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UNIVERSITI TENAGA NASIONAL
COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
MEMB333 - MACHINE DESIGN
SEMESTER 2 2012/2013
PROJECT TITLE : DESIGN OF TURBINE GEAR-BOX
NAME STUDENT ID
MOHAMAD ASYRAF BIN MOHAMAD AZMI ME087004
MUHAMMAD FADIL ARSAD BIN MOHD USOPE ME087018
MUHAMMAD AMIN BIN ZAKARIA ME087006
SYARIR AKRAM BIN JAMALUDDIN ME087022
SECTION : 01B
LECTURER :MUHAMMAD FAIRUZ BIN ABDUL JALAL
Due Date Submitted Date
30/12/2012 30/12/2012
ABSTRACT
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A! "#$ "%"&$' (D$!%)* +, T./%*$ G$.-B+' %3&%$!' "#%! .+5$" .$%.$! ! "+
*&!%! *9 9$!%)* "./%*$ )$. /+: T+ 9$!%)* "#$ )$. /+' ;$ #&&"%+*! *9 $$.%3$*"! %*
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TABLE OF CONTENT
C!"#$"# P%&$
1'0 I*".+9"%+*
2'0 P.+5$" T%"&$ 4
3'0 P.+5$" O/5$"%&&"%+* @-16
*'0 S#," >&&"%+* 17-22
+'0 B$.%*) >&&"%+* 2-24
,'0 K$! >&&"%+* 2@-28
'0 M!! *9 >+!"! 2
10'0D%!!!%+* *9 >+*&!%+* 0
11'0A$*9%$! 1-@
12'0R$,$.$*$! 6
1'0 INTRODUCTION
2
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A "./%*$ %! /!%&& .+". 3$#*%& 9$
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2'0 PROJECT TITLE
D$!%)* +, T./%*$ G$.-B+:
3'0 PROJECT OBJECTIVE
T+ 9$!%)* "./%*$ )$.-/+ ;#%# +*!%!"! +, !. )$.!' .+&&%*) $&$3$*" /$.%*)!' !#,"!'
?$! +. .$!! ,%"!' !$&! *9 #+!%*):
('0 SPECIFICATIONS
G$. /+ !$%,%"%+*!
$%)#" M%*%3& *9 +3"
S%=$ M%*%3& *9 +3"
D$!%)* &%,$ 10 $.! %* +*"%*+! +$."%+*
$? &%*? 9$!%)* D$!%)* "#$ %*" !#," ?$ +. +"" !#," ?$ "+ %$&9 ,"+. +,
!,$" /+" 1:@
P.$9$"$.3%*$ + !%*) ,&& &+9 +*9%"%+*!' FS 2:0
D$!%)* )$.! R0 FS, 1:2 !.,$' 1:@ /$*9%*)
O"#$. ."! R0 FS, 2:0' FS 2:0
4
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)'0 GEARS CALCULATION
M+"+. %*" 00? ;""!
O"" !$$9 +"" !#," .+""%+* [email protected]
A!!3"%+*!
1: T#$ 9$!%)* +, "#$ )$. /+ %! "+ %*.$!$ "#$ !$$9 ,.+3 "#$ %*" .3: $ %*.$!$ %" /
:612 ,.+3 "#$ %*" .3:
T#$.$,+.$' "#$ %*" !$$9 %!-
2@0 .3 :612 816:@ .3
T#$ )$. ."%+ %! 1 :612
2: I*" )$.-
D%3$"$. @ %*
T#%?*$!! 1:@ %*
N) 1@ "$$"#
: O"" )$. %*%+*-
D%3$"$. 2 %*
T#%?*$!! 1:@ %*
N N):612
7 "$$"#
@
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G$. "++"# !$%,%"%+*!
P9 6
T#$.$,+.$' +.!$ %"# P9 20
P.3$"$. E"%+* ' P9 6 %.&. "++"# "#%?*$!! 1:@71P9 0:262
F%&&$" .9%!-/!% .? 0:00P9 0:0@0
M%*%33 /!% &$.*$ 0:2@0P9 0:042
M%*%33 ;%9"# +, "+ &*9 0:2@0P9 0:042
>&$.*$!#
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816:@ .3 (816.5 rpm)x2
60 8@:@0 .9!$
T P
(402.3hp )(
6600 lb .sechp
)
85.50 rad /sec 10@4:74 &/:%*
T3 10@4:74 &/:%*
T3%* 0 &/:%*
T T3 T3%* 2
1@@27:7 &/:%*T3 T3 T3%* 2
1@@27:7 &/:%*
"3 T3 .)
10@4:74 &/:%* 11:2@ %*
2760:42 &/
"3%* T3%* .)
0
" 1@@27:7 &/ %* 11:2@ %*
180:21 &/
"3 1@@27:7 &/ %* 11:2@ %*
180:21 &/
)'2 O## G$% P4"4!"5
7
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2@0 .3 (2950 rpm)x2
60 08:2 .9!$
T P
(402.3hp )(
6600 lb .sechp
)
308.92rad /sec 8@@:04 &/:%*
T3 8@@:04 &/:%*
T3%* 0
T T3 T3%* 2 427:@2 &/:%*
T3 T3 T3%* 2
427:@2 &/:%*
"3 T3 .
8@@:04 &/:%* :08 %*
270:@ &/
"3%* T3%* .
0
" 427:@2 &/:%* : 08 %*
1@:2 &/
"3 427:@2 &/:%* : 08 %*
1@:2 &/
B "?%*) "#$ .$!!.$ *)&$ ! 2@ *9 !%*) "#$ ,+.3& " +! 2@' "+ &&"$ "#$
,+.$! "#" $%!" +* $# ." +, "#$ !!"$3:
F+. )$. ." F+. %*%+* ."
"3 2760:42 &/ "3 270:@ &/
"3 180:21 &/ "3 1@:2 &/
" 180:21 &/ " 1@:2 &/
8
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)'3 O6$% G$% C%7%#4!"
F+. "#$ )$. &&"%+*' "#$.$ %! +*& +*$ ." +, &&"%+* "#" %! %*" )$.-%*%+* +""
!%*$ %" %! "#$ !%*)&$ !")$ )$. /+:
A!!3"%+*
1: T#$ !".$!!$! "#" ;%&& /$ *&!$! .$ "#$ /$*9%*) !".$!! *9 "#$ !.,$! !".$!!:
2: T#$ /$*9%*) !".$!! $"%+* ,+. !".$!!
/ Wt .Pd .Ka .Km. Ks. Ka . Kb. Ki
F .J . Kv
" 2760:42 &/
/ P9 6
F$ ;%9"# ,"+.' F 12 P9
2
9 A!!3$ AGMA &%" F"+. %! ,+. %..," $*)%*$ 9.%
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5 M+*"%*) F"+.'
!!3$ F' F$ ;%9"# 2
K3 1:6 R$,$. "+ T/&$ 12-16
K 1:0 9$ "+ *%,+.3 &+9 R$,$. "+ T/&$ 12-17
? A!!3$ /$*9%*) )$+3$". ,"+.' J ,+. 2@ ' ,&& 9$"# "$$"# ;%"# HPST> &+9%*)
J) 0:@4
J 0:487@
& T?%*)!!3$ -
K! 1
K/ 1
KI1
3 T#$ /$*9%*) !".$!! ,+. %*%+* *9 )$.
/)Wt .Pd . Ka .Km. Ks .Ka . Ki
F . J . Kv
(2760.42611.6111)
20.5430.79
0887: !%
0:0088 M!%
/Wt .Pd . Ka .Km. Ks .Ka . Kb
F .J . Kv
(2790.59611.6111)
20.48750.79
4780:48 !%
0:0@M !%
10
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: S.,$ S".$!!
T#$ !.,$ !".$!! ,+. %*%+*-)$. - !!3$ "#$ 3"$.%& ,+. "#$ %*%+* *9 )$. 39$ +,
!"$$& !+ E E) 0E6 !% C C 0:28 ,.+3 "/&$ 12-18
E&!"% +$,,%%$*" ,+. !"$$&' > 2276 F.+3 $"%+* 12:2
S.,$ ,"+.' >, 1 $&& ,%*%!#$9 )$. / +*'>3'>
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P4"4!" I8$5
1 . 1P9 - .+!
12 /Pd +!
:08 16 - :08 +! 2@ Q 0:@ 6 +! 2@Q
1:18
2 > !%* - 1
. .) !%* - 1
:08 11:2@ !%* 2@ 1:18
4:87
I +!1/
/1 12 9
+! 2@ 11:18 14:876:16
0:14
9 S.,$ !".$!! %* %*%+*-)$. 3$!#
!!3$ >'>3'>
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4: >&&"$ +..$"$9 /$*9%*) ,"%)$ !".$*)"#
F+. )$.
% !!3$ !%*) AGMA &!! A4 !"$$&' "#.+)# #.9$*$9 "+ @0HB
T#$ *+..$"$9 /$*9%*) ,"%)$ !".$*)"# -
S,/ 62@ 174HB - 0:126HB2 ----- !%*) ).9$ 2 3%33
62@ 174@0 - 0:126@02
@1700 !%
0:0@17 M!%
%% N3/$. +, &$!-
A!!3$ 10 $. &%,$ %* +*"%*+! +$."%+*:N [email protected] 3%*#.8760#.. 10 $.
1:@@E10 &$!
%%% T#$
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% !!3$ !%*) AGMA &!! A@ !"$$&' "#.+)# #.9$*$9 "+ 400HB
T#$ *+..$"$9 /$*9%*) ,"%)$ !".$*)"# -
S,/ 62@ 174HB - 0:126HB2 ----- !%*) ).9$ 2 3%33
62@ 174400 - 0:1264002
@@67@ !%
0:0@6 M!%
%% N3/$. +, &$!
A!!3$ 10 $. &%,$ %* +*"%*+! +$."%+*:
N [email protected] 3%*#.8760#.. 10 $.
1:@@E10 &$!
%%% T#$
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@: >&&"$ +..$"$9 !.,$ ,"%)$ !".$*)"#
F+. )$. -
% F+. * AGMA A4 !"$$&' "#.+)# #.9$*$9 "+ 60 HB
S, 27000 64HB ---- !%*) ).9$ 2 3%33
27000 6460
1@8040 !%
0:1@8 M!%
%% >L2:466 1:@@E10 -0:0@6
0:66%%% >" K"1
%.K.0:8@
H 1 !!3$ )$. *9 %*%+* +, "#$ !3$ #.9*$!! 3"$.%&
L:>H >T:>. S,
0:66110:8@Q 0:1@8 M!%
0:12 M!%
F+. %*%+* -
% F+. * AGMA A@ !"$$&' "#.+)# #.9$*$9 "+ 400 HB
S, 27000 64HB ---- !%*) ).9$ 2 3%33
27000 64400
172600 !%
0:17 M!%
1@
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%% >L2:466 1:@@E10 -0:0@6
0:66
%%% >" K"1
%.K.0:8@
H 1 !!3$ )$. *9 %*%+* +, "#$ !3$ #.9*$!! 3"$.%&
L:>H >T:>. S,
0:66110:8@Q 0:17 M!%
0:182 M!%
6:F"+. +, !,$" ,+. )$.' %*%+* *9 !.,$ )$.-%*%+*
% FS)$. S,/ /)
0:0478 M!% 0:0088 M!%
N/ )$. 1:@@
%% FS%*%+* S,/ /
0:0@181M!% 0:04780M !%
N/ %*%+* 1:@
%%% FS%9&$.-)$. S, %-)
0:12 M!% 0:11 M!%
N %9&$.-)$. 1:1
%
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*'0 SHAFT CALCULATION
I* "#%! !#," *&!%!' )+" 2 !#,"! *$$9$9 "+ /$ *&!%! ;#%# .$ %*" !#," *9 "#$ +""
!#,":
I* "#$ !3$ "%3$' ;$ !!3$ "#" /+"# !#,"! !%*) "#$ !3$ 3"$.%& "#! "#$ ;%&& ##"$. 6:6
L+9 >&+9 1 /$*9%*) &+9
S%=$ >!%=$ 1
S.,$ R$,$. T/&$ 6- A 2:7/ -0:26@ 3#%*$9 +&9
.+&&$9
>!.,$ A: S"/ 2:7 64 -0:26@ 0:84
T$3$.".$ >"$3 1
R$&%/%&%" >.$&%/ 0:87 R 0 R$,$. T/&$ 6-4
M+9%,%$9 E*9.*$ L%3%"
S, >&+9: >!%=$: >!., : >"$3 : >.$&%/ : S,
24111:6 ?!%
17
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*'1 A"%94 !; I"# S
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"m="a=99.1995lb .
@: F%*9%*) m *9 a
m=max+mi#
2
a=maxmi#
2
a=m=186.4340
2
a=m=93.217 lb .
6: >&&"%*) *+..$"$9 $*9.*$ !".$*)"#' $%
$%=0.5 $&t
$%=0.5(64000)
$%=32000psi #$.$ "#$ 3"$.%& !$9 %! SAE 1018 +&9-.+&&$9 !"$$& ;%"# $&t 64 ?!% *9 $' @4
?!% )%
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#$.$ *+"# !$*!%"%
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*'2 A"%94 !; O## S
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(*f"a )
2+3
4(*fsa)
2
($ f+ (
*fm"m )
2
+
3
4 (*fsmm)
2
$&t
)
1
3
32Nsf
d(&tp&t=
2
(
(99.1995
))
2+3
4((2.15)(37.2868))2
2
(99.1995())
(2+ 34 ((2.15)(37.2868))2
64000 )
32(2.5)
d(&tp&t=
d(&tp&t= 0:610@ %*
22
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*'3 A"%94 !; S
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+'0 BEARING CALCULATION
1: I*" /$.%*)
dshaft=0.6872
beari#g #&mber=6304
C=3000 lb
C(=1930 lb
P=
/shaft=
186.434
4=46.6085 lb
K0=0.21(0eliabilit'99 )
C(
P
1930
46.6085
/10=
/P=K0/10=0.21(71.003x103)=14.911x 103 c'cles
A!!3$9
&9 0:7@
S+ /$.%*) &$*)"#' & 0:7@0:6872 %*
0:@1@4 %*
R$,$. F%).$ 11-2T$"/++? M#%*$ D$!%)* 4"#E9%"%+* ): 688
B$.%*) *3/$. 604
B+.$I*"$.*& 9%3$"$. 0:7874 %*
O"$. 9%3$"$. 2:0472 %*
%9"# 0:@06 %*
24
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2: O"" /$.%*)
dshaft=0.6105
beari#g #&mber=6303
C=2320 lb
C(=1460 lb
P=
/shaft=
93.217
4=23.3043 lb
K0=0.21(0eliabilit'99 )
C(
P
1460
23.3043
/10=
/P=K0/10=0.21(2.459x105)=5.164x104 c'cles
A!!3$9
&9 0:7@
S+ /$.%*) &$*)"#' & 0:7@ 0.6105 %*
0:4@7 %*
R$,$. F%).$ 11-2T$"/++? M#%*$ D$!%)* 4"#E9%"%+* ): 688
B$.%*) *3/$. 60
B+.$I*"$.*& 9%3$"$. 0:66 %*
O"$. 9%3$"$. 1:8@04 %*
%9"# 0:@118 %*
2@
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,'0 =E>S CALCULATION
1: 1!"S#," )$. !#,"
M$* "+.$ :217 &/: %* D%3$"$. 0:6872 %*
A&"$.*"%*) "+.$ :217 &/: %*
F3 Fa=a
r=
93.217
0.3436=271.295 lb
A!!3"%+* X %*# +, "#$ &"$.*"%*) *9 3$* !#$. !".$!! +3+*$*"!
B!$9 +* T/&$ 10-2 T$"/++?: A!!3$9 ?$ &$*)"# 0:@ %*
1a= Fa
A s h ear=
271.295
(0.187 )(0.5)= 201:@@ !%
1m=Fm
A shear=
271.295
(0.187 )(0.5)=2901.55psi
C+* M%!$! $%
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N,
1
2 a
$e +
2 m
$&t
= 1
4103.411
24111.36+4103.411
64000
=4:268
M%33 ,+.$ +, "#$ ?$
2max=
Fm+FaA beari#g
=271.295+271.295
0.125(0.5) =8681.44psi
S,$" ,"+. ,+. /$.%*) ,%&.$
Ns= $'
max=
54000
8681.44=6.22
A&& "#$ !!3"%+* %! ,+. ;+.!" !$ !$*.%+: T+ ,%*9 "#$ !,$" ,"+.' ,%.!"' ;$ 3!" ,%*9 "#$
r /d ."%+! ,+. "#%! $."%* +%*" *9 )$" "#$
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Kfsm=Kfs= 1:8@
d1=
{32Nf
[(Kf
"a
$ f
)
2
+3
4
(Kfsm
m
$'
)
2
]
1 /2
}
1/3
Nf= 4:1
2: 2*9 S#," %*%+* !#,"
M$* "+.$ 7:287 &/: %* D%3$"$. 0:610@ %*#
A&"$.*"%*) "+.$ 7:287 &/: %*
Fa=a
r = 37.287
0.30525=122.152 lb
Fm=m
r =
37.287
0.30525=122.152 lb
A!!3"%+* X %*# +, "#$ &"$.*"%*) *9 3$* !#$. !".$!! +3+*$*"!
A!!3$9 ?$ &$*)"# 0:@ %*#
1a= Fa
A s h ear
= 122.152
(0.187)(0.5)
= 106:4 !%
0.187
0.5
()
1m= Fm
A sh ear=
122.152
C+* M%!$! $%
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2m=x
2+'2x
2'
2+3 12x'=3(1306.439 )=2262.819psi
F.+3 "#%! ;$ #%$
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Kts1Kfs=1+,
Kfs=1+0.5 (2.751 )=1.875
Kfsm=Kfs= 1:87@
d2={32Nf [(Kf "a$f)
2
+3
4 (Kfsm m$')2
]1 /2
}1/3
Nf= :1
'0 MASS AND COSTS
P %#M %
? &5
C ! #
RM5
G$.! 14:20 7:10
S#,"! K$! *9 B$.%*)! 4:86 2:41
H+!%*) 20 1@:00
T!#% :06 24:@1
T%.$ 2: M!! * 9 >+ ! " ! + , E # P. "
H$*$' "#$ "+"& 3!! +, "#$ )$./+ %! .+*9 :06 ?): T#$ .; 3"$.%&! +!" ;! /+"
RM 24:@1: I*&9%*) "#$ ;+.?3*!#%' "#$ "+"& +!"! .$# /+" RM 200:00:
0
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10'0 DISCUSSION AND CONCLUSION
F.+3 "#%! (D$!%)* +, T./%*$ G$.-B+ .+5$"' ;$ #
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"./%*$ )$./+ #
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D4%&%@ 2I*" S#,"
D4%&%@ 3 O"" S#,"
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D4%&%@ ( P%*%+* 1
D4%&%@ ) O"!%9$
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D4%&%@ * B$.%*)' S. G$. *9 K$
@
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D4%&%@ + G$./+ %* %*93%&& "./%*$
6
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12'0 REFERENCES
1: T$"/++?
M#%*$ D$!%)*' A* I*"$)."$9 A.+#' 4"#E9%"%+*
2: I*"$.*$"
#""$*:;%?%$9%:+.);%?%T./%*$
#""$*:;%?%$9%:+.);%?%T.*!3%!!%+*V3$#*%!
#""$*:;%?%$9%:+.);%?%A$!!+.V9.%