FACULTY OF MECHANICAL ENGINEERING

MACHINE ELEMENTS
PROJECT
PROJECT : Horizontal Cylindrical Single Step
Speed Reducer

Contents
Contents..........................................................................................................2
1.STRUCTURAL SCHEME, TORQUES AND ROTATIONS FOR EACH
SHAFT.............................................................................................................4
1.1. Structural scheme................................................................................4
1.2. Establishing the rotational speed and the torques for each shaft........5
2. PRE -DIMENSIONING OF THE GEAR.......................................................6
1. Input data...............................................................................................6
1.1. Rotation of the pinion........................................................................6
1.2. The torque at the pinion....................................................................6
1.3. The gear ratio....................................................................................6
1.4. The imposed lifetime.........................................................................6
1.5. Functioning conditions......................................................................6
1.6. Loading cycles...................................................................................6
1.7. The no. of loading cycles in the case of one complete rotation for
the pinion 1 ..........................................................................................6
1.8. The reference racks profile................................................................6
2. Choosing the materials treatments and limit stresses...........................7
2.1. Choosing the materials treatments and the hardness.....................7
2.2. Limit stresses for contact: Hlim 1.2,Flim 1.2, Mpa ...............................7
3. Pre-dimensioning of the gear..................................................................7
3.1. Number of teeth for the pinion and wheel z1, z2................................7
3.2. The real gear ratio.............................................................................7
3.3. The contact calculus factor...............................................................8
3.4. The bending calculus factors.............................................................8
3.5. Load correction factors......................................................................9
3.6. Allowable stress
Fp 1,2

Hp 1,2

for crushing, respectively for bending

in MPa.......................................................................................10

3.7. Pre dimensioning of the distance between the axes.......................11

2

GEAR FORCES CALCULUS..........................................................................13

Calculus of forces.......................................................................................13
Calculus scheme and establishing of the forces direction..........................13
4.Shaft calculus..........................................................................................14
Pre-dimensioning calculus..........................................................................14
4.1. Choosing the bearing assembling for the input and output shaft
.......................................................................................................................15
5. Choosing and verifying the assembling through key between the
driven wheel and output shaft.................................................................20
6. Choosing and verifying the bearings assembling of the input shaft
.......................................................................................................................21
7. Choosing and justifying the sealing devices.....................................23
8. DESIGN OF THE BELT.............................................................................24
9. JUSTIFICATION ON CHOSE OF MATERIALS AND CONSTRUCTIVE
SOLUTIONS FOR THE MAIN PARTS OF THE MECHANISM......................28
10. RULES OF SAFETY AT WORK..............................................................29

1.STRUCTURAL SCHEME, TORQUES AND

ROTATIONS FOR EACH SHAFT
1.1. Structural scheme

Figure1.1
M - electric motor
P - power of the electric motor
n rotation of the motors shaft
Mtn torque at the motors shaft
iL ratio of the chain drive transmission
iR speed reducers ratio
I input shaft of the speed reducer
II output shaft of the speed reducer
TI torque at the input shaft
4

nI rotational speed of the input shaft

TII the torque at the output shaft
nII the rotational speed of the output shaft
1 pinion
2 wheel
A,B,C,D bearings
W.M. working machine

1.2. Establishing the rotational speed and the torques for each
shaft
The motors shaft
Rotational speed:
n = 930 rot/min
The torque:
P
7.5
M tn =9.55 106 =9.55 106
=77016.13 Nmm
n
930
The input shaft
The torque:
M t 1=T I =M tn i c =77016.131.16=89338.71 Nmm

Rotational speed:

n 930
n I= =
=801.72 rot /min
i c 1.16

The output shaft

The torque:
M t 2=T II =T I i R =89339.175=446693.55 Nmm
Rotational speed:

n II =

n I 801.72
=
=160.344 rot /min
iR
5

2. PRE -DIMENSIONING OF THE GEAR

1. Input data
1.1.

Rotation of the pinion

1.2.

The torque at the pinion

1.3.

The gear ratio

1.4.

The imposed lifetime

n1=930 rot / min

T 1 =89338.71 Nmm
udat =i r =5
Lh=8500 h

1.5.

Functioning conditions

1.6.

Loading cycles

1.7.

The no. of loading cycles

The motor: ASYNCHRONUS M

The machine:
SMALL SHO
The load:
UNIFOR
Contact: Pulsating
Bending: Pulsating

in the case of one

1,2=1

complete rotation for the

pinion

1
n=20 ,h an=1, cn =0.25 , fn =0.38

1.8.

The reference racks profile

For inclined tooth profile.

2. Choosing the materials treatments and limit stresses

MATERIAL:
2.1.

Choosing the materials

treatments and the
hardness

2.2.

Limit stresses for contact:

18MnCr20

r 1.2=1500

TREATMENT:
CEMENT
02 1.2=635 MPa

Hlim1,2=1500 Mpa , Flim1,2=430 Mpa ,

Hlim1.2 , Flim 1.2 , Mpa

3. Pre-dimensioning of the gear

z 1max =

aw
2
2

cos=50
cos 7=16.
mn u dat + 1
5+1

( )

aw
=40 50 annealing=50
mn
3.1. Number of teeth for the

=6 14 =7

pinion and wheel z1, z2

It is chosen

z1 = 17 teeth

z 2=z 1 udat =17 5=85

z 2=85 teeth
u=
3.2.

The real gear ratio

z2
=5
z1

|| |

u
5
= 1 =0 u =0.03The condition is acco
udat
5

3.3. The contact calculus factor

3.3.1. The elasticity factor
Z E=189.8 MPa

Z E , MPa

Z H =2.49 cos=2.49 cos 7=2.48

3.3.2. The contact zone factor

3.3.3. The gearing factor

Z=

3.3.4. The tooth inclination factor

1
1
=
=0.95

1.1

Z = cos= cos 7=0.9962

3.4. The bending calculus factors

3.4.1. The number of teeth for the
equivalent wheels

z n1 =

z n1,2

z1
3

cos

17
=17.38
cos 3 7

z n 2=

z2
3

cos

3.4.2. The profiles displacements

85
=86.92
3
cos 7

x n1,2 =0

coefficients
Y Fa 1=Y Fa 1 ( z n 1, x n1 ) =Y Fa 1 (17.38 ; 0 )=2.94
3.4.3. The teeth shape factors

Y Fa 2=Y Fa 2 ( z n 2, x n2 ) =Y Fa 2 ( 86.92; 0 )=2.25

Y Sa 1=Y Sa1 ( z n1, x n 1 )=Y Sa1 ( 17.38 ; 0 )=1.55

3.4.4. The stress correction factors

3.4.5. Covering grad factor

Y Sa 2=Y Sa2 ( z n 2, x n 2 )=Y Sa 2 ( 86.92 ; 0 )=1.77

Y =0.25+

0.75
0.75
cos 2 =0.25+
cos2 7=0.9

1.1

Y =1

3.4.6. Factor of the inclined tooth

7
=1
=0.84
120
120

3.5. Load correction factors

3.5.1. Working condition factors

K A =1.1

KA

K =1.05 1.10=1.07

3.5.2. Dynamic factor

3.5.3. Uniform distrib. factor of the
load on the tooth width

K H =1.5 1.75=1.5

K H

K F =1.5 1.7=1.5
crushing and

K F

bending

stresses
3.5.4. Uniform distribution factor of
the load in frontal plan
crushing and

K F

K H

K H =K F =

bending

cos

1.1
=1.11 1.4
cos 2 7

The condition is accomplished.

stresses

3.6.

Allowable stress

Hp 1,2

Hp 1=

Hlim Z N 1
Z L Z Z R Z W Z x =1000 MPa
S Hmin

Hp 2=

Hlim Z N 2
Z L Z Z R Z W Z x =1000 MPa
S Hmin

for crushing, respectively

for bending

Fp 1,2

in MPa

Hp 1=min ( Hp 1 , Hp 2)=1000 MPa

S Hmin =1 1.3=1.2 for usualtransmission

Where:
ZL

- lubricating factor

- speed factor

ZR

- roughness factor of the active flanks

Z L Z Z R=1

for rectified tooth gear with

Z W =1

torque factor of the material

Z x =1

measurement factor

ZN1

=1.21

Z N2

=1.25

- no cips admitted

Hp 1=

Hp 2=

Hlim Z N 1
1500 1.21
Z L Z Z R Z W Z x=
1=151
S Hmin
1.2

Hlim Z N 2
1500 1.25
Z L Z Z R Z W Z x =
1=156
S Hmin
1.2

For generally used speed reducers

9

R A 0.4 m

Allowable stress for bending

FP 1=

Flim 1 Y ST Y N 1
Y 1 Y R 1 Y x
S Fmin

FP 2=

Flim 2 Y ST Y N 2
Y 2 Y R 2 Y x
S Fmin

Y ST =2

correction factor

Y 1,2=1

(relative sensibility factor at the tension concentrator

addendum)
Y R 1,2

= 1.0 for roughness of the application zone of the teeth

Y N 1,2=1
Y X =1

durability factors for bending for the wheels

size factor

S Fmin =1.6

FP 1=

usual industrial transmission

Flim 1 Y ST Y N 1
560 2 1
Y 1 Y R 1 Y x =
1 1 1=700 M
S Fmin
1.6

560 2 1
1 1 1=700 MPa
1.6

Y Y
FP 2= Flim 2 ST N 2 Y 2 Y R 2 Y
S Fmin
x=

3.7. Pre dimensioning of the distance between the axes

a 0.60 v=2 10 m/ s
3.7.1.Width coefficient:

a=0.6

d
d =

10

u+1
5+1
a=
0.6=1.8
2
2

3.7.2. Distance between the axes from the

condition of the bending stress

a wF , mm

3.7.3. Distance between the axes from the

condition of the contact stress

a wH ,mm

a wF =

T 1 z1 (u+1)2
Y Y
3 893
K A K v K F K Fy Y Y Fa sa =
2 a cos
Fp

a wH =( u+1 ) 3

T 1 K A K v K H K H
2 a u HP

( Z E Z H Z Z )2= (5+ 1 ) 3

89

a w =max ( a wH , awF )=max (73.595, 78.815 )=78.815

3.7.4. Adopting the distance between the

axes in pre dimensioning

aw

It is chosen

a w =80 mm STAS 6055

b2= a aw =0.6 80=48

3.7.5. Preliminary width of the wheels
b1=b2 + b

b1,2 , mm

=50 mm

b=1 3 mm=2 m

11

GEAR FORCES CALCULUS

Calculus of forces
Radial force:
2T 2 89339.17
Ft 1,2= 1 =
=6569.056 N
d w1
27.2
Fr 1,2=
Axial force:

Ft
6569.056
tg wn=
tg18.80074=2253.178 N
cos
cos 7

Fa 1,2 =Ft 1 tg=6569.056 tg 7=806.578 N

Calculus scheme and establishing of the forces direction

4.Shaft calculus

Pre-dimensioning calculus
Input shaft
dI =

16 T I 3 16 89338.71
=
=31.52mm
at 1
16

at 1 =15 20 MPa=16 MPa

Output shaft
3 16 T II
16 446693.55
d II =
=3
=39.45 mm
at 2
40

at 2=35 45 MPa
It is adopted :

dI

=40 MPa
=32mm
d II

=40 mm

4.1. Choosing the bearing assembling for the

input and output shaft
d rul1 d1 (2.....7) 32 2 30mm
d rul 2 d 2 (1....7) 40 5 35mm
Bearing choosing
d

Co

Referenc

Limit

Designatio

30

55

17

35.8

44

e speed
9000

speed
12000

n
32006 X/Q

II

35

62

18

42.9

54

8500

11000

32007 X/Q

c- dynamic load
Co-static load

4.2. Verifying the input shaft at composed loads

Determining the reaction from the 2 planes

In horizontal plane :
M A 0 Fa1

HB

Fa1

dw
l
Fr1 H B l 0
2
2

dw
l
27.2
60
Fr1
806.578
2253.178
2
2
2
2 1309.41N
l
60

M B 0 H A l Fa1

HA

Fa1

dw
l
Fr1 0
2
2

dw
l
27.2
60
Fr1
806.578
2253.178
2
2
2
2 943.76 N
l
60

In vertical plane
M A 0 VB l Ft1

VB

l
60
6569.056
2
2 3284.52 N
l
60

Ft1

M B 0 V A l Ft1

VA

l
0
2

l
0
2

l
60
6569.056
2
2 3284.52 N
l
60

Ft1

The reactions from the two camps

R B H B2 V B2 1309.412 3284.52 2 3535.90 N

R A H A2 V A2 943.76 2 3284.52 2 3417.41N

Drawing the bending moments diagram in the 2 planes

Bending moments

d
l
60
27.2
M iH H A Fa1 w1 943.76 806.576
39282.23 Nmm
2
2
2
2
M iV V A

l
60
3284.52
98535.6 Nmm
2
2

Total bending moments

2

M i M iV M iH2 39282.232 98353.6 2 106077.13 Nmm

Identifying the loads

-compression of Fa1

4 Fa1
4 806.578

1,14 MPa
2
d t1
30 2

-torsion

t1

16T1
16 89338.71

16.85MPa
3
d t1
30 3

-bending

32T1
32 89338.71

33.7 MPa
3
d t1
30 3

l1 c2 4( t1 ) 2 1,14 2 4(0,27 16.85) 2 9.17 MPa

ai II 90

0,27
ai I 330

l 1 9.17 MPa ai II 90 MPa

5. Choosing and verifying the assembling

through key between the driven wheel and
output shaft

5.
1. Determing the length calculus

4T
F 4TII 1
1
4 446693.55

as l c II

47.72mm
A d II flc
d II as h
40 120 8

l 47.72 8 55.72mm

lstas=60mm

Because

2T II
as
l c bd II

l b2

there are chosen 2 keys A8 x10 x32 STAS 1004-8 1

2 446693.55
39 Mpa as 100 MPa
47.72 12 40

6. Choosing and verifying the bearings

assembling of the input shaft

Verifying the bearings assembling

Choosing the bearings radial-axial with conic roles on one row in

 Verifying the bearings assembling after the dynamic load

Setting the suplementary axial forces
F
943
FaA' 0,5 rA 0,5
249.68 N
Y
1,6
FaB' 0,5

FrB
1309
0,5
409.06 N
Y
1,6

B bearing
FaA 806

16.79
C0r
48
FaB 806.5

0.61
FrB 1309

Equivalent dynamic load

PB f P (VP X FrB Y FaA ) 1,16(1 0,4 1309 1,6 806) 2103.3 N

Durability of the bearing

60 n I Ln 60 801.72 8500
L

408.9mil. rot.
10 6
10 6
Needed dynamic load capacity

C r nec B PB P L 2103.3 3 408.9 15611.34 N

Durability assured by the bearing

 C
L r
PB

15611.34

2103.3

408.9mil.rot .

Functioning time
106 L 106 408.9
Lf

7327.77ore
60n
60 930

7. Choosing and justifying the sealing devices

dm1=drul1-(23)=30-2=28 mm
dm2=drul2-(23)=35-3= 32mm

There are chosen two simerings : A28x40 and A32x40 STAS 7950/2-72

Nr

dm

28

40

II

32

10

50

7.1. Heads of the shaft calculus

Nr
da
(mm)
I
24
II
28

36
42

8
10

8. DESIGN OF THE BELT

8.1 Calculus power at driving shaft :
P=7.5 KW
P
Pc
= =7.89 kw
=0.850.95 transmission efficiency
=0.95
8.2 Driving wheel speed
n1=930 rot/min
8.3 Driven wheel speed
n2=801.72 rot/min
8.4 Transmission gear ratio
n1
930
=1.16
i= n2 = 801.72
8.5Workin regime of the transmission
Lh=8500h
8.6Type of belt
It is chosen belt type SPZ
8.7 Primitive diameter of the wheel
D1=140mm
8.8 Primitive diameter of the big wheel
Dp2=iD1=1.16*140=162.4 mm

8.9 Primitive diameter of the belt wheels

Dpm=(Dp1+Dp2)/2=(140+162.40)/2=151.2mm
8.10 Distance between axes :
Preliminary

0.7 (Dp1+Dp2) A 2 (Dp1+Dp2)

0.7 (140+162.4) A 2 (140+162.4)
211.68 A 604.8 => A=400 mm
8.11 Angle between belt arms:
( Dp2Dp1)
(162.4140)
=2arcsin
=2acrsin
=3.22
2A
2400
8.12 Winding angle on small wheel
=180-3.56=176.44
8.13 Winding angle on big wheel
2=180+==183.56
8.14 Primitive length of the belt
1

Lp=2*A*sin 2 + 360 * ( 1 D p 1+ 2 D p 2 ) = 2*400*sin

176.8
+
2

360 *

(176.8 140+183.2 162.4) =1275.3 mm => it is adopted 1400 mm

Distance between axes ( definite)
Lp
A=

( 1 D p1 + 2 D p 2 ) 1400
(176.8 140+183.2 162.4)
360
360
=
=462.36 m/ s
1
176.8
2
sin
2 sin
2
2

8.15 Pheripheral speed of the belt

v=*Dp1*n1/60000= *140*801.72/60*1000=5.87m/s
8.16 Functioning coefficient
Cf=1.2(816h) neglijable variations of the work regime
8.17 Length coefficient
CL==0.96
8.18 Winding coefficient
C=0.99
8.19 Nominal powertransmited by the belt
Po=2,87 kw
8.20 Nr of belts coefficient

Cz=0.90
8.21 Number of belts
Zo=Cf*P/Cl*Po*C=1.2*7.89/0.96*0.99*2.87=3.47
Z=Zo/Cz=3.47/0.90=3.84 => z=4 belts
8.22 Number of transmission wheels :
Constructively we choose x=2
8.23 Bending frequency of the belt:
f=103*x*v/Lp=103*2*5.87/1400=8,38 H
8.24 Periferic transmitted force
F=103*Pc/v=103*7.89/5.87=1344
8.25 Tensile strength of the belt :
F=(1.52)F=1.6*1344.12=2314.6 N
8.26 Distance between axes modifying levels :
X 0.003 Lp ; X 42
Y 0.015 Lp ; Y 21
8.27 Simbolization and designation of the belt:SPZ 1400 STAS 7192
8.28 Simbolization and designation of the wheel of the belt :RCT 140 A 382 STAS 1162

9. JUSTIFICATION ON CHOSE OF MATERIALS

AND CONSTRUCTIVE SOLUTIONS FOR THE
MAIN PARTS OF THE MECHANISM

For proper operation of the speed reducer the input shaft, the output
shaft should be stiff enough for good transmission of power, for

reduced wear of the teeth.

For this reason it is chosen l 18MnCr20 for the shafts.
Also there are chosen angular contact ball bearings, because the are
taking over medium radial loads and, small to medium axial loads

acting on one way. The are mounted in X.

Axial clearance of the bearings are adjusted during the fixing of the

assembling, through relatively displacement of the rings.

The cap and the body of the speed reducer will be manufactured
from regular materials, low alloy steels for general construction

usage from STAS 500/2.

The separation plane between the body and the cap should have
relatively small roughness to ensure a good sealing so that dust and

other impurities can not get inside the speed reducer.

Screws should be resistant enough to ensure a good fixing of the
bearings, in this way reducing the radial and angular movements of

the shafts.
Also for proper sealing there are chosen proper Oil Retaining Rings.

10. RULES OF SAFETY AT WORK

At work or in the operation of the gears you will need to take into
account the following provisions relating to rules of safety at work.
1. The device has to be fixed with screws to the workbench.
2. Do not use reducers that have missing parts, components.
3. Do not change the oil during operation.
4. Do not check the oil during operation.
5. Defective or worn parts will replace the corresponding ones.
6. There are no adjustments to the play from ball bearings during
operation.
7. Follow the exchange of oil ranges and bearings.
8. It aims to overcome the operating hours to load.