Example 14-8
Design a 4:1 spur-gear reduction for a 74.54 kW, three-phase squirrel-cage induction motor
Cr
running at 1120 rev/min. The load is smooth, providing a reliability of 0.95 at 109 revolutions
ea
of the pinion. Gearing space is meager. Use Nitralloy 135M, grade 1 material to keep the gear
te
size small. The gears are heat-treated first then nitrided. Say that center to center shafts
d
distance is 285.75 mm.
wi
mG ≔ 4 W ≔ 74.54 kW n ≔ 1120 R ≔ 0.95 Ncp ≔ 10 9 rev
th
c ≔ 285.75
PT
C
----------------“Materials Properties ”
Ma
Nitrally 135M grade 1 (Table 14-5, p742)
th
⎛ 32 + 36 ⎞
HRC ≔ ⎜――― HRC = 34 HB ≔ 8.570 ⋅ HRC + 27.6 HB = 318.98
ca
⎟
⎝ 2 ⎠
d
St ≔ ((0.594 ⋅ HB + 87.76)) Table 14-3 & Fig 12-2
Ex
pr
St = 277.234 MPa
es
s.
Sc ≔ 1172 MPa Table 14-6
Se
-------------“basic input calculations”
ew
using the mG & c equations
ww
2⋅c
dp ≔ ――― dp = 114.3 mm dG ≔ mG ⋅ dp dG = 457.2 mm
.m
1 + mG
at
k≔1 ϕ ≔ 20 ° m ≔ mG
π ⋅ dp ⋅ n
hc
V ≔ ―――
ad
60000
2⋅k ⎛ ⎞
⋅ ⎝m + ‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾
m 2 + ((1 + 2 ⋅ m)) ⋅ ((sin ((ϕ)))) 2 ⎠
. co
Np ≔ ――――――― Np = 15.444
((1 + 2 ⋅ m)) ⋅ ((sin ((ϕ)))) 2
m
Np ≔ 16
fo
NG ≔ mG ⋅ Np NG = 64
rm
--------------“module & Diametral Pitch”
or
Np 1
ei
P ≔ ―― P = 0.14 m≔― m = 7.144 mm
dp P
nf
---------------Ko
or
Ko ≔ 1
ma
--------------Kv
tio
π ⋅ dp ⋅ n m ft
V ≔ ――― V = 6.703 m/s v ≔ 6.7 ― v = ⎛⎝1.319 ⋅ 10 3 ⎞⎠ ――
n.
60000 s min
π ⋅ dp ⋅ n m ft
V ≔ ――― v ≔ 6.7 ― v = ⎛⎝1.319 ⋅ 10 3 ⎞⎠ ――
60000 s min
Qv ≔ 9 B ≔ 0.52 A ≔ 76.88
Cr
⎛ ⎞B
ea
⎜ A + ‾‾‾‾‾‾
200 ⋅ V ⎟
Kv ≔ ――――― Kv = 1.225
te
⎜⎝ A ⎟⎠
d
--------------Ks
wi
π
th
p≔― b≔4⋅p Assumption b = 89.771 b ≔ 90 mm
P
PT
Yp ≔ 0.296 YG ≔ 0.425 using Y table for Np=16 teeth &
C
NG=64
Ma
⎛ b ⋅ ‾‾‾
Yp ⎞
0.0535
th
Ksp ≔ 1.192 ⋅ ⎜――― ⎟ Ksp = 1.631
ca
⎜⎝ P ⎟⎠
d
⎛ b ⋅ ‾‾‾
YG ⎞
0.0535
Ex
Ksg ≔ 1.192 ⋅ ⎜――― ⎟ Ksg = 1.647
⎜⎝ ⎟⎠
pr
P
es
-------------------Km
s.
b
Cmc ≔ 1 Cpf ≔ ――― - 0.0375 + 4.92 ⋅ 10 -4 ⋅ b Cpf = 0.086
Se
10 ⋅ dp
ew
⎛ b ⎞ -4 ⎛ b ⎞
2
Cpm ≔ 1 Ce ≔ 1 Cma ≔ 0.127 + 0.0158 ⋅ ⎜―― ⎟ - 0.930 ⋅ 10 ⋅ ⎜―― ⎟ Cma = 0.182
⎝ 25.4 ⎠ ⎝ 25.4 ⎠
ww
Km ≔ 1 + Cmc ⋅ ⎛⎝Cpf ⋅ Cpm + Cma ⋅ Ce⎞⎠ Km = 1.267
.m
---------------KB
at
KB ≔ 1 mB=(tr/ht)>1.2
hc
ad
------------------Yj
. co
YJp ≔ 0.27 YJG ≔ 0.427 Fig 14-6
m
----------------------------------ZE, ZR, ZI
fo
ZE ≔ 191 Table 14-8 ZR ≔ 1 mN ≔ 1
rm
cos ((ϕ)) sin ((ϕ)) mG
or
ZI ≔ ――――― ⋅ ――― ZI = 0.129
2 ⋅ mN mG + 1
ei
---------------------------------- YN (Figure 14-14)
nf
Lp
Lp ≔ 10 9 LG ≔ ―― LG = 2.5 ⋅ 10 8
or
mG
ma
YNp ≔ 1.3558 ⎛⎝Lp⎞⎠ -0.0178 YNp = 0.938
tio
YNG ≔ 1.3558 ⎛⎝LG⎞⎠ -0.0178 YNG = 0.961
n.
---------------------------------- ZN (Figure 14-15
YNG ≔ 1.3558 ⎛⎝LG⎞⎠ -0.0178 YNG = 0.961
---------------------------------- ZN (Figure 14-15
Cr
ZNp ≔ 1.4488 ⎛⎝Lp⎞⎠ -0.023 ZNp = 0.9
ea
te
ZNG ≔ 1.4488 ⎛⎝LG⎞⎠ -0.023 ZNG = 0.929
d
wi
---------------------------------- YZ
th
YZ ≔ 0.658 - 0.0759 ⋅ ln ((1 - R)) YZ = 0.885
PT
Yθ ≔ 1
C
Ma
let HB,p = HB, G
th
A' ≔ 0 CH ≔ 1 ZW ≔ CH
ca
d
Claculate the face width with factor of saftey 2 and check b=90 mm
Ex
W
pr
Ft ≔ ― Ft = 11.121 kN Fd ≔ 2 ⋅ Ft SF ≔ 1 SH ≔ SF
V
es
s.
Bending Fd = 22.241
Se
⎛⎝10 3 Fd⎞⎠ ⋅ Ko ⋅ Kv ⋅ Ksp ⋅ Km ⋅ KB ⎛ SF ⋅ Yθ ⋅ YZ ⎞
b ≔ 1000 ―――――――――― ⋅ ⎜――――― ⎟ b = 99.398 mm
ew
⎛⎝m ⋅ 10 -3⎞⎠ ⋅ YJp ⎜⎝ ⎛⎝10 St⎞⎠ ⋅ YNp ⎟⎠
6
ww
wear
.m
⎛⎝10 3 Fd⎞⎠ ⋅ Ko ⋅ Kv ⋅ Ksp ⋅ Km ⋅ ZR ⎛ SH ⋅ Yθ ⋅ YZ ⋅ ⎛⎝10 3 ⋅ ZE⎞⎠ ⎞ 2
b ≔ 1000 ―――――――――― ⋅ ⎜――――――― ⎟ mm
at
⎛⎝dp ⋅ 10 -3⎞⎠ ⋅ ZI ⎜⎝ 10 6 ⋅ Sc ⋅ ZNp ⎟⎠
hc
ad
b = 98.557
. co
Second attempt
m
--------------Ks
fo
π
rm
p≔― b≔4⋅p Assumption b = 89.771 b ≔ 105 mm
P
or
Yp ≔ 0.296 YG ≔ 0.425 using Y table for Np=16 teeth &
ei
NG=64
nf
⎛ b ⋅ ‾‾‾
Yp ⎞
0.0535
or
⎜
Ksp ≔ 1.192 ⋅ ――― ⎟ Ksp = 1.644
ma
⎜⎝ P ⎟⎠
tio
⎛ b ⋅ ‾‾‾
YG ⎞
0.0535
Ksg ≔ 1.192 ⋅ ⎜――― ⎟ Ksg = 1.66
n.
⎜⎝ P ⎟⎠
-------------------Km
⎛ b ⋅ ‾‾‾
YG ⎞
0.0535
Ksg ≔ 1.192 ⋅ ⎜――― ⎟ Ksg = 1.66
⎜⎝ P ⎟⎠
-------------------Km
Cr
b
Cmc ≔ 1 Cpf ≔ ――― - 0.0375 + 4.92 ⋅ 10 -4 ⋅ b Cpf = 0.106
ea
10 ⋅ dp
⎛ b ⎞ -4 ⎛ b ⎞
2
te
Cpm ≔ 1 Ce ≔ 1 C ma ≔ 0.127 + 0.0158 ⋅ ⎜―― - ⋅
⎟ 0.930 ⋅ 10 ⎜―― ⎟ Cma = 0.191
d
⎝ 25.4 ⎠ ⎝ 25.4 ⎠
wi
Km ≔ 1 + Cmc ⋅ ⎛⎝Cpf ⋅ Cpm + Cma ⋅ Ce⎞⎠ Km = 1.297
th
---------------KB
PT
KB ≔ 1 mB=(tr/ht)>1.2
C
Ma
------------------Yj
YJp ≔ 0.27 YJG ≔ 0.427 Fig 14-6
th
ca
----------------------------------ZE, ZR, ZI
d
ZE ≔ 191 Table 14-8 ZR ≔ 1 mN ≔ 1
Ex
pr
cos ((ϕ)) sin ((ϕ)) mG
es
ZI ≔ ――――― ⋅ ――― ZI = 0.129
2 ⋅ mN mG + 1
s.
---------------------------------- YN (Figure 14-14)
Se
Lp
Lp ≔ 10 9 LG ≔ ―― LG = 2.5 ⋅ 10 8
ew
mG
YNp ≔ 1.3558 ⎛⎝Lp⎞⎠ -0.0178 YNp = 0.938
ww
YNG ≔ 1.3558 ⎛⎝LG⎞⎠ -0.0178 YNG = 0.961
.m
at
---------------------------------- ZN (Figure 14-15
hc
ad
ZNp ≔ 1.4488 ⎛⎝Lp⎞⎠ -0.023 ZNp = 0.9
. co
ZNG ≔ 1.4488 ⎛⎝LG⎞⎠ -0.023 ZNG = 0.929
m
fo
---------------------------------- YZ
rm
YZ ≔ 0.658 - 0.0759 ⋅ ln ((1 - R)) YZ = 0.885
or
Yθ ≔ 1
ei
let HB,p = HB, G
nf
or
A' ≔ 0 CH ≔ 1 ZW ≔ CH
ma
tio
n.
Claculate the face width with factor of saftey 2 and check b=100 mm
Claculate the face width with factor of saftey 2 and check b=100 mm
Cr
W
Ft ≔ ― Ft = 11.121 kN Fd ≔ 2 ⋅ Ft SF ≔ 1 SH ≔ SF
ea
V
te
Bending Fd = 22.241
d
⎛⎝10 Fd⎞⎠ ⋅ Ko ⋅ Kv ⋅ Ksp ⋅ Km ⋅ KB ⎛ SF ⋅ Yθ ⋅ YZ ⎞
3
wi
b ≔ 1000 ―――――――――― ⋅ ⎜――――― ⎟ b = 102.547 mm
⎛⎝m ⋅ 10 -3⎞⎠ ⋅ YJp ⎜⎝ ⎛⎝10 St⎞⎠ ⋅ YNp ⎟⎠
6
th
PT
wear
C
⎛⎝10 3 Fd⎞⎠ ⋅ Ko ⋅ Kv ⋅ Ksp ⋅ Km ⋅ ZR ⎛ SH ⋅ Yθ ⋅ YZ ⋅ ⎛⎝10 3 ⋅ ZE⎞⎠ ⎞ 2
Ma
b ≔ 1000 ―――――――――― ⋅ ⎜――――――― ⎟ mm
⎛⎝dp ⋅ 10 -3⎞⎠ ⋅ ZI ⎜⎝ 10 6 ⋅ Sc ⋅ ZNp ⎟⎠
th
ca
b = 101.68
d
Ex
pr
es
s.
Se
ew
ww
.m
at
hc
ad
. co
m
fo
rm
or
ei
nf
or
ma
tio
n.