VIET NAM NATIONAL UNIVERSITY – HO CHI MINH CITY

HO CHI MINH CITY UNIVERTSITY OF TECHNOLOGY

FALCUTY OF MECHANICAL ENGINEERING
🙞···☼···🙜

MACHINE ELEMENT (ME2007)

CASE STUDY 01 REPORT

TOPIC:
DESIGN THE TRANSMISSION SYSTEM FOR THE MIXING MACHINE
Instructors: Professor. Doctor. Nguyễn Hữu Lộc
Class: CC01
Semester: 241

Student’s full name Student’s ID

Nguyễn Phan Khánh Toàn 2252821

Ho Chi Minh city – September 5th, 2022

Ho Chi Minh University of Technology – Vietnam National University HCMC
Faculty of Mechanical Engineering - Department of Machine Design

DETAIL SUBJECTS AND SUPPLIED DATA FOR CALCULATION

Subject: Machine element (ME2007) - Class: CC01 – Semester 241
Project: Design the transmission system for the mixing machine

Student’s Group
N Email Work
ID members
Nguyễn
Phan Topic 14,
1 2252821 [email protected]
Khánh Problem 08
Toàn

Instructor’s comment:
…………………………………………………………………………………………
…………………………………………………………………………………………
………………………………………………………………………………………….

Instructor’s signature Student’s signature

Mr Nguyễn Hữu Lộc Nguyễn Phan Khánh Toàn

2
INTRODUCTION:
Our country is on an upward trajectory, with science and technology playing a
crucial role in the ongoing process of industrialization and modernization. The
application of science and technology is essential to increasing labor
productivity, effectively replacing manual labor, and ensuring worker safety.
These advancements help lay a strong foundation for future development. To
achieve this, we must invest in, research, educate, and develop science and
technology from within our universities.
The Machine Detail course project is a fundamental subject that introduces
Machine Building students to the field of mechanical design, which is central to
every mechanical engineer's career. Excelling in this course helps students
envision their future careers and gain a clearer understanding of their academic
journey, boosting their enthusiasm for learning. Additionally, this project serves
as a practical challenge, requiring students to apply skills acquired in previous
years, such as mechanical drawing and proficiency in software tools like
AutoCAD, AutoCAD Mechanical, and Autodesk Inventor. It also draws on
foundational knowledge from courses such as Machine Principles, Machine
Parts, and Tolerances and Measuring Techniques.
COMMITMENT:
We hereby pledge:
- This is the engineering design project done via my effort.
- All data presented in this design project is truthful and has just been consulted
in other studies.
- All quotes and results for comparison in this design project are cited in the
reference section within our range of knowledge at utmost accuracy.
ACKNOWLEDGEMENT:
Firstly, we would like to express our special thanks and gratitude to Prof.
Nguyen Huu Loc for giving us a golden opportunity to complete this project on
the topic of transmission system for the mixing machine systems. We are also
grateful that you have shown us an abundant amount of knowledge about
Fundamentals of the transmission or machine element so far. This is an
opportunity for us to perform research about the Fundamental of transmission
system for the mixing machine. We also understand that transmission system for
the mixing machine to the world of Mechanical Engineering, especially in the
field of material science. Not only does the project give us knowledge but also
ideas for future projects. Finally, we would like to express our sincerest
gratitude to all the other unnamed people who helped us to complete this report.

3
 TABLE OF CONTENTS

CHAPTER 1: SELECTING ELECTRIC MOTOR AND SPEED RATIO

DISTRIBUTION. .................................................................................................. 8
1. The power of the mixing blade:................................................................ 8
2. Determine the efficiency of each element: ............................................... 8
3. The power required for the motor: ........................................................... 8
4. Select motor for using: ............................................................................. 8
5. The rotation speed mixer blade: ............................................................... 8
6. General transmission: ............................................................................... 9
7. The table of components of electrical motor for SGA: (table 1) ............. 9
8. The system transmission ratio: ............................................................... 10
9. The rotational speed of the V- belt: ........................................................ 10
10. Select the motor: ..................................................................................... 10
11. The properties of each shaft in the system can be computed in the below
table: ................................................................................................................ 10
CHAPTER 2: CALCULATION OF V-BELTS DRIVE .................................... 11
1. Initial parameter:..................................................................................... 11
2. Choose type of V-belt and calculate the diameter of the driving driver: 12
3. Calculate the velocity of the driving driver: ........................................... 13
4. Calculate the diameter of the driven driver: ........................................... 13
5. Condition of the distance between two center of driver (a) and calculate
this value as the diameter of driven pulley: .................................................... 13
6. Calculate the contact angle of driving driver, length of the belt via
formula: ........................................................................................................... 14
7. Choose the exact length of belt and recalculate the value of a: ............. 14
8. Check the number of turns i: .................................................................. 14
10. Calculate the circumferential force of the belt: ...................................... 15
11. Check slip condition: .............................................................................. 15
12. Calculate the force loaded on the belt: ................................................... 15
13. Calculate the series of factors C: ............................................................ 16
15. Find stress of the belt: ............................................................................. 18
4
 16. Service life of belts: ................................................................................ 19
17. Force, acting to the shaft: ....................................................................... 20
18. Summary table: ....................................................................................... 20
CHAPTER 3: CALCULATING SINGLE STAGE SPUR GEAR REDUCER . 21
1. Initial parameter:..................................................................................... 21
2. Choose the material of the spur gear: ..................................................... 21
3. Determine the limited allowable contact and bending stress: ................ 23
4. Determine the number of fundamental work cycle: ............................... 24
5. The number of equivalent work cycles in contact pressure: .................. 24
6. The value of the coefficient KHL (the condition of no bending in the
surface of teeth) in contact pressure: ............................................................... 24
7. The contact pressures are allowed basically: ......................................... 25
8. The number of equivalent work cycle in bending pressure: .................. 25
9. The value of the coefficient KHL (the condition of no bending in the
surface of teeth) in bending pressure: ............................................................. 26
10. The bending pressures are allowed basically: ........................................ 26
11. Allowable overload stress:...................................................................... 26
12. The table of elements properties: ........................................................... 26
13. Selecting the width of the rim teeth:....................................................... 27
14. The shaft distance between two gears: ................................................... 30
15. Calculate the coefficient of mechanical properties of materials ZM: ..... 31
16. Calculate generally the diameter of driving and driven gears:............... 32
17. The module of teeth: ............................................................................... 32
18. Determine the condition of the number of teeth on driving gear Z1 : ..... 32
19. The number of teeth:............................................................................... 33
20. Determine the helix angle  : ................................................................. 33
21. Determine again the axial distance aw: ................................................... 33
22. Compute again the transmission ratio: ................................................... 33
23. Check all the value computed based on the standard series: .................. 34
24. Geometrical properties of the gear system: ............................................ 34
25. Calculate the lap velocity of this gear system: ....................................... 37
26. Choose the precision grading of the transmission: ................................. 37
5
 27. Determine the coefficient of vertical meshing of the gear system: ........ 38
28. Determine the concentration of weight on the gears: ............................. 38
29. Determine the magnitude and direction of force acting to the driving
gear (1) and driven gear (2):............................................................................ 38
30. Determine the coefficient of loading on gear system: ............................ 40
31. Determine the computational pressure  H on meshing area: ................. 43
32. Determine the equivalent number of teeth of helical spur gear: ............ 44
33. Determine the coefficient of bending pressure YF: ................................ 44
34. Comparing the properties of the ability of bending pressure: ................ 45
35. Computing the bending pressure: ........................................................... 45
CHAPTER 4: DESIGNING SHAFTS ................................................................ 46
CHAPTER 5: SELECTING BEARINGS........................................................... 46
CHAPTER 6: SELECTING LUBRICATIONS METHODS ............................. 46
CHAPTER 7: SELECTING KEYS, COUPLINGS............................................ 46

6
 TOPIC 14 AND PROBLEM 8 DATA SUPPLIED
DESIGN THE TRANSMISSION SYSTEM FOR THE MIXING MACHINE

Picture 1
The simple diagram of this machine can be seen in the next photo:

The given data in problem 8 is:

Number Description Data
1 Mixer output torque T, 330
(N.m)
2 Rotational speed mixer 80
blade, n (rpm)
3 Service life L, years 8
Transmission system one-way rotation, two work shifts (1 year working 260
days, 2 shift working 8 hours).

7
CHAPTER 1: SELECTING ELECTRIC MOTOR AND SPEED RATIO
DISTRIBUTION.

1. The power of the mixing blade:

T n 330  80
Pmixing −blade = = = 2.7644(kW )
9.55 103
9.55 103

2. Determine the efficiency of each element:

We can easily point out the efficiency of all elements in the transmission:
 Belt = 0.94
 Gear = 0.96
 Coupling = 0.98
 Rolling = 0.99
  =  Belt Gear Coupling  Rolling 3 = 0.94  0.96  0.98  0.993 = 0.8581

3. The power required for the motor:

Pmixing −blade 2.7644
Pmotor = = = 3.2215 (kW)
 0.8581

4. Select motor for using:

The motor needs to be more than Pmotor => Pmotor − selected = 4.0kW

5. The rotation speed mixer blade:

nmixing −blade = 80(rpm)

8
6. General transmission:

- Select the ugear in standard series of number:

Via the standard series number of the transmission ratio of reducer as
below, we can easily find out the ugear for four motors as the table shown:

- In four motors as we choose in SGA table, and from two tables of

choosing the transmission ratio of the single stage spur gear ratio, we can
select with decreasing the rotational speed of the motor respectively: 8.0;
6.3; 5.0; 4.0

7. The table of components of electrical motor for SGA: (table 1)

Motor nMotor (RPM) usys ugear uV-belt
1 2895 36.1875 8.0 4.5234
2 1440 18.0000 6.3 2.8571
9
 3 965 12.0625 5.0 2.4125
4 720 9.0000 4.0 2.2500
Table 1

8. The system transmission ratio:

nMotor 2895
usys = = = 36.1875
nmixing −blade 80

nMotor 1440
usys = = = 18
nmixing −blade 80
nMotor 965
usys = = = 12.0625
nmixing −blade 80
nMotor 720
usys = = =9
nmixing −blade 80

9. The rotational speed of the V- belt:

usys 36.1875
uV −belt = = = 4.5234
uspur − gear 8.0
usys 18.0000
uV −belt = = = 2.8571
uspur − gear 6.3
usys 12.0625
uV −belt = = = 2.4125
uspur − gear 5.0
usys 9.0000
uV −belt = = = 2.2500
uspur − gear 4.0

10.Select the motor:

- For the table of the motor of SGA in table 1, we select the motor 3 for this
mechanism system.
Type Motor Pmotor(kW) nMotor usys ugear ubelt
(RPM)
132MA 3 4 965 12.0625 5 2.4125

11.The properties of each shaft in the system can be computed in the below
table:
Shafts Motor I II Mixing
blade
Properties
Power P, kW 4.0 3.7224 3.5378 3.4324

10
 Transmission 2.4125 5 1
ratio u
Rotational speed 965 400.0000 80.0000 80.0000
n, RPM
Moment T, Nm 39.5855 88.8723 422.3249 409.7428
Table 2
+ The power on each shaft:
PMotor = 4.0kW

PI = PMotor  Belt  Rolling = 4  0.94  0.99 = 3.7224kW

PII = PI Gear  Rolling = 3.7224  0.96  0.99 = 3.5378kW

PMixing −blade = PII  Rolling Coupling = 3.5378  0.99  0.98 = 3.4324kW

+ The rotational speed on each shaft:

nmotor = 965( RPM )

nmotor 965
nI = = = 400( RPM )
ubelt 2.4125

nI 400
nII = = = 80( RPM )
uGear 5

nmixing −blade = nII = 80.0000( RPM )

+ Moment on each shaft:

9550  Pmotor 9550  4
TMotor = = = 39.5855( Nm)
nmotor 965

9550  PI 9550  3.7224

TI = = = 88.8723( Nm)
nI 400

9550  PII 9550  3.5378

TII = = = 422.3249( Nm)
nII 80

9550  Pmixing −blade 9550  3.4324

TMixing −blade = = = 409.7428( Nm)
nmixing −blade 80

CHAPTER 2: CALCULATION OF V-BELTS DRIVE

1. Initial parameter:
o Power of driving driver: Pdriving −driver = Pmotor = 4kW

11
 o Number of revolutions: nmotor = 965RPM
n1 965
o Transmission ratio: u = = = 2.4125
n2 400
o Working condition: one-way rotation, two work shifts (1 year
working 260 days, 2 shift working 8 hours)

2. Choose type of V-belt and calculate the diameter of the driving driver:
- We have the power and number of revolutions of driving driver, we select
the type of belt based on the below picture:

 Through this picture, we can depict type B of belt that adapt all of
dimension of all n and P.
- We continue determining the minimum diameter of driving driver though
the next picture:

 With type B of V – belt, it can be chosen the minimum diameter of the

belt being d1min = 125mm

12
 - We have the coefficient of relative sliding  to give the value of u to be a
normal number, so it should be:
1 1
uv −belt = ubelt  (1 −  ) = 2.4125  (1 −  ) = 2.4125  (1 − ) = 2.4 and  =
193 193
- The percentage different of uv-belt with the initial ubelt is:
2.4 − 2.4125
100% = 0.5208%  3%
2.4
- We compute the driving driver’s diameter via this formula:
d1 f = 1.2  d min = 1.2 125 = 150mm
- Because the driving driver of V – belt have to be selected via the series:

So, it must satisfy the condition that d1 f  d1 => d1 = 160mm

3. Calculate the velocity of the driving driver:

  d1  n1  160  965
v1 = = = 8.08m / s < [v] =25 m/s with ordinary V – belt
60000 60000
drive, so we can accept with this diameter of driving pulley.

4. Calculate the diameter of the driven driver:

- The diameter of the driven driver can be computed by:
d 2 = d1  u = 160  2.4 = 384mm
- Choose the value in the series, which is as same as d1, we have the nearest
number is 315mm, so we have d2 = 355mm

5. Condition of the distance between two center of driver (a) and calculate
this value as the diameter of driven pulley:

- In the condition of a considering to the series as below, we can choose the

value of a is approximately 1.2*d2=1.2*355=426 mm because u = 2.4.

13
6. Calculate the contact angle of driving driver, length of the belt via
formula:
  (d 2 + d1 ) (d 2 − d1 )2   (355 + 160) (355 − 160) 2
Lf = 2  a + + = 2  426 + + = 1683.2752mm
2 4a 2 4  426

7. Choose the exact length of belt and recalculate the value of a:

- Because the length of V – belt must be chosen in the series, also adapted
the condition that: L f  L

 L = 1800 mm is the value chosen!!

- Recalculate the value of a in below equation:
d 2 − d1 355 − 160
= = = 97.5mm
2 2
  (d1 + d 2 )   (160 + 355)
k = L− = 2800 − = 1991.0399mm
2 2
k + k 2 − 8   2 1991.0399 + 1991.03992 − 8  97.52
a= = = 990.7223mm
4 4
- With type B of V – belt, we have: h = 10.5 mm
- Condition of a:
2  (d1 + d 2 )  a  0.55  (d1 + d 2 ) + h
 2*(160 + 355)  a  0.55*(160 + 355) + 10.5
 1030  a  293.75
 a = 990.7223 mm is satisfied this factor, so we have enough reason to
choose this value!!

8. Check the number of turns i:

v1 8.08
i= = = 4.49  [i ] = 10 , for V – belt, the number [i] is 10 s-1
L 1.8

 That is good for the value of a and L.

9. Calculate the contacting angle of driving pulley:

d 2 − d1 355 − 160
1 =  − = − = 2.94(rad )
a 990.7223

14
10.Calculate the circumferential force of the belt:
1000  P 1000  4
Ft = = = 495.059( N )
v 8.08

11. Check slip condition:

Ft e f 1 + 1
[ 0 ]  A  F0   f 1
2 e −1
- Choose the factor of coefficient (f) via this below table:

 Assumed that the material manufacturing the flat belt is Leather

chrome tanned and pulley material is wood, so we can decide that the
value of f is 0.40
- We have the value of some parameter that we have known before:
1 = 2.94rad

 f flat −belt = 0.40
- For V – belt, we have to compute the value of f through the formula:
f
f'=
 
sin  
2
We usually choose the  = 36o or  = 38o , but in this case, we select  = 36o
0.40
 f'= = 1.29
 36o 
sin  
 2 
Ft e f 1 + 1 495.059 e1.292.94 + 1
 F0   =  1.292.94 = 258.94( N )
2 e f 1 − 1 2 e −1

12. Calculate the force loaded on the belt:

- We select the initial loaded on the belt is same as the minimum, so:
F0 = 258.94( N )

15
- We calculate the force on 2 side of the belt (tight side and loose side) as
below:
 Ft 495.059
 F1 = Fo + 2 = 258.94 + 2
= 506.47( N )

 F = F − Ft = 258.94 − 495.059 = 11.41( N )
 2 o
2 2
- Because the velocity of the driving belt is under 30(m/s) => FV = 0( N )

13. Calculate the series of factors C:

- Via the below table, it is considerable to select the allowable effective
power:

 Because the velocity of the driving driver pulley is 8.08 m/s, so we

choose the nearest value in the table is 10 m/s, also the V – belt in this
case is type B and the diameter of driving driver pulley in this case is
160mm, so the [P0 ] = 3.15kW .
- We have the value based on the previous table:
 L = 2240mm

v = 10m / s
- Via the next table, we can calculate all the factor C needed:

16
 CV = 1 − 0.05  (0.01 v 2 − 1) = 1 − 0.05  (0.0110 2 − 1) = 1
2.94180
−
−1 
C = 1.24  (1 − e 110
) = 1.24  (1 − e 110
) = 0.97
u = 3.0156  2.5  CU = 1.12
L 6 1800
CL = 6 = = 0.96
L0 2240
CZ = 1.0
CR = 1.0
P1 4
z =  1.22
[P0 ]  C  Cv  CL  CU  CZ  CR 3.15 1 0.97 1.12  0.96 11
The integer number is the nearest to that value is 2, so the number of belts
in this case must be 2 => z=2
14. Find the width of the belt and the outer diameter of the pulley:
- As data in the below table:

17
 Table: The geometric properties of V- belt on distinct types.
- As the V – belt in this type is type B, we have:
bp = 14.0mm

b = 4.2mm
 H  10.8mm

e = 19mm
 f = 12.5mm

r = 1o

 = 36  b1 = 16.7 mm
0

- In diagram, above parameter can show us the value of belt as picture

below:

15. Find stress of the belt:

- Via the below table, we can find out the properties of belt materials:

18
  We assume that the materials of belt in previous task is Leather, so in
this case, we continue use this material to have the basic properties:
 A1 = 138mm 2

 y0 = 4mm

 d1 = 160mm
 E = 10 MPa

- Find out the value of F1 via the Euler formula:
We have the initial parameter for the next formula:
 Ft = 495.059 N

 f ' = 1.29
 = 2.94rad
 1
e f 1 e1.292.94
F1 = Ft  = 495.059  = 506.47 N , as same as the value we
e f 1 − 1 e1.292.94 − 1
have recently computed.
- The maximum of stress that the belt must be contained
2  y0 F F
 max =  E + 0 + t +   v 2 10−6
d1 A 2 A
24 258.94 495.059
= 10 + −6
+ + 1.15  8.082 10−6 = 3.67( MPa)
160 138 10 2 138 10−6

16. Service life of belts:

- We have again the number of turns in a second is:
v1 8.08
i= = = 4.49  [i ] = 10
L 1.8
- We choose the value of parameter m in the equation of service life of belts
via:

 Through this theory, we easily have m = 8 for V – belts

- We continue choosing the value of parameter  r in the next equations
via:

19
  Through this theory, we easily have  r = 9 for V – belt.
- The total number of cycles of load application up to failure:
m
  
8
 9 
N E =  r  107 =   10 = 1.3110 (number − of − cycles)
7 10

  max   3.67 
- Service life in hours:
NE 1.311010
Lh = = = 405221.48( Hours)
2  3600  i 2  3600  4.49

17. Force, acting to the shaft:

   2.94 
Fr = 2  F0  sin  1  = 2  258.94  sin   = 515.25( N )
2  2 

18. Summary table:

Parameter Symbol Value
Belt type Type B
Belt cross – section A 138 mm2
(mm2)
Belt number z 2
Center distance (mm) a 990.72 mm
Belt length (mm) L 1800 mm
Contact angle (radian) 1 2.94 rad
Revolution of belt (s-1) i 4.49
Diameter of driving d1 160 mm
pulley (mm)
Diameter of driven d2 355 mm
pulley (mm)
Maximum belt stress  max 3.67 MPa
(MPa)
Initial tension (N) F0 258.94 N
Force, acting to the shaft Fr 515.25 N
(N)
Circumferential force Ft 495.059 N
Service life (Hours) Lh 405221.48 Hours

20
CHAPTER 3: CALCULATING SINGLE STAGE SPUR GEAR
REDUCER

1. Initial parameter:
- Power of the driving gear: P1 = 3.7224kW
- Moment T: TI = 88.8723Nm
- Rotational speed of driving gear: n1 = 400rpm
- Rotational speed of driven gear: n2 = 80rpm
- Transmission ratio: u = 5
- 1 year working 260 days, 2 shift working 8 hours =>
Lh = 8  260  2  8 = 33280( Hours)

2. Choose the material of the spur gear:

- Because the power P of both driven and driving gear are larger than 2 but
under than 7.5kW, so considering this table to choose the appropriate
material for the driving and driven gear:

 We choose the material for driving and driven gear is steel C45
- Next, we choose the HB for C45 of the driving and driven gear though
this below table:

21
 We have the basic properties for driven and driving gear as below:
45C − Steel
Im provement

 S  60mm
Driving − gear : 
 Hardness : HB 241..285
 b1 = 850 MPa

 ch1 = 580 MPa

22
 45C − Steel
Im provement

 S  60mm
Driven − gear : 
 Hardness : HB 241..285
 b 2 = 850 MPa

 ch 2 = 580 MPa

3. Determine the limited allowable contact and bending stress:

- According to the next table, we determine the allowable contact stress,
bending stress, safety factor when exposing and bending as below:

 OH lim = 2 HB + 70
 s = 1.1
  H
 OF lim = 1.8 HB
 sF = 1.75

In which: + : Allowable contact stress;

23
 + : Allowable bending stress;
+ SH: Safety factor when exposing;
+ SF: Safety factor when bending.
- Choosing the hardness of driving gear is HB1 280 and driven gear is HB2
240 because HB1 - HB2 = 40 HB in allowed zone and all of HB are always
under 350 HB.
 OH lim1 = 2  280 + 70 = 630 MPa

 OH lim 2 = 2  240 + 70 = 550 MPa

 OF lim1 = 1.8  280 = 504 MPa
 OF lim 2 = 1.8  240 = 432 MPa

4. Determine the number of fundamental work cycle:

- We have the value of NHO for the driving gear (1) and driven gear (2)
respectively as below:
N HO1 = 30  HB12.4 = 30  2802.4 = 22402708.60(cycles )
N HO 2 = 30  HB2 2.4 = 30  2402.4 = 15474913.67(cycles )
N FO1 = N FO 2 = 5 106 (cycles )

5. The number of equivalent work cycles in contact pressure:

- The number of articulated gears in one cycle: (single stage spur gear)
c =  ('' number − of − gear '') − ('' driving − gear '') = 2 − 1 = 1
- The gears are working with stable load mode and the rotational speed, so
we have:
N HE1 = 60  c  n1  Lh = 60 1 400  33280 = 798720000(cycles)
N HE 2 = 60  c  n1  Lh = 60 1 80  33280 = 159744000(cycles )

6. The value of the coefficient KHL (the condition of no bending in the

surface of teeth) in contact pressure:
- Because the value of N HE1 is larger than N HO1 , when we compute the value
of K HF 1 , we set N HE1 is equal to N HO1
N HO1 6 22402708.60
 K HF1 = m H = =1
N HE1 22402708.60
- Because the value of N HE 2 is larger than N HO 2 , when we compute the value
of K HF 2 , we set N HE 2 is equal to N HO 2
N HO 2 6 15474913.67
 K HF 2 = m H = =1
N HE 2 15474913.67

24
7. The contact pressures are allowed basically:
 OH lim1  0.9 630  0.9
 H 1  =  K HL = 1 = 515.45MPa
sH 1.1

 OH lim2  0.9 550  0.9

 H 2  =  K HL = 1 = 450MPa
sH 1.1

Z R  ZV  Kl  LxH
- The full formula in this case is:  H  =  OH lim   K HL with
sH
Z R = 1 with the coefficient of surface roughness is Z a = 1.25  0.63 m ,
ZV = 0.85  v 0.1 = 0.85 1.430.1 = 0.88 with both of driving and driven gear are
under HB 350, K l = 1 with normal lubrication condition,
d
K xH = 1.05 − = 1.023 with the effect of the size of teeth, and d in this
104
case is the diameter of the divided diameter of driving or driven gear is
accepted because if we draw the graph to survey the formula of KxH, the
number is going to near 1. Therefore, we have the multiply equation is
nearly to 0.9 as below: Z R  ZV  Kl  LxH = 0.9
  H  = Min  H 1  ;  H 2  = 450MPa because in this case, the gears are
spur gear with helix angle  = 0o
  H  = 0.5  ( H 1 2 +  H 2 2 ) = 0.5  (515.452 + 4502 ) = 483.83MPa because
in this case, the gears are spur gear with helix angle   0o
- The condition to accept the value of  H  as below:
 H min   H   1.25   H min
 450   H   562.5
 This value does not break the rule!

8. The number of equivalent work cycle in bending pressure:

- The number of articulated gears in one cycle: (single stage spur gear)
c =  ('' number − of − gear '') − ('' driving − gear '') = 2 − 1 = 1
- The gears are working with stable load mode and the rotational speed, so
we have:
N FE1 = 60  c  n1  Lh = 60 1 400  33280 = 798720000(cycles)
N FE 2 = 60  c  n1  Lh = 60 1 80  33280 = 159744000(cycles )

25
 9. The value of the coefficient KHL (the condition of no bending in the
surface of teeth) in bending pressure:
- Because the value of N FE1 is larger than N FO1 , when we compute the value
of K FL1 , we set N FE1 is equal to N FO1
N FO1 6 5 106
 K FL1 = mH = =1
N FE1 5 106
- Because the value of N FE 2 is larger than N FO 2 , when we compute the value
of K FL 2 , we set N FE 2 is equal to N FO 2
N FO 2 6 5 106
- K FL 2 = mH = =1
N FE 2 5 106

10.The bending pressures are allowed basically:

 OF lim1  K FC 504
 F1  =  K FL = 1 = 288MPa
sF 1.75
 OF lim2  K FC 432
 F 2  =  K FL = 1 = 246.86MPa
sF 1.75
YR  Yx  Y  K FC
- The full formula in this case is:  F  =  OF lim   K FL with
sF
YR = 1 with the tooth is milling, Yx = 1 with both of driving and driven gear
are improvement as mentioned before,
Y  1.082  0.172}  Y = 1.082 − 0.082 = 1 with the sensitivity of tooth
materials, which affect to the concentration of weight when working.
Therefore, we have the multiply equation is nearly to 1.0 as below:
YR  Yx  Y = 1.0
- In which, the value of K FC is 1 because the mechanical system is one –
way directional motion.

11.Allowable overload stress:

 H max = 2.8   ch 2 = 2.8  580 = 1624MPa
 F 1 max = 0.8   ch1 = 0.8  580 = 464MPa
 F 2 max = 0.8   ch 2 = 0.8  580 = 464MPa

12.The table of elements properties:

Elem Material Dbillet/Sbille Heat HB1/HB b  ch  H   F 
ent t treatment 2

26
Drivi Steel 45C 60 Improvemen 280 85 58 515. 288
ng t 0 0 45
gear
Driv Steel 45C 60 Improvemen 240 85 58 450 246.86
en t 0 0
gear
Total Steel 45C 60 Improvemen x 85 58 483. x/464
(Bot t 0 0 83/1
h/ma 624
x)
- In which, x is no value or undefined value

13.Selecting the width of the rim teeth:

- Through this below table, we can find out the value of  ba :

 Because the gear system is symmetrical, and H1 and H 2 are under 350
HB, so we choose the value of  ba is from 0.30 to 0.50.

 We select  ba is equal to 0.40 in the table and it must satisfy its

standard series.
- We compute the value of  bd as follow:
 ba  (u + 1)
0.40  (5 + 1)
 bd = = = 1.2
2 2
- Checking the value of  bd in the below table:

27
  The value that we have recently found out is in the allowable zones of
symmetrical and both of hardness of driving and driven gears are
under HB 350, so the number we select is acceptable!
- Redeem the calculation between the HB and HRC:

 Most of them are simply understood as 1 HRC = 10HB with slightly

differential.
- We select the calculated loading coefficient K H = K H  as this table below:

 Because the hardness of C45 steel – the material of two driving and
driven gear is under HB 350 = 35 HRC, and the gear system is
symmetrical, we have:
K H  = 1.0 + 0.0086  bd = 1.0 + 0.0086 1.2 = 1.01032  1.01

28
- Conducting a comparison with the standard number of K H  in this below
table, we conclude that:

 In this table, the number of K H  with two conditions is 1.05, but in

calculation, we only find out that number is 1.01, so we have to use the
percentage error to consider which value can be used in this case:
1.01 − 1.05
= 100% = 3.81%  4%
1.05
 We select K H  = 1.05 for further calculation!
- Next, we find out the value of K F  - an important value for upcoming
formulas in this below table:

29
  In this table, responding to  bd = 1.2 and both the driving and driven
gear are under HB 350, we can realize that the value of K F  is 1.14.
But in the nearest previous table compared to this table, the value is
only 1.10 for symmetrical gear system, so we must to do again the
percentage error as below:
1.14 − 1.10
= 100% = 3.64%  4%
1.10
 Selecting K F  = 1.14 is acceptable!

14.The shaft distance between two gears:

- Selecting the value of K a in the standard table as below:

30
  Because the material of driving and driven gear in this case is steel –
steel, so according to this table, we choose the K a = 43 with single stage
spur gear, specially for helical spur gear.
- The formula and value of aw - gear shaft distance can be calculated as
below:
T1  K H  88.8723*103 1.05
aw  K a  (u + 1)  3  43  (5 + 1)  3 = 158.17 mm
 ba   H   u 2 0.40  4502  5
2

 This is just the value we compute in the formula, but in this case, aw
must be satisfied with both the condition in the formula, and the
standard series as below:

 Because the gear system is correctly standard, we must choose the

nearest value is aw = 160mm (*)

15.Calculate the coefficient of mechanical properties of materials ZM:

E1  E2
ZM = = 191.65
   E2  (1 − 12 ) + E1  (1 −  2 2 ) 

31
  E1 = E2 = 2.1105 MPa
In which: 
 1 = 2 = 0.3

16.Calculate generally the diameter of driving and driven gears:

T1  K H   (u + 1)
d1  K d  3
 bd   H   u
2

(**)
88.8723 10 1.05  (5 + 1)
3
= 67.5  3 = 49.67( mm)
1.2  483.832  5

d 2  u  d1 = 248.39mm

17.The module of teeth:

- Because the hardness of both driving and driven gear are under HB 350,
we can find out the module of the teeth as below:
m = ( 0.01  0.02 )  aw = ( 0.01  0.02 ) 160 = (1.6  3.2)
- Based on this below table, we choose the module of the teeth for spur
gear:

 Priority to the first series, we can conclude that m = 3mm is satisfied

all of the necessary condition.

18.Determine the condition of the number of teeth on driving gear Z1 :

- Relationship between center distance aw and helix angle  and normal
module m:
m  ( Z1 + Z 2 ) m  (Z1 + Z 2 ) m  Z1  (u + 1)
aw =  cos  = =
2  cos  2  aw 2  aw

- From here we deduce:

20o    8o

32
 2  aw  cos8o 2  aw  cos 20o
  z1 
m  (u + 1) m  (u + 1)
 17.60  z1  16.71

19.The number of teeth:

- Because the helical spur gear is given, the angle of  - gear tilt angle is
different than zero, so the number of the driving gear is satisfied the
previous condition, so to ensure that the number of teeth have to be a
normal number (N), so the number of teeth should be Z1 = 17 (teeth).
- The total number of teeth:
2  aw
Z = Z1 + Z 2 = = Z1  (1 + u ) = 17  (1 + 5) = 102(teeth) , because the total
m
number of teeth of both driving and driven gear must be a normal number.
- Compute the number of teeth on the driven gear:
z2 = z − z1 = 102 − 17 = 85(teeth)

20.Determine the helix angle  :

- After computing the number of teeth on both driving and driven gears, we
find out the value of the helix angle as below:
 m  ( Z 2 + Z1 )   3 102 
 = arccos   = arccos   = 17.01  17 0'38.62"
o o

 2  aw   2  160 

21.Determine again the axial distance aw:

- The axial distance can be computed again as follow:
Z m 102  3
aw = = = 159.9994(mm)
2  cos  2  cos(17.01)
- The error of that new value compared to that value that we use the
standard series, which to ensure that the value of aw in the previous part
can be applied:
159.9994 − 160
= 100% = 3.75*10−4%  4%
159.9994

22.Compute again the transmission ratio:

85
u= =5
17

33
23.Check all the value computed based on the standard series:
- Via the series, for example the standard series of SEV229-75 for aw as
below:

 All of number finding out are satisfied the standard, so we can

conclude that all of data, considering to now are correct!

24.Geometrical properties of the gear system:

- Via the below table, we can easily to find out all of compulsory data of
geometry for these driving and driven gears:

34
 - The results are computed in the next table:

Symbols
Names of
of Formulas Units Values
properties
properties
Module m x mm 3
Number of z1 and z 2 x teeth 17 and 85
teeth
Axial aw x mm 160
distance
Helix  x Degree 17.01
angle
Height of
h 2.25  m mm 6.75
teeth
Clearance c 0.25  m mm 0.75
Radius of
rounded  =
m
mm 1
corner of 3
tooth roots
m  z1
d1 =
The pitch cos  53.33 and
d1 and d 2 mm
diameter m  z2 266.67
d1 =
cos 
Divided
axial a a = 0.5  (d1 + d 2 ) mm 160
distance
Roller d w1 and d w1 = d1 53.33 and
circle d w2 = d2
mm
d w2 266.67
diameter
Top of d a1 and d a1 = d1 + 2  m 59.33 and
teeth da2 = d2 + 2  m
mm
da 2 272.67
diameter
Bottom of d f 1 and d f 1 = d1 − 2.5  m 45.83 and
teeth d f 2 = d 2 − 2.5  m
mm
df2 259.17
diameter
Porphin 0 According to TCVN 1066 - 71 degree 20
angle
Wheelbase db1 and db1 = d1  cos  50.11 and
db 2 = d 2  cos 
mm
diameter db 2 243.54

35
 Porphin
teeth angle  tan( 0 ) 
 tw  tw = arctan   degree 20.84
(Contact  cos  
angle)
Coefficient
of   z1  tan  a1 + z2  tan  a 2 − ( z2 + z1 )  tan tw 
x 2.35
horizontal 2
matching

b1 search via the table below (picture

Width of b1 and b2 3) mm 67.84 and 64
tooth rim
b2 =  ba  a

- Some note of the previous table:

+ x: Already have in previous chaps and parts; or none – it means no
existence.
+  : The angle for helical gear, in this case it seems to zero.
+ inv: a function that should be considered in this below picture (2)
+ For aw to calculate contact angle, total moving coefficient using the
value of aw in the equation (1)
+ x1; x2; y are computed in the previous part, but when using these
number to calculate, the result of axial distance or relative parameters are
as nearly same as axial distance that we have in the series, so in this case,
we can accept these values for less caution as explained in the previous
part.
 db1 
+  a1 = arccos  
 d a1 
 db 2 
+  a 2 = arccos  
 da 2 
+ The value of the pitch diameters are satisfied with the equation (**), so
no change in this case can be foreseen.
+ Table of the ratio for the width of tooth rim as below (3):

36
 Picture 2

Picture 3

25.Calculate the lap velocity of this gear system:

- The lap velocity of this gear system can be computed in this below
formula:
  d1  n1   53.33  400
v= = = 1.12m / s
60000 60000

26.Choose the precision grading of the transmission:

- Via this below table, the transmission in this case is helical spur gear and
the value of v can help us to choose the suitable precision grading:

37
  In this case, the precision grading for the transmission is 9.

27.Determine the coefficient of vertical meshing of the gear system:

- The width of contacting tooth rim:
bw
 ba =  bw =  ba  aw = 0.4 160 = 64mm
aw
- The coefficient of vertical meshing of the gear system (helical spur gear)
can be computed as follow:
sin  sin17.01
 b  bw  = 64  = 1.99  1.1
 m  3
 The transmission is satisfied with the minimum requirement to work
ordinary!

28.Determine the concentration of weight on the gears:

- Because the coefficient affecting to longitudinal meshing of the gears is
depended on the longitudinal and vertical meshing coefficient  a and  b
as follow:
 Both of the value of the coefficient  a and  b are not normal numbers,
so in this case, K = 0.9 → 1 and in this report, we choose K = 0.95
- The concentration of weight on the gears is described as lH with its value:
K  bw    0.95  64  2.35
lH = = = 149.42mm
cos  cos(17.01)

29.Determine the magnitude and direction of force acting to the driving gear
(1) and driven gear (2):
- In helical spur gear, there are three main types of force, which are
components of a force namely a normal force ( Fn ), including: tangent
force, axial force and radius force ( Ft ; Fa and Fr )
- The magnitude of each force is expressed as below:

38
 2  T1 103  cos  2  88.8723 103  cos(17.01)
Ft 2 = Ft1 = = = 3332.72( N )
m  Z1 3 17
F  tan  nw 3332.72  tan(20)
Fr1 = Fr 2 = t1 = = 1268.50( N )
cos  cos(17.01)
Fa1 = Fa 2 = Ft1  tan  = 3332.72  tan(17.01) = 1019.55( N )
Ft1 3332.72
 Fn 2 = Fn1 = = = 3729.15( N )
cos tw  cos  cos(20.84)  cos(17.01)
- The direction of forces acting to the gears as below picture:
+ Important notice:

+ In this case, the direction of both driving and driven gear are expressed
as below:

39
30.Determine the coefficient of loading on gear system:
- Determine the outside loading coefficient ( K A ): It depends on engine
loading and mixing – blade loading, which are considered by real
experiment and ordinary working, and in this design report, for easier, we
select this value as normal. Therefore, its value is K A = 1.0 .
- Determine the coefficient of concentration of weight loading ( K  ):
Because in reality, elastic distortion of shafts, elastic movement and
abrade of bearing, the manufacturing errors, the contact of gear system are
uneven a little, which considered as the width of tooth rim. Hence, that
coefficient is determined by two components, that is K H  - followed as
contacting pressure, and K F  - followed as bending pressure. Those
values have been found out in part 13 of this chapter, so in this part, we
only mention again this value: K H  = 1.05 and K F  = 1.14 .
- Determine the efficient of moving loading KV : Because the distortion of
tooth with the pitch error, the shape of tooth, … the transmission ratio will
be changed, this causes to the moving loading when meshing. This
coefficient continuously divides into two components as follow: K HV - will
derived from the contacting pressure and K FV - will derived from the
bending pressure. Those values are determined by this below table, which
fit to helical spur gear system:

 Because the precision grading for this transmission system is 9 and

both of driving and driven gears have under HB 350, and the lap
velocity of this gear system is only non – significantly higher than 1
m/s, so those values for K HV and K FV are 1.02 and 1.04 respectively.

40
 + If we check again these values by the formular, we can do these
steps:
• Check the values of  H and  F - which derived from the meshing
error of the gear system:

 The value of  H = 0.002 and  F = 0.006 , which helical spur gear reducer.
• Check the values of g o , which derived from the error of the
pitch circle of driving gear and driven gear as below picture:

 Because the precision grading of this reducer is 9, and module m of

this gear system is 3, so the value we select is g o = 73 .
• The intensity of loading concentration based on contacting and
bending pressure are computed as below:
aw 160
vH =  H  go  v  = 0.002  73 1.12  = 0.925( N / mm)
u 5
aw 160
vF =  F  go  v  = 0.006  73 1.12  = 0.278( N / mm)
u 5

41
  Both of the values are widely lower than vH max and vF max are shown in
this below picture, so those value in the formula will be chosen:

 The precision grading of this reducer is 9, and the module m of the

gear system is 3, so the value of vH max = vF max = 700( N / mm)
• The value of K HV and K FV , if we calculate by the formula, will
be:
vH  bw  d w1 0.925  64  53.33
K Hv = 1 + = 1+ = 1.015
2 10  T1  K H  K H 
3
2 103  88.8723 1.13 1.05

vF  bw  d w1 0.278  64  53.33
K Fv = 1 + = 1+ = 1.003
2 10  T1  K F  K F 
3
2 10  88.8723 1.37 1.14
3

• We compare these values with the values that we have recently

found out in the table as follow:
1.015 − 1.02
= 100% = 0.49%  4% => the value in the table is
1.015
trustable.
1.003 − 1.04
= 100% = 3.68%  4% => the value in the table is
1.005
trustable.
- Determine the concentration of uneven concentration between teeth ( K ):
It continuously divides into two components K H , which derived from the
contacting pressure, and K F , which derived from the bending pressure.
+ The value of K H can be found out in this below picture:

42
  With the precision grading of the reducer is 9, and lap velocity of this
transmission system is under 2.5 m/s, so the value of K H = 1.13 .
+ Because the vertical meshing coefficient  b is widely higher than 1, so
if we want to find the value of K F , it should be as follow:
4 + (  − 1)  (ncx − 5) 4 + (2.35 − 1)  (9 − 5)
K F = = =1
4   4  2.35
+ If we check the value of K F in the below table, there is a noticeable
error that we have to consider as follow:

 The error can be computed by follow:

1.37 − 1
= 100% = 27.01%  4% => so, we select the number in the table to
1.37
compute!

31.Determine the computational pressure  H on meshing area:

- Determine the coefficient of surface - shape meshing ( Z H ) by given
formula:

43
 4  cos  4  cos(17.01)
ZH = = = 2.398
sin(2   tw ) sin(2  20.84)
- Determine the coefficient of the total length contacting of the teeth:
1 1
Z = = = 0.652
 2.35
- Determine the coefficient of mechanical properties, with have already
calculated in part 15 of this chapter, so we repeatedly used this value for
further computation: Z M = 191.65
- Determine the contacting pressure of the gear system:
Z M  Z H  Z 2 103  T1  K H  (u + 1) 191.65  2.398  0.652 2 103  88.8723 1.05 1.02  (5 + 1)
H =  =  = 335.68( MPa)
d w1 bw  u 53.33 64  5

- Comment: This value of contacting pressure of the reducer is significantly

lower than the allowable contacting pressure  H  = 483.83MPa , so we do
not need to change any value of the diameter, axial distance, or materials
as below:
335.68 − 483.83
= 100% = 44.13%  4%
335.68
In which K H = K H   K Hv

32.Determine the equivalent number of teeth of helical spur gear:

- The equivalent of the number of teeth on the driving gear in straight spur
gear as below:
Z1 17
zv1 = = = 19.44  20(teeth)
cos  cos (17.01)
3 3

- The equivalent of the number of teeth on the driven gear in straight spur
gear as below:
Z2 85
zv 2 = = = 97.21  98(teeth)
cos  cos (17.01)
3 3

33.Determine the coefficient of bending pressure YF:

- Because in helical spur gear, there is no moving teeth coefficient so x = 0.
- The coefficient of bending coefficient for driving gear:
13.2 13.2
YF 1 = 3.47 + = 3.47 + = 4.25
Z1 17
- The coefficient of bending coefficient for driven gear:
13.2 13.2
YF 2 = 3.47 + = 3.47 + = 3.63
Z2 85

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34.Comparing the properties of the ability of bending pressure:
- We take the lower allowable bending pressure  F 1  = 288MPa and
 F 2  = 246.86MPa
 In this case, we choose the lower value, so  F  = 246.86MPa is selected
- The ability of bending pressure on driving gear:
 F  = 246.86 = 58.08
YF 1 4.25
- The ability of bending pressure on driven gear:
 F  = 246.86 = 68.01
YF 2 3.63

35.Computing the bending pressure:

- Determine the coefficient of longitudinal meshing:
1 1
Y = = = 0.43
 2.35
- Determine the coefficient of tooth tilt angle to bending pressure:
 17.01
Y = 1 −  b  = 1 − 1.99  = 0.72
120 120
- Determine the bending pressure for driving gear:
YF 1  Ft1  K F  Y  Y 4.25  3332.72 1.14 1.04  0.43  0.72
 F1 = = = 27.08MPa
bw  m 64  3
- Determine the bending pressure for driving gear:
YF 2  Ft 2  K F  Y  Y 3.63  3332.72 1.14 1.04  0.43  0.72
F2 = = = 23.13MPa
bw  m 64  3
• In which: K F = K F   K Fv
- Comparing the bending stress we have recently found with the allowance
bending stress before:
 Both values are extensively lower than  F  = 246.86MPa , so we do not
need to change the number of teeth or materials.

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CHAPTER 4: DESIGNING SHAFTS

CHAPTER 5: SELECTING BEARINGS

CHAPTER 6: SELECTING LUBRICATIONS METHODS

CHAPTER 7: SELECTING KEYS, COUPLINGS

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