Gearbox 2018

Design Aladdin Adel

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Introduction

Under Supervision Of:

Prof. Dr. Eng A. M. Abdelhay.

Professor of Mechanical Engineering

My task is to disassemble an old generation GearBox to

Understand its main parts and earning some knowledge from the
previous Designer and apply the principles we have studied at this year
to re design the gearbox

So here is some assumptions

Power is 34 kw

Speed of the input shaft is 4000 rpm

All units in mm,g,s,N , Mpa

A layout we be drawn with help of the remaining parts

 1
GearBox layout
hand drawn based on the available gearbox in the work shop
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First Gear & Pinion
f

Given

*P=34 Kw *Nm =4000 rpm

*Z =13Te *Z2 =53 Te

Ψ=30 *Ǿn =20

M =3.5975882236

Helical Gear Design

Gear & Pinion dimensional

Drive “1” Driven “2”

“P” “g”
rb 21.97 89.58
Pb 10.62 10.62
P 11.3 11.3
Pn 9.78 9.78
Pa 19.57 19.57
a 3 3
b 3.75 3.75
F 22.5 22.5
Ht 4.89 4.89
Ze 15 61
Clearance 1.5 1.5
d 46.77mm 190.67mm
 1
First Gear & Pinion

To calculate Gear load

P=T x w
2 𝜋 4000
T=34𝑥103 / = 81 N.m
60

Tangential Force
2𝑇 2𝑥81𝑥103
Wt =𝑑 = = 3465.76 𝑁
1 46.77

Radial Force
tan(20)
Wr =Wt tan-1(cos(30)) = 14455.32𝑁

Axial force

Wa= Wt tanΨ =3463.76 tan(30) =1999.8N

Normal Gear load

3463.76
Wn =cos(22.79)+cos(30) = 4338.29 𝑁

1.1) Fatigue Bending Stress

𝑊
𝑡
σb =𝐹.𝑚.𝐽 𝐾𝑣 𝐾𝑜 𝐾𝑠 𝐾𝑚 𝐾𝐵

to calculate Geometry factor (J)

JPinion =J1 .Jmult

From table 16 Appendix (BB)

J1 =0.38

Jmilt =0.98

Jpinion =0.372

Kv from table 4
𝜋𝑑𝑁
V=1000 𝑥 60 = 24.4 m/s >20

D=46.77

N=4000

QD =8 Kv =1.35
 1
First Gear & Pinion

Ks =1/Kb =1.06

From table 6

Kb =0.942 for m =3.597598236

Assume 1-Driven machinery uniform

2- Source of power moderate

Ko =1

From Table 7 “accurate mounting”

Km=1.3

From Table 8
𝑡𝑔 2𝐻𝑡
KB = 1 for mB =𝐻 = =2
𝑡 𝐻𝑡

3463.76
σb for pinion 22.5 𝑥 3.597598236 𝑥 0.375 (1.35)(1)(1.06)(1.3)(1) = 213.98𝑀𝑃𝑎

1.2 Material Strength

𝐾𝐿
Sb =𝐾 𝑥 𝑆𝑒
𝑅 𝐾𝑇

KL =1 assume from table “10” 107 Life cycle

KR =0.85 From Table “11”

KT =1 For temperature <120 from table”12

U=1540 MPa

From table “9”

Material Nickel chromium steel (30 Ni4CrL)

Se =0.5 σU =770

Sb =905.88

Factor of Safety
𝑆𝑏 905.88
nbpinion= 𝜎 = 213.98 = 4.2 > 2
𝑃𝑖𝑛𝑖𝑜𝑛

Design is Safe

2.1 Pitting Stresses

𝑊
σH for pinion =𝐶𝑝 √𝐹.𝑑 𝑡.𝐼 𝐶𝑉 𝐶𝑂 𝐶𝑆 𝐶𝑀 𝐶𝐵
𝑝 𝑝

𝑊𝑡
σH for gear =𝐶𝑝 √ 𝐶𝑉 𝐶𝑂 𝐶𝑆 𝐶𝑀 𝐶𝐵
𝐹.𝑑𝑔 .𝐼𝑔

𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑃
IP=
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First Gear & Pinion
𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑃
IP= 2𝑅𝑙 𝐼𝑃 +1

𝑃𝑏 “𝑝𝑖𝑛𝑖𝑜𝑛”
RL= 0.95𝐿𝑐

Lc =√(𝑟𝑝𝑖𝑛𝑖𝑜𝑛 + 𝑎)2 − 𝑟𝑏 𝑝𝑖𝑛𝑖𝑜𝑛 2 + √(𝑟𝑔𝑒𝑎𝑟 + 𝑎)2 − 𝑟𝑏 𝑔𝑒𝑎𝑟 2 –(r1 + r2)sinǾ

=109.27
𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑔
IP= 2𝑅𝑙 𝐼𝑔 +1

𝑃𝑏 “𝑝𝑖𝑛𝑖𝑜𝑛”
RL= = 0.1023
0.95𝐿𝑐

Ip =1.4

Cv ,Co ,Cs ,Cm ,Cb as Kv ,Ko ,Ks ,Km ,Kb

Cv = 1.35 Cs =1.06

Co = 1 Cm =1.3

CB = 1 Cp from Table “13”

Cp =191

3463.76
σh for pinion =191√22.5𝑥46.77𝑋1.4 (1.35)(1)(1.06)(1.3)(1) =399.4MPa

3464.76
σh for gear =191√22.5𝑥190.67𝑋1.4 (1.35)(1)(1.06)(1.3)(1) 197.8MPa

2.2 Material Strength

𝐶 𝐶
SH = 𝐶𝐿𝐶𝐻 𝑆𝑐
𝑡 𝑅

From table 14

Sc for pinion =2.8(Bhn)-69 =1174.2 MPa

Sc for gear =2.8(Bhn)-69 =572.2 MPa

CL =1

Ct =1

Cr =0.85

Ch =1 as Hp/ Hg =1.9 from table “15”

SH for pinion =1381.4 MPa

SH for gear =673.18MPa

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First Gear & Pinion
Factor of Safety
𝑆 1381.4
nH for pinion =𝜎𝐻 = = 3.46
𝐻 399.4

unsafe change pinion material

𝑆 673
nH for gear =𝜎𝐻 = 197.8 = 3.4
𝐻

safe design
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Second Gear & Pinion

𝑂/𝑝 𝑁 𝑍
For i2 = = 𝑁4 = 𝑍3
𝐼/𝑝 3 4

∅n= 20 Ψ = 35
tan ∅
∅=tan-1( 𝑐𝑜𝑠𝛹𝑛)= 24

Drive “3” Driven “4”

“P” “g”
m 2.713 2.713
mn 2.2 2.2
Z 43 12
rb 44.6 12.45
Pb 7.8 7.8
P 8.5 8.5
Pn 6.98 6.98
Pa 12.17 12.17
a 2.2 2.2
b 2.7 2.7
F 14 14
Ht 17.5 17.5
C 74.6 74.6
Clearance 1.1 1.1
d 116.66 32.556

P=34 Kw
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Second Gear & Pinion

P=34 Kw
𝑃 𝑃 𝑥 60
T= 𝑤 = = 81.17N.m
2𝜋𝑁

2𝑇
Wt3 =𝑑 = 1662.17
3

Wa = Wt tan(Ψ) =1163.8693 N

Wr = Wt tan(∅)=740 N

Safe Design against two mode of failure [ Bending +Surface Pitting]

1.1) Fatigue Bending Stress

𝑡𝑊
σb =𝐹.𝑚.𝐽 𝐾𝑣 𝐾𝑜 𝐾𝑠 𝐾𝑚 𝐾𝐵

to calculate Geometry factor (J)

JPinion =J75 .M =0.48

From table 16 Appendix (BB)

J75 =0.51

M =0.94

Jg =J75 .M=0.34

J75 =0.35

M=0.97
Kv from table 4
𝜋𝑑𝑁
V=1000 𝑥 60 = 24.4 m/s >20

D=116.66

N=4000

QD =12 Kv =1.1

Ks =1/Kb 1.03

From table 6

Kb =0.965 for m =2.7

Assume 1-Driven machinery uniform

2- Source of power moderate

Ko =1
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Second Gear & Pinion

From Table 7 “accurate mounting”

Km=1.3

From Table 8
𝑡𝑔 2𝐻𝑡
KB = 1 for mB =𝐻 = =2
𝑡 𝐻𝑡

1662.17
σb for pinion 14 𝑥 2.713 𝑥 0.48 (1.1)(1)(1.03)(1.3)(1) = 134.2 𝑀𝑃𝑎

as Jgear =0.34

σb for gear =189.58 MPa

1.2 Material Strength

𝐾𝐿
Sb =𝐾 𝑥 𝑆𝑒
𝑅 𝐾𝑇

KL =1 assume from table “10” 107 Life cycle

KR =0.85 From Table “11”

KT =1 For temperature <120 from table”12”

U=1540 MPa

From table “9”

Material Nickel chromium steel (30 Ni4CrL)

Se =0.5 U =770

Sb =905.88

Factor of Safety
𝑆𝑏 905.88
nbpinion= 𝜎 = 134.285 = 6.7 > 2
𝑃𝑖𝑛𝑖𝑜𝑛

𝑆𝑏 905.88
nbGear= 𝜎 = 189.58 = 4.77 > 2
𝐺𝑒𝑎𝑟

Design is Safe
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Second Gear & Pinion

2.1 Pitting Stresses

𝑊
σH for pinion =𝐶𝑝 √𝐹.𝑑 𝑡.𝐼 𝐶𝑉 𝐶𝑂 𝐶𝑆 𝐶𝑀 𝐶𝐵
𝑝 𝑝

𝑊
σH for gear =𝐶𝑝 √𝐹.𝑑 𝑡.𝐼 𝐶𝑉 𝐶𝑂 𝐶𝑆 𝐶𝑀 𝐶𝐵
𝑔 𝑔

𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑃
IP= 2𝑅𝑙 𝐼𝑃 +1

𝑃𝑏 “𝑝𝑖𝑛𝑖𝑜𝑛”
RL= = 0.34
0.95𝐿𝑐

Lc =√(𝑟𝑝𝑖𝑛𝑖𝑜𝑛 + 𝑎)2 − 𝑟𝑝𝑖𝑛𝑖𝑜𝑛 2 + √(𝑟𝑔𝑒𝑎𝑟 + 𝑎)2 − 𝑟𝑔𝑒𝑎𝑟 2 − (𝑐)

= 24.23
𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑔
IP= 2𝑅𝑙 𝐼𝑔 +1

𝑃𝑏 “𝑝𝑖𝑛𝑖𝑜𝑛”
RL= = 0.34
0.95𝐿𝑐

Ip =0.43

Ig =0.12

Cv ,Co ,Cs ,Cm ,Cb as Kv ,Ko ,Ks ,Km ,Kb

Cv = 1.1 Cs =1.03

Co = 1 Cm =1.3

CB = 1 Cp from Table “13”

Cp =191

1662.17
σh for pinion =191√14𝑥116.66𝑋0.43 (1.1)(1)(1.03)(1.3)(1) =356.61MPa

1662.17
σh for gear =191√ (1.1)(1)(1.03)(1.3)(1) =695.23MPa
14𝑥116.6𝑋0.12

2.2 Material Strength

𝐶 𝐶
SH = 𝐶𝐿𝐶𝐻 𝑆𝑐
𝑡 𝑅

From table 14

Sc =2.8(Bhn)-69 =1174.2
CL =1

Ct =1

Cr =0.85
Ch =1 as Hp/ Hg =1 from table “15”
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Second Gear & Pinion

Ch =1 as Hp/ Hg =1 from table “15”

SH =1381.4 MPa

Factor of Safety
𝑆 1381.4
nH for pinion =𝜎𝐻 = = 3.8 > 1.2
𝐻 356.6

𝑆 1381.4
nH for gear =𝜎𝐻 = 675.23 = 1.9 > 1.2
𝐻

Design is Safe
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Third Gear & Pinion

tan 20
tanǾ = cos 35 Ǿ = 23.96

Drive “5” Driven “6”

“P” “g”
m 2.713 2.713
mn 2.48 2.48
rb 47.11 21.1
Pb 7.79 7.79
P 8.52 8.52
Pn 6.98 6.98
Pa 12.17 12.17
a 2.48 2.48
b 3.1 3.1
F 14 14
Ht 17.45 17.45
C 74.61 74.61
d 103.1 46.12

P=34 Kw
𝑃 𝑃 𝑥 60
T= 𝑤 = = 81.17N.m
2𝜋𝑁

2𝑇
Wt3 =𝑑 = 1574.57
3

Wr = Wt tan(Ψ) =699.727 N

Wa = Wt tan(∅)=1102.526 N
Ma =Wa r=56835.215N
 1
Third Gear & Pinion

Ma =Wa r=56835.215N

1.1Fatigue Bending Stress

𝑊𝑡
σb =𝐹.𝑚.𝐽 𝐾𝑣 𝐾𝑜 𝐾𝑠 𝐾𝑚 𝐾𝐵

to calculate Geometry factor (J)

JPinion =J75 .M =

From table 16 Appendix (BB)

JPinion =0.37

Kv from table 4

Kv =1.13

Ks =1/Kb =1.0267

Assume 1-Driven machinery uniform

2- Source of power moderate

Ko =1

From Table 7 “accurate mounting”

Km=1.3

From Table 8
𝑡𝑔 2𝐻𝑡
KB = 1 for mB =𝐻 = =2
𝑡 𝐻𝑡

1574.57
σb for pinion 14 𝑥 2.713 𝑥 0.37 (1.13)(1)(1.0267)(1.3)(1) = 168.988𝑀𝑃𝑎

1.2 Material Strength

𝐾𝐿
Sb =𝐾 𝑥 𝑆𝑒
𝑅 𝐾𝑇

KL =1 assume from table “10” 107 Life cycle

KR =1 From Table “11”

KT =1 For temperature <120 from table”12”

U=1540 MPa

From table “9”

Material Nickel chromium steel (30 Ni4CrL)

Se =0.5 U =770

Sb =770
Factor of Safety
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Third Gear & Pinion

Factor of Safety
𝑆𝑏 770
nbpinion= 𝜎 = 168.998 = 4.56 > 2
𝑃𝑖𝑛𝑖𝑜𝑛

Design is Safe

2.1 Pitting Stresses

𝑊
σH for pinion =𝐶𝑝 √𝐹.𝑑 𝑡.𝐼 𝐶𝑉 𝐶𝑂 𝐶𝑆 𝐶𝑀 𝐶𝐵
𝑝 𝑝

𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑃
IP= 2𝑅𝑙 𝐼𝑃 +1

Lc =√(𝑟𝑝𝑖𝑛𝑖𝑜𝑛 + 𝑎)2 − 𝑟𝑝𝑖𝑛𝑖𝑜𝑛 2 + √(𝑟𝑔𝑒𝑎𝑟 + 𝑎)2 − 𝑟𝑔𝑒𝑎𝑟 2 − (𝑐)

= 10.5467
𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑔
IP= 2𝑅𝑙 𝐼𝑔 +1

𝑃𝑏 “𝑝𝑖𝑛𝑖𝑜𝑛”
RL= = 0.7775
0.95𝐿𝑐

Ip =0.1649

Cv ,Co ,Cs ,Cm ,Cb as Kv ,Ko ,Ks ,Km ,Kb

Cv = 1.13 Cs =1.0267

Co = 1 Cm =1.3

CB = 1 Cp from Table “13”

Cp =191
σh for pinion =603.314MPa

2.2 Material Strength

𝐶𝐿 𝐶𝐻
SH = 𝑆𝑐
𝐶𝑡 𝐶𝑅

From table 14

Sc =2.8(Bhn)-69 =1174.2

CL =1

Ct =1
Cr =0.85

Ch =1 as Hp/ Hg =1 from table “15”

SH =1381.4 MPa
Factor of Safety
𝑆𝐻 1381.4
 1
Third Gear & Pinion

Factor of Safety
𝑆 1381.4
nH for pinion =𝜎𝐻 = 603.314 = 2.29 > 1.2
𝐻

Design is Safe
 1
Fourth Gear & Pinion

tan 20
tanǾ = cos 35 Ǿ = 23.96

Drive “7” Driven “8”

“P” “g”
m 2.713 2.713
mn 2.22 2.22
Z 32 22
rb 39.66 27.27
Pb 7.79 7.79
P 8.52 8.52
Pn 6.98 6.98
Pa 12.17 12.17
a 2.22 2.22
b 2.775 2.775
F 14 14
d 86.81 59.68

P=34 Kw
𝑃 𝑃 𝑥 60
T= 𝑤 = = 81.17N.m
2𝜋𝑁

2𝑇
Wt3 =𝑑 = 1870.04
3

Wr = Wt tan(Ψ) =831.03 N

Wa = Wt tan(∅)=1309.42N

Ma =Wa r=56835.38N
 1
Fourth Gear & Pinion

1.1) Fatigue Bending Stress

𝑊𝑡
σb =𝐹.𝑚.𝐽 𝐾𝑣 𝐾𝑜 𝐾𝑠 𝐾𝑚 𝐾𝐵

to calculate Geometry factor (J)

JPinion =J75 .M =

From table 16 Appendix (BB)

JPinion =0.37

Kv from table 4

Kv =1.3

Ks =1/Kb =1.02

Assume 1-Driven machinery uniform

2- Source of power moderate

Ko =1

From Table 7 “accurate mounting”

Km=1.3

From Table 8
𝑡𝑔 2𝐻𝑡
KB = 1 for mB =𝐻 = =2
𝑡 𝐻𝑡

σb for pinion 229.39𝑀𝑃𝑎

1.2 Material Strength

𝐾𝐿
Sb =𝐾 𝑥 𝑆𝑒
𝑅 𝐾𝑇

KL =1 assume from table “10” 107 Life cycle

KR =1 From Table “11”

KT =1 For temperature <120 from table”12”

U=1540 MPa

From table “9”

Material Nickel chromium steel (30 Ni4CrL)

Se =0.5 U =770

Sb =770
Factor of Safety
𝑆𝑏 770
nbpinion= = = 3.36 > 2
𝜎𝑃𝑖𝑛𝑖𝑜𝑛 229.39
 1
Fourth Gear & Pinion
Factor of Safety
𝑆𝑏 770
nbpinion= 𝜎 = 229.39 = 3.36 > 2
𝑃𝑖𝑛𝑖𝑜𝑛

Design is Safe

2.1 Pitting Stresses

𝑊
σH for pinion =𝐶𝑝 √𝐹.𝑑 𝑡.𝐼 𝐶𝑉 𝐶𝑂 𝐶𝑆 𝐶𝑀 𝐶𝐵
𝑝 𝑝

𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑃
IP= 2𝑅𝑙 𝐼𝑃 +1

Lc =√(𝑟𝑝𝑖𝑛𝑖𝑜𝑛 + 𝑎)2 − 𝑟𝑝𝑖𝑛𝑖𝑜𝑛 2 + √(𝑟𝑔𝑒𝑎𝑟 + 𝑎)2 − 𝑟𝑔𝑒𝑎𝑟 2 − (𝑐)

= 9.67
𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑔
IP= 2𝑅𝑙 𝐼𝑔 +1

𝑃𝑏 “𝑝𝑖𝑛𝑖𝑜𝑛”
RL= = 0.85
0.95𝐿𝑐

Ip =0.129

Cv ,Co ,Cs ,Cm ,Cb as Kv ,Ko ,Ks ,Km ,Kb

Cv = 1.3 Cs =1.02

Co = 1 Cm =1.3

CB = 1 Cp from Table “13”

Cp =191
σh for pinion =866.08 MPa

2.2 Material Strength

𝐶 𝐶
SH = 𝐶𝐿𝐶𝐻 𝑆𝑐
𝑡 𝑅

From table 14

Sc =2.8(Bhn)-69 =1174.2

CL =1

Ct =1

Cr =0.85
Ch =1 as Hp/ Hg =1 from table “15”

SH =1381.41 MPa
Factor of Safety
𝑆 1381.4
nH for pinion =𝜎𝐻 = 866.08 = 1.595 > 1.2
𝐻
 1
Fourth Gear & Pinion

Factor of Safety
𝑆 1381.4
nH for pinion =𝜎𝐻 = 866.08 = 1.595 > 1.2
𝐻

Design is Safe
 1
Fifth Gear & Pinion

*P=34 Kw *Nm =4000 rpm

*Z9 =49Te *Z10 =47 Te

Ψ=36 *Ǿn =20

M =1.480931952

Helical Gear Design

Gear & Pinion dimensional

Drive “9” Driven “10”
“P” “g”
rb 13.6217mm 14.2020311mm
Pb 4.02mm 4.02mm
P 4.28 4.65
Pn 3.46 3.46
Pa 5.89 5.89
a 1.198099117 1.98099117
b 1.497 1.497
F 6.77 6.77
Ht 1.73 1.73
Z 49 47
Clearance 0.5990 0.5990
D 72.5 69.6mm
 1
Fifth Gear & Pinion

P=T x w
2 𝜋 4170
T=34𝑥103 / = 77.85 N.m
60

Tangential Force
2𝑇 2𝑥77.85𝑥103
Wt =𝑑 = = 2332.41 𝑁
1 66.76

Radial Force
tan(20)
Wr =Wt tan-1(cos(30)) = 848.9𝑁

Axial force

Wa= Wt tanΨ =2332.4 tan(30) =1694.59N

Normal Gear load

2332.4
Wn =cos(22.79)+cos(36) = 1345.95 𝑁

1.1) Fatigue Bending Stress

𝑊
𝑡
σb =𝐹.𝑚.𝐽 𝐾𝑣 𝐾𝑜 𝐾𝑠 𝐾𝑚 𝐾𝐵

to calculate Geometry factor (J)

JPinion =J1 .Jmult

From table 16 Appendix (BB)

J1 =0.38

Jmilt =0.98

Jpinion =0.372

Kv from table 4
𝜋𝑑𝑁
V=1000 𝑥 60 = 24.4 m/s >20

D=46.77

N=4000

QD =8 Kv =1.1

Ks =1/Kb =1
From table 6

Kb =0.942 for m =3.597598236

Assume 1-Driven machinery uniform

2- Source of power moderate

 1
Fifth Gear & Pinion

Assume 1-Driven machinery uniform

2- Source of power moderate

Ko =1

From Table 7 “accurate mounting”

Km=1.3

From Table 8
𝑡𝑔 2𝐻𝑡
KB = 1 for mB =𝐻 = =2
𝑡 𝐻𝑡

2332.41
σb for pinion 14 𝑥 1.198099117×0.52 (1)(1)(1.1)(1.3)(1) = 389.89𝑀𝑃𝑎

1.2 Material Strength

𝐾𝐿
Sb =𝐾 𝑥 𝑆𝑒
𝑅 𝐾𝑇

KL =1 assume from table “10” 107 Life cycle

KR =0.85 From Table “11”

KT =1 For temperature <120 from table”12”

U=1540 MPa

From table “9”

Material Nickel chromium steel (30 Ni4CrL)

Se =0.5 σU =770

Sb =905.88

Factor of Safety
𝑆𝑏 905.88
nbpinion= 𝜎 = 389.89 = 42.323 > 2
𝑃𝑖𝑛𝑖𝑜𝑛

Design is Safe

2.1 Pitting Stresses

𝑊
σH for pinion =𝐶𝑝 √𝐹.𝑑 𝑡.𝐼 𝐶𝑉 𝐶𝑂 𝐶𝑆 𝐶𝑀 𝐶𝐵
𝑝 𝑝

𝑊
σH for gear =𝐶𝑝 √𝐹.𝑑 𝑡.𝐼 𝐶𝑉 𝐶𝑂 𝐶𝑆 𝐶𝑀 𝐶𝐵
𝑔 𝑔

𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑃
IP= 2𝑅𝑙 𝐼𝑃 +1

𝑃𝑏 “𝑝𝑖𝑛𝑖𝑜𝑛”
RL= 0.95𝐿𝑐

Lc =√(𝑟𝑝𝑖𝑛𝑖𝑜𝑛 + 𝑎)2 − 𝑟𝑏 𝑝𝑖𝑛𝑖𝑜𝑛 2 + √(𝑟𝑔𝑒𝑎𝑟 + 𝑎)2 − 𝑟𝑏 𝑔𝑒𝑎𝑟 2 –(r1 + r2)sinǾ

 1
Fifth Gear & Pinion

Lc =√(𝑟𝑝𝑖𝑛𝑖𝑜𝑛 + 𝑎)2 − 𝑟𝑏 𝑝𝑖𝑛𝑖𝑜𝑛 2 + √(𝑟𝑔𝑒𝑎𝑟 + 𝑎)2 − 𝑟𝑏 𝑔𝑒𝑎𝑟 2 –(r1 + r2)sinǾ

=109.27
𝑐𝑜𝑠∅ 𝑠𝑖𝑛∅ 𝐼𝑔
IP= 2𝑅𝑙 𝐼𝑔 +1

𝑃𝑏 “𝑝𝑖𝑛𝑖𝑜𝑛”
RL= 0.95𝐿𝑐

Ip =0.606

Cv ,Co ,Cs ,Cm ,Cb as Kv ,Ko ,Ks ,Km ,Kb

Cv = 1.1 Cs =1

Co = 1 Cm =1.3

CB = 1 Cp from Table “13”

Cp =191

2332.4
σh for pinion =191√14×66.7×06‫ز‬06 (1.3)(1)(1. )(1.1)(1) =448.7MPa

2332.4
σh for gear =191√14×696‫ز‬0380×06‫ز‬49 (1.1)(1)(1. )(1.3)(1) =424.15MPa

2.2 Material Strength

𝐶 𝐶
SH = 𝐶𝐿𝐶𝐻 𝑆𝑐
𝑡 𝑅

From table 14

Sc for pinion =2.8(Bhn)-69 =1174.2 MPa

Sc for gear =2.8(Bhn)-69 =572.2 MPa

CL =1

Ct =1

Cr =0.85

Ch =1 as Hp/ Hg =1.9 from table “15”

SH for pinion =1381.4 MPa

SH for gear =673.18MPa

Factor of Safety
𝑆𝐻 1381.4
nH for pinion = = = 3.08
𝜎𝐻 448.15

safe pinion material

𝑆 1381.4
 1
Fifth Gear & Pinion

Factor of Safety
𝑆 1381.4
nH for pinion =𝜎𝐻 = 448.15 = 3.08
𝐻

safe pinion material

𝑆 1381.4
nH for gear =𝜎𝐻 = 424.15 = 3.25
𝐻

safe design
 1
First Shaft

Wt =3463.76 N

Wr =1455.32N

Wa =1999.8 N

force analysis

at horizontal plane

Σ Ma =0

-RB x100 +3463.7x50 = 0

RB =1731.88N
Σ Fy =0

RA +1731.88 =3463.7

RA = RB =2972.1

Bending Moment Diagram

At point A B.M.D)A =0

At point B B.M.D)B =0

At point C B.M.D)C =RA x 50 =+86594N.mm

At vertical plane

ΣMa = 0
120.67
-1999.8 x -1455.32 x 50 +RB x100=0
2

RB=478.91933N

Σ Fy =0

RA+478.91933+1455.32 =0

RA =-1934.239N

Bending Moment Diagram

At Point A & B B.M.D =0

At point C (Wa=0) =-1934.239 x 50= -96711.9665 N.mm

At point C (Wa=1999.8) = (-1934.239 x 50) + (1999.8x d1/2) =23945.96 N.mm

B.M.D)B)Max =-96711.9665
 1
First Shaft

Resultant Bending Moment Diagram

At point A =At Point B = 0

R.B.M.D)C = √(86594)2 + (−98711.9665)2 = 129814.1953 N.mm

ASME code

P=34KN N=4000rpm
𝑃 𝑥 60
T= 2𝜋 𝑁 = 81.169𝑁. 𝑚

16𝑇𝑒
𝜏𝑎𝑙𝑙 =
𝜋𝑑3
Assume ASIS 1020 cold drawn 𝜏𝑎𝑙𝑙 = 56.7𝑀𝑃𝑎

Te=√(𝑘𝑚 + 𝑀)2 + (𝑘𝑡 + 𝑇)2

Assume Steady load gradually applied

Km =1.5 Kt =1
Te =153101.6998
16𝑇𝑒
d3 =𝜋𝜏
𝑎𝑙𝑙

d = 35.089 mm

Standard dsh =40 mm

 1
First Shaft

Standard dsh =40 mm

The design is safe

 1
Second Shaft

force analysis

at horizontal plane

Σ Ma =0

-RB x290 -2238.5x265 +3463.7x25

RB =1746.9

Σ Fy =0

RA +2238.5 =1746.9+3463.7

RA =2972.1

Bending Moment Diagram

At point A B.M.D)A =0

At point B B.M.D)B =0

At point C B.M.D)C =RA x 25 =74302.5N.mm

At point D B.M.D)D=RB x 25 =43672.5N.mm

At vertical plane

ΣMa = 0

-1455.3x25 +1043.27x265+RB x290=0

RB=827.87N

Σ Fy =0

RA+1043.27 = 827.87 +1455.3

RA =1239.9 N

Bending Moment Diagram

At Point A & B B.M.D =0

At point C (Wa=0) =-1239.9 x25= -30997.5 N.mm

At point C (Wa=1999.8) = (1239.9x25) + (1999.8x d1/2) =14997.9 N.mm

At point D (Wa =0) =-827.87x 25 =-20696.75 N.mm

Resultant Bending Moment Diagram

R.B.M.D)C = √(74302.5)2 + (30997.5)2 = 80509

R.B.M.D)D = √(43672.5)2 + (38243.8)2 = 58050.6

 1
Second Shaft

ASME code

P=34KN N=4000rpm
𝑃 𝑥 60
T= 2𝜋 𝑁 = 81.169𝑁. 𝑚𝑚

16𝑇𝑒
𝜏𝑎𝑙𝑙 =
𝜋𝑑3

Te=√(𝑘𝑚 + 𝑀)2 + (𝑘𝑡 + 𝑇)2

Assume Steady load gradually applied

Km =1.5 Kt =1

Te =145507.3
16𝑇𝑒
d3 =𝜋𝜏 =17866.9
𝑎𝑙𝑙

d = 26.13mm

Standard dsh =30 mm

The design is safe

 1
Third Shaft

d10 =64.6mm

Wt =2233.9 N

Wr =1043.27N

Wa =1625.5N

force analysis

at horizontal plane

Σ Ma =0

-RB x290 -2233.9 x265 =0

RB =2041.322

Σ Fy =0

RA +2041.322=2233.9

RA =192.578

Bending Moment Diagram

At point A B.M.D)A =0

At point B B.M.D)B =0

At point C B.M.D)C =RA x 265 =51033.06.mm

At vertical plane
ΣMa = 0

-1043.27x265 -1625.5x64.6/2-RB x290 =0

RB=-1134.38N

Σ Fy =0

RA+1043.27= 1134.38

RA =91.11N

Bending Moment Diagram

At Point A & B B.M.D =0

At point C (Wa=0) =91.11 x 265=24144.15 N.mm

Resultant Bending Moment Diagram

At point A =At Point B = 0

R.B.M.D)C = √(51033.06)2 + (24144.15)2 =56456.295N.mm

 1
Third Shaft

ASME code

P=34KN N=4000rpm
𝑃 𝑥 60
T= 2𝜋 𝑁 = 81.169𝑁. 𝑚𝑚

16𝑇𝑒
𝜏𝑎𝑙𝑙 =
𝜋𝑑3

Te=√(𝑘𝑚 + 𝑀)2 + (𝑘𝑡 + 𝑇)2

Assume Steady load gradually applied

Km =1.5 Kt =1

Te =117302.4355 N.mm
16𝑇𝑒
d3 =𝜋𝜏
𝑎𝑙𝑙

d = 22.1465mm
Standard dsh =30 mm

The design is safe

 1
First Shaft Bearing

From dsh =40

At point A

Bearing design 6208

C =22165 Co =15495
Wa1 =1999.8 N
𝐹𝑎 1999.8
= = 0.13
𝐶0 15495

e=0.37

𝐹𝑟 = √𝑅𝐴𝐻 2 + 𝑅𝐴𝑉 2 = √1731.82 + 1934.22 = 2596.2𝑁

𝑊𝑎 1999.8
= = 0.77
𝑉. 𝐹𝑟 1 + 2596.2
𝑊𝑎
>𝑒
𝑉. 𝐹𝑟
X=0.56 y=1.4
Fe =[ X * V * Fr] +[Fa * y]

F =[0.56 x 1 x 2596.2] +[1999.8 x 1.4] = 4253.5

 1
First Shaft Bearing
Fe =[ X * V * Fr] +[Fa * y]

Fe =[0.56 x 1 x 2596.2] +[1999.8 x 1.4] = 4253.5

𝑐′
(𝐹 )𝑘 𝑥 106 =Lh x 60 x nII
𝑒

Assume Lh =2000 Hours

Ln =2000 x 60 x4000
𝑐′
(𝐹 )3 𝑥 106 =Lh x 60 x nI
𝑒

c’ =33303.7> c

the design is unsafe

we takes 6208

C =31380 Co =20990
𝐹𝑎
= 0.07
𝐶0

e=0.27

𝐹𝑟 = 2596.2𝑁
𝑊𝑎
>𝑒
𝑉. 𝐹𝑟
X=0.56 y=1.6

Fe =[ X * V * Fr] +[Fa * y] = 4653.5

𝑐′
(𝐹 )3 𝑥 106 =480 x 106
𝑒

c’ =36436> c

the design is unsafe

so take 6408
 1
First Shaft Bearing

at point D

Bearing design 6208

C =22165 Co =15495

Wa1 =0N

𝐹𝑟 = √𝑅𝐴𝐻 2 + 𝑅𝐴𝑉 2 = 2596.2𝑁

X=1 y=0

Fe =Fr = 2596.2
𝑐′
(𝐹 )3 𝑥 106 =480 x 106
𝑒

c’ =20327< c

the design is safe

 1
Second Shaft Bearing

From dsh =30

Bearing design 6206

C =14710 Co =9805
At point A

Wa1 =1999.8 N
𝐹𝑎 1999.8
= = 0.25
𝐶0 9805
e=0.37

𝐹𝑟 = √𝑅𝐴𝐻 2 + 𝑅𝐴𝑉 2 = √2972.12 + 1239.92 = 3220.36𝑁

𝑊𝑎 1999.8
= = 0.62
𝑉. 𝐹𝑟 1𝑥3220.36
𝑊𝑎
>𝑒
𝑉. 𝐹𝑟
X=0.56 y=1.2

Fe =[ X * V * Fr] +[Fa * y]

Fe =[0.56 +1+3220.36] +[1999.8 *1.2] = 4203.16

𝑐′
(𝐹 )𝑘 𝑥 106 =Lh x 60 x nII
𝑒
 1
Second Shaft Bearing
𝑐′
(𝐹 )𝑘 𝑥 106 =Lh x 60 x nII
𝑒

Assume Lh =2000 Hours

Ln =2000 x 60 x4000

c’ =32908.4 > c

the design is unsafe

so choose 6306

e=0.31

Fr=3220.36

X=0.56 y=1.4

Fe =[ X * V * Fr] +[Fa * y] =4603.12

c’ =36040.3> c

the design is unsafe

at 6406 c= 43.6 KN

co =23.6KN

e=0.07

Fr=3220.36

X=0.56 y=1.6

Fe =[ X * V * Fr] +[Fa * y] =5003

𝑐′
(𝐹 )3 𝑥 106 = 480
𝑒

c’ < c

the design is safe

 1
Second Shaft Bearing

At point B

Wa =1625.5N

6406 c=43.6KN
𝐹𝑎 1625.5
= = 0.07
𝐶0 23.6𝑥 103
e=0.27

𝐹𝑟 = √𝑅𝐴𝐻 2 + 𝑅𝐴𝑉 2 = 1933𝑁

𝑊𝑎
= 0.84
𝑉. 𝐹𝑟
𝑊𝑎
>𝑒
𝑉. 𝐹𝑟
X=0.56 y=1.6

Fe =[ X * V * Fr] +[Fa * y] = 4203.16

𝑐′
(𝐹 )3 𝑥 106 =480 x106
𝑒

c’ =28838,48 < c

the design is safe

 1
Third Shaft Bearing

From dsh =25 nIII =4170

At point A

Bearing design 6205

C =10690 Co =6965

Wa1 =1625.5N
𝐹𝑎 1625.5
= = 0.25
𝐶0 6965

e=0.37

𝐹𝑟 = √𝑅𝐴𝐻 2 + 𝑅𝐴𝑉 2 = 213𝑁

𝑊𝑎 1625.5
= = 0.62
𝑉. 𝐹𝑟 1 + 213
𝑊𝑎
>𝑒
𝑉. 𝐹𝑟
X=0.56 y=1.2

Fe =[ X * V * Fr] +[Fa * y] =2069.8

𝑐′
( )3 𝑥 106 =Lh x 60 x nII
𝐹𝑒
 1
Third Shaft Bearing

𝑐′
(𝐹 )3 𝑥 106 =Lh x 60 x nII
𝑒

Assume Lh =2000 Hours

Ln =2000 x 60 x4000

c’ =16432.3 > c

the design is unsafe

Bearing design 6305

C =15985 Co =10150
𝐹𝑎 1625.5
= = 0.31
𝐶0 10150

e=0.31
𝑊𝑎
>𝑒
𝑉. 𝐹𝑟
X=0.56 y=1.4

Fe =[ X * V * Fr] +[Fa * y] =2394.9

𝑐′
(𝐹 )3 𝑥 106 =Lh x 60 x nII
𝑒

Assume Lh =2000 Hours

Ln =2000 x 60 x4000

c’ =18751> c

the design is unsafe

so take 6405
 1
Third Shaft Bearing

At point B

Wa=0

Bearing design 6205

C =10690 Co =6965

𝐹𝑟 = √𝑅𝐵𝐻 2 + 𝑅𝐵𝑉 2 = 2335.2

𝑊𝑎
>𝑒
𝑉. 𝐹𝑟
y=0 X=1

Fe =[ X * V * Fr] +[Fa * y] =2335.2

𝑐′
(𝐹 )3 𝑥 106 =Lh x 60 x nII
𝑒

Assume Lh =2000 Hours

Ln =2000 x 60 x4000

c’ =18539> c

the design is unsafe

so take 6405
1
1
1