UNIT-1 DESIGN OF TRANSMISSION SYSTEMS FOR FLEXIBLE ELEMENTS

Part - B

1. A V-belt drive is to transmit 15 KW to a compressor. The motor runs at 1150 rpm

and the compressor is to run at 400 rpm. Determine: (i) belt specifications (ii)
number of belts (iii) correct centre distance and (iv) drive pulley diameter.

DESIGN OF ‘V’ BELT DRIVE

Given:

From PSG 5.124 standard power 15 KW @ 1150 rpm

We required 70 rpm to run the work spindle. The reduction of the speed follow by using
V-belt drive and set of gears.

For power P= 15 KW

Driver pulley N1 = 1150 rpm

Driven pulley N2 = 400 rpm

The design calculations are,

Step 1: Selection of belt section

From PSG data book 7.58

For power 15 kw ‘C’ section is selected

Step 2: Selection of pulley diameter (d and D)

Smaller pulley diameter from PSG DB 7.58

𝐷
d= 200 mm, speed ratio i =𝑑 = 3

𝐷 = 3 × 200 = 600 𝑚𝑚

∴ Bigger pulley diameter D= 600 mm

Step 3: Calculation of center distance

From PSG DB 7.61

𝐶
For i=3 =1
𝐷

C= 1 X 600 therefore C=600 mm

Step 4: Determination of nominal pitch length

𝜋 (𝐷−𝑑)2
𝐿 = 2𝐶 + (2 ) (𝐷 + 𝑑) + 4𝐶

𝜋 (600−200)2
= (2 × 600) + ( 2 ) (600 + 200) + 4×600

L= 2522.66 mm

Nominal inside length for L=2522.66 mm is L=2667 mm

Therefore belt designation is a V-belt cross section ‘A’ and of nominal inside length of 2667 mm
(35.98 inches) shall be designed as a 914/35.98 IS: 2494

Step 5: Calculation of actual center distance

Cactual =A+√𝐴2 − 𝐵

Where,

𝐿 𝐷+𝑑
𝐴= −𝜋[ ]
4 8

2667 600+200
= −𝜋[ ]
4 8

A= 352.75mm

(𝐷 − 𝑑)2
𝐵=
8

(600 − 200)2
=
8
 B = 20000 mm

Cactual = 352.75 +√352.752 − 20000

Cactual= 675.910mm

Lower limiting value =1.5% of L

1.5
= 100 × 2667= 40.005 mm

Higher limiting value= 3%L

3
= 100 × 2667 = 80.01 mm

Step 6: Determination of number of belt

𝑃 × 𝐹𝑎
𝑛𝑏 =
𝑘𝑤 × 𝑓𝑐 × 𝑓𝑑

Step 7: Selection of various modification factors

(i) Length correction factor (fc)

Fc = 0.94
(ii) Correction factor for arc of contact (fd)
𝐷−𝑑
Arc of contact =180° − ( ) × 60°
𝐶
600−200
= 180° − ( 675.910 ) × 60°

=144.49°
From PSG DB fd = 0.91
(iii) Service factor (fa)
For heavy duty fa=1.5

(iv)Calculation of maximum power capacity (kw)

19.62
𝑘𝑤 = (0.45𝑆 −0.09 − − 0.765 × 10−4 𝑆 2 ) × 𝑆
𝑑𝑒
 𝜋𝑑𝑁1 𝜋 × 0.2 × 1150 𝑚
𝑆= = = 12.03
60 60 𝑠

𝑑𝑒 = 𝑑𝑝 × 𝑓𝑏 =200 X 1.14

∴ 𝑑𝑒 = 228 𝑚𝑚

19.62
𝑘𝑤 = (0.45 × 12.03−0.09 − − 0.765 × 10−4 𝑋12.032 ) × 12.03
228

=3.15 kw

15 ×1.5
=3.15×0.84×0.91

Number of belts = 8.35 = 8

Step 8: Dimensions of V-groove pulley

Pitch width Ip=19mm

Minimum distance down to pitch line b=5.7 mm

Pulley pitch diameter dp =200 mm

Minimum depth bellow pitch line h= 14.3mm

Centre to center distance of groove e= 25.5 mm

Edge of pulley to first groove center f=17 mm

Table no: 1.1 Specification of v belt and pulley

V-BELT AND PULLEY SPECIFICATION

Length of belt (L) 2667 mm
Center distance (C) 675.91 mm
Pulley pitch diameter 200 mm
Pitch width 19 mm
Minimum depth below pitch line (h) 14.3mm
 2. Design a V-belt drive and calculate the actual belt tensions and
average stress for the following data. Driven pulley diameter, D=500 mm,
Driver pulley diameter, d=150 mm, Centre distance, C=925 mm, Speeds
nl=1000 rpm, n2 = 300 rpm and Power, P = 7.5 kW.

DESIGN OF ‘V’ BELT DRIVE

Given:

From PSG 5.124 standard power 7.5 KW @ 1000 rpm

For power P= 7.5 KW

Driver pulley N1 = 1000 rpm

Driven pulley N2 = 300 rpm

Driven pulley diameter D = 500 mm

Driver pulley diameter d = 150 mm

Center distance C= 925 mm

The design calculations are,

Solution:

Power transmission Capacity of belt

𝑃=(𝑇1−𝑇2) V

Step 1: Velocity of belt

V = (𝜋 𝑑 𝑛)/(60 ×1000)

V = (𝜋× 150 × 1000)/(60 ×1000)

V = 7.85 m/s

Step 2: Tensile strength of belt

P = 2 𝜋 N T / 60
 T = 7.5 X 60 X 2 X 𝜋 X 1000

T = 2826000 Nmm

Step 3: mass of belt per unit length

m = Area x unit length x density)

m = 9 x 250 x 1 x 980 x 10-6

m = 2.2 kg/m

Step 4: Centrifugal tension

Tc = m v2

Tc = 2.2 x 7.852

Tc = 135.56 N

Step 5: Belt tensions

T = T1 + Tc

T1 = 2826000 – 135.56

T1 = 2825864.43 Nmm

Ratio between the tensions of tight side and slack side

𝑇1
= 𝑒 𝜇𝜃
𝑇2

π
Assume 𝜃 = 120 𝑋 180

3.14
𝜃 = 120 𝑋 = 2.09
180

2825864.43
= 𝑒 (0.35 𝑥 2.09)
𝑇2
 𝑇2 = 1359768.29 Nmm

Step 6: Determine average stress

Ft= σ b t

From PSG pg no : 7.58

Belt width for ‘C’ cross section b = 22 mm

Nominal belt thickness for ‘C’ t = 14 mm

Torque T = Ft

2826000 = σ X 22 X 14

σ = 9175.32 N/mm2

3. Two shafts whose centres are 1 metre apart are connected by a V-belt drive. The
driving pulley is supplied with 100 kW power and has an effective diameter of 300
mm. It runs at 1000 rpm, while the driven pulley runs at 375 r.p.m. The angle of
groove on the pulleys is 40°. Permissible tension in 400 mm2 cross-sectional area
belt is 2.1 MPa. The material of the belt has density of 1100 kg/m3. The driven
pulley is overhung, the distance of the centre from the nearest bearing being 200
mm. The coefficient of friction between belt and pulley rim is 0.28. Estimate the
number of belts required.

Given:

Power supplied = 100 KW

Effective diameter d = 300 mm

Driver pulley running speed N1 = 1000 rpm

Driven pulley running speed N2 = 375 rpm

Angle of groove on the pulleys = 40°

Cross sectional area = 400 mm2

Belt density = 1000 kg/m3

 Centre distance C = 200 mm

Coefficient of friction = 0.28

Power transmission Capacity of belt

𝑃=(𝑇_1−𝑇_2)V

Step 1: Velocity of belt

V = (𝜋 𝑑 𝑛)/(60 ×1000)

V = (𝜋× 300 ×1000)/(60 ×1000)

V = 15.8 m/s

Step 2: Tensile strength of belt

Ft= σ b t

Ft= 2 x 32 x 19

Ft= 1216 N

Step 3: Determination of nominal pitch length

C/D = 1

D = 200 mm

𝜋 (𝐷−𝑑)2
𝐿 = 2𝐶 + (2 ) (𝐷 + 𝑑) + 4𝐶

𝜋 (200−300)2
= (2 × 200) + ( 2 ) (200 + 300) + 4×200

L= 1197.5 mm

Nominal inside length for L= 1197.5 mm is L= 3048 mm

Therefore belt designation is a V-belt cross section ‘A’ and of nominal inside length of
3048 mm (35.98 inches) shall be designed as a 914/35.98 IS: 2494
 Step 4: mass of belt per unit length

m = Area x unit length x density)

m = 400 x 3048 x 1000 x 10-6

m = 1219.2 kg/m

Step 5: Centrifugal tension

Tc = m v2

Tc = 1219.2 x 15.82

Tc = 304361.08 N

Step 6: Belt tensions

Tt = T1 + Tc

Tt = Ft

T1 = 1216 – 304361.08

T1 = 303145.08 N (take positive value)

Ratio between the tensions of tight side and slack side

𝑇1
= 𝑒 𝜇𝜃
𝑇2

303145.08
= 𝑒 (0.28 𝑥0.69)
𝑇2

𝑇2 = 249887.67 N

Step 7: Determine number of belt required

𝑃 × 𝐹𝑎
𝑛𝑏 =
𝑘𝑤 × 𝑓𝑐 × 𝑓𝑑
Step 8: Selection of various modification factors

(iv) Length correction factor (fc)

Fc = 0.86
(v) Correction factor for arc of contact (fd)
𝐷−𝑑
Arc of contact =180° − ( ) × 60°
𝐶
300−200
= 180° − ( ) × 60°
200

=150°
From PSG DB fd = 0.93
(vi) Service factor (fa)
For heavy duty fa=1.5

(iv)Calculation of maximum power capacity (kw)

19.62
𝑘𝑤 = (0.45𝑆 −0.09 − − 0.765 × 10−4 𝑆 2 ) × 𝑆
𝑑𝑒

𝜋𝑑𝑁1 𝜋 × 0.3 × 1000 𝑚

𝑆= = = 15.7
60 60 𝑠

𝑑𝑒 = 𝑑𝑝 × 𝑓𝑏 =300 X 1.14

∴ 𝑑𝑒 = 342 𝑚𝑚

19.62
𝑘𝑤 = (0.45 × 15.7−0.09 − − 0.765 × 10−4 𝑋15.72 ) × 15.7
342

= 4.317 kw

100 ×1.5
=4.317×0.86×0.93

Number of belts = 43.9 = 44

Step 8: Dimensions of V-groove pulley

Pitch width Ip= 27mm

Minimum distance down to pitch line b= 8.1 mm

 Pulley pitch diameter dp =300 mm

Minimum depth bellow pitch line h= 19.9 mm

Centre to center distance of groove e= 37 mm

Edge of pulley to first groove center f=24 mm

Table no: 1.1 Specification of v belt and pulley

V-BELT AND PULLEY SPECIFICATION

Length of belt (L) 3048 mm
Center distance (C) 200 mm
Pulley pitch diameter 300 mm
Pitch width 27 mm
Minimum depth below pitch line (h) 19.9 mm

4. A V-belt drive is required to transmit 16 kW power to a compressor. The motor

speed is 1440 rpm and the speed reduction ratio is 3.6. Design the belt drive. Sketch
the details of pulley.

Given:

From PSG 5.124 standard power 16 KW @ 1440 rpm

For power P= 16 KW

Driver pulley N1 = 1440 rpm

Speed ratio i = D/d = 3.6

C/D = 1

The design calculations are,

Step 1: Selection of belt section

From PSG data book 7.58

 For power 16 kw ‘C’ section is selected

Step 2: Selection of pulley diameter (d and D)

Smaller pulley diameter from PSG DB 7.58

𝐷
d= 200 mm, speed ratio i =𝑑 = 3.6

𝐷 = 3.6 × 200 = 720 𝑚𝑚

∴ Bigger pulley diameter D= 720 mm

Step 3: Calculation of center distance

From PSG DB 7.61

𝐶
For i= 3.6 =1
𝐷

C= 1 X 720 therefore C= 720 mm

Step 4: Determination of nominal pitch length

𝜋 (𝐷−𝑑)2
𝐿 = 2𝐶 + (2 ) (𝐷 + 𝑑) + 4𝐶

𝜋 (720−200)2
= (2 × 720) + ( 2 ) (720 + 200) + 4×720

L= 2978.2 mm

Nominal inside length for L=2978.2 mm is L= 3048 mm

Therefore belt designation is a V-belt cross section ‘A’ and of nominal inside length of 3048 mm
(35.98 inches) shall be designed as a 914/35.98 IS: 2494

Step 5: Calculation of actual center distance

Cactual =A+√𝐴2 − 𝐵

Where,
 𝐿 𝐷+𝑑
𝐴= −𝜋[ ]
4 8

3048 720+200
= −𝜋[ ]
4 8

A= 400.9 mm

(𝐷 − 𝑑)2
𝐵=
8

(720 − 200)2
=
8

B = 31250 mm

Cactual = 400.9 +√400.92 − 31250

Cactual= 760.7 mm

Lower limiting value =1.5% of L

1.5
= 100 × 3048= 45.72 mm

Higher limiting value= 3%L

3
= 100 × 3048 = 91.44 mm

Step 6: Determination of number of belt

𝑃 × 𝐹𝑎
𝑛𝑏 =
𝑘𝑤 × 𝑓𝑐 × 𝑓𝑑

Step 7: Selection of various modification factors

(vii) Length correction factor (fc)

Fc = 0.97
(viii) Correction factor for arc of contact (fd)
𝐷−𝑑
Arc of contact =180° − ( ) × 60°
𝐶
 720−200
= 180° − ( ) × 60°
720

=136.66°
From PSG DB fd = 0.88
(ix) Service factor (fa)
For heavy duty fa=1.5

(iv)Calculation of maximum power capacity (kw)

19.62
𝑘𝑤 = (0.45𝑆 −0.09 − − 0.765 × 10−4 𝑆 2 ) × 𝑆
𝑑𝑒

𝜋𝑑𝑁1 𝜋 × 0.2 × 1150 𝑚

𝑆= = = 12.03
60 60 𝑠

𝑑𝑒 = 𝑑𝑝 × 𝑓𝑏 =200 X 1.14

∴ 𝑑𝑒 = 228 𝑚𝑚

19.62
𝑘𝑤 = (0.45 × 12.03−0.09 − − 0.765 × 10−4 𝑋12.032 ) × 12.03
228

=3.15 kw

16 ×1.5
=3.15×0.88×0.97

Number of belts = 8.9 = 9

Step 8: Dimensions of V-groove pulley

Pitch width Ip=19mm

Minimum distance down to pitch line b=5.7 mm

Pulley pitch diameter dp =200 mm

Minimum depth bellow pitch line h= 14.3mm

Centre to center distance of groove e= 25.5 mm

Edge of pulley to first groove center f=17 mm

 Table no: 1.1 Specification of v belt and pulley

V-BELT AND PULLEY SPECIFICATION

Length of belt (L) 2667 mm
Center distance (C) 675.91 mm
Pulley pitch diameter 200 mm
Pitch width 19 mm
Minimum depth below pitch line (h) 14.4mm

5. It is required to design a leather crossed belt drive to connect 7.5 kW, 1440 rpm

electric motor to a compressor running at 480 rpm. The distance between the
centres of the pulleys is twice the diameter of the bigger pulley. The belt
should operate at 20 m/s approximately and its thickness is 5 mm. Density
of leather is 950 kg/m3 and permissible stress is 5.6 MPa.

Given:

Power P= 7.5 kw

Belt drive rpm = 1440 rpm

Compressor rpm = 480 rpm

Belt velocity v = 20 m/s

Thickness t = 5 mm

Belt density = 950 kg/m3

permissible stress = 5.6 MPa

C=2D

Step 1: Belt tensions from Power transmission Capacity of belt

𝑃 = (𝑇1 − 𝑇2 ) V

Velocity of belt

WKT, the power transmission capacity

7500 = (𝑇1 − 𝑇2 ) 20
 𝑇1 − 𝑇2 = 375 N

Given

7.5 = (2 X 3.14 X 1440 X T)/ 60

T1 = 49.76 Nm

T2 = 325.23 Nm

Step 2: Width of Belt

maximum tension
Width of belt (b) =
belt rating

(belt rating = 145N in 10mm width or 14.5N per mm width)

325.23
(b) =
14.5
b = 110 mm

The standard width of belt b = 112mm

Step 3: Diameter of shaft

Torque transmitted P=Txω

𝑃 𝑥 60
T= 2𝜋𝑁

7500 𝑥 60
T = 2 𝜋 𝑥 1440

T = 49.76 N m
𝜋
 Torque transmitted T = 16 × 𝜏 × 𝑑 3

3 16×49.76
d= √
𝜋×5.

d = 35.6 mm.

Step 4: Dimensions of pulley

Refer PSGDB 7.56

Step 4(a): Width and thickness of pulley

width of pulley rim B = b + 13 (PSGDB 7.54)

 B = 112 + 13

B = 125 mm
𝐷
thickness of pulley rim t = 200 + 3(PSGDB 7.57)

900
t = 200 + 3

t = 7.5 mm

 Step 4(b): Dimensions of arm

Refer PSGDB 7.56

Number of arms =6

cross section of arm = elliptical

3 125 ×900
thickness of arm (near boss) = 2.94 √ 4×6

= 50 mm

thickness of arm (near rim) = (2/3) x (2x 35)

= 46.66 mm

minimum length of bore (l) = (2/3) x width of pulley

= (2/3) x 125

= 85 mm

diameter of bore = diameter of shaft

UNIT - 2 SPUR GEARS AND PARALLEL AXIS HELICAL GEARS

 Part - B

DESIGN OF SPUR GEAR

1. A motor shaft rotating 1440 rpm has to transmit 15 KW power to a low speed shaft
rotating at 500 rpm. A 200 pressure angle involute tooth gear pinion is used. The
pinion has 25 teeth. Design a suitable gear drive.

SPECIFICATIONS:

The motor shaft rotating at N1=1440 rpm, N2=500 rpm

Reduction i=N1/N2

Therefore i =1440/500= 2.88,

STEP 1: Material selection:

Material for pinion and Gear C45 is selected.

Material properties from (PSG DB 1.9)

𝑘𝑔𝑓 𝑘𝑔𝑓
𝜎𝑢 = 6700 ; 𝜎𝑦 = 3600 ;HB=229
𝑐𝑚2 𝑐𝑚2

STEP 2: Minimum center distance

From Data book page no.: 8.13,

3 0.74 2 𝐸[𝑀𝑡 ]
𝑎 > (𝑖 + 1) √( [𝜎 ] ) , for the pressure angle α = 200
𝑐 𝑖𝛹

Gear ratio, i =2.88

Eeq = 2.15×106 kgf/cm2 (From PSG Data book page no.: 8.14)

[σc]= 5000 kgf/cm2

Ψ = b/a = 0.3 (initial assumption)

[Mt] = Mt ×k×kd
 97420×𝑘𝑤×𝑘𝑑 ×𝑘
[Mt] = = 1217.75 kgf cm
𝑛

3 0.74 2 2.15×106 ×1217.75

𝑎 = (2.88 + 1) √(5000) 1×0.3

a ≥ 22.35 cm

STEP 3: Minimum module:

From PSG Data book page no.: 8.13,

3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √𝑦[𝜎
𝑏 ]𝛹𝑚 𝑍1

Ψm = b/m = 10 (initial assumption)

y = 0.389 for Z =20(from PSG Data book page no.: 8.18)

3 1217.75
𝑚 ≥ 1.26 √0.389×1400×10×20

≥ 0.28 cm

m = 3 mm (from Data book page no. : 8.2)

STEP 4: Calculation of number of teeth

2𝑎 2 × 22.35
𝑍1 = =
𝑚(𝑖 + 1) 0.3 × 3.88

𝑍1 = 38.4 = 39; 𝑖 = 𝑍2/𝑍1

𝑍2 = 148.9 = 149

For pinion, d1 = mZ1 = 11.7 cm

For Gear, d2 = mZ2 = 44.7 cm

STEP 5: Corrected center distance

𝑧1 +𝑧2 39+149
a =m ( )= = 94 cm
2 2
It is greater than the minimum center distance our design is ok.

STEP 6: Calculation of face width

Face width, b = Ψ × a = 0.3×94 = 28.2 cm

b = 𝛹𝑚 ×m = 10×0.3 = 3 cm

Take b = 28.2 cm (higher value)

Calculation of correction factors

𝛹𝑝 =b /d1 = 28.2/11.7 =2.4

From PSG Data book page no.: 8.15,

Corresponding k = 1

𝜋dN 𝜋×117×1440
Pitch line velocity, v = 60×1000 = = 8.81m/s
60×1000

From PSG Data book page no.: 8.16,

By taking IS Quality as 5 and HB ≥ 350,

Corresponding kd = 1.2

97420×15×1.2×1
[Mt] = 1440

= 1217.75 kgf.cm

STEP 7: Checking of induced compressive strength

From PSG Data book page no.: 8.13,

𝑖+1 𝑖+1
𝜎𝑐 = 0.74 √ 𝐸[𝑀𝑡 ] ≤ [𝜎𝑐 ]
𝑎 𝑖𝑏

2.88+1 (2.88+1)×2.15×106 ×1217.75

= 0.74 × √
94 2.88×28.2

𝜎𝑐 = 341.60 kgf/cm2 < [𝜎𝑐 ] Our Design is safe.

STEP 8: Checking of bending strength:

From PSG Data book page no.: 8.13A,

(𝑖+1)×[Mt]
𝜎𝑏 = ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦

(2.88+1)×1217.75
= 94×0.3×28.2×0.479

𝜎𝑏 = 12.4 kgf /cm2 < [𝜎𝑏 ]

Our Design is safe.

STEP 9: Checking for plastic deformation

Under surface contact stress

(𝑀𝑡 )𝑚𝑎𝑥
𝜎𝑐𝑚𝑎𝑥 = 𝜎𝑐 √ ≤ [𝜎𝑐 ]𝑚𝑎𝑥
𝑀𝑡

[𝜎𝑐 ]𝑚𝑎𝑥 = 3.1𝜎𝑦 = 11160 𝑘𝑔𝑓/𝑐𝑚2

𝜎𝑐𝑚𝑎𝑥 = 341.6 × √2

𝜎𝑐𝑚𝑎𝑥 =483.022 𝑘𝑔𝑓/𝑐𝑚2 ≤ [𝜎𝑐 ]𝑚𝑎𝑥

Our design is safe.

Under bending

(𝑀𝑡 )𝑚𝑎𝑥
𝜎𝑏𝑚𝑎𝑥 = 𝜎𝑏 ≤ [𝜎𝑏 ]𝑚𝑎𝑥
𝑀𝑡

𝜎𝑏 𝑚𝑎𝑥 = 2𝜎𝑏

[𝜎𝑏 ]𝑚𝑎𝑥 = 0.8 𝜎𝑦 = 2880 𝑘𝑔𝑓/𝑐𝑚2

𝜎𝑏𝑚𝑎𝑥 = 24.8 𝑘𝑔𝑓/𝑐𝑚2 ≤ [𝜎𝑏 ]𝑚𝑎𝑥

 Our design is safe.

STEP 9: GEAR PARAMETERS:

From PSG Data book page no.: 8.22,

i) module, m = 3 mm
ii) Tooth depth, h = 0.33cm
iii) Tip diameters:

da1 = (Z1+2 f0)×m = 12.3 cm da2 = (Z2+2 f0)×m = 45.3 cm

iv) Root diameters:

df1 = (Z1-2 f0)×m – 2c = 9.1cm df2 = (Z2-2 f0)×m – 2c =42.1cm

Table no: 2.1 Spur gear specification

S.NO PARAMETERS PINION GEAR

1 material C45 steel C45 steel
2 center distance 94 cm 94 cm
3 module 0.3 cm 0.3 cm
4 Number of teeth 39 149
5 Face width 28.2 cm 28.2 cm
6 Tooth depth 0.33 cm 0.33 cm
7 Pitch diameter 11.7 cm 44.7 cm
8 Tip diameters 12.3 cm 45.3 cm
9 Root diameters 9.1 cm 42.1 cm
 2. An electric motor is to be connected to a reciprocating pump through a gear pair.
The gears are overhanging in their shafts. Motor speed = 1440 rpm. Speed reduction
ratio = 5. Motor Power = 36.8 kW. The gears are to have 20° pressure angle. Design
a spur gear drive. See data book for involute 20○

SPECIFICATIONS:

The motor shaft rotating at N1=1440 rpm, Reduction i = 5

i=N1/N2

Therefore Z2 =1440/5= 288 rpm

STEP 1: Material selection:

Material for pinion and Gear C45 is selected.

Material properties from (PSG DB 1.9)

𝑘𝑔𝑓 𝑘𝑔𝑓
𝜎𝑢 = 6700 ; 𝜎𝑦 = 3600 ;HB=229
𝑐𝑚2 𝑐𝑚2

STEP 2: Minimum center distance

From Data book page no.: 8.13,

3 0.74 2 𝐸[𝑀𝑡 ]
𝑎 > (𝑖 + 1) √( [𝜎 ] ) , for the pressure angle α = 200
𝑐 𝑖𝛹

Gear ratio, i =5

Eeq = 2.15×106 kgf/cm2 (From PSG Data book page no.: 8.14)

[σc]= 5000 kgf/cm2

Ψ = b/a = 0.3 (initial assumption)

[Mt] = Mt ×k×kd assume kd X k = 1.3

97420×𝑘𝑤×𝑘𝑑 ×𝑘
[Mt] = = 3236.5 kgf cm
𝑛
 3 0.74 2 2.15×106 ×3236.5
𝑎 = (5 + 1) √(5000) 5×0.3

a ≥ 27.99 cm

STEP 3: Minimum module:

From PSG Data book page no.: 8.13,

3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √𝑦[𝜎
𝑏 ]𝛹𝑚 𝑍1

Ψm = b/m = 10 (initial assumption)

y = 0.389 for Z =20(from PSG Data book page no.: 8.18)

3 3236.5
𝑚 ≥ 1.26 √0.389×1400×10×20

≥ 0.39 cm

m = 4 mm (from Data book page no. : 8.2)

STEP 4: Calculation of number of teeth

2𝑎 2 × 27.99
𝑍1 = =
𝑚(𝑖 + 1) 0.4 × 6

𝑍1 = 23.32 = 24; 𝑖 = 𝑍2/𝑍1

𝑍2 = 5𝑋24 = 120

For pinion, d1 = mZ1 = 120 cm

For Gear, d2 = mZ2 = 600 cm

STEP 5: Corrected center distance

𝑧1 +𝑧2 24+120
a =m ( )= = 72 cm
2 2

It is greater than the minimum center distance our design is ok.

STEP 6: Calculation of face width

Face width, b = Ψ × a = 0.3×72 = 21.6 cm

b = 𝛹𝑚 ×m = 10×0.4 = 4 cm

Take b = 21.6 cm (higher value)

Calculation of correction factors

𝛹𝑝 =b /d1 = 21.6/120 =0.18

From PSG Data book page no.: 8.15,

Corresponding k = 1

𝜋dN 𝜋×1200×1440
Pitch line velocity, v = 60×1000 = = 90.432 m/s
60×1000

From PSG Data book page no.: 8.16,

By taking IS Quality as 5 and HB ≥ 350,

Corresponding kd = 1.2

97420×36.8×1.2×1
[Mt] = 1440

= 2987.54 kgf.cm

STEP 7: Checking of induced compressive strength

From PSG Data book page no.: 8.13,

𝑖+1 𝑖+1
𝜎𝑐 = 0.74 √ 𝐸[𝑀𝑡 ] ≤ [𝜎𝑐 ]
𝑎 𝑖𝑏

5+1 (5+1)×2.15×106 ×2987.54

= 0.74 × √
72 5×21.6

𝜎𝑐 =1164.90 kgf/cm2 < [𝜎𝑐 ] Our Design is safe.

STEP 8: Checking of bending strength:

From PSG Data book page no.: 8.13A,

(𝑖+1)×[Mt]
𝜎𝑏 = ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦

(5+1)×2987.54
= 72×0.4×21.6×0.479

𝜎𝑏 = 60.15 kgf /cm2 < [𝜎𝑏 ]

Our Design is safe.

STEP 9: Checking for plastic deformation

Under surface contact stress

(𝑀𝑡 )𝑚𝑎𝑥
𝜎𝑐𝑚𝑎𝑥 = 𝜎𝑐 √ ≤ [𝜎𝑐 ]𝑚𝑎𝑥
𝑀𝑡

[𝜎𝑐 ]𝑚𝑎𝑥 = 3.1𝜎𝑦 = 11160 𝑘𝑔𝑓/𝑐𝑚2

𝜎𝑐𝑚𝑎𝑥 = 1164.9 × √2

𝜎𝑐𝑚𝑎𝑥 =1647.16 𝑘𝑔𝑓/𝑐𝑚2 ≤ [𝜎𝑐 ]𝑚𝑎𝑥

Our design is safe.

Under bending

(𝑀𝑡 )𝑚𝑎𝑥
𝜎𝑏𝑚𝑎𝑥 = 𝜎𝑏 ≤ [𝜎𝑏 ]𝑚𝑎𝑥
𝑀𝑡

𝜎𝑏 𝑚𝑎𝑥 = 2𝜎𝑏

[𝜎𝑏 ]𝑚𝑎𝑥 = 0.8 𝜎𝑦 = 2880 𝑘𝑔𝑓/𝑐𝑚2

𝜎𝑏𝑚𝑎𝑥 = 120.3 𝑘𝑔𝑓/𝑐𝑚2 ≤ [𝜎𝑏 ]𝑚𝑎𝑥

Our design is safe.

STEP 9: GEAR PARAMETERS:

From PSG Data book page no.: 8.22,

i) module, m = 4 mm
ii) Tooth depth, h = 0.33cm
iii) Tip diameters:

da1 = (Z1+2 f0)×m = 10.4 cm da2 = (Z2+2 f0)×m = 48.8 cm

iv) Root diameters:

df1 = (Z1-2 f0)×m – 2c =6.8cm df2 = (Z2-2 f0)×m – 2c = 46.8cm

Table no: 2.1 Spur gear specification

S.NO PARAMETERS PINION GEAR

1 material C45 steel C45 steel
2 center distance 72 cm 72 cm
3 module 0.4 cm 0.4 cm
4 Number of teeth 24 120
5 Face width 21.89 cm 21.89 cm
6 Tooth depth 0.33 cm 0.33 cm
7 Pitch diameter 120 cm 600 cm
8 Tip diameters 10.4 cm 41.8 cm
9 Root diameters 6.8 cm 46.8cm
DESIGN OF ELICAL GEARS

3. Design a pair of helical gears to transmit 30 kW at a speed reduction ratio of 4:1.

The input shaft runs at 2000 rpm. Both pinion and gear are 15Ni2crlMol5 under
carburized condition.

SPECIFICATIONS:

The motor shaft rotating at N1=2000 rpm,

Reduction i= 4 = N1/N2

Therefore N2 =2000/4= 500 rpm

STEP 1: Material selection:

Material for pinion and Gear 15Ni2crlMol5 is selected.

Material properties from (PSG DB 1.9)

𝑘𝑔𝑓 𝑘𝑔𝑓
𝜎𝑢 = 10000 ; 𝜎𝑦 = 7000 ;HB=260
𝑐𝑚2 𝑐𝑚2

STEP 2: Minimum center distance

From Data book page no.: 8.13,

3 0.74 2 𝐸[𝑀𝑡 ]
𝑎 > (𝑖 + 1) √( [𝜎 ] ) , for the pressure angle α = 200
𝑐 𝑖𝛹

Gear ratio, i =4

Eeq = 2.15×106 kgf/cm2 (From PSG Data book page no.: 8.14)

[σc]= 11000 kgf/cm2

Ψ = b/a = 0.3 (initial assumption)

[Mt] = Mt ×k×kd

97420×𝑘𝑤×𝑘𝑑 ×𝑘
[Mt] = = 1899.69 kgf cm
𝑛
 3 0.74 2 2.15×106 ×1899.69
𝑎 = (4 + 1) √(11000) 4×0.3

a ≥ 12.44 cm

STEP 3: Minimum module:

From PSG Data book page no.: 8.13,

3 [𝑀𝑡 ]
𝑚 ≥ 1.15 𝑐𝑜𝑠𝛽 √𝑦[𝜎
𝑏 ]𝛹𝑚 𝑍1

Ψm = b/m = 10 (initial assumption) [𝜎𝑏 ] = 4000 𝑘𝑔𝑓/𝑐𝑚𝑚2

y = 0.389 for Z =20(from PSG Data book page no.: 8.18)

for helical gear 𝛽 = 25 𝑑𝑒𝑔𝑟𝑒𝑒

3 1899.69
𝑚 ≥ 1.15 𝑐𝑜𝑠25 √0.389×4000×10×20

≥ 0.19 cm

m = 2 mm (from Data book page no. : 8.2)

STEP 4: Calculation of number of teeth

2𝑎 𝑐𝑜𝑠𝛽 2 × 12.44 𝑋 cos 25

𝑍1 = =
𝑚(𝑖 + 1) 0.19 × (4 + 1)

𝑍1 = 23.7 = 24; 𝑖 = 𝑍2/𝑍1

𝑍2 = 94.9 = 95

STEP 5: Calculation of pitch diameter

mn = 2a 𝑐𝑜𝑠𝛽 / (Z1 + Z2)

mn = (2x12.44xcos 25)/(24+95)

mn= 0.18 cm = 2 mm
 For pinion, d1 = mZ1 / 𝑐𝑜𝑠𝛽 = 5.29 cm

For Gear, d2 = mZ2 / 𝑐𝑜𝑠𝛽 = 19 cm

STEP 6: Corrected center distance

𝑚 𝑧1 +𝑧2 0.2 24+95

a =𝑐𝑜𝑠𝛽 ( ) = cos 25 = 13.13 cm
2 2

It is greater than the minimum center distance our design is ok.

STEP 7: Calculation of face width

Face width, b = Ψ × a = 0.3× 13.13 = 3.93 cm

b = 𝛹𝑚 ×m = 10×0.2 = 2 cm

Take b = 3.93 cm (higher value)

Calculation of correction factors

𝛹𝑝 =b /d1 = 3.93/5.29 = 0.74

From PSG Data book page no.: 8.15,

Corresponding k = 1.06

𝜋dN 𝜋×52.9×2000
Pitch line velocity, v = 60×1000 = = 5.53m/s
60×1000

From PSG Data book page no.: 8.16,

By taking IS Quality as 5 and HB ≥ 350,

Corresponding kd = 1

97420×30×1×1.06
[Mt] = 2000

= 1548.97 kgf.cm
STEP 8: Checking of induced compressive strength

From PSG Data book page no.: 8.13,

𝑖+1 𝑖+1
𝜎𝑐 = 0.74 √ 𝐸[𝑀𝑡 ] ≤ [𝜎𝑐 ]
𝑎 𝑖𝑏

4+1 (4+1)×2.15×106 ×1548.97

= 0.74 × 13.13 √ 4×3.93

𝜎𝑐 = 9889.79 kgf/cm2 < [𝜎𝑐 ] Our Design is safe.

STEP 9: Checking of bending strength:

From PSG Data book page no.: 8.13A,

(𝑖+1)[𝑀𝑡 ]
𝜎𝑏 = 0.7 ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦

0.7 𝑋(4+1)×1548.97
= 13.13×0.2×3.93×0.414

𝜎𝑏 = 1268.88 kgf /cm2 < [𝜎𝑏 ]

Our Design is safe.

STEP 10: GEAR PARAMETERS:

From PSG Data book page no.: 8.22,

i) module, m = 2 mm
ii) Tooth depth, h = 2.25 X 0.2 = 0.45 cm
iii) Tip diameters:

da1 = (Z1/ 𝑐𝑜𝑠𝛽 +2 f0)×m = 5.69 cm da2 = (Z2/ 𝑐𝑜𝑠𝛽 +2 f0)×m = 21.36 cm

iv) Root diameters:

df1 = (Z1/ 𝑐𝑜𝑠𝛽 -2 f0)×m – 2c = 4.89cm df2 = (Z2/ 𝑐𝑜𝑠𝛽 -2 f0)×m – 2c =20.56cm
 Table no: 2.1 Spur gear specification

S.NO PARAMETERS PINION GEAR

1 material C45 steel C45 steel
2 center distance 13.13 cm 13.13 cm
3 module 0.2 cm 0.2 cm
4 Number of teeth 24 95
5 Face width 3.93 cm 3.93 cm
6 Tooth depth 0.45 cm 0.45 cm
7 Pitch diameter 5.29 cm 19 cm
8 Tip diameters 5.69 cm 21.36 cm
9 Root diameters 4.89 cm 20.56cm

4. Design a pair of helical gears to transmit 30 kW power at a speed reduction ratio of

4:1. The input shaft rotates at 2000 rpm. Take helix and pressure angles equal to
250 and 200 respectively. The number of teeth on the pinion may be taken as 30.

SPECIFICATIONS:

The motor shaft rotating at N1=2000 rpm,

Reduction i= 4 = N1/N2

Therefore N2 =2000/4= 500 rpm

STEP 1: Material selection:

Material for pinion and Gear 15Ni2crlMol5 is selected.

Material properties from (PSG DB 1.9)

𝑘𝑔𝑓 𝑘𝑔𝑓
𝜎𝑢 = 10000 ; 𝜎𝑦 = 7000 ;HB=260
𝑐𝑚2 𝑐𝑚2

STEP 2: Minimum center distance

From Data book page no.: 8.13,

 3 0.74 2 𝐸[𝑀𝑡 ]
𝑎 > (𝑖 + 1) √( [𝜎 ] ) , for the pressure angle α = 200
𝑐 𝑖𝛹

Gear ratio, i =4

Eeq = 2.15×106 kgf/cm2 (From PSG Data book page no.: 8.14)

[σc]= 11000 kgf/cm2

Ψ = b/a = 0.3 (initial assumption)

[Mt] = Mt ×k×kd

97420×𝑘𝑤×𝑘𝑑 ×𝑘
[Mt] = = 1899.69 kgf cm
𝑛

3 0.74 2 2.15×106 ×1899.69

𝑎 = (4 + 1) √(11000) 4×0.3

a ≥ 12.44 cm

STEP 3: Minimum module:

From PSG Data book page no.: 8.13,

3 [𝑀𝑡 ]
𝑚 ≥ 1.15 𝑐𝑜𝑠𝛽 √𝑦[𝜎
𝑏 ]𝛹𝑚 𝑍1

Ψm = b/m = 10 (initial assumption) [𝜎𝑏 ] = 4000 𝑘𝑔𝑓/𝑐𝑚𝑚2

y = 0.389 for Z =20(from PSG Data book page no.: 8.18)

for helical gear 𝛽 = 25 𝑑𝑒𝑔𝑟𝑒𝑒

3 1899.69
𝑚 ≥ 1.15 𝑐𝑜𝑠25 √0.389×4000×10×20

≥ 0.19 cm

m = 2 mm (from Data book page no. : 8.2)

STEP 4: Calculation of number of teeth

2𝑎 𝑐𝑜𝑠𝛽 2 × 12.44 𝑋 cos 25

𝑍1 = =
𝑚(𝑖 + 1) 0.19 × (4 + 1)

𝑍1 = 23.7 = 24; 𝑖 = 𝑍2/𝑍1

𝑍2 = 94.9 = 95

STEP 5: Calculation of pitch diameter

mn = 2a 𝑐𝑜𝑠𝛽 / (Z1 + Z2)

mn = (2x12.44xcos 25)/(24+95)

mn= 0.18 cm = 2 mm

For pinion, d1 = mZ1 / 𝑐𝑜𝑠𝛽 = 5.29 cm

For Gear, d2 = mZ2 / 𝑐𝑜𝑠𝛽 = 19 cm

STEP 6: Corrected center distance

𝑚 𝑧1 +𝑧2 0.2 24+95

a =𝑐𝑜𝑠𝛽 ( ) = cos 25 = 13.13 cm
2 2

It is greater than the minimum center distance our design is ok.

STEP 7: Calculation of face width

Face width, b = Ψ × a = 0.3× 13.13 = 3.93 cm

b = 𝛹𝑚 ×m = 10×0.2 = 2 cm

Take b = 3.93 cm (higher value)

Calculation of correction factors

𝛹𝑝 =b /d1 = 3.93/5.29 = 0.74

From PSG Data book page no.: 8.15,

 Corresponding k = 1.06

𝜋dN 𝜋×52.9×2000
Pitch line velocity, v = 60×1000 = = 5.53m/s
60×1000

From PSG Data book page no.: 8.16,

By taking IS Quality as 5 and HB ≥ 350,

Corresponding kd = 1

97420×30×1×1.06
[Mt] = 2000

= 1548.97 kgf.cm

STEP 8: Checking of induced compressive strength

From PSG Data book page no.: 8.13,

𝑖+1 𝑖+1
𝜎𝑐 = 0.74 √ 𝐸[𝑀𝑡 ] ≤ [𝜎𝑐 ]
𝑎 𝑖𝑏

4+1 (4+1)×2.15×106 ×1548.97

= 0.74 × 13.13 √ 4×3.93

𝜎𝑐 = 9889.79 kgf/cm2 < [𝜎𝑐 ] Our Design is safe.

STEP 9: Checking of bending strength:

From PSG Data book page no.: 8.13A,

(𝑖+1)[𝑀𝑡 ]
𝜎𝑏 = 0.7 ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦

0.7 𝑋(4+1)×1548.97
= 13.13×0.2×3.93×0.414

𝜎𝑏 = 1268.88 kgf /cm2 < [𝜎𝑏 ]

Our Design is safe.

STEP 10: GEAR PARAMETERS:

From PSG Data book page no.: 8.22,

i) module, m = 2 mm
ii) Tooth depth, h = 2.25 X 0.2 = 0.45 cm
iii) Tip diameters:

da1 = (Z1/ 𝑐𝑜𝑠𝛽 +2 f0)×m = 5.69 cm da2 = (Z2/ 𝑐𝑜𝑠𝛽 +2 f0)×m = 21.36 cm

iv) Root diameters:

df1 = (Z1/ 𝑐𝑜𝑠𝛽 -2 f0)×m – 2c = 4.89cm df2 = (Z2/ 𝑐𝑜𝑠𝛽 -2 f0)×m – 2c =20.56cm

Table no: 2.4 Spur gear specification

S.NO PARAMETERS PINION GEAR

1 material C45 steel C45 steel
2 center distance 13.13 cm 13.13 cm
3 module 0.2 cm 0.2 cm
4 Number of teeth 24 95
5 Face width 3.93 cm 3.93 cm
6 Tooth depth 0.45 cm 0.45 cm
7 Pitch diameter 5.29 cm 19 cm
8 Tip diameters 5.69 cm 21.36 cm
9 Root diameters 4.89 cm 20.57cm
 UNIT-3 BEVEL, WORM AND CROSS HELICAL GEARS
Part – B

DESIGN PROCEDURE FOR BEVEL GEARS

1. Design a pair of bevel gears for two shafts whose axes are at right angles. The power
transmitted is 30kW. The speed of pinion is 300rpm and of the gear is 120 rpm.
Select the materials and design the drive. (April/May 2015)

Design of bevel gear

Specification

Power P = 30 KW N1 = 300 rpm N2= 120 rpm

Material for pinion and Gear : C45 steel

Gear ratio i= N1/N2 = 300/120 = 2.5

DESIGN STEPS:

STEP 1: Calculation of minimum cone distance:

3 2
0.72 𝐸[𝑀𝑡 ]
𝑅 ≥ 𝛹𝑦 √𝑖 2 + 1 √((𝛹 )
𝑦 −0.5)[𝜎 ]
𝑐 𝑖

Design Torque, [Mt] = 𝑀𝑡 ×k×kd

Assume k×kd = 1.3 initially

97420×𝑘𝑤×𝑘𝑑 ×𝑘
[Mt] = = 12664.6 kgf cm
𝑛

From Data book page no.: 8.14,

For C45 steel,

Eeq = 2.15×106 kgf/cm2 [σc] = 5000 kgf/cm2

𝑅
Ψy = 𝑏 = 3
 3 0.72 2 2.15×106 ×12664.6
𝑅 ≥ 3√2.52 + 1 √((3−0.5)5000) 2.5

R≥ 26.7 cm

STEP 2: Average module:

3 [𝑀𝑡 ]
𝑚𝑎𝑣 = 1.28√𝑦
𝑣 [𝜎𝑏 ]𝛹𝑚 𝑍1

𝑏
[σb] = 1400 kgf/cm2 Ψm = =10 initially
𝑚𝑎𝑣

Assume Z1 = 20 initially

Yv = Form factor based on number of teeth

𝑍1
Zv = 𝑐𝑜𝑠𝛿1 (for pinion)

From Data book page no.: 8.39,

tan δ2 = i = 2.5

δ2 = tan-1 (2.5) = 68.190

δ1 = 90 – 68.190 = 21.800 (δ1 + δ2 = 900)

𝑍1 20
Zv = 𝑐𝑜𝑠𝛿1 = cos 21.80 = 21.54 = 22

From Data book page no.: 8.18,

Form factor, yv = 0.402 (for Zv = 22)

3 12664.6
𝑚𝑎𝑣 = 1.28√0.402×1400×10×20

𝑚𝑎𝑣 ≥ 0.61 cm

STEP 5: Calculation of transverse module:

𝛹𝑣 3
mt = mav × 𝛹 = 0.61 × 3−0.5 = 0.30 cm=3 mm standard module
𝑣 −0.5
STEP 4: Calculation of number of teeth:

R = 0.5× mt×Z1× √𝑖 2 + 1

𝑅
Z1 = = 66.1 = 66
0.5× mt×√𝑖 2 +1

𝑍
i = 𝑍2 Z2 = i ×Z1 = 165
1

STEP 5: Final cone distance:

R = 0.5× 0.3× 66× √2.52 + 1 = 26.65 cm

It is less than the transverse module. So increase the transverse module. Take mt = 0.4 cm

Therefore R = 35.54 cm

Since the final cone distance is greater than initial cone distance,

Our Design is safe.

STEP 6: Calculation of face width:

𝑅 35.54
b=𝛹 = = 11.87 cm
𝑦 3

STEP 7: Checking of compressive strength:

0.72 √(𝑖 2 +1)3 𝐸[𝑀𝑡 ]

𝜎𝑐 = (𝑅−0.5𝑏) √ ≤ [𝜎𝑐 ]
𝑖𝑏

0.72 √(2.52 +1)3 2.15×106 ×12664.6

= (35.54−0.5×11.87) √ 2.5×11.87

𝜎𝑐 = 8.012 kgf/cm2 ˂ 5000 kgf/cm2

Design is safe.

STEP 8: Checking of bending stress:

𝑅√𝑖 2 +1×[𝑀 ]
𝑡 1
σb = (𝑅−0.5𝑏)2 ×𝑏×𝑦 × cos 𝛼
𝑣
 35.54√2.52 +1×12664.6 1
= (35.54−(0.5×11.87))2 ×11.87×0.402 × cos 200

= 308.37 kgf/cm2 ˂ 1400 kgf/cm2

Design is safe.

STEP 9: Reference diameters:

d1 = mZ4 = 224 mm d2 = mZ5 = 660 mm

Tip circle diameters:

da1 = mt× (Z + 2cosδ1)

= 4× (66+2cos21.80) = 271.4 mm

da2 = mt× (Z + 2cosδ2)

= 4× (66 + 2cos 68.190) = 266.9 mm

Standard dimensions:

i) Addendum angle,
𝑚𝑡 ×𝑓0
θa1 = θa2 = tan-1( )
𝑅

0.4×1
= tan-1( 35.54 ) = 0.64

ii) Dedundum angle,

𝑚𝑡 ×(𝑓0 +𝑐)
θf1 = θf2 = tan-1( )
𝑅
0.3×(1+0.2)
= tan-1( ) = 0.580
35.54

iii) Tip angle:

For pinion, δa1 = δ1 + θa1
= 21.80 + 0.640 = 2.820
For Gear, δa2 = δ2 + θa2
= 68.190 + 0.640 = 68.830
 iv) Root angle:

For pinion, δf1 = δ1 - θf1

= 21.80 – 0.580 = 21.220

For Gear, δf2 = δ2 - θf2
= 61.190 – 0.580 = 60.610

Table no: 3.1 Bevel gear specification

S.NO PARAMETERS PINION GEAR

1 Material c45 steel c45 steel
2 cone distance 35.53 cm 35.53 cm
3 Transvers module 0.4 cm 0.4 cm
4 Face width 11.87 cm 11.87 cm
5 Number of teeth 66 56
6 Reference diameter 224 cm 660 cm
7 Tip diameter 271.4 cm 266.9 cm
8 Addendum angle 0.640 0.640
9 Dedendum angle 0.580 0.580
10 Tip angle 2.820 68.830
11 Root angle 21.220 60.610

2. Design the teeth of a pair of bevel gears to transmit 18.75 KW at 600 rpm of the
pinion. The velocity ratio should be about 3 and the pinion should have about 20
teeth which are full depth 200 involute. Find the module, face width, diameter of the
gears and pitch core angle for both gears.

Design of bevel gear

Specification

Power P = 18.75 KW, N1 = 600 rpm, velocity ratio i= 3

Material for pinion and Gear: C45 steel

Gear ratio i= N1/N2 => 600/3 therefore N2= 200 rpm

DESIGN STEPS:

STEP 1: Calculation of minimum cone distance:

3 2
0.72 𝐸[𝑀𝑡 ]
𝑅 ≥ 𝛹𝑦 √𝑖 2 + 1 √((𝛹 )
𝑦 −0.5)[𝜎 ]
𝑐 𝑖

Design Torque, [Mt] = 𝑀𝑡 ×k×kd

Assume k×kd = 1.3 initially

97420×𝑘𝑤×𝑘𝑑 ×𝑘
[Mt] = = 3957.6 kgf cm
𝑛

From Data book page no.: 8.14,

For C45 steel,

Eeq = 2.15×106 kgf/cm2 [σc] = 5000 kgf/cm2

𝑅
Ψy = 𝑏 = 3

3 0.72 2 2.15×106 ×3957

𝑅 ≥ 3√32 + 1 √((3−0.5)5000) 3

R≥ 20.02 cm

STEP 2: Average module:

3 [𝑀𝑡 ]
𝑚𝑎𝑣 = 1.28√𝑦
𝑣 [𝜎𝑏 ]𝛹𝑚 𝑍1

𝑏
[σb] = 1400 kgf/cm2 Ψm = 𝑚𝑎𝑣 =10 initially

Assume Z1 = 20 initially

Yv = Form factor based on number of teeth

𝑍1
Zv = 𝑐𝑜𝑠𝛿1 (for pinion)
From Data book page no.: 8.39,

tan δ2 = i = 3

δ2 = tan-1 (3) = 71.560

δ1 = 90 – 71.560 = 18.430 (δ1 + δ2 = 900)

𝑍1 20
Zv = 𝑐𝑜𝑠𝛿1 = cos 18.43 = 21.08 = 22

From Data book page no.: 8.18,

Form factor, yv = 0.402 (for Zv = 22)

3 3957.6
𝑚𝑎𝑣 = 1.28√0.402×1400×10×20

𝑚𝑎𝑣 ≥ 0.41 cm

STEP 5: Calculation of transverse module:

𝛹𝑣 3
mt = mav × 𝛹 = 0.41 × 3−0.5 = 0.49 cm= 0.5 cm =5 mm standard module
𝑣 −0.5

STEP 4: Calculation of number of teeth:

R = 0.5× mt×Z1× √𝑖 2 + 1

𝑅
Z1 = = 25.3 = 26
0.5× mt×√𝑖 2 +1

𝑍
i = 𝑍2 Z2 = i ×Z1 = 78
1

STEP 5: Final cone distance:

R = 0.5× 0.5× 26× √32 + 1 = 20.55 cm

Since the final cone distance is greater than initial cone distance,

Our Design is safe.

STEP 6: Calculation of face width:

𝑅 20.55
b=𝛹 = = 6.85 cm
𝑦 3

STEP 7: Checking of compressive strength:

0.72 √(𝑖 2 +1)3 𝐸[𝑀𝑡 ]

𝜎𝑐 = (𝑅−0.5𝑏) √ ≤ [𝜎𝑐 ]
𝑖𝑏

0.72 √(32 +1)3 2.15×106 ×3957.6

= (20.55−0.5×6.85) √
3×6.85

𝜎𝑐 = 50.08 kgf/cm2 ˂ 5000 kgf/cm2

Design is safe.

STEP 8: Checking of bending stress:

𝑅√𝑖 2 +1×[𝑀 ]
𝑡 1
σb = (𝑅−0.5𝑏)2 ×𝑏×𝑦 × cos 𝛼
𝑣

20.55√32 +1×3957.6 1
= (20.55−(0.5×6.85))2 ×6.85×0.402 × cos 200

= 338.9 kgf/cm2 ˂ 1400 kgf/cm2

Design is safe.

STEP 9: Reference diameters:

d1 = mZ1 = 130 mm d2 = mZ2= 390 mm

Tip circle diameters:

da1 = mt× (Z + 2cosδ1)

= 5× (26+2cos 18.430) = 139.48 mm

da2 = mt× (Z + 2cosδ2)

= 5× (78 + 2cos 71.560) = 396.3 mm

Standard dimensions:

v) Addendum angle,
𝑚𝑡 ×𝑓0
θa1 = θa2 = tan-1( )
𝑅

0.5×1
= tan-1( 20.55 ) = 1.39

vi) Dedundum angle,

𝑚𝑡 ×(𝑓0 +𝑐)
θf1 = θf2 = tan-1( )
𝑅
0.5×(1+0.2)
= tan-1( ) = 1.670
20.55

vii) Tip angle:

For pinion, δa1 = δ1 + θa1
= 18.430 + 1.390 = 19.820
For Gear, δa2 = δ2 + θa2
= 71.560 + 1.390 = 72.950

viii) Root angle:

For pinion, δf1 = δ1 - θf1

= 18.430 – 1.670 =16.76 0

For Gear, δf2 = δ2 - θf2
= 71.560 – 1.670 =69.89 0

Table no: 3.2 Bevel gear specification

S.NO PARAMETERS PINION GEAR

1 Material c45 steel c45 steel
2 cone distance 20.55 cm 20.55 cm
3 Transvers module 0.5 cm 0.5 cm
4 Face width 6.85 cm 6.85 cm
5 Number of teeth 26 78
6 Reference diameter 130 cm 390 cm
 7 Tip diameter 139.48 cm 396.3 cm
8 Addendum angle 1.390 1.390
9 Dedendum angle 1.670 1.670
10 Tip angle 19.820 72.950
11 Root angle 16.760 69.890

3. Design a worm gear drive with a standard centre distance to

transmit 7.5 kW from a worm rotating at 1440 rpm to a worm wheel at 20 rpm.
Hint: Given: Power=7.5kW, N1=1440rpm, N2=20rpm.

DESIGN OF WORM GEAR DRIVE

Power = 7.5 kW, N1 = 1440 rpm, N2 = 20 rpm

Assume i = 1440/20 = 72;

Step 1: Selection of material

Worm – steel

Worm wheel – bronze

Step 2: calculation of initial design wheel torque [Mt]

𝐾𝑊
[Mt] = 97420 × ×ɳ×𝑖
𝑛1

7.5
= 97420 x 1440 𝑥 0.86 𝑥 72

[Mt] = 31417.95 kgf.cm

Step 3: selection of teeth

For small hp z=40

Step 4: selection of [σb] and [σc]

For Bronze Wheel [σb] = 600 kgf/cm2 is selected, for rotation in one direction.
 [σc] = 1520 kgf/cm2 is selected, assuming vs = 3 m/s.

Step 5: calculation centre distance (a)

2
3
𝑧 540
𝑎 ≥ ( + 1) √( 𝑧 ) [𝑀𝑡 ]
𝑞 [𝑀𝑡 ]
𝑞
2
3
40 540
𝑎 ≥ ( + 1) √( ) [31417.95]
11 40
[31417.95]
11

a≥4.12 cm. {q=11, initially chosen}

Step 6: calculation of axial module (mz)

3 [𝑀𝑡 ]
𝑀𝑥 ≥ 1.24 √𝑧 𝑦
𝑣 [𝜎𝑏 ]

𝑧
𝑧𝑣 = cos 𝛾3 (𝛾 = 𝑙𝑒𝑎𝑑 𝑜𝑟 ℎ𝑒𝑙𝑖𝑥 𝑎𝑛𝑔𝑙𝑒)

𝑍
𝛾= tan−1 𝑞

3
= tan−1 (11)

= 15.255°

40
𝑧𝑣 = cos 15.253= 44.5 ≅45

From data book

𝑦𝑣 = 0.471

3 31417.95
𝑀𝑥 = 1.24 √40×11×0.471×600

𝑀𝑥 = 0.78 cm= 8 mm

Take 𝑀𝑥 = 8mm
Calculation of centre distance

a= 0.5 𝑀𝑥 (q+𝑧2 +2x)

a= 0.5× 0.8(11 + 40)= 20.4 cm

This is greater than the minimum centre distance so it is ok.

𝜋𝑑 𝑛
1 1
Sliding velocity 𝑣𝑠 = 60×1000×cos 𝛾

𝑑1 = q𝑀𝑥 = 11× 0.8= 8.8 cm

𝛾= 15.255

𝜋×88×1440
𝑣𝑠 =60×1000×cos 15.255

𝑣𝑠 = 6.87 m/ sec

Take [𝜎𝑐 ]= 1490 𝑘𝑔𝑓/𝑐𝑚2 from 8.45

Step 7: check for bending

1.9 [𝑀𝑡 ]
𝜎𝑏 = 3 ≤ [𝜎𝑏 ]
𝑚𝑥 .𝑞 .𝑧2 .𝑦𝑣

1.9[31417.95]
= 0.83 ×11×40×0.471

𝑘𝑔𝑓
𝜎𝑏 = 562.58 𝑐𝑚2 < [𝜎𝑏 ]

So our design is safe...

Step 8: check for wear

𝑧2 3
540 +1
𝜎𝑐 = ( 𝑧2 ) √( 𝑞𝑎 ) [𝑀𝑡 ] ≤ [𝜎𝑐 ]
𝑞

40 3
540 +1
= ( 40 ) √(11 ) [31417.95]
11
20.4
 𝜎𝑐 = 285.19 kgf/cm2 ≤ [σc]

Our design is safe.

Step 9: calculation of length of the worm

Length of worm L ≥ (12.5 + 0.09𝑧)𝑚𝑧

L≥(12.5+0.09(40)) 0.8

L≥12.88 cm

Increased length L1 for ground worm is

L1=L+25mm

=12.88 + 2.5

L1=15.38 cm

Number of teeth on worm gear

𝐿 12.88
𝜆= 𝜋𝑚 = 𝜋×0.8
𝑥

= 5.12 ≈ 6

Length of worm = 6× 𝜋𝑚𝑥

= 6× 𝜋 × 0.8

= 15.07 cm

Face width = 0.75𝑑1 = 0.7 X 8.8

= 6.16 cm

Step 10: Parameters of worm

Reference diameter 𝑑1 = 𝑞 × 𝑚𝑥 = 11× 0.8= 96.8 cm

Tip diameter 𝑑𝑎1 = 𝑑1+2𝑓0 𝑚𝑥

 = 96.8 + (2× 1 × 0.8)= 98.4 m

Root diameter 𝑑𝑓1 = 𝑑1 −2𝑓0 𝑚𝑥 −2𝑐 (take 𝑓𝑜 = 1 and c= 0.2)

= 96.8 − 2 × 1 × 0.8 − 2 × 0.2

= 94.8 cm

Pitch diameter 𝑑1′ = 𝑚𝑥 (𝑞 + 2𝑥) (assume x=0)

= 0.8(11+2(0))

= 8.8 cm

Step 11: Parameters of wheel

Reference diameter d2 =Z2 ×mx

=40 × 0.8 = 32 𝑐𝑚

Tip diameter 𝑑𝑎2 = (𝑍2 + 2𝑓0 + 2𝑋)𝑚𝑥

= (40+2)0.8

𝑑𝑎2 = 33.6 𝑐𝑚

Root diameter 𝑑2′ = d2 = 32 cm

Step 12: Efficiency of worm gear drive

tan γ
Efficiency of worm gear drive 𝜂 = tan(𝛾+𝜌)

tan 𝜌 = 𝜇 = 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑐𝑜 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡

𝜇= 0.056, 𝜌 = 𝑡𝑎𝑛−1 0.056 = 3.2

tan 15.255
𝜂=
tan(15.255 + 3.2)

𝜂 =81.72%
Step 13: Check for cooling arrangement

Heat generated (Hg)

𝑘𝑔𝑓𝑚
Hg = (1- 𝜂) × 𝑖𝑛𝑝𝑢𝑡 𝐻𝑝 × 4500 𝑚𝑖𝑛

= (1- 0.817) × 2.011 × 4500

𝑘𝑔𝑓𝑚
Hg =1654.05 𝑚𝑖𝑛

Heat dissipated (Hd)

𝑘𝑔𝑓𝑚
Hd =hcr × 𝐴 × ∆𝑡 𝑚𝑖𝑛

A=57.2 a1.7 cm2 =57.2× (20.55)1.7

A=9753.85 cm2, hcr =0.16 kgfm/sq.cm min℃

Hd =0.16 × 9753.85 × 10

𝑘𝑔𝑓𝑚
Hd = 15606.16 𝑚𝑖𝑛

Here Hd > Hg

There is no cooling arrangement is required.

Table no: 3.3 worm and worm gear specification

S.NO PARAMETERS WORM GEAR

1 material Hardened steel bronze
2 Center distance 20.4 cm 20.4 cm
3 Axial module 0.8 cm 0.8 cm
4 Length of worm 15.07 cm -
5 Face width - 6.16 cm
6 reference diameter 96.8 cm 32 cm
7 Tip diameter 98.4 cm 33.6 cm
 8 Root diameter 94.8 cm 32 cm
9 Pitch diameter 8.8 cm 32 cm

4. Design a worm gear drive for the following data: Power to be transmitted: 20 kW,
Worm speed: 1440 rpm, Speed reduction: 24:1.

DESIGN OF WORM GEAR DRIVE

Power = 20 kW, N1 = 1440 rpm, Speed reduction i = 24/1 = 24

Step 1: Selection of material

Worm – steel

Worm wheel – bronze

Step 2: calculation of initial design wheel torque [Mt]

𝐾𝑊
[Mt] = 97420 × ×ɳ×𝑖
𝑛1

20
= 97420 x 1440 𝑥 0.86 𝑥 24

[Mt] = 27927.06 kgf.cm

Step 3: selection of teeth

For small hp z=40

Step 4: selection of [σb] and [σc]

For Bronze Wheel [σb] = 600 kgf/cm2 is selected, for rotation in one direction.

[σc] = 1520 kgf/cm2 is selected, assuming vs = 3 m/s.

Step 5: calculation centre distance (a)

2
3
𝑧 540
𝑎 ≥ ( + 1) √( 𝑧 ) [𝑀𝑡 ]
𝑞 [𝑀𝑡 ]
𝑞
 2
3
40 540
𝑎 ≥ ( + 1) √( ) [27927.06]
11 40
[27927.06]
11

a≥ 4.28 cm. {q=11, initially chosen}

Step 6: calculation of axial module (mz)

3 [𝑀𝑡 ]
𝑀𝑥 ≥ 1.24 √𝑧 𝑦
𝑣 [𝜎𝑏 ]

𝑧
𝑧𝑣 = cos 𝛾3 (𝛾 = 𝑙𝑒𝑎𝑑 𝑜𝑟 ℎ𝑒𝑙𝑖𝑥 𝑎𝑛𝑔𝑙𝑒)

𝑍
𝛾= tan−1 𝑞

3
= tan−1 (11)

= 15.255°

40
𝑧𝑣 = cos 15.253= 44.5 ≅45

From data book

𝑦𝑣 = 0.471

3 27927.06
𝑀𝑥 = 1.24 √40×11×0.471×600

𝑀𝑥 = 0.75 cm= 8 mm

Take 𝑀𝑥 = 8mm

Calculation of centre distance

a= 0.5 𝑀𝑥 (q+𝑧2 +2x)

a= 0.5× 0.8(11 + 40)= 20.4 cm

This is greater than the minimum centre distance so it is ok.

 𝜋𝑑 𝑛
1 1
Sliding velocity 𝑣𝑠 = 60×1000×cos 𝛾

𝑑1 = q𝑀𝑥 = 11× 0.8= 8.8 cm

𝛾= 15.255

𝜋×88×1440
𝑣𝑠 =60×1000×cos 15.255

𝑣𝑠 = 6.87 m/ sec

Take [𝜎𝑐 ]= 1490 𝑘𝑔𝑓/𝑐𝑚2 from 8.45

Step 7: check for bending

1.9 [𝑀𝑡 ]
𝜎𝑏 = 3 ≤ [𝜎𝑏 ]
𝑚𝑥 .𝑞 .𝑧2 .𝑦𝑣

1.9[27927.06]
= 0.83 ×11×40×0.471

𝑘𝑔𝑓
𝜎𝑏 = 500.08 𝑐𝑚2 < [𝜎𝑏 ]

So our design is safe...

Step 8: check for wear

𝑧2 3
540 +1
𝜎𝑐 = ( 𝑧2 ) √( 𝑞𝑎 ) [𝑀𝑡 ] ≤ [𝜎𝑐 ]
𝑞

40 3
540 +1
= ( 40 ) √(11 ) [27927.06]
11
20.4

𝜎𝑐 = 2688.80 kgf/cm2 ≤ [σc]

Our design is safe.

Step 9: calculation of length of the worm

Length of worm L ≥ (12.5 + 0.09𝑧)𝑚𝑧

 L≥(12.5+0.09(40)) 0.8

L≥12.88 cm

Increased length L1 for ground worm is

L1=L+25mm

=12.88 + 2.5

L1=15.38 cm

Number of teeth on worm gear

𝐿 12.88
𝜆= 𝜋𝑚 = 𝜋×0.8
𝑥

= 5.12 ≈ 6

Length of worm = 6× 𝜋𝑚𝑥

= 6× 𝜋 × 0.8

= 15.07 cm

Face width = 0.75𝑑1 = 0.7 X 8.8

= 6.16 cm

Step 10: Parameters of worm

Reference diameter 𝑑1 = 𝑞 × 𝑚𝑥 = 11× 0.8= 96.8 cm

Tip diameter 𝑑𝑎1 = 𝑑1+2𝑓0 𝑚𝑥

= 96.8 + (2× 1 × 0.8)= 98.4 m

Root diameter 𝑑𝑓1 = 𝑑1 −2𝑓0 𝑚𝑥 −2𝑐 (take 𝑓𝑜 = 1 and c= 0.2)

= 96.8 − 2 × 1 × 0.8 − 2 × 0.2

= 94.8 cm
Pitch diameter 𝑑1′ = 𝑚𝑥 (𝑞 + 2𝑥) (assume x=0)

= 0.8(11+2(0))

= 8.8 cm

Step 11: Parameters of wheel

Reference diameter d2 =Z2 ×mx

=40 × 0.8 = 32 𝑐𝑚

Tip diameter 𝑑𝑎2 = (𝑍2 + 2𝑓0 + 2𝑋)𝑚𝑥

= (40+2)0.8

𝑑𝑎2 = 33.6 𝑐𝑚

Root diameter 𝑑2′ = d2 = 32 cm

Step 12: Efficiency of worm gear drive

tan γ
Efficiency of worm gear drive 𝜂 = tan(𝛾+𝜌)

tan 𝜌 = 𝜇 = 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑐𝑜 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡

𝜇= 0.056, 𝜌 = 𝑡𝑎𝑛−1 0.056 = 3.2

tan 15.255
𝜂=
tan(15.255 + 3.2)

𝜂 =81.72%

Step 13: Check for cooling arrangement

Heat generated (Hg)

𝑘𝑔𝑓𝑚
Hg = (1- 𝜂) × 𝑖𝑛𝑝𝑢𝑡 𝐻𝑝 × 4500 𝑚𝑖𝑛

= (1- 0.817) × 2.011 × 4500

 𝑘𝑔𝑓𝑚
Hg =1654.05 𝑚𝑖𝑛

Heat dissipated (Hd)

𝑘𝑔𝑓𝑚
Hd =hcr × 𝐴 × ∆𝑡 𝑚𝑖𝑛

A=57.2 a1.7 cm2 =57.2× (20.55)1.7

A=9753.85 cm2, hcr =0.16 kgfm/sq.cm min℃

Hd =0.16 × 9753.85 × 10

𝑘𝑔𝑓𝑚
Hd = 15606.16 𝑚𝑖𝑛

Here Hd > Hg

There is no cooling arrangement is required.

Table no: 3.3 worm and worm gear specification

S.NO PARAMETERS WORM GEAR

1 material Hardened steel bronze
2 Center distance 20.4 cm 20.4 cm
3 Axial module 0.8 cm 0.8 cm
4 Length of worm 15.07 cm -
5 Face width - 6.16 cm
6 reference diameter 96.8 cm 32 cm
7 Tip diameter 98.4 cm 33.6 cm
8 Root diameter 94.8 cm 32 cm
9 Pitch diameter 8.8 cm 33 cm
 UNIT- 4 DESIGNS OF GEAR BOXES

Part - B

1. In a drilling machine, 12 different speeds in the range of 100 rpm and 355 rpm are
required. Design a three stage gear box with a standard step ratio. Sketch the layout
of the gear box, indicating the number of teeth on each gear. The gear box receives 5
kW from an electric motor running at 360 rpm. Sketch also the speed diagram.
2. Design a 9 speed gear box for the following data: Minimum speed: 100 rpm, Step
ratio: 1.25. The input is from a 4 kW, 1400 rpm motor. Draw the speed diagram and
indicate the number of teeth on each gear in a kinematic diagram.(April/May 2015)
3. In a milling machine, 18 different speeds in the range of 35 rpm and 650 rpm are
required. Design a three stage gear box with a standard step ratio. Sketch the
layout of the gear box, indicating the number of teeth on each gear. The gear box
receives 3.6 kW from an electric motor running at 1,440 rpm. Sketch also the speed
diagram.
4. A six speed gearbox is required to provide output speeds in the range of 125 to 400
rpm, with a step ratio of 1.25 and transmit a power of 5kW at 710 rpm. Draw the
speed diagram and kinematic diagram. Determine the number of teeth module and
face width of all gears, assuming materials for gears. Determine the length of the
gear box along the axis of the gear shaft. [May/June 2016]
 UNIT- 5 DESIGNS OF CAM, CLUTCHES AND BRAKES
Part - B
1. A dry single plate clutch is to be designed for an automotive vehicle whose engine is
rated to give 100kW at 2400r.p.m. and maximum torque 500N-m. The outer
radius of the friction plate is 25% more than the inner radius. The intensity of
pressure between the plate is not to exceed 0.07N/mm2.The coefficient of
friction may be assumed equal to 0.3. The helical springs required by this
clutch to provide axial force necessary to engage the clutch are 8. If each spring
has stiffness equal to 40 N/mm. Determine the dimensions of the friction
plate and initial compression in the springs.
Given:
Rated power = 100 kw
Speed n = 2400 rpm
Maximum torque = 500 Nm
ro = 1.25 ri.
Pressure intensity = 0.007 N/mm2
Coefficient of friction = 0.3
Number of helical spring = 8
Stiffness K = 40 N/mm

STEP 1: Determination of Clutch Shaft Diameter

Pg 7.89

Transmitted torque

97400 𝐾𝑊
𝑀𝑡 =
𝑛
Design torque

[𝑀𝑡 ] = 𝑘𝑤 . 𝑀𝑡

𝑘𝑤 = 𝑘1 + 𝑘2 + 𝑘3 + 𝑘4

97400 × 100
𝑀𝑡 =
2400
𝑀𝑡 = 4058 𝑘𝑔𝑓. 𝑐𝑚

Pg 7.90 Factor

𝑘1 = 0.5 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)

𝑘2 = 1.25 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)
 𝑘3 = 0.43 (1800 𝑟𝑝𝑚 𝑔𝑟𝑒𝑎𝑡𝑒𝑟 𝑡ℎ𝑎𝑛 1500 𝑟𝑝𝑚)

𝑘4 = 0.20 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)

𝑘𝑤 = 𝑘1 + 𝑘2 + 𝑘3 + 𝑘4

𝑘𝑤 = 2.38

Pg 7.89 Diameter of clutch shaft

3 49500 × 𝑘𝑤 × 𝐾𝑊
𝐷=𝑑= √
𝑛 [𝜏]

Let the clutch shaft be C-45 steel

[𝜏] = 300 𝑘𝑔𝑓/𝑐𝑚2

𝐷 = 4 𝑐𝑚 𝑐𝑚

STEP 2: Determination of Clutch Plate Dimensions

Pg 7.89 No. of friction surface

[𝑀𝑡 ]
𝑖𝑚𝑖𝑛 =
2𝜋 × 𝑃𝑎 × 𝑏 × 𝜇 × 𝑟𝑚2

𝑖𝑚𝑖𝑛 = 2

𝑃𝑎 = 𝑘 𝑃𝑏

k = speed factor from graph pg 7.90

k = 1 (assumed) k can’t be obtained from graph.

𝑃𝑎 = 𝑃𝑏

𝑃𝑏 = 𝑠𝑡𝑒𝑒𝑙 𝑑𝑟𝑦 2 𝑡𝑜 2.5 𝑘𝑔𝑓/𝑐𝑚2

𝑃𝑏 = 2.3 𝑘𝑔𝑓/𝑐𝑚2

𝑏 = 𝑟𝑜 − 𝑟𝑖

𝑏 = 1.25𝑟𝑖 − 𝑟𝑖 = 0.75 𝑟𝑖

Given
 𝑑𝑜 𝑟𝑜
= = 1.5
𝑑𝑖 𝑟𝑖

𝑟𝑜 = 1.25 𝑟𝑖

𝜇 = 0.3 (𝑔𝑖𝑣𝑒𝑛)
𝑟𝑜 + 𝑟𝑖
𝑟𝑚 = 𝑚𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠 =
2
1.25𝑟𝑖 + 𝑟𝑖
=
2
𝑟𝑚 = 1.125 𝑟𝑖

[𝑀𝑡 ]
𝑖𝑚𝑖𝑛 =
2𝜋 × 𝑃𝑎 × 𝑏 × 𝜇 × 𝑟𝑚2

4058
2=
2𝜋 × 2.3 × 0.75 𝑟𝑖 × 0.3 × (1.125 𝑟𝑖 )2

𝑟𝑖 = 0.126 𝑐𝑚
𝑟𝑜
= 1.25
𝑟𝑖

𝑟𝑜 = 0.158 𝑐𝑚

𝑏 = 𝑟𝑜 − 𝑟𝑖

= 0.158 − 0.126 = 0.03 𝑐𝑚

b = 0.03 cm

2. In a single block brake, the diameter of the drum is 250 mm and the angle of
contact is 90°. If the operating force of 700 N is applied at the end of lever which is
at 250 mm from the centre of the brake block. The coefficient of friction between
the drum and the lining is 0.35. Determine the torque that may be transmitted.
Fulcrum is at 200 mm from the centre of brake block with an offset 50 mm from the
surface of contact.
Given:
Diameter of drum D = 250 mm
Angle of contact = 90 degree
Operating force P= 700 N
Coefficient of friction µ= 0.35
 Offset distance from the surface of contact 𝑒 1 = 50 mm
Lever length from the center of the brake drum ‘a’= 250 mm
Length of the fulcrum from the center of brake ‘b’= 200 mm
Step 1: determine frictional force
From the data book PSG pg 7.97
Take case 3
Line of action of F passing at a distance e1 above the fulcrum
𝑃𝑎
𝐹=𝑏
+𝑒 1
𝜇

Assume it was running at anti clockwise direction

Therefore F = 281.6 N
Step 2: Determine the torque transmitted
From the PSG pg n0 7.98
Take
∅/2
𝑀𝑡 = 𝜇 𝑝𝑚𝑎𝑥 𝑊 𝑟 2 ∫−∅/2 cos 𝛼 𝑑 ∝ = 𝜇𝑁𝐿
4𝑟 sin ∅/2
𝐿= ∅+𝑠𝑖𝑛∅
L = 3.88 mm
N = pmax Wr/2 (∅ + sin ∅)
N = 56875 kgf
Therefore 𝐌𝐭 = 𝟕𝟕𝟐𝟑. 𝟔𝟐𝟓 𝐤𝐠𝐟 𝐜𝐦.

3. A multi - disc clutch has three discs on the driving shaft and two on the driven shaft
is to be designed for a machine tool, driven by an electric motor of 22 kW running at
1440 rpm. The inside diameter of the contact surface is 130mm. The maximum
pressure between the surfaces is limited to 0.1/N/mm2. Design the clutch. Take
µ=0.3, n1 = 3; n2 =2. (Apr 2011)
Given:
Electric motor power = 22 kw
Speed n = 1440 rpm
Maximum pressure between the surfaces = 0.1 N/mm2
Coefficient of friction µ = 0.3
Discs on the driving shaft n1= 3
Discs on the driven shaft n2 = 2

STEP 1: Determination of Clutch Shaft Diameter

Pg 7.89

Transmitted torque
 97400 𝐾𝑊
𝑀𝑡 =
𝑛
Design torque

[𝑀𝑡 ] = 𝑘𝑤 . 𝑀𝑡

𝑘𝑤 = 𝑘1 + 𝑘2 + 𝑘3 + 𝑘4

97400 × 22
𝑀𝑡 =
1440
𝑀𝑡 = 1488.05 𝑘𝑔𝑓. 𝑐𝑚

Pg 7.90 Factor

𝑘1 = 0.5 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)

𝑘2 = 1.25 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)

𝑘3 = 0.43 (1800 𝑟𝑝𝑚 𝑔𝑟𝑒𝑎𝑡𝑒𝑟 𝑡ℎ𝑎𝑛 1500 𝑟𝑝𝑚)

𝑘4 = 0.20 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)

𝑘𝑤 = 𝑘1 + 𝑘2 + 𝑘3 + 𝑘4

𝑘𝑤 = 2.38

Pg 7.89 Diameter of clutch shaft

3 49500 × 𝑘𝑤 × 𝐾𝑊
𝐷=𝑑= √
𝑛 [𝜏]

Let the clutch shaft be C-45 steel

[𝜏] = 300 𝑘𝑔𝑓/𝑐𝑚2

𝐷 = 1.81 𝑐𝑚

STEP 2: Determination of Clutch Plate Dimensions

Pg 7.89 No. of friction surface

[𝑀𝑡 ]
𝑖𝑚𝑖𝑛 =
2𝜋 × 𝑃𝑎 × 𝑏 × 𝜇 × 𝑟𝑚2

𝑖𝑚𝑖𝑛 = 2
 𝑃𝑎 = 𝑘 𝑃𝑏

k = speed factor from graph pg 7.90

k = 1 (assumed) k can’t be obtained from graph.

𝑃𝑎 = 𝑃𝑏

𝑃𝑏 = 𝑠𝑡𝑒𝑒𝑙 𝑑𝑟𝑦 2 𝑡𝑜 2.5 𝑘𝑔𝑓/𝑐𝑚2

𝑃𝑏 = 2.3 𝑘𝑔𝑓/𝑐𝑚2

𝑏 = 𝑟𝑜 − 𝑟𝑖

𝑏 = 1.25𝑟𝑖 − 𝑟𝑖 = 0.75 𝑟𝑖

Assume

𝑑𝑜 𝑟𝑜
= = 1.25
𝑑𝑖 𝑟𝑖

𝑟𝑜 = 1.25 𝑟𝑖

𝜇 = 0.3 (𝑔𝑖𝑣𝑒𝑛)
𝑟𝑜 + 𝑟𝑖
𝑟𝑚 = 𝑚𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠 =
2
1.25𝑟𝑖 + 𝑟𝑖
=
2
𝑟𝑚 = 1.125 𝑟𝑖

[𝑀𝑡 ]
𝑖𝑚𝑖𝑛 =
2𝜋 × 𝑃𝑎 × 𝑏 × 𝜇 × 𝑟𝑚2

3541.55
4=
2𝜋 × 2.3 × 0.75 𝑟𝑖 × 0.3 × (1.125 𝑟𝑖 )2

𝑟𝑖 = 0.166 𝑐𝑚
𝑟𝑜
= 1.25
𝑟𝑖

𝑟𝑜 = 0.2 𝑐𝑚

𝑏 = 𝑟𝑜 − 𝑟𝑖
 = 0.2 − 0.166 = 0.04 𝑐𝑚

b = 0.04 cm

4. Determine the capacity and the main dimensions of a double block brake for the
following data. The brake sheave is mounted on the drum shaft. The hoist
with its lead weights 45 kN and moves downwards with a velocity of 1.15 m/s.
The pitch diameter of the hoist drum is 1.25m. The hoist must be stopped with in a
distance of 3.25 m. The kinetic energy of the drum may be neglected.
5. A 50kg wheel, 0.5m in diameter turning at 150 rpm in stationary bearings is
brought to rest by pressing a brake shoe radially against the rim with a force of 100
N. If the radius of gyration of wheel is 0.2m, how many revolutions will the wheel
make before coming to rest?. Assume that the co-efficient of friction between shoe
and the rim has the steady value of 0.25. [May/June 2016]
Given:
Mass of the wheel m = 50 kg
Diameter D = 0.5m
Speed = 150 rpm
Force applied = 100 N
Radius of gyration of wheel = 0.2 m
Coefficient of friction = 0.25
Step 1: determine frictional force
From the data book PSG pg 7.97
Take case 3
Line of action of F passing at a distance e1 above the fulcrum
𝑃𝑎
𝐹=𝑏
+𝑒 1
𝜇

Assume it was running at anti clockwise direction

Therefore F = 281.6 N
Step 2: Determine the torque transmitted
From the PSG pg n0 7.98
Take assume pressure angle 90 degree
∅/2
𝑀𝑡 = 𝜇 𝑝𝑚𝑎𝑥 𝑊 𝑟 2 ∫−∅/2 cos 𝛼 𝑑 ∝ = 𝜇𝑁𝐿
4𝑟 sin ∅/2
𝐿= ∅+𝑠𝑖𝑛∅
L = 3 mm
N = pmax Wr/2 (∅ + sin ∅)
N = 56000 kgf
Therefore 𝐌𝐭 = 𝟒𝟐𝟎𝟎 𝐤𝐠𝐟 𝐜𝐦.