I've used http://www.phillystran.com/index.htm for larger Kevlar ropes. Not sure how small of an assembly they'll make, but it might be worth checking.
Torque is Force (lb) x distance (ft). Where you're getting confused is not understanding that the torque in the shaft/sprocket is the same everywhere in the shaft/sprocket. The tangential force is different depending on the perpendicular distance to the axis of rotation. Here's how the...
The unit as shown has a total reduction of 125:1, entirely due to the torque multiplier. As previously pointed out, gears of the same diameter do not change torque. To get the required input torque divide the desired output torque by the total gear ratio (125).
On careerbuilder.com I find 410 engineering jobs from the last 30 days using the search string "entry level electrical". Took me about 1 minute. I don't think H1B's and automation are your problem.
Here's one I found, I can't tell you if it works or not...
Belt length in feet = A x number of coils x 0.131
A = Diameter of coil in inches + Diameter of coil hole in inches
Looks like Enerpac has 200-ton and up cylinders with up to 48" stroke.
http://www.enerpac.com/Main_Navigation/products/industrial_tools/home.htm
Click on "General Purpose" under "Cylinders"
Bigger shafts isn't the answer. Get rid of the stress concentrations and you'll have it. It looks like your small shaft failures occured at the transition to the hex outside the gearbox. If that's true, there's no reason you can't make a smooth transition from the large diameter down to the...
Shaft failures 1, 2, and 3 (from left to right) are all due to stress concentration at the sharp transition between the diameters. The concave appearance of the shaft ends shows that the reduced diameter actually pulled material away from the shaft as it cracked. This is classic stress...
Another vote for Anvil top (or equivalent). Ever try rolling a tool box (filter cart, welder, torch rig, hand truck) over imbedded rails? Install the anvil top in strips to accomodate the gauge of the tracked equipment.
infomine.com. Good luck, I've got somebody in here peddling wear plate just about every week. Most of our business goes to the guy providing the best service (measuring, cutting, forming, etc) and best availability of plate.
No, EP oils should not be used with yellow metals. EP additives work by chemically reacting with the metal surfaces. This reaction is too aggressive for yellow metals, resulting in rapid corrosion.
