Elements - II (Code : 302048) Semester VI - Mechanical Engineering (Savitribai Phule Pune University) Design of Machine [Strictly as per the New Credi Savitribai Phule Pune University w.e4. R. B. Patil MLE. (Mech) (Design Engg.) Professor, Department of Mechanical Engineering, ‘Army Institute of Technology, Pune. Maharashtra. “Tech. Maxricion.rne , hout” Engineering Division ‘ni PE249B il il i |Design of Machine Elements ~ IT RB. Patil ‘Scmester VI - Mechanical Engineering (Savitribai Phule Pune University) Copyright © by Tech-Max Publications. All rights reserved. No part of this publication may be reproduced, copied, or Stored in a retrieval system, distributed or transmitted in any form or by any means, including photocopy, recording, or other lectronic or mechanical methods, without the prior written permission of the publisher. ‘This book is sold subject to the condition that it shall not, by the way of trade or otherwise, be lent, resold, hired out, of otherwise circulated without the publisher's prior written consent in any form of binding or cover other than which itis ‘Published and without 2 similar condition including this condition being imposed on the subsequent purchaser and without limiting the rights under copyright reserved above. First Printed in India + January 2006 First Edition + January 2018 Second ‘Thoroughly Revised Edition : January 2019 This edition is for sale in India, Bangladesh, Bhutan, Maldives, Nepal, Pakistan, Sri Lanka and designated countries in ‘South-East Asia. Sale and purchase of this book outside of these countries is unauthorized by the publisher. Printed at: Image Offset, Dugane Ind. Area Survey No. 28/25, Dhayari Near Pari Company, Pune - 41, Maharashtra State, India. E-mail :rahulshahimage @ gmail.com ISBN 978-93-87235.48-9 Published by ‘Tech-Max Publications ‘Head Office : B/S, First floor, Maniratna Complex, Taware Colony, Aranyeshwar Comer, Pune - 411 009, Maharashtra State, India Ph : 91-20-24225065, 91-20-24217965, Fax 020-24228078. Email : info@techmaxbooks.com, Website : www tectimaxbooks.com [302048] (FID : 1P348/408) (Book Code : PE249B)~R.B. PatilPreface ‘It gives@ great pleasure to present this book on ‘Design of Machine Elements - 11’. This book has been written for the second course in ‘Machine Design’ especially forthe pre-final year students of mechanical engineering. This isthe second book of the series on ‘Machine Design’ which comprehensively covers the design concepts ‘and the design of various transmission elements. The main objective ofthis book isto bridge the gap between the reference books written by the renowned international authors and the requirements of undergraduate students The book has been presented in a simple language without compromising the qulity of text. The concepts have been developed from the fundamentals. The main eniphass has been ‘given on explaining the concepts rather ‘han merely providing the information. Every concep is illustrated with the help of numberof solved examples Which ae aanged inthe order of increasing degree of dificult, The ls of formulae has been given atthe end of each chapter forthe ready reference, This book is an outcome of the years of classroom interaction withthe smdents 1 would like to express my. thanks to the Publishers, Shri. Sachin Shah and Late Shri. Pradeep Lunawat of “Tech-Max Publications’ for their efforts in publishing this book. My thanks are also due to Mr. Prashant Patel andthe staff of “Tech-Max Publications’ for their untiring effort in bringing this book. Last but not least, my special thanks go to all my students whose continuous feedback while teaching this subject is the source of inspiration behind this book. ‘A feedback, in the form of suggestions and comments, from the readers for further improvement of this book will be highly appreciate. .Syllabus Savitribai Phule Pune University, Pune Third Year of Mechanical (2015 course) Course Code: 302048 Course Name : Design of Machine Flements ~ IL Teaching Scheme : Examination Scheme : ‘TH : - 04 Hrshweek : TH InSem:--30 End-Sem: 70 —FRi E02 Hn - TWi-25 OR: 25 Course Objectives : 1. Enable students to attain the basic knowledge required to understand, analyze, design and select machine elements required in transmission systems. Reinforce the philosophy that real engineering design problems are open-ended and challenging, [mpart design skills to the students to apply these skills forthe problems in real life industrial applications Inculcate an attitude of team work, critical thinking, communication, planning and scheduling through design projects. Create awareness amongst students about safety, ethical, legal, and other societal constraints in execution of their design projects 6. Develop an holistic design approach to frd out pragmatic solutions to realistic domestic and industrial problems. Course Outcomes : ‘The student should be able to~ €O 1 : To understand and apply principles of gear design to spur gears and industrial spur gear boxes. CO 2:: To become proficient in Design of Helical and Bevel Gear, CO 3 : To develop capability to analyse Rolling contact bearing and its selection from manufacturer's Catalogue. CO 4:: To learn a skill to design worm gear box for various industrial applications. COS : To inculcate an ability to design belt drives and selection of belt, rope and chain drives CO 6 : To achieve an expertise in design of Sliding contact bearing in industrial applications. Course Contents Unit: Spur Gears (08 hrs) Introduction to gears : Gear Selection, material selection, Basic modes of tooth failure, Gear Lubrication Methods. Spur Gears : Number of teeth and face width, Farce analysis, Beam strength (Lewis) equation, Velocity factor, Service factor, Load concentration factor, Effective load on gear, Wear strength (Buckingham’s) equation, Estimation of module based on beam and wear strength, Estimation of dynamic tooth load by velocity factor and Buckingham’s equation. (Refer Chapter 1) Unit I: Helical and Bevel Gears (08 hrs) ‘Types of helical and Bevel gears, Terminology, Virtual number of teeth and force analysis of Helical and Straight Bevel Gear, Design of Helical and Straight Bevel Gear based on Beam Strength, Wear strength and estimation of effective load based on Velocity factor (Barth factor) and Buckingham’s equation. Mountings of Bevel Gear. (No numerical on force analysis of helical & Bevel Gear). (Refer Chapters 2 and 3)Unit It: Rolling Contact Bearings (08 hrs) "pes of rolling contact bearings, Static and dynamic load carying capacities, Stibeck’s Equation, Equivalent bearing load, Load-life relationship, Selection of bearing life, Selection of rolling contact bearings from manufacturer's catalogue, Design for cyclic loads and speed, Beating with probability of survival other than 906% Taper roller beating : Fore analysis and selection criteria (Theoretical Treatment onl). (Refer Chapter 4) Unit iv : Worm and worm gear terminology and proportions of worm and worm gear, Force analysis of wom gear drives, Friction in Worm gears, efficiency of worm gears, Worm and worm gear material, Stength and wear ratings of worm Bears Bending stress factor, speed factor, surface stress factor, zone factor) IS 1443-1974, Thermal consideration in ‘worm gear drive, Types of failures in worm gear drives, Methods of lubrication, (Refer Chapter 5) Unit V: Belt drive: Materials and constuction of fat and V belts, geometric relationships for length of belt, power rating of belts, concept of sip & creep, inital tension, effect of centrifugal force, maximum power condition, Selection of Flat and V-belts fom manufacturer's catalog, belt tensioning methods, eave advantages and limitation of Flat and V-belts, construction and applications of timing bets. ‘Wire Ropes (Theoretical Treatment Only): Consruction of wire ropes, lay of wire rope, stresses in wire rope, selection of wire ropes, rope drums construction and design. Chain Drives (Theoretical Treatment Only): Types of chains and its Geomety, selection erteria for chain drive, Polygon effect of chain, Modes of failure for chain, Lubrication of chains (Refer Chapter 6) Unit VI: Classification of sliding contact beating, Lubricating ols: Properties, additives, selection of lubricating oils, Properties & selection of bearing materials Hydrodynamic Lubrication : Theory of Hydrodynamic Lubrication, Pressure Development in ofl film, 2D Basie Reynolds Equation, Somerfield number, Raimondi and Boyd method, Thermal considerations, Parameters of bearing design, Length to Diameter ratio, Unit bearing Pressure, Radial Clearance, minimum ol film thickness, (Refer Chapter 7) aaa)Ef benign et necine ements 1°) 1 bit Cains an 4122 RaloFacor() 120 118 EtectheLced on Sur Ger Tooth Chapter 1: Spur Gears 1-1 to 1-55. (Feb. 16(In Sem.) 1-20 [ sytius : Introduction to gears Goar Selection, Material at eens ommaeaaetr ad a Cancetaton Factor 121 $192 Madman Tengontal Foe (Fr) 121 spur Gears: Number of Teoh and Face Wh, Force Anal SO ee cae, || 1488 Oya tzaionceToah ants Ces tad Cacerraton Fei, eco Load on Gest, Wear Song fF 1510 Sem) 12 (Guckingran's Equator), Eston of Module Based on Beam || #194 18 Gear Grodes 122 and Wear Stengt, Estimation of Dynare Tooth Lead by va syllabus Tope: Veoky Facer, Estimation of | Fano en Bcknghars Equation Dyer Teath oa by Vly Factor and Saucon 2 Biekingh's Ea.atn 12 — 2 | 495° aos ol Estmaton janie oe nd eee aes Efloc ad (ab 6 (hn Sem) May 1). 22 etal ear (ee. 18) seg | 104 Sally of CoP 125 ee ee Te yabus Tole: xno Mot Based ee oon “ tn Beam Seength and Wear Seng 125 Fe tyra | US besser 125 15 Minimum Number of Teeth to Avoid Interference.. 18 ae Power Tansmiting Gapacty of Spur Gear Par “2 Se eee at asunan 7 Sylabus Tope: ear Lubteaton Mead on V2 eae ns) cctg | 17 oar tubiatn 182 y Shun Tope: Nontert tooth wo } 1874 Pupose ot eer Lteston 152 eee eee cacaa Twn tte... 1a | M72 bios ein ns 152 17 Effects of Pressure Angle (Dec. 14), so | 7 Modes of Gear Lubrication 1-53 5 ee Tit | 174 Hoa Deepaton 159 ae eT Tian sage Gear Resoor 188 ¥ ‘Syllabus Topic : Basic Modes of Tooth Failure... 112 18 Ust of Formulae, 154 418 Types Medes) ot Gear Toot Faure + crater Enis 155 (hy 1, May 1, Dee. 16, Feb 7 Se). 12 E 7] oa ‘Syllabus Topic : Material Selection. 114 SEITE 1.40 Gear Materials. : 4-14 | Chapter 2: Helical Gears 2-1 to 235, 1101 esate Properis of oar Mal o | eS anni | Sybil Go, Temi, itl Rin ee Soon ccn Team, Foe Aras of Hole Gear, Design of Hele! Gor fecal or Boum Svongh, Wear Srengh and Extaton of Equation 118 |) Effective Load based on Velocity Factor ( Barth Factor) and at ‘Beam Strength of Spur Gear Tooth Buckingham’s Equation, (No Numericals on Force Analysis of (Occ. 12, Dez 15) 146 || pace 1.41.4 Assumptions in Analysis of Beam Strength 416 | 24 Diference botween Spur and Helical Gears 22 1.112 Lowi Equaon for Boum Segth % Syllabus Topic: Types of Heal Gara 22 ot Spr Goa Tooth (ee 18). 131 | 22 Types of Hela eas 22 ee ae 118 | 2:5 Advantages and Limitations of Helical Gears 23 1.11.4 Bending Endurance Strength (0, ) ee ‘Syllabus Topic : Helical Gear Terminology. 23 ¥ Syllabus Topi: Face Wah 24 Hale ear Temirogy Lins Face With) +18 aerate aera 7 1148 Woakert ea and Prion 110 | Syn Tones Vad Nunta Tet - Z syllabus Topi: Wear Stonah 25 Eqvlot Spr Goa and Vital Naber of Tet (Guckinghams Equator aoe oe (Dec. 13, May 14, Feb. 15 (In Sem.), Dec. 15, 112 Wear Seong ot Spur eer Toth (08612) 18 Cee aaa cot 1121 __Load-Stees Factor (6) 120. | 26 Minimum Number of Teeth on Helical Pinion 28ET bos ot Mecin Een (SPU) “ ‘Siilabus Topic : Force Analysis of Helical Gears... 2-9 27 Force Analysis of Helical Gears 29 Y Syllabus Tople : Design of Hetcal Gears based fon Beam Stongth. ns = aa 28 Beam Strength of Helical Gear Tooth 2at 28.41 Lewis Form Factor Based on Virtual Number of Teeth (Y') vs aay 282 Bending Endurance Strength 22 288 Face Width = 212 284 — Weaker of Gear and Pini wernsnusnes ae ¥ Syllabus Topic : Design of Helical Gears based on Wear Strength ven BB 29 Wear Strength of Helical Gear TOON. nnmsnnen 212 210 Etfective Load on Helical Gear Tocth (May 17) ono. 213, 2.101 Theoretical Tangential For08 (F) cnsnainsnnnnnnen B43 2402 Maximum Tangential Force Fa) 243 ¥ Syllabus Topic : Estimation of Etectve Load Based on Velocity Factor (Barth Factor) and Buckingham Equation, sine AE 2103 Methods of Estimation of Dynamic Load and Effective Load (May 17)... pon BN 211 Safety of Helical Gear Pat 245 242 Listof Formulae 288 4 Chapter End nm : 295 Chapter 3: Bevel Gears 341 to 9-38 Syllabus : Types of Bovel Gears, Terminology, Vitual Number of Teeth, and Force Analysis of Straight Bevel Gear, Design of ‘Straight Bevel Gear based on Beam Strength, Wear Strength and Estimation of Etfectve Load based on Velocity Factor (Barth Factor) and Buckingham's Equation, Mountings of Bevel Gear. (No Numerical on Force Analysis of Bevel Ger) 8.4 Intoduetion snus soni SB ¥ Syllabus Topie : Terminology of Bevel Gears ou..n.92 82 Terminology of Bevel Gears (Feb. 17 (In Sem) wou. 92 ¥ Syllabus Topie : Vital Number of Teoth, 34 33° Formative Number of Teeth (Tredgoles Approximation) (Feb. 16 In Sem) ne 4 34 Minimum Number of Teeth on Bevel PION wv wcnene 35 Syllabus Topic: Force Analysis of Straight Bovol Gears... os set 3S 35 Force Analysis of Straight Bevel Gears (May 13, Dec. 15, Dec. 16, May 17).vvensonsnanns 95 36 Types (Modes) of Bevel Gear Tooth Fal wuss $7. 37 Materials for Bevel Gears. 37 ¥ Syllabus Topic: Design of Bevel Gears Based ‘on Beam Strength.» oo 87 38 Beam Strength of Straight Bevel Gear Tooth (Way 12, Dec. 13, Feb, 15(n sem)... 37 Table of Contents 38.1 Lewis Form Factor Based on Vitwal Number of Teeth (Y') . vo 38 38.2 Pernissble Bending Stress 38 383 Face Width vi 39 884 — Weaker of Gear and ition nnn so 8D ¥ Syllabus Topic : Design of Bevel Gears Based on Wear Strength 30 39 Wear Strength of Straight Bevel Gear Tooth (May 17) . 39 89.1 Load-Stess Factor (K) = 40 ¥ Syllabus Topic : Estimation of Effective Load ‘Based on Velocity Factor ( Barth Factor) and Bs kingham’s Equation sn 3-10 8.10 Effective Load on Straight Bovel Gear Tooth... 310 84101 Theoretical Tangential Force (F,) 30 3102 Maximum Tangential Force (Fic) tt 3.108 Methods of Estimation of Dynamic Load and Eftectve Load on Straight Bevel Gear Tooth an 311 Safety of Bevel Gear Pat 343 ¥ "Syllabus Topic : Types of Bevel Gears, 3.82 342 Typesot Bevel Gears (May 11, Dec. 14, May 15, May 16, Dee, 18)... 9-92 ¥ Syllabus Topic : Mounting of Bevel Gears 3.35 3.13 Mounting of Bevel Gears (May 15) 3.95 3.414 Ustof Formulae. o = 3.96 + Chapter Ends 3.38 UNIT. a — Chapter 4 : Rolling Contact Bearings 4110 451 ‘Syllabus : Types of Roling Contact Bearings, Static and Dynamic Load Carrying Capacties, Stbeck's Equation, Equivalent Boating Load, Load - Life Relationship, Selection of Bearing Life, Selection ‘of Roling Contact Bearings from Manufecturers Catalogue, Design for Cyelic Loads and Speed, Bearing with Probabilty of Survival other than 90%, Taper Roller Bearings : Force Analysis and Selection Criteria, (Theoretical Treatment only) 44 Introduction 10 Beating ron : 42 41.4 Typos of Beatings so 42 42 Nomenclature of Roling Contact Bearing. 42 43 Types of Loads on Roling Contact Bearings. 43 ¥ Syllabus Topie : Types of Roling Contact Bearing...4-3 44 Types of Raling Contact Bearing... 43 441 Ball Bearings : 43 442 — Role Bearings sett eB 443 Comparison between Ball and Roller Bearings (ec. 14) : 46 444 Applications of Roling Contact Bearings (Bec. 14, B26. 15) nnn 47It (F besign of tachine Elements I (SPPU) Teble of Contents 45 48 47 416 4.164 4162 4a7 4.18 419 420 4201 4202 421 442i Designation of Roting Contact Bearings, Factors Atfecting Selection of Bearing Type. Syllabus Topic : Static Load Canying Capacity. Basic Static Capacity (Basic Static Load Rating) of Bearings (C,) ‘Syllabus Topic: Stibeck's Equation ‘Stibeck’s Equation for Basi Static Capacity of Bearings (May 11, Dec. 14, Dec. 13, Feb, 16(In Sem), Feb. 17(In Sem)) Equivalent Static Load, Bearing Lite ‘Syllabus Topi Capacity. Basic Dynamic Capacity (Basic Dynamic Load Rating) of Bearings (0) (Dec. 13, May 18) Syllabus Top: Equivalent Bearing Load. Equivalent Dynamic Load (P,) (Dee. 12) Syllabus Topic : LoadLite Relationship. Load-Lite Relationship (Dee. 12). ‘Syllabus Topic : Selection of Beating Life ‘Selection of Bearing Lite Syllabus Tople : Selection of Beating from Manufacturer's Catalogue ‘Selection of Bearing From Manufacturer's Catalogue (May 12, May 15). ‘Syllabus Topic : Bearing with Probably of ‘Survival other than 90%. Bearings with Probeabity of Survival Higher ‘than 90 Percent, ‘Adjusted Life of Bearing Aelabily of Bearing System Syllabus Topic : Design for Cycle Loads ‘and Speed... Equivalent Dynamic Load for Bearing Under yale Loads. Equivalent Dynamic Load for Continuously Variable Cyctic Loads. ‘Mounting of Bearings (May 14, Feb .15(In Sem.) Feb .17(In Sem), May 18) ronn Syllabus Topic : Taper Roller Bearing. ager Roller Bearing, : Nomenclature of Taper Roller Bearing .. Dynamic Load Carrying Mounting of Taper Roller Bearings (Dec, 11, May 12, Dec, 12, May 16). Preloading of Bearings (May 14, Dec. 16)... Objectives (Purpose) of Preloading (Dec. 12). 48 8 | 49 49 410 410 an 412 413 4313 413 413 44 414 4t4 44 418 415 425 so 25 425 4.96 434 447 448 448 4212 Methods of Prloading (Dee, 11, Dec, 12, Dec. 16) 448 422 allure of Roting Contact Bearings. 449 4.22.1 Typos (Modes) of Falures of Rong Contact Bearings (Feb. 16(In Som). 449 423° Ustof Formulae 450 + Chapter Ends 451 UNIT IV. Chapter 5: Worm Gears 541 10 533 [ Syllabus : Worm and Worm Gear Terminology, Proportions of ‘Worm and Worm Gears, Force Analysis of Worn Gear Drives, Friction in Worm Gears, Efficiency of Worm Gears, Worm ané | Worm Gear Material, Strength and Weer Ratings of Worm Gears (Bending Sess Factor, Speed Factor, Surface Stress Factor, | Zone Factor) IS 7448-1974, Thermal consideration n Worm Gear | Dive, Types of Falluras in Worm Gear Drives, Methods of | Lubriaton. _ _ 8.1 Introduction. 52 Advantages and Limitations of Worm 53 54 55 651 552 553 56 87 58 584 582 59 Gear Drives Syllabus Topic : Worm and Worm Gear ‘Terminalogy “Terminology of Worm and Worm Gears (May 13) Designation of Worm and Worm Gear Par Syllabus Topic : Force Analysis of Worm ‘and Worn Gear Dives Force Analysis of Worm and Worm Gea Pair (May 14, ay 16, May 18) ‘Components of Force Acting on Worm Components of Force Acting on Worm Gear Direction of Components of Foroes on Worm ‘and Worm Gear Sling (Rubbing) Velocty in Worm an Worm Geer Pair (May 19). Syllabus Topie :Fretion in Worm ‘and Worm Gear: Coefficient of Friction in Worm ‘and Worm Goar Pai Syllabus Tople : Efficiency of Worm and Worm Gear Par. Efficiency of Worm and Worm Gear Pair (Dee. 11, May 12, Dec. 14, May 15, Dec. 16). Factors Affecting tceney of Worm Gear Pair ‘SeltLocking Worm Gear Pir (May 13, May 17). Syllabus Tople : Typos of Failures in Worm Gear Drives... “Types (Modes) of Failures in Worm Gear Pir (ay 11) 52 52 54 56 58 58 58 50 5.10 510 ett 541 51 5.12 57 57 52[PP design of machine Elements -l(SPPU) 4 Table of Contents ¥ ‘Syllabus Topic : Worm and Worm Gear 6.41 Speed Ratio Neglecting Sip 65 Matetls 517 | 642 Speed Ratio Considering Sip (SPPU- May 18)....65 5.40 Worm and Worm Gear Materials, 517 |v syllabus Topie : Geometrical Relationships for 5.40.1 Materia for Worm 57 Length of Bek 6s 540.2 Matai for Worm Gears 5.18 | 65 Geometica Relationships for Bet Drives. 6s 5.40.3 Why Dissimilar Materals fr Worm and Worm 65.1 Open Belt Dive (SPPU-Dec. 15)... 68 Whee! ?(SPPU- May 11, May 19, May 18)...--549 | 652 Crossed Be Drive 63 5.104 Why Worm Gear Alvays Govern the Design? 66 Crowning of Puey (May 14, May 18). 67 (SPPU May 18, Dec. 15,May 18,Dee.18).....-519 | 6.7 Tol Tensionin Bet ; 68 5.41 Power (Load) Rating of Worn and Worm ¥ Syllabus Topic: Etect of Centtugal Force 68 Semmmmeenies 549 | 67.4 Gentitugal Tension in Bk (May 18). 68 ¥. Syllabus Topic : Strength Ratings of Worm Gear. 29 | 67.5 Liming Rato of Etectve Tension for 5.14.1 Beam Strongth Rating of Worm Gear 1S 7443 a. 20 Pat Bats (oy 1). a ¥ Syllabus Topic : Wear Ratings of Warm Gear...521 | y Syllabus Tople: Inia! Tension. a 5.11.2 Wear Strength Rating of Worm Gear-I8 7443 ...521 | gy inal Tension in Bot (May 18). aa ¥ Syllabus Topic: Thermal Considerations in A eee ott ore “523 | 6.49 Maximum Power Tansmiting Capacty §:12 Thermal Considerations in Worm Gear Dive eps ea Cerrar he cee “523 | 610.1 Maximum Ponsr Transmiting Capacty Based on 5.19 Arrangements of Worm Gear Reduce. 590 Fron Gapacty (lay 11, Deo, 1), a 5.14 Lutwoaton of Worm Geers. 531 | 6.102 Mexmum Power Transmiting Capacity Based 5.14.1. Purpose of Worm Gear Lubrication 5st an Bek Strength and Friction Capacity 5.142 Lubviants Used in Won Goats. sat (May 12, Dec. 18) 613 5.15 Lisof Formulae 522 | 6.11 StossosinBet ote 4 Chapter Ed... 523 |“ Syllabus Topic: Selection of Fat Betis from Manufacturer's Catalogue. ote 6.12 Slectinot iat ats From Marta Catalogue (Dee. 12, Dee. 13, Dee 15, May 17) ....544 Chapter 6: Belt, Rope and Chain Drives_6-110663 | / ——syiabus Topi : Matarals and Construction of ‘Sylabus : Belt dive : Mates and Construction of Flt and V Vet 629 Bats, Geometric Relationships for Length of Bet, Power Rating of || 6.19 traduction to V-Bots. 629 Bats, Conceat of Sip & Craep, inal Tension, Effect of Centrifuge || 6.13.1 Construction of V-Belt 629 Force, Maximum Power Condition, Selection of Fat and V-belts || 130 Features of V-Ret aa ‘rom Manufacturers Catalog, Bet Tensoring Methods, Relate || 6 154 Standard Crose-Sedions of V-Bats 09 Advantages an Linas of Fit nd V- ele, Conus and || 7 ea apes and Appleations of ining Bets. Limitations of Flat and V- bets 630 Wire Ropes (Theoretical Treatment Only): Construction of Wire Ropes, Lay of Wire Rope, Stesses in Wire Rope, Selection of || 184 Relate Advantages and Limtatons of Flat ‘Wire Ropes, Rope Drum Construction and Desig. eee 630 Chain Drives (Theoretical Treatment Only) : Types of Chains || &195 Uses (Applications) of V-Bets Le) and tis Geometry, Solocion Citra for Chain Drive, Polygon || 614 Ratio of Limiting Tensions fr Vet 6-90 Elect of Chin, Modes of Faure for Chalo, Lubrication of Chains. ||“ Syllabus Topic: Selection of Vets fom 61 Advantages an Liitatons of Bolt DPS. 62 Manufacturere Catalogue. 531 62 Typesof Bets aoe gg | 615. Selection of V-Bets From Manufacturer's ¥ Syllabus Topie Materials and Construction eee ene 6a. | % — Silabus Topic : Concopt of Creep ou 63 Materials and Construction of Flat Belt 4g | 818 Creep in Botts (May 16, May 18). on (631 Destrable Properties of Materials used for Bats .....63 | ‘Syllabus Topic : Bett Tensioning Methods. 645 63.2 Material usd for Bots og | 617 Bat Tenaoning Method 64 Speed Ratio of Bot Drv. me oa | ae naa cenaten en nplene “648 ¥ Syllabus Topic: Concept of SIP nnn nnnnnnnin BS EASE ee(foes arate USEF Table of Contents 648 Timing Or Toothed Bat. 618 Introduction to Wire Ropes. ¥ Syllabus Topic : Construction of Wie opes 6419.1 Construction of Wir Rope (Dec. 11, May 18). 6492 Designation of Wire Rope (Dee. 11, May 12), 619.3 Applications of Wire Rope (Dec. 11, May 12) ¥ Syllabus Topic : Lay of Wire Rope: 6419.4 —Layot Wire Ropes 620 Modes of Failures of Wire Rope (May 11)... 620.1 Static Failure Due to Tense Stess 6202 Fatigue Failure Due to Bearing Pressure 6203 Factor of Safety for Wire Ropes ¢ Syllabus Topic : Stresses in Wire Ropes 8204 Summary of Stresses in Wire Ropes (Dec. 18, May 16, May 17, May 18) ¥ Syllabus Tople : Selection of Wire Ropes. 621 Selection of Wire Ropes (Dee. 11, May 13, May 18) + Rope Drum Construction 622 Rope Drum os 622.1 Construction of Rope Drum 6222 Design of Rope Drum (May 14)... 6.223 Safely of Rope Drum 623 Introduction to Chain Drives. ¥ Syllabus Tople : Types of Chains. 624 Typeeof Power Transmission Chains (May 15, May 18) 624.1 Roler Chains 6242. nvertad-Tooth or Silent Chains ¥ Syllabus Topic: aman oi 6.25 Geometry of Chain ns Syllabus Topic: Polygon Effect of Chain... 626 Polygon Effect in Chain (May 15, Dec. 18) Syllabus Tople : Modes of Flture for Gnain 6.27 Modes of Ror Chain Faliure (May 16, Dec. 16). ¥ Syllabus Topic: Selecton Criteria for Chain Deve. 6.28 Selection of Raller Chains from Manufacturer's Catalogue ¥ Syllabus Tope : Lubrication of Chains. 6.29 Lubrication of Chains. 6.29.1 Methods of Lubrication 6.90 Listof Formulae "+ Chapter Ends 650 650 651 6st ose 652 653 654 654 1 654 655, 655 656 6-56 657 687 658 658 6-60 661 661 663 UNET Vi —_— ‘Chapter 7: Sliding Contact Bearings : Hydrodynamic Bearings 7A to7-70 Syflabus : B|| | ciasstcation of Sting Contact Beating Lubricating oils: Properties, Adcves, Selection of Luticatng | Ole, Properties & Selection of Bearing Materia | | theory of HycrodynamicLubieton, Pressure Development in Oi Fim, 2D-Basic Reynolds Equation, Somertld Number, Raimond and Boyd Mothod, Thermal Considerations, Parametars of Beating Design, Length to Diametar Rati, Unit Bearing Pressure, Rasa Clearance, Minimum Oil Film Thickness. | 74 Lubrication and Lubricants... 72 71.4 Functions of Lubricants... 72. 72 Physical and Chemical Propertas of Lubricants ....7-2 2A Vis nn o 72. 722 Viscosity Index 76 723 Oiness . 718 724 Specie Gravity or Relative Density 77 725 Speci Heat 77 726 Flash Point a 1 7.2.7 Fire Point = 7 72.8 PourPoint : o 7 729 Foaming 74. 7.240 Oxidation Stability 7 7241 Acidity 77 72.12 Alkalinity : c 7 72.43 Demulsilty 78 7.3 Desirable Properties of Lubricant 78 74 Classitcation of Lubricants (May 18). 78 7.4.1 Luroating Oils (Liquid Lubricants) (May 13, Doc. 16, May 17) 79 742 Gr00808 on 7412 743 Sold Lubricants 748 75 Selection of Lubricants 749 76 Beating Materials. = L743 7.6.1 Desirable Properties of Bearing Materials (May 12, May 13, Dec. 14, Dec. 15, May 17, May 18) 7.62 Mateils for Bearings 7.7 Basic Modes of Lubrication. ¥ Syllabus Tople : Pressure Development in oFiim . 748 78 _Typecl Ghar Cota Bangs 7.49 7.8.1 Classification of Sliding Contact Bearings Based ‘on Made of Lubrication nn 749 782 Classica of Siding Contact Beerings Based on Relative Motion between Contacting Suraces «ou 721[BFE Design of Machine Elements I SPPU) 79 730 mH 738 724 7122 738 734 718 748A 7.152 Potroffs Equation fr Hydrodynamic Journal Bearings (May 12, May 14, May 15, Dec. 16, May 17). ‘Nomenctature (Terminology of Hydrodynamic Joumal Beating. : 1.23 Syllabus Topic : Theory of Hydrodynamic Lubrication o 7.25 Regimes (Theory) of Hydrodynamic Lubrication (000.11). se 728 ‘leymolds Equation for Hydrodynamic Lubrication ee 7:26 ‘Assumptions in Reynola's Equation (May 12)...0ou 7-26 Syllabus Topic : 20-Reynoids Equation, sw TAT Roynold's Equation for Two-Dimensional Flow (B06. 18) onsnnnsnn sennne PO ‘Types of Hydrodynamic Journal Boarng8 osm 7-28 ‘Design Considerations in Finite Length Hydrodynamic Joural Bearings (Way 15, May 16) vn 72 Syllabus Topic: Raimond and Boyd Method nn. 7-30 Relations of Variables fr Finite Length Hydrodynamic Journal Bearings (Raimond! ‘and Boyd Method) (Dec. 13, May 17) 7.90 Design and Performance Variables (Dee. 12, May 16). 731 Dimensionioss Parametor sen 71 Syllabus Topic : Sommerfeld Number... 732 733 ‘Syllabus Topic : Thermal Considerations... 7.18 7164 7182 7183 7164 7185 7.186 77 718 739 720 > Table of Contents “Temperature Riso in Frito Length Hydrodnamic Bearings with Féed Lubrication 7.83 otal lw of Lubricating ol (Q) 7.94 Rete of Heat Generation (H,) (Dec. 15). 7.34 Rate of Heat Dissipation (H,) : 7.34 Temperature Rise (AT) (May 11). 7.95 Viscosity of Lubricating Of (x) 7.95 Average Temperature of Lubricating OM (Ty) nnn 7-95 “Temperature Rise in Fite Length Hydrodynamic Set-Contained or Set- Cooled Bearings. 735 ‘Syflabus Topic : Parameters of Bearing Design - Length to Diameter ratio, Unit bearing Pressure, Radial Clearance, minimum oll fi hike o 7.37 Selection of Bearing Design Variables for Finite Length Hydrodynamic Journal Bearings (May 14) nrnnan 737 ‘Comparison of Siding and Roting Contact Boating (Dee. 15, May 16) 767 List of Formulae. 789 Chapter Ends... 770 Solved University Question Paper of March 2018 (in Som) Solved University Question Paper of May 2018 University Question Papers. gagNM Chapter Spur Gears = SYLLABUS Introduction to Gears : Gear Selection, Material Selection; Basic Modes of Tooth Failure, Gear Lubrication] Methods, ‘Spur Gears : Number of Teeth and Face Width, Force Analysis, Beam Strength (Lewis) Equation, Velocity Factor, Service Factor, Load Concentration Factor, Effective Load on Gear, Wear Strength (Buckingham’s Equation), Estimation of Module Based on Beam’and Wear Strength, Estimation of Dynamic Tooth Load by Velocity Factor and Buckingham's Equation. }1.1 Introduction 1.11. Beam Strength of Spur Gear Tooth 1.2 Classification of Gears 1.12 Wear Strength of Spur Gear Tooth 11.3 Selection of Type of Gears 1.13 Effective Load on Spur Gear Tooth 1.4 Spur Gear Terminology 1.14 Safety of Gear Pair 1.5 Minimum Number of Teeth To Avoid Interference 4.15 Design of Spur Gear Pair 1.6 Standard Systems of Gear Tooth 4.18 Power Transmitting Capacity of Spur Gear Pair 1.7 Effects of Pressure Angle 4.47 Gear Lubrication 1.8 Force Analysis of Spur Gears 1.18 Multi-Stage Gear Reducer 1.9 Types (Modes) of Gear Tooth Failure 1.19 List of Formulae {1.10 Gear MaterialsLB oesign of Machine Elements I(SPPU) 12 Spur Gears 1.1 INTRODUCTION + Gear cam be defined asthe mechanical element used for transmitting power and rotary motion from one shaft another by means of progressive engagement of projections called teeth, + Gears operate in pais, the smaller ofthe pairs called the pinion and the larger is called the gear. 1.2 CLASSIFICATION OF GEARS + Fig, 1.2.1 shows the classification of gears. Acconding to the position of the axes of the two shafts between which the motion isto be transmitted, the gears are broadly clasified into four groups 1. Parallel Axes Gears 2 Intersecting Axes Gears fon-Intersecting and Perpendicular Axes Gears 4, _Non-Iotesecting and Non-parallel Axes Gears Esernal Gear Par [Rack and Pen Parallel Axes Gears Intersecting Axes oars Nonintorsecting and Perpendicular Axes Gears Toninersecing and Non-Parallel Axes Gears ‘Types of Gears feof Gear Helical - Gear) Helical Pinion(LH) In spur gears, the teeth are cut parallel tothe axis of | In helical gears, the teeth are cut at an angle, known as the gear | helix angle, withthe axis of the gear.[Bl design of Machine Elements - Il (SPPU) 13 Spur Gears Sr, ‘Type of Gear ‘Type of Gear : No. - % j (a | Hervingbone Gears (Double Helical Gears 3. | NON INTERSECTING AND PERPENDICULAR = AXES GEARS on |e Tema . — ver meat | Yoon LH isi... ‘wo sinning appear a as connesedby worm gears. The wor gers consist of | Mersinghone gear cons of two identical Htc aes || sea tutofoposthadscuton te ane inke ||| ~ (ii) | Hypoid Gears 2._ | INTERSECTING AXES GEARS (BEVEL GEARS) 4 | NON INTERSECTING AND NON-PARALLEL Bevel Pision | Two intersecting axes shafts are connected by gears ‘known as bevel gears. ‘Two non-intersecting and non-parallel axes shafts are connected by spiral or erossed helical gears. However, the crossed helical gears have only point ‘contact and hence, are only suitable for transmitting AXES GEARS (CROSSED HELICAL OR SPRIAL | GEARS) small powers ce seers[Eoecign ot Machine Elements -Il(SPPU) 14 spur Goa 1.2.1 Comparison of Worm Gears and Crossed Helical Gears : > (Dec. 15) — Mem tet) 2. |Meshing Members: : Worm and worm wheel Helical pinion and helical gear, 7 = 4, |Load Carrying Capacity High - Low : : 7 Pe nd. : SVaGaIE Tope Gai SoNTDoEl 1. Relative Position of input and Output Shafts ‘© If the axes of two shafts are parallel, spur, helical, or 1.3 SELECTION OF TYPE OF GEARS Herringbone gears are used. + IF the axes of two shafts intersect at right angles, ‘The various factors that are to be consideted while selecting straight bevel gears or spiral bevel gears are used. the typeof ger drive forthe given application ae a follows cles ease © If the axes of two shafts are non-intersecting and perpendicular, worm gears are used. 2 Speed Ratio : ‘The normal reduction ratios obtained with different types of the gear drives are given in Table 13.1 5. Power to be Transmitted {Power to be Transmitted : ‘Table 1.3.1 : Reduction Ratios for Different Gear Drives | [Bl design of Machine Elements -II(SPPU) 15. Spur Gears | | | | & Gear Dive delieton + Spur and helical gears can be used fo tans very ‘No. Ratio large power (up to 18000 KW). 1. | Single Stage Spur or Helical Gear | 6: 1 + However, because of low efceney, worm gear drive ! pas || is not preferred for high power transmission. 2. | two Suge Spur or Hele Gear] 38 : 1 Cost Dive | i : : + Spur gears are easy to manufacture and cheapest, | 3 | Three Stage Spur or Hetial Gear | 200 <1 followed by helical gear and bevel gear. Drive =a © Due to bimetallic construction of worm wheel and 4._ | Bevel Gear Drive 6:1 specialized manufacturing methods, worm gears are 5. _| Single Stage Worm Gear Drive Wl an 6, | Two Stage Worm Gear Drive max 4900: 1 ~ 1] 4.4 SPUR GEAR TERMINOLOGY 3. Efficiency : I The efficiencies for the different types of gear drives are i see a ar | gvenintiie 32, below |Table 13.2: Bites or Dern Types of Ger Drives veh cio mua cule ‘Sr.No. Gear Drive Eiiciency Pitch Point Pressure Angle 1, | Sparor Helical Gear Pair 96-99% Circular Piteh Module 2. _| Bevel Gear Pair 95-98% | Diametral itch Addendum 3. _| Worm and Worm Whee! 45-91% Dedendurn Addendum Cirele 4. Input Speed : Dedendum Circle ‘Total Depth In spur gear, the engagement between the two meshing ‘Working Depth Circle ‘Working Depth teeth isa sudden line contact over the entire face width Clearance “16. Base Circle which results in the generation of noise and higher ‘Tooth Thickness ‘Tooth Space dynamic load, Hence, spur gears are used for low speed applications. Generally, spur gears are not used above ee ae pitch line speed of 20 ms. Frank of Tooth “Face Width + In helical gears, the engagement between the two Speed Ratio Centre Distance meshing eth begins as a point contact and gradually ung Tooth Crowning of Gear Tooth extends diagotlly along the gear tooth surface, resulting in quiet operation. Hence, helical gears are used for high speed applications,Design of Machine Elements - Il (SPPU) 16 "Fig. 1.4.1 : Spur Gear Terminology Pitch Circle It is an imaginary circle which by pure rolling action would transmit the same motion asthe actual gear. Pitch Circle Diameter (): Iti the diameter of the pitch circle, The size of the gear is usually specified by the pitch circle diameter: Pitch Point : Itis the common point of contact between two pitch circles. Pressure Angle or Angle of Obliquity (6): isthe angle between the common normal to the 1w0 ‘meshing teeth at the point of contact and common tangent to the two pitch circles atthe pith '* The standard pressure angles are: 14.5°, 20°, 22.5” and ‘25°. The most widely used pressure angle is 20°. (Circular Pitch (,) It is the distance measured along the circumference of the pitch cle, from «pont on one toh othe corexponding int on the next tooth ae 2 w(t) ‘Spur Gears, Where, p, = cieular pitch, mum 4 = pitch circle diameter, mm numberof teth 6 Module (m) : ‘© Its the ratio of the pitch circle diameter in millimeters to the number of teeth. The gear tooth size is specified sje asd aay sai atin (42 ie 1.40, asm «sy ‘+ Standard modules recommended by ISO (in mm) ‘Table 1.4.1 : Standard Modules 1.0, 1.25, 15, 2,25,3, 4, 5,6, 8,10, 12, 16, 20, 25, 32, 40 and 50. [| 1.125, 1.375, 1.75, 225, 2.75, 35, 45,55, 7,9, I, -| 14, 18, 22,28, 36 and 45 10. ‘The fist choice modules are prefered. Diametra Pitch (p,) tis the ratio of the number of teth tothe pitch circle diameter. Py (144) a or by 4s) ‘Addendum (b= Itis the radial distance between the tp land of the teeth and the pitch ciel Dedendum (1) : It's the radial distance between the bottom land of the teeth and the pitch circle. ‘Addendum Circle: It is the concentric circle tothe piteh circle, drawn through the top land ofthe teeth,eC NI I [PF oesign ot Machine Elements -I(SPPU) 47. Spur Gears Addendum circle diameter = Pitch eitcle diameter +2 Addendum 46) U1, Dedendum Circle : It is the concentric circle tothe pitch circle, drawn through the botiom land of teeth. Dedendum circle diameter = Pitch circle diameter -2xDedendum aay 12, Total Depth : I is the radial distance between the addendum circle and edendum circle, Its equal tothe sum of the addendum and dedendum. ‘Total depth = Addendum + Dedendum=h, thy «(148) 13, Working Depth Circle: kis the concentric citcle tothe pith circle and tangent to the addendum cle ofthe mating ger. 14, Working Depth : Itis the radial distance berween the addendum circle and the working depth circle. It is equal tothe sum of the addenda of the two mating gears. Working depth = Addendum of gear + Addendum of pinion. 15, Clearance (C, ): Ttis the distance by which the dedendum of a gear exceeds the addendum ofits mating gear c= bh 49) 16, Base Circle: + Itis the circle on which the involute profit ofthe gear tooth is generated, The profile below the base circle is son invoute . ‘+ Base citcle diameter = Pitch circle diameter x cos @ 11410) 17. Tooth Thickness : Itis the width ofthe tooth measured along the pitch circle. 18, Tooth Space : It is the width of space between the two adjacent teeth measured slong the pitch cre 19, Backlash : ‘+ This the amount by which the width ofthe tooth space exceeds. the thickness of the mating gear tooth, measured along the pitch circle ‘+ Purpose of providing backlash : (The main purpose of providing the backlash i to ‘prevent the jamming of mating gear teeth and 10 censure that no contact is made on both sides of the tooth simultaneously. () Hallows room for anol film under all conditions of thermal expansion and contraction, 4+ ffeets of backlash : (i) Too litle backlash may lead to overloading, ‘overheating, jamming, seimre, and eventual failure of the gear teeth (ii) Excessive backlash may cause non-uniform transmission of motion, nose, and imp. 20, Face of Tooth : Itis the surace ofthe tooth above the pitch surface. 21, Flank of Tooth : Itisthe surface of the tooth below the pitch surface. 22, Face Width (0): Itis the length ofthe gear tooth measured along line parallel tothe gear axis 23, Speed Ratio or Gear Ratio (G): ‘+ Tris the ratio ofthe pinion speed to the gear speed. 4 Thean aso be defined as the ratio ofthe number of teeth con the gear othe number of teeth on the pinion. Let, G =. speedratio or gear ratio 4, = number ofteth on pinionTBP. LB Design of Machine Elements -I(SPPU) 18 Spur Gears numberof teeth on gear = pitch citele diameter of pinion, mim pitch ctele diameter of gear, mam 8, = pinion speed, rpm. n= gearspoed, xp. G 14.) ao G (Ae? 24, Centre Distance (a) : + Ttis the distance between the axes of the two mating ears. tis given by, +4, nc ati + Siig pt L419 in 8, b= BRS BHD ay 25 tng Te: > (May 13, May 16) + In gear pir, if gear ratios an integer umber or rato of integer numbers such as 1, 32, 4/3, 5/4, 2, 3, 4 et Same oth on ger wil come in conte with same tooth on pinion repetitively, This leads to increase in wear of teeth and reduce the life of gear pair + Amestra tooth onthe gear wll void the integer number or ratio of integer numbers as gear rato. In such ease, any tooon pinion wil contzet every tooth onthe gear before encountering the same tooth, This extra tooth is celled hunting tooth, + The hunting tooth spreads the wear evenly over all the ‘gear as wel as pinion teeth, thereby increasing the life of the gear pair. 26. Crowning of Gear Toth: > (ay 13, ay 16) Q. Explain the term : Crowin tooth. In a meshing of gear teeth, there is a possibility of excess load atthe end ofthe tooth along the flank, ‘This excess or non-uniform distribution of load is due to (inaccuracies in tooth profile; (i) misalignment of gear and pinion shafts; and (ii) deflection of gear and pinion shafts under load. In order fo minimize this excessive loading atthe end of the tooth, the ends of tooth are made slightly thinner so 8 to give barrel shape along the flank, as shown in Fig. 142, This process of making the ends of tooth thinner is nown as erowning of gear tooth, Crowring Fig, 1.42 : Crowning of Gear Tooth 1.5 MINIMUM NUMBER OF TEETH TO AVOID INTERFERENCE The contact of portions of tooth profiles whick are not conjugate is called interference. In shor, interference isthe meshing of two nonconjugae profiles. ‘The phenomenon of interference, which is present in invohte teeth is absent in eycloidalteth In involute teeth, the interference can only be prevented ifthe addendum circles of the two mating gears cut the path of[FT oesign of Machine Elements I (SPPU) 19 ‘Spur Gears onuct or the common tangent 9 wo base circles between the points of tangency. In practice, the minimum of teeth on pinion are calculated by considering te pinion in mesh with rack oat SN Pech cle Pic Le of Rack Fig LSA rom Fig. 1.5.1, itis seen that to avoid the interference, nee mB mG Now, MN = PM sing= (OP-sing)sing= OP. sin'@ geen m = module, mm 2, = umber of teeth on pinion = pressure angle ‘Substituting Equation (1.5.2) in Equation (1.5.1), we get, rma, sin? on 2h, 2 Sty asa) Fence, the minimum number of teth on pinion to avoid the imerference is given by, (L54) Addendum Modification Addenda) : 1541 (Unequal > (Dec. 15, May 18) ‘What is addendum modification in gears ? How itis done ? ISPPU - Dec. 15] Q, What is addendum modification in gears? State the | advaniages and limitations o ions oft SRURITENATA | © Addendum modification = ‘©The interference in involute gear pair is mainly between the flank ofthe pinion tooth andthe face of the gear tooth + Therefore, the interference can be avoided by reducing the addendum of gear and the dedendum of pinion, as shown in Fig. 15.2. In order to maintain the path of contact and contact ratio, the addendum of pinion and dedendum of gear are increased by same amount, (4) Pinion Tooth (b) Gear Tooth Fig. 1.5.2: Unequal Addenda © Advantages of Addendum Modification : (Lesser number of teeth can be used on pinion without interference, (ii) Pinion tooth becomes thicker at base, and hence, becomes stonger. 7 Limitations of Addendum Modification : (i) Gear tooth becomes thin at base, and hence, becomes weaker. (i) Sliding velocity inereases atthe tip of pinion tooth, (ii) Tooth surface stresses increase.[Pl besign of Machine Elements Il SPPU) 1:10 Spur Gears Syllabus Topic : Number of Teeth 1.6 STANDARD SYSTEMS OF GEAR TOOTH > (May 14) ‘+ Tooth system : A tooth system isa standard which specifies the pressure angle and the relations for addendum, dedendum, working depth, tooth thickness, and fllet radius in terms of module or diametral pitch. ‘© Objective of standard tooth system : The main objective of the standard tooth systems isto attain the interchangeabilty of gears ofall tooth number, but of the same pressure angle ‘and module, + Standard systems of gear tooth : 14.5°full- depth involue, 14.5° composite system, 20° ful-depth involute, 22.5°full-depth involue, 25° full-depth involute, and 20° stub-ooth involute, ‘+ Most commonly used tooth system : 20° full-depthinvolute {s most common and widely used tooth system, * Proportions for different standard gear tooth systems : ‘Table 1.6.1 : Proportions for Standard Gear Tooth Systems Pressure Angle (6) was | a. | ase Minimum Number ot | 32 18 2 Teeth (yin) | ‘Addendum(h,) Im Im Im | Dedendum (h) {125m | 125m | 125m 1.7 EFFECTS OF PRESSURE ANGLE > (0e0. 14) —— /@. State the advantages of tooth system wih 20? pressure angie, Sree ‘Advantages of Smaller Pressure Angle : (Low radial or separating force, and (Gi) High contact ratio, and hence, quietness of operation ‘Limitations of Smaller Pressure Angle (Relatively larger numberof teoth are required on pinion {o avoid the interference, Gi) High bending stresses, and Gi) High contact stresses ‘Advantages of Larger Pressure Angle : (Lesser number of teth are required on pinion to avoid the interference, i) Low bending stresses due to large tooth thickness at the base, and (Gi) Low contact stresses due to larger radi of curvature at the pitch line © Limitations of Larger Pressure Angle : Large radial or separating force, and ii) Low contact ratio, and hence, ran with more noise, |[Boesign of Machine Elements —IL(SPPU) +1 Syllabus Topic : Force Analysis 41.8 FORCE ANALYSIS OF SPUR GEARS © Direction of Resultant Force : “The resultant force ‘F between the meshing teth acs along, the pressure line, as shown in Fg. 1.8.1). The resultant force ‘F” acting on the diving andthe driven member are equal in magnitade and opposite in directions, as shown in Fig. 18.100). © Components of Resultant Force : ‘The resultant force “F" can be resolved (Fig. 1.8.1 (©) into ‘wo components 1. ‘Tangential Component or Tangential Force (,) 2. Radial Component or Radial Force (F,) ring Poa © . Fig. 18.1 : Spur Gear Tooth Forces ‘Spur Gears 4. Tangential Component or Tangential Force (Fi): ©The tangential component ‘F,’ is useful component an js responsible for transmitting the power, Tis tangent f0 the pitch circle atthe pitch point Itis given by. et eyran (8 ‘where, -F, = tangential force, N P = powertransmitted, W pitch line velocity, mis dn, Rdg ‘x 1000 x 1000 ea torque acting on pinion, Nemam torque acting on gear, Nema pitch cree diameter of pinion, mm pitch circle diameter of gear, im pinion speed, rpm. ear speed, pn. + The tangential component of force “Fy acting on the driving gear opposes the rotation of the driving gear, ‘whereas on the driven gear it assists the ration, 2. Radial Component or Radial Force (F,): ‘¢ The radial component ‘F,” is not useful component and serves no purpose. Its given by, Fetano (183) where, F, = radial force, N; @ = pressure angle 1s The radial component ‘F,? tends to separate the two ‘gears. It acts along the radial line through the pitch point and is directed towards the centre, 3. Resultant Force (F) = ‘The resultant force on the gear tooth is given by, 184)B vesign ot Machine Elements =I (SPPU) 112 Spur Gears Example 1.8.1 : AA spur pinion, rotating in clockwise direction, receives 3 kW ower at 1440 rpm. from an electric motor and drives a spur gear ‘The number of teth on pinion and gear are 35 and 65 respectively, ‘The tooth system is 20° fll-depth involute. Ifthe module is 6 mm, determine the components of forces acting on pinion and gear. Solution : Given: P W=3000 ; = Wo; ay =35; m= 65 (Tangential Component of force (F,): : dg = m-74=6%35=210mm dy = m2 =6%65 =390 mm Pitch line velocity, x 210% 1440 15.833 mis F,-tan § = 189.48 x tan 20 = 68.97 N 189.48N and 68.97 N..Ans. The components of forces acting on pinion and gear are shown in Fig. P. 18.1 Fig. P. 1.8.1 (ii), Resultant force (F) ‘The resultant force on pinion and gears given by, i NE) +R) = (189.48) + (68.97) o© Fy = 0164N ws, Syllabus Topic : Basic Modes of Tooth Failure 4.9 TYPES (MODES) OF GEAR TOOTH FAILURE > (tay 12, May 16, Dec. 16, Feb. 171m Sem) Sil and explain the diferent types of gear tooth jain various modes of fares of gear 2 einai ©The different modes of gear tooth failures are broadly lasiied into two categories (Fig, 1.9.1] 1. Bending Failure or Tooth Breakage 2. Wear Failure FAILURES Fig. 19.1: Types of Gear Tooth Failure 1. Bending Failure or Tooth Breakage : + Geartoth behaves ikea canlever beam subjected to @ repetitive bending sess. The tooth bredkage cous when the repetitive bending stress induced in a gear tooth exceeds the bending endurance strength ofthe _gear tooth.[ET besign of Machine Elements I (SPPU) 143 ‘+ _Inother words, the tooth breakage occurs when the total load (ce. sum of static and dynamic loads) acting on the gear tothexceds the beam strength ofthe gear tooth + Methods to avoid bending fature (a) improving bending endurance stenath, Cb) Ioreasing module, (©) creasing face with, nd (© _ Increasing pressure angle 2, Wear Failure : ‘© Wear is @ phenomenon which removes the complete layer of the surface or makes craters or scratches gn the surface. +The different types of wear failures in gear teeth are discussed below @ Pitting; Gi) Scoring (Scuffing or Galling); (Gi) Abrasive Wear, and Gv) Comosive Wear. Pitting is a surface fatigue failure due to repetitive contact, stresses. The pitting is of two types (@) Initial piting () Destructive pitting (0) Initial pitting + + In inal iting, the high spots on the gear tooth surface, due to surfs iegulartis, ae progressively ‘wom-out The pits of smal diameter (05mm 0 1m) are formed at high pos +The ina piting is due to eros in tooth profile, surface iregularies, and miligament of gears. The inal piting normally oocurs for a wile and then stops. It can be minimized by improving the surface finish and proper alignment of gears. ‘Spur Gears (b) Destructive pitting: ‘The secand phase of piting is destructive pitting. The destructive piting isthe surface fatigue failure due to repetitive contact stresses. Ie stats when the maximum contact stress induced on the gear toth surface exceeds the surface endurance sirength ofthe toth In otber words, the destuetive iting stats when the total load (ie, sum of static and dynamic loads) acting on the gear tooth eiceeds the wear strength of the tooth The destructive piting begins as @ mio-rack on the surface and progressively develops iw a bg pit onthe surface. IF the pinion drives the gear end both are having the same surface hardness, then most of the pitting willbe onthe pinion. Methods to avoid destructive pitting : (@) Improving surface endurance strength oF surface hardness, (b) Increasing module, (©) Increasing face width, and (@) Increasing number of tet. Scoring Scutfing or Galling) : Scoring is essentially a lubrication faire. Inadequate Inbrication, high tooth load and poor surface: finish result in breakdown ofthe oil film and causes the metal- to-metal contact. ‘The high coefficient of sliding fiction resting from inadequate Inbrication, poor surface finish, high tooth toad and high sliding velocity result in high rate of beat generation inthe localized region of the metal retal contact, This causes rapid allemate welding and tearing at high spots which is known as stick-slip ‘phenomenon. Methods to avoid scoring : (@) Providing an adequate lubrication (adequate ‘quantity of lubricant, quality of lubricant, and proper method of lubrication),[42 design of Machine Elements -IL(SPPU) 144 Spur Gears (©) Providing the prope sufve fish, (©) Maintaining the sliding velocity within the limit, and (@) Keeping thetooth pressure within the limit t) Abrasive Wear : + Abrasive wear isa surface injury or damage caused by particles trapped between the matting teeth surfaces. ‘These particles serach o brinel the tooth surface. + These panicles may be present in the lubricant as impurities, may be the dit entering the gear box from ‘outside or may be flakes of material detached from the tooth surfaces: + Methods to avoid abrasive wear : (2) Proper iteration ofthe lubricant, (6) Providing complete enclosure for gears, (©) Increasing the surface hardness, and (@ Use of high viscosity oils ‘+ The thick oi film developed by lubricant allows the fine particles to pass without sratchin, (Corrosive Wear : ‘+ Corrosive wear is due to the chemical action by the improper lubricant or sometimes it may be due to surrounding atmosphere which may be of corosive nature, ‘+ Methods to avoid corrasive wear (@) Using proper lubricant with proper aditive, and () Providing complete enclosure for gears Syllabus Topic : Material Selection 1.140 GEAR MATERIALS 1.10.1 Desirable Properties of Gear Material : ‘The desirable properties ofthe gear material are (High endurance strength in bending : (Gi) High surface endurance strength (ii) Low coefficient of fiction; and @ (iv)_Low and consistent thermal distortion The gear material should have high endurance strength in Dending to avoid the bending failure (i) The gear material should have high surface endurance ‘strength to avoid the destructive piting, (ii) The gear material should have a low coefficient of friction to avoid the scoring, (iv) The gear material should have low and consistent thermal distortion during heat treatment 1.10.2 Gear Materials : ‘The different materils used for gears are discussed below [Fg 1.10.1): fiesum Caben Sees Fig, 1.104: Gear Materials 1. Cast rons : ‘The goats of large size and complicated shape are made of cast irons| [design of Machine Elements (SPPU] 145 Spur Gears ‘© Advantages of Cast Irons as Gear Material : eee Giese | Hlantonea BAN They ae eat expensive pane Strength, (i) They have good damping property, and hence damp out | | ‘Nowa? eet HLNodular (Duetile) Cast Iron \ (i) They have good surface endurance strength aa fa ; (iv) A graphite present in cast irom acts as @ lubricant, | 56 70942 700 reducing the possibility of sein faite. sooo pee (0) They can we easy cs int complicated shapes, a TT 500 (i), They have excellent machinabiity. | sear 400 © Limitations of Cast Irons as Gear Material : They have low bending endurance strength. (Gi) They are brite, and hence cannot be used for gears subjected to shock loading. ‘© Types of Cast irons Used for Gears : ‘The different types of cast ions used for gears are (Gray cast irons, (ii) Malleable cast iron, and (ii) Nodular (utile) cast irons. ‘Table 1.10.1 : Mechanical Properties of Cast Irons Used as Gear Materials “Material ‘Ultirnate ‘Hardness, BHN: | Gray cast tron: ; Fo 200 20 9-23 F620 20 wim 70380 260 21m ro 380 icarweaes) | 350 Min 300 Il, Malleable Cast | | } i 4 | MCIB 320-350 ‘Max. 149 [vera sa0-100 | Max 9 Steels : ‘There ae large numberof steels used for gears ranging from plain carbon stels to highly alloyed steels and low carbon steels to high carbon steels, © Advantages of Steels as Gear Material : (They have high bending endurance strength (ii). They have high surface endurance strength Gi) Because of the ductile case, they can absorb the shock, Hence, they can be used for gears subjected to shock loading ‘© Limitations of Steels as Gear Material : (They are expensive, (Gi) They have poor damping property (ii) They are subjected to thermal distortion or warping during the heat treatment. This is. major problem, especialy, in plan carbon steels. '® Use of Steel as Gear Material : +The plain carbon steels are used for medium duty applications, wheress, alloy steels are used for heavy duty applications. A good combination is often a steel pinion and a cast iron gear ‘+. The mechanical properties of the plain and alloy steels used as gear materials are given in Table 1.10.22 besgn of Machine Elements I (SPPU) 146 Spur Gears Table 1102: Meshal Propet of Ste ea Gear ee ee timing devices, toys, ete. Nekieoun Ultimate 5. Non-Metals : ‘Tensile Strength, Nini? ‘Some of the non-metals used as gear materials are : Bakelite, Plain Carbon Steels Nylon, Pasties and Composites, 3508 0 200 “Syllabus Topic : Beam Strength(Lewis) Equation 4008 580 207 45C8 630 2 1.11 BEAM STRENGTH OF SPUR Pa a aa GEAR TOOTH 588 70 265 40C8 580, 145 (core) 460 (case) 598 70 200 (eor) $20 os Beam strength of the gear tooth is the maximum tangential Alloy Steels load the gear tooth can take without tooth breakage. ais) 700 200-250 1.11.1» Assumptions in Analysis of Beam. 40Cr4 700 200-250 Strength : 40cesMo2 00 200-250 35Mn6Mo4 800 230-280 40Nil4 200 230-275 4ON6CMG 800 230-275 4ONi6CeAM03 800 230-275 AoNi6cesMo2 800 250 (core) 600 (case) 40NiLOCE3Mo06 1000 285-340 BONILECS 1250 Min. 440 40Ce13Mo10V2 1300 360-440 Non-Ferrous Metal ‘The non-ferrous metals like : copper, zine, tin, aluminum, and manganese are used in various combinations as” gear taterals, The most common alloy is bronze. 4, Sintered Metals : ‘© In recent years, the sintered gears made by powder metallurgical processes from iron and copper powder ae used a low cost gars where strength snot a prime consideration. These gears are wear resistant and easy to ® Fig, 11:1: Gear Tooth as Cantilever Beam lubricate.[PT oesign of Machine Elements (SPPU) 1417 Spur Gears In analysis of beam stength, following assumptions are made (@) The full load is acting tthe tip ofa singe tooth i) The effet of the radial force is neglected. ii) The Load is uniformly distributed across the full face width (iv)_Efect ofthe stress concentration i neglected (0) Frictional forces due to teeth siding are neglected, i) The full load is acting atthe tip ofa single tooth : + This is a conservative assumption, because full load is never acting at the tip ofthe single tooth, + When the contacts atthe ip, the louis being shared by more than one pair an the load is aken by a single ‘ir, only when the contact point moves down some distance fom the ip. (i) The effect of the radial force is neglected : ‘The radial force “F,” which induces the direct compressive sires, is relatively small ‘The load is uniformly distributed across the full face width : ‘The non-uniform distribution of the load across the face wih is accounted by a Toad distribution factor in the design process, (iv) Biect of the stress concentration is neglect It is accounted by a stress concentration factor in the design process. (9) Frictional forces due to teeth sliding are neglected : ‘The effect of {frictional force on the tooth bending is insignificant. 1.11.2 Lewis Equation for Beam Strength of ‘Spur Gear Tooth : > (Dec. 15) @._ Derive an expression for beam strength of spur gear tooth, ISPPU - Dec. 15} 0 “iy ach tooth is considered as a cantilever beam fixed at the base as shown in Fig. L111 "The normal force “F * acing at the tip of the gear tooth is resolved into two components (Radial force (F,) (i) Tangential force (F,) Radial force (F, ) : The radial force “F, * induces a direct compressive stress of relatively sinall m:enitude and hence its effect is neglected. induces a Tangential force (F, ) : The tangential foree bending stress which tend to break the tot ‘The section BC is the section of maximum bending moment, and hence maximum bending stress. Let, M = maximum bending moment at section BC, Nemm =F, ‘tangential force acting on gear toth, N 1 = length ofthe tooth, mm thickness ofthe tooth at section BC, mm te face width of the gear tooth, min 1 = moment of inertia of tooth section BC about the neutral axis N, mum = 75 b¢ ‘The maximum bending stess at point B is given by. EXxD(/2) FG g = Ma xde ah @ 13 ne From Equation (), the tangential force acting on ger tooth is given by, ain ) The variables ‘t” and ‘T depend upon the size of the gear tooth and its profile Let t= kp and T= kp © where, pe = circular pitch, mmFE ocagn natn omens (SPU) a Spur Gears yk = constants ‘Table 1.11.1: Lewis Form Factor Y + Substituting Equations (c)in Equation (b), we get, o:b-k-p, ky Pe oR = obey (8) were, Lewis form factor based on circular pitch 5 ane 02607 2 ao 7a 4 0.2356 02765 is 0.2545 0.2890 Equation (@ can be writen a, 16 0.2592 0.2953 oe bem-ay " 0.2639 03016 or R= oebem¥ © le 2 8 02702 03079 where, Y = Leis form factor = ny off) 9 0.2765 03142 + From Equition (¢), when the bending stress reaches the 20 02827 03204 limiting value ie. bending endurance strength or a 0.2860 03267 Permissible bending stress ‘0,", the corresponding a os aes tangential force is called the beam strength, ee 2B 0.2953 0.3330 ‘+ Substituting 0, = 6, and F,= F, in Equation (), the beam oe ea fan strength of spor gear tooth is given by, ne ae 25 03087 03393 y= Oy be ms ALD ao 7 ay 2% 03079 0.3456 ‘Where, FR, = beam strength of gar tooth, N 5 0310 03487 6, = bending endurance strength or permissible 8 03142 03519 ‘bending stress, Nan? 30 03173 03581 Equation (.11.1) is known as Lewis equation for beam 4 03267 o3701 strength ofa spur gear tooth. 38 03330 0.3833 1.11.3 Lewis Form Factor (Y) : a 03393 03958 +The Lewis form factor ‘Y” depends upon : ea 03456 me aoe o 03580 0.4210 Gi) Tooth system, and 15 03613 04335 (Gi) Point of application of load un) ans a! 150, 03738 0.4587 # The values of Lewis form factor *Y” for different tooth 300 03833 oan systems fr tp load conditions are given in‘Table L.1 1. Rack 0.3895 0.4838[Ef oecign ot Machine Elements I (SPPU) 119 Spur Gears ‘+ If the table forthe values of Lewis form factor “Y? is not available, then the approximate values of Lewis form factor ¥" con be calculated by empirical relations given below ; y= 0486 222) 20" deh ini <2 . ve 055-28 | pearnianme 1119 ¥ = 039-75 | for 145° fulldepthinvotute and : composite 1.11.4 Bending Endurance Strength ( cy): ‘The gear tooth is subjected to repeated bending stress. The ‘bending endurance strength or permissible bending stress for the _gear or pinion is given by, Kyo Ky Ky Ky KK S, = KKK Ky KK, x05 8, (13) = ultimate tense strength, N/mm? S, = endurance limit of test specimen, N / mim? Syllabus To} Face Width 1.11.5 Face Width (b): + The face width of goa taken between 9 and 15 times the module ie.9m < b<1Sm ana) + The most common value of face width is, b= 10 m or 12m. 1.11.6 Weaker of Gear and Pinion : + In the design of a gear pai, it is necessary to decide the ‘Weaker member between the gear and pinion in bending, + According to Lewis equation, the beam strength of a gear ora pinion tooth is given by, o,-b-m-¥ us) ‘© This seem that ‘b” and ‘a’ are same for gear as well as pinion. ‘© Hence the product ( 0, x Y ) decides the weaker member between the gear and pinion in bending, # TE (OXY )pen <(O5*Y Mpar # Pinion is weaker in bending. TCG Y pina (XY yur + Bear AS weaker in bending. + When the gear and pinion sre made ofthe same material, then 9," is same for both the members and hence *Y" is deciding factor. In such case, pinion is always weaker because *Y” is lesser for pinion as compared to gear — ‘Syllabus Topic : Wear Strength (Buckingham’s Equation) ee 1.12 WEAR STRENGTH OF SPUR GEAR TOOTH > (Dec. 12) —_— SES “Datine wear svength of spur gear tooth, ‘+ Wear strength of the gear tooth is the maximum tangential load the gear tooth can take without pitting failure. ‘© Ina gear pair, as the two mating teeth surfaces are pressed against each other, the contact stresses are induced on the rating surfaées. The pitting failure is due to repetitive contact stresses. ‘+ When the tangential force, ‘R'is increased, the contact stress, “cq also increases © When the contact stress reaches the limiting value. surface endurance strength ‘o,’, the corresponding tangential force is called the wear strength. “The wear strength of spur gear tooth is given by, FL = dybeQK (21) where, Fy = Wearstrength of gear toth, NPoesian of Machine Elements - Il (SPPU) 1-20 Spur Gears X= fxd fo Wi? x= os[@2] wim? 29 @ ras (1122) | 4.42.2 Ratio Factor (Q) : = Ratio factor for external gear pair + Ratio factor for extemal gear pair is given by, uation (1.12.1) is known as Buckingham’ equation for o- a (129) wear strength of a gear tooth, 1.12.1 Load-Stress Factor (K) : ‘+The load-stress factor fora gear paris given by, of sng-coso ftv 5+ 7 ye] (1.23) ‘The surface endurance strength can be expressed in terms of Brinell hardness number as, o¢ = 2.65 BHN (1.124) ‘Simplified expression for the load-stress factor *K? Inthis case, o= OF =0292 (1.125) and 20710" Nimm? Substituting Equations (1.124) and (1.125) in Equation (1.12.3), the load-stess factor for steel gear par is sent, x= 2SSBHI sin 20-008 20 | 20700 + {1 — 0.292") / 20700 eae ena = ois [8], a = 06 [BS] sniem? sane 2. Caton pin and cat ga: elon st ication gi gy x= oaf BE] we? can 2. Stel phon and ct apa ‘The load-suess factor for steel pinion and cast iron gear is sivenby, ‘+> Ratio factor for internal-exteral gear par is given by, 22, 5% Q= (1.12.10) 1.13 EFFECTIVE LOAD ON SPUR GEAR TOOTH > (Feb. 1641 Sem)) Effective load on the gear tooth is the tot maximum ‘angel fore acting on the gear tooth 1.13.1 Theoretical Tangential Force ( F, ‘The theoretical tangential force acting on the gear tooth due to the power transmitted is given by, (1.13.1) theoretical tangential force acting on the geartoth,N Ty, = torque ating onthe pinion and gear respectively, Nom yd, = pitch cic diameters of pinion and gear respectively, mm: P = powertransmited, W V = pitch ine velocity, mee pads pee Be 0% 1000 * 60% 1000 1.13.2) 1», = pinion and gear speeds respectively, p.m,(design of Machine Elements Il (SPPU) +21 spur Gears ‘Syllabus Topic : Service Factor, Load ‘The nature of loads for different applications are given Concentration Factor in Table 1132 4.13.2. Maximum Tangential Force ( Finax) : ‘Table 1.132: Type of Loads for Different Applications + The torque, and hence, the tangential force given in above || SF | Typeof ‘Driven Machine Now | Load Equation (1.13.1) ae the mean values. = s 1. | Uniform | Generators, liquid mixing agitators, ee mixers, centrifugal blowers, centrifugal Aistibution ofthe load across the face width are accounted by compressors, centrifugal pumps, medium | duty conveyors, fans, ete © This fluctuation in the tangential for. application factor °K,’ and load distribution factor (losd concentration factor) ‘Ky respectively. 2. | Moderate | Liquid and sole mixing agitators, ma Shock | epinderrexiprosting compressor, 4 Hence the maximum tangential force acing onthe gear tosh | ruleyindereiprocating pumps, is given, heavy dy conveyors, sugarcane crash, hoists, concrete mixers, textile machinery Fe = BR | at «Rae KE | (1133) || 3. | Heay | Single-cylinder reciprocating Shock | compressors, single-cylinder 1. Application factor or service factor or reciprocating pumps, sone casters, ‘overload factor (K,) : passenger it, beavy day hoists, bbammer mills, presses, rolling mills, ‘+The application factor 'K,’ depends upon the prime mover tumbling barrels, printing presses, et. and the driven machine. The values of the application factor | — 2. Load distribution factor or load concentration ‘or service factor ate given in Table 1.13. factor (Km): ‘Table 1.13.1 : Application Factor or Service Factor (K, ) | ‘The load distribution factor or load concentration facto Sr..| Prime | Duration Drivest Machinery accounts for the non-uniform distribution of Toad across the No. e =] -e width, Ta ives the values of the loa Mover | ofService |, lg face width, Table 1.133 gives the values of the load i ‘hoursiday) Soa | Sek Aistribution factor Ky, 1 ‘Table 1.13.3 : Load Distribution Factor ‘K,. for Spur Gears L. | Electric 12 100 | 125 | 195 Motor mw 125 us | 200 Sr. or el Steam Turbine | fos Pal aa a ie 15 | 200 ||| 1 | Accurtemounings, | 13 | 14 | 15 | 18 | small bearing i Cylinder | 94 18 Lis | 225 | | clearances, minimum | deflection, precision Engine ears. 3. | Single- 2 1s 17s | 225 2. | ressrigidmoonings, | us | 17 | 18 | 20 cylinder] 2g | urs | 20 | as m : ;* | les accurate gers, 1c. | Engine | ‘contact across the full faceA Design of Machine Elements - (SPPU) 1-22 ‘Spur Gears ‘Characteristics of Face Width, mm al ‘Table 1.13.4 IS Gear Grades Support i Upto | Upto | Upto: | Upto i : 80] 180 | 225°} 400 || suet that ess than full | | 12 | vertow | catingor — | uedtorow | veto L_[freeeonact eine Aca | woaig. | pein 1.13.3 Dynamic Load on Gear Tooth and its 2 bes Causes : voce | tow | bi Vedforiow | V<20 D (Fob 15(InSom)) || 1 | Accuncy | sharine.or | med ean SS © __| nite _ 8or9 | Mediam | Fnchobtingor | Uedtor | 20 V.2s ‘What are the causes of dynamic load in gears? ee Ss © | fotowedoy | stow spent savin | indo ges © — The gear teeth are never perfect but have some errors. The |[ ] ~ Gor? | Medium | Stavingand | Usdfortte! | 252 <30 tooth erors combined with the mass ofthe pinion and gear ae |e | result in inertia foroes. The addtional forces arising out of the Acricy | enphnison | and media inertia effets are known a ‘dynamic loads’, | prodesionte | spe indtat : ratertn | ga + Causes of dynamic load on gear tooth | ice uy ‘Thus the dynamic load between the meshing teth arises due |} or5 | igh | Suvingand | Uacste | v2.30 to the following factors Accuracy | fine grinding. | ewbine geaing, | “ secospace Tnaccuracies in tooth profile; seating, and Errors in tooth spacing; | cried nds ga, Run out ofthe gear; 1,2or | Usa igh | Finish grinding | Useéformister | 40:< V <200 3 | Accurey | follonedty — | gears, teeth passthrough the meshing cycle; (Aa) | boning Gear mesh stiffness variation as the gear (%) Inertia of rotating masses; Syllabus Topic : Velocity Factor, Estimation of (i) Deflection of the teeth; and Dynamic Tooth Load by Velocity Factor and Buckingham’s Equation (vit) Stiffness of the rotating pas. 1.13.5 Methods of Estimation of Dynamic 1.13.4 IS Gear Grades : Load and Effective Load : + Based on the accuracy of the gear tooth, 1S has classified the D (Feb 16 (In Sem), May 16) gears into twelve different grades from grade Ito grade 12 in the decreasing order ofthe precision + Table 1.134 specifies the manufacturing methods, typicel applications, and permissible pitch line velocities for different grades of gears,i onan ot activa lori SPU) 1. Preliminary 1.23 Spur Gears + There are two basic methods to estimate the dynamic Joad and effective load: Methods to Estimate Dynamic Load and Effective Load] 1. Preliminary estimation by velocity factor 2, Precise estimation by Buckingham’s equation Estimation of Dynamic Load and Effective Load by Velocity Factor : 4 Inthe preliminary stages ofthe gear design, the dynamic load is approximately accounted by the multiplying factor‘ known as velocity factor. The velocity factor ‘K,’ depends ‘upon the pitch ine velocity and the accuracy of gear teeth. +The velocity factors or dynamic factors for various accuracy levels are given in Table 1.135. ‘Table 1.13.5 : Velocity Factor K, for Spur Gears Accuracy | moulding ® 6 too | Low | Hobbing, vero ate 11 | Aecurey | shaping © ili. | as | 8or9 | Medium | Finehobbinger | 205V<25 ns ee Accuracy | bobbing ©. | fatowesby saving 6or7 | Medi | Faitedty | 255V.<20 igh | saving aowed Aecarcy_ | by ine ® ors | nigh | eishesty ven | Accarey_ | saving lowed [Needs (6)__| by fin idig 2or | UieaHigh | Fisted by ne | 4o KF, tangential force, N = plese teererouvbo cee Paste ae resets et concentration factor” ech eeen as = deforma fer dui et, Nam Eis ewe [ BE] 30 (G) : = moduli of elasticity of pinion and gear material respeptively, Nimm? = sumoferors onthe meshing teeth, mm K = tooth form factor. = 0.111 for 20° full-depth involute(sign ot Machine Eisen Il (SPPU) 124 Spur Gears = 0.115 for 20° stub-toothinvolute or C = 89006,Nimm (L312) = 0.107 for 14,50 full-depth involute and (Gil) Steel pinion and cast iron gear : composite system Inthis case, + Effective load (Fi) © = 10000, Nim (1.13.13) ‘The effective load between the meshing teeth in tangential Aiection is given by, Pitch errors on meshing teeth (e): ‘Sum of the pitch erors between two meshing tecth is given Pq = KK R+Fy 4113.7) | by + eformation ctor or dynamic factor (C) c= ste, (1314) ‘The deformation or dynamic factor °C’ depends upon the | Whe" &» = pitch error for pinion teeth, rm accuracy of gear teeth; material of the meshing gears, and = pitch error for gear teeth, mm tot form . The toleranoes fr ajacent pitch err‘ for dee gear ce (113.8) | grades ae given in Table L136 ‘Table 1.136; Tolerances fo the Adjacent Pitch Error ‘The expresin for dtomation factor ‘C” canbe simplied | pm = aes for dierent pinion and gear mati combinations and 20° | | ESGRIHES | Adiacent ich Bron ioons) ‘Pressure angle as follows 2 [ 63.00 + 5.006, @) Steel pinion and steel gear : u 45.00 + 3.559, Inthis ese, ay eee 22.00 + 1.80. K = 0111 } o. + ats E,=E, = 207% 10° Nim +139) 5 1 11.00 +0.90 4, bsiing uation (1.139) in 139), the a Substiuing Eypaion (1.139) in Bguation (1.138, mae defomation ator fost gar aris gven by, 5 0 5 5.00 +0.40 9, © = onre| A aT) see = (207 x 10} + 207% 105, 4 3.204025 4, oC = 11500e,Nimm (0.13.10) 3 2.00 + 0.16 9, (Cast iron pinion and cast iron gear : 2 1.25+0.10 4, In this case, 7 1 0.80 + 0.06 9, K = Olt } where, = m+0.254d (1.13.15) E,=E, = 160x10' Nam? 0.13.11) = ‘twlerinse facor Substituting Equation (1.13.11) in Equation (1.13.8), the defomaton factor’ for csr gear pais given by, [tex 10160108 C= tare OME m= module, mm = pitch circle diameter, ramroe EEA (Ef oie ttn Eure 60 1-25 Sour Gears 4.14 SAFETY OF GEAR PAIR 4, Safety Against Bending Failur ‘+ In order to avoid the bending failure or tooth breakage, the beam strength ofthe gear tooth'must be greater than the effective load between the meshing teeth. Therefore, R> Far (1.14.1) Introducing factor of safety, B= Neo By (1142) where, Ny = factor of safety 2. Safety Against Wear Failure : © In order to avoid the pitting failure oF wear failure, the ‘wear strength ofthe gear tooth must be greater than the cffective load between the meshing teeth, Therefore, FL > Far 1.143) “© Introducing factor of safety, (144) where, Np = factor of safety. + Normally the recommended factor of safety for gears is between 15 to 2: However, in some critical applications, itcan be up to 3. SNe een Syllabus Topic : Estimation of Module Based on Beam Strength and Wear Strength ES 1.15 DESIGN OF SPUR GEAR PAIR Design ofa spur gear pair includes ‘Selection of tooth system; Selection of numberof eth on pinion and gear; Selection of materials for pinion and gear; Selection of surface hardness for pinion and gear; Selection of gear grade; Estimation of module, face width pitch circle diameters. “The procedute forthe design of spur gear paris outlined in Fig. 115.1 Fig. 115: (Contd...)[Ef besign ot Machine Elements (SPPU) 4-26 Spur Gears ' i , i i‘ [Poesign of Machine Elements - II (SPPU) 127 Spur Gears [As pinion and gear are made of same materia, pinion is | © Rstimation of module weaker than gear in bending. Hence itis necessary 0 design | 4 geet voi the pit alae, the pinion for bending Ne Fa @ + Assuming 20° fulldepthinvolute tooth system, 281 _g4g4 281. vy, = 0491-297 4s4— 2 asats Let us assume b = 10 m. o,-b.m-¥,=220% 10 mxmx03405 oF = 749.1 m,N a) + Wearstrengt 4, = m-7,=20m 2m ax 24 2x80 16 Q = Fee 80+20~ For see! pion and stel gear, BEN] x = a1 [28] -015 [$3] ~196Nan wt] dy-b-Q-K=20mx 10mx 1.61.96 or Ry = 6272m, 0) As Ry < Fy » gear pair is weaker in piting, and hence, it should be designe for the safety against pitting failure. + Bifective load : Md My x 20mx 1440 Y= BO ae ing = 508m, mis 10000. _ 66313 R= veTs0m= m 'N Assuming the gear pair is manufactured by hobbing, shaping «milling, the velocity factor can be taken as, 6 6 TV" Es 150m KK R, Fy = ee aK Ls 66313 (=m) * 1657.82 (6+ 1,508 m) 16578216 + 1508 m) or Fag 4) ‘Substituting Bguations (a) and (c) in Equation (2), 157 onan = 1, (6+ 1.508 m) 217546975 m Solving above Equation by ial and error, we ge, m = 378mm From Table 1.4.1, the standard value of module under first choice is 4 mm. + Dimensions of gear pair : m= 4mm; 20; a= 85 b= Wm=10x4=40mm; = 20 80 mm ; 4, = m-1,=4%80= 320mm; by = Lm=4mm; hy =125m=Smm5 a= G@y+d)/2=(80+ 320)/2= 200mm. Ans. ‘+ Available factor of safety against bending fallure (Nq) + 1657.82 (6+ 1.508 m) _ 1657.82 (6+ 1.508 x4) orPy = 4986.7 e R= o nhs, © Available factor of safety against wear failure (N,,.) rR Fe 1003526 Nae epee 201 Ans, Examplet.15.2 TEEN ‘A pit of spar gears wih 20° full dephinvolue txt sw be sed {or speed reduction of 41. The pinion shaft is to be comer t 10 XW, {440 rpm. electric motor. The staring torque of am[Er ong ot ace mers (SPU) 125 ‘Spur Gears eee motors 150% ofthe sted torue. The pinto a wl ‘8c 6 made of pain carbon steel 40CR (S, = 600 Ninn). Tae facioe of safety is 15. Assuming the velocity factor, K, = pe ‘ccouis forthe dy loo, design the gear pir. Sugeest ‘fiesharéess fo gear pi. Solution : Given: @ = 20° 5 Ge 4; P= 10x10'W 15 I N= 15 + Beam strength : For 20° ful-depth involute tooth system, tke 2, = 18 Sx _ 600 ae oe =P = 200 Nim 281 281 ose. je” = 0.3285 = 0484 10m o,-b-m- ¥p=200% 10 mx mx 0.3245 or 649 m?N a) nda, me ye ee a x 100 * BOxc1000 seem 18 1440 = Reet 357mm 10% 10° _ 7369.19 BS ¥= 135mm oN 0) 3 K > 3yv "301m fe Keak we OK 451.0% 7369.19 1 .6(3-+ 1357 we ig = 36 a ‘+, Estimation of module: In order to avoid the bending failure, 640mt = 1 $y 36848041357 m) 7 2555+ 11556m Solving above equation by trial and error, we get, m= 42mm From Table 14.1, the standard value of module under firs, + Dimensions of gear pair : Smm 34 X18=72 ; b= 10m=10x5=0mm; x18=90 mm} mz,=8x72=360mm; m=Smm ; — by=125m=625 mm; 4, #4).2=00+360) 72 = (00+ 360/2=225 mm, ks, + Surface hardness : x, ae k= 16 [App] sin? Be = 4.b.Q.K = 90X50 1.6% 0.16 [BHN/IO0F ot Fy = 1152 (BHN/00],N @ _ 684606+1357m) = $5866 2135729) po 35y In onder to avoid te piting failure, R= N Be 1152 (BHN/IOOy = 15721076 BEN = 30640°310 BUN = 310 hs.[PP oesign of Machine Elements -II(SPPU) 1.29 Sour Gears. Example 1.15.3: ISPPU - Dec. 1 “The following dara is given for 2 spur gear pair made of see! and transmitting 5 KW power” from an electric motor ranning at 720 pmo. machine ¢ Number of teeth on pinion = 21 © Number oftesth on gear = 4 © Face width 210m © Ulimate tensile strength for pinion material = 600 Nim? © Ultimate tensile strength for gear material =400 Nim? © Tooth system = 20° Ful dephinvotte © Service factor 125 + Loadconcenttaton factor. = 16 © Factor of safety: #20 © Tooth form factor for pinion = 0326, © Tooth form factor for gear = 02389 # Velo fico a ¢Ledsceis oe 0.16 {BEN 1007, Ninn + Standard module it mm 1, 125,20,25,30,40, 50,60, 8.0, 10.0 : bi Cceuae : (the module; (i) the main dimensions of gear pair and (Gi) the surface hardness. Solution : Given: P= SOW 5 = T20epm z= Hu B b= 10m 5 Sy = 600Nimm'; Sy = 400Nimm? ; - § = 20%, i Ky = 16s Ny = 20 + Y, = 0326; Y, = 0389 K, = 66+¥) Now, Oy: ¥p and Oy: ¥, = 13333%0389=51.87 Nin [As Oy, ¥,< 0h," Yp, Bear is weaker than pinion in bending. Hence, itis necessary 1 design the gear for bending, ong b.m Vy = 133.33 10mxmx 0389 or Fy = 518.66 m",N @ © Effective load : Sioa = 07917 mw 12516 63155 6 SF 07917 oe Fy = 2OSAG 02910) A + Estimation of module: In order to oid the bending false, NF © Substituting Equations (a) and (b) in Equation (c), 4874643 Solving shove Equstion by tial and ero, we ge, m= 424mm “The standard vale of module under fist choices 5 mm + Dimensions of gear pair: m= Smm 5 n= 5& Design of Machine Elements - Il (SPPU) 1-30. ‘Spur Gears 4, = m-z,=Sx21=105mm ; Solution : i dy = mn,=5x40=200 mm; Given: = 20° + Re 2; | b= imsSmm ; hy = 1.25m=6.25mm; y= 60 4} tp = 1000r-pm; | a = @,+d)/2=(105+200)/2=1825mm. Ans. = 20x10°W Gey = Oxy = 260 MPa; «Surface bariness : e = 40x10%mm; C= 11500eNinm; ~ 2% 2x40 K, = 13 + KL = 125; Q = Feat aoea 13 6 2 N= 14 oR ay BHNT' 2 «= 016 [BEY Winn + Beam strength: i R= 4boK 108 50% 1.311 x0.16 [BHN/00]? 1101.24 [BEIN/100}*, N 2108.17 (6 + 0.7917 m) m 2105.17 (6 + 0.7917 x5) 3 fd) =419287 N nord t avoid piting failure, F, NeRep 1101.24 (BHN/IOO}? = 2.0% 4192.87 BEN AAs pinion and gear are made of same matetial, pinion is weaker than gear in bending. Hence, it is necessity to design pinion for bending. Assume, b= 12m R= oy: bem-¥,=260%12mxmx 0.3405 or Fy = 106236m,N -@) + Bifective toad: = ER _ 20m x 1000 _ Ve ‘Bx 1000 =~ 60x 1009 = 10472 ms P_ 20x10" _ 1909859 B= v= jomm =m oy 6 6 K = SV" Sr lonm KKeR 15x13 Rg = Rope 1x (jE oe Fy = BGs LTE ie + Estimation of module In oder to avoid the pitting faiure, Ne Ea = 4 SE2SBIG+ 1.0672 m 40947.138m Solving above equation by trial and eror, we get, m= 413mmog sneer orrmennnoruse remeron _erererersinanannsnimnieststl or N= Ld [BF oesign of Machine Elements - I (SPPU) 131 Spur Gears From Table 1.41, the standard value of module under first choice is S mm. Dimensions of gear pair : ‘As te avilable factor of safety is equal tothe required factor of safety, the designs ste © Surface hardness : 2a ms Smm ; 4 = 205 Q- Tae a= 6 5b = 10m=I2xs K = 016 (BHN/100]° 4g, = m2,25%20= 100mm 5 R= 4b OK = m7, =$x60=300 mm; = 10060 x 1.5 x0.16 [BANOO b= lmeSmm ; hy = 128m=625mm; | oe =) a = (@+6)/2= (100+ 300)/2= 200mm. Ans. eee By = Ne Far + Precise estimation of dynamic load by Buckingham's ‘equation (check for design): 1440 [BHIN/IOO] = 1.4 x 18858.48 BUN = 42819 0490 The Buskngtan’ eqution forthe dyamic a ia geal etn ven, 21 (C+) 19098.59 _ 19098.59 pe 3819.71.N fe = Kye Kg: F,= 1.25% 13%3819.71 = @20T01N V = 10s72m=10472x5=5.236 mis © = 11500e=11500%40% 10"? = 460 Nima 21 x 5.236 (60 460 + 6207.04 21 x5.236 + [60 x 460 + 6207.04 = 1265145N ~@) ‘+ Available factor of safety: Fa = Ky Ky Ret Ry 1.25% 1.3 3819.71 + 12651.45 oF Fy = 1885848 0) From Equation (9), Given: 4 = 20° + = 1000cpm; Fy = 1062.36 m’ = 1062.36 x (5)"= 26559 N P=75x10W ; m= S00rpm; ene the available factor of safety i, Sq = 40Nmm? =; K = 1255 Bie, N, = 175 : Ve Sims; A No = Ry? Te868.48 ADS. iMa Design of Machine Elements - Il (SPPU) 1.32 Spur Gears © Number of teeth: For 20° full-epth involute, the minimum number of teeth | sspiedapiini «18 aoe 2% 100 _ | m7 eX + Dam see: Tg bat0m x, = 04622 nat 22 cosas ; abn, 136.67 x 10m x mx 0.32455 443.56 m,N a) y = ete May = Gx 1000 * 601000 mx 18x 1000 2 Oe 196 m,mis 7 ps0 o ‘Assuming gear pair is manufactured by hobbing, shaping or miling, Estimation of module : In order to avoid the bending failure, = NeRe 2 xi ‘nso? - V2Sxisasa m= 416mm From Table 1.4.1, the standard value of module under first hice is am, + Dimensions o gar pair m= Smm jz, = 185 22% 5b = 10m=10x5=50mm; x18 = 90mm; 5x36 = 180mm 5 m=Smm; by = 1,25m=625 mm; (4, +4,)/2 =(90 + 180) /2= 135 mm, ‘+ + Precise estimation of dynamic load by Buckingham’s equation (check for design Forgndes, © = 80+063(m+025fa) Forpinion, ¢, = 80+063(m+025Y4,) 8.0-+-0.63 (5 +0.25 9190 ) = 12.64 um 8.04063 (m+0.25 4.) 8.04063 (54025180) = 13.26 4m ey beg= 1264+ 13.26 259 wm =25.9x 1 The Buckingham's equation for dynamic load in tangential iretion is given by, DLV (0C+ Figg) eo GiveVtGrhiae Now, C= ce=11400% 259 10°? = 295.26 Nim V = 094m=084x5=47 ws a TSIM _ 795714 _ 155155 y m 5 Fang = Ky Kg*F,= 125 10x 1591.55 = 1989.43 N f, = 21X41 (50%295.26 + 198943 214.7 +99 50% 295.26 + 1989.43 7247.86 N @[BF oesign ot Machine Elements (SPU) +33 Sour Geare «Available factor of sfety Sa = 00 mm? 5 1s Fa = Ky ky RFs N, = 20 = 9x10? mm = 125% 1.0% 159155 + 724786 + Number of eth or Fy = 92373 fo | Garrats, From Equation, . = 10898 4) | 11089 250 = 373 oN, = 12 Ans. ne Example 1.156: ee mz, = 100 100 a- @ ‘A pir of spur gears is to be used for driving 2 compressor at 250 rpm, by a7.5 KW, 1000 rpm. electtic motor. The center sistance is 250 im, The gears are tobe made of plain carbon steel SOC4 having ultimate tensile sireagth of 100 MPa. The service factor is 15 while factor of saferyis 2. (@Inikally- using: velocity factor, design the gear pair and specify ter dimensions. (Gi) Assome Grade 6 of manufactur, find exact dynamic load using Buekingham’s equation, (ii) Find the avaiable factor of safety forthe designed gear pir in bending i) Specify the required surface hardness, Use the following data © Pressureangle, 6 = 20° © Levisttomfaser, ¥ = 0484— © ForGrade6, ¢ = 39m 21 (ee + Fan) Te ee © Deformation factor;© = 11400 Nim? © Standard module : 1,125, 15, 2.0,2.5,30, 4.0, 5.0, 60, 80, 10, 12, 16,20 mm Solution : Given: n, = 250rpm. ; m= 1000rpmy p= 700W a = 250mm, ‘The pressure angle is 20°, Hence, the mumber of teeth on pinion should be 2,2 18. The numberof teeth on pinion is selected as follows 4, 19 2» 100 : mep | 555 5.26 5 a, ‘Remark | Not feasible | Not feasible | Feasible | 2% = 20” and m= ‘Take b= 12m=12x5=60mm ‘+ Dimensions of gear pair : m= Smm 5 ty = Ga,=4x20 b= 2m=12x5=60mm; ma, =$%20= 100mm ; x80 = 400 mm; bh = 1m=Smm; by = 1.25 m=6.25 mm; (aed) (S24) 100110 ym, nsSpur Gears Design f Machin Elements 1(SPPU) 134 «Beam steagih Su a o, = 8-20 -09,35 Nin 1s po and ger a made of sme materi, pion eal in beng Hence, eer i he pion fo venig B= obo Y,22839x00%5x05405 or (3834.66 N- (a) + Dynamic load : For grade 6, ¢ = 39x10? mm C= com 003910" = 4446 Nim 60 x 1000 23 40a Sx 10x 48408 2215105 21 -V (bce + Fina) Fi = Five boot Fyn A1V C4 Fea) * ive tcrF,,., 225 6p 64 215105 BixsaseV order aS10 eer, = ns29%6N st + Ayala tctr off asat ening are: oe = sx tenis 1132196 or Bap = 13474.01N “b) . F, _ 23834.66 Hence.N, = F2 = [a741 ee Ne wn toe Te sale ur of ley au Deadig (1.7 Sigh estan ged ar of sly 2) ‘There is restriction on center distance, and hence, module can not be increased. The factor of safety can be inereased by selecting the material with higher valu of ulimate ensle strength, + Material selection for achieving required factor of safety : 20 = “7407 20x 1347401 = 6, x60x5x0:3405 Su 20x 1347401 = x 60x5x0.3405 791.4 0° 800 Nim? ‘The material selected should have ultimate tensile strength of 800 Nimm’, sures tana: 24 24 em Q= Fay +0 716 = o16[ 2] rn? 4b QK msonrencas| = 100 or 1536 [icc Hy ] (0) node to avoid the piting failure, Bee NR 1536 DET = 20% 1347401 BUN = 4188 or 420 wich the oad distbuon ecto i 14. "The: gears are to be[Eh si of tzcine Elements =I (SEPU) me 35, ‘Spur Gears fachined: 10 meet the specifications of grade 7 for which ‘deformation factor is 240 Nimm, If the fector of safety sequicedagsinst bending failure is = 15, design the gear pair by using the dynamic’ factor eas loa. (the factor of safety requir against pining failure is 20, specty the surface hardness. Solution : = 20 : Sj, = 580Nimm? ; P = 15000 K=2 o= 20° b= 2m; Ne = 15 Nw = 20 ¢ = 240Nimm, +” Beam strength : 193.33 x 0.3405 = 65.82 Nimm® 86.67 x 0.4502 = 39,02 Nim? AS Oye * Y, < Op * Yp, gear is weaker than pinion in ‘bending. Hence it is necessary to design the gear for bending, Fy = oyy-bem-¥,= 86.67 x 12mxmx04502 ot Fy = 468.22 m*,N (a) + Bective load : ve eet | Ox 1000 = Ox 1000 _ xmx20x 1440 _ = Ron = 1508 m, mis : | and Buckiaghems equation for dynamic 15000, _ 9947.18 1508m ~~ om oN ®) uss 106m or fy = M2026 Ey © © Estimation of module : In onder to avoid the bending failure, BL = Ny Pye 1 5p 2.02 6-4 1.508 m) 468.22 nF N 89.228 + 22.426 m Solving above equation by tral and eror, we get, m = 61mm From Table 14.1, the standard value of module under first choice is 8 mn, © Dimensions of gear pair : m= 8mm ; 2, = 20; m= 5 b= Rm=12x8=9mm; 4, = m-7,=8%20= 160mm; m7, 28X85 = 680 mm ; bh, = 1m = 8mm; by (4, +4,)/2= (160 + 680)/2= 420mm. Ans, 1.25m = 10mm; ‘+ Precise estimation of dynamic load by Buckingham’s equation (Check for design) : ‘The Buckingham's equation for the dynamic load in tangential direction is given by, VOC, aver Yor, % = BEML ‘oat KyPocsign ot Machine Elements - 1! (SPPU) 1-36 v 1,508 m = 1.508 x 8 = 12.064 mis 2112064 (96 240 + 34815) 8 21x 12.064 + Y96%240 + 3481.51 161439 a) + Available factor of safety : = KK eR +R 2x 14% 1243.39 + 161439 1962539 N ©) - From Equation (2), Fy, = 468.22 m’ = 468.22 x (8) = 29966.08 N ..(f) Hence, the available factor of safety is, Ne 1527 > 15 Ans. ‘As the available facor of safety is higher than the required factor of safety, the gear ais safe against bending ale. * Surface hardness : Q K QK = vase taro. BY o 4447632 [BEN / 1007," ls) Inorder to avoid the pitng failure, Fy = Ne Far 4476.32 (BHN/O0" = 2.0% 1962539 BHN = 296.11 0300 BEN = 300 ws, Example 1.15.8: ‘A. spur gear_psir, ‘made of plain carbon steel S5CB (S,,= 720 Nimm’ and E = 210 GPa), is required to transmit 7.5 kW power from an electric motor running at 1440 rpm, to @ machine running at 370 ran. The tooth system is 20° fll-depth involute Spur Gears int nero eh server ft nd od soon tre 125 a 12 rape The of ay oid 125015 Tee wan mete eh ee pa be mine rt seater cs eer te vay ae Ky = $25 ad Bags eatin fr are a6 minimum as possible. The dynamic load. Suggest the case hardness for gear pair. Use vaneennCntt| 8) om Solution : Given: Sy, = 720N/mm 5 P= 750W a, = 370rpm = % = Ta 3K = 125; kK, = 12 5 ON, = 1251015; b= 12m kK apy ‘+ Number of teeth: For 20° fall-depth involute, the minimum number of teeth required on pinion i, z= 18 21440 oS 4 6 Es & 39919 = 75 2, = 7005 0°70 F, = o:bemY, = 240% 12mxmx 032455 or R= 9472m,.N @ ere eeeee aR [i vesign ot Machine Elements il(SPPU) 137 ‘Spur Gears + Eiffective load : nin, a2, 0x 1000 * 601000, ve mmx 18x 1440 60x 1000 7500 357 m, mis 5526.89 0) K = sey aFLaTm , fy = _ Ansxizessi6g9 m 3 (rm) erg = Mose o Estimation of module : In order wo avoid the bending failure, Fy = Ne Fug Initially taking factor of safety, Nj= 1.5, 1.5.x 2763.44 3 + 1357 m) 934.72 m a 13346018 Solving above equation by til and er, we get, m= 32mm From Table 14.1, the standard value of module unde first choice is 4mm, ‘+ Dimensions of gear pair: m= 4mm 5 2, = 185 m™ 3b 2m=12x4=48 mm; 4, = m,=4x18= 72mm; x70 = 280 mm ; bh = 1m=4mm; b= 125m=Smm; a = (d,+4)/2=(12+280)/2= 176mm, ...Ans. ‘+ Precise estimation of dynamic load by Buckingham's equation (check for design): Forgrade?, € = 110+09(m+025V8) For pinion, 11.0+09 (m+0.25-4, ) = 1104094402573) =165 um Forgear, «= 110+09(m+0254f%) = 11.0409 (4 + 025-280) = 18.36 wm € = 6, ¥e,=165 + 1836 34,86 ym = 34.86 x 10° mm ‘The Buckinghamn’s equation for dynamic Toad in tangential rection is given b 21VOC+E, DV +afbC# Fa EE, oan «| EE 21031020 10") 33486 10°? | OIC 221010 oanasono” [Feigao] Now, = 40629 Ninn V = 135Tm=1357x4=5.428 mis 5526.89 _ 5526.89 ™ 4 381.72N Ko Kyo F, = 1.25% 1.2% 1381.72 = 27258N = 215428 (48 x 406.29 + 2072.58) 21 5.428 +f 48 x 406.29 + 2072.58 = 9427 @ + Available factor of safety Ra = Ky Ke RF, = 195% 1.2 1381.7249427 or Fay = 1149958 © From Equation R= 93472m*= 93472 47 = 149555 o) Hence the available factor of safety is, By _ 149555 = Fy = 1149958[4 esign of Machine Elements il (SPPU) or Np = 13> 125 As the available factor of safety in higher than the required factor of safety, the gear pai is safe against bending failure, Surface hardness : 2 2. OF ay K = 016 = db: Q-K = 72x 48x 1,590.16 [BHN/1007° 879.2 [BEN 100)" (8) In order to avoid the ping failure, By = Ne Be Taking Np = 15, 879.2 [BHN/100]° = 1.5 x 11499.58 < BHN = 442.93 or 445 ‘Spur Gears = 1OON/mm? —; € = 10um=10% 107? mm; C = 11400, Ninm; K, = K,=N)=1.0. ‘Number of teeth and module : = 2b Mo. Gea n0 +d, m2,+mz, eee mG +7) m(e+Gy 2 2 Bh wae arm eo @ w |» eal Next [ aste Ae = 0 p= 002420040 tne Bean rng: v= 04-22

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