FIRST PARTIAL

REPORT
Prepared by: Darline Y. Ferrer Cabán
Joshua Rosario Avilés
Darién Meléndez Escalante
Eric Nieves Colon
I. Problem Statement
Data Value Element Slope at location (radians)
Group # 1 Bearing (Ball) 0.0012
Power EM (kw) 40
RPM (EM) 1500 Gear (Spur) 0.0008
X 0.6
N1 1.5 Pulley 0.0024
N2 1.25
N3 1.3 Table #2: Given Data Restrictions
AD 70 Safety Factor 2.0
AG 150
AJ 200 Tensile Strength 928 Mpa
AM 250 Yield Strength 758 Mpa
dG 180 Material selection AISI 5120 Steel
dD 120
Treatment Cold Rolled
dJ 280
𝜃1 60 Elastic Modulus 200 Gpa
𝜃2 30 D/d ratio 1.1
𝜃3 15 r/d ratio 0.06
Table #1: Given Data K - Reliability 97.5 %

Table #3: Assumptions and selection

Figure #1: Diagram; Group #1
II. Free Body Diagrams

Figure #2: Free body diagram with forces and reactions Figure #3: Free body diagram plane reactions (X-Y) and (X-Z)
III. Calculations
Torque: Pulley reactions:
Equations: 16,000𝑊 𝑇1 = 14 ∗ 𝑇2 229.183𝑁 ∗ 𝑚
2π 𝑇𝐷 = = 152.788𝑁 ∗ 𝑚
• ω = RPM ∗ 60s 104.72 𝑟𝑎𝑑/𝑠 = 14 ∗ 𝑇2 − 𝑇2 ∗ 0.140𝑚
P
1RPM 40,000𝑊 229.183𝑁 ∗ 𝑚
• T= 𝑇𝐺 = = 381.971𝑁 ∗ 𝑚 𝑇2 = = 125.925𝑁
W 104.72 𝑟𝑎𝑑/𝑠 13 ∗ 0.140𝑚
• P = PEM ∗ X 24,000𝑊 𝑇1 = 14 ∗ 125.925𝑁 = 1,762.946𝑁
T 𝑇𝐽 = = 229.183𝑁 ∗ 𝑚 280𝑚𝑚 − 224𝑚𝑚
• Ft = 104.72 𝑟𝑎𝑑/𝑠 𝛼 = 𝑠𝑖𝑛−1 = 4.01°
r
• Fr = tan(Pressure angle) ∗ Ft 2 ∗ 400𝑚𝑚
T
• R = T1 → T1 = R ∗ T2 Tangential forces: Diameters:
2 152.788𝑁 ∗ 𝑚 𝑑𝐽 280𝑚𝑚
• τ = T1 − T2 ∗ r 𝐹𝑡𝐷 = = 2,546.46𝑁 𝑑𝑁 = = = 224𝑚𝑚
RPMb d d 0.060𝑚 𝑁2 1.25
• N2 = = d J → dN = NJ 381.971𝑁 ∗ 𝑚
RPMp N 2 𝐹𝑡𝐺 = = 4,244.12𝑁
RPME RPME 0.090𝑚
• RPMG
= N1 → RPMG = N1
Resultant moment:
MB = (−16.566)2 +(7.644)2 = 18.244 N ∗ m
Radial forces:
Angular velocity of the shaf𝐭: 𝐹𝑟𝐷 = tan 20° ∗ 2,546.46𝑁 MC = (−198.792)2 +(91.73)2 = 218.935 N ∗ m
1500 = 926.84𝑁 MD = (−231.924)2 +(107.018)2 = 255.424 N ∗ m
RPMG = = 1000RPM
1.5 𝐹𝑟𝐺 = tan 20° ∗ 4,244.12𝑁 ME = (−238.060)2 +(124.668)2 = 268.727 N ∗ m
2π
= 1,544.73𝑁 MF = (−274.890)2 +(230.57)2 = 358.785 N ∗ m
W = 1000RPM ∗ 60s
1RPM MG = (−281.015)2 +(248.220)2 = 374.943N ∗ m
= 104.72 rad/s Critical Point: MH = (−258.120 )2 +(231.272)2 = 346.572N ∗ m
MG = 374.943N ∗ m MI = (−189.434)2 +(180.427)2 = 261.608N ∗ m
Power: MJ = (−166.539)2 +(163.479)2 = 233.367 N ∗ m
PJ = 40kW ∗ 0.6 = 24kW MK = (−133.231)2 +(130.783)2 = 186.694N ∗ m
PD = 40kW ∗ (1 − 0.6) = 16kW ML = (−16.654)2 +(16.348)2 = 23.336. N ∗ m
IV. Reactions and Moments
Reactions at D: Reactions at X-Y:
F Dy = −FrD ∗ sin θ3 − FtD ∗ cos(θ3 )
෍ 𝑀𝐴 = 0 → −2,699.574𝑁 ∗ 0.070𝑚 + −2,903.149𝑁 ∗ 0.150𝑚 + −1,041.264𝑁 ∗ 0.250𝑚 + 𝑀𝑦 ∗ 0.250𝑚 = 0
F Dy = −926.836 ∗ sin 15° − 2,546.46 ∗ cos(15°)
F Dy = −2,699.574 N 𝑀𝑦 = 3,330.781𝑁
F Dz = −FrD ∗ cos θ3 + FtD ∗ sin(θ3 )
෍ 𝐹𝑦 = 0 → 𝐴𝑦 −2,699.574𝑁 − 2,903.149𝑁 − 1,041.264𝑁 + 3,330.781𝑁 = 0
F Dz = −926.836 ∗ cos 15° + 2,546.46 ∗ sin(15°)
F Dz = −236.182 N 𝐴𝑦 = 3,313.206𝑁

Reactions at G: Reactions at X-Z:

෍ FGy = 1,544.733N ∗ sin 30° − 4,244.12N ∗ cos(30°) ෍ 𝑀𝐴 = 0 → −236.182𝑁 ∗ 0.070𝑚 + 3,459.838𝑁 ∗ 0.150𝑚 + 1,574.766𝑁 ∗ 0.200𝑚 + −𝑀𝑧 ∗ 0.250𝑚 = 0

FGy = −2,903.149N 𝑀𝑧 = −3,269.585𝑁

෍ FGz = 1,544.733N ∗ cos 30° + 4,244.12N ∗ sin(30°) ෍ 𝐹𝑧 = 0 → −𝐴𝑧 − 236.182𝑁 + 3,459.838𝑁 + 1,574.766𝑁 − 3,269.585𝑁 = 0

FGz = 3,459.838N 𝐴𝑧 = −1,528.837𝑁

Reactions at E:
Bending Moments:
෍ FJy = −T2 ∗ cos θ + α − T1 ∗ cos θ − α
𝑀𝐷𝑥𝑦 = 3,313.206𝑁 ∗ 0.070𝑚 = 231.924𝑁 ∗ 𝑚
𝑀𝐺𝑥𝑦 = 231.924𝑁 ∗ 𝑚 + 613.632𝑁 ∗ 0.080𝑚 = 281.015𝑁 ∗ 𝑚
෍ FJy = −125.925N ∗ cos 60° + 4.01° − 1,762.946N ∗ cos 60° − 4.01°
𝑀𝐽𝑥𝑦 = 281.015𝑁 ∗ 𝑚 + −2,289.517𝑁 ∗ 0.050𝑚 = 166.539𝑁 ∗ 𝑚
= −1,041.264N
𝑀𝐷𝑥𝑧 = −1,528.837𝑁 ∗ 0.070𝑚 = −107.018𝑁 ∗ 𝑚
෍ FJz = T2 ∗ sin θ + α + T1 ∗ sin θ − α 𝑀𝐺𝑥𝑧 = −107.018𝑁 ∗ 𝑚 + −1,765.019𝑁 ∗ 0.080𝑚 = −248.220𝑁 ∗ 𝑚
𝑀𝐽𝑥𝑧 = −248.220𝑁 ∗ 𝑚 + 1,694.819N ∗ 0.050m = −163.480N ∗ m
෍ FJZ = 125.925N ∗ sin 60° + 4.01° + 1,762.946N ∗ sin 60° − 4.01°

= 1,574.567N
V. Shear Diagrams
Shear Diagram X-Y Shear Diagram X-Z
4000 4000

3000
3000

2000
2000
1000
1000
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0
-1000 0 0.05 0.1 0.15 0.2 0.25 0.3
-1000
-2000

-3000 -2000

-4000 -3000

Shear X-Y Shear X-Z

Figure #4: Shear Force Diagram in X-Y Figure #5: Shear Force Diagram in X-Z
VI. Moment Diagrams
Moment Diagram X-Y 0
Moment Diagram X-Z 0
281.015
300 274.89 0
238.06 0 0.05 0.1 0.15 0.2 0.25 0.3
258.12
231.924 -7.644 -16.348
250 -50

198.792 189.434
200 -91.73
166.539 -100
-130.783
133.231 -107.018
150 -150
-124.688 -163.48
100 -200 -180.427
16.654 -231.272
50 -230.57
-250
0 16.566 0 -248.22
0
-300
0 0.05 0.1 0.15 0.2 0.25 0.3

Figure #6: Moment Diagram in X-Y Figure #7: Moment Diagram in X-Z
Bending Moments (X-Y): Bending Moments (X-Z):
MDxy = 3,313.206N ∗ 0.070m = 231.924 N ∗ m MDxz = −1,528.837N ∗ 0.070m = −107.018 N ∗ m
MGxy = 231.924N ∗ m + 613.632N ∗ 0.080m = 281.015 N ∗ m MGxz = −107.018N ∗ m + −1,765.019N ∗ 0.080m = −248.220 N ∗ m
MJxy = 281.015N ∗ m + −2,289.517N ∗ 0.050m = 166.539 N ∗ m MJxz = −248.220N ∗ m + 1,694.819N ∗ 0.050m = −163.480 N ∗ m
VII. Resultant Moment and Torque Diagrams
Moment Resultant Torque Diagram
374.943
400 358.786 200
346.573
350 268.728 150
261.609
233.368 100
300 255.424
50
250 218.935 186.694 0
200 0 0.05 0.1 0.15 0.2 0.25 0.3
-50
150 -100
-150
100 18.244
23.337 -200
50
0 0 -250
0
0 0.05 0.1 0.15 0.2 0.25 0.3 Torque (N*m)

Figure #8: Resultant Moment Diagram Figure #9: Torque Diagram

Resultant moment: Torque:
16,000W
MB = (−16.566)2 +(7.644)2 = 18.244 N ∗ m TD = = 152.788 N ∗ m
104.72 rad/s
MC = (−198.792)2 +(91.73)2 = 218.935 N ∗ m 40,000W
TG = = 381.971 N ∗ m
104.72 rad/s
MD = (−231.924)2 +(107.018)2 = 255.424 N ∗ m 24,000W
… Slide 4 TJ =
104.72 rad/s
= 229.183 N ∗ m
Critical Point: 80,000W
Tmax = 104.72rad/s = 763.942 N ∗ m
MG = 374.943N ∗ m
VII. Design Application and Material Selection
◦ Chosen material is AISI 5120 Steel. This material is commonly used in the automotive industry for
components such as transmission gears, crank shafts, piston pins, etc. As such, it is also known for its high
hardness and wear resistance, extending usage life for components. Since the required components for this
project will be under constant calculated stresses, the common safety factor is between 1.5 and 4.0. As the
mechanical system is prone for constant inspection the determined safety factor is 2.0 to compensate for
material fatigue.
Element Content (%) Property Value
Carbon, C 0.17-0.22 Yield Strength 758 MPa
Chromium, Cr 0.70-0.90 Ultimate Tensile Strength 938 MPa
Iron, Fe 97.605-98.28 Hardness (Brinell) 285
Manganese, Mn 0.70-0.90
Percent of Elongation 16%
Phosphorus, P ≤ 0.035
Condition Normalized 925°C, pseudo carburized, reheated to
Silicon, Si 0.15-0.30 845°C , 150°C temper
Sulfur, S ≤ 0.040 Table #5: AISI 5120 Steel Properties
Table #4: Percentage of each element of AISI 5120

Data obtained for samples of machined to 25mm from Matweb, referenced by ASM Metals Reference Book
IX. Shaft Diameters
Poin Distance (m) Minimum Diameters Diameter D/d (mm)
t (mm)
Calculations:
A 0 0 28.55 D r
= 1.1 , = 0.06
d d
B 0.005 12.631 31.41 D 2t r 2t t 1.1−1
= 1 + r (d) = 1.1= 1+ r 0.06 = r = 2(0.06) = 0.833 →
r
= 1.2005
d t
Ts 938
C 0.06 34.11 34.55 σe,𝑐 = 2 = 2 *1*1*0.810*0.843*0.735=235.768 MPa

D 0.07 36.692 38.00

E 0.08 31.083 41.80 Stress Concentration Equation and calculations:
1
Kt = 1 +
F 0.14 34.169 45.98 r r r r d
A t + 2B (1 + 2 )2 + C( )z ( )
d d t D
G 0.15 42.150 50.58 1
10.1 Kt = 1 +
H 0.16 40.041 45.98 1
1.2 3.4 + 2 19 (0.06) (1 + 2(0.06))2 + (1.2)3 (
1.1)
I 0.19 30.966 41.80 K t =1.34817
1
J 0.20 36.234 38.00 Kb = 1 +
1
1.2 + 2(5.8)(0.06) (1 + 2(0.06))2 + 0.2(1.2)3 (
K 0.21 32.411 34.55 1.1)

L 0.245 13.712 31.41 K b =1.71958

M 0.25 0 28.55
Table #6: Shaft Diameters
 Stress Concentration Factors

X. Diameters Calculations
Minimum Diameter:
𝟏
D/d

r/d
1.1

0.06
Punto d3 [mm]
𝟏 𝟑

𝟏𝟔∗𝑺𝑭 𝟐∗𝑲𝒇 ∗𝑴𝒂𝒎𝒑 𝟐 𝟑∗𝑲𝒔𝒇 ∗𝑻𝒎𝒆𝒂𝒏

𝟐 𝟐 A 0 Kb 1.5754
𝒅= 𝝅 𝝈𝒆𝒏𝒅
+ 𝝈𝒚𝒊𝒆𝒍𝒅
A 0
𝟏 B 12.631 Kt 1.2784
𝟏 𝟑
𝟐 B 12.631
𝟏𝟔∗𝟐 𝟐∗𝟏.𝟓𝟕𝟓𝟒∗𝟏𝟖.𝟐𝟒𝟒 𝟐 𝟑∗𝟏.𝟐𝟕𝟖𝟒∗𝟎 𝟐
𝒅𝑩 = + C 34.179
Ys 758MPa
𝝅 𝟐𝟑𝟓.𝟕𝟔𝟖∗𝟏𝟎𝟔 𝟕𝟓𝟖∗𝟏𝟎𝟔
C 34.179
𝑑𝐵 = 12.631𝑚𝑚 D 36.923
D 37.081
SF 2.0
E 31.083
E 31.083 YM 200GPa
𝑪𝒓𝒊𝒕𝒊𝒄𝒂𝒍 𝑷𝒐𝒊𝒏𝒕: 𝒅𝑮 = 𝟒𝟐. 𝟏𝟓𝟎𝒎𝒎 F 34.169
F 34.169
𝑑𝐴 = 𝑑𝐵 ÷ 𝑟𝑎𝑡𝑖𝑜 = 31.41 ÷ 1.1 = 28.55𝑚𝑚 G 42.046 Table #8: Stress concentration factors
𝑑𝐵 = 𝑑𝐶 ÷ 𝑟𝑎𝑡𝑖𝑜 = 34.55 ÷ 1.1 = 31.41𝑚𝑚 G 42.15
𝑑𝐶 = 𝑑𝐷 ÷ 𝑟𝑎𝑡𝑖𝑜 = 38.00 ÷ 1.1 = 34.55𝑚𝑚 H 40.041
𝑑𝐷 = 𝑑𝐸 ÷ 𝑟𝑎𝑡𝑖𝑜 = 41.80 ÷ 1.1 = 38.00𝑚𝑚 H 40.041 Punto d3 [mm] Corrected Real D [mm]
𝑑𝐸 = 𝑑𝐹 ÷ 𝑟𝑎𝑡𝑖𝑜 = 45.98 ÷ 1.1 = 41.80𝑚𝑚 I 30.966 C 34.179 34.179*1.06 36.229
𝑑𝐹 = 𝑑𝐺 ÷ 𝑟𝑎𝑡𝑖𝑜 = 50.58 ÷ 1.1 = 45.98𝑚𝑚 I 30.966
𝑑𝐺 = 𝑑𝐺 ∗ 𝑟𝑎𝑡𝑖𝑜 = 42.150 ∗ 1.2 = 50.58𝑚𝑚 H 40.041 40.041*1.06 42.443
J 36.234
𝑑𝐻 = 𝑑𝐺 ÷ 𝑟𝑎𝑡𝑖𝑜 = 50.58 ÷ 1.1 = 45.98𝑚𝑚 K 32.411 32.411*1.06 34.355
J 35.828
𝑑𝐼 = 𝑑𝐻 ÷ 𝑟𝑎𝑡𝑖𝑜 = 45.98 ÷ 1.1 = 41.80𝑚𝑚 K 32.411
𝑑𝐽 = 𝑑𝐼 ÷ 𝑟𝑎𝑡𝑖𝑜 = 41.80 ÷ 1.1 = 38.00𝑚𝑚 Table #10: Corrected diameters for snap rings
K 32.411
𝑑𝐾 = 𝑑𝐽 ÷ 𝑟𝑎𝑡𝑖𝑜 = 38.00 ÷ 1.1 = 34.55𝑚𝑚 L 13.712
𝑑𝐿 = 𝑑𝐾 ÷ 𝑟𝑎𝑡𝑖𝑜 = 34.55 ÷ 1.1 = 31.41𝑚𝑚 L 13.712
𝑑𝑚 = 𝑑𝐿 ÷ 𝑟𝑎𝑡𝑖𝑜 = 31.41 ÷ 1.1 = 28.55𝑚𝑚 M 0
M 0

Table #9: Minimum Diameters

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 Index of comments

10.1 This is your critical point...

as the stress concentrators for a snap ring are higher.
Where are the stress concentrators for the keys and the snap ring??

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