School of Aerospace, Mechanical and Manufacturing

Engineering
MIET 2136 Mechanical Design 1
Assignment 1 Drive and Mounting Arrangement for a Shaft on a
Factory Food Mixer

P1: Amyrul Zakwan Aluwie (s3399804)

P2: Che Ku Noorbaizura Che Ku Adnan (s3400399)

Table of Contents
1

Executive Summary................................................................................................. 4

Selection of Belt and Pulleys..................................................................................... 5

2.1

Belt Selection................................................................................................... 5

2.2

Choosing the pulleys combination........................................................................5

2.3

Calculating standard belt length.............................................................6

2.4

Calculation of number of belts.............................................................................7

2.5

Final Selection of Pulley.................................................................................8

Sizing of the Shaft................................................................................................... 9

3.1

Determining the peak hub load............................................................................9

3.2

Calculation of reaction forces at the bearings......................................................10

3.2.1

Using weight............................................................................................ 10

3.2.2

Using static hub load................................................................................. 11

3.2.3

Using dynamic hub load............................................................................. 11

3.3

Resultant Bending Moment, Mq at Peak Shaft Load..............................................12

3.3.1
3.4

Peak Torque of the Motor................................................................................. 16

3.5

Trial shaft diameter........................................................................................ 17

3.6

Desired shaft diameter..................................................................................... 17

3.6.1

Calculating the minimum diameter of shaft....................................................18

3.6.2

First iteration............................................................................................ 18

3.6.3

Second iteration........................................................................................ 19

3.6.4

Third iteration........................................................................................... 19

3.7
4

Calculation of shear forces and bending moment at the bearings.....................12

Shaft selection................................................................................................ 19

Selection of Bearing............................................................................................... 20
4.1

Radial Load from static hub load.......................................................................20

4.2

Radial load from dynamic hub load....................................................................21

4.3

Selection of bearing A...................................................................................... 22

4.4

Selection of bearing B...................................................................................... 23

2

CAD Drawings using CATIA.................................................................................... 24

Bibliography......................................................................................................... 33

Appendices.......................................................................................................... 34

1 Executive Summary
The main objectives of Mechanical Design courses are to work knowledge of
machine elements, strengthen problem solving methodology and design openform systems using standard machine elements. This year, the focus is on
designing a drive and mounting arrangement for a shaft on a factory food mixer.
Our group will need to consider all the parts related to a horizontal driveshaft that
receives power from an electric motor via belt and delivers the power to a flexible
coupling attached to the input shaft. All measurements are in mm.
The motor given has rated output of 18.5kW at its rated speed of 1475 rpm.
Based on the speed ratio calculated, we listed out seven combinations of pulleys.
Using predetermined center distance, we calculate the belt lengths and choose
the best belt length from Australian Standard 2784 - 2002. As we obtained the
power per belt of our design power of the speed of faster shaft and speed ratio,
the number of belts can be determined. We included correction factor for arc of
contact and belt length in the calculation.
At the first place, we listed out seven combinations of pulleys that match the
speed ratio required. The best pulley is chose according to four criteria which are
closest to the speed ratio, within the tolerance, less belt and light.
The next step is sizing the shaft. We needed to find the peak shaft bending
moment and equivalent torque to get the trial shaft diameter. Using the value of
trial shaft diameter, we iterated the value to obtain the minimum diameter. Then,
a standard shaft size is chosen.
The bearings are chosen based on the radial loading from the static and dynamic
load of both bearings. The bearings we chose are capable to withstand these
forces by a hefty amount. This is mainly due to the size of our shaft forcing us to
choose bearings of larger bore.

2 Selection of Belt and Pulleys

2.1 Belt Selection
Based on the last digit of our student numbers, the average power transmission
is 18.8 kW. Now, considering the service factor from Table A1 of AS 2784, our
design is in class 2 with a heavy start running between 10 and 16 hours per day;
yielding a service factor of 1.3. The design power of our motor will be the product
of the average power transmission and the service factor.
18.8 X1.3 = 24.44 kW.
From the data above and the table provided in Australian Standards, the belt
suitable for our design is B V-belt.

2.2 Choosing the pulleys combination

The most important criterion for pulleys combination is the speed ratio, which is
determined by dividing the speed of faster with the speed of slower shaft giving a
value of 3.207. The speed ratio is then used as the ratio of the smaller pulley and
the larger pulley. The smallest pitch diameter for a B V-belt is 125 therefore; the
pitch diameter of the larger pulley is 401. Referring to AS 2784, the standard
pitch diameter closest to the value we want is 400. As there are a difference in
the actual pitch diameter desired and the standard pitch diameter, we have to find
the actual speed ratio provided by this pulley combination, given by dividing the
larger pitch diameter with the smaller pitch diameter resulting in 3.200. Next, we
checked if the speed ratio obtained from the pulley combination is within the
tolerance specified. If the speed ratio is not within the tolerance, we immediately
reject the pulley combination.
Speed ratio, SR

= 1475/475
= 3.207

Calculating large pulley diameter from small pulley diameter,

Pitch diameter of small pulley X SR

= 125 X 3.207
= 401

Actual speed ratio

= standard large pulley diameter/small pulley diameter

= 400/125

= 3.20
D outside

SR
measured

Output
Shaft
Speed

Within
Tolerance

400

407

3.200

461

yes

423

400

407

3.030

487

yes

147

449

500

507

3.571

413

no

150

157

481

500

507

3.333

442

yes

160

167

513

500

507

3.125

472

yes

180

187

577
Table 1 Pulley630
Selection

637

3.500

421

yes

200

167

641

637

3.150

468

yes

d outside

pitch
diameter
desired

pitch
diameter
standard

125

132

401

132

139

140

Pitch
diameter
1

630

From Table 1, combination 4 can be eliminated as the speed of input shaft is not
within the tolerance.

2.3 Calculating standard belt length

Calculation is made with a pre-determined center distance of 500mm obtained by
choosing a value greater than 1/2(D+d).
D=400,
1/2(D+d) = 262.5
2

From here, the belt length is calculated using

L=2 C+1.57 ( D+ d ) +

(Dd )
4C

For Combination 1,

(400125)
L=2(500)+1.57 ( 400+125 )+
4(500)

1884.04
The belt length calculated is not a standard one so we pick the nearest standard
length from AS 2784 which is 1760. From here, the actual center distance is
2
calculated using C=A + A B

( D+d )
L
A=
4
8

B=

( Dd )
8

Center distance,
C=(

( 400+ 125 )
( 400+125 )
( 400125 )
1760
1760

)+ (

) (
)
4
8
4
8
8
C=435

Table 2 Standard Belt Length and Centre Distance

The rest of the calculation is tabulated below with combination 4 left out
Combinatio
n
1

Belt length
calculated
1884.04

standard
length
1760

Centre Distance

228.34

9453.13

435

1893.13

1760

225.59

8978.00

430

2091.58

1950

230.67

16200.00

423

2115.98

2300

310.32

14450.00

596

2394.93

2300

251.42

25312.50

446

2372.73

2300

259.27

27612.50

458

2.4 Calculation of number of belts

After getting the pulley combinations and the center distance, the number of belts
can now be calculated. It is given by
Design power rating
Power rating per beltXarc of contact correction factorXbelt length correction factor
Power rating per belt = power rating + power increment
Arc correction factor is the proportion of 180-degree rating from the calculation of
Dd
C
Sample calculation using Combination 6
Power rating per belt = 5.24+0.48=5.72
7

Dd
=1.01
. From Table 12 in AS2784, the correction factor is 0.82
C

Belt length correction factor for belt length of 2300 B V-belts is 1.

24.44
Therefore, number of belt is 5.72 X 0.82 X 1.00 = 3.50
Rounding up to the next whole number, the number of belt required for this pulley
combination is 4.

Table 3 Power Rating per Belt

combination
1
2
3
Combination4 (D-d)/C
5
1
0.63
6
2
0.62
7
3
0.85
5
0.57
6
1.01
7
1.03

power rating
power increment
2.79
0.48
3.12
0.48
3.49
0.48
correction
Belt pitch
correction
3.94
0.48
factor
length
factor
4.38
0.48
0.91
1760
0.95
5.24
0.48
0.91
1760
0.95
6.06
0.48
0.86
1950
0.97
0.92
2300
1.00
0.82
2300
1.00
0.82
2300
1.00

power total
3.27
3.60
3.97
No of Belts
4.42 Belts
4.86 required
6.46 5.72
7
5.87 6.54
6
5.14
6
4.63
5
3.50
4
3.06
4

Table 4 Belt Length and Number of Belts

2.5 Final Selection of Pulley

From the data obtained, now we can choose the pulleys we want. For this particular
design, we chose pulley combination 5 which the smaller pulley of pitch diameter

160 and large pulley of pitch diameter 500 with output shaft speed of 472 RPM
which is within the tolerance. The number of belt required for our design is 5.

3 Sizing of the Shaft

3.1 Determining the peak hub load
Using interpolation equation also to find the value of from the value of arc of
contact on smaller pulley based on Table A12 of AS2784.
Dd
C

0.55

0.57

0.60

Arc of contact on
smaller pulley,
degree

148

145

0.570.55
( 148145 ) +148
0.600.55

=149.2o

Static Hub load

W s =2 nT stat sin

( 2 )

2 ( 5 )( 12.5 x 32 ) sin

( 149.2
2 )

3856.38 N

Dynamic Hub Load

10

T
( statK ) sin

( 2 )

W r=2 n

2 ( 5 )( 400116.05 ) sin

( 149.2
2 )

2737.58 N

Static hub load is the highest force on the pulley. Thus, static hub load is chosen
as the peak hub load.

11

3.2 Calculation of reaction forces at the bearings

Assuming all weight acts through their center, the weight of pulley is 0.05m from
the end of the shaft. Also, the weights of the bearings are much smaller than the
weight of the pulley so they are negligible. We separate bearing A from the pulley
by a distance of 0.3m so that there is enough room for the pulley and guard before
the bearing. Bearing B is 0.5m from bearing A to help support the middle structure
of the shaft.

RA

0.05m

0.3m

0.5m

Mg

3.2.1

0.15m
RB

Using weight

Calculating RA
+

MB = 0
62.789(9.81)(0.8) RA(0.5) = 0
RA = 985.54 N

Calculating RB
+

MA = 0
62.789(9.81)(0.3) RB(0.5) = 0
RB = 369.58N

12

RA

0.05m

0.3m

Ws

0.5m

0.15m
RB

3.2.2
3.2.3

Using static hub load

Calculating RA
+

MB = 0
3856.38(0.8) RA(0.5) = 0
RA = 6170.21 N

Calculating RB
+

3.2.4

MA = 0
3856.38(0.3) RB(0.5) = 0
RB = 2313.83 N
Using dynamic hub load

Calculating RA
+

MB = 0
2737.58(0.8) RA(0.5) = 0
RA = 4380.13 N

Calculating RB
+

MA = 0
2737.58 (0.3) RB(0.5) = 0
RB = 1642.55 N

13

3.3 Resultant Bending Moment, Mq at Peak Shaft Load

3.3.1

Calculation of shear forces and bending moment at the bearings

3.3.1.1 Using weight

BA

MA

x
Mg
0 0.3 X

Calculating the shear force

+

Fy = 0
BA 62.789(9.81) = 0
BA = 615.96N

Calculating the bending moment

+

Mo = 0
MA + 615.96(x) =0
MA = -615.96(x)
When x = 0.3m,

985.54 N

0.3m

BB

MA = -184.79Nm

MB

Mg
0 0.5 X

Calculating the shear force

+

Fy = 0
BB + 985.54 615.96 = 0
BB = -369.58N
14

Calculating the bending moment

+

Mo = 0
MB + 615.96(x+0.3) 985.54(x) = 0
MB = 985.54(x) 615.96(x+0.3)
When x = 0.5m,

MB = 0

The shear force and bending moment diagram:

Z X plane
RA

0.05m

0.3m

0.5m

0.15m

Mg
615.96N

RB

-369.58N

-184.79Nm

15

3.3.1.2 Using static hub load

BA MA
x
4514.95N

Calculating the shear force

+

Fy = 0
BA 3856.38 = 0
BA = 3856.38N

Calculating the bending moment

+

Mo = 0
MA + 3856.38(x) =0
MA = -3856.38 (x)
When x = 0.3m
6170.21N

0.3m
3856.38N

MA = -1156.91Nm
BB

MB

Calculating the shear force

+

Fy = 0
BB + 6170.21 3856.38 = 0
BB = -2313.83N

16

Calculating the bending moment

+

Mo = 0
MB + 3856.38(0.3+x) 6170.21(x) = 0
MB = 6170.21(x) 3856.38(0.3+x)
When x = 0.5m,

MB = 0

The shear force and bending moment diagram

Y X plane
RA

0.05m

0.3m

0.5m

0.15m

Mg

RB

3856.38N

-2313.83N

-1156.91Nm

17

Therefore, the resultant bending moment

M q= M weight 2 +M hubload 2
M q= (184.79)2+(1156.91 Nm)2
M q=1171.58 Nm

3.4

Peak Torque of the Motor

Full load torque and breakdown torque, 4 poles, 50Hz, 18.5kW motor (WEG
motor catalogue).
Full load torque = 119.5Nm
Breakdown torque = 290%
Service factor = 1.3
Actual speed ratio = 3.125
Peak torque = full load torque x breakdown torque x service factor x actual speed
ratio
= 119.5 x 290% x 1.3 x 3.125
= 1407.86Nm
Torque Diagram
Torque(Nm)

1407.86

x(m) 0

0.05

0.3

0.5

0.15

18

3.5 Trial shaft diameter

A trial shaft diameter is to be read directly from graph in page 21 in AS 14032004(see appendix) after we got the value of equivalent torque (TE).
T E =1.15 M q2 +0.75 T q 2
T E =1.15 1171.58 2+0.75 (1407.86)2
T E =1944.54 Nm

From the value of equivalent torque calculated above, the trial shaft diameter
obtained from the graph is 55mm with endurance limit of 193MPa and ultimate
tensile strength of 390MPa (using low strength alloy as our material).

3.6 Desired shaft diameter

The size factor can be obtained using the value of trial shaft diameter.
Ks=

F R x D3
12000 T E

Ks=

193 x 55
12000(1944.54)

K s =1.37

19

Calculating the minimum diameter of shaft

104 F s
D=
Ks K
FR
3

Pq D 2 3 2
M q+
+ Tq
8000
4

where,
Fs = 1.2
given in the formula in AS 1403-2004
FR = 193MPa
endurance limit of low strength alloy
Ks = 1.26
from the calculation above
K = 1.2
from figure 5, page 15 in AS 1403-2004.
Mq = 1171.58Nm
Pq = approximately zero as the value is too small
Tq = 1407.86Nm
The shaft diameter is calculated by using iteration method to obtain more
accurate value.

3.6.1

First iteration

Ks = 1.26
104 ( 1.20 )
2 3
D=
(1.37)(1.2) (1171.58 +0 ) + (1407.86)2
193
4

D=55.7 mm

If

DR =

D 1D0
= 1 ,
0.01 D1

then the iteration stop. If >1%, continue the iteration until

the best diameter can be evaluated.

DR =

55.755
=1.2
0.01(55.7)

20

3.6.2

Second iteration

Ks = 1.45
3

D=

4
10 ( 1.20 )
2 3
2
(1.45)(1.2) ( 1171.58 +0 ) + (1407.86)
193
4

D=56.8 mm

DR =

3.6.3

56.855.7
=1.9
0.01(56.8)

Third iteration

Ks = 1.47
3

D=

4
10 ( 1.20 )
2 3
2
(1.47)(1.2) (1171.58 +0 ) + (1407.86)
193
4

D=57.0 mm

DR =

57.056.8
=0.35
0.01(57.0)

As a result, a shaft diameter of 60mm is selected from the AS 1403-2004.

3.7 Shaft selection

The minimum diameter of shaft must be able to satisfy the maximum torque
acting and accommodate the maximum bending moment along the shaft. Apart
from that, a 1030 carbon steel shaft has been selected as this material has a
very good ductility and strength. The 1030 carbon steel also displays a great
fatigue strength that we cannot take for granted as it shows us how the material
will react when undergoing cyclic stress; either it will fatigue or not. As a
conclusion, as the fatigue strength increases, the diameter of the shaft will be
decreases.

21

4 Selection of Bearing
4.1 Radial Load from static hub load
R= W s2+ W 2
R= (3856.38)2 +(615.96)2
R=3905.26 N

-3905.26
x(m) 0

0.05

0.3

0.5

0.15

Fy = 0
Assumes that reaction at A is upwards and reaction at B is downwards.
R+ R AR B=0
R A =R+ RB
+

MB = 0
22

3905.26(0.8) RA(0.5) = 0
RA = 6248.42N

For bearing A :
Co = 6248.42N

RB = 2343.16N

For bearing B :
Co = 2343.16N

4.2 Radial load from dynamic hub load

R= W r2+ W 2
R= 2737.582 +615.962
R=2806.02 N

-2806.02
x(m) 0

0.05

0.3

0.5

0.15

Calculation
Fy = 0
Assumes that reaction at A is upwards and reaction at B is downwards.
R+ R AR B=0
R A =R+ RB

23

MB = 0
2806.02(0.8) - RA(0.5) = 0
RA = 4486.63N
RB = 1683.61N

4.3 Selection of bearing A

F R=V x R A (dynamic )

(rotational factor, V = 1 because of the inner race of the

bearing)
F R=1 x 4486.63 N

(rotates)

F R=4486.63 N
Ld =t hours x RPM x 60 min/hour
Ld =40000 x 472 x 60
Ld =1.13 x 109 cycles
L =K R x 106

(KR for 95% reliability is 0.64)

6

L =0.64 x 10

C=F R

Ld
L

( )

1
k

1.13 x 10
C=4486.63
0.64 x 1 06

1
3.333

24

C=42275.35 N

where k = 3.333 for a roller bearing

From the diameter of the shaft, static and dynamic loading, we found a suitable
spherical roller bearing for our system in Spherical Roller bearing with Adapter
Sleeve Catalogue.
D = 60mm

C=

42275.35 N

Co = 6248.42N

Thus, the most suitable bearing A based on this value is 22212CJ model.

25

4.4 Selection of bearing B

F R=V x R B (dynamic)
F R=1 x 1683.61N
F R=1683.61 N
Ld =t hours x RPM x 60 min/hour
Ld =40000 x 472 x 60
Ld =1.13 x 109 cycles
L =K R x 106

(KR for 95% reliability is 0.64)

L =0.64 x 106

C=F R

C=

Ld
L

( )

1
k

1683.61

C=15875.63 N

1.13 x 10
6
0.64 x 10

1
3.333

where k = 3.333 for roller bearing

From the diameter of the shaft, static and dynamic loading, we found a suitable
spherical roller bearing for our system in Spherical Roller bearing with Adapter
Sleeve Catalogue.
D = 60mm

C=

15875.63 N

Co = 2343.16N

26

Thus, the most suitable bearing B based on this value is 22212CJ model.

27

5 CAD Drawings using CATIA

After doing all the calculations, we started our design using CATIA and sketched our
drawings.

Figure 1 - Assembly Drawing

28

Figure 2 - Large Pulley

29

Figure 3 - Small Pulley

30

Figure 4 - Belt

31

Figure 5 - Shaft

32

Figure 6 - Bearing

33

Figure 7 - Bearing Housing

34

Figure 8 - Guard

35

Figure 9 - Motor

36

6 Bibliography
1.
2.
3.
4.
5.
6.
7.

Australian Standard 2784-2002

Australian Standard 1403-2004
Fenner Pulley
BEARING Timken-Spherical-Roller-Bearings-Catalogue
WEG motor catalogue
CATIA Tutorial 1 Shaft by Nita Wiroonsup
CATIA Tutorial 2 Pulley by Nita Wiroonsup

37

7 Appendices

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58