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Module 3

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Veerabhadra H S
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11 views46 pages

Module 3

Class notes..

Uploaded by

Veerabhadra H S
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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3 2. 4 Design of Machine Elemen, st Dedendum angle Addendum angle ‘ ° Fig. 2. i ( Mitre gear 2A pair of bevel gears ofthe same size and the shafts intersect at right angles are called Mitre gears, Crown gear Ifthe pitch angle ofthe bevel is 90° ie, the pitch cone becomes plane thee the gear is called crown gear, Spiral bevel gear : Spiral bevel ears have curved and obli teeth. The tooth elemens are theoretically spirals, but in ee Practice they are made circular arcs because of the ease Scanned with CamSeanner Bevel And Worm Gears 325 Fig: 53 Hypoid gears Hypoid gears are used to transmit power between nonparallel, non intersecting shafts, They are usually made for shafts which are at 90°, are made in pairs, and are not interchangeable. In ‘appearance, hypoid gears resemble spiral bevel gears except that the pinion axis is offset above or below the gear axis, The pitch surfaces of hypoid gears are hyper boloids of revolutions. The gear teeth are parallel to the line of contact hence there is sliding along the tooth elements which is a disadvantage, Hypoid gears Operate more quietly then spiral bevel gears. Hypoid gears are widely used for automotive rear axle drives because the offset pinion permits lowering the drive shaft and use of a lower body. A hypoid gear is shown inFig.5.4. Zerol Bevel gear Zerol gears are a special form of spiral bevel gear with curved teeth and having a zero degree ‘mean spiral angle. Zerol gear impose the same loads on their support bearings as straight bevel gear. From Fig. 5.5 (a) R = Cone distance or slant height of cone b = face width 8 = half pitch cone angle 8, = half pitch cone angle for pinion Scanned with CamSeanner 326 Design of Macy INe Eig Me h angle for gear = shaft angle = 8,4 8, h, = Addendum hy = Dedendum Fig: 5.5 (a) v, = Addendum angle vy, = Dedendum angle 9, = Cutting angle = 5 -v, @, = face angle = 5 +, Fig :55(b) | Scanned with CamSeanner = ey gevel And Worm Gears po ee ‘Acute bevel gear (Fig. 5.6 a) A ( For acute bevel gear 2 < 90° Right,angle bevel gear (Fig. 5.6 b) For right angle bevel gear = 90° obtuse bevel gear (Fig. 5.6 ¢) For obtuse bevel gear Y > 90° Fig : 5.6 (b) Fig: 5.66 5.2 FORMATIVE OR VIRTUAL OR EQUIVALENT NUMBER OF TEETH ‘The dimensions of a bevel gear are shown in Fig. 5.7. The pitch lines of the teeth lie in the surface of an imaginary cone with the apex at O. The distance R is called the cone distance. The angled which the pitch line makes with the axis ofthe gear, is called the pitch angle. The dimensions ‘of the bevel gear are always specified and measured at the large end of the tooth. The addendum if ot, the dedendum h, and the pitch circle diameter d are specified at the large end of the tooth as 0 iycsipminthe Fi. 57. i os D yon an sit oa OP Ie ot h so) (o oy , gat’ an ae 3 hy en A ort cor $2 ar Back Cone Uj Cc Ded Pitch Line 8 Scanned with CamSeanner Design of Machine Slements-1 and its elements are perpendicular to the elements of the the back cone radius. For the purpose of design, an imaginary perpendicular to the tooth at the large end. r, is thie pitch circle s and z, the number of teeth on this gear. This gear is called tte the number of teeth Z, on this gear are called virtual or formative number of —o% Where m is the module at the large end of the tooth. If z is the actual number of teeth on the bevel gear. then é ea —6 m : Fron @and@@ = = = —@ zd From AABC i AB sin ZBCA = AC : _ — (4/2) ie, sin(90-8) = —— tr é a — 2086 : ‘Substituting the above value in equation (ii) eee ae z | 2, = —= Formative number of teeth on bevel gear =) | 2 es 5.3 BEAM STRENGTH OF BEVEL GEARS. ‘The size of the cross-section of the tooth of a bevel gear varies along the face width as shown in Fig. 5.8. In order to determine the beam strength of the bevel gear, it is considered to be equivalent to 2 formative spur gear in a plane perpendicular to the tooth element. Consider an elemental section of the tooth at a distance x from the apex O and having a width dx. Applying the Lewis equation to a formative spur gear at a distance x from the apex, __—— Scanned with CamSeanner Bevel And Worm Gears a(F) = mbo,y where 3(F.) = beam strength of the elemental section in N module for the section in mm face width in mm —@ Y = Lewis form factor based on virtual number of teeth. From the figure, — Gi) — (ii) n= (iv) z From (iii) and (iv) = m(> —) m= o(;) Alsob, = dx (vi) Substituting (v) and (vi) in (i) we have mo,Yx dx — (ii) &F) = ae From (ii) and (vii) Cea eee Scanned with CamSeanner oo 330 Design of Machine Fleme, a ‘The lefthand side indicates the torque M, nl moYr) fags RY Joey) jb gt = mbo,yr |! Rt 3RF M, Ci Assuming beam strength (F,) as the tangential force at the large end of tooth, er aes ai From (viii) and (ix) by F, = mbo,¥| 1-2 + 3p by The face width of the bevel gear is limited to one -third of the cone distance. Therefore, the Jast in the bracket will never be more than 1/27 and hence neglecting the last term, ia F, = mbo,Y|I-2 beam strength of the tooth in N m = module atthe large end of the tooth in mm b = face width in mm As per modified form of Lewis equation equivalent tangential force at the larger end ofthe R bevel gear is F, = 0, C,b Y m (2) =0,C,baym (2) 22062 1 aa™ where R = Cone distance = > Ja? +d} = > a 2414 : R R Width of gear face should lie between a: sbs 3 = 248 Velocity factor C, for teeth finished with form cutters ae 555 = 5554 Jug, forthe generated system Scanned with CamSeanner Bevel And Worm Gears 331 R The face width of the bevel gear is generally taken as 10m or z which ever is smaller, 5.4 DYNAMIC LOAD In addition to the static Load due to power transmission there is a dynamic load between the meshing teeth. According to Buckingham’s modified equation. 2ty,,(F, +bC) Dynamic load F, =F + 2.4400 Diva + YR FOC 5.5 WEAR LOAD ‘The wear strength F, indicates the maximum value of the tangential force at the large end of the tooth that the tooth can transmit without pitting failure. d,bOK The limiting wear load F, = “So5 85, where K = Load stress factor = ~~ 23.161 (New DDHB) E\E, E,+E, = Equivalent young’s modulus = = Limiting stress for surface fatique = (2.75 H,-69) MPa 23,168 (New DDHB) 22, Q = Radio factor = —— 1,42, b = face width inmm itch circle diameter of pinion in mm half pitch cone angle of pinion 5.6 STRAIGHT TOOTH BEVEL GEAR FORCES In force analysis, it is assumed that the resultant tooth force between two meshing teeth of bevel gears is concentrated at the midpoint along the face width of the tooth, This radius is given by, ‘d, _ bsin6, mala 2 diameter of pinion, 8, = pitch angle ofthe pinion, The resultant force has two components F, and F, as shown in Fig. 5: | where +,, = mean radius of pinion, b = face width of tooth face, d, = pitch Scanned with CamSeanner 332 Design of Machine Elements .y F, = tangential force which is perpendicular to the plane of paper, separating force. Now, where M, = torque transmitted by the gears. F, = F, tan [Link] o: = Pressure angle. “The separating force is further resolved into two components i.e, axial and radial as shown in Fig. 59. Forpinion, F, = F,cos 6, = F, tan 0, cos 8, F= F,sin8, = F tanasin 6, pa where tan §, = 2 a 1 na . 6, = tan! 7” = tan =| for right angle-bevel gear 2 ---- 2.402 (DDHB) number of teeth on pinion, z, = Number of teeth on gear ‘i 2 Gear ratio = % | ‘The components of the tooth force acting on the gear can be determined by considering actions and reactions as equal and opposite. As seen from the figure 6.17, the radial component of the gears equal to the axial component on the pinion. Similarly, the axial component on the gearis equal tothe radial component on the pinion. :. Axial or thrust on pinion and radial load on gear F, = F, tan 0: sin 8, Radial load on pinion and Axial or thrust on gear F, = F, tan at cos 8, Scanned with CamSeanner pevel And Worm Gears 333 Gear. Driven Pinion, Driver Fig :59 M Tangential force F, = Measnaes Fig ‘dy bsind, jean radius of pinion +, = [7-9 : 1 Pitch angle ofpinion 8, = tar |=] for right angle bevel gear. 5,7 PROCEDURAL STEPS FOR THE DESIGN OF BEVEL GEAR ‘The design procedure for bevel gear is almost the same as that of spur gear (i) Identity the weaker member Particulars , y Gy Remarks Pinion Gy, yy Oy, Gear Son Ya S02 | The gear whose value of 0,y is less is the weaker member Scanned with CamSeanner 334 = Design of Machine Eten inion is weaker if OY, < 5, gear is weaker Design should be based on weaker member. From Table 2.16 (Old DDHB) ; Table Bag (New DDB) obtain the allowable static stresses 6, and 0, for the given materials. For the cl tooth form Lewis form factor y for pinion and gear can be obtained usi pressure angle following formulae, 0. = 0.124 ~ 284 or say tnvotute ie Biven Mg the ~~ 2.97014) ; 23.115 (New Dorp 0. y = 0.154- = for 20° full depth involute ---- 2.98(Old) ; 23.116 (New DDHB) 0.95 y= 017- for 20° stub involute where Virtual number of teeth = ——~ cos6 Virtual number of teeth on pinion 7, Virtual number of teeth on gear 2, Acute bevel gear tan 8, Rr, OF right angle bevel gear 1 wan 8, = tan 6, = 1 Vo, T obtuse bevel gear sin(180-2) tan 8, = os(I80-2) ~~ 2.99(Old) ; 23.117 (New DDHB) --- 2.418 (DDHB) ---- 2.419 (DDHB) w= 2.400 (DDHB) ---- 2.401 ( 2.402 ( 2,403 cope anes 2,404 pon | ae Se Scanned with CamSeanner ppHB) ppH® B) sevel ANd Worn Gears 335 | tan 8, = —sin(180-5) —2.405 z 7. 0s{180-2) my ii) Design a) Tangential tooth load = 9550%1000NC, _ 9550%1000PCs here rin mm | i = Or ar d where r= Pj 7 + = Pitch circle radius of weaker member in mm = 2 C, = service factor Table 2.33 (Old); Table 23.13 (New DDHB) or Table 2.86 Peed of the weaker member = Power in kW b) Tangential tooth load from Lewis equation —— 2.426 a (DDHB) | = is 1 ? m 2 raed) wie R= cone dstnee= 2 JGTyay = @ aeeay 2.414 (DDHB) R R For face width = = 2387324146 Nom | Pitch angle of pinion, | | 150 _ 40sin3687° | | Mean radius of Pinion r, TT |S mm | 387324146 + Tangential tooth force F, = ag = 3189.4N Axial force on pinion and Radial load on gear F,= F,tanatsin8, =3789.4 x tan 20°x sin 36,87 = S7S4N Radial load on pinion and axial force on gear = F,= F, tan 0.c0s 5, = 3789.4 x tan 20? x cos 3657 = 1103.38 N ‘The free body diagram of the forces is shown in Fig. 5.10 | %, 1103.38. N 3189.4N ft Fay 4 at | 3789.4N-h | f ' 1,=75 mm 300 rpm i PINION i Fig : 5.10 { Example 5.2 of bev connect twso shafis at 60°. The gearsare alloy steel of case hardencd and precision cut with form cutters. The gear ratios 5:1. The power transmitted is 30 kW at 900 rpm oft Pinion. The teeth are 20° full depth. The pinion has 24 teeth. Suggest suitable surface hardness for the gar Pair. : Data: =30 KW; n,=900 rpm; c.=20° full depth involute; z, =24 —— Scanned with CamSeanner wae govel And Woirn Gears 339 solution : e Speed of gear n, Number of teeth on gear 2, j ‘Table2A18 (New DDHB) for alloy see case hardened (SAE2320) os 0, = 0,,=345 MPa=345 Nimm? , | | | | Asshaflangle 3-<9¢*tisaemre-tevet gear Foracute bevel gear tan, = 240 . pitch cone angle of pinion, | tan, —2401 | «pitch cone angle of gear 8, = 51,05" Formative numberof teeth ina straight tooth bevel pinion 3 zy 24 4 = Gasb) * asm "28296 nee 1 Formative numberof teth in a straight tooth bevel gear 120 = = 1909 — 2419 cos8, ~ c0s51.05 0912 Lewis form factor for 20° full depth involute y=0.154- ~~ —2.98 (Old DDHB) 23416 (New DDHB) 0.912 = 01154-2795 =0.11646 Form factor for pinion y, = 0.154. Form factor for gear y, = 0.154 ~- () Identity the weaker member |... Aspinion and gear are ofthe same material pinion is the weaker member. Therefore design should be based an pinion Scanned with CamSeanner —_—— ee Design of Machine E 440 ®) Tangential tooth load, = 2S80X100ONC, _ 9550 HOPES wee rin mm nt nt ---- 23.87b (New DDip) Ta 9550%1000NC, 9550x1000PC, * Tangential tooth toad of the weaker member Fy =a, ‘From Vabl 2550100030415 _ 39791,667 je F Z ae 900% 12m m 9 bYTangential tooth load from Lewis eq) + Tangential tooth Joad of the weaker member Fi, vib 75 R For faci & a For face width 10m, take face width b= 10m | 3 — | 188m-10m F, = (845) (10m (C,) (x 0.11646) Ege = 1055.96 mC, —ti) Equating equations (i) and (ii) ; 3979.67 m i imc, 2 37683! 5 fa nd : Mean pitch line velocity of the weaker member v, = 6495, lili Sea Scanned with CamSeanner 1055.96m*C, = geval Ard Wotrn Gears 341 mmzn, xx mx 24 x 900 = "60.000 =" 60,000 =4mm [Select std. module from Table 2.3 (Old DDHB) : Table 233 (New DDHB)} 131%4=4.524 m/sec Forteeth finished with form cutters, =1.13Im “Trial: 1 Assume 3 3 3+¥,, ~ 344524 ~ Velocity factorC, 04 From equation @)04 > 37683 256 < 37683 Not suitable 1:2 Assume m=5 mm ‘Tri 1.131. x5=5.655 m/sec +. Velocity factor C, =034662 345655 From equation (ii) (5°) (0.34662) > 37.683 43307 > 3168 Hence suitable, :. Module m=$ mm ©) Check for the stress (0y,C,) = (345) (0.34662) = 119.584 N/mm? § Induced sess 0,,=(0,C),,= ep ? 24% ova) aM Allowable stresso, 39791.667 : (10x5)(nx0J 146))( Since (6,,C,)qy<(6,,C,),, the design is satisfactory. Also in order to avoid the breakage of gear tooth due to bending, the beam sirength should be more than the effective force between the meshing teeth ie, R2Fy , (1 10x5 _ =€5)(10%5) 845) (x 0.11646) |! Gr gg x5 F, =mbo,Y (- = 26399 N= Beam strength of the weaker member Scanned with CamSeanner | ee) eg, Design of Mt 3a2 {7 of Machine fern. F since C, is already considered ), 159.82N | oaaeen = | ASF, > Fig the design is satisfactory from strength point it ili) Dimensions ' From Table 2.1 (Old DDHB); Table 23.1 (New DDHB) for & = 20° full depth Addendum h, = Im=1xS=Smm Dedendum h, = 1.25m=125%5=625mm Working depth ht = 2m=2x5= 10mm ‘Total depth h = 225m=11.25mm ‘Tooth thickness § 3 4527854 nm Minimumelearmeee = 0.25m=025x5= 125mm Pitch circle diameter of pinion dmv, = 524 = [20mm Pitch circle diameter of gear d, 120= 600mm Outside diameter of pinion d 20-+2x5= 130mm Outside diameter of gourd, = d,t2ha, =600+2%5=610mm Dedendum circle diameter of piniond,, =d,-2h, = 120-2%6.25= 107mm Dedendum circle diameter of gear d, = 587.5mm_ | For Addendum angle, tany, = —USi@®, _ 2x5xsin895 -2406@DHy) | | reeds 120 | ++ Addendum angle v, | , For dedendum angle,tan, = 2x625xsin895 ~~2401 (DDB) “ Dedendumangle vy, | Face angle of pinion 0, | Face angle of gear, | Cutting angle of pinion, = §-1j=8.95-0,9284=8,0216° | Cutting angle of gear, = §,-v,=51,05~0.9284=50.1216° | | | Tangential tooth load = 22791657 _ 39791667 _ 7959.33 | | t m 5 | Face width b = 10m=10x5=50mm | Cone distance R = 61,188m =61.188x5=305 94=306mm | | ee | Scanned with CamSeanner ee ae ree pe tee govel And Worm Gears 343 Mean pitch line velocity v, = $.65SnvsSee | Velocity factor C, =0.34062. Service faciorC, = 15 iv) Checking a } (a) Dynamic load i ‘According to Buckingham’s equation 7 | : Alva (F,+0C) ge? i Dynamicload F, = F+ Liv, + Rabe / —-2.440.a (DDHB) | From Fig 2.29 (Old DDHB) ;23.34a (New DDB) for pr le2.35 (Old DDHB) ; Table 23.32 (New DIB) foro.= 20” full depth, stel - steel combination 10125 mm From’ and error Dynamic factor C = 145 " = 145 Nim se, = rosasya 21%5#581795838 45041451 Ke Fy = 7958.34 9156554 4 7958.33+50% 14S IS419N (0) Wear load | According to Buckingham's equation neglecting deflection effect wear load d)bQK 056, 24410 Baya 2x190.9 itt, 2429641909 Ratio factor. = = 1,712 Forsafer design F, 2 F, | ic, URQK > Fa | 8 { 120x50x1.7742x K ie, ——cosg95. 2 15419 eK 2 1431Nimm? From Table 23.37B (New DDHB); Table 2.40 (Old DDHB) fora.= 20° ; K = 1.431 N/mm? ‘Surface hardness for pinion = 350BHN Surface hardness for gear = 300BHN 0 ee Scanned with CamSeanner 344 Design of Machine Elements - i) Exghiple 5.3 Design a pair of bevel gears to transmit a power of 25 kW from a shaft rotating at 1200 rpm toa perpendicular shaft to be rotated at 400 rpm. (VTU, Jan/Feb 2006, Jan/Feb 2008) Data: N= 25 kW3 n, = 1200 rpm; n, Shafts are perpendicular to each other .. £=90° (00 rpm Solution : Assume © Pressure angle = 20° full depth involute Gi Moderate medium shock and 8 to 10 hrs duty/day =. From Table 2.33 (Old DDHB); Table 23.13 (New DDHB) or Table 2.86, Service factor C,= 1.5 Gi) Pinion material as Alloy steel, case hardened (SAE 2320) «Table 23.18 (New DDHB),6,,=345 N/mm? (iv) Straight tooth bevel gears Select the minimum number of teeth on pinion to avoid interference for 20° full depth involute system, (Referring Table 2.92) z, = 15 £. Number of teeth on gearz, Gear ratio For right angle bevel gear i Pitch angle of pinion, -—-2.402(DDHB) Pitch angle of gear, 3 =71,565° 2.403 (DDHB) Formative number of teeth ina straight teeth bevel pinion | 15 = Se a | % = 958, 7 cos18435 7 5.8114 2.418 (DDHB) | Formative number of teeth in a straight teeth bevel gear t 45 ye —2.419(DDHB) | a ~ “cos8, — cos 71.56! Lewis form factor for 20° full depth involute system j Scanned with CamSeanner 345 } ue osi2 factor for piniony, = 0.154~ oe Form fat pi %, 158114 09632, 0912 rm factor for gear y, = 0,154- )154— =0.1476 Fo Bath 54- Too 3001 ‘Toselect gear material equate o,y, toa, y, ive, 345%009632 = 0,,0.1476; :. 0,,=225.138Nimm? From Table 23.18 (New DDHB), select the gear material such that its value of 6, must be nearer to 95.138Nimmt. Hence selectstel, SAE 1045, Hardened by WOT as gear material Oj) = 220 N/mm? enti the weaker member Particulars 7, : oy, Remarks Nim? Pinion 35 005632 IE Gear 2m 01496 L 32472 weaker AS Gq) < OY gear is the weaker member. Therefore design should be based on gear. (i) Design 5 9550x1000xPC, or —=2387b (New DDHB) (@) Tangantal tooth load F where rin mm 9550x1000NC, _ 9550x1000PC, * Tangetl oot lado he weaker member R= ae Pitch circle radius of gears, = X45 95m inant cok i pam ee ae 9550%1000x25x15 _ 3979L67N F = 2550%1000« 25x15 _ 3970167 ae iS 400% 225m (©) Tangential oth oud fom Lewis equation F,=0,C,bYm —~2426a(DDHB) Tangential oth ad ofthe weaker member F E Conedi n : E ne ditanceR =O oF a} ais 45" =23.717m _—2414(0DHB) EE Scanned with CamSeanner Ms Design of Machine, Elen, 346 ens For fi ‘dt E b _ ‘orface width | F i) Dimensioning From'Tuble2.1 (Old DDHB) Table 23,1 (New DDHB) foree=20° full depth Addendum by = Lm=1x3=3mm Dedendum 25 x3=3.75 mm Working depth Total depth, 25x3=6.75 mm Tooth thickness Minimum clearance Pitch circle diameter of pinion Pitch cirele diameter of gear Outside diameter of pinion Outside diameter of gear 6042x3=66mm, 29442x3=300mm b= 60-2%3.75 = 52.5 mm Dedendum circle diameter of pinion df= d,—2h,=294-2.x3.75=286.5 mm (Sass Seb tase Addendum angle 2xR75xsin1 1535 Dedendum angle ye om ( a ) an (eens) 1.432° Face angle of pinion 6, = §+0, Face angle of gear 8, Cutting angle of pinion ® 10.103 Cutting angle of gear 77.033° Scanned with CamSeanner Bevel And Worm Gears 353 eee ee eee Eee sien 9744.9 ‘Tangential tooth toad 7 38a Face width b 10m=10x3=30mm Cone distance R = 50m=50x3=150mm Mean pitch line velocity ¥,, = 4.618 mise Velocity factor ¢, = 07209 Service factor C= 135 () Cheeking (6) Dynamiclond ‘According to Buckingham equation, 2lva(F +bC) Y Dynamiclond = F355 9 FEC —2440a From Fig. 230 (Old DDHB) ; Fig.23.35a (New DDHB) forv, =4.168 msec Enorf = 007mm From Table 2.35 (Old DDHB); Table 23.32 (New DDHB) for 20° full depth, stel-steel combination Forerror f = 0.075 mm; C=870kNim=870N/mm Forérror f =/00Smm;C=S80kNim=580Nimm By interpolation 810 Nimm x 870-580 kk 007-005 = 0075=005 580Nimm x= 32Nmm = Seer Se 0.0Smm 0.07 0.075 mm Pehla! 21x4618[32483 + 30x812] ee =a eae 21x4.618+132483+30x812 on(") amen Fe) R-b Endurance strength ofthe weaker member pinion F,=0, by zm (2) From Table 23.33 (New DDHB) ; Table 239 (Old DDH for Surface hardness =320 BHN Endurancelimita, = 0,= 6 ,=551.8Nimm? 1) Endurancestrength 3 Endurance strength F. 150-30 = (551.8) (30) (0.1094) (3)| 55 — ] = 13654.67N ASF, =F, >F, the design is satisfactory from the stand point of strength. Scanned with CamSeanner 354 Design of Machine Elements «I ©) Wearstrength According to Buckingham's equation neglecting the deflection effect _ dibQk «= “cos6, 22, 2x490 ZZ 30442490 ForcarbonsteelfromTable 2.8 (Old DDHB - Vol-1) or Table 2.10 (New DDHB Vol-1) Young's modulus E, = E, 106 x 10° Nimm? F, d,bQK (60)(30X1.883)(K) in Gogb, 2 2LAB6S hey cgyigas) 2 13421436 -. K23.88 Nimm* i eee ig, Ase S0 5 3.59. ie, 0, 2127837Nimm*: eu.2.75H,—69 2 1278.37;H,2 4899 206% 10° :. For safer design the average surface hardness of the gear pair should not be less than 500 BH. + Surface hardness for pinion = 500 BHN; Surface hardness for gear= 500 BHN le 5.5 ne ir of straight bevel gears transmit 15kW at 1250 rpm of 120 mm diameter pinion. The speed reductions 35- Use 1477 hall depth tooth system. The pinion is made of alloy stee! of case hardened and (SAE 2320) gear is cast steel 0.20% C heat treated. Determine module, face width and number of teeth on pinion and gear. Suggest suitable hardness f the wear strength has to be more than the dynamic load. Data: rea P=N = 1SkW5n,=1250rpm;¢, = 120 um; i=3.5; a= 147" inion material - Alloy steel case hardened (SAE 2320) Gear material ~ Cast steel 0.20% C heat treated \ Solution : dh be | med o~ i z Scanned with CamSeanner er GRE =_ > OC gevel ‘And Worn Gears 355 I Speed of gear n, pitch circle diameter of gear d,.= id,=3.5%120=420mm ‘assume right angle bevel gear ie, 2=90" _f I «itch cone angle of pinion , = war(2) a (3)- 5945" ee | | ; | A 35, | pitch cone angle of gear 8, = tan-(i)=tan-!(35)=74,055" ae | From: Table 23.18 (New DDHB) | ‘Allowable static stress of pinion, =345 Nimm? ‘Allowable static stress of geara..= 173N/mn? } ‘oidentfy the weaker member mporaily assume, = 2 20 3.5x20=70 8, = cosisgas “O* ] I Formative number of teeth on pinion z, ne f % 10 Formative numberof eth on gear 1. S55 = Lewis form factor for 141° involutey =0.124~ 2684 __9.97 01d DDHB):23.115 (New DDHB) zy 0.684 0.684 tor of pinion y, =0.124——— = 0,124 = Form factorof pinion y, = mg TO = 254.79 | | | 0.684 Form factor of geary,=0.124— > — 124-2 0.1213 * @ Identify the weaker member | Pariculars | gfe y SY Remarks Pinion 35 00911 314295 (Gear 13 01213 | 209849 Weaker Since 6,,Y, < Gp, Bear is weaker. Therefore design should be based on gear ii) Design 9550X1000NCs _ 9550x1000PCs Or “| ar a) Tangential tooth load where rin mm 9550x1000NCs _9550x 1000PCs nh = th = Tangential tooth load of weaker member gear F, = ‘Assume moderate medium shock and 8-10 hrs duty per day ., FromTable2.33 (Old DDHB) ; Table 23.13 (New DDHB) or Table 2.86, service factor C= 1.5 Scanned with CamSeanner Serene Design of Mach Ino a 2 210mm K . 9550X 1000 15X15 865 N 3574x210 ©) Tangent — went fi Rob al oth Noa from Lewis equation reoe wn R } rey apy, For weak ae , ermember F, = 0,,C,by,m{ Fe Mean pitet Wine velocity of a y of weaker member v= Sony = ——@000 = 7-854 miseg Assume the tecthiare Renerated $55 555 5554 Wq 5.554+V7.854 ! fi20 +420" =218.4mm * Velocity factor ¢, .6645, Cone distance R For face width, £ wb Take face width b Lewis form factor y, ~0.1z4 Peo | . | .684 e088, x 68 | = orn 058400852 X _ 9 14 0.68400574.055%xm dy 420 | = 0.124-4474 x 104m | 2184-70 * 2865 = (173) (0.6645) 70) (n)(0.124—4.474 x 10+m)m| Sigg — ie, 0.1668 = 0.124m-4.474 x 10“m* ic.4.474 x 104m? 0,124 m+0.1688=0 ie, m?-~277.2m+37282=0 24 N21 F ~4%1x37282 | 4271: 2x1 = 27535 mmor1.35mm ‘Select the smaller value « From Table 2.3 (Old DDHB) ; Table 23.3 (New DDHB) select the standard module + Module m= 1.5 sum Scanned with CamSeanner oval And Woim Gears 357 $$ 6) Check for the stress Allowable stress (G1gC,)y # 173X0.6645 = 114,96? Fa Induced stess 0, = (0,C)),2 26a | bry | ‘ | a 2865 ey 2184-70 . (70)(n)(0.124 - 4.474 x 10 xsi 2184 ] | 108.64Nimm? Since (0,;C,)qu<(O,.C,)yp the design is satisfactory, i ‘Also in order to avoid the breakage of gear teeth due to bending, the beam strength should be more 1 than the effective force between the meshing tecth, t ie, F 2 Fy b mboyy,(-— F, i) | = (1.5)(10)(173)(n) (0.124 4.474 x104x 19 a) | = 478224N } FCs Fu, 2865 0.6645 } Since F, > Fj, the design is satisfactory from the stand point of beam strength. ++ Modulem = 15mm Face width b = 70mm Cone distance R = 2184mmn nce C, is already considered =4115N Number of teeth on gear 2, Checking \ According to Buckingham's equation 2lv,,(F, +bC) = Dynamic load F, = F+3iy 4 JR F6C j ._. FromFig 2.30 (Old DDHB) ; Fig. 23.35a (New DDHB), for v, =7.854 m/sec | ~*- Enorf=0.0461 mm Scanned with CamSeanner 358 Design of Machine Elements. ' From Tuble 2.35 (Old DDN): Forenorf=0.025 mm; Forerorf=0.05 min; By interpolation hible 23.32 (New DDHB) foro.= 144°, steel steel combination 279,48 Nim = 279.48 Nim 7 58.8 Nim =558.8 N/mm 558.8 Ning 279.48 Némm x 0.0461 - 0.025 5588-27948 ~~ 0,05-00025 5 paloNom, 0.025 0.0461 5279.48+235.146=515.226N 21x 7.854|28654+70% 515,226) 21% 7.854 4 J2865+70X51 According to Buckingham’s equation neglecting the effect of deflection 4,bQK Bear ila 0.05 ¢. Forerror {= 0.0961 mm; 8654+ = 20590,7N Wear load F, Ratio factor Q 99.84 2122309 * gpgasiaz300 7/8? Given F, > F, dbQK >F, ie , Me 058, 120x70%1849%K i cosis945 7 25907 Load stress factor K > 1.2747Nimm? | FromTable 2.40 (Old DDHB) ; Table 2337B (New DDHB) for o.= Hardness of pinion = 400BHN Hardness of gear = 300BHN A iple 5. A pair of bevel gear wheels with 20° pressure angle consist of 20 teeth pinion meshing with 30 teeth ‘gear. The module is 4mm while the face width is 20mm. The surface hardness of both pinion and gearis 40) BEIN. The pinion rotates at S00rpm and receives power from an electric motor. The starting torque ofthe motors 150 percent of the rated torque. Determine the safe power that can be transmitted considering the dynamic load, wear strength and endurance strength. The allowable bending stress may be taken 2 240MPa. ie., |4¥4° and load stress factor K = 1.2747 Nima? (NTU Feb. 2002) Seen ey Scanned with CamSeanner yoval And Worn Goats 359 rol Data: 4220? Assume fll depth); 7, =20; 2,305 m=4mmsb=20mm Surface hardness of phnlon and gear = 400 BIEN; n, = 500rpm; C, = 1.5; 0, =0,,=240MPa Solution * Velocity ratio = 500 speedo earn, = AE = 5 =333.33 rpm aft angle Y= 90° ‘Assume right angle bevel gear, For right angle bevel gear 1 Pitch cone angle of pinion 5, = (4) 333.69" —2.402 (DDHB) Pitch cone angle of gear 5, = tan-!(i)= tan-'(1,5)=56.31° —2403(DDHB) 4 Formative number of teeth on Pinion z,, = cos, cosaagp = 4% 4 0 “2” 60552 ~ cos5631 Formative numberof teeth on gear, =54.08 a912 Lewis form factor for 20° full depth, y=0.154— > —298 (Old DDHB) ; 23.116 (New DDHB) 0912 <- Form factor for pinion y, = 0.154-—— aL = 0154 22 0.11606 oe A984 0912 = 04st 2 ois7i4 5 5408 ‘As the same material is used for both pinion and gear, the pinion is weaker than the gear. Therefore ‘design should be based on pinion. Scanned with CamSeanner 2 Design of Machine Elements. Pitch circle diameter of pinion d= mz, =4x20=80mm Pitch citclediameterof geard, = mz,=4%30= 120mm. | 1 | Cone distance R => fd)? +43? = sean | Beam Strength | According to Lewis equation b Beam strength F, =mbo,Y (-3} b +. Beam strength of weaker member F,, = mba, (ry,) ( -3] 20 = seznx210(eo.1600 (1-2) =5058.96N Wear Strength dybQK According to Buckingham’s equation, Wear strength F, = “cos5, —2.441 a(DDkn) In the case of bevel gears, either the pinion or the gear is generally overhanging and hence itis subjected to deflection under the action of tooth forces. Considering this effect wear streng 0754,bQK | FL cos6, | ea a 2g _2x54.08 ae | \ atiofactorQ = zy 24045408 | f | bi Limiting stress for surface fatigues, = 0 , = (2.75 H, ~69) MPa—~ 2.291¢ (Old) ;23.168a (New DD | = (2.75 x400-69) = 1031 Nimm? ‘Assume the material for both pinion and gear are steel ‘Therefore from Table28 (Old DDHB-Vol. 1); Table 2.10 (New DDHB - Vol. 1), E, =E,: 2, : f E48, 7206x10Ni Equivalent Young's modulus B, = 4302, sino. ii + Load stress factor K Scanned with CamSeanner Bova, An Worm Gears Etfecy 175)0)(20) 138454) 25237) | | MTective weasrength F, = (cas{eofoon suseiese) at a 252 sassy } | Pynamictoad cei Srding o Prof MH, Spots Dynamic load F, = for steel pinion and gear Where © = Totalertor'? H 1, = Speed of pinion = 500mm 2, = Number of teeth on pinion= 24 'b’ = Axial width of gearblank b cos6, =20c08 33.69 1664immn = Pitch circle radius of pinion = 4, = Pitch crcl radius of gear= Mean pitch tne velocity ofthe weaker member ition ; dyn x 60x50 , vow eh 2 1:57081misec Q s 60,000 = 60,000 sume the gears are First class commercial gears ‘Therefore fromFig?.29 (Old DAB) ;Fig.23.34a (New DDHB)formodulem=4nm,enorf= 005mm (castsnensnn 253040" + 60" ++ Dynamic load F, = = 109.456N Endurance strength 1 1) Endurance strength of the weaker member F, = Z I From Table23.33, for BHN =400,0,,=0,= 689.6 N/mm? k ® + Endurance strength F,, = (6896) (20)(0.11606) (m«4) Safe power In order to avoid failure ofthe gear tooth due to bending F, =F, (FOS) where F,,=C,F,+F considering the factor of safety as unity F, =CF+F, B In order to avoid failure ofthe gear tooth due to pitting F, = Fy (FOS) considering FOS as unity F =CF+F, In order to avoid failure ofthe gear tooth due to fatique F,= F=CF+Fe = F,, (FOS). Considering FOS as unity ‘As wear strength is lower than beam strength and endurance strength, wear failure (due opthing) is the criterion of design. |, Scanned with CamSeanner R=CEe ie, NUS = LSE HOSS x ‘Tangential tooth aad of the weaker member E, = 3286.6N if SHOX 100 ‘ ay ato F, SHNIONP xed Sa SehpaecteNP SANTA GTR SD) ia, RRS = ‘Tease oral VAN HTMANT TART NY Che pinion hasa serge handnasof WN) BAN and the ger dace herdaa NBN, Tetadhyraektobeatbe ls E fulldepth involute snd mnie, ‘Sno. Mremnitecaitveadheamdhe gion S Nisin’ sho gear has gS tewwh, The face width b 40mm. Deze w ae wqarsmengihaTuhe gu, Wha waa be dhe newer Sat can be transmitted based on the she we crag Date pian saat SAU cm, YIU. Acres my Dens J = WS Seieedardoawaipinion= NOBRN ‘Suetardewatger = WANE gusting, =Nb RES Daas R= oe, Svhaim: Eecginnge ted son nich ome amg of pimion geen) ~ Fihomeangbefger & = an@=m0eLS=S8° Pachoiedamerrefgmand, = mz ={s= Dem 2 Fomatnemumicrofesthonginims, = <= =SS5s cee a ac eli Scanned with GamSeanner ' | pat tnd wor” Ges s | ‘Average value of BHN forthe gear pair = = 250 Seed Limiting stress for surface fatigue 6, =o,.= (275H,~69)MPa=275 x 250-69 = 618.5 Nimae Assume samme material (ste) is used for both pinion and gear. Therefore pinion is weaker than the gpa tense design shouldbe based on pinion, a ForsteelE, = E,=206x10'Ninn? = BE L206x10'N mam? E+E, = Leaxsiss' xsintst » Loadsmess fer K = <= —_ 7 uf R 205x105 = Q66SNe? _Acoonding to Buckingham equation neglecting overhanging and dafection effect |b cage Wearkeod F, = SE 2.481 a(DDHB) } + = “xsd | s INAV! _ GDIAESINES _oy es} x Naghoting oveshangingend defiscin eft. wear bead = SUR67N Tnonder toavedd fare ofthe gear tosh dost IAT 5 = E)RON=CEHEIRS Agvonding to Prof MH Sees, a Dyasibhatt, = Jeqq Gag beselpinionand sr Rolex? And widhof gurtimk =boosd = on &, = Finhcisieradiosofgear=' Assome the gears ae few clas commercial gees + Broa fig. 229 (OiDDSS): Fig 23.342 (New DDE) forme (ROS IREENISMISSSNANEANK) DSNer +95 Assmesnie fixer, = LSmi0Sasmnity - FE = CFE, ie SUBST = LSE+HTSt Tengeatial oad of the meats member F =22575N SLTSEN sE= Scanned with GamSeanner Design of Machine Elements. we 988X100 XN _ 95501000 P Also \ ah ah ae 9550 100% P tev aene 144060 < Powertransmitted 2376kW + If factor of safety is unity then the power transmitted based on wear strength P= N = 23,76 kW Example 5.8 A pair of mitre gears have pitch diameter 280 mm and face width of 36 mm and run at 250 rpm. Thy teeth are of 14¥5°involuteand accurately cut and transmit 6 kW. Neglecting friction angle find the fllovigg i) Outside diameter of gears ii) Resultant tooth load tangent to pitch cone Radial load on the pinion iv) Thruston thepinion VTU, July/Aug 2002 | Data: Mitre gear;d= 280mm; b=36mm;n=250rpm_ a = 14%; Precision cut; P=N=6 kW Solution » — 280 mm. a ) \,= 250 rpm Shaft angle 2 = 9° a Velocity ratioi = 1 | (D) Outside diameter of gears | Assume the material for both the gears ae low carbon cast stee! 0.2% C heat treated. From Tuble?318 (NewDDHB) Allowable static stress. 6, 73 MPa= 173 Nimm? ‘ | Lewis form factor for 14%°involute y =0.124- 28% | Lewis form factor forpiniony,=0.124~ 2-284 = 0,124 9684 xcos: A uy 0.684 x cos 45xm = 0,124 258400801 Xm 5 9194-9 ry 280 = 0,124-1.72736x 10°m=y, be ee ee a | Scanned with CamSeanner | _ gevol And Worn Geors - ee ee eerste eee eee Covedisunce R= 3 Jaf 4 fr <198mm — —2414(DDHB) Mean pitch line velocity y= Tit _ 280X250 _ = = 3.6652 misec Assume the teeth are generated ' s 555 + Velocity factor = a 955 ___ 9.74359 5554 Wvq "5354 (3680 Tangent tooth fat, = 2950 ICOOPCS rn mand assume service factor C=1S nF ++ Tangential tooth load on the pinion F, = 2550%!000%6%15 _ 9455 7143 280 2s0x{ 2 2 “Tangential tooth load from Lew Re genial tooth load fom LewisequaonF, =o YC For pinion F, open *) S20 : 198-36 i.e,,2455.7143=(173) (36) (m)(0.124~ 1.72736x 102m) corsa a 198 ) yy ie 0:20632 = 0.124m=1.72736x 10m? isc.,m?-71.8 m+ 119.442’ = 0. 4718+ 718? 4x 1x119.442 =70.) mmor 1.7mm 2xt ams Selecting the smaller value, module m= 1.7 mm FromTable2.3 (Old DDHB) ; Table 23.3 (New DDHB) select the standard module :- Modulem = 2mm Check for the stress Allowable stress 04, = (0,,C,)4 =(173)(0.74352)= 128.63 N/mm? Induced tess Oy, = (06C)yy=$—— gp 14260 (DDHB) bay &* 245571143, 36 36x mx (0.124— 1.72736 x10 x 2)(2)| 110.08 N/mm? Since (0,C Jy < (GC), ithe design is satisfactory. ‘Also in order to,avoid the breakage of gear teeth due to bending, the beam strength should be more than the effective force betwéen the meshing teth ie, F, > F,, ~ Scanned with CamSeanner samc ii lace eet perenne et 7 ) (173) (a) 0.124 = 1.72736 ¢ 1ox2,(1.36 i) " Bffectiveloadorforce Fy = ASF, >F,p the design is satisfactory from the stand point of beam strength. “Module m = 2mm. Face width b = 36mm Cone distance R = 198mm Number of teeth on pinion z, = == =140 Number of teeth on gear, =140 From Table 2.1 (Old DDHB); Table 23.1 (New DDHB) Addendum h, = Im=1x +. Outside diameter of pinion da, =d, +2ha=280+2x2=284mm Outside diameterof gear da, = 284mm fi) Resultant tooth load tangent to pitch cone Mean radius of pinion r, 2 127.272mm sh] [= 36sin45 a 2 r ache |— Pinion Fig. 1 60x108 xPC Torque on the pinion shaft M, = 7 Ml nn [Considering the service factor] ee) Scanned with CamSeanner povel And Wom Gears 367 x196,, = 6x15 nap 137468Nmm My 4377468 fy ay =270LIN + Tangential force at the mean radius tit) Radial load on the pinion Rep iv) Thustloadonthepinion "~ “''""6s5,=2701.1xtan 14% cos 45 2499 95N F,hasng,=2701.1xton Maxsind5 =493.95N NOTE: According to Prof. MLE Spots Introducing factorof safety where F, f Beam strength = mbo,Y ( BC, Fo = Effective load = —(i) B= Allowable tending srse(= of the weaker member = Face width Cone distance module b R m C, = Velocity factor ©, = Service factor 6, = Ultimate stiength; Y=ny FOS = factor ofsafety; y= Re 9550x 1000N : or 1 = Pitchcireleradius of weaker member in mm n= Speed ofthe weaker member in rpm ‘The module obtained from equation (i is based on beam strength Considering dynamic load according to spots Lewis form factor of the weaker member Fu = CR+R, —iii) eny2i8 ty 2530\r? +13 where = Dynamic load = for stee! pinion and steel gear ¢ = lotalerror({) axial width of gear blank = b cos6, Scanned with CamSeanner Sa ee 1 368 Dosign of Machine Elornonts,y nr Considering the dynamic load to avoid fallure ofthe gear tooth due to bending, F&F, (FOS) = (CEFF) FOS) vmllyy bk Wes cob, load FL = Considering the effect of overhanging and deflection, effective we To avoid failure of gear tooth duc to pitting, FL = F,(FOS) (CF + F,)FOS) 0 kK ‘The gear can also be designed using Prof. MF Spotts equations. Also according to American Gear Manufactures Association (AGMA) for straight tooth bevel gears, mo,nd,byn(R-05b\[__ 555 i) Peakload powerrating N= eo R [etre] owable stress ofthe weaker member in Nimm? orm factor of the weaker member m = moduleinmm 1, = speed of pinion 4, = pitch circle diameter of pinion in mm face widthin mm R = Conedistance inmm ‘mean pitch ine velocity in misec. N = powerinkW Merial factor from table 2.90 ox Based on wear or durbilltyN = 235K Cb puss whereC, = 10/4, «| 555 7 ies re 6,.,arcin meter #, = 5 (Speedin ps) v_ in m/sec; b = face widthin meters Scanned with CamSeanner z ‘ and worn Goals ump ha Design orte power N, = No where: + ® Service fctor fom K = M, N —2A5I table 2.46 lateral Factor from table 2,4) & Rated power inkW H 5 WORM GEAR Worm gears are similar to crossed heliegy Bears. Wis shown in Fig, 5.12 i in Fig. 5. i Fig, 5.12 | The pinion or worm has a smaller numberof teth usually one to four, and since they completely ‘wrap around Wie pit ie pitch cylinder they are called threads/ ts mating gear is called a worm gear, which js nota true helical gear. ie, [A worm and worm gear are used to provide a high angular velocity reduction between non- | intersecting shafts which are usually at right angles,"The worm gear is not a helical gear because its } face is made concave to fit the curvature of the worm in order to provide line contact instead of point contact. Because of the line contact, worm gearing can transmit high tooth loads. The _ disadvantage of worm gearing isthe high sliding velocities across the teeth. Scanned with CamSeanner

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