Unit 47 applications oF Formulas to cutting speed, revolutions per minute, and cutting time 333

complex Problems
The solution of the following problems requires more than one formula and the rearrangement of formulas.
3.1416DN pDN
Use C 5 or for customary units and
12 12
3.1416DN pDN
C5 or for metric units.
1000 1000
12C 12C
N5 or for customary units and
3.1416D pD
1000C 1000C
N5 or for metric units.
3.1416D pD
L
T5
FN
45. A 3.000-inch diameter cylinder is turned for an 11.300-inch length of cut. The
cutting speed is 300 feet per minute and the cutting time is 1.02 minutes. Calculate
the tool feed in inches per revolution. Round the answer to 3 decimal places.
46. A combination drilling and countersinking operation on bronze round stock is
3
performed on an automatic screw machine. The length of cut per piece is 1 inches.
4
1
The total cutting time for 2300 pieces is 6 hours running at 1600 rpm. What is the
2
tool feed in inches per revolution? Round the answer to 3 decimal places.
1
47. Steel shafts, 1 inches in diameter, are turned on an automatic machine. One
4
finishing operation is required for a 16.5-inch length of cut. The tool feed is 0.015
inch per revolution using a cutting speed of 200 feet per minute. Determine the
number of hours of cutting time required for 1500 shafts. Round the answer to the
nearest hour.

48. A carbide milling cutter is used for machining a 560.00-millimeter length of stainless
steel. The cutting time is 11.95 minutes, the cutting speed is 60.000 meters per minute,
and the feed is 0.250 millimeter per revolution. What is the diameter of the carbide
milling cutter? Round the answer to 1 decimal place.
5 1
49. Aluminum baseplates are produced that are 1 inches thick. Six -inch-diameter
8 4
holes are drilled in each plate using a feed of 0.004 inch per revolution and a
cutting speed of 300 feet per minute. Setup and handling time is estimated at 0.5
minute per piece. What is the total number of hours required to produce 850 aluminum
baseplates? Round the answer to 1 decimal place.

cutting Speed table

Refer to the cutting speed table under the heading “Using Data from a Cutting Speed Table” earlier in this unit. Use the
4C
table values and the simplified revolutions per minute formula, N 5 . Compute the revolutions per minute to the
D
nearer revolution for each problem in the following table.

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 334 Section 4 Fundamentals oF algebra

Cutting Tool or Workpiece Speed

Material Machined Operation Tool Material Diameter (inches) (rpm)
50. Aluminum (5052) Milling High-Speed Steel 3.500

51. Stainless Steel (305), BHN 225–275 Turning Carbide 5.200

52. Alloy Steel (4320), BHN 220–275 Reaming High-Speed Steel 0.480

53. Manganese Bronze, cold drawn Drilling High-Speed Steel 0.375

54. Brass, annealed Milling High-Speed Steel 4.000

55. Carbon Steel (1020), BHN 175–225 Turning Carbide 6.100

56. Beryllium Copper, annealed Drilling High-Speed Steel 1.100

Malleable Cast Iron (32510), BHN
57. 110–160
Milling Carbide 3.000

58. Alloy Steel (4320), BHN 220–275 Milling Carbide 2.500

59. Aluminum (5052) Turning High-Speed Steel 5.800

60. Carbon Steel (1020), BHN 175–225 Milling Carbide 4.500

61. Brass, annealed Turning High-Speed Steel 2.750

62. Stainless Steel (305), BHN 225–275 Reaming Carbide 0.620

Malleable Cast Iron (32510), BHN
63. 110–160
Turning Carbide 7.000

64. Carbon Steel (1020), BHN 175–225 Drilling High-Speed Steel 0.375

UNIT 48 Applications of Formulas to Spur Gears

Objectives After studying this unit you should be able to
●● Identify the proper gear formula to use depending on the unknown and the given data.
●● Compute gear part dimensions by substituting known values directly into formulas.
●● Compute gear part dimensions by rearranging given formulas in terms of the unknowns.
●● Compute gear part dimensions by the application of two or more formulas in order to determine an unknown.

Gears have wide application in machine technology. They are basic to the design and operation of machinery.
Most machine shops are equipped to cut gears, and some shops specialize in gear design and manufacture. It is
essential that the machinist and drafter have an understanding of gear parts and the ability to determine gear
dimensions by the use of trade handbook formulas.

dEScription of gEarS
Gears are used for transmitting power by rotary motion between shafts. Gears are designed
to prevent slippage and to ensure positive motion while maintaining a high degree of ac-
curacy of the speed ratios between driving and driven gears. The shape of the gear tooth
is of primary importance in providing a smooth transmission of motion. The shape of most

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 Unit 48 applications oF Formulas to spur gears 335

gear teeth is an involute curve. This curve is formed by the path of a point on a straight line
as it rolls along a circle. Spur gears are gears that are in mesh between parallel shafts. Of two
gears in mesh, the smaller gear is called the pinion and the larger gear is called the gear.

Spur gEar dEfinitionS

Spur gears and the terms that apply to these gears are shown in Figures 48-1 OUTSIDE DIAMETER
PITCH DIAMETER
and 48-2. It is essential to study the figures and gear terms before computing
ROOT DIAMETER
gear problems by the use of formulas.
Pitch Circles are the imaginary circles of two meshing gears that make
contact with each other. The circles are the basis of gear design and
gear calculations. ROOT CIRCLE
Pitch Diameter is the diameter of the pitch circle. PITCH CIRCLE
Root Circle is a circle that coincides with the bottoms of the tooth
Figure 48-1
spaces.
Root Diameter is the diameter of the root circle.
Outside Diameter is the diameter measured to the tops of the gear teeth.
Addendum is the height of the tooth above the pitch circle.
Dedendum is the depth of the tooth space below the pitch circle.
Whole Depth is the total depth of the tooth space. It is equal to the addendum plus
the dedendum.
Working Depth is the total depth of mating teeth when two gears are in mesh. It is
equal to twice the addendum.
Clearance is the distance between the top of a tooth and the bottom of the mating
tooth space of two gears in mesh. It is equal to the whole depth minus the work-
ing depth.
Tooth Thickness (Circular) is the length of the arc, on the pitch circle, between the two
sides of a tooth.
Circular Pitch is the length of the arc measured on the pitch circle between the centers
of two adjacent teeth. It is equal to the circumference of the pitch circle divided by
the number of teeth on the gear.
Diametral Pitch (Pitch) is the ratio of the number of gear teeth to the number of
inches of pitch diameter. It is equal to the number of gear teeth for each inch
of pitch diameter.

PITCH CIRCLE
TOOTH
THICKNESS
CIRCULAR PITCH
CLEARANCE
CLEARANCE

WHOLE DEPTH
WORKING DEPTH PITCH CIRCLE

DEDENDUM
ADDENDUM

Figure 48-2

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