Mechanical Drives

Lecture Notes on Gear Part-I

Involute straight & Helical Tooth

Gear and Gear Box Designg

By:
y Prof. R. Maiti,MED, IIT Kgp.
gp

1
Involute Toothed Gear : Fundamental Relations :

Referring to straight tooth spur Gear:

Pitch diameter
d p 2rp Z m
Circular pitch (arc)

p c 2rp / Z m
Base circle radius

rb rp cos

2
Involute Toothed Gear : Fundamental Relations (Contd.):
Referring to straight tooth spur Gear:

Tip or Addendum circle Tooth thickness (t t ) and space (t )
radius s
Z
ra a f m at standard pitch circle of
2
uncorrected (standard) gear
( - for internal toothed
gear)
ts

tt they are equal (arc).

Root or Dedendum circle radius
Z
tt ts
rd d f m
2
= pc / 2 = m / 2

( + for internal toothed gear)

3
Minimum Number of Teeth in a Gear, Interference
and Undercut

2a f
Zc
sin 2

4
Strength of gear teeth-Lewis equation (Contd.) : Straight tooth spur gear

Fr Stress at root is derived as:

My M(t / 2)
= =
I (bt 3 ) / 12
Line of Action Fn 6M 6F h
Pressure Line = 2 = t2
bt bt
Pitch Point
Ft Where, b is the width of gear.
P
pc
t2
h = y(mn ) = Ymn
6h
t
Weakest Section y is called the Lewis form factor

Y ((= y) is Modified Lewis form factor It is expressed as:

Y = 0.484 - 3.28 / Z
Z = Z / cos 3 () Formative number of teeth.

Is the helix angle, which is zero in case of straight tooth spur gear.
5
Strength of gear teeth-Lewis equation (Contd.) : Straight tooth spur gear

Rearranging:
Velocity Factor cv is expressed as:
Ft = bYmn 3
cv Milled Gear
Introducing Allowable Strength So 3V
and velocity factor ( c
v ),
) the
cv
4 .5 A
Accurately
t l cutt Gear
G
maximum tangential load: 4 .5 V
6
Ft = So cv bYmn cv
6 V
More Accurately cut Gear

3 .5
cv Fine Finished Gear
Now Ft can expressed in terms of 3 .5 V
transmitted Torque T , as: Hardened & Ground
5 .5
Ft =
2T
=
2T cv Gear
dp Zmn 5 .5 V

Also, width b can be limited by a

factor multiplied by normal Rearranging:
module m n
:
2T
Therefore,, equation
q Ft = S o c v bYm n mn = 3
can be modified to: (So cv )Z
)ZY
Y
T = (So cv ZYmn3 ) / 2 6
Strength of gear teeth-Lewis equation (Contd.) : Straight tooth spur gear

Looking into lubrication condition

and taking into wear in consideration 2T
c
another factor w is introduced. mn =
3 So cv
Therefore, to estimate module we use: ZY
cw
Lubrication /wear load factor c w is taken between 1 to 1.25 for force
lubrication to splash lubrication respectively.
= 10 to 12 for straight tooth spur and 14 to 16 to helical spur gear
is in design
g common p practice.

Design of Helical Gear :

Z Formative number of teeth

is expressed as:

Z
Z
cos 3

7
Design of Helical Gear (Contd) :

Pitch Diameter of Helical Gear and

Centre Distance of Mating Helical Gear Pair

Z p pc Z p p cn Z g pc Z g pcn
Dp = = Dg = =
cos cos
Z p mn
= Z g mn
cos =
cos

A ( D p Dg ) / 2 A
mn
Z p Z g
2 cos

The Lewis Formula for module calculation on the 2Tcos

basis of bending strength. (Both for st. & helical): mn = 3
So cvYZ

8
 A Typical Gear Box Design Problem

A helical gear reduction unit has to transmit 30

Nm input torque at 1500 rpm with a total
reduction of about 37 to 40.
At starting
t ti the
th torque
t may go as high
hi h as 200%
and also there is medium shock loads during
operation.
The material for pinion is EN 19A and for gear
wheel it is EN 18A. Assembled plan view is of 3-stage gear box.

The gear box may be an ordinary industrial

class unit preferably with uncorrected gears.
It is continuous duty with medium shock and
overhauling time is Two years.
(
(Alternatively
y -the bearing
g life should not be
below 10,000 hours).

Photographic plan view is of 4-stage gear box.

9
Preliminary Layout of Gear Box :
Step-1
Selection of stages, Gear Ratios
& Teeth numbers.

Step-2 Design of Gears.

Step-3 First layout is made.

Step-4
Rough shape to the shafts are given.

Step-5 Bearings are selected preliminarily.

Step-6 After putting the bearings in layout load calculations become possible.
Step-7 Lives of all bearings are estimated.

Step-8
If estimated lives are not satisfactory then a new set of bearings are chosen.
If necessary shaft(s) dimensions are also altered and lives are re
re-estimated.
estimated.
Further, gear design may need to be altered.
10
Preliminary Layout of Gear Box (Contd.): Recapitulation

Step-1 Knowing the direction of Input & Output Selection of ratios, type of
Gears & teeth numbers.
Rules and Limitations: Stage ratio not more than 6.
Number of teeth, Zcr-min 2/sin2 (Pressure Angle).

Note: Normally helical gears are chosen rather than straight tooth spur gears.

' 3
Therefore,, we consider formative number of teeth: Z = Z / cos

Where, is helix angle which is commonly between 12

o o
to 20
for single helical gear .

F which
For hi h considering
id i Z' = 1
17 , Z may b
be taken
t k as 16 to
t 14 respectively.
ti l

Considering cutter geometry, speed of gears and manufacturing

methods this number may further be lowered.
i
Selection of number of stages for a Total Transmission Ratio t= 37 to 40.

In choosing the numbers of teeth and stage ratios, not only the size
optimization is considered but also the roundness in centre distances with
uncorrected gears is taken care* of:
11
A Typical Helical Gear Box Design Problem

1st. Step (Contd). Selection of number of stages for a Total

Transmission Ratio t i = 37 to 40.
40

Considering two stage reduction the numbers of teeth of pinions and

gears were selected as follows:

1st. Stage:
Z 2 81
i1 4.76
Z 1 17
2nd. Stage:
Z 4 131
i2 8.19
Z 3 16
Therefore, total ratio becomes:

ii1
ii2
Z2 Z4 81 131

it
Z1 Z3 17 16

3
9
.
0
1
4.768.19
Assembled plan view is of 2-stage
2 stage gear box
box.
This is acceptable.

12
A Typical Helical Gear Box Design Problem
2nd. Step. In next step gears are designed:

1st. Stage
2Tcos
Module Estimation on Strength Basis: mn = 3
So cvYZ
Power
Input Torque (Nominal): Ti
2 i
In this problem input continuous torque = 30 Nm. i.e. Ti 30 Nm

As starting torque is 200% we may take the design torque as: Tid 2 Ti 60 Nm
Suggested Materials for Pinion , Gear & Shaft
Pinion Gear Shaft
EN 19A EN 18A EN 8

Ultimate Strength : Su 940 MPa Su 860 MPa Su 570 MPa

S y 550 MPa Su 280 MPa

Yield St
Strength
ength : S y 600 MPa
BHN (Hardened 300-340 250-300
and Tempered) :
13
A Typical Helical Gear Box Design Problem
2nd. Step (Cont.) Design of Gears Module estimation (Contd.):
1st. Stage (Cont.)
In a gear pair which one to be designed?
2Tcos
mn = 3
So cvYZ
YZ
Compare (SoY)gear with (SoY)pinion
Z Pinion = 17 ZGear = 81
Assembled plan view is of 2-stage gear box.

2 5 = 240 MPa = 240 106 Pa

(So )pinion = (S y )EN 19 A / 2.5
(So )gear = (S y )EN 18 A / 2.5 = 220 MPa = 220 106 Pa
YPinion 0.484 28 / Z 00.484
0 484 33.28 484 33.28
28 / (17 / cos3 12o ) 00.303
303

YGear 0.484 3.28 / Z 0.484 3.28 / (81/ cos3 12o ) 0.446

(SoY)gear = 220 00.446
446 = 98
98.12
12 (SoY)pinion = 240 0.303 = 72.72

(SoY)pinion < (S o Y)gear means pinion is weaker and it is to be designed.

14
A Typical Helical Gear Box Design Problem
2nd. Step (Cont.) Design of Gears Module estimation (Contd.):
1st. Stage (Cont.)
Pinion shaft is the input shaft. Therefore:
4.5 4.5
T = 60 Nm = 12
o
= 20 cv 0.75
4.5 V 4.5 1.5
Substituting the values:

2Tcos 2 60 0.978
mn = 3 = 3
6
= 1.85 10 -3 m
So cv
YZ ((240
40 10
0 ) 0.75 200 0.303 177

Therefore, 1st stage normal module may be taken as 2.5 mm .

Verification for wear load: Fw = KbdppQ

2dgp 2 81
Q= = 1.653 b = 2.5 20 10-3 5 10-2 m
dgp + dpp 98

17 2.5 For 300 BHN in gear and 350 BHN in

dpp 10 -3 43.456 10 -3 m
0.978 pinion K=1.8x106 Pas for 20o Involute.

Fw = 1.80 5 43.456 1.653 = 646.5 N

15
A Typical Helical Gear Box Design Problem
2nd. Step (Cont.) Design of Gears (Contd.): 1st. Stage (Cont.)

Probable dynamic load: Fd = Ft / c V

Ft
2T
=
2 30
10 3 = 1381 N Fd = Ft / c V 1381 / 0.75 = 1841 N
d pp 43.456

Wear load capacity should be higher than probable

dynamic load. i.e., Fw Fd

In this primary calculation it is not satisfactory. After a revised calculation

finally:
Estimated 1st. Stage module is mn1 3 mm and 2nd. Stage module is mn 2 4 mm

With a suitable selection of helix angle, 1 2 11 2652 , for which

o

cos 1 cos 2 0.98 and centre distances become:

( Z1 Z 2 ) mn1 (17
( 81) 3 98 3
A1 150 mm*
2 cos 1 2 0.98 2 0.98

( Z 3 Z 4 ) mn 2 (16 131) 4 147 4

A2 300 mm*
2 cos 2 2 0.
0 98 2 0.9
0 98

16
Gear Data
First Stage Second Stage
Sl. No. Description
Pinion Gear Pinion Gear

1. Z ,, Number of Teeth 17 81 16 131

2. Profile 20 o Involute Full Depth, Un corrected
3
3. m n , Normal module 3 mm 4 mm
4. , Helix Angle 11o 2652
11 2652
o

RH LH LH RH
5
5. Addendum Height (mm) f a mn = 1.0 mn 30
3.0 40
4.0

6. Dedendum Height (mm)

fd mn 1.25 mn 3. 75 5.0

7. , Pitch Circle Diameter (PCD)

( ) (mm)
( ) 52.04 247.96 65.306 534.69
dp
8. , Addendum or Tip Diameter (mm) 58.04 253.96 73.30 542.70
da
9. Dedendum or Root Diameter (mm) 44.54 240.46 55.30 524.70
dd
10. b , Face width. (mm) 63 58 68 63
11. Material EN 19A EN 18A EN 19A EN 18A
12
12. S f
Surface H
Hardness
d (BHN) 350 300 350 300
(Through Hardened)
p and g may be added to subscript of Nomenclature to indicate pinion and gear respectively. Similarly 1 and 2 can
be added to indicate stage of Gear. 17
3rd. Step. Layout & Bearing Selection

Layout of pinion and gears is made in next step. Shafts are automatically shaped.

Then Bearing types are chosen taking

into account service severity and life.

Taper
p Roller Bearingg to be used in p
pair.
Other Bearings- may be used in pair
or in combination.

For an examplep both spherical

p roller and
ball bearing can be combined with
Distance between Bearing
(Taper Roller) supports. cylindrical roller bearing in the other end.

Choice depends
p on type
yp of loading
g mainly.
y

Locking of bearings with shaft and

housing is to be decided at this stage.
Spherical Roller
Bearing Sharing
h i off reaction
i lloads
d bby b
bearings
i
depends also on of bearing Locking
arrangement.

With distance between bearing supports

Ball Bearing the shaft is considered as simply
Cylindrical Roller (Deep Groove) supported beam. 18
Bearing
 3rd. Step: Layout & Bearing Selection (Contd..)

Layout of a single stage Gear Box

Roller Bearings:

Assembled plan view of

a 2-stage gear box. (Not taper roller
in this case).
case)

Considering
C id i
bearing widths,
15 to 25 mm 15 to 25 mm
((Typical)
yp ) 10 to 15 mm (Typical) (Typical)

53 50
finally distances
are marked.
marked
1 8
178
Layout of Intermediate Shaft (Referring to Design Problem) 19
4th. Step. Loads on Gear, Pinion Teeth and on Bearings. Recapitulation
2T
Tangential Load: Ft
dp
Z mn
Where, d
p
cos
Normal Load: F
Ft
cos
tn

Ftn
Fn Ft sec .sec n
cos n
Radial Load:

Fr = Fn .sinn
= Ft sec.secn .sinn

Fr Ft sec .tan n
( Ft tan )
Axial Load:

Fa Fn sin Ft tan 20
4th. Step (Contd): Calculation of Loads and Reactions on Shaft & Bearing
For Intermediate Shaft (Referring to Design Problem)
Torque (T n 2) Flow Path
Nominal Torque = Input Torque x Ratio
Z2 (81)
pcd 248 mm Z2
Tn 2 Tn1 31 4.76 148 Nm
Z1
Ft2 = 2 Tn2 / 0.248 N = 1193.5 N
Z3 (16)
pcd 65.3 mm

53 50 Fr2 = Ft2 sec1 .tan

tann

178 = 1193.5 sec(11o 26 52) tan(20 o )

= 1193.5 1.02 0.364 = 443 N
Intermediate Shaft with gears and Bearings
Fa2 = Ft2tan1

Fr 3 = 1193.5 tan(11o 26 52)

Fa 3 Fa2 = 240.65
240 65 N
Similarly forces (rounded of) at pinion ( Z3 )
Ft 3 Ft 2 Fr 2 of 2nd. Stage:
Ft

Fr
=1683 N
3

3
= 4533 N
Fa

Applied Loads, Reactions & Moments due to Axial Loads

= 914 N
3

21
4th. Step (Contd): Calculation of Loads and Reactions on Shaft & Bearing
For Intermediate Shaft (Referring to Design Problem)
o que (T n 2) Flow
Torque o Path
at Loads and reactions are calculated on the
Z 2 (81) basis of Nominal Torque & approximate
pcd 248 mm
bearing width = 25 mm.
L R
Bending
g Moment due to Axial Load:
d p2 240.65 0.2479
Z 3 (16)
pcd 65.3 mm
M a 2 Fa 2 30 Nm
2 2
53 50
d p3 914 00.0653
0653
178 M a 3 Fa 3 30 Nm
2 2
Intermediate Shaft with gears and Bearings
For moment equilibrium (horizontal plane) about R
RVL Fr 3 RVR 1683 0.125 443 0.05
Fa 3 Fa 2 RHL
30

30
0.178 0.178 0.178 0.178

=
7
2
0
.
6
N
RHL RHR
Ft 3 Ft 2 Fr 2 1182 124.4 168.5 168.5
From force equilibrium- RHR = 520 N
M a3 M a2 Similarly computing for vertical plane:
Ft

Fa Fa
Fr F
3

= 914 N
3

=1683 N
3

= 4533 N
RVL = 3518.5 N RVR =2208 N
Ft
2

= 240.65 N
2r

= 1193.5 N =443 N
Applied Loads, Reactions & Moments due to Axial Loads 22
5th. Step:

Bearing Selection
Life Estimation of Rolling Element Bearing

Equivalent Load Acting on bearing

P C1 XVFr YFa

Where,
C1 A factor on nature of shock load
V Outer race rotation factor (1 for fixed & 1.2 for
rotating) Fr
Fa Net radial load acting on bearing
X Net axial load acting on bearing
Y Radial Load Factor (From Catalogue)
Axial Load Factor ,, ,,
23
5th. Step:
Bearing Selection
Equivalent Load Acting on bearing
Recommended X & Y Factors P C1 XVFr YFa

24
5th. Step:
Bearing Selection
Equivalent Load Acting on bearing
Recommended X & Y Factors Contd. P C1 XVFr YFa

25
5th. Step: Bearing Life Estimation
For Intermediate Shaft (Referring to Design Problem)
Equivalent Load Acting on bearing is
q (T n 2) Flow Path
Torque expressed as: P C XVF YF 1 r a
Z2 (81)
pcd 248 mm Life of Rolling Element bearing in
Number of Revolution is expressed as:
L R
C
L N 10 6 Revolution

Z 3 (16)
P
pcd 65.3 mm Life in hours is then estimated as:
LN
53 50 L H Hours
N 60
178 Loads from Gear teeth were estimated as:

Ft Ft

Fa F a
Fr
3
= 914 N

3
=1683
683 N

3
= 4533 N

Fr
Intermediate Shaft with gears and Bearings (Plan View) 2
= 240.65 N

2
=443 N

2
= 1193.5 N
RVL
Fr 3
RVR

3
0
N
m
Fa 3 Fa 2 Also, moments due to axial forces were
estimated as: Ma2 Ma3
RHL RHR
Ft 3 Ft 2 Fr 2 Finally Bearing reactions (radial) were estimated as:
RHL = 720.6 N RVL = 3518.5 N
M a3 M a2 RHR = 520 N RVR =2208 N
Applied Loads, Reactions &
Moments due to Axial Loads Bearing reactions (axial) yet to be estimated. 26
5th. Step (Contd): Bearing Life Estimation
The Final bearing reactions:
Radial reactions are From details of loading resultant right
not in same plane.
b
bearing
i (radial)
( di l) reaction
ti is
i calculated
l l t d as:

Fr R RVR
2 2
+ RHR = 2208 2 + 520 2
Fa Net 2268.4 N
It is acting at an angle R with vertical plane,
Fr L

1
3
.
2
5
Fr R

o
53 50
derived as R tan
1
R HR RVR .
Bearing Reactions (& Locking)
Fr Similarly, F RVL
2
RHL
2
3518.52 720.62
R rL
Fr L
o

1
1
.
5
7

3591.5 N
o

11
11
5.
7
RVL Fr 3 o

o
1
3
2
5
1
3
.
2
5
L tan 1 RHL RVL

5
7
Fa 3 Fa 2 RVR and,

RHL RHRFa Resultant axial load may act only on one

Ft 3 Ft 2 Fr 2 bearing irrespective of its direction (i.e.,
direction of shaft rotation).
rotation)
Ft

Fa Fa
Fr F
3

= 914 N
3

=1683 N
3

= 4533 N
It depends on bearing locking arrangement.
Ft
2

= 240.65 N
2 r

= 1193.5 N =443 N
In this case it is on right bearing which is
RHL = 720.6 N RVL = 3518.5 N with less radial load.
load
Net axial load Fa Net Fa Fa 3 Fa 2
RHR = 520 N RVR =2208 N
6
7
3
.
3
5
N
Details of loading & Resultant bearing Reactions. 27
5th. Step (Contd):
Bearing Life Estimation
Consider deep groove
ball bearing
g SKF 6309
as both end supports
of intermediate shaft:

d=55.3 mm
Equivalent load on
left bearing:

6
7
8
N
=
6
7
3
.
3
5
N
PL C1 XVFr ( L ) YFa ( L )
FaFa

X
=
1
&
Y
=
1
.
6
3
6
2
0
N

1.5 (1.0 1 3591.5 Y 0)

3
6
2
0
N

2
2
5
5
7
5
N
5
.
7
Fr L 53

5
3
8
7
.
2
5
N
3591 5 N
3591.5 FFrrRR 50
2268 4 N
2268.4

Inner Outer Width Corner Basic Load Capacity [Note: C 1 is taken as
Dia. Dia. (B) Radius (r)
Dynamic Static 1.5 considering medium
Bearing
ea g (d) ((D)) Approx.
No.
C Co shock load (given) on
mm mm mm mm Newton Newton the estimated load on
6309 45 100 25 2.5 40130 29200 bearings based on
nominal torque.]
Life (in hrs) of left bearing:
L

L N (L)
(40130 / 5387.5) 3 10 6

H
L

N 60 (1500 17 / 81) 60
6
0
.
0
2
1
8
8
0

1
0
h
r
s
=
2
1
,
8
8
0
h
r
s
28
5th. Step (Contd): Bearing Life Estimation
Ball bearing SKF 6309 is selected for both end supports of intermediate shaft:
Similarly,y, estimated equivalent
q load and
life of right bearing:

5
0
1
8
.
6
4
N
,
PR 1.5 (1.0 1 2268.4 1.6 673.35)

L
(40130 / 5018.64) 3 10 6

HH
RR


(1500 17 / 81) 60

6
=
6
7
3
.
3
5
N
6
7
8
N

0
.
0
2
7
0
6
7

1
0
h
r
s
=
2
7
,
0
6
7
h
r
s
FaFa
Note: Estimated lives of both bearings are
3
6
2
0
N
3
6
2
0
N

2
2
5
5
.
7
5
N
Fr L 53
3591.5 N FFr rR R 50
2268.4 N more or less
l same & above
b the
h
L

2
7
,
0
6
7
h
r
s
.
L

2
1
,
8
8
0
h
r
s
.

required specified life (10,000 hrs).

H
R
H
L

Now it can be examined the life with bearing

g of lower load capacity:
p y
Inner Outer Width Corner Radius Basic Load Capacity
Bearing Dia. (d) Dia. (D) (B) (r) Approx.
No. Dynamic Static
C Co As the root diameter of
mm mm mm mm Newton Newton pinion is 55.39 mm then
6309 45 100 25 2.5 40130 29200 a bearing of id 55 mm
(maximum) may be
6308 40 90 23 2.5 31000 21400 selected.
6211 55 100 21 2.5 32100 25415

If SKF 6308 or 6211 is selected then life will be reduced by (C6309/C6308 or 6211)3 i.e.,
2.17 or 1.95 times respectively, which is acceptable.
29
However, design with SKF 6309 will perhaps be preferred.
6th. Step Shaft Design Bending moment on Intermediate Shaft due to Tangential Forces
(Vertical Plane)
In case of gear box the diameters of a shaft is
dominated by the size (root diameter) of the
integral pinion and optimum bearing size mainly. L R
The length is determined by the placement of
gear, pinion, bearings, coupling, key size,
seals
l etc. andd the
h optimum
i gap required
i d
53 mm 75 mm 50 mm
between two consecutive elements.
Layout
The a shaft is automatically shaped RVL = 3518.5 N
during first layout and bearing RVR =2208
2208 N
selection, as shown earlier.

Ft
Therefore, instead of designing the

2
= 1193.5 N

Ft
shaft the critical sections are verified

3
= 4533 N
for developed stresses. Load Diagram.
1014.5 N

Bending
e d g Moment
o e t ((respective
espect e plane)
p a e) Calculation
Ca cu at o =2208 N
=3518.5 N
B
M

1
8
6
.
5
N
m

3518.5 0.053
P
3
V

Shear Force Diagram (SFD).

B
M

1
1
0
.
4
N
m

-
1
1
0
.
4
N
m
G
2
V

3518.5 0.128 4533 0.075

G
2
V

-
1
8
6
.
5
N
m
Bending Moment Diagram (BMD).30
Shaft Design (Contd) Bending moment on Intermediate Shaft due to Tangential Forces
(Horizontal Plane)
Bending Moment (respective
plane) Calculation (Contd)
(Contd )

Considering from left support Bending L R

M =
a3
2
Moment just left of section 3-3:

0
N
m
M =
B
M

3
8
.
2
N
m

a3
3
P
3
H
-
720 0.053

0
N
m
53 mm 75 mm 50 mm

And just right of section 3-3: 3-3 2 -2

Layout
=
3
8
.
2
+
3
0
B
M

=
6
8
.
2
N
m

Fr
P
3
H
++

=1683 N

3
P
3
H

Similarly, BM just left of section 2-2:

Fr
2
=443 N
B
M

-
4
N
m
RHL = 720 N RHR= 520 N
G
2
H
-

720 0.128 1683 0.075 30 Load Diagram.

= 720 N
And BM just right of section 2-2: 520 N
943 N
B
M

2
6
N
m

443 N
G
2
H
+

4.1 30 Shear Force Diagram (SFD).

6
8
.
2
N
m

2
6
N
m
3-3 2 -2
Bending Moment Diagram (BMD).
31
6th. Step (Contd.) Shaft Design
Second Step: Resultant Bending
Moment and Critical Section
It is to be noted that in a rotating shaft outer layer L R
experiences maximum flexural bending stress.
79 mm

As bending stress is expressed by bending moment 53 mm 75 mm 50 mm

divided by section modulus, it is necessary to verify
3-3 2 -2
those for probable critical sections. 3 -2 Layout

-
1
1
0
.
4
N
m
-
1
8
6
.
5
N
m
In the Intermediate shaft, any of sections 2-2,
3-2 & 3-3 may be critical i.e., experiences
maximum bending stress.
Bending Moment-Vertical Plane.

6
8
.
2
N
m

2
6
N
m
3-3 2 -2
Bending Moment-Horizontal Plane.

32
6th. Step (Contd.) Shaft Design
Next: Resultant Bending Moment
and Critical Section ((Contd))
L R
Reasons are as follows:
79 mm

Among these three sections, through which 53 mm 75 mm 50 mm

full torque transmits, section 3-3 has 3-3 2 -2
maximum bending moment, although it has 3 -2 Layout
also the maximum diameter.
It has medium stress concentration as it is

-
1
1
0
.
4
N
m
roots of teeth.

-
1
8
6
.
5
N
m
Sections 2-2 & 3-2 have equal diameters but
diff
different
t stress
t concentration
t ti factors.
f t
Bending Moment-Vertical Plane.
At section 3-2 there is step, where as at
section 2-2 a there is keyway.

6
8
.
2
N
m

2
6
N
m
Therefore, section 22-2
2 may be severe than
section 3-2 in stress concentration point of
view.
3-3 2 -2
Again 2-2 usually experiences less BM. Bending Moment-Horizontal Plane.

33
6th. Step (Contd.) Shaft Design
Resultant Bending Moment and Critical Section (Contd)

L R
Resultant bending moment at 3-3:
B
M

=
1
9
8
.
6
N
m

68.22 186.52 79 mm
R
3
-
3

53 mm 75 mm 50 mm
Resultant bending moment at 2-2: 3-3 2 -2
3 -2 Layout
B
M

=
1
1
3
.
4
2
N
m
R
2
-
2

262 110.42

-
1
1
0
.
4
N
m
-
1
8
6
.
5-
N1
m39
.
8
1
N
m
Resultant bending moment at 3-2
is estimated as follows:
=
3
5
1
8
.
5
0
.
0
9
9
-
4
5
3
3
0
.
0
4
6
B
M

=
1
3
9
.
8
1
N
m
Bending Moment-Vertical Plane.

V
3
-
2

6
8
.
2
N
m
=
7
2
0
.
6
0
.
0
9
9
+
3
0
-
1
6
8
3
0
.
0
4
6
B
M

=
2
3
.
9
2
N
m

2
6
N
m
H
3
-
2

2
3
.
9
2
N
m

2 -2
B
M

=
1
4
1
.
8
4
N
m

3-3 3 -2
R
3
-
2

23.922 139.812 Bending Moment-Horizontal Plane.

34
6th. Step (Contd.) Shaft Design
Bending Stress and search for Critical Section (Contd)

d=55.3 mm

d=50 mm
Maximum bending stress in any section of L R
rotating shaft (solid):

=
79 mm
Myy 32 M
b fc fc
I d3 53 mm 75 mm 50 mm

I d 4 / 64 3-3
3 -2
2 -2
Layout
(Section modulus and
y d /2
fc stress concentration factor ).

-
1
1
0
.
4
N
m
-
1
8
6
.
5-
N1
m39
.
8
1
N
m
Maximum bending stress at section 3-3:

1
8

1
0
1.5 32 198.6 Bending Moment-Vertical Plane.
6

b
3
-
3

Pas
0.05533

6
8
.
2
N
m

2
6
N
m
2
3
.
9
2
N
m
fc is taken 1.5 for hob cut gear.
3-3 2 -2
3 -2
Bending Moment-Horizontal Plane.

35
6th. Step (Contd.) Shaft Design
Bending Stress and search for
Critical Section ((Contd))

d=55.3 mm

d=50 mm
L R
Maximum bending stress at section 3-2:
79 mm

1
7
.
3
4

1
0
1.5 32 141.84
b
3
-
2

Pas 53 mm 75 mm 50 mm
0.053 3-3 2 -2
3 -2 Layout
fc is taken 1.5 for well designed step.

-
1
1
0
.
4
N
m
-
1
8
6
.
5-
N1
m39
.
8
1
N
m
Maximum bending stress at section 2-2:

1
8
.
5

1
2 32 113.42 0
b
3
-
2

Bending Moment-Vertical Plane.

Pas
0.053

6
8
.
2
N
m

2
6
N
m
fc is taken 2 for milled keyway.
keyway

2
3
.
9
2
N
m
2 -2
It is apparent that section 2-2 is critical. 3-3 3 -2
Bending Moment-Horizontal Plane.

36
6th. Step (Contd.) Shaft Design
Lastly: Verification of Overall factor of safety at Critical Section
As already mentioned earlier, in gear unit design the size of the gear shaft usually
biased by the sizes of gears, bearing layout and centre distances.
Particularly in case of shaft integral with the pinion there is little scope of pre-
designing the shaft.
In such cases maximum stresses in the shaft are estimated identifying critical sections.
sections
Then a factor of safety f s can be estimated using the following formula,
which is base on maximum shear stress theory under combined, bending,
torsion and direct normal stresses.
2
Sy Sy
m k f a 4 m2
fs Sen
Where,
S y = Yield strength of shaft material
S en = Endurance strength
g of shaft material
m = Mean (average) stress at considered section due to axial load.
a = Maximum alternating stress at considered section due to bending.
m= Maximum shear stress at considered section due to torsion.
k f = A factor considering the feature of section and severity of service.
It is chosen considering on what basis a has been calculated.
37
6th. Step (Contd.) Shaft Design
Verification of Overall factor of
safety
y at Critical Section ((Contd))

d=55.3 mm
In present design, the pinion is integral with

d=50 mm
L R
shaft therefore shaft material is EN19A.
Therefore, for the critical section 2-2: 79 mm

S y = 600 MPa, 53 mm 75 mm 50 mm
S en = 420 MPa (About 45% of Su for well 3-3
3 -2
2 -2
Layout
finished /ground shaft),

Fa

-
1
1
0
.
4
N
m
673.5
m fc

-
1
8
6
.
5-
N1
m3
2
d2 0.052

9
.
8
1
N
m
0
.
1
7

1
0
P
a 1
s 8
2

.
5

1
0
6
Bending Moment-Vertical Plane.
a
b
3
-
2

Pas

6
8
.
2
N
m

2
6
N
m
1 6T 16 148

2
3
.
9
2
N
m
m fc 2
d3 0 .0 5 3
1
2
.
1

1
0
P
a
s
6

3-3 2 -2
3 -2
Bending Moment-Horizontal Plane.
fc is taken 2 in general for milled single keyway.
keyway

38
6th. Step (Contd.) Shaft Design
Verification of Overall factor of
safety
y at Critical Section ((Contd))

d=55.3 mm

d=50 mm
Substituting values f S for the critical L R
section 2-2 is calculated as follows:
79 mm

2 53 mm 75 mm 50 mm
600 10 6
600
0.172 1.5 18.5 106 4 (12.1106 ) 2 3-3
3 -2
2 -2
Layout
fs 420
46.6 106

-
1
1
0
.
4
N
m
-
1
8
6
.
5-
N1
m39
.
8
1
N
m
Therefore,
1
2
.
8
7

600 Bending Moment-Vertical Plane.

fs

6
8
.
2
N
m
46.6

2
6
N
m
2
3
.
9
2
N
m
This is highly satisfactory.

3-3 2 -2
3 -2
Usually
y f s is taken as 2.5 to 3. Bending Moment-Horizontal Plane.

39
 6th. Step (Contd.) Shaft Design
Input Shaft
The Input Shaft is also integral with the 1st. stage pinion.
Therefore, the material is EN19A.
Shaft design verification is done in same way as it is done for intermediate shaft.
Output
p Shaft
The Output Shaft not integral with the gear.
Therefore, medium carbon steel (C40 or C45, Equivalent to EN8), having
ultimate strength- 560 MPa and yield strength- 280 Mpa, is taken as the
material.
16To
The Shaft diameter is initially estimated
do 3
S sa
on transmitted torque as follows:
In the present design considering a factor of 1.5 with nominal torque
the Output torque:
1
8
1
8
N
m
To 1.5
1 5 31 39 1
39.1
Considering allowable shear stress ( S sa ) of material is 60 MPa.
5
3
.
6
5
m
m

Nominal do
Considering the end bearings of ID 55 mm (Say SKF Ball Bearing 6311) Shaft
design verification is done in the same way as is done for intermediate shaft.
40
Bibliography

1. Spotts M. F., Design of Machine Elements, Prentice Hall of India.

2. Shigley's Mechanical Engineering Design (McGraw-Hill Series in Mechanical

E i
Engineering)
i ) Hardcover
H d January
J 27
27, 2014 by
b Richard
Ri h d Budynas
B d (A th ) Keith
(Author), K ith
Nisbett (Author).

3. Maleev V. L. , Hartman J. B. and Shigley J. E., Machine Design.

4. SKF Bearing Catalogue.

5. PSG Design Data Book.

41