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HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY
PROJECT
MACHINE DESIGN
DESIGN A SUGARCANE HARVESTER
Students: Nguyễn Quang Trường
Lê Dương Khánh Duy
Huỳnh Đức Nguyên
Khúc Lâm Đồng
Instructor: Prof. Lê Khánh Điền

Table of Contents
CHAPTER 1: PROJECT INTRODUCTION ................................................................ 1
1.1. ABSTRACTS: ....................................................................................................... 1
1.2. LITERATURE REVIEW ...................................................................................... 1
1.2.1. Cutting mechanism: ..................................................................................... 2
1.2.2. Conveyor system: ........................................................................................ 5
CHAPTER 2: CUTTING MECHANISM DESIGN ...................................................... 7
2.1. OVERVIEW: ......................................................................................................... 7
2.2. BELT DRIVE DESIGN AND MOTOR SELECTIONS ...................................... 8
CHAPTER 3: BELT CONVEYOR CALCULATION ................................................ 19
3.1. INITIAL PARAMETERS: .................................................................................. 19
3.2. PRELIMINARY CALCULATIONS: ................................................................. 19
3.3. ACCURATE CALCULATION: ......................................................................... 20
CHAPTER 4: CALCULATING AND CHOOSING MOTOR AND

DISTRIBUTING TRANSMISSION RATIO................................................................ 23
4.1. CHOOSING MOTOR: ........................................................................................ 23
4.2. DISTRIBUTE TRANSMISSION RATIO: ......................................................... 24
4.3. DISTRIBUTE TRANSMISSION RATIO: ......................................................... 24
CHAPTER 5: DESIGNING SPUR GEAR ................................................................... 26
5.2. CALCULATION: ................................................................................................ 26
CHAPTER 6: DESIGNING SPUR GEAR ................................................................... 30
6.2. CALCULATION: ................................................................................................ 30

CHAPTER 7: DESIGNING CHAIN DRIVE ............................................................... 34
7.1. INITIAL PARAMETERS: ................................................................................. 34
7.2. CALCULATION: ............................................................................................... 34
CHAPTER 8: SHAFTS, BEARINGS, KEYS ............................................................... 37
8.1. CALCULATION OF SHAFT II:......................................................................... 37
8.2. CALCULATION OF SHAFT I: .......................................................................... 41
8.3. CALCULATION OF SHAFT III: ....................................................................... 45
CHAPTER 9: DESIGNING PAIRS OF ROLLER BEARINGS FOR GEARBOX . 49
9.1. DESIGNING THE TAPERED ROLLER BEARING ON SHAFT I:................. 49
9.2. DESIGNING THE TAPERED ROLLER BEARING ON SHAFT II: ............... 50
9.3. DESIGNING THE BALL BEARING ON SHAFT III: ...................................... 51
CHAPTER 10: THE DESIGN OF GEARBOX SHELL ............................................. 53
10.1. PARTS RELATE TO THE COMPOSITION OF GEARBOX: ..................... 55
10.1.1. Cotter-pin: .................................................................................................. 55
10.1.2. Bearing cover screw: ................................................................................. 55
10.1.3. Inspection hole’s cover: ............................................................................. 56
10.1.4. Steam escape valve: ................................................................................... 56
10.1.5. Oil drain plug: ............................................................................................ 57
10.1.6. Dip stick: .................................................................................................... 57
10.1.7. Hanging flange:.......................................................................................... 57
10.1.8. Separating screw for the lid and the body of the gearbox: ........................ 57
10.2. Other components: ............................................................................................ 57
10.2.1. Bearing cover washer: ............................................................................... 57
10.2.2. Oil seal: .......................................................................................................... 58

10.3. Tolerance and Assembly: ................................................................................. 58
10.3.1. Bearings tolerance: .................................................................................... 58
10.3.2. Assemble gear shaft:...................................................................................... 58
10.3.3. Assemble bearing cap and casing: ................................................................. 58
10.3.4. Assemble latch: ............................................................................................. 58
REFERENCES: ............................................................................................................... 59
ACKNOWLEDGMENT
Our group would like to express my deep gratitude to Professor Le Khanh Dien, our research
supervisor, for his useful critiques, enthusiastic encouragement and valuable suggestions during
the planning and development of this research work. His willingness to give his time so
generously has been very much appreciated.
We would also like to extend my thanks for all of my friends in class CC16CDT and CC16CK2
for their help in offering me the resource.
Finally, we wish to thank our parents for their support and encouragement throughout my study.
CHAPTER 1: PROJECT INTRODUCTION
1.1. ABSTRACTS:
Agriculture is the backbone of Vietnam, where the labor shortage is the problem that almost all
farmers had to face. In today's world we required faster productivity in less time. Meanwhile,
sugarcane is one of the major economic crops in Vietnam. It is used as a raw material in sugar
manufacturing. Generally, farmer groups are a small-farming groups (1 to 3 ha). The agriculture
relies heavily on human labor which results in low productivity per area of per labor so it wastes
a lot of time on working process and also the quality of output product. Human labor shortage
tends to be a serious problem in the challenge list of rapid agricultural industrial development.
Result in development of the agricultural machinery used to harvest.
1.2. LITERATURE REVIEW

In general, we can categorize sugarcane harvester into whole stalk harvesters and chopper
harvesters. A typical whole stalk harvester system consists of a topper, a base cutter, a feeding
mechanism, and a discharging mechanism (fig. 1). The topper is designed to sever cane tops and
then discharge the severed tops to the side of harvesting rows. Later, topped cane stalks are then
cut by the base cutters at about 30 mm above the ground level (Esquivel et al., 2008). The
feeding mechanism includes a set of rollers to transfers the cane stalks to the discharging
mechanism. The discharging mechanism then delivers harvested cane stalks to either a wagon or
onto the field. The other type of harvester is the chopper harvester. Except for the components of
whole stalk harvesters, chopper harvesters include extra component such as chopper and
extractors.
Cane Cutting Feeding Discharging Whole

plant mechanism mechanism Mechanism stalks
Knockdown Roller + Conveyor

In this research paper, we will focus on whole stalk harvester but with less component:
The cutting mechanism is the significant part of any harvesting machine, and for sugarcane
harvester, the cutting mechanisms are designed based on two main systems: cutter-bar cutting
1
system and rotating cutting system (Patil and Patil, 2013). Rotating cutting mechanism with
blades is used more often than cutter-bar cutting mechanism for thick stalks (such as sugarcane)
that have more cutting resistance. During time of research, we meet some drawback in redesign
these kind of mechanism in our machine cause by the lack of technology in part processing such
as bevel gear or cutting base, etc. we use chainsaw mechanism as replacement method instead.
The feeding and discharging mechanism of the machine will replace as the conveyor to transfer
the cut one to a wedge, with the help of a big knockdown roller.
1. Cutting
mechanism
2. Knockdown roller
3. Conveyor
4. Wheel
1.2.1. Cutting mechanism:

Following to the research paper of Jiří Dvořák and Tomáš Kuvik et al.(2017), deal with the
calculation of the cutting force and cutting power. We have the formulas for calculating the
cutting force and input power according to Mikleš and Holík (2005) and Mikleš et al (2011) are
shown below (Eq. 1 and 2).
𝑣𝑓
𝐹𝑟 = 𝑘. 𝑏. 𝐻. (1)
𝑣
𝑃𝑟 = 𝑘. 𝑏. 𝐻. 𝑣𝑓 (2)
where:
𝑃𝑟 - input cutting power (W)
𝐹𝑟 - cutting force (N)
𝑘 - specific cutting work in crosscut sawing of dry pine (MJ.m-3) (Tab. 1)
𝑏 - saw kerf width (m)
𝐻 - saw kerf height (m)
𝑣𝑓 – feeding velocity (m/s)
𝑣 – chain velocity (m/s)
2
With
𝑘 = 𝑘𝑏𝑜𝑟 . 𝐾𝑑 . 𝐾𝑤 . 𝐾𝑟
Where:
𝑘𝑏𝑜𝑟 - specific cutting work in cross pine sawing of dry pine (MJ.m-3)
𝐾𝑑 , 𝐾𝑤 - correction coefficients representing the impact of tree species and their moisture
content.
𝐾𝑟 - correction coefficients representing the impact of blunting.
We got 𝑘 ≈ 𝑘𝑏𝑜𝑟 when 𝐾𝑑 . 𝐾𝑤 . 𝐾𝑟 = 0.9 ÷ 1.5 (Mikleš and Holík, 2005). In the other hand, Tab.
1 of the paper shows us some 𝑘𝑏𝑜𝑟 factor of dry pine
The specific cutting work in cross pine sawing of dry pine for various type of chain from
8 ÷ 18 𝑚𝑚 kerf width are variation around 10 × 10−3 ÷ 30 × 10−3 𝐽. 𝑚𝑚−3. Meanwhile, the
specific cutting work for sugarcane stalk is about 8.7 × 10−3 𝐽. 𝑚𝑚−3 (Somjet and Thanya,
2016) as peak cutting force. So that, by referent some data of commercial chainsaw product, we
can apply these data to redesign the chainsaw mechanism for cutting part without a deeply study
on cutting properties of sugarcane stalk when using a chainsaw.
-Basically, a chainsaw has 3 significant parts for making a cut:

A saw chain - Made up of several parts that work together and must be maintained properly for
maximum performance and safety.
A guide bar - Well-known as chainbar, supports and guides the saw chain.
A chain sprocket – The toothed wheel that drives the saw chain, imported the transmission from
engine using a clutch or directly transmission from engine to sprocket.
3
-For saw chain, our option is find it on the market, the machine will have long guide bar, and the
saw with 3/8” pitch is the most popular one, which support long bar and sell as long chain roll in
the market (100FT), that make our machine is easily for attachment and repair.
-Otherwise, because of sugarcane grow as bush cane, so the chain bar have to get the length
about 30 − 40 𝑐𝑚 to make sure all cane could be cut. Furthermore, What is the relationship
between Bar length and Cutting Power? In fact, the chainsaw which support long chain bar have
bigger output power than the shorter one, the reason is people use the long chain bar for the
cutting the tree or workpiece have a great cross section, therefore the increasing in Power to
make sure the cutting performance is constant and gain some more power to pull the chain.
From eq. 1 and eq. 2, we have the cutting force rely on the chain speed, but the output power
doesn’t. Overview, in this work, have been used different machines, which represent the most
advanced technology available for operators, provided from the market. Small chainsaws were
selected, since light compact equipment, are necessary for pruning with very short bars, because
of the diameter of the branches cut that rarely exceeds 10-15 cm, meanwhile the diameter of a
sugarcane stalk is about 2-4cm as diameter. At the same time, a quick look as power is
necessary, to cut easily sugarcane stem
They were taken into consideration:

+ Pellenc Selion C15- top handle backpack battery chainsaw;
+ Pellenc Selion C20- top handle backpack battery chainsaw;
+ Stihl MS200T- 2-stroke pruning chainsaw;
Technical data
Pellenc Selion Pellenc Selion
Feature U.M. C15 C20 Stihl MS200T
Power kW 1.5 at 5400 rpm 2 at 6200 rpm 1.7
Chain speed m/s 10.3 14.4 26
Guide bar cm 30 30 35
Oregon ¼ Micro Oregon ¼ Micro
Saw chain 3/8 P
Chisel 25AP Chisel 25AP
From these data, it can clearly be seen that the output power and the chain speed of these types at
between 1.5-2 kW and varies from 10.3-26 respectively.
4
1.2.2. Conveyor system:
-Overview about conveyor:
Belt conveyors are most commonly used in transportation of bulk materials (grain, salt, coal, ore,
sand, etc.).
Belt conveyors have attained a dominant position in transporting bulk materials due to a number
of inherent advantages like the economy and safety of operation, reliability, versatility and
practically unlimited range of capacities. In addition, they are suitable for performing numerous
processing functions while supporting a continuous flow of material between operations.
The capacity of belt conveyor depends on speed, shape and width of belt, method of feeding and
solid properties. Belt conveyor are the most common form of material handling system used in
manufacturing and mining industries thermal plants and in construction projects.
-History of conveyor:
Primitive conveyor belts were used since the 19th century. In 1892, Thomas Robins began a
series of inventions which led to the development of a conveyor belt used for carrying coal, ores
and other products. In 1901, Sandvik invented and started the production of steel conveyor belts.
In 1905, Richard Sutcliffe invented the first conveyor belts for use in coal mines which
revolutionized the mining industry. In 1913, Henry Ford introduced conveyor-belt assembly
lines at Ford Motor Company's Highland Park, Michigan factory. In 1972, the French society
REI created in New Caledonia the longest straight-belt conveyor in the world, at a length of
13.8 km. Hyacynthe Marcel Bocchetti was the concept designer. In 1957, the B. F. Goodrich
Company patented a conveyor belt that it went on to produce as the Turnover Conveyor Belt
System. Incorporating a half-twist, it had the advantage over conventional belts of a longer life
because it could expose all of its surface area to wear and tear. Mobius strip belts are no longer
manufactured because untwisted modern belts can be made more durable by constructing them
from several layers of different materials. In 1970, Intralox, a Louisiana-based company,
registered the first patent for all plastic, modular belting.
-Belt conveyor safety system:
Conveyors used in industrial settings include tripping mechanisms such as trip cords along the
length of the conveyor. This allows for workers to immediately shut down the conveyor when a
5
problem arises. Warning alarms are included to notify employees that a conveyor is about to turn
on.
Picture 1.1: Industrial application of conveyor

In this project, our group will design a belt conveyor used to transfer sugar cane from field to
storage in countryside.
We would like to send our most sincere appreciation for Dr. Lê Khánh Điền for guiding and
supporting us during our time of completing this project.
Because of our own inexperience and limited knowledge, despite consulting references such as
books, websites or previous projects, mistakes were unavoidable. We look forward to hearing
your comments and judgements on this report to improve ourselves and our future projects.
1.2.3. What we have learned:
Calculation:
 Choosing motor, transmission ratio
 Spur gear drive
 Chain drive
 Shafts, keys, bearings
 Belt conveyor
 Chainsaw mechanism
Technical drawing:
 Drafting
 AutoCAD
6
CHAPTER 2: CUTTING MECHANISM DESIGN
2.1. OVERVIEW:
From the reference data above, choose 1.5kW as output power and 10.3 m/s as chain speed,
connect motor directly to shaft, therefore:
The speed of motor:
𝑛. 𝑍. 𝑝𝑐
𝑣𝑐ℎ𝑎𝑖𝑛 =
60000
Where:
𝑣𝑐ℎ𝑎𝑖𝑛 : Chain speed (m/s)
𝑛: The speed of motor (rpm)
𝑍 : Number of sprocket teeth
𝑝𝑐 : The chain pitch (mm)
The target chain speed is about 10.3 m/s (9.7 m/s ~ 10.6 m/s) , so that we got:
1 1
𝑛. 𝑍 = 60000 × 𝑣𝑐ℎ𝑎𝑖𝑛 × = 60000 × 10.3 × = 64881.88976
𝑝𝑐 3
8 × 25.4
We got:
No. of Rotation Sprocket Choose:

sprocket speed Diameter Teeth number = 7
teeth (rpm) (mm)
7 9268.841 21.95289 With the rotation speed = 9269 rpm
9 7209.099 27.84924 We can easily find the 7 teeth sprocket for saw chain on the
13 4990.915 39.80099
market, and we use belt drive for transmission from motor
21 3089.614 63.90805
23 2820.952 69.95105 to working shaft instead of directly connect 23 sprocket
27 2403.033 82.04635 teeth to 2850 rpm motor because of some negative in
finding a standard design for chainsaw sprocket.
7
The picture is the sketch of the
cutting mechanism of our machine,
where the part draw as the drive
chain part is the chain saw part.
2.2. BELT DRIVE DESIGN AND MOTOR SELECTIONS

(All data, formula, and design in this section will follow the instruction of
Trinh Chat-Le Van Uyen (2016) [1]
DRB® Design Manual for Power Transmission Belts [2] and
CONTI-V MULTIRIB® multiple V-Ribbed belt catalogue) [3]
The transmission ratio: u = 9269/2850 = 3.252

The rpm of faster shaft is about 9269 rpm
This number passed the limit velocity n=5000 rpm for normal V-belt or Narrow V-Belt, so that,
Ribbed Belt V-belt or Timing Belt is considered.
Reference V-Ribbed Belts (Đai nhiều chêm) calculation of DRB Design Manual, we got:
Step 1:
The power requirement for the drive:
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = 𝑃𝑜𝑤𝑒𝑟 × (𝑆𝑒𝑟𝑣𝑖𝑐𝑒 𝐹𝑎𝑐𝑡𝑜𝑟 + 𝐼𝑑𝑙𝑒 𝑠𝑒𝑟𝑣𝑖𝑐𝑒 𝐹𝑎𝑐𝑡𝑜𝑟)
8
Figure from DRB® Design Manual
for Power Transmission Belts
Choose the service factor is 1.3 for 3-8 hours Seasonal with Crusher characteristics, no use of
idler pulley, therefore:
𝑇ℎ𝑒 𝑑𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = 1.5 × 1.3 = 1.95 (𝑘𝑊)
For the transmission, the transmission power efficiency of around 94% due to a pair of bearing
and the belt drive.
Choose electric motor 3K112S2 2.2kW and provide 2850 rpm of Hanoi Electromechanical
Manufacturing JSC (efficiency 83% + 34kg weight for flange mounting).
9
Figure from HANOI
ELECTROMECHANICAL
MANUFACTURING JSC
Step 2:
Select the proper V-Ribbed Belt Section:
Figure from DRB® Design Manual for Power Transmission Belts
With the Speed of small Pulley reach 9975 rpm for the small pulley, and the horsepower of the
system is 2.2kW < 5kW.
Then,
Choose J type (or PJ in some manufacturer)
10
Step 3:
Select the Pulley Combination, Belt Length and Center Distance
With the J Belt Type, the recommended Pulley Diameter is 31.5 mm, choose d1 = 31.5 mm
The diameter of large pulley:
𝑛1 9269
𝑛2
𝑑2 = 𝑑1 × = 31.5 × 2850 = 104.53 [1]
(1 − 𝜀) 1 − 0.02
Choose d2 = 100 mm
We got the new ratio = 3.17 is allowable ratio in comparison with the ratio between n1 and n2
(97%~103%)
The center distance:

𝐾 + √𝐾 2 − 32(𝑑2 − 𝑑1 )2
𝐶= [2]
16
Where:
𝐾 = 4𝐿𝑝 − 2𝜋(𝑑1 + 𝑑2 )
𝐿𝑝 : 𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑏𝑒𝑙𝑡 𝑙𝑒𝑛𝑔𝑡ℎ (𝑚𝑚)
𝐶: 𝐴𝑝𝑝𝑟𝑜𝑥𝑖𝑚𝑎𝑡𝑒 𝑐𝑒𝑛𝑡𝑒𝑟 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 (𝑚𝑚)
𝑑1 , 𝑑2 : 𝑇ℎ𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑠𝑚𝑎𝑙𝑙 𝑎𝑛𝑑 𝑙𝑎𝑟𝑔𝑒 𝑝𝑢𝑙𝑙𝑒𝑦
With Lp = 610 mm, we

got the center distance C
approxiate 198.82 mm
Figure from DRB® Design Manual for Power

Transmission Belts
Step 4:
Calculate the Number of Belt Ribs: (this formula is similar with the formula 4.16 in [1] )
𝑃𝑑
𝑁= [2]
𝑃𝑟 × 𝐾𝜃 × 𝐾𝑙
11
Where:
N : Number of ribs(EA)
Pd : Design power(kW)
Pr : Basic power rating per rib (kW/Rib)
Kθ : Arc of contact correction factor
Kl : Length correction factor
Figure from DRB® Design

Manual for Power
Transmission Belts
Kθ=0.95
Where the arc of contact of the Small Pulley
570
𝛼 = 1800 − (𝑑2 − 𝑑1 ) × = 160.360 [1]
𝐶
Figure from DRB® Design

Manual for Power
Transmission Belts
Kl=0.89
12
Where l = 610mm
Figure from DRB® Design Manual for Power Transmission Belts
Pr = 0.24+0.07 = 0.31
So that,
1.95
𝑁= = 7.52
0.31 × 0.89 × 0.94
So that, the number of rib is N=8
According to ISO 9982: For J (PJ) section type, we got:
Figure from CONTI-V MULTIRIB®

multiple V-ribbed belts
13
For roller: ISO designation for PJ belt drive sprocket:
Material: Gray cast iron
Diameter db: Small: 31.5 mm ; Large: 100 mm;
Groove Spacing: e = 2.34 mm ± 0.03 mm;
fmin = 1.8 mm;
Groove angle α = 400 ± 0.050;
Top radius ra min = 0.2 mm;
Bottom radius ri max = 0.4 mm;
Face width (min) = 19.98 mm
For belt:
Ribbed belt with section type J
Number of rib: 8
Belt length: 610 mm
For the belt drive:

Center distance: C = 198.82 mm
14
2.3. DESIGN OF SHAFT:
Drive shaft:
Connect the drive pulley (large pulley) to the motor:

The output shaft of motor 3K112S2 have:
With:
D = 28; F= 8; GA = 31
Choose: Square Key 8x7x42
Driven shaft:
We have the belt tension force is determined with the following formula:
𝑃𝑑
𝐹0 = 780 × + 0.1 × 𝑞𝑚10 × 𝑧 × 𝑣 2 = 123.324 (𝑁)
𝑣 × 𝐾𝛼
Where:
Pd = 1.95 kW ;
Cα = Kθ = 0.95 (Arc of contact correction factor);
z: Number of gib (z=8)
qm10 : mass of a 1 meter 10 gib belt (take qm10 = 0.09 kg/m, which 0.09 is the mass of belt type
K, type J is lighter)
v: belt drive velocity, determined as: v = π x d2 x n2/60000 = 14.9226 m/s. (drive pulley)
Fv: tangential force (Fv=0.1 x q x z x v2 = 16.83 N)
The force applied on the driven shaft:

𝛼1 1600
𝐹𝑟 = 2 × 𝐹0 × sin ( ) = 2 × 123.324 × sin ( ) ≈ 243.03 (𝑁)
2 2
On the driven shaft:

Power = 1.95 x 94,05% = 1.834 (kW)
n = 2850 x (100/31.5) = 9047 rpm
15
Choose Steel Class A., Name C45,
With allowable shear stress σ = 600 MPa; allowable torsional stress [τ ]= 12 .. 20 MPa
Preliminary calculate the shaft diameter using torque only, we have:
3 𝑇
𝑑≥√
0.2[𝜏]
With:
𝑃
𝑇 = 9.55 × 106 ×
𝑁
Where: P: the power of motor (kW)

T: Torque (N.mm)
N: motor speed (rpm)
1.834
𝑇 = 9.55 × 106 × ≈ 1935.8 𝑁𝑚𝑚
9047
With [𝜏] is the allowable twisting moment MPa, choose CT5 mild steel as material with [𝜏] =
15
𝑑 ≥ 9.31
The tension force cause by belt drive
𝛼
𝐹𝑟 = 2 × 𝐹𝑜 × 𝑧 × sin ( ) = 168.914 (𝑁)
2
The tension force caused by chainsaw (Otto and Parmigiani)
𝜋 × 𝑇𝑀 𝜋 × 1935.8
𝐹𝑟 = = = 91.17 (𝑁)
𝑝×𝑧 3
8 × 25.4 × 7
Where:
Fr: The force acted on the shaft (N)
Tm: Drive-sprocket Torque (Nmm)
z: number of teeth of the sprocket
p: the chain pitch (mm)
Belt drive installation:
Consider 2 tension force is applied with the angle of 90 degree (in fact these two vectors applied
an angle >90 degree
2.4 BEARING SELECTION:
Dynamic equivalent load:
16
𝑄 = (𝑋𝑉𝐹𝑟 + 𝑌𝐹𝑎 )𝑘𝑡 𝑘𝑑
Where:
Fr : Centrifugal force ( Fr = 243.3 = √168.9142 + 91.172 )
Fa: Axial loading ( Known as weight of pulley, taper bushes, shaft and chainbar + chain in this
situation),
V: rotating factor (V=1 in case the inner ring rotate)
kt: temperature factor (set kt = 1 )
kd: load factor (light load and short term overload; kd =1.2)
Vertical shaft with Fr/Fa > 1.5, service in high rotation speed, so that, choose Angular Contact
Bearing Choose:
𝐹
X=1; Y=0, α = 150 ( keep 𝐹𝑎 ≤ 𝑒 )
𝑟
Q= 291.644 (N)
Dynamic equivalent load ability:

𝑚
𝐶𝑑 = 𝑄 × √𝐿
Where: L: life-time of bearing; (million rounds)
m = 3 for roller bearing
Also have:
𝐿ℎ = 106 𝐿/(60𝑛)
Where: Lh is about 10000 hours for agriculture machinery
Therefore, we have
3 𝐿ℎ
𝐶𝑑 = 291.644 × √60 × 9048 × = 5125.71 (𝑁) ≈ 5.13 𝑘𝑁
106
Choose bearing 7003C of NSK with:
d = 17 mm ; D = 35 mm; B = 10 mm
r (min) = 0.3 mm; r1 (min) = 0.15 mm; C = 8600 N ; Co = 3800 N
NOTE:
Following GOST 831-75:
Choose bearing 36103
17 x 35 x 10
r = 0.5 ; r1 = 0.3; C = 5710 N ; Co = 3580 N
17
The chainsaw sprocket would fabricated following this
image, with 7 teeth and 3/8” pitch, inner diameter equal
14mm and 50mm for outer circle
Therefore, we have an overview about the shape

of shaft.
18
CHAPTER 3: BELT CONVEYOR CALCULATION
3.1. INITIAL PARAMETERS:

_ Feature of Product:
 Type: sugar cane

 Length: l= 2.6 m
 Diameter: d= 28 mm
 Weight: G= 2 kg
 Distance between each package: a=0.1 m
_ Transport distance:
 Length: L=13.4 m
 Height: H=5 m
 Angle: α = 22o
3.2. PRELIMINARY CALCULATIONS:

_ First, we choose:
 Belt width: B = 0.65 m

 Belt speed: v = 0.9 m⁄s
_Choose the number of layer i = 4 follow table 3.4 – [4], the thick of belt δ1 = 6 mm at
working surface and δ2 = 1,5 mm follow table 3.5 – [4]. Weight of 1m belt:
q b = 1,1B(1,25i + δ1 + δ2 ) = 8,94 kg⁄m
_ Weight of product in 1m:
G 60 kg
q vl = = = 75 ⁄m
l + a 0,7 + 0,1
2
q vl = = 0.74(kg⁄m)
2.6 + 0.1
_ Conveyor capacity:
Q = 3,6 × q vl × v = 3,6 × 0.74 × 0.9 = 2.5 T⁄h
_According table/11: γ = 1.1 T/m3

19
_ Choose idler pulley follow table 4.3 – [4]:
o Diameter: 0.108 m
o Distance between each in load path: lr = 0,3 m
_ Weight of rotating part of idler pulley follow table 4.3 – [4]:
Gcl = 7 × B + 4 = 8,55 kg
_ Weight of rotating part of idler pulley in 1m tight side:
3.3. ACCURATE CALCULATION:

Divide belt into 4 paths, the force in each path is calculated in the following:
4 Driver shaft
Driven shaft
2
Picture 2.1
_ Resistance force in path 1-2:
W1−2 = q b × L × cos(α) × ω + q b × H = 40.5 kg
The conveyor works outdoor with heavy load, we choose ω = 0.035 (table 4.4 – [4])
_ Tension force at point 2 calculated follow equation (2.51 – [4]):
20
S2 = S1 + W1−2
_ Resistance force in path 2-3calculated follow equation (2.45 – [4]):
W2−3 = 0,07 × S2 = 0,07 × (S1 + W1−2 )
_ Tension force at point 3:
S3 = S2 + W2−3 = 1,07 × (S1 + W1−2 )
_ Resistance force in path 3-4:
W3−4 = (q b + q vl ) × L × cos(α) × ω + (q b + q vl ) × H = 52.61 kg
_ Tension force at point 4:
S4 = S3 + W3−4 = 1.07 × (S1 + W1−2 ) + W3−4
_ we have:
S1 = Sout
Sin = S4 = Sout × efα
Follow table 2.1 – [4], when α = 180° Choosef = 0.2, efα = 1,87.
1,07 × (S1 + W1−2 ) + W3−4 = 1,87 × S1
S1 = 130.75 kg
S2 = 179.34 kg
W2−3 = 12.55 kg
S3 = 191.89 kg
S4 = 244.50 kg
_ Check the deflection of belt (2.62-[4])
q b × l2r
Smin = = 13.41 kg
8 × f′
_ Resistance force in driver sheave:
Wdd = 0,03 × (Sin + Sout ) = 67,6 kg
_ Traction force:
21
WT = S4 − S1 + Wdd = 750 kg
22
CHAPTER 4: CALCULATING AND CHOOSING MOTOR AND
DISTRIBUTING TRANSMISSION RATIO
4.1. CHOOSING MOTOR:
 Efficiency of system:
η = ηl ηg 2 ηc ηbea 4
The efficiency of drives is chosen from table 3.3 of reference [1]:
ηl = 0,98 : coupling’s efficiency
ηg = 0,96: gear drive’s efficiency
ηc = 0,95: chain drive’s efficiency
ηbea = 0,99: bearings’ efficiency
η = 0,98. 0,962 . 0,95. 0,994 = 0,8242
 Maximum power on chain drive’s shaft:
Ft v
Pmax = = (k1 Ln v + 15 × 10−4 × Q × L + 24 × 10−4 × Q × H)k 2 = 0.38 kW
1000
 Relative power on chain drive’s shaft:
T 2
∑n1 ( i ) t i 12 . 20 + 0,72 . 20
√ T √
Pre = Pmax = Pmax = 4,4625 kW
∑n1 t i 20 + 20
 Required power on chain drive’s shaft:

Pmax 0.38
Pneeded = = = 0.461 kW
η 0.8242
 Rotational speed of working element:
60v 60000 × 0,9
N= = = 70 rpm
D×π 28 × π
 System transmission ratio:
nmotor
u = uc usg . uhg =
nworking
 Choose preliminary transmission ratio according to table 3.2 in reference [1]:
uchain = 1
ulow stage = 3.27
23
ufast stage = 5.98
→ u = uchain . uslow stage . ufast stage = 19.55
nmotor = nworking . u = 1368 rpm
Choose 3 phase motor 4A71A4Y3 with P=0.55 kW, n=1370 rpm
4.2. DISTRIBUTE TRANSMISSION RATIO:

 System transmission ratio:
nmotor 1370
u = uc uslow stage ufast stage = = = 19.57
nworking 70
Choose according to table 3.1 in reference [1]: uc=1

u
→ uslow stage . ufast stage = 2 = 9.79
uslow stage .ufast stage

ufast stage=3.77 → uslow stage = = 2.59
.ufast stage
4.3. DISTRIBUTE TRANSMISSION RATIO:

 Work acting on shafts:
PIV = Pmax = 0.38 kW

P
IV
PIII = 0,95.0,99 = 0.404 kW
PIII
PII = 0,96.0,99 = 0.425 kW
PII
PI = = 0.477 kW
0,96.0,99
1370
Ratio: u = = 19.57
70
Choose uchain = 2 ufast stage = 3.77
uslow stage = 2.59
24
Rotational speed on shafts:
nmotor−coupling = 1370 rpm

1370
nI = = 360.53rpm
3.8
363.40
nII = = 138.66rpm
2.6
140.31
nIII = = 70.03 rpm
1.98
Torsion on shafts:
PIII
TIII = 9,55. 106 . = 51732 Nmm
nIII
PII
TII = 9,55. 106 . = 27497.68 Nmm
nII
PI
TI = 9,55. 106 . = 11168.82Nmm
nI
Pcoupling
Tcoupling = 9,55. 106 . = 3325.07 Nmm
ncoupling
Pmotor
Tmotor = 9,55. 106 . = 3325.07 Nmm
nmotor
Table 4.1:
shaft motor coupling I II III
Parameter
Power P (kW) 0.55 0.477 0.425 0.404 0.38
Ratio u 1 3.8 2,6 1.98
Rotational speed 1370 1370 360.53 138.66 70.03

n (rpm)
Torsion (N.mm) 3833.94 3325.07 11168.82 27497.68 51732
25
CHAPTER 5: DESIGNING SPUR GEAR

 Power: P = 0.477 kW
 Transmission ratio u = 3.8
 Rotational speed of driving shaft: n1 = 1370 rpm
 Rotational speed of driven shaft: n2 = 360.53rpm
 Torsion: T = 3325.07 Nmm
 Working time: Lh = 100 × 8 × 3 = 2400 hours
5.2. CALCULATION:
Choose material
 Choose 45 surface-hardening steel
Allowable stress:
 Allowable contact stress:

o The number of basis working cycles:
 NHO1 = 30 × 2002,4 = 9990638.49 cycles
 NHO2 = 30 × 1852,4 = 8285780.09 cycles
mH⁄
Ti 2
o Relative working cycles according to load:NHE = 60c ∑ (T ) ni t i
max
T 3 20 0,7T 3 20
 NHE1 = 60 × 1370 × [(T) +( ) ] × 2400 = 132.47 × 106
40 T 40
T 3 20 0,7T 3 20
 NHE2 = 60 × 363.40 × [(T) +( ) ] × 2400 = 35.14 × 106
40 T 40
 Since NHE > NHO for both gear:

6 N
 → K HL1 = √NHO1 = 0.65
HE1
6 N
 → K HL2 = √NHO2 = 0.79
HE2
o Contact fatigue limit according to the number of basis working cycles (t6.2)
 σ0Hlim1 = 2 × 200 + 70 = 470
 σ0Hlim2 = 2 × 185 + 70 = 440
26
 sH=1,1
0,9KHL1
o [σH1 ] = σ0Hlim1 = 249.95 MPa
sH
0,9KHL2
o [σH2 ] = σ0Hlim2 = 284.4 MPa
sH
[σH1 ]+[σH2 ]
→ Calculated contact stress: [σH ] = = 267.18 MPa
2
Satisfies condition: [σH ] ≤ 1,25[σH ]min
 Allowable bending stress:

Ti 6
o The number of corresponding working cycles: NFE = 60c ∑ (T ) ni t i
max
T 6 20 0,7T 6 20
 NFE1 = 60 × 1 × 1370 × [(T) +( ) ] × 2400 = 110.24 × 106
40 T 40
cycles
T 6 20 0,7T 6 20
 NFE2 = 60 × 1 × 363.40 × [(T) +( ) ] × 2400 = 29.24 × 106
40 T 40
cycles
o The number of basis working cycles: NFO=4 × 106
o NFE1>NFO1, NFE2>NFO2 therefore KFL1=1, KFL2=1
o From table 6.13 of [I], bending fatigue limit:
 σ0F lim 1 = 1.8 × 200 = 360 MPa
 σ0F lim 2 = 1.8 × 185 = 333MPa
 sF=1.75
KFL1 .KFC1
o [σF1 ] = σ0Flim1 = 205.71 MPa
sF1
KFL2 .KFC2
o [σF2 ] = σ0Flim2 = 190.29 MPa
sF2
Calculate parameters:
 Choose coefficient of teeth width ψba according to standard:

o From table 6.6 in reference [I], we have ψba = 0,4
 From table 6.7, we choose KHβ=1,04, KFβ=1,02
 Shaft distance:
3 T1 KHB
o aw = 49.5(u + 1) √ψ 2
= 48 mm
ba [σH ] u
27
According to standard, choose aw=70 mm
 Choose m:
o m = (0,01 ÷0,02)aw=0.7÷1.4
Choose m=1.25
2a
 w
Total number of teeth: z1 = m(u+1) = 23
 z2 = u × z1 = 87
z
 u = z2 = 3.78
1
 Pitch diameter
o d1 = z1 m = 28.75 mm
o d2 = z2 m = 108.75 mm
 Addendum diameter:
o da1 = d1 + 2m = 31.25 mm
o da2 = d2 + 2m = 111.25 mm
z1 +z2
 Recalculate shaft distance: aw = m = 68.75 mm
2
 Dedendum diameter
o da1 = d1 − 2m = 28.75mm
o da2 = d2 − 2m = 106.25 m
 Teeth width: bw1 = ψba . aw + 5 = 32.5 mm and bw2 = ψba . aw = 27.5 mm
1πd n
Tangential velocity of gear: v = 60000 = 2.06 m/s
 Force acting on gear drive:

o Tangential force Ft:
2T1
Ft1 = = 231.31 N
d1
o Axial force Fa:
Fa1 = 0
o Radial force Fr:
Fr1 = Ft1 tanαnw = 84.19 N
 Check mating strength
28
ZM ZH Zε 2T1 KH (u+1)
o σH = √
dw bw u
274 × 1 × 0,7674 2 × 3325.07 × 1,119 × (3.77 + 1)

= √
655.875 27,5. 3.77
= 7.92 MPa < [σH ] = 267.18

 Check bending strength:
YF Ft KF Yc Yβ 187,84. 1756,6. 1,06575. 0.863145
o σF = =
bμ m n 3. 56
o σF = 180,672 MPa < [σF ]

13,2 27,9x
o YF = 3,47 + − + 0,092x 2 = 187,84
Zv Zv
29
CHAPTER 6: DESIGNING SPUR GEAR

 Power: P = 0.425 kW
 Transmission ratio u = 2.59
 Rotational speed of driving shaft: n1 = 360.53 rpm
 Rotational speed of driven shaft: n2 = 138.66rpm
 Torsion: T = 11168.82 Nmm
 Working time: Lh = 100 × 8 × 3 = 2400 hours
6.2. CALCULATION:
Choose material
 Choose 45 surface-hardening steel
Allowable stress:
 Allowable contact stress:

o The number of basis working cycles:
 NHO1 = 30 × 2002,4 = 9990638.49 cycles
 NHO1 = 30 × 1852,4 = 8285780.09 cycles
mH⁄
Ti 2
o Relative working cycles according to load:NHE = 60c ∑ (T ) ni t i
max
T 3 20 0,7T 3 20
 NHE1 = 60 × 363.40 × [(T) +( ) ] × 2400 = 35.14 × 106
40 T 40
T 3 20 0,7T 3 20
 NHE2 = 60 × 140.31 × [(T) +( ) ] × 2400 = 13.57 × 106
40 T 40
6 N
→ K HL1 = √NHO1 = 0,81
HE1
6 N
→ K HL2 = √NHO2 = 0.92
HE2
o Contact fatigue limit according to the number of basis working cycles

 σ0Hlim1 = 2 × 200 + 70 = 470 MPa
 σ0Hlim2 = 2 × 185 + 70 = 440 MPa
 sH=1.1
30
0,9KHL1
o [σH1 ] = σ0Hlim1 = 311.48 MPa
sH
0,9KHL2
o [σH2 ] = σ0Hlim2 = 331.2 MPa
sH
[σH1 ]+[σH2 ]
o → Calculated contact stress: [σH ] = = 321.34 MPa
2
 Allowable bending stress:

Ti 6
o The number of corresponding working cycles: NFE = 60c ∑ (T ) ni t i
max
T 6 20 0,7T 6 20
 NFE1 = 60 × 1 × 363.40 × [(T) +( ) ] × 2400 = 29.24 × 106
40 T 40
cycles
T 6 20 0,7T 6 20
 NFE2 = 60 × 1 × 140.31 × [(T) +( ) ] × 2400 = 11.29 × 106
40 T 40
cycles
o The number of basis working cycles: NFO=4.106
o NFE1>NFO1, NFE2>NFO2 therefore KFL1=1, KFL2=1
o From table 6.13 of [I], bending fatigue limit:
 σ0F lim 1 = 1.8 × 200 = 360 MPa
 σ0F lim 2 = 1.8 × 185 = 333MPa
 sF=1.75
KFL1 .KFC1
o [σF1 ] = σ0Flim1 = 205.71 MPa
sF1
KFL2 .KFC2
o [σF2 ] = σ0Flim2 = 190.29 MPa
sF2
Calculate parameters:
 Choose coefficient of teeth width ψba according to standard:

o From table 6.15 in reference [I], we have ψba = 0,4
o ψbd = 0.53ψba (u + 1) = 0.8
 From table 6.4, we choose KHβ=1,04, KFβ=1,02
 Shaft distance:
3 T2 KHB
o aw = 49.5(u + 1) √ψ 2u
= 84.77mm
ba [σH ]
According to standard, choose aw=85mm

 Choose m:
31
o m = (0,01 ÷0,02)aw=0.85÷1.7
Choose m=1.25
2a
 w
Total number of teeth: z1 = m(u+1) = 38
 z2 = u × z1 = 99
z
 u = z2 = 2.6
1
 Pitch diameter
o d1 = z1 m = 47.5 mm
o d2 = z2 m = 123.75 mm
 Addendum diameter:
o da1 = d1 + 2m = 50mm
o da2 = d2 + 2m = 123.25 mm
z1 +z2
 Recalculate shaft distance: aw = m = 85.63 mm
2
 Teeth width: bw1 = ψba . aw + 5 = 39 mm and bw2 = ψba . aw = 34 mm

1 πd n
Tangential velocity of gear: v = 60000 = 0.55 m/s
 Force acting on gear drive:

o Tangential force Ft:
2T2
Ft2 = = 470.26 N
d1
o Axial force Fa:
Fa2 = 0
o Radial force Fr:
Fr2 = Ft2 tanαnw = 171.16 N
 Check mating strength

ZM ZH Zε 2T1 KH (u+1)
o σH = √
dw bw u
274 × 1 × 1 2 × 11168.82 × 1.176 × (2,59 + 1)

= √
610.3 39 × 2.59
= 13.7 MPa < [σH ] = 321.34 MPa
32
 Check bending strength
YF Ft KF Yc Yβ 725,4. 3561,37. 1,06575
o σF = =
bμ m n 2. 45
o σF = 305,91 MPa < [σF ]

13.2 27.9x
o YF = 3.47 + − + 0,092x 2 = 725,41
Zv Zv
33
CHAPTER 7: DESIGNING CHAIN DRIVE

 Power: p = 0.404 kW
 Speed: n = 138.66
 Transmission ratio: u=1.98
 Working condition: One-direction rotation, small impact, periodic lubrication.
7.2. CALCULATION:
 With u=2choose the number of small sprocket: z1 = 29 − 2u = 25 so choose z1 = 25
(teeth).
 Choose the number of teeth on driven sprocket:
 z2 = z1 × u = 50
 *Efficiency of using condition of K:
 K: K= Kr.Ka.K0.Kdc.Kb.Klv
 Kr = 1,2: dynamic action of the load.
 Ka = 1: efficiency of center distance.
 K0 = 1: efficiency of position of the drive.
 Kdc =1: efficiency of possibility of adjusting the center distance of the drive.
 Kb =0,8: efficiency of lubrication.
 Klv = 1,12: efficiency of operating conditions of the drive.
 SoK=1,2 .1.1.1.0,8.1,12 = 1,0752.
 Efficiency of rotation of drive shaft:
200
o K n = 138.66 = 1,43
 Efficiency of tooth of driven chain sprocket:

Z01 25
o Kz = = 25 = 1
Z1
 Choose one-side chain so: K x = 1

 Calculating power:
K.Kz .Kn 1,0752×1×1.43
o pt = .p = × 0.404 = 0.621(kW)
Kx 1
34
 Base on table 5.4 in reference, choose:
o pc = 25,4 d0 = 7,95 b0 = 22,61
 Average speed:
n.pc .Z1 140.31×25.4×25
o v= = = 1,48(m/s)
60000 60000
 Effective pull:
1000p 1000×0.404
o Ft = = = 272.97(N)
v 1,48
3 p.K
 Check again Pc: pc ≥ 600. √z = 11.1 => Satisfied
1 .n.30.Kx
 Choose center distance:a = (30 ÷ 50). pc

 Choose: a=40 × pc = 40 × 25,4 = 1016(mm)
 The number of links:
2a Z1 +Z2 (Z2 −Z1 )2 .pc 2.1016 25+50 (50−25)2 .25,4
o X=p + + = + + = 117.90
c 2 4π2 a 25,4 2 4π2 .1016
 Choose x=118, recalculate the center distance:

2 Z2 −Z1 2
o a = 0,25pc {Xc − 0,5(Z2 + Z1 ) + √(Xc − 0,5(Z2 + Z1 )) − 2 ( ) }=
π
2 50−25 2
0,25.25,4 {118 − 0,5(25 + 50) + √(124 − 0,5(25 − 50)) − 2 ( ) }=
π
1017.33 mm
o In order to avoid too much load, we decrease amount of a=0,003.a≈ 3,052(mm)
o So center distance is: a= 1014.28 (mm)
 Chain length:
o L = pc . X = 25,4.118 = 2997.2(mm)
 Total impact of chain in 1s:
z1 .nz 25×140.31
o i= = ≈ 1.98 < [i] = 15
15.X 15×118
 Checking the strength of chain:

Q
o s=F
1 +F0 +Fv
 We have: Q=56.7 (kN), q= 2.6 (kg)

o F1 = Ft = 272.97(N)
 Tension caused by centrifugal force: Fv = q × v 2 = 2.6 × (1.48)2 = 5.70(N)
35
9,81×kf qa
 Initial tension:F0 = = 103.48(N)
1000
 Force effects on shaft:Fr = k x × Ft = 313.92(N)

Q
o s=k = 129.82
d ×Ft +F0 +Fv
 With n= 140.31 (rpm) [s] = 7 so s>[s]: chain drive is persistent enough

 Diameter of sprockets:
p
o d1 = sin(πc⁄z ) = 202.66 (mm)
1
π
o da1 = p [0.5 + cotg (z )] = 326,44 + 0,7.25,4 = 213,76 (mm)
1
pc
o d2 = = 404.51 (mm)
sin(π⁄z2 )
π
o da2 = p [0.5 + cotg (z )] = 416.42 (mm)
2
Properties of chain drive:
 P=0.404(kW)
 u= 2
 pc = 25,4
 z1 = 25 tooth, z2 = 50 tooth
 a = 1014.28
 L = 2997.2(mm)
 d1 = 202.66(mm)
 da1 = 213,76 (mm)
 d2 = 404.51(mm)
 da2 = 416.42(mm)
36
CHAPTER 8: SHAFTS, BEARINGS, KEYS
8.1. CALCULATION OF SHAFT II:
Shaft material: C45 steel with σb=638 MPa
Choose preliminary dimensions:
 Smallest shaft section under torsion:
3 T
d= √ = 13.07 mm
0.2[τ]
→ Choose d=15 mm
With T=11168.82 Nmm; [τ]=20÷25 MPa, choose [τ]=25 MPa
 From table 10.3 of [1]:
o e=50 mm
o u=50 mm
o x = 15 mm
o f≥50 mm
o w=40 mm
 b2=39 mm (width of driving spur gear), (1÷1,5)d=15÷22.5
→ choose hub length l2=40 mm
 b3=27.5 mm (width of driven spur gear), (1÷1,5)d=15÷22.5
 Distance between bearings: l=l2+l3+3x+w=153 mm
 From figure 10.17 we have:
o d0=15 mm
Force and bending moment:
37
Picture 8.1: Shaft II
 Oyz:
Picture 8.2: Shaft II inertial force and moment diagram on Oyz plane
 Oxz:
38
Picture 8.3: Shaft II inertial force and moment diagram on Oxz plane
Torsion: T=11168.82 N.mm
Dangerous section: section used to attach spur gear
M = √Mx2 + My2 + 0,75T 2 = 23244 Nmm
3 M
d≥ √ = 7.14 mm < 15mm
0,1[σ]
Shaft evaluation:
 From table 9.1a of [2], choose key with

o b=5 mm
o t1=3 mm
o t2=2.3 mm
39
 Bending:
π d3 b t (d−t)2
o W= − = 248.23 mm3
32 2d
o M = √Mx 2 + My 2 = 21135.91 Nmm

M
o σa = σmax = W = 85.15 MPa
 Torsion:
π d3 b t (d−t)2
o W0 = − = 579.57 mm3
16 2d
o T = 11168.82 Nmm
τmax T
o τa = τm = = W = 19.27 MPa (shaft rotates in one direction)
2 0
 Table 10.9, page 413, [1]:

o K σ = 1.6; K τ = 1,4
 Table 10.3, page 411, [1]:
o ψσ = 0,1; ψτ = 0,05
 Table 10.4, page 411, [1]:
o εσ = 0,81; ετ = 0,76
 Figure 2.9, page 43, [1]:
o β = 0,99
 Factor of safety:
o Bending:
 σ−1 = 0,45 × σb = 287,1
 σm = 0
σ−1
 Sσ = Kσσa = 3,01
+ ψσ σm
εσ β
o Torsion:
 τ−1 = 0,25 × σb = 159,5
σ−1
 Sτ = Kσσa = 9,81
+ ψσ σm
εσ β
o Safety factor:
Sσ Sτ
 S= = 2,88 > [s] = 1,5→Satisfied
√Sσ 2 + Sτ 2
40
8.2. CALCULATION OF SHAFT I:
3 T
d= √ = 8.72 mm
0.2[τ]
→ Choose d=10mm
With T=3325.07 Nmm; [τ]=20÷25 MPa, choose [τ]=25 MPa
o e=60 mm
o u=50 mm
o f≥ 50 mm
o w=40 mm
 b=32,5 mm (width of driving spur gear), (1÷1,5)d=33÷49,5
 Distance between bearings: l= 85mm choose l=203 mm
o d0=10 mm
 Choosing elastic shaft connector:
o From table 16.10a of [3]:
 d=33 mm
 D=67 mm
 L=51mm
 D0=45 mm
 Z=3 mm
2T
 Ft = D = 49.26 N
0z
 Fr = 0,2Ft = 9.85 N
41
Picture 8.4: Shaft I
 Oyz:
Picture 8.5: Shaft I inertial force and moment diagram on Oyz plane
 Oxz:
42
Picture 8.6: Shaft I inertial force and moment diagram on Oxz plane
Torsion: T=3325.07N.mm
Dangerous section: section used to attach helical gear
M = √Mx2 + My2 + 0,75T 2 = 8683.52 Nmm
3 M
d≥ √ = 5.14 mm < 10 mm
0,1[σ]
Shaft evaluation:

o b=3 mm
o t1=1.8 mm
o t2=1.4 mm
 Bending:
43
π d3 b t (d−t)2
o W= − = 75.98 mm3
32 2d
o M = √Mx 2 + My 2 = 8192.16 Nmm

M
o σa = σmax = W = 107.82MPa
 Torsion:
π d3 b t (d−t)2
o W0 = − = 174.15mm3
16 2d
o T = 3325.07Nmm
τmax T 3325.07
o τa = τm = = = = 19.09 MPa (shaft rotates in one direction)
2 W0 174.15
 Table 10.9, page 413, [1]:

o K σ = 1,6; K τ = 1,4
 Table 10.3, page 411, [1]:
o ψσ = 0,1; ψτ = 0,05
 Table 10.4, page 411, [1]:
o εσ = 0,91; ετ = 0,89
 Figure 2.9, page 43, [1]:
o β = 0,99
o Bending:
 σ−1 = 0,45 × σb = 287,1
 σm = 0
σ−1
 Sσ = Kσσa = 2,81
+ ψσ σm
εσ β
o Torsion:
 τ−1 = 0,25 × σb = 159,5
σ−1
 Sτ = Kσσa = 15,47
+ ψσ σm
εσ β
o Safety factor:
Sσ Sτ
 S= = 2,76 > [s] = 1,5→Satisfied
√Sσ 2 + Sτ 2
44
8.3. CALCULATION OF SHAFT III:
3 T
d= √ = 17.65 mm
0.2[τ]
→ Choose d=20 mm
With T=27497.68 Nmm; [τ] =20÷25 MPa, choose [τ] =25 MPa
o e=70 mm
o u=60 mm
o f≥65 mm
o w=40 mm
 b=34 mm (width of driven spur gear), (1÷1,5)d=34÷51
 Distance between bearings: l= 88 mm choose l=138mm
o d0=20 mm
Picture 8.7: Shaft III

 Oyz:
45
Picture 8.8: Shaft III inertial force and moment diagram on Oyz plane
 Oxz:
Picture 8.9: Shaft III inertial force and moment diagram on Oxz plane
Torsion: T=27497.68 Nmm
Dangerous section: section used to attach spur gear
M = √Mx2 + My2 + 0,75T 2 = 36392.59 Nmm
46
3 M
d≥ √ = 8.29 mm < 20mm
0,1[σ]
Shaft evaluation:

o b=6 mm
o t1=3.5 mm
o t2=2.8 mm
 Bending:
π d3 b t (d−t)2
o W= 32
− 2d
= 608.03 mm3
o M = √Mx 2 + My 2 = 23870.49 Nmm

M
o σa = σmax = W = 39.26 MPa
 Torsion:
π d3 b t (d−t)2
o W0 = − = 1393.43 mm3
16 2d
o T = 27519.61Nmm
τmax T
o τa = τm = = W = 19.75 MPa (shaft rotates in one direction)
2 0
 Table 10.9, page 413, [1]:

o K σ = 1,7; K τ = 1,7
 Table 10.3, page 411, [1]:
o ψσ = 0,1; ψτ = 0,05
 Table 10.4, page 411, [1]:
o εσ = 0,91; ετ = 0,89
 Figure 2.9, page 43, [1]:
o β = 0,99
o Bending:
 σ−1 = 0,45 × σb = 287,1
 σm = 0
47
σ−1
 Sσ = Kσσa = 5,25
+ ψσ σm
εσ β
o Torsion:
 τ−1 = 0,25 × σb = 159,5
σ−1
 Sτ = Kσσa = 12,1
+ ψσ σm
εσ β
o Safety factor:
Sσ Sτ
 S= = 4,81 > [s] = 1,5→Satisfied
√Sσ 2 + Sτ 2
48
CHAPTER 9: DESIGNING PAIRS OF ROLLER BEARINGS FOR GEARBOX
9.1. DESIGNING THE TAPERED ROLLER BEARING ON SHAFT I:

 Radial force:
Acting on ball bearing A :
FrA = R A = √R2Ax + R2Ay = √157.092 + 57.232 = 167.19 N
Acting on ball bearing B :
FrB = R B = √R2Bx + R2By = √74.012 + 26.962 = 78.77 N
Choose: e = 0.3
FsA = e. FrA = 50.157 N
FsB = e. FrB = 23.631 N
FaA = FsB + Fa1 = 23.631 N
FaB = FsA + Fa1 = 50.157 N
Choose bearing 6301 with:
Bearing 6301 parameters
d(mm) D(mm) B(mm) r(mm) C(kN) C0 (kN)
12 37 12 1 8.5 4.15
With X=1 and Y=0 so that:
 Equivalent load on bearing A: QA = (XVFrA + YFa1 )K σ K t = 167.19 N

with K σ = 1; K t = 1 (According to table 11.2 of reference [1]) and V = 1 (Fa = 0)
 Equivalent load on bearing B: QB = (XVFrB + YFa1 )K σ K t = 78.77 N
49
Because QA>QB so we calculate for bearing A
 Conventional load:
3 ∑(Q3i Li ) 3 3 3 20 20
QAE = √ = √QA [1 ( ) + 0,73 ( )] = 146.41 N
∑ Li 40 40
 Service life in millions of revolutions:

60Lh n1 60×5000×70
L= = = 21 million revolutions
106 106
 Calculated dynamic load capability :

3 3
Ctt = QAE √L = 146.41 × √21 = 403.93 < C = 10000 N (sastify)
9.2. DESIGNING THE TAPERED ROLLER BEARING ON SHAFT II:

 Radial force:
FrA = R A = √R2Ax + R2Ay = √326.282 + 4.32 = 326.31 N
FrB = R B = √R2Bx + R2By = √375.292 + 82.672 = 384.29 N
Choose: e = 0.3
FsA = e. FrA = 97.89 N
FsB = e. FrB = 115.29 N
FaA = FsB + Fa1 = 115.29 N
FaB = FsA + Fa1 = 97.89 N
Bearing 6202 parameters (P2.7)
50
15 35 11 0.6 6.7 3.75

 Equivalent load on bearing B: QB = (XVFrB + YFa1 )K σ K t = 384.29 N
Because QB<QA so we calculate for bearing A
3 ∑(Q3i Li ) 3 3 3 20 20
QBE = √ = √QB [1 ( ) + 0,73 ( )] = 336.52N
∑ Li 40 40

60Lh n2 60×5000×140
L= = = 42 million revolutions
106 106

3 3
Ctt = QBE √L = 336.52 × √42 = 1169.75 < C = 10000 N→satisfy condition Ctt<C
9.3. DESIGNING THE BALL BEARING ON SHAFT III:

 Radial force:
FrA = R A = √R2Ax + R2Ay = √169.052 + 205.152 = 265.83 N
FrB = R B = √R2Bx + R2By = √301.212 + 347.912 = 460.18 N
51
Choose: e = 0.3
FsA = e. FrA = 79.749 N
FsB = e. FrB = 138.054 N
FaA = FsB + Fa1 = 138.054 N
FaB = FsA + Fa1 = 74.749 N
Table 9.3: Bearing 6304 parameters (P2.7)
20 52 15 1.1 13.9 7.8

 Equivalent load on bearing B: QB = (XVFrB + YFa1 )K σ K t = 460.18 N N
Because QB>QA so we calculate for bearing B

3 ∑(Q3i Li ) 3 3 3 20 20
QBE = √ = √QB [1 ( ) + 0,73 ( )] = 402.97 N
∑ Li 40 40

60Lh n3 60×5000×363.40
L= = = 109.02 million revolutions
106 106

3 3
Ctt = QBE √L = 402.97 × √109.02 = 1925.05 < C = 10000 N→satisfy condition Ctt<
52
CHAPTER 10: THE DESIGN OF GEARBOX SHELL
Table 10.1: Gearbox shell calculation
*Thickness: Body of the gearbox, δ δ = 0,03 × a + 3 = 7,6 (mm)
Lid of the gearbox, δ1 Choose δ = 8 mm > 6
δ1 = 0,9. δ = 7,2 (mm)
Choose δ1 = 7 mm
*Tendon stiffness:
Thickness, e e = (0.8÷1).δ = 6.4÷8→Choose e=7 (mm)
Height, h h < 58: Choose h=55 (mm)
Slope Slope approximates 2 degrees
*Diameter:
Base bolt, d1 d1 > 0.04a +10 =16.13⇒ Choose d1= 20 (mm)
Bolt next to bearing, d2 d2 = (0.7 ÷ 0.8) × d1 ⇒Choose d2 = 15 (mm)
Bolt to fasten body and lid, d3 d3 = (0.8 ÷ 0.9) × d2 ⇒Choose d3 = 13(mm)
Screw graft fitting drive, d4 d4 = (0.6 ÷ 0.7) × d2 ⇒ Choose d4 = 8 (mm)
Screw graft testing oil, d5 d5 = (0.5 ÷ 0.6) × d2 ⇒ Choose d5 = 8 (mm)
* Flanged Flanges and Stem Flanges:
Thickness of flange body, S3 S3 =(1.4 ÷ 1.5)× d3 choose S3 = 19(mm)
Box flange thickness, S4 S4 = ( 0.9 ÷ 1) S3 => choose S4 = 18 (mm)
Flange width of box, K 3 K 3 = K 2 −( 3÷5 )mm => choose K 3 =44 (mm)
*Dimension of bearing pillars: External Determined by the size of the cover of the table 18.2 we have:
diameter and screw hole center, D3 , D2 Shaft I: D= 37 (mm), D2=51 mm, D3=72 mm, h=8 mm, Z=4, d4=6
53
Coupling flange: K 2 mm
Center of bolt hole: E2 Shaft II: D=35 (mm), D2=49 mm, D3=70 mm, h=8 mm, Z=4, d4=6
mm
k is the distance from the center of the bolt to
the edge of the hole Shaft III: D=52 (mm), D2=65 mm, D3=80 mm, h=8 mm, Z=4,
d4=6 mm
Height h
K 2 = E2 + R 2 + (3 ÷ 5) mm => Select K 2 = 48 (mm)
E2 = 1.6d2 = 1.6 × 15 = 24 (mm) => choose E2=24 (mm)
R 2 = 1.3d2 = 1.3 × 15 = 19.5(mm) =>choose R2=20 (mm)
k ≥ 1.2.d2 = 18⇒ k = 18
*Gearbox base: S1 = (1,3 ÷ 1,5) d1 ⇒S1 = 28 (mm)
Thickness: When no convex S1 Dd determined by the diameter of the chisel
When there are convex parts: Dd , S1 and S2
Width of base box, K1 and q K1 ≈ 3d1 ≈ 60 (mm)
q = K1 + 2 δ = 76 (mm)
*The gap between the details: Between the Δ ≥ (1 ÷ 1.2)δ ⇒ Δ = 9 (mm)

gears and the wall in the box
Δ1 ≥ (3 ÷ 5) δ⇒ Δ1 = 32 (mm)
Between the top of the big gear and the
Δ2 = πr 2 ≥ δ = 8 (mm)
bottom of the box
Between the sides of the gears together.
*Number of base bolts Z Z = (L + B) / (200 ÷ 300)=4
L and B: Length and width of the box (choose preliminarily

L=500 mm, B=300 mm)
 Dimension of shaft: outer diameter and screw hole center:
54
D3 ≈ D + 4,4d4
D2 = D + (1,6 ÷ 2)d4
Table 10.2:
Shaft D D2 D3
I 37 mm 51 mm 72 mm
II 35 mm 49 mm 70 mm
III 52 mm 65 mm 80 mm
10.1. PARTS RELATE TO THE COMPOSITION OF GEARBOX:

10.1.1. Cotter-pin:
-Joined surface between the lid and the body lies on the plane contains the centerline of
shafts. Opening of cylinder (with diameter D) is mounted on the lid and the body is
processed simultaneously. To ensure the relative position of the lid and body before and
after processing and assembly, we use two cotter-pins. Due to the cotter-pin, when we
tighten the bolt, it does not distort the outer ring of the bearings (due to the relative
position of the lid and the body), therefore we can eliminate one of the causes of making
bearings be broken.
-We use the cone cotter-pin with:
Table 10.3. cotter-pin parameters
d c l
6 1 45
10.1.2. Bearing cover screw:

- Prevent dust from entering bearings
- Made of GX14-32.
55
Table 10.4: The composition of bearing cover screw in the gearbox
Shaft D D2 D3 D4 h d4 z
I 37 mm 51 mm 72 mm 42 mm 8 mm 6 mm 4
II 35 mm 49 mm 70 mm 65 mm 8 mm 6 mm 4
III 52 mm 65 mm 80 mm 75 mm 8 mm 6 mm 4
10.1.3. Inspection hole’s cover:

-To examine and observe the machine elements in the gearbox when assembling and to pour oil
into the gearbox, the top of the box has to have an inspection hole’s cover. The inspection hole’s
cover is covered with a lid. On the lid, there is a steam escape valve. Table 9.5: The size of the
inspection hole’s cover is chosen according to the table 18-5 [1]
A B A1 B1 C C1 K R screw numbers
100 75 150 100 125 _ 87 12 M8x22 4
10.1.4. Steam escape valve:

-When working, the temperature inside the gearbox increases. In order to reduce the pressure and
regulate air inside and outside of the gearbox, a steam escape valve is used. The steam escape
valve is mounted on the access.
Table 10.6: Steam escape valve size
A B C D E G H I K L M N O P Q R S
M27x2 15 30 15 45 36 32 6 4 10 8 22 6 32 18 36 32
56
10.1.5. Oil drain plug:
-After a period of time working, lubricating oil inside the box gets dirty (due to dust and abrasive
grain) or degenerated, so we need to replace it. To remove the dirty oil, at the bottom of the
gearbox is the oil drain. While working, the drain is sealed by the oil drain plug.
Table 9.7: The structure and size of the oil drain plug is chosen according to 18-7 [1]
d b M f L c q D S D0
M16x1.5 12 8 3 23 2 13.8 26 17 19.6
10.1.6. Dip stick:

- When the gear velocity is less than or equal to 12m/s, gears are soaked in oil. The oil level
inside the gearbox is indicated by different kinds of oil level indicators. In our case, we use a
dipstick.
10.1.7. Hanging flange:

- In order to move the gearbox easily (during manufacturing, assembly, etc.).
- Thickness: S = (2 ÷ 3). δ = 16 mm
- Diameter of the hole of the hanging flange: d = (3 ÷ 4). δ = 24 mm
10.1.8. Separating screw for the lid and the body of the gearbox:
- In order to separate the lid and the body of the gearbox, we use M14x30 screw.
10.2. Other components:
10.2.1. Bearing cover washer:

-Bearing cover washer is an indirect sealing liner intended to protect the ball bearings from dust,
dirt, hard particles, and other impurities entering the bearings. These substances cause wear and
tear. In addition, the bearing cover washer also prevents oil from flowing out. Longevity of the
bearings depends on the bearing cover washer.
57
-Bearing cover washers are widely used because of their simple structure and ease of
replacement. However, there are disadvantages in form of abrasion and friction when the surface
of the shaft has high roughness.
10.2.2. Oil seal:

- In order to prevent consistent lubricant from the oil in the gearbox.
10.3. Tolerance and Assembly:
10.3.1. Bearings tolerance:

The inner of the bearings is under cyclic load, they are assembled in an intermediate shaft system
so that the bearings do not slip on the shaft surface when working. Therefore, we must choose
the fitting k6, the middle resin with residuals, making it possible to wear evenly (in the course of
work it will rotate evenly)
The outer of bearings does not rotate so it has local load, we assembly due to the hole system.
For the bearings to move along the shaft axis when the temperature rises during the work, we
choose the type of intermediate is H7/k6.
10.3.2. Assemble gear shaft:

Gear on shaft withstand moderate load, changing load, light impact, we choose assembling type
H7/k6.
10.3.3. Assemble bearing cap and casing:

-For easy assembling and modifying, we choose loosen assembling type H7/k6.
10.3.4. Assemble latch:

-According to the width, we choose assembling type on shaft D10/h9 and on bearing H7/k6.
58
REFERENCES:
[1] Nguyễn Hữu Lộc, Phạm Anh Tú, 2016, Giáo trình cơ sở thiết kế máy, Nhà xuất bản
ĐHQG-HCM, Tp. Hồ Chí Minh
[2] Trịnh Chất – Lê Văn Uyển, Nguyễn Văn Mậu, 2006, Tính toán thiết kế hệ dẫn động cơ
khí, hai tập, Nhà xuất bản giáo dục Tp. Hồ Chí Minh
[3] Nguyễn Hồng Ngân (chủ biên) – Nguyễn Danh Sơn, Phạm Anh Tú, 2014, Kỹ thuật nâng
chuyển (Tập 2) –Máy vận chuyển lien tục, Nhà xuất bản ĐHQG-HCM, Tp. Hồ Chí Minh
[4] Lê Khánh Điền, 2016, Vẽ kĩ thuật cơ khí, Nhà xuất bản ĐHQG-HCM, Tp. Hồ Chí Minh
[5] Dongil Rubber Belt Co., Ltd, Design Manual for Power Transmission Belts
[6] Somjet Thanomputra, Thanya Kiatiwat (2016): Simulation study of cutting sugarcane using
fine sand abrasive waterjet
[7] Jiří Dvořák and Tomáš Kuvik et al.(2017): Impact of the selected factors on the cutting
force when using a chainsaw
[8] Patil, M., & Patil, P. D. (2013). Optimization of blade angle for cutting system of sugar
cane harvester., International indexed and referred research journal 42(4), 49-52.HAINSAW
[9] Esquivel, M., Marrero, S., Ponce, E., Guerrero, A., Stainlay, T., Villaruz, J., & Bella, L. D.
(2008). Evaluation of the automatic base-cutter control system in the Australian sugarcane
industry. Proc. 2008 Conf. Australian Soc. Sugar Cane Tech. (pp. 322-327). Townsville,
Australia: Australian Society of Sugar Cane Technologists
[10] S.Ma, M.Karkee, P.A.Scharf, (18 January 2015): Sugarcane harvester technology: A
critical overview, Q.Zhang, Research gate Vol.30(5): 729-739.
[11] Otto, A., Parmigiani, J. (2015): Velocity, Depth-of-cut, and Physical Property Effects on
Saw Chain Cutting, “Saw chain cutting”, BioResources 10(4), 7273-7291
[12] OREGON® Forestry Product Catalogue
[13] ContiTech Holding GmbH, Hannover, 2002, CONTI-V MULTIRIB® multiple V-ribbed
belts
59

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HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY

DESIGN A SUGARCANE HARVESTER

Students: Nguyễn Quang Trường

Lê Dương Khánh Duy

Huỳnh Đức Nguyên

Khúc Lâm Đồng

Instructor: Prof. Lê Khánh Điền

1.1. ABSTRACTS: ....................................................................................................... 1

1.2. LITERATURE REVIEW ...................................................................................... 1

1.2.1. Cutting mechanism: ..................................................................................... 2

1.2.2. Conveyor system: ........................................................................................ 5

CHAPTER 2: CUTTING MECHANISM DESIGN ...................................................... 7

2.1. OVERVIEW: ......................................................................................................... 7

2.2. BELT DRIVE DESIGN AND MOTOR SELECTIONS ...................................... 8

CHAPTER 3: BELT CONVEYOR CALCULATION ................................................ 19

3.1. INITIAL PARAMETERS: .................................................................................. 19

3.2. PRELIMINARY CALCULATIONS: ................................................................. 19

3.3. ACCURATE CALCULATION: ......................................................................... 20

CHAPTER 4: CALCULATING AND CHOOSING MOTOR AND

4.1. CHOOSING MOTOR: ........................................................................................ 23

4.2. DISTRIBUTE TRANSMISSION RATIO: ......................................................... 24

4.3. DISTRIBUTE TRANSMISSION RATIO: ......................................................... 24

CHAPTER 5: DESIGNING SPUR GEAR ................................................................... 26

5.1. INITIAL PARAMETERS: .................................................................................. 26

5.2. CALCULATION: ................................................................................................ 26

CHAPTER 6: DESIGNING SPUR GEAR ................................................................... 30

6.1. INITIAL PARAMETERS: .................................................................................. 30

6.2. CALCULATION: ................................................................................................ 30

7.1. INITIAL PARAMETERS: ................................................................................. 34

7.2. CALCULATION: ............................................................................................... 34

CHAPTER 8: SHAFTS, BEARINGS, KEYS ............................................................... 37

8.1. CALCULATION OF SHAFT II:......................................................................... 37

8.2. CALCULATION OF SHAFT I: .......................................................................... 41

8.3. CALCULATION OF SHAFT III: ....................................................................... 45

CHAPTER 9: DESIGNING PAIRS OF ROLLER BEARINGS FOR GEARBOX . 49

9.1. DESIGNING THE TAPERED ROLLER BEARING ON SHAFT I:................. 49

9.2. DESIGNING THE TAPERED ROLLER BEARING ON SHAFT II: ............... 50

9.3. DESIGNING THE BALL BEARING ON SHAFT III: ...................................... 51

CHAPTER 10: THE DESIGN OF GEARBOX SHELL ............................................. 53

10.1. PARTS RELATE TO THE COMPOSITION OF GEARBOX: ..................... 55

10.1.1. Cotter-pin: .................................................................................................. 55

10.1.2. Bearing cover screw: ................................................................................. 55

10.1.3. Inspection hole’s cover: ............................................................................. 56

10.1.4. Steam escape valve: ................................................................................... 56

10.1.5. Oil drain plug: ............................................................................................ 57

10.1.6. Dip stick: .................................................................................................... 57

10.1.7. Hanging flange:.......................................................................................... 57

10.2. Other components: ............................................................................................ 57

10.2.1. Bearing cover washer: ............................................................................... 57

10.2.2. Oil seal: .......................................................................................................... 58

10.3.1. Bearings tolerance: .................................................................................... 58

10.3.2. Assemble gear shaft:...................................................................................... 58

10.3.3. Assemble bearing cap and casing: ................................................................. 58

10.3.4. Assemble latch: ............................................................................................. 58

1.2. LITERATURE REVIEW

Cane Cutting Feeding Discharging Whole

Knockdown Roller + Conveyor

1.2.1. Cutting mechanism:

1 of the paper shows us some 𝑘𝑏𝑜𝑟 factor of dry pine

-Basically, a chainsaw has 3 significant parts for making a cut:

They were taken into consideration:

-Belt conveyor safety system:

Picture 1.1: Industrial application of conveyor