KATHMANDU UNIVERSITY

SCHOOL OF ENGINEERING
DEPARTMENT OF MECANICAL ENGINEERING

Report on Whiteboard Shifter

Submitted By:
Aklesh Teli [32116]
Samrat Khanal[32103]
Submitted To:
Assot.Pratisthit Lal Shrestha

10 July 2019

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Table of Contents
Introduction:...............................................................................................................................................3
Problem Definition:.................................................................................................................................3
Mechanism:.............................................................................................................................................3
Working principle:...................................................................................................................................3
Calculation:..................................................................................................................................................4
Calculation of required power:................................................................................................................4
Calculations for the pinion.......................................................................................................................5
Material Selection and Strength Analysis:...................................................................................................6
Check for tangential load.........................................................................................................................6
Check for dynamic load...........................................................................................................................7
Check for static load or endurance load...................................................................................................7
Check for wear........................................................................................................................................7
Heat dissipation.......................................................................................................................................8
Design of the Pinion shaft:.......................................................................................................................8
Calculation For Rack...............................................................................................................................9
Dimension of Pinion gear according to the American Standard............................................................10
Calculation of Intermediate Gear...........................................................................................................11
Material Selection and Strength Analysis:.................................................................................................11
Check for tangential load(spur).............................................................................................................12
Check for dynamic load.........................................................................................................................12
Check for static load or Endurance load................................................................................................13
Check for wear......................................................................................................................................13
Design of the Pinion shaft:.....................................................................................................................14
Dimension of Spur gear according to the American Standard...............................................................15
Dimension of Gear according to the American Standard.......................................................................15
Design of ratchet and pawl mechanism:...................................................................................................16
Conclusion.................................................................................................................................................18
Problem Definition:...............................................................................................................................18
References.................................................................................................................................................19

2
Introduction:
Over the years, engineers have extolled the different forms of board that is white boards,
chalk boards making ease in learning and teaching process being very efficient yet
continue to seek new form of design for its mobility up and down or sideways. Rack and
pinion is the combination of gears which can provide us the linear motion, horizontally or
vertically by converting the rotating motion and vice versa. Ratchet and pawl mechanism
can be used to lock the motion in reverse direction.

Problem Definition:
A whiteboard made of plywood attached with mica Sheet for the easy dry clean. The
velocity with which the board moves upward is desired to be 4 cm/s . Dimension of the
board is 120 cm× 80 cm× 1.5 cm.

Mechanism:
The board is shifted vertically up and down with the aid of rack and pinion. The ratchet
and pawl mechanism is used to lock the board at the desired position.

Ratchet and pawl Rack and pinion

Working principle:
The whiteboard is attached to the max channel in which rack slides over the sliding
bearing with the rotation of pinion. The shaft connecting the pinion consists of another
spur gear meshing with other gear in the main shaft. These intermediate gears are only
responsible for the speed reduction as per required. The ratchet is also connected on the
main shaft and the pawl to the frame. It locks the reverse direction of the board due to its

3
weight when it is lifted to certain height. Handle is connected on the main shaft to
provide the required power to lift the board.

Calculation:
Calculation of required power:
Desired velocity of the whiteboard ( v)=4 cm/ s =0.04m/s

Dimension of the whiteboard: 120 cm× 80 cm× 1.5 cm

Volume of the whiteboard V =1.25 × 0.8× 0.015=0.015 m3

Density of the whiteboard material (plywood) From design databook,

ρ=650 kg/m3

Therefore weight,

Taking g=9.81m/s2 W 1= ρ× V × g=95.60 N

Volume of the Mica Sheet

V =1.25 × 0.8× 0.003=0.003 m3

Density of the Mica Sheet material

From design databook, ρ=1570 kg/ m3

Therefore weight,
W 2 =ρ× V × g=46.2 N

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Volume of the Rack
V =.83 × 0.0325× 0.02=0.00056 m 3

Density of the Cast Iron material

From design databook, ρ=7874 kg /m3
Therefore weight
W 3 =ρ× V × g=43.2 N

The Total Weight

W =W 1 +W 2 +W 3

¿ 185 N

Required power
P=W × v =7.4 W

Calculations for the pinion

1
⇒ frequency (n2 )= rev / s=¿ 1 revolution in 8 seconds
8

In 16 seconds the board shifts by4 cm/s × 8 s=32 cm.

Therefore 2 πr 2 =320 mm
⇒ radius(r 2)=50.93mm .

Let’s assume 80 teeth on the rack.

⇒ tooth /cm

⇒ 4 teeth /s

In 8 seconds 32 teeth of rack are displaced in a complete revolution of pinion.

Therefore
number of teeth ( z 2)=32
2 πr 2
circular pitch( p¿ ¿2)= =10 mm ¿
z2
p2
module (m¿¿ 2)= =3.18 mm ≅ 3.25 mm ¿
π

5
Module is taken as 3.25mm From table 12.2
Assumption: 20° stub tooth involute system.
φ n=20 °for ¿ From Table12.4(b).
Material Selection and Strength Analysis:
Rack and Pinion gear are chosen to be Cast Iron.

Since both are made up of same material .Pinion is weaker and hence calculation for
pinion is done below.

Check for tangential load

The face width in terms of module can be taken in the range 9.5 m ≤b ≤ 12.5 m. But in
special case we can take 6m either. From eq 12.5(f)

We chooseb=6 m1=19.5 mm

According to Lewis equation F t=σ d C v bYm From Eq 12.5(a)

Where,

σ d=47.1 MN /m2is the allowable static stress for Cast Iron. From Table 12.7

3.05
C v= =0.433 is the velocity factor From Eq 12.6(a)
3.05+v

0.95
y=0.175− =0.1453is Lewis form factor for 20 °
z2

Stub tooth involute system From Eq 12.5(e)

Y= πy=.456 Form Factor.

The permissible tangential force on the worm gear is σ d Cv bYm=589.37 N .

Here permissible tangential force F t=589.37 N is much higher than that of applied force
on the teeth of the gear F 2t =W =185 N , hence justified.

Check for dynamic load

We know that the dynamic load,

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 Ft
F d= =1.361 KN
Cv

Since F d=1.361 KN the dynamic load is much higher than F 2t =W =185 N , so the design is
safe from the dynamic load point of view as well.

Check for static load or endurance load

Flexural endurance limit of cast iron is σ en=83.5 MPa∨N /mm2
From Table 12.15

Therefore, static load or endurance strength is

F s=σ en bYm=2.413 KN From Eq 12.13(a)

Here F s=2.413 KN is much greater than F 2t =W =185 N and hence the design is justified.

Check for wear

As the material for Pinion as Cast Iron, Checking for Wear

Therefore, limiting load for wear is

F w =d 2 bQ=m Z 1 bQk From Eq 12.15(a)

Load Stress Factor K=1.814 From Table 12.16

2 Z2
The Ratio Factor Q= =1.43 From Eq 12.15(c)
Z1 + Z 2

Module(m)=3.25mm

Face width(b)=32.5mm

so, F w =d 2 bQ=m Z 1 bQk=5.260 KN From Eq 12.15(a)

Here F w =5.260 KN > > F 2t =W =589.3 N , so it is safe from the wear load point of view.

Heat dissipation
Since there is no sliding action, only rolling. Hence there is No Heat generation.

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Torque

P × 60 Dp
T= ∨¿W T ×
2× π × N p 2

WT=W Since total load calculated act as the tangential load

= 185N

Dp = Z1*m

=104mm

T =9.62 KN

Normal Load (WN)

WT
WN=
cos ∅

=196.88N

Design of the Pinion shaft:

Torque acting on Pinion gear shaft,

T =9.62 KN

Weight of Pinion (Wp) =0.00118 × b ×m 2 × Z 1 From R.S Khurmi

=7.77N

Resultant weight acting on pinion

W R= √ W 2N +W 2P +2 ×W N ×W P cos ∅

¿ 204.2 N

Bending Moment on the shaft due to resultant load (M).

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 Dp
M =W R ×
2
¿ 10.618 KN

Twisting Moment on the shaft (Ts)

Dp
T s=W T ×
2

¿ 9.62 KN

Equivalent Twisting Moment (TR)

T R =√ M 2 +T 2

¿ 14.32 KN

Diameter of the Shaft for Pinion (dp)

The Shear Stress for the Cast Iron (Ꞇiron)=400Mpa

π
T R= ×Ꞇ iron × d3P From R.S Khurmi
16

d P=5.67 mm

Calculation For Rack

Length of Rack (L)

L= Z × π ×m

¿ 819.98 mm

¿ 82 cm

Hence the length of the Rack is about 82cm. Before, the weight calculation for the rack is
also for 83cm.Hence satisfy for the contribution for the load.

Pitch Diameter of Rack (dr)

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Taking Number of modules in pitch diameter q=11 From R.S Khurmi

For Mating Gear Module is same. Hence m=3.25mm

d r =m× q From R.S Khurmi

¿ 35.75 mm

Tip Diameter (da)

d a =d r +2 ×m

¿ 42.25 mm

Root Diameter(dR)

d R=dr −2 ×m−2 × c (c=Clearance)

¿ 27.95 mm

Dimension of Pinion gear according to the American Standard

Table 12.4(a)

Pressure=20 °

Addendum=0.8m=2.6mm

Minimum Dedendum =m=3.25mm

Minimum total Depth=1.8m=5.85mm

Minimum clearance=0.2m=.65mm

Thickness of Tooth=1.571m=5.1mm

Approximate Fillet Radius=0.209m=0.67mm

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Calculation of Intermediate Gear
The Whiteboard shift with the 7.5 rpm as we suppose earlier. Assuming the gear ratio 6.
The motor is of 45 rpm. The power transmitted is 7.4watt. Thus the specification of
motor is 45rpm with 7.4watt power.
According to the assumption of gear ratio 6, the number of teeth in gear and pinion
should be
Zgear=36 Zspur=6 Ngear=7.5rpm Nspur=45rpm
As our calculation the whiteboard is shifted with the linear velocity 4cm/s. Hence the
gear should also have same linear velocity.
V =π × d gear × N gear

0.04 m
=π × d gear ×.125 rps
s
d gear=101.8 mm

Now
d gear N spur
=
d spur N gear
d spur =17 mm

We Know
d spur
m=
Z spur
m=2.83 mm

From the Table 12.2 the module is taken 3mm.

The new Diameter of Gear and Spur according to module 3mm is
d spur =18 mm

d gear =108 mm

Material Selection and Strength Analysis:

Gear and Spur are chosen to be Cast Iron.

Since both are made up of same material .Spur is weaker and hence calculation for Spur
is done below.

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Check for tangential load(spur)
The face width in terms of module can be taken in the range 9.5 m ≤b ≤ 12.5 m. But in
special case we can take 6m either. The linear velocity of spur is 4.02cm/s.
From eq 12.5(f)

We chooseb=10 m1=30 mm

According to Lewis equation F t=σ d C v bYm From Eq 12.5(a)

Where,

σ d=47.1 MN /m2is the allowable static stress for Cast Iron. From Table 12.7

3.05
C v= =0.986 is the velocity factor From Eq 12.6(a)
3.05+v

0.95
y=0.175− =0.1453is Lewis form factor for 20 °
z2

Stub tooth involute system From Eq 12.5(e)

Y= πy=.456 Form Factor.

The permissible tangential force on the worm gear is σ d Cv bYm=217 N .

Here permissible tangential force F t=217 N is much higher than that of applied force on
the teeth of the gear F 2t =W =185 N , hence justified.

Check for dynamic load

We know that the dynamic load,

Ft
F d= =220.52 N
Cv

Since F d=220.52 N the dynamic load is much higher than F 2t =W =185 N , so the design is
safe from the dynamic load point of view as well.

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Check for static load or Endurance load
Flexural endurance limit of cast iron is σ en=83.5 MPa∨N /mm2
From Table 12.15

Therefore, static load or endurance strength is

F s=σ en bYm=390.78 N From Eq 12.13(a)

Here F s=390.78 N is much greater than F 2t =W =185 N and hence the design is justified.

Check for wear

As the material for Pinion as Cast Iron, Checking for Wear

Therefore, limiting load for wear is

F w =d 2 bQ=m Z 1 bQk From Eq 12.15(a)

Load Stress Factor K=1.814 From Table 12.16

2 Z2
The Ratio Factor Q= =1.71 From Eq 12.15(c)
Z1 + Z 2

Module(m)=3mm

Face width(b)=30mm

so, F w =d 2 bQ=m Z 1 bQk=1675 N From Eq 12.15(a)

Here F w =1675 N > > F 2t =W =217 N , so it is safe from the wear load point of view.

Torque

P × 60 Dp
T= ∨¿W T ×
2× π × N p 2

WT=W Since total load calculated act as the tangential load

= 217N

Ds = Z1*m
13
 =18mm

T =3.9 KN

Normal Load (WN)

WT
WN=
cos ∅

=230.92N

Design of the Pinion shaft:

Torque acting on Pinion gear shaft,

T =3.9 KN

Weight of Pinion (Wp) =0.00118 × b ×m 2 × Z 1 From R.S Khurmi

=1.92N

Resultant weight acting on pinion

W R= √ W 2N +W 2P +2 ×W N ×W P cos ∅

¿ 232.71 N

Bending Moment on the shaft due to resultant load (M).

Ds
M =W R ×
2
¿ 2.094 KN

Twisting Moment on the shaft (Ts)

Ds
T s=W T ×
2

¿ 3.9 KN

Equivalent Twisting Moment (TR)

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T R =√ M 2 +T 2

¿ 4.42 KN

The Shear Stress for the Cast Iron (Ꞇiron)=400Mpa

π
T R= ×Ꞇ iron × d3s From R.S Khurmi
16

d s =3.8 mm

Dimension of Spur gear according to the American Standard

Table 12.4(a)

Pressure=20 ° Zspur=6m=3mm dspur=18mm

Addendum=0.8m=2.4mm

Minimum Dedendum =m=3mm

Minimum total Depth=1.8m=5.4mm

Minimum clearance=0.2m=.4.71mm

Thickness of Tooth=1.571m=4.71mm

Approximate Fillet Radius=0.209m=0.62mm

Dimension of Gear according to the American Standard

Table 12.4(a)

Pressure=20 ° Zgear=36 m=3mm dgear=108mm

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Design of ratchet and pawl mechanism:
Material for ratchet- steel

Material for pawl- steel (hardened)

Since both ratchet and pawl are made up of steel material, the design stress of them is
considered as:

[Pb]= 165 N/mm2

T =F × d

=185 × 0.5

=92.5 Nm

Torque to be arrested

Mt =100* 103 Nmm

Calculation of ratchet dimension:

Number of teeth [Z =14 ]

1. Module (m) = 2 × [Mt /Z× (b/m) × Pb]1/3

Let us assume¥ =¿ (b/m) = 2.5
{ where b =face width and m is the module

¥ is the ratio of face width and module }

So, m = 5.17

= 6 mm

2. Outer diameter of ratchet [D] = m ×Z

=84 mm

3. Face width of teeth [b] =15 mm

Checking for the edge pressure :

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p=P/b

{here P is the peripheral force}

P=2×Mt /D

=2380.5 N

So, p= 158.73 N/mm2

Since this pressure is far less than the max pressure (300 N/ mm), our design is safe.

4. Tooth thickness a= m =6 mm
5. Tooth height h = 0.75 ×m = 4.5 mm
6. Circular pitch pc= 18.85 mm

Pawl dimension
7. The diameter of pawl pin is given by:
d= 2.71 [p / 2 Pb × (b/2 +a1) ] 1/3
{ here clearance is taken 10 mm between ratchet and frame }

So, d = 13.6 mm
8. Length of pawl , L:
Using formula:
Tanα>µ+ (µ1×α)/2 cos2α
{α = ratched tooth angle =15 degree

µ= coefficient of friction between ratchet tooth and pawl = 0.1

µ1 = coefficient of friction between pawl and pin = 0.1}

on solving:
L = 4.35 mm
{which is very small compared to the size of ratchet diameter}
So, using empirical formula :
L = 2 ×pi ×m
=37.7 mm
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 Checking the induced bending strength:
The pawl is subjected to total stress of:
Ptot = P/bx + 6 P×e/bx2
e= 1.5 × d = 20.4 mm
x=d=13.6
Ptot=16.82 N/mm2
Since Pb > Ptot
Our design is safe.

Conclusion
Whiteboard is shifted vertically up to 80 cm in 20 second by the help of rack and pinion
arrangement. And it is locked there, using ratchet and pawl mechanism.

Problem Definition:
A whiteboard made of plywood attached with mica Sheet for the easy dry clean. The
velocity with which the board moves upward is desired to be 4 cm/s . Dimension of the
board is 120 cm× 80 cm× 1.5 cm.

References
A. A textbook of machine design(2005) R.S Khurmi

18
B. Design data book (2013) K.Mahadevan ,K.Balaveera Reddy
C. International Research Journal of Engineering and Technology (IRJET),'Design
and Fabrication of Rack and Pinion Jack'

19