Mechanics of Machine

1. RESEARCH PROGRESS IN MECHANICAL AND MANUFACTURING ENGINEERING VOL. 0 NO. 0
(2000) 000–000
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RPMME
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Combination of Single Helical Gear with Flat
Belt System
Norazilah Yunus1
, Hani Arina Amran2
*, Syafiq Syazwan Peer
Mohamed1
, Nur Fatihah Abd Rahman, Noofarhanah Hajihil3
,
1
Faculty of Mechanical and Manufacturing Engineering
Universiti Tun Hussein Onn Malaysia (UTHM), Parit Raja, 86400, MALAYSIA
2
Faculty of Mechanical and Manufacturing Engineering
Universiti Tun Hussein Onn Malaysia (UTHM), Parit Raja, 86400, MALAYSIA
*Faculty of Mechanical and Manufacturing Engineering
Universiti Tun Hussein Onn Malaysia (UTHM), Parit Raja, 86400, MALAYSIA
DOI: https://doi.org/10.30880/rpmme.00.00.0000.00.0000
Received 00 Month 2020; Accepted 01 Month 2020; Available online 02 Month 2020
Abstract: Based on parameters considered for this paper, the combination of a
single gear with flat belt system is being proposed. Scoring occurs when failure in
lubricant oil. This will create asperity-to-asperity contact between twinning gears.
The flat belt does not require grove and consequently no wedging in and pulling out
from the grooves. Helical gears were arranged vertically as it allows the systems to
attain higher gear ratios and speed. The chosen material of helical gear is C45 steel
which strong and capable in preventing breaking tooth, withstand shock loads acting
on gears. In addition, the C45 is capable to withstand heat treatment and hardening.
Keywords: Helical gears, flat belt
1. Introduction
The ball mill machine has been commonly used in the chemical, cement line and ceramic
industry for grinding material. This ball milling machine is the larger machine and needs a suitable
power transmission that rotates the shaft connected to the Mill’s Cylindrical Body with an outer
diameter of 2000 mm. The ball milling device usually consists of a cylindrical vessel mounted on an
appropriate basis at both ends which allows rotation of the vessel around the center axis. The mill is
driven by a girth gear bolted to the shell of the vessel and a pinion shaft moved by a prime mover.[1]
The prime movers are usually synchronous motors equipped with an air clutch or gear transmission.

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The comminution process is dependent on the rotation of the mill to lift the grinding media
for reducing particle size, including abrasion, crushing and impaction. Scoring occurs when failure in
lubricant oil.[2] This will create asperity-to-asperity contact between twinning gears. Usually it will
affect the teeth of pinion and gears. Due to this problem, wear and tear can also happen when slurry
removing of lubricant oil during maintenance is done. Moreover, another major problem in a gear
mesh is a teeth breaking or failure. It usually happen cause of high load from either static load or
impact loading.
Based on parameters considered for this paper, the combination of a single gear with flat belt
system is being proposed. The flat belt is known as material that provides economical, flexible and
durable material.[3] Helical gears are one of the cylindrical gears that have slanted tooth traces. The
helical gears have the large contact ratio and produce less vibration and capable of transmitting large
force. A combination of helical gears has the exact helix angle but opposite helix hand. Based on
figure 1.1, it shows the condition of combination single helical gear. [3]
Figure 1.1: The condition of combination single gear.
2. Literature Review
Designing a ball mill machine for a specific purpose and to solve its problem might be
challenging as different industries may require different types of ball mill. As for the flour mill
industry, a ball mill that rotates is commonly used to grind powdery materials. In an industry, ball
milling is one of the mechanical techniques that used to grind powders into fine particles and blend
materials (Moosakazemi et al., 2017). [4] It has a simple working principle, impact and attrition. Ball
mills can operate dry and even to process a water suspension. Following the drum rotation, balls or
the bearing will rise by rolling along the cylindrical wall and then descending in a cascade from a
height (Jean-Paul Duroudier, 2016). As the ball drops from the top of the rotating hollow cylindrical
container, this is where the size reduction will take place.
Working principle of a ball mill machine shows that the ball mill body rotates at a certain
speed with the transmission system. Nonetheless, there are certain limitations to the maximum speed

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that can be employed depending on the design (C. Suryanarayana, 2001). [6] The machine composed
of some major parts. There are feeding inlet, feeding outlet, rotating and driving system (speed
reducer, transmission gear, motor and electrical controller). There are a few factor that can varied the
nanostructure size such as varying the number and size of balls, the material used for both surface of
the cylinder and balls, the rotation speed and as well as the choice of material to be milled (Dr.
Sumanth Kumar et al., 2018). [7]
Ball mill is easy to install, however, the vertical mill is complex and its installation is more
compact. Installing a ball mill may give a few advantages such as the cost of installation and grinding
medium is low, produces very fine powder and it is also suitable for continuous operations (Carmen
C. Piras et al., 2019). [8] However, the ball mill also comes with shortcomings such as un-handiness
and large weight, noise during working and grinding high specific energy consumption. A mill is
filled with balls and working idle which makes it consume approximately a much higher energy at its
full-scale capacity during grinding. Nevertheless, it is much more disadvantageous to use it at its less-
scale capacity (Oleg D. Neikov, 2009).
3. Materials and Methods
The components used in designing the ball mill machine which is the pulley, flat belt and
single helical gear will be explained thoroughly. The specifications of each component also were
included in this section. Figure 3.1 shows the rough design of the system.
Figure 3.1: Rough design of the system
3.1 Pulley
Conveyor pulleys were chosen for this system as it changes the direction of the conveyor belt,
push the belt, and provide the belt with tension. They are composed of rolled shells with flexible end
discs and assemblies for locking. Generally, they are positioned at one end of the conveyor or near the
engine [10]. The material chosen for the pulleys are steel as it has higher strength and also high shock
resistance. One of the pulleys must be crowned in order to prevent the belt from running off. The

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crown profile shape should be regular symmetrical curve. The pulley width should be set at least 1.05
to 1.1 times of belt width [11]. Table 3.1.1 shows the specifications of the conveyor pulleys.
Table 3.1.1: Specifications of conveyor pulley
Type Material Pulley diameter
(mm)
Pulley width
(mm)
Pulley crown
height (mm)
Conveyor pulley Steel 50 0.3 25
3.2 Flat Belt
Flat belt is chosen in designing this system rather than V-belt. This is because flat belts are
designed for high performance conveying. It is best optimized with smaller pulleys and large central
distances [12]. Flat belts have high power transmission efficiency and cost-effective. It is also easy to
install, low maintenance and produces low noise generation. In addition, flat belt can withstand high
load and have longer lifespan. Flat belt smoothens the operation and suitable to operate at long drive.
Flat belt drives only require small cross-section for frictional engagement on the outer pulley surface
thus makes the belt very flexible [12].
Flat belt is also chosen because it does not require groove and consequently no wedging in
and pulling out from the grooves. Therefore, there is no energy loss and takes longer time for the belt
to wear off. In designing this system, polyamide rubber has been chosen as the material of the belt.
The material is chosen as it is very reliable and provides long lifespan. It is also shock resistant and
able to withstand the operating temperature until 100 degree Celsius. Table 3.2.1 shows the
specification of the belting system chosen for the design requirements of the ball mill machine.
Table 3.2.1: Specifications of flat belt
Material Density
(kg/m3
)
Thickness
(mm)
Permissible
working stress
(MPa)
Angle of
contact
(°)
Maximum operating
temperature
(°C)
Polyamide
rubber
1100 9.55 2.5 165 100
3.3 Single Helical Gear
Single helical gears were chosen for this ball mill system design. The helical gears were
arranged vertically and used at the diameter mills. This is to allow the system to obtain higher gear
ratios and also and implement low cost motor but higher speed. It also to ensure smoother continuous
overlapping tooth action of helical gearing and make it more practical as there is no intermediate
transmission element at the belting system. Helical gear can be developed on most modern machines
for cutting gears [13]. It also capable in carrying loads more than fifty percent [13]. Helical gears also
provide minimum noise and easy to design to fit in the desired center distances as there were many
parameters that can be arranged.
The material chosen for the helical gear and its pinion shaft is C45 steel. The material
undergoes through hardened treatment which includes annealing or normalised process [14]. The

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material is heat treated before machining to avoid heat distortion. The material for gears and pinions
needs to be selected carefully in order to prevent malfunction and disruption during the working
process of the machine as these components plays a vital role in the system. C45 steels are strong and
capable in preventing breaking of the gear tooth, withstand shock loads acting on the gears and also
resist any kind of stresses acting on the shaft. Table 3.2.2 shows the specifications of the single helical
gear for the system.
Table 3.2.2: Single helical gear specifications
Material Process Face width ratio Arrangement
C45 steel Through hardened
(normalised or quenched &
tempered)
1-1.3 Vertical and parallel
axis
4. Results and Discussion
Calculation for Ball Mill System Upgrade:
Given:
Outer diameter, d = 2000mm @ 2m
Torque, Ʈ = 1000Nm
Rotational, N = 30rpm
Allowable slip = 2.3
Angle of contact, Ɵ = 2.88rad
Coefficient, µ = 0.3
*referring to rubber belt specification

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The specifications of each component chosen are based on considered parameters. The
material used for pulley is steel as it has higher strength and shock resistance. Flat belt designed to
transmit high performance, withstand high load and have longer lifespan. Besides, the flat belts also
have high power transmission efficiency and considered practical.[12] The flat belt does not require

7. Author 1 et al., Research Progress in Mechanical and Manufacturing Engineering Vol. 0 No. 0 (2000) p. 1-4
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grove and consequently no wedging in and pulling out from the grooves. Helical gears were arranged
vertically as it allows the systems to attain higher gear ratios and speed.[13] The chosen material of
helical gear is C45 steel which strong and capable in preventing breaking tooth, withstand shock loads
acting on gears. In addition, the C45 is capable to withstand heat treatment and hardening.
The calculation of the ball mill systems is referring to the specification of the rubber belt.
Velocity calculated is 3.142 m/s, tension on the tight side is 1726N and tension on the slack side is
726N. The value of tension on the tight side does require high force which acting as driver. The
tension caused by centrifugal force also called centrifugal tension. The lower belt speed is less than 10
m/s whereby it can be ignored. The widths of the flat belt calculate only if centrifugal force take note
as it is correlation to the size of the pulley. The final result of width is 0.073m which acceptable based
on standard belt thickness and width. [14] Further calculation on a rubber belt lifespan will proof if
the company run on three shifts operating time which 7 hours and 1 hour rest, the estimation of years
will be 5 years minimum. Compare to standard lifespan that approximately 2 years. [15]
Therefore, for the further development the flat belt on helical gear system can be interchange
to v-groove belt with compound gear. From there, the friction will be reducing as the system is
according to belt and gear and not gear to gear.
5. Conclusion
In the conclusion, by upgrading the system of the ball mill machine the problem of scoring, pitting,
and teeth brakeage will sustained and approximately cut the maintenance of the system. Theoretically,
these paper manage to achieve the requirement of the project.
6. References
[1] Piras, C.C., Fernández-Prieto, S. & De Borggraeve, W.M. (2019) Ball milling: a green
technology for the preparation and functionalisation of nanocellulose derivatives. N.A.
https://pubs.rsc.org/en/content/articlelanding/2019/na/c8na00238j#!divAbstract
[2] T. H. McCloskey, “Troubleshooting Bearing and Lube Oil System Problems,” Proceedings of the
Twenty-Fourth Turbomachinery Symposium, Gas Turbine Laboratories, Texas A&M University,
Texas, (1995)
[3] Masao Kubota, Haguruma Nyumon, Tokyo : Ohmsha, Ltd., 1963
[4] F. Moosakazemi, M. R. T. Mohammadi, M. Mohseni, M. Karamoozian and M. Zakeri, Effect of
design and operational parameters on particle morphology in ball mills, Int. J. Miner. Process., 2017,
165, 41–49
[5] Duroudier, J.P. (2016) in Size Reduction of Divided Solids. N.A.
https://www.sciencedirect.com/topics/engineering/ball-mills

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[6] Suryanarayana, C. (2007) Mechanical alloying and milling. N.A.
https://www.researchgate.net/publication/44564802_Mechanical_alloying_and_milling_C_Suryanara
yana
[7] Piras, C.C., Fernández-Prieto, S. & De Borggraeve, W.M. (2019) Ball milling: a green
technology for the preparation and functionalisation of nanocellulose derivatives. N.A.
https://pubs.rsc.org/en/content/articlelanding/2019/na/c8na00238j#!divAbstract
[8] Bhagyaraj, S.M., Oluwafemi, O.S., Kalarikkal, N. & Thomas, S. (2018) in Synthesis of Inorganic
Nanomaterials. N.A.
[9] Neikov, O.D. (2009), in Handbook of Non-Ferrous Metal Powders. N.A.
https://www.sciencedirect.com/topics/engineering/ball-mills
[10] More about pulleys. (26 December 2020 – 11.00 a.m.)
https://www.habasit.com/en/getToolDownloadFile.htm?DocId=7973&language=2&ACWeb=54,
Power Transmission Belts
[11] Zixin Yin,Yuxing “Impact Load Behavior between Different Charge and Lifter in a Laboratory-
Scale Mill” Published: 31 July 2017
[12] Flat Belts. (26 December 2020 – 12.00 p.m.)
https://www.globalspec.com/learnmore/motion_controls/power_transmission_mechanical/flat_belts
[13] Andrzej, Zbigniew, Design Basic of Industrial Gear Boxes, Calculation and Design Case.
Department of Vehicles and Fundaments of Machine Design.
[14] R.S. KHURMI, J.K. GUPTA, A Textbook Of Machine Design
[15] Jim Hammond, Belt it best. JUL 01, 2008