MD Full Report

ABSTRACT
Machine design is a subject that helps students to study about the theory of machine
and design the mechanism. In this course, we are requested to do a group project. In this
project, students are given a task to design a Single Girder Overhead Crane Gear-Box. The
task required us to design a gear-box which consists of spur gears, rolling element bearings,
shafts, keys or press fits, seals and housing.
In order to investigate the mechanism, knowledge that we learn in static, dynamic
mechanic of material, theory of machine is used. We start with the design of the housing and
determine the length of the shaft. With that, we can then determine the factor of safety of the
shaft. After we got all the data and values, we can start to design the gear, bearing and the
key. Then, we can determine that the output key is the weakest.
Other than manual calculation, some computer program also being used to make to
progression of work faster. Those computer programs that used by student are programs that
we learned before. We used Microsoft Excel in our calculation, PTC Creo Paramatic for the
design and drawing of the gears, shaft, bearings and also the housing. With the help of these
software, we can get more accurate results and a better design of the gear-box.
OBJECTIVE
The objective of the project is to allow us to have a chance to design a suitable
dimension for a gear-box that suit to be used in a Single Girder Overhead Crane Gear-Box. A
good or a poor design is depends on the safety factor. When the safety factor is too low, the
mechanism will reach failure and break. Thus, in order to achieve a successful designing of
mechanism, the mechanism must have a safety factor of 1 or higher than 1.
Other that designs the dimension, another objective of this experiment is to choose a
suitable material for this mechanism. By choosing a stronger material, a higher ultimate
strength can be obtained and consequently a higher safety can be obtained too. Another
advantage of choosing the suitable material is cost efficiency. It is better to choose a cheap
material that provide desired safety factor than choose an expensive material that provide
over high safety factor which will cause over designed.
Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)
INTRODUCTION
A crane is a type of machine, generally equipped with a hoist, wire ropes or chains,
and sheaves that can be used both to lift and lower materials and to move them horizontally.
It is mainly used for lifting heavy things and transporting them to other places. It uses one or
more simple machines to create mechanical advantage and thus move loads beyond the
normal capability of a human. Cranes are commonly employed in the transport industry for
the loading and unloading of freight, in the construction industry for the movement of
materials and in the manufacturing industry for the assembling of heavy equipment. One of
the most commonly used crane example is single girder overhead crane.
This type of crane is a Top Running Overhead Cranes or Bridge Cranes are the
most effective lifting solution as we can cover more ground for moving items. We choose the
single girder overhead crane compared to the double girder is just because it provide us with
a better value for our application, lower production cost and therefore lower price. Other than
that, top running overhead cranes are low dead weight and more headroom by using a low
headroom monorail hoist. It is the most economical solution in buildings with a span over 90
ft. Single girder design allows us to be cost effective without reducing its performance. Over
the lifetime of the crane, we will have saved up on a new support structures as it has reduced
wheel loads which will allows us to add more lifting capabilities to our runway structure
without upgrading.
A crane main funtionally part is the gearbox. Gearbox is assembly of parts including
the speed-changing gears and the propeller shaft by which the power is transmitted from an
engine to a live axle. It uses gears and gear trains to provide speed and torque conversions
from a rotating power source to another device. The gearbox in a single grider overhead crane
consists of a train gear, three shafts, six bearings and three keys. Figure 1 below shows an
example of a single girder overhead crane which is a Top Running Overhead Cranes.
Figure 1 : Top Running Overhead Crane
LITERATURE REVIEW (BACKGROUND RESEARCH)
1)
Bridge - The main travelling structure of the crane which spans the width of the bay
and travels in a direction parallel to the runway. The bridge consists of two end trucks
and one or two bridge girders depending on the equipment type. The bridge also
supports the trolley and hoisting mechanism for up and down lifting of load.
2)
End trucks - Located on either side of the bridge, the end trucks house the wheels on
which the entire crane travels. It is an assembly consisting of structural members,
wheels, bearings, axles, etc., which supports the bridge girder(s) or the trolley cross
member(s).
3)
Bridge Girder(s) - The principal horizontal beam of the crane bridge which supports
the trolley and is supported by the end trucks.
4)
Runway - The rails, beams, brackets and framework on which the crane operates.
5)
Runway Rail - The rail supported by the runway beams on which the crane travels.
6)
Hoist - The hoist mechanism is a unit consisting of a motor drive, coupling, brakes,
gearing, drum, ropes, and load block designed to raise, hold and lower the maximum
rated load. Hoist mechanism is mounted to the trolley.
7)
Trolley - The unit carrying the hoisting mechanism which travels on the bridge rails
in a direction at right angles to the crane runway. Trolley frame is the basic structure
of the trolley on which are mounted the hoisting and traversing mechanisms.
8)
Bumper (Buffer) - An energy absorbing device for reducing impact when a moving
crane or trolley reaches the end of its permitted travel, or when two moving cranes or
trolleys come into contact. This device may be attached to the bridge, trolley or
runway stop.
A gear box is a machine which consists of a power source and a power transmission
system, which provides controlled application of the power. Merriam-Webster defines
transmission as an assembly of parts including the speed-changing gears and the propeller
shaft by which the power is transmitted from an engine to a live axle. Often transmission
refers simply to the gearbox that uses gears and gear trains to provide speed and torque
conversions from a rotating power source to another device. A gear train is formed by
mounting gears on a frame so that the teeth of the gears engage. Gear teeth are designed to
ensure the pitch circles of engaging gears roll on each other without slipping, this provides a
smooth transmission of rotation from one gear to the next. Transmission shafts, or just shafts,
are used in virtually every piece of rotating machinery to transmit rotary motion and torque
from one location to another part of machine.
DESIGN SPECIFICATIONS
Motor:
5 hp, with 1800 rpm
Capacity:
1360 kg. (Maximum amount of weight it can carry, plus some safety factor)
Lift height:
10 meters
(Height at which the crane will be placed)
Lift speed:
10 m/min
(Speed at which the weight will be lifted upwards)
We choose the single grider overhead crane for our project because it is the most
suitable overhead crane design for this project compared to the other design. The single
girder overhead crane is normally used in light duty load which is perfect for this project
since the load capacity is only 1360kg. Secondly, The it is the crane with the least component
and simple parts which makes it the cheapest among the other design .
The gear box design will be a gear box that have an input from a 5hp motor with a
1800rpm. The output must be able to lift a 1360kg loads with a speed of 10m/min and a
safety factor more than one. All of the specifications are been verified in our calculations
below.
MATERIAL SELECTION
Gears
Material
Steel
Type
Spur Gears
Reason
o Low cost
o Ease of machining
o Internal damping
Bearing
Material
Reason
Tin Bronze
o Softer
o Good strength
o Machinability
o Corrosion resistance
o Can withstand boundary lubrication
o Can support high loads and high temperature
Shafts
Material
Reason
Steel (Low to medium carbon steel)
o Has high modulus of elasticity

o Minimizes deflection as combination of bending moment and torque on
rotating shaft creates multi-axial stresses
Keys
Material
Soft cold-rolled iron
Type
Woodruff Key
Reason
o Material with ductile properties is used as keys are loaded in shear
Lubrication Scheme
Type
o SAE 30 (Engine Oil)

o 85W (Gear oil)
Reason :
o Good lubricants
o Good thermal stability
o By calculation and referring to the table, this type of lubrications suits the
gearbox at its best
Housing
Material
Steel
Type
Stainless steel
GEAR DESIGN
Shaft
Among the forces acts as a load on the shaft is the weight of the gear. The weight of the gear
helps us determine the stress that acts on the shaft. The material utilized in the design of the
shaft is chosen based on cost consideration and the complexity of design of the entire
gearbox.
Calculation of the input shaft
For the calculation regarding the 1st shaft, few forces and stresses were determined. The axial
force is due to the weight of the gear that acts on the center of the shaft. The torque that acts
on the shaft is the product of the power input from the motor. The power input along with the
input angular velocity is obtained from the website provided in the project description sheet
handed out.
Pin=5 hp
1 = 1800rpm
Tm = Tin
= 14.59 ib.ft = 20 Nm
Assume,
Sut= 340 MPa
n=1
q =0.7
qs =0.8
Bending stress
Kfs = 1 + qs(Kts-1)
Torsional stress
Kf = 1 + q(Kt-1)
= 1 + 0.8(1.5-1)
= 1 + 0.7(1.7-1)
= 1.4
= 1.49
AISI1015 (hot rolled) was chosen as it had the lowest safety factor but still remaining a safe
design compared to the others. Furthermore, this material is the cheaper choice compared to
its counterparts. Therefore, is material was our preferred choice among the other options.
(
The moments on the shaft can now be found. The gears were assumed, will be centered
between the simply supported bearings that are set 4 in apart. The bearing reaction forces are
then half of the gear forces and the bending moments peak in the center with a magnitude of
( )
The shaft diameter now can be found by using safety factor of 1, which is the safety of factor
of surface, N. Use DE-Goodman criterion equation. This criterion is good for the initial
design, since its simple and conservative. With Ta = Mm = 0
{
( ) ((
{
)(
( )(
( )(
))
( )((
]}
)(
))
]}
Spur Gear
The simplest mean of transferring rotary motion from one shaft to another shaft is by using a
gear train. It consists of its own set of gear ratios that the gears have on each shaft. In our
design of the gear box for Single Girder Overhead Crane Gear-Box, the gear ratio of the gear
box was set to 1:5.209. The gear train that was designed consists of two spur gears. Spur
gears are the most common type of gears. They have straight teeth, and are mounted on
parallel shafts. Sometimes, many spur gears are used at once to create very large gear
reductions. The gear train was designed based on the Shingleys Mechanical Engineering
Design reference on page 937 (Gear Specifications).
2 =1800 rpm
di = 47.9mm
5 = 66.34 rpm
For a compound reverted gear train,
For smallest package size let both stages be the same reduction. Also, by making the two
stages identical, the line condition on the input and output shaft will automatically satisfied.
10
From the ratio above, find the minimum number of teeth,N p.
(
( )
(
))
))
= 15.79 = 16 teeth
Assume,
Pressure angle, = 20
Gear Ratio = 5.209
Find outer and intermediate speed (rpm)
To determine the torque, return to the power relationship,

T2 = 20 N.m
T3 = T 4 = T2
T5 = T2
= 20* (
20* (
103.74 Nm
11
Estimate minimum diametric pitch for overall gearbox height = 22 in and assume clearances
and wall thickness as 1.5 in.
(
)
(
Start with P = 7 teeth/in

Diametral pitch,
Circular Pitch
Base Pitch
Nominal Center
Addendum/Dedendum
12
Whole Depth
Clearance
Outside Diameter
Pinion:
(
Gear:
Get pitch line velocities and transmitted loads for input and output gears,
(
Face width F is typically from 3 to 5 times circular pitch.

For gear 4 and 5,
Since loading is less on gear 2 and 3, assume F = 1.3
13
Perform free body diagram for output shaft analysis to get reaction force at the bearings.
Wt23=152.9 ibf =680.13 N
Wt54=794.45ibf =3533.9 N
Wr23 =152.9*tan(20)
Wr54 =794.45*tan(20)
=55.65ibf = 247.54N
= 289.16ibf =1286.25N
(
(
)
)
(
(
)
)
14
)
(
(
)
)
(
-397.22ibf
15
Perform free body diagram for intermediate shaft analysis to get reaction force at the
bearings.
(
(
)
)
(
(
16
(
(
)
)
)
(
(
)
)
(
17
Calculation of the output shaft

For the calculation regarding the 2nd shaft, few forces and stresses were determined. The axial
force is due to the weight of the gear that acts on the end point of the shaft because the crane
carry load at output shaft. The torque that acts on the shaft is the result of the torque of the
gear. The torque output of the shaft is calculated based on the ratio of the gear,
Tm= 103.74 Nm
Ma = 967.266 Nm
{
( ) ((
{
( )(
))
)(
( )((
( )(
)(
]}
))
]}
Calculation of the intermediate shaft

For the calculation regarding the intermediate shaft, few forces and stresses were determined.
The axial force is due to the weight of the gear that acts on the center of the shaft. The torque
that acts on the shaft is the result of the torque of the gear. The torque output of the shaft is
calculated based on the ratio of the gear,
Tm= 538.2 Nm
Ma = 967.266 Nm
{
( ) ((
{
( )(
)(
))
( )((
( )(
)(
]}
))
]}
18
Deflection on the shaft

A shaft deflects transversely due to the load applied. The angular deflection, for a shaft of
length, l, shear modulus G, polar moment of inertia J, with torque T is
Input Shaft
(
The deflection on the input shaft was found to be
. Therefore, it can be
concluded that the shaft has minimal deflection due to the load.
Output Shaft
(
The deflection of the output shaft was determined to be
concluded that the shaft has maximum deflection due to the load applied.
Intermediate Shaft
(
The deflection of the output shaft was determined to be
concluded that the shaft has minimal deflection due to the load applied.
19
20
BEARING
The bearings utilized in the design of the gearbox are ball bearings. Ball bearings use a
retainer that keeps the balls properly spaced around the raceway. (2) The assumptions made
in the computation regarding the bearings was that the tangential forces were assumed to be
equally distributed to both bearings. Several factors were considered during the consideration
of the bearing, such as the diameter of the shaft, the dynamic loading and the static loading,
in order to calculate the factor of safety for the bearing. The fatigue life of (the bearing was
determined based on the reliability factor that was provided to be 99% reliable, using the
equation given below;
(
)
( )
N=
(factor of safety)
There are two bearings (one fixed and the other floating) for both the first and the second
shaft. The reaction forces are calculated based on the maximum torque of the shaft. The
dynamic load ratings and static load ratings are determined using Table 11-2 (Shigleys
Mechanical Design 9th Edition) based on the shaft diameter. Thereafter, the load life of the
ball bearing is computed based on the equations given above.
Bearing (Input Shaft) Fixed
Type of bearing : Ball bearing
Bearing number : 6310 (based on Figure 11-23 Machine Design 4th Edition)
Based on the bearing number stated above, a lifetime of 1.869x10 9 revs. is achieved, with a
factor of safety of 12.43.
21
Bearing (Input Shaft) Floating

Similar to the fixed bearing for the input shaft.
Bearing(Intermediate Shaft)-Fixed
Type of bearing: Ball bearing
Based on the bearing number stated above, a lifetime of 1.5039x10 11 revs. Is achieved, with a
Bearing(Intermediate Shaft)-Floating
Based on the bearing number stated above, a lifetime of 8.969x10 9 revs. Is achieved, with a
Bearing (Output Shaft) Fixed
Based on the bearing number stated above, a lifetime of 1.2327x 10 9 revs. is achieved, with a
Bearing (Output Shaft) Floating
Based on the bearing number stated above, a lifetime of 3.77x 10 6 revs. is achieved, with a
22
The detailed calculation of the number of cycles and factor of safety of the bearing:
Bearing Design
Bearing (input)
P=
Diameter bore=47.9mm
From Table 11-2 (Machine Design 9TH
C = 36.9kN ,
Edition)
( )
(
=
)(
(
)
)
The calculations for the floating bearing for the input shaft is similar, as the load is
assumed to be equally distributed.
23
Bearing (intermediate)
Perform free body diagram for intermediate shaft analysis to get reaction force at the
bearings.
(
(
)
)
(
(
)
)
24
Bearing (Intermediate Fixed)

P = Ra,y = 96.87ibf x
= 430.878N
From Table 11-2 (Machine Design
9TH C = 38.55kN ,
Edition)
( )
(
)(
Bearing (Intermediate Floating)

P = Rb,y =247.94ibf x
= 1102.837N
9TH C = 38.55kN ,
Edition)
( )
(
)(
25
Bearing (output)
Perform free body diagram for output shaft analysis to get reaction force at the bearings.
Wt23=152.9 ibf =680.13 N
Wt54=794.45ibf
Wr23 =152.9*tan(20)
Wr54 =794.45*tan(20)
=55.65ibf = 247.54N
=3533.9
= 289.16ibf =1286.25N
(
(
)
)
(
(
)
)
26
Bearing (Output Fixed)

P = Ra,y = 460.37 ibf x
=2047.73N
9TH C = 36.94kN ,
Edition)
( )
(
)(
Bearing (Output Floating)

P = Rb,y = 3171.21 ibf x
= 14105.54N
9TH C = 36.94kN ,
Edition)
( )
)(
27
LUBRICATION
Engine lubricants are generally used to reduce friction between moving parts within the
interior engine. In addition to the lubricating function, motor oil also serves as a coolant,
corrosion protector, and method of removing contaminants from the engine filter. In other
words, motor oil holds the same importance to an engine that blood holds for humans. Loss
of any essential function of the motor oil will lead to serious engine damage if not treated.
Through the oxidation of motor oil, its essential functions are destroyed. This degradation
usually begins to cause severe engine damage.
V45 from gear = 3927.75 ft/min = Vt
Assume temperature 40 celcius
Viscosity
From the graph SAE ENGINE OIL 30 while SAE GEAR OIL 85W
28
Additive
Purpose
Typical Compounds
Functions
Type
Antiwear
Reduce friction Zinc
dithiophosphates, Chemical reaction with metal
EP and wear and organic phosphates, acid surface to form a film with
and
prevent scoring phosphates, organic sulfur lower shear strength than the
Agent
and seizure
and chlorine compounds, metal,

sulfurized
fats,
thereby
preventing
sulfides metal-to-metal contact
and disulfides
Corrosion
and
Prevent
Zinc
Rust corrosion
Inhibitor
dithiophosphates, Preferential
adsorption
of
and metal
phenolates,
basic polar constituent on metal
rusting of metal metal
sulfonates,
fatty surface to provide protective
parts in contact acids and amines
film, or neutralize corrosive
with
acids
the
lubricant
Detergent
Keep
surfaces Metallo-organic
free of deposits
compounds
Chemical
of
reaction
with
sodium, sludge and varnish precursors
calcium and magnesium to neutralize them and keep

phenolates,
phosphonates them soluble.
and sulfonates
Dispersant
Keep insoluble Alkylsuccinimides,

contaminants
Contaminants are bonded by
alkylsuccinic esters, and polar attraction to dispersant
dispersed in the mannich reaction products
molecules, prevented from
lubricant
agglomerating and kept in

suspension due to solubility
of dispersant
Friction
Alter
Modifier
coefficient
friction
Organic fatty acids and Preferential

of amides,
lard
oil,
adsorption
of
high surface-active materials
molecular weight organic
In an analysis, the temperature rise will first be estimated. This allows for the viscosity to
determined from the chart when the value is 111.7 cSt. With the value of the viscosity, the
analysis is performed where the temperature is computed. For this project the SAE 30 engine
oil are used and 85W for the gear oil.
29
KEYS
In engineering concept, keys and pin are used on shafts to secure rotating element, such
as gears, pulley, or other wheel. Keys are located at each gear and are used to enable the
transmission of torque from the shaft to the shaft-supported element. The input shaft key is
design to get a yield factor of safety of about 1.6 and make it the weakest link in the system.
From the text book, 2 type of keys which is gib-head key and woodruff key.
For this project, woodruff key are used. The woodruff key is of generally usefulness,
especially when a wheel is to be positioned against a shaft shoulder, since the key slot need
not be machined into the shoulder stress concentration region.
Pinion (Woodruff Key)
Minimum factor of safety,
Diameter of output shaft
= 48.3 mm
w=12mm
Diameter of intermediate shaft
= 48 mm
w=12mm
Diameter of input shaft
= 47.9 mm
w=12mm
Material of key must be ductile material.
Keys are loaded with shear; assume the environment is not corrosive.
Woodruff key is made of SAE 1015 cold-rolled.

o Where
30
Failure by shear across the area ab will create a stress of ;
= F/tl
o Where t = 0.012 (for all case)

(
)
(
)
(
(
)
)
Length for key of output shaft
= 3.1028 mm
Length for key intermediate shaft
= 1.5497 mm
Length for key input shaft
= 0.7325 mm
Since all gears have the same bore diameter but different transmit torque, the same key
specification cannot be used for all.
31
GEARBOX HOUSING
The gearbox housing is a non-rotating member of the gearbox. It is the centre part of the
gearbox, to fix all the components like bearings, flanges, shafts and spiral bevel gears. The
base to fit the gears with a defined tooth bearing and backlash are the angle of the housing
and the offset of axis of the holes. This guarantees the optimum running of the gears and
quality
of
transmission
to
run
smoothly
without
any
disruptions
occurring.
Gearbox housings are generally made from plastic called nylon. The heat is normally
dissipated by radiation through the gearbox housing surfaces and through convection to the
surrounding air, surrounding structures and components. There is a bearing pocket in the
gearbox housing. An additional bearing is inserted into it that centres the shaft ensuring
proper alignment and a permanent seal. The gearbox housing alignment should be inspected
well at periodic intervals.
Here is a sample of the gearbox housing:
The figure above shows a sample of a gearbox housing.
32
The housing gearbox material that has been choosen is; AISI1010 (cold rolled)
6/6 with long fiberglass fill.
Dimension of Gearbox housing

The housing gearbox in this project is a rectangular cuboid. As mentioned before the length
of the intermediate shaft is 11.5 inch and outer diameter of the gear input is 2.29inch and the
outer diameter of the gear output is 11.86inch. Shown below is the calculation of the housing
gearbox :
Length : 11.5 inch +1 inch +1 inch =13.5inch
Height : 11.86 inch +1 inch +1 inch = 13.86 inch
Width : 11.86 inch+1.15 inch+5.93 inch+1 inch+1 inch=20.94 inch
Note
1 inch is the extra space from both sides for avoiding any failure or damage.
Therefore the dimension of the gearbox housing is :
13.5 inch x 13.86 inch x 20.94 inch
33
COST ANALYSIS
Materials used
Shaft input AISI 1015 (HR)
Key input AISI 1015 (CD)
Bearing input Bearing number 6310
Spur gear Steel A1-A5
Shaft intermediate AISI 1015 (HR)
Key intermediate AISI 1015 (HR)
Bearing intermediate Bearing number 6311
Shaft output AISI 1015 (HR)
Key output AISI 1015 (cold rolled) rod aluminium alloy
Bearing output Bearing number 6311
Pinion gear Steel A1-A5
Cost analysis for materials used
AISI 1050 (CD)
per tonne = RM 2800

per kg = RM 2.80
Total weight of AISI 1050 (CD) used = 0.1 kg {shaft input} + 0.030 kg {shaft output}
= 0.130 kg
Cost
= 0.130 kg X USD 2.80

= RM 0.364
SCM 415
per tonne = RM 7000

per kg = RM 7
34
Total weight of SCM 415 used
= 0.1 kg {spur gear} + 0.030kg {pinion gear}

= 0.130 kg
Cost
= 0.130 kg X RM 7
= RM 0.910
Lubricant
Gear oil SAE 30 = RM 39 / BOTTLE
Engine oil 85 w= RM 274 / BOTTLE
Total = 0.364 + 0.910 + 39 + 274
= RM 314.274
From the analysis we can see that, the main criterion factor in choosing the
materials is the price per tonne. The safety factor also plays a role in choosing the material.
Hence, we chose AISI 1015 (hot rolled) and SCM 415 because after the stress analysis a
higher strength 1050 CD. It also reduces the critical stress without further increasing the shaft
diameter. The prices for the materials are also appropriate with the strength as well since we
wanted a strong gearbox with a low cost.
35
CONCLUSION
Designing is not an easy process. In this project, we are required to design a crane
which requires the knowledge of statics, dynamics, mechanics of materials, programming,
CAD laboratory and machine design. We have learnt the steps and processes in designing a
single girder overhead crane which consists of spur gears, bearings, shafts, keys, lubricants
and as well as housing.
Other than that, we also learnt about the methods and ways to apply the formulas
learnt in Machine Design correctly while maintaining the specifications required in the
designing process. Valid and acceptable assumptions such as number of teeth gear, the length
of keys and the ratio of gear have been made in this project to complete the whole designing
processes.
In addition, we have also taken into consideration the weight as well as the size of the
gear-box for 10 years continuous operation. We also have managed to identify the weak link
in this design so that we can determine the failure of the gear-box. As an engineer, we should
always apply what we have learnt in our studies so that we can appreciate what we have,
create and implement new things for future generation.
Overall, we enjoy designing the project although it is a very challenging task. A few
challenges we faced was the not knowing what material to pick, what dimensions suit best
and the dimensions didnt telly on or another. After all, we manage to overcome the
problems. From the project we have done, we know that the minimum safety factor for all
components are more than 1. Therefore, we can now conclude that the objective of this
project is achieved. Lastly, we want to take this opportunity to thank our Machine Design
lecturer, Dr. Omar Suliman Zaroog for his guidance and support in completion of this project
successfully.
36
APPENDIX A MODEL OF THE PROJECT
Intermediate shaft
Input shaft
Key
37
Output shaft
Bearing
Housing
38
Gear2
Gear3
39
Gear4
Gear5
40
Gearbox
Exploded view gearbox
41
42
REFERENCES
Shingleys Mechanical Engineering Design Ninth Edition, Richard G. Budynas, 2011
Norton Machine Design Fourth Edition, Robert L. Norton, 2006
Report on Economic Design of EOT Cranes, Ashutosh Kumar, 2013
www.enhrances.com/overhead-bridge-cranes/single-girder-top-running-cranes
en.wikipedia.org/wiki/transmission_(mechanics)
en.wikipedia.org/wiki/crane_(machine)
http://www.alibaba.com/showroom/cold-drawn-1050-alloy-steel-bar.html
43

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ABSTRACT

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Figure 1 : Top Running Overhead Crane

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

LITERATURE REVIEW (BACKGROUND RESEARCH)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

5 hp, with 1800 rpm

(Height at which the crane will be placed)

(Speed at which the weight will be lifted upwards)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Steel (Low to medium carbon steel)

o Has high modulus of elasticity

Soft cold-rolled iron

o Material with ductile properties is used as keys are loaded in shear

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

o SAE 30 (Engine Oil)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Sut= 340 MPa

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

From the ratio above, find the minimum number of teeth,N p.

Gear Ratio = 5.209

Find outer and intermediate speed (rpm)

To determine the torque, return to the power relationship,

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Start with P = 7 teeth/in

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Face width F is typically from 3 to 5 times circular pitch.

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Calculation of the output shaft

Calculation of the intermediate shaft

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Deflection on the shaft

The deflection on the input shaft was found to be

The deflection of the output shaft was determined to be

The deflection of the output shaft was determined to be

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Bearing (Input Shaft) Floating

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

From Table 11-2 (Machine Design 9TH

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Bearing (Intermediate Fixed)

From Table 11-2 (Machine Design

Bearing (Intermediate Floating)

From Table 11-2 (Machine Design

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Bearing (Output Fixed)

From Table 11-2 (Machine Design

Bearing (Output Floating)

From Table 11-2 (Machine Design

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Machine Design Project Report Semester 1, 2014/2015 (Group 3B1)

Reduce friction Zinc