UME 408 Machine Design- 1

Redesign of an angle cutter/grinder

ASSIGNMENT MODULE- 1

FORCE AND STRESS ANALYSIS OF BEVEL GEAR

&
SELECTION OF BEARING

Total Points: 20
Submission Due: 15th April 2019 to 19th April 2019

Note:
 Complete this module in group; copying will be dealt with severely.
 The print of this document alongwith graphs, excel spreadsheets and CAD drawings
stapled together (or spiral bound) is to be submitted by the due date as mentioned
above.
 Submit your documents on time to the tutorial instructor. No extensions will be
granted.

Tutorial Group:_______________ Project Group____________

NAME:_______________________________ Roll No:_______________

NAME:_______________________________ Roll No:_______________
NAME:_______________________________ Roll No:_______________
NAME:_______________________________ Roll No:_______________
NAME:_______________________________ Roll No:_______________

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Part A: Q1 to Q4 have been devised based on designing the bevel gear used in the drive system
of angle grinder. Complete Q1-Q4. Note: Excel spreadsheet to be created for Q2 and Q3.
Perform stress analysis of pinion based on ANSI/AGMA 2003-B97 standard or equivalent
code.

Q1 .Measure the distance between points marked in Figure 1. Calculate the forces acting on the
pinion at the midpoint of the tooth. (2 points)

Figure 1

Figure 2

Power to be transmitted =
Torque transmitted (N-mm) =
Rotations per minute of pinion =

2
Face width of gear tooth =
Referring to Figure 2, fill the information in Table 1
Table 1 Design parameters
Parameters of pinion Forces at contact point
No. of No. Pitch Cone Radius Normal Equivalent Tangential Radial Axial
teeth of angle distance at mid Pressure number of force (N) force Force
on teeth (deg) (mm) point angle teeth on (N) (N)
pinion on (mm) (ϕ) pinion
gear
γ A0 rav 𝑧𝑝′ Wt Wr Wa

Select three gear materials and list the properties in Table 2

Table 2 Properties of Gear materials
S.No. Material SAE or AISI Yield Tensile Density Hardness
number strength strength
(Grade) (Min.) (Min.)
S.I. Units
(i)
(ii)
(iii)

Q2 . Calculate the required module for pinion for three different gear materials. (3 points)
Service factor =
Velocity factor =
Contact ratio =
Effective load on gear tooth (Weff) =
Factor of safety =

Table 3 Gear tooth proportions from beam strength considerations

S.No. Material Beam Module of Face width of Corrected Corrected
strength of gear in gear (mm) pitch circle cone
gear tooth (N) mm diameter distance
(standard (mm) (mm)
value)
(i)
(ii)
(iii)

3
 Table 4 Factor of safety
S.No. Material Wear Maximum Deformation Dynamic load Factor of
strength expected factor for calculated by safety
of gear error pinion Buckingham’s against
tooth (N) between gear equation (N) pitting
teeth (mm) failure

(i)
(ii)
(iii)

Q3 . Insert a plot of pitch angle (γ = 15°, 45°, 90°, 120°) against tangential force (Wt). Comment on
the magnitude of the values of Wt when compared to the beam strength of gear tooth. (2 points)

Q4 . Model the bevel gear (pinion only) using any CAD software. Only one gear tooth profile should
be constructed on the basis of findings of the studies on different materials and different pitch
angles. (3 points)

4
Part B: The following tasks have been based on selection procedure of deep groove ball
bearings given in the product catalogue of SKF®. Complete the tasks mentioned in Q5-Q8.

Q5 . Draw the free body diagram of output shaft. The forces which act on the non-threaded portion
of stepped shaft should be taken from the “Annexure I”. (2 points)

Figure 1

Figure 2 : Free body diagram of output shaft

Q6 . Calculate the Reaction forces (Rx, Ry, Rz) acting on bearing at C as shown in Figure 1.
(3 points)
Rx =

Ry =

Rz =

5
Q7 . Recommend a suitable deep groove ball bearing at C. Specify the bearing number, static load
carrying capacity and dynamic load carrying capacity of selected bearing also.
(3 points)
Radial force acting at C (N) Thrust forces acting at C (N) Equivalent dynamic force (N)

Radial load factor (X) Thrust load factor (Y) Race rotation factor (V)

Service/ load factor Bearing life for cutter Bore diameter of bearing
application/ reliability

Designation of Bearing Basic load ratings

C C0

Q8 . List all the equations used for selection of bearing. (2 points)

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