Department of MechanicaI and Design

Engineering

Engineering Design 2 2010/11

Unit reference: MED2 (U10396B)

4:rsew4rk: Marine Transmission

Hand in DeadIine: Week 10, Wednesday 11
th
May, 3.30 pm

Examiner: Dr Andrew LittIe

$:-mitted -y: Gro:p n:m-er 22

1. Kyriako:, Konstantinos 3. AI HaiIa, A-d:Iaziz
2. AIhar-i, Fawaz $ 4. Vargas G:tierrez, NataIy





Contents
CompIete the ta-Ie after finishing the report.

$ection TitIe Prepared -y Pages
1. Introd:ction
1.1 The sc45e 4f w4rk
1.2 Descri5ti4n 4f machine elements in a gearb4
2. Design Data
2.1 Basic Design Data
2.2 Additi4nal Data & Ass:m5ti4ns
3. Concept:aI Design
4. Design CaIc:Iations
4.1
4.2
5. Selecti4n 4f Machine elements
6. Limits and Fits
7. Design S:mmary f4rm
8. References
9. Drawings




























1. Introd:ction

1.1 The scope of work

n this c4:rse w4rk the design 4f a Marine transmissi4n is 5resented in detail.
This w4rk is aiming t4 5resent the design a55r4ach t4 machine transmissi4n
elements taking int4 c4nsiderati4n the availability 4f standard c4m54nents in the
market and the c4st im5licati4ns in selecting the 5r45er materials and 5arts f4r a c4st
effective man:fact:re.
n additi4n, in this c4:rse w4rk engineering kn4wledge and e5erience fr4m 4ther
:nits 4f st:dies are c4mbined in an eff4rt t4 5resent a c4m5rehensive design w4rk
al4ng with c4nstr:cti4n drawings t4 BS8888.
The basic design data and ass:m5ti4ns are 5resented in secti4n 2. n secti4n 3 the
c4nce5t:al design is intr4d:ced giving a clear 5ict:re 4f the seq:ence 4f tasks that
will be :ndertaken in 4rder t4 finalise the design w4rk. All calc:lati4ns related t4 the
main elements are detailed in secti4n 4. n t:rn, the individ:al machines elements are
selected 4n the basis 4f the w4rk 5resented in 5revi4:s secti4ns and taking int4
acc4:nt the c4nce5t 4f c4st effective man:fact:re. n secti4n 6 the fits and limits 4f
the gearb4 assembly are identified and in secti4n 7 the detail c4nstr:cti4n drawings
with views and secti4ns as well as a c4m5rehensive list 4f 5arts are ill:strated.


1.2 Description of machine eIements in a gear-ox

Gear-ox.
A transmission 4r gear-ox 5r4vides s5eed and t4rq:e c4nversi4ns fr4m a r4tating
54wer s4:rce t4 an4ther device :sing gear rati4s. n British English the term
transmissi4n refers t4 the wh4le drive train, incl:ding gearb4, cl:tch, 5r45 shaft (f4r
rear-wheel drive), differential and final drive shafts. n American English, h4wever,
the distincti4n is made that a gearb4 is any device which c4nverts s5eed and
t4rq:e, whereas a transmissi4n is a ty5e 4f gearb4 that can be "shifted" t4
dynamically change the s5eed: t4rq:e rati4, s:ch as in a vehicle. The m4st c4mm4n
:se is in m4t4r vehicles, where the transmissi4n ada5ts the 4:t5:t 4f the internal
c4mb:sti4n engine t4 the drive wheels. S:ch engines need t4 45erate at a relatively
high r4tati4nal s5eed, which is ina55r45riate f4r starting, st455ing, and sl4wer travel.
The transmissi4n red:ces the higher engine s5eed t4 the sl4wer wheel s5eed,
increasing t4rq:e in the 5r4cess. Transmissi4ns are als4 :sed 4n 5edal bicycles,
fied machines, and anywhere else r4tati4nal s5eed and t4rq:e needs t4 be ada5ted.
Often, a transmissi4n will have m:lti5le gear rati4s (4r sim5ly "gears"), with the ability
t4 switch between them as s5eed varies. This switching may be d4ne man:ally (by
the 45erat4r), 4r a:t4matically. Directi4nal (f4rward and reverse) c4ntr4l may als4 be
5r4vided. Single-rati4 transmissi4ns als4 eist, which sim5ly change the s5eed and
t4rq:e (and s4metimes directi4n) 4f m4t4r 4:t5:t.
n m4t4r vehicle a55licati4ns, the transmissi4n will generally be c4nnected t4 the
crankshaft 4f the engine. The 4:t5:t 4f the transmissi4n is transmitted via driveshaft
t4 4ne 4r m4re differentials, which in t:rn drive the wheels. While a differential may
als4 5r4vide gear red:cti4n, its 5rimary 5:r54se is t4 change the directi4n 4f r4tati4n.
4nventi4nal gear/belt transmissi4ns are n4t the 4nly mechanism f4r s5eed/t4rq:e
ada5tati4n. Alternative mechanisms incl:de t4rq:e c4nverters and 54wer

transf4rmati4n (e.g., diesel-electric transmissi4n, hydra:lic drive system, etc.). Hybrid
c4nfig:rati4ns als4 eist.

$hafts
A drive shaft, driving shaft, propeIIer shaft, 4r Cardan shaft is a mechanical
device f4r transferring 54wer fr4m the engine 4r m4t4r t4 the 54int where :sef:l w4rk
is a55lied. M4st engines 4r m4t4rs deliver 54wer as t4rq:e thr4:gh r4tary m4ti4n:
this is etracted fr4m the linear m4ti4n 4f 5ist4ns in a reci5r4cating engine; water
driving a water wheel; 4r f4rced gas 4r water in a t:rbine. Fr4m the 54int 4f delivery,
the c4m54nents 4f 54wer transmissi4n f4rm the drive train.
Drive shafts are carriers 4f t4rq:e: they are s:bject t4 t4rsi4n and shear stress, which
re5resents the difference between the in5:t f4rce and the l4ad. They th:s need t4 be
str4ng en4:gh t4 bear the stress, with4:t im54sing t44 great an additi4nal inertia by
virt:e 4f the weight 4f the shaft.





$p:r gears
The s5:r gear is the sim5lest ty5e 4f gear man:fact:red and is generally :sed f4r
transmissi4n 4f r4tary m4ti4n between 5arallel shafts. The s5:r gear is the first
ch4ice 45ti4n f4r gears ece5t when high s5eeds, l4ads, and rati4s direct t4wards
4ther 45ti4ns. Other gear ty5es may als4 be 5referred t4 5r4vide m4re silent l4w-

vibrati4n 45erati4n. A single s5:r gear is generally selected t4 have a rati4 range 4f
between 1:1 and 1:6 with a 5itch line vel4city :5 t4 25 m/s. The s5:r gear has an
45erating efficiency 4f 98-99%. The 5ini4n is made fr4m a harder material than the
wheel. A gear 5air sh4:ld be selected t4 have the highest n:mber 4f teeth c4nsistent
with a s:itable safety margin in strength and wear. The minim:m n:mber 4f teeth
4n a gear with a n4rmal 5ress:re angle 4f 20 degrees is 18.


The standard n:mber 4f teeth in a s4:r gear is as f4ll4ws

P:IIeys & BeIts
A p:IIey, als4 called a sheave 4r a dr:m, is a mechanism c4m54sed 4f a wheel 4n
an ale 4r shaft that may have a gr44ve between tw4 flanges ar4:nd its
circ:mference. A r45e, cable, belt, 4r chain :s:ally r:ns 4ver the wheel and inside
the gr44ve, if 5resent. P:lleys are :sed t4 change the directi4n 4f an a55lied f4rce,
transmit r4tati4nal m4ti4n, 4r realize a mechanical advantage in either a linear 4r
r4tati4nal system 4f m4ti4n. Tw4 4r m4re 5:lleys t4gether are called a bl4ck and
tackle.

Bearings
A -earing is a device t4 all4w c4nstrained relative m4ti4n between tw4 4r m4re
5arts, ty5ically r4tati4n 4r linear m4vement. Bearings may be classified br4adly
acc4rding t4 the m4ti4ns they all4w and acc4rding t4 their 5rinci5le 4f 45erati4n as
12,13,14,15,16,18, 20, 22, 24, 25, 28, 30, 32, 34,38, 40, 45, 50, 54, 60,64, 70, 72,
75, 80, 84, 90, 96, 100, 120, 140,150,180, 200, 220, 250

well as by the directi4ns 4f a55lied l4ads they can handle. n the 5resent w4rk the
sim5lest ty5e 4f bearings, ball bearings, are :sed.

Keys and keyways
n mechanical engineering, a key is a machine element :sed t4 c4nnect a r4tating
machine element t4 a shaft. Thr4:gh this c4nnecti4n the key 5revents relative
r4tati4n between the tw4 5arts and all4ws t4rq:e t4 be transmitted thr4:gh. F4r a key
t4 f:ncti4n the shaft and r4tating machine element m:st have a keyway, als4 kn4wn
as a keyseat, which is a sl4t 4r 54cket f4r the key t4 fit in. The wh4le system is called
a keyed joint. A keyed j4int still all4ws relative aial m4vement between the 5arts.



L:-rication
L:-rication is the 5r4cess, 4r techniq:e em5l4yed t4 red:ce wear 4f 4ne 4r b4th
s:rfaces in cl4se 5r4imity, and m4ving relative t4 each an4ther, by inter54sing a
s:bstance called l:bricant between the s:rfaces t4 carry 4r t4 hel5 carry the l4ad
(5ress:re generated) between the 4554sing s:rfaces. The inter54sed l:bricant film
can be a s4lid, (e.g. gra5hite, M4S
2
)
[1]
a s4lid/liq:id dis5ersi4n, a liq:id, a liq:id-liq:id
dis5ersi4n gasses ece5ti4nally a gas.
n the m4st c4mm4n case the a55lied l4ad is carried by 5ress:re generated within
the fl:id d:e t4 the fricti4nal visc4:s resistance t4 m4ti4n 4f the l:bricating fl:id
between the s:rfaces.
Adeq:ate l:bricati4n all4ws sm44th c4ntin:4:s 45erati4n 4f eq:i5ment, with 4nly
mild wear, and with4:t ecessive stresses 4r seiz:res at bearings. When l:bricati4n

breaks d4wn, metal 4r 4ther c4m54nents can r:b destr:ctively 4ver each 4ther,
ca:sing destr:ctive damage, heat, and fail:re.

$haft seaIing
Radial shaft seals are :sed t4 seal r4tary elements, s:ch as a shaft 4r r4tating b4re.
4mm4n eam5les incl:de str:t seals, hydra:lic 5:m5s seals, ale seals and 54wer
steering seals. Early radial shaft seals :tilized rawhide as the sealing element. The
advent 4f m4dern elast4mers re5laced rawhide, ind:stry als4 added a garter s5ring
which hel5s the sealing li5 c4m5ensate f4r li5 wear and elast4mer material changes.
The seal c4nstr:cti4n will c4nsist 4f a s5r:ng main sealing li5 which has a 54int
c4ntact with the shaft. The 54int c4ntact is f4rmed by tw4 angles, with the air side
angle :s:ally less than the 4il side angle. The shall4wer the sl45e 4n the 4il side 4f
the seal the wetter the seal will r:n. The s5ring is 54siti4ned s:ch that aially the
centerline 4f the s5ring is biased t4 the air side 4f the li5 c4ntact 54int.


CircIips
The cli5s are kn4wn as wrist 5in cli5s 4r wrist 5in retainers when :sed t4 retain 5ist4n
wrist 5ins. The m4st c4mm4nly :sed circli5 f4r this a55licati4n is a sim5le s5ring steel
sna5 ring, 4r 5lain wire ring.
4mm4n eam5les incl:de "E-cli5s" (e-ring) and the (b4th internal and eternal)
sna5 ring 4r circli5. This general ty5e 4f fasteners are sized t4 5r4vide an
interference fit 4nt4 (4r int4, in the case 4f an internal fastener) a gr44ve 4r land
when in :se, s:ch that they m:st be elastically def4rmed in 4rder t4 install 4r rem4ve
them.





2. Design Data

2.1 Basic Design Data
A drive train is needed t4 5r4vide a 54wer fr4m an engine t4 a 54wer shaft and
alternat4r. The design val:es are:

$peed
increase
Inp:t
Power
kW
Inp:t
$peed
r5m
AIternator
Power
kW
AIternator
speed
r5m
BeIt
AngIe
degrees
RATO PWR

AltPwr
ALT
d
2 30 850 5 1100 20









































T
D

u
ROTATO
VIEW ON ARROW "A"

A
# 2

0mm
BELT (TO SMALL
ALTERATOR)
BELT (TO SMALL
ALTERATOR)
VIEW ON $IDE OF GEARBOX
(ELEVATION)

BASE OF
GEARBOX
OETO TO
LOAD (OUTPUT
SHAFT)
# 1

OETO
TO EGE
(PUT SHAFT)
BELT (TO SMALL
ALTERATOR)
ETRE LE OF GEARS
4m
m
4m
m



2.2 AdditionaI Data & Ass:mptions

GEARBOX
O 4 req:irements f4r ne:tral 4r reverse gear.
O n5:t and 4:t5:t c4nnecti4ns t4 be made by 4thers.
O P4wer in5:t fr4m 3-cylinder engine.
O 4 l4sses thr4:gh the gear train.
O F4r assembly 5:r54ses the gearb4 is t4 be s5lit in the h4riz4ntal 5lane.
O M4:nting details 4f the gearb4 t4 be d4ne by 4thers. Only f4:r str4ng 54ints
(M16 wired thread inserts) 4n gearb4 casing are t4 be incl:ded in the 5resent
design.
O The transmissi4n is e5ected t4 last f4r 15 years and is t4 be 45erated f4r 250
days a year at an average 4f 6 hrs 5er day.
O Pr4visi4ns are t4 be made f4r l:bricati4n 4f the gearb4. Ass:ming n4 l4ses
thr4:gh the gear train.

ALTERNATOR DRIVE
O Alternat4r is belt driven :sing a Fenner wedge belt.
O enter distance between main drive 5:lley and alternat4r 5:lley t4 be 600-
800mm.
O Fenner belts and 5:lleys t4 be SPZ,SPA,SPB 4r SP series.
O The belt s5eed is relatively l4w s4 T

(Fenner n4tati4n) is taken as zer4.

O The radial l4ad 4n the shaft d:e t4 the belt T
D
is eq:al t4 the s:m 4f static
tensi4ns T
S
acting 4n the 5:lley (ie. T
D =
2 T
S
).
O The belt fact4r t4 be a55lied t4 T
D
shall be taken t4 be 1,0.

GEAR$
O Gear with 20
0
inv4l:te t44th 5r4file.
O Pini4n with at least 20 teeth.
O Gears t4 be attached 4nt4 the shaft by means 4f rectang:lar keys.
O Key material has a yield stress 4f 300MPa.
O Safety fact4r 4f 2.0 4n key material yield strength.
O Use HP catal4g:e f4r selecting gears.
O 4 c4st 5enalty in machining the D 4f gears t4 fit t4 the shaft diameter.
O Ma. yield stress in shear=0,5 4f direct yield stress.
O Direct yield stress=0,6 4f UTS (:sed f4r shaft sizing)
O UTS val:es are given in hand4:t sheets, HT gear catal4g:e and/4r 4ther
references.

INPUT AND OUTPUT $HAFT$
O Use ma. eq:ivalent t4rq:e TEQU' f4r the in5:t and 4:t5:t shaft calc:lati4ns
O A safety fact4r 4f 2,5 4n yield in shear is t4 be :sed f4r shaft calc:lati4ns.
O The self weight 4f the shaft and the gears are t4 be ign4red.

BEARING$
O The bearings are t4 be the dee5 gr44ve ball bearing ty5e fr4m SKF catal4g:e.
O Traditi4nal SO eq:ati4n f4r basic rating life is t4 be :sed f4r bearings
selecti4n.




Marine Transmission
Co:rsework -rief
review
Ta-:Iate design data
and ass:mptions
Research on gear-ox
:nits and reIevant
machine eIements
Design CaIc:Iations
Inp:t & O:tp:t $haft
sizes
Design CaIc:Iations
and seIection of
-earings
$eIection of aIternator
p:IIeys and -eIt(s)

Preparation of detaiI
drawings with parts Iist

Design CaIc:Iations
and seIection of gears

3. Concept:aI Design

On the basis 4f the design data and general descri5ti4n 4f the machine elements f4r
the marine 54wer transmissi4n system 5resented in the 5reviews secti4ns as well as
additi4nal inf4rmati4n and :nderstanding gained 4:t 4f the research fr4m vari4:s
references 5resented in secti4n 8 4f this re54rt a detail ste5 by ste5 design a55r4ach
has been established.
F4r ease 4f reference this c4nce5t:al design a55r4ach is 5resented herebel4w in
bl4ck diagram f4rmat.






































4. Design CaIc:Iations

4.1 Inp:t shaft caIc:Iations

H4riz4ntal f4rces 4n n5:t shaft
Th B
2





1

0.05 0.045 0.045

Th 1202.8 N
3601.5 N

Sheer f4rces 4n n5:t shaft

Moment
2

Th (0.14)
1
(0.090) (0.045) 0
1202.8 (0.14)
1
(0.090) - 3601.5 (0.045) 0

1

1202.8 (0.14) - 3601.5 (0.045)
0.090
70.27 N
Th
2

1

2

1
Th
3601.5 70.27 1202.8 2468.97 N












Bending m4ment 4n n5:t shaft








X 0 0

X 0.05 T
x
1202.9 0.05
60.14 N
X 0.95
T
x

1
(X 0.05) 60.14 70.27 (0.045) 9.18 N

B
1

B
2

G T
60.14
9.18
0
1202.8
- 2468.97
1132.53
T B
1

+
G B
2

-

X 0.14 T
x

1
(X 0.05) 6 (X 0.095) 0



'ertical f4rces 4n in5:t shaft
Tv


1

2



0.05 0.045 0.045
Tv 437078 N
1310.83 N
* Sheer Iorces
_ moment
2

Tv (0.14)
1
(0.090) (0.045) 0

1

437.78 (0.14)+ 1310.83 (0.045)
0.090
1336.4 N
Tv
1

2

2

1
Tv
1336.4 437.78 1310.83 412.21 N













Bending m4ment 4n n5:t shaft








X 0 0
X 0.5 Tx 437.78
X 0.05 21.889
X 0.095
Tx
1
(x 0.05) 21.889 898.62 (0.045) -18.54
X 0.14
Tx
1
(X 0.05) (X 0.095) 0






437.78
412.21
-898.62
+ +
-
Tv
B
1

B
2

G
B
1

B
2

G Tv
21.889
18.51

Res:ltant M4ment 4n n5:t shaft

1

2
+
2
(.)
2
+ (.889)
2

63.99 Nm

2
+
2
(9.8)
2
+(8.)
2

20.66 Nm













T4rq:e f4rces 4n n5:t shaft

T
T

510
3
89.01
56.173 Nm
T

2510
3
89.01
280.86 Nm
T

3010
3
89.01
337.04 Nm








Eq:ivalent T4rq:e f4rces 4n n5:t shaft

Tequ H
2
+
2

1T
(.99)
2
+(.)
2
85.147 Nm

T
(.)
2
+(.)
2
337.67 Nm
















56.173 Nm

280.86 Nm

B
1

B
2

G
Tv
63.99 Nm
20.66 Nm
B
1

B
2
G
T
56.173 Nm
85.147 Nm
337.67 Nm
337.04 Nm
B
1
B
2
G T


4.2 O:tp:t shaft caIc:Iations

H4riz4ntal f4rces 4n 4:t5:t shaft










Sheer f4rce 4n 4:t5:t shaft


_ Fh 0
Where
3r

4r

-2
r

3601.5
-2
1800.75 N










Bending M4ment 4n 4:t5:t shaft










X 0.045 Tx -1800.75 0.045 -81.03 N


'ertical F4rces 4n 4:t5:t shaft










3

3r

3r
0.045

0.045

3601.5




-
- 1800.75 N

1800.75 N

3
h

4
h

h
3

3r

3r
0.045

0.045

G 1310.83


-

3
h h
4
h
-81.03 N


Sheer F4rces 4n 4:t5:t shaft

_ Fh 0 where
3
r
4
r
-2
r


-1310.83
-2
655.415 N











Bending m4ment 4n 4:t5:t shaft










X 0.045 Tx 655.415 0.045
29.49 N


Res:ltant m4ments 4n 4:t5:t shaft

T
eqv
H
2
+
2

T
(8.)
2
+(9.9)
2
86.23 Nm














T4rq:e f4rces 4n 4:t5:t shaft

T

2510
3
178.02
140.43 Nm



-
- 655.415 N

655.415 N

3
h

4
h

h
+

3
h
h

4
h
29.49 N
+

3
h
h

4
h
86.23 Nm








Eq:ivalent t4rq:e f4rces 4n 4:t5:t shaft

T
eqv
H
2
+
2

T
(8.)
2
+(.)
2
164.79 Nm









4.3 Inp:t and O:tp:t $haft Diameters

Design Yield Stress

SaIety Iactor 2.5 as indicated in coursework instructions
y Max. Yield stress in shear 0.5 yield stress (direct)
y Yield stress 0.6 UTS 0.6 520 312 MPa
y 0.5 y 0.5 312 156 MPa


n5:t shaft minim:m diameter

d
min
1.1
16
n

1cqu maxsu]ct ]uctu
:
3

1.1
16
n

337.672.5
156 10
6
3
33.22 mm

O:t5:t minim:m shaft diameter

d
min
1.1
16
n

164.792.5
156 10
6
3
26.15 mm



140.43 Nm

4

164.79 Nm

3T

4T
140.43 Nm 140.43 Nm

T

4.4 Bearings caIc:Iations and seIection

Res:ltant Bearing L4ads n5:t Shaft

- earing (1):

1res

1
2
+
1h
2

(.)
2
+(.)
2
1338.24 N

- earing (2):

2res

2
2
+
2h
2

(.)
2
+(8.9)
2
2503.14 N

Res:ltant Bearing L4ads O:t5:t Shaft

- earing (3,4):

3,4res

3,4
2
+
3,4h
2

(.)
2
+ (8.)
2
1916.31 N

Bearing basic rating life

A rough method Ior estimating bearing liIe is to use the basic rating liIe equation according to
ISO 281:2007
L
10
(C/P)
p


Where
L
10
basic rating liIe (at 90 reliability) |millions oI revolutions|
C asic dynamic load rating |kN|
P quivalent dynamic bearing load |kN|
p xponent oI liIe equation 3 Ior ball bearings
N #otational speed |r/min|

L
10h
liIe in operating hours 15years x 250 days/year x 6h/day 22500 h
N
input
850 rpm , N
output
1700 rpm
Using the bearing monograph chart we deIine C/P and L
10
Ior ball bearings with respect to the
rotational speed N and liIe in operating hours L
10h


Bearings (1) & (2):

C
P
10.47
_
( 8

6
]
1
3

C
b1

C
P

1res
10.47 1338.28 14 KN
C
b2

C
P

2res
10.47 2503.14 26.2 KN





From SKF catalogue we can now select the appropriate bearings based on the calculated basic
dynamic load C and the minimum shaIt diameter (input shaIt diameter ~33.2mm and output
shaIt diameter ~26.15mm).
Selected bearings are:
For 1: 6007 with internal diameter oI 35mm and external diameter oI 62mm and a thickness
oI 14mm.
Despite oI the lower dymanic load to 2 compared to 1 we select the same bearing in order
to have uniIormity.For 2 : 6207 with internal diameter oI 35mm and external diameter oI
72mm and a thickness oI 17mm.
Bearing (3) & (4):

C
P
13.19

C
b3,4

C
P

3,4res
13.19 1916.31 25.2 KN


Selected bearings are:
For 3 & 4: 6306 with internal diameter oI 30mm and external diameter oI 72mm and a
thickness oI 19mm.



4.4 Gears caIc:Iations and seIection

Speed Iactor Ior strength diIIerent Ior W & Pi

Speed Iactor Ior wear diIIerent Ior W & Pi
Y Strength Iactor diIIerent Ior W & Pi
Z Zone Iactor same Ior W & Pi

Material rating (surIace stress)

Material rating (bending stress)

K Pitch Iactor (DP)
0.8
power
F Face width (inches)
DP 25.4/MOD

The selection oI the spur geras is based on the Ioloowing criteria:
1. The input and output shaIt diameters
2. The speciIied bore oI the geras in HPC cataloque
3. The required Torgue
4. The speed ration that reIlects the number oI teeth on wheel and pinion gear
5. The minumum number oI teeth (20) Ior the pinion
We can thereIore select the Iollowing.
Standart gears
3-26 Ior the pinion and 3-52 Ior the wheel
Heavy duty gears
Y3-22 Ior the pinion and Y3-46 Ior the wheel




Calculation for wbeel and pinion

Z1
26-20
26-20
X(. - ) + = .

Z2
26-20
26-20
X(. - .89) + .89 = .

Z
52-50
60-50
X(. - .) + . = .

1400

17000


= mm = .9 = 1. 37795

=
.

=
.

= 8. 47


= (8.)
0.8
= 5. 523
Calculation for wbeel:

Xc
850-800
1000-800
X(. - .) + . = .

Xb
850-800
1000-800
X(.9 - .) +. = .

Y1
26-20
26-20
X(. - .9) +.9 = .

Y2
26-20
26-20
X(. - .8) + .8 = .

Y
52-50
60-50
X(. - .) +. = .

Weai
w
=

=
. . .9
.
= .8 lbs .8
= .

`ieng`
w
=

=
. . .9
8.
= . lbs .8
= .
Calculation for Pinion:

Xc
1700-1000
2000-1000
X(.9 - .) +. = .

Xb
1700-1000
2000-1000
X(. - .9) +.9 = .

Y1
52-50
60-50
X(. -.99) + .99 = .

Y2
52-50
26-20
X(.98 -.8) + .8 = .88

Y
26-20
26-20
X(. - .88) + .88 = .

Weai
w
=

=
. . .9
.
= .9 lbs .8
= .

Stiength
w
=
X
b
Y S
b
F
BP
=
...9
8.
= .8 lbs .8 = .9kN


Teeth (mm) Speed (rpm) (rad
-1
)
Pinion 26 84 1700 178.02
Wheel 52 162 850 78.01



Angular Velocity (e) Ior wheel 2 x a x 850/60 89.01 rad/s

Angular Velocity (e) Ior pinion 2 x a x 1700/60 178.02 rad/s

Torque input shaIt Power on shaIt / Angular velocity (30-5) x 10
3
/ 89.01

280.86 N
Wheel PCD
523
1000
0.156 m
Pinion PCD
263
1000
0.078 m

nsert some explanation for the formulas calculations. See comments on other (Ellis)
report.




F
t

280.86
0.156
3601.5 N

Wheel
Xc 0.34625
Xb 0.30625
Y 0.622
Z 2.256
Pinion
Xc 0.3035
Xb 0.267
Y 0.7042
Z 2.256

F
v
F
t
tan (20) 3601.5 TAN (20) 1310.83 N
T
D
2 T
S
N 2 (16 20) 2 1280 N
T
Dh
T
D
cos 20 1202.8 N
T
DV
T
D
sin 20 347.78 N




Belts
As indicated in 4:r c4:rse w4rk brief we had :sed FPZ catal4g:e t4 select and size
the a55r45riate 5:lleys and belt(s) f4r the alternat4r drive.

Find h4w many belts we have t4 :se:

O S5eed Rati4 = 1100/850=1.2941

O Service Fact4r=1

O Design P4wer= Service Fact4r*Alt P4wer=5*1=5,0 Kw

O Belt Secti4n and Ty5e= fr4m the tables we f4:nd that we will :se SPZ

O Minim:m 5:lley Diameter. Fr4m the table1 5age 38 (Wedge Belt Drives
Selecti4n) we have f4:nd that we had t4 take 80 mm f4r minim:m P:lley
Diameter. We had c4mbined 5,0 Kw 4f design P4wer and 1200r5m S5eed 4f
faster Shaft.

O P:lley Pitch Diameters. Referring t4 the drive selecti4n tables 4n 5age 40 we
had decided that f4r the driver 5:lley we c4:ld get a val:e 4f 140mm 4f 5itch
and f4r Driven 5:lley we c4:ld get a val:e 4f 180mm 5itch diameter.

O Belt Length, enter distance and 4rrecti4n Fact4r. Fr4m 4:r c4:rsew4rk
brief we have been asked t4 :se a belt with a center distance 4f 600mm t4
800mm.S4 we went back t4 the 5age 40 and fr4m the r4w we were interested
in, we have f4:nd a val:e between 600 and 800 mm. This val:e was 648 f4r a
center distance. On the head 4f the c4l:mn we g4t the val:e 4f 1800mm 4f
belt length. This n:mber had a c4rrecti4n fact4r 4f 1.

O Basic P4wer 5er Belt. Fr4m the table in 5age 52 and in the first table
c4mbining a 5:lley 5itch diameter 4f 140mm and a 1100r5m f4r the faster
shaft we g4t a Basic P4wer 4f 3.48Kw 5er belt.

O S5eed Rati4 P4wer ncrement. Fr4m the same 5age 52 b:t fr4m the bel4w
diagram(Additi4nal P4wer 5er belt f4r s5eed) and c4mbining rev4l:ti4n 4f the
Faster Shaft 1100r5m and 4:r s5eed rati4(1.29) we g4t a val:e 4f 0.12

O 4rrected P4wer 5er belt= (s5eed rati4 54wer increment + Basic P4wer 5er
Belt)*4rrecti4n Fact4r=(0.12+3.48)*1=3.6 Kw/Belt

O :mber 4f Belt req:ired=Design P4wer/4rrected P4wer Per
Belt=5/3.6=1.38=2

L4ads 4n the Belts


648*16=10368


We have a diameter of 80mm
So we go to the first row.


Give exact part n:m-er from FPZ cataIog:e for -oth -eIts and p:IIeys

Limits and Fits. Make reference to the B$ standards and s:ggest to
see the Iimits on the drawings.







































3. 083 Summary form (Mak0 8ur0 to compl0t0 th8
ESGN SUMMARY FORM (Sheet 1 of 2)


roup Members roup No.


1. elts


elt Type No oI elts earbox Pulley PCD:mm Other Pulley:mm



#esultant load on input shaIt due to pulley(s), T
D
N



Factor to be applied to " T
D
" Ior bearing selection, Factor 1.0



Total load, on input shaIt due to pulley, including Iactor ie (T
D
) x (Iactor)

T
D
N

2. ears

Module mm


PCD oI pinion (output shaIt) mm PCD oI wheel (input shaIt) mm


No oI teeth on pinion No oI teeth on wheel


Pinion material Wheel material


#esultant load on input shaIt due to gear, N


3. combined bending and torsion criteria (input shaIt)

ShaIt material: UTS MPa Tormax MPa


Minimum shaIt diameter based upon combined bending and torsion (increased by a Iactor oI
1.1 to compensate Ior keyways, and a Iactor oI saIety oI 2.5 on max. yield strength in shear).

Minimum shaIt diameter Ior bending and torsion considerations, Dmin mm



ESGN SUMMARY FORM (Sheet 2 of 2)


4. earing Loads Ior earing Selection (input shaIt)


Vertical and Horizontal Components:

earing 1, 1V N earing 2, 2V N


earing 1, 1H N earing 2, 2H N

#esultants:

earing 1, 1 N earing 2, 2 N




5. Position oI pulley, gear and bearings on input shaIt

earing spacings (relative to the pulley and gear) ie dimensions A, and C (in accordance
with Figure 1):

A mm mm C mm




6. Design Proposal

Proposed nominal diameter oI input shaIt to satisIy the "bending & torsion" criteria :

D mm



7. earings Chosen (input shaIt only)

Type oI bearings chosen (eg taper roller, needle roller, deep groove ball etc) :

earing 1 earing 2



SKF bearing part numbers :

earing 1 earing 2




4. #0f0r03c08

Book8 a3/ artcl08

O http://en.wikipedia.org/wiki/Gear-ox_$oftware
O http://simpIe.wikipedia.org/wiki/Driveshaft
O http://www.roymech.co.:k/Usef:I_Ta-Ies/Drive/Gears.htmI
O http://en.wikipedia.org/wiki/P:IIey
O http://en.wikipedia.org/wiki/Bearing_(mechanicaI)
O http://en.wikipedia.org/wiki/Key_(engineering)
O http://en.wikipedia.org/wiki/L:-rication















5. raw38