Design Calculations ALL in 1

8/13/2019 Design Calculations ALL in 1

1/18

SELECTION OF MOTOR

INPUTS OUTPUTS

Pressure 320 bar

Displacement 280 lpm

Torque required 23 KNm

Speed Required 60 rpm

Power

Displacement

Max. Attainable Speed


2/18

SHAFT DESIGN CALCULATION

distance beeween bearings(L) 1160 INPUT

diameter of the shaft(mm) 105 INPUT

value of T(Nmm) 23800000 INPUT

value of M(Nmm) 0 INPUT

K(radius of gyration) 26.25

alpha 1.241369526

Km 1.5 INPUT

Kt 1.5 INPUT

F(N) 160384

Te(Nmm) 35795508.96

shear stress,t(MPa) 157.4851804Me(Nmm) 19204320.73

bending stress(MPa) 168.9833703

Allowable stress (Mpa) 350 INPUT

fos 2.222431336


3/18

SELECTION OF MOTORINPUTS OUTPUTS

Pressure available,p 320 320 bar FOR MAX. TORQUE REQUIREMENT

Flow rate avilable,Q 280 280 LPM MS 50 MS 83

Torque required,T 23 23 kNm Flow Rate 262.5 253.125 LPMSpeed required,N approx 60 approx 60 rpm Speed 52.54203 60.7889 rpm

Torque 24.93667 20.78389 kNm

Motor inputs MS 50 MS 83

Full Disp. Half Disp. FOR MAX. SPEED REQUIREMENT

Power,P 140 135 kW MS 50 MS 83

Displacement,D 4996 4164 cc/rev Pressure 300 289.2857 bar

Max. attainable speed 70 60 rpm Speed 56.04484 67.24304 rpm

MOTOR SELECTED MS 50


4/18

P = p x QN = Q / D (rpm)

T = 1.59 x 9.81 x 10-3

x p x D

P = p x Q

N = Q / D (rpm)


5/18

DRUM DESIGNINPUTS

Outer diameter of the drum 545.3 mm radius of gyration k

Inner diameter of the motor 495.3 mm k

Maximum bending moment 2870000 N-mm aAxial force F 40000 N effective torque Te

torque T 25410000 N-mm t

length ,L 600 mm T all

km 4 FOS

kt 4

T 380 Mpa 34Co Mb4

Bearing A

Axial load

C A


6/18

OUTPUTS

0.9083074 mm k = di / do

184.16606 K = (do2+ di

2)

1/2/4

1.0145434 a = 1/ (1- 0.0044(L/K))102975113 N-mm [{Kbx Mb+ ( x Fox dox (1+k2))} 2+ (Ktx T) 2]10.128495 Mpa t= 16 x Te/ (px do

3x (1

k

4))

219.26 Mpa

21.647837 FOS= t/T all

Bearing B

Radial load

BD

E


7/18

STRUCTURE DESIGNINPUTS

Outer diameter of the drum D 457.2 mm radius of gyration k

Inner diameter of the motor d 405 mm k

Maximum bending moment Mb 10770000 N-mm aAxial force F 40000 N effective torque Te

torque T 25410000 N-mm t

length ,L 1120 mm T all

km 4 FOS

kt 4

T 380 Mpa 34Co Mb4

Axialload

Bearing A Bearing B Bearing C

A

B

E


8/18

OUTPUTS

0.885826772 mm k = di / do

152.6959479 K = (do2+ di

2)

1/2/4

1.033349587 a = 1/ (1- 0.0044(L/K))112105253.5 N-mm [{Kbx Mb+ ( x Fox dox (1+k2)/8)} 2+ (Ktx T) 2]15.54707766 Mpa t= 16 x Te/ (px do

3x (1

k

4))

219.26 Mpa

14.10297194 FOS= t/ T all

Axial

load

Bearing D

C D


9/18


10/18

ON30000

A

FrA= 15000

OUTPUTS

radial load axial (Ka) Fr FaA FaB Equi N

30000 40000 15000 12000 32000 0.006218

30000 0.04 15000 12000 12000.02 155.4403

0.03 40000 0.015 0.012 20000.01 155.4403

15000 20000 7500 6000 16000 1865.283

22500 10000 11250 9000 14000 3730.566

0.03 0.04 0.015 0.012 0.032 93.26415

6000

Y Pa Pb (Ni*Qi*Pi3)A (Ni*Qi*Pi3)B

0.78 38400 49130 3.5206E+11 7.37333E+11

0.78 24360 24330.0248 2.24696E+15 2.23868E+15

0.78 0.02436 24800.0243 0.00224696 2.37094E+15

0.78 12180 24565 3.37044E+15 2.765E+16

0.78 18270 24447.5 2.27505E+16 5.45102E+16

0.78 0.02436 0.04913 0.001348176 0.011059998

2.83682E+16 8.67706E+16

Co Nm 60

123000 PmA 16783.9286 life of A 28.88955241 8024.876

123000 PmB 24363.5418 life of B 75.55973108 20988.81


11/18


12/18

SHAFT DESIGN CALCULATION

INPUTS OUTPUTS

Total length of the shaft(L) 1168 K(radius of gyration) 23.75

Diameter of the shaft(mm) 95 alpha 1.276141

Value of T(Nmm) 25400000 Load factor for motor 50.12

Value of M(Nmm) 0 F(N) 160384

Km 1.5 Te(Nmm) 31842892

Kt 1.25 shear stress,t(MPa) 189.1563

Allowable stress (Mpa) 375 Me(Nmm) 17136689

bending stress(MPa) 203.5959

FOS 1.982488


13/18

k = di / do

K = d/4

a = 1/ (1- 0.0044(L/K)) [{Kbx Mb+ ( x Fox d /8)} 2+ (Ktx T) 2]t= 16 x Te/ (px do

3x (1

k

4))

FOS= t/ T all


14/18

FASTENER SELECTION

INPUTS FLANGE DRUM STRUTURE OUTPUTS

a (Ref. Fig) 401 575.3 457.2 a

b (Ref. Fig) 361 535.3 430 Cos a

F (Ref. Fig) 60000 60000 60000 Max. Tensile Force, F1 ( N )

L (Ref. Fig) 265 600 225.5 Fb

No. of Bolts, 8 12 12 Maximum Tensile Load

Bolt area (Ac) 192 157 84.3 Tensile stress calculated

Tensile Stress Allowable,sall 640 640 640 FOS

shear stress allowable,tall 480 480 480 Shear load

shear stress

FOS

Torque 25000000 shear stress due to loadFOS

Ka 40000 40000

tensile stress 21.23142 39.54132068

i


15/18

FLANGE DRUM STRUTURE FORMULAE

22.5 15 15 a=1800.923879533 0.965926 0.965925826 cos(a*p/180)

6460.655979 6910.127 3263.208121 F1=2FL(a+bcos a)/(2a^2+b^2)

7500 5000 5000 Fb=F1/

11396.41756 9532.683 6891.084245 Ft = ( F1 + ( F1^2 + 4 x Fb^2)^)

59.35634147 81.94915 121.2860923 s = Ft /Ac + sa

10.78233571 7.809721 5.276779786 FOS = sall/ s

8166.089573 6077.62 5259.480184 Ft = ( F1^ + 4 x Fb^2)^)

42.53171653 38.71095 62.39003778 Ft= t/ Ac

11.28569546 12.39959 7.693535973 FOS = tall/ t

24.78916 t = Ft/(i* Ac * a)19.3633 FOS = tall/ t

i

i

i


16/18

By normal stress theory

By maximum shear stress theory

Stress due to torque


17/18

DESIGN OF SPLINEINPUTS LEFT RIGHT OUTPUTS LEFT

Displacement of the MS50 motor 4996 4996 cc/rev Torque on the splines T 2541.965

Pressure 320 320 bar PCD 120

Module m 5 5 OD male 129

Nominal diameter 130 95 mm Profile displacement 0.8

Pressure angle 20 20 deg Tooth thickness at PCD 10.76574

Number of teeth N 24 17 Tooth height 4.5

Effective length 120 120 mm Material shear strength 328.89

Application factor ka 1.8 1.8 Spline shear stress at PCD 8.198474

Load distance factor km 1 1 Spline shear stress at PCD 80.42703

Life factor kf 0.3 0.3 Compressive stress 2.179325

Material yeild strength 570 650 Mpa Compressive stress 21.37918

FOS 4.089297


18/18

RIGHT

2541.965 Nm

85 mm

94 mm

0.8 mm

10.76574 mm

4.5 mm

375.05 Mpa

16.34021 kgf/mm2

160.2975 MPa

4.343568 kgf/mm2

42.61041 MPa

2.339713

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Design Calculations ALL in 1