MECG1022 Design Project Report

Design of an Overhanging Countershaft

Date: 11/29/2018

Name: Byron Andrés Macı́as Balda

Desing Project No: 1

Instructor: Professor Carlos Gabriel Helguero

Mechanical Engineering Faculty

ESPOL
Índice
1. Objectives and Introduction 3
1.1. Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Design criteria and assumptions 4

3. Design procedures and descriptions with abridged derivations 4

3.1. Step 1: V-Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2. Step 2: Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3. Step 3: Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4. Step 4: Wedges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5. Step 5: Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4. Results and discussions 6

5. Conclusions and recommendations 6

6. Appendix 7
6.1. V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2. Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3. Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.4. Wedger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.5. Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Índice de figuras
1. V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Charges in the Countershaft . . . . . . . . . . . . . . . . . . . . . . 12
3. Shear strength X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. Momentum in X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. Shear strength Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Momentum in Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Torque delivered by the motor . . . . . . . . . . . . . . . . . . . . . 18
1. Objectives and Introduction
1.1. Objectives
The objectives of this project, is the design of a countershaft that rotates with
a nominal power of 10.5 hp, other elements such as belts and gears are found
along the countershaft, must design the gears and select the right type of belt.

1.2. Introduction
The countershaft is a component whose purpose is to transmit mechanical
energy through its rotation, is subject to the force of torsion and bending. The
countershaft is also an element subject to a product of repeated load of the other
components, such as gears, belts, which carry these entails to the fault mecha-
nical for fatigue.The cross section of a countershaft is usually circular although
occasionally it may have another type of section such as corrugated or polygonal,
the circular diameter of the countershaft is determined based on the efforts it
supports, the material used and the conditions of manufacture and use that are
will give.
The other part of the design is the V-belts selection, knowing that the rated power
of the countershaft is 10.5 hp and the angular speed of the engine is 2000 rpm, a
suitable diameter was selected for the engine, as well as a step length and type of
band; this in order that the number of bands to use is not too high in addition to
the time of life of the belt this in a suitable range.
After obtaining the angular velocity of the countershaft, the gears were determi-
ned and designed, selecting a number of teeth for the gear and also determining
the appropriate material so that the safety factors for the bending effort and the
surface stress are at least greater than one. The gears are common components in
the countershaft and serve to transmit a circular movement through the contact
of the gear.

3
2. Design criteria and assumptions
The main criteria in the design were to obtain values of safety factors sui-
table for each element, in addition that the highest is for the countershaft with
the purpose that the last component that fails due to fatigue is this. Among the
assumptions that were made were:

For gears :

• Number of gear teeth 35.

• Material used AGMA maximum grade brinell hardness equal to 380.
• Reliability of 90 %
• Factor Ka in uniform impact of driving machine and uniform driven
machine
• Cycle life N = 5,54 × 108

For V-Belts:

• Diameter on the motor pulley is seven inches.

• V-Belt B180

Countershaft:

• Material AISI 1050 with Sut = 100Kpsi

Bearing

• Ball bearing #6310 with internal diameter d=1.96 in

3. Design procedures and descriptions with abridged

derivations
The total system design is composed of the following component design: V-
Belts, Gears, Countershaft, Wedge, Bearing.

3.1. Step 1: V-Belts.

Started in the design of the V-Belts to determine the angular velocity of the
countershaft, a type B belt was selected for power ranges between 1-25 hp with
width 0.65 in.
Then the type of belt was determined by testing the different available step length
values, where the minimum diameter for the smaller pulley is 5.4 in., The selec-
tion focused on obtaining the least amount of belts possible to use.

4
 V-Belt Selected:

• B180
• d= 7 in
• # Belt: 3

3.2. Step 2: Gears

Having the angular velocity of the countershaft, a number of gear teeth of the
35 was selected, knowing the nominal power of 10.5 hp, the torque of the pinion
was obtained, as well as the tangential and radial loads. Then the bending efforts,
contact effort, the design factors from the selected material and the conditions in
which the gears will be applied were determined.

3.3. Step 3: Countershaft

To design the countershaft the section was first determined along the axis
where shoulders would be placed, to diminish the concentration of efforts, roun-
ded shoulders were preferred. Then, given the safety factor of 1.85, the diameter
of the contershaft and the diameter of the shoulder were obtained, where the gear
was placed using a wedge, as the value of bending moments and torques is the
maximum winged of the gears, it was assumed that the The same man can be
used on the side of the V-Belts, assumptions of the factors Kb , Kt , Kts are made in
a moment as it is solved in Appendix.

3.4. Step 4: Wedges

Knowing the diameter of the shoulder and the thickness of the gear, at this
point the calculations for the wedge are obtained, since the wedge is designed
where there are greater bending moments, the same design can be used to place
on the end pulley of the countershaft .

3.5. Step 5: Bearing

The bearings were selected according to the diameter of the countershaft and
the contershaft was modified so that the bearings were adjusted, ball bearings
were used and the number of millions of revolutions was calculated using the
axial force P = 600 N and the magnitude of the reactions as the radial force in the
bearing.

5
4. Results and discussions
The results obtained give adequate safety values, such as a high life time for
each component, and it is possible that the material used for the countershaft
allows the ultimate fatigue failure to be countershaft, which is what is recom-
mended for each element. a different type of material was selected less for the
wedge which the same material as the countershaft.

5. Conclusions and recommendations

In conclusion the components of the countershaf will fail first by fatigue in a
period of time high by the materials that were selected for this design, to achieve
this it is advisable to use a software like excel or matlab to test with different ma-
terials such as for gears, to go by varying the diameter of the pulley in the motor,
the length of the passage that will be used and for the conuntershaft. Materials
that result in small safety factors should not be used.

6
6. Appendix
6.1. V-Belt
d= 7 in
D=15.748 in
C=72.90 in
N=2000 rpm
V-Belt: B180

Figura 1: V-Belt

Lp = 181,8
Hnom = 10,5hp
  r 2 
 π π 
C = 0,25  Lp − (D + d) + Lp − (D + d) − 2(D − d)2 
2 2
C = 72,90in

πdN
V =
12
V = 3665,19f t/min

D −d
θ = π − 2sin−1
2C
◦
θ = 86,56 , 3,02rad

2
V

Kc = 0,965 → Fc = Kc
1000

7
 Fc = 12,96N

K1 = 0,143543 + 0,007648θ − 0,000015052θ 2 −→ K1 = 0,69

K2 = 1,2
Htab = 4,83
Ha = K1 K2 Htab
Ha = 4hp

Ks = 1,1, nd = 1 −→ Hd = Hnom Ks nd
Hnom = 11,55hp

Hd
NB ≥ = 2,85 −→ 3
Ha

63025 Hd
Nb
4F =
N (d/2)
4F = 34,66

4exp(0,5123θ)
F1 = Fc +
exp(0,5123θ) − 1
F1 = 56,99N

F2 = F1 − 4F
F2 = 22,33N

Ha Nb
nf s =
Hnom Ks
nf s = 1,04

Kb = 576
Kb
T1 = F1 +
d

8
 Kb
T2 = F1 +
D
T1 = 139,27lb, T2 = 93,56lb

K = 1193, b = 10,928
!−b −1
 K −b
 !
K 
Np =  + 
T1 T2 
Np = 1,54 × 1010

Lp
t=
720V
t = 352188,712

6.2. Gears
Nω = N ∗ Dd ←→ 889,002rpm
Np = 24
Ng = 35
pd = 10
φ = 20◦ HP ST C

P
Tp =
Nω
Tp = 744lb − in

2Pd Tp
Wt =
Nω
Wt = 620,327lb
Wr = Wt tan(φ)
Wr = 1387,77lb

Nω
dp = = 2,4in
pd

9
 Ng
dg = = 3,5in
pd

dp Nω π
Vt =
12
V = 558,57f t/min
Qv = 7

Flexion effort

Wt pd Ka Km
σb = Ks KB KI
FJ Kv
Jg = 0,376
Jp = 0,352
12
F= = 1,2in −→ Km = 1,6
pd
Ka = 1

!B
A
Kv = √ −→ B = 0,73, A = 65,12
A + Vt
Kv = 0,79

Kf = Kb = KI = 1

σbp = 2973,3psi
σbg = 27844,8psi

KL
Sf b = S 0
KT KR f b
AGMA GRADE 2 HB=380
Sf b 0 = 6235 + 174HB − 0,126HB2
Sf b 0 = 54160,6

!
60min 2080h
 
N = 889,002rpm (5years)(1turn)
1h turn − year

10
 N = 5,54 × 108

KL = 1,3558N −0,0178
KL = 0,947

460 + T◦F
KT =
620
T◦C = 75 −→ 167◦ F
◦

Kt = 1,01

KR = 0,85

Sf b = 59743,8
Sf b
np = =2
σbp
Sf b
ng = = 2,145
σbg

Contact effort

r
Wt Ca Cm
σc = C p Cs Cf
FId Cv
Ca = 1,25
Cm = 1,6
Cv = 0,76
ν = 0,28, E = 30 × 106 Kpsi −→ Cp = 2276
ρp = 0,35, ρg = 0,65 −→ I = 0,089
dp = 2,4in

σc = 162459psi

CL CH
Sf c = S 0
CT CR f c

11
 AGMA GRADE 2 HB=380

Sf c 0 = 2700 + 364HB −→ Sf c 0 = 165320psi

CR = 1
CT = 0,86
CH = 1
CL = 1,4488N −0,023 −→ CL = 0,91
Sf c = 178237psi
Sf c 2
!
nsc =
σc
nsc = 1,16

6.3. Countershaft

Figura 2: Charges in the Countershaft

WT = 620,327lb
Wr = 1387,44lb
P = 600lb
F1 + F2 = 79,32lb
W = 225,4lb

12
 For
P X
+ Mox = 0
−1387,77(9,84) − Rrx (20,46) = 0
Rrx = −667,432lb

X
+& Fx = 0

Rox + 1387,77 − 667,432 = 0

Rox = −720,338lb
For Y

X
+ Moy

−620,327(9,84) + Rry (20,46) − 79,32(30,97 + 32,27 + 31,62) − W (31,62) = 0

Ry = 1014,44lb

X
+↑ Fy = 0

Roy + Rry − 79,32(3) − 620,327 − 225,4 = 0

Roy = 69,247lb

13
Shoulder to 10.57 in to the origen
Ma = 6627,53lb − in
Tm = 744,39
Ka = 0,79
Kb = 0,9 −→ supposed
Kd = 1,01
Ke = Kc = 1
Kf = 1,7, Kf s = 1,5 −→ supposed
n = 1,85

Sut] = 100KP si −→ AISI1050

Se = 0,5 ∗ 0,79 ∗ 0,9 ∗ 1,019 ∗ Sut
Se = 35,90KP si
i 1/3
2 1/2 
  h
  2(K M )
 16n  f a 3(K T
fs m ) 
d =   + 
 π  Se Sut



d = 1,84in
Typical shoulder relationship
D = 1,2(d) = 2,2in
r/d= 0,1 −→ r = 0,184
Looking at concentration tables
Kt = 1,6, Kts = 1,45
qt = 0,87, qts = 0,9
Kf = 1,52, Kf s = 1,405
Then the safety factor value is recalculated
Ka = 0,82, Kd = 1,01, Kb = 0,82
Se = 37,88KP si

32Kf Ma
σa 0 = = 16924,1KP si
πd 3
σm 0 = 1481

1 σ 0 σ 0
= a + m
nf s Se Sut
nf s = 2,16

14
6.4. Wedger
The wedge is centered on the gear side.

F = 1,2in

D = 2,2in −→ Wnominal = 0,5in

Ta = 6627,57lb − in
Tm = 744,39lb − in
Se = 37,38KP si
Sut = 100KP si

2Ta
Fa = = 6025,03lb
D
2T
Fa = m = 676,718lb
D

Fa
τa = = 10041,7P si
w∗F
F
τm = m = 1127,86P si
w∗F

q
σa 0 = 3(τa )2 = 17392,7P si
q
σm 0 = 3(τm )2 = 1953,51P si

1
nf s = σa 0
Se + σSmut0
nf s = 2,06

Pressure effort
Fm + Fa
σcontac = = 11169,6P si
Acontac
Sy
Sy = 84KP si −→ ns =
σcontac
ns = 7,52

15
6.5. Ball Bearing

ForRo
√
Fr = 720,3382 + 69,2472 = 723,659lb
Fa = P = 600lb
Bearing −→ #6310, d = 1,96in
C = 10600lb
Co = 8150lb

Fa
= 0,073 −→ e = 0,27
Co
Fa
V = 1, = 0,83 > e
VF r
X = 0,56, Y = 1,61
P = XCFr + Y Fa = 1371,25
 3
C
L10 = = 461,92millionsof revolution
P
ForRR
Fr = 1214,31lblb
Fa = P = 600lb
Bearing −→ #6310, d = 1,96in
C = 10600lb
Co = 8150lb

Fa
= 0,073 −→ e = 0,27
Co
Fa
V = 1, = 0,49 > e
VF r
X = 0,56, Y = 1,61
P = XCFr + Y Fa = 1646,01
 3
C
L10 = = 267,06millionsof revolution
P

16
Figura 3: Shear strength X

Figura 4: Momentum in X

Figura 5: Shear strength Y

Figura 6: Momentum in Y

17
Figura 7: Torque delivered by the motor

18