Overview - Unit 4

Unit 4
Over view Design of Transmission System
Procedure for Gear box Design (method 1)

1. From the given problem
a) Decide the amounted of power to be transmitted
b) Motor Speed
c) Maximum and minimum speed
d) Number of speed required
2. Calculate the Required diff Speed of gear box
a)
Find the progression ratio () =(Nmax/Nmin) 1/r-1
Where
Nmax =Maximum speed of gear box
Nmin =Minimum speed of gear box
r = Number of speed required
Case 1
Find out whether multiples of ratio 1.06(refer PSG data book P.NO.7.20)
To take the value from R40 series. Skipping S -1 speed
Where S No of multiples
Example
=1.32
1.06 X (1.06 x 1.06 x 1.06 x1.06) =1.32
To take the value from R40 series.Skipping 4 speed
Case 2
Case 3
Case 4
Case 5
If not satisfactory above conditions
Find the speed
(N min, Nmin x 2-1 ,Nmin x 3-1,N min x 4-1.. ,N min x r-1)
3. To form the structural formula [ Z (X) ]
To spilt value of No of required speed into multiple of 2 & 3
Exmple
(Z =P1, P2, P3 ..)
a) No of Speed Required is 9 = 3 3
b) No of Speed Required is 8 = 2 2 2
c) No of Speed Required is 12 = 2 2 3
Z (X) = P1(X1) P2(X2) P3(X3) .
Where X1 =1, X2 =P1,X3 =P1P2 ..
Example
No of Speed required are 9
Z=3X3
Z (X) =3(1) 3(3)
4. To find the number of shaft based on No of stage
Number of shaft = Number of stage + 1
Example
Prepared by Mr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology
Unit 4
Z (X) = 3(1) 3(3)
From 3(1) is first stage, 3(3) is second stage
Number of shaft = 2 + 1 = 3
5. To draw a kinematic diagram
From structural formula to draw kinematic diagram
Z (X) = P1(X1) P1(X1) P1(X1)
P= number pair gear required at the stage (or) number of out speed between at the
stage
X = Intervals between the point
Example
Z (X) = 3(1) 3(3)
Stage 1
3(1) Number of gear pair required is 3 Between Shaft -1 and Shaft - 2
Stage 2
3(3) Number of gear Pair required is 3 Between Shaft -2 and Shaft - 3
6. To draw a Ray diagram
Z (X) = P1(X1) P2(X2) P3(X3)
P= number pair gear required at the stage (or) number of out speed between at the stage
Unit 4
Shaft 3
a) To find the No of points on the shaft
No of points on shaft =No of Pair Gear between the Shaft
Example: -No of pair Gear is (P) = 3 for Stage 2
b) To Mark a point A at lower speed of Gear box
c) To Mark a Point B from the point A in the Interval of (X2=3)
d) To Mark a Point C from the point B in the Interval of (X2=3)
Shaft 2
a) To find the No of points on the shaft
Example: - No of pair Gear is (P) = 3 for Stage 1
b) To take any speed of on ray diagram (N input )
And check
N max
2
N input
N min
1/4
N input
Example
(1)
(2)
Nmax =C
Nmin =A
Ninput =D
c) To Mark a point D (N
inpu
t)at lower speed of Gear box
Unit 4
d) To Mark a Point E at from the point of D and Interval of (X1=1)
e) To Mark a Point F at from the point of E and Interval of (X1=1)
To complete the Ray diagram
a) To draw parallel
b) To draw parallel
c) To draw parallel
Similarly
d) To draw parallel
e) To draw parallel
f) To draw parallel
7. Calculate No of teeth
Stage 2
line Parallel to DA from the point at E

line Parallel to DB from the point at E
line Parallel to DC from the point at E
line Parallel to DA from the point at F
line Parallel to DB from the point at F
line Parallel to DC from the point at F
Unit 4
To select the speed of n7,n8,n9,n10,n11,n12 from Diagram

Ex
Lower Input Speed of Shaft (3) or Lower out speed of shaft (2) = n7,n9,n11 = N5
Out speed of Shaft (3) = n8,n10,n12 = N1,N4,N7
Pair 1 -(Take First Lower Speed -DA line)
Z 7 n8
=
Z 8 n7
Take Z7 = 20 (assume)
Pair 2 - (Take Second Lower Speed -DB line)
Since center distance same, the total number of teeth of engaging pair equal
Z7+Z8 = Z9+Z10= Z11+Z12
Z9+Z10= Z11+Z12----------------(1)
Z 9 n10
=
Z 10 n9
-------------------------- (2)
To solve 1 & 2 We get Z9 ,Z10

Pair 3 - (Take Second Lower Speed -DC line)
Z7+Z8 = Z9+Z10= Z11+Z12
Z7+Z8= Z11+Z12----------------(1)
Z 7 n8
=
Z 8 n7
-------------------------- (2)
[Stage 1]
Unit 4
To select the speed of n1, n2, n3, n4, n5, n6 from Diagram
Example:Lower Input Speed of Shaft (3) or Lower out speed of shaft (2) = n 1,n3,n5 = N( motor out
speed)
Ex
Pair 1 - (Take First Lower Speed -GD line)
Z1 n2
=
Z2 n1
Take Z1 = 20 (assume)
Z1+Z2 = Z3+Z4= Z5+Z6
Z1+Z2= Z3+Z4----------------(1)
Z 3 n4
=
Z 4 n3
-------------------------- (2)

Z1+Z2 = Z3+Z4= Z5+Z6
Z1+Z2= Z5+Z6----------------(1)
Unit 4
Z 5 n6
=
Z 6 n5
-------------------------- (2)
8. To calculate Module
a) To take lowest speed of gear box (n)
b) To find the torque (based on Power)
P =2nT/60
Where
n Speed (rpm)
P Power (W)
T Torque (N-m)
c) To find the tangential force in terms of m
Torque = Tangential force x perpendicular distance (Radius)

T = Ft x r
Where
r=Zm /2
Z=number of teeth on gear (Z12 -lowest gear)
m = module
d) To find the module (m)
m=
Where
Ft
m M
m =b/m=10 (assume)
M = Material constant
= 100 for 40 Ni2 Cr1 Mo 28
=80 for 15 Ni2 Cr1 Mo 15
= 30, for C45

To take standard module value in PSG Data book (refer PSG data book P.NO.8.2)
9. To find b
m =b/m=10
10. To find center distance(refer PSG data book P.NO.8.22)
a) Center distance in stage 1(a1)
a1=
z1 + z 2
z +z
z +z
m= 3 4 m= 5 6 m
2
2
2
) (
) (
b) Center distance in stage 2(a2)

Unit 4
a1=
( z +2 z ) m=( z +2z ) m=( z +2 z )m

7
10
11
12
Procedure for Gear box Design (method 2)

1. From the given problem
e) Decide the amounted of power to be transmitted
f) Motor Speed
g) Maximum and minimum speed
h) Number of speed required
2. Calculate the Required diff Speed of gear box
b)
Find the progression ratio () =(Nmax/Nmin) 1/r-1
Where
Nmax =Maximum speed of gear box
Nmin =Minimum speed of gear box
r = Number of speed required
c) N1 = N min
N2 = N min x 2- 1
N3 = N min x 3-1
N4 = N min x 4-1
N5 = ..
Nr = N min x r-1
*Note (select the standard value in PSG Data book Page No: 7.20 & R20 series)
3. To form the structural formula [ Z (X) ]
To spilt value of No of required speed into multiple of 2 & 3
Exmple
(Z =P1, P2, P3 ..)
d) No of Speed Required is 9 = 3 3
e) No of Speed Required is 8 = 2 2 2
f) No of Speed Required is 12 = 2 2 3
Z (X) = P1(X1) P2(X2) P3(X3) .
Where X1 =1, X2 =P1,X3 =P1P2 ..
Example
No of Speed required are 9
Z=3X3
Z (X) =3(1) 3(3)
Unit 4
4. To find the number of shaft based on No of stage
Number of shaft = Number of stage + 1
Example
Z (X) = 3(1) 3(3)
From 3(1) is first stage, 3(3) is second stage
Number of shaft = 2 + 1 = 3
5. To draw a kinematic diagram
Z (X) = P1(X1) P1(X1) P1(X1)
P= number pair gear required at the stage (or) number of out speed between at the
stage
Example
Z (X) = 3(1) 3(3)
Stage 1
3(1) Number of gear pair required is 3 Between Shaft -1 and Shaft - 2
Stage 2
3(3) Number of gear Pair required is 3 Between Shaft -2 and Shaft - 3
6. To draw a Ray diagram
Z (X) = P1(X1) P2(X2) P3(X3)
P= number pair gear required at the stage (or) number of out speed between at the stage
Unit 4
Shaft 3
e) To find the No of points on the shaft
f) To Mark a point A at lower speed of Gear box
g) To Mark a Point B from the point A in the Interval of (X2=3)
h) To Mark a Point C from the point B in the Interval of (X2=3)
Shaft 2
f) To find the No of points on the shaft
g) To take any speed of on ray diagram (N input )
And check
N max
2
N input
N min
1/4
N input
Example
(1)
(2)
Nmax =C
Nmin =A
Ninput =D
Unit 4
h) To Mark a point D (N input)at lower speed of Gear box
i) To Mark a Point E at from the point of D and Interval of (X1=1)
j) To Mark a Point F at from the point of E and Interval of (X1=1)
To complete the Ray diagram
g) To draw parallel line Parallel to DA from the point at E

h) To draw parallel line Parallel to DB from the point at E
i) To draw parallel line Parallel to DC from the point at E
Similarly
j) To draw parallel line Parallel to DA from the point at F
k) To draw parallel line Parallel to DB from the point at F
l) To draw parallel line Parallel to DC from the point at F
7. Selection of material(refer PSG data book P.NO.8.4 & 8.5)
To take Value of Permissible bending stress [b] &Permissible contact stress [c] from PSG
data book P.NO.8.4 ( If not given assume Material)
8. Calculate Young Modulus(E) (refer PSG data book P.NO.8.14 and Table 9)
9. To calculate torque[Mt] (approximate value)(refer PSG data book P.NO.8.15)
[Mt] =Mtkd k
kd k = 1.3 (assume)
P =2n1Mt/60 => Mt =P*60 /2*3.14*n1
P power in W,n1 speed in RPM
10. Calculate No of teeth on Gear Z7,Z8,Z9,Z10,Z11,Z12[Stage 2]
Unit 4

Ex
Pair 1 - (Take First Lower Speed -DA line)
(i)Calculate center distance between shaft (2) and Shaft (3)
Center distance (a) (refer PSG data book P.NO.8.13 and Table 8)
c
t
M
a= (i+1)
2

0.74
i Speed ratio =nmax/nmin

nmax =Maximum speed Between n12 and n11
nmin =Minimum speed Between n12 and n11
E Equivalent youngs modulus (refer PSG data book P.NO.8.14 and Table 9)
- To select value in table 10 (refer PSG data book P.NO.8.14)
(ii)To calculate module (m) (refer PSG data book P.NO.8.13A and Table 8)
M
[ t]
y [ b ] m Z
m=1.26 3
m 10 (Assume)
Unit 4
Z = 20 (Assume)
y = 0.389 for Z = 20 & X=0 (refer PSG data book P.NO.8.18 and Table 18)
To take standard module value (refer PSG data book P.NO.8.2)
(iii)To Calculate No of teeth on Gear Pair (Z
2a
Z 11 =
m(i +1)
11
& Z12) (refer PSG data book P.NO.8.22)
Z 12=i Z 11
(iiI) To Revise the center distance module (a) (refer PSG data book P.NO.8.22)
a=m
Z 1 + Z2
2

Z7+Z8 = Z9+Z10= Z11+Z12
Z9+Z10= Z11+Z12----------------(1)
Z 9 n10
=
Z 10 n9
-------------------------- (2)

Z7+Z8 = Z9+Z10= Z11+Z12
Z7+Z8= Z11+Z12----------------(1)
Z 7 n8
=
Z 8 n7
-------------------------- (2)
11. Calculate No of teeth on Gear Z1,Z2,Z3,Z14,Z5,Z6 [Stage 1]
Unit 4
To select the speed of n1, n2, n3, n4, n5, n6 from Diagram
Example:Lower Input Speed of Shaft (3) or Lower out speed of shaft (2) = n 1,n3,n5 = N( motor out
speed)
Ex
Pair 1 - (Take First Lower Speed -GD line)
(i)Calculate center distance between shaft (1) and Shaft (2)
Center distance (a) (refer PSG data book P.NO.8.13 and Table 8)
c
t
M
a= (i+1)
2

0.74
Unit 4
i Speed ratio =nmax/nmin
nmax =Maximum speed Between n12 and n11
nmin =Minimum speed Between n12 and n11
E Equivalent youngs modulus (refer PSG data book P.NO.8.14 and Table 9)
- To select value in table 10 (refer PSG data book P.NO.8.14)
(ii)To calculate module (m) (refer PSG data book P.NO.8.13A and Table 8)
M
[ t]
y [ b ] m Z
m=1.26 3
m 10 (Assume)
Z = 20 (Assume)
y = 0.389 for Z = 20 & X=0 (refer PSG data book P.NO.8.18 and Table 18)
(iii)To Calculate No of teeth on Gear Pair (Z 1& Z2) (refer PSG data book P.NO.8.22)
Z 1=
2a
m(i+1)
Z 2=i Z 1
(iiI) To Revise the center distance module (a) (refer PSG data book P.NO.8.22)
a=m
Z 1 + Z2
2

Z1+Z2 = Z3+Z4= Z5+Z6
Z1+Z2= Z3+Z4 ----------------(1)
Z 3 n4
=
Z 4 n3
-------------------------- (2)

Z1+Z2 = Z3+Z4= Z5+Z6
Z1+Z2= Z5+Z6 ----------------(1)
Z 5 n6
=
Z 6 n5
-------------------------- (2)
12. To calculate induced stresses

(To take lowest center distance and corresponding high speed ratio of pair gear in that
stage)
Unit 4
Induced bending stresses (b)
b =0.7
i+1
[M t ] (Refer PSG data book P.NO.8.13)
amby
And check permissible value

Induced contact stress stresses (c)
c =0.7
i+1 i+1
E [M t ] (Refer PSG data book P.NO.8.13)
a
ib
And check permissible value

Overview - Unit 4

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Overview - Unit 4

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Unit 4

Over view Design of Transmission System

Procedure for Gear box Design (method 1)

t)at lower speed of Gear box

line Parallel to DA from the point at E

To select the speed of n7,n8,n9,n10,n11,n12 from Diagram

To solve 1 & 2 We get Z9 ,Z10

To solve 1 & 2 We get Z3 ,Z4

Torque = Tangential force x perpendicular distance (Radius)

= 30, for C45

b) Center distance in stage 2(a2)

( z +2 z ) m=( z +2z ) m=( z +2 z )m

Procedure for Gear box Design (method 2)

g) To draw parallel line Parallel to DA from the point at E

To select the speed of n7,n8,n9,n10,n11,n12 from Diagram

i Speed ratio =nmax/nmin

& Z12) (refer PSG data book P.NO.8.22)

Pair 2 - (Take Second Lower Speed -DB line)

To solve 1 & 2 We get Z9 ,Z10

11. Calculate No of teeth on Gear Z1,Z2,Z3,Z14,Z5,Z6 [Stage 1]

Pair 2 - (Take Second Lower Speed -DB line)

Pair 3 - (Take Second Lower Speed -DC line)

12. To calculate induced stresses

And check permissible value

And check permissible value

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