Department of Mechanical Engineering

Lab Manual

Machine Design Lab

(MEC 305)

Laboratory Location: ED Hall (Room No.: 302) & Computer

Aided Design Centre (Room No.: 105)

Department of Mechanical Engineering

INDIAN INSTITUTE OF TECHNOLOGY

(INDIAN SCHOOL OF MINES), DHANBAD
 INDEX
Sl .No. Particulars Page
1 Safety in the lab 3
2 Lab report format 4-5
3 General Laboratory rules for Machine Design 6
4 List of Experiments Machine Design Lab 7
5 Instruction Manual Machine Design Lab 8 – 57

2
 Safety in the Lab

 You are only allowed in the laboratory when there is a 'responsible person' present such
as a demonstrator or the laboratory staff.
 Do not touch any equipment or machines kept in the lab unless you are asked to do so.
 A tidy laboratory is generally safer than an untidy one, so make sure that you do not have
a confused tangle of electrical cables. Electrical equipment is legally required to be
regularlychecked, which means it should be safe and reasonably reliable: do not tamper
or attempt torepair any electrical equipment (in particular, do not rewire a mains plug or
change a fuse -ask one of the laboratory staff to do it). Never switch off the mains using
the master switchesmounted on the walls. Please make yourself aware of the fire exits
when you first come intothe lab. When the alarm sounds please leave whatever you are
doing and make your way quickly, calmly and quietly out of the lab. You must always
follow instructions from your demonstrators and the laboratory staff.
 You must keep walkways clear at all times and in particular coats and bags must be
stowedaway safely and must not pose a trip hazard.
 It is important that you make a point of reading the "Risk Assessment" sheet included in
themanuscript of each experiment before you start work on the experiment.
 Please take notice of any safety information given in your scripts. If an experiment or
project requires you to wear PPE (personal protective equipment) such as gloves and
safety glasses,then wear them.
 Always enter the lab wearing your shoes. It is strictly prohibited to enter the lab without
shoes.
 There must be NO smoking, eating, drinking, use of mobile phones or using personal
headphones in the laboratory. This last point is not because we dislike your choice of
musicbut because you must remain aware of all activity around you and be able to hear
people trying to warn you of problems.
 Keep the lab neat and clean.

3
 Lab Report Format

Title

 Provide a title that is a description of your lab followed by a lab number.

 The title should clearly identify the experiment’s variables (independent &
dependent)

Objective/Purpose/Problem:
 This is the place to explain what you are trying to find out or what you are going to
doin the lab.
 Include information about the variables involved.

Hypothesis: “If………then………because………”

 This is a cause/effect statement.

 This is a prediction of what the expected outcome of the lab will be.
 Relate the hypothesis to the purpose/problem of the lab.
 Try to focus your hypothesis on the information/research you collected.

Materials:
 List all items in a column.
 Make sure to record the exact size and amount of each item required.

Procedures:
 List and number each step.
 Use complete sentences (begin with a capital letter and use end punctuation).
 Should be clear enough for someone else to use as instructions for repeating
yourexperiment.

Observations/Data:
 Be sure to accurately record your observations/data in a chart or table.
 Create a graph to provide a visual of your data.
 Provide a verbal description of your data.
 List all quantitative (numbers) and qualitative (words) data.
 List all variables and explain what your control was.

Conclusion: “When…………….then… ........................ ”

 Match your conclusion to the purpose or the problem.

 Base your conclusion on your analysis of your observations and any data that has
beencollected.
 Explain: (The following are just suggestions and DO require elaboration.)
 What you did in the experiment

4
  What you observed (trends/patterns in your data that supported or
did notsupport your hypothesis)
 What you learned from the lab
 If you think it was a fair test (i.e. – was there anything that may have
impactedthe accuracy of your results)
 Questions for further research and investigation
 Application: Can you think of an analogous situation that applies to real life?

5
GENERAL LABORATORY RULES FOR MACHINE
DESIGN:
 Revise and be prepared with all the basics of machine design theories taught
in theory class by instructor. Students are advised to bring class notes of
Machine Design.
 Read the procedure as set forth in the lab manual before you begin any design.
 It is compulsory to bring machine design data book in laboratory.
 For numerical calculations students have to bring scientific calculator without
fail.
 Use of mobile phones other than design purpose is strictly prohibited in the
laboratory.
 Drawing of the machine components is to be prepared with AutoCAD.
 Final report of a design is to be submitted in the subsequent Lab class.

6
 List of Experiments
Sl. No. List of design of machine element Page No.

1. Design of shaft 8 – 11

2. Design of rigid coupling 12 – 14

3. Design of flexible coupling 15 – 17

4. Design of helical spring 18 – 22

5. Design of leaf spring 23 – 27

6 Design of brake 28 – 31

7 Design of clutches 32 – 36

8. Design of Journal Bearing 37 – 39

9. Selection of rolling element bearing 40 – 43

10. Design of Spur Gear 44 – 49

11. Design of Helical Gear 50 – 53

12. Design of Bevel Gear 54 – 57

Note:

1. At least eight design problems are to be completed in the semester from the
above list.

2. Two more designs of machine components are to be carried out as designed

and set by the instructor as per the scope of the syllabus.

7
 Experiment 1: Design of Shaft
1. AIM OF THE EXPERIMENT: Calculate the value of diameters of shaft for given loads and
layout.
2. OVERVIEW OF SHAFTS

• A shaft is a rotating member usually of circular cross-section (solid or hollow), which

transmits power and rotational motion.

• Machine elements such as gears, pulleys (sheaves), flywheels, clutches, and sprockets
are mounted on the shaft and are used to transmit power from the driving device (motor
or engine) through a machine.

• Press fit, keys, dowel, pins and splines are used to attach these machine elements on the
shaft.

• The shaft rotates on rolling contact bearings or bush bearings.

• Various types of retaining rings, thrust bearings, grooves and steps in the shaft are used
to take up axial loads and locate the rotating elements.

• Couplings are used to transmit power from drive shaft (e.g., motor) to the driven shaft
(e.g., gearbox, wheels).

3. DESIGNING OF SHAFT

Designing shaft is to calculated value its diameters at critical section. The critical section is a
section on the shaft which is highly stressed. The value stresses are calculated with the help of
layout and free body diagram.

 The shafts may be designed on the basis of:

 1. Strength, and 2. Rigidity and stiffness.
 In designing shafts on the basis of strength, the following cases may be considered :
 Shafts subjected to twisting moment or torque only,
 Shafts subjected to bending moment only,
 Shafts subjected to combined twisting and bending moments, and
 Shafts subjected to axial loads in addition to combined torsional and bending loads.

8
3.1. Considerations in shaft design:

o Size and spacing of components

o Material selection, material treatments
o Deflection and rigidity
o Stress and strength
o Frequency response
o Assembly, manufacturing & servicing constraints

4. LOADS ON SHAFT:

9
5. FLOW CHART FOR SHAFT DESIGN:

6. COMMON FORMULA TO DESIGN SHAFT IN COMBINED LOADING:

10
 L/k > 115

L/k < 115

Where alpha is column factor

di
k
do
Km = Combined shock and fatigue factor for bending, and
Kt = Combined shock and fatigue factor for torsion.

Value of Km and Kt by using following table:

7. VALUE BENDING STRESS AND SHEAR STRESS IS OBTAINED FROM DESIGN

DATA BOOK FOR THE SELECTED MATERIAL:

Prob.
A hollow shaft of 0.5 m outside diameter and 0.3 m inside diameter is used to drive a propeller
of a marine vessel. The shaft is mounted on bearings 6 metre apart and it transmits 5600 kW
at 150 r.p.m. The maximum axial propeller thrust is 500 kN and the shaft weighs 70 kN.
Determine :
1. The maximum shear stress developed in the shaft, and
2. The angular twist between the bearings.

11
 Experiment 2: Design of a rigid coupling

1. AIM OF THE EXPERIMENT: Find the value of dimensions of rigid coupling.

2. THEORY: Shafts are usually available up to 7 metres length due to inconvenience in

transport. In order to have a greater length, it becomes necessary to join two or more pieces of
the shaft by means of a coupling.
Purposes of couplings:
I. To provide for the connection of shafts of units that are manufactured separately such
as a motor and generator and to provide for disconnection for repairs or alternations.
II. To provide for misalignment of the shafts or to introduce mechanical flexibility.
III. To reduce the transmission of shock loads from one shaft to another.
IV. To introduce protection against overloads.
V. It should have no projecting parts.

The usual proportions for an unprotected type cast iron flange coupling, as shown in figure
above, are as follows :
If d is the diameter of the shaft or inner diameter of the hub, then

12
Outside diameter of hub,
D = 2 (d)
Length of hub, L = 1.5 (d)
Pitch circle diameter of bolts,
D1 = 3(d)
Outside diameter of flange,
D2 = D1 + (D1 – D) = 2 D1 – D = 4 d
Thickness of flange, tf = 0.5 d
Number of bolts = 3, for d up to 40 mm
= 4, for d up to 100 mm
= 6, for d up to 180 mm

3. DESIGN FOR HUB

The hub is designed by considering it as a hollow shaft, transmitting the same torque (T) as that
of a solid shaft.

The outer diameter of hub is usually taken as twice the diameter of shaft. Therefore, from the
above relation, the induced shearing stress in the hub may be checked.
The length of hub (L) is taken as 1.5 d.
The material of key is usually the same as that of shaft. The length of key is taken equal to the
length of hub.

4. DESIGN FOR FLANGE

The flange at the junction of the hub is under shear while transmitting the torque. Therefore,
the torque transmitted,
T = Circumference of hub × Thickness of flange × Shear stress of flange × Radius of hub

5. DESIGN FOR BOLTS

The bolts are subjected to shear stress due to the torque transmitted. The number of bolts (n)

13
depends upon the diameter of shaft and the pitch circle diameter of bolts (D1) is taken as 3 d.
We know that

Prob:

Design a cast iron protective type flange coupling to transmit 15 kW at 900 r.p.m. from an
electric motor to a compressor. The service factor may be assumed as 1.35. The following
permissible stresses may be used:
Shear stress for shaft, bolt and key material = 40 MPa
Crushing stress for bolt and key = 80 MPa
Shear stress for cast iron = 8 MPa
Draw a neat sketch of the coupling.

14
 Experiment 3: Design of Flexible coupling
1. AIM OF THE EXPERIMENT: Find the value of dimensions of rigid coupling.

2. THEORY: Flexible coupling is used to join the abutting ends of shafts when they are not
in exact alignment. In a direct electric drive from an electric motor to a machine tool, a
flexiblecoupling is used so as to permit an axial misalignemnt of the shaft without undue
absorption of the power which the shaft are transmitting. Following are the different types of
flexible couplings :

1. Bushed pin flexible coupling, 2. Oldham's coupling, and 3. Universal coupling.

Bushed pin flexible coupling

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16
Since the pin is subjected to bending and shear stresses, therefore the design must be checked
either for the maximum principal stress or maximum shear stress by the following relations,

Prob.
Design a bushed-pin type of flexible coupling to connect a pump shaft to a
motor shaft transmitting 32 kW at 960 r.p.m. The overall torque is 20 percent more than
mean torque. The material properties are as follows :
(a) The allowable shear and crushing stress for shaft and key material is 40 MPa and 80
MPa respectively.
(b) The allowable shear stress for cast iron is 15 MPa.
(c) The allowable bearing pressure for rubber bush is 0.8 N/mm2.
(d) The material of the pin is same as that of shaft and key.
Draw neat sketch of the coupling.

17
 Experiment 4: Design of Helical Spring

1. AIM OF THE EXPERIMENT: Design a helical spring based on given maximum force
and deflection to consider. Analyze the steps involved in designing the helical spring.

2. OBJECTIVE FOR THE DESIGN:

 The spring should possess sufficient strength to withstand the external load.
 It should have different load-deflection characteristic.
 It should not buckle under the external load.

3. TYPES OF SPRINGS:

Helical Torsional
spring Conical or volute spring

Disc spring Laminated or leaf spring

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3.1. Two basic types of helical spring:

(i) Compression spring: shorten under the action of external load

(ii) Extension spring: elongate under the action of external load

Compression helical Extension helical

spring

4. HELICAL COMPRESSION SPRING DESIGN:

The main dimensions of a helical spring subjected to
compressive force are shown in the figure. They are:

 d = wire diameter of the spring (mm)

 Di = inner diameter of the spring (mm)
 Do = inner diameter of the spring (mm)

 D = mean diameter of the spring (mm)

D = (Di + Do) / 2
 p = pitch of the spring (mm)
 C = Spring index = D / d
 For lower C values (C < 3): The actual stresses in the wire
are excessive due to curvature effect.
 For higher C values (C > 15): Spring is prone to buckling and tangle easily during
handling.
 A spring index from 4 to 12 is considered best from manufacturing conditions.

19
5. TERMINOLOGIES USED IN HELICAL SPRINGS:

 Solid Length: It is defined as the axial length of the spring, which when compressed, the
adjacent coils touch each other. No compression is possible beyond this point.
Solid length = Ntd, Nt = Total no. of coils.
 Compressed Length: It is defined as the axial length of the spring, which is subjected to
maximum compressive force. In this case, the spring is subjected to a maximum deflection of
δ. Some gap is provided between the adjacent coils to prevent their clashing.
Clashing allowance = 15% of maximum deflection. Also, 1 - 2 mm gap between the adjacent coils
is provided as a thumb rule.

Total gap = (Nt - 1)xGap between adjacent coils.

 Free Length: It is defined as the axial length of the unloaded spring. In this case, no external
force acts on the spring.
Free length = compressed length + δ
= solid length + total axial gap + δ

 Pitch: It is defined as the axial distance between the adjacent coils in the uncompressed state.
p = free length/(Nt - 1)
 Stiffness: k = P/ δ
P = Axial Spring Force
δ = Axial deflection of spring corresponding to force P.

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6. PROCEDURES FOR DESIGNING A HELICAL SPRING:
The basic procedure for the design of helical spring consists of following steps :
(i) For the given application, maximum spring force (P) and corresponding deflection (δ) are to be estimated.
In some cases, maximum spring force (P) and the stiffness (k) of the spring is specified.

(ii) A suitable spring material is to be selected and its ultimate tensile strength has to be ascertained. The
permissible shear stress for the spring wire is estimated by :


τ P = 0.3 - 0.5 σ UT

(iii) Depending on the application, appropriate spring index (C) has to be choosen. In general, a 'C' value of
8 is considered as a good value. However, 'C' value should not be less than 3.

(iv) The Wahl's factor is to be calculated using the following relationship :

4C - 1 0.615
KW = +
4C - 4 C

(v) The wire diameter (d) is evaluated using the following eqn,

 8PD   8PC 
τ = KW  3 = K W 2
 πd   πd 
(vi) The mean diameter (D) of the coil is obatined using,
D = Cd

(vii) The number of active coils is determined using the following eqn,
3
8PD N
δ=
4
Gd

(viii) Depending upon the type of the ends for a spring, the no. of inactive coils are determined. Total no. of
coils (N t ) can be found out by adding no. of active and inactive coils.

(ix) The solid length of the spring = N t d

3
8PD N
(x) Actual deflection δ =
4
Gd

21
  
(xi) Total axial gap between the coils = N t - 1 x gap between adjacent coils. In some cases, total gap is

taken as 15% of the maximum displacement.

(xii) Free length of the spring is to be determined using,

Free length = Solid length + total gap + δ

(xiii) Pitch (p) of the spring is found out as,

Free length
p=
 N t - 1

(xiv) The stiffness (k) is calculated using,

4
Gd
k =
3
8D N

Experiment 5: Design of Leaf Spring

22
1. AIM OF THE EXPERIMENT: Find dimension of leave spring and assure that the value
of stresses are within the limit.
2. THEORY:

Leaf springs (also known as flat springs) are made out of flat plates. The advantage of leaf
spring over helical spring is that the ends of the spring may be guided along a definite path as
it deflects to act as a structural member in addition to energy absorbing device. Thus the leaf
springs may carry lateral loads, brake torque, driving torque etc., in addition to shocks.

L = length of the cantilever or half the length of semi-elliptic spring (mm)

P = force applied at the end of the spring (N)

Pf = portion of P taken by the extra full-length leaves (N)

Pg = portion of P taken by the graduated-length leaves (N)

The group of graduated-length leaves along with the master leaf can be treated as a triangular
plate, as shown in Fig. give in next slide. In this case, it is assumed

23
24
  The deflection at the load point is given by,

Since the deflection of full-length leaves is equal to the deflection of graduated-length leaves,

25
Bending stresses in full-length leaves are 50% more than those in graduated-length leaves.

3. NIPPING OF LEAF SPRINGS

One of the methods of equalising the stresses in different leaves is to pre-stress the spring. The
pre-stressing is achieved by bending the leaves to different radii of curvature, before they are
assembled with the centre clip. The initial gap C between the extra full-length leaf and the
graduated-length leaf before the assembly, is called a ‘nip’.

26
The deflection at the end of the spring is determined as given below:

The deflection of the multi-leaf spring due to the external force P is the same

Prob:
A semi-elliptic leaf spring used for automobile suspension consists of three extra full-length leaves
and 15 graduated-length leaves,
including the master leaf. The centre-to-centre distance between two eyes of the spring is 1 m. The
maximum force that can act on the spring is 75 kN. For each leaf, the ratio of width to thickness is 9:1.
The modulus of elasticity of the leaf material is 207 000 N/mm2. The leaves are pre-stressed in such a
way that when the force is maximum, the stresses induced in all leaves are same and equal to 450
N/mm2. Determine
(i) the width and thickness of the leaves;
(ii) the initial nip; and
(iii) the initial pre-load required to close the gap C between extra full-length leaves and graduated-
length leaves.

27
 Experiment 6: Design of Brake
1. AIM OF THE EXPERIMENT: To design a block brake with short shoe.
2. THEORY: A brake is defined as a mechanical device that is used to absorb the energy
possessed by a moving system or mechanism by means of friction. The primary
purpose of brake is to slowdown or completely stops the motion of a moving system,
such as rotating drum, machine or vehicle. It is also used to hold the parts of the system
in position at rest.
3. TYPES OF BRAKES:
I. Mechanical Brakes: These are operated by mechanical means such as levers,
spring &pedals. Type of block brake is Block Brake, Internal Brake or External
Shoe Brake, disc brake, band brake.
II. Hydraulic & pneumatic brakes: These are operated by fluid pressure such as
oil or air pressure.
III. Electrical brakes:
These are operated by magnetic forces.
4. ENERGY EQUATIONS:
The braking torque depend upon the amount of energy absorb by the brake. For a translating
body, the kinetic energy (K.E) absorbed by brake during

 Braking Period: K.E. = 1/2 m(v12-v22)

 For a rotating body: K.E=1/2 I(w12 –w22)

 In hoist application
The potential energy(P.E) stored by the brake during braking period =
mghWhere h=distance by which mass m falls during braking period.
E=MTϴ
Where E= total energy absorbed by the brake.
MT= braking torque
ϴ= angle through which brake drum rotate during the braking period .

5. DESIGN OF A BLOCK BRAKE WITH SHORT SHOE:

A block brake consists of a simple block, which is pressed against the rotating drum by
mean of lever. The friction between the block & brake drum causes the retardation of
drum.

28
 Fig. 1.1 Single Block Brake

The analysis is based on following assumption:

1. The block is rigidly attached to the lever.

2. The angle of contact between the block and brake drum is small resulting in a
uniform pressure distribution. Considering the forces acting on the brake drum, M T=
µNR, where R=radius of brake drum.
The dimensions of block are determined by the following expression: N=plω
Where p = permissible pressure between block & brake drum. l &ω= length and width
of the block respectively.
 Generally, drum dia./4< ω <drum dia./2

Fig. 1.2. Free Body Diagram (Clockwise Rotation)

 Considering the equilibrium of forces in vertical and horizontal direction: .

 Taking moment of forces acting on the lever about hinge point 0.
Using Equations:
P×b-N×a+μN  C=0

29
 N
P=  a-µC  ×  
b
Case 1: a>µC: partially self energising brake.
Case 2: a=µC: self locking brake
Case 3: a<µC: uncontrolled braking and grabbing
condition.

6. TO DESIGN A DIFFERENTIAL BAND BRAKE:

The band brake in which one of the band passes through the fulcrum is called simple
band brake, while the band brakes in which neither of the band end passes through the
fulcrum is called differential band brake.

Fig. 1.3. Differential Band Brake

The design steps are as follows:

P μθ
 Step 1: Tension in Bands: 1 =e
P2


P2 a - be
μθ

 Step 2: Actuating Force: P =
l

 Step 4: Torque Capacity of brake: M t =(P1 -P2 )R

30
 P  0 or negative
 Step 5: For self-locking condition:
or a  b  e 

a
Hence, the condition for self-locking is given by    e 
b

31
 Experiment 7: Design of clutch
1. AIM OF THE EXPERIMENT: To understand the functioning of a friction clutch and
obtain the dimensions of a friction clutch for a given application.

2. THEORY:

 Clutch: Clutch is a mechanical device used to engage and disengage power

transmission from a driving shaft to a driven shaft. Different types of clutches:

Clutch Terminology

1. Crank Shaft
2. Flywheel
3. Friction Disk or clutch disk
4. Pressure Plate
5. Friction Lining
6. Diaphragm spring, kept between pressure plate and outer cover
7. Splines
8. Cover or cover of pressure plate
9. Friction Material: Asbestos fibre

Figure 1: Clutches force balance

32
 Figure 2: Different parts of a friction clutch

Figure 3: Actual pictures of a clutches

 Positive clutches: Positive clutches have no slip. Simultaneously, they can not be
engaged and disengaged in rotating conditions

33
 Cones: green
cone and blue

Figure 4: Positive clutches

cone 2. Shaft: the blue is sliding on splines 3. Friction material: usually on the green
cone 4. Spring: brings the blue cone back after using clutch control 5. Clutch
control: separating both cones by pressing 6. Rotating direction: both directions of the axis
are possible

34
 Figure 5: Cone clutch

 Derivations for frictional torque:

The pressure between the contacting surfaces should have a uniform distribution over the
surface. In such cases, wear will be greater at a larger diameter. The loss of material due to
higher wear results in a change in pressure profile. The disk will now follow the uniform
wear condition. A new clutch is close to uniform pressure condition and a worn-out clutch
follows a uniform wear condition.

1. Uniform pressure condition: We need an expression for torque in axial force,

friction coefficient, and disc size.

Figure 6: Differential ring of thickness dr.

35
 The normal force acting on a differential ring element is given by

Here, p is the (uniform) pressure. The total normal force acting on the plate is

.
The torque that is produced due to frictional forces is given by,

Here the coefficient of friction is f.

The total torque that can be developed is given by,

Replacing the pressure p in terms of axial force P, and for N number of plates,

2. Uniform wear theory: Wear rate is proportional to friction work, i.e., friction force
times the rubbing velocity.
Hence, for uniform wear, we have

Expression of torque is given by

Exercise: A plate clutch consists of one pair of contacting surfaces. The inner and outer
diameters of the friction disk are 120 and 250 mm respectively. The coefficient of
friction is 0.12 and the permissible intensity of pressure is 2 N/mm 2. Assuming uniform
wear theory, calculate the power transmitting capacity of the clutch at 750 rpm.
Calculate the power transmitting capacity of the clutch using the uniform pressure
theory.

36
 Experiment 8: Design of Journal Bearing
1. AIM OF THE EXPERIMENT: Design of journal bearing

2. THEORY: Journal bearings are mechanical components used to support shafts of a machine.
Journal bearings are therefore designed to carry radial loads. The load carrying capacity is
developed due to the generation of pressure by the fluid film formed in the clearance space
between the bearing and journal. The shape of the clearance space is shown in Figure 1. The
expression for film thickness can be easily determined from the geometry of the film shape.

Figure 1. Journal bearing geometry

 Material: Cast iron, alloy steel, bronze, aluminium etc.

 Design equations:
o Eccentricity (e) = distance ObOj, where Ob= axis of bearing, Oj = axis of
journal
o Radial clearance (c) = Rb - R, where Rb = radius of bearing, R= radius of
journal
o Eccentricity ratio (ɛ) =
µ
o Somerfield number (S) = , where µ = viscosity of lubricant, 𝑁 = shaft

speed

37
 Sliding velocity (U) = ωR , ω =2πN
 Film thickness (h) = AB which is the film thickness at B at angle θ from line of
action
For simplicity assumed << 1, so then
h = Rb - sin 𝜃 − 𝑠𝑖𝑛 𝑠𝑖𝑛 𝜃 h = c(1+ ɛ cos θ)
L= length of bearing

 Infinitely long bearing approximation (L/2R) > 2,

p=
µ ɛ ( ɛ ) where, P = Pressure
( ɛ )( ɛ )
W = Radial load
ɛ
W = 12µ𝑈𝐿 (
W = Normal load
ɛ )( ɛ )
ɛ W = Total load carrying capacity
W = 6µ𝑈𝐿 Ф = Attitude angle
( ɛ )( ɛ )

ɛ ɛ 𝑓 = Coefficient of friction
W= 6µ𝑈𝐿 ( ɛ )( ɛ )
√ ɛ
Ф= 𝑡𝑎𝑛 =
ɛ
ɛ ɛ
𝑆= (
ɛ ɛ ) ɛ
ɛ Ф
𝑓= +
( ɛ )

 Infinitely short bearing approximation (L/2 R) < 1

p=
µ
−𝑦
ɛ where, P = Pressure
( ɛ )
W = Radial load
µ ɛ
W =− ( W = Normal load
ɛ )
µ ɛ W = Total load carrying capacity
W =
( ɛ ) Ф = Attitude angle
W=
µ ɛ
[(𝜋 (1 − ɛ ) + 16ɛ ] 𝑓 = Coefficient of friction
( ɛ )
𝑄 = Leakage flow rate
√ ɛ
Ф= 𝑡𝑎𝑛 = F = Friction force
ɛ
ɛ
𝑆=
ɛ[( ( ɛ ) ɛ ]

𝑓=
( ɛ )
𝑄 = ɛULc
µ
F=
( ɛ )

38
  Finite journal bearing design: For finite journal bearing, solution of Raimondi and
Boyd method can be used. Dimensionless performance parameters are available in the
form of Charts and tables. It can be used for solving problems.

Power loss (𝑃 ) = 2πRNF where J = mechanical equivalent of

Temperature rise (ΔT) = 𝑄 heat
𝑐 = specific heat

Refer machine design data book for required data if needed.

Problems:

Problem 1: Write a computer program for design of journal bearing.

Problem 2: A full journal bearing of width 20 cm with a journal of diameter 10 cm has
diametric clearance of 100 micro meters. The journal rotates at 1200 rpm. The absolute
viscosity of lubricant at 20° C is 0.04 Pas. For an eccentricity ratio of 0.6, determine the
minimum film thickness, load carrying capacity, attitude angle, Sommerfeld number, friction
factor. Mass density, and specific heat of the oil at constant pressure may be taken as 900
kg/m3 and 2.0 J/g/0K, respectively.
Problem 3: A journal bearing is operating under following operating conditions: Journal
diameter = 20 cm, bearing length = 10 cm and journal speed = 600 r.p.m. Clearance ratio
may be chosen between 0.5, 1, 1.5, and 2.0 mm/m. Select a clearance ratio and determine load
carrying capacity, oil flow rate, power loss, and temperature rise of lubricant while the
viscosity of the oil at 38°C is 100cS and at 100°C is 12cS. Specific gravity of the oil is 0.9. The
bearing is designed to run at an eccentricity ratio 0.6.

39
 Experiment 9: Selection of Rolling Element Bearing
1. AIM OF THE EXPERIMENT: Selection of Rolling Element Bearing from
Manufacturer’s Catalogue

2. THEORY: Bearing is mechanical device that permits relative motion between two parts,
such as the shaft and the housing, with minimum friction. Bearings are classified in different
ways the most important criterion to classify the bearings is the type of friction between the
shaft and the bearing surface. Depending on type of friction, bearings are classified into two
main group Sliding contact bearing and Rolling contact bearing.

Rolling contact bearing: Rolling contact bearing are also called antifriction bearings or simply
ball bearing. Rolling element such as balls or rollers, are introduced between the surfaces that
are in in relative motion. Figure 1 shows rolling contact bearing. Rolling contact bearing are
used in following applications: Machine tool spindle, Automobile front and rear axle, Gear
boxes, Small size electric motors and Rope etc.

Figure 1. Rolling Contact Bearing

The types of rolling contact bearing, which are frequently used are:

(i) Deep Groove Ball bearing (ii) Cylindrical roller bearing (iii) Angular contact bearing (iv)
Self-aligning bearing (v)Taper roller bearing (vi) Thrust ball bearing. Different types of
rolling contact bearing are shown in Figure 2.

40
 Figure 2. Types of Rolling Contact Bearing

Materials: Chrome Steel - SAE 52100, Stainless Steels, Stainless Steel Bearings– ACD34
/KS440 / X65Cr13 etc.

Selection of Rolling Element Bearing:

The information given here should serve to indicate which are the most important of the
following points to be considered when selecting bearing type and thus facilitate an
appropriate choice.

• Cylindrical & Needle roller – pure radial load.

• Thrust (cylindrical roller, ball), four point angular contact ball bearings – pure axial load.

• Taper roller, spherical roller, angular contact ball bearings – combined Load.

• Cylindrical roller, angular contact ball bearing– high speed.

• Deep groove, angular contact, and cylindrical roller bearing – high running accuracy.

Design equations/data:

 Equivalent dynamic load:

𝑃 = equivalent dynamic load (N)

𝑃 = 𝑋𝑉𝐹 + 𝑌𝐹 𝐹 = radial load acting on bearing (N),
𝐹 = axial or thrust load acting on bearing
𝑉 = race- rotation factor
𝑋 = radial factor,
𝑌= thrust factor

41
  Load life equation:
𝐶 where, 𝐿 = rating bearing life (in
𝐿 =
𝑃 million revolutions)
C = dynamic load capacity (N)
p = 3 (for ball bearings)
p = 10/3 (for roller bearing)

 Life in hours:
60𝑛𝐿 where, 𝐿 = rated bearing life (hours)
𝐿 =
10 𝑛 = speed of rotation (rpm)
 Cyclic loads and speed:

⋯ where N = 𝑁 + 𝑁 + ⋯ 𝑁
𝑃 = [ ]
⋯ 𝑃 = equivalent dynamic load for
complete work cycle (N)
∑ 𝑁𝑃 𝑃 , 𝑃 … 𝑃 = dynamic load during first,
𝑃 = [ ]
∑𝑁 second, .... nth element of work cycle
𝑁 , 𝑁 … 𝑁 = number of revolutions
completed by first, second.... nth element
of work cycle
N = life of complete work cycle (rev)
 Cyclic loads and speeds (continuous variation of load):
1
𝑃 =[ 𝑃 𝑑𝑁] ⁄
𝑁
 Bearing with probability of survival other than 90%:
( ⁄ )
𝑅 = 𝑒 , where 𝑅 = reliability (in fraction), L = corresponding life (in million of
revolution), 𝑎 and 𝑏 = constants (𝑎 = 6.84 and 𝑏 = 1.17)

⁄
= [ ] , where 𝐿 = life corresponding to a reliability of 90% or

𝑅 ,𝑅 = 0.9
 System reliability: 𝑅 = (𝑅) , where 𝑁 = number of bearings in the system (each
having the same Reliability 𝑅), 𝑅 = reliability of the complete system
Refer machine design data book for required data if needed.

Problems:

Problem 1: Write a computer program for selection of ball bearing from SKF/FAG
manufacturer catalogue.
Problem 2: A ball bearing operates on the following work cycle:

42
 Element Radial load Speed Element time
No (N) (rpm) (%)

1 3000 720 30

2 7000 1440 50

3 5000 900 20

The dynamic load capacity of the bearing is16.6 kN. Calculate (i) the average speed of
rotation; (ii) the equivalent radial load; and (iii) the bearing life.
Problem 3: A ball bearing is subjected to a radial force of 2500 N and an axial force of 1000
N. The dynamic load carrying capacity of the bearing is 7350 N. The values of X and Y factors
are 0.56 and 1.6 respectively. The shaft is rotating at 720 rpm. Calculate the life of the bearing.
Problem 3: The gear-reduction unit shown has a gear that is press fit onto a cylindrical sleeve
that rotates around a stationary shaft. The helical gear transmits an axial thrust load T of 1kN
as shown in the figure. Tangential and radial loads (not shown) are also transmitted through
the gear, introducing radial ground reaction forces at the bearings of 3.5kN for bearing A and
2.5 kN for bearing B. The desired life for each bearing is 90 kh at a speed of 150 rev/min with
a 90 percent reliability. The first iteration of the shaft design indicates approximate diameters
of 28mm at A and 25mm at B. Select suitable tapered roller bearings from TIMKEN catalogue.

43
 Experiment 10: Design of Spur Gear
1. AIM OF THE EXPERIMENT: Design of spur gear

2. THEORY: In spur gears, the teeth are cut parallel to the axis of the shaft. As the teeth are
parallel to the axis of the shaft, spur gears are used only when the shafts are parallel. The profile
of the gear tooth is in the shape of an involute curve and it remains identical along the entire
width of the gear wheel. Spur gears impose radial loads on the shafts. Spur gear nomenclature
and a pair of spur gear is shown in Figure 1 and Figure 2 respectively.

Figure 1. Gear nomenclature

Figure 2. Spur gear

44
o Material: Steel, hardened teeth, cast iron, bronze, stainless steel, aluminium etc.
o Design equations/ data:

 Module of gear

P= where ,d = pitch circle diameter (mm),

z = number of teeth on the gear
m=
P = Diametral Pitch
d = mz m = Module (mm)

 Recommended series of module (mm)

1 1.25 1.5 2 2.5 3 4

Choice 1
5 6 8 10 12 16 20
1.125 1.375 1.75 2.25 2.75 3.5 4.5
Choice 2
`5.5 7 9 11 14 18 -
Choice 3 3.25 3.75 6.5 - - - -

 Gear Ratio and transmission ratio

where, np = speed of pinion,

i= = ng = speed of wheel,
zp = number of teeth on the pinion,
zg = number of teeth on the wheel

 Basic Relationship

P= where p = Circular Pitch (mm),

d = pitch circle diameter (mm),
p=
z = number of teeth on the gear
P×p = π P = Diametral Pitch
( )
a= m = Module (mm)
a = centre-to-centre distance (mm)
zp = number of teeth on the pinion,
zg = number of teeth on the wheel

45
  Standard proportions of gear tooth for 20° full depth involute system

Dimension Notation Proportion

Addendum ha ha = m
Dedendum hf hf = 1.25m
Clearance c c = 0.25m
Working depth hk hk = 2 m
Whole depth h H = 2.25 m
Tooth thickness s s = 1.5708m
Tooth space …. 1.5708m
Fillet radius …. 0.4m

 Spur gears - Component of tooth force

Mt =
× ( ) where Mt = Torque transmitted by gear (N-mm)
np = speed of pinion (rpm)
Pt = Pt = Tangential component of resultant tooth force (N)
Pr = Pt tanα Pr = Radial component of resultant tooth force (N)
dp = mzp α = Pressure angle (°)
dp = pitch circle diameter of pinion (mm)

 Minimum number of teeth

Pressure angle (α) 14.5° 20° 25°

zmin (theoritical) 32 17 11
zmin (practical) 27 14 9
Note: The minimum number of teeth to avoid interference is given by, zmin =

 Face width of tooth

Optimum range of face width : (8m) < b < (12m) or (b=10m)

 Beam Strength of gear tooth (Lewis’ equation)

Beam strength (Sb) indicates the maximum value of tangential force that the tooth can
transmit without failure:

𝑆 = 𝑚 𝑏𝜎 𝑌 Sb= beam strength of gear tooth (N)

1 σb= permissible bending stress (MPa)
𝜎 =𝑆 = 𝑆
3 Y= Lewis form factor based on virtual number of teeth
Se= endurance limit (MPa)
Sut=ultimate tensile strength (MPa)

 Wear strength of gear tooth (Buckingham’s Equation)

46
Q= (for external gear) Q = Ratio factor
𝑧 = number of teeth on pinion
Q= (for internal gear) 𝑧 = number of teeth on wheel
Sw = b.Q.dp.K Sw = wear strength of the gear tooth (N)
𝜎 𝑠𝑖𝑛𝛼𝑐𝑜𝑠𝛼
1
+ 1/𝐸𝑔 dp = pitch circle diameter of pinion (mm)
𝐸𝑝 K = load-stress factor (MPa)
K =
1.4
σc = Surface endurance strength of the material
(MPa)
α = pressure angle
Ep = modulus of elasticity of pinion materials
(MPa)
Eg = modulus of elasticity of wheel materials
(MPa)

 For steel gears with 20° pressure angle

where BHN = Surface hardness of gears
K = 0.16
(Brinell hardness number)
According to G. Niemann: σc = 0.27(BHN) kgf/mm2 = 0.27 (9.81) (BHN) N/mm2

 Values of Modulus of elasticity and poisson’s ratio for gear materials

Material Modulus of elasticity E (MPa) Poisson’s ratio
Steel 206000 0.3
Cast Steel 202000 0.3
Spheroidal cast iron 173000 0.3
Cast tin bronze 103000 0.3
Tin bronze 113000 0.3
Grey cast iron 118000 0.3

 Effective load on gear tooth

Tangential force due to rated torque or rated power (P t)
Mt =
× ( ) Pt = Tangential force due to rated torque (N)
Mt = rated torque (N-mm)
Pt = Kw = power transmitted by gears (kW)
np = speed of pinion (rpm)
dp = pitch circle diameter of pinion (mm)
Effective load on gear tooth (Peff) – Preliminary gear design
Peff = Peff = effective load on gear tooth (N)
CS = Service factor
Cv = Velocity factor
Effective load on gear tooth (Peff) – Final gear design
Peff = (CSPt+Pd) Pd = incremental dynamic load (N)
(Buckingham’s equation)

47
  Service factor for speed reduction gearboxes (Cs)

Working characteristic of Working characteristic of driven machine

driving machine Uniform Moderate shock Heavy shock
Uniform 1.00 1.25 1.75
Light shock 1.25 1.50 2.00
Medium shock 1.5 1.75 2.25
Note : For Electric motors, Cs =

 Velocity factor (Cv)

For ordinary and commercially cut gears made with form cutters and with (v<10 m/s)
Cv =

For accurately hobbed and generated gears with (v<20 m/s)

Cv =
For precision gears with shaving, grinding, and lapping operations and with (v>20 m/s)
.
Cv =
. √

𝑣= where, 𝑣 = pitch line velocity (m/s)

×
Pd = dynamic load or incremental dynamic load (N)
Pd =
( ) 𝑣 = pitch line velocity (m/s)
( )
C = deformation factor (MPa or N/mm2)
e = sum of errors between two meshing teeth (mm)
b = face width of tooth (mm)
Pt = tangential force due to rated torque (N)

 Deformation factor (C)

Deformation factor C depends upon moduli of elasticity of materials for pinion and
gear and the form of tooth or pressure angle
k = constant depending upon the form of tooth
C= Ep = Modulus of elasticity of pinion material (MPa or N/mm2)
[ ]

Eg = Modulus of elasticity of wheel material (MPa or N/mm2)

The values of k for various tooth forms are as follows:
k = 0.107 (for 14.5° full depth teeth)
k = 0.111 (for 20° full depth teeth)
k = 0.107 (for 20° stub teeth)

48
  Values of deformation factor C
Materials 14.5° full 20° full depth
20° stub teeth
Pinion Material Gear Material depth teeth teeth
Grey C.I. Grey C.I. 5500 5700 5900
Steel Grey C.I. 7600 7900 8100
Steel Steel 11000 11400 11900

Refer machine design data book for required data if needed.

Problems:

Problem 1: Write a computer program for design of spur gear.

Problem 2: It is required to design a pair of spur gears with 20° full-depth involute teeth based
on the Lewis equation. The velocity factor is to be used to account for dynamic load. The pinion
shaft is connected to a 10kW, 1440 rpm motor. The starting torque of the motor is 150% of the
rated torque. The speed reduction is 4:1. The pinion as well as the gear is made plain carbon
steel 40C8 (Sut = 600 N/mm2). The factor of safety can be taken as 1.5. Design the gears, specify
their dimensions and suggest suitable surface hardness for the gears.
Problem 3: A pair of spur gears with 20° full-depth involute teeth consists of a 20 teeth pinion
meshing with a 41 teeth gear. The module is 3 mm while the face width is 40 mm. The material
for pinion as well as gear is steel with an ultimate tensile strength of 600 N/mm 2. The gears
are heat treated to a surface hardness of 400 BHN. The pinion rotates at 1450 rpm and the
service factor for the application is 1.75. Assume that velocity factor accounts for the dynamic
load and the factor of safety is 1.5. Determine the rated power that the gears can transit.
Problem 4: A pair of spur gears consists of a 24 teeth pinion, rotating at 1000 rpm and
transmitting power to a 48 teeth gear. The module is 6 mm, while the face width is 60 mm. Both
gears are made of steel with an ultimate tensile strength of 450 N/mm2. They are heat treated
to a surface hardness of 250 BHN. Assume that velocity factor accounts for the dynamic load.
Calculate (i) beam strength; (ii) wear strength; and (iii) the rated power that the gears can
transmit, if service factor and the factor of safety are 1.5 and 2, respectively.

49
 Experiment 11: Design of Helical Gear
1. AIM OF THE EXPERIMENT: Design of helical gear.

2. THEORY: A pair of helical gears is shown in Figure 1. The teeth of these gears are cut at
an angle with the axis of the shaft. Helical gears have an involute profile similar to that of spur
gears. However, this involute profile is in a plane, which is perpendicular to the tooth element.
The magnitude of the helix angle of pinion and gear is same; however, the hand of the helix is
opposite. A right-hand pinion meshes with a left-hand gear and vice versa. Helical gears impose
radial and thrust loads on shafts.

Figure 1. Helical gear

Material: Cast iron, alloy steel, bronze, aluminum etc.

Design equations:

No. of teeth on pinion (Zp), No. of teeth on gear (Zg), Helix angle (ψ), normal pressure angle
(αn), normal module (m), Rotational speed (N)

 Basic equations of helical gears

pn = p𝑐𝑜𝑠𝜓 where p= transverse circular pitch(mm)
Pn = P/𝑐𝑜𝑠𝜓 pn= normal circular pitch(mm)
mn = 𝑚𝑐𝑜𝑠𝜓 ψ = Helix angle
pa = p/𝑡𝑎𝑛𝜓 Pn= normal diametric pitch(mm)
Cos ψ = tanαn/tanα αn P = tranverse diametric pitch(mm)
d = zmn/cos ψ mn= normal module(mm)
m (𝑧 + 𝑧 ) m = transverse module(mm)
a =
2 pa = axial pitch(mm)
αn = normal pressure angle (0)

50
 𝑤 𝑧 α=transverse pressure angle (0)
𝑖= =
𝑤 𝑧 d=pitch circle diameter(mm)
z= number of teeth
a=center to center distance(mm)
i=speed ratio
𝑧 = number of teeth on pinion
𝑧 = number of teeth on wheel

Recommended series of normal module (mn) in mm is: 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8 and 10.

 Standard proportions of helical gears

𝑧 where, Addendum(ha)=mn
𝑑 =𝑚 +2
𝑐𝑜𝑠 𝜓 Dedendum(hf)=1.25mn
𝑧 Clearance(c)=0.25mn
𝑑 =𝑚 − 2.5
𝑐𝑜𝑠𝜓 da=addendum circle diameter(mm)
df=dedendum circle diameter (mm)

 Components of tooth force

60𝑥10 (𝑘𝑊) Suffix p is used for pinion

𝑀 =
2𝜋𝑛 Mt = torque transmitted by gears (N-mm)
2𝑀 (kW) = power transmitted by gears
𝑃 = np= speed of pinion (rpm)
𝑑
Pt= tangential component of resultant tooth force (N)
𝑡𝑎𝑛𝛼 Pr= radial component of resultant tooth force (N)
𝑃 =𝑃
𝑐𝑜𝑠𝜓 Pa= axial or thrust component of resultant tooth force (N)
dp= pitch circle diameter of pinion (mm)
𝑃 = 𝑃 𝑡𝑎𝑛𝜓
αn= normal pressure angle (0)
𝑧 𝑚
𝑑 =
𝑐𝑜𝑠𝜓

 Design by Lewis and Buckingham’s Equations

Beam Strength of gear tooth (Lewis’ equation)

Beam strength (Sb) indicates the maximum value of tangential force that the tooth can
transmit without failure

𝑆 = 𝑚 𝑏𝜎 𝑌 Sb= beam strength of gear tooth (N)

σb= permissible bending stress (MPa)
Y= Lewis form factor based on virtual number
of teeth (z’)

51
 1 Se= endurance limit (MPa)
𝜎 =𝑆 = 𝑆
3 Sut=ultimate tensile strength (MPa)

 Wear strength of gear tooth (Buckingham’s equation)

Wear strength (Sw) indicates the maximum value of tangential force that the tooth can
transmit without pitting failure.
𝑏𝑄𝑑 𝐾 Sw= wear strength of thr gear tooth (N)
𝑆 =
𝑐𝑜𝑠 𝜓 Q= ratio factor
dp= pitch circle diameter of pinion (mm)
K= load-stress factor (MPa)
𝑄= (for external gears) zp= number of teeth on pinion
zg= number of teeth on wheel
𝑄= (for internal gears)
σc= surface endurance strength of the
𝜎 𝑠𝑖𝑛𝛼 𝑐𝑜𝑠𝛼 (1 𝐸 + 1 𝐸 ) material(MPa)
𝐾= 𝛼 = normal pressure angle(0)
1.4
𝐸 = modulus of elasticity of pinion material
(MPa)
𝐸 = modulus of elasticity of wheel material
(MPa)
0
For steel gears with 20 pressure angle, BHN= surface hardness of gears (Brinell
𝐵𝐻𝑁 Hardness Number)
𝐾 ≈ 0.16
100
According to G. Niemann,
σc=0.27(BHN) kgf/mm2 = 0.27(9.81)(BHN) N/mm2

 Effective Load on gear tooth

Tangential force due to rated torque or rated power (Pt)

60 ∗ 10 (𝑘𝑊) Pt= tangential force due to rated troque (N)
𝑀 =
2𝜋𝑛 Mt = rated torque(N-mm)
2𝑀 (kW) = power transmitted by gears
𝑃 = np= speed of pinion (rpm)
𝑑
dp= pitch circle diameter of pinion (mm)

Effective load on gear tooth (Peff) – Preliminary gear design

𝐶𝑃 Peff= effective load on gear tooth (N)
𝑃 =
𝐶 Cs= service factor
5.6 Cv= velocity factor
𝐶 =
5.6 + √𝑣 v= pitch line velocity (m/s)

52
 Effective load on gear tooth (Peff) – Final gear design
𝑃 = (𝐶 𝑃 + 𝑃 ) Pd= incremental dynamic load (N) (Buckingham’s
equation)

Refer machine design data book for required data if needed.

Problems:

Problem 1: Write a computer program for design of helical gear.

Problem 2: A pair of parallel helical gear consists of an 18 teeth pinion meshing with a 45
teeth gear. 7.5kW power at 2000 rpm is supplied to the pinion through its shaft. The normal
module is 6mm, while the normal pressure angle is 200. The helix angle is 230. Determine the
tangential, radial and axial components of the resultant tooth force between the meshing teeth.
Problem 3: A pair of parallel helical gears consists of 20 teeth pinion meshing with a 100 teeth
gear. The pinion rotates at 720 rpm. The normal pressure angle is 200, while the helix angle is
250. The face width is 40 mm and the normal module is 4 mm. The pinion as well as the gear
is made of steel 40C8 (Sut=600N/mm2) and heat treated to a surface hardness of 300 BHN. The
service factor and the factor of safety are 1.5 and 2 respectively. Assume that the velocity factor
accounts for the dynamic tool load and calculate the power transmitting capacity of the gears.

53
 Experiment 12: Design of Bevel Gear
1. AIM OF THE EXPERIMENT: Design of bevel gear

2. THEORY: Bevel gears, as shown in Figure 1, have the shape of a truncated cone. The size
of the gear tooth, including the thickness and height, decreases towards the apex of the cone.
Bevel gears are normally used for shafts, which are at right angles to each other. This, however,
is not a rigid condition and the angle can be slightly more or less than 90 degrees. The tooth of
the bevel gears can be cut straight or spiral. Bevel gears impose radial and thrust loads on the
shafts.

Figure 1. Bevel gear

Material: Cast steel, Plain carbon steels, Alloy steels etc.

Design Equations:

 Pitch angle formulas

Pinion (𝛳 ) = tan
VR= Velocity Ratio
𝜃 = the angle between the shafts.
sin 𝛳
Gear (𝛳 ) = tan
1
+ cos 𝛳
𝑉𝑅

54
  Components of tooth force

Suffix p is used for pinion

60 ∗ 10 (𝑘𝑊) Mt = torque transmitted by gears (N-mm)
𝑀 = (kW) = power transmitted by gears
2𝜋𝑛
𝑀 np= speed of pinion (rpm)
𝑃 = Pt= tangential component of resultant tooth force (N)
𝑟
𝑃 = 𝑃 𝑡𝑎𝑛 𝛼 𝑐𝑜𝑠𝛾 Pr= radial component of resultant tooth force (N)
𝑃 = 𝑃 𝑃 𝑡𝑎𝑛 𝛼 𝑠𝑖𝑛 𝛾 Pa= axial or thrust component of resultant tooth force (N)
𝐷 𝑏 sin 𝛾 𝑟 = radius of pinion at the midpoint along the face width (mm)
𝑟 = − 𝛼 = pressure angle (0)
2 2
𝐷 = pitch circle diameter at large end of the tooth (mm)

 Design by Lewis Equations

Beam Strength of gear tooth (Lewis’ equation)
Beam strength (Sb) indicates the maximum value of tangential force that the tooth can transmit
without failure

𝑏 Sb= beam strength of gear tooth (N)

𝑆 = 𝑚𝑏𝜎 𝑌 1 −
𝐴 σb= permissible bending stress (MPa)
Y= Lewis form factor based on formative
𝐷 𝐷 1
𝑤ℎ𝑒𝑟𝑒 𝐴 = + 𝑏= 𝐴 number of teeth
4 4 4 m= module at the large end of the tooth (mm)

1 Se= endurance limit (MPa)

𝜎 =𝑆 = 𝑆
3 Sut=ultimate tensile strength (MPa)

 Standard proportions of bevel gears

Addendum, (a) = 1 m; Dedendum (d) = 1.2 m Clearance= 0.2 m Working depth= 2 m Thickness
of tooth = 1.57 m
 Equivalent number of Teeth for Bevel Gears- Tredgold’s Approximation:

𝑇 = 𝑇 sec 𝛳𝑝 𝑜𝑟 𝑔

 Outside diameter for the Bevel Gears ( 𝑫𝟎 ) = 𝐷 + 2𝑎 𝑐𝑜𝑠 𝛳

/
 The relation between 𝑨𝟎 , 𝑫𝒑 , 𝜭𝒑 is: sin 𝛳 =

 Wear strength of gear tooth (Buckingham’s equation)

55
Wear strength (Sw) indicates the maximum value of tangential force that the tooth can
transmit without pitting failure.
Sw= wear strength of thr gear tooth (N)
Q= ratio factor
𝑏𝑄𝐷 𝐾
𝑆 = .75 Dp= pitch circle diameter of at large end of
𝑐𝑜𝑠 𝛾
the tooth (mm)
K= load-stress factor (MPa)
2𝑧 zp= number of teeth on pinion
𝑄=
𝑧 + 𝑧 tan 𝛾 zg= number of teeth on wheel

σc= surface endurance strength of the

𝜎 𝑠𝑖𝑛𝛼 cos 𝛼 (1 𝐸 + 1 𝐸 ) material(MPa)
𝐾= 𝛼 = normal pressure angle(0)
1.4
𝐸 = modulus of elasticity of pinion material
(MPa)
𝐸 = modulus of elasticity of wheel material
(MPa)
For steel gears with 200 pressure angle, BHN= surface hardness of gears (Brinell
𝐵𝐻𝑁 Hardness Number)
𝐾 ≈ 0.16
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According to G. Niemann,
σc=0.27(BHN)kgf/mm2 = 0.27(9.81)(BHN) N/mm2

Refer machine design data book for required data if needed.

Problems:

Problem 1: Write a computer program for design of bevel gear.

Problem 2: A pair of straight bevel gears is required to transmit 10 kW at 500 rpm from motor shaft
to another shaft at 250 rpm. The pinion has 24 teeth. The pressure angle is 20°. If the shaft axes are
at right angles to each other find the module, face width, addendum, outside diameter and slant
height. The gears are capable of withstanding a static stress of 60 MPa. The tooth form factor may
.
be taken as . 154 − , where 𝑇 is equivalent number of teeth. Assume velocity factor 𝐶 =

.
where 𝑣 the pitch line speed in m/s.
.

Problem 3: A 35 kW motor running at 1200 rpm drives a compressor at 780 rpm. The arrangement
is made through a 90ᵒ bevel gearing arrangement. The pressure angle of the teeth is 14.5ᵒ. The
allowable static stress for both pinion and gear are 85 MPa. Determine the number of teeth on the
gear, face width, addendum, dedendum outside diameter and slant height, thickness of tooth. Also

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check your design from the standpoint of wear. Take surface endurance limit as 690 MPa and
Modulus of Elasticity as 89kN/ 𝑚𝑚 .

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