Abu-Dhabi University

College of Engineering
&Computer Science
Department of Mechanical Engineering
MEC430 Machine Design
Mini Project 2
Project Title: Shaft Design

Student name

Student ID

Abdul Ahad Iqbal

1000536

Bilal Ahmad

1029653

Ibrahim Ramzi Awad

1006869

Signature

Table of Contents
Table of Contents..................................................................................................... 2
Abstract..................................................................................................................... 3
Introduction................................................................................................................ 3
1

Preliminary Design.................................................................................................. 4
Function Decomposition Analysis............................................................................4
Sub-Function Decomposition Analysis.....................................................................5
Conceptual Design and Generation of Alternatives:................................................5
Assessment of Alternatives..................................................................................... 9
Preliminary Analysis for Sizing Main Components:................................................10
Main Design Calculations...................................................................................... 14
Shaft Design.......................................................................................................... 14
Gear Forces........................................................................................................... 17
Diameter of Bolts.................................................................................................. 19
Selection of a Clutch............................................................................................. 20
Appendix............................................................................................................... 22
CAD Drawings:...................................................................................................... 22
References................................................................................................................ 24

Abstract
This design project aims at the design of different components of a gear box for an
industrial saw. The main design component for this project is the shaft along with the keyways,
fillet radius, bearing seats and splines. The design has to be done through a preliminary analysis
followed by the detailed calculations of the forces and stresses.

Introduction
A gear box can be defined as a set of gears that are present in an enclosed system and are
used to deliver mechanical energy from a prime mover to an output device. (ToolingU SME,
2013) The task given to the group deals with designing a speed reducer for a saw that is used to
cut tubing for vehicle exhaust systems. The specifications of its operation have been defined
along with the diameter of the shaft that is used in the motor. The NEMA frame 284T motor will
be required to have a shaft which can accommodate 1/2x1/2 inch key.
The machine has a band type saw and the selection of a desired clutch mechanism with a
suitable engagement/disengagement function is also one of the objectives of the project.
Secondly, the housing in the shaft is assumed to be fixed by four bolts. The sizes and the forces
on them are to be calculated after the detailed analysis of the shaft. The requirements of the
project also state that cost of production is a key aspect in terms of all the calculations done as
the owner wants the cost to be put ahead in terms of any decision regarding the design of the
reducer. Thirdly, the project verifies the operating durations of the machine along with the
environmental factors in which it will be placed. The design has to be done in such a manner that
the life of the shaft is expected to be at least five years. The additional requirements of the
project are based on the sizing of components like pulleys, sprockets and lastly followed by an
assembly drawing of the shaft with all the components.

Figure 1: Assembly of a shaft (Shafts and Bearings)

Preliminary Design
Function Decomposition Analysis
Speed Reducer for Saw

Power supply Coupling on motor side

Speed reducer

Clutch engagement mechanism

Clutch

Sub-

Function
Bearing attachment

Decomposition Analysis

Frame attachment

Conceptual Design and Generation of Alternatives:

The conceptual design and generation of alternatives phases are
normally preceded by intensive searches in all possible channels. Some of
these would be:

Literature search
Web search
Market search
Patent search
Internal company search

The following alternatives have been arrived at by doing web search. In

other projects some of the above searches would be important and critical,
especially patents search.
Alternative 1: Spur Gear Reducer

Alternative-2: Bevel Gear Reducer

Alternative-3:
Worm Gear
Reducer

Assessment
of
Alternatives
Assessment of alternatives may depend on the novelty in each
alternative, the size of the project and criticality of the choice. These
methods may range from subjective techniques, simple analysis, more
detailed analysis, simulation methods and experimental methods. Some of
the methods that may be used are listed below:

Decision matrix
Decision tree
Simple analysis
Detailed analysis
Simulation and numerical methods
Experimental methods

For the above alternatives we use the following choice matrix:

Decision Matrix for Gear Box Alternatives

Alternative
Criteria

Weig
ht

Spur Gear Type

Bevel Gear Type

Worm Gear Type

Score

Score *
Weight

Score

Score *
Weight

Score

Score *
Weight

Efficiency(1)

0.2

10.0

2.0

10.0

2.0

5.0

1.0

Simplicity

0.2

10.0

2.0

8.0

1.6

9.0

1.8

Cost

0.15

10.0

1.5

8.0

1.2

9.0

1.35

0.15

10.0

1.5

10.0

1.5

2.0

0.3

0.2

8.0

1.6

9.0

1.8

10.0

0.1

10.0

1.0

9.0

0.9

9.0

0.9

Reduction
ratio(2)
Space
requiremen
t
Ease of
maintenanc
e
weight *
score

1.0

9.6

9.0

7.35

(1) Spur and bevel gears have much higher efficiency (>95%) than worm gears (may be as low as 65%)
because the rolling friction (in spur and bevel) versus sliding friction (in worm gears).
(2) We may achieve much higher reduction ratio in worm gears but the speed ration is integer.

Preliminary Analysis for Sizing Main Components:

A. PRELIMINARY SIZING

OF

SHAFTS:

We need to have an initial size for the main components to start the
design process. We find an approximate size for the shaft and from that size
we find other component sizes by proportions.
The drive shaft receives power of 35 hp.
The speed of the shaft is 500 rpm. We use the following relations:
2 n d d n
d


60 2
60
2

d n
lb ft
d
, T Ft , hp 550
12
sec
2
F V
T
Tn
hp t
, hp

33000
6600 63000

10

where:

d:

pitch diameter (inch)

(rpm)

n:

gear rotational speed

We use the following equation for the torque on the motor shaft:
T (lb.in )

63000 hp 63000 * 35( hp )

1,260 lb.in
n
1750( rpm )

And we make sure that the torque on the saw shaft is equal or more than the
required:
T (lb.in )

63000 hp 63000 * 35( hp )

4,410 lb.in
n
500( rpm )

which is more than the minimum required torque of 3,750 lb-in.

We chose a shaft material: AISI 1030 CD with the following:
Sy = 50,000 psi,
Su = 79,800 psi,
E=29.7x106 psi,
G=11.6x106 psi, and
HBN=179
To obtain an initial estimate for the shaft diameter, we assume an
initial factor of safety of 4.0 and we use 50% more torque to account for
other loads (bending moment, shear and axial force) as well as stress
concentration and fatigue stress concentration, then:
ib .

16(1.54410)
d
T( )
Tc
2
16 T
= =
= 3 =
4
J
d
d
( )
32
Which gives

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d=1.75
This is quite in agreement with the given data for the motor shaft
which has a diameter of 1.875 in. Therefore, we will use
d=1.875

B. PRELIMINARY SIZING

OF

GEARS:

The figures show the dimensional parameters of the gear and the tooth
and the first table gives the AGMA Standard Gear Specifications whereas the
second table shows standard selection values for diameter pitches.
It should be noted that all dimensions are function of the circular pitch p or
the diameter pitch pd and we have these relations:
Circular pitch:

p=

d
N
= , p d= ,d :diameter of the pitch
N Pd
d

We start by the pinion gear and we try to minimize space requirements

and, therefore we use a small pinion with no web as shown in figure:

From the above figure, we assume the pitch diameter of the pinion to be:
d pinion =d p=2.0 d shaft=2.01.875 3.75

From the table of standard diameter pitches, we chose:

3.75N=30tooth
tooth
N N
pd =8 , whichg ives p d=8= =
dp

12

Using the table with the proportional dimensions, we obtain all geometrical
dimensions for the pinion.
For the gear, we must have the diameter pitch for proper engagement, and
we have:
d p g ng 500 rpm
1,750 rpm
= = =
which gives :d g=d p
=13.125
d g p n p 1,750 rpm
500 rpm
Once again, using the table with the proportional dimensions, we obtain all
geometrical dimensions of the gear.

13

C.

PRELIMINARY
ESTIMATES OF
FORCES:

GEAR

The following relations may be used to calculate gear forces noting

that the standard pressure angle is equal to 20o.
2 n d d n
d


2
60 2
60

d n
lb ft
d
V
, T Ft , hp 550
12
sec
2
F V
T
Tn
hp t
, hp

33000
6600 63000

where:
d: pitch diameter (inch)
rotational speed (rpm)

n: gear

Ft Fn cos Wt
Fr Fn sin Wr

Ft: Tooth tangential

force
Fr: Tooth radial force
D. PRELIMINARY SIZING

OF

KEYS

AND

SHAFT

Fn::
LENGTH

Tooth normal force

One of the most common ways of transmitting torques between the

shafts and the gears is by use of the keys. The keys work in a way in which a
longitudinal groove is machined on the shaft called a keyway and a
corresponding grove is made into the bore of the hub. The key is then able to
fit simultaneously in both grooves. The following figure gives approximate

14

proportional dimensions for square and flat keys. We chose a square key
(most common) and use the following relations:
Ls =

4T fs
4T fb
Lb =
S yt DW
k S yc DH

where:

Ls :key lengthbased on shear strength( factor of safety :f s)

Lb : key length based on bearing strength ( f actor of safety : f b )
D: Shaft diameter , W :key width , L :key length
H : half key height , S yt :Yield strengthtension , S yt :Yield strengthcompression
k :Triaxial stress factor , 1.0 k 1.5

Main Design Calculations

Shaft Design
Assumptions:
Length of shaft is 7 in, and radius of fillet r = 0.1 in
Forces are Ft = 4704 lb and Fr =

1712 lb (Found using values from

preliminary analysis)
These forces are applied at the center of the gear, which is 4.5625 in from
the center of bearing 1. The reaction forces are applied at the center of the
bearings.
Assuming a reliability of 99% reliability
Ta = Mm = 0, and factor of safety = 2

15

Mz = 0 => ( 1712)(4.5625) + (Ry,2)(6) = 0

Ry,2 = 1302 lb
Fy = Ry,1 + 1301.8

1712 = 0

Ry,1 = 410 lb
My = 0 => ( 4704)(4.5625) + (Rz,2)(6) = 0
R = 3577 lb
z,2

Fz = Rz,1 3577 + 4704 = 0

Rz,1 = 1127 lb
Figure 2: Shear and Bending Moment Diagrams

Total moment at beginning of keyway =

(4198)2 +(1527)2

= 4467 lb.in

Material chosen for shaft: AISI 1030 Steel, as rolled

Se/ = 0.5 (Sut) = 0.5 (79800) = 39900 psi
ka = a (Sut)b = 39900 (79800) -0.995 = 0.529
kb = 0879 (d) -0.107 = 0879 (1.875) -0.107 = 0.82
kc = 1
16

kd = 1.008
ke = 0.814
q = 0.78
Kt = 1.59

Kf = 1 + q (Kt

1) = 1.46

qs = 0.83
Kts = 1.5
Kfs = 1 + qs (Kts

1) = 1.42

Se = (0.529)(0.82)(1)(1.008)(0.814)( 39900) = 14201 psi

Using Goodmans criterion; d = 2.2, Assuming d = 2.0 in
A common ratio of D/d = 1.2
D = 1.2 (2) = 2.4 in, Assume D = 2.5 in
Se/ = 39900 psi
ka = 0.529
kb = 0.816
kc = 1
kd = 1.008
ke = 0.814
q = 0.78
qs = 0.83
Kt = 1.93
17

Kts = 1.62
Kf = 1.7254
Kfs = 1.5146
Se = 14132 psi
Using Goodmans criterion again; d = 2.3 in, Assuming d = 2.25 in
D = 1.2 (2.25) = 2.7 in, Assuming D = 2.75
These estimates give D/d = 1.22 1.2. Therefore, D = 2.75, and d = 2.25
a = (Ma y)/I = 2188 psi
m = (Tm c)/J = 1080 psi
From calculations, the preliminary diameter of the output shaft of the
speed reducer will be 1.875 in, and the torque that this shaft will carry is 4410
lb.in.
Key Design
Assumptions:
A square key is chosen (1/2 x 1/2 in)
fs = fb = 2
k (triaxial stress factor) = 1
Material chosen = AISI 1015 Steel, cold drawn
Tensile Strength, Ultimate = 55800 psi
Tensile Strength, Yield = 47100 psi
This material is chosen since it is weaker than the shaft material (AISI
1030 Steel, as rolled), which has a yield strength of 50000 psi. The key

18

should break first before the shaft in case of overloading. Assuming that the
tensile strength is the same as compressive strength;
Ls =

4T f s
S yt DW

Lb =

4T f b
k S yc DH

4 (4410)(2)
(47100)(2.75)(0.5)

= 0.54 in

4 ( 4410)(2)
(1)( 47100)(2.75)(0.25)

= 1.1 in

Let the length of the key in this case 1.5 in, as this will ensure ample
strength to resist both failure by shearing and failure by crushing.
Gear Forces
Assumptions:
The tangential force on the shaft is the same as that on the gear.

= 20o
Factor of safety = 2.0
T = Ft

Ft =

( d2 )
2T
d

2( 4410)
2.75

= 3207 lb

Ft = Fn cos

Fn =

Ft
cos

3207
cos ( 20 )

= 3413 lb

Fr = Fn sin = 3413 sin (20) = 1167 lb

Ft = 3207 lb
Fr =

1167 lb
19

Assuming the face width (F) to be 1.5 in

Circular tooth thickness (t) =

1.571
pd

1.571
8

= 0.196 in/tooth

At = t x Face width = 0.196 x 1.5 = 0.294 in2

Dedendum =

Vg =

1.25
pd

= 0.15625 in/tooth

3207 lb

Mpg (Moment due to tangential force at base of tooth) = (

(0.15625) =

501 lb.in/tooth
(501 )

max =

Mc
I

max =

( 32 )( AVt )

( 0.196
2 )

F ( t )3
12

(735 )
=

1.5 ( 0.196 )3
12

16362 psi

Using Mohrs circle;

1 =

2 =

( )

= 79882 psi

( )

2 2
+
2

2 2
+
2

( 0.196
2 )

3351 psi

3 = 0

20

= 76531 psi

3207)

/ =

79882 ( 79882 )(3351 )+ (3351 )

2

= 81609 psi

Sy = 2 (81609) = 163218 psi

Material chosen for gears: AISI 4053 Steel (UNS G40530)
Tensile Strength, Yield = 223100 psi > 163218 psi
(Louie, 2012)
Diameter of Bolts
a/ = Kf x a = 3775 psi
m/ = (3 (Kfs x m)2)1/2 = 2833 psi
/max = a/ + m/ = 6608 psi
Assuming that the load on the bolts is /max, and increasing this by 100% to
account for any unknown loads, and using a factor of safety 4;
Sy = 4 x 2 x 6608 = 52864 psi
Let the bolt material be SAE grade 2, with bolt diameter of 0.75 in, since
these have minimum yield strength of 57000 psi > 52846 psi.
The application of pulleys, sprockets are not applicable in our design of shaft.

Selection of a Clutch
The group decided to implement a centric centrifugal clutch based
upon the operation of the saw and the ease of its engagement and
disengagement mechanism. A centrifugal clutch has a great deal of
advantages in different applications that are motor driven. The use of
centrifugal clutch allows the selection of a normal torque motor for running
loads rather than the choice of high torque motors for starting loads. (Prof.

21

Nitinchandra R. Patel, April 2013) This type of clutch is based upon the
principle of utilizing two forces which are the centrifugal and the friction
force. The reasons behind our choice of the centric centrifugal clutches were
based upon the delayed engagement along with the automatic engagement
and disengagement. There are no slippages when the operation is at full
speed and it also provides acceleration which can be considered as
controlled. This type of clutch mechanism also provides resistance to shock
loads during the process of start up. They can be customized as to meet the
specific requirements of the system. The choice of this clutch enables
efficient protection from the shock loads which can cause catastrophic
damages to the components of the drive. Secondly, it also eradicates the
need of implementing high factors of safety in order to protect these
components against these shocks. Our choice was also based on the fact
that centrifugal clutches are able to reduce the requirements needed for the
start up while keeping the heat losses to a minimal when there is a direct
start of a drive. (CENTRIC CENTRIFUGAL CLUTCHES).

22

Figure 3: Centrifugal Clutch (Prof. Nitinchandra R. Patel, April 2013)

Figure 4: Centrifugal Switch (CENTRIC CENTRIFUGAL CLUTCHES)

23

Appendix
CAD Drawings:

24

25

References
CENTRIC CENTRIFUGAL CLUTCHES. (n.d.). Retrieved 2014, from
http://www.gmbassociates.co.uk/catalogues/pdf/92.PDF
Prof. Nitinchandra R. Patel, S. D. (April 2013). Design of Centrifugal Clutch by
Alternative Approaches used in Different Applications. International Journal of
Innovative Research in Science, Engineering and Technology , 9.
Shafts and Bearings. (n.d.). Retrieved 2014, from
https://www.engineersaustralia.org.au/sites/default/files/shado/Learned
%20Groups/National%20Committees%20and%20Panels/Engineering
%20Design/Part%205.pdf
ToolingU SME. (2013). Retrieved from Tooling University:
http://www.toolingu.com/definition-560120-25178-gearbox.html
Louie, A. (2012, July 15). Spur gear tooth Stress, Strain, and Deflection for
Static Loading. Retrieved May 25, 2014, from PSAS:
http://psas.pdx.edu/lv2cguidance/spur_gear_tooth_stress__44___strain__44__
_and_deflection_for_static_loading/

26