Project I Problem Statement-

It is required to design a gear train for two roller sugarcane crusher. The gear train
reduces the speed in two stages. The gear train receives power from a four stroke Engine.
The force of failure of sugarcane for rate of 15 Kg/hr is 140 N. Consider factor of safety
of 1.75 for failure force. Consider factor of safety 2 for gear design. Choose suitable
material for gear and design the components of the unit such as gears, shaft key also
select suitable bearings belt and pulleys.

Given:
m = 15 kg/hr, (F)failure= 140 N, (FOS)crusher = 1.75,
(FOS)geardesign= 2, (n)output =35 rpm, (D)crusher = 130 mm
Belt drive reduction = 4:1

Solution:
I]First we determine torque.
1) Force required for crushing (Pc) = (F)failure * (FOS)crusher = 140*1.75 = 245 N
2) Let us consider 4 sugarcane passes through rollers,
Total crushing force (Pt) = 4*Pc = 980 N
3) Torque (Mt) = Pt * (R)crusher= 980*(130/2) = 63700 Nmm
4) Power required for crushing = (2π*n*Mt)/(60*106) = (2π*35*63700)/(60*106)
= 0.23347 kW
5) Let (η)motor = 80%
6) Power of motor required = 0.23347/0.8 = 0.29184 kW

II] Selecting standard motor of 1 HP = 0.7457 kW

1)Input Speed at gear train = 1440/4 = 360 rpm (Due to belt reduction)
Output speed at gear train = 35 pm
2) Transmission ratio (i’) = 360/35 = 10.2857
3) Gear ratio = i = √i’ = 3.2017

III]
1)We select first CI material(FG260) with Sut= 260 n/mm2
2) Designing Gear pair for First stage
n1= 360 rpm, n2=n3= 112.25 rpm, n4= 35 rpm,Z1=18, Z2= 58, Z3= 18,Z4= 58

For 200 Pressureangle,

Zp= 18 ,Zg = i*Zp = 58
Assume pitch line velocity (v) = 5 m/s
Cv= 3/(3+v) = 3/(3+5) = 0.375
From table 17.4, For heavy shock and uniform, Cs = 1.75
Lewis form factor for 18 teeth (y) = 0.308
For First stage,
m = {(60*106/π)*(P*Cs*FOS)/[Z1*n1*Cv*(b/m)*(Sut/3)*y]}1/3
= {(60*106/π)*(0.7457*1.75*2)/[18*360*0.375*10*(260/3)*0.308]}1/3
m = 5 mm
d1’ = 5*18 = 90 mm
d2’= 5*58 = 290 mm
b = 10*5 = 50 mm

IV] By using Buckingham’s Equation

Sb = m*b*σb*y = 5*50*(260/30)*0.308 = 6673.33 N
Tangential Force,
Torque = (60*106*P)/(2π*n1) = (60*106*0.7457)/(2π*360) = 19780..3Nmm
Pt= (2*Toque)/d1’ = (2*19780.3)/90 = 439.56 N
Now dynamic load
1) Pinion (grade 8)
e = 16+1.25ϕ,
but, ϕ = m+0.25√d1’
ep= 16+1.25(5+0.25√90) = 25.214 µm

2) Gear
Here, ϕ = m+0.25√d2’
eg= 16+1.25(5+0.25√290) = 27.57 µm
now,
e = ep+eg = 52.7856 µm = 52.7856*10-3mm
Deformation factorC for CI material is 5700.
v = (π*d1’*n1)/(60*103) = 1.6964 m/s

Pd= {21*v*(C*e*b+Pt)}/{21*v*√(C*e*b+Pt)}
= 6919.54 N

Peff = (Cs*Pt)+Pd = (1.75*439.56)+6919.54 = 7688.77 N

But Peff>Sb, Hence design is not safe.
Hence we need to increase the module.
Let us consider m = 8
d1’ = 8*18 = 144 mm
d2’= 8*58 = 464 mm
b = 8*10 = 80 mm
By using Buckingham’s Equation
Sb = m*b*σb*y = 8*80*(260/30)*0.308 = 17083.73 N
Torque = (60*106*P)/(2π*n1) = (60*106*0.7457)/(2π*360) = 19780.3 Nmm
Pt= (2*Toque)/d1’ = (2*19780.3)/144 = 274.72 N

Now dynamic load

1) Pinion (grade 8)
e = 16+1.25ϕ,
but, ϕ = m+0.25√d1’
ep= 16+1.25(8+0.25√144) = 29.75 µm

2) Gear
Here, ϕ = m+0.25√d2’
eg= 16+1.25(8+0.25√464) = 32.73 µm
now,
e = ep+eg = 62.48 µm = 62.48*10-3mm

Deformation factor C for CI material is 5700.

v = (π*d1’*n1)/(60*103) = 2.714 m/s
Pd= {21*v*(C*e*b+Pt)}/{21*v*√(C*e*b+Pt)}
= 7235.1249 N

Peff = (Cs*Pt)+Pd = (1.75*274.72)+7235.1249 = 7715.8849 N

FOS = Sb / Peff = 2.214 > 2. Hence design is safe and acceptable.

Also, Sw= FOS*Peff = 7715.88*2.214 = 17083.719 N

But Sw= b*q*dp’*k = 80*(2*58/58+18)*144*(BHN/100)2*0.16
(BHN/100)2 = 6.072
BHN = 246.41
Now mass of gear and pinion,
Ρ = 7000 kg/m3
Mp=π*(d1’)2*b*ρ/4 = 9.12 kg = 89.72 N
Mg = π*(d2’)2*b*ρ/4 = 94.69 kg = 928.92 N

V] Design for second stage

n3 = 112.25 rpm, n4 = 35 rpm, y = 0.308
Cs = 1.75, Cv= 3/(3+v) = 3/(3+5) = 0.375
m = {(60*106/π)*(P*Cs*FOS)/[Z1*n1*Cv*(b/m)*(Sut/3)*y]}1/3
= {(60*106/π)*(0.7457*1.75*2)/[18*112.25*0.375*10*(260/3)*0.308]}1/3
m = 6.2697 ~ 8 mm

d3’ = 8*18 = 144 mm

d4’= 8*58 = 464 mm
b = 8*10 = 80 mm

By using Buckingham’s Equation

Sb = m*b*σb*y = 8*80*(260/30)*0.308 = 17083.73 N
Torque = (60*106*P)/(2π*n3) = (60*106*0.7457)/(2π*112.25) = 63437.95Nmm
Pt= (2*Toque)/d3’ = (2*63437.95)/144 = 881.08 N

Now dynamic load

1) Pinion (grade 8)
e = 16+1.25ϕ,
but, ϕ = m+0.25√d3’
ep= 16+1.25(8+0.25√144) = 29.75 µm

2) Gear
Here, ϕ = m+0.25√d4’
eg= 16+1.25(8+0.25√464) = 32.73 µm
now,
e = ep+eg = 62.48 µm = 62.48*10-3mm

Deformation factor C for CI material is 5700.

v = (π*d3’*n3)/(60*103) = 0.84635 m/s
Pd= {21*v*(C*e*b+Pt)}/{21*v*√(C*e*b+Pt)}
= 2759.8 N
Peff = (Cs*Pt)+Pd = (1.75*881.08)+2759.8 = 4301.69 N
FOS = Sb / Peff = 3.9713> 2. Hence design is safe and acceptable.

Also, Sw= FOS*Peff = 3.9713*4301.69 = 17083.301 N

But Sw= b*q*dp’*k = 80*(2*58/58+18)*144*(BHN/100)2*0.16
(BHN/100)2 = 6.072
BHN = 246.41

VI] Design for third stage

N5 = 35 rpm, n6 = 35 rpm, y = 0.308, Z5 = Z6 = 37,
Cs = 1.75, Cv= 3/(3+v) = 3/(3+5) = 0.375
m = {(60*106/π)*(P*Cs*FOS)/[Z5*n5*Cv*(b/m)*(Sut/3)*y]}1/3
= {(60*106/π)*(0.7457*1.75*2)/[37*35*0.375*12*(260/3)*0.308]}1/3
m = 6.3802~ 7 mm

d5’ = 7*37 = 259 mm

d6’= 7*37 = 259 mm
b = 7*12 = 84 mm
M= π*(d5’)2*b*ρ/4 = 30.97 kg = 303.90 N

By using Buckingham’s Equation

Sb = m*b*σb*y = 7*84*(260/30)*0.308 = 19137.33 N
Torque = (60*106*P)/(2π*n5) = (60*106*0.7457)/(2π*35) = 203454.58 Nmm
Pt= (2*Toque)/d5’ = (2*203454.58)/259 = 1571.07 N
e = 2*ep= 2*[16+1.25(7+0.25√259)] = 59.55 µm = 5955*10-3
v = (π*d1’*n5)/(60*103) = 4.746*10-3 m/s
Pd= {21*v*(C*e*b+Pt)}/{21*v*√(C*e*b+Pt)}
= 1.5817 N

Peff = (Cs*Pt)+Pd = (1.75*1571.07)+1.5817 = 2750.95 N

FOS = Sb / Peff = 6.95> 2. Hence design is safe and acceptable.

Also, Sw= FOS*Peff = 6.95*2750.95 = 19119.1025 N

But Sw= b*q*dp’*k = 84*[(2*37)/(37+37)]*259*(BHN/100)2*0.16
(BHN/100)2 = 5.4927
BHN = 234.36

VII] Design of Pulley

Motor speed = 1440 rpm
ω = 2πN/60 = 150.79 rad/s
Motor torque = Motor Power / ω = (0.7457*103)/150.79 = 4.9450 Nm
Motor pulley diameter (Dm) = 58*(Motor torque)1/3 = 58*(4.9450)1/3 = 98.8136 ~ 100mm

Now,
Dm/Ds = N2/N1 ... (where Ds is shaft diameter).
100/Ds = 360/1440
Ds = 400 mm
Let weight of pulley = 26 N

VIII] Belt Design

Let thickness of belt = 11 mm … (selected B pulley)
Center distance (C) = 0.55*(D1+D2)+tb = 0.55*(100+400)+11 = 286 mm

Length of belt (L) = 2*C+[π*(D1+D2)/2]+[(D1+D2)/4*C]2

= 2*286+[π*(100+400)/2]+[(100+400)/4*286]2
= 1.357 m
From standard catalogue,
L = 1.37 m

Angle of wrap(α):
sin(β)= (r2-r1)/C = 0.5244
β = 31.630
1)For motor pulley, α1 = 180-2β = 116.730
2) For shaft pulley, α2 = 180+2β = 243.2620

Belt tension,
(T1-T2)*D2/2 = Torque = 19780 Nmm
(T1-T2) = 19780*2/400 = 98.9 N
Also,
T1/T2 = eµθ
Let µ = 0.24 and θ = 243.260 = 4.246c
T1/T2 = e0.24*4.246 = 2.7703
T1 = 2.7703*T2
Hence,
(2.7703-1)*T2 = 98.9
T2 = 55.8654 N
T1 = 111.7308 N

IX] Design of Shaft

1) Shaft 1

Let material of shaft is 50C4

Sut = 700 N/mm2
Syt = 460 N/mm2
Permissible Shear stess,
= 0.3*Sut=138 N/mm2
= 0.18*Syt = 126 N/mm2
τmax = 0.75*126 = 94.5 N/mm2
i)Horizontal Plane
Taking Moment about D,
(-167.59*700)+(500*RA)+(RB*140) = 0
RB*140 = 117313-500*RA
But,
RA+RB = 267.57 N
RB = 45.75 N and RA = 221.81 N
Bending moment at A = 167.59*200 = 33518 Nmm
Bending moment at B = 99.98*140 = 13997.2 Nmm

ii) Vertical Plane

RA+RB = 390.44 N
Taking Moment about A,
(364.44*500)-(RB*360)-(26*200) = 0
RB = 491.72 N

Hence, RA = -101.28 … (It means RA is in opposite direction).

RA = 101.28 N
Bending moment at B = 364.44*140 = 51021.6 Nmm
BMmax = 51021.6 Nmm

d3 = {(16/π*τmax)*√[(1.5*BMmax)2+(1.5*Torquemax)2]}
 = {(16/π*94.5)*√[(1.5*51021.6)2+(1.5*19780)2]}
= 4423.72
Hence, d = 16.41 mm
From standard catalogue d = 20 mm

2) Shaft 2

i)Horizontal Plane

Taking Moment about C,

(99.98*500)-(360*RD)-(320.6*40) = 0
RD = 103.23 N
But,
RC+RD = 420.66 N
RC = 317.4211 N
Bending moment at C = 12827.2Nmm
Bending moment at D = 99.98*140 = 13997.2 Nmm

ii) Vertical Plane

RC+RD = 2174.44 N
Taking Moment about C,
(1203.64*500)-(RD*360)-(970.8*40) = 0
RD = 1563.85 N
Hence, RC = 610.58 N
Bending moment at C = 970.8*40 = 38832 Nmm
Bending moment at D = 1203.64*140 = 168509.6 Nmm
BMmax = 168509.6Nmm

d3 = {(16/π*τmax)*√[(1.5*BMmax)2+(1.5*Torquemax)2]}
= {(16/π*94.5)*√[(1.5*168509.6)2+(1.5*63437.95)2]}
= 4423.72
Hence, d = 24.41 mm
From standard catalogue d = 25 mm

3) Shaft 3

Crusher roller material is stainless steel.

Ρ = 8000 kg/m3
Roller diameter = 130 mm
Mass of roller = (π/4)*(0.130)2*0.3*8000 = 31.85 kg = 312.5 N

i)Horizontal Plane

RE+RF = 671.8 N
Taking Moment about E,
(571.82*390)-(RF*350)-(99.98*40) = 0
RF = 625.74 N
RE = 46.055 N
Bending moment at E =99.98*40 = 3999.2Nmm
Bending moment at F = 571.82*40 = 22872.4Nmm
ii) Vertical Plane

RE+RF = 3684.97+(1.04*300) = 3996.97 N

Taking Moment about E,
(1874.97*300)-(RF*350)+(1.04*300*175)-(1810*40) = 0
RF = 2038.39 N
Hence, RE = 1958.57 N
Bending moment at E = 1812*40 = 72400Nmm
Bending moment at F = 1874.97*40 = 74998.8 Nmm
BMmax = 74998.8Nmm
Torque = 203454.58 Nmm

d3 = {(16/π*τmax)*√[(1.5*BMmax)2+(1.5*Torquemax)2]}
= {(16/π*94.5)*√[(1.5*74998.8)2+(1.5*203454.58)2]}
Hence, d = 25.97 mm
From standard catalogue d = 30 mm
4) Shaft 4

i) Horizontal Plane

RG+RH = 571.82 N
Taking Moment about G,
(571.82*390)-(RH*350) = 0
RH = 67.17 N
Hence, RG = -65.35 N … (It means RG is in opposite direction).
RG = 65.35 N
Bending moment at H = 571.82*40 = 22872.8 Nmm
ii) Vertical Plane
RG+RH = 1874.32+1.04*300 = 2186.32 N
Taking Moment about G,
(1874.32*390)-(RH*350)+(1.04*300*175) = 0
RH = 2244.528 N
Hence, RG = - 58.208 N … (It means RG is in opposite direction).
RG = 58.208 N
Bending moment at H = 1874.32*40 = 74972.8 Nmm
BMmax = 74972.8 Nmm
Torque = 203454.58 Nmm

d3 = {(16/π*τmax)*√[(1.5*BMmax)2 + (1.5*Torquemax)2]}
= {(16/π*94.5)*√[(1.5*74972.8)2 + (1.5*203454.58)2]}
= 17528.56
Hence, d = 25.97 mm
From standard catalogue d = 30 mm

X] Bearing Selection [We use single row deep groove ball bearing]
1) Shaft 1
n = 360 rpm, d = 20 mm, L10h = 20000 hrs, Load factor = 2.5
From shaft design,
PHA = 221.81 N , PHB = 45.75 N
PVA = 101.25 N , PVB = 491.72 N
PA = √[(PHA)2 +(PVA)2] = √[(221.81)2 +(101.25)2] = 243.83 N
PB = √[(PHB)2 +(PVB)2] = √[(45.75)2 +(491.72)2] = 493.84 N
This Bearing reaction are in radial direction, Axial reactions = 0
L10 = (60*n*L10H)/106 = (60*360*20000)/106 = 432 million rev.

Dynamic load carrying capacity,

CA = PA*(Load factor)*(L10)1/3 = 4608.09 N
CB = PB*(Load factor)*(L10)1/3 = 9332.99 N

At A, bearing no.16404 with C = 7020 N and

At B, bearing no.6204 with C = 12700 N are selected.

2) Shaft 2
n = 112 rpm, d = 25 mm, L10h = 20000 hrs, Load factor = 1.4
From shaft design,
PHC = 317.42N , PHD= 103.23 N
PVC= 610.58N , PVD = 1563.85 N
PC = √[(PHC)2 +(PVC)2] = √[(317.42)2 +(610.58)2] = 688.15 N
PD = √[(PHD)2 +(PVD)2] = √[(103.23)2 +(1563.85)2] = 1567.253 N
This Bearing reaction are in radial direction, Axial reactions = 0
L10 = (60*n*L10H)/106 = (60*112*20000)/106 = 134.4 million rev.
Dynamic load carrying capacity,
CC = PC*(Load factor)*(L10)1/3 = 4934.89 N
CD = PD*(Load factor)*(L10)1/3 = 11239.15 N

At C, bearing no.16005 with C = 7610 N and

At D, bearing no.6205 with C = 14000 N are selected.

3) Shaft 3
n = 35 rpm, d = 30 mm, L10h = 20000 hrs, Load factor = 1.4
From shaft design,
PHE = 46.05 N , PHF = 625.74 N
PVE = 1958.57 N , PVF = 2038.39 N
PE = √[(PHE)2 +(PVE)2] = √[(46.05)2 +(1958.57)2] = 1959.11 N
PF = √[(PHF)2 +(PVF)2] = √[(625.74)2 +(2038.39)2] = 2132.27 N
This Bearing reaction are in radial direction, Axial reactions = 0
L10 = (60*n*L10H)/106 = (60*35*20000)/106 = 42 million rev.

Dynamic load carrying capacity,

CE = PE*(Load factor)*(L10)1/3 = 9533.88 N
CF = PF*(Load factor)*(L10)1/3 = 10376.55 N

At E, bearing no.16006 with C = 11200 N and

At F, bearing no.16006 with C = 11200 N are selected.

4) Shaft 4
n = 35 rpm, d = 30 mm, L10h = 20000 hrs, Load factor = 1.4
From shaft design,
PHG= 65.35N , PHH= 637.17 N
PVG= 58.208N , PVH = 2244.528 N
PG = √[(PHG)2 +(PVG)2] = √[(65.35)2 +(58.208)2] = 87.51 N
PH = √[(PHH)2 +(PVH)2] = √[(637.17)2 +(2244.528)2] = 2333.21 N
This Bearing reaction are in radial direction, Axial reactions = 0
L10 = (60*n*L10H)/106 = (60*35*20000)/106 = 42 million rev.

Dynamic load carrying capacity,

CG = PG*(Load factor)*(L10)1/3 = 425.8619 N
CH = PH*(Load factor)*(L10)1/3 = 11354.42 N

At G, bearing no.61806 with C = 3120 N and

At H, bearing no.6006 with C = 13300 N are selected.