GEAR BOX FOR PROGRAMMABLE GUILLOTINE PG 115

MAIN PROJECT PRESENTATION

Presented By

Guided By
FAHIM E HAMZA MOHAMMED SAFEER RAQEEB MOHAMED ROSHAN P.R SANAD SHAJAHAN SULAIMAN MR. SAGAR M NARAYANAN MR. SAMPATH KUMAR

Year of starting 1963 Year of commissioning 1964 Year of inauguration 1966 Initial investment on starting: MTD Rs. 7.5 CRORE PMD Rs 4.28 CRORE No: of Divisions TWO

Total No: of Employees

3095 reduced to 300 on 2012. Turn over- 64.6 crore (HMT Ltd. -360 crore)

Gearbox used in PG 115 is bought from a supplier

If manufactured in HMT, helps in considerable cost reduction To design a speed reducing gear box for paper cutting machine, PG 115.

PROGRAMMABLE GUILLOTINE -PG 115

 Fastest Guillotines with a mechanical cutting speed of 47 cuts per minute Uses a pendulum action on the knife carriage bar which guarantees minimal absorption of energy by working parts resulting in reduced wear and easy accessibility for maintenance of the knife carriage and related functions

Knife is powered using a 4-pole 3 phase induction motor of 3.7 KW

Back gauge position accurate to 0.04 mm.

 The hydraulic unit is dedicated to maintaining clamp height

Uses a hydraulic system consisting of separate units with an independent electrical motor to ensure correct and constant pressure and cutting speed. CNC controlled closed loop mechanism for control of the back gauge movement.
A.C servo drive motor for control of the back gauge movement to give fast forward and reverse travel of the back gauge The front face of the clamp has a protective insert to prevent the blade grazing or interfering with clamp face. Stainless steel cladding on table for surface protection

PG 115 - SPECIFICATIONS
mm Cutting width Clamp opening Speed of mechanical cut/minute Hydraulic pressure 1150 165 47 150-4500 kgs

Space occupied
Total power

2350x 2610
6.7 kW

Components of a gearbox
Gears for transmitting power from one shaft to another by means of the positive contact of successively engaging teeth.

Shafts for mounting gears.

Suitable bearings (mostly ball or roller bearings) to support the shafts. Sufficient space for lubricating oil reservoirs. Provisions to prevent axial movement of gears. Provisions for easy assembly and disassembly.

Helical Gears:
The leading edges of the teeth are not parallel to the axis of rotation, but are set at an angle. WHY helical gear over spur gear ? The angled teeth engage more gradually than do spur gear teeth, causing them to run more smoothly and quietly. For same tooth size (module) and equivalent width, helical gears can handle more load than spur gears because the helical gear tooth is effectively larger since it is diagonally positioned.

Given Parameters:

Output rpm = 47 Input rpm to the v belt pulley = 2910 Clutch weight = 340 N Horizontal Forces acting at distance perpendicular to output shaft, FH = 1262 N Vertical Forces acting at distance perpendicular to output shaft, FV = 1802 N

 Perpendicular distance at which force is acting = 152mm Flywheel weight = 340.5 N Center Distance between input and output shaft = 390- 400mm

Maximum inside dimensions of casing : Length = 660mm Breadth = 240mm Height = 370mm

 Motor pulley PCD = 160mm

Flywheel PCD = 388 mm

Gear ratio of pulleys = 388/160 = 2.4

 RPM of input shaft to the gearbox = 2910/2.4 = 1212.5

Gear ratio of gearbox = 1212.5/47 = 25 :1

Selecting a two-stage gearbox

Gear ratio in each stage = 5:1

 SELECTION OF MOTOR RATING :

Horizontal Forces, FH =1262 N Vertical Forces, FV = 1802 N Resultant Force, FR = = = 2838.2 N Output Torque =FR Perpendicular distance = 2838.2 152 = 431406.4 N-mm = 431.406 N-m

Torque at intermediate shaft, T1= = 86.28 N-m

Torque at input shaft, T2

=
= 17.26 N-m

Torque at belt shaft from motor, T3=

= 7.19 N-m T=
Required power of motor, P =

= 2189.9 W = 2.2 KW

Factor of safety = 1.5 { from HMT Electrical dept }

Final motor power, P = 1.5 2.2 = 3.3 KW

Available 4 pole, 3 phase AC induction motor is of 3.7KW

GEAR DESIGN(INPUT SHAFT) :

NA= 1212.5 rpm NB = 235 rpm

Material used for the gears is an alloy steel 15 Ni 2 Cr 1 Mo15

Gear ratio, i = 5 Design Surface Stress of gear A [b]A= 950 N/mm2 Design Surface Stress of gear B [b]B= 950 N/mm2 Assume: center distance ,a = 175
= 175

Da = 58.3 mm 59 mm Db = 5 59 = 295 mm Torque at input shaft, T =

=

= 29.15 N-m = 29.15 103 N-mm

Tangential Force Ft =

988.1 N

Pitch line velocity, V = =

Velocity Factor, Cv = = 3.74 m/s

= 2.24

Design Tangential Load, FD = Ft Cv = 988.1 2.24 = 2213.3 N

Assume :
Za = =

Z = 27 &

= 230

= 34.61 35

Form factor, Y

= 0.449 (for Z = 35)

bbmY FD 95010mm0.449 2213.3

m2

m2 0.518 m 0.719 mm Fw <Fd for m = 2, m = 3 Take, m = 4mm b = 10x4 = 40mm

Number of teeth of gear A, Za = =

= 14.75 15

Number of teeth of gear B, Zb= 5 15 = 75 Pitch circle diameter of gear A, Da = = = 65.18 66 mm Pitch circle diameter of gear B, Db= 5 66 = 330 mm

Corrected beam strength , FD= b b m Y = 950 40 4 0.493 = 74936 N

Dynamic load on helical tooth, Fd = Ft +

{since Y = 0.493 for Za = 15}

c=

= = 309 N/mm2

Fd= 988.1 +
= 5452.6 N FD >Fd , Hence the design is safe
Ratio factor, Q =

=
Sin n 1.4

= 1.66 2

Load stress factor, Kw = (e) 2

1 E1

1 E2

tan n = tan cos tan n = tan 20 cos 23 n= 18.86

Kw = (550)
2

Sin ( 18.86 ) 1.4

1 2.15 10 5

1 2.15 10 5

= 0.664 1 Limiting load for wear, Fw =

Da b Q Kw cos 2
=
66 40 2 1 cos 2 (23)

= 6231. 3 N

Fw >Fd , Hence the design is safe

SIMILARLY, the module for the 3rd and 4th gears were found to be 5mm.

Dc = 66 mm
Dd= 330 mm

SHAFT DESIGN(INTERMEDIATE SHAFT) :

Input Torque, T =
60 2 3700 60 2 1212 .5

= 29.15N-mm = 29.15 103 N-mm Torque transmitted by gear = 29.15103 5 = 145.75103 N-mm

Tangential force on Gear B, FTB =

/2

145.75 10 3 (
330 ) 2

= 883.3N Radial Force on Gear B, FRB = FTB

tan cos
tan 20

= 883.3 cos 23 = 349.2N

CONSIDERING VERTICAL LOADING

Taking moment about X RYV 212 = FTB60+FTC147 RYV212=883.360+4416.6147 RYV212=52998+649240.2 RYV212=702238.2

RYV=

702238 .2 212

= 3312N()

RXV = 1987.4N()

CONSIDERING HORIZONTAL LOADING Taking moment about X RYH 212 + FRB60 - FRC 147 = 0 RYH212 + 349.260 - 1746.33147 = 0 RYH = 235758.51/212 = 1112.06 N RXH = 285.07N

VERTICAL BENDING MOMENT At X, MXV = 0 At B, MBV = -1987.4 60 = -11924 N-mm At C, MCV = - 3312.465 = - 215806N-mm At Y, MYV = 0

HORIZONTAL BENDING MOMENT At X, MXH = 0 At B, MBH = 285.07 60 = 17104.2 N-mm At C, MCV = 1112.06 65 = 72833.9N-mm At Y, MYH = 0

RESULTANT BENDING MOMENT At B, MB =

=

= 20850.3 N-mm

At C, MC =
=

= 227291.5 N-mm

Equivalent twisting moment, Te =

=

= 444.94103 N-mm

Material selected for the shaft is an alloy steel 15 Ni 2 Cr 1 Mo15

Design shear stress for shaft = 125 N/mm

D=( ) 125
16

=(

16 444.94 10 3 125

= 26.27mm

Select diameter of the shaft, D = 30 mm

BEARING DESIGN (INTERMEDIATE SHAFT)

Since helical gears are used, there are both axial and radial loads Hence taper roller bearing is selected.
T=

=
= 29.15 103 N mm

Torque transmitted by gear B = 29.15 103 5 = 145.75 103 N mm Tangential force =

=

= 883.3 N

Life = 25000 hours n = 235 rpm

FaB = FTB tan = 883.3 tan23 = 374.93 N

C=

= = = 2007.74 N = =

= 3494.09 N

Life in million revolution, L=

=
= 352.5 mr Tangential Force
=

= 4416.6N

= = 4416.6 = 1746.33 N

= = 4416.4 = 1874.7 N
ROLLER BEARING AT X

= 374.3N = 2007.79N

= 0.186

X=1 , Y=0

C=
= = 23327.93 N From page 4.25 PSG select Brg for C23327.93N and for shaft diameter 30 Bearing number SKF32206A (C = 43800N)

ROLLER BEARING AT Y = = 0.536

X=0.4 Y=1.6 V= Race of rotation =1

C=

= 51078.04N From page 4.25 PSG , select bearing for C51078.04 & for shaft diameter 30 Bearing number SKF32306A (C = 66000N)

DRG NO. 01 02 03 04

DESCRIPTION INPUT SHAFT INTERMEDIATE SHAFT OUTPUT SHAFT HELICAL PINION

QUANTITY 1 1 1 1

COST 850 350 1250 6000

05
06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21

HELICAL GEAR
HELICAL PINION HELICAL GEAR END COVER END COVER END COVER END COVER END COVER CASING TOP CASING BOTTOM OIL SEAL (INPUT) OIL SEAL (OUTPUT) SPACER SPACER TAPER BEARING (SKF32306A) TAPER BEARING (SKF32206A) TAPER BEARING (SKF32208A)

1
1 1 1 2 1 1 1 1 1 1 1 2 2 2 2 2

8000
6500 8000 150 300 150 200 200 2250 2250 125 155 210 150 8200 6100 2500

MATERIAL COST = Rs53890

ORIGINAL GEARBOX (3 STAGE) = RS 1.8 LAKHS

HENCE MORE PROFITABLE THAN THE PREVIOUS GEARBOX

Uses 2-stage helical gear The design is simple and not complicated when compared with the existing gear box. Reduces the cost of speed reducing gear box considerably.

The design of the gearbox for the specified requirement is done, considering all the design specifications and objectives.

The required reduction is achieved through two stages. Considerable cost reduction of gearbox compared with the existing gearbox.

Textbook of Machine Design by S. Md. Jalaludeen Design Data, PSG College of Technology

Shigley J E, Mechanical Engineering Design

THANK YOU!!!