DTS Notes 1

WWW.VIDYARTHIPLUS.
COM
UNIT 1
DESIGN PROCEDURE OF FLAT BELT
STEP-1: Calculation of diameter
From the data given, take the centre distance, dia. of the pulley & speed ratio.
STEP-2: Calculation of belt speed
Determine the belt speed, v=dN/60
m/s.
STEP-3: Calculation of arc of contact

Determine the arc of contact.
Refer PSG 7.54.
STEP-4: Selection of power rating

Take the rating of the belt at 10 m/s.
Refer PSG 7.54.
STEP-5: Calculation of power rating

Determine the power rating of the belt speed, v= power rating *v/10 kW for 10 m/s.
v=actual belt speed given in the problem.
STEP-6: Calculate the design power
Determine the design power,
Rated power x service factor (ks)
Design power=--------------------------------------------------------------Diameter factor(kp) x arc of contact factor(ka)
Diameter factor (kp):
SMALL PULLEY DIAMETER(mm)
100
100-200
200-300
300-400
400-750
Above 750
PSG7.53
PSG7.54
kp
0.5
0.6
0.7
0.8
0.9
1.0
STEP-7: Calculation of width

Calculate the width of the belt,
Design power (kW)
Width=----------------------------------------Rating of the belt
Take the nearest standard width from
PSG7.52.
STEP-8: Calculation of pulley width

Calculate the pulley width from
PSG7.54.
STEP-9: Calculation of length

WWW.VIDYARTHIPLUS.COM
V+ TEAM
Calculate the length of the belt from
PSG7.53
Design a fabric belt to transmit 12kW at 450rpm from an engine to be a line

shaft at 1200rpm. Diameter of the engine pulley is 600mm and the distance of
the shaft from the engine is 2m.
Step: 1 Given:
Diameter of the larger pulley,
D=600 mm
Speed of the driver pulley,
N=450 rpm
Speed of the driven pulley,
n=1200rpm
Power,
P=12kW
Center distance,
C=2m = 2000 mm
Step: 2
I=
d= (
600
1200
) 450
d = 225 mm.
Belt speed, V=
60
2251200
60
=14137.166 mm/s.
V = 14.137
Step: 3
Arc of contact, = 180
[()60]
= 180
[(600225)60]
2000
= 168.75o
Step: 4
(Refer PSG, Pg no: 7.54)
Load (or) power rating 10 m/s /.

HI SPEED 878g duck 0.023 kW per mm per ply.
Step: 5
V+ TEAM
Power rating for 14.14 m/s
Power rating for 10m/s *

=
10
0.02314.14
10
= 0.03252 kW / mm / ply.
Step: 6
[Refer PSG, pg.no:7.53]
Design power =
[ ()]
[ () ()]
Here line shaft and intermediate load =1.3

Diameter factor ( ) =0.7
[Refer PSG,pg.no:7.54]
Arc of contact factor, = 1.04

Design power =
121.3
0.71.04
= 21.428 kW.
Step: 7
Width =
=

21.428
0.03252
= 658.917 mm plies of belt

For d = 225mm and belt speed is 10m/s/mm/ply.[Refer PSG, pg no: 7.52]
No. of plies = 6
Belt width, b=
658.917
6
= 109.8mm
The standard width of the belt = 112mm.
Step: 8
[Refer PSG, pg no: 7.52]

Width of the pulley = 112+13

=125mm
V+ TEAM
Step: 9 Length of the belt,
For open belt drive,
L = 2C + ( + ) +
2
()2
4
(600225)2
42000
= 2*2000 + (600 + 225) +

L = 5313.48mm
For 6 plies, reduce the length by 1% for initial tension[Refer PSG , pg no:7.53]
L = 5313.48 - 53.13
= 5260.35mm
L = 5.26m.
Step: 10 Specifications:
*Diameter of the larger pulley,
D = 600mm
* Diameter of the smaller pulley,
d = 225mm
*Width of the belt,
b = 112mm
*No. of plies
=6
*Width of the pulley
= 125mm
*Length of the belt,
L = 5.26m
*Centre distance,
C = 2m
A Flat belt is required to transmit 30kW for 600rpm to a machine pulley

1200mm diameter. Distance between the pulley centres 3000mm and speed
ratio 3:1. Service factor, Ks=1.5.Design the belt drive.
Step: 1
Diameter of the larger pulley,
D = 1200 mm
Speed of the driver pulley,
N = 600 rpm
V+ TEAM
Power,
P = 30 kW
Centre distance,
C = 3000 mm
Speed ratio
= 3:1
Service factor,
Ks = 1.5
Step: 2
Speed ratio, I =
d=(
600
1800
) 1200
d = 400 mm.
Belt speed, V=
60
V=37699.11 mm/s.
Step: 3
Arc of contact, = 180
= 180
[()60]
[(1200400)60]
3000
= 164o
Step: 4
(Refer PSG Pg no: 7.54)
Load (or) power rating 10 mm/s per mm per ply.

HI SPEED 878g duck 0.023 kW per mm per ply.
Step: 5
Power rating at 37.69 m/s =
0.0233769
10
= 0.0867 kW per mm per ply.

Step: 6
Design power=
Service factor (Ks)

() ()
V+ TEAM
30 1.5
0.8 1.4
Design Power = 54.086 kW.

Step: 7
Width=
54.086
0.0866
= 624.549 mm piles of belt

For belt speed 10 m/s and d= 400 mm
No. of piles = 6
Belt Width, b=
624.549
6
= 104.09 mm.
The Standard width of the belt = 125 mm.
Step: 8

Width of the pulley = 125 + 25

= 150 mm.
Step: 9
For open belt drive,
L= 2 + 2 (D + d) +
()
(1200400)2
43000
= (2 3000) + (1200 + 400) +

L= 8566.61 mm.
For 6 piles reduce the length by 1% for initial tension (Refer PSG Pg no: 7.53)
L= 8566.61 85.66
V+ TEAM
= 8480.95 mm.
= 8.48 m.
Step: 10 Specifications
1.
Diameter of the larger pulley, D = 1200 mm.
2.
Diameter of the smaller pulley, d = 400 mm.
3.
Width of the belt, v
= 125 mm.
4.
Length of the belt, L
= 8.48 m.
5.
No. of the piles
=6
6.
Width of the pulley
= 150 mm.
7.
Centre distance, C
= 3000 mm.
DESIGN PROCEDURE OF V-BELT

Step 1: Selection of belt section
PSG 7.58
Select the cross section of belt based on power to be transmitted
Step 2: Selection of pulley diameter

Select if not in the question.
Select larger diameter of pulley for the given speed ratio.
PSG 7.58
Step 3: Selection of centre distance C
PSG 7.61
Step 4: Determination of nominal pitch length L

V-belts are designated by cross section & inside length.
Standard inside length from PSG 7.58, 7.59, 7.60.
PSG 7.61
Step 5: Calculation of design power

Design power =Rated power x service factor
PSG7.69
V+ TEAM
Arc of contact factor (PSG7.68) x correction factor length

Step 6: Determination of max. Power capacity of V-belt
PSG 7.62
Step 7: Determination of no. of belt

No. Of belt = Design power
Rating of belt
Step 8: Recalculation of centre distance
C=A+A2-B
A=L/4 - (D+d)/8
B=(D-d)2/8
PSG 7.61
Step 9: Calculate the details of V-groove pulley
PSG 7.70
Step 10: Write the specifications of the drive.
A 50 kW motor running at 1000 rpm is required to drive pump pulley at 400 rpm
space restrictions limit the size of motor pulley 0.3 m and the center distance is 2.5
m. The pump is located in a shed and is expected to run for 16 hr/day . Select a
suitable V belt drive and design.
Step 1:
Power
(P) = 50 kW
Speed of driving pulley
( N )= 1000 rpm
Speed of driven pulley
( n )= 400 rpm
Dia. of driving pulley
(D) = 0.3 m
Centre distance
( c )= 2.5 m
Selection of cross section of belt based on power transmitted.
For 50 kW V belt C (or) D can be selected.
[Refer from PSG P.No 7.58]
Here C section is selected for the power range is 7.5 75 kW.
The recommended minimum pitch diameter of pulley is d n
V+ TEAM
Step 2:
Speed ratio ( i ) =
i =
0.4 =
d
400
1000
= 0.4
0.3
0.3
0.4
= 0.75 = 750 mm
Step 3:
Select the center distance ( c )
= 2.5 x 1000
= 2500 mm
Step 4:
Nominal pitch length of the belt
Refer PSG Design data book [ P.No 7.61]
( )2
L = 2c + ( D + d ) +
( 0.30.75 )2
42.5
= 2x2.5 + ( 0.75 + 0.3 ) +

= 6.67 m
Nearest nominal pitch length
[Refer PSG., P.No 7.60]
L = 6.863 m
Nominal pitch length = 6.863 m
Nearest nominal inside length 6807 mm is selected.
Designation of selected V belt is C6807
Step 5:
Design power =
Rated power x service factor

Arc of contact factor x Correction factor
Refer PSG Design data book [ P.No 7.69]

Service factor Fa = 1.2 ( medium duty )
V+ TEAM
= 180O 60O (
Arc of contact factor Fd
0.750.3
2.5
= 169.2o
Arc of contact factor Fd
= 0.97
Correction factor Fc = 1.14

Design Power =
50 x 1.2
0.97 x 1.14
[Refer PSG P.No., 7.60 ]
= 54.26 kW
Step 6:
Load rating of the belt
Refer PSG Design Data book [ P.No 7.62 ] at section c
kW
= ( 1.475-0.49 -
de
= dp x Fb
42.7
2.34 x 10-4 s2 ) s
= 0.2 x 1.13
Speed ratio =
0.75
0.3
= 2.5
Fb
= 1.13
de
= 0.200 x 1.13
de
= 0.226 m
Speed S
=
=
60
x 0.3 x 1000
60
= 15.71 m/s
kW
= ( 1.1473 0.63142 0.0578 ) 15.71

= 7.196 kW
Step 7:
No. of belt
Design power
rating of the belt
V+ TEAM
54.26
7.196
= 7.54 ~ 8
Step 8:
No. of belt
=8
Recalculate the center distance from
[PSG P.No 7.61]
C = A + 2
A=
(+)
8
= 1.6675 0.41233
A = 1.255 m
B=
()2
8
B = 0.0253 m3
C = 2.499 m
Step 9:
Dimension of V groove pulley
Refer PSG Design data book [P.No. 7.70]
Maximum depth (h)
= 14.3 mm = 0.0143 m
Center distance groove (e) = 25.5 mm = 0.025m

Pitch width (lb)
= 19 mm = 0.019m
Edge of the pulley to first groove center (f)
= 17 mm = 0.017 m
Min. distance down to pitch line (b)
= 5.7 mm = 0.0057 m
Outer dia. Of smaller pulley
= d + 2b
= 0.3 + 2 ( 0.0057)
= 0.7614 m
Core dia. Of the pulley

= d 2h
V+ TEAM
= 0.3 2 ( 0.0143)
= 0.2714 m
Width of the pulley = ( No. of belt 1 ) x e + 2f
= 7 x 0.025 + (2 x 0.017)
= 0.209 m
Step 10:
Specification of V belt drive
Pitch dia. Of smaller pulley dp
= 0.200 m
Pitch dia. Of larger pulley Dp
= 0.750 m
No. of belt
=8
Selection of B belt used
= C6807
Arc of contact
= 169.2O
Center distance (c )
= 2.499 m
Specification of pulley
Outer dia. Of smaller pulley
= 0.3114 m
Outer dia. Of larger pulley = 0.7614 m

Core dia. Of the pulley
Width of the pulley
= 0.2714 m
= 0.209 m
DESIGN PROCEDURE OF ROPE DRIVE

STEP-1: Calculation of design load
Assume large factor of safety (say 15), If not given.
Calculate the DESIGN LOAD:
Design load =factor of safety x load to be lifted.
STEP-2: Selection of wire rope diameter
Take the design load as the breaking strength.
Obtain the rope diameter by referring data book.
(PSG. 9.4 to 9.6).
STEP-3: Calculation of drum diameter

V+ TEAM
By referring PSG.9.1, Take the ratio of drum diameter to the rope diameter.
Obtain the drum diameter D.
Drum diameter should be sufficiently larger to reduce the bending stress.
STEP-4: Selection of the area of useful cross-section of the rope (A)
Determine the area of useful cross section of the rope using the following table.
TYPE OF CONSTRUCTION
METALLIC AREA OF ROPE (A) IN mm2
6*7
0.38d2
6*19
0.40d2
6*37
0.40d2
STEP-5: Calculation of wire diameter (dw)
Determine the diameter of the wire, using the formula dw = d/1.5i
Where,
i=number of wires in the rope = no. of strands x no. of wires in each strand.
STEP-6: Selection of weight of rope (Wr)
Weight of the rope is obtained by referring data book
(PSG 9.4 to 9.6).
STEP-7: Calculation of various loads and effective loads:

Calculate the various loads using the relations given below:
Direct load, Wd=W+Wr.
1.
2.
Bending load, Wb=b*A
3.
Acceleration load, Wa=((W+Wr)*a/g)
4.
Starting load, Ws=2(W+Wr)
Effective load on the rope during normal working
1.
Effective load on normal working, Wne=Wd+Wb.
2.
Effective load on starting, Wse=Ws+Wb.
3.
Effective load on acceleration, Wae=Wa+Wd+Wb.
STEP-8: Calculation of working factor of safety and check for design
Calculate the working factor of safety,
(Fs)w= Braking load for the selected rope (PSG 9.4-9.6) / Effective load during acceleration.
This (Fs)w should not be less than the recommended factor of safety given in
PSG(9.1).
If the working factor of safety (Fs)w is not satisfactory, choose some other rope with greater
braking strength (or) no. Of ropes should be increased.
STEP-9: Calculation of number of ropes
No. Of ropes = Recommended factor of safety / Working factor of safety.
Select a suitable wire rope to lift 11kN of debris from a well 60m deep. The
weight is being lifted with a maximum speed of 150m/min and the maximaum
speed is obtained in 1min. Determine also stressed induced in wire rope due to
starting with an initial slack of 0.25m.Take Er =0.75*105N/mm2.The weight of
the bucket is 4kN.
V+ TEAM
Step1:
WL
= 11kN ( weight of load)
WB
= 4kN (weight of bucket)
Max. speed = 150m/min

Initial slack distance = 0.25m
W
= WL+WB
= 11+4 = 15kN
= 0.75*105 N/mm2
Er
Assume larger FOS = 15

Design load = FOS * load to be lifted
= 15*15
=225 kN
=225000N
Step2:
[Refer PSG, pg no:9.6]
Since the rope is for hoisting purpose,let us select 6 19

(i.e. for lifts and hoist)
No. of strands=6
No. of wires in strands=19
For u=1100-1250 N/mm2 as breaking strength
[1 ton= 10kN]
Breaking strength = 23tonne

= 230kN
Corresponding diameter of rope is, d= 25mm.
Step3:
Determine sleeve diameter(drum)
[Refer PSG, PG no:9.1]
For ratio of drum diameter to rope diameter

V+ TEAM
Corresponding to cranes and hoists,6 19

Take class 4,
So
Dmin
d
= 27
As the lifting speed is 150m/min,the ratio has to be modified. It is to be

increased by 8% for each additional 50m/min
Now modify,
Dmin
d
= 27 1.082 = 31.49 35
Diameter of drum, D =35*d

=35*25 = 875mm.
Step4:
Area of useful cross- section of the rope for 6 19 construction.
Area of the rope = 0.4d2
= 0.4 252
= 250 mm 2
Step 5:
Dia. Of wire dw
=
=
dw
Step 6:
d
1.5i
25
1.56x19
= 1.560 mm
Weight of wire (wR)

Weight of rope
[ Refer PSG P.No 9.6]
= 2.25 kgf/ m
= 22.5 N/m
Weight of full length rope
WR
= 22.5 x 60
= 1350 N
Step 7:
Calculation of other loads
V+ TEAM
1.
Direct load, wd
= w + wR
= 15 + 1.35
= 16.35 kN = 16350 N
2.
Bending load, wb = . A
b
= Er x
= 0.75 x 10 5 x
1.560
875
= 133.8 N/ mm2
wb
= 133.8 x 250
= 33450 N.
iii)
Acceleration load, Wa
15+1.35
=(
9.81
) x 2.50
= 4166.66 N
iv)
Starting load, Ws = 2 ( w + wr )
= 2 ( 15 + 1.35), kN
= 32,700 N
Effective load on the rope during normal working

Wne
Wne
wd + wb
16350 + 33450
49800 N
Effective load during acceleration, wae = wa + wd + wb

wae
53.9 kN
V+ TEAM
Step 8:
(Fs)w =
=
Breaking load
Effective load during acceleration
230 x 1000
= 4.267
53.9
From PSG Design data book [P.No. 9.1] we find the recommend F.O.S
for their application to be 6
Therefore the rope is not safe.
Step 9:
To achieve this F.O.S we may either choose rope & drum dia. With larger
dia. ( or ) increase no. of ropes
No. of ropes
n (recommended FOS)
(FOS)W
6
4.26
= 1.41 ~ 2
Effective load on rope during starting with slack

Wse
ws + wb
Ws
wd [ 1 +
16350 [ 1 +
ws
41.864.51 kN
wse
41865.51 + 33450
75315.51 N
1+2aS hxEr
b lg
1+2x2.5x0.25x1000x0.75x105
65.4x 60x1000x9.81
Step 10: Specification

Diameter of rope (d)
25 mm
Selected rope
6 x 19
Dia. Of Drum
875 mm
Dia. Of wire
( dw) =
1.56 mm
No. of ropes
8
V+ TEAM
DESIGN PROCEDURE OF CHAIN DRIVES

STEP-1: Selection of transmission ratio (i)
Select a preferred transmission ratio (i) from
PSG 7.74.
STEP-2: Selection of number of teeth (Z1)

Select the no. of teeth on the pinions sprocket.
NOTE:
Where the space is a problem, Z1min=7.
STEP-3: Determination of number of teeth (Z2)
Determine the no. Of teeth on the driven sprocket by using transmission ratio(i).
Z 2= i x Z 1 .
Z2 should not be greater than Z2max .Z2max=100 to 120.
STEP-4: Selection of standard pitch (p)
Determine the range of chain pitch using the formula,
Optimum centre distance, a = (30 to 50)p
From the pitch range obtained, consulting table, obtain max.
Speed of the rotation of the pinion W1max.
STEP-5: Selection of chain
Assume any chain from
STEP-6: Calculation of total load, PT.
Total load on the driving side of the chain,
PT = Pt + PC + PS.
Where,
Pt=tangential force due to power transmission.
Pt=1020N/v
N.
N-transmitted power
in kW.
v-chain velocity
in m/s.
2
Pc-centrifugal tension=mv .
m -mass of chain per
m
v -velocity of chain.
Ps-tension due to sagging.
Ps=k x W x a
N.
K - co-efficient of sagging
W- weight per m length if chain.
1.
centre distance.
PSG 7.74
PSG 7.74
PSG 7.71-7.73
PSG 7.71 to 7.73
PSG 7.78
STEP-7: Calculation of service factor, ks.

V+ TEAM
Ks=k1 x k2 x k3 x k3 x k4 x k5 x k6.
Where,
k1 - load factor.
k2 - factor for distant regulation.
k3 - factor for centre distance of sprocket.
k4 - factor for position of sprocket.
k5 - lubrication factor.
k6 - rating factor.
PSG 7.76 & 7.77.
STEP-8: Calculation of design load and checking

Calculate the design load,
Design load= total load on chain x service factor.
For the selected chain, the breaking load Q is obtained from
PSG7.71 to 7.73.
Actual factor of safety = Q / design load.
This actual F.O.S should not be lesser than the recommended f.O.S given in
PSG7.77.
If it is not satisfactory, one more chain may be added to the existing one or increase the
pitch.
STEP-9: Check for bearing stress
Check for bearing stress in the roller using formula,
= Pt x kS / A
Where, A-bearing area taken from
This is compared with permissible value given in
PSG 7.71 to 7.73.

PSG7.77.
STEP-10: Calculation of length of chain

Calculate the length of the chain in terms of no. Of links (correct to even number).
lp = 2ap+(Z1Z2/2)+((Z2-Z1)/2)2/ap.
Also calculate the final centre distance corrected to an even no. of links using the equation.
a = ((+(2-8m)) x p/4.
PSG 7.75.
2.
m = ((Z2-Z1)/2)
= lp-((Z1-Z2)/2)
STEP-11: Calculate diameter of sprocket
Dia. of small sprocket, d1=p / (sin (180/Z1))
Dia. of largest sprocket, d2=p / (sin (180/Z2)).
PSG 7.78
Sprocket outside diameter, do=d+0.8dr.

dr -diameter of roller.
PSG 7.71-7.73
V+ TEAM
Design a chain drive to run a compressor from 11Kw electric motor, running at
970rpm the compressor being 330rpm. The compressor operates 16hours/day.
The centre distance should be approximately 500mm. the chain tension may be
adjusted by shifting the motor slides
STEP 1: Given Data
Power
(p) =11Kw
Motor speed
=970rpm
Compressor speed
= 330 rpm
Center distance
(a) = 500mm
Transmission ratio
(i) =
motor speed
compressor speed
= 2.939
STEP 2: selection of number of teeth on the pinion (Refer the PSG pg.no: 7.74)
Recommented z1, for i= 2-3
No. of teeth on the sprocket z1, = 25
STEP 3: selection of number of teeth on the sprocket (Refer the PSG: 7.74)
Z2 = z1,
= 2.94 * 25 =75
STEP 4:
optimum center distance.(a)
(Refer the P.S.G pg.no: 7.74)

V+ TEAM
a = (30 to 50)p
If 30 is used
500
pmax =
30
pmin =
500
50
=16.66
=10
always select larger pitch value

standard pitch is 15.875 is choosed
(Refer the PSG pg.no: 7.74)
pitch p=15.875
STEP 5:
selection of chain
Assume the chain to be duplex.

The chosen chain number is 10A-2/DR50
STEP 6:
Total load on the driving side of the chain
(Refer the P.S.G 7.78)
PT = Pt +Pc +Ps
Pt =
v=
1020
(tangential force due to power transmission)
no of teeth on the sprocket pitch speed

60
v =6416.14mm/s
Pt =
102011
2515.875970
60
=6.42m/s
=1747.66 N
6.42
w.k.t
Pc =
(centrifugal tension )
for mass m to be found for selected during fine mass per unit length
(
1.7810
10
) m=1.78
V+ TEAM
Pc =1.78*6.4162 =73.273N
w.k.t
Ps =k.W.a
Assuming horizontal position k=6 ,W=1.78x10 =17.8N/m , a= 500mm

Ps = 6x17.8x.5 =53.4 N
PT =1748.75+73.273+53.4 = 1875.423N
STEP 7:
service factor (ks)
(Refer the PSG pg.no: 7.76 to 7.77)
ks= k1 x k2 x k3 x k4 x k5 x k6
k1 =1(load factor)
k2 ( factor for distance regulation) =1.25
assuming center distance
k3 ( factor for center distance of sprocket) =1
for (30 to 50)p
k4 ( factor for the position of sprocket) =1

k5 (lubrication factor ) =1.5
k6( rating factor) =1.25
ks=1 x 1.25 x 1 x 1 x 1.5 x1.25 =2.343
STEP 7:
Design load
(from the PSG pg.no: 7.72)
Design load = pt x ks = 1875.423 x 2.343 =4394.116N

Q = 4440 x 10 = 44400
Actual factor of safety =
44400
4394.116
Recommended FOS is obtained

=10.10
(from P.S.G pg.no: 7.77)
V+ TEAM
The recommended FOS for the speed of rotation of small sprocket for
330rpm is 8.55
The actual FOS > recommended FOS
So the design is safe
STEP 9: check for the bearing stress
the bearing stress is found by using the formulae
=pT x ks/A
A = bearing area
(from the PSG pg.no: 7.71 to 7.73)
A = 1.40 cm2 = 1.40x 10-4 mm2

=
4394.116
1.40104
= 31.39 N/mm2
The permissible allowable stress calculated (from the P.S.G pg.no: 7.77)
Permissible allowable stress=2.87 x10 =28.7 N/mm2
STEP 10:
calculate the length of chain
length of chain in terms of link connected to even numbers

lp =2ap +
1 +
2
2
( 1 2)
2
=a0/p = 31.50
lp=115mm
a=
+( 2 8)
e =ip -
4
1 +
2
= 65mm
a = 31.49 x 15.875 =499.98mm

STEP 10:
calculate the pitch circle diameter:
Dia of the small sprocket (d1) =
sin(
180
)
1
=126.66mm
V+ TEAM
(d2) =
180
)
2
sin(
=379.10mm
(d0) = d +.8 dr
(dr) =10.16mm
(d0) = d1 +.8 dr =126.66+8.128= 134.79mm

(d0) = d2 +.8 dr = 387.23mm
STEP 10 : SPECIFICATION:
Power
(p) =11Kw
Motor speed
=970rpm
Compressor speed
= 330 rpm
Center distance
(a) = 500mm
Transmission ratio (i) =
motor speed
compressor speed
= 2.939
z1, = 25
z2, = 75
pitch
p=15.875
The choosen chain number is 10A-2/DR50

PT = 1875.423N
Ks=2.343
Design load = 4394.116N
V+ TEAM
UNIT 2
DESIGN PROCEDURE OF SPUR GEAR
STEP 1:
Calculation of Gear Ratio

Use i=N1/N2=Z1/Z2
STEP 2: Selection of Material

If the material is not given select a suitable material from
PSG.8.5
STEP 3: Calculation of Gear Life

If the gear life is not given assume the gear life as 20,000 hrs.
STEP 4: Calculation of Initial Design Torque
[Mt] = Mt K Kd
Kd K = 1.3 (initially assume the symmetric scheme from PSG 8.15
Ko = 1.5 (assuming medium shock or medium load from table)
STEP 5: Calculation Of Design Bending Stress [b] and Design Contact Stress [c]
To find [b]: Refer the formula
PSG.8.18
To find [c]: Refer the formula
PSG .8.16
STEP 6: Calculation of Centre Distance (a) Refer the formula
PSG.8.13
STEP 7: Selection of Number of Teeth (Z1 & Z2)

If not given assume Z1 = 20
Z2 = i Z1
STEP 8: Calculation of Module (m) Refer the formula
PSG.8.22
STEP 9: Recalculation of Centre Distance(a) Refer the formula
PSG8.22
STEP 10: Calculation of b, d1, v and p

b=a
d=mZ
for refer PSG 8.14 table 10
V+ TEAM
v = D N / 60
p = b / d
STEP 11: Selection of Suitable Quality of Gear
Refer
PSG.8.16 table no 15
STEP 12: Recalculation of Design Torque [Mt]

[Mt] = Mt K Kd Ko
K = Refer the value from
Kd = Refer the value from
Ko = Refer the value from the table
STEP 13: Check for Bending Stress

STEP 14: Check for Contact Stress
Refer
PSG. 8.13A
Refer PSG.8.13 table no 8 for spur gears
STEP 15: Calculation of Basic Dimensions of the Gear Pair Refer the formulas PSG.8.22.
DESIGN PROCEDURE OF HELICAL GEAR
STEP 1:
Calculation of Gear Ratio

Use i=N1/N2=Z1/Z2
STEP 2: Selection of Material

If the material is not given select a suitable material from
PSG.8.5
STEP 3: Calculation of Gear Life

If the gear life is not given assume the gear life as 20,000 hrs.
STEP 4: Calculation of Initial Design Torque
[Mt] = Mt K Kd
Kd K = 1.3 (initially assume the symmetric scheme from PSG 8.15
Ko = 1.5 (assuming medium shock or medium load from table)
STEP 5: Calculation Of Design Bending Stress [b] and Design Contact Stress [c]
To find [b]: Refer the formula
PSG.8.18
To find [c]: Refer the formula
PSG .8.16
STEP 6: Calculation of Centre Distance (a) Refer the formula
PSG.8.13 for helical gears
STEP 7: Selection of Number of Teeth (Z1 & Z2)

If not given assume Z1 = 20
Z2 = i Z1
STEP 8: Calculation of Module (m) Refer the formula
PSG.8.22 for helical gears
STEP 9: Recalculation of Centre Distance(a) Refer the formula PSG8.22 for helical gears
STEP 10: Calculation of b, d1, v and p
V+ TEAM
b=a
d=mZ
v = D N / 60
p = b / d
for refer PSG 8.14 table 10
STEP 11: Selection of Suitable Quality of Gear
Refer
STEP 12: Recalculation of Design Torque [Mt]

[Mt] = Mt K Kd Ko
K = Refer the value from
Kd = Refer the value from
Ko = Refer the value from the table
STEP 13: Check for Bending Stress
STEP 14: Check for Contact Stress
Refer PSG. 8.13A for helical gears

Refer PSG.8.13 table no 8 for helical gears
STEP 15: Calculation of Basic Dimensions of the Gear Pair Refer the formulas PSG.8.22.
UNIT 3
DESIGN PROCEDURE FOR BEVEL GEARS
STEP: 1: Selection of Materials
PSG 1.40
STEP: 2: Calculation of no of teeth on bevel gears

Z1 and Z2 .. initially assume Z1 17
Step: 3 : Calculation of pitch angle [ (ie) 1 and 2 ] and the virtual number of teeth (ie) Zp1
and Zp2 using the following relations ,
Pitch angle =>
tan 2 = i
and 1 = 90- 2
For the right angled bevel gears,
Zv1 =
Z1
and
Zv2 = Z 2
Cos 1
Cos 2
Step: 4: Calculate the tangential load using the relation
Ft = P x Ko
v
Step: 5: Calculate the preliminary value of dynamic load using the relation
Fd = F t
Cv
where Cv =
5.6
5.6 + V
where V = 5 m/s
Step : 6: Calculate the beam strength Fs in terms of transverse module using the following
relation
Fs = x mt x b x [b ] x x [ R b ]
R
V+ TEAM
Step : 7: Calculate the transverse module mt by equating the Fs and Fd

Step : 8: Calculate the values of b , d and v
Using the following relations
Face width b = 10 x mt
Pitch circle diameter d = Z x mt
Pitch line velocity V = d N
60
Step : 9: Recalculate the beam strength
R
Step : 10: Calculate the dynamic load , using Buckinghams equation ,
Fd = Ft + 21 V ( bc + Ft )
21 V +( bc +Ft)
Step :11: Check for the beam strength or tooth breakage , if Fd Fs , the gear tooth has
adequate beam strength.
Step: 12: Calculate the maximum wear load , using the following relation
Fw = 0.75 x d1 x b x Q x Kw
Cos 1
Step : 13: Check for wear strength if Fd < Fw , the gear tooth has adequate wear capacity ,
and will not wear out, thus the design is safe and satisfier.
Step :14: Calculate the basic dimensions for the gear and pinion.
Problem:
A pair of 20 full depth involute teeth bevel gear connects two shafts at right angles
having a velocity ratio of 3.2: 1. The gear is made of cast steel with an allowable static stress
as72 N/mm, and the pinion is made of steel having a static of 100 N/mm. The pinion
transmits 40kW and at 840 rpm. Find the module, face width, and pitch diameter from the
stand point of the beam strength, and check the design from the stand point of wear.
Given data:
= 90 , = 20 , i = 3.2 , [b2 ] = 72 N/mm, [b1] = 100 N/mm, P = 40 kW ,
N1= 840 rpm
To find:
Module, face width, and pitch diameter of the gears.
Solution:
Step: 1: Selection of materials
Material for gear : Cast Iron
Material for pinion: Steel
Step: 2: Assume Z1 = 20 , then Z2 = i x Z1
Z2 = 3.2 x 20 = 64
Z2 = 64
V+ TEAM
Step : 3: Calculation of pitch angle [ (ie) 1 and 2 ] and the virtual number of teeth (ie) Zp 1
and Zp2 using the following relations ,
tan 2 = i = 3.2 or 2= tan -1 (3.2) = 72.64
then 1 = 90 - 2
1= 90 - 72.64 = 17.36
The virtual number of the teeth on the gears is given by
Zv1 =
Z1 =
20
Cos 1
cos 17.36
Zv1 = 21
Zv2 =
Z2 =
64
Cos 2
cos 72.64
Zv2 = 215
Then form factors based on virtual number of teeth are given by
1 = 0.154 0.912
Zv1
1 = 0.1106
2 = 0.154 0.912
Zv2
2 = 0.1497
For pinion: [b1] x 1 = 100 x .0116 = 11.06 N/mm
For gear: [b2] x 2 = 72 x 1497 = 10.78 N/mm
Hence the value of gear is less than pinion. Thus we have to design for gear only.
Step : 4: Calculating the tangential load using the relation We know that ,
Ft =
P x Ko
v
where v = d1 N1 = x N1 x ( mt x Z1)
60
60
1000
= x 840 x ( mt x 20)
= .879 mt
60
1000
Ko = 1.25 , assuming medium shock
Ft =
40 x 10
0.879 mt
x 1.25 =
56841
mt
Step :5:
Fd =
Ft
Cv
where Cv =
5.6
5.6 + V
where V = 5 m/s
Cv = 0.715
Fd = 56841 x
1
mt
0.715
Fd = 79497.9
mt
V+ TEAM
Step: 6: Calculating the preliminary value of dynamic load using the relation
R
b = 10 mt
; 2 = 0.1497
[b2] = 72 N/mm
; R= 0.5 mt x ( Z1 + Z2 ) = 33.53 mt
Fs = x mt x 10 mt x 72x 0.1497x [33.53 mt - 10 mt]
33.53 mt
Fs = 237.62 mt
Step :7:
Calculation of transverse module mt
We know that
Fs Fd
Where
237.62 mt 79497.9
mt
mt 6.94 mm
Step : 8:
Calculate the values of b , d1 and v
Face width
b = 10 mt = 10 x 7 = 70 mm
Pitch circle diameter d1 = mt x Z1 = 7 x 20 = 140 mm
Pitch line velocity
V2 = V1 = d N = 6.61m/s
60
Step : 9:
Recalculation of the beam strength
Fs = 237.62 x mt = 11643.38 N
Step: 10:
Calculation of the dynamic load , using Buckinghams equation ,
Fd = Ft +
21 V ( bc + Ft )
21 V +( bc +Ft)
Ft =
P = 40 x 10 = 6493.55 N
v
6.16
c = 11860 x 0.017 = 201.62 N/mm
Fd = 6493.5 + 21 x 6.16 x 10 x ( 70 x 201.62 + 6493.5)
21 x 6.16 x 10 +( 70 x 201.62 + 6493.5)
Fd = 27077.55 N
Step :11:
Check for the beam strength or tooth breakage, but Fd >> Fs
Taking module as 14
Face width
b = 10 mt = 10 x 14 = 140 mm
Pitch circle diameter d1 = mt x Z1 = 14 x 20 = 280 mm
Pitch line velocity
V2 = V1 = d N = 12.315m/s
V+ TEAM
60
Fs = 237.62 x mt = 237.62 x 14 = 46573.52 N
Ft =
P = 40 x 10 = 3248 N
v
12.315
c = 11860 x .025 = 296.62 N/mm
Fd =
3248 + 21 x 12.315 x 10 x ( 140 x 296.5 + 3248)

21 x 12.315 x 10 +(140 x 296.5 + 3248)
Fd = 47969.4 N
We find Fs > Fd , now the design is safe and satisfactory against the tooth failure.
Step: 12:
Calculation of wear load (Fw)
Fs = 0.75 x d1 x b x Q x Kw
Cos 1
Q = Ratio Factor = 2 x Zv2 =
2 x 215 = 1.822, and
Zv1 Zv2
21 + 215
Kw = 0.919 N/mm , for steel gears hardened to 250 BHN ,
Fs = 0.75 x 280 x 140 x 1,822 x 0.919
= 51578.25 N
Cos 17.36
Step : 13:
Checking for wear , we found that Fw > Fd , it means the gear tooth has adequate
wear capacity and will not wear out. Thus the design is safe against wear failure also.
Step : 14
Module
mt = 14 mm
Face width
b = 10 x mt = 140 mm
Pitch diameter d1 = mt x Z1 = 14 x 20 = 280 mm
d 2 = mt x Z2 = 14 x 64 = 896 mm
Problem on bevel gear:

Design a cast iron bevel gear drive for a pillar drilling machine to transmit 1875 W, at 800
Rpm, to a spindle at 400 rpm. The gear is to work for 40 hours per week for 3 years.
Pressure angle is 20.
Given Data:
P= 1875 W, N1= 800 rpm, N2= 400 rpm, = 20
To find:
Design a bevel gear dive
Solution:
Since the materials of pinion and gear are same we have to design only the pinion
1.
Gear ratio:
V+ TEAM
i = N1 / N2 = 800 / 400 = 2
pitch angle : for right angle bevel gear, tan 2 = I = 2
or 2= tan (2) = 63.43
and 1 = 90 2 = 26.57
2.
Material for pinion and gear:
Cast iron grade 35 heat treated
u = 350 N/ mm, from PSG 1.40
3.
Gear life in hours = ( 40 hrs/ week) x (52 weeks / year x 3 years) = 6240 hours
Gear life in cycles, N = 6240 x 800 x 60 = 29.952 x 10 cycles
4.
Calculation of initial design torque:
We know that , [ Mt] = Mt x K x Kd
= (
Where
60
2
=
= (
60 1875
2 800
) = 22.38 N-m and
K.Kd = 1.3 ( as per assumption)

[Mt] = 22.38 x 1.3 = 29.095 N-m
5.
Calculation of Eeq , [b], [c]:

To find Eeq: Eeq = 1.4 x 10 N/ mm for cast iron, u > 280 N/ mm PSG 8.14
To find [b] =
107
1.4
.
x 1 , for rotation in one direction
PSG 8.20
= 0.8852, for CI
K = 1.2 ;
n = 2,
-1 = 0.45 u
PSG 8.19
PSG 8.19
PSG 8.19
u = 350 N / mm
PSG 1.40
-1 = 0.45 x 350 = 157.5 N/ mm
V+ TEAM
Then [b] = ( 1.4 x 0.8852 x 157.2 / (2x 1.2) ) = 81.33 N/ mm

To find [c] :
[c] = Cb x HB x Kcl
Cb = 2.3
PSG 8.16
Hb = 200 to 260
PSG 8.16
107
107
Kcl = =
29.952 107
[
= 0.833, for C I
c] = 2.3 x 260 x 0.833 = 498.08 N/ mm
6.
Calculation of cone distance (R):
We know that ( ( 2 + 1 )) { [
0.72
]
0.5[]
[]
=3
R 50.2
R= 51 mm
7.
Assume Z1= 20, Then Z2 = I x Z1= 2 x 20 = 40
Virtual number of teeth Zv = Z / cos = 20 / (cos 26.57) = 23

And Zv = Z / cos = 40 / ( cos 63.43) = 90
8.
=
Calculating the transverse module (mt):
(0.5 12 + 22 )
= 2.28 mm take as 2.5
PSG 8.2
9.
Revision of cone distance R:
we know that ,
= (0.5 12 + 22 ) = 0.5 2.5 ( 202 + 402 )= 55.9 mm
10.
Calculation of b, Mav,
d1av, v, and y:
V+ TEAM
Face width (b) ; b = R / y = 55.9 / 3 = 18.63 mm

Average module (mav) : mt ( b sin / Z1) = 2.0863 mm
Average pcd of pinion ( d1 av) = d1av = mav x Z1 = 2.083 x 20 = 41.66 m
Pitch line velocity v :
x d1av x N1
60
= 1.745 m /s
y = b / d1av = 18.63 / 41.66 = 0.477
11.
IS quality bevel gear is assumed From PSG 8.3
12.
Revision of design torque [Mt]
We know thet [Mt] = Mt x K x Kd

K= 1.1 for b / d1av 1 , PSG 8.15
Kd = 1.35 P SG 8.16
[Mt] = 22.38 x 1.1 x 1.35 = 33.24 N- m
13.
Check for bending stress
We know that the induced bending stress

={
( 2 + 1 )[]
)
( ( 0.5)2 1 )
Where Yv= 0.408 for Zv = 23 .,,
PSG 8.18
b = 100.75 N/ mm
Which is not satisfactory
Recalculate with various b, dav ,v, y, mav ,,
14.
Check for wear strength :We know that the induced contact stress,
1
2
( 2 + 1)3
0.72
= (
) ((
) []]
( )
0.5
V+ TEAM
= 439.33 N / mm
We find that c < [c], thus the design is safety
15.
Calculation of basic dimensions of pinion and gear :
Transverse module : mt = 3 mm
Number of teeth : Z1 = 20, Z2 = 40
Pitch circle diameter : d1= mt x Z1 = 3 x20 = 60 mm and
D2 = Mt x Z2 = 3 x 40 = 120 mm
Cone distance R = 67.08 mm
Face width b = 22.36 mm
Pitch angle = = 26.57, and = 63.43
Height factor : fo = 1
Clearance : c = 0.2
Virtual number of teeth : Zv= 23, and Zv= 90
DESIGN PROCEDURE OF WORM GEARS

STEP-1: Selection of Material
PSG. 8.5
STEP-2: Calculation of Initial Design Torque

[Mt]=Mt x K x Kd.
Initially, Assume K x Kd = 1.
Mt=60 x p / 2N.
STEP-3: Selection of Z1&Z2.
Select Z1 FOR VARIOUS EFFICIENCIES
Z 2 = i x Z 1.
STEP-4: Selection of [b] & [c]
PSG. 8.46
PSG.8.45
V+ TEAM
STEP-5: Calculation of Centre Distance
PSG.8.44
a = [(z/q)|+1] x [540/(Z/q) x [c]]2 x [Mt] / 10

STEP-6: Calculation of Axial Module
m= 2a / (q+z)
PSG.8.43
STEP-7: Calculation of Revised Centre Distance

a=0.5m (q+Z2)
PSG.8.43
STEP-8: Calculation of d, v, , Vs.

d=qx m
v = dn / 60
= tan-1 {Z/q}
Vs = v/cos
STEP-9: Recalculation of Design Contact Stress Using Vs.
PSG.8.45
STEP-10: Revise K, d, Mt Values.

STEP-11: CHECK FOR BENDING STRESS
PSG.8.44
[b] = 1.9[Mt] / m x q x z x y
STEP-12: Check for Wear c
PSG.8.44
STEP-13: Check for Efficiency

=0.95 x tan /tan (+)
=TAN-1()
STEP-14: Calculation of Cooling Area Required
(1-) x INPUT POWER = Kt x A (to-ta)
STEP-15: Calculation of Basic Dimensions
PSG.8.43
PROBLEM ON WORM GEARS

A steel worm running at 240 rp , receives 1.5 kw from its shaft. The speed reduction is 10:1,
design the drive so as to have an efficiency of 80 %, also determine the cooling area
required, if the temperature rise is restricted to 45 C, and take overall heat transfer co
efficient as 10 W / m C.
Given data:
N1= 240 rpm, P= 1.5 kW, I= 10, desired = 80%, to ta = 45C, Kt = 10 W/ m C.
To find:
1.
Design the worm gear drive
2.
The cooling area required
V+ TEAM
Solution:
STEP-1: Selection of Material
Worm Steel
Wheel Bronze ( sand cast), selected from Table
PSG. 8.5
STEP-2: Calculation of Initial Design Torque

[Mt]=Mt x K x Kd.
Initially, Assume K x Kd = 1.
Mt=60 x p / 2N.
Mt= ( 60 x 1.5 x 10 / 2N2) = 596.83 N-m
K.Kd = 1
[Mt]= 596.83 N-m
STEP-3: Selection of Z1&Z2.
Select Z1,
desired = 80%,, Z1 = 3
Z2 = i x Z1.= 10 x 3 = 30
PSG. 8.46
STEP-4: Selection of [b] & [c]

PSG.8.45
For bronze wheel u < 390 N / mm, [b]= 50 N/ mm is selected in one rotation in one
direction
[c]= 159 N / mm is selected
STEP-5: Calculation of Centre Distance
PSG.8.44
a = [(z/q)|+1] x [540/(Z/q) x [c]]2 x [Mt] / 10

a = [(30/11)|+1] x [540/(30/11) x [c]]2 x [596.83x 10] / 10
a = 168.6 mm
STEP-6: Calculation of Axial Module
m= 2a / (q+z)
m= 2168.6/ (11+30) = 8.22 mm
PSG.8.43
STEP-7: Calculation of Revised Centre Distance

a=0.5m (q+Z2)
PSG.8.43
a=0.5x 10 (11+30) = 205 mm

STEP-8: Calculation of d, v, , Vs.
d=qx m
d 1= q x m= 11 x 10 = 110 mm
V+ TEAM
d 2= Z2 x m= 30 x 10 = 300 mm
v = dn / 60= 1.382 m / s
v= dn /60= 0.377 m / s
= tan-1 {Z/q} = 15.25
Vs = v/cos = 1.432 m/s
STEP-9: Recalculation of Design Contact Stress Using Vs.
For vs = 1.432 m /s , [c] = 172 N/ mm
PSG.8.45
STEP-10: Revise K, d, Mt Values.
[Mt]=Mt x K x Kd.
= 596.83 x 1 x1 = 596.83 N-m
STEP-11: CHECK FOR BENDING STRESS
PSG.8.44
[b] = 1.9[Mt] / m x q x z x y
[b] = 1.9 x 596.863 x 10 / 10 x 11 x 30 x 0.432
= 7.6 N / mm
STEP-12: Check for Wear c
c = 540 / (Z2/q) (( Z2/ q) +1) / a ) x ( Mt / 10)
= 118.59 N / mm
STEP-13: Check for Efficiency
=0.95 x tan /tan (+)
=TAN-1() = 2.862
=0.95 x tan /tan (+) = 80%
STEP-14: Calculation of Cooling Area Required
(1-) x INPUT POWER = Kt x A (to-ta)
`
(1 0.8) x 1.5 x 10 = 10 x A x 45
= 0.666 m
STEP-15: Calculation of Basic Dimensions

PSG.8.43
Axial module = Mx = 10 mm
Number of starts = Z1 = 3
Number of teeth = Z2 = 30
Length of worm 152 mm ( L (12.5 + 0.09 x Z2 ) mx = 152 mm
Center distance = a = 205 mm
Height factor = 1
V+ TEAM
UNIT - 4
DESIGN OF GEAR BOX
Procedure for typical gear box design.
V+ TEAM
Step 1:
Calculate the progression ratio ()
Progression ratio = = Z-1(where Z= number of speed)
Step 2:
Write the structural formulae
Z1 = p1 (x2) x p2(x2) xp3(x3) x p4(x4)
X1 = 1, X2=p1, X3= p1p2, X4= p1p2 p3
1.
2.
3.
4.
5.
Preferred Structural Formulas

6 speeds: 2 x 3 or 3 x 2
8 speeds: 2 x 4 or 4 x 2 or 2 x 2 x 2
9 speeds: 3 x 3
12 speeds: 3 x 2 x 2 or 2 x 2 x 3 or 2 x 3 x 2
16 speeds: 4 x 2 x 2 or 2 x 4 x 2 or 2 x 2 x 4
Step 3:
Draw the ray diagram or speed diagram
Step 4:
Draw the kinematic diagram.
Step 5:
Calculate the number of teeth.
REQUIREMENT TO OBTAIN THE OPTIMIUM DESIGN:
To reduce the large diameter of gear wheels and also limit the pitch line velocity of
the gear drives the following principle to be followed.
1.
No. of gear on the last stage should be minimum.
2.
No .of gear on the shaft should not be more than 3.(but some cases it may be 4)
3.
It is necessary to have Nmax Ninput Nmin ( in all strages except in the 1st stage)
4.
The transmission ratio between the drive and driven shaft should be maximum
2 and .25( in all strages except in the 1st stage)
V+ TEAM
Problem: Design a 12 speed gear box speed range 100 rpm to 255 rpm
To calculate
1.
2.
3.
4.
Draw ray diagram

Draw kinematic diagram
No. of teeth on each gear
Also calculate the percentage deviation of the obtainable speeds from the calculated
ones.
Solution:
Step 1: Progression ratio
Progression ratio = =z-1
Z=number of speed=12
355
100
=12-1 = 11
11 =3.55
= 1.127
(PSG ddb pg no 7.20)
The progression ratio =1.122 coincide with R 20 series therefore select R 20 series speeds
N1 = 100 rpm N2 = 112 rpm N3 = 125 rpm N4 = 140 rpm
Step 2: Structural formulae

Z1 = p1 (x2) p2(x2) p3(x3) p4(x4)
X1 = 1, X2= p1, X3= p1p2, X4= p1p2 p3
No of speed =12 speed
Preferred structural formulae is =3 x 2 x 2 or 2 x 3 x 2 or 2 x 2 x 3
Let us select 3 x 2 x 2
Where p1 =3, p1 =2, p3 =2, X1 = 1, X2 = 3, X3 = 6
Z= 3(1) .2(3). 2(6)
V+ TEAM
Step 3: Ray diagram

3(1)
2(3)
2(6)
Procedure for the construction of ray diagram

3rd stage: 2 speed, 6 spaces
Locate point (A) minimum speed as at 100rpm leave 6 interval and mark point (B)
maximum speed as at 200rpm.
Locate point(C) input speed as at 160rpm and check the conditions
( 2 )
( .25 )
200
=1.25 2
160
100
160
= .625 .25
V+ TEAM
Selected input speed is satisfactory

2rd stage: 2 speed , 3 spaces
Locate point (C) minimum speed as at 160rpm leave 3 interval and mark point (D)
maximum speed as at 224rpm.
Locate point (E) input speed as at 200rpm and check the conditions
( 2 )
( 0 .25 )
224
=1.24 2
180
160
180
= .88 .25
Selected input speed is satisfactory

1st stage: There are 3 speeds with 1 space interval.
Therefore mark (F) and (G)
Assume input speed as the engine speed and mark point (H).
(For first stage it is not necessary to satisfy the condition)
Step 4: Structural Diagram
V+ TEAM
12 possible speeds are:

1.
Z9 Z10 Z5 Z6 Z1Z2
2.
Z9 Z10 Z5 Z6 Z3Z4
3.
Z9 Z10 Z7 Z8 Z1Z2
4.
Z9 Z10 Z7 Z8 Z3Z4
5.
Z11Z12 Z5Z6
Z1Z2
6.
Z11Z12 Z5 Z6
Z3Z4
7.
Z11 Z12 Z7Z8
Z1Z2
8.
Z11 Z12 Z7Z8
Z3Z4
V+ TEAM
9.
Z13 Z14 Z5Z6
Z1Z2
10.
Z13 Z14 Z5Z6
Z3Z4
11.
Z13 Z14 Z7Z8
Z1Z2
12.
Z13 Z14 Z7Z8
Z3Z4
Step 5: Calculation of no. of teeth on each gear.

Third stage:
1st pair :( reducing gear)

100
1
2
=2
1
20
= , Z1 = 32 teeth
160 Z1
2nd pair :( increasing speed gear)

3
4
=4
3
Z3 +Z4 = Z1 +Z2
Z3 +Z4 = 32
200
160
Z4
=52Z4 = 1.25(52 Z4 ) = Z4
Z4 =29, Z3 =23
Second stage:
1st pair :( reducing gear)

160
180
5
6
=6
5
20
=Z5, Z5 = 23 teeth
2nd pair :( increasing speed gear)

7
8
8
7
Z6 +Z5 = Z7 +Z8
Z7 +Z8 = 43
224
180
Z8
=43Z8 = 1.244(43 Z8 ) = Z8
Z8 =24, Z7 =19
V+ TEAM
First stage:
In this stage there are 3 speeds and 3 pairs of gears are required. To avoid interference of gear
of one shaft with the gear of the other shaft while shifting following condition has to be
satisfied to avoid interference.
Z12 Z10 4
Z12 Z14 4
1st pair:(reducing speed)
9
=

180
355
10
10
9
20
= , Z9 = 40 teeth , 10 =20 teeth

Z9
2nd pair:(intermediate speed)

11
12
12
11
Z9 +Z10 = Z11 +Z12

Z11 +Z12 = 60
200
355
Z12
60Z12
= 0.563(60 Z12) = Z12

Z11 =38, Z12 =22
3rd pair:(high speed)

13
14
14
13
Z9 +Z10 = Z14 +Z13

Z14 +Z13 = 60
224
355
Z14
=60Z14 = 0.613(60 Z14 ) = Z14
Z14 =23, Z13 =27
V+ TEAM
RESULT:
1st stage:
Z14 =23 teeth
Z13 =27 teeth
Z11 =38 teeth
Z12 =22 teeth
Z9 = 40 teeth
10 =20 teeth
2nd stage:
Z8 =24 teeth
Z7 =19 teeth
Z5 = 23 teeth
Z6 = 20 teeth
3rd stage :
Z4 =29 teeth
Z3 =23 teeth
Z1 = 32 teeth
Z2 = 20 teeth
Step 6: Calculate the percentage of deviation

Obtainable speed calculation.
Os1 = IS x
Os2 = IS x
Os3 = IS x
Os4 = IS x
Os5 = IS x
Os6 = IS x
Os7 = IS x
Os8 = IS x
Os9 = IS x
10
9
10
9
10
9
10
9
12
11
12
11
12
11
12
11
x
x
x
x
x
x
x
x
6
5
6
Os10 = IS x
Os11 = IS x
Os12 = IS x
14
13
14
13
14
13
4
3
2
1
4
3
2
7
8
1
4
13 5
14 6
6
5
8
7
8
7
3
2
1
x
x
x
4
3
2
1
4
3
20
= 355 x
40
20
= 355 x
20
40
20
= 355 x
22
22
38
= 355 x
= 355 x
= 355 x
20
20
24
38
19
22
38
23
27
= 355 x
24
20
23
20
27
23
23
24
27
19
23
27
24
19
= 111.69
32
29
= 225.3
23
= 162.25
29
= 327.33
23
20
23
20
32
19
= 282.7
20
= 140.13
32
23
23
20
23
= 194.61
29
19
22
= 355 x
= 355
24
29
23
19
38
= 355 x
24
= 96.46
32
23
40
= 355 x
20
20
23
40
= 355 x
20
= 119.9
32
x
x
29
23
20
32
29
23
= 241.19
= 174.2
= 351.63
V+ TEAM
Sl.No
Calculated speed Obtainable

(nC) rpm
(nobt) rpm
speed Deviation
nobt - nC
% deviation
Deviation x 100 / nC
1.
100
96.46
-3.54
-3.54
2.
112
111.69
-0.31
-0.27
3.
125
119.90
-5.1
-4.08
4.
140
140.13
0.13
0.09
5.
160
162.25
2.25
1.40
6.
180
174.20
-5.8
-3.22
7.
200
194.61
-5.39
-2.69
8.
224
225.30
1.3
0.58
9.
250
241.19
-8.81
-3.52
10.
280
282.70
2.7
0.96
11.
315
327.33
12.33
3.91
12.
355
351.63
-3.37
-0.94
The permissible deviation = 10(-1)%

= 10(1.127-1)%
= 1.27
From the above table we find, the deviations are well within the permissible
limits.
V+ TEAM
Unit 5 : CAM, Clutch and Brakes
V+ TEAM
V+ TEAM
PROBLEM:
An automobile single plate clutch consists of two pair on contacting surface. The inner and
outer radii of the friction plate are 120mm and 250mm respectively. The co-efficient of
friction is 0.25 and the total axial force is 15KN. Calculate the power transmitting capacity of
the clutch plate at 500rpm, using
1.
Uniform wear theory
2.
Uniform pressure theory
GIVEN DATA:
N=2
R1=250mm= 0.25m
R1=120mm= 0.12m
= 0.25
W=15KN= 15X 103
TO FIND:
Power transmitting using
1.
Uniform wear theory
2.
SOLUTION:
Using uniform wear theory
Torque transmitted on clutch is given by
1+2
T=n X X W X 2
=2 X 0.25 X 15 X 103
T= 1387.5 N.m
Power transmitted P =
0.25+0.12
2
2
60
2 500 1387.5
=
60
P=72.65 kW
Using uniform pressure theory
2
T = n W 3 X r13 r23 / r12 r22

2
= 2 X 0.25 X 15 X 103 X 3 X (0.25)3 (0.12)3 / (0.25)2 (0.12)2

T = 1444.6 N.m
Power transmitted, P =
2
60
2 X 500 X 1444.6
=
60
P = 75.64 kW
RESULT:
Power transmitted,
1.
Uniform wear theory
2.
P=72.65kW
P =75.64kW
V+ TEAM
PROBLEM NO: 2:
A car engine has its rated output of 12kW. The maximum torque developed is 100N.m.The
clutch used is single plate type having two active surfaces. The axial pressure in not to
exceed 85KN/mm2. The external diameter of the friction plate is 1.25 times of the internal
diameter. Determine the dimensions of the friction plate and the axial force exerted by the
springs. Co-efficient of friction is 0.3
GIVEN DATE:
P = 12kW=12 X 103 W
T = 100 Nm.
N=2
Pmax= 85KN/mm2 =85 X 103 N/mm2
d1=1.25d2
= 0.3
TO FIND:
1.
Dimensions of the friction plate
2.
Axial force exerted on the springs
SOLUTION:
(i)Dimensions of the friction plate,
Torque developed, T=100 N.m
Design torque, [T] = T x Ks
Surface factor Ks= K1 + K2 + K3 + K4
K1 = 0.33 (for machines with low starting torque characteristics)
K2 = 1.25 (assume)
K3 = 0.32 (assume 100rpm)
K4 = 0.9 (assuming 48 engagement/ shift)
Ks= 0.33 + 1.25 + 0.32 + 0.9 = 2.8
Design torque, [T] = 100 X 2.8
[T] =280 N-m
Intensity of pressure is maximum at the inner radius (r2)
Pmax X r2 = C
C = 85 X 103 X r2 N/m
Axial force exerted by the springs
W = 2C (r1-r2)
V+ TEAM
= 2 X X 85 X 103 X r2 (1.25 r2 - r2)

W = 1.335 X 105 r22 N
Torque transmitted,[T] = n X X W X
1+2
2
280 = 2 X 0.3 X 1.335 X 105 X r22

R2 =0.1459 m or 145.9 mm
1.252+2
2
R1 =1.25r2
R1 = 0.1823 m or 182.3 mm
(ii)Axial force exerted on the springs:
W = 2C (r1-r2)
= 1.335 X 105 X (r22)
w = 2841.79 N
RESULT:
Dimension of the friction plate
r2 = 145.9mm
r1 = 182.3 mm
Axial force exerted on the springs
w = 2841.79 N
PROBLEMS ON MULTI PLATE CLUTCH:

A multi plate disc clutch is to be designed for a machine tool driven by an electric velocity
ration is 24:1. Motor of 12.455 kW running at 1400 rpm. Space restriction limit the outside
diameter to 100mm. Determine approximate values for disc diameter, total number of
discs, and clamping force.
GIVEN DATE:
D1 = 100mm
P= 12.455 kW
N= 1400 rpm
R1= 50mm
TO FIND:
1.
Disc diameter
2.
Total number
3.
Clamping force
SOLUTIONS:
Assume r2= 0.6 X r1
= 0.6 X 50
r2=30mm
[T]= n x x W x R
= n x x 2 x Pmax x r2 (r1-r2) x
1+2
2
V+ TEAM
[T] =n x x x Pmax x r2 x (r12-r22)

Assume,
Pmax = 1.45 MPa = 0.06
[T] =n x 0.06 x x 1.45 x 0.030 (0.052 -0.032)

[T]= 12660.5n N.
[T] = T x Ks
Surface factor Ks= K1 + K2 + K3 + K4
K1 = 0.5
K2 = 1.25
K3 = 0.38
K4 = 0.9
Ks= 0.5 + 1.25 + 0.38 + 0.9 = 3.03
60
T=
12.455 103 60
2 1400
T= 84.954 Nm.
T= 84954.63 Nmm.
[T] = T x Ks
[T] = 84954.63 x 3.03
[T] = 257.45 x 103 N-mm
Number of pairs of contact surfaces
257.45 x 103 = 12660.5 n
N= 20.33
N= 21
No. of plate n =21+1
N=22
[T] = n x x W x
257.45 X
103
1+2
2
= 21 X 0.06 X 12.455 X 103 X

D2 = 655.2 mm
0.05+2
2
Clamping force
W = 2C (r1-r2)
= 2 X Pmax X r2 X (r1-r2)
V+ TEAM
= 2 X 1.45 X 0.327 X (0.05-0.327)

W =5362.5 N
RESULT:
1.
D2 =655.2 mm
2.
N=21
3.
W=5362.5N
CONE CLUTCH:
A leather faced conical clutch has cone angle of 30. The pressure between the contact
surfaces is limited to 0.35N/mm2 and the breadth of the conical surface is not to exceed to
1/3 of the mean radius. Find the dimensions of the contact surfaces to transmit 22kW at
2000 rpm. Also calculate the force required to engage the clutch. Take coefficient of friction
is 0.15
GIVEN DATA:
= 30
Pn= 0.35N/mm2
B=r/3
= 0.15
P=22kW
N=2000rpm
TO FIND:
1.
Dimensions of contact surface (r1, r2)
2.
Forces required engaging clutch
SOLUTION:
P=
22 X 103 =
2
60
2 X 2000 X
60
T= 105.4 Nm.
Assuming service factor Ks =2.5
Design torque [T} = 105.4 X 2.5
T= 262.60N.m
T =2 x x x Pn x R2 x b
262.60 = 2 x x 0.15 x 0.35 x R2 x 3 x 103

R=1.336 m
B=3=
1.336
3
V+ TEAM
B = 0.445m
12
= sin
r1-r2 = b X sin = 0.445 x sin (15)

r1-r2 = 0.1151m
Mean radius, R =
1+2
2
r1+r2 = 2.672
r1-r2 = 0.1151
r1+r2 = 2.672
2 r1= 2.781
r1 =1.393m
r2 = 1.279m
Force required:
W = 2C (r1-r2)
= 2 X Pn X r2 X (r1-r2)
= 2 X 0.35 X 1.279 X (1.393-1.279)
W = 3206.44N
RESULT:
R1 = 1.393 mm
R2 = 1.279 mm
W = 3206.44N
Problem: 3
A leather faced conical friction clutch has a cone angle of 300 . The intensity of pressure
between the clutch surface is not exceed 6x104 N/2 and the breadth of the conical
surface is not to be greater than 1/3 of the mean radius if = 0.20 and the clutch transmit
37 KW at 2000 rpm. Find the dimension of contact surfaces
Given :
b
0
= 30
= 6x104 N/
r1
b = R/3
= 0.2
r2
P = 37 KW = 37x103 W
N = 2000 rpm
V+ TEAM
To find :
Dimensions of contact surfaces : ( 1 2 )
Solution :
2
Power transmitted (P) = 60
T = 176.66 Nm
Torque transmitted is also given by T = 2 2
176.66 = 2 x 0.2 x 6 x 104 x 2 ( 3 )

=25132.74 3
R = 0.19155 m (or) 191.55 mm
6.19155
Face width is given by b = 3 = 3 = 2.06 m
Result: Face width b = 2.06 m
Problem: 4. A cone clutch is to transmit 7.5 KW at 900 rpm. The cone has a face angle of
120 the width of the face is half of the mean radius and the normal pressure between the
contact faces is not to exceed 0.09 N/2 . Assuming uniform wear and the co-efficient of
friction between contact faces as 0.2. Find the main dimensions of the clutch and the axial
force required to engage the clutch.
Given data:
P = 7.5 KW
N = 900 rpm
= 120
b = R/2
= 0.09 /
= 0.2
Solution :
1.
To find main dimensions of the clutch
Given: b = R/2
we know that
=
1 2
= sin
(1 2 )
sin
and mean radius R =

1 2
sin
1 + 2
1 + 2
4
[ = 2 , given ]
sin 120 ( + )
1
2
1 2 =
4
= 0.052 1 + 0.052 2
1 = 1.1096 2
Power P =
------------ (i)
2
60
V+ TEAM
7.5 x 103 =
2900
60
T = 79.58 Nm
For uniform wear, the intensity of pressure is maximum at the inner radius
x 2 =
( + )
Torque transmitted T = w 1 2 2
but W = 2 C (1 2) = 2 x 2 (1 2 )
then T = [2 x 2 (1 2 ) ]
(1 + 2 )
2
= x Pmax 2 (12 22 )
79.58 = 0.2 x x 0.09 x 106 x 120 x 2 [ (1.10962 )2 22 ]
2 = 0.108 m or 108 mm
Then
1 = 1.1096 2 = 1.1096 ( 108 ) = 119.8 mm
R=
1 + 2
2
119.8+108
Face width, b =
= 113.9
113.9
2
= 56.95
ii) To find the axial force required:

W = 2C(1 2 )
= 2 x 2 (1 2 )
= 2 x 0.09 x 106 x 0.108(0.1198 0.108)
= 720.65 N
Result:
1.
Dimension of the clutch : Face width=56.95mm
2.
The axial force required to engage the clutch=720.65 N
Brakes
V+ TEAM

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WWW.VIDYARTHIPLUS.

STEP-3: Calculation of arc of contact

Refer PSG 7.54.

STEP-4: Selection of power rating

Refer PSG 7.54.

STEP-5: Calculation of power rating

STEP-7: Calculation of width

STEP-8: Calculation of pulley width

STEP-9: Calculation of length

Calculate the length of the belt from

Design a fabric belt to transmit 12kW at 450rpm from an engine to be a line

Speed of the driver pulley,

Speed of the driven pulley,

(Refer PSG, Pg no: 7.54)

Load (or) power rating 10 m/s /.

Power rating for 14.14 m/s

Power rating for 10m/s *

[Refer PSG, pg.no:7.53]

Here line shaft and intermediate load =1.3

Arc of contact factor, = 1.04

= 658.917 mm plies of belt

[Refer PSG, pg no: 7.52]

Width of the pulley = 112+13

Step: 9 Length of the belt,

[Refer PSG, pg no: 7.53]

For open belt drive,

= 2*2000 + (600 + 225) +

* Diameter of the smaller pulley,

*Width of the belt,

*Width of the pulley

*Length of the belt,

A Flat belt is required to transmit 30kW for 600rpm to a machine pulley

Speed of the driver pulley,

(Refer PSG Pg no: 7.54)

Load (or) power rating 10 mm/s per mm per ply.

= 0.0867 kW per mm per ply.

Service factor (Ks)

Design Power = 54.086 kW.

= 624.549 mm piles of belt

(Refer PSG Pg no: 7.52)

(Refer PSG Pg no: 7.52)

Width of the pulley = 125 + 25

(Refer PSG Pg no: 7.53)

For open belt drive,

= (2 3000) + (1200 + 400) +

Diameter of the larger pulley, D = 1200 mm.

Diameter of the smaller pulley, d = 400 mm.

Width of the belt, v

Length of the belt, L

No. of the piles

Width of the pulley

DESIGN PROCEDURE OF V-BELT

Step 2: Selection of pulley diameter

Step 3: Selection of centre distance C

Step 4: Determination of nominal pitch length L

Step 5: Calculation of design power

Arc of contact factor (PSG7.68) x correction factor length

Step 7: Determination of no. of belt

Step 9: Calculate the details of V-groove pulley

Step 10: Write the specifications of the drive.

= 2x2.5 + ( 0.75 + 0.3 ) +

[Refer PSG., P.No 7.60]

Rated power x service factor