Machines and Mechanisms Coursework
Machines and Mechanisms Coursework
Coursework
by Shabab Gul
1
Abstract
This Report will showcase the designing of a gear and pulley system and it will be based
upon the 2-lab experiment that were conducted on gear systems and belt friction. Hand
calculation will be carried out based upon the gear system and the belt will also be
calculated based upon the motor that is running. The input and output values of the system
will also be obtained. In addition, the results obtained from the design system will be
analysed and critically discussed using understanding of the gearbox and belt and a
conclusion will also be presented. The completion of this assignment should improve
understanding to the 2 systems and allow the underlying principles of the two systems to be
established and applied in order to solve engineering problems.
2
1
Table of Contents
Abstract 2
Table of Figures 4
Table of Equations 4
Introduction 5
Theory 6
1
Literature review 7
Design proposal 8
3
Table of Figures
Figure 1-Free Body Diagram of compound gear system 8
Figure 2-Schematic of compound gear system 9
Figure 3-Schematic of belt drive system 9
1
Table of Equations DH Split it
4
Introduction
Gear systems are used in many mechanical devices, and they are the most used
mechanism for power transmission and motion conversion. They are widely used within
industrial application and can be found in a many mechanical devices, for example:
clocks,
1
instrumentation, and equipment. In addition, they are also used to reduce or increase speed
and torque in a variety of devices such as motorcycles, aeroplanes, and machines. Gear
10
systems consist of toothed, mechanical transmission elements and theses are used to
4
transfer motion and power between mechanical components. Each of these gear or toothed
9
components are attached to the shaft or base component of the machine. Hence, when the
gear that provides the initial rotational input (driving gear) rotates with the shaft component,
this causes the driven gear to rotate its shaft components. The gear pair can have different
4
designs and constructions and depending on these, a change of direction of rotation or
4
movement can occur due to the transference of motion between the driving shaft and driven
shaft. Several gears pairs connect in series to form a gear train and this as a result
increases the total reduction ration. Furthermore, gear systems are considered to be a
1
simple mechanism, but they have mechanical advantages such as requiring lower power to
transmit torque with the help of a gear ratio. There are many different types of gears that can
be found, and these include spur, compound helical, bevel, etc. Similarly, belt drives can be
used to transmit power in mechanical engineering. Belt drives are made up of a strip of
13
flexible material, and they can be used to link two or more rotating shafts mechanically. In
1
belt drives, one pulley drives the belt whereas, the other pulley is driven by the belt. Belt
drives are also widely found within industrial application, for example: transmission of power,
replacement of rigid type power transmission systems and used in conveying systems.
Using knowledge obtained through both experiments within the lab on gear and belt
systems, this knowledge will be put into practice within this report by designing and
1
analysing a compound gear system made of a same gear type coupled with a belt drive
system of two pulleys and one V-shape belt to transfer the power generated by an electric
motor to a piece of machinery. When designing the system key parameters for the gear
1
system will be obtained such as: equivalent moment of Inertia of the system, resistive
1
torque, power, and angular velocities. For the belt, key parameters such as: lap angle,
maximum allowable tension, and maximum power transmitted without belt slipping
will be obtained.
nnj
5
Theori
WithinI
' 1
bnd gear system, the speed of the first gear is normally the biggest speed
1 1
produced by the motor once it has hit its max speed. Equation 1 compares the velocity with
1
the preceding gear and number of teeth to obtain the velocity. This equation can be used to
obtain the different velocities on each shaft in the system.
(On
= Wtnnl = 67171217132 7in(n 1)-
As tm
yoi ne shaft to another the power should gradually decrease in the system due
nai t cause it to be lost. Parameters such as friction and gear winding cause
to paraa'meter
^
this. Torque on the other hand, increases from one shaft to another as the gear reduction
increases. Hence, the angular speed at shaft 4 should be greater than the angular speed at
1
shaft 1. The power at each shaft can be determined by using the torque applied and angular
speed while considering the transmission efficiency relating to the shafts.
P = T XCJ
IEQ(I) —
Ii
+
hnfi
1121
I3 n2in|2
rl21rl32
| ^
Un n
rl21Tl32rl43
nj)
^.
Equation 3- Used to determine the moment of Inertia (Hermanto, 2022)
The same parameters are then used to calculate the friction torque of the shaft, the formula
below is used to obtain the resistive torque of the shaft.
Tn + + ^ rl nrlin _ _
F3 2
21 32
32
j
TF4n21n32n43
rl21rl32 rl43
Tm 4-- Used to determine
Equation ( resistive torque. (Hermanto, 2022)
) the
Throughout the belt drive system, torque transmits via a belt and pulley system through
)>
friction. When force is applied to the driver pulley this causes the belt to rotate and transmit
the applied force to the driven pulley. For torque to be successfully conveyed, the belt must
be effectively tensioned. The tension in the belt generates the conventional reaction force
1
between the belt and pulleys, facilitating the transmission of torque. The lap angle is known
as angle from where a part of the belt touches the surface of both sides of the pulley.
6
1
B = 2 cos )
'
Literature review
Many factors relating to the Gear tooth are responsible for the failure of spur gears. Fatigue
6
caused by Cyclical loading on the gear tooth leads to failure as it evolves beyond the
6
endurance limit of the material. Generally, spur gears fail due to bending and contact stress.
6 6
At the root of the tooth bending stress is developed whereas, contact stress is developed at
the surface. This repeated stress causes fatigue cracks to initiate. (Agrawal et al., 2022)
These cracks are very common tooth faults, in the early stages these exert vibration signals,
2
after the early stages, they start to propagate rapidly and this can lead to the tooth breaking
in a short time(Yang et al., 2023).This investigation shows increasing the fillet radius causes
the maximum stress near the tooth root generated to decrease hence providing a spur gear
that is more durable (Agrawal et al., 2022).
The surface wear and grip of the gear tooth is another factor that makes Spur gears prone to
3
failure. Hence, impacting the lifespan of the gear transmission. Oil lubrication can be used in
14
order to protect the gear surface. Oil film thickness and is vital in the lubrication of tooth
12
surface as increasing the oil film thickness leads to a decrease in the friction coefficient
(Yang et al., 2023). During the gear transmission process, there is a poor lubrication effect,
and this causes the friction coefficient to increase and hence causing adhesive wear to occur
3
and eventually leading to gear tooth failure. In order to improve the gear life, very vital to
improve tooth surface lubrication to reduce surface friction and wear. Study shows, Groove
3
texture leads to better lubrication performance and friction reduction performance when it is
wider and shallower. (Chang et al., 2023)
7
Belt drives are used to transmit motion and power. Usually during the power transmission
process of belt drives, vibrations and noise can occur. The source of this is usually the
7
transverses vibrations of belt spans, rotational vibrations of pulleys and belt slip and friction
on pulley. These lead to negative consequences such as: reducing the performance of the
7
belt and shortening the lifespan of the belt. (Zhu et al., 2021) Vibrations are generated as a
11
result of irregularity and unbalance of the idlers and poor geometry of the belt splices.
(Bortnowski et al., 2022) Another factor that causes vibrations is misalignment of the belt.
Moreover, uneven load will cause onside of the belt to not be evenly distributed hence,
causing the belt to oscillate and generate vibrations therefore, making it an important factor.
7
Within the belt drive system, vibrations can be reduced or eliminated in a number of different
ways. Making sure that the belt is properly centred on the pulleys and that the pulleys are
aligned with each other is one technique that can be used. Balance weights can be used to
rectify uneven loads by dispersing the load and reducing vibrations. Additionally, routine
maintenance can assist in identifying and replacing worn or damaged components that may
be causing vibrations. This may entail checking for wear on bearings, inspecting pulleys for
damage, and replacing frayed or damaged belts. Vibration dampening devices such as
rubber pads or spring mounts, can be used to absorb or isolate vibrations, helping to lessen
their negative impact on the system. These different techniques can help address vibrations
in belt systems and enhance their performance and reliability. (Homi§in et al., 2019)
Design proposal
The design consists of a compound gear system (similar to that used within experiment 1)
1
and this has been combined with a belt drive system which consists of two pulleys and one
V-shape belt, and it aims to transform the power generated by an electric motor to a piece of
machinery. A free body diagram of the working system can be seen in Fig.1, below. In
addition, further schematics of the system can be seen in Fig.2 and Fig.3 below.
Compound gear
Belt drive system
system
Belt
2
Motor 1
F ] Output
8
How many gears ?
1
/ , = 22.6 x 110
= 90.4%
—
— TPI 2.19 x r]ri
’kgnr Vii =94.1%
/2 23.8 x 10 \ 10 ’Nm »734 =97.9%
gm 2 TF = 3.63 x 10 " 3
Nm2
/3 = 26.1 x 10
TFi = 3.12 x
'kgm- 3
10 "
Nm
/4 = 14.0 x 10 "
TF4 = 3.11 x 10
kgm-
(
3
Nm
Calculations:
^
1
Resistive torque and moment of
inertia: 7’.3n2 in32 TF4n2in32n43
TR( ) = TF +
M )
f
I 1
*121*132 *143
121*132 •
Equation 6- Used to determine the resistive torque. (Hermanto, 2022)
)) (s.UxlO °) " 3
°)
(
^ ^§ )
TR{I) = (2.19 xl0 ) ‘3
+ + (0.904)(0.941)
0.904 3
- ( ) (0.904)
+ 1(3.63xl0 )
(0.941) ( )(§f)(
(0.979)
TR(D = 0.282 Nm
-[ +
I2
*i| h n 2 l n3 2 i
4 n 2 ln 32**43
Equation 7
"
- Used
EQ( I )
1
*121 *121*132
to determine the moment of Inertia. (Hermanto, 2022)
*121*132*143
2 2
©© ©©®
2 2
/ 90 X
/EQ(I) — 22.6 x 10 3 23.8 X 2 26.1 X 10-3 14 X 10-3
+ 10
-3
V 30 /
0.904 (0.904) (0.904)(0.941)(0.979)
(0.941)
Torque at each shaft: IEQ(1) = 65.196 kgm2
TI-TR(I>= IEQ(I) a( 1)
Equation 8- Used to determine torque for shaft 1
Ti-0.282 = 65.196 X 61
,
T = 3977.328Nm
Hi —Zk
n2 T\
T2= 7’1n21
3977.328 X 90
T2 = = 11931.984Nm
30
T3=
T3
11931.984 X 96 — T2n32
= 47727.936 Nm DH Unit missing
24
T4 — T 2 n
^2
10
T4= =
47727.936 X 100
20 238624.68 Nm
Angular Velocity at each shaft:
u)
i= ax Time
u)i= 61x 2 =
122rad/s
oi2
122 X 90
= oo1n2 i
=366 rad/s
30
a), = 122 X
ai3
—— X
oi1n21ri32
= 1464 rad/s
3
30 24
oi4 — a)in21n32n43
« = 122 X X X 7320rad/s
4
*
—
30 —
24 —
20
Pi=Ti x u)i
Equation 9- Used to determine power. (Hermanto, 2022)
11
Pulley system part:
The belt drive system which consists of 2 pulleys has parameter given on the lab sheet.
These parameters include:
RE =
90mm RF
= 30mm
d=0.15
1
Belt mass = 60 g/m
Omax = 7.5 N/ mm2 CJ belt
0.03 - 0.09
2 cos~ 1 ( o .i ) = 3.965 radians
s
Lap angle 8 = 3.965 radians
Lap angle 9 =227.178 Degrees
Ri X u)i = R2 X u)i
Equation 12-Used to determine angular velocity of pulley(Hermanto, 2022)
—roi
«
= U )f
2
12
(30 X 10~3)
(7320) = OJf
(90 X 10"3)
The velocity of an object will often reduce over time if the motor is replaced with a mass.
This is attributed to the fact that the motor's mass is being substituted with a larger mass,
which will result in a slower movement of the object due to a stronger gravitational pull. The
size, mass, and beginning velocity of the object will all have an impact on how fast it moves.
The consequence of adding a mass could be less evident if the object has a high beginning
velocity. The result of adding a mass will, however, be more perceptible and may force the
object to come to a stop if the initial velocity is low.
1. Typically, a gear system's capability to transmit power can be impacted by both the
resistance torque and moment of inertia. A gear with a big moment of inertia may be more
challenging to accelerate or decelerate, resulting in lower efficiency. Similarly, a gear with a
high resistance torque may endure more drag and be less effective at transmitting power. As
a results, these elements must be considered by engineers when constructing a gear system
in order to ensure peak effectiveness and efficiency.
2. If a motor that is driving a load is stopped, and it was also experiencing angular velocity,
the motor will come to a halt as there is not torque being transmitted. The angular velocity
will reduce as the motor slows and eventually it will reach zero as the motor stops. Similarly,
its acceleration will also decrease until it eventually reaches zero once the motor has halted.
Factors such as the amount of friction and external forces acting on the motor, in addition to
1
the mass of the motor will determine how quickly the motor will come to a stop.
3. If a motor is not powerful enough to transmit the required torque to carry out a specific
task, this will cause the output speed and torque to be reduced and therefore, the motor will
not be able to reach the desired speed in order to perform the specific task. As a results of
this, this can lead to a number of problems in the system, such as the reduced efficiency
and increased wear on the motor.
4. The system can be made more effective and efficient in a plethora of way:
• Utilising high quality material: Using high quality materials for the gears, bearings and
other parts of the system can help improve the performance and durability of the
system.
13
• Regular maintenance: Frequently maintaining the system, such as leaning and using
lubrication can help improve the performance and lifespan of the system.
• Adoption of a more effective design: The system efficiency can be increased by
selecting a gear or belt system with a more efficient design, for instance a planetary
gear system or timing belt system.
• Adding a cooling system: The use of an external cooling system or lubrication system
can help in decreasing the systems optimum temperature hence, enhancing its
performance
• Using better quality gears: Higher-quality gears are more precisely machined and
hence, they have a better surface finish, which can help them reduce the noise they
generate.
• Employing lubrication: Minimising metal to metal contact between the gears can be
achieved by using lubrication and this can result in reducing the noise the gears
produce.
6. The performance of a belt driving system can be impacted significantly by the belt angle. A
larger belt angle can prolong the belts lifespan as a result of reducing the amount of
bending stress on the belt however, it can induce more sliding between the belt and the
pulley. On the other hand, a smaller belt angle decreases the sliding that takes place
however, the bending stress is increased which can impact the longevity of the belt.
7. When a system has several belts, and these are combined, they may encounter the
following effects:
• Efficiency boost: By combining various belts into a single belt, the systems efficiency
is improved as this results in the amount of slippage in the system that takes place
reducing.
• Greater power transmission ability: A single belt that has a bigger width
and/or thickness can transfer more power than several belts that are thinner.
• Increased belt lifespan: Using a single belt may result in reducing the wear on the
belt compared to using multiple belts hence, this would potentially increase the
belt's lifespan.
8. When a belt drive system loses tension over time, this causes it to start slipping on the
pulley hence, resulting in a reduced amount of power being transferred to satisfy the
demand hence, causing the efficiency of the system to decrease and leading to wear being
caused on the belt. Sometimes the belt may even come off the pulley entirely, which could
14
damage to the system. To appropriate a belt that has lost its tension, a belt tensioner which
is a tool that exerts presser on the belt, can be used to keep the belt properly tensioned.
Conclusions.
In conclusion, the hand calculations that have been obtained in this report demonstrate that
the gear box system that has been designed reduces in power, however, increases in torque
1
by transmitting high torque at a low angular velocity from the input motor to the output belt
drive system.
Recommendations.
• Reducing stress and enhancing the gear system’s overall performance by using
high- quality gears comprised of robust materials like steel or bronze.
• Lubrication can also be used in order to decrease stress on the gear and improve
their lifespan.
• The design of gear systems can be improved using design optimisation and this
would lead to enhanced performance and improved lifespan.
15
References.
1
A. P. Agrawal, S. Ali, and S. Rathore, “Finite element stress analysis for shape optimization
of spur gear using ANSYS,” Materials Today: Proceedings, vol. 64, pp. 1147-1152,
2022.
1
X. Yang, E. Tofighi-Niaki, M. J. Zuo, Z. Tian, M. S. Safizadeh, and D. Qin, “Analysis of spur
gearbox dynamics considering tooth lubrication and tooth crack severity progression,"
Tribology International, vol. 178, p. 108027, 2023.
2
Y. Yang, J. Tang, N. Hu, G. Shen, Y. Li, and L. Zhang, “Research on the time-varying mesh
stiffness method and dynamic analysis of cracked spur gear system considering the
crack position,” Journal of Sound and Vibration, vol. 548, p. 117505, 2023.
1
H. Zhu, W. D. Zhu, and W. Fan, “Dynamic Modeling, simulation and experiment of Power
Transmission Belt Drives: A systematic review,” Journal of Sound and Vibration, vol.
491, p. 115759, 2021.
8
P. Bortnowski, W. Kawalec, R. Krbl, and M. Ozdoba, “Identification of conveyor belt tension
with the use of its transverse vibration frequencies,” Measurement, vol. 190, p.
110706, 2022.
5
^
J. Homi§in, R. Grega, P. KasSay, G. Fedorko, and V. Moln r, "Removal of systematic failure
of belt conveyor drive by reducing vibrations,” Engineering Failure Analysis, vol. 99,
pp. 192-202, 2019.
16
Machines and Mechanisms Coursework
ORIGINALITY REPORT
23
SIMILARITY
INDEX
% 3%
INTERNET SOURCES
7%
PUBLICATIONS
19%
STUDENT PAPERS
PRIMARY SOURCES
4
Submitted to Visayas State University
Student Paper
5
annals.fih.upt.ro
Internet Source
1%
1%
6 Anant Prakash Agrawal, Shahazad Ali, Sachin
Rathore. "Finite element stress analysis for
shape optimization of spur gear using ANSYS",
Materials Today: Proceedings, 2022 1%
Publication
9
Submitted to utcluj
Student Paper
10
Submitted to Furness College <1 %
Student Paper
13
Submitted to Ngee Ann Polytechnic
Student Paper
14
Computational Design of Rolling Bearings,
2016.
<1 %
Publication
<1 %
Off Exclude bibliography
Off
Machines and Mechanisms Coursework
GRADEMARK REPORT
FINAL GRADE
GENERAL COMMENTS
Instructor
The abstractis good.
66
There is no glossary (required for a formal report)
Calculation is
very good.
Critical
analysis does not exist.
PAGE 1
PAGE 2
PAGE 3
PAGE 4
QM
Split it (Dani Harmanto)
Split it
PAGE 5
PAGE 6
PAGE 7
PAGE 8
Text Comment. (Dani Harmanto) This is not correct schematic of the gear system
PAGE 9
PAGE 10
QMUnit missing (Dani Harmanto) Unit ?
PAGE 11
PAGE 12
PAGE 13
Text Comment. (Dani Harmanto) What happen with the power and number of belts ?
PAGE 14
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