SELECTION OF MOTOR

INPUTS
Pressure
Displacement
Torque required
Speed Required
Power
Displacement
Max. Attainable Speed

OUTPUTS
320
280
23
60

bar
lpm
KNm
rpm

SHAFT DESIGN CALCULATION

distance beeween bearings(L)
diameter of the shaft(mm)
value of T(Nmm)
value of M(Nmm)
K(radius of gyration)
alpha
Km
Kt
F(N)
Te(Nmm)
shear stress,t(MPa)
Me(Nmm)
bending stress(MPa)
Allowable stress (Mpa)
fos

1160
105
23800000
0
26.25
1.241369526
1.5
1.5
160384
35795508.96
157.4851804
19204320.73
168.9833703
350
2.222431336

INPUT
INPUT
INPUT
INPUT

INPUT
INPUT

INPUT

SELECTION OF MOTOR
INPUTS
Pressure available,p
Flow rate avilable,Q
Torque required,T
Speed required,N
Motor inputs
Power,P
Displacement,D
Max. attainable speed

OUTPUTS
320
280

320
280

bar
LPM

FOR MAX. TORQUE REQUIREMENT

MS 50
MS 83

23

23

kNm

Flow Rate

approx 60 approx 60 rpm

MS 50
MS 83
Full Disp. Half Disp.
140
135
kW
4996

4164

70

60

253.125 LPM

52.54203

Torque

24.93667 20.78389 kNm

60.7889 rpm

FOR MAX. SPEED REQUIREMENT

MS 50
MS 83

cc/rev Pressure
rpm

262.5

Speed

Speed

MOTOR SELECTED

300 289.2857 bar

56.04484 67.24304 rpm

MS 50

P=pxQ
N = Q / D (rpm)
T = 1.59 x 9.81 x 10-3 x p x D

P=pxQ
N = Q / D (rpm)

DRUM DESIGN
INPUTS
Outer diameter of the drum D
Inner diameter of the motor d
Maximum bending moment Mb
Axial force F
torque T
length ,L
km
kt
T

545.3
495.3
2870000
40000

mm
mm
N-mm
N

25410000 N-mm
600 mm
4
4
380 Mpa

radius of gyration k
k
a
effective torque Te
t
T all
FOS
34Co Mb4

Axial load
Bearing A

OUTPUTS
0.9083074 mm
184.16606
1.0145434
102975113 N-mm
10.128495 Mpa
219.26 Mpa
21.647837

k = di / do
K = (do2 + di2)1/2 /4
a = 1/ (1- 0.0044(L/K))

[{Kb x Mb + ( x Fo x do x (1+k2))} 2 + (Kt x T) 2]

t= 16 x Te / (p x do 3 x (1 k4))
FOS= t/T all

Radial load

Bearing A

Bearing B

STRUCTURE DESIGN
INPUTS
Outer diameter of the drum D
Inner diameter of the motor d
Maximum bending moment Mb
Axial force F

457.2
405
10770000
40000

torque T
length ,L
km
kt
T

25410000 N-mm
1120 mm
4
4
380 Mpa

mm
mm
N-mm
N

Bearing A

radius of gyration k
k
a
effective torque Te
t
T all
FOS
34Co Mb4

Bearing B

Axial
load
A

Bearing C

E
B

OUTPUTS
0.885826772 mm
152.6959479
1.033349587
112105253.5 N-mm
15.54707766 Mpa
219.26 Mpa
14.10297194

k = di / do
K = (do2 + di2)1/2 /4
a = 1/ (1- 0.0044(L/K))

[{Kb x Mb + ( x Fo x do x (1+k2)/8)} 2 + (Kt x T) 2]

t= 16 x Te / (p x do 3 x (1 k4))
FOS= t/ T all

Bearing D

Axial
load

BEARING SELECTION
INPUTS
speed (rpm)
max axial load
max radial load

60
40000
30000

Ka = 40000
B
FrB = 15000

Load conditions
One of the cutters is taking up all load
Cutter is plunged in
Axial loading
Equal loads
Actual working condition
idle condition

%Radial
100
100
0.0001
50
75
0.0001

Bearing
A
B

%axial
100
0.0001
100
50
25
0.0001

time
0.0001
2.5
2.5
30
60
1.5
96.5001

%time
0.00010363
2.59067089
2.59067089
31.0880507
62.1761014
1.55440253
100

N(rpm)
60
60
60
60
60
60

e
0.8
0.8
0.8
0.8
0.8
0.8

X
0.63
0.63
0.63
0.63
0.63
0.63

Y
1.24
1.24
1.24
1.24
1.24
1.24

X
1
1
1
1
1
1

Thickness
19.05
19.05

C
51500
103000

Inner dia. Outer dia.

457.2
495.3
457.2
495.3

G SELECTION
30000

A
FrA= 15000
OUTPUTS
radial load axial (Ka)
30000
40000
30000
0.04
0.03
40000
15000
20000
22500
10000
0.03
0.04

Y
0.78
0.78
0.78
0.78
0.78
0.78

Pa
38400
24360
0.02436
12180
18270
0.02436

Pb
49130
24330.0248
24800.0243
24565
24447.5
0.04913

Co
123000
123000

Nm
PmA
PmB

60
16783.9286
24363.5418

Fr
15000
15000
0.015
7500
11250
0.015

FaA
12000
12000
0.012
6000
9000
0.012

(Ni*Qi*Pi3)A
3.5206E+11
2.24696E+15
0.00224696
3.37044E+15
2.27505E+16
0.001348176
2.83682E+16

(Ni*Qi*Pi3)B
7.37333E+11
2.23868E+15
2.37094E+15
2.765E+16
5.45102E+16
0.011059998
8.67706E+16

life of A
life of B

28.88955241
75.55973108

FaB
32000
12000.02
20000.01
16000
14000
0.032

8024.876
20988.81

Equi N
0.006218
155.4403
155.4403
1865.283
3730.566
93.26415
6000

SHAFT DESIGN CALCULATION

INPUTS

OUTPUTS

Total length of the shaft(L)

1168

K(radius of gyration)

23.75

Diameter of the shaft(mm)

Value of T(Nmm)

95
25400000

alpha
Load factor for motor

1.276141
50.12

Value of M(Nmm)

Km

1.5

Kt

1.25

Allowable stress (Mpa)

375

F(N)

160384

Te(Nmm)
shear stress,t(MPa)

31842892

Me(Nmm)
bending stress(MPa)
FOS

17136689
203.5959
1.982488

189.1563

k = di / do
K = d /4
a = 1/ (1- 0.0044(L/K))

[{Kb x Mb + ( x Fo x d /8)} 2 + (Kt x T) 2]

t= 16 x Te / (p x do 3 x (1 k4))
FOS= t/ T all

FASTENER SELECTION
INPUTS

FLANGE

DRUM

STRUTURE

OUTPUTS

a (Ref. Fig)

401

575.3

457.2

b (Ref. Fig)

361

535.3

430

F (Ref. Fig)

60000

60000

60000

Max. Tensile Force, F1 ( N )

L (Ref. Fig)

265

600

225.5

Fb

a
Cos a

No. of Bolts, i
Bolt area (Ac)
Tensile Stress Allowable,sall

12

12

Maximum Tensile Load

192

157

84.3

Tensile stress calculated

640

640

640

FOS

shear stress allowable,tall

480

480

480

Shear load
shear stress
FOS

Torque

25000000

Ka
tensile stress

40000
40000
21.23142 39.54132068

shear stress due to load

FOS

FLANGE

DRUM

STRUTURE

22.5

15

15

0.923879533
6460.655979
7500

FORMULAE
a=180 /

i
cos(a*p/180)
0.965926 0.965925826
6910.127 3263.208121 F1=2FL(a+bcos a)/(2a^2+b^2)
5000

5000

Fb=F1/ i

Ft = ( F1 + ( F1^2 + 4 x Fb^2)^)

11396.41756

9532.683 6891.084245

59.35634147
10.78233571

81.94915 121.2860923 s = Ft /Ac + sa

7.809721 5.276779786 FOS = sall / s

8166.089573

6077.62

42.53171653

38.71095 62.39003778

11.28569546

12.39959 7.693535973 FOS = tall / t

24.78916
19.3633

5259.480184 Ft = ( F1^ + 4 x Fb^2)^)

Ft = t / Ac

t = Ft/(i* Ac * a)
FOS = tall / t

By normal stress theory

By maximum shear stress theory

Stress due to torque

DESIGN OF SPLINE
INPUTS
Displacement of the MS50 motor
Pressure
Module m
Nominal diameter
Pressure angle
Number of teeth N
Effective length
Application factor ka
Load distance factor km
Life factor kf
Material yeild strength

LEFT
4996
320
5
130
20
24
120
1.8

RIGHT
4996
320
5
95
20
17
120
1.8

0.3
570

0.3
650

OUTPUTS
cc/rev Torque on the splines T
bar
PCD
OD male
mm
Profile displacement
deg
Tooth thickness at PCD
Tooth height
mm
Material shear strength
Spline shear stress at PCD

LEFT
2541.965
120
129
0.8
10.76574
4.5
328.89
8.198474

Spline shear stress at PCD

80.42703

Compressive stress
Compressive stress
FOS

2.179325
21.37918
4.089297

Mpa

RIGHT
2541.965
85
94
0.8
10.76574
4.5
375.05
16.34021

Nm
mm
mm
mm
mm
mm
Mpa
kgf/mm2

160.2975 MPa
4.343568 kgf/mm2
42.61041 MPa
2.339713