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Machine Design Databook PDF
Machine Design Databook PDF
Mechanical Design Data Book
1
Contents:-
1 Friction Clutches
2 Brakes
3 Belt Drives
• Geometrical Relationships………………………………………………………12
• Analysis of Belt Tensions………………………………………………………13
• Condition for Maximum Power…………………………………………………13
• Selection of Flat Belts from the Manufacture’s
Catalogue…………………………………………………………………………………………………13
• Selection of V-Belts……………………………………………………………………15
4 Chain Drives
• Roller Chains………………………………………………………………………………………20
• Geometrical Relationships………………………………………………………20
• Power Rating of Roller Chains……………………………………………21
• Sprocket Wheels…………………………………………………………………………………24
• Stribeck’s Equation………………………………………………………………………25
• Equivalent Bearing Load……………………………………………………………26
7 Spur Gears
8 Helical Gears
9 Bevel Gears
• Force Analysis……………………………………………………………………………………57
10 Worm Gears
• Proportions of Worm Gears………………………………………………………62
• Force Analysis……………………………………………………………………………………64
• Friction in Worm Gears………………………………………………………………64
• Strength Rating of Worm Gears……………………………………………65
• Wear rating of worm gears………………………………………………………67
FRICTION CLUTCHES
Notations:-
Cone Clutches
Uniform pressure theory
π
P= (D 2 − d 2 )
4
μPz (D3 − d 3 )
(Mt ) f =
3sinα (D2 − d 2 )
Centrifugal Clutches
mω 12 rg
Ps =
1000
μ mr g rd z (ω 22 − ω 12 )
(M t ) f =
1000
Note: - here z = number of shoes.
Brakes
Notations:-
M t = μNR
Where
Mt = Braking Torque
R = Radius of the Brake Drum
μ = Coefficient of Friction
N = Normal reaction
N = plw
Where
p = Permissible pressure between the block and
the brake drum
l = length of the block
w = width of the block
R X = μN
RY = ( N − P )
(a − μc)
P= ×N
b
M t = 2 μR 2 wp max sin θ
1
RX = Rwp max ( 2θ + sin 2θ )
2
1
RY = μRwp max (2θ + sin 2θ )
2
Mn − M f
P= (Clock wise rotation of the brake drum)
C
Mn + M f
P= (Anti clock wise rotation of the brake drum)
C
φ max = 90 0 when θ 2 > 90 0
φ max = θ 2 when θ 2 < 90 0
Where
p max = maximum intensity of pressure.
μ = coefficient of friction.
Band Brakes
Thermal Considerations
E
Δt =
mc
Belt Drives
GEOMETRICAL RELATIONSHIPS
P1 − mv 2 fα
= e
P2 − mv 2 (For flat belts)
P1 − mv 2 fα sin(
1
θ)
=e 2
P2 − mv 2 (For V-belts)
Power transmitted= ( P1 − P2 )v
Type of load
Fa
(i) Normal load 1.0
(ii) Steady load, e.g. centrifugal pumps-fans-light
machine tools-conveyors 1.2
(iii) Intermittent load, e.g. heavy duty fans-
blowers-compressors- reciprocating pumps-line 1.3
shafts-heavy duty machines
(iv) Shock load, e.g. vacuum pumps-rolling mills-
hammers-grinders 1.5
α s (degrees) 120 130 140 150 160 170 180 190 200
SELECTION OF V-BELTS
Dimensions of standard cross-sections
Belt Section Width Thickness Minimum pitch
W(mm) T(mm) diameter of pulley(mm)
A 13 8 125
B 17 11 200
C 22 14 300
D 32 19 500
E 38 23 630
(transmitted _ power _ in _ kW ) × Fa
Number _ of _ belts =
kW _ rating _ of _ belt × Fd × Fl
Where Fa = correction factor for industrial service
Fd = correction factor for arc of contact
Fl = correction factor for belt length
Li Belt section
A B C D E
3658 - 1.11 1.00 0.90 -
4013 - 1.13 1.02 0.92 -
4115 - 1.14 1.03 0.92 -
4394 - 1.15 1.04 0.93 -
4572 - 1.16 1.05 0.94 -
4953 - 1.18 1.07 0.96 -
5334 - 1.19 1.08 0.96 0.94
6045 - - 1.11 1.00 0.96
6807 - - 1.14 1.03 0.99
7569 - - 1.16 1.05 1.01
0.9
0.8
Fd
0.7
0.6
0.5
120 150 180
α s (Degrees)
Chain Drives
Roller Chains
Dimensions and breaking loads of roller chains
Geometric Relationships
n1 z
Velocity ratio, i = = 2
n2 z1
zpn
Average velocity, v =
60 × 10 3
Length of the chain, L = Ln × p
Number of links in the
⎛ a ⎞ ⎛ z1 + z 2 ⎞ ⎛ z 2 − z1 ⎞ ⎛ p ⎞
2
⎧ 2 2⎫
p ⎪⎡ ⎛ z1 + z2 ⎞⎤ ⎡ ⎛ z1 + z2 ⎞⎤ ⎡ z2 − z1 ⎤ ⎪
a = ⎨⎢Ln − ⎜ ⎟⎥ + ⎢Ln − ⎜ ⎟⎥ − 8⎢ ⎥ ⎬
4 ⎪⎣ ⎝ 2 ⎠⎦ ⎣ ⎝ 2 ⎠⎦ ⎣ 2π ⎦ ⎪
⎩ ⎭
(kW _ to _ be _ transmitted ) × K s
kW rating of chain =
K1 × K 2
SPROCKET WHEELS
360
β=
z
Where
z is number of balls
⎛ z ⎞
⎜ ⎟ is practically constant and Stribeck suggested a value of
⎝M ⎠
⎛ z ⎞
5 for ⎜ ⎟
⎝M ⎠
⎛1⎞
C 0 = ⎜ ⎟ zP1
⎝5⎠
Stribeck’s Equation
kd 2 z
C0 =
5
Equivalent Bearing Load
P = XFr + YFa
Where, P= equivalent dynamic load
Fr = radial load
Fa = axial or thrust load
X and Y are radial and thrust factors respectively and
there values are given in the manufactures catalogue.
⎛ Fa ⎞ ⎛ Fa ⎞
⎜⎜ ⎟⎟ ≤ e ⎜⎜ ⎟⎟ > e e
⎛ Fa ⎞ ⎝ Fr ⎠ ⎝ Fr ⎠
⎜⎜ ⎟⎟
⎝ C0 ⎠
X Y X Y
0.025 1 0 0.56 2.0 0.22
0.040 1 0 0.56 1.8 0.24
0.070 1 0 0.56 1.6 0.27
0.130 1 0 0.56 1.4 0.31
0.250 1 0 0.56 1.2 0.37
0.500 1 0 0.56 1.0 0.44
P = XFr + YFa
0.5Fr
Fa =
Y
Where Y is the thrust factor
1b
⎡ ⎛1⎞ ⎤
⎢ log e⎜ ⎟ ⎥
⎛ L ⎞ ⎢ ⎝ R⎠ ⎥
⎜⎜ ⎟⎟ =
⎝ 90 ⎠ ⎢⎢ log ⎛⎜ 1 ⎞⎟ ⎥⎥
L
e⎜ ⎟
⎢⎣ ⎝ R90 ⎠ ⎥⎦
Where b = 1.17
(kW ) p = Q( Pi − P0 )(10 −6 )
( kW ) p = power loss in pumping
⎡ ⎤ μn ( R0 − Ri )
2 4 4
1
(kW ) f = ⎢
⎣ 58.05 × 10 ⎥⎦
6
h0
( kW ) f = power loss due to friction
( kW ) t = ( kW ) p + ( kW ) f
( kW ) t = total power loss
Reynold’s Equation
∂ ⎡ 3 ∂p ⎤ ∂ ⎡ 3 ∂p ⎤ ⎛ ∂h ⎞
⎢ h ⎥ + ⎢h ⎥ = 6 μU ⎜ ⎟
∂x ⎣ ∂x ⎦ ∂z ⎣ ∂z ⎦ ⎝ ∂x ⎠
c = R-r
Where c = radial clearance (mm)
R = radius of bearing
r = radius of journal
e
ε=
c
Where e =eccentricity ratio,
ε = eccentricity ratio
⎛ h0 ⎞
ε = 1− ⎜ ⎟
⎝ c ⎠
Where h0 =film thickness
⎛ h0 ⎞
⎜ ⎟ is called the minimum film thickness variable
⎝c⎠
The Sommerfed number is given by
⎛ r ⎞ μn s
2
S =⎜ ⎟
⎝c⎠ p
Temperature Rise
8.3 p (CFV )
Δt =
( FV )
Δt
Tav = Ti +
2
Spur Gears
The pitch circle diameter is given by
d 1 = mz
Centre to centre distance,
mn ( z p + z g )
a=
2
zg np
Here transmission ratio i = =
zp ng
Force Analysis
60 × 10 6 (kW )
Mt =
2πn
2 mt
pt =
d1
Pr = Pt tan α
Pt
PN =
cosα
Number of Teeth
2
z min =
sin 2 α
Pressure angle (α ) 14.5 0 20 0 25 0
z min (Theoretical) 32 17 11
z min (Practical) 27 14 9
Face Width
(3m)<b< (12m)
In preliminary stages of gear design, the face width assumed
as ten times of module.
6
Cv =
6+v
(3) For precision gears with shaving, grinding and lapping
operations and with v>20m/s,
5 .6
Cv =
5 .6 + v
The pitch line velocity is given by
πd ' n
v=
60 × 10 3
The effective load between two meshing teeth is given by
C s Pt
Peff =
Cv
n the final stages of gear design, when the gear dimensions
are known, the errors specified and the quality of gears
determined, the dynamic load is calculated by the equations
derived by Prof. Spotts. The effective load is given by
Peff = (C s Pt + Pd )
where Pd is the dynamic load
Depending upon the materials of the pinion and the gear,
there are three equations for the dynamic load.
(1) Steel Pinion with steel gear:
en p z p br1 r2
Pd =
2530 (r12 + r22 )
Source of power
Type of driven
machines Electric Turbine/Multi Single-cylinder
motor cylinder engine engine
Generators-feeding
mechanisms-belt conveyors-
blowers-compressors-agitators 1.10 1.25 1.50
and mixers
σ c2 sin α cos α (1 E1 + 1 E 2 )
K=
1.4
S w = bQd 1p K
2z g
Q=
zg − z p
Expression for the load stress factor K can be simplified
when all the gears are made of steel with a 20 0 pressure
angle . in this special case,
E1 = E 2 = 207000 N mm 2
α = 20 0
σ c = 0.27(9.81)( BHN ) N mm 2
where BHN=Brinell Hardness Number.
Therefore,
2
⎛ BHN ⎞
K = 0.16⎜ ⎟
⎝ 100 ⎠
S w = 2 Pd
Sw
Pt = Pd =
2
Helical gears
P
Pn =
cosψ
mn = m cosψ
m n = normal module
m = transverse module
p
pa =
tanψ
tan α n
cosψ =
tan α
zmn
d=
cosψ
m n ( z1 + z 2 )
a=
2 cosψ
ω p zg
i= =
ωg zp
Where i=speed ratio for helical gear
Suffixes p and g refer to the pinion and gear respectively
a is the centre to centre distance between two helical gears
having z1 and z 2 as the number of teeth.
The normal pressure angle is usually 20 0 .
Tooth proportions
In helical gears, the normal module mn should be selected
from standards. The first preference values of the normal
module are m n (mm) 1, 1.25, 1.5, 2, 2.5,3,4,5,6,8 and10.
The standard proportions of the addendum and dedendum
are,
Addendum (ha ) = mn
Dedendum (h f ) = 1.25mn
Clearance (c) = 0.25mn
Addendum circle diameter d a is given by
⎡ z ⎤
d a = mn ⎢ + 2⎥
⎣ cos ψ ⎦
⎡ z ⎤
d f = mn ⎢ − 2 .5 ⎥
⎣ cosψ ⎦
πm
b ≥ n
sin ψ
This is the minimum face width.
Force Analysis
p t = Tangential component
p r = Radial component
⎡ tan α n ⎤
p r = pt ⎢ ⎥
⎣ cosψ ⎦
2 mt
pt =
d
Beam strength of helical gears
S b = m nσ b Y
60 × 10 6 (kW )
Mt =
2πn
2M t
Pt =
d
C s Pt
Peff =
Cv
C s = service factor (from table)
C v = velocity factor
The velocity factor ,
5.6
Cv =
5.6 + v
Dynamic load is given by
en p z p br1r2
Pd =
2530 r12 + r22
S b = Peff ( fs )
bQd p K
Sw =
cos 2 ψ
2 z1g
Q=
z1g + z1p
2 zg
Q=
zg + z p
for internal helical gear
2 zg
Q=
zg − z p
⎡1 1 ⎤
σ c2 sin α n cos α n ⎢ + ⎥
K= ⎣ E1 E2 ⎦
1.4
2
⎛ BHN ⎞
K = 0.16⎜ ⎟
⎝ 100 ⎠
S w = Peff ( fs )
Bevel Gears
D
rb =
2 cos γ
z
z1 =
cos γ
zp
tan γ =
zg
zg
tan Γ =
zp
π
γ +Γ =
2
Mt
Pt =
rm
Ps = Pt tan α
⎡ b ⎤
S b = mbσ bY ⎢1 − ⎥
⎣ A0 ⎦
Where S b beam strength of the tooth
m = module at the large end of the tooth
b = face width
σ b = permissible bending stress ( S ut
3)
Y = Lewis form factor based on formative number of
teeth
A0 = cone distance
2M t
Pt =
D
face width of the bevel gear is generally taken as (10 m) or
( A0 3 ) whichever is smaller
2z g
Q=
z g + z p tan γ
⎡ 1 1 ⎤
σ sin α cos α ⎢
2
c + ⎥
K= ⎣⎢ p
E E ⎥
g ⎦
1. 4
When pinion as well as the gear is made of steel with 20 0
pressure angle, the value of K is given by
2
⎛ BHN ⎞
K = 0.16⎜ ⎟
⎝ 100 ⎠
2M t
Pt =
D
C s Pt
Peff =
Cv
C s = service factor (from table)
Source of power
Type of driven
Electric Turbine/Multi Single-cylinder
machines motor cylinder engine engine
Generators-feeding
mechanisms-belt conveyors-
blowers-compressors-agitators 1.10 1.25 1.50
and mixers
C v = velocity factor
The velocity factor for cut teeth is given by
6
Cv =
6+v
S w = Peff ( fs )
Worm Gears
Notations:-
z1 = number of starts on the worm
z2 = number of teeth on the worm wheel
q = diametral quotient
m = module
d1 = pitch circle diameter of the worm
d a1 = outer diameter of the worm
d a 2 = outer diameter of the worm wheel
d 2 = pitch circle diameter of the worm wheel
l = lead of the worm
p x = axial pitch of the worm
a = the centre distance
i = the speed ratio.
F = the effective face width
lr = the length of the root of the worm gear teeth.
d1
q=
m
l = p x z1
d 2 = mz 2
p x = πm
l = π mz 1
1
a= m( q + z 2 )
2
z2
i =
z1
F = 2m (q + 1)
⎛ F ⎞
l r = (d a1 + 2c) sin −1 ⎜⎜ ⎟⎟
⎝ a1
d + 2c ⎠
Force Analysis
( P1 ) t = tangential component on the worm
( P1 ) a = axial component on the worm
( P1 ) r = radial component on the worm
2M t
( P1 ) t =
d1
( P1 ) a = ( P1 ) t ×
(cos α cos γ − μ sin γ )
(cos α sin γ + μ cos γ )
sin α
( P1 ) r = ( P1 ) t ×
(cos α sin γ + μ cos γ )
( 60 )( 1000 )
πd 1 n1
vs =
(60000 ) cos γ
η=
(cosα − μ tan γ )
(casα + μ cot γ )
m = module
l r = the length of the root of the worm gear teeth.
d 2 = pitch circle diameter of the worm wheel
γ= lead angle of the worm
Power transmitting capacity of the worm gear based on the
beam strength is given by
2π nM t
kW =
60 × 10 6
Where ( M t) is the lower value between ( M t)1 and ( M t) 2 .
Thermal Considerations
H g = 1000(1 − η )kW
Where H g = rate heat generation