UME 408 Machine Design- 1

Redesign of an angle cutter/grinder

ASSIGNMENT MODULE- 1

FORCE AND STRESS ANALYSIS OF BEVEL GEAR

&
SELECTION OF BEARING

Total Points: 20

Note:
 Complete this modulein group; copying will be dealt with severely.
 The print of this document alongwith graphs, excel spreadsheets and CAD drawings
stapled together (or spiral bound) is to be submitted by the due date as mentioned
above.
 Submit your documents on time to the tutorial instructor. No extensions will be
granted.

Tutorial Group: MEE1 Project Group: 5

NAME: Sanskaar Dadhich Roll No. 101888023

NAME:Abhinav Chaudhary Roll No: 101888026
NAME:Aakash Aggarwal Roll No: 101888017
NAME:Tejpal Verma Roll No:401758002

1
Part A: Q1 to Q4 have been devised based on designing the bevel gear used in the drive system
of angle grinder. Complete Q1-Q4.Note: Excel spreadsheet to be created for Q2 and Q3.
Perform stress analysis of pinion based on ANSI/AGMA 2003-B97 standard or equivalent
code.

Q1 .Measure the distance between points marked in Figure 1. Calculate the forces acting on the
pinion at the midpoint of the tooth. (2points)

Figure 1

Figure 2

Power to be transmitted = 670W

Torque transmitted (N-mm) = 581.639 N-mm
Rotations per minute of pinion = 11000 rpm

2
Face width of gear tooth = 7.7 mm
Referring to Figure 2, fill the information in Table 1
Table 1Design parameters
Parameters of pinion Forces at contact point
No. No. Pitch Cone Radius Normal Equivalent Tangential Radial Axial
of of angle distance at mid Pressure number of force (N) force Force
teeth teeth (deg) (mm) point angle teeth on (N) (N)
on on (mm) (ϕ) pinion
pinion gear
γ A0 rav 𝑧𝑝′ Wt Wr Wa
9 32 15.7086 24.49 7.5126 20 9.35 77.42 27.13 7.34
Select three gear materials and list the properties in Table 2
Table 2 Properties of Gear materials
S.No. Material SAE or AISI Yield Tensile Density Hardness
number strength strength (kg/m3)
(Grade) (Min.)N- (Min.)
mm2
S.I. Units
(i) Cast Iron FG200 - 200 6800-7800 220
(ii) PCSteel 40C8 320 600 7850 380
(iii) Steel 50C4 930 750 7850 400

Q2 . Calculate the required module for pinion for three different gear materials. (3points)
Service factor = 1.25
Velocity factor = 0.233
Contact ratio = 1
Effective load on gear tooth (Weff) = 415.3433

Factor of safety = 1.5

Table 3 Gear tooth proportions from beam strength considerations
S.No. Material Beam Module of Face width of Corrected Corrected
strength of gear in gear (mm) pitch circle cone
gear tooth (N) mm diameter distance
(standard (mm) (mm)
value)
(i) Cast Iron 462.5916 2 11.08051 18 33.24154
(ii) PCSteel 462.5916 1.25 6.925321 11.25 20.77596
(iii) Steel 50C4 462.5916 1 5.540257 9 16.62077

3
 Table 4 Factor of safety
S.No. Material Wear Maximum Deformation Dynamic load Factor of
strength of expected factor for calculated by safety
gear tooth error pinion Buckingham’s against
(N) between gear equation (N) pitting
teeth (mm) failure

(i) Cast Iron 223.0272 0.05 11400 4675.782 0.723188

(ii) PCSteel 259.92 0.05 11400 2744.827 0.842817
(iii) Steel 184.32 0.05 11400 2124.823 0.597676
50C4

Q3 . Insert a plot of pitch angle (γ = 15°, 45°, 90°, 120°)against tangential force (W t). Comment on
the magnitude of the values of Wt when compared to the beam strength of gear tooth.(2points)

rm Mt Wt
ɣ
15 7.5585 581.639 76.9516
45 5.8326 581.639 99.722
90 4.705 581.639 123.6214
120 5.2208 581.639 111.4082

Wt vs ɣ
140
Tangential Force Wt

120
100
80
60
40
20
0
0 20 40 60 80 100 120 140
Pitch Angle ɣ

Beam strength

4
Q4 . Model the bevel gear (pinion only) using any CAD software. Only one gear tooth profile should
be constructed on the basis of findings of the studies on different materials and different pitch
angles.(3points)

5
Part B: The following tasks have been based on selection procedure of deep groove ball
bearings given in the product catalogue of SKF®. Complete the tasks mentioned in Q5-Q8.

Q5 . Draw the free body diagram of output shaft. The forces which act on the non-threaded portion
of stepped shaft should be taken from the “Annexure I”. (2points)

Figure 2 : Free body diagram of output shaft

6
Q6 . Calculate the Reaction forces (Rx, Ry, Rz) acting on bearing at C as shown in Figure 1.
(3 points)
Rx = 27.14 N

Ry= 11.93 N

Rz= 28.54 N

Q7 . Recommend a suitable deep groove ball bearing at C. Specify the bearing number, static load
carrying capacity and dynamic load carrying capacity of selected bearing also.
(3points)
Radial force acting at C (N) Thrust forces acting at C (N) Equivalent dynamic force (N)

27.13 11.93 55.53

Radial load factor (X) Thrust load factor (Y) Race rotation factor (V)

0.56 1.8 1

Service/ load factor Bearing life for cutter Bore diameter of bearing
application/ reliability

2.4 17085million rev 12

Designation of Bearing Basic load ratings

C C0

61801 1430 695

Q8 . List all the equations used for selection of bearing. (2points)

P=XVFr+YFz
𝐶
L10=( )p
𝑃

--------- END ----------

7
8