MECG1043 DESIGN PROJECT

REPORT
Faculty of Mechanical Engineering and Production Sciences.

Design Project

Design of an Overhanging Countershaft

Date:

December, 2, 2020

Name:

Adriana Belén Rodrı́guez Torres

Instructor:

Ing. Carlos Helguero Alcı́var, PhD.

II Término - 2020

Guayaquil - Ecuador
Contents
List of Figures 1

List of Tables 1

1 Introduction and Objectives 2

1.1 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.1 General objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.2 Specific Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Design criteria and assumptions 2

3 Design procedures and descriptions with abridged Derivations 3

4 Results and discussions 3

5 Conclusions and Recommendations 4

References 5

A Appendix 6
A.1 Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A.2 Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A.3 Counter-shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A.3.1 Critical rotating speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B Design planes 23
List of Figures
1 X-Z plane loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Shear stress diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Bending moment diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 X-Y plane loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Shear stress diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Bending moment diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Torque diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Shaft loads, english system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9 Detail of the dimensions for the shaft . . . . . . . . . . . . . . . . . . . . . . . . . 23
10 Detail of the dimensions for the spur gears . . . . . . . . . . . . . . . . . . . . . . 24

List of Tables
1 Results of the countershaft design . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Detail of the value of the factors used to bending stress . . . . . . . . . . . . . . 12
3 Detail of the value of the factors used to correct the fatigue strength . . . . . . . 15

1
1 Introduction and Objectives
1.1 Objectives
1.1.1 General objective
Design a countershaft or transmit to power of 5 hp at 2000 rpm. The same is comprised of a
hanging pulley and gear. Using the methodology learned for the design of mechanical elements.

1.1.2 Specific Objectives

(i) The slope of the countershaft at the bearings O and R should not exceed 0.06 for good
bearing life.

(ii) Make appropriate assumptions for the design of the mechanical system, justifying them
through the calculations.

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

1.2 Introduction
Drive shafts are a fundamental part of transmissions in the field of mechanical engineering
and have a wide application in the machine industry. The transmission shaft is subjected to
a constant torsional stress that causes a shear flow and bending stresses of a variable type, in
addition there is an axial load that arises from the gear on the transmission element, which
must preferably be deflected towards the ground, through the use of non-friction type bearings
to support axial loads.
In this project, an axis is designed with a power to transmit of 5 hp at 2000 rpm, whose
elements will be made up of a pinion-gear, a V-type pulley and two bearings. The type V
pulley is cantilevered and is in charge of transmitting the movement granted by the motor and
its driving pulley, for which the studied design criteria are used, thus allowing the dimensions
of each element to be established.

2 Design criteria and assumptions

For this project, it is established that the diameter of the driving pulley, that is, of the motor, has
10.5 in so that the speed delivered by it is equivalent to 3000 rpm, likewise, it was considered that
the pulley will be type B, as indicated by table 17-9 of Shigley’s book [1] with a circumference
length equal to 93, which according to the specifications meets the requirements indicated by
the initial project document, hence the established step length for layout equals 94.8 in with
26.66 in center distance. In addition, since the loads indicated for the shaft are d light type, a
service factor Ks equal to 1.5 and a tabulated power (Table 17-12) of 490 hp was established,
finally for the case of the pulley, a friction coefficient equal to 0.5123 was used according to
the criteria of the Gates Rubber Company, which recommends this value as effective in the
case of V-pulleys. In the case of the gears, a transmission ratio between gears was established
equal to 1.96, so the pinion teeth being determined by the problem with a value of 24, the gear
teeth were determined with a value of 47, which they also allow to avoid undermining in the
element; additionally the pressure angle φ is considered to be 20 °. For the design of the shaft,
the material recommended by the project document was selected, which indicates AISI 1018
steel cold rolled for this application with a working temperature equal to 75 ° C. Finally, the
dimensions for each section of the shaft in the variation of the diameters are specified in the
section of drawings of the appendices.

2
3 Design procedures and descriptions with abridged Derivations
The process carried out for the design of the transmission system consisted of three parts divided
according to each element present, that is; pulley, pinion-gear, shaft. Therefore, the starting
point is the selection of the type of pulley that meets the design specifications, from which,
using the tables provided by the manufacturers set out in the guide text [1], allow defining
the circumference and pitch length , for the subsequent analysis of the forces implicit in the
element; With these defined data, the distance between centers with which the coverage angles
are defined was obtained, which in turn depends on the values between the diameters of the
driven and driving pulley, a value that arises from the relationship between pulleys. Afterwards,
the power allowed by the band is established, which consists of the application of correction
factors of the coverage angle K1 and the correction of band length K2 , the design power is
obtained from the design factor that suggests the project with 1.85 and of service, considered of
slight impact. In this way, the corresponding relationship for the number of bands is obtained,
which defines the use of 3 bands in V as necessary.Finally, the loads that the band will experience
(detailed in the pulley section of the appendices) are obtained to obtain the factor security and
life in hours of the pulley. For the calculation of gears, the relationship defined in the previous
section was used, for which it was possible to obtain the base pitch, circular pitch, and internal
and external diameters of the pinion and gear, in addition to the variables indicated for the
addendum, deddendum and element contact ratio. For both bending and surface stresses, it is
necessary to define the existing loads on the pinion-gear, primarily the tangential load, which
depends only on the applied torque and the pinion diameter; subsequently, the factors related
to the formula corrected by AGMA for the efforts are determined and in this way the validity
of the design is verified with the calculation of the corresponding safety factors for each case.
Finally, for the shaft design, the starting point is to obtain the material properties to determine
the uncorrected fatigue resistance, which allows finding the corrected fatigue resistance using
the factors detailed in the shaft calculations section in appendices, thus obtaining the resistance
that the shaft supports for the established working conditions, then statics is applied to the
element to determine the forces and reactions in the bearings to finally apply the equation
provided in Mott’s book, for the calculation of diameters of axis.[2].

4 Results and discussions

D1 0.127 in
D2 0.691 in
D3 0.820 in
D4 1.11 in
D5 1.32 in
D6 0.363 in
Wcrit 2049.27 rpm

Table 1: Results of the countershaft design

With the results obtained for the dimensions of the shaft, it is observed that the calculated
diameters are the minimum value required so that the system does not present any problem,
thus complying with the necessary requirements for the preparation of the project, however,
new values can be established using a safety factor other than the one suggested, in order to
guarantee better durability in the design. In addition, it is appreciated that the critical speed of
the shaft, which represents the point where the natural vibration and the angular speed reach
the same value, is within the ranges allowed to guarantee the operation of the system, said
value is obtained from the Approximation of the Rayleigh-Ritz method from the calculation of

3
deflections (detailed in the annexes section). In the case of the loads supported by the bearings,
due to the existence of axial load generated by the pinion, the use of non-friction bearings
is required to absorb said load towards the ground. Finally, it is obtained that the stresses
supported by the pulley and the loads caused by the gears do not exceed the limits of resistance
to fatigue of the material used for the shaft and for the other elements.

5 Conclusions and Recommendations

With what was obtained through the calculations, it is appreciated that the presented design
meets the necessary requirements, allowing it to fulfill the power transmission function along
the axis and its elements. Furthermore, it is appreciated that the elements are designed with
the minimum necessary dimensioning, which implies a reduction in manufacturing costs by
requiring less material; in addition, in the case of bearings used for the shaft, spherical knee
bearings and cylindrical roller thrust bearings are established, so that they can counteract the
effect of misalignment and the load applied to the gear, indicated among the determining factors
of the draft. In addition, a retainer groove is suggested for, so that a better fit can be obtained
on the elements, specifically on the gear. Corresponding design parameters could be established
according to the indications for the length of the V-pulley, as well as for the gear ratio. The
system design has a life in hours of 15966 for the 3 V pulleys and an operating cycle equivalent
to 1.5x109 cycles for the gear, in addition the shaft is designed for infinite life from the respective
stress analysis of bending moment, this being variable and the torque transmitted by the pulley,
which remains constant.

It should be noted that the most optimal way to carry out the coupling of elements on the
shafts are the shoulders, for this reason there are section changes in the final design, which
in turn help to reduce vibration levels. As a recommendation, it is suggested to keep short
distances from the axis, so that the effects of bending due to the moment can be minimized,
as well as to use wedges or keyways in the design to obtain a better transmission of power; In
addition, the possibility of iterating with the formula used from the mott’s book mot to find
new diameter values that are within the permissible range at a value of a safety factor acceptable
to the designer. Finally, despite the fact that the system fulfills the functions and conditions
set out initially, it is advisable to consider a change in the type of pulley used in the overhang,
since for this type of applications it is more convenient to use flat belts than to their own. They
allow to reduce costs and time in the manufacture of the same and also consider a motor with
a larger diameter of pulley in case of requiring to reduce the investment price in the raw material.

4
References
[1] R. G. Budynas and J. K. Nisbett, Diseño en ingenierıa mecánica de Shigley. McGraw-Hill
Interamericana, 2012, vol. 8.
[2] R. L. Mott et al., Machine Elements In Mechanical Design by Robert L Mott: Machine
Elements In Mechanical Design. Digital Designs, 1992.
[3] R. L. Norton, Diseño de máquinas. TJ233. N67 1999. 1999.

5
A Appendix
A.1 Pulley
For this project, a motor that delivers a speed of 3000 rpm is taken into consideration, therefore
the diameter of the driving pulley will be:

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

Lp = L + Lc

Lp = 93 + 1.8 = 94.8 in

The distance between centers of the pulley will be:

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

The rotational speed is given by the following expression:

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

For the forces acting on the pulley, it is necessary to find the angle of coverage:
 
D−d
φ = θd = π − 2 arcsin
2C
 
15.748 − 10.5
φ = θd = π − 2 arcsin
2 ∗ 26.66
φ = θd = 2.94 rad

Power allowed by the band:

Ha = k1 K2 Htab

According to Shigley’s book [1], Htab =4.90 hp, k1 =0.967 and k2 =1.

6
Tables: 17-12, 17-13 and 17-14 respectively.

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

Design Power:

Hd = Hnom ks nd

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

Hd = 5 ∗ 1.2 ∗ 1.86
Hd = 11.1 hp

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

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

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

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

According to table 17-16, kc =0.425.

2625π 2
Fc = 0.425 ∗ ( )
1000
Fc = 28.9 lbf Fc = 128.55 N

The largest tension F1 :

∆F e(f φ)
F1 = Fc +
e(f φ) − 1

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

7
 F1 = 47.93 lbf F1 = 213.2 N

Lowest tension F2 :

F2 = F1 − ∆F F2 = 33.12 lbf = 147.33 N

Factor of safety:
Ha Nb
ηf s =
Hn omKs

4.74 ∗ 3
ηf s = ηf s = 2.3
5 ∗ 1.2

Durability correlations:

kb
T1 = F1 + F (b )1 = F1 +
d

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

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

Therefore the number of passes that can give the band until it complies with its life, is given
by:

K −b K −b −1
Np = [( ) + ) +]
T1 T2
728 −12.464 728 −12.464 −1
Np = [( ) + ) +]
69.83 62.54
Np = 3.91x1012

As the value of Np > 109 , and its range of validity is limited by that value, Np = 109 is used:

Np Lp
t=
720V
109 ∗ 94.8
t=
720 ∗ 2625π
t = 15966 h

8
A.2 Gear
For the design of the gear train consisting of a pinion 24 teeth with a diametral pitch of 10 and
a gear 47 teeth, the following is established:

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

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

Base Pitch:
Pb = Pc cos φ

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

Pb = Pc cos 20

Pb = 0.295 in Pb = 7.49 mm

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

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

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

Nominal distance between centers:

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

9
Adendum and Dedendum from Table-8-1.[3]
1
a=
Pd
1
a=
10
a = 0.1 in a = 2.54 mm

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

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

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

Outer diameter of the pinion and gear:

Dop = dp + 2a

Dop = 2.4 + 2 ∗ (0.1)

Dop = 2.6 in Dop = 66.04 mm

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

Contact Ratio:
z
mp =
Pb

To know the contact ratio, it is necessary to find the action length, which is given by the
following equation:
q q
Z = (rp + a)2 − (rp cos φ)2 + (rg + a)2 − (rg cos φ)2 − C sin φ

10
 r r
dp dp dg dg
Z = ( + a) − ( cos φ) + ( + a)2 − ( cos φ)2 − C sin φ
2 2
2 2 2 2
r r
2.4 2.4 4.7 4.7
Z= ( + 0.1)2 − ( cos 20)2 + ( + a)2 − ( cos 20)2 − 3.55 ∗ sin 20
2 2 2 2
Z = 0.494 in Z = 12.548 mm

0.494
mp =
0.295
mp = 1.67

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

Solving for T:
63000 P
T =
n
63000 ∗ 5
T =
2000
T = 157.5 lbf.in T = 17.79 N.m

Tangential component of force in Pinion:

T
Wt =
rp

T
Wt = dp
2
157.5
Wt = 2.4
2
Wt = 131.25 lbf Wt = 583.83 N

Radial component of force in Pinion:

Wr = Wt ∗ tan φ

Wr = 131.25 ∗ tan 20
Wr = 47.77 lbf Wr = 212.49 N

Total load:
Wt
W =
cos φ
131.25
W =
cos 20

11
 W = 139.67 lbf W = 621.28 N

The bending stress in the gear elements is obtained from the equation modified by recommendation
of AGMA:

Wt ∗ Pd Ka Km
σb = Ks KB KI
FJ Kv

Service Factor KA 1
Size Factor Ks 1
Ring thickness factorKB 1
Idler gear factor KI 1
Load distribution factor Km 1.6
Dynamic Factor Kv 0.821

Table 2: Detail of the value of the factors used to bending stress

For the case of KA it is considered uniform load and for KB the gear made of solid disk is
chosen. For the dynamic factor the following applies:

A
Kv = ( √ )B
A + Vt
2
(12 − Qv ) 3
B=
4
A = 50 + 56(1 − B)

ft
Quality Qv is used with a value of 9 by the tangential velocity equal to 1256.63 min .
2
(12 − 9) 3
B= = 0.52
4
A = 50 + 56(1 − 0.52) = 76.88
76.88
Kv = ( √ )0.52
76.88 + 1256.63
Kv = 0.821

Finally, the geometric factor for the pinion and gear is obtained from Figure 9-10 [2].

Jp = 0.355 Jg = 0.40

131.25 ∗ 10 1 ∗ 1.6
σbp = ∗1∗1∗1
1.2 ∗ 0.3555 0.821
σbp = 6.004 ksi
131.25 ∗ 10 1 ∗ 1.6
σbg = ∗1∗1∗1
1.2 ∗ 0.4 0.821
σbg = 5.329 ksi

12
Stress to surface fatigue:
s
Wt CaCm
σc = Cp ∗ Cs Cf
F Idp Cv
Being analogous to the effort previously calculated, we obtain:

Ca = KA , Cm = Km , Cv = Kv , Cs = Ks

For finishing surface factor Cf , is considered equal to 1, since the manufacturing will be carried
out using conventional methods. The elastic coefficient Sp is used with a value of 2300 = [psi]0.5
for a steel-steel combination of the gear pinion[2].
The surface geometric factor is obtained from I:
cosφ
I= )dp
( ρ1P+ ρ1g

Where curvature radius of the pinion and gear equals:

r
1 + xp 2 π
ρp = (rp + ) − (rp cos φ)2 − cosφ
Pd Pd
r
2.4 1 2.4 π
ρp = ( + )2 − ( cos 20)2 − cos20
2 10 2 10
ρp = 0.352 in

ρg = Cφ − ρp
2.4 + 4.7
ρg = ( )20 − 0.352
2
ρg = 0.862 in

cos20
I= 1 1 )2.4
( 0.352+ 0.862
I = 0.098

Finally: r
131.25 1 ∗ 1.6
σc = 2300 ∗ 1∗1
1.2 ∗ 0.098 ∗ 2.4 0.821
σc = 69.24 ksi

Now it is necessary to find the resistance of the material:

For bending:
KL
Sf b = Sf b0
KT KR

Sfb’ represents the resistance of the material not corrected to fatigue, which, according to table

13
8-20 corresponding to fully hardened A1 steel, is equivalent to 27 ksi:
For the life factor KL it is necessary to determine the number of cycles N:
60 min 2030 hr
N = 2000 rpm ∗ ( )∗( ) ∗ (6 años) ∗ (1 turno)
1 hr turno − año
N = 1.5x109 ciclos
Thus
KL = 1.3558(1.5x109 )−03.0178
KL = 0.93
Finally, like KT = 1, because T < 250°F, and KR = 1 because the reliability is 99
0.93
Sf b = Sf b0
1∗1
Sf b = 25.11 ksi
Therefore, the factor of safety for the pinion and gear is

Sf b
Nbp =
σbp
25.11
Nbp =
6.004
Nbp = 4.2

Sf b
Nbg =
σbg
25.11
Nbg =
5.329
Nbg = 4.7

For surface stress:

CL CH
Sf c = Sf c0
CT CR

As in the previous case, CT = KT ,CR = KR and CH = 1: Using the same amount of cycles,
the life factor CL for surface stress:
CL = 1.4488N −0.023
CL = 1.4488(1.5x109 )− 0.023
CL = 0.89

Using Sfc’=87 ksi, from table (8-21):

0.89 ∗ 1
Sf c = ∗ 87
1∗1
Sf c = 77.43 ksi

Therefore, the factor of safety for the pinion and gear is:
Sf c 2
Nc = ( )
σc
77.43 2
Nc = ( )
69.24
Nc = 1.3

14
A.3 Counter-shaft
The material used in this shaft is AISI 1018 Cold rolled type. The properties of the same are
as follows:

Sy = 53.7 ksi Sy = 370 M P a

Sut = 63.8 ksi Su t = 440 M P a

Uncorrected fatigue strength is obtained as:

Se0 = 0.5 ∗ Sut

Se0 = 0.5 ∗ 63.8

Se0 = 31.9 ksi

To correct the fatigue strength, the following factors are taking in consideration:

Size factor Cta 1 Is considered equal to one for shaft design

Temperature factor CT 1 Working temperature less than 450 °C
Load factor Cca 1 Combined stresses equivalent to Von misses sigma axial load
Surface factor Csup 0.9 Machined surface
Reliability factor CR 0.814 Employing 99% reliability

Table 3: Detail of the value of the factors used to correct the fatigue strength

Therefore, the corrected fatigue strength will be:

Se = Cca CT Cta Csup CR Se0

Se = (0.814) ∗ (0.9) ∗ (31.9)
Se = 23.37 ksi
For loads on the shaft, it is solved through statics;dividing the analysis for forces and moments
into two planes:

XZ Plane:

Figure 1: X-Z plane loads

15
 ↑ X
+ Fz = 0
Oz − W rA + Rz = 0

xX
+ Mo = 0
−W rA (0.25) + Rz (0.25 + 0.27) = 0
212.49(0.25)
Rz =
0.52
Rz = 102.16 N Rz = 22.97 lbf

Oz = W rA − Rz
Oz = 212.49 − 102.16
Oz = 110.33 N Oz = 24.80 lbf

Shear stress and bending moment diagrams:

Figure 2: Shear stress diagram

16
 Figure 3: Bending moment diagram

XY Plane:

Figure 4: X-Y plane loads

↑ X
+ Fy = 0
Oy − W tA + Ry − By = 0

xX
+ Mo = 0
−W tA (0.25) + Ry (0.25 + 0.27) − By (0.25 + 0.27 + 0.3) = 0

By represents the pulley forces:

By = 213.2 + 147.33 + 7 ∗ 9.8

By = 429.13 N By = 96.47 lbf

429.13(0.82) + 583.83(0.25)
Ry =
0.52
Ry = 957.39 N Ry = 215.23 lbf

17
 Oy = By + W tA − Ry
Oy = 429.13 + 583.83 − 957.39
Oy = 55.57 N Oy = 12.49 lbf

Shear stress and bending moment diagrams:

Figure 5: Shear stress diagram

Figure 6: Bending moment diagram

18
For the shaft diameters, the formula obtained from Mott’s book is used[2]:
s 1
3
32 N Kt M 2 3 T 2
D=[ [ ] + [ ] ]
π Se 4 Sy

It is necessary to remember that the torque experienced by the shaft will be constant from A
to B:

Figure 7: Torque diagram

For ease of calculation, since most of the variables calculated throughout this process have been
presented in the english system, the system will choose to keep in calculating the diameters.

O point:

At this point no torque or moment is experienced, however there is a vertical force that is
applied to the bearing at O, therefore the suggested diameter for the design will be:

r
Kt V N
D1 = 2.94
Se
q 2
V = Vy 2 + Vz
p 2
V = 12.492 + 24.80
V = 27.768 lbf
Kt = 2.5, for stress concentration factor because of the small fillet radius necessary to permit
the firm seating of the face of the bearing race.
r
2.5 ∗ 27.768 ∗ 1.85
D1 = 2.94
46.74x103

19
 r
2.5 ∗ 27.768 ∗ 1.85
D1 = 2.94
23.37x103
D1 = 0.127 in

A point

To the left of A there is no torque, so the formula simplifies to the following:

r 1
32 N Kt M 2 3
D2 = [ [ ] ]
π Se

Using Kt equals to 1.5 for well-rounded fillet, and for the resultant moment:

MAY = 13.8925 N MAY = 122.959 lb.in

MAZ = 27.583 N MAY = 244.13 lb.in

q
MA = MAz 2 + MAy 2
p
MA = 244.132 + 122.9592
MA = 273.35 lbf.in

r 1
32 1.85 2 ∗ 273.35 2 3
D2 = [ [ ] ]
π 23.37x103
D2 = 0.691 in

To the right torque exists, therefore, with Kt = 2.5:

r 1
32 ∗ 1.85 2.5 ∗ 273.35 2 3 157.5 2 3
D3 = [ [ ] + [ ] ]
π 23.37x103 4 53.7x103
D3 = 0.820 in

R point

Using Kt = 1.5 for well rounded fillet:

MRy = 128.7377 N MRy = 1139.424 lb.in

MRz = 0 N = 0 lb.in
MR = 1139.424 lb.in

20
 r 1
32 1.85 1.5 ∗ 1139.424 2 3 157.5 2 3
D4 = [ [ ] + [ ] ]
π 23.37x103 4 53.7x103
D4 = 1.11 in

Using Kt = 2.5, sharp fillet:

r 1
32 1.85 2.5 ∗ 1139.424 2 3 157.5 2 3
D5 = [ [ ] + [ ] ]
π 23.37x103 4 53.7x103
D5 = 1.32 in

B point

There is no bending moment:

r 1
32 1.85 3 157.5 2 3
D6 = [ [ ] ]
π 4 53.7x103
D6 = 0.363 in

A.3.1 Critical rotating speed

To find the critical speed of rotation, it is used the following formula using the values calculated
in the English system.

Figure 8: Shaft loads, english system

Using singular functions:

d2 y
EI = 12.48 < x − 0 > −131.25 < x − 9.85 > +215.23 < x − 20.48 >
dx2
dy 12.48 131.25 215.23
EI = < x − 0 >2 − < x − 9.85 >2 + < x − 20.48 >2 +C1
dx 2 2 2
12.48 131.25 215.23
EIy = < x − 0 >3 − < x − 9.85 >3 + < x − 20.48 >3 +C1 x + C2
6 6 6

Boundary conditions:

x=0 y=0 x = 32.29 y = 0

21
Solving for C1 and C2 :

C2 = 0
12.49 131.25 215.23
0= (32.29)3 − (22.44)3 + (11.81)3 + C1 (31.29)
6 6 6
C1 = 3654.7

For the deflections needed:

π 4
The inertia will be calculated as I = 64 d , and Young module E = 30x106 :

Oy=12.48 lb (x=0)
30x106 ∗ 1.25x10−5 y1 = 0
y1 = 0

WtA=131.25 lb (x=9.85 in)

12.48
30x106 ∗ 0.011 y2 = < 9.85 − 0 >3 +3654.7(9.85)
6
y2 = 0.0011

RA=215.23 lb (x=20.48 in)

12.48 131.25
30x106 ∗ 0.0075 y3 = < 20.48 − 0 >3 − < 20.48 − 9.85 >3 +3654.7(20.48)
6 6
y3 = 0.0031

By=215.23 lb (x=32.29 in)

30x106 ∗ 8.523x10− 4 y4 = 12.48

6 < 32.29 − 0 >3 − 131.25
6 < 32.29 − 9.85 >3 + + 215.23
6 <
3
32.29 − 20.48 > +3654.7(32.29)
y4 = 3.2x10−6

Finally:
X
Wi yi = 12.49(0) + 131.25(0.001) + 215.23(0.031) + 96.47(3.2x10− 6)
X
Wi yi = 5.8x10−4
X
Wi yi2 = 12.49(0)2 + 131.25(0.001)2 + 215.23(0.031)2 + 96.47(3.2x10− 6)2
X
Wi Yi2 = 4.86x10−6

s P
Wi yi
W = 386 P
Wi yi2
r
5.8x10− 4
W = 386
4.86−6
W = 214.6 rad/s W = 2049.27 rpm

22
B Design planes

Figure 9: Detail of the dimensions for the shaft

23
Figure 10: Detail of the dimensions for the spur gears

24