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With Two
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Qu~stions & ~. '-,
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.'
_'
.... ~.\,.,\ '
Answers \
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Selection of V belts and pulleys - Selection of Flat belts and pulleys - Wire ropes and pulleys -
Selection of Transmission chains and Sprockets. Design of pulleys and sprockets.
Design of plate clutches - Axial clutches - Cone clutches - Internal expanding rim c1l1tches-
.Internal and external shoe brakes.
TUTORIALS 30 hrs.
TOTAL: 75 hrs.
CONTENTS
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Introduction - Advantages and limitations of gear drive over chain and belt drives -
Definition of gear - Classification of gears - Spur gears - Gear nomenclature - Law of
gearing - Forms of gear tooth profile - Standard systems of gear tooth - Standard
proportions of gear systems - Gear materials - Selection of gear material - Gear
manufacturing - Gear tooth failure - Force analysis on spur gears - Tooth stresses
(Lewis beam strength equation) - Gear blank design - Gear design using Lewis and
Buckingham's equations - Beam strength of gear tooth - Dynamic effects - Tangential
load on tooth - Dynamic tooth load (Buckingham's equation for dynamic load) -
Estimating gear size - Standard module - Fatigue strength of gear tooth (wear tooth
load) - Number of teeth - Face width - Factor of safety - Design procedure - Gear
design based on gear life - Dynamic load - Induced bending stress - Design bending
stress - Design contact stress - Surface compressive stress - Design procedure - Check.
for plastic deformation - Gear design for variable loading - Design of gears with
reliability factor - Design of internal gears - Design of non-metallic gears - Review and
summary - Review questions - Problems for practice.
Internal expanding rim clutches - External contracting rim clutches - Energy dissipation
during clutching (Energy considerations) - Temperature rise - Review and summary -
Review questions - Problems for practice.
INDEX
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Whenever power has to be transmitted from one shaft to another shaft, flexible machine
elements such as belts, ropes or chains are frequently used. Pulleys are mounted on the shaft
and a continuous belt or rope is passed over them. In belts and ropes, power is transmitted
due to friction between them and the pulleys. In case of chain sprocket wheels are
used. When the distance between the shaft is large, then
smaller distances, gears are used. The amount of power upon several
factors such as velocity of the belt, tensions i belt, arc of contact
between the belt and the smaller pUlle.1iilllllt":
1.2. CLASSIFICA
., Drives
l
Flexible drives
~
Direct drives
l
Belt
1
Rope
~
Chain
l
Gear drive
~
Cam drive
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3. Slip 1 to 5% 1 to 5% Nil
4. Tension High Less Very less
5. Shock resistance Good Good Fair
6. Resistance to wear Good Fair Good
7. Dressing Required Not required Not required
8. Initial cost Less Less Moderate
1.3
-
Flat Belts and Pulleys
--
Tight side
Fi • 1.2.
2. Open belt drive with one idler pulley: Used with shafts arranged parallel and when
an open belt drive cannot be used due to
small angle of contact on the smaller pulley.
Idler pulleys (also known as Jockey pulleys)
are provided to obtain high velocity ratio and
when the required belt tension cannot be
obtained by other means.
Fig. 1.3.
3. Open bell drive wuh many idler pulleys: Used when it is desired to transmit motion
from one shaft to several parallel shafts.
Fig. 1.4.
)
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FE =7' 'nmt 5 27 WE; liEF? au YIMiII'· .... ..,
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4. Crossed or twisted belt drive: Used with shafts arranged parallel and
rotating in the opposit~ direction.
FI . 1.5.
s. Used with shafts arranged at right angles and
rotating in one definite direction.
FI • 1.6.
6. Quart~r twist bett drive will, guide Used with shafts arranged at right angles
pul/~y : when the reversible motion is desired.
FI • 1.7.
7. St~PfNdor cone pulley driv«: Used for changing the speed of the driven
shaft while the main or driving shaft runs at
constant speed.
n« t.s.
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I.S
[Iat Belts and Pulleys
----------~--------------I
Types of drives Applications
Fi • 1.9.
9. Compound drive: Used when several units are to be driven
from one central shaft.
Fi . 1.10.
Belts are specified according to the number of layers. e.g., single-ply, double-ply or triple-
ply belts. Double-ply (or triple-ply) belts are made by cementing two strips (or three strips) of
leather together with hair sides out.
2. Fabric and cotton bells:~ These belts are made by stitching together three or more plies
(or layers) of canvas or cotton duck. The fabric is treated with linseed oil to make it water-
proof.These belts are cheap. They are most suitable for farm work, quarry and saw mills.
J. Rubber belts: These belts are made up of plies of fabric impregnated with vulcanised
rubber or synthetic rubber. The main advantage of these belts is that they can be easily made
endless. Saw mills, creameries, chemical plants and paper mills largely use the rubber belts.
4. Bnlaln ~/ts: Balata is gum similar to rubber. Balata belts are made in the same manner
as the rubber belts except that balata is substituted for rubber. These belts are acid proof and
water-proof. The balata belts cannot be used at temperature above 40°C because at this
temperature it begins to soften and becomes sticky.
5. Nylon core belts
6. Camel's hair belts.
The commonly used belt materials for various belt types are given in Table 1.3.
N2 (02 D
Velocity ratio, -N = = ... (1.1)
) (0) d
I Note lin practice the combined effect of slip and creep is called simply slip and the combined
effect should not exceed three percent.
Law of belting states that the centre line of the belt, as it approaches the pulley, must lie in
a plan~ perpendicular to the axis of that pulley or must lie in the plane of the pulley,
otherWise the belt will run off the pulley.
2a = The angle subtended between the straight portions of the belt in degrees,
as = Wrap angle (or angle of contact / lap) for small pulley in degrees, and
aL = Wrap angle for large pulley in degrees.
. -1 0- d
Sin -
I 2C
,~
I,
I
--\----C-----
Fig. 1.11. Open belt drive
As seen from the Fig.I.II,
O-d
sma = --
2C
also as = (180-2a) and aL = (180+2a) ... (1.6)
For crossed belt drive: A crossed belt drive is shown in Fig.l.12, with notations having
the usual meanings.
. -1 D+d
Sin --
2C I
,..--,
I,
• For derivations of the formulas used in this chapter, the readers are suggested to refer any 'KinematicS of
Machines' book.
Sill U = (02+cd)
and Us = uL = (180 + 2 n) ... (1.8)
Therefore, wrap angles for smaller and larger pulleys are same and is given by
3. Initial tension in belt (To) : The tension of the belt when a belt is fitted to a pair of
stationary pulleys, is termed as the initial tension of tile belt (To).
TJ +T2
:. Initial tension, To = 2 ... [Neglecting centrifugal tension] ... (1.12)
TJ+T2+2Tc
= 2 ... [Considering centrifugal tension] ... (1.13)
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INotes I I. Maximum tension to which the belt can be subjected due to centrifugal tension,
... (1.14(a))
T = T 1+ T C
Thus, the centrifugal tension has 110 effect on the power transmitted.
4. For a belt speed of upto 10 mls the centrifugal tension is negligible. But for belt speed more than
10 mis, the centrifugal tension should be considered without fail.
Let TI and T2 = Tensions on tight and slack sides of the belt respectively,
a = Angle of wrap (i.e., angle of contact) of belt with the pulley, and
11
Tension ratio, = ell a ... [Neglecting centrifugal tension] ... (1.15)
T2
TI-mv2
and
T2 -mv2 = ella ... [ Considering centrifugal tension] ... (1.16)
INotes I I. It should be borne in mind that 'a' in the tension ratio equations must be in radians.
2. Condition for the transmission of maximum power: The power transmitted shall be maximum
when the centrifugal tension (Tc) is one third of the maximum belt tension (T).
T == 3 Tc ... (1.17(a»
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The coefficient
. of friction
. between the belt material and tlie pv IIey sur face d epen d s upon
the belt material,. material . of. the pulley.' surface the belt speed an d th e be It I' A verage
Sip.
values of coefficients of friction for design purposes are given in Table 1.4.
Table 1.4. Mean coefficient of frlctlon, J.I
Pulley material
Belt material Compressed
Wood Steel Cast iron
paper
-
Leather (oak-tanned) 0.33 0.30 0.25 0.25
I.' 2
where
b = Width of the belt, and
1 = Thickness of the belt.
2. Stress due 10 bending of the bell over tile pulley (a,,) :
E·,
ab = d
where E = Young's modulus of the belt material, and
d = Diameter of the smaller pulley.
3. Stress due 10 the effect of centrifugal force (uj :
2
_ Centrifugal force _ mv = 2
ac - Cross-sectional area of the belt - b· I Pv
where P = Density of the belt material in kg/m '.
It. is noted that the stress will be maximum when the belt moves over the smaller pulley.
Therefore the maximum stress in the tight side of the smaller pulley is given by
amax = at + ab + ac
1.17. INTRODUCTION
In order t~ design a flat belt. drive, we need the diameters of driving and driven u lie s.
Thus the design of belt pulleys IS to be done first Since the velocitv rati p Y
pulley diameters, therefore the pulleys should be s~lected caref:I~~lty ratio depends upon the
Rim
Now, select the diameter of the pulley (D) referring to Table 1.5.
Table 1.5. Recommended pulley diameters ill mm (from data book, page 110. 7.54)
(ii) Width of tile pulley (a) : If the width of the belt is known, then select the width of the
pulley referring to Tables 1.6(a) and (b).
Table 1.6(0). Pulley width (from data book, page no. 7.54)
Table 1.6(b). Recommended series of width of flat pulleys, mm (from data book, page 110. 7.55)
20, 25, 32, 40, 50, 63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250,
280, 315, 355, 400, 450, 500, 560 and 630.
(iii) Arms taper: The arms are tapered from hub to rim.
Taper = 4 mm per 100 mm ... [From data book, page no.7.56]
3. Dimensions of hub:
(i) Diameter of the hub (d 1) :
Diameter of the hub (d1) = (1.7 to 2.0) x Diameter of the shaft (d2)
or d, = (1.7 to 2.0) d2
(ii) Length of the hub (/) :
Table 1.7(a). Crow" of flat pulleys (40 to 355 mm diameter) (from data book, page no. 7.55)
(crow" is unrelated to the width ill this diameter range)
Diameter D, mm Crown h, mm
40 to 112 0.3
125 and 140 0.4
160 and 180 0.5
200 and 224 0.6
250 and 280 0.8
315 and 355 1
Table 1.7(b). Crow" offlat pulleys (40 to 2000 mm diameter) (from data book, page no. 7.55)
(crown varies with tire width in this diameter range)
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"'"
I
I Example 1.1 I Design a cast iron pulley to transmit 20 kW at 300 r.p.m: The diameter
of the pulley is 500 mm and the angle of lap is 180 ~ The pulley has four arms of elliptical
cross-section with major axis twice the minor axis. The coefficient of friction between the
belt and the pulley surface is 0.3. The allowable belt tension is not to exceed 250 N in 10
mm width. The allowable shear stress for the shaft material may be taken as 50 Nlmml.
Given Data: P = 20 kW = 20 x 103 W; N = 300 r.p.m.; D = 500 mm = 0.5 m ;
a = 1800 = 1t rad; n = 4' , J.1 = 0.3; TI = 2.5 N in 10 mm width of the belt;
as = 50 N/mm2.
To flnd : Design a cast iron pulley.
7t·D·N 7t x 0.5 x 300
© Solution: Velocity of the pulley or belt, v = 60 = 60 = 7.854 m/s
1. Dimensions of pulley :
(i) Diameter 0/the pulley (D) is given as 500 mm. Now referring Table 1.5, the
recommended diameter of the pulley is also 500 mm. Ans. "
(ii) Width of the pulley (a) : In order to find the width of the pulley let us find the width
of the belt first.
Let TI and T2 = Tensions on the tight and slack side of the belt respectively.
TI
and ratio of tensions, = e~Q
T2
, = eO.3)( 1t or T, = 2.566 T2 ... (ii)
T2
INou I Since the velocity of the belt (or pulley) is less .han )0 mIs, therefore the centrifugal
tension need not to be considered.
Let b = Width of belt
Since the allowable tension (i.e., maximum tension) is 250 N in 10 mm width or 25 N/mm
width, therefore width of the belt
T, 4171.68
b = -
25
= 25
= 166.86mm
Referring to Table t.t3, the standard width of 4 ply belt is 200 mm.
l1lerefore width of the pulley (a), referring the Table 1.6(a), is given by
= Belt width + 25 mm = 200 + 25 = 225 mm
Then, referring to Table 1.6(b), the standard pulley width is 250 mm. Ans."
b ~ 2.94 Wn for single belt ... [From data book, page no. 7.56]
3
(iii) Radius of the cross-sections of arms = 4 x M'ajor axis
.
3
= 4 x 60 = 45 mm Ans. ~
T = ~ xo x d3
16 s
= 166.67 mm ADs.'"
4. Crown height of tire pulley (lr) : For 500 mm pulley diameter and 250 mm pulley
width, from Table 1.7(b), the crown height is selected as h = 1.5 mm ADs. y .
I Example 1.2 I Design' an overhanging pulley'for the following specifications,' Power
= 18 kW; Speed = 200 r.p.m.; Angle of contact = 165"; Coefficient of friction = 0.25;
Overhanging length (i.e., the distance of the pulley centre line from tire nearest bearing) =
0.30 m; Belt thickness = 10 mm; Safe sirear stress for shafts = 40 MPa; Safe stress for belt
= 2.5 MPa; Safe stress for rim = 4 MPa; Density of the leather = 1000 kg/m'.
rt
Given Data: P = 18 kW = 18 x 103 W; N = 200 r.p.m.; a = 165 = 165
0
x 180
23.57
= 7txDx200
60 or D = 2.25 m ADS. ~
(i;) Width of tirepulley (a): In order to find the width of the pulley, let us find the width
of the belt first.
Let T, and T2 = Tensions on the tight and slack sides of the belt re pectively, and
b ;; Width of the belt.
Since the velocity of the belt (or pulley) is more than 10 mis, therefore centrifugal tension
must be taken into consideration. Assuming a leather belt for which the density is given as
1000kg/m-'.
We know that centrifugal tension, Tc = In' v2
Therefore, width of the pulley (a), referring the Table 1.6(a), is given by
For single belt, t = 2~0 + 3 mm ... [From data book, page no. 7.57]
2250
= 200 + 3 = 14.25 mm
1.20
2. Dimensions 0/ arms :
(i) Number of arms (n) :
6 (for diameters over 450 rnm) 7 56]
Number of arms, n = ... [From data book, page no. .
3. Dimensions of tile II ub :
(i) Diameter of the hub : In order to find the diameter of the hub, let us find the diameter
of the shaft first.
Let d = Diameter of the shaft
We know that the torque transmitted by the shaft,
p x 60 18 x 103 x 60
T = 2 1t N = 21t X 200 = 859.44 N-m
and bending moment on the shaft due to the tensions of the belt ,
M = (T) + T2 + 2 Tc) L = (1487.62 + 724.25 +2 x 5.5 x 90) 0.3
=
960.56 N-m '" (.,' Tc = 5.55 b N)
We know that equivalent twisting moment (Te),
T, = ~ T2 + M2 = ~ (859.44)2 + (960.56)2
= 1288.92 N-m = 1288.92 x 103 N-mm
We also know that equivalent twisting moment (T ),
e
7t
1288.92 x 103 == 1 6 x as x d3 - ~
16 x 40 x d3
or
Diameter of the shaft. d = 54 75
. . mm say 55 mm,
2
(ii) Length of the hub = 3 x Width of the pulley (a)
2
= 3" x 112 = 74.66 mm ADS • ...,
4. Crown height of tire pulley (II) : For 2250 mm pulley diameter and 112 mm pulley
width, from Table 1.7(b), the crown height is selected as h = 2 mm ADS • ...,
~I.~n
Design a/Transmission Systems
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Load classification Ks
Nonnalload 1.0
Stead load-screens, centrifugal pumps, agitators, belt conveyors, 1.2
light machine tools, etc.
Intermittent loads - Reciprocating pumps and compressors, heavy 1.3
machine tools, heavy duty fans and blowers, etc.
Shock loads - Crushing machinery, hammers, presses, grinders, 1.5
rolling mills, etc.
(ii) Arc 0/ contact factor (KaJ': The load rating (i.e., rated power capacity) is given for
1800 of contact. So, it has to be corrected for actual arc of contact. A decrease in arc of
contact implies additional load.
.. Arc of contact = 1800 _ (D ~ d) x 600 ... [From data book, page no. 7.54]
(iii) Small pulley factor (K~ : This factor is used to account for the amount of bending or
flexing of the belt and how this affects the life of the belt. Use Table 1.11 for small pulley
factor.
Table 1.11. Small pulley factor, Kd (from data hook, page no. 7.62)
3. Selection of a belting :
Select a belt referring to Table 1.12.
Table 1.12. Load rating of fabric belts per mm width per ply at 1800 are of contact at
lQ m/s belt speed (from data book, page no. 7.54)
.:/ 1.24
Design a/Transmission Systems
L = 2C
7t)
+ ( "2 (0 + d) +
(0 + d)2
4C
For crossed belt drive:
... [From data book, page no. 7.53]
I Example 1.3 lIt is required to select a flat-belt drive/or a/an running at 360 r.p.m:
which is driven by a 10 kW, 1440 r.p.m: motor. Tile belt drive is open-type and space
available for a centre distance 0/ 2 m approximately. The diameter 0/ a driven pulley is
1000mm.
Given Data: N) = 1440 r.p.m.; N2 = 360 r.p.m; P = 10 kW = 10 x 103 W ;
C = 2m; D = 1000 mm.
Tofind : Select (or design) a open flat belt drive.
© Solution: The given arrangement is shown in Fig.l.14.
1. Calculation of pulley diameters: 360 r.p.m.
--;--....
Driven pulley diameter, D = 1000 mm o
D
We know that velocity ratio = Fan
d
d
_ Driver pulley speed N) 1440
- Driven pulley speed - N2 = 360 = 4
Consulting Table 1.5, the recommended driver pulley diameter = 250 mm Ans. ~
2. Calculation of design power in k W :
Rated kW x Load correction factor (Ks)
Design kW =
Arc of contact factor (KJ x Small pulley factor (Kd)
(i) Rated kW = 10 kW
... [Given]
(ii) Referring to Table 1.9, load correction factor K, = 1.2 for steady load.
(iii) To find arc of contact factor (Ka) : '
1000 - 250 ) 0
= 180 0
- ( 2000 x 60 = 157.50
Consulting Table 1.10, arc of contact factor for 157.50, Ka::::: 1.08.
(iv) Consulting Table 1.11, small pulley factor, Kd = 0.7
lOx 1.2
Design kW = 1.08 x 0.7 = 15.873 kW ADS.~
3. Selection of belt:
Consulting Table 1.12, HI-SPEED duck belting is selected. Its capacity is given as 0.023
kW/mmJply.
4. Load rating correction:
7t x 0.25 x 1440
Velocity of the belt, V = = 60
= 18.85 mls
. V
Load rating at V mls = Load rating at 10 mls x TO
Load rating at 18.85 m/s = Load rating at 10 mls x (18.85 ItO)
= 0.023 x (18.85 I 10) = 0.04335 kW I mm I ply
5. Determination of belt width :
For 250 mm smaller pulley diameter and velocity of 18.85 mIs, consulting Table 1.8, the
number of plies can be selected as 5.
Design power
Width of belt =
Load rating x No. of plies
15.873
= 0.04335 x 5 = 73.23 mm
Consulting Table 1.13, the calculated belt width should be rounded off to the standard belt
width.
:. For 5 ply belt, standard belt width = 76 mm ADS. ~
L = 2 C + ~ (D + d) + {_D- d)2
. 2 4C
I
/i
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1.26
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== 20 x 103 W ,. ROlling
machine
N I == 720 r.p.m.; (driven)
d
Speed ratio == 3 ;
C == 3 m; D == 1.2 m.
To flnd : Design a belt drive. Fig. 1.15.
Consulting Table 1.5, the recommended driver pulley diameter == 400 mm ADS."
2. Ca/cularion of design power ill kW:
Rated k W x Load correction factor (Ks)
Design kW == Arc of contact factor (Ka) x Small pulley factor (Kd) i
7t (1200 - 400)2 _
= 2 x 3000 + 2' (1200+400) + 4 x 3000 = 8~66.6 mm Ans. ~
In a belt drive, when the drive is transmitting maximum power without slip (i.e., at the
point of slipping) the tensions in belt are governed by the following equation,
T -my2 ...!!!!...
1 = esin ~ = ella. cosec ~
T2-mY2 '" (1.20)
1. If the coefficients of friction are same for both the pulleys (i.e., both the pulleys are of
same material), then the smaller pulley governs the design. Because for open belt drive, the
smaller pulley has the wrap angle smaller than that of the larger pulley and hence the smaller
pulley will have the smaller value of eJ.lQ cosec P than the larger pulley. Therefore smaller
pulley will slip first.
~
Design a/Transmission Systems
1.28
2 If the coefficients of friction are different for both the pulleys (i.e., both th~tUlle;s ar~
of different material), then the pulley which has the smaller tension ratio (or sma er va ue 0
eJUlcosec j3 ) governs the design.
~ Use the smaller tension ratio in designing the belt drive.
I Example 1.5 I A leather belt is used to supply power/rom a compensator ~tart electric
motor to a reciprocating air compressor. Tile specifications 0/ the belt drive are as follows:
Power (in k W) 25 -
Speed (in r.p.m.) 1440 360
Pulley diameter (in mm) 250 1200
--
Angle 0/ lap (in radians) 3.8 4.7
Coefficient 0/ friction 0.3 0.25
The density of the belt is 1000 kg/mJ. The permissible tension is not to exceed 145 N in
10 mm width. TI,e thickness of tbc belt may be taken as 8 mm. Determine which pulley is
governing the design 0/ the drive and find the necessary width to transmit the required
power taking into account the centrifugal tension also.
Given Data: P = 25 kW = 25 x 103 W; NI ,= 1440 r.p.m.; N2 = 360 r.p.m.;
d = 250 mm; D = 1200 mm; (11 = 3.8 rad; (12 = 4.7 rad; J..LI= 0.3; J.i2 = 0.25;
P = 1000 kg/rn-; Tl = 145-N in 10 mm width; t = 8 mm.
We know that a pulley which has the smaller value of e~a· cosec ~ will govern the design.
Since the coefficients of friction are different for both the pulleys, first we have to evaluate
e~ (since 2~ = 1800 for flat belts) separately.
:. For smaller pulley : e~l at = eOJ x 3.8 = 3.127
P = (TI - T2) v
25 x 103 = (TI - T2) 18.85 or TI - T2 = 1326.29 ... (i)
T)-2.84b
or (T)-1326.29)-2.84b = 3.127 ... (ii) [.: T2 = TI - 1326.29, from (i) ]
It is given that permissible tension (T) is 145 N in 10 mm width or 14.5 N/mm width.
, ',1 • I
I Example 1.6 I Find the width of the belt necessary to transmit 7.5 kW to a pulley of
JOOmm diameter, if the pulley makes 1600 r.p.m; and the coefficient of friction between
the belt and the pulley is 0.22. Assume the angle of contact as 2100 and the maximum
tensionin the belt is not to exceed 8 Nlmm width.
GivenData: P = 7.5 kW = 7500 W " d = 300 mm = 0.3 m ; N - 1600 r.p.m.;
J.L = 0.22; C1 = 210 = 210
0 0
x 1:00 = 3.6652 rad.
TI
Also = ella = eO.22 x 3.6652 = 2.2396 or TI = 2.2396 T2 ... (ii)
T2
Solving (i) and (ii), TI = 539.15 Nand T2 = 240.734 N
N2 d,
We know that Speed ratio = -
N, d2
240 0.25
- = -d or d2 = 0.75 m
720 2
d2-d, 0.75 - 0.25
For an open belt drive, SIl1 a = 2C
= = 0.2
2 x 1.25
TI = e)lUs = =
We know that eO.25 x 2.74 1.983 or TI=1.983T2 ... (i)
T2
Also P = (TI - T2) v
12xI03 = (TI-T2)9.425 or TI-T2= 1273.2 ... (ii)
1t
165 x 180 = 2.88 rad; J.L = 0.3.
Tofind: Design a rubber belt (i.e., width and thickness of the belt).
1t dN 1t x 0.2 x 2250
© Solution: Velocity of belt, Y = 60 = 60 = 23.6 mls
Cross-sectional area of the belt = bxt ::: b x 10 = lOb mm- = lOb x 10-6 m2
We know that mass of the belt per metre length,
( Example 1.10 , A leather belt 125 mm wide and 6 mm thick, transmits power from a
pulley with the angle of lap 1500 and u = 0.3. If the mass of 1 m3 of leather is 1Mg and the
stress in the belt is not to exceed 2.75 MPa, find the maximum power that can be
transmitted and the corresponding speed of the belt.
GivenData: b=125mm=0.125m; t=6mm=6x 10-3m;
1t
e = 150 0
= 1500 x 180 = 2.62 rad; J.L = 0.3; p = 1 Mg/m3 = 1000 kg/m! ;
o = 2.75 MPa = 2.75 x 106 N/m2.
To find: Maximum power and corresponding speed.
©Solution:
Speed of the belt for maximum power: We know that maximum tension in the belt,
T = o xbx t = 2.75 x 106 x 0.125 x 6 x 10-3 = 2062.5 N
and mass of the belt per meter length,
m = Density x Area x Length = p b . t . I
_~!tt~. _
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TI
We know that = ella = eOJ x 2.62 = 2.195
T2
TI 1375
_--
or T2 = 2.195 2.195
= 626.53 N
I Example 1.11 lIn a belt drive, the tension ratio is 2.6. The mass of the belt is J kg/m
length. It runs at a speed of 5 m/s and at this speed, power transmitted is 8 k W. What
should be tile initial tension in the belt and what should be the streng til of the belt?
TI
Given Data: T = 2.6; In = 1 kg/rn ; v = 5 m/s ; P = 8 kW = 8 x 103 W.
2
TI
Given that,
T2
= 2.6 or TI = 2.6 T2 ... (ii)
2600
= = 1825 N Ans. ~
I Example 1.12 IA 2.5 k W of power is transmitted by (III open belt drive. Tlte linear
velocity of the belt is 2.5 m/s. TI,e angle of lap on the smaller pulley is 165 ~ The coefficient
of friction is 0.3. Determine the effect on power transmission in the following cases:
(i) Initial tension in the belt is increased by 8%,
(ii) Initial tension ill the belt is decreased by 8%,
(iii) Angle of lap is increased by 8% by the use of all idler pulley, for the same speed
and the tension on the tight side, and
T, +T2
or = To' = 1328.3 N or T1 + T2 = 2656.6 N ... (iii) ___
2
T, .
As ~ and a remain unchanged, ella or T is same. So, T, = 2.37 T2•
2
-
P-v
I
T1
and New tension ratio, T = ella' = eO.3 x 3.1104 = 2.54 or T I = 2.54 T 2 ... (v)
2
Tension on the tight side remains same as before. i.e., TI = ] 729.9 N
Then from equation (v), T2 = 680.5 N
... Percentaze
ercen age imcrease in
. power = [ 2.6242.5- 2.5 ] = 0.04 96 or 4 .96 % Ans • ..,
I Example 1.13 I The layout of a crossed leather belt drive is shown in Fig. 1.16. The
bell, 6 mm thick, transmits 7.5 kW and operates at a velocity of 13 mls approximately. The
coefficient of friction is 0.3 and the permissible tensile stress for the belt material is
1. 75 N/~. The density of leather is 0.95 gm/cc. Calculate: (i) the diameter of pulleys;
(ii) the length and width of the belt; and (iii) belt tensions on the tight and loose sides. Take
length of the belt, 1% less to give initial tension.
Given Data: 6 mm = 6 x 10-3 m ;
t = o
P = 7.5 kW .= 7.5 x 103 W; v = 13 mls ;
J.L = 0.3; o = 1.75 Nzrnm? = 1.75 x 106 N/m2;
p = 0.95 grn/cc = 950 kg/m ' d
N 1 = 1000 r.p.m.; N2 = 500 r.p.m. ; .
C = 1500 mm = 1.5 m. 1--- 1500 mm ---1.1
Fig. 1.16.
,.j
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@Solution :
(i) Diameter of pulleys:
Speed ratio,
n
d
n
d or 0=2d ... (i)
1t d Nl
and velocity, v =
60
1t X d x 1000
13 = 60 or d = 0.248 m
1.38
= 950x6bx
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Design o/Transmission
Belt tension on the tight side = T I + Tc = 867.56 + 96.3 = 963.86 N. ADS. "
and belt tension on the loose side = T2 + Tc = 290.64 + 96.3 = 386.94 N ADS. ~
N2 d, + t
(ii) = ... [when considering the thickness of the belt]
N/ d2 + t
N2 dJ + I [ S ]
(iii) = d2 + t 1- 100 ... [when considering the slip of the belt]
N/
N2 a, E+{a;
(iv) NJ - d2 x E + ~ '" [when considering the effect of creep of belt]
L
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L = 2 C + !I (D + d) + (D + d)2
2 'I 4C ... [For cross belt drive}
where d and D = Diameters of smaller and larger pulley diameters, and
C = Centre distance between the pulleys .
./ Wrap angle or angle of contact of pulleys (a) :
For open belt drive:
and Wrap anglefor larger pulley, aL = 180 + 2 -sin:' (D2 ~d) degrees
./ Power transmitted, P = (IJ - T~ v
TJ
./ Tension ratio: = epa
T2
./ Centrifugal tension: Tc = mvl
where m = Mass per unit length of bell.
./ Initial tension (IoJ of the belt is given by
{./ In this chapter, the design of flat belt pulleys are presented with step by step proced
./ Design of flat belt pulleys: To find (i) Dimensions of pulley (includes diameter,
and thickness of the pulley),· (ii) Dimensions of arms (includes number of arms,
. section of arms and arms taper),' and (iii) Dimensions of hub (includes diameter
length of hub).
./ Two different design procedures used for belt drives are: (i) using the manufacture
data,' and (ii) using the basic equations.
,/ Step by step procedure for the design of 'flat belts using the manufacturer's data is g
in this chapter with sufficient example problems.
,/ Flat bell design: To find: (i) Type of bell (i.e., Hi-speed or Fort), (ii) Bell width
number of plies, and (iii) Belt length.
./ Design ustn« basi . 'h
• G OSICequations: Ti e pulley which has the smaller value of tension ra
WIll govern the design of the drive.
REVIEW QUESTIONS
1.
Enumerate the various types of belts used for the transmission of pow
2.
What are the materials used in flat belts. er.
3.
Explain the following terms: (i) velocity ratio (Oo) I' Oo.
4. Wha ' II S JP and (Iii) creep in b It
t is the effect of centrifugal tension on power tr '. e s.
s. Wh t ." be ansmlsSlon by a flat belt?
. ~ WI the effect on the limiting ratio of . .
Ihetlon between the belt and rim of pull . d tensIons of a belt if the coefficient of
same? ey IS oubled while angle of I .
[Ans . R . . ap remams the
6. What is the purpose of having an idler pull . b '. ano of tensIOn will be squared1
7. L'1Stout the losses in belt d . ey In elt dnve ?.
, . fives.
8. What are the v .
9. 'T anous s~sses set up in a belt?
What is the ,.ffi f .
l'" ect 0 centre distance and d'
10. Wh t' l8ltleter of puJJey h
a IS crowning of pulleys? on t e life of a belt?
POWl:r. kW 20 -
1.42
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14. In an open belt drive, the linear velocity of the belt is 3 mls. The angle of lap on the
smaller pulley is 166°, the coefficient of friction is 0.3 and the power transmitted is
3 kW. Determine the effect of power transmission in the following cases:
(i) Initial tension in the belt is increased by 10%,
(ii) Initial tension in the belt is decreased by 10%,
(iii) Angle of lap is increased by 10% by the use of an idler pulley, for the same speed and
the tension on tight side, and
(iv) Coefficient of friction is increased by 10% by suitable dressing to the friction surface of
the belt.
[ Ans : (i) % increase in power = 10% ~ (ii) % decrease in power = 10%;
(iii) % increase in power = 6.23% ~ (iv) % increase in power = 8.85%]
- Arthur C Garke
2.1. INTRODUCTION
V -belts are used with electric motors to drive blowers, compressors, appliances (like
mixer, grinder, etc.), machine tools (like lathe, drilling machine, farm and industrial
machinery, and so on. V-belts are endless and run in pul grooved pulleys
that V -belts run in are called sheaves.
2.2
Table 2.1.
2. Dimensions of sheaves:
The cross-section of a sheave (i.e., V-grooved pulley) for V-belt drives IS shown In
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No. of
Groove Groove
sheave
Ip dp
cross- b angle (2P) h e I grooves
section in degrees
(n)
A 11 3.3 7S 32,34,38 8.7 IS 10 6
B 14 4.2 125 32,34,38 10.8 19 12.5 9
C 19 5.7 200 34,36,38 14.3 25.5 17 14
0 27 8.1 355 34,36,38 19.9 37 24 14
E 32 9.6 SOO - 23.4 44.5 29 20
Design Procedure: The two steps involved in designing a V-grooved pulley are:
I. Select the cross-section of the belt (i.e., type of belt) depending on the power to be
transmitted, by consulting Table 2.3.
Table 2.3. Data on standard V-belt sections (from data book, page no. 7.58)
Recommended
Cross Nominal top Nominal Mass per
Usual load minimum
section Area, mm2 width, W thickness, T metre, m
of drive, kW pulley pitch
symbol mm mm kg/m
dia, d, mm
A 80 0.7S - 5 75 13 8 0.106
B 140 2 -15 125 17 11 0.189
C 230 7.5-75 200 22 14 0.343
0 475 22 -ISO 355 32 19 0.596
E 695 30-190 500 38 23 -
2. For the selected cross-section of the oelt, consulting Table 2.2, select the various
required dimensions of the V-grooved pulley.
2.5
V-Belrs and Pulleys
Design procedure:
1. Sttection of belt section:
,
Consulting Table 2.3, select the cross-section of a belt (i.e., type of belt) depending on the
power to be transmitted.
2. Selection o/pulley diameters (d and D) :
Select small pulley diameter (d) from Table 2.3. Then using the speed ratio, calculate the
large pulley diameter (D). These pulley diameters should be rounded off to a standard
diameter by using Table 1.5.
;<Selection of centre distance (C) :
Select the centre distance, if not given, from Table 2.4.
Table 2.4. Selection of centre distance, C (from data book, page 110. 7.61)
L = 2C + (n)'2 (D-d)2
(0 + d) + - 4 C
For the calculated nominal inside length and belt section, consulting Table 2.5, select the
next standard pitch length.
INote I ./' Tile nominal pitch length is defined as the circumferential length of the belt at the pitch
width (i. e., the width at the neutral axis of the belt). The value of the pitch width remains constant for
each type of belt irrespective of the groove angle .
./' For pitch length, add with inside length, 36 mm for A belt, 43 mm for B, 56 mm for C. 79 mm
for 0 and 92 mm for E belt.
5. Selection of various modification factors:
In order to calculate the design power. the following modification factors have to be
determ ined.
Table 1.5. Nominal Inside length, nominal pitch length and length correction/actor/or standard
sizes 0/ JI-belts (from data book, page 110. 7.58, 7.59 and 7.60)
(The values for a few cases only given)
Arc of contact = 1800 - (D-d) C x 600 ... [From data book, page no. 7.68]
~ For the calculated arc of contact, select the correction factor from Table 2.6.
~ Arc of contact factor is taken into account because the power transmitted may be
limited by slipping of the belt on the smaller pulley.
Table 2.6. Arc 0/ contact/actor, Fd (from data book, page no. 7.68)
(The values/or a few cases are given below)
Correction factor (proportion of 1800 ratine)
Arc of contact on smaller
V-V V-Flat
pulley (in degrees)
V-belt on V-pulley V-belt on flat pulley
180 1.00 0.75
171 0.98 0.77
160 0.95 0.80
151 0.93 0.82
139 0.89 0.85
130 0.86 0.86
120 0.82 0.82
INote I The details of driving units and driven machines under different duties are available in the
data book, page no. 7.69.
6. Calculation of maximum power capacity :
Calculate the maximum power capacity (in kW) of a V-belt using the formulas given in
Table 2.8.
Table 2.B. (from data book, page no. 7.62)
Maximum value of
Belt cross-section
Formula 'de' in the formula
symbol
mm
where kW = Maximum power in kW at 1800 arc of contact for a belt of average length,
S = Belt speed, mis,
de = Equivalent pitch diameter = dp x Fb'
dp = Pitch diameter of the smaller pulley, mm, and
Fb = Small diameter factor to account for variation of arc of contact, from
Table 2.9.
~V.~-B~e~/u~~an~d~P~u~I~/~~~~ ~~
where A=~-n[D;dJ
B :c: ill~df, and
L ::: Nominal pitch length of the belt from Table 2.5 (refer step 4).
I ExaMple 2.2 I Design a V-belt drive to the following specifications :
Power to be transmitted = 7.5/rW .
Speed of driving wheel - 1440 r.p.m;
Speed of driven wheel := 400 r.p.m.
Diameter of driving wheel =- 300 mm
Centre distance =- 1000"""
Service =- 16 hours / day
Speed ratio
=
D
300
Nt 1440
d = N2 = 400 = 3.6
mill
C~~~)... (Given)
Referring Table 1.5, the preferred smaller pulley diameter, d = 315 mm.
.. Larger pulley diameter, D = 3.6 d = 3.6 x 3) 5 = I) 34 mm
Referring Table 1.5, the preferred larger pulley diameter, D = 1250 mm.
3. Setection of centre distance (C) :
Centre distance, C = 1000 mm
(0/
... (Given)
4. Determination of nominal pitch lengtt: :
= 2x 1000+(¥) (1250+3IS)+(I~5~~:d:)2
= 4676.85 I11Ill
For this nominal inside length and 0 section. consulting Table 2.5. the next standard pitch
length is selected as 4996 mm.
S. Selection of various modlflcotion factors :
(i) Length correction factor (F cJ : For B section. referring Table 2.5.
length correction factor, Fe -= 1.18
{ii) Correction factor for arc of contact (F ,J :
tr _
-_.-It
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For this arc of contact, consulting Table 2.6, correction factor for arc of contact is selected
as Fd=O.83.
(iii) Service factor (F J: Consulting Table 2.7, for light duty 16 hours continuous
service, for driving machines of type.Il, service factor is selected as Fa = 1.3 ..
7tdN)
where S = Belt speed = 60 = 7t x 0.3 ~~ x 1440 = 23.75 mls
7.5 x 1.3
=
5.445 x 1.18 x 0.83 = 1.828:::: 2 belts ADS."
Cactual = A + \} A 2 - B
where A = 4 L _ [D+dJ 7t 8
4996
---4
- " [ 1250 + 315 ]
8
= 634.42
{D-d)1 {1250 - 315}2
and B = 8 = 8 = 109278
I
[!xamele 2.3 A centrifugal pump running at 340 r.p.m: is to be driven by a 100 kW
motor running at 1440 r.p.m. The drive is to work for atleast 20 hours every tillY. Tile
centre distance between the motor shaft anti the pump shaft is 1200 mm. Suggest a suitable
multiple V-belt drivefor this application. Also calculate the actual belt tensions and stress
induced.
Given Data: N2 = 340 r.p.m.; P = 100 kW; N) = 1440 r.p.m.; C = 1200 mm = 1.2 m
Tofind: (i) Design a V -belt drive, and
(ii) Actual belt tensions and stress induced.
@Solution :
1. Selection of tile belt section:
Consulting Table.2.3, for power 100 kW, D section is selected.
2. Selection of pulley diameters (d and D) :
Since diameters of both pulleys are not given, therefore first select the smaller pulley
diameter from Table 2.3.
.. Consulting Table 2.3', for power 100 kW, smaller pulley diameter, d = 355 mm.
D N) 1440
Speed ratio = -d = -N2 = -340 = 4235
.
7t (1600 - 355)2
= 2x 1200 + '2 (1600+355) + 4x 1200
= 5793.83 mm
For this nominal inside length and 0 section, consulting Table 2.5, the next standard pitch
length is selected as 6124 mm.
5. Selection of various modification factors:
(i) Length correction factor: For 0 section, referring Table 2.5, length correct i '," "actor,
Fe = 1.00.
2. l.i
"-8 !,~ I" I "lit ."
~ -------- -----'-'-~
(ii) Correction factor for arc of contact (F; :
J 600 - 355)
Arc of contact = 1800 _ (D ~ d ) x 60° = 180° - ( 1200 600
= 117.75°
For 117.75°, consulting Table 2.6, correction factor for arc of contact Fd = 0.81.
(iii) Service factor (F,.):For light duty, for over 16 hours continuous service, for driving
machines of type II, consulting Table 2.7, the service factor, Fa = 1.3.
1t d NI 1t x 0.355 x 1440
where S = Belt speed = 60 = 60 = 26.76 mls
de = dp x Fb
dp = Smaller pulley diameter = 355 mm
Fb = Small diameter factor, for speed ratio of 4.235, from Table 2.9 = 1.14
506.7 )
Power, kW = ( 3.22 x 26.76-0.09 - 404.7 - 4.78x 10-4 x 26.762 26.76
= 21.44 kW
7. Determination 0/ number 0/ belts (n,) :
P x Fa
We know that nb = kW x Fe X Fd
100 X 1.3
= 21.44 X 1 X 0.81 = 7.486 ~ 8 belts Ans."
, ..
"'::-.
~
t
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Design of Transmission Systems
2.14
We know that,
power transmitted per belt =
100 x 103
... "(i)
8
From Table 2.3, mass per metre length, m = 0.596 kglm
From Table 2.2, groove angle (2(3) = 34°.
o 1t
Already found that arc of contact for smaller pulley, a. = 117.75 x 1800
= 2.055 radians
We know that the tension ratio for V -belts considering centrifugal tension,
Tl - mv'l
= ef.UX I sin P = ef.UX· cosec ~
T2-mv2
T, - 0.596 (26.76)2
= eOJ x 2.055 x cosec 17° = 8.237
T2 - 0.596 (26.76)2
or Tl - 8.237 T2 = - 3088.68 ... (ii)
( Example 2.4 IA V-belt having a lap of 180 0 has a cross-section area of 2.5 cml and
groove angle as 4S~ The density of a belt is 0.0015 kglcmJ and maximum stress is limil~d
to 400 x 1(J4 Nlml. If J.l = 0.15, find the power that can be transmitted, if the wheel has a
mean diameter of 300 mm and runs at 1000 r.p.m:
2.IS
"
1
p = 0.0015 kg I em! = 0.0015 x 1()6 kg 1m3; a = 400 x 104 N/m2; J.l = 0.15 ;
d = 300 mm = 0.3 m;N = 1000 r.p.m.
Tofind: Power transmitted (P).
1tdN
e SO/lIIion : v =
60
=
1t x 0.3 x 1000
60 = 15.71 m1s
T
We know that, Tension ratio T: = e~' cosec p = eO.IS x 7t x cosec 22.SO
= 3.426
or TI = 3.426 T2 ... (i)
Mass per unit length of belt, m = Density x Area x Length
= 0.0015 x 106 x 2.5 x 10-4 x 1
= 0.375 kg I m
... Centrifugal tension, Tc = mv2 = 0.375(15.71)2 = 92.65N
T, 907.5
From equation (i), T2 = 3.426 - 3.426 = 264.9 N
I Examp/e 2.5 I Two shafts whose centres are 1 m apart are connected by a V-belt
drive. The driving pulley is supplied with 100 k Wand has an effective diameter of 300 mfIL
It runs at 1000 r.p.m: while the driven pulley runs at 375 r.p.m: The angle of groove on the
pulleys is 40 ~ The permissible tension in 400 mm2 cross-sectional area of belt is 2.1 MP".
The dellSity of the belt is 1100 kg/ml. Taking JJ = 0.28, estimate the number of belts
nqllued. Also calculate the lengll, required of each belt.
Given Data: C = l m ; P = 100 k W = 100 x 103 W; d = 300 mm = 0.3 m ;
N. = 1000 r.p.m.; N2 = 375 r.p.m.; 2P = 40° or p = 20°; a = 400 mm2 = 400 x l~ m2:
(J = 2.1 MPa = 2.1 x 106 N/m2 ; p = 1100 kg 1m3; J.l = 0.28.
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. N2 d
Speed ratio, N I = 0
NI 1000
or D = N2 x d = 375 x OJ = 0.8 m
= 2.636 rad
T
Tension ratio, T~ = e.,.e· cosec Ii = eO.28 x 2.636 x cosec 20° = 2.158
or TI = 2.158 T2 ... (i)
L = 2 C + ~ (0 + d) + (D - d)2
2 2C
pulleys is 0.17,find
(i) Velocity of the belt for maximum power, and
(ii) Power transmitted at this velocity.
Given Data: m = 0.9 kg/m ; T = 2.2 kN = 2200 N ; 2J3 = 45° or J3= 22.5° ;
7t
e = 170° = 170° x 1800 = 2.967 rad; J.l = 0.17.
To find: (i) Velocity of the belt ("), and (ii) Power transmitted (P).
© Solution:
(i) Velocity of the belt:
Velocity of the belt for maximum power to be transmitted,
. v -
- -\j];
- fl ---~
-\j 3 x 0.9 = 28.545 mls Ans."
or ... (i)
Centrifugal tension for the maximum power,
Tc = m v2 = 0.9 (28.545)2 = 733.33 N
Maximum tension 2200
or For maximum power transmitted, Tc = 3 = -3- = 733.33 N
[Example 2.71 A compressor is driven by a 1400 r.p.m. motor by means of a flat belt
of thickness 20 mm and width 250 mm. The motor pulley is 115 mm diameter and the
compressor pulley is 1250 mm. TIle stmft centre distance is 1200 mm anti an idler is used to
make the angle of lap on tile smaller pulley 2100 and Oil larger pulley 280". Coefficient of
friction is 0.25 on tire smaller pulley and 0.3 011 tile larger pulley. The maximum allowable
rr
belt stress is 2.J Nlmml and the belt weighs 1 x I 5 Nrmm', Determine the power of tile
drive.
To eliminate idler pulley, tire smaller pulley is changed with Vsgroove pulley with
groove angle of 14". J.J = 0.1. Larger pulley and other data remaining the same, what shall
be the power transmitted?
Given Data: N) = 1400 r.p.rn.; Thickness = 20 mill; Width = 250 mm
d = 315 mm = 0.315 m; D = 1250 mm = 1.25 m C = 1200 mm = 1.2 m
7t' 7t
as = 210° = 210° x 1800 = 3.665 rad ; aL = 280° = 280° x 1800 = 4.886 rad ; ~s = 0.25 ;
III = OJ ; o = 2.1 N/mm2 = 2.1 x 106 N/m2 ; Weight density of belt = 1 x 100s Nzrnrn ' =
1 x 104 N/m3 ; 213 = 34° or 13= 17°.
©Solution:
J. Power transmitted by the flat belt drive:
Since the friction coefficients for both pulleys are different, therefore first we have to find
the pulley which governs the design. So we have to evaluate ells as and ellL al for the
pulleys.
ellS as = eO.25 x 3.665 = 2.5
. 1 x 104
Weight density = 1x 104 N/m3 or Mass density = 9.81 kg/m '
= 5.096 kg/m
Centrifugal tension, Tc = m v- = 5.096(23.09)2 = 2717.37N
r;~~~~1
~Belts ~
and Pu eys __ ---------:- ---.:.2~19
---...
= 10500-2717.37 = 7782.63 N
= 7782.63 = 3 113 N
Slack side tension, T2 = 2.5
Power transmitted, P = (T 1 - T 2) v
n n
and <lL = (1800 + 2(1) 1800 = (1800 + 2 x 22.930) 1800 = 3.94 rad
Again we have to calculate the tension ratios for both pulleys to find the governing pulley.
TI)
( T2 _ ell as . cosec 11 = eO.) x 2.)4 x cosec 17° = 11.03
S -
1
and (T .) = el1QL = eO.3 x).94 = 3.26
T2 L
TI 7782.63
Slack side tension, T2 = 3.26 =
3.26 = 2386.6 N
Power transmitted, P = (T1 - T2) v
t2.10.1. Introduction
Ribbed V-belts is a cable cord reinforced
transmission belt with 'V' shaped ribs along the
circumference of the belt, as shown in Fig.2.3. It is
flexible, with high power capacity per unit width and
is designed on completely integrated construction.
The ribbed surface provides maximum area of contact
and reduced face pressure. Fig. 2.3. Ribbed V-belt
The ribbed V-belt is gaining wide acceptance in the automotive field due to the
advantages it exhibits over conventional V-belts. These belts are particularly good for high
speed and I or high ratio applications which conventional belts are unable to handle. The
smooth, vibration free performance and excellent reverse bend characteristics of this belt
enable the design of single belt, compact drive systems.
2.10.2. Applications
Ribbed V-belts have been selected for use on many applications. These applications range
from iil:: single multi-rib accessory drive concept (SMAC) for passenger cars to water pump,
alten\ator, and air conditioning drives on heavy trucks.
\.
2.10.3. Special Features of Ribbed V-8elts
./ Highly flexible and can be used with smaller pulley diameter resulting in lighter
and compact drive .
./ Higher power rating per unit width compared to conventional belt - 40% higher.
./ Almost eliminates the slippage due to maximum wedge contact on the pulleys .
./ Being thinner, the rear side can be used to drive additional accessories I idlers
without affecting belt life.
./ Gives noise-free power transmission in every application .
./ Eliminates the necessity to use multiple I matched set of belts .
./ Can be used at higher speed more than 40 m/sec .
./ Give lesser wear and longer life to the pulleys due to lesser static tension and belt
slippage.
'" Reduces down time and hence belt replacement cost.
~V~-B~p~/~~~a~"~~~P~u~/I~~~'~~
-----------------------------------------------~
a belt. The "J" section belt has a smaller rib than the "K" belt and the overall thickness of the
"J" is less than the "K". Refer Table 2.10.
PH Type PJ Type PK Type
(d) (e)
The polyester tension cords are embedded into the belt to achieve longitudinal stability.
Then crosswise fibres are incorporated into the polychloroprene substructure for unsurpassed
transverse bending strength, finally the belts are ensured for maximum resistance to
temperature fluctuations and ozone.
Table 2. J O.Dimensions of various ribbed V-belts
REVIEW QUESTIONS
1. What are the advantages and disadvantages of V-belt drive when compared with flat belt
drive?
2. Why slip is less in the case of V-belts when compared with flat belts ?
3. Why V-belts are preferred than flat belts?
6. What are the materials used for sheaves (or V-grooved pulleys)?
7. Write an engineering brief about (a) Ribbed V-belts, and (b) Timing belts.
- Francis Baro"
3.1. INTRODUCTION
Wire ropes are used whenever large power is to be transmitted over long distances (upto
150 m). The wire ropes are extensively used in elevators, oil II drilling, mine hoists,
cranes, hauling devices, conveyors, tramways, suspension s and other material
handling equipments. Wire ropes are preferred than and man-made fibre
ropes because of its greater strength and reliabil
~._.----.
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Steel wire ropes are manufactured by special machines. In the process of manufacture the
wire rope is subjected to special heat treatment, which combined with cold drawing, gives
high mechanical properties to the wire.
The wire ropes are specified (or designated) by the number of strands and the number of
wires in each strand. For example, a 6 x 7 rope means a rope made from six strands with
seven wires in each strand. Refer Fig.3.t.
The wire rope is selected based on its application. The Table 3.1 shows the standard
designation of wire ropes and their applications.
Table 3.1. Selection of wire rope
Standard designation Application
6 x 7 rope Used as haulage and guy rope in mines, tramways and power transmission.
6" 19 rope Used a hoisting ropes in rmnes. quarries. cranes. derricks. dredges.
elevators, tramways. well drilling, etc.
6x37rope Used as an extra flexible hoisting rope in steel mill laddies, cranes. high
speed elevators.
8 x 19 rope Used as an extra flexible hoisting rope.
mtd
~~~~~-----~---------------------------------------------.
Wire RnIW..' Pfllleys l)
. W+W,
.. Direct dress, CJd = ... (ll)
A
2. Bending stress wilen the rope passes over the sheave or drum (ut) :
We know that when a wire rope is wound over the sheave, then the bending stresses are
induced. The bending stress induced is directly proportional to the wire diameter and
inversely proportional to the diameter of the sheave.
. E, x dw
Bending stress, CJb = D ... (3.2)
... (3.3)
where a = Acceleration of rope and load during hoisting (not at starting or stopping)
V2 -VI
= I ; (v2 - vI) is the change in speed in 'I' seconds.
3.4
Design of Transmission Systems
/iij When there is slack in the rope beta .
I' :/1 re starlmg or I . h h .
considerable impact load on the rope. s opping, t en t ere will be a
.. «, = W+W, [
1 + 2'a ·h·E ]
A 1+ S r
... (3.5)
ad·j·g
where as = Acceleration during starting or stopping,
h = Slack during starting, and
j =
Length of the rope.
5. Effective stress:
(i) Effective stress in the rope during normal working,
aen = ad + 0b ... (3.6)
(ii) Effective stress in the rope during starting,
°est = ast + 0b ... (3.7)
(iii) Effective stress in the rope during acceleration
, of the load ,
.,. (3.8)
The greatest of the stresses mentioned above should be less than the ultimate strength of
the wire material divided by factor of safety.
Table 3.2. Recommended factor of safety for wire ropes, n' (from data book, page no. 9.1)
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Ttlb/~ 3.3. (D".;,/d) as a/unction o/tlle number of bends (from data book, page no. 9./)
No. of
I 2 3 4 5 6 7 8 9 10 I1 12 13 14 IS
-
16
bends
Dmi,/d 16 20 23 25 26.5 28 30 31 32 33 34 35 36 37 37.S 38
-
I!------------------------------------ o~D~e~si~gn~oJ~T.~r~an~s~m~~~s~iO~n~S~ys~te~m~s~o
~H~~~n~R~~~.~~Qn~d~P~u/~/e~y~~ ~
1 + 2'a .s .« r ]
Starting load W" = CJ" xA = (W + W,) [ I + (Jd·l·g
S
... (3.10)
INote I Generally effective load during starting (W cst) is not used for calculating the working factor
of safety. It is used to calculate the induced stress.
I Example 3.1 I Design a wire rope for an elevator in a building 60 metres high and/or
a total load of 20 kN. The speed of the elevator is 4 m/sec and the full speed is reached in
10 seconds.
Given Data: Height = 60 m; W = 20 kN = 20 x 103 N ; v = 4 m/sec = 240 mlmin;
t=lOsec.
Tofind: Design a wire rope.
e Solution:
1. Selection of suitable wire rope: Given that the wire rope is used for an elevator, i.e..
for hoisting purpose. So lets use 6 x 19 rope (refer Table 3.1).
-
3.8
Design o/Transmission Systems
2 Calculatiolt of design load: Assuming a larger facto f f f . .
.
calculated. rosa ety 0 15, the design load IS
Since the given lifting speed is 240 mlmin (= 4 m/s), therefore Dm;,/d ratio should be
modified. Thus for every additional speed of 50 mlmin, Dm;,/d ratio has to be increased by
8%.
Dmin
Modified d = 27 X (1.08)5-1 = 36.73 say 40. [ ... 240 - 5
50 .... J
The sheave diameter, D= 40 x d = 40 x 25 = 1000 mm
5. Selection of tire area of useful cross-section 0/ the rope (A): From Table 3.6, for
6 x 19 rope,
A = 0.4 d2 = 0.4 (25)2 = 2S0 mm2
d
Wire diameter, dw == 1.5 {i
E,·dw
(ii) Bending load, W b = Clb x A. =' D x A
5
= 0.84 x 10 x 1.56 x 250 = 32760 N
1000
[Take E, = 0.84 x lOs N / mm21
'jii)
, Acceleration load, Wa = (w:w,) a
v2 - vI 4-0
where a = Acceleration of the load = t ---
- 10
I
= 0.4 m/s2
= 21416+32760 = 54176N
(ii) Effective k:.ld Juring acceleratio.. of the load, Wea = W d + W b + Wa
Work ing factor of safety = Breaking load from Table 3.4 for the selected ru~
, . Effective load during acceleration (Wea)
:I '(' • •
340000 .
.. • :
'.
. ."
..
. •
= 55049.23
'" c
= 6.176
: ..• •• 0. ". .'. .f".
~ : . (,. Q ...
11. 'Check for' safe de~ii:it t . F(O,m·1:ahle 3.2; for hoists and class ~, .the rt!commend.ed
factor'ofsafety = 6. . ." '. '.. . . .
Since the working factor of safety is greater than the 'recommended' factor of :iafety·
therefore the design is safe.
~ ---------------------------- ~D~~~i~gn~o~if~n~ra~m~m~·~~s~w~
~ele 3.~ 1 Fo~ t~~ data of Example 3.1, determine the stress induced in the rope
due '0t Slarling with an initia! slack of rope of 0. 2 m. • .
Given Data: h = 0.2 m.
T'O find: Stress induced in the rope due to starting.
@So!ulion: We know that the load dueto starting when there is a slack of 0.2 m on the
rope,
1 +. 2·a s ·h·E r J
ad·/·g
W = 20000 N; Wr = 1416 N; E, = 0.84 x 105 N/mm2 = 0.84 x 1011N/m2 ;
Wd 21416
Wb = 32760 N; ad = A = 250 = 85.66 N/mm2 = 85.66 x 106 N/m2 ;
West _ 56862 _ 2
.. Stress induced = A - 250 - 227.45 N/mm Ans. ~
I Examp/e 3.3 I· Select a wire rope for a vertical mine hoist to lift 1500 tons of ore in 8
hours shift from a depth of 900 m: Assume a two-compartment shaft with the hoisting skips
in balance. Use a maximum velocity of 12 m/sec with acceleration and deceleration period
'0/15 sec each and a rest period of 10 sec for discharging and loading the skips. A hoisting
skip weighs approximately 0.6 of the capacity. Take E, = 0.84 x lOS Nlmm2.
Given Data: Weight to be lifted= 1500 tons = 1500 x 103 kg = 1500 x 103 x 9.81 =
14715 kN; Depth = 900 m; E, = 0.84 x 105 N/mm2 = 0.84 x 1011 N/m2; v = 12 mls =
720 m/min.
Tofind: Select a wire rope.
@ Solution: Let us first find the total load to be lifted (W).
v2 - VI 12 - 0
Acceleration, as = I = 15 = 0.8 m/s2
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________ --.-------:..:3.11
Total = 85 sec
~ -------------------- ~D~~~~~n~o~if~n~ra~m~m~U~Si~o
dw d 48
= _r = --;:::.====- = 3mm
I.S V ; 1.5 ~ 6 x 19
t. Weight of the rope (W,): Refer Table 3.4.
Since the value of working factor of safety. is greater than the recommended factor of
safety,therefore the design is safe.
0.006 \
\
1 0.004
[\
-;
~ ~
.9:
0.002
I~ ~ 6 x 37_
~ r-6 x 19
o 5 s
2x10 4x10 6x105 8x10S 106
Fig. 3.3.
The fatigue diagram is plotted on cartesian co-ordinates, in which the number of bends is
taken as abscissa and a dimensionless quantity (pIau) as ordinate. The figure indicates that
the 6 x 19 rope has long (i.e., infinite) life if the value of ratio p/O'uis less than 0.0012.
I Example 3.4 I A 6 x 19 wire rope withfibre ~ore and tensile designation 1420 is used
I to raise a load. TI,e nominal diameter of the wire rope and the sheave diameter are 10 and
4S0 mm respectively. Assuming long life on the basis. of fatigue consideration, determine
the maximum load that the wire rope can carry. _
Given Data: 6 x 19 wire rope; au = 1420 N/mm2; d = 10 mm ; D = 450 mm.
Tofind: Maximum load that the wire rope can carry.
© Solution: Tensile designation 1420 means au = 1420 N/mm2.
_'"•
We know that the 6 x 19 wire hope has long life when piau = 0.0012 .
. , Contact pressure between the rope and drum, p = 0.0012 x au
or T = II kN
We know that the contact pressure between
the rope and the sheave,
2T
P = dD
2 x 11000
= IOx550
= 4 N/mm2
4
piau = 1750
= 0.00228 Fig. 3.4.
· 3 3 the life of the wire rope is obtained as 2.8 x 105 bends
From the fatigue diagram, F Ig..,. ,
before failure;
2.8 x lOS
= 5bO weeks'
.. Life = 500
2.8 x 105 = 10.77 years Ans.~
or = 500 x 52
3.15 1,
Wire Ropes and Pulleys
!
,. b .1
'I
e
t _j ..r:::
r2
3.16
Design o/Transmission Systems
wireTherefore,
rope first. in order to design a sheave for wire rope, one should find the diameter of the
Whenever more than one wire rope is used, one has to use rope drums to enable the rope
to be wound in several layers. The drum diameter is selected in the same manner as the
selection of diameter of sheaves. Drums for steel wire ropes are made of cast iron, more
rarely of steel castings or weldments.
With a power drive, the drum should always be provided with helical grooves so that the
rope winds up uniformly and is less subject to wear. The radius of the helical grooves should
be selected so as to prevent jamming of the rope. The standard and deep grooved drums for
wire ropes are shown in Fig.3.6. Table 3.8 gives the dimensions of standard and deep grooves
for drums.
Fig. 3.6.
. . D'tmensto. ns of d.rum groovesfor wireropes, mm (from data book,page no. 9.9)
t.able 38
Standard Groove Deep Groove
Ropedia, d
4.8
8.7
'.
3.5
S)
7
C)
2
'2
5.5
8.0
S2
9
C2
4.5
5 II 3 13 6.5
13 8 15 4 11.0 19 9.5
19.5 11.5 22 5 15.5 27 13.5
28 15.5 31 8 20.5 36 18.0
..._ 39 21 42 12 28.0 50 24.5
CExample3.6 I A 6 x 19 stee w
. rope IS. use d for tile elevator in the building. The
Ire I
if200 m/min. The weight of the elevator cage
. •
Hlelghtis being lifted with a maxi 'mum speed
• N. '7'1. tlfting sheaves are of the trac tiIon .J.
0 t1J'Pe•
. gers IS 8 k . tne
ts 12 kN and the weight of passen, k factor of safety as 10.
Design a suitable wire rope sheave. Ta e . . W = 12 kN; W"""nge< = 8 kN ;
Given Data: 6 x 19 wire rope ; v = 200 rn/min , elevator
FS::::: 10.
@Solution :
Calculation 0/ rope diameter (d) : We know that, in order to design a wire rope sheave,
first one should find the diameter of rope.
Total load to be lifted = Weight of the elevator cage + Weight of passengers
= 12 kN + 8 kN = 20 kN
Design load = Total load to be lifted x Factor of safety
= 20 kN x 10 = 200 kN
Taking the design load as the breaking strength, consulting Table 3.4, the diameter of the
rope is selected as 25 mm.
:. d = 25 mm for au = 1100 to 1250 N/mm2 and breaking strength = 230 kN.
Design 0/ wire rope sheave: The cross-section of standard sheave groove for steel wire
rope is shown in Fig.3.5. (refer data book, page no. 9.10).
Knowing the diameter of rope and consulting Table 3.7, the proportions of sheave grooves
are given below.
a = 65 rnrn ; b = 50 mm; c = 10 mm ; e = 1.5 mm ;
h = 37.5 mm; I = 18 mm ; r = 14.5 mm ;
r2 = 5 mm ; r3 = 20 mm ; r4 = 15 mm.
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Since the given rope speed is 600 mlmin ti.e., 6 0 0= 12 times 50 m/min). Therefore.
5 0
_ / d ratio has to be modified.
D",m
Dmin
= 27 x (1.08)12 - I = 62.95 say 65
d
Drum diameter, D = 65 d = 65 x 38 = 2470 mm Ans. ~
Various dimensions of drum grooves: The standard drum groove for the wire rope is
shown in Fig.3.6(a). (refer data book, page no. 9.9). Knowing the diameter of rope and
consulting Table 3.8, the various dimensions of drum grooves are given below.
rl = 21 mm; SI = 42 mm and C1 = 12 mm Ans."
~
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3.19
~w.~/~re~R~o~p~e~s~an~d~P~u~/~/e~ys~
------------------------------------~--
REVIEW QUESTIONS
1. What are the applications of wire ropes?
2. What are the advantages of a wire rope when compared with chains and fibre ropes?
3. How can you specify a wire rope? What do you understand by 6 x 17 construction in
wire ropes?
4. Give the application of the following wire ropes:
(a) 6x7rope; (b) 6x 19 rope, and (c) 6x37rope.
5. Distinguish regular-lay and lang-lay ropes.
6. Explain the various stresses induced in the wire ropes.
7. How can you select a wire rope sheave or drum for the given wire rope?
1-~.20~------------------------ ~D~e~~I~gn~of~~~a~m~m~U~Ji~On~Sy
7. A 6 x 19 wire rope with fibre Core and tensile designation of 1570 is used to raise the
load of20 kN as shown in Fig.3.5. The nominal diameter of the wire rope is 12 mm and
the sheave has 500 mm pitch diameter. Determine the expected life of the rope assuming
506 bends per week. [Ans: 12.5 years]
8. A 6 x 19 wire rope with fibre core and tensile designation 1600 (i.e., au = 1600 N/mm2)
is used to raise the load. The nominal diameter of the wire rope and the sheave diameter
are 12 mm and 540 mm respectively. Assuming infinite life (i.e., pIau = 0.0012) on the
basis of fatigue consideration, determine the maximum load that the wire rope can carry.
[Ans : 6220.8 N]
Problems on design of wire rope sheaves and drums :
9. A 6 x 19 steel wire rope is used in a hoist to lift the ore in a copper mine. The weight of
the car and cage is 25 kN. The maximum rope speed is 10 m/s. Design a suitable wire
rope sheave.
10. A four 6 x 19 steel wire rope of diameter 28 mm is used in a crane. The maximum rope
speed is 8 mls. Calculate the drum diameter and various dimensions of drum grooves for
wire ropes.
Chain Drives
"My grandfather once told me that there were two kinds oJpeOple:
those who do the work and those who take the credit. He told me to try to be in the first grOUp;
there was much less competition. "
-Indira GtuuIIU
4.1. INTRODUCTION
The chain drive is intermediate between belt and gear drives. It has the major advantages
of both belt and gear drives. Chain drives are used for velocity ratios less than 10 with chain
velocities upto 25 mls and power ratings upto 125 kW. Chain drives are popularly used in the
transportation industry such as bicycles, motor cycles and automobile vehicles. They also
find wide applications in agricultural machinery, metal and wood working machines, textile
machinery, building construction and materials handling machinery.
Advantages:
./ They can be used for long as well as short centre distances .
./ They are more compact than belt or gear drives .
./ There is no slip between chain and sprocket. So they provide positive drive .
./ One chain can be arranged to drive several sprockets .
./ Higher efficiency (upto 98%) of the drive .
./ They transmit more power than belt drives .
./ Smaller load on the shafts than in belt drives .
./ They can be operated under adverse temperature and atmospheric conditions.
Disadvantages :
./ They require precise alignment of shafts than the belt drives .
./ They require proper maintenance (particularly lubrication) and slack adjustment
compared with belt drives .
./ Noisy operation .
./ They require the take-up devices (to compensate the increase in chain pitch due to
wear of chain joints). .
More complicated design. I
~ __---~~----------------------------~D~~~~~n~Of[TI~r~a~m~m~~~s~;o~n~s~~s~
I LINK CHAINS I
4.4. LINK CHAINS
Link chains, also known as welded load chains, are widely used
./ In low capacity hoisting machines such as hoists, winches and hand operated
cranes as the main lifting appliances .
./ As slings for suspending the load from the hook or other device.
Pitchedchain .
. (6) Calibrated chalns : When the permissible deviations is within i 0.1 d of the nominal
Slze in pitch and outside width, then the chain is known as calibrated chain.
r~~~
Q1ain Drives
------ 4.3
--..
o
(8)
o (b) (c) (d)
SC~h~a~;n~D~r~N~~=- ---------------------------~
.
the inner plates are called roller link. Th e 0th er parts of a roller chain are d i bushing Irwj
fi pin,
roller. Pins are press fitted into the outer plates whereas bus/res ar~ pre.ss Itte into ~heinllt:
plates. The pin and the bush form a swivel joint and the outer !mk IS free to sWivel wi~
respect to the inner link. The chain rollers mounted on the bushings roll over the sprOcket
teeth.
Pitch. P
Fig. 4.5.
From the trigonometry of the figure, Fig. 4.6. Engagement of a chain and sprocket
. a n/2
sin - = ~
2 D/2
= P p
= [ .,'a = 3~0 ]
or
D sin (~) SIO. (180)
-
z
'" (4.3)
INote I The angle aI2, through which the link swings as it enters sprocket, is called the angle of
articulation.
Transmission (or velocity) ratio of chain drive (i) :
Let N 1 and N2 = Speeds of rotation of driving and driven sprockets respectively, and
zi and z2 = .Number of teeth on driving and driven sprockets respectively.
N) z2
Transmission ratio, i = N-
2
=;- 1 ... (4.4)
Pitch dituneters of sprockets:
Let d) and d2 = Diameters of driving and driven sprockets respectively.
Then, the equation (3.2) can be' rewritten as
p
Diameter of driving sprocket, d1 = sin (1801 z)
... (4.5)
p
and Diameter of driven sprocket, d2 = ... (4.6)
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--------------------------
-
L~lIgth of th« chaill (L) : . (or pitches).
. f the number of tanks
The length of the chain is always expressed In terms 0 ••. (4.8)
. L = Ip xp
where L = Length of the chain in mm, and .
I = Number of links (or pitches) in the cham.
p
N"",ber of lillo in th« chain (I,) :
. . . h hai be determined by using the
The approximate number of links (or pitches) m t e c am can
following formula.
The centre to centre distance between the axes of the two sprockets corrected to an even
number of links can be determined by using the following relationship.
__ e+..Je2-SM
Centre distance, a - 4 xp [from d ata b ook, page no. 7.75] ... (4.10)
where e =
M = (Z2 2: 1
z
r' a constant.
on ~:ctual Pkractiche~
a small amount of sag is essential for the links to take the best position
sproc et w eel. Therefore in 0 d t
should be decreased b th r er 0 accommodate the initial sag, centre distance
y e amount fla.
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-~-----~l--- ~ ---------j--------_.
, Pitch
circle r
c
t r
-----L --1
(a) (b)
7t 0 N cos ( i) 7t DN
... (4.12)
60 and Vmax = 60
Because of chordal action, a chain drive is analogous to a belt drive running with a prism.
~ In order to reduce the variation in c/,ain speed, the number of teeth on the
sprocket should be increased.
[!Vote) It is better to use an odd number of teeth (such as 17, 19 or 21) for the driving sprocket.
The odd number of teeth of the sprocket, in combination with an even number of chain links, facilitates
moreuniform wear.
Table 4.2. Transmission rallo, I (from dala book, page no. 7.74)
Recommended value of l2: z2max = 100 to 120 ... [from data book, page no. 7.74]
Now check whether the calculated z2 is less than the recommended z2 max' Because, when
z2 is large, the stretched chain may slip off the sprocket for a small pull.
4. Selection of standard pilch (P) :
Knowing (or assuming) the initial centre distance (a), detennine the range of chain pitch
by using the relation
21 1800
2400 2100
27 1500
2100 1800
35 1300
1800 1600
45 1200
s. Selection of the chain • .. 1600 1400 1000
Select the chain type and hal
-
.. c am number, by using the selected
Table 4.5. Initially assume simplex or d I hai standard pitch, from
up ex cam.
Table 4.5. (from data book, page nos. 7.71, 7.72 and 7. 73.
This table gives some detailsfor afew c/.alns.)
~
I
I
Designation between
diameter, area, A load, Q (average)
ISO No. No. mm
d"mm inner plates,
mm2 newton m,kg/m
b,mm
088-1 Rl278 12.7 8.51 50 18200 0.70 8.00
088-2 DR1278 12.7 8.51 100 31800 1.32 8.00
088-3 TR1278 12.7 8.51 150 45400 1.95 8.00
lOA-I R50 15.875 10.16 70 22200 1.01 9.55
IOA-2 DR50 15.875 10.16 140 44400 1.78 9.55
IOA-3 TR50 15.875 10.16 210 66600 3.02 9.55
12A-1 R60 19.05 11.9 105 32000 1.47 11.90
12A-2 DR60 19.05 11.9 210 63600 2.90 11.90
12A-3 TR60 19.05 11.9 315 95400 4.28 11.90
p.. = k- W· a
... (4.17)
k 6 4 2 I
Table 4.8. Factor lor distance regulation, k 1(from data book, page no. 7. 76)
Table 4.9. Factor lor centre distance 0/ sprockets, k J (from data book, page no. 7.76)
Ip 1.25
> I or Dp < 2Sp
zi + z2
Ip 1.0
.. I.S or Dp = (30 to 50)p
%. +Z2
Ie ~ 2.0 or Dp "'" (60 to 80)p 0.8
zi +z2
.
_ Length of chain in multiples of pitches (number of links)
z +z [(Z2-ZI)/27t]2
I 2 + [to be corrected to a greater even be J
== 2 op + 2 op Dum r
Types of lubrication kS
Continuous (oil bath or forced lubrication) 0.8
Periodic 1.5
Factor of safety = Breaking load ~:~:~~ from Table 4.5 - P';Xk. ... (4.20)
10.Check/or/actor ofsafety:
Compare the working factor of safety with the recommended minimum value of factor of
safetygiven in Table 4.13.
~C~M~i!n~Dr~~~ ~~
Tab/~ 4.13. Factor of safety, n '(from data book, page no. 7. 77)
-
Pitch Speed of smaller sprocket, rpm
-
p.lDm
9.525
upto 50 200 400 600 800 1000 1200 1600 2000 2400
-
2800
12.7 7.0 7.8 8.55 9.35 10.2 11.0 11.7 13.2 14.8 16.3 18.0
15.875
If the working factor of safety (FSw) is greater than the recommended minimum value of
factor of safety (n'), then the design is safe and satisfactory.
If the working factor of safety is not satisfactory, one more chain may be added (i.e.,
simplex to duplex or duplex to triplex) to the existing one or the chain pitch may be
increased.
11. Check/or the bearing stress in the roller:
./ Calculate the bearing stress in the roller using the formula
o = Tangentialload = P, x ks
Bearing area A ... (4.21)
Table 4.14. AUowable bearing stress, Ia/, Nlmm2 (from data book, page no. 7.77)
(Z2 -;1 )2
Ip = 2Qp +
[ ZI +2 Z2 ] +
2
[from data book, page no. 7.75]
Qp
4.14
Design o/Transmisslon Systems
./ Correct the calculated number of links (/ ) into
p an even number .
./ Now calculate the actual length (L) of chain using the formula
L = / x p
p [from data book, page no. 7.75]
1J. Calculation of exact centre distance:
where
and M = (Z22~ZI r =
Decrement in centre distance for an initial sag, Sa
constant
=
[from data book, page no. 7.75)
0.01 a
Exact centre distance = Q- 0.01 a = 0.99 Q
I Example 4.1 I A truckequipped with a 9.5 kW engine uses a roller chain as theflnal
drive to the rear axle. The driving sprocket runs at 900 r.p.m: and the driven sprocket at
400 r.p.m. with a centre distance of approximately 600 mm. Select the roller chain.
GivenData: N = 9.5 kW; N) = 900 r.p.m.; N2 = 400 r.p.m.; Qo = 600 mm.
TOflnd: Select (i.e., design) the roller chain.
@Solution :
1.Determination of the transmission ratio (i) :
.. .. N) 900
Transmission ratio, , = N2 = 400 = 2.25
(Since the transmission ratio can be calculated from the given data, therefore we need not
to COnsultTable 4.2)
a 600
and Minimum pitch, Pmin = 50
--50
= 12mm
Any standard pitch between 12 mm and 20 mm can be chosen. But to get a quicker
solution, it is always preferred to take the standard pitch closer to Pmax' Refer Table 4.4.
... Standard pitch, p = 15.875 mm is chosen .
S. Selection 0/ the chain:
Assume the chain to be duplex. Consulting Table 4.5, the selected chain number is
10.40-2/ DRSO.
6. Calculation 0/ total load on the driving side 0/ the chain (P r) :
(i) Tangential force (P; :
t020N
P, - v
where N = Transmittedpower in kW = 9.5 kW
v = Chain velocity in m/s
_ z. xpxNI _ 27 x 15.875 x 900
- 6.43 m/s
60 x 1000 - 60 x 1000
1020 N 1020 x 9.5
PI = v - 6.43 = 1507 N
(Ii) Centrifugal tension (PJ :
Pc - mvl
From Table 4.5, m -
...
1.78 kglm
Pc - 1.78 (6.43)2 = 73.59 N
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~-----------------------------------------------~
. on f.bIe 4.14. for II1\.IIIer .pmc:kd speed of 900 r.p.m. and picdl 1 S.175 nun. lilt
al belting .uesl is 22.4 Nlmml. Theftfore !he induced smss is less than lilt
• ...t* bearing.-o· Thus till Msip ,. RIf, -'"' 1IJIis/adtH7.
t1/ I~"gt" of cl"u"
U..CIk_lIIllMf (L) :
%, +~) ( (%2 - :,) / 2" J2
Number of links, Ip = 2 Qp + ( .2 + Qp
I
p
= 2 (37 <795)
.' < +
( 27 + 61)
2
. (61
+
- 27) I 2Jt
37.795
J2 ::I: 120.36
We know that Q = e+ y e4 2
- 8M x P
ZI+Z2) (27+61) 78
e = Ip - ( 2 = 122 - 2 -
M = (Z2-ZI)2 = (61-27)2 _
and 27t 2n - 29.28
78 +y 782 - 8 x 29.28
Q = 4
x 15.875 = 613.11 mm
Larger sprocket:
Pcd of larger sprocket, d 2 = P =----15.875
sin (180 / z2) sin (180 / 61)
= 308.38 mm
and Sprocket outside diameter, d02 - d2 + 0.8 d,
- 308.38 + 0.8 x 10.16 = 316.51 mm
[Example 4.21 The transporter of a heat treatment furnace is driven by a 4.5 kW,
1440r.p.m. induction motor through a chain drive with a speed reduction ratio of 2.4. The
transmission is horizontal wlth bath type of lubrication. Rating is continuous with 3 sid/is
per day. Design the complete chain drive.
Given Data: N = 4.5 kW; Nt == 1440 r.p.m.; i = 2.4.
Tofind: Design the chain drive.
@Solution:
N) 1440
1. Transmission ratio, i = 2.4 (Given) :. N2 = i = 2.4 = 600 r.p.m.
4.: Standard pitel, (p): Since the centre distance is not given, we have to assume the
initial centre distance, say a = 500 mm.
We know that a = (30 - 50) P
... Pmax =
a
30
500
--
30
- 16.6 mm
a 500
and Pmin - -
50
--50
=lOmm
From Table 4.4, in between 10 and 16.6 mm, a standard pitch, p = 15.875 mm is chosen.
5. Selection 0/ cl,ain : Assume the chain to be simplex.
From Table 4.5, the JOA-J / R50 chain number is chosen.
6. Calculation of total load on the driving side (P r) :
PT - PI + P, + P,
(i) 1020N
PI - v
Where N - Transmitted power in kW = 4.5 kW (Given)
~C~ha~i~n~D~rr~v~~
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~~
From Table 4.13, for smaller sprocket speed 1440 r.p.m. and pitch 15.875 mm, the
recommended minimum value of factor of safety (n') is 13.2. Since the working factor of
safety is greater than the recommended minimum value of factor of safety, therefore the
design is safe and satisfactory.
f/fI' ..
10. Bearing stress in the roller: From Table 4.5, A = 70 mm2
P, x ks = 446.19 x 1.5 = 9.56 N/mm2
0' = A 70
-
4.20
pm
allowable bearing stress is 18.5 N/mm2 Since the' d r · · . an.d pitch 15.875 mm, the
. m uce d stress IS I th
bearing stress, the design is safe and satisfactory. ess an the allowable
where a = ao 500
p p = 15.875 = 31.496
Ip = 2 (31.496) + (27 + 65) [ (65 - 27) 1 2n J2
2 + 31.496
= 110.153 ~ 112 (rounded off to an even number)
Actual length of chain, L = Ip xp = 112 x 15.875 = 1778 mm
a = xp
r
where
a =
66 + V 662 4- 8 x 36.57 x 15.875 = 514.92 mm
-~~--------------------------------~~
eMi" I!!:!"es
::::;;---
'Example 4.3 I A compressor is to be actuated/rom aID kW electric motor. The ".o~o,
skatis 970 r.p.m: and that o/the compressor is to be JJO r.p.m. The compress~r opertll'''1
in two shifts. The minimum centre distance should be 1000 mm: Design a suuable chili"
drive.
Given Data: N = 10 kW; N. = 970 r.p.m.; N2 = 330 r.p.m.; ao = 1000 mm.
a 1000
and P",in = 50 = So = 20 mm
It can be seen that, in Table 4.4, there is no standard pitch in between 20 mm and
33.33 mm. Therefore we cannot proceed further.
Now take a = (60 to 80)p (refer Table 4.9)
1000
.. Pmar = 60
a
--60
= 16.66 mm
1000
and p""" =
-a --- = 12.5 mm
80 80
Any standard pitch between 12.5 mm and 16.66 mm can be chosen. Therefore, from Table
4.4, the standard pitch (closer to Pmar) is selected as 15.875 mm.
5. Other design par~ten: Knowing the standard pitch, the chain selection, total load
calculation, service factor selection, design load calculation, check for factor of safety, check
for bearing stress in the roller, actual length and centre distance calculations, and sprocket
diameters calculations can be proceeded as discussed in the previous examples.
[ EXllmfJle 4.4 IA bucket elevator is to be driven by a gear motor and a roller chaill
drive. Gear motor power = 7.5 kW: Speed 0/ gear motor = 1400 r.p.m.; Transmission ratio
-10: I; AssulM a minimum centre distance belween sprockets = 550 mill. Sekct a suiJoblt
cltaht.
Glvell Data: N = 7 5 k~; N = 1400 r.p.n.. ; i = 10 . .I•. -= 550 !nfT'.
3. Other design parameters: Now proceed the problem as discussed in Examples 4. I and
4.2, to find the other design parameters such as standard pitch, chain type, design load,
workingfactor of safety, induced stress in the roller, actual chain length, exact centre distance
and sprocket diameters.
(d)
(a) (b) (c)
Flg.4.8.
F . d in design practice. They are :
OUrstyles·of sprockets are standardize . . 8( )
. nsions as shown In Fig.d. a.
~ Style A is a flat plate with no hub exte ,
~C~'h~a/~'n~D!!_r~iv~!S:!_ ~
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--:- 4.23
./ Style B has a hub extension on one side of the plate (flange), as shoWn ill
Fig.4.8(b) .
./ Style C has hub extensions on both sides of the flange, as shown in.Fig.4.8(c) .
./ Style D has a detachable hub, as shown in Fig.4.8(d). The style D hub is normally
attached to the flange with bolts.
The five important sprocket diameters are pitch, outside, bottom, caJiper and maximum
hub diameters, as shown in Fig.4.9.
.. '.
Caliper
diameter
Max hub
diameter
I I~ Bottom diameter -
(iv) Caliper diameter = Pitch diameter x cos (:0) _ Roller outside diameter
-
4.24
Design a/Transmission Systems
Fig. 4.10.
Table 4.15. Proportions of the sprocket wheel (refer Figs.4.10(a) and (b))
(lm;n = [ 140 -7
090 ]
ha
0.8p
11. Tooth height above the pitch polygon (ha )max = 0.625 p - 0.5 d; + z
12. rx (rx)m;n p
Tooth side radius
bj1 bj1 0.93 bl ifp S 12.7 mm
13. Tooth width
bj1 = 0.95 bl if p > 12.7 mm
ba ba 0.1 p to 0.15p
.__ 14. Tooth side relief
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Therefore, knowing the chain pitch (P) and the chain type, we can determine the various
dimensions of the sprocket wheel using the relations given in Table 4.15.
INote I Instead of using the relations, the various dimensions of the sprocket wheel can be straight
away selected from the data book. So refer data book, page no. 7.79 and 7.80.
I Example 4.5 IAssumethe dtda of Example 4.2, and calculate the following
dimensions of the driving sprocket wheel: (i) outer diameter; (ii) roller sealing radius;
(iii) root diluneter; (iv) tooth flank radius; (v) tooth side radius; (vi) tooth width; and
(vii) tooth side relief.
,Given Data: From the Example 4.2,
pitch, p = 15.875 mm; chain type = simplex and lOA - I/R50;
Number of teeth on the driving sprocket, zi = 27.
15.875
= = 136.74 mm
. (180)
SID 27
From Table 4.5, Roller diameter, d, = 10.16mm
and Width between inner plates, bl = 9.SS mm
(i) OUler diameter of driving sprocket (DoJ :
From Table 4.1 S, Do = D + 0.8 d,
= 136.74 + 0.8 x 10.16 = 144.86 mm ADI.'"
{ii) Roller setl/ing radius (rJ :
--
4.26
4.24. CONSTRUCTION
Silent chains consist of toothed link plates that are pin-connected to permit articulation, as
shown in Fig.4. J 1. The link teeth and the corresponding sprocket teeth are usually straight-
sided.
Various provisions are made to prevent the chain from sliding off the sprockets. They are:
(i) Centerguide chain: It has central guide links that fit central grooves in the wheels,
as shown in Fig.4.] I(b).
(ii) Side-j1ange silent chain: Fig.4.] I(c) shows a chain with side guide links that
straddle the sprocket face.
(lii,i1
'J Duplex (or bend back) chain: It has teeth on both sides, as shown in Fig.4.II(d). It
can be used in 'serpentine drives whereby sprockets are driven from both sides of
the chain.
Chain Drives
-------------------- -'4.27
___
4.28__..------------------ !!:_~.~.r~~~~~
eSlgn OJ ransmission Systems
I
Disadvantages:
./' More heavier .
./' More complex .
./' More expensive .
./' More difficult to manufacture .
./' Require more careful maintenance.
Due to the above reasons, the silent chains have limited app I'icanons.
.
5
2. Pin diameter, dp = 16x pitch
3. Chain width (i.e., the distance between the roller link plates) :
b, = 8'5 x pitch
.
I
4. Thickness of link plates, tp = 8' x pitch
~~~~--------------------------------~
£_hain DriveS
5
I. Roller diameter:
dr = -8 x pitch
5
= -8 x 12.7 = 7.9375 mm
5 . h
2. Pin diameter: dp = 16 x prtc
5
= 16 x 12.7 = 3.9687 mm
3. Chain width (i.e., the distance between the roller link plates) :
hi = i pitch = 7.9375 mm
._ .1
-8 x . 12.7 = 1.5875 mm
~~ ---------------------------- ~D~u~~~n~o~if~ff~a~m~m~u~·~
" Designprocedure fo~ roller c~ain : 1. Tofin~ number of teeth in the driving and driven
sprockets; 2. Selection of pitch; 3. Selection of chain type; 4. Calculation of PT;
5.Calculation of design load; 6. Check for factor of safety; 7. Checkfor bearing stress
on roller; and 8. Calculation of actual length of chain and exact centre distance.
" A sprocket is a wheel with teeth of a special profile. The design of sprocket for the
selected chain is also presented
" The inverted chains are also called silent chains because of their relatively quiet
operation. The construction, types, advantages, disadvantages and dimensions of the
silent chains are discussed at the end of the chapter.
REVIEW QUESTIONS
I. Discuss the advantages and disadvantages of chain drive.
2. Write the applications of chain drive.
1 Classify the chains.
4. Write short notes on link chains.
5. How can you specify a roller chain?
6. Write an engineering brief about the chordal action of a chain drive.
7. In chain drives, the sprocket has odd number of teeth and the chain has even number of
links. Why?
8. What are the materials used for making chains and sprockets?
9. Write short notes on sprocket wheels.
10. What is a silent chain? In what situations, silent chains are preferred?
II. List out the advantages and disadvantages of silent chains.
12. Explain the construction of silent chains.
hou~day. . .
2. Design a roller chain to transmit power from a 7.5 kW motor t:; ~c:roca:mg. p~:~
The pump is to operate continuously 24 hours per day. The spe 0 t e. mo or IS I
. 600 m The motor can be located at a distance not ess
r.p.m. and that of the pump IS r.p..
than 700 mm.
~C~h~Q~m~D~r~w~e~s ~
Spur Gears
"Opportunity is missed by most people because it comes
dressed in overalls and looks like 'Work."
- T"om"~ Edison
5.1. INTRODUCTION
Gears are toothed wheels used for transmitting motion power from one shaft to
another when they are not too far apart and when locity ratio is desired. In
comparison with belt, chain and friction drive compact, can operate at
high speeds and can be used wher e. Iso gear drives are used when
large power is to be trans, ......
·~ o the gears in position is much less
than in an equivalent frictio in lower bearing pressure, less wear 011 the
bearing surfac
Advantages
1. Since there is no slip, so exact velocity ratio is obtained.
2. It is capable of transmitting larger power than that of the belt and chain drives.
3. It is more efficient (upto·99%) and effective means of power transmission.
4. It requires less space as compared to belt and rope drives.
5. It can transmit motion at very low velocity, which is not possible with the belt
drives.
limitations :
1. The manufacture of gears require special tools and equipments.
2. The manufacturing and maintenance costs are comparatively high.
3. The error in cutting teeth may cause vibrations and noise during operation.
5.1.2.·Definition of Gear
.A circular body of cylindrical shape or that of the shape of frustum of a cone and .of
uOifonnsmall width, having teeth of uniform formation, provided on its outer circumferenual
surface, is called a gear or toothed gear or toothed wheel.
-_
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./ Bevel gt~rs have tee~h form~d on conical surfaces. They are mostly used for
transmitting monon between mtersectmg shafts. A straight-tooth bevel gear is shown in
Fig.S.l(C).
./ Worm gears consist of a worm and a worm wheel, as shown in Fig.S.l(d). Worm and
worm wheel can be visualised as a screw and nut pair. They are used to transmit motion
between non-parallel non-intersecting shafts.
In this chapter, the design of spur gears will be discussed.
~oltJ The smaller of two gears in mesh is called pinion and the bigger gear is called whee! or
Itllr.
5.3. SPURGEARS
In spur gears, the teeth are straight and parallel to the axis of the wheel. The gearing so
formed is called spur gearing. They are used to transmit rotary motion between parallel
shafts. This gearing may be internal or external. External gears rotate in opposite directions
while internal gears rotate in the same direction.
,-' . -'
~d8\~\)11'
oeO~\)11'
_ .
Clearance Circle
Oedenaum CIrcle
1. Pinion: A pinion is the smallest of two mating gears. The larger is often called the gear
or the wheel.
2. Pitch circle: It is an imaginary circle which by pure rolling action, would give the same
motion as the actual gear.
3. Pitch circle diameter: It is the diameter of the pitch circle. The size of the gear is
usually specified by the pitch circle diameter. It is also called as pitch diameter.
4. Pitch point: It is a common point of contact between two pitch circles.
5. Pitch sur/ace: It is the surface of the, rolling discs which the meshing gears have
replaced at the pitch circle.
6. Pitch: Pitch of two mating gears must be same. It is defined as follows:
(a) Circular pitch (Pc) :
It is the distance measured along the circumference of the pitch circle from a point on one
tooth to the corresponding point on the adjacent tooth.
Circular pitch,
I. r, -- 1t
z
D . I ... (5.1)
7. Addendum circle (or Tip circle) : It is the circle drawn through the top of the teeth and
is concentric with the pitch circle.
8. Addendum: It is the radial distance of a tooth from the pitch circle to the top of the
tooth.
9. Dedendum circle (or Root circle): It is the circle drawn through the bottom of the circle.
10. Dedendum : It is the radial distance of a tooth from the pitch circle to the bottom of the
tooth.
11. Clearance: It is the radial distance from the top of the tooth to the bottom of the tooth,
in a meshing gear. A circle passing through the top of the meshing gear is known as
clearance circle:
Spur Gears
5.5
12. Total depth: It is the radial distance between th
dd d
e a en urn and the dedendum of a gear.
Total depth = Addendum + Dedendum '
13. Working depth: It is the radial distance from th dd d .
. I I' I e aen urn circle to the clearance
eire e. tIS equa to the sum of the addendum ofth tw hi
e 0 mes 109 gears.
14. Tooth thickness: It is the width of the tooth measured al ong th e pitc
. h eire
. Ie.
15. Tooth space: It is the width of space between the two adiacenr t th
. h . I ~
d I
ee measure a ong the
pitc eire e.
16. Backlash: It is the difference between the tooth space and the tooth thickness along the
pitch circle.
Backlash = Tooth space - Tooth thickness
17. Face width: It is the width of the gear tooth measured parallel to its axis.
18. Top land: It is the surface of the top of the tooth.
19. Bottom land: The surface of the bottom of the tooth between the adjacent fillets.
20. Face: Tooth surface between the pitch circle and the top land.
21. Flank: Tooth surface between the pitch circle and the bottom land including fillet.
22. Fillet: It is the curved portion of the tooth flank at the root circle.
23. Pressure angle (or Angle of obliquity) (;) : It is the angle between the common normal
to two gear teeth at the point of contact and the common tangent at the pitch point. The
standard pressure angles are 14 Y:z0 and 200•
24. Path of contact: It is the path traced by the point of contact of two teeth from the
beginning to the end of engagement.
25. Length of path of contact (or Contact length) : It is the length of the common normal
cutoff by the addendum circles of the wheel and pinion.
26. Arc of contact: It is the path traced by a point on the pitch circle from the beginning to
the end of engagement of a given pair of teeth. The arc of contact consists of two parts.
Theyare:
(a) Arc of approach: It is the portion of the path of contact from the beginning of the
engagement to the pitch point.
(b) Arc of recess: It is the portion of the path of contact from the pitch point to the end
of the engagement of a pair of teeth.
27. Velocity ratio: It is the ratio of speed of driving gear to the speed of the driven gear.
I i = ~ = ~ 1 . ". (5.4)
where NA and NB = Speeds of driver and driven respectively, and,
= Number of teeth on driver and driven respectively,
ZA and ZB
28. Contact ratio: The ratio of the length of arc of contact to the circular pitch is Im.own as
contact ratio. The value gives the number of pairs of teeth in contact.
Spur Gears
5.7
I. 14Y2° composite system,
2. 14~o full depth involute system;
3. 20 full depth involute system, and
0
I. Addendum 1m 1m 0.8 m
I Examp/~ 5.1 lIn Q pair of spur gears, the number of teeth on the pinion and the gear
0
tin 20 and 100 nsp~cliv~/y. The module is 6 mm. The pressure angle is 20 full depth.
Ctdclllale:
(i) the cemr« distance,
(ii) the pilch circle diameters of the pinion and the gear,
@Solution :
(i) Centre distance (a): The centre to centre distance between two gears is given by
C = 6(20+100)
2
-360
- mm
A
ns. ~
(iii) Addendum and dedendum: From Table 5.2, for 20° full depth involute system,
Addendum = 1m = 1x 6 = 6mm Ans. ~
I Example 5.2 I A pinion with 25 teeth and rotating at 1200 r.p.m: drives a gear which
rotates at 200 r.p.m: The module is 4 mm. Calculate the centre distance between the gears.
Given Data: z) = 25; N) = 1200 r.p.m.; N2 = 200 r.p.m.; m = 4 mm.
Tofind: Centre distance between the gears (C).
__ z2 _ N) _ 1200
e Solution: Gear ratio, i
z)
-
N2
-
200
= 6
. I Example I
~.4 A ~oothed wheel lias 112 teeth. Its module is 1.75 mm: Find pitch
diameter, the circular pitch and the diameteral pitch.
~.JvtData: z == 112; m = 1.75 mm.
,,!.f:'d: (i) Pitch diameter (D), (ii) Circular pitch (Pc)' and (iii) Diameteral pitch (pd)'
©Solution:
(i) Pitch diameter (D) : D == m- Z == 1.75 x 112 == 196 mm Ans."
nD 7t x 196
(ii) Circular pitch (pc) : Pc = == == 5.497 mm Ans.~
Z 112
z 112
(iii) Diameteral pitch (p tJ: P d = D = 196 = 0.57 tooth/mm Ans."
../ The plain carbon steels used for medium duty applications are 50 C 8, 45 C 8, 50 C 4
and 55 C 8. For heavy duty applications, alloy steels 40 Cr I, 30 Ni 4 Cr I and 40 Ni 3 Cr 65
Mo 55 are used. For planetary gear trains, alloy steel 35 Ni I Cr 60 is recommended.
(b) Cast iron: ../ It is used extensively as a gear material because of its low cost, good
machinability, and moderate mechanical properties .
../ Generally, large size gears are made of grey cast iron of Grades FG 200, FG 260 Or
FG 350 .
Table 5.3. Gear materials and their properties (from data book, page no. 1.40)
5.11
r--
Tensile Yield point
"bferia' Condition strength (au), stress (0,), BUN
N/mm2 N/mm2
3- CdSlnls
(i) Grade 1 (i.e., CS 65) - 650 400 190 min
(ii) Grade 2 li·e .. CS 71) - 710 570 207 min
(iii) Grade 3 (i.e., CS 85) - 850 710 248 min
(iv) Grade 4 (i.e., CS 105) - 1050 870 31 i min
(,.) Grade 5 (i_e., CS 125) - 1250 1020 363 min
4. Fo,,~ SIMs
(.) CtUbtHI stub
(i) C 14, C 15 Normalised 490 240 137
(ii) C 30 Hardened and tempered 600 300 179
(iii) C 40 " 630 330 217
[iv) C 45 " 700 360 229
(v) C 60 Normalised - 750 420 255
(b) Alloy st~~1s
2. Gear generating: ,( In the generating process, teeth are formed in a series of passes
by a generating tool shaped somewhat like a mating gear. Either hobs or shapers can be used.
Surface finishes as fine as about 1.6 urn can be obtained.
v" Robbing: The hob is simply a cutting tool which is shaped like a worm. Hobbing can
produce almost any external tooth form except bevel gear teeth. Hobbing closely controls
tooth spacing, lead, and profile.
~ Shaping: Using a shaper, teeth may be generated with either a pinion cutter or a rack
cutter. They can produce external and internal spur, helical, herringbone, and face gears.
3. Gear molding: ,( Mass production of gears can be achieved by molding.
v" Injection molding produces light weight gears of thermoplastic material.
v" Die casting is a similar process using molten metal. Zinc, brass, aluminium, and
magnesium gears are made by this process.
v" Sinter;ng is used in small, heavy-duty gears for instruments and pumps. Iron and brass
are mostly used for this process.
v" Investment casting and shell molding produce medium-duty iron and steel gears for
rough applications.
§J!!!!_Gears 5. I 3
(6) PiJtillg and spalling : Pi~ing is the process during which small pits are formed on the
active surfaces of gear tooth. It IS a surface fatigue failure which occurs when the load on the
gear tooth exceeds the surface endurance strength of the material.
(c) Scorin.g.or seizure: .Sc~ring ~an OCcur under heavy loads and inadequate lubrication.
At this condition, the lubrication 011 film breaks down and metal-to-metal contact occurs.
Hence high temperatures result and the mating spots of the two surfaces weld together. This
phenomenon is known as scoring or seizure.
F, \._ P •
F
lZfFr F
Fr~
~Ft
1>('
/' P .
( d2) ~;:~rde
F
\\ Illg •
Wheel ( .~ ,
\ -_./
(b)
(a)
Fig. 5.3.. t F is a useful component.
The tangential componen t . ed
1. Tangential component (F,) : f F the magnitudes of torque and transnutt
ing the value 0 t'
Because it transmits power. U s
power can be detennined. = F . .
. Transmitted load, W t t F' eparating force which IS always
.. d' I mponent IS a s ful
. nt (F ) : The ra ia co 'k S it is not really a use
2. RadiIIJ com pone f. F does no wor. 0 erse
directed towards the centre· of the ~ear'ft~e shaft. The force F, is also called as transv
es bend 109 0
component. This force F , caus
force or bending force.
2· M,
or F, = d
From Fig.5.3(b), Radial component, , Fr = F,' tan ~ I ... (5.5)
... (5.6)
./ As the point of contact moves, the magnitude of resultant force F changes. This
effect is neglected. .
I
I
I
[§.rame/~ 5.5 A draft horse walks at a steady pace of 5 miles per hour (lit 2.23 m/s).
What st~ady force must it exert if the power output is exactly 1 horse power (lit 745 W).
Giv~n Data: v = 2.23 m/s ; P = 745 W.
Tofmd: Steady force exerted (F I)'
o Solution: We know that the transmitted power,
P = F, x v
or 745 = F, x 2.23
Steady force exerted, F, = 333.37 N Ans. ~
[§xamele 5.6 I A pinion of 120 mm pitch diameter, running at 900 r.p.m: transmits
5 kW of power to gear whose pitch diameter is 360 mm. For straight tooth, the angle of
pressure is 20 ~ Determine the tangential force, the transverse or bending force on shafts
and torques on driving and driven shafts.
Given Duta: d1 = 120 mm = 0.12 m ; N, = 900 r.p.rn.; P = 5 kW = 5 x 103 W;
d2 = 360 mm = 0.36 m ; ~ = 20°.
Tofind: (i) Tangential and transverse forces (i.e., F, and F r)' and
(ii) Torques on driving and driven shafts (i.e., T, and T2)·
N, _ d2 _ 360 = 3
@ Solution: Gear ratio, i = N2 - d , - 120
N, 900
N2 = 3 = 3 = 300 r.p.m.
1td,N, 1td2N2
=
The pheripheral speed, V = 60 60
1t (0.12) 900 = 5 655 m/s
= 60 .
/:. F. and F) .
(i) Tangential and transverse/Drees u.e., t f. •
. d p-Fxv
We know that the power transmltte, - ,
3
_ ~ = 5 x 10 = 884.19 N Ans.~
or Tangential force, F, - V 5.655
. onent) force is given by
The transverse (i.e., radial comp _ 19 tan 200 = 321.82 N Ans.~
F = F/ x tan ~ - 884. x
r
'u'r} d . 'ng and driven shafts (i.e., T} and T} :
{I 'I Torques on "VI ..
. ' h ft = Torque transmitted by plDlon
Torque on dnvtng s a
/ 5.16
Design of Transmission Systems
I Example 5.71 A train of spur gears is shown in Fig.5A(a). Pinion 1 runs at 1750
r.p.in. hnd transmits 2.5 kW power to idle gear 2. The teeth are cut on the 200 full-depth
system and have a module of 2.5 mm: The number of teeth on gears 1, 2 and 3 are 20, 50
and 30 respectively. Calculate:
(i) the torque on each gear shaft, and
(ii) the components of gear tooth forces.
Also draw a free body diagram of gear 2 showing all the forces which act upon it and
determine the reaction on the idler gear shaft.
y
,
I,
I
-~vt,2 ' b ----- X
I Y
Fb2 -----, Fb2
II
(a) (b)
Fig. 5.4.
Given Data: N) = 1750 r.p.m. ; P = 2.5 kW = 2.5 x 103 W ; ~ = 200; m = 2.5 mm ;
z) = 20; z2 = 50; z3 = 30.
@Solution: The pitch circle diameters of gears I, 2 and 3 are given by
d) = m z) = 2.5 x 20 = 50 mm ;
d2 = .~ z2 = 2.5 x SO = 125 mrn ; and
d3 = m z3 = 2.5 x 30 = 75 mm.
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§pur Gears
5.17
All three gears have the same pitch I' .
. . . me velocity (v) Th
velocity IS given as . erefore for pinion 1, th e pitc
. h I'me
_1tdINI
VI _ 60 = 1t(50 x 10-3) 1750
60 = 4.581 m/s
Considering pinion 1 and gear 2 :
Let the tangential force of pinion 1 .
on gear 2 IS F' 12 an d iIS given
. by,
P = F ,x v
or = f = 2.5 x 103
V 4.581 = 545.67 N ADs."
F
F'
= _!L _ 545.67
12 cos ~ _ cos 200 = 580.69 N ADs. ~
Considering gears 2 and 3: Since gear 2 is an idler, it transmits no torque (power) to its
shaft.
Torque transmitted by the gear 2, T 2 = 0 ADS. ~
Since gear 2 is an idler, whatever torque it receives from pinion 1 is transmitted to gear 3.
Therefore, the tangential component between gears 2 and 3 must be equal to the tangential
component between gears 1 and 2, as shown in Fig.5.4(b). Therefore
F~2 = F~2 = 545.67 N
or NIT, = N)T)
Reaction on the idler gear shaft: The shaft reactions in the x and y directions are
R~2 = -(F~2+F;2)and
Here (-)ve sign is for reaction. Because reaction is always opposite in direction to the
force applied.
I Example I
5.B A train of spur
gears is shown in Fig.5. 5. Gear J is
the driving gear and transmits 5 k W
power at 720 r.p.m: The number of
leeth on gears J, 2, 3 and 4 are 20,
.~O, 30 and 60 respectively. The
modllie for all gears is <I mm. The
gears Itave a 20° full deptlt invohu«
profile. Calculate lite langOltiaJ and
radial components of the tooth force
between:
(i) Gears I and 2, and
(ii) Gears 3 and 4.
Fig. 5.5.
Given Data : P = 5 kW = 5 x 1()3 w ~ N. = 720 r.p.m.; Zt = 20; z2 = 50; z).== 30;
Z4 :: 60; ." = 4 rnm ; q, = 20°.
@ So 'ulion: The pitch circle diameters of the gears 1, 2, 3 and 4 are given by
SpurGears
5.19
dl = mZI = 4 x 20 = 80mm;
d2 = mZ2 = 4 x 50 = 200 mm ;
d3 = mZ3 = 4 x 30 = 120 mrn ; and
d4 = mZ4 = 4 x 60 = 240 mm,
The pitch line velocity for gear I is given as
(i) Considering gears 1 and 2: The tangential force of gear 1 on gear 2 is given by
I P 5xl03
F 12 = vI = 3.016 = 1657.86 N Ans. ~
F;2 1657.86
F
12
= --
cos q, = cos 200
= 1764.26 N Ans. ~
Since gears 2 and 3 are coaxial, the speeds are same i.e., N2 = N3·
I Example 5.9 I A train of spur gears with 200 full depth involute teeth Is showII ill
Fig.5.6. Gear 1is the driving gear and transmits 50 kW power at 300 r.p.m: to the gear
train. The number of teeth on gears 1, 2,3 and., are 30, 60, 25 and 50 respectively, White
the module for all gears is 8 mm. Gears 2 and 3 are mounted on the same shaft. Gear 1 ;,
rotating in a clockwise direction when seen from the left side. Calculate: (i) the tangelltiat
. and radial components of tooth forces between gears 1 and 2, and gear 3 and 4; alld
(ii) draw afree body diagram of forces acting on each gear.
I
I
I
-----r---I
Fig. 5.6.
Given Data: ~ = 20°; P = 50 kW = 50 x 103 W' 'I N = 300 •.p.m. ,r •
z3 = 25 ; z4 = 50; m = 8 mm.
Tofind : (i)
F, and F, of tooth forces between gears 1 and 2, and gears 3 and 4; and
(ii) Free body diagram of forces acting on each gear.
@Solution : The pitch circle diameters of gears 1 2 3 and 4 . by
_ ' , are given
d , - m zi = 8 x 30 = 240 mrn .,
d2 = m z2 = 8 x 60 = 480 mrn ,.
d3 = m Z3 = 8 x 25 = 200 mm ; and
d4 = m z4 = 8 x 50 = 400 mm.
(i) Tangential and radial components of tooth forces:
(a) ConSidering gears 1 and 2· We kn th h . .
. ow at t e pitch line velocity of gear 1
VI = 1tdiNI = 1txO.240x300 '
60 60 = 3.77 mls
We know that th ta .
e ngential component of tooth force betw
een gears 1 and 2
F;2 = -P = 50 x 103 _ '
VI 3.77 - 13262.9 N Ans.""tJ
and the radial component of tooth force betw
een gears 1 and 2 ,
L
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Spur Gears
I
5.21
,. - F' tan ....
- 12 x 't' = 13262.9 x tan 20 = 4827.3 N Ans. ~
0
F34
NI 300
Speed of gear 2, N2 = 2 = T = 150 r.p.m.
Since gears 2 and 3 are coaxial, therefore speeds are same. i.e., N2 = N3.
p 50 x 103
= = 1.571 = 31830.99 N Ans."
= 11585.53 N ADS. ~
FI
Then the resultant force, F34 = __lL = 31830.99 = 33873.83 N
cos <p cos 200
(ii) Free body diagrams: The free body diagram of forces acting on gears and the shaft
Be is shown in Fig.5.7.
I Example 5.10 I The layout of a two-
stage gear box is shown in Fig.5.B. The
number of teeth on the gears are as
follows: ZI = 20; Z2 = 100; Zj = 25 ;
z" = 150.
Pinion 1 rotates at 1100 r.p.m. in all
anticlockwise direction when observed
from the left side and transmits 12 k W
power to the gear train. The pressure
angle is 20 ~ Calculate:
(i) torques acting on shafts A, B
and C;
(ii) tangential and radial 200 100
components of tooth forces
between gearj' 1 and 2, and
gears 3 and 4,' and Fig. 5.8.
(iii) resultant reactions at bearings E and F.
Also draw afree body diagram of the gear tooth forces.
Given Data: z, = 20; z2 = 100; 13 = 25 ; Z4 = 150' NI :: 1100 r.p.m. ;
P = 12 k W = 12 x 103 W ; <p = 20 0
.
Z2 100
We know that, - zi
-- -20 -- 5
NI 1100
Speed of gear 2, N2 = 5 = -5- = 220 r.p.m.
60 x P 60 x 12 x J03
Torque on shaft B, (M')B =
27t x N2 = 2n x 220 = 520.87 N-m Ans.-c»
Z4 150
COlISidering gears 3 and 4 : - z -- -25 = 6
NJ 220
and speed on gear 4, N4 = 6 = 6 = 36.66 r.p.m.
[.: N = N2 = 220 r.p.m.]
F~2 = ~ = 12
X
2S
!()3 = 4166.% N ADS."C>
== 1516.65 N ADS. ~
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The free body diagram of forces acting on gears and the shaft EF is shown in Fig.5.9.
F'2 r
F~ F34
lCS$--------- F'2
I •
F12 -
,
Shaft EF
Shaft EF
•
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Fig.5.10.
Tofind reactions (RF)v and (R Fiv : Consider vertical forces.
Sum of upward forces = Sum of downward forces
Sum of right hand side forces = Sum of Jeft hand side forces
Spur Gears
5.27
p 7.5 x 103
Tangential force of gear A on gear B, F~ = =---
vA 26.38 = 284.2 N Ans. ~
and radial force of gear A on gear B, F~ = F~ x tan ct> = 284.2 x tan 200
= 103.44 N Ans."
Then resultant force of gear A on gear B,
i'
"I
F~B 284.2 j
Considering gears Band C: Since the gear C (also known as ring gear) is fixed, therefore
forces acting on gear B is same as that of gear A, as shown in Fig.5.12.
(;;) Torque thai the arm EF can deliver to its output shaft: The free body diagram of
forces acting on each gear and arm EF are shown in Fig.5.12.
Arm EF ,
,
"
Fee = FAa
Gear A GearC
Fig. 5./1.
= 568.4 N
b." : (F,/b)
/..... f
, .'
.
.' ,,
,
,: ,:
F
•
·· .:: .'..
·r-----
:"
f
/-
(a)
(b)
The resultant force F . Fig. 5.13.
JS resolved into tw
0/ Th 0 component .
e tangential component f s I. e., FI and F
break the tooth 0 tooth force FI induces a b . ,..
0/.
The radial eanng st ress W
h.ich tends to
component F indUces
,. a compressive stress.
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~~~~~------------------ ~5~.2~9~
Since the direct compressive stress is very small as compared to the induced bending
therefore the effect of compressive stress on the tooth may be neglected Hence the
streSS'. '. . ,
be"d;"g stress IS used as the basISfor desIgn calculations.
From Fig.5.13(b), it is known that the section XX is the section of maximum stress or the
criticalsection.
Let Mb = Maximum bending moment at the critical section XX = FI x h,
MultiplyiQgthe numerator and denominator on the right hand side by PC' we get
The values of the Lewis form factor (y) are given in Table 5.5.
INote I I. In order to avoid the breakage of gear tooth due to bending, the beam strength should be
more than the effective force between the meshing teeth.
2. In the design of gears, it is required to decide the weaker between pinion and gear. In equation
5.9, the beam strength depends on the product (ob x y) since the m and b are same for pinion as well as
for gear.
(a) When the same material is used for pinion and gear the pinion is always weaker than the gear.
(b) When different materials are used, the product (ob y) decide the weaker between pinion
and gear. The Lewis form factor y is always less for pinion corn pared with gear.
(ii) Gear design using basic relations (or gear design based on gear life), which is the
conventional method.
. The beam .stren~th is the maximum value of the tangential force that the tooth can trl.lnsmil
WIthout bending failure. Replacing F by F o by []. .
I S' b cr b ' ' we get
.>I
The following table shows the values of allowable static stresses for the different gear
materials.
• Note that we have two types of form factors, viz., form factor based on circular pitch (y) and form factor
based on diarneteral pitch (Y). y = Y . In this text we have used form factor 'y'.
1t
~5.~J2~
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z
TlIb/~ 5.5. Fomt/tlclor
14 ~ ° FD 100FD
Y III Lewts ~quatlon (y
10° Stub
II: YIII) (from datil book, page no. 8.53)
12
0.176
0.192
0.201
0.226
0.261
0.289
37
40
0.330
0.336 0.389
0.454
0.459
-
14 0.236 0.276 0.339 45 0.340 0.399 0.468
-
16 0.255 0.295 0.360 50 0.346 0.408 0.474
-
18 0.270 0.308 0.377 55 0.352 0.415 0.480
(iii) For precision gears with shaving, grinding and lapping operations and with v> 20
mls:
0.75
Cv = 1 + v + 0.25
Sp~0~e=a~N~ ~~
~ 5.33
5.16. TANGENTIAL LOAD ON TOOTH (F,)
Type of load Ko
Steady 1.0
Light shock 1.25
Medium shock 1.5
Heavy shock 2.0
INote' If the starting and rated torques. data are given in the problem, then service factor can be
calcuJated as below.
. Starting torque
Service or shock factor, Ko = R ated torque
For example, the starting torque of motor is 140% of the rated torque, then service factor, Ko = 1.4.
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Table 5.7. (a} Value of c Table 5.. (b) Expected error (e) In
(fro", data book, page no. 8. 53) 100111 profiles. ;11 mm
i.e.,
Module, m ~ F(
CV X 7t X b x [ ob ] x y ... (5.13)
The failure of the gear tooth is mostly because of wear between two meshing teeth. For
example, pitting is a surface fatigue failure. In order to avoid this type of failure, the
proportions of the gear tooth and surface properties, such as surface hardness, should be
selectedin such a way that the wear strength of the gear tooth is more than the effective load
betweenthe meshing teeth.
The maximum wear load (or wear strength of the gear tooth) mainly depends upon the
radii of curvature of the tooth profiles and surface fatigue limits of the materials. Therefore
themaximum or the limiting wear load of gear tooth is given by
I Fw = d)· b· Q. Kw I ... (5.14)
where Fw = Maximum or limiting wear load in newtons,
d) = Pitch circle diameter of pinion in mm (use d) irrespective of whether
pinion or gear is designed),
b = Face width of the pinion in mm,
Q = Ratio factor
2x i 2zg
= ---
i+1
= Zg +zp
, for external gears ... (5.15a)
2x i 2Z
= = g ., for internal gears .. , (5.15b)
i-I Zg -zp
where i = Gear (or velocity) ratio = z/zp, and
Z
p
and z g = Number of teeth in pinion and gears respectively.
= f;s·sinq,
1.4
(J..+_l)
Ep Eg
(
... 5.16)
~lY ilMlW&e tooth profile with 14 'h 0 or 20° pressure angle is used.
herefolle, aaswne zi as given below:
./ ZI ~ 17, for 200 full depth system, and
~~-------------------------- ~S.~37~
Where
.I ..
c
v
= Velocity factor. The value of v used in velocity factor formula may be
F, = 1t. m . b . [ crb ] . y
6. Calculation of module (m) : Since the gear is designed on the basis of beam strength,
therefore F s ~ F d: So equating Fsand F tP find the module.
Then select the nearest higher standard module value from Table 5.8.
7. Calculation of b, d and v :
./ Find face width (b): b = 10m
./ Find pitch circle diameter (d I): d 1= Z . m
l I
./ Find
m oipitc hi' me ve I'ocity ()v : V = 1td60
N
8. Recalculation of the beam strength (FJ: Recalculate the beam strength of the gear
tooth using the relation
F, = 1t. m . b . [ crb] . Y
9. Calculation of accurate dynamic load (F{J: Calculate the dynamic load more
accurately using Buckingham's equation as given below.
21 v (be + Ft)
F = F +F = F + ----;::=====-
d tit 21 v + '.} be + F,
./ If F d ~ F s' then the gear tooth has adequate beam strength and it will not fail by
breakage, Thus the design is satisfactory .
./ If Fd > Fs' then the design is not satisfactory. Now increase the face width, module
or both. Usually, to reduce the dynamic load (F d)' the gear should be carefully cut
(i.e., to reduce the deformation factor (cj), Even for precision gears, F d > Fs' then
increase the face width, till F d < F s:
=
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~~a~n-------------------- ~5'23~9
Table 5.10. Basic dimensions of spur gears (from data book, page no. 8.22)
always weaker than the gear. ] decid the weaker between pinion
d hroduct [ob x y eCI es
3. When different materials are use , t e p . . d [ ] for the gear are calculated. Tile
and gear. That is, the product [obI ] YI fior the pinion. an 0b2 Y2
°
element which has lower I ub I y va lue s h uld be designed.
I Example I
5.12 Design a spur gear drive required to transmit 451flr at a pinion sPeed
of 800 r.p.m: TI,e velocity ratio is 3.5 : 1. The teeth are 200 f u/l depth involute with 18 teeth
on the pinion. Both the pinion and gear are made of steel with a maximum safe static stress
of 180 Nlmm2. Assume medium shock conditions.
Given Data: P = 4? kW; N, = 800 r.p.m.; i = 3.5; <I> = 20°; Zt =: 18 .,
[ 0b ] = 180 Nzmm-.'
1td1N1 1txmz1xNt
where V = 60 = 60 x 1000 ... [.: d I = m . Z I and 'm' is in mm]
1t X m x 18 x 800
= 60 x 1000 = 0.754 m
6
=: :: 0.333
6 + 12
74603 1 223809
Fd = m x 0.333
=
In
21 v (be + Ft)
Dynamic load, Fd = F, + 21 v + '.} be + F,
P 45 x 103
where F, = = = 7462.68 N,
v 6.03
e = Deformation factor, from Tables 5.7(a) and (b),
= 11860 e, for 200 FD, steel and steel, from Table 5.7(a), and
e = 0.038, for module upto 8 and carefully cut gears, from Table 5.7(b).
= 50908.19 N
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5.42
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5.43
dfl = (zl-2fo)m-2c
= (63:- 2 x 1) 8 - 2 x 2 = 484 mm
Ij;X4m:f't5:~{J .tt compressor running at 300 r.p.m: is driven by a 15 kW, 1200 r.p.m.
motor thr(Jllgh ,,14l1z 9ful! dept" spur gears. The centre distance is 375 mm. The motor
pi"lon Is to be of C 30 forged steel hardened and tempered, and tile driven gear is to be of
~ast ir(Jn. Assumlnll mf!4ium slmck condition, design tile gear drive completely.
'J
,n'
Given Data: N~ = 300 r.p.m.; P = 15 ~W; NI = 1200 r.p.m.; ~ = 14 12 ; a = 375 mm. 1 0
Assume zi = 18.
Z2 = i x z, = 4 x 18 = 72
Forpinion: Form factor, Y, = 0.270, from Table 5.5, for z, = 18, and
Permissible static stress, [ob] = 112 Nrrnrn-, from Table 5.4, for forged steel.
0.270 YI
[ crbl ] y, = 112 x -7t- = 9.625 ... [ ... y 1---]
7t
For gear : Form factor, Y 2 = 0.360, from Table 5.5, for z2 = 72, and
Permissible static stress, [crb h = 56 N/mm2, from Table 5.4, for cast iron.
Y2
[ .: Y2 = -]7t .
We find [ crb2 ] Y2 < [ crbl ] YI i.e., the gear is weaker than the pinion. Therefore, we have
tod .
eSIgnthe gear only.
m (z, +z2)
a =
2
or 375 = m (18 + 72)
2
or Module, m = 8.333
From Table 5.8, the nearest higher standard module under choice 1 is 10 mm.
3. Calculation of iJ, d and v :
../ Face width (b): b = 10 x m = 10 x 10 = 100 mrn
../ Pitch circle diameter of pinion (d ) . d = m
,., .z, -- 10 x 18 = 180 mm
../ Pitch circle diameter of gear (d ). d-
2' 2 - m . Z2 = lOx 72 = 720 rnrn
../ Pitch line velocity (v): l' = 'It d2 N2 'It x 720 x 10-3 x 300
60 = 60 = 11.31 m/s
4. CalCulationof beam strength (FJ :
Beam strength, F = 'It. m .b.[ ]
s CJh 2' Y2
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Spur Gears
5.45
....
~ 25~.4~8 ------~-~.=-~-~-~-
~~ __~~~ D_e_si~gn~of_Tl_t_an_s_m_~_s_io_n_S~~_~/~ern~s
.. r 0bi])it == 8S x 0.330
n = 8.93 N/mm2 Yt = ~]
n
[ .,'
For gear: Form factor, Y2 = OA40, for %2 = 88 (by interpolation), from Table ~.5.
1t x m x 22 x 600
= 60 x 1000 = 0.691 m
Starting torque _
Ko = Mean torque - 1.25
~~Ge~a~~s ----------~~~------~--------~------------5_.4_7-
::r;--
5. Calculation of r,:
Beam strength, F, = 1t. m . b · [ ObI] • YI .
P 32 x 103
where F, = v - 6.91 = 4629.96 N,
=
(520)2 x sin 200 [I
1.4 1.2 x lOs + I x lOs
I J = 1.211 N/mm2
10 (22 + 88)
= 2 = 550 mm
dOl =
dill =
~~S-------------------- ~S~.4~9
[]Xnmplt 5.1~ I A bakelite pinion driving a cast iron gear. Tile pinion rotating at
700r.p.m. transmits 5 k ~ to a gear. Th~ velocity ratio is 3, the teeth are 200 full depth, and
-d is smooth. Design tire gear drive. Take the allowable static stress for bakelite as
tht I.,..
40NI",nr2·
Given J)ata: N. = 700 r.p.m.; P = 5 kW; ; = 3; ~ = 20°; [ob] = 40 N/m~2.
To find: Design the gear drive.
@ Solution: Since bakelite is a non-metallic material, bakelite pinion is weaker than the
cast iron gear. Therefore we have to design the pinion only.
1. Material: Pinion - Bakelite, and Gear--Cast iron. . .. (Given)
2. Assume z. = 18; and z2 = ; x z. = 3 x 18 = 54.
P
3. Calculation of F, : F, = -v xK 0
1t d. N. 1txmxz.xNI 1t X m x 18 x 700
where v = 60 = 60 x 1000
= 60 x 1000
= 0.66 m
Ko = 1, for smooth load, from Table 5.6.
5 x 103 7578.81
F, = 0.66 m x 1 = m
F,
4. Calculation initial F d: Fd =
clI
y = Form factor -.
- 0 154 - (0 .912/z I) , for 20° full depth system
= 0.154-(0.912/18) = 0.1033
Fs = 1t X m x 10m x 40 x 0.1033
= 129.85 m2
or Module, m ~ 5.38
From Table 5.8, the nearest higher standard module under choice-] is 6 mm.
7. Calculation of b, d and v :
./ Face width: b = 10m = lOx 6 = 60 mm
./ Pitch circle diameter: d1 = m- zl = 6 x 18 = 108 mm
= 1t X 6 x 60 x 40 x 0.1033 = 4673.18 N
9. Calculation of dynamic load: We know that the Buckingham's equation for dynamic
load is not applicable to non-metallic gears. Therefore the dynamic load for non-metallic gear
can be calculated as
F,
Fd = Cv
p 5 x 10
where F, = -v = 3.96
= 1262.62 N, and
· . c.
V e Iocrty ( 0.75 )
c, = tactor = ·1 + v + 0.25
0.75 )
= ( 1 + 3.96 + 0.25 = 0.4012
1262.62
Fd = 0.4012 = 3147.12 N
./ Face width: b = 60 mm
./ Height factor: f0= I
./ Bottom clearance: c = 0.25 III = 0.25 x 6 = 1.5 mm
./ Tip diameter: ·dal = (zl + 2 f 0) m = (18 + 2 xl) 6 = 120 mm; and
da2 = (z2 + 2 f 0) m = (54 + 2 x 6) 6 = 336 mm.
./ Root diameter: dJ1 = (z I - 2 f 0) m = (I 8 - 2 x I) 6 = 96 mm ; and
I Example 5.16 lIt is required to design II two stage spur gear reduction unit (Fig. 5.14)
with 200full depth involute teeth. The 'input shaft rotates at 1440 r.p.m. and receives 10 kW
power through a flexible coupdng .. TIre speed of output shaft should be approximately 180
r.p.m. All the gears are made of plain steel 45 C 8 (a"l = 700 Nlmm2). Tire service factor
1t X m x z) x N)
where v = =
60 x 1000
IT X Tn x 18 x 508.23
= 60 x 1000 = 0.479 m, and
~
where Cv = Velocity factor = _]___ =
3+v 3+5
.)
= 0.375, - assuming =5 S
31315.2-i 83507.3
Fd = x =
m 0.375 m
~~ ---- ~5~.5~3~
y = Form factor = 0.154 - (0.912 I zl)' for 20° full depth system
= 0.154-(0.912/18) = 0.1033
F, = tt x m x IOmx233.33xO.1033 = 757.22m2
6. Calculation of module: We know that, F s ~ F d:
757.22 m2 ~ 83507.3
In
or Module, m ~ 4.79
From Table 5.8, the nearest higher standard module under choice-l is 5 mm.
7. Calculation of b, d and v :
./ Face width (b): b = 10 m = 10 x 5. = 50 mm.
-/' Pitch circle .diameter (d3): d3 = m- z3 = 5 x 18 = 90 mm
7t d3 N3 7t x 90 x 10-3 x 508.23 Ii
Beam strength, F s = 7t X m . b . [ a b ] . y
= 7tx5x50x233.33xO.l033 = 18930.44 N
10 x 103
where 2.395 = 4175.36 N,
'j
5 -4
--:?.--.---
(0. Chec*/or ben'" strength (or tootl' breakage) :
· fi d F ,. F therefore tl.e design is satisfactOry.
We nn S o :
11. Calcllla/ion 0/ maximum wear load (F",) :
Wear load, f.. ~ d I x b x Q x 1(" 2 i 2 . Z4 ~- 1.478, and
18 + 51
where Q ~ Ratio factor ~ i+1 ~ 0 -
1<,,, ::: Load streSS factor.
~ 2.553 N/mm2, for 400 BJ:IN steel, from Table 5.9.
./
TIp dIameter:
Root diame.tcn:
d
da 2 == dda4 -- «Z2
. + 2 xl) 5 - 265 mrn
+ 2 f 0) m = (51
f2
/4 = z2 - 2 f 0) m - 2· c
_. (51 - 2 xl) 5 - 2 x 1 25 -
II. GEA . - 242.5 mm
R DES.IGN BASED
(GearDesign usin9 Basrc
~NRelations)
GEAR LIFE
5.24.AsDYNAMIC
di LOAD (OR DESIGN TORQUE)
ther
. i S ection
iscussed In . 5.17· . mg
. . teeth.
e are dynamic loads betw een ,m addition
the-mesh. to the st aftc ,oad due t 0 power transmission,
P = Power transmitted,
N = Speed of pinion,
Table 5.11. Load concentration foetor, k for cyttnartcut gears (from data book.page no. 8.15)
Table 5.12. Dynamic load factor, Kit (from data book, page 110. 8.J 6)
IS Quality Pinion Spur & Straight Bevel Helical & Spiral Bevel
surface Pitch line velocity. m/s, upto
Cylindrical Conical
hardness
.._ gear gear 1.0 3.0 8.0 12.0 3.0 8.0 12.0 18.0
HB
< 350 - - 1.2 1.4 - 1 1.1 1.2
5 -
.._ > 350 - - 1.2 1.3 - I 1.0 1.1
-- 6
8
5
6
> 350
< 350
-
1
1.2
1.35
1.3
1.55
-
-
I
1.1
I
1.3
1.1
1.4
1.2
-
).
- 5-6
---
- CEO BENDING STRESS, Gb . t'on for beam strength) is given
5.25. INDU . (. modified LewIS equa I
di stress equatIon i.e.,
Lnducedben mg
by ... (5.23)
== i±I [M,l
°b a . m . b· y
== Form factor, from Table 5.13.
where
Y fi y (from data book, page no. 8.18)
Table 5.13. Form actor,
y
y z
z
35 0.452
12 0.308
40 0.465
14 0.330
45 0.471
16 0.355
0.377 50 0.477
18
0.389 60 0.490
20
22 0.402 80 0.499
I Noiil The above values are divided by 0.8 for stub teeth.
=
x 0_1, for gears having two directions of rotation ... (5.24)
where
Kb/ = Life factor in bending, from Table 5.14,
5.57
Table 5. U. Life factor for bemllng, Kb/ (from datu book, page no. 8.10)
< 25 x 10'
~IO'/N
Cast Iron - - ~IO'/N
• If the case hardness HB > 350 and the core hardness HB < 350, then the coefficient Kb/ is obtained for HB < 350.
Table 5.15. Stress concentration factor for fillet, Ka (from data book, page no. 8.19)
Table 5.16. Endurance limit, u_I (from data book, page 110.8.19)
Table 5.17. Factor of safety, n (from data book, page no. 8.19)
Mode of
Material Heat treatment Factor ofsafety, n
manufacture
Steel, Cast No heat treatment 2.5
Cast iron Cast Tempered or normalised 2.0
Steel Cast or Forged Case hardened 2.0
Forged Surface hardened 2.5
Normalised 2.0
~ 107 1
Steel S 350
< 107
~ 107 IN
~ 25 x If)7 0.585
Steel > 350
<25 x 107
~ 107 IN
Cast iron
~ 107 IN
Spur Gears
5.59
o = 0.74 i ± I "'
c a
I i± 1 x
\j i b Eeq [M,} ... (5.26)
) 5.60
...::.:::..:...... Design
_:;_:__~ of Transmisstnn S"SI'e'lis
_::_:::..:..=.:::.:...:::!_J'
Table 5.21. Width to centre distance ratio, f// (from data book, page 110. 8.14)
I Note I For light and medium duty b s d I ; For heavy duty b s 1.5 d I
where b - face width, and d I - pinion diameter.
If gear ratio is not specified, it may be assumed to be unity. In case of multistage speed
reducers, the sped ratio may be selected from R 20 series.
2. Selection of materials:
Consulting Table 5.3, knowing the gear ratio i, choose the
suitable combination of materials for pinion and wheel.
3. If not given, assume gear life (say 20,000 Ius).
4. Calculation of inittal design torque I M, J :
Calculate the design torque using the relation
[ Mt] = Mt• K . Kd
. 60 x p
where = Transmitted torque = 2 7t N '
,,L Since datas are inadequate to select the values ofK and K,b initially assume K· Kd:::: I.3.
(The above details are taken from data book, page no.8.15.)
5.61
G IrS
~
5. Calculation of E~q' f ubi and I uel :
I consulting Table 5.20,' calculate the equivalent Young's modulus (Eeq ).
I consulting Table 5.16, calculate the design bending stress [ CJb ].
I Tofilld I ue I : Calculate the design contact stress [ CJc 1 using the relation
[ CJc 1 = CB· HB . Kc/ or [CJc] = CR . HRC . Kc/
where CB or CR = Coefficient depending on the surface hardness,
from Table 5.18,
HB or HRC = Brinell or Rockwell hardness number , and
,
KcI = Life factor for surface strength, from Table 5.19.
The above relations are taken from data book, page no.8.16.
.,
(
I
"
I
6. Calculation of centre distance (a): Calculate the centre distance between gears based
on surfacecompressive strength using the relation
a~ (i+I)
0.74)2 Eeq [MIl
[from data book, page no. 8.13, Table 8]
I
( [CJc] x i\V
Using the calculated module value, choose the nearest higher standard module from
TableS.S.
. 9. Revision of centre distance (a) : Using the chosen standard module, revise the centre
distance value (a).
m (zi + z2)
a =
2
10. Clllculation of b, til' v and VIp:
b
./ Calculate the value of 'tip : 'tip = d
1
•
11. Selection of quality of gears: Knowing the pitch line velocity (v) and consulting
Table 5.22, select a suitable quality of gear.
Table 5.22. Penpheral speed of gear (from data book, page 110. 8.3)
Straight bevel
-
IS quality Preferred quality Cylindrical gears
gears
,/ Revise I Mil: Using the revised values of K and Kd, calculate the revised design
torque [Mt] value. Use [Mt] = M, . K . Kd.
./ Compare the induced bending stress 0b and the design bending stress [ 0b ]. For
the value of [ 0b ], refer step 5. If 0b s [0b l. then the design is satisfactory.
i±l A/i±l
°c = 0.74 -;;- \j ib Eeq [Mt] [from data book, page no. 8.13]
./ Compare the induced contact stress 0c and the design contact stress [ 0c ]. For the
value of [ 0c ], refer step 5. If crc s [ 0c ], then the design is safe and satisfactory·
L
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5.63
pinion.
./' If the materials for pinion and gear are different, design the pinion first and check both
pinion and gear.
/
16. C!teck/or gear:
(i) C!teekfor bending:
./ Calculate the induced bending stress using the relation
or O"b2 =
where crbl and O"b2 = Induced bending stress in the pinion and gear respectively, and t
YI and'Y2 = Form factors of pinion and gear respectively, from Table 5.13.
./ Calculate the design bending stress for gear [(Jb2], consulting Table 5.16. I
./ Compare the induced bending (Jb2 and the design bending stress [ (Jb2 ]. I
,
If crb2s [(Jh2 ], then the design is satisfactory.
./
Calculate the design contact stress for gear [ (Jc2 ] as discussed
Compare the induced bending stress O"c2 and the design bending
in step 5.
stress [ (Jc2 ]. If
I
cre2:s; [ (Je2 ], then the design is safe and satisfactory. i
I)
I
,17. Calculation of basic dimensions of pinion
anti gear: Calculate all the basic
,,
dImensionsof pinion and gear using the relations listed in Table 5.10.
[§xample 5.17] In a spur gear drive for a stone crusher, tile gears {Ire made of C40 I(
el III
;te . Tlte pinion is transmitting 30 kW {It 1200 r.p.m. Tile gear ratio is 3. Gear is to work 8
lOursper d.ay, SIX
',1 •
u(IYS a week and for 3years.
D'estgn t l.te {,lri
rtve. I
= 30 kW; N I = 1200 r.p.m.; i = 3.
Given Data:
TOjilld·
.
0 .
Pinion and gear materials:
1. Gear ratio: j = 3.
... (Given)
2. Material selection: Pinion and gear are made of C 40 steel.
'" (Given)
Assume surface hardness> 350.
3. Gearlife: Given that the gear i.s to work 8 hours per day, six days a week; and for 3
years. Therefore gear life in terms of hours is given by
60 x P , 60 x 30 x 103
where M, = = 238.73 N-m
21t NI = 21t x 1200
K· x, = 1.3.
(i) To find Eeq : From Table 5.20, for C 40 steel, Eeq = 2.15 x 105 N/mm2
1.4 Kb/
[ab ] =
n . Ka . a_I, assuming rotation in one direction only' .
where =
Kb/
0.7 for HB > 350 and N ;:::25 x 107, from Table 5.14,
n = 2, for steel tempered, from Table 5.17,
Ka == 1.5, for steel, from Table 5.15, and
a-I ==
0.35 all + 120, for C 40 alloy steel, from Table 5. ~6.
But
au == 2
630 N/mm , from Table 5.3, for C 40 steel.
Q'
-I = 0.35 x 630 + 120
== 340.5 N/mm2
Then, 1.4 x 0.7
==
2 x 1.5 x 340.5
== 111.23 N/mm2
where CR :c 26.5, for C 40 steel hardened and tempered, from Table 5.18, and
HRC = 40 to 55, for C 40 steel, from Table 5.18, and
Kcl = 0.585, for HB > 350 and N ~ 25 x 107, from Table 5.19.
[ CJ,] = 26.5 x 55 x 0.585 = 852.64 N/mm2
6. Calculationof centre distance (a) :
0/ \V:.E_
P d = ~85 -06
- .,
l
12.
F RI!.IS'
. Oil 0'~ design 10rguI! of gear I
= 0.6 an d ror
~ bearings close to gears, K
.; Revise • ,. 8, HB > 350
./ . K'
Revise From Table 5.11, for 'l'p
Kd: From
Table 5.12, for IS qua rty ,
and v:::: 5.3
e i+l ~ !i+l
cr = 0.74 -;;-" V ib x Eeq [Mil
3+I 3+I ; J
= 0.74 x
::: 765.9 N1mm2
170 3x 51 )( 2.15)( 10- )( 344.24 x 10
e e
Qnd Satisfactory.
.; We find cr <: ( cr J (i.e., 765.9 Nlmm2 <: 152.64 N1mm2). Therefore Ilze design is safe
J S. .;Ctl/culation
MOdule: Of hasic dilllensions pinion mid gear:
5 mm
III = Of Refer Table 5. I O.
V Face Width:
V Height factor: h :::::51mb)
wi' Bottom clearance: fo = I, for full depth teeth.
V Tooth depth :
e = 0.25 In = 0.25 )( 5 = 1.25 mm.
.; Pitch circle di3Jneter: d, ===
h = 2.25 m =
2.25 )( 5 = 11.25 Ill"I .
tn zi = 5 x 17 = 85 Illlll; and
tl2 = '" z2 = 5 x 51 = 255 Illlll.
= 242.5 mm
I
(LYole In the above problem, both gears are made of same material. Hence design of pinion alone
is sufficient. So, we need not to check for gear.
[Example 5.18 IA cast steel 24 teeth spur pinion operating at 1150 r.p.m. transmit
3 kW to a cast steel spur wheel. The gear ratio is 2.25. The tooth profile is 200 full depth
involute. Design the gears and check for stresses.
Given Data: ZI = 24; NI = I 150 rpm; p = 3 kW; i = 2.25; ~ = 200•
2. Material selection:
Pinion: CI5 steel, case hardened to 55 RC and core hardness'< 350, and
Wheel: C.1. grade 30. ... (Given)
__ ----------------_::D:...::e:::.s::.!::ig::....n-o~if-T.-,.a-n-s-.m-is-.s-io_n-..:S~i)'sle",
--
5.68:
where M, =
60 x P = 60 x 22.5 x 10
21tNI 21t x 900
3
---..:!.
= 238.73 N-m, and
where b
\jJ = a == 0.3
... (assumed initially)
~~~ __ ------------________________________________~ __
9
7. Tofind %/ lind Z2 : I
i
(i) For 20° full depth system, select zl = 18.
..
(ii) z2= i x z, = ~.5 x 18=45
II
I
I
b 47.25
./ 'Vp = d = ~ = 0.525.
l
(i + I)
(Jb = a. m . b . y [Mt]
Where y = Form factor = 0.377, for zi = 18, from Table 5.13.
3
'. = (2.5 + 1) x 344.24 x 10 = 85:89 Nzrnm"
(Jb 157.5 x 5 x 47.25 x 0.377
'" We find CJb < ( OR). Therefore the design is satisfactory .
.....
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~~ ----------------------------------_D~e~s./~g~n~O~if~TJ~r~a_n_s_m_i_ss_i_o_n_S~~~
~.'70
14. Check/or wearstrength:
./ Calculation0/ induced contact st_re_s_s,_O"c-:
_---
i+1 i+1
CJc = 0.74 --;- Tb_X_E_eq_[_M_,_]~ -------
= 684.76 N/mm2
../ We find CJ < [oc]' Therefore the design is safe and satisfactory.
c
15. Checkfor wheel:
(i) Calculationof I ublwheel and I uclwheel :
1.4 x KbI
[ CJb ]wheel = n .K x CJ_I' assuming rotation in one direction only.
c
./ From Table 5.14, for cast iron wheel, Kb/ ~ \]"W ~ 107
2l.6 x 107 = 0.918 .
./ From Table 5.17, for cast iron, n = 2 .
./ From Table 5. I 5, for cast iron, Kcr = 1.2.
../ From Table 5.16, for cast iron, 0_1 = 0.45 aU"
But from Table 5.3, for cast iron, au = 290 Nzrnrn-'.
:.[cr]
Kd ~
=
-\fW = 6 107
21.6xl07 = 0.879, for cast iron, from Table 5.19.
c wheel 2.3 X 260 x 0.879 = 525.64 N/mm2
Spur Gears
5.71
../ We find Gh2 < [ CJb JWhc:e1' Therefore the design is satisfactory.
(iii) Check for wear strength: Since contact areais same, therefore CJ
e
wheel = CJe pinion
= 684.76 Nzrnm-, Here CJe wheel> [ CJe ]wheel' It means, wheel does not have the required
wear resistance. So, in order to decrease the induced contact stress, increase the face width
(b) value 'or in order to increase the design contact stress, increase the surface hardness, say to
340 HB. Increasing the surface hardness will give [ CJe ] = 2.3 x 340 x 0.879 = 687.34
N/mm2, Now we find CJc < [CJc J. SO the design is safe and satisfactory.
16. Calculation of basic dimensions of pin ion and wheel : Refer Table 5.10.
~.
./ Module: m = 5 mm
./ Face width: b = 47.25 mm
./ Height factor: /0= 1 for full depth teeth,
______ ~ __ ,~,.·T-~_~_. _
di (i±l)
0b= Idnuce db en mgstress=ambY[Mt],
· I . . 60 x P
M t = N omma pimon torque = 2 1t N '
[Mt ]max
... (5.28)
°bmax = °b Mt
Compare 0b max value with permissible bending stress [ 0b ] max given by Table.5.23. If
° b max s [ o b ]max ' then the design is satisfactory.
No heat treatment
Steel 0.8 cry
HB < 350
Heat treated
Steel 0.36 cU I K (J
HB> 350
= 0.74 i ± 1 ""
a \j
I i i±b1 x Eeq [M t ]
= p ..
ermissible contact stress, from Table 5.24.
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Table 5.24. Permissible contact stress I cre Inrax (from data book, page 110. 8.21)
[ M, ]ma.x
... (5.29)
°c max = °c M ,
If 0c max < [Oc ]maJP then the design is safe and satisfactory.
1<", = I, for steel, HB $' 350 and N ? 107, from Table 5.19.
[ ac 1 == 2.5 x 300 x I == 750 N/mm1
6. Cent,.e distance (a): Assume 4J == 0.3.
a ~ (i + 1) "'\J / (JUi_) 1 x E q [M I 1
V [a 1 'JI
V(~;n
c I
? (3 + I) 2
Spur Gears
5.75
12. Revised design torque 1M,I:
From Table 5.11, for \jI == 0.6, K == 1.03.
From Table 5.12, for IS quality 8 HB
, S; 350 and v == 3.77 mis, Kd== ] .55.
[M/] == M I ·K·K d
.. (3 + 1) .
CJb = 120 x 2.5 x 36 x 0.4]4 x ]01.63 x ]03 = 90.9 N/mm2
We find CJb < [ CJb ]. Thus the design is satisfactory.
1
= 0.74(31;0 ) (::3]6)X2.15X]05XI01.63XI03
= 701.71 N/mm2
We find CJc < [ CJc ), thus the design is safe anti satisfactory.
(ii) Check for wear strength: Induced contact stress due to maximum instantaneou
torque is given by S
[ M, ]max
O'c max = O'c X
M,
82.758 2
= 701.71 x 63.66 = 912.22 N/mm
From Table 5.24, for steel HB s 350, permissible contact stress is given by
[O'c]max = 3.10'y = 3.1 x540 = 1674N/mm2
Since O'c max <[ O'c ]max ' the design is safe and satisfactory against plastic de/ormation
also.
16. Basic dimensions of pinion and gear: Refer Table 5.10 .
.,/ Module: m = 2.5 mm
.,/ Face width: b = 36 mm
.,/ Height factor: /0 =1
= 173.75 mm.
I Example 5.21 I Design a spur gear drive to transmit 12 kW at 1440 r.p.m: with a
'peed ratio of 3. The starting torque is 50% more than the mean torque. Assume suitable
1If/IJerials.
Given Data: P = 12 kW; NI = 1440 r.p.m.; i = 3; [M, ]max = 1.5 M,.
Tofind: Design a spur gear.'
e Solution:
Material selection: Take same materials for both pinion and gear. Assume case twdened
alloy steel 15 Ni2 Crl Mo 15 material.
Now the problem is very similar to the previous problem. So proceed this problem as
discussed in Example 5.20. I
I,
Since the starting torque value is given, therefore the design should be checked for plastic I!
I'
deformation without fail. I
I'
I,
I
t1
J t2 t3 ~
I I I I
r r .
Mt1
f Mt3
Mt2 _t
1
Mt4
1 ~ +
Time in hrs (or) No. of cycles
NI = N2 = N3 = 700 r.p.m.
60
.. Neq = -3 [M:I x 700 x 1256.72 + (0.6 M/I)3 x 700 x 4189.06 +
MIl
(0.2 Mil? x 700 x 2932.34 ]
or Neq = 9.177 x 107 cycles Ans."
I Example 5.23 I In a non-reversible type rolling mill drive, a gear is designed to run
20 hours per day, transmitting power in the following manner: (i) 3.5 kW for 4 seconds,
550 times a day, (ii) 1.2 kW for remaining day and (iii) 5.25 kW maximum (i.e., momentary
peak load) all at a constant speed of 50 r.p.m. Take the life of the gears is to be 8 years.
Determine the equivalent number of loading cycles.
LiJllr Gears
5.79
Gb~n Data: PI - 3.5 kW; P2 = 1.2 kW. P _
life of gears = 8 years. ' ,"cu - 5.25 kW ; NI = N2 = Nmax = SO r.p.m. ;
60 x PI
where Mil = = 60 x 3.5 x I03
2 7t NI 27t x 50 = 668.45 N-m [Maximum torque]
60 x P2 60 x 1.2 x 103
Ma = = = 229.18 N-m
2 7t NI 27t x 50
II = 4 seconds, 550 times a day
Use this modified [ erb ] and [ ere ] values to calculate centre distance (a), and to
check for bending and wear strength .
./' Then proceed the design in the same manner as discussed in Example 5.17.
~~a~N------------ ~5.~8~1
:
./ Use negative sign in the induced contact stress formula. Now equation (5.26)
becomes
c = 0 74
C •
L=J. .... Ii - 1
a \j i b x Eeq [M I ] ... (5.33)
./ Similarly use negative sign in the induced bending stress formula also. Now
equation (5.23) becomes
i-I
crb = a- m . b . Y [Ml] ... (5.34)
(z2-Zt)m
./ Centre distance (a) formula becomes, a = 2 ... (5.35)
Table 5.26. Design bending stress/or non-metallic materials (from (lata book, page no. 8.20)
Material ( Gb I, N/mm2
Textolite 50
Vulcanised fibre gears 36
Plastics 60
Bakelite 56
lli'ot~ ./ The design bending stress [ crb ] for non-metallic materials can also be calculated by
using therelation [crb] = au / n.
Where a = Ultimate strength of material, and
u
./ Standard systems of gear tooth: (i) 14 VJ ° composite, OJ) 14 Y2°full depth involute
,
(iii) 20 °full depth involute, and (iv) 20 °stub involute system .
./ Gear materials: 1. Metallic materials - steel, cast iron, bronze, etc; and 2. Non-metallic
materials - wood, rawhide, compressed paper, bakelite, etc .
./ Gear manufacturing: 1. Gear milling; 2. Gear generation includes hobbing and
shaping; and 3. Gear molding.
./ Gear tooth failure: 1. Tooth breakage; and 2. Surface failure which includes abrasi
"
pttting an d scoring. lon,
p
(i) Tangential component of tooth force, F,
V
=
(ii) RadiaI component of tooth force, F;
Ij = F, x tan ¢
(iii) Resultant tooth force, F = F, / cos ¢
where
m = module,
b = Face width = 10 x module ,
= Allowable static stress, and
1; Y = Lewis form factor.
o accountfior dyna . I ad'
mtc 0 mg, a velocity fi t .
./ Buckin ham'. ac or Cv IS used.
g s equatIOn for dynamic load (F J :
Fd :: F + 21 v (be + FJ
I
where c - D.I'. 21 v + \} be + FI
-- - eJormation factor.
-
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where Q = 2i
Ratio factor - -- =
i+1
s; = Load stressfactor =
j2 sin t/J
es 1.4 Lr Ep1 1 ]
+ Eg
./ Factor of safety:
(F . shendillg
.; When both pinion and gear are made of the same material, then pinion should be
designed. When different materials are used, the product [ ab 1 .y decides the weaker
between pinion and gear. The element which has lower [ ab 1x y value should be
designed .
.; Design procedure: 1. Equate F, and initial Fd, to get module; 2. Calculate Fs"
3. Calculate accurate Fd;- 4. Check for beam strength (or tooth breakage) (F" 5 F..):
5. Calculate Fw; 6. Check for wear (Fd < F,j; and 7. Calculate basic dimensions of
pinion and gear.
II. Gear design based on gear life:
./ Design torque: [Mfl = M, . K . Kd
1.4 Kbl
./ Design bending stress: [ ab 1 = n. K x a_I' for one direction of rotation
(1
i+1 ~ /i+1
./ Induced contact stress: ac = 0.74 --;;- \j ib x Eeq [Mfl
--
t::
5.S4~
Design procedure:
D_e_'7s_ign=--_;of:......_1J_ra_'_Js_m
~
stress [ a" i and [ ac t. 4. Determine centre distance,' 5. Calculate module; 6. Checlc r'
JO,.
bending (a" s [ a" l): 7. Check for wear strength (o; S [ ac J); 8. Check for plastic
deformation (if required); and 9, Calculate basic dimensions of pinion and gear .
./' If the material is same for both pinion and gear, only the pinion is designed If th
materials are different, pinion is designed and checks are carried out for both Pinio;
and gear .
./' At the end cf this chapter, the special topics such as gear design for variable loadin
gear design with reliability factors, design of internal gears, and design of non-melal/~
gears are 'also presented.
REVIEW QUESTIONS
I. State the advantages and limitations of gear drive over belt and chain drives,
2. Why is gear drive known as direct and positive drive?
3. How can you classify gears? What different types of teeth are used in gears?
4. Make a neat sketch of a gear and indicate the terminology used for it.
5. Explain the following terms: (i) module, (ii) pressure angle, (iii) circular pitch, and
(iv) pitch point.
6. State the law of gearing.
7, Write an engineering brief about various forms of gear tooth profile.
8. List out the gear materials used.
9. Write short notes on gear manufacturing.
10. Explain the two modes of gear failures.
11. Deduce the expressions for tangential and radial components of tooth force in a spur
gear.
)2. Deduce the Lewis equation for beam strength.
f
) 3. What are the assumptions made in deriving Lewis equation?
14. Why is a gear tooth subjected to dynamic loading?
15. What is Lewis form factor?
16. Write the Buckingham's equation for dynamic load and expression for limiting wear
load.
17, Why is pinion made stronger than gear?
18. Discuss the design procedure of spur gears recommended by AGMA.
)9. How can you calculate the equivalent number ofloading cycles when gears are subjected
to variable loading?
20.
Explain the design procedure of internal gears.
PROBLEMS FORPRACnCE
Problemon basic dimensions of spur gear:
I. In a pair of spur gears, the number of teeth on the pinion and the gear are 20 and ') 20
respectively ..The mod~le is 4 mm. If the pressure angle is 20° full depth, calculate : (i)
the centre distance, (II) the pitch circle diameters of the pinion and gear, (iii) the
addendum and dedendum, (iv) the tooth thickness, (v) the bottom clearance, and (vi) the
gear ratio.
[Ans: (i) 280 mm; (ii) 80 mm and 480 rnrn; (iii) 4 mm and 5 mm; (iv) 6.2832 mm;
(v) 1 mm; and (vi) 6]
Problemson force analysis of spur gear:
2. A pinion of 100 mm pitch diameter, running at 1000 r.p.m. transmits 6.25 kW of power
to gear whose pitch diameter is 300 mm. For straight tooth the angle of pressure is 20°.
Determine the tangential force, the transverse or bending force on shafts and torques on
driving and driven shafts. [Ans: 1193.75 N; 434.43 N; 119.375 N-m; 358.125 N-m]
3. A pinion driving.a gear about 1110 of its speed transmits 20 kW of power at 2000 r.p.m.
The number of teeth for a full depth pinion of addendum equal to module should be such
that undercutting by a rack cutter is eliminated. The pressure angle is 20°. The sum of
teeth on pinion and gear is required to be 200 while module is 5 mm. Calculate:
(i) number of teeth on pinion and gear; (ii) actual gear ratio; (iii) pitch circle diameters of
pinion and gear; (iv) tangential force; (v) radial force; and (vi) torque on driving shaft.
[Ans: (i) 18 and 182; (ii) 10.111; (iii) 90 mm and 910 mm; (iv) 2120 N; (v) 772 N;
(vi) 95.5 N-m]
4. The pitch circles of a train of spur gears are
shown in Fig.5.16. Gear A receives 3.5 kW
power at 700 r.p.m. through its shaft and rotates
in the clockwise direction. Gear B is the idler
gear while gear C is the driven gear. The number
of teeth on gears A, Band Care 30, 60 and 40
respectively, while the module is 5 mm.
Calculate: (i) the torque on each gear shaft; and
(ii) the components of gear tooth forces; (iii)
Draw a free-body diagram of forces and
determine the reaction on the idler gear shaft.
Assume the 20° involute system for the gears. Fig. 5.16.
[Ans: (i) (M')A = 47746.48 N-mm; (M,>S = 0; (M,)c = 63661.98 N-mm; (ii) 636.62 N
and 231.71 N; (iii) 1228 N]
j
l
I
i.I·
t,
.j
) ~5.~86~ ------------------------
Design of Transmission Syste~
__ ~~~~~~~~---
r'
z2 -- 50',z3 = 20'' and z4 = 50.
Pinion 1 rotates at 1440 r.p.m. 10 'an
c
anticlockwise direction when. observed 175
from the left side and transmits 10 kW
power t 0 the gear train '. The pressure
angle is 20°. Calculate: (I) the ------- .1._
tangential and radial components of
tooth forces between gears 1 and 2, and
gears 3 and 4; and (ii) the resultant
reactions at bearing E and F. Also draw 200 100
•
a free body diagram of the gear tooth
forces. Fig. 5.17.
Fig. 5./8.
[Ans: Ci) F:W = 552.62 N; F~ = 588 N; (ii) 198.95 N-mm]
Spur Gears
5.87
constituting OJ of the cycle time. The mean utilization of the machine time is 0.35. The
required service life is to be 100,000 hours. Find the equivalent number of cycles at the
maximum sustained load, speed being 750 r.p.m.
[Ails: 10.81 x 107 cycles]
21. In a non-reversible type rolling mill drive, a gear is designed to run 20 hours per day,
transmitting power in the following manner: (i) 2000 W: normally (ii) 5420 W for 4
seconds, 550 times a day, (iii) 7900 W maximum (momentary peak load) all at a
constant speed of 45 r.p.m. The life of the gears is to be 7 years. Determine the
equivalent number of cycles at the maximum sustained load. [Ans: 12.5 x 106 cycles]
Problem on gear desigll considering reliability factor:
22. A 3.5 k~ gas turbine running at 1400 r.p.m. will be used to drive the generator at 500
r.p.m. A life of SO hours with 99% reliability is required. Design the spur gear pair.
·Helical Gears
"Sixty years ago I knew everything; now I know nothing;
education is a progressive discovery of our own ignorance ."
- Durant, Will
-
or mary spur gears. e tea gear has tee In the
form of helix around the gear. The use of helical
gears is most common in automobiles, turbines and
high speed applications. A pair of helical gears is
shown diagramatically in Fig.6.1. It can be seen
that the teeth of the two wheels are of opposite
hand. The helixes may be. right handed on one
wheel an~~~ed on the other. ~ ~1. Single-helical gear set.
a... __
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~~ ----------~D~e~S~ign~o~if_TJ_~_uns--m_I.~U~fu~n~Sy
~.2 ~
J. Manufacturing: A limited number of standard cutters are used to cut a wide V8tiel) Of
helicai'gears simply by varying the helix angle.
helical) gears. ~ I
TYPES OF HELICAL GEARS .
, ~"'Ii
6.3
b
4. Normal circular pitch (p,J: The
distance between corresponding points on
(a)
adjacent teeth measured in a plane
perpendicular to helix is known as normal Basic rack
circular pitch.
Pn = P I x cos A
I-' = n-.. mn, ... (6.2)
p = - PI = - Pn =
1t • mn
. A ••• (6.
3)
a tan J3 sin J3 stu I-'
(e)
6. Normal diametral pitel. (p,J: The reciprocal. of the normal module is ,knoWnas
normal dlametral pilch.
'" (6.4)
7. Transverse pressure angle (aJ : The pressure angle measured in transverse plane i.e.,
along the plane A-A is known as transverse pressure angle, ar
B. Normal pressure angle (a,.) : The pressure angle measured in normal plane i.e., along
the plane B-B, is known as normal pressure angle, an'
... (6.6)
i.e., b ~ 1t. mn
Pa or b ~ . A ... (6.9)
sm p
In practice,
b = 10 mn ::= 3 Pn is generally used in the initial stages of the design.
Table 6.1. Basic dimensions of heuca! gears (from data book, page no. 8.22)
I. Normal module mn mm
- mn = ( 2a ) x cos
zl + z2
J3 s:::-dZ
ml mn 2a
2. Transverse module mm ml = --
cos P
= zl +z2
f
c mm c 0.25 mn
5. Bottom clearance
= 0.3 mn, for stub teeth
mm h 2.25 mn
6. Tooth depth h
= 1.9 mn, for stub teeth
d mm mn
7. Pitch circle diameter or reference d1 = cos p x zi ; and
-
diameter mn .
d2 = --x zi.
- cos P
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(c::f3 + 2/0)
(Addendum circle diameter)
d a2 = mn·
9. Root diameter
dj2 = (C::f3-2/o)mn-2c
PI mm
dl
13. Transverse circular pitch
PI = 'It·m I
=1tx-
z]
= Pn Icosp
I '
165 - (_i_)
cos 13
x (25 + 50) or cos
2
13 = 0.909
= 207.05 mm Ans. ~
I Example 6.3 I A pair of parallel /Ielical gears consists of an 18 teeth pinion meshing
with a 63 teeth ,gear. The normal module is 3 mm: The helix angle is 230 whlle the normal
pressure angle is 20 ~ Calculate:
(I) the transverse module;
(ii) the transverse pressure angle; and
(iii) the axial pltch.
Given Data: Z I = 18 ; z2 = 63 ; mn = 3 mm; A
tJ = 23°', an = 20°.
Tofind: (i) m.: (ii) 0.1; and (iii) Po'
@Solutlon :
(I) Transverse module (mt) : We know that the transverse module is identical to module
for spur gears.
d d, d2
... Transverse module, ml _-=-=-
Z zi Z2
Axial pitch, p a
1tx3
or Pa = . 230 = 24.12 mm Ani • ."
Sin
I
nln = 0.4 = 2.5 mm.
Pn 1t x 2.5
Transverse circular pitch: Pc-
cos f3 - cos 20°
- 8.36 mm Ans.""
nI, =
P, -
it
_
it x
Pn
_.;.;,._
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d, =: ~ 2.S
COs ~ x %, ~ cos 200 x ,19 &II ~O.S5 mm ; and
2.5
--cos 20Q xS7., 151.64nun Ans. ..,
I
[Example 6.5 A pair of paralleillel/elli gellrs cOlIs/~·tsof a 1.l/eelll plnlon meshing
willt a 46 teeth gear. Tire helix allcle is 240 mU/llw Iwrlllill pressur« tIIlgle 21 ~ The normal
module is 4 mm. Calculate :
(iii) the axial pitch; (Iv) the pilclt circle (litll"Cler~'of lilt! pinion and the gear;
(v) II,e centre distallee; and
(vi) the addendum and dedendum circle dlameter« (If the pili/Oil,
GivenData: zl = 23 ; z2 = 46; 13 = 24°; 0.,,::::: 210; III" == 4 111m,
©Solution:
(i) Transverse module (mJ : We know that
(iv) Pitch circle diameters OJ·I'tl,epin/on and the gear (i.e, d I anti d ~ "
- ( cosm) 13
__!L x
(ZI +2 z2 )= ( cos424 0
) x (23 +2 46) = 151.06 mm ADS."'CI
a -
b 7
A c
o Fa
J (b) (c)
~PiIctr
• .' qtinda
-i-" -----*"---+~ x
\~.~./
la)
Let F -
Resultant or total force
FI - Tangential or t .'
ransmltted force (or load)
tot~J' -
Fr Radial force , '
Fa - Axial or thrust force ,
M - t Transmitted torque,
d - Pitch circle diameter of gear,
J3 - Helix angle, and
0,/ and an - Transverse and n I
. orma pressure angles respectively.
From triangle ABC (refer Fig.6.4(b »,
Fr - F· sin an
... (i)
We know that the tangential component F, acts at the pitch circle radius. Therefore,
d
F t x-2 = 'M I
60 x P .: P = 2 it N~ .,
where M I = 21t N [
60 j
•
./ Thrust force dlrectlon is given by treating the driving gear as a screw. The foHow~
guidelines can be used to determine the direction of the thrust component:
(i) For the driving gear, use right hand for RH-helix and left hand for LH-heJix.
(ii) Keep the fingers in the direction of rotation of the gear and the thumb will ind~
the direction of the thrust component for the driving gear.
(iii) The thrust component on the driven gear is equal and opposite to that for the dmrffig
gear.
The above said guidelines can be verified 'by using the illustration shown in Fig.6.5.
li!mnple 6.6 I A pair of parallel helical gears consists of an 18 teeth pinion meshing
with a 45 teeth gear. A 7.5 kW power at 2000 r.p.m: is supplied to the pinion through itJ
.,·Iut/l. Tile normal module is 6 mm, w!Ii!e the normal pressure angle is 20'! The helix angle
Is 23 '! Determine the tangential, radial and axial components of the resultant toot/t f~
between the meshing teeth.
GlvenData: z,=18; z2=4S; P=7.SkW = 7.Sxl()3W; N1=2000r.p.m.;
mn = 6 mm ; a; = 20°; J3 = 23°.
To find: (i) F/; (ii) Fr; and (iii) Fa'
@Solution :
(J) Tllngenli(ll componelll of the resultant tootk force (F J :
2· MI
We know that, F/ = d
I Example 6.7 I A torque of 250 N-m acts upon tile shaft of a helical gear whose pitch
circle diameter is 300 mm. The gear has 60 teeth and runs at 250 r.p.m: The pressure angle
of teeth in transverse plane is 180 and angle of helix is 28 ~ Calculate (i) Power
transmitted; (ii) Driving force; (iii) Normal force on gear tooth , and (iii) Force
transmitted to shaft.
Given Data: M, = 250 N-m; d, = 300 mm = 0.3 m; zl = 60; N, == 250 r.p.m.; ,
0./ = 18° ;. 13 = 28°.
Tofind: (i) Power (P); (ii) Ft; (iii) Fr; and (iv) F Q'
@ Solution :,
(i) Power transmitted (P) : We know that,
21t N Mt 2 1t x 2~0 x 250
p = 60
60 = 6.544 kW Ans."
The normal pressure angle (an) can be calculated using the relation
tan an - tan at . cos f3 = tan 18° x cos 28° = 0.287
Fig. 6.6-
Given Data: P = 7.5 kW = 7.5 x loJ W; NA = 900 r.p.m.; mn = 4 mm;
an = 18°; J3 = 25°.
©So/ulion:
(i) Components of the resultant toothforce (i.e; F1' F, and FtJ:
60 x P 60 x 7.5 x IoJ
We know that, = 79.58 N-m
27t x 900
mn 4 132.4 mm
Pitch circle diameter of pinion, dA -
cos t-'f.t x zA = cos 250 x 30 =
- 2 (MJA 2 x 79.58
Therefore, the tangential component F, = dA - 132.4 x 10-3
- 1202.11N Au. ~
,
,, ,
'~...... _'-
" .... 1-·--.
'
.... ,
, B
-_-_-.L ~I ---...._
,
"", I --
,,
Fig. 6.7.
Inn 2.12
The pitch 'Circle diameter of pinion, d, - cos f3 X zi - cos 300 X 18 = 44.06 mm
(i) Components of tooth force:
60 x P 60 x 745
Transmitted torque, M I
- 21tNI = 21t x 1800 = 3.952 N-m
Radial component, Fr - F
I
[tan an]
f3
cos
FrX(250+75)-FQx(~I) - F~ x250 = 0
IFX -:
F~_~l/F~
I
1-: C / •
Fa
z
/'
/ 7-~A--rl--:-=:':_ _
Mt~z
'/-1 B
FY
_j -- x
BIB
Fig. 6.9.
For L Fy = 0, we get
F~ -FY A
-F r
= 0
or 88.892 - F~ - 75.4 = 0
or FY - 13.492 N
A
or FZB = 233.23 N
For L F, = 0, we get
FZA _Fz B + FI = 0
or F~ - 233.23 + 179.41 = 0
or FZA - 53.82 N
I
'Example 6.10 The pitch circles of a
train of helical gears are shown in Fig. 6. 10.
Gear A, in the figlU~ has 16 teeth, a 200
transverse ang/~ a 150 helix angle, and a
normal module of 3 nun. Gear A drives the
idler gear B on shaft 'b', which has 36 teeth.
The driven gear on shaft 'c' has 28 teeth. If
the driver rotates at 1720 r.p.m. and transmits
5.5 k W,find the radial and thrust load on each
shaft
Fig. 6.10.
mn 3
dB - --13
cos
XZB - cos 150 x 36 = 111.81 mrn ; and
mn 3
de = cos 13 x ze = cos 150 x 28 = 86.96 mm
Normal pressure angle, tan an - tan at' cos 13 = tan 20° x cos IS° = 0.3515
2 x (M,)A 2 x 30.54
Ft - - - 1229N
AD dA 49.69 x 1<r3
FrAD - F'
AD
[tIDcos a.13 ]
- 1229[ tID 1937° ]
. _cos 15°
= 447.32 N Ans."
and Fa
AD
- F~ x tan f3 = 1229 x tan 15° = 329.31 N Ans....,
or N
NB == ~ 1720
2.25 ::::225 ::::764.44 r.p.m,
Then velocity ratio between gears B
andC,
i ::::~ == Zc 28
Nc zB::: 36 :::: o.ns
or ~ 764.44
Nc :::: 0.778 :::: 0.778 ::::982.~5 r.p.m,
Since the same power is transmitted from gear Ate
o gear • Therefore
Torque transmitted (~lt)c :::: 60 x p _ 60 x 5.5 x 103
, 2 1t Nc - 2 1t x 982.85 ::: 53.4 N-m
F~c = Fr
CB -
- F'
Be:
[mna.]t3
cos
It can be seen that, since gear B is idler, whatever torque it receives fu."'IID ~.1r' A ~
transmitted to gear C. Thus, the tangential component between gears B and C m~ be ~~
to the tangential component between gears A and B. Since the tangential ~~:S iL~
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._.___ , - __, G ,__ De.'18!!.!1..r"Qn6m~
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module • -1.'2 • S mm), J S tellt/I, tlntl tl normat prelfNure angle of 20 D and INcut left-hUlldtd
wltl' a helix lIngle 0/1 J ~Milling R'lif 1/ 11(181/.1 teeth.
Find tile nllllJnltude 1",,1 dlractll)n III th« force eXINel1 by tl,e beurlnlll lit C IInll D
Oh
"lil,{llb'. A.Nun,e bear/ng C can luke ,)nly rad/fll/l)od whil« bellrlng D Is mounted 10lallt
botl' 'I,d/al l,nlllllfUNt 1o,,,/.
y
--0
--- 8
•
I 76 •
37.6-
Fig. 6./1.
Given Data : (M')J =135.58 N-m; mnl = mn2 = 3.175 mm; zJ = 14; ani = 20° ;
(3J == (32 == 30°; z2 = 36; mn3 = mn4 = 5 mm ; z3 == J 5 ; an3 == 200; 133 = 134 = 15°; z4 = 45.
Tofind: Magnitude and direction of the force exerted by bearings C and D.
@ Solutio,,: The pitch circle diameters of gears 1,2,3 and 4 are given by
mnJ 3.175
dJ == cos 131 x zJ == cos 300 x 14 = 51.33 mm;
mn2 3.175
d2 =
cos 132
xz
2
= cos 300 x 36 = ]31.98 mm;
mn3 5
d3 = xz = cos] 50 x 15 = 77.65 mrn ; and
cos 133 3
mn4 5
d 4 = cos (34 x Z4 - cos 15'0 x 45 == 232.94 mm
9~::../~G~e~
__~__ -- ~ ~~~
~ 6.2'1
2,(M)
'd - U:::
o_ 2 x 13S.58
d1 51.33 x 10-3 ::: 5282.68 N
and F~2 - F~2 . tan fil ::: 528:i:68 -x truf30° ::: 3050 N
2 (M 1)3 _ 2 (3~8.6)
F~4 - d3 - 77.65 x 10-3 = 8978.75 N-m
F,r
34 - F~ [~Sa;:] = 8978.75 [:~ ~~: ] = 3383.28 N
The forces acting on the gears 2 and 3, and the components of the bearing reactions are
shown in Fig.6.12.
f
~I
;,
"
t:
Fig. 6.12.
. .' ant and taking moments about bearing C, we get
ConsIdering the forces III vertical pi (d )
o Ff> x (75 + 87.5 + 50)'- F~2
(d
x 2 ) -
_1 r
F 12 (
75 + 87.5) -
.
F04
3
x -3
2
+ F'34 x 75 = 0
3383.28)( 7S
:::0
or Fb = 1890.41 N
or pYc - 3053.5 N
Considering the forces in horizontal plane and taking moments about bearing C, we get
- F~ x (75 + 87.5 + 50) + p/12 x (75 + 87.5) + P~4 x 75 - 0
or - 212.5 x F~ + 5282.68 x 162.5 + 8978.75 x 75 - 0
or FXD - 7208.67 N
For E H = 0, i.e., considering the equilibrium of horizontal forces, we get
F~ - F ~4 - F~2+ ~ - 0
or F~ - 8978.75 - 5282.68 + 7208.67 - 0
or FXc - 7052.76 N
For E F, = 0, i.e., considering the equilibrium of axial forces, we get
... ;:.
F~4-F~2 -F~ - 0
or 2405.85 - 3050 - F~ - 0
or F~ - - 644.15 N
The negative sign indicates that F~ acts in the opposite direction to the direction shown in
Fig.6.12.
Therefore, resultant reaction at bearing C - -v '(F~)2 + (F~ )2 + (F~ )2
- ~ (7052.76)2 + (3053.5)2 + 0
- 7685.39 N AIJs. ~
Helical Gears
:;;--- 6.23
I
i
I
DESIGN OF HELICAL GEARS
1 I
I
,
I. HELICAL GEAR DESIGN USING LEWIS
(Helical Gear Design Recomme n d ed by AND BUCKINGHAM'S EQUATIONS
AGMA) I
6.9. BEAM STRENGTH OF HELICAL G
As discussed in Section 6.4 the f ~RS (Lewis Equation for Helical Gears)
. 1 ,ormattve gear is . .
peepend leu ar to the tooth element It . d an imagmary spur gear in a plane
• • IS un erstood that th b
virtual) gear IS nothing but the beam stre gth . e earn strength of formative (or
. . n of helical gear Th f .
equation IS used to determine the beam str h . . ere ore a modified Lewis
F _ engt of a hehcal gear. It is given by
s - 1t. mn· b [ CJb ] • y'
F _ B t gth ... (6.13)
where s earn s ren of helical gears,
mn - Normal module ,
b - Face width = 2Pn to 4 Pn (or) 10 m.,
where Pn = Normal circular pitch = 1t. mn
[ CJb] - Permissible or allowable static stress, from Table 5.4, and
y' _ Tooth form factor or Lewis factor based on virtual or formative
or equivalent number of teeth.
The beam strength (Fs) indicates the maximum value of tangential force that the tooth can
6.10. DYNAMIC LOAD ON HELICAL GEAR TOOTH (Effective Load on Gear Tooth)
As discussed in previous chapter, in addition to the static load due to power transmission,
there is dynamic load betWeen the meshing teeth. In order to account for dynamic loads, the
following two methods are used.
I. Approximate estimation of dynamic load using the velocity factor, which is used in
Fd ::: Cv
where F, _ Tangential load considering service factor
_ -P x Ko'
v
b = Face width,
c = Deformation or dynamic factor in N/mm, from Tables 5.7(a) and (b), and
13 = Helix angle.
~ ~::i~~I~G~e_~_~
~~ __ ~ ~~
6.25
_ W __2z2
i-I - z2 -;; , for internal gears
The value ofv used in velocity factor formula may be initially taken from 10 to 15 mls.
5. Calculation of beam strength (FJ: Calculate the beam strength (Fs) in terms of
normal module using the relation
F, = 1t·mnb[O'b]Y'
y' = Form factor based on virtual number of teeth, from Table 5.5.
6. Calculation of normal module (m,J : Since the gear is designed on the basis of beam
strength, therefore Fs ~ Fd' So equating Fs and Ftb find the normal module.
Then select the nearest higher standard module value from Table 5.8.
7. Calculation of b, d and" :
./ Find face width (b): b = 10 mn
m
./ Find pitch circle diameter (dt): d, =~ x zl
cos p
. 7td1N1
./ Find pitch line velocity (v): v = 60
8. Recalculation of the beam strength (F J : Recalculate the beam strength of the gear
tooth using the relation
Fof = 7t. mn . b [0' b ] Y'
9. Calculation of accurate dynamic load (FttJ: Calculate the dynamic load more
accurately using Buckingham's equation as given below.
Fd = F,+Fl
21 v (cb . cos213 + F,) . cos 13
= Ft +
21 v + -.J cb cos213 + F,
. wh~re c . = Deformation factor, from Tables 5.7(a) and (b).
Wh1le calculating the dynamic load (Fd), the value of tangential load (F) should be
calculated.by neglecting service factor 0<0). '
p
i.e., F, = -;
l
j
-Helical Gears
6,.27
10. Checkfor beam strength (or tooth breaka •
./ Compare Fd and Fs: rge) •
./ If F d S FoS' the gear tooth h
b aka Th th as adequate beam strength and it will not fail by
re gee us e design is satisfactory
./ If Fd > FS' then change face width d .
I d (F ) th ,mo ule or both. Usually, to reduce the dynamic
;a fi d , e .g~ should be carefuHy cut (i.e., reduce the deformation factor (c».
ven or precision gears, if Fd > Fs then increase the face width till F < F
11. Calculation of the maximum ' ad ' d s:
wear ..0 (F.,): Calculate the maximum or limiting
wear load using the relation
d1xbx9xK,.,
cos2 f3
. 2; 2z2
where Q - RatIO factor = -.- = d
I+ 1 z I + z2' an
~., - Load stress (or material combination) factor, from Table 5.9.
12. Check for wear:
./ Compare the calculated values of dynamic load (Fd) and wear strength (Fw)'
./ If Fd < Fw' the gear tooth has adequate wear capacity and will not wear out. Then
the design is safe and satisfactory.
13. Calculation of basic dimensions ofpinion and gear: Finally, calculate the basic
dimensions of pinion and gear by consulting Table 6.1.
I Example 6.12 I Design a helical gear to transmit 15 kW at 1400 r.p.m: to the
JoUowing specifications: Speed reduction is 3; Pressure angle is 20~ Helix angle is 15~
The material of both the gears is C45 steel: Allowable static stress 180 N/nun2; Sur/ace
endurance limit is 800 N/nutf1; Young's modulus of materia: = 2 x lOSN/nun2.
Given Data: P = 15 kW; Nl = 1400 r.p.m.; i = 3; ~ = 20°; J3 = 15° ;
2
[ CJb] = 180 N/nun2; f es = 800 N/mm2; El =~ = 2 x lOS N/mm •
2. Calculation of Zl and Z2 :
./ Assume z 1 = 20
./ z2 = i x zi = 3 x 20 = 60
6.21
v -
... 12353.45
x 0.286 -
1 43237.075
zi 20
where Zeq - cos3 ~
= cos3 15° = 22.192::t: 23
or
646.62mi ~
mn ~ 4.058 mm I
From Table 5.8, the nearest higher standard normal module is S mm.
7. Calculation of b, d and v :
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6,29
== 7tx5x50x
180xO.1143 = 16]5878N
9. Calculation of accurate dunaml
'J
•
C .oad (F,J :
.
where
F == ~_ 15 x ]03 ~ e, ~3 .
I V - 7.59 = ]976.28 N
,
c = Deformation factor, from Tables 5.7 (a) and (b).
- 11860 e, for steel and steel, 20° full depth, from Table 5.7(a). _
e = 0.025, for mn upto 5 and carefully cut gears, from Table 5.7(b). ~ ~ :S~ '
... c = 11860 x 0.025 = 296.5 N/mm :;
=.
10863.26 N
Now we find Fs > F d' It means the gear tooth has adequate beam strength and will not fail
by breakage. Thus the design Is satis/adory.,
=
s, x h x Q x x, ~
We know that, Fw COl2 f3
21 2~3
where Q - Ratio factor :: 1 + J :i+ 3+J 1,5
+ 1. ]
Kw - f ./ 1.4
sin (1.. [_'
E. ~
(800)2 x sin 20" [ ,
-
1.4 2 x JO~ h" 'IP ]
::
1.5635 N/mm2
12. Check for wear: We find Pw > Ftl It means the gear tooth ha~ adt€r~ wt;lr
capacity and will not wear out. Thus the design is safe and 6atJsfactOry.
13. Calculation of basic dimensions of pinion and gear: Refer Table 6, J,
Normal:
./ Normal Module: mn = 5 mm
./ Number of teeth: Zl = 20; and Zz = 60.
m;z 5
./ Pitch circle diameter: d1 :: 103.53 mm; and dz = cos f3 / Z]. = cm,l~
'I
60
::
310.58 mm
(c:: /0) f3 - 2 m. - 2 c
ZI 20
cos! f3 - cos! 150 = 22.192 ~ 23; and
z2 60
zv2 = cos! f3 - cos3 150 = 66 .57 ~ 67
I Example 6.13 I For the above example, calculate the end thrust on the gear.
Given Data: Refer Example 6.12. . '. ..
Tofind: End thrust on the gear.
@ Solution : We know that the end thrust or axial load on the gear,
p
Fa = FI X tan
.
J3 = -
v
X tan f3
15 X 103
- 7.59 X tan 15° = 529.54 N Ans."'tJ
[Example 6.14 IA compressor running at 360 r.p.m: is driven by a 140 kW, 1440
I'.p.m. motor through a pair of 200 full depth helical gears having helix angle of 25 ~ The
centre distance is appl'oximately 400 mm: The motor pinion is to be forged steel and the
dl'iven gear is to be cast steel. Assume medium shock conditions. Design the gear pair.
Given Data: N2 = 360 r.p.rn; P = 40 kW; Nt = 1440 r.p.m.; ~ = 20°; J3 = 25° ;
a=400mm.
Tofind: 'Design the ~eJical gear pair,
@ Solution: Since th~,materials for pinion and gear are different, first we have to
evaluate ,[ (J~1 ] Y~ 'and [(J b2] y; to' find out the weaker element.
1440
Gear ratio, ; = 360 = 4
Assume zi
... Z2 - ; x ZI = 4 x 20 = 80
zi 20
Virtual number of teeth : zvl - cos3 J3 - cos! 250 ~ 27; and
80
Zv2 = cos3 250 ~ 108
Given that the pinion is to be forged steel and the gear is to be cast steel. ~
consulting Table 5.3, the following steels are selected.
Pinion - Forged steel, and
Gear - Grade 1 i.e., CS 65 cast steel
For pinion: From Table 5.4,
[ crbl] - 112 N/mm2, for forged steel; and
0.912)
- 0.154 - ( 27 = 0.1202
0.912)
- 0.154 - ( 108 = 0.1455
We find (crbl) Y; < [ Cfb1 ) y;, i.e., the pinion is weaker. Thus, we have to design the
pinion only.
1. Material selection: Pinion - 40 Ni 2 Crl Mo28; and Gear - Grade 1 cast steel
2. ZI = 20 and z2 = 80. . .. (Already caJcutated)
3. Calculation of module: Since the centre distance is given, we need not to equate f,
and Fd to calculate the module. The module can be calculated using the relation
a = (;'-li) x(ZI;~)
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-
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6.33
,/ ./ NI
Pitch line velocity (v): v == 'It d) = 'It x 176.54 X 10-3 x 1440
60 60 = 13.31 mls
5. Calculation of beam strength (Fs) :
We know that, FS = 'It. mn . b . [ CJb' ] y'
- 46865.44, N
7. Check for beam strength (or breakage): We find Fd> F" So the design is
10(Jlh
unsatisfactory. Since the difference between Fd and F, is high, we can increase the face width
I by increasing the normal module from 8 mm to 9 mm.
= 198.61 mm ;
I
cos cos
'It d1 NJ _ 'It x 198.61 x 10-3 x 1440 = 14.97 mls;
Pitch line velocity, V = 60 60
I
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6.34 Design of Transmission $y3Ie""
~
p 140 x 103
Tangential load, F/ = V - 14.97 = 9352 N ; and
9. Checkfor wear: We find F,., > Fr It means the gear tooth has adequate. wear capacity
and will not wear out. Thus the design is safe and satisfactory.
10. Calculation of basic dimensions of pinion and gear: Refer Table 6.1.
-/ Normal'module : mn = 9 mm
./ Face width: b = 90 mm
./ Number of teeth : zJ = 20; and Zl = 80
-Helical Gears
6.35
'" Centre distance :
a = (~)
cos f3 x
(ZJ+Z)
-2 2
= _ 9_ (20+80)
'" Height factor: 10= 1 cos 25° - 2 == 496.52 mm
_ ( 20 )
- cos 25° + 2 x J 9 == 216.61 mm; and
= (CO:~50+ 2 I ) 9 X = 812.43 mm
./ Root diameter: d
fJ =
(ZJ
cos f3 - 2 f
) 2 0 mIl - c
20 ) -
= ( cos 250 -2 x I 9-2 x 2.25 = 176.11 mm; and
[Example 6.15 , A pair of 20" full depth involute teeth 30 D helical gears having u
velocity ratio of 3. Tile pinion is made of steel with allowable static stress of 100 N/nuttl
and the gear is made of cast steel will, allowable static stress of 70 N/nuttl. The pinion
transmits 40 kWat 1500 r.p.m. Determine all the basic dimensions of the gear pair.
.
Assume width of face as 3 times the normal pitch and tooth form factor as
0.154 - 0.0912 where z is the equivalent number of teeth.
z'V V
e Solution: Since the materials for pinion and gear are diffemJt, f.. ~ ~ II
evaluate [ O'bl ] y'l and [ 0b2 ] y;
to find out the weaker element. Assume z, = 20.
Then, Z2 - i x z 1 = 3 x 20 = 60
ZI 20
VirtlUll number of teeth: zYI - cos313 - cos3300 = 30.79 ~ JJ, and
Z2 60
zY2 _ cos3 f3 - cos) 300 = 9238 ~ 93
- 0.154_(°;112) = 0.1246
... [Obl]~ _ 100 x 0.1246
= 12.46 N/mm2
We find [(61) Y; < [ 0'61 ) y;, i.e., the gear is weaker. Thus we have to tU:sigII 1MP
only.
1. Material selection: Pinion - Steel, and Gear- Cast steel
2. z 1 = 20; and z2 = 60. ... (Already cakuJafed)
3. Calculation of tangential load on tooth (FJ :
P
We know that, FI = -v X Ie
&~
where v = _ 7t d2 N2 = 7t x N. (mIJ ~)
60 60 cos P x 1000
[ mil . . I11'1
... '.' d I = cos Px ZI and mil IS ID
j; ...
'uP"
7tx 1500 x mn x 20
- 60 x 1000 x cos 300 = 1.814 mn
... FI = 40 x 1()l
1.814 mn x 1.25 =
21566.44
mil
We know that,
6
c y
== 6+;, for 'V == 5 t 20 mI
o s and carefully cut gears
6
- 6 + IS = 0.286, assuming v = IS mls.
·.· F d == 27566.44
mIl
1 96386.17
x 0.286 = ----0..;..;;..;..
mil
S. 0Ilcuhrti01l of bmm stre"gth (F j :
Weknow~ F, - 7t. mil • b . [ Gb2 ] • y;
where b - 3 PIt = 3 x 7t x mII ~ 10m II ... (Given)
·.· Fs - 7txm"x IOmllx70xO.144 = 316.67m2
II
6. Clzkllllllioll of1f017IUJ/ modul~ (m,J:
Weknowth~ Fs ~ Fd
96386.17
316.67 m2 ~
" mil
P _ 40 x 1()3 == 3149.61 N
F, - v - 12.7
. factor , from Tables 5.7(a) and (b).
_ J)efonnaDon
c c.. st I and steel 20° FD, from Table 5.7(8).
_ 11860 e, lor ee '
m upto 7 from Table 5.7(b).
e - 0.017.JDDl, for" '
c = 11860 x 0.017 == 201.62 N/mm
·.·
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6.38 Des ign of Transmission Sy'lenr
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~
... Fw
_ 161.66 x 70 x 1.5 x 0.912 = 20799.17 N
cos2300
12. Check for wear: We find Fw> F II- It means the gear tooth has adequate wear capacit
and will not wear out. Thus the design is safe and satisfactory.
13. Calculation of basic dimensions of 'pinion and gear: Refer Table 6.1 .
./ Normal module: mn = 7 mm
./ Number of teeth: ZI = 20; and Z2 = 60
mn
./ Pitch circle diameter: dl = 161.66mm; and d2= A XZ2
cos tJ
7
- cos 300 x 60 = 484.97 mm
7 20+60)
./ ( 2 = 323.3 mm
cos 30°
./ Height factor: 10 - 1
./ Bottom clearance: c - 0.25 mn = 0.25 x 7 = 1.75 mm
./ Tooth depth : h = 2.25 mn = 2.25 x 7 = 15.75 mm
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HelicalGears
6.39
d Q2 = (0::13 10) m.
+-2
= (co:~oo + 2 x I) 7 = 498.97 mm
~ Root diameter; d
/1 =
(ZIcos f3 - 2f0
) mn - 2 c
NI z2
where 1 = Gear ratio = N; - -,
zi
•
y" = Form factor based on virtual number of teeth, from Table S.13, 8JJd
[ M I] = Design torque.
Kbl
- x a_I' for rotation in both directions ... (6. J9(b))
n·K 0-
2 EJ E2
or
EJ +E2
where El and ~ Young's moduli of pinion and gear respectively.
a:2:(i±l)
3 (_0.7)2 Eeq x [Mil ... (6.22)
[ael i",
Helical Gears
6.41
6.14. DESIGN PROCEDURE
Though the design p~ocedure for helical gears is same as for spur gears, .the step by step
design procedure for helical gears is given below for ready reference.
.
1. Calculation of gear ratio (i): Use 1. = Nt
- z2
= _
N2 Zt
2. Select the suitable combinatioll of materials for pinion and wheel, consulting
Table 5.3.
Since datas are inadequate to select the values of K and Kd, initially assume K· Kd = 1.3.
./ To find [ob]: Calculate the design bending stress [ob] using the equation 6.19 .
./ To find [ 0c]: Calculate the design contact stress [ ere] using the equation 6.21.
2a A
In == ) x cos I-'
n (z) +z2
111"
./' Calculate the pitch diameter of pinion (d I): Use d I cos ~ x z,
1t el, N,
Calculate the pitch line velocity (v): Usc v > 60
b
Calculate the value of\Vp: Use \jlp = ell
./' Revise I MIl: Using the revised values of K and Kd, revise the design torque
[ M I]. Use [M I] = MI X K x Kd
~~/~G~e~ar._~_·'_' ~ -: ~~
6.43
0ot!l
./ The above listed procedure is for th desi . .
e esign of pinion .
./ As discussed in Section 5 31 If Il
(le.fi"II only tile pin! 1'1';" te malerlals of.tlle pinion and gear are sallie, then
lJ on. 'J me materials of til I I .
the pin 1011first (III I l 'kfi e p ~~on «..~-gear are dlfferent, then des/gil
c C tee or botl: pill/Oil (lIldHell,:
./ The induced bending stress in th ( -'
e gear ob2) can lit!' determined by using the relation
Obi Yvl = °h2Yv2 ... (6.23)
where CJ b I and cb2 = Induced bending stresses of pinion and gear respectively, and'
Yvl and Yv2 = Form factors of pinion and gear respectively based on the
virtual number of teeth.
Since the contact area is same, the induced contact stress is same for both pinion and gear.
i.e., Oct = CJc2'
I Example '6.16 I For intermittent duty of (lII elevator, two cylindrical gears have to
1'(IIIs»I;112.5 kW lit II pinion speed of 1200 r.p.m: Design tile gear pair for tile following
specifications: Gear ratio 3.5, pressure angle 20 ~ involute fuJI dept", helix angle 15 ~
Gears are expected to work 6 "ours a dayfor 10 years.
Given Data : P = 12.5 kW; N, = 1200 r.p.m.; i = 3.5; q, =20~ FO'; f3'= 15°.
© Solution :
... (Given)
1. Gear ratio: i = 3.5
2. Selection 01 material : For both pinion and gear, alloy steel 40 Ni 2 Cr 1 Mo 28 can
be se'I ecte d, consu I'ting T a hie 5.3. AoJ,Since tile gears are
,
of same material, we design only tile
pinion.
3. Gear life: Given that gears are to work 6 hours a day for 10 year.
.. Gear life = 6 hours / day x 365 days / year x 10 = 21,900 hours
Assume K· Ko
== 1.3 (_PS 6\ a , \~ )
== 99.47 x 1.3 == 129.31 N-m
1.4 Kb/
[ CJb] = n- K, x O'_J , for rotation in one direction
{
~. tV
where Kb/ - 0.7, for HB > 350 and N ~ 25 x 107, from Table 5.14,
Ka = 1.5, for steel hardened, from Table 5.15,
b
where \V - -a =03. ... (initially assumed)
Then, Z2 = i X Zt = 3.5 x 20 = 70
• • . 1t X mn 1t x3
=. Sin 15° = 364" mm We find b> Po'
AXIal pitch, Pa = .
A
Sin tJ
..
'" Pitch diameter of pinion (d,): d L_.= -cos
--~ f3 X ':"
-I -- cos3150 x 20 = 62 . 12 mm
11. Selection of quality of gear: From Table 5.22, for HB > 350 and v upto 8 m/s,
IS quality 8 is selected.
12. Revision of design torque I Mt}-:
We know that, [ M/] = MI x K x K"
where K :::: 1.045, for \fIp = 0.676, from Table 5.11, and
zvl -
z.
cos f33
20
= cos! J 5°
% 22
- 0.7 ( 139.76
3.5 + I) --------------------------
3.5 + 1
42 2.15 UP
3.5 x x
.
JOJ x x 124,74 Yo
- 645.8 N/mm2
We find ac < [ ac J. Thus the design is safe and satisfactory.
15. Calculation of basic dimensions of pinion and gear: Refer Table 6.1.
~ Normal module: mn = 3 mm
mn 3
~
R X Z,
cos..... - = cos 150. x 70 = 217..4 mm
da2 = (c:13 + 2 f 0 ) m.
6.47
./ Root diameter: d /1 - (~ 2f )
cos '(3 - 0 n1n - 2 c
d f2 - (0:: 13 - 2 f 0) »,- 2 c
( cos7015° - 2 x 1 ) :\)
- "1::" 2 x 0.75 = 209.91 mm
. : . N! 3000 = 3
1. Gear ratio I =N = 1000
2
2. Selection of material :
Pinion = Heat treated cast steel - Grade 1 i.e., CS 65
J. Gear life: Given that n = 10,000 hours. T-hen the gear Iife in terms of number of
cycles is given by
N = 10000 x 3000 x 60 = 180 x 107 cycles
We know that, [ M I] = MI X K x x,
60 x P 60 x 12.5 x 1()3
where 27t x 3000 = 39.788 N-m, and
27tN
K· Kd - 1.3. ..! (initially assumed'
[Mt] = 39.788 x 1.3 = 51.725 N-m
5. Calculation 0/ Eeq, 1000bl and I OCl :
../ Tofind Eeq : From Table 5.20, for steel pinion and C.l. gear (au> 280 N/mm2),
].4 Kb/
- 11 K x a_I' for rotation in one direction
(J
where Kb/ - I, for steel pinion, HB s 350, N ~ 107, from Table 5.14,
For CS 65, all = 650 Nzmm? and ay = 400 Nzrnm-', from Table 5.3.
].4 x ] _ 2
Then, - 2 x 1.5 x 281 - 131.133 N/mm
(i + I) 3 (0.7
[ae]
J 2 x
~::~G~~ __6 ~~
6.49
.
.. a (3
i:. I) ( J~'~6) 2 x 1.7 x lOS x 51.725 x 1<P
3 x 0.3
or a i:. 54.23 say a %.I: 60 mm
7. As~ume z. - 20.
Then, Zl - ix ZI = 3 x 20 :; 60
8. Calculation 0/ normal module (m,) :
We know that m 2a 2; 60
~ n = {z, + zV x COS p = (20Y~ 60) x cos 25° = 1.359 mm
./ b 26.48
To find '¥p: '¥p = d, = 44.14 = 0.6
11. Selection of qUlIlity of gear: From Table 5.22, for v upto 8 mis, the IS quality 8 gear
is selected.
12. Revision of design torque I MIl:
We know that, [ M I] - M I Y. K x Kd
K ::: 1.03, for 'Vp = 0.6, from Table 5.11, and
where
Kd::: 1.3, for IS quality 8 and v upto 8 mis, from Table 5.12.
zi 20
zvl - cos! J3 - 3 250 = 26.86 ~ 27
cos
Yvl
~ 0.43, for zvl = 27, from Table 5.13.
Gc = 0.7 e: -vW 1
) x Eeq x[Mtl
- 677.39 N/mm2
We find ac < [ ac]. Thus the design is safe and satisfactory.
15'. Check for wheel: Wheel material = Cast iron-Grade 35.
First we have to calculate [ ab ]wheel and [a c ]wheel .
107
= 0.8195
60 x 107
Ka - 1.2, for cast iron, from Table 5.15,
n = 2, for cast iron, from Table 5.17,
a_I - 0.45 aU' for cast iron, from Table 5.16.
For C.I Grade 35, au - 350 N/mm2, from Table 5.3.
... 0'_1 - 0.45 x 350 = 157.5 N/mm2
1.4 x 0.8195
Then, [ O'b ]wheel - 2 x 1.2 x 157.5 .= 75.29 N/mm2
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~::../~O~ea_~_~ ~~
6.51
HB = 200 to 260, for CI. Grade 35, from Table 5.18, and
'J
t
Kc{ = «f .for cast iron, from Table 5.19.
=
107
60 x 107 = 0.742
.. [ crc ]whec:1 = 2.3 x 260 x 0.742 = 443.62 N/mm2
(i! Che~k for bending: The induced bending stress for wheel can be calculated using the
reIanon
crbl Yvl = °b2Yv2
where Yvl = 0.43, for zvl = 27, from Table 5.13.
z2 60
zv2 = cos) (3 = cos) 25° ~ 81
d 02 = C:: f3+ 2 f 0 ) »,
INote I Though the terms herringbone and double helical are used interchangeably, when there ~s
no groove in between the gears, is specifically known as herringbone gears (Fig.6.13). When there IS
The design formulas, the design procedure and other parameters of Herringbone gears are
exactly the same as that for parallel helix gear. Thus in order to design a Herringbone gear,
one can follow the procedure presented in Sections 6.12 and 6.14, without any modifications.
In order for two helical gears to operate as crossed-helical gears, they must have the same
normal diametral pitch and normal pressure ~n' But the gears need not to have the same helix
angle or be opposite of hand. In most crossed gear applications, the gears have the same hand.
where [31 and [32 = Helical (or spiral) angles of gear teeth for pinion and
gear respectively.
N) z2
i-Gear ratio = N2 - z 1 '
or
Since the normal pitch is same for both the spiral gears,
therefore
Pn = Pnl = Pn2 = PII X cos 131
= Pt2 x cos 132 [.,' Pn = PI' cos 13] Fig. 6.14. Centre distance/or a pail
of spiral gears
Pn d Pn
or
PII = cos 131 an Pt2 = cos 132 ... Oi)
,
Substituting equation (ii) in (i), we get
d = », X zl
and d
Pn x z2
= ___;;_.:.:...._.......::.- .. , (iii)
I 1t x cos 131 2 1t x cos 132
But we know that the centre distance,
a = dl+d2
2
=l[ 2
pnxz1
1t x cos 131
... (6.21(a»
= e, zl
21t
[I cos
i
13, + cos 132
]
... [
... i = zl
z2 J ... (6.24(b»
Vs,.
I
= [vi + v; - 2 VI • V2 x cos e ]112 ... (6.27(a»
where VI and v2 = Pitch line velocity of pinion and gear respectively, and
e = Shaft angle.
When the shafts are at right angles (i.e., e = 90°), then the sliding velocity will be
VI
V
s
= cos (32
... (6.27(b»
a = Pn zl
27t
[ I +
cos l31 cos
j J_
f32 -
Pn
27t
z) [
cos
I+i ]
l3) ••• [ •.• 1-')
A =A2]
P
18 x z)
400 = [ 1+3 ] = 12.64 z)
27t cos 25°
400
or z, = 12.64 = 31.64 or 32 ADS. "
----___ -- ~6~.5!_
11 :<'j} (~ ~) cos f3 t
CUs (~, "" - == COs (f3) + $)
JlI -Itll cos 132 cos (~_~) [.: PI == I3V
e ~ (25(' ~~
C{)s (25(' - 6(,) == 0.907
- 90.7% ADS. '"t>
and Pn~ 12 x 50
d2 = = = 297 mm
1t cos f32 1t x cos 50°
d , + d2 1] 0 + 297
Centre distance between shafts. a = 2 =
2
= 203.5 mm ADS."
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6.58 Design of TransmissionSY.fl
----------------------------------------------~~------ __ .~ e~
3 cos PI
-
2 cos (80° - PI)
2 (cos 80° . cos PI + sin 80° sin PI) = 3 cos PI
Centre distance, a =
r, zl
21t
[1 cos
i
131 + cos 132
]
125
_ lOx zi
21t
[1cos 53.4° +
(~) ]
cos 26.6°
125 - 5.34 zi or zi = 23.4 say 24 ADS."
3
and z2 = i z) = 2: x 24 = 36 Ans. ~
a >"
E.n ~
21t
[--A 1
coS ......1
-1-
~
coS 132
,ADS. 1:1
_ 154.2 OUD
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6.60 Design of Transmis.fion S)l.f~
~
REVIEW AND SUMMARY ...
,
./' A helical gear has teeth in the form of helix around the gear .
./' Advalltage.f of hetica! gears: Less noisy, greater load carrying capacity, and
manufacturingfeasibiltty .
./' Disadvantages of helical gears : They are subjected to axial thrust loads .
./' Types: 1. Parallel helical gears,' and 2. Crossed-helical (or spiral) gears .
./' The helical gear nomenclature and its kinematics are presented in the beginning ofthiJ
chapter .
./' Helical gear nomenclature:
xd, Pn
(i) Transverse circular pitch: PI = 7r' ml - -
z, cos f3
(ii) Normal circular pitch : Pn = PI X cos P = «<»,
-7r
J.
(iv) Normal diametral pitch: Pd - -
n1n Pn
(v) Relation between fJ, at and an: tan an = tan a
l
. cos f3
./' An imaginary spur gear considered in the normal plane is called as the virtual or
formative spur gear. The number of teeth on the virtual spur gear in the normal plane is
known as virtual or formative or equivalent number of teeth. It is given by
z
z =
eq cost p
Tooth proportions and basic dimensions of helical and herringbone gears are tabu/aled
in Table 6.1.
Force Qllalysis on helical gears:
Three components of resultant force on the gear tooth are :
~~e~~=~================~
_ ~~ 6.61
I 21 v + cb . cos2 f3 + F, -v
trr
(ii) rr ear toot
h I 0ad, F __ d J x bx Qx~
W cos2 P
.; .Herringbone or double helical gear consists of teeth having a right and left' handed
helix cut on the same blank. Herringbone gears are used to overcome the difficulty of
end thrust in the single helical gear.
Crossed-helical or Spiral gears:
.; For connecting non-parallel and non-intersecting shafts, crossed helical gears are used
.; Crossed helical gears transmit relatively small amounts of power because of point
contact between teeth
.f Kinematics of spiral gears :
{l) Shaft angle, 0 = PI + P2' when both gears of same hand
= pI - P»- when gears are of opposite hand
2
(ii) Centre distance (a): a = ~; [c~JpJ + c~2P2 ] =0.5 m.[ c~JpJ + CO: P2 ]
NJ zl d2 cos P2
(iii) Gear ratio: / I = N2 = zl = d, cos PJ
cos (0+ ;J + J
and 17max = cos (0- ¢) + J
where the notations have usual meanings.
liP) MOM
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.i"~
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Determine the tangential, radial and axial components of the resultant tooth force
between the meshing teeth. [Ans: 715.24 N; 287.14 N; 33352 ~1
9. A helical gear of 60° helix angle is required to transmit 10 kW of power at 500 r.p.m,
The pressure angle measured in a transverse plane is 20°. Calculate (a) driving force; (b)
radial force acting as bending force on the shaft; and (c) the axial force on the shaft.
The gear meshes with a pinion rotating at a speed of 914.5 r.p.rn. and sum of number of
teeth on pinion and gear is 99. The module of gears in a plane normal to the tooth is 4
mm. Calculate the angle of pressure in a plane normal to the tooth.
[Ans: (a) 12993 N; (b) 473 N; (e) 750 Nand 115°1
RH
z=2D
A
10. A pair of parallel helical gears is shown in Fig.6.15 '. A 5 kW
.' A th ough Its shaft
power at 720 r.p.m. is supplied to pmron r ..
. 5 rnrn and the normal pressure angle IS
Th e norma I mo d u Ie IS. d t th while the gear has left-
200. The pinion has nght-han . 300 ee ,The arrow .indIcates
. the
hand teeth. The helix angle IS
direction of rotation when seen th fi
from the right-hand side.
Also draw a free
t
ts fthe too orce.
Determine the componen 0 . h 'nion and the gear.
LH
body diagram showing the forces on t e pi
Fig. 6./5.
[Ans: 11486., N' 482 .73 N; 663.14 N]
6.64 . . "--
. 5h own In
I I' I gear .box 15 . Fig .6 -16_ Pinion A 'ISn-
i!!l.e W-Jl~
1 The layout of a double- ie rca li d to it through ;1:5 shan D .J. ~ llllJnle
I . d 10 kW power at 720 r.p.m. IS supp ie . • ~ 50' z ~ 2{)' and _ ~ [, ""
gear
O
an . I are' Z = 20, -B ~ C
f teeth on different helica gears . A . f helical .o:-e.arsA and IR :bf fut:h
. 200 For the pair I(} ...,11::=> _ _
normal pressure angle for all gears IS " F the pair C and I), the MIX an e''k> '!5 2::'"
angle is 30°, and the normal module IS, :~~ ~~t handed helical teerh, ,,~ • pirilD .
and the normal module is 5 mm. Pml~n and B are mounted on shaft no.] i:n ;;ocih > 't'
has a left handed helix. The beanngs I . 2 . B an take hoJ;b "",,,,I... ,~ :a;
I k adial load while bearing 2 c
that bearing B) can on y ta e r " f bearinz reactions on shpn.:J
. t Iie magn itude and direction
thrust load. Determine D RH o ~
RH
Fig. 6./6.
[Ails: FBI
r
= 5044.58 N ; FYBI = 2'64
.) .);- N , = 479456 N:
FJ:B_~
14. A pair of helical gears is to transmit 40 kW at 1800 r.p.m. The speed reduction n:quin><i
is 4 and helix angle is 15'. Design the drive for COntinuous service with moderate sMct
loads. Pressure angle is 20·. Assume the suitable materials for the drive.
IS. Design a helical gear drive to transmit 5 kW at 1440 r.p.m. Speed ratio is 2.5. SeI«'
suitable material for the gears.
~~~~~~~----------------~
}6.
.'
A helical cast steel with 30° helix an I .
bas 24 tee
th determi gels to transm't 36 kW
etermme the necessary modul . I.
6.65
Bevel Gears
"A good scientist is a person with original ideas. A good engineer is a perUJriwh&
makes a design that works with as few original ideas as possible
There are no prima donnas in engineering. .-
- Freeman DyJO"
7.1. INTRODUCTION
(Bevel gears are used to transmit power
~o intersecting shafts. Bevel gears are
commonly used in automotive differentials. The
gears are formed by cutting teeth along the
elements of frustum of a cone. That is, the pitch
surface in the bevel gears are truncated cone,
one of which rolls over the other, as shown in
Fig.7.!. When teeth formed on the. cones are
straight, the gears are known as slrlliglzt bev!!j
and when inclined, they are known as spiral or
helical beveL Fig. 7.1. Bevel gear
Bevel gears are mounted on intersecting shafts at any desired angJe, although 90° shaft
angle is most common. Bevel gears are not interchangeable. Because they are designed and
manufactured in pairs.
The bevel gear teeth can be cast, miJIed, or generated. But the generated teeth is more
accurate than cast and milled teeth. _. -
••2. TYPES OF BEVEL GEARS
~-~~~=-------~--------------
iral sevel Gears
__ _JD~e~s~ign~O~if~Tl~ran~s~m~~~s~ro~n
2.SP~
Jrhell the teeth of a bevel gear are inclined at an
I to the face of the bevel, they are known .
a"g,e . . as spITal
)eve Ig
earS ' as shown In Flg.7.3. To reduce th e norse,
.
beII'cal teeth is.,used on these bevel gears . TIley are
sllloother in action and quieter than straight tooth bevels
as there is gradual load application and low impact
stresses.
However, an axial thrust exists in the spiral bevel
geMS, so it requires stronger bearings and supporting
assemblies.These gears are used for the drive to the
differentialof an automobile, Fig. 7.3. Spiral bevel gear
4.~oid gears :
Hypoid gears are similar in appearance to
spiral-bevel gears. They differ from spiral gears
inthat the axis of pinion is offset from the axis
of the gear, as shown in Fig.7.S. The other
difference is that their pitch surfaces are
hyperboloids rather than cones.
In general, hypoid gears are most desirable
for those applications involving large speed
reduction ratios. They operate more smoothly
Fig. 7.5. Hypoid gears
andquietly than spiral bevel gears.
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Bevel Gears
2. Internal bevel gear: When the pitch angle of a bevel gear exceeds 90°, it is called
internal bevel gear. Because of the manufacturing difficulties, the internal bevel gears ~
rarely used.
3. Mitre gears: When two meshing bevel gears have a shaft angle of 90° and bave the
same number of teeth, they are called mitre gears. In other words, mitre gears have a speed
ratio of 1. Each of the two gears has a 45° pitch angle.
Cone centre
,.
.. ,
\
, I /
\
,/,
Back
cone ""I' 6\~~
\, ! / .vO~0~
\ I
'\JY .
I ~~~
•
1
~---------------------------_Q~~~~~~~~
Transmission Systems
.;
°
.
R -
_ [(dl)22 (d2)2]~
+"2 1
= 2" ~ d~ + d; ... (7.2)
'i
I,
~ For right angle gears, R = 0.5 111,~ =~ + =~ = 0.5 m, x z, ...J ;2 + I ... (7.3) i•
i
where j = Gear ratio = -I
~ t:-2' !
5. Addendum angle (oa) : It is the angle subtended by the addendum of the tooth at the
cone centre. Mathematically,
j
~
\
6. Dedendum angle (Od) : It is the angle subtended by the dedendum of the tooth at the
cone centre. Mathematically,
Dedendum angle,
'-', ad = tarr ' ( cone
ded~~d=
IS ce ) = tarr ' (hRf) . .. (7 .)S"
7. Tip (orfa.cM.~~/e : It is the angle subtended bv the face of the tooth at the cone centre.
Mathematically,~ ./
Tip angle = Pitch angle + Addendum angle = 0 + ea ... (7.6)
8. Root angle: It is the angle subtended by the root of the tooth at the cone centre. r
,I
11
Mathematican@_) . ~
r
9. Back (or normal) cone: It is an imaginary cone, perpendicular to the pitch cone at the
end of the tooth.
10. Back cone disttmce (or back cone radius) : It is the length ofthe back cone.
!
1
11. Backing (B) : It is the distanc~ of the pitch point from the back of the boss, parallel to
the axis of the gear. "
12. MOUII/ing height : It is the distance of the back of the boss from the cone centre. I
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~B~ev~e=I~G~e~a~~~ Downloaded From : www.EasyEngineering.net ~
o - Pitch angle.
,
I
tan 01 -
sin e
(z2 / ZI) + cos e
e
and tan ° 2 -
(zI / z2)
sin
+ cos e ... (7.10)
and
In order to simplify the design calculation and analysis, bevel gears are replaced by
equivalent spur gears. An imaginary spur gear considered in a plane perpendicular to the
toroth at the larger end, is known as vinuai orformative or equivalent spur:gear. The virtual
spur gear has pitch circle radius equal to the pitch cone radius 'R' of the bevel gear.
...
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zz -
v - --
cos 0
where z = Actual number of teeth on th b ... (7.13)
e evel gear.
~ The virtual number of teeth is Used f I .
~ or se ectIngthe cun . .
bevelgears. ers and In all desJgn calculations of
The basic dimensions of straight bevel gears are listed in Table 7.1.
Table 7.1. Basic dimensions of bevel gears (from data book, page no. 8.38)
mm b sin 0
2. Mean module mm Inm = mt- z
3. Normal module mn mm
4. Cone distance R mm
wheel
BB~eevvEe~ll(GIEe~a~rs~ ---------------------------------~
Units Formula ,
S.No. Nomenclature Symbol
2 X cos °
9. Minimum number of teeth Zu - Zu - . ?~
; (X I. for ~
sm-
on pinion to avoid l
gears) I
undercutting
I
Of 8
18. Root angle degrees / - 0 - S/
19. Tooth height Ii mrn h = Iza + hi
-=-. -
I
:· ¥ 7
·, .' 1
:, ,,/ Fs
,
,,
"
11 _
(b)
(a)
tf
j
J
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-,B~~~\~~·/~.!~t~1~~·~~ --------------------------------__
~
7
60 x P
where M, ::.: Transmitted torque = 21tN '
P == Power transmitted,
N = Speed of the gear,
d1tll, = Average diameter of the pinion, at midpoint along the face width
The above derived expressions are used to determine the components of the tooth forceon
the pinion.
~---------------------------- ~D~~~ign~~of~TJ~~~a~ns~n~u~ss~io~n~~
./ Similarly, the
.
axial component
'"
on the gear is equal to th e radilaI component on the
pinion, but m opposite direction, .
.. (F a )gear = - (F r )pinion
§i!J The three forces FI' Fr' and Fa are perpendicular to each other and can be used to
detennine the bearing loads by using the methods of statics.
[§xample 7.2 I A pair of straight bevel gears has a velocity ratio of 2: 1. Tile pitch
circle diameter of the pinion is 80 mm at the large end of the tooth. A 5 kW power is
suppliedto the pinion, which rotates at 800 r.p.m: TI,e face width is 40 mm and the
pressure angle is 20 ~ Calculate the tangential, radial and axial components of the
resultallt
toothforce acting on the pillion.
GivenDtua : i=2; d1=80mm; P=5kW; N1=800r.p.m.; b=40mm;a=200.
To find: FI' Frand Fa on pinion.
@) Solution: In order to calculate the force components, first let us find pitch angles I
(°1 and °2), and the mean radius of pinion. I
Weknow that, tan 02 - i = 2, for shaft angle, e = 90°.
or 02 - tarr ' (2) = 63.43°
and 01 - 90° - 02 = 90° - 63.43° = 26.57°
. of the puuon
TIie mean radius . , at rruidnoi
porn a
t long the face width is given by,
d1 b . sin 81
r; = "2" 2
80 40 x sin 26.57° = 31.054 mrn
- 2 2
Bevel Gears
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7
v:
i
~~~~----------------------------------~
(iii) Axial component (FoJ :
We know that, Fa - F, X tan a x sin 0,
= 1921.91 x tan 20° x sin 26.57° = 312.89 N Ans."
I Example 7.3 I For the data of above example, calculate the tangential, radilll and
axial components of the resultant tooth force acting on the gear wheel
Nl 800
Given Data: Refer Example 7.2; N2 = i =2 = 400 r.p.m.
(i) Tangential component (FJ : We know that the tangential force on the pinion and gear
are equal in magnitude and opposite in direction. Therefore,
(Fr)gear = (F,)pinion = 1921.91 N Ans."
INote I The above result can be verified as below.
60 x P 60 x 5 x 103
where (M r)gear = = = 119.366 N-m
2n N2 2n x 400
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Bevel Gears
{iii} Torque produced about the shaft axis (i.e., torque on the gear shaft}:
60 x p NJ (60 x ')
We know that, Ma = ix Mtl [.: Ma= 21tN2 =N 21tN =j.<M,!
2 J
, Exanlple 7.5 I A pair of bevel gears transmitting 15 kWat 600 r.p.m: .as ~ho"'nin
Fig.7.8(a). The pressure angle is 200. Determine the components of the resuitantgearJooIlJ
force and draw a free body diagram of forces acting on tire pinion and the gear.
2751.93 N
600 rpm
Fig. 7.8.
Given Datil: P = IS kW; N} = 600 r.p.m. ; a = 20°' , d, = 200 mrn ;
h . sin 0 ]
2 - - ..1
21t X 600 == 238.73 N-m
~ [~ _10 x Si03~]
1. (i) Force conlponents acti 2 == 86.75 rnrn
Ing on the pinion:
[§xamele 7. 6) A he vel pinion shown in Fig. 7. 9 rotates at 600 r.p.m. in the direction
~o,.,n and transmits 3.75 k W. The mounting distances, the location 0/ all bearings, and
1. e average pitch radii of the pinion and gear are shown in Fig.7.9. For simplicity, the
.teetIi /Iave been replaced by the pitcll cones. Bearings A and C shotdd take the radial and
thrllSt10(ltis, while bearings Band D can only take radial loads. Find the bearing forces (or
reacti
°ns at the bearings) on the gears/loft.
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~B~ev~e~IG~e~a~~~'------------------------------~
y
1---- 160 _-~ 7S
-,----"0
65
. )(
+J0;-::~-~'"~
92
J__
1_--- 225
---
V
,.'hO ~ ----------------------- _JD~e~s~i~~o'[_~Til~·a·
. Systems
I1srmSSlOn
corees acting on the gearshnft : The forces acting on the gearsna1 ft :IS shown In
I", .. Flg.7.1Q.
Bevel Gears
I Example 7. 71 For the data of Example 7.6, determine the bearing forrn 011 dt
pinion shaft ie., reactions at the bearing A and B. Assume that the bearing A C'tUr ,.
radial as well as thrust load, while the bearing B can only take radial load
Given Data: Refer Example 7.6.
Tofind: Bearing forces on the pinion shaft (FA an Fa)
~ F~
<,~
. I.'".> ."'.'"
FI1 'Fz
A
<,
",.
",.', '>t'"
.',
• F
81 P
",. a
l.S,;.
I' Fr1
Fig. 7.11.
Forces in the xy plane: For L Y = 0, i.e., considering equilibrium of forces, we get
FYA = Frl + FYa ... (.)I
Taking moments offorces about bearing B, we get
pY =
B 1102.15 - 644.59 = 457.56 N ADS.-CJ
For LX = 0,
FXA = Fal = 218.8 N ADS."
Forces in the xz plane: For I:z = 0 . '. ..
, I.e., ~onsldenng equilibrium of forces, we get
A
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Y1,18------·-----------=~--~--------iD~~~i~~O'[-Tl~~~.~.~~
- ransmiSSIon Systems
F~ - F 11 + FZB
'og moments of forces about bearing B ... (ii)
'f ale 1 , we get
·F/lx[(160-95.91)+751-F~ x75 :::: 0
= 1659.52 N ADs."
I Example 7.8 I A differential planetary gear train is shown in Fig.7.12(a). The input
sllaft receives 7.5 kW power at 300 r.p.m. The pitch circle diameters of bevel gears A, B, C
Qlld D at the midpoint along the face width are 200, 100, 200 and 400 mm respectively. The
pitchcircle diameters of spur gears E and Fare 200 and 300 mm respectively. The gears
rotateat constant speed. Determine the various forces acting Oil various gears and the
torqueon each of the two output shafts.
Power at
I-------I-t---_.__
\
N1 rpm
Output shaft-2
Output
shaft 1
(b)
Fig. 7.12.
Given Data: P = 7.5 kW; N) = 300 r.p.m ; (dm)A = 200 mm', (dm)n·; 100 rnrn.
(dm)c = 200 mm ; (dm)D = 400 rnm ; dE = 200 mm ; dF = 300 mm. ; ,
2 x 238.73
= 200 x 10-3 = 2387.32 N ADS. ~
or 2387.82 x (0.1
-2- 00) = (F,)co x (0.200)
-2-
(ii) Torque on each of the two output shafts: The torque on the output shaft 1, referring
Fig.7.12(b), is given by
= 2387.82 x (° 2
3
. ) = 358.17 N-m Ans."
7.9. DYNAMIC LOAD ON BEVEL GEAR TOOTH (Effective Load on Gear Tooth)
As discussed in Section 6.10, in order to account for dynamic loads, Ole following tw,
where ell = Pitch circle diameter of the big end of the pinion,
b = Face width,
Q' = Ratio factor, based on virtual number of teeth
2x zv2
= zvl + zv2
, for external gears
2x zv2
= zv2 -zvl
, for internal gears
=
ex. Pressure angle, and
Ep and Eg = Young's modulus of pinion and gear respectively.
.f zl Z
z,,1 ==
cos 01 an d zv2 == cos2 O
2
6. Calculate the beam strength Fs in te rms 0f transverse module using the relation
e"
"
F s == 1t X mt x b' x [ a b ] x y' x ( R; b)
Initially assume b = 10 mt •
r, = 1t x m, x bx [ O"b ] x y' x (R ~ b)
10. Calculate the dynamic load more accurately using Buckingham's equation,
21 v (be + Ft)
Fd = Ft + 21 v + ..J be + F t
11. Check for beam strength (or tooth breakage). If Fd ~ FoJ' the gear tooth has adequate
beam strength and will not fail by breakage. Thus the design is satisfactory.
. . 0.75xd1xbxQ'xl<w
12. Calculate the maximum wear load using the relation Fw = cos Ul
!:!
13. Check for wear strength. If Fd < Fw' the gear tooth has adequate wear capacity and
will not wear out. Thus the design is safe and satisfactory.
14. Calculate the basic dimensions of pinion and gear using the Table 7.1.
Bevel Gears
7.23
\ Example 7.9 I Design a pair of bevel gears If) Ir"II.\'",11 J(J kW (1/ a pln;(.m SPetd ..
1440 r.p.m. Required transmission rutlo ls 4. Malerlallilr . gears ts 15 Ni ler J III J
mo SIS Of
Tile tootlt profiles of tile gears lire (~l2() cmnpo,\'lIe/i)rm. (J ltd.
Given Data : P> 10 kW~ NI r.:: 14401'.1',111, ; i ..-: 4; CJ. = 20°.
zvl = COS 01
Z, ~ _
L:OS
20
_._;;...__-
14.040
= 20 61 :::::21, and
Z2 HO c: 329.7() :::::330.
zI/2 ::; cos 02 cos 75.96°
~ x K
We know that, F, == v 0
lln
1td,N, _1tNI (In/XZI] [.. d = m x ZI andm , isin'n '!
where v == 60 = 60 1000·" . . I I
~-----------~---------------- __ ~D~e~SI~'gn~Of~T~~a~n~sm~l~ss~;~on~~~s~r
5.6
- 5.6 + ,\(5- - 0.714, assuming v == 5 mls
8289.32) 1 11599.23
( n1, xO.714-
.' 117,
of beam strength
~ Calculation (F.J :
We know that, Fs - 1t X mix bx lab] x x(R;b)
j/
where b = 10 m,
... (initially assumed)
[ CYb ] = 450 N/mm2, for alloy steel, from Table 5.4.
y' - Form factor based on virtual number of teeth
0.912
- 0.154 - , for 20° full depth
zvl
0.912
- 0.154- 21 = 0.1106
41.23177,-10117,)
Fs = 1t X 111, X 10 n7, x 450 x 0.1106 x ( 41.23111,
- 1184.38111;
Or In, ~ 2.14
From Table 5.8, the nearest higher standard transverse module is 3 rnm,
S.Calculation 0/ b, d, and v :
-/ Face width: b = 10m, = 10 x 3 = 30 mrn
-/ Pitch circle diameter: dI = m, x ZI :::: 3 x 20 = 60 rnm
1t d) NI 1t x 60 x 10-3 x 1440 ::::4.52 rn/3
-/ Pitch line velocity:' v:::: 60:::: 60
Transmission Systems
P lOx 103
F, - v -
7.54 == 1326.26 N
./ Height factor: 10 = 1
c = 0.2
./ Clearance:
mt x fo
./ Addendum angle:
tan 9al = tan 9a2 == R
.2 xL;::: 0.02425
;::: 206.15
eal == eal == 1.4°
or 5 (1 + O.~ == 0.0291
m/Uo +c)
= 206.15
tan ell == taD 912 == R
./ Dedendum angle :
0
9 == 9/2 == .67
fl
or
Bevel Gears 7
~~~~-------------------------------------~
,/ Tip angle: e
0a' = 0, + a, = 14.04° + 1.4° = 15.44°; and
© Solution : Since the materials of pinion and gear are different, we have tc evaluate
z 64
and 2v2 = cos 82
= cos 72.64°
~ 215
8llltllllJruJn of tangential/oad :
p
FI = V ~ Ko
1[ dl Nt
v = 60
m, ~ 6.94 mm
b =
./ Pitch circle diameter: d1 = m, x Z 1 = 7 x 20 = 140
1t d1 N1
:PitCh line velocity : v2 - VI = 60 -
r, = 237.62 x m;
Calculation of accurate dynamic load (F J :
21 V (bc + F/)
F = F +--~==-
d I 2 I V + be + Ft -v
p 40 x 1()3
F/ = V = 6.16 = 6493.5 N
De.\'
Transmission
237.62 x m2 = 23762
pt. x 142 r:: 46573.52 N
F t _ - __ 40 x 103
v 12.315 = 3248N
c ~ , 11860 x e = II 860 x 0 ,025 ~ 296.5 N/l11m
r, = 3248+
21 x 12.315 x 103(I40x 296.5+32~
21 x 12.3) 5 x 103 \) 140 x 296,5 + 3248-
= 47969.4 N
We find F, >. F d' Now the design
. is safe and satisfacto ry llgmllst
. tile tooth failure.
12. CalculatIOn of wear load (Fw) :
0.75 x d1 x b x Q' x K IV
We know that, FlI' - COS 0,
2 x zv2 2 x 215
Q' - Ratio factor = = = 1.822, and
where z,,1 ± zv2 21 + 215
1<.,,, - 0.919 N/mm2, for steel gears hardened to 250 BHN , from
Table 5.9.
0.75 x 280 x 140 x 1.822 x 0.919 = 51578.25N
Fw = cos 17.360
13.Check for wear: We find Fw> Ft/. It means the gear tooth has adequate wear capacity
andwill not wear out. Thus the design is safe against wear failure also.
14.Basic dimensions ofpillion and gear,' Refer Table 7.1 .
./ Module: m, - 14 mm
lOx 14 == 140mm
./ Face width: b - lOxn7{ ::
14 x 20 == 280 mm; and
./ 'Pitch diameter: dl - m, x Zl ==
= 896 mm.
. d - m, x z2 == 14 x 64
r
2
R-Vfl+l [MIl
(R-o.s b)2· b- m,· Yv
R = Cone distance,
N. = z2
i = Gear ratio = -
N2 z. '
b - Face width,
ml - Transverse module, and
HBC
K - Rockwell hardn ess number
.
Life factor for surface strenzth
cI - . and'
(vi) COile di>'tallce (RJ : 0 • trom Table 5.19.
... (7.26)
. Ilowing
to (vii) Transverse module
cone distance equation 1 • Th e transverse mod I
(m ".
I'
ue (m.) can be found by using the
,- ')..,)
R = 0.5 m (\j
- r _2 -r_2
-1 -2
•• , \ 1.- I
.. , t":.2S)
R
or n1t =
0.5 -J=~ -l- =~
R
b -
'i'y
b sin 51
Calculate average module (mav): maY = ml - zi
• " of Transmwion
c"lell/II/I011 of basic ci,nlensions 01" h
16. . . d . 'J I e gear pai .
of the pll\lOn an gear using the equ a tiIons listed
. r : Calculate all th bas" .
in T bl e ic dimensions
~ a e7_1.
where a b I and a b2 = Induced bending stresses of pinion and gear respectively, and
y", and .",'2 = Form factors of pinion and gecr respectively based on the
\ irtual number of teeth .
.; Since the contact area is same. the induced contact stress is some for both pinion and
gear. i. e.. acl = O'c'2'
[!:xlIlJlp/e 7.11 ] Design a cast iron bevel gear drive for a pillar drilling nuichlne 10
Irlllls/llit 1875 JV at 800 r.p.tn. TO a spindle at .IOUr.p.m. The gear is 10 work/or.:flJ Iuutrs
per week/or 3 yelLrs. Pressure angle is 200.
Given Data: P = 1875 \V: Nl = 800 r.p.m.: }..2 = 400 r.p.m.: u. = :u=_
pinion.
NI 800 ""I
==:=
For right angle bex el gears. mil O2
Pitch angles : " ,-'0
s:: == tarr ' (2) == 6 J.-U
U,
or "00 6"" ~o
'"'\
== _(J.:-
--0
_9 ~ 9 107
~\J.'~' = 29.952 X 107
1.2, for C.I, from Table 5.15.
0.45 CJu'
of Transmission
'Vy = R/ b -- 3,Initially
. " assumed.
3rr[~~0.~72~~J~2~~~C------
(3 _ 0.5) 498.08 x 1.4 x 10.1 X ~ 7.905 x loJ
..
'
~ 50.2
R - 51 mm
or
7. Assume ZI == 20; Then z2 :::; i x Z I :::; 2 x 20 = 40
ZI 20
- ~ 23 " and
Virtualnumber of teeth : cos 01 cos 26.57°
Z2 40
cos O2 = cos 63.430 ~ 90
From Table 5.8, the nearest higher standard transverse module is 2.5 mrn
b _ ~.61 == 0.447
./ To find '?y: \jJy == -d - 41.66
lav
11 L'C'!. . d from Table 5.22.
. ~ quality 6 bevel gear IS assume ,
12. Revision of design torque I Mt J :
We know that, [Mt] == Mt)( K)( Kd
again, we get
R 67.08
b = -'l'y = - 3
= 22.36 mm
b 22.36
\11 = - =- = 0447
v» d11n' SO .
R - 67.08 mm
.; Cone distance :
b - 22.36 mm
.;
.;
Face width :
Pitch angtes :
° 1
_ 26.57°; and 82 == 63.43°
d ! - m, (ZI + 2 cos 81) = 3 (20 + 2 cos 26.57°)
.; Tip .diameter : a
_ 65.37 mm ; and 0
+2cosb) == 3 (40+2 cos 63.43 )
- m, (Z2 2
_ 122.68 mID
.; Height factor:
10 - 1
c - 0.2
.; Clearance:
or
./ Tip angle :
IExample 7.12 , Design a straight bevel gear drive between two shafts at right IIn""
to each other. Speed of the pinion shaft is 360 r.p.m: and 'lie speed of the gear wl'te/ s/,
is 120 r.p.m: Pin;oll is of steel and wheel of cast iron. Eac" gear is expected to HlO'k~
hours I day for 10 years. The drive transmits 9.37 kW.
Given Data: e = 90 0; Nl = 360 r.p.m.; N2 = 120 r.p.m.; P = 9.37 kW.
Then,
2. Material selection: Pinion - C45 Steel, crll = 700 Nzrnm? and cry = 360 N/m2
3. Gear life in hours = (2 hours/day) x ( 365 days / year x ] 0 years) = 7300 hours
60 x p 60 x 9.37 x 103
where = 2 1t x 360 = 248.6 N-m, and
21tNJ
'" Tofind E~q : Eeq = 1.7 X 105 Nzrnrn-', from Table 5.20.
Tofind I UbI J: We know that the design bending stress for pinion,
1.4 Kbl
[ O'bl] = n- K x 0'_1 , for rotation in one direction
a
elmo
[ Gel] = CR· lIRC x ~
CR = 23 from Table S.I8,
HRC - 40 to 55, tiom Table S.I8, aod
Kcl -
[ ael] - _3 x 50 x I = l150Nfmml
> 99.36
R = lOOmm.
2
= 612.33 N/mm
O'cl < [ act ]. Thus the design Is sotl'sftlc~tomvJM'J1mJ
_ N··
_PlnlQ!L ==
, N - 3
·_6.~ 6 107
-\j. N: = 5.256 x 107
2.3 x 260 x 0.758 = 453.284 N/mm2
- CI ta x ;)1,,2
Y"l - 0.402, for z"l = 22, from Table 5.13, and
Y,,2 ~ 0.520, for Z,,2 = 190, from Table 5.13.
- CIb2 x 0.520
CIb2 = 77.6 N/mm2
and tooth form factors as 0.154 - (0.912 I zv) where z" is the virtual
Rroblems on bevel gear design, based on gear life:
(1) Gears are of same material :
16. Design a bevel gear drive to transmit 7.5 kWat 1440 r.p.m. Gear- ratio
gear are made of C45 steel; Life of gears 10000 hrs.
IV.. Design a bevel gear drive to transmit a power of 9 kW at 20 r
ratio is to be 3. Material to be used is C20. CJ
u
= 500 N/mm2;
expected gear life as 10000 hours.
Worm Gears
"/"1m II"'y ignore you, then lhey laugh ot you,
IIIe" they fi,g h I you, then you win. "
- Mahatma Gandhi
8.1. GUCTION
(Rte. worm gears ~re used to Worm lhreAd.
tri\l\SRllt
. . . power between t wo non-
mtersectmg, non-parallel shafts, The
angle ~etween the nou-lntersccting
sha~s IS usually, but not necessarily,
a n~ht angle. As discussed in tho
previous chapters, crossed hellcal
and hypoid gears are also used to
connect non-intersecting non-
parallel shafts. But crossed-helicnl
and bypoid gears are suitable only
for low speed ratios (upto 8) and low .
power ratings. Whereas worm gears
can b df . GIIU' WhGlll
e use
hi g h as 300 :.'01.j.r hlgh speed ratios as ~ Fig. 8.1. Worm "lid Wor", gears
The worm .r drive consists of. worm nt d II worm wheel, as shown in Fig.S.I. If a tooth
of a helical gear makes complete revolUlio s on the pitch cylinder, the resulting gear is
known as a worm: The maling Sear is called w!!!!!!J!."'tr or """", Hlh"!!: The worm in worm
and worm ge;;;: drIve is same as screw In scr~Wand nut pair.
8.1.1.
WormQatlons
gear drives arc wide used as 1\ speed reducer in materials handling equipmen~
.
8.~.eAdv~ntages . . r be
. 08.
of Worm used for .peed ratios as high 8S 300: I.
Drives
l'he worm gear drIves can
. th nnd silent .
./ The operation IS slllOO
-,,'"
.,
l
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B.3
,
1. {",GIl ,.._~ .,. liaftJr pile' (P.J: It is the distance between two consecutive teeth,
~ s.k~ the a.'ris of the worm. In other words, it is the distance between a point on a
~"l(U\ throtd and a. CQm!SpOnding point on the adjacent thread measured parallel to the axis,
~tically~ Px = It)( nix ..• (B.2)
"Ix - Axial module of the worm.
l. L811 1.) : It is the distance travelled by a thread when one complete revolution is given
ro ~ worm, Mathematically,
Lead L = Px X!, = 1t X nix x Z, '" (B.3)
- Axial pitch x Number of threads in the worm
Tberefore, fur single start worm, lead is equal to axial pitch; for double start worm
thresd, lead is twice the axial pitch and so on.
It is also clear that the axial pitch of the worm will be equal to the circular pitch of
the worm gear i.e., Px = Pc = 1t X nix'
Pitch
ciImeter (d,) Pitch cylinder
~on. .
To find r:When one thread of a wonn IS
developed, it becomes the hypotenuse of ,a
triangle, as shown in Fig.B.3. The base of this
triangle is equal to the circumference of the
Worm., While the altitude is equal to the lead of
thewonn.
Fig. 8.3, Dn~/opme"t o/wonn tltru4
4. Tooth pressure angle: It is measured in a plane contain ing the axis of the worm and is
equal to one-half the thread profile angle.
5. Helix angle (P) : It is the angle between the tangent to the thread' helix on the pitch
cylinder and the axis of the worm. The worm helix angle is the complement of wonn lead
angle, i.e.,
J3 = 90° - 'Y
6. Normal pitch: It is the distance measured along the normal to the threads between two
corresponding points on two adjacent threads of the worm. Mathematically,
Normal pitch, Pn = Px X cos y ." (8.5)
1t
and normal diametral pitch, Pdn = ... (8.6)
d1 • sin y Pn
The various proportions of the worm and worrn gears are tabulated in Table 8~I.
~---------------- 8.5
Table 8.1. Tootll pro1'0rtlo
./
-
particulars Symbol Unit
nso/w arm gears
Worm .,
~ ha hal-m Worm gear
~ Addendum rnm x
u- Dcdendum
~
~
h
f mm h_tt = (2.2 cos y 1) m x
ha2 mx(2 cosy
hp - mx (I + 0.2 cos 1)
I)
~ c mm c 0.2 mx cos y
Clcnt1lI1Ce
u- outside diameter
.-
4-
da mm dal d I + 2 hal mx(q + 2) da2 -d2+2ha2
mx (z2 + 4 cos y z)
l-- Root dinmeter df
5.
mm "It dl 2 hj1
d /2 = d2 - 2 hfl
= nlx(q +2 4.4 cosy) mx(z2 2 0.4 cosy)
L--
8.6.1. BasiCDimensions of Worm Gears
Thebasic dimensions of worm and worm gear s are tabulated .In Table 8.2.
Table 8.2. Busic dimensions of worm gea rs ('I;' - book ,pa ge no.
,. rom data .
8 43~
il'".
"
L 70
and Axial module, mx =
1t x zl
= 7t X 3 = 7.43 mm
or
r, 22
cos y = P
x
- 23.33 = 0.943
d 1
Lea ang e, y cos-1 (0.943) =: 19;440
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8.7
or
«- >;
tan Y
3
tan 19.44 =: 8.5
Therefore, the centre distance is given by, .
a = 0.5 mx (q + Z2)
= 0.5 x 7.43 (8.5 + 42) = 187.6 mm
Ans. "
AlternateMethod: We know that,
63.12 + 31.1.9
Therefore, centre distance, a = = 187.5 mm Ans. "
2
CEXmnDle8.3] A triple-thread worm has a pitch diameter of 125 mm. The hob for
cutting the worm wheel has a normal dlametral pitch equal to O.OBlmm. Find the pitch
diameterof the worm wheel if the reduction is 12 : 1.
GivenData : zl = 3; dl = 125 mm ; Pdn = 0.08/ mm; i= 12.
TOflnd: Pitch diameter of the worm wheel (d2)·
@SOlution: We know that, i = z2 / zl
" z2 = i X zl = 12 x 3 = 36
P t.
d1 • sin y d2 . cos Y
,
We also know that, normal module, I1ln =
'" (i)
ZI x mn 3x 8
From equation {i), we can write Sill Y = d , = 100 = 0.24
or y = sirr ! (0.24) = 13.88°
NO\\1 again from equation (i), we have
__z2 x I1ln __ 45 x 8
d = 370.84 mm Ans."
2 COS Y cos 13.88°
I Example 8.5 I A double threaded worm has a lead of 65 mm: The gear has 411etJII
and is cut witll a hob of module 8 mm perpendicular to the teeth. Find the pitch dillltldtlS
of the worm and gear, and the centre distance of the shafts.
Given Data: zl = 2; L = 65 mm; z2 = 42; I1ln = 8 mm.
To find: (i) d, and d2; and (ii) centre distance, a.
© Solution: We know that, Lead L = Pr X Z I
L 65
Axial pitch, Pr = -
z, - _? = 32.5 mm
, I
AS1SC~.
d I .
dri"ingmember, while the worm wheel is the driven member. Fig.8.4 illustrates the three
the nentsof the gear tooth force acting on a worm and worm wheel.
C(lIl1PO F F 1 and F,al = Tangential, radial and axial components of the worm
Let t1' r '.
respectively, and
Fa. F r2 and F a2 = Tangential. radial and axial components of the worm wheel
respectively .
._
,~
/ (b) :It
/ /
(8) ... ::,.~;:;; .
\
F,
·•~ ---z
I ••
••
I •
•• (e)
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10 Design oI'Transrn,'ss' ",-
~.~------------------------------~----~~~~~~
<
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.~
./ The forces on a worm wheel are equal in magnitude to that of worqt, but
in direction. -' . , : .-, o~Pas~
./ Therefore, Fa - -Fa)
Fr2 - -Frl
F'I -
'" (8.16)
M, = Transmitted torque = 60 x P
2 1t N) ,
P = Power transmitted,
NI = Speed of the worm, and
d) = Pitch diameter of the
2.1be axial force (F.,) in terms oftangeotiaJ force worm..
I ---;:=- _ _:_(F..::.I)~' fro=m:..:equatJ~:ODS (8.13) and (8.14), is given as
F = F (cosa·cosy-J.l·siny)
3. Similarlv.jhe radi
01
(cos a· sm r
tl x
cos 7)
.-
+". ... (8.17)
given as y, the radial force in terms of tan gen tiaI forte (F,).1iom equatioos (8.14) '"'" (&'15), is
I'F 1
-
-
F
II
sin a
x (cos a . sin 7 + " . cos 7) ... (&.18) I
die 4. The directi 00 of rotation of the worm wheel can be found by CQIISideriDg the wonn as saew """
worm wheel as nut.
[!'XiiInf1e 8.6 IA pair of worm and worm whul is ~ lIS 1IS2I1fJ14.
t~O kif' power at 720 r.p.m. is supplied to the worm shtift. TIle coe.IfideJII D/.frit:tiot' is
of~ lind the pressure angle is 20 ~ Calculate the tllllgeJdial, tIJCiII/ IllUi mdittI ~
. resultant gear tooth fora oding on the worm and the worm wh«L
p~ ~::"~ata: (2152110/4): (z/z/qlm); ZI = 2; ~ = 52; q = 10; m" = 4 mm ;
... Y = tan
-I (1.)
10
== 1131°
I Example 8.7 I A double threaded worm drive has an axial pitch of 25 mm and apitd
circle diameter of 70 mm. The torque on the worm gear shaft is 1400 N-m. Thepitch ~
diameter of the worm gear is 250 mm and the tooth pressure angle is. 25~ FiJfJ·
-flrcto~
1. Tangential force on the worm gear; 2. Torque on the worm shaft; 3. Separat/lfg 0 (tIi
the worm; and 4. Velocity ratio. Take the coefficient of friction benveen the worliith
and gear teeth as 0.04.
~ 1400 ~-J1I;
Given Data: z} = 2; Px = 25 mm; d 1 = 70 nun; (M/)worm gear
d2 = 250 mm; mm; a = 25°; J.1 = 0.04.
Tofind: (i) Ft2; (ii) Mil; (iii) Frl ; and (iv) i.
_ or • 11ft]
x [':Px-"
© Solution: (i) Axial module, mx = P = 25 = 7.96 mm
1t 1t
dl
Diametral quotient, q = 70 = '8.8
mx = 7.96
F11::::: 2X 16 - 2546.48N
~I
d .
I
254648
.
_ 2 xM
-::;::--1!_
or Torque on the w 70 x 10-3
"":} {I. orrn shaft, M - 89
,Ulj ~eparatlng fo,ce ~ie' II - .13N-rn A
(. ., 'ad,Q! fi lIS '-I)
Weknow that, orce) Oil the Hlor",(F,. •
F ,J.
1'1 - FQI x tan ex
(iv) Gear ,atio (il : - 11200 x tan 250
v == 5222.65 N
ADS. "
We know that,
normal module , mn == P i n == P
_x
x cos_y
n
n
:::: 25 x cos 12.810
7r == 7.76 rnrn
We also know that , d2 . cos y
normal module , m. n
z2
Or
d2 x cos y
z2 :::: = 250 x cos 12.810
mn 7.76
:::: 31.4 ~ 32
'. G '.
ear ratio, I == -;-
z2
="232 = 16 Ans. ~
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x~~
~.14
----------------_D_e_~=gn~of_n_rmu~m~u~~fun&
~
y
Worm pitch
cylinder
'" I "
),,/- I'"
,/'"
Fig. 8.5.
Tofind : (i) L, P» and a,
Leadangle:
. where q =
~ 8.15
:1 forcecomponen~on the won« and
(ill Wor", gea
force co",ponents on the worm: ., :
M 60 x P 60
where tl -2-1[ N == - x 0.7~6 x 1()3
I 27t x 1200 - = 5.94 N-m
F _ 2 x 5.94
.' tl 50 x 10-3 == 237.46 N Ans.-tJ
I Radial force, Fr 1 _ F II x (
sm IX
.
cos IX . sin Y + Il' cos 1)
= ,237.46 x .' sin 14.5°
(cos 14.5° x sin 9.75° + 0.03 x cos 9.75'
== 307.23 N Ans. ~
{
Axial force, "Fai =', - F/I = '237.46 N ADS. ~
(iii) Force exerted by the bearing A a~d B 'against the worm gear:
The force~ acting on the worm ge~,and its shaft~are shown in Fig.8.6.
For L Fx::: 0, i.e., consideringthe. ~uilibrj1.!m offorces in x direction, we get
.. ,
.,."
' . .-
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De8ign ofT'OIII~
8.16
Fig. 8.6.
For I Fy = 0, i.e., considering the equilibrium of forces in y direction, we get
FYA + pYB - F Jt
T,I.
= 0
or F~ + 263.62 - 307.23 = 0
F~ = 43.61 N ADs. ~
FZA + FZB - Fa = 0
or F~ + 436.686 - I I 64.S7 = 0
:. F~ == 727.88N Au. ~
'(
f/2 x ~2
n-
f'I x VI
The coefficient of fr!cHop (J.1) in worm gear drives depends upon the sliding velocity, i.e.,
rubbing speed.
Sliding velocity, Vs -
sin y ... (8.20)
The variation
,\ of the coefficient of friction with respect to rubbing velocity is shown in
Fig.8.? ,
Q. 0.12
e
.s LL I 1 1
II 'L\ Steel worm
..:
:::L
c 0.09
. ~ "." <,
j I
15
CD
" I~
...... ._
r-- k::'
'" Cast Iron worm wheel
BronzeiWOhn.Wheel ,
.r
~ -............ ,
o 0.06 r-.. L '.'.
r-- c
16
s
13
it O.O.~
-
00." e:s 1.0 1;5
,
2.0 ..
2.5 3.0 3.5
Sliding velocity. mls
,/
F/~. ~.7.
,.~.1.P,Q'WerLost in Friction
It is give~ ~y~~Tebltio~ ;-,
, ~ '1,10=-. ,
,- ~:
8.8.2. Self-locking and Overrunning Drives
Self-locking drive: The drive is calied self-locking if the worm gear cannot dri i
worm, It is possible only when friction force exceeds the driving force. Ve the
In other words, if p ~cos a .tan y, then the drive is self-locking.
Overrunning drive: If the worm gear can act as driver, then it is known as an
overrunning or backdriving gearset
The theoretical criterion for an overrunning wonn drive is
J.l < cos a . tan y
I Example B.9 I A pair of worm gears is designated as 1/52/10/8.
The worm transmits BOOW power at 1000 r.p.m: and-the normal pressure angle Is 20~
Determine the coefficient of friction and the efficiency of the worm gears. Also fllld IlIl
power lost in friction.
Velocity of sliding, Vs = ~ __ n d , Nl
cos y 60 x cos 'Y
1t X 80 x 10-3 x 1000
= 60xcos5.710 = 4.21 mls
. From Fig.8.7, for Vs = 4.21 mls and bronze worm wheel , the coefficient of friction is
Interpreted as 0.027. Ans." .
8.19
~~ae4fS- 0A double threaded wo"", drivr is IWfIlilq lor 1'0_ ""-rissio.
"rfll having their axes at right angln to ~ OlItu. 1lre _ ..... U %.
tfIO slra IScenJn distance is apProximatdy 200 I11III. If rile axial pitd 01tile _
~ ttttJr. fh~ angle is 23 ~find 1. lead; 2 pbelt clrcIe dUrntetus of ""''''' IIIfII ""'''''
~~J' filii' IIId /eo I if the worm; and 4. efficiency 01 the ~ if tile IWffIdat of/rit:IiInt
,j. "tli.~ang e 0
tI;j.
":r'" Data.. zl = 2' ' 9 = 90"; a = 14 Y, 0; a = 200 mm ; p. = 30 nun;
GiVt" '1 = 230; Jl = O.OS.
1. L' , 2. d 1 and d2; 3.(3; and 4. 11.
Tofidill
e
'
n j
eSDIuJio :
:1 Lead (L): L = Px x z[ = 30 x 2 = 60 mm ADs." !
P, • We know that,
n" -Pilch diameters. Z[ • m.
,U, Zl Zl = __
45 +d2
or 200 = 2
2
= 355 mm Ans. ~ . ~
d
13 = 90° - 'Y = 90
0 _ 230 = 6'" AIls.
(iii) Helix angle (/1) : cos a _ fl' tan 1)
145 - . ~O)
- {cos 14'50 + 0.05 x cot 23
(cos . . e w"dltu or
rile ~ If'" is sdf-
r-r&anw--t-e-8:""":.l::-:l-"Fo,' the above pro b/~nr, dderllUn .
]
'~
The following guidelines may be used while selecting the materials for Worm and ""~
wheel. Refer Table 8.3.
Table 8.3. Selection of Mal~r411
Mat~rial
S.No. Condition
Worm WormWhed
5
BHN250 I
3. High speeds, heavy loads with shock .Hardened molybdenum Phosphorbronze(~
conditions steel or chrome vanadium
steel
8.14.EFFICIENCY
In Section 8.8, we have discussed the efficiency of wonn gears without considering the
klsses in the worm gearing. In actual design practice, losses in the worm gear drive should be
considered.The main losses in the worm gear are
-/ due to friction in sliding (i.e., gearing loss), and
-/ due to the churning and splashing of lubricating oil.
The efficiency of the wonn gearing, considering only the gearing losses is given by
8.15 TH GEARING
. ERMAL RATING OF WORM . I 'derable amount of
contInUOUS y, CODSa • •
heatIn.the Worm gearing, when the worm gear ~ lost (i.e., power loss) in frictJOO must
.IS generated. This heat generated due to
be dlSs' driv and lubricating oil.
.' fthe e
lpated in order to avoid over heaf1Jlg 0
The . f the drive is given by
COndition to avoid overbeatiDg 0.. to the atmOSPhere (H~
Heat generated 0Ig) := Heat dJSSlpated
pSi. _gAP
.~. Li .
'"
Hd = K, x A x (to - t a)'
K, - Heat transfer coefficient of housing walls (W/m20C),
A - Effective surface area of the housing (m2),
10 = Temperature of lubricating oil eel, and
t = Temperature of the atmospheric air (OC).
. a I
, Example 8.12 , A worm gear box ;"ith an effective surface area of 0.25 ",z.Afad
mounted on the worm shaft to circulate air over the surface of the fins. The coeffldtnJ~
heal transfer can be taken as 25 Wlm2 °C The permissible tempera/we rise of 1M
lubricating oil above the atmospheric temperature is 45 cr:: The coefficient of jridio. i
0.035 and the normal pressure angle is 20'! The pair of worm gears is desig1ulItd IS:
1/40/ 10/4. Calculate the power transmitting capacity based on thermal considofdiDtU.
Given Data: A = 0.25 m2; K, = 25 W/m20C; to - fa = 45°C; J.l = 0.035; ex ==20°;
zl = 1 ; z2 = 40; q = 10; mx = 4 mm.
8.2.3
F, - 1t X m); x b x [ CI ] x y'
b
m); - Axial module , ... (8.25)
! 1t
_ E x~
v
. factor from Table 5.6, and
Ko - Shock / Service '
Cv
_ Velocity factor.
- - 6
6 +v
. I'ty
_ p'tch hne ve oct
. mI
of tl]e worm gear 10 s.
where v - t ~
OTH LOAD FOR WORM ~EAR)
l1l O"!AGS (WEAR TO
'¥EAR STRENGTH Of WORM GP"I' . . en by
lbe li_:..c· • I ad for wear (F....
) IS gIV .. , (8.27)
QIll{UDg or maximum 0 l'
F.. · = d2 x b x I<"
..}i( .. IUf
8.24
F
..L
Dynomlc lend, Pd F
ell
6
where where v = 5 rrils is assumed.
6+v'
F
- 6
6+5
:;:= 0.545
be
... rd ;;:;1
66371.68
mx
1
x 0.545 -
121681.4
mx
6. e(I/cli/(lII(m (if belli" .\·lrIJIII/I/, (F,,) In terms of axial module:
Bellm strength, F" ;;:; 1t x mx x b x [ (Jb ] x y'
where h r;;; 0.75 d,. from Table 8.6,
I:l 0.75xqmx = 0.75 x Ilmx = 8.25m,l'
(ob] = 80 N/mm2, from Table 8.9, and c
01' mx ~ 7.77 mm
From Tobie 5.8, the nearest higher 8tand~d axial pitch is 8 mm.
i .
,1,# db
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8.27
!f!r .~
...,.;#,~
Dynamic load, Fd = -
Ft ,
c" !/
where cv =
6
= 6 + 1.808
6
= 0.768, and
I
6+v
66371.68 66371.68
Ft = = = 8296.46 N
mx 8
8296.46
.. Fd = 0.768 = 10802.68 N
II. Checkfor beam Fd < FS" It means that the gear tooth has adequate
strength : We fmd
beam strength and will not fail by breakage. Thus the design.is s.atisfactory.
12, Calculationof maximum wear load (F.J :
~ar load, F11' = d2 x b x K,
where ~v = 0.56 N/mm2, from Table 8.8.
,
" F 11' = 576 x 66 x 0.56 = 21288.96 N
13. Check/or wear: We find F d < FW"It means that the gear tooth has adequate wear
C4pacity and will not wear out. Thus the design is safe and satisfactory.
14.Check/or efficlency : We know that,
tany
TJactuaI = 0.95 tan (1 + p)
Where ,.
p = Friction angle = tarr! J.1 [.: J.1 = tan p]
.'
= tan-I (0.03) = 1.7 0
••• ['.' J.1 = 0.03, assumed]
'I
tan 15250 .
.. - 0 95 x ') = 0.8498 or 84.98%
TJ -. tan (15.250 +1.70
d2 = z2 x mx = 72 x 8 = 576 mm
./ Tip diameter: dOl = d 1+ 2 /0 . mx = 88 + 2 x 1 x 8 = 104mm;aoi
df2 = (z2 _ 2 f 0) mx _ 2 . c
_
(72 _ 2 x I) 8"'- 2 x 2 .= 556 mm.
IExample 8.14 I For the data of above example, determine the required coolingattlf
the ovenall heat transfer coefficient for the housing can be assumed as 15 WI"r C(' tUJ4 tit
temperature rise of the lubricant is restricted to 50 't:
Given Data: Refer Example 8.13; K, = 10 W 1m2 °C; At = to =!» = 5OOC.
(l-O.8498)xI2xl03 - IOxAx50
8~29
---
Method of Rotation in one
lIlaterial N/mml directions
casting of wheel direction only
64
Bronze 78
Sand >390 90
110
Chill >390 35
50
Sand <390 40
55
Chill <390 47
60
Centrifugally cast <390
Cast iron 20
30 :
GIldc25 250 27.5
- 40
350
~
540 [ (~ I q) + IJ 2 [M,]
efe = (z2Iq) a 10 '--/t..}) ,
~
a = Centre distance
Tabl« 8.10. D6ign contaa stress I ur.J, NhttJn2 (from dIlJa book, JNlK~ no.1.4S)
120 100 70
3
-
•
-
Bronze 190 18S 176 168 159 U;
-
8.20.6. Centre Distance (a)
1. Select the suitable combination of materials for worm and worm wbeel, coomDn!
Tables 8.3 and 8.9.
2. Calculate the initial design torque [ M,]. Use [M, 1 = M, x K x Kd• InitiallyJ55II!It
K· Kd = 1.
3. Selection 0/Z1 and Z2:
S. Calculate the centre distance (a) using the equation 8.31. Choose initiallY ~
factor, q = 11. q can vary from 8 to 13.
, Sliding velocity : v = ~
s cos y
9. Recalculatetile design contact stress [ucl for the actual VS' using Table 8.10.
10. Revise1(, Kd and [M,l for the actual velocity of the worm wheel (v2)'
11. Checkfor bending:
, Calculate the induced bending stress using the equation 8.29 .
./ Compare the induced bending stress with the design bending stress .
./ If <Jb s [O"b ], then the design is satisfactory.
12.If crb > [ O"b], then the design is not satisfactory. Then increase the axial module.
8.32
to', m
F imt'nuz tFrom
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t
Design of Trans",. .
l$)v
~'.
Given Data: Nt = 240 r.p.m.; P = 1.5 kW; i = 10 ; lldcsired = 80%; t _I
K,= 10 W/m2 DC. o o::t 4sec
I
60 x P 60 x 1.5 x I ()3
where M, = Wheel torque = 21t N2 - 2x x 24
- 596.83 N-m
K· Kd = 1, assumed initially.
:. Design wheel torque, [ M,] - 596.83 x I = 596.83 N-m
3. Selection of'l.1and'l.1 :
./' 'From Table 8.10, [ac] = 159 N/mm2 is selected, assuming Vs -= 3 mls.
... Q =
[(30/11) + 1]
3 [ 540,]
(30/11) 159
2
x
596.83 x 1~
10
= 168.6 mm
8.33
i f~
. (;4lCJllllli"" 0/ oxiDl module (mx) :
6. m = 2 a _ 2 x .168.6
x (q + z2) - (11 + 30) = 8.22 mm
,I
f(Olll 'fable5.8, the nearest higher standard axial mo du Ie .IS 10 mm :H
'I
BeVision o/centre distance (a) : . ::I
II
d2 = z2 x mx = 30 x 10 = 300 mm.
/ VI 1.382
v Sliding velocity: Vs - cos'Y
- -
- cos 15.250 ==. 1 432 mIs
dQ]. :::: 8
I Root diameter:
d'l ::::
::::
d'2 ::::
::::
I chapter.
The worm gear nomenclQture and its lcinenzatics are presented in the beginning of this
I Tables 8.1 and 8.2. and basic dimensions of Wortn and worm gears ore labulaled in
Tooth proportions
,I Force analysis on Worm gearing .-
sin a
Frl = ~I x (cos a . sin r+ p .cos JI)
(cos a .cos r-If .sin 12
Fal = ~I X (cosa . sin r+ p . cos r)
" Fol'ces on lhe WOr", "'heel: . F =_F ; and Fa2 = _ F,J
F = -Fal' r2 rl r
t2 • 12 cos Q_ p .tan
(cos aa..sin
" I!JJklency: '1 = tan y x (cos ·sm ~"' = cos a + II .col r
+ IIII .cos
cosyy-
" PoWerIOSlIn friction = (I _ 1J) x P .£'
" If
, Ii ~ cos a . Ian y,
. ' then the drIVe
. l" oVl!rrllJlnmg.
Hl~
_~.36 ------------------_D_e_S~ign~o~if_TJ_ra_n~~m~u~~~
. - ~
./ Materitll: Usually, worm is of steel and worm wheel may be brass or cast iron.......____
./ Two method" of designing a worm and worm gear: 1. Worm gear de.fign UN/nK l,f'ltll
and Buckingham's equations; and 2. Worm gear design based on basic equal/on.',
The step by step procedure for the above said two methods are presented wllh luflklttt
illustrative problems.
./ Lewis beam strength for worm gears: F, = 1! X mx x b x [ O"bi x r'
./ Dynamic load on worm gear: Fd = F/ / Cv
REVIEW QUESTIONS
1. Under what situation worm gear drives are used?
2. What are the advantages and disadvantages of worm gear drives?
3. What is irreversibility in worm gear drives?
4. What are single-enveloping and double-enveloping worm drives?
5. How can you speci fy a pair of worni gears?
6. Define the following terms used in worm gearing: (a) Axial pitch; (b) Lead; (c) Lead
angle; and (d) Helix angle.
7. What are the various forces acting on a worm and worm gear? Deduce the expressions
of them.
8. Differentiate self-locking and overrunning drives.
9. Write the expressions for beam strength, dynamic load, and limiting wear load for worm
and worm gears and explain the various terms used in it.
10. Write an engineering brief about the thermal calculations in worm gearing.
11. Why is the efficiency of a worm gear drive comparatively low?
,.
es es with a €It-.. L .. '
831
»
! ,
J.
p:~I circular pitc or
'.
mm. Find the centre di
..
gear Havmg 45 tt.tth and
stalll:e betw~ the shafl.. if Ihey are
[AIlS: 22(J mm J
J. J. trlrhas a pitch perpendicular to the teeth of)2 :' J~ ~ob for ~ing the worm
wbeegear if the reduction is 12 : 1. m U es. Find the pitch diamettr c;f
onn
w ble-threaded worm has a lead of 60 mm The j . h [Alii: 454.36 mm]
A dou ' gear as 30 teeth and is cut 'Ih
:d
4. b of module 8.5 mm perpendicular to the teeth. Find the itch dis
gear, and the centre distance of the shafts. P
'. WI.
JamL1ers of the worm
a
l
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~ ------------ ~D~es_:;g~n~O_if_1i~r~Q~ns~m~is_s_iO_"-!SY&lelft.&
---.:..
~9.2
d i G P it has the following advantages Over the
However, when the speeds are arrange an .',
other progressions.
1 The speed loss is minimum.
. . d Avai lable speed
.t.e., Speed loss = Desired optImum spee -
The number of gears to be employed is minimum.
2. f . die speeds at each step.
3. G.P. provides a more even range 0 span
4. The layout is comparatively very compact. led'
5. Productivity of a machining operation, i.e., surface area of the meta remov In unit
time, is constant in the whole speed range.
6. G ..P mac hime tool spindle speeds can be selected .easily from preferred numbers.
Because preferred numbers are in geometric progression.
Preferred numbers are the conventionally rounded off values derived from geometric
series. There are five basic series, denoted as R 5, RIO, R 20, R 40 and R 80 series. The
symbol 'R' is used as a tribute to French engineer Charles Renard, who introduced the
p~efer:red num~rs first. Preferred numbers assist the designer in avoiding the selection of
sizes m an arbitrary manner.
9.3
ae '. .
senes factor Th' .
'eshas I·t: own step ratio
~ t.e.,
. e serres factor for various series are
ch ser I
68. fable 9.1.
'vell 111 • / •
gl liable 9.1. Step ratio sertes tacto« (from data book , p age no. 7.19
. '/11
Basic series
Step ratio <cI»)
R5
Vw = 1.58
RIO l~ = 1.26
R20 2~ 10 = 1.12
R40 4~ = 1.06
R80 8~ = 1.03
The series of preferred numbers is obtained by multiplying a step ratio with the first
number to get the second number. The third number is obtained by multiplying a step ratio
wilh the second number. Similarly the procedure is continued until the series is completed.
Table 9.2 shows the basic series of preferred numbers.
Table 9.2. Basic series of preferred numbers (from data book, page no. 7.20)
R 20 (~= 1.12) 1.00, 1.12, 1.25, 1.40, 1.60, 1.80, 2.00, 2.24, 2.50, 2.80, 3.15,
3.55,4.00,4.50,5.00,5.60,6.30, 7.10, 8.00, 9.00, 10.00
R 40 (~ = 1.06) 1.00,1.06,1.12,1.18,1.25,1.32,1.40,1.50,1.60,1.70,1.80,
1.90, 2.00, 2.12, 2.24, 2.36, 2.50, 2.65, 2.80, 3.00, 3.15, 3.35,
3.55,3.75,4.00,4.25,4.50,4.75,5.00,5.30,5.60, 6.00, 6.30,
6.70, 7.10, 7.50, 8.00, 8.50, 9.00, 9.50,10.00.
I EXample: Machine tool spindle speeds under R 20 series is given by 100, 112, 125, 140,
60, 180 and 200 r.p.m.
N2 N3 N4 Nn = constant = ~
If' , . ~ = N2 = N3 = ......... Nn - 1
n IS the n
umber of steps of speed, then
2. Spindle speeds: Since the calculated <t> (= 1.12) is a standard step ratio for R 20 series.
Therefore the spindle speeds from R 20 series are
100,112,125,140,160,180,200,224,250,280,3]5 and 355 r.p.m. Ans. ~
I Example 9.2 , Select the spindle speeds for the following data: 12 speeds, between50
and 600 r.p.m:
Given Data: n = 12; Nmin = 50 r.p.m.; Nmax = 600 r.p.m.
Tofind: Spindle speeds.
We find the calculated <P is a standard step ratio for R 10 series. So from R 10 series, the
spindle speeds are 50, 63, 80, 100, 125, 160, 200, 250, 315, 400, 500 and 630 r.p.m. ADS. "CJ
It can be seen that the calculated Nmax630 r.p.rn., which is greater than the required
=
maximum speed. Therefore we have to check whether the deviation is within the pennissib1e
range or not.
Permissible deviation = ± 10 (<I> - 1) %
- ± 10 (1.253 - 1) % = ± 2.53%
50
Then, Actual deviation - (630 _..:600) x 600 = 2.5
Since the actual deviation is less than the permissible deviation, therefore we can accept
the deviation. Ans • ..,
I Note I If the actual deviation is more than the permissible deviation, then non-standard speedsmay
be used.
9.S
We find
stand' J. -
'I' -.
I 2866 IS
. 110t a s t an d ar d ratio . So let us find out whether multiples of
Ward ratio 1. 12 or 1.06 come close to 1.2 86 .
e can write, 1.12 x 1.12 = 1.2544- and 1.24 x 1.12 x ]. 12 = 1.4
Then I 1 06 1 06 x 1 06 x 1.06 = 1.34
, .06 x 1.06 x 1.06 x 1.06 = 1.26 and 1.06 x. x.· .
Soboth .' t It means 1.286 IS not a
staoda d ~tandard ratios 1.12 and 1.06 not satisfy the reqUlrem.en .
r raho· Th . dl dare obtamed as
50 . erefore the non-standard spm e spee s
, 50 x 1 28 3
2
6 rhus the '. 6, 50 x 1.286 , 50 x 1.268 , 758 226.2, i'90.8, 374,481,
81.5and79~p~ndle speeds are 50, 64.3, 82.7, 106.3, 136.7,] .,
. r·P·m. Ans."
structural formula -
l. 6 speeds (i) 3(1) 2(3)
(ii) 2 (I) 3 (2)
7.
15 speeds
16 speeds
(i)
(i)
3(1)3(3)2(6)
8. 18 speeds
(iii)
(i)
2(1)2(2)4(4)
pulley
[ rfb l
[ J
Shan 1 (Driving shaft)
Shaft 2 (I I '
n ermedaate shaft)
Pulley
P2 = 3 (i.e"lOstage ,
, XI =
1; and X2::::: PI :::::3
, Stru
etural formula z == 3 (1) . 3 (3). the driven shaft
~re ' ds available at
n = Number ofspee
:::::9
_ PI . P2 == 3 x 3
9.9.1. Procedure
./ In this diagram, shafts are shown by vertical equidistant and parallel lines .
./ The speeds are plotted vertical on a logarithmic scale with log $ as a unit.
./ Transmission engaged at definite speeds of the driving and driven shafts are
shown on the diagram by rays connecting the points on the shaft lines representing
these speeds .
./ Fig.9.2 shows the ray diagram for a 9 speed gear box, having the structural
formula, z = 3 (I)· 3 (3).
N;npul
Nmax
ilNQX = s2 ... (9.3a) Nmin
N;npul
. Fig. 9.3.
2. For stable operation, the speed ratio at any stage should not be greater than 8.
Nmax )
In other words, -- ~ 8 .. , (9.3b
N":'1;"
laUd'
'I lagram'
PfOced • . idi tant lines to
. caI eqUI IS
UTe : d ew 3 verU
{ S. . . atic layout, r
Inee there are 3 shafts In kinem . to represent
'd'stant [ines
represent shafts. 6 horizontal equ1 I . Fig.9.4(a).
{ S' d draW shown lfi d
lnee there are 6 spindle spee s, .ZO ntallines, as In the secon
he hort 0 stages. d (3)
{ s))eeds.Then mark the speeds on t that there are tw"1 ble in a stage an
F it is clear ds aval a
rom the structural formula, I mber of spee d
sta ts the nu spee s.
ge, i.e., in 2 (3), 2 represen those tWO
represent" thp ctpn, or intervals betWeen
nmax I 1 nmax
- >
- -4 and -- ~2
ninput ninpllt
Nmax
Ninpl!t
Thus the requirements are satisfied. Note that the above conditions are met for other inp.r
speeds.
'3 (1) '2 (3)
250
.,... .,...
I
.200
/
I
==
IV
s: ==
IV
s: ==
IV
s:
CJ) CJ) CJ)
160
.".
A A
(a) (b)
9.11
--------
P1 =3
---- __ -- -- . Input shaft - 1
-----. ...
----. Shaft-2
9.12
1
= 0.32> 4' and
Nmax 1000
,
.t: I----.t:
N
,
-+---- 236
= 560
IV ttl
Ninpul
s: s:
en en
= 1.78 < 2
.. Ratio requirements are satisfied.
Fig. 9.6. Speed diagram for 9 speed gear box
Kinematic arrangement: The kinematic arrangement for 9 speed gear box is drawn, as
shown in Fig.9.7.
Z3 = 29
------------.--- Shaft-1
Zg = 53
Shaft - 2
Ze = 48
Z,2 = 63
Z,0 = 30
Fig. 9.7. Kinematic arrangement for 9 speed gear box
Second pair: Now co.nsider the ray that gives the minimum speed reduction from
560 r.p.m. to 425 r.p.m. This can be achieved by using the gears 7 and 8.
z7 Ng 425
Zg - N7 = 560 or z7 = 0.76 Zg ... (i) .
We know that the centre distance between the shafts are fixed and same. Therefore, the
sum of number of teeth of mating gears should be equal. So we can write
z7 + Zg = zil + z12 = 20 + 63 = 83 ... (ii)
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Design a/Transmission Syste1n3
9.14
Z5 _ 20 = 47.14 ~ 48.
or z6 = 0.4242 - 0.4242
Second pair:
. id the speed reduction from 1320 r.p.m. to 750 r.p.m. This can
C
onsi er
be
achieved by gears 1 and 2.
ZI N2 750
.. = =- or Zt = 0.57 z2 ... (v)
z2 Nt 1320
Third pair: Finally consider the speed reduction from 1320 r.p.m. to 1000 r.p.m. This can
be achieved by gears 3 and 4.
Z3 N4 1000
.. = = 1320 or z3 = 0.76 z4 '" (vii)
z4 N3
I Example 9.7 I For the data of the above problem, calculate the percentage deviation
of the obtainable speeds from the calculated ones.
Given Data: Refer Example 9.6.
Tofind: Percentage deviation of the speeds.
@ SolllJion : It is understood from the kinematic arrangement (Fig.9.7) that the
combinations of gears I and 2 (in the first stage), gears 7 and 8, gears 9 and 10, and gears 11
and 12 (in the second stage) are to give three output speeds. Then, the combinations of gears
3 and 4 (in the first stage), gears 7 and 8, gears 9 and 10, and gears 11 and 12 (in the second
stage) provide the next three output speeds. Similarly when gears 5 and 6 are engaged, we
obtain three more speeds. Thus we can achieve totally 9 output speeds.
Calculatlon of output speeds: Let N, and No:: Input and output speeds of the gears.
From the ray diagram (Fig.9.6), input speed N, = 1320 r.p.m.
Z, z7 24 35
No, = Nx-
t z2
x-
Zg
= 1320 x 44 x 48 = 525 r.p.m.
z, z9 S3
N02 = Nx-
, %2 xTO = 1320 x 24
x 30 = 1272 r.p.m.
44
z, zll 24 20
N03 = Nx-
I z2
x- = 1320 x 44 x = 228.57 r.p.m.
zl2 63
== 1320 x ~ 35
39 x 48
- == 715.7 r.p.m.
Nos =
Z3
N,x - x-
z9
Z4 zlO == ]320 x ¥ 9
x~
30 == 1734 r.p.m.
z3 zJJ
::: N,x - x- == ]320 ~ 20
N06 z4 z,2 x 39 x -
63 == 3]].6 r.p.m.
Zs z7
= NIx - x- - 1320 ~ 35
N07 z6 Zs x 48 x 48 == 401 r.p.m.
Zs z9
Nos = NIx- x-
z6 zlO
- ]320 20
x 48 x 30
53
== 971.66 r.p.m.
Zs zJJ
N09 - N1x- x-
z6 zl2
- 1320 x 20 20
48 x 63 == 174.6 r.p.m.
Calculationof % deviation:
,
rs.NO. I Obtainable speed Calculated speed exo deviation = Nb-N
0 I cal 1
(Nobt' r.p.m.) (Ncal' r.p.m.) N x 100
cal
1. 174.6 180 3
2. 228.57 236 3.'S
3. 311.6 315 LOS
4, 401 425 5.65
5. 525 560 6.25
6, 715.7 750 4.57
----.:.
9.81 A gear
I 1800
@ofilld: ConstructlOn
. of the speed diagram and the kmematIc
.' arrangement .
SOlutio" •
Select •
10" 01' •
..,spindle speeds:
\Vek
now that , -
Nmax
N min
_ ~n-I
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9.16
Design a/Transmission s
~
2000 = cpl2 - 1 or cp = 1.258
or 160
We can write, 1.12 x 1.12 = 1.254 . '" (skip one speed)
So cp = 1.12 satisfies the requirement. Therefore the spindle speeds from R 20 series
skipping one speed, are given by ,
160, 200, 250, 315, 400, 500, 630, 800, 1000, 1250, 1600 and 2000 r.p.m.
Structural/ormula: For 12 speeds, the preferred structural formula
= 3 (1) 2 (3) 2 (6)
1st stage 2nd stage 3rd stage
Speed diagram (or Ray diagram) :
Procedure:
../ Since there are 4 shafts, draw 4 vertical equidistant lines to represent shafts .
../ Since there are 12 spindle speeds, draw 12 horizontal equidistant lines .
../ From the structural formula, it is clear that there are three stages. In the third stage,
i.e., in 2 (6), 2 represents the number of speeds available in that stage and (6)
represents the steps or intervals between these two speeds .
../ Locate the first point A on the lowest speed i.e., at 160 r.p.m., on the last shaft. After
6 steps above, locate the second point B at 630 r.p.m. These are the two output
speeds .
../ Locate the input speed at any point on the preceding shaft (i.e., shaft 2), meeting the
ratio requirements. We find, the input speed 400 r.p m. at point C satisfies the ratio
requirements .
./ In the second stage, there are two speeds. Lowest speed is at C, which is already
located. Now locate point D on the 3rd shaft, above point C, in a three step interval.
For these two output speeds in the second stage, the input should be from shaft 2. We
find, the input speed 630 r.p.m. at point E on shaft 2 satisfies the ratio requirements .
../ In the first stage, there are three speeds. Lowest speed is at E, which is already
located. Now locate points F and G on the shaft 2, above point E, in a single step
interval.
./ Input speed can be located anywhere on shaft 1 meeting the ratio requirements. But in
this problem, given that, input speed is at 1600 r.p.m.
,./' In stage 2, we find input speed at E gives two output speeds at C and D. Similarly,
input speeds at F and G, should give' two output speeds. This can be achieved by
drawing lines parallel to EC and ED, from points F and G, as shown in Fig.9.S.
,./' Now for stage 3, to get the output speeds to all the input speeds in shaft 3, draw lines
parallel to CA and CB. Thus we have located all the input and the output speeds. The
completed ray diagram is shown in Fig.9.8.
------ 2.-
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Stagt 3 : -Nmin
Njnpu1
160
= - 1
400 = 0.4 > - 4 and
9.17
-Nmax
N;nput
630
= 400 = 1.57 < 2. 3 (1)
Stogt 2: -Nm;n
N;npu'
= 630
400 H
1
= 0.63> 4" and
Nmax 800
-
N;npu,
-
630
= 1.27 < 2.
Nmin
Siage 1:
Nin;UI
= -
630
1600 400
1 . 315
= 0.39 > 4" and
250
Nmax 1000 . N
. C')
,
= 1600 ;::
nI
s:
;::
III
.c
c
III C
200
N;npu' III Stage 1 IJ) Stage 2 .c
IJ) StagB 3
III
.c
IJ)
160
= 0.625 < 2.
:. Ratio requirements are satisfied. Fig. 9.S. Ray diagram/or 12speed gear box
Kinematic arrangement: The kinematic arrangement for 12 speed gear box is drawn, as
shownin Fig.9.9.
Shaft-2
Shaft - 3
Shaft - 4
-------- ------ -o
12 speed gear box
Fig. 9.9. Kinematic arrangementfor tis with the output speeds
£. . t have 12 spee , 2x2
'Gil' xa", Ie 9.9 A machine tool gear box IS 0 d diaoratnS for 2 x 2 x 3, 3 x ,
g'"g fj the spee" ?
j ~4 r-p.m: to 2800 r.p.nt. Draw
rOIn 63 h' h is better anti why.
Qlld"
)(3 schemes. Among these sc e h mes w IC
l .
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ueslgn oj Transmission SYSI
~~
~.18 --------------------------------------~~~------~~ ~ e~v
© Solution:
Selection of spindle speeds:
Nmax = ~n-I
We know that,
2800
or
63 = ~ 12 - 1 or ~ = 1.4 12
We can try, 1.06 x (1.06 x 1.06 x 1.06 x 1.06 x 1.06) = 1.418 ... (skip 5 speeds).
So ~ = 1.06 satisfies the requirement. Therefore the spindle speeds from R 40 series,
skipping 5 speeds, are given by
63,90,125,180,250,355,500,710,1000, 1400,2000 and 2800 r.p.m.
Speed diagrams for various schemes:
(i) 2 x 2 x 3 scheme: Structural formula = 2 (1) 2 (2) 3 (4). Refer Fig.9.1 O.
Nm;n 63 1
Stage 3 : N = 250 = 0.252> 4 ~ and
input
Nmax 1000
= = 4> 2
N;npUI 250
In this stage, it is not possible to satisfy the ratio requirement . So treat as an exceptional
case. 2(1) 2(2) 3(4)
-------.--------~ 2800
Nm;n 250 :
Stage 2: = - :
Nrnpul 500 I--------+--------~----~~2000
1 :
= 0.5 >4 and j--------t--------~--~~:~1400
Nmax 500
= 500
N;npul
710
= 1 < 2.
500
Ratio requirements are satisfied.
Nmrn 500 355
Stage 1 :
N;npUf
= 1000
2.50
1
= O.S > "4 and 180
Nmax 710
NrnpUf
= --
1000
125
, .., •
0.71<2. = 'i r----- c::-t---- :: c::
90
~
fA Stage , ~ " Stage 2 s: s:
Ratio requirements are satisfied. --------~----~~~~~~~ rJl Stage J (fJ
~ 2 x2...scheme:
~A'''l
3(1) 2(3) 2(6)
(ii) 3 x 1'1 . 63
• _.!!!!!!- == 250
Stllg' 3 . 1'1input 1
== 0.252 > 4 ; and
1'1",ax 500
.-:--- == -250
1'1input
== 2~2
Ninput
== 500
250
-
1
e\ == O .5 > 4'
- . and
-
N",ax
Ninput
== 500
710
-
1.42 < 2
== .... N ('I') ......
90
500 1 ' 1---- '+--- -+----'
N",in == -1400 = 0.36> -4 ; and ~
«rii «rii Stage 'i !
Stagel: N
input
~
Stage 1 ~
~
2 ~ Stage 3
~------_63
(/)
A
Nmax 1400
== == 1.97 < 2.
Ninput 710
Slage 1: Nmin == 71 0
Ninput 2000
I
= 0.35> 4 and
Nmax
-
N tnpu:
= 2000
1400 L_ __ ----~------~63
= 0.7 < 2.
., Ratio requirements are satisfied.
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9.20 ~
Design o/Trans",. .
ISS 1011 IS
:)ISte"",
(iv) 4 xJ Scheme: Structural formula = 4 (I) 3 (4).
Rt:fer Fig.9.13. 4 (1)
3 (4)
Nmin 63
Stage 2: =
500
NinpU1
1
- 0.125 < 4' and H
Nmax 1000
- 500
Ninpul
- 2~2
In this stage, it is not possible to satisfy
the ratio requirements. So treat as an
exceptional case.
Nmin 500
Stage 1: - --
Ninpul 1400
1
- 0.36>4' and
Nmax 1400
= = 1<2.
Ninpul 1400
:. Ratio requirements are satisfied. Fig. 9./3. Ray diagram/or 4 x 3 scheme
Conclusion: Out of the four schemes, 3 x 2 x 2 scheme is better than other schemes.
Because, only 3 x 2 x 2 scheme satisfies the ratio requirements. i.e.,
Nmax Nmin 1 Nmax
Ninput < 2; N > 4- ; and -N s 8,
input min
in all stages. It means the speed reduction in all stages is minimum which results in
compact units.
, Example 9.10 I Sketcb the speed diagram and the kinematic layout/or an 18 speed
gear box for the following data:
Motor speed = 1440 r.p.m; ,. Minimum output speed = 16 r.p.m: ,. Maximum output
speed = 800 r.p.m: ,. Arrangement = 2 x 3 x 3.
List the speeds of all the shafts when the output speed is 16r.p.m:
Given Data: n = ] 8 ; Ninput = ] 440 r.p.m. ; Nmin = 16 r.p.m. ;
Nmax = 800 r.p.m. ; 2 x 3 x 3.
To find: Construction of the speed diagram and the kinematic layout.
@Solution:
Selection of spindle speeds :
Nmax
We know that, _ cpn - I
Nmin
800 9.21
16 - ~18-1 Or ~:::: 1.258
or 1.12 x 1.12 - 1.254
cafl write, .
we 1 12 satisfies the requirement. Therefore the e-« '" (skip one speed)
SO .1\::; • b
'l1gIf'one speed, are given y . from R 20 series,
e sPindle speeds
~1Ppl 25 31.5,40, 50, 63, 80, 100, 125, 160,200,250, 315 400 500
16, 20,urUl-'fiormula:
'. .'
Given that, 2 x 3 x 3 (l.e',Pr P2 .P ) , , 630 and 800 r.p.m.
Ilct 3
St1 (OIo\\' that, Structural formula = PI (Xl) P2 (X ) P3 (X )
2 3
We
where
X::: 1;
I
X2 = PI = 2; X3 = PI . P2 == 2 x 3 ::::6
Structural formula = 2 (1) 3 (2) 3 (6)
..ttd diagram: The speed diagram is drawn, as shown in Fig.9.14, using the procedure
51 _All' Example 9.8.
~iSCUSscu JO 2 (1)
3 (2) 3 (6)
~----------Ir-----------r--------~800
, 630
, ,
,,' ,,' 500
R:·l.;·-'!,,;·:·_--·- .... 80
Dr\..·-·" ....... ". B 63
I" ..
'\.
,,"..
'. ". ".
.. ..
". ".
"
50
•••••• ~ 31.5
'\. ••~ 25
l -------~- ~20
.,....
I
1..----- ~-I- ~ _--1------ "\ 16
l....-------.2! ¢:
-t-
~
en A
....f.--I4..-.
--- - -- -- -- -- -- -- --
1
- Shaft - 1
jiflIin8 one~: ;50, 315, 400, 500, 630, 800, 1000, 1250, 1600, 2000 and 2500 r.p.m.
125,160, . 'mula: For 14 speeds, the preferred structural fonnula
StrJl(/urtdfo~ = 3 (I) 3 (3) 2 (5)
Speed diagram: The speed diagram is drawn, as shown in Fig.9.16.
min
N - 125 3 (1) 3 (3)
2 (5)
S1Dgt3 : N;npul - 315 '-- _ _':"_~-' I __ -1 2500
-_-~--:::--:-:-:-
1
- 04>
. -4' . and L--------+-----~~--~-----~~~2000
. ~'" , _.- ..... .....
I l_-------+--~-~··~·~--~'~~·~·~··11600
Nmax 400
- -
N;npul 315
- 1.27 < 2.
~t2: -Nmin
N;npul
-
315
800
1
- 0.39> 4' ,. and
N
~ mat 1250
N;"PUI
- -
800
- l.56 < 2
'e].. N.
800
~
N;lIput == -
1600
for 14 speeds
. gspee ddiagram
1 • fa}6 Over/appm
- 05>
. -4'- . and Fig. 7. •
N~ . ents ar e satisfied.
~
'npUt
== -
1250
1600
= 0.78 < 2.
.
.. RatiO
requlrem
~ t- r-
f-
Shaft - 3
--------~
'--
'-
Spindle (Shaft - 4)
Fig. 9.18.
7. Calculationof centre distance in all stages: Calculate the centre distance in each
!!age by usingthe relation
where zx and zy = Number of teeth on the gear pair in engagement in each stage.
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---r Shalt-a
• 20 mm .1. 7b
Fig. 9.19.
r Shaft - 3
Gear
Fig. 9.20.
./ Calculate the maximum bending moment due to normal load (Fn) using the
relation
M= ... (9.9)
" F,
where Fn = Normal load on gear = -- I
cos a. I
9.27
Table 9.5. Permissible sl, ear stress I TI,N
'Imml
Shaft material
S.r-Io. l 't 1. N/mml
~ C14 (as supplied)
\. 25
@Solution :
1. Selection of spindle speeds :
600
or <\>12-1 = 2s
or c\> ~ 1.335 ..' (skip 4 speeds).
06) :=: 1.338 .es
06 x 1 06)( 1. fr R 40 sert ,
We can write, 1.06 x (1.06 x·' 1 indle speeds om
. ent. Therefore the sp
So ~ = 1.06 satisfies the requlrem
~. Plngfour speeds, are given as 450 and 600 r.p- ro .
250 335, 9 21
25, 33.5 45 60 80 106 140, 190,' h .~t11 in Fig. . . l
2. . constructe ,
lay diagram: The ray diagram IS
Design. (JITrammbsiol1
9.28
~
1i
.c
1i
.c
IV
.c
CIJ Stage 1 CIJ Stage 2 CIJ Stage 3
Nmax 190 25
N;npul
= 140 A
20mm
10mm 7b
Second pair: Consider the other ray that gives speed increase from 80 1
nding gears are 11 and 12. r.p.m. to 40 r.p.m,
The correspo
zll NI2 140
-
zl2
=-=-
Nil 80
orz II -
-175. zl2 ... (i)
We alsoknow that the sum of number of teeth of mating gears should be equal.
" zJJ + zl2 = z13 + zl4 ::: 20 + 64 = 84 ... (ii)
II
Stage 2:
Fisf pair : Consider the ray that gives maximum reduction from 140 r.p.m. to 80 r.p.m.
11Jecorrespondinggears are 9 and 1'0. Assume z9 = 20 (driver).
z9 NIO 20 80 _
Z10 = N9 or ZJO = 140; :. zlO - 35
Second pair : Consider the other ray that gives speed increase from 140 r.p.m, to
190r·p.m. The corresponding gears are 7 and 8.
'. z7 Ns 190 1357 ... (iii)
Zs = N7 = 140 or z7 =. Zs
... (iv)
and Z
7
+ Zs - ""9 + Z 10
- ~ = 20 + 35 = 55
N6 20 140
-'
. == ~4.28 = 65.
Zs
- = - or - == 450' .. z6
z6 Ns z6
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5. Material selection: C 45
6. Calculation of module:
./ To find torque: In this case, the lowest speed 25 r.p.m. is obtained by meshing
gears 13 and 14. Therefore torque at 25 r.p.m. is given by
P x 60 2.25 x 103 x 60
T 14 = 2 1t N = 2 1t x 25 = 859.44 N-m
./ Tofind tangentialforce on gear 14 :
T 2x T14
F
'14
= r - Z14 xm
2 x 859.44 x 103 26857.5
= = ... [where module (m) is in mm]
64xm m
= (30+55)
2 x 5 = 212.5 mm
.; Centre distance in stage 2, a2 = (Z7; Zs) In
= (31 +
2
24) x 5 = 137.5 mm
= (53 + 31) 5
2
2
= 10mm
I, Calculationof face width: b = \V x m = lOx 5 = 50 mm
9, Calculationof length of shaft (i.e., distance between the bearings) :
Lengthof shaft, L = 25 + 10 + 7 b + 20 + 4 b + 20 + 4 b + 10 + 25 = 110 + IS b
= I 10 + (15 x 50) = 860 mm
10, Designof shafts :
~)Designo/spindle i.e., output shaft:
,I Tofind maximum bending moment (M) :
Fn x L
M = 4
where
F, = (26857.5 / m)
Fn = Normal load on gear = cos a. cos a.
= (26857.5/5) = 5716.23 N
cos 20°
5716.23 x 860
.. Maximum bending moment, M = 4 = 12.29 x 105 N-mm
~i
9.32 Design of T,ansrn iss
We know that,
650
or 4>18-1 = or 4> = 1.1875
3S
9.33
. AI:::; 1.06satIsfiesthe requirem
SO. ., 2 speeds, are given
• by ent, Therefore the . ." (skip 2 speed
~PPI~g . SPIndle speed s)
35. , 42.5, 50, 60, 71, 85, 100, 118, 140 1 s from R 40 series,
d 6705 r.p.m. ' 70, 200, 236 280
.0 • Th . ' , 335 400
, Bay diagram. e ray diagram is ' , 475, 560
i' . constructed
SJfuctllra}lormula: 2 (I) 3 (2) 3 (6) , as shown in Fig.9.23.
Stille 3'• N
---- = -140 - 3 (2)
,:====---t---_::+=~="'
. . l'
inpJlI ~ 3~
1 I
• ......,560
670
- 0,253 > 4 and I" ,,1'
Nm~ 280 -
~
""-~H _-------
"
:"...' ........335
400
....
.' " ." ,
'
.:
~475
'
- 140 = 2
N;npul - _ ""' _.........
..__ F '..f-:,~...
..,,:" .' , .'
'.: __. ,__
_"_ , ,. ....
'• .'(- .-7 ··e 280
Nmin 140 ... ... f ,.." , ...
Stage 2: Ninput - -
236
G ~.- ,."
E
..
,....
''(.,'/
'f' ,.....
',' ....
....
236
1
0.59>4 and
D ~': ,: ........ 140
. , ' , .. ,"
Nmax 280 , " .. 'II
- -
236
NinpUI \ " ',',",:, 100
- 1.186
\ " "
' \ " ''-' '' 85
, "
\ ,' ,' ,," ~' 71
,' ,
Nm;n 236
Stage 1: - - \ , '. ' 60
N;npul 475 \ '. '
.... 50
1 \\ 42.5
- 0.497> 4 and
~ __S_ta_ge_1~I--S_m~ge_2--~~S=ta~ge~3~\~ 35.5
A
280
-
475
. _ 0.59 < 2 Fig. 9.23. Ray diagram/or 18 speed gear box
'.
J. Ratio re qUlrements
. are satisfied. .
,~draWn
. KlIIelllat·tc arrangement: The kinematic arrangement for the given 18 speed gear box
, as shown in Fig.9.24.
T
58
79
20 35.5
---
- 140
Second pair: Consider the other ray that gives speed reduction from 140 r.p.m. to
100 r.p.m. The corresponding gears are 11 and 12.
zll NI2 100
zI2 = Nll = 140 or zll = 0.714 z12 ... (i)
•. , (iv)
and zl3 + zI4 - zI5 + zI6 = 20 + 79 = 99
On solving the equations (iii) and (iv), we get
zI4 = 33 and zI3 = 99 - 33 = 66
Zs _ N6 200
.' z6 Ns == 236 or Zs == 0.847 Z
d z +z 6 ... (v)
an . . 5 6 - Z9+ZIO==20+34=54
On solvmg the equatIOns (v) and (v i), we get ... (v i)
z6 = 29.24 ~ 30 and
, . Zs -- 54 - 30 = 24
Third paIT: Consider the other ray that giv es th e speed mcreas
. f 2
rIm.Thecorresponding gears are 7 and 8. e rom 36 r.p.m. to 280
z7 Ng 280
Zg - N7 = 236 or z7 = 1.186 z8 ... ( VlIii)
Slage 1"
First pair,' Consider the ray that gives maximum speed reduction from 475 r.p.m. to
.J~r.p.m.The corresponding gears are 3 and 4.
Assume z3 - 20 (driver)
Z3 N4 20 _ ~ . :. Z4 == 40.25 ~ 41
_ - or - - 475 '
z4 N3 z4
St • • d reduction from 475 r.p.m. to 280
,.~f411d Pill': Consider the other ray that gIVes spee
.Thee orresponding gears are 1 and 2. ... (ix)
zl N2 _ ~ or Z ::::0.59z2
- :::: - - 475 1 ..' (x)
z2 NJ .
and :::: 20 + 41 ::::61
I'L Z1 + z2 :::: z3 + Z4
vn sol'
Vlog the equations (ix) and (x), we get d ZI ~ 61 - 39 ~ 22
z2 :::: 38.37 ~ 39 an
Design o/Trans",is .
-~~
~.36 ------------------------------------~~~--~~1~ ~
'. 40 N i 2 Cr I Mo 28 (hardened and tempered)
5. Material selection. Take
6. Calculalion of module: _
16 has the lowest speed of .;,5.5 r.p.m .
./ Tofind torque: T he gear
p x 60 3.75 x 10J x 60 _
T 16 = = 2 35 5 - 1008.7) N-m
21t N 1t x .
T
F1 =
r
16
b
where \11
Tm
= -m = 10 and
'
or module, m = 2.945 mm
= 110 + 18 x 30 = 650 mm
• II O/sha/lS :
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M = 9058.79 x 650
... 4 = 1.472 x 106 N-mm
, Equivalent torque,
- ~ (1.472 x 106)2 + (1008.73 x 103)2
- 1.784 x 106 N-mm
ds = [
161t x[ ~Teq J
1 3 where [t 1= 55 N/mm', from Table 9.5.
1
6
_ _16 x 1t x 55x 10 J3 = 54.87
1.784 mm '" 56 mm (R 40 series)
[
Weknow that ,
75.39 x 103 - 0.2 x d~l x S5 Ill (R 40 series)
19 IIl
:::: 18.99 mm ~
ds1
or
(b)Diameter 0/ shaft 2 :
Minimum speed
Torque
Or
da :::::
REVIEW QUESTIONS
I. What situations demand use of gear boxes ?
2. What are the requirements of a speed gear box?
3. The speeds in machine tool gear boxes are in geometric progression. Why?
4. What are preferred numbers?
5. Explain briefly the term 'progression ratio'.
6. Write an engineering brief on :
(i) Kinematic layout of gear box; and (ii) Ray diagram.
r
1. Oitferen tiate ray diagram and structural d'
lagram.
6. t the basic rules to be followed for .
~ist 011 Optrmum gear box d .
9· . the step by step procedure to design th eSlgn.
W(Ite e gear box.
/0.
PROBLEMS. FOR PRACTICE
construction of ray diagram and kine-,. .
blelflS 0" . . ".utlC layout:
~ . need gear box IS to provIde a speed rang f 1
A SIX Sr- d h k" e 0 00 rpm t 100
/. d diagram an t e rnemanc layout of the gear b . . . 0 0 r.p.m. Draw the
spec . _' ox.
minimum and maximum speed of 6 Speed ge bo
2.
The
. truct the spee
d d'
ragrarn and the kinematic arranar ox are to be 500 and 1600 r.p.m.
Cons '. gement of the gear box.
'ne speed gear box IS required to give output spe d .
, AnI . e s rangmg from 100 6
J. The input power IS 4 kW at 1000 rpm D h r.p.m. to 00
r.p·m. f . . . raw t e structural diauram and th
k inematic arrangement 0 gears. Also calculate the 0-" e
f percentage deviation of th
obtainablespeeds rom t h e calculated ones. e
w the kinematic arrangement and the speed diagram of th h d t k
4.. Dra .' e ea soc gear box ofa
tuITetlathe having arrangement for 9 spmdle speeds ranging from 50 r.p.m. to 1500
r.p.m.Calculate the number of teeth on each gear if the minimum number of teeth on a
gear is 23.
5. A machine tool gear box is to have 9 speeds. The gear box is driven by an electric motor
whoseshaft rotational speed is 1400 r.p.m. The gear box is connected to the motor by a
belt drive. The maximum and minimum speeds required at the gear box output are 1000
r.p.m.and 200 r.p.m. Suitable speed reduction can also be provided in the belt drive.
Whatis the step ratio and what are the values of 9 speeds? Sketch the arrangement.
Obtainthe number of teeth on each gear and also the actual output speeds.
6. A 12 speed gear box is to provide a minimum speed of 30 r.p.m. with a step ratio of
l.I2. Using standard step ratios, find the number of teeth on all gears.
7. Draw the speed diagram of a 12 speed gear box to give speeds in the ran~e of 63 to 2800
f·p.m. Consider any 4 possible different alternates and indicate the best wIth reasons.
8. A mach'me tool gear box is to provide . 14 spm. dl e speeds ranging from 20 to 400 r.p.m.
Draw the kinematic
' arrangement and the ray d'lagram.
9. AI' of 100 r.p.m. to 560 r.p.m. Sketch
6 speed gear box is to furnish speeds m the range . .
the k' V t dard progresSIOnrano.
lOematic layout and speed diagram. se san. . d
10. A '. . of a milling mach me. Maxlm~m an
.~ear box IS to grve 18 speeds for a spmdle 800 rpm respectively. Fmd the
nlIn d 16 to . . .
Imum speeds of the spindle,. are to be aroun d the structural diagram and the
:~ ratios which will give the desired speeds and raw
Inemat'
ICarrangement of the drive.
Q~~ --------------------------_D--eS_ig~n~Of~Tr_a~nr~rn=/~ss~ns
!!.40 ~
Clutches
"One Ues ore t ,L'
0' a t,,/IIgsfro", /L_
TIe valley.
only s",al/ things from the peat ..
INTRODUCTION
I~f. . . . - G.K. Cllmenoll
'he clutch ISa mechanical device which .
l . IS used to conn t .
,,~J at the operator s Will. The use of clutch . . ec or disconnect the SOurce f
,\1 h . . . es IS mostly f d' 0
.i jII~JlI'''Iobile clutc IS a transmiSSion device whiICh IS
. used to oun In automobile . In an
,nlltl the engine to the rest of the system. engage and disengage the power
For me above said reason,
. the clutch is locat e d im be tween the .
_. When the clutch IS engaged to the engin . engme and the transmission
~). . e, power IS transm'tt d
JL~aged, the power IS not transmitted to the rest f hie to the wheels. If it is
J1JIIIIing and hence the vehicle stops. Therefore for co 0 , t thesyste~ even though engine is
. . . 1
up mg e engme smooth I t th
i Q1IISlI1isslon during starnng from rest and gear shifting , c Iu tCh IS
. used. y 0 e power
Disc Disc
Driving disc
Driven disc
Fig. 10.1.
01 Mel/lods :
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,co"tr .
Mechanical control IS achiev db'
I e y ltnka '
cams or we d ges. Th e actuatinb f ges at by b
. '. e orce can 1.._ ails Or t II
electrtC motor, air cylmder, or hYd . ue suppli..... 0 trs workinabv
rauhc ra ~ rnanuall e er
lectrical control of friction or t h Ill. "1 Or by solenoid
I E oot cl h •
electrically and releasing it by spr] f utc es ofteh invol
Ing orce ves engagingth
I Pneumatic or hydraulic Control' . e clutch
'nflatable tubes or bladders. IS accomplished b
I y actuating P'iston nd
. I f s a
I AutomatIc contro 0 clutches implie th
s at they react to ed I
Engine
shaft -_
clUtCh shaft
Friction surface
<a) (b)
'2 to '"
T = J
r2
27t Il P r2 dr = 27t 11P [ ~ ] : = 2" 11P [ r: ; r~]
W
T = 21t #l x 1t (I'; _ I'~) [I': 3-ri]
or ... (10.2)
= P2' 1'2 = C]
T = f
'2
2x,,· e .r . dr = 2x" e[ ~ r
'2
l
T = 1t fl C [r~ - r; ]
or ... (10.6)
INote I
I. In general, totalfrictional torque acting on thefriction sur/ace or on the clutch is given by
T = n·J.l·W·R
C/~fC"es 10.9
. .a the problem, if the word 'new clutch' i .
'Iesolvmb f ,S gIVen, then considi
J If'" Bul if Ihe word old clutch is given, then II I. er as an uniform prt!$sur~
, ble"" s an uniform '
prO hen uniform wear should be considered w~arprob/~m. If nothing ;s
fPted. I .'
S • uf pressure IS maximum at the inner radius (r_j •
l Intensll)! rfi ]I a"d mlmmum at the outer radius (r·1 or
'ctionsu ace. 1/ 'J
thefr I
J
roue pressure
'{he {IV e b
(Pd on the friction or contact suna
'J'
. .
ce IS given by
o: = Total {orce on/ticlion surface
r a» Cross-sectional area 0/'frtctton s.r.
UIjQce = frlr1 W
_ } 1 ...(10.7)
J r1
Driven aha1!
Engine shaft
10.7.1 D
. eSignof a Multiplate Clutch
let (Torquetransmitted on Multiplate Clutch)
nl = Number of discs on the driving shaft, and
l
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--------------------~
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10.10
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---------------------D--es-l=gn~of~Tr-a-n-s-m~~~s~;n~ns
~
R = ~ [r1-rn
3 rl-r2J
[For uniform pressure]
rl +r2
R = [For uniform wear]
2
Table 10.2. Driver dynamic characteristic factor, k J (from data book, page no. 7.9IJ)
Factor k)
Type of drh'ing system For direct coupling For belt transmissions
or when ~ar box is used
Electric motor directly connected
0.5 0.33
to mains
Machines with low starting torque
0.33
characteristics, turbines, etc.
-
Table 10.3. Driven dynamic characteristic/actor, k2 (from data book, page no. 7.91)
0.43
a oolc,page no. 7.91)
~ofeng
~
Igements in En
~r sbift
I
\
1
0
8
0.2 0.55
16 32 48 96 240 480
0.75 0.9 1.2
~ . . 1.8 2.00
r.;:;l The service factor IS used mostly an those probl hi .
~ I t h ems w ich require the calculation of
~ions of the c u c .
2
,31 -'2-
T - n f1 W '3 [ ;~ -r~ . 0.25 _ 0.12 ] ~ 1444.6N-m
x ~ x [ 025 - (0.12i
_ 2 x 0.25 x 15 x 103 3 ( . 4 k'W Ans. ~
" .... '>l 500~ :::::75.6
:.p~ 21tNT == ~
I Example I
10.3 A single plate clutch transmits 25 kW at 900 r.p.m. The mtJXiIruII
pressure intensity between the plates is 85 kNlntZ. The ratio of radii is 1.25. Both the ~
of the plate are effective and the coefficient of friction is 0.25. Determine (i) the bfM1
diameter of the plate, and (ii) the axial force to engage the clutch. Assumt theory~
uniform wear.
Given Data: P = 25 kW = 25 x 103 W ; N = 900 r.p.m.: ,,/'2:::: 1.25;
t T = 265.26 N-rn
" of • tensity of pressure is maximurn at th .
e an e anne .
t '~ce th r radius ( )
51 Pmax . 1'2 = C or C - 85 '2 ,
t - x 1()3
" . '2 N/rnrn
, ial thrust transmitted to the frictional ..c.
d the aX SUI lace,
,JJ W == 21t C (I'. -1'2) = 2n x 85 x 103
'2 (1.25 r _ )
== 1.335 x lOs (1'2)2 2'2 '" [.,' 'I == 1.25 '2]
= 3096.57N Ans."
IExample10.4 , Outer and inner diameters of a single plate clutch, having ferodo
fridion linings on both sides are 300 mm and 200 mm respectively. The coefficient of
frrtionbetween the contacting surfaces is 0.35. Assuming uniform rate of wear, determine
~ -imum power tllat can be transmitted by the clutch at 1500 r.p.m: when the
trxUnum pressure is not to exceed 15 x 1fJ4 Nlm2. Also, determine the axial thrust to be
~U~~e¥rinponpn~unpm~
3
Given Data: d , = 300 mm = 300 x 10-3 m; d2 = 200 mm = 200 x 10- m;
. = 15 X )04 N/m2,
IJ. = 0.35; N = ] 500 r.p.m.: Pmax
@ Sol' . . . m at the inner radius ('2)'
~ utlOn: Since the intensity of pressure (p) IS maxunu
fore for 'c
unhOrm wear
0-3 == 15000 N/m
Prnax.·r2 = C or C = 15 x l()4x ]OOX ]
A>:iaJ thru
st exerted by the springs is given by 3 100 x 10-3)
(150X 10--
W = 27t C (I'I - 1'2) == 27t x 1500 O x
ro, = 4712.39 N Ans. 1)
qUe trans .
llutted for uniform wear,
_1_O._14 D_a~ign~Ozif~TJ~rQ~~~-.
.
.. ,ISS IOn S
~
T = n- J.I • W ("; '2 )
(ii) Minimum pressure: Since the intensity of pressure is minimum at the outerradius
(r1), therefore
d, = 1.25 d2 or ~ - I2
d2 - • 5 or -
r, == 1 25 .
r2 " Il == OJ
Iplion : (i) Dimensions of the friction plate· A
fJ So • ssume uniformwear
Given that the torque developed, T == 100 N-m .
Design torque, [T] == T· k
s
.'
where service factor, Ie == Ie + Ie + 1- + k:
s '2 113 4
From Table 10.2, k, - 0.33 (for machines with low start'
109 torquecharacteristics)
From Table 10.3, k2 = 1.25 (assume)
From Table 10.4, k3 - 0.32 (assuming 1000 r.p.m.)
From Table 10.5, k4 - 0.9 (assuming 48 engagements/shift)
ks = 0.33 + 1.25 + 0.32 + 0.9 = 2.8
Design torque, [T] = 100 x 2.8 = 280 N-m
Sincethe intensity of pressure is maximum at the inner radius (r2)' therefore
Pmax. x r2 = C or C = 85 x 103 x r2 N/m
We know that the Power transmitted P = 2nNT = 27t x 250 x 72.38 = 1895W
'60 60
Also T = I a, where a isangular acceleration.
72.38 = 6.5 x a or a = 11.135 rad/sec-
(J)
We also know that, a = I = 11.135
11.135 10.17
21t X 250
60xt == 11.135 0
.. r I::: 2JS
he full speed IS attained by the. sec Ana
fltLlS t ••• machine in 2 .~
oe energy lost In slipping of the I .35 seconds
(P) I/J C utch: .
A ogle turned by the driving shaft, 91
r» == (1)1 ::: ~
60 XI::: ~
== 61.52 rad 60 X 2.35
== 0
+ -21 ·X II. 135 X (2.35)2 .::: 30.75 rad
.' Energy lost in friction -
-
72.38 x (61.52 - 30.75) ::: 2226 N-m Ans.~
(iii) Intensity of pressure, if the condition is unifior.m pressure :
Intensity of pressure , p = 2W 2
1t (r I - r2)
1507.96
= 1t [(100 x 10-3)2-(60 x W-3)2]
T == 73.89 N-m
Pow . . n by
er transmitted with uniform pressure IS give
2nNl
p == - 60
2n x 25~ ::: 1934 W
::: ~
125
I x 0.3 x 600 (0.2 +2°. ) = 20 xa
80 x 10-3
or r, = 0.7
1'2
= 0.7 =0.JJ43m
We know that the maximum intensity of pressure (Pmax) is at the inner radius ('2)'
.. Pmax . r2 = C or C = 160 x 1()3 x 80 x 10-3 = 12800 N/m
= 2i~~;8 = 10.887 ~ 11
Hence, there wiD be 12 total plates, in which driving and driven shafts having Jix
plates each. Ans. ~
I Example 10.11 I A multi-disc clutch has three discs on the driving shaft and two 0"
the driven shaft is to be designed for a machine tool, driven by an electric motor of 22 kW
running at 1440 r.p.m: The inside diameter of the contact surface is 130 nun. The
maximum pressure between the surfaces is limited to 0.1 Nlmm2. Design the dutch. Take
J.l = 0.3 ; n I = 3 ; n2 = 2.
Given Data: P = 22 kW = 22 x ]03 W; N = 1440 r.p.m.; d2 = 130 rnrn or
r2 = 65 mm ;Pmax = 0.1 N/mm2 = 0.1 x 106 N/m2•
To find: Design the clutch (i.e., determine the outside diameter of disc, total number of
discs, and clamping force).
© Solution: Assume uniform wear.
I. Outside ~iameter of disc (d J: We know that the torque transmitted,
T = P x 60 = 22 x 103 x 60
21tN 2 x 1t x 1440 = 145.89 N-m
Design torque, [T] = T x ks
where Service factor , ks = k, +~+~ +k4
From Table 10.2, k.
= 0.5 (for electric motor)
From Table 10.3,
~ = 1.25 (for machine tools)
From Table 10.4',
k3 = 0.38 (for 1440 r.p.m.)
From Table 10.5, k4 = 075 ( .
. assummg 32 engagements / shift)
Ks = 0.5 + 1.25 + 0.38 + 0.75 = 2.88
Design torq~e, [T] = 145.89 x 2.88 = 420.16 N-m
We know that maximum intensity of pressure . '.
. r _ (Pmax) ISat the Inner radius (,~. Therefore,
max
. P 2 - C or C = 0.1 x 106 x 65 x 10-3 = 6500 N/m
For umform wear, axial force exerted' .
IS given by
W = 21tC(', - '2)
= 21tx 6500 (, 65 3
•- x 10- ) = 40840.7 ('. _ 0.065) .. , (i)
"forque
transmitted, [TJ = n·". W (~ ;3) ..
420. J 6 = 4 x 0.3 x 40840 7 (
. r - 0.065)
(I'
_!
+00
.65)
420.16 = 24504.42 (1'2 _ 4 225 2 -
, . x J 0-3)
T, = 0.14618 m or 146.18 mm
W - 1273J N
or w = 1404 N
The axial force exerted (W) can also be given by
W = 21tC (r, - r2)
or W = 21t x Pmax X r (r
2 l - r2)
or ]404
= 21t x Pmax x 0.06 (0. ]2 - 0.16)
Pmax = 62.07 x I()3 N/m2 = 62 kN/m2
Ans. "
10.8. CONE CLUTCH
In a cone clutch, contact surfaces are in th h
tw . e s ape of cones h . .
o cones A and B are 10 contact when the cl t h . ' as SOwn rn Fig.l 0.5(a). The
tight with the help of springs. Thus torque] u c . IS engaged. The contact is complete and
fro . .' e IS transmitted d .
ictron cones from driving shaft to driven sh ft F . urmg engagement of clutch through
pulled back by means of a lever system co a . ~r disengaging, the clutch of the cone B is
friction surface in these cone clutches The lo pressmg the springs. There is only one pair of
. s ope angle a .
vanes from 80 to ]50.
~
~-----~::::~~---------------- JI~O~.2~3
Clutch pedal
Driven shaft
SprIngs
dr
(d)
(c)
(b)
Fig. 10.5.
Let P = Normal intensity of pressure on friction surface,
n
. c. angle of the cone or the angle of the friction
a = Semi-angie of cone or lace
surface with the axis of the clutch,
r) = Outer radius of friction surface,
...:.1~O~.2~4 D__u~~~n_o~if~Tro~mus·
-~S}'.Jt
~
rl + r2
R = Mean radius of the friction surface = 2 '
W= f'. 27tr·dr·P n
'2
[ r2 ] r. [y2 _y2 ]
=
27tPn 2" r2 = 27tPn • 2 2
102S
'1
..
'
W = f 2ltC . dr
'1
= 2lt C [ r 1'2
'I == 2rcC (rl- r2)
.. , (10.14)
w _
or C == 2tt ('1 - '2)
The fro . • • iven by
Ictaonaiforce acting on the f1ng IS gr' dr . cosec a
F = 11. IiW. = 11' p.: 2lt
r
.1~O=.2~6 D_u~~~n~o~if~Tr~a~~~m·
.
- la!la" S
~
and frictional torque acting on the ring is given by
T = F r x r = J.1' Pr . 2nr . dr . cosec a x r
C
= J.1x - x 2nr2 • dr . cosec a
r
= 21tJ.1 . C cosec a x r . dr
:. Total frictional torque acting on the clutch,
rl
T = f 21tJ.1· C . cosec a .r . dr
r2
or J.1. W . R . cosec a I
rl + r2
where R = 2 = Mean radius of the friction plate
25 x 103 == 2n x 750 x T
60 -
or T = 3 18.3 I N-m
Nonnal load acting on friction surface can be obtained by
T == J.!' Wn· r
or
W == L == 318.31
n 11r 0.25 x 0.2 = 6366.2 N
The axialforce required to engage the cone clutch is given by
We == W n (sin a + J.! cos a) = 6366.2 (sin 10° + 0.25 cos 10°)
== 2672.85 N Ans. -e
IExample10.15 , The following data relate to a cone clutch : Minimum and maximum
'llface contact radii are 125 mm and 150 mm respectively; Semi-cone angle = 200;
,Ylo~able normal pressure is 14 x 1(11Nlm2; p = 0.25. Find (a) The axial load, and
~)The powertransmitted, if the speed is 700 r.p.m.
GivenData : r} == ISO mm = 0.15 m ; r2 == 125 mm = 0.125 m;
(6) Po
wer transmitted:
3 3 ] .
To
rque, T == -2 W
'1 -'2
cosec a.
3
II
r- [ ,2 _,2
1 2
{9 150)3 - (0 115\3] cosec 200
_ .!:.;:.L- ::::304.73 N-m
_
1_O_.2_8 D~u~~~n~O~if~ff~Q~~~m~;.
'
...$,o" S
~
27t NT 27t x 700 x 304.73
Power transmitted, P = =
60 60
•.
= 22.34 kW Ans. ~
R
b = 3 , J.l = 0.2 ;
P - 37 kW = 37 x 103 W;
N = 2000 r.p.m.
R
Tofind: Dimensions of contact surface ('1 and '2)'
21tN T
@ Solution :Power transmitted, P = 60
21t x 2000 x T Fig. 10.6.
37 x 103 = 60
. T == 176.66 N-m
of Assuming servIce factor, ks == 2.5,
Design torque, [T1 == 176 .6 6X25-
. - 441 6
srTlitted is also given by, T == 2 . 5 N-m
,(1Ue tran 1tJ.l P" . R2 . b
rOI'f
441.65 == 27t x 0 2
. x6x l04xR2(E)_
R == 0.25998 3 - 25132.74 R3
R m or 259.98 mm
idth is given by, h == - _ ~25998
Fsccw 3 - 3 -
== 0.08666 m or 86.66 mm
or r -'2 == 0.02242 m
... (i)
r +'2
and Mean radius, R == 2 = 0.25998 m
i80 r.p.m.The normal pressure between the surfaces in contact is not to exceed
1600 iNlm2.The widtll of tile friction surfaces is Iial/ of the mean diameter.Assume p =
Us.Determine:
(i) The outer and inner diameters of the plate, and
. (ii) The axial force 10 engage tile clutcll.
GIVe" Data: a == 150' P == 10 k W = lOx J 03 W; N = 600 r.p.m. ;
, D
2 b - - = R' Jl = 0.25.
P" == 100 kNlm2 = 100 x 103 N/m; - 2 '
lO/l"d., (i) Outer and inner diameters of the plate (d, and d2), and
e (ii) Axial force to engage the clutch (We)' .' h t face width b is
SOllllio late' It IS gIVen t a
~1Ja1 to th ": (i) Outer and inner diameters o/Ihe p .
.. e lIlean radius of the friction surface R.
h - R . s problem]
~ekn [Refer prevlOU
Ow that , sin a
'1 - '2 \
or b = sin a
'1 + '2
and Mean radius, R = 2 \
'1 -'2
I
So, =
sin a
'1 -'2 =
or T = 159N-m
Assuming service factor k, = 2.5,
Design torque, [T] = T x ks = 159 x 2.5 = 397.5 N-m
Assume uniform wear.
Since intensity of pressure is maximum at the inner radius, so
Pmax X '2 = C
r
Pulley Brake lining
oriven
'\
Spring
J------------- -- -----J
, ~
VI/~
~ \_
Driven shaft
-Cover
,\\,I:~'1
The shoes are mounted radially and springs keep them away from inner rim of the pulley,
Shoes have some mass. As the speed of the driving shaft rises, the centrifugal forceonthe
shoes increases causing them to move radially outward within the guides provided.
When the centrifugal force is less than the spring force, brake lining cannot makeany
contact with the pulley rim. But when the centrifugal force is equal to the spring force,the
shoe is just floating. When the centrifugal force just exceeds the spring force, the shoemoves
outward and comes into contact with the driven member and presses against it to transmitthe
torque.
Fig. 10.8.
I - R· e ,., (10.19)
From Fig.l 0.8 ,
•• rea of contact of the shoe. A '" /. b
Net force acting on the shoe '" Fe - Fs '" A xp lne'" /. b' P
From tho expression, the width of the shoes (b) can be oblll. h d . •11l ricJiDn.1S kg tJIId
r:=IS
~/e 1 I h eOC hlJ1l g a tJIIISS OJ
"'u,U. 0.20 A centrifugal clldch hUSfour s oes of thef .urflJ£t 411
is
:~...... ;,ntre of gravity at a radiUS of 60"''''' The dwn;tt;:OO r.PO""/)eIe,.",;nethl
10
"" _.. e cllllch is to trans",it 6 kif' pOHIer ttl II speed of",. 11 Is gf{1llUJlity ;ncrt/lS
fro leh lit eed of rot... J~
_'<II ust be exerted bv each spring. I/ the sp , rake p'" 0. , •
• /11 w6 J •• ",it torque ·
or T = 57.29N-m
Total frictional torque transmitted can also be given by
T = n· (Fe - Fs) . J.L. R
57.29 = 4 x (Fe - Fs) x 0.35 x 75 x 10-3
2lt x 1000)2
Centrifugal force, Fe = m (1)2 r = 5x ( 60 x 60 x 10-3
= 3289.9 N
Then the force exerted by the spring is obtained by
Fe - Fs = 545.67
or Fs = Fe-545.67 = 3289.9-545.67 = 2744.1N Aas.~
(ii) Speed at which transmission begin: Transmission will begin when centrifugalforc
is equal to spring force.
27tNT
power transmitted, P =
60
2x 900 x T
15 x 103 =
60
or T = 159N-m
Centrifugalforce on each shoes,
Fe = m (02 r = m (94.26)2 0.12 = 1066 m N
Springforce on each shoe, i.e., the centrifugal force at the engagementspeed (I)"
Fs = m «(O1}2 r = m (70.7)2 0.12 = 600 m N
We know that, Fe - Fs = l- b· P i
I
6
1066 m - 600 m = {).1571 x b x 0.1 x 10
466m = 466 }(2.27 = 0.1571 x b x 0.1 x 106
or b = 0.0673 m or 67.3 mm Ans. ~
I Example I
10.22 A centrifugal friction clutch has a driving member c .
• onsUUn
spider carrying four shoes which are kept from contact wIth the clutch case by , 0/ Q
flat springs until increase of centrifugal force overcomes the resistance of the! ~Q1tt Of
the power is transmitted byfriction between the shoes and the case. rp"ng, lIIfd
Determine the necessary mass of each shoe if 22.5 kW is to be transmitted
with engagement beginning at 75% of the running speed The inside d!n_-* III 750,.p.""
. -,ac,e, Of th
IS 300 mm and the radial resistance of the centre of gravity of each shoe from th e tit".,
is 125 mm. Assume IJ = 0.25. e ShaftIltir
Given Data: n = 4; P = 22.5 kW = 22.5 x 103 W ,.
N = 750 r.p.m. ; N I = 75% N or COl = 75% co;
D = 300 mm or R = 150 mm = 0.15 m ,
.
r = 125 mm = 0.125 m ; J.l = 0.25
Tofind: Mass of each shoe (m) :
=
by
n- F . R
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10.37
./' In these clutches, the fluid flow can be controlled remotely using solenoid valves.
INo'~lln the arrangement shown in Fig.lO.9, if the external rim is fixed then the devicefunctions
as a internal expanding rim brake. For force analysis and other details, refer Chapter II.
10.12.2. Working
From Fig.10.10, it is understood that the
externalrim is rigidly bolted with the outer
casing. Whenever the compressed air is fed into
theflexibletube, the external rim contracts (i.e.,
theflexible tube expands internally because it
cannot expand externally). This contraction of
external rim provides the required clamping
force. Thus the driving and driven members are
engaged. In order to disengage these members,
~e pressureof the compressed air is regulated by
asuitable control mechanism. Fig. 10.10. An external contracting clutch
~ In the arrangement shown in Fig.1 0.1 0, if the internal rim is fixed,thenthe devicefunctions
asan ext . d h d tails referChapter 11.
emal contracting rim brake. For force analYSISan ot er e ,
-6_f_:ngin~-i-L·H-~-·F~~~+6
W1 11
. ~ 12 (1)2
Clutch
10.41
011 the
as acceleration in sha ft 2 and its .
isgi~.o d2 equatIon of motion
9
12 . dt2 = T
re e :::: Angle displacement in time 'I' '" (ii)
weh .
.n.e angular velocity of shaft 1 is determined bY .mtegratin th
1J'
deI 2
_T g e equation (i).
del -T
-dt = -
II
.I + co I ... (iii)
= (~~ x 1+ 001) - (~ x I+ ~ )
. Tillierequired for complete operation {tJ: The clutching operation is completed at the
Instant in w hiich the two angular velocities COl and (1)2 become equal.
~t . operation
I, = Time required for the entire .
IIO~.~42~--------------------------------~D~~~~n~~Q
~ 11.tltli!!iO
l ment (8)· By integrating the equation (10.20) on
..I' II ~'Ftl
Angular uup ace . . " , e can ti
.
displacement e d urm. g clutching operation over a time mterva\ of t). Ind 11.._
"It ~
,') T (I + I' ~
e = I de = I (00)-002)dl-~ JI
o 0 1)'12
o
"d,
or
or
'" (10.22)
Energy dissipated during clutching operation (E) :
The work done by torque T or the energy dissipated during clutching operation' .
IS glven~
E = T·e .
The above equation indicates that energy dissipated is independent of clutch torquebm
directly proportional to square of the difference of the angular velocities of drivinganddriven
shafts at the start of clutching.
The temperature rise of the clutch can be calculated by using the relation
I aT = {; I .. , (\0.24)
I A
T,
T
l~'~t
··
·
..
. ....
'
AT
1
(""I 0.1.
f,&'
.
.
2Te",perature-tlmerelationshipfor
.
a l.
TIme (I)
12 - 4.5 kg-m2.
~44
~----------------~--~~
(i) Torque Produce
d by the motor (1'),
De.rigno/r,UIU' ...,
'"
Tojind:
(ii) power developed (P), and
'ssl'pated by the clutch (E).
(iii) Energy d I
@Solulion:
(i) Torque produced by II,e molor ('T) :. .
. uired for completmg the clutching Operation (
We know that the time req COns~.
only 12),
... [using eqUation(I
0.2~)1,
12 • 0>1
=
4.5 x 36.65 I
or Torque, T =
II 3
I
= 54.98 N-m Ans. ~
Given that the driven shaft starts from rest. i.e., 0>2 = O.
From example 10.23, .12 = 4.5 kg-m- ; 0>1 = 36.65 rad/s
Substituting these values in 'II' equation, we get
rI r developed (P) :
~) for;t h t power, p = T x (co. - co2)
owt a
Wekf1 = 21.74 x (36.65 - 0) = 796.83 W
ADs.~
~ dissipated (EJJ: The energy dissipated is given b
~~~ y
E2 ~ ! x I.· 12 (co. - co2)2
2 (I. + 12) •.. [from equation (10.23)J
(M Comparison:
E. 3022.25
~ = 717.14 = 4.214 Ans . ...,
It shoWSthat the moment of inertia of the driving machine heJps to reduce the energy
dissipation
and hence rise in temperature.
- I
J
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Design o/r,aru",#&
~1~O_'4_6 ------------------------------------~
Multiplat~ Clutch: , ,
./ itted on the multiple plate clutch IS given by
Toi'qtletransmt T = n- J.l . W ,R
where n = Number of pair of contact surfaces == n +
n I = Number of discs on the driving shaft. ~ "2 - J
n1 = Number of discs on the driven shaft,
W
=
n(r/ -ri)
, Total torque required
Number offriction surfaces required = Torque required per surface and
Total number of plates = Number of pairs of contact surface + J
Cone Clutch:
./ Torque transmitted on the cone clutch is given by
T = J.l' W . R cosec a
where R = 2
3
[rl-rl]
r/-ri [Considering uniform pressure]
· 1 ~:-.-~~----__ 10,41
! "d size of the shoes: -------- _
II fO ft Fe - Fs - I· b .p
where
1·= Contact length of the h
b - Wi'dh s oes
I t. of the shoes, and '
p = Intensity of
, pressure exerted on the shoe
'[he internal expandmg and external contracting rim clutc .
, c/VJ[lltr. . hes are also presented in this
~
dissipation during clutching (considerinae}@
I dI'-~
7:
I .iIIi
5. Explain with a neat sketch the working of a single plate clutch. Derive an eq .
. h uatlon fI
the torque transmitted by the single plate clute . ~
6. Describe with a neat sketch a multiplate clutch and explain how the number of J
P ales art
calculated in the multiplate clutch.
8. Show that the torque transmitted in case of a cone clutch is given by,
T = 2
-3 Il W . cosec a
[rI3-r23J
2 2 with usual notations.
rl =r:
9. Explain with a neat sketch the working of a centrifugal clutch. Deduce an expressi~n f~
the total torque transmitted.
10. Why service factor must be considered while designing a clutch?
II. The semi-cone angle in cone clutches is normally taken as J 2.5°. Why?
J 2. Contrast internal expanding and external contracting rim clutches.
13. List out the actuating mechanisms used in external contracting rim clutches.
14. While designing a clutch, energy dissipation during clutching should be considered.
Why?
15. What are the effects of temperature rise in clutches?
I
unl'~onn d rAns: 25.3 x J ()4 N/m ]
, It wear an 1.1 = 0.3. t·
r. . . 2 kW at 3000 r.p.m. The plates
A multJplate friction clutch is required to transmit 89.5 ." The coefficient of
,I are I d they run In or .
a temately of steel and phosphor bronze an . 0 8 times the radius of the
I &icti . fro ti surface IS •
on IS 0.08. The internal radius of the IC on JI\.f N/m2. If the maximum
e~- I . I' 't d to 20 x U" be f
d:'''''na surface. The axial pressure IS nm e 250 mm d.:termine the num r 0
laJneterof the frictional surfaces is not to exceed' fAns: JOJ
! Plates reqUired.
I' 0" COile dutch: .01. The seOli-cone angle !s
~COni '. . 90 kW at J500 r.p e bearing surface rs
200 cal fr,ction clutch is used to transmit th mean diameter of thti d the dimensions
2
3iS and the COefficient of frictic!~ is 0.2. If e eed 0.25 N/mm , '"
QlIn • not to exc
Ofthe ~d the intensity of pressure IS. load required. 785 mm ; 5045 NJ
COnIcal bearing surface and the ax.al fAns: J 96.5 mm; J •
. h . I Co • OCJ\lmulll
transmitted at 750 r.p.m. Also determme t e axia rorce required to hold ~er
Assume uniform pressure. [Ans: 17.15 kW~e CIIitch.
12. A cone clutch with cone angle 20° is to transmit 7.5 kW at 750 r.p.m. Th .78 kN]
intensity of pressure between the contact faces is not to exceed 0.12 Nt e ~onnal
th
coefficient of friction is 0.2. If face width is 1/5 of mean diameter, find (i)~~ . ~
dimensions of the clutch, and (ii) Axial force required while running. e main
[Ans: b = 46.8 mm ; r, = 125 mm ; r2 = 109 rnm . 139
, S N]
Problems on centrifugal clutch:
13. A centrifugal clutch has four shoes with an inside diameter of the drum 300 mm and
radial distance of the centre of gravity of each shoe from the shaft is 120 mm . Assummg
~
J.L = 0.25, determine the necessary mass of the each shoe if 29.42 kW poweris to be
transmitted at 800 r.p.m. with engagement beginning at 75% of the running speed.
[Ans : 1.8 kg]
14. A centrifugal clutch has four shoes which slide radially in a spider keyed to thedriving
shaft and make contact with the internal cylindrical surface of a rim keyed to thedriven
shaft. When the clutch is at rest, each shoe is pulled against a stop by a springso as to
leave a radial clearance of 5 mm between the shoe and the rim. The pull exertedby the
spring is then 500 N. The mass centre of the shoe is 160 mm from the axis of theclutch.
If the internal diameter of the rim is 400 mm, the mass of each shoe is 8 kg, the stiffness
of each spring is 50 N/mm and the J.L is 0.3; then find the power transmitted by theclutch
at 500 r.p.m. [Ans: 36.1 kW]
Problems on energy dissipation in clutches :
15. An electric motor rotating at 300 r.p.m. drives a machine through a plate whoseboth
sides are effective. When the clutch is engaged it takes 2.6 sec for the driven machi~eto
attain the speed of motor. The moment of inertia of driven machine reduced to dn7n
shaft is 4.78 kg-m-, Calculate the torque produced by the motor and its power.~;
calculate the energy dissipated from the clutch. [Ans: 57.2 N-m; 1797.22 W ; 2334. late
16. If in the previous problem, the moment of inertia of electric motor is 1.2 kg-ro2, calc~ine
the same quantities with same properties of clutch lining, assumin~ that drive~~c.AlS(1
starts from rest when clutch is engaged and takes 1.5 sec to attain motor s~
compare the energy dissipated in two cases. . 4951
. E /~:: .
fAns: 20.05 N-m; 0.63 kW ; 427 J, ,
by the brake. ~he energy absorbed by the brake is converted into heat energy and dissipated
to the surroundmgs.
The capacity of any brake depends upon the unit pressure between the braking surface, the
coefficientof friction between them, velocity of brake drum, heat dissipation capacity of the
brake, etc.
A dynamometer is a brake incorporating a device to measure the frictional resistance
applied. This is used for measuring the driving force or torque transmitted and hence the
power developed by the machine. It may work on the principle of absorption or transmission.
11.1.1.Clutch Vs Brake ,
The functional difference between a clutch and a brake is that a clutch connects two .
movingmembers of a machine whereas a brake connects a moving member to a stationary
member.That is, if any one of the moving member of a clutch is fixed, then the device
becomesa brake.
11.2.CLASSIFICATION OF BRAKES
A classification scheme for brake is presented in Fig.II.I.
F . h main types of mechanical brakes:
rom Our subject point of view, the followlOg are t e
I. Block or shoe brake ,
(i) Single block brake, and (ii) Double block brake
2. . Band brake
, . I b d brake
(i) Simple band brake, and (ii) Differentia an
_j
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Simple
$;L_
Band
Differential
External ~
Actuation
Short shoe
L-------' 0
Mechanical
L..--_In_temal
__ .... -0-
Pneumatic &
Hydraulic Leading & ~
Trailing shoe ~
Electrical
Two leading ~
Drum shoes ~
Automatic
DuoseNO
Full disk
Caliper disk
Electrically on
Magnetic
Electrically off
11.3
prpkes ~. ffi .
~ A high and uniform coe rcient of friction.
I h ability to withstand high temperatures t th . .
Ire 'ty , oge er with high heat dissipation
capac I .
I Adequate mechanical and thermal strengths.
I }-lighresistance to wear.
sistance against environmental conditions such' .
I Re . , as moisture and OIl.
Types of Brake Linings
11.3.1. f I' .
basic types 0 nungs are:
Three
1.Organiclinings: Organic linings are generally compounded of six basic ingredients.
(i) Asbestos: For heat resistance and high coefficient offriction.
(ii) Friction modifier: To give desired friction qualities. Example: The oil of
cashew nut shells.
(iii) Fillers: To control noise. Example: Rubber chips
(iv) Curing agents: To produce the desired chemical reactions during manufacture.
(v) Other materials: For improved overall braking performance. Example:
Powdered lead, brass chips, and aluminium powders.
(vi) Binders: For holding the ingredients together. Example: Phenolic resins.
2. Semi-metallic linings: These linings substitute iron, steel, and graphite for part of the
asbestos and organic components of an organic lining.
J. Metalliclinings: For further details, refer Chapter 10, Section 10.5.
The Table 11.1 shows the materials commonly used for brake lining and their properties,
,..._
Table 11.1. Properties of brake lining materillis
114
'. BLOC
I . K ~R SHOE BRAKE d inst the rim surface of a
L Il thiS h, h s are presse agal
Otake d ')'pe of brake, one or more blocks Of s oe . bbe compound, cast iron or of any
rum. Th e blocks are made of wo od,as bestos In ru r
b F
Drum
F~~
2. Self-energizlng Brake
From equation (ii), it is observed that the moment of applied force (F .1) and the moment
of the frictional force (Jl RN . c) about 0 are in the same direction. Thus frictional force
~~) helps in applying brake. This type of brake is known as a seJ/-ellergised 1J1'tIke.
.
where
~
RN =
29
RN = p x b x w
Normal reaction 0f
= Angle of contact.
1 Dimensions ol"the block: The dimensions of the block are determined by the rei .
t h e bl oc,k
~- "·01.4)
I Example J 1.1 I A single block brake is shown in Fig. 11.4. The diameterof the drll1ft
is J 80 mm and the angle of contact is 60 ~ If the operating force of 400 N is applitdat IItt
end of a lever and the coefficient of friction between the drum and the lining is 0.30,
determine
(i) the torque that may be transmitted by the block brake,
(ii) the rate of heat generated during the braking action,' when the initialbrake spttd
is 300 r.p.m, and
(iii) the dimensions of the block if the intensity of pressure between the block QIId
brake drum is 1 Nlmm2. Tile breadth of the block is twice its width.
200mm 250mm
,
I
,
I
'160 mm
400N
Fig. 11.4.
(b) counter clockwise, and the angle of contact (i). 35 ~ and (ii) 100 ~ Gi~e aJ CloCkIV
n Ihal
mm, b = 150 nun and c = 25 mm. Also find the new values of 'c' for self loc . a::::
brake. Ie'"g Of
a
a = 800 mm
b= 150mm
c= 25mm
r= 0.5 m
I IIIe 01'
~(l 'J.
'c' for self-locking of the b k
ra e :
Ie)fre~ king the externally appl ied force F
I' If~IOC ' d Th must be
forse tion of the rum. us equation (i) c be zero. This is .
~ise rota RN . b == 0 + R an Written as POssIble for COUnter
c'f . I! N' c Or b-
c == b == QJ1 - I!c
I! 0.32 == 0.469 m == 469 mm
" angle of contact, 2 (} = 1000. Ans. "
';1 fhi" .
(II! th angle of contact is more than 400 the c
s'nce e ' rei ore the coeffi .
I u' = 4 J.l sin 8 IClentof friction
28 + sin 28
4 x 0.32 x sin 500
1t = 0.359
100 x 180 + sin ]00"
or RN = 1337 N
(a) Rotation of drum clockwise:
Takingmoments about fulcrum 8, we get
F . a = RN· b + Il' RN . c
F x 0.80 = 1337 x 0.15 + 0.359 x 1337 x 0.025
F = 265.7 N ADS. ~
(6)Rolation of drum counter clockwise:
Takingmoments about fulcrum 0, we get
F . a = RN· b - Il' RN c .., (ii)
F x 0.80 = 1337 x 0.15 - 0.359 x 1337 x 0.025
" F = 235.7 N ADS. ~
''icrio" 0 The short shoe block brake shown In Fig. b' orbed What ac/ua/jllg
It .j . is 10 be a >S
tree it'e ' ~frICtional power of 14. 924 k W at 650 r.p.""
91lired , C ". '6 ,
. an the brake be self-loe"zn" .
......._
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~ ----------------
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!IQ___-----------------------------------D-e-s~ig.~n-O~if~TJ~ra~nsrn·
ISS1.
_!1I.10
01H ..
~
a
a = 1.0 m
r = 0.375m
d = 0.375 m
c = 0.05 m
Fig. 11.6.
3
GivenData: I-l = 0.3; P = 14.924 kW = 14.924 x 10 W ; N = 650 r.p.m;
r = 0.375 rn ; a = ].0 m ; c = 0.05 m; d = 0.375 m.
Toflnd: (i) Actuating force (F) required, and
(ii) Checking the brake for self-locking.
@) Solution: (i) Required actuating force:
Let RN = Normal force pressing the block against the wheel,
Jl RN = Frictional force, and
28 = Angle of contact of the block with the wheel.
Taking moments about fulcrum 0, we have
RN . d = F· a + I-l RN . c
or RN (d - Jl c) = F· a
F'a
or RN = d-I-lc
F'a ." (iJ
Braking torque is given by, TB = I-l RN r = Jl'
d-I-lc
·r
.. TB = 219.25 N-m
ofspring
LeI force. S ~ Spring force required t et the blocks on the drum,
r ::: Radiu f drum,
RNI and fl RNI ~ N rmal reaction and the braking f ret on the left hand side shoe, and
RNl and fl RN I = N ron a I react i I' and the brak ing f ret on the right hand side shoe.
lhe drum i r tatin ' in the I kwise dire tion. Taking moments about the fulcrum 0"
." (i)
= RNI'
·b
i)
l
blL silO( brfd.
[)o
Fig. II.· M ", (ii)
I runl \"e get
"I'
ta ill 1'1
I ment
::::: R 2' a
The values 0 f RN1 an d R N2 can be obtained from equations (I) and (II). This l'Ilay be
substituted in equation (11.6) to get T B'
IA = 2rb sin e I
'" (11.7)
Bearing pressure on the lining material is given by
Ip = ~ I ". (11.8)
where RN = Maximum normal ioad on any shoe.
ET = Change in K.E. of load + Change in P .E. of load -4- Change in K.E. of all other
rotating parts
I 2 2 )
= 2" m (VI - v2) + w x X + 2" I w2
'" (11.9)
2. Brakillg torque in terms of total energy absorbed by a brake is given by
60 x E-r
TB =
7txNlxt ". (11.10)
where NI = Initial speed of brake drum, and
= Time of application of brake.
F2 F2
- [0.!~9 -13.5 ] Fl RN2 == Jl' == 0.409 ]
45 x 3500 = 35.4 F2
or F2 = 4449.2 N
Consider
right hand side brake shoe :
Takingmoments about fulcrum ° 1, we get
S (20 + 25) - RNI x 20 + Fl (17.5 -4)
[ ..• F 1 = II' R .
r Nl >
45 S = FJ [ 0.!~9 + 13.5]
45 x 3500 - 62.39 F)
Or
FI - 2524.1 N
Braking torque T B is given by, T B = (F) + F2) r
_ (2524.1 + 4449.2) x 0.175
_ 1220.32 N-m Ans. ~
(ii) JJlit/1
I.e h of the brake shoe (b) : . mm
t 'b _ Width of the brake shoes m
Wekn .
Ow that projected bearing area for one shoe,
Since the maximum normal force is on the left hand side of the shoe, therefore We h
. . i: aVe to
design the shoe for RN2 i.e., the maximum normal rorce.
10878.24
0.3 = 303.116
160 + 65 ]
. 320 S = F, [ 0.344
F, = 0.604 S
'" [.. -
• RNI - "itF ]
I
II,silfer
left hand side brake shoe:
CD. moments about fulcrum 02' we get
rakJ08
S (160 + 160) = (RN2 x 160) - F2 (125 - 60)
160 ]
320 S = F2 [ 0.344 - 65
or
F2 = 0.8 S
Brakingtorque is given by
TB = (F) + F2) r
Table 11.1. Limiting values of pv (from data book, page no. 7.130)
-
Operating conditions pv (mPa) (mls)
- -
Continuous service, poor heat dissipation 1.05
Intermittent service, poor heat dissipation 2.1
Continuous service, good heat dissipation as in oil bath 3.0
Neglecting
the kinetic energy of the drum,
1 (2 _ v2 ) + W . x
Er = 2 m VI 2 .. ' [Given]
== 1.15 m/s
Initial velocity of loa d , VI
T8 := 1t xNJ xl
60 x 149.283 x 103
Braking torque, T 8 = n x 17.57 x 5.652
= 28.71 kN-m Ans.~
.f!!ij] The above problem 'can also be solved by selecting the initial brake drum diamettr and
~ldthfrom the Table 11.3, and checking it for permissible induced bearing pressure. If the dtsign is
00/ safe, then increase brake drum diameter and width, and again check it for permissible inductd
~g pressure. Continue the same procedure till the safe design has been reached.
But in th . .' d be . g pressure ;s cbostn and tbtn
1..... e above problem, first the safe permissible. mduce arm
lIf~edrum d' .
lameter and wIdth are calculated. '
'll. eiNNO' . . T:
BRAKE
In band b d ' belt is
JiaJria]f rake system, a flexible ban or .
applied
Y Wra d
ppe around a brake drum..
A force IS T
I
~
···(11.11)
B B
"-
lever Lever
r-- Table 11.3. Dimensions of brake drum (from dala book,page no. 7.98)
~er of the motor, kW Brake drum diameter, mm Brake drum width, mm
7.36 50
160
11.04 65
200
14.72 80
250
25.76 100
320
44.16 400 125
73.6 160
500
110.4 200
630
184 250
800
6. Check for bearing pressure: Calculate the maximum bearing pressure betweenband
and drum using the relation
Holding 1.5
C.I. drum
0.6
on metal drum
0.8
---
0.6
0.4
Lowering 1.0 0.3 0.4
r--------.,. h 500 "",. /o1lg·
I Example 11. 7 IA simple band brake is operated by a lever of lengt if the
5/8 0
The brake drum has a diameter of 500 mm and the brake band embraces h ot~e'
hile t e .
circumference. One end of the band is attached to the fulcrum of the lever w. d to the e"J
is attached to a pin on the lever 100 mm from the fulcrum. If the effort app/,e .tnJ1lt ~J
of the lever is 2000 N and the coefficien: of friction is 0.25, then design the SI
brake.
r
~I
6fV'''P
~'(l,'
~(I:
a ~ 50;
00 mm
(l:::: 5
:::: 0.1 m ; F = 2000
= 0.5 m; d= 500 rnm or
N; Il == 0.25.
r ::;250 m m == 0.25 m .
'
00 ml11
b~ 1 • the simple band brake.
i: peslgn . . . .
fof'" Considermg anticlockwise rotatIon of drum th
filIP/ion: . Fig 1 I II(b). ' e arrangement of simple
~Jv • hown JO I. .
brake IS S 5
~ Angle of contact, e = 8 x 21t = 3.927 rad
T)
Tension ratio is given by, T2 = ella = eO.25 x 3.927 == 2.669
T, = 2.669 T2
or ... (i)
. moments about the fulcrum 0, we get
rakJIlg
F· a = T2· b
2000 x 0.5 = T2 x 0.1
or T2 = 10000 N
From equation (i), TJ = 2.669 T2 = 2.669 x 10000 = 26690 N
1. Brakingtorque:
Braking torque, TB = (TJ - T2) r
(J = 26690 ~ [at]
twx 2.5
180
== 4.713 rad
TI
Tension ratio is given by, = ella = eO.25 x 4.713 = 3.248
T2
.. , (i)
or TI - 3.248 T2
We know that the braking torque (Ts),
Ts =
225 = (T) - T2) x 0.225
.. , (ii)
or = 1000 N
11.25
~ ...
. uations (I) and (11), we get
solving eq T
2 = 444.84 Nand TI = 1444.84 N
. oments about fulcrum 0, we get
faking m
. F· a = T2 x b
= 288.97 N Ans. ~
[_Example 11.9 IA simple band brake
shoHinin Fig.lJ.13, is applied to a shaft
carryinga flywheel of mass 250 kg and of
radiusof gyration 300 mm. The shaft speed is
200 r.p.m: The drum diameter is 200 mm and T, 1= 280 mm
the coefficient of friction is 0.25. The a = r = 100 mm
dimensions'a' and 'I' are 100 mm and 280
mm respectively and angle p = 135 ~
Determine:
(i) The brake torque when a force of
J 20 N is applied at the lever end, Fig. 11.13.
(ii) The number of turns of the flywheel before it comes to rest, and
336 = 2.67 x T2
or T2 = 125.84 N
Braking torque is given by, T8 = (T) - T2) r
= (336 - 125.84) x 0.10 = 21.01 N-m Ans. "
(ii) Number of turns of flywheel before it comes to rest (n):
We know that kinetic energy of flywheel,
1 2 [ 21t x 200 ] 2
= 2" x 250 x (0.30) 60 . = 4934.80 N-m
This kinetic energy is used to overcome the work done due to the braking torque (TB)'
K.E of flywheel = TB x (I) = T 8 x 21t n [n = numberof turns]
4934.8 = 21.0 I x 21t n
or n = 37.38 revolutions Ans. ~
= 0.1868 minutes
= 11.208 sAns. "
11.27
A B
~----4-------~
b F
T, T1
~
' .
·······(:r········ .~ .
8
8
Thus T2 . C > T 1 • b
TI
Or
> -b
C
T2 !
I
I
I
If T) = be , then F = O.
T2
In this case, e must be Jess than b for proper braking.
I I
Example J1.J 0' Design a differential band brake for a crane lifting a load
•
I(
oJ 50
through a rope wound round a barrel of 550 mm diameter, as shown in Fig.ll.l
S
brake drum to be keyed to the same shaft is to be 650 mm in diameter and the an I. . 1
of the brake band over the dr~m is 240'! Operating arms of the brake are 45 ",,,,K e of l
. • • •• and 2
mm, as shown In Flg.J1.J6. Operating lever IS 1.5 m long. Take u= 0.25. .
T
550mm ----
~
-
I 650 mm
777 "_""'~~--J j_ 777
j_
~
~~~------------------------------~---~~~
ltion ofT} and T]:
Ca1ell a
J T,
Tension ratio, T2 = el!9 = eO.25 x 4.188
== 2.849 "
T, = 2.849 T2
or ... (i)
Braking torque, TB = (T I - T2) x r
We 1,"0"' that,
r.J'
= 42307.69
or ... (ii)
solvingequations (i) and (ii), we get
Tl = 65189 Nand 1'2 = 22881.39 N
65189
crt = w x 3.25 s [crt]
65189
w x 3.25
s 50 N/mm2 [.: [ crt] = 50 N/mm2 is assumed]
65189
= -__;_;_--~
Pmax = = 0.495 N/mm2
w -r 650)
405 x ( T
From Table 11.1, for steel band on steel drum, [p] == 1.5 N/mm2
Since Pmax < (p ), therefore the design is safe and satisfactory.
T2
F = 220N
0
a b
60mm 120mm
c
240mm
Fig. 11.17.
or ." (i)
11.31
kes
B,(J ation of the d rum IS
. C lockwi . T and T are reversed. In that case
oc wise, then the tension
~ If the ro t . 1 2
~ . ay be obtained by taking moments about O.
. ibrturo ro _
tile eqllJI F . c - T I . a - T2 • b - 0
500mm p
Fig. 11.18.
r = 250 mrn = 0.25 m ;
Given Data: d = 500 rnm or
TB = 1 kN-m = 1 x 103 N-m; J.1 = 0.3 ; a = 08 = 500 mm = 0.5 m ;
b = OA = 80 mm = 80 x 10-3 m ; c = 00 = 100 mm = 0.1 m ;
Or T) - T2 = 4000
o A
~----:.r------..J
b
B
Fi1!. J.1_ 1s. (a'/.I b > C«rF uswar dS, drum antictockwise
~ -------- ~1~1.3~3
wn
AS sho
t{1 Fig.11.18(a), the ends of band are att h d
T
.
ac e to pomts 0 and A.
Tension ratio, TI2 = ello = eX.0.25 4 188' = 2:849
a
o
_.-J.-
I
Fig. /l.J8(b)
Both the tensions are negative, so the band will be loosened on the drum. In order to apply
brakes, the direction of force F should be reversed.
.. Braking torque, T8 = (TI - T2) r = (4950.4 - 1737.6) x 0.375
= 1204.8N-m Ans."
Aa ·1
b
F T1
(c) b > c, F downwards, drum anticlockwise (d) b > c, F downwards, drum clockwise
Fig.II.JB.
(b) Brake drum rotating in clockwise direction:
This case is shown in Fig.I1.18( d).
. TI
T·ension ratio, T = 2.849 . .. [same as equation (i)l
2
Taking moments about the fulcrum 0, we get
F . a + Tl . b - T2· C
11.35
... (v)
or . geq uations (i) and (v), we get
~v~ T
1 = -17376N and T2=-6099N
band will be loosened as T I and T 2 are negative. Thus force F must act in upward
"" apply brakes.
, tlOo to
dire' Braking torque, TB = (17376 - 6099) x 0.375 =- 4228.88 N-m Ans. ~
shD with the rim of the brake drum. When the brake is applied, the blocks are pressed
con~ac: the drum. The advantage of using wooden blocks is that they provide higher
agaJO~ientof friction and they can be easi ly and economically replaced after being worn out.
coeffiLet T = Tension in the band on tight side,
n
To = Tension in the band on slack side,
T 1 = Tension in band between the first and second block,
T2 = Tension in band between second and third block,
T3 = Tension in band between third and fourth blocks and so on,
n = Number of wooden blocks,
Jl = Coefficient of friction between the block and the drum,
28 = Angle subtended by each block at the drum centre, and
RN = Normal reaction on the block,
(a)
1 + Jl tan e =
I-Jltane
or
T. = 1 + Jl tan e
To I - J..l tan e
Similarly, it can be proved for each of the blocks that
l+J..Ltane
Therefore, = ---
1 - J.l tan e
So the ratio of tensions for all 'n' blocks is given by
r, T. T2
To = T0 x:r I xT2
T3
X .••••• xT
r, = [1 + J..l tan
1 - J.l tan
e] n
e
.. , (11.17)
n-I
. [the belt]
T B = (T I - T 2) ( d ~ 21) [Considering the thickness 0
-
J
T n = [ 1 + IJ. tan 6 n - [ 1 + QJ6 tan 9° ] 10 ,
To 1 - ,.H
. an 6· - 1_ 0.36 tan 90 = (1.209)10
Tn
To = 3.13 Ans. ~
[Example 11.15 I In the band anti block brake shown in Fig.l1.20, the band is lined
witlt 12 blocks each of which subtends an angle of 15° at the centre of the rotating drum.
Tirethickness of the block is 75 mm and the diameter of the drum is 850 mm: If, when the
brake is ill action, the greatest and least tensions in the brake trap are T] and T')7 show that
I . tl. coefficient of friction for the blocks. Find the least force required at 'C'
W tere f.1IS te W 240 m: The coefficient of friction between the band
for the blocks to absorb 225 k at r.p. F
Given Data:
n = 12 ,.
26 = 15° or 6 - 7.5° ; T1
t = 75 rnrn
= 75xlo-3m; 12
d = 850 mrn
11
= 0.85 m ;
p = 225 kW
= 225 x 103 W ;
Fig. 11.20.
N = 240 r.p.m ;
Il = 0.4 ;
....:.]~I~.3~8~ --------------_D_e_sl=g_n_o~if_Tl_ra_n_s_m~~~s~funs
- ~
OA = c = 150mm = 0.15 m;
OB = b = 30 mm = 30x lo-3m;
OC = a = 500 mm = 0.5 m
© Solution: (i) Ratio between the greatest and least tensions:
Since OA > OB, so force at C must act downwards. Also the drum rotates clockwis
t h e b and attached to A will experience slack side
. havi . T2 (I east tension) ande,thS
avmg tension
.
band attached to B will be tight side having tension T, (greatest·tensJOn).
T,
T2
= [1 + J..l tan 8
] - J..l tan e
J n
= 3.5449
or T, = 3.5449 T2 ... (i)
7tDN
Power absorbed, P = (T, - T2) x
60
7t x 1 x 240
225 x 103 = (T, - T2) x
60
T,-T2 .. , (ii)
or = 17905
F'a = T2·b-T1.c
1
F x 0.5 = 7035.7 x 0.15 -24940.7 x 0.03
F = 614.3 N Ans. ~
Ie 11.16 A band. and b~oCk brake having 12 blocks, each of which subtends
Downloaded From : www.EasyEngineering.net
11.39
ngle OJ.r J 6 at the centre, IS applied to a rotating drum of diameter 600 mm. The blocks
an a m thick. The drum and the flywheel mounted on the same shaft have a mass of
are 75 mand have a com me
bi d
ra
dl
IUS 0
if gyrattOn
. of 600 mm. The two ends of the band are
00
18 k;d to pins on the opposite sides of the brake fulcrum at distances of 40 mm and 150
attach the fulcrum. If a force of 250 N is applied at a distance of 900 mm from the
",m [rom
fulcr"m,' fi
nd'
.
(i) The maximum braking torque,
(ii) Tire angular retardation of the drum, and
":' The time taken by the system to be stationary from the rated speed of 300 r.p.m.
(Ill,
-tticient of'J friction
Take coe)} I .
between the blocks and tire drum as 0.3.
I = 75 mm = 0.075 m;
m = 1800 kg ;
k = 600 mill = 0.6 In'
Drum
= D = 4 mIn
= 4 III ;
11.40
~---- Design of TrnnsmissirJn SYSletns .i;
". 0)
or
Taking moments about 0, we get
F·a+T,·c = T2·b
250 x 0.9 + T, x 0.04 = T 2 x 0.15
or 225 + 0.04 T, = 0.15 T 2 '" (ii)
. d (..) we get
Solving equations (I) an II, 36 Nand T, = 15511 N
T2 = 56
. torque T B is given by
Maximum braking
06+2 x 0.075 ]
= (15511 - 5636) [ 2
(iii) Time taken by the system to come to rest from tile speed of 300 r.p.m.:
11.9.1. Introduction
As the name implies this type of brake is provided internally on the brake drum.
days band brakes were used in automobiles, which were exposed to din and water. The" ally
Ino~:
diIssipalion
'. . was a Iso poor. These days, band brakes have been rep Iace d by Intern
capacity 1 in
'. shoe brakes havmg atleast one self-energizing shoe per wheel. Th'IS resu [5
expandmg
tremendous friction, giving great braking power without excessive use of pedal pressure.
~ Jt'( -------
v- orking principle
11.9.2. 'II ) 5ho'\l5 an internal shoe automobile brake. It consists of two semi-circular
I 22(a . d itl ~.. I .
fig. I . d 5, ",11ich are line WIt 1 a I nctiona material such a fcrrodo. When brakes are
.,eS51 all . -tores which pushes the shoes outx ards to press the brake lining against the rim
~ arn ,0 a
,pplied. C A soon as the brakes are off, the shoes are pushed inside by the spring.
, drum. s
• ~lf1he oted that for the anticlockwise direction, the left side shoe i known as primary
I• a)' be n .
It!l1. , e while the right hand shoe ISknown as trailing or secondary shoe.
dmg s,1O
Dr len Cam operating level
._.y,)
J-.-.
Fulcrum
Fig. 11.22.
11.9.3.
Determination of Pressure and Brake Torque
Considerthe forces on the brake when the drum rotates in anticlockwise direction, as
snown in Fig.II.22(b).
leI
PI = Maximum intensity of normal pressure,
PN = Normal pressure,
r = Internal radius of the drum,
b = Width of brake lining,
TB ::::
Braking torque,
FI =:
Force exerted by the cam 011 the leading or primary shoe,
F2 =:
Force exerted by the cam on the trailing or secondary shoe,
RN ::::
Normal force,
Design of Transmission S
11.42
~
F = ~.}'rictional
force,
~J.l = Coefficient of friction between shoe and drum,
MN = Moment of normal force, and
MF = Moment of frictional force.
Consider a small. . element AB of brake lining subtending an angle 09 at the centr e of tL_
°
drum. Join 01to ..It is assumed that the pressure distribution on the shoe is nearly ~~. "Ie
However, the. shoe wears out more at the free end. The rate of wear of the shoe linin v ."
directly as the perpendicular distance from 01 to B i.e., ole. ganes
From the geometry of the Fig.11.22(b)~ -
~.
I
1
and Normal
.
pressure at B, .
.
.- ',PN cc sin 9 or PN = PI sin 9
:. Normal force acting on the element, . ,:
oRN . = Normal pressure x Area'of the dement
= J.l PI sinB . b . r 09 . r
= J.l PI sin 9 . b r2 09
.c->:
V 92
11.43
MN -- P , . b· r- 00, J sin29 . d9
92 1
J 2 (I - cos 29) . de
::= p, . b . r . 00,
9, [.: sin2 9 = t (I - cos 29)]
::=
21 p, . b . r . 00, [sin
92 - 2292 - 8, + sin 229, ]
J9
00, 2
= J.l PI . b . r [ - r cos 9 + -4- cos 28 9
1
= Jl.PI· b . r [ r (cos 61 - cos 62) + O~I (cos 262 - cos 261) J ... (11.19)
ForIe di .
a mg shoe, take moments about 0"
F MN-MF
1 x I ::: MN - MF or F1 = I ... (11.20)
and for tr T
at 109 shoe, take moments about 02'
MN+MF
F2 x I = MN + MF or F2 = I ... (11.21)
COlli/it'
IOn for Self-Locking:
IfM :::.M ki
F F, then the brake becomes self-Ioc mg.
[Examele 11.17 I Fig. 11.23 shows the arrangement 0/ two brake shoes ..,hich act
~
the internal surface of a cylindrical brake drum. The braking forces FI and F2 are a ~
• rpPlttd
as shown and each shoe pivots on its fulcrum 01 and 02" The width of the brake linin .
35 mm and the intensity of pressure at any point A is -I x lOS sin (J Nlml, ..,here ~ ~
measured as shown from either pivot. TIle coefficient of friction is 0.40. Determine thI
braking torque and the magnitude of the forces FI and F2" - e
I 30'
.~
:1
ir
Fig. 11.23.
Given Data: b = 35 mm = 0.035 m; PN = 4 x ] 05 sin e N/m2; Il = 0.4.
To find: I. Braking torque (TB)' and
2. Magnitude of the forces FI and F2.
I = 200 mm = 0.2 m
Distance of force F2 from fulcrum 02'
I = 200 mm = 0.2 m
We know that the braking torque T B '
Ts = IlPI ·h·r2(cos81-cos82)
11.45
and
92 = 125° = 125° x I~O = 2.]8 rad
e geometry of Fig.ll.23, we get
Fromth
O,B 100
00 I
= cos 25° = cos 250 = 11034
. mm
== ~ x 4 x lOs x 0.035 x 0.] 5 x 0.11034 [ (2.18 - 0.436) + ~ (sin 50° - sin 250°) ]
= 300.86 N-m
Momentof friction force Mr about 01 is given by
M, " ~p,. b . r [ r (cos 6, - cos 62) + O~, (cos 262 - cos 26,) ]
0.11034 ]
:: 0.4 x 4 x 105 x 0.035 x 0.15 [ 0.15 (cos 25°--<:os125°) + 4 (cos 250°--<;os 50°)
.
:: 163.65 N-m
For leading shoe : Taking moments about the fulcrum 01' we get
FI x I = MN-Mr
F1xO.200 = 300.86 + 163.65
Or
F, = 686.05 N Ans. ~
For trailing shoe: Taking moments about the fulcrum ° 2, we get
F2 I = MN+Mr
F2 x 0.200 = 300.86 + ) 63.65
Or
F2 = 2322.55 N Ans. ~
J
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1~1~.4~6~ lSSIOn S .
------------------------D_e_SI=·gn~Of~T~~an~sm·.
""
...:
. . ~
I Example 11.18 I An automotive type Internal expanding double-shoe sir
Fig. 11.11 is 300 mm in diameter and is actuated by a mechanism
'~~h that exerts thesa~~ ill o~"
F on each shoe. The shoes are identical and have a fiace WI", of 32 mm; The .. JO,Cf
moulded asbestos having a coefficient of friction of 0.31 and a pressure lilllitat:lIn"" ;,•
kPa ~n~J~
• 27'
~
126'
Fig. /1.24.
force F IS found on the basis that the maximum pressure will occur on this shoe. For the right "
hand shoe, l
.
file to
1 . b . r : 001
r (92 - 91) +
I
1
2 (sin 2 91 - sin 2 9 ) ]
IS given by
... 'PI _ 2
,
.~I~:::2
< i' 1000 x 103 x 32 x 10- x
3 (03)
2
[
x 0.12265 (2.199-0) + ~ (sin 0° - s'in (2x J 260»]
[ (0.3)
T [cos 0° - cos 126° ] + 0 . 12265
4 [ cos (2 x 126°) - cos 0°] J"
= 365.83 N-m
III ~e torque contributed by the left hand shoe cannot be obtained until we know its
aXlmum
and M operatlllg . .
pressure. For identical shoes, It can be seen from th e ~xpres~lor.s
. ~f M N
I
I
F
press .
that both are proportional to P For left hand shoe, the maximum mtensity of
ure IS taken as p ,
I.
I.
11.48
Ilpl'
10 "PI'
....~ 8. -. .. 0.112 .
lin == 445.04 kPa
r 44 . <1 ' I
11
w t rque applied by left hand shoe i gi en by
)
To' = J..l' PI' . b . r (cos 91 - C '
,
__j
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jl..:I::.5~O~ -- D_es__,;;gn:::::....._.....::of:..._T~_a:.:...:n=sm~issio
- ~
1
(ii) .
Kinetic energy of rotation: KE = -2 I (1)2
Hg = f.l·p·A,v [ .: p= ~ ] .. , (11.23)
RN = Normal reaction,
A = Projected area, and
" = Peripheral velocity of drum.
11.11.3. Heat Dissipated in Brakes
. " . . . iveo bY
The heat generated due to friction should be dissipated. The rate of dissipatIOn IS g )
_ . " (11,24
a, -
C· A ·.1T = C x A (Is -10) .
Exal1l Ie 11.19 Two externally closing shoes 120 mm wide and subtending angles of
I at tne drum centre are applied on drum whose diameter is 450 mm and width
90° eac,' • .
Determine tile heat dissipated by tile brake. Tile radiation heat transfer coefficient
}50 m""
~given by
Co;:Co(1 + a LJt), where Co = 2.9 Wlm2 K and a= 0.076 per K
TIre temperature difference between tile drum surface and surrounding is 150 K.
' Data' . b sh oe
Gwen = 120 mm ; D = 450 mm; bdrum = 150mm ;
C=Co(l +allt); Co=2.9W/m2K; a=0.076perK; ~I = 150K.
= 1!. D x bshoe 7t
2 3
0 15)_ - (0.45) (0.12)
45 - 2.25 x 10- )( . 2
A = 7t (0.45) (0.15) + 1t (0.
2 W Ans. "'CJ
=0.338 m2 x 150 == 1824.4
l'hen, heat dissipated, Hd ::: 35.96 x 0.338
INote I Since the concepts of energy considerations and temperature rise are same for both
clutches and brakes, readers can see Chapter 10, Section 10.14 for more details.
I Example 11.21 I Aflywheel of mass 950 kg and radius of gyration 300 mm is rotating
at 400 r.p.rn. It is brought to rest by means of a brake. The mass of the brake drum
assembly is 4 kg. The specific heat of cast iron brake is 460 J/kg 'C. Assuming tha: the
total heat generated is absorbed by the brake drum only, calculate the temperature rise.
Given Data: mr = 950 kg; k, = 300 111m = 0.3 m ; N 1 = 400 r.p.m. ;
11.53
I
= - I «(1)2 2
Total energy, Er 2 I - (1)2) = 2I m, k; «(J)~ - (I)~ )
1
= 2 x 950 x (0.3)2 (41.882 - 0) = 74980.69 J
E,. 74980.69
=-_.:....;;,..:..::..:.
tet11perature nse, ~t - 460 x 4 = 40.7SoC Ans. ~
Cxm
rllen t Ile
j
I
,
REVIEW AND SUMMARY
,
!
Brake is a mechanical device by means of which motion of a body is retarded for
I
1 I slowing down or to brmg It to rest, by applying artificial frictional resistance.
Thernain types of mecltanical brakes are block or shoe brakes, band brakes, band and
1
I
i
I blockbrakes, internal expandmg shoe brakes, and external contracting brakes.
Threetypes of brake linings used are organic, semi-metallic and metallic linings.
I Braking torque in Block or shoe brake is given by
I / ,I TB /:!..F·l·r
= ~ [when the rotation of drum is clockrviseJ
,a/ a - f.1 c
/:!..F·l·r [when the rotation of drum is anliclockwiseJ
(b) TB = a + uc
where T8 - Braking torque,
r = Radius of drum,
F = Force applie.} at lever end,
f1 .- Coefficient offriction, and
a, c & I = Dimensions of lever. 0
t •• / I) d hen 2B> 40 ;s given by
! I Equivalent coefficient offTictlOn {iiI use w
4/:!. sin 0
f.1' = 20 + sin 2()
where 2() = Angle of contact
l uble sltoe brake is given by
I Braking torque in Double block or c 0
T8 = f.1 r (RN/ + RNJ)
where r = Radius of drum, . d . ht hand side shoes respectively.
RNJ & RN2 = Normal reaction on the left an rig
.(
In Band brake system,
Tj eJ.lB,and
Tension ratio, r; =
= (T - TJ) r .h d slack sides respectively,
Braking torque, TB J. . the band on Ilg I an
= Tenszon in
Where TJ and T2
::::Angle 0/ lap. and
e di Of the drum.
r ::::Ra
--------~~~-- IUS 'J
r~~------------------------------------------------------~
../ Force applied on the lever in Simple band brake is given by
(i) F = T,!!.a [For clockwise rotation of the drum}
(iO F = T,!!.
·a
[For anticlockwise rotation of the drum}
For notations a, b, T, and T2, refer Fig. II. II.
Tension ratio in Band and block brake is given by
Tn = [ I + J.l tan ()] n
To I - f..J tan ()
where Tn = Tension in the band on tight side (maximum tension),
To = Tension in the band on slack side (minimum tension),
2 () - Angle sub tended by each block at the drum centre, and
n = Number of wooden blocks.
Internal expanding shoe brake (Refer Fig. 11.22) :
Moment of normal force, MN ~ ~ .Pi . b . r . DO, [ (0, - 0,) + ~ (sin 20,- sin 20J) 1
Moment of frictional force, M F = f..J . Pt . b . r x
(i) Total energy absorbed by brake: Er = '12 mv? + 'I2 loJ + W'x
I 1.55
REVIEW QUESTIONS
.do ntiate a brake and a clutch.
DllIere
I· Differentiate brakes and dynamometers.
2· r nerate the qualities of the friction material used in brakes
cnOl .
3· What are the various types of brakes?
4.
What is a self actuating or self energizing brake? When a brake becomes a self-
5.
locking?
What is the difference in simple and differential band brake? Which would be
I 6.
preferred?
Explain the arrangement done in band and block brake system. In what way it is superior
7.
to band brake?
8. Show that, in a band and block brake, the ratio of maximum and minimum tensions in
the brake strap is
I +J.Ltan9]n
= [ 1-J.Ltan9
9. Describe with the help of a neat sketch the principles of operation of an internal
expanding shoe. Also deduce the expression for the braking torque.
10. Describe with the help of a neat sketch the principles of operation of an external
contracting sh e.
II. Write short note on (i) Heat generated and heat dissipated in brakes, and
(ii) Temperature rise.
11.57
0" di/ferentlfli hand brake:
1 ~~t",s. h the rope supports a load Wand is W d
p' "llnc, k oun round a b I
l In II . I band bra e acts on a drum 800 d' arre 450 mm diameter. A
1 cr. rentla mm lameter wh' h .
'dille the barrel. The two ends of the bands rc IS keyed to the same
ft as are attached to .
1 Shll I rum of the brake lever and at distances f? 5 prns on opposite sides of
the fu C Ie of lap of the brake band is 2500 and tOI... mrn ~nd 100 mm from the fulcrum.
l e ang . ie coefficient of fricti .
f1 'mum load W which can be supported b h ncnon IS 0.25. What is
" maxI . y t e brake wh f .
IJle . d to the lever at a distance of 3000 rnm fi h en a orce of 750 N IS
apphe rom t e fulcrum?
. [Ails: 309 kN when drum rotates CW]
'a'erential band brake acting on the :xth of the c· c
A dIll' .. Ircumlerence of a drum of 450 mm
~. dlam . , is to provide a braking torque of 225 N-m . 0ne en d 0 f t h e band IS
. eter . attached to a
pm. 100 mrn from the fulcrum '. of the lever and the other end to ano th er pin. 25 mm firom
the fulcrum on .'the other Side of It where the operating force . IS i a Iso actmg.
. If t h e
operatingforce IS applied at 500 mm from the fulcrum and the coefficient of friction is
0.25, find the two values of the operating force corresponding to two directions of
I rotationof the drum. [Ails: 16.6 N for CW; 266.6 N for CCW]
, ~ A differential band brake, as shown in Fig.l1.14, has an angle of contact of 225°. The
,I. bandhas a compressed woven lining and bears against a cast iron drum of 350 mm
I diameter. The brake is to sustain a torque of 350 N-m and the coefficient of friction
betweenthe band and the drum is 0.3. The dimensions 'a', 'b' and 'c' are 500 mm, 35
mm and 150 mm respectively. Find: (1) The necessary force (P) for the clockwise and
anticlockwise rotation of the drum; and (2) The value of 'OA' for the brake to be self-
locking,when the drum rotates clockwise.
[Ans: (1) 64 N for CW; 804 N for CCW; (2) 1]4 mm]
..
j
I Man.' idler pulley are u ed when it is desired to transmit motion from one shaft to
e eral parallel haft.
S. Wire" do., ou U~'C fast and loose pulley drive ? hi e shaft is to be started or
II dri c i 1I ed when the dri en or mac in
fa I and I puucy .n . . ('. 't11the driving shaft.
.1 . d \ .,It1
ppcd x h nevcr d sire Ut uucrtennu WI
. I I [or bellllri,'e ?
6. Wlwl are II,e mat riots WiC( J' B I ta and 5. Nylon.
I. Lather. _. I-abri . and tt n, Rubber, 4. aa ,
bell drive. . .r d .
Define velo il)' rauo oJ . d the follower or riven.
(I
. , f the driver an
It i th rati et« ecn vel It~· I '1 ratio?
. rJjrreclS II,e ve OCI.v
8, R helher lire 11,; kness of a belt OJ'
y
ut It I' n i I .
1 _ Belt thickness.
= I ""here 1- • ,
( I 'Iy ralio of a bell drive .
li on .'e OCI
9. De'ine ,,'p 0 a h II. rVlral is lire effe I of SiP he belt and pulley.
J I n bcn",een t .
"f II d th r tsnv 111 u
::::SI,po
. fthebeltdnve.
!
'
".)
i ,
,
....:::
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t.ji The phenomenon of sudden contraction and expansion of belt when it passes fromslack
'.,_
i:
side to tight side is called as creep.
11. State the law of belting?
, ' hiethe pulley must Ii 'In
Law of belting states that the centre line of the belt as it approaches ~at~
I
a plane' perpendicular to the axis of that pulley or must re 111 t e pane of the pulley, .11 ~ ·O~
I" ((''Ctl ~
ot herwise the belt will run off the pulley, J~aJ"e•
12. What is meant by ply in aflat belt?
If'hat I
Belts are specified according to the number of layers, e.g., single-ply, double-ply or V·
'fOe \c
triple-ply. I
13. What are the factors on which the coefficient of friction bet wee" the belt and pulley (i) ,
depend? (ii)
1. Material of belt; 2. Material of pulley;
(iii)
3. Slip of belt; and 4. Speed of belt.
(iY)
14. In an open belt drive, which side of the belt is tight, whether upper side or lower side?
)1. A 10
J-Vhy?
./ In an open belt drive, the lower side of the belt is tight.
The
The
./' Because the driving pulley pulls the belt from lower side and delivers it to the upper wh:
side. So it is obvious that the lower side of the belt is tight.
fati
15. What is centrifugal effect on belts?
13. WJ
./' In operation, as the belt passes over the pulley the centrifugal effect due to its self
.f
weight tends to lift the belt from the pulley surface. This reduces the normal reaction
and hence the frictional resistance .
./' The centrifugal force produces an additional tension in the belt.
17. Centrifugal tension has no effect on the power transmitted. Justify the statement.
25.
When centrifugal tension is taken into account,
then total tension in the tight side, T'I = T I + Te
and total tension in the slack side, T 12 = T 2 + Te
We know that, power transmitted, P = (Ttl - T 12) v
= [(T I + Tc) - (T2 + Te)1 V
= (TI - T2) v
].OIl/hat
"j will be the effect on the Il'm't'
I Ing ratio 01' '
[Ans . th ]
' ree
riction
fi ? between the belt and rim ,/, 'J tenSIOnsof a belt if th .I'r. .
oJ pulley is doubt d' e coeJJ,clentof
same. [Ans . e .whlle angle of lap remains
21. Whatare the losses in belt drives ? . The ratro of tension will be squared]
called as wipping.
v" Wipping can be avoided . Iidl er s pulleys
by usrng 0 •
of a pulley is crowned?.
25. Wlun is crowning of pulley? (or) wily Ilteface d This slight convexity is known
. htl towards the e ges.
v" The pulley rims are tapered slig y .
while in motion.
as crowning. on a pulley nrn
o
.
0
I belt in centre
v" The crowning tends to keep t re . It drives,
26 L'
. ISIII,e different types of pu IIe"'S
J
used In be
(0)I Solid pulleys, . 0) S lit pulleys.
and (11 p
CHAPTER - 2: V-BEL T5
1. What type of belt would you prefer if the centre distance between the pulleys is small?
V-belt.
2. State reasons for V-belt drive being preferred to flat belt drive ?
V-belt drive is preferred to flat belt drive due to the following advantages:
./ Power transmitted is more due to wedging action in the grooved pulley .
./' Higher velocity ratio (upto 10) can be obtained .
./' V-belt drive is more compact, quiet and shock absorbing .
./' The drive positive because the slip is negligible.
3. Why slip is less in the case of V-helts when compared with flat belts?
The slip is less due to the wedging action in the grooved pulley.
4. The included angle for V-belt groove is usually between and
_____ degrees. [Ans : 32° ; 38°]
5. The included angle for the V-belt is usually _
6. What are the different cross sections of a V-belt ?
A, B, C, D and E type V-belts.
7. How can you specify (or designate) V-belts ?
V-belts are designated by its type and nominal inside length.
8. How will you determine the number of belts required in the design of V-belt drives?
Total power transmitted
Nurn ber 0fV - beIts = .
Power transmitted per belt
9. Wluu is a 'Vsflat' drives?
In V-belt dr~ve, if the large grooved pulley is replaced by a flat faced pulley (and smaller
pulley remams V-grooved), then the drive is known as V -flat drive.
10. What are the materials used for Vrgrooved pulleys ?
Cast iron, pressed steel, formed steel and die cast aluminium.
should be increased.
13.In chain drives, the sprocket has odd number of teeth and the chain has (!liennumber
0/ /inks.
Reason: Why?
To facilitate more uniform wear, i.e., the wear will be evenly distributed and
17. What are the possible waysby wh!IC h a chain drive mayfail ?
The four basic modes of chain failure are:
(i) Near; (ii) Fatigue; (iii) Impact; and (iv) Galling.
18. What is 'back sliding' in chain drives?
The wear of the chain results in the elongation of the chain. In other words, the pit h
length is increased. This makes the chain 'to ride out' on the sprocket teeth, resultinginc
faulty engagement. This is known as 'back sliding' of chain. a
19. Roller chains are designedtofail not in tension but by wear. Explain.
The chain links may not fail by tensile loading. But the rollers and pins mostly willfail
by wear. Therefore roller chains are designed based on wear.
20. Whatyou mean by galling of roller chains? .
Galling is a stick-slip phenomenon between the pin and the bushing. When the loadis
heavy and the speed is high, the high spots (i.e., joints) of the contacting surfacesare
welded together. This phenomenon of welding is called as galling of roller chains.
I . h - 2!_ I I
(ii) Diametra pitc , Pd - Pc == m == 6' == 0.166 mm Ans."
(iv) 20° stub involute system. full deplh. [Ans: 20° involute]
13, Thebest gear system to resist wear is . [Ans: 200 involute system]
14. Thecommonly used gear looth profile is d.
th 10 lake heavy loa'S.
15. system ahs a strong too [Ans: 200 stub involute system]
L ewrs. rorm
c. c.
ractor
. di .
imensionless quantity. Since the dimensions t, h an c
IS a
d pare
. d . I . alwayS
Increase proportionate y when the gear is enlarged, the form factor value IS
constant.
26. Why is a gear tooth subjeclet/lo dynt,mic loading?
In a gear tooth, dynamic loads are due to the following reasons:
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I I Elasticity 0 f parts,
I Deflection of teeth undcr load , v'
.t'
Irrcgul '.
Misalignment bctwec be . '
D
. antics in tooth profile
n ~nngs
B ki h '
write the uc Ing ams equation fi dna ynamic ubI ance of rota" .
1. or ynumic load a . 109 mas ses.
load lid aprasion for li"'iting W~ar
difficulty? . loads.
v' . aXIal thrust
. d . I (. herringbone)
to
SIngle helical gears are subJecte . double hellca i.e.,
, d by uSing
V . b elimmate
ThIs axial thrust loads can e
gears.
4. In helical gears, the right hand helixes on one gear will mesh heli"._ ..
[A -c ..011
the other gear. ns : Left hand]
5. What hands of helix are used in parallel helical gears ?
In parallel helical gears, opposite hands of helix are used. i.e., a right hand pinion meshes
with a left hand gear and vice versa.
6. Define axial pitch of a helical gear.
The distance between corresponding points on adjacent teeth measured in the plane
parallel to the shaft axis is known as axial pitch.
7. The helix angle for single helical gears ranges from [Ans : 15°to 250]
8. What helix angle is adopted for a double helical gear ?
45°
9. What is virtual (orformative) number of teeth in helical gears?
The number of teeth on the virtual spur gear in the normal plane is known as virtual
number of teeth (zeq ).
Z
Zeq - cos! J3
where Z - Actual number of teeth on a helical gear, and
J3 - Helix angle.
10. A pair of helical gears consists of a 20 teeth pinion meshing with a 70 teeth gear. The
normal module is 3 mm. Find the required value of the helix angle if the centre
distance is exactly 150 mm.
or 150 - ( cos3 J3 ) x eo +
2
70)
or Helix angle, J3 - 25.840 Ans. "
11. What are the components of resultant forces acting on a gear tooth of a helical gear?
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D_ej_'/..:::·g:_n_o...:.if_r;_rU_1I_1.\_,m--....:..:ission
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. vel ears over straight bevel gears?
3. What are the advantages of spiral be g .
. and quieter than straight bevel gears
. bevel gears are srnoo ther in action
Spiral .
Back cone distance i the len til f the ba k , )Ill:. 0," k IlC an rmaginar cone,
perpendicular t the pitch c nc at the end I rh I )111.
11. What are the forces acting 011 a bevel gear ?
I. Tangential force,
2. Axial force and
3. Radial force.
CHAPTER - 8: WOR
1. Under what situation, worm gears are used? M GEARS
Design of Transmiss'
Q&A.16 IOns
~
. h
hni arrelationship between the normal lead (L.I
7. For worm gear, give t e tee ntc IV" IOlJd (
. -14
and lead angle (r).
LN = L x cosy
z2 54
... Gear ra ti10, t = Z1
- = -2 = 27 Ans. ~
16. For transmitting large power, worm reductions gears are not generally prefemd.
Why?
In worm drive, meshing occurs with sliding action. Since sliding occurs, the amountof
heat generation and power loss are quite high.
17. Why is dynamic loading rarely considered in worm gear drives?
In worm gear drive, dynamic load is not so severe due to the sliding action betweenthe
worm and worm gear.
~j~~~------------ ~Q~&~A~.1~7
~
/9.
I"
-~
,.,0'''' gearing
heat +: is an important design requirement. Why?
the worm gear drives produce much h t U I
eeause. .. ea . ness proper heat removal IS
S 'd d the drive may eventually fall by seizure
proVI e , .
J.
Jl'haJ situations =: CHAPTER - 9: GEAR BOX
use of gear boxes ?
boxes are required wherever the variable spindle ds i
Gear spee s IS necessary.
Jl'rite any two requirements of a speed gear box.
1. I Gear box should provide the designed series of spindle speeds.
I Gear box should transmit the required amount of power to the spindle.
1J'/Iy G.P. series is selected for arranging the speeds in gear box?
].
I The speed loss is minimum, if G.P. is used.
I The number of gears to be employed is minimum, if G.P. is used.
I G.P. provides a more even range of spindle speeds at each step.
I The layout is comparatively very compact, if G.P. is used.
4. List any two methods used for changing speeds in gear boxes.
I. Sliding mesh gear box, and
2. Constant mesh gear box.
5. What are preferred numbers?
Preferred numbers are the conventionally rounded off values derived from geometric
series.There are five basic series, denoted as R 5, RIO, R 20, R 40 and R 80 series.
~ What is step ratio? (or) Define progression ratio.
Whenthe spindle speeds are arranged in geometric progression, then the ratio between
thetwo adjacent speeds is known as step ratio or progression ratio.
7, What is kinematic arrangement as applied to gear boxes?
The kinematic layout shows the arrangement of gears in a gear box. It also provides
infonnations like number of speeds available at each spindle and the number of stages
used.
.'
~&A.)9
~
.
.. _
ish between dry and wet operation of clutches.
pistl"g" .
~ hen a clutch operates m the absence of a lubricant, then that clutch is known as dry
I ~utch. In dry clutch the torque capacity is high but the heat dissipating capacity is
iow-
I When a clut~h ~perates '~et.' (i:e., with lubrication), then torque capacity is low but
the heat disslpatmg capacity IShigh.
Jrhy a service factor is used/or calculating tile design capacity of a clutch ?
7. _ In order to start a load from rest an~ accelerate it, a clutch should have torque capacity
b tantially greater than the nom mal torque requirement so that the load can be
SU s .h . I' S .
accelerated Wit ~ut. excessive Sip. 0 service factor is used to account for driver and
driven source variation and frequency of operation.
In cone clutches semi-cone angle should begreater than 12 ~ Why ?
8.
We know that the torque capacity is inversely proportional to sin a. The value of a
should be as small as possible. But when 'a' is less than the angle of static friction (4)>),
the clutch has a tendency to grab, resulting in self-engagement. The self-engagement is
not desirable because the clutch should engage or disengage only at the operator's will.
To avoid self-engagement and to facilitate disengagement,
a > Angle of static friction.
a > tarr ' {u)
Taking the coefficient of friction as 0.2, we get
a > tarr-' (0.2) or a> 11.3°
Therefore, the semi-cone angle should be greater than 12°.
9. What is the axial force required at the engagement and disengagement 0/ cone
clutch?
W = W n (1 + Jl cot a)
10.Whatis the difference between cone and centrifugal clutches?
Coneclutch works on the principle of friction alone. But centrifugal clutch uses principle
ofcentrifugal force in addition with it.
1I.Compare disc clutches and cone clutches .
./' In disc clutches , friction lined flat plates are used.
./' In cone clutches friction lined frustum of cone is used.
I '
2. ListOutthe elements of internal expanding rim clutc/Jes.
1. The mating friction surface,
2. The means of transmitting the torque, and
3. The actuating mechanism.
CHAPTER - 11 : BRAKES
1. Wtuu is thefunction of a brake?
Brake is a mechanical device by means of which motion of a body is retarded for I .
down or to bring.it to rest, by applying artificial frictional resistance. S OWmg