SOLUTION (15.1) Known: A pinion with 32 teeth and 8 diametral pitch meshes with a gear having 65 teeth. Find: Calculate the standard center distance. Schematic and Given Data: Ny =65 Assumptions: 1. The gears are spur gears. 2. The gears have teeth of standard involute profile. 3. The gears mesh along their pitch circles. Analysis: 1. From Eq. (15.3): P = N/d = Np/dp = Ne/dy P=8,N,=32. Hence, dy = 4.0 in P 3. N,=65. Hence, dy = 8.125 in. dy +4, 4. The center distance, ¢ = ae = 6.0625 in. os Comments: 1. If the gears did not mesh at the theoretical pitch circles the measured (actual) center distance would not be equal to the sum of the theoretical pitch circle radii of the gears. It should be evident that meshing gears must have the same diametral pitch. 15-1SOLUTION (15.2) Known: A spur gear has a size 8 diametral pitch. Find: Calculate the thickness of the spur gear tooth measured along the pitch circle. Schematic and Given Data: Assumption: The gear has teeth of standard involute profile. Analysi 1, From Eq. (15.5); pP=1 P=8. Hence, p= 0.3927 in. 2. Tooth thickness, t = p/2 : t= 0.1963 in, . 15-2SOLUTION (15.3) Known: A pair of gears with a known gear ratio and at a specified center distance have a diametral pitch of 6. Find: Determine the number of teeth in each gear. Schematic and Given Data: Assumptions: 1. The gears are spur gears. 2. The gears have teeth of standard involute profile. 3. The gears mesh along their pitch circles. Analysis: 1. A gear ratio of 2:1 indicates a 2:1 ratio in the gear diameters. Hence dg = 2dp. 2. Center distance, ¢ = (dg + dp)/2. Hence, dp + dp= 10 in 3. Substituting dg = 2dp in part 2, we obtain 3dp = 10 in. Hence, dp = 10/3 in. 4. Diametral pitch, P = Np/dp, and Np = (10/3)(6) = 20. 5. Since the gear ratio is 2:1, the number of teeth on the gear, Nz = 2Np- Therefore, Np = 40. Comments: T. If the gear teeth were not of involute profile it would still be possible to have a constant speed ratio provided it is ensured that the pitch point is stationary. 2. It should be evident that meshing gears must have the same diametral pitch. 3. If the diametral pitch were chosen to be higher, then the number of teeth would be greater on both the pinion and gear (other parameters being kept the same). 15-3SOLUTION (15.4) Known: A pinion with 20 teeth and 6 diametral pitch meshes with a gear having 55 teeth. Find: Calculate the standard center distance. Schematic and Given Data: Np=20 P=6 N, =55 Assumptions: 1. The gears are spur gears. 2. The gears have teeth of standard involute profile. 3. The gears mesh along their pitch circles. Analysis: 1 From Eg. (15.3): P = N/d 2. P=6N, 20. Hence, 3 5. Hence, dy 4. The center distance, c = 2 $ Sp - 625 in. 7 Comments: I. If the gears did not mesh at the theoretical pitch circles the measured (actual) center distance would not be equal to the sum of the theoretical pitch circle radii of the gears. 2. It should be evident that meshing gears must have the same diametral pitch. 15-4SOLUTION (15.5) Known: A spur gear has a 6 diametral pitch. Find: Calculate the thickness of the spur gear tooth measured along the pitch circle. Schematic and Given Data: Assumption: The gear has teeth of standard involute profile. Analysis: 1. From Eq, (15.5); pP=7 P=6. Hence, p= 0.5236 in. 2. Tooth thickness, t = p/2 : t= 0.262 in. . 15-5SOLUTION (15.6) Known: A pair of gears with a known gear ratio and at a specified center distance have a diametral pitch of 4. Fi Determine the number of teeth in each gear. Schematic and Given Data: Pod Ns c=6in 5 Speed ratio 31 Assumptions: 1. The gears are spur gears. 2. The gears have teeth of standard involute profile 3. The gears mesh along their pitch circles. Analysis: 1. A gear ratio of 3:1 indicates a 3:1 ratio in the gear diameters. Hence dg = 3dp. 2. Center distance, c = (dg + dp)/2. Hence, dy + dp = 12 in. 3. Substituting dg = 3dp in part 2, we obtain dp = 12 in. Hence, dp = 12/4 = 3.0 in. 4. Diametral pitch, P = Np/dp, and Np = Pdp = (4)(12/4) = 12 5. Since the gear ratio is 2:1, the number of teeth on the gear, Ng = Therefore, Ng = 36. Comments: 1. If the gear teeth were not of involute profile it would still be possible to have a constant speed ratio provided it is ensured that the pitch point is stationary. 2. It should be evident that meshing gears must have the same diametral pitch. 3. If the diametral pitch were chosen to be a larger number, then the number of teeth would be greater on both the pinion and gear (other parameters being kept the same). 15-6SOLUTION (15.7D) Known: A web site address is given as http://www.grainger.com. Find: Search the web site and select a spur gear with 32 pitch, 14.5° pressure angle, and 20 teeth. List the manufacturer, description, and price of the gear. Analysis: The web site provides the following information: Mfg. Name: Boston Gear Description: Spur Gear-32 Pitch, Steel-14 1/2 Deg. Pressure Angle-20 Teeth Price: $11.28 SOLUTION (15.8) Known: A pinion of known pitch and number of teeth rotates at 2000 rpm and drives a gear at 1000 rpm. Find: Determine the number of teeth on the gear, theoretical center distance and circular pitch. Schematic and Given Data: 2000 rpm. Assumptions: 1. The gears are spur gears 2. The gears have teeth of standard involute profile 3. The gears mesh along their pitch circles. Analysis: 1. A 2:1 speed ratio requires a 1:2 ratio in number of teeth. Hence,Ng=40 il = 40-5 in, dp= = 25: i = et dp 2. dg=4)= Sin. dp= >= 25 im. Theoretical center distance, ¢ = “#5: 3.75 in. a 15-7© 3. Circular pitch, p=: p= in. . Comments: I. If the gear teeth were not of involute profile it would still be possible to have a constant speed ratio provided it is ensured that the pitch point is stationary. If the gears did not mesh along the pitch circles the speed ratio would not be constant and also the center distance would not be equal to the sum of the pitch circle radii of the gears. 3. It should be evident that meshing gears must have the same diametral pitch. nv SOLUTION (15.9) Known: A pair of spur gears provide a given speed ratio at a specified center distance and have a diametral pitch of 8 Find: Determine the numbers of teeth and the pitch diameters of the gears Schematic and Given Data: P=8 oo, is4:1 ¢=7.5in Assumption: The spur gears mesh at the pitch circles. 15 in. For 4:1 speed ratio, dg = 4dp ; Hence Sdp = 15 in., dp = 3 in; dg = 12 in. / 3. For P=8, Np =24; Ng = 96 . anos The assumption to have spur gears meshing at the pitch circles ensures that the given center distance is the theoretical center distance and is equal to the sum of the pitch radii of the gears. 2. If the diametral pitch were chosen to be higher then the number of teeth would be more on both the pinion and gear (other parameters being kept the same) 15-8SOLUTION (15.10) Known: A pinion with known module and number of teeth rotates at 2400 rpm and drives a gear at 800 rpm Find: Determine the number of teeth on the gear, circular pitch and theoretical center distance. Schematic and Given Data: 4 m=2mm 2400 rpm. Ng=? 800 rpm Assumption: The spur gears mesh along their pitch circles. Analysis: 1. For the 3:1 velocity ratio, Ng = 24(3) = 72 . 2. p=xm=2amm . 3. d=Nm_; Hence dp = 48 mm, dg = 144 mm 4. = 485 M4 - 96 mm . Comments: 1. Similar to the diamewal pitch, the module must be the same for a pair of meshing ears. 2. If the module were a higher value the pitch diameters of the gears and the theoretical center distance would have been higher (other parameter values remaining the same). 15-9SOLUTION (15.11) Known: A pair of spur gears of known velocity ratio, center distance, diametral pitch, and pressure angle are given. Find: Draw a full-size layout of the spur gears and label the following: (a) pitch circle, (b) base circle, (c) pressure angle, (d) addendum (for both the pinion and the gear), (e) dedendum (for the pinion only) Assumption: The gears mesh along their pitch circles Schematic and Given Data and Analysis: (o> \ © Dedendun] @ Addendurd (b) Base circles ~ : Pia . 7] Seem mpew : (@) Addendura] 20 SS 1 Interference does exists Gear addendum shouta| bbe cut back this much.| \\, Gear axis For velocity ratio = Fore=10in,4, +4, ‘Therefore, d , +44, Dedendum == Note: This drawing is not drawn to scale. 15-10SOLUTION (15.12) Known: For a pair of standard 20" full-depth spur gears the diametral pitch, velocity ratio, number of teeth on the pinion and its direction of rotation are given. Find: Draw a full-size layout of the spur gears in the region of tooth contact and show the following: (a) pitch circle, addendum circle, dedendum circle, and base circle of the gear, (b) interference, (c) path of contact, (d) angle of recess for the pinion and the gear. Assumption: The gears mesh along their pitch circles, Schematic and Given Data and Analysis: reduction needed to eliminate interference \ Pitch circle Angle of recess Base circle Center of gear Dedendum dg = (dp\(velocity ratio) = 6 in.(2) = 12 in.= dy ‘Addendum = 1/P = 1/4 i, Dedendum = 1.157/P = 0.289 in. Note: This drawing is not drawn to scale] 15-11SOLUTION (15.13) Known: A pair of involute gears of known base circle diameters with (a) center distance = 120 mm and (b) center distance = 100 mm is given. Find: Determine the pressure angles of the gears for cases (a) and (b), and the ratio of, pitch diameters. Schematic and Given Data: yp = 60 mm Pressure Angle = @ yg = 120 mum Assumption: The spur gears mesh along their pitch circles. Analy: 1, Let rp and rpg represent pinion and gear base circle radii, respectively Toy qT oe e Cl 0. 60 In case (a), ¢ = tp + tg = 120 mm cos 6 * cos cos 6 = 0.75, 0 = 0.7227 rad = 41.4° a 2. Similarly, in case (b), cos ¢ = 3 = 0.9, d = 0.4510 rad = 25.8° 3. dy/dp = dpg/dpp = 120/60 = 2 (for any center dist.) . Comments: 1. With fixed base radii, reduction in center distance resulted in a reduction in pressure angle. 2. Changes in the pressure angle for the gear pair did not affect the ratio of pitch diameters since the pressure angle must be the same for meshing gears and the ratio of base diameters is fixed in this case. 15-12SOLUTION (15.14) Known: A gear has a known outside diameter, diametral pitch and pressure angle. Find: Determine the pitch diameter, the circular pitch, the addendum, the dedendum of the gear, and the number of gear teeth. Schematic and Given Data: Outside diameter of gear = 3.000 in, ‘Circular pitch Pitch circle Dedendum circle Dedendur Assumptions: 1. The gear is a spur gear. 2. The gear has teeth of standard involute profile. Analysis: 1. Addendum, a = 1/P = 0.05 in. Pitch diameter, dp = [(outside diameter) - 2a] dp = 3.0 - (2)(0.05) = 2.9 in. : 2. Module, m = 1/P = 0.05 in. = 1.27 mm. From Eq (15.5), circular pitch, p = xm. Therefore, 3.99 mm. a 3. Dedendum, d = 1.25 a = 1.25(0.05) = 0.0625 in. Hence, d = 0.0625 in. a From Eq (15.4), the number of gear teeth, N = dp/m Therefore, N = 58. 7: 15-13SOLUTION (15.15) Known: A pair of mating gears of known pressure angle, numbers of teeth, and center distance is given. The pinion has stub teeth and the gear has full involute teeth. Find: Calculate the contact ratio and the diametral pitch. Schematic and Given Data: c=10in, Assumptions: 1. The gears are spur gears. 2. The gears mesh along their pitch circles. Analysis: 1. The ratio of the number of teeth, Ng/Np = 36/18 = 2/1. Hence, dp/dg = 2/1. Center distance, c= (dp + dg)/2 Therefore, dp = 20/3. dy = Diametral pitch, P = N/d = 2.7 = For full deep involute teeth, the gear addendum, a = I/P = 0.37. The addendum circle radius of the gear rag = rg + a = 7.037 in. From the textbook, the addendum for a 20° stub system is 0.8/P. The addendum of the pinion, ap = 0.296 in. The addendum circle radius of the pinion, rap = tg + ap = 3.63 in. 4. The base circle radius of the gear, hg = tpg COs = (20/3) cos 20° = 6.26 in. The base circle radius of the pinion, rbp = (10/3) cos 20 = 3.33 cos 20° = 3.13 From Eq. (15.10), the base pitch, pp = (ndp/N), pp = 1.09 in From Eq. (15.9), contact ratio, _ Vt, +11, -c sind ~ Po we au CR = 13.652 = 3.15! + VT.03T?- 6.26 - 10 sin 20° _ | 4og 1.09 Hence, CR = 1.5 . 15-14SOLUTION (15.16) Known: For a given pair of mating gears, the pressure angle, diametral pitch and the numbers of teeth are known. Find: (a) Determine the arc of approach, arc of recess, arc of action, base pitch and the contact ratio. (b) Estimate the addendum, dedendum, circular pitch, tooth thickness and the base diameter for the pinion and gear. Schematic and Given Data: Gear 2 Driven BB = point of initial Contact C= Point of final contact Addendum, ited \ rele Assumptions: 1. The gears are spur gears. 2. The gears mesh along their pitch circles. 3. The gears have teeth of standard involute profiles. 4. Interference (contact below the base circle) does not occur. Analysis: 1. Diametral pitch, P = Ne/dg. Hence, dp = 2.625 in. Since Ng/Np = dg/dp = 84/17, dp = 0.53125 in. Center distance, ¢ = (dy + dp)/2 = 1.57813 in. 2. Addendum, a = 1/P = 0.03125 in. Dedendum, d = 1.25a = 0.039 in From Eq. (15.5), circular pitch, p = 0.098 in. = 2.5 mm. 15-153. Tooth thickness, t = p/2 = 1.25 mm. . 4. Base circle diameter of the gear, dog = dg cos dyg = 2,625 cos 20° = 2.47 in . Base circle diameter of the pinion, dip = dp cos dbp = 0.53125 cos 20° = 0.49921 in. . 5. From Eq. (15.10), base pitch, p, = (mdp)/N). Therefore, p, = 0.092 in. 6. Addendum circle radius of the gear, rag = 1.34 in, Addendum circle radius of the pinion, rap = 0.296 in. From Eq. (15.9); contact ratio, cr = Viet + VG sin @ Po _M/0.296" - 0,249" + 71.34" 1.235" - 1.5781 sin 20° _ 1 595 2 : . 7. Arc of action = (CR)p = (1.525)(0.098) = 0.15 in. 1: Comment: Although an assumption was made that interference (contact below the base circle) would not take place, a calculation needs to be performed to determine whether there will be interference when standard full-depth teeth are used. Following SAMPLE PROBLEM 15.1, we first determine the base circle radii of pinion and gear. 53125/2) cos 20° = 0.2496 in. and tpg = (2.625/2) cos 20° = 1.2333 in. Substitution in Eq. 15.8 gives rap(max) = 0.59467 for the pinion and ragimax) = 1.34624 for the gear. The limiting outer gear radius is equivalent to an addendum of Tag(max) - fg = 0.03374 in., whereas a standard full-depth tooth has an addendum of 1/P = ,03125 in. So, the use of standard teeth should not cause interference. SOLUTION (15.17) Known: For a pair of mating gears, the diametral pitch, center distance and the number of teeth are given. The center distance is increased by 0.125 in Find: Determine the contact ratio and the pressure angle Schematic and Given Data: c= 1.7031 in, 15-16Assumptions: 1 2 The gears are physically the same spur gears as in Problem 15.16. The base and outside diameters of the gear and pinion remain the same as in Problem (15.16). 3. The gears mesh along their actual (not theoretical) pitch circles. 4. The gears have teeth of standard involute profile. Analysis: 1 If the center distance is increase by 0.125 in., the pinion and gear will no longer mesh -- see the following diagram. 2. If the center distance is increased by 0.0125 in., the gears will mesh along their actual (not theoretical) pitch circles. O; 3125 t 03125, nl Pitch Addendum. circle circle 3. From the analysis of Problem (15.16) and the given data, center distance, c = 1.5781 + 0.0125 = 1.5906 in. 4. Np/Ng = dp/dg = 17/84. Hence, dg = 4.9412dp c= (dp + dg)/2 = 1.5906. Solving for dy and dp, dy = 2.64575 in., dp = 0.53545 in 5. dog = 2.4667 = dy cos $ = 2.64575 cos @. Solving for 6, 6 = 21.20°, Therefore, pressure angle, 6 = 21.20° . 15-176. Addendum circle radius of the gear, rag = 1. ‘Addendum circle radius of the pinion, Tap From Eq. (15.9); contact ratio, crue Met VE -e sino Po _¥0.296"- 0.249" + 1.34" 092 SOLUTION (15.18) Known: A pair of mating spur gears of known module, pressure angle and numbers of teeth is given. Find: (a) Sketch drawings showing geometric details. (b) Determine the lengths of path of contact, angles of approach and recess, and contact ratio. Schematic and Given Data: Dedendum circle Base circle Pitch circle ‘Addendum circle Pressure ang] Angle of approach, A. Angle of recess, R Addendum circle Pitch circle Base and dedendum circles virwally coincide in this case. Path of contact Gear axis Note: This drawing is not drawn to scale. 15-18Assumption: The spur gears mesh along their pitch circles. Analy From Eq, (15.4); dy = m Np = 8(30) = 240 mm dg = m Ng = 6(60) = 360 mm addendum mm dedendum 0mm 2. From Eq, (15.10); py = wre (240 cos(0.35)) 30 Pp = 23.6 mm contact ratio = length of line of action/p, from the drawing, CR = 38/23.6 = 1.610. a eo Increasing the contact ratio of the gear pair for the same numbers of teeth can be achieved by increasing the diametral pitch for the gears. 2. If the gears have a 6 mm module, then the contact ratio CR can be calculated as follows. From Eq. (15 4) dp 5m No = 6(30) = 180 mm dg = m Ng = 6(60) = 360 (180 cos(0.35)) 30 From Eq. (15.10); p= ae P Pp = 17.7 mm contact ratio = length of line of action/p, from the drawing, CR = 38/17.7 = 2.15. SOLUTION (15.19) Known: A pair of standard spur gears of known pressure angle, center distance and velocity ratio is given. Number of teeth on pinion is specified. Find: (a) Determine diametral, circular and base pitches. (b) Sketch drawings showing geometric details. () Determine if interference results from choice of standard tooth proportions. (@)_ Determine length of path of contact from drawing and compute contact ratio. 15-19Schematic and Given Data: Assumption: The spur gears mesh along their pitch circles. Anal 1 g(x) 83 in. ath of contact Tin, Gear axis Note: This drawing is not drawn to scale. Ly si c= 10=tp+rp and rp hence, rp = 2 in. and rg P = Ny/dp = 20/4 ; hence, P = 5 p= A/5 ~ 0.6280 in. Pp =P cos = 0.628 cos 20° = 0.590 in 1 ee 5 in. = 0.2 in Dedendum = 1.25(1/5) = raptmax) ~ 4.0 in., rag(max Hence, no interference. Path of contact ~ 1.0 in, Addendum 25 in. 3 in. 15-20cR= See ees = 1.0/.590 = 1.695 . Hence, CR = roughly 1.7 : SOLUTION (15.20) Known: A pair of standard spur gears of known pressure angle, center distance and velocity ratio is given. Number of teeth on pinion is specified. Find: Compute the contact ratio using equations in Section 15.3 and compare with graphical results of Problem 15.19. Schematic and Given Data: Base circle Pitch circle Dedendum Gear axis Note: This drawing is not drawn to scale. Assumption: The gears mesh along their pitch circles. Analysis: 1, From Eq, (15.11), nop = tp cos @ = 2.0 cos 20° = 1.879 in. Tpg = Tz cos 0 = 8 cos 20° = 7.517 in. 15-21From Eq. (15.8), Fap(max) = V1.879" + 10.0" sin’'20° = 3.90 in. / rag(max) = V7.517" + 10.0°sin'20° = 8.26 in. / (this agrees with graphical solution) 2. From Eq. (15.9), (with rap = 2.2 and rag = 8.2 from Problem 15.19) CR = 1.69 (which is more accurate than the graphical solution.) a Comment: The contact ratio can be increased by choosing a greater number of teeth on the gears and/or increasing the diametral pitch, SOLUTION (5.21) Known: A two stage spur gear speed reducer is given which uses a countershaft and identical gear pairs in each stage. Gear and shaft geometry is specified such that input and output shafts are collinear Find: (a) Determine the rotation speeds of countershaft and output shaft, pitch diameters and circular pitch of the pinion and gear (b) Determine the torques carried by each shaft assuming (i) 100% gear efficiency and (ii) 95% efficiency of each gear pair. (©) Determine the radial loads applied to bearings on countershaft. Schematic and Given Data: 45 teeth i 1 KW, 1200 rpm coupled ‘motor coupled aa to this shatt 45 teeth 15-22Assumptions: 2 oN aHpENE The gears mesh along their pitch circles. The shafts are all parallel Friction losses in the bearings can be neglected (given) All the gear radial and tangential load is transferred at the pitch point. Bending deflection of the countershaft is negligible. The location of the bearing loads can be idealized to points due to small bearing widths. The location of the tooth loads can be idealized to points due to small tooth face width. The gears are rigidly connected to their shafts. Analysis: 1 The pitch diameters: dp = 13 = 3 in, dg = 4 = 9 in. . The circular pitch: p = n/5 = 0.63 in. . 1pm of (b) = 1200 x 15/45 = 400 rpm 1pm of (c) = 400 x 15/45 = 133.3 rpm In case (i): From Eq, (1.2). 9549(1 KW) the torque in shaft (a) = “T36G pmq = 7-96 Nem . the torque in (b) = Th = 7.96 x $ = 23.88 Nem . the torque in shaft (c) = Te = 23.88 xBen 64. Nem . n case (ii): Th = (23.88)(0.95) = 22.69 Nem . = (22, 69300 95) = 64.65 Nem a tp = 1.5 in, = 38,1 mm, rp = 4.5 in. = 114.3 mm tangential force on the motor pinion = radial force on the motor pinion = 209 N * tan 25° = 97.5N. Forces on the countershaft pinion are 3 times as large i.e., = 627 N and PaO 8 G 15-23292.5.N For the horizontal plane: =Ma =0: 209025) + + 627(125) - BH(100) = hence, Bu = 836. SF = 0 : 836.0 - 627 + 209- AH=0 hence, Au = 418.0N For the vertical plane: SMa = 0: 97,5(25) -292.5(125) + By(100) = 0 hence, By = 341.25 N EF = 0 : 97.5 + 292.5 - 341.25 - Ay=0 hence, Ay = 48.75 N ‘The radial loads are: Ac = V418" + 48.75" = 420.83: Ar = 420 N : By = 1836" + 341.257 = 902.96: By = 903 N . Comments: 1. The effect of power losses in each stage (efficiency 95%) was to decrease the torque transmitted to the output while keeping the speeds ratios the same. Thus, each stage reduces the torque transmitted by a factor. The effect of considering friction losses in the bearings will also be to reduce the torque transmitted to the output shaft. Large bending deflections of the countershaft will render our calculation of force and moment equilibrium inaccurate due to changes in the force directions and moment arms. If the bearing widths or gear face widths were significant relative to the length of the countershaft, location of the forces and reactions as point loads would lead to inaccurate estimates of bearing loads The pinion of the countershaft has higher tooth loads than the gear of the countershaft leading to higher radial loads on the bearing closer to the pinion. 15-24SOLUTION (15.22) Known: A two stage spur gear speed reducer is given which uses a countershaft and identical gear pairs in each stage. Gear and shaft geometry is specified such that input and output shafts are collinear. Find: (a) ) (©) Determine the rotation speeds of countershaft and output shaft, pitch diameters and circular pitch of the pinion and gear. Determine the torques carried by each shaft assuming (i) 100% gear efficiency and (ii) 95% efficiency of each gear pair. Determine the radial loads applied to bearings on countershaft. Schematic and Given Data: 62 teeth P=5,9=25° 21 weeth LEW, 1200 rpm coupled ‘motor coupled tothis to this shaft shaft e2teetn 23 mm Assumptions: oyaenr The gears mesh along their pitch circles. The shafts are all parallel Friction losses in the bearings can be neglected (given). All the gear radial and tangential load is transferred at the pitch point. Bending deflection of the countershaft is negligible. The location of the bearing loads can be idealized to points due to small bearing widths The location of the tooth loads can be idealized to points due to smal] tooth face width The gears are rigidly connected to their shafts. 15-25Analysis: 1. The pitch diameters: dp = 21/5 = 4.2 in., dg = 62/5 = 12.4 in. The circular pitch: p = m/5 = 0.63 in. rpm of (b) = 1200 X 21/62 = 406.5 rpm rpm of (c) = 400 X 21/62 = 135.5 rpm 2. Incase (i): From Eq. (1.2), . 9549(1 kW) the torque in shaft (a) ol 7.96 N-m ry the torque in (b) = Ty = 7.96 X $2 = 23.5 Nm . the torque in shaft (c) = Te = 23.5 X $2 = 69.4 Nem . In case (ii): Th = (23.5)(0.95) = 22.325 Nm 1. Te = (22. 325820. 95) = 62.6 N-m . 3. p= 2.1 in, = 53.34 mum, rg = 6.2 in. = 157.5 mm tangential force on the motor 2.96 Nan — 149 N pinion = radial force 3 ‘te motor pinion = (149 N)tan 25° = 69.5 N 4. Forces on the countershaft pinion are 3 times as large; i.e., = 447 N and 208.5 N 2085N 5. For the horizontal plan SMa =O: 149(25) + 447(125) - By(100) = 0 hence, By = 596.0 N ZF =0: 596.0- 447+ 149- An=0 hence, Au = 298.0 N 6. For the vertical plane: YMa = 0: 69.5(25) - 208.5(125) + By(100) = 0 hence, By = 243.25 N 15-26IF =0: 69.5 + 208.5 - 243.25 - Ay = hence, Ay = 34.75 N 7. The radial loads are: Ar = 12982 + 34.75% = 300: Ar = 300 N . By = ¥596" + 243.25 = 643.73: Br = 644 N a Comments: T. The effect of power losses in each stage (efficiency 95%) was to decrease the torque transmitted to the output while keeping the speeds ratios the same. Thus, each stage reduces the torque transmitted by a factor. 2. The effect of considering friction losses in the bearings will also be to reduce the torque transmitted to the output shaft. 3. Large bending deflections of the countershaft will render our calculation of force and moment equilibrium inaccurate due to changes in the force directions and moment arms 4. If the bearing widths or gear face widths were significant relative to the length of the countershaft, location of the forces and reactions as point loads would lead to inaccurate estimates of bearing loads. 5. The pinion of the countershaft has higher tooth loads than the gear of the countershaft leading to higher radial loads on the bearing closer to the pinion. SOLUTION (15.23) Known: A two stage spur gear speed reducer of specified geometry is given Fin : Determine the radial loads applied to the countershaft bearings. Schematic and Given Data: \ coupes 201i caer mr tg 80 i 15-27Assumptions: y Friction losses in gears and bearings can be neglected (given), 3. The shafts are all parallel 4. All the gear radial and tangential load is transferred at the pitch point. 5. Bending deflection of the countershaft is negligible. 6. Gear face width and bearing widths are negligible relative to countershaft length. 7. The gears are rigidly connected to their shafts. Analysis: 35.5 tn 25°= 16.58 lb 20m( Fite) 1. Pitch diameter of input pinion = 2in. 2. For the horizontal plane: Ma=0: 20 Ib (2 in.) + 35.55 Ib (10 in.) - Bu(12 in.) = 0 hence, By = 32.96 Ib SUF = 0 : 20 Ib + 35.55 Ib - 32.96 Ib- An =0 hence, Ay = 22.59 Ib 3. For the vertical plane: Ma =0: 9.33 Ib (2 in.) - 16.58 Ib (10 in.) + By(12 in.) = 0 hence, By = 12.26 Ib SF=0 poco iene 12.26 Ib + Ay =0 hence, Ay = 5.01 Ib 4. The bearing radial loads are: The gears mesh along their pitch circles Arad = ¥22.59" + 5.01” = 23.14 Ib, hence, Arad = 23.14 Ib Brad = 732.967 + 12.26" = 35.17 Ib, hence, Brad = 35.17 Ib . 15-28Comments: 1. The effect of considering friction losses in the gears and bearings is to reduce the torque transmitted to the output shaft while keeping the speed ratios the same. A reduction in torque transmitted will result in lower gear tooth loads and hence lower radial loads on the countershaft bearings. 2. The pinion on the countershaft has higher tooth loads than the gear on the countershaft because the pinion has a smaller radius while transmitting the same torque. The higher tooth load on the pinion leads to a higher radial load on the bearing closer to the pinion. 3. The effect of choosing a smaller diametral pitch for the gears in the second reduction stage is to provide larger teeth to withstand the higher torques and tooth loads of the second stage. 4. If load sharing between teeth is considered, the transfer of gear tooth forces is not strictly at the pitch point and will lead to different radial forces in the bearings SOLUTION (15.24) Known: A two stage spur gear speed reducer of specified geometry is given. Fin Determine the radial loads applied to the countershaft bearings. Schematic and Given Data: To driven machine Coupled to 20 Ib-in. torque motor rotating at $00 1pm Assumptions: 1. The gears mesh along their pitch circles. 2. Friction losses in gears and bearings can be neglected (given). 3, The shafts are all parallel. 1509NOW All the gear radial and tangential load is transferred at the pitch point. Bending deflection of the countershaft is negligible. Gear face width and bearing widths are negligible relative to countershaft length The gears are rigidly connected to their shafis Analysis: 20 ibn, Tin. = 18.021 18.02 tm 25°=8.4 Ib 32.04 tan 25°= 14.94 Tb Pitch diameter of input pinion = For the horizontal plane: =Ma =0 18.02 Ib (2.0 in.) + 32.04 Ib (10 in.) - BH(12 in.) = 0 Hence, Bu = 29.7 Ib SF = 0 : 18.02 Ib + 32.04 Ib - 29.7 Ib - Ay = 0 Hence, Ax = 20.36 Ib For the ed plane: =Ma=0: ea om) eee iO 2) Hence, By = 11.0: XF=0: "Bip + 14.94 Ib 11.05 Ib + Av =0 Hence, Ay = 4.51 Ib ‘The bearing radial loads are: Arad = 720.36 + 4.51" = 20.85 Ib Brad = ¥29.7° + 11.05 = 31.69 Ib Comments: The effect of considering friction losses in the gears and bearings is to reduce the torque transmitted to the output shaft while keeping the speed ratios the same. A reduction in torque transmitted will result in lower gear tooth loads and hence lower radial loads on the countershaft bearings. 15-30 = 20/9 = 2.22 in.2. The pinion on the countershaft has higher tooth loads than the gear on the countershaft because the pinion has a smaller radius while transmitting the same torque. The higher tooth load on the pinion leads to a higher radial load on the bearing closer to the pinion. 3. The effect of choosing a smaller diametral pitch for the gears in the second reduction stage is to provide larger teeth to withstand the higher torques and tooth loads of the second stage 4. If load sharing between teeth is considered, the transfer of gear tooth forces is not strictly at the pitch point and will lead to different radial forces in the bearings. SOLUTION (15.25) Known: For a single stage speed reducer, gear geometry, overhang and the horsepower transmitted are specified Find: Estimate the forces on the pinion, gear and shafts Schematic and Given Data: Ny=18 1, = 1800 rpm 2in. =| ) Pitch circle, pinion Pitch circle, gear 15-31Assumptions: The gears are spur gears. ‘The gears mesh along their pitch circles. Friction losses in the gears and bearings can be neglected. The shafts are parallel Bending deflection of each shaft is negligible. The gears are rigidly connected to their shafts. The weight of the gear on its shaft can be neglected. nalysis: Pitch diameter of the input pinion, dp = N/p = 18/6 = 3 in. Pitch line velocity, V = ndn/12 = m(3)1800/12 = 1413.7 fumin. 2. From Eg. (15.14), the power transmitted, W = (FrV/33000) (33000) _ aT a 167M From Eq. (15.12), F, = Fy tan @ = (11.67) tan 20°. Hence, F; = 4.25 Ib. Therefore, the force on the pinion, F = VF? +F? Hence, F = V11.67" + 4.25" = 12.42 Ib. 3. From Newton's third law, the force on the gear tooth equals the force on the pinion tooth. Hp aauboERe F SOLUTION (15.26) Known: Three identical spur gears are used to transmit power from a motor to a machine through an idler with all three gears simply supported between identical bearings. Fin |: Determine the relative loadings on the six bearings. Schematic and Given Data: Driven machine 15-32Assumptions: 1. The gears mesh along their pitch circles. 2. Friction losses in the gears and bearings are negligible. 3. All the tooth loads are transferred at the pitch point. 4. The shafts are all parallel. Analysis: motor torque gear radius let this be equal to 2 (in arbitrary units) 2. For the motor shaft: 1. The tangential gear force = tang TA 2tano bearing radial loads are /1 + tan" for = 25°, load = 1.10 3. For the idler shaft: 2tang 15-33,bearing radial loads = 2.0 a 4. For the output shaft itis the same as the motor shaft 5. Conclusion: Idler shaft bearing loads are nearly double those applied to the other shafts. Comments: 1. The equal and opposite radial tooth loads on the idler cancel each other and hence do not contribute to the bearing loads for the idler in this case. However, if the radii of the input and output gears were not equal the radial tooth loads would be unequal and would then effect the bearing loads for the idler. 2. Friction losses in the gears and bearings reduce the torque transferred to the driven gears. A reduction in torque and consequently tooth loads would result in reduction in bearing loads 3. A reduced pressure angle of 20° for the gears would reduce the radial loads on the motor and machine shaft bearings to 1.06 units but retain each idler bearing load at 2.0 units. 15-34,SOLUTION (15.27) Known: Three spur gears transmit power from a motor shaft to a machine shaft ina given geometric arrangement. The middle gear acts as an idler and is supported by two bearings. Find: (a) Determine the radial load on idler shaft bearings for a given direction of motor shaft rotation. (b) Determine the radial load on the bearings for the motor shaft rotation opposite to a). (c) Give an explanation as to why answers to (a) and (b) are different. Schematic and Given Data: 1700 1pm motor 100 Ib-in, tocque Diametzal pitch, Pressure angle. 9 = 20° Assumptions: 1, The gears mesh along their pitch circles. 2. All the gear tooth loads are static and are transmitted at the pitch point. 3. Friction losses in the gears and bearings are negligible. 4. Shaft bending deflections can be neglected Analysis: (a) Pitch diameter of idler = x = 2 4.0 in. 15-35(b) (©) 100 Ib tan 20°= 36.4 Ib 100 Bb-in motor! 1.00 in. motor pinion radius 1001 364 Ib 100 1b 4136.47 + 136.47 = 192.9 Rp=96.1 Ib ra) R,= 289 Bearing radial loads: Ra = 289 Ib, Rp = 96.1 Ib Bearing loads are reduced by factor of 90/192.9 to give: Ra = 135 Ib, Rp = 45 Ib 36.4 Ib 1001 36.4 Ib 1001b 63.6" + 63.6" =90 Ib Reversing direction of rotation reversed tangential forces, causing tangential and radial components to subtract, rather than add. 15-36Comments: 1. This problem illustrates the use of gear trains for purposes other than strictly speed or torque changing. Idlers are frequently used to convey rotary motion short distances from driver to driven shafts or to drive multiple shafts. 2. The location of bearings for the idler shaft in this problem caused a large radial load on the bearing closer to the idler and a smaller radial load on the other bearing. Although location of bearings on either side of the idler could have equalized the radial loads, such an arrangement may or may not be allowed by space constraints or accessibility requirements in actual applications. 3. For cases in which the rotation of the shaft is reversed from that shown in the figure, the explanation in part (c) reveals that the arrangement of the gears can be changed, putting the driven gear to the left of the idler in the figure to obtain lower bearing loads SOLUTION (15.28) Known: Three identical spur gears are used to transmit power from a motor to a machine through an idler. Motor rpm is specified. Find: (a) Determine the gear most vulnerable to tooth bending fatigue failure. (b) Determine the values for V, P, p, Ky. J Schematic and Given Data: Driver Tdentcal gears cut with best commercial cuter Idler Driver Assumption: 1. The gears mesh along their pitch circles and transmit all the load at the pitch point, 2. Friction losses can be neglected and load sharing is absent. Analysis: (a) The gear most vulnerable to tooth bending fatigue failure is the idler because it is subjected to 2-way bending; others are bent only 1-way, thus: 15-37(b) Idler Input and output v="8) 1000 : V = 2094 fi/min 7 P= 80/8: P= 10 teetlvin . p=n/l0: p= 0314 in 7 +2094 y= O48 et Ky= 192 J=0.375 (Fig. 15.23b; no load sharing) Comments: 1, Larger diameters and higher rpm for gears produce larger values for Ky 2. A pressure angle of 20° instead of 25° would reduce the value of the geometry factor from 0.375 to 0.31. SOLUTION (15.29) Known: A pair of mating spur gears of specified geometry, material and manufacturing quality is given. The pinion is driven by an electric motor of specified rpm and the gear drives a blower. Design life is specified. Find: Determine the horsepower rating of the gear set for a safety factor of 1.5 and 99% reliability based only on bending fatigue. Schematic and Given Data: 1100 rpm Pinion: ip = 20 Material: Steel, heat treated to 350 Bhnn Standard full depth teeth Accurate mounting P=8 o=20° b=1 in. Gear: Design life: 5 yrs, 60 hr/wk, Ng=40 50 wkd operation ‘Top quality hobbing operation for ‘manofacturing 15-38Assumptions: The gears mesh along their pitch circles. All the gear tooth loads are transmitted at the pitch point. There is no loadsharing between the teeth. The electric motor and blower constitute uniform load driver and driven equipment. 5. Top quality hobbing operation for manufacturing corresponds to curve C in Fig 15.24 (to estimate velocity factor Ky). Rene Analy: 1. From Bq. (15.17): 6 = 57 Ky Ko Km Ky requires finding the Bich line velocity as, adn _ x(20/8)110 12 12 from Curve C of Fig. 15.24, V= 720 fpm Ky = 04720 = 54 50 from Fig. 15.23(a), J = 0.24 (for the pinion, as it is weaker - and with no load sharing) = 1.6 (from Table 15.2 - probably best judgement) 0 (from Table 15.1- uniform driving and driven torque) Therefore, F,(8) 5 = TOI (1-54)1.0)(1.6) = 82.1 Fr 2. From Eg. (15.18): Sn = Sn’ CLG Co ke kt kms = (250 X 350)(1)(1)(0.66)(0.814)(1)(1.4) = 65,812 psi where Sn’ = 250 (Bhn) = 250 X 350 psi for infinite life, since design life = 5 yr X (50 wk/yr) X (60 hr/wk) X (60 min/hr) X 1100 rpm =99 ‘ 108 > 108 cycles 1.0, 0 since P > 5 .66 from Fig. 8.13 0.814 from Table 15.3 ky = 1 and Kis = 1.4 since the pinion is not an idler 3. For SF = 1.5 : 82.1(.5 Fi) = 65,812 hence, F, = 534.4 Ib FAV _ (934.4)(720) _ 000 = 33,000__= 11.66 hp ‘Answer : approximately 11.7 hp . wComments: 1 Xv The bending stresses can be reduced for the specified rpm by decreasing P or increasing b. But these parameters as well as the factors Ky and J are closely interrelated. Decreasing P for the same number of teeth increases pitch diameter which leads to larger pitch line velocity and hence to larger values of Ky and 6. Decreasing P for the same pitch diameter decreases the number of teeth resulting in a smaller value of J and a larger value of 6. Increasing the value of b requires accurate mounting and manufacturing to utilize the entire face width and ultimately tends to increase the value of Km. Thus choice of suitable values for gear geometry parameters for specific applications requires balancing the parameter vaiues with other side effects. In this problem the design life of the gear pair did not enter into the solution except to determine whether the gears were to be rated for finite or infinite life. (15.30) Known: A pair of mating spur gears of specified geometry, material and manufacturing quality is given, The pinion is driven by an electric motor of specified rpm and the gear drives a blower. Design life is specified. Find: Determine the Bhn of gear so that gear and pinion teeth have the same factor of safety with respect to bending fatigue. Schematic and Given Data: 1100 rpm | Pinion Np=20 ‘Material: Steel, heat treated to 350 Bho| Standard full depth teeth Accurate mounting, Gear: Design life: 5 yrs, 60 he/wk, Ng=40 50 wk/yr operation Top quality hobbing operation for ‘manufacturing Assumptions: woReRE The gears mesh along their pitch circles. All the gear tooth loads are transmitted at the pitch point. There is no loadsharing between the teeth. The electric motor and blower constitute uniform load driver and driven equipment. Top quality hobbing operation for manufacturing corresponds to curve C in Fig 15.24 (to estimate velocity factor Kx) 15-40Analysis: 1. J for gear = 0.285 from Fig. 15.23a 2. From the analysis of Problem 15.29, gear tooth stress is only os times pinion stress 3. Since all parameters and factors are identical for the pinion and gear except Bhn and Cy, (gear Bhn) « C. could theoretically be (350 + 0.66)/.2:24 = 194.5. From Fig. 8.13 by trial and error: gear Bhn = 274 (and Cs = 0.71) 7 Comment: The gear material can have a lower strength than the pinion material because the stress concentrations at the root of the gear teeth are lower than at the root of the pinion teeth as a result of the gear having a larger diameter. SOLUTION (15.31) Known: A spur gear speed reducer is driven by an electric motor and drives a load involving "moderate shock". The gear teeth are standard full depth and of specified geometry and material. Required life is 10° pinion revolutions for a specified transmitted load Find: Determine an estimate of the reliability of the speed reducer with respect to bending fatigue failure Schematic and Given Data: 1500 rpm Pinion: 260 Bhn low-cost average quality cutting process Gear: 235 Bhn Assumptions: 1. The spur gears mesh at the pitch circles. 2. Load sharing is not expected since the cutting process is of average quality. 3. The effects corrected by the velocity factor, Kv, correspond to the middle of the range in Fig. 15.24 with manufacture by form cutters. 15-414. The pinion is driven by a uniform power motor while the gear drives a load involving "moderate shock" (given). 5. The tooth fillet radius is approximately equal to 0.35/P (to enable the use of Fig. 15,23 to estimate geometry factor J). Analysis: From Fig. 15.23(a), with no load sharing, J = 0.24. From Eq. (15.13a), (18)(1500) (200) = 706.8 fvmin From Fig. 15.24, with V = 706.8 fvmin, Ky = 2.0 From Table 15.1, Ko 25 2. From Eq. (15.17) applied to the pinion. c ue Ky Ko Km= i aaoay (2.0)(1.25)(1.8) G = 18,750 psi = 18.75 ksi 3. From Eq. (15.18) applied to the pinion: Sn = Sn’ CL Co Cs ke kt kms = (65)(1)(1)(0.72)ke(1)(1.4) = 65.52kr ksi since, Sy = 500(Bhn) = 500(260) psi = 130 ksi. Sn’ = Sy/2 = 65 ksi and for bending loads, Cy = 1.0, for P > 5, Cg = 1.0, from Fig. 8.13, Cs = 0.72 Therefore 18.75 = 65.52k, ; hence, k, = 0.29 4. Similarly for the gear, J = 0.27, Sp’ = 58.75 ksi, Cs = 0.75; hence, ky = 0.30 5. From Table 15.3, reliability is >> 99.999% a i omments: The reliability estimated in this problem is based on considering failure only by bending fatigue. A more accurate estimate of reliability must consider failure by surface fatigue also 2. Increasing the hardness of the gears will result in new choices in transmitting a higher load and higher rpm or choosing a smaller face width or a larger diametral pitch (Le, with finer teeth). 3. The choice of a harder material for the pinion gives approximately the same reliability for both the pinion and gear in this case. ‘Thus choice of a harder material for the pinion reflects consistency in the strength design of the gears. 15-42SOLUTION (15.32) Known: An identical pair of standard full depth spur gears of given geometry and material rotate at a given rpm. Find: Determine an estimate of the horsepower that can be transmitted with 99% reliability based on tooth bending fatigue. Schematic and Given Data: ‘Identical spur gears N=60 $= 20° P=12 b= L0in, Alloy stee! material, case hardness 680 Bhan, core hardness 500 Bhn. Tooth profiles finished and ground to requirement of curve A in Fig. 15.24, Overload factor, Ko = 1.1 Assumptions: 1. The gears are mounted on accurate mountings to mesh along their pitch circles. 2. Loading of the gears involves only mild shock (given). 3. High precision gears with fine ground tooth profiles allow the use of curve A in Fig. 15.24 to estimate velocity factor Ky (given), 4. Load sharing between teeth can be assumed to estimate geometry factor J (given). 5. The core hardness will be used to estimate the strength of the tooth with respect to bending fatigue (given). 6. The tooth fillet radius is approximately equal to 0.35/P (to enable use of Fig. 15.23 to estimate geometry factor J) 7. Neither of the spur gears act as idler gears in the described application. 8. The operating temperature for the gears is less than 160 °F. Analysis: 1. Pitch line velocity, a = 6545 fpm 2. Velocity factor, Ky= 4/ B+ 16545. 1.43 a 3. From Fig. 15.23(a), geometry factor, J = 0.451 4. From Table 15.2, the mounting factor, Km =1.3 and Ko = 1.1 (given) 15-435. From Eq. (15.17): F.(12) | (.0)0.451) 6. From Eq, (15.18): Sp = (125 ksi(1)(1)(.73)(.814)(1)(1.A) = 104 ksi o= (1.43)(1.1)(1.3) = 54.4 Fy 73 from Fig. 8.13, 814 from Table 15.3, and kms = 1.4 (for one-way bending). 7. Equating stress o and strength Sn, 54.4 Fi = 104,000 psi ; hence Fx = 1911.76 Ib Horsepower that can be transmitted, F,V_ _ 1911.76(6545 fpm) _ 33,000 33,000. = 3/9 hp 2 Ww Comments: 1. ‘The horsepower that can be transmitted was estimated here based only on tooth bending fatigue, a more accurate estimate of the horsepower rating must consider the possibility of failure by surface fatigue Use of the core hardness to estimate the bending strength resulted in a smaller horsepower rating. This is a conservative assumption since the highest bending stress occurs on the tooth surface which has a higher hardness. 3. Ifeither gear were acting as an idler the teeth would have been loaded in two way bending for that gear and the effective bending strength would have reduced by 40% resulting in a lower horsepower rating. nv 15-44SOLUTION (15.33) Known: Three identical standard full depth spur gears of given geometry and material rotate at a given rpm. Find: Determine an estimate of the horsepower that can be transmitted with 99% reliability based on tooth bending fatigue Schematic and Given Data: Identical spur gears: N=60 @ = 20° P=12 b =10in, Alloy steel material. case hardness 680 Bhn, ‘core hardness 500 Bhn. ‘Tooth profiles finished and ground to requirement of curve A in Fig. 15.24 Overload factor. Ko = 1.1 Assumptions: 1. The gears are mounted on accurate mountings to mesh along their pitch circles. 2. Loading of the gears involves only mild shock (given) 3. High precision gears with fine ground tooth profiles allow the use of curve A in Fig. 15.24 to estimate velocity factor Ky (given), 4. Load sharing between teeth can be assumed to estimate geometry factor J (given). 5 The core hardness will be used to estimate the strength of the tooth with respect to bending fatigue (given) 6. The tooth fillet radius is approximately equal to 0.35/P (to enable use of Fig. 15.23 to estimate geometry factor J). 7. One of the spur gears acts as an idler gear in the described application, 8. The operating temperature for the gears is less than 160 °F Analysi 1. Pitch line velocity, Rdn _ %(60/12)5000 12 12 2. Velocity factor, Ky =4/ 28 ae =143 3. From Fig. 15.23(a), geometry factor, J = 0.451 v = 6545 fpm 15-45From Table 15.2, the mounting factor, Km =1.3 and Ko = 1.1 (given) 5, From Eq, (15.17): = D1 43)(1.1)(1.3) = 54.4 F S= ToyO451) ¢ 3)(1.1)(1.3) = 54.4 Fy 6. The gear most vulnerable to tooth bending fatigue is the idler because it is subjected to 2-way bending; others are bent only 1-way, thus kins =1. From Eq. (15.18) Sn = (125 ksiy(1)(1)(-73)(814)(1)(0.0) = 74.3 ksi Since, 0.73 from Fig. 8.13, .814 from Table 15.3, and kms = 1 for the idler (two-way bending). 7. Equating stress o and strength Sq, 54.4 F, = 74,300 psi ; hence F; = 1365 Ib Horsepower that can be transmitted, F,V__ 1365(6545 fpm) __, W= 33.0007 33,000 = Comments: 1 The horsepower that can be transmitted was estimated here based only on idler tooth bending fatigue, a more accurate estimate of the horsepower rating must consider the possibility of failure of the idler gear tooth by surface fatigue 2. Use of the core hardness to estimate the bending strength resulted in a smaller horsepower rating. This is a conservative assumption since the highest bending stress occurs on the tooth surface which has a higher hardness. 3. The input and the output gears would be loaded only in one way bending and the effective bending strength for each of these gears would be 1.4 times larger resulting in a higher horsepower capacity for these two gears. 15-46SOLUTION (15.34) Known: For a pair of spur gears the pressure angle, modulus, number of teeth, and the speed of the pinion are given Find: Determine graphically the sliding velocity between the teeth (a) at the start of contact, (b) at the pitch point, and (c) at the end of contact. Schematic and Given Data: Base circle Gear | Pitch exrcle Vp NS Sliding Sliding | velocity velocity = = 760 mm/s = 560 mm Vip Pitch circle Base Circle Addendum circle ‘Note: This drawing is not drawn to scale Assumption: The spur gears mesh along their pitch circles. Analysis: 1. module, m = d/N Therefore, tp = 90 mm, rg = 180 mm 2. Addendum, a= m Therefore, tap = 96 mm, rag = 186 mm 15-47Case (a): Start of contact 3 Gear contact Figure (a) 4. From Fig. (a): tpq = 82 mm, req = tag = 186 mm Hence, Vpa = @ptpa = Aen) (82) = 1803 mnvs 105m) 60 Vea = @etes = (186) = 2045 mm/s 5. From Fig. (a), the sliding velocity is 760 mm/s. Case (b): Pitch point 6. Sliding velocity = 0 [See Fig. 15.26(b)] 15-48Case (c): End of contact 7 Gear End of contact Figure (c) 8. From Fig. (c): typ = 169 mm, tpp = rap = 96 mm. 210CM ye Fp (98) = 2111 mms Hence, Vpp = @ptpp Vep = @gt—p = “222 (169) = 1858 mms 9. From Fig. (c), the sliding velocity is 560 mm/s. . SOLUTION 15.35) Known: A pair of mating spur gears of specified geometry, material and manufacturing quality is given. The pinion is driven by an electric motor of specified rpm and the gear drives a blower. Design life is specified. Find: Determine the horsepower rating of the gear set for a safety factor of 1.5 and 99% reliability based on surface durability. 15-49Schematic and Given Data: 1100 rpm Pinion: Np=20 Material: Steel, heat treated to 350 Bhn| Standard full depth teeth ‘Accurate mounting P28 o= 20 b=lin Gea: Design life: 5 yrs, 60 hr/wk, Np=40 50 wk/yr operation ‘Top quality hobbing operation for ‘manufacturing Assumptions: 1 ae 3 4 The gears mesh along their pitch circles. The gear tooth loads are transmitted at the pitch point. Tooth contact surfaces are approximated by cylinders. Surface stresses are unaffected by lubricant and sliding friction. Analysis: 1 Xv From Eq. (15.24) ou=Cpal 5a 7 Ke Ko Kn hh] = Sin. cos@ _R__ sin 20° cos 20° wit ne ¥ and b = | in., Ky = 1.54, Ky = 1.0, Km = 1.6, dp = NP = (20/8) in, (from the analysis of Problem 15.25), From Eq. (15.25): Sir Ste = 0.4 (Bhn) - 10 ksi = (0.4)(350) - 10 = 130 ksi design life = 1100 cyl/min X 60 min/hr X 60 br/wk X 50 wk/yr X 5 yr = 9.9 x 108 cycles hence, Cyj = 0.8 Su= 1300 8)(1) = 104 ksi For SF = 1.5 104,000 = 6980.5V71.5 F, ; Fy = 148 Ib FV _ 148(720) 33,000 ~ 33,000 Therefore, the horsepower rating with respect to surface durability is approximately 3.2 hp. We = 3.23 hp 15-50Comment: The horsepower rating of the gear pair is much lower when analyzed with respect to surface durability than with respect to bending fatigue (Problem 15.29) With other choices of material and geometry the opposite result can also occur. This problem illustrates the need for considering both bending fatigue and surface durability in the design and analysis of gears. SOLUTION (15.36) Known: A pair of mating spur gears of specified geometry, material and manufacturing quality is given. The pinion is driven by an electric motor of specified rpm and the gear drives a blower. Design life is specified. Find: Determine the horsepower rating of the gear set for a safety factor of 1.5 and 99% reliability based on surface durability and bending fatigue. Schematic and Given Data: 1100 rpm Pinion: Np=20 Material: Steel, heat teated 0 350 Bhn for the gear, and heat treated to 400 Bhan forthe pinion Standard full depth teeth ‘Accurate mounting Gear: Ng=40 Design life: 5 yrs, 60 hr/wk, 50 wk/yr operation ‘Top quality hobbing operation for ‘manufacturing Assumptions: 1. The gears mesh along their pitch circles 2. The gear tooth loads are transmitted at the pitch point. 3. Tooth contact surfaces are approximated by cylinders 4. Surface stresses are unaffected by lubricant and sliding friction. Analysis: For surface durability: For the pinion: 1. From Eq, (15.24): OH = Cp 5 gry Kv Ko Kaw P = sin cos _R__ sin 20° cos 20°, _2_ with I= Sin cos? —R— $ 524 = 0.107 and b = 1 in., Ky = 1.54, Ko = 1.0, Km = 1.6, dp = Np/P = (20/8) in. (from the analysis of Problem 15.29), 15-51Therefore, on = 2300 2. From Eq. (15.25): Si = Sfe Ci Cr Ste = 0.4 (Bhn) - 10 ksi = (0.4)(400) - 10 = 150 ksi design life = 1100 cyl/min X 60 min/hr X 60 br/wk X 50 wk/yr X 5 yr =9.9 X 108 cycles 6980.54/F, hence; Cha= 08 SH = 150(0.8)(1) = 120 ksi 3. ForSF=15: 120,000 = 6980.5V1.5 Fy : Ft = 197 Ib FV _ 148(720) 33,000 ~ 33,000 We =43 hp For the gear: 4. From Eq, (15.24); oy =C, K.KoKn, ! dy = 40/8. Hence, 6 = 4936 Vy 5. From Eq. (15.25); Su = Ste Ci Cr Sfe = 0.4 (Bhn) - 10 ksi = 0.4(350) - 10 = 130 ksi. Hence, Sq = 130 (0.8)(1) = 104 ksi. 6. For SF = 1.5 104,000 = 4936 VI3F;; Fy = 295.95 Ib iy — FIV _ 295.95(720) _ 33,000 33,000 Itis evident that the gear is stronger than the pinion based on surface durability. ‘Therefore, the horsepower rating with respect to surface durability is approximately 4.3 hp. For bending fatigue For the pinion: F 1, From Eq. (15.17): 6 = 45 Ky Ko Km Ky requires finding the pitch line velocity as, Ry) from Curve C of Fig. 15.24, ky = 04072 «54 50 from Fig. 15.23(a), J = 0.24 (for the pinion - and with no load sharing) Also, Km = 1.6 (from Table 15.2 - probably best judgement) 15-52and Ko = 1.0 (from Table 15.1- uniform driving and driven torque) Therefore. _Fi(8) - TOO. 28) ( 2. From Eq. (15.18) Sn = Sn’ CLG Cs ke kt kms = (250 X 350)(1)(1)(0.66)(0.814)(1)(1.4) 812 psi (1.54)(1.0)(1.6) = 70.37 Fr where Sq’ = 250 (Bhn) = 250 X 350 psi for infinite life, since design life = 5 yr X (50 wk/yr) X (60 hr/wk) X (60 minvhr) X 1100 rpm = 9.9 X 108 > 10° cycles =1 1.0 since P > 5 0.66 from Fig. 8.13 ky = 0.814 from Table 15.3 and kms = 1.4 since the pinion is not an idler 1.5: 70.37(1.5F) = 65,812 = b For the gear: 4. From Eq. (15.17): 6 = FP bs Ky requires finding the pitch line velocity as. Ky Ko Km _ dn _ n(20/8)1100 ay 720 fom from Curve C of Fig. 15.24, Ky = 044720 = 120 1 54 from Fig. 15.23(a), J = 0.28 (for the gear - and with no load sharing) Also, Km = 1.6 (from Table 15.2 - probably best judgement) and Ko = 1.0 (from Table 15.1- uniform driving and driven torque) 7 9= THES A 54)(1.0)(1.6) = 82.1 Fr 5. From Eq. (15.18) S in’ CLC Cs kr kt Kms = (250 X 400)(1)(1)(0.66)(0.814)(1)(1.4) = 75,214 psi 15-53where Sn’ = 250 (Bhn) = 250 X 400 psi for infinite life, since design life = 5 yr X (50 wk/yr) X (60 hr/wk) (60 min/hr) X 1100 rpm 9.9 X 108 > 10° cycles 1.0, 1.0 since P > 5 66 from Fig. 8.13 k, = 0.814 from Table 15.3 ky = Land kms = 1.4 since the pinion is not an idler 6. For SF = 1.5 : 82.1(1.5 Fy) = 75,214 hence, Fr= 610.75 Ib «FeV (610.75)(720) _ W= 33,000 =" 33,000 > 13325 hp S It is evident that the gear is stronger than the pinion based on the surface durability. Therefore, the horsepower rating with respect to bending fatigue failure is approximately 13.325 hp Comments: 1. The horsepower rating with respect to surface durability is much less than with respect to bending fatigue. This homework problem illustrates the need to consider both bending fatigue and surface durability in the design and analysis of gears. It also shows the need for calculating the strengths of both the gear and the pinion for comparison when the hardness of the gear materials differ, unlike the case where the hardness of both the materials is the same, and we could carry out our design calculations for the smaller of the two gears, 2. The bending stresses can be reduced for the specified rpm by decreasing P or increasing b. But these parameters as well as the factors Ky and J are closely interrelated. Decreasing P for the same number of teeth increases pitch diameter which leads to larger pitch line velocity and hence to larger values of Ky and s. Decreasing P for the same pitch diameter decreases the number of teeth resulting in a smaller value of J and a larger value of s. Increasing the value of b requires accurate mounting and manufacturing to utilize the entire face width and ultimately tends to increase the value of Km. Thus choice of suitable values for gear geometry parameters for specific applications requires balancing the parameter values with other side effects. 3. Itis evident that the gear is stronger than the pinion based on surface durability. Therefore, the horsepower rating based on surface fatigue is 4.3 hp. 4. The horsepower rating of the gear pair is much lower when analyzed with respect to surface durability than with respect to bending fatigue (Problem 15.29). With other choices of material and geometry the opposite result can also occur. This problem illustrates the need for considering both bending fatigue and surface durability in the design and analysis of gears. 15-54SOLUTION (15.37) Known: A pair of mating spur gears of specified geometry, material and manufacturing quality is given. The pinion is driven by an electric motor of specified rpm and the gear drives a blower. Design life is specified. Find: (a) Determine the horsepower rating of the gear set for a safety factor of 1.5 and 99% reliability based on surface durability. (b) Estimate the value to which the gear hardness can be reduced without making the gear teeth weaker than the pinion teeth based on surface fatigue. Schematic and Given Data: 1100 rpm Pinion: Np=20 Material: Steel, beat ueated to 350 Bhn for the gear, and heat treated to 400 Bhn for the pinion. Standard full depth teeth ‘Accurate mounting Gear: Ng=40 Design life: 5 yrs, 60 hi/wk, 50 wk/yr operation ‘Top quality hobbing operation for ‘manufacturing Assumptions: 1. The gears mesh along their pitch circles. 2. The gear tooth loads are transmitted at the pitch point 3. Tooth contact surfaces are approximated by cylinders 4. Surface stresses are unaffected by lubricant and sliding friction. Analysi 1. Eorthe pinion: From Eq. (15.24): oa = Cp with I and b = | in., Ky = 1.54, Ko = 1.0, Km = 1.6, dp = Np/P = (20/8) in. (from the analysis of Problem 15.29), cereeeev From Eq, (15.25): Sti = Ste Ci Cr Ste = 0.4 (Bhn) - 10 ksi = (0.4)(350) - 10 = 130 ksi design life = 1100 cyl/min X 60 min/hr X 60 hr/wk X 50 wk/yr X 5 yr = 9.9 X 108 cycles hence, Cri = 0.8 Sy = 130(0.8)(1) = 104 ksi 3. For SF = 1.5 104,000 = 6980.5VI-5F; ; Fr = 148 Ib F,V__ 148(720) 33,000 ~ 33,000 Therefore, the horsepower rating with respect to surface durability is approximately 3.2 hp. = 3.23 hp 4. For the gear: From Eg, (15.24); 6a = = Singcos® RR See 2. Is 2 R+I Deol b= 1 in., Ky = 1.54, Ko = 1.0, Km = 1.6, No/P = 40/8 in. (from the analysis of Problem 15.29). Therefore, (148 54.6) - = ABCD). = 6004 Gu = 2300-4) Tocgeray(O. TOT)” 00049 Psi = 60 ksi 5. From Eq, (15.25); Su = Ste Cui CR Ste = 0.4 (Bhn) - 10 ksi Su = (0.4 (Bhn) - 10 ksi) (0.8) (1) = 0.32 (Bhn) - 8 = 60 ksi. Solving for Bhn, Bhn = 187.65. . Comment: The gear hardness can be reduced to 187.65 Bhn without making the gear teeth weaker than the pinion teeth based on surface fatigue. 15-56SOLUTION (15.38) Known: A spur gear speed reducer is driven by an electric motor and drives a load involving “moderate shock”. The gear teeth are standard full depth and of given geometry and material. Required life is 10° pinion revolutions for a specified transmitted load. Find: Determine an estimate of the reliability of the speed reducer with respect to surface durability Schematic and Given Data: Pinion: 260 Bhn Gear: 235 Bhn ‘Tooth cut with Jow-cost average quality cutting process Assumptions: 1. The gears mesh at the pitch circles. 2. Load sharing is not expected since the cutting process is of average quality. 3. The effects corrected by the velocity factor, Ky, correspond to the middle of the range in Fig. 15.24 with manufacture by form cutters. 4. The pinion is driven by a uniform power motor while the gear drives a load involving "moderate shock" (given). 5. The surfaces at the contact region of the teeth can be approximated by cylinders 6. The surface stress distribution is unaffected by the presence of the lubricant. 7. Surface loads due to sliding in the tooth contact region are negligible Analysis: 1. The pitch diameters of the gears are, dg = Ng/P = 36/10 = 3.6 in. dp = NpP = 18/10 = 1.8 in. 2. Ratio of pitch diameters, R = 2, 3. Pitch line velocity, nN, din. ENp Pp _7(18)(1500) _ 796 8 fumin 125 apes 1210) 15-57from Fig. 15.24, with V = 706.8 ft/min, Ky = 2.0 from Table 15.1, Ko = 1.25 20.107 4. From Eq. (15.23): 1 = S02! a 5. From Eq. (15.24): jeer 0 Ratmtee = 2300) (LOVG.8}OTOT) = 111,174 psi = 111.2 ksi 6. From Table 15.5, an estimate of surface fatigue strength, (2.0)(1.25)(1.8) (BI f BI sie = 0.4 Bia of gear + Bhn of pinion) 9 and from Fig. 15.27, ch 1.12 7. Therefore, from Eq. (15.25): Su = Ste Cui CR =[0.4[235+ 260) _ 101.12) Cr = 99.68 Cr Equating stress and strength 111.2 = 99.68CR ; hence Cr = 1.11 8. Interpolating the rough data from page 489 of the text Ce Reliability 1.25 50% 1.00 99% 0.80 99.9% A rough approximation of the reliability for Cr = 1.11 is reliability ~ 80% . Comments: 1. The estimate of reliability from the value of Cp is very approximate. As the textbook suggests, data on reliability factors for surface durability are scarce 2. In comparing the reliability obtained in Problem 15.31 for bending fatigue for the same speed reducer, we find that the estimate of reliability of the gears is much lower for surface fatigue. This indicates that the speed reducer is more likely to fail due to surface damage than bending fatigue 3. The change in contact pressure distribution due to the presence of a lubricant and sliding loads on the tooth are not explicitly considered in the Hertz equation used for calculating maximum stress in the contact region. These considerations are by implication absorbed in the surface strength data obtained from experiments. It is thus important to judge if the lubrication and sliding effects in the application are similar to those in experiments from which this data is obtained SOLUTION (15.39) Known: An identical pair of standard full depth spur gears of given geometry and material rotate at a given rpm. 15-58Find: Determine an estimate of the horsepower that can be transmitted for 10° cycles with 90% reliability based on surface fatigue Schematic and Given Data: Identical spur gears N=60 9 =20° Pai2 =10in Alloy steel material, case hardness 680 Bin, core hardness 500 Bhan ‘Tooth profiles finished and ground to requirement of curve A in Fig. 15.24. Overload factor, Ko = 1.1 Assumptions: ‘The spur gears mesh at the pitch circles using accurate mountings. Loading on the gears involves only mild shock (given). High precision gears with fine ground tooth profiles allow the use of curve A in Fig, 15.24 to estimate velocity factor Kv (given). Load sharing between teeth is expected in these high precision gears but the full transmitted load will be applied to a tooth to make a conservative estimate of horsepower. The surfaces at the contact region is approximated by cylinders. The surface stress distribution is unaffected by the presence of lubricant. Surface loads due to sliding in the tooth contact region are negligible. ‘The operating temperature for the gears is below 160 °F wee B wo sAn Analysis: 1. Pitch line velocity, 1(60/12)5000 12 = 2 2. Velocity factor, Ky = 4/ zi 3. Pitch diameters are, d = ¥ = so = Sin. Ratio of pitch diameters, R = | 4. From Table 15.2, the mounting factor, Km = 1.3 and Ko = 1.1 (given) = 6545 fpm 15-595. From Eq, (15.23): the geometry factor, =sin20" cos 20°/_1_\_ ye 47 + 7) = 9.080 6. From Eg. (15.24): the surface stress, on= 23000 Toso 1 49-DE) 2004, 7. From Table 15.6: Cr = 1.06 for 90% reliability From Fig. 15.27, Cui = 0.8 8. From Eq. (15.25) and Table 15.5: Sx = |0.4(680) - 10|(0.8)(1.06) Equating stress and strength 5200¥F 9. Horsepower that can be transmitted, FV 1826.3 1b(6545 fpm) _ 350007 33,000 = 362-2 hp / 222 ksi 22,222 psi : F, = 1826.3 Ib W Comments: 1. Comparing the horsepower rating of the drive unit with respect to bending fatigue estimated in Problem 15.32. it is evident that the horsepower rating determined by consideration of surface fatigue is more critical. While the horsepower rating is 379 hp with a 99% reliability with respect to bending fatigue failure, the horsepower rating is only 362 hp with a 90% reliability with respect to surface fatigue failure, However, the process of failure and its consequence are substantially different in bending fatigue and surface fatigue. Bending fatigue failure is sudden and drastic while surface fatigue failure is gradual and provides easily observable indications of failure. If the surface of the teeth were not made harder than the core, the durability of the teeth with respect (0 surface fatigue would be further reduced and the horsepower v = surface hardness} rating would drop by a factor of approximately 1.36 | = “Com harness | £0 about 266 hp. 3. The horsepower rating is unaffected whether the gears act as idlers or not as far as surface fatigue failure is concerned. This is in contrast to the case of bending fatigue where the strength is less by a factor of 1.4 for idler gears due to two way tooth bending. 4. If the solution of SAMPLE PROBLEM 5.5 is followed rather than the solution of SAMPLE PROBLEM 5.4, Figure 9.21 gives Sq = 120,000 psi, and a smaller transmitted horsepower rating is calculated (estimated) SOLUTION (15.40) Known: A two stage gear speed reducer is given which uses a countershaft and has identical gear pairs in each stage. Gear and shaft geometry is specified such that the input and output shafts are collinear. Find: Determine the relative strengths of the gears for serving in the high-speed and low-speed positions considering both bending fatigue and surface durability with 107 cycles life for the high speed gear 15-60Schematic and Given Data: 45 wet P=5,6=25° 15 teeth A machine KW, 1200 rpm. coupled ‘motor coupled toihis tw this shaft shaft 45 teeth Assumptions: The high-speed and low-speed gears are mounted to mesh identically. Load sharing need not be considered. The high speed and low speed gears operate at the same temperature. The countershaft can be considered to be rigid so that both gears have the same overload conditions determining the value of the overload factor, Ko. 5. The friction in the gears and bearings can be neglected REN Analy 1. Pitch line velocity of gear in high speed position is, 7d, Ny _ 7(15)(1200) igh = oats = = 7(15)(1200) _ 949.4 Voigh=T3 =a2> 12P 126) a Pitch line velocity of gear in low speed position is, ran, Ny, _7(45)(1200/9) ae ae Me _ ™(45)(1200/9) _ tow = SE oa} 314.1 fvmin Ratio of tangential tooth loads in low-speed and high-speed positions for the Fe tow i gears is, Fee» = Vash - 3 Funigh Viow For bending fatigue, using Eq. (15.17) R Stn _ [Fuse [Koto Gua” [Fewn|“(Reaa) 15-61= 2.8 with Ky from curve A in Fig. 15.24. . = 2.12 with Ky from curve D in Fig. 15.24. : 3. Eq. (15.18) for Sp is the same for both applications Thus for bending fatigue, the low speed application is more severe by factor of 2.12 to 2.8 depending on the manufacturing accuracy . 4. For surface fatigue, using Eq. (15.24): Sit ow 5 ~aes*? _ ¥2.8 = 1.67 with Ky from curve A and . Suthisp 2.12 = 1.46 with Ky from curve D 7 Stitowsp _ Cistow _ 1.03 Sutisp Cuitign 1.0 because the low speed gears accumulate fatigue cycles only a third as rapidly at the high speed gears and the high speed gear must have a life of 107 cycles 6. Thus, for surface fatigue, the low speed application is more severe by a 5. From Eq. (15.25): 1.03 : factor of about ' ca =142to 467 1.62, depending on manufacturing accuracy. . Comments: 1. Unlike the surface fatigue strength, the bending strength is unaffected by the fact that the low-speed gear accumulates fatigue cycles only a third as rapidly as the high-speed gear. This is because, while the endurance limit for bending stress is reached at 10® cycles the surface strength continues to decrease well past 107 cycles. 2. Since the surface fatigue stress is proportional to the root of the velocity factor, Ky, the relative severity of service for the low-speed gear is not as high as in the case of bending fatigue. 3. If friction forces in the gears and bearings were taken into consideration, the tangential tooth loads for the low-speed and high-speed gears would not be precisely in the inverse ratio of their speeds. SOLUTION (is.41D) Known: A two stage spur gear speed reducer is given which uses a countershaft and has identical gear pairs in each stage. Gear and shaft geometry is specified such that the input and output shafts are collinear. Shafts and mountings correspond to good industrial practice but not "high precision” Find: Determine a design of the gears for 10 cycles with 99% reliability and safety factor of 1.2. 15-62Schematic and Given Data: 10 Hp Motor Load 2700 rpm x 300 mpm (Lien shock) (Mod, shock) Decisions: 1. Choose steel for gear material with pinion material 10% harder than the gear material. 2. Choose standard full depth teeth with pressure angle, = 20° 3. Select number of teeth for pinion, Np = 20. 4. Choose manufacturing precision between curves C and D in Fig. 15.24 to estimate velocity factor, Ky. 12 P 6. The surface hardness and core hardness for the teeth are equal. The tooth fillet radius is 0.35/P (to enable use of Fig. 15.23(a) to estimate J). 5. Choose face width for gears as b Assumptions: The gears are mounted at their theoretical center distance. Friction losses in gears and bearings can be neglected. No load sharing is expected and all tooth loads are transmitted at the pitch point. ‘The operating temperature for the gears is below 160 °F. Surface stress can be estimated by approximating tooth contact region by cylinders: Surface stress distribution is unaffected by lubricant. Surface stress due to sliding friction is negligible. OUD a2 Design Analysis: 1. With a center distance of 8 in., the 9:1 reduction requires 3:1 reduction by each gear set. Hence, dp = 4 in., dg = 12 in 2. With 20 pinion teeth, P = 20 .P=5 . 3. With b= 12, b= 2.4 in . 4. Pitch line velocities are, V = (4/12) * 2700 = 2827 fpm (high speed set) and similarly V = 942 fpm (low speed set) 5. With manufacturing precision between curves C and D, from Fig. 15.24, Ky = 1.7 (low speed) and 2.7 (high speed) . 15-63Since F; + Ky is the greatest on the low speed set, we design the gears for this application FV. F, (942) 33,000 * 10= 33,990 + Fr = 350 Ib, with a safety factor of 1.2, Fy = 350(1.20) = 420 Ib Having chosen steel gears with 6 = 20°, we find hardness needed for surface fatigue criterion: from Eq. (15.24): (L.7)C.5)(.6) on = 23004) 5a teO Mao = 88,707 psi where, from Eq. (15.23), 1 = sin 20° cos 20° 5 since, from Table 15.4a, Cp = 2300 psi, from Table 15.1, Ko = 1.5, from Table 15.2, Km = 1.6 and Ky = 1.7 Equating stress and strength, 88.7 ksi = SH = Ste CLi CR 88.7 = (0.4 Bn - 10)(1)(1) : hence, Bhn = 247 specify gear hardness as 250 Bhn, pinion hardness as 275 Bhn To verify that the above solution is adequate for bending fatigue: from Eq. (15.17) 420(5) _ 6 = 400.24) (1-7)01.5)C1.6) = 14,875 psi where, from Fig. 15.23(a), J = 0.24, and Ky = 1.7, Ko = 1.5, Km = 1.6. from Eq, (15.18): Sn 23 (1)(0.85)(0.71)(.814)(1.4) = 47.283 ksi = 47,283 psi where, Sn’ = }(Bhn) ksi coetitcn 0.85, Cs = 0.71 _ = 137.5 ksi, kr = 0.814 from Table 15.3, 1.4 from Eq. (15.19) hence the gears are more than adequate to resist bending fatigue. Design results: 60. standard full depth teeth. 10°, steel gears, pinion hardness 275 Bhn, gear hardness 250 dp = 4 in., dy = 12 in, 15-64Tooth fillet radius = 9:35. = 0,07 in Manufacturing precision between curves C and D in Fig. 15.24, Shafts and mountings of ordinary good engineering practice. . te Comments: 1. Specifying a higher surface hardness and a lower core hardness for the gear teeth would have resulted in a more balanced factor of safety for bending fatigue and surface fatigue. 2. _ By specifying a material of 250 Bhn using design calculations which required a hardness of 247 Bhn for the pinion, separate design calculations for the gear were avoided. Since the pinion is always more severely stressed than the corresponding gear. By selecting pinion material 10% harder than the gear an additional factor of safety is provided. 3. If alarger number of teeth for the pinion were selected, the diametral pitch would have been larger and a proportionately smaller face width could be selected. These decisions would result in a higher value of bending stress as well as a higher value of surface stress thus requiring harder gear material specifications SOLUTION (15.42D) Known: A pair of standard spur gears are to transmit a specified hp from an electric motor to a machine with minimum size and weight. Case hardened alloy steel gears of specified Bhn are to be used. Find: Determine a design of the spur gears for 10” pinion revolutions at full load and 99% reliability and a factor of safety of 1.2. Schematic and Given Data: Decisions: 1. Select curve A in Fig. 15.24 for high precision manufacturing accuracy with shaved and ground teeth. Select standard full depth teeth with pressure angle, = 20°, Choose number of teeth on pinion, Np = 18. Choose face width, b = 14/P. Choose velocity factor, Ky = 1.4, Km = 1.3 (to be verified later) Core hardness of the teeth will be specified from bending fatigue considerations. Choose tooth fillet radius as 0.35/P (to enable use of Fig. 15.22(a) to estimate J) BAUER 15-65No significant shock load is present and thus the overload factor, Ko 2. The operating temperature of the gear set is less than 160 °F. 3. The gears are mounted at the theoretical center distance. 4. Load sharing between the teeth can be expected since the gears are of high 5 precision Surface stress can be estimated by approximating tooth contact region by cylinders. 6. Surface stresses are unaffected by sliding friction and presence of lubricant. Design Analysis: : y (M 5200| 1. With Np = =N{we)= | $200) = ith Np = 18, Ng None) 3 300 72 2. Pitch line velocity, 18 24504, Fp (6520012 = “5 fi‘min V = ndp(5200)/12 = 3. Tangential tooth load, Fy = (60 BPG3.000) (1 9) = 96.96P = at "design overload” 4. We solve for P with on = Su at design overload conditions: Cf ERK, Ke Km = Ste Ci PV Daet Ke Ke Km = Ste Cui CR with I = (sin 20° cos 20°/2)(4/5) = 0.128 from Eq. (15.23) Ky = 1.4, Km =1.3 (must be checked later) Ko=1, sie = 04500 660) 10 = 242 ksi Cui = 1, Cr = 1, Cp = 2300, b = 96.96P yaya) Therefore, 23004) campycrepy. 128) (4V)0.3) = 242,000 from which P = 12.6. We choose P=12. (note: choosing P = 14 would require b > 14/P) 5. Then, V = 24994 = 2042 fpm for which Ky = 1.25 (therefore, decision of Ky = 1.4 is conservative) 6. To solve for b: 96.9612) 23004) Sgariayco Tey (011.3) = 242,000 b= 0.996 in. specify b = 1 in (note: Km = 1.3 is satisfactory, and b = 42 which is satisfactory) 15-667. To check contact ratio: = 0.75 in. and similarly rg = 3.0 in. adding addendum = 4: rap = 0.833 in., P Tag = 3.083 in, from Eq. (15.11): typ = 0.75 cos 20° = 0.7048 in Tog = 3.0 cos 20° = 2.8190 in. from Eq. (15.11): poe 5 os 20° = 0.2460 in. center distance, ¢ = tp + Tg = 3.75 in . from Eq. (15.9): = WOB3S"— 0704" + V3.08F2- 28190" - 3.75 sin 20° _ a 0.2460 as CR = 1.66 is satisfactory 8. To check core hardness for bending fatigue from Eq. (15.17) (96.96 x 12)(12) 4. ae ; Tas (1-25)(1.0)(1.3) = 6731.3 psi where from Fig. 15.23(a), J = 0.34. Equating this value to Sn in Eq. (15.18), 66731 = of (DOORN) 5 CG = 1, Cy = 1, kr = 0.814, ky = 1, and kms = 1.4 o= Sn’ = 58, rey psi This requires Sy = 117 ksi, or approximately 235 Bhn. We specify core hardness > 235 Bhn 9. Design results: Case hardened alloy steel gear and pinion. Pinion: surface hardness is 660 Bhn Gear: surface hardness is 600 Bhn Core hardness for gears is at least 235 Bhn. Np= 18, Np=72, 0 = 20°FD. P=12,b=1in, c= 3.75 in, dp = 1.5 in,, dg = 6.0 in. Tooth fillet radius = 0.35/P = 0.03 in Manufacturing accuracy is high precision with shaved and ground teeth. Comment: Choice of a lower surface hardness for the pinion and gear would have resulted in a lower surface strength and consequently a lower value of diametral pitch. A smaller diametral pitch implies thicker teeth and a smaller contact ratio leading to less quieter and less smoother operation. A smaller diametral pitch also implies larger pitch diameters for the same numbers of teeth requiring a larger center distance. 15-67SOLUTION (15.43) Known: A simple planetary gear train is used as an automotive overdrive unit, Speed ratio when the overdrive is engaged is specified and number of teeth on the planet is given Find: (a) Determine the number of teeth on the sun and ring. (b) Determine whether four equally spaced planets can be used. (c) Determine whether three equally spaced planets can be used. Schematic and Given Data: Planet, 20 teeth Ring, output ‘Arm, input Sun, fixed Overdrive engaged: speed ratio= 1.43, Overdrive disengaged: sun, arm, ring rotate as one unit speed ratio is 1:1 Assumptions: 1. The gears are mounted to mesh at the pitch circles. 2. The planets are equally spaced (given). Analysis: 1. From Eq, (g): 143=1 +8 where R=$ + 2P=S +40 Therefore, 0.43 = F-Sz5 , or S = 30.175, or $ = 30 teeth . R = 70 teeth (exact ratio = 1 + es = 1.4286) 7 15-682. For four planets: ~ 20 tooth planet (top position) engages with ring tooth and with sun tooth in position shown. - Bottom position requires planet engagement with ring tooth and sun tooth; Side position requires engagement with ring space and sun space. ‘This works with 20 tooth (even number) planets. Use of four equally spaced planets is workable . 3. For three planets: 15-69An even-numbered planet (as 207) will not fit the 120° position shown. Three equally spaced planets is not workable. . Comment: It is evident from this problem that if equally spaced planets are chosen from manufacturing and maintenance considerations, the speed ratios available are limited by geometric constraints. SOLUTION (15.44) Known: There is a need for a planetary gear train providing a speed ratio of 2.0. Find: Determine an explanation of why it is theoretically impossible to provide a speed ratio of 2 with a planetary gear train. Schematic and Given Data: Planet Am Sun Ring Assumptions: 1. The gears mesh at their pitch circles. 2. Atleast one among ring, arm and sun is fixed with the other gears acting as input or output, 3. The speed ratio required is exactly 2 Analysi 1, With the sun fixed: wr/@a = 1 + $ which can only equal 2 if S = R, and this requires planets of zero size. 2. With the ring fixed: a vector diagram like Fig. 15.32 shows that again, a ratio of 2 requires planets of zero size. 3. With the arm fixed: (not a true planetary train, as all gear axes are fixed.) A vector diagram like Fig, 15.32 shows that the ratio is negative, and numerically equal to 2 only if planets have zero size. Comment: This problem provides an important lesson in design problem solving: it is sometimes revealing to analyze a configuration of design using a symbolic model to establish the limits of its performance rather than iteratively choosing values of parameters to satisfy design requirements or estimate sensitivity. 15-70SOLUTION (15.45) Known: A planetary gear train for a bicycle is capable of three operating states (annulus (ring) is connected to input, sun is fixed and arm is connected to output (low gear). (ii) direct engagement between input and output. (ii) arm is connected to input, sun is fixed and annulus is connected to output (high gear) There are four planet gears of specified pitch diameters and numbers of teeth. Find: (a) Determine the number of teeth on the annulus and the diametral pitch of the gears. (b) Determine the ratio of wheel rpm to sprocket rpm for each operating state using two of the three methods given in text. () Determine an explanation of operation when the bicycle coasts in each operating state Schematic and Given Data: Low (L) Neutral (N) [High @ 15-71Hub@ can “over-run! inthis direction Membe@) Pashes ove. Disco ) Assumption: The gears mesh along their pitch circles. Analysis: 1 v Annulus dia. = sun dia. + 2(planet dia.) Since all the gears must have the same P. teeth on annulus = teeth on sun + 2(teeth on planet) 5 + 2(25) = 75 teeth 25 7g = 40 Free Body Diagram Method for Low Gear: annulus = input, carrier = output let T = input torque 7/150 730 130 ™s as Ve Oat” BE | —~— - {+ 6—F isd ’ | tise © ans 7150 130 caries torque = 455 = hence, output speed = 3/4 of input speed 15-723. Velocity Vector Method for Low Gear: 2 ¥ output (carrier) @ = 25 2Vv input (annulus) w= 325 eae so On =35 Loy a From Eg. (15.30): S$ _ OR Oy 25 R@s-@, 75 O- al -4 OR - OA= 3 OA hence, wr (in) = BOA (out) . or ox 3 Mou 2 3 . Win 4 4. neutral gear : cs = 1.0, and high gear: 2 qa 43 . While Sa since the drive is always through a L-way clutch. the sprocket stops and the wheel continues to rotate. The I-way clutch over-runs, causing a clicking noise: low gear: pawls 9 is over-run neutral gear: pawls 3 and 9 are both over-run 7 high gear: pawls 3 and 9 are both over-run 7 Comments: 1. The application described in this problem demonstrates the compactness with which a speed-torque changing transmission can be implemented using planetary gear trains. A significant advantage of using planetary gear trains over ordinary spur gear trains in this application is the retention of circular symmetry of the transmission unit 2. For applications in which more speed ratios are required it is possible to arrange sets of planetary gear trains in serial and parallel arrangements. 15-73SOLUTION (15.46) Known: A planetary gear train operates with the ring fixed, the sun driven at a given speed and torque and the arm driving a machine. Gears are of a specified module and pressure angle. There are two planets with a specified number of teeth Find: Determine: (a) (b) (c) Co) (e) (fp) (g) the circular pitch, p of the gears the free-body diagram of each member in equilibrium the output torque the rpm and direction of rotation of the arm the pitch line velocity of each gear the nominal radial loads on bearings supporting each gear. the torque to be applied to the ring to keep it fixed. Schematic and Given Data: Ring fixed Number of teeth = 70 Sun, input Torque = 16 Nm Planets Number of teeth = 20 Arm, output m= 2.0 (mam/tooth) Pressure angle = 20° Assumptions: 1. All gears mesh along their pitch circles 2. Friction losses in gears and bearings are negligible. 3. All the tooth loads are transferred at the pitch point. 4. Centripetal forces will not be considered in this analysis (ie., the gears are considered massless). Analysis: (a) From Eq. (15.6): p = mm : p= 2.0n mm (b) Since pitch diameter, d = Nm, planet diameter = 20(2) = 40 mm ring diameter = 70(2) = 140 mm sun diameter = R - 2P = 60 mm 15-74,(©) Tow = Ta = 53 1/3 Nm (@) 4 = @a(TyTa ) = 800 rpm (16/53.33) (a = 240 rpm clockwise (e) With respect to the arm, the sun rotates 560 rpm. V = mdn = 7(0.06)(560/60) = 1.76 m/s () The bearings supporting each planet carry a total radial load of 533 1/3 N. Bearings supporting the other members carry zero nominal load. (8) Torake = Tr = 37 1/3 Nm Comments: 1. Choice of a higher module for the gears would have resulted in larger diameter gears and correspondingly smaller tooth loads and smaller radial bearing loads for the planets (other parameter values remaining the same). 2. If friction forces in the gears and bearings were included then the output torque. the braking torque as well as the planet radial bearing loads would be lower. 3. Consideration of masses and centripetal forces would tend to reduce the radial tooth loads between the planets and the sun and increase the radial tooth loads between the planets and the ring. Further, there will be an additional radial load on the planet bearings. However, the input, output and ring braking torque would remain unaffected. SOLUTION (15.47) Known: A planetary gear train with double planets, two suns and no ring gear is given, Numbers of teeth on the planets and one of the suns are specified. One sun is the input member, the other sun is fixed and the arm is the output member. Find: Determine the input-output speed ratio. 15-75Schematic and Given Data: PI (40 teeth}-——__ P2 (32 teeth). 2 ia Output !n9—— J — SI (30 teeth) s2- =A P2 PL Assumption: The gears mesh along their pitch circles. Analysis: 1. Free body analysis method For a unit clockwise torque applied to S1, forces on the planet-pair are as follows. (Let $1, Pl, etc, represent relative radii of the members): Summing moments to zero =0:F= 2 (PL Mo =0:F2= ¢- (BH Summing forces to zero Ble ge El) SF = 0: hence, Fo = 3] i pu) ‘Therefore, arm torque = Fo (arm radius) 1 4 _2y =yll PIS +P) 15-76ali 0 | 1-B\q0) = = -0.5833 For 100 % efficiency, 24 = @s1 Tsi @, hence, 24 =—1 = -1.714 . 0.5833 — 2. Velocity vector solution P2 Velocity =-~5F2- Point of zero velocity Axbitrary unit velocity vector We assign unit velocity, as shown in the figure. let PI, SI, etc. represent relative radii From known point of zero velocity, we determine planet velocity = - P2 P1-P2 From @ = V/r P2_) s _\ PL PD), SI @s SI+P1 I 3. _Input-output speed ratio, Oa 21.714 . Os: ae As this problem illustrates, it is not essential to have a ring gear to achieve speed changes in planetary gear trains. Here, the ring (an internal gear) is replaced by a second sun (an external gear) to perform the same function. 2. The use of two suns and two planets allows more flexibility in achieving speed ratio than if a ring gear were used because the pairs $1, Pl and S2, P2 can be independently chosen as long as $1 + P] = $2 + P2. 15-77SOLUTION (15.48) Known: A planetary gear train with double planets, two suns and no ring gear is given, Numbers of teeth on the planets and one of the suns are specified. One sun is the input member, the other sun is fixed and the arm is the output member. Find: Determine the input-output speed ratio Schematic and Given Data: PI (30 teeth): P2 (24 teeth) — qo om upu T—S1 (28 teeth) Input 92 Pp el Assumption: The gears mesh along their pitch circles. Analysis: 1. Free body analysis method For a unit clockwise torque applied to S1, forces on the planet-pair are as follows. (Let $1, Pl, etc. represent relative radii of the members): Unit torque _1 SI Summing moments to zero: 15-78Summing forces to zero: : hence, Fo Therefore, arm torque = Fo (arm radius) =yyll- Bois +P L(y - 305g) =- #(! 3g 58) = - 0.5178 Ta. For 100% effi ah = Os ‘or efficiency, p= Ge M 1 hence, oe [Osis > - 1.931 a si 2. Velocity vector solution 2 PI-P2 Velocity = Point of zero velocity We assign unit velocity, as shown in the figure. let P1, SI, etc. represent relative radii P2 PI-P2 From known point of zero velocity, we determine planet velocity = - From w = V/r P2_) Pi-P2), $1 @s: S1+P1 1 28 + 30 : 3. Input-output speed ratio, Oa =~ 1,931 7 Os, Comments: I. As this problem illustrates, it is not essential to have a ring gear to achieve speed changes in planetary gear trains. Here, the ring (an internal gear) is replaced by a second sun (an external gear) to perform the same function. 15-792. The use of two suns and two planets allows more flexibility in achieving speed ratio than if a ring gear were used because the pairs $1, PI and $2, P2 can be independently chosen as long as $1 + PI = S2 + P2. Known: A planetary gear train with double planets, two suns and no ring gear is given. Numbers of teeth on the planets and one of the suns are specified. One sun is the input member, the other sun is fixed and the arm is the output member. Find: Determine the input-output speed ratio. Schematic and Given Data: PI (36 teeth): 2 (30 teeth) —_ a A oe }——S! (32 teeth) $2, = PI Assumption: The gears mesh along their pitch circles. Analysis: 1. Eree body analysis method For a unit clockwise torque applied to S1, forces on the planet-pair are as follows. (Let $1, Pl, etc. represent relative radii of the members):Summing moments to zero: = = {Pl YMo = 0: F2= 31 [By ‘Summing forces to zero: SF = 0: hence, Fo = a Therefore, arm torque = Fo (arm radius) = ay (- fyi + Pp 1 (1. 36\6g) =- 0.425 a ‘ 1 - 35 k68) = - 0.425 For 100% efficiency, > = ou SS hence, SA = —ylagg =~ 2353 Velocity vector solution . Axbitrary unit velocity vector We assign unit velocity, as shown in the figure. let P1, SI, etc. represent relative radii From known point of zero velocity, we determine planet velocity = - From w = Vir: (sip Slee Pig lems s7-esom ieee Input-output speed ratio, Oa = 2.353 . @s; 15-81Comments: 1. nv As this problem illustrates, it is not essential to have a ring gear to achieve speed changes in planetary gear trains. Here, the ring (an internal gear) is replaced by a second sun (an external gear) to perform the same function The use of two suns and two planets allows more flexibility in achieving speed ratio than if a ring gear were used because the pairs $1, PI and $2, P2 can be independently chosen as long as $1 + P1 = S2 + P2. SOLUTION (15.50) Known: A planetary gear train with double planets, two suns, and no ring gear is given, Numbers of teeth on planets and suns are specified. The arm acts as the input member, one of the suns is fixed and the other sun acts as the output member. Find: Determine the input-output speed ratio. Schematic and Assumptio: __--—— PI (101 teeth) P2 (102 teeth) $2 (99 teeth) Output Input S1 (100 teeth) —J : All gears mesh along their pitch circles. Analysis: 1 Let the center distance be unity; ie., 1 a1 (PI + SI) = 5(P2 + $2) PL P1+S1 *PL+S1 Rotate input member (arm A) so as to give the unit linear velocity vector shown; thus S1 = radius of PI = radius of $1, etc. =o, = Woo 1S oes radius mie 15-823. Using the velocity vector method, = = Vv. Mout = Ost TF Si } Si+Pi where the pitch line velocity of S1 is p2ee)e ee +52) P2-P1 Par) _ 2-PI)S1+P1) See) (P2)(S1) 1+Pl/ _ (102- 101)(100 + 101) _ - (102)(100) acre and 25% = 40,0197 . ©, PL (101) P2102) 1 (unit velocity) 1 (unit distance) $1 (100) $2(99) Comment: Increasing the number of teeth on all the gears while keeping the difference in number of teeth, SI - S2 = P2 - P1 = 1, will produce an even lower speed (P2-PI(S1+Pl) _ S1+P1 _ 1 (P2)(S1) (PIMS1) PI out ratio: “= Qin 15-83SOLUTION (15.51) Known: A planetary gear transmission has three suns, three planets (all planets mounted on the same arm), and no ring gear. Numbers of teeth on all gears are specified. The arm is the input. In each of two operating states, exactly one of two sun gears is fixed and the third sun gear acts as output. Find: Determine the transmission ratios for each operating state. Schematic and Given Data: 3 a3 1eeu) ee) “7 Peeateam <1 FLY SI (27 teeth) $3 (21 a $20 input —, ee teeth) ouput (EE I) Low brake band 2 holds $3 fixed ail Reverse brake band holds $2 fixed Analysis: 1. Velocity Vector Method for Low Gear: ‘Assigning unit linear velocity as shown =oa=—-l — i On = OA= STs Pi * 27427 54 on the same basis: _ yector"V" _ (P3-P1)/P3 _ (33 - 27)3 Sou =O1=" ST ST 27 =m _[1) 327) _ Therefore, speed ratio = 28 = i Gm 7275 ‘Therefore, transmission ratio = 22 15-84,PI (27 teeth) 3 (33 teeth) unit velocity 83 (Fixed) $1 (27 teeth) I Free Body Analysis Method for Reverse Gear: A given Tin =Ta produces the vector Fin shown. Summing moments to zero gives Fj, (P2) Fou = ee? 2) correspondingly, Tout = Fa) (51) 1-P2 Therefore, Torque ratio, be PPS) ways) Ti, Ty (P1-P2) (SI +PI)PI-P2) ~ 2427) 8 © (27+ 27)(27 - 24) aoe The diagram shows a clockwise input torque, producing Fin acting to the right. Vector Fou acting on the output member (S1) is equal and opposite to vector Fout shown acting on the planet. Thus Tout is counterclockwise, and the transmission ratio in reverse gear = ~4.00 ' 15-85PI (27 teeth) P2.(24 teeth) Fout ‘Reaction isa XY ‘/ NX si aren (rt I iae0 \ - Lp =— Comment: The idea illustrated in this problem can be extended if more operating states and speed ratios are required, i.e., more sun gears and/or ring gears can be incorporated and other speed ratios can be obtained by fixing or freeing the suns/rings 15-86