SPUR GEAR:

G*: P=10kw, Ni=500rpm; Reduction ratio=3:2

Step 1: selection of mtl.

1]selection of pinion & wheel to get better strength & life..i<4
Pinion- 40Ni2Cr1mo28 σb=400N/mm² ; σc= 1100N/mm²
Wheel-15Ni2Cr1mo15 σb=320N/mm² ; σc= 950N/mm²
Step 2: system selection & checking for strength of pinion & pinion wheel closed system
Select 20˙ full depth teeth.
Lewis form factor 1]Y1= π(0.154-0.912/Z1)
2]Y2=π(0.154-0.912/Z2)…..{psg 8.50}
No. of teeth on pinion 3] Z1= 2/sin²X= α=full depth angle.
4] Z1=? \\ Z2= iZ1\\ Z2=?
5] Corrected value of P=Z2/Z1
6] Y1=? Y2=?
7]Strength of pinion=Y1*[σb]1=?
Strength of wheel = Y2*[σb]2=?
8] If P<W Design P based on beam strength
Step3: Cal. Of module based of beam strength.
3
1] m≥1026 (Mt 1)/Y 1 [ σb ] φmz 1…..{psg8.13}
√
2]Y1=G*\\Z1=G*\\[σb1]=?\\P=2πN1[Mt1]/60\\[Mt1]=?(N.mm)
3] Design of twisting moment\\[Mt]=[Mt1]*Kd*k
Where, Kd*k=service factor=1.3 for symmetric scheme {psg 8.15}
[Mt1]=?(N.mm)
4]φ m=10…..{psg 8.14}
m≥__?
Selecting – psg 8.2\\m=?
Step4: For contact stress
1] σc= 0.74i+1 /a√ i+1/ib∗E 1[Mt 1]…..{psg8.13}
2] i=___\\b=φ m*M=____ [Mt1]=____ E1=2.15*10^5N/mm² {psg8.14}
3] a=m(Z1+Z2)/2=? \\ σc=___>[σc1]
4] Then increase module m=4…..{psg8.2}
σc=? <σc1
Step5: Lewis dynamic load cond.
1] Fs≥Fd {psg8.51}
2]Fs=[σb]b*yPc…..psg8.50 where; y=y1
Fs=? Fd=Ft*Cv…..psg8.50
3]ft=p/Vm Vm=πd1N1/60 where; d=(mZ1) Ft=?
4] Cv= 5.5*Vm^(1/2)/5.5…..{psg8.51} Cv=?
5] Fd=Ft*Cv=? Fs>Fd…..safe.
If design fail (Fs=Fd)
Step 6: buckingham’s dynamic load
1] Fs≥Fd…..{psg8.51}
0.164 Vm(c∗b+ Ft )
Fs= static load 2]Fd=Ft* …..{psg8.51}
0.164 Vm+1.485 √ c∗b+ Ft
P
3] Ft= =? Vm=mean vel. In m/min=Vm*60
Vm
b=width=G* C=11860*e & α=20…..{psg8.53}
e=0.125 for precision gears & m=4…..{psg8.53}
c=? Fd=? As Fs>Fd…..safe.

DESIGN DATA---PSG TECH 7.115

step7: wear load.
1] Fw>Fd(lewis)…..{psg8.51}
Where; Fd=Lewis dynamic load…..{Fd=Ans step:5]
2]Fw=dQkb…..{psg8.51} d=mZ1
1 1
2i [ δc1 ] ²∗sinα [ + ]
3] Q= \\ 4]k= E 1 E 2 …..{psg8.51}
i+1
1.4
5] k=? Fw=? Fw≥Fd__design safe.
Step8] Principle dimension……{psg8.22}
Step9] constructional details.
1] Pinion & wheel= C45, FOS=4, σy=360N/mm²…..{psg1.9}
δy
2] z
τ=
FOS
3] Equivalent twisting moment [Mt]eq=[Mt1]*1.2….{Mt1=step3 ans}
Torsional failure [Mt]eq=π/16*ds1³[τ ¿……ds=?
4] ds2=ds1(i)⅓…… ds2=?...(apply step1—9)
TYPE2: If mtl is given Check psg8.5; find σb & σc=? ;ds1 & ds2
Step 2: ρCI …..psg1.1 (0.072)N/cm²=0.072/10*1000=kg/mm³
π π
Mp={ ∗¿[da1²-dh1²]b+ ∗¿[dh1²-ds1²](b+4) ρCI __\\ Mpc=?kg
4 4
Step 3: Sol. Of wheel ds1&ds2
Mw= [π/4*(da²-do²)b + π/4(dh2²-ds2²)(b+4)]*1.1* ρCI Mw=?kg
TYPE 3: If mtl is not found in PSG then;
Step1; Step2- σb=1.4kbl/nkσ* σ-1…..{psg8.18}
Kbl=1…..{psg8.20} \\ n=2.5…..{psg8.19} kσ=1.5\\ σ-1=0.25(σu+σy+500)…{psg8.19}
σu&σy…..{psg1.9} σb=?
Step3: Contact strength….(σc)=Cb(BHN)kcl…..{psg8.16}
Where; BHN=265 CB=25…..{psg8.16} kcl=1 σc=?
TYPE 4: If wheels fails then equals static tangential & dynamic tang. Force & final module;
Step1… Step2….Step5 Fs=Fd m=?
Step4: Checking beam strength….. σb=i±1/amby1[Mt1]≤[ σb1]…..{psg8.13A}
I=?; a=m(Z1+Z2)/z…. b=M*φm
[Mt1]= P*60/2πN1.. [Mt1]=Mt1*kdk σb=? Then step4=?

DESIGN DATA---PSG TECH 7.115

HELICAL GEAR:
β=18˙ ….. If not mentioned
Perpendicular to teeth (Mn)… Normal module.
Parallel to teeth (Mt)… Transverse module.
Mt=Mn/Cos β ……{psg8.22}
Normal Module; φ m=b/Mn
Step 1: Sel. of mtl
Pinion - 40Ni2Cr1mo28 σb=400 σc=1100
Wheel - 15Ni2Cr1mo15 σb=320 σc=950
Step 2: System sel & strength of P&W
Z1= 2/sin²α Z1=? Z’2=iZ1 Z’2=?
Z2=Z2’+1 Z2=?
Corrected value= i=Z2/Z1 i=?
Zv1= Z1/cos³β zv1=? Zv2=Z2/cos³β Zv2=?....{psg8.1, 8.51}
Lewis factor; Pinion; Yv1=π[0.154-0.912/zv1]…..{psg8.50}
Wheel; Yv2=π[0.154-0.912/zv2] Yv1=? Yv2=?
Strength of pinion= [σb1]*Yv1=?
Strength of wheel= [σb2]*Yv2=? Pinion is weaker calculate more..
[ Mt ] 1
Step 3: Mn≥1.15 cosβ

P∗60
√
3

Yv 1 [ σb ] ψ mZ 1
……{psg8.13A}

[Mt1]= Mt1=? [Mt]=Mt1*kd*k …..{psg8.15}

2 πN 1
Ψm=b/Mn…..psg8.14 Mn≥? …..{psg8.2}
Mn
Transverse module; Mt= Mt=?
cosβ
Step 4: Contact
Σc= 0.7*i+1 /a√ i+1/ib E [ Mt ] 1 ≤ [σc]…..{psg8.13}
Mt [Z 1+ Z 2]
a= …..{psg8.5} a=? b=ψ*Mn b=?
2
E=std=2.15*10⁵N/mm² σc>σcind
If σc>σcind increase Mn……{psg8.2} σc>σcind…..(safe)
Step 5: Lewisdynamic load……{psg8.15}
Fs≥Fd……{psg8.51}
Fs=[σb]1*b*yv1*Pcn where; Pcn=πMn
Fs=? Fd=Ft*Cv Ft=P/Vm Vm=πd1N1/60

d1=(Mt*Z1) Ft=? Cv=

5.5+V m1 /2 …… {psg8.51} Cv=?
5.5
Fd=Ft*Cv Fd=? Fs>Fd …….(safe)
Step 6: Buckingham’s dynamic load Fs>Fd……{psg8.51}
0.164 Vm ( CbCo s 2 β+ Ft ) Cosβ
Fd= Ft+ ……{psg8.51}
0.164 Vm+1.485 √ Cbcos ² β+ Ft
Vm=pitch vel*60 b=G* β=G* Ft=G*
C=11860*e ….for mtl comb.n steel & α=20̊…..{psg8053}
e= errors in action …..{psg8.53} c=? Fd=?N
Fs>Fd……(safe)
Step 7: wear load Fw>Fd (lewis)……{psg8.51}
bd 1 Qk
Fw= …..{psg8.51} where; b=G*, d1=MtZ1, θ=2i/i+1
cos ² β

DESIGN DATA---PSG TECH 7.115

 sinαn
K=[σc]² [1/E1+ 1/E2]……{psg8.51}
1.4
Tanαn= tanα cosα α=? Fw=? If ,Fw>Fd…..(safe)
Step 8: Principle dimensions……{psg8.22} pinion-wheel

BEVEL GEARS:
rp1= pitch circle radia of pinion b= width of gear
rp2= pitch circle radia of wheel R=cone radius=3b…..{psg8.55}
S1= semicone angle of pinion ∑=δ1+δ2
S2= semicone angle of wheel
Step 1: 1)i=N1/N2; 2)δ1= tanˉ1(sin∑/i+cos∑) where; ∑=75̊
3) δ2=∑-δ1 4)ψm= Z1/5*sinδ1
Step 2: Sol of mat.
Pinion - 40Ni2Cr1mo28 σb=400 σc=1100 …..{psg 8.4& 8.5}
Wheel - 15Ni2Cr1mo15 σb=320 σc=950
Step 3: system selection & check for strength p&w
1) Z1= 2/sin²α; Z1=?; Z2=iZ1; Z2=Z2+1=? Corrected value; i=Z2/Z1
2) Zv1= Z1/cos³β; Zv1=? Zv2=Z2/cos³β....{psg8.1, 8.51};
3) Zv2=Z2/ cos³β; Zv2=? 4)Yv1=π[0.154-0.912/Zv1] Yv1=?
5) Yv2= π[0.154-0.912/Zv2] Yv2=?......{psg8.50} ;strength of pinion=[σb1]Yv1=? N/mm2
Strength of wheel =[σb1]Yv1= ? N/mm2
[ Mt 1]
Strength 3: Mavg≥ 1.28

(Mt)= P*60/2πN1=Mt1=?
√ Yv 1 [ σb 1 ] ψmZ 1
[Mt1]=Mt1*kd*k=?……{psg8.15}
…..{psg8.13A}

Ψm=Z1/5sinδ1 Z1=? Mavg≥?....St module…..{psg8.2}

Mt= 1.2* Mavg=?
Step 4: contact stresses

√
3
1) σc= 0.72/(R-0.5b) √√ ( i ± 1 ) E [ Mt ] 1 …….{psg8.13}
2

ib
2) R=3B 3)b=Ψm*Mavg E=std= 2.15*10⁵ N/mm² 4) σc<σcind….(safe)
[ σb ] 1 bYv 1[1− b ]
Step 5) 1) Fs≥Fd…..{psg8.52} 2)Fs= R =? Where; 1/Pd=Mt……{psg8.52}
Pd
3) Fd= Cv.Nsf.Km.Ft……{psg8.52}; 4) Ft=P/Vm ; 5) Vm=πd1N1/60; 6)d1=Mt=Z1

7) Cv=
3.5+V m1 /2 ; 8)Nsf=1.5…..{psg8.52}; km=1……{psg8.52}; Fd=?
3.5
Fs>Fd……….design is safe
Step 6) Buckingham’s dynamic load 1)Fs≥Fd……{psg8.52}
0.164 Vm(c∗b+ Ft )
2)Fs=G*; 3) Fd=Ft+[ ¿…..{psg8.52}….where 1/Pd=Mt
0.164 Vm+1.485 √ Cb+ Ft
4) Ft=G*; 5)Vm=πd1N1/60
Correction factor C=11860*e…..{psg8.53} & pr. Angle 20̊ full depth
Where; e=0.0125…..for ,Mavg=3 & c=? b=G* & Fd=?
As Fs> Fd……design is safe.
Step 7) Principle dimensions……{psg8.89}

DESIGN DATA---PSG TECH 7.115

Worm & Worm WheelFor->β1=90-γ ; lead angle(γ);Wormwheel->β2

G*=P,N1,N2,I;-Step1 Seln nof matSteelworm [C45]{σb-140,110}{σc-500,149psg8.5,8.45

Step2-system seln &chan of strength of worm and worm wheel ź+z>40…Psg8.52i=ź/z=>ź=iz=>
ź+z>40(iz+z)>40=>z(i+1)>40=>z>40/i+1…z>?
Taking worm z=2=>No. of teeth of wheel ź=i*2
z
For lead angle & helix angle=>tanγ= …Psg8.43=>q=Dia factor=11…assumed…Psg8.44
q
γ=?=>Helix angle of worm…β1=90-γ=?°
Helix angle of wheel β2=γ=?°
z
Lewis form factor=>zv1= …Psg8.1=>zv1=?
cos3 β 1
ź
Virtual nos of teeth on wheel zv2= 3 =>zy=?°
cos ∗β 2
0.912 0.912
Yv1=π[o .154− ]…Psg8.50…yv1=?...yv2= π[o .154− ]=>yv2=?
zv 1 zv 2
Strength of worm= [σb1]*Yv1=?
Strength of wheel= [σb2]*Yv2=?
Step3-Correction modulus based on Contact stress
540 2
ź
q
3[
a=( +1)* ź
√
q
[ σc ] 2
] ∗[ Mt 2 ] …Psg8.44

Where G*ź;q;[σc2]…[Mt2]=Mt2*kd*k…Psg8.44
p∗60
Mt2= *Kd*k where Kd*k=1=>[Mt2]=?=>a=?
2π
a=0.5*Mx(q+ź+2x)…Psg8.43 …Assume x=0…a=G*
a=0.5*Mx(q+ź)=>Mx=?=>Axial module(Mx)=? Psg8.2
Mn
Mx=Mt=>Mt= =>Mn=Mt*cosβ2=>Mn=?
cosβ 2
1.9[ Mt 2]
Step4-Beam Strength=>σb= =>σb<=σbind…safe
Mx 3∗qź∗yv 2
Step5-Lewis dynamic load=> Fs>=Fd….Psg8.52
[ σb 2 ]∗yv 2∗b∗Pcn
Fs= where Pcn=π*Mb
π
Where b=0.75*d1 for Z=z[Psg8.43 Table38-Psg8.48]

DESIGN DATA---PSG TECH 7.115

 6+Vmg
Fs=?...Fd=( )*Ff…Psg8.52
6
P π∗d 2∗N 2
Where Ft1= =>Vmg= =>d2=Mt*ź =>d2=?
Vmg 60
Vmg=? ; Ft1=? ; Fd=? ; Fs>FdDesign safe
Step6-wear load => Fw>=Fd..Psg8.51
Fd=G*…Fw=Dg*b*Kw =>d2*d*Kw
Where Kw=wear factor …(psg 8.54)=8.8kgf/cm 2
Fw=(Mt*ź)b*Kw=>Fw=?N =>Fw>FdDesign safe
Step 7-Thermal=>Hd>=Hg=P(1-η)…Psg 8.52
tanγ
η= =>ρ=Frictional angle=> tan−1 μ
tan ( γ + ρ )
μ can be det n from graph…psg 8.44
π∗d 1∗N 1
X1= =>X1=?
60
Sliding velocity(Vs)≈V1=X1(z=2)
Μ=0.035 from graph=> ρ= tan−1 μ =?° & η=?%
1870
Hg=---watt* *60 kgm/min…(1)
10
Hd=hcr*A*Δt (Kgf m/min)…Psg 8.52
hcr=Combined Heat transfer coeff => convection & ratio g=0.18 kgf-m/cm 2 min°C=>Psg 8.54
A=57.2a 1.7cm 2
a=26.5cm ; A=57.7(26.5)1.7=15038.086cm
Hd=0.18*15038.086*Δt…(2)=>Equating (1)&(2)
Δt=th-ta => th=Housing temp & ta=Ambient temp Assuming 30°C

DESIGN DATA---PSG TECH 7.115