MECH 2410

MACHINE DESIGN

Group 1

AARYAN NAIR
ITAY RUBIN
KEVINDRA GHAMANDI
EDMOND LEE

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TABLE OF CONTENTS
Page Numbers

➢ GEAR METALLURGY…………………………………………………………………………………………… 3

➢ GEAR DESIGN………………………………………………………………………………………………………… 5

➢ SHAFT DESIGN…………………………………………………………………………………………………………8

➢ KEY DESIGN………………………………………………………………………………………………………………12

➢ BEARINGS……………………………………………………………………………………………………………………13

➢ CASING……………………………………………………………………………………………………………………………14

➢ REFERENCES……………………………………………………………………………………………………………15

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GEAR METALLURGY
There are three major factors to consider while opting for gear materials. They are strength, durability, and cost.
The cost can be thought of as three individual costs- workability & processing costs, manufacturing, and the
inherent material cost. High load capacity requires a tough, hard material that is difficult to machine; whereas
high precision favors materials that are easy to machine and therefore have lower strength and hardness ratings.
Choosing the right combination of materials can ensure the gear can be used for the desired length of time
without safety hazards due to fracture.
Common Materials for gears and pinions

For the purpose of this project, based on the requirement that the gearbox is expected to operate 16 hours per
day, 5 days per week, with a design life of 5 years, with approximately 20,000 hours of operation, we plan to use
SAE AISI 1020 Cold rolled steel for the major gears, cast iron for the largest gear, and 1060 cold rolled steel for
the pinions.

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In the phrase, “1020 Cold Rolled steel” “10” refers to the alloy found in the Steel- Carbon, while “20” refers to
the 0.20% of Carbon found. This composition gives the metal reasonable strength and ductility. The phrase cold
rolled steel refers to the type of processing done to the steel. Cold rolled would mean that the steel would be
processed at cold reduction mills which would lead to a slight delay in time. This would make the cold rolled
steel have a higher finish and concentricity albeit being more expensive.

Processing the Material

Heat Treatment

When the grinding of gear teeth is not practicable and a high degree of accuracy is required, hardened steels may
be drawn or tempered to a hardness that will permit the cutting of the teeth. This treatment gives a highly refined
structure, great toughness, and, in spite of the low hardness, excellent wearing qualities.

The lower strength is somewhat compensated for by the elimination of the increment loads due to the impacts
which are caused by inaccuracies. When steels that have a low degree of hardness penetration from surface to
core are treated in this manner, the design cannot be based on the physical properties corresponding to the
hardness at the surface.

Since the physical properties are determined by the hardness, the drop in hardness from surface to core will give
lower physical properties at the root of the tooth, where the stress is greatest. The quenching medium may be
either oil, water, or brine, depending on the steel used and hardness penetration desired. The amount of
distortion, of course, is immaterial because the machining is done after heat-treating.

Making the pinions harder than the gear

Beneficial results from a wear standpoint are obtained by making the pinion harder than the gear. The pinion,
having a lesser number of teeth than the gear, naturally does more work per tooth, and the differential in
hardness between the pinion and the gear (the amount being dependent on the ratio) serves to equalize the rate
of wear. The harder pinion teeth correct the errors in the gear teeth to some extent by the initial wear and then
seem to burnish the teeth of the gear and increase its ability to withstand wear by the greater hardness due to the
cold working of the surface.

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GEAR DESIGN

Gear Configuration Schematic

Gear Design Calculations (Summarized)

Gear 1 and 2 Configuration

Initial Input Data (Gear 1) Location or Equation Value Units

Over Load Factor (Ko) TABLE 9-7 1.50 N/A
Transmitted Power (P) 8.0 HP
Designed Power (Pdes) Pdes = (Ko*P) 12.00 HP
Diametral Pitch (Pd) FIGURE 9-24 10 N/A
Input Speed (np) 3,000 RPM
Number of Pinion Teeth (Np) 18 N/A
Desired Output Speed (nG) 1,350.0 RPM

Nominal Velocity Ratio (VR) (Gear 2) VR= (np/ng) 2.22 N/A

Computed Number of Gear Teeth NG = nP(VR) 39.96 N/A
Chosen Number of Gear Teeth (NG) Choose a Logical Value (Teeth) 40 N/A

Computed Data Location or Equation Value Units

Actual Output Speed (nG) nG= nP (Np/Ng) 1,350.0 RPM
Gear Ratio (mG) mG = (Np/Ng) 2.22 N/A
Pitch Diameter - Pinion (Dp) Dp = (Np/Pd) 1.800 in
Pitch Diameter - Gear (Dg) Dg = (Ng/Pd) 4.000 in
Center Distance (C) C = (NP+NG)/(2*Pd) 2.900 in
Pitch Line Speed (vt) vt = (pi*Dp*Np)/12 1,414 ft/min
Transmitted Load (Wt) Wt = 33,000*(P)/ (vt) 187 lb

Secondary Input Data Location or Equation Value Units

LOWER LIMIT NOMINAL UPPER LIMIT
Face With Guidelines (in) 0.800 1.200 1.600
Enter Face Width (F) Choose a Value From Above 1.250 N/A
Ratio: Face width / pinion diameter (F) (F/Dp) 0.56 N/A

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Stress Analysis: Bending Location or Equation Value Units

Pinion: Required (stP) See FIGURE 9-11 12,211 PSI
Gear: Required (saG) TABLE 9-5 9,679 PSI
Pinion: Required (satP) [Final Answer] Equation 9-28 15,900 PSI
Gear: Required (satG) [Final Answer] Equation 9-28 12,346 PSI

Stress Analysis: Pitting

Expected Contact Stress Equation 9-23 105,898 PSI
Pinion: Required (sacP) [Final Answer] See FIGURE 9-12 or 143,883 PSI
Gear: Required (sacG) [Final Answer] TABLE 9-5 139,339 PSI

Hardness Location or Equation Value Units

Required Hardness of Pinion HB Equations in FIGURE 9-12 GRADE 1 356.5 HB
Required Hardness of Gear HB Equations in FIGURE 9-12 GRADE 1 342.4 HB
Specify Materials, alloys and heat treatment for most severe requirement

Gear 3 & 4 Configuration

Initial Input Data Location or Equation Value Units

Over Load Factor (Ko) TABLE 9-7 1.50 N/A
Transmitted Power (P) 8.0 HP
Designed Power (Pdes) Pdes = (Ko*P) 12.00 HP
Diametral Pitch (Pd) FIGURE 9-24 10 N/A
Input Speed (np) 1,350 RPM
Number of Pinion Teeth (Np) 30 N/A
Desired Output Speed (nG) 500.0 RPM

Nominal Velocity Ratio (VR) VR= (np/ng) 2.70 N/A

Computed Number of Gear Teeth NG = nP(VR) 81.00 N/A
Chosen Number of Gear Teeth (NG) Choose a Logical Value (Teeth) 80 N/A

Computed Data Location or Equation Value Units

Actual Output Speed (nG) nG= nP (Np/Ng) 506.3 RPM
Gear Ratio (mG) mG = (Np/Ng) 2.67 N/A
Pitch Diameter - Pinion (Dp) Dp = (Np/Pd) 3.000 in
Pitch Diameter - Gear (Dg) Dg = (Ng/Pd) 8.000 in
Center Distance (C) C = (NP+NG)/(2*Pd) 5.500 in
Pitch Line Speed (vt) vt = (pi*Dp*Np)/12 1,060 ft/min
Transmitted Load (Wt) Wt = 33,000*(P)/ (vt) 249 lb

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Stress Analysis: Bending Location or Equation Value Units

Pinion: Required (stP) See FIGURE 9-11 16,259 PSI
Gear: Required (saG) TABLE 9-5 12,888 PSI
Pinion: Required (satP) [Final Answer] Equation 9-28 21,171 PSI
Gear: Required (satG) [Final Answer] Equation 9-28 16,439 PSI

Stress Analysis: Pitting

Expected Contact Stress Equation 9-23 94,655 PSI
Pinion: Required (sacP) [Final Answer] See FIGURE 9-12 or 128,607 PSI
Gear: Required (sacG) [Final Answer] TABLE 9-5 124,546 PSI

Hardness Location or Equation Value Units

Required Hardness of Pinion HB Equations in FIGURE 9-12 GRADE 1 309.0 HB
Required Hardness of Gear HB Equations in FIGURE 9-12 GRADE 1 296.4 HB
Specify Materials, alloys and heat treatment for most severe requirement

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Shaft Design

We will be calculating the length of the shaft, bending force, shear force, and reaction forces at the
support.

We will be doing the calculations for the following to make the assessments:
I. Centre Shafts
II. Pinion Shafts
III. Output shafts

I. Centre Shaft
We will be measuring the reaction forces, pinned supports, and the point loads on the beam.

Now, we can make assessments on the reaction forces at the two ends of the beam, and we can
draw the shear force diagram.

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Now, by integrating the shear force diagram, we can determine the bending moment. The
maximum bending moment is a vital part of the next stage.

The bending moment was found to maximum of 130.525 lb-in. The results are summarized below.

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The calculations for the pinion shaft and the output shafts are summarized below.
an do the same for the pinions to determine the bending and shear force.
Pinion Shaft

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Output Shaft

The full set of

the calculations for each of the beams can be found in the appendix.

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Key Design

A key is a piece of metal used to connect a rotating machine element to the shaft. A key prevents a
relative rotation between the two parts and may enable torque transmission to occur. For a key to
function properly, both the shaft and rotating elements (gear, pulley and coupling) must have a keyway
and a key seat.

Various Shafts Shaft 1 Shaft 2 Shaft 3

HP 8.00 8.00 8.00

RPM 3,000 1,350 506.3

Torque (ft-lb) 14.01 31.12 82.99

Torque (in-lb) 168.06 373.48 995.84

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Bearing Calculations

0.75 inch = ¾ inch

Dynamic load rating C 12.7 Basic Rating Life L10 93312 10^6 Revolutions
Bearing load P 0.28 Basic Rating Life L10h 51840 hours
Rotational speed n 30000
Coefficient p 3

0.875 inch = 7/8 inch

Dynamic load rating C 14 Basic Rating Life L10 79934 10^6 Revolutions
Bearing load P 0.325 Basic Rating Life L10h 51240 hours
Rotational speed n 26000
Coefficient p 3

1.0 inch
Dynamic load rating C 17.8 Basic Rating Life L10 84898 10^6 Revolutions
Bearing load P 0.405 Basic Rating Life L10h 58957 hours
Rotational speed n 24000
Coefficient p 3

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Casing

For the casing of the case, we have chosen to use cast iron for it’s general workability, and material
strength. The casing is 0.2 inches thick to ensure the structural integrity while keeping the design as
light (and therefore cheaper to manufacture) as possible.

There are three major design modifications on the casing. We have designed 4 ribs on either side as a
material strength reinforcement. This will also significantly reduce the material weight without
compromising on the strength. Apart from this, the lip of the casing is thicker than the general body,
since stresses are likelier to be higher in those areas. After the casting there are process to bring the
things to the right measurements for the bearing housing.

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References

Alambra, K., & Swanson, N. (2022, April 14). Gear ratio calculator. Omni Calculator. Retrieved May
22, 2022, from https://www.omnicalculator.com/physics/gear-ratio

Brian Dengel -. (2021, January 19). Brian Dengel. Gear Solutions Magazine Your Resource to the
Gear Industry. Retrieved May 22, 2022, from https://gearsolutions.com/features/finding-the-
ideal-materials-for-gears/

Comino, P. (2022, March 18). Free online beam calculator: Skyciv Engineering. SkyCiv Cloud
Structural Analysis Software | Cloud Structural Analysis Software and Calculators. Retrieved
May 22, 2022, from https://skyciv.com/free-beam-calculator/

Mechanisms, C. (n.d.). Gear Materials: Study. Gears. Retrieved May 22, 2022, from
https://www.creativemechanisms.com/gears

Read "Polymer science and engineering: The shifting research frontiers" at nap.edu. 3.
Manufacturing: Materials and Processing | Polymer Science and Engineering: The Shifting
Research Frontiers |The National Academies Press. (n.d.). Retrieved May 22, 2022, from
https://nap.nationalacademies.org/read/2307/chapter/5

GROUP 1 MACHINE DESIGN MECH 2410 CAPSTONE PROJECT