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Where:
R= radius of the roll
L= distance between rolls, 1 in.
d= diameter of the feed, 2 3/8 in.
= Nip angle, 20
)
R= 6.067001948 in.
D= 12.1340039
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
12
For the roll diameter, the calculated diameter is not available in the market so I use D = 15
available at http://www.gundlachcrushers.com/crushers/roll-crushers-coal-salts-lime-
minerals.cfm with a chisel tooth profile.
Solving for Feedrate:
Q= 60DWL
B
(t/h)
Where:
Q= crusher capacity
D= diameter of roll, m (15 in= 0.381 m)
W= width of the roll, m (50 in = 1.27 m)
= roll speed, 130 rpm
L= distance between rolls, m (1 in = 0.0381 m)
B
= bulk density of feed material, t/m
3
(.833 t/m
3
)
For the
B
of coal,
refer to http://wiki.answers.com/Q/What_is_the_density_of_coal.
Q= (60)(0.381)(1.27)(130)(0.0381)(.833)
Q= 376.3077383 t/h
Solving for the Crusher Power
From: http://www.gundlachcrushers.com/crushers, with data from a 2000 Series Roll Crusher I
can get the power required for the roll.
For a 2000 Series Roll Crusher
Single-stage and two-stage models
15" diameter rolls (380 mm)
Roll face up to 60" (1525 mm) wide
Motor Power, 20 kw (26.80965147 hp)
Capacity up to 400 tph
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
13
From the Design Hp Formula:
Design Hp =Transmitted Hp x Nsf
Where:
Nsf = 1.4+0.2 (Table 17.7 by Faires, p. 460)
Design Hp = 26.80965147 Hp
Transmitted Hp = 26.80965147 / 1.6
= 16.75603217 Hp
Comparing the power and the feedrate for commercial crusher.
P
1
/C
1
= P
2
/C
2
Where:
P
1
and C
1
= Power and Capacity for the crusher to be design
P
2
and C
2
= Power and Capacity for a commercial crusher
=
P
1
= 15.76356142 hp
Solving for Torque
P= 2TN
T=
Where:
P= 15.76356142 hp
N= 130 rpm
T=
x
T= 636.8615984 lb-ft
Solving for the Force Required
F=T/r
F =
x
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
14
F = 1018.978557 lb
Design horsepower to drive mechanism including losses
According to Morse, p.452, losses in V-belt is 5%.
Transmitted power on V-belt
Transmitted power on V-Belt= Required power to drive the crusher/0.95
= 15.76356142 / 0.95
= 16.59322255 hp
DRIVING SYSTEM DESIGN
V-Belt Design
Design Consideration:
Motor type: squirrel cage motor
Type of service: continuous (16 hr/day) service
V-belt material: Leather belt
From: http://www.engineeringtoolbox.com/electrical-motors-hp-torque-rpm-d_1503.html,
Power versus torque and motor velocity in electric motors Table.
Nearest capable of driving is:
Motor Power = 20 hp
RPM= 500 rpm
Solving for Design Hp
Design Hp =Transmitted Hp x Nsf
Where:
Nsf = 1.4+0.2 (Table 17.7 by Faires, p. 460)
Design Hp= 16.59322255 x (1.4+0.2)
= 26.54915608 Hp
(From figure 17.14 Belt Selection from Horsepower and Speed by Faires, p.457, I choose
section D)
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
15
Solving for the diameter of the drive and driven sheave
N
2
D
2
=N
1
D
1
Where:
N
1
= Motor speed, 500 rpm
N
2
= Crusher speed, 130 rpm
D
2
= diameter of the driven sheave
D
1
= diameter of the drive sheave
From: Table 17.3, Standard V-belt Lengths; Horsepower Constants (Faires, p. 458)
If D
2
= 48 in. and D
1
= 13 in.
N
2
= (13x500)/48
N
2
= 135.4166667 rpm
If D
2
=58 in. and D
1
= 16 in.
N
2
= (16x500)/58
N
2
= 137.9310345 rpm
If D
2
=58 in
and D
1
= 14 in.
N
2
= (14x500)/ 58
N
2
= 120.6896552 rpm
I choose D
2
=48 in. and D
1
= 13 in. which is nearest to 130 rpm.
Solving for center distance
(Eq. by Faires, p, 457)
C= [(D
2
+D
1
)/2]+D
1
or C =D
2
whichever is longer
C= [(48+13)/2]+13
C= 43.5 in.
I choose C = 48 in. which is longer
Note: The center distance is made adjustable so that the belts can be mounted into the grooves
without harmful stretching and so that initial tension can be maintained (Faires, p. 457).
Solving for belt length
(Eq. by Faires, p. 446 )
L = *(/2)(D
2
- D
1
)] + 2C + [(D
2
- D
1
)
2
/ 4C]
L = *(/2)(48
- 13)] + 2(48) + [(48
- 13)
2
/ 4(48)]
L=157.3580798 in.
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
16
From table 17.3, Standard V-belt length (by Faires p. 458) at section D, select D158 with pitch
length equal to 161.3 in.
Solving for V-belt speed
V
m
= D
1
N
1
/ 12
= (13)(500)/12
V
m
= 1701.696021 ft/min
Solving for kd (small diameter factor)
From: table 17.4, by Faires, p.459
D
2
/D
1
= (48/13)= 3.692307692
Kd= 1.14
Solving for Rated Hp
From equation by Faires, p.456
* (
Where :
V
m
= belt speed, 1701.696021 ft/min
Kd = 1.14
Rated hp constants:
a= 18.788
c= 137.7
e= 0.0848
Rated hp constants (from table 17.3, by Faires, p. 458)
* (
Rated Hp = 9.505200567 Hp
Solving for Adjusted Hp
Horsepower rating must be corrected for length of belt (Kl) and arc of contact (K). (Faires,
p.457)
Adjusted Hp = k
xk
l
(Rated Hp)
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
17
Where:
K
l
= Length correction factor, 0.92 from table 17.6 Length Correction Factors by Faires, (p.459)
k
0.80 0.87
K
= 0.884166668
Therefore,
Adjusted Hp = 0.92 x 0.884166668 x 9.505200567
= 7.731846993 Hp
Solving for Number of Belts
Number of Belts = Design Hp/ Adjusted Hp
= 26.54915608 / 7.731846993
= 3.433740489
Say 4 belts
Use 4 D158 leather V-belts with pitch length equal to 161.3 in. from section D, b x t = 1 in., 3/4
in., figure 17.14, Belt Section from Horsepower and Speed by Faires, p. 457.
Solving for the Tension
F1
F2
F
1
/ F
2
= e
f
Eq. 1
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
18
Where:
F
1
= total tension on the tight side, lb
F
2
= total tension on the slack side, lb
f = coefficient of friction, 0.25 from Table 16-15 Coefficient of Friction for Belts,
for leather on cast iron pulley
= arc of contact, rad
Computing the arc of contact
= , 180 2sin
-1
[ (D
2
D
1
) / 2C + - ( / 180)
= { 180 2sin
-1
[ (48 13) / 2(48) + - ( / 180)
= 2.395222057 rad
From eq.1
F
1
/ F
2
= e
f
F
1
= e
(.25) (2.395222057)
F
2
F
1
= 1.819943605 F
2
Eq.2
Power Transmitted on V-belt
From equation 16.7 (Daughtie and Vallance, p.383)
Hp = [ (F
1
F
2
) / 550 ] x V
m
Where:
Hp= transmitted Hp, 16.59322255 hp
F
1
=total tension on the tight side, lb
F
2
= total tension on the slack side, lb
m
= belt speed, 28.36153368 ft/sec
(F
1
-F
2
)= 550(16.59322255)/28.36153368
(F
1
-F
2
)= 321.7827023 Eq. 3
Equating equation 2 and 3
1.819943605 F
2
F
2
= 321.7827023
F
2
= 392.4449198 lbs.
F
1
= 1.819943605 (392.4449198)
F
1
= 714.2276221 lbs.
Solving for thickness of the sheave
T = width of the belt x number of belt
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
19
= (1 )x 4
T = 5 in.
Computing the weight of the motor sheave
W
1
= (/4) D
1
2
t
Where:
D
1
= diameter of the small sheave, 13 in.
t = thickness of small sheave, 5 in.
= density of pulley material used, 0.256 lb/in for ordinary cast iron from
Table 2-1, General Properties of commonly used materials (Doughtie and
Vallance, p.11)
W
1
= (/4)(13)
2
(5)(0.256)
W
1
= 169.8973307 lbs.
Computing the weight of the Driven sheave
W
2
= (/4) D
2
2
t
Where:
D
2
= diameter of the driven sheave, 48 in.
t = thickness of sheave, 5 in.
= density of pulley material used, 0.256 lb/in for ordinary cast iron from
Table 2-1, General Properties of commonly used materials (Doughtie and
Vallance, p.11)
W
2
= (/4)(48)
2
(5)(0.256)
W
2
= 2316.233432 lbs
SHAFT DESIGN
Shaft 1
Design Consideration:
Material Used: AISI C1117 Normalized Carbon Steel
Tensile strength: 63,700 psi
Yield strength: 35,000 psi
From Table AT 8 Typical Properties of Steel (Faires, p.578)
Shaft diameter: 4 in
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
20
8" 36" 36"
Fx1
F
1
Fx2
F
y
2
F
2
Fy1
Ft
Fr
Components of shaft 1
Computing the Angle of Wrap
Cos = (D
2
-D
1
)/2C from eq. by Spotts, p.293
Where:
D
= diameter of big sheave, 48 in
D
= 68.61805742
Solving for Forces on Belt at Section A
F
1
= 714.2276221 lbs.
F
2
= 392.4449198 lbs.
F
x1
= F1sin = 714.2276221 (sin 68.61805742)
F
x1
= 665.0678856 lbs
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
21
F
y1
= F
1
cos = 714.2276221 (cos 68.61805742)
F
y1
= 260.3954756 lbs (downward)
F
x2
= F
2
sin = 392.4449198 (sin 68.61805742)
F
x2
= 365.4449198 lbs
F
y2
= F2cos = 392.4449198 (cos 68.61805742)
F
y2
= 143.0788706 lbs (upward)
Horizontal Component, F
x
= F
x1
+ F
x2
F
x
= 665.0678856 + 365.4449198
F
x
= 1030.512805 lb (to the right)
Vertical Component, F
y
= F
y1
- F
y2
F
y
= 260.3954756 143.0788706
F
y
= 117.316605 lbs (downward)
Forces at Section A Due to Weight of the Sheave, W
2
W
2
= 2316.233432 lbs
Total Load at section A
F
HA
= 1030.512805 lbs
F
VA
= 117.316605 + 2316.233432
F
VA
= 2433.550037 lbs.
Solving for the weight of the roll
Roll material: high carbon steel
w= v
where:
= density of the roll, 0.283244983 lb/in
3
(Material Science and Engineering 4
th
Edition,
V. Raghavan, p.396)
v= roll volume
v= (/4)(D-d)
2
w
where:
D= diameter of the roll, 15 in.
d= shaft diameter, 4 in.
w= roll width, 50 in.
v= (/4)(15-4)
2
(50)
v= 4751.658889 in
3
therefore,
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
22
w = (4751.658889) (.283244983)
w = 1345.883541 lbs.
Solving for the Force Required to Crush the Coal (Fr)
= F/A
where:
= compressive strength of coal, 500 psi, (Table 8.2, Handbook of Coal Analysis by J.G. Speight)
A= area of the coal to be crushed
Solving for area:
e= effective length of the roll, 60%
1 1/2
3/4
19/16
w
x
X = (
X = 0.920682491
W = 2(0.920682491)
W = 1.841364983
Therefore:
A = (1.841364983)(50)(0.6)
A = 55.24094949 in
2
F
r
= 500 x 55.24094949
F
r
= 27620.47475 lbs.
F
t
= force required to drive the crusher, 1018.978557 lb
Total Roll Load
F
VC
= w - F
t
F
VC
= 1345.883541- 1018.978557
F
VC
= 326.904984 lbs (downward)
F
HC
= F
r
= 27620.47475 lbs
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
23
Solving for Vertical Component of the Bearing
8" 36" 36"
Fva Fvc
Rvb Rvd
F
VA
= 2433.550037 lbs
F
VC
= 326.904984 lbs
M
B
= 0
72 Rvd = 8 (2433.550037) - 36(326.904984)
Rvd = 106.9419566 lbs
Y = 0
Rvb = Fva + Fvc + Rvd
Rvb = 2433.550037 + 326.904984 + 106.9419566
Rvb = 2867.39678 lbs
8"
2433.550037 lbs
6.53809968 lb/in
2867.396978 lbs 106.9419566 lbs
11" 50"
11"
A
C B
D E
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
24
Shear Diagram
2433.550037 lbs
0
106.941957 lbs
433.846941 lbs
Moment Diagram
0
19468.4003 in-lb
14696.08395 in-lb
1176.386495 in-lb
Solving for Horizontal Component of the Bearing
8" 36" 36"
FHA
RHB
FHC
RHD
F
HC
= 27620.47475 lbs. (left)
F
HA
= 1030.512805 lbs. (right)
M
B
= 0
72 R
HD
= 36(27620.47475) + 8(1030.512805)
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
25
R
HD
= 13924.7388 lbs
Y = 0
R
HB
+ F
HC
= F
HA
+ R
HD
R
HB
= 1030.512805 + 13924.7388 27620.47475
R
HB
= -12665.22315 lbs
Therefore: R
HB
= 12665.22315 lbs (upward)
8"
1030.512805 lbs
12665.22315 lbs
552.409495 lb/in
13924.7388 lbs
0
50"
11" 11"
A
B E D C
Shear Diagram
1030.512805 lbs
13695.73596 lbs
13924.7388 lbs
X = 24.79326224 in
Moment Diagram
153172.1267 in-lb
0
328678.1846 in-lb
8244.10244 in-lb
158897.198 in-lb
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
26
Resultant moment
M
B
=
M
B
= 21141.99223 in-lb
M
c
=
M
C
= 159575.3565 in-lb
M
D
=
M
D
= 153176.6461 in-lb
M
F
=
M
F
= 328678.1846 in-lb
Therefore, maximum moment occurs at section F.
Data for the Loading at Shaft 1
Section
Load
Resultant
Vertical Horizontal
A 2433.550037 lbs 1030.512805 lbs 2642.749028 lbs
B 2867.396978 lbs 12665.22315 lbs 12985.75538 lbs
C 326.904984 lbs 27620.47475 lbs 27622.40924 lbs
D 106.9419566 lbs 13924.7388lbs 13925.14945 lbs
Data for the Moment at Shaft 1
Section
Moment
Resultant
Vertical Horizontal
B 13468.4003 in-lb 8244.10244 in-lb 21141.99223 in-lb
C 14696.08395 in-lb 158897.198 in-lb 159575.3565 in-lb
D 1176.38695 in-lb 153172.1287 in-lb 153176.6461 in -lb
F 0 328678.1846 in-lb 328678.1846 in -lb
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
27
Bearing Selection for Shaft 1
The maximum actual radial load of the bearing is at section D
F
r
= 13925.14945 lbs.
From eq. 9-17 by Doughtie and Vallance, p.209
F
c
= (K
a
K
l
) K
o
K
p
K
s
K
t
F
r
When a rolling bearing turns while receiving a load, a lot of stress is repeatedly placed on the
small contact surface of the bearing rings and rolling elements, and the bearing must maintain
high precision while rotating. That means bearing materials must satisfy the following demands.
Must be hard.
Rolling fatigue life must be long.
Wear must be slight.
Must be shock-resistant.
Dimensions must not vary largely with the passing of time.
Must be economical and easy to machine.
Design Consideration:
Material Used for the bearing: High Carbon Chrome Bearing Steel
The expected life of operation for the bearings is 10 years for 16 hrs/day operation.
Shaft diameter may be reduced to accommodate the bearing.
Where:
F
c
= catalog rating of bearing, lb (Table 9-7 & 9-8)
F
r
= actual radial load on the bearing, 4643.7678 lbs
K
a
= application factor taking into account the amount of shock (Table 9-4), 1.0
for uniform and steady load
K
l
=
, life factor
H
a
= desired life of bearing, hours of use
H
c
= catalog rated life, 10,000 hrs.
K
rel
= reliability factor (Table 9-3), 1.0
H
a
= 10(365)(16)
H
a
= 58400 hrs.
H
c
=10,000 hrs.
K
l
=
= 1.800822669
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
28
K
o
= oscillation factor, 1.0 for constant rotational speeds of the races
K
p
= preloading factor, 1.0 for non-preloaded ball bearings
K
s
=
, speed factor
N
a
= rotational speed of bearing, 135.4166667 rpm
N
c
= catalog rated rotational speed, 500 rpm
K
r
= rotational factor, 1.0 for bearing with fixed outer races and rotating inner
races
K
s
=
= 0.646994673
K
t
= thrust factor, 1.0 for no thrust-load component
Therefore,
F
C
= (1.0 x 1.800822669 ) x 1.0 x 1.0 x 0.646994673 x 1.0 x 13925.14945
F
C
= 16224.50736 lbs
From Table 9-7 Typical radial capacity F
c
of ball bearings (Doughtie and Vallance, p.212).
I select SAE 419 Two-row angular type ball bearing with radial capacity (F
c
) of 20300 lbs and
shaft diameter be reduced to 3.7402 in.
From Table 8 outside diameter is equal to 9.8425 in and width 2.1654 in.
Design for Key for the Pulley on Shaft 1
Design consideration of Key:
Material used: AISI C1117, Normalized Carbon Steel, same as the material used in shafting
S
u
= 63,700 psi
S
y
= 35,000 psi
From Table AT 19 Key Dimension (Faires, p.594)
For shaft diameter of 3.7402 in
b= 7/8 t = 5/8
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
29
Shearing Stress, S
s
S
s
=
Where:
S
y
= yield stress, 35,000 psi
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one
direction, gradual mild shock (Faires, p.20)
Therefore,
S
s
=
= 5833.3333333 psi
Compressive Stress, S
c
S
c
=
Where:
S
y
= yield stress, 35,000 psi
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one
direction, gradual mild shock (Faires, p.20)
Therefore,
S
c
=
= 11,666.66667 psi
Solving for the Maximum Torque, T
Hp =
Where:
Hp = transmitted power, 16.59322255 hp
T = maximum torque
N = rpm of the shaft, 135.4166667 rpm
Therefore,
T =
T =
T = 643.5654046 ft-lb or 7722.784855 in-lb
Then,
F =
F =
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
30
F = 4129.610638 lbs.
Solving for the Length of the Key
a. Based on the bearing stress of the shaft and since the shaft and the key have the same
material it is also equal to the bearing stress of the key.
S
c
=
11,666.66667 =
L = 1.132693203 in.
b. Based on the shearing stress of the key
S
s
=
5833.3333333 =
L = 0.809066574 in.
Therefore, I use L =1.132693203 in. and
in x
in Key.
Bolt Design for the Bearings on Shaft 1
Bearing housing design is a four bolt flange housing design.
Design Condition:
Material Used: AISI C1117, Normalized Carbon Steel
S
y
: 35,000 psi
S
u
: 63,700 psi
From Table AT 8 Typical Properties of Steel (Faires, p.578)
Number of bolts: 4 bolts
Fs = 3.0, from Table 1.1 Factors of Safety, based on yield strength of steel, ductile metals (Faires,
p.20)
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
31
To compute for the size of bolt I will use the resultant force that will cause shearing (F =
27622.40924 lbs) divided by the number of bolts.
Solving the Size of the Bolt
Based on Shearing stress
S
s
=
Where:
S
y
= yield stress, 35,000 psi
F
s
= factor of safety, 3.0
S
s
=
Where:
F = maximum shear force, 27622.40924 lbs
A= cross sectional area of the bolt
Therefore,
=
(
)
d= 1.227714667 in.
From Table 6-1 Unified & American National threads, coarse, fine, and extra-fine series
(Doughtie and Vallance, p.130) I select 1
M
E
= 324925.0439 in-lb
M
B
= M
C
=
M
B
= M
C
= 152092.574 in-lb
maximum moment occurs at section E.
Data for the Loading at Shaft 2
Section
Load
Resultant
Vertical Horizontal
A 672.417705 lbs 13810.23738 lbs 13826.59763 lbs
B 1345.883541 lbs 27620.47475 lbs 27653.24625 lbs
C 672.417705 lbs 13810.23738 lbs 13826.59763 lbs
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
35
Data for the Moment at Shaft 2
Section
Moment
Resultant
Vertical Horizontal
E 15801.81607 in-lb 324540.578 in-lb 324925.0439 in-lb
B or C 7396.594755 in-lb 151912.6112 152092.574 in-lb
Bearing Selection for Shaft 2
The maximum actual radial load of the bearing is at section A or C.
F
r
= 13826.59763 lbs.
From eq. 9-17 by Doughtie and Vallance, p.209
F
c
= (K
a
K
l
) K
o
K
p
K
s
K
t
F
r
When a rolling bearing turns while receiving a load, a lot of stress is repeatedly placed on the
small contact surface of the bearing rings and rolling elements, and the bearing must maintain
high precision while rotating. That means bearing materials must satisfy the following demands.
Must be hard.
Rolling fatigue life must be long.
Wear must be slight.
Must be shock-resistant.
Dimensions must not vary largely with the passing of time.
Must be economical and easy to machine.
Design Consideration:
Material Used for the bearing: High Carbon Chrome Bearing Steel
The expected life of operation for the bearings is 10 years for 16 hrs/day operation.
Shaft diameter may be reduced to accommodate the bearing.
Where:
F
c
= catalog rating of bearing, lb (Table 9-7 & 9-8)
F
r
= actual radial load on the bearing, 1794.885353 lbs
K
a
= application factor taking into account the amount of shock (Table 9-4), 1.0
for uniform and steady load
K
l
=
, life factor
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
36
H
a
= desired life of bearing, hours of use
H
c
= catalog rated life, 10,000 hrs.
K
rel
= reliability factor (Table 9-3), 1.0
H
a
= 10(365)(16)
H
a
= 58400 hrs.
H
c
=10,000 hrs.
K
l
=
= 1.800822669
K
o
= oscillation factor, 1.0 for constant rotational speeds of the races
K
p
= preloading factor, 1.0 for non-preloaded ball bearings
K
s
=
, speed factor
N
a
= rotational speed, 135.4166667 rpm
N
c
= catalog rated rotational speed, 500 rpm
K
r
= rotational factor, 1.0 for bearing with fixed outer races and rotating
inner races
K
s
=
= 0.646994673
K
t
= thrust factor, 1.0 for no thrust-load component
Therefore,
F
C
= (1.0 x 1.800822669 ) x 1.0 x 1.0 x 0.646994673 x 1.0 x 13826.59763
F
C
=16109.71837 lbs
From Table 9-7 Typical radial capacity F
c
of ball bearings (Doughtie and Vallance, p.212).
I select SAE 419 Two-row angular type ball bearing with radial capacity (F
c
) of 20300 lbs and
shaft diameter be reduced to 3.7402 in.
From Table 8 outside diameter is equal to 9.8425 in and width 2.1654 in.
Bearing Housing Design on Shaft 2
Material Used: AISI C1117, Normalized Carbon Steel
2012 [DOUBLE ROLL CRUSHER DESIGN]
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37
SPRING DESIGN
Design Consideration:
Load: F = 27620.47475 lbs (based on horizontal reaction for shearing)
Number of Spring: 8
Load = 27620.47475 / 8
Load = 3452.559344 lbs
Spring material: Hard drawn Wire, squared and ground ends
Type of service: average service
From Table 9 Century Spring Catalog, I use 4053 spring with wire diameter, Dw = 1.00 in with
maximum suggested load = 4200 lbs
Free Length = 10 in
Dm = 3 in
Deflection = .4 in
Solving for Spring Index
C = Dm/Dw
C = 3 / 1
C = 3
Solving for Stress Factor
K=
K =
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
38
K= 1.58
Stress Because of the Load
S
s
= k
S
s
= 1.58
S
s
= 38.67346463 ksi
Design stress
S
sd =
0.324 S
u
Where:
S
u
= 140/ Dw
0.19
S
sd
= 47.304/Dw
0.19
(.85)
S
sd
= 40.2084/1
0.19
S
sd
= 40.2084 ksi
S
sd
> S
s
(Applicable)
Solving the Number of Active Coils
Nc =
Nc =
(
Nc = 6.168263649 or 6 active coils
Solving for Solid Height
At Table At 16 Approximate Free Length and Solid Heights (Faires, p.589)
Solid Height = DwNc + 2Dw
= (1)(6) + 2 (1)
= 8 in
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39
Scale of Spring (k)
k= F/
k= 3452.559344/.4
k= 8631.39836 lb/in
Force to Compress the Spring to Solid Height
Fc = k (free length solid height)
Fc = (8631.39836)(10 8)
Fc = 17262.79672 lbs
Solving For Solid Stress
S
solid stress
= (Ss/F)(Fc)
S
solid stress
= (38.67346463/3452.559344)(17262.79672)
S
solid stress
= 193.3673232 ksi
Permissible Solid Stress
Ss =
Where:
Q = 70
X= 0.19
Ss =
Ss = 70 ksi.
The spring would take a permanent set if compressed to solid height.
Solving for Pitch
At Table At 16 Approximate Free Length and Solid Heights (Faires, p.589)
Free length = PNc + 2Dw
10 = P (6) + 2 (1)
P = 1.33333333 in
Solving for Pitch Angle
Pitch Angle, = tan
-1
(1.33333333/2)
= 11.98081357
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MACHINE DESIGN 2
40
Spring Mounting
Bolt design for Mounting the Crusher
Design Condition:
Material Used: AISI C1117, Normalized Carbon Steel
S
y
: 35,000 psi
S
u
: 63,700 psi
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MACHINE DESIGN 2
41
6
9
i
n
58 in
1030.512805 lbs
19 in
8 in
TOP VIEW
Fd
Fm
r
Fr
1
4 3
2
B
Solving for the Maximum Tensile Force
T
1
= T
2
T
3
= T
4
= (1.5/70.5) F
1
D= 1.5 in
D
=
1
.
5
i
n
69 in
2
5
i
n
1030.512805 lbs
1.5 in
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MACHINE DESIGN 2
42
M
o
= 0
1030.512805 x 25 = 2 (70.5) T
1
+ 2 (1.5) T
3
1030.512805 x 25 = 2 (70.5) T
1
+ 2 (1.5) (1.5/70.5) T
1
T
1
= 182.6323599 lbs
Max = (
)
Where:
x
= T
A
/ A
r
y
= 0
= F
r
/ n A
r
Max =
N = number of bolts
Ar = stress area
Fs = 3.0, from Table 1.1 Factors of Safety, based on yield strength of steel, ductile metals (Faires,
p.20)
Solving for F
m
r =
r = 45.06939094 in
1030.512805 (19) = 4 (45.06939094) F
m
F
m
= 108.6088745 lbs
F
m
Components:
tan = 29/34.5
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43
= 40.46222749
F
my
= 108.6088745 sin 40.46222749
F
my
= 70.4813605 lbs
F
mx
= 108.6088745 cos 40.46222749
F
mx
= 82.63331921 lbs
Solving for F
r
F
r
=
F
r
= 1104.090756 lbs
= (
)
5833.3333333 =
Ar = 0.263546125 in
2
From Table 6-1 Unified & American National threads, coarse, fine, and extra-fine series
(Doughtie and lVallance, p.130) I select in-10 UNC bolt with A
r
= 0.334 in
2
and minor diameter
of 0.6273 in.
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MACHINE DESIGN 2
44
DESIGN SUMMARY
Elements Specifications Loadings
Motor 20 Hp
500 rpm
V-belt C = 48 in
L = 161.3 in
V
m
= 1701.696021 ft/min
N = 4 leather belts
b x t = 1 x in
Hp
Transmitted
= 16.59322255
Sheave of V-belt D
1
= 13 in
D
2
= 48 in
T = 5 in
C = 48 in
N
1
= 500 rpm
N
2
= 135.4166667 rpm
W
1
= 169.8973307 lbs
W
2
= 2316.233432 lbs
Shaft 1 AISI C117 Normalized Carbon
Steel
D = 4 in
L = 80 in
@ section F,
M
max
= 328678.1846 in-lb
T = 7722.784855 in-lb
Bearing on Shaft 1 High Carbon Chrome Bearing
Steel
H
a
= 58400 hrs.
SAE 419 Two-row Angular
Type Ball Bearing
Bore = 3.7402 in
F
r
= 13925.14945 lbs
Key at Shaft 1 AISI C117 Normalized Carbon
Steel
b = 7/8 in
t = 5/8 in
L= 1.132693203 in
T = 7722.784855 in-lb
F = 4129.610638 lbs
Bolt on Bearing @ Shaft 1 AISI C117 Normalized Carbon
Steel
A
r
= 0.969 in
2
N= 4 bolts
1 in-11 UNC bolt
F = 27622.40924 lbs
Shaft 2 AISI C117 Normalized Carbon
Steel
D = 4 in
L = 72 in
@ section E
M
max =
324925.0439 in-lb
Bearing on Shaft 2 High Carbon Chrome Bearing
Steel
H
a
= 58400 hrs.
SAE 419 Two-row Angular
Type Ball Bearing
Bore = 3.7402 in
F
r
= 13826.59763 lbs
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
45
Spring Hard drawn wire
Squared and Ground ends
Dw = 1 in
Free length = 10 in
Dm = 3 in
Deflection = 0.4 in
Nc = 6 active coils
P = 1.3333333 in
= 11.980811357
C = 3 in
Solid height = 8 in
F = 3452.559344 lbs.
S
s
= 38.67346463 ksi
S
sd
= 40.2084 ksi.
Fc = 17262.79672 lbs.
k= 8631.39836 lb/in
S
solid stress
= 193.3673232 ksi
S
permissible
= 70 ksi.
Bolt on Crusher AISI C117 Normalized Carbon
Steel
N= 4 bolts
A
r
= 0.334 in
2
select in-10 UNC bolt
T
1
= 182.6323599 lbs
F = 1030.512805 lbs
F
r
= 1104.030756 lbs
F
m
= 108.6088745 lbs
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
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LIST OF REFERENCES
Books :
Doughtie, V.L., &Vallance, A. (1978).Design of Machine Members(4
th
ed.).New York: McGraw-
Hill, INC.
Faires, V.M. (1969). Design of Machine Elements (4
th
ed.). New York: MacMillan Company.
Morse, F. (1953).Power Plant Engineering. Philippines: Litton Educational Pubishing, INC.
Spotts, M.F. (1991). Design of Machine Elements (6
th
ed.). Singapore: Simon & Schuster (Asia) Pte
Ltd.
Internet:
Engineering Tool Box, electrical motors - Hp, torque and rpm. Retrieved July 5,2012 from
http://www.engineeringtoolbox.com/electrical-motors-hp-torque-rpm-d_1503.html
Handbook of Coal Analysis. Retrieved July 5, 2012 from http://info.com/Handbookofcoalanalysis
Roll Crusher. Retrieved August 17, 2012 from http://www.gundlachcrushers.com/crushers/roll-
crushers-coal-salts-lime-minerals.cfm
What is the density of Coal.Retrieved August 17, 2012 from http://wiki.answers.com/Q/What
BL Precision Bearings Radial Ball Bearings Catalog. Retrieve September 12, 2012 from
http://www.qbcbearings.com/BuyRFQ/ThrustB_Bearing_B_CSBW.htm
Century Compression Spring Catalog. Retrieved Sept 12, 2012 http://www.centuryspring.com
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
47
APPENDIX:
Power
Motor Velocity (rpm)
3450 2000 1000 500
Torque
hp Kw
(in
lb
f
)
(ft lb
f
) (Nm)
(in
lb
f
)
(ft lb
f
) (Nm)
(in
lb
f
)
(ft lb
f
) (Nm)
(in
lb
f
)
(ft lb
f
) (Nm)
1 0.75 18 1.5 2.1 32 2.6 3.6 63 5.3 7.1 126 10.5 14.2
1.5 1.1 27 2.3 3.1 47 3.9 5.3 95 7.9 10.7 189 15.8 21.4
2 1.5 37 3.0 4.1 63 5.3 7.1 126 10.5 14.2 252 21.0 28.5
3 2.2 55 4.6 6.2 95 7.9 10.7 189 15.8 21.4 378 31.5 42.7
5 3.7 91 7.6 10 158 13.1 18 315 26.3 36 630 52.5 71
7.5 5.6 137 11 15 236 20 27 473 39 53 945 79 107
10 7.5 183 15 21 315 26 36 630 53 71 1260 105 142
15 11 274 23 31 473 39 53 945 79 107 1891 158 214
20 15 365 30 41 630 53 71 1260 105 142 2521 210 285
25 19 457 38 52 788 66 89 1576 131 178 3151 263 356
30 22 548 46 62 945 79 107 1891 158 214 3781 315 427
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MACHINE DESIGN 2
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40 30 731 61 83 1260 105 142 2521 210 285 5042 420 570
50 37 913 76 103 1576 131 178 3151 263 356 6302 525 712
60 45 1096 91 124 1891 158 214 3781 315 427 7563 630 855
70 52 1279 107 145 2206 184 249 4412 368 499 8823 735 997
80 60 1461 122 165 2521 210 285 5042 420 570 10084 840 1140
90 67 1644 137 186 2836 236 321 5672 473 641 11344 945 1282
100 75 1827 152 207 3151 263 356 6302 525 712 12605 1050 1425
125 93 2283 190 258 3939 328 445 7878 657 891 15756 1313 1781
150 112 2740 228 310 4727 394 534 9454 788 1069 18907 1576 2137
175 131 3197 266 361 5515 460 623 11029 919 1247 22058 1838 2494
200 149 3654 304 413 6302 525 712 12605 1050 1425 25210 2101 2850
225 168 4110 343 465 7090 591 801 14180 1182 1603 28361 2363 3206
250 187 4567 381 516 7878 657 891 15756 1313 1781 31512 2626 3562
275 205 5024 419 568 8666 722 980 17332 1444 1959 34663 2889 3918
300 224 5480 457 620 9454 788 1069 18907 1576 2137 37814 3151 4275
350 261 6394 533 723 11029 919 1247 22058 1838 2494 44117 3676 4987
400 298 7307 609 826 12605 1050 1425 25210 2101 2850 50419 4202 5699
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MACHINE DESIGN 2
49
Table 1 Power versus torque and motor velocity in electric motors
Table 8.2 Variation Of Compressive Strength by Rank
Figure 17.14 Belt Selection from Horsepower and Speed
450 336 8221 685 929 14180 1182 1603 28361 2363 3206 56722 4727 6412
550 410 10047 837 1136 17332 1444 1959 34663 2889 3918 69326 5777 7837
600 448 10961 913 1239 18907 1576 2137 37814 3151 4275 75629 6302 8549
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MACHINE DESIGN 2
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Table 17.7 Service Factors
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MACHINE DESIGN 2
51
Table 17.5 Arc-of contact
factors
Table 17.4 small diameter
factor
Table 17.3 Standard V-belt Lengths;
Horsepower Constants
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
52
Table 16-5 Coefficient of Friction For Belts
Table 17.6 Length Correction Factors
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
53
Table AT8 Typical Properties of Steel-Various Sizes and Conditions
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
54
Table 9-3 Typical Reliability Factors for rolling element bearings
Table 9-4 Typical Values of application factor for roller and ball bearings
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
55
Table 9-2 SAE and International Standard dimensions for ball and Roller Bearings
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
56
Table 8 Ball Bearing specification
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
57
Table 9-7 Typical Radial Capacity for Ball bearings
Table 9-4 Typical Values of Application factor for roller and ball bearings
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
58
Table AT 19 Key Dimensions
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
59
Table 6-1 Uniform and American National Threads, coarse, fine and extra-fine.
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
60
Table 1.1 Factors of safety
Table 9 Century Spring Catalog
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
61
Figure AF 15 Stress Factor
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2
62
Table AT 17 Mechanical Properties of Wire for Coil Springs
2012 [DOUBLE ROLL CRUSHER DESIGN]
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63
Table AT 16 Approximate Free Lengths and Solid Heights