330:148 (g) Machine Design

Design Project

Design statement: Design a power transmission for an industrial saw that will be used to
cut tubing for vehicle exhaust pipes to length prior to the forming process. The saw will
receive 25 hp from the shaft of an electric motor rotating at 1750 rpm. The drive shaft for
the saw should rotate at approximately 500 rpm.

Functions of the project:

1. To receive the power from an electric motor through a rotating shaft

2. To transmit the power through machine elements that reduces the rotational speed
to a desirable value
3. To deliver the power at the lower speed to an output shaft which ultimately drives
the saw

Design requirements

1. The reducer must transmit 25 hp

2. Input shaft speed is 1750 rpm. Use a motor frame size of 284T with a shaft size of
1.875 in and keyway of 0.5 × 0.5 in
3. The output speed should be around 500 rpm
4. High mechanical efficiency of say 95%
5. Minimum torque delivered should be 2950 lb-in
6. Cutting operation is smooth, but moderate shock when saw teeth are engaged
7. Flexible coupling are used
8. Compact size may be important since it will be mounted close to the base of the
saw.
9. Saw will operate for 16 hours per day, 5 days a week and a life of 5 years. That
means a total of 20,000 hours of operation.
10. Moderate cost for the reducer to be successful in the market
11. Production quantity may be of the order of 5000 units per year.

Selection criteria used

1. Safety
2. Cost
3. Small size
4. High reliability
5. Low maintenance
6. Smooth operation

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Design alternatives examined for the various components

Belt drive
Chain drive
Single stage gear reducer with couplings

Criteria Belt Chain Gear reducer

Safety 6 6 9
Cost 9 8 7
Small size 5 6 9
High reliability 7 6 10
Low maintenance 6 5 9
Smooth operation 8 6 9

Based on the above, Single stage gear reducer with couplings is chosen.

Detailed design of the individual components in the system such as housing, gears,
shafts, bearings, seals, couplings, etc.

Gears

Start from Table 7.5

General purpose industrial drive; Pinion – 350 BHN; Gear – 300 BHN
Pitch line speed = 1000 fpm; X-factor = 350; m = 3.5
Let the face width, W = 0.5 in
31,500 25 (3.5 + 1) 3
Centre distance, C2 × (0.5) = × × = 33.47
350 1750 3.5
Centre distance, C = 8.18 in
Centre distance, C = 8.18 = (Dp + Dg)/2 = 4.5 Dp / 2
Dp = 3.636 in; Dg = 3.5 Dp = 12.728 in
Assuming a diametral pitch of 5, No of teeth in the pinion, Np = 5 × 3.636 = 18
No of teeth in the gear, Ng = 3.5 × 18 = 63
The actual diameter of Gear, Dg = 63 / 5 = 12.6 in
The actual diameter of pinion, Dp = 18 / 5 = 3.6 in
The actual centre distance, C = (12.6 + 3.6 ) / 2 = 8.1 in
2 Dg
Check for wear strength, FW = D p W K
D p + Dg
2 × 12.6
= 3.6 × 0.5 × 196 × = 549 lb
3.6 + 12.6

Tangential force coming on the gear can be calculated from the HP to be transmitted

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 hp × 63,000 25 × 63000
Tangential force, F = = = 500 lb
ωr 1750 × 1.8
Hence wear strength is satisfactory

Pitch line velocity, V = π × 3.6 × 1750 / 12 = 1649.336 fpm

600
Velocity factor, k = = 0.2667
600 + 1649.336
From Table 7.2, Y = 0.308
SWYk 20000 × 0.5 × 0.308 × 0.2667
Allowable bending strength, Fbd = = = 164 lb
P 5

This is less than the force, hence W needs to be increased. Make, W = 2 in

Allowable bending strength = 4 × 164 = 656 lb

Base circle diameter of pinion, = d cos φ = 3.6 × cos 20 = 3.383 in

Base circle diameter of gear, = d cos φ = 12.6 × cos 20 = 11.84 in
Addendum, a = 1/5 = 0.2

To calculate the contact ratio, we need Z which is given by

2 2
Z= (R + a) 2 − R b + (r + a) 2 − rb − c sinφ
2 2 2
 3.383   12.6   11.84 
= (1.8 + 0.2) 2 −   +  + 0.2  −   − 8.1 sin 20
 2   2   2 

= 0.9811 in

Circular pitch, p = π / P = π / 5 = 0.6283 in

Z 0.9811
Contact ratio = = = 1.6616 in
p cos φ 0.6283 × cos 20
Since contact ratio is greater than 1.4, it is satisfactory

Final parameters as designed:

The actual diameter of Gear, Dg = 12.6 in
The actual diameter of pinion, Dp = 3.6 in
The actual centre distance, C = 8.1 in
Face width, W = 2 in
Diametral pitch, P = 5

Design of Shafts

Input shaft:

63000 × 25
Torque transmitted, T = = 900 lb-in
1750

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In addition to this there is a force of 500 lb coming from the gear set acting in the
pressure angle direction, which needs to be taken into account while calculating the shaft
diameter.

Assuming a shaft length of 8 inches to accommodate the gear, keyways, and bearings at
both ends,

Horizontal force component = 500 × cos 20 = 469.846 lb

The shear force acting at the bearing points, R = 234.9 lb

Maximum bending moment, M = 234.9 × (8 / 2) = 939.69 lb-in

Vertical force component = 500 × sin 20 = 171 lb

The shear force acting at the bearing points, R = 85.5 lb

Maximum bending moment, M = 85.5 × (8 / 2) = 342 lb-in

Total BM acting = 939.69 2 + 342 2 = 1000 lb-in

Step 1: Equivalent torque method

Equivalent torque, TE = 900 2 + 1000 2 = 1345 lb-in
16 TE 16 × 1345
Shaft dia, d = 3 = 3 = 1.045 in
πτ π × 6000

Step 2: Equivalent bending moment method

Equivalent bending moment, ME = 0.5 × (1000 + 1345) = 1172.5 lb-in

32 M E 32 × 1172.5
Shaft dia, d = 3 = 3 = 0.9984 in
π S π ×12000

Take the larger value, d = 1.045 in

Output shaft:

63000 × 25
Torque transmitted, T = = 3150 lb-in
500

Total BM acting = 1000 lb-in (same as in Input shaft)

Step 1: Equivalent torque method

Equivalent torque, TE = 3150 2 + 1000 2 = 3305 lb-in

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 16 TE 16 × 3305
Shaft dia, d = 3 = 3 = 1.41 in
πτ π × 6000

Step 2: Equivalent bending moment method

Equivalent bending moment, ME = 0.5 × (1000 + 3305) = 2152.5 lb-in

32 M E 32 × 2152.5
Shaft dia, d = 3 = 3 = 1.2225 in
π S π ×12000

Take the larger value, d = 1.41 in

Shaft diameter, therefore can be taken as 1.5 in.

Keys

Keyway in the motor shaft is 0.5 × 0.5 in. Taking the same cross section, calculate the
length of the key

T 900
Input shaft Key length, l = = = 0.2 in
wrτ 0.5 × 1.8 × 5000

T 3150
Output shaft Key length, l = = = 0.7 in
wrτ 0.5 × 1.8 × 5000

Bearings

Calculate for the output shaft:

Since there is no axial load, we use single row deep groove ball bearings.
The radial load = 500 lb
The life required = 20000 × 500 × 60 = 600 × 106 revolutions
b 3
L1  C  600  C 
=  ; = 
L2  R  90  500 

Radial capacity, C = 941 lb

From the tables NSK, we select 6208 bearings to suit the purpose

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6
Couplings

From Love joy S-flex coupling selection procedure (http://www.lovejoy-

inc.com/catalog/sf.pdf):

Application service factor = 1.5

Design torque = 1.5 × 3150 = 4725 lb-in

Size 12 coupling can be selected.

Housing

Lubrication

Seals

Final layout drawing of the assembly of individual component components of the

designed power transmission showing all the necessary dimensions.

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 9.5

Ø1.5

INPUT

8.1
18
OUTPUT