Tutorial - 1

Machine Design II

1. In a drive, a velocity ratio of 2.5 with a centre distance of 70 mm is desired. Select a gear set
with suitable module and determine (a) the pitch diameter of the gears with 200 full depth
involute teeth; (b) Is there any interference in the system? If so, how will you avoid it? (c)
Determine the contact ratio, (d) Find the dedendum, addendum, root diameters and the
tip clearance, (e) If the centre distance is increased by 1.5%, what will be the new pressure
angle? Ans. d1=40mm,d2 =100mm, new Φ = 22.210
2 A 21 teeth gear has 200 full depth involute teeth with a module of 12mm. (a) Calculate the
radii of pitch circle, base circle and addendum circle (b) Determine the tooth thickness at base
circle, pitch circle and addendum circle. Comment on the top land thickness.
Ans. Tooth thickness at base = 21mm, at addendum ta = 8.2 mm, ta > tamin
3 For a spur gear set with φ = 200, while avoiding interference, find:
(a) The smallest pinion tooth count that will run with itself
(b) The smallest pinion tooth count at a ratio mG = 2.5, and the largest gear tooth count
possible with this pinion
(c) The smallest pinion that will run with a rack Ans. (a) 13, (b) 15, 16, (c) 18
4 Shaft a in the figure 1 has a power input of 75 kW at a speed of 1000 rev/min in the
counterclockwise direction. The gears have a module of 5 mm and a 20◦ pressure angle. Gear
3 is an idler.
(a) Find the force F3b that gear 3 exerts against shaft b.
(b) Find the torque T4c that gear 4 exerts on shaft c.
5 The gears shown in the figure 2 have a module of 12 mm and a 200 pressure angle. The pinion
rotates at 1800 rev/min clockwise and transmits 150 kW power through the idler pair to gear
5 on shaft c. What forces do gears 3 and 4 transmit to the idler shaft?
6 A 24 tooth 3 module 200 pinion a rotates clockwise at 900 rpm and transmits 2kW to the
planetary gear train. Pinion a is meshed with an external gear b with 40 teeth. Gear b is
meshed with an internal gear c with 104 teeth. Pinion a and gear b are connected with an arm
d. What torque can arm d deliver to its output shaft? Draw a free body diagram of the arm and
of each gear, and show all forces which act upon them. Ans.Torque 113 N-m
7 In a step down gear set power is transmitted from a multicylinder engine to a moderate shock
machine. The gears are supported on less rigid mountings. They are precision cut gears and
contact across full face may be assumed. The input pinion is made of 18 teeth, 2.5 mm
module, 200 full depth teeth of hardness 340Bhn and runs at 1720rpm. The driven gear is of
hardness 280Bhn and runs at 860 rpm. Face width of wheels is 35mm. The ultimate tensile
strength of pinion and gear materials is 420 and 385MPa respectively. The gears are made by
hobbing process. Find the maximum power that can be transmitted by the drive with a factor
of safety 1.2 for a life of 108 cycles.
8 A commercial enclosed gear drive consists of a 200 spur pinion having 16 teeth driving a 48-
tooth gear. The pinion speed is 300 rev/min, the face width 50 mm, and the module 4 mm. The
gears are grade 1 steel, through-hardened at 200 Brinell, made to No. 6 quality standards,
uncrowned, and are to be accurately and rigidly mounted. Assume a pinion life of 108 cycles
and a reliability of 0.90. Determine the AGMA bending and contact stresses and the
corresponding factors of safety if 4 kW is to be transmitted.
9 A 20o spur pinion with 20 teeth and a module of 2.5 mm transmits 120 W to a 36-tooth gear.
The pinion speed is 100 rev/min, and the gears are grade 1, 18 mm face width, through-
hardened steel at 200 Brinell, uncrowned, manufactured to a No. 6 quality standard, and
considered to be of open gearing quality installation. Find the AGMA bending and contact
 stresses and the corresponding factors of safety for a pinion life of 108 cycles and a reliability
of 0.95.
10 A 20o full-depth steel spur pinion rotates at 1145 rev/min. It has a module of 6 mm, a face
width of 75 mm, and 16 milled teeth. The ultimate tensile strength at the involute is 900 MPa
exhibiting a Brinell hardness of 260. The gear is steel with 30 teeth and has identical material
strengths. For a design factor of 1.3 find the power rating of the gear set based on the pinion
and the gear resisting bending and wear fatigue.
11 In a conveyor system a step-down gear drive is used. The input pinion is made of 18 teeth, 2.5
mm module, 20o full depth teeth of hardness 330Bhn and runs at 1720 rpm. The driven gear is
of hardness 280Bhn and runs with moderate shock at 860 rpm. Face width of wheels is 35 mm.
The gears are supported on less rigid mountings, less accurate gears and contact across full
face may be assumed. The ultimate tensile strength of pinion and gear materials is 420 and
385MPa respectively. The gears are made by hobbing process. Find the tooth bending strength
of both wheels and the maximum power that can be transmitted by the drive with a factor of
safety 1.5. The layout diagram is shown in the Fig 4.
Ans. 3.84 kW
12 In a conveyor system a step-down gear drive is used. The input pinion is made of 18 teeth, 2.5
mm module, 20o full depth teeth of hardness 340Bhn and runs at 1720rpm. The driven gear is
of hardness 280Bhn and runs with moderate shock at 860 rpm. Face width of wheels is 35mm.
The gears are supported on less rigid mountings, less accurate gears and contact across full
face may be assumed. The ultimate tensile strength of pinion and gear materials is 420 and
385MPa respectively. The gears are made by hobbing process. From surface durability
consideration, find the maximum power that can be transmitted by the drive with a factor of
safety 1.2 for a life of 108 cycles. Drive layout is shown in the Fig 1. Ans.3.51kW
13 Design a spur gear set to transmit a power of 20 kW. Gears are to be finished by hobbing.
Driving shaft is connected to an four stroke I.C.Engine and output shaft is connected to a
moderate shock machine. Mounting is such that less than full-face contact exits. Other data
may be assumed suitably and mentioned clearly.

Fig.1 Fig.2 Fig.3