%NAME – A S M NORUL AMIN; ROLL NO.

- 18ME8140; SUB - MES-752;

%MACHINE DESIGN SESSIONAL 2; ASSIGNMENT - DESIGN OF A GEARBOX;
clc
clear all
%given data
KW = 5.5; %input('Enter the transmitted power : ');
%transmission ratio is 3
i = 3;
%considering spur gear
zp = 18;
zg = i*zp;
np = 1800; %input('Enter the speed of pinion in rpm = ');
Yp = 0.484 - (3.28/zp);
Yg = 0.484 - (3.28/zg);
%for better wear strength 20MnCr5 material is used
Sut = 1215;
Sen = 0.45*Sut; %Sen endurance strength of the material
fos = 2.5;
So = Sut/fos;%So = Basic allowable stress of the material
%check weaker wheel
%as we used same material for pinion and gear and its spur gear therefore
%pinion is weaker
Cs = 1.5;
x = 11; %x =b/m;
Cw = 1.15;
Tp = (Cs*60*(10^6)*KW)/(2*3.14*np);
cv1 = 0.5;
M1 = (2*Tp*Cw)/(So*x*cv1*Yp*zp);
m1 = M1^(1/3);
v1 = (3.14*m1*zp*np)/60000;
cv2 = 3/(3 + v1);
M2 = (2*Tp*Cw)/(So*x*cv2*Yp*zp);
m2 = M2^(1/3);
v2 = (3.14*m2*zp*np)/60000;
cv3 = 3/(3 + v2);
M3 = (2*Tp*Cw)/(So*x*cv3*Yp*zp);
m3 = M3^(1/3);
v3 = (3.14*m3*zp*np)/60000;
cv4 = 3/(3 + v3);
M4 = (2*Tp*Cw)/(So*x*cv4*Yp*zp);
m4 = M4^(1/3);
mn = m4;
if (1<mn)&&(mn<1.25)
m = 1.25;
elseif (1.25<mn)&&(mn<1.5)
m = 1.5;
elseif (1.5<mn)&&(mn<1.75)
m = 1.75;
elseif (1.75<mn)&&(mn<2)
m = 2;
elseif (2<mn)&&(mn<2.25)
m = 2.25;
elseif (2.25<mn)&&(mn<2.5)
m = 2.5;
else
m = 3.0;

end
module = m;
b = x*module;
fprintf('Face width is %4.2f \n',round(b));
v = (3.14*module*zp*np)/60000;
cv = 3/(3 + v);
dp = module*zp;
dg = module*zg;
%calculation of dynamic load
%Fd = Ft + Fi
Fd1 = 2*Tp/(cv*dp);
Ft = 2*Tp/dp;
row = 7.88*10^-6;
mp = (3.14/8)*(dp^2)*b*row;
mg = (3.14/8)*(dg^2)*b*row;
M = (mp*mg)/(mp + mg);
G = 0.1801447448*((2/dp)+(2/dg));
v = (3.14*dp*np)/60000;
F1 = 2000*G*M*v^2;
E = 2.12*10^5;
k = (b)/(18/E);
ep = 8 + 3.55*((3.14*m)^0.5);%for class 7 manufacturing
eg = ep;
e = ep + eg;
F2 = k*e*10^-3 + Ft;
Fa = F1*F2/(F1+F2);
Fi = (Fa*(2*F2 - Fa))^0.5;
Fd = Ft + Fi;
BHN = 650;
Senc = 2.8*BHN - 70;
K = ((Senc^2)*sind(20)/1.4)*(2/E);
Q = 2*zg/(zp + zg);
Fw = dp*b*K*Q;

fprintf('The module is %4.4f \n',module);

fprintf('pitch line velocity is %4.4f \n',v);
fprintf('velocity factor is %4.4f \n',cv);
FoS = (Fw/Fd);
fprintf('The factor of safety in wear is : %4.4f \n',FoS);
fprintf('The type of gear is : spur \n');
fprintf('The gear material is : 20MnCr5 \n');
fprintf('The normal pressure angfle is : 20 deg \n');
fprintf('pinion teeth number is : %d \n',zp);
fprintf('gear teeth number is : %d \n',zg);
fprintf('The pitch circle diameter of pinion is : %4.4f \n',dp);
fprintf('The pitch circle diameter of gear is : %4.4f \n',dg);
%forces on pinion
d = dp;
Pt = 2*Tp/d;
Pr = Pt*tand(20);
Pet = (Cs/cv)*Pt;
Per = (Cs/cv)*Pr;
fprintf('Effective tangential force is %4.4f \n',Pet);
fprintf('Effective radial force is %4.4f \n',Per);

%selection of bearing
%2 years of bearing life
%everyday 8 to 10 hours
fprintf('bearing is selected from SKF bearing catalogue inner race dia =
17mm, outer dia = 62 mm, width = 17mm \n');

%diameter of pinion shaft

Mb = 66184.464;
Mtp = 35014.087;
Tmax = 164.0235;
Kb = 1.5;
Kt = 1.5;
c = 0.6;
Dp = (16/(3.14*Tmax))*(((Kb*Mb)^2)+((Kt*Mtp)^2))^0.5;
Dop = (Dp/(1-c^3))^(1/3);
Dip = c*Dop;
dsp = Dp^(1/3);
fprintf('Outer diameter of pinion shaft is %4.4f \n',Dop);
fprintf('Inner diameter of pinion shaft is %4.4f \n',Dip);
fprintf('Solid shaft diameter of pinion shaft is %4.4f \n',dsp);
%diameter of gear shaft
Mb = 66184.464;
Mtg = 3*35014.087;
Tmax = 164.0235;
Kb = 1.5;
Kt = 1.5;
c = 0.6;
Dg = (16/(3.14*Tmax))*(((Kb*Mb)^2)+((Kt*Mtg)^2))^0.5;
Dog = (Dg/(1-c^3))^(1/3);
Dig = c*Dog;
dsg = Dg^(1/3);
fprintf('Outer diameter of gear shaft is %4.4f \n',Dog);
fprintf('Inner diameter of gear shaft is %4.4f \n',Dig);
fprintf('Solid shaft diameter of gear shaft is %4.4f\n',dsg);