Spur Gear For I P

DME Spur Gear DME Spur Gear
0
Spur gear 6. A pair of straight teeth spur gears, having 20 involutes full depth teeth is
to transmit 12 kW at 300 rpm of the pinion. The speed ration is 3 : 1. The
1. Derive Lewis equation for strength of gear teeth and state the assumptions
allowable static stress for a gear of CI and pinion of steel are 60 MPa and
made
105 MPa respectively. Assume number of teeth of pinion = 16 ; face width
2. Differentiate between spur and helical gears .
3. A pair of carefully cut gears with 200 FDI profile is used to transmit 12 kW = 14 times the module ; velocity
= , v being the pitch line
.
.

at 1200 rpm of pinion. The gear has to rotate at 300 rpm. The material velocity in m/s and tooth form factor = 0.154 − . design
.
used for both pinion and gear is medium carbon steel whose allowable the spur gear and check the gear for wear given = 600 , =
202 ⁄ , = 100 ⁄ .
bending stresses may be taken as 230 MPa. Determine the module and
(Dec 2011)( Marks 20)
m
face width of spur pinion and gear. Check the pair for wear strength
o
against dynamic load. Take 24 teeth on pinion. Assume modulus of
. c
elasticity as 202 GPa. (Dec.09/Jan. 10)( Marks 15) 7. A air compressor is driven by a 20 kW, 1200 rpm motor, trough a pair of
T

14 involute spur gears. The speed of the compressor is 300 rpm and the
E

4. A spur pinion of cast steel = 140 ⁄ is to drive a spur gear of centre distance is approximately 400 rpm. The pinion is to be of cast steel,
N

cast Iron = 55 ⁄ . The transmission ratio is to be 2 ti 1. The heat treated and the gear is of CI, grade 35. Assume the gears are
A

L
subjected to medium shock and working 8 – 10 hrs/ day. Design the gears
diameter of the pinion is to be 105 mm & the teeth are full depth involutes
P
and check the design for wear load. (Dec. 2010)( Marks 14)
form. Design for the greatest number of teeth. Determine the necessary
U
module and face width of the gears for strength only. Power to be
T
transmitted is 20 kW at 900 rpm of the pinion. (Dec.08/Jan. 09)( Marks 15)
8. A gear drive is required to transmitted a maximum power of 2.25 kW. The
.V
velocity ratio is 1 :2 and speed of the pinion is 200 rpm. The approximate
w
center distance between the shafts may be taken as 600 mm. the teeth has
5. A pair of spur gears has to transmit 20 kW from a shaft rotating at 1000
200 stub involutes profile. The static stress for the gear material ( which is
w
rpm to a parallel shaft which is to rotate at 310 rpm. Number of teeth on
CI) may be taken as 60 MPa and face width as 10 times the module. Design
pinion is 31 with 200 full depth involute tooth form. The material for pinion
w
the spur gear and check dynamic and wear loads. The deformation or
is steel C40 untreated with allowable static stress 207 MPa and the
dynamic factor. May be taken as 80 and the material combination factor
material for gear is cast steel 0.20% C untreated with allowable static stress
for wear as 1.4. (June / July2011)( Marks 15)
138.3 MPa. Determine the module and face width of the gear pair. Also
find dynamic tooth load on the gears. Take the service factor as 1.5 and
check the wear resistance of the gear. (May/June 2010)( Marks 20)
IP Dept, AIT, Ckm. PRASHANTH N, 9964676521 1 IP Dept, AIT, Ckm. PRASHANTH N, 9964676521 2
Design procedure for spur gear For the given pressure angle and tooth form, the number of teeth on gears &
lewis form factor ‘y’ for pinion and gear can be obtained by using the following
Step 1:- Selection of materials for gear & pinion Ref(T12.7)(P 186)
formulas,
Case (i). Same material for pinion & gear.
0.684 1
= 0.124 − 14
. ( − 12.17)( − 163)
Such as cast steel 0.2 % C steel untreated = 138.3 ⁄ , or steel 2
C 40 untreated = 207 ⁄ 0.912
= 0.154 − 20
. ( − 12.17)( − 163)

Case (ii). Two different material for pinion & gear
0.95
= 0.175 − 20 ℎ . ( − 12.17)( − 163)

m
Note:- It is to noted that while selecting different materials for gear and
o
pinion, the material selected for pinion must be stronger than the material Note:- if teeth are unknown, it is advisable to select minimum 16 teeth on
. c
selected for gear in other words the material selected for pinion should posses pinion.
higher value of allowable static stress compared to that of gear.
T
Since the load carrying capacity of the tooth is a function of the product .
E
The gear where value of is less is the weaker member.
Step 2:- Identifying the weaker member of gears pair.
N
i.e., if < , .
LA
(i). When gear and pinion are made of same material, pinion is weaker member if < , .
P
and the design is based on pinion.
U
Design should be based on weaker member.
(ii). When gear and pinion are made of different materials, the strength factor
T
is computed as shown and the member with smaller value of is
.V
taken as the weaker member and the design is based on that member. Step 3 :- (i) Tangential tooth load
w
Calculation of module (m) of gears.
w
To decide the weaker member among the two, the following table has to be 1000 × ×
= … … 12.20 ( )
w
formulated.
Particulars Remarks Where, P = Power in kW.

=
12.8 − 187
Pinion
gear
From table (T 12.7)(P-186) obtain the allowable static stress & for the [ 1.25 1.5 ! ]

= ℎ
", ⁄
given material.
, ⁄ (∴ ! = # )

= = Governing equation of module

Case (i) when diameter of gear & pinion are known or the center distance B/w
(ii) Tangential tooth load from lewis equation:
gears is known
= " $ … … 12.15( 163 )
In the modified lewis equation used to calculate module
Where, = " ℎ " 12.7
= % " $
b = face width 9.5m ≤ b ≤ 12.5 m … … 12.18( 164 )

i.e., = … … 12.15 163
y = Lewis form factor of the weaker member … … 12.5( 184 ) ! " #
m
( = ( $ )
$ = % =
o

1000 × ×
c
= … … 12.20 − 164
.
= & [ ' ℎ ]
T " ! !

≤ 8 ⁄ … … 12.19 ( 164 )
E
.
=
N
. Since diameter are known, velocity ‘v’ and hence , can be computed based on
LA
velocity range.

≤ 13 ⁄ … … 12.19 "( 164 )
.
= ‘y’, the lewis form factor is retained as ‘y’ since the number of teeth are
P
.
unknown.
=
.
.

≤ 6 ⁄ 20 ⁄ … … 12.19 ( 164 )
T U Note:- when diameter of gears are known, the designer is to compute the
V
number of teeth ‘Z’ on gear & hence ‘y’ is retained as ‘y’.
.

over 20 ⁄ … … 12.19 !( 164 )
After substitution in lewis equation, we obtain
w
.
=
.
] " = [ )
]
w
Note:- Since is based on velocity ‘v’ which in turn depends on diameter ‘d’.
w
And this equation is taken as the governing equation.
Its value can be calculated only if diameter is known.
If diameter is unknown is unknown, velocity ‘v’ and hence in the equation of

module.
Cases (ii) Diameter of gears are unknown Trails to find ‘m’
In the modified lewis equation used to calculate module Note:- Continue the trails with increasing or decreasing values of standard
= % " $
module till the quantity LHS equals the numerical values of the RHS of governing
equation of module or less than the numerical values of the RHS of equation.

i.e., = … … 12.15 163
! " #
( = ( $ ) Dimensions

1000 × ×
= … … 12.20 − 164 Calculate all important geometric parameter of tooth profile by using the
m

equations given in Table (T 12.4)( P 183)
! ( ! = *)
o

.c
Properties of involutes teeth

Therefore, " . ., = ⋯ … … … …
T
Tooth 1଴ ଴

20

20଴
ℎ

.
E
14
! " ( 12.7)( 186) Characteristics 2
N
1
ℎ
ℎℎ !$!

20 20
Pressure

LA
angle 14
2
′
" $ ! ! . Addendum ℎ m m 0.8 m
P
Dedendum ℎ 1.57 m 1.57 m m
ℎ ! ℎ ! + .
U
Thickness of
t 1.571 m 1.571 m 1.571 m
b = face width is taken as 9.5m ≤ b ≤ 12.5 m … 12.18( 164 )
the tooth
T
Teeth z
V
ℎ ! "
.
Pitch circle
d
diameter
" ℎ " ℎ .
w
Check for the stress
w
16 teeth on pinion with the substitution of the above values. Calculate the induced stress by the equation
w

$ = $ = … … 12.15( 163 )
After substitution in lewis equation, we obtain the controlling equation as
governing equation for module reduced to " $
] " = [ )

]
Calculate the allowable stress by the equation
Is used to determine ‘m’. the allowable module by selecting a standard %&&' = %&&'
preferred module table (T 12.2)(P 182) If $ < %&&' , then the design is satisfactory.
Checking for dynamic load From Table (T 12.16 & 12.17)
Acc to bucking ham’s equation Surface endurance limit
Dynamic load = +
( ! "
… … 12.33( 166 ) = 2.75 '2 − 70 … … 12.36 !( 167 )
( )! "
'2 = ' ℎ ! "
Where C = load factor, using table (T 12.12) the load factor C can obtained
Select core hardness no for given material and value of from Table (T-
If the class of gear is known then the error ‘e’ can be obtained from (T 12.13)(Fig 12.15)(P-192)
12.3)(P 205)
For safer design ' must be greater than , ≤ '
m
(Explained in detail in numerical example)
o
If ' > then make one or more following changes
. c
(i). calculate the dynamic load by decreasing the tooth error ‘e’
T
Endurance strength of the gear tooth
E
(ii). Decrease the module ‘m’
= " , … … 12.34( 166 )
N
(iii). Increase the face width ‘b’
Where , = % , = - ℎ ".
For safer design must be less than the allowable endurance strength <
L A
(iV). Increase the surface hardness.
Note:- Allowable static stress used in the lewis equation is 1.3 of ultimate
U P
T
stress and = 0.5 * .
.V
Check for wear load
w
Acc to bucking ham’s equation wear load
w
Where ratio factor / = =

w
' = ! " / … … 12.36 ( 167 )

… … 12.36 ( 167 )

+$ ∝
Load stress factor =
0 + 1 … … 12.36 "( 167 )
. , ,
BEAM STRENGTH OF SPUR GEAR TEETH OR LEWIS EQUATION beam of uniform strength. But since the tooth is larger than the parabola at every
The beam strength of gear teeth is determined from an equation known as lewis section except BC, it concludes BC is the critical section.
.
equation. The load carrying ability of the gears as determined by this equation The maximum value of bending stress at BC is given by, = . where
/
given satisfactory results. Lewis assumed that the load is being transmitted from
one gear to another; it is all given and taken by one tooth. When contact begins, = 3 "! ' = 3 ℎ
the load is assumed to be the end of the driven teeth and as contact ceases, it is at
the end of driving teeth. = , = ℎ ℎ
2
Consider each tooth as a cantilever beam loaded by a normal load as shown in "
4 = , " = !ℎ ℎ
m
below Figure. It is resolved into two components (i) tangential component ( ) 12
o
(ii) Radial component (- )
× 0 1
c

4
∴ = =
.
-

2 3 "
E T ∴ = × " ×

N
6 ℎ

LA
b Profile Since t and h are variables which depends upon the shape of tooth and circular

pitch, the quantity may be replaced by ‘p y’ where y is known as lewis form
P
Tangential to base circle
A
factor or tooth form factor. Therefore the final form of strength formula is
U
h
= " $ . This equation is called lewis equation or beam strength of tooth.
T
B C Parabola The value of ‘y’ for various tooth system are
V
t
.
0.684 1
= 0.124 − 14
. ( − 12.17)( − 163)
w
2
w
0.912
The tangential component induces a bending stress which tends to break the = 0.154 − 20
. ( − 12.17)( − 163)

w
tooth. The radial component - induces compressive stress of relatively small 0.95
= 0.175 − 20 ℎ . ( − 12.17)( − 163)
magnitude therefore its effect on the tooth may be neglected. Hence the bending
stress is used as the basis for design calculations.
The permissible stress in lewis equation depends upon materials, pitch line velocity and load
The critical section may be obtained by drawing a parabola through A and condition, according to Barth formula the permissible stress
= × , =
!
tangential to the curve at B and C. this parabola shown in dotted line outlines a
= " " ( − 12.7) 0
1. A pair of carefully cut gears with 20 FDI profile is used to transmit 12 kW
at 1200 rpm of pinion. The gear has to rotate at 300 rpm. The material

≤ 8 ⁄ … … 12.19 ( 164 )
3.05
=
3.05 +
used for both pinion and gear is medium carbon steel whose allowable
bending stresses may be taken as 230 MPa. Determine the module and

≤ 13 ⁄ … … 12.19 "( 164 )
.
= face width of spur pinion and gear. Check the pair for wear strength
.
against dynamic load. Take 24 teeth on pinion. Assume modulus of

≤ 6 ⁄ 20 ⁄ … … 12.19 ( 164 )
. elasticity as 202 GPa. (Dec.09/Jan. 10)( Marks 15)
=
.
=
.
.

over 20 ⁄ … … 12.19 !( 164 )
Data:
o m
∝ = 20 54 ; = 12 6 ; = 1200 $ ; = 300 $ ; =
= 230 ; * = 24 ℎ ; = = 202 ;

=

, ⁄ (∴ ! = # )
. c $ .
T
=

E
Therefore the final form of lewis equation for tangential tooth load in terms of Solution: Note: - Since the diameters are unknown, it is possible to design for
N
circular pitch = " $ smallest pitch diameter.
L A
Velocity ratio (i)
P
* !
= = =
* !
T U =
1200
.V
=4
300
∴ Velocity ratio = 4
w ∴ * = * = 4 × 24 = 96 ℎ
w
w
To determine ‘y’ the lewis form factor
For 200 FDI profile

0.912
= 0.154 − 20 4
.
#
− 12.17" − 163 ( + )
⁄
0.912
= ℎ
",
, = 0.154 −
#
% ! % # ⁄ ∴ ! = # ( + )
0.912
= = ,
= 0.154 −
60000 60000
% ! % # % × × 24 × 1200
24
= 0.116
= = =
60000 60000 60000
0.912
= 1.508 ⁄
, = 0.154 −
#
1000 × 12 × 1.5
∴ =
m
0.912
= 0.154 −
1.508
o
96 11936.34
= … … … + ()
c
= 0.1445
Identifying the weaker member
T .
Particulars
Pinion

230

0.116

26.68
Remarks
Weaker E
N = " $ … … 12.15( 163 ) ( + )
LA
gear 230 0.1445 33.235
Since < , ". = " $ (5 + )
Design should be based on Pinion (weaker member).
U P Where, = " ℎ $ = 230
T
Tangential tooth load b = face width 9.5m ≤ b ≤ 12.5 m … … 12.18 164
.V
× ×!
= … … 12.20 ( − 164 ) ( + ) Take face width, b = 10 m

w
1000 × × = Lewis form factor of the Pinion
= (5 + )
w

= 0.116
w ℎ, $ = %
Where, P = 12 kW= Power in kW.
=
12.8 − 187 = 230 × × 10 × × 0.116 × % ×
) ! ℎ ! 8 − 10 ℎ ! $ ! = 838.177 … … … + ()
= 1.5 ; $! = = 1200 $

= 6.032 ⁄
Equating equation (i) & (ii)
11936.34 & 7 ' ℎ 8
838.177 =

3.05
= (5 + )
= 14.241 … … … + ()

3.05 +

3.05
=
To find module ‘m’
3.05 + 6.032
Trial 1:- Let select ‘m = 3’
= 0.3358
&
= 1.508 = 1.508 × 3

= 4.524 ⁄
Now from equation ….. (iii)
o m
c
≥ 14.241 … … … + ()
.
& 7 ' ℎ 8

T
4 × 0.3358 = 14.241
≤ 8 ⁄ … … 12.19 ( 164 ) (
)
E
3.05
=
3.05 + 21.49 > 14.241 ∴ ".
=
3.05
(5 + )
N ∴ = 4
LA
3.05 +

∴ Face width ‘b’ b = 10 m = 10 x 4 = 40 mm.
P
3.05
=
U
11936.34 11936.34
∴ = =
3.05 + 4.524
= 2984.085

T
= 0.4027
4
.V
w
≥ 14.241 … … … + ()
w
Allowable stress by the equation
3 × 0.4027 = 14.241
%&&' = %&&' ( + )
w
10.873 < 14.241 ∴ ".
%&&' = 9 :
%&&'
(5 + )
%&&' = 230 × 0.3358

Trial 2:- Let select ‘m = 4’
%&&' = 77.234
&
= 1.508 = 1.508 × 4
Induced stress

= = … … 12.15( 163 ) (
) Checking for dynamic load

Acc to bucking ham’s equation

$ = $ = (5 + ) Dynamic load

" $
2984.085 +
$ = = + … … 12.33 166

40 × 0.116 × % × 4 + +
$ = 51.178 ;
9 " + :
= + 5 +
If $ < %&&' 51.178 < 77.234 , then the design is satisfactory. ;
+ <9 " + :
o m
c
From Table T(12.13) (P- 191) for carefully cut gears for m = 4 mm
.
Dimensions
T
Machining error, e= 0.0254 mm
E
Calculate all important geometric parameter of tooth profile by using the
From T(12.12) (P- 190) for e = 0.0254 mm = = 20 54 and steel pinion – steel
N
gear
A
L
343.3

P
Tooth C =?
200 FDI Error ‘e’ C 228.9 0.02 228.9
Characteristics
U
0.0254 C
Addendum ℎ% m 4 4 0.02 228.9
T
Dedendum ℎ 1.57 m 6.28 6.28 0.0254 ?
.V
0.03 343.3
Thickness 0.02 0.0254 0.03
t 1.571 m 6.284 6.284
of the tooth
w
No of
z 24 96 × 0.02 = 228.9 × 0.0254
w
Teeth
Pitch circle
w
228.9 × 0.0254
=
d mz 96 384
diameter
0.02
= 290
Where, = 2984.085 ; ; = 20.67 ;
= 6.032 ⁄ ;
C = 290 MPa; b = 40 mm;
20.67 × 6.032 × 290 × 40 + 2984.085 Check for wear load '
= 2984.085 +
20.67 × 6.032 + >290 × 40 + 2984.085 Acc to bucking ham’s equation wear load
' = ! " / … … 12.36 ( 167 ) +

1818364.72
= 2984.085 +
245.45
' = ! " / 5 +
= 2984.085 + 7408.29

= 10392.4 Where ratio factor / = = … … 12.36 ( 167 )

2 * 2 × 96
/=
m
=
* + * 96 + 24
Check for endurance strength?56
= " , … … 12.34 166

c o / = 1.6
= " , ! "

T .
From table (T-12.15)(P-192) for = 345 Core(BHN)=200
BHN ' ℎ ! "
In lewis equation the allowable bending stress is approximately of ultimate

N E
Surface endurance limit
A = 2.75 '2 − 70 … … 12.36 !( 167 )

stress.
∴ Ultimate stress of the pinion material* ,
* = 3 × = 3 × 230 = 690

P L = 2.75 × 200 − 70
U
= 480
T
Now endurance limit = 0.5 × * = 0.5 × 690 = 345 +$ ∝
Load stress factor = 0, + , 1 … … 12.36 "( 167 )
.V

.
Where, = 345 ; " = 40 ; , = % = % × 0.116 =

0.3644 ⁄ ; m = 4 mm. 480 20
w

1 1
= @ + A
2.02 × 10 2.02 × 10
w
1.4
= 345 × 40 × 0.3644 × 4
= 0.5573
= 20114.88
w
Since > 20114.88 > 10392.4 , the design will be satisfactory
i.e., ' = ! " / = 96 × 40 × 1.6 × 0.5573
' = 3424.05
from the point of wear or durability.
Since ' < 3424.05 < 10392.4 , the design will be unsatisfactory
For safer design 2. A pair of spur gears has to transmit 20 kW from a shaft rotating at 1000
' ≥
rpm to a parallel shaft which is to rotate at 310 rpm. Number of teeth
on pinion is 31 with 200 full depth involute tooth form. The material for
. . , ! " / ≥ pinion is steel C40 untreated with allowable static stress 207 MPa and
. . , 96 × 40 × 1.6 × the material for gear is cast steel 0.20% C untreated with allowable
≥ 10392.4 static stress 138.3 MPa. Determine the module and face width of the
gear pair. Also find dynamic tooth load on the gears. Take the service
∴ - ! ≥ 1.70
factor as 1.5 and check the wear resistance of the gear.
∝ 1
m
1 (May/June 2010)( Marks 20)
. . , @ + A ≥ 1.70

OR
o
1.4
c
20 From the Table (T 12.16)(P- 193) for
.
Data: ∝ = 20 54 ; = 20 6 ; = 1000 $ ; = 310 $ ; * =
1
. . , @

2.1 × 10 = = 20
T
31 ℎ ; = 1.5.
1.4
≥ 1.70
E
1
+ A ≥ 1.70
2.1 × 10 $ − 40 ! ;
N
Surface hardness no for pinion =
∴ ≥ 730658.72 − 0.20% ! ;
LA
400 BHN
∴ ≥ 854.8 From table (T-12.7)(P-186) allowable stress for
P
Surface hardness no for gear = 300
. . , 2.75 × '2 − 70 ≥ 854.8 $ − 40 !; = 207
U
BHN
. . , '2 ≥ 336
T
− 0.20% !; = 138.3
. V Solution: Note: - Since the diameters are unknown, it is possible to design for
w
Hence suggested average surface hardness for the gear pair ≥ 350 '2 smallest pitch diameter.
w
Hence if the average surface hardness of the gear pair is more than 350 BHN, Velocity ratio (i)
w
then the design will be satisfactory from the stand point of durability or wear * !
= = =
* !
also.
1000
= = 3.2258
310
∴ Velocity ratio = 3.2258
IP Dept, AIT, Ckm. PRASHANTH N, 9964676521 23 Mech Dept,AIT, Ckm Prashanth N, 9964676521 24
∴ * = * = 3.2258 × 31 = 100 ℎ Tangential tooth load
1000 × ×
= … … 12.20 ( − 164 ) (
)

1000 × ×
= (5 + )

0
For 20 FDI profile
0.912
= 0.154 − 20 54 .
#
=
12.8 − 187
− 12.17" − 163 ( + )
m
) ! ℎ ! 8 − 10 ℎ ! $ !
o
0.912
= 0.154 − = 1.5 ; $! = = 310 $
#
.c

= ℎ
", ⁄
ET
0.912
= 0.154 −
31 # $ # ⁄ ∴ $ = (
)
= ,
N
= 0.1246
=
60000 60000
A
% ! % # % × × 100 × 310
= 0.154 −
0.912

= =
L
=
# 60000 60000 60000
= 0.154 −
0.912
U P
= 1.623 ⁄
T
100 1000 × 20 × 1.5
∴ =
= 0.14488
.V
1.623
18484.3
= … … … + ()
w

w

w
Particulars Remarks
Pinion 207 0.1246 25.8
Gear 138.3 0.14488 20.037 Weaker = " $ … … 12.15( 163 ) ( + )
= " $ (5 + )
Since < , ".
Where = " ℎ $ = 138.3
Design should be based on Gear (weaker member).
Mech Dept,AIT, Ckm Prashanth N, 9964676521 25 Mech Dept,AIT, Ckm Prashanth N, 9964676521 26
b = face width 9.5m ≤ b ≤ 12.5 m … … 12.18 164 = 0.3196
Take face width, b = 10 m Now from equation ….. (iii)
= Lewis form factor of the Pinion ≥ 29.36 … … … + ()
= 0.14488 4 × 0.3196 = 29.36
ℎ, $ = % 20.45 < 29.36 ∴ ".
= 138.3 × × 10 × × 0.14488 × % ×
m
= 629.48 … … … + () Trial 2:- Let select ‘ m = 5’
o
&
= 1.623 = 1.623 × 5
.c

= 8.115 ⁄
T
18484.3
629.48 =

E
& 7 ' ℎ 8
≥ 29.36 … … … + ()

A N =
4.58
4.58 +

≤ 13 ⁄ (5 + )
Trial 1:- Let select ‘ m = 4’
P L =
4.58
U
&
= 1.623 = 1.623 × 4
4.58 + 8.115
T
= 0.36077

= 6.492 ⁄
& 7 ' ℎ 8
.V
w
= 29.36 … … … + ()

≤ 8 ⁄
3.05
=
3.05 +
w 5 × 0.36077 = 29.36
=
3.05 w
… … 12.19 ( 164 ) ( + )
(5 + )
45.096 > 29326 ∴ ".
∴ = 5
3.05 +

3.05
= 18484.3 18484.3
3.05 + 6.492 ∴ = = = 3696.86
5

$ = $ = (5 + )
Dimensions
" $
3696.86
equations given in Table (T 12.4)( P 183) $ =
50 × 0.14488 × % × 5
$ = 32.49
Tooth
Characteristics
200 FDI If $ < %&&' 32.49 < 50 , then the design is satisfactory.
Addendum ℎ% m 5 5
m
Dedendum ℎ 1.57 m 7.85 7.85
Checking for dynamic load
o
Thickness
t 1.571 m 7.855 7.855
c
of the tooth
.
No of
z 31 100
T
Teeth Dynamic load
E
Pitch circle
d mz 155 500 +
= + … … 12.33 166

N
diameter
+ +
LA
;
9 " + :
= + 5 +
%&&' = %&&' ( + )

U P ;
+ <9 " + :
T
V
%&&' = 9 : (5 + )
.
%&&' Machining error, e= 0.0277 mm
w
%&&' = 138.3 × 0.361 From T(12.12) (P- 190) for e = 0.0277 mm = = 20 54 and steel pinion –
w
%&&' = 50 steel gear
w
343.3
induced stress
C =?
Error ‘e’ C 228.9
$ = $ =
0.02 228.9

" $ 0.02 228.9 0.0277 C
… … 12.15( 163 ) ( + )

0.0254 ?
0.03 343.3
0.02 0.0277 0.03
× 0.02 = 228.9 × 0.0277 = 23610.9
228.9 × 0.0277 Since > 23610.9 > 14357.86 , the
=
design will be
0.02 satisfactory from the point of wear or durability.
= 317
Where, = 3696.86 ; ; = 20.67 ;
= 8.115 ⁄ ;
Check for wear load
C = 317 MPa; b = 50 mm; Acc to bucking ham’s equation wear load
20.67 × 8.115 × 317 × 50 + 3696.86
= 3696.86 + ' = ! " / … … 12.36 ( 167 ) +
20.67 × 8.115 + >317 × 50 + 3696.86
o m
' = ! " / 5 +
. c
3278732.633
= 3696.86 + Where ratio factor
T
307.55
E
= 3696.86 + 10660.8 / =
2 !
=
2 *
… … 12.36 ( 167 )
! + ! * + *
N
= 14357.66
A
2 * 2 × 100
Check for endurance strength?56 /=
L
=
* + * 100 + 31
P
= " , … … 12.34 166
/ = 1.527
= " , ! "
T U From table (T-12.15)(P-192) for = 207.5

BHN ' ℎ ! "
Core (BHN) = 120
.V


w
stress. From table (T-1.1)(P-7) for carbon steel
∴ ultimate stress of the pinion material, * = 3 × = 3 × 138.3 = Young’s modulus = = = 202 = 202 × 10
w
w
415 Surface endurance limit
Now endurance limit = 0.5 × * = 0.5 × 690 = 207.5 = 2.75 '2 − 70 … … 12.36 !( 167 )
Where, = 207.5 ; " = 50 ; , = % = % × 0.14488 = = 2.75 × 120 − 70

0.45515 ⁄ ; m = 5 mm.
= 260
= 207.5 × 50 × 0.45515 × 5
Load stress factor

∝ 1 1 Hence suggested average surface hardness for the gear pair ≥ 282.86 '2
= @ + A … … 12.36 "( 167 )
1.4
Hence if the average surface hardness of the gear pair is more than 282.86
260 20 1 1 BHN, then the design will be satisfactory from the stand point of wear or
= @
+ A
1.4 2.02 × 10 2.02 × 10 durability also.
= 0.1635
i.e., ' = ! " / = 155 × 50 × 1.527 × 0.1635
' = 1934.9
Since ' < 1934.9 < 14348 , the design will be unsatisfactory
o m
c
For safer design
T .
E
' ≥
. . , ! " / ≥
155 × 50 × 1.527 × ≥ 14348
A N
∴ - ! ≥ 1.212 OR
P L
. . ,
∝ 1 1
@ + A ≥ 1.212

From the Table (T 12.16)(P-
193) for = = 20
T U
.V
1.4
20 1 ≥ 1.212
. . , @
1.4 2.02 × 10
w
w
1 Surface hardness no for pinion
+ A ≥ 1.212
2.02 × 10 = 350 BHN
∴ ≥ 501072.24
∴ ≥ 707.9
w
Surface hardness no for gear =
250 BHN
. . , 2.75 × '2 − 70 ≥ 707.9

. . , '2 ≥ 282.86
0
3. A pair of straight teeth spur gears, having 20 involutes full depth teeth ∴ * = * = 3 × 16 = 48 ℎ
is to transmit 12 kW at 300 rpm of the pinion. The speed ration is 3 : 1.
The allowable static stress for a gear of CI and pinion of steel are 60
MPa and 105 MPa respectively. Assume number of teeth of pinion = 16 For 200 FDI profile
.
; face width = 14 times the module ; velocity
= , v being the 0.912
. = 0.154 − 20 4
.
pitch line velocity in m/s and tooth form factor = 0.154 − #
.

. design the spur gear and check the gear for wear given − 12.17" − 163 ( + )
.
= 600 , = 202 ⁄ , = 100 ⁄ . 0.912
, = 0.154 −
m
(Dec 2011)( Marks 15) #
c o = 0.154 −
0.912
Data:∝ = 20 54 ; = 12 6 ; = 300 $ ; = 3.1 ;

T . = 0.097
16
= 105 ; = 60 ; * = 16 ℎ ; = 202 ;
N E , = 0.154 −
0.912
#

LA
= 100 ; " = 14; = 600 ;
0.912
= 0.154 −
P
; = 0.154 − .
4.58 0.912
=
. ℎ
48
4.58 +
T U = 0.135
Solution: Note: - Since the diameters are unknown, it is possible to
. V
w
design for smallest pitch diameter. Identifying the weaker member

w
Velocity ratio (i) Particulars Remarks
Pinion 105 0.097 10.185
w
* !
= = = gear 60 0.135 8.1 Weaker
* !
3 =
300 Since < , ".

Design should be based on Pinion (weaker member).
∴ = 100
= " $ … … 12.15( 163 ) ( + )
Tangential tooth load = " $ (5 + )
Where, = " ℎ $ = 60

=
× ×! Given face width, b = 14 m
… … 12.20 ( − 164 ) ( + )

= Lewis form factor of the Pinion
1000 × ×
= (5 + ) = 0.135

m
ℎ, $ = %
o
= 60 × × 14 × × 0.135 × % ×
c
=
12.8 − 187
) ! ℎ ! 8 − 10 ℎ ! $ !
T . = 356.26 … … … + ()
= 1.5 ; $! = = $

= ℎ
", ⁄
N EEquating equation (i) & (ii)
A

71713.15
356.26 =

L
% ! % #

= ,
P
= = 201.3 … … … + ()
60000 60000
⁄ ∴ ! = # ( + )
U

=
% ! % #
=
% × × 48 × 100
T
.V
= Trial 1:- Let select ‘m =5’
60000 60000 60000
&
= 0.251 = 0.251 × 5

= 0.251 ⁄
w
= 1.255 ⁄
w
1000 × 12 × 1.5
∴ =
& 7 ' ℎ 8
w
0.251
71713.15
= … … … + ()
4.58
=
4.58 +
≤ 8 ⁄ … … 12.19 ( 164 ) (
)
4.58
= (5 + )
(ii) Tangential tooth load from lewis equation: 4.58 +
4.58 &
= 0.251 = 0.251 × 7
=

= 1.757 ⁄
4.58 + 1.255
= 0.7849
& 7 ' ℎ 8
4.58
= (5 + )
≥ 201.3 … … … + ()

4.58 +
5 × 0.7849 = 201.3 4.58

=
4.58 + 1.757
88.5625 < 201.3 ∴ ".
m
= 0.6345
c o
.
Trial 2:- Let select ‘m =6’
T
≥ 201.3 … … … + ()
&
= 0.251 = 0.251 × 6

= 1.506 ⁄
N E 7 × 0.6345 = 201.3
217.63 > 201.3 ∴ ".
LA
& 7 ' ℎ 8

∴ = 7
P
4.58
= (5 + )
4.58 +
U
∴ Face width ‘b’ b = 14 m = 14 x7 = 98 mm.
T
4.58 71713.15 71713.15
= ∴ = =
V
= 10244.74

.
4.58 + 1.506 7
= 0.67
w
w
Now from equation ….. (iii) Check for the stress
w
≥ 201.3 … … … + () Allowable stress by the equation
6 × 0.67 = 201.3 %&&' = %&&' ( + )
144.72 < 201.3 ∴ ". %&&' = 9 : (5 + )
%&&'
∴ = %&&' = 60 × 0.6345

Trial 3:- Let select ‘m =7’ %&&' = 38.07
Induced stress Checking for dynamic load

= = … … 12.15( 163 ) (
) Acc to bucking ham’s equation

Dynamic load

$ = $ = (5 + )
" $
+
10244.74 = + … … 12.33 166

$ = + +
98 × 0.135 × % × 7
;
9 " + :
$ = 35.212 = + 5 +
If $ < %&&' 35.212 < 38.07 , then the design is
o m
;
+ <9 " + :
. c
satisfactory.
E T
Machining error, e= 0.0353mm
N
From T(12.12) (P- 190) for e =0.0353 mm = = 20 54 and steel pinion –
Dimensions
A
Calculate all important geometric parameter of tooth profile by using the C I gear
L

U P 314.6
T
C =?
Tooth
200 FDI Error ‘e’ C 235.9
.V
0.03 235.9
Characteristics
0.03 235.9 0.0353 C
Addendum ℎ% m 7 7
w
0.0353 ?
Dedendum ℎ 1.57 m 10.99 10.99
0.04 314.6
w
Thickness 0.03 0.0353 0.04
of the t 1.571 m 10.997 10.997
w
tooth
No of × 0.03 = 235.9 × 0.0353
z 16 48
Teeth 235.9 × 0.0353
Pitch circle =
d mz 48 144 0.03
diameter
= 277.57
Where, = 10244.74 ; ; = 20.67 ;
= 1.757 ⁄ ;
C = 277.57 MPa; b = 98 mm; Check for wear load '
20.67 × 1.757 × 277.57 × 98 + 10244.74
= 10244.74 +
20.67 × 1.757 + >277.57 × 98 + 10244.74 '
1359955.3 = ! " / … … 12.36 ( 167 ) +
= 10244.74 +
229.83 ' = ! " / 5 +
= 10244.74 + 5917.22
Where ratio factor
= 16162 / =

=

… … 12.36 ( 167 )
m

o
2 * 2 × 48
/=
c
= " , … … 12.34 166

=
* + * 48 + 16
= " , ! "
T . / = 1.5
In lewis equation the allowable bending stress is approximately of

N ESurface endurance limit
= 2.75 '2 − 70 … … 12.36 !( 167 )
LA
ultimate stress.
∴ Ultimate stress of the pinion material* , = 600
* = 3 × = 3 × 60 = 180
U P 600 = 2.75 '2 − 70
T
Now endurance limit = 0.5 × * = 0.5 × 180 = 90 '2 = 243.64
= 90 ; " = 98 ; , = % = % × 0.135 =

. V
+$ ∝
Where, Load stress factor =
0 + 1 … … 12.36 "( 167 )

0.424 ⁄ ; m = 7 mm.
. , ,
w 600 20
w
1 1
= 90 × 98 × 0.424 × 7 = @
+ A
1.4 1 × 10 2.02 × 10
w
= 26177.76
Since > 26177.76 > 16162 , the design will be

= 1.315
! = # = × 16 = 7 × 16
satisfactory from the point of wear or durability.
! = 112
i.e., ' = ! " / = 112 × 98 × 1.5 × 1.315
' = 21650.16 4. A air compressor is driven by a 20 kW, 1200 rpm motor, trough a pair of

Since < ' 16162 < 21650.16 , the design will be 14

involute spur gears. The speed of the compressor is 300 rpm and
satisfactory from the point of wear or durability. the centre distance is approximately 400 rpm. The pinion is to be of
cast steel, heat treated and the gear is of CI, grade 35. Assume the
Hence suggested average surface hardness for the gear pair ≥ 250 '2
gears are subjected to medium shock and working 8 – 10 hrs/ day.
Hence if the average surface hardness of the gear pair is more than 250 Design the gears and check the design for wear load.
BHN, then the design will be satisfactory from the stand point of durability (Dec. 2010)( Marks 14)
or wear also.
Data:
m
From the Table (T 12.16)(P- 193) for = = 20
o
1
≥ 1.315 ∝ = 14 54 ; = 20 6 ; ! = 105 ; = 1200 $ ;
. c
2
= 300 $ ; = 400 ;
T
Surface hardness no for Steel - Pinion = 250 BHN
E
− ;
Surface hardness no for C I - Gear = 180 BHN
N
− 35 ;
LA
allowable stress for
P
− ! ; = 138.3
T U − ; = 56.4
. V
Solution: Velocity ratio (i)
* !
w
= = =
* !
w =

w =

1200
300
∴ & = 4
! + ! ! + ! ! 1 +
! , = =
=
2 2 2
Particulars Remarks
! 1 + 4 5 × !
400 = = ∴ ! = ! Pinion 138.3 0.0898 12.42
2 2
! = 160 Gear 56.4 0.11545 6.51138 Weaker
∴ ℎ ! ! = 160 Since < , ".
∴ ! = ! ; ! = 4 × 160 Design should be based on Gear (weaker member).
m
∴ ℎ ! ! = 640 Tangential tooth load
c o
1000 × ×
.
= … … 12.20 ( − 164 ) (
)

T
.
= 0.124 − 14 54 . 1000 × ×

E
= (5 + )
− 12.17 − 163 ( + )
N
LA
Temporarily Assume # = 20 ℎ Where, P = 20 kW= Power in kW.
# = 20 ℎ, ∴ # = 4 × # = 4 × 20 = 80 ℎ =

12.8 − 187
= 0.154 −

0.912
#

U P ) ! ℎ ! 8 − 10 ℎ ! $ !
T
= 1.5 ; $! = = 300 $
V
⁄
.

= ℎ
",
0.684
= 0.124 −
20
w
# $ # ⁄ ∴ $ = (
)
= 0.0898 = = ,
w
60000 60000
0.684 % ! % × 640 × 300
w
= 0.124 −
= =
# 60000 60000
0.684
= 10.053 ⁄
= 0.124 −
80
1000 × 20 × 1.5
= 0.11545 ∴ =
10.053
= 2984.2 … … … + ()
0.684 ×
= 0.124 −
!
= " $ … … 12.15( 163 ) ( + )
0.684 ×
= " $ (5 + ) = 0.124 −
640
Where = " ℎ $ = 55 = 0.124 − 1.06875 × 107
b = face width 9.5m ≤ b ≤ 12.5 m … … 12.18 164
Take face width, b = 10 m = 56.4 × 0.313 × 10 × × × % ×
m
ℎ, $ = % = 554.6 … … … + ()
&
= 10.053 ⁄
c o
.
& 7 ' ℎ 8
T
554.6 = 2984.2

≤ 13 ⁄
E ≥ 5.38 … … … + ()
4.58
=
N
4.58 +
LA
… … 12.19 ( 164 ) ( + )
P
4.58
= (5 + )
4.58 +
= 0.124 − 1.06875 × 107
=
4.58
T U = 0.124 − 1.06875 × 107 × 5
. V
4.58 + 10.053
= 0.11866
= 0.313
w
w
≥ 9.1956 … … … + ()
w
= 0.124 −
0.684
#

5 × 0.11866 ≥ 5.38
2.9665 < 5.38 ∴ ".
0.684
= 0.124 −
!
B C

Trial 2:- Let select ‘ m = 6’ Dimensions
= 0.124 − 1.06875 × 107 Calculate all important geometric parameter of tooth profile by using the
= 0.124 − 1.06875 × 107 × 6

= 0.11759
Now from equation ….. (iii) Tooth

200 FDI
Characteristics
≥ 9.1956 … … … + ()
m
6 × 0.11759 ≥ 5.38 Addendum ℎ% m 7 7
4.233 < 5.38 ∴ ".

o
Dedendum ℎ 1.57 m 11 11
. c
T
Trial 1:- Let select ‘ m = 7’ Thickness
t 2.571 m 18 18
E
of the tooth
= 0.124 − 1.06875 × 10 7
N
No of
= 0.124 − 1.06875 × 107 × 7 z 24 92
LA
Teeth
= 0.11652
Pitch circle
P
d mz 160 640
Now from equation ….. (iii) diameter
≥ 9.1956 … … … + ()
T U
V
7 × 0.11652 ≥ 5.38
.
5.7095 > 5.38 ∴ ".
w
∴ = 7
w
%&&' = %&&' ( + )
w
%&&' = 9 : (5 + )
%&&'
.
= 0.11652; = 0.124 − %&&' = 56.4 × 0.313

0.684 %&&' = 17.65

∴ 0.11652 = 0.124 −
#
induced stress 303.2
C =?

$ = $ =
Error ‘e’ C 227.4 0.03 227.4
" $ 0.03 227.4 0.0353 C
… … 12.15( 163 ) ( + ) 0.0353 ?
0.03 343.3 0.03 0.0353 0.04
$ = $ = (5 + )

" $
× 0.03 = 227.4 × 0.0353
2984.2
$ =
70 × 0.11652 × % × 7
m
227.4 × 0.0353
=
o
$ = 15.73
0.03
c
= 267.574
If $ < %&&' 15.73 < 17.65 , then the design is satisfactory.
T .
Where, = 2984.2 ; ; = 20.67 ;
= 10.053 ⁄ ;

N E C = 267.574 MPa; b = 70 mm;
20.67 × 10.053 × 267.574 × 70 + 2984.2
LA
Acc to bucking ham’s equation = 2984.2 +
20.67 × 10.053 + >267.574 × 70 + 2984.2
P
Dynamic load
U
4512150.67
+ = 2984.2 +
T
= + … … 12.33 166
355.15
+ +
= 2984.2 + 12705
= +
;
9 " + :
. V
5 + = 15689.2
;
+ <9 " + :
w
w Check for endurance strength?56
w
Machining error, e= 0.0353 mm = " , … … 12.34 166

= " , ! "

From T(12.12) (P- 190) for e = 0.0353 mm = = 14 54 and steel pinion – C

I - gear In lewis equation the allowable bending stress is approximately of ultimate

stress.
∴ ultimate stress of the pinion material, * = 3 × = 3 × 56.4 = From table (T-12.15)(P-192) for = 84.6 Core (BHN) = 160
169.2 BHN ' ℎ ! "
Now endurance limit = 0.5 × * = 0.5 × 169.2 = 84.6 From table (T-1.1)(P-7) for carbon steel & C I
Young’s modulus = 202 = 202 × 10
Where, = 82.5 ; " = 100 ; , = % = % × 0.123252 = = 100 = 100 × 10

0.3872 ⁄ ; m = 7 mm.
= 84.6 × 70 × 0.3872 × 7
= 2.75 '2 − 70 … … 12.36 !( 167 )
= 16051
o m = 2.75 × 160 − 70
.c
Since > 16051 > 15689.2 , the design will be satisfactory = 370
T
E
Load stress factor
N
∝ 1 1
= @ + A … … 12.36 "( 167 )
LA
1.4
Check for wear load 370 14.5
P
1 1
= @
+ A
1.00 × 10
U
Acc to bucking ham’s equation wear load 1.4 2.02 × 10
= 0.366
T
' = ! " / … … 12.36 ( 167 ) +
V
i.e., ' = ! " / = 160 × 70 × 1.6 × 0.366
.
' = ! " / 5 +
' = 6558.72
w
Where ratio factor
w
2 ! 2 * Since ' < 6558.72 < 15689.2 , the design will be
/ = = … … 12.36 ( 167 )
w
! + ! * + * unsatisfactory from the point of wear or durability.
2 ! 2 × 640
/= =
! + ! 640 + 160
/ = 1.6
For safer design 5. A spur pinion of cast steel = 140 ⁄
is to drive a spur gear

' ≥ of cast Iron = 55 ⁄ .
The transmission ratio is to be 2 to

1. The diameter of the pinion is to be 105 mm & the teeth are full depth
. . , ! " / ≥ OR
involutes form. Design for the greatest number of teeth. Determine the
160 × 70 × 1.6 × ≥ 15689.2 From the Table (T 12.16)(P- necessary module and face width of the gears for strength only. Power
∴ - ! 193) for = = 14.5 to be transmitted is 20 kW at 900 rpm of the pinion.
≥ 0.8755
≥ 0.8755 (Dec.08/Jan. 09)( Marks 15)
∝ 1 Data: assume tooth profile system = 20 54
m
1
. . , @ + A ≥ 0.8755
Surface hardness no for Steel -
∝ = 20 54 ; = 20 6 ; ! = 105 ; = 900 $ ;
o
1.4 Pinion = 250 BHN
c
% 14.5 − ;
.
1
. . , & Surface hardness no for C I -
T
1.4 2.02 × 10
− ;
1 Gear = 180 BHN
' ≥ 0.8755
E
+
1.00 × 10
N
allowable stress for
∴ ≥ 327438
A
− ; = 140
∴ ≥ 572
. . , 2.75 × '2 − 70 ≥ 572
P L − ; = 55
. . , '2 ≥ 233
U
Solution: Note: - the power to be transmitted the rpm of the pinion and pitch
T
diameter of pinion are also specified and therefore the tangential load to be
.V
transmitted at the pitch point from pinion to gear may be strained. Equating
this to beam strength of tooth, the required module may be calculated.
w While selecting a standard module, check that the number of teeth obtained
w
Hence suggested average surface hardness for the gear pair ≥ 250 '2 for these values of module for both pinion and gear. Should be whole no’s
w
using the information of the transmission ratio (ang velocity ratio)
Hence if the average surface hardness of the gear pair is more than 250
BHN, then the design will be satisfactory from the stand point of wear or Velocity ratio (i)
durability also. * !
= = =
* !
! 0.912
2.5 = = 0.154 −
! #
105 0.912
2.5 = = 0.154 −
! 80
∴ 5 ! = 262.5 ≈ 263 = 0.13576

=

Particulars Remarks
m
900
2.5 =
Pinion 140 0.1084 15.176
c o
.
105 Gear 55 0.13576 7.4668 Weaker
2.5 =
!
T
Since < , ".
E
∴ $! = 360 $
N
Design should be based on Gear (weaker member).
LA
P
Tangential tooth load
0
For 20 FDI profile 1000 × ×
U
= … … 12.20 ( − 164 ) (
)

T
0.912
= 0.154 − 20 54 .
# 1000 × ×
V
= (5 + )
.
− 12.17" − 163 ( + )
Temporarily Assume # = 20 ℎ

w Where, P = 20 kW= Power in kW.
w
# = 20 ℎ, ∴ # = 2.5 × # = 2.5 × 20 = 50 ℎ =
12.8 − 187
w
= 0.154 −
0.912
#

) ! ℎ ! 8 − 10 ℎ ! $ !
= 1.5 ; $! = = 360 $
0.912

= ℎ
", ⁄
= 0.154 −
20
# $ # ⁄ ∴ $ = (
)
= 0.1084 =
60000
=
60000
,
% ! % × 263 × 360 = Lewis form factor of the Pinion

= =
60000 60000
0.912

= 4.957 ⁄ = 0.154 −
#
1000 × 20 × 1.5
∴ =
0.912
= 0.154 −
!
B C
4.957

= 6052.05 … … … + ()
0.912 ×
= 0.154 −
!
m 0.912 ×
o
= 0.154 −
= " $ … … 12.15( 163 ) ( + )
.c
263
= 0.154 − 3.4677 × 107
= " $ (5 + )
Where = " ℎ $ = 55

E T
N
= 55 × 0.3809 × 10 × × × % ×
b = face width 9.5m ≤ b ≤ 12.5 m … … 12.18 164
Take face width, b = 10 m
L A = 658.148 … … … + ()
ℎ, $ = %
P
&
= 4.957 ⁄
T U 658.148 = 6052.05
.V
≥ 9.1956 … … … + ()
& 7 ' ℎ 8
w

≤ 8 ⁄
3.05
=
3.05 +
w
… … 12.19 ( 164 ) ( + )
w
= 0.154 − 3.4677 × 107
= 0.154 − 3.4677 × 107 × 5
3.05
= (5 + )
3.05 +

= 0.13666
3.05
=
3.05 + 4.957 Now from equation ….. (iii)
= 0.3809 ≥ 9.1956 … … … + ()
5 × 0.13666 ≥ 9.1956 # = 28 ℎ
3.4165 < 9.1956 ∴ ". # 28
∴ # = = = 12 ℎ
2.5 2.5
∴ = 10
= 0.154 − 3.4677 × 107
= 0.154 − 3.4677 × 107 × 6
Dimensions
m
= 0.1332
o
c
.
≥ 9.1956 … … … + ()

6 × 0.1332 ≥ 9.1956
E T
4.795 < 9.1956 ∴ ".
A N
Tooth
L
Trial 3:- Let select ‘ m = 10’ 200 FDI
Characteristics
= 0.154 − 3.4677 × 107
= 0.154 − 3.4677 × 10 7
U P Addendum ℎ% m 10 10
T
× 10
Dedendum ℎ 1.57 m 15.7 15.7
.V
= 0.119323
Thickness
w
Now from equation ….. (iii) t 1.571 m 15.71 15.71
of the tooth
w
≥ 9.1956 … … … + () No of
z 12 28
w
Teeth
10 × 0.119323 ≥ 9.1956
11.9323 < 9.1956 ∴ ". Pitch circle
d mz 105 263
.

diameter
= 0.119323; = 0.154 −

0.912
∴ 0.119323 = 0.154 −
#
Check for the stress ;
9 " + :
= + 5 +
Allowable stress by the equation ;
+ <9 " + :
%&&' = %&&' ( + )
%&&' = 9 : (5 + )
%&&' Machining error, e= 0.0445 mm
%&&' = 55 × 0.3809 From T(12.12) (P- 190) for e = 0.0455 mm = = 20 54 and steel pinion – C I
%&&' = 21 - gear
m
induced stress
o
471.9
C =?

.c
$ = $ =
Error ‘e’ C 314.6 0.04 314.6
" $
ET
0.04 314.6 0.0445 C
… … 12.15( 163 ) ( + ) 0.0445 ?
N
0.03 343.3 0.04 0.0445 0.06
$ = $ = (5 + )
A
" $
× 0.04 = 314.6 × 0.0445
$ =
6052.05
100 × 0.119323 × % × 10
P L =
314.6 × 0.0445
$ = 16
U
0.04
T = 350
.V
If $ < %&&' 16 < 21 , then the design is satisfactory.
Where, = 6052.05 ; ; = 20.67 ;
= 4.957 ⁄ ;
w C = 350 MPa; b = 100 mm;
w
20.67 × 4.957 × 350 × 100 + 6052.05
w
Acc to bucking ham’s equation = 6052.05 +
20.67 × 4.957 + >350 × 100 + 6052.05
Dynamic load
4206241.9
= 6052.05 +
+ 305.07
= + … … 12.33 166

+ +
= 6052.05 + 13787.8
= 19839.85
Check for endurance strength?56 2 ! 2 × 263
/= =
! + ! 263 + 105
= " , … … 12.34 166

/ = 1.43
= " , ! "
From table (T-12.15)(P-192) for = 82.5 Core (BHN) = 160

BHN ' ℎ ! "
stress.
From table (T-1.1)(P-7) for carbon steel
∴ ultimate stress of the pinion material, * = 3 × = 3 × 55 =
Young’s modulus = 202 = 202 × 10
m
165
= 100 = 100 × 10
o
Now endurance limit = 0.5 × * = 0.5 × 165 = 82.5
. c
Where, = 82.5 ; " = 100 ; , = % = % × 0.119323 =
T

0.3746 ⁄ ; m = 10 mm. = 2.75 '2 − 70 … … 12.36 !( 167 )
= 82.5 × 100 × 0.3746 × 10
N E = 2.75 × 160 − 70

= 370
LA
= 30904.5
Since > 30904.5 > 19839.85 , the
P
design will be Load stress factor
∝ 1
U
satisfactory from the point of wear or durability. 1
= @ + A … … 12.36 "( 167 )

T
1.4
V
370 20
.
1 1
= @
+ A
1.00 × 10
w
1.4 2.02 × 10
Check for wear load
= 0.5
w i.e., ' = ! " / = 105 × 100 × 1.43 × 0.5
w
' = ! " / … … 12.36 ( 167 ) +
' = ! " / 5 +
' = 7507.5
Since ' < 7507.5 < 19839.85 , the design will be
Where ratio factor unsatisfactory from the point of wear or durability.
2 ! 2 *
/ = = … … 12.36 ( 167 )
! + ! * + *
DME Spur Gear
DME Spur Gear 6. A gear drive is required to transmit a maximum power of 22.5 kW. The
For safer design
velocity ratio is 2:1 and speed of the pinion is 200 rpm. The
' ≥ approximate center distance between the shafts may be taken as 600
mm. the tooth has 200 stub involutes profile. The static stress for the
. . , ! " / ≥
gears material (which is CI) may be taken as 60 MPa and face width as
105 × 100 × 1.43 × OR 10 times the module. Design the spur gear and check dynamic and wear
≥ 19839.85 loads. The deformation or dynamic factor May be taken as 80 and the
From the Table (T 12.16)(P-
∴ - ! ≥ 1.32 193) for = = 20
material combination factor for wear as 1.4.
(June / July2011)( Marks 15)
∝ 1 ≥ 1.32
m
1
. . , @ + A ≥ 1.32
Data:
o
1.4
Surface hardness no for Steel -
c
20 ∝ = 20 " 4 ; = 22.5 6 ; = 200 $ ; = 600 ;
.
1
. . , @
Pinion = 250 BHN
2.02 × 10
T
1.4 = 80 ; & −
Surface hardness no for C I -
E
1
A ≥ 1.32
allowable stress for & , = = 60
+
1.00 × 10 Gear = 180 BHN
∴ ≥ 361405.46
N
LA
Solution: Velocity ratio (i)
∴ ≥ 601 * !
= = =
P
. . , 2.75 × '2 − 70 ≥ 601 * !
. . , '2 ≥ 244
T U 2 =
200

. V =
200
w
2
w
∴ $! = 100 $
w
! + ! ! + ! ! 1 +
Hence suggested average surface hardness for the gear pair ≥ 282.86 '2 ! , = = =
2 2 2
! 1 + 2 3 × !
Hence if the average surface hardness of the gear pair is more than 282.86
BHN, then the design will be satisfactory from the stand point of wear or 600 = = ∴ ! = !
2 2
durability also.
! = 400
∴ ℎ ! ! = 400 Identifying the weaker member

∴ ! = ! ; ! = 2 × 400 Particulars Remarks
∴ ℎ ! ! = 800 Pinion 60 0.1275 7.65 Weaker
Gear 60 0.15125 9.075

To determine ‘y’ the lewis form factor Since < , ".
For 20 " profile Design should be based on Gear (weaker member).

m
0.95 1
= 0.175 − 14 54 .
Tangential tooth load
#
o
2
1000 × ×
= … … 12.20 ( − 164 ) (
)
c
− 12.17 − 163 ( + )
T . =
1000 × ×

(5 + )
Temporarily Assume # = 20 ℎ
# = 20 ℎ, ∴ # = 2 × # = 2 × 20 = 40 ℎ
N E
Where, P = 2.25 kW= Power in kW.
= 0.175 −

0.95

L A =
12.8 − 187
P
# ) ! ℎ ! 8 − 10 ℎ ! $ !
= 0.175 −
0.95
20
T U = 1.5 ; $! = = 100 $

= ℎ
", ⁄
.V

= 0.1275
# $ # ⁄ ∴ $ = (
)
w
= = ,
0.95
= 0.175 −
60000 60000
w
# % ! % × 800 × 100

= =
w
0.95 60000 60000
= 0.175 −
40
= 4.189 ⁄
= 0.15125 1000 × 22.5 × 1.5
∴ =
4.189
= 8056.8 … … … + ()
0.95 ×
= 0.175 −
!
= " $ … … 12.15( 163 ) ( + )
0.95 ×
= " $ (5 + ) = 0.175 −
400
Where = " ℎ $ = 60 = 0.175 − 2.375 × 107
b = face width 9.5m ≤ b ≤ 12.5 m … … 12.18 164
Take face width, b = 10 m = 60 × 0.4213 × 10 × × × % ×
ℎ, $ = % = 794.13 … … … + ()
&
= 4.189 ⁄
o m
.c
& 7 ' ℎ 8

794.13 = 8056.8
ET

≤ 8 ⁄ ≥ 10.145 … … … + ()
3.05
=
3.05 +
… … 12.19 ( 164 ) ( + )
A N
L
3.05 To find module ‘m’
= (5 + )
P
3.05 +
=
3.05
3.05 + 4.189
T U = 0.175 − 2.375 × 107
.V
= 0.175 − 2.375 × 107 × 5
= 0.4213
= 0.163
w
w
w
≥ 10.145 … … … + ()
0.95
= 0.175 − 5 × 0.163 ≥ 10.145
#
0.95 4.075 < 10.145 ∴ ".
= 0.175 −
!
B C

Trial 2:- Let select ‘ m = 8’ Dimensions
= 0.175 − 2.375 × 107 Calculate all important geometric parameter of tooth profile by using the
= 0.175 − 2.375 × 107 × 8

= 0.156
Now from equation ….. (iii) Properties of involutes teeth
≥ 10.145 … … … + () Tooth

200 Stub
Characteristics
7 × 0.156 ≥ 10.145
9.984 < 10.145 ∴ ". Addendum ℎ%
o m0.8 m 7 7
. c
Trial 3:- Let select ‘ m = 9’ Dedendum ℎ m 9 11
= 0.175 − 2.375 × 107

= 0.175 − 2.375 × 10
Thickness
E
of the toothTt 1.571 m 15 18
N
7
× 9
A
No of
= 0.1536 z 44 88
L
Teeth
P
Pitch circle
U
≥ 10.145 … … … + ()
d mz 400 800
diameter
9 × 0.1536 ≥ 10.145
T
12.44 > 10.145 ∴ ".
.V Check for the stress
∴ = 9
w
w
.

= 0.1536; = 0.175 − %&&' = %&&' ( + )
w

0.95 %&&' = 9 : (5 + )

∴ 0.1536 = 0.175 − %&&'
#
%&&' = 60 × 0.413
# = 46
%&&' = 24.78
20.67 × 4.189 × 80 × 90 + 8056.8

= 8056.8 +
Induced stress 20.67 × 4.189 + >80 × 90 + 8056.8
= 8056.8 +
1321034.9
$ = $ =
" $ 210.1
= 8056.8 + 6287.65
… … 12.15( 163 ) ( + )
= 14344.3
$ = $ = (5 + )
" $
m
8056.8
$ =
90 × 0.1536 × % × 9
o
= " , … … 12.34 166

.c
$ = 20.61
= " , ! "
ET
If $ < %&&' 20.61 < 24.78 , then the design is satisfactory.


N
stress.
A
∴ ultimate stress of the pinion material, * = 3 × = 3 × 60 =
P L 180
U
Dynamic load Now endurance limit = 0.5 × * = 0.5 × 180 = 90
T
+
= + … … 12.33 166
= 90 ; " = 90 ; , = % = % × 0.1536 =
.V
Where,
+ +
0.4825 ⁄ ; m = 9 mm.
w
;
9 " + : = 90 × 90 × 0.4825 × 9
= + 5 +
w
;
+ <9 " + : = 35177.8
w
The deformation or dynamic factor, = 80
Since > 35177.8 > 14344.3 , the
satisfactory from the point of wear or durability.
design will be
Where, = 8056.8 ; ; = 20.67 ;

= 4.189 ⁄ ;
C = 80 MPa; b = 90 mm;
DME Spur Gear
Check for wear load
' = ! " / … … 12.36 ( 167 ) +

' = ! " / 5 +
Where ratio factor
2 ! 2 *
/ = = … … 12.36 ( 167 )
! + ! * + *
m
2 ! 2 × 800
/=
o
=
! + ! 800 + 400
/ = 1.33
. c
= 1.4
ET
N
i.e., ' = ! " / = 400 × 90 × 1.33 × 1.4
' = 67183.2
L A
P
Since < ' 14344.3 < 67183.2
From the Table (T 12.16)(P- 193) for = = 20 "

T U
= 1.4
.V
w
w
Surface hardness no for C I - Pinion = 250 BHN
w
Surface hardness no for C I - Gear = 180 BHN
The design will be satisfactory from the point of wear or durability.
Mech Dept,AIT, Ckm Prashanth N, 9964676521 79

Spur Gear For I P

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Spur Gear For I P

Uploaded by

Copyright:

Available Formats

DME Spur Gear DME Spur Gear

Particulars Remarks Where, P = Power in kW.

T    "    !  !  

If diameter is unknown is unknown, velocity ‘v’ and hence  in the equation of

(   =  (   $   ) Dimensions

  ]  " = [ )    

Acc to bucking ham’s equation Surface endurance limit

For 200 FDI profile

N  =  " $ … …  12.15( 163 ) (  + )

Design should be based on Pinion (weaker member).

U P Where, =  "     ℎ $ = 230

Now from equation ….. (iii)

%&& ' = 230 × 0.3358

C = 290 MPa; b = 40 mm;

' = ! " /  … …  12.36 ( 167 )   + 

 =  " ,  … …  12.34 166    

 =  " ,  ! "   

A  = 2.75 '2 − 70 … …  12.36 !( 167 )

∴ Ultimate stress of the pinion material* ,

* = 3 × = 3 × 230 = 690

To find module ‘m’

Trial 1:- Let select ‘ m = 4’

Allowable stress by the equation

%&& ' =  %&& ' (  + )

… …  12.15( 163 ) (  + )

T U From table (T-12.15)(P-192) for  = 207.5

For safer design

. . , 2.75 × '2 − 70 ≥ 707.9

Data:∝ = 20 54 ; = 12 6 ;  = 300 $ ;  = 3.1 ;

= 105 ; = 60 ; * = 16 ℎ ;  = 202  ;

Solution: Note: - Since the diameters are unknown, it is possible to

Tangential tooth load   =  " $ (5 + )

Where, =  "     ℎ $ = 60

 = 1.5 ; $! =  = $

5 × 0.7849 = 201.3 4.58

6 × 0.67 = 201.3 %&& ' =  %&& ' (  + )

∴    =  %&& ' = 60 × 0.6345

Properties of involutes teeth

In lewis equation the allowable bending stress is approximately of

N ESurface endurance limit

 = 2.75 '2 − 70 … …  12.36 !( 167 )

∴ Ultimate stress of the pinion material* ,  = 600

U P 600 = 2.75 '2 − 70

 = 90 ; " = 98  ; , = % = % × 0.135 =

Since  >  26177.76  > 16162  , the design will be

T U      −   ; = 56.4

# = 20 ℎ, ∴ # = 4 × # = 4 × 20 = 80 ℎ  = 

  = 0.154 −

Trial 1:- Let select ‘ m = 5’

T U = 0.124 − 1.06875 × 107 × 5

= 0.124 − 1.06875 × 107 × 6

Now from equation ….. (iii) Tooth   

4.233 < 5.38 ∴    ".

0.684 %&& ' = 17.65

… …  12.15( 163 ) (  + ) 0.0353 ?

 0.03 343.3 0.03 0.0353 0.04

$ =  $ = (5 + )

Checking for dynamic load

Machining error, e= 0.0353 mm  =  " ,  … …  12.34 166    

 =  " ,  ! "   

Young’s modulus  = 202  = 202 × 10

Where,  = 82.5 ; " = 100  ; , = % = % × 0.123252 =  = 100  = 100 × 10

o m  = 2.75 × 160 − 70

T " ! !

If diameter is unknown is unknown, velocity ‘v’ and hence in the equation of

( = ( $ ) Dimensions

] " = [ )

N = " $ … … 12.15( 163 ) ( + )

U P Where, = " ℎ $ = 230

%&&' = 230 × 0.3358

' = ! " / … … 12.36 ( 167 ) +

= " , … … 12.34 166

= " , ! "

A = 2.75 '2 − 70 … … 12.36 !( 167 )

∴ Ultimate stress of the pinion material* ,

%&&' = %&&' ( + )

… … 12.15( 163 ) ( + )

T U From table (T-12.15)(P-192) for = 207.5

. . , 2.75 × '2 − 70 ≥ 707.9

Data:∝ = 20 54 ; = 12 6 ; = 300 $ ; = 3.1 ;

= 105 ; = 60 ; * = 16 ℎ ; = 202 ;

Tangential tooth load = " $ (5 + )

Where, = " ℎ $ = 60

= 1.5 ; $! = = $

5 × 0.7849 = 201.3 4.58

6 × 0.67 = 201.3 %&&' = %&&' ( + )

∴ = %&&' = 60 × 0.6345

= 2.75 '2 − 70 … … 12.36 !( 167 )

∴ Ultimate stress of the pinion material* , = 600

U P 600 = 2.75 '2 − 70

= 90 ; " = 98 ; , = % = % × 0.135 =

Since > 26177.76 > 16162 , the design will be

T U − ; = 56.4

# = 20 ℎ, ∴ # = 4 × # = 4 × 20 = 80 ℎ =

= 0.154 −

T U = 0.124 − 1.06875 × 107 × 5

= 0.124 − 1.06875 × 107 × 6

Now from equation ….. (iii) Tooth

4.233 < 5.38 ∴ ".

0.684 %&&' = 17.65

… … 12.15( 163 ) ( + ) 0.0353 ?

0.03 343.3 0.03 0.0353 0.04

$ = $ = (5 + )

Machining error, e= 0.0353 mm = " , … … 12.34 166

= " , ! "

Young’s modulus = 202 = 202 × 10

Where, = 82.5 ; " = 100 ; , = % = % × 0.123252 = = 100 = 100 × 10

o m = 2.75 × 160 − 70

∝ 1 Data: assume tooth profile system = 20 54

∴ 5 ! = 262.5 ≈ 263 = 0.13576

Temporarily Assume # = 20 ℎ

Where = " ℎ $ = 55

… … 12.15( 163 ) ( + ) 0.0445 ?

$ = $ = (5 + )

= 82.5 × 100 × 0.3746 × 10

N E = 2.75 × 160 − 70

Since > 30904.5 > 19839.85 , the

∴ ℎ ! ! = 400 Identifying the weaker member

= 0.175 −

… … 12.19 ( 164 ) ( + )

= 0.175 − 2.375 × 107 × 8

≥ 10.145 … … … + () Tooth

= 0.175 − 2.375 × 107

0.95 %&&' = 9 : (5 + )

20.67 × 4.189 × 80 × 90 + 8056.8

Check for endurance strength?56

Where, = 8056.8 ; ; = 20.67 ;

' = ! " / … … 12.36 ( 167 ) +

From the Table (T 12.16)(P- 193) for = = 20 "