Machine Design LAB

Machine Design LAB
Gear Box Design
Problem Definition
Sachin Dhavane
S P DHAVANE Mechanical MIT AOE

Gear Box Design
Problem Definition
1.What is Application ?
2.What are Operating Parameters ?
3.Which Type Of Gearbox to be Selected ?

Gear Box Design
1.What is Application ?
S P DHAVANE Mechanical MIT AOE Courtesy : NORD DRIVE SYSTEMS

Gear Box Design
1.Where is Gearbox in That Application ?
Courtesy : NORD DRIVE SYSTEMS

Gear Box Design
2.Operating Parameters Gearbox ?
What is Speed / Velocity Requirements of Conveyor Belt ..? 1. O/P Speed
What is Max. Load to be Handled by Conveyor ..?
πDN
V
60
2πNT
P
60

Gear Box Design
What is Speed / Velocity Requirements of Conveyor Belt ..? 1. O/P Speed
http://www.endmemo.com/physics/rpmlinear.php

Gear Box Design
Input Power =?
I/P Speed =?
3 HP PINION
Input Power
I/P Speed
1440 RPM GEAR +PINION= GEAR PAIR

GEAR
Speed Reducers
1. O/P Speed 200 RPM
2. Power Required. 2.8 HP

Gear Box Design
How Many Stages Are Required ?
3.Which Type Of Gearbox to be Selected ?
Which Gears Are to be Used in Each Stage.?
Layout
Spur Gears
Spur Gears Helical Gears Helical Gears
Bevel Gears
Parallel Shaft Parallel +Perpendicular Shaft

Gear Box Design
Selection of Type of Gear
Type of Shaft layout Speed Input Speed and Cost

gear reduction Power to be
transmitted
Spur Parallel 6:1 (10:1) Low and medium Cheape
speed st
Helical Parallel 6:1 (10:1) High speed power Costlier
transmission Spur Gears Helical Gears
Bevel Perpendicular 1:1 (3:1) Low speed Costlier
Worm Perpendicular 60:1 (100:1) Low speed Costlier

and non-intersecting
Bevel Gears
Worm & Worm Wheel Gears

Sachin Dhavane Mech Engg MIT AOE
Gear Box Design
3.Which Type Of Gearbox to be Selected ? Which Gears Are to be Used in Each Stage.?
Input Power 3 HP
How Many Stages Are Required ?
I/P Speed 1440 RPM
Total Speed Reduction Ration of Gearbox ?

O/P Speed 200 RPM I Stage
Speed Reduction Ration of Each Stage ?

1440 RPM
1440
i  2 i ' For 2 Stages i  2 7.2  2.68
i 
'
200
i  3 i ' For 3 Stages 2.68 2.68 7.2 II Stage
i 
'
or 7.2 : 1 200 RPM
I Stage II Stage 1
In a Multi Stage Gearbox , Single Stage Should Not Exceed 6:1

Problem Definition
Gear Box Design
1.What is Application ? Airport Luggage Conveyors
Input Power 3 HP
I/P Speed 1440 RPM
O/P Speed 200 RPM
3.Which Type Of Gearbox to be Selected ? Two Stage Helical Bevel
Problem Statement: Design a Two stage Helical-Bevel Gearbox which is used in

Airport Luggage Conveyors where Input Speed is 1440 rpm , Output Speed is 200
rpm and Power requirement is 3 HP .

Gear Box Design
S P DHAVANE Mechanical MIT AOE Courtesy : PSG DESIGN DATA BOOK

Gear Box Design
S P DHAVANE Mechanical MIT AOE Courtesy : PSG DESIGN DATA BOOK

Lab 5
Machine Design LAB
Gear Box Design
Material Selection & Force Analysis
Sachin Dhavane Amit Belvekar-Patil

EXTRA READING SECTION
Page Number 671 in V B BHANDARI (VBB)

Type of Shaft layout Speed Input Speed Cost
gear reduction and
Power to be
transmitted
Spur Parallel 6:1 (10:1) Low and Cheap
medium speed est
Helical Parallel 6:1 (10:1) High speed Costlie
power r
transmission
Bevel 1:1 (3:1) Low speed Costlie
Perpendicular r
Worm 60:1 (100:1) Low speed Costlie
Perpendicular r
and non-
intersecting

Gear Box Design Selection Of Material for Gears
Selection of Material is based on Gear Ratio in each stage
Page Number 8.4 in Design Data Book (DDB)
i  2 7.2  2.68
Courtesy : PSG DESIGN DATA BOOK

i  2 7.2  2.68 <4
# Select Material for Pinion is C45 & For Wheel C35Mn75

Find
# Find Properties of C45 & C35Mn75 Sut: Ultimate Tensile Strength,
Syt: Yeild Strength,
Page Number 1.10-1.12 in Design Data Book (DDB)
BHN: Brienel Hardness Number
For C45
Sut  700 N / mm 2
Syt  380 N / mm 2

# Find Properties of C45 & C35Mn75

Page Number 1.10-1.12 in Design Data Book (DDB)
For C35Mn75
Sut  700 N / mm 2
Syt  400 N / mm 2

# Find Properties of C45 & C35Mn75 Find Hardness
Page Number 1.9 & 1.13 in Design Data Book (DDB)
300 For C35Mn75
330 For C45

Gear Box Design Page Number 8.4 in Design Data Book (DDB)

Rough Force Analysis
I Stage
1440 RPM
II Stage

Force Analysis

Force Analysis
DRIVING
P
Ft 
V
d p n p
V
60 x 1000
d g n g
V
60 x 1000 DRIVEN
Fr  Ft tan φ
F  FT2  FR2
Force Analysis

Force analysis of Helical gear Page Number 699 in V B BHANDARI (VBB)
øn Fr Fa
øt Ѱ
Ft 900
900 Ѱ
Mr. Sachin Dhavane Assistant Professor Mech Engg

Forces on gear tooth
Fn
Fr
øn
øt Ѱ
Fa
Ft

EXTRA READING SECTION
Page Number 707 V B BHANDARI (VBB)

Magnitude of forces in Helical gear
Tangential force Ft Radial force Fr
Ft tan n
Ft 
P( KW ) Fr  Ft tan t 
V cos 
Tp Tg
Ft  
dp dg Axial force Fa Fa  Ft tan 
2 2
Resultant force F
F  Ft  Fr  Fa
2 2 2

Direction of Axial force in Helical gear
 Axial component in helical gear is undesirable

 Depends upon
Whether the gear under consideration is driving or driven gear
The hand of helix
Direction of gear
 To find the direction of axial component
Apply hand rule to the driving gear
RH helix
Mr. Sachin Dhavane Assistant Professor Mech Engg Driving gear

Force analysis

Page Number 8.56 in Design Data Book (DDB)

Lab 6
Machine Design LAB
Gear Box Design
Gear Design
Sachin Dhavane

STEP 1 Beam Strength of a Spur Gear Tooth Spur Gear
Step 1: Beam Strength of teeth using Lewis Weaker of Gear & Pinion in bending
equation
Pinion
F  m.b. b .Y
b Gear
( Sut ) p ( Sut ) g
 bp   bg 
3 3
2.87 2.87
Y p  0.484  Yg  0.484 
Zp Zg
 bp .Yp  bg .Yg
 bp .Yp
<  bg .Yg Pinion is weaker in bending Fb  m.b. bp .Yp
 bp .Yp
>  bg .Yg Gear is weaker in bending Fb  m.b. bg .Yg
STEP 2 Wear Strength of a Spur Gear Tooth Spur Gear
Step 2: Wear strength Maximum tangential load gear tooth can take without wear/pitting failure
Fw  d p b.Q.K
dp= Pitch Circle Diameter of pinion d p  m.Z p
in mm
2Z g
Q=Ratio factor for external gear Q
(Z g  Z p )
pair
2
K= load stress factor N/mm2  BHN  When Pinion & Gear made with Steel- Steel
K  0.16 
 100 
2
 BHN 
K  0.18 When Pinion & Gear made with Steel- Cast Iron
 100 
2
 BHN  When Pinion & Gear made with Cast Iron- Cast Iron
K  0.21
 100 
Q=Ratio factor for Internal gear pair 2Z g

Q
(Z g  Z p )
STEP 3 Spur Gear
Beam Strength V/s Wear Strength
Fb  σ b bmY Fw  d p b.Q.K
Fb < Fw Gear Pair is weaker in Bending
Fb > Fw Gear Pair is weaker in Pitting

STEP 4 Spur Gear
Ft Tangential Force
Ft max Max Tangential Force
Feff Total Max Tangential Force

STEP 4 Spur Gear
 Maximum Tangential Load F tmax :
 Maximum Tangential Load (Ftmax ) is given by
Ft max  k a K m Ft
Where Ka is Service / Application / Overload factor
Ks Depends upon application
Driving and Driven elements Compressor
Max Torque
Ka 
Rated Torque
Motor
Ka is Service / Application / Overload factor Spur Gear

Spur Gear
Load Distribution Factor/ Load concentration Factor Km

Spur Gear
Calculation Dynamic load (Fd)
Preliminary Estimation Precise Estimation
STEP 4 STEP 5

STEP 4 Preliminary Estimation By Velocity factor Kv: Spur Gear
Ft max K a Ft K m
Feff  
kV KV
3 m 6 m
KV  V  10 KV  V  20
3 V s 6 V s
3 .6 m
KV  20  V  25
3 .6  V s
Module  m
5 .6 m
KV  25  V  30
5 .6  V s
STEP 5 Precise Estimation By Buckinghams Equation Fd:
Spur Gear
• According to Buckingham Approach Fd is given by
21V bC  Ft max 

Fd 
21V  bC  Ft max 
ke  E p Eg 
C   ke  
 1  E E  C =Deformation factor
  1  p g 
E E 
 p g 
K is constant, depends on tooth
E =modulus of Elasticity form
K=0.107 -14.50
K =tooth Form factor
K=0.111 - 200 Full depth
e = Combined Tooth Error K=0.115 - 200 stub
STEP 5 C =Deformation factor Spur Gear
ke  E p Eg 
C   ke   e = Combined Tooth Error
 1  E E 
  1  p g 
E E  e = ep + eg
 p g 

Spur Gear
STEP 5
e = ep + eg

STEP 5 Spur Gear
 Effective Load on Gear Tooth
 Actual Load on gear tooth to transmit power
 Tangential Load + Dynamic Load
Effective Load Feff
Tangential Load Dynamic Load

Ftmax Fd
Feff  Ftmax  Fd
STEP 6 Design Check Check the Safety of gear Pair Spur Gear
Check the Safety Against bending failure
In order to avoid the bending failure Fb > Feff

By Considering the FOS Fb  N f Feff
In order to avoid the Pitting failure Fw > Feff

By Considering the FOS Fw  N f Feff
Gear Design Spur Gear
STEP 1 Beam Strength
Helical Gear
STEP 2 Wear Strength

Bevel Gear
STEP 3 Beam Strength V/s Wear Strength
STEP 4 Preliminary Estimation By Velocity factor Kv:
STEP 5 Precise Estimation By Buckinghams Equation Fd:
STEP 6 Design Check

GearBox Design
Helical -Spur Gearbox

STEP 1 Gear Pair for I & II Stage
Helical -Helical Gearbox
STEP 2 Shaft & Key Design (I , II , III Shaft)

Helical -Bevel Gearbox
STEP 3 Bearing Selection for I , II, III Shafts

Bevel-Helical Gearbox
STEP 4 Casing Design (Upper Casing + Lower Casing)
STEP 5 Selection of Standard Parts in Gearbox
STEP 6 Final Drawing Preparation

Gear Box Design
Problem Definition Helical -Bevel Gearbox
1.What is Application ? Airport Luggage Conveyors
Input Power 3 HP
I/P Speed 1440 RPM
O/P Speed 200 RPM
3.Which Type Of Gearbox to be Selected ? Two Stage Helical Bevel
Problem Statement: Design a Two stage Helical-Bevel Gearbox which is used in

Airport Luggage Conveyors where Input Speed is 1440 rpm , Output Speed is 200
rpm and Power requirement is 3 HP .

Sample Problem For Gears
A spur pinion having 21 teeth to be made of plain carbon steel 55C8 ( Sut=720 N/mm2) is to mesh
with a gear to be made of plain carbon steel 40C8 ( Sut=580 N/mm2).The gear pair is required to
transmit 22 KW power from an IC engine running at 1000 rpm to a machine running at 300 rpm.
The starting torque required is 200% of rated torque while the load distribution factor is 1.5. The
factor of safety required is 1.5. The face width is ten times module and tooth system is 20 full
depth involute. The gears are to be machined to meet the specifications of grade 6. The gear and
pinion are to be case hardened to 400 BHN and 450 BHN resp. The deformation factor C for gear
pair is 11500e N/mm. Design the gear pair by using dynamic factor Kv= 6/6+v and the
buckingham’s equation for dynamic load.

STEP 1 Gear Pair for I & II Stage Input Power I/P Speed O/P Speed
Power Ka FOS Kv
Km
Gear Pinion
Material Gear Ratio G Material C  Deformation or Dynamic factor
e = Combined Tooth Error

S ut gear S ut pinion
Facewidth & Module Relation

S yt Gear
S yt pinion
Type of standard Tooth System
BHN gear BHN pinion
Grade to which the Gears are Manufactured
Zg Zp
Helix Angle in Case of Helical Gears
Ng Np
Ka is Service / Application / Overload factor Page Number 707 in V B BHANDARI (VBB)

Kv Velocity Factor Spur Gear Helical Gear
Bevel Gear


Type of standard Tooth System
Zp
Zp
Zp
Page Number 653-654 in V B BHANDARI (VBB)

C  Deformation or Dynamic factor
Page Number 8.53 in PSG DESIGN DATA BOOK (DDB)

C  Deformation or Dynamic factor Page Number 680 in V B BHANDARI (VBB)
e = Combined Tooth Error
ke  E p Eg 
C   ke  
 1  E E 
1
    p g 
E 
 p Eg 

Helix Angle in Case of Helical Gears

FOS
Page Number 707 in PSG DESIGN DATA BOOK (DDB)

Machine Design LAB

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Machine Design LAB

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Machine Design LAB

Gear Box Design

S P DHAVANE Mechanical MIT AOE

2.What are Operating Parameters ?

3.Which Type Of Gearbox to be Selected ?

S P DHAVANE Mechanical MIT AOE

S P DHAVANE Mechanical MIT AOE Courtesy : NORD DRIVE SYSTEMS

1.Where is Gearbox in That Application ?

Courtesy : NORD DRIVE SYSTEMS

2.Operating Parameters Gearbox ?

What is Speed / Velocity Requirements of Conveyor Belt ..? 1. O/P Speed

What is Max. Load to be Handled by Conveyor ..?

S P DHAVANE Mechanical MIT AOE

2.Operating Parameters Gearbox ?

What is Speed / Velocity Requirements of Conveyor Belt ..? 1. O/P Speed

S P DHAVANE Mechanical MIT AOE

1440 RPM GEAR +PINION= GEAR PAIR

2. Power Required. 2.8 HP

S P DHAVANE Mechanical MIT AOE

Spur Gears Helical Gears Helical Gears

Parallel Shaft Parallel +Perpendicular Shaft

Type of Shaft layout Speed Input Speed and Cost

Bevel Perpendicular 1:1 (3:1) Low speed Costlier

Worm Perpendicular 60:1 (100:1) Low speed Costlier

Worm & Worm Wheel Gears

Total Speed Reduction Ration of Gearbox ?

Speed Reduction Ration of Each Stage ?

In a Multi Stage Gearbox , Single Stage Should Not Exceed 6:1

1.What is Application ? Airport Luggage Conveyors

O/P Speed 200 RPM

3.Which Type Of Gearbox to be Selected ? Two Stage Helical Bevel

Problem Statement: Design a Two stage Helical-Bevel Gearbox which is used in

S P DHAVANE Mechanical MIT AOE

S P DHAVANE Mechanical MIT AOE Courtesy : PSG DESIGN DATA BOOK

S P DHAVANE Mechanical MIT AOE Courtesy : PSG DESIGN DATA BOOK