AIN SHAMS UNIVERSITYFACULTY OF ENGINEERING

DESIGN & PRODUCTION ENGINEERING DEPARTMENT

Third Year Mechanical, Power Section

1st Semester, 2006-2007 Time: 3 HourslI

]

i

Machine Construction andDesign of Machine EquiPment

, Students mav s:ssume finy missinq do(a.

The attached drawing shows the layout of rolls used to crush rocks by

rotating them in opposite directions. The crusher is driven by 15 Kw-

1125 rpm motor and rotates at 75 rpm. The speed is reduced by a V-belt

ur.urrg"*"nt, with a reduction ratio of 3:1, and pair of helical spur gears'

Roll lhaft [B] is 100 mm diameter and rotates in two Rolling Bearing

f,rxed to the frame. Ths other roll rests on two Movable Rolling Bearing

which should be designed to be movable along the ffame to avoid injury

to machine if large siie rocks fall into the space between the rolls'

Helical spur gear drive

Nr*be. of Pinion teeth I 40

Center distance between gears | 600 mm

Tooth width | 100 mm

Pressure angle I 20 de

V- belt drive

Smaller pulleY diameterCenter distance between PulleYsV-belt cross-section angle

Coefficient of friction between belts and puiley

Over load factor

200 mm1000 mm340 -

0.2t.2

You are asked to:

l- Design the pair of Helical Gears based on strength bnly and checks

its dynamic load.

2- Design the V-belt drive [Speciff the number and size of the belts]'

3- Calculate the capacity and select the suitable rolling bearing for the

driving shaft [a], if ttre expected bearings life is 20000 hr.

4- Check the strength of the 80 mm diameter driving shaft [A].

5- Draw a construItional drawing for the driving shaft [A] to show all

the shaft assemblY.

Extrrrriner: Prof/ Heshsm Aly Senbel

tl^l:^-!I tgrl9qr uEal J

Ground Lev

\

V-Belt pulley

oo\t

ooo

a,

Mac h in e D es ig n-Jan u a ry- 2 0 0 7 - rh b W!:!!t gl, pow er s ectro n [pag e : 3 /4 J

Useful Data. Gears Design EquAtions:

. Pt:0b.b.m.K K:Ku.KrlK.Kr. Modified form factor: 0.4g - [2.g5 I Zr]. Deformation factor: 0. ll e l;ifeo + tfe;. Lubrication factor : 1.25

. Velocify factor :31(3+v)

. Service factor: 1.8

. Speed factor :2 u / [1 + u]

. E,t: (21 x10a Mpa) E6y: (12 xl04 Mpa)n P.n:1.2P6. P"n:oen.kr.b.m. P*:k*.kn.b.Dolcos2 y. Pr:P,tan asec y. Pu: Prtan y. p _pr AcosT'd ^ t t+q15JE

VA:ka.b.cos2y*Pr

e : Probab e erTorModule Commercial Accurate Precision

uD to 4.) 50 ')512

6 60- 30 157 70 35 t7o 80 40 20t2 100 50 2525 t20 60 30

e** : Permissible (maximum)error, [pm]

V-Belts Desisn Equations :

0: l80o + 2o,

:lg0o+2sin-r LD-d/ZCl

R

4,r'0

Module series in mm

2 J 4 5 6 7 8 9 l0 t2 l5 20 25 30 35 40 50125 100 95 86 63 55 50 44 39 38 26 25 l4 l3 t2 u l0 9

Angular contact factor (K1

OI 180 170 160 150 140 130 t20 lt0 r00 90 80 70KI 1.0 0.98 0.9s 0.92 0.89 0.86 o.82 0.78 0.73 0.68 0.63 0.58

b 5 6 8 l0 l3 t7 20 22 25 32 40 50h 3 4 5 6 8 l1 t2.5 l4 16 20 25 32d- 22 32 45 63 90 t25 180 212 250 355 500 710

\, .- -.-41 , _L"_

*'i#d-

..

Macirine Design-Jonuary-2006- Third Year Mechanical, Power Section [Page: 4/4J

Transrnitted Power rrer Belt. [Kw]\

Ilelt rvidth, mm

) o ai 10 13 17 2A 22 25 aa AA <A

q

c)

u

2 0.018 0.037 0.074 0.1 40 0.212 0515 0.'136 0.8r0 1 .104 1.766 2.723 4.416

4 0.035 4.074 0.1 40 0.212 0.545 0.957 L398 r.693 2.208 3.459 5.446 6.6)Z

6 0.050 0 t0 0.206 0.405 0.810 1.398 2.061 2.502 3.238 5.t52 8.096 t3.25

8 0.063 0. 40 0.265 0.530 030 1.840 2.',]23 )-L)6 4.t95 6.'771 0.30 r6.93

10 0.074 0 62 0.316 0.640 .251 2.282 3.3t2 3.90 I 5.078 8.170 2.51 20.61

12 0.081 0 84 0.353 0.736 412; 2.650 ).6/- I 4.490 5.888 9.421 4.72 23.55

L4 0.081 0 91 0.3 83 0.8 10 .6ty 2.944 4.269 5.152 6.624 0.60 6.19 2.6.s0

L6 0.081 n 99 0.412 0.883 766 3.165 4.631 s.520 7.2t3 r.56 1.66 28.10

18 0.074 0 91 0.4t2 0.883 9t4 J.J 60 4.931 5.88 8 7.654 2.22 9.14 30.91

20 0.059 0 77 0.397 0.957 98'7 i.533 5.078 6.035 7 _875 2.59 9.87 31.65

22 0.037 0 55 0.361 0.883 981 3.53 3 5.152 6.i09 8.022 9.8'7 32.3 8

24 0 IO 0.309 0.8 l0 914 3.459 5.005 6.035 7.58 r 2.51 9. !4 J I,.J d

26 0.059 0.221 0.736 840 3.312 4.'784 5.741 1.434 1.85 8.40 30.1 8

28 0.132 0.66 693 3.018; 4.416 5.226 6.845 0.89 6.93 27.23

30 4',t2 3.650 3.154 4.563 5.88 8 9.568 4.72 23.5s

Strength of somc materials

flJltimate and Yield Stress, MPa),!

r r^+:;;^l

c22c35c45c60

550600660750

300:zo400490

st 34sr 37

sr 42

st 50

st 60

st70

340310420

500600700

190

200220250300340

30Mn537MnSi542 Cr lvlo ,1

36 Cr Ni N4o 4

34 Cr Ni it4o 630 Cr Ni N4o 8

600900980I 000I 100

r250

550800760900900I 050

Material o,, 6,.

c10ct5

420500

250300

GG IEGG22GG 26GG 30GGG 40

GTW 40

GTW 35

180

2202603004C0

400350

250220200

GS 38

GS 45

GS 52

GS 60

380450520600

r80220250360

15Cr316MnCr5lSCrNi8

600800

I 200

400600800

#

@ O"" ign o l'eh'.^[ $ear

=7-.) ,,-t:o - lt25 -7s

G *. s-=d rafi,; =' SR*r = 6oo

A= Zoo

E2oo4o

Ne - ttZS3 = 315 r.fl.-

t5

"^^J v-Le:^t g?..Jr.[a = I

-ra x2oar 3iS6o ooo = 3.1

^/s

RrD

Ifl=

1f=

kv=

6=

Zp=rP

k t-'rk{=

3

-:

6.q3j.3+3.g

co.-r 4.5 ---s- = 25.84"

Zo _ Aox1= Li.l .Z'9 C-osa zs.g

iIIt

f,g11i

E

did?s,l4

fI

I

4oGs3 zs.g

o.4g .-

o.48 -

l5 aaa

= 54.8

2.8s54. ga2'8s

-

214.\

= o.hz8

: o.47

Pt= 38 2o

o. h 33 xo.\2-8/.8 x t.ZS

N

x loox$

6r=

t3qJ3-

3.9

6"rb

g1.-t Hfa

a. \7

HF 27 I /tf

6(e= ZSl HPa

=."..* €o,ll

= 635 Nlmo

{, =;l39 :

Hf

/q t+1

lrx 2lxto'

22

cos 25.84 + 3tzo

-.. 1t = 3 .9 ,yls

-

g^"r: 8G ,p

kJ= R.q!/.E =z

A = 635 ( Joo r

o.lt x SSr tJ3

= 552=6 N

atl .: .:r'' 4li. ---' ;4:'

p;-...;-1",r'4 ;--

_,21 \).1,*1 552s6 CoS 25.8382o +

= 382o + 49lS\

55L56

81?5 ru

o.l>' t 3:Tz

P.np = o.5 x 218 t a.4ZB x iooxS = 23746 N

D,"^J= o.5 x ZStt y a.h7 x too x 5 = Znghs N

Bett Arive

T KZoo x\125

s'$ "

s-?.

: l'j

1t',,t

= ll.6o aeo

o= t*o-isri'9Z#kr -- o.1h

, 1", V- zo --+

Vr=190

N= l5 x t-Z3'8 xo.94 xl.tt

'/s

ts4.r x e= 2. 17

7g

.J

2ao - l'tt

L'7\ x llZS

([- r. ) *::S.3 L : \2-r.3,

6.1

t-r= l5l3 N

f,*F. = t753

15 ooo x 6o

38Lc, x t-qn2o Sec

38Zo ,, -trrn 25.?h

6.3

t27. 3 N. m

= o.r ((- c)

--------? F, = 2/t o

N

z6.sq = !S_4s

= l85o A/

=S

l-t-

l\

Fr=l-\L-

d

't P r r, Zoo. ' !o'l b = t-l --_-a <z = l:-'.1tz>

N= l5 x l'Z 4,e2.6 x o.?4 xl.6

o 'Z xz,6isint{ '

v

@

H=,s4Sx(oo;1s4soo

R.=h,l12te3-s+)+(q<46)z

= 5o6z A/

o /-o' =/ (€r*-,ro)t * ( ? re).= lo36 N

N. i\rr

F.

\'

(,

Buo.rr.,4 g-<

L = '"'"" ^ ,to* ,rt. = 4so

C= 3g.a knDe-art2? F

Q*1 = to36 + /.Z(ras.; : szs6 N__

= 24.9 k r,r

@ stroaqfft o-* *

l".i =

= /S 16 r to3 N. r_r*.

T = 5o-o^6o-------l21 irt = 38 2 xt1

| // , ' - ^to N""*'

r- =^-j€_<l"l h: t6,. 3 npa

=*p.

,g,a l6ls ^f' \ ff

,i:{=,s4s1753

[ ,er.

-----=-.=.-

:r --t--r 1da ar.6 a€49

6t 8*-

)"Hx

t4jr;