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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?
F = Face width
DP = Diametrical pitch
V = Velocity in FPM
S = Safe stress per square inch of material
Y = Outline factor
Where,
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
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:
= tooth thickness on the pitch circle for ideal gearing (no backlash)
Backlash, measured on the pitch circle, due to operating center modifications is defined
by:
where:
= pressure angle
7. Where must be the formative number of teeth of bevel gears used? Why?
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
Now,
R B R sec p
2 R sec p
T sec p
TE = 2 RB / m = m
IS 8830(2007)
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.
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.
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
It is given that the materials used are hardened steel and chilled bronze.
Initial assumptions:
q=11
Vs = 3m/s
𝑘 × 𝑘𝑑 = 1
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
Assuming Vs = 3m/s
𝜇 = 0.035
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
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.
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
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