CC01 Group 4

VIETNAM NATIONAL UNIVERSITY
HCMC UNIVERSITY OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING
DIVISION OF MACHINE DESIGN
TRANSMISSION SYSTEM PROJECT
DESIGN OF A TRANSMISSION SYSTEM FOR

THE EXTRUSION MACHINE
STUDENT: Trần Thiên Bảo - 2153215

Cao Nhật Quang - 2152902
INSTRUCTOR: Assoc. Prof. Dr. Lê Thanh Long
Ho Chi Minh City, 12/2023

DESIGN OF A TRANSMISSION SYSTEM FOR THE EXTRUSION MACHINE
ACKNOWLEDGEMENT
Our country is on the path of development, which means science and technology play
an essential role in human life. The application of science and technology is increasing labor
productivity and replacing workers' employment most effectively, ensuring their safety during
work. Mechanical systems are a great replacement for human power in automating production
and increasing labor productivity. Combined with controlling them, we will contribute to the
modernization of automation that Vietnam is implementing.
Transmission system project is a subject that helps us majoring in Mechatronics and
Mechanical Engineering gain basic knowledge about the design of mechanical transmission
systems. Therefore, we can have a perspective on the manufactured system, controlling
automatic systems of factories, plants, or workshops. Within the scope of the project,
knowledge from basic subjects such as Kinematics and Dynamics of Machines, Machine
Elements, Mechanical Engineering Drawing... can be applied to help students have an
overview of a transmission system. During the project implementation, ability in AutoCad,
SolidWork is improved significantly. From here, combined with specialized knowledge, we
can access practical systems and gain a more general view to prepare for your next project
and graduation thesis.
I sincerely thank Assoc. Prof. Dr. Le Thanh Long for dedicatedly guiding us to
complete the transmission system project. We would also like to express my sincere gratitude
to the teachers instructing me this semester because the project review sessions have helped
me gain more knowledge and experience when making drawings.
This is the first mechanical system project, so lack of calculation and choosing details
cannot be avoided. We hopefully receive further guidance from teachers so that our group can
consolidate our knowledge and gain valuable experiences for our future career.
i Class CC01 – Topic 4

TABLE OF CONTENTS
ACKNOWLEDGEMENT.........................................................................................................i
TABLE OF CONTENTS.........................................................................................................ii
LIST OF FIGURES.................................................................................................................iv
LIST OF TABLES....................................................................................................................v
CHAPTER 1. MOTOR SELECTION AND TRANSMISSION RATIO DISTRIBUTION
.....................................................................................................................................................2
1.1. Motor selection....................................................................................................................
1.2. Parameters of transmission system......................................................................................
1.3. Summary for motor selection and transmission ratio distribution.......................................
CHAPTER 2. DESIGN AND SELECT FOR V-BELT DRIVERS......................................6
2.1. Type of belt and pulleys’s diameter.....................................................................................
2.2. Parameters of V-belt drivers................................................................................................
2.3. Checking for stress condition.............................................................................................11
2.4. Service life of belt..............................................................................................................11
2.5. Summary for V - belt drivers.............................................................................................12
CHAPTER 3. DESIGN AND SELECT FOR GEAR DRIVERS.......................................13
3.1. Material selection...............................................................................................................13
3.2. Number of circle to the inflection of the fatigue curve......................................................13
3.3. Determine allowable contact stress....................................................................................13
3.4. Determine allowable bending stress..................................................................................14
3.5. Parameters of gear drivers.................................................................................................15
3.6. Checking for stress condition.............................................................................................20
3.7. Summary for gear drivers..................................................................................................21
CHAPTER 4. DESIGN AND SELECT FOR SHAFT........................................................24
4.1. Material and allowable stress selection..............................................................................24
4.2. Parameters of shaft.............................................................................................................24
4.3. Checking for strength of shaft and key..............................................................................32
4.4. Summary for shaft design..................................................................................................33
CHAPTER 5. DESIGN AND SELECT FOR BEARING AND COUPLING...................35
5.1. Bearing...............................................................................................................................35
5.2. Coupling.............................................................................................................................37
CHAPTER 6. DESIGNING GEARBOX AND OTHER AUXILIARY ELEMENTS.....38
ii Class CC01 – Topic 4

6.1. Initial parameters...............................................................................................................38

6.2. Choose the material for gearbox cover..............................................................................38
6.3. Calculation and designing gearbox cover..........................................................................39
6.4. Other auxiliary machine elements.....................................................................................40
6.5. Lubrication for gear box....................................................................................................42
CHAPTER 7. THE TOLERANCE.......................................................................................43
7.1. Bearing’s tolerance............................................................................................................43
7.2. Assembly elements............................................................................................................43
7.3. Summary of assembly tolerance........................................................................................43
CHAPTER 8. DESIGN OF TRANSMISSION SYSTEM...................................................45
8.1. Extrusion machine.............................................................................................................45
8.2. Spiral screw........................................................................................................................46
8.3. Design for spiral screw......................................................................................................47
REFERENCES........................................................................................................................48
iii Class CC01 – Topic 4

LIST OF FIGURES
Figure 2-1: Select the belt type (belt cross-section) according to the power and.......................6
Figure 2-2: Pulley parameters...................................................................................................10
Figure 3-1: Forces acting on gear mesh....................................................................................18
Figure 4-1: Preliminary length of shaft I..................................................................................25
Figure 4-2: Preliminary length of shaft II.................................................................................26
Figure 4-3: Shaft I design.........................................................................................................28
Figure 4-4: Shaft II design........................................................................................................31
Figure 8-1: Extrusion machine..................................................................................................45
Figure 8-2: Holton Crest Continuous Rotary Extrusion Machine............................................46
Figure 8-3: Single screw extruder.............................................................................................46
Figure 8-4: Structural parameters of Screw blade diameter and pitch......................................47
iv Class CC01 – Topic 4

LIST OF TABLES
Table 1-1: Ratio of mechanical drives........................................................................................2

Table 1-2: Motor SGA with 11 kW power.................................................................................3
Table 1-3: Transmission ratio calculation and distribution........................................................4
Table 2-1: Cross section of V-belt, diameter of pulleys ISO 1081 - 95.....................................6
Table 2-2: Ratio factor................................................................................................................8
Table 2-3: Factor taking into account the influence of the load conditions................................9
Table 2-4: Pulley parameters......................................................................................................9
Table 2-5: Linear mass density of belt......................................................................................10
Table 2-6: Parameter for V-belt drivers....................................................................................12
Table 3-1: Material of gear (H – hardness; H 1: driving gear hardness; H 2: driven gear
hardness)...................................................................................................................................13
Table 3-2: Factor KHβ , KFβ ....................................................................................................15
Table 3-3: Grade of accuracy denpends on peripheral velocity...............................................17
Table 3-4: Factor KHv and KFv of spur helical gear...............................................................19
Table 3-5: Factor KHα ..............................................................................................................20
Table 3-6: Summary for gear design........................................................................................22
Table 3-7: Summary for stress condition..................................................................................23
Table 4-1: Geometry parameter of shaft...................................................................................24
Table 4-2: Shaft section diameter (Unit: mm)..........................................................................26
Table 4-3: Strength condition of shaft I....................................................................................33
Table 4-4: Strength condition of shaft II...................................................................................33
Table 4-5: Stress property of shaft design................................................................................34
Table 5-1: Parameter of 36205 bearings...................................................................................36
Table 5-2: Parameter of 36208 bearings...................................................................................37
Table 5-3: Coupling specification.............................................................................................37
Table 6-1: Parameters and calculation of gearbox cover..........................................................39
Table 6-2: Ring bolt and hook parameter.................................................................................40
Table 6-3: Gearbox cap parameter............................................................................................41
Table 6-4: Parameter of access door.........................................................................................41
Table 6-5: Air vent parameter...................................................................................................41
Table 6-6: Oil drain plug parameter........................................................................................41
Table 6-7: Oil level indicator parameter...................................................................................42
v Class CC01 – Topic 4

Table 7-1: Assembly tolerance.................................................................................................43

Table 7-2: Tolerance for Assembly of Deep Groove Ball Bearings.........................................44
Table 7-3: Tolerance for Thread Assembly..............................................................................44
vi Class CC01 – Topic 4

CHAPTER 1. MOTOR SELECTION AND TRANSMISSION RATIO

DISTRIBUTION
1.1. Motor selection

1.1.1. General efficiency of transmission system
Table 1-1: Ratio of mechanical drives
Efficiency η
Machine elements
Lubrication Open
Spur gear 0,96 ÷ 0,98 0,93 ÷ 0,95
Bevel gear 0,95 ÷ 0,97 0,92 ÷ 0,94
Worm gear
- z 1=1 0,70 ÷ 0,80
- z 1=2 0,75 ÷ 0,85
- z 1=4 0,80 ÷ 0,90
Wave gear reducer 0,72 ÷ 0,82
Planetary reducer
Single stage 0,95 ÷ 0,97
Double stage 0,92 ÷ 0,96
Chain drives 0,92 ÷ 0,98 0,90 ÷ 0,93
Friction drives 0,90 ÷ 0,96 0,70 ÷ 0,88
Belt drives 0,94 ÷ 0,96
Rolling-contact bearings 0,99 ÷ 0,995
Sliding-contact bearings 0,98 ÷ 0,99
Couplings 0,98
According to Table 1-1, we chose the efficiencies of machine elements as follows:
The efficiency of V-Belt:
ηbelt =0.95
The efficiency of rolling-contact bearings:
ηrolling =0.99
The efficiency of gear:
η gear=0.97
The efficiency of couplings:
η couplings=0.98
The efficiency of sliding-contact bearings:
η slidings=0.98
7 Class CC01 – Topic 4

The general efficiency of transmission system:

η general =ηbelt ×η rolling × ηrolling × η gear × ηcouplings × ηslidings
( 1.1 )
¿ 0.95 ×0.99 × 0.99 ×0.97 × 0.98× 0.98=0.8674
1.1.2. Required power of motor
Working power of system according to formula:
Fv
P= EQ /¿
1000
¿
Rotational speed of screw impeller, formula (2.2):
60000 v
n= EQ /¿
πD
¿
Required power of motor, formula (2.3):
P
P pre = EQ /¿
ηgeneral
¿
in which P pre is the preliminary power for the motor.
1.1.3. Motor selection
According to the calculated required power, we choose the standard motor power as 11
kW. With that standard motor power, we have the following options to choose our motor as
well as its rotational speed and transmission ratio.
Table 1-2: Motor SGA with 11 kW power
Rotational General
V-belt ub Spur gear ug
speed rpm transmission u
Motor 1 2935 16.22 3.24 5
Motor 2 1460 8.07 2.561 3.15
Motor 3 970 5.36 2.144 2.5
Motor 4 730 4.03 1.61 2.5
Based on Table 1-2, we choose motor 2.
1.2. Parameters of transmission system
1.2.1. Working power on each shaft
Required power of motor:
Pmotor =9.0622(kW )Working power on shaft II:
P 7.8605
P II = = =8.1846(kW )
ηslidings × ηcoupling 0.98 × 0.98
( 1.5 )
Working power on shaft I:

PII 8.1846
P I= = =8.5230(kW )
ηgear × ηrolling 0.97 × 0.99
Working power of motor:
PI 8.5230
Pmotor = = =9.0622(kW )( satisfied )
ηbelt ×ηrolling 0.95 ×0.99
1.2.2. Rotational speed on each shaft
Rotational speed of motor:
n motor=1460 (rpm)
Rotational speed of shaft I:
nmotor 1460
nI= = =570.0930 (rpm)
ubelt 2.561
( 1.6 )
Rotational speed of shaft II:
n I 570.087
n II = = =180.9819(rpm)
u gear 3.15
Rotational speed of spiral screw:
n spiral screw=nII =180.9819(rpm)
1.2.3. Torque on each shaft
Torque of motor:
P motor 9.0621
T motor=9550 × =9550 × =59.2765(Nm)
nmotor 1460
( 1.7 )
Torque of shaft I:
PI 8.5203
T I =9550 × =9550 × =142.7739 (Nm)
nI 570.087
Torque of shaft II:
PII 8.1846
T II =9550 × =9550 × =431.8831 (Nm)
n II 180.98
Torque of spiral screw:
Pspiral screw 7.8605
T spiral screw =9550 × =9550× =414.7806(Nm)
n spiral screw 180.98
1.3. Summary for motor selection and transmission ratio distribution
Table 1-3: Transmission ratio calculation and distribution
Shaft
Motor I II Working
Parameter
u 2.56 3.15 1

n [rpm] 1460 570.09 180.98 180.98
P [kW] 9.06 8.52 8.18 7.86
T (N∙m) 59.28 142.77 431.88 414.78
In which:
 Shaft Motor: connecting the motor to the V-belt drive.
 Shaft I: connecting the V-belt drive to the 1-stage helical spur gear reducer.
 Shaft II: connecting the 1-stage helical spur gear reducer to the couplings.
 Shaft Working: connecting the couplings to the spiral screw.

CHAPTER 2. DESIGN AND SELECT FOR V-BELT DRIVERS
2.1. Type of belt and pulleys’s diameter

Select the belt type (belt cross-section) according to the power and number of
revolutions according to the graph Figure 2-1. Then look up Table 2-1 for other belt data:
Figure 2-1: Select the belt type (belt cross-section) according to the power and
number of revolutions
Table 2-4: Cross section of V-belt, diameter of pulleys ISO 1081 - 95
Diameter
bp bo h yo A Belt length Torque
Type d1
(mm) (mm) (mm) (mm) (m m )
2 (mm) T 1 (N.m) min
(mm)
Z 8.5 10 6 2.1 47 400 ÷ 2500 < 25 64 (50)
A 11 13 8 2.8 81 560 ÷ 4000 11 ÷ 70 90 (75)
B 14 17 10.5 4.0 138 800 ÷ 6300 40 ÷ 190 125 (125)
V-belt
C 19 22 13.5 4.8 230 1800 ÷ 10600 110 ÷ 550 200 (200)
D 27 32 19 6.9 476 3150 ÷ 15000 450 ÷ 2000 315 (355)
E 32 38 23.5 8.3 692 4500 ÷ 18000 1100 ÷ 4500 500 (500)
SPZ 8.5 10 8 2 56 630 ÷ 3550 < 500 63
SP
Narrow 11 13 10 2.8 93 800 ÷ 4500 90 ÷ 400 90
A
V-belt
SPB 14 17 13 3.5 159 1250 ÷ 8000 300 ÷ 2000 140
SPC 19 22 18 4.8 278 2000 ÷ 8000 2000 224
Following the graph above and Table 2-1, with the given data n=1460 rpm, P=11 kW ,
we choose belt type B with
2
b o=17 mm , b p =14 mm , h=10.5 mm , y o=4 mm , A=138 mm , d min =125 mm .

2.2. Parameters of V-belt drivers

2.2.1. Diameter of the small pulley
Calculate the diameter of the small pulley:
d 1=1.2 × d min=1.2 ×125=150(mm)
( 2.1 )
So the standard value of d 1 is 160 mm.
2.2.2. Calculate the belt velocity
Velocity of driving pulley:
π ×d 1 ×n1 π × 160× 1460
v 1= = =12.2313(m/ s)
60000 60000
( 2.2 )
In which:
- d 1 : diameter of driving pulley
- n1 : rotation of driving pulley
The belt velocity is 12.2313 (m/s) < [v]=25 (m/s) (satisfied)
2.2.3. Diameter of the big pulley
Choose the creep factor: ξ=0.01
Diameter of the big pulley:
d 2=d 1 ×u × (1−ξ )=160 ×2.561 × ( 1−0.01 )=405.6601(mm)
( 2.3 )
So the standard value of d 2 is 400 mm.
The real transmission ratio of belt drive:
d2 400
u 'b = = =2.5253( mm)
d 1 ×(1−ξ ) 160 ×(1−0.01)
( 2.4 )
Error of transmission ratio:
% ∆ u=¿ u b −ub∨ ¿ × 100 %=1.3953 % ¿ ( 2.5 )
'
ub
Deviation from the preselected value 1.3953% < 4% (satisfied)
2.2.4. The center distance
Calculation for center distance:
2 × ( d 1 +d 2 ) ≥ a ≥ 0.55× ( d 1 +d 2 ) +h
( 2.6 )
2 × ( 160+ 400 ) ≥ a≥ 0.55 × (160+ 400 ) +10.5
1120 ≥ a ≥ 318.5
We can choose a = 480 (mm)
2.2.5. Belt length L
Determination of belt length:

2
π (d 1 +d 2 ) (d 2−d 1)
L=2 a+ +
2 4a
( 2.7 )
2
π × ( 160+ 400 ) ( 400−160 )
¿ 2 ×480 + + =1869.6459 (mm)
2 4 ×480
So the standard value of L is 1800 mm
2.2.6. Number of turns
Check for number of turns:
v 12.2313 −1 −1
i= = =6.7951 s <10 s (satisfied )
L 1800
1000
( 2.8 )
Recalculate center distance a:
k + √ k 2−8 ∆2
a=
4
( 2.9 )
In which: k and ∆ can be determined by these formula:
d 1+ d 2 160+400
k =L−π × =1800−π × =920.3541(mm)
2 2
( 2.10 )
d 2−d 1 400−160
∆= = =120(mm)
2 2
( 2.11 )
Thus:
920.3541+ √ 920.35412−8 ×120 2
a= =443.9593 mm
4
The value of a is still within the acceptable range:
1120 ≥ a ≥ 318.5
2.2.7. Contact angle
Calculation for contact angle:
d 2−d 1 400−160
α 1=180−57× =180−57 × =149.1864 °> 120°
a 443.9593
( 2.12 )
α 1=2,6010 rad
⟹ Satisfy the condition
2.2.8. Calculate factors of belt drives
Contact angle correction factor:

( ) ( )=0.9205
−α 1 −149.1864 °
C α =1.24 × 1−e 110 =1.24 × 1−e 110
( 2.13 )
Velocity correction factor:
C v =1−0.05× ( 0.01 × v 2−1 )=1−0.05 × ( 0.01 ×12.2313 2−1 )=0.9752
( 2.14 )
Belt length correction factor and allowable effective power:
C L= 6
√ √L 6 1800
L0
=
2240
( 2.15 )
=0.9642
[ P0 ]=3.1874 kW when d 1=160 mm∧v 1 =12.2313 m/ s

Transmission ratio correction factor:
According to Table 2-2:
C u=1.14 because u=2.56>2.5
Table 2-5: Ratio factor
u 1 1.1 1.2 1.4 1.8 ≥ 2.5
Cu 1 1.0 1.07 1.1 1.12 1.14
Factor taking into account the influence of uneven load distribution between belts:
We assume number of belt correction factor:
C z =¿0.9
Factor taking into account the influence of the load conditions:
Table 2-6: Factor taking into account the influence of the load conditions
Static Slight oscillation Strong oscillation Impact
1 0.9 ÷ 0.8 0.8 ÷ 0.7 0.7 ÷ 0.6
C r=0.9 (working two shifts, static)
2.2.9. Number of belts
Calculation for number of belts:
PI 9.0601
z≥ = =3.5571
[ P0 ] C α C u C L C z Cr C v 3.1874 ×0.9205 ×1.14 ×0.9642 ×0.9 × 0.9× 0.9752
( 2.16 )
We choose z = 4.
2.2.10. Width and outside diameter of the pulleys
Table 2-7: Pulley parameters
φ=34 ° φ=36 ° φ=38 ° φ=40 °
Type H h0 t e
d bt d bt d bt d bt

10.
O 10 2.5 12 8 63…71 10 80…100 10.1 112…160
2
≥180 10.3
125… 13.
A 12.5 3.3 15 10 90…112 13.1
160
13.3 180…400
4
≥450 13.5
12. 180… 17.

Б 16 4.2 19
5
125…160 17
224
17.2 250…500
4
≥ 560 17.6
224… 23.
B 21 5.7 25.5 17 200 22.7
315
22.9 355…630
1
≥ 710 23.3
10.
УO 12.5 2.5 12 8 63…80 10 - - >80
2
- -
13.
УA 16 3 15 10 90…112 12.8 - - >112
1
- -
12. 16.
УБ 21 4 19
5
140…180 16.4 - - >180
7
- -
22.
УB 24 5 26 17 224…315 22 - - >315
4
- -
φ
bf
bt
h0
H−h0 d
Do
Figure 2-2: Pulley parameters

We choose pameter of pulleys as follow:
h 0=4.2 ( mm ) ; t=19 ( mm ) ; e=12.5 ( mm ) ; B=82 ( mm ) ; d a 1=168.4 (mm); d a 2=408.4 (mm)
2.2.11. Force on each belt
- Initial tension force:
F 0= A × σ 0=z × A1 ×σ 0=4 ×138 ×1.2=662.4(N )
( 2.17 )
- Tension force on each belt:
F 0 662.4
= =165.6 (N )
z 4
( 2.18 )

- Circumferential force:
1000 × P1 1000 × 9.0602
F t= = =740.9021(N )
v1 12.2313
( 2.19 )
- Circumferential force on each belt:
F t 740.9021
= =185.2255( N )
z 4
- Shaft load:
F r ≈3 × F0 ×sin ( α2 )=3× 662.4 × sin ( 2,60102 rad )=1915.0491(N )

1
( 2.20 )
- Centrifugal tension:
Table 2-8: Linear mass density of belt
Belt cross section symbol O A B Б УO УА УБ УB
q m , kg/m 0.061 0.105 0.178 0.300 0.069 0.118 0.196 0.363
Base on the type B belt drive, we have q m = 0.178 kg/m
2 2
F v =q m × v =0.178× 12.2313 =26.6295 (N)
( 2.21 )
in which q m is the length density of belt (kg/m)
2.2.12. Friction coefficient
Base on the diameter of type B V-belt drive d 1=160 mm , we choose γ =34 o
- From formula 4.24 − page 136:

F t ef ' α + 1 1
F 0= × f ' α + F v =662.4(N )
2 e −1 1
( 2.22 )
→ f ' =0.5125
- Minimum friction coefficient that prevent slipping on belt drive:
f min =f ' ×sin ( 2γ )=0.1498

( 2.23 )
2.2.13. Force acting on each side
The force on the tight side:

Ft 740.9021
F 1=F o+ =662.4 + =1032.8511(N )
2 2
( 2.24 )
The force on the loose (slack) side:
Ft 740.9021
F 2= f ' α + F v = 0.5125× 2.6010 +26.6295=291.9489(N )
e −1 1
e −1
( 2.25 )
2.3. Checking for stress condition
Maximum belt stress in belt drive:
F0 Ft 2 −6 2× y 0
σ max= + + ρ m v × 10 + ×E
A 2A d1
( 2.26 )
662.4 740.9021 2 −6 2× 4
⇒σ max= + +1100× 12.2313 × 10 + ×100
4 ×138 2 × 4 ×138 160
⇒σ max=¿ 7.0357 MPa < 10 MPa=[σ ] k (satisfied)

2.4. Service life of belt
( )
m
σr
( )
8
9
×10
7
× 107
σ max 7.0357
Lh = = =1465.4274 (hours )
2× 3600 ×i 2 ×3600 ×6.7951
( 2.27 )
In which:
- Fatigue strength of belt σ r=9 MPa (V-belt)
- Exponent of fatigue curve m = 8 (V-belt)

2.5. Summary for V - belt drivers

Table 2-9: Parameter for V-belt drivers
Parameter Value
Belt type B-type V-belt
Number of the belts z 4
Center distance a (mm) 443.9593
Belt length L (mm) 1800
Warp angleα 1 (° ) 149.1864
Pulley’s width B (mm) 82
The number of Belt's turn per second ( s−1 ¿ 6.7951
Driving pulley’s diameterd a 1 (mm) 168.4
Driven pulley’s diameterd a 2 (mm) 408.4

Maximum belt stress 7.0357
Initial tension F 0 (N) 662.4
Tangential force F t(N) 740.9021
Shaft load Fr (N) 1915.0491
The force on the tight side 1032.8511
The force on the loose (slack) side 291.9489
Service life of belt Lh (hours) 1465.4274

CHAPTER 3. DESIGN AND SELECT FOR GEAR DRIVERS
3.1. Material selection

Table 3-10: Material of gear (H – hardness; H 1 : driving gear hardness; H 2 : driven gear hardness)
Spur gear drive with small power
Helical spur gear drive with
(P ≤ 2 kW), average power (2kW
P>7.5 kW
Value ≤P ≤ 7.5 kW)
Driving gear,
Driven gear Driving gear, Screw Driven gear
Screw
C35, C45, 35L, 40L steel
Material C40, 40Cr, 40CrNi, 35CrMo, 45L 40Cr, 40CrNi, 35CrMo steel
steel
Normalization Structural
Structural
Annealing improvement +
Structural improvement improvement
induction hardening
Selection for hardness of gear H ≤ 350HB,
H 1−H 2=20 …50
When H ≥ 45 HRC , H ≤340 HB ,
H 1−H 2=70 HB
Driving gear: choose 40Cr steel with hardness HB 1=550 HB, through induction
hardening, structural improvement.
Driven gear: choose 40Cr steel with hardness HB 2=350 HB, structural improvement.
3.2. Number of circle to the inflection of the fatigue curve
Number of cycles to the inflection of the fatigue curve:
Driving gear:
2.4 2.4 6
N HO =30 HB 1 =30 × 550 =113237874.6408 ≈ 113.2379×10
1
( 3.1 )
Driven gear:
2.4 2.4 6
N HO =30 HB 2 =30 × 350 =38272299.9055≈ 38.2723 × 10
2
6
N FO =N FO =5 ×10
1 2
3.3. Determine allowable contact stress

3.3.1. Contact endurance limit
For driving gear:
550
σ OHlim 1=17 HR C 1+ 200=17 × +200=1135 ( MPa )
10
( 3.2 )
For driven gear:

σ OHlim 2=2 HB 2 +70=2× 350+70=770 ( MPa)

( 3.3 )
Safety factor: S H 1=1.2; S H 2=1.1
3.3.2. Working time
Calculation for working time:
Lh=La ×365 × K year ×24 × K n=7 × 300 ×2 ×8=33600(hours )
( 3.4 )
3.3.3. Equivalent loading circle number
The equivalent number of cycles if the gear is working with working load and number
of revolution n is constant:
N H E =N FE =60 × c × n1 × Lh
1 1
( 3.5 )
7
N HE 1=N FE =60 ×1 ×570.0930 ×33600=1149307500.4088 ≈ 114.9308×10
1
N H E =N FE =60× c × n2 × Lh
2 2
6
N H E =N FE =60× 1× 180.9819× 33600=364859523.9393 ≈ 364.8595 ×10
2 2
3.3.4. Service life coefficient

Determine the life coefficient:
K HL=
√
6 N HO
N HE
( 3.6 )
Because N HE > N HO, so N HO=N HE. Thus K HL1=K HL2=1
3.3.5. Allowable contact stress
For driving gear:
0.9 × σ OHlim 1 × K HL 0.9 ×1135 ×1
[ σ H ]= 1
sH
= 1
1.2
=851.25 ( MPa )
1
( 3.7 )
For driven gear:
0.9 × σ OHlim 2 × K HL 0.9 ×770 × 1
[ σ H ]=2
sH
2
=
1.1
=630(MPa)
2
With the helical gear, we have:

[ σ H ]= √0.5 ×([ σ H 1 ] + [ σ H 2 ] )=√ 0.5 ×(851.252 +6302 )=748.8413(MPa)
2 2
(3.8 )
Checking with the condition: [σ ¿¿ H ]min ≤ [σ ¿¿ H ]≤1.25 [σ ¿¿ H ]min ¿ ¿ ¿ (satisfied)
3.4. Determine allowable bending stress
3.4.1. Contact endurance limit
For driving gear:

σ OFlim 1=900 ( MPa )

For driven gear:
σ OFlim 2=1.8 × HB 2=1.8 ×350=630(MPa)
( 3.9 )
Safety factor: s F =s F =1.75
1 2
Coefficient of turning direction: K FC =1 (one-way rotation)

3.4.2. Service life coefficient
Determine the life coefficient:
K FL=
√ N FO
9
N FE
( 3.10 )
Because N FE> N FO , so N FO=N FE. Thus K FL =K FL =1 1 2
3.4.3. Allowable contact stress

For driving gear:
K K 1 ×1
[ σ F ]=σ OFlim 1 × FCs FL 1 =900× 1.75 =514.2857 ( MPa )
1
H
( 3.11 )
For driven gear:
K FC K FL 1 1 ×1
[ σ F ]=σ OFlim 1 ×
2
sH
=630 ×
1.75
=360( MPa)
3.5. Parameters of gear drivers

3.5.1. Ratio face width
We choose ψ ba=0.25
From here infer:
ψ ba (u+1) 0.25×(3.15+1)
ψ bd = = =0.5188
2 2
( 3.12 )
We choose K Hβ=1.03 and K Fβ=1. 05.
Table 3-11: Factor K Hβ, K Fβ
Near one bearings
Symmetrically Overhanging
between bearings L L position
Factor ≤3 ÷ 6 >6
d d
ψ ba
HB HB HB HB HB HB HB HB
¿ 350 ¿ 350 ¿ 350 ¿ 350 ¿ 350 ¿ 350 ¿ 350 ¿ 350
Factor K Hβ
0.2 1.00 1.00 1.01 1.00 1.06 1.02 1.15 1.07

0.4 1.01 1.00 1.05 1.02 1.12 1.05 1.35 1.15

0.6 1.03 1.01 1.09 1.04 1.20 1.08 1.60 1.24
0.8 1.06 1.03 1.14 1.06 1.27 1.12 1.85 1.35
1.0 1.10 1.04 1.18 1.08 1.37 1.15 - -
1.2 1.13 1.05 1.25 1.10 1.50 1.18 - -
1.4 1.15 1.07 1.32 1.13 1.60 1.23 - -
1.6 1.20 1.08 1.40 1.16 - 1.28 - -
Factor K Fβ
0.2 1.00 1.00 1.02 1.01 1.10 1.05 1.25 1.13
0.4 1.03 1.01 1.07 1.04 1.20 1.12 1.35 1.28
0.6 1.05 1.02 1.13 1.07 1.30 1.17 1.90 1.50
0.8 1.08 1.05 1.20 1.11 1.44 1.23 2.30 1.70
1.0 1.15 1.08 1.27 1.15 1.57 1.32 - -
1.2 1.18 1.10 1.37 1.20 1.72 1.40 - -
1.4 1.25 1.13 1.50 1.25 1.85 1.50 - -
1.6 1.30 1.16 1.60 1.32 - 1.60 - -
3.5.2. The center distance
Center distance a w:
a w ≥ 430 × ( u+1 ) ×
√
3 T 1 K Hβ
2
ψ ba [σ ¿¿ H ] u
¿ ( 3.13 )
a w ≥ 430 × ( 3.15+1 ) × 3
√ 142.7739× 1.03
025 ×748.8413 2 ×3.15
⇒ aw ≥ 123.6902(mm)
According to the standard series we choose a w =125 mm
3.5.3. Module of gear drives
The module m can be calculated according to the center distance a w:
m=( 0,0125 ÷ 0,025 ) × aw = ( 0,0125÷ 0,025 ) ×125=1.5625 ÷ 3.1250
( 3.14 )
We choose a w =3.
3.5.4. Number of teeth
In case helical gear, we have the following condition:
8 ° ≤ β ≤20 °
So that:

mn z 1 ( u+1 )
cos 8o ≥ ≥ cos 20 °
2 aw
( 3.14 )
o o
2 aw cos 8 2 aw cos 20
≥ z1 ≥
m ( u+1 ) m ( u+1 )
o o
2× 125× cos 8 2 ×125 ×cos 20
≥ z1 ≥
3 × ( 3.15+1 ) 3 × ( 3.15+1 )
19.8849 ≥ z 1 ≥18.8693
We choose z 1=19.
Calculation for number of teeth of driven gear:
z 2=z 1 × ugear =19× 3.15=59.85
( 3.15 )
We choose z 1=60
3.5.5. Geomketry parameters of gear drive
Helix angle:
(z ¿ ¿1+ z 2 ) 3(19+ 60)
β=arccos m =arccos =18.5584 ° ¿ ( 3.16 )
2 aw 2 ×125
Pitch circle diameter of the driving gear:
z1 m 19× 3
d 1= = =60.1266 (mm)
cos β cos 18.5584 °
( 3.17 )
Pitch circle diameter of the driven gear:
z2 m 60 ×3
d 2= = =189.8734 (mm)
cos β cos 18.5584 °
Rolling circle diameter:
d w =d 1=60.1266(mm)
1
d w =d 2=189.8734( mm)
2
Outside diameter of driving gear:

d a =d 1+ 2m=60.1266+2 ×3=66.1266(mm)
1
( 3.18 )
Outside diameter of driven gear:
d a =d 2+ 2m=189.8734 +2 ×3=195.8734( mm)
2
Root diameter of driving gear:

d f =d 1−2.5 × m=60.1266−2.5 ×3=52.6266 (mm)
1
(3.19 )
Root diameter of driven gear:

d f =d 2−2.5 × m=189.8734−2.5 ×3=182.3734(mm)

2
Driven gear width:

b 2=a w ×ψ ba=125 × 0.25=31.2500=b w
( 3.20 )
Driving gear width:
b 1=b2 ×1.09=31.25× 1.09=34.0625
Pressure angle:
α nw =20 °
Pressure angle in helical gear:
tan α
tan α tw =
cos β
( 3.21 )
Then: α tw =21.0035 °
3.5.6. Peripheral velocity
π d 1 n1 π ×60.1266 × 570.0930
v= = =1.7948 m/s
60000 60000
( 3.22 )
Table 3-12: Grade of accuracy denpends on peripheral velocity
Grade of accuracy
Type of gear Type of teeth 6 7 8 9
Maximum peripheral velocity, m/s
Straight 15 10 6 3
Spur gear
Helical 30 15 10 6
Bevel gear Straight 9 6 4 2.5
We choose grade of accuracy 9 with v gh=6 m/s
3.5.7. Forces acting on gear mesh
Peripheral force Ft:
2T 1 2×142.7739 × 103
F t 1=F t 2= = =4749.1100 ( N )
dw1
60.1266
( 3.23 )
Axial force Fa:
F a 1=F a2 =F t 1 ×tanβ =4749.11× tan 18.5584 ° =1594.4101(N )
(3.24 )
Radial force Fr:

F t 1 × tan α nw 4749.11× tan 20o

F r 1=F r 2= = =1823.3488 ( N )
cosβ cos 18.5584 °
( 3.25 )
Pulley Driving gear
Shaft I
Fa 1
Ft 1 Fr 1
Fr 2
Ft 2
Fa 2
Shaft II
Coupling
Driven gear
Figure 3-3: Forces acting on gear mesh

3.5.8. Dynamic load factors

Table 3-13: Factor K Hv and K Fv of spur helical gear
Grade K Hv K Fv
of Hardness Peripheral velocity v, m/s
accurac
y 1 5 10 15 20 1 5 10 15 20
H 1∧H 2 >350 HB
1.01 1.06 1.08 1.12 1.16 1.01 1.06 1.08 1.12 1.16
6
H 1∨H 2 >350 HB
1.01 1.06 1.13 1.19 1.26 1.03 1.13 1.26 1.38 1.51
H 1∧H 2 >350 HB
1.01 1.05 1.10 1.15 1.20 1.01 1.05 1.10 1.15 1.20
7
H 1∨H 2 >350 HB
1.02 1.08 1.16 1.24 1.32 1.03 1.16 1.32 1.48 1.64
H 1∧H 2 >350 HB
1.01 1.06 1.12 1.18 1.24 1.01 1.06 1.12 1.18 1.60
8
H 1∨H 2 >350 HB
1.02 1.10 1.19 1.29 1.38 1.04 1.19 1.38 1.58 1.77
H 1∧H 2 >350 HB
1.01 1.07 1.14 1.21 1.28 1.01 1.07 1.14 1.21 1.28
9
H 1∨H 2 >350 HB
1.02 1.11 1.22 1.34 1.45 1.04 1.22 1.45 1.67 -
According to Table 3-4, we choose K Hv =1.0371 and K Fv =1.0764

Table 3-14: Factor K Hα

Grade of accuracy
Peripheral velocity, m/s
5 6 7 8 9
2.5 1 1.01 1.03 1.05 1.13
5 1 1.02 1.05 1.09 1.16
10 1.01 1.03 1.07 1.13 -
15 1.01 1.04 1.09 - -
20 1.02 1.05 1.12 - -
25 1.02 1.06 - - -
According to Table 3-5, we choose K Hα =1.13:
Factor considers the influence of manufacturing errors in the pinion and the wheel on
the load distribution between the teeth:
4+(ε α −1)(n acc −5) 4+(1.5720−1)(9−5)
K Fα= = =2.4712
4εα 4 ×1.5720
(3.24 )
In which:
 Contact ratio ε α can be determined as follow:
[
ε α = 1.88−3.2
( 1 1
+
z1 z2 )]
cos β=1.5720
( 3.25 )
 n acc: grade of accuracy
3.6. Checking for stress condition
3.6.1. Contact stress factor
Factor taking into account the shape of the contact surface:
ZH=
√ 4 cos β
sin 2 α tw √
=
4 cos 18.5584 °
sin(2 ×21.0035 °)
( 3.26 )
=2.3804
Elasticity factor that takes into account gear material properties:
√[
E1 E2
ZM=
π E 2 ( 1−μ1 ) + E 1 ( 1−μ2 )
2 2
]
( 3.27 )
√
2
( 2.1× 105 )
ZM= =191.6457
π [ 2.1 ×10 ( 1−0.3 ) +2.1 ×10 ( 1−0.3 ) ]
5 2 5 2
In which:
 E1 , E2 : modulus of elasticity

 μ1 , μ 2: Poisson’s ratio
Factor taking into account the effect of total contact length:
Z ε=
√ √ 1
εα
=
1
1.5720
(3.28 )
=0.7976
Load ratio:
K H =K A × K Hβ × K Hv × K Hα =1 ×1.03 ×1.0371 ×1.13=1.2071
( 3.29 )
3.6.2. Contact stress condition

Contact stress:
σ H=
dw 1 √
Z M Z H Z ε 2 ×10 3 T 1 K H (u ±1)
( 3.30 )
bw u
√
3
191.6457 ×2.3804 × 0.7976 2 ×10 ×142,7739 ×1.2071(3.15+1)
σ H=
60.1266 31.25 ×3.15
σ H =729.4645 MPa<[σ ¿¿ H ](satisfied )¿
3.6.3. Bending stress factor
Factor takes into account the form of the tooth and stress concentration:
13.2 27.9 x 2
Y F=3.47 + − +0.092 x
z z
( 3.31 )
13.2
Y F =3.47+ =4.1647
1
19
13.2
Y F =3.47 + =3.6900
2
60
Load factor:
K F=K Fv K Fβ K Fα =1.0764 × 1.05× 2.4712=2.7930
( 3.32 )
Factor that takes teeth overlap into account:
1 1
Y ε= = =0.6361
ε α 1.5720
( 3.33 )
Vertical coincidence coefficient:
sin β sin 18.5584 °
ε β ≈ bw =31.25 × =1.0553
πm 3π
(3.34 )
Factor considers the tilt angle of the tooth in helical gearings:

β
Y β=1−ε β =0.8368
120
( 3.35 )
Bending stress:
Y F Ft KF Y ε Y β
σ F=
bw m n
(3.36 )
4.1647 × 4749.1100 ×2.7930 × 0.6361× 0.8368
σF = =313.6663 ( MPa ) < [ σ F 1 ]
1
31.25 ×3
3.6900 × 4749.1100 × 2.7930× 0.6361 ×0.8368
σF = =277.9116 ( MPa ) < [ σ F 2 ]
2
31.25× 3
3.7. Summary for gear drivers
Table 3-15: Summary for gear design
Parameter Value
Type of gear Helical spur gear
Material 40Cr Steel
Center distance a w, mm 125
Module m, mm 3
Helix angle β , degree 18.5584
Number of teeth:
- Driving gear z 1 19
- Driven gear z 2 60
Pitch circle diameter:
- Driving gear d 1, mm 60.1266
- Driven gear d 2, mm 189.8734
Outside diameter:
- Driving gear d a , mm1 66.1266
- Driven gear d a , mm
2
195.8734
Root diameter:
- Driving gear d f , mm1 52.6266
- Driven gear d f , mm
2
182.3734
Gear width:
- Driving gear b 1, mm 34.0625
- Driven gear b 2, mm 31.2500
Forces acting:

- Peripheral force F t , N 4749.11

- Axial force F a, N 1594.4101
- Radial force F r, N 1823.3488
Torque, Nm 142.7739
Peripheral velocity, m/s 1.7948

Table 3-16: Summary for stress condition
Parameter Allowable value Calculated value Conclusion

Contact stress σ H , MPa 748.8413 729.4645 Satisfied
σ F 1 , MPa 313.6663 514.2857 Satisfied
Bending stress
σ F 2 , MPa 277.9116 360 Satisfied

CHAPTER 4. DESIGN AND SELECT FOR SHAFT
4.1. Material and allowable stress selection

Choose C45 steel with the allowable stress and the allowable torsion:
σ b=736 MPa
[ σ ]=65 MPa
Allowable torsional stress: [ τ ]=20 ÷ 25 MPa
Preliminary choosing allowable torsional stress [ τ ]1=[ τ ]2=25 MPa for both shaft.
Preliminary diameter of shaft can be determined as:
d ≥10 3
√ 16 T
π [τ ]
( 4.1 )
d 1 ≥10
√3 16 T 1
π [ τ ]1 √
=10
3 16 ×142.7739
π ×25
=30.7534 (mm)
√ √
3
3 16 T 2 3 431.8831 ×10
d 2 ≥10 =10 =44.4767(mm)
π [ τ ]2 π × 25
Select d 1=30 (mm); d 2=45(mm).

4.2. Parameters of shaft
4.2.1. Distance between the bearings
Distance between bearings in helical spur gear can be determined as follow:
l ≈l 1 +2 x+ w
( 4.2 )
In which:
 l 1=b 1=ψ ba a w
 w – according to Table 4.1

Table 4-17: Geometry parameter of shaft
Torque T, Nm e, mm u, mm f, not less than, mm w, mm
<10 40 ÷ 65 30 ÷ 55 35 ÷ 50 20 ÷ 40
10 ≤T <20 45 ÷ 70 35 ÷ 60 40 ÷ 55 25 ÷ 45
20 ≤ T < 40 50 ÷ 80 40 ÷ 65 55 ÷ 65 25 ÷ 50

40 ≤ T < 60 55 ÷ 85 45 ÷ 75 50 ÷ 70 25 ÷ 55
60 ≤ T <80 60 ÷ 90 50 ÷ 80 55 ÷ 75 30 ÷ 55
80 ≤ T <100 65 ÷ 100 55 ÷ 90 60 ÷ 80 30 ÷ 60
100 ≤T <200 70 ÷ 120 60 ÷ 100 60 ÷ 90 30 ÷ 70
200 ≤ T < 400 80 ÷ 145 70 ÷ 130 70 ÷ 105 40 ÷ 80
400 ≤ T < 600 100 ÷ 160 90 ÷ 140 80 ÷ 115 45 ÷ 85
600 ≤ T <800 115 ÷ 175 105 ÷ 155 90 ÷ 125 50 ÷ 90
800 ≤ T <1000 130 ÷ 185 120 ÷ 160 95 ÷ 135 55 ÷ 95
With shaft I, we choose x=10 ( mm ) , w=50 ( mm ) , f =75(mm)
l=b +2 x + w=42.5+2 ×10+50=112.5(mm)
75 mm 56.25 mm 56.25 mm
A Fv B
b
C D
Fa 1
FH b
Ft 1
Fr 1
Figure 4-4: Preliminary length of shaft I

With the shaft II, choose x=10 ( mm ) , w=65 ( mm ) , f =100(mm)
l=b +2 x + w=90+2× 10+65=122.5(mm)

61.25 mm 61.25 mm 100 mm

Ft
Fr 2
2
Fa 2
F cp
A B C D
Figure 4-5: Preliminary length of shaft II

4.2.2. Mayo length
Table 4-18: Shaft section diameter (Unit: mm)
Coupling or
rotating Coefficient Oil retaining ring Gear Bearing
elements
Shaft
t d2 d3
d1 r_max d2 d3 d4
(standard) (standard)
f'
3,5
I 30 3 37 40 41.6 42 40
1,6
4
II 45 3 53 50 51.6 55 50
2
Shaft I:
Mayo length of helical spur gear:
l gear =( 1 …1.5 ) d1 =( 1… 1.5 ) ×30=30 … 45 ( mm )
( 4.3 )
Choose l gear =gear width=42.5 (mm)
Mayo length of belt drive:
l belt = (1.2 … 1.5 ) d 1=( 1.2 … 1.5 ) ×35=36 … 45 ( mm )
( 4.4 )
Choose l belt =45(mm)
Shaft II:

Mayo length of helical spur gear:

l gear =37.5(mm)
Mayo length of coupling:
l coupling =40(mm)
4.2.3. Forces acting on shaft I

Force acting from helical gear:
+ Peripheral force: F t 1=4749.1100 (N)
+ Centrifugal force: F r 1=1823.3488 (N)
+ Axial force: F a 1=1594.4101(N)
Moment caused by axial force:
d1 60.1266 ×10
−3
M a 1=F a 1 × =1594.4101 × =47.9332(Nm)
2 2
( 4.5 )
The torque acting on the shaft:
T I =142.7739(Nm)
Equilibrium equations for y-z plane:
−3 −3 −3
∑ M B =RBy ×160 ×10 −F r 1 × 80× 10 + F vb ×230 ×10 −M a 1=0
−3 −3 −3
R Dy ×160 × 10 −684.802 × 80× 10 +247.998 ×230 × 10 −3.39=0
R Dy =2301.2847(N )
∑ F y =R By + F vb + R Ay−F r 1=0
7.09+247.998+ R Ay−684.802=0
R Ay =1923.2417(N )
Equilibrium equations for x-z plane:

−3 −3 −3
∑ M A =RBx × 160 ×10 −F Hb × 230 ×10 −F t 1 × 80× 10 =0
−3 −3 −3
R B x ×160 ×10 −681.37 ×230 ×10 −1876.78 × 80× 10 =0
R Dx =3212.1451(N )
The force equilibrium equation on x axis is:

∑ F x =R Bx −F Hb + R Ax −Ft 1=0
1917.86−681.37+ R Ax −1876.78=0
R Bx=280.5796

4.2.4. Diagram of bending moment and torque diagram of shaft I

75 mm 56.25 mm 56.25 mm
z
x
FH b
y
Fa 1
FV b
Ft 1
Fr 1
129.4473 Nm
108.3974
81.5135 Nm
Mx
My
87.9470 Nm
165.6690 Nm
142.7739 Nm
TI
∅ 30 ∅ 40 ∅ 42 ∅ 40
40 42 40
Figure 4-6: Shaft I design

According to moment distribution diagram, the most critical position is section C:

M tdC =√ M 2Cx + M 2Cy +0.75 × T 2I
( 4.6 )
M tdC =√ 165.6690 2+129.4473 2+ 0.75× 142.77392=243.9080( Nm)
Shaft diameter at section C have following condition:
dC ≥
√
3 32× 10−3 × M tdC
π ×[σ]
( 4.7 )
dC ≥
√
32× 10−3 ×243.9080
3
π × 65
=33.6851(mm)
Since there is a keyway at C so we increase 5% and get 35.3693 mm. (Satisfied)

Equivalent moment at A:
M tdA =√ M Ax + M Ay +0.75 ×T I =√ 0.75 ×142.7739 =123.6458(Nm)
2 2 2 2
Shaft diameter at section A have following condition:
√ 32 ×10−3 × M tdA
√
−3
3 32 ×10 × 123.6458
3
dA≥ = =26.8589 ( mm ) (Satisfied )
π ×[σ] π × 65
Equivalent moment at B:
M tdB =√ M 2Bx + M 2By +0.75 ×T 2I
M tdB =√ 87.947 02 +108.397 4 2 +0.75 ×142.77392=186.4751 (Nm)
Shaft diameter at section B have following condition:
√ 32 ×10−3 × M tdB
√
−3
3 3 32 ×10 × 186.4751
d B≥ = =30.8013(mm)(Satisfied)
π ×[σ] π ×85
4.2.5. Reaction forces acting on shaft II
Moment caused by axial force:
d2 195.8734 ×10
−3
M a 2=F a 2 × =1594.4101 × =156.1513 (Nm)
2 2
The torque acting on the shaft:
T II =431.8831 Nm
The radial force acting on the shaft from the coupling:
F rc=( 0.2 ...0.3 ) × F t=( 0.2...0.3 ) ×6644.3557=( 1328.8711… 1993.3067 ) N
2 ×T II 2 ×431.8831
With: F t= = −3
=6644.3557 ( N )
D0 130 ×10
We choose F rc=1500 N
Equilibrium equations for y-z plane:
−3 −3
∑ M A =Fr 2 ×61.25 × 10 −R Cy × 122.5× 10 −M a2 =0

−3 −3
1823.3488 ×61.25 ×10 −RCy ×122.5 × 10 −156.1513=0
RCy =910.3997 N
∑ F y =R Ay + RCy −F r 2=0
R Ay +910.3997−1823.3488=0
R Ay =912.9491 N
Equilibrium equations for x-z plane:

−3 −3
∑ M A =Ft 2 × 61.25× 10 −R Cx × 122.5× 10 + F cp ×222.5=0
−3 −3
1823.3488 ×61.25 ×10 −RCx ×122.5 × 10 +1500 ×222.5=0
RCx =2598.9599 N
∑ F y =F rc−RCx −R Ax + F t 2=0
1500+2598.9599−R Ax −4749.11=0
R Ax =3.650 .1501 ( N )
4.2.6. Diagram of bending moment and torque diagram of shaft II
According to moment distribution diagram, the most critical position is section B:
M tdB =√ M Bx + M By +0.75 ×T II =√ 135.8922 +66.069 +0.75 × 431.8831 =403.3907 ( Nm)
2 2 2 2 2 2
Shaft II is made of Normalized 45-steel  Allowable bending stress [𝜎] = 65 𝑀𝑃a

Shaft diameter at section B is determined:
√ 32 ×10−3 × M tdB
√
−3
3 3 32 ×10 × 403.3907
d B≥ = =41.8273(mm)
π ×[σ] π × 65

Figure 4-7: Shaft II design
Class CC01 – Topic 4

4.2.7. Calculation for static strength:

Equivalent moment at C:
M tdC =√ M 2C x + M 2C y +0.75 ×T 2II =√ 1352 +02 +0.75 × 431.88312=397.6396 (Nm)
Shaft diameter at section C is determined:
√ 32× 10−3 × M tdC

√
−3
3 3 32× 10 ×397.6396
dC ≥ = =39.6453 ( mm ) (Satisfied )
π ×[σ] π×65
Equivalent moment at D:
M tdD =√ M 2Dx + M 2Dy +0.75 × τ 2=√ 02+ 02 +0.75 × 431.88312=374.0218(Nm)
Shaft diameter at section D is determined:
√ 32× 10−3 × M tdD

√
−3
3 3 32× 10 ×374.0218
dD≥ = =38.8444 (mm)(Satisfied)
π ×[σ] π ×6 5
4.2.8. Preliminary key for the shaft
We choose the flat key with the parameter:
b × h× l× t(the width, heighth , length ,depth of keyway )
Shaft I: {The key of the gear :12 ×8 ×5 (mm)

The key of the belt :8 ×7 × 4(mm)
Shaft II: { The key of the gear :16 ×10 × 6(mm)

The key of the coupling :14 × 9× 5.5(mm)
4.3. Checking for strength of shaft and key
sσ sτ
s= 2 2 ≥[s ]
√ s σ +s τ
( 4.8 )
With
σ−1 τ−1
sσ = ; s τ=
Kσσa Kτ τ a
+ѱ σ σ m +ѱ τ τ m
εσ β ετ β
Shaft I
σ −1=0.4 σ b=331.2( MPa); τ −1=0.25 σ b=172.96(MPa)
- According to Table 11.4 [2]: ε σ− I =0,8747 ; ε τ− I =0.8225; ѱ σ=0.1; ѱ τ =0.05
- According to Table 11.5 [2]: β=2
- According to Table 10.6 [2]: K σ =2.3239 ; K τ =2.1859

M √ Mx+M y
2 2
T
σ a= = ; σ m=0 ; τ a=τ m =
W W 2W o
3 3
πd πd
W= ; W o=
32 16
4.4. Summary for shaft design
Table 4-19: Strength condition of shaft I
A B C D
3
W ( mm ) 1959.5188 5242.7853 6162.7152 5.242.7853
3
W o (mm ) 4610.2376 11525.9706 13436.2876 11525.9706
σ a ( MPa) 0 26.6247 34.1156 0
τ a=τ m (MPa) 15.4844 6.1936 5.3130 6.1936
sσ  9.3646 7.3084 
sτ 2.0818 5.2047 6.0673 5.67
s  4.5493 > 2.5 4.6682 > 2.5 5.2047 > 2.5
Shaft I satisfied the fatigue strength condition
Table 4-20: Strength condition of shaft II
A B C D
3
W ( mm ) 10877.9263 14762.2638 10877.9263 7729.3760
3
W o (mm ) 23149.7726 31096.0912 23149.7726 16675.5519
σ a (MPa) 0 10.2357 12.4105 0
τ a=τ m (MPa) 9.3280 6.9443 9.3280 12.9496
sσ  24.3589 20.0903 
sτ 3.4558 4.6420 3.4558 2.4893
s  4.5599 > 2.5 3.4057 > 2.5 

Shaft II satisfied the fatigue strength condition
Test for static durability
To prevent large elasticity deformation on shafts or break down when being subjected to
sudden load (such as when starting the motor). Testing each shaft static durability at the
section where the largest moment is located, the result must satisfy the equation below:

σ tđ = √σ 2+3 τ 2 ≤ [ σ qt ] ≈ 0.8 σ ch=0.8 × 638=510.4 (MPa)

( 4.9 )
Where:
M max
σ= 3
0.1× d
( 4.10 )
T max
τ= 3
0.2× d
( 4.11)
Substitute for each remaining cases:
Table 4-21: Stress property of shaft design
Shaft σ τ σ tđ
A 0 0 0
B 82.06 25.9 93.52
I
C 71.05 25.9 84.03
D 0 48.83 84.58
A 0 0 0
B 72.58 36.51 96.26
II
C 63.09 30.76 82.58
D 0 43.79 75.85

CHAPTER 5. DESIGN AND SELECT FOR BEARING AND COUPLING
5.1. Bearing
5.1.1. Reaction force acting on the bearing
Shaft I
F rB=RB =√ R2Bx + R2By = √ 1497.59482 +280.5796 2=1523.6519(N )
(5.1 )
F rD=R D= √ R2Dx + R 2Dy = √ 1875.63772 +3212.14512=3719.6631( N )
Shaft II
F rA=R A =√ R2Ax + R 2Ay=√ 912.94912 +3650.15012=3762.5885( N )
F rC =RC = √ R2Cx + R2Cy =√ 2598.95992 +910.39972=2753.8010(N )
Preliminary choosing the bearing:
{
'
Shaft I :308 :C=31.9 kN ; C o=21.7 kN ; α=12 ° ; e A =0.36 ; eB '=0.42
Shaft II : 310 C=48.5 kN ; Co =36.3 k N ; α =12° ; e 'A=0.35; e B '=0.34
5.1.2. Basic dynamic load
Shaft I
S1=S A =e ' FrA =630.37(N ); S 2=S B=e ' FrB=540.61(N)
Because S2 < S1 and F a=132.88> S1 −S 2=89.76
{ F a 1=S1=630.37(N )
Fa 2=S 1+ F a=763.25 (N )
Because F a 1< F a 2 so we calculate the load at B with the formula:
Q=Q r=(XV F r +Y F a )K t K σ
( 5.2 )
Q=Q a=( X F r +Y F a )K t K σ
( 5.3 )
Fa 132.88
Where: V =1 ; K t =1 ; K σ =1.2 and = =0.014
Co 9240
Fa
Because =0.2773< e=0.45, we have: X = 1, Y = 0 with bearing at B on the
V (F rB)
shaft I
Q=Q r=( XV F r +Y F a ) K t K σ =( 1× 1× 1287.17+0 ×1056.365 ) ×1 ×1.2
¿ 2784.72 N
Q=Q a=( X F r +Y F a ) K t K σ =( 1× 1287.17+0 ×1056.365 ) ×1 ×1.2=2784.72 N
The life in million revolutions L of the bearing:

60 Lh n 60 × 276.68× 2× 8 ×300
L= 6
= 6
=79.68
10 10
( 5.4 )
(million revolutions)
With this Lh, we have to change the bearing on the shaft I after 1 year (1 day 2 shifts, 1
shifts 8 hours, 1 year 300 days)
The basic dynamic load:
1 1
m 3
C tt =Q L =2784.72 ×91.26 =12537.6 ( N ) <C=13100 N (satisfied)
Re-calculate the life time with the formula:
Q3 L=C 3
( 5.5 )
L= 104.1 (million revolutions)
6
10 L
Lh=
60 n
Lh=5475.1 ( h )
Table 5-22: Parameter of 36205 bearings
Number of bearing d (mm) D (mm) B (mm) r (mm) C (kN) C o (kN)

308 40 90 23 2.5 31.9 21.7
Shaft II:
S1=S A =e ' FrA =612.857(N ); S 2=S B=e ' FrB =458.45(N )
Because S1 > S2 and F a=132.88>0
{ F a 1=S 1=612.857(N )
Fa 2=S 1+ F a=1225.714 (N )
Because F a 1< F a 2 so we calculate the load at B with the formula:
Q=Q r=(XV F r +Y F a )K t K σ
Q=Q a=( X F r +Y F a )K t K σ
Fa 132.88
Where: V =1 ; K t =1 ; K σ =1.2 and = =0.0056
Co 23700
Fa
Because =0.287< e=0.45, base on the Table 9.4 [2], we have: X=1, Y=0 with
V (F rB)
bearing at B on the shaft II
Q=Q r=( XV F r +Y F a ) K t K σ =( 1× 1× 1348.37+0 ×1516.675 ) ×1 ×1.2
¿ 2686.848 N
Q=Q a=( X F r +Y F a ) K t K σ =( 1× 1348.37+0 ×1516.675 ) ×1 ×1.2=2686.848 N
The life in million revolutions L of the bearing:

60 Lh n 60 × 43.92 ×2 ×8 ×300 × 6
L= 6
= 6
=63.24 (million revolutions )
10 10
With this Lh, we have to change the bearing on the shaft I after 5 years (1 day 2 shifts, 1
shifts 8 hours, 1 year 300 days)
The basic dynamic load:
1 1
C tt =Q L m =2686.848 ×68.45 3 =10990.8(N )<C=30600 N (satisfied)
Re-calculate the life time with the formula:
3 3
Q L=C
L= 1477.2 (million revolutions)
6
10 L
Lh =
60 n
Lh=621544.5 ( h )
Table 5-23: Parameter of 36208 bearings
Number of C o (kN)
d (mm) D (mm) B (mm) r (mm) C (kN)
bearing
310 50 110 27 3 48.5 36.3
5.2. Coupling
5.2.1. Initial parameters
Torque acting on shaft II: T =431.8831 Nm
The tangential force acting on the shaft from the chain coupling: F t=1500 N
The rotational speed of the chain coupling: n=180.9819rpm
According to Table 16.6 [2], we have:
Table 5-24: Coupling specification
d1 d2 D dm h
[T] (Nm) n max (rpm) Radial misalignment
(mm) (mm) (mm) (mm) (mm)
600 1000 45 48 210 65 80 <2

5.2.2. Calculate and check the safety factor
Q
S= ≥[ S]
( 1.2 ÷1.5 ) F t
( 5.6 )
Where:

Q 70000
S= = =31.11÷ 38.89
( 1.2 ÷1.5 ) F t ( 1.2÷ 1.5 ) 1500
(5.7 )
According to table 16.7 [4] with p=38.1 mm and n=101.3395rpm, we choose [ S ] =¿ 8.5
⇒ S ≥ [ S ] so the safety factor of chain coupling is satisfied.

CHAPTER 6. DESIGNING GEARBOX AND OTHER AUXILIARY

ELEMENTS
6.1. Initial parameters

The center distance between shafts: a=160(mm)
The length of shaft I: l 1=195(mm)
The length of shaft II: l 2=205(mm)
6.2. Choose the material for gearbox cover

The gear housing plays an integral part when designing the gearbox. It helps to keep
elements and parts of the machine well intact, distribute the load evenly, as well as to protect
the machine elements from getting dusty.
The critical standard for the gearbox is to have high stiffness and low weight, so cast
iron GX15-32 is used as the material.
To facilitate installation, the cap and housing unit are cast separately.

6.3. Calculation and designing gearbox cover

Table 6-25: Parameters and calculation of gearbox cover
Parameters Calculation
Gearbox body, δ δ=0.03 a+ 3 ≈ 8 mm

Width
Gearbox cover, δ 1 δ 1=0.9 δ ≈ 7.3851 mm
e=( 0 , 8 ÷ 1 ) δ=6.4 ÷ 8 ( mm )
Width, e
Choose e=7 (mm)
Rib
Height, h h<58 (mm)
Slope Approximately 20
Based bolt, d 1 M 16
Bearing side bolt, d 2 M 12
Body-cover-assembly bolt,
Diameters M 10
d3
Screw for oil caps, d 4 d 4 =¿
Screw for top oil cap, d 5 d 5=¿
Body’s top thickness, S3 S3=¿
Cover’s top thickness, S4 S4 =( 0.9÷ 1) S 3=14.4 ÷ 16 ( mm )=15(mm)

The part
E2 ≈ 1.6 d 2=21(mm)
between the
cover and R2 ≈ 1.3 d 2=17(mm)
body Widths:
K 2=E 2+ R 2+ ( 3÷ 5 ) =41(mm)
K 3 ≈ K 2−( 3 ÷ 5 )=38(mm)
Bolt center’s diameter of Shaft I: D2=130

The bearing
seat areas shafts, D2 Shaft II: D2=110
Outer diameter of shafts, Shaft I: D3=80

D3 Shaft II: D3=95
Diameter of screws, d 4 Shaft I and II: d 4 M8
Height, h Shaft I and II: h=20 (mm)
Z Z=6
Distance from bolt’s center

k ≥ 1.2 d 2=15.6(mm)
to edge of hole, k
Thickness, S1 S1=¿
The gearbox
K 1 ≈ 3 d 1=51(mm)
body’s bottom Width, K 1, q
q ≥ K 1 +2 δ=67( mm)
Gap between Between gears and

∆ ≥ ( 1 ÷1.2 ) δ =8 ÷ 9.6 ( mm )=9.8468(mm)
elements gearbox inner wall
Between bigger gear and

∆ 1 ≥ ( 3 ÷5 ) δ=24 ÷ 40 ( mm )=24(mm)
gearbox body’s bottom
Between gear faces ∆ ≥ δ=8 (mm)
6.4. Other auxiliary machine elements

6.4.1. Ring bolt and hook
To lift and move the gearbox (when manufacturing, assembling…), we usually add ring
on its body and lid.
C20 steel is chosen as material for this.
According to table 18.3b [1], the center distance of our gearbox is a=160 mm so the
weight selected is Q=80 kg.
Table 6-26: Ring bolt and hook parameter
Thread d d1 d2 d3 d4 d5 h h1 h2 l≥ f b c x r r1 r2
M8 36 20 8 20 13 18 6 5 18 2 10 1.2 2.5 - 4 4
6.4.2. Dowel pin

To ensure the relative position of the body and the lid, we use 2 conical dowel pins.
Here, we use the bevel locating bolt. According to table 18.4b [1], the parameters for
the pin: d=6 ( mm ) c=1 ( mm ) l=35 ( mm ) .

6.4.3. Gearbox cap

To seal the bearing, prevent dust, and secure the outer ring of the bearing on the
housing. We use 2 types of caps, which are:
 Solid gearbox Cap: a cover that does not have a hole or an opening for a shaft to
pass through.
 Shaft - passing Gearbox Cap: a cover designed with a hole or opening that
allows a shaft to pass through.
The bearing cap is mould from gray cast iron GX15-32. From Table 18-2 [2]:
Table 6-27: Gearbox cap parameter
Gearbox
D (mm) D2 (mm) D3 (mm) D4 (mm) h (mm) Z d4 (mm)
Cap
I 90 110 135 85 12 6 M8
II 90 110 135 85 12 6 M8
6.4.4. Access door
We make an access door on top of the housing, on which there is an air vent, to check
the inside the gearbox and for pouring oil. The parameters based on table 18.5 [1]:
Table 6-28: Parameter of access door
A B A1 B1 C C1 K R Screw Quantity
150 100 190 140 175 - 120 12 M8 x 22 4
6.4.5. Air vent

On top of the housing, we make an air vent to alleviate the heat and pressure, control the
air inside and outside the gearbox.
According to Table 18.6 [1], we have the parameters for the air duct.
Table 6-29: Air vent parameter
A B C D E G H I K L M N O P Q R S
M 27× 2 15 30 15 45 36 32 6 4 10 8 22 6 32 18 36 32
6.4.6. Oil drain plug

After a period of time of working, the oil will be contaminated (because of dust and
other factors), that’s when we need to replace the oil. To drain the contaminated oil, an oil
discharge is designed at the bottom of the gearbox.
According to Table 18.7[2], the parameters for the plug are:

Table 6-30: Oil drain plug parameter
d b m f L c q D S D0
M 16 × 1.5 12 8 3 23 2 13.8 26 17 19.6
6.4.7. Oil level indicator

To check the oil level we use the level indicator g. To avoid interference from the oil
wave, the indicator has a cover.
Table 6-31: Oil level indicator parameter
d d1 d2 D D1 L1 l l1 b
M 12 ×1.25 5 6 18 12 30 12 6 3
6.4.8. Oil seal

The seal consists of 3 triangular cross-sectional grooves with an angle at the vertex is
60o. The distances between vertices is 3 (mm). The distance from the seal and the inner edge
of the gearbox housing should be 0.5÷1 (mm). The clearance gap between the outer shell and
the outer surface of the threaded ring is 0.43 (mm).
6.4.9. Spacer
The spacer is used to support the bearing, making it convenient for assembly and
adjustment of bearing components while protecting the bearing from dust and dirt. The
thickness of spacer should be  = 6…8 mm, so we choose  = 8mm.
6.4.10. Dust seal
A dust seal is a type of tight-fitting, indirectly dynamic seal designed to protect bearings
from dust, dirt, hard particles, and various contaminants from entering the bearing. These
substances can lead to rapid wear and corrosion of the bearing. Additionally, it prevents oil
from leaking out. The service life of the roller bearing depends greatly on the dust seal.
Dust seal are widely used due to their simple structure and ease of replacement.
However, they have the disadvantage of wearing out quickly and causing high friction when
the shaft surface has a high roughness..
6.4.11. Grease seal
To prevent grease in the bearing from mixing with the oil in the housing, we typically
use grease (oil) seals. These seals consist of 2 ÷ 3 grooves with a triangular cross-sectional
profile. The oil shield is installed in such a way that it is spaced approximately 1 ÷ 2 mm from
the inner edge of the housing. The clearance gap between the outer shell (or bushing) and the
outer surface of the threaded ring is about 0.4 mm.

6.5. Lubrication for gear box

Lubrication is applied to reduce frictional losses, decrease gear wear, ensure effective
heat dissipation, and prevent corrosion of machine components. Continuous lubrication is
necessary for the gear assemblies within the gearbox.
The viscosity of the lubricant is chosen depending on its velocity.
The helical gears have the speed of v gear =1.3584 (m/ s) and they are made from C45
steel so the method we use to lubricant is deep oil feed lubrication.
Deep oil feed lubrication: Oil level equal 1/6 of driving gear.
According to table 18.11 [2], we choose oil with 186 Centistoc and 16 Engel at 50℃.

CHAPTER 7. THE TOLERANCE
7.1. Bearing’s tolerance

The inner ring of the roller bearing experiences cyclic loads, so it is chosen to be
assembled using an intermediate shaft system to ensure that the inner ring does not slip on the
shaft surface during operation. Therefore, we need to choose a fit with a fit class of k6, which
provides a suitable interference fit condition for even wear of the bearing (during operation, it
will rotate and wear evenly).
The outer ring of the roller bearing does not rotate and thus experiences localized loads.
It is assembled using a hole system. To allow the bearing to move axially as the temperature
increases during operation, we choose an intermediate fit type of H7.
7.2. Assembly elements
7.2.1. Assembly of the gears and the shafts.
For the gears mounted on the shaft, the fitting type chosen is H7/k6.
7.2.2. Assembly of the bearing cap and the housing body.
To facilitate disassembly and adjustment, we choose a loose fit type of H7/h6.
7.2.3. Assembling of the oil shield on the shaft
To facilitate disassembly, we choose an intermediate fit type of H7/k6.
7.2.4. Assembly of the Positioning Pins
To ensure concentricity and prevent loosening, we choose a fit type of H7/p6.
7.2.5. Assembly of the key
In the axial direction, the fit type on the shaft is P9, and the fit type on the bearing is
D10.
7.2.6. Assembly of Positioning Pins
To ensure concentricity and prevent loosening, we choose a fit type of H7/p6.
7.2.7. Assembly of Threads
In the axial direction, the fit type on the shaft is P9, and the fit type on the bearing is
D10
7.3. Summary of assembly tolerance
Table 7-32: Assembly tolerance
Machine ES es EI ei
Assembly N max (µm) Smax (µm)
elaments (µm) (µm) (µm) (µm)
Gear in shaft ∅55H7/k6 +30 +21 0 +2 21 28

II
Grease seal on
∅45H7/k6 +21 +6.5 0 -6.5 6.5 27.5
shaft I
Grease seal on
∅53H7/k6 +25 +8 0 -8 8 33
shaft II
Spacer on
∅35H8/h11 +33 -40 0 -73 -40 106
shaft I
Spacer on
∅45H8/h11 +39 -50 0 -89 -50 128
shaft II
V-belt drive in
∅30k6 - +15 - +2 - -
shaft I
Coupling in
∅42k6 - +18 - +2 - -
shaft II
Table 7-33: Tolerance for Assembly of Deep Groove Ball Bearings
Inner ring
Element Assembly ES es EI ei
Shaft I ∅40H7/h6 - +15 - +2
Shaft II ∅50k6 - +18 - +2
Outer ring
Element Assembly ES es EI ei
Shaft I ∅90H7 +30 - +0 -
Shaft II ∅90H7/h6 +30 - +0 -
Table 7-34: Tolerance for Thread Assembly
Thread Allowance for Allowance Allowance

Allowance for the
Cross- the Width of Limit on the Limit on the
Width of the
Sectional the Thread Shaft, t 1 Bearing, t 2
Thread Groove
Dimension Groove on the
on the Shaft
bxh Bearing

P9 D10
+0.098 +0.2 +0.1

8x7 -0.015
+0.040
+0,120 +0.2 +0.2

12x8 -0.018
+0,050
+0,120 +0.2 +0.2

14x9 -0.061
+0,050
+0,120 +0.2 +0.2

18x11 -0.061
+0,050
CHAPTER 8. DESIGN OF TRANSMISSION SYSTEM
8.1. Extrusion machine

Extrusion machine uses compression extrusion technology to create plastic pipes,
plastic sheets, plastic floors, plastic films, etc. The main function of the machine is to make a
molten plastic mixture in a short time to shape products. After that, the plastic will
immediately cool down and maintain its solid shape according to the product extrusion mold.
Extrusion machine play a very important role in the plastic production line, specifically
as follows:
 As equipment used to shape and produce plastic products, the adjusting machine is
the most important in a complete plastic production line.
 Can handle a variety of thermoplastics such as PP, PE, ABS, PVC, PS, PET,...
 Quality extrusion machines also help the plastic to be shaped quickly, creating
beautiful, uniform finished products.
Regardless of the application, the extrusion machine is driven by a gear driver. In the
extrusion machine, there will be a shaft connected to the output of the gearbox. When the
motor rotates, this shaft will rotate and the mixing tank system will also rotate to perform its
function.
The transmission systems used in extrusion machines are very diverse, such as: worm
gear drive, coaxial gear drive with spur gears, helical gears, bevel gears, ...
In the scope of this project, the transmission is designated as a 1-stage helical spur gear
reducer, and the output shaft is connected to a V – belt drive before reaching the working
shaft.

Figure 8-8: Extrusion machine
Figure 8-9: Holton Crest Continuous Rotary Extrusion Machine

8.2. Spiral screw

Figure 8-10: Single screw extruder

Single screw extrusion is one of the main type of polymer processing operation. The
principal function of a single screw extruder is to build up pressure in thepolymer melt so that
the polymer can be extruded through the die. Most of the single screw extruders are
plasticating which mean that the solid resin balls or powders melt in the screw due to the
pressure. However, some single screw system can be used for mixing also. Single screw
extruder is useful when pure polymer like HDPE is used.
Single screw extruder basically consist of a screw, barrel, drive mechanism, resin feed
arrangement and controls. The constantly turning screw moves the resin through the heated
barrel where it is heated to proper temperature and blended into a homogeneous melt. A
turbulent back pressure is build up which pushes the melt out of the extruder in the shape of
the die. The resin sometimes is not compltely melted in the basic extrusion screw. The barrier
screw in designed to counter this problem. Sometimes, additional flights are attached to the
transition section so as to separate molten and solid plastic to different channels. As the solid
pellet moves forward it melts due to shear against the wall and thus melts and flows into the
liquid channel. Thus the solid channel narrow gradually and the liquid channel widens.
The ability of a screw to manufacture products of good quality with high productivity
and low cost is called its performance. At the design stage of an extrusion Single Screw
Extruderprocess, evaluation of screw performance is very important. The deformation
measure or stretching which materials undergo due to the regular flows inside a conventional
screw channel increases linearly with the extruder channel length.
8.3. Design for spiral screw
The pitch of the screw blade not only determines the rising angle of the screw, but also
determines the sliding surface of the material under a certain filling coefficient, so the pitch
directly affects the conveying process of the material.
Generally, for solid blade, the pitch of screw blade can be determined:

S=0.8 D
( 8.1 )
In which: D is the diameter of blade. So that, S = 168 (mm).
∅ 210
168 168
Figure 8-11: Structural parameters of Screw blade diameter and pitch

REFERENCES
[1] Trịnh Chất, Lê Văn Uyển (2007), Tính toán thiết kế hệ dẫn động cơ khí, Tập 1&2,
NXB Giáo dục, Hà Nội.
[2] Nguyễn Hữu Lộc (2004), Cơ sở thiết kế máy, NXB Đại học Quốc gia TP.HCM, TP
Hồ Chí Minh.
[3] Ninh Đức Tốn (2001), Dung sai và lắp ghép, NXB Giáo dục, Hà Nội.
[4] Trần Văn Địch (2008), Công nghệ chế tạo máy, NXB Khoa học Kỹ thuật, Hà Nội.
[5] John A.Schey (2000), Introduction to Manufacturing Processes, 3rd edition,
McGraw-Hill Education, New York – London.
[6] Hassan El-Hofy (2019), Fundamentals of machining processes: conventional and
nonconventional processes, 3rd edition, CRC Press/Taylor & Francis Group, New
York.
[7] Fuqiang He, (2019), “Optimization of Spiral Shaft Parameters of Particle Type
Conveyor Based on Particle Swarm Optimization”, Advances in Engineering
Research, 181, Beijing.

CC01 Group 4

Uploaded by

Copyright:

Available Formats

CC01 Group 4

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CC01 Group 4

Uploaded by

Copyright:

Available Formats

VIETNAM NATIONAL UNIVERSITY

HCMC UNIVERSITY OF TECHNOLOGY

TRANSMISSION SYSTEM PROJECT

DESIGN OF A TRANSMISSION SYSTEM FOR

STUDENT: Trần Thiên Bảo - 2153215

Ho Chi Minh City, 12/2023

i Class CC01 – Topic 4

ii Class CC01 – Topic 4

6.1. Initial parameters...............................................................................................................38

iii Class CC01 – Topic 4

iv Class CC01 – Topic 4

Table 1-1: Ratio of mechanical drives........................................................................................2

v Class CC01 – Topic 4

Table 7-1: Assembly tolerance.................................................................................................43

vi Class CC01 – Topic 4

CHAPTER 1. MOTOR SELECTION AND TRANSMISSION RATIO

1.1. Motor selection

7 Class CC01 – Topic 4

The general efficiency of transmission system:

8 Class CC01 – Topic 4

9 Class CC01 – Topic 4

n [rpm] 1460 570.09 180.98 180.98

P [kW] 9.06 8.52 8.18 7.86

T (N∙m) 59.28 142.77 431.88 414.78

10 Class CC01 – Topic 4

CHAPTER 2. DESIGN AND SELECT FOR V-BELT DRIVERS

2.1. Type of belt and pulleys’s diameter

11 Class CC01 – Topic 4

2.2. Parameters of V-belt drivers

12 Class CC01 – Topic 4

13 Class CC01 – Topic 4

[ P0 ]=3.1874 kW when d 1=160 mm∧v 1 =12.2313 m/ s

14 Class CC01 – Topic 4

12. 180… 17.

Figure 2-2: Pulley parameters

15 Class CC01 – Topic 4

F r ≈3 × F0 ×sin ( α2 )=3× 662.4 × sin ( 2,60102 rad )=1915.0491(N )

Base on the diameter of type B V-belt drive d 1=160 mm , we choose γ =34 o

- From formula 4.24 − page 136:

- Minimum friction coefficient that prevent slipping on belt drive:

f min =f ' ×sin ( 2γ )=0.1498

16 Class CC01 – Topic 4

⇒σ max=¿ 7.0357 MPa < 10 MPa=[σ ] k (satisfied)

17 Class CC01 – Topic 4

2.5. Summary for V - belt drivers

Driven pulley’s diameterd a 2 (mm) 408.4

18 Class CC01 – Topic 4

CHAPTER 3. DESIGN AND SELECT FOR GEAR DRIVERS

3.1. Material selection

3.3. Determine allowable contact stress

19 Class CC01 – Topic 4

σ OHlim 2=2 HB 2 +70=2× 350+70=770 ( MPa)

3.3.4. Service life coefficient

With the helical gear, we have:

20 Class CC01 – Topic 4

σ OFlim 1=900 ( MPa )

Coefficient of turning direction: K FC =1 (one-way rotation)

3.4.3. Allowable contact stress

3.5. Parameters of gear drivers

21 Class CC01 – Topic 4