MECG1043 DESIGN PROJECT

REPORT
Facultad de Ingenierı́a Mecánica y Ciencias de la Producción

Advance Project

Design of an Overhanging Countershaft

Date:

November, 18, 2020

Name:

Adriana Belén Rodrı́guez Torres

Instructor:

Ing. Carlos Helguero Alcı́var, PhD.

II Término - 2020

Guayaquil - Ecuador
Contents

1 Introduction 1
1.1 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 General objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Specific Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Calculations performed 2
2.1 Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Overall geometry of the shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Bibliography 8
Chapter 1

Introduction

1.1 Objectives
1.1.1 General objective
Design a countershaft or transmit to power of 5 hp at 2000 rpm. The same is comprised of a hanging
pulley and gear. Using the methodology learned for the design of mechanical elements.

1.1.2 Specific Objectives

(i) The slope of the countershaft at the bearings O and R should not exceed 0.06 for good bearing life.
(ii) Make appropriate assumptions for the design of the mechanical system, justifying them through
the calculations.

(iii) Discuss the feasibility of the design from the indicated requirements, to determine if it is optimal
for its manufacture or if it requires changes in the initial parameters

1
Chapter 2

Calculations performed

2.1 Pulley
For this project, a motor that delivers a speed of 3000 rpm is taken into consideration, therefore the
diameter of the driving pulley will be:

N1 D1 = N2 D2
N2 D2
D1 =
N1
2000 ∗ 15.748
D1 =
3000
D1 = 10.498 ≈ 10.5 in
The standard V-pulley selected for the design will be type B93, therefore, the step length obtained,
according to the catalog values is (Table 17-11)[1]:

Lp = L + Lc

Lp = 93 + 1.8 = 94.8 in

The distance between centers of the pulley will be:

r
π π
C = 0.25 ∗ [(Lp − (D + d)) + 2 (Lp − (D + d))2 − 2(D − d)2 ]
2 2
r
π π
C = 0.25 ∗ [(94.8 − (15.748 + 10.5)) + 2 (94.8 − (15.748 + 10.5))2 − 2(15.748 − 10.5)2 ]
2 2
C = 26.66 in

The rotational speed is given by the following expression:

π∗d∗N
V =
12
π ∗ 10.5 ∗ 3000
V =
12
V = 2625π f t/min

For the forces acting on the pulley, it is necessary to find the angle of coverage:
 
D−d
φ = θd = π − 2 arcsin
2C
 
15.748 − 10.5
φ = θd = π − 2 arcsin
2 ∗ 26.66

2
 φ = θd = 2.94 rad

Power allowed by the band:

Ha = k1 K2 Htab

According to Shigley’s book [1], Htab =4.90 hp, k1 =0.967 and k2 =1.
Tables: 17-12, 17-13 and 17-14 respectively.

Ha = (0.967)(4.90)
Ha = 4.74 hp

Design Power:

Hd = Hnom ks nd

The design factor given by this project is nd =1.85 and the service factor taken for the operation is ks =1.2
(Light impact).

Hd = 5 ∗ 1.2 ∗ 1.86
Hd = 11.1 hp

Now, it is necessary to know the number of pulleys in V, required for the design.
Hd
Nb >
Ha
Nb > 2.3 Nb = 3

Power transmitted by the band, is given by ∆F = F1 + F 2:

63025Hd
3
∆F =
N d2
63025∗11.1
3
∆F =
3000 10.5
2
∆F = 14.81 lbf

Centrifugal tension:
V 2
Fc = kc ∗ ( )
1000

According to table 17-16, kc =0.425.

2625π 2
Fc = 0.425 ∗ ( )
1000
Fc = 28.9 lbf

The largest tension F1 :

∆F e(f φ)
F1 = Fc +
e(f φ) − 1

According to Gates Rubber Company, declares that the effective friction coefficient is 0.5123 to pulleys
in V.[1][880]
14.81 ∗ e(0.5123∗2.94)
F1 = 28.9 +
e(0.5123∗2.94) − 1

3
 F1 = 47.93 lbf

Lowest tension F2 :

F2 = F1 − ∆F F2 = 33.12 lbf

Factor of safety:
Ha Nb
ηf s =
Hn omKs

4.74 ∗ 3
ηf s = ηf s = 2.3
5 ∗ 1.2

Durability correlations:
kb
T1 = F1 + F (b )1 = F1 +
d

According to table 17-16, corresponding to band parameters, it is obtained kb =230.

230
T1 = 47.93 +
10.5
T1 = 69.83 lbf
kb
T2 = F1 + F (b )2 = F1 +
D
230
T2 = 47.93 +
15.748
T2 = 62.54 lbf

Therefore the number of passes that can give the band until it complies with its life, is given by:
K −b K −b −1
Np = [( ) + ) +]
T1 T2
728 −12.464 728 −12.464 −1
Np = [( ) + ) +]
69.83 62.54
Np = 3.91x1012

As the value of Np > 109 , and its range of validity is limited by that value, Np = 109 is used:
Np Lp
t=
720V
109 ∗ 94.8
t=
720 ∗ 2625π
t = 15966 h

4
2.2 Gear
For the design of the gear train consisting of a pinion 24 teeth with a diametral pitch of 10 and a gear
47 teeth, the following is established:

Gear ratio:
Ng
MG =
Np
47
MG = = 1.96
24

Circular Pitch:
π
Pc =
Pd
π
Pc =
10
Pc = 0.314 in Pc = 7.98 mm

Base Pitch:
Pb = Pc cos φ

For this design, a pressure angle φ for the pinion equal to 20 is considered:

Pb = Pc cos 20

Pb = 0.295 in Pb = 7.49 mm

Pitch diameters of the pinion and gear, are obtained as follows:

Np
dp =
Pd
24
dp =
10
dp = 2.4 in dp = 60.96 mm

Ng
dg =
Pd
47
dg =
10
dg = 4.7 in dg = 119.38 mm

Nominal distance between centers:

C = rp + rg
dp dg
C= +
2 2
2.4 4.7
C= +
2 2
C = 3.55 in C = 90.17 mm

Adendum and Dedendum from Table-8-1.[2]

1
a=
Pd

5
 1
a=
10
a = 0.1 in a = 2.54 mm

1.25
b=
Pd
1.25
b=
10
b = 0.125 in b = 3.175 mm

Total depth:
ht = a + b
ht = 0.1 + 0.125
ht = 0.225 in ht = 5.715 mm

Blacklash
c=b−a
c = 0.125 − 0.1
c = 0.025 in c = 0.635 mm

Outer diameter of the pinion and gear:

Dop = dp + 2a
Dop = 2.4 + 2 ∗ (0.1)
Dop = 2.6 in Dop = 66.04 mm

Dog = dg + 2a
Dog = 4.7 + 2 ∗ (0.1)
Dog = 4.9 in Dop = 124.46 mm

Contact Ratio:
z
mp =
Pb

To know the contact ratio, it is necessary to find the action length, which is given by the following
equation: q q
Z = (rp + a)2 − (rp cos φ)2 + (rg + a)2 − (rg cos φ)2 − C sin φ
r r
dp dp dg dg
Z = ( + a) − ( cos φ) + ( + a)2 − ( cos φ)2 − C sin φ
2 2
2 2 2 2
r r
2.4 2.4 4.7 4.7
Z= ( + 0.1)2 − ( cos 20)2 + ( + a)2 − ( cos 20)2 − 3.55 ∗ sin 20
2 2 2 2
Z = 0.494 in Z = 12.548 mm

0.494
mp =
0.295
mp = 1.67

6
To determine the loads experienced by the shaft through the pinion, it is necessary to calculate the
torque transmitted, obtained as follows:
T n
P =
63000

Solving for T:
63000 P
T =
n
63000 ∗ 5
T =
2000
T = 157.5 lbf.in

Tangential component of force in Pinion:

T
Wt =
rp
T
Wt = dp
2
15.5
Wt = 2.4
2
Wt = 131.25 lbf Wt = 583.83 N

2.3 Overall geometry of the shaft

It is often more optimal to position the shaft between bearings. It is also recommended to keep
short lengths of shafts to minimize bending moments and deflections; With this in mind, the following
provisional design of the shaft is established.

Figure 2.1: Shaft design proposal

The primary means for coupling a shaft, are shoulders, which in turn help reduce the effects of vibration,
therefore, the geometry presented are considered four shoulders, and a retainer member for the section
of the pinion , so that axial load can be minimized.

7
Bibliography

[1] R. G. Budynas and J. K. Nisbett, Diseño en ingenierıa mecánica de Shigley. McGraw-Hill Interamericana,
2012, vol. 8.
[2] R. L. Norton, Diseño de máquinas. TJ233. N67 1999. 1999.