Professional Documents
Culture Documents
Systems
Exact velocity ratio Transmit large power Used for small centre
distances High efficiency Reliable service Compact layout
Require special tools and equipments to produce Improper cutting of teeth
produce vibration and noise Lubrication is must
TERMINOLOGIES USED IN GEARS
Driver pinion
Arc of recess: Portion of the path of contact from the pitch point
to the end of the engagement of a pair of teeth.
Line of Action
Center Distance
Module
Face width
1
Diameter d1 can be expressed in terms of center distance ‘a’ as
So induced bending stress < Design bending strength of the material
Design surface compressive strength [σc]
σc α HB or RC
Therefore,
σC = CB × HB N/cm2
= CR × RC N/cm2
CB and CR are constants depending on the material
and heat treatment.
Also the design compressive strength depends on load conditions.
Hence correction factor is introduced.
Kcl =
Where N – number of fatigue cycles the pinion teeth has undergone
in its life period of T hours.
n = factor of safety
Gear materials
Commonly used materials cast iron and steel
Non metallic materials Laminated fabric, Bakelite and mica (to reduce
noise)
Gear Failures
Teeth breakage: due to fatigue
Pitting: hard and smooth working surfaces of the teeth reduce the danger
of pitting
The common normal to the tooth profile at the point of contact should
always pass through a fixed point, in order to obtain a constant
velocity ratio.
They have teeth cut in the form of helix on their pitch cylinders. Teeth are not
parallel to the axis of rotation.
More than one pair of teeth are in engagement. Runs smoothly because of the
gradual engagement of teeth. Higher peripheral speeds are permissible in
helical gears.
Limitation: Axial thrust
By providing another helical gear of opposite hand, the axial thrust can be
balanced. They are called as double helical or herringbone gears.
Cos β = π mn / π m
Therefore,
Cos β = mn / m
Centre distance =
Forces acting on a Helical gear tooth
Design of Bevel Gear
Pitch cone: Imaginary cone that the surface of which contains the pitch lines of all
teeth in the bevel gear.
Cone center: The apex of the pitch cone is called cone center.
Cone distance: Length of the pitch cone element also called as pitch cone radius.
Pitch angle: Angle that the pitch line makes with the axis of the gear is called the
pitch angle.
Face angle: Angle subtended by the face of the tooth at the cone center.
Transverse module mt : It is based on the pitch circle diameter at the outer portion.
Average module mav : It is based on pitch circle diameter at the centers of the teeth.
When two identical gears are mounted on
shafts, that are intersecting at right angles,
then they are called as Miter gears.
In this case the pitch angle of the internal gear is more than 90°
and the apex point is on the backside of the teeth on the gear.
Skew bevel gear: When two straight bevel gears are mounted on
shafts, which are non parallel and non intersecting, then they are
called as skew bevel gears
Hypoid Bevel Gear
Worm
Higher speed
(Driver)
reduction and
more torque
at the output
is possible
through
worm drive.
Worm wheel
(Driven)
Worm always drives the worm wheel. It is a self locking drive. Reversible
direction of power transmission is not possible.
Consider a single start worm and a 20 teeth worm gear will reduce the
speed by the ratio of 20:1.
The gear ratio of a worm gear is
i=
If this speed reduction is achieved by spur gears, then a gear of 12 teeth (the
smallest size permissible) would have to be matched with a 240 tooth gear to
achieve the same ratio of 20:1.
Therefore according to the physical size of the 240 tooth gear to that of the 20
tooth gear, the worm arrangement is considerably smaller in volume.
Applications
Self-locking Worm Gear
The worm always acts as a driving gear and the spur gear as a driven gear- vice
versa is not possible. If you try to run it in opposite direction, it will lock
automatically.
A worm and gear will be self-locking depends on the lead angle, the pressure angle,
and the coefficient of friction;
If the tangent of the lead angle of the worm gear is less than the coefficient of
friction between the worm and the gear, then the worm gear train should be a self-
locking type.
Seizure and wear are the two major failures in worm gear drive.
Types:
Functions of bearings :
Disadvantages
Machine tool spindles automobile front and rear axles gear boxes
small size electric motors rope sheaves, crane hooks and hoisting drums
Single row Angular Contact Ball Bearing
STIBECK’S EQUATION
The minimum life in this definition is the L10 life, which 90% of the
bearings will reach or exceed before fatigue failure.
Equivalent bearing load [P]:
The equivalent dynamic load is defined as the constant radial load in radial
bearings (or thrust load in thrust bearings), which if applied to the bearing would
give same life as that which the bearing will attain under actual condition of forces.
P = X .V. Fr + Y . Fa
Where
Fr radial load
Fa axial load
X and Y radial and thrust factors from manufacturer’s catalogues
V Race factor
Load factor in bearings:
Load factors are used in applications involving gear, chain and belt drives.
Lubricant film is relatively thin and there is partial metal to metal contact
Thin film bearings
The factor ZN / p is termed as bearing characteristic number and
is a dimensionless number
Between Q and R Partial metal to metal contact
(The viscosity (Z) or the speed (N) are so low, or the pressure ( p) is so
great that their combination ZN / p will reduce the film thickness)
On the other hand, when the value of ZN / p is less than K, then the oil
film will rupture and there is a metal to metal contact.
Critical pressure of the journal bearing
The pressure at which the oil film breaks down so that metal to
metal contact begins, is known as critical pressure or the
minimum operating pressure of the bearing.
Clutch is a mechanical device which
transmits power from the driving shaft to the
driven shaft when it is engaged and cuts the
power when it is disengaged.
Multiplate Clutch
Method of Analysis
The torque transmitted by a clutch is a function of
Geometry
Since the speed at which the engagement begins to take place is generally
taken as 3/4th of the running speed, therefore the inward force on each
shoe exerted by the spring is given by
Therefore, Net outward radial force (i.e. centrifugal force) with which the
shoe presses against the rim at the running speed
The frictional force acting tangentially on each shoe
According to
physical
condition
According to
method of
linking
Cemented
joints
Laced
joints
Hinged
joints
Open belt drives Cross belt drives
frictional force N
The motion of the belt and pulley assuming a firm frictional grip between the belts
and pulleys. Sometimes, the frictional grip becomes insufficient and may cause
forward motion of a pulley without carrying the belt. This is called slip of the belt.
When the belt passes from the slack side to the tight side, a certain portion
of the belt extends and it contracts again when the belt passes from the tight
side to slack side. Due to these changes of length, there is a relative motion
between the belt and the pulley surfaces. This relative motion is termed as
creep.
Classification of Belt Drives
Belt materials
Based on power
transmission
Leather
Light duty drives (Oak tanned or chrome tanned)
About 5 kW power, velocity up to 10m/s
Example: Pumps fabrics
(Canvas or woven cotton ducks)
rubber
medium duty drives
(Canvas or cotton duck
5 kW to 20 kW power, velocity up to 20
impregnated with rubber, For
m/s
greater tensile strength, the
Example: punch and printing
rubber belts are reinforced with
machinery
steel cords or nylon cords)
Based on cross
section
Flat belts
V belts ( single V belt, multiple V belt, ribbed belt)
Toothed or timing belt
Round belt
Power to be
transmitted
Space
Service availability for
conditions installation
Velocity ratio
Disadvantages: large space, belt slipping, exert heavy load on the shaft and bearings,
power loss due to friction, shorter life
Flat belt drive Applications
Packing Industry
Baggage Handling
Coal Industry
Applications of belt drives
The belt thickness can be built up with a number of layers. The number of layers is
known as ply.
Typical Belt drive specifications Material No. of ply and Thickness Maximum
belt stress per unit width Coefficient of friction of the belt material Density of
Belt material
Centrifugal Tension in the Belt
Where,
TC = Centrifugal tension
Pulleys are provided with a slight conical shape or convex shape in their
outer rim surface to prevent the belt from running off the pulley due to
centrifugal force. This is known as crowing of pulley.
Usually crowning height may be 1/96 th of the pulley width.
Sag in the belt drive
In horizontal belt drive, loose side is usually kept on the top. On the
upper side, the sag of the belt due to its own weight slightly increases the
arc of contact with the pulleys and increases the efficiency of the drive.
If the lower side is slack side, then sag will reduce the angle of contact
with the pulleys. This has to be avoided to gain the power transmission.
In case of vertical belt drive, due to gravitational force on the belt, it will
try to fall away from the lower surface of the lower pulley. This causes
slip and reduces the efficiency of the drive. To run such a drive, the belt
has to run with excessive tension with consequent increase in bearing
reactions and reduced belt life.
Timing belt or Ribbed belt
Timing belt has toothed shape in
their inner surface. Their
engagement with toothed pulley
will provide positive drive without
any belt slip where as in the case of
ordinary V – belts chances for slip
are more.
Round belts are limited to light duties dish washer drives, sewing
machines, vacuum cleaner, light duty textile machinery.
In order to prevent the belt from leaving the pulley, the width of the face of the
pulley should be greater or equal to 1.4 b, where b is width of belt.
when the reversible motion is desired, then a quarter turn belt drive with a guide
pulley, may be used.
Design of V – Belt Drive
In case of V – belt drive, power is transmitted by the wedging action between
the belt and the v – groove in the pulley or sheave.
When one of the set of belts break, the entire set should be replaced at the
same time. If only one belt is replaced, the new unworn and unstretched belt
will be more tightly stretched and will move with different velocity.
Forces acting on an element of V – Belt
The force components T, T+ dT and Centrifugal force are same as like flat
belt element. But the normal reaction which act on the sides of the V – belt.
Different failures in
belt drives
Design of Wire rope
Wire rope is a type of rope which consists of several strands of metal wire
twisted into a helix. Lighter in weight silent operation withstand shock
loads do not fail suddenly more reliable
Applications: Elevators - mine hoists – cranes – conveyors - hauling devices -
suspension bridges
Left-hand Lang's lay (RHLL) wire rope Right-hand Lang's lay (RHLL) wire rope
Strands are twisted into a left hand side Strands are twisted into a right hand side
When a large amount of power is to be transmitted over long distances from
one pulley to another (i.e. when the pulleys are upto 150 meters apart), then
wire ropes are used.
Parallel or lang lay ropes direction of twist of the wires in the strands is
same as that of strands in the rope
Composite or reverse laid ropes wires in the two adjacent strands are
twisted in the opposite direction
Wire rope
applications
Stresses in Wire Ropes
Direct stress due to axial load lifted and weight of the rope
Bending stress when the rope winds round the sheave or drum
The approximate value of the bending stress in the wire as proposed by Reuleaux
Equivalent bending load on the rope
Roller chain
Used for transmitting
power from one shaft to
another shaft
Types of roller chain
Silent chain
Inverted tooth chain – formed by laminated steel plates – each plate has two teeth
with space to accommodate tooth of the sprocket – for high speed applications –
silent operation
Breaking load: The maximum tensile
load which if applied will result in chain
failure is known as breaking load.
Chain sag: catenary effect
3
1. Drop lubrication