Unit I DME II Spur Gears by Sachin Dhavane

Design of Machine Elements - II
Prof.Sachin Dhavane Mech Engg Sinhgad

Institue of Technology
John Deere 3350 tractor cut in Technikmuseum Speyer Museum
DME -II SYLLABUS STRUCTURE

Reference Books

Termwork

Spur Gears
Prof.Sachin Dhavane Mech Engg Sinhgad Institue of Technology
SPUR GEARS
Presentation on Spur Gear

Mechanical Drives
Need of mechanical drives
Types of mechanical drives
1. Transmitting power by means of friction.

e.g. Belt drives and Rope drives
2. Transmitting power by means of engagement.

e.g. Chain drives and Gear drives

Selection of Proper Mechanical Drive

1. Centre distance
2. Speed ratio
3. Shifting arrangement
4. Maintenance considerations
5. Cost

Gear Drive Significance

1. Positive drive
2. Compact construction
3. Large power transmission
4. Power transmission at very low speed
5. Very high efficiency
6. Wide range of velocity ratio

Classification of Gears
1.
2.
3.
4.
5.
Spur gears
Helical gears
Bevel gears
Worm gears
Rack and pinion

Classification of Gears


Selection of Type of Gear

Type of
gear
Shaft layout
Speed
reduction
Input Speed and

Power to be
transmitted
Cost
Spur
Parallel
6:1(10:1)
Low and medium

speed
Cheapest
Helical
Parallel
6:1(10:1)
High speed power

transmission
Costlier
Bevel
Perpendicular
1:1(3:1)
Low speed
Costlier
Worm
Perpendicular
and non-intersecting
60:1(100:1)
Low speed
Costlier

Meshing of Gear Teeth

Meshing of Gear Teeth

GEAR NOMENCLATURE

Gear Pinion Meshing Nomenclature

Gear Pinion Meshing Nomenclature

NOMENCLATURE.
Pitch surface: The surface of the imaginary rolling cylinder
(cone, etc.) that the toothed gear may be considered to replace.
Pitch circle: Curve of the intersection of pitch surface of
revolution and plane of rotation.
Addendum circle: A circle bounding the ends of the teeth, in a
right section of the gear.
Root (or dedendum) circle: The circle bounding the spaces
between the teeth, in a right section of the gear.
Addendum(ha): The radial distance between the pitch circle
and the addendum circle.
Dedendum(hf): The radial distance between the pitch circle
and the root circle.
Clearance: The difference between the deddendum of one gear
and the addendum of the mating gear. C=hf-ha
NOMENCLATURE.
Face of a tooth: That part of the tooth surface lying outside
the pitch surface.
Flank of a tooth: The part of the tooth surface lying inside the
pitch surface.
Circular thickness (also called the tooth thickness): The
thickness of the tooth measured on the pitch circle. It is the
length of an arc and not the length of a straight line.
Tooth space: pitch diameter The distance between adjacent
teeth measured on the pitch circle.
Backlash: The difference between the circle thickness of one
gear and the tooth space of the mating gear.
Circular pitch Pc: distance measured along circumference of
pitch circle from point on one tooth to corresponding tooth.
Pc=(d/z)
Module:(m)=d/z ( Diametral pitch :Pd=1/m)
Gear ratio : G=Zg/Zp=mZg/mZp=dg/dp
Center Distance: (a)=(dp+dg)/2
Interference
A minimum number of teeth are required on the pinion to avoid
interference.

Backlash in Gears


Scoring Failure of Gear Tooth


Corrosive Wear of Gear Tooth




Pitting Failure of Gear Tooth




Standard Systems Of Gear Tooth

Standard Systems Of Gear Tooth

Standard Proportions of Gear Tooth

Concept Module..???

Force Analysis

Beam Strength of a Spur Gear Tooth

Beam Strength :
Maximum tangential load the gear tooth can take without
tooth breakage (bending failure).
Assumptions:
1. Full load acting at tip of single tooth.
2. Radial force effect neglected.

3. Load uniformly distributed across the full face width.
4. Frictional forces due to teeth sliding are neglected.
5. Effect of stress concentration neglected.

Beam Strength of a Spur Gear Tooth


Lewis Form factor (Y)

Function
of tooth shape (but not size) and the point of

application of load.
Y
1.No of teeth 2.Tooth system 3.Pt application of load
2.87
Y 0.484
( 20 full dep th)
Z
2.64
Y 0.55
( 20 stub)
Z
2.15
Y 0.39
(14.5 full dep th)
Z
Wear Strength of a Spur Gear Tooth

Wear Strength :
Maximum tangential load the gear tooth can

take without pitting failure.
Fw= dp*b*Q*k
Q=Ratio factor for external gear pair
=2 Zg /(Zg+Zp)
K= load stress factor N/mm2
Effective Load on Gear Tooth

Actual Load on gear tooth to transmit power
Tangential Load + Dynamic Load
Effective Load Feff
Tangential Load
Ftmax
Dynamic Load
Fd
Feff Ft max Fd
Maximum Tangential Load F tmax :

Maximum Tangential Load (Ftmax ) is given by
Ft max ka K m Ft
Where Ka is Service / Application / Overload factor
Ks Depends upon application
Driving and Driven elements
Compressor
Max Torque
Ka
Rated Torque
Motor
Calculation Dynamic load (Fd)
Preliminary Estimation
Precise Estimation
Preliminary Estimation:
3
m
KV
V 10
3 V
s
6
m
3.6
m
KV
V 20
KV
20 V
25
6 V
s
3.6 V
s
5.6
m
KV
25 V
30
5.6 V
s
Kv factor accounts dynamic load
Feff
Ft max
Ka Ft Km
kV
KV
Precise Estimation
Buckingham Approach
According to Buckingham Approach Fd is given by
Fd
21V bC Ft max
E p Eg
C
ke
E E
1
1
g
p

E
E
g
p
ke
bC Ft max
21V
K is constant, depends on
tooth form
K=0.107
-14.50
K=0.111
- 200 Full depth
K=0.115
- 200 stub



Problem 1 : A spur pinion having 21 teeth to be made of plain carbon steel

55C8 ( Sut=720 N/mm2) is to mesh with a gear to be made of plain carbon steel
40C8 ( Sut=580 N/mm2).The gear pair is required to transmit 22 KW power from

an IC engine running at 1000 rpm to a machine running at 300 rpm. The
starting torque required is 200% of rated torque while the load distribution factor
is 1.5. The factor of safety required is 1.5. The face width is ten times module and
tooth system is 20 full depth involute. The gears are to be machined to meet the
specifications of grade 6. The gear and pinion are to be case hardened to 400
BHN and 450 BHN resp. The deformation factor C for gear pair is 11500e N/mm.
Design the gear pair by using dynamic factor Kv= 6/6+v and the buckinghams
equation for dynamic load.

Problem 2 : A spur gear pair is used to transmit 20 KW power from an

electric motor running at 1440 rpm to the machine tool expected to run exactly
at 600 rpm. The pinion and gear are to be made of alloy steel 40Ni2Cr1Mo28
(Sut=800 N/mm2) and plain carbon steel (Sut=700 N/mm2) resp. The service
factor and factor of safety are 1.5 and 1.35 resp. The face width is 12 times the
module for which load distribution factor is 1.4.The tooth system is 20 full depth
involute. The gears are to be machined to meet the specifications of grade 7.The
pinion and gear are to be case hardened to 400 BHN and 350 BHN. Design the
gear pair by using the velocity factor Kv=6/6+v and buckingham equation for
dynamic load.

Note

Solution 2 :
Beam Strength:
6bp= 266.67 N/mm2
6bg=233.33 N/mm2
Yp=0.3405
Yg=0.4242
6bp*Yp=90.80 N/mm2
6bg*Yg=98.98N/mm2
Fb=1089.61 m2 N
Fw=664.09 m2 N
V=1.508 m m/s
Ft=(13262.6/m)
Problem 3 : A spur gear pair made of plain carbon steel 55C8 (Sut=720
N/mm2 and E=210 Gpa) is required to transmit 7.5 KW power from an electric
motor running at 1440 rpm to a machine running at 1440 rpm to a machine
running at 370 rpm. The tooth system is 20 Full depth involute and no of teeth
on pinion are as minimum as possible. The service factor and load
concentration factor are 1.25 and 1.2 resp. The factor of safety required is 1.25
to 1.5. The face width is 12 times the module. The Gears are to be machined to
meet the specifications of grade 7.Design the gear pair by using velocity factor
kv=3/3+v and buckinghams equation for dynamic load. Suggest the case
hardness for gear pair. Use following relation C=0.111e (Ep*Eg/Ep+Eg) N/mm.
Problem 4 : A pair of spur gear with 20 full depth involute teeth

consists of 21 teeth pinion meshing with 60 teeth internal gear. The
pinion shaft is directly coupled to a 10 hp electric motor running at

1440 rpm. The gear shaft is transmitting a power to a machine. The
application factor is 1.5 . The pinion as well as gear made of alloy steel
30Ni4Cr1(Sut=1500 N/mm2).The module and face width of gears are 3
mm and 35 mm resp. The gears are machined to meet the specifications

of grade 8 and heat treated to a surface hardness of 400 BHN. The
deformation factor is 11500e N/mm. Assuming the dynamic load is
accounted by Buckinghams equation. Calculate i)FOS against bending
failure ii)FOS against pitting failure.(1 Hp=735 Watts)
In Semester Paper

In Semester Paper

End Semester Paper

End Semester Paper

Gearbox Of A Motor Cycle Using Spur Gears

Unit I DME II Spur Gears by Sachin Dhavane

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Design of Machine Elements - II

Prof.Sachin Dhavane Mech Engg Sinhgad

John Deere 3350 tractor cut in Technikmuseum Speyer Museum

DME -II SYLLABUS STRUCTURE

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad Institue of Technology

Presentation on Spur Gear

Prof.Sachin Dhavane Mech Engg Sinhgad

Need of mechanical drives

Types of mechanical drives

1. Transmitting power by means of friction.

2. Transmitting power by means of engagement.

Prof.Sachin Dhavane Mech Engg Sinhgad

Selection of Proper Mechanical Drive

Prof.Sachin Dhavane Mech Engg Sinhgad

Gear Drive Significance

6. Wide range of velocity ratio

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Selection of Type of Gear

Input Speed and

Low and medium

High speed power

Prof.Sachin Dhavane Mech Engg Sinhgad

Meshing of Gear Teeth

Prof.Sachin Dhavane Mech Engg Sinhgad

Meshing of Gear Teeth

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Gear Pinion Meshing Nomenclature

Prof.Sachin Dhavane Mech Engg Sinhgad

Gear Pinion Meshing Nomenclature

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Scoring Failure of Gear Tooth

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Corrosive Wear of Gear Tooth

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Pitting Failure of Gear Tooth

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Standard Systems Of Gear Tooth

Prof.Sachin Dhavane Mech Engg Sinhgad

Standard Systems Of Gear Tooth

Prof.Sachin Dhavane Mech Engg Sinhgad

Standard Proportions of Gear Tooth

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Prof.Sachin Dhavane Mech Engg Sinhgad

Beam Strength of a Spur Gear Tooth