ME 306 DESIGN OF MECHANICAL DRIVES

ASSIGNMENT 1

SUBMITTED BY
PP
MECHANICAL ENGINEERING (VI – SEM)
ROLL NO. :
1. Discuss the selection of pressure angle for spur gear design.

 Pressure angle is the angle formed by the line of action with the common
tangent to the pitch circles of mating gears. For involute system of gears, the
pressure angle is constant and it maybe 14.5° or 20°.
 The pressure angle figures into the geometry or form of the gear tooth. 14.5°
degree pressure angle tooth were the original standard design. While, they are
still widely available, the 20° pressure angle teeth have wider bases and can
transmit greater loads.
 The smaller the pressure angle the thinner the teeth will be. Older gears with
a 14.5 degree pressure angle will not be as strong as modern 20 or 25 degree
gears.
 For 14-1/2°–Change in Center Distance = 1.933 x Change in Backlash For
20° –Change in Center Distance = 1.374 x Change in Backlash

2. What are the factors that determine the choice of face width PPof spur gears?

 Wider face width increases the bending performance of gears

 Wider face width increases the resistance to pitting
 To determine the face width:

F = Face width
DP = Diametrical pitch
V = Velocity in FPM
S = Safe stress per square inch of material
Y = Outline factor

3. How is minimuPPm tip diameter of spur gears determined?

Tip diameter is highly concentric with the pitch circle
Calculation of tip diameter is essential for processing the gear blanks
Tip diameter: da = d + 2m
where d = reference diameter
m = module
Initially minimum module is calculated using,
1 3
 [M t ] 
m min  1.26 
[ b ] m z1 y 

Then minimum tip diameter is calculated using, d a  m( z1  2 f  )

Where,

[ M t ]] =Design twisting moment

[ b ] = Design bending stress

 m = face width to module ratio

z1 = number of teeth of pinion

y = form factor
m = module
4. What is the role played by virtual number of teeth of helical gears?

 In order to simplify the design of helical gear, the concept of virtual number of teeth
can be adopted. The virtual spur gear is an imaginary spur gear which is having
equal strength and pPPower transmitting capacity with actual existing helical gear.
 The virtual number of teeth of a helical gear is the number of teeth which can be
generated on the surface of a cylinder having a pitch radius equal to the radius of
curvature of the point at the tip of the minor axis of an ellipse obtained by taking a
section through the helical gear in a plane which is normal to the tooth at that point.
Z
 Virtual number of teeth, Z v 
cos 3 
 Where,
 Z= actual number of teeth of helical gear
   helix angle

5. Write briefly on BIS standards for spur/helical gear design.

 IS 8830(2007)

6. Discuss the backlash in spur gears and helical gears.

 Backlash is the amount by which a tooth space exceeds the thickness of a gear
tooth engaged in mesh. The general purpose of backlash is to prevent the gears
from jamming by making conPPtact on both sides of their teeth
simultaneously
 There are several kinds of backlash:
CIRCUMFERENTIAL BACKLASH, RADIAL BACKLASH, ANGULAR
BACKLASH, NORMAL BACKLASH

 Backlash
 Depending on the application, backlash may or may not be desirable. It is unavoidable
for nearly all reversing mechanical couplings, although its effects can be negated or
 compensated for. In many applications, the theoretical ideal would be zero backlash,
but in actual practice some backlash must be allowed to prevent jamming. Reasons for
the presence of backlash include allowing for lubrication, manufacturing
errors, deflection under load, and thermal expansion.

 Factors affecting the amount backlash required in a gear train include errors in profile,
pitch, tooth thickness, helix angle and center distance, and run-out. The greater the
accuracy the smaller the backlash needed. Backlash is most commonly created by
cutting the teeth deeper into thPPe gears than the ideal depth. Another way of
introducing backlash is by increasing the center distances between the gears. [2]

 Backlash due to tooth thickness changes is typically measured along the pitch
circle and is defined by:

where:

= backlash due to tooth thickness modifications

= tooth thickness on the pitch circle for ideal gearing (no backlash)

= actual tooth thickness

Backlash, measured on the pitch circle, due to operating center modifications is defined
by:

where:

= backlash due to operating center distance modifications

= difference between actual and ideal operating center distances

= pressure angle

7. Where must be the formative number of teeth of bevel gears used? Why?

 Formative or Equivalent Number of Teeth for Bevel Gears – Tredgold’s

Approximation
 We have already known that the involute teeth for a spur gear may be generated
by the edge of a plane as it rolls on a base cylinder. A similar analysis for a
bevel gear will show that a true section of the resulting involute lies on the
 surface of a sphere. But it is not possible to represent on a plane surface the
exact profile of a bevel gear tooth lying on the surface of a sphere. Therefore, it
is important to approximate the bevel gear tooth profiles as accurately as
possible. The approximation (known as Tredgold’s approximation) is based
upon the fact that a cone tangent to the sphere at the pitch point will closely
approximate thePP surface of the sphere for a short distance either side of the
pitch point. The cone (known as back cone) may be developed as a plane surface
and spur gear teeth corresponding to the pitch and pressure angle of the bevel
gear and the radius of the developed cone can be drawn.

 The action of bevel gears will be same as that of equivalent spur gears.
 Since the equivalent number of teeth is always greater than the actual
number of teeth, therefore a given pair of bevel gears will have a larger
contact ratio. Thus, they will run more smoothly than a pair of spur
gears with the same number of teeth.

Let,
p
= pitch angle

R = Pitch circle radius of the bevel pinion or gear, and

RB = Back cone distance or equivalent pitch circle radius of spur pinion

or gear.

Now,
R B  R sec  p

Formative number of teeth equals,

2 R sec  p
 T sec p
TE = 2 RB / m = m

Where, T=Actual number of teeth

Formatted: Font: 12 pt, Bold, Font color: Red

Formatted: Indent: Left: 0 cm

8. What is the role played by gear ratio in bevel gear pair

 Higher speed reductions may be obtained by these gears in a minimum of space.

 Differing of tPPhe number of teeth (effectively diameter) on each wheel
allows mechanical advantage to be changed. By increasing or decreasing the ratio
of teeth between the drive and driven wheels, one may change the ratio of
rotations between the two, meaning that the rotational drive and torque of the
 second wheel can be changed in relation to the first, with speed increasing and
torque decreasing, or speed decreasing and torque increasing.

9. Write briefly on BIS standards for bevel/worm gear design

IS 8830(2007)

10. What are the features of zerol bevel gears?

 Zerol bevel gears are an intermediate type between straight and spiral bevel gears.
Their teeth are curved, but not angled. Zerol bevel gears are designed with the intent
of duplicating tPPhe characteristics of a straight bevel gear but they are produced
using a spiral bevel cutting process
 

 Zerol bevel gears are similar to spiral bevel gears but they have a spiral angle of
zero degrees. The Zerol bevel gears have a profile which somewhat resembles an
involute curve. The pressure angle of the tooth varies slightly in going across the
face width, This is caused by the lengthwise curvature of the tooth. Zerol bevel
gears are favoured over straight bevel gears in applications in which both high
accuracy and higher speedPPs are required

11. With a neat sketch explain the relationship between tooth load and tooth
thickness for a bevel gear.

 Tooth load (tangential) is directly proportional to the square tooth thickness. As

shown in the figure for a bevel gear tooth, the:-

 Ft = (σ*b*t2)/6

 Hence, we see that a thicker tooth will withstand more tangential force than a
thinner tooth.
12. Discuss the relation of axes for bevel gears.

Bevel gears are used to connect two intersecting shafts with any given speed ratio.
Bevel gears are cut on conical blanks.

 In Straight tooth gears, the axes intersect generally at right angles. The elements of
the teeth are straight lines that converge at the apex of the pitch cone.
 Spiral bevel gears are PPmade with curved teeth. They have smoother tooth
engagement, quiet operation, greater strength and higher permissible velocities.
 The axes of zerol bevel gears intersect, and the teeth are curved and can be ground.
 Face gears consist of a spur or helical pinion in combination with a conjugate gear
of disc form.
 Skew bevel gears are non-parallel and non-intersecting, and the teeth are straight.
 The axes of hypoid gears are non-parallel and non-intersecting, and the teeth are
curved.

13. Write on the thermal capacity of bevel gear pair.

  Customary procedure in calculating thermal capacity is based on finding the
maximum horsepower that a unit can carry for 3 hours without the sump temperature
exceeding 93°C, when the ambiePPnt air temperature is not over 38°C.
 Gear drives are often splash lubricated by a quantity of liquid oil in the gearbox.
Without a pumped oil system and oil coolers, the gearbox is cooled by the
surrounding air. Such a spiral bevel drive will have a thermal rating (or capacity) and
that value should not be exceeded.
 Thermal Capacity depends on the following variables: Gearbox size, input pinion
speed and the speed reduction ratio.
 For the same size unit, the thermal capacity drops rapidly as the speed is increased,
effect from the ratio is pretty mild, and increase in gearbox size increases the thermal
capacity.

14. Suppose that it is desired to design speed-reducing worm gear pair

that will have a reduction ratio of 1:50 and an operating centre distance Commented [PP1]:

of 25 cm. the worm will have a single tooth, normal pressure angle of 20 o
and will be made of hardened steel. The worm gear will be made of bronze
using a chill casting process. Find the capacity (power) of this worm gear
set and determine its input power requirement.

Given:
i = 50
Z1 = 1
Therefore, Z2 = 50
a = 25 cm
Ø = 200

Material selection and design stresses:

It is given that the materials used are hardened steel and chilled bronze.

[σc] = 1590 kgf / cm2 for Vs = 3 m/s (assumed)

[σb] =550 kgf / cm2

Initial assumptions:
q=11

Vs = 3m/s

Speed = 600 rpm

𝑘 × 𝑘𝑑 = 1

Based on foPPrmula for minimum center distance:

2 1/3
𝑍2 540
𝑎 ≥ ( 𝑞 + 1) ((𝑍2 ) [𝑀𝑡 ]) in cm
[𝜎𝑐 ]
𝑞

Thus,
2 1/3

𝑍2 540
25 ≥ ( + 1) ( ) [𝑀𝑡 ]
𝑞 𝑍2
[𝜎𝑐 ]
( 𝑞 )

2 1/3
50 540
→ 25 ≥ (11 + 1) ((50 ) [𝑀𝑡 ]) (q assumed as 11 initially)
(1590)
11

→ [𝑀𝑡 ] ≤ 16412.3 𝑘𝑔𝑓/𝑐𝑚2

Therefore maximum value of [𝑴𝒕 ] = 𝟏𝟔𝟒𝟏𝟐. 𝟑 𝒌𝒈𝒇/𝒄𝒎𝟐

For worm gear, 𝒌 × 𝒌𝒅 = 𝟏 (assumed)

Therefore: 𝑴𝒕 = 𝟏𝟔𝟒𝟏𝟐. 𝟑 𝒌𝒈𝒇/𝒄𝒎𝟐

Assuming Vs = 3m/s

From plot of frictional coefficient and sliding velocity:

𝜇 = 0.035

𝜌 = 𝑡𝑎𝑛−1 (𝜇) = 𝑡𝑎𝑛−1 (0.035) = 2.0040

𝑍1 1
𝛾 = 𝑡𝑎𝑛−1 ( ) = 𝑡𝑎𝑛−1 ( ) = 5.19440
𝑞 11

tan(𝛾)
𝜂= = 0.719
tan(𝛾 + 𝜌)
 97420 × (𝑖𝑛𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟) × 𝑖 × 𝜂
𝑀𝑡 =
𝑛1

𝑛1 = 𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑤𝑜𝑟𝑚 = 600 𝑟𝑝𝑚 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)

Thus input power = 2.81 kW

𝐏𝐨𝐰𝐞𝐫 𝐜𝐚𝐩𝐚𝐜𝐢𝐭𝐲 𝐨𝐟 𝐰𝐨𝐫𝐦 = 𝟐. 𝟖𝟏 × 𝟎. 𝟕𝟏𝟗 = 𝟐. 𝟎𝟐 𝒌𝑾

15. A gear is to transmit a torque of 500 N-m at 600 rpm in a simple gear train that
consists of two gears the details of which are given below. The length of the each
shaft on which thPPe gears are mounted is 450mm.

Item Gear Pinion

Module, mm 4 4
No. of teeth 50 25
Type Involute Spur Involute Spur
Pressure Angle 20 20
Give an account of forces involved in the drive. State clearly any
assumption.

Assumptions:
Entire load Pn is distributed along one line of contact with length equal to the wheel
width b.
Ψpin = 0.3
Ψm = 10
Solution:
𝑑1 = 𝑚 × 𝑍1
𝑑1 = 0.004 × 25 = 0.1𝑚
2 × 𝑀𝑡1
𝑃=
𝑑1
2 × 500 𝑁 − 𝑚
𝑃=
0.1 𝑚
𝑃 = 10000 𝑁
𝑃𝑟 = 𝑃 × tan(𝛼)
𝑃𝑟 = 10000 × tan(20°) 𝑁
𝑃𝑟 = 3639.7 𝑁
 𝑃
𝑃𝑛 =
cos(𝛼)
10000 𝑁
𝑃𝑛 =
cos(20°)
𝑃𝑛 = 10641.77 𝑁

𝑑2 = 𝑚 × 𝑍2
Gear:
𝑑2 = 0.004 × 50 = 0.2𝑚
2 × 𝑀𝑡1
𝑃=
𝑑2
2 × 500 𝑁 − 𝑚
𝑃=
0.2 𝑚
𝑃 = 5000 𝑁
𝑃𝑟 = 𝑃 × tan(𝛼)
𝑃𝑟 = 5000 × tan(20°) 𝑁
𝑃𝑟 = 1819.85 𝑁
𝑃
𝑃𝑛 =
cos(𝛼)
5000 𝑁
𝑃𝑛 =
cos(20°)
𝑃𝑛 = 5320.88 𝑁
𝑏 = 𝑚 × 𝛹𝑚
𝑏 = 0.004 × 10 𝑚
𝑏 = 0.04 𝑚

𝑎 = 𝑏⁄𝛹

𝑎 = 0.04 𝑚⁄0.3

𝑎 = 0.133 𝑚
 2
1
𝑘𝑐 = 1 + [0.16𝛹𝑝𝑖𝑛
𝑘𝐸

4
𝑙𝑠ℎ 5.3
+ 0.016𝛹𝑝𝑖𝑛 (1.5 − 0.5) (1 + )] (𝑘𝑟𝑢𝑛 𝑘𝐸 𝑘𝑘𝑒 )
𝑏 2 2𝜋𝑎
𝛹𝑝𝑖𝑛 sin ( )
𝑙𝑠ℎ

𝑘𝑐 = 1 + [0.16 × 0.32 + 0.016

0.45 5.3
× 0.34 (1.5 × − 0.5) (1 + )] (1.1.1)
0.04 2𝜋 × 0.133
0.32 sin ( )
0.45
𝑘𝑐 = 1.1467

𝑘𝑑 = 1.3⁄𝑘
𝑐

𝑘𝑑 = 1.1337
𝑃𝑑
𝑘𝑑 = 1 +
𝑃𝑛
𝑃𝑑 = (𝑘𝑑 − 1) × 𝑃𝑛

Pinion: 𝑃𝑑 = 0.1337 × 10641.77𝑁 = 1422.8𝑁

Gear: 𝑃𝑑 = 0.1337 × 5320.88𝑁 = 711.4𝑁
To Summarize:
Forces Involved in the drive:
Pinion: PPP = 10000N, Pn = 10641.77N, Pr = 3639.7N, Pd = 1422.8N
Gear: P = 5000N, Pn = 5320.88N, Pr = 1819.85N, Pd = 711.4N