Professional Documents
Culture Documents
Unit - 1: V+ Team
Unit - 1: V+ Team
COM
UNIT – 1
100 0.5
100-200 0.6
200-300 0.7
300-400 0.8
400-750 0.9
Above 750 1.0
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Calculate the length of the belt from PSG7.53
Step: 1 Given:
600
d= (
1200
) ∗ 450
d = 225 mm.
𝜋𝑑𝑛 𝜋∗225∗1200
Belt speed, V= = =14137.166 mm/s.
60 60
V = 14.137𝑚⁄𝑠
Step: 3
[(𝐷−𝑑)∗60]
Arc of contact, 𝜃 = 180 −
𝐶
[(600−225)∗60]
= 180 −
2000
𝜃= 168.75o
Step: 5
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
𝑉
Power rating for 14.14 m/s Power rating for 10m/s *
10
0.023∗14.14
=
10
= 0.03252 kW / mm / ply.
Step: 7
𝑑𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟
Width =
𝑟𝑎𝑡𝑖𝑛𝑔 𝑜𝑓 𝑏𝑒𝑙𝑡
21.428
=
0.03252
No. of plies = 6
658.917
Belt width, b=
6
= 109.8mm
The standard width of the belt = 112mm. [Refer PSG, pg no: 7.52]
=125mm
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Step: 9 Length of the belt, [Refer PSG, pg no: 7.53]
𝜋 (𝐷−𝑑)2
L = 2C + (𝐷 + 𝑑) +
2 4𝑐
𝜋 (600−225)2
= 2*2000 + (600 + 225) +
2 4∗2000
L = 5313.48mm
For 6 plies, reduce the length by 1% for initial tension[Refer PSG , pg no:7.53]
L = 5313.48 - 53.13
= 5260.35mm
L = 5.26m.
Step: 10 Specifications:
*No. of plies =6
*Centre distance, C = 2m
Step: 1
d = 400 mm.
𝜋𝐷𝑁
Belt speed, V=
60
V=37699.11 mm/s.
Step: 3
[(𝐷−𝑑)∗60]
Arc of contact, 𝜃 = 180 −
𝐶
[(1200−400)∗60]
= 180 −
3000
𝜃 = 164o
Step: 5
0.023∗37⋅69
Power rating at 37.69 m/s =
10
Step: 6
𝑅𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 ∗ Service factor (Ks)
Design power=
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 (𝐾𝑝) ∗ 𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑓𝑎𝑐𝑡𝑜𝑟 (𝐾𝑎)
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
30 ∗ 1.5
=
0.8 ∗ 1.4
Design Power = 54.086 kW.
Step: 7
𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑜𝑤𝑒𝑟
Width=
𝑅𝑎𝑡𝑖𝑛𝑔 𝑜𝑓 𝐵𝑒𝑙𝑡
54.086
=
0.0866
For belt speed 10 m/s and d= 400 mm (Refer PSG Pg no: 7.52)
No. of piles = 6
624.549
Belt Width, b=
6
= 104.09 mm.
The Standard width of the belt = 125 mm. (Refer PSG Pg no: 7.52)
= 150 mm.
𝜋 (1200−400)2
= (2 ∗ 3000) + (1200 + 400) +
2 4∗3000
L= 8566.61 mm.
For 6 piles reduce the length by 1% for initial tension (Refer PSG Pg no: 7.53)
L= 8566.61 − 85.66
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
= 8480.95 mm.
= 8.48 m.
Step: 10 Specifications
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Arc of contact factor (PSG7.68) x correction factor length
A 50 kW motor running at 1000 rpm is required to drive pump pulley at 400 rpm
space restrictions limit the size of motor pulley 0.3 m and the center distance is 2.5
m. The pump is located in a shed and is expected to run for 16 hr/day . Select a
suitable V belt drive and design.
Step 1:
Power (P) = 50 kW
Speed of driving pulley ( N )= 1000 rpm
Speed of driven pulley ( n )= 400 rpm
Dia. of driving pulley (D) = 0.3 m
Centre distance ( c )= 2.5 m
Selection of cross section of belt based on power transmitted.
For 50 kW V belt C (or) D can be selected. [Refer from PSG P.No 7.58]
Here C section is selected for the power range is 7.5 – 75 kW.
The recommended minimum pitch diameter of pulley is d n
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Step 2:
𝐷 𝑛
Speed ratio ( i ) = =
𝑑 𝑁
400
i = = 0.4
1000
0.3
0.4 =
𝑑
0.3
d = = 0.75 = 750 mm
0.4
Step 3:
= 2500 mm
Step 4:
𝜋 ( 0.3−0.75 )2
= 2x2.5 + ( 0.75 + 0.3 ) +
2 4∗2.5
= 6.67 m
L = 6.863 m
Step 5:
Rated power x service factor
Design power =
Arc of contact factor x Correction factor
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
0.75−0.3
Arc of contact factor Fd = 180O − 60O ( )
2.5
= 169.2o
Step 6:
de = dp x Fb
= 0.2 x 1.13
𝐷 0.75
Speed ratio = = = 2.5
𝑑 0.3
Fb = 1.13
de = 0.200 x 1.13
de = 0.226 m
𝜋𝐷𝑁
Speed S =
60
π x 0.3 x 1000
=
60
= 15.71 m/s
= 7.196 kW
Step 7:
Design power
No. of belt =
rating of the belt
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
54.26
=
7.196
= 7.54 ~ 8
Step 8:
No. of belt =8
C = A + √𝐴2 − 𝐵
𝐿 𝜋(𝐷+𝑑)
A= −
4 8
= 1.6675 – 0.41233
A = 1.255 m
(𝐷−𝑑)2
B=
8
B = 0.0253 m3
C = 2.499 m
Step 9:
= 0.3 + 2 ( 0.0057)
= 0.7614 m
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
= 0.3 – 2 ( 0.0143)
= 0.2714 m
= 7 x 0.025 + (2 x 0.017)
= 0.209 m
Step 10:
No. of belt =8
Specification of pulley
(Fs)w= Braking load for the selected rope (PSG 9.4-9.6) / Effective load during acceleration.
This (Fs)w should not be less than the recommended factor of safety given in PSG(9.1).
If the working factor of safety (Fs)w is not satisfactory, choose some other rope with greater
braking strength (or) no. Of ropes should be increased.
Select a suitable wire rope to lift 11kN of debris from a well 60m deep. The
weight is being lifted with a maximum speed of 150m/min and the maximaum
speed is obtained in 1min. Determine also stressed induced in wire rope due to
starting with an initial slack of 0.25m.Take Er =0.75*105N/mm2.The weight of
the bucket is 4kN.
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Step1:
W = WL+WB
= 11+4 = 15kN
Er = 0.75*105 N/mm2
= 15*15
=225 kN
=225000N
No. of strands=6
= 230kN
Step3:
Take class 4,
Dmin
So = 27
d
=35*25 = 875mm.
Step4:
= 0.4× 252
= 250 mm 2
Step 5:
d
Dia. Of wire dw =
1.5√i
25
=
1.5√6x19
dw = 1.560 mm
= 22.5 N/m
WR = 1350 N
Step 7:
= 15 + 1.35
= 16.35 kN = 16350 N
2. Bending load, wb = 𝜎𝑏 . A
𝑑𝑊
σb = Er x
𝐷
1.560
= 0.75 x 10 5 x
875
σb = 133.8 N/ mm2
wb = 133.8 x 250
= 33450 N.
𝑤+𝑤𝑟
iii) Acceleration load, Wa = a
𝑔
15+1.35
=(
9.81
) x 2.50
= 4166.66 N
= 2 ( 15 + 1.35), kN
= 32,700 N
Wne = wd + wb
= 16350 + 33450
Wne = 49800 N
wae = 53.9 kN
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Step 8:
Breaking load
(Fs)w =
Effective load during acceleration
230 x 1000
= = 4.267
53.9
From PSG Design data book [P.No. 9.1] we find the recommend F.O.S
for their application to be 6
Step 9:
To achieve this F.O.S we may either choose rope & drum dia. With larger
dia. ( or ) increase no. of ropes
n (recommended FOS) 6
No. of ropes = (FOS)W
= = 1.41 ~ 2
4.26
Wse = ws + wb
1+2aS hxEr
Ws = wd [ 1 + √ ]
σb lg
1+2x2.5x0.25x1000x0.75x105
= 16350 [ 1 + √ ]
65.4x 60x1000x9.81
ws = 41.864.51 kN
= 75315.51 N
Selected rope = 6 x 19
No. of ropes = 8
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Ks=k1 x k2 x k3 x k3 x k4 x k5 x k6. PSG 7.76 & 7.77.
Where,
k1 - load factor.
k2 - factor for distant regulation.
k3 - factor for centre distance of sprocket.
k4 - factor for position of sprocket.
k5 - lubrication factor.
k6 - rating factor.
= lp-((Z1-Z2)/2)
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Design a chain drive to run a compressor from 11Kw electric motor, running at
970rpm the compressor being 330rpm. The compressor operates 16hours/day.
The centre distance should be approximately 500mm. the chain tension may be
adjusted by shifting the motor slides
STEP 2: selection of number of teeth on the pinion (Refer the PSG pg.no: 7.74)
STEP 3: selection of number of teeth on the sprocket (Refer the PSG: 7.74)
Z2 = z1, * i
= 2.94 * 25 =75
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
a = (30 to 50)p
If 30 is used
500
pmax = =16.66
30
500
pmin = =10
50
pitch p=15.875
STEP 6: Total load on the driving side of the chain (Refer the P.S.G 7.78)
PT = Pt +Pc +Ps
1020𝑁
Pt = (tangential force due to power transmission)
𝑣
v =6416.14mm/s =6.42m/s
1020∗11
Pt = =1747.66 N
6.42
𝑚𝑣 2
w.k.t Pc = (centrifugal tension ) (Refer the PSG pg.no: 7.78)
𝑔
for mass m to be found for selected during fine mass per unit length
1.78∗10
( ) m=1.78
10
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Pc =1.78*6.4162 =73.273N
Ps = 6x17.8x.5 =53.4 N
PT =1748.75+73.273+53.4 = 1875.423N
STEP 7: service factor (ks) (Refer the PSG pg.no: 7.76 to 7.77)
ks= k1 x k2 x k3 x k4 x k5 x k6
k1 =1(load factor)
Q = 4440 x 10 = 44400
44400
Actual factor of safety = =10.10
4394.116
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
The recommended FOS for the speed of rotation of small sprocket for
330rpm is 8.55
σ =pT x ks/A
The permissible allowable stress calculated (from the P.S.G pg.no: 7.77)
STEP 10: calculate the length of chain (from the PSG pg.no: 7.72)
𝑎𝑝 =a0/p = 31.50
lp=115mm
𝑒+√(𝑒 2 −8𝑚)𝑝
a=
4
𝑧1 + 𝑧𝑎
e =ip - = 65mm
2
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
𝑝
(d2) = 180 =379.10mm
sin( )
𝑧2
STEP 10 : SPECIFICATION:
Power (p) =11Kw
z1, = 25
z2, = 75
pitch p=15.875
PT = 1875.423N
Ks=2.343
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
UNIT – 2
STEP 5: Calculation Of Design Bending Stress [σb] and Design Contact Stress [σc]
To find [σb]: Refer the formula PSG.8.18
To find [σc]: Refer the formula PSG .8.16
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
v = ∏ х D х N / 60
ψp = b / d
STEP 14: Check for Contact Stress Refer PSG.8.13 table no 8 for spur gears
STEP 15: Calculation of Basic Dimensions of the Gear Pair Refer the formulas PSG.8.22.
DESIGN PROCEDURE OF HELICAL GEAR
STEP 5: Calculation Of Design Bending Stress [σb] and Design Contact Stress [σc]
To find [σb]: Refer the formula PSG.8.18
To find [σc]: Refer the formula PSG .8.16
STEP 6: Calculation of Centre Distance (a) Refer the formula PSG.8.13 for helical gears
STEP 8: Calculation of Module (m) Refer the formula PSG.8.22 for helical gears
STEP 9: Recalculation of Centre Distance(a) Refer the formula PSG8.22 for helical gears
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
b=ψхa for ψ refer PSG 8.14 table 10
d=mхZ
v = ∏ х D х N / 60
ψp = b / d
STEP 13: Check for Bending Stress Refer PSG. 8.13A for helical gears
STEP 14: Check for Contact Stress Refer PSG.8.13 table no 8 for helical gears
STEP 15: Calculation of Basic Dimensions of the Gear Pair Refer the formulas PSG.8.22.
UNIT – 3
DESIGN PROCEDURE FOR BEVEL GEARS
Step: 3 : Calculation of pitch angle [ (ie) δ1 and δ2 ] and the virtual number of teeth (ie) Zp1
and Zp2 using the following relations ,
Pitch angle => tan δ 2 = i
and δ1 = 90°- δ2
For the right angled bevel gears,
Zv1 = Z1 and Zv2 = Z 2
Cos δ1 Cos δ2
Step: 4: Calculate the tangential load using the relation
Ft = P x Ko
v
Step: 5: Calculate the preliminary value of dynamic load using the relation
Fd = F t
Cv where Cv = 5.6
5.6 + √V where V = 5 m/s
Step : 6: Calculate the beam strength Fs in terms of transverse module using the following
relation
Fs = ∏ x mt x b x [Ϭb ] x ý x [ R – b ]
R
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Step : 7: Calculate the transverse module mt by equating the Fs and Fd
Step : 8: Calculate the values of b , d and v
Using the following relations
Face width b = 10 x mt
Pitch circle diameter d = Z x mt
Pitch line velocity V = ∏ d N
60
Step : 9: Recalculate the beam strength
Fs = ∏ x mt x b x [Ϭb ] x ý x [ R – b ]
R
Step : 10: Calculate the dynamic load , using Buckingham’s equation ,
Fd = Ft + 21 V ( bc + Ft )
21 V +√( bc +Ft)
Step :11: Check for the beam strength or tooth breakage , if Fd ≤ Fs , the gear tooth has
adequate beam strength.
Step: 12: Calculate the maximum wear load , using the following relation
Fw = 0.75 x d1 x b x Q x Kw
Cos δ1
Step : 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 satisfier.
Step :14: Calculate the basic dimensions for the gear and pinion.
Problem:
A pair of 20° full depth involute teeth bevel gear connects two shafts at right angles
having a velocity ratio of 3.2: 1. The gear is made of cast steel with an allowable static stress
as72 N/mm², and the pinion is made of steel having a static of 100 N/mm². The pinion
transmits 40kW and at 840 rpm. Find the module, face width, and pitch diameter from the
stand point of the beam strength, and check the design from the stand point of wear.
Given data:
Θ = 90° , ά = 20° , i = 3.2 , [σb2 ] = 72 N/mm², [σb1] = 100 N/mm², P = 40 kW ,
N1= 840 rpm
To find:
Module, face width, and pitch diameter of the gears.
Solution:
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Step : 3: Calculation of pitch angle [ (ie) δ1 and δ2 ] and the virtual number of teeth (ie) Zp 1
and Zp2 using the following relations ,
tan δ 2 = i = 3.2 or δ2= tan -1 (3.2) = 72.64°
then δ1 = 90° - δ2
δ1= 90° - 72.64° = 17.36°
The virtual number of the teeth on the gears is given by
Zv1 = Z1 = 20
Cos δ1 cos 17.36°
Zv1 = 21
Zv2 = Z2 = 64
Cos δ2 cos 72.64°
Zv2 = 215
Then form factors based on virtual number of teeth are given by
Ý1 = 0.154 - 0.912
Zv1
Ý1 = 0.1106
Ý2 = 0.154 - 0.912
Zv2
Ý2 = 0.1497
For pinion: [σb1] x ý1 = 100 x .0116 = 11.06 N/mm²
For gear: [σb2] x ý2 = 72 x 1497 = 10.78 N/mm²
Hence the value of gear is less than pinion. Thus we have to design for gear only.
Step : 4: Calculating the tangential load using the relation We know that ,
Ft = P x Ko
v
where v = ∏ d1 N1 = ∏ x N1 x ( mt x Z1)
60 60 1000
= ∏ x 840 x ( mt x 20) = .879 mt
60 1000
Ko = 1.25 , assuming medium shock
Step :5:
Fd = Ft
Cv where Cv = 5.6
5.6 + √V where V = 5 m/s
Cv = 0.715
Fd = 56841 x 1
mt 0.715
Fd = 79497.9
mt
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Step: 6: Calculating the preliminary value of dynamic load using the relation
Fs = ∏ x mt x b x [Ϭb ] x ý x [ R – b ]
R
Where b = 10 mt ; Ý2 = 0.1497
[σb2] = 72 N/mm² ; R= 0.5 mt x √ ( Z1² + Z2² ) = 33.53 mt
Fs = ∏ x mt x 10 mt x 72x 0.1497x [33.53 mt - 10 mt]
33.53 mt
Fs = 237.62 mt²
Step :7:
Calculation of transverse module mt
We know that Fs ≥ Fd
Step: 10:
Calculation of the dynamic load , using Buckingham’s equation ,
Fd = Ft + 21 V ( bc + Ft )
21 V +√( bc +Ft)
Ft = P = 40 x 10ᶾ = 6493.55 N
v 6.16
c = 11860 x 0.017 = 201.62 N/mm
Fd = 27077.55 N
Step :11:
Check for the beam strength or tooth breakage, but Fd >> Fs
Taking module as 14
Face width b = 10 mt = 10 x 14 = 140 mm
Pitch circle diameter d1 = mt x Z1 = 14 x 20 = 280 mm
Pitch line velocity V2 = V1 = ∏ d N = 12.315m/s
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
60
Fs = 237.62 x mt² = 237.62 x 14² = 46573.52 N
Ft = P = 40 x 10ᶾ = 3248 N
v 12.315
c = 11860 x .025 = 296.62 N/mm
Step: 12:
Calculation of wear load (Fw)
Fs = 0.75 x d1 x b x Q x Kw
Cos δ1
Q = Ratio Factor = 2 x Zv2 = 2 x 215 = 1.822, and
Zv1 ± Zv2 21 + 215
Kw = 0.919 N/mm² , for steel gears hardened to 250 BHN ,
Given Data:
P= 1875 W, N1= 800 rpm, N2= 400 rpm, α= 20°
To find:
Design a bevel gear dive
Solution:
Since the materials of pinion and gear are same we have to design only the pinion
1. Gear ratio:
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
i = N1 / N2 = 800 / 400 = 2
3. Gear life in hours = ( 40 hrs/ week) x (52 weeks / year x 3 years) = 6240 hours
Gear life in cycles, N = 6240 x 800 x 60 = 29.952 x 10 ⁷ cycles
60 𝑥 𝑃
Where 𝑀𝑡 = ( )
2𝜋𝑁
=
60 𝑥 1875
𝑀𝑡 = ( ) = 22.38 N-m and
2 𝜋 𝑥 800
To find Eeq: Eeq = 1.4 x 10⁵ N/ mm² for cast iron, бu > 280 N/ mm² PSG 8.14
1.4 𝐾𝑏𝑙
To find [бb] = x 𝜎−1 , for rotation in one direction PSG 8.20
𝑛 . 𝐾𝜎
107
𝐾𝑏𝑙 = ⁹√ = 0.8852, for CI
𝑁
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Then [бb] = ( 1.4 x 0.8852 x 157.2 / (2x 1.2) ) = 81.33 N/ mm²
To find [бc] :
[бc] = Cb x HB x Kcl
107 107
Kcl = ⁶√ 𝑁 = ⁶√
29.952 𝑥 107
= 0.833, for C I
[ бc] = 2.3 x 260 x 0.833 = 498.08 N/ mm²
0.72 2 [𝑀𝑡]
We know that 𝑅 ≥ 𝜓𝑦 ( √(𝑖 2 + 1 )) { ³√[ ] 𝑥 𝐸𝑒𝑞 }
𝜓𝑦 – 0.5[б𝑐] 𝑖
𝑅
𝜓𝑦 = =3
𝑏
R ≥ 50.2
R= 51 mm
𝑅
𝑀𝑡 = = 2.28 mm take as 2.5 PSG 8.2
(0.5 √ 𝑍12 + 𝑍22 )
π x d1av x N1
Pitch line velocity v : 60
= 1.745 m /s
Ψy = b / d1av = 18.63 / 41.66 = 0.477
𝑅 √( 𝑖 2 + 1 )[𝑀𝑡]
Б𝑏 ={ )
( ( 𝑅 − 0.5𝑏)2 𝑥 𝑏 𝑥 𝑚𝑡 𝑥 𝑌𝑣1 )
Б b = 100.75 N/ mm²
14. Check for wear strength :We know that the induced contact stress,
1
2
0.72 √(𝑖 2 + 1)3
Б𝑐 = ( ) (( ) 𝑥 𝐸𝑒𝑞 [𝑀𝑡]]
𝑅 – 0.5𝑏 (𝑖 𝑥 𝑏)
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
= 439.33 N / mm²
[Mt]=Mt x K x Kd.
Initially, Assume K x Kd = 1.
Mt=60 x p / 2ΠN.
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
STEP-5: Calculation of Centre Distance PSG.8.44
[σb] = 1.9[Mt] / mЗ x q x z x y
A steel worm running at 240 rp , receives 1.5 kw from its shaft. The speed reduction is 10:1,
design the drive so as to have an efficiency of 80 %, also determine the cooling area
required, if the temperature rise is restricted to 45° C, and take overall heat transfer co
efficient as 10 W / m² ° C.
Given data:
N1= 240 rpm, P= 1.5 kW, I= 10, η desired = 80%, to – ta = 45°C, Kt = 10 W/ m² °C.
To find:
1. Design the worm gear drive
2. The cooling area required
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Solution:
[Mt]=Mt x K x Kd.
Initially, Assume K x Kd = 1.
Mt=60 x p / 2ΠN.
Mt= ( 60 x 1.5 x 10³ / 2πN2) = 596.83 N-m
K.Kd = 1
a = 168.6 mm
[Mt]=Mt x K x Kd.
= 596.83 x 1 x1 = 596.83 N-m
[σb] = 1.9[Mt] / mЗ x q x z x y
= 7.6 N / mm²
= 118.59 N / mm²
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
UNIT - 4
Step 2:
Step 3:
Step 4:
Step 5:
To reduce the large diameter of gear wheels and also limit the pitch line velocity of
the gear drives the following principle to be followed.
2. No .of gear on the shaft should not be more than 3.(but some cases it may be 4)
3. It is necessary to have Nmax ≥Ninput ≥Nmin ( in all strages except in the 1st stage)
4. The transmission ratio between the drive and driven shaft should be maximum
𝑁𝑚𝑎𝑥 𝑁
≤ 2 and 𝑁 𝑚𝑖𝑛 ≥ .25( in all strages except in the 1st stage)
𝑁𝑖𝑛𝑝𝑢𝑡 𝑖𝑛𝑝𝑢𝑡
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Problem: Design a 12 speed gear box speed range 100 rpm to 255 rpm
To calculate
Z=number of speed=12
355
=φ12-1 = φ11
100
φ11 =3.55
The progression ratio φ =1.122 coincide with R 20 series therefore select R 20 series speeds
N9 = 250 rpm N10 = 280 rpm N11 = 315 rpm N12 = 355 rpm
Let us select 3 x 2 x 2
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Locate point (A) minimum speed as at 100rpm leave 6 interval and mark point (B)
maximum speed as at 200rpm.
𝑁 100
(𝑁 𝑚𝑖𝑛 ≥ .25 ) 160
= .625 ≥ .25
𝑖𝑛𝑝𝑢𝑡
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
Selected input speed is satisfactory
Locate point (C) minimum speed as at 160rpm leave 3 interval and mark point (D)
maximum speed as at 224rpm.
Locate point (E) input speed as at 200rpm and check the conditions
𝑁 224
(𝑁 𝑚𝑎𝑥 ≤ 2 ) =1.24 ≤ 2
𝑖𝑛𝑝𝑢𝑡 180
𝑁 160
(𝑁 𝑚𝑖𝑛 ≥0 .25 ) = .88≥ .25
𝑖𝑛𝑝𝑢𝑡 180
Assume input speed as the engine speed and mark point (H).
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
1. Z9 Z10 Z5 Z6 Z1Z2
2. Z9 Z10 Z5 Z6 Z3Z4
3. Z9 Z10 Z7 Z8 Z1Z2
4. Z9 Z10 Z7 Z8 Z3Z4
6. Z11Z12 Z5 Z6 Z3Z4
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
9. Z13 Z14 Z5Z6 Z1Z2
Third stage:
100 20
= , Z1 = 32 teeth
160 Z1
Z3 +Z4 = Z1 +Z2
Z3 +Z4 = 32
200 Z4
=52−Z4 = 1.25(52 – Z4 ) = Z4
160
Z4 =29, Z3 =23
Second stage:
160 20
=Z5, Z5 = 23 teeth
180
Z6 +Z5 = Z7 +Z8
Z7 +Z8 = 43
224 Z8
=43−Z8 = 1.244(43 – Z8 ) = Z8
180
Z8 =24, Z7 =19
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
First stage:
In this stage there are 3 speeds and 3 pairs of gears are required. To avoid interference of gear
of one shaft with the gear of the other shaft while shifting following condition has to be
satisfied to avoid interference.
Z12 – Z10 ≥ 4
Z12 – Z14 ≥ 4
180 20
= , Z9 = 40 teeth , 𝑍10 =20 teeth
355 Z9
Z11 +Z12 = 60
200 Z12
= = 0.563(60 – Z12) = Z12
355 60−Z12
Z14 +Z13 = 60
224 Z14
=60−Z14 = 0.613(60 – Z14 ) = Z14
355
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
RESULT:
𝑍10 𝑍6 𝑍4 20 20 29
Os2 = IS x x x = 355 x x x = 194.61
𝑍9 𝑍5 𝑍3 40 23 23
𝑍10 𝑍8 𝑍2 20 24 20
Os3 = IS x x x = 355 x x x = 140.13
𝑍9 𝑍7 𝑍1 40 19 32
𝑍10 𝑍8 𝑍4 20 24 29
Os4 = IS x x x = 355 x x x = 282.7
𝑍9 𝑍7 𝑍3 40 19 23
𝑍12 𝑍6 𝑍2 22 20 20
Os5 = IS x x x = 355 x x x = 111.69
𝑍11 𝑍5 𝑍1 38 23 32
𝑍12 𝑍6 𝑍4 22 20 29
Os6 = IS x x x = 355 x x x = 225.3
𝑍11 𝑍5 𝑍3 38 23 23
𝑍12 𝑍8 𝑍2 22 24 20
Os7 = IS x x x = 355 x x x = 162.25
𝑍11 𝑍7 𝑍1 38 19 32
𝑍12 𝑍8 𝑍4 22 24 29
Os8 = IS x x x = 355 x x x = 327.33
𝑍11 𝑍7 𝑍3 38 19 23
𝑍14 𝑍6 𝑍2 23 20 20
Os9 = IS x x x = 355 x x x = 119.9
𝑍13 𝑍5 𝑍1 27 23 32
𝑍14 𝑍6 𝑍4 23 20 29
Os10 = IS x x x = 355 x x x = 241.19
𝑍13 𝑍5 𝑍3 27 23 23
𝑍14 𝑍8 𝑍2 23 24 20
Os11 = IS x x x = 355 x x x = 174.2
𝑍13 𝑍7 𝑍1 27 19 32
𝑍14 𝑍8 𝑍4 23 24 29
Os12 = IS x x x = 355 x x = 351.63
𝑍13 𝑍7 𝑍3 27 19 23
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
= ± 10(1.127-1)%
= ±1.27
From the above table we find, the deviations are well within the permissible
limits.
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
PROBLEM:
An automobile single plate clutch consists of two pair on contacting surface. The inner and
outer radii of the friction plate are 120mm and 250mm respectively. The co-efficient of
friction is 0.25 and the total axial force is 15KN. Calculate the power transmitting capacity of
the clutch plate at 500rpm, using
1. Uniform wear theory
2. Uniform pressure theory
GIVEN DATA:
N=2
R1=250mm= 0.25m
R1=120mm= 0.12m
µ= 0.25
W=15KN= 15X 103
TO FIND:
Power transmitting using
1. Uniform wear theory
2. Uniform pressure theory
SOLUTION:
Using uniform wear theory
Torque transmitted on clutch is given by
𝑟1+𝑟2
T=n X µ X W X 2
0.25+0.12
=2 X 0.25 X 15 X 103 2
T= 1387.5 N.m
2π𝑁𝑇
Power transmitted P = 60
2π 𝑋 500 𝑋 1387.5
= 60
P=72.65 kW
2
T = n µ W 3 X r13 – r23 / r12– r22
2
= 2 X 0.25 X 15 X 103 X 3 X (0.25)3 – (0.12)3 / (0.25)2– (0.12)2
T = 1444.6 N.m
2π𝑁𝑇
Power transmitted, P =
60
2π X 500 X 1444.6
= 60
P = 75.64 kW
RESULT:
Power transmitted,
1. Uniform wear theory P=72.65kW
2. Uniform pressure theory P =75.64kW
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
PROBLEM NO: 2:
A car engine has its rated output of 12kW. The maximum torque developed is 100N.m.The
clutch used is single plate type having two active surfaces. The axial pressure in not to
exceed 85KN/mm2. The external diameter of the friction plate is 1.25 times of the internal
diameter. Determine the dimensions of the friction plate and the axial force exerted by the
springs. Co-efficient of friction is 0.3
GIVEN DATE:
P = 12kW=12 X 103 W
T = 100 Nm.
N=2
Pmax= 85KN/mm2 =85 X 103 N/mm2
d1=1.25d2
µ = 0.3
TO FIND:
1. Dimensions of the friction plate
2. Axial force exerted on the springs
SOLUTION:
𝑟1+𝑟2
Torque transmitted,[T] = n X µ X W X 2
1.25𝑟2+𝑟2
280 = 2 X 0.3 X 1.335 X 105 X r22 2
R2 =0.1459 m or 145.9 mm
R1 =1.25r2
R1 = 0.1823 m or 182.3 mm
(ii)Axial force exerted on the springs:
W = 2πC (r1-r2)
= 1.335 X 105 X (r22)
w = 2841.79 N
RESULT:
Dimension of the friction plate
r2 = 145.9mm
r1 = 182.3 mm
Axial force exerted on the springs
w = 2841.79 N
GIVEN DATE:
D1 = 100mm
P= 12.455 kW
N= 1400 rpm
R1= 50mm
TO FIND:
1. Disc diameter
2. Total number
3. Clamping force
SOLUTIONS:
Assume r2= 0.6 X r1
= 0.6 X 50
r2=30mm
[T]= n x µ x W x R
𝑟1+𝑟2
= n x µ x 2π x Pmax x r2 (r1-r2) x 2
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
[T] =n x µ x π x Pmax x r2 x (r12-r22)
Assume,
Pmax = 1.45 MPa µ= 0.06
𝑃 𝑋 60
T= 2𝜋𝑁
12.455 𝑋 103 𝑋 60
= 2𝜋 𝑋 1400
T= 84.954 Nm.
T= 84954.63 Nmm.
[T] = T x Ks
[T] = 84954.63 x 3.03
[T] = 257.45 x 103 N-mm
𝑟1+𝑟2
[T] = n x µ x W x 2
0.05+𝑟2
257.45 X 103 = 21 X 0.06 X 12.455 X 103 X 2
D2 = 655.2 mm
Clamping force
W = 2πC (r1-r2)
= 2π X Pmax X r2 X (r1-r2)
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
= 2π X 1.45 X 0.327 X (0.05-0.327)
W =5362.5 N
RESULT:
1. D2 =655.2 mm
2. N=21
3. W=5362.5N
CONE CLUTCH:
A leather faced conical clutch has cone angle of 30˚. The pressure between the contact
surfaces is limited to 0.35N/mm2 and the breadth of the conical surface is not to exceed to
1/3 of the mean radius. Find the dimensions of the contact surfaces to transmit 22kW at
2000 rpm. Also calculate the force required to engage the clutch. Take coefficient of friction
is 0.15
GIVEN DATA:
α = 30˚
Pn= 0.35N/mm2
B=r/3
µ= 0.15
P=22kW
N=2000rpm
TO FIND:
1. Dimensions of contact surface (r1, r2)
2. Forces required engaging clutch
SOLUTION:
2π𝑁𝑇
P= 60
2π X 2000 X 𝑇
22 X 103 = 60
T= 105.4 Nm.
Assuming service factor Ks =2.5
Design torque [T} = 105.4 X 2.5
T= 262.60N.m
T =2 x π x µ x Pn x R2 x b
𝑅
262.60 = 2 x π x 0.15 x 0.35 x R2 x 3 x 103
R=1.336 m
𝑅 1.336
B=3= 3
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
B = 0.445m
𝑟1−𝑟2
= sinα
𝑏
r1+r2 = 2.672
r1-r2 = 0.1151
r1+r2 = 2.672
2 r1= 2.781
r1 =1.393m
r2 = 1.279m
Force required:
W = 2πC (r1-r2)
= 2π X Pn X r2 X (r1-r2)
= 2π X 0.35 X 1.279 X (1.393-1.279)
W = 3206.44N
RESULT:
R1 = 1.393 mm
R2 = 1.279 mm
W = 3206.44N
Problem: 3
A leather faced conical friction clutch has a cone angle of 300 . The intensity of pressure
between the clutch surface is not exceed 6x104 N/𝑚2 and the breadth of the conical
surface is not to be greater than 1/3 of the mean radius if µ = 0.20 and the clutch transmit
37 KW at 2000 rpm. Find the dimension of contact surfaces
Given :
b
0
α = 30
𝑃𝑛 = 6x104 N/𝒎𝟐
r1
b = R/3 R
r2
µ = 0.2 α
P = 37 KW = 37x103 W
N = 2000 rpm
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
To find :
Dimensions of contact surfaces : ( 𝑉1 𝑎𝑛𝑑 𝑉2 )
Solution :
2𝜋𝑁𝑇
Power transmitted (P) = 60
T = 176.66 Nm
Torque transmitted is also given by T = 2πµ 𝑃𝑛 𝑅 2 𝑏
𝑅
176.66 = 2π x 0.2 x 6 x 104 x 𝑅 2 ( 3 )
=25132.74 𝑅 3
R = 0.19155 m (or) 191.55 mm
𝑅 6.19155
Face width is given by b = 3 = 3 = 2.06 m
Given: b = R/2
𝑟1 − 𝑟2
we know that 𝑏
= sin 𝛼
(𝑟1 − 𝑟2 )
𝑏= sin 𝛼
𝑟1 + 𝑟2
and mean radius R = 2
𝑟1 − 𝑟2 𝑟1 + 𝑟2 𝑅
= [ ∵ 𝑏 = 2 , given ]
sin 𝛼 4
1 sin 120 (𝑟 + 𝑟 )
2
𝑟1 − 𝑟2 =
4
= 0.052 𝑟1 + 0.052 𝑟2
WWW.VIDYARTHIPLUS.COM V+ TEAM
WWW.VIDYARTHIPLUS.COM
2𝜋900𝑇
7.5 x 103 = 60
T = 79.58 Nm
For uniform wear, the intensity of pressure is maximum at the inner radius
∴ 𝑃𝑚𝑎𝑥 x 𝑟2 = 𝑐
(𝑟 + 𝑟 )
Torque transmitted T = µ w 𝑐𝑜𝑠𝑒𝑐 𝛼 1 2 2
(𝑟1 + 𝑟2 )
then T = µ [2π 𝑃𝑚𝑎𝑥 x 𝑟2 (𝑟1 − 𝑟2 ) ] 𝑐𝑜𝑠𝑒𝑐 𝛼 2
𝑟2 = 0.108 m or 108 mm
Then
𝑟1 = 1.1096 𝑟2 = 1.1096 ( 108 ) = 119.8 mm
𝑟1 + 𝑟2 119.8+108
R= = = 113.9 𝒎𝒎
2 2
𝑅 113.9
Face width, b = = = 56.95 𝒎𝒎
2 2
Result:
Brakes
WWW.VIDYARTHIPLUS.COM V+ TEAM