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No.
1
Title
Page
1.1
Structural scheme
1.2
GEAR CALCULUS
2.1
DIMENSIONING CALCULUS
3.1
Inputs
3.2
Results
4.1
Calculus of forces
4.2
10
SHAFT CALCULUS
10
5.1
Predimensioning calculus
10
5.2
Choosing the bearing mountings for both input and output shafts
10
5.3
11
11
12
12
13
14
15
16
10
16
11
19
EXECUTION DRAWING
ENSEMBLE DRAWING
Fig 1.1
1.2 The torques and rotations for each shaft
The motor's shaft:
9,55106P 9,5510618,5
M tn=
=
=59486,531987 Nmm
n
2970
The input shaft:
2. GEAR CALCULUS
2.1 Predimensioning gear calculus
Table 2.1
No.
Parameter
Calculus
INPUT DATA
1.1
nI =
1.2
1.3
i R=4
1.4
L h=10000 hrs
n 2970
=
=1523,076923 rpm
i C 1,95
1.5
Functioning conditions
1.6
Loading cycles
1.7
1 =1 2=1
1.8
2.1
2.2
PREDIMENSIONING CALCULUS
3.1
aw
a
=40...50 for carburising : w =45
mn
mn
=6 ...14 for carburising : =10
aw
2
2
z 1=
cos( )=45
cos (10 )
mn u dat + 1
4+ 1
z 1=17,7265418
z 2= z 1u dat =184=72
3.2
u=
3.3
3.3.1
Z E =189,8 MPa
3.3.2
3.3.3
Z =
3.3.4
3.4
z 2 72
= =4
z 1 18
1
1
=
=0,845
1,4
z n1,2 =
z 1,2
cos3 ( )
z1
18
z n1=
=
=18,845954
3
3
cos ( ) cos (10 )
z
72
z n2 = 32 =
=75,383816
3
cos ( ) cos (10 )
3.4.1
3.4.2
u
=00,03
u dat
coefficients
3.4.3
Y Fa 1,2=Y Fa ( z n1 ,2 , x n1,2 )
Y Fa1 =2,85 Y Fa2 =2,25
3.4.4
Y Sa 1,2 =Y Sa ( z n1 ,2 , x n1,2 )
Y Sa1=1,54 Y Sa2 =1,76
Y 0,25
0,75
cos 2
3.4.5
3.4.6
3.5
3.5.1
K A =1,6
3.5.2
Dynamic factor
K =1,05...1 ,1 K =1,05
3.5.3
K H =1,3...1 ,8 K H =1,5
K F =1,25...1 ,75 K F =1,5
3.5.4
K H =K F =
3.6
HlimZ N1
Z LZ Z RZ W Z X
S Hmin
15001
HP1 =
11111=1250 MPa
1,2
HlimZ N2
HP2 =
Z LZ Z RZ W Z X
S Hmin
15001
HP2 =
11111=1250 MPa
1,2
HP=min HP1 , HP2 =1250 MPa
3.6.1
3.6.2
Lubrication factor
Z L =1
3.6.3
Speed factor
Z =1
3.6.4
Roughness factor
Z R=1
3.6.5
Z W =1
3.6.6
Size factor
Z X =1
3.6.7
3.6.8
Y 0,25
Y =1
0,75
cos 2 10 =0,7696
1,4
10
=1
=0,9167
120
120
cos
1,4
=1,44351,4
2
cos 10
HP1 =
S Hmin=1,2
Flim1Y ST Y N1
Y 1Y R1Y X1
S Fmin
50021,05
FP1 =
111=700 MPa
1,5
Y Y
FP1= Flim2 ST N2 Y 2Y R2Y X2
S Fmin
50021,1
FP1 =
111=733,333 MPa
1,5
FP1 =
3.6.9
Y ST =2
Y 1,2 =1
3.7
3.7.1
Y N1 =1,05
Y N2 =1,1
S Fmin =1,5
PREDIMENSIONING - AXES
DISTANCE
Width coefficients
a=0,35
u+ 1
4+ 1
b=
a =
0,35=0,875
2
2
a WH =(u+ 1) 3
3.7.2
T I K AK K HK H
2
2 au HP
2
(Z EZ H Z Z )
115998,7371,61,051,51,44
a WH =(4+ 1) 3
20,35412502
3
2
(189,82,4710,8450,924) =123,100256 mm
a WF =
3.7.3
T 1z 1(u+ 1)
K AK K F K FY Y
2 acos( )
aWF = 3
Y FaY Sa
FP
115998,737185
1,61,051,51,440,770,917
20,35cos(10 )
0,00627=62,459413 mm
Y FaY Sa
Y Y
Y Y
=max ( Fa1 Sa1 , Fa2 Sa2 )=0,00627
FP
FP1
FP2
3.7.4
a w =max ( a WH , a WF )=123,100256 mm
we select a W =125 mm STAS 6055
3. DIMENSIONING CALCULATION
3.1 Inputs
Table 3.1
Parameter
Symbol
Value
Inputs
Power
P, kW
18.5
Lifetime
Lh, hrs
10000
Functioning factor
KA
1,6
Type of engine
Load variation
Medium shocks
Rotation at pinion
nI, rpm
1523.08
Gear ratio
udat
Helical angle
10
Center distance
aW, mm
125
Width factor
0,35
Materials
Steel
Carburised
Type
18MnCr11
Superficial hardness
HRC
>58
Inside hardness
HB
270...360
MPa
1500
Hlim1,2, MPa
1500
MPa
500
Flim1,2, MPa
500
Teeth numbers
z1
18
z2
72
Machining information
Profile roughness
Ra, m
>0,4
Root roughness
Ra, m
3,2
Functioning conditions
Pulsatory
Minimal safety coefficients
SHmin
1,2
SFmin
1,5
3.2 Results
Table 3.2
Parameter
Gear
Pinion
Wheeel
Gear Parameters
Center distance
aW= 125mm
a= 124,26283 mm
Normal module
mn= 2,75 mm
Frontal module
mt=
Helix angle
= 10
b= 9,39129
t= 20,28356
Gearing angle:
frontal
wt= 21,17892
normal
wn= 20,88168
mm
xsn= 0,27377
frontal
= 1,52
helical
= 0,88
total
= 2,40
v= 4,01 m/s
Precission
Lubricant viscosity
Roughness:
active profile
Ra= 0,80 m
fillet (root)
Ra= 1,60 m
Pinion and wheel parameters
Addendum diameters
da1= 57,71223 mm
da2= 203,25638 mm
Deddendum diameters
df1= 45,36862 mm
df2= 190,91277 mm
Pitch diameters
d1= 50,26362 mm
d2= 198,26205 mm
dw1= 50,56180 mm
dw2= 199,43820 mm
db1= 47,14669 mm
db2= 185,96751 mm
Numbers of teeth
z1= 18
z2= 71
Width
b1= 42 mm
b2= 40 mm
xn1= 0,36
xn2= -0,08623
xt1=
xt2=
xnmin1= -0,105
xnmin2= -3,357
San1= 1,48 mm
San2= 2,23 mm
Sanmin2= 1,1 mm
zn1= 18,78
zn2= 74,07
Pitch diameters
dn1= 51,63857 mm
dn2= 203,68545 mm
dbn1= 48,52438 mm
dbn2= 191,40172 mm
Addendum diameters
dan1= 59,08718 mm
dan2= 208,67979 mm
Center distance
awn= 128,339631 mm
Contact degree
n= 1,56
Parameter
Gear
Contact
Bending
Calculus factors
Functioning factor
KA= 1,6
Dynamic factor
K= 1,00
KH= 1,57
KF= 1,48
KH= 1,47
KF= 1,47
Elastic factor
ZE= 189,8
Contact factor
ZH= 2,41
Z= 0,99
Y= 0,92
Shape factor
YFa1= 2,32
YFa2= 2,27
YSa1= 1,73
YSa2= 1,73
Lubricating factor
ZL= 1,04
Speed factor
ZV= 0,98
Roughness factor
ZR= 0,97
YR= 1
Sensitive factor
Number of
cycles:
pinion
NL1= 3,3*108
wheeel
NL2= 4,6*107
Y1= 0,993
Y2= 0,987
Lifetime factors
ZN1= 1
ZN2= 1
YN1= 1
YN2= 1
SHmin= 1,2
SFmin= 1,5
Stresses
preliminary
a= 0,35
final
arec= 0,31
Control elements
N1= 3
N2= 9
WNn1= 21,69735 mm
WNn2= 71,70059 mm
Tooth width
Normal tooth width
Scn1= 4,45074 mm
Scn2= 3,66195 mm
Sct1= 4,44267 mm
Sct2= 3,65531 mm
hcn2= 1,83075 mm
hct2= 1,82169 mm
Fig 4.1
5. SHAFT CALCULUS
5.1 Predimensioning calculus
theinput shaft
dI=
16T I 3 16115998,737
=
=27,00436927 mm
atI
30
atI =25...35 MPa ; we select atI =30 MPa [13]
3
10
5.2 Choosing the bearing mountings for both input and output shafts
Symbol
d (mm)
D (mm)
B (mm)
Table 5.1
C0
Cr
input
6204
20
47
14
12700
6550
output
6205
25
52
15
14000
7800
Fig 5.1
Input shaft's length: l=73 mm (measured on the drawing)
d w1
l
+ F r1 HBl =0
2
2
d
l
30,09259
73
F a1 w1 + Fr1
809,057713
+ 1777,4602
2
2
2
2
H B=
=
=1168,917857 N
l
73
d
M B =0 H Al+ F a1 2w1 F r1 2l =0
d
l
30,09259
73
F a1 w1 + F r1
809,057713
+ 1777,4602
2
2
2
2
H A=
=
=608,542319 N
l
73
d w1
l
73
50,56180
M imaxH =H A + F a1
=608,542 + 809,057713
=42665,501772 Nmm
2
2
2
2
M A=0 F a1
11
Fig 5.2
M A=0 V Bl + F t1 2 =0
V B=
F t1
l
2
4588,394297
=
73
2
99
=2294,197148 N
l
M B =0 V AlF t1 2 =0
V A=
F t1
l
l
2
4588,394297
=
73
2
99
=2294,197148 N
l
73
M imaxV =V A =2294,197148 =83738,195914 Nmm
2
2
Fig 5.3
2
2
2
2
M i= M imaxH + M imaxV = 42665,501 + 83738,1959 =93981,01136 Nmm
5.3.2 Calculating the reactions in the bearings
12
Compression:
c=
Torsion:
t1=
4F a1
2
f1
d
16T I
d
4809,057713
=0,50047 MPa
45,3692
16115998,737
=6,3264 MPa
45,369 3
3
f1
Bending:
i=
32T I
d 3f1
32115998,737
=12,6528 MPa
45,3693
Fig 6.1
F 4T II 1
s= =
as
A
d II
f lc
4T II
1
4463994,949495
1
l c=
=52,251684 mm
d II
ash
37
1208
l=52,251684+ 10=62,251684 mm ; we select l stas=28 mm STAS1004
l c =(l stas b)3=( 2810)3=54 mm
2T II
2463994,949495
f=
=
=46,445941 MPa as =100 MPa
l cbd II
541037
13
Fig 7.1
We select a radial bearing mounting with balls, in X
Fig 7.2
Checking the ball-bearing mounting by the dynamic load capacity
Durability of the bearing
14
L=
60n ILh
10
601523,07692310000
=913,846154 milions of rotations
6
10
F a 809,057713
=
=0,12352 e=0,48
C0
6550
F a 809,057713
=
=0,455176< e=0,48 Y =0 X =1
F r 1777,460176
P= X V F r + Y F a=111777,460176+ 0809,057713=1777,460176
p
3
C j=P L=1777,460176 913,846154=17248,747917> C r=12700
p=3 for ballbearings
3
3
Cr
12700
L=( ) =(
) =364,7636270082
P
1777,460176
6
L10 364,763627008210 6
Lh =
=
=3991,5211711667 hrs
60n I
601523,076923
the ballbearings must be replaced every 3990 hours of functioning
for Fa / Fr e , X = 1 and Y = 0;
for Fa / Fr > e, X = 0,4 and Y is chosen from the table
Table 7.1
Fa / C0
0,025
0,04
0,065
0.12
0,17
0,5
0,4
0,42
0,44
0,48
0,5
0,56
1,42
1,36
1,27
1,16
1,11
15
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.
9. CHOOSING THE SEALING DEVICES
Fig 9.1
dm1=drul1 - (2...3)=20-2=18 mm
dm2=drul2 - (2...3)=30-3=22 mm
we select a felt cuff A 18x30 STAS 7950/2-72 with h=7 mm for the input shaft
we select a felt cuff A 22x40 STAS 7950/2-72 with h=10 mm for the output shaft
10. CHAIN TRANSMISSION CALCULUS
Table 10.1
No.
Parameter
Calculus
INPUT DATA
1.1
Power
P=4 kW
1.2
Transmission ratio
iL=1,95
16
9,5510 P
=59486,531987 Nmm
n
1.3
1.4
n=2970 rpm
1.5
Working conditions
2.1
z1=28
2.2
M tn=
p 3
2.3
Pitch
5800
=3
5800
n z 2970 28
2
=28,070915 mm
p1
19,05
=
=170,143251 mm
180
180
sin(
) sin (
)
z1
28
p2
25,4
D d12 =
=
=226,857668 mm
180
180
sin(
) sin (
)
z1
28
p3
25,4
D d13 =
=
=226,857668 mm
180
180
sin(
) sin(
)
z1
28
D d11 =
2.4
p1
19,05
=
=333,690608 mm
180
180
sin(
) sin(
)
z2
55
p2
25,4
Dd22 =
=
=444,920811 mm
180
180
sin (
) sin (
)
z2
55
p3
25,4
D d23 =
=
=444,920811 mm
180
180
sin(
) sin(
)
z2
55
D d21 =
2.5
Medium speed
z 1 p1n 2819,052970
=
=26,4033 m/ s
601000
601000
z 1p 2n 2825,42970
v m2=
=
=35,2044 m/ s
601000
601000
z 1p 3n 2825,42970
v m3=
=
=35,2044 m/ s
601000
601000
2.7
As1=a 1d 3=15,625,72=89,3464 mm
A s2=a 1d 3=22,617,92=179,0712 mm2
A s3=a 1d 3=25,458,28=210,726 mm2
v m1=
2.6
17
3.1
K e =K dK AK i K rK u K f
K e =1,311,251,251,51=3,047
3.1.1
3.1.2
K A =1
3.1.3
K i=1,25
3.1.4
K r=1,25
3.1.5
K u=1,5
3.1.6
K f =1
P a1
8
=89,3464
=234,591573 N
Ke
3,047
P a2
6
F ua2 =A s2
=179,0712
=352,632517 N
Ke
3,047
P
6
F ua3= As3 a3 =210,726
=414,968123 N
Ke
3,047
F ua1=As1
3.2
F ua1v m1 234,59157326,4033
=
=6,193 kW
1000
1000
F ua2v m2 352,63251735,2044
P ua2 =
=
=12,414 kW
1000
1000
F v
414,96812335,2044
P ua3 = ua3 m3 =
=14,608 kW
1000
1000
P ua1 =
3.3
3.4
Number of rows
P
4
=
=0,6457873
P ua1 6,193
P
4
z r2 =
=
=0,3222113
P ua2 12,414
P
4
z r3=
=
=0,2738093
P ua3 14,608
3.5
4.1
4.2
Number of links
z 1+ z 2 2A prel
z 2z 1 2
p
W=
+
+(
)
2
p
2
A prel
2
28+ 55 2762 5528
19,05
W=
+
+(
)
=121,961
2
19,05
2
762
W =122
4.3
L=W p=12219,05=2324,1 mm
z r1=
18
4.4
z 1+ z 2
z 1+ z 2 2
z2 z1 2
+ (W
) 8(
)]
4
2
2
2
2
2
Arec = 19,05 [122 28+ 55 + (122 28+ 55 ) 8( 5528 ) ]
4
2
2
2
Arec = p [W
Arec =828,248704 mm
A= Arec[1(0,002...0 ,004)]=828,2487(10,002715)=826 mm
5
5.1
F q=K pq
5.1.1
K p=6
5.1.2
q=mg= 3,69,81=35,316 N / m
5.2
5.3
5.4
Useful force
F u=
5.5
5.6
F r 86298,52
=
=25,502215> c a =7...14
F 2 3383,9617
F r=S r9,80665=88009,80665=86298,52 N
5.7
Q= K gF u=1,15699,252324=804,140173 N
5.8
Wheel's width
A
826
=635,316
=175,026096 N
1000
1000
2M tn 259486,531987
=
=699,252324 N
D d1
170,143251
c=
19
20