Machine Design II

Overhead Crane Design

Project progress report

Team Work:
1-Abd-Elfatah Hashem Abd-Elfatah 5142013
2-Mohamed Salah Eldin 5142029
3-ElsayedZidanElsayed 5142085

Instructor:
Prof. Dr.Tarek Othman
T.A:
Eng. Ahmed Hamed

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 Contents
1 Abstract ....................................................................... 4
2 Introduction ................................................................. 5
3 Motor Selection Procedure ............................................ 6
3.1 Chosen Speed ................................................................................ 6
3.2 Motor Standards ............................................................................ 6
3.3 Standard Horsepower Ratings ....................................................... 6
3.4 Motor Power Needed .................................................................... 6
3.5 Motor Selection ............................................................................. 7
4 Overhead travelling cranes types .................................... 8
4.1 Single girder top running crane ..................................................... 9
4.2 Single girder under slung crane ..................................................... 9
4.3 Double girder top running crane ................................................... 9
5 Decision-Matrix .......................................................... 10
6 Conceptual design ...................................................... 11
6.1 Alternative 1 ................................................................................ 11
6.2 Alternative 2 ................................................................................ 12
7 Mechanical Design Procedure ...................................... 13
7.1 At first a design scheme (lay out) ................................................ 13
7.2 The forces .................................................................................... 13
7.3 Material........................................................................................ 14
7.4 Stress, Strain and Strength .......................................................... 14
7.4.1 Stress ..................................................................... 14
7.4.2 Strain ..................................................................... 15
7.4.3 Strength ................................................................. 15
7.5 The dimensions of the part.......................................................... 16
7.6 Finally, .......................................................................................... 16
8 Mechanical Design Criteria .......................................... 17
8.1 Strength ....................................................................................... 17
8.2 Rigidity ......................................................................................... 17
8.3 Wear Resistance .......................................................................... 17

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 8.4 Resistance to vibrations............................................................... 17
9 Gearbox..................................................................... 18
9.1 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 .................................................................................. 18
9.2 Second stage ............................................................................... 18
9.3 Third stage .................................................................................. 18
9.4 Pinion calculation ....................................................................... 18
10 Shaft Design and Bearing Selection ............................... 21
10.1 Shaft A .......................................................................................... 21
10.2 Shaft B .......................................................................................... 26
10.3 Shaft C .......................................................................................... 31
10.4 Shaft D.......................................................................................... 36
10.5 Finite Element .............................................................................. 39
11 Coupling .................................................................... 41
11.1 Coupling calculations Design (Rigid Type-Finger tight) ............... 41
11.1.1 Checks on the coupling dimensions ...................... 42
11.1.2 Check on bolts ....................................................... 42
11.1.3 Bearing pressure check on bolts ........................... 42
11.1.4 Shear on the flange Hub........................................ 42
11.1.5 Shear on Key .......................................................... 43
11.1.6 Crushing on key ..................................................... 43
11.1.7 Coupling Assembly ................................................ 43
11.2 Coupling calculations Design (Flexible Coupling) ........................ 44
12 Clutch........................................................................ 46
13 Rope and hoisting ....................................................... 48
13.1 Selection of rope .......................................................................... 48
13.2 Length of wire Rope..................................................................... 49
14 hoisting drum ............................................................. 50

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1 Abstract

This report will discuss the problem definition, the design Procedure for
each component and represent the calculations.

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2 Introduction

It is required to design an overhead crane to lift a load of 15 tons to a

height of 7 meters, and design and select the crane components.

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3 Motor Selection Procedure

3.1 Chosen Speed

V=0.1 m/s

3.2 Motor Standards

η, overall system efficiency, is assumed 0.9 since there is still no detailed
design.

3.3 Standard Horsepower Ratings

Standard horsepower ratings of electrical motors - 1 to 4000 HP are indicated
below:

1, 1 1/2, 2, 3, 5, 7 1/2, 10, 15, 20, 25, 30, 40, 50, 60, 75, 100, 125, 150, 200, 250,
300, 350, 400, 450, 500, 600, 700, 800, 900, 1000, 1250, 1500, 1750, 2000, 2250,
2500, 3000, 3500, 4000

3.4 Motor Power Needed

𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 ∗ 𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉 150000 ∗ 0.1

𝑃𝑃 = = = 16.66 𝐾𝐾𝐾𝐾 = 22.35 𝐻𝐻𝐻𝐻
ῃ 0.9

Power Selected 25 HP

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3.5 Motor Selection

Description
HP 25 HP
RPM 975 RPM
Poles 4
Voltage 230/460 Volts
Phase 3
HZ 60 HZ
Frame 286TC
Mounting Rigid

𝑃𝑃 = 𝑇𝑇 ∗ 𝜔𝜔
𝑃𝑃 9.5488 ∗ 𝑃𝑃𝑘𝑘𝑘𝑘 9.55 ∗ 18.64𝑘𝑘𝑘𝑘
𝑇𝑇 = = = ∗ 103 = 182.576 𝑁𝑁. 𝑚𝑚
𝜔𝜔 𝜔𝜔 975 𝑟𝑟𝑟𝑟𝑟𝑟

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4 Overhead travelling cranes types

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4.1 Single girder top running crane
Single Girder Top Running Crane These are utilised for medium to heavy fabrication
and are ideally suited to low buildings, where a high hook lift height is required.
I. Capacity up to 20 ton.
II. Spans up to 36 meters
III. Pendant or radio control
IV. Single or dual hoist options

4.2 Single girder under slung crane

Single Girder Top Under slung Crane These are usually suspended from roof trusses,
are mainly utilised inside pumping stations and small workshops, for maintenance
purposes. The cranes are compact in design and construction, making them ideal for
low buildings where maximum hook height is required.
I. Capacity up to 10 ton
II. Span up to 18 meters
III. Pendant or radio control

4.3 Double girder top running crane

Double Girder Top Running Crane This is a very heavy-duty crane, normally used by
larger manufacturers and steel warehouses. Among their features are:
I. Capacity up to 100 ton
II. Spans up to 36 meters
III. Walkways
IV. Trolley platforms
V. Various types of connections
VI. Pendant or radio control
VII. Main and Aux hoist options

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5 Decision-Matrix

Factors Single girder top Single girder under Double girder

running crane slung crane

Wt. 1 2 3

Cost 4.0 3 4 1

Capacity 5.0 3 2 5

Space 4.0 3 4 2

Lift Height 4.0 4 2 5

safety 5.0 4 2 3

Maintainability 4.0 3 2 1

Reliability 3.0 3 2 2

velocity 2.0 3 1 2

Scores 102 76 86

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6 Conceptual design

6.1 Alternative 1

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6.2 Alternative 2

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7 Mechanical Design Procedure

7.1 At first a design scheme (lay out)

is drawn in which the shape of the part being designed and the nature of its connection with
other elements are presented in a simplified form while the forces acting on the part are
assumed to be either concentrated or distributed in conformity with some simple law;

7.2 The forces

acting on the part in the process of machine operation are then determined;

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7.3 Material
is selected and the allowable stresses are found accounting for all the factors that affect the
strength of the part;

7.4 Stress, Strain and Strength

The quality of a mechanical system depends on the relationship of the maximum stress to
the component strength.

7.4.1 Stress
is a state property of a body which is a function of: load, geometry, temperature and
manufacturing process? Stress is denoted with Greek letters and has unit [N/m2]
𝐹𝐹
σ= – normal stress (tensile or compressive).
𝐴𝐴

𝐹𝐹
τ= 𝐴𝐴𝑝𝑝– shear stress.

Various marks denote various kinds of stress:

σ1 – principal stress – stress in the direction of a principal axis.

σ𝑦𝑦 – coordinate stress component.

σ𝑟𝑟 – radial stress component.

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7.4.2 Strain
is defined as deformation of a solid due to stress in terms of displacement of material;

Strain is denoted with Greek letters:

∆𝐿𝐿
𝜀𝜀 = [m/m]
𝐿𝐿°
∆𝑆𝑆
𝛾𝛾 = [m/m]
𝑆𝑆°
Elastic Modulus are ratio of stress / strain:
𝜎𝜎
𝐸𝐸 = [N/m2]- Young’s modulus Modulus of Elasticity.
𝜀𝜀

𝜏𝜏
𝐺𝐺 = [N/m2]- Shear Modulus of Rigidity.
𝛾𝛾

7.4.3 Strength

is an inherent property of a material built into the part because of the use of a material and
process? Strength is denoted with capital letter S [N/m2]

SE – Yield strength (lowest stress that produces permanent deformation).

SG – Shear strength (lowest shear stress that produces permanent deformation).

St – Tensile or ultimate strength (limit state of tensile stress).

Sd – Fatigue strength – dynamic loading.

Si – Impact strength.

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7.5 The dimensions of the part
required by the design criteria (strength, rigidity, wear resistance etc.) corresponding to the
accepted design scheme, are determined.

7.6 Finally,
the drawing of the part is made indicating all dimensions, accuracy of manufacture, surface
finish and other information necessary for the manufacture of the part.

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8 Mechanical Design Criteria

8.1 Strength
A component should not fail or have residual deformations under the effect of the forces
that act on it. This is satisfied if the induced stress is smaller than the material strength.

8.2 Rigidity
is the ability of parts to resist deformations under the action of forces? Proper rigidity is
necessary to ensure that machine as a whole and its elements operate effectively. In many
cases this parameter of operating capacity proves to be most important. Therefore, apart
from the strength calculations, rigidity of a number of parts is also calculated as ratio of the
actual displacements (deflections, angles of turn, angles of twist) with allowable (rated)
displacements.

8.3 Wear Resistance

Wear is the principal cause of putting machine elements out of commission. Problems:
frequent stops, loss of machine accuracy etc. Calculations of wear are usually of an arbitrary
nature and carried out together with calculations of strength.

Heat resistance: The liberation of heat involved in the working process or sometimes due to
friction between moving surfaces, causes the components of some machines to operate
under conditions of increased temperature. An increased temperature (> 100o C) impairs
the lubricating ability of oils; Continuous operations involving temperatures > 300-400o C
causes slow plastic deformations called creep. Thermal deformations may reduce the
accuracy of a machine. Effective cooling and special calculations for heat to find the working
temperature of the machine elements, evaluate the working stresses and compare them
with the creep limits for the material of the part.

8.4 Resistance to vibrations

The term implies the ability of a machine to operate at the assigned speeds and loads
without impermissible oscillations Dynamic analysis after finalizing the design to avoid
inherent unbalances.

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9 Gearbox

Our gearbox is a triple stage gearbox with a reduction ratio of 100, using spur gears to
transmit power and provide the needed reduction ratio with the first stage having reduction
ratio of 5:1, the second stage also having 5:1, and the third reduction ratio having 6:1.

𝑣𝑣
1 − 𝑤𝑤 =
𝑟𝑟
Diameter of drum 300 mm
0.1
𝜔𝜔 = = 0.66
(150 ∗ 10−3 )
0.666 ∗ 60
𝜔𝜔 = = 6.5 𝑟𝑟. 𝑝𝑝. 𝑚𝑚
2𝜋𝜋
We use spur gear and reduction to three stages ( 5: 1 ) … (5: 1) … (6: 1)

𝜔𝜔𝑖𝑖𝑖𝑖 = 975 𝑟𝑟. 𝑝𝑝. 𝑚𝑚

9.1 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓

1
𝜔𝜔 = ∗ 975 = 195 𝑟𝑟. 𝑝𝑝. 𝑚𝑚
5

9.2 Second stage

1
𝜔𝜔 = ∗ 195 = 39 𝑟𝑟. 𝑝𝑝. 𝑚𝑚
5

9.3 Third stage

1
𝜔𝜔 = ∗ 39 = 6.5 𝑟𝑟. 𝑝𝑝. 𝑚𝑚
6

9.4 PINION CALCULATION

𝑵𝑵𝑵𝑵 = 𝟏𝟏𝟏𝟏 𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕
𝑷𝑷 = 𝟐𝟐𝟐𝟐 𝑯𝑯𝑯𝑯
𝑹𝑹𝑹𝑹𝑹𝑹 = 𝟗𝟗𝟗𝟗𝟗𝟗
𝑷𝑷𝑷𝑷𝑷𝑷(∅) = 𝟐𝟐𝟐𝟐°
FROM GRAPH AND PREFERRED VALUES O F MODULE M=6

𝒅𝒅𝒅𝒅 = 𝟔𝟔 ∗ 𝟏𝟏𝟏𝟏 = 𝟏𝟏𝟏𝟏𝟏𝟏 𝒎𝒎𝒎𝒎

𝒇𝒇 = 𝟑𝟑 ∗ 𝝅𝝅 ∗ 𝟔𝟔 = 𝟓𝟓𝟓𝟓. 𝟓𝟓𝟓𝟓 𝒎𝒎𝒎𝒎

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FOR BENDING STRESS ON PINION TOOTH

𝟐𝟐𝟐𝟐 (𝟐𝟐 ∗ 𝟏𝟏𝟏𝟏𝟏𝟏. 𝟓𝟓𝟓𝟓𝟓𝟓)

𝒘𝒘𝒘𝒘 = = = 𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑 𝑵𝑵
𝑫𝑫𝑫𝑫 (𝟏𝟏𝟏𝟏𝟏𝟏 ∗ 𝟏𝟏𝟎𝟎−𝟑𝟑 )
𝟔𝟔 𝟔𝟔
𝑲𝑲𝑲𝑲 = = = 𝟎𝟎. 𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓
𝟔𝟔 + 𝒗𝒗 𝟗𝟗𝟗𝟗𝟗𝟗
�𝟔𝟔 + �𝝅𝝅 ∗ 𝟏𝟏𝟏𝟏𝟏𝟏 ∗ 𝟏𝟏𝟎𝟎−𝟑𝟑 ∗ � 𝟔𝟔𝟔𝟔 ���

From Table:
𝒚𝒚 = 𝟎𝟎. 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐

𝑾𝑾𝑾𝑾 𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑
𝑺𝑺 = = = 𝟔𝟔𝟔𝟔. 𝟗𝟗𝟗𝟗 𝑴𝑴𝑴𝑴𝑴𝑴
(𝒇𝒇 ∗ 𝑲𝑲𝑲𝑲 ∗ 𝒎𝒎 ∗ 𝒚𝒚) (𝟓𝟓𝟓𝟓. 𝟓𝟓𝟓𝟓 ∗ 𝟎𝟎. 𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓 ∗ 𝟔𝟔 ∗ 𝟎𝟎. 𝟐𝟐𝟗𝟗𝟑𝟑𝟑𝟑𝟑𝟑)

𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴: 𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝑸𝑸&𝑻𝑻 ∗, 𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺 = 𝟖𝟖𝟖𝟖𝟖𝟖𝑴𝑴𝑴𝑴𝑴𝑴, 𝑺𝑺𝑺𝑺 = 𝟔𝟔𝟔𝟔𝟔𝟔𝑴𝑴𝑴𝑴𝑴𝑴

𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪:

𝐹𝐹𝐹𝐹𝐹𝐹 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙:

𝐾𝐾𝐾𝐾 = 0.69

𝐾𝐾𝐾𝐾 = 0.894

𝐾𝐾𝐾𝐾 = 0.897

𝐾𝐾𝐾𝐾 = 1

𝐾𝐾𝐾𝐾 = 1

𝐾𝐾𝐾𝐾 = 1

𝑆𝑆𝑆𝑆’ = 848/2 = 424 𝑀𝑀𝑀𝑀𝑀𝑀

𝑆𝑆𝑆𝑆 = 0.69 ∗ 0.894 ∗ 0.897 ∗ 1 ∗ 1 ∗ 1 ∗ 260 = 234.6 𝑀𝑀𝑀𝑀𝑀𝑀

𝐹𝐹𝐹𝐹𝐹𝐹 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠:

𝑅𝑅𝑅𝑅 = 5 𝑎𝑎𝑎𝑎𝑎𝑎 𝑁𝑁𝑝𝑝 = 18, 𝑠𝑠𝑠𝑠; 𝑁𝑁𝑔𝑔 = 90; 𝑏𝑏𝑏𝑏 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖, 𝐽𝐽 = 0.3506265

𝑤𝑤𝑤𝑤
𝑆𝑆𝑆𝑆 =
(𝐾𝐾𝐾𝐾 ∗ 𝐹𝐹 ∗ 𝑚𝑚 ∗ 𝐽𝐽)
𝑆𝑆𝑆𝑆 = 73.14 𝑀𝑀𝑀𝑀𝑀𝑀

𝐾𝐾𝐾𝐾 = 1

𝐾𝐾𝐾𝐾 = 1.4

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𝑆𝑆𝑆𝑆 = 2

𝑺𝑺𝑺𝑺 ∗ 𝑲𝑲𝑲𝑲 ∗ 𝑲𝑲𝑲𝑲 ∗ 𝑺𝑺𝑺𝑺

= 𝟐𝟐𝟐𝟐𝟐𝟐. 𝟕𝟕𝟕𝟕 𝑴𝑴𝑴𝑴𝑴𝑴 𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘 𝒊𝒊𝒊𝒊 𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔 𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕 𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂 𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃 𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔 (𝑺𝑺𝑺𝑺
= 𝟐𝟐𝟐𝟐𝟐𝟐. 𝟔𝟔 𝑴𝑴𝑴𝑴𝑴𝑴)

− 𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺 𝐵𝐵𝐵𝐵𝐵𝐵 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴

𝜔𝜔1 𝑑𝑑2 𝑁𝑁2

𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 : = =
𝜔𝜔2 𝑑𝑑1 𝑁𝑁1

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 1 ∶ 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑁𝑁 = 18 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡ℎ 𝑑𝑑 = 108 𝑚𝑚𝑚𝑚

𝑚𝑚𝑚𝑚𝑚𝑚ℎ 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 𝑑𝑑 = 540 𝑚𝑚𝑚𝑚

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 2 ∶ 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑁𝑁 = 20 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡ℎ 𝑑𝑑 = 120 𝑚𝑚𝑚𝑚

𝑀𝑀𝑀𝑀𝑀𝑀ℎ 𝑔𝑔𝑒𝑒𝑒𝑒𝑒𝑒 𝑑𝑑 = 600 𝑚𝑚𝑚𝑚

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 3 ∶ 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑁𝑁 = 22 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡ℎ 𝑑𝑑 = 132 𝑚𝑚𝑚𝑚

𝑀𝑀𝑀𝑀𝑀𝑀ℎ 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 𝑑𝑑 = 792 𝑚𝑚𝑚𝑚

| P a g e 20
10 Shaft Design and Bearing Selection

10.1 Shaft A

-Given Data:

T=182.576 N.m

-For Pinion

Assume M=6, N=18, ᵩ=20

D=6*18=108 mm
𝐷𝐷
𝑇𝑇 = 𝐹𝐹𝑡𝑡 ∗
2
𝐹𝐹𝑡𝑡 = 3381 𝑁𝑁
𝐹𝐹𝑟𝑟 = 𝐹𝐹𝑡𝑡 ∗ 𝑇𝑇𝑇𝑇𝑇𝑇(20) = 1230.6 𝑁𝑁

X-Z Plane
3381 ∗ 10 = 𝑅𝑅1 ∗ 30
𝑅𝑅1𝑥𝑥−𝑧𝑧 = 1127 𝑁𝑁
𝑅𝑅2𝑥𝑥−𝑧𝑧 = 2254 𝑁𝑁
𝑀𝑀1𝑥𝑥−𝑧𝑧 = 225.4 𝑁𝑁. 𝑚𝑚

| P a g e 21
Shear Force Diagram and Bending Moment Diagram (X-Z)

| P a g e 22
X-Y Plane
1230.6 ∗ 10 = 𝑅𝑅1𝑥𝑥−𝑦𝑦 ∗ 30

𝑅𝑅1𝑥𝑥−𝑦𝑦 = 410.2 𝑁𝑁

𝑅𝑅2𝑥𝑥−𝑦𝑦 = 820.4 𝑁𝑁

𝑀𝑀1𝑥𝑥−𝑦𝑦 = 82 𝑁𝑁. 𝑚𝑚

Shear Force Diagram and Bending Moment Diagram (X-Y)

| P a g e 23
 𝑀𝑀3 = �(82)2 + (225.4)2 = 239.85 𝑁𝑁. 𝑚𝑚

Shaft Diameters
Assume

Material AISI 1050 (𝑆𝑆𝑦𝑦 = 325 ∗ 106 𝑃𝑃𝑃𝑃)

F.S.=2 ,𝐶𝐶𝑚𝑚 = 1.5 , 𝐶𝐶𝑡𝑡 = 2

Maximum Shear Stress Criterion

3 32 ∗ 𝐹𝐹. 𝑆𝑆. 1
𝑑𝑑 = � ∗ ((𝐶𝐶𝑚𝑚 ∗ 𝑀𝑀)2 + (𝐶𝐶𝑡𝑡 ∗ 𝑇𝑇)2 ) �2
𝜋𝜋 ∗ 𝑆𝑆𝑦𝑦

| P a g e 24
D at Bearing (1,2) ‘’M=0, T=T’’
𝑑𝑑 = 28.3 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 30𝑚𝑚𝑚𝑚
D at Pinion ‘’M=239. 85N.m, T=T’’
𝑑𝑑2 = 31.79 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 35 𝑚𝑚𝑚𝑚

Bearing Selection of Shaft, A

Assume Life of two Bearing 12000 hr., D.G.B.B, a=3
At 1

𝑃𝑃1 = �(𝑅𝑅1𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅1𝑥𝑥−𝑦𝑦 )2 = 1199.3 𝑁𝑁

𝑎𝑎 60 ∗ 𝑛𝑛
𝐶𝐶 = 𝑃𝑃 ∗ � ∗ 𝐿𝐿10ℎ = 10.6 𝐾𝐾𝐾𝐾
106

Designation 6006
At 2

𝑃𝑃2 = �(𝑅𝑅2𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅2𝑥𝑥−𝑦𝑦 )2 = 2398.6 𝑁𝑁

𝑎𝑎 60 ∗ 𝑛𝑛
𝐶𝐶 = 𝑃𝑃 ∗ � ∗ 𝐿𝐿10ℎ = 21.3 𝐾𝐾𝐾𝐾
106

Designation 6206 ETN9

| P a g e 25
10.2 Shaft B

-With Gear Ratio

𝑇𝑇2 𝜔𝜔1
=
𝑇𝑇1 𝜔𝜔2
𝑇𝑇2 = 912.8 ~ 913 𝑁𝑁. 𝑚𝑚

Gear (2) Gear (3)

D=6*20=120 mm 𝐹𝐹𝑡𝑡 = 3381 𝑁𝑁

𝐹𝐹𝑡𝑡 = 15216.7 𝑁𝑁𝐹𝐹𝑟𝑟 = 1230.6 𝑁𝑁

𝐹𝐹𝑟𝑟 = 5538.4 𝑁𝑁

X-Z Plane

𝑅𝑅1𝑥𝑥−𝑧𝑧 ∗ 30 = 3381 ∗ 10
+ 15216.7
∗ 20
𝑅𝑅1𝑥𝑥−𝑧𝑧 = 11271.5 𝑁𝑁
𝑅𝑅4𝑥𝑥−𝑧𝑧 = 7326.23 𝑁𝑁
𝑀𝑀2𝑥𝑥−𝑧𝑧 = 1127.15 𝑁𝑁. 𝑚𝑚
𝑀𝑀3𝑥𝑥−𝑧𝑧 = 732.623 𝑁𝑁. 𝑚𝑚

| P a g e 26
Shear Force Diagram and Bending Moment Diagram (X-Z)

| P a g e 27
X-Y Plane

𝑅𝑅1𝑥𝑥−𝑦𝑦 ∗ 30 = 1230.6 ∗ 10 + 5538.4 ∗ 20

𝑅𝑅1𝑥𝑥−𝑦𝑦 = 4102.5 𝑁𝑁

𝑅𝑅4𝑥𝑥−𝑦𝑦 = 7326.23 𝑁𝑁

𝑀𝑀2𝑥𝑥−𝑦𝑦 = 410.25 𝑁𝑁. 𝑚𝑚

𝑀𝑀3𝑥𝑥−𝑦𝑦 = 266.65 𝑁𝑁. 𝑚𝑚

Shear Force Diagram and Bending Moment Diagram (X-Y)

| P a g e 28
 𝑀𝑀2 = �(1127.15)2 + (410.25)2 = 1199.48 𝑁𝑁. 𝑚𝑚

𝑀𝑀3 = �(732.623)2 + (266.65)2 = 779.64 𝑁𝑁. 𝑚𝑚

Shaft Diameters
Assume

Material AISI 1050 (𝑆𝑆𝑦𝑦 = 325 ∗ 106 𝑃𝑃𝑃𝑃)

F.S.=2 ,𝐶𝐶𝑚𝑚 = 1.5 , 𝐶𝐶𝑡𝑡 = 2

Maximum Shear Stress Criterion

3 32 ∗ 𝐹𝐹. 𝑆𝑆. 1
𝑑𝑑 = � ∗ ((𝐶𝐶𝑚𝑚 ∗ 𝑀𝑀)2 + (𝐶𝐶𝑡𝑡 ∗ 𝑇𝑇)2 ) �2
𝜋𝜋 ∗ 𝑆𝑆𝑦𝑦

| P a g e 29
D at Bearing (1,4) ‘’M=0, T=T’’
𝑑𝑑 = 48.5 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 50𝑚𝑚𝑚𝑚
D at Gear 2 ‘’M=1199. 48N.m, T=T’’
𝑑𝑑2 = 54.36 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 55 𝑚𝑚𝑚𝑚
D at Gear 3 ‘’M=779. 64N.m, T=T’’
𝑑𝑑3 = 51.41 𝑚𝑚𝑚𝑚 𝑡𝑡𝑎𝑎𝑎𝑎𝑎𝑎 55 𝑚𝑚𝑚𝑚

Bearing Selection of Shaft, B

Assume Life of two Bearing 12000 hr., D.G.B.B, a=3
At 1

𝑃𝑃1 = �(𝑅𝑅1𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅1𝑥𝑥−𝑦𝑦 )2 = 11.99 𝐾𝐾𝐾𝐾

𝑎𝑎 60 ∗ 𝑛𝑛
𝐶𝐶 = 𝑃𝑃 ∗ � ∗ 𝐿𝐿10ℎ = 62.3 𝐾𝐾𝐾𝐾
106

Designation 6310
At 4

𝑃𝑃4 = �(𝑅𝑅4𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅4𝑥𝑥−𝑦𝑦 )2 = 7.8 𝐾𝐾𝐾𝐾

𝑎𝑎 60 ∗ 𝑛𝑛
𝐶𝐶 = 𝑃𝑃 ∗ � ∗ 𝐿𝐿10ℎ = 40.54 𝐾𝐾𝐾𝐾
106

Designation 6310

| P a g e 30
10.3 Shaft C

-With Gear Ratio

𝑇𝑇3 𝜔𝜔2
=
𝑇𝑇2 𝜔𝜔3
𝑇𝑇3 = 4565 𝑁𝑁. 𝑚𝑚

Gear (2) Gear (3)

𝐹𝐹𝑡𝑡 = 15216.7 𝑁𝑁 D=6*22=132 mm

𝐹𝐹𝑟𝑟 = 5538.4 𝑁𝑁𝐹𝐹𝑡𝑡 = 69166.67 𝑁𝑁

𝐹𝐹𝑟𝑟 = 25174.6 𝑁𝑁

X-Z Plane
𝑅𝑅1𝑥𝑥−𝑧𝑧 ∗ 30 = 69166.67 ∗ 10
+ 15216.7 ∗ 20
𝑅𝑅1𝑥𝑥−𝑧𝑧 = 33200 𝑁𝑁
𝑅𝑅4𝑥𝑥−𝑧𝑧 = 51183.35 𝑁𝑁
𝑀𝑀2𝑥𝑥−𝑧𝑧 = 3320 𝑁𝑁. 𝑚𝑚
𝑀𝑀3𝑥𝑥−𝑧𝑧 = 5118.335 𝑁𝑁. 𝑚𝑚

| P a g e 31
Shear Force Diagram and Bending Moment Diagram (X-Z)

| P a g e 32
X-Y Plane

𝑅𝑅1𝑥𝑥−𝑦𝑦 ∗ 30 = 25174.6 ∗ 10
+ 5538.4 ∗ 20

𝑅𝑅1𝑥𝑥−𝑦𝑦 = 12083.8 𝑁𝑁

𝑅𝑅4𝑥𝑥−𝑦𝑦 = 18629.2 𝑁𝑁

𝑀𝑀2𝑥𝑥−𝑦𝑦 = 1208.38 𝑁𝑁. 𝑚𝑚

𝑀𝑀3𝑥𝑥−𝑦𝑦 = 1862.92 𝑁𝑁. 𝑚𝑚

Shear Force Diagram and Bending Moment Diagram (X-Y)

| P a g e 33
 𝑀𝑀2 = �(1208.38)2 + (3320)2 = 3533.069 𝑁𝑁. 𝑚𝑚

𝑀𝑀3 = �(1862.92)2 + (5118.335)2 = 5446.83𝑁𝑁

Shaft Diameters

Assume

Material AISI 1050 (𝑆𝑆𝑦𝑦 = 325 ∗ 106 𝑃𝑃𝑃𝑃)

Maximum Shear Stress Criterion

3 32 ∗ 𝐹𝐹. 𝑆𝑆. 1
𝑑𝑑 = � ∗ ((𝐶𝐶𝑚𝑚 ∗ 𝑀𝑀)2 + (𝐶𝐶𝑡𝑡 ∗ 𝑇𝑇)2 ) �2
𝜋𝜋 ∗ 𝑆𝑆𝑦𝑦

| P a g e 34
D at Bearing (1,4) ‘’M=0, T=T’’

𝑑𝑑 = 65.8 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 70𝑚𝑚𝑚𝑚

D at Gear 2 ‘’M=3533. 069N.m, T=T’’

𝑑𝑑2 = 87.1 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 90 𝑚𝑚𝑚𝑚

D at Gear 3 ‘’M=5446. 83N.m, T=T’’

𝑑𝑑3 = 91.5 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 95 𝑚𝑚𝑚𝑚

Bearing Selection of Shaft, B

Assume Life of two Bearing 12000 hr., D.G.B.B, a=3

At 1

𝑃𝑃1 = �(𝑅𝑅1𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅1𝑥𝑥−𝑦𝑦 )2 = 35.3 𝐾𝐾𝐾𝐾

𝑎𝑎 60 ∗ 𝑛𝑛
𝐶𝐶 = 𝑃𝑃 ∗ � ∗ 𝐿𝐿10ℎ = 107.29 𝐾𝐾𝐾𝐾
106

Designation: 6314

At 4

𝑃𝑃4 = �(𝑅𝑅4𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅4𝑥𝑥−𝑦𝑦 )2 = 54.46 𝐾𝐾𝐾𝐾

𝑎𝑎 60 ∗ 𝑛𝑛
𝐶𝐶 = 𝑃𝑃 ∗ � ∗ 𝐿𝐿10ℎ = 165.5 𝐾𝐾𝐾𝐾
106

Designation: 641

| P a g e 35
10.4 Shaft D

-With Gear Ratio

𝑇𝑇4 𝜔𝜔3
=
𝑇𝑇3 𝜔𝜔4
𝑇𝑇4 = 27390 𝑁𝑁. 𝑚𝑚

Gear (3)

𝐹𝐹𝑡𝑡 = 69166.67 𝑁𝑁
𝐹𝐹𝑟𝑟 = 25174.6 𝑁𝑁

X-Z Plane

𝑅𝑅1𝑥𝑥−𝑧𝑧 ∗ 30 = 69166.67 ∗ 10
𝑅𝑅1𝑥𝑥−𝑧𝑧 = 23055.56 𝑁𝑁
𝑅𝑅4𝑥𝑥−𝑧𝑧 = 46111.1 𝑁𝑁
𝑀𝑀3𝑥𝑥−𝑧𝑧 = 4611.1 𝑁𝑁. 𝑚𝑚

| P a g e 36
X-Y Plane

𝑅𝑅1𝑥𝑥−𝑦𝑦 ∗ 30 = 25174.6
∗ 10
𝑅𝑅1𝑥𝑥−𝑦𝑦 = 8391.53 𝑁𝑁

𝑅𝑅4𝑥𝑥−𝑦𝑦 = 16783.07 𝑁𝑁

𝑀𝑀3𝑥𝑥−𝑦𝑦 = 1678.3 𝑁𝑁. 𝑚𝑚

𝑀𝑀3 = �(4611.1)2 + (1678.3)2 = 4907.02𝑁𝑁. 𝑚𝑚

| P a g e 37
Shaft Diameters

Assume

Material AISI 1050 (𝑆𝑆𝑦𝑦 = 325 ∗ 106 𝑃𝑃𝑃𝑃)

Maximum Shear Stress Criterion

3 32 ∗ 𝐹𝐹. 𝑆𝑆. 1
𝑑𝑑 = � ∗ ((𝐶𝐶𝑚𝑚 ∗ 𝑀𝑀)2 + (𝐶𝐶𝑡𝑡 ∗ 𝑇𝑇)2 ) �2
𝜋𝜋 ∗ 𝑆𝑆𝑦𝑦

D at Bearing (1,4) ‘’M=0, T=T’’

𝑑𝑑 = 119.7 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 120𝑚𝑚𝑚𝑚

D at Gear 3 ‘’M=4907.02 N.m, T=T’’

𝑑𝑑3 = 151.33 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 155 𝑚𝑚𝑚𝑚

Bearing Selection of Shaft, B

Assume Life of two Bearing 12000 hr., D.G.B.B, a=3

At 1

𝑃𝑃1 = �(𝑅𝑅1𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅1𝑥𝑥−𝑦𝑦 )2 = 24.53 𝐾𝐾𝐾𝐾

𝑎𝑎 60 ∗ 𝑛𝑛
𝐶𝐶 = 𝑃𝑃 ∗ � ∗ 𝐿𝐿10ℎ = 41 𝐾𝐾𝐾𝐾
106

Designation 61924

At 4

𝑃𝑃4 = �(𝑅𝑅4𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅4𝑥𝑥−𝑦𝑦 )2 = 49.07 𝐾𝐾𝐾𝐾

𝑎𝑎 60 ∗ 𝑛𝑛
𝐶𝐶 = 𝑃𝑃 ∗ � ∗ 𝐿𝐿10ℎ = 82.08 𝐾𝐾𝐾𝐾
106

Designation 602

| P a g e 38
10.5 Finite Element

Shaft A

| P a g e 39
| P a g e 40
11 Coupling

11.1 Coupling calculations Design (Rigid Type-Finger tight)

𝑁𝑁𝑁𝑁. 𝑜𝑜𝑜𝑜 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 = 𝑛𝑛 = 0.02 ∗ (𝑑𝑑) + 3 = 0.02 ∗ 50 + 3 = 4

𝑑𝑑
𝑑𝑑1 = 0.5 ∗ = 12.5 𝑚𝑚𝑚𝑚 ≈ 14.
𝑛𝑛0.5
𝐷𝐷1 = 4𝑑𝑑 = 4 ∗ 50 = 200 𝑚𝑚𝑚𝑚.
𝐷𝐷2 = 2 ∗ 50 = 100 𝑚𝑚𝑚𝑚.
𝐷𝐷 = 5 ∗ 50 = 250 𝑚𝑚𝑚𝑚.
𝑡𝑡 = 1.2 ∗ 𝑑𝑑1 = 1.2 ∗ 14 = 16.8 𝑚𝑚𝑚𝑚.
𝑓𝑓 = 4 𝐹𝐹𝐹𝐹𝐹𝐹 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆.

| P a g e 41
11.1.1 Checks on the coupling dimensions

𝑆𝑆𝑦𝑦 = 0.7 ∗ 370 = 259 𝑀𝑀𝑀𝑀𝑀𝑀

16𝑇𝑇 16 ∗ 182.161
𝜏𝜏𝑎𝑎𝑎𝑎𝑎𝑎 = 3
∗ 𝐾𝐾𝑆𝑆 = ∗ 1.3 ∗ 10−6 = 9.648 𝑀𝑀𝑀𝑀𝑀𝑀
𝜋𝜋𝑑𝑑 𝜋𝜋 ∗ (50 ∗ 10−3 )3

11.1.2 Check on bolts

2𝑇𝑇 2 ∗ 182.161
𝐹𝐹𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = = = 455.4 𝑁𝑁
𝑛𝑛 ∗ 𝐷𝐷1 4 ∗ 200 ∗ 10−3
𝐹𝐹𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 455.4
𝜏𝜏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 𝜋𝜋 = 𝜋𝜋 ∗ 10−6 = 2.958333 𝑀𝑀𝑀𝑀𝑀𝑀
2
𝑑𝑑 1 ∗ (14 ∗ 10−3 )2
4 4

0.5𝑆𝑆𝑦𝑦
𝜏𝜏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 ≤ ≤ 9.648 𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔
𝑓𝑓. 𝑠𝑠.

11.1.3 Bearing pressure check on bolts

𝑆𝑆𝑏𝑏 = 2𝑆𝑆𝑦𝑦 = 2 ∗ 259 = 518 𝑀𝑀𝑀𝑀𝑀𝑀

𝐹𝐹𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 455.4
𝜎𝜎𝑏𝑏 = = = 1.8071 𝑀𝑀𝑀𝑀𝑀𝑀
𝑑𝑑1 ∗ 𝑡𝑡 14 ∗ 18
𝑆𝑆𝑏𝑏
𝜎𝜎𝑏𝑏 ≤ ≤ 86.33 𝑀𝑀𝑀𝑀𝑀𝑀 𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺
𝑓𝑓. 𝑠𝑠.

11.1.4 Shear on the flange Hub

2𝑇𝑇 2 ∗ 182.161
𝜏𝜏 = 2 = ∗ 10−6 = 8.4148 ∗ 10−1 𝑀𝑀𝑀𝑀𝑀𝑀
𝜋𝜋𝐷𝐷2 𝑡𝑡 𝜋𝜋 ∗ (87.5 ∗ 10−3 )2 ∗ 18 ∗ 10−3
0.5𝑆𝑆𝑢𝑢
𝜏𝜏 ≤ ≤ 91.071 𝑀𝑀𝑀𝑀𝑀𝑀
𝑓𝑓. 𝑠𝑠.

| P a g e 42
11.1.5 Shear on Key

Material of key is assumed with Tensile strength = 1500 mpa

Dimensions of key: L= 80 mm, W= 16 mm, H=16 mm

2𝑇𝑇 2 ∗ 182.161
𝜏𝜏 = = ∗ 10−6 = 1.7789 ∗ 10−5 𝑀𝑀𝑀𝑀𝑀𝑀
𝐷𝐷𝐷𝐷𝐷𝐷 (80 ∗ 16 ∗ 16) ∗ 10−3

11.1.6 Crushing on key

𝐹𝐹 7286.44
𝜎𝜎𝑏𝑏 = = = 12.562 𝑃𝑃𝑃𝑃
𝐴𝐴 580

11.1.7 Coupling Assembly

| P a g e 43
11.2 Coupling calculations Design (Flexible Coupling)

𝑛𝑛 = 0.02𝑑𝑑 + 3
𝑛𝑛 = (0.02 ∗ 50) + 3 = 4
Then take n= 6
0.5∗𝑑𝑑
2- 𝑑𝑑1 =
√𝑛𝑛

𝑑𝑑1 = 10.2 𝑚𝑚𝑚𝑚

Take 𝑑𝑑1 = 12𝑚𝑚𝑚𝑚

3- 𝐷𝐷1 = 2𝑑𝑑 + 5 = 105𝑚𝑚𝑚𝑚

4- 𝐷𝐷𝐷𝐷2 = 2𝑑𝑑 = 100𝑚𝑚𝑚𝑚

5- 𝑙𝑙1 = 1.25 ∗ 𝑑𝑑 = 75𝑚𝑚𝑚𝑚

6-𝑙𝑙2 = 1.375 ∗ 𝑑𝑑 = 68.75𝑚𝑚𝑚𝑚

7- 𝐷𝐷 = 4𝑑𝑑 = 200
2𝑇𝑇
8- 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 =
𝑛𝑛𝑛𝑛1

9- 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 = 579.6𝑁𝑁
𝑑𝑑1
10- 𝑑𝑑2 =
0.72

𝑑𝑑2 = 16.6 = 18𝑚𝑚𝑚𝑚

| P a g e 44
11- 𝑑𝑑3 = 3𝑑𝑑1 = 36𝑚𝑚𝑚𝑚

12- 𝑐𝑐 = 𝑑𝑑3 = 36𝑚𝑚𝑚𝑚

𝜋𝜋𝜋𝜋1
13- 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑓𝑓𝑓𝑓𝑓𝑓 𝑏𝑏𝑏𝑏𝑏𝑏ℎ𝑖𝑖𝑖𝑖𝑖𝑖 =
𝑛𝑛

𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑓𝑓𝑓𝑓𝑓𝑓 𝑏𝑏𝑏𝑏𝑏𝑏ℎ𝑖𝑖𝑖𝑖𝑖𝑖 = 54.97 > 36 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡

𝐷𝐷∗tan 2
14- 𝛿𝛿 =
2

δ = 3.49𝑚𝑚𝑚𝑚
𝑐𝑐
15- 𝑒𝑒 = + 𝛿𝛿
2

𝑒𝑒 = 21.49𝑚𝑚𝑚𝑚
32𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓∗𝑒𝑒
16- 𝜎𝜎 = = 73.42 𝑚𝑚𝑚𝑚𝑚𝑚
𝜋𝜋(𝑑𝑑1)3

Choose material St37

Sy = 259 MPA

Fs = 2
𝑆𝑆𝑆𝑆
𝜎𝜎 =
𝐹𝐹𝐹𝐹
259
𝜎𝜎 ≤
2
73.42 ≤ 129.5
Safe
𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓
17- 𝑡𝑡 = 𝜋𝜋 = 5.12 𝑚𝑚𝑚𝑚𝑚𝑚
�4∗(𝑑𝑑1)2

0.5𝑆𝑆𝑆𝑆
𝜏𝜏 ≤
𝐹𝐹𝐹𝐹
5.12 ≤ 64.75
safe
𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓
18 – 𝜎𝜎𝑏𝑏 = = 0.44
𝑐𝑐𝑐𝑐3

𝑆𝑆𝑆𝑆
𝜎𝜎𝜎𝜎 ≤
𝐹𝐹𝐹𝐹
Sb = 2 Sy

0.44 ≤ 259
safe

| P a g e 45
12 Clutch

| P a g e 46
Clutch calculations:

Preliminary Design

𝑇𝑇 ′ = 98.67 𝑁𝑁. 𝑚𝑚 Ks = 2.5

𝑇𝑇 = 𝑇𝑇 ′ ∗ 𝐾𝐾𝐾𝐾 = 246.675 𝑁𝑁. 𝑚𝑚

Using the maximum values for dry asbestos as friction material

𝜇𝜇𝑚𝑚𝑚𝑚𝑚𝑚 = 0.5

𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = 0.54 × 106 𝑃𝑃𝑃𝑃

Using only one plate

𝑛𝑛 = 1
Assuming a value for outer diameter to satisfy the condition 𝐷𝐷0 ≥ 6𝑑𝑑

𝐷𝐷𝑜𝑜 = 0.3 𝑚𝑚
𝐷𝐷𝑖𝑖 = 0.8 × 0.3 = 0.24 𝑚𝑚
𝜋𝜋
𝑇𝑇 = ∗ 𝑛𝑛 ∗ 𝜇𝜇 ∗ 𝑃𝑃𝑚𝑚𝑚𝑚𝑚𝑚 ∗ (𝐷𝐷𝑜𝑜3 − 𝐷𝐷𝑖𝑖3 )
8
𝑇𝑇 = 1397 𝑁𝑁. 𝑚𝑚
The clutch can transmit the required torque.

Detailed Design

Assuming the following constants

𝐾𝐾𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 1.5
𝐾𝐾𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 1
𝑇𝑇 = 𝑇𝑇 ′ ∗ 𝐾𝐾𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 ∗ 𝐾𝐾𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 148.005 𝑁𝑁. 𝑚𝑚
Calculating actuating force

𝐹𝐹𝑎𝑎 = 𝜋𝜋 ∗ 𝑃𝑃 ∗ 𝐷𝐷𝑖𝑖 /2 ∗ (𝐷𝐷𝑜𝑜 − 𝐷𝐷𝑖𝑖 ) = 12214.5 𝑁𝑁

Assuming uniform pressure

𝜋𝜋
𝑇𝑇𝑓𝑓 = ∗ 𝑛𝑛 ∗ 𝜇𝜇 ∗ 𝑃𝑃𝑚𝑚𝑚𝑚𝑚𝑚 ∗ (𝐷𝐷𝑜𝑜3 − 𝐷𝐷𝑖𝑖3 )
12
𝑇𝑇𝑓𝑓 = 931.36

𝑇𝑇𝑓𝑓 > 𝑇𝑇

Calculating actuating force

𝜋𝜋
𝐹𝐹𝑎𝑎 = ∗ 𝑃𝑃 ∗ �𝐷𝐷𝑜𝑜2 − 𝐷𝐷𝑖𝑖2 � = 13741.3 𝑁𝑁
4 𝑚𝑚𝑚𝑚𝑚𝑚

| P a g e 47
13 Rope and hoisting

Our application is an overhead crane lifting a weight of maximum 15 tons which is about

15000N. we needed to select an appropriate steel wire that would be both strong enough to
carry the required loads and light weight and resistive to abrasive wear.

13.1 Selection of rope

Next, we selected the type of rope that is suitable with our type of crane (the overhead
crane)

| P a g e 48
We selected the ½ inch diameter wire that can carry 15.5 tons to be safe as the lifting
process involves human lives and expensive equipment that can’t be risked.

13.2 Length of wire Rope

L= (7 m) *2+(4 m) *2+(2 m) *2+(1 m) *2=28 m

| P a g e 49
14 hoisting drum

We selected the ½ inch diameter wire

Pitch Dia. Drum=12 inches ≈ 300 mm

For Interpretation only

You can only use one Element from (Rigid Coupling, Flexible Coupling,
and Clutch)

| P a g e 50