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Chapter 18

The document outlines the design sequence for power transmission systems, emphasizing the interdependence of components such as gears, shafts, and bearings. It details the iterative design process, starting from power and torque requirements to final analysis, and includes a case study to illustrate the application of these principles. Key considerations include gear specifications, shaft layout, material selection, and stress analysis to ensure efficient power transmission.

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2 views35 pages

Chapter 18

The document outlines the design sequence for power transmission systems, emphasizing the interdependence of components such as gears, shafts, and bearings. It details the iterative design process, starting from power and torque requirements to final analysis, and includes a case study to illustrate the application of these principles. Key considerations include gear specifications, shaft layout, material selection, and stress analysis to ensure efficient power transmission.

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2015me193
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF or read online on Scribd
Power Transmission Case Study « a ‘hanojphotography/123RF Chapter Outline 18-1 Design Sequence for Power Transmission 937 18:2 Power and Torque Requirements 938 Gear Specification 938 Shaft Layout 945, REE Force Analysis 947 le Shaft Material Selection 947 IS Shaft Design for Stress 948 E | Shaft Design for Deflection 948 Bearing Selection 949 18-10 Key and Retaining Ring Selection 950 18-11 Final Analysis 953 Transmission of power from a source, such as an engine or motor, through a Page 936_ machine to an output actuation is one of the most common machine tasks. An efficient means of transmitting power is through rotary motion of a shaft that is supported by bearings. Gears, belt pulleys, or chain sprockets may be incorporated to provide for torque and speed changes between shafts, Most shafts are cylindrical (solid or hollow), and include stepped diameters with shoulders to accommodate the positioning and support of bearings, gears, etc. The design of a system to transmit power requires attention to the design and selection of individual components (gears, bearings, shafts, etc.). However, as is often the case in design, these components are not independent. For example, in order to design the shafts for stress and deflection, it is necessary to know the applied forces. If the forces are transmitted through gears, it is necessary to know the gear specifications in order to determine the forces that will be transmitted to the shafts. But stock gears come with certain bore sizes, requiring knowledge of the necessary shaft diameters. It is no surprise that the design process is interdependent and iterative, but where should a designer start? ‘The nature of machine design textbooks is to focus on each component separately. This chapter will focus on an overview of a power transmission system design, demonstrating how to incorporate the details of each component into an overall design process. A typical two- stage gear reduction such as shown in Figure 181 will be assumed for this discussion. The design sequence is similar for variations of this particular transmission system. ‘The following outline will help clarify a logical design sequence. Discus: each part of the outline affects the overall design process will be given in sequence in this in of how. chapter. Details on the specifics for designing and selecting major components are covered in separate chapters, particularly Chapter 7 on shaft design, Chapter 11 on bearing selection, and Chapters 13 and 14 on gear specification. A complete case study is presented as a specific vehicle to demonstrate the process. Figure 18-1 ‘A-compoune reverted gear tran. Page 937 CASE STUDY EXAMPLE 18-1, PART 1 PROBLEM SPE CITICA TION necessary, A subse of the pertinent dosan are given here. | Poet be delered, 20-bp = oa ay compan rtered gotta suck a shown Figur 0 wil bo degned. ts chp, edn of the inlermediate shaft and te components is presente taking inio account the olher shatls as, ree the dog lal cach 1750 rym Outpt speed: 82-88 revi Usually low shock lavls, occa | —$ 12 00 ould. geal [Link] dat. 14 x 14- base, 22-4 height boars nfite shaft lie 18-1 Design Sequence for Power Transmission There is not a precise sequence of steps for any design process. By nature, design is an iterative process in which it is necessary to make some tentative choices, and to build a skeleton of a design, and to determine which parts of the design are critical. However, much time can be saved by understanding the dependencies between the parts of the problem, allowing the designer to know what parts will be affected by any given change. In this section, only an outline is presented, with a short explanation of each step. Further details will be discussed in the following sections. + Power and torque requirements. Power considerations should be addressed first, as this, will determine the overall sizing needs for the entire system. Any necessary speed ot torque ratio from input to output must be determined before addressing gear/pulley sizing + Gear specification. Necessary gear ratios and torque transmission issues can now be addressed with selection of appropriate gears. Note that a full force analysis of the shafts is not yet needed, as only the transmitted loads are required to specify the gears. + Shaft layout. The general layout of the shafts, including axial location of gears and bearings, must now be specified. Decisions on how to transmit the torque from the gears to each shaft need to be made (keys, splines, etc.), as well as how to hold gears and bearings in place (retaining rings, press fits, nuts, etc.). However, it is not necessary at this point to size these elements, since their standard sizes allow estimation of stress- concentration factors. + Force analysis. Once the gear/pulley diameters are known, and the axial locations of the gears and bearings are known, the free-body, shear force, and bending moment diagrams for the shafts can be produced, Forces at the bearings can be determined. + Shaft material selection. Since fatigue design depends so heavily on the material choice, it is usually easier to make a reasonable material selection first, then check for satisfactory results + Shaft design for stress (fatigue and static). At this point, a stress design of each shaft should look very similar to a typical design problem from the shaft chapter (Chapter 7). Shear force and bending moment diagrams are known, critical locations can be predicted, approximate stress concentrations can be used, and estimates for shaft diameters can be determined. Page 938 + Shaft design for deflection, Since deflection analysis is dependent on the entire shaft geometry, it is saved until this point. With all shaft geometry now estimated, the critical deflections at the bearing and gear locations can be checked by analysis. Bearing selection. Specific bearings from a catalog may now be chosen to match the estimated shaft diameters. The diameters can be adjusted slightly as necessary to match the catalog specifications. Key and retaining ring selection. With shaft diameters settling in to stable values, appropriate keys and retaining rings can be specified in standard sizes. This should make little change in the overall design if reasonable stress-concentration factors were assumed in previous steps. Final analysis. Once everything has been specified, iterated, and adjusted as neces sary for any specific part of the task, a complete analysis from start to finish will provide a final check and specific safety factors for the actual system. 18-2 Power and Torque Requirements Power transmission systems will typically be specified by a power capacity, for example, a 40-horsepower gearbox. This rating specifies the combination of torque and speed that the unit can endure. Remember that, in the ideal case, power in equals power out, so that we can refer to the power being the same throughout the system. In reality, there are small losses due to factors like friction in the bearings and gears. In many transmission systems, the losses in the rolling bearings will be negligible. Gears have a reasonably high efficiency, with about 1 to 2 percent power loss in a pair of meshed gears. Thus, in the double-reduction gearbox in Figure 18-1, with two pairs of meshed gears the output power is likely to be about 2 to 4 nce this is a small loss, it is common to speak of simply percent less than the input power. S the power of the system, rather than input power and output power. Flat belts and timing belts have efficiencies typically in the mid to upper 90 percent range. V belts and worm gears have efficiencies that may dip much lower, requiring a distinction between the necessary input power to obtain a desired output power. Torque, on the other hand, is typically not constant throughout a transmission system, Remember that power equals the product of torque and speed. Since power in = power out, we know that for a gear train H=T,w, = T,w, (18-1) ‘With a constant power, a gear ratio to decrease the angular velocity will simultaneously increase torque. The gear ratio, or train value, for the gear train is e=0,/w; = T/T, a8-2) A typical power transmission design problem will specify the desired power capacity, along with either the input and output angular velocities, or the input and output torques. There will usually be a tolerance specified for the output values. After the specific gears are specified, the actual output values can be determined, 18-3 Gear Specification With the gear train value known, the next step is to determine appropriate gears. As a rough guideline, a train value of up to 10 to 1 can be obtained with one pair of gears. Greater ratios can be obtained by compounding additional pairs of gears (see Section 13-13). The compound reverted gear train in Figure 18-1 can obtain a train value of up to 100 to 1. Since numbers of teeth on gears must be integers, it is best to design with teeth Page 939 numbers rather than diameters. See Examples 13-3, 13-4, and 13-5 for details on designing appropriate numbers of teeth to satisfy the gear train value and any necessary geometry condition, such as in-line condition of input and output shaft. Care should be taken at this point to find the best combination of teeth numbers to minimize the overall package size. If the train value only needs to be approximate, use this flexibility to try different options of tooth numbers to minimize the package size. A difference of one tooth on the smallest gear can result in a significant increase in size of the overall package. If designing for large production quantities, gears can be purchased in large enough quantities that it is not necessary to worry about preferred sizes. For small lot production, consideration should be given to the trade-offs between smaller gearbox size and extra cost for odd gear sizes that are difficult to purchase off the shelf. If stock gears are to be used, their availability in prescribed numbers of teeth with anticipated diametral pitch should be checked at this time. If necessary, iterate the design for numbers of teeth that are available. Page 940, CASE STUDY EXAMPLE 18-1, PART 2 SPEED, a mi Jee toan ouput speed S2revimin < o, < 88 rev/min Dohler: ‘and ouput sats ‘or the input, intermediate ‘shafts, o transit 20 eee ATION r pot jh coun hae eres | the range ues of Bee eee oy 8s * a” 1750 ~/2059 fanapon et |For a compound reverted gear train, Py Ce 1M = -Equatibr(13-30}-] 3059 Ns Ns For smallest package size, Identical, the inline condi let both slages be the same reduction. Ale, by making the two slages on the pat MM Ns Ns caipl shaft wll auiomatically be sal eget > \ns0 7 454 (13-10) For ths rata, assuming a babe angle i = 20°, the minimum number of tet fom Equation 2) 458 + VES a 6 teeth + 24 S4)}si? 20" Na=Ny= 16 eth Ny 4 54(N 2) = 7264 “Thy roading down and chat sie a o- Gla) | Proesed wi | )) = 8642 revimin _Acgeptable ra) a) aca) aia) 270 Ibe ft 1215 ht fe If a maximum size for the gearbox has been specified in the problem specification, a minimum diametral pitch (maximum tooth size) can be estimated at this point by writing an expression for the gearbox size in terms of gear diameters, and converting to numbers of teeth through the diametral pitch. For example, from Figure 18-1, the overall height of the gearbox is Y =d;+d,/2 + ds/2 + 2/P + clearances + wall thicknesses where the 2/P term accounts for the addendum height of the teeth on gears 3 and 5 that extend beyond the pitch diameters. Substituting d; = NyP gives Y =N3/P + No/(2P) + Ns/(2P) + 2/P + clearances + wall thicknesses Solving this for P, we find Page 941 P= (Ny + N>/2 + Ns/2 + 2)/(¥ — clearances — wall thicknesses) 18-3) This is the minimum value that can be used for diametral pitch, and therefore the! ) maximum tooth size, to stay within the overall gearbox constraint. It should be rounded up to the next standard diametral pitch, which reduces the maximum tooth size. The AGMA approach, as described in Chapter 14, for both bending and contact stress should be applied next to determine suitable gear parameters. The primary design parameters to be specified by the designer include material, diametral pitch, and face width, A recommended procedure is to start with an estimated diametral pitch. This allows determination of gear diameters (d = NP), pitch-line velocities [Equation (13-34)], and transmitted loads [Equation (13-35) or (13-36)]. Typical spur gears are available with face widths from 3 to 5 times the circular pitch p. Using an average of 4, a first estimate can be made for face width F = 4p = 4m/P. Alternatively, the designer can simply perform a quick search of online gear catalogs to find available face widths for the diametral pitch and number of teeth, Next, the AGMA equations in Chapter 14 can be used to determine appropriate material choices to provide desired safety factors. It is generally most efficient to attempt to analyze the most critical gear first, as it will determine the limiting values of diametral pitch and material strength. Usually, the critical gear will be the smaller gear, on the high-torque (low- speed) end of the gearbox. If the required material strengths are too high, such that they are either too expensive or not available, iteration with a smaller diametral pitch (larger tooth) will help. Of course, this will increase the overall gearbox size. Often the excessive stress will be in one of the small gears, Rather than increase the tooth size for all gears, it is sometimes better to reconsider the design of tooth counts, shifting more of the gear ratio to the pair of gears with less stress, and less ratio to the pair of gears with the excessive stress, This will allow the offending gear to have more teeth and therefore larger diameter, decreasing its stress. If contact stress turns out to be more limiting than bending stress, consider gear materials that have been heat treated or case hardened to increase the surface strength. Adjustments can be made to the diametral pitch if necessary to achieve a good balance of size, material, and cost. If the stresses are all much lower than the material strengths, a larger diametral pitch is in order, which will reduce the size of the gears and the gearbox. Everything up to this point should be iterated until acceptable results are obtained, as this portion of the design process can usually be accomplished independently from the next stages of the process. The designer should be satisfied with the gear selection before proceeding to the shaft. Selection of specific gears from catalogs at this point will be helpful in later stages, particularly in knowing overall width, bore size, recommended shoulder support, and maximum fillet radius. Page 942 CASE STUDY EXAMPLE 18-1, PART 3 GEAR SRE CInIC ATION. Continue te case sadly ly spectyng appropraie Topend prick dameter, demetal pick, ‘face width, and material. Ac ce tl 2 dn Solution _| ~Eelimate the mixnnum diamelal plc for eral gerbe. height = 22. From Equalion (18-3) and Figure 18-1, Allow 1.5 i for clearonces and wall thickness, | (2+8+F+2) | ae 15) ey = 267 in 05 = 864 rev/min AQETVATSOY 93 ie é p13 min ‘Equation (13-24) 2115 f/min wh ome = ane) smo ean 2-25) | 3 Sect ms wy =o -s90m0(,2,) 20 i Vas, ans) ‘Start with gear 4, sine i 6 the smallest gear, the longest laa. it wl likely be erica. Start with wear by conlact trees, since 1 Ie offen the limiting factor. Gear U Wear ett (8) et aaa For K,, assume Q, = 7.8 = 0731,A= 651 soba k= (SEY as -Equatfon (14-27) ‘Face width F is typically from 3 to 5 times circular pitcke Try | ] a | reaff)as)a300 | Sine gear specications are ready avaiable on the In well hoc. fr commonly availble face widlhs. On wes [Link], entering P = 6 leeth/in d= 2.67 in sock spur gears Grom several cues ave Tae wid of TS in of 2.0 iT moshing gear 5 with d= 12m. I Choose F = ‘ae alco awille for the L= 215 600 psi From Table, 14-6 this

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