Académique Documents
Professionnel Documents
Culture Documents
Mayuram
Module 2- GEARS
A pair of bevel gears is transmitting 10 kW from a pinion rotating at 600 rpm to gear
mounted on a shaft which intersects the pinion shaft at an angle of 60o. The pinion has
an outside pitch diameter of 200 mm, a pressure angle of 20o and a face width of 40
mm, and the gear shaft is rotating at 200 rpm. Determine ( a ) the pitch angles for the
gears, ( b ) the forces on the gear, and ( c ) the torque produced about the shaft axis
n1 600
Solution: (a) i 3
n2 200
d 2 = i d 1 = 3 x 200 = 600 mm
r 1 = 0.5 d 1 = 0.5x200 = 100 mm
r 2 = 0.5 d 2 = 0.5x600 = 300 mm
sin sin60o
tan γ 2 = = =1.0392
1 1
+cos +cos60o
i 3
γ 2 = 46.1o
γ 1 = ∑ - γ 2 = 60 – 46.1 = 13.9o
r 2av = r 2 – 0.5bsin γ 2 = 300 - 0.5x40x sin46.1 = 285.59 mm
r 1av = r 1 – 0.5bsin γ 1 = 100 - 0.5x40x sin13.9 = 95.2 mm
Solution: (b)
V 1 = πd 1av n 1 /60000 = π x (2x95.2)x600 /60000
= 5.98 m/s
1000W 1000x10
Ft 1673N
V1av 5.979
Ft 1673
Fn 1780N
cos cos20o
Solution: (c)
----------------------
The bevel pinion shown in Fig.14.2 rotates at 960 rev/min in the clockwise direction,
viewing from the right side and transmits 5 kW to the gear. The mounting distances, the
location of all bearings, and the radii of the pitch circles of the pinion and gear are
shown in pitch cones in the figure. Bearings A and C should take the thrust loads. Find
the bearing forces on the gear shaft.
Data:
n 1 = 960 rpm, W = 5 kW, Z 1 = 15, Z 2 = 45, m = 5 mm
d 1 = 75 mm, d 2 = 225 mm
Solution:
The pitch angles are
d 75
1 tan1 1 tan1 18.43o
d2 225
d 225
2 tan1 2 tan1 71.57
o
d1 75
d 1av = d 1 - b sinγ 1 = 75 – 30sin18.43o = 65.52 mm
d1 n1 x 65.52x960
Vav = 3.29 m / s
60000 60000
Where F r is acting - x direction and F a is in the –y direction. All forces are acting at a
distance of 98.27 mm from the shaft centre line and 32.76 mm from the apex of the
pitch cones as in Fig.14.3.
Fig.14.3 Various forces acting on the bevel gear and the shaft reactions
--------------------
A bevel gear pair has to be designed to transmit 6 kW power at 750 rpm. The shaft
angle is 90o. Speed ratio desired is about 2.5. The prime mover is induction motor and
the driven side is connected to a belt conveyor.
Solution:
To solve the problem the following assumptions are made.
1. The gears are to be mounted on anti-friction bearings in a gear box and are subjected
to extensive shock due to sudden loading of the belt conveyor.
2. The conveyor gearbox has to last for 20 years for which hardened gears are
selected.
3. The gears are of continuous duty and are straddle mounted on antifriction ball
bearings.
4. The pinion material is made of C45 steel of hardness 380 Bhn and tensile strength
σ ut = 1240 MPa. The gear is made of ductile iron grade 120/90/02 of hardness 331 Bhn
and tensile strength σ ut = 974 MPa. Both gears are hobbed, HT and OQ&T and ground.
5. A factor of safety of 1.5 and 1.2 on bending and contact fatigue strengths of the
materials was assumed.
Solution:
We will first determine the allowable stresses for the pinion and gear materials.
For pinion material, σ ut = 1240 MPa,
Hardness=380 Bhn
σ sf ’ = 2.8 (Bhn) – 69 = 2.8x380-69=995 MPa
k f = fatigue stress concentration factor. Since this factor is included in J factor, its value
is taken as 1.
k m = Factor for miscellaneous effects. For idler gears subjected to two way bending,
= 1. For other gears subjected to one way bending, the value is taken from the Fig.14.7.
Use k m = 1.33 for σ ut less than 1.4 GPa.
σ sf = σ sf ’ K L K H K R K T
σ sf ’ = surface fatigue strength of the material = 2.8 (Bhn) – 69 From Table 14.2
= 2.8 x 380 -69 = 995 MPa
Table 14.2 Surface fatigue strength σ sf ’ (MPa) for metallic spur gears
(107 cycle life, 99% reliability and temperature <120oC)
2n1 2x750
1 78.5rad / s
60 60
F 2T1
σb1 t K v K o Km K v K o Km
bmJ 8m3 Z1J
Z1 20
Z v1 21.5
cos 1 cos 21.4o
Z2 51
Z v2 139.2
cos 2 cos 68.5o
Driven Machinery
2T1 2x(76.43x103 )
σb1 = K v K o K m = x1.25x1.75x1.25
8m3 Z1J 8m3 x20x0.37
7060.4
σb1 =
m3
7060.4
σb1 = [ σb1 ] 218MPa
m3
m = 3.2 mm
Similarly for the gear: J =0.375 for Z v2 = 139.2 mating with Z v1 =21.5 from Fig. 14.10
2T2 2x(2.55x76.43x103 )
σb2 = K v K o K m = x1.25x1.75x1.25
8m3 Z2 J 8m3 x51x0.375
6966.3
σb2 = [σb2 ] 182.5
m3
Fig. 14.12 Geometry factor I for straight bevel gear pressure angle 20o and shaft
angle 90o
I = 0.107 from Fig.14.12. Other factors are same in bending fatigue stress equation.
K v = 1.11 for V = 3.14 m/s from Fig. 14.11, for quality 10 gears
Ft 1911
σH =Cp K V K o K m =154.38 1.11x1.75x1.25
b dI 32x80x0.107
---------------------