Chapter POWER TRANSMISSION CN 2.1 INTRODUCTION aft to another by means of belts, ropes, chains and gears. ropes and chains are used, whereas for small are flexible types of connectors. Belts and ropes er transmitted exceeds the Power is transmitted from one shi For large distances between the shafts, belts, distances, gears are used. Belts, ropes and chains y transmit power due to friction between them and the pulleys. Tf the pow! soe ee force of friction, the belt or rope slips over the pulley. During motion, these are straine tensions in them, So due to slipping and straining action, belts and ropes are not positive type of drives as their velocity ratio is not constant whereas, chains and gears have constant rain! ratio. In this chapter, we shall study belts, ropes and chains from the power transmission point of view. 2.2 BELT AND ROPE DRIVES The flexible wrapping connectors (belt and ropes) are used to transmit power from one shaft to another. When the wrapping connector takes the form of a band, whose thickness is small in comparison to width, it is called a belt. If the cross-section of wrapping connector is circular or approximately circular, it is called a rope. Belts and ropes are endless, their ends are joined by fasteners. To transmit power from one shaft to another, an endless belt or rope is passed over pulleys mounted on the two shafts. The belt or rope must be kept in tension so that the motion is transmitted from one shaft to another without slip. _In case of belt drives, either Mat or grooved pulleys are used depending upon the cross- section of belt, but in case of rope dives, grooved pulleys are used. The rope is gripped on its sides as it bends down in the groove reducing the chances of slipping. For an unstreched belt mounted on the pulleys, the outer f; 1 ; onth ‘ace is under tension and the inner face is under compression as shown in Fig. 2.1. In between, there is a sec under tension nor under compression and is known as the considered at half the thickness of the belt, The effective radius of a pulley is the sum of h pulley. tion, which in neither neutral section. This is usually alf of the belt thickness and the radius of thepower Transmission 25 | Outer face i i | Driven pulley t= | | \ Thickness, 1 2.1: Open Belt Drive Rope drives were preferred till recent times for long distance power transmission, but these days, the use of rope drives has become limited. 2.3. TYPES OF BELTS These days, there are many types of belts in use. Some important types of belts are as follow: 1, Flat Belt : A belt having rectangular cross-section is known as flat belt as shown in fig. 2.2(a). It is mostly used in factories for moderate power transmission from one pulley to another at a distance not more than 8 metres. In this case, the rim of the pulley is slightly crowned as it helps to keep the belt running centrally on the rim of the pulley. 2. V-Belt : The belt having trapezoidal cross-section is known as V-belt as shown in Jig. 2.2 (b). Itis mostly used in factories and workshops for transmitting large amount of power, When the two pulleys are close to each other. To take the advantage of wedge action, the groove on the rim of the pulley is made deeper. The belt does not touch the bottom of the groove. It needs little adjustment. Due to wedging action, it can transmit more power as compared to flat belt, For {ransmitting more power between two pulleys, multiple V-belts can also be used. 3. Circular Belt or Rope : The belt having circular cross-section is known as belt or rope as shown in fig. 2.2(c). In factories, it is used for power transmi distance between the two pulleys is more than 8 metres. Willa “i () (a) Plat Belt (6) V- Bolt (c) Rope Fig. 2.2 : Types of BeltsISHAN'S Theory of Machines BELTS OVER FLAT 26 2.4 ADVANTAGES AND DISADVANTAGES oF V+ BELTS Advantages : 5 ing action in the 1. V-Belts can transmit more power as compared to flat belts due 10 wedging grooves. These are more suitable for power transmission be centre distance. To compensate for wear or scratch, V-Belts require little adjustment. By using multiple V-belt system, large power can be transmitted. ‘These have has longer life and can be easily installed and removed. The V-belt drives are smooth as these are made endless. The high velocity ratio can be obtained. Due to negligible slip between the belt and the pulley, the V-belt drives are positive. V-belts give cushioning effect when machines are started. tween two shafts having a short eer arry Disadvantages : 1. V-Belt drives are not suitable for large distances power transmission. 2. The construction of pulleys for V-belts is more complicated than flat belts. 3 V-belts are not suitable for constant speed application due to certain amount of creep in V-belts. 4. The V-belts are not so durable. 5. The change in temperature, mismatching of belt lengths and improper belt tension affect the life of V-Belt. 2.5 MATERIAL FOR BELTS AND ROPES , ‘The material used for belts and ropes must be strong, flexible and durable. It must have a high co-efficient of friction. The selection of material is also influenced by climatic as well as service conditions. Usually leather, canvas, cotton and rubber are the i ich are + canvas, materials which a flat belts. V-belts are made of rubber impregnated fabric. The material for ropes Staten na a wh Pes are cotton, hemp, 2.6 TYPES OF BELT DRIVES The belt drives may be any of the following types 1. Open belt drive, 2. Crossed belt drive, 3. Angular drive, 4. Belt drive with idler pulleys,Power Transmission » 5. Stepped pulley drive, 6. Fast and loose pulley drive, 7. Compound drive. 1, Open Belt Drive : Fig. 2.3 shows an open belt drive. this drive, both the shafts are arranged parallel and rotate in the same direction. This drive is generally used, where the centre distance between the two parallel shafts not more than 8 metr 10 vibrate in a direction perpendicul If the distance is too large, then lar to the direction of motion which shortens the belt life and also there will be a loss of power. In case of very small centre distance, the belt slip increases. In case of horizontal drives shown in fig. 2.3, the tension in the lower side is more and is known as tight side, whereas the tension in the upper side is less and is known as slack side. Driver Tight side | Driven pulley « pulley : ' Fig. 2.3 : Open Belt Drive 2. Crossed Belt Drive : Fig. 2.4 shows the crossed belt drive. In this case, the shafts are arranged parallel and rotate in opposite direction. If the centre distance remains same, then the angle of contact is more in case of crossed belt drive as compared to open belt drive. So the belt slip, in this drive, is greatly reduced, but the wear and tear is more at a point where the belt crosses, Fig. 2.4 : Crossed Belt DriveISHAN'S Theory of Machines Jeys connected by the belt + non-intersecting. When drive shown in fig. 2.5. * ic the pull jation Of 3. Angular Drive : In this drive, the ares a ve omrorsectng may be at right angle or at any other angle which may a arte! », iris known as qu the two connecting pulleys are at right angle, 118 Fig. 2.5 : Angular Drive 4. Belt Drive with Idler Pulleys: Fig. 2.6 shows the belt drive with idler pulleys. This drive is used to provide large velocity ratio in short centre distance, thus saving the floor area. The idler pulley is free to rotate on its axis. It presses the belt on the driven side, resulting in the increase of angle contact of the belt. Thus the slippage reduces, hence the belt life increases. Driven pulley— Idler pulley Fig. 2.6: Hell Drive with taller PulleyPower Transmission 5. Stepped Pulley Drive angular speed of the driv Fig, 2.7 : Stepped Pulley Drive 29 2 This drive shown in figure 2.7 is used for changing of the shaft, while the angular speed of the driving shaft remains constant. 6. Fast and Loose Pulley Drive : This drive shown in figure 2.8 is used when the driven shaft is to be rotated or stopped too often. Two pulleys are mounted on the driven shaft, one of which is keyed on to the shaft and is called fast pulley. The other pulley runs freely on the shait and is called the loose pulley. When the driven shaft is to be stopped, the belt is pushed on to the loose pulley from fast pulley by means of a lever. Driven shaft Fast pulley Loose pulley Drivor shaft, Fig, 2.6 : Fast and Loose Pulley Drive20 ISHAN'S Theory of Machines 2.9 is used when large velocity ratio i 1y 7. Compound Drive : This drive shown in fig. be obtained. Fig. 2.9 : Compound Drive 2.7. VELOCITY RATIO It is the ratio of the speed of the driven pulley to that of driving pulley. Let us consider an open belt drive shown in fig. 2.10. Let the smaller pulley is driver and tt bigger pulley is driven. ‘Tight side Driven pulley Fig. 2.10 : Open Belt DrivePower Transmission a1 Let Nj and Nz = Rotational speeds of driver and driven pulleys in r.p.m. respectively, D, and D;= Diameters of driver and driven pulleys respectively, 1= Thickness of the belt. Linear speed of belt at driver pulley =. D, N; Linear speed of belt at driven pulley = sr D; Ny Neglecting thickness of the belt and also assuming that there is no slip between the belt and the pulleys, then xD, N, =1D)N; N,_D, Velocity Ratio = ~2 = 21 ° Ni Dy The thickness of belt is not considered in the above relation. When the belt passes over a pulley, the inner side of the belt is under compression, while the outer side of belt is under tension. So the neutral surface lies mid way between the outer and the inner surfaces. So considering the thickness of the belt f N Velocity ratio = Nz = Pitt Ny D, +e 2.8 SLIP If the difference in tension between tight and slack sides of the belt is too large to be resisted by friction between the belt and the pulley, then whole of the portion of the belt which is in contact with the pulley begins to slide. This results in relative motion between the belt and the pulley and is called slip. It is generally expressed in percentage. The effect of the slip is to reduce the velocity ratio of the drive. Let _S, = Percentage slip between the belt and the driving pulley, Sy = Percentage slip between the belt and the driven pulley, @, = Angular velocity of the driving pulley, @2 = Angular velocity of the driven pulley. Now the peripheral speed of driving pulley = wR, 100-8, 100 But speed of belt at driven pulley = Speed of belt at driving pulley, 100- 100100 If the total percentage slip between the belt and the pulleys is S, then Speed of belt at driving pulley = a Ri X Peripheral speed of driven pulley = «1 Ry xISHAN'S Theory of Machines 32 jo0-S a2 Ry = Ri X Top 100-S _100-S) ,100= 100 «100 100 (10.01) =(1 -0.01 S)) (1 - 0.01 S2) + S2— 0.01 S; Sz or i= running at 100 r.p.m. drives another pulley le in diameter Gee waco a ee aoe Bek diameter of the driven pulley : at 150 r.p.m. through a belt drive. Determine the (i) When thickness of belt is neglected. (i) When belt thickness is taken as 6 mm. (iii) When a total slip of 4% is considered. (jv) When a slip of 2% is considered on each pulley. Solution. Given, N, = 100 r,p.m., D, = 600 mm, Nz = 150 rpm. Let Dp is the diameter of driven pulley. (We know that velocity ratio, Ny _ Dy Ni” Dp 150 _ 600 or = a 100 ~ D2 or D2 = 400 mm Ans, (ii) We also know that Ny _ Dyt+t N, D, +7 or 150 _ 600+6 100 D3 +6 or (y+ 6) = BEXI0 150 or D; = 398 mm Ans, (iii) Velocity ratio with a total slip of 4%, We know that No - (Re 104 Ny poe) ess or 150 _ (600+6) ( 100 100 @, +6) “\ Too ) or D2 +6 =387.8 mmPower Transmission oc D2 = 381.8mm Ans, (iv) Velocity ratio with a slip of 2¢ on each pulley, We know that No _(Dite (tees. 100-S, N, Dy +r 100 100 150 _ (600+6) (952)(90=2) 100 (D, +6) “100 \ 100 or Dz = 382 mm Ans. Problem 2.2. A pulley having 300 mm diam, belt to another pulley at a distance of 3 m. The Totational speed of second pulley is 120 r.p.m. The thickness and the width of the belt are 5 m im and 150 mm respectively. Allowing a slip of 3% between the belt and each pulley, determine the size of second pulley and percentage of total effective slip. Solution. Given, eter running at 200 r.p.m. is connected by a Dy = 300 mm, Ny = 200 r.p.m.,N; = 120 rpm, t= 5mm S1 = 3%, S:=3% We know that Total effective slip, S =S,+S,-0.01 8; =34+3-001x3x3 = 5.91 % Ans, Let Dz is the diameter of second pulley. We know that N. _(D,+t (mes) N, (D) +1} "\ 100 120 _ 2-8 (100-591) 200 ~ D2, +5 100 or D, = 473.3 mm Ans. 2.9 CREEP OF BELT When a belt passes from tight side to slack side, a certain portion of the belt contracts and it extends again when the belt passes from slack side to tight side. Due to these changes in length, relative motion occurs between the belt and surface of pulley which is known as creep. Due to creep, the speed of driven pulley reduces slightly. After considering the effect of creep, the Velocity ratio is given by34 ISHAN'S Theory of Machines where E = Young's modulus for the material of the belt, : @) and gy = Stress in the belt on tight and slack side respectively. 2.10 CROWNING OF PULLEYS If the pulley face is kept flat, then the belt tends pulley face is never kept flat, but is given a convex curva i pulleys, It helps the belt to run in the centre of the pulley width. The crowning ma, rounded off as shown in fig. 2.11(a) and fig. 2.11(b) respectively. —+1Face width to fall off the pulley. To prevent this, the urvature. This is called crowning of the yy be conical or t ——Height of crown (a) Tapered or Conical Crown (6) Rounded Crown Fig. 2.11 Let us consider tapered or conical crown, Let the belt is in the process of falling off the pulley. Then, the belt stretches more at side AC than at side FE. So, it will be strained on side AC This strain is opposed by the belt material and the crowning of the pulley helps in automatic adjustment of the belt position, so that the centre line of the belt coincides with the ridge of the crowned surface of the pulley. In other words, with the help of crowning, the belt runs centrally. a 1 : ‘The amount of crowing is usually kept as 5- of the width of pulley face. 2.11 LAW OF BELTING It state that the centre line of the belt as it approaches the pulley must lie in a plate perpendicular to the axis of the pulley or must lie in the plane of the puth i ai will run off the pulley. pulley, otherwise, thePower Transmission 35 2.12 LENGTH OF BELT (a) Open Belt Drive : Fig. 2.12: Open Belt Drive Let d = Distance between the centres of the pulleys, rand R = Radii of the pulleys, Ly = Length of the belt. Let us draw AN parallel to CD. “ 4CAJ = ZDBK = ZNAB=a 2 [intnt Be af O40") 2d? 2 Aeind 8t0 +4] 2° 2d u =(R+ra+ - RAY od d 2 = ane BED 424 2.13 RATIO OF TENSIONS 1. fig. 2.14, Flat Belt : Let us consider a driven pulley rotating in clockwise direction as shown in. Let T, =Tension on tight side of the belt, ‘T = tension on slack side of the belt, 6 = Angle of contact between the belt and pulley, 1 = Coefficient of friction between the belt and pulley. Let us consider a short strip of belt subtending an angle 40 at the centre of the pulles38 Fig. 2.14 : Ratio of Tensions for Flat Belt Let R = Normal reaction between the belt length and the pulley, T = Tension on slack side of the short strip AB, (T+ 5f) = Tension on tight side of the short strip AB. For short strip AB to be in equilibrium, UR +T cos 2 = r+ sTyeos 2 (Resolving the forces in tangential direction 2 2 ‘As 60 is small, so cos l wR+T =T+0T or HR =6T sli 30. 88 Further, R= weipeat T sin" (Resolving the forces in radial direction ie i or Ra(t+orx Bary 28 [: 60 is small, so, sin22 a er or R=TXx 2 copa rel 2 Since, the product of two small quantities can be neglected p= 100 , 188 2° 2 or R=T.60 ie 9 i) Substituting the value of R equation (ii) in e “ equation (i), we ge 17.50 =6T apation ). we get = 100 Integrating both sides within proper limits,Power Iransmission yz 6 39 tye J ado tone =O or z = eit0 2. V-Belt : 2R sin « Fig. 2.15 : Ratio of Tensions for V-Belt In case of V-belt, there are two normal reactions, so that the radial reaction is equal to 2R sina. Total frictional force = 2R. For short strip AB to be in equilibrium, 60 56 2UR + T cos $ = (T+ST)eos-F (Resolving the forces in tangential direction) 1 60 ‘As 60 is very small, so cos sei 66 , 00 Further, 2R sina =T sin at (T+6T) sin > (Resolving the forces in radial direction) dO dd QR sina =T x 2 +(T+6T) x % [: 60 is small, so sin =“ 00 QR sina = THO [++ Product of two small quantities ST X — is neglected] TOO = iv) sinaISHAN'S Theory of Machines 40 . i) we get, Substituting value of R from equation (iv) in equation (1?) p= ap 10 OT = 2p ina oT _ WoO T sina Integrating both sides within proper limits, 2.14 ANGLE OF CONTACT If two pulleys of different diameters connected by an open belt transmit power, then the force of friction will be less on the smaller pulley and due to this, slip will occur first on the smaller pulley. So the angle of contact on smaller pulley must be considered. However, it should be noted that in crossed belt drive, the angle of contact on both the pulleys is same. 2.15 POWER TRANSMITTED BY A BELT Let T, = Tension on the tight side of the belt in Newtons, T2 = Tension on the slack side of the belt in Newtons, v = Linear velocity of the belt in m/s, P = Power transmitted in Watts, Then P =(T,-T2) x v Watts, 2.16 CENTRIFUGAL TENSION When the belt continuously moves over the pulley, the tends to li it from the pulley. This centrifugal force produces equal t side of the belt known as centrifugal tension, eustons on tight and slack centrifugal force due to its own weightPower Transmission a Fig. 2.16 : Centrifugal Tension Let us consider a short strip PQ of the belt subtending an angle 46 at the centre of pulley O as shown in fig. 2.16. Let im = Mass of the belt per unit length, 4inear velocity of the belt in m/s, adius of the pulley, ‘entrifugal tension on tight and slack sides acting on the belt at P and Q Centrifugal force acting on the short strip PQ, F, = Mass of short strip PQ x Acceleration = (Length of short strip PQ x Mass per unit length) x Acceleration 2 F. =(r.60 X m) x — (> Length of short strip PQ= rd 4 r or F, = mv°60 a Also from fig., _ 60 F, =2T.sin 5 As 60 is small, snot, 28 sin p, 22t, x 2 21,00 (i) From equations (i) and (ii), we get T,.00 = mv'00 or T. =m which shows that centrifugal tensi the belt and depends upon the velocity of the belt over the pulley Centrifayal tension(T,) of cross ~ section of belt ion is independent of the tensions on tight and slack side of Centrifugal stress in the belt =ISHAN'S Theory of Machines 42 Total tension on tight side = Friction tension + Centrifugal tension T=T +k Also, Total tension on slack side = T> +7. 2.17 CONDITION FOR TRANSMISSION OF MAXIMUM POWER We know that power transmitted by a belt, P=(T\-T)v Where T; = Tension on the tight side of the belt, T = Tension on the slack side of the belt, v = Velocity of the belt. We also know that the ratio of tensions is given by i) T a. T, T, or m= ef! Putting the value of T, in equation (i), we get =TiKv, where K = ( Wealso know that T; = T-Ty where T = Maximum tension to which the belt will be subjected to and T.= Centrifugal tension, P =(T-T.) Kv = 2 = (T-mv'\Ky (2 T. =m) = TKy- mvK For transmission of maximum power, ap a7 or 4 rky mK) =0 av or T-3m? =0 T-3T. =0 orpower Transmission Ny or and 2.18 INITIAL TENSION OF THE BELT When a belt is fitted to a pair of pulleys, an initial tension Ty is given to the belt. While transmitting power, the tension on the tight side increases to T, and that on slack side decreases to T. If it is assumed that the material of the belt is perfectly elastic i.e. the strain in the belt is directly proportional to stress in it and the total length of the belt remains unchanged, the tension on the tight side will increase by the same amount as the tension on the slack side decreases. Change in tension on tight side = Change tension on slack side Ti -Ty =To-T2 i+T) 2 which shows that initial tension is the mean of the tension on tight and slack side of the belt. or To (© Problem 2.3. In a belt derive, the ratio of tensions on the tight and slack side is 2.5. The mass of belt is 1kg/m length. It runs at a speed of 4m/s and at this speed, the power transmitted is 6 kW. What should be the initial tension in the belt and what should be the strength of the belt ? Solution. Given, 2 = 2.5, m= 1 kg/m length, v= 4 m/s, P= 6 kW = 6000 W 2 We know that P =(T,-T2) Xv 6000 = (T,-Ta) x 4 or T\-T) = 1500N 0) Further, dL a3 Go T, From equations (i) and (ii), we get T, =2500N T, = 1000N We know that T, =mv=1x 4 =16N T+O)+(+®) Initial tension, T= OG a (2500+ @) + (1000+) _ gon Ans, 2ISHAN'S Theory of Machines 44 ‘otal tension on tight side 1+Te = 2500+ 16 = 2516 N Ans. Strength of belt ers 450 mm and 150 mm are mounted on to a Problem 24, Two pulleys of diameters 450 mim A a power which can he parallel shafts 2 m part and are connected by a am, Thi Riedie transmitted by the belt when the larger pulley rotates at 180 rp. i permissible tension in the belt is 1kN and the coefficient of friction ee wae of and the pulley is 0.25. Also find the length of belt in crossed belt drive and the a contact between the belt and the pulleys. Solution. Given, D, = 450 mm, Dz = 150 mi m, d= 2m = 2000 mm, Ni = 180 r,pm.,T) = 1000 N, = 0.25 We know that Z +D sing = 450 +150 * 3x 2000 =0.15 ‘ asin’ Angle of contact, 0 = 180° + 2 = 180° +2 x 8.6° 97. ‘The angle of contact is 197.2° and is same on both the pulleys. Ans. Now we know that Ts ue mR ° 1000 _ (025 ax 2) t or T, =423 N. & Power transmitted, P=(T,-T2) x = (TT x 2BiNt 60 = (1000~ 423) x 2% 0-45 x 180 60 = 2447 W = 2.447 kw Ans,Power Transmission ‘i 45 Length of crossed belt, L, = “Pi+D2) , (Di+Day? 4, 2 4d = 30454015), (0.45-+0.15)? 2 4x2 +2RZ = 4.987m Ans. ® problem 2.8. What power will be transmitted by a belt running over a pulley of 400 mm diameter at 200 p.m. The coefficient of friction between the belt and the pulley is 0.3, angle of lap 165° and the maximum tension in the belt is 2500 N. Solution. Given, D = 400 mm, N = 200 rpm., t= 0.3, 8 = 165°, T, = 2500 N. We know that at =? ; oan 2 or Power Transmitted, x0.4X 200 60 = 6058 W = 6.058 kW Ans. = (2500-1053.7) x Problem 2.6. A pulley running at 200 rp.m. drives another pulley at 400 r.p.m. It transmits 10 kW through an open belt. The width and thickness of the belt is 70 mm and 10 mm respectively. The centre distance between the pulleys is 5 m. The smaller pulley is of 600 mm diameter and the coefficient of friction between the belt and pulley is 0.25. Calculate the stress in the belt. Solution. Given, N= 200 r-p.m., Nz = 400 rp.m., P = 10 KW, b= 70 mm, ¢= 10 mm, d= 5m = $000 mm, D2 = 600 mm, 4c = 0.25 We know that Ny _ D+t N, Dj,+¢ 400 _ D, +10 200 ~ 600+10 or D, =1210mmISHAN'S Theory of Machin 46 a(D) +) XN2 Velocity of belt, v= "Gy 1(600-+10) x 400 = 27(600+10) x 400 - 60 = 12776 mm/s = 12.78 mis. Dj—Dy _ 1210-600 _ 9 96) Now, sin = FI ="9x5000 (0,061) = 3.5° Angle of contact on smaller pulley. . 6 = 180° - 2a = 180° -3.5° x 2= 173 a We know that 0.25% x173 A 180 =2.13 ali) Further, power transmitted, P = (T, —T;) v 10 x 10° = (T,-T,) x 12.78 ” T,-T: =782.5N wall From equations (i) and (ii), we get T, = 1475 N and T; = 692.5 N T_ 1475 Maximum stress in the belt = —L = bxt 70x10 © Problem 2.7. A belt connecting two Pulleys of qual diameter}has initial tension 3000 N. If the coefficient of fri 'y is 0.3, determine the tension in the EAlso calculate the power transmitted .1 N/mm? Ans. by the belt if the speed of the belt is 1.2 ms, Solution, Given, To = 3000 N, 4 = 0.3, 6 = 180° We know that Ty BEG 2 T1+T: =2 x 3000 = 6000N a Ate Be yom T, = 2.566 ll) From equations (i) and (ii), we getPower Transmission Power transmitted, 47 Ti =4317N Ans. T, = 1682.4 .N Ans. =(T1-T)v 4317 ~ 1682.4) x 1.2 =3162W 3.162 kW Ans. Problem 2.8. The pulleys of diameters 450 mm and 200 mm mounted on two parallel shafts 1.5 metres apart are connected by leather belt 150 mm wide. If the maximum safe tension of the belt is 15 N/mm width, calculate the maximum power transmitted in case of (i open belt drive, (i) crossed belt drive. Take speed of belt as 9 m/s and the coefficient of friction between the and the pulley rim as 0.25. Solution. Given, Dj= 450 mm, D, = 200 mm, d= 1.5 m, b = 150 mm, v = 9 mV/s, w = 0.25 Maximum safe tension of the belt =15 x 150=2250N ‘The maximum tension on the tight side should not exceed maximum safe tension. (i For open belt drive : T, =2250N D,-D, _ 450-200 sme Fd 21500 = 0.0833 a =4,78° Angle of contact on the smaller pulley Now Power transmitted, = 180° — 2a = 180° - 2 x 4.78° = 170.44° (i) For crossed belt drive : x Tye _ 28cm) yy Tt T__ 2250 = —L == =10694N T= Fy04~ 2.104 P=(T)-T2v = (2250 - 1069.4) x 9 = 10625 W = 10.625 kW Ans. sing: = DEED 2 = 4504200 _ 9 947 2d -2x1500 a@ =sin™' (0.217) = 12.5°48 ISHAN'S Theory of Mating, 9 = 180° + 2a = 180° + 2 ¥ 12.5° = 205° 7 205° Now Te “it 200" 45 Power transmitted, Pp =(T)-T)¥ = (2250 -918.4) x 9 = 11984 W = 11.984 KW Ans. Qprobtem 2.9. A rope drive transmits 400 kW from a pulley of effective diamete, 3 metres, which runs at a speed of 120 r.p.m. The angle of lap is 165°, the angle of grog, 45°, the coefficient of friction 0.28, mass of rope 1.5 kg/m and the allowable tension in eag, rope 2400 N. Find the number of ropes required. Solution. Given, P =400 kW, D=3m, N= 120 rp.m., 6 = 165°, 2a = 45°, e = 22.5°, m= 1.5 kg/m length, T =2400N, u = 0.28 We know that velocity of the rope, DN 60 _ @X3x120 60 ve =18.85 m/s Centrifugal tension, T. = mv? = 1.5 x (18.85) = 532.98 N Tension on the tight side of the rope, T, = T-T, = 2400 ~ 532.98 = 1867.02 N Let T, = Tension on the slack side of the rope. : 0.28x—, 1 (cmt Now, sel sin. or Power Transmitted per ropepower Transmission “0 =(T)-T)v = (1867.02 - 227) x 18.85 = 30914 Ww 00 1000 30914 Number of ropes = =12.94=13 Ans. Problem 2.10. A rough rule for a leather belt is belt is that effective tension in it shall not exeeed 20 N/mm of its width for a belt of 12 mm thickness. This rule is applied to determine the width of a belt required, in order to transmit 3.7 kW under the following conditions : Angle of lap 160°, coefficient of friction 0.28, belt speed 25 m/s, density of jeather 0.001 g/mm’. Find the width of the belt required. Assuming limiting friction between the belt and pulley rim, find the total stress in the tight side of the belt. Solution. Given, Total tension = 20 N/mm width, ¢ = 12mm, P = 3.7 KW, @ = 160°, = 0.28, 25m/s, p= 0.001 g/mm* Let, width of belt = 6 mm. Mass of belt per unit length, m= 0.001 x b X 12 = 0.0126 g/mm = 0.012 b kg/m Total tension of the belt = 20 x b=20bN Centrifugal tension, T, = mv’ = 0.012 b x (25)°=7.5bN Total tension = T, + T, 20b =T) +756 T, =12.50N We know that Ts T, x 0.28% 160 ( 580 ) or Power transmitted, .7bN ‘T,-T2) Xv 12.5 b-5.7 b) X 25 or or Total tension on tight side, T = 20 b = 20 x 21.8=436N . T Total stress on tight side ee 436 = =~ = 1.667 N/mm’ Ans. 12x21.8 . _ Problem 2.11. The transmission of power is done by V-belt drive whose included angle ‘30°. The belt is 18 mm wide and 20 mm thick, Determine the maximum powerISHAN'S Theory of Machines ction between belt and pulley rim j, is a. 1 allowable stress is 1.4 MP: 50 ; jent of fri transmitted if angle of contact is 145°, coefficien 0-15, mas of et i 38 gman maximum MO, = 20mm = 0.02 m, Solution. Given, 26 = es “ a F yr0.35 kgf, Grex = 1-4 MPA = 14 X 10 Nin? = 145°, = 015, ‘Area of cross ~ section of the belt 18 = 504 N Maximum tension in the belt = Stress * = 1.4 x 10° x 0.02 x 0.0 For transmission of maximum power, Velocity of the belt, v 504 3x0.35 =21.9 m/s Now we know that Now, T, =T-T, = 504-168 = 336N 336 T= la 229N Maximum power transmitted =(T\-Tr)v = (336 - 229) x 21.9 = 2343 W = 2.343 kW Ans, Problem 2.12. A leather belt is required t. F 'o transmit 10 kW fi i running at 180 r,p.m. The angle of contact is 160° are a , and the coeffici icti veen bell and pally is 0.25. The density of leather is 1099 kg/m? and ey a ee - leather is LS MPa. If the thickness of belt is 10 mm, find ah oo baie the centrifugal tension. » lind the width of the belt considering Solution. Given, P = 10kW,D=2m, N= 180 6 _ yNS “pm, @= p, # =025,p = 1000 kg/m, = 1.5 Mp. ss ¢= 10mm, " Let b is the width of the belt in mmpower Transmission a We know that velocity the belt, es 2(D+1)N a 60 = 2(2+0.01)x180 69. 18.94 m/s Power transmitted by the belt, P=(T\-T)v 10 x 10° = (T,-Ty) x 18.94 om T,-T; =528N li) T al = QH0 Further q oe Tt or T, =2.01 T, .- fii) From equations (i) and (ii), we get T, = 1050.8 N, T,=522.8N Mass of the belt per unit length, 000 x 0.001 b x 0.01 kg/m .01 b kg/m Centrifugal tension, T. =my* =0.01 b x (18.94)' = 3.59 bN Maximum tension in the belt, T =obt 5 X 10° x 0.001 bx 0.01 But, bY 156 or b =92.1 mm Ans. 2.19 CHAIN DRIVE A chain drive consists of an endless chain running over two sprockets, driver and driven. These are used where positive drive is required. The velocity ratio is constant upto some extent. The chains are mostly used to transmit motion and power from one shaft to another, when the centre distance between the shafts is short such as in bicycles, motorcyc'es, agricultural Machinery etc, The chain drive has the following advantages over a belt drive :ISHAN'S NeOTY OF Machingg 52 nces. (i) Itisa positive drive. or short centre distar atively long ch for atively 18, occupy Lesser space and therefore, y under ideal conditions. (id) Itcan be employed b (iii) This small and compact size drive (iv). The drive can have 98% efficienc: (v) Iegives The disadvantage of a chai of chain joints. Its costs is relatively high. Its oJ lubrication is also required. Chains are made up of rigi are classified as per their use : 1. Hoisting chains, constant velocity ratio. ‘onstant velocity al stretching of chain due tothe weap « is that there is gradu a x in i peraton is noisy. This drive is heavier ang .d links which are hinged together. Chains are of various types ang 2. Conveyor chains, 3. Power transmission chains. 1. Hoisting Chains : The hoisting chains are used for hoisting and hauling purposes These are of two types : (i) Chains with oval links and (ii) Chains with square links. The former consists of oval links. It has a special type of sprocket. It is used only at lox speeds such as in chain hoists am’ anchors for marine works. These are also known as coilei chains, Another type of hoisting chain as shown in fig. 2.17 (b) consist of links of square shape. This type of chain is used in hoists, cranes etc. The main disadvantage of this chain is that it will 22° kink or tangle easily on overloading. NED) 4p 3H (a) Chain with Oval Links (6) Chain with Square Links Fig. 2.17 : Hoisting Chains 2. Conveyor Chains : mines and factories. These are of two types : 1. Detachable or hook joint type chain, 2. Closed and pintle type chain, The former is also known as Ewort chain, Conveyor chains are mz ed malleable iron castings or of press steel links and are best san cn MMe UP of unmachi conditions. ited for non abrasive operatilé Conveyor chains " * S are used for handling the materials in ™power Transmission AEE i \ i | (a) Detachable or Hook Joint Type Chain 53 (6) Closed or Pintle Type Chain Fig, 2.18 : Conveyor Chains These chains are used for power transmission , when the distance between the centres of shafis is small. These chains have provision of efficient lubrication. These chains are accurately machined and these run on carefully designed sprockets. 3, Power Transmission Chains : The power transmitting chains are of the following types : () Block Chains : These chains are used for transmission at low speeds. Sometimes, these are also used as conveyor chains at low speeds (ii) Roller Chains : The roller chain is used mainly as power transmission chain. A bush is fixed to the inner plate, whereas the outer plate has a pin fixed to it. A roller surrounds each bush. The roller turns freely on the bush and the bush turns freely on the pin. A good roller chain is quieter and wears less as compared to a block chain. Se = FE oS (a) Block Chain Pin’ [Pitch —>}+—Piteh—e . (b) Roller Chain | Lebo | 'ISHAN’S Ineory oF wacnings 54 (c) Silent Ch Fig. 2.19 : Power Transmission Chains i oth chains. It is widely used (ii) Silent Chain : The silent chain is also known ee sity be nade in any ed «le dsateed Tia soni ‘eeudl z when noiseless running is desired. Its Cae She onl Race tect 76 doand to suit the load to be carried. Silent chains do not h is chain gives durabl to give an included angle cither of 60° or 75°. When properly lubricated, this cl gi le service and runs very smoothly and quietly. 2.20 TERMINOLOGY 1. Sprocket : The chains are fitted on wheels called sprockets. A sprocket has projected teeth which fit into the corresponding recesses in the chain links. The chain passes round the sprocket as a series of chordal links, , , 2. Pitch of the Chain : It is the distance between the hinge centres of two adjacent links, Itis denoted by P. Fig. 2.20 : Pitch of the Chain 3. Pitch Circle : A circle drawn through the hinge centres, when the chain is wrapped round a sprocket, is known as pitch circle. 4. Pitch Circle Diameter (PCD) : The diameter of the pitch circle is known as pitch circle diameter. It is denoted by d. 2.21 ROPE DRIVE When a large amount of power is to be transmitted over a consi or cables are used in place of belts. The flat belt drive is limited to Power transmission, it would result in excessiv, drive is more as compared to V-drive. Also with ‘0 several pulleys from one driving pulley. Ij well drilling etc, derable distance, then ropes a distance of 8 m and for large on. The frictional grip of rope "Ves, power can be transmitted inning mills, transways, cranes, € belt cross-sectig h the help of rope d s used in hoists, spipower Transmission The rope drives use two types of ropes 1. Fibre ropes, 2, Wire ropes 55 2.21.1 Advantages of Rope Drives These have low cost and operation is economical. These have high mechanical efficiency. The outdoor conditions affect these very little. The shaft may be out of strict alignment. These have smooth, steady and quiet operation irrespective of amount of power transmitted and centre distance. ypRee Pe 6. Power may be taken off in any direction and in fractional parts of the whole amount. 2,22 GEARS In modern mechanical engineering world, gears are the most common means of transmitting power. The size of the gears may be very small as used in watches or it may be vary large as used in bridge lifting mechanisms, marine speed reducers etc. Gears are the toothed wheels used to transmit power between two shafts, when the centre distance between these is small. In case of belts and ropes, the drive is not positive as there is slip and creep, but the gear drive is a positive and smooth drive. Gears transmit power by direct contact ie. these do not use any intermediate link or connector. In the early stages, the power between two shafts was transmitted by using two plane cylinders or discs D, and D2 having friction on the surfaces of contact as shown in fig. 2.21. A definite motion of D, can be transmitted to Dz or vice-versa, if there is no slip between them. Such wheels are known as frictional wheels. i {hye Fig. 2.21 : Friction WheelsISHAN'S Theory of Machines 56 tion between the discs will not be definite ti ‘and to transmit a definite motion of one ie on the two discs so that they can mesh he discs. The discs with the teeth are But in case of large power transmission, the m due to slippage. So, to prevent slip between the surfac disc to the other, projections and recesses can be mad with each other. This leads to the formation of teeth on # known as gears or gear wheels. A gear may be defined as ofa cone having uniform smaiy “A body of circular shape or that of the shape of. frusrum of surface is called a gear op width and teeth of uniform formation on its outer circumferem internal surface, it is known ax toothed gear or toothed wheel.” When teeth are provided on its in! rovided on its extemal internal gear or annular wheel or simply annulus. When teeth ape lesbian surface, it is known as external gear. The error in tooth meshing may cal and noise during operation. eile eames cast or teeth are cut on a circular plate known as gear blank. The smaller gear is called the pinion and bigger one the gear wheel. 2.22.1 Uses Gears are used in many machines such as metal cutting machine tools, automobiles, hoists, rolling mills, watches, tractors etc. 2.23 ADVANTAGES AND DISADVANTAGES OF GEAR DRIVE Advantages : Gear drive has the following advantages over other transmission devices : Due to short centre distances, gear drive is very compact. It gives positive drive and constant speed ratio, thas high efficiency, reliable service and simple operation, It can be used for precise timing. Its maintenance cost is less and has the mechanical drives. Yen > longest service life as compared to other Due to its unlimited sizes, it can take much he: It can be used for a wide ran; tens of thousand of kW. 8. Itcan drive loads subjected to shock at speeds upto 20 nis. ‘avier loads than other drives, 8¢ of transmission of power ie. from one-tenths of kW to ae Disadvantages : Gear drive has the following disadvantages 1. Itis not suitable for large centre distances bee; 2. Its manufacturing is eompex, so special tools ana equipm is costlier. pave ‘ause the drive will become bulky. re needed and hence, it 3. The errors and inaccuracy in the manufacturing ma ala j . may cause vibrations during operation, & May cause Undesirable noise andpower Transmission 2.24 CLASSIFICATION OF GEARS 57 The gears can be classified in the following ways 1. Depending upon the relative position of ates the sh Depending upon the housing design, Depending upon the peripheral velocity. Depending upon the type of gearing, Depending upon the shape of teeth of the gears. aft, yer 2.24.1 Depending upon the Relative Position of Axes of the Shafts The axes of two shafts between which the motion is to be transmitted may be : (a) Parallel, (6) Intersecting, (c) Non-parallel and non-intersecting, shown in figs. 2.22(a). (and (c) respectively. Sy = Surfaces of frusta of cones (a) Fig. 2.22: Relative Position of Axes of Shafts (a) Parallel Shafts : The following type of gears are used between parallel shafts : (Spur Gears : These are usually cylindrical in shape and have straight teeth which are parallel 10 the axis of rotation. These impose only radial londs. These are slow speed gears, but if Toise is not a problem, these can be used for any speed. The most usual arrangement is an external gear and pinion combination. If centre distane is to be reduce the internal gear with €xternal pinion combination may be used. Gears rotate in opposite direction in case of external gearing and in same direction in case of internal gearing. Fig. 2.23(a) shows the spur gears. These ate generally used in lathes for speed change mechanism.ISHAN’S Theory of Machines 58 ; i rs rri he (a) SpurGears () Rack and Pinion (0) Helical Gears (d) Herringbone Gears 2.23 : Parallel Shafts type of spur gear. Jt has infinite pitch tary motion into translatory motion or i) Spur Rack and Pinion : Spur rack is a special diameter. The spur rack and pinion combination converts ro vice-versa, Fig. 2.23(b) shows the rack and pinion. (ii) Hetical Gears : Fig. 2.23(c) shows the helical gear. In helical gears, teeth are inclined to the axis ofthe shaft and are in the form of helix. Two meshing gears have the same helix angle, but have teeth of opposite hands i.e. a right hand pinion meshes with a left hand gear and a left hand pinion meshes with a right hand gear. These gears are considered as high speed gears and can take higher loads as compared to the equal size spur gears. Single helical gears impose both radial and thrust loads on their bearings. (i») Double Helical Gears : These gears have two sets of opposed helical teeth i.e. one has right handed helix and other left-handed helix. The teeth of two rows are separated by a groo? used for tool run-out, These can be run at higher speeds without noise and vibrations. There is 1° axial thrust on the bearings. (») Herringbone Gears : These gears are shown i s he same asthe double helical gears but in these are there ee tteaaate excel sets of helical teeth. These are used in turbines. ® cana ‘Tandellowing ‘ypes of gears are used between intersecting shatis: @ Straight Bevel Gears : Fig. 2.24 shows the straight bevel gears. When motion is to be transmitted between shafts whose axes intersect, some form of bevel Bei 3 motion is es a ig! TS Is rey ed. In straig! bevel gears, teeth are straight and radial to the point of intersection fine wee oe en variation in peepee their length, Although these are m: ‘ plc axis. pias . 90°, but these can be used for almo: © made for a shaft angle o! not interchangeable. Straight bevel gen fae in pairs and hence, ate Har to spur gears, There can be bevel pears vel nears of same size with shaft angle there is no space separating the nvo oppos y angle, Bevel ge: 1 Stra make the line cor internal bevel gears similar to internal spur years. ‘Two b of 90° are known as mitre gears.power Transmission 59 (a) Straight Bevel Gears (6) Spiral Bevel Gear (0) Zero Bevel Gear Fig. 2.24: Intersecting Shafts (i) Spiral Bevel Gears : In these bevel gears, the teeth are curved and oblique. These are most suitable for high speeds. These can run more quietly and can take up more load than straight bevel gears, but the thrust loads are greater. These are in the differential of an automobile. Fig, 2.24(b) shows spiral bevel gears, (iii) Zero Bevel Gears : These are similar to straight bevel gears, but the teeth are curved in the lengthwise direction. These curved teeth are arranged in such a manner that the effective spiral angle is zero. These are used in cutting machines used for cutting spiral bevel gears 3. Non-Parallel and Non-Intersecting Shafts : The axes of such shafts cross in space. The shaft which lie in parallel may be skewed at any angle between 0° and 90°. The following types of gears are used between such shafts : () Crossed-Helical Gears : These are also called spiral gears. There is no difference between these gears and helical gears until they meshed with each other. A pair of meshed crossed helical gears usually have the same hand. The teeth of these gears have point contact with each other and are used for low loads. (i) Worm Gears : Fig. 2.25 shows the worm gear. In such gears, one gear has screw threads. Due to this factor, these are quiet, vibration free and give a smooth run. These gears are Used with shafts angles of 90°, but other angles are also possible. The worm gear is normally the driven member of the pair and is made to wrap around the worm. Worm who Fig. 2.25 : Worm and Worm GearISHAN'S Theory of Machines 60 - ears with the difference that the axe, vel (iii) Hypoid Gears : These are similar to spiral beve! ze re meen a hypoid pinion asa Of the shafts do not intersect. The term ‘offset’ is the distan ‘al bevel gears, if the offset is zero, the axis of the hypoid gear. Hypoid gears become spiral a en fie oft Te shafi angie is usually 90°, but other angles are also possible. The i is a combination of rolling and sliding along a straight lin 2.24.2 Depending upon the Housing Design i ir i follow = The types of gear drive based on the housing design are as - @ Open Drives : The gear drive without casing and is subjected to the action of dust and dirt is known as open drives. : i) Closed Drives : The gear drives which are enclosed in special casings and are protected against dirt and dust and are properly lubricated are known as closed drives. e.g. gear drive used in automobiles etc. 2.24.3 Depending upon the Peripheral Velocity of the Gears The gears may be divided into following types depending upon their peripheral velocity : (@ Low Velocity Gears : These gears have peripheral velocity less than 3 m/s. (ii) Medium Velocity Gears : These gears have peripheral velocity between 3m/s and 15m/s. iii) High Velocity Gears : These gears have peripheral velocity more than 15 m/s. 2.24.4 Depending Upon the Type of Gearing The gears may be divided into following types depending upon the type of gearing : (a@) External gearing, (b) Internal gearing, (c) Rack and pinion. (a) External Gearing : In fig. 2.26(a), external gears are shown, In this case. the teeth are provided on the external surfaces. When the gears of the two shafts mesh extemally with each other, it is known as external gearing. In this case, the motion of the two Sears is always opposite. ‘The larger gear is known as spur wheel, while the smaller the pinion, ° (a) External Gearing yi ») Invernal Gearing Fig. 2.26power Transmission 61 th . He teeth are provided on its internal surface. Fig. 2.26 we ‘ Bears of Wo shafis mesh internally with each other. far wheel while the sma ion. 1 Scio he smaller wheel, the pinion. The direction of (©) Rack and Pinion : Spur rack is a special case of diameter. The spur rack and pinion combination c vice-versa. Fig. 2.23(b) shows the rack and pinion (b) Internal Gearing : In this case, (b) shows the internal gearing, in which t ‘The larger wheel is Known as annul a spur gear. ft has infinite pitch ‘Onverts rotary motion into translatory motion or 2.24.5 Depending upon the Shape of Teeth of the Gears The gears may be classified as : (i) Straight Teeth Gears : These are usually cylindrical in shape and have straight which are parallel to the axis of rotation, These impose only radial loads. These are slow spe gears, but if noise is not a problem, these can be used for any speed. The most usual arrange is an external gear and pinion combination, If centre distance is to be reduced, the internal with external pinion combination may be used. Gears rotate in opposite direction in case external gearing and in same direction in case of internal gearing. Fig. 2.23(a) shows the spur gears. These are generally used in lathes for speed change mechanism. (ii) Helical Teeth Gears : Fig. 2.23(c) shows the helical teeth gears. In helical gears, are inclined to the axis of the shaft and are in the form of helix. Two meshing gears have the san helix angle, but have teeth of opposite hands i.e. a right hand pinion meshes with a left hand ge and a left hand pinion meshes with a right hand gear. These gears are high spec! take higher loads as compared to equal size spur gears. Single helical gears impose bor and thrust loads on their bearings. (iii) Herringbone Teeth Gears : These gears are shown in fig essentially the same as the double, helical gears but in these gears, there is no sp, ‘wo opposed sets of helical teeth. These are used in turbines. (iv) Curved Teeth Gears t In the spiral bevel gears, the teeth are enrved and ob! y These are most suitable for high speeds. These can run more quietly and can take uy more load than straight bevel gears, but the thrust loads ar greater. These are used in the tferentil of an automobile, Fig. 2.24(b) shows spiral bevel gears. 2.25 GEAR NOMENCLATURE The terminology of gear tecth is illustrated in Figure piven belowISHAN'S Theory of Machines addendum circle ‘Top Jan Addendum dedendum 7 ibe Working depth pitch circle i" ‘Tootkr thickness ‘Tooth space WA Root or dedendum circle Circular pitch Total depth Clearance Clearance or working depth circle Fig. 2.27 : Gear Nomenclature (i) Pinion : A pinion is the smaller of two mating gears. The larger is often called the gear or the wheel. (ii) Rack : Itis a gear with infinite diameter as shown in fig. 2.23(b). (iii) Pitch Cylinder : Pitch cylinders of a pair of gears in mesh are the imaginary friction cylinders which roll together without slip to give the same velocity ratio as the pair of mating gears. (iv) Pitch Circle : It is the theoretical circle on which all calculations are usually based. The pitch circles of a pair of mating gears touch each other. The diameter of the pitch circle is called pitch circle diameter. (v) Pitch Point : It is the point of contact of two pitch circles. MMe oth. Mathematically, : , ad Circular pitch, Pea i where Pe = Circular pitch, d = Pitch circle diameter, T = Number of teeth. The angle subtended by the circu ite angle. : i lar pitch at the centre of the pitch circle is called pitch (vii) Module (m) Mathematically, + It is the ratio of the pitch ¢j OF the pitch circle diameter to the number of tetPower Transmission Module, m= ad Poe Se co oP Sam (iii) (viii) Diametral Pitch (P,) : It is the numbe: of teeth on the gear per unit of the pitch diameter. Mathematically, gear pr of the pitch circle . T Diametral pitch, Pas a From equations (i) and (iv), we get ad T Pox P= Exton ” (éx) Addendum Circle : It is the circle passing through the top of the teeth and is concentric with the pitch circle. It is also called tip circle. (x) Addendum : It is the radial distance from the pitch circle to the top of the tooth. Its standard value is one module. (xi) Dedendum Circle : it is the circle drawn through the bottom of the teeth and is concentric with pitch circle. It is also called root circle. (xii) Dedendum : It is the radial distance from the pitch circle to the bottom of the tooth. Its standard value is 1.157 m. (xiii) Clearance : It is the difference between dedendum and addendum. Clearance = 1.157 m- m=0.157 m. (xiv) Backlash : It is the amount by which the width of a tooth space exceeds the thickness of the engaging tooth on the pitch circles. Backlash = Tooth space - Tooth thickness. (xv) Top Land : /t is the surface of the top of the tooth. (xvi) Face Width : It is the length of the tooth parallel to the gear axis. (xvii) Face : It is the tooth surface between the pitch circle and the top land. (xviii) Flank : It is the tooth surface between the pitch circle and the bottom land. (xix) Bottom Land : It is the surface of the bottom of the tooth between adjacent fillets. (xx) Fillet : [1 is the curved portion of the tooth flank at the root circle. (xxi) Total Depth : /t is the radial distance between the addendum circle and the dedendum circle of a gear. It is equal to the sum of addendum and dedendum. Total depth = Addendum + Dedendum. (exii) Working Depth : It is the maximum depth in which a tooth penetrates into the tooth Space of the mating gear. Working depth = Sum of addenda of the two mating gears (xxiii) Line of Centres : [1 is the line connecting the centres of a pair of mating gears.ISHAN'S Theory of Maching, 64 iquity : Iris the inclination of the line of actgy (xiv) Pressure Angle or Angle of Oblig® ntto the pitch circle at the pitch point e wnt fangel we dra hetween the common normal t0 the to gear : + ihe pitch point. The standard pressure ange between a pair of mating teeth to the lin ru In other words, we can say that it is the angle at the point of contact and the common tange are ut and 20°. 2.26 SOME IMPORTANT TERMS 1. Gear Ratio : The ratio of the number of teeth on gear ratio. gear to that on the pinion is known a, Gear ratio t where T = Number of teeth on gear, t = Number of teeth on pinion. 2. Speed Ratio : It is the ratio of the angular velocity of the driver gear to that of driven gear, -o = Angular speed of driver a Speed ratio = “Angular speed of driven ~ 1», — 2aN; Ni _ dy : © 2aN, Ny dy where w; = Angular speed of driver, @2 = Angular speed of driven, N, = Speed of driver in r.p.m. Np = Speed of driven in r.p.m., d = Pitch circle diameter of | driver, 4; = Pitch circle diameter of driven, Also 420 a, Velocity ratio 2.27 GEAR TRAIN A gear train is a combination shaft to some driven shaft. The function of a gear train i; clocks, watches, lathes etc. It may ¢ of v0 oF more geary © Bears used 19 transmit power from a driving S similar to that of at of belt, i is » 0) as n nsist Of spur, bevel ar Sbital pen chain drives, It is used ! “ars,Power Transmission é 2.28 TYPES OF GEAR TRAINS The different types of gear trains are as follow : Simple gear train, Compound gear train. Reverted gear train, Epicyclic or planetary gear train. Pes 2.28.1 Simple Gear Train A simple gear train is a series of gears capable of receiving and transmitting motion from one gear to another. In this train, there is only one gear on each shaft as shown in fig. 2.28. It may be constituted by spur or bevel gears. Idle or intermediate gear Driver: SS £ | t i i i 2.28 : Simple Gear Train Ina simple gear train, I. The two gears meshed externally always rotate in opposite direction. 2. If the number of gears in the train are even, then the direction of rotation of last gear is reversed and if it is odd, then the direction of rotation of last gear is same as that of first gear. 3. Speed ratio = SPeed of driver peed of driven Speed ratio will be negative if the direction of rotation of input and output gear is opposite and it will be positive when the input and output gear rotate in same direction, Train value of the Bear train is reverse of the speed ratio. Let T = Number of teeth on a gear, N = Speed of gear in r.p.m.“ ISHAN'S Theory of Machin es 66 Refer to Fig, 2.28, N% (i) N, 1 NB iy and uo] Multiplying equations (i) and (ii), we get Ni No Ny N3 speed ratio = Nin B Speed ratio = 5° = 5, Train value = NB = 2 Further, rain value = NG From the above, we see that intermediate gears do not affect speed ratio, so these are calles idler gears. The purpose of idler gears is to connect gears when a large centre distance is require: and to control the direction of the gears. 2.28.2 Compound Gear Train A compound gear train consists of a series of gears connected in such a way that two « more gears rotate about an axis with the same angular velocity i.e. there are more than one gee) on a shaft. Fig. : "8: 2.29 Compound Gear TrainPower Transmission @ Let us consider a compound gear train as shown in fig, 2.29. Gears 2 and 3 are on the same shaft, Let gears 1 and 2 are the driver and driven respectively. Then, Nb , en, N77 -) Ny _ Ty and Na = yh ii) Multiplying equations (é) and (ii), we get NN yl Ny Ne T But Nz =N3 (Gears being on the same shaft) | oN Speed ratio = —L: 4 _ Product of number of teeth on driven gears Product of number of teeth on driving gears »Aiti) 2.28.3 Reverted Gear Train In a compound gear train, when the axes of first and the last gears are co-axial i.e, on the same axis shown in fig. 2.30, then it is known as reverted gear train. Such an arrangement has its application as speed reducers, clocks (to connect hour hand to minute hand), machine tools, automative transmission and lathe back gears. 4° Coaxial shafts Fig. 2.30 : Reverted Gear Train In fig. 2.30, gear 1 drives the gear 2 in the opposite direction. As gears 2 and 3 are on the same shaft Le. they form compound gears, so the direction of rotation of gears 2 and 3 is same. Gear 3 drives gear 4 in opposite direction, but the direction of rotation of gear 4 and gear 1 isISHAN'S Theory of Machings 68 tation of first and | f rot ast pear, irection of ar train, the direct same, Thus we see that in a reverted gear (rain same. An number of teeth and pitch circle radius of gear Let Nj, Ty and 7, are the speed in 1-7-4» arvin rp.ttt, arly, NacINq, Ny = Speed of respective Bears 1 FPA Similarly. Na Na ei eospective £645 Ts, Ty, Ty = Number of te Pp ta, ta = Pitch circle ra rs | and 2= As the centre distance between gears | an ; 7 us of gear 1+ Pitch circle radius of gear 2: dii of respective gears. Centre distance between gears 3 and 4 Pitch circle radius of gear 5, Pitch cirele radi Pitch circle radius of gear 4. T)+T2=Ts+Ts mT “» Circular piteh, Po = = mor r=—2~» where mis the mage Product of number of teeth on driven gears Speed ratio = F Guct of number of teeth on driving gears sessdvations NEI Speed ratio = = 1 _qxu and Train value = ————= Speed ratio T; XTy 2.28.4 Epicyclic or Planetary Gear Train ‘In all the gear trains discussed so far, the axes of the wheels remain fixed relative 10 o~ another. but in the epicyclic gear trains, the axis of one or more gears move relative to the frame In fig. 2.31, gear | meshes with gear 2 and their axes are connected by an arm 3. If Am? fixed, then these will consitute a simple gear train, Fig. 2.31: Epicyclic or Planetary Gear Trai ‘ar Train In fig. 2.31, gear 2 rotates about its fixed gear J. As gear 2 rolls on the Outsidk an epicycloid and that is why, it is know centre O,, cof p of while ity centre rotates. act about centre O1 +4 Point on the g ; st urtace of gear 2 will gene" ar |Power Transmission ° It is also called planetary gear train, because the fixed gear acts as sun and the gears moving about it act as planets. The epicyclic gear train can provide large velocity ratio for a given number of gears. These are widely used in differential of automobiles, wrist watches, hoists, pulley blocks etc. 2.29 VELOCITY RATIO OF EPICYCLIC GEAR TRAIN For finding out the velocity ratio of an epicyclic gear train, the following two methods may be used : 1, Tabular method, 2. Relative velocity method. 1, Tabular Method : This method is based upon the principle of superposition, according to which the resultant revolutions or turns of any gear may be found out by taking the number of tums it makes with the arm plus the number of turns it makes relative to the arm. It is the easier and mostly used method for solving the problems on epicyclic gear trains. Let us consider an epicyclic gear train as shown in fig. 2.31. Let T; and T; be the number of teeth on gears 1 and 2 respectively. The steps which are followed in tabular method are as follow : (i) Let arm 3 is fixed. Let gear 1 makes one revolution in anticlockwise direction, then gear 2 will make z revolutions in clockwise direction. Let us consider the clockwise Hy direction as negative and anticlockwise as positive. Thus, if gear | makes +1 revolution, then gear 2 will make (=) revolutions shown in Table 2.1 2 (ii) Multiply all the quantities in first row by x and write in the second row. (iii) Add +y revolutions to the various quantities of second row to account for rotation of arm, Table: 2.1 Revolutions of elements Step no. Operation — | r Arm3 | Gearl | Gear2 =T (| Arm3 fixed, + I revolution given to gear! | 0 +1 = | 2 | " qT (ii) | Multiply by x 0 +e “= in Tq (iii) Add + y revolutions to all elements +y xty [oO aayISHAN'S Theory of Machines 70 f ‘om these, values of x, y can be In the last row, out of three quantities, two are known and fr calculated. . number of equati 2. Relative Velocity or Algebraic Method : In this ee the caution, a depends upon the number of elements in the gear (rain. For ‘ici are sufficient. conditions (i.e. one element is fixed and the other has specified mots Refer figure 2.31. Speed of gear | relative to arm 3 = Nis = Ni~Ns and speed of gear 2 relative to arm 3 = Nos = No—- Ns Nis ae Now No OMEN The -ve sign signifies the rotation of gears 1 and 2 in the opposite direction. If the arm 3 is fixed, then Ns =0 N _h NT N._ 7 “ NG If the gear 1 is fixed, then N,=0. 0-N; No —N3 Np 7 2 si¢at “ Ng Tt Problem 2.13. Determine the pitch circle diameter, toothed gear having 36 teeth and circular pitch of 13 mm, Solution. Given, T =36,Pe=13mm We know that diametral pitch and module of a Circular pitch, p. = 24 T xT so gn BXT _ 1336 a na = 148.97 mm = 149 mm (say) Ans, T Diametral pitch, Py =| | Power Transmission 71 = 26.024 Toothimm Ai = 149 . ‘ooth/mm Ans. d I 1 Module = {=—=—!_ =4, TB oa 4mm Ans. Problem 2.14.Two mating gears have 60 and 40 teeth. Their common module is 5 mm. Find the centre to centre distance between the axes of gears. Solution. Given, Ty = 60, T: = 40, m= 5mm. Let C be the centre to centre distance between the axes of gears. Now, dy = mT, and d= mT> ce tee) 2 mT, +miTy or a = n{ 22) 55 (2200. 250 mm Ans. Problem 2.15. A toothed gear A is to drive another toothed gear B. The centre distance between the shafts is exactly 400 mm. Speed of gear A is 500 r.p.m and that of gear B is 300 r.p.m. approximately. If each gear is of module 5 mm, determine what should be the number of teeth on each gear ? Solution. Given, C = 400 mm, Na = 500 r-p.m., Ng = 300 r.p.m.,m=5 mm Let T, and Tp are the number of teeth on gear A and gear B respectively We know that dy tdy cae or dy + dg =2C = 400 x 2=800 mm or m (Ta, +Ts) = 800 mm or Ty Ty = ee = 60mm Ad) m 5 Na _ 45 Na da, or Ne _ mle Th Na mT, Ty 300 _ Th 300 TyISHAN'S Theory of Machingg 72 or The 31 ti From equations (i) and (ii), we get «= 60 Ans. Ty = 100 Ans. Problem 2.16, A toothed gear A is to drive another toothed gear B. The centre to centr, distance between their axes of rotation is to be exactly 375 mm. pies of gear - 10 be 500 rpm. and approximate speed of gear B is 350 r.p.m. If each gear is of modu, 5, determine what should be the number of teeth of each gear ? In that case, what would be the actual speed of B ? Assume that gears are available with their teeth number divisible by 5, Solution. Given, C =375 mm, Ny = 500 r.p.m., m= 5mm Let T, and Ty are the number of teeth on gears A and B respectively and let Ng is the actual speed of gear B. We know that dytdp c= AT _ mT, +mTp = Mae _ m(T, +Tp) = MET) 375 = a +Te) 2 or Ta+Tp = 150 i Also Na _th Na Ty 500 _ Ty 350 ~ T, or Th _ 10 Ta 7 10 “ he 7 ee (i) From equations (i) and (ii), we get Tr $61.76 Ty = 88.24 Let the selected gear tecth divisible by 5 are - Ta = 60 Ans,Power Transmission Tp =90 Ans, Actual speed of gear B, - 500 x 60 90 No 33.33 rpm, Ans. Problem 2.17. A toothed wheel has 108 teeth. Its module is 1.25 mm. Find the circular pitch, diametral pitch and pitch circle diameter. Solution. Given, T = 108, m= 1.25 mm We know that Pitch circle diameter, d =mT = 1.25 x 108 = 135 mm Ans. 1 125 =0.8Tooth/mm Ans. Diametral pitch, m ad _xXx135 Circular pitch, == = a T 108 =3.93 mm Ans. Problem 2.18. Two mating gears have 20 and 60 teeth. Determine the pitch circle radii of the gears, if the circular pitch is 50 mm. Solution. Given, T, =20, T, = 60, p= 50 mm Let r; and r be the pitch circle radii of the mating gears. We know that 2 Circular pitch, P, = == 7 x py = Pelt 2 50%20 _ 159.09 mm Ans. 2a n= FeTp _ 50% 60 _ 477.97 mm Ans. 2 on Problem 2.19. A spur gear has 40 number of teeth and rotates at 300 r.p.m. If it has a module of 2 mm, then find : (Circular pitch, (ii) Pitch line velocity. Solution. Given, T =40,N=300rp.m.,m=2mm (@ Cireularpitch, oem =m X 2= 6.28 Ans. mT Gi) Pitch tine velocity, v, =0 x r= x 2ISHAN'S Theory of Machines 74 2aN _ 2x X300 _ 3443 radls. where w= = oO 40 Now, vy = 3143 = 1257.2 mm/s Ans. 20 to 1 is required in two steps by means e largest 120 teeth and number of teeth 9, train of gears and also calculate Problem 2.20. A total speed reduction of spur gears. The smallest wheel has 20 teeth, th intermediate gears increase in steps of 5. Choose a suitable the number of teeth on each gear and give a sketch of gear train. Solution. . _ _ 20 Given, Velocity ratio = | 20 Gear ratio = T As the reduction takes place in 2 steps, . 11 Gear ratio = 5% ‘This is feasible with a compound gear train, which is shown in figure (2.32). Ans. Now,Gearratio, Nt - yD N & % 20 30 oly dy, 230 100 120 (As smallest gear is of 20 teeth and largest is of 120 teeth) Ans Hence the number of teeth on drivers are 20 and 30 and that on followers are 100 and 120. Fig. 2.32Power Transmission 5 Problem 2.21. The lead screw of a lathe has a right handed single thread of pitch 6 mm. The smallest change wheel has 20 teeth and largest onc has 80 teeth. The number of teeth on intermediate gears increase in steps of S. Find the gear train suitable for connecting the spindle and lead screw when (@) right hand screw with 0.8 thread per mm has to be cut. (6) left hand screw with 0.8 thread per mm has to be cut. Solution. (a) Pitch of lead screw = 6mm for cutting 0.8 threads per mm. Pitch of work = u mm 0.8 Speed of driven : 10 Speedofdriver 08° 6 4.8 3 16 Since the pitch of screw and threads to be cut are of same nature, so no idler gear is required. Gear ratio = 20 50 Hence, Ge tio = —x— lence, ear ratio = Xo Number of teeth on the gears will be T, =20 T; =50 Ts =80 ‘The gear train is shown in fig. 2.33, which is a compound gear train. Ans. ' 4 lz Fig. 2.33 : Gear Train (6) In this case, threads of opposite nature are to be cut Therefore, direction of rotation of spindle and lead screw should be opposite. I Pitch of work = oa Pitch of lead screw = 6 mmISHAN'S Theory of Machin, 1 _1,10 x10 6 48 3°16 76 Speed of driven Gear ratio = Speed of driver 08 2 Hence, Gear ratio = The number of teeth of gears will be An intermediate gear of suitable size is to be used as idler for getting the motion of lead screw in opposite direction to that of spindle. Let it be with 60 teeth. The arrangement is shown below : Idler gear Fig. 2.34 Problem 2.22. The following data refer to the simple icycli i i figure 2.35, 7, = 607, -90 ple epicyclic gear train shown in The arm makes 100 revolutions, Determine the speed of the wheel P, when (@) The wheel S is stationary. (ii) Wheel S makes 200 revolutions in o ‘ite directi, Pposite dij eoniian. rection to the arm. Fig. 2.35r Transmission Power 7 Using the tabular method. the table is prepared as below : SSS ee — — Step no. Operation Revolution | Revolution | Revolution of | ofarm | of wheelS | _ wheel P Fix the arm and give one (| revolution to wheel § in 0 +1 -2 | | anticlockwise direction. Tm | | | (ii) Multiply by x 0 ‘x is, | Tp | (ii) | Addy 7 eg | ery Tp Let us apply the given conditions (i) Wheel S$ is stationary, o x+y =0 and y = 100 x=-100 Ty -90 Speed of wheel P = ——S x + y=——x(—100) +100 Tp 60 = mre +100= 250 r.p.m. Ans. (ii) Wheel S makes 200 revolutions opposite to arm, ” x+y =-200 and y =100 3 x =-300 Ts Speed of wheel P = -——S.x+y Tp = — 22 x (—300) +100 0 = 550 r.p.m. Ans. Problem 2.23. The speed ratio of a reverted gear train is 10. The module of gears Land 2is 2 mm and that of gears 3 and 4 is 1.25 mm, Calculate the suitable number of teeth for the gears. The centre distance between the gear shaft is 200 mm Solution. Given, N x Speed ratio = 7 10, y= my = 2mm, my = my = 125 mM 478 ISHAN'S Theory of Machin Fig. 2.36 Since speed reduction is in two steps, N, _10_ 0, Vio Ne ot oto oo Let T, Tz, Ts and T, are the number of teeth on gears 1, 2, 3 and 4 respectively. We know that nth =ry+74=200mm or dy + dy =d +d,=400 mm or miTy + mzT> = m3Ty + m4Ty = 400 mm or 2% T) +2 Tz = 1.253 + 1.25 Ty = 400 mm or 21, +72) = 1.25 (1; +T,) = 400 mm fs Ti +Tz =200 wld and Th+T, =400 Ai) Further, MLM YNs Na Np Ng oT aye Ty =, 17 BM yt Vio =~ and —4 ~ VIO q 1 TZ 7Power Transmission 79 or T= Vi0T, = iii) and T. = VI0T; iv) From equations (i), (ii), (i) and (iv), we get T, = 48, T, = 152, T; = 77, Ty = 243 Ans, Problem 2.24. In a reverted epicyclic gear train as shown in fig. 2.37, the arm A carries two gears 1 and 2 at the centre of rotation 01 and a compound gear 3 and 4 at centre of rotation 02. The gear 1 meshes with gear 4 and gear 2 meshes with gear 3. The number of teeth are T; = 80, T; = 40 and T; = 100. Find the speed and direction of gear 2 when gear 1 is fixed and the arm makes 120 r,p.m. clockwise. Assume alll gears to be of the same module. Solution. Given, T, = 80, T; = 40, Ts = 100, Na = 120 r-psm. (Clockwise) From fig. (2.37), ntmsntry Ti+Ts=T2+Ts Ty =T,+T3-Ty = 40 + 100-80 =60 Fig. 2.37ISHAN'S Theory of Maching 80 ——+ — Zevolutions of elements _) ‘Arm A|Compound| Geart | Gear? hp Operation gear 3 and no. : _| ‘Arm A fixed and compound ty ts (y [Bears 3. and 4 are rotated] 4 +1 a + through = 1-——revolution (Anticlockwise) : alt 5b (i) |Muttiply by x 0 +x "F “ Tj 1 (ii) |Addy y x+y myty mat) Since gear 1 is fixed, Ty _ nary =0 60) -x{~|+y <0 (5) ” or -O.75x+y =0 a As arm A makes 120 rp.m. (Clockwise), y =-120 i) From equations (i) and (i), we get + == 160 rpm, Speed of gear 2, = 280 r-p.m. (Anticlockwisey Ans, Problem 2.25. As shown in fig. 2.38, and 3. The internal gear 1 has 60 teeth a Sear 1 and gear 3 and is carried on an arm A whe anticlockwise If gear 1 is fixed, then find the speed Solution. Given, Ti = 60, T5=30, y= 3 id jee Bear train consists of three gears 1,2 S30 teeth, The gear 2 meshes with bot h rotates about the centre O at 30 rps of gears 2 ana 3, 0 pm,Power Transmission at \ - Fig. 2.38, Using tabular method : Step : Revolutions of elements Operation no. Arm A | Gear 3 Gear 1 | Gear2 p |ATMA fixed and I revolution is} 4 given to gear 3 (Anticlockwise) (ii) | Multiply by x 0 +x (i) | Add y y | xty When gear 1 fixed, Ts -rSty = agty <0 30 =x{—=]+30 = 4(32)+30 =0 or x =60 Speed of gear 3, iG aeey = 60 + 30 = 90 r.p.m. (Anticlockwise) Ans. Now ye wll a Zz82 or or or Speed of gear 2, ISHAN'S Theory of Mach, ) 2d, + dy =) 27, +73 =T; 2T, + 30 = 60 T, =15 N. Ty +y =-—x|—> 2 T> 30 = —60| = }+30 (=) =-90 r.p.m, = 90 rp.m. (Clockwise) Ans. ————— i.