In a spur gear drive for a stone crusher, the gears are made of C40 steel.

The pinion
is transmitting 30kW at 1200 r.p.m. The gear ratio is 3. ear is to !ork " hours per
da#, si$ da#s a !eek and for 3 #ears. %esign the drive.
P = 30 kW, N
1
= 1200 rpm, i = 3
Since the pinion and gear are made of same material, therefore we have to do the design
of pinion alone.
&aterial selection Pinion and gear are made of ! "0 Steel,
#ss$me s$rface hardness % 3&0
'ear life = ( ) &2 ) * ) 3 = +"(( ho$rs
,ife in n$m-ers of c.cles, N = *0 ) +"(( )1200 = &3./ ) 10
+
c.cles
!alc$lation of initial design tor0$e 12
t
3
4esign tor0$e 12
t
3 = 2
t
. 5. 5
d
= 1.3 ) 23(.+3 = 310.3" Nm
Calculation of '
e(
, )*
+
,, )*
c
,-
6
e0
= 2.1& ) 10
&
N7mm
2
n = 2 5
8
= 1.& , N= &3./) 10
+
c.cles9 5
-l
=0.+, 8
$
= *30 N7mm
2
2
1
7 & . **2 120 3& . 0 mm N
u
+

1
" . 1
3 1

nK
K
bl
b
= 111.23 N7mm
2
!:= 2*.& ;:! = && 5
cl
= 0.&(&
[ ] Kcl HRC
R
C
c

= (&2.*" N7mm
2
Center distance #ss$me < =0.3
[ ]
[ ]
3
2
+" . 0
= 1 >

,
_

,
_

+
i
t
M
eq
E
c
i a
= 1&& mm
?
1
= 1+, ?
2
= i.?1 = 3 ) 1+ = &1
2 1
2

z z
a
m
+

= ".&* mm standard m = & mm

.evised Center distance a = 1+0 mm
Calculation of +, d
1
, v and /
p
-
- = <.a = 0.3 ) 1+0 = &1 mm
d
1
= m.?
1
= & ) 1+ = (& mm
Picth line velocit. >v= =
2 1


1 1
z z
N d
+

= &.3" m7s
<
p
= -7d
1
= 0.* 5 =1.03 5
d
= 1." .evised %esign tor(ue )&
t
, 0 344.24 1m
Check for 2ending-
abmy
t
M i
b
3 =1 1 > +
= (*.+( N7mm
2
@ 18
-
3
Check for !ear strength-
ib
i
t
M
eq
E
a
i
c
1
3 1
= 1 >
+" . 0
+ +
= +*&./ N7mm
2
@ 18c3
3 helical gear !ith 30
o
heli$ angle has to transmit 34 kW at 1400 rpm !ith a speed
reduction ratio of 2.4. If the pinion has 24 teeth, %esign the gear for 20
o
full depth
teeth and service is continuous. 3ssume 401i2Cr1&o2" material for +oth pinion
and !heel.
Selection of material properties
8
$
= 1&&0 N7mm
2
S$rface hardness && :! and core hardness%3&0A;N
!alc$lation of design stresses
n = 2.& 5
8
= 1.& N= 10000 ) *0 ) 1&00 =/0 ) 10
+
c.cles9 5
-l
=0.+
1
" . 1
3 1

nK
bl
K
b
= 1+3.1N7mm
2

2
7 & . **2 120 3& . 0
1
mm N
u
+

!:= 2*.& ;:! = && 5
cl
= 0.&(&
[ ]
cl
K HRC
R
C
c

=(&2.*N7mm
2
12
t
3 = 2(/.** N.m 6 = 2.1)10
&
i = 2.& < =0.&
[ ]
[ ]
3
2
+ . 0
= 1 >
,
_

,
_

+
i
t
M E
c
i a
= 112.03 mm
2 1
cos 2

z z
a
n
m
+

= 2."+ mm Standard mod$le = 2.& mm

:evise the !enter distance a = 122.&mm
!alc$late - = < a = *1.2& mm
:evise design tor0$e
5 =1.0* k
d
= 1.2
12t3 = 2(3." Nm
v
y
n
abm
t
M i
b
3 =1 1 > + . 0 +

= (1.(/ N7mm
2
@ 18
-
3
ib
i
t
M E
a
i
c
1
3 1
= 1 >
+ . 0
+ +
= +3+ N7mm
2
@ 18c3

%esign a hardened steel !orm and phosphor +ron5e !orm !heel to transmit 14 kW
from an electric motor running at 1440 rpm to a shaft running at "0 rpm. 3ssuming
the friction coefficient +et!een !orm and !orm !heel as 0.03, calculate the
transmission efficienc# of the !orm drive. 3lso check for heat dissipating capacit#.
Selection of material
Worm B Steel Wheel B Aron?e >Sand !ast=
8
$
@ 3/0 N7mm2 18
-
3 = &0 N7mm2 >:otation in one direction=
!alc$lation of !entre distance
Speed red$ction i = 1(9 No of starts C = 3 ? = i C = &"9 0 = 11
#ss$me 18
c
3 = 1&/ N7mm
2
at Ds = 3 m7s 9 kk
d
= 1
Wheel tor0$e 12t3 = 1+/0."/N.m
[ ]
10
3 1
3 =1 7 >
&"0
1 = 7 >
2
3
t
c
M
q z
q z a
1
]
1

= 2*0.&2 mm
!alc$lation of a)ial mod$le
m
)
= 2a7>0E?= = (.01mm Standard m
)
=10mm
:evise a and o-tain d
1
a = 0.& m
)
>0E?= = 32& mm
Pitch circle diameter of worm = d
1
=0 m
)
= 110 mm
Ds=D17cosF tanF= C70 = % lead angle F = 1&.2&
o
D1 = Pitch line velocit. of the worm
=

,
_

1000 *0
1 1
n d
= (.3 m7s
:evised 18
c
3 = 12+ N7mm
2
%etermination of induced stresses
10
3
1 = 7 >
7
&"0
1
1
]
1

1
1
]
1

t
M
a
q z
q z
c

= 120 N7mm
2
@ 18c3
[ ]
v x
t
b
qzy m
M
3
/ . 1

= 2.33 N7mm
2
@ 18
-
3
= tan>
tan
/& . 0

= 0.("/
6eat .emoval 3nal#sis
>1GH= ) Inp$t Power = 22*0 Nm
%esign a 12 speed gear +o$ for an all geared headstock of a lathe. &a$imum and
minimum speeds are 700 rpm and 24 rpm respectivel#. The drive is from an electric
motor giving 2.24 kW at 1440 rpm.
Progression ratio
1
1
min
ma)

,
_

N
n
n
= 1.33& Where N B No of Speeds in gear -o)
Jrom :"0 series Speed >Skip " speeds= B 2&,33.&, "&, *0, (0, 10*, 1"0, 1/0, 2&0, 33&, "&0 and
*00 rpm
Str$ct$ral form$la for 12 speeds
= 3>1= 2>3= 2>*=
3 machine tool gear +o$ po!ered +# 11 kW, 890 rpm motor is to give 14 spindle
speeds ranging from 20 to 400 rpm. %ra! the kinematic arrangement and the speed
chart.
Progression ratio
1
1
min
ma)

,
_

N
n
n
= 1.2&/ Where N B No of Speeds in gear -o)
Jrom :10 series Speed B 20,2&,31.&,"0,&0,*3,(0,100,12&,1*0,200,2&0,31& and "00 rpm
Str$ct$ral form$la for 1( speeds
= 3>1= 3>3= 2>/=
1" Speeds are re0$ired
Str$ct$ral form$la for 1" speeds
= 3>1= 3>3= 2>/G"=
5inematic #rrangement for 1" speed gear -o)
:a. diagram