TABLE OF CONTENTS
1. Abstract
2. Problem Understanding
3. Design Assumptions
4. Spur Gear Design
5. Shaft Design
6. Bearing Selection
7. Material Selection
8. Assembly Layout
9. Conclusions
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1. ABSTRACT
This report presents the complete design and analysis of a conveyor shaft
assembly used for transmitting 10 kW power from an electric motor to a
driven roller through a spur gear mechanism. The assembly consists of a
transmission shaft, spur gears, and rolling element bearings.
The design process includes gear ratio determination, spur gear sizing,
shaft diameter calculation under combined bending and torsional loading,
and bearing selection based on dynamic load rating and life calculations.
All calculations were performed using machine design principles,
standard engineering equations, and relevant assumptions to ensure
safe operation, manufacturability, and cost effectiveness.
2. PROBLEM UNDERSTANDING
The conveyor system requires the transmission of mechanical power from
a high-speed electric motor operating at 1200 rpm to a driven roller
operating at 400 rpm. Since the driven roller rotates at one-third
the motor speed, a spur gear reduction system is required.
The shaft is supported on rolling bearings separated by a distance
of 0.8 m. The shaft must safely withstand torsional and bending loads
generated during power transmission while maintaining a minimum
factor of safety of 2.
The design must also ensure economical manufacturing, adequate fatigue
strength, and compatibility with standard engineering components.
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3. DESIGN ASSUMPTIONS
• Spur gears are assumed to transmit steady power.
• Shock and fatigue factors are selected according to ASME recommendations.
• Bearing loading is assumed primarily radial.
• Standard module system is adopted for gear sizing.
• Medium carbon steel is selected for shaft material.
• Standard deep groove ball bearings are considered.
4. SPUR GEAR DESIGN
4.1 Gear Ratio
Gear ratio is determined using:
G = N₁ / N₂
G= 1200 / 400
G = 3.0
4.2 Number of Teeth
Assume pinion teeth:
Tₚ = 20
Gear teeth:
Tg = i × Tₚ
Tg = 3.0 × 20
Tg = 60
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4.3 Pitch Circle Diameter
Pitch circle diameter equation:
D=m×T
For pinion:
Dₚ = 4 × 20
Dₚ = 80 mm
For gear:
Dg = 4 × 60
Dg = 240 mm
4.4 Pitch Line Velocity
Pitch line velocity is calculated using:
V = πDN / 60
V = π × (80/1000) × 1200 / 60
V = 5.027 m/s
4.5 Tangential Force
Tangential force acting on gear teeth:
Fₜ = P / V
Fₜ = 10000 / 5.027
Fₜ = 1989.44 N
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4.6 Lewis Bending Equation
Lewis form factor:
y = 0.154 − (0.912 / Tₚ)
y = 0.154 − (0.912 / 20)
y = 0.1084
Face width:
b = 10 × m
b = 10 × 4
b = 40 mm
Lewis bending stress equation:
σ = Fₜ / (b × m × y)
σ = 1989.44 / (40 × 4 × 0.1084)
σ = 114.70 MPa
The calculated bending stress is within safe allowable limits, therefore the selected spur
gear dimensions are acceptable.
5. SHAFT DESIGN
5.1 Torque Transmitted
Torque transmitted by the shaft:
T = (9550 × P) / N
T = (9550 × 10) / 1200
T = 79583.33 N-mm
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5.2 Bending Moment
Assumed bending moment:
M = 2T
M = 2 × 79583.33
M = 159166.67 N-mm
5.3 Equivalent Torque
Equivalent torque according to ASME code:
Te = √[(KbM)² + (KtT)²]
Kb = 1.5
Kt = 1.2
Te = √[(1.5 × 159166.67)² + (1.2 × 79583.33)²]
Te = 257141.62 N-mm
5.4 Shaft Diameter
Allowable shear stress:
τ = σ_allow / FOS
τ = 250 / 2
τ = 125.00 MPa
Shaft diameter equation:
d = [16Te / (πτ)]^(1/3)
d = [(16 × 257141.62) / (π × 125000000.00)]^(1/3)
d = 0.22 mm
Selected standard shaft diameter:
d = 35 mm
The selected shaft diameter provides adequate strength under
combined bending and torsional loading conditions.
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6. BEARING SELECTION
6.1 Radial Load
Assume radial load on bearing equals tangential force:
Fr = Ft
Fr = 1989.44 N
6.2 Bearing Life
Required bearing life:
L10 = 20000 hours
Life in million revolutions:
L = (60 × N × L10) / 10⁶
L = (60 × 1200 × 20000) / 10⁶
L = 1440.00 million revolutions
6.3 Dynamic Load Rating
Dynamic load rating:
C = Fr × L^(1/3)
C = 1989.44 × (1440.00)^(1/3)
C = 22465.58 N
Selected Bearing:
6207 Ball Bearing
The selected bearing satisfies the required life and loading conditions while maintaining
availability and economical cost.
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7. MATERIAL SELECTION
AISI 1045 medium carbon steel is selected for the shaft because of its good
machinability, torsional strength, and cost efficiency.
Alloy steel is selected for spur gears because of improved wear
resistance and fatigue strength.
Standard hardened chromium steel bearings are selected
due to their high fatigue life and industrial availability.
8. ASSEMBLY LAYOUT
The assembly layout below illustrates the arrangement of the
shaft, bearings, and spur gear within the conveyor transmission
system.
9. CONCLUSIONS
The conveyor shaft assembly was successfully designed for transmitting 10 kW power
from a 1200 rpm motor to a 400 rpm driven roller.
The designed spur gear system achieves the required velocity ratio of 3:1 while
maintaining safe bending stress levels.
The shaft diameter of 35 mm satisfies combined bending and torsional loading
requirements with a factor of safety greater than 2.
The selected rolling bearing satisfies dynamic load and life requirements while ensuring
manufacturability, availability, and economical operation.