Mechanical Design Data Book

1
Design Data Hand Book

Contents:1 Friction Clutches
Single plate clutches05 Multi plate clutches05 Cone clutches06 Centrifugal clutches06
2 Brakes
External Contracting Brakes08 Internal Expanding Brake09 Band Brakes10 Thermal Considerations11
3 Belt Drives
Geometrical Relationships12 Analysis of Belt Tensions13 Condition for Maximum Power13 Selection of Flat Belts from the Manufactures Catalogue13 Selection of V-Belts15
4 Chain Drives
Roller Chains20 Geometrical Relationships20 Power Rating of Roller Chains21 Sprocket Wheels24
5 Rolling Contact Bearings

Stribecks Equation25 Equivalent Bearing Load26
A MEADinfo Publication
Shinto Mathew
2 Load Life Relationship26 Selection of Bearing from the Manufactures Catalogue27 Selection of Taper Roller Bearings32 Design for Cyclic Load and Speed38 Bearing With a Probability of Survival Other Than 90 Percent38
6 Sliding Contact Bearings

Effect of Temperature on Viscosity39 Hydrostatic Step Bearing40 Energy Losses in Hydrostatic Bearing40 Reynolds Equation41 Raimondi and Boyd Method41 Temperature Rise43 Bearing Design Selection of Parameters44
7 Spur Gears
Standard System of Gear Tooth45 Force Analysis50 Beam Strength of Gear Tooth47 Effective Load on Gear Tooth48 Estimation of Module Based on Beam Strength50 Wear Strength of Gear Tooth50 Estimation of Module Based on Wear Strength51 Gear Design for Maximum Power Transmitting Capacity51
8 Helical Gears
Virtual Number of Tooth52 Tooth Proportions53 Beam Strength of Helical Gears54 Effective Load on Gear Tooth54 Wear Strength of Helical Gears55
9 Bevel Gears
Force Analysis57
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3 Beam Strength of Bevel Gears58 Wear Strength of Bevel Gears59 Effective Load on Gear Tooth60
10 Worm Gears
Proportions of Worm Gears62 Force Analysis64 Friction in Worm Gears64 Strength Rating of Worm Gears65 Wear rating of worm gears67
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FRICTION CLUTCHES
Notations:D = outer diameter of friction disk. d = inner diameter of friction disk. p = intensity of pressure. P = total operating force. M t f = torque transmitted by friction. z = number of pairs of contacting surfaces, for single plate clutch z=one. (z = number of plates 1). = coefficient of friction.
pa
= intensity of pressure at the inner edge. = semi cone angle. = radius of the drum.
= radius of the centre of gravity of the shoe in engaged position. m = mass of each shoe.
rd rg
Pcf = centrifugal force. Ps Spring force

2
= running speed. (Rad/sec) = speed at which engagement starts. (Rad/sec)
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Single Plate & Multi Plate Clutches

Uniform pressure theory
P
Mt
f
(D 2
d2)
Pz (D3 d 3 ) 3 (D 2 d 2 )
Uniform wear theory pad P (D d ) 2
Mt
Pz (D 4
d)
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Cone Clutches
Uniform pressure theory
P
Mt
f
(D 2
d 2)
Pz (D3 d 3 ) 3sin (D2 d 2 )
Uniform wear theory pad P (D d ) 2
Mt
Pz (D 4 sin
d)
Centrifugal Clutches
Ps
M
t
2 1 g
1000
mr g rd z (
f 2 2 2 1
1000
Note: - here z = number of shoes.
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Brakes
Notations:E = total energy absorbed by the brake. K.E = kinetic energy absorbed by the brake. P.E = potential energy absorbed by the brake. m = mass of the system. I = mass moment of inertia of the rotating body. k = radius of gyration. v1 , v2 = Initial and final velocities of the system
1
= Initial and final angular velocities of the body
M t = braking torque.
= angle through which the brake drum rotates during the braking period.
1 2 m(v12 v 2 ) 2 1 2 K .E I ( 12 2) 2 1 2 K .E mk 2 ( 12 2) 2 P.E mgh K .E
Mt
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External Contracting Brakes

Block brake with short shoe
Mt
Where
Mt
NR
= Braking Torque R = Radius of the Brake Drum = Coefficient of Friction N = Normal reaction
plw
Where p = Permissible pressure between the block and the brake drum l = length of the block w = width of the block
RX RY
N (N P)
(a b
c)
Pivoted block brake with long shoe
P
h
Pmax cos
4R sin 2 sin 2
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Mt
RX
RY
2 R 2 wp max sin
1 Rwp max ( 2 2 1 Rwp max (2 2 sin 2 )
sin 2 )
Internal expanding brake

p max Rw 4 R cos Mn
2
Mf
cos 4 sin
1
2 max
h cos 2
2
cos 2
1
pmax Rwh 2
cos
sin 2
max
sin 2
4 sin
2
Mt
R p max w(cos 1 sin max
P
P
Mn C
Mn C
Mf
Mf
(Clock wise rotation of the brake drum)
(Anti clock wise rotation of the brake drum)

2
max max
90 0 when
2
90 0 90 0
when
Where p max = maximum intensity of pressure. = coefficient of friction.
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M f = moment due to friction. M n = moment due to normal force. M t = elemental torque due to frictional force.
R = radius of the brake lining. w = face width of frictional lining.
Band Brakes
P = tension on the tight side of the band. 1 P2 = tension on the loose side of the band.
= angle of wrap (rad).
M t = torque capacity of the brake.

R = radius of the brake drum.
Mt ( P1 P2 ) R
p pmax
P Rw P 1 Rw
p = intensity of pressure. w = width of the frictional lining. Differential band brake. P2 (a b e ) p l
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Thermal Considerations
E mc
Where t = temperature rise of the brake drum assembly (0C ) E = total energy absorbed by the brake m = mass of the brake drum assembly c = specific heat of the brake drum material
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Belt Drives
GEOMETRICAL RELATIONSHIPS
Open belt drive
s
D d ) 2C d 1 D 180 2 sin ( ) 2C 180 2 sin 1 (

2C (D d ) 2 (D d ) 2 4C
Cross belt drive

s b
180 2 sin 1 (
(D d ) 2 ( D d )2 4C
D d ) 2C
2C
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Analysis of belt tension
P1 P2
mv 2 mv 2
ef
(For flat belts)
P1 P2
mv 2 mv 2
sin(
1 ) 2
(For V-belts)
Power transmitted= ( P 1
P2 )v
Condition for maximum power transmission
Pi 3m
SELECTION OF FLAT BELT FROM THE MANUFACTURES CATALOGUE

(kW ) max Fa (kW )
Where (kW ) max = power transmitted by the belt for the design purpose
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(kW ) = actual power transmitted by the belt
Fa = load correction factor

Type of load (i) Normal load (ii) Steady load, e.g. centrifugal pumps-fans-light machine tools-conveyors (iii) Intermittent load, e.g. heavy duty fansblowers-compressors- reciprocating pumps-line shafts-heavy duty machines (iv) Shock load, e.g. vacuum pumps-rolling millshammers-grinders
Fa
1.0 1.2 1.3
1.5
Arc of contact factor

s
(degrees) 120 130 140 150 160 170 180 190 200 1.33 1.26 1.19 1.13 1.08 1.04 1.00 0.97 0.94 Fd
HI-SPEED FORT
0.0118 kW per mm width per ply 0.0147 kW per mm width per ply
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Standard widths of the belt are as follows

3-Ply 25 4-Ply 40 5-Ply 76 6-Ply 112 40 50 63 76 44 50 63 76 100 112 125 152 125 152 180 200 90 100 112 125 152
( kW ) corrected
For HI-SPEED belt,
(kW ) max
Fd
Corrected kW rating= For FORT belt, Corrected kW rating=
0.0118v (5.08) 0.0147v (5.08)
SELECTION OF V-BELTS
Dimensions of standard cross-sections Belt Section Width Thickness Minimum pitch W(mm) T(mm) diameter of pulley(mm) A 13 8 125 B 17 11 200 C 22 14 300 D 32 19 500 E 38 23 630
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Conversion of inside length to pitch length of the belt Belt section A B C D E Difference between pitch length and inside length (mm) 36 43 56 79 92 Preferred values for pitch diameters (mm) 132 140 150 160 170 180 190 200 212 224 250 265 280 300 315 355 375 400 425 450 500 530 560 600 630 670 710 750 800 900
125 236 475 1000
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Number _ of _ belts
Where
(transmitted _ power _ in _ kW ) Fa kW _ rating _ of _ belt Fd Fl
Fa = correction factor for industrial service Fl = correction factor for belt length
Fd = correction factor for arc of contact
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Li
3658 4013 4115 4394 4572 4953 5334 6045 6807 7569
A -
B 1.11 1.13 1.14 1.15 1.16 1.18 1.19 -
Belt section C 1.00 1.02 1.03 1.04 1.05 1.07 1.08 1.11 1.14 1.16
D 0.90 0.92 0.92 0.93 0.94 0.96 0.96 1.00 1.03 1.05
E 0.94 0.96 0.99 1.01
0.9 0.8
Fd
0.7 0.6 0.5 120 150 180
(Degrees)
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Chain Drives Roller Chains

Dimensions and breaking loads of roller chains
ISO chain number Pitch p (mm) Roller diameter d1 (mm) Width b1 (mm) Transverse Breaking load for pitch p t single strand chain (kN) (mm)
06 B 08 B 10 B 12 B 16 B 20 B 24 B 28 B 32 B 40 B
9.525 12.70 15.875 19.05 25.40 31.75 38.10 44.45 50.80 63.50
6.35 8.51 10.16 12.07 15.88 19.05 25.40 27.94 29.21 39.37
5.72 7.75 9.65 11.68 17.02 19.56 25.40 30.99 30.99 38.10
10.24 13.92 16.59 19.46 31.88 36.45 48.36 59.56 58.55 72.29
10.7 18.2 22.7 29.5 65.0 98.1 108.9 131.5 172.4 272.2
Geometric Relationships
Velocity ratio, i
n1 n2 z2 z1 zpn 60 10 3
Average velocity, v Length of the chain, L Number of links in the chain, L n

a 2 p z1 2 z2
Ln
p
2
z 2 z1 2
p a
Where a = centre distance between the axis of the driving and driven sprockets.
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p 4
Ln
z1 z2 2
Ln
z1 z2 2
z z 8 2 1 2
POWER RATING OF ROLLER CHAINS

kW P1v 1000
Where
P1 = allowable tension in the chain (N)

v = average velocity of chain
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kW rating of chain = Where
kW _ to _ be _ transmitted K1 K 2
Ks
K s = service factor
Multiple strand factors ( K1 ) Number of strands
K1
1 2 3 4 5 6
1.0 1.7 2.5 3.3 3.9 4.6
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Tooth correction factor ( K 2 ) Number of teeth on the K 2 driving sprocket 15 0.85 16 0.92 17 1.00 18 1.05 19 1.11 20 1.18 21 1.26 22 1.29 23 1.35 24 1.41 25 1.46 30 1.73
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SPROCKET WHEELS
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Rolling Contact Bearing

Stribecks Equation
C0
2 1 23 2 1
P1
2 P2 cos
2 P3 cos 2
.......... .....
cos P2 P 1
C0
Where, M
P1 M
1 2 cos
5 2
2 cos 2
5 2
C 0 = Static load
1
... = radial deflections at the respective balls.
360 z
Where z is number of balls
z M
is practically constant and Stribeck suggested a value of

z M
5 for
C0
1 zP1 5
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Where d is, the ball diameter and factor k depends upon radii of curvature at the point of contact and on the modulii of elasticity of the materials. Stribecks Equation
P1
kd 2
C0
kd 2 z 5
Equivalent Bearing Load

P XFr YFa
Where, P= equivalent dynamic load Fr = radial load Fa = axial or thrust load X and Y are radial and thrust factors respectively and there values are given in the manufactures catalogue.
Load Life Relationship

C L P Where L = bearing life (in million revolutions) C = dynamic load capacity (N) p=3 (for ball bearing) p = 10/3 (for roller bearing)
p
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Relationship between life in million revolutions and and life in working hours is given by 60nLh L 10 6 Where Lh =bearing life (hours) n = speed of rotation (rpm)
Selection of bearing from manufactures catalogue

X and Y factors for single-row deep groove ball bearings
Fa C0
Fa Fr
X
Fa Fr
X 0.56 0.56 0.56 0.56 0.56 0.56
Y 0 0 0 0 0 0
Y 2.0 1.8 1.6 1.4 1.2 1.0 0.22 0.24 0.27 0.31 0.37 0.44
0.025 0.040 0.070 0.130 0.250 0.500
1 1 1 1 1 1
XFr
YFa
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Dimensions and static and dynamic load capabilities of singlerow deep groove ball bearings. Principal dimensions (mm) d D B 10 19 5 26 8 30 9 35 11 12 21 5 28 8 32 10 37 12 15 24 5 32 9 35 11 42 13 17 26 5 35 10 40 12 47 14 62 17 20 32 7 42 8 42 12 47 14 52 15 72 19 25 37 7 47 8 47 12 Basic load ratings(N) C 1480 4620 5070 8060 1430 5070 6890 9750 1560 5590 7800 11400 1680 6050 9560 13500 22900 2700 7020 9360 12700 15900 30700 3120 7610 11200
C0
Designation
630 1960 2240 3750 695 2240 3100 4650 815 2500 3550 5400 930 2800 4500 6550 11800 1500 3400 4500 6200 7800 16600 1960 4000 5600
61800 6000 6200 6300 61801 6001 6201 6301 61802 6002 6202 6302 61803 6003 6202 6303 6403 61804 16400 6004 6204 6304 6404 61805 16005 6005
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30
35
40
45
50
55
52 62 80 42 55 55 62 72 90 47 62 62 72 80 100 52 68 68 80 90 110 58 75 75 85 100 120 65 80 80 90 110 130 72
15 17 21 7 9 13 16 19 23 7 9 14 17 21 25 7 9 15 18 23 27 7 10 16 19 25 29 7 10 16 20 27 31 9
14000 22500 35800 3120 11200 13300 19500 28100 43600 4030 12400 15900 25500 33200 55300 4160 13300 16800 30700 41000 63700 6050 15600 21200 33200 52700 76100 6240 16300 21600 35100 61800 87100 8320
6950 11400 19600 2080 5850 6800 10000 14600 24000 3000 6950 8500 13700 18000 31000 3350 7800 9300 16600 22400 36500 3800 9300 12200 18600 30000 45500 4250 10000 12300 19600 36000 52000 5600
6205 6305 6405 61806 16006 6006 6206 6306 6406 61800 16007 6007 6207 6307 6407 61808 16008 6008 6208 6308 6408 61809 16009 6009 6209 6309 6409 61810 16010 6010 6210 6310 6410 61811
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60
65
70
75
90 90 100 120 140 78 95 95 110 130 150 85 100 100 120 140 160 90 110 110 125 150 180 95 115 115 130 160 190
11 18 21 29 33 10 11 18 22 31 35 10 11 18 23 33 37 10 13 20 24 35 42 10 13 20 25 37 45
19500 12200 28100 17000 43600 25000 71500 41500 99500 63000 8710 6100 19900 13200 29600 18300 47500 28000 81900 48000 108000 69500 11700 8300 21200 14600 30700 19600 55900 34000 92300 56000 119000 78000 12100 9150 28100 19000 37700 24500 61800 37500 104000 63000 143000 104000 12500 9800 28600 20000 39700 26000 66300 40500 112000 72000 153000 114000
16011 6011 6211 6311 6411 61812 16012 6012 6212 6312 6412 61813 16013 6013 6213 6313 6413 61814 16014 6014 6214 6314 6414 61815 10615 6015 6215 6315 6415
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Dynamic load capacity

L C P
p
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Selection of Taper Roller Bearings

0.5Fr Y
Fa
Where Y is the thrust factor Equivalent dynamic load for single row taper roller bearings is given by
P P
Fr when Fa Fr 0.4 Fr
e e
YFa when Fa Fr
Dimensions, Dynamic capabilities and calculation factors for single row taper roller bearing d D B C Designation e Y 20 42 15 22900 32004X 0.37 1.6 47 15.25 26000 30204 0.35 1.7 52 16.25 31900 30304 0.30 2.0 52 72.25 41300 32304 0.30 2.0 25 47 15 25500 32005X 0.43 1.4 52 16.25 29200 30205 0.37 1.6 52 19.25 34100 32205B 0.57 1.05 52 22 44000 33205 0.35 1.7 62 18.25 41800 30305 0.30 2 62 18.25 35800 31305 0.83 0.72 62 25.25 56100 32305 0.30 2 30 55 17 33600 32006X 0.43 1.4 62 17.25 38000 30206 0.37 1.6 62 21.25 47300 32206 0.37 1.6 62 21.25 45700 32206B 0.57 1.05
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30
35
40
45
50
62 72 72 72 62 72 72 72 72 80 80 80 80 68 75 80 80 80 85 90 90 90 75 80 85 85 85 95 95 100 100 100 100 80
25 20.75 20.75 28.75 18 18.25 24.25 24.25 28 22.75 22.75 32.75 32.75 19 26 19.75 24.75 32 33 25.25 25.25 35.25 20 26 20.75 24.75 32 29 36 27.25 27.25 38.25 38.25 20
60500 52800 44600 72100 40200 48400 61600 57200 79200 68200 57200 89700 88000 49500 74800 58300 70400 96800 114000 80900 69300 110000 55000 79200 62700 74800 101000 84200 140000 101000 85800 132000 128000 57200
33206 30306 31306 32306 32007X 30207 32207 32207B 33207 30307 31307 32307 32307B 32008X 33108 30208 32208 33208 T2EE040 30308 31308 32308 32009X 33109 30209 32209 33209 T7FC045 T2ED045 30309 31309 32309 32309B 32010X
0.35 0.31 0.83 0.31 0.46 0.37 0.37 0.57 0.35 0.31 0.83 0.31 0.54 0.37 0.35 0.37 0.37 0.35 0.35 0.35 0.83 0.35 0.40 0.37 0.40 0.40 0.40 0.88 0.33 0.35 0.83 0.35 0.54 0.43
1.7 1.9 0.72 1.9 1.3 1.6 1.6 1.05 1.7 1.9 0.72 1.9 1.1 1.6 1.7 1.6 1.6 1.7 1.7 1.7 1.72 1.7 1.5 1.6 1.5 1.5 1.5 0.68 1.8 1.7 0.72 1.7 1.1 1.4
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50
60
70
80 85 90 90 90 100 105 110 110 110 110 95 95 100 110 110 110 115 115 125 130 130 130 130 110 110 120 125 125 125 130 140 140 150
24 26 21.75 24.75 32 36 32 29.25 29.25 42.25 42.25 23 27 30 23.75 29.75 38 39 40 37 33.5 33.5 48.5 48.5 25 31 37 26.25 33.25 41 43 39 32 38
64400 80900 70400 76500 108000 145000 102000 117000 99000 161000 151000 76500 85800 110000 91300 119000 157000 157000 183000 145000 161000 134000 216000 205000 95200 121000 161000 119000 147000 190000 220000 168000 264000 209000
33010 33110 30210 32210 33210 T2ED050 T7FC050 30310 31310 32310 32310B 32012X 33012 33112 30212 32212 33212 T5ED060 T2EE060 T7FC060 30312 31312 32312 32312B 32014X 33014 33114 30214 32214 33214 T2ED070 T7FC070 T4FE070 3014
0.31 0.40 0.43 0.43 0.40 0.35 0.88 0.35 0.83 0.35 0.54 0.43 0.33 0.40 0.40 0.40 0.40 0.54 0.33 0.83 0.35 0.83 0.35 0.54 0.43 0.28 0.37 0.43 0.43 0.40 0.33 0.88 0.44 0.35
1.9 1.5 1.4 1.4 1.5 1.7 0.68 1.7 0.72 1.7 1.1 1.4 1.8 1.5 1.5 1.5 1.5 1.1 1.8 0.72 1.7 0.72 1.7 1.1 1.4 2.1 1.6 1.4 1.4 1.5 1.8 0.68 1.35 1.7
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70
80
90
100
150
150 150 150 125 125 130 140 140 140 145 170 170 170 170 140 140 150 155 160 160 190 190 190 145 150 150 165 180 180 180 215 215 215 225
38 54 54 29 36 37 28.25 35.25 46 46 42.5 42.5 61.5 61.5 32 39 45 46 32.5 42.5 46.5 46.5 67.5 24 32 39 47 37 49 63 51.5 56.5 77.5 48
176000 275000 264000 128000 157000 168000 140000 176000 233000 264000 255000 212000 358000 336000 157000 205000 238000 270000 183000 238000 308000 251000 429000 119000 161000 212000 292000 233000 297000 402000 380000 352000 539000 347000
31314 32314 32314B 32016X 33016 33116 30216 32216 33216 T2ED080 30316 31316 32316 32316B 32018X 33018 33118 T2ED090 30218 32218 30318 31318 32318 T4CB100 32020X 33020 T2EE100 30220 32220 33220 30320 31320X 32320 32030X
0.83 0.35 0.54 0.43 0.28 0.43 0.43 0.43 0.43 0.31 0.35 0.83 0.35 0.54 0.43 0.27 0.40 0.33 0.43 0.43 0.35 0.83 0.35 0.48 0.46 0.28 0.31 0.43 0.43 0.40 0.35 0.83 0.35 0.46
0.72 1.7 1.1 1.4 2.1 1.4 1.4 1.4 1.4 1.9 1.7 0.72 1.7 1.1 1.4 2.2 1.5 1.8 1.4 1.4 1.7 0.72 1.7 1.25 1.3 2.1 1.9 1.4 1.4 1.5 1.7 0.72 1.7 1.3
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150
200
300
270 270 320 320 280 310 360 360 420
49 77 72 82 51 70 64 104 76
402000 682000 765000 837000 446000 704000 737000 1140000 990000
30230 32230 30330 31330X 32940 32040X 30240 32240 32960
0.43 0.43 0.35 0.83 0.40 0.43 0.43 0.40 0.40
1.4 1.4 1.7 0.72 1.5 1.4 1.4 1.5 1.5
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Design for Cyclic Load and Speeds
Pe
BP 3 N
Bearing With a Probability of Survival Other Than 90 Percent

1b
L L90
log e log e
1 R 1 R90
Where b = 1.17
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Sliding Contact Bearing

Effect of Temperature on Viscosity
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Hydrostatic Step Bearing

The following notations are used in the analysis, W = Trust load
R0 = outer radius of the shaft Ri = inner radius of the shaft

Pi = supply of inlet pressure Po = outlet or atmospheric pressure
h0 = fluid film thickness

Q = flow of the lubricant = viscosity of the lubricant
Q
3 Pi h0
6 log e
R0 Ri
Pi 2
R 02 log
e
R i2 R0 Ri
Energy Losses in Hydrostatic Thrust Bearing

(kW ) p
(kW ) f
Q( Pi
P0 )(10 6 )
n 2 ( R04 Ri4 ) h0
( kW ) p = power loss in pumping
1 58.05 10 6
( kW ) f = power loss due to friction
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(kW ) t
( kW ) p
( kW ) f
( kW )t = total power loss
Reynolds Equation
x h3 p x z h3 p z 6 U h x
Raimondi and Boyd Method

Dimensionless performance parameters for full journal bearings with side flow
l d
h0 c
0 1.0 0.1 0.9 0.2 0.8 0.4 0.6 0.6 0.4 0.8 0.2 0.9 0.1 0.97 0.03 1.0 0 0 1.0 0.1 0.9 0.2 0.8 0.4 0.6 0.6 0.4 0.8 0.2 0.9 0.1
r f c
70.92 69.10 4.80 67.26 2.57 61.94 1.52 54.31 1.20 42.22 0.961 31.62 0.756 _ _ 0 0 85 79.5 26.4 74.02 12.8 63.10 5.79 50.58 3.22 36.24 1.70 26.45 1.05
Q rcns l
Qs Q
p p max
0.240 0.123 0.0626 0.0389 0.021 0.0115 _ 0 1.33 0.631 0.264 0.121 0.0446 0.0188
0 3.03 0 2.83 0 2.26 0 1.56 0 0.760 0 0.411 0 _ 0 0 0 0 3.37 0.150 3.59 0.280 3.99 0.497 4.33 0.680 4.62 0.842 4.74 0.919
_ 0.826 0.814 0.764 0.667 0.495 0.358 _ 0 _ 0.540 0.529 0.484 0.415 0.313 0.247
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0.97 0.03 0.00474 15.47 1.0 0 0 0 0 1.0 88.5 0.1 0.9 4.31 81.62 0.2 0.8 2.03 74.94 0.4 0.6 0.779 61.45 0.6 0.4 0.319 48.14 0.8 0.2 0.0923 33.31 0.9 0.1 0.0313 23.66 0.97 0.03 0.00609 13.75 1.0 0 0 0 0 1.0 89.5 0.1 0.9 16.2 82.31 0.2 0.8 7.57 75.18 0.4 0.6 2.83 60.86 0.6 0.4 1.07 46.72 0.8 0.2 0.261 31.04 0.9 0.1 0.0736 21.85 0.97 0.03 0.0101 12.22 1.0 0 0 0
0.514 0 85.6 40.9 17.0 8.10 3.26 1.60 0.610 0 322.0 153.0 61.1 26.7 8.8 3.50 0.922 0
4.82 0 3.43 3.72 4.29 4.85 5.41 5.69 5.88 _ 3.45 3.76 4.37 4.99 5.60 5.91 6.12 _
0.973 1.0 0 0.173 0.318 0.552 0.730 0.874 0.939 0.980 1.0 0 0.180 0.330 0.567 0.746 0.884 0.945 0.984 1.0
0.152 _ _ 0.523 0.506 0.441 0.365 0.267 0.206 0.126 0 _ 0.515 0.489 0.415 0.334 0.240 0.180 0.108 0
c = R-r Where c = radial clearance (mm) R = radius of bearing r = radius of journal
e c
Where e =eccentricity ratio, = eccentricity ratio
1 h0 c
Where h0 =film thickness
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h0 c is called the minimum film thickness variable The Sommerfed number is given by
r c
ns p
Where n s =journal speed p = unit bearing pressure The Coefficient of Friction Variable (CFV) is given by r (CFV ) f c Where f is the coefficient of friction Frictional power ( kW ) f
2 n s fWr 10 6
The Flow Variable (FV) is given by Q ( FV ) rcn s l Where l = length of the bearing Q= flow of the lubricant
Temperature Rise
t 8.3 p (CFV ) ( FV ) t Ti 2
Tav
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Bearing Design Selection of Parameters
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Spur Gears
The pitch circle diameter is given by
d1
a
mz
mn ( z p 2
zg zp np ng
Centre to centre distance,
zg )
Here transmission ratio i
Standard System of Gear Tooth

Choice 1 1.00 1.25 (preferred) 5.00 6.0 Choice2 1.12 1.375 5.5 7.00 1.50 8.00 1.75 9.00 2.00 10.00 2.25 11.00 2.5 12.00 2.75 14.0 3.00 4.0 16.00 20.00 3.50 4.5 18.00
Addendum ha =(m) Dedendum h f =1.25m Clearance(c) =0.25m Tooth thickness = 1.5708m Fillet radius = 0.4m
Shinto Mathew
46
Force Analysis
Mt 60 10 6 (kW ) 2 n
pt
Pr
2 mt d1
Pt tan
Pt cos Number of Teeth PN
2 sin 2 Pressure angle z min
14.5 0
20 0
25 0
z min (Theoretical) z min (Practical)
32 27
17 14
11 9
Face Width (3m)<b< (12m) In preliminary stages of gear design, the face width assumed as ten times of module.
Shinto Mathew
47
Beam Strength of Gear Tooth
Sb
mb
Values of the Lewis form factor Y for 20 0 full depth involute system z Y z Y z Y 15 16 17 18 19 20 21 22 23 24 25 26 0.289 0.295 0.302 0.308 0.314 0.320 0.326 0.330 0.333 0.337 0.340 0.344 27 28 29 30 32 33 35 37 39 40 45 50 0.348 0.352 0.355 0.358 0.364 0.367 0.373 0.380 0.386 0.389 0.399 0.408 55 60 65 70 75 80 90 100 150 200 300 Rack 0.415 0.421 0.425 0.429 0.433 0.436 0.442 0.446 0.458 0.463 0.471 0.484
Shinto Mathew
48
Effective Load on Gear Tooth (1)For ordinary and commercially cut gears made with form cutters with v<10m/s
Cv
3 3 v 6 6 v
5 .6 5.6 v
(2) For actually hobbled and generated gears with v<20m/s,
Cv
(3) For precision gears with shaving, grinding and lapping operations and with v>20m/s,
Cv
The pitch line velocity is given by d 'n v 60 10 3 The effective load between two meshing teeth is given by
Peff
C s Pt Cv
n the final stages of gear design, when the gear dimensions are known, the errors specified and the quality of gears determined, the dynamic load is calculated by the equations derived by Prof. Spotts. The effective load is given by
Peff
C s Pt
Pd
where Pd is the dynamic load Depending upon the materials of the pinion and the gear, there are three equations for the dynamic load. (1) Steel Pinion with steel gear: en p z p br1 r2 Pd 2530 r12 r22
Shinto Mathew
49
(2) C.I Pinion with C.I gear: en p z p br1r2 Pd 3785 r12 r22 (3) Steel Pinion with C.I Gear en p z p br1r2 Pd 3260 r12 0.92 r22 e = sum of errors between two meshing teeth (mm)
e ep eg
where e p =error for pinion e g =error for gear Source of power Type of driven machines
Generators-feeding mechanisms-belt conveyorsblowers-compressors-agitators and mixers Electric motor Turbine/Multi cylinder engine Single-cylinder engine
1.10
1.25
1.50
Machine tools-hoist and cranes-rotary drives-piston pumps-distribution pumps
1.25
1.50
1.75
Blanking and shearing presses -rolling mills-centrifuges-steel work machinery
1.75
2.00
2.25
Shinto Mathew
50
Estimation of Module Based on Beam Strength

13
60 10 6
kW C s fs b S ut znCv Y m 3
Wear Strength of Gear Tooth

K
2 c
sin cos 1 E1 1 E 2 1 .4
Shinto Mathew
51
Sw
Q
bQd 1 K p
2z g zg zp
Expression for the load stress factor K can be simplified when all the gears are made of steel with a 20 0 pressure angle . in this special case,
E1
c
E2
20 0
207000 N mm 2
0.27(9.81)( BHN ) N mm 2 where BHN=Brinell Hardness Number. Therefore,

K BHN 0.16 100
2
Estimation of Module Based on Wear Strength

13
60 10 6
kW C s fs b z 2 n p Cv QK p m
Gear Design for Maximum Power Transmitting Capacity

Sw
Pt Pd
2 Pd
Sw 2
Shinto Mathew
52
Helical gears
Pn
mn
P cos
m cos
mn = normal module
m = transverse module
pa
cos d
p tan
tan tan zmn cos
n
a
i
m n ( z1 z 2 ) 2 cos
p g
zg zp
Where i=speed ratio for helical gear Suffixes p and g refer to the pinion and gear respectively a is the centre to centre distance between two helical gears having z1 and z 2 as the number of teeth. The normal pressure angle is usually 20 0 .
Virtual number of teeth

z1 z cos 3
Shinto Mathew
53
Tooth proportions
In helical gears, the normal module mn should be selected from standards. The first preference values of the normal module are m n (mm) 1, 1.25, 1.5, 2, 2.5,3,4,5,6,8 and10. The standard proportions of the addendum and dedendum are, Addendum ( ha ) mn Dedendum (h f ) 1.25m n Clearance (c) 0.25mn Addendum circle diameter d a is given by
da mn z cos 2
Dedendum circle diameter d f is given by

df mn z cos 2.5
n
m sin
This is the minimum face width. Force Analysis
pt pr pa pt
pa
Tangential component Radial component Axial or thrust component
p cos
p t tan
cos
Shinto Mathew
54
pr
pt
tan cos
2 mt pt d Beam strength of helical gears

Sb mn
b
Effective load on gear tooth

60 10 6 (kW ) 2 n
Mt
Pt
2M t d
Peff
C s Pt Cv
C s = service factor (from table)

C v = velocity factor
The velocity factor ,
Cv 5.6 5.6 v
Dynamic load is given by
Shinto Mathew
55
Pd
en p z p br1r2 2530 r12 r22
Peff
(Cs Pt
Pd cos
cos )
Sb
Peff ( fs )
Wear strength of helical gears

Sw bQd p K cos 2
Q Q
2 z1 g z1 g zg z1 p zp 2 zg
for internal helical gear
2 zg zg zp
2 c
sin
n cos
1 E1
1 E2
1.4
Shinto Mathew
56
Normal pressure angle

BHN 0.16 100
2
(20 0 )
Sw
Peff ( fs )
Shinto Mathew
57
Bevel Gears
rb z1
tan
tan
D 2 cos z cos zp
zg zg
zp
The cone distance
A0 is given by
2
A0
Dp 2
Dg 2
Force Analysis
rm Dp 2 b sin 2
Where rm = radius of the pinion at the mid point along the face width b = face width of the tooth
Shinto Mathew
58
Pt
Ps
Mt rm
Pt tan
Where Pt = tangential or useful component which is perpendicular to the plane of the paper.
Ps = the separating force between the two meshing

teeth Pr Pt tan cos
Pa
Pt tan sin
Beam Strength of Bevel Gears

Sb mb
bY 1
b A0
Where S b beam strength of the tooth m = module at the large end of the tooth b = face width = permissible bending stress ( S ut 3 ) Y = Lewis form factor based on formative number of
b
teeth
A0 = cone distance
Pt 2M t D
face width of the bevel gear is generally taken as (10 m) or ( A0 3 ) whichever is smaller
Shinto Mathew
59
b = (10 m) or A0 3
(Whichever is smaller)
WEAR STRENGTH OF BEVEL GEARS

Buckinghams equation
Sw
bQd 1 K p
Where
S w = wear strength
b = face width of gears Q = ratio factors d 1 = pitch circle diameter of the formative pinion p K = material constant
d1 p
2rb
Sw
Q
0.75bQD p K cos
2z g zg
2 c
(Buckinghams equation)
z p tan
1 Ep 1 Eg
sin cos
1. 4 When pinion as well as the gear is made of steel with 20 0 pressure angle, the value of K is given by
K BHN 0.16 100
2
Shinto Mathew
60
EFFECTIVE LOAD ON GEAR TOOTH

Mt 60 10 6 ( kW ) 2 n
Pt
2M t D
Peff
C s Pt Cv
Source of power Type of driven machines
Electric motor Turbine/Multi cylinder engine Single-cylinder engine
C s = service factor (from table)
Generators-feeding mechanisms-belt conveyorsblowers-compressors-agitators and mixers
1.10
1.25
1.50
Machine tools-hoist and cranes-rotary drives-piston pumps-distribution pumps
1.25
1.50
1.75
Blanking and shearing presses -rolling mills-centrifuges-steel work machinery
1.75
2.00
2.25
C v = velocity factor
The velocity factor for cut teeth is given by
Shinto Mathew
61
Cv
For general teeth,
Cv
6 6 v
5.6 5.6 v
Dynamic load is given by en p z p b1 r1 r2 Pd 2530 r12 r22
r1 , r2 Radii of the pinion and gear respectively b1 Axial width of the gear blank
r1
r2
Dp 2
Dg 2
b sin 2
b cos 2
Peff
(C s Pt
Pd )
Stress in gear tooth due to bending S b Peff ( fs ) Stress in gear tooth due to pitting
Sw
Peff ( fs )
Shinto Mathew
62
Worm Gears
Notations:z1 = number of starts on the worm z2 = number of teeth on the worm wheel q = diametral quotient m = module d1 = pitch circle diameter of the worm
d a1 = outer diameter of the worm d a 2 = outer diameter of the worm wheel d 2 = pitch circle diameter of the worm wheel
l = lead of the worm
p x = axial pitch of the worm

a = the centre distance i = the speed ratio. F = the effective face width lr = the length of the root of the worm gear teeth.
Proportions of Worm Gears
Shinto Mathew
63
d1 m p x z1
d 2 mz 2 px m
l
a
mz 1
1 m( q 2 z2 )
Shinto Mathew
64 z2 z1 2m (q 1)
i F
lr
( d a1
2c) sin
F d a1 2c
Force Analysis
( P1 ) t = tangential component on the worm ( P ) a = axial component on the worm 1 ( P1 ) r = radial component on the worm
( P1 ) t 2M t d1
( P1 ) a
( P1 ) r
( P1 ) t
( P1 ) t
cos cos cos sin

sin (cos sin
sin cos
cos )
Friction in worm gears

v s = rubbing velocity v1 = pitch line velocity of the worm
v2 = pitch line velocity of the worm wheel d 1n 1 v1 ( 60 )( 1000 )

vs d 1 n1 (60000 ) cos cos tan (cas cot )
Shinto Mathew
65
Strength Rating Of Worm Gears

( M t )1 (M t ) 2 17.65 X b1 S b1ml r d 2 cos 17.65 X b 2 S b 2 ml r d 2 cos
( M t )1 , ( M t ) 2 = permissible torque on the worm wheel

, X b 2 = speed factors for the strength of worm and worm wheel
b1
b1
Sb2
= bending stress factors for worm and worm
wheel
Shinto Mathew
66
m = module
l r = the length of the root of the worm gear teeth.

d 2 = pitch circle diameter of the worm wheel
= lead angle of the worm Power transmitting capacity of the worm gear based on the beam strength is given by
kW
Where
(M t)
2 nM t 60 10 6
is the lower value between (M t)1 and (M t) 2 .
Shinto Mathew
67
Wear Rating of Worm Gears

(M t ) 3 (M t ) 4 18.64 X c1 S c1YZ ( d 2 )1.8 m 18.64 X c 2 S c 2YZ (d 2 )1.8 m
( M t )3 , ( M t ) 4 = permissible torque on the worm wheel
X c1 , X c 2
worm wheel
= speed factors for the strength of worm and
S c1 , S c 2 = surface stress factors of the worm and worm

wheel
Yz = zone factor
Thermal Considerations H g 1000(1 ) kW Where H g = rate heat generation
Shinto Mathew
68
= efficiency of the of the worm gear (fraction) kW = power transmitted by the gears
Hd
k (t t 0 ) A
Where H d = rate of heat dissipation k = overall heat transfer coefficient of housing 20 walls W m C t = temperature of the lubrication oil. ( 0C )
t 0 = temperature of the surrounding air ( C )

0
A = effective surface area of housing
kW t
k (t t 0 ) A 1000(1 ) 1000(1 )kW t0 kA
Shinto Mathew

Mechanical Design Data Book

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Mechanical Design Data Book

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1

Design Data Hand Book

5 Rolling Contact Bearings

6 Sliding Contact Bearings

Pcf = centrifugal force. Ps Spring force

= running speed. (Rad/sec) = speed at which engagement starts. (Rad/sec)

Single Plate & Multi Plate Clutches

Uniform wear theory pad P (D d ) 2

Pz (D3 d 3 ) 3sin (D2 d 2 )

Uniform wear theory pad P (D d ) 2

Note: - here z = number of shoes.

= Initial and final angular velocities of the body

External Contracting Brakes

Pivoted block brake with long shoe

Internal expanding brake

R p max w(cos 1 sin max

(Clock wise rotation of the brake drum)

(Anti clock wise rotation of the brake drum)

Where p max = maximum intensity of pressure. = coefficient of friction.

R = radius of the brake lining. w = face width of frictional lining.

= angle of wrap (rad).

M t = torque capacity of the brake.

p = intensity of pressure. w = width of the frictional lining. Differential band brake. P2 (a b e ) p l

D d ) 2C d 1 D 180 2 sin ( ) 2C 180 2 sin 1 (

Cross belt drive

Analysis of belt tension

(For flat belts)

Condition for maximum power transmission

SELECTION OF FLAT BELT FROM THE MANUFACTURES CATALOGUE

(kW ) = actual power transmitted by the belt

Fa = load correction factor

Arc of contact factor

Standard widths of the belt are as follows

Corrected kW rating= For FORT belt, Corrected kW rating=

0.0118v (5.08) 0.0147v (5.08)

125 236 475 1000

(transmitted _ power _ in _ kW ) Fa kW _ rating _ of _ belt Fd Fl

Fd = correction factor for arc of contact

B 1.11 1.13 1.14 1.15 1.16 1.18 1.19 -

E 0.94 0.96 0.99 1.01

0.7 0.6 0.5 120 150 180

Chain Drives Roller Chains

Average velocity, v Length of the chain, L Number of links in the chain, L n

POWER RATING OF ROLLER CHAINS

P1 = allowable tension in the chain (N)

kW rating of chain = Where

Multiple strand factors ( K1 ) Number of strands

1.0 1.7 2.5 3.3 3.9 4.6

Rolling Contact Bearing

... = radial deflections at the respective balls.

is practically constant and Stribeck suggested a value of

Equivalent Bearing Load

Load Life Relationship

Selection of bearing from manufactures catalogue

0.025 0.040 0.070 0.130 0.250 0.500

52 62 80 42 55 55 62 72 90 47 62 62 72 80 100 52 68 68 80 90 110 58 75 75 85 100 120 65 80 80 90 110 130 72

Dynamic load capacity

Selection of Taper Roller Bearings

62 72 72 72 62 72 72 72 72 80 80 80 80 68 75 80 80 80 85 90 90 90 75 80 85 85 85 95 95 100 100 100 100 80

270 270 320 320 280 310 360 360 420

402000 682000 765000 837000 446000 704000 737000 1140000 990000

30230 32230 30330 31330X 32940 32040X 30240 32240 32960

0.43 0.43 0.35 0.83 0.40 0.43 0.43 0.40 0.40