Moulay Ismail University, Ecole Nationale Superieure d'Arts et Métiers - Meknes

FINAL REPORT
Design and sizing of a mixer-beater
Directed by: • • Supervisor: • Academic Year: 2006-2007 Mr. ABOUSSALAH Hamdaoui
Mohamed Amine ELMEKKAOUY Abderrahim
Contents
1. Preliminary Calculation .............................................. ......
............................................ ................................. 4
. 1.1. 1.2. Select Motor ........................................... ...........
....................................... .................................... 4 G
ears of gear .......... .................................................. .....
............................................. ....... 4 Choosing the type of gea
r ..................................... ........................................
.......... ............ 4 Calculation modules m ................................
. .................................................. ...........................
5 Verification interference ................... ...............................
................... .......................... 6
I.1.1. I.1.2. I.1.3. 1.3.
Shaft diameter ............................................... .................
................................. ............................ 6
2. Calculation audit ............................................. .............
..................................... ............................... 7 3. Sizin
g mating ........... .................................................. ........
.......................... 10 3.1 3.2.. Choice .......... ......................
............................ ..................................................
Verification ................................... 10 ............. ..............
.................................... ...........................................
....... ....................... 11.
4. Sizing Bearings ............................................. ...............
................................... 12 4.1 ..... 4.2 4.3.. 4.4. bearings of the
shaft 1 ............................... ........................................
.......... bearings .................................... 12 of the shaft 2 .....
.. .................................................. ..........................
........................ .......... 13 Adjustment relating to bearings .........
.......................... .................................................. ..
............. 13 Sheet bearings (APPENDIX1) ........................... ........
.......................................... .... 13
5. Sizing Bearings ............................................. ...............
................................... ...... 14 5.1. bearings of the shaft 3 .....
.............................. .................................................
. .................................. 14
It was the torsor efforts: .......................................... ..........
........................................ ............................... 14 5.2
5.3.. pad shaft 4 ........ .................................................. ..
................................................ ............ 15 Adjustment rela
ting to bearings ................................. .............................
..................... ................... 15
6. Sizing Keys ............................................. ...................
............................... ......... 16 6.1. 6.2 6.3.. 6.4. Clavette for ge
ar .......................... 2 ................................................
.. .................................... 17 Clavette gear for 4 ....... .........
......................................... ......................................
............ ..... 18 Clavette gear for 5 ......................................
.................................................. ........................ 18
Clavette for gear ................... 6 ........................................
.......... ........................................... 18
7. Choice Elastic rings and Seals ...................................... .......
................. 20 7.1. 7.2. Circlip ................... .....................
............................. ..................................................
......... 20 Seals .................................... .......................
........................... ........................................ 20
8. Choice of Carter and covers .................................................
............................ ......................... 20

1. Preliminary Calculation
1.1. Select Motor
Data: • • • Rated Operating Torque 65 Nm C = speed of rotation of the propeller
1 N1 = 50 rpm rotation speed of the propeller 2 N2 = 40 rpm
From the above data, we have: ω1 = = ω2 So:

= 5236 rad / s = 4189 rad / s

P1 = ω1. 340 339 C = W = P2 ω2. Pmoteur C = W = 272,271
P P
Then:
=
. .
.
W = 840,344
It enhances the po er found by a safety factor KS (Safety Factor of service), h
ere: Pmoteur Pmoteur corrected = 1260,516 = W * KS (KS = 1.5) Thus, referring to
the catalog engine, the engine is chosen ith the follo ing characteristics: •
• • Rated speed Designation BA112M B8 N = 750 rpm, P = 1.5 KW
Rated
1.2. Gears gearbox
I.1.1. Choosing the type of gear
Referring to the load specification of the propellers must have a speed of rotat
ion and 50tr/min 40tr/min. And since the engine speed is N = 750 rpm and respect
ing the kinematic, e
must provide a reduction ratio r = 15. By breaking this report into a product of
t o number t o storey Gear
A possible decomposition gives: Where And And
r = 15 = 3.75 * 4 = 75 Z2 Z4 Z6 = 72 = 25
3.75 4 1.25
So therefore Z3 Z1 = 20 = 18 = 20 So Z5

All gears are helical selected.

I.1.2. Calculation modules m value of the module should be as follo s:
2.34
Ft: tangential force applied to the tooth Re: Yield stress of material = 650 MPa
k: Safety factor = 10 No e have:

(1)
Ft =
.
. .

(2)
(1) + (2) =>

10951.2
. . . R
Can increase the value of po er by that of the rated motor.
Gear 1 2 3 4 5 6 1.885861 2.890305 1.1719 Module Calculated Standardized Module
Width 1.5 2 3 15 20 30
In the calculation, e considered the choice of a steel yield strength = 650 MPa
Remin. The final choice of the type of steel ill be made in the audit.

I.1.3. Interference checking

We must verify:

With: • • • Where: Z1min = 15.69 = 15.64 Z3min Z5min = 13.91 So there is no inte
rference. (J) heel and (i) the pinion. Y2 = 1 ( normal teeth) α = 20 °
1.3. Sh
ft di
meter
Applying the formul
, we find
n
pproxim
te v
lue of the di
meters of trees:
130
Thus, we h
ve:
130 1.5 750 27.5 38.07 53.56 46.01 20 30 45 45
130 1.5 0.98 200 130 1.5 0.98 50 130 0.67 0.98 40
The holding of these trees in st
tic
nd f
tigue will be checked in the
udit.

2. C
lcul
tion Verific
tion

2.1. Check the sh
ft 4
Di
gr
m of she
r
nd bending moment:

We m
de the following
ssumption: In the room the two constr
ints reign m
ximum
torsion
nd bending. Torque m
ximum bending moment = 286 Nm m
ximum Mt Mf = 108
355 Nm
I.1.4. Verific
tion by the ASME code is the presence of stress concentr
tion: b
= 0.75 is chosen
s
m
teri
l whose ch
r
cteristics XC38 steel: Re = 490 MP
=
630.83 MP
Rrt
σ adm = 85.5 MPa
In addition we have Cm = 1.5 and Ct = 1.5
Thu : τmax
=
   
= 80.52 MPa Diame er = 45 mm is valid A safe y fac or according o ASME code s =
1.06
    
I.1.5. Checking he Calcula ion of he fa igue endurance limi σD: We know that:
Now k  = 0.75 kg = 0.KT = 85 = 1 1 kp k  = k  = 1 kg σD kp kF σ'D kT
= 201 MPa σD
Checking in on the key dynamic: It ha  a wedge-type = 1.42 Kff The torque and be
nding moment
σt = 16 MPa
Ktf = 1.6
Kto = 1.7
qf = 0.6
qt = 0.8
KFO = 1.56
Mt = 286 Nm ( tatic) Mf = 109 Nm (dynamic) and σf = 13 MPa
After correction coefficient  of tre  concentration σt = 25 MPa, and = 18.5 MP
a and σf
σm (eq) = 43.4 MPa σa (eq) = 18.5 MPa
From the diagram of Haig, one i  in Zone I: S = 7.9
Checking in wa  key in Static  σt = 16 MPa and 13 MPa = σf
After adju ting the coefficient  of tre  concentration: σt = 27.2 MPa = 20.8 M
Pa σf Then the equivalent tre  of Von Mi e : σeq = 45.14 MPa Thu   = 10.8
Note: Becau e the material u ed i  the lea t expen ive on the market, we keep ou
r choice of material even if the afety factor  are very large.

3. Sizing mating
3.1. Choice
Calculation of nominal torque: C (Nm) = P / w = (1500 * 30) / (750 * pi) C (Nm)
= 19 Nm
Safety factor: On irregular Inertia An average tart  per hour K1 = 1.4 K2 = 1 K
3 = 1 = 27 Nm CNOM
4 hour  of operation per day rated torque coupling: Where:
CNOM = K1 * K2 * K3 * C
Hence there i  a choice between MPP and MINIFLEX.
According to the catalog the motor haft diameter d = 30mm So we cho e a flexibl
e coupling MINIFLEX 633,044
Who e technical characteri tic :

3.2. Verification
Since we do not know the method to calculate the tarting torque i  e timated Cm
ot Cd = 4 = 76 Nm Or choo e to mate, it Cmax = 80 Nm> Cd So the choice i  valid
with re pect to the afety factor Relatively nominal torque at maximum torque S1
= 2.1 S2 = 1.05
4. De ign of Bearing 
4.1. A haft bearing 
It wa  the effort  tor or under A: FA 0 0 0 XR 20.21 FT TL YL = YR = 0 TR = 30 Z
R Teng1 FR FT ZL -30 0 -30 ZR YR FT 30 FR Hence we have the following equation :
And C/20.21 FT = 0 = 0 = YR - (FR + YR) ZR = - (FT + ZR)
FT = ZL YL = EN
In addition, we have: FR = FT tan (α) Thus,the torques in their points of
pplic

tion
re: -546 0 0 0 546 0 398 0 TL = TL = 0 TENG1 -796 = 398 0945 0945 -1890 0
0 So: Be
ring in
nnul
r line
r b
ll be
ring in 2021 N = EN EN N = 1025 N = 546
FA = FA 0 N To
void more errors in the c
lcul
tion, we preferred to use softw

re for the selection of be
rings b
sed on the SNR c
t
log (CD enclosed). In orde
r
lifesp
n of five ye
rs, with four hours of oper
tion per d
y, we must h
ve 7
300 hours = L10h Thus, chosen from the possibilities provided by the softw
re ru
nning the following
nd th
t for the two sh
ft be
rings:
Ch
r
cteristics of 6304 = 20 D = 52 B = 15 C = C0 = 15,900 7900 = 10,821 hours L
10h (minimum of 2 shifts)
4.2. Sh
ft be
rings 2
It w
s the efforts torsor under A:
0 0 0 XR FA2 FA3 22 65 625 FT2 FT3
TL YL = 0 TR = 165 YR = ZR Teng2 FR2 FR3 = 95 Teng3 FT2 FT3 ZL 65 ZR-0 165YR FT2
FT3 -65 -95 FR2 FR3
Hence we h
ve the equ
tions:
+22 65 625 FT2 FT3 = 0 ZR = - (95 FT2 FT3 65) / 140 YR = - (95 65 FR2 FR3) / 140
And

XR = FA2 + FA3 YA = - (FR2 + FR3 + YR) ZA = - (FT2 FT2 + + ZR)

 the equ
tions t
king into
ccount the rel
tions: FA FT = t
n (β) and
By solving
FR FT = an (α) / cos (β) 0 0378 0546 -1628 0 0 168 0 TL = TR  = 619
 = 398 0 0 Te
ng2 Teng3 = 0 1369 -1185 0505 0945 -2819 0 0 So: Bearing in all earings
 in
 ann
ular
 linear EN EN N = 800
 N = 1380 N =
  378 FA = FA 0 N
 From he lis of sui a le
earings, we selec ed he same for o h working capi al:
 
Charac eris ic 6006

d = 30 D = 55 B = 13 C = C0 = 12,600 8200 = 63,429 hours L10h (minimum of 2 shif

s)

    
4.3. Adjusmen
 rela ing o earings     
According o he NF-E 22-396
 and 397 and a all
 earing,
 i is recommended ha
he following adjus men s: • • Bearing / shaf : g6 earing / hu : J7

4.4. Technical earings (APPENDIX1)
5. Sizing Bushings        
Since i has a low ra e ofro a ion of he shaf can hen use  pads
 ins ead of e
arings.
 We choose for all earing padsin GLACIERS ACETAL.S udy he life:
  Accor
ding o
   INA ca alogs
 dura ion life of he earing is direc ly rela ed o he pro
duc y he rela ionship PV: L10h = fT fP fR fV L

Wi h
       
fP: load correc ion fac or FT is he  correc ion fac or fV empera urecorrec ion
fac or for speed fR correc ion fac or for roughness L: life uncorrec ed.
    
All hese fac ors are derived direc ly from he char s (MECHANICAL SYSTEM).
 
5.1.
 Bearings
 of he shaf 3
I was he effor s orsor: 0 0 0 0 43.3 FA6 FT6 Tc1 = Tc2 = 0 Yc1 Yc2 75 ZR Teng
6 FR6 = 37.5 0 ZC2 ZC2 FT6 FT6 YR -75 -37.5 FR6 So we have: 0 0 0 0867 0 Tc1 = 0
-315 -315 0 Teng6  = Tc2 = 730 0 -750 -750 0 0 0 1500 Hence he wo pads was N =
814 Fr In addi ion we have V = (40 * π * 0.045) / ( 60) = 0.05 m / s Alying t
he rincile of ressure ermissible diametral we have L ≥ 3.59 mm, and alying
the thermal rincile, we must have L ≥ 5.51mm Thus we choose from the standard
INA bearings, the bearing with characteristics: d = 45 mm
D = 50 mm

L = 30 mm
Using the abacus manufacturers is: So fV fP = 1 = 1, fT = 0.8 fR = 0.75 L = 1600
0h
L10h = 9600 Hours

5.2. Bearing of shaft 4

Alying the same aroach, found in the ad characteristics: d = 45 mm in this
case is PV = 0.1 D = 50 mm L = 30 mm
Using the abacus manufacturers is: So fV fP = 1 = 1, fT = 0.8 fR = 0.75 L = 1400
0h
L10h = 8400 Hours
5.3. Adjustment relating to bearings
We selected for mounting ads adjustments: • • Pad / tree: f7 Bearing / Hub: H7
6. Sizing Keys
According to the standard NF E 22-175 (AFNOR) for any tree of diameter d is a ke
y section of a × b. So standard it remains to determine the nominal lengths of t
he keys to ensure the transfer of ower. For this one must check the following c
ondition:  ≤ Padma. we view oerating conditions fairly good, it takes PADME =
70 MPa Now we have:

With:
C: torque transmitted L: length of the key J'nom: Housing key in the tree BLastN
ame: height of the wedge d: nominal diameter of the tree s: radius of curvature
(Tables 5.2, 5.4, age 254, 256 Mechanical Systems: Theory and design)
2 - -

Adjustments of the shaft and hub (inner diameter gear) We want to rovide a slid
ing connection between the shafts and hubs so it is recommended that the adjustm
ent is more f7 H7 is chosen keying a normalresulting adjustments: N9 + h9 + wedg
e between the shaft and hub and between H9 JS9 key for each gear we will calcula
te the dimensions of the in to use and it will set the ricing of the shaft and
hub (inside diameter 'reaing) and tolerances of symmetry. We define: J1min gam
e minimum diametrical shaft / hub J2min minimum lateral lay key / keyway tM and
tA are the tolerances of tree symmetry (resectively hub)
tA = tM = (J1min J2min +) / 2
6.1. Clavette for gear 2
In this case we have the following data: d = 30 mm section of the in 7 J = 8 ×
4 mm = 0.2 mm ITJ smax = 0.4 mm
C = 71 620 = 7 mm N.mm BLastName Where:
ITB = 0.036 mm

L ≥ 28.86 mm
According to the standard values, we selected the key: Parallel key, Form A, 8 ×
7 × 30 NF E 22-177 1. Tree hub H7 f7 30o 2. Clavette hub 8 JS9 h9 3. Clavette T
ree 8 N9 H9
Thus, we have:
J2min J11min = 0 .020 = 0.018 = 0 J12min
J2max = 0 .62 = 0.054 J11max J12max = 0072
Tree (Figure 1) • • • • • • Hub (Figure 2) • • • • • Diameter Ø30 H7 dmin = 30 d
max = 30 021 Slot 8 has N9 = 8 amin amax = 14 = 14 043 = 33.3 k = kmin kmax = 33
.1 rmin rmax = 33.3 0.25 0.4 0019 M = A M Diameter Ø30 f7 dmin dmax = 29 959 = 2
9.98 N9 Slot 8 = 8036 a = amax amin 8 = 8 J = 26 8.25 = Jmin Jmax = 26 = 0.4 rma
x rmin = 0.25 Tolerance of symmetry 0019 M S A M
6.2. Clavette for gear 4
In this case we have the following data: d = 45 mm section of the in 9 J = 14 ×
5.5 mm = 0.2 mm ITJ smax = 0.6 mm
C = 286 480 = 9mm N.mm BLastName Where:
ITB = 0.036 mm

L ≥ 61.33 mm
According to the normalized values, we selected the key: Parallel key, Form A, 1
4 × 9 × 60, NF E 22-177
6.3. Clavette gear for 5
In this case we have the following data: d = 45 mm section of the in 9 J = 14 ×
5.5 mm = 0.2 mm ITJ smax = 0.6 mm
C = 170 767 = 9mm N.mm BLastName Where:
ITB = 0.036 mm

L ≥ 36.63 mm
According to the normalized values, we selected the key: Parallel key, Form A, 1
4 × 9 × 40, NF E 22-177
6.4. Clavette gear for 6
In this case we have the following data: d = 45 mm section of the in 14 × 9 J =
5 .5 mm ITJ = smax = 0.2 mm 0.6 mm
C = 144 667 = 9 mm N.mm BLastName Where:
ITB = 0.036 mm

L ≥ 34.48 mm
According to the normalized values, we selected the key: Parallel key, Form A, 1
4 × 9 × 35, NF E 22-177
Adjustment of the shaft and the hub view of the gears 4,5 and 6 are the same sec
tions of the key, and the same assembly conditions, we have: 1. H7 Tree hub 45o
f7 2. Clavette hub 14 JS9 h9 3 . Clavette Tree N9 14 h9
Thus, we have:
J2min = 0 .05 = 0.025 J11min J12min = 0

J2max = 0 .128 J11max J12max = 0075 = 0086

Tree (Figure 3) • • • • • • Hub (Figure 4) • • • • • • Diameter Ø45 H7 dmin = 45
dmax = 45 025 14 Groove JS9 amax = 14,043 a = 14 = 14 amin = 48.8 k = kmin kmax
48.6 48.8 = 0.4 rmax = rmin = 0.25 Tolerance of symmetry 0037 M A M Diameter Ø4
5 f7 Groove has 14 N9 = 14 J = 39.5 0.25 = rmin rmax = 0.4 tolerance = 44.95 ami
n symmetry dmin = 14 dmax = 39.4 Jmin = 44975
amax = 14,043 Jmax = 39.5 A M
0037 M P
7. Choice of elastic rings and seals
7.1. Circli
To eliminate the translation of gears are used Circlis whose dimensions are
defined by the NF-E 22-165: Circli for shaft 45 × 1.75 Circli for shaft 20 × 1
.5 Circli for shaft 30 × 1.75 Circli for hole 52 × 2
7.2. Seals
Is used for sealing, it was decided to use li seal radial contact (DIN) NBR wit
h the following names on trees: a tree: The tree 3: Li seal, AS tye, 20 × 40 ×
7 li seal, tye AS, 45 × 62 × 8
Adjustment:
Tree: h11 Hub: H8 Failure coaxiality: a tree: Tree 0.05 3: 0.15 Circularity: IT8
surface condition: 0.2 ≤ Ra ≤ 0.8 (shaft) and Ra ≤ 3.2
Beat <0.3
To seal the housing using a seal Kraft aer form in order that it is the least
exensive.
8. Choice of Carter and lids
The casing is rismatic in shae to the dimensions imosed by trees and gear (se
e ic definition). For manufacturing the casing and lid, it is recommended to us
e
cast iron EN-JL 1010, for the good roerties it has (moldability, workability,
resistance to wear by friction ...). According INDUSTRIAL DESIGNER'S GUIDE, it i
s recommended to use a wall thickness e = 5 mm, because the length does not exce
ed 300mm. covers and the housing will be achieved by molding rocess. The study
of casting out of context for the urose of this design.