CHAPTER SIX

DESIGN CALCULATION

6.1 DESIGN CONSIDERATION

235/70 R16 tire will be used for design calculation

6.2: MACHINE PARTS

I. Cutting blades
II. Spacer
III. Shafts
IV. Spur gear
V. Coupling
VI. Gear box

6.3; ESTIMATION OF MAXIMUM SHREDDING FORCE

Tire profile consist of rubber material and steel wire. For estimation of shredding force parameter
of steel wire will be used because Steel wire in tires has a tensile strength of 1,500–2,000 MPa,
~50–100× higher than tire rubber (10–30 MPa). Since steel reinforcement dominates tire
structural integrity, shredding force calculations must prioritize steel’s properties.

I. Physical properties for wire in 235/70 R16 tire

 Average wire diameter =0.259mm
 Stress of wire=1388.54MPa
 Approximate number of steel wire cable=64
Source: (Edison O.Arguello, 2024)

II. Cross section area of steel wire (A)

2
A=π r ………………………..equation 01

A=π X0.12952

A=0.052685294 mm2

Cross section area of steel wire =0.052685294 mm2

III. Total force for 64 steel wires (F)

F=64 ∂ A …………………………….equation 02

Where
  ∂ =stress of wire
 A=cross section area

F=64X0.052685294 mm2X1388.54MPa

F=4681.960858N

Shredding force (F)= 4681.960858N

There is shear cut of 2 blades at time

Ftotal=4681.960858N X2

Ftotal =9363.92 N

6.4: DETERMINATION MOTOR TORQUE OF FORCE

Recall,

T=FXd …………………..equation 03

Where ;

 T=motor torque
 F= shredding force
 d= distance from the shaft to blade tooth
let distance from shaft to blade tooth = 80mm

T=9363.92 N X0.08m

T=749.1136NM

Therefore motor torque of force =749.1136NM

6.5: DETERMINATION OF MOTOR -GEAR BOX POWER

Recall

P=Tw ………………………….equation 04

Where ;

 P= power of motor
 T=torque of force
 W=gear box output speed
Gear box output speed =30rpm
Now ;

2 π x 30 rpm
P=749.1136NMX
60

P=2.3534Kw

Power required = 2.3534 KW

6.6 SHREDING BLADE DESIGN

Estimation of number of blades

For this machine let ;

total length for spacer and blades =300mm

blade thickness =5mm

spacer thickness= 3 mm

recall ;

total shaft length

number of blade= …………………….equation 05
blade thickness+ spacer thickness

300 mm
number of blade =
3 mm+5 Mm

number of blades =25 blade

number of blades per shaft =25total blades required =50blade

material selection of blade and space

selected material :A36 (structural steel)

6.7;DESIGN OF SPUR GEAR

6.7.1 Specifying gear geometry

I. Pressure angle(ф) =20° (involute teeth)

II. estimation of Pitch circle diameter of spur gear

initial parameters

 distance from axis of shaft to blade tooth=80mm

 spacer diameter =50mm
 clearance between spacer and blade =2mm
minimum PCD of the two mating spur gears while ensuring no collision

PCD=(80mm+2)X2…………………equation 06

PCD=164mm

Therefore pitch circle diameter for spur gear =164mm

III. Selection of number of teeth

According to (l.m, 2004) the number of teeth in the pinion is a critical design decision because
the size of the system depends on this value. Ensure against interference. An initial trial value of
NP = 17 to 20 is often a good choice.

N=20 teeth ,

Selected number of teeth is 20 teeth

IV. Determination of module of gear (m)

Recall ;

PCD
m= ………………….equation 07
N

m=164mm/20

m=8.2mm

therefore module for spur gear =8mm or diametral pitch Pd=3 per inch

V. Nominal face width

Recall ;

12
face width ( w )= …………………..equation 08
pd

W=12/3

W=4inch=100mm

Therefore norminal face width is 100mm

VI. Summary of spur gear design specifications

• Pressure angle(ф) =20° (involute gear )

 • diametral pitch pd=3,module=8mm

• number of teeth = 20 teeth

• norminal face width= 50mm

• Pitch circle diameter is 164mm

6.7.2 forces acting on spur gear

I. initial data
 power of motor P=2.3534 KW
 torque of force on shredding shaft T=749.1136NM

II. tangential force (wt)

recall;
T
w t= …………………………equation 09
r
749.1136 NM
w t=
164 mm
Tangential force =4567.77N

III. radial force (wr)

recall;

w r=wt tan θ………equation 10

wr=4567.77N Xtan20°

wr=1662.53 N

IV. therefore radial force is

1662.53N normal force (wN)

recall
w n=√ ¿ ¿……………………….equation 11
Wn=√(1662.53 N 2+4567.77N 2)

Wn=4860.92N

V. Summary of forces acting on each spur gear

 tangential force = 4567.77N

 radial force = 1662.53N
  normal force = 4860.92N

6.7.3 material selection for gear

material selected :SAE 4140 (alloy steel)

reasons;

• High strength
• Suitable wear resistance

6.7.4 Gear teeth feature

I. Addendum
Recall
a=1m ………………………………….equation 11
a=1x8mm
therefore addendum =8 mm
II. dedendum
recall;
b=1.25m …………………………………equation 12
b=1.25x8mm
b=10 mm
therefore dedendum =10 mm
III. working depth (d)
recall;
d=2m ……………………………………..equation 13
d=2X8mm
d=16mm
therefore working depth = 16mm
IV. tooth thickness (t)
recall;
t=1.5708m……………………………………equation 14
t=1.5708X8
t=12.5664mm
V. minimum clearance ( C)
recall;
c= 0.25m ………………………………equation 15
c= 0.25x8mm
c=2mm
VI. fillet radius root
recall ;
r=0.4m…………………………………….equation 16
r=0.4 X8mm
r=1mm
therefore fillet radius root =3.2mm
6.8 DESIGN OF SHAFT
I. Initial data
 Torque of force of shaft =749.1136Nm
 Rotation speed of shaft =30rpm
II. Material selection

Material for shaft :SAE1144 0QT steel

 Properties of steel for shaft

 Tensile strength (Sy) =113ksi=779MPa
 Yield strength (Su)=87ksi=600MPa
 Percentage elongation =19%
Thus, material has good ductility

III. estimation of modified endurance strength

 Estimating initial endurance strength of shaft

Estimated endurance strength =180MPa from below

 Estimating size factor of shaft

Since shaft will be used to transmit power of 2.44kw therefore small diameter shaft will be used

Estimated size factor Cs=0.95 from appendix C

  Estimating reliability factor
Estimated reliability factor CR=0.75 ,means that only 0.1% shaft is likely to fail

Determining of modified endurance strength

Recall;
˙ =SNX CRXCS………………………………………….equation 18
SN
˙ =180MPa X 0.75X 0.95
SN
˙ =124.2MPa
SN

Therefore modified endurance strength = 124.2 Mpa

IV. Arrangement of machine element on shaft and free body diagram

Effective force due to cutting blade=4881.96N located along length of 500mm

Effective force due to spur gear ( normal force 0 = 4860.92N

Figure 6.1 : arrangement of machine element on shaft and location of forces acting shaft

V. Determination of reactions at bearing A and B

Sum of vertical forces is equal to zero

RA+ RB+ 4881.96N =4860.92 N + 4860.92 N

RA+ RB= 4839.88N ………………………….equation 19

Consider total moment at bearing A , let clockwise moment is postive and anti -clockwise
moment to be negative

Now ;

4860.92x 350mm=4881.96x150mm+ 300mmRB+4860.92x10mm

RB=3068.06 N …………………………..equation 20

Then ; RA= 4839.88N-RB = 4839.88N-3068.06 N

RA= 1771.82N

Therefore ;
 reaction at bearing A = 1771.82N
 Reaction at bearing B =3068.06 N
VI. Shear force and bending moment diagram

Figure 6.2 :showing resultant shear force and bending moment diagram

Bending moment at the following points

 At spur gear A=48.6Nm=430.15 lbin

  At bearing A=57.7Nm=510.69lbin
 At center of blade = 1082Nm=9576.51 lbin
 At bearing B=137.87Nm =1220.25 lbin
 At spur gear B= 437.48NMm =3872.02 lbin
VII. Determination of diameters of shaft at each machine element

Recall formula for diameter of shafter ;

Recall

[ √( ) ( ) ] ………. In inches ………………equation 21

1
2
32 N kt M 3 T 2 3
D= +
π ˙
SN 4 SY

Where

 D=diameter
 N=design factor =2
 Kt=stress concentration factor
 ˙ =modified endurance strength =124.2 MPa= 18.014Ksi
SN
 T=torque force =749.1136NM=6630.214lbin
 Sy=tensile strength =779MPa =112.98KSi
 Diameter of shaft at spur gear A

Kt=1.5 (profile key seat )

[ √( )]
1

) (
2 2 3
32 x 2 1.5 x 430.15 lbin 3 6630.214 lbin
D= +
π 18.014 ksi 4 112.98 ksi

D=1.08 in =27.432 mm

 Diameter of shaft at spur gear B

Kt=1.5 (profile key seat )

[ √( )]
1

) (
2 2 3
32 x 2 1.5 x 1220.25 bin 3 6630.214 lbin
D= +
π 18.014 ksi 4 112.98 ksi

D=2.09890440267in =53.31mm
  Diameter of shaft at blade and spacers

Kt=1.5 (

[ √( )]
1

) (
2 2 3
32 x 2 1.5 x 9576.51 bin 3 6630.214 lbin
D= +
π 18.014 ksi 4 112.98 ksi

D=2.53434796042 in=64.37 mm

Diameter of shaft at bearing A

Kt=1.5

[ √( )]
1

) (
2 2 3
32 x 2 1.5 x 510.69 bin 3 6630.214 lbin
D= +
π 18.014 ksi 4 112.98 ksi

D=1.10520174601in=28.07 mm

 Diameter of shaft at bearing B

[ √( )]
1

) (
1.5 x 3872.02 bin 2 3 6630.214 lbin 2 3
32 x 2
D= +
π 18.014 ksi 4 112.98 ksi

D=1.8804398431 in=47.76mm

Note ; economically let diameter of shaft at bearing A be equal to diameter at bearing B

=47.76mm and diameter of shaft at spur gear A be equal to diameter of spear B =53.31 mm

VIII. Adjusting diameter of shaft based on bearing standard diameter

Calculated diameter Standard bearing diameter Element at point

27.43mm 54mm Spur gear A

53.31 mm 54mm Spur gear B

64.37mm 65mm Blades

28.08mm 55mm Bearing A

47.76mm 55mm Bearing B

6.9 : SELECTION OF BEARING :RADIAL LOAD ONLY

I. Initial data
 Shaft rotation speed =30rpm
  Shaft diameter at both bearing =50mm
II. Acceptable radial loads
 For bearing A:RA= 1771.82N
 For bearing B:RB=3068.06N
Since radial force for bearing B is greater than that of A for selection of bearing radial force of
3068.06 =689.73lbf is used

III. Specifying design load (P)

P=RXV

Where

 R=acceptable radial load

 V =rotation factor
for this load it a pure radial load and the inner race is to be pressed onto the shaft and rotate with
it. Therefore, the factor V = 1.0

then

P=R

IV. Selection of type of bearing

Type of bearing selected : single-row, deep-groove ball bearing

V. Selection of bearing life

From the appendix xx

Selected design bearing life :9000h

min
Then , Ld =hN ( rpm ) X 60 ( )
h

min
Ld =9000 hx 30 rpmX 60( )
h

Ld=1.62 x107

VI. Determination of dynamic loading rating

 1
Ld k
Recall C=Pd X ( 6
)
10

Where ;

Pd=689.73lbf

K=3 for ball bearing

6 1
1.62 x 10 3
C=689.73 lbf ( 6
)
10

C=810.06

VII. Summary of selected bearing

The following is selected bearing

 Bearing number :6010

 Bore diameter =50mm
 Outside diameter =80mm
 Maximum fillet radius =1mm
 Width =16mm
 Maximum housing shoulder diameter =75mm
 Bearing mass =0.26 kg
 Bearing Housing: Plummer Block (Pillow Block) Housing= P210[SKF standandrds]
 Recommended Lubrication System: Grease Lubrication

6.10 SELECTION OF GEAR BOX

I. Define service factor

Shredders experience shock loads and operating hours let be 3- 10 hours ,to ensure durability
selected service factor is 1.75

Adjusted Power=2.3534kW×1.75=4.047848kW(5.43HP)
 II. Defining stage of speed reduction ,Gear ratio and output shaft speed

Output shaft rotation speed:30rpm

Gear ratio( i)

Recall

motor RPM
i=
output shaft RPM

1440 rpm
i=
30 rpm

i=48:1

Suitable Gearbox Types:

 Helical Gearbox
 Worm Gearbox
 Helical-Worm Gearbox
stages of reduction ;

 Option 1: Two-stage helical gearbox (e.g., 6:1 + 8:1 = 48:1).

 Option 2: Single-stage worm gearbox (direct 48:1 ratio).
III. Gearbox type selection

parameter Helical gearbox Worm gearbox

Efficiency 95% 60-70%

Shock load Excellent Moderate

Size Large compact

Cost Higher Lower

Recommendations

Helical gearbox is best choice due to high efficiency, durability, and shock-load resistance.

Gearbox-Motor Compatibility
Motor Requirements:

 Power: 3.53 kW (to meet SF-adjusted load).

 Speed: 1440 RPM (standard 4-pole motor).
 Mounting: Foot-mounted (B5)
Environmental and Lubrication Requirements

 Housing: Cast iron with corrosion-resistant paint (for industrial environments).

 Lubrication: Pre-filled with synthetic oil (ISO VG 220) for high torque and thermal
stability.
 Seals: Double-lip seals to prevent debris ingress
IV. Summary of selected gearbox type
 Type: Two-Stage Helical Gearbox
 Ratio: 48:1
 Input power: 4.047848kW(5.43HP)
 Input speed: 1440 rpm
 Output speed :30rpm
 Output torque : 800Nm(10% safety margin)
 Backlash : ≥10 arcmin
 Mounting : Foot-mounted (B5)
 Model:S87 DRN100L4 BMG HR [ based on SEW-EURODRIVE standard]
6.11 DESIGN OF COUPLING

I. Selection of type of coupling

Type of coupling selected :flange coupling

II. Material for coupling

Selected material: cast iron

III. Specifying features of coupling

Consider sketch below

 Figure 6.3: parameters of flange coupling

IV. Specifying number of bolts

Number of bolts=4 bolts

V. Shaft diameter

d=55mm

VI. determination of outside diameter of hub (D)

recall;

D=2d

D=2x55mm

D=110mm

VII. Determination length of hub (L)

Recall

L=1.5d
 L=1.5x55mm

L=82.5mm

VIII. Determination of pitch circle diameter of bolt (D1)

Recall;

D1=3d

D1=3x55mm

D1=165mm

IX. Determination of outside diameter of flange (D2)

Recall

D2=4d

D2=4x55mm

D2=220mm

X. Determination of thickness of flange (Tf)

Recall

Tf=0.5d

Tf=0.5x55mm

Tf =27.5mm

XI. Design of bolts for flange coupling

XII. Design of key for flange coupling

6.12 DESIGN OF KEY BETWEEN SHAFT AND SPUR GEAR

Data given
  Material for shaft = SAE1144 0QT steel(sy=600MPa)

 Material for spur gear = alloy steel,SAE 4140 (sy=372Mpa )

 Shaft diameter=55mm

 Torque transmitted =749.1136NM

I. Material selection for key

Selected material for key =SAE 1018 (441MPA)

Material for spur has lowest strength ;248.1MPA<441MPa<600MPa

II. Selection of width and heigh of key

From appendix C ; selected width=16mm and selected height =10mm

III. Determination of length of key

Since pulley is weakest part ,then length of key is given as

4T
Lmin =
∂d DH

Where

 T=torque transmitted by shaft

 D=shaft diameter
 H=height of shaft

∂ d=design stress for compression =sy/N

Now

∂ d= sy/N; N =design factor for key =3

∂ d= 441MPa/3

∂ d= 147MPa

Now

4 X 749.1136 NM
Lmin =
147 MPaX 0. 5 5 X 0.0 1
Lmin =0.003706

Lmin=3.706mm

Minimum key length =3.706mm ,let specify to be 15mm

IV. Determination of key way height (Y)

Consider figure below ;

Recall ;

D− √(D 2−W 2 )
y=
2

55−√(55 −16 )
2 2
Y=
2

Y=1.2mm

Minimum key way height =1.2mm

V. Determination of key seat depth (d)

Consider figure below

Recall;

S=D-y-H/2

S=55mm-1.2mm-10mm/2

S=48.8mm
d=55mm-48.8mm

d=6.2mm

therefore minimum keyseat depth =6.2 mm

determination of key fillet radius

H/2=5mm =0.196in

Selected fillet radius from appendix C =1/32in =0.79375mm

VI. Summary of key design

 Type :rectangular key ( profile key )

 Height :10mm

 Width:16mm

 Length :15mm

 Key way height :1.2mm

 Key seat height:6.8mm

 Material for key :SAE 1018

 Fillet radius : 0.79375mm

 APPENDIX

APPEND A

Endurance limit modified for surface condition

Size factor
APPENDIX B

Bearing life

Dimensions for Single Row, Deep-groove Ball Bearings

APPENDIX C

Number of bolts for marine type flange coupling. [According to IS : 3653 – 1966 (Reaffirmed
1990)

Key Size vs. Shaft Diameter

Fillet Radii and Key Chamfers