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‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬

‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬


‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Design of a WORM GEARING


According to given data
INPUT POWER:
H = 1.5kW
INPUT NUMBER OF REVOLUTION:
n = 1500 rpm
TOTAL TRANSMISSION RATIO:
i = 40
SERVICE LIFE OF USED BEARING:
Lh = 8000 hr
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

LIST OF SYMBOLS

Hi INPUT POWER
I TRANSMISSION RATION
Sut UITIMATE STRENGTH
Sy YIELD STRENGTH
Ssy SHEAR YIELD STRENGTH
m MODULE
n SAFETY FACTOR
η EFFICIENCY
a CENTER DISTANCE
dw PITCH DIAMETER OF WORM
z NUMBER OF GEAR TOOTH
γ LEAD ANGLE
dmaj ADDENDUM DIAMETER OF WORM
dmin DEDENDUM DIAMETER OF WORM
b1 WORM THREADED LENGTH
d2 PITCH DIAMETER OF WORM WHEEL
L WORM WHEEL LENGTH
ρ ANGLE OF FRICTION
Vs SLIDING VELOCITY
μ COEFFICIENT OF FRICTION
Vw PITCH LINE VELOCITY OF WORM
фn NORMAL PRESSER ANGLE
ψ HELIX ANGLE
fg FACE WIDTH OF GEAR
mn NORMAL MODULE
ka SURFACE FACTOR
kb SIZE FACTOR
kc RELIABILITY FACTOR
kd TEMPERATURE FACTOR
kc MODIFVING FACTOR
kf MISCELLANEOUS – EFFECTS FACTOR
ks FACTOR FOR CYLINDER WORM GEAR
kt FATIGUE STRENGTH CONC. FACTOR
kv VELOCITY FACTOR
km CORRECTION FACTOR
k1 COOLING FACTOR
k2 TRANSMISSION RATIO FACTOR
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

k3 MATERIAL FACTOR
k4 DRIVE FACTOR
ds1 INPUT SHAFT DIAMETER
ds2 OUTPUT SHAFT DIAMETER

LIST OF SYMBOLS

T1 Input torque
T2 Output torque
WF Tangential force due to friction
τ Shear stress
σlim Limiting value of allow. Load factor
σmax Max. bending stress during oper
F12 Max. tangential force on worm wheel
b Arc length of tooth width

Sb Safety factor against bending


Plim Lim. Value of contact presser
P Actual contact press. In system
Se Endurance lim. Of mech. Element
Se Endurance limit of rotating
Beam specimen
Wwt Tangential force on the worm
Wwa Axial force on worm
Wwr Radial force on worm
WGa Axial force on worm wheel
WGt Tangential force on the worm wheel
WGR Radial force on worm wheel
σm Mean normal stress
σa Amplitude normal stress
τm Mean shear stress
nd
I 2 moment of inertia
Lw Distance bet . bearing of worm
Fp Permissible deflection
Sd Safety factor of deflection
St Temp. safety factor
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

F Deflection
Df Duty factor
FeA Equivalent force on bearing A
FrA Resultant force at bearing A
Cr Dynamic load rating
Co Static load rating
Lh Life in hours
Acr Crushing area
Ash Shearing area
Lcr Length of feather
b Width of feather
h Height of feather

1.1SELECTION OF GEARBOX PARAMETERS :


MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

At standared dimensional of worm gearing i=40

FOR i=40 ….from handbook of gear design


i m Z1 dw γ c
40 5 1 50 5.7106° 125
mm mm

dg = mzg = 5×40 = 200 mm

1.2calculation of output shaft revolutions : -


nw
i =ng ng = 1500/40=37.5rpm

1.3CALCULATION OF INPUT SHAFT TORQUE


H1
T1 ω
= =H*30/Лn=150000/4712.38=31.83N.m

1.4Some Important relations:-

αn=20°
αa =20.09°

1.5 CALCLATION OF WORM EFFICIENCY :-

πXdWXNW
60X1000
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

VW =

π x 50 × 1500
= 60 × 1000= 3.927m/s

Vw
Vs = cos λ
3.927
= cos 5 .7 106 = 3.947m/s

From Hand Book of Gear Design:-


Form fig . ( 14- 7 ) ……………………… μ = 0.028

Cosα n-µtanγ
η = Cosαn-µtanγ

Cos 20-0.028tan 5.7106


= Cos 20+0.028tan 5.7106 =0.90=90%

1.6 CALCLATION OF output shaft torque :-

Tout = T2 = Ti . η .i LET η = 1
= 31.83* 40=1273.24N.m

1.7 Check Of Power rating:-

For Centrefugal- cast bronze ks = 1000


for i = 40………k m = 0.815 … table ( - )
for Vs =3.95.….k v 0.285 …table ( - )
fe= ⅔ dw = ⅔ x 50 = 33.3mm or fe=30 less
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

W G = β.K V. K S. K M. d G 0.8 . fe
T

= 0.0131* 1000(200)0.8 *30*0. 815 *0.285

W G = 6327.3N
T

WF = μ XWw
=
T .028* 1273.24
cos α
= 294.692 Nn. sin λ + μ cos λ
cos 20 . sin 5.7106 +..028cos 5.7106
HL=Wf*Vs=294.692*3.95=1164.03343W
Vgt=π ngdg/60=0.9m/s
HO =Wgt*Vgt=6327.3*0.9=5694.57W
H=Ho+Hl=1164.033+5694.57= 6858.6W>5000

Safe

2.1 DESIGN OF WORM :-

d a = dw + 2 m = 50+ 2 * 5= 60 mm
w

d d = dw – 2.5 m = 50 - 2.5 * 5 =37.5 mm


w
——_

2.2 DESIGN OF WORM WHEEL:-

d g = m x zg = 5 * 40 =200 mm

d a = dg + 2m =200 + 2* 5 = 210 mm
g

d d = dg – 2.5 m = 200 - 2.5 * 5 = 187.5mm


g

2.3 Selection of input shafts material : -

Assume that the input shat has the same material of the
worm .
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

According to ref. ( 1 )
Steel 080M30 (HR)
sy = 245 Mpa ,
Sut = 490Mpa .
Ssy = 0.5 ( 245 ) = 107.5Mpa

2.4 calculation input shaft diammeter : -


sy
τ = 0.5 ……..
n Assume n = 3
245
= 0.5 3 = 40.833Mpa
16Ti
3
ds = πXτ
I

=3 16 *31.83*103 =15.5mm
π X40.8333

2.5Selection of output shafts material :

For material steel 640 M 40


Sy = 680Mpa ,
Sut = 850Mpa .

2.6 output shaft diammeter : -


sy
τ = 0.5 ……..
n Assume n =1.5
680
= 0.5 * 1.5 = 226.7 Mpa
16T0
πXτ
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

dos = 3
=3 = 29.9
16 *1273.24 *10 3 mm
π X 226.7

TAKE OUT PUT SHAFT DIAMETER = 30 mm

3.1 CALCLATION OF FORCES ACTS ON WORM SHAFT :-

5000
Hi VW
wwt= = 3.927 = 1273.24N
w= wwt/Cosαn Sinγ =1273.2/Cos20 Sin 5.7106
=13616.67N
W
wwa=wgt=wCosαn Cosγ =13616.67Cos20Cos 5.7106
=12731.98N
wwr = wgt = wsin Φ
= 13616.67 sin 20=4657.2N

3.2Force Analysis Including


Frction:-
Wwt =wwt-µw Sin γ =1273.24
Wwa=wwa+µwCosγN. =9780N
=7131.8

Wwr=3588.2 N

3.3Calculation of the Worm Gear Force:-

Wga=Wwt = 1273.24 N

Wgt=Wwa = 9780 N

Wgr=Wwr = 3588.16 N

3.4.1 reactions on input shaft :-


a) In (x - Y ) plane : -
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

WWa

Wr

107.5 107.5
Ax Bx
∑MB = 0
Ax (215)- wr (107.5) - Wwa (25)= o

Ax =2931.289 N

∑Fx = 0
Ax+Bx=wr
2931.289+Bx = 3588.16
Bx =656.87

Bending moment diagram :


At ( x-y )
-3
Mmax(x) = Ax X107.5X10 =322.4585N.m
M1X= Ax X (15) X 10-3 =2931.289 X 7.5X 10-3
=37.4951N.m

B) In ( x-Z ) plane : -

Ay = By = = 636.62 N

Bending Moment diagram :-


Mmax(y) = Ay ( 107.5 ) 10-3 = 68.437N.m

M1Y = By X(15) X 10-3 =37.5 N.m


MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Mx2 + My2

Mmax= = 322.46N.m

M 1x2 + M1y2 (M1)t =

=37.5 N.m


[ (M/Se )+(T/Sy) ]

3.4.2WORM SHAFT DESIGN:-


(under the worm gear)

Se = s’e * Ka * Kb * Kc * Kd * Ke * Km

Ka = 0.66 surface factor(CD) fig. ( 7-8 )


Kb = 1.189d -0.097
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

= 1.189 * 37.5 -0.097


= 0.87
Kc = 0.897 Reli.of 90%
Kd = 1 Temp . < 350 0

Take …… Km = 1
Ke=1/kf Kf=1+q(Kt-1)
Ke =1 there is no stress concentration there
Se = 0.5S ut
= 0.5X490
= 245Mpa

Se = s’e * Ka * Kb * Kc * Kd * Ke * Km
=245 * 0.66 * 0.87 * 0.897 = 126.2.Mpa
3
Πd
n=
32 [(TO /Sy)2 +(Mmax /Se)2]1/2
3
Π(37..5)
=
32 [(31380 / 245)2 +(322458.5/ 126.22)2]1/2
=2.5>2 (safe)
The final dimension as shown in fig

3.4.3Checking on the input shaft under bearing:-


Se = s’e * Ka * Kb * Kc * Kd * Ke * Km

Ka = 0.66 surface factor(CD) fig. ( 7-8 )


Kb = 1.189d -0.097
= 1.189 * 25 -0.097
= 0.87
Kc = 0.897 Reli.of 90%
Kd = 1 Temp . < 350 0

Take …… Km = 1
Ke=1/kf Kf=1+q(Kt-1)
For r =2 q=.75 (fig .7-13) Shegly
D/d=28/25=1.12
r/d=2/25=0.08
Kt=1.85
Kf =1+0.75*0.85=1.6375
Ke =1/1.6375=0.61
Se = 0.5S ut
= 0.5X490
= 245Mpa
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Se = s’e * Ka * Kb * Kc * Kd * Ke * Km
= 245 * 0.897 * 0.87 *0.66* 0.61 = 77.Mpa
3
Πd
n=
32 [(TO /Sy)2 +(Mmax /Se)2]1/2
3
Π(25)
=
32 [(31380 / 245)2 +(37495.3/ 77)2]1/2
=4>2 (safe)
The final dimension as shown in fig.

3.5 FORCE ACTING ON OUTPUT SHAFT:-


a) In ( y– z ) plane :

CX 40 40 DX

Wga Wgr

∑MC = 0

Dx ( 80 ) - Wgr ( 40)+ Wga ( 60 ) =0

( -1756.24 * 45
80Dx- 40 + 954.92+ (1273.24
x 3588.15 104 ) x 100=0
90 Dx= 202.525N

∑Fx=0
Cx + Wr + Dx =0
Cx = 3385.6 N
Bending Moment diagram :

Mmax y = ( 3385.6 ) ( 40 * 10-3 ) = 135.424 N.m

B ) In ( X – Z ) plane :- WgT
Wgt = Cz + Dz 40 40

Cz Dz

Wgt
Cz = Dz= 2 = 4890 N
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Mmax = 4890 * 40 * 10 -3 = 195.6 N

Bending Moment diagram :-

Mmax = ( My2 + Mz2 )

= √ ( 135.42 ) + ( 195.6 ) = 237.9 Nm


2 2

3.5.2 OUTPUT SHAFT DESIGN FOR FATIQUE STRENGTH :-

The output shaft under gear :-


Ka = 0.9 surface factor(CD) fig. ( 7-8 )
Kb = 1.189d -0.097
= 1.189 * 45 -0.097
= .827
Kc = 0.897 Reli.of 90%
Kd = 1 Temp . < 350 0

Take …… Km = 1
Take …… Ke=1/1.6 =0.625 due to feather stress concentration
Se = 0.5S ut
= 0.5X850
= 425Mpa

Se = s’e * Ka * Kb * Kc * Kd * Ke * Km
= 425 * 0.897 * 0.9 * 0.827 * .625= 177.34.Mpa
3
Πd
n=
32 [(TO /Sy)2 +(Mmax /Se)2]1/2
3
Π(45)
=
32 [(237905.5 / 177.34)2 +(1273240 / 680)2]1/2
=3.88>2 (safe)

3.5.3 OUTPUT SHAFT DESIGN FOR FATIQUE STRENGTH :-


The output shaft under bearing :-
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Ka = 0.73 surface factor(CD) fig. ( 7-8 )


Kb = 1.189d -0.097
= 1.189 * 30 -0.097 = 0.855
Kc = 0.897 Reli.of 90%
Kd = 1 Temp . < 350 0
Take …… Km = 1
Ke=1/kf Kf=1+q(Kt-1)
For r =2 q=0.8 (fig .7-13) Shegly
D/d=32/30=1.1
r/d=2/30=0.067
Kt=1.75
Kf =1+0.8*0.75=1.6
Ke =1/1.6=0.625
Se = 0.5S ut = 0.5X850= 425Mpa
Se = s’e * Ka * Kb * Kc * Kd * Ke * Km
= 425 * 0.897 * 0.849 * 0.73 * 0.625*1 = 112.92.Mpa
3
Πd
n=
32 [(TO /Sy)2 +(Mmax /Se)2]1/2
3
Π(30)
=
32 [(1273242/680)2 +(109.97 / 112.92)2]1/2
=3>2 (safe)
The final dimension of the output shaft as shown in the fig.

3.6 Check on the deflection of the worm shaft :


F.lw3
F1 =48E.I

F1 = ( wwt )2 + ( wwr )2

= ( 1273.24 )2 + ( 3588.16 )2 = 3806.9N

I=(Πd4)/64 =(Π*504)/64 =306796.15 mm4

F1= 3806.9 X(100)³ =0.0258mm


48X210X10³X306796.15
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Permissible deflection Fp

Fp=dw/1000 =50/1000 =0.05 mm


Sd =Fb/F1=0.05/0.0258 =1.94>1 (safe)

BENDING STRESS CALCULATION:


(ON THE WORM WHEEL TEETH)

SAFETY FACTOR
Sb=бmin / бmax = π mn bˆ /Fmax
Бmin (limiting value of load factor from table 4-5)
(worm steel-worm gear bronze )
бmin=23.5MPa
бmax=wgt /( Π mn bˆ)
bˆ is the length of face width of wheel teeth at the root
bˆ=r' *ф/180 r'=(dai/2)+C
C(top clearance )
C=1
r'=60/2+1=31
sin (ф/2) =b2/2r'
ф=57.877
bˆ=31 * Π * 57.877 / 180=31.314mm
mn= m cosγ =5cos5.7106=4.975

Sb=π(4.975)(31.314) (235)/9770=1.2>1 (safe)

( 4 – 1 ) selection of input shaft bearing :-


we shall choose taper roller bearing :-

FrB = ( Ax )2 + ( Ay )2
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

= ( 2931.289)2 + ( 636.62 )2 = 2474.6

FrA = ( Bx )2 + ( By )2

= ( 656.87 )2 + ( 636.62 )2 = 915.5 N

Ka = Wwa = 9780 N
FrB FrA
YA = YB = 1.5 YB YA

2
FrB FrA
Kas > 0.5 -
YB YA

> 0.5 1547.7 - 316.56 = 854.9


1.5 1.5

FaB0.5
= FrB 0.5
= * 2474.6 = 824.9
YA 1.5

FaA = Fab + Ka = 9780 + 824.9=10604.9 N

We Will Take the big From FrA ‘ FrB .

FeA = 0.4 FrA + YB * FaA .

= 0.4 * 2474.6 + 1.5 * 10604.9=16273.1 N

FeB = 2474.6 N

FOR RELABILITY R=90%


1/a

[
C=Z *Fe (Lh/Lr)(nh/nr) ]
3/10

[
=16273.1 (10000/500)*(1500/33.3) ]
=125.25 KN ….. there is no in tapper bearing
in the required diameter
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

that we cannot use taber roller bearing)


so we must use thrust ball bearing

calculation of thrust ball bearing


Fe= P =Fa = 9780N
1/a

[
C=Z *Fe (Lh/Lr)(nh/nr) ]
3/10

[
= 9780 (10000/500)*(1500/33.3) ]
C= 75.268 KN

Calculation of additional ball bearing

Fa = Fr = 3588.16
1/a

[
C=Z *Fe (Lh/Lr)(nh/nr) ]
Cr =27.615 KN

TRUST BEARING DESIGNATION : 52408 SKF

BALL BEARING DESIGNATION : 6207 SKF

( 4 – 2 ) selection of out put shaft bearing :-


(we shall used taber roller beaing)

Frc = Cz2 + Cx2

= ( 4890)2 + ( 3385.6 )2 == 5947.6N

FrD = Dz2 + Dx2

= ( 4890 )2 + ( 202.5 )2 == 4894.2 N

for first ateratin


MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Fa = 1272.24 N
Fa / C0 = 1272.24/3450 = .3688
e = 0.4036 x = 0.56 y = 1.296
Fa / Fr = 1272.24/5947.6 =0.214 < e
Fe = Fr = 5947.6
1/a

[
C=Z *Fe (Lh/Lr)(nh/nr) ]
C = 45.774 KN

for second ateration

Fa / C0 = 1272.24/36500 = 0.0348
e = 0.23314 x = 0.56 y = 1.9314
Fa / Fr = 1272.24/59476 =0.214 < e
Fe = Fr = 5947.6
1/a

[
C=Z *Fe (Lh/Lr)(nh/nr) ]
C = 41.774 KN

BALL BEARING DESIGNATION : 6305 SKF

5.1CALCULATION OF IN PUT SHAFT FEATHER: -


We choose feather : -

CSN 02 2562 WITH ROUNDED END

h = 6 mm b = 6mm
L=25-110mm take L = 25 mm.
Choose Material 080 M 20 HR (steel B.S)

Sy = 215 Mpa
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Sut = 430 Mpa

5.1.1Check on shear stress : -

F=2T/d
2 * 31.83
Ft = 0.02 = 3183 N

τ = F/Ashear < [τ all ]

[τ all ] =Sy/2n =280/(2*2) = 62 Mpa

Ash=L*b=25*6=150 mm 
F
τ all = Ash

τ all = 3183 = 21.22 MPa


150

( safe)

5.1.2 Check on crush stress : -

F F
∴σ = =
Acr t * Lcr

2*T Sy
σ= t * d * Lcr≤ [σall ]= n
[σall ]= 215/2=107.5 Mpa

σ =3183/(25*3.5) =36.37 MPa

[σcr ] ≤ [σall ]
safe
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

5.2CALCULATION OF OUT PUT SHAFT FEATHER: -


We choose feather : -

CSN 02 2562 WITH ROUNDED END

h = 8 mm b = 10mm
L=25-110mm take L .= 35
Choose Material (steel B.S)

Sy = 1020 Mpa

Sut = Mpa
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

5.1.1Check on shear stress : -

F=2T/d
2 * 1273.24
Ft = 0.03 = 3183 N

τ = F/Ashear < [τ all ]

[τ all ] =Sy/2n =1020/(2*2) = 294.27 Mpa

Ash=L*b=35*10=350 mm 
F
τ all = Ash

τ all = 1273.24 = 242.5 MPa


350

( safe)

5.1.2 Check on crush stress : -

F F
∴σ = A=cr t * Lcr

2*T Sy
σ= t * d * Lcr≤ [σall ]= n
[σall ]= 1020/2=680 Mpa

σ =3183/(35*4.5) =538.9 MPa

[σcr ] ≤ [σall ]
safe
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

7.1 introductions
Improperly lubricated gear will not last long .this is true, of course, for any part
subjected to friction.
There are two types of lubricants:
1) Compounded gear oils.
2) Synthetic gear lubricants.

1) Compounded gear oils:


Compounded oils are a blend of petroleum-based oil with 3% to 10% fatty oils
or synthetic fatty oils. Used frequently in worm gear lubrication.
2) Synthetic gear lubricant:
Synthetic gear lubricants are diesters, polyglycol and synthetic hydrocarbons
used in enclosed drivers for special operating conditions; they will operate over a
wider temp.
Range than mineral oils, but have disadvantages such as incompatibility with
other lube system components. Good results with synthetics have been obtained
with worm gear drives.
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Note:
Important to change oil in enclosed drives periodically. For units the first change
should be made after 500 operating or four weeks which ever occurs first.
Subsequent changes should be every 2500 operating hours or six months which
occurs first.
Lubrication system contains following elements:

Oil supply:

Through a covered hole in the upper casing. The cover prevents dust from
entering the gearbox causing abrasive wear.

Oil level in oil gage:


Controls the level of oil after gearbox operation.
More oil …more viscosity and weight, more power loss.
Less oil …more friction and increased wear,

Drain plug:
Drains the used oil after a period of time.

Gefro seal:
Prevents oil form leakage through the clearance between the shaft and the cover.

Gaskets:
Are used to prevent oil leakage from mating surfaces.
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

4TH YEAR MECHANICAL .

ROCKETS DEPARTMENT
GIVEN CALCULATIONS RESULTS
H=1.5 KW Quantity of oil :-
(Calculation of oil required for lubrication )

Input power = H =1.5 KW


Every 1 KW required ( 0.3 : 0.7 ) litters oil
No of litters oil = 0.4 * H = 0.6 litters
We need 0.6L oil that volume of oil
V = 6*105 mm3

CALCULATE OF OIL LEVEL


Max. width = 70 mm
Max. length = 154 mm

AREA OF GEARBOX

A = w * L = 154*70=10780 mm2

HIGHT OF OIL LEVEL


H = VOLUME OF OIL / AREA OF GEARBOX :

6*105
= 10780 = 55.66 mm
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Group (1) of the worm shaft:


Press the cover (7) and it's gasket by 4 bolt (31).
Press the input shaft (4) and bearing 19 from the left side of casing.
Press the other bearing on the other side then put gafero sealing (35) and its
cover (6) by 4 bolt (31).
But that assembly in its place on the casing.

Group (2) of the out put shaft:


Put rather (22).
Press worm gear (5) into its position on shaft (4).
Push distance tube (18).
Press the bearing (20) into position on shaft (4).
Put snap ring (16).
Press the other bearing the other side.
Put that assembly in its place on the casing.
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

Group (3) :
Mount pins in the lower case.
Mount gaskets to cover.
Mount the gafro seals.
Mount the drain plug and the oil gauge it's position.

Disassembly:
By reversing the previous steps for assembly beginning with dismounting the
drain plug to empty the oil.

The gearbox has to be checked periodically.


Checking oil level before using the machine.
Oil must be changed as mentioned in lubrication chapter.
Checking gearbox over heating.
Checking oil leakage form covers and gaskets.

DEFECTS: CAUSES AND THEIR REMEDY:-


(A)Leakage of oil:
Causes:
Damage of gaskets or cracks in the casting
Remedy
Replace gaskets or weld casting
MDP 401 Machine Design Project ‫شعبة الهندسة الميكانيكية‬
Term: Winter 2008 – 2009 ‫قســم التصميم الميكانيكى و النتاج‬
4th year Mechanical ‫مشروع التصميم‬

(B)Noisy operation of the gearbox:


Causes:
Damage of bearing or gear.
Incorrect gear assembly.
Insufficient lubrication.
Remedy
Correct assembly.
Change bearing or gear.
Correct lubrication.
(C)Over heating of the gear box:
Causes:
Absence or bad quality of oil.
In correct assembly.

Remedy
Checking oil used.
Reassemble the gear box.
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬
‫‪MDP 401 Machine Design Project‬‬ ‫شعبة الهندسة الميكانيكية‬
‫قســم التصميم الميكانيكى و النتاج ‪Term: Winter 2008 – 2009‬‬
‫‪4th year Mechanical‬‬ ‫مشروع التصميم‬