1

Spur Gears
Important Solved Examples

Example 1.21

Given data : P = 18 kW = 18 10 3 W, n P = 720 rpm, n G = 300 rpm,

Solution :

(S ut ) P = 780 N mm 2 , (S ut ) G = 680 N mm 2 , K a = 1.5,

FOS = 1.35, b = 12 m, K m = 1.4, f = 20
(BHN) P = 450, (BHN) G = 350
To find :

Design a gear pair.

Step - 1 : Calculate the number of teeth on pinion and gear

Gear ratio, G =

nP
720
=
= 2.4
nG
300

The number of teeth on gear and pinion should be selected such that the gear ratio must
be exactly 2.4. For 20 full-depth involute system, the minimum number of teeth on pinion
should be 18.
Gear ratio is,
or

G=

ZG
ZP

\ Z G = G Z P

Z G = 2.4 Z P
ZP

ZG

Remark

18

2.4 18 = 43.2

Not possible

19

2.4 19 = 45.6

Not possible

20

2.4 20 = 48

Possible

\ Selecting Z P = 20 and Z G = 48
Step - 2 : Check whether gear is weaker or pinion is weaker
We know that,
s bP =

(S ut ) P
780
=
= 260 N mm 2
3
3
1 - 1

Design of Machine Elements - II

Spur Gears
and

s bG =

(S ut ) G
680
=
= 226.6666 N mm 2
3
3

Lewis form factor is,

and

YP = 0.484 -

2.87
2.87
= 0.484 = 0.3405
ZP
20

YG = 0.484 -

2.87
2.87
= 0.484 = 0.4242
ZG
48

Now,

s bP YP = 260 0.3405 = 88.53 N mm 2

and

s bG YG = 226.666 0.4242 = 96.1519 N mm 2

... (Given)

As
s bP YP < s bG YG , pinion is weaker than the gear in bending. Therefore, it is
required to design a pinion for bending.
Step - 3 : Calculate the beam strength of pinion
Fb = s bP b m YP = 260 12 m m 0.3405
\

Fb = 1062.36 m 2 , N

... (i)

Step - 4 : Calculate the wear strength of gear pair

Fw = d P b Q K
But,

... (ii)

d P = m Z P = 20 m, mm
Q =

2 ZG
2 48
=
= 1.4117
ZG + ZP
48 + 20

BHN
K = 0.16

100

... (Given)

Considering smaller value of BHN.

\

350
K = 0.16
= 1.96 N mm 2
100

and
b = 12 m
Substituting all these values in equation (ii),
\
Fw = 20 m 12 m 1.4117 1.96
\

Fw = 664.0636 m 2 , N

... (iii)

As
Fw < Fb , gear pair is weaker in pitting. Hence, it is required to design a gear
pair against the pitting failure.
Step - 5 : Calculate the effective load on gear pair
K a K m Ft
Feff =
Kv
p dPnP
p 20 m 720
But,
V =
=
60
60
V = 0.7539 m 103 mm sec = 0.7539 m , m sec
\
1 - 2

... (iv)

Design of Machine Elements - II

Spur Gears
Ft =
Kv =

23.8732 103
P
18 103
=
=
,N
V
0.7539 m
m
6
6
=
6 + V 6 + 0.7539 m

... (Given)

K a = 1.5 and K m = 1.4

Substituting all these values in equation (iv),
23.8732 103
1.5 1.4

Feff =

m
6

6+ 0.7539 m

... (Given)

Feff

8355.6345 (6 + 0.7539 m)
m

Feff

50.1338 103 + 6.2993 103 m

m

Step - 6 :

Calculate the value of module and other dimensions

... (v)

For safety against pitting failure,

Fw = FOS Feff
Substituting the values of equation (ii) and (v),
50.1338 103 + 6.2993 103 m
\ 664.0636 m 2 = 1.35

491.8989 m 3 = 50.1338 103 + 6.2993 103 m

Solving the above cubic equation, we get

m = 5.5754 mm
Selecting standard value of module from the given data,
m = 6 mm
\
Other dimensions
b = 12 m = 12 6 = 72 mm

... Ans.

d P = m Z P = 6 20 = 120 mm
dG = m Z G = 6 48 = 288 mm
C. D. =

dP + dG
120 + 288
=
= 204 mm
2
2

h a = 1m = 1 6 = 6 mm
hf

= 1.25 m = 1.25 6 = 7.5 mm

... Ans.

Step - 7 : Calculate the dynamic load by using Buckingham's equation

Buckingham's equation for dynamic load is,
21 V (bC + Ft max )
Fd =
21 V + bC + Ft max
1 - 3

... (Given) ... (vi)

Design of Machine Elements - II

Spur Gears
V = 0.7539 m = 0.7539 6 = 4.5234 m sec

But,

b = 72 mm
Ft =

23.8732 103
23.8732 103
=
= 3978.8666 N
m
6

Ft max = K a K m Ft = 1.5 1.4 3978.8666 = 8355.6198 N

Now, pitch error for grade 7,
e = 11+ 0.9 [m + 0.25 d ]
\

... (Given)

For pinion,

e P = 11 + 0.9 [m + 0.25 d P ]

e P = 11+ 0.9 [6 + 0.25 120] = 18.8647 mm

For gear,

e G = 11+ 0.9 [m + 0.25 d G ]

e G = 11+ 0.9 [6 + 0.25 288] = 20.2183 mm

But,

e = e P + e G = 18.8647 + 20.2183

e = 39.083 mm = 39.083 10- 3 mm

E E
Deformation factor, C = 0.111 e P G
EP + EG
\

... (Given)

207 103 207 103

C = 0.111 39.083 10-3

207 103 + 207 103

C = 449 N mm
\
Substituting all these values in equation (vi),
21 4.5234 (72 449 + 8355.6198)
\
Fd =
21 4.5234 + 72 449 + 8355.6198
\

Fd

= 13.0255 103 N

Step - 8 : Calculate the available factor of safety

Effective load for precise estimation is,
Feff = Ft max + Fd = 8355.6198 + 13.0255 10 3
\

Feff

= 21.3811 103 N

As gear pair is weaker in pitting,

Fw = FOS Feff
\

FOS =

Fw
664.0636 (6) 2
=
Feff
21.3811 103

FOS = 1.1180 < 1.35

As the available factor of safety of gear pair is lower than the required factor of safety, the design of
gear pair is unsafe.
1 - 4

Design of Machine Elements - II

Spur Gears
Step - 9 : Calculate the modified dimensions of gear pair
As the design of gear pair is unsafe, selecting next standard value of module from the
given data i.e. 8 mm.
Modified dimensions
m = 8 mm
b = 12 m = 12 8 = 96 mm
d P = m Z P = 8 20 = 160 mm
dG = m Z G = 8 48 = 384 mm
C.D. =

d P +d G
160 + 384
=
= 272 mm
2
2

h a = 1 m = 1 8 = 8 mm
hf
Step - 10 :

= 1.25 m = 1.25 8 = 10 mm

... Ans.

Calculate the dynamic load by using Buckingham's equation

Buckingham's equation for dynamic load is,

21 V (bC + Ft max )
Fd =
21 V + bC + Ft max

... (Given) ... (vii)

V = 0.7539 m = 0.7539 8 = 6.0312 m sec

But,

b = 96 mm
Ft =

23.8732 103
23.8732 103
=
= 2984.15 N
m
8

Ft max = K a K m Ft = 1.5 1.4 2984.15 = 6266.715 N

Now, pitch error for grade 7,
e = 11+ 0.9 [m + 0.25 d ]

... (Given)

For pinion,

e P = 11 + 0.9 [m + 0.25 d P ]

e P = 11+ 0.9 [8 + 0.25 160] = 21.046 mm

For gear,

e G = 11+ 0.9 [m + 0.25 d G ]

e G = 11+ 0.9 [8 + 0.25 384 ] = 22.609 mm

But,

e = e P + e G = 21.046 + 22.609

e = 43.655 mm = 43.655 10-3 mm

E E
Deformation factor, C = 0.111e P G
EP + EG

... (Given)

1 - 5

Design of Machine Elements - II

Spur Gears
\

207 103 207 103

C = 0.111 43.655 10-3

207 103 + 207 103

C = 501.5304 N mm

Substituting all these values in equation (vii),

\
\
Step - 11 :

Fd =
Fd

21 6.0312 (96 501.5304 + 6266.715)

21 6.0312 + 96 501.5304 + 6266.715

= 19.1479 103 N

Calculate the available factor of safety

Effective load for precise estimation is,

Feff = Ft max + Fd = 6266.715 + 19.1479 10 3
\

Feff

= 25.4146 103 N

As gear pair is weaker in pitting,

Fw = FOS Feff
Fw
664.0636 (8) 2
=
Feff
25.4146 103

FOS =

FOS = 1.6722 > 1.35

As the available factor of safety of gear pair is higher than the required factor of safety, the design
of gear pair is safe.
Example 1.22

Solution : Given data : f = 20 , Z P = 24, Z G = 50, m = 4 mm

b = 50 mm, (S ut ) P = (S ut ) G = 600 N mm 2 , BHN = 450
n P = 1440 rpm, K a = 1, FOS = 1.5
To find : Power (P)
Step - 1 : Calculate the beam strength for pinion
When pinion and gear are made of same material, at that time pinion is weaker than the
gear in bending. Hence, it is necessary to find beam strength of pinion.
Fb = s bP b m YP
But,

s bP =

... (i)

(S ut ) P
600
=
= 200 N mm 2
3
3

b = 50 mm, m = 4 mm
YP = 0.484 -

2.87
2.87
= 0.484 = 0.3644
ZP
24
1 - 6

... (Given)

Design of Machine Elements - II

Spur Gears
Substituting all these values in equation (i),
\

Fb = 200 50 4 0.3644 = 14576.6666 N

Step - 2 : Calculate the wear strength of gear pair

Fw = d P b Q K

... (ii)

d P = m Z P = 4 24 = 96 mm, b = 50 mm

But,

Q =

2 ZG
2 50
=
= 1.3513
ZG + ZP
50 + 24
2

BHN
450
K = 0.16
= 0.16
= 3.24 N mm 2
100
100

... (Given)

Substituting all these values in equation (ii),

Fw = 96 50 1.3513 3.24 = 21015.4176 N

Step - 3 : Calculate the rated power transmitted by gear pair

As Fb < Fw , the gear pair is weaker in bending.
For safety against bending failure,
Fb = FOS Feff
\

14576.6666 = 1.5 Feff

Feff

= 9717.7777 N

Now,

Feff

K a K m Ft
Kv

... (iii)

p dPnP
p m ZP n P
p 4 24 1440
=
=
60
60
60

But,

V =

V = 7.2382 103 mm sec = 7.2382 m sec

Kv =

3
3
=
= 0.2930
3 + V 3 + 7.2382

... (Given)

K a = 1 and assuming K m = 1
Substituting all these values in equation (iii),
\
\

9717.7777 =

1 1 Ft
0.2930

Ft = 2847.4975 N

Power transmitted by gear pair is,

P = Ft V = 1235.9177 4.5553
\

P = 20610.7565 W = 20.6107 kW

1 - 7

... Ans.

Design of Machine Elements - II

Spur Gears
Example 1.23

Solution : Given data :

f = 20 , Z P = 25, Z G = 60, m = 5 mm
b = 45 mm, n P = 500 rpm, (S ut ) P = (S ut ) G = 600 N mm 2
BHN = 220, K a = 1.75, FOS = 2, K m = 1

To find : i) Fb

ii) Fw

iii) Ft

iv) P

Step - 1 : Calculate the beam strength for pinion

When pinion and gear are made of same material, at that time pinion is weaker than the
gear in bending. Hence, it is necessary to find beam strength of pinion.
... (i)
Fb = s bP b m YP
But,

s bP =

(S ut ) P
600
=
= 200 N mm 2
3
3

b = 45 mm, m = 5 mm
YP = 0.484 -

2.87
2.87
= 0.484 = 0.3692
ZP
25

... (Given)

Substituting all these values in equation (i),

\

Fb = 200 45 5 0.3692

Fb = 16.614 10 3 N

... Ans.

Step - 2 : Calculate the wear strength of gear pair

Fw = d P b Q K
But,

... (ii)

d P = m Z P = 5 25 = 125 mm, b = 45 mm
Q =

2 ZG
2 60
=
= 1.4117
ZG + ZP
60 + 25

BHN 2
220 2
K = 0.16
= 0.16
= 0.7744 N mm 2
100
100

... (Given)

Substituting all these values in equation (ii),

\

Fw = 125 45 1.4117 0.7744

Fw = 6149.3652 N

... Ans.

Step - 3 : Calculate the rated power transmitted by gear pair

As Fw < Fb , the gear pair is weaker in pitting failure,
For safety against pitting failure,
Fw = FOS Feff
1 - 8

Design of Machine Elements - II

Spur Gears
\

6149.3652 = 2 Feff

Feff

= 3074.6826 N

Now,

Feff

K a K m Ft
Kv

... (iii)

p dPnP
p m ZP n P
p 5 25 500
=
=
60
60
60

But,

V =

V = 3.2724 103 mm sec = 3.2724 m sec

Kv =

6
6
=
= 0.6470
6 + V 6 + 3.2724

... (Given)

K a = 1.75 and K m = 1
Substituting all these values in equation (iii),
\
\

3074.6826 =

1.75 1 Ft
0.6470

Ft = 1136.8975 N

... Ans.

Power transmitted by gear pair is,

P = Ft V = 1136.8975 3.2724
\

P = 3720.3835 W = 3.7203 kW

... Ans.

Example 1.24

Solution : Given data :

Z P = 22, Z G = 48, (S ut ) P = 800 MPa
(S ut ) G = 530 MPa, P = 7 kW = 7 103 W, n P = 1440 rpm
K a = 1.5,

BHN = 350, FOS = 2

b = 10 m, Assume K m = 1, K v =

6
6+ V

To find : Design a gear pair.

Step - 1 : Check whether gear is weaker or pinion is weaker
We know that,

and

s bP =

(S ut ) P
800
= 266.6666 MPa
=
3
3

s bG =

(S ut ) G
530
= 176.6666 MPa
=
3
3

Assuming 20 full-depth involute system,

\

YP = 0.484

2.865
ZP
1 - 9

Design of Machine Elements - II

Spur Gears
\

YP = 0.484

2.865
= 0.3537
22

Similarly,

YG = 0.484

2.865
ZG

YG = 0.484

2.865
= 0.4243
48

Now,

s bP YP = 266.6666 0.3537 = 94.32 MPa

and

s bG YG = 176.6666 0.4243 = 74.96 MPa

As s bG YG < s bP YP , gear is weaker than the pinion in bending. Therefore, it is required

to design a gear for bending.
Step - 2 : Calculate the beam strength of gear
Fb = s bG b m YG = 176.6666 10 m m 0.4243
\

Fb = 749.596 m 2 , N

... (i)

Step - 3 : Calculate the wear strength of gear pair

Fw = d P b Q K
But,

... (ii)

d P = m Z p = 22 m, mm
Q =

2 ZG
2 48
= 1.3714
=
ZG + Zp
48 + 22

For steel pinion and steel gear,

BHN
K = 0.16

100
\

K = 1.96 N mm 2

and

b = 10 m, mm

350
= 0.16

100

Substituting all these values in equation (ii),

\

Fw = 22 m 10 m 1.3714 1.96

Fw = 591.3476 m 2 , N

(iii)

As Fw < Fb , gear pair is weaker in pitting. Hence, it is required to design a gear pair
against the pitting failure.
Step - 4 : Calculate the effective load on gear pair
K a K m Ft
Feff =
Kv

(iv)

p dP nP
p 22 m 1440
=
60
60

But,

V =

V = 1.658 m 103 mm/sec. = 1.658 m, m/sec.

1 - 10

Design of Machine Elements - II

Spur Gears
Ft =
Kv =

P
7 103
4221.9541
,N
=
=
V
1.658 m
m
6
6
=
6 + V 6 + 1.658 m

K a = 1.5 and K m = 1

(Given)

Substituting all these values in equation (iv),

1.5 1
4221.9541

m
6

6 + 1.658 m

Feff

Feff

1055.4885 (6 + 1.658 m)
m

Feff

6332.9312 + 1750 m
m

(v)

Step - 5 : Calculate the value of module and other dimensions

For safety against bending failure,
Fb = FOS Feff
Substituting the values of equation (i) and (v),
6332.9312 + 1750 m
\ 749.5963 m 2 = 2

m
\

379.7981 m 3 = 6332.9312 + 1750 m

Solving the above cubic equation, we get

m = 3.1472 mm

(Neglecting negative values)

The standard value of module under first choice is 5 mm.

m = 4 mm
\
Other dimensions :
b = 10 m = 10 4 = 40 mm

Ans.

d P = m Z p = 4 22 = 88 mm
dG = m Z G = 4 48 = 192 mm
C. D. =

dP + dG
88 + 192
= 140 mm
=
2
2

h a = 1 m = 1 4 = 4 mm
hf

= 1.25 m = 1.25 4 = 5 mm

Ans.

Example 1.25

Solution : Given data : n G = 200 rpm, P = 7 kW = 7 10 3 W, n P = 800 rpm,

1 - 11

Design of Machine Elements - II

Spur Gears
C.D. = 300 mm, K a = 1.5, (S ut ) P = (S ut ) G = 700 N mm 2 ,
f = 20, FOS = 2
To find : i) Design a gear pair
iii) Feff and (FOS) bending

ii) Fd
iv) Surface hardness

Step - 1 : Calculate the beam strength of pinion

When pinion and gear are made of same material, at that time pinion is weaker than the
gear in bending. Hence, it is necessary to find beam strength of pinion.
Beam strength of pinion is,
Fb = s bP b m YP
But,
Assume,

s bP =

d P +d G
2

\ 300 =

d P +d G
2

600 = d P + d G
G =

(S ut ) P
700
=
= 233.333 N mm 2
3
3

b = 10 m
C.D. =

... (i)

... (a)

nP
d
= G
nG
dP

800 d G
=
200 d P

dG = 4 dP

... (b)

Solving equations (a) and (b),

d P = 120 mm
Now, Lewis form factor is,
YP = 0.484 -

and

d G = 480 mm
d

... Q m = P
ZP

2.87
2.87
= 0.484 ZP
(120 m)

2.87 m
120
Substituting all these values in equation (i),
2.87 m
\
Fb = 233.333 10 m m 0.484

120
\

YP = 0.484 -

Fb = 1129.3317 m 2 - 55.8054 m 3

... (ii)

As hardness of gear pair is unknown, we can't find wear strength of gear.

Step - 2 : Calculate the effective load on gear pair
K a K m Ft
Feff =
Kv

1 - 12

... (iii)

Design of Machine Elements - II

Spur Gears
p dP nP
p 100 800
=
60
60

But,

V =

V = 5.0265 103 mm sec = 5.0265 m sec

Ft =

P 7 103
=
= 1392.6057 N
V 5.0265

Kv =

3
3
=
= 0.3737
3 + V 3 + 5.0265

... (Q K v = Cv )

K a = 1.5 and Assume K m = 1

Substituting all these values in equation (iii),
\

Feff

1.5 1 1392.6057
= 5589.8007 N
0.3737

Step - 3 : Calculate the value of module and other dimensions

For safety against bending failure,

F b = FOS Feff
(1129.3317 m 2 - 55.8054 m 3 ) = 2 5589.8007
(1129.3317 m 2 - 55.8054 m 3 ) = 11.179 10 3
Solving the above cubic equation, we get
m = 3.5573 mm
... (Selecting smaller positive value)
Selecting standard value of module from the Table 6.1,
m = 4 mm
... Ans.
\
Other dimensions
b = 10 m = 10 4 = 40 mm
d P = 120 mm and dG = 240 mm
ZP =

dP
120
=
= 30
m
4

ZG =

dG
480
=
= 120
m
4

h a = 1m = 1 4 = 4 mm
hf

= 1.25 m = 1.25 4 = 5 mm

... Ans.

Step - 4 : Calculate the value of dynamic load by using Buckingham's equation

Buckingham's dynamic load is,
21 V (bC + Ft )
Fd =
21 V + bC + Ft
But,

... (iv)

b = 40 mm, Ft = 1392.6057 N, V = 5.0265 m sec

1 - 13

Design of Machine Elements - II

Spur Gears
Pitch error for grade 6,
e = 8 + 0.63 [m + 0.25 d ]

... (Given)

For pinion,

e p = 8 + 0.63 [m + 0.25 d P ]

e p = 8 + 0.63 [4 + 0.25 120] = 12.2453 mm

For gear,

e G = 8 + 0.63 [m + 0.25 d G ]

e G = 8 + 0.63 [4 + 0.25 480] = 13.9706 mm

But,

e = e P + e G = 12.2453 + 13.9706

e = 26.2249 mm = 26.2249 10-3 mm

Deformation factor, C = 11400 e

\

C = 11400 26.2249 10-3 = 298.9644 N mm

Substituting all these values in equation (iv),

21 5.0265 (40 298.9644 + 1392.6057)
21 5.0265 + 40 298.9644 + 1392.6057

Fd =

Fd = 6374.2505 N

... Ans.

Step - 5 : Calculate the effective load by precise estimation

Feff = Ft max + Fd = K a K m Ft + Fd
\

Feff

= 1.5 1 1392.6057 + 6374.2505

\
Feff = 8463.1591 N
For safety against bending failure,
Fb = FOS Feff
\

FOS =

... Ans.

Fb
Feff

But,

Fb = 1129.3317 m 2 - 55.8054 m 3

Fb = 1129.3317 (4) 2 - 55.8054 (4) 3 = 14.4977 103 N

... [From equation (ii)]

14.4977 103
8463.1591

FOS =

FOS = 2.0295

... Ans.

Step - 6 : Calculate the surface hardness for gears

Wear strength is given by,
Fw = d P b Q K
But,

... (v)

d P = 120 mm, b = 40 mm

1 - 14

Design of Machine Elements - II

Spur Gears
Q =

2 ZG
2 120
=
= 1.6
ZG + ZP
120 + 30

BHN 2
K = 0.16

100

... (Given)

Substituting all these value in equation (v),

\

BHN 2
Fw = 120 40 1.6 0.16

100

BHN 2
Fw = 1228.8
,N
100

For safety against pitting failure,

Fw = FOS Feff
BHN
\ 1228.8

100

= 2.0295 8463.1591

BHN = 373.8696

BHN 375

... Ans.

qqq

1 - 15

Design of Machine Elements - II

Helical Gears
Important Solved Examples

Example 2.13

Solution : Given data :

Z P = 20,
Z G = 40,
f n = 20,

a = 25,

m n = 3 mm

To find : i) m t and f t

ii) d P and d G iii) p a

Step - 1 : Calculate the transverse module and transverse pressure angle

We know that,
mt =

mn
3
= 3.3101 mm
=
cos a
cos (25)

tan f n = cos a tan f t

\

tan f t =

Ans.
[From equation (2.5)]

tan f n
tan (20)
= 0.4015
=
cos a
cos (25)

f t = 21.8802

Ans.

Step - 2 : Calculate the PCD of pinion and gear

Now,
d P = m t Z P = 3.3101 20
\

d P = 66.202 mm

Ans.

d G = m t Z G = 3.3101 40
\

dG = 132.404 mm

Step - 3 : Calculate the axial pitch

pt
p m t
p 3.3101
=
=
pa =
tan a
tan a
tan (25)
\

pa = 22.3006 mm

Ans.

Example 2.14

Solution :

Given data :
Z P = 20, Z G = 100, (S ut ) P = (S ut ) G = 600 MPa, f n = 20, m n = 4
2 - 1

Design of Machine Elements - II

Helical Gears
(BHN) P = (BHN) G = 300,

K a = 1.5,

FOS = 2,

a = 25

b = 40 mm, n P = 720 rpm,

To find : Power P
Step - 1 : Calculate the beam strength of pinion
When the pinion and gear are made of same material, at that time always pinion is
weaker than the gear in bending.
Beam strength of pinion is,
Fb = s bP b m n YP
s bP =
Z P =

(i)

(S ut ) P
600
= 200 MPa
=
3
3
ZP
cos 3 a

YP = 0.484

20
(cos 25) 3

= 26.8659

2.87
2.87
= 0.3771
= 0.484 26.8659
Z P

Substituting all these values in equation (i),

\
Fb = 200 40 4 0.3771
\

Fb = 12.0672 103 N

(ii)

Step - 2 : Calculate the wear strength of gear pair

dP b Q K
Fw =
cos 2 a
But,

d P = mt Z P =

(iii)

mn
4
ZP =
20 = 88.2702 mm
cos a
cos (25)

b = 40 mm
Q =

2 ZG
2 100
= 1.6667
=
ZG + ZP
100 + 20

BHN
K = 0.16

100
\

... (Given)

300
K = 0.16
= 1.44 N / mm 2
100

... (Selecting smaller value of BHN)

Substituting all these values in equation (i),

\

Fw =

88.2702 40 1.667 1.44

(cos 25) 2

= 10.3167 103 N

As Fw < Fb , gear pair is weaker in pitting than the bending. Therefore, it should be
designed for safety against pitting failure.
2 - 2

Design of Machine Elements - II

Helical Gears
Step - 3 : Calculate the power transmitting capacity of gear pair
Effective tooth load is,
K a K m Ft
Feff =
Kv

(ii)

p dP nP
p 88.2702 720
=
60
60

But,

V =

V = 3.3277 103 mm/sec = 3.3277 m/sec

Kv =

5.6
5.6
= 0.7542
=
5.6 + V
5.6 + 3.3277

K a = 1.5 and assuming, K m = 1

Substituting all these values in equation (i),
\

Feff

1.5 1 Ft
= 1.9888 Ft
0.7542

For safety against pitting failure,

Fw = FOS Feff
10.3167 103 = 2 1.9888 Ft
\

Ft = 2593.7104 N

Power transmitting capacity of gear pair is,

P = Ft V = 2593.7104 3.3277
\

P = 8.6310 10 3 W = 8.6310 kW

... Ans.

Example 2.15

Solution : Given data : P = 10 kW = 10 10 3 W, n P = 1000 rpm, n G = 500 rpm,

Z P = 18, C.D. = 180 mm, a = 26, b = 12 m n ,
f n = 20, s bP = s bG = 100 N / mm 2 , K a = 1.25,
K m = 1.1,

e = 40 mm = 40 10 -3 mm,

C = 11600 e N/mm

To find : i) (FOS) bending ii) (FOS) pitting

Step - 1 : Calculate the normal module of gear pair
nP
Z
Gear ratio
G =
= G
nG
ZP
\

ZG
1000
=
18
500

Z G = 36
2 - 3

Design of Machine Elements - II

Helical Gears
Centre distance is given by,
mn
C.D. =
(Z P + Z G )
2 cos a
mn
(18 + 36)
2 cos (26)

180 =

m n = 5.991 mm

mn

= 6 mm

Other dimensions
mt =

mn
6
= 6.6756 mm
=
cos a
cos (26)

d P = m t Z P = 6.6756 18 = 120.161 mm
dG = m t Z G = 6.6756 36 = 240.322 mm
b = 12 m n = 12 6 = 72 mm
h a = 1 m n = 1 6 = 6 mm
hf

= 1.25 m n = 1.25 6 = 7.5 mm

Step - 2 : Calculate the dynamic load by using Buckingham's equation

Buckingham's equation for dynamic load is,
Fd =

21 V [bC cos 2 a + Ft max ]

21 V + bC cos 2 a + Ft max

cosa

(Given) ... (i)

p dP nP
p 120.161 1000
=
60
60

But,

V =

V = 4.5299 103 mm/sec = 6.2916 m/sec

C = 11600 e = 11600 40 10 -3

... (Given)

C = 464 N/mm
Ft =

P
10 103
= 1589.4169 N
=
V
6.2916

Ft max = K a K m Ft = 1.25 1.1 1589.4169 = 2185.4483 N

Substituting all these values in equation (i),
21 6.2916 [72 464 (cos 26) 2 + 2185.4483]
Fd =
cos (26)
21 6.2916 + 72 464 (cos 26) 2 + 2185.4483
\

Fd = 12.7242 10 3 N

Effective load for precise estimation is,

\

Feff

= Ft max + Fd = 2185.4483 + 12.7242 10 3

Feff

= 14.9096 103 N
2 - 4

Design of Machine Elements - II

Helical Gears
Step - 3 : Calculate the beam strength and wear strength of gear pair
When the pinion and gear are made of same material, at that time always pinion is
weaker in bending.
Beam strength of pinion is,
Fb = s bP b m n YP
But,

... (ii)

s bP = 100 N / mm 2 , b = 72 mm, m n = 6 mm
Z P =

ZP
cos 3 a

YP = 0.484 -

18
(cos 26) 3

= 24.7908

2.87
2.87
= 0.3682
= 0.484 24.7908
Z P

Substituting all these values in equation (ii),

\

Fb = 100 72 6 0.3682 = 15.9062 103 N

Wear strength of gear pair is,

d b Q K
Fw = P
cos 2 a
But,

d P = 120.161 mm,
Q =

... (iii)
b = 72 mm

2 ZG
2 36
= 1.333
=
ZG + ZP
36 + 18

2
BHN 2
350
K = 0.16
= 0.16

100
100

... (Assume)

K = 1.96 N / mm 2
\
Substituting all these values in equation (iii),
\

Fw =

120.161 72 1.333 1.96

(cos 26) 2

= 27.9809 103 N

Step - 4 : Calculate the factor of safety against bending and pitting failure
For safety against bending failure,
Fb = (FOS) bending Feff
\ 15.9062 103 = (FOS) bending 14.4413 103
\ (FOS) bending = 1.0668

... Ans.

For safety against pitting failure,

Fw = (FOS) pitting Feff
\ 27.9809 103 = (FOS) pitting 14.9096 103
\

(FOS) pitting = 1.8767

... Ans.
2 - 5

Design of Machine Elements - II

Helical Gears
Example 2.16

Solution : Given data : P = 15 kW = 15 10 3 W, n P = 700 rpm, Z P = 35, Z G = 70,

f n = 20, a = 23, b = 35 mm, (S ut ) P = (S ut ) G = 650 N / mm 2
K a = 1.25,

FOS = 2.5,

C = 11400 e N/mm

To find : i) Normal module and other dimensions ii) Fb

iii) Fd

iv) Surface hardness

Step - 1 : Calculate the beam strength of pinion

When the pinion and gear are made of same material, at that time always pinion is
weaker in bending.
Beam strength of pinion is,
Fb = s bP b m n YP
(S ut ) P
650
But,
s bP =
=
= 216.666 N / mm 2
3
3
Z P =

ZP
cos 3 a

35
(cos 23) 3

... (i)

= 44.8734

Assume, Lewis form factor is,

YP = 0.484 -

2.87
2.87
= 0.42
= 0.484 44.8734
Z P

Substituting all these values in equation (i),

... (ii)
Fb = 200 40 m n 0.42 = 3185 m n , N
As surface hardness of gear pair is unknown, we cannot find the wear strength of gear
pair.

Step - 2 : Calculate the effective load on gear pair

K a K m Ft
Feff =
Kv

... (iii)

But,

V =

p d P NP
p mt Z P n P
p mn Z P n P
=
=
60
60
cos a 60

V =

p m n 35 700
= 1.3936 m n 103 , mm/sec
cos (23) 60

V = 1.3936 m n , m/sec
Ft =
Kv =

P
15 103
10.7634 103
,N
=
=
V 1.3936 m n
mn
5.6
5.6
=
5.6 + V 5.6 + 1.3936 m n
2 - 6

Design of Machine Elements - II

Helical Gears
K a = 1.5 and assuming K m = 1
Substituting all these values in equation (iii),
10.7634 103
1.5 1

mn
5.6

5.6 + 1.3936 m n

Feff

Feff

2883.0535(5.6 + 1.3936 m n )
mn

Feff

16.1451 103 + 4.0178 103 m n

mn

Step - 3 : Calculate the value of module and other dimensions

For safety against bending failure,
Fb = FOS Feff
\

16.1451 103 + 4.0178 103 m n

3185 m n = 2.5

mn

1274 m 2n = 16.1451 103 + 4.0178 103 m n

Solving the above quadratic equation, we get

m n = 5.4703 mm
Selecting the standard value of module,
\

mn

= 6 mm

... Ans.

Other dimensions
mt =

mn
6
= 6.5181 mm
=
cos a
cos (23)

d P = m t Z P = 6.5181 35 = 228.1356 mm
dG = m t Z G = 6.5181 70 = 456.2713 mm
C.D. =

d P +d G
228.1356 + 456.2713
= 342.2034 mm
=
2
2

h a = 1 m n = 1 6 = 6 mm
hf

= 1.25 m n = 1.25 6 = 7.5 mm

... Ans.

Substituting these values in equation (ii),

\

Fb = 3185 m n = 3185 6

Fb = 19.11 10 3 N

... Ans.

2 - 7

Design of Machine Elements - II

Helical Gears
Step - 4 : Calculate the dynamic load by using Buckingham's equation
Buckingham's equation for dynamic load is,
21 V [bC cos 2 a + Ft max ]
Fd =
cosa
21 V+ bC cos 2 a + Ft max

... (iv)

V = 1.3936 m n = 1.3936 6 = 8.36 m/sec

But,

b = 35 mm
Ft =

10.7634 103
10.7634 103
= 1793.9 N
=
mn
6

Ft max = K a K m Ft = 1.5 1 1793.9 = 2690.85 N

Now, pitch error for grade 6, e = 8 + 0.63 [m n + 0.25 d ]
For pinion,

e P = 8 + 0.63 [m n + 0.25 d P ]

e P = 8 + 0.63 [6 + 0.25 228.1356] = 14.1589 mm

For gear,

e G = 8 + 0.63 [m n + 0.25

e G = 8 + 0.63 [6 + 0.25 456.2713] = 15.14428 mm

dG ]

But,

e = e P + e G = 14.1589 + 15.14428

e = 29.3031 mm = 29.3031 10-3 mm

Deformation factor, C = 11400 e

\

... (Given)

C = 11400 29.3031 10-3 = 334.0553 N/mm

Substituting all these values in equation (iv),

21 8.6 [35 334.0553 (cos 23) 2 + 2690.85]

Fd =

Fd = 7684.7320 N

21 8.6 + 35 334.0553 (cos 23) 2 + 2690.85

cos (23)
... Ans.

Step - 5 : Calculate the surface hardness of gear pair

Wear strength of gear pair is,
d b Q K
Fw = P
cos 2 a
But,

... (v)

d P = 228.1356 mm, b = 35 mm
Q =

2 ZG
2 70
= 1.333
=
ZG + ZP
70 + 35

BHN 2
K = 0.16

100

... (Assume)

2 - 8

Design of Machine Elements - II

Helical Gears
Substituting all these values in equation (v),
BHN
228.1356 35 1.333 0.16

100

Fw =

BHN
Fw = 2009.8288
,N
100

(cos 23) 2
2

For safety against pitting failure,

Fw = FOS Feff
BHN
2009.8288

100

... (Q Feff = Ft max + Fd )

= 2.5 (2690.85 + 7684.7320)

BHN = 359.2499

BHN 360

... Ans.

Example 2.17

Solution : Given data : P = 150 kW = 150 10 3 W, n P = 1440 rpm, n G = 360 rpm,

C.D. 435 mm, a = 24, b = 14 m n ,
s bP = 152 N / mm 2 ,
K a = 1.53,

Z P = 20,

s bG = 125 N / mm 2 ,

e = 0.0406 mm,

f n = 20,

C = 11600 e N/mm

To find : (i) (FOS) bending (ii) Surface hardness, if FOS = 1.5

Step - 1 : Calculate the normal module of gear pair
nP
Z
Gear ratio
G =
= G
nG
ZP
\

ZG
1440
=
20
360

Z G = 80

Approximate centre distance is given by,

C.D.
\

435

mn

mn
(Z P + Z G )
2 cos a
mn
(20 + 80)
2 cos (24)

7.9478 mm

Considering the nearest standard value i.e.

m n = 8 mm
2 - 9

Design of Machine Elements - II

Helical Gears
Now, the exact centre distance is,
C.D. =
\

mn
8
(Z P + Z G ) =
(20 + 80)
2 cos a
2 cos (24)

C.D. = 437.8545 mm

Step - 2 : Calculate the effective load on gear pair

Effective load for precise estimation is,
Feff = Ft max + Fd = K a K m Ft + Fd ... (i)
But,

V =

p dP nP
p mt Z P n P
p mn Z P n P
=
=
60
60
cos a 60

V =

p 8 20 1440
= 13.2053 103 mm/sec
cos (24) 60

= 13.2053 m/sec
Ft =

P
150 103
=
= 11.359 103 N
V
13.2053

Ft max = K a K m Ft = 1.53 1 11.359 103

\

Ft max = 17.3793 103 N

... (Assuming K m = 1)

Dynamic load is given by,

Fd =

21 V [bC cos 2 a + Ft max ]

21 V+ bC cos 2 a + Ft max

cos a

But,

C = 11600 e

C = 11600 0.0406 = 470.96 N/mm

and

b = 14 m n = 14 8 = 112 mm

... (a = y)
... (Given)

21 13.2053 [112 470.96 (cos 24) 2 + 17.3793 103 ]

Fd =

Fd = 29.6227 103 N

21 13.2053 + 112 470.96 (cos 24) 2 + 17.3793 103

cos ( 24)

Substituting all these values in equation (i),

Feff

= 17.3793 103 + 29.6227 103 = 47 103 N

Step - 3 : Check whether gear is weaker or pinion is weaker

ZP
20
= 26.2342
=
Z P =
3
cos a
(cos 24) 3
and

ZG
=

ZG
cos 3 a

80
(cos 24) 3

= 104.9299
2 - 10

Design of Machine Elements - II

Helical Gears
By interpolation for 26.2342,
YP = 0.3456 +
\

(0.3487 - 0.3456) (26.2342 - 26)

(27 - 26)

YP = 0.3463

Similarly, by interpolation for 104.9299,

YG = 0.4461 +
\

(0.4587 - 0.4461) (104.9299 - 100)

(150 - 100)

YG = 0.4473

Now, s bP YP = 152 0.3463 = 52.6376 N / mm 2

and

s bG YG = 125 0.4473 = 55.9177 N / mm 2

As s bP YP < s bG YG , pinion is weaker than the gear in bending. Therefore, it is

required to design a pinion for bending.
Beam strength for pinion is,
Fb = s bP b m n YP = 152 112 8 0.3463
\

Fb = 47.1632 103 N

Step - 4 : Calculate the factor of safety against bending failure

For safety against bending failure,
Fb = (FOS) bending Feff
\

(FOS) bending =

Fb
47.1632 103
=
Feff
47 103

\ (FOS) bending = 1.0034

... Ans.

Step - 5 : Calculate the surface hardness of gear pair

Wear strength of gear pair is,
d b Q K
Fw = P
cos 2 a
But,

d P = mt Z P =

... (ii)

mn
8
ZP =
20 = 175.1418 mm
cos a
cos (24)

b = 112 mm
Q =

2 ZG
2 80
= 1.6
=
ZG + ZP
80 + 20

BHN
K = 0.16

100

... (Given)

Substituting all these values in equation (ii),

2 - 11

Design of Machine Elements - II

Helical Gears
BHN
175.1418 112 1.6 0.16

100

Fw =

BHN
Fw = 6017.1034

100

(cos 24) 2
2

For safety against pitting failure,

Fw
BHN
6017.1034

100

= FOS Feff
= 1.5 47 103

BHN

= 342.2952

or

BHN

345

... Ans.

qqq

2 - 12

Design of Machine Elements - II

Bevel Gears
Important Solved Examples

Example 3.14

Solution : Given data : Z P = 36 , Z G = 80, (S ut ) P = 700 N mm 2 ,

q = 90

(S ut ) G = 660 N mm 2 , P =10 kW = 10 103 W, n P = 1000 rpm

K a = 2, (BHN) P = (BHN) G = 300, FOS = 1.5
To find : Design the gear pair
Step - 1 : Check whether gear is weaker or pinion is weaker
We know that,

and

s bP =

(S ut ) P
700
=
= 233.3333 N mm 2
3
3

s bG =

(S ut ) G
660
=
= 220 N mm 2
3
3
ZP
36
=
ZG
80

tan g P =

\ g P = 24.2277

g G = q - g P = 90 - 24.2277 = 65.7723
Now,

Z P =

ZP
36
=
= 39.4770
cos g P
cos (24.2277)

and

Z G =

ZG
80
=
= 103.6431
cos g G
cos (65.7723)

Lewis form factor is,

and
New,

YP = 0.484 -

2.87
2.87
= 0.484 = 0.4112
39.4770
Z P

YG = 0.484 -

2.87
2.87
= 0.484 = 0.4563
103.6431
Z G

s bP YP = 233.3333 0.4112 = 95.9466 N mm 2

3 - 1

Design of Machine Elements - II

Bevel Gears
and

s bG YG = 220 0.4563 = 100.386 N mm 2

As s bP YP < s bG YG , pinion is weaker than the gear in bending. Therefore, it is required

to design a gear for bending.
Step - 2 : Calculate the beam strength of pinion
b
Fb = s bP b m YP 1 AO
But,

... (i)

s bP = 233.3333 N mm 2 , YP = 0.4112
d P = m Z P = 36 m, mm
d G = m Z G = 80 m, mm
AO =

(d P 2) 2 + (d G 2) 2 =

(36 m 2) 2 + (80 m 2) 2 = 43.8634 m, mm

b =

AO
or 10 m } whichever is smaller
3

b =

43.8634 m
or 10 m } whichever is smaller
3

b = 14.6211 m or 10 m } whichever is smaller

b 10 m, mm
\
Substituting all these values in equation (i),
\

10 m
Fb = 233.3333 10m m 0.4112 1 43.8634 m

Fb = 740.7268 m 2 , N

... (ii)

Step - 3 : Calculate the wear strength of gear pair

0.75 d P b Q K
Fw =
cos g P
But,

... (iii)

d P = 36 m, mm, b = 10 m, mm
Q =

2 Z G
2 103.6431
=
= 1.4483
103.6431 + 39.4770
Z G + Z P

BHN 2
300 2
K = 0.16
= 0.16
= 1.44 N mm 2
100
100

... (Given)

Substituting all these values in equation (iii),

0.75 36 m 10 m 1.4483 1.44
\
Fw =
cos (24.2277)
Fw = 617.1860 m 2 , N

... (iv)

As Fw < Fb , gear pair is weaker in pitting. Hence, it is required to design a gear pair
against the pitting failure.

3 - 2

Design of Machine Elements - II

Bevel Gears
Step - 4 : Calculate the effective load the gear pair can transmit
K a K m Ft
Feff =
Kv
But,

K a = 2 and Assuming
V =

... (v)

Km = 1

p dP np
p 36 m 1000
=
60
60

V = 1.8849 m 103 , mm sec = 1.8849m, m sec

Ft =

10 103
P
5.3051 103
=
=
,N
V 1.8849 m
m

As the gear pair is manufactured by generation, assuming

Kv =

6
6
=
6 + V 6 + 1.8849 m

Substituting all these values in equation (v),

21
5.3051 103

\
Feff =
m
6

6 + 1.8849m

Feff

1768.3666(6 + 1.8849m)
m

Feff

10.6102 103 + 3.3331 103 m

m

... (vi)

Step - 5 : Calculate the value of module and other dimensions

For safety against pitting failure,
Fw = FOS Feff
\
\

10.6102 103 + 3.3331 103 m

617.1860 m 2 = 1.5

3
3
3
925.779 m = 31.8306 10 + 10.0048 10 m

Solving the above equation by using trial and error method, we get
m = 4.32 mm
Selecting standard value of module from the given data,
m 5 mm
\
Other dimensions
b = 10 m = 10 5 = 50 mm

... Ans.

d P = m Z P = 5 36 = 180 mm
dG = m Z G = 5 80 = 400 mm
AO = 43.8634 m = 43.8634 5 = 219.317 mm
3 - 3

Design of Machine Elements - II

Bevel Gears
h a = 1 m = 1 5 = 5 mm
hf

= 1.25 m = 1.25 5 = 6.25 mm

... Ans.

Example 3.15

Solution : Given data : Z P = 30, Z G = 45, m = 6 mm, b = 50 mm,

(S ut ) P = (S ut ) G = 600 MPa
To find : i) Fb
Step - 1 : Calculate the beam strength of pinion
When both the pinion and gear are made of same material, pinion is always weaker than
the gear in bending. Hence, it is necessary to design the pinion for bending,
Beam strength for pinion is,
b
Fb = s bP b m YP 1 AO
But,

s bP =

... (i)

(S ut ) P
600
=
= 200 MPa
3
3

b = 50 mm, m = 6 mm
d P = m Z P = 6 30 = 180 mm
d G = m Z G = 6 45 = 270 mm
AO =
tan g P =

(d P 2) 2 + (d G 2) 2 =
ZP
30
=
ZG
45

(180 2) 2 + (270 2) 2 = 162.2498 mm

\ g P = 33.6900

g G = q - g P = 90 - 33.6900 = 56.3099
Now,

Z P =

ZP
30
=
= 36.0554
cos g P
cos (33.69)

and

Z G =

ZG
50
=
= 90.1387
cos g G cos (56.3099)

... (Assume q = 90)

Assume,

Y = 0.484 -

2.87
Z

YP = 0.484 -

2.87
2.87
= 0.484 = 0.4044
36.0554
Z P

Substituting all these values in equation (i),

50
\
Fb = 200 50 6 0.4044 1 162.2498
\

Fb = 16786.6410 N

... Ans.

3 - 4

Design of Machine Elements - II

Bevel Gears
Example 3.16

Solution : Given data : Z P = 24, Z G = 48, m = 6 mm, b = 50 mm,

(S ut ) P = (S ut ) G = 220 MPa, f = 20, n P = 300 rpm, K a = 1.5
(BHN) P = (BHN) G = 250, (FOS) bending = 2
To find : i) Fb

ii) Fw

iii) Ft

iv) P

Step - 1 : Calculate the beam strength of pinion

When both the pinion and gear are made of same material, pinion is always weaker than
the gear in bending. Hence, it is necessary to design the pinion for bending,
Beam strength for pinion is,
b
Fb = s bP b m YP 1 AO
But,

s bP =

... (i)

(S ut ) P
220
=
= 73.333 MPa
3
3

b = 50 mm, m = 6 mm
d P = m Z P = 6 24 = 144 mm
d G = m Z G = 6 48 = 288 mm
AO =
tan g P =

(d P 2) 2 + (d G 2) 2 =
ZP
24
=
ZG
48

(144 2) 2 + (288 2) 2 = 161 mm

\ g P = 26.565

g G = q - g P = 90 - 26.565 = 63.435
... (Assume q = 90)
Now,

Z P =

ZP
24
=
= 26.8328
cos g P
cos (26.565)

and

Z G =

ZG
48
=
= 107.3314
cos g G cos (63.435)

Assume,

Y = 0.484 -

2.87
Z

YP = 0.484 -

2.87
2.87
= 0.484 = 0.377
26.8328
Z P

Substituting all these values in equation (i),

50
\
Fb = 73.333 50 6 0.377 1 161

3 - 5

Design of Machine Elements - II

Bevel Gears
\

Fb = 5718.1976 N

... Ans.

Step - 2 : Calculate the wear strength of gear pair

0.75 d P b Q K
Fw =
cos g P
d P = 144 mm,

But,

Q =

... (ii)

b = 50 mm

2 Z G
2 107.3314
=
= 1.6
107.3314 + 26.8328
Z G + Z P

Assume,

BHN 2
K = 0.21

100

250 2
K = 0.21
= 1.3125 N mm 2
100

...(Gear pair is made of cast iron)

Substituting all these values in equation (ii),

0.75 144 50 1.6 1.3125
cos (26.565)

Fw =

Fw = 12.6784 10 3 N

... Ans.

Step - 3 : Calculate the maximum static load the gear can transmit
Effective load on gear pair is,
Feff
But,

K a = 1.5
V =

K a K m Ft
Kv
and

... (iii)
Km = 1

Assuming

p dP nP
p 144 300
=
60
60

V = 2.2619 103 mm sec = 2.2619 m sec

As the gear pair is manufactured by generation,

Kv =

5.6
5.6
=
= 0.7882
5.6 + V 5.6 + 2.2619

Substituting all these values in equation (iii),

Feff

1.5 1 Ft
= 1.903 Ft , N
0.7882

For safety against bending failure,

Fb = FOS Feff
\
\

5718.1976 = 2 1.903 Ft
Ft = 1502.4167 N

... Ans.
3 - 6

Design of Machine Elements - II

Bevel Gears
Step - 4 : Calculate the rated power the gear pair can transmit
Power transmitted by gear pair is,
P = Ft V = 1502.4167 2.2619
\

P = 3.3983 10 3 W = 3.3983 kW

... Ans.

Example 3.17

Solution : Given data : q = 90, Z P = 40, Z G = 65, f = 20 ,

(S ut ) P = (S ut ) G = 600 N mm 2
m = 3 mm, b = 35 mm
To find : i) Fb

ii) Fw

Step - 1 : Calculate the beam strength and wear strength of gear pair
When pinion and gear are made of same material, pinion is always weaker than the gear
in bending. Hence it is required to design the pinion for bending.
Beam strength of pinion is,
b
Fb = s bP b m YP 1
AO

... (ii)

d P = m Z P = 3 40 = 120 mm
d G = m Z G = 3 65 = 195 mm
But,

s bP =

(S ut ) P
600
=
= 200 N mm 2
3
3

b = 35 mm, m = 3 mm
AO =
tan g P =

(d P 2) 2 + (d G 2) 2 =
ZP
40
=
ZG
65

(120 2) 2 + (195 2) 2 = 114.4825 mm

\ g P = 31.6075

g G = q - g P = 90 - 31.6075 = 58.3925

Z P =

ZP
40
=
= 46.9671
cos g P
cos (31.6075)

Z G =

ZG
65
=
= 124.0227
cos g G
cos (58.3925)

YP = 0.484 -

2.87
2.87
= 0.484 = 0.4228
46.9671
Z P

3 - 7

Design of Machine Elements - II

Bevel Gears
Substituting all these values in equation (ii),
35
\
Fb = 200 35 3 0.4228 1 114.4825

Fb = 6164.3141 N

Ans.

Wear strength of gear pair is,

Fw =
But,

0.75 d P b Q K
cos g P

... (iii)

d P = 120 mm, b = 35 mm
Q =

2 Z G
2 124.0227
=
= 1.4506
124.0227 + 46.9671
Z G + Z P

BHN 2
300 2
K = 0.16
= 0.16
= 1.44 N mm 2
100
100

... (Given)

Substituting all these values in equation (iii),

0.75 120 35 1.4506 1.44
\
Fw =
cos (31.6075)
\

Fw = 7726.0109 N

Ans.

Example 3.18

Solution : Given data : q = 20 , Z P = 18, Z G = 36, q = 90

m = 8 mm, b = 40 mm, s bP = s bG = 73.33 MPa,
K a = 1.5, FOS = 2, n P = 500 rpm, (BHN) P = (BHN) G = 230
To find : i) Fb

ii) Fw

iii) Ft iv) P

Step - 1 : Calculate the beam strength of pinion

When both pinion and gear are made of same material, pinion is always weaker than the
gear in bending, hence, it is necessary to design the pinion for bending.
Beam strength of pinion is,
b
Fb = s bP b m YP 1
AO
But,

... (i)

s bP = 73.33 MPa, b = 40 mm, m = 8 mm

d P = m Z P = 8 18 = 144 mm
d G = m Z G = 8 36 = 288 mm
AO =
tan g P =

(d P 2) 2 + (d G 2) 2 =
ZP
18
=
ZG
36

(144 2) 2 + (288 2) 2 = 160.9968 mm

\ g P = 26.565
3 - 8

Design of Machine Elements - II

Bevel Gears
g G = q - g P = 90 - 26.565 = 63.435
\

Z P =

ZP
18
=
= 20.7246
cos g P
cos (26.565)

Z G =

ZG
36
=
= 80.4985
cos g G
cos (63.435)

YP = 0.484 -

2.87
2.87
= 0.484 = 0.3455
20.7246
Z P

Substituting all these values in equation (i),

40
\
Fb = 73.33 40 8 0.3455 1 160.9968
\

Fb = 6093.3765 N

... Ans.

Step - 2 : Calculate the wear strength of gear pair

0.75 d P b Q K
Fw =
cos g P
But,

d P = 144 mm,
Q =

... (ii)

b = 40 mm

2 Z G
2 80.4985
=
= 1.5905
80.4985 + 20.7246
Z G + Z P

Assume,

BHN 2
K = 0.21

100

230
K = 0.21
= 1.1109 N mm 2
100

... (Gear pair is made of cast iron)

Substituting all these values in equation (ii),

0.75 144 40 1.5905 1.1109
\
Fw =
cos (26.565)
\

Fw = 8.5338 10 3 N

... Ans.

As Fb < Fw , gear pair is weaker in bending than the pitting. Therefore it is necessary to
design a gear pair against bending.
Step - 3 : Calculate the maximum static load the gear can transmit
Effective load on gear pair is,
K a K m Ft
Feff =
Kv
But,

K a = 1.5
V =

and

... (iii)
Assuming

Km = 1

p dP nP
p 144 500
=
60
60

V = 3.7699 103 mm sec = 3.7699 m sec

3 - 9

Design of Machine Elements - II

Bevel Gears
Kv =

5.6
5.6
=
= 0.7425
5.6 + V
5.6 + 3.7699

Substituting all these values in equation (iii),

1.5 1 Ft
= 2.0200 Ft
\
Feff =
0.7425
For safety against bending failure,
Fb = FOS Feff
\

8.5338 = 2 2.0200 Ft

Ft = 1508.2029 N

... Ans.

Step 4 : Calculate the rated power the gear pair can transmit
Power transmitted by gear pair is,
P = Ft V = 1508.2029 3.7699
\

P = 5.6857 10 3 W = 5.6857 kW

... Ans.

qqq

3 - 10

Design of Machine Elements - II

Rolling Contact Bearings

Important Solved Examples

Example 4.34

Solution : Given data : Type of bearing = Single-row-deep groove ball bearing

L 05h = Rating life of bearing = 10000 hours
Sr. No.

Fraction of cycle

Radial load (Fr ) N

R.P.M.

1.

25%

3000 N

1440

2.

50%

5000 N

720

3.

25%

2500 N

1440

To find : i) Basic dynamic load capacity, C

Step - 1 : Equivalent dynamic (radial) load during first element, (Pe1 )
Pe = Fr 1 = 3000 N
1

Step - 2 : Revolutions of bearing during first element, (N1 )

L
60 n 1
N1 = 0.25 10h
106
= 0.25
or

L10h 60 1440
106

N1 = 0.0216 L10h million revolutions

Step - 3 : Equivalent dynamic (radial) load during second element, (Pe 2 )

Pe = Fr 2 = 5000 N
2

Step - 4 : Revolutions of bearing during second element, (N 2 )

L
60 n 2
N2 = 0.5 10h
106
= 0.5
or

L10h 60 720
106

N2 = 0.0216 L10h million revolutions

4 - 1

Design of Machine Elements - II

Rolling Contact Bearings

Step - 5 : Equivalent dynamic (radial) load during third element, (Pe 3 )
Pe = Fr 3 = 2500 N
3

Step - 6 : Revolutions of bearing during third element, (N 3 )

L
60 n 3
L
60 1440
= 0.25 10h
N3 = 0.25 10h
6
10
106
or

N3 = 0.0216 L10h million revolutions.

Step - 7 : Equivalent dynamic (radial) load during entire work cycle, (Pe )
Pe

N1 (Pe ) a + N2 (Pe ) a + N3 (Pe ) a

1
2
3
=

N1 + N2 + N3

1a

0.0216 L10h (3000) 3 + 0.0216 L10h (5000) 3 + 0.0216 L10h (2500) 3

=

0.0216L10h + 0.0216 L10h + 0.0216 L10h

or

13

Pe = 3823.0136 N

Step - 8 : Rating life of bearing, (L10 )

i) Rating life of bearing for 90% reliability, (L10h )
L10 = N1 + N2 + N3
= 0.0216 L10h + 0.0216 L10h + 0.0216 L10h
or
L10 = 0.0648 L10h
ii) Rating life of bearing for 90% reliability (L10h )
L 05h
L10h

1 1.17
log e (1 R 95 )
=
log e (1 R 90 )

1 1.17
10000
log e (1 0.95)
=
L10h
log e (1 0.90)

or

L10h = 18500.96 hours

L10 = 0.0648 L10h
= 0.0648 18500.96

or

L10 = 1198.8622 million revolutions

Step - 9 : Basic dynamic load capacity, (C)

a
C
L10 =
Pe
3
C

1198.8622 =
3823.0136

or

C = 40612.7376 N

... Ans.

4 - 2

Design of Machine Elements - II

Rolling Contact Bearings

Example 4.35

Solution : Given data :

Type of bearing = Single-row deep-groove ball bearing
L = Center distance between bearings = 100 mm
P = Power transmitted by shaft = 5 10 3 W
n = Speed of shaft = 3000 r.p.m.
Dg = Pitch diameter of gear pinion = 80 mm
f n = Normal pressure angle of gear pinion = 20
y = Helix angle of gear pinion = 19
L 05h = Rating lift of bearing at 95% reliability = 8000 hours
K a = Load application factor = 1.25
X = Radial load factor = 0.56
Y = Axial load factor = 1.2
To find :

i)

Basic dynamic load capacity at 90% reliability, C

Consider the power transmission through helical gear as shown in Fig. 4.1.
FtG
FrG
Bearing 'A'

FaG

Helical gear 'G'

Bearing 'B'

(a)
FtG
FrG

RAH
RAV
50 m

FaG

m
50 m

(b)

RBH
RBV

Fig. 4.1
4 - 3

Design of Machine Elements - II

Rolling Contact Bearings

Step - 1 : Radial load, (FrA and FrB )
i) Pitch line velocity of gear, (VG )
VG =
=
or

p Dg n
60 1000
p 80 3000
60 1000

VG = 12.5663 m/s

ii) Power transmitted by the gear, (P)

P = FtG VG
5 10 3 = FtG 12.5663
FtG = 397.8873 N

or

iii) Radial force by the gear, (FrG )

tan f n
FrG = FtG

cos y
tan 20
= 397.8873

cos 19
FrG = 153.1637 N

or

iv) Axial force by the gear, (FaG )

FaG = FtG tan y
= 393.8873 tan 19
or

FaG = 137.0035 N

v) Resultant load on the bearings, (R A and R B )

Refer Fig. 4.1 (b), considering moments about bearing 'A' in the vertical plane,
FtG 50 R BV 100 = 0
397.8873 50 - R BV 100 = 0
R BV = 198.9436 N

Refer Fig. 4.1 (b), considering moments about bearing 'B' in the vertical plane,
R AV 100 - FtG 50 = 0
R AV 100 - 397.8873 50 = 0

R AV = 198.9436 N
4 - 4

Design of Machine Elements - II

Rolling Contact Bearings

Refer Fig. 4.1 (b), considering moments about bearing 'A' in the horizontal plane,
FrG 50 - FaG 40 - R BH 100 = 0
153.1637 50 - 137.0035 40 - R BH 100 = 0
R BH = 21.7804 N

Refer Fig. 4.1 (b), considering moments about bearing 'B' in the horizontal plane,
R AH 100 - FrG 50 - FaG 40 = 0
R AH 100 - 153.1637 50 - 137.0035 40 = 0
R AH = 131.3832 N

Resultant radial load at bearing 'A'

RA =
=

(R AV ) 2 + (R AH ) 2
(198.9436) 2 + (131.3832) 2

R A = 238.4116 N

or

Resultant radial load at bearing 'B'

RB =
=

or

(R BV ) 2 + (R BH ) 2
(198.9436) 2 + (21.7804) 2

R B = 200.1323 N

Radial load on bearing 'A' = R A = FrA = 238.4116 N

Radial load on bearing 'B' = R B = FrB = 200.1323 N

Thrust (axial) load on bearing 'A' and 'B' = FaA = FaB = FaG = 137.0035 N

Step - 2 : Equivalent dynamic load, (Pe )

Bearing 'A' has more radial load as compared to bearing 'B', hence, selecting the
bearing based on load at 'A'.
Pe = (X V FrA + Y FaA ) K a
= (0.56 1 238.4116 + 1.2 137.0035) 1.25

or

Pe = 372.3933 N

Ans.

Step - 3 : Rating life of bearing, (L10 )

i) Life of bearing for 95% reliability, (L 05 )
L 05 =

L 05h 60 n
106
4 - 5

Design of Machine Elements - II

Rolling Contact Bearings

=
or

8000 60 3000
10 6

L 05 = 1440 million revolutions

ii) Life of bearing for 90% reliability, (L10 )

1 1.17
L 05
log e (1 R 95 )
=

L10
log e (1 R 90 )
1 1.17
1440
log e (1 0.95)
=
L10
log e (1 0.90)

L10 = 2664.1382 million revolutions

Step - 4 : Basic dynamic load capacity, (C)
C
L10 =
Pe

3
C

2664.1382 =
372.3933

or

C = 5162.4292 N

Ans.

Example 4.36

Solution : Given data :

Types of bearing = Single-row deep-groove ball bearing
n = Speed of shaft rotation = 1750 r.p.m.
Co = Basic static load capacity = 11600 N
C = Basic dynamic load capacity = 17600 N
L h = Life of bearing = 4000 hours
To find : i) Reliability of the bearing, (R)
Step - 1 : Radial and axial load factor, (X and Y)
The radial and axial load factor are obtained from the given information
Radial Axial load
load (Fr )
(Fa )

Fa Fr

Fa Co

Gear

4000 N

3250 N

0.8125

0.2801

0.3784

0.56

1.18

First gear

2750 N

500 N

0.1818

0.0431

0.2448

Second gear

2750 N

50 N

0.01818

4.31 10-3

< 0.22

Third gear

nil

nil

Fourth gear

4 - 6

Design of Machine Elements - II

Rolling Contact Bearings

Step - 2 : Equivalent dynamic (radial) load during first gear, (Pe1 )
Pe1 = (X1 V1 Fr1 + Y1 Fa1 ) K a
1

= (0.56 1 4000 + 1.18 3250) 1

or

Pe1 = 6075 N

Step - 3 : Revolutions of bearing during first gear, (N1 )

L
60 n 1
N1 = 0.01 10h
106
= 0.01
or

L10h 60 1750
106

N1 = 1.05 10-3 L10h million revolutions

Step - 4 : Equivalent dynamic (radial) load during second gear, (Pe 2 )

Pe = (X 2 V2 Fr2 + Y2 Fa 2 ) K a
2

= (1 1 2750 + 0) 1
or

Pe

= 2750 N

Step - 5 : Revolutions of bearing during second gear, (N 2 )

L
60 n 2
N2 = 0.03 10h
106
L
60 1750
= 0.03 10h
106
or

N2 = 3.15 10-3 L10h million revolutions

Step - 6 : Equivalent dynamic (radial) load during third gear, (Pe 3 )

Pe 3 = (X 3 V3 Fr3 + Y3 Fa 3 ) K a
= (1 1 2750 + 0) 1
or

Pe 3 = 2750 N

Step - 7 : Revolutions of bearing during third gear, (N 3 )

L
60 n 3
N3 = 0.21 10h
106
= 0.21
or

L10h 60 1750
106

N3 = 0.02205 L10h million revolutions

Step - 8 : Equivalent dynamic (radial) load during fourth gear, (Pe 4 )

Pe = (X 4 V4 Fr4 + Y4 Fa 4 ) K a
4

or

Pe

= 0 N

4 - 7

Design of Machine Elements - II

Rolling Contact Bearings

Step - 9 : Revolutions of bearing during fourth gear, (N 4 )
L
60 n 4
N4 = 0.75 10h
106
= 0.75

L10h 60 1750
106

N4 = 0.07875 L10h million revolutions

or

Step - 10 : Equivalent dynamic (radial) load during entire work cycle, (Pe )

Pe

N1 (Pe ) a + N 2 (Pe ) a + N 3 (Pe ) a + N 4 (Pe ) a

1
2
3
4

=
+
N
+
N
+
N
N
1
2
3
4

1a

=
1.05 10 -3 L 10h (6075) 3 + 3.15 10 -3 L 10h (2750) 3 + 0.02205 L 10h

(2750) 3 + 0.07875 L 10h (0) 3

1.05 10 -3 L

3
10h + 3.15 10 L 10h + 0.02205 L 10h + 0.07875 L 10h

or

13

Pe = 1933.9481 N

Step - 11 : Rating life of bearing, (L10 )

i) Rating life of bearing, (L10 )
C
L10 =
Pe

17600 3
=

1933.9481

or
L10 = 753.7086 million revolutions
ii) Actual revolutions completed by bearing during entire workcycle, (L a )
L h 60 n
4000 60 1750
=
La =
6
10
106
or

L a = 420 million revolutions

Step - 12 : Reliability of bearing, (R a )

1 1.17
La
log e (1 R a )
=
L10
log e (1 R 90 )
1 1.17
420
log e (1 R a )
=
753.7086
log e (1 0.90)

R a = 0.9380
or

R a = 93.80 %

... Ans.

4 - 8

Design of Machine Elements - II

Rolling Contact Bearings

Example 4.37

Solution : Given data :

Type of bearing = Single row deep groove ball bearing
L10h = Rating life of bearing = 10000 hours
X = Radial load factor = 1
Y = Axial load factor = 1.5
V = 1 (assumed)
To find :
i) Basic dynamic load capacity, C
Step - 1 : Equivalent dynamic (radial) load during first element, (Pe1 )
Pe1 = (X V Fr1 + Y Fa1 ) K a1 = (1 1 3500 + 1.5 1500) 3
or

Pe1 = 17250 N

Step - 2 : Revolutions of bearing during first element, (N1 )

L
60 n 1
0.35 10,000 60 550
=
N1 = 0.35 10h
6
106
10
or
N1 = 115.5 million revolutions
Step - 3 : Equivalent dynamic (radial) load during second element, (Pe 2 )
Pe2 = (X V Fr2 + Y Fa2 ) K a2 = (1 1 3300 + 1.5 1000) 2
or

Pe2 = 9600 N

Step - 4 : Revolutions of bearing during second element, (N 2 )

L
60 n 2
10,000 60 650
= 0.35
N2 = 0.35 10h
6
10
106
or
N2 = 136.5 million revolutions
Step - 5 : Equivalent dynamic (radial) load during third element, (Pe 3 )
Pe3 = (X V Fr3 + Y Fa3 ) K a3 = (1 1 2400 + 1.5 1000) 1.5
or

Pe3 = 5850 N

Step - 6 : Revolutions of bearing during third element, (N 3 )

L
60 n 3
N3 = 0.3 10h
106
10,000 60 750
= 0.3
106
or
N3 = 135 million revolutions
Step - 7 : Equivalent dynamic (radial) load for the entire work cycle, (Pe )
N (Pe1 ) a + N2 (Pe2 ) a + N3 (Pe3 ) a
Pe = 1

N1 + N2 + N3

4 - 9

1/a

Design of Machine Elements - II

Rolling Contact Bearings

or

Pe

115.5 (17250) 3 + 136.5 (9600) 3 + 135 (5850) 3

=

115.5 + 136.5 + 135

= 12415.5884 N

1/3

Step - 8 : Rating life of the bearing during the entire work cycle, (L10 )
L10 = N = N1 + N2 + N3
= 115.5 + 136.5 + 135
or

L10 = 387 million revolutions

Step - 9 : Basic dynamic capacity of the bearing, (C)

a
C
L10 =
Pe
3
C

387 =
12415.5884

or

C = 90476.8825 N

... Ans.

Example 4.38

Solution : Given data :

Types of bearing = Single-row deep-groove ball bearing
L = Length of shaft = 180 mm
n = Speed of shaft rotation = 4000 r.p.m.
L 05h = Rating life of bearing = 8000 hours
To find : i) Basic dynamic load capacity, (C)

Refer Fig. 4.2 for the various loads acting on the bearings
400 N
RAH

450 N

RAV

60 m

m
50 m

m
70 m

RBH

RBV

Fig. 4.2
Step - 1 : Radial load (FrA and FrB ) acting on the bearings

Refer Fig. 4.2, considering moments about bearing 'A' in the vertical plane,
400 60 - R BV 180 = 0

or

R BV = 133.3334 N
4 - 10

Design of Machine Elements - II

Rolling Contact Bearings

Refer Fig. 4.2, considering moments about bearing 'B' in the vertical plane,
R AV 180 - 400 120 = 0

or

R AV = 266.6667 N
Refer Fig. 4.2, considering moments about bearing 'A' in the horizontal plane,
450 110 - R BH 180 = 0

or

R BH = 275 N

Refer Fig. 4.2, considering moments about bearing 'B' in the horizontal plane,
R AH 180 - 450 70 = 0

or

R AH = 175 N
Resultant radial loud at bearing 'A'
FrA = R A =
=

or

(R AV ) 2 + (R AH ) 2
(266.6667) 2 + (175) 2

FrA = 318.9610 N

Resultant radial load of bearing 'B'

FrB = R B =
=

or

(R BV ) 2 + (R BH ) 2
(133.3334) 2 + (275) 2

FrB = 305.6187 N

Axial load on bearings 'A' and 'B' is zero.

Step - 2 : Load application factor, (K a )

K a = 1.5

(assumed)

Step - 3 : Equivalent dynamic load, (Pe )

At bearing 'A',
PeA = (X V FrA + Y FaA ) K a = (1 1 318.9610 + 0) 1.5
or

PeA = 478.4415 N

At bearing 'B'
PeB = (X V FrB + Y FaB ) K a = (1 1 305.6187 + 0) 1.5
or

PeB = 458.4280 N

We will consider designing the bearing 'B' as it has higher equvalent dynamic load.

4 - 11

Design of Machine Elements - II

Rolling Contact Bearings

Step - 4 : Rating life of bearing, (L10 )
i) Life of bearing for 95% reliability, (L 05 )
L 05 =
=
or

L 05h 60 n
106
8000 60 4000
10 6

L 05 = 1920 million revolutions

ii) Life of bearing for 90% reliability, (L10 )

1 1.17
L 05
log e (1 R 95 )
=
L10
log e (1 R 90 )
1 1.17
1920
log e (1 0.95)
=
L10
log e (1 0.90)

or

L10 = 3552.1843 million revolutions

Step - 5 : Basic dynamic load capacity, (C)

C
L10 =
Pe

3
C

3552.1843 =
458.4280

or

C = 6994.7087 N

Ans.

qqq

4 - 12

Design of Machine Elements - II

Worm Gears
Important Solved Examples

Example 5.21

Solution : Given data : As per designation of worm gear drive,

Z W = 2, Z G = 52, q = 10, m = 4 mm
Pi = 10 kW = 10 103 W, n W = 720 rpm, m = 0.04, f n = 20
To find : i) Components of tooth force
Step - 1 : Calculate the component of tooth force acting on the worm gear pair
d W = m q = 4 10 = 40 mm
d G = m Z G = 4 52 = 208 mm
ZW
2
tan l =
\ tan l =
q
10
\

l = 11.31
p dW nW
p 40 720
VW =
=
60
60
= 1.5079 10 3 mm sec = 1.5079 m sec
tan f v = m v =

m
cos f n

\ tan f v =

0.04
cos (20)

\
f v = 2.4374
Tangential force acting on the worm is,
Pi
10 103
FWt =
=
VW
1.5079
\
FWt = 6631.7395 N = FGa
Axial force acting on the worm is,
FWa =
\

... Ans.

FWt
6631.7395
=
tan (2.4374 + 11.31)
tan ( f v + l )

FWa = 27107.0102 N = FGt

... Ans.
5 - 1

Design of Machine Elements - II

Worm Gears
Radial force acting on the worm is,
tan l
tan f n

FWr = FWt
sin l
f
+
l
tan
tan

v
\

tan (11.31)
tan (20)
FWr = 6631.7395
tan (2.4374) + tan (11.31) sin (11.31)

FWr = 10147.9279 N = FGr

... Ans.

Example 5.22

Solution : Given data : As per designation of worm gear pair,

Z w = 1, Z G = 40, q = 10, m = 4 mm, (S ut ) G = 245 N mm 2
(S ut ) W = 700 N mm 2 , m = 0.04, f n = 20 , K = 0.825 N mm 2 , Ka = 1.25
To find : i) Pib

ii) Piw

Step-1 : Calculate the beam strength of worm gear

d W = m q = 4 10 = 40 mm
d G = m Z G = 4 40 = 160 mm
b = 2 m q + 1 or 0.73 d W } whichever is larger
\
\
\

Now,
But,

b = 2 4 10 + 1 or 0.73 40 } whichever is larger

b = 26.5329 or 29.2 } whichever is larger
b = 29.2 mm
d + dG
40 + 160
C.D. = W
=
= 100 mm
2
2
ZW
1
\ tan l =
tan l =
q
10
l = 5.7105
nW
Z
G =
= G
nG
ZW

1000 40
=
nG
1

n G = 25 rpm
(S ut ) G
245
s bG =
=
= 81.667 N mm 2
3
3
Fb = s bG b m Y cos l
2.87
2.87
Y = 0.484 = 0.484 = 0.4122
ZG
40

Fb = 81.667 29.2 4 0.4122 cos (5.7105)

Fb = 3.9128 103 N
5 - 2

Design of Machine Elements - II

Worm Gears
Step - 2 : Calculate the wear strength of worm gear
Fw = d G b K = 160 29.2 0.825
\

Fw = 3.8544 103 N

... (ii)

Step - 3 : Calculate the input power rating based on beam strength

K F
Feff = a Gt
Kv
VG =

p dG nG
p 160 25
=
= 0.2094 103 mm sec = 0.2094 m sec
60
60

Kv =

6
6
=
= 0.9662
6 + VG
6 + 0.2094

Feff =

1.25 FGt
= 1.2936 FGt
0.9662

But,

... (iii)

For safety against bending failure,

Fb = FOS Feff
\

3.9128 103 = 1 1.2936 FGt

FGt = 3.0246 103 N

Now, output power based on beam strength (Pob ) is,

Pob = FGt VG = 3.0246 103 0.2094 = 633. 3636W
cos a - m tan g
cos a + m cot g

Now,

h =

h =

h = 0.6984 = 69.84 %

... (Given) ... (a = f n and g = l )

cos (20) - 0.04 tan (5.7105)

cos f n - m tan l
=
1
cos f n + m cot l
cos (20) + 0.04
tan (5.7105)
... (iv)

Input power based on beam strength (Pib ) is,

\
\

h =

Pob
Pib

\ 0.6984 =

633.3636
Pib

Pib = 0.9068 10 3 W = 0.9068 kW

... Ans.

Step - 4 : Calculate the input power rating based on wear strength

For safety against pitting failure,
Fw = FOS Feff
\
\

3.8544 103 = 1 1.2936 FGt

... [From equation (ii) and (iii)]

FGt = 2979.5918N
5 - 3

Design of Machine Elements - II

Worm Gears
Now, output power based on wear strength (Pow ) is,
Pow = FGt VG = 2979.5918 0.2094 = 623.9265 W
Input power based on wear strength (Piw ) is,

Pow
Piw

623.9265
Piw

... [From equation (iv)]

Piw = 0.8933 10 3 W = 0.8933 kW

... Ans.

h =

\ 0.6984 =

Example 5.23

Solution : Given data : A = 0.25 m 2 , h = 25 W/m 2 C, DT = 45 C, Z w = 1, Z G = 40,

q = 10, m = 4 mm, n w = 1000 rpm, f n = 20 , m = 0.035.
To find : Pit
Step - 1 : Calculate the input power based on thermal consideration
tan l =

Zw
1
=
q
10

tan f v = m v =

\ l = 5.7105

m
cos f n

\ tan f v =

0.035
cos( 20)

\
f v = 2..1330
Efficiency of worm gear pair is,
h =
\

tan (5.7105)
tan l
=
tan( f v + l) tan (2.1330 + 5.7105)

h = 0.7259 = 72.59 %

Input power based on thermal consideration is,

Pit =
\

hADT 25 0.25 45
=
(1 h )
(1 0.7259)

Pit = 1.0260 10 3 W = 1.0260 kW

Ans.

Example 5.24

Solution : Given data : d W = 48 mm, d G = 190 mm, p a = 18 mm, f n = 20 ,

L = 18 mm, b = 40 mm, n W = 3700 rpm, s bG = 85 N mm 2 ,

K = 0.63N mm 2 , m = 0.03, h = 18 W m 2 C.
To find : i) Dimensions of worm gear pair
iii) Temperature rise

ii) Input power

iv) Is fan necessary ?

5 - 4

Design of Machine Elements - II

Worm Gears
Step - 1 : Calculate the dimensions of worm gear pair
L = p a ZW
18 = 18 Z W
\
\

ZW

= 1

... Ans.

pa = p m
\

18 = p m

m = 5.7295 mm 6 mm

... Ans.

d W = m q
\

48 = 6 q

q = 8

Ans.

d G = m Z G

190 = 6 Z G

ZG = 31.666 mm 32 mm

G =
\

... Ans.

nW
Z
= G
n G ZW

3700 32
=
nG
1

tan l =

n G = 115.625 rpm
tan l =

ZW
q

1
8

l = 7.125

... Ans.

Designation of worm gear pair, 1 32 8 6

... Ans.

C. D. =
LW

dW + dG
48 + 192
=
= 119 mm
2
2

... Ans.

Z
32

= p m 4.5 + G = p 6 4.5 + = 96.8867 mm

50
50

... Ans.

For l < 15,

h a = 1m = 1 6 = 6 mm
hf
mn

... Ans.

= 1.25 m = 1.25 6 = 7.5 mm

... Ans.

= m cos l = 6 cos (7.125) = 5.9536 mm

... Ans.

Step - 2 : Calculate the beam strength and wear strength of gear tooth
Fb = s bG b m Y cos l
But,

Y = 0.484 -

2.8
2.8
= 0.484 = 0.3965
ZG
32

Fb = 85 40 6 0.3965 cos (7.125)

Fb = 8026.1391 N

Similarly,

Fw = d G b K = 190 40 0.63

\
Fw = 6308 N
As Fw < Fb , gear pair is weaker in pitting. Hence, pitting failure is the design criterion.
5 - 5

Design of Machine Elements - II

Worm Gears
Step - 3 : Calculate the static load the worm gear can transmit
K a FGt
Feff =
Kv
p d G n G p 190 115.625
=
60
60

But,

VG =

VG = 1.1502 103 mm sec = 1.1502 m sec

Kv =

Feff

6
6
=
= 0.8391
6 + VG 6 + 1.1502
1 FGt
= 1.1917 FGt
0.8451

... (i)

For safety against pitting failure,

Fw = FOS Feff
\

6308 = 1 1.1917 FGt

FGt = 5293.2185 N

Step - 4 : Calculate the input power rating based on strength

Po = FGt VG = 5293.2185 1.1502 = 6088.2599 W
cos a - m tan g
... (Given) ... (a = f n and g = l )
cos a + m cot g
cos f n - m tan l cos (20) - 0.03 tan (7.125)
=
h =
1
cos f n + m cot l
cos (20) + 0.03
tan (7.125)

h =
\

\
But,
\

h = 0.7933 = 79.33 %
P
6088.2599
h = o
\ 0.8218 =
Pi
Pi
Pi

= 7673.8449 10 3 W = 7673.8449 kW

... Ans.

Step - 5 : Calculate the temperature rise of lubricating oil

Effective area of housing,
A = 9 10-5 (a)1.88
\

... (Given) (a = C. D. )

A = 9 10-5 (119)1.88 = 0.7182m 2

Total power loss in friction is,

Pf

= Power lost due to friction in teeth

Pf

= (Pi - Po )

Pf

= (6.4871 103 - 5.3311 103 )

Pf

= 1585.585 W
5 - 6

Design of Machine Elements - II

Worm Gears
This power loss in friction is equal to the rate of heat generated i.e.
Hg = Pf = 1585.585W

... (ii)

Temperature rise of lubricating oil with fan

Overall heat transfer coefficient with fan is,
h = 15.2 + 8.25 10- 3 n W

... (Given)

h = 15.2 + 8.25 10-3 3700 = 45.725 W m 2 C

Rate of heat dissipation is,

Hd = h A ( DT) = 45.725 0.7182 ( DT)
\

Hd = 32.8396 ( DT), W

But

Hg = Hd

\
\

... (iii)

1585.585 = 32.8396 ( DT)

( DT) with fan

... [From equations (ii) and (iii)]

= 48.2825 C

... Ans.

Temperature rise of lubricating oil without fan

Overall heat transfer coefficient without fan is,
h = 18 W m 2 C

... (Given)

Rate of heat dissipation is,

Hd = h A ( DT) = 18 0.7182 ( DT)
\

Hd = 12.9276 ( DT), W

But,

Hg = Hd

... (iv)

1585.855 = 12.9276 ( DT)

\ ( DT) without fan = 122.6511 C

As ( DT) without fan > 50 C, fan is necessary for effective dissipation of heat.

... Ans.
... Ans.

qqq

5 - 7

Design of Machine Elements - II

Belt, Rope and Chain Drives

Important Solved Examples

Example 6.26

Solution : Given data :

Type of drive = open type flat belt drive
P = power to be transmitted by belt = 30 103 W
n = speed of driving (small) pulley or electric motor = 1000 r.p.m.
N = speed of driven (big) pulley or pump = 500 r.p.m.
C = center distance between the shafts = 6000 mm
Refer an open type flat belt drive as shown in Fig. 6.1.
Step 1 :

(i)

Assume belt speed as V B = 17.8 m/s

(ii) Diameter of pulley (d)

Driving
pulley

For driving (small) pulley,

VB =
\
\

17.8 =

pd n
60 1000

p d 1000
60 1000

d = 339.9549 mm

Step 2 :

Fig. 6.1 : Open-type Flat Belt Drive

(i) Select nearest standard diameter of

pulleys
From the given standard pulley diameters,
selecting
d = 355 mm
Now,

Driven
pulley

Ans.

N
d
=
n
D

6 - 1

Design of Machine Elements - II

Belt, Rope and Chain Drives

\

500
355
=
1000
D

D = 710 mm
\
(ii) Actual belt speed (V B )
p 355 1000
p d n
=
= 18.58 m s
VB =
60 1000
60 1000
Step 3 : Load correction factor Fa = 1.2

Ans.

given

Step 4 : Design power (Pd )

Design power is given by,
Pd = Fa P
= 1.2 30 103
or

Pd = 36 103 W

Step 5 :
(i) Calculate angle of contact (q s )
D - d
- 1 710 - 355 = 1.6952
a = sin - 1
= sin
2 6000
2C

a = 1.6952 or a = 0.0295 rad

For open type flat belt,

q s = p - 2a = p - (2 0.0278) = 3.0824 rad
\
q s = 3.0824 rad or 176.6095
(ii) Angle of contact correction factor (Fd )
The angle of contact correction factor is obtained by interpolation from given data
Fd = 1.04 -

(1.04 - 1.00) (170 - 176.6095 )

(170 - 180 )

= 1.0135
Step 6 : Power Rating of belt (P.R.)
The power rating of belt per ply per mm width is,
P.R. = 0.023 103 W ply mm
This power rating is at angle of contact of 180 and belt speed of 10 m/s.
Step 7 : Modified power rating (P. R. ) M
Modified power rating is given by,

(P.R.) M =

6 - 2

V
(P.R)
B
Fd
10
Design of Machine Elements - II

Belt, Rope and Chain Drives

0.023 10 3
18.58

1.0135
10

= 0.04216 10 3 W ply mm
Step 8 : Product (Belt width Number of plies)

Belt width Number of plies =

Pd
(P.R.) M
36 10 3
0.04216 10 3

= 853.7932 ply-mm
Step 9 : Select standard width (b) and number of plies
We have, (Belt width Number of plies) = 853.7932

853.7932
= 213.44 mm
4
853.7932
belt width =
= 170.75 mm
5

For 4 plies,

belt width =

For 5 plies,
From the data given, selecting,
number of plies = 6

... Ans.

width of belt (b) = 180 mm

Ans.

Step 10 : Length of belt (L)

For open type flat belt drive,
p (D + d)
(D - d) 2
L = 2C +
+
2
4C
= 2 6000 +

p (710 + 355 )
(710 - 355 ) 2
+
2
4 4500

= 13678.45 mm
or

L = 13679 mm

Ans.

Example 6.27

Solution : Given data :

Type of drive = open type V-belt
PT = total power to be transmitted = 10 103 W

6 - 3

Design of Machine Elements - II

Belt, Rope and Chain Drives

n = speed of driving (small) pulley = 1440 r.p.m.
d = pitch diameter of driving (small) pulley = 200 mm
2f = groove angle of pulley = 34
m = coefficient of friction between belt and pulley = 0.2
m = mass of belt = 0.5 kg/m
Tmax = maximum allowable tension in belt = 500 N
q s = angle of contact for small pulley = 157 = 2.7401 rad
To find :
Driving
pulley

(i) Number of belts required (z)

Consider an open type V-belt drive as
shown in Fig. 6.2.

Driven
pulley
D

(i) Number of belts required (z)

The total power to be transmitted by

the belt system is given.

To calculate, number of belts

required, we need to calculate power
transmission capacity of each belt.
(1) Pitch line velocity of belt (V B )
p d n
VB =
60 100
=

Fig. 6.2 : Open-type V-Belt Drive

p 200 1440
= 15.0796 m s
60 1000

(2) Centrifugal tension (Tc )

Tc = m (VB ) 2
= 0.5 (16.96) 2
or
Tc = 113.6978 N
(3) Limited tension ratio
m q

Tft
= e sin
Tfs

0.2 2.7401

sin 17

= e
or

Tft
= 6.5168
Tfs

... (a)

6 - 4

Design of Machine Elements - II

Belt, Rope and Chain Drives

(4) Belt tension in tight side due to frictional effect (Tft )
We have

Tmax = Tft + Tc

500 = Tft + 113.6978

or

Tft = 386.3022 N

... (b)

(5) Belt tension in slack side due to frictional effect (Tfs )

Substituting equation (b) in equation (a), we get
Tft
= 6.5168
Tfs
or
or

386.3022
= 6.5168
Tfs
Tfs = 59.2778 N

(6) Power transmission capacity of each belt (P)

P belt = (Tft - Tfs ) VB
= (386.3022 - 59. 3778 ) 15.0796
= 4931.3956 W
(7) Number of belt required (z)
z =
=
or

Total power to be transmitted (PT )

Power transmission capacity of each belt (P)
10 103
= 2.02
4931.3956

z = 2

... Ans.

Example 6.28

Solution : Given data :

Type of drive = open type V-belt
z = number of belts = 1
d = pitch diameter of driving (small) pulley = 300 mm
D = pitch diameter of driven (big) pulley = 700 mm
n = speed of driving (small) pulley = 1000 r.p.m.
C = center distance between pulleys = 1000 mm
M = mass of belt per unit length = 0.5 kg/m
m = coefficient of friction between belt and pulley = 0.3
6 - 5

Design of Machine Elements - II

Belt, Rope and Chain Drives

2f = groove angle of pulley = 38
Tmax = maximum allowable tension in belt = 900 N
To find :
(i) Power transmitting capacity of belt (P)
(ii) Initial tension in the belt (Ti )
Consider an open type V-belt drive as shown in Fig. 6.3.
Driving
pulley

Driven
pulley
D

Fig. 6.3 : Open type V-belt drive

(i) Power transmitting capacity of belt (P)
(1) Angle of contact (q )

D - d
-1 700 - 300
a = sin -1
= sin
2 1000
2
C

\
For driving (small) V-belt :

a = 11.5369

qS
m q S

e sin f

Product
For driven (big) flat-belt :

or a = 0.2014 rad

= p - 2a = p - (2 0.2014) = 2.7388 rad

0.3 2.7388

sin 19

= e

= 12.4748

q B = p + 2a = p + (2 0.2014) = 3.5444 rad

em q B = e 0.3

Product

3.5444

= 2.8959

m qs
Since product e sin f
(em q B ) flat

V- belt
Hence design of belt is governed by flat pulley.
(2) Limiting tension ratio
Tft
= em q B
Tfs
= e 0.3
or

3.544

Tft
= 2.8959
Tfs

... (a)
6 - 6

Design of Machine Elements - II

Belt, Rope and Chain Drives

(3) Pitch line velocity of belt (V B )
p 300 1000
p d n
=
= 15.70 m s
VB =
60 1000
60 1000
(4) Centrifugal tension (Tc )
Tc = m (VB ) 2
= 0.5 (15.70) 2
or

Tc = 123.3700 N

(5) Belt tension in tight side due to frictional effect (Tft )

We have, Tmax = Tft + Tc
900 = Tft + 123.37
or

Tft = 776.6299 N

... (b)

(6) Belt tension in slack side due to frictional effect (Tfs )

Substituting equation (b) in equation (a), we get,
Tft
= 2.8959
Tfs
\
or

776.6299
= 2.8959
Tfs
Tfs = 268.1825 N

(7) Power transmitting capacity of belt (P)

P = (Tft - Tfs ) VB
= (776.6299 - 268.1825) 15.70
= 7982.6228 W
or

P = 7.982 kW

... Ans.

(ii) Initial tension in belt (Ti )

Ti =
=

Tft + Tfs + 2Tc

2
776.6299 + 268.1825 + (2 123.3700)
2

Ti = 645.7762 N

... Ans.

6 - 7

Design of Machine Elements - II

Belt, Rope and Chain Drives

Example 6.29

Solution : Given data :

m = coefficient of friction between belt and pulley = 0.3
2f = groove angle of pulley = 70
q = angle of contact = 160 or 2.7925 rad
To find : i) Percentage increase in power transmission
(i) Increase in power transmission by V-belt over flat belt
(1) Power transmission by flat belt (Pf )

Since the material, cross-sectional area and speed of both the belts are same, hence the
maximum tension (Ttt ) in both the drives will also be equal.
This implies that maximum tension on tight side due to frictional effect in both drives
will be equal.
For flat belt,
Limiting tension ratio,
Tft
= emq = e 0.3 2.7925
Tfs
or

Tft
= 2.3111
Tfs

or
Tfs = 0.4326 Tft
Power transmission capacity of flat belt, (Pf )
Pf = (Tft - Tfs ) VB
= (Tft - 0.4326 Tft ) VB
or

Pf

= 0.5673 Tft VB

(a)

(2) Power transmission by V-belt (Pv )

For V-belt drive,
Limiting tension ratio,
m q
f

Tft
= e sin
Tfs
or

0. 3 2.7925
e sin 35

Tft
= 4.3084
Tfs

or
Tfs = 0.2321 Tft
Power transmission capacity of V-belt drive (Pv )
Pv = (Tft - Tfs ) VB
= (Tft - 0.2321 Tft ) VB
or

Pv = 0.7678 Tft VB
6 - 8

Design of Machine Elements - II

Belt, Rope and Chain Drives

(3) Percentage increase in power transmission of V-belt over flat belt drive
P - Pf
% increase in power = v
100
Pf
=

0.7678 Tft VB - 0.4326 Tft VB

0.4326 Tft VB

= 0.7748
or

% increase in power = 77.48 %

... Ans.

Example 6.30

Solution : Given data : t = 12 mm, b = 300 mm, Ratio of friction tensions = 2.4,
2
3
3
g/mm

s t per = 2 MPa = 2 N/mm , r = 1.1 10

To find : Maximum power to be transmitted (Pmax)

Step - 1 : The maximum tension in tight side of belt should equal belt strength
\

Tmax = Ttt = s t

per

b t = 2 300 12

Ttt = 7200 N

Step - 2 : Calculate the velocity of belt (VB)

i) Centrifugal tension (Tc )
T
7200
= 2400 N
Tc = tt =
3
3
ii) Tension in tight side of belt due to belt friction (Tft )
\

Ttt = Tft + Tc
Tft = 4800 N

We have,

Tc = m (VB ) 2 = (Density Volume) (VB ) 2

Tc =

\
\

(r

7200 = Tft + 2400

b t) (VB ) 2

2400 = (1100

300
12
) (VB ) 2

1000 1000

VB = 24.6182 m/s

Step 3 : Calculate maximum power transmitted by belt (Pmax)

i) Tension in slack side of belt due to belt friction (Tfs )
We have,
Tft
= em q
Tfs

4800
= 2.4
Tfs

Tfs = 2000 N

ii) Maximum power transmitted by belt (Pmax )

Pmax = (Tft - Tfs ) (VB ) = (4800 - 2000) (24.6182)
\

Pmax = 68930.96 W = 68.930 kW

6 - 9

Ans.
Design of Machine Elements - II

Belt, Rope and Chain Drives

Example 6.31

Solution : Given data : N = 90 r.p.m., P = 10.5 kW = 10.5 103 W,

b = 11.5 cm = 115 mm, t = 12 mm, n = 225 r.p.m., d = 60 cm = 600 mm,
C = 2.75 m = 2750 mm, m = 0.25

To find : Stress in belt (s t per )

Step - 1 : Calculate speed ratio (S.R)
N d
90
600
=
=
S.R =
\
n
D
225
D
\

D = 1500 mm

Step - 2 : Calculate the actual belt speed (VB)

pd n
p 600 225
=
= 7.0685 m/s
VB =
60 1000
60 1000
Step - 3 : Calculate power transmitted by the belt
P = (Tft Tfs ) VB \ 10.5 103 = (Tft Tfs ) 7.0685
\

Tft Tfs = 1485.4461 N

(a)

Step - 4 : Calculate the angle of contact

D- d
1500 - 600
a = sin -1
= sin -1
= 9.4180 = 0.1643 rad
2C
2 2750
q s = p - 2 a = p - ( 2 0 . 1463) = 2.8128 rad
Step - 5 : Calculate limiting tension ratio
Tft
= em q = e 0 . 25 2 . 8128 = 2.0202
Tfs
\

Tft = 2.0202 Tfs

(b)

Step - 6 : Calculate tensions in belt due to belt friction (Tft) an (Tfs)

Substituting equation (b) in equation (a)
Tft + Tfs = 1485.4461 \ 2.0202 Tfs + Tfs = 1485.4461
\
\

3.0202 Tfs = 1485.4461

Tfs = 491.8324 N

Tft = 2.0202 Tfs = 993.5998 N

Step - 7 : Calculate Stress in the belt

i) Centrifugal tension (Tc)
Assuming density of the belt r = 0 (As belt is weightless)
Tc = 0
ii) Total tension in tight side of belt (Ttt)
Ttt = Tft + Tc = 993.5998 + 0 = 993.5998 N
6 - 10

Design of Machine Elements - II

Belt, Rope and Chain Drives

iii) Maximum tensile stress in the belt (s t per )
s t per =

993 5998
Ttt
= 0.7199
=
115 12
bt
2

s t per = 0.7199 N/mm

Ans.

Example 6.32

Solution : Given data :

Type of drive = Open type flat belt, n = 600 r.p.m., N = 220 r.p.m.,
P = 10 kW = 10000 W, C = 1.25 m = 1250 mm, d = 250 mm, m = 0.25,
2

s t per = 2.5 N/mm , r = 0.001 gm/mm = 1000 kg/m , t = 12 mm

To find : Width of the belt (b)

Step - 1 : Speed ratio (S.R)
S.R =
\

N d
=
n
D

220 250
=
600
D

D = 681.8181 mm

Step - 2 : Calculate the width of belt (b)

i) Actual belt speed (VB)
p 250 600
p d n
= 7.8539 m/s
=
VB =
60 1000
60 1000
ii) Power to be transmitted by belt (P)
P = (Tft Tfs) VB
10,000 = (Tft Tfs) 7.8539
\
Tft Tfs = 1273.2527
\
iii) Angle of contact (q s )
D- d
681 . 8181 - 250
a = sin -1
= sin -1

2 1250
2C

(a)

\
a = 9.9464 or a = 0.1735 rad
For open type belt drive,
q s = p - 2 a = p 2(0.1735) = 2.7945 rad
iv) Limiting tension ratio
Tft
= em q = e 0 . 25 2 .7945 = 2.0109
Tfs
Tft = 2.0109 Tfs N
\
v) Tension in belt due to belt friction (Tft) and (Tfs)

(b)

Substituting equation (b) in equation (a),

Tft Tfs = 1273.2527

2.0109 Tfs Tfs = 1273.2527

6 - 11

Design of Machine Elements - II

Belt, Rope and Chain Drives

Tfs = 1259.5238 N
and

Tft = 2.0109 Tfs = 2.0109 1259.5238 = 2532.7764 N

vi) Centrifugal tension (Tc)

Tc = m (VB)

= (Density Volume) VB2

b
t
= r

1 VB2
1000 1000
b
12
2
Tc = 1000

1 7.8539 = 0.7402 (b) N

1000 1000

vii) Total tension in tight side of belt (Ttt)

Ttt = Tft + Tc
Ttt = 2532.7764 + 0.7402 (b)
viii) Maximum tensile stress in the belt (s t per )
s t per =
\
\
\

Ttt
b t

2.5 =

2532 . 7764 + 0.7402 ( b)

(b) 12

30 (b) = 2532.7764 + 0.7402 (b)

29.2598 (b) = 2532.7764
b = 86.5616 mm = 87 mm

Ans.

qqq

6 - 12

Design of Machine Elements - II

Sliding Contact Bearing

Important Solved Examples

Example 7.16

Solution : Given data :

d = Diameter of shaft (journal) = 60 mm
l = Length of bearing = 30 mm
n s = Speed of journal = 1000/60 r.p.s.
e = Eccentricity = 30 10-3 mm
c = Radial clearance between journal and bearing = 40 10 -3 mm
m = Absolute or dynamic viscosity of fluid = 0.030 10-6 N -s mm 2
Step - 1 : Velocity at surface of journal, (U)
U = p d n s
= p 60
or

1000
60

U = 3141.5926 mm s

Step - 2 : Eccentricity ratio, ()

e
=
c
=
or

30 10-3
40 10-3

= 0.75

Step - 3 : Type of bearing

Length to diameter ratio,
l
30
=
= 0.5
d
60
Since (l/d) ratio is equal to 0.5, the journal bearing is considered as infinitely short
hydrodynamic journal bearing.

7 - 1

Design of Machine Elements - II

Sliding Contact Bearing

Step - 4 : Load carrying capacity, (W)

W =

p m U l3
4c 2

(1- 2 ) 2

16

2
- 1 + 1
2
p

p 0.030 10 -6 3141.5926 (30) 3

4 (40

10 -3 ) 2

0.75
(1 -

0.75 2 ) 2

16

0.75 2
- 1 + 1
p2

= 5925.9136 N
or W = 5.9259 kN

.. Ans.

Step - 5 : Flow rate of lubricant, (Q s )

Qs = U c l
= 3141.5926 (40 10-3 ) 0.75 30
= 2827.4333 mm 3 s
= 2827.4333 10-9 103 60 l min
Q s = 0.1696 l min

or

... Ans.

Example 7.17

Solution : Given data : W = 50 10 3 N, n s = 1440/60 r.p.s., d = 100 mm, l = 100 mm,

c = 0.12 mm, m = 16 10 - 9 N-s mm 2

To find :

(i)

Coefficient of friction, (f)

(ii) Power lost in friction, (Pf )

(iii) Minimum oil-film thickness, (h o )

Step - 1 : Load per unit projected area, (p)
50 103
W
=
p =
l d
100 100

or

p = 5 N mm 2

Step - 2 : Sommerfeld number, (S)

r 2 m n s 50 2
1440
1
S =

16 10- 9
=
c p 0.12
60
5
or

S = 0.0133

Step - 3 : Dimensionless parameters

Refer Table 7.4, we get the following information :

7 - 2

Design of Machine Elements - II

Sliding Contact Bearing

S

l
d

(ho c)

r
c f

0.0133

0.0726

0.8403

Step - 4 : Co-efficient of fluid friction, (f)

For (l/d) = 1 and For (l/d) = 1 and
S = 0.0188
S = 0.00474

For (l/d) = 1 and S = 0.0133

ho
c

0.1

0.03

(h o c) 0.1
0.1 0.3
=
0.01333 0.00474
0.0188 0.00474
ho
= 0.0726
c

r
f
c

1.05

1.70

(r c) 1.70
1.05 1.70
=
0.00133 0.00474
0.0188 0.00474
r
f = 0.8403
c

r f = 0.8403
c
\

50 f = 0.8403
0.12
f = 2.0167 10 3

or

Ans.

Step - 5 : Power lost in friction, (Pf )

2.0167 10 3 50 10 3 50
(2 p n s ) (f W r)
1440
= 2p
Pf =

60
106
10 6
or

Pf

= 0.76 kW

Ans.

Step - 6 : Minimum oil-film thickness, (h o )

h o = 0.0726

c
ho
= 0.0726
0.12

h o = 0.008712 mm

or

Ans.

Exmaple 7.18

Solution : Given data : m = 50 mm, d = 50 mm, W = 7.5 kN = 7.5 10 3 N,

h s = 4500/60 r.p.s., c = 0.1 mm, m = 30 10 9 N - s mm 2 , r = 0.86, Cp = 2.09 kJ/kgC

To find :

(i) h o , (ii) f, (iii) Pf , (iv) Q, (v) Q s , (vi) Tavg

Step - 1 : Load per unit projected area, (p)
W
p =
l d
7 - 3

Design of Machine Elements - II

Sliding Contact Bearing

=

7.5 103
50 50

p = 3 N / mm 2

or

Step - 2 : Sommerfeld number, (S)

r 2 mn s
S =

c p
25
=
0.1
or

4500
1
30 10- 9

60
3

S = 0.046

Step - 3 : Dimensionless parameters

We have,
l
50
=
=1
d
50
and

S = 0.046

Refer Table 7.4, we get the following information

For ( l / d) = 1 and

For ( l / d) = 1 and

S = 0.121

S = 0.0446

For ( l / d) = 1 and S = 0.046

ho

c

0.4

0.2

(h0 / c) - 0.2
0.4 - 0.2
=
0.046 - 0.0446 0.121 - 0.0446
ho
= 0.2036
c

r
f
c

3.22

1.70

r
c f - 1.70

3.22 - 1.70
=
0.046 - 0.0446 0.121- 0.0446
r
f = 1.7278
c

r c ns l

4.33

4.62

- 4.33

r c ns l
4.62 - 4.33
=
0.121- 0.0446
0.121- 0.046
Q
= 4.6146
r Cnsl

Qs
Q

0.680

0.842

(Qs / Q) - 0.680
0.842 - 0.680
=
0.121- 0.0446
0.121- 0.0446
Qs
= 0.8390
Q

Step - 4 : Minimum oil-film thickness, (h o )

ho
= 0.2036
c
7 - 4

Design of Machine Elements - II

Sliding Contact Bearing

ho
= 0.2036
0.1
h o = 0.02036 mm
or

h o = 20.36 microns

... Ans.

Step - 5 : Coefficient of fluid friction, (f)

r f = 1.7278
c
25 f = 1.7278
0.1
or

f = 0.006911

... Ans.

Step - 6 : Power lost in friction, (Pf )

(2 p n s ) (f W r)
Pf =
106
=
or

Pf

2 p 4500
0.006911 75 103 25

60
10 6

= 0.6165 kW

... Ans.

Step - 7 : Total flow rate of lubricating oil, (Q)

Q
= 0.8390
r c ns l
Q
= 0.8390
4500
25 0.1
50
60
Q = 43261.875 mm 3 / s
= 43261.875 10-9 60 m 3 / min
= 43261.875 10-9 60 103 lit/min
or

Q = 2.5957 lit/min

... Ans.

Step - 8 : Side leakage of lubricating oil, (Q s )

Qs
= 0.8390
Q
Qs
= 0.8390
2.5957
Q s = 2.1778 lit/min

... Ans.

Step - 9 : Temperature rise of lubricant, ( DT)

Neglecting effect of side leakage,
DT =

(2 p n s ) (f W r)
103
r Q Cp

7 - 5

Design of Machine Elements - II

Sliding Contact Bearing

4500
0.00691 7.5 103 25
= 2 p
103

60
860 43261.875 2.09
DT = 7.85 C

or

Ans.

Step - 10 : Average temperature of lubricant, (Tavg )

DT
Tavg = T1 +
2
= 30 +

7.85
2

Tavg = 33.92 C

or

... Ans.

Example 7.19

Solution : Given data : W = 15 10 3 N, n s = 1000/60 r.p.s., l d = 1, e = 0.03 mm,

c = 0.04 mm, l = 100 mm, r = 0.86, C p = 2.09 kJ/kgC
To find :

(i)

Minimum oil-film thickness, ( h o )

(ii) Coefficient of friction, (f)

(iii) Power lost in friction, (Pf )
(iv) Absolute viscosity of lubricating oil, (m )
(v) Total flow rate of lubricating oil, (Q)
(vi) Side leakage of lubricating oil, (Q s )
(vii) Average temperature of lubricating oil, (Tavg )
Step - 1 : Eccentricity ratio, ()
e 0.03
=
= 0.75
=
c 0.04
Step - 2 : Dimensionless parameters
l
We have,
= 1
d
and

ho

c

= 0.75
For (l d ) = 1

For (l d ) = 1

and = 0.6

and = 0.8

0.4

0.2

7 - 6

For (l d ) = 1
and = 0.75
(ho c) - 0.2 0.4 - 0.2
=
0.8 - 0.75
0.8 - 0.6
ho
= 0.25
c

Design of Machine Elements - II

Sliding Contact Bearing

r
c f

3.22

1.70

r
c f - 1.70

3.22 - 1.70
=
0.8 - 0.75
0.8 - 0.6
r
f = 2.08
c

0.121

0.0446

S - 0.0446
0.121 - 0.0446
=
0.8 - 0.75
0.8 - 0.6
S = 0.0637

Q
r c ns l

4.33

4.62

Q
- 4.33

r c ns l
4.62 - 4.33
=
0.75 - 0.6
0.8 - 0.6
Q

r c n l = 4.5475

Qs
Q

0.680

0.842

(Qs Q) - 0.680
0.842 - 0.680
=
0.75 - 0.6
0.8 - 0.6
Qs
= 0.8015
Q

Step - 3 : Minimum oil-film thickness, (h o )

ho
= 0.25
c
ho
= 0.25
0.04
h o = 0.01 mm
or

h o = 10 microns

Ans.

Step - 4 : Coefficient of fluid friction, (f)

r f = 2.08
c
100 2

f = 2.08
0.04
or

f = 0.001664

Ans.

Step - 5 : Power lost in friction, (Pf )

0.001664 15 103 (100 2)
(2 p n s ) (f W r)
= (2 p 1000 60)
Pf =
106
106
or

Pf

= 0.1306 kW

Ans.

Step - 6 : Load per unit projected area, (p)

W
15 103
=
p =
l d 100 100
or

p = 1.5 N mm 2
7 - 7

Design of Machine Elements - II

Sliding Contact Bearing

Step - 7 : Absolute viscosity of lubricating oil, (m)
We have Sommerfeld number as,
r
S =
c

m n s

100 2
0.0637 =

0.04

1000
1
m

60
1.5

m = 3.6691 10- 9 N-s mm 2

m = 3.6691 cP

or

Ans.

Step - 8 : Total flow rate of lubricating oil, (Q)

= 4.5475

l
r
c
n

s
Q
= 4.5475
(100 2) 0.04 (1000 60) 100
Q = 15158.3333 mm 3 s
= 15158.3333 10 - 9 60 m 3 min
= 15158.3333 10 - 9 60 10 3 lit/min
or

Q = 0.9095 lit/min

Ans.

Step - 9 : Side leakage of lubricating oil, (Q s )

Qs
= 0.8015
Q
Qs
= 0.8015
0.9095
Q s = 0.7289 lit/min

Ans.

Step - 10 : Temperature rise of lubricant, ( DT)

Neglecting effect of side leakage,
DT =

=
or

(2 p n s ) (f W r)
103
r Q Cp
2p (1000 60) 0.001664 15 103 (100 2)
103
860 15158.3333 2.09

DT = 4.7967 C

Step - 11 : Average temperature of lubricating oil, (Tavg )

4.7967
DT
= 30 +
Tavg = T1 +
2
2
or

Tavg = 32.3983 C

Ans.
7 - 8

Design of Machine Elements - II

Sliding Contact Bearing

Example 7.20

Solution : Given data :

d = Journal diameter = 60 mm
n s = Journal speed = 1000/60 r.p.s.
l = Bearing length = 60 mm
m = 20 10- 9 N-s mm 2
To find :

(i)

Radial load on bearing, (W)

(ii) Total flow rate of lubricating oil, (Q)

Step - 1 : Minimum oil-film thickness, (h o )
The minimum oil-film thickness in this case is given by,
h o = 5 (1.6 + 0.8) = 12 microns
or

h o = 0.012 mm

Step - 2 : Radial clearance, (c)

Refer BIS standards, for the class of fit H8d8, the limits for the hole and shaft
are :
Hole limits : (60 + 0.000) and (60 + 0.039) mm
Shaft limits : (60 0.119) and (60 0.080) mm

When the process of manufacturing is centered,

0.000 + 0.039
Average diameter of bearing, (Davg ) = 60 +
= 60.0195 mm

2
- 0.119 - 0.080
Average diameter of journal, (d avg ) = 60 +
= 59.9005 mm

2
Davg - d avg
60.0195 - 59.9005
=
2
2
c = 0.0595 mm

Radial clearance, c =
or

Step - 3 : Dimensionless parameters

and

We have,

l
60
=
=1
d
60

ho
0.012
=
= 0.2017
c
0.0595

7 - 9

Design of Machine Elements - II

Sliding Contact Bearing

Refer Table 7.4, we get the following information :

For (l d) = 1

For (l d) = 1

and (ho c) = 0.2

and (ho c) = 0.4

0.0446

0.121

For (l d) = 1
and (ho c) = 0.2017
S - 0.0446
0.121 - 0.0446
=
0.2017 - 0.2
0.4 - 0.2
S = 0.04525

r c ns l

4.62

4.33

- 4.33

r c ns l
4.62 - 4.33
=
0.4 - 0.2
0.4 - 0.2017
Q

= 4.6175

r c ns l

Step - 4 : Load per unit projected area, (p)

We have Sommerfeld number as,
r
S =
c

m n s

30 2
1000
1
0.04525 =

20 10- 9
0.0595
60
p

p = 1.8727 N mm 2
Step - 5 : Radial load on bearing, (W)
We have load per unit projected area as,
W
p =
l d
1.8727 =
or

W
60 60

W = 6741.7282 N

Ans.

Step - 6 : Total flow rate of lubricant, (Q)

Q

= 4.6175
r c n s l
Q
30 0.0595

1000
60
60
Q

= 4.6175
= 8242.24 mm 3 s = 8242.24 10- 9 60 m 3 min
= 8242.24 10- 9 60 103 lit/min

or

Q = 0.4945 lit/min

Ans.

qqq
7 - 10

Design of Machine Elements - II