clc

shaft_distance=64;

Rgsmall=28;
Rgbig=36;
shredderweight= 100; %weigth of shredder unit

tp=2.5;

tb=8;
Rb=40;
ht=6;
YS= 70;
motorrpm=3000;
gearratio=80;
eff=0.5;
Bladerpm= motorrpm/gearratio;
D_R= pi/180;

% angled shear cutting analysis

L=13;
delang= 18.5;
time = (delang/360)/Bladerpm*60;
alpha =70;
As= tp*tp/tan(alpha*D_R);
C1=0.7;
C2= 0.5;
thaoS=C1*YS;
Ps= thaoS*As;
totalPsSingleTooth=2*Ps;
Es=C2*totalPsSingleTooth*L*10^-3*tan(alpha*D_R);
teethincontact=5;
PowerNeed_ideal= Es*teethincontact/time

PowerNeed_ideal = 242.1030

PowerNeed_actual= PowerNeed_ideal/eff

PowerNeed_actual = 484.2061

%force analysis shaft with big gear

Fteeth=totalPsSingleTooth;

Mteeth=Fteeth*Rb*10^-3

Mteeth = 8.9173

d1=95;

1
d2=160;
d3=215;
alpha1=60*D_R;
alpha2=10*D_R;
alpha3=35*D_R;

Fteeth1_y=Fteeth*cos(alpha1)

Fteeth1_y = 111.4659

Fteeth2_y=Fteeth*cos(alpha2)

Fteeth2_y = 219.5449

Fteeth3_y=Fteeth*cos(alpha3)

Fteeth3_y = 182.6150

Fteeth1_z=Fteeth*sin(alpha1)

Fteeth1_z = 193.0646

Fteeth2_z=Fteeth*sin(alpha2)

Fteeth2_z = 38.7117

Fteeth3_z=Fteeth*sin(alpha3)

Fteeth3_z = 127.8684

distanceA_x= 26;
distanceB_x= 274;

syms By;

MomentWRTBearing_A_zaxis= Fteeth1_y*(d1-distanceA_x)+Fteeth2_y*(d2-distanceA_x)+Fteeth3_y*(d3-d

B_y= double(solve(MomentWRTBearing_A_zaxis,By))

B_y = -288.8081

syms Ay;

ForceEquiWRT_y_axis= Ay+B_y+Fteeth1_y+Fteeth2_y+Fteeth3_y==0;

A_y = double(solve(ForceEquiWRT_y_axis,Ay))

A_y = -224.8177

2
syms GearF;

MomentEQuiWRTShaftAXis= GearF*Rgbig+Fteeth*Rb*3==0;

GearForce= double(solve(MomentEQuiWRTShaftAXis,GearF));
GearForce=abs(GearForce)

GearForce = 743.1059

syms Bz;

MomentWRTBearing_A_yaxis= GearForce*(distanceA_x)+ Fteeth1_z*(d1-distanceA_x)+Fteeth2_z*(d2-dis

B_z = double(solve(MomentWRTBearing_A_yaxis,Bz))

B_z = -249.9867

syms Az;

ForceEquiWRT_z_axis = -GearForce +Az +Fteeth1_z+Fteeth2_z+Fteeth3_z+B_z==0;

A_z = double(solve(ForceEquiWRT_z_axis,Az))

A_z = 633.4479

R_A= sqrt(A_y^2+A_z^2)

R_A = 672.1602

R_B= sqrt(B_y^2+B_z^2)

R_B = 381.9731

%force analysis shaft with small gear ( powered shaft)

d1_shaft2=91;
d2_shaft2=150;
d3_shaft2=212;

distanceC_x= 27;
distanceD_x=274;

syms Dy;

MomentWRTBearing_C_zaxis= -Fteeth1_y*(d1_shaft2-distanceC_x)-Fteeth2_y*(d2_shaft2-distanceC_x)-

3
D_y= double(solve(MomentWRTBearing_C_zaxis,Dy))

D_y = 274.9863

syms Cy;

ForceEquiWRT_y_axis_shaft2= Cy+D_y-Fteeth1_y-Fteeth2_y-Fteeth3_y==0;

C_y = double(solve(ForceEquiWRT_y_axis_shaft2,Cy))

C_y = 238.6395

syms torque;

MomentEQuiWRTShaftAXis_shaft2= GearForce*Rgsmall+Fteeth*Rb*3+ torque==0;

input_torque= (double(solve(MomentEQuiWRTShaftAXis_shaft2,torque)))*10^-3

input_torque = -47.5588

syms Dz;

MomentWRTBearing_C_yaxis= -GearForce*(distanceC_x)+ Fteeth1_z*(d1_shaft2-distanceC_x)+Fteeth2_z

D_z = double(solve(MomentWRTBearing_C_yaxis,Dz))

D_z = -83.8440

syms Cz;

ForceEquiWRT_z_axis_shaft2 = GearForce +Cz +Fteeth1_z+Fteeth2_z+Fteeth3_z+D_z==0;

C_z = double(solve(ForceEquiWRT_z_axis_shaft2,Cz))

C_z = -1.0189e+03

R_C= sqrt(C_y^2+C_z^2)

R_C = 1.0465e+03

R_D= sqrt(D_y^2+D_z^2)

R_D = 287.4844

4
% bolt force analysis for fixing worm gear

d1_bolt= 20;
d2_bolt= 100;

syms P;

MomentEquiWRT_gearboxTippingPoint= input_torque*1000 +2*P*d1_bolt+2*5*P*d2_bolt==0;

P_= double(solve(MomentEquiWRT_gearboxTippingPoint,P))

P_ = 45.7296

WormBoltForce_1= P_

WormBoltForce_1 = 45.7296

WormBoltForce_2= 5*P_

WormBoltForce_2 = 228.6480

% bolt force analysis for fixing shredder unit to the brackets

d1_shredderUnit= 85+shaft_distance/2;
d2_shredderUnit= 85-shaft_distance/2;

ratio = d1_shredderUnit/d2_shredderUnit

ratio = 2.2075

syms unitbolt;

MomentEquiWRT_shredderunitRotatingPoint= abs(input_torque)*1000+shredderweight*shaft_distance/2

shredderUnit_sideBoltForce1= double(solve(MomentEquiWRT_shredderunitRotatingPoint,unitbolt))

shredderUnit_sideBoltForce1 = 81.5316

shredderUnit_sideBoltForce2=ratio*shredderUnit_sideBoltForce1

shredderUnit_sideBoltForce2 = 179.9848

shredderunit_bracketboltForce=shredderUnit_sideBoltForce2

shredderunit_bracketboltForce = 179.9848

5
% R_A % rADIAL LOAD
% R_B % rADIAL LOAD
% R_C % rADIAL LOAD
% R_D % rADIAL LOAD
% GearForce % bildigimiz spur gear mesh force u (tangential)
% WormBoltForce_1 % TENSILE LOAD
% WormBoltForce_2 % TENSILE LOAD
% shredderUnit_sideBoltForce1 % SHEAR LOAD
% shredderUnit_sideBoltForce2 % SHEAR LOAD
% shredderunit_bracketboltForce % TENSILE LOAD

% NOT: shredder uniti tutan bracket kuvvetleri shredderunit_sideBoltForce a

% esit

%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%BEARING ANALYSIS%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%
%axial loads neglected, thus R_i=P_i
P_A=1e-3*R_A; %kN conversions
P_B=1e-3*R_B;
P_C=1e-3*R_C;
P_D=1e-3*R_D;

shaft1rpm= 0.75*motorrpm/gearratio;
shaft2rpm= motorrpm/gearratio;
a1= 0.1; %for 99.9% reliability
a23= 1; % safe approach, can also use suggested value for deep groove ball bearings a23=2.2
p=3; %life exponent for ball bearings, switch with 10/3 for roller bearings

%try 6005 deep grove ball bearing which was used in the mockup because it
%matches up with the desired shaft diameter

d_6005=25;
D_6005=47;
dm_6005=0.5*(d_6005+D_6005);
Ciso_6005= 8.62;
C0iso_6005= 6.00;

life_A= a1*a23*(Ciso_6005/P_A)^p*(1e6/(60*shaft1rpm))

life_A = 1.2499e+05

life_B= a1*a23*(Ciso_6005/P_B)^p*(1e6/(60*shaft1rpm))

life_B = 6.8105e+05

life_C= a1*a23*(Ciso_6005/P_C)^p*(1e6/(60*shaft2rpm))

life_C = 2.4840e+04

life_D= a1*a23*(Ciso_6005/P_D)^p*(1e6/(60*shaft2rpm))

6
life_D = 1.1981e+06

Life_bearings= min([life_A, life_B, life_C, life_D])

Life_bearings = 2.4840e+04

Life_bearings_in_cycles= Life_bearings/(1/(60*shaft2rpm))

Life_bearings_in_cycles = 5.5889e+07

fprintf("The minimum life of the bearings is: %.0f hours (%.1f years for 2 hour per day average

The minimum life of the bearings is: 24840 hours (34.0 years for 2 hour per day average use).

%%%%%%%%%%%%%%%%%%%%%GEAR ANALYSIS%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%
%assume full depth involute

pressure_angle=20*pi/180;
module=4;
facewidth=30;
N_G=Rgbig*2/module; %teeth numbers
N_P=Rgsmall*2/module;
VR= N_G/N_P; %velocity ratio
HB= 300; %brinell hardness, range of aisi4130 (nitrided through hardened)
Qv=5; %assumed
N_cycle= Life_bearings_in_cycles; %for consistency

V_pitchline= pi*shaft2rpm*N_P*module*1e-3/60;
Wt=GearForce

Wt = 743.1059

St= 0.568*HB+83.8; %MPA, grade 1 for safety, fig14-3s

Sc= 1050; %MPA, table 14-6

YJ_P= 0.37; %fig14-6

YJ_G= 0.38; %almost the same, no need to further investigate gear as pinion will be more critic
ZI= 0.5*cos(pressure_angle)*sin(pressure_angle)*(VR/(VR+1));

B_forKv= 0.25*(12-Qv)^(2/3);
A_forKv= 50+56*(1-B_forKv);
Kv= ((A_forKv+sqrt(200*V_pitchline))/A_forKv)^B_forKv;

ZE= 191; %sqrtMPA, table 14-8

Ko= 1.25; %uniform source, medium shock application
ZR=1;
Ks=1;
KH=1; %not applicable as gear is not between bearings

7
ZW=1; %same material gears

YN= 1.6831*N_cycle^(-0.0323); %fig 14-14 safe approach

ZN= 2.466*N_cycle^(-0.056); %fig 14-15 safe approach

YZ= 1.25; %for 99.9% reliability, table 14-10

Y0=1;
KB=1;

%agma stresses for pinion (critical)

sigma_bending= Wt*Ko*Kv*Ks*KH*KB/(facewidth*module*YJ_P)

sigma_bending = 22.5537

sigma_contact= ZE*sqrt(Wt*Ko*Kv*Ks*KH*ZR/(2*Rgsmall*facewidth*ZI))

sigma_contact = 490.4716

sigma_bending_allowable=St*YN/(Y0*YZ)

sigma_bending_allowable = 192.3697

sigma_contact_allowable=Sc*ZN*ZW/(Y0*YZ)

sigma_contact_allowable = 762.8197

safetyfactor_bending= sigma_bending_allowable/sigma_bending

safetyfactor_bending = 8.5294

safetyfactor_contact= sigma_contact_allowable/sigma_contact

safetyfactor_contact = 1.5553

safetyfactor_gears=min([safetyfactor_contact, safetyfactor_bending])

safetyfactor_gears = 1.5553

fprintf("\nThe safety factor of the spur gears are: %.1f .\n",safetyfactor_gears)

The safety factor of the spur gears are: 1.6 .

%%%%%%%%%%%%%%%%%%%%% WORM GEAR CIVATA %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

% M8 Bolt %
% Nominal Major Diameter : 8 mm %

8
% Assumption - Fine-Pitch Series : pitch : 1 mm (Table 8.1) %
% Tensile Stress Area : 39.2 mm^2 (Table 8.1) %
% Square Thread %
% Assumption - Property Class:4.6 (Table 8.11)(safe approach)(en dandik) %
% Min Proof Strngth : 225 MPa, Min Tensile Strngth : 400 MPa (Table 8.11)%
% Min Yield Strength : 240 MPa (Table 8.11)%
% Since there's no shear stress, by using Yielding Theory ; %
n = 25; % factor of safety(assumption) %
YS = 240 ;
A = 39.2 ;
if (YS/n)*A > WormBoltForce_2
fprintf("\nWORM GEARBOX BOLTS OK FOR SAFETY FACTOR OF %.0f",n) ;
else
fprintf("\nWORM GEARBOX BOLTS FAIL FOR SAFETY FACTOR OF %.0f",n) ;
end

WORM GEARBOX BOLTS OK FOR SAFETY FACTOR OF 25

%%%%%%%%%%%%%%%%%%%%% SHREDDER UNIT SIDE CIVATA %%%%%%%%%%%%%%%%%%%

% M6 Bolt %
% Nominal Major Diameter : 6 mm %
% Coarse-Pitch Series : pitch : 1 mm (Table 8.1) %
% Tensile Stress Area : 20.1 mm^2 (Table 8.1) %
% Square Thread %
% Assumption - Property Class:4.6 (Table 8.11)(safe approach)(en dandik) %
% Min Proof Strngth : 225 MPa, Min Tensile Strngth : 400 MPa (Table 8.11)%
% Min Yield Strength : 240 MPa (Table 8.11)%
% by using Maximum Shear Stress Theory (tek yönlü shear var sadece); %
n = 25; % factor of safety(assumption) %
YS = 240;
YS_s = 0.5 * YS; % yield strength in shear %
A = pi*(3*3) ;
Tmax = (shredderUnit_sideBoltForce2/A)/2 ; %(eqn 5.1)%
if (YS_s/n) > Tmax
fprintf("\nSHREDDER UNIT SIDE BOLTS OK FOR SAFETY FACTOR OF %.0f",n) ;
else
fprintf("\nSHREDDER UNIT SIDE BOLTS FAIL FOR SAFETY FACTOR OF %.0f",n) ;
end

SHREDDER UNIT SIDE BOLTS OK FOR SAFETY FACTOR OF 25

%%%%%%%%%%%%%%%%%%%%% SHREDDER UNIT BRACKET CIVATA %%%%%%%%%%%%%%%%%%%

% M6 Bolt %
% Nominal Major Diameter : 6 mm %
% Coarse-Pitch Series : pitch : 1 mm (Table 8.1) %
% Tensile Stress Area : 20.1 mm^2 (Table 8.1) %

9
% Square Thread %
% Assumption - Property Class:4.6 (Table 8.11)(safe approach)(en dandik) %
% Min Proof Strngth : 225 MPa, Min Tensile Strngth : 400 MPa (Table 8.11)%
% Min Yield Strength : 240 MPa (Table 8.11)%
% by using Yielding Theory (tensile stress var sadece); %

n = 25; % factor of safety(assumption) %

YS = 240 ;
A = 20.1 ;
if (YS/n)*A > shredderunit_bracketboltForce
fprintf("\nSHREDDER UNIT BRACKET BOLTS OK FOR SAFETY FACTOR OF %.0f",n) ;
else
fprintf("\nSHREDDER UNIT BRACKET BOLTS FAIL FOR SAFETY FACTOR OF %.0f",n) ;
end

SHREDDER UNIT BRACKET BOLTS OK FOR SAFETY FACTOR OF 25

%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% DEHUMIDIFIER CALCULATIONS %%%%%%%%%%%%%%%%%%%%%%%%

U = 3; %Air speed by fan[m/s]

d_fan = 0.12; %Diameter of the fan [m]
A = pi*(d_fan/2)^2; %Area of the fan [m^2]
rho_air = 1.21; %Density of the air [kg/m^3]
m_dot = rho_air*A*U; %mass flow rate of air [kg/s]
T_amb = 22; %Ambient Temperature is at 22 degree C
T_desired = 50; % Desired Temperature is at 50 degree C%
c_p = 1.004;
V_output = 12; %Voltage given by by power converter [V]

%Calculations
q = m_dot*c_p*(T_desired-T_amb) %Required power output [W]

q = 1.1541

R = V_output^2/q %Resistance of the Resistor [Ohm]

R = 124.7705

I = V_output/R %Current that the resistor gets [A]

I = 0.0962

10