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UNit-2 Numerical Problems

The document contains several numerical problems related to spur gear design and analysis. It includes calculating gear dimensions, torque, forces, center distances, pitch circle diameters, addendums, dedendum, tooth thickness, bottom clearance, and gear ratios for various gear configurations. It also includes problems on designing spur gears based on material properties, load calculations, and specifying surface hardness to satisfy factors of safety for bending and pitting. Dynamic load calculations using Buckingham's equation and velocity factors are employed. Design modifications are discussed to satisfy design conditions if initially unsatisfactory.

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Marthande
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3K views16 pages

UNit-2 Numerical Problems

The document contains several numerical problems related to spur gear design and analysis. It includes calculating gear dimensions, torque, forces, center distances, pitch circle diameters, addendums, dedendum, tooth thickness, bottom clearance, and gear ratios for various gear configurations. It also includes problems on designing spur gears based on material properties, load calculations, and specifying surface hardness to satisfy factors of safety for bending and pitting. Dynamic load calculations using Buckingham's equation and velocity factors are employed. Design modifications are discussed to satisfy design conditions if initially unsatisfactory.

Uploaded by

Marthande
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Numerical Problems

• A pair of spur gears consists of a 20 teeth pinion meshing with a 120


teeth gear. The module is 4 mm. Calculate
(i) The centre distance;
(ii) the pitch circle diameters of the pinion and the gear;
(iii) the addendum and dedendum;
(iv) the tooth thickness;
(v) the bottom clearance; and
(vi) the gear ratio.
Given zp = 20 zg = 120 m = 4 mm
Numerical Problems
• The pitch circles of a train of spur gears are shown in Fig. Gear A receives 3.5 kW
of power at 700 rpm through its shaft and rotates in the clockwise direction. Gear
B is the idler gear while the gear C is the driven gear. The number of teeth on
gears A, B and C are 30, 60 and 40 respectively, while the module is 5 mm.
Calculate
(i) the torque on each gear shaft; and
(ii) the components of gear tooth forces.

Draw a free-body diagram of forces and determine the


reaction on the idler gear shaft. Assume 20° involute
system for the gears.
Numerical Problems
• The layout of a two-stage gear box is
shown in Fig. The number of teeth on
the gears are as follows:
z1 = 20 z2 = 50 z3 = 20 z4 = 50
Pinion 1 rotates at 1440 rpm in the anti-
clockwise direction when observed from
the left side of the page and transmits 10
kW of power to the gear train. The
pressure angle is 20°. Draw a free-body
diagram of the gear tooth forces and
determine the reactions at bearings E and
F
Numerical Problems

• In a pair of spur gears, the number of teeth on the pinion and the
gear are 20 and 100 respectively. The module is 6 mm. Calculate
(i) The centre distance;
(ii) The pitch circle diameters of the pinion and the gear;
(iii) Addendum and dedendum;
(iv) Tooth thickness and bottom clearance; and
(v) The gear ratio
Numerical Problems
• It is required to design a pair of spur gears with 20° full-depth involute
teeth based on the Lewis equation. The velocity factor is to be used to
account for dynamic load. The pinion shaft is connected to a 10 kW,
1440 rpm motor. The starting torque of the motor is 150% of the rated
torque. The speed reduction is 4:1. The pinion as well as the gear is
made of plain carbon steel 40C8 (Sut = 600 N/mm2). The factor of
safety can be taken as 1.5. Pinion has 18 no of gear teeth and lewis
form factor for pinion is 0.308. Design the gears, specify their
dimensions and suggest suitable surface hardness for the gears.
Sw=bQdpK
Sw= 50*1.6*90*0.16 (BHN/100)2

Q= 2Zg/(Zg+Zp)= 2*(72)/(72+18)=1.6

K=0.16 (BHN/100)2
Sw=Peff (fs)
50*1.6*90*0.16 (BHN/100)2 =1.5*7223.77

BHN = 306.59
Sb Peff= Cs*Pt/Cv

Sw Peff= (CsPt)+ Pd
Numerical Problems
• It is required to design a pair of spur gears with 20° full-depth involute
teeth consisting of a 20-teeth pinion meshing with a 50 teeth gear. The
pinion shaft is connected to a 22.5 kW, 1450 rpm electric motor. The
starting torque of the motor can be taken as 150% of the rated torque.
The material for the pinion is plain carbon steel Fe 410 (Sut = 410
N/mm2), while the gear is made of grey cast iron FG 200 (Sut =200
N/mm2). The lewis form factor for pinion an gear can be takes as
0.32 and 0.408 respectively. The factor of safety is 1.5. Design the
gears based on the Lewis equation and using velocity factor to account
for the dynamic load.
Numerical Problems
• A pair of spur gears with 20° full-depth involute teeth consists of a 19 teeth pinion
meshing with a 40 teeth gear. The pinion is mounted on a crankshaft of 7.5 kW single
cylinder diesel engine running at 1500 rpm. The driven shaft is connected to a two-stage
compressor. Assume the service factor as 1.5. The pinion as well as the gear is made of
steel 40C8 (Sut = 600 N/mm2). The module and face width of the gears are 4 and 40 mm
respectively.
Take form factor for pinion as 0.314 and deformation factor can be taken as
11400N/mm2
• (i) Using the velocity factor to account for the dynamic load, determine the factor of
safety.
• (ii) If the factor of safety is two for pitting failure, recommend surface hardness for the
gears.
• (iii) If the gears are machined to meet the specifications of Grade 8, determine the factor
of safety for bending using Buckingham’s equation for dynamic load.
• (iv) Is the gear design satisfactory? If not, what is the method to satisfy the design
conditions? How will you modify the design?
Numerical Problems
• It is required to design a spur gear speed reducer for a compressor running at 250
rpm driven by a 7.5 kW, 1000 rpm electric motor. The centre distance between the
axes of the gear shafts should be exactly 250 mm. The starting torque of the motor
can be assumed to be 150% of the rated torque. The gears are made of carbon steel
50C4 (Sut = 700 N/mm2). The pressure angle is 20°. The factor of safety is 2 for
preliminary design based on the use of velocity factor.
• Assume 25 no teeth on pinion and form factor for pinion is 0.314 and
deformation factor can be taken as 11400N/mm2
• (i) Design the gears and specify their dimensions.
• (ii) Assume that the gears are manufactured to meet the requirements of Grade 6
and calculate the dynamic load by using Buckingham’s equation.
• (iii) Calculate the effective load.
• (iv) What is the actual factor of safety against bending failure?
• (v) Using the same factor of safety against pitting failure, specify suitable surface
hardness for the gears.
Numerical Problems
• It is required to design a pair of spur gears with 20° full-depth involute teeth. The input shaft
rotates at 720 rpm and receives 5 kW power through a fl exible coupling. The speed of the output
shaft should be 144 rpm. The pinion as well as the gear are made of steel Fe 410 (Sut = 410
N/mm2). The service factor for the application is 1.25. The gears are machined to meet the
specifications of Grade 6.
Assume 18 no teeth on pinion and form factor for pinion is 0.308 and deformation factor can
be taken as 11400N/mm2
• For preliminary calculations, assume the pitch line velocity as 5 m/s and the factor of safety as 2.
Estimate the module and select the first preference value of the module.
• Using this value of the module, calculate the pitch circle diameters of the pinion and gear and the
face width.
• Determine static load and the dynamic load by Buckingham’s equation. Also, calculate the beam
strength and the correct value of factor of safety based on beam strength.
• Using a factor of safety of 2 for wear strength, specify the surface hardness for gears
Sb= mb

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