Machine Design II

(MCE-C 311)
Mechatronics Engineering Program,
Faculty of Engineering,
Fayoum University

Dr. Ahmed Salah Abou Taleb

Mechanical Engineering Dept.,
Faculty of Engineering, Fayoum University
1
Gears Design

2
 Introduction
• This section gives a design guidelines for iterating
design process from which we can select an optimum
design for given conditions..

3
 Introduction
In designs involving gear drives, the designer must know:

1- The required speeds of rotation of the gear,

2- The amount of power that the drive must transmit,

3- The environment and operating conditions the drive

will be subjected,

4- The type of driving device, and

5- The driven machine..

4
 Introduction
The designer must decide:

1- The type of gears to use (spur gear, helical gear, bevel

gear, worm and worm gear,),

2- The arrangement of the gears and their shafts,

3- The materials of the gears, and

4- the geometry of the gears: numbers of teeth, diametral

pitch, pitch diameters, tooth form, face width, quality
numbers..
5
 Introduction
• The design procedure accounts for:

1- The bending fatigue strength of the gear teeth, and

2- The pitting resistance (surface failure).

• This procedure makes extensive use of the design

equations and of the tables, as well as , charts of design
factors.

• You should understand that there is no one best

solution to a gear design problem, several good designs
are possible.. 6
 Introduction
• Your judgment and creativity and the specific
requirements of the application will greatly affect the
final design selected.

• But as a beginner, try to work hard to create a

reasonable design..

7
 Design Objective
• Some overall objectives of a design are listed below.

• The resulting drive should:

1- Be compact and small,
2- Operate smoothly and quietly,
3- Have long life,
4- Be low in cost,
5- Be easy to manufacture, and
6- Be compatible with the other elements in the
machine, such as bearings, shafts, the housing,
the driver, and the driven machine..
8
 Design Procedure

Gear Design Procedure

Preliminary
Detailed Design
Design

Bending Fatigue Surface Failure

9
Spur Gear Design

10
 Design Procedure
Preliminary Design
1- From given figure, by
knowing the pinion speed
and transmitted power one
can get the module.

3
kv 
3 V
11
 Design Procedure
Preliminary Design
2- Assume number of teeth for pinion or from shown table
select suitable number of pinion teeth.

3- Get pinion diameter by multiply the teeth number by the

obtained module..
12
 Design Procedure
Preliminary Design
4- From the SR one can get gear diameter and number of teeth of
the gear.
5- Calculate the face width (F = 3 - 5 π m).
So, Fmin = 3 π m and Fmax = 5 π m or you can select an average
number for face width
6- Get the Tangential Force.
7- Calculate linear velocity.
3
8- Calculate the Dynamic Factor.. kv 
3 V

13
 Design Procedure
Preliminary Design
9- Get The Lawis Form Factor
Y from table 12 PP. 203.
10- Calculate the bending
stress Ft

kvWmY

11- Use a factor of safety (3-5)

to get yield stress.
12- Select the suitable
material for the
pinion/gear…

14
 Design Procedure
Detailed Design (against bending fatigue)
Ft
1-Calculate bending fatigue stress a 
kvWmJ
The geometry factor (J) can be found in Fig. 10 PP 204 & 205.
The dynamic factor (kv) can be found in Fig. 11 PP 206 & Table 9 PP.
196. Or as in next slides..

15
Geometry factor (J)
16
Dynamic factor (Kv)

17
 Design Procedure
Detailed Design (against bending fatigue)
2- Calculate the endurance limit  e  ka kb kc kd ke k f  e
 ut
Factors (k):  e 
2
Ka: surface condition modification factor, k a  a Sutb
Kb: size modification factor,
Kc: load modification factor,
Kd: temperature modification factor,
Ke: reliability factor, and
Kf: miscellaneous factor,

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(Ka) surface factor

(Kb) Size factor

19
(Kc) Load factor

(Kd) Temperature factor

= ST/SRT

20
 (Ke) Reliability factor

(Kf) miscellaneous factor

21
 Design Procedure
Detailed Design (against bending fatigue)
3- Calculate the factor of safety for gear e
nG 
a
4- Calculate the regular factor of safety; must be > 2
nG
The factors k0 & km from table 15 & 16 PP. 208 n
k0 k m
If n<2, change material or increase face width
Km: load distribution factor,
K0: application factor,

22
 (Km) Load distribution factor

Application factor, Ka

(K0) application factor…

23
 Design Procedure
Detailed Design (against surface failure)
1- Calculate the surface compressive stress Ft
 h  Cp
cvWd p I
CP elastic coefficient from table 17 PP 209
The dynamic factor (cv) can be found in Fig. 11 PP 206 & Table 9 PP.
196.
dP pinion diameter
I geometry factor from Fig. 15 PP 209
2- Calculate surface fatigue strength Sc= 2.76 HB – 70 For steel
HB: Brinell hardness number of steel

24
Dynamic factor (Cv)

25
Elastic Coefficient (CP) 26
Geometric factor (I)

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 Design Procedure
Detailed Design (against surface failure)
3- Make correction SH 
CLCH
Sc
CT CR
SH: Corrected fatigue strength
CL: life factor
CH: Hardness ratio factor = 1.0 for spur gear.
CT: Temperature factor = 1.0 for operating temperature up to 250 0C
CR: reliability factor

Factors (C) from table 18 PP. 210 or next slide

4- Get the regular factor of safety n
S H  k0km n h

28
Reliability factor CR Surface life factor (CL)

………………………………….

29