Mechanical Design (2) Formula Sheet Dr.

Ahmed Sobhi

Formula
Sheet
Final Exam version – Fall’23

Page 1 of 4 Best of luck to all

Mechanical Design (2) Formula Sheet Dr. Ahmed Sobhi
Spur Gear • Wear Tooth Load • Load-stress factor (material combination factor)
• Power transmitted: 𝑾𝒘 = 𝑫 × 𝒃 × 𝑸 × 𝑲
𝑾𝒕 × 𝒗 (𝝈𝒆𝒔 )𝟐 × 𝐬𝐢𝐧 ∅𝑵 𝟏 𝟏
𝑷= 𝑲= ( + )
𝑪𝒔 • Ratio factor 𝟏. 𝟒 𝑬𝒑 𝑬𝑮
• Module: 𝟐 × 𝑻𝑮 • Normal pressure angle
𝑫𝒑 𝑫𝒈 𝑸=
𝒎= = 𝑻𝑮 + 𝑻𝒑 𝐭𝐚𝐧 ∅𝑵 = 𝐭𝐚𝐧 ∅ × 𝐜𝐨𝐬 𝜶
𝑻𝒑 𝑻𝒈 • Load-stress factor (material combination factor)
• Circular Pitch:
(𝝈𝒆𝒔 )𝟐 × 𝐬𝐢𝐧 ∅ 𝟏 𝟏
𝝆𝒄 = 𝝅 × 𝒎 =𝝅×
𝑫𝒑
= 𝝅×
𝑫𝒈 𝑲= ( + ) Bevel Gear
𝑻𝒑 𝑻𝒈 𝟏. 𝟒 𝑬𝒑 𝑬𝑮
• Proportions for Bevel Gears
• Diametral Pitch:
𝑻 Addendum, a= 1m
𝝆𝒅 =
𝑫
Helical Gear
• Normal pitch Dedendum, d = 1.2 m
• Gear Ratio:
“For reduction” 𝝆𝑵 = 𝝆𝒄 × 𝐜𝐨𝐬 𝜶 Clearance = 0.2 m
• Face width “b” Working depth = 2 m
𝒊𝒏𝒑𝒖𝒕 𝑵𝒑 𝑫𝒈 𝑻𝒈
𝑽𝑹 = 𝑮𝑹 = = = = ✓ Minimum face width
𝒐𝒖𝒕𝒑𝒖𝒕 𝑵𝒈 𝑫𝒑 𝑻𝒑 Thickness of tooth = 1.5708 m
𝟏. 𝟏𝟓 × 𝝆𝒄
• Minimum number of teeth on the pinion
𝒃𝒎𝒊𝒏 =
𝐭𝐚𝐧 𝜶 • Main dimensions for Bevel Gears
𝟐 ✓ Maximum face width
𝑻𝒑 = Dd = DP - 2 d cos θP
𝟏 𝟏 bmax = 12.5 m to 20 m
𝑮𝑹 [√𝟏 + ( + 𝟐) 𝒔𝒊𝒏𝟐 ∅ − 𝟏] DO = DP + 2 a cos θP
𝑮𝑹 𝑮𝑹
bmax = (20 m to 30 m) … “In case of double helical or herringbone gears” • Pitch Angle for Bevel Gears “When the angle between the shaft axes (𝜽𝒔) is 90o”
• Centre Distance
𝑫𝒑 + 𝑫𝒈 • Velocity factor 1
𝑪𝒅 = 𝟔 𝜃𝑃1 = tan−1 ( )
𝟐 𝑪𝒗 = , for peripheral velocities from 5 m/s to 10 m/s. 𝑉. 𝑅
𝟔+𝒗
• Lewis Bending Equation 𝜃𝑃2 = tan−1(𝑉. 𝑅)
𝟏𝟓
𝑾𝒕 = 𝝈𝒘 × 𝒃 × 𝝅 × 𝒎 × 𝒚 = (𝝈𝒐 × 𝑪𝒗 ) × 𝒃 × 𝝅 × 𝒎 × 𝒚 𝑪𝒗 = , for peripheral velocities from 10 m/s to 20 m/s.
𝟏𝟓+𝒗 • Forces Acting on a Bevel Gear
𝟎.𝟕𝟓
• “Lewis form factor” or “tooth form factor” 𝑪𝒗 = , for peripheral velocities greater than 20 m/s. WT = WN cos φ,
𝟎.𝟕𝟓+√𝒗
𝟎.𝟔𝟖𝟒 1o 𝟎.𝟕𝟓 WR = WN sin φ = WT tan φ
𝒚 = 𝟎. 𝟏𝟐𝟒 − for 14 full depth involute system. 𝑪𝒗 = + 𝟎. 𝟐𝟓 , for non-metallic gears.
𝑻 2 𝟏+𝒗 WRH = WR sin θP = WT tan φ . sin θP “axial force”
𝟎.𝟗𝟏𝟐
𝒚 = 𝟎. 𝟏𝟓𝟒 − for 20 o full depth involute system. • Formative or Equivalent Number of Teeth WRV = WR cos θP = WT tan φ. cos θP
𝑻
𝑻 • Modified Lewis Bending Equation
𝟎.𝟖𝟒𝟏 𝑻𝑬 =
𝒚 = 𝟎. 𝟏𝟕𝟓 − for 20 o stub involute system. 𝑪𝒐𝒔𝟑 𝜶 𝑳−𝒃
𝑻
𝑾𝒕 = (𝝈𝒐 × 𝑪𝒗 ) × 𝒃 × 𝝅 × 𝒎 × 𝒚′ × ( )
• Velocity factor • Modified Lewis Bending Equation 𝑳
𝟑
𝑪𝒗 = , for ordinary cut gears operating at velocities upto 12.5 m/s. 𝑾𝒕 = 𝝈𝒘 × 𝒃 × 𝝅 × 𝒎 × 𝒚′ = (𝝈𝒐 × 𝑪𝒗 ) × 𝒃 × 𝝅 × 𝒎 × 𝒚′ • “Lewis form factor” or “tooth form factor”
𝟑+𝒗
𝟎.𝟔𝟖𝟒 1o
𝟒.𝟓 • “Lewis form factor” or “tooth form factor” 𝒚′ = 𝟎. 𝟏𝟐𝟒 − for 14 full depth involute system.
𝑪𝒗 = , for carefully cut gears operating at velocities upto 12.5 m/s. 𝑻𝑬 2
𝟒.𝟓+𝒗 𝟎.𝟔𝟖𝟒 1
′
𝒚 = 𝟎. 𝟏𝟐𝟒 − for 14 o full depth involute system. 𝟎.𝟗𝟏𝟐
𝑪𝒗 =
𝟔
, for very accurately cut and ground metallic gears operating at
𝑻𝑬 2 𝒚′ = 𝟎. 𝟏𝟓𝟒 − for 20 o full depth involute system.
𝑻𝑬
𝟔+𝒗 𝟎.𝟗𝟏𝟐
𝒚′ = 𝟎. 𝟏𝟓𝟒 − for 20 o full depth involute system. 𝟎.𝟖𝟒𝟏
velocities upto 20 m/s. 𝑻𝑬 𝒚′ = 𝟎. 𝟏𝟕𝟓 − for 20 o stub involute system.
𝑻𝑬
𝟎.𝟕𝟓 𝟎.𝟖𝟒𝟏
𝑪𝒗 =
𝟎.𝟕𝟓+√𝒗
, for precision gears cut with high accuracy and operating at 𝒚′ = 𝟎. 𝟏𝟕𝟓 − for 20 o stub involute system. • Velocity factor
𝑻𝑬

velocities upto 20 m/s. 𝟑

• Dynamic load 𝑪𝒗 = , for teeth cut by form cutters.
𝟑+𝒗
𝟎.𝟕𝟓 𝟐𝟏 × 𝒗 × (𝒃 × 𝑪 × 𝒄𝒐𝒔𝟐 𝜶 + 𝑾𝒕 ) × 𝐜𝐨𝐬 𝜶 𝟔
𝑪𝒗 = + 𝟎. 𝟐𝟓 , for non-metallic gears. 𝑾𝑫 = 𝑾𝒕 + 𝑪𝒗 = , teeth generated with precision machines.
𝟏+𝒗 𝟔+𝒗
𝟐𝟏 × 𝒗 + √𝒃 × 𝑪 × 𝒄𝒐𝒔𝟐 𝜶 + 𝑾𝒕 • Cone distance
• Buckingham equation “Dynamic load” • Static Tooth Load
𝟐𝟏 × 𝒗 × (𝒃 × 𝑪 + 𝑾𝒕 ) 𝑫𝑮 𝟐 𝑫𝑷 𝟐
𝑾𝒔 = 𝝈𝒆 × 𝒃 × 𝝅 × 𝒎 × 𝒚′ 𝑳 = √( ) +( )
𝑾𝑫 = 𝑾𝒕 + 𝟐 𝟐
𝟐𝟏 × 𝒗 + √𝒃 × 𝑪 + 𝑾𝒕 • Wear Tooth Load • Dynamic load
• Static Tooth Load 𝑫×𝒃×𝑸×𝑲 𝟐𝟏 × 𝒗 × (𝒃 × 𝑪 + 𝑾𝒕 )
𝑾𝒔 = 𝝈𝒆 × 𝒃 × 𝝅 × 𝒎 × 𝒚 𝑾𝒘 = 𝑾𝑫 = 𝑾 𝒕 +
𝒄𝒐𝒔𝟐 𝜶 𝟐𝟏 × 𝒗 + √𝒃 × 𝑪 + 𝑾𝒕

Page 2 of 4 Best of luck to all

Mechanical Design (2) Formula Sheet Dr. Ahmed Sobhi
• Static Tooth Load
• Maximum Tension in the Belt
𝑳−𝒃 • Table (1): Standard Proportions of Gear Systems:
𝑾𝒔 = 𝝈𝒆 × 𝒃 × 𝝅 × 𝒎 × 𝒚′ × ( )
𝑳 𝑻 = 𝝈. 𝒃. 𝒕
• Wear Tooth Load
𝑫×𝒃×𝑸×𝑲
𝑾𝒘 =
𝐜𝐨𝐬 𝜽𝑷 Chain Drive
• Ratio factor • Pitch circle diameter of chain sprocket
𝟐 × 𝑻𝑬𝑮
𝑸= 𝝆
𝑻𝑬𝑮 + 𝑻𝑬𝒑 𝑫=
𝟏𝟖𝟎
• Load-stress factor (material combination factor) 𝒔𝒊𝒏 ( )
𝑻
(𝝈𝒆𝒔 )𝟐 × 𝐬𝐢𝐧 ∅ 𝟏 𝟏
𝑲= ( + ) • Velocity of the chain
𝟏. 𝟒 𝑬𝒑 𝑬𝑮
𝝅𝑫𝑵 𝑻𝝆𝑵
• Formative or Equivalent Number of Teeth 𝒗= =
𝟔𝟎 𝟔𝟎
𝑻 • Table (2): Minimum number of teeth on the pinion
𝑻𝑬 =
𝐜𝐨𝐬 𝜽𝑷 • Length of Chain
𝑻𝟏 +𝑻𝟐 𝟐𝒙 𝑻𝟐 −𝑻𝟏 𝟐 𝝆
𝑳 = 𝑲. 𝝆 𝑲= + +[ ]
𝟐 𝝆 𝟐𝝅 𝒙
Belt Drive • Factor of Safety
𝑾𝑩
• Velocity Ratio “thickness and slipping of the belt are considered.” Factor of safety =
𝑾
𝑵𝟐 𝒅𝟏 + 𝒕 𝒔
= (𝟏 − ) • Table (3): Standard Gear Modules:
𝑵𝟏 𝒅𝟐 + 𝒕 𝟏𝟎𝟎
W = 𝑭𝑻 + 𝑭𝑪 + 𝑭𝑺
• Angle of contact (θ) 𝑷
𝝅 𝑭𝑻 = 𝑭𝑪 = 𝒎. 𝒗2 𝑭𝑺 = 𝒌. 𝒎𝒈. 𝒙
Open Belt Drive 𝜽 = (𝟏𝟖𝟎° − 𝟐𝜶) 𝒓𝒂𝒅 𝒗
𝟏𝟖𝟎
𝝅 k = (2 - 6), when chain drive inclined with angle less than 40º.
Cross Belt Drive 𝜽 = (𝟏𝟖𝟎° + 𝟐𝜶) 𝒓𝒂𝒅
𝟏𝟖𝟎 k = (1 – 1.5), when chain drive inclined with angle greater than 40º.
• Length of Belt Drive

Open Belt Drive

𝝅
𝑳 = (𝒅𝟏 + 𝒅𝟐 ) + 𝟐𝒙 +
(𝒅𝟏 −𝒅𝟐)𝟐 • Power Transmitted • Table (4): Allowable static stress
𝟐 𝟒𝒙
𝝅 (𝒅𝟏 +𝒅𝟐 )𝟐 𝑾𝑩 × 𝒗
Cross Belt Drive 𝑳 = (𝒅𝟏 + 𝒅𝟐 ) + 𝟐𝒙 + 𝑷=
𝟐 𝟒𝒙 𝒏 × 𝑲𝒔
• Power Transmitted
P = (T1 – T2) 𝒗 𝑲𝒔 = 𝑲𝟏 . 𝑲𝟐 . 𝑲𝟑

• Ratio of Driving Tensions Load factor (K1) = 1, for constant load

𝑻𝟏 = 1.25, for variable load with mild shock
Flat Belt Drive = 𝒆𝝁𝜽
𝑻𝟐 = 1.5, for heavy shock loads
𝝁𝜽 Lubrication factor (K2) = 0.8, for continuous lubrication
𝑻𝟏
Vee Belt Drive = 𝒆 𝒔𝒊𝒏 𝜷
= 1, for drop lubrication
𝑻𝟐
= 1.5, for periodic lubrication
T1 = T – Tc Rating factor (K3) = 1, for 8 hours per day
• Centrifugal tension = 1.25, for 16 hours per day
= 1.5, for continuous service
Tc = m.𝒗2

Page 3 of 4 Best of luck to all

Mechanical Design (2) Formula Sheet Dr. Ahmed Sobhi
• Table (12): Characteristics of roller chains.
• Table (5): Deformation factor (C)
• Table (8): Flexural endurance limit “elastic limit stress” (σe)

• Table (6, 7): Tooth error in action • Table (9): Surface endurance limit • Table (13): Factor of safety (n) for bush roller chains.

• Table (14): Permissible speed of smaller sprocket or pinion in r.p.m.

• Table (10): Service factor:

• Table (15): Power rating (in kW) of simple roller chain.

• Table (11): Dimensions of standard V-belts

• Table (16): Number of teeth on the smaller sprocket.

Page 4 of 4 Best of luck to all