MECH3460 Mechanical Design 2
Assignment 3
Shaft Methodologies – Chain Drive Mixer

Introduction:
Assignment 3 focuses on the use of two analysis methods in order to arrive at suitable design of a shaft
to suit the chain drive to a mixer. The layout of the drive is shown pictorially on Figure 1.0 below and
in the SALA catalogue (compare old and new), available on CANVAS. Note the use of a shaft mounted
gearbox.

Operating Environment:
It is intended to use an available appropriate synchronous motor rated to operate at 1440 rpm. The
motor which weighs 40 kg will be directly coupled to the input shaft of the gearbox, (not using a belt
drive as shown on Figure 1.0.) The output of the gearbox is to run at 100 rpm within about 5%. The
pitch circle diameter of the chain sprocket is to be approximately 330 mm. The tension in the chain
will vary with the volume and density of the material in the mixer drum, but it has been determined
that the highest tension will be 15.0 kN and that the high-tension leg of the chain will be within 15⁰ of
vertical. The movement of the material within the mixing drum will produce essentially no shock loads.
The SALA catalogue also specifies other factors to be considered. This installation will be operated
for single shifts of 12 hours per day (i.e., 12 hours continues operation), with less than 20 starts per
hour and all starts will be carried out with an empty drum. The operating environment is quite dusty.



















Figure 1.0







Torque reaction arm, here
shown to include a load cell.
Without the torque link the
gear box would be free to rotate
in the opposite direction to the
load.
A load cell can allow
monitoring over the life of the
mixer and power cut-off in the
event of an overload. Welded steel frame
Plummer bearing block

Figures 2.0 and 3.0 below, show views of the SW models of the proposed drive assembly. They
show the gearbox, bearing blocks and shaft.

A pictorial view of a tentative
arrangement of the drive assembly
is shown at left.
Designers typically begin with a
proposed layout which depending
upon their experience may end up
being close to the final
arrangement.

The proposed layout provides
estimated dimension which are
used in initial calculations.
Depending on the outcome of those
calculations some or all of the
details may be reconsidered. The
design analysis is reiterated until a
good practical outcome is reached.



Figure 2.0





















Figure 3.0



Minimum clearance between
gearbox and bearing block to
be 20mm.
Possible top view of the proposed gear drive.
The bearing block width is
estimated to be 110 mm and their
mounting bolts CL separation
(shown here) to be 330 mm.
The weight of the gearbox and motor, and the torque reaction
by the link, may all be assumed to act through the mid-plane
of the gearbox. The location for the attachment of torque link
to the gear box is given in the catalogue. The C of M (center
of mass) of the assembly may also be assumed to be at the

Torque
reaction arm
Chain sprocket
mounted on boss

Assignment Requirements:

Shaft Material:
The initial expectation is that the shaft will be made from high quality shaft ground stock, of Su 350
to 500 N/mm2 grade. You will need to reference a suitable grade that you have selected. The shaft is
initially expected to be a parallel sided cylinder bar (no steps).


Core Assignment Requirements:
You are to prepare an EXCEL spreadsheet for an engineering manager, showing step by step how
you have arrived at:
• Design a suitable shaft diameter using two analysis methods covered within the course notes:
AS1403, Gerber, Goodman or ASME.
• State the diameter and length of the stock material you are proposing to use to manufacture
one off your shaft design and the material property.
• Select a gearbox from the SALA catalogue provided.
• Determine a suitable key between your shaft and the boss on which the chain sprocket is
mounted.
• Produce a detail drawing of your shaft design on an A3 size drawing sheet to AS1100.
• Reference to APA7th or Harvard are to be included in your spreadsheet at each key point.

The EXCEL spreadsheet is to be easily read and also serve as a guide for new graduates that will
learn from you and extend your design to other applications.

Your EXCEL spreadsheet is to be preceded by an executive summary. In it you must specify
concisely what you propose to buy and what to make. This summary is not to be a general
discussion, but brief and to the point. Higher level managers only read this summary, unless
something goes wrong, then the details will be examined.



Additional Design Aspects to be Considered:
• Select bearings and bearing plummer blocks to suit this installation. To do this you must
determine the angular misalignment of the shaft at the bearings, to allow bearings and or
plummer blocks be selected that can function with that misalignment.
• Suggest tolerances for the coplanar alignment of the mounting faces for the two plummer
blocks, and their deviation from the horizontal.
• Determine lateral deflection of the shaft at the sprocket and assess its effect.
• Produce a detail drawing of the steel frame to deal with the points above on an A3 size
drawing sheet to AS1100.





Paul Briozzo
29/09/2022

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