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Machine Design (MEMB333) Mini Project

Sem I - 2018/2019
DUE DATE: Project report to be submitted by week 12 (refer to class Plan)

The required rotation speed for your system is 150 rpm, however, the available motor provides a much higher
speed, 1200 rpm. Therefore, you need to design a speed reducer to fit this motor with your system. You are
required to use a double-step reduction, with either Spur or Helical gears. For alignment issues, you must insure
that the input and output shafts are aligned as shown in Figure 1.

Figure 1: Sample gear system

The power transmitted to from the motor to your machine equals to [The last 4 digits of the ID number of group
leader (or first name in the list) in watts, e.g. if ME097475, the power is 7475 watts, or 7.4 kW]. All shafts are
supported by two ball or roller bearings; their selection is part of the design. For your design, it is desired to have
an overall reliability of 95%, and a design life of 20.000 h.

1. Chapter 13: Determine/Select/Decide on the geometry of the gears: number of teeth, diameters, tooth
systems, etc. Also, perform Gear Mechanics: determine the transmitted load Wt, the axial load Wa, and the
radial load Wr, acting Torque, rotation speeds, and transmitted power for each gear.

2. Chapter 14: Based on that information, decide on a number of factors related to gear design, this include
gear material, quality level, face width, surface quality. Use that information to determine the applied
stresses and strengths for each gear, which in turn would allow you to calculate the factors of safety.

3. Chapter 3: Now that you know the forces acting on each gear, as well as their diameters and locations
along each shaft (which you decide as well), you are now able to determine the maximum torque and
bending moment acting on each shaft, by developing the shear and bending moment diagrams for each
shaft. Also, you can calculate reactions acting on each support (the bearings) of every shaft.

4. Chapter 7: Knowing the forces, torques, and bending moments acting on each shaft, you are now ready to
design each shaft. You can select material of each shaft, determine its radiuses. The minimum value for the
Factor of safety of 2.0, any values lower than that will not be accepted. Remember that for every shaft there
are multiple radiuses to be found, as there are keyways, shoulders, and other fittings on each shaft creating
stress concentration, which you need to determine and consider it in your design. Also, design of shafts
ALSO includes design of its keys & keyways, as well as its holding rings.

5. Chapter 11: Based on the values of the reactions found in step 1, you can select an appropriate bearing for
each support of each shaft. In this selection, the design life, the design speed, and reliability requirements
should all be considered. Note that the speeds of the shafts are not the same.

6. Chapter 10: To add some stability to the designed gear box, add a number of compression springs at the
bottom of the box. Assume the springs would be (in-a-hole), and determine the number of springs needed,
wire diameter needed, and materials used.

7. Chapter 8: To add some stability to the designed gear box, add a number of fasteners to hold the box in
place. Determine how many screws (with or without bolts, your decision) would be needed to hold the box
on the ground, as per procedures discussed in this chapter.
8. Chapter 5: Design the casing (box) that would hold the designed speed reducer. (Bearings would be fixed
to it). Consider the total weight of all shafts, gears, bearings, and the case itself as a static load acting on the
box, and determine its factor of safety (static loading)

9. For each component of the project (gears, shafts, etc.) you must include the following:
 Decisions & Assumptions: explain the choices you made, and why.
 Calculations & Analysis: the actual design procedure
 Findings & Discussion: a Table showing a summary of your design (dimensions found, etc.),
followed by a discussion on your findings, did you achieved the requirements? Did you face any
issues? Did you notice any anomalies? (This is the most important part of your project)

10. Refer to the attached Mini-project rubric to learn how to create a proper report and how to maximize your
chances of scoring high marks, as well as obtaining bonus points.

The following list of some of the important parameters for all gears should be in table:

 The number of teeth, N (such as: N2, N3, N4, and N5.)
 The size of the teeth as indicated by the module, m [mm.] (Note that the module m23 of gear pair-23
may be different from the module m45 of gear pair-45.)
 The face width of the teeth, F [mm.] (F23 is not necessarily equal to F45!)
 The pitch diameter (dp)for each of the gears, [mm.]
 The means of attaching the gear to its shaft (such as: keys and keyways)
 The means of locating the gear axially on the shaft (collars, retaining rings etc.)
 The degree of precision of the gear teeth (You will need to decide on Q V based on the pitch line
velocity V of the pair (Noting that V23 ≠ V45)).
 Other geometry related to spur gears.

Note: Each group must file their own project report.

 Do provide the dimensional units whenever appropriate.

 For your report A4-Plain papers are recommended.
 Your findings must be justifiable and should be based on sound engineering judgment.

All the best