~ VA - ---

• J ['
1/3
,r
.J V V rpm
C == P (L10) (15.7)
Step 1: Bearing life
For all types of roller bearings, (L
10)
60nT
C= p (LIOJ\0.3 (15.8) lio==~_6(
. .
The relat1onsh1~ between life tn mt ffton
. • 106 - .._
revolutions and hie . orking hours is given by == 144 million
tn w
Step 2: Equivalen rev
60 n ½oh t rad·
Lio= 6 (15.9) 1a1
10
From Eq. (15.8),
c It == P(L
where, L10h = rated bearing life (hours) •
• I
n = speed of rota . ( •• p= C _ 26000
tion rpm ) , 03-----
(tO
~ \n a particular app ) • 044)0.3
&uv•1s11. -i• lica Since the bearing
ri o a d acting on- . · 5 kN andtiothn, the radial is sub1e
a ball be~nng ~s ee load,
\ife for 90% of th 8000 hr Calcuxpected J cted
late the
dynamic load cae ~eanngs '~ of the bearing
the shaft. rotates rrying capacity , when
[S] [LO 3] Fr= P =5854.16 N
at 1450 rpm.
Solution 15.10 SE
Given Fr= SkN LECTION OF
L1oh = 8000 LIFE
n = 1450rpm hr

Step 1: Bearing While selecting th

iife (L1o) e proper size
it is necessary
to specify the
60 n Lioh 60 (1 of the bearing fo 1
½o= 450 )( 8000) r the given app1
10
6 = 6 information regar
10 ding the life
= 696 million re is generally vagu
v. e and values b:i:
experience are use
Step 2: Dynamic d. F
load capacity the speed of rotati or all kinds
Since the bearing on is not consra
is subjected to p desired life is ex
load, urely radial pressed in terms 1
o f revolutions. T
he recommended~
P = Fr = 5000N for wheel applicati
ons is given in T..:
From Eq. (15.7),
rin life for wheel a•
C = P ( li ) 113 =
0 ( 5000 )( 696 )1 13 \\'he~l applicatio
n
= 44 310.48 N
Automobile cars ..~I
Example 15.2
(Ans.)
Trucks, 100
A taper rolle
dynamic load
capacity o f 26 r bearing has a Trolley cars 5(ll
for 90% o f the kN. The desi
bearings is 8 0 red life
is 3 0 0 rpm. Ca 0 0 h r and th e Railroad cars 10))
lculate the equ speed
the bearing ca ivalent radial lo
n carry. ad th a t
[S] [LO 3]
S, M, D denote S
imple, Medium
and Difficult leve
ls o f complexity
respectively.
 Rolling Conroct Bearings 675

Prom Eq. ( I 5.3),

15 9
from Bq, ( ' )',. 60( 600 )(30000) P = X Fr + Y Fu = 0.56 (8000) + 1.5 (3000)
6011'-'I0h __. : . . -6 - - - - = 8980 N
Lio;;::~- 10
Prom Eq. ( 15.9),
:::: 1080 mill ion rev.
L _ 60nLioh = 60(1200)(20000)
Eq (J5.7), 113
frofll • )1/3::: (3000 )( I 080 ) = 30 779.57 N 10- 106 106
c::=P(lio
. Selection of bearing = 1440 million rev.
Step 2• .a b • From Eq. ( 15.7),
In Table ]5.5, six ?1uerent earmgs are
. ble for the shaft diameter of 40 mm. They C = P(L.. 0 ) 113 = (8980)( 1440) 113
ava1 1a
are 61808, l 6008, _6008, 6208, 6308 and 6408.
= 101 406.04 N
Out of these, Bearing No. 6208 (C = 30 700 N)
is suitable for the above application. The small From Table 15.5, it is observed that for the
difference between the expected and actual shaft of 75 mm diameter, Bearing No. 6315
dynamic capacities, viz. (30 779 .57 - 30 700 = (C = 112000) is suitable for the above data. For
79.57 N) is considered to be negligible. this bearing,
C0 = 72000 N
j&1MM~ti• A single-row deep groove ball Therefore,
bearing Is subjected to a radial force of 8 kN and a
thrust force of 3 kN. The shaft rotates at 1200 rpm.
The expected life l 10h of the bearing is 20 000 hr.
The minimum acceptable diameter of the shaft
(;, )= (:: )= 0.375
is 75mm. Select a suitable ball bearing for this
application. [D] [LO 5]
and ( Fa
co
)= ( 3
000
72000
)= 0.04167
Solution
Referring to Table 15.4,
Given Fr= 8 kN Fa= 3 kN L1oh = 20 000hr
n= 1200 rpm d = 75 mm
Step I: X and y factors
e = 0.24 (approximately) and ( i, )>e

When the b • . . The value of Y is obtained by linear

as ax· earmg is subjected to radial as well
ia11 oad the
interpolation.
obtained f ' va Iues o f X and Y factors are
proced rom Table 15.4 by the trial and error (1.8 - l.6)
ure. It is ob d
b<._ Y = 1.8 - - - - - X (0.04167- 0.04) = 1.79
values of X serve from Table 15 .4 that (0.07 - 0.04)
varies onl . are constant and the values of Y and X = 0.56
Yin case when
' Step 2: Dynamic load capacity
P = X Fr + Y Fa = 0.56(8000) + 1. 79(3000)
In th·
( ~·) >e
Fr • = 9850 N
2.o IS case, the V . . 113
fir· 'We Will ass alue of Y vanes from 1.0 to C = P (LI0) 113 = 9850 ( 1440) = 111 230.46 N
X~t trial value ~;e th e average value 1.5 as the
Step 3: Selection of bearing
'0,56 \/ factor Y. Therefore
,- I ' From Table 15.5, BearingNo.6315(C= I 12000)
- .S Fr = 8000 N FH = 3000 N
is suitable for the above application.
jed series of module
In the crown ing proces s th ntre distanc e;
• ' e end (I) the c~ h circle diamet ers of the pinion
are mad e shghtl y thinne r b an ~ s of a t0oth ~ the p1tc
• • y d the gear;
crown ing 1s done by shavin cutters ~••0 unt c 'l't (ii)
2.0 2.5 3.0 4.0 • g -r, • 'Ile an ddend um and deden dum;
20 c 1s very small and dependS Upon• th • he cro (iii) th e :ooth thickne ss;
10 12 16 \\in
• (IV) the bottom clearan ce; and
s 2.25 2.75 3.5 4.5 d e fl ect.10n of teeth in operat·ton In e elast·1c
. (V) t~= gear ratio.
I I 14 18 the crown c ts usually taken • Practic
(vi) t
(0.000 5 b). as (0.0Qo3 b) ~•
0
1s of the gear tooth in In the design of gears the sotution == 20 = 120 m = 4 mm
) 0 full depth system are • • ' OUJnber of teeth Zg
1s decide d from the speed rati· The llloct GI·ven Zp
• t
o. • uJe is . Centre dis ance
calcula ted from streng th and 1
param etear equations . Step •
Knowi ng these two ers, the Oth frorn Eq. (l? .5),
5 m) • .
d unens1ons can be calculated b er
y the above 120) _
m) •
propor tions. Th e conven tional r (z +zg ) =4(20+
- - - - - - 280 mm (i)
• epresentati mp
2
(2 m) a parr of spur gears is ilJustrated in F'tg. 17 13onThor a==- 2
• h • l .
.25 m) p1tc crrc es of pmion and gear ar • • • ine
(1.5708 m) e llllportant . Pitch circle diame ters of pinion and
Step 2•
8 m) gear
) pinion d = m zP = 4(20) = 80 mm
f strengthening the gear d: = m z = 4(120) = 480 mm (ii)
8
uring operation, there is
pressure along the face Step 3: Addendum and deden dum
to the following reasons: addendum (ha)= m = 4 mm
tooth profile caused by dedendum (hr)= 1.25 m = 1.25(4) = 5 mm (iii)
~s and distortion during I --~,
1/ Step 4: Tooth thickness
I I \

tooth thickness = 1.5708 m = 1.5708(4)

bly.
)fl of shaft due to gear ----. (-----$---- ) = 6.2832 mm (iv)
I bearing reactions. Step 5: Bottom clearance
\~ ! )
the maximum pressure to (v)
gear '~ I .,,.~ clearance (c) = 0.25 m = 0.25(4 ) = 1 mm
the face width. This load '- - ----=
--- -
Step 6: Gear ratio
• the middle of face width
as illustrated in Fig. 1?_12_ Fig. 17.13 Conve ntiona l Representation 2
i- g 120 (vi)
--=-=6
the drawing becaus e pitch surfaces roll toge~er
2p 20
withou t slip during engagement. The• •pitch to
circles are shown by centre lines. In addiaon
17.7
GEAR TRA INS L02
pitch circles, the addend um circles are ctrawn A gear tra·10 •
with full lines. transm. . consis ts of two or more gears
crowning . . g shaft t? ctr·1ven
llting power fr. om dnvm
t shaft. The
~i11M¢ifJ1 A pair of spur gears consiS s ~fh!
th 2] follow· gear trams are classified mto the
Nning of gear tooth 20-teet h pinion meshin g with a 120-tee 9j[~O
. lllg categories:
module is 4 mm. Calcula te: [S
(i) Si
ledium and Difficult level . (ii) c:le gear train
s of complexity respectively.
Pound gear train
 Spur Gears 801

The minimum number of teeth for 20° pressure

angle is 18. Therefore,
zp = 18

( b)
zg=i zr=4(18)=72
rnn1 pq, (17.33).
f l Qd K =m - Q(mzp)K 6
60x t0 {IO)
6
5='J P Ill M = 60x l0 (kW)
\\
I =
2 Ti "r 2 ,r (1440)

(b)
_ ,n2 _ Q zp K (c)
or s" - 111
=66 314.56 N-mm
. . (b) and (c) in (a), we have The Lewis form factor is 0.308 for 18 teeth
0
(Table 17.3)
Su b:,t1tullnc, 60 x 106 { (kW) C~ }
' b z K = - - - - - - ~ (/5) Y= 0.308
,,,-[;;; )Q , " m ,, n, C,,
starting torque
C~ = - - - - - = 1.5
rated torque
60><106 (kW)Cs<fs)
The velocity factor is unknown at this stage.
m'•-;- ,; 11, C,,(,~ }K Assuming a trial value for the pitch line velocity

l
as 5 mis,

C =-3-=_3_= I
60xl06 (kW)Cs (fs) 1113 V 3+V 3+5 8

m= -;-- z~ "r cv(!?_)Q K (17.36) It is assumed that the ratio (blm) is IO. From
✓ 111
Eq. ( 17.30),
1/J
Ui-~•m-.jr.1111-WIt is required to design a pair
irl:lriJ:11
or spur gears with 20° full-depth involute teeth
based on Lewis equation. The velocity factor is to 60x 106 (kW) C~ (js)
be used to account for dynamic load. The pinion m=
Ti
shaft is connected to a 10 kW, 1440 rpm motor. The
starting torque of the motor is 150% of the rated
torque. The speed reduction Is 4:1. The pinion

l
Iii
as well as the gear is made of plain carbon steel
2
40C8 (Sui = 600 N/mm ). The factor of safety can
be taken as 1.5. Design the gears, specify their (10) (1.5) (1.5)
dimensions and suggest suitable surface hardness
for the gears. [DJ [LO 5] (18) (1440) ( i }10) ( "," )co,o•> I
J
Solution
= 4.16 mm
Giren kW= lO 11 = 1440 rpm i = 4
Sut = 600 N/mm 2 (fs) = 1.5 Step 2: Selection of module
starting torque= 150% (rated torque) The first preference value of the module is 5 mm.
Trial 1
Step 1: Estimation of module based on beam
strength m=5mm
s·ince both gears are made of the same dp =m zp =5(18)=90mrn
material, the pinion is weaker than the gear.
I02 Design of Mac/line Clements
✓
(I
g = 111 zg = 5(72) = 360 mm •#:J.1 11 j,j¢1,J:i
It Is required to design a Pair
gears with 20• full-depth Involute teeth c or 5PtJr
b= tOm= 10(5)=50mm of a 20 teeth pinion meshing with a :slsting
gem. The pinion shaft Is connected to a teeth
Check for design 22
1450 rpm electric motor. The starting torque -~f w,,
motor can be taken as 150% of the rated t the
p = 2 M, = 2 (66 314.56) =
1473 _66 N The material for the ~Inion Is plain carbonor:e.
' dp 90 Fe 410 (Sur = 410 N/mm ), while the gear Is mad el
grey cast Iron FG 200 (Su,= 200 N/mm2). The fa~
of safety is 1.5. Design the gears based on Le,,~
v = ,r dP nP = 1C (90) (1440) = 6.7858 mis equation and using velocity factor to account fo~
60 X I 0 3
60 XI 03 the dynamic load. [0] [LOS]

3 3 Solution
C = - - = - - - = 0.3066
V 3 + V 3 +6.7858 Given kW= 22.5 n = 1450 rpm zP == 20
zg = 50 starting torque= 150% (rated torque)
Perr - c
- Cs p - J.5 (1473.66) = 7209.69 N
1 -
V
o.3066 (Js) = 1.5
For pinion, Su, = 410 N/mm2
From Eq. (17.16),
For gear, Su1 = 200 N/mm2
Sb= m b ab Y = 5(50)(200)(0.308) = 15 400 N
Step 1: Deciding weaker between pinion and
_ Sb _ 15 400 = 2 14 gear
(fs) - peff - 7209.69
~
• The materials of pinion and gear are different
The design is satisfactory and the module From Table 17.3, the Lewis form factors for 20
should be 5 mm. and 50 teeth are 0.32 and 0.408 respectively.
For pinion,
Step 3: Surface hardness for gears
a = Sut = 410 = 136.67 N/mm2
Q= 2 zg = 2 (72) = 1. b 3 3
6
zg + zp 72 + 18 (ab X Y) = 136.67 X 0.32 = 43.73
For gear,
K= 0.16(BHN )2
100 a = Sut = 200 = 66.67 N/mm2
3 3
J
b

SW= b Q dp K = 50(1.6)(90)(0.16{ ~ : ( O'b X Y) = 66.67 X 0.408 = 27.20

The product (ab x Y) is less for the gear. The
gear is weaker than the pinion and it is necessary
=1152(~:J to design the gear.
Since, Sw = Peff lfs) Step 2: Estimation of module based 00 beam
2 strength
1152 ( BHN ) = 7209.69 (1.5) For gear,
100
n = 1450(20) = 580 rpm
BHN = 306.39 or 310 g 50
 Spur Gears 803

it factor is unkno~n at this stage.

p = cs P. = 1.5 (2116.84) _
'fl1e veJoc Y •tch line velocity as 5 mis,
·og the P1 eff Cv t _ - 8800.61 N
Assurn1 3 3 0 3608
3 --=-
Cl' -
- 3-+-V - 3 + 5 8 2
Sb= m b ab Y = 7(70{ ~ }0.408) = 13 328 N

8q, (I 7.30),
frortl 1/3 (fs) = ~ = 13 328 = 1.51
Peff 8800.61
6 (kW) Cs (fs)
60>< 10 The design is satisfactory and the module
:..---
/II::: ft should be 7 mm.

(l~mnm1ii·=: A pair of spur gears with 20° full-

1/3 pth involute teeth consists of a 19 teeth pinion
meshing with a 40 teeth gear. The pinion is
6 ( 22.5) (1.5) (1.5) mounted on a crankshaft of 7.5 kW single cylinder
60X 10
-
- -
IC
I 2
(50) (580) ( }10) ( ~) (0.408)
diesel engine running at 1500 rpm. The driven shaft
is connected to a two-stage compressor. Assume
the service factor as 1.5. The pinion as well as the
gear is made of steel 40C8 (Sut = 600. N/mm2 ).
::6.89 mm The module and face width of the gears are 4 and
Step 3: Selection of module 40 mm respectively. [DJ [LO 6)
(i) Using the velocity factor to account for
The standard value of the module under Choice 2 the dynamic load, determine the factor of
ofTable 17.2 is 7 mm. safety.
(ii) If the factor of safety is two for pitting
Trial 1 failure, recommend surface hardness for
m=7mm the gears.
(iii) If the gears are machined to meet the
dp = m zp = 7(20) = 140 mm specifications of Grade-8, determine
the factor of safety using Buckingham's
dg= m zg = 7(50) = 350 mm equation for dynamic load.
(iv) Is the gear design satisfactory? If not.
b = IO m = 10(7) = 70 mm what is the method to satisfy the design
conditions? How will you modify the
Check for design
design?

M = 60 X 106 (kW)_ 60 x 106 (22.5) Solution

t -
2 7t ng 2 1! (580) Given kW= 7.5 n = 1500 rpm zP = 19
=370 446.85 N-mm zg =40 m=4mm b=40mm C5 =1.5
Sut = 600 N/mm2 Grade of machining - 8
~==:.Ml= 2 (370 446.85) = 2116.84 N Step 1: Factor of safety based on dynamic
dg 350
load by velocity factor
7r d n
V=:--L.p_ - 1[ (140) (1450) = 10.63 m/S Beam strength
60 X 103 - 60 X 103 Since both gears are made of the same materi~,
the pinion is weaker than the gear. The Lewis
cv===~- 6 form factor for 19 teeth is 0.314 (Table !7.3).
6+
V
-
6 + 10.63
= 0.3608 The permissible bending stress is one-third of
 804 Design of Machine Elements

the ultimate tensile strength or 200 N/mm 2 • 1/Step 3: Factor of safety based
Therefore, load by Buckingham's equation on dynamic
Sb= m b ab Y = 4(40)(200)(0.314) = 10 048 N For Grade - 8, e = 16 + 1.25 </J
Tangential force due to rated torque For pinion,
dp = m zp = 4(19) = 76 mm = m + 0.25
</> [ci;
=4 + 0.25 Ji6
60 X 106 (7.5)
60 X 106 (kW) 16
ep = + 1.25 </>
Mt=
2
,r np =
2 ,r 0500 ) =16 + 1.25[4 + 0.25 ✓76]
23 72
= 47 746.48 N-mm = • µm
For gear,
2 Ml 2 (47 746.48)
P.t = - - = - - - - = 1256.49 N dg = m zg = 4( 40) = 160 mm
dp 76
Effective load
</> = m + 0.25 Jci: = 4 + 0.25 ft6o
eg = 16 + 1.25 </J
,r dp np ,r (76) (1500)
V = ---'--;;._ = - - - - = 5.969 m/s
3 = 16 + 1.25 [4 + 0.25 ✓l6Q]
60 X 10 60 X 103
= 24.95 µm
3 3
CV= - - = - - - = 0.3345 e = eP + eg = 23.72 + 24.95 = 48.67 µm
3+ V 3 + 5.969
or (48.67 x 10-3) mm
cs p 1.5 (1256.49) From Table 17.7, the value of deformation
Peff = -C = = 5634.48 N
V
t 0.3345 factor C is 11 400 N/mm2 . Also,
Factor of safety v = 5.969 mis b = 40 mm P1 = 1256.49 N
From Eq. (17.26),
(/s) =~ = 10 048 = 1.?8
Peff 5634.48 _ 21 v (Ce b + ~)
Pd -
Step 2: Surface hardness for gears with (fs) 21v+J(Ceb+ ~)
as 2 = 21 (5.969) [ l l 400 (48.67 x 10-3 )(40) + 1256.49]
Sw = Peff (fs) = 5634.48 (2.0) = 11 268.96 N
21 (5.969) + [ l I 400 (48.67 x 10-3 )(40) + 1256.49]
Q= 2 zg = 2 (40) = 1.356 = 10 555.17 N
zg + zp 40 + 19
peff = (Cs Pt+ Pd)= 1.5(1256.49) + 10 555.17
K= 0.16(BHN )2 = 12 439.91 N
100 Since,
Sw= b Q dp K Sb= 10 048 N and Sw = 11 268.96 N
2 • Sb < peff and Sw < peff
or l l 268.96=40(1.3 56)(76)(0.16)(B HN) The design is unsatisfactory both from the
100
standpoint of strength and wear.
BHN = 413.35 or 420

L
a

Spur Gears 805

dification of design streng th of 600 N/mm 2 . The gears are heat-t reated
steP 4: l\'1° finer grade for the manufacture to a surfac e hardn ess of 400 BHN. The pinion rotate s
at 1450 rpm and the servic e factor for the applic ation
will select a .c load It is assumed that the is 1.75. Assum e that veloc ity factor accou nts for
we duce thedy na;:e d ac~ording to Grade - 6. the dynam ic load and the factor of safety is 1.5.
1ore rnanufac
ears
g · are d e = 8 + 0.63 ¢ [M] [LO 6]
gra e, Deter mine the rated powe r that the gears can
for thtS
transm it.
for pinion, 0 25 'd = 4 + 0.25 -J76
tp== m + • ...;up Solution
_ g + 0.63 ¢ Given n = 1450 rpm zp = 20 z = 41
g
eP: 8 + 0.63[4 + 0.25 -J76] m = 3 mm b = 40 mm Cs= 1.75 (fs) = 1.5
== 11.893 µm BHN =400 Sut =600 N/mm2
Step 1: Beam strength
forge~,== m + 0.25 [ci; = 4 + 0.25 ✓16fJ Since the same material is used for the pinion
e == 8 + 0.63 ¢ and the gear, the pinion is weaker than the gear.
g == 8 + 0.63[4 + 0.25 ✓16fJ] From Table 17 .3, the Lewis form factor is 0.32
== 12.512 µm for 20 teeth.
e==e p+eg =ll.8 93+ 12.512
<Tb= (: )su, = (: )<60 0) = 200 N/mm 2
== 24.405 µm or (24.405 x 10-3) mm
From Eq. (17 .26), Sb= m b Y = 3(40 )(200 )(0.3 2) = 7680 N
ab

21v (Ceb +Pt ) Step 2: Wear strength

Pd= 21v +,.j( Ceb +~) 2 zg 2 (41)
Q= -~ = --= l.3 44
= 21 (5.969) [ 11 400 (24.405 X I 0-3 ) ( 40) + 1256.4 9] zg + zp 41 + 20
21 (5.969) + ✓
2 2
[ 11 400 (24.405 X I0-3 ) ( 40) + 1256.49] K= 0.16 (BH N ) = 0.16 ( 400 ) = 2.56
100 100
=6560.53 N
peff = ( C5 pt+ pd) = 1.5(1256.49) + 6560.53
dp = m zp = 3(20) = 60 mm
= 8445.265 N SW= b Q dp K = 40(1.344)(60)(2.56)
The beam strength is lower than the wear
Slrength. Therefore
= 8257.54 N
' Step 3: Effective Load
(fs) == ~ = 10 048 = 1. l 9 v = 7r dp np O450) = 4.5553 mis
7r ( 60)
peff 8445 .265
60 X 103 60 X 103
~~e
h a ~iss
lls • factory.
3 3
1

de~th i~volut• A pair of spur gears with 20° full-

C =- -= --- =0 .39 7
meshing Withe teeth consis ts of a 20 teeth pinion
V 3 + V 3 + 4.5553
While the f a 41. teeth gear. The modu le is 3 mm
Pini0 ace Width •
naswellas e . is 40 ~m. The mater ial for Perr= Cs pt= 1.75 p = (4.41 P) N
9 ar is steel with an ultima 1
te tensil e CV 0.397 1
 806 Design of Machine Elements

Step 4: Static load Step 1: Estimation of module based on b

In this example, the beam strength is lower than strength earn
the wear strength. Therefore, beam strength is 1 l
the criterion of design. a= (dp + dg) or 250 = -(d + d )
2 2 p g
Sb= Petrlfs) or 7680 = (4.41 Pl) (1.5) ... (dP + dg) = 500 mm
... pl= 1161 N (a)
d n 1000
Step 5: Rated power Also, _!_ = _£_ = - - = 4
dP ng 250 (b)
M = P._ dp = 1161(60) = 34 830 N-mm
From (a) and (b ),
t 2 2
_ 2 ,r np Mt _ 2 ,r (1450)(34 830) dp = 100 mm and dg = 400 mm
kW - ---"- - - - - - - - - = 5 ·29
6
60 X 10 6
60 X 10 1l dp np 1! (100) (1000)
I (Ans.)
V =
60 x 103
3
60 xl0 3
= 5.236 m/s

Example 17.11 It is required to design a spur 3

C = - = 0.3643
I gear speed reducer for a compress or running
at 250 rpm driven by a 7.5 kW, 1000 rpm electric
motor. The centre distance between the axes of the
gear shafts should be exactly 250 mm. The starting
V 3 + V 3 + 5.236
The face width is assumed to be ten times that
torque of the motor can be assumed to be 150% of module. The Lewis form factor is unknown
of the rated torque. The gears are made of carbon at this stage. It varies from 0.32 (for 20 teeth) to
steel 50C4 (Sut = 700 N/mm 2 ). The pressure angle is 0.358 (for 30 teeth). Assuming an intermediate
20°. The factor of safety is 2 for preliminary design
based on the use of velocity factor.
value,
[D] [LO 6]
(i) Design the gears and specify their Y= 0.34
dimensions.

J (ii) Assume that the gears are manufact ured

to meet the requireme nts of Grade - 6
and calculate the dynamic load by using
Buckingh am's equation.
(iii) Calculate the effective load.
Sb= m b c,b Y = m(IOm { ?~ }o.34)

= (793.33 m 2 ) N
(c)

(iv) What is the actual factor of safety against 60 X 106 (kW) 60 X 106 (7.5)
bending failure? M - ------ - -----
(v) Using the same factor of safety against
t - 21ln - 21r(lOO0)
p
pitting failure, specify suitable surface
hardness for the gears.
= 71619.93 N-mm

Solution p = 2 Mt = 2 (71 619.93) = 1432.39 N

Given kW = 7 .5 nP = 1000 rpm t dp 100
ng = 250 rpm a = 250 mm p = Cs p = 1.5(1432.39)
589 ?.85 N (d)
starting torque= 150% (rated torque) eff C t 0.3643
V

Sut = 700 N/mm2 (fs) = 2 From (c) and (d), 7

Grade of machining - 6 Peff (fs) = Sb or 5897.85(
2) = 793.33 n(
m= 3.86mm
 Spur Gears 807

dirnensions
= 21 (5.236) [11 400 (25.765 X I0-3 ) (40) + 1432.39]
steP z: Gear value of the module is 4 mm.
rst preference
r11efi - 4 mm
21 (5.236) + J[1 I 400 (25.765 xio- 3) (40) + 1432.39 J
m- ,n == 10(4) == 40 mm = 6448.30 N
b::: I0
Step 5: Effective load
dP -~==25
Zp ::: - ; - 4 Perr = ( Cs Pt+ Pd)= 1.5( 1432.39) + 6448.30
= 8596.89 N
zg- ---
m
dg -~=100
4 Step 6: Actual factor of safety against
e J: Beam strength bending failure
5t p ~ ble 17 .3, the Lewis
form factor for
from .a
... (fs) = Sb = 12 693.33 = 1.48
25 teeth is 0.34. ( 700 ) Peff 8596.89
Sb== m b ab Y = 4(40) - - (0.34)
3 The design is satisfactory and the module
== 12 693.33 N should be 4 mm.
Step 4: Dynamic load by Buckingham's Step 7: Surface hardness for gears
equation
Q = 2 zg = 2 (100) = 1. 6
For Grade - 6,
zg + zp 100 + 25
e = 8 + 0.63 </>
For pinion,
Petr (fs) = Sw or Petr (fs) =b Q dp K

q,= m + 0.25 Ji;=

4 + 0.25 ✓100 :. 8596.89(1.4 8)=40(1.6)( 100)(0.16)( BHN )
2

ep = 8 + 0.63 </> 100

BHN =352.49 or 360
= 8 + 0.63[4 + 0.25 ✓100]
= 12.095 µm Step 8: Dimensions of gears
For gear, (i) number of teeth on pinion = 25
(ii) number of teeth on gear = l 00
q, = m + 0.25 fci: = 4 + 0.25 ✓400
(iii) module = 4 mm
eg =8 + 0.63 </> (iv) face width= 40 mm
= 8 + 0.63[4 + 0.25 .f400] (v) pitch circle diameter of pinion= 100 mm
=13.67 µm (vi) pitch circle diameter of gear = 400 mm
e = eP + eg ==12.095 + 13.67 (vii) addendum (m) = 4 mm
= 25.765 µm or (25.765 x 10-3) mm (viii) dedendum (1.25 m) = 5 mm
(ix) clearance (0.25 m) = I mm
;rom Table 17.7, the value of deformation
(x) tooth thickness ( 1.5708 m) = 6.2832 mm
actor C is 11 400 N/mm2 . Also,
(xi) fillet radius (0.4 m) = 1.6 mm
v == 5•236 mis b == 40 mm Pt= 1432.39 N
From Eq. ( 17 .26), • Exam le 17.12 It is required to design a two-stage
spur gear reduction unit with 20° full depth involute
teeth. The input shaft rotates at 1440 rpm and
Pd:::: 2lv(Ceb +~) ~ receives10kW powerthrough aflexiblecoup ling. The
21 v +.J (Ce b + ~) speed of the output shaft should be approximately
 utan1/12 p or b> P
- tan 1/1
From Eq. (\8.3),
p - nm nm zm
- - -
tan 1/1 tan 111 - -----= -"=--- - n
tan 111
T cos 1/f
- •
T sin 1/1
Therefore
) '
b ~ 7r mn
. (18.14)
Sli l 1/f

Jf This is the minimum face width.

.4. J ? .® M f· & A pair of parallel helical gears
consists of a 20 teeth pinion meshing
with a
40 tee th gear. The helix angle is 25° and the
normal
pressure ang\e is 20°. The normal module
is 3 mm.
Ca\cu\ate:
\b {\) transverse module;
[S] [L03]

l {ii) transverse pressure angle;

{\ii) axial pitch;
{iv) pitch circle diameters of the pinion
and
the gear~
{v) centre distance~ and
{vi) addendum and dedendum circle
diameters of the pinion.

·els of complexity respectively.

 1111
•
820 Design of Machine Elements

Solution 18.5 FORCE ANALYSIS

Given zP = 20 zg = 40 m0 = 3 mm The resultant force P acting on th
f// = 25° an = 20° . . e to
he1tea1 gear ts reso1ved into three
corn
Step 1: Transverse module Pt, Pr and Pa as shown in Fig. 18.S(a),,1
m 3 Pt = tangential component (N)
m= n - =3.31 mm (i) Pr= radial component (N)
cos f// cos (25°)
Pa = axial or thrust component (N)
Step 2: Transverse pressure angle The normal pressu~e angle ~ is in pla
shaded by dots, while the helix angle tp
tan an tan (20) (t't') lower plane BCD.
tan a= - - - - or a= 21. 880
cos f// cos (25) From triangle ABC,
Step 3: Axial pitch Pr= P sin a 11
p Hm H (3.31) BC= Pcos a 0
p = - - = - - = - - - = 22.3 mm (iii)
a tan f// tan f// tan (25)

Step 4: Pitch circle diameters of pinion and

gear
d = zp mn = 20 (3) = 66.2 mm
P cos f// cos (25)

d = zg mn = 40 (3) = 132.4 mm
g cos f// cos (25) (iv)
Step 5: Centre distance
dp + dg 66.2 + 132.4 ntre line
a= - =99.3mm (v) fteeth
2 2
_tfilep 6: Addendum and dedendum circle .:::::::::r-
__, diameters of pinion
n~M@ ........
1 ······
~tch
da = mn [ z + 2] ·-::\:'//://:: cylinde
cos f//
(a
20 B
= 3[ + 2 ] = 72.2 mm
cos (25°)

df = m 11 [ z - 2.5]
cos f//

20
= 3[ - 2.5] = 58.7 mm (vi)
cos(25°)
 Helical Gears 827

, and z~ respectively. The ratio Example 18.4 A pair of parallel helical gears
consists of a 20 teeth pinion meshing with a
~ernal helical gears is given by 100 teeth gear. The pinion rotates at 720 rpm.
The normal pressure angle is 20°, while the helix
(d) ~le is 25°. The face width is 40 mm and the
v111ormal module Is 4 mm. The pinion as well as the
gear is made of steel 40C8 (Sut = 600 N/mm 2 ) and
heat treated to a surface hardness of 300 BHN.
The service factor and the factor of safety are 1.5
Zg ' zp and 2 respectively. Assume that the velocity factor
and z =
3 accounts for the dynamic load and calculate the
3
os f// P cos f//
power transmitting capacity of gears. [M] [LO 5]
! have
Solution
2 zg
(18.25) Given = 720 rpm zP = 20
nP zg = 100
g +zp
mn = 4 mm b = 40 mm
,r a pair of internal helical gears, it
f/1 = 25°an= 20° Sut = 600 N/mm2
!d that
BHN = 300 Cs= 1.5 (fs) = 2
(18.26) Since both gears are made of the same material,
zg- zp
the pinion is weaker than the gear.
md zP are actual number of teeth Step 1: Beam strength
tr and the pinion respectively. The
rlgle in a plane perpendicular to the z 20
z' = P --- = 26.87
.entis an. The Kfactor in Eq. (18.24) P cos3 f// cos3 (25)
f
From Table 17.3,
;man cosan _ (0.348 - 0.344)(26.87-26) = 0 3475
y - 0 •344 + (27-26) •
(18.27)
1.4
• ~
,c:: sur1ace endurance strength (N/mm )
2 a = Sut = 600 =
200 N/mm2
b 3 3
·2:: moduli of elasticity of materials for
Sb= mn b ab Y= 4(40)(200)(0.3475) = 11 120N
.pinion and gear (N/mm2)
f -
·n - normal pressure angle (20°) Step 2: Wear strength
g to Section 17 .21 Eq. (17 .35), Q= 2 zg = 2(100) = 1.667
===0.16(BHN \2 zg + zp 100 + 20
(18.28)
100 ) 2
ve equ t' . applicable for steel gears d = P mn = 20(4 ) = 88.27 mm
0 a ion 1s P cosf// cos(25°)
. normal pressure angle. In order to
ilure of gear tooth due to pitting,
":::,. peff
K = 0.16 (BHN J2
100
:ing a factor of safety, 2
f (fs)
(18.29)
3
= 0.16 ( 00
100
J = 1.44 N/mm 2
 828 Design of Machine Elements

(ii) Select the first preference valu

b Q dp K 40(1.667)(88.27)(1.44) e Of t1.
norma I module and calculate th "1!:
Sw = cos2 lf/ cos2 (25) dimensions of the gears. e lllain
(iii) Determine the dynamic load .
= 10 318.58 N Buckingham's equation and find using
effective load for the above dime~~ the
Since wear strength is lower than beam strength, What is the correct factor of saf styions.
pitting is the criterion of failure. bending? e . for
(iv) Specify surface hardness for the
Step 3: Tangential force due to rated torque assuming a factor of safety of 2 fo(ears,
consideration. Wear
v= Jrdp np = ,r (88.27) (720) = _ mis
3 3
3 328 Solution
60 X 10 60 X 10
Given kW= 2.5 nP = 5000 rpm zP == 24
C = 5.6 = 5.6 = 0.7543 i = 4 lf/ = 23° an= 20° Sut = 750 N/rnm2
V 5.6 + ✓v 5.6 + ✓3.328 C5 = 1.5 (fs) = 2 Grade of machining== 4
From Eqs. ( 18.29) and ( 18.19),
Step 1: Estimation of module based on
sw =Cs-PtC- -(fs)- dynamic load by velocity factor
V 60 x 106 (kW) 60 x106 (2.5)
M=------
10 318.58 = l. ~ < )
5 2
or t 2 1! np 2 ,r (5 000)
0.7543
... Pt = 2594.43 N = 4774.648 N-rnm
z mn 24 m
Step 4: Power transmitting capacity of gears d = P - n = (26.073 m0 ) mm
P cos lf/ cos (23)
M _ ~ dp _ 2594.43(88.27)
t - 2 - 2 p = 2 M, = 2(4774.648) =(366.25]N
-l-,
p = 114 505.39 N-mm t dp 26.073 mn m0

2,r nP Mt 2,r(720)(114 505.39) C = 5.6 5.6 = 0.6391

kW = ---=-----
60 X10 6 60 X 106 5.6+ ✓v
l
v 5.6+M
= 8.63 (Ans.) P ff = Cs Pt = 1.5 (366.25 )= (859.61 N (a)
e Cv 0.6391 mn mo
Example 18.5 A pair of parallel helical gears ✓
consists of 24 teeth pinion rotating at 5000 rpm
2
, =
2
p = 24 30.77 =
and supplying 2.5 kW power to a gear. The speed P 3 3( )
reduction is 4:1. The normal pressure angle and cos lf/ cos 23
helix angle are 20° and 23° respectively. Both gears
are made of hardened steel (Sut = 750N/mm 2). The
From Table 17.3,
service factor and the factor of safety are 1.5 and -(0.364 - o.358)(30.77-~:::o.36
2 respectively. The gears are finished to meet the y = 0.358 + (32-30)
accuracy of Grade-4. [D] [LO 5]
(i) In the initial stages of gear design,
assume that the velocity factor accounts ab= Sut = 750 = 250 N/mm2
for the dynamic load and that the face 3 3 ~
width is ten times the normal module. Sb = mn b ab y = mn( 10 mn)(250)(0.3 (b)
Assuming the pitch line velocity to be
10 m/s, estimate the normal module. = (900 m~) N
 Helle

I
lue e = eP + eg =
3.9659 + 4.356
5 :::: Peff (/s)
theor 1he t Since, = 8.3226 µm or (8.3226 x
main ( b) and (b),
ld I froJJl a ] Also, C = 11400 N/mm 2 b = 15 r.
d llsJrig
2_ (859.61 (2.0)
Ou/ 1/i Pr= 244.16 N
lens/one I 900 ,nn - m0
afety ,; 1t dP nP 1t (39.11)(5000)
(i)
,nn -- 1241nm
• V = --=----=- - = - - - - - - = 1(
e' 9ears,
~~. I I
fhe first P
• ,nm.
aJ<en as 15
t
reference va Iue of the module is

M •n dimensions of gears
60 X J0 3
From Eq. (18.2 J),
60 X 10 3

_ 21 v (Ceb cos 2 1/J'+ ~) co

Step 2: a1 Pd -
::: 24 mn == I.5 mm 21 v +J (Ceb cos 2 I//+ f
b == IO mn = 10(1.5) = 15 mm
21 (10.24) [ I 1400(8.3226 x io-3 ) (15) cos 2 (23)+ 244.
z m 24 (1.5) _
d - P 0 = - - - - 39. l l mm 21 (I0.24) + [11400(8.3226 x io-3 ) (I 5) cos 2 (23)-t
d on P - cos1/)' cos(23)
= I 133.94 N
d _ zg mn = ( 24 x 4 )(1.5) = 156.44 mm (ii) From Eq. (18.22),
g - cosYJ" cos(23)
~ff= (C5 Pt+ Pd)= 1.5(244.16) +JI
Step 3: Effective load based on dynami c load = 1500.18 N
by Buckingham's equatio n
Step 4: Correct factor of safety
m Beam strength
Sb= m0 b O'b Y = 1.5 ( 15)(250 )(0.36) = 2025 N ... (fs) =
S
_b
2025
= - - = 1.35
Tangential force due to rated torque
~ff 1500.18
Step 5: Surface hardness for gears
p 2 Mt 2(4774. 648)
t == = - - - - = 244.16 N zg = i zp = 4(24) = 96
dp 39.11
Dynamic load
SW = ~ff (fs) = 1500.18 (2.0) = 3000.:
From TabJ 17 8 Q = 2 z8 = 2 (96) . = l.
by e • , the error for Grade-4 is given 6
z + zP 96 + 24
8
e == 3.20 + 0.25 </J S = bQdPK
Where ¢- r:
For ..- mn + 0.25 -yd 2
Pinion
'
• </J:::: m.n + 0.25 ✓d P =1.5 + 0.25 ✓39.11 w cos ~5 (1.6)(39.11) [0.16 (~:

+ 0.25 (1.5 + 0.25 ✓39.11)

3 20
eP:::: •
3000.36 = cos 2 ( 23 )
For gear :::: 3.9~59 µm
' :. BHN = 411.44 or 420.
</>::::111 +o 25 r:
e _" -Yd g = 1.5 + 0.25 ✓156.44
• Example 18.6 A pair of parallel helical g
g =· 3 20
~ 0.25 (l.5 + 0.25 ✓156.44)
-4.3567 µm
consists of 30 teeth pinion rotating at 4000
and supplying 10 kW power to a gear. The sp
reduction is 4.5:1. The normal pressure angle
 832 Design of Machine Elements

forces automatically position the other

gear so that no external forces are present. d = 2 P mn _ 26(2)
P COS'lf - cos(25) === 57.38 lllJn
Herringbone and double helical gears are used
in high power applications such as ship drives p = 2 Mt = 2(132629.12)
and turbines. t dp 57 .38 ::: 4622.83 N
The helix angle for a single helical gear is
Step 2: Effective load
from 15° to 25°. Herringbone and double
helical gears permit higher helix angle because v = 1l dP nP = 1l (57.38) (3600)
there is no thrust force. The helix angle for 3
60 X 10 60 X 103 :: 10.82 lll/s
herringbone and double helical gears is from
20° to 45°. The design procedure and design C = 5.6 = 5.6
equations for herringbone and double helical V 5.6 + ✓v 5.6 + ✓Irl82, :: 0.63
gears are the same as for a single helical gear. p _ cs ~ _ 1.25 (4622.83)
In design, herringbone or double helical gear eff - Cv - 0.63 = 9172.28 N
is considered as equal to two identical helical
gears, each transmitting one half power. Step 3: Beam strength
d.F\11\.1/W(:Q A herringbone speed reducer Z
, = 2
p 26
----=34.93
I. .Jconsists of a 26 teeth pinion driving a 104 teeth P cos 'If 3
cos3 (25)
' gear. The gears have a normal module of 2 mm. The
pressure angle is 20° and the helix angle is 25°. The From Table 17.3,
pinion receives 100 kW power through its shaft and
rotates at 3600 rpm. The face width of each half is y = 0.367 + (0.373 - 0.367)(34.93-33)
35 mm. The gears are made of alloy steel 30Ni4Cr1
(Su, = 1500 N/mm2) and heat treated to a surface
(35 -33)
hardness of 450 BHN. The service factor is 1.25. = 0.37279
[M] [LO 6]
Determine the factor of safety against bending failure O"b = Sut = 1500 = 500 N/mm2
and against pitting failure. 3 3
Sb= m0 b O"b Y = 2(35)(500)(0.37279)
Solution
= 13 047.65 N
Given kW= 100 nP = 3600 rpm zP = 26
Step 4: Wear strength
zg = 104 m0 = 2 mm b = 35 mm
'If = 25° ~ = 20° Sut = 1500 N/mm2 2 zg 2(104)
Q = ____;~ = - - = 1.6
BHN = 450 Cs = 1.25 zg+zp 104+26
Since herringbone gear consists of two identical
pairs of helical gears, the power transmitted by K = 0.16 (BHN )2
100
each pair.is (100/2) or 50 kW.
2
45 2
Step 1: Tangential force due to rated torque = 0.16 ( o) = 3.24 N/mm
100
60 x 106 (kW) 60 xl0 6 (50) bQd K 35(1.6)(57.38)~
M ------ - ----
t - 2 1l nP - 2 1l (3600) S -- p _..::...::_::,.__~~-
- ?
w cos2 'If cos- (25)
= 132 629.12 N-mm
= 12 674.83 N
 Helical Gears 833

safety 2 674.83 138

Step S: Factor o f ( ft ) = SW = 1 (ii)
9172.28 =
~ ff
s ) == Sb 13 047.65 _ 2 (i)
(/ 8 - l. 4
~ff 9172.2

End Note Hill In c.

echanics o f Gears' - McGraw
al M
rle - 'Analytic
/Buckingham Ea

with sli]?.ti-Jfhswers lical ge ar? [LO 61

Questions le he
~ .. . ub
•..·.: :-!!'!-~-::: •-- a do
18.9 0 What is gb on e he lical gear? [LO 61
rrin
t between mating teeth o f 18.10 0 What is
a he
en ce between double
and
ntac di ff er
l8.1 0 Compare the co [LO 11 18.11 0 What
is the
ge ar s?
[LO 61
ears. e he lic al
spur and helical g s o f h elical gears over herringbon
es of herringbone an
d double
18·2 I What are the
ad v an ta g e
[LO 11 e
18.12 State tw o ad va ntag
CLO 61
d
s.
spur gears? [LO 11 helical ge ar
an tage s of herringbone an61
183 0 Where do you u
se h elic a l g ea rs ?
[LO 1
1
18
_1
3
e State two di sa dv
s.
CLO
a r? lic al ge ar double
18 .4 0 What is a parallel
helical ge [L O 1
1 double he
re do yo u us e
d
herringbone an {LO 6/
A Wh
18•5 0 What is a crossed h
elical gear? e
r fo n na tiv e h e lical gear? [LOn21d 18.14 V
helica l ge ars?
~·6 I What is v
irtual o a
re latio n sh ip between actual ?
1 •7 0 What is th e le.
tee th a nd the helix ang~
. o f ~
virtu,al number
•ng1e
si
an ta g e o f a
18.8 0 What is the main disadv [L O
61

ical gear? W ha t is the remedy? . , 1 mJll, The

helix angle
• 200 •
hel is -
1odule I pressure angle is
I n {LO 3/
The norma e norma
is 230 while th
Prob/ems for Pr
actice
5 teeth module;
. 8 2 Calculate:
s of 1 (i) transverse re
ssure angle; and
18.J OA Par.r of helical gears consist ml
.
ith a 5 0 te e th gear. The no;~:C .') transveitc
·aJ
rse p
h. . 57°(iii)24.JJm
oa sists o f lll1
w
PIilion meshing re qu ire d va_Jue oactly (JJ
(iii! axi p() J 26 !ll lfl ( ll) 2I.
ar. The
. Fin d th e e 1s ex lical gears c th ge
ill~duJe is 4 mm . · ' ~ le i h e
[LO 31 [A!lS mthfOUgh
heJix angle, if the centre d1 st anc
a ir o_f p m es hing with a45 tee h·1 the
(J A p
Wpawer at• 206()m0illrp, w 1 e
165 [Ans- 24.620] 18.4 J 8 tee th p in io n
of a . 1 5k gle. is
mm. m o dul; is e helix an
1 c~~~ inion rece 1v e~ o;m a1 d aJ1al
is 20.• Th dial an tween
8.2 AV A · e lic a l g e ars. . 3.1. The t. T he angl e
p shaf re tangenual, ra ~ rce be
rallel h • ratio is is•5 IJ1lll·
20 Pair .o.f pa al pressu (LO 4J
teeth p1n1on and the velo ity c 1 [LO 31 1ts
tefOVoe th~sultaJll tooth o
her e n orm a l rn o du e oo~fllpe th -" 259.10 NJ
Je i.~ 150 and th A the ,.,,ts of e . -,J1.36 anu