1.

STRUCURAL SCHEME, TORQUES AND ROTATION FOR

EACH SHAFT

1.1 Structural scheme

Figure 1
M - the electric engine
P - the power of the electric motor
n - the rotation spead of the motor shaft
Mtn - the nominal torque at the motor shaft
i L - the ratial af the chain
I - the imput shaft

TI

- the torque of the imput shaft

n I - the rotation spead of the imput shaft

II - the output shaft

TII - the torque of the output shaft
n II - the rotation spead of the output shaft
1 - the pinion
2 the driver wheel
A,B,C,D the bearings
i r - the spead redurer ratio
W.M. - the working machine

1.2 Torque and rotations for each shaft

Engine

n 960rot / min
M t 9,55 10 6

P
4
9,55 10 6
39791,6 Nmm
n
960

Input shaft (I)

nI

n
ic / l

960
800rot / min
1,2

M tI M t ic / l 39791,6 1,2 47749,992 Nmm

Output shaft (II)

n II

n I 800

225,35rot / min
ir 3,55

M tII M tI ir 47749,992 3,55 169512,47 Nmm

2. PROJECT PARAMETERS
INPUT DATA
2.1 Pinion speed n1, rot/min
n1 = 800 rot/min
2.2 The torsion torque at the pinion of the gearing T1, Nmm
T1 = 47749,992 Nmm
2.3 Gearing ratio udat
udat = 3,55
2.4 Minimum functioning time of the gearing Lh, hours
Lh = 8500 hours
2.5 Functioning conditions of the gearing
Driver machine: electrical motor
Driven machine: fans
Type of load: uniform
2.6 The loading cycles for the teeth
contact load : pulsatory cycle
bending load : pulsatory cycle
2.7 Number of load cycles of the tooth flank, at a full rotation 1 for the pinion, 2
for the driven wheel
1,2 = 1
2.8 The reference rack profile
For inclined teeth
n = 200; h*an = 1,0; c*u = 0.25; *fn = 0.38

3. CHOOSING THE MATERIALS, HEAT TREATMENTS AND THE

LIMIT STRESSES
3.1 Choosing materials and treatments
We choose 40Cr10 from STAS 791
Hardness - external 50 HRC
- internal 260 HB
r = 900 MPa
02 = 670 Mpa
3.2 Limit stresses, Hlim1,2, at contact and Flim1,2 at bending, MPa
Hlim1,2 = 770 MPa
Flim1,2 = 320 MPa

4. PRE-DIMENSIONING CALCULUS
4.1 Number of teeth z1, of the pinion, respectively z2 of the driven wheel.

a 2
2
z1 max w
cos 75
cos12 32,24
3,55 1
mn u dat 1
aw
75
mn

12
We choose: z1 30
z 2 z1 u dat 30 3,55 106,5

We choose z 2 107
4.2 Real gearing ratio u

z 2 107

3,56
z1 30

u
u
u dat

0.0028 0.03
4.3 The contact calculus factors [21,60]
4.3.1 The elasticity factor of the wheels material zE,

zE

MPa

1
1 12 1 22

E
E2
1

1 2 0,3
E1 E 2 2,06 10 5 MPa
Z E 189,8 MPa
4.3.2 The contact area factor zH
z H 2,49 cos 2,49 cos12 2.46

4.3.3 The covering factor z

1
1

0.84

1.4
1 .4
4.3.4 Inclining factor of the teeth z
Z

cos

1
1,01
cos12

4.4 The factor for the bending calculus

4.4.1 Number of teeth for the equivalent wheels

z1
30

32,055
3
cos cos 3 12
z2
107
zn2

114,332
3
cos cos 3 12
z n1

4.4.2 The displacement coefficient of the profile in the normal plane xn1,2
x n1, 2 0

4.4.3 Shape factor of the teeth YFa 1,2

Y Fa1 Y Fa ( z n1 , x n1 ) Y Fa (32,055;0) 2,5

Y Fa 2 Y Fa ( z n 2 , x n 2 ) Y Fa (114,332;0) 2,18
4.4.4 Correction factor of stress YSa 1,2

Y Sa1 Y Sa ( z n1 , x n1 ) Y Sa (32,055;0) 1,63

Y Sa 2 Y Sa ( z n 2 , x n 2 ) Y Sa (114,332;0) 1,77
4.4.5 Covering factor Y
0.75
0.75
Y 0.25
cos 2 0.25
cos 2 12 0.76

1 .4
1 .4
4.4.6 Inclined factor for the teeth Y
Y 1

12
1
0.9
120
120

4.5 Load correction factor

4.5.1 The functioning regime factor ka
k A 1,35

4.5.2 Dynamic factor kv

k v 1,10

4.5.3 Distribution (uneven) factor for load on the width of the teeth kH for
contact and kF for bending

k H 1,45
k F 1,50
4.5.4 The uneven distribution factor of the frontal plane kH at contact and
kF for bending

1.4

1.46 1.4
2
cos cos 2 12
4.6 The allowable resistances HP1,2 at contact and FP1,2 for bending [MPa]
k H k F

Z L ZV Z R 0,92
N L1 60n1 LH 1 60 800 8500 1 4,08 108
N L 2 60n2 LH 2 60 225,35 8500 1 11,49 10 7

z w 1.0
zx 1
z N 1 1,12
z N 2 1,21
S H min 1,3

HP1

H lim z N 1
770 1,12
Z L ZV Z R ZW Z X
0.92 1 1 610,31MPa
S H min
1.2

HP min( HP1 , HP 2 )
HP 2

H lim z N 2
770 1,21
Z L ZV Z R ZW Z X
0.92 1 1 659,35MPa
S H min
1.2

HP min(610,31;659,35) 610,31
FP1

F lim 1YST YN 1
320 2 1 1 1 1
Y 1YR1Yx
426,66MPa
S F min
1,5

FP 2

F lim 2 YST YN 2
320 2 2 1 1 1
Y 2YR 2 Yx
853,33MPa
S F min
1,5

4.7 The distance between the axis at pre-dimensioning

4.7.1 Wide coefficient a, d
a 0,3
u 1
3,56 1
a
0,3 0,684
d =
2
2

4.7.2 Distance between the axis from the strength condition at contact awH,
mm

a wH (u 1)3

T1k A kV k H k H

(Z E Z H Z Z ) 2

2a u HP
46000 1,35 1,10 1,45 1,46
(3,56 1)3
(189.8 2.46 0.84 1,01) 2 139,308mm
2
2 0,3 3,56 (610,31)
2

4.7.3 Distance between axis from the strength condition at bending awF, mm

Y Y
T1 z1 (u 1) 2
a wF 3
k a k v k F k F Y Y Fa Sa
2 a cos
FP
46000 30 3,56 1
3
1,35 1,1 1,50 1,46 0,76 0,9 0,0045
2 0,3 cos12
47,52mm
YFa YSa
Y Y Y Y
max( Fa1 Sa1 , Fa 2 Sa 2 ) 0.0045
FP
FP1
FP 2
4.7.4 Adopting the distance between the axis at predimensioning aw, mm
aw = max (awH,awF) = max (139,308;47,52) = 139,308mm ;
We adopt from STAS 6055 the following aw = 140 mm.
4.7.5 The preliminary lengths of the wheels

b2 a aW 0.3 139,308 41,79mm

b1 b2 b 41,79 2 43,79mm
b 1...3; b 2

KINEMATIC SCHEME OF THE SPEAD REDUCER

5. GEARING FORCES CALCULUS

5.1 Forces calculus
5.1.1 Tangential force Ft, N;

Figure. 5.1

Ft1

2T1 2 47749,992

1546,19 N
d w1
61,76471

Ft1 Ft 2 1546,19 N
5.1.2 Radial force Fr, N;

Fr1

Ft1
1546,19
tg wn
tg 21,01003 607,103N
cos
cos12

Fr 2 Fr1 607,103 N

5.1.3 Axial force Fa, N;

Figure. 5.2

Fa1 Ft1 tg 1546,19 tg12 328,653N

Fa1 Fa 2 328,65 N
5.2 Choosing the sense of rotation and applying forces

Figure. 5.3

10

6. CALCULUS OF THE SHAFTS

6.1 Pre-dimensioning calculus:
dI 3

16 TI
16 47749,992
3
25.31mm
atI
3,14 15

d II 3

16 TII
16 169512,47
3
27,84mm
atII
3,24 40

6.2 Choose of bearing mounting for input and output shafts:

Figure. 6.1

d(b)I,II = dI,II (28)mm

11

Table 6.1
Simbol
Sarcina radiala
Dinamica
Statica

d
[mm]

rs
[min]

Masa
[kg]

dI

20

47

14

0,118

6204

12,7

5,7

dII

25

52

15

0,142

6205

14

6,95

6.3 Check of the input shaft for composed stresses.

6.3.1 Horizontal plane
[H]
Fa1

Fr1

RAH

RBH

Figure 6.2

12

M B 0
R AH (l1 l 2 ) Fr1l 2 Fa1

R AH

d w1
0
2

d w1
61,76471
607,103 51 328,65
2
2
367,06 N
(l1 l 2 )
51 61

Fr1 l 2 Fa1

RBH Fr1 R AH 607,103 367,06 240,03N

6.3.2 Vertical plane

[V]

Ft1

RAV

RBV

l1

M B 0

Figure 6.3

R AV (l1 l 2 ) Ft1 l 2 0
R AV

Ft1 l 2 1546,19 51

704,06 N
l1 l 2
61 51

RBV Ft1 R AV 1546,19 704,06 842,13N

6.4 Determining of the reactions in the 2 bearings

13

l1

Mih
Miv
Mt
T

Figure 6.4

M iV max R AV l1 704,06 61 42947,66 Nmm

M iH max R AH l1 367,06 61 22390,66 Nmm

6.5 Stresses identification

6.5.1 Torsion

16 T1
16 47749,992

1,36 MPa
3
d f 1 3,14 (56,34044) 3

6.5.2 Bending
2

32 M iH M iV

d 3f 1

32 (22390,66) 2 (4297,66) 2

1,29MPa
3,14 (56,34044) 3

6.6 Equivalent stress

eq 2 4 2 aiIII

eq

(1,42) 2 4 0,27 1,36

1,75 aiIII

t ( c ) i 0,13 1,29 1,42MPa

t (c)

4 Fa1

d f1

4 328,653
0,13MPa
3,14 (56,34044) 2

aiIII
0.27
aiI

aiIII 90 MPa

aiI 330MPa

14

7. DESIGN OF THE ASSEMBLE BETWEEN THE ENHECE AND

THE OUTPUT SHAFT

Figure 7.1
We choose from STAS 1004-81: b=8; h=7
lc

4M t
4 47749.992

10,91
d h as
25 7 100

as 65...100 MPa [13]

To fix the wheel 2 on the intermediate shaft is chosen to parallel type 7X8X25 STAS
1004 81.

l = lc + b = 10,91 + 8 =18,91 mm
l=20 mm STAS 1004-81
Table 7.1

I
II
II

d
14
20
25

b
5
6
8

h
5
6
7

15

8. CHECH OF THE BEARING MONTINGS FOR THE IMPUT SHAFT

Figure 8.1
FA 328,65

0.52 => e=0,44

Co
630
FA

FR

FA1
2

R AH R AV

X=1
Y=0
328,65

367,06 2 704,06 2

0.017 e

FA
e P FR 19332,35
FR
FA
e P X FR Y FA
FR
p

C nec P L C r 19332,35 3 408 143385,32

p3
L

60 n I Lh 60 800 8500

408mil rot
10 6
10 6

16

9. COOSING AND JUSTIFYING THE OILING SYSTEM AND

SEALING SYSTEM
Oiling the gearings:

The gears from speed reducers are grease through splashing in the oil bath.
For this aim in which a gear from the gearing mechanism is introduce in the oil
bath until a tooth is covered with oil, not more than 10 mm, and without passing
six time the modulus.
In case of speed reducers with more steps (when the wheels dont reach the
bath), the grease is made with a parasite gear, or with the help of some discs or
splashing spoons which are creating am oil fog.
The grease through splashing is applied on gearing mechanisms that are
working periodically, with speeds up to 15m/s. For greater peripheral speeds, the
grease is done with oil injectors. The oil pressure is about 0.1-0.8at. For greasing,
mineral oils are use with the viscosity of 3-60 degrees E50^C.
With how much the peripheral speed is smaller, the contact pressure
and the roughness are higher, and more viscous oils are used.
On speed reducers with more gears, the oil is choused with a viscosity
corresponding to the steps that transmit the biggest torque. For the oil bath
volume are considered 0.25-0.5l of oil over a horsepower. The period of oil change
is about 1000-5000 hours of functioning (for the case when the gearing
mechanism is sealed and the oil is filtrate every 2500 hours). For filtering can be
used magnetic filters. When the speed reducer is new, the oil must be changed
after 200-300hours.
Oiling the ball-bearings:

The choose of lubricants for ball bearings and establishing the grease
intervals, is done considering the dimension, number of revolutions, load and work
temperature of the bearing.
Generally, the liquid lubricants have more advantages then the consistent
ones: higher physical-chemical stability, can be used at high speeds and
temperatures, and also at very low temperatures, easier evacuation of heat
produced in the bearing, smaller resistance sported by the rolling bodies.
Disadvantages: difficult bearing sealing, loses through leakages in time, etc.
Grease lubrication is more advantageous because leads to: simpler bearings
construction, easy to seal, with a lower cost, better protection of the balls to
external impurities, lower lubricant looses.
Gaskets: due to high levels of revolutions trees cuffs sealing is
accomplished by rotation.

17

10.GHOOSING THE MATERIALA AND MANUFACTURING

SYSTEM

It is choosen 18MnCr11 steel hardening and tempering to achieve the shaft

and gear wheel transmission because this steel has good resistance to bending and
also has a high resistance to fatigue.
Materials used for speed reducer construction.
Materials used for gears:
Steel
It is used great steel: steel with carbon0.4-0.6 %C and steel with 0.35-0.45%C
low alloyed with Mn, Cr, Cr-Mo, Cr-Ni etc. Steel non alloyed with Cr, Cr=Mo, CrNi, with cyaniding
Cast irons
Cast irons are used at gearing which has a easy working, change wheels which
dosent functioning every time.When it is asking a silent condition may be used
normal iron ash.
Used material for axels execution:
Generally the axel which don t have a heat treatment are made by normally steel
carbon: OL 50, OL 60, Stas 500-78
For axel which a big lifting power we can use carbon steel of quality: OLC 35,
OLC 45, OLC 60, according to STAS 880-66.
In case of axel which have a strong load and are required small dimension are used
steel alloyed with crom, Cr-Ni or Cr-Mn.
Marerials used for producing the body.
The body because of the stiffness are made by cast irons or by casting steel. Most
of the body are made by cast iron with average resistance Fc 200, Fc 250.

18

11.TECHNICAL SECURITY RULES WORK

Reducer by definition in a speed reduction mechanism while increasing torque

transmition. Like any reducer mechanism involves compliance with specific
employment security tehmica's grave. It is absolutely mandatory:
-Location reducer in the vertical position;
- Lubricant oil changes to term limits;
- Replace bearings after the number of operating hours provided;
- An immediate replacement of any assembly or subassembly as soon as it
has found its damage;
- Fixing a reducer on the pedestal before putting it into operation;
- Expanding the level of lubricant if you have found a fall below its
minimum;
- Periodic verification of the status reducer;
In prohibits:
- Introducing lubricating oil other than reducing the limit;
- Introducing the reducing of any material that could damage the gears;
- Changing the oil or lubricant of any assembly or subassembly sin reducer
component during its operation;
- Clogging ventilation holes;

19