Spur and Helical Gears 361 Using Tables 2.34 (Old) and 2.35 (Old) or Fig. 23.35a (New) and Table 23,32 (New) the load factor C can be obtained. If the class of gear is known then the error f can be obtained from Fig, 2.29 (Old); Fig. 23.34a (New). ii) Endurance strength of the gear tooth F = 0, bY m. = 0, bY m - 2.153(Old); 23.158 (New) where Y = my, y =Lewis form factor of the weaker member. ©, oro,= Endurance limit Table 23.33 (New) : Table 2.39 (Old) For safer design F, must be less than the allowable endurance strength, Note : Allowable static stress (6,) used in the Lewis equation is ; of ultimate stress and o , iti) Check for wear load According to Buckingham’s equation wear load F, = d,bQK ~--- 23.160/12,15(a) 2 : where Ratio factor Q = —2— ---- 2.163(Old); 23.163 (New) 2, +2) 143(6_,,)° sina Load stress factor. K = ——— ie 28 -2.161(0ld); 14365, ae = 23.161 (New) 2E,E, Equivalent Young's Modulus E, = --- 2.162(Old); 23.162 (New) E, +E, Limiting stress for surface fatigue o,,. or &_, , = (2.75 HB — 69) MPa ~~ 2,168 c(Old); 23.168 (New) H,, = Brinell Hardness Number For safer design F,, must be greater than F, IfF., == = From Table 2.1 (Old); Table 23.1 (New) for 20° Full depth involute system ii) Addendum nh, =1m=1x5=5mm iii) Dedendum h,= 1.25 m= 1.25 x5=6.25 mm iv) Whole depth h=2.25m=2.25x5= 11.25 mm y) Clearance c= 0.25 m=0.25 x 5= 1.25 mm vi) Outside diameter of pinion da, = (2, + 2)m=(20+2)5= 10mm Outside diameter of gear da, = (z, +2) m= (80+ 2) 5 = vii) Tooth thickness s 2 m= x5=7.854 mm Viti) Working depth h'=2m=2x5=10mm ix) Circular pitch p=mm=nx5=15.7 mm —~ 2.2,(Old); 23.2 (New) eon K = 5p 77 since v,.<7Smiseo ~~ 2.128(Old); 23.134a (New) SHV ig S57 = 0.70478 p = tm=nx4= 12.566 mm ‘Tangential tooth load on gear F., = (103) (40) (0.1388) (12.566) (0.70478) = 5064.51 N (Weaker member) : NC, _9550PC, : Also tangential tooth load _F.,=9550 eae 87(Old); 23.87b (New) 0 At) > My 4 where n, = Speed of gear; r, = pitch circle radius of gear in meters; N = Power ii kW d, _ 240 : B= =p = 120mm = 0.12 m5 C, = Service factor = 1 (Assume stready shock and 8 to 10 hrs duty per day, page 237 b) 9550xP ie ie, 506451 = Ta . Power transmitted P=N = 6.364kWSpur and Helical Gears 365, Example : 5.4 ‘Two spur gears are to be used for a rock crusher drive and are to be of minimum size. The gears are to be designed for the following requirements: Power to be transmitted is 18 kW, speed of pinion 1200 rev/min: velocity ratio 3.5 to 1, tooth profile 20° stub involute, Determine module and face width for strength requirements only. Data: P=N=18kW; n, = 1200 rpm; i=3.5; & = 20° stub; Solution : ‘The diameter of the gears and the number of teeth on the gears are unknown. Referring Table 2.6 (Ola); 23.6 (New), minimum number of teeth on pinion to avoid interference for 20° stub tooth is 14 , Select number of teeth on pinion 7, = 16 Number of teeth on gear z, = iz, =3.5 x 16 =56 n, _ 1200 Speed of gear 342.857 rpm As the gear drive is to be of minimum or compact size, select strong materials for both pinion and gear. Select SAE 3245 (C, —N, steel) for both pinion and gear. From Table 23.18 (New) for SAE 3245 (C.=N, steel) 6, =6,, = 418 ~ 517 MPa select 6, = 6,,=515 MPa. 0.95 Lewis form factor for 20° sub. y=0.17 92° ~~ 2.99(Old); 23.117 (New) . Lewis form factor for pinion y,=0.17- 222 = 0.17- 2 = 0.110625 yy Lewis form factor for gear y,=0.17- 225 =0.17- = = 0.153036 Identify the weaker member As pinion and gear material are the same, pinion is the weaker member. Therefore design should be based on pinion. ) Design ) Tangential tooth load on pinfon F, = 2 = OONCs _ oa nit i 4 my De As the gears are used for rock crusher, assume intermittent with heavy shock. . From Table 2.33 (Old); Table 23.13 (New) (Page 23.76) service factor C, = 1.5 _ 9550%1000%18x15 _ 26859,375 ian iapeea orca —o where 1, = pitch circle radius of pinion in mmDesign of Machine Elements = Se ‘b) Lewis equation for tangential tooth load F, = o,bypC,=0, bypK, ~~ 2.93(Old); 23.93 (New) ince pinion is the weaker member x by, PC,=0,, by, PK, mm to4nmmor9.5m 15; i.e., 27.34 > 15 ; Hence suitableSpur and Helical Gears 367 +: Module m=4 mm. ¢) Check for the stress Allowable stress, K,),= 515 x 0.4273 = 220.06 Nimm* (9, Induced stress G,, = (6,, K.),,y= > ---- 2,93(Old); 23.93 (New) 4 ~ (10% 4)(0:110625) (x x4) AS(,K,),,. < (0, C.)yy the design is safe. Module m = 4mm Face width b = 10m=10x4=40mm = ( 2) = 120,76 Nimm* Eeample : 5.5 A pair of carefully cut spur gears with 20° full depth inyolute profile is used to transmit 12 kW at %2% revolutions per minute of pinion. The gear has to rotate at 300 revolutions per minute. The ‘ssaterial used for both pinion and gear is medium carbon steel whose allowable bending stress may be ‘sehen as 230 MPa. Determine the module and face width of the spur pinion and gear. Suggest suitable Seeiness. Take 24 teeth on pinion. Modulus of elasticity may be taken as 210 GPa (VTU February 2002) Den 20° FD involute; P= N= 12 KW; n, = 1200 rpm: n, = 300 rpm; G,, =o, = 230 MPa; z, = 24; 10 GPa =210 x 10° Nimm?; Carefully cut spur gear. Velocity ratio i = =4x24=96 2 * 0.912 Lewis form factor for 20° FD involute_y=0.154— --- 2.98(Old); 23.116 (New) z Lewis form factor for pinion _y, 154 — ose =0.154- oe =0.116 st 0.912 0.912 Lewis form factor for gear_y, = 0.154 50.154— = = 0.1445 = ® Identify the weaker member As pinion and gear material are the same, pinion is the weaker member. Therefore design should be based on pinion,“368 Design of Machine Elements~ i) Design a) Tangential tooth load 9550x1000NC, _ 9550x1000 PC, R= nr or where r in mm, N = P= Power in KW 9550 x1000xPXC, -. ‘Tangential tooth load on the weaker member pinion, =———— + it Assume medium shock and 8-10 hours duty per day =. From Table 2.33(Old); Table 23.13 (New) (Page 23.76) service factor C, = 1.5, dj ma _ mx24 Rape Sg =e z 9550%1000x12x15 119375 i @ i 1200 12m. m b) Lewis equation for tangential tooth load F, = a, by p C,=9, by pK, -—- 2.93(Old); 23.93 (New) Since pinion is the weaker member F, = 9, by, pC,=9,, by, pK, Face width b = 3mmto4mmor9.5m 14.242; 21.248 > 14.242. Hence suitable : Module m = 4mm ©) Check for the stress Allowable stress o,, = (6, K,),, = 230 x 0.332 = 76.36 Nimm* Fay — 2.93(Old); 23.93 (New) by\P (18) . = 51.183 Nimm* ~ (10x 4)(0.116)(x4) Induced stress 6,,, = (F Kga= Since (6,, K,)juy<(G,, K )yy the design is safe Also in order to avoid the breakage of gear tooth due to bending, the beam strength should be more than the effective force between the meshing teeth z Fic, Fug z ‘ Effective force Fq = ~~" =~ since C, is already considered 18) 4 = = 8989.1 N ae 7 Beam strength of weaker member F,, = ,, by, P= (230) (10% 4) (0.116) (wx 4) = 13410.83 N Rie Fe Fy _ 1341083 s=— = = en ae ‘The design is satisfactory and hence module should be equal to-4.mm. <. Module m = 4mm Face width b = 10m=10x4=40mm & Dynamic load 21Vq(F, +bC) 1 — ee 2.148 a(Old); 23.155 (New) From Fig. 2.29 (Old): Fig. 23.34a:(New) for carefully cut gears (Class-II gears) for m= 4mm Exar f = 0.025 mm From Table 2.35 (Old); Table 23:32 (New) forf =0.025 mm, 0: = 20° full depth and Steel pinion — Steel gear. 2) Dynamic load F, =370 Design of Machine Elem 2908 290 Nira m 119: 119375, ee y= 2984375 N Dynamic load factor C Tangential tooth load F, om 21 6.032[2984.375 +40 x 290) Hei 2 2 Saeoae LE ee . Dynamicload F = 10450.6 N b) Wear load F, =d, bQK 2.160 (Old); 23.160 22, 2x96 yerane TO ++ 2.163 (Old); 23.163 Ratio factor Q = Fs 96 Equivalent Young's Modulus E, ---- 2.162(Old); 23.162 2.21010? X210x10° = = 210 x 10° Nim? 21010" +210%10° or oe 3o2,, sing 1430; sine E, Ey Load stress factor K Pitch circle diameter of pinion d, = mz, =4 x 24=96 For safer design F, 2 F, ie, d,bQK = 104506 ise, (96) (40) (1.6) K” 2 10450.6 :. Load stress factor K > 1.701 N/mm? 143¢7,6 sino. Iv 1.701 > 1.701 > 854.6 Nimm? From Table 2.40 (Old); Table 23.37B (New) for % = 20° FD, K 2 1.701 N/mm 6,,, 2 854.6 Némm? Surface hardness for pinion = 400 BHN Surface hardness for gear = 300 BN Example : 5.6 Design a pair of spur gears to transmit 20 kW from a shaft rotating at 1000 rpm toa shaft which is to rotate at 310 rpm. Assume number of teeth on pinion 31 and 20° full form. The material for pinion is C 45.steel untreated and for gear cast steel 0.20% C unt \ ‘(VTU AtSpur and Helical Gears 371 Data P= untreated; Gear material ~ Solution = a, ists a ©. Velocity ratio i = Number of feeth on gear 7 Lewis form factor for 20° FD involute y = 0.154 — 2.98(Old); 23.116 (New) ‘ 12. Lenina orion pion Osea Spiisa at = 0.12458 zy Lewis form factor for gear y, = 0.154 — Oe =0.154— ee = 0.14488 Dy 100 From Table 23.18 (New) Allowable stress for CAS Steel untreated (i.e., Steel SAE 1045 untreated) 6, = 207 MPa Cast stee! 0.20% c untreated 64, = 138 MPa i) Identify the weaker member 4 s, y oy Remarks Particulars Meee Pinion 207 0.12458 25.788 Gear i 138 0.14488 19,9934 Weaker AS Ou,¥,<9,, ¥p Gear is weaker: Therefore design should be based on gear. ii) Design a) Tangential tooth load 9550 x1000xNC,_ 9550x1000xPC, or Ed where rin mm, 9550 1000x PC, Tat a 2 2 ae Assume medium shock and § ~ 10 hrs duty per day From Table 2.33 (Old); Table 23.13 (New), (Page 23.76), service factor €, Pitch circle radius of gear 1,372 . Design of Machine Elements - Ii 9550x1000% 20X15 _ 18483871 0 oS eee == ie. R= ie Fy 310%50m m b) Lewis equation for tangential tooth load F,= 0, by pC, —- 2.93(Old); 23.93 (New) As gear is the weaker member F, = 0, by, pC,=6,, by, p K, Face width 3 3mmto4nmor9.5m 29.428 20.224 < 29.428 . Not suitable ‘Trail :2 , Select module m = Smm Va = 1.623 x5 = 8.115 m/sec 45 45 ‘Velocity factor K, = = 0.35672. ( v,< 12.5 m/sec.) = U54v, | 4548115 =-++2.129(Old); 23.1358 Now from equation ( (5) (0.35672) > 29.428; 44.59 > 29.428, Hence suitable Module m = 5mm ©) Check for the stress Allowable stress Gy = (6, K,),, = (138) (0.35672) = 49.227 Nimm* Indore nies 6, = (6, Ky = 2.93 Old); 23 ‘Sour and Helical Gears 373 (eee 2 ~ (0x5)(014488) (2x5) = 32.488 N/mm? Since (6,, K,)js. < (Gj K,),y, the design is safe. Aiso in order to avoid the breakage of gear tooth due to bending, the beam strength should be more than the effective force between the meshing teeth FCF Effective force F.q= HC since C, is already considered ) 5 = +2 = 10363.24N 035672 Beam strength of weaker member F,, = 6,, by,p = (138) (10 x 5) (0.14488) (x 5) = 15702.81.N R, > Fy SFOS = 2 2 SW281 sis Fg — 1036324 The design is satisfactory and hence the module should be equal to 5 mm. : Module m = 5mm Dimensions Module m = Smm From Table 2.1 (Old); Table 23.1 (New) for 20° full depth involute system Addendum bh, = 1m=1x5=5mm Dedendum h, 1,25 x 5=6.25 mm Working depth h’ = 10mm Total depth h 2.25.5 = 11.25 mm Tooth thickness s Minimum clearance c = 0.25 Pitch diameter of pinion d, Pitch diameter of gear d,= zm (00 mm Outside or Addendum diameter of pinion d,, = (z, +2) m= (31 +2) 5=165 mm Outside or Addendum diameter of gear da, = (2, +2) m= (100 +2) 5=510 mm Centredistance a = (2, +2, $1 + 100)=3275 mm-— 2.19(Old); 23.19 (New) 55 ~2 x 6.25 = 142.5 mm ~-- 2.16(Old); 23.16 (New) 00 ~ 2.x 6.25 = 487.5 mm Base circle diameter of pinion d,, =d, cos = 155 cos 20= 145.652 --- 2.9(Old); 23.9 (New) Base circle diameter of gear d,. = d, cos 0 = 500 cos 20 = 469.846 3.87) 3. ee es aa =3696.774N --+ from (i) Dedendum.or Root circle diameter of pinion d, Dedendum circle diameter of gear d, = d, ~ 2h,374 Design of Machine Elements - | Mean pitch line velocity v,, = 8.115 m/sec Face width b = 10m=10x5=50mm. Circular pitch p = mm=nx5 = 15.708 mm Velocity factor K,=C, = 0.35672; service factor C, = 1.5 iv) Checking a) Dynamic load See 2Iv,, (Fy +bC) Papa © [uate EES From Fig. 2.30 (Old); Fig. 23.35a (New) for y, Error f = 0.045 mm From Table 2.35 (Old); Table 23.32 (New) for steel pinion-steel gear and 20° full depth 8.115 m/sec kN 580 Némm For error F= 0.025 mm, C= 290 “= 290 N/mm : kV For ertorF= 0.05 mm, © = 580 = 580.Némm By interpolation 290 Néaim _ 0045-0.025 90 ~ 0.050.025 x = 32N/mm For errorf = 0.045 mm; Load factor C = 290 +232 = 522N oe gee s 21x8.115[3696.774 + 50x 522] Hes, Fy= 3696774 + 518115 + (3006 774+ 50% 520 +. DynamicloadF, = 18499.507 N b) Wear load Wear load F, = d,bQK —- 2,160(Old); 23.160 22, 2x10 +2, 314100 For safer design F, > F, ie, d, bQK > F, (155) (50) (1.52672) (K) > 18508.11 Load stress factor K > 1.5642 Némm? From Table 2.40 (Old) ; Table 23.37 B (New) for a= 20° FD and K > 1.5642 Nimm? Surface hardness for pinion = 350 BHN Surface hardness for gear = 300 BHN Ratio factor Q 52672 0 Example : 5.7 3 Design a bronze spur gear 81.4 MN/m? and mild steel pinion 101 MN/m? to transmit 5} 1800 rpm. The velocity ratio is 3.5:1. Pressure angle is 144°. Not less than 15 teeth are to be:Spur and Helical Gears 376 cither gear, Determine the module and face width. Also, suggest suitable surface hardness for the weaker member based on dynamic and wear considerations. [VTU, June/July 2015] Data: 6, = 101 MN/m?= 101 Nimm®; 6,, = 81.4 MN/m? = 81.4 Nimm’; P=N=5 kW; n, = 1800 rpm; 35; a= 146"; 2,215 Solution : ay 0 Velocity ratio ae te eetae 1800 EO e14 2 y= Pegg = 514.285 pm Select number of teeth on pinion 2, iz, = 3.5 x 16= 56 0.684 Speed of gear . Number of teeth on gear 7, Lewis form factor for 144° involute_ y = 0.124 — ---- 2,97(Old); 23.115 (New) Za Lewis form factor for pinion y, = 0.124 - 5 16 7.08125 4 684 Lewis form faster for gear y, 20124220194 mo tti79 2 56 i) Identify the weaker member aaa 6, y oy Remarks Particulars ee ' Pinion 101 0.08125 8.206 Weaker Gear 814 0.11179 94 Since 64, y, 19.293 Hence suitable <. Module m = 4mm ©) Check for the stress Allowable stress 64, = (6,, K,),,= (101) (0.3322) = 33.552 N/mm? 122. iE (0) Kgs = oe -— 2.93(Old); 23.93 (New) (2) 4 (10%4)(0.08125)(x4) Induced stress 0, = 30.447 N/mm?Spur and Helical Gears 377 Since (0,, K yg < (Gy, Ky» the design is safe. Also in order to avoid the breakage of gear tooth due to bending, the beam strength should be more than the effective force between the meshing teeth. oF uae fs . 4 K, 7K, siteeC, is aleady considered = “Tea Effective force F_ = =3743.2N Beam strength of weaker member F, =0,, by, P = (101) (10 x 4) (0.08125) (wx 4) = 4124.91 N >F ‘The design is satisfactory and hence the module should be equal to 4 mm Module m = 4mm Face width b = 10m=10x4=40mm. =) Checking 21v,, (F, +bC) a) Dynamic load F,=F,+ 2V, + JR, FBC +++ 2.148 a(Old); 23.155 (New) 396 _ 4973.96 Tangential tooth load _F, ones = =1U35N —— from (i) Mean pitch line velocity. v,, = 6.032 m/sec From Table 2.30; (Old); Fig. 23.35a (New), for v,, = 6.032 m/sec Error f = 0.0625 mm ‘Seem Table 2.35 (Old); Table 23.32 (New) for 0. = 144°, taking steel — CI combination For £=0,05 mm; C=384.16 SN = 384.16 Nimm 576.34 N/mm m For f=0.075mmic = 57694 SS 2.724 14363, xsinee ie; = 2 2724 143 of. xsin 14.5 130.967 10° Limiting stress for surface fatigue o,_ 2998.2 N/mm? From Table 23.378 (New) foro, =998.2 N/imm? Surface hardness of pinion = 400 BEN Surface hardness of gear = 400 BHN ie., 2 2.724 Example : 5.8 In an automobile gear box. the second speed gear shaft is to be driven from main shaft yelocity ratio 1.5:1, Main shaft transmits 12 kW at 3000 rpm. The shaft centre distance = 80 Pinion material is cast steel heat treated and gear material is cast steel untreated. Profile of the gear: 20° stub involute. Determine (i) Module, (ii) Face width (iii) Number of teeth on pinion and gear, Data : j= 1.5; P=N=12 kW; n, = 3000 rpm; a=80 mm; o-= 20° stub involute Pinion material - Cast steel heat treated. Gear material — Cast steel untreated. Solution + dis, Mee a Velocity ratio i= > = > ats, Speed of gear a, d, (+i) Centre distance a= + 2.19(Old); 23.19Spur and Helical Gears 379 4, (+15) 2 Pitch circle diameter of pinion d, =64mm Pitch circle diameter of gear d, = id, = 1.5 x 64=96 mm From Table 23.18 (New) For cast steel heat treated o,, = 173 MPa = 173 N/mm* For cast steel untreated ,, = 138 MPa = 138 N/mm? To identify weaker member temporarily.assume z, =20 =iz, = 15x20=30 ie, 80 = Fy 0.95 Lewis form factor for 20° stub involute y= 0.17 -—— ---- 2.99(Old); 23.117 (New) z 9 = Lewis form factor for pinion" y, 07 2° 0,17 a = 0.1225 zy Lewis form fector for gear y,=017—-02> =0117-22> 20,1383 a 30 © Identify the weaker member BS Paticulars oor y SY aS } Nimm* _— Pinion 173. 0.1225 21.1925, . Gear 138 0.1383 19.0854 Weaker Since G,, Y, 7.8576 ie, 7.4286 < 7.8576 2. Not suitable Trail :2 Select module m = 4mm 40,0582 x 4° > 7.8576 12.2752 > 7.8576. Hence suitable » module m ©) Check for the stress i Allowable stress Oy, = (Gy, K,),, = (138.34) (0.3092) = 42.6696 Nimm? v 4mm F, Induced sess. Oy = (us Kus = Fy = 2.93(Old): 23.93 (Ne al 1790.625 327.315 Ni (104) (0.17-9.896x107 x4) (2x4) a Since (Fy, K)g < (Gy. Kg» the design is safe. Also in order to avoid the breakage of gear tooth to bending, the beam strength should be more than the effective force between the meshing ee Effective force Fg = since C, is already considered. 1790.625 paver = SB12NSu ond Helical Gears 381 Beam strength of weaker number F, =0,, by,p = (138) (10 x 4) (0.17 — 9.896 x 10 x 4) (mx 4) = 9046.484 N F> FB, R, 9046.484 eat = £1582 Hs Ee 5791.2 ‘The design is satisfactory and hence the module should be equal to 4 mm . Module m = 4mm face width b = 10x4=40mm 5 4; 64 Number of teeth on pinion 2, =" => =16 4, Number of teeth on gear 7,=—™ = Example : 5.9 A pair of carefully eut (Class - 11) spur gear transmit 20 kW at 230 rpm of the gear, Reduction easio is 5:1. The pinion is made of cast steel heat treated with allowable stress 197 MN/m*. Gear is ~ snade of cast iron with allowable stress 56 MN/m*. Determine module, face width and number of teeth = Pinion and gear. Also suggest sultable surface hardness for the gear par. Pitch line velocity of Pinion is not to exceed 7.5 m/sec. Buta: N=20; ¥_S75 misec ; m, = 230 rpm; 6,, = 197 MN/m? = 197 N/mm*; o,, = 56 MN/m*= 56 N/mm’; Velocity ratio, a = pe ny 21 dy *. Speed of pinion n, = in, =5x 230= 1150 1pm Pitch line velocity of pinion’ v,, $7.5 m/sec Le, ee < 7.5 m/sec 60000 mxd, X1150 60000 = d, < 124556 mm Select pitch diameter of pinion d, =120mm ~ Pitch diameter of gear d, =i x 120 = 600 mm To identify the weaker member temporarily assume 2,=20 + 2,=i2, = 5x20= 100 Assume o, = 20° full depth involute ic, S75 Lewis form factor for 20° full depth involute_y = 0.154 — ---- 2.98(Old); 23.116 (New)382 . Design of Machine Elements =I 0.912 0.912 =0.154-—— = 154 70 0.1084 Lewis form factor for pinion y, = 0.154 ~ a 0.912 0.912 ‘Lewis form factor for gear y, = 0.154 — 1.154 — 7 = 0.14488 Ss = i) Identify the weaker member : °, y oy Remarks Particulars Nim? Pinion 197 0.1084, 21.3548 Gear é: 56 0.14488. 8.11328 Weaker Since 6g, ¥, <0, Ys Sear is weaker member. Therefore design should be based on gear. ii) Design 10 9550x1000 xPC a) Tangential tooth load F, PSS NTMOZNE aS syherer intam 9550 x 1000NC 9550 x1000PC, nat Dar . Tangential tooth load of the weaker member F, Assume medium shock and 8-10 hours duty per day . From Table 2.33 (Old); Table 23.13 (New) (Page 23.76), service factor C= 1.5 dy _ 600 Pitch circle radius of gear r, 3. => = 300mm 95501000 20x15 ie. Se 52. Be 230x300 ae equation F, = 6, byp C,= a, byp b) Tangential tooth load from Lewi ---- 2,93(Old); 23.93 (Ne ‘Tangential tooth load of the weaker member F. = 6, by.p C,=0,, by,p K, Face width b = 3rmto4amor95m 52.2384 Hence suitable . Module m = 8mm ©) Check for the stress Allowable stress 6, = (6, K.), = 56 x 0.2934 = 16.4304 N/mm? ‘ BR, 4152.2 Induced stress ,,,= (Gy, K,)yy = > = ———_— = 14.56 Nimm? byop (10x8)(0.154-152x10 x8)(nx8) ~--- 2.93(Old); 23.93 (New) Since (6,, K,)u,< (Oy, K,)yy the design is safe, Also in order to avoid the breakage of gear tooth due to-bending, the beam strength should be more than the effective force between the meshing teeth. B.C. 41522 K 0.2934 Beam strength of weaker member F, =o, by,p = (56) (10 x 8) (0.154 — 1.52 x 10? x 8) (wx 8) = 15970.43 N ey 1597043 14152 F = __ Since C, in already considered = = 14152N Effective force F.,= =1.13 The design is satisfactory and hence the module should be equal to 8 mm -. Module m = 8mm Face width b = 10m=10x8=80mm Number of teeth on pinion z, = dd, Number of teeth on gear z,= aries 75 ~~ 2.160(Old); 23,160 (New)384 Design of Machine Elements - it Checking : 21y,, x(F, +bC) a) Dynamicload Fy=R.+ 5, abe ‘Tangential tooth load F, =F, = 4152.2 Mean pitch line velocity v= 7.2257 m/see Face width b = 80mm From Fig. 2.29 (Old) Fig. 23.34a (New) for carefully cut gear when m= 8 mm, Error f= 0.0375 mm From Table 2.35 (Old); Table 23,32 (New) for o.=20° full depth, steel - Cl combination For f= 0.025 mm; C= 192.14 KN/m= 192.14 N/mm. 398.28 N/mm For f = 0.05 mm; C = 398.28 KN/m = 398.28 N/mm By interpolation x _ 0,0375=0.025 30828-19214 0.050.025 192.14 N/mm * x = 103.07 N/mm For errorf = 0.0375 mm, c 92.14 + 103.07 = 295.2] Nimm 5 21x 7.2257[4152.2 + 80 x 295.21] Le ee oo ie, Fy=41522+ = 17386.9N 217.2057 + 4152.2 + 80x 205.21 b) Wear load F, = 4, bOK -— 2.160(O1d); 23.160 (New) Patio actor (Qe ee 2,42, 15x75 For safer design F25, ie, d, bQK > F, ie, (120) (80) (1.667) K > 17 s. K 2 1.0865 Nim? From Table 2.40 (Old); Table 23.378 (New) for o:= 20 FD and’K > 1,0865N/mm? Surface hardness for pinion = 300 BEN Surface hardness for gear = 250 BHN Example : 5.10: Design a pair of spur gears to transmit.a power of 18 kW from ashaft running at 1000 rpnr parallel shaft to be run at 250 rpm maintaining a distance of 160 mm between the shaft Suggest suitable surface hardness for the gear pair. (VTU Jan/Feb 2005, Jan / Feb 2006, June/JulySpur and Helical Gears 385 Data: N= 18 kW; n, = 1000 rpm; n, = 250 rpm; a = 160 mm. Solution = Assume CLASS - III Precision gears Pressure angle 0: = 20° full depth involute system. Medium shock and 8 to 10 hours duty per day. -. From Table 23.13 (New), service factor C, = 1.5 Pinion material SAE 3245 (C,—N, steel) as the centre distance is small Table 23.18 (New), So, = 448-517 MPa Take Oo, = 500 MPa _ ™ _ 1000 Seid 5020) _ ditd, — djtid) — dy(l+i) fe eerie ae ie,, 160 = ee = 64mm and d, = 256 mm 0912 © Lewis form factor for 20° FD involute system y = 0.154 ——— 2,98 (Old) ; 23.116 (New) To identity the weaker member temporarily assume z, = 20 om = iz,=4x20=80 0912 0.912 sy, = O1S4- Oca OS alr pag as 0912 0.912 = 01542 0s yy = 0154 = 0.154 = = 0.1426 To select the gear material equate Sp,y, 10 Fo, y, ive., 500 x 0.1084 = Go, x 0.1426 2. 6p, = 380,084 N/mm" From Table 23.18 (New), Select the gear material such that its value of Op, must be nearer to & N/mm’. Hence select SAE 4640 Hardened by OQT as gear material 2.69, = 379N/mm?386 Design of Machine Elements - Il (i) Identify the weaker member Particulars 6, N/mm? y siy | Remarks Pinion 500 0.1084 54.21 Gear 379 0.1426 | 54.045_| Weaker As 0p, y, < Go, ¥, gear is the weaker member. Therefore design should be based on gear. (ii) Design 4550 x1000xNC, _ 9550x1000x PC, a, we where rinmm (a) Tangential tooth load 9550x1000xNC, _ 9550%1000%PC, +. Tangential tooth load of weaker member 5, = ———————+_ = T3t Nok Assume medium shock and 8-10 hrs duty per day +. From Table 2,33 (Old) : Table 23.13 (New) (Page 23.76) Service factor C, = 1.5 256 2 = oe = 128mm _ 9550 1000% 18% 15 250x128 (b) Tangential tooth load from Lewis equation F = o,bypK, ne 2.93 (Old) ; 23.93 (NeI Tangential tooth load of the weaker member F,, = 6p, by, pC, = So, by, pK, Face width b = 3nm to 4nm or 9.5 m 9.3Sour and Helical Gears 387 Trail: 1 Select m= 3 mm [Select standard module from Table 2.3 (Old) Table 23.3 (New)] 8.3755 < 93 +: Not suitable Trail : 2 Select m= 4mm 14.52 > 9.3. Hence suitable Module m= 4mm. (©) Cheek for the stress Allowante stesso, = (6, K,),y = 379 x 0.4724 = 179.0396 Nimm? F, 7. Induced siresso,, = (6,, K)uy =p 2> = st _ byaP (10x 4)(0.154—35625 x10 *x4)(nx4) = 114.708 Nimm? Since (6,, K)g,< (Og Ky, the design is safe +. module m=4 mm. -&© Dimensions modulem = 4mm Face widthb = 10m=10x4=40 mm a, _ 64 Number of teeth on pinion z, = — =— =16 m 4 d, _ 256 Number of teeth on gear z, = a ae 64 Centre distance a = 160.mm From Table 23,1 (New) ; Table 2.1 (Old) for 20° full depth involute system Addendumh, = 1m x4=4mm Dedendumh, = 1.25m=125x4=5mm Working depth h! = 2m=2x4=8mm Total depth h = 2.25m=2,25 x 4=9mm mm _ x4 Tooth thickness s = F" a 6.2832 mm Minimum clearance ¢ = 0.25 m=0.25 x4= 1mm Pitch circle diameter of pinion d, = 256 mm Pitch circle diameter of gear d, = 64 min : Outside or Addendum circle diameter of pinion da, = (z,+2)m = (16 + 2) 4=72 mm Outside’or Dedendum circle diameter gear da, = (2, +2) m= (64 +2) 4 =264 mm Root or Dedendum circle diameter of pinion 4, = d, —2h, 23.16 (New) = 64-2x5=54mm388 Design of Machine Elernents - Il Root or Dedendum circle diameter of gear d. = d,—2h,= 256-2 x 5 = 246 mm ‘Tangential tooth load F, = 8057.81 N Mean pitch line velocity v,, = 3.351 m/sec Velocity factor K, = C,=0.4724 Service factor, = 1.5 Circular pitch P = nm=nx4 = 12.56.64 mm (iv) Checking ic load FE Ziv 60) 23.155 a) Dynamic loa Be F Ut cg eae ~~ 23.155 (New) Tangential tooth load F, = F,, = 8057.81 N Mean pitch line velocity v,, = 3.351 m/sec Face width b = 40mm From Fig. 2.29 (Old) ; Fig. 23.34a (New) for Class - III Precision gears when m = 4mm; f=0.0125 mm. From Table 2.35 (Old) ; Table 23.32 (New) for 0. = 20° Full depth, Steel — Steel combination £= 0.0215 mm Dynamic load factor = 145 kN/m = 145 N/mm 21x3.351 (8057.81+ 40145) eae: 21x3.351+V8057.814+40x145 — ae (b) Wear load FL = d,bQK so 2.160 (Old) ; 23.160 (Ne = 8057.81 + Ratio factorQ = a = ae =16 For safer design F,2F, ie, d.QK 2 F, 64 x40x 1.6xK 2 132425 ie, K > 3.233 N/mm? From Table 2.40 (Old) ; Table 23.37B (New) for c= 20FD and K 2 3.233 N/mm? ‘Surface hardness for pinion = 450 BHN. Surface hardness for gear = 450 BHN. Example : 5.11 z A compressor running at 400 rpm is driven by a 25 kW, 1200 rpm motor through a pair of 1 involute spur gear. The centre distance is around 400 mm. The pinion is made of forged steel of allowable stress 190 MN/m? and 350 BN. Gear is to be made of cast steel of static allowable stress MN/mm and 300 BHN. Design the gear for safe continuous operation. Check the gear for wear and dynamic strength. Name the class of the gear.Spur and Helical Gears 389 200 rpm; o= 144°; a=400 mm; ©, = 180 MN/m? = 300 Némm? Surface hardness of pinion = 350 BAN Surface hardness of gear = 300 BHN Solution : 8 2 a ody SA a dtd, dytid, (tid, | Sos = oe ae Pitch circle diameter of pinion d, =200 mm “Pitch circle diameter of gear d, = id, = 3 x 200 = 600 mm To identify the weaker member temporarily assume z, = 20 z,=iz, = 3x20=60 ay Velocity ratio. i= | ny Centre distance Lewis form factor for 14%” involute_y = 0.124 — Des ).0898 06 8 Lewis for factor for pinion. y, = 0.124— 2°84 _o 14— - 2g 06 Lewis form factor for gear_y, = 0.124 ——~ = 0,124 — Z i) Identify the weaker member Particulars o y oy Remarks N/mm? Pinion 190 0.0898 17.062 Weaker + Gear 180 0.1126 20.268 Since 64, Y, < Oy ¥,, pinion is weaker member. Therefore design should be based on pinion, ii) Design 9550%1000xNC, _ 9550x1000 xPC, nr nr 9550x1000NC, — 9550x1000PC, mn a) Tangential tooth oad F, = where rinmm Tangential tooth load of the weaker member 11 From Table 14.4 (Old.Volume-I) or Table 14.7 (New) for the driven mechanism compressor load factor i.e, service factor C, = 1.75 Pitch circle radius of pinion 1, =>390 Design of Machine Elements ~ te F = 9550%1000%25%1.75 4 + 1200x100 b) Tangential tooth load from Lewis equation F,=0, bypC,=0,bypK, — --~- 23.93 (Net Tangential tooth load of the weaker member F, =9,, by,pC,=9,, by,pK, Face width b = 3mmto4nmor9.5m 14.555 Trail : 1 Select module m=4mm_ [Select standard module from Table 2.3 (Old); Table 23.3 (New)] ie, 4°-0.02758x4 > 14.555 14.235 < 14.555 ~ Not suitable Trail : 2 Selectmodule m = 5mm ie, 5*-0.02758 x 5? > 14.555 21.5525-> 14.555 Hence suitable “» Module m = 5mm ©) Cheek for the stress Allowable stress o,, = (6, K,)., = 190 x 0.3232 = 61.408 N/mm? F, 34818 byP (10x5)(0.124-3.42 x10 7 x5)(nx5) —- 2.93(O1d); 23.9. Induced stress 6,,= (Jy, K,)j 1.47 N/mm?Spur and Helical Gears 391 Since (0, K,)yy < (Oy, K,),y the design is safe. Also in order to avoid the breakage of gear tooth due to bending, the beam strength should be more than the effective force between the meshing teeth, Effective force Fy since C, is already considered = 28 Sie eN ger3 5s a Beam strength of weaker member F, =<, by,p = (190) (10 x 5) (0.124 —3.42 x 10° x 5) (7 x 5) = 15952.2N > Fy eee bus 22) FOSS eee 107920 ‘The design is satisfactory and hence the module should be equal to 5 mm -. Module m = 5mm. Dimensions Module m = 5mm; Face width b=10m=10x5= 50mm Number of teeth on gear 2 Circular piteh ‘p = mm=mx5= 15.708 mm Tangential tooth load F, = 3481.8N Velocity factor K,=C, = 0.3268 Service factor ©, = 1.75 Mean pitch line velocity v,, = 12.5664 m/sec Base circle diameter of pinion d, = d, cos = 200 cos 14¥4 = 193.63 mm Base circle diameter of gear d,, = d, cos = 600 cos 14¥2 = 580.89 mm Pitch circle diameter of pinion d, =200 mm Pitch circle diameter of gear d, = 600 mm From Table 2.1 (Old); Table 23.1 (New) for 14%4° involute system Addendum h, = 1m=1x5=5mm Dedendum h, = 1.157 m= 1.157 x5 =5.785 mm Working depth hi = 2m=2x5=10mm Minimum total depth b = 2.15 m= 2,155 = 10.75 mm Outside diameter (Addendum diameter) of pinion da, = (@, +2) m = (40+2)5=210 mm Outside diameter of gear d, = (2, + 2)m= (120 +2)5=610mm u wa ™ Tooth thickness 3 x5= 0.7854 mm Minimum clearance c = S 1.157 m = 0.157 x 5 = 0.785 mm392 Design of Machine Elemer Dedendam circle diameter of pinion d, = d, ~ 2h, = 200 225.785 = 188.43 moma |, - 2h, = 600-2. 5,785 = 588.43 mm Dedendum circle diameter of gear d, iy) Cheeking a) Dyriamic load F, <--- 24148 a (Old); 23.155 (Ne IF, +bC From Fig. 2.30 (Old); Fig. 23.35a (New), for v,, = 12.5664 m/sec Error f = 0.03 mm From Table 2.35 (Old); Table 23.32 (New) for c: = 147° and steel — steel combination When error f = 0.025 mm ; C= 279.48 KN/m = 279.48 Némm. When error f = 0.05 mm ; C = 558.8 KN/m = 558.8 N/mm. 588.8 N/mm By interpolation x 0.03—0.025 5588-279.48 — 0,050,025 x = 55.864Nimm 979.43 Nimm For error f = 0.03 mm; Dynamic factor C= 279.48 + 55.864 = 335.344 Nimm te. Fon 3agi g + 21%!25664[34818-+50%335344] 3 21125664 + ¥34818+50x 335344 = 1663.1 N 0025 0.03 00) b) Endurance strength F,=F_, =, b ¥m=o,b Ym ~--- 2.153(Old); 23.158 (New) where Y = my,=m [0.124 —3.42 x 10° x 5] =0.336 From Table 2.39 (Old); Table 23.33 (New) for surface hardness = 350 BHN Select endurance limit =o. = 620.5 Nimm? : = (620.5) (50) (0.336) (5) = 52122 N AsF.=F,>F, the design will be satisfactory from the standpoint of strength. ©) Wear taut F,=d,bQK : Se oan Average surface hardness for the Ratio factor Q = —+— 350 +300 z+z, 40+120 — gear pair H, = = 325 BHN Surface fatigue stress 0,, = © ,. = (2.75 H, ~69) MPa -++- 2.168 ¢ (Old); 23.168 (New) = (2.75 x 325 - 69) = 824.75 Némm? From Table 2.8 [Old Volume Ij or Table 2.10 (New Vol-) For steel Young's modulus E, 206 GPa = 206 x 10° Nimm? ee Load stress factor K = ae oe —- 2,161(Old); 23.161 (New),Spur and Helical Gears 393 1.43 x (824.75)? xsin 14.5 3 206x10° Wear load F, = (200) (50) (1.5) (1.18226) = 17733.9N As F, >F,, the design will be satisfactory from the stand point of wear or durability. 1.18226 y) Class of gear From Fi, 29 (Old); Fig 23.34a (New) for module m = 5 mm_ and error f = 0.03 mm The class of the gear is, fF, F, ic.,d,b Qk 2 F, 2k 2 ---N/mm? Suggest suitable hardness for the gear pair using Table 23.37B (New) for the calculated alue of K. irst class commercial gear’. Note: Example : 5.12 Design a pair of spur gears to have the following specifications: Power transmitted = 10 kW ; Speed of pinion = 1000 rpm ; Speed of gear = 200 rpm ; Material of the pinion - CrNi steel ; Material of the gear - cast steel. Number of teeth selected on the pinion should not be less than the theoretical minimum [i.e Minimum number of teeth on pinion to avoid interference] Data : N = P=10kW5n, = 1000 rpm; n, = 200 rpm ; Pinion material - CrNi steel Gear material - Cast steel. Selution : u Gear ratio é Assume, pressure angle . = 20° Full depth involute system Medium shock and 8 to 10 hrs duty per day From Table 23.13 (New), service factor C, = 1.5 Select the gear material as 0.20 % C cast steel untreated From Table 23.18 (New) for GrNi steel Allowable static stress 6,, = 448-517 MPa, take 6,, = 482.5 Nimm? For 0.20% C, Cast steel untreated ©,, = 138 N/mm? Theoretical minimum number of teeth on a pinion to ayoid interference394 Design of Machine Elements - Il eis 15 ibe si a +2) er 5 5 From Table 23.6 (New) for 20° full depth involute system , ‘Minimum number of teeth on a pinion to avoid interference z, = 17 Therefore select number of teeth on pinion z, = 17 ee a <. Number of teeth on gear z, 5x 17=85 ; , 0912 Lewis form factor for 20° FD involve system y = 0.154~—— = — 23.11 [ogi torn ort piobay, = O1SIe = ose 10035 % Lewis form factor for gear y, = 0154 — “en = ouse— 22 = 0.14327 2 (i) Identify the weaker member Particulars |o,, N/mm? y oy Remarks | Pinion TRIS 010035 _| 484188 Gear 138 0.14327 [19.77 Weaker As Go, Y> 27.1326 Hence suitable © Module m = 4mm (©) Cheek for the stress Allowable stress ¢, = (6,,K,)_, = (138)(04573) = 63,1074 Nim? 16852.94 é cbpoeat = = 58.5046 Nim L = ee Ind bynp (WOxA)(O14327)(0xA) 4) As (9.,4y), , <(BusKy), the design is safe, +. Module m = 4mm Modulem = 4mm From Table 23.1 (New) for 20° Full depth involute system Addendumh, = m=1x 4=4mm Dedendumh, = 1.25m=1.25x4=5mm Pitch circle diameter of pinion d, =mg, =4* 17 = 68 mm Pitch circle diameter of gear'd, = mz, =4x85=340 mm dy d; _ 684340 BR es Face width = 10m=10x4=40 mm Circular pitch p = wm=mx 4 = 12.566 mm 16852.94 _ 16852.94 ee Centre distance a = = 204mm Tangential tooth load F, 4213.235 N396 Design of Machine Elements - II Velocity factor G, = K, =0.4573 laut Service factor C, = 1.5 Mean pitch line velocity v, = 3.56 m/sec dv) Checking 870N/mm, k (a) Check for Dynamic load From Fig, 23.35a (New) for vy, =3.56 m/sec Error f = 0.085 mm 0.075 0.085 0.100 From Table 23,32 (New) for steel pinion - ste! gear and 20° full depth For error = 0.075 mm, Dynamic factor C = 870 KN/m = 870 N/mm For error f = 0.100 mm, Dynamic factor C = 1116 kN/m = 1116N/mm By interpolation x _ 0085-0075 1116-870 ~ 0100-0075 “x = 984N/mm . Forerrorf = 0.085 mm, Load factor © = 870 + 98.4 = 968.4 Nimm Lyris Gat pee) 23,155 Trane qe ets diva (Bree ae oro 21x 356[4213.235+ 40x 9684] area © "21x56 + {4213.235+ 40x 9684-— ‘ q Endurance strength F, = ©,,b¥m - 23.158 (New) From Table 23.18 (New) For 0.20 % C cast steel untreated, Brinal Hardness Number = 180. For CrNi steel, Brinal Hardness Number = 475 From Table 23.33 (New) for Hardness = 180 H, take o, = 344.8 MPa . F, = (344.8) (40) (x 0.14327)(4) = 24830.9N (- ¥=ny2) Fy; _ 248309 i pe = 1592 > Now, Margin safety’ = =~“ Tagg 979 - '592> 15 +. Design will be satisfactory from the stand point of strength. () Check for wear load = 4,bOK ---23.160 (NeSpur and Helical Gears 397 = = 1.667 at 2 qtz, 17+85 23.161 (New) 14367, sino Load stress factor K = ~~ Se enna 2E,E Equivalent Young's Modulus £, = pg, From Table 2.10 (Vol - 1) For Nickel steel, Young's modulus E, = 207 GPa For Carbon steel, Youngs modulus £, = 206 GPa £,= eal = 2065 GPa = 206.5 x 10° N/mm? Surface fatique stress for steel 6,,. = (2.75H, 69) MPa = 2.75 x 327.569 = 831.625 N/mm? =~ 23.168 (New) fet 3275 hi 0 Average surface hardness for the gear pair 2 625" xsi 2065%10° :. Wear load F, = (68) (40) (1.667) (1.638) = 7427.236 N As F, 3.44 N/mm? and ot = 20° Surface hardness for pinion = $50 BHN Surface hardness for gear = 550 BHN 25.13 Design a spur gear drive to transmit 12 kW from 1500 rpm motor to a compressor run at 50 rpm N= 12kW; n, =.1500 rpm; n, =50 rpm Velocinynig t= 2h Se a0 sc eee Se 0 As the velocity ratio is more than 10, multistage reduction is recommended, Factorising 30 into 5 x 6, atwo stage reduction drive as shown in Fig. 5.7 can be used,398 Design of Machine Elements - Il Select the smaller speed pair for the gear design, sens z 4G . Speed of pinion n, = 300xpm Speed of gear n, = 50 rpm Assume 0, = 20° full depth involute system ‘As the centre distance or diameter of gears or number of teeth on the gears are not given, refering Table 2.6 (Old); Table 23.6 (New) the minimum number of teeth on pinion to avoid interference for 20” full depth involute tooth is 17. Select number of teeth on pinion 2, = 18 Numbér of teeth on gear z, =i2, = 6x 18 = 108 300rpm SOrpm COMPRESSOR Fig 57 SOTO [ae OS, Assume cast steel 0.20% C heat treated for pinion. From Table 23.18 (New) for cast steel (0.20% C heat treated steel Allowable static stress, = 173 MPa = 173 N/mm? 0.912 Lewis form factor for 20° FD involute y= 0.154 — 2.98(Old); 23.116 (New) y= pasa %y yy = 0.154 - eas = Equating 6,, y, 100m Y> ic, Gon ¥1 = Soo Ya 173 x 0.1033 = 9, x 0.1456 o,, = 122.74 Nimm?Spur and Helical Gears 399 From Table 23.18 (New) the nearest value to 122.74 N/mm is 124 N/mm? ©. Select SAE 1020 case hardened and WQT as gear material Hence G,, = 124N/mm?* Assume medium shock and 8-10 hours duty per day From Table 14.4 (Old) or 14.7 (New) vol-I for the driven mechanism compressor load factor i.c., i) Identify the weaker member $ (4 y oy Remarks Particulars Ree Pinion 173 0.1033 17.8709 Weaker Gear 124 0.1456 18,0544 Since 6,, y, <,, ¥» pinion is weaker. Therefore design should be based on pinion. Design, dimensions, dynamic load, wear load surface hardness number, ete are as explained in earlier examples. Note : According to Prof. MF Spotts In order to avoid failure of gear tooth due to bending in the initial stages of design, F, > Fa Introducing factor of safety F, =F, (FOS) ==155) where F, = Beam strength =o, mbY RG, F,,, = Effective load = acc FOS = Factor of safety 6, G, = Allowable bending stress = ~° (weaker member) 6, = Ultimate strength Y=n - y = Weaker member form factor m = Module b = Face width C, = Service factor C, = Velocity factor = 2550x1000N or Pitch circle radius of weaker member in mm. Speed of weaker member in rpm N = Power in kW Bs wou400 Design of Machine Elements - ‘The module obtained from equation (i) is based on beam strength Considering dynamic load according to Spots F4=C,F,+F, ii) bi, — ST for steel pinion and steel gear 253015 +1 where F, = Dynamic load by nO — for Cl gear and Cl pinion 3785 qn +2 ibr,r, F, = <1 — for steel pinion and CI gear 3260/1? +17 where e = Sum of error between two meshing teeth in mm =f ¢, + ¢,= error for gear + error for pinion n, = Speed of pinion 2, = Number of teeth on pinion b = Face width r, = Pitch circle radius of pinion r, = Pitch circle radius of gear Considering the dynamic load to avoid failure of the gear tooth due to bending F, = F.,, (FOS) = @C,+F,) (FOS) =a In order to avoid the failure of the gear tooth due to pitting B, > By Considering factor of safety F, = (,,) (FOS) where FP, = Wear load = d,bQK d, = Pitch circle diameter of pinion b = Pace width Olt ade Se ge ake 14367 ,¢ si K = Load stress factor = a 2E,E E, = Equivalent Young's movulus= 5 BE, E, = Young's modulus for gear material © = Pressure angle Limiting surface fatigue stress = (2.75,H, ~ 69) MPa Hardness Number (BHN) of the weaker member ‘Young's modulus for pinion material uw WISpur and Helical Gears: 401 ) " C.F, +F, considering dynamic load CF Neglecting dynamic load. Considering dynamic load to avoid failure of gear due to pitting F, = (C,R.+F) FOS —() Considering the FOS as unity F,=C,F,+F, ‘The gear can also be designed using Prof. MF Spott's equations. ALTERNATIVE METHOD Example : 5.14 Design a pair of spur gears with 20° full depth involute teeth hased on the Lewis equation. The velocity factor is to be used to account for dynamic load. The pinion shaft is connected to a 10 kW, 1440 rpm motor. The starting torque of the motor is 150% of the rated torque. The speed reduction is 4:1. Both pinion and gear is made of plain carbon steel with ultimate tensile stress 600 Némn’. Factor of safety is 1.5. Design the gears, specify their dimensions and suggest suitable surface hardness for the gears. Data: a= 20° ED involute ; N=P=10 kW; n, = 1440 rpm Solution : 15; 0,, = 600 Nimm’ ; FOS = 1 ns = “ = 200N /mm? Lewis form factor for 20° FD involute system 091 y = 0.154 2 , ~--- 23.116 From Table 23.6 (New)/12.4(b) for 20° FD inyolute system minimum number of teeth on a Baion to avoid interference z, = I7or 18 Table, z, = 18 . 2, = i2,=4x18=72 2 0.912 Lewis form factor for pinion, y, = 0.154-— >= 0.1033402 Design of Machine Elements = 912 Lewis form factor for gear, y, = ous4 282 = 01413 2 Y, = my, =mx 0.1033 = 0.3245 Y, = my, =1x 0.1413 = 0.4439 c= Suatingtorgue _ ‘s ~ Rated torque (i) Identity the weaker member As the pinion and gear material are the same, pinion is the weaker member. Therefore design should be based on pinion. (ii) Torque transmitted M, = S0x10°xN $ 2nn ~. Torque transmitted by the weaker member 60x10°xN _ 60x10°x10 = = 66314.56Nm 2nxn, anxiagy 6084 56Nmm (ii) Module based on beam strength & 6 Module, m = {52x10 BESS ze zxnxc,x(2 (Se m2 Considering the weaker member K 60x10° NxC, xFOS | alee ea || a NAG ESS c, x( 2) xf Sa. apxnxe.x(®)p()h Velocity factor C, is unknown. For the trial value, assume the pitch line velocity as 5 m/s Bes, emia = =0375 4 Ke mye a5 Sais A 1 Assume face width, b= 10m; -- 2 Nn. 10 Sat ae {eel 10X1.5x15 Bt ape x ae aoSpur and Helical Gears 403 (iv) Selection of module First preference value of the module from Table 23.3 / 12.2 is 5 mm Trail : 1 m dg, 4, b= 10mm= 10x 5= 30mm Check for design 2M, Tangential tooth Joad on pinion F, ==" ese =147366N 1 md, mx 901440 Pitch line velocity of pinion, Ym = E599 = go,900 = ©/858m/ see 3 3 +. Velocity factor, C,=K, = 355 = gnease ~ 03008 --- 23.134(a) C, 1.5% 1473.66 Effective force, Fy= GF, =—gaggg = 720996N Beam strength of weaker member, F, = 9p, by, P= oo, by, (nm) = op, bY\m = 200 x 50 x 0.3245 x 5 = 16225 N FOS = Fg 7209.69 The design is satisfactory. . Module, m =5 mm =) Surface hardness for gears 2z, x72 att, 18472 ---- 23.163 (New) 2 Load stress factor K = 0.16 Ge) - This relationship is suitable if both the gears are made f sel with a pressure angle of 20° FD involute. Wear strength of gear tooth, F, = d; bQk -+-- 23.160 (New) BHN)” = 90x 50x 1.6.x 0.16 a 0.1152 (BHN? As, F, =(F.,) (FOS) (According to prof. MF spotts] 0.1152 x (BHN)? = 7209.69 x 1.5 . BHN = 306.392, Take BHN = 310 Surface hardness for gears = 310 BHN’