Академический Документы
Профессиональный Документы
Культура Документы
By:
y Prof. R. Maiti,MED, IIT Kgp.
gp
1
Involute Toothed Gear : Fundamental Relations :
rb rp cos
2
Involute Toothed Gear : Fundamental Relations (Contd.):
Referring to straight tooth spur Gear:
Tip or Addendum circle Tooth thickness (t t ) and space (t )
radius s
Z
ra a f m at standard pitch circle of
2
uncorrected (standard) gear
( - for internal toothed
gear)
ts
tt they are equal (arc).
Root or Dedendum circle radius
Z
tt ts
rd d f m
2
= pc / 2 = m / 2
2a f
Zc
sin 2
4
Strength of gear teeth-Lewis equation (Contd.) : Straight tooth spur gear
My M(t / 2)
= =
I (bt 3 ) / 12
Line of Action Fn 6M 6F h
Pressure Line = 2 = t2
bt bt
Pitch Point
Ft Where, b is the width of gear.
P
pc
t2
h = y(mn ) = Ymn
6h
t
Weakest Section y is called the Lewis form factor
Y = 0.484 - 3.28 / Z
Z = Z / cos 3 () Formative number of teeth.
Is the helix angle, which is zero in case of straight tooth spur gear.
5
Strength of gear teeth-Lewis equation (Contd.) : Straight tooth spur gear
Rearranging:
Velocity Factor cv is expressed as:
Ft = bYmn 3
cv Milled Gear
Introducing Allowable Strength So 3V
and velocity factor ( c
v ),
) the
cv
4 .5 A
Accurately
t l cutt Gear
G
maximum tangential load: 4 .5 V
6
Ft = So cv bYmn cv
6 V
More Accurately cut Gear
3 .5
cv Fine Finished Gear
Now Ft can expressed in terms of 3 .5 V
transmitted Torque T , as: Hardened & Ground
5 .5
Ft =
2T
=
2T cv Gear
dp Zmn 5 .5 V
Z
Z
cos 3
7
Design of Helical Gear (Contd) :
Z p pc Z p p cn Z g pc Z g pcn
Dp = = Dg = =
cos cos
Z p mn
= Z g mn
cos =
cos
A ( D p Dg ) / 2 A
mn
Z p Z g
2 cos
8
A Typical Gear Box Design Problem
9
Preliminary Layout of Gear Box :
Step-1
Selection of stages, Gear Ratios
& Teeth numbers.
Step-4
Rough shape to the shafts are given.
Step-6 After putting the bearings in layout load calculations become possible.
Step-7 Lives of all bearings are estimated.
Step-8
If estimated lives are not satisfactory then a new set of bearings are chosen.
If necessary shaft(s) dimensions are also altered and lives are re
re-estimated.
estimated.
Further, gear design may need to be altered.
10
Preliminary Layout of Gear Box (Contd.): Recapitulation
Step-1 Knowing the direction of Input & Output Selection of ratios, type of
Gears & teeth numbers.
Rules and Limitations: Stage ratio not more than 6.
Number of teeth, Zcr-min 2/sin2 (Pressure Angle).
Note: Normally helical gears are chosen rather than straight tooth spur gears.
' 3
Therefore,, we consider formative number of teeth: Z = Z / cos
F which
For hi h considering
id i Z' = 1
17 , Z may b
be taken
t k as 16 to
t 14 respectively.
ti l
In choosing the numbers of teeth and stage ratios, not only the size
optimization is considered but also the roundness in centre distances with
uncorrected gears is taken care* of:
11
A Typical Helical Gear Box Design Problem
1st. Stage:
Z 2 81
i1 4.76
Z 1 17
2nd. Stage:
Z 4 131
i2 8.19
Z 3 16
Therefore, total ratio becomes:
ii1
ii2
Z2 Z4 81 131
it
Z1 Z3 17 16
3
9
.
0
1
4.768.19
Assembled plan view is of 2-stage
2 stage gear box
box.
This is acceptable.
12
A Typical Helical Gear Box Design Problem
2nd. Step. In next step gears are designed:
1st. Stage
2Tcos
Module Estimation on Strength Basis: mn = 3
So cvYZ
Power
Input Torque (Nominal): Ti
2 i
In this problem input continuous torque = 30 Nm. i.e. Ti 30 Nm
As starting torque is 200% we may take the design torque as: Tid 2 Ti 60 Nm
Suggested Materials for Pinion , Gear & Shaft
Pinion Gear Shaft
EN 19A EN 18A EN 8
2Tcos 2 60 0.978
mn = 3 = 3
6
= 1.85 10 -3 m
So cv
YZ ((240
40 10
0 ) 0.75 200 0.303 177
16
Gear Data
First Stage Second Stage
Sl. No. Description
Pinion Gear Pinion Gear
RH LH LH RH
5
5. Addendum Height (mm) f a mn = 1.0 mn 30
3.0 40
4.0
Layout of pinion and gears is made in next step. Shafts are automatically shaped.
Taper
p Roller Bearingg to be used in p
pair.
Other Bearings- may be used in pair
or in combination.
Choice depends
p on type
yp of loading
g mainly.
y
Roller Bearings:
Considering
C id i
bearing widths,
15 to 25 mm 15 to 25 mm
((Typical)
yp ) 10 to 15 mm (Typical) (Typical)
53 50
finally distances
are marked.
marked
1 8
178
Layout of Intermediate Shaft (Referring to Design Problem) 19
4th. Step. Loads on Gear, Pinion Teeth and on Bearings. Recapitulation
2T
Tangential Load: Ft
dp
Z mn
Where, d
p
cos
Normal Load: F
Ft
cos
tn
Ftn
Fn Ft sec .sec n
cos n
Radial Load:
Fr = Fn .sinn
= Ft sec.secn .sinn
Fr Ft sec .tan n
( Ft tan )
Axial Load:
Fa Fn sin Ft tan 20
4th. Step (Contd): Calculation of Loads and Reactions on Shaft & Bearing
For Intermediate Shaft (Referring to Design Problem)
Torque (T n 2) Flow Path
Nominal Torque = Input Torque x Ratio
Z2 (81)
pcd 248 mm Z2
Tn 2 Tn1 31 4.76 148 Nm
Z1
Ft2 = 2 Tn2 / 0.248 N = 1193.5 N
Z3 (16)
pcd 65.3 mm
Fr
=1683 N
3
3
= 4533 N
Fa
21
4th. Step (Contd): Calculation of Loads and Reactions on Shaft & Bearing
For Intermediate Shaft (Referring to Design Problem)
o que (T n 2) Flow
Torque o Path
at Loads and reactions are calculated on the
Z 2 (81) basis of Nominal Torque & approximate
pcd 248 mm
bearing width = 25 mm.
L R
Bending
g Moment due to Axial Load:
d p2 240.65 0.2479
Z 3 (16)
pcd 65.3 mm
M a 2 Fa 2 30 Nm
2 2
53 50
d p3 914 00.0653
0653
178 M a 3 Fa 3 30 Nm
2 2
Intermediate Shaft with gears and Bearings
For moment equilibrium (horizontal plane) about R
RVL Fr 3 RVR 1683 0.125 443 0.05
Fa 3 Fa 2 RHL
30
30
0.178 0.178 0.178 0.178
=
7
2
0
.
6
N
RHL RHR
Ft 3 Ft 2 Fr 2 1182 124.4 168.5 168.5
From force equilibrium- RHR = 520 N
M a3 M a2 Similarly computing for vertical plane:
Ft
Fa Fa
Fr F
3
= 914 N
3
=1683 N
3
= 4533 N
RVL = 3518.5 N RVR =2208 N
Ft
2
= 240.65 N
2r
= 1193.5 N =443 N
Applied Loads, Reactions & Moments due to Axial Loads 22
5th. Step:
Bearing Selection
Life Estimation of Rolling Element Bearing
P C1 XVFr YFa
Where,
C1 A factor on nature of shock load
V Outer race rotation factor (1 for fixed & 1.2 for
rotating) Fr
Fa Net radial load acting on bearing
X Net axial load acting on bearing
Y Radial Load Factor (From Catalogue)
Axial Load Factor ,, ,,
23
5th. Step:
Bearing Selection
Equivalent Load Acting on bearing
Recommended X & Y Factors P C1 XVFr YFa
24
5th. Step:
Bearing Selection
Equivalent Load Acting on bearing
Recommended X & Y Factors Contd. P C1 XVFr YFa
25
5th. Step: Bearing Life Estimation
For Intermediate Shaft (Referring to Design Problem)
Equivalent Load Acting on bearing is
q (T n 2) Flow Path
Torque expressed as: P C XVF YF 1 r a
Z2 (81)
pcd 248 mm Life of Rolling Element bearing in
Number of Revolution is expressed as:
L R
C
L N 10 6 Revolution
Z 3 (16)
P
pcd 65.3 mm Life in hours is then estimated as:
LN
53 50 L H Hours
N 60
178 Loads from Gear teeth were estimated as:
Ft Ft
Fa F a
Fr
3
= 914 N
3
=1683
683 N
3
= 4533 N
Fr
Intermediate Shaft with gears and Bearings (Plan View) 2
= 240.65 N
2
=443 N
2
= 1193.5 N
RVL
Fr 3
RVR
3
0
N
m
Fa 3 Fa 2 Also, moments due to axial forces were
estimated as: Ma2 Ma3
RHL RHR
Ft 3 Ft 2 Fr 2 Finally Bearing reactions (radial) were estimated as:
RHL = 720.6 N RVL = 3518.5 N
M a3 M a2 RHR = 520 N RVR =2208 N
Applied Loads, Reactions &
Moments due to Axial Loads Bearing reactions (axial) yet to be estimated. 26
5th. Step (Contd): Bearing Life Estimation
The Final bearing reactions:
Radial reactions are From details of loading resultant right
not in same plane.
b
bearing
i (radial)
( di l) reaction
ti is
i calculated
l l t d as:
Fr R RVR
2 2
+ RHR = 2208 2 + 520 2
Fa Net 2268.4 N
It is acting at an angle R with vertical plane,
Fr L
1
3
.
2
5
Fr R
o
53 50
derived as R tan
1
R HR RVR .
Bearing Reactions (& Locking)
Fr Similarly, F RVL
2
RHL
2
3518.52 720.62
R rL
Fr L
o
1
1
.
5
7
3591.5 N
o
11
11
5.
7
RVL Fr 3 o
o
1
3
2
5
1
3
.
2
5
L tan 1 RHL RVL
5
7
Fa 3 Fa 2 RVR and,
Fa Fa
Fr F
3
= 914 N
3
=1683 N
3
= 4533 N
It depends on bearing locking arrangement.
Ft
2
= 240.65 N
2 r
= 1193.5 N =443 N
In this case it is on right bearing which is
RHL = 720.6 N RVL = 3518.5 N with less radial load.
load
Net axial load Fa Net Fa Fa 3 Fa 2
RHR = 520 N RVR =2208 N
6
7
3
.
3
5
N
Details of loading & Resultant bearing Reactions. 27
5th. Step (Contd): Bearing Life Estimation
Consider deep groove
ball bearing
g SKF 6309
as both end supports
of intermediate shaft:
d=55.3 mm
Equivalent load on
left bearing:
6
7
8
N
=
6
7
3
.
3
5
N
PL C1 XVFr ( L ) YFa ( L )
FaFa
X
=
1
&
Y
=
1
.
6
3
6
2
0
N
2
2
5
5
7
5
N
5
.
7
Fr L 53
5
3
8
7
.
2
5
N
3591 5 N
3591.5 FFrrRR 50
2268 4 N
2268.4
Inner Outer Width Corner Basic Load Capacity [Note: C 1 is taken as
Dia. Dia. (B) Radius (r)
Dynamic Static 1.5 considering medium
Bearing
ea g (d) ((D)) Approx.
No.
C Co shock load (given) on
mm mm mm mm Newton Newton the estimated load on
6309 45 100 25 2.5 40130 29200 bearings based on
nominal torque.]
Life (in hrs) of left bearing:
L
L N (L)
(40130 / 5387.5) 3 10 6
H
L
N 60 (1500 17 / 81) 60
6
0
.
0
2
1
8
8
0
1
0
h
r
s
=
2
1
,
8
8
0
h
r
s
28
5th. Step (Contd): Bearing Life Estimation
Ball bearing SKF 6309 is selected for both end supports of intermediate shaft:
Similarly,y, estimated equivalent
q load and
life of right bearing:
5
0
1
8
.
6
4
N
,
PR 1.5 (1.0 1 2268.4 1.6 673.35)
L
(40130 / 5018.64) 3 10 6
HH
RR
(1500 17 / 81) 60
6
=
6
7
3
.
3
5
N
6
7
8
N
0
.
0
2
7
0
6
7
1
0
h
r
s
=
2
7
,
0
6
7
h
r
s
FaFa
Note: Estimated lives of both bearings are
3
6
2
0
N
3
6
2
0
N
2
2
5
5
.
7
5
N
Fr L 53
3591.5 N FFr rR R 50
2268.4 N more or less
l same & above
b the
h
L
2
7
,
0
6
7
h
r
s
.
L
2
1
,
8
8
0
h
r
s
.
If SKF 6308 or 6211 is selected then life will be reduced by (C6309/C6308 or 6211)3 i.e.,
2.17 or 1.95 times respectively, which is acceptable.
29
However, design with SKF 6309 will perhaps be preferred.
6th. Step Shaft Design Bending moment on Intermediate Shaft due to Tangential Forces
(Vertical Plane)
In case of gear box the diameters of a shaft is
dominated by the size (root diameter) of the
integral pinion and optimum bearing size mainly. L R
The length is determined by the placement of
gear, pinion, bearings, coupling, key size,
seals
l etc. andd the
h optimum
i gap required
i d
53 mm 75 mm 50 mm
between two consecutive elements.
Layout
The a shaft is automatically shaped RVL = 3518.5 N
during first layout and bearing RVR =2208
2208 N
selection, as shown earlier.
Ft
Therefore, instead of designing the
2
= 1193.5 N
Ft
shaft the critical sections are verified
3
= 4533 N
for developed stresses. Load Diagram.
1014.5 N
Bending
e d g Moment
o e t ((respective
espect e plane)
p a e) Calculation
Ca cu at o =2208 N
=3518.5 N
B
M
1
8
6
.
5
N
m
3518.5 0.053
P
3
V
1
1
0
.
4
N
m
-
1
1
0
.
4
N
m
G
2
V
-
1
8
6
.
5
N
m
Bending Moment Diagram (BMD).30
Shaft Design (Contd) Bending moment on Intermediate Shaft due to Tangential Forces
(Horizontal Plane)
Bending Moment (respective
plane) Calculation (Contd)
(Contd )
M =
a3
2
Moment just left of section 3-3:
0
N
m
M =
B
M
3
8
.
2
N
m
a3
3
P
3
H
-
720 0.053
0
N
m
53 mm 75 mm 50 mm
=
6
8
.
2
N
m
Fr
P
3
H
++
=1683 N
3
P
3
H
Fr
2
=443 N
B
M
-
4
N
m
RHL = 720 N RHR= 520 N
G
2
H
-
= 720 N
And BM just right of section 2-2: 520 N
943 N
B
M
2
6
N
m
443 N
G
2
H
+
6
8
.
2
N
m
2
6
N
m
3-3 2 -2
Bending Moment Diagram (BMD).
31
6th. Step (Contd.) Shaft Design
Second Step: Resultant Bending
Moment and Critical Section
It is to be noted that in a rotating shaft outer layer L R
experiences maximum flexural bending stress.
79 mm
-
1
1
0
.
4
N
m
-
1
8
6
.
5
N
m
In the Intermediate shaft, any of sections 2-2,
3-2 & 3-3 may be critical i.e., experiences
maximum bending stress.
Bending Moment-Vertical Plane.
6
8
.
2
N
m
2
6
N
m
3-3 2 -2
Bending Moment-Horizontal Plane.
32
6th. Step (Contd.) Shaft Design
Next: Resultant Bending Moment
and Critical Section ((Contd))
L R
Reasons are as follows:
79 mm
-
1
1
0
.
4
N
m
roots of teeth.
-
1
8
6
.
5
N
m
Sections 2-2 & 3-2 have equal diameters but
diff
different
t stress
t concentration
t ti factors.
f t
Bending Moment-Vertical Plane.
At section 3-2 there is step, where as at
section 2-2 a there is keyway.
6
8
.
2
N
m
2
6
N
m
Therefore, section 22-2
2 may be severe than
section 3-2 in stress concentration point of
view.
3-3 2 -2
Again 2-2 usually experiences less BM. Bending Moment-Horizontal Plane.
33
6th. Step (Contd.) Shaft Design
Resultant Bending Moment and Critical Section (Contd)
L R
Resultant bending moment at 3-3:
B
M
=
1
9
8
.
6
N
m
68.22 186.52 79 mm
R
3
-
3
53 mm 75 mm 50 mm
Resultant bending moment at 2-2: 3-3 2 -2
3 -2 Layout
B
M
=
1
1
3
.
4
2
N
m
R
2
-
2
262 110.42
-
1
1
0
.
4
N
m
-
1
8
6
.
5-
N1
m39
.
8
1
N
m
Resultant bending moment at 3-2
is estimated as follows:
=
3
5
1
8
.
5
0
.
0
9
9
-
4
5
3
3
0
.
0
4
6
B
M
=
1
3
9
.
8
1
N
m
Bending Moment-Vertical Plane.
V
3
-
2
6
8
.
2
N
m
=
7
2
0
.
6
0
.
0
9
9
+
3
0
-
1
6
8
3
0
.
0
4
6
B
M
=
2
3
.
9
2
N
m
2
6
N
m
H
3
-
2
2
3
.
9
2
N
m
2 -2
B
M
=
1
4
1
.
8
4
N
m
3-3 3 -2
R
3
-
2
34
6th. Step (Contd.) Shaft Design
Bending Stress and search for Critical Section (Contd)
d=55.3 mm
d=50 mm
Maximum bending stress in any section of L R
rotating shaft (solid):
=
79 mm
Myy 32 M
b fc fc
I d3 53 mm 75 mm 50 mm
I d 4 / 64 3-3
3 -2
2 -2
Layout
(Section modulus and
y d /2
fc stress concentration factor ).
-
1
1
0
.
4
N
m
-
1
8
6
.
5-
N1
m39
.
8
1
N
m
Maximum bending stress at section 3-3:
1
8
1
0
1.5 32 198.6 Bending Moment-Vertical Plane.
6
b
3
-
3
Pas
0.05533
6
8
.
2
N
m
2
6
N
m
2
3
.
9
2
N
m
fc is taken 1.5 for hob cut gear.
3-3 2 -2
3 -2
Bending Moment-Horizontal Plane.
35
6th. Step (Contd.) Shaft Design
Bending Stress and search for
Critical Section ((Contd))
d=55.3 mm
d=50 mm
L R
Maximum bending stress at section 3-2:
79 mm
1
7
.
3
4
1
0
1.5 32 141.84
b
3
-
2
Pas 53 mm 75 mm 50 mm
0.053 3-3 2 -2
3 -2 Layout
fc is taken 1.5 for well designed step.
-
1
1
0
.
4
N
m
-
1
8
6
.
5-
N1
m39
.
8
1
N
m
Maximum bending stress at section 2-2:
1
8
.
5
1
2 32 113.42 0
b
3
-
2
6
8
.
2
N
m
2
6
N
m
fc is taken 2 for milled keyway.
keyway
2
3
.
9
2
N
m
2 -2
It is apparent that section 2-2 is critical. 3-3 3 -2
Bending Moment-Horizontal Plane.
36
6th. Step (Contd.) Shaft Design
Lastly: Verification of Overall factor of safety at Critical Section
As already mentioned earlier, in gear unit design the size of the gear shaft usually
biased by the sizes of gears, bearing layout and centre distances.
Particularly in case of shaft integral with the pinion there is little scope of pre-
designing the shaft.
In such cases maximum stresses in the shaft are estimated identifying critical sections.
sections
Then a factor of safety f s can be estimated using the following formula,
which is base on maximum shear stress theory under combined, bending,
torsion and direct normal stresses.
2
Sy Sy
m k f a 4 m2
fs Sen
Where,
S y = Yield strength of shaft material
S en = Endurance strength
g of shaft material
m = Mean (average) stress at considered section due to axial load.
a = Maximum alternating stress at considered section due to bending.
m= Maximum shear stress at considered section due to torsion.
k f = A factor considering the feature of section and severity of service.
It is chosen considering on what basis a has been calculated.
37
6th. Step (Contd.) Shaft Design
Verification of Overall factor of
safety
y at Critical Section ((Contd))
d=55.3 mm
In present design, the pinion is integral with
d=50 mm
L R
shaft therefore shaft material is EN19A.
Therefore, for the critical section 2-2: 79 mm
S y = 600 MPa, 53 mm 75 mm 50 mm
S en = 420 MPa (About 45% of Su for well 3-3
3 -2
2 -2
Layout
finished /ground shaft),
Fa
-
1
1
0
.
4
N
m
673.5
m fc
-
1
8
6
.
5-
N1
m3
2
d2 0.052
9
.
8
1
N
m
0
.
1
7
1
0
P
a 1
s 8
2
.
5
1
0
6
Bending Moment-Vertical Plane.
a
b
3
-
2
Pas
6
8
.
2
N
m
2
6
N
m
1 6T 16 148
2
3
.
9
2
N
m
m fc 2
d3 0 .0 5 3
1
2
.
1
1
0
P
a
s
6
3-3 2 -2
3 -2
Bending Moment-Horizontal Plane.
fc is taken 2 in general for milled single keyway.
keyway
38
6th. Step (Contd.) Shaft Design
Verification of Overall factor of
safety
y at Critical Section ((Contd))
d=55.3 mm
d=50 mm
Substituting values f S for the critical L R
section 2-2 is calculated as follows:
79 mm
2 53 mm 75 mm 50 mm
600 10 6
600
0.172 1.5 18.5 106 4 (12.1106 ) 2 3-3
3 -2
2 -2
Layout
fs 420
46.6 106
-
1
1
0
.
4
N
m
-
1
8
6
.
5-
N1
m39
.
8
1
N
m
Therefore,
1
2
.
8
7
6
8
.
2
N
m
46.6
2
6
N
m
2
3
.
9
2
N
m
This is highly satisfactory.
3-3 2 -2
3 -2
Usually
y f s is taken as 2.5 to 3. Bending Moment-Horizontal Plane.
39
6th. Step (Contd.) Shaft Design
Input Shaft
The Input Shaft is also integral with the 1st. stage pinion.
Therefore, the material is EN19A.
Shaft design verification is done in same way as it is done for intermediate shaft.
Output
p Shaft
The Output Shaft not integral with the gear.
Therefore, medium carbon steel (C40 or C45, Equivalent to EN8), having
ultimate strength- 560 MPa and yield strength- 280 Mpa, is taken as the
material.
16To
The Shaft diameter is initially estimated
do 3
S sa
on transmitted torque as follows:
In the present design considering a factor of 1.5 with nominal torque
the Output torque:
1
8
1
8
N
m
To 1.5
1 5 31 39 1
39.1
Considering allowable shear stress ( S sa ) of material is 60 MPa.
5
3
.
6
5
m
m
Nominal do
Considering the end bearings of ID 55 mm (Say SKF Ball Bearing 6311) Shaft
design verification is done in the same way as is done for intermediate shaft.
40
Bibliography
41