MECG 1022 Design Project Report

Design of an Overhanging Countershaft

Project advance

Date: June 5, 2019

Name: Jorge Adalberto Cárdenas Benavides
Design Project No.: 1
Instructor: Professor Carlos Gabriel Helguero

Mechanical Engineering Faculty

ESPOL
Calculations:
Technical data:

 𝐻𝑛 = 10.5 ℎ𝑝
 𝐷𝑝 = 400𝑚𝑚
 𝜔𝑠 = 2000𝑟𝑝𝑚
 𝐾𝑠 = 1.25 𝑛𝑑 = 1.85
For V-belt:
𝐻𝑑 = (10.5)(1.25)(1.85)
𝐻𝑑 = 24.28 ℎ𝑝
From table-17.12, Shigley, Pag 881, for 𝐻𝑛 = 10.5 ℎ𝑝, it chooses section C, 𝑉 = 4000 𝑓𝑡/𝑚𝑖𝑛:

Calculations for the rotational speed of the shaft:

𝜔2 𝑑
=
𝜔1 𝐷
Where:
𝜔2 : Rotational speed of the shaft [rpm]
𝜔1 : Rotational speed of the motor [rpm]
𝑑: Diameter of the motor pulley [in]
𝐷: Diameter of the shaft pulley [in]
𝜔2 12
=
2000 15.748
𝜔2 = 1524 𝑟𝑝𝑚
The distance between centers is assumed as 7 ft.
Calculation of the angle:
𝐷−𝑑
𝜙 = 𝜙𝑑 = 𝜋 − 2𝑠𝑒𝑛−1 ( )
2𝐶
15.748 − 12
𝜙 = 𝜋 − 2𝑠𝑒𝑛−1 ( )
2(7)(12)
𝜙 = 3.0969 𝑟𝑎𝑑
For effective coefficient of friction:

𝑓 = ℮0.5123𝜙

𝑓 = ℮0.5123𝑥3.0969
𝑓 = 4.887
For permissible power:
𝐻𝑎 : Permissible power [hp]
𝑘1 : Contact angle correction factor
𝑘2 : Band length correction factor

𝐻𝑎 = 𝑘1 𝑘2 𝐻𝑡𝑎𝑏
From table 17.12 𝐻𝑡𝑎𝑏 is 10.9 hp, from table 17.13 𝑘1 is 0.76, from table 17.14 𝑘2 is 0.90:
 𝐻𝑎 = (0.76)(0.90)(10.9) = 7.46 ℎ𝑝
Calculation of number of belts:
𝐻𝑑 24.28
𝑁𝑏 ≥ = = 3.25 ∴ 4 𝑏𝑒𝑙𝑡𝑠
𝐻𝑎 7.46
For centrifugal stress:

𝑉 2
𝐹𝑐 = 𝑘𝑐 ( )
1000
Where:
𝐹𝑐 : centrifugal stress [lb]
𝑘𝑐 : correction factor
V: speed of the belt [rpm]
Getting 𝑘𝑐 from table 17.16 Shigley, pag 883:

4000 2
𝐹𝑐 = 1.716 ( ) = 27.456 𝑙𝑏𝑓
1000
Difference of forces transmitted:
24.28
(63025)𝐻𝑑 /𝑁𝑏 (63025)( 4 )
∆𝐹 = = = 31.88 𝑙𝑏𝑓
𝑑 12
𝑁( ) (2000)( 2 )
2
Greater tension:
∆𝐹 exp(𝑓∅) (31.88)(4.887)
𝐹1 = 𝐹𝑐 + = 27.456 + = 67.54 𝑙𝑏𝑓
exp(𝑓∅) − 1 4.887 − 1
Lower tension:
∆𝐹 = 𝐹1 − 𝐹2 → 𝐹2 = 𝐹1 − ∆𝐹 = 67.54 − 31.88 = 35.66 lbf
The initial stress:
𝐹1 + 𝐹2 67.54 + 35.66
𝐹𝑖 = − 𝐹𝑐 = − 27.456 = 24.144 𝑙𝑏𝑓
2 2
Safety factor:
𝐻𝑎 𝑁𝑏 (7.46)(4)
𝑛𝑓𝑠 = = = 2.27
𝐻𝑛𝑜𝑚 𝑘𝑠 (10.5)(1.25)
Maximum tension:
𝑘𝑏
𝑇1 = 𝐹1 +
𝑑
Where 𝑘𝑏 it gets from table 17.16 shown above:
1600
𝑇1 = 67.54 + = 200.87 𝑙𝑏𝑓
12
𝑘𝑏 1600
𝑇2 = 𝐹1 + = 67.54 + = 169.14 𝑙𝑏𝑓
𝐷 15.748
Number of passes:
−1
𝑘 −𝑏 𝑘 −𝑏
𝑁𝑝 = [( ) + ( ) ]
𝑇1 𝑇2

From table 17.17 Shigley pag 886:

−1
2038 −11.173 2038 −11.173
𝑁𝑝 = [( ) +( ) ] = 7.10 ∗ 1010
200.87 169.14
Shaft Design
63025 (𝐻𝑑 ) 63025 (24.28)
𝑇= = = 1004.1 𝑙𝑏𝑓 ∗ 𝑖𝑛
𝑁 1524
Diameter of pinion:

𝑁𝑝 24
𝑑𝑝 = = = 2.4 𝑖𝑛
𝑝𝑑 10
𝑇 1004.1
𝑤𝑡 = = = 836.74 𝑙𝑏𝑓
𝑑𝑝 2.4⁄
⁄ 2
2
𝑤𝑟 = 𝑤𝑡 𝑡𝑔 20 = 304.55 𝑙𝑏𝑓
Plane YX

𝑂𝑦 𝑊𝑡 𝑅𝑦 𝑊𝐵

𝐹1 + 𝐹2 + 𝑚𝑔 = 103.2 𝑙𝑏𝑓 + 496.9 𝑙𝑏𝑓 = 600.1 𝑙𝑏𝑓

∑ 𝑀𝑜 = 0: 20.47𝑅𝑦 − 836.74(9.84) − 600.1(32.28) = 0

𝑅𝑦 = 1348.55 𝑙𝑏𝑓 ↑

∑ 𝐹𝑦 = 0: 𝑂𝑌 − 𝑤𝑡 + 𝑅𝑦 − (𝐹1 + 𝐹2 ) − 𝑤 = 0

𝑂𝑦 − 836.74 + 1348.55 − 600.1 = 0

𝑂𝑦 = 88.29 𝑙𝑏𝑓 ↑

Plano XZ

𝑂𝑧 𝑊𝑟 𝑅𝑍

∑ 𝑀𝑜 = 0 : − 9.84𝑤𝑟 + 20.47𝑅𝑧 = 0

𝑅𝑧 = 146.4 𝑙𝑏𝑓 ↑

∑ 𝐹𝑦 = 0: 𝑂𝑧 − 𝑤𝑟 + 𝑅𝑧 = 0

𝑂𝑧 = 158.15 𝑙𝑏𝑓 ↑
Fatigue stress
Shaft surface cold drawn and machined AISI 1018
75𝑜 𝐶
𝑆𝑦 = 32 𝑘𝑝𝑠𝑖
{ →→ 𝑆𝑒′ = 0.5𝑆𝑢𝑡 = (0.5)(49.5) = 24.75 𝑘𝑝𝑠𝑖
𝑆𝑢𝑡 = 49.5 𝑘𝑝𝑠𝑖
𝑆𝑒 = 𝑘𝑡𝑎𝑚 𝑘𝑠𝑢𝑝 𝑘𝑐𝑎𝑟𝑔 𝑘𝑡𝑒𝑚𝑝 𝑘𝑐𝑜𝑛𝑓 𝑆𝑒′

Confiabilidad 99.99%
𝑘𝑐𝑎𝑟𝑔 = 1 𝑘𝑡𝑒𝑚𝑝 = 1 𝑘𝑐𝑜𝑛𝑓 = 0.702 𝑘𝑡𝑎𝑚 = 1 𝑘𝑠𝑢𝑝 = 1.06

𝑆𝑒 = (1)(1)(0.702)(1.06)(1)(24.75) → 𝑆𝑒 = 18.42 𝑘𝑝𝑠𝑖

Calculation diameters
𝑞𝑠 = 0.65
𝑞 = 0.50
𝑘 = 2.2
It is assumed { 𝑡
𝑘𝑡𝑠 = 3.0

𝑘𝑓 = 1 + 0.5(2.2 − 1) = 1.6

𝑘𝑓𝑠 = 1 + 0.65(3.0 − 1) = 2.3

𝑘𝑓𝑠 = 𝑘𝑓𝑠𝑚

For pulley
1/3
2 3 2
√(𝐾𝑓𝑚 𝑀𝑚 ) + 3 (𝐾𝑓𝑠𝑚 𝑇𝑚 )
2 2
32𝑁𝑓 √(𝐾𝑓 𝑀𝑎 ) + 4 (𝐾𝑓𝑠 𝑇𝑎 ) 4
𝑑= +
𝜋 𝑆𝑓 𝑆𝑢𝑡
{ [ ]}
1/2 1/3
(1.85) 3 1
𝑑 = {(32) [ ((2.3)(1004.1))2 ] }
𝜋 4 49500

𝑑 = 0.92 𝑖𝑛

For Gear

𝑀𝑎 = √8233.52 + 29972
𝑀𝑎 = 8762 𝑙𝑏𝑓 𝑖𝑛
1/3
2 3 2
√(𝐾𝑓𝑚 𝑀𝑚 ) + 3 (𝐾𝑓𝑠𝑚 𝑇𝑚 )
2 2
32𝑁𝑓 √(𝐾𝑓 𝑀𝑎 ) + 4 (𝐾𝑓𝑠 𝑇𝑎 ) 4
𝑑= +
𝜋 𝑆𝑓 𝑆𝑢𝑡
{ [ ]}
 1/3
3
(1.85) √(1.6 ∗ 8762)2 √4 (2.3 ∗ 1004.1)
2
𝑑 = (32) +
𝜋 18420 49500
{ [ ]}
𝑑 = 2.47 𝑖𝑛

For bearing
𝑀𝑜 = 15926 𝑙𝑏𝑓 𝑖𝑛
1/3
3
(1.85) √(1.6 ∗ 15926)2 √4 (2.3 ∗ 1004.1)
2
𝑑 = (32) +
𝜋 18420 49500
{ [ ]}
𝑑 = 2.99 𝑖𝑛

Bearing
Gears Bearing
Pulley
Bearing

2.47 in 0.92 in
2.99 in 2.99 in