Course in Machine Design

Course in Machine Design
Gears and mechanical transmissions Udvekslinger og mekaniske transmissioner
Machine Design Computational Mechanics, AAU, Esbjerg
Outline
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Product design and development [Ch. 1] Steel design [Ch. 3, App. D] Gears and mechanical transmissions [Ch. 11, 12, App. C] Mechanism and dynamics [Ch. 3, notes] Shafts, keys, and couplings [Ch. 9, App. B, C] Shafts, keys, and couplings [Ch. 9, App. B, C] Tolerances [Notes] Fatigue I [Ch. 4, 5, App. E] Fatigue II [Ch. 5, 6, App. E] Fasteners – fatigue [Ch. 14]
Machine Design Gears and mechanical transmissions Computational Mechanics, AAU, Esbjerg
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Case study
• Life saving system for beaches
– Mobility: terrain, offroad – Non buoyant – Load: 2 persons + rescue equipment
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Program
• Case study • Project management
– – – – Vision Mission Objective/goal Strategy
• • • • •
Power considerations Discussion of Gears Gears Spur Gears Bevel gears
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Gears
• Mechanical power transmission devices between two rotating shafts
Friction Gears Friction ensures contact. Since contact point velocity is constant
ω1R1 = ω 2 R2
ω1 R2 = ω 2 R1
Speed ratio
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Gears
Spur Bevel
Helical
Worm
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Gears: Constant Speed Ratio
Two arbitrary profiles in contact.
ω2 ω1
O1
C
O2
Desired: We want the ratio of angular velocity to be constant as different points come in contact.
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ω2 ω1
O1
C
O2
v1 = ω1O1C
v2 = ω1O1C
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v2
θ2
θ1
v1
Note: The tangential components of the velocities O2 ω 2 need not be equal … they can slip relative to each other
ω1
O1
C
Key: The component of the velocities along the common normal must be equal … else the parts will lose contact or interfere
v1 cosθ1 = v2 cosθ 2 ω1O1C cos θ1 = ω2O2C cos θ 2
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O1
θ1
D1 θ1
C
D2 θ2
θ2
From previous: ω1O1C cosθ1 = ω 2O2C cosθ 2 But
90 − θ1
O1C cosθ1 = O1D1
ω1O1D1 = ω 2O2 D2
ω1 O2 D2 = ω 2 O1D1
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D2 O1
P
D1
C
From previous:
By similarity triangles
ω1 O2 D2 = ω 2 O1D1
P: Pitch point.
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ω1 O2 D2 O2 P = = ω 2 O1D1 O1P
P
ω2
ω1
O1
O2
P: Pitch point. Intersection of normal at contact and line joining centers. Law of conjugate action • The ratio of angular velocities remains constant only if the pitch point remains fixed!! • There are many ways to ensure conjugate action
Machine Design Gears and mechanical transmissions Computational Mechanics, AAU, Esbjerg 12
ω1 R2 = ω 2 R1
Spur gears
• Spur gears achieve constant speed ratio through involute teeth. See animation at: http://auto.howstuffworks.co m/gear7.html
Pressure angle also remains constant!
• Pitch point does not move for two involute-profile teeth gears in contact
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Spur Gears
rb
2πrb N= pb
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Spur Gears
Pressure angle governed by intended pitch circle
cos ϕ =
rpb rp
Gears behave like two friction gears in contact except high power transmission
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Spur Gears: Definitions
Involute for rack is a straight line! Tool Gear being manufactured
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Spur Gears: Definitions
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Spur Gears: Definitions
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Spur Gears: Meshing
• For two gears to mesh, they must have the same:
– Nominal pressure angle – Nominal circular pitch
• But can have different
ω1 N 2 = ω 2 N1
– Number of teeth – Pitch diameter dp, dg
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Spur Gears
• Actual center distance determines
– – – – – – Actual pressure angle Actual circular pitch Actual tooth thickness Back-lash Interference Contact ratio
• Smaller = Pinion • Larger = Gear
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Spur Gears
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Gears: Forces
Two components of force: Ft: Useful tangential force Fr: Radial force
Fr = Ft tan ϕ Torque = rFt Power = ωrFt
The tangential force is determined from the power being transmitted.
Gears: Stresses
Contact Stresses Need to design gear against both types of stresses. Bending stresses
Fatigue stresses!
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Gears: Bending Stress
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Gears: Bending Stresses
Two approaches:
– Simplistic Lewis Equation – Modern AGMA method
• Lewis assumptions:
– Neglect radial force – Force acts at tip – Uniform force distribution – No stress concentration – No sliding force – Zero contact velocity
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Mc σ (bending ) = I M = Ft h c =t/2 bt I= 12 6 Ft h σ= 2 bt
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Ft σ= 2 = b bt 6 Ft h ⎛ 6h ⎞ ⎜ ⎟ ⎜ 2⎟ ⎝t ⎠
Function of diametral pitch
Ft ⎛ P ⎞ σ= 2 = ⎜ ⎟ b ⎝Y ⎠ bt Y : Lewis Factor 6 Ft h
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Example : Ft = 100lbf b = 0.1" ; P = 4; ϕ = 20; N = 28 Y = 0.35 Ft σ= b ⎛ P⎞ ⎜ ⎟ = 11.45ksi ⎝Y ⎠
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AGMA model: • Neglect radial force • Force acts at tip • No sliding force • Non-uniform force distribution • Stress concentration • Non-zero contact velocity
Ft ⎛ P ⎞ σ = ⎜ ⎟Kv Ko Km b ⎝J⎠ J : geometry factor K v : velocity factor K o : overload factor K m : mounting factor
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Geometry factor J: allows for 2 different assumptions
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Velocity factor Kv: also depends on how gear is manufactured
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• Overload factor Ko: depends on power source and driven machinery Table 15.1 • Light shock power and moderate shock machinery, Ko = 1.5 • Mounting factor Km: depends on accuracy of mounting and face width Table 15.2 very accurate and width of 4”, Km = 1.4
Gears: Bending Stress
σm σ
1 + = Sut S n n
σa
1 + = 2 Sut 2 S n n
S n = (Other factors) * CG C LCS 0.5Sut S n ≈ 0.4 Sut
σ
σ 0.4σ 1 + = 2S n 2S n n ...
1 = 1.4 S n n
σ
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For the idler
σm
1 + = Sut S n n σ 1 = Sn n
σa
Include 1.4 for regular gears as a factor in Sn
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S n = kt k r k ms CG C LCS 0.5Sut kt : temperature factor k r : reliability factor 1 for idler k ms :} 1.4 for other
Conclusion
σ : AGMA
S n : From above 1 = Sn n or design ' b' for a given safety factor
σ
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Gears: Bending Strength - Example
Problem info: • Pinion: 20 teeth, gear: 40 teeth • 20 degrees pressure angle; P = 8 • Accurate mounting • Material: Steel, heat treated to 350 Bhn. • Standard full depth teeth • Required life: 5 years, 60 hours/week, 50 week/year, 1100 rpm (pinion) • Find: max horsepower that can be transmitted with a safety factor of 1.5, and 99% reliability, based only on bending strength.
Assumptions: • AGMA method of analysis • Gear tooth loads transmitted at pitch point • No load sharing • Assume top quality hobbing operation
Ft ⎛ P ⎞ σ = ⎜ ⎟Kv Ko Km b ⎝J⎠ V : 720rpm(pitch line velocity) From Curve C (Fig.15.24) K v = 1.54 From Fig.15.23a J = 0.24 (pinion is weaker) K m = 1.6(assumption) K o = 1.0(assumption)
1 = Sn n
σ
σ = 82.1Ft
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S n = kt k r k ms CG C LCS 0.5Sut kt : 1 k r : 0.814 k ms : 1.4 CG : 1; C L : 1.0; CS : 0.66 S n = 65812 psi
1 = Sn n
σ
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82.1Ft = 65812 / 1.5 Ft = 534lb HP = 11.7 hp
1 = Sn n
σ
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Gears: Hertzian Contact Stress
As before
Find : Eeq Req Area of contact Max stress... But also include the various factors
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Gears: Hertzian Contact Stress
Buckingham model
Ft σ H = Cp Kv Ko Km bd p I C p : E and ν dependent (Table 15.4) d p : Pinion pitch diameter I : Geometry factor (Eqn 15.23)
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Gears: Contact Strength
Recall contact stress problems have only finite life. Table 15.5 provides typical contact strength values Sfe for 107 cycles, 99 percent reliability and temp < 250 F To find strength at a different number of cycles and temperature use eqn. 15.25
S H = S feC Li C R
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Bevel Gears
Note: b: Face width L: Pitch cone length γ: Pitch cone angle d: pitch dia
Bevel gears are not interchangeable!
Gears: Forces
Fr
Ft Fa
Determined from power requirements
Fr = Ft tan ϕ cos γ Fa = Ft tan ϕ sin γ
Note: What is axial force for one bevel gear is radial force for the other.
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Both bending and contact stresses Bending stress and strength
Gears: Stresses
Ft σ= b
S n = kt k r k ms CG C LCS 0.5Sut
Factors similar or slightly different for Bevel gears Contact stress and strength
⎛ P⎞ ⎜ ⎟Kv Ko Km ⎝J⎠
Ft σ H = Cp Kv Ko Km bd p I
S H = S feC Li C R
Factors similar or slightly different for Bevel gears
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Course in Machine Design

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