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Chapter11 Prob01

1) The idler gear experiences the highest bending stresses of 34.2 MPa. 2) The recommended face width for the idler is 30 mm. 3) The safety factors for bending stress are all above 7, with the idler having the lowest value of 7.77. 4) The surface stresses are 480.56 MPa for the pinion-idler mesh and 348.4 MPa for the idler-gear mesh. The safety factors for surface stress cannot be determined from the information given.

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211 views13 pages

Chapter11 Prob01

1) The idler gear experiences the highest bending stresses of 34.2 MPa. 2) The recommended face width for the idler is 30 mm. 3) The safety factors for bending stress are all above 7, with the idler having the lowest value of 7.77. 4) The surface stresses are 480.56 MPa for the pinion-idler mesh and 348.4 MPa for the idler-gear mesh. The safety factors for surface stress cannot be determined from the information given.

Uploaded by

imranakhtar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Gear Design

50T
4

Problem: Pinion 2 is shown in the figure


3

Output
(gear)

runs at 1750 rpm and transmits 2.5 kW to

60T

idler gear 3. The teeth are cut on the 200


20T

full-depth system and have a module of

2
Input
(pinion)

m = 2.5 mm.

a) Draw a free-body diagram of gear 3 and show all the forces and compute the torques on
the output gear 4
dp

T = Wt

Wt : tangential force

dp : pitch diameter

H = T *

H = Wt *

H: Power
: angular rotation

d p 2

*
*2
2 60

(rev/min) =

H =

(rev/sec)

60

d p *

= 2

*W

60

(rad/sec)

where,

60 * 10

H : (kN)

2 : (rev/min)
dp : (mm)
Wt : (kN)

60 * 10

* H

dp= N*m:
2

N: number of teeth
m: module (mm)

60 * 10

* H

(N * m )*

60 * 10

* ( 2 .5 )

= 0.546 kN

( 20 * 2 . 5 ) * 1750

Thus, the tangential force of gear 2 on gear 3 is 0.546 kN. The radial force is;
W

= W t * tan 20

= 0 . 546 * tan 20

= 0 . 199 kN

The tangential reaction of gear 4 on gear 3 is also equal to Wt

Wt
Gear
3

Fx
Fy

Wr

Wt
Wr

Forces on shaft of gear 3;


FX = - ( - 0.546 + 0.199) = 0.347 kN
FY = - ( 0.199-0.546 ) = 0.347 kN
The output Torque:

4 r2 N 2
= =
2 r4 N 4
N
N

= (

N
N

2
3

) * (

N
N

T2 = Wt * r2
T4 = Wt * r4
2

3
4

) =

20
60

T4 =

r4
N
* T2 = 4 * T2
r2
N2

T4 =

60
50
* T2 = 3 * (0.546 * )
20
2

T2 =13.65 Nm
T4 =40.95 Nm

b) Compute the mean and alternating loads on 1) pinion, 2) gear and, 3) idler.

The repeated loads on pinion and gear:


R=0=

min
max

(since min = 0 )

Wt 0.546
=
= 0.273 kN
2
2
W 0.546
Wtalternating = t =
= 0.273 kN
2
2
Wtmean =

The fully-reversed loads on the idler:

min
max
= max

R = -1 =

min

Wtalternating = Wt = 0.546 kN
Wtmean = 0 kN

c) Determine a suitable face width and the bending stresses in the idler gear (3)

b =

Wt * Pd K a * K m
*
* KS * KB * KI
F*J
Kv

Recommended face-width range is

Pd

<F<

Take

16
Pd

F=

Pd = diametral pitch = 25.4/m

12
Pd

8m
16m
<F<
25.4
25.4

( SI units )

The relation between Pd (U.S. specification) and the module m (S.I. unit) is

25.4
= 2.5 mm/teeth
Pd
Hence, Pd = 10.16 teeth/inches.
m=

The face width (F):


12
F=
= 1.81 inches = 3 cm = 30 mm
10.16

The load distribution factor (Km)


4

Using Table 11 16
Km=1.6

(for F=1.81 inches = 30 mm)

The application factor:


(assume uniform loading; table 11 -17)
Ka = 1
The velocity factor:

A
KV =
A + 200 * V
t

Vt : pitch-line velocity
dp
d
Vt =
* = 3 * 3
2
2
Gear 3:
d3 = m N3 = 2.5*50 = 125 mm
N
3 = 2 * 2
N3
20
3 = * 1750
50
rev
3 = 700rpm *
min
2
3 = 700 *
= 73.266 rad/sec
60

Vt = 4.58 m/s = 274.76 m/min


Note that Vt ( ft / min) = Vt (m / sec) *196.85
Vt = 901.5 ft/min

since 1 ft = 12 inches = 30.48 cm

The quality index (Qv)


Using Table 11-7 (page 710)
Vt
Qv
0- 800
6-8
901.5 ft/min ?
800-2000
8-10

Take Qv = 8

(12 8) 2 / 3
= 0.63
4
A = 50 +56(1-B) =7 0.72
B=

70.72
KV =

70.72 + 200 * 4.58

0.63

= 0.8

The size factor KS=1 for all gears


The rim thickness factor KB= 1

(assume no rim)

The idler factor KI = 1 for gears 2 and 4, KI = 1.42 for the gear 3.
The bending geometry factor J for 200 presume angle (full depth teeth with HPSTC
loading)
pinion : 20 T (200)
gear : 60 T (200)
idler : 50 T (200)

First, calculate the Jpinion, and Jgear based on pinion (gear 2 in the figure) and idler (gear 3
in the figure) interactions:

idler
(gear)

50T

20T

pinion

Using Table 11- 9 (p.716)


Jpinion 0.34
Jgear(idler) 0.39

b =

Wt * Pd K a * K m
*
* KS * KB * KI
F*J
Kv

since F=

b =

12
Pd

Wt * Pd2 K a * K m
*
* KS * KB * KI
12 J
Kv

also,
Pd =

25.4
m

25.4
Wt *

m * Ka * Km * K * K * K
b =
S
B
I
12 J
Kv

b =

Wt * (53.76) K a * K m
*
* KS * KB * KI
Kv
m2 * J

m = 2.5 mm
then

b is in MPa

Wt = 0.546 kN

pinion

b
b

gear

0.546 * (53.76) 1 * 1.6


*1 *1 *1
*
0. 8
( 2.5) 2 * (0.34)

= 27.63

pinion

pinion

MPa

0.546 * (53.76) 1 * 1.6


*
* 1 * 1 * 1.42
( 2.5) 2 * (0.39)
0 .8

= 34.2

MPa

Second, calculate the Jpinion, and Jgear based on idler (3) and gear (4) interactions:

60T

Using Table 11- 9 (p.716)

50T

Jpinion(idler) 0.42
Jgear 0.43

gear

idler

Note: The idler has a slightly different J factor when considered to be the gear in mesh with
the smaller pinion (0.42) than when considered to be the pinion in mesh with the larger gear
(0.43).

idler

0.546 * (53.76) 1 * 1.6


*
* 1 * 1 * 1.42
2
0.8
(2.5) * (0.42)

= 31.75 MPa

gear

0.546 * (53.76) 1 * 1.6


*
*1 *1 *1
2
0 .8
(2.5) * (0.43)

= 21. 84 MPa

d) All gears are made of steel (AGMA grade 2 with Brinell Hardness number of 250 HB).
The service life required is 5 years of one-shift operation. Operating temperature is 2000 F.
Calculate the safety factor for bending stress (Assume 99 % reliability).

Sf b=

KL
* S f b
KT * K R

S f b = 280 MPa

(from the Figure 11-25, pp.733 for HB = 250)

piniom =1750 rpm


idler =700 rpm
gear =583.3 rpm

60 min
2080hr
*
* 5 yr
hr
shift year
=1.092*109 cycles

N pinion = 1750rpm
N pinion

Nidler = 0.4368*109 cycles


8

Ngear = 0.364*109 cycles


The life factor:
KL(pinion)= 1.3558*N-0.0178

(Fig. 11-24, N>108 commercial app)

= 0.936
KL(idler) = 0.951
KL(gear) = 0.955
The temperature factor:
KT=1

(T<2500)

The reliability factor:


KR=1

(%99 reliability)

262
= 9.48
27.63

S f b pinion = 262 MPa

N b pinion =

S f b idler = 266 MPa

N b idler =

266
= 7.77
34.2

S f b gear = 267.4 MPa

N b gear =

267.4
= 12.24
21.84

Hence, idler is the most critical (it is exposed to fully reversed stresses).

e) Determine the surface stresses for


1) pinion- idler mesh
2) idler-gear mesh
and the safety factor for surface stresses.

c = cp

Ca * Cm * Cs * C f

F *I *d

Cv

Ca = Ka = 1
Cm = Km = 1.6

Cv = Kv = 0.8
F = 30 mm
Notes:
d (pitch diameter) is the smaller of mating gears
I is the smaller of mating gears
Be careful with the +/- signs in equations 11.22a and 11.22b.
Eq. 11.22a (+ : external, -: internal)
Eq. 11.22b (- : external, +: internal)

Cs= 1 (size factor)


Cf = 1 (surface finish factor)
The elastic coefficient:
Cp =

1
1 v

2
p

E p

1 v g2
)+(
)
E g
v =0.3

All gears are made of steel

(Table 11-18 assumes that v = 0.3)

Ep = 30*106 psi = 2*105 MPa


Instead of calculating the Cp using the equation; you can directly get the value from the table if
the material is available.
UNIT
pinion
steel
gear

Cp=2300

psi

Cp=191

MPa

steel

Surface Geometry Factor (I)


I=

cos
1
1

*d

p
p g

p = (rp +

1+ xp
pd

use + sign for external gears and - for internal gears

) 2 (rp * cos ) 2

g = c sin m p

pd

* cos

-: external gears

10

+ : internal gears

pinion-idler mesh
rp=

dp
2

ridler=

m * N pinion
2

2.5 * 20
= 25 mm
2

d idler 2.5 * 50 125


=
=
mm
2
2
2

= 20 0
m=

25.4
pd

Pd =

25.4
= 10.16
m

The pinion addendum coefficient xp= 0


(xp= 0 for full-depth teeth and xp= 0.25 for 25 % long-addendum teeth)

p = (25 +

1
10.16

) 2 (25 * cos 20 0 ) 2

10.16

p = 8.54 mm
gear = c sin 1 = (25 +
gear =21.39 mm
I=

cos
1
1

*d
+
p

p g

125
) * sin 20 0 8.54
2

= 0.115

Idler gear mesh


idler
125
rp=
m
2
150
rp=
mm
2
= 20 0

11

* cos 20 0

p = (62.5 +

1
10.16

) 2 (62.5 * cos 20 0 ) 2

10.16

* cos 20 0

p =21.37 mm
g = c sin m p = (62.5 + 75) * sin 20 0 21.37
g = 25.7 mm
Iidler(pinion) =

cos
= 0.175
1
1
+

* 62.5
21.37 25.7

The surface stress for pinion-idler mesh:

cp = c p

Ca * Cm * C s * C f

F * I pinion * d p

Cv

0.546 *10 3 N 1 * 1.6 * 1 *1


30 * 0.115 * 50
0.8
cp = 480.56 MPa
= 191 *

The surface stress for idler-gear mesh:

cidler = 191 *

0.546 * 10 3 1 *1.6 *1 *1
30 * 0.175 * 62.5
0.8

cidler = 348.4 MPa

Sfc=

CL * CH
* S'f c
CT * C R

S ' f c 820MPa

(for HB= 250 and Grade II ) Table 11-27, page 737

CT=1

(T< 2500 F)

CR=1

(%99 reliability)

CH=1

(Hardness Ratio factor)

12

C L pinion = 1.4488 N 0.023 = 1.4488(1.092 *10 9 ) 0.023

(Fig. 11-26, pp.734)

=0.898
C L idler = 0.917
C L gear = 0.92

= 820 * 0.898 = 736MPa

Sfc

pinion

Sfc

idler

Sfc

gear

=752 MPa
= 754 MPa

N c pinion idler

736
=
= 2.4
480.56
2

N c idler gear

752
=
= 4.7
348.4

Hence; pinion-idler surface is more critical.

Note: we take the square of the safety factor because the surface stress is related to the
square root of the load.

13

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