Overhead Crane Design PDF

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Machine Design II Overhead Crane Design Project progress report Team Work: 1-Abd-Elfatah Hashem Abd-Elfatah 5142013 2-Mohamed Salah Eldin 5142029 3-ElsayedZidanElsayed 5142085 Instructor: Prof. Dr.Tarek Othman T.A: Eng. Ahmed Hamed |Page1 Contents 1 Abstract ............................................

Description

Machine Design II Overhead Crane Design Project progress report

Team Work: 1-Abd-Elfatah Hashem Abd-Elfatah

5142013

2-Mohamed Salah Eldin

5142029

3-ElsayedZidanElsayed

5142085

Instructor: Prof. Dr.Tarek Othman T.A: Eng. Ahmed Hamed

|Page1

Contents 1

Abstract ....................................................................... 4

2

Introduction ................................................................. 5

3

Motor Selection Procedure ............................................ 6 3.1

Chosen Speed ................................................................................ 6

3.2

Motor Standards ............................................................................ 6

3.3

Standard Horsepower Ratings ....................................................... 6

3.4

Motor Power Needed .................................................................... 6

3.5

Motor Selection ............................................................................. 7

4

Overhead travelling cranes types .................................... 8 4.1

Single girder top running crane ..................................................... 9

4.2

Single girder under slung crane ..................................................... 9

4.3

Double girder top running crane ................................................... 9

5

Decision-Matrix .......................................................... 10

6

Conceptual design ...................................................... 11 6.1

Alternative 1 ................................................................................ 11

6.2

Alternative 2 ................................................................................ 12

7

Mechanical Design Procedure ...................................... 13 7.1

At first a design scheme (lay out) ................................................ 13

7.2

The forces .................................................................................... 13

7.3

Material........................................................................................ 14

7.4

Stress, Strain and Strength .......................................................... 14

7.4.1

Stress ..................................................................... 14

7.4.2

Strain ..................................................................... 15

7.4.3

Strength ................................................................. 15

7.5

The dimensions of the part.......................................................... 16

7.6

Finally, .......................................................................................... 16

8

Mechanical Design Criteria .......................................... 17 8.1

Strength ....................................................................................... 17

8.2

Rigidity ......................................................................................... 17

8.3

Wear Resistance .......................................................................... 17 |Page2

8.4 9

Resistance to vibrations............................................................... 17 Gearbox..................................................................... 18

9.1 9.2 9.3 9.4 10

𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 .................................................................................. 18 Second stage ............................................................................... 18 Third stage .................................................................................. 18

Pinion calculation ....................................................................... 18 Shaft Design and Bearing Selection ............................... 21

10.1

Shaft A .......................................................................................... 21

10.2

Shaft B .......................................................................................... 26

10.3

Shaft C .......................................................................................... 31

10.4

Shaft D.......................................................................................... 36

10.5

Finite Element .............................................................................. 39

11

Coupling .................................................................... 41 11.1

Coupling calculations Design (Rigid Type-Finger tight) ............... 41

11.1.1

Checks on the coupling dimensions ...................... 42

11.1.2

Check on bolts ....................................................... 42

11.1.3

Bearing pressure check on bolts ........................... 42

11.1.4

Shear on the flange Hub........................................ 42

11.1.5

Shear on Key .......................................................... 43

11.1.6

Crushing on key ..................................................... 43

11.1.7

Coupling Assembly ................................................ 43

11.2

Coupling calculations Design (Flexible Coupling) ........................ 44

12

Clutch........................................................................ 46

13

Rope and hoisting ....................................................... 48

14

13.1

Selection of rope .......................................................................... 48

13.2

Length of wire Rope..................................................................... 49 hoisting drum ............................................................. 50

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1 Abstract This report will discuss the problem definition, the design Procedure for each component and represent the calculations.

|Page4

2 Introduction It is required to design an overhead crane to lift a load of 15 tons to a height of 7 meters, and design and select the crane components.

|Page5

3 Motor Selection Procedure 3.1 Chosen Speed V=0.1 m/s

3.2 Motor Standards

η, overall system efficiency, is assumed 0.9 since there is still no detailed design.

3.3 Standard Horsepower Ratings Standard horsepower ratings of electrical motors - 1 to 4000 HP are indicated below: 1, 1 1/2, 2, 3, 5, 7 1/2, 10, 15, 20, 25, 30, 40, 50, 60, 75, 100, 125, 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 800, 900, 1000, 1250, 1500, 1750, 2000, 2250, 2500, 3000, 3500, 4000

3.4 Motor Power Needed

𝑃𝑃 =

𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 ∗ 𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉 150000 ∗ 0.1 = = 16.66 𝐾𝐾𝐾𝐾 = 22.35 𝐻𝐻𝐻𝐻 ῃ 0.9

Power Selected 25 HP

|Page6

3.5 Motor Selection

Description

HP RPM Poles Voltage Phase HZ Frame Mounting

𝑇𝑇 =

25 HP 975 RPM 4 230/460 Volts 3 60 HZ 286TC Rigid

𝑃𝑃 = 𝑇𝑇 ∗ 𝜔𝜔

𝑃𝑃 9.5488 ∗ 𝑃𝑃𝑘𝑘𝑘𝑘 9.55 ∗ 18.64𝑘𝑘𝑘𝑘 = = ∗ 103 = 182.576 𝑁𝑁. 𝑚𝑚 𝜔𝜔 𝜔𝜔 975 𝑟𝑟𝑟𝑟𝑟𝑟

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4 Overhead travelling cranes types

|Page8

4.1 Single girder top running crane Single Girder Top Running Crane These are utilised for medium to heavy fabrication and are ideally suited to low buildings, where a high hook lift height is required. I. II. III. IV.

Capacity up to 20 ton. Spans up to 36 meters Pendant or radio control Single or dual hoist options

4.2 Single girder under slung crane Single Girder Top Under slung Crane These are usually suspended from roof trusses, are mainly utilised inside pumping stations and small workshops, for maintenance purposes. The cranes are compact in design and construction, making them ideal for low buildings where maximum hook height is required. I. II. III.

Capacity up to 10 ton Span up to 18 meters Pendant or radio control

4.3 Double girder top running crane Double Girder Top Running Crane This is a very heavy-duty crane, normally used by larger manufacturers and steel warehouses. Among their features are: I. II. III. IV. V. VI. VII.

Capacity up to 100 ton Spans up to 36 meters Walkways Trolley platforms Various types of connections Pendant or radio control Main and Aux hoist options

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5 Decision-Matrix Factors

Single girder top running crane

Single girder under slung crane

Double girder

Wt.

1

2

3

Cost

4.0

3

4

1

Capacity

5.0

3

2

5

Space

4.0

3

4

2

Lift Height

4.0

4

2

5

safety

5.0

4

2

3

Maintainability

4.0

3

2

1

Reliability

3.0

3

2

2

velocity

2.0

3

1

2

102

76

86

Scores

| P a g e 10

6 Conceptual design

6.1 Alternative 1

| P a g e 11

6.2 Alternative 2

| P a g e 12

7 Mechanical Design Procedure 7.1 At first a design scheme (lay out) is drawn in which the shape of the part being designed and the nature of its connection with other elements are presented in a simplified form while the forces acting on the part are assumed to be either concentrated or distributed in conformity with some simple law;

7.2 The forces acting on the part in the process of machine operation are then determined;

| P a g e 13

7.3 Material is selected and the allowable stresses are found accounting for all the factors that affect the strength of the part;

7.4 Stress, Strain and Strength The quality of a mechanical system depends on the relationship of the maximum stress to the component strength.

7.4.1 Stress is a state property of a body which is a function of: load, geometry, temperature and manufacturing process? Stress is denoted with Greek letters and has unit [N/m2] 𝐹𝐹 𝐴𝐴

σ= – normal stress (tensile or compressive).

𝐹𝐹

τ= 𝐴𝐴𝑝𝑝– shear stress. Various marks denote various kinds of stress: σ1 – principal stress – stress in the direction of a principal axis. σ𝑦𝑦 – coordinate stress component. σ𝑟𝑟 – radial stress component.

| P a g e 14

7.4.2 Strain is defined as deformation of a solid due to stress in terms of displacement of material;

Strain is denoted with Greek letters:

𝜀𝜀 =

𝛾𝛾 =

∆𝐿𝐿 𝐿𝐿°

[m/m]

∆𝑆𝑆 𝑆𝑆°

[m/m]

Elastic Modulus are ratio of stress / strain:

𝜎𝜎

𝐸𝐸 = [N/m2]- Young’s modulus Modulus of Elasticity. 𝜀𝜀

𝜏𝜏

𝐺𝐺 = [N/m2]- Shear Modulus of Rigidity. 𝛾𝛾

7.4.3 Strength is an inherent property of a material built into the part because of the use of a material and process? Strength is denoted with capital letter S [N/m2]

SE – Yield strength (lowest stress that produces permanent deformation). SG – Shear strength (lowest shear stress that produces permanent deformation). St – Tensile or ultimate strength (limit state of tensile stress). Sd – Fatigue strength – dynamic loading. Si – Impact strength.

| P a g e 15

7.5 The dimensions of the part required by the design criteria (strength, rigidity, wear resistance etc.) corresponding to the accepted design scheme, are determined.

7.6 Finally, the drawing of the part is made indicating all dimensions, accuracy of manufacture, surface finish and other information necessary for the manufacture of the part.

| P a g e 16

8 Mechanical Design Criteria

8.1 Strength A component should not fail or have residual deformations under the effect of the forces that act on it. This is satisfied if the induced stress is smaller than the material strength.

8.2 Rigidity is the ability of parts to resist deformations under the action of forces? Proper rigidity is necessary to ensure that machine as a whole and its elements operate effectively. In many cases this parameter of operating capacity proves to be most important. Therefore, apart from the strength calculations, rigidity of a number of parts is also calculated as ratio of the actual displacements (deflections, angles of turn, angles of twist) with allowable (rated) displacements.

8.3 Wear Resistance Wear is the principal cause of putting machine elements out of commission. Problems: frequent stops, loss of machine accuracy etc. Calculations of wear are usually of an arbitrary nature and carried out together with calculations of strength. Heat resistance: The liberation of heat involved in the working process or sometimes due to friction between moving surfaces, causes the components of some machines to operate under conditions of increased temperature. An increased temperature (> 100o C) impairs the lubricating ability of oils; Continuous operations involving temperatures > 300-400o C causes slow plastic deformations called creep. Thermal deformations may reduce the accuracy of a machine. Effective cooling and special calculations for heat to find the working temperature of the machine elements, evaluate the working stresses and compare them with the creep limits for the material of the part.

8.4 Resistance to vibrations The term implies the ability of a machine to operate at the assigned speeds and loads without impermissible oscillations Dynamic analysis after finalizing the design to avoid inherent unbalances.

| P a g e 17

9 Gearbox Our gearbox is a triple stage gearbox with a reduction ratio of 100, using spur gears to transmit power and provide the needed reduction ratio with the first stage having reduction ratio of 5:1, the second stage also having 5:1, and the third reduction ratio having 6:1. 𝑣𝑣 𝑟𝑟 Diameter of drum 300 mm 1 − 𝑤𝑤 = 𝜔𝜔 =

𝜔𝜔 =

0.1 = 0.66 (150 ∗ 10−3 )

0.666 ∗ 60 = 6.5 𝑟𝑟. 𝑝𝑝. 𝑚𝑚 2𝜋𝜋

We use spur gear and reduction to three stages ( 5: 1 ) … (5: 1) … (6: 1)

𝜔𝜔𝑖𝑖𝑖𝑖 = 975 𝑟𝑟. 𝑝𝑝. 𝑚𝑚

9.1 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓

𝜔𝜔 =

1 ∗ 975 = 195 𝑟𝑟. 𝑝𝑝. 𝑚𝑚 5

9.2 Second stage

𝜔𝜔 =

1 ∗ 195 = 39 𝑟𝑟. 𝑝𝑝. 𝑚𝑚 5

9.3 Third stage

𝜔𝜔 =

1 ∗ 39 = 6.5 𝑟𝑟. 𝑝𝑝. 𝑚𝑚 6

9.4 PINION CALCULATION 𝑵𝑵𝑵𝑵 = 𝟏𝟏𝟏𝟏 𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕

𝑷𝑷 = 𝟐𝟐𝟐𝟐 𝑯𝑯𝑯𝑯

𝑹𝑹𝑹𝑹𝑹𝑹 = 𝟗𝟗𝟗𝟗𝟗𝟗

𝑷𝑷𝑷𝑷𝑷𝑷(∅) = 𝟐𝟐𝟐𝟐°

FROM GRAPH AND PREFERRED VALUES O F MODULE M=6

𝒅𝒅𝒅𝒅 = 𝟔𝟔 ∗ 𝟏𝟏𝟏𝟏 = 𝟏𝟏𝟏𝟏𝟏𝟏 𝒎𝒎𝒎𝒎

𝒇𝒇 = 𝟑𝟑 ∗ 𝝅𝝅 ∗ 𝟔𝟔 = 𝟓𝟓𝟓𝟓. 𝟓𝟓𝟓𝟓 𝒎𝒎𝒎𝒎

| P a g e 18

FOR BENDING STRESS ON PINION TOOTH

𝒘𝒘𝒘𝒘 =

𝑲𝑲𝑲𝑲 =

𝟐𝟐𝟐𝟐 (𝟐𝟐 ∗ 𝟏𝟏𝟏𝟏𝟏𝟏. 𝟓𝟓𝟓𝟓𝟓𝟓) = = 𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑 𝑵𝑵 (𝟏𝟏𝟏𝟏𝟏𝟏 ∗ 𝟏𝟏𝟎𝟎−𝟑𝟑 ) 𝑫𝑫𝑫𝑫

𝟔𝟔 𝟔𝟔 = = 𝟎𝟎. 𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓 𝟗𝟗𝟗𝟗𝟗𝟗 𝟔𝟔 + 𝒗𝒗 �𝟔𝟔 + �𝝅𝝅 ∗ 𝟏𝟏𝟏𝟏𝟏𝟏 ∗ 𝟏𝟏𝟎𝟎−𝟑𝟑 ∗ � 𝟔𝟔𝟔𝟔 ���

From Table: 𝒚𝒚 = 𝟎𝟎. 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐 𝑺𝑺 =

𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑 𝑾𝑾𝑾𝑾 = = 𝟔𝟔𝟔𝟔. 𝟗𝟗𝟗𝟗 𝑴𝑴𝑴𝑴𝑴𝑴 (𝒇𝒇 ∗ 𝑲𝑲𝑲𝑲 ∗ 𝒎𝒎 ∗ 𝒚𝒚) (𝟓𝟓𝟓𝟓. 𝟓𝟓𝟓𝟓 ∗ 𝟎𝟎. 𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓 ∗ 𝟔𝟔 ∗ 𝟎𝟎. 𝟐𝟐𝟗𝟗𝟑𝟑𝟑𝟑𝟑𝟑)

𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴𝑴: 𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝑸𝑸&𝑻𝑻 ∗, 𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺 = 𝟖𝟖𝟖𝟖𝟖𝟖𝑴𝑴𝑴𝑴𝑴𝑴, 𝑺𝑺𝑺𝑺 = 𝟔𝟔𝟔𝟔𝟔𝟔𝑴𝑴𝑴𝑴𝑴𝑴 𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪:

𝐹𝐹𝐹𝐹𝐹𝐹 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙: 𝐾𝐾𝐾𝐾 = 0.69 𝐾𝐾𝐾𝐾 = 0.894 𝐾𝐾𝐾𝐾 = 0.897 𝐾𝐾𝐾𝐾 = 1 𝐾𝐾𝐾𝐾 = 1

𝐾𝐾𝐾𝐾 = 1

𝑆𝑆𝑆𝑆’ = 848/2 = 424 𝑀𝑀𝑀𝑀𝑀𝑀

𝑆𝑆𝑆𝑆 = 0.69 ∗ 0.894 ∗ 0.897 ∗ 1 ∗ 1 ∗ 1 ∗ 260 = 234.6 𝑀𝑀𝑀𝑀𝑀𝑀

𝐹𝐹𝐹𝐹𝐹𝐹 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠:

𝑅𝑅𝑅𝑅 = 5 𝑎𝑎𝑎𝑎𝑎𝑎 𝑁𝑁𝑝𝑝 = 18, 𝑠𝑠𝑠𝑠; 𝑁𝑁𝑔𝑔 = 90; 𝑏𝑏𝑏𝑏 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖, 𝐽𝐽 = 0.3506265

𝑆𝑆𝑆𝑆 = 73.14 𝑀𝑀𝑀𝑀𝑀𝑀

𝑆𝑆𝑆𝑆 =

𝑤𝑤𝑤𝑤 (𝐾𝐾𝐾𝐾 ∗ 𝐹𝐹 ∗ 𝑚𝑚 ∗ 𝐽𝐽)

𝐾𝐾𝐾𝐾 = 1

𝐾𝐾𝐾𝐾 = 1.4 | P a g e 19

𝑆𝑆𝑆𝑆 = 2

𝑺𝑺𝑺𝑺 ∗ 𝑲𝑲𝑲𝑲 ∗ 𝑲𝑲𝑲𝑲 ∗ 𝑺𝑺𝑺𝑺 = 𝟐𝟐𝟐𝟐𝟐𝟐. 𝟕𝟕𝟕𝟕 𝑴𝑴𝑴𝑴𝑴𝑴 𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘 𝒊𝒊𝒊𝒊 𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔 𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕 𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂 𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃 𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔 (𝑺𝑺𝑺𝑺 = 𝟐𝟐𝟐𝟐𝟐𝟐. 𝟔𝟔 𝑴𝑴𝑴𝑴𝑴𝑴)

− 𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺 𝐵𝐵𝐵𝐵𝐵𝐵 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 :

𝜔𝜔1 𝜔𝜔2

=

𝑑𝑑2 𝑑𝑑1

=

𝑁𝑁2 𝑁𝑁1

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 1 ∶ 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑁𝑁 = 18 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡ℎ 𝑑𝑑 = 108 𝑚𝑚𝑚𝑚 𝑚𝑚𝑚𝑚𝑚𝑚ℎ 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 𝑑𝑑 = 540 𝑚𝑚𝑚𝑚 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 2 ∶ 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑁𝑁 = 20 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡ℎ 𝑑𝑑 = 120 𝑚𝑚𝑚𝑚 𝑀𝑀𝑀𝑀𝑀𝑀ℎ 𝑔𝑔𝑒𝑒𝑒𝑒𝑒𝑒 𝑑𝑑 = 600 𝑚𝑚𝑚𝑚

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 3 ∶ 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑁𝑁 = 22 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡ℎ 𝑑𝑑 = 132 𝑚𝑚𝑚𝑚 𝑀𝑀𝑀𝑀𝑀𝑀ℎ 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 𝑑𝑑 = 792 𝑚𝑚𝑚𝑚

| P a g e 20

10 Shaft Design and Bearing Selection 10.1 Shaft A -Given Data: T=182.576 N.m -For Pinion Assume M=6, N=18, ᵩ=20 D=6*18=108 mm 𝑇𝑇 = 𝐹𝐹𝑡𝑡 ∗

𝐷𝐷 2

𝐹𝐹𝑡𝑡 = 3381 𝑁𝑁

𝐹𝐹𝑟𝑟 = 𝐹𝐹𝑡𝑡 ∗ 𝑇𝑇𝑇𝑇𝑇𝑇(20) = 1230.6 𝑁𝑁

X-Z Plane

3381 ∗ 10 = 𝑅𝑅1 ∗ 30 𝑅𝑅1𝑥𝑥−𝑧𝑧 = 1127 𝑁𝑁

𝑅𝑅2𝑥𝑥−𝑧𝑧 = 2254 𝑁𝑁

𝑀𝑀1𝑥𝑥−𝑧𝑧 = 225.4 𝑁𝑁. 𝑚𝑚

| P a g e 21

Shear Force Diagram and Bending Moment Diagram (X-Z)

| P a g e 22

X-Y Plane 1230.6 ∗ 10 = 𝑅𝑅1𝑥𝑥−𝑦𝑦 ∗ 30 𝑅𝑅1𝑥𝑥−𝑦𝑦 = 410.2 𝑁𝑁

𝑅𝑅2𝑥𝑥−𝑦𝑦 = 820.4 𝑁𝑁

𝑀𝑀1𝑥𝑥−𝑦𝑦 = 82 𝑁𝑁. 𝑚𝑚

Shear Force Diagram and Bending Moment Diagram (X-Y)

| P a g e 23

𝑀𝑀3 = �(82)2 + (225.4)2 = 239.85 𝑁𝑁. 𝑚𝑚

Shaft Diameters Assume

Material AISI 1050 (𝑆𝑆𝑦𝑦 = 325 ∗ 106 𝑃𝑃𝑃𝑃)

F.S.=2 ,𝐶𝐶𝑚𝑚 = 1.5 , 𝐶𝐶𝑡𝑡 = 2

Maximum Shear Stress Criterion

3

𝑑𝑑 = �

32 ∗ 𝐹𝐹. 𝑆𝑆. 1 ∗ ((𝐶𝐶𝑚𝑚 ∗ 𝑀𝑀)2 + (𝐶𝐶𝑡𝑡 ∗ 𝑇𝑇)2 ) �2 𝜋𝜋 ∗ 𝑆𝑆𝑦𝑦

| P a g e 24

D at Bearing (1,2) ‘’M=0, T=T’’ 𝑑𝑑 = 28.3 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 30𝑚𝑚𝑚𝑚

D at Pinion ‘’M=239. 85N.m, T=T’’

𝑑𝑑2 = 31.79 𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 35 𝑚𝑚𝑚𝑚 Bearing Selection of Shaft, A Assume Life of two Bearing 12000 hr., D.G.B.B, a=3 At 1 𝑃𝑃1 = �(𝑅𝑅1𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅1𝑥𝑥−𝑦𝑦 )2 = 1199.3 𝑁𝑁 𝑎𝑎

𝐶𝐶 = 𝑃𝑃 ∗ �

60 ∗ 𝑛𝑛 ∗ 𝐿𝐿10ℎ = 10.6 𝐾𝐾𝐾𝐾 106

Designation 6006 At 2

𝑃𝑃2 = �(𝑅𝑅2𝑥𝑥−𝑧𝑧 )2 + (𝑅𝑅2𝑥𝑥−𝑦𝑦 )2 = 2398.6 𝑁𝑁 𝑎𝑎

𝐶𝐶 = 𝑃𝑃 ∗ �

60 ∗ 𝑛𝑛 ∗ 𝐿𝐿10ℎ = 21.3 𝐾𝐾𝐾𝐾 106

Designation 6206 ETN9

| P a g e 25

10.2 Shaft B -With Gear Ratio 𝑇𝑇2 𝜔𝜔1 = 𝑇𝑇1 𝜔𝜔2

𝑇𝑇2 = 912.8 ~ 913 𝑁𝑁. 𝑚𝑚 Gear (2)

Gear (3)

D=6*20=120 mm

𝐹𝐹𝑡𝑡 = 3381 𝑁𝑁

𝐹𝐹𝑡𝑡 = 15216.7 𝑁𝑁𝐹𝐹𝑟𝑟 = 1230.6 𝑁𝑁 𝐹𝐹𝑟𝑟 = 5538.4 𝑁𝑁

X-Z Plane

𝑅𝑅1𝑥𝑥−𝑧𝑧 ∗ 30 = 3381 ∗ 10 + 15216.7 ∗ 20

𝑅𝑅1𝑥𝑥−𝑧𝑧 = 11271.5 𝑁𝑁

𝑅𝑅4𝑥𝑥−𝑧𝑧 = 7326.23 𝑁𝑁

𝑀𝑀2𝑥𝑥−𝑧𝑧 = 1127.15 𝑁𝑁. 𝑚𝑚 𝑀𝑀3𝑥𝑥−𝑧𝑧 = 732.623 𝑁𝑁....