷 Hours
𝐿10𝑚ℎ,𝐸 Hours
𝐿10𝑚ℎ,𝐹 Hours

24