2. DETAILED ANALTSIS FOR STAGE 2.

2.1 Gear contact ratio

Number of teeth of driven gear
Gear contact ratio = .
Number of teeth of driver gear

Driven – 78 teeth.
Driver - 26 teeth.
78 3
Gear ratio = 26 = 1

This is written as 3꞉1

2.2 ALLOWABLE BENDING LOAD.

In any pair of gears having unlike number of teeth, the gear which have fewer number of teeth
(i.e. pinion) will be the weaker, because the tendency toward undercutting of teeth becomes more
pronounced in gears as the number of teeth becomes smaller.

Consider each tooth as a cantilever beam loaded by a normal load (FT ) as shown in Fig. It is
resolved into two components i.e. tangential component (FT ) and radial component (FR ) acting
perpendicular and parallel to the center line of the tooth respectively. . The tangential component
(FT ) induces a bending stress which tends to break the tooth. The radial component (FR ) induces
a compressive stress of relatively small magnitude, therefore its effect on the tooth may be
neglected. Hence, the bending stress is used as the basis for design calculations.
Allowable bending load (FT ) =σw .b.𝜋.m.y

The value of y in terms of the number of teeth may be expressed as follows;

0.912
y = 0.154 - for 20° full depth involute system.
Z

Where z = 26; therefore

0.912
y = 0.154 - = 0.119.
26

But also;
σw = σo × CV
In order to get CV we must find first the pitch line velocity of the gear;
𝜋dN
Velocity = (m/s)
60
𝜋 × 0.052 × 300
= = 0.82 (m/s)
60

Since the pitch line velocity (v) is less than 12.5 m/s, therefore velocity factor CV is obtained
from;
3 3
CV = 3+v = 3+0.82 = 0.79

Consider the following table 2(i).

Taking σo as 105 N/mm2

Now; σw = 105N/mm2 × 0.79
= 82.53 N/mm2
b = 20mm and m = 2mm.
Therefore;
FT = 82.53 N/mm2 × 20mm × 𝜋 × 2 mm. × 0.119. = 1.23 KN.
Therefore allowable bending load is 1.23 KN.
2.3 DYNAMIC TOOTH LOAD
The dynamic loads on a gear are due to;
 Inaccuracies of tooth spacing
 Irregularities in tooth profiles, and
 Deflections of teeth under load.
A closer approximation to the actual conditions may be made by the use of equations based on
extensive series of tests, as follows:
FD = FT + FI .
21v +(b.c +FT )
Where; FI = .
21v+ √b.c +FT

c – A deformation or dynamic factor in N/mm

A deformation factor (C) depends upon the error in action between teeth, the class of cut of the
gears, the tooth form and the material of the gears.

K.𝑒
C= 1 1
+
EP EG

K = A factor depending upon the form of the teeth.

= 0.111, for 20° full depth involute system
Since the material of the pinion is the same as the gear then Ep is equal to EG hence the equation
becomes;
E.K.𝑒
C= .
2

From the table 2(ii) below young’s modulus of gray cast iron is 105 Gpa
Therefore;
1
C = 105 × 103 N/mm2 × 0.111 ×0.05mm × 2

C = 291.375N.mm
 Table 2(ii).

Where v is 0.82m/s, b is 20mm and FT is 1.23 KN, therefore

21v +(b.c +FT ) 21×0.82 +(0.02×0.291 +1.23 ×1000)

FI = = = 23.85N.
21v+ √b.c +FT 21×0.82 +√0.02×0.291 +1.23 ×1000

From; FD = FT +FI .
FD = 1.23 × 103 N + 23.85N
FD = 1253.85N
Dynamic tooth load is 1253.85N.
2.4 WEAR TOOTH LOAD.
The maximum load that gear teeth can carry, without premature wear, depends upon the radii of
curvature of the tooth profiles and on the elasticity and surface fatigue limits of the materials.
The maximum or the limiting load for satisfactory wear of gear teeth, is obtained by using the
following Buckingham equation, i.e.
FW = d.b.Q.K
Where Q is a ratio factor
2 ×V.R
Q = V.R +1 for external gears.

Since V.R is 3. Now;

2 ×3
Q= = 1.5
3+1

K = Load-stress factor (also known as material combination factor) in N/mm2

The load stress factor depends upon the maximum fatigue limit of compressive stress, the
pressure angle and the modulus of elasticity of the materials of the gears. According to
Buckingham, the load stress factor is given by the following relation:
(σes )2 sinϕ 1 1
K= (E + E )
1.4 P G
The values of surface endurance limit (σes ) are given in the table 2(iii)

Table 2(iii)

Since the material of gear and pinion is grey cast iron (σes ) is 630N/mm2.

Since the material of the pinion is the same as the gear then Ep is equal to EG hence the equation
becomes;
 2(σes )2 sinϕ 2(630)2 sin20
K= = 1.4×1O5×103 = 1.85N/mm2
1.4E

d =52mm and b = 20mm.

Therefore;
FW = 52mm × 20mm × 1.5 × 1.85N/mm2 = 2886N.
FW = 2886N.
Therefore wear tooth load is 2886N.

2.5 DETAILED CALCULATION OF ALL SHAFT.

2.5.1 INPUT SHAFT.
Material of the shaft is mild steel with permissible shear stress (τ𝑦 ) 56N/mm2.

Power input = 5.5 KW.

From; P = T. w
60.P
T = 2𝜋 . where N is 1000 rpm. Therefore;
N

60 ×5.5 × 103
T= = 52.52N.m
2𝜋 ×1000

Torque on input shaft is 52.52N.m

The diameter of the shaft will be determined from;
𝜋
T = 16 τ𝑦 .d3

3 16T 3 16×52.52
d = √𝜋.τ = √𝜋 ×56 × 106 = 16.84mm. ≈ 17mm.
𝑦

The diameter of shaft is 17mm.

Dimensions of the key for input shaft.

The type of key used will be rectangular key.
The width and thickness of the key are in given in standards derived from the diameter of the
given range of shaft diameter. Consider table 2(iv). Which shows the proportions of standard
parallel, tapered and gib head keys, according to IS: 2292 and 2293-1974 (Reaffirmed 1992).
Table 2(iv). Proportions of standard parallel, tapered and gib head keys.

From the table the shaft with diameter 12 up to 17 mm and including its key section will be 5mm
width and 5mm thickness.
Determining the length of the key
Since the shaft and the key have the same material. The length of key will be given as
Length of key = 1.571 × diameter of shaft.
LK = 1.571 × 17mm
LK = 26.71mm ≈ 27mm

To avoid crushing failure of the key

d d
T = (8 LK ). σc . 2. Where σc is the crushing stress developed in the key.

16.T 16×52.52
This gives σc = = (0.027) × = 107.69N/mm2.
LK . d2 (0.017)2
Note; The permissible crushing stress for the used key material is at least twice the permissible
shearing stress.

Permissible crushing stress of the material will be 2 × 56N/mm2 = 112 N/mm2.

Since the calculated crushing stress is less than allowable crushing stress our design is safe.

2.5.2 INTERMIDIATE SHAFT.

Note;
If we neglect the transmission loss, power at input and output shaft will remain the same as per
conservation of energy

Torque on intermediate shaft

60.P
T = 2𝜋 . N

N for intermediate shaft is 300 rpm

60 ×5.5 × 103
T= = 175.07 N.mm.
2𝜋 ×300

Torque for intermediate shaft is 175.07 N.mm.

The diameter of the intermediate shaft will be determined from;

𝜋
T = 16 τ𝑦 .d3

3 16T 3 16×175.07
d = √𝜋.τ = √𝜋 ×56 × 106 = 25.16mm. ≈ 26mm.
𝑦

The diameter of intermediate shaft is 26mm.

Dimensions of the key for intermediate shaft

From table 2(iv) the shaft with diameter 22 up to 30 mm and including its key section will be
8mm width and 7mm thickness.

Determining the length of the key for intermediate shaft

Since the shaft and the key have the same material. The length of key will be given as
Length of key = 1.571 × diameter of shaft.
LK = 1.571 × 26mm
LK = 40.84mm ≈ 41mm

To avoid crushing failure of the key

d d
T = (8 LK ). σc . 2.

16.T 16×175.07
This gives σc = = (0.041) × =101.06 N/mm2.
LK . d2 (0.026)2

Since the calculated crushing stress is less than allowable crushing stress our design is safe.

2.5.2 OUTPUT SHAFT.

Torque on intermediate shaft

60.P
T = 2𝜋 . N

N for output shaft is 100 rpm

60 ×5.5 × 103
T= 2𝜋 ×100
= 525.21 N.mm.

Torque for output shaft is 525.21 N.mm.

The diameter of the output shaft will be determined from;

𝜋
T = 16 τ𝑦 .d3

3 16T 3 16×525.21
d = √𝜋.τ = √𝜋 ×56 × 106 = 36.28mm. ≈ 37mm.
𝑦

The diameter of output shaft is 37mm.

Dimensions of the key for output shaft
From table 2(iv) the shaft with diameter 30 up to 38 mm and including its key section will be
10mm width and 8mm thickness.

Determining the length of the key for intermediate input shaft

Since the shaft and the key have the same material. The length of key will be given as
Length of key = 1.571 × diameter of shaft.
LK = 1.571 × 37mm
LK = 58 mm
To avoid crushing failure of the key
d d
T = (8 LK ). σc . 2.

16.T 16×525.21
This gives σc = = (0.058) × =105.83 N/mm2.
LK . d2 (0.037)2

Since the calculated crushing stress is less than allowable crushing stress our design is safe.

Summary
Shaft Diameter Key dimensions
(mm) Width (mm) Thickness (mm) Length (mm)
Input shaft 17 5 5 27
Intermediate shaft 26 8 7 41
Output shaft 37 10 8 58