Project 2

Hybrid Spindle Design

4/5/2010

Jason Hopkins
ME 360
Section 2
Contents

1. Find all reaction forces

a. Draw a Free-body diagram
b. Solve for all unknowns

2. Choose a Ball Bearing

a. Calculate lifetime
b. Calculate C
c. Choose a bearing exceeding C and fulfilling geometric requirements

3. Design the Hydrodynamic Bearing

a. Find e using the stiffness and geometric analysis
b. Find eccentricity ratio
c. Ensure that radial clearance, Ocvirk number, and power loss is acceptable
d. Design the bearing sleeve

4. Final Design
1. Find all reaction forces
a. Draw a Free-body diagram
• assume both bearings are centered in the 2.25" sections of the housing
• dimensions are gathered from the SolidWorks model

b. Solve 6 equations for 6 unknowns

2. Choose a Ball Bearing for the Right Side
a. Calculate lifetime limitations (assume 10% failure rate)

b. Calculate C using the equations in the NSK bearing catalog

 c. Choose a ball bearing from the NSK catalog
• Only five bearings will fit comfortably inside the housing and around the shaft: 35, 40,
and 45 of the BNRS19 series and the 35 and 40 of the BNRS10 series.
• All of these bearings exceed the calculated C value, and should not fail within more than
ten years.
• The smaller bearings technically would work, but would create geometries that would be
impossible to assemble, meaning the housing would have a smaller inner diameter than
the diameter of the parts that must fit inside it.
• Choosing the largest of these bearings to avoid assembly conflicts, we have the
45 BNRS 19 TY DF L P4. The rest of the designations were either given or assumed
based on the problem description.

3. Design a Hydrodynamic Bearing

a. Find e using the stiffness and geometric analysis

This x=0.0002 inches is the maximum allowable deflection at the grinding wheel.

We find that the maximum deflection in the hydrodynamic bearing must be less than
0.000136 inches.
b. Find eccentricity ratio

Given this function:

We obtain an equation
for epsilon.

By using excel to find a value of epsilon that satisfies the equation above and makes
sense within the context of the problem, we find that epsilon = 0.0334.
c. Ensure that radial clearance, Ocvirk number, and power loss is acceptable

Radial clearance is in the proper range.

Ocvirk number is very low, meaning there should be a relatively low power loss.
 The power loss in the bearing is 0.167 HP, which is less than 6% of the power of
the motor (3 HP)

d. These calculations were performed assuming L=2 and d=1.8. The physical properties of the
bearing are now designed:

L=10
d=1.8 + 2* Radial Clearance = 1.8082 in

4. Final Design
1. Spindle
• The dimensions of the shaft were chosen to best fit each attachment.
• Ledges were created where necessary to ensure proper alignment of each component.
• The maximum radius is determined from the NSK catalog to ensure that the bearings
align properly.
2. Hydrodynamic Bearing Sleeve
• The length and diameter were calculated.
• Other geometries were created in order to facilitate oil flow and accommodate O-rings
to seal the oil in.
3. Spindle Housing
• Designed so that the shaft can be mostly assembled, then slid through the pulley side.
• Fillet radius determined to allow proper bearing alignment.
• Places for O-rings were determined for the oil passages into the cast housing.
4. Cover Plate
• Holds the O-ring in place to seal all oil within the chamber
• Accommodates screw heads to keep them away from the grinding wheel
5. Preload devices
• Each screws onto the shaft or housing sleeve with a custom thread
• Each has a hex head to allow a torque wrench to tighten it

Engineering Drawings are included on the next pages to aid in manufacturing. Tolerances were chosen
according to importance of precision. Many dimensions have wide tolerances to allow for cheaper
manufacturing.
 A
B

O-RINGS
CHOOSE TO FIT

DETAIL B
SCALE 1 : 1
UNLESS OTHERWISE SPECIFIED:
Jason Hopkins
DIMENSIONS ARE IN INCHES

DETAIL A TITLE:
TOLERANCES:
NO DECIMAL
ONE PLACE DECIMAL
Spindle Assembly
SCALE 2 : 1
TWO PLACE DECIMAL
THREE PLACE DECIMAL
Section View
MATERIAL

SIZE DWG. NO. REV

FINISH
A
DO NOT SCALE DRAWING SCALE: 1:2 SHEET 1 OF 6
3 2 1
 10.3

9.55

7.55

7.0 6.0

2.224 2.35
1.25 0.5

5/8 BSF 3/4 BSF

MAX FILLET TPI 12
RADIUS 0.022 OD 1.772
1.8000 ±0.0005

ID 1.622
0.625

2.072

1.772

0.750
1.01

UNLESS OTHERWISE SPECIFIED:

Jason Hopkins
DIMENSIONS ARE IN INCHES
TITLE:
TOLERANCES:

Spindle
ONE PLACE DECIMAL 0.1
TWO PLACE DECIMAL 0.01
THREE PLACE DECIMAL 0.001

MATERIAL
Steel SIZE DWG. NO. REV
FINISH
A
DO NOT SCALE DRAWING SCALE: 1:2 SHEET 2 OF 6
3 2 1
 3.09 TPI 12
MAX FILLET
RADIUS 0.011 OD 2.827

0.063
0.75 ID 2.677

0.063
0.50
6x #8-32

0.250 0.300
0.375 0.425
2.500

2.250

2.125

2.400

2.677

3.000
2.995
0.063
0.67
1.60

5.94
7.88

UNLESS OTHERWISE SPECIFIED:

Jason Hopkins
DIMENSIONS ARE IN INCHES

TOLERANCES: TITLE:
ONE PLACE DECIMAL 0.1
TWO PLACE DECIMAL
THREE PLACE DECIMAL
0.01
0.001
Spindle Housing Sleeve

MATERIAL

Steel SIZE DWG. NO. REV

FINISH
A
DO NOT SCALE DRAWING SCALE: 1:1 SHEET 3 OF 6
3 2 1
 0.19

2.06

0.38

1.21
1.31
0.22
0.30 0.125
6x 0.063

6x 0.177

50
2.

1.8082 ±0.0005
1.93
0.063

2.125
SCALE 1:1

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN INCHES

Jason Hopkins
TOLERANCES: TITLE:
ONE PLACE DECIMAL 0.1
TWO PLACE DECIMAL
THREE PLACE DECIMAL
0.01
0.001
Hydrodynamic Bearing
Sleeve
MATERIAL

Bronze SIZE DWG. NO. REV

FINISH
A
DO NOT SCALE DRAWING SCALE: 1:2 SHEET 4 OF 6
3 2 1
6x 8-32
Counterbore
depth 0.164

1.820
1.810

2.50

3.00
0
2.99
5

0.25

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN INCHES

Jason Hopkins
TOLERANCES: TITLE:
ONE PLACE DECIMAL 0.1
TWO PLACE DECIMAL 0.01
THREE PLACE DECIMAL 0.001 Cover Plate
MATERIAL

Steel SIZE DWG. NO. REV

FINISH
A
DO NOT SCALE DRAWING SCALE: 1:1 SHEET 5 OF 6
3 2 1
 TPI 12
OD 2.827
ID 2.677
TPI 12
OD 1.772
ID 1.622

1.73 0.25

1.30 0.50
8
1.25 0.25 2.2
0.35

2.68
1.77

2.17
0.93

Spindle Preload Device Housing Preload Device

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN INCHES

Jason Hopkins
TOLERANCES: TITLE:
ONE PLACE DECIMAL 0.1
TWO PLACE DECIMAL 0.01
THREE PLACE DECIMAL 0.001 Preload Devices
MATERIAL

Steel SIZE DWG. NO. REV

FINISH
A
DO NOT SCALE DRAWING SCALE: 1:2 SHEET 6 OF 6
3 2 1