WEC projects (Pty) Ltd

water and wastewater treatment solutions

Item
3.1
3.2
3.3
3.4

Symbol
FT
FA1
FR1
FR2

dk = 180

Value
0.12
650
2470
0.3
800

Lk = 120

2.2
2.3
2.4
2.5

Symbol
PMOTOR
TM
TG
NM
Mscraper

FORCE INPUTS
Units
Description
kW
Motor Power
N.m
Motor Output Torque
N.m
Torque seen by the shaft sprocket
rev/min
Motor Output Speed
Kg
Scraper assembly mass

FORCE OUTPUTS
Value
Units
10833.33
N
7848.00
N
3882.84
N
6950.50
N

DSHAFT,SPR = 510

Description
-

DSHAFT = 80

STRESS ANALYSIS RESULTS SUMMARY

-20000
20000
0

1000
0

5000
0

10000
0

SHEAR STRESS DIAGRAM [Mpa]

BENDING STRESS DIAGRAM [MPa]

2.5

30

25

1.5

20

15

0.5

10

0
0

-0.5

100

200

300

400

500

600

-1

5
0

-1.5

100

TORSIONAL STRESS DIAGRAM [MPa]

200

300

400

500

600

500

600

AXIAL STRESS DIAGRAM [MPa]

80

1.6
1.595
1.59
1.585
1.58
1.575
1.57
1.565
1.56
1.555

70
60
50
40
30
20
10
0
0

100

200

Item
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10

Symbol
sx,B
sx,A
smax
smin
xy
sa
sm
sa'
sm'
n1st cycle

Value
Units
27.53069297
MPa
1.596891435
MPa
29.1275844
MPa
25.93380153
MPa
73.70863302
MPa
1.596891435
MPa
27.53069297
MPa
127.6770841
MPa
130.6017871
MPa
1.800379558
-

Item
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9

Symbol
Se'
ka
kb
kc
kd
ke
kf
Se
nf

Value
Units
350
MPa
0.794740895
MPa
0.758912698
MPa
1
MPa
1
MPa
1
MPa
1
MPa
211.0986349
MPa
1.263590048
-

300

400

500

600

100

200

300

400

FAILURE ANALYSIS RESULTS SUMMARY

MIDRANGE AND ALTERNATING STRESS CALCULATION
Description
Bending along x
Axial along x
Bending + Axial
Bending - Axial
Torsional (Vertical Shear = 0 at the chosen point)
Alternating Stress
Midrange Stress
Note: tau.xy = tau.a and tau.m as vertical shear has no effect
Note: tau.xy = tau.a and tau.m as vertical shear has no effect
First cycle factor of safety (Red = failure)
FATIGUE ANALYSIS
Description
Rotary beam test specimen endurance limit
Surface factor
Size factor
Loading factor
Temperature factor
Taken into acc. By using lowest Sut in calc.
Misc. factor
Modified endurance limit
Fatigue safety factor: Modified Goodman (Red = failure)

dT = 550

Item
2.1

d1 = 50

SHAFT DIMENSIONAL INPUTS

Value
Units
Labels/Description
50
d1 = 50
212
dTG = 212
302.5
d2 = 302.5
180
dk = 180
120
Lk = 120
550
dT = 550
80
DSHAFT = 80
510
DSHAFT,SPR = 510
120
Gearbox sprocked diameter
14
Key end diameter
8
Key depth
2.2
Bending Stress conc.
3
Torsional Stress conc.
465
Mpa
Yield strength of material
700
MPa
Ultimate strength of material

dTG = 212

Symbol
d1
dTG
d2
dk
Lk
dT
DSHAFT
DSHAFT,SPR
DGEAR,SPR
Dkey
tkey
Kkey.b
Kkey.T
sy
sUT

d2 = 302.5

Item
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15

11/18/2014

50

CALCULATION

0 < x < 247.5

247.5 < x < 338
338 < x < 500
500 < x < 550
SHEAR FORCE DIAGRAM
L/R
x-Position
DRAWING
LABELS

SECTION 1:
SECTION 2:
SECTION 3:
SECTION 4:
Region
1
1
2
2(ks)
2(ks)
2
3
3(ke)
3(ke)
3
4
4

Region
1
1
2
2(ks)
2(ks)
2
3
3(ke)
3(ke)
3
4
4

0
247.5
247.5
250
250
338
338
370
370
500
500
550

L
R
L
R
L
R
L
R
L
R

L/R

BENDING MOMENT DIAGRAM

x-Position
0
247.5
247.5
250
250
338
338
370
370
500
500
550

L
R
L
R
L
R
L
R
L
R

2(ks) - Keyway starts in region 2

3(ke) - Keyway ends in region 3

Region
1
1
2
2(ks)
2(ks)

L/R
L
R
L
R

TORQUE DIAGRAM
x-Position
0
247.5
247.5
250
250

2
3
3(ke)
3(ke)
3
4
4

Region
1
1
2
2(ks)
2(ks)
2
3
3(ke)
3(ke)
3
4
4

L
R
L
R
L
R

338
338
370
370
500
500
550

AXIAL FORCE DIAGRAM

x-Position

L/R

0
247.5
247.5
250
250
338
338
370
370
500
500
550

L
R
L
R
L
R
L
R
L
R

FAILURE ANALYSIS

Item

MIDRANGE AND ALTERNATING STRESS CALCU

Symbol
Value

1.1

sx,B

27.53069297

1.2

sx,A

1.596891435

1.3

smax

29.1275844

1.4

smin

25.93380153

1.5

xy

73.70863302

1.6

sa

1.596891435

1.7

sm

27.53069297

1.8

'

127.6770841

1.9
1.10

Item
2.1
2.2

sa
sm'
n1st cycle

Symbol
Se'
ka

130.6017871
1.800379558

Value

FATIGUE ANALYSIS

350
0.794740895

2.3
2.4
2.5
2.6
2.7
2.8
2.9

kb
kc
kd
ke
kf
Se
nf

0.758912698
1
1
1
1
211.0986349
1.263590048

[1] dT-d2 = 247.5

[2] dT-dTG = 338
[3] dT-d1 = 500
[4] x (tot) = 550

FORCE

S
T

Region
1
1
2
2(ks)
2(ks)
2
3
3(ke)
3(ke)
3
4
4

0
0
6950.49505
6950.49505
6950.49505
6950.49505
-3882.838284
-3882.838284
-3882.838284
-3882.838284
0
0

B
A

50
0

L/R x-Position
0
L
247.5
R
247.5
L
250
R
250
L
338
R
338
L
370
R
370
L
500
R
500
550

Mpa
0
0
1.843676073
1.843676073
1.885692493
1.885692493
-1.05342698
-1.05342698
-1.02995484
-1.02995484
0
0

BENDING STRESS DIAGRAM

Region L/R x-Position
Mpa
0
0
1
L
247.5
0
1
R
247.5
0
2
250 0.345689264
2(ks) L
250 0.76051638
2(ks) R
L
338 27.53069297
2
R
338 27.53069297
3
370 22.09253139
3(ke) L
370 10.04205972
3(ke) R
L
500
0
3
R
500
0
4
550
0
4

N.m
0
0
0
17.37623762
17.37623762
629.019802
629.019802
504.7689769
504.7689769
0
0
0

2470
2470
2470
2470
2470

S
T

4
3

N.m

-5
5
0

5000
0 10000
0
100
0
1.55
1.6
SHEAR
STRESS
DIAGRAM

B
A

-20000
20000
01000
0

STRESS

32
3
TORSIONAL STRESS DIAGRAM
Region L/R x-Position
Mpa
0 24.56954434
1
L
247.5 24.56954434
1
R
247.5 24.56954434
2
250 24.56954434
2(ks) L
250 73.70863302
2(ks) R

2470
0
0
0
0
0
0

2
3
3(ke)
3(ke)
3
4
4

L
R
L
R
L
R

338 73.70863302
338
0
370
0
370
0
500
0
500
0
550
0

16
3
AXIAL STRESS DIAGRAM
Region L/R x-Position
Mpa
0 1.561309992
1
L
247.5 1.561309992
1
R
247.5 1.561309992
2
L
250 1.561309992
2(ks)
250 1.596891435
2(ks) R
L
338 1.596891435
2
R
338 1.596891435
3
370 1.596891435
3(ke) L
370 1.561309992
3(ke) R
L
500 1.561309992
3
R
500 1.561309992
4
550 1.561309992
4

N
7848
7848
7848
7848
7848
7848
7848
7848
7848
7848
7848
7848
=

16
3

FAILURE ANALYSIS

LTERNATING STRESS CALCULATION

Units

Description

MPa

Bending along x

MPa

Axial along x

MPa

Bending + Axial

MPa

Bending - Axial

MPa

Torsional (Vertical Shear = 0 at the chosen point)

MPa

Alternating Stress

MPa

Midrange Stress

MPa

Note: tau.xy = tau.a and tau.m as vertical shear has no effect

MPa

Note: tau.xy = tau.a and tau.m as vertical shear has no effect

First cycle factor of safety (Red = failure)

ATIGUE ANALYSIS
Units
MPa
MPa

Description

Rotary beam test specimen endurance limit

Surface factor

=
=

MPa
MPa
MPa
MPa
MPa
MPa
-

Size factor
Loading factor
Temperature factor
Taken into acc. By using lowest Sut in calc.
Misc. factor
Modified endurance limit
Fatigue safety factor: Modified Goodman (Red = failure)

[1] dT-d2 = 247.5

[2] dT-dTG = 338
[3] dT-d1 = 500
[4] x (tot) = 550


2
+
2