Q2)Two shaft at right angles in the same plane connected by gear train ,the input and output shaft

rotates at 1000rpm and 430 rpm resp.The power to be transmitted is 12 KN with a moderate shock
of 8-10 hrs operation. Design the gear comtletely and also mention the suitable hardness(Assume
the no of teeth on pinion is 20-25).The shafts are at right angle to each other( Bevel gear).

Ans:
Given :
N1=1000
N2=430
P=12 KN
Assume Z1=20 teeth

Step 1:

i=N1/N2
=1000/430 =2.32

i=Z2/Z1
Z2=i*Z1 =2.32*20 =47 teeth

Step 2:
Assume tooth profile is 14 1/2 full depth

Step 3:
Material Selection

For pinion = Forged steel 0.3% C(Heat treated)

σd =220 N/mm^2 BHN=200
For gear =Cast steel 0.2 C (Heat treated )
σd=193.2 N/mm^2 BHN=250

Step 4:
Pitch cone angle
For pinion
δ1=tan-1(1/i)
=23.31°
δ2=tan-1(i)
=66.68°

Step 5 :
Virtual no. Of teeth
Ze1 =Z1/cos(δ1)
=25/cos(23.3)
=21.77
Ze2 =Z2/cos(δ2)
=47/cos(66.68)
118.72

Lewis form factor:

y=0.124 – 0.684/Ze
y1 =0.124 – 0.684/21.77
=0.0925
y2=0.124 – 0684/66.68
=0.1137

Check for Strength

σdy(pinion)=220*0.0925
=20.35N
σdy(gear)=193.2*0.1137
=21.96N

From here we can say that pinion is weaker and needs to be designed

Design for Pinion:

Lamis Equation:

m^3=2Mt/(CvKyz1πσd) where k= z1/9 *√(1+i^2) k=5.61

m^3 Cv = 2Mt/(Kyz1πσd)

Mt=(9.55*106 *12)/10000*Cs
Cs=1.5
Mt=171900 N-mm

m^3(Cv)=47.92 (required value)

Assume value of Cv=0.5(0.4-0.7 for bevel gear)

Therefore m=4.57 mm

From T12.2
Std value of m=5 (Preffered I)

Pinion diameter
d1=m*Z1
=5*20
=100mm

Pitch line velocity

V=(d1*N1*π)/60
=5.23 m/s

Cv from Eqn 12.38 (a)

Cv=3.05 /(3.05+v)
=0.368

Therefore m^3(Cv)(adopted)=46
Here m^3(Cv)(adoptted)<m^3(Cv)(required)

Hence for safe design the value of m should increased

Take m=6 mm (T 12.2)

Therefore d1=6*20
=120mm

V=(120*1000*π)/60*1000
=6.28 m/s

Cv=3.05/(3.05+6.28)
=0.3269

m^3(Cv)(adopted)=6^3*0..3269
=70.61
Therefore
m^3(Cv)(adoptred)>m^3(Cv)(requirred)

b=mZ1/6 *√1 + i^2

=50.52mm 51mm(approx)

Dynamic load :

Fd=Ft + K3*V(Cb+Ft)/K3 *V +√ (Cb+Ft)

Ft=2Mt/d1
=2865 N
K3= 20.67
V=5.23
b=51
C from T12.13
For m=6 e=0.0652(Class I)
e=0.06 C=662
e=0.04 C=441.3
e=0.065 C=612.165

Fd=14176.3 N

Wear load

Fw=d1*b*Q*k/cos(δ1)

d1=100mm
b=43mm
Q=(2*118.72)/(118.72+21.77)
=1.69

Fw=7912.8 *k
=7912.8*0.902
=7137.39N
Here Fd>Fw, which is unsafe

For safe design:

Fw>=Fd

7912.8*k=14176.3

Therefore k= 1.78

From T12.16,we get

BHN (pinion)=400
BHN (gear)=350