2012

Machine Design II

Joseph Caesar B. Torres

5MEB

Driver
I.C.E

Mechanical
Shaft Belt Chain Ropes

System

Motor

Water Wind

Power Power Wave

Clutch

Driven

Pump Mixer

Compressor Crusher Hoist

Elevator

BELTS
*Flat Belt *V Belt

Flat Belt

( (

) )

Nomenclature:

F1 F2 Fc f b t S

- tight side tension - slack side tension - centrifugal tension - coefficient of friction (text) - arc of contact - belt width - belt thickness (text) - allowable stress on belt = 400 - efficiency of joint (text) ex: - belt density (text) - belt speed

V N g

Length of Belt (Open Belt)

Where: L D d C - length of belt - diameter of large pulley - diameter of small pulley - centerline distance

Another method of solving for belt width develops by American Leather Belt Association (ALBA):

( )

Rated HP Name plate transmitted

text

Belt Width

Correction factor (text) Cm kind of driven motor Cp size of pulley Cf1 correction factor Cf2 - for environmental Cf3 condition

A 25 HP, 870 rpm induction motor is used to drive a ventilating fan at 485 . The motor pulley is 10 inches in diameter. Determine the following: a) minimum angle of contact, b) cross-sectional area of the leather belt, c) what is the width of medium double-belt, cemented joint, d) what is the length of the belt.
485 fan pulley

25HP

870rpm

f = 0.3 leather on steel f = 0.5 leather on paper pulley

C = 5ft

Solving for DB: ( )

For angle of contact, : ( )

[ For velocity:

) ]

( Tension Ratio
( ( )( )(

) )

For the cross-sectional area: ( )

 Where:

) + *

( (

)( )(

) )

For medium ply leather

For the length of belt:

A flat leather belt medium double ply 300mm wide is used to transmit the power at 350 . The driving and driven pulley are both 1.2m in diameter. Centerline distance is 5m. Using the data available in your text, estimate the capacity of the leather belt drive. Use cemented joint. What is the length of the belt and total weight? At page 350; MD Faires; For Medium Double Ply:

Where the driving and driven pulley are both 1.2m in diameter, therefore the angle of contact is equal to 180 . ( )

Where: ( )

For Stress:

For density: ( For Tension Ratio:

( ( )( ) )( )

For velocity: ( )

For the length of belt:

( )

For the weight:

BELT CONVEYOR LAYOUT

Simple Conveyor Layout

- Alternate - Material conveyed - Maximum loading rate - Belt (width, speed, and type) - Center to center distance - Pulley - Idlers - Type of loading

Driver

Driven

A 420rpm blower is belt driven by 10HP synchronous motor at 1800rpm. Determine the standard suitable size and number of V-belt and suitable pitch diameter on sheave based on a belt speed of 3500 . Find the length of belt

and specify standard V-belt, center distance between sheave should be approximately 32in.
3500 420rpm blower sheave

1800rpm 10HP motor

sheave motor

32in

I.

Design HP = Transmitted HP (Nameplate HP)(service factor)

*Text SF = 1.2 at table 17.7 p.460 Design HP = 10 x 1.2 = 12

II.

Section A, B, C, D

*Figure 17.14 p.457

A
1800rpm

Section B:

b t
12HP

III.

Sheave Sizes *consult your text, standard size p. 458 table 17.3; use the column for section B

Actual Velocity:

IV.

HP/strand [ ( ) ]

*page 456 MD by Faires Section A B C D a 2.684 4.737 8.792 18.788 c 5.326 13.962 38.819 137.7 E 0.0136 0.0234 0.0416 0.0848

[ (

( )

For Corrected HP/Strand:

Where: K ; arc of contact factor *table 17.5 p.459

KL; length of belt factor [ ] ( [ ) ] ( )

Use B128 pitch length of 129.8in *table 17.3 p.458 Table 17.6 p.459 B128 KL = 1.08

Say use 2 strands, B128 V-belt with pitch length of 129.8

A centrifugal pump is to deliver 7,500 shaft speed of 375 by 1180 Determine:

of water against a head of 40m at

. The pump which has an efficiency of 65% is driven motor compensator started.

a) The power required to drive the pump b) c) For a multiple V-belt drive, find a suitable size, number of V-belt and suitable sheave for a belt speed of 4000 45in. Specify the length of belt.
Power out

. Center distance is about

Power in
Eff 65% pump

I.

Design HP Design HP = (75.38KW)(1.2) = 90.46KW = 121.3 HP

II.

Section Referring to Faires M.D, at page 457 At 1180 rpm and 121.3 HP SECTION D Sheave sizes

III.

Actual Velocity:

IV.

HP/strand [ ( ) ]

*page 456 MD by Faires Section A B C D a 2.684 4.737 8.792 18.788 C 5.326 13.962 38.819 137.7 E 0.0136 0.0234 0.0416 0.0848

[ (

( )

For Corrected HP/Strand:

Where: K ; arc of contact factor *table 17.5 p.459

KL; length of belt factor [ ] ( [ ) ] ( )

Use D173 pitch length of 176.3in *table 17.3 p.458 Table 17.6 p.459 D173 KL = 0.93

Say use 6 strands, D173 V-belt with pitch length of 176.3in

Corrected center to center distance: [ ] ( )

Seatwork:
An oil field pumping jack is filled with gear reduction unit delivery 30, 000 inlb torque at 26 . The reduction in the gear is 40%. The gear unit is filled with 13in pitch diameter pulley and is driven by a 1200 motor. The centerline distance is about 50in. Determine the V-belt drive to be used. a) b) c) d) e) Estimate the power requirement Section Sheave style; standard size No. of belt Belt length

f) Corrected centerline distancE Power: ( ( ) ( ) )

Speed Reducer

( (

( )

I. Design HP Design HP = (transmitted HP) (service factor) = 15HP x 1.2 = 18 HP II. Section Referring to Faires M.D, at page 457 At 1200 rpm and 18 HP SECTION B Sheave sizes

III.

Actual Velocity:

V.

HP/strand [ ( ) ]

*page 456 MD by Faires Section A B C D a 2.684 4.737 8.792 18.788 c 5.326 13.962 38.819 137.7 e 0.0136 0.0234 0.0416 0.0848

[ (

( )

For Corrected HP/Strand:

Where: K ; arc of contact factor *table 17.5 p.459

KL; length of belt factor [ ] ( [ ) ] ( )

Use B128 pitch length of 129.8in *table 17.3 p.458 Table 17.6 p.459 B128 KL = 1.08

Corrected center to center distance: [ ] ( )

1400 400mm

1200 mm

{
) )

Leather belt drive f = 0.3 efficiency of joint is 80% Medium double ply leather belt b = 300mm belt width Estimate the power that can be handled by the belt drive

3000mm

Stress = 400

Chain
Roller Silent inverted tooth Block tooth cylinder *tension ration is negligible because of the occurrence of tooth

Direct Drive

Driver

Driven

Dual Drive:
Driver

Driven

Driven

Driver

idler

USEFUL EQUATIONS:
Driven Driven

[ , [ ( )]

] -

Where: V P Ns L T D S.F. C = velocity,

= pitch, inch = of small sprocket = length of chain in links = no. of teeth = pitch diameter = service factor = centerline distance ( )

Standard Chain No. RC 25 35 41 40 50 60 80 100

( )

( )

Silent Chain Standard No. SC 3 ( ) SC 4 SC 5 SC 6 SC 8 SC 10 SC 12 SC 16 ( )

In chain, tension ratio is not applicable.

F1=___ _

F2 0

Service Factor
Uniform average load Moderate shock Heavily Shock 1.0 1.2 1.4 1.2 1.4 1.7

A 10 HP motor running at 1150 rpm is to drive a compressor by means of a roller chain. The compressor runs about 350 rpm and is to be located at about 20 inches from the motor shaft. Due to space limitation the motor sprocket must have a diameter of about 5 inches. Determine the following: a) Pitch of the chain b) No. of teeth on motor and compressor c) Length of chain

d) No. of strands
10 HP 1150 rpm motor

Belt drive

Compressor

Pitch of the Link:

( ) For number of teeth:

For velocity:

Length of chain: ( )

For

: , [ ( )] -

{ [ ( )] }

For no. of strands:

Say used 1 strand, RC 60 with a pitch of 0.75 inches 101 links for length of chain 21 teeth for the smaller sprocket 69 teeth for the bigger sprocket

For a dual drive shown, estimate the power that can be transmitted by the roller chain drive if it is made of 1 strand RC 41. Use a service factor of 1.2.
Driver idler
N=100rpm 11 teeth sprocket

Driven

Driven

Solving for

: , [ ( )] -

Where:

{ [ ( )] }

For transmitted power:

Solving for Torque:

A dual chain drive consists of a double strand RC 120 has a driving sprocket A has 11 teeth rotating at 100 rpm. While the driven sprocket B has 17 teeth and requires 5KW power. The driven sprocket C has 21 teeth and requires 7 KW power. For the system shown, find: a) Torque on shaft B and shaft C b) Service factor of the drive c) Tension on various sections
A

Wire Rope 6x7 6 x 19 6 x 37

Strands x Wire

D, rope

Application: 1. 2. 3. 4. 5. 6. 7. Elevators 8 to 12 Hoist 3 to 5 Haulage Derricks Tramways Cable Car Guard Roil etc

Elevator

Where:

Nomenclature: Fu - ultimate load or breaking load F.S. - factor of safety Ft - total load Fb - equivalent bending load k A dw Ds Wp Ws Wr Wacc - 12x106 constant for steel rope

- Cross-sectional area - wire diameter - sheave or drum diameter - weight of passenger - weight of skip or cage - weight of rope (text) - load due to acceleration =( )

Values for C for wire rope Rope diameter C 1.09 1.083 1.076 1.07 1.064 1.054 Rope diameter C 1.046 1.04

Recommended minimum factor of safety Track

3.2

Cable Guy wires Mine Hoist Haulage Cranes Sling Elevators

3.5 5 to 8 6 6 8 8 to 12

P T5 T4 T3 T2 T1

Where:

Therefore:

) ( (

( [ ) )

( ( (

) ] ) )

( (

) )

For Smooth Pulley

Find the force P Given:

T4

T3

T2

T1

Solution:

Where:
Q=5KN

[ [ [

] ] ]

BRAKES

Band Brake Block Brake Disk Brake

Band Brake
Useful Equation *Tension Ratio

*Net Pull

*Power ( )

Max Band Pressure:

Tensile Stress on Band

Nomenclature

F1 tight side tension F2 slack side tension f coefficient of friction arc of contact Tq brake torque D drum diameter P band pressure

St tensile stress on band V peripheral speed of brake drum ( F1 F2 ) net pull w band width t band thickness

Block Brake
FL friction resistance on block FR friction resistance on block 2 arc of contact PL normal reaction (FL + FR) = Tq FL + FR = D drum diameter

f equivalent coefficient of friction = f [

pv design factor p pressure v rubbing velocity Aproj projected area Aproj = 2hw

Example: The band brake shown is to absorb 15kW at 1500 rpm. Estimate the force Q required to absorb the power f = 0.3; b = 1.75m; d = 1m

 = 270 Tension Ratio

( )( )

F1 = 4.11 F2

Tq = 95.5 Nm > torque to be absorbed Tq = (F1 + F2) x F1 F2 = =

( )( )

= 191 N

4.11F2 F2 = 191 F2 = = 61 N F1 = 4.11(61) = 252 N m @ 0 = 0 0 = F1 (280) + F2 (280) Q (1750) ( ) ( )

Example: For the band break shown, find Q need to absorb 18kW at 500 rpm, f = 0.3 Calculate the tensile stress on band if band width and thickness is 120 mm and 12 mm, respectively.

 = cos-1

= 41.41

= 360 41.41 90 = 228.59

( )( )

m @ 0 = 0 Tq = 343.77 Nm F1 F2 = 3.31F2 F2 = F2 = 992.12 N F1 = 3283.92 N

( ( ) )

0 = F2 (150mm) Q (760mm) Q = 195.81 Nm

St = St = St = 2.28 MPa x
( )

Example: The 300 mm diameter brake drum is used in a band brake that absorbs 18kW at 520 rpm, f = 0.4. Estimate the force Q to operate the system. What is the max tensile stress on the band of width and thickness are 120mm and 12mm, respectively. What is the band pressure? Calculate the power loss at 1500 rpm for the double block brake drum shown.

f = 0.3

angle of contact, 2 = 110 Ddrum = 200 mm Equivalent coefficient of friction

f=f[

] = 0.3 [

f = 0.343
F=fxP

(FL + FR) lever

= Tq

(1713.6 + 1502) N (0.1m) Tq = 321 Nm

m @ B = 0 0 = Ah (75) 350 (450) m @ A = 0 Ah = 2100 N 0= Bh (75) 350 (450) Fv = 0 Bh = 2100 N 0 = Bv 350 Bv = 350 Power = 50 kW

Left Block m @ D = 0 0 = Ch (300) PL (125) FL =

( )

Right Block m @ E = 0 0 = Bh PR (125) + FR (150 110) FR =

( )

= 1502 N

Spring Set Brake

Spring d = 8 mm diameter wire c=6= spring index Brake D = 300 mm diameter a = 200 mm b = 250 mm f = 0.4 N = 300 rpm a.) Determine the spring force on spring to absorb the torque 800 Nm at 300 rpm b.) Calculate the shoe width based on design pv = 28000 c.) Determine the spring rate and compressed length of the spring

ne = 12 active coils G = 80 GPa

Spring Rate ( ( ) ( ) )

( ( )

(S)(1.585 +0.775) = 5333 N

Left Block

Right Block

m @ 0 = 0

m @ 0 = 0 S (450 mm) = PR (200 mm) + FR (150 = (200 mm) + FR (150 mm)

PL (200 mm) = S (450 mm) + FL (150 mm) mm) (200 mm) FL (150 mm) = S (450 mm) FL = 1.58 mm (S) FL = 3585 N

FR = 0.77 mm (S) FR = 1747 N

Compressed Length LC = Lf LC = 240 mm 71.7 mm = 168.3

Pave = 5795 N x V = DN = V = __ x (

x )( = 927

= 1300 lbs )

FLYWHEEL
Flywheel and governor are devices to control the speed variation in an engine. The difference being that flywheel redistributes the energy within in a cycle of control speed while the governor controls the amount of fuel supplied to an engine to match the load requirement to maintain a specified speed. Flywheels are mechanical device which is used to store energy and distribute it when needed. It is also used to smoothen power transmission where energy input or output are varying.

Useful Equation Kinetic Energy, KE = 1/2m = 1/2w /g

Change in Kinetic [ [ ] ]

Nomenclature: Wf- Weight of flywheel = Wrim + W(hub+arm) V2- Final Velocity V1- Initial Velocity g- Gravitational Acceleration (V2+V1)/2 = Va, Average Velocity (V2-V1)/Va = Cf, Coefficient of Fluctuation (see text) - Density of Steel = 0.28 lb/cu.in. - Density of Cast Iron = 0.26 lb/cu.in. Cb- 1/Cf Coefficient of Steadiness

CLUTCH (Disk Clutch and Plate Clutch)

Disk Clutch
T = Torque P = Axial Force f = Coefficient of Friction D = Outside Diameter d = Inside Diameter P = pressure n = No. of Friction Surface N = No. of Plate (Driver and Driven)

New Clutch ( )* ( )[ Total Torque = RT Old Clutch ( )[ *Wear is proportional to the work of friction ] + ]

( ) [ ] ( )[ ]

Power = Total Torque (Angular Speed)

Cone Clutch

D = Outside Diameter X = D/2 = d/2 X = (D-d)/2

Sin [ ] ( )( )

A multi-disk clutch has six pairs of contact surfaces of an alternate steel and aspestus line steel. The outside diameter and inside diameter of contact surface are 250mm and 180mm respectively. If the coefficient of friction is taken as 0.2 and the pressure is taken as 130kPa. Determine the power that can be handled at 1000rpm. Assume new clutch. ( )* + ( )( )* +

T = 6650N*mm = 6.65 N*m Power Total = 6615 (6) = 339 N*m Power = Total Torque (Original Angular Speed)
( )( )( )

P=

( )( P = 3,073 N

A plate clutch has a single pair of mating surface. OD is 200mm and ID = 100mm. The coefficient of friction is taken as 0.3. What is the maximum pressure corresponding to an actuating force at 15kN. Estimate the power that can be handled at 1000rpm.

SPUR GEAR
A device used to transmit power between shafts that are parallel to each other at a constant angular velocity ratio. Proportions of tooth profile (page 362; Machine Design by Faires)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Addendum Distance Dedendum Distance Clearance Tooth thickness Space width Backlash Face width Diametral pitch Circular pitch Whole depth Working depth Fillet radius Addendum circle Dedendum circle Module

Lewis Equation for Induced Stress

Where: T Dp n y Cp K

- torque - diametral pitch - number of teeth - lewis tooth form factor - circular pitch - 3 to 4

Barth Equation For Allowable Stress

Where: So - basic static sale stress Cv - velocity factor

Common Standard Diametral Pitch 1 2 5 9 6 10 1 2 1 1 3 4 7 8 12 14

16 18 20 24

Buckingham Equation for Dynamic Tooth Load

( Where: Wt - tangential load V - velocity F - face width C - deformation factor )

Buckingham Equation for Weak Tooth Load

Where: D - pitch diameter F - face width Q - ratio factor

Ses - surface endurance limit Ses = 400(BHN) 10000psi - pressure angle Ep - elasticity of Pinion Eg - elasticity of Gear

- load stress factor [ ]

Dynamic Stress
Where: f margin of safety f = 1.25 ; steady load

f = 1.35 ; pulsating load f = 1.5 ; shock load For gear tooth to be satisfactory on standpoint of dynamic loading Sd< Sef flexural endurance limit. For gear tooth to be satisfactory on standpoint of wear Wd < Ww For Common Material Static Gate Stress Cast iron ordinary Cast iron medium grade Cast iron highest grade Cast iron 0.20% C untreated Cast iron 0.20% C heat treated Forged Carbon Steel SAE1020 SAE1030 SAE1035 SAE1040 SAE1045 Cage hardened Untreated Untreated Untreated Heat Treated 18,000 20,000 23,000 25,000 25,000 SD, psi 8,000 10,000 15,000 20,000 28,000

Gear

Pinion

V Velocity Da Db - Pitch Diameter na nb number of teeth Dp diametral pitch Na Nb rpm CL - centerline distance

A cargo winch of a maritime vessel is driven by a 35 HP motor at 480 rpm, through single reduction gear mechanism so that the speed of the drum is 60 rpm. Using the burs equation determine a) which of the gears has weaker teeth b) diametral pitch c) pitch diameter d) face width proportions of tooth profile. The number of teeth on the pinion is 22. Material for pinion SAE 1040 Si = 25,000 psi and gear material is cast steel with So = 20,000 psi.

Tq g=

Tq =

Tq = 4595 in lb

Pinion gear

SAE1040 Cast steel

So= 25,000 So= 20,000

n 22 176

Y 0.404 0.518

SY 10100 10360

npNp = ngNg ng = =
( )

= 176 teeth ] = Sa = 25000 ( ) = 8332

Sa = SoCv = So [ S= =
( [ ) ]( )

= 94

Dp = 4.4 tentative If SoYp < SoYg , the pinion is weaker than gear.

Based the design on pinion 0.3 to 0.4 ~ 0. 333 or 1/3 Dp Si = 94 D=

(

4 6015 5.5in 691 11,600

5 11,700 4.4 550 13,000

6 20,300 3.67 460 14,100

=
)

V = DN = Sa= 25000 (Cv)

Si is closest Sa when Dp = 5 Therefore, used Dp = 5 proceed to the proportions of tooth profile from your text Addendum Dedendum Whole Depth Space width Tooth thickness Backlash Clearance