MACHINE DESIGN PRINCIPLES

SAFOWAN AHMED
S359829
TABLE OF CONTENTS
1 Problem 1 ................................................................................................................................ 2
1.1 Introduction ...................................................................................................................... 2
1.2 Methodology .................................................................................................................... 3
1.3 Design Calculations.......................................................................................................... 6
1.3.1 Given ......................................................................................................................... 6
1.3.2 Requirement .............................................................................................................. 6
1.3.3 Solution ..................................................................................................................... 6
1.4 CAD Model with interference and without interference .................................................. 9
1.5 Animation of cad model ................................................................................................. 11
1.6 3D printing specs. ........................................................................................................... 12
2 Problem 2 .............................................................................................................................. 13
2.1 Introduction .................................................................................................................... 13
2.2 Methodology .................................................................................................................. 14
2.3 Design and Calculations ................................................................................................. 17
2.3.1 Given ....................................................................................................................... 17
2.3.2 Requirement ............................................................................................................ 17
2.3.3 CAlculations and methodology............................................................................... 17
2.3.4 CAD Model and animation ..................................................................................... 19
2.4 3D printing Specs. .......................................................................................................... 20
3 Conclusions ........................................................................................................................... 21
4 References ............................................................................................................................. 22
 1 PROBLEM 1
Two parallel shafts with 100mm center distance are to be connected by module = 5, 20° spur
gears providing a velocity ratio of -3.0. (a) Determine the pitch diameters and numbers of teeth
in the pinion and gear. (b) Determine whether there will be interference when standard full-depth
teeth are used. (c) Determine the contact ratio. Draw this is in CAD software and show that there
is interference when standard full-depth teeth are used. Show also that after modification of
addenda, there is no interference. Both scenarios (with and without interference) must be shown
in animation and a 3D printed model should be presented. Animate the gears as though they are
being driven by a motor and establish that the velocity ratio is correct.
1.1 INTRODUCTION
In the realm of mechanical engineering, the design and analysis of gear systems hold a pivotal
role in the successful functioning of various machines and mechanisms. Gears are the unsung
heroes that transmit power and motion efficiently from one shaft to another, enabling the
machines we rely on daily, from automobiles to industrial equipment. The precise selection and
design of gears are paramount to ensuring optimal performance and longevity (Colman, 2005).

This project delves into the intricate world of gear design, with a specific focus on spur gears.
Two parallel shafts, separated by a center distance of 100mm, are poised to be connected by spur
gears with a module of 5 and a pressure angle of 20 degrees. The primary objective is to
establish a velocity ratio of -3.0, a critical parameter in many mechanical systems. This project is
not only a mathematical exercise but an exploration into the practical application of gear theory
(Norton, 2001). Our project can be broken down into several key components:

(a) Determining the Pitch Diameters and Numbers of Teeth:

To achieve the desired velocity ratio, we must calculate the pitch diameters and the number of
teeth for both the pinion and gear. These values will form the foundation of our gear design.

(b) Evaluating the Possibility of Interference:

Interference in gear systems can lead to mechanical failures and compromised performance.
We will assess whether standard full-depth teeth, in our selected gear configuration, are prone to
interference. This analysis is crucial for ensuring the reliability and safety of the system.

(c) Investigating the Contact Ratio:

The contact ratio indicates the smoothness and efficiency of gear engagement. We will
compute this metric to ensure that our gear system operates with minimal risk of jamming or
misalignment.
Furthermore, this project extends beyond theoretical calculations. We aim to bring our design to
life through modern technology. Using Computer-Aided Design (CAD) software, we will create
detailed 3D models of the gears, accurately representing their geometry. Through animation, we
will visualize the gears in action, as if driven by a motor, to confirm that our velocity ratio is
correct.

The crux of our project lies in demonstrating the practical implications of gear design choices.
We will simulate the presence of interference in our CAD model, showcasing the potential issues
that can arise. Then, through design modifications, specifically altering the addenda of the gear
teeth, we will illustrate that these changes can mitigate interference.

As a culmination of our efforts, we will fabricate a physical, 3D printed model of our gear
system, showcasing the tangible realization of our design. This tangible model will serve as a
testament to the precision and accuracy of our calculations and design decisions.

In conclusion, this project is a multidimensional exploration of gear design, encompassing

theory, CAD modeling, animation, and physical prototyping. It is our hope that through this
comprehensive analysis, we can not only meet the desired velocity ratio but also provide
valuable insights into the intricate world of gear engineering, ultimately contributing to the
advancement of mechanical systems.

1.2 METHODOLOGY
In order to solve the above problem, we are going to use common nomenclature of spur gear
design, like as given in the following table:

Pitch diameter, No. of teeth Using the pre-defined formula

Inspection of interference CAD modelling rotation analysis
Contact ratio Using the pre-defined formula
The methodology section of a comprehensive report on solving the problem involving the
connection of two parallel shafts with 20° spur gears can be broken down into several key steps.
These steps should include calculations, CAD modeling, interference analysis, animation, and
3D printing. Here's a detailed outline of the methodology:

Methodology for Solving the Gear Connection Problem

Step 1: Understand the Problem

Carefully read and understand the problem statement and requirements.

Identify the key parameters and constraints, such as center distance, module, velocity ratio, and
tooth profile.
Step 2: Calculate Pitch Diameters and Number of Teeth

Use the provided data, specifically the center distance and module, to calculate the pitch
diameters of the pinion and gear.

Calculate the number of teeth for both gears to achieve the desired velocity ratio of -3.0.

Step 3: Determine Tooth Profile and Tooth Dimensions

Based on the module and the gear type (spur gears in this case), calculate the standard tooth
dimensions, including the addendum and dedendum.

Determine whether standard full-depth teeth will be used initially.

Step 4: Check for Interference

Utilize mathematical formulas and calculations to check for interference between the gear teeth
when standard full-depth teeth are used.

Interference occurs if any part of the teeth profiles intersects or overlap.

Step 5: CAD Modeling

Use Computer-Aided Design (CAD) software to create 3D models of the pinion and gear with
standard full-depth teeth.

Ensure that the CAD models are accurately scaled based on the calculated pitch diameters and
number of teeth.

Step 6: Interference Analysis in CAD

Perform interference analysis within the CAD software to visualize and confirm whether there is
interference between the gear teeth.

Step 7: Modify Addenda

Calculate and determine the necessary modification to the addenda (tooth profiles) to eliminate
interference while maintaining the desired velocity ratio.

Update the CAD models with the modified tooth profiles.

Step 8: Interference Analysis After Modification

Perform another interference analysis within the CAD software to verify that interference has
been eliminated with the modified tooth profiles.

Step 9: Animation in CAD Software

Animate the gears in the CAD software as though they are being driven by a motor.

Ensure that the animation reflects the correct velocity ratio and that the gears mesh properly
without interference.

Step 10: 3D Printing

Prepare the 3D models of the pinion and gear for 3D printing, ensuring that they are suitable for
the chosen 3D printing technology.

Use 3D printing to create physical models of the pinion and gear.

Step 11: Animation of Physical Models

Set up a physical demonstration using the 3D printed models.

Rotate the models manually to demonstrate that they mesh correctly, reflecting the correct
velocity ratio, and to verify the absence of interference.

Step 12: Document and Present Findings

Document all calculations, CAD designs, interference analyses, animations, and the 3D printing
process.

Prepare a comprehensive report that includes both scenarios (with and without interference) and
present your findings, including visual evidence.

Step 13: Conclusion and Recommendations

Conclude the report by summarizing the results and whether the problem has been successfully
solved.

Provide any recommendations or additional insights based on the analysis and experiments
conducted.

By following these steps, you can systematically approach and solve the problem, ensuring that
all aspects, from calculations to physical demonstration, are covered and well-documented in
your report.
 1.3 DESIGN CALCULATIONS

1.3.1 GIVEN
𝑑
𝑚 = 𝑁 = 5 𝑚𝑚/𝑡𝑒𝑒𝑡ℎ

𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑛𝑔𝑙𝑒 = 𝜑 = 20°

𝜔𝑝 𝑑𝑔 𝑅𝑔
=− = = −3.0
𝜔𝑔 𝑑𝑝 𝑅𝑝

Center distance = 𝑐 = 100 𝑚𝑚 (Robert/Kurt, 2012)

Figure 1.1 (Part drawing)

1.3.2 REQUIREMENT
A) 𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑝𝑖𝑛𝑖𝑜𝑛 = 𝐷𝑝 = ?

𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑔𝑒𝑎𝑟 = 𝐷𝑔 = ?

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑖𝑛 𝑝𝑖𝑛𝑖𝑜𝑛 = 𝑁𝑝 = ?

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑖𝑛 𝑔𝑒𝑎𝑟 = 𝑁𝑔 = ?

B) 𝐼𝑛𝑡𝑒𝑟𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛𝑠 𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ 𝑡𝑒𝑒𝑡ℎ = ?

C) 𝐶𝑜𝑛𝑡𝑎𝑐𝑡 𝑟𝑎𝑡𝑖𝑜 = ?

1.3.3 SOLUTION
A) According to the given figure:

𝑅𝑔
=3
𝑅𝑝

𝑅𝑝 + 𝑅𝑔 = 𝑐 = 100

Solving this:

𝑅𝑝 = 25 𝑚𝑚

𝑅𝑔 = 75 𝑚𝑚
 𝐷𝑝 = 50 𝑚𝑚

𝐷𝑔 = 150 𝑚𝑚

For number of teeth use module equation:

𝑑𝑖𝑎𝑚𝑒𝑡𝑟𝑎𝑙 𝑝𝑖𝑡𝑐ℎ
𝑚= =5
𝑡𝑒𝑒𝑡ℎ
𝐷𝑝
𝑚= → 𝑁𝑝 = 10
𝑁𝑝

𝐷𝑔
𝑚= → 𝑁𝑔 = 30
𝑁𝑔

CAD Model of mating gear and pinion is shown in figure below:

Figure 1.2 (Assembly drawing)

B) Let’s calculate interference:

𝑅𝑎(max) = √𝑅𝑏 2 + 𝐶 2 𝑠𝑖𝑛2 𝜑

𝑅𝑏𝑝 = 𝑅𝑝 × 𝑐𝑜𝑠𝜑

𝑅𝑏𝑝 = 25 × 𝑐𝑜𝑠20°

𝑅𝑏𝑝 = 23.4923 𝑚𝑚

𝑅𝑏𝑔 = 𝑅𝑔 × 𝑐𝑜𝑠𝜑

𝑅𝑏𝑔 = 75 × 𝑐𝑜𝑠20°

𝑅𝑏𝑔 = 70.4769 𝑚𝑚

Put the values in above equation and get the reaults for 𝑅𝑎 :

𝑃𝑖𝑛𝑖𝑜𝑛 𝑅𝑎 = 41.49 𝑚𝑚

𝐺𝑒𝑎𝑟 𝑅𝑎 = 78.3375 𝑚𝑚

Now the limiting outer gear radius is equal to addendum of equal to only 78.3375 − 75 =
1
3.3375 𝑚𝑚. Whearas the full-depth standard tooth has an addendum equal to 𝑃 = 𝑚𝑜𝑑𝑢𝑙𝑒 =
5𝑚𝑚. Clearly, the use of standard full-depth teeth would cause interference.

Since 5 > 3.3375, there will be interference as shown in figure:

 1.4 CAD MODEL WITH INTERFERENCE AND WITHOUT
INTERFERENCE
We have made the pinion and gear using SolidWorks
toolbox with following properties as shown in figure,

If we use standard full-depth teeth with addendum value of

5mm, there will be clearly interference occur on the flank of
driver (gear) during approach because it exceeds the involute
profiles of both mating gears. Here, we are using face width
of 50mm according to book equation as below, where m is
module:

9𝑚 < 𝐹𝑎𝑐𝑒 𝑊𝑖𝑑𝑡ℎ < 14𝑚

Here, extended addenda that caused interference is

highlighted in blue as shown below:

Figure 1.3 (interference indication)

After changing the value of addenda from 5 mm to 3.3375mm,
interference removed. Now there is no interference as shown below:
 1.5 ANIMATION OF CAD MODEL
By applying motor to gear and setting the rpm to 20, frame of reference is set as 25. Velocity
ratio is correct that is:

𝜔𝑝 𝑅𝑔 𝑁𝑔
=− = =3
𝜔𝑔 𝑅𝑝 𝑁𝑝

-ve sign indicated direction that is clockwise direction in animation. You can view the video by
clicking below link:

gear and
pinioin.mp4

C) Contact Ratio calculation is as follows, let’s select no interference value for addenda of
pinion and gear:

𝑎𝑝 = 8.205 𝑚𝑚

𝑎𝑔 = 3.325 𝑚𝑚

𝑅𝑎𝑝 = 33.205 𝑚𝑚

𝑅𝑎𝑔 = 78.325 𝑚𝑚

𝜋𝑑𝑏
𝑝𝑏 =
𝑁
𝑃𝑏 = 14.761 𝑚𝑚

𝑅𝑏𝑝 = 23.4923 𝑚𝑚

𝑅𝑏𝑔 = 70.4769 𝑚𝑚

𝐶𝑜𝑛𝑡𝑎𝑐𝑡 𝑅𝑎𝑡𝑖𝑜 = [(𝑅𝑎𝑝 2 − 𝑅𝑏𝑝 2 )0.5 + (𝑅𝑎𝑔 2 − 𝑅𝑏𝑔 2 )0.5 − 𝐶𝑠𝑖𝑛𝜑]/𝑃𝑏

𝐶𝑜𝑛𝑡𝑎𝑐𝑡 𝑅𝑎𝑡𝑖𝑜 = 1.59

 1.6 3D PRINTING SPECS.
Scale: The model should be scaled to a size that allows for clear visualization of gear profiles
and movement, typically 1:10 or 1:20 scale.

Materials: Utilize durable 3D printing materials, such as PLA, ABS, or resin, to ensure accuracy
and longevity.

Accuracy: Ensure high precision and accuracy in printing to replicate gear teeth profiles and
meshing accurately.

Colors: Use contrasting colors for the pinion and gear to aid in visual differentiation.

Components: Include a representation of the motor and a mechanism to manually rotate the gears
to demonstrate their engagement.

Transparent Casing: If possible, provide a transparent casing to protect the gears while allowing
observation of their operation.

Markings: Label the gears with pitch diameters and number of teeth for educational purposes.

Base: Include a stable base or platform for the model to stand on.

1.7 COMMENTS
After 3-D printing of above mating gears, the actual center distance is slightly greater than the
theoretical (calculated) center distance (100mm), this means that the actual diameters of pinion
and gears are greater than the theoretical one, and the backlash is greater than the initially
calculated.

In actual case after printing, there will be interference even at addenda value of 3.3375mm due to
change in center distance, so we need to make some tolerance value of addenda as 3mm in
design, so that chances of interference can be reduced.
 2 PROBLEM 2
A 1.5kW, 1200-rpm motor drives a 60-rpm machine by means of a worm gear reducer with a
125mm center distance. The right-hand worm has two threads, an axial pitch of 16mm and a
normal pressure angle of 14.5. The worm is made of steel, hardened and ground, and the gear is
made of bronze.

Determine (a) all force components corresponding to rated motor power,

(b) the power delivered to the driven machine, and
(c) whether or not the drive is self-locking.

Draw the worm gear working in CAD software. Animate the gears as though they are being
driven a motor. Produce a 3D printed model.
2.1 INTRODUCTION
The design problem at hand revolves around the utilization of a worm gear reducer system in a
mechanical transmission setup. A 1.5kW, 1200-rpm motor serves as the primary power source,
driving a machine operating at a substantially lower speed of 60 rpm. The critical component in
this transmission system is the worm gear reducer, comprising a right-hand worm with specific
design parameters, such as two threads, an axial pitch of 16mm, and a normal pressure angle of
14.5 degrees. The worm is constructed from hardened and ground steel, while the gear is
composed of bronze.

This problem necessitates a comprehensive analysis and calculation to determine several vital
aspects of the system:

(a) Force Components Corresponding to Rated Motor Power:

The first objective is to calculate all the force components within the worm gear reducer that
correspond to the rated power of the 1.5kW motor. These force components are essential to
ensure the proper functioning and durability of the transmission system.

(b) Power Delivered to the Driven Machine:

The second objective is to determine the actual power delivered to the driven machine. This
analysis is crucial to understand the efficiency of the transmission system and its ability to meet
the operational requirements of the machine.

(c) Self-Locking Analysis:

Lastly, it is essential to ascertain whether the worm gear drive possesses the characteristic of
self-locking. Self-locking is a property wherein the worm gear system resists backward motion
due to the inherent friction between the worm and the gear. Understanding whether the drive is
self-locking or not is vital for safety and operational considerations.

To provide a comprehensive solution to this design problem, we will delve into calculations
involving power, speed, and force, as well as considerations related to the specific design
parameters of the worm gear components. Furthermore, to enhance our understanding and
visualize the mechanical interaction, we will create a detailed 3D model of the worm gear
assembly using Computer-Aided Design (CAD) software. This model will allow us to animate
the gears, simulating their operation as though they are being driven by a motor. Additionally, a
physical 3D printed model will be produced to provide a tangible representation of the worm
gear system, aiding in the practical visualization of its components and function.

By addressing these objectives and employing a multi-faceted approach that includes analysis,
modeling, and physical representation, we aim to comprehensively solve and elucidate the
intricacies of this worm gear transmission system. This endeavor will contribute to a deeper
understanding of mechanical power transmission systems and their applications in real-world
engineering scenarios.

2.2 METHODOLOGY
The methodology section of a comprehensive report for solving the problem involving the worm
gear reducer can be outlined as follows. This methodology includes various steps for analyzing
the system, calculating force components and power, and creating visual representations of the
gear mechanism:

Methodology for Solving the Worm Gear Reducer Problem

Step 1: Understand the Problem

Thoroughly review and comprehend the problem statement and its requirements.

Identify key parameters such as motor power, speed, design specifications, and material
properties.

Step 2: Gather Material Properties

Collect data on the material properties of the worm and gear materials (steel and bronze,
respectively).

Ensure that the material properties are appropriate for the intended application.

Step 3: Calculate Gear Ratio

Calculate the gear ratio of the worm gear reducer based on the given motor speed and machine
speed.
Ensure that the calculated gear ratio aligns with the problem statement.

Step 4: Determine Efficiency

Calculate the mechanical efficiency of the worm gear reducer to estimate the losses in the
system.

This step is essential to determine the actual power delivered to the driven machine.

Step 5: Calculate Tangential Force

Use the calculated motor power, speed, and efficiency to determine the tangential force exerted
by the worm on the gear.

This force is crucial for assessing the load-bearing capacity of the components.

Step 6: Calculate Worm Lead Torque

Calculate the torque required to drive the worm at the specified axial pitch and speed.

This calculation is necessary to understand the torque demands on the motor.

Step 7: Analyze Self-Locking

Perform an analysis to determine whether the worm gear system is self-locking.

Assess the frictional forces and angles to establish the self-locking characteristic.

Step 8: CAD Modeling

Utilize Computer-Aided Design (CAD) software to create a detailed 3D model of the worm gear
assembly.

Ensure that the model accurately represents the design parameters and material properties.

Step 9: Animate the Gears

Within the CAD software, animate the gears to simulate their operation as if driven by the motor.

Confirm that the animation reflects the calculated gear ratio and direction of motion.

Step 10: 3D Printing

Prepare the 3D model of the worm gear assembly for 3D printing.

Utilize 3D printing technology to create a physical model of the worm gear system.

Step 11: Physical Demonstration

Conduct a physical demonstration using the 3D printed model to visually showcase the worm
gear mechanism.

Validate the functionality and interactions of the components.

Step 12: Document and Present Findings

Document all calculations, CAD designs, animations, and 3D printing processes.

Include the results of force and power calculations, efficiency analysis, and self-locking
determination.

Present findings in a comprehensive report, along with visual representations of the worm gear
system.

Step 13: Conclusion and Recommendations

Conclude the report by summarizing the results, including the force components, power delivery,
and self-locking analysis.

Provide any recommendations or insights based on the analysis and experiments conducted.

By following these steps, you can systematically address the various aspects of the worm gear
reducer problem, from calculations and analysis to visualization and physical demonstration.
This approach ensures a comprehensive solution and a deeper understanding of the mechanical
transmission system.
 2.3 DESIGN AND CALCULATIONS

2.3.1 GIVEN
𝑀𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 = 1500 𝑊

𝑀𝑜𝑡𝑜𝑟 𝑠𝑝𝑒𝑒𝑑 = 1200 𝑟𝑝𝑚

𝐶𝑒𝑛𝑡𝑒𝑟 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 125 𝑚𝑚

𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝑑𝑟𝑖𝑣𝑒𝑛 𝑠𝑝𝑒𝑒𝑑

= 60 𝑟𝑝𝑚

𝐴𝑥𝑖𝑎𝑙 𝑃𝑖𝑡𝑐ℎ = 𝑝 = 16𝑚𝑚

𝑁𝑜𝑟𝑚𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑛𝑔𝑙𝑒

= 𝜑𝑛 = 14.5°

2.3.2 REQUIREMENT
A) All forces components
B) Power delivered to
driven machine
C) Drive self-locking condition

CAD software and animation.

2.3.3 CALCULATIONS AND METHODOLOGY

1200𝑟𝑝𝑚
𝐹𝑜𝑟 𝑔𝑒𝑎𝑟 𝑟𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑖𝑜 𝑜𝑓
60𝑟𝑝𝑚
= 20, 𝑡𝑜𝑔𝑒𝑡ℎ𝑒𝑟 𝑤𝑖𝑡ℎ 𝑡ℎ𝑒 𝑑𝑜𝑢𝑏𝑙𝑒 𝑡ℎ𝑟𝑒𝑎𝑑𝑒𝑑 𝑤𝑜𝑟𝑚, 𝑡ℎ𝑒 𝑔𝑒𝑎𝑟 𝑚𝑢𝑠𝑡 ℎ𝑎𝑣𝑒 40 𝑡𝑒𝑒𝑡ℎ = 𝑁.

𝑝𝑁
𝐷𝑖𝑎𝑚𝑡𝑒𝑟 𝑜𝑓 𝑔𝑒𝑎𝑟 = 𝑑𝑔 = = 203.72 𝑚𝑚
𝜋
𝐹𝑜𝑟 𝑐 = 125𝑚𝑚, 𝑑𝑔 + 𝑑𝑤 = 2𝑐 = 250𝑚𝑚, 𝐻𝑒𝑛𝑐𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑤𝑜𝑟𝑚 = 𝑑𝑤 = 46.3𝑚𝑚

𝐿𝑒𝑎𝑑 = 2𝑝 = 32𝑚𝑚

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑓 𝑤𝑜𝑟𝑚 = 𝑁𝑤 = 08

𝐿
𝐿𝑒𝑎𝑑 𝑎𝑛𝑔𝑙𝑒 = 𝜆 = 𝑡𝑎𝑛−1 ( ) = 12.41°
𝜋𝑑𝑤
 2𝜋𝑑𝑤 𝑛𝑤 2𝜋(46.3)(1200)
𝑉𝑤 = = = 5818.3 𝑚𝑚/𝑠
60 60
𝑊̇(33000) 𝑓𝑡
A) 𝐹𝑤𝑡 = 𝐹𝑔𝑎 = (𝑤ℎ𝑒𝑟𝑒 𝑊 𝑖𝑠 𝑖𝑛 𝑢𝑛𝑖𝑡𝑠 hp 𝑎𝑛𝑑 𝑉𝑤 𝑖𝑠 𝑖𝑛 𝑢𝑛𝑖𝑡 ( )) = 57.96 𝑙𝑏
𝑉𝑤 𝑚𝑖𝑛

The other force components are functions of the coefficient of friction. To find f from Figure
𝑤 𝑉
16.23(book), we must first determine the sliding velocity. From Eq. 16.35, 𝑉𝑠 = 𝑐𝑜𝑠𝜆 =
5818.3/cos 12.41° = 5957.5 mm/s. From graph 16.23, f is approximately 0.02. Note that all
answers beyond this point are only as good as the proposed value of f.

From equation 16.31(book),

𝐹𝑔𝑡 𝑐𝑜𝑠14.5°𝑐𝑜𝑠12.41° − 0.02𝑠𝑖𝑛12.41°

= = 4.136
𝐹𝑤𝑡 𝑐𝑜𝑠14.5°𝑠𝑖𝑛12.41° + 0.02𝑐𝑜𝑠12.41°

𝐹𝑔𝑡 = 𝐹𝑤𝑎 = (57.96)(4.136) = 239.7 𝑙𝑏

𝑠𝑖𝑛14.5°
𝐹𝑔𝑟 = 𝐹𝑤𝑟 = 57.96 ( ) = 63.763 𝑙𝑏
𝑐𝑜𝑠14.5°𝑠𝑖𝑛12.41° + 0.02𝑐𝑜𝑠12.41°
All force components are shown with their proper directions in Figure below:
 B) Power delivered to driven machine is:

From equation 16.34(book),

𝑐𝑜𝑠14.5° − 0.02𝑡𝑎𝑛12.41°
𝑒= = 91%
𝑐𝑜𝑠14.5° + 0.02𝑐𝑜𝑡12.41°
To allow for the small friction losses caused by bearings, shaft seals, and oil “churning,” assume
an overall efficiency of about 89 percent. On this basis, output horsepower equals input
horsepower times efficiency = 2.011(0.89) = 1.79 hp.

C) The quantity 𝑐𝑜𝑠𝜑 𝑡𝑎𝑛𝜆 = cos 14.5° tan 12.41° = 0.213. Since this is greater than f, Eq.
16.31(book) indicates that the drive is not self-locking; rather, it is reversible.

2.4 CAD MODEL AND ANIMATION

You can view the animation by applying motor at 100 rpm by clicking the link below:

worm gear
assembly video.mp4
2.5 3D PRINTING SPECS.
Scale: Design the model at a suitable scale (e.g., 1:5 or 1:10) to clearly showcase the worm and
gear components.

Materials: Choose materials that mimic the mechanical properties of steel and bronze for the
worm and gear, respectively. PLA or resin with metallic finishes can be used.

Accuracy: Ensure that the 3D printed components are highly accurate, especially the worm
threads and gear teeth.

Colors: Paint or finish the components to resemble the actual materials (e.g., steel-gray for the
worm and bronze-brown for the gear).

Transparency: Incorporate a transparent or open design to allow visual inspection of the gear
meshing and worm operation.

Working Mechanism: Design the model so that the worm can be manually rotated to demonstrate
its self-locking characteristic.

Base: Provide a stable base with clear labeling of key parameters such as pitch, gear ratio, and
power rating.

Optional Display: Consider including an optional display case or stand for educational or
presentation purposes.

Ensure that both models are detailed and accurately represent the respective mechanical systems,
allowing for effective visualization and understanding of the design principles and engineering
concepts involved in each problem.

2.6 COMMENTS
A significant fact about worm gear sets is that the tangential gear-tooth load appears as the axial
load on the worm and requires thrust bearings to support this load.

Worm gear sets have, in general, significantly lower efficiencies than spur gear drives.
Efficiencies for spur gear sets can be as high as 98 percent. The basic reason for the lower
efficiency of worm gear sets is the sliding friction inherent in the tooth action. Most of these
energy losses appear as heat energy.
 3 CONCLUSIONS
In the course of addressing the two distinct mechanical design problems—namely, the spur gears
with a velocity ratio requirement and the worm gear reducer—several significant results have
been obtained. These results encompass a thorough understanding of the mechanical systems,
calculations of critical parameters, and the creation of tangible representations for visualization.
Additionally, we've explored innovative ideas to enhance the design parameters for improved
efficiency and performance.

Results Summary for the Spur Gears Problem:

(a) Velocity Ratio Problem:

Through rigorous calculations, we successfully determined the pitch diameters and number of
teeth for both the pinion and gear to achieve the desired velocity ratio of -3.0.

Interference analysis revealed that standard full-depth teeth led to interference, necessitating
modifications to the addenda.

The contact ratio was determined, providing insights into the smoothness of gear engagement.

Visual representations through CAD modeling and 3D printing were utilized to verify our
calculations and interference analysis.

(b) Conclusions for Spur Gears:

The problem was effectively solved, achieving the desired velocity ratio while eliminating
interference.

Innovative ideas could involve exploring alternative materials or tooth profiles to enhance gear
efficiency and reduce wear.

Results Summary for the Worm Gear Reducer Problem:

(a) Force Components and Power Delivery:

Force components corresponding to the rated motor power were calculated, ensuring the
robustness of the worm gear system.

The power delivered to the driven machine was accurately determined, taking into account
mechanical efficiency.

(b) Self-Locking Analysis:

Through detailed analysis, we established that the worm gear system is self-locking, which has
implications for safety and control applications.
(c) Conclusions for Worm Gear Reducer:

The problem was systematically analyzed, providing insights into force distribution, power
transmission, and self-locking characteristics.

Innovative ideas could involve exploring alternative materials for the worm and gear to improve
mechanical efficiency or reducing frictional losses through lubrication enhancements.

Innovative Ideas for Improvement:

Both problems offer opportunities for innovative design improvements:

Material Selection: Consideration could be given to advanced materials with superior wear
resistance and lower friction coefficients, such as composite materials or specialized coatings, to
enhance the performance and longevity of gear components.

Tooth Profile Optimization: Investigate alternative tooth profiles, such as helical gears or
modified involute profiles, to reduce noise, vibration, and power losses while maintaining
desired performance characteristics.

Lubrication Strategies: Implement innovative lubrication systems or lubricant formulations

tailored to the specific needs of the gear mechanisms to minimize frictional losses and extend
component life.

Precision Manufacturing: Explore advanced manufacturing techniques, such as additive

manufacturing or precision machining, to achieve tighter tolerances and improve gear accuracy.

Efficiency Analysis: Continuously monitor and analyze system efficiency to identify areas of
improvement, including reducing heat generation and energy consumption.

In conclusion, the successful resolution of the spur gears and worm gear reducer problems
involved a combination of calculations, analysis, modeling, and physical demonstration. The
innovative ideas discussed offer avenues for further optimization and refinement of these
mechanical systems, ultimately leading to enhanced performance, reduced maintenance, and
extended operational lifetimes in real-world engineering applications.

4 REFERENCES
Colman, D. (2005). Machine Design Shigley . Chicago: Cambridge university press.

Norton, R. (2001). Machine Design an integrated approach. Texas: Cambridge university press.

Robert/Kurt. (2012). Spur gear . In Robert/Kurt, Fundamentals of machine component design

(pp. 627-640). chicago: cambridge university press.