Group No: 32

FINAL REPORT
ME3200

Hoisting machine (Load<1000kg)

By

Marks
Index No. Name
from (5)

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka

1
Contents
1 Problem definition ............................................................................................................. 3

2 Project brief ........................................................................................................................ 4

3 Conceptual design .............................................................................................................. 5

4 Concept selection ............................................................................................................... 6

5 Design calculations .......................................................... Error! Bookmark not defined.

6 Final design ...................................................................... Error! Bookmark not defined.

7 Manufacturing process ..................................................... Error! Bookmark not defined.

8 Annexes............................................................................ Error! Bookmark not defined.

2
1. Problem definition
Hoist for light loads is selected the application for this project. It is not an easy task to lift most of
the loads which are used in domestic small-scale construction, repairing, and etc. One speed hoists
are commonly available in the market but they are unable to increase the efficiency of the whole
process (time consuming) or even perhaps only one motion is available (mostly vertical)

Three speed gearbox with one reverse is used to make the whole task easy, efficient and labour
free. Load is lifted by the hoist and has the ability to move it horizontally. This hoist will have
speed variations enabling to enhance the overall efficiency of the whole task. The speeds can be
varied for the vertical motion and the hoist can move the load horizontally other than lifting.

3
2. Project brief
The project is focused on building a solution to provide three speeds for a hoist for light loads to
increase the efficiency of the task being done to save time. From the survey conducted to find the
common most effective speeds of the hoists available in the current market, 0.407, 0.2038 and 0.13
ms -1 were selected for the weight ranges 0-300kg, 300-700kg and 700-1000kg. The heaviest load
range is lifted at a bit slower speed and the light ranges are lifted faster.

After designing the gear pairs according to the gear ratios required, shafts were designed according
to the type of the gear box and to withstand to loads of the gears. A sliding mesh gear box type is
selected and the gears on the output shaft is shifted using a fork mechanism. Output shaft is
designed as a splined shaft due to the movement of the gears. Also the overall size of the gear box
was concerned to design the shafts and the gears since the compactness was a major requirement
for the applications and compatibility of the size of the gearbox with the application is important
to minimize the overall cost. Then the bearings were selected according the requirements. Gear
shifting mechanism was incorporated to shift gears conveniently.

The group’s objective was to design an optimized and convenient gear box to fulfil requirements
and provide a satisfactory solution for the problem identified.

4
3. Conceptual design

5
4. Concept selection

Based on object methods to lift the object, methods to clamp the object, hoisting medium, five
conceptual designs were created as dented above. The best option is selected using conceptual
analysing criteria.

Initially the morphological chart was made to determine the options available for each and to
determine the concepts which can be evaluated. Each conceptual design was evaluated under
manufacturability, ruggedness, cost, durability and safety allocating weights according the
importance each held on the conceptual design. Three group members scored the five concepts
individually and most suitable design was selected accordingly. More optimizations were done
after the model was created.

6
5. Design Calculations
Calculation

Description: Determining required power of the motor

Iteration: 1st iteration assuming the drum diameter and full load hoisting speed

Calculation

Find: Power of the motor

Data:

1. Motor RPM= 1200

2. Maximum load = 1000kg

Assumptions:

1. Drum diameter = 10 cm

2. Safety factor (load) = 1.5

3. Hoisting speed at maximum load = 0.13 m/s

4. Safety factor (Motor) = 1.5

Formulae:

𝑃 = 𝐹. 𝑉

Calculations:

• Considering equilibrium at uniform speed

𝑇 = 𝑚𝑔 = 1500 ∗ 9.81 = 14715 𝑁
T
𝑃 = 𝐹 ∗ 𝑉 = 𝑇 ∗ 𝑉 = 14715 ∗ 0.13 = 1912.95 𝑊
𝑷 ≈ 𝟐𝒌𝑾
• Power of the motor = 2kW*1.5 = 3 kW

Conclusion: P= 3kW
• Cumulative compound DC motor of full load power 3 kW at 1200rpm is
selected for the application. N= 1200 rpm

References:

7
[1]"Why are DC series motors used in a hoist? - Quora", [Link], 2020. [Online]. Available:

[Link] [Accessed: 29- Aug- 2020].

Calculation

Description: Determining hoisting speeds at each gear, Speed of output, Gear ratio

Iteration:

Calculation

Find: Hoisting speeds at each gear at weight range, shaft output speed, gear ratio

Data:

1. Input power = 2kW

Assumptions:

1. Input power is at 2kW at each transmission

2.

Speed Weight range (kg) Design weight range (kg)

3 0-300 0-500
2 300-700 500-1000
1 700-1000 1000-1500

Formulae:

𝑃 =𝐹∗𝑉

𝑃 =𝜏∗𝜔
𝑉
=𝜔
𝑟
Calculations:

At speed 2

2000 = 1000 ∗ 9.81 ∗ 𝑉2

𝒎
𝑽𝟐 = 𝟎. 𝟐𝟎𝟑𝟖
𝒔

8
 𝟎. 𝟐𝟎𝟑𝟖 𝟔𝟎
𝝎𝟐 = ∗ = 𝟑𝟖. 𝟗𝟑 ≈ 𝟑𝟗 𝒓𝒑𝒎
𝟎. 𝟎𝟓 𝟐𝝅
𝟑𝟗
• Gear ratio = 𝟏𝟐𝟎𝟎 = 𝟎. 𝟎𝟑𝟐𝟓

** Similar calculation is done for other speeds.

Conclusion

Speed Hoisting speed Shaft rpm Gear ratio

3 0.407 78 0.065
2 0.2038 39 0.0325
1 0.13 25 0.0208

Calculation

Description: Determining gear parameters of the common gear pair (input shaft to lay shaft)

Iteration:

Calculation

Find: Gear module, Centre distance, Number of teeth, face width of the common gear pair

Data:

1. Power transmitted = 2kW

2. Gear material = High grade cast iron- FG150 (Allowable static stress = 150 MPa)

3. Youngs modulus of cast iron = 117.2 GPa

4. Surface endurance limit of cast iron = 630 N/mm2

Assumptions:

1. 20-degree stub involute profile

2. Lay shaft rpm = 400 (Gear ratio = 3)

3. Service factor (Cs) = 1.8 (24 hours, Medium shock)

4. Velocity factor (Cv) = 4.5/(4.5+v) (carefully cut gears, speeds up to 12.5 m/s)

5. Deformation factor (C) = 59 N-mm (0.001 tooth error in action)

6. Face width = 9*module

9
Formulae:

Calculations:

• Tangential tooth load is calculated (Equation 1).

2.0×1000×1.8 𝟓𝟕.𝟐𝟗
𝑊𝑇 = 1200 = 𝒎𝑻
where 𝐷 = 𝑚𝑡 , m = module
𝜋×𝑚𝑇×
60
• Another expression for tangential tooth load is obtained by Lewis equation (Equation 3)
10
 4.5 0.841
𝑊𝑇 = 150 × 106 × × 9𝑚 × 𝜋 × 𝑚 × (0.175 − )
𝜋 × 𝑚𝑇 × 1200 𝑇
4.5 +
60

• Minimum pinion teeth to prevent interference is calculated (Equation 2)

2
𝑇𝑚𝑖𝑛 = = 14.98 ≈ 15
1 1
3 × [√1 + 3 (3 + 2) × 𝑠𝑖𝑛2 (20) − 1]

• By equating expressions for tangential tooth loads at T= 15

𝑚 = 2.23 ≈ 2.5 𝑚𝑚
• Calculating dynamic tooth load (Equation 4)
21 ∗ 2.35 ∗ (22.5 ∗ 59 + 848.82)
𝑊𝐷 = 848.82 + = 𝟏𝟗𝟔𝟗. 𝟎𝟏 𝑵
(21 ∗ 2.35) + √22.5 ∗ 59 + 848.82
• Calculating static tooth load (Equation 5)
𝑊𝑠 = 120 ∗ 106 ∗ 0.0225 ∗ 𝜋 ∗ 0.0025 ∗ 0.1189 = 𝟐𝟓𝟐𝟐. 𝟎𝟕 𝑵
• Calculating wear tooth load (Equation 6, 7)
6302 ∗ sin(20) 2
𝐾= ∗( ) = 1.6546
1.4 117.2 ∗ 1000
2 ∗ 45
𝑊𝑊 = 37.5 ∗ 22.5 ∗ ∗ 1.6546 = 𝟐𝟎𝟗𝟒. 𝟏𝟕
45 + 15
• 𝑾𝒔 > 𝑾𝑾 > 𝑾𝑫

Conclusion:

Pinion Gear
Module 2.5 mm 2.5 mm
Teeth 15 45
Diameter 37.5 mm 112.5 mm
Face width 22.5 mm 22.5 mm

• Centre distance between shafts = 75 mm

References:

[3]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 1021-1065.

11
Calculation

Description: Determining gear parameters of transmission gears on output and lay shafts

Iteration:

Calculation

Find: Material, Module, face width, number of teeth, diameter of transmission gears

Data:

1. 20-degree stub involute profile

2. Power transmitted = 2kW

Assumptions:

1. Centre distance between shafts = 75 mm

2. module of the gears = 1.75 mm

3. Output shaft to final drive reduction = 4

4. Gear material = AISI 4140 (Allowable static stress = 415 MPa)

5. Service factor (CS) = 1.8

6. Velocity factor (CV) = 4.5/(4.5+v)

Formulae:
𝐷
𝑚= 𝑇
1
𝐷𝐺𝑒𝑎𝑟
= 𝐺 , (𝐺 > 1) 2
𝐷𝑝𝑖𝑛𝑖𝑜𝑛

12
 4

Calculations:

• Gear wheel diameters are calculated to achieve same centre distance of 75mm. (Equation 1,2)
𝐷𝑝𝑖𝑛𝑖𝑜𝑛 + 𝐷𝑔𝑒𝑎𝑟 = 150𝑚𝑚
• Gear ratios of output shaft to lay shaft
Transmission speed Lay shaft rpm Output shaft rpm Gear ratio
1 400 100 4
2 400 156 2.564
3 400 312 1.282

• 𝐷𝑝𝑖𝑛𝑖𝑜𝑛 (1 + 𝐺) = 150 𝑚𝑚

Transmission speed Pinion diameter (Lay) Gear diameter (Output)

1 30 120
2 42.08 107.91
3 65.73 84.27

• Calculating minimum number of teeth required to prevent interference (Equation 3)

For the 1st gear pair
2
𝑇𝑚𝑖𝑛 = = 15.44 ≈ 16
√ 1 1 2
4 × [ 1 + 4 (4 + 2) × 𝑠𝑖𝑛 (20) − 1]

Transmission speed Minimum number of teeth

1 16
2 15
3 14

• Considering standard module of each gear as 1.75mm

30
𝑇𝑝𝑖𝑛𝑖𝑜𝑛 = = 17.14 = 17
1.75

13
 Transmission speed T pinion T gear
1 17 69
2 24 62
3 38 48

• Determining face width of each gear (Equating equations 4 and 5)

1.8 4.5 0.841
2000 ∗ = 415 ∗ 106 ∗ ∗ 𝜋 ∗ 𝒃 ∗ 0.00175 ∗ (0.175 − )
400 400 17
𝜋 ∗ 0.03 ∗ 4.5 + 𝜋 ∗ 0.03 ∗
60 60
𝒃 = 𝟐𝟐. 𝟕𝟗 𝐦𝐦 ≈ 𝟐𝟑 𝐦𝐦

Transmission speed Face width of gears

1 23 mm
2 16 mm
3 10 mm

Conclusion:

• Module = 1.75 mm
• Material – AISI 4140

Speed D pinion D gear T pinion T gear Face width

1 29.75 120.75 17 69 23 mm
2 42 108.5 24 62 16 mm
3 66.5 84 38 48 10 mm
• Centre distance between shafts = 150.5 mm (error = 0.5 mm)

References:

[3]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 1021-1065.

Calculation
Description: Determining gear parameters for the idler gear system (For horizontal movement of
the hoist)
Iteration:

Calculation

Find: Face width, number of teeth, diameter of idler gear pair

Data:
1. 20-degree stub involute profile
2. Power transmitted = 2Kw
3. Diameter of output shaft gear = 84 mm
Assumptions:
1. Centre distance between gears = 75 mm
2. module of the gears = 1.75 mm
3. Output shaft to final drive reduction = 4
4. Gear material = Gear material = AISI 4140 (Allowable static stress = 415 MPa)
5. Service factor (CS) = 1.8
6. Velocity factor (CV) = 4.5/(4.5+v)
7. Final drive rpm = 30
14
Formulae:
𝐷
𝑚=𝑇 1

𝐷𝐺𝑒𝑎𝑟
= 𝐺 , (𝐺1 > 0) 2
𝐷𝑝𝑖𝑛𝑖𝑜𝑛

Calculations:

• Lay shaft to output gear ratio = 400/120 = 3.3333

• Calculating the diameter of pinion at lay shaft
84 84
𝐷𝑝𝑖𝑛𝑖𝑜𝑛 = = = 25.2 𝑚𝑚
𝐺 3.3333
• Teeth on the pinion gear
25.2
𝑇𝑝𝑖𝑛𝑖𝑜𝑛 = = 14
1.75

• Minimum gear ratio required to prevent interference between idler and pinion
2
𝑇𝑚𝑖𝑛 = = 13
1 1
𝐺 × [√1 + 𝐺 (𝐺 + 2) × 𝑠𝑖𝑛 (20) − 1]
2

𝐺 = 1.2654
• Let G= 1.2 then,
𝐷𝑖𝑑𝑙𝑒𝑟 = 1.2 ∗ 25.2 = 30.24 𝑚𝑚
30.24
𝑇𝑖𝑑𝑙𝑒𝑟 = = 17
1.75
• Gear ratio between output gear and idler
𝐺 1 = 2.8235

15
 • Minimum gear ratio required to prevent interference between output gear and idler
2
𝑇𝑚𝑖𝑛 = = 14.87 < 17
1 1
2.8235 × [√1 + 𝐺 (𝐺 + 2) × 𝑠𝑖𝑛 (20) − 1]
2

• Therefore, no interference will occur.

• Determining face width by equating equation 4 and 5 (for pinion gear).

1.8 4.5 0.841
2000 ∗ = 415 ∗ 106 ∗ ∗ 𝜋 ∗ 𝒃 ∗ 0.00175 ∗ (0.175 − )
400 400 14
𝜋 ∗ 0.0252 ∗ 4.5 + 𝜋 ∗ 0.0252 ∗
60 60

𝒃 = 𝟐𝟗. 𝟎𝟔 𝒎𝒎 ≈ 𝟐𝟗 𝒎𝒎
• Since this is large, we selected AISI A514 grade E alloy steel (Allowable static stress = 690
MPa) for the idler system

• Determining face width by equating equation 4 and 5 (for pinion gear).

1.8 4.5 0.841
2000 ∗ = 690 ∗ 106 ∗ ∗ 𝜋 ∗ 𝒃 ∗ 0.00175 ∗ (0.175 − )
400 400 14
𝜋 ∗ 0.0252 ∗ 4.5 + 𝜋 ∗ 0.0252 ∗
60 60

𝒃 = 𝟏𝟖. 𝟒𝟖 𝒎𝒎
• Face width required by output gear

1.8 4.5 0.841

2000 ∗ = 415 ∗ 106 ∗ ∗ 𝜋 ∗ 𝒃 ∗ 0.00175 ∗ (0.175 − )
120 120 48
𝜋 ∗ 0.084 ∗ 4.5 + 𝜋 ∗ 0.084 ∗
60 60

𝒃 = 𝟐𝟎. 𝟐𝟏 𝒎𝒎
• Therefore, 20mm face width is selected.

Conclusion:

Output gear pinion idler

Teeth 48 14 17
Diameter (mm) 84 25.2 30.24
Face width (mm) 20 20 20
Material AISI 4140 AISI A514 grade E AISI A514 grade E
References:
[3]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 1021-1065.

Calculation
Description: Determining gear parameters of the final drive system
Iteration:

Calculation

Find: Face width, module, diameters of gears at final drive

Data:
1. 20-degree stub involute profile
2. Power transmitted = 2Kw

Assumptions:
1. module of the gears = 1.75 mm (initial assumption)
3. Final drive gear ratio = 4
4. Gear material = Alloy steel, case hardened (Available static stress = 350 MPa) (initial assumption)
16
5. Service factor (CS) = 1.8
6. Velocity factor (CV) = 4.5/(4.5+v)

Formulae:
𝐷
𝑚= 𝑇
1
𝐷𝐺𝑒𝑎𝑟
= 𝐺 , (𝐺 > 1) 2
𝐷𝑝𝑖𝑛𝑖𝑜𝑛

Calculations:

• Calculations are done to the pinion at output shaft

• Minimum number of teeth required (Equation 3),
2
𝑇𝑚𝑖𝑛 = = 15.44 ≈ 16
√ 1 1 2
4 × [ 1 + 4 (4 + 2) × 𝑠𝑖𝑛 (20) − 1]
• Calculating face width and diameters for each module assumption

Let module be 1.75mm then,

𝐷𝑝𝑖𝑛𝑖𝑜𝑛 = 18 ∗ 1.75 = 31.5 𝑚𝑚
𝐷𝐺𝑒𝑎𝑟 = 16 ∗ 4 ∗ 1.75 = 126 𝑚𝑚
Required face width (Equation 4 and 5) [At lowest rpm = 100]

1.8 4.5 0.841

2000 ∗ = 350 ∗ 106 ∗ ∗ 𝜋 ∗ 𝒃 ∗ 0.00175 ∗ (0.175 − )
100 100 18
𝜋 ∗ 0.0315 ∗ 4.5 + 𝜋 ∗ 0.0315 ∗
60 60

𝑏 = 91.66 𝑚𝑚 (𝑻𝒐𝒐 𝒍𝒂𝒓𝒈𝒆)

17
 Module (mm) D pinion D gear D pinion + D gear Face width
1.75 31.5 126 157.5 91.66
2 36 144 180 70.53
2.5 45 180 200 45.59
2.75 49.5 198 247.5 37.87
3 54 216 260 31.98

• Although face width reduces with the module, the size of the gears increases largely. Therefore,
a material with higher allowable static stress required.
• Gear material = AISI 8642 (Allowable stress = 738 MPa)
• Calculations are done again;
Module (mm) D pinion D gear D pinion + D gear Face width
1.75 31.5 126 157.5 43.47
2 36 144 178 33.45
2.5 45 180 225 21.62

• Similarly, the diameter and teeth count of the gear for the horizontal motion output can
be calculated.
Conclusion:

❖ Gear material – AISI 8642 Alloy steel (Allowable stress = 738 MPa)
❖ Gear module – 2 mm
❖ Face width – 33.5 mm

Pinion Winch Horizontal Mo.

Teeth 18 72 45
Diameter 36 144 90

References:
[3]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 1021-1065.

Calculation

Description: Determining shaft diameter of the input shaft

Iteration:

Calculation

Find: Input shaft diameter, shaft material

Data:

1. RPM of input shaft = 1200

2. Power transmitted = 2Kw

Assumptions:

1. Shaft material – 40C8 carbon Steel (𝜎𝑢 = 660 𝑀𝑃𝑎 )

18
2. 𝐾𝑚 = 1.5 , 𝐾𝑡 = 1
3. Safety factor = 1.5
Formulae:

𝑊𝑟 = 𝑊𝑡 ∗ tan (𝜑) 2
Maximum shear stress criteria
𝟏𝟔
𝝉𝒎𝒂𝒙 = 𝝅∗𝒅𝟑 √(𝑲𝒎 𝑴)𝟐 + (𝑲𝒕 𝑻)𝟐 3

𝝉𝒎𝒂𝒙 = 𝟎. 𝟏𝟖 ∗ 𝝈𝒖 4

Calculations:

• Calculating torque applied on the shaft

1.5
𝑇 = 2000 ∗ = 23.873 𝑁𝑚
2𝜋
1200 ∗ 60
• Tangential tooth load (tangential force on the shaft)
23.873
𝐹𝑡 = 𝑊𝑡 = = 1273.22 𝑁
0.0375
2
• Radial tooth load (Radial force on the shaft)

23.873
𝐹𝑟 = 𝑊𝑟 = ∗ tan (20) = 463.41 𝑁
0.0375
2
• Since it is an over hanged shaft, Maximum bending moment (M)

𝑀 = 0.2125 ∗ √𝐹𝑡2 + 𝐹𝑟2 = 0.02125 ∗ √1273.22 + 463.412 = 28.60 𝑁𝑚

• Calculating diameter of the shaft (Equations 3 and 4)

16
0.18 ∗ 660 ∗ 106 = ∗ √(1.5 ∗ 28.60)2 + (1 ∗ 23.873)2
𝜋 ∗ 𝑑3
𝒅 = 𝟏𝟐. 𝟖𝟏 𝒎𝒎 ≈ 𝟏𝟓 𝒎𝒎

Conclusion:

• Input shaft diameter = 15 mm

19
 • Shaft material = 40C8 carbon Steel

References:

[1]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 509-557.

[1]"40c8 Carbon Steel Round Bars", [Link], 2020. [Online]. Available:

[Link]

[Accessed: 06- Sep- 2020].

Calculation

Description: Determining shaft diameter of the output shaft

Iteration:

Calculation

Find: Diameter of output shaft.

Data:

1. RPM of output shaft = 100

2. Power transmitted = 2Kw

Assumptions:

1. Maximum torque transfer at the 1st gear transmission

2. Shaft material – 40C8 Carbon Steel (𝜎𝑢 = 660 𝑀𝑃𝑎)

3. 𝐾𝑚 = 1.5 , 𝐾𝑡 = 1
4. Safety factor = 1.5

20
`Formulae:

𝑊𝑟 = 𝑊𝑡 ∗ tan (𝜑) 2
Maximum shear stress criteria
𝟏𝟔
𝝉𝒎𝒂𝒙 = 𝝅∗𝒅𝟑 √(𝑲𝒎 𝑴)𝟐 + (𝑲𝒕 𝑻)𝟐 3

𝝉𝒎𝒂𝒙 = 𝟎. 𝟏𝟖 ∗ 𝝈𝒖
4

Calculations:

• Calculating maximum torque acting on the gears (at 1st transmission speed) (Equation 1)

𝑃 = 𝑇𝜔
1.5
𝑇 = 2000 ∗ = 286.47 𝑁𝑚
2𝜋
100 ∗ 60

• Calculating tangential and radial loads on the shaft at 1 and 2 (Equation 2)

1
𝐹𝑡1 = 286.47 = 4744.99 𝑁 𝐹𝑟1 = 4744.99 ∗ 𝑡𝑎𝑛20 = 1727.03 𝑁
120.75
2 ∗ 1000
1
𝐹𝑡2 = 286.47 = 13035 𝑁 𝐹𝑟2 = 15625.9 ∗ 𝑡𝑎𝑛20 = 4744.35 𝑁
44
2 ∗ 1000
• Calculating bearing loads (tangential and axial).
By considering moments and force equilibrium;

21
 Tangential

𝑹𝑩 = 𝟗𝟔𝟎𝟑. 𝟓 𝑵
𝑹𝑨 = 𝟏𝟑𝟏𝟑. 𝟒𝟗 𝑵

Radial

𝑺𝑩 = 𝟑𝟕𝟗𝟏. 𝟐𝟓𝟑 N
𝑺𝑨 = 𝟐𝟔𝟖𝟎. 𝟏𝟐 𝑵

• Constructing shear force and bending moment diagrams to determine maximum

bending moments along each plane.

22
Tangential

Radial

23
 𝑴𝒕 = 𝟓𝟓𝟗. 𝟒 𝑵𝒎
𝑴𝑟 = 𝟐𝟐𝟎. 𝟖𝟒 𝑵𝒎
• Calculating resultant maximum bending moment.

𝑴 = √𝟓𝟓𝟗. 𝟒𝟐 + 𝟐𝟐𝟎. 𝟖𝟒𝟐 = 𝟔𝟎𝟏. 𝟒𝟏 𝑵𝒎

• Calculating the required minimum diameter (Equation 3 and 4)
16
0.18 ∗ 660 ∗ 106 = ∗ √(1.5 ∗ 601.41)2 + (1 ∗ 286.47)2
𝜋 ∗ 𝑑3
𝒅 = 𝟑𝟒. 𝟑 𝒎𝒎 ≈ 𝟑𝟓 𝒎𝒎
• Since the diameter is large, we use AISI 8275 Alloy steel (𝜎𝑢 = 1476 𝑀𝑃𝑎)
16
0.18 ∗ 1476 ∗ 106 = ∗ √(1.5 ∗ 601.41)2 + (1 ∗ 286.47)2
𝜋 ∗ 𝑑3
𝒅 = 𝟐𝟒. 𝟔𝟕 𝒎𝒎 ≈ 𝟐𝟓 𝒎𝒎

Conclusion:

• Output shaft diameter = 25 mm

• Shaft material = AISI 8275 Alloy steel

References:

[1]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 509-557.

[2]P. Comino, "Free Online Beam Calculator", SkyCiv Cloud Structural Analysis Software, 2020.
[Online]. Available: [Link] [Accessed: 06- Sep- 2020].

[3]"AISI 8750 Alloy Steel (UNS G87500)", [Link], 2020. [Online]. Available:
[Link] [Accessed: 06- Sep- 2020].

24
Calculation

Description: Determining shaft diameter of the Lay shaft

Iteration:

Calculation

Find: Diameter of Lay shaft.

Data:

1. RPM of lay shaft = 400

2. Power transmitted = 2Kw

Assumptions:

1. Maximum torque transfer at the 1st gear transmission

2. Shaft material - AISI 8275 Alloy steel (𝜎𝑢 = 1476 𝑀𝑃𝑎)

3. 𝐾𝑚 = 1 , 𝐾𝑡 = 1
4. Safety factor = 1.5
`Formulae:

𝑊𝑟 = 𝑊𝑡 ∗ tan (𝜑) 2
Maximum shear stress criteria
𝟏𝟔
𝝉𝒎𝒂𝒙 = 𝝅∗𝒅𝟑 √(𝑲𝒎 𝑴)𝟐 + (𝑲𝒕 𝑻)𝟐 3

𝝉𝒎𝒂𝒙 = 𝟎. 𝟏𝟖 ∗ 𝝈𝒖
4

Calculations:

• Calculating maximum torque acting on the gears (at 1st transmission speed) (Equation 1)

25
 𝑃 = 𝑇𝜔
1.5
𝑇 = 2000 ∗ = 71.62 𝑁𝑚
2𝜋
400 ∗ 60

• Calculating tangential and radial loads on the shaft at 1 and 2 (Equation 2)

1
𝐹𝑡1 = 71.62 ∗ = 1273.23 𝑁 𝐹𝑟1 = 1273.23 ∗ 𝑡𝑎𝑛20 = 463.42 𝑁
112.5
2 ∗ 1000
1
𝐹𝑡2 = 71.62 = 4814.78 𝐹𝑟2 = 4814.78 ∗ 𝑡𝑎𝑛20 = 1752.44 𝑁
29.75
2 ∗ 1000
• Calculating bearing loads (tangential and axial).
By considering moments and force equilibrium;

Tangential

𝑹𝑩 = 𝟏𝟖𝟐𝟏. 𝟖 𝑵
𝑹𝑨 = 𝟏𝟕𝟏𝟗. 𝟕 𝑵

26
 Radial

𝑺𝑩 = 𝟕𝟑𝟖. 𝟖𝟓𝟐 N
𝑺𝑨 = 𝟏𝟒𝟕𝟕. 𝟎𝟎 𝑵
• Constructing shear force and bending moment diagrams to determine maximum bending
moments along each plane.
Tangential

27
 Radial

𝑴𝒕 = 𝟐𝟖𝟒. 𝟐𝟏 𝑵𝒎
𝑴𝑟 = 𝟏𝟏𝟓. 𝟐𝟔 𝑵𝒎
• Calculating resultant maximum bending moment.

𝑴 = √𝟐𝟖𝟒. 𝟐𝟏𝟐 + 𝟏𝟏𝟓. 𝟐𝟔𝟐 = 𝟑𝟎𝟔. 𝟔𝟗 𝑵𝒎

• Calculating the required minimum diameter (Equation 3 and 4)
16
0.18 ∗ 1476 ∗ 106 = ∗ √(1 ∗ 306.69)2 + (1 ∗ 71.62)2
𝜋 ∗ 𝑑3
𝒅 = 𝟏𝟓. 𝟖𝟏 𝒎𝒎 ≈ 𝟏𝟓 𝒎𝒎

Conclusion:

• Lay shaft diameter = 15 mm

• Shaft material = AISI 8275 Alloy steel

References:

28
[1]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 509-557.

[2]P. Comino, "Free Online Beam Calculator", SkyCiv Cloud Structural Analysis Software, 2020.
[Online]. Available: [Link] [Accessed: 06- Sep- 2020].

[3]"AISI 8750 Alloy Steel (UNS G87500)", [Link], 2020. [Online]. Available:

[Link] [Accessed: 06- Sep- 2020].

Calculation

Description: Determining shaft diameters of the final drive shafts

Iteration:

Calculation

Find: shaft diameter, shaft material for final drive shafts (winch drum and horizontal motion)

Data:

1. RPM of winch shaft = 25

2. RPM of Horizontal motion shaft = 48

2. Power transmitted = 2Kw

Assumptions:

1. Shaft material – 40C8 Steel (𝜎𝑢 = 660 𝑀𝑃𝑎)

2. 𝐾𝑚 = 1.5 , 𝐾𝑡 = 1
3. Safety factor = 1.5

Formulae:

29
 𝑊𝑟 = 𝑊𝑡 ∗ tan (𝜑) 2
Maximum shear stress criteria
𝟏𝟔
𝝉𝒎𝒂𝒙 = 𝝅∗𝒅𝟑 √(𝑲𝒎 𝑴)𝟐 + (𝑲𝒕 𝑻)𝟐 3

𝝉𝒎𝒂𝒙 = 𝟎. 𝟏𝟖 ∗ 𝝈𝒖 4

Calculations:

For the winch shaft

• Calculating torque applied on the shaft

1.5
𝑇 = 2000 ∗ = 1145.91 𝑁𝑚
2𝜋
25 ∗ 60
• Tangential tooth load (tangential force on the shaft)
1145.91
𝐹𝑡 = 𝑊𝑡 = = 15915.41 𝑁
0.144
2
• Radial tooth load (Radial force on the shaft)

1145.91
𝐹𝑟 = 𝑊𝑟 = ∗ tan (20) = 5792.73 𝑁
0.144
2
• Since it is an over hanged shaft, Maximum bending moment

𝑀 = 0.05825 ∗ √𝐹𝑡2 + 𝐹𝑟2 = 0.05825 ∗ √15915.412 + 5792.732 = 986.57 𝑁𝑚

• Calculating diameter of the shaft (Equations 3 and 4)

16
0.18 ∗ 660 ∗ 106 = ∗ √(1.5 ∗ 986.57)2 + (1.0 ∗ 1145.91)2
𝜋 ∗ 𝑑3
𝒅 = 𝟒𝟑. 𝟏𝟑 𝒎𝒎 ≈ 𝟒𝟓 𝒎𝒎

For the horizontal movement shaft

• Calculating torque applied on the shaft

1.5
𝑇 = 2000 ∗ = 596.83 𝑁𝑚
2𝜋
48 ∗ 60
• Tangential tooth load (tangential force on the shaft)
596.83
𝐹𝑡 = 𝑊𝑡 = = 13262.88 𝑁
0.090
2
• Radial tooth load (Radial force on the shaft)

477.46
𝐹𝑟 = 𝑊𝑟 = ∗ tan (20) = 4827.29 𝑁
0.072
2
• Since it is an over hanged shaft, Maximum bending moment

30
 𝑀 = 0.02325 ∗ √𝐹𝑡2 + 𝐹𝑟2 = 0.02325 ∗ √13262.882 + 4827.292 = 328.15 𝑁𝑚

• Calculating diameter of the shaft (Equations 3 and 4)

16
0.18 ∗ 660 ∗ 106 = ∗ √(1.5 ∗ 328.15)2 + (1.0 ∗ 596.83)2
𝜋 ∗ 𝑑3
𝒅 = 𝟑𝟐. 𝟏𝟐 𝒎𝒎 ≈ 𝟑𝟓 𝒎𝒎

Conclusion:

• Winch shaft diameter = 45 mm

• Horizontal movement shaft diameter = 35 mm
• Shaft material = 40C8 Steel

References:

[1]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 509-557.

[1]"40c8 Carbon Steel Round Bars", [Link], 2020. [Online]. Available:

[Link]

[Accessed: 06- Sep- 2020].

Calculation

Description: Determining shaft diameters for the idler gear

Iteration:

Calculation

Find: Diameter, material of the idler shaft

Data:

1. Power transmitted = 2kW

Assumptions:

1. Shaft material = AISI 8275 Alloy steel (𝜎𝑢 = 1476 𝑀𝑃𝑎)

2. 𝐾𝑚 = 1.5 , 𝐾𝑡 = 1

3. Safety factor = 1.5

31
Formulae:

𝑊𝑟 = 𝑊𝑡 ∗ tan (𝜑) 2
Maximum shear stress criteria
𝟏𝟔
𝝉𝒎𝒂𝒙 = 𝝅∗𝒅𝟑 √(𝑲𝒎 𝑴)𝟐 + (𝑲𝒕 𝑻)𝟐 3

𝝉𝒎𝒂𝒙 = 𝟎. 𝟏𝟖 ∗ 𝝈𝒖 4

Calculations:

• Calculating torque applied on the shaft

1.5
𝑇 = 2000 ∗ = 95.94 𝑁𝑚
2𝜋
333.33 ∗ 60
• Tangential tooth load (tangential force on the shaft)
85.94
𝐹𝑡 = 𝑊𝑡 = = 5684.16 𝑁
0.03024
2
• Radial tooth load (Radial force on the shaft)

85.94
𝐹𝑟 = 𝑊𝑟 = ∗ tan (20) = 2068.86 𝑁
0.03024
2

• By resolving into horizontal and vertical components.

𝑋⃖ = 11680.85 𝑁
⃖ = 2459.35 𝑁
𝑌
• Maximum bending moment,

𝑀 = 0.01 ∗ √𝐹𝑥2 + 𝐹𝑦2 = 0.01 ∗ √11680.852 + 2459.352 = 119.36 𝑁𝑚

• Calculating diameter of the shaft (Equations 3 and 4)

16
0.18 ∗ 1476 ∗ 106 = ∗ √(1.5 ∗ 119.36)2 + (1.0 ∗ 95.94)2
𝜋 ∗ 𝑑3
𝒅 = 𝟗. 𝟕𝟗 𝒎𝒎 ≈ 𝟏𝟎 𝒎𝒎

Conclusion:

• Lay shaft diameter = 15 mm

32
 • Shaft material = AISI 8275 Alloy steel

References:

[1]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 509-557.

[2]"AISI 8750 Alloy Steel (UNS G87500)", [Link], 2020. [Online]. Available:

[Link] [Accessed: 06- Sep- 2020].

Calculation

Description: Determining bearings for each shaft

Iteration:

Calculation

Find: Bearing type and code for each shaft

Data:

1. NSK Bearing catalogue

2. Bearing loads obtained in shaft calculations

Assumptions:

1. Bearings are mounted at the ends of each shaft

2. Bearing life = 5 years of 24 hours continuous working

3. Tapered roller bearing, and deep grove ball bearings are preferred

4. Bearing type is decided upon the selection method supposed in NSK bearing catalogue

5. Maximum rpm at output shaft and final drive shafts are considered.

6. In case of idler shaft small sized needle roller bearing is selected.

Formulae:

**Where L – Bearing life (106 revolutions)

Calculations:

Input shaft

33
 • Calculating the resultant load on the bearing (P)
𝑃 = √1273.222 + 463.412 = 𝟏𝟑𝟓𝟒. 𝟗𝟑 𝑵
• Estimated life (L)
𝐿 = 1200 ∗ 60 ∗ 24 ∗ 365 ∗ 5 = 𝟑𝟏𝟓𝟑. 𝟔 × 𝟏𝟎𝟔 𝒓𝒆𝒗
• For 95% reliability,

𝐶 3
𝐿 = 0.62 ( ) ; 𝐵𝑎𝑙𝑙 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠
𝑃
10
𝐶 3
𝐿 = 0.62 ( ) ; 𝑅𝑜𝑙𝑙𝑒𝑟 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠
𝑃

𝑪𝑩𝑩 = 𝟐𝟑𝟑𝟎𝟏. 𝟕𝟒 𝑵
𝑪𝑹𝑩 = 𝟏𝟕𝟓𝟑𝟐. 𝟑𝟗 𝑵

• Selected bearing = HR30302 J (Single row tapered roller bearing) [C= 23600 N]

Lay shaft

• Calculating the resultant loads at bearing P and Q

𝑃𝑝 = √1719.72 + 1477.02 = 𝟐𝟐𝟔𝟔. 𝟗𝟏 𝑵
𝑃𝑄 = √1821.82 + 738.852 = 𝟏𝟗𝟔𝟓. 𝟗𝟐 𝑵
• Estimated life (L)
𝐿 = 400 ∗ 60 ∗ 24 ∗ 365 ∗ 5 = 𝟏𝟎𝟓𝟏. 𝟐 × 𝟏𝟎𝟔 𝒓𝒆𝒗
• For 95% reliability,

At P
𝑪𝑩𝑩 = 𝟐𝟕𝟎𝟑𝟏. 𝟐𝟏 𝑵
𝑪𝑹𝑩 = 𝟐𝟏𝟎𝟗𝟕. 𝟎𝟖 𝑵

• Selected bearing = HR30302 J (Single row tapered roller bearing) [C= 23600 N]

At Q
𝑪𝑩𝑩 = 𝟐𝟑𝟒𝟒𝟐. 𝟏𝟐 𝑵
𝑪𝑹𝑩 = 𝟏𝟖𝟐𝟗𝟓. 𝟗𝟎 𝑵

• Selected bearing = HR30302 J (Single row tapered roller bearing) [C= 23600 N]

Output shaft

• Calculating the resultant loads at bearing P and Q

34
 𝑃𝑝 = √1313.492 + 2680.122 = 𝟐𝟗𝟖𝟒. 𝟔𝟕 𝑵
𝑃𝑄 = √9603.52 + 3791.252 = 𝟏𝟎𝟑𝟐𝟒. 𝟕𝟔 𝑵
• Estimated life (L)
𝐿 = 312 ∗ 60 ∗ 24 ∗ 365 ∗ 5 = 𝟖𝟏𝟗. 𝟗𝟑 × 𝟏𝟎𝟔 𝒓𝒆𝒗
• For 95% reliability,

At P
𝑪𝑩𝑩 = 𝟑𝟐𝟕𝟔𝟏. 𝟎𝟔 𝑵
𝑪𝑹𝑩 = 𝟐𝟓𝟕𝟖𝟏. 𝟕𝟏 𝑵

• Selected bearing = HR32005 XJ (Single row tapered roller bearing) [C=27400 N]

At Q
𝑪𝑩𝑩 = 𝟏𝟏𝟑𝟑𝟐𝟗. 𝟏𝟓 𝑵
𝑪𝑹𝑩 = 𝟖𝟗𝟏𝟖𝟓. 𝟕𝟓 𝑵

• Selected bearing = HR32305 J (Single row tapered roller bearing) [C=92500 N]

Final Drive shafts

Winch shaft

• Calculating the resultant load on the bearing (P)

𝑃 = √15915.412 + 5792.732 = 𝟏𝟔𝟗𝟑𝟔. 𝟖𝟐 𝑵
• Estimated life (L)
𝐿 = 78 ∗ 60 ∗ 24 ∗ 365 ∗ 5 = 𝟐𝟎𝟒. 𝟗𝟖 × 𝟏𝟎𝟔 𝒓𝒆𝒗
• For 95% reliability,

𝑪𝑩𝑩 = 𝟏𝟏𝟕𝟏𝟏𝟑. 𝟎𝟎 𝑵
𝑪𝑹𝑩 = 𝟗𝟔𝟓𝟐𝟐. 𝟑𝟑 𝑵

• Selected bearing = HR33209 J (Single row tapered roller bearing) [C=111000 N]

Horizontal movement shaft

• Calculating the resultant load on the bearing (P)

𝑃 = √13262.882 + 4827.292 = 𝟏𝟒𝟏𝟏𝟑. 𝟗𝟔 𝑵
• Estimated life (L)
𝐿 = 60 ∗ 60 ∗ 24 ∗ 365 ∗ 5 = 𝟏𝟓𝟕. 𝟔𝟖 × 𝟏𝟎𝟔 𝒓𝒆𝒗
• For 95% reliability,

𝑪𝑩𝑩 = 𝟖𝟗𝟒𝟐𝟏. 𝟕𝟔 𝑵
𝑪𝑹𝑩 = 𝟕𝟒𝟑𝟒𝟕. 𝟎𝟓 𝑵

• Selected bearing = HR30307 J (Single row tapered roller bearing) [C=76000 N]

Idler shaft

• Calculating the resultant load on the bearing (P)

𝑃 = √11680.852 + 2459.352 = 𝟏𝟏𝟗𝟑𝟔. 𝟗𝟒 𝑵
• Estimated life (L)
𝐿 = 333.33 ∗ 60 ∗ 24 ∗ 365 ∗ 5 = 𝟖𝟕𝟓. 𝟗𝟗 × 𝟏𝟎𝟔 𝒓𝒆𝒗
• For 95% reliability
𝑪𝑹𝑩 = 𝟗𝟏𝟏𝟐. 𝟔𝟏𝟎 𝑵

35
 • Selected bearing = NA4900TT (Needle roller bearing)

Conclusion:

• Single row tapered roller bearings are selected due to compact diameter and lower load rating
requirement.
• Needle roller bearing is selected for idler shaft

Shaft Left end (P) Right end (Q)

Input HR30302 J ----
Lay HR30302 J HR30302 J
Output HR32005 XJ HR32305 J
Winch ---- HR33209 J
Horizontal movement ---- HR30307 J
Idler NA4900TT ---
References:

[4]M. by NSK, Rolling bearings for industrial Machinery. NSK, 2020.

Calculation

Description: Spline design for Output shaft

Iteration:

Calculation

Find: Number of splines, spline thickness, spline depth

Data:

1. Diameter of the output shaft = 25 mm

2. Maximum torque transferred (1st transmission speed) = 286.47 Nm

Assumptions:

1. SAE standard parallel sided splines

2. Maximum bearing length of the spline = (23+33.5)*2 mm

3. Pressure 1000psi

Formulae:

𝑻 = 𝟏𝟎𝟎𝟎 ∗ 𝑵 ∗ 𝑹𝒎𝒆𝒂𝒏 ∗ 𝒉 ∗ 𝑳

36
Where,

𝑇 = Torque in pounds inch

N = Number of splines

𝑅𝑚𝑒𝑎𝑛 = Mean radius of the spline in inches

ℎ = Spline depth in inches

𝐿 = Load bearing length

𝐷+𝑑
𝑅𝑚𝑒𝑎𝑛 =
4

Calculations:

• Shaft diameter = 25 mm (D≤40mm)

• Let N = 16, Selecting values for d,w and h using data sheet.

• d = 0.81 D
• h = 0.095 D
• w = 0.098 D
• calculating minimum load bearing length of the spline.
1.81𝐷
2535.47 = 1000 ∗ 16 ∗ ∗ 0.095𝐷 ∗ 4.44
4
𝐷 = 0.911 𝑖𝑛𝑐ℎ = 23.13 𝑚𝑚 ≈ 25 𝑚𝑚

Conclusion:

❖ SAE standard parallel splines of

𝑵 = 𝟏𝟔
𝑫 = 𝟐𝟓 𝒎𝒎
𝒅 = 𝟐𝟎. 𝟐𝟓 𝒎𝒎
𝒘 = 𝟐. 𝟒𝟓 𝒎𝒎
𝒉 = 𝟐. 𝟑𝟕𝟓 𝒎𝒎

References:

❖ SAE standard – Parallel side splines (SAE J498c)

37
Calculation

Description: Determining the parameters of keys used in gears at Input, Lay and final drive shafts

Iteration:

Calculation

Find: Respective Length, width, height of keys at each shaft

Data:

1. IS 2292 and 2293-1974 standard key dimensions

Assumptions:

1. Key material (40C8 steel) [𝜎𝑢 = 660 𝑀𝑃𝑎]

2. Safety factor = 1.5

38
Formulae:

𝝉𝒎𝒂𝒙 = 𝟎. 𝟏𝟖 ∗ 𝝈𝒖 1
𝒅
𝑻 = 𝒍 × 𝒘 × 𝝉𝒎𝒂𝒙 × 𝟐 2

𝟐𝝉𝒎𝒂𝒙 ≤ 𝝈𝒄 3

𝒕 𝒅
𝑻 = 𝒍 × 𝟐 × 𝝈𝒄 × 𝟐 4

Calculations:

For the input shaft

❖ d = 15 mm therefore;
𝑤 = 5 𝑚𝑚 , 𝑡 = 5 𝑚𝑚
**Square keys are equally strong in shearing and crushing
❖ Calculating key length for shearing strength.
1.5
2000 ∗ = 𝑙 ∗ 0.005 ∗ 0.18 ∗ 660 ∗ 106 ∗ 0.0075
2𝜋
1200 ∗ 60
𝑙 = 𝟓. 𝟑𝟓 𝒎𝒎 < 𝟐𝟐. 𝟓 𝒎𝒎 (𝑭𝒂𝒄𝒆 𝒘𝒊𝒅𝒕𝒉 𝒐𝒇 𝒈𝒆𝒂𝒓)

For the Lay shaft

❖ d = 15 mm therefore;
𝑤 = 5 𝑚𝑚 , 𝑡 = 5 𝑚𝑚

❖ Calculating key length for shearing strength.

1.5
2000 ∗ = 𝑙 ∗ 0.005 ∗ 0.18 ∗ 660 ∗ 106 ∗ 0.0075
2𝜋
400 ∗ 60

𝑙 = 𝟏𝟔. 𝟎𝟕 𝒎𝒎 > 𝟏𝟎 𝒎𝒎 (𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑎𝑐𝑒 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑔𝑒𝑎𝑟𝑠 𝑎𝑡 𝑙𝑎𝑦 𝑠ℎ𝑎𝑓𝑡)

❖ **Therefore, material has been changed to AISI 8645 [𝜎𝑢 = 1158 𝑀𝑃𝑎]

1.5
2000 ∗ = 𝑙 ∗ 0.005 ∗ 0.18 ∗ 1158 ∗ 106 ∗ 0.0075
2𝜋
400 ∗ 60

𝑙 = 𝟗. 𝟏𝟔 𝒎𝒎 < 𝟏𝟎 𝒎𝒎 (𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑎𝑐𝑒 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑔𝑒𝑎𝑟𝑠 𝑎𝑡 𝑙𝑎𝑦 𝑠ℎ𝑎𝑓𝑡)

For the final drive shafts

Winch shaft

❖ d = 45 mm therefore;
𝑤 = 14 𝑚𝑚 , 𝑡 = 9 𝑚𝑚

❖ Calculating key length for shearing strength.

1.5
2000 ∗ = 𝑙 ∗ 0.014 ∗ 0.18 ∗ 660 ∗ 106 ∗ 0.0225
2𝜋
25 ∗ 60

39
 𝑙 = 𝟑𝟎. 𝟔𝟐 𝒎𝒎 < 𝟑𝟑. 𝟓 𝒎𝒎

❖ Calculating key length for crushing strength.

1.5
2000 ∗ = 𝑙 ∗ 0.0045 ∗ 2 ∗ 0.18 ∗ 660 ∗ 106 ∗ 0.0225
2𝜋
25 ∗ 60
𝑙 = 𝟒𝟕. 𝟔𝟑 𝒎𝒎 > 𝟑𝟒. 𝟐 𝒎𝒎

❖ **Therefore, material has been changed to AISI 8645 [𝜎𝑢 = 1158 𝑀𝑃𝑎]

❖ Calculating key length for crushing strength.

1.5
2000 ∗ = 𝑙 ∗ 0.0045 ∗ 2 ∗ 0.18 ∗ 1158 ∗ 106 ∗ 0.0225
2𝜋
25 ∗
60
𝑙 = 𝟐𝟕. 𝟏𝟒 𝒎𝒎 > 𝟑𝟒. 𝟐 𝒎𝒎

Horizontal movement shaft

❖ d = 35 mm therefore;
𝑤 = 10 𝑚𝑚 , 𝑡 = 8 𝑚𝑚

❖ Calculating key length for shearing strength.

1.5
2000 ∗ = 𝑙 ∗ 0.01 ∗ 0.18 ∗ 660 ∗ 106 ∗ 0.0175
2𝜋
60 ∗ 60

𝑙 = 𝟐𝟐. 𝟗𝟔 𝒎𝒎 < 𝟑𝟑. 𝟓 𝒎𝒎

❖ Calculating key length for crushing strength.

1.5
2000 ∗ = 𝑙 ∗ 0.004 ∗ 2 ∗ 0.18 ∗ 660 ∗ 106 ∗ 0.0175
2𝜋
30 ∗ 60

𝑙 = 𝟐𝟖. 𝟕𝟎 𝒎𝒎 < 𝟑𝟑. 𝟓 𝒎𝒎

Conclusion:

** All dimensions are in mm.

Shaft Key material Width Thickness Keyway depth

Input 40C8 steel 5 5 2.3
Lay AISI 8645 5 5 2.3
Winch AISI 8645 14 9 3.8
Horiz. Motion 40C8 steel 10 8 3.3
References:

[1]R. Khurmi and J. Gupta, A textbook of machine design, 14th ed. 2005, pp. 470-506.

[2] Gates production application notes, Shaft and hub keyway and key sizes, Volume 56, No-03,

April-2009.

40
Summery

1. Spur gears (200 stub involute)

Common gear

Pinion Gear
Module 2.5 mm 2.5 mm
Teeth 15 45
Diameter 37.5 mm 112.5 mm
Face width 22.5 mm 22.5 mm
Material High grade cast iron- FG150

Transmission gears (speed 1,2,3)

❖ Gear material – AISI 4140

Speed Module D pinion D gear T pinion T gear Face width

(mm) (mm) (mm) (mm)

1 1.75 29.75 120.75 17 69 23 mm

2 1.75 42 108.5 24 62 16 mm
3 1.75 66.5 84 38 48 10 mm

Idler system

❖ Module – 1.75 mm

Output gear pinion idler

Teeth 48 14 17
Diameter (mm) 84 25.2 30.24
Face width (mm) 20 20 20
Material AISI 4140 AISI A514 grade E AISI A514 grade E

Final drive system

❖ Gear material – AISI 8642 Alloy steel (Allowable stress = 738 MPa)
❖ Gear module – 2 mm
❖ Face width – 33.5 mm

Pinion Winch Horizontal

Teeth 18 72 36
Diameter 36 144 72

41
 2. Shafts

Shaft Material Diameter (mm)

Input 40C8 carbon steel 15
Lay AISI 8275 alloy steel 15
Output AISI 8275 alloy steel 25
Winch 40C8 carbon steel 45
Horz. Motion 40C8 carbon steel 35
Idler AISI 8275 alloy steel 10

3. Bearings

Shaft Left end (P) Right end (Q)

Input HR30302 J ----
Lay HR30302 J HR30302 J
Output HR32005 XJ HR32305 J
Winch ---- HR33209 J
Horizontal movement ---- HR30307 J
Idler shaft NA4900TT ---

4. Lay shaft spline

❖ SAE standard parallel splines of

𝑵 = 𝟏𝟔
𝑫 = 𝟐𝟓 𝒎𝒎
𝒅 = 𝟐𝟎. 𝟐𝟓 𝒎𝒎
𝒘 = 𝟐. 𝟒𝟓 𝒎𝒎
𝒉 = 𝟐. 𝟑𝟕𝟓 𝒎𝒎

5. Keys for shafts

** All dimensions are in mm.

Shaft Key material Width Thickness Keyway depth

Input 40C8 steel 5 5 2.3
Lay AISI 8645 5 5 2.3
Winch AISI 8645 14 9 3.8
Horiz. Motion 40C8 steel 10 8 3.3
Idler AISI 8275 steel 5 5 2.3

6. Circlips (to lock axial motion of gears and shafts)

❖ DIN 471 standard circlips suitable for shaft diameter are used in bearing, gear ends to prevent
sliding of shaft and gears axially.

42
 6. Lubrication and Cooling

The gear box is designed such that at least one gear of almost all meshing gear pairs is immersed in
lubrication fluid.

Selected lubrication type – Splash lubrication

The lubrication fluid is moved by the gear wheels in the output shaft in such a way that it splashes on the
gearbox housing and moves along it. The lubrication fluid which absorbs the heat transfers the heat to the
housing. The cooling fins attached along the splashed region helps to improve the dissipation of heat
absorbed during operation.

The breather valve helps to release the expanding and contracting air due to heating up and cooling down
of the gear box.

Selected Lubrication – ISO VG100 (Listed in annexes)

43
6. Final Design

44
45
7. Manufacturing Process

This gearbox is an enclosed system of assembled gears that is capable to change it speed, direction and
torque. Also, it can be used to transmit mechanical energy from an electric motor to an output device
(winch). This sliding mesh gear box consists of spur gear wheels, cylindrical shafts with keyways, keys,
splined shafts, circlips, roller bearings, shifting forks.

Manufacturing process of this gearbox involves several stages like:

• machining (turning, milling or thread cutting, slotting, gear cutting)

• heat treatment (carburizing, hardening and quenching)
• grinding
• assembling
Manufacturing process of shafts

In order to machine this part, we use cylindrical bar steel with having excess diameter 1.5mm in radial and
axial directions to be machined in finishing operations. Here we use different raw materials as follows.

• Input/winch/Horz. motion shafts - 40C8 carbon steel

• Lay /output /Idler shafts - AISI 8275 alloy steel
Making cylindrical shafts employs CNC lathe machine and splined shafts are made by broaching method
by using CNC milling machine. Also, CNC milling machine used for making external grooves.

Then we do heat treatment for the shafts by carburizing process.

**The idler gear and shaft is machined from a single piece due to its smaller size.

Manufacturing process of gears

The raw materials for gear wheels are from forging process. Because of better machinery property and it’s
faster than using raw parts from steel bar. Also here we use different raw materials as follows.

• Common gear - FG150

• Transmission gears - AISI 4140
• Idler systems - output - AISI 4140
Pinion/idler - AISI A514 grade E
• Final drive system - AISI 8642
We start machining the part by taking out front surface with CNC lathe machine. Then boring operation
done to have the bore. Next step is making chamfers on edges. When we making splined hole gears we use
broaching machine to make the internal geometry. After that we move to gear machine (CNC milling
machine) to make external gears. Here we maintain the appropriate cutting speed, tool ration speed and part
rotation speed to achieve well finished surface of the gear.

46
Then we do the heat treatment for these gears by carburizing process over the tooth surface with depth 1mm
to get higher hardness. Here we heat the part to 900-930 C in the carburizing oven which has more
concentration of carbon than in the part. Then we do the quenching process and finally tempering process.

Manufacturing process of shifting forks

Mainly shifter folks manufacture by casting and forging process. The engaging part has an engaging surface
which comes in contact with a coupling sleeve, and the engaging surface is formed in a bulging shape by
high precision aluminum die-casting.

Manufacturing process of casing

Here we use aluminum casting process. The casting part has the rough shape similar to the final shape. But
the shape of raw part from casting is not exactly same as the final shape because there are several limitations
for casting. After the forecasting process flat the joining surfaces by using CNC milling machine. Using
drilling tool make holes on casing for fit the two parts of the casing. Then make the treads on holes by using
Tap grant.

Assembly process of the gearbox

Fit the gear wheels in the input shaft, lay shaft, output shaft, idler gear shaft, winch shaft and horizontal
movement gear shaft using interference fit method. Then using circlips make sure fit properly gearwheels
to the Lay shaft, idler shaft, horizontal movement shaft and winch shaft. Then clamp the shifting forks to
related gear wheels in output shaft. After that fix the bearings to the shafts and position the bearing on the
already created bearing mounts in the casing. Then place the gasket and fix the top part of casing on gasket
layer. Place the oil seals and end caps to make sure mechanical seal. Then fit the top part and bottom part
by using bolts

47
[Link]

48
49
50
51
AISI 4130

AISI 4140

52
AISI A514 Grade E

AISI 8750

AISI 8645

53
54
55
56
57
58
59
60
61
62