Professional Documents
Culture Documents
Design a pair of helical gears to transit 30 KW power at a speed reduction ratio of 4:1.The input
shaft rotates at 2000 rpm. Take helix and normal pressure angles equal to 25 and 20,
respectively. Both pinion and gear are made of steel. (The following data is given.)
Permissible stress
55 MPa
40 MPa
BHN
340
300
z 1 = 4 30 = 120
1='
'
2
z1
3
cos
z
30
cos3 25
z2
=
cos
120
3
cos 25
30
0.744
= 40.3, say,41
120
0.744
0.912
162
0.912
)
z'
) = 0.4661
Ft =
P 1000
v
d2N
60 1000 =
2
Tangential force,
30 1000
3.141 m =
Ft =
C wear F
Cv
Fmax =
9551
m N
1.25 9551
=
0.35 m
34,110.7
N
m
Since ma = m cos
Fmax =
34,110.7
cos 25 =
ma
30,914.8
N
ma
Fbeam = b m a Y d
= 279.66 m a
For safe design, the beam strength should be greater than or equal to maximum force.
Therefore,
30914.8
ma
= 279.66 ma
OR
ma = 4.8 mm, say, 5 mm
Pitch diameter of the pinion, d 1 =
d2
120 5
cos 25
Z1m
cos
600
0.906
30 5.0
cos 25
= 662 mm
150
0.906 = 165.5 mm
dN
60
Tangential force,
Ft =
9551.0
=
m
= 17.33m/s
9551.0 cos 25
=
5
9551.0 0.906
=
5
1731.23 N
Velocity factor, C v =
15.25
15.25+17.33 = 0.468
Fmax =
1.25 1731.23
= 4624 N
0.468
Fdyn =
K 3 v ( cb cos2 + Ft )cos
K 3 v + cb cos2 + F t
K 3 = constant = 20.67
e
1 1
K 1( + )
1 2
A permissible profile error for 17 m/s velocity is 0.01925. This order of error can be obtained
in class 3 gears with 5 mm module, which gives e =0.015 mm. Thus,
C=
cb cos
+ Ft
= 109.54
Fdyn
= 1731.23
3528757.55
467.75
=1731.23 +
8327.97= 10,059.2 N
For safe design, the endurance strength of the gear should be equal to 1.25 times the dynamic
load for steady load conditions, i.e.
Fen = b m n Y en
1.25 Fdyn
Or
en
1.25 10,059.2
15 5 5 0.4661
2
= 71.93 N/ mm
Therefore,
Core BHN required =
en
1.75
71.93
1.75
= 41.1
d 1 bQK
2
cos
F dyn
'
Q=
2 Z2
'
'
Z 2+ Z 1
2 162
162+ 41
= 1.596
F dyn cos
d 1 bQ
2
10,059.2 cos 25
165.5 75 1.596
10,059.2 0.821
165.5 75 1.596
= 0.417
Also,
K=
1.4
E1 E2
2
Therefore,
2
K=
6
es sin 20
2 0.2 10
6
6
1.4
0.2 10 0.2 10
8258.60
19810.25
2
es
0.0411 106
0.684
es
106
=0.060
2
= 413.15 N/ mm
es +70
2.75
==
413.15+70
2.75
= 175.7
Which is less than the core hardness. Hence there is no need for surface hardening.
A pair of parallel helical gear consists of a 20 teeth pinion of the velocity ratio is 3:1. The
helix angle is 15 and the normal module is 5 mm. Calculate
The pitch circle diameter of the pinion and gear and
The centre distance
ANS :
Zp =20
Helix angle=15
m=5
Zg =3 Zp
=320
=60
1: The pitch circle diameter
For pinion dp =mtzp
Where mt =transverse module
Mt=mn/cos=5/cos15
=5.176mm
Now
dp =mtzp
=5.17620
( dp =103.52 mm)
For gear
dg =mtzg
=5.17660
dg = 310.56 mm
2)Centre distance
a= (dp + d g)/2
= (103.52+310.56)/2
a=207.04 mm
Helical Gears
Example: A pair of helical gears consists of 24 teeth pinion meshing with 72 teeth gear. Normal
pressure angle is 20, and helix angle is 24. The pinion rotates at 720 RPM. Normal module of
gear is 5 mm and face width is 50 mm. Both, pinion and gear are made of steel with ut =
600MPa. Gears are heat treated to a surface hardness of 360 BHN.
What power can be transmitted by gears if service factor is 1.4 and factor of safety is 2? Assume
that velocity factor accounts for the dynamic load.
Solution:
Normal Module, mn = 5mm
Face width, b= 50mm
Helix angle, = 24, cos
= 0.9135
Beam strength, S b = b mn b Y
Allowable bending stress, b
ut
3
= 600/3 = 200MPa
Zp
Zp
3
cos
24
cos3 24
24
0. 7624
= 31.48
= wearing strength =
b d p QK
cos2
( in transverse direction)
d p = pitch circle diameter of pinion
mn
cos
Zp =
2Zg
Z p +Z g
Q = ratio factor =
5 24
cos 24
2 72
72+24
= 120/0.9135 = 131.36 mm
= 1.5
BHN
360
K = 0.16 ( 100 ) = 0.16 ( 100 ) = 2.0736
Sw
50 131 . 36 1 .5 2. 0736
cos 2 24
= 24,478.8 N
Sb < Sw
Power transmission will depend upon beam strength, S b .
Service factor C s = 1.5
Factor of safety, FOS = 2
5.6
5 . 6+ v
Velocity factor, C v =
2 720
60
2 N
60
131 . 36
2
dp
2
1
1000
1
1000
= 4.95m/s
Cv =
5.6
5 . 6+ 4 . 95
Peff = Pt
Cs
Cv
Sb =
5. 6
5 . 6+2 . 22
Pt
Peff
= 4.19 Pt
Pt
1. 5
0. 716
FOS
= 2.095 Pt 2
5.6
7 . 82
= 0.716
= 2.095 Pt
= 20,429/0.8345
=
Power =
18 , 120
4 .19
= 4,324.6N
Pt v Nm
= 4,324.64.95 W
= 21406.7 = 21,406 kW
HELICAL GEAR
A single stage helical gear receiver is to receive is to receive power from a 1440 rpm 25 KW
induction motor. The gear tooth profile is involute full depth width. 20Normal pressure angle
the helix angle is 23.No of teeth on pinion is 20 and the gear ratio is 3.Both the gears are made
of steel with allowable beam stresses of 90Mpa and hardness 250Mpa.
Design the gears for 20% overload carrying capacity from stand point of bending strength and
wear.
If the increment dynamic load of 8 KN is estimate in tangential plane. What will be the safe
power transmitted by the pair at the same speed.
Solution:
Given data:
Power (P) = 25 KW
Hardness = 250Mpa
Zp
= 20
Z g = 60
b
= 90Mpa
= 20
= 23
K = 1.2
BEAM STRENGTH:
Z 'p
Z 'g =
Zp
3
cos
Zg
cos3
= 25.64
= 76.92
Y 'p = 0.484
2 . 87
Z 'p
= 0.372
Y 'g
2 . 87
'
Zg
= 0.447
= 0.484
'
b Y p = 900.372 = 33.48
Now,
Now,
Fb
EFFECTIVE LOAD
mn Z p
dp = m Zp =
cos
d p np
60 ,000
V=
Ft
P
v
25
1 . 638 mn
Cv =
Now
K a = 1.2,
Peff
Fb
mn
3 . 14 1 . 72 1440 mn
60 ,000
Velocity factor,
Again
= 21.72
= 1.638 mn m/sec
15 . 261
KN
mn
5.6
5 . 6+ v
5 .6
5 . 6+ 1 .33 mn
Km = 1
K aK F
Cv
m
15261
1 . 2 1
5 .6+ 1 . 33 mn
(
mn
5.6
= FOS Peff
2
334.8 mn = 2 Peff
3
18312. 86+3771 . 32 mn
334.8 mn = 2
)
(18312. 86+3771. 32 mn )
mn
5
0. 9 2
= 5.435mm
= 20
dp =
mt Z p = 5.435 20 =109 mm
Z g = 60
dg
= mt Z g = 5.43560 = 326mm
ha
= 5 mm
hf
= 1.255 = 6.25 mm
a = + d g )/2 = 217.5mm
d p
) = 12.79 m
dg
) = 13.99
3
e = e p + e g = 26.78 10 mm
Ft
Ftmax =
15.261
KN = 3052N
mn
Ka Km Ft
= 3662.6N
V=
1.638 mn = 8.19m/s
C = 11500e=307.97N/mm
Fd
2650575.55
301.41
21 v + cb cos + F tmax
2
=8793.92N
Peff
Ka Km Ft
Fd
= 3662.6+8793.92 = 12456.52N
WEAR STRENGTH
Fw =
d p bQK
cos
F w = FOS
109 50 2 60
0.85 80
250
0.16 ( 100 )
Peff
eff
Ka Km Ft
P=19495.74
P=19 KW
Fd
P
12456.52 =1.21 V
+ 8000
=16193.47 N