Example 17.2 The pitch circles ofa train of spur gears are shown in Fig, 17.23. Gear A receives 3.5 KW of power at 700 rpm through its shaft and rotates in the clockwise direction. Gear Bis the idler gear while the gear Cis the driven gear. The number of teeth on gears A, B and C are 30, 60 and 40 respectively, while the module is 5 mm. Calculate (9 the torque on each gear shaft; and (ii) the components of gear tooth forces. Fig. 1723 Drawa ree-body diagram offorces anddetermine the reaction on the idler gear shaft. Assume 20° involute system for the gears. Solution WH3S n= 700mm z,=30 40. m=Smm a= 20° Step Torque acting on shafts A, Band © ai,= mz, = 5(30) = 150 mm df= my = 5 (60) = 300 mm = mz, = 5(40) = 200 maa (a, = DXEGW) _ oo 1040.5 2a, (700) = 47746.48 Nemm Gear Bis the idler gear and does not transmit any torque tits shaft. Therefor, G)g=0 Since the same power is transmitted from the gear lt the gear C (ng = Oye Xe ms) (40 anal | ar 746a0)x{ 5) = 63661.98 N-mm 0 M)Step I Components of gear tooth forces The components of the gear tooth force between gears A and B ate given by, 2147 746.88) _ 656 6 150 (Pap = (Pag tan 01 = 636,62 tan(20) =231,71N ai) Since the gear B is the idler, whatever torque it receives from the gear A is transmitted to the gear C. Therefore, a x Pax F = Pac 2 or, (Poe Pac = Py ‘The tangential component between gears B and C must be equal to the tangential component between gears A and B. Since the tangential components are ‘equal, the radial components (P, tan of) must be equal Step IM Free-body diagram of forces The free-body diagram of forces is shown in Fig. 17.24. Gear A is rotating in the clockwise direction. It is a driving gear and the direction of tangential component is opposite to that of rotation, Therefore, the tangential component at the point-1 ‘on the gear A will act towards the upper right-hand comer of the page. Since the action and reaction are Fig. 17.24. Free-body Diagram of Forces ‘equal and opposite, the tangential component at the point2 on the gear B will act towards the lower left- hhand comer of the page. Between gears B and C, B is the driving gear and C is the driven gear. Gear C is rotating in the clockwise direction, The direction of tangential component for driven gear is same as that of rotation. Therefore, at the point-4 on the gear , the tangential component will act towards the upper left-hand corner of the page. Since the action ‘and reaction are equal and opposite, the tangential ‘component at point-3 on the gear B will act towards Tower righthand comer of the page, The radial ‘components at points 1, 2, 3 and 4 will act towards the centres of respective gears, Step IV Reaction on idler gear shaft ‘Consider the equilibrium of forces acting on the gear B, in two planes inclined at 45° to the vertical, The forces are acting at points 2 and 3 and their reactions at the shaft. Each component of the reaction Ry on these planes is equal to (P, + P,). Therefore, the reaction Rg on the idler gear shaft is given by, {pupyapaPye Ry = VR +R) +R +BY pinnae = y2(636.62 + 231.71)" 228 N Example 17.3 4 planetary gear train is shown in Fig. 1725. The sun gear A rotates in a clockwise direction and transmits 5 KW of poser at 1440 rpm to the gear train. The number of teeth on the sun gear A, the planet gear B and the fixed ring gear Fig. 17.25 Planetary Gear Train Care 30, 60 and 150 respectively, The module is 4 ‘mm and the pressure angle is 20°. Draw a free-body diagram of forces and calculate the torque that the arm D can deliver to its output shaftSolution Given KW=5 n= 1440rpm_ 24-30 zp 60 27150 m=4mm_ a=20° Step 1 Free-body diagram of d= mz,= 430) dj = mzy~ 4(60) = 240 mm die mze= 4(150) = 600 mm The length L of the arm D is given by, itd 1204240 66 en 2 2 ‘The tangential component of the gear tooth force on the sun gear 4 is calculated inthe following way. 6010%(KW) _ 601055) 2an, 2440) =33 157.28 N-mm _ 2633 157.28) 120 ‘The free-body diagram of forces is shown in Fig. 17.26. Gear 4 is rotating in the clockwise direction Its a driving gear and the direction of the tangential component is opposite to that of rotation Therefore, the tangential component at point-1 on the gear A will act towards the left side ofthe page. P L, a= = 552,62. Since the action and reaction are equal and opposite, the tangential component at point-2 on the gear B will act towards the right side of the page. Gear Cis, fixed in the housing and will resist the motion of the gear B. Therefore, in relative terms, the gear B is the driving gear in relation to the gear C. The direction of tangential component for the driving gear is ‘opposite to that of rotation, Therefore, at point-3 ‘on the gear B, the tangential component will act towards the right-hand side of the page. The radial ‘components at points 1, 2 and 3 will act towards the ccontres of respective gears. Step shaft Considering the equilibrium of horizontal forces acting on the gear B, the magnitude of reaction at point 5 will be (2) and it will act towards the left side of the page. Since the action and reaction are ‘equal and opposite, the tangential force at point-6 ‘on the arm D will be (2P)) and it will act towards the right side of the page. The torque about the axis Q is given by, Torque that the arm D can deliver to its output Torque = 2P{Lp) = 2(552.62)(180) = 198943 N-mm. ‘or Torque ~ 198.94 N-m Example 17.4 The gearbox for the rotating ‘rum of a concrete mixer is shown in Fig. 17.27. The mixing drum receives 5 KW of power and rotates at 250 rpm. Two pins are rigidly fixed ta the drum and each carries an identical planetary spur gear F. The Fig. 1727 spur gears E and C are integral with the shaft and rotate at the same speed. The spur gear Ais the fixed ring gear. The number of teeth on gears A, B, C and E are 65, 20, 80 and 35 respectively. The module is 5 ‘mm for all gears. The pressure angle is 20°. Assume that each planetary gear shares an equal part of Toad and neglect frictional losses. Calculate:(Components of tooth force between gears E and F. ii) Components of tooth force between gears B and C. Solution Given kW-5 n= 2501pm_ a 20 24-65 2=20 2-80 2p=35 m=Smm Step Free-body diagram of forces di mz,= 5(65) = 325 mm d= my = 5(35) = 175 mm. dé-= mze= $(80) = 400 mm ‘The centre distance between two pins, which are fixed to the drum, is denoted by a. 325-+175 di td 2 2 The output torque on the mixing drum is given = 250mm by, 60 x10%(KW) _ 602105) 2mm 2 (250) = 190 985.93 N-mm @ Refer to Fig, 17.27 for the flow of power. B is the input pinion. Power is supplied from the pinion B to the gear C and then from the gear E tothe gear F. Therefore, between gears E and F, the gear E is the driving gear and the gear F is the driven gear. The construction ofa free-body diagram of forces is illustrated in Fig. 17.28. Let us denote F, and F, as upper and lower planetary gears F. Refer to Fig.17.28(a) (0) Itis assumed thatthe gear i rotating inthe clockwise direction. Therefore, geats F and F, will rotate in anti-clockwise direction. is a fixed internal gear. (ii) During working operation, the point 1 on the sear E and the point on the gear F will be in contact with each other. Similarly, points 3 and 4, points 5 and 6, and points 7 and 8 will be in contact with cach other. Refer to Fig.17.28(0) (@) Gear F; is the driven gear as compared to the gear £. It is made to rotate in the ant- clockwise direction. Therefore, atthe point 2, the tangential component (P))ze will act towards the right. For this component, there will be an equal and opposite reaction on the gear F at the point 1. Therefore, the tangential component (P))xp will act towards left at the point | on gear E. A ZZ (Pence. MCPS, ig na @ c) Fig. 17.28 Free Boily Diagram of Forces i) Gear F; is also a driven gear as compared to the gear B, It is made to rotate in anti- clockwise direction. Therefore, at the point 4, the tangential component (P))ye will act towards the left, For this component, there will be equal and opposite reaction on the gear E atthe point 3. Therefore, the tangential component (P))ge will act towards the right at the point 3 on the gear E. ii) Gear A is fixed in the housing and will resist the motion of planetary gears F, and F,, Therefore, in relative terms, gears F and F; are driving gears with respect to the gear A, For the driving gear, the tangential component acts in opposite direction of the ‘motion. Therefore, atthe point 5 on the gear F,,(P))pq Will act towards the right. Similarly,at the point 7 on the gear F, (P))qq will act towards the left. (iv) Gears F, and Fy ate planetary gears and do not transmit any torque to their pins Considering the forces on the gear F), (Pag X radius of F, = (P)p, radius of Fy or Pose Psa ‘The pin of the gear F, is subjected to a force 2(P)gp towards the right. Similarly it can be proved that the pin of the gear F is subjected to a force 2(P gp towards the left. The forces acting on the ‘two pins ate illustrated in Fig. 17.28(c). The pins are fixed to the drum. Therefore, the torque acting on the drum is given by, a (a) M, =2F Dee «(220 (5 = Uap Xa o) Step 11 Component of tooth force between gears Eand F From (a) and (0), 190 985.93 = 208 )pp (250) (P)er= 381.97 N (Per (Ppp tan oe 381.97 an 20) = 139.03 N ® Step IM Components of tot force behocen gears B ole Considering the tangential components on gears E and C, de de 2D ae ($= Pree F ear x{ = rrenxf 2) (175) (400 38197 - 400 2008197 x{ = (nay x{ 2) Pea =33422 N Pea~ (Pog tan = 334.22 tan (20) 121.65 N. ) Bxample175 The layout of a two-stage gear box is shown in Fig, 17.29. The number of teeth on the gears are as follows: 2)=20 2,=50 25-20 2,750 Pinion I rotates at 1440 rpm in the anti-clockwise direction when observed from the left side ofthe page and transmits 10 kW of power to the gear train. The pressure angle is 20°. Draw a free-body diagram of the gear tooth forces and determine the reactions at bearings E and F. 15.78 18,75 Fig. 17.29 Solution Given KW=10 n= 1440—pm_@=20° 4=20 23750 4520 24-50 a= 175mm Step 1_ Free-body diagram of forces From Eq. (17.5), 2a 2075) _ Gra) 20+50) 5(20)= 100 mm ds mz,~ $(50) = 250 mm The forces between gears I and 2 are calculated in the following way 60% 10%(KW) _ 6010810) ama, (My = 2am, 2a( 1440) = 66 314.56 N-mm p= 2s _ 166314858) _ys9¢ 9. a 100 P, > Ptan t= 1325.29 tan (20) = 482.73 N The corresponding forces between gears 3 and 4 are denoted by Pyand P*. Since, px born 2 2 (45 (250 r= Rx| | =1326.29 ‘ (4) 6 (iar) = 3315.13 P= Pf tan ec= 3315.73 tan (20) = 1206.83 N‘The free-body diagram of forces acting on the shaft EF is shown in Fig. 17.30, The pinion-1 is rotating in anti-clockwise direction when observed from the left side of the page. Therefore, the gear-2 and the shaft EF are rotating in clockwise direction. Power is transmitted from the gear-I to the gear-2, and then from gear-3 to the gear-4, Therefore, the gear-2 is driven gear and the gear-3 is the driving gear. The direction of tangential component for the driven gear is the same as that of rotation. Therefore, atthe point ‘of contact on the gear-2, the tangential component ‘will act towards the lower right-hand comer of the page. The direction of tangential component for diving gear is opposite to that of rotation. Therefore, al the point of contact on the gear-3, the tangential component will act towards the upper leftchand ‘comer of the page. The radial components will act towards the centres of respective gears ew Step II Reactions at bearings E and F The forces acting in vertical and horizontal planes are shown in Fig. 17.31 Considering vertical forces and taking momer about the bearing £, PX 50 * Px 250= (Rp), X 300 482.73 x 50 1206.83 % 250 = (Rp), x 300 (Rpy= 1086.15 N @ Pot Pe= (Rp * (Rey 4462.75 + 1206.83 = 1086.15 + (R,), (Rp), = 603.41 N w@ Considering horizontal forces and taking moments about the bearing E, P/x.250~ P, x 50~ (Ry),300 3315.73 x 250 — 1326.29 x 50 = (Rp) x 300 {py 2542.06 N ‘ip (Bny+ P= Bey + Pe 2542.06 + 1326.39 = (Rp),~ 3315.73 (Rp) = 552.62 N tv) “RH Pearson Gear overdesign and how to avoid i’-Machine Design (Rey (Rely (2) Vertical plane Pr (Poh 5 A rod te (b) Horzontal plane Fig. 17.31 17.12_GEAR TOOTH FAILURES There are two basic modes of gear tooth failure— breakage of the tooth due to static and dynamic loads and the surface destruction®:®, The complete breakage of the tooth can be avoided by adjusting the May 9, 1968, vol. 40, no, 11, p. 153. 5 Bugene E Shipley — “Gear failures—how to recognize them, wht causes them and how to avoid them?’—Machine Design—Dec 7, 1967, vol. 39, no. 28, . 152.parameters inthe gear design, such as the module and the face width, so that the beam strength of the gear toothis more than hesum ofstaticanddynamicloads, The surface destruction or tooth wear is classified according to the basis of their primary causes. The principal types of gear tooth wear are as follows: (Abrasive Wear Foreign particlesin the lubricant, such as dirt, rust, weld spatter or metallic debris ccan scratch or brinell the tooth surface, Remedies against this type of wear are provision of oil filters, increasing surface hardness and.use of high viseosity oils. A thick lubricating film developed by these oils, allows fine particles to pass without scratching. G9 Corrosive Wear The corrosion of the tooth surface is caused by corrosive elements, such as extreme pressure additives present in lubricating oils, and foreign materials due to external contamination, ‘These elements attack the tooth surface, resulting in fine wear uniformly distributed over the entire surface. Remedies against this type of wear are, providing complete enclosure for the gears free from extemal contamination, selecting proper additives and replacing the lubricating oil at regular intervals. ii) Initial Pitting The initial or corrective pitting is a localized phenomenon, characterized by small pits at high spots, Such high spots are progressively ‘worn out and the load is redistributed. Initial pitting is caused by the errors in tooth profile, surface irregularities and misalignment, The remedies against initial pitting are precise machining of gears, adjusting the correct alignment of gears so that the load is uniformly distributed across the full face width, and reducing the dynamic loads. (io) Destructive Pitting Destructive pitting is a surface fatigue failure, which occurs whenthe loadon the geartooth exceeds the surface endurance strength of the material, This type of failure is characterized by pits, which continue to grow resulting in complete destruction of the tooth surface and, in some cases, even premature breakage of the tooth, Destructive pitting depends upon the magnitude of the Herta” contact stress and the number of stress cycles. This {ype of failure can be avoided by designing the gears in such a way that the wear strength of the gear tooth is more than the sum of static and dynamic loads. The surface endurance strength can be improved by inereasing the surface hardness, (©) Scoring Excessive surface pressure, high surface speed and inadequate supply of lubricant result in the breakdown of the oil film. This results in excessive frictional heat and overheating of the meshing teeth. Scoring is a stick-slip phenomenon, in which altemate welding and shearing takes place rapidly at the high spots, Here, the rate of wear is faster, Scoring can be avoided by selecting the parameters, such as surface speed, surface pressure and the flow of lubricant in such a way that the resulting temperature at the contacting surfaces is within permissible limits. The bulk temperature of the lubricant can be reduced by providing fins on the outside surface of the gear box and a fan for forced circulation of air over the fins. 17.13 SELECTION OF MATERIAL The desirable properties of gear material are as follows: (The load carrying capacity of the gear tooth depends upon the ultimate tensile strength or the yield strength of the material. When the goar tooth is subjected to fluctuating forces, the endurance strength of the tooth is the deciding factor. The gear material should have sufficient strength to resist failure due to breakage of the tooth, Gi) In many cases, it is “wear rating’ rather ‘than ‘sirength rating’ which decides the dimensions of the gear tooth. The resistance to wear depends upon alloying elements, grain size, percentage of carbon, and surface hardness. The gear material should have sufficient surface endurance strength to avoid failure due to destructive pitting iii) For high-speed power transmission, the sliding velocities are very high and the material should have low coefficient of friction to avoid failure due to seoring, (iv) The amount of thermal distortion or warping during the heat treatment process is a major problem in gear applications. Dueto warping, the load gets concentrated at one comer of the gear tooth. Alloy stcels are superior to plain carbon steels in this respect, due to consistent thermal distortion,Gears are made of cast iron, steel, bronze and phenolic resins. Large size gears are made of grey cast iron of Grades FG 200, FG 260 or FG 350. They are cheap and generate less noise compared with steel gears. They have good wear resistance. Theit main drawback is poor strength. Case-hardened steel gears offer the best combination of a wear- resisting hard surface together with a ductile and shock-absorbing core, The plain carbon steels used for medium duty applications are SOC8, 45C8, S0C4 and 55C8. For heavy duty applications, alloy steels 40Crl, 30NI4CrI and 4ONi3Cr65MoSS are used. For planetary gear trains, alloy steel 35NilCr60, is recommended, Although steel gears are costly, they have higher load carrying capacity. Bronze is mainly used for worm wheels due to its low coefficient of friction and excellent conformability It is also suitable where resistance to corrosion is an important consideration in applications like water pumps. Their main drawback is excessive cost. ‘Non-metallic gears are used under the following conditions: (The load is light and the pitch line velocity is Tow. i) A tong life is expected, ii) 11 is required to have quiet operation free from noise and vibrations. (iv) The gears are likely to be affected by water and oil In non-metallic gear drives, only the pinion is ‘made of non-metals such as molded nylon, laminated phenolies like Bakelite or Celoron, ‘The non- ‘metallic pinions generally run with east iron gears Gears made of phenolic resins have low modulus of elasticity and work on marginal lubrication. They can tolerate errors in the tooth profile. 1714_GEAR BLANK DESIGN Depending on the purpose and the size, there are different constructions for gears. These constructions are broadly classified into the following three groups: (Small size gears; Gi) Medium size gears; and Gii)_goars with large diameter. Inthis article, we will consider the salient features of these constructions. (@ Smalt Sized Gears A pinion with root diameter neat to the required diameter of the shaft is made integral with the shal. This type of construction is shown in Fig. 1732. The rule of thumb for making integral gear is as follows: ‘I the diameter of dedendum circle (dj exceeds the diameter of the shaft (d), at the point where the pinion is ted, by less than (d/2), the pinion is made integral with the shaft’ ——e TAYZ4 aFr 4 Ll aa fey. Fig. 1732 Integral Gear The dimensions ofthe pinion are as follows: (2) Pitch circle diameter = d’ = mz (b) Addendum circle diameter = d, = d" ~ 2h, ime + 2m) = me +2) (6) Dedendum circle diameter = d,~ d’ ~2hy mz ~ 2(1.25 m) = m(2~2.5) (@) Shaft diameter = d, () Width of gear~ face wid The advantages of integral construction are as follows: (@) It reduces the amount of machining since there is no need to cut keyways on the shaft and the pinion (©) Tt reduces the mumber of parts since there is no key. This reduces the cost (6) Itinereases the rigidity ofthe shaft and also increases the accuracy of contact. However, integeal construction can be used only when the size of pinion is small, If the diameter of 4edendum circle is considerably larger than the shaft «ameter, the pinion is made separate from the sha (i) Medium Sized Gears ‘There are two methods to manufacture medium size gears, They include ‘machining from bar stock and forging. Gears of addendum circle diameter upto 150mmaremachined ‘on rolled steel bars. The gear blanks in this ease are tumed on lathe, Gears of addendum circle diameterfrom 150 mm to 400 mm are mostly forged in open or closed dies, It again depends upon the volume of production, Even small diameter gears are forged, if the volume of production is large. Forged gears offer the following advantages: (a) The factor of material utilisation is equal to (1/3) when the gear is machined from bar stock. Incase of forgings, material utilization factor is (2/3), which is twice. This reduces the cost of the material (b) Forged gear has lightweight construction which reduces inertia and centrifugal forces (©) The fibre lines of the forged gears are arranged in a predetermined way to suit the direction of external force. In case of gears, prepared by machining methods, the ‘original fibre lines of rolled stock are broken, ‘Therefore, the forged gear is inherently strong compared with machined gear. ‘The limiting factor governing the choice of forged gears is their high cost. The equipment and tooling required to make forged gears is costly. Forged gears become economical only when they are manufactured on large seal, Figure. 17.33 shows a gear in the form of a flat circular disk, which is machined from bar stock. The gear blank in this case is tumed on the lathe. This {ype of construction is used for gears with addendum circle diameter up to 150 mm or when the gears are ‘manufactured on small scale, It is more economical than forged gear bb te ty + Fig. 17.33 Machined Gear The main dimensions of the gear blank are as follows: (a) Pitch cirele diamet (b) Addendum circle diameter = d, (c) Dedendum circle diameter = d (@) Shaft diameter = d, (©) Width of ge: (e+2) m(z 2.5) face width = b The construction of a forged gear is shown in Fig, 17.34, Itis made of three parts—hub, web and rim, The web connects the hub with the rim. Holes are provided in the web for clamping the gear blank during machining, It also reduces the weight. The inner surface of the rim and the outer surface of the © ke Fig. 17.34 Forged Gear hhub are provided with draft for easy removal from the dies. The dimensions of forged gears are based ‘on the following thumb rules: (@) The thickness of the rim (f,) up to the root cirele diameter is taken as (2m) to (3m). (©) The thickness of web (6) is taken as (0.25) 10 (0.35). (©) The outer diameter of ub (d,) is taken as (15d) to 2.04), The main dimensions of the gear blank of forged ‘gear are as follows: (a) Pitch circle diameter = d’ = mz (b) Addendum circle diameter = d= m(z +2) (©) Dedendum circle diameter = dy~ m(2—2.5) (@) Shaft diameter = d, (e) Outer diameter ofhub=d, =(1.5d,)t0(2.0d,)(8 Length of hub = length of key or width of gear (maximum value) (g) Width of web = 6, = (0.25) to (0.36) (2) Inner diameter of rim = d= (dj 2r,) @ Outer diameter of rim = dedendum circle diameter = dy G) Thickness of rim = 1,= 2m to 3m &) Diameter of holes in web = dy = (dy —a)'4 (0) Pitcheirclediameterofholes~ dy (dy'+ah)/2 (an) Width of rim = face width = b ‘Whatever the computed dimensions, care should be taken to make the gear a ‘sound’ forging and modify the dimensions, if required. The guidelines for designing a forging ate explained in Section 3.3 ‘on Design considerations of Forgings. These rules related to uniform thickness, minimum section thickness, fillet and comer radii and provision of draft ‘must be applied to final drawing of gear blank (i) Gears with Large Diameter There are two varieties of large size gears—solid cast gears and rimmed gears. When the addendum circle diameter i up to 900 mm, a solid cast iron gear with one wed is recommended, When the addendum circle diameter is more than 1000 mm, two webs are provided. A solid cast gear with two webs is shown in Fig. 17.35, Solid east iron geats are extensively used due to low cost. Though cast iron gears are cheaper than steel ‘gears, their torque transmitting capacity is low. The dimensions of cast iron gears are determined by thumb rules and principles of casting design. ‘The main dimensions of cast iron gear, illustrated in Fig. 17.35 are as follows (a) Pitch circle diameter = d= mz (b) Addendum circle diameter = d= m(z +2) (c) Dedendum circle diameter = dj = m(z ~ 2.5) (@) Shaft diameter = d, (6) Outer diameter of hub = d= 2.04, Oe ee avoaody length of key (e) Width of web 0.5 to 0.6 of circular pitch (hy mer diameter of tim = d= (d; ~21) (i) Outer diameter of rim = dedendum circle diameter =d )) Thickness of rim = 4, 0.56 x circular pitch (k) Width of rim = face width = b Whatever the computed values of dimensions, care should be taken to make the gear a “sound tasting and modify the éimensions, if required. The tuidelines for designing a casting are explained in Section 3.2 on Design considerations of Casting These rules related to uniform thickness, minimum section thickness, ile nd corer radi and avoiding concentration of metal at aay junction must be applied to the final drawing of ger blank VA rimmed gear consists of a steel rim fitted on the central eating with hb, arms or webs. The tim is forged from alloy scl. There are two varieties ofrimmed gears, which ae Mustated in Figs 1736 (a) and (6). Inthe fst eas, the rim is press fed fon the casing and setscrews are used to prevent fisplacement of the sim with respect to casing In the second type of construction, the rim is bolted to the central casting, Rimmed gears save costly high stength material, but they are more expensive tormaafactur, The thickness of the rim from the inside diameter to the roa isle diameter of tooth usually taken as (7m) to im) Castiron hub ©) ) Fig. 17.36 Rinned Gears‘When the pitch circle diameter of cast iron gear is large, arms are used in place of web, The arms are also called spokes, The cross-section of an arm can be elliptical, I-seetion, H-section or cross (+). The recommended number of arms is as follows: Pitch circle diameter (nim) Number of arms (h) 300500 4 500-1500 6 1500 - 2400 8 > 2400 10-12 In some eases, itis required to design the eross- section of the arm. Figure 17.37 shows the arm of a cast iron gear. The analysis is based on the following assumptions! (a) The arm is assumed as a cantilever beam, fixed at the hub and subjected to a force Pat the piteh line (b) The rim is rigid so that each arm takes equal share of total tooth load. Fig. 1737 ‘The transmitted torque produces bending moment ‘on arm. Suppose, M, = transmitted torque (N-mm) n= number of arms P = force acting on each arm (N) = length of cantilever beam (mm) ‘The bending moment (¥,) on each arm is given by, My=PxL @ ‘The torque transmitted by each arm is given by, PxL 0) M, oa o Also, a, =e -(4} @ For the elliptical crosssection, 12TH oot yan © The major axis is usually taken as twice the minor axis, Also, the major axis isin the plane of rotation Therefore, b=n2 ‘Substituting this value in Eq. (¢), HE and y= H2 o From (d) and (f), (M,\__ (xm) = [2r} dimensions (/) of cross-section of the arm. The : ann 5, ro) A higher factor of safety should be used because the above method is approximate, the assumptions ‘are not exactly valid and stress concentration is neglected, The cross-section of arm is given a taper 1:16 from the hub to the rim, 17.15 NUMBER OF TEETH In the design of gears, it is required to decide the number of teeth on the pinion and gear. There is a limiting value of the minimum number of tecth on the pinion. As the number of teeth decreases, a point is reached when there i interference and the standard tooth profile requires modification. The minimum number of teeth to avoid interference is given by, 2 Faia. = Sg (7.2 Inpractice, givinga slight radius to the tip of tooth ‘can further reduce the value of zyi,, Theoretical and practical values of the minimum number of teeth on the pinion are as follows:Pressure angle (a) 145° 20°25 Zan (theoretical) ——<32—~*dNSTSCST nin (practical) ma 4 8 For the 20° full-depth involute tooth system, it is always safe to assume the number of teeth on the pinion as 18 or 20. This does not requite any ‘modification inthe profile. Once the number of teeth on the pinion is decided, the number of teeth on the gear is calculated by the velocity ratio (i= zs). There is a concept of ‘hunting’ tooth for unkform distribution of tooth wear. Suppose (z, = 20) and (2, 40), then after every two revolutions of the pinion, the same pair of teeth will engage. If however, we take (2, = 20) and (z, = 41), the pinion will rotate 41 times before the same pair of teeth will engage again, This extra tooth is called the hunting tooth, Itresults in more even distribution of wear. For the provision of hunting tooth, it should be permissible to alter the velocity rato slightly In a multi-stage gearbox consisting of two or three stages, the velocity ratio at each stage should not exceed 6 : 1, The intermediate speeds, in this cease, are arranged in geometric progression. If "is, the total transmission ratio, ic., the ratio of angular velocity of the first driving gear to that of the last driven gear, then the speed reduction at each stage (iis obtained in the following way. For two stages, inv 7.13) For three stages, ind a7.aay AAs the number of teeth inereases, the piteh circle diameter and the size ofthe gear wheel also increase, thus increasing the cost. Therefore, the mumber of teeth on the pinion as well as on the gear should be kept as small as possible, 1716 FACE WIDTH In the design of gears, it is required to express the face width in terms of the module. In the Lewis ‘equation, itis assumed that the tangential force P, is uniformly distributed over the entire face width If the face width is too large, there is a possibility of concentration of load at one end of the gear tooth due toa number of factors, ike misalignment, elastic deformation of shafts, and warping of gear tooth. On the other hand, gears with a small face width hhave a poor capacity to resist the shock and absorb Vibrations. They also wear at a faster rate. A narrow face width results in @ coarse pitch. In practice, the ‘optimum range of the face width is (8m) 20 mis, c 6 «7.22 where vis the pitch line velocity in mvs. The pitch line velocity is given by, d'n 60x10" The effective load between two meshing teeth is given by, (17.23) «a7.2a ‘The velocity factor is an empirical relationship developed by past experience. This method of calculating dynamic load has the following advantages: (i) It is much easier to calculate the velocity factor and design gears, i) Velocity factors “have sanctions of the ‘American Gear Manufacturing Association (AGMA) (iii) They were used in the past for many years and given satisfactory results The disadvantages of the velocity factor method are as follows: (The dynamic load depends upon a number of factors such as the mass of gears, mass connected to the gear shaft and properties of the gear material, like modulus of a elasticity. A gear tooth of a material with Tow modulus of elasticity will deflect more than the gear (ooth of a material with higher ‘modulus of elasticity, and other things being ‘equal, will absorb the energy of impact and reduce the dynamic load. Velocity factor © Buckingham method neglects these factors. It assumes that dynamic load depends only upon pitch line velocity, Gi) Use of velocity factor is restricted to a limited range of pitch line velocities. It is not possible to extrapolate the values. In the final stages of gear design, when gear dimensions are known, errors specified and the quality of gears determined, the dynamic load is caleulated by equations derived by Earle Buckingham. The effective load is given by, Por (CP Pa) (17.25) where, (P,) is the dynamic load or additional load due to dynamic conditions between two meshing teeth, Buckingham has used a term ‘incremental dynamic load’ for (P,). The dynamic load! is given by, 2iv(Ceb+P) 2iv+ YiCeb+ F) 1726) jynamic load or incremental dynamic load (N) v= pitch line velocity (avs) jeformation factor (Nimm") e= sum of errors between two meshing teeth (um) 1b = face width of tooth (mm) P, = tangential force due to rated torque (N) The deformation factor C depends upon the ‘moduli of elasticity of materials for pinion and gear and the form of tooth or pressure angle. It is given by, 727 where, ‘onstant depending upon the form of tooth ‘modulus of elasticity of pinion material (Nimm?) iodulus of elasticity of gear material (Nimm? ) = Analytical Mechanies of Gears’ ~ MeGraw-Hill Ine, 1948,‘The values of & for various tooth forms are as follows: 107 (for 14.5° full depth teeth) 111 (for 20° full depth teeth) = 0.115 (for 20° stub teeth) The ready made values of C for various conditions are given in Table 17.7, ‘Table 17.7 Values of deformation factor C (Nim!) Materials TAS al depth ch [20° fil depth eth [20° stb eth Pinion macial | ear atl Grey Grey CI 5500 00 5900 Stel Grey cr 7600 7900 s100 Stel Stel 11000 aco 11300 ‘Te incremental dynamic load (P,) ealeulated gems o2s 7 nas) by Buckingham’s equation is far more than the corresponding load calculated by the velocity factor method. Very often, itis three to four times the load (P,) due to power transmission. It has been observed that in most of the practical cases, the actual dynamic load is Tess than that of the calculated values by Buckingham’s equation. This is because the equation is mainly applicable to large gears with connected masses that rotate at moderate speeds. The actual dynamic load is less in the following cases: (small gears transmitting low power; (ii) high-speed light-load gears; (ii) small gears on small shaft; (iv) gear shafts up to 50 mm diameter; and (v) small gears transmitting less than 15 kW of power. Gears on small-diameter shaft casily twist through an angle equivalent to the effective tooth error and the dynamic load is reduced. ‘The error e in Eq, (17.26) is given by, ¢ «a7.28) where, ror for pinion ror for gear ‘The etvor depends upon the quality of the gear and the method of manufacture. There are twelve different grades from Gr. 1 to Gr. 12 in decreasing order of precision’. The expected error on the gear tooth is considered to be equal to tolerance. The tolerances for adjacent pitch ermor (e) are given in Table 17.8, These tolerances are calculated by using the following basic equation: 18 3681 166: General pian for spur and helical gears, where, 9= tolerance factor ‘m= module (mm) 4’ = pitch circle diameter (mm) Table 178 Tolerances on the adjacent pitch Grade eae T 080 0066 125+0.0 9 2004 0164 3.200256 5.00-+0.40 6 £00 1 0.63 6 1,00 +090 @ 16.00 + 1.25 9 22.00 + 1.80 g 32.00-+ 2.50 9 45003559 63.00 + 5.00 The method of manufacture for gears depends upon, the grade of the gear. Gears of Grade 11 and Grade 12 are manufactured by casting. Gears of Grade 8 ‘and Grade 9 require rough and fine hobbing, Gears of Grade 6 are oblained by hobbing and rough grinding, while Grade 4 requires shaving and finish grinding. 1720 ESTIMATION OF MODULE BASED ON BEAM STRENGTH Inorder to avid flue of gear tooth duc to bending Sy> PagIntroducing a factor of safety, Sy~ Pes (B) @ The recommended factor of safety is from 1.5 10 2, The tangential component is given by, p=2M, 2M, _2 (60x10) 1d mz ome 2nn From Eq, (17.24), Pag = Gig = PO © From Eq. (17.16), a(b)\(Se) 5, =mboyy =m? {®){ Sey © (a) From (a), (b) and (c), amc. |] 4730) =Car ms The above equation is used in the preliminary stages of gear design 1721 WEAR STRENGTH OF GEAR TOOTH TThe failure of the gear tooth due to pitting occurs when the contact stresses between two meshing tecth exceed the surface endurance strength of the material, Pitting is a surface fatigue failure, characterized by sinall pits on the surface of the gear tooth. In order to avoid this type of failure, the proportions of the gear tooth and surface properties, such as surface hardness, should be selected in such ‘away that the wear strength of the gear tooth is more than the effective load between the meshing teeth. The analysis of wear strength was done by Earle Buckingham, in his paper ‘The relation of load to wear of gear teeth’, which was submitted before the American Gear Manufacturing Association (AGMA) in 1926. Buckingham’s equation gives the ‘wear strength of the gear tooth. Buckingham’s equation is based on Hertz theory of contact stresses. When two cylinders are pressed together as shown in Fig. 17.42(a), the contact stress is given by, _ 2? % @ and © where, = maximum value of the compressive stress (Nimm?) P= force pressing the two cylinders together (N) b= half width of deformation (mm) 1 = axial length of the eylinder (mm) 4d,, d, = diameters of the two cylinders (mm) Ey, Ey = modulii of elasticity of two eylinder materials (N/mm?) [= Poisson's ratio {exaggeratea) © Fig. 17.42 Contact Stresses Due to deformation under the action of load P, 4 rectangular surface of width (26) and length (D) is formed between the two cylinders. The elliptical stress distribution across the width (26) is shown in Fig. 17.42(0) and (c). Substituting Eq, (b) in Eq. (a) and squaring both sides,where r), rp are the radii of two cylinders. Substiing Ge-03), oi ~oa5(2) @) I 1d \ ‘ (E+) ‘The above equation of the contact stress is based. on the following assumptions: (i) The eylinders are made of isotropic materials. Gi) The elastic limit of the material is not exceeded. Gil) The dimensions r,, rare very large when compared to the width (26) of the deformation, Figure 17.43 shows the contact between two meshing teeth at the pitch point, The radii r, and r, Fig. 1743 in Eq, () are to be replaced by the radii of curvature atthe pitch point. Therefore, asin ay di, sin or 2 Thee ae two reasons for tking the rai of carve athe pitch pint. The wear onthe gear toth generally cceu's ator nese the ich ie ‘When only one pir of teeth cas the ene loa, the contact occurs at the pteh point. When the Conic takes place a the fp or the btm the tooth prof, usually vo pars of meshing eth Stare the fa Te dynamic oad is imposed onthe feat toth neat the pc line re. Therefore, is toe resonable f sles he radi ofeurvary at the pith point (11) (2 [3 | © 4; A ato itor Qs dened as, (17.31) non) sine 2, +2, Substituting, (df, = ms,) and (a, = mz,) in Ea, (730), nd; aed, o Therefore, Lilet 2 qa) apa” Oa ® From (e) and (2), (1.1) 4 lita} oa sina ® The force acting along the pith ine in Fig. 17.43 is Py Therefore Paha 0 The axial length of the gears i the face width 6, " [nb wo Substituting Eqs (h),() and (ko) in Eq, (@), ee AR, "50d; sinwcosaE, +E) Aload-stress factor K'is defined as, a2 sinet cos at 14 sue) a2Substituting the above equation in Eq, (), = bOd,K ) This cquation’ gives "a relationship. between the tangential force P, and the corresponding contact stress g, (or K). When the tangential force is increased, the conlact sires also increases Pitting occurs when the contact stress reaches the magninude of the surface endurance strength, The corresponding value of P, is called wear strength Therefore, the wear strength isthe maximum value of the tangential force thatthe tooth can transmit without pitting failure, Replacing (P) by (Sy). Ea (0m) is written as S.= bod, K (1733) where, 'S, ~ wear strength ofthe gear tooth (N) 6. surface endurance strength ofthe material (Nim?) Equation (17.33) is known ax Buckingham’ equation for wear The rato factor fr intemal gears is defined as, 225 Q or (17.35) The above equation is applicable only when both the gears are made of steel with a 20° pressure angle. In other cases, Eg, (17.32) should be used, Table 17.9 gives the material properties for the calculation of K. In order to avoid failure of the gear tooth due to pitting, the wear strength should be more than the cffective force between the meshing tech, Table 17.9 Values of modulus of elasticity and Poisson's rato for gear materials ‘Material ‘Modulus of Poisson’ ratio elasticity (Winn) Steel 206.000 03 Cast steel 202 000 03 Spheroidal cast iron 173.000 03 Cast tin bronze 103 000 03 Tin bronze 113 000 03 Grey cast iron 118.000 03 «7.34 ‘The expression for the load-stress factor K can be simplified when both the gears are made of stee] with a 20° pressure angle. In this special ease, E, = Ey = 206 000 Nira? a= 20 According to G Niemann,’ ¢.= 0.27 (BHN)_ketimm? 27 (9.81\BHN) Nimm? ‘where BIIN is the BrinellIlardness Number. Therefore, Gf sinercose (WE, +/Ex) 14 (0279.81) (BHN: K= _ sin (20) cos (20)(2/206 000) 14 (iw) =0, 156 To 1722 ESTIMATION OF MODULE BASED ON WEAR STRENGTH Tn order to avoid failure of gear tooth due to pitting, S.> Pe Introducing a factor of safety, Sy= Pea) @ The recommended factor of safety is from 1.5 to 2. As discussed in Section 17.20(Bq, b), the effective load is given by, a Oo) 60108 | (KW)C, x | menC, bom Pa.ctt3%, : s.-haipe=n( 2) ae * Gustav Niemann—"Machine Flements—Design and Calculations in Mechanical Engineering’—Springer-Verlag, Berlin, Vol. 1, page 240,or S.= m(2)oc,e © Substituting (b) and (c) in (a), we have 60108 ances | 1736 7 \anc2 Example 17.7 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 shaftis connected to a 10 KW, 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 of plain carbon steel 40C8 (Sy = 600 Nimm2). The factor of safety can be taken as 1.5. Design the gears, specify their dimensions and suggest suitable surface hardness for the gears. Solution Given KW=10 n= 1440 pm i= 4 Sy/= 600 Nimm? (fi) = starting torque = 150% (rated torque) Step I Estimation of module based on beam strength ‘Since both gears are made of the same material, the ppinion is weaker than the gear. The minimum number of teeth for 20° pressure angle is 18, Therefore, 2,18 2,71, 4(18) = 72 au, = SO 10%CW) _ 60310°C) 2an,, 2m(1440) = 66 314.56 N-mm ‘The Lewis form factor is 0.308 for 18 teeth. (Table 17.3) ¥=03308 starting torque rated torque The velocity factor is unknown at this stage. Assuming a trial value for the pitch line velocity as Sms, 3 Bey + It is assumed that the ratio (bim) is 10. From Eq. (1730), 60 x108 anasas) (3 (600 7 Javaso(JJoo(% 0306 | 4.16 mm Step I Selection of module ‘The first preference value of the module is $ mm. Trial 1 d; 5(18) = 90 mm f= mz, = 5(72) = 360 mm b= 10 m= 10(5) = 50 mm Check for design 2M, _ 2(66 314.56) = 1473.66 N a ne a tility FOO) 6436 Goxi0'~ soxi0 3. 3 = 0.3066 ng = Sip «15.9 sop go 03066 From (1736 Sy mbep7=5 (0) 200) (0308) = 15800 51840 wo Pe 7209.69 The design is satisfactory and the module should be S mm.Step IIL Surface hardness for gears 22) 1g 72418 s, =, 1.004010 (2) aun? =niso( 55) 100 or 310 Example 178 [1 is required to design a pair OF spur gears with 20° full-depth involute teeth consisting of a 20-teeth pinion meshing with a 50 teeth gear. The pinion shaft is connected to a 22.5 KW, 1450 rpm electric motor. The starting torque of the motor can be taken as 150% of the rated torque. The material for the pinion is plain carbon steel Fe 410 (Sq = 410 Ninn’), while the gear is made of grey cast iron FG 200 (Sy =200 N/mm). The factor of safety is 1.5. Design the gears based on the Lewis equation and using velocity factor to account for the dynamic load, Solut ven KW=22.5 n= 14501pm_z,=20 0_startng torque = 150% (rated torque) (6)=15 Forpinion, 5, =410 Nimm? For gear, Syy=200 Nimm” Step I Deciding weaker between pinion and gear ‘The materials of pinion and gear are different, From Table 17.3, the Lewis form factors for 20 and 50 teeth are 0.32 and 0.408 respectively. For pinion, = 19 2136.67 Ninn 3 (0x ¥) = 136.67 x 0.32 = 43.73 For geat, 20 61 Mi (0, x ¥) = 66.67 x 0.408 = 27.20 The product (0, x Y) is less for the gear. The ‘gear is weaker than the pinion and it is necessary to ‘design the gear. Step I Estimation of module based on beam strength For gear, 1450(20) ne 580 rp The velocity factor is unknown at this stage. ‘Assuming the pitch line velocity as 5 mis, “333 Say 545 8 From Ea, (1730), _| oxo} amcua cx =e aoe ]00( 2 oan 60x108 = 6.89 mm Step IIL Selection of module ‘The standard value of the module under Choice 2 of Table 17.2 is 7 mm, Trial 1 120) = 140 mm di, = mz, = 1(50) = 350 mm b= 10m=10(7)=70 mm Check for design 60x10%(kW) _ 60%10°(22.5) ( Qan, —_2(580) = 370 446.85 N-mm 2370 446.85) 2116.84 N adin, 60x10" 6 bry 6(2116.84) ty 280061 eos $5 =mbeur=7170{ 22) 04m =1338 5.1308 s) = Py The design is satisfactory and the module should be 7 mm. 8800.61 Example17.9 4 pair of spur gears with 20° full-depth involute teeth consists of a 19 teeth ‘pinion meshing with a 40 teeth gear. The pinion is ‘mounted on a crankshaft of 7.5 KW single cylinder diesel engine running at 1500 rpm. The driven shaft is connected ta a two-stage compressor, Assume the service factor as 1.5. The pinion as well as the gear is made of steel 40C8 (Sy = 600 N’mm?). The ‘module and face width of the gears are 4 and 40 mm respectively. (Using the velocity factor to account for the dynamic load, determine the factor of safer: (i) Ifthe factor of safety is to for pitting failure, recommend surface hardness for the gears. (iii) If the gears are machined to meet the specifications of Grade’, determine thefactor of safety for bending using Buckingham’: equation for dynamic load. (iv) Isthe gear design satisfactory? Ifnot, what is the method to satisfy the design conditions? How will you modify the design? Solution iven KW=75 n=1500rpm =, 2,=40 mm 5=40mm C=15 Si, 600 Nimm? Grade of machining - 8 Step Factor of safety based on dynamic load by velocity factor Beam strength Since both gears are made of the same material, the pinion is weaker than the gear, The Lewis form factor for 19 teeth is 0.314 (Table 17.3). The permissible bending stress is one-third of the ultimate tensile strength or 200 Nimm?, Therefore, 5, = mbo,¥ = 4(40(200)(0.314) = 10 048 N Tangential force due to rated torque di, = m2, = 4(19) = 76 mm ay, = GOX10%eW) _ 60 x10°(7.5) (oan, 2x(1500) =47 746.48 Namm p 2M, a Effective load don, _ mi ir TBS) «5 969 yyy Gox10 60x10 = 023345 15025649) _ 5654.48 03345 Factor of safety S_ 10088 DO” Pa 565448 Step I Surface hardness for gears with (f) 482 S,= Pair (8) = 5634,48(2.0) = 11 268.96 N 2 2 Q 249) _1 356 +2, 40419 noa,K ( BHN or 1268.96 = 40(1.356)(76)(0.16) [ T5- BHN= 413.35 or 420 Step IIT Factor of safety based on dyramic load by ‘Buckinghamn’s equation o- mos dz 4025 V7 6,161.25 6» 23.72 m Forge, mz, = 40) 160 mm go m02s dy =4+025 Via eg = 16+ 1.259 = 24.95 pm ee, +e, ~ 23.72 + 24.95 = 48.67 um (48.67% 105) mmFrom Table 17.7, the value of the deformation factor C is 11400 Nimm?. Also, 969 m's_6=40 mm | P,= 1256.49 N From Eq, (17.26), 2Iv(Geb+P) m= eb B) 21(5.969)] 11400 48.67 x10 )(40) + 1256.49 213.969) + [i400 aRAT TO a0) 12569] = 10555.17 Pays (CyP,* P)= 150125649) + 1055.17 = 1243991 Since ‘S,=10048N and S, = 11268.96N S 10-2) mm From Eq, (17.26), 2v (Ceb+B) 2ivs JiCeb+ Fy 216.969) [11 400 24.405 1040) +1256.49 21(6.969) + [11800 24.405 x 107) 40) + 1256.49) = 6560.3 Pag (CP, + PD 8445.26 Py 1,5(1256.49) + 6560.53 The beam strength is lower than the wear strength. Therefore, Sy, _ 10048, Pg 8445.26 = The design is satisfactory. Example 17.10 4 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. 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 transmit Solution Given n= 1450:pm z= 20. z,=41 m=3mm b=40mm C,=175 (G)=15 BHN= 400. $,,~ 600 Nimm* Step 1 Beam strength Since the same matcrial is used for the pinion and the ‘gear, the pinion is weaker than the gear. From Table 17.3, the Lewis form factor is 0,32 for 20 teeth, - (5) (600) = 200 Nin? S,=mbo, ¥ 3(40}(200)(0.32) = 7680 N Step IL Wear strengtt 22, 2 24D ayy 41420 re saso( NY or) 100 (00 df, = mz, = 3(20) = 60 mm S= bQd;K = 40(1.344)(60)(2.56) 8257.54.NStep IIL Effective Load ndin, ite _ ISOIIASD) _ 4 5555 ays Gxi0 60x10 c 3 3 0.397, Sev 3445553 re = CR = AS p= Aa RYN c. 1 0397" Step IV. Static toad In this example, the beam strength is lower than the wear strength. Therefore, beam strength is the criterion of design 5,=Pyg(f) or P,~M61N 7680 = (4.41 P) (15) Step V_ Rated power _ Pedy _1161(60) M, =34 830 N-mm Wa > 4 830N- 2 1450004 £30) _ 595 60x10" Example 17.11 {ris required to design a spur gear Speed reducer Jor a compressor running at 250 rpm driven by a 7.5 kW, 1000 rpm electric motor. The centre distance between the axes of the gear shafis should be exactly 250 mm. The starting torque of the motor can be assumed to be 150% of the rated torque. The gears are made of carbon steel 50C4 (Su. = 700 Nimm2). The pressure angle is 20°, The factor of safety is 2 for preliminary design based on the use of velocity factor (@ Design the gears and dimensions, (i) Assume that the gears are manufactured to meet the requirements of Grade 6 and calculate the dynamic load by using Buckingham’s equation. (iti) Calculate the effective load. (iv) What is the actual factor of safety against bending failure? (0) Using the same factor of safety against pitting failure, specify suitable surface hardness for the gears. specify their Solution Given kW=75 1, = 1000 rpm ng=2501pm a= 250mm starting torque = 150% (rated torque) Se= 700 Nimm? (5) = 2 Grade of machining-6 Step Estimation of module based om beam strength 1 1 aah +di) or 250-1 (ar +a shea) 3d, +d) (dj, 4dz) = 500 mm @ A Ie Mp _ 1000 » AN Gy hy 250 ® From (a) and (6), = 100mm and d= 400 mm dyn, xi Hy A00010000) 5906 wy 60x10" 60x10 3 3 03643 Bey 345236 The face width is assumed to be ten times that of the module. The Lewis form factor is unknown at this stage. It varies from 0,32 (for 20 teeth) to 0.358 (for 30 teeth). Assuming an intermediate value, Y= 0.34 5, = mba, = maom (7) (0.34) = (793.33 m?)N © 0x 105(kW) _ 60 10°(7.5) oan, 271000) = 71 619.93 Nemm 2M, _ 247161995 100 — Gop 151043239) C' 03683 From (c) and (d), Pag (f)= Sy oF m= 3.86 mm 1432.39 N Pry =589785N @) 5897.85(2) = 793,33 m? Step It Gear dimensions ‘The first preference value of the module is 4 mm.m=4mm Bo tom 194) = 40 en " de 100 4g mod ” = 4-4 _199 mo Step IM Beam strength From Table 17.3, the Lewis form factor for 25 teeth is 0.34. 200) 034 =1200338 5, = mba = 4(40)| Step IV Diynamic lad by Buckingham’s equation For Grade 6, e=8+0636 For pinion, bm+02s fd =4+025 Sido 8+ 0.63 9= 12.095 um For gear, o=m-+o2s Jay =4+025 VA00 +063 6 13.67 um 12.095 + 13.67 = 25.765 jum or (25.765 10-9) mm From Table 17.7, the value of deformation factor Cis 11400 Nimm? Also, v=5.236 m/s b=40 mm P,= 1432.39N From Eq. (17.26), __2lw (Ceb +B) 2iv+ y(Ceb +P) 21 (5.236){11400(25.765 x 107° )(40) + 1432.39], 245.236) + yf11400(25.765 x10" )(40) +1432.39] = 6448.30 N Step V_ Effective load Pag (CP,+ PD) 596.89 N 1,5(1432.39) + 6448.30 Step VI Actual factor of safety against bending faiture Sy 12693.33 a 1.48 =p. 9596.89 The design is satisfactory and the module should be 4 mm. Step VIL Surface hardness for gears 2s, s__ 20000) _| +2, 100425 Pag (f)=Sy ot Pag (ft) = 600K / 8596.89 (1.48) = 40(1.6)(100)(0.16) ( BEX (00 BHN = 352.49 or 360 Step VII Dimensions of gears (i) number of teeth on pinion = 25 Gi) number of teeth on gear= 100 (iii) module = 4 mm (iv) face width (¥) pitch circle diameter of pinion = 100 mm (vi) pitch circle diameter of gear = 400 mm. (vii). addendum (mm) = 4 mm. (viii) dedendum (1.25 m) = 5 mm (ix) clearance (0.25 m) = 1 mm (&) tooth thickness (1.5708 m) (xi) fillet radius (0.4 m) = 1.6 mm 40 mm 6.2832. mm, Example 17.12 1 is required to design a two- Stage spur gear reduction unit with 20° full-depth involute teeth. The input shaft rotates at 1440 rpm and receives 10 kW power through a flexible coupling. The speed of the output shaft should be approximately 180 rpm. The gears are made of plain carbon steel 45C8 (Sy = 700 Nimm?) and heat: treated to a surface hardness of 340 BHN. The gears are to be machined to the requirement, of Grade 6, The service factor can be taken as 1.5 (@ Assuming that the dynamic load to be proportional to the pitch-line velocity, estimate the required value of the module. The factor of safety ts 1.5 (ii) Select the first preference value of the module and determine the correct value of factor of safety for bending, using Buckingham's equation. (ii) Determine the factor of safety against piling, (iv) Give a list of gear dimensions.Solution Given WV=10 n= 1440%pm_C,= 1.5 Sy 700Nimm? (fi) 1.5 BEN 340, Grade of machining speed of output shaft = 180 rpm ‘Step Estimation of module based on beam strength ‘The total transmission ratio i” is given by, ._ angular velocity of the first driving gear "angular velocity ofthe last driven gear 1440 180 As discussed in Section 17.15, the speed reduction at each stage (i) is given by, 8 For a 20° pressure angle, the minimum number of teeth to avoid interference is 18, zo 18 and. 2,12, ~ 2.8284 (18) = 50.91 or SI The layout of gears is shown in Fig. 17.44, For ease of manufacturing, the pinions 1 and 3 ate made identical, while gears 2 and 4 are also made identical, 8284 Input shat 7 LA ese shat Fig. 1744 2,727 18 and 2 The speeds of the shafts are as follows, n= 1440 pm. ) tox) -s035 = 508.235 x( B)-1 38 rpm (si The speed of the output shaft is 179.38 or approximately 180 rpm. The velocity factor is unknown at this stage. Assuming the piteh line velocity as 5 m/s, 3.303 3458 Bay The pairat the second stage, i., pinion 3 and gear 4, transmits more torque than the pair consisting of ‘gears | and 2, Therefore, pinion 3 and gear 4 are to bbe designed. From Table 17.3, the Lewis form factor for 18 teoth is 0.308, From Eq. (17,30), naa | wale 60x10° ox) coasas * Vamoa(2Jon) oso] 559mm Step I Gear dimensions The frst preference value of the module is 6 mm. m=6mm d= mz, = 6(18) = 108 mm d= mz,~ 651) = 306 mm b= 10 m= 10(6)= 60 mm Step TIT Factor of safety using Buckinghuam’s equation Beam sirength (700 S, = mbo,¥ = 6x00) ) (0.308) - 25872 Tangential force due to rated torque1, — SOXIOTEKW) _ 60100) (~"Dny —~ 2x(508.235) =187 891.36 N-mm p= 2M. _ 2087 89139) a4pg gyn a 108 Dynamic load For Grade 6, eo 8 +0636 For pinion, amt 025 (di =6+0.25 JOR 6,780.63 6= 13.4168 um For gear, g-m+025 fd; —6+0.25 J306 e, = 8+ 0.63 = 14.5351 um =e, + 6,= 13.4168 + 14,5351 = 27.9519 pm or (27.9519 x 10) mm From Table 17.7, the value of deformation factor Cis 11 400 Nimm*, 2(L08)(508.235) 60x10° ding Gox108 = 2874 mis Also, = 60mm —P, From Eq. (17.26), 2iv(Ceb +B) 3479.47 N 212876 {1400 219519310? 60)+347947] 2102874) + | [11400279519 «107 \60)+3479.47] = 6873.80 fetve toad Pag (C, Prt Pi) 15347947) + 6473.80 11693N Factor of safety Sy__ 25872 Pe 11693 ‘The design is satisfactory and the module should, be 6 mm. 221 co) Step IV Factor of safety against pitting 2s, g- 2 = 26) 1 goes ate, SU+18 Y (340" Od, K = 60(1.4783)(108)(0.16){ =“) {00} =17718.03N Su =m The design is satisfactory and the factor of safety is adequate against pitting failure. Step V_ Gear dimensions (i) module =6 mm Gi) face width = 60 mm. (iii) addendum = 6 mm (iv) dedendum = 7.5 mm (¥) fillet radius = 2.4 mm Gear I and 3 (i) pitch circle diameter = 108 mm (ii) addendum circle diameter = 120 mm (iii) dedendum cirele diameter = 93 mm Giv)_mumber of teeth = 18 Gear 2 and 4 (i) pitch circle diameter = 306 mm Gi)_addendum circle diameter = 318 mm (iii) dedendum circle diameter = 291 mm (iv) number of teeth = 51