Design Transmission Systems

DESIGN PROCEDURES
DESIGN OF TRANSMISSION SYSTEMS

UNIT
DESIGN PROCEDURE FOR FLAT BELT DRIVE:-
STEP: 1 Calculation of pulley diameters:

Velocity ratio (i) =
Where N1 = Driver pulley speed in rpm.

N2 = Driven pulley speed in rpm.
D = Diameter of driven pulley.
d = Diameter of driver pulley.
STEP: 2 Calculation of the design power in KW:
Design KW =
Rated Kw is given in the problem.

Load correction factor (Ks) Taken from PSG DDB Page No: 7.54
Arc of contact factor (Ka) Taken from PSG DDB Page No: 7.54 for that we
much calculated the
= 180
) X 60
If C is not Given Assume 1 meter ( 1000mm)

Small pulley factor (Kd) Taken from PSG DDB Page No: 7.62.
STEP: 3 Selection of Belt:
Select a belt referring from PSG DDB Page No: 7.54.
STEP: 4 Load rating correction:
Load rating at V m/s = Load rating at 10 m/s
Velocity of belt (V)
m/sec
From DDB Page No: 7.54.
DESIGN PROCEDURES
STEP: 5 Determination of belt width:
Width of the belt =
No of Piles Taken from PSG DDB Page No: 7.52. Plies based on the Belt
Speed in m/sec.
STEP: 6 Determination of Pulley Width:
Based on Belt width Ref table From PSG DDB Page No: 7.54.
STEP: 7 Calculation of length of the belt:
Referring from PSG DDB Page No: 7.53. Which type of drive given
corresponding Drive formula used (Ex. Open belt drive)
DESIGN PROCEDURES

UNIT
DESIGN PROCEDURE FOR FLAT BELT PULLEY:STEP: 1 Calculate the Dimensions of the Pulley:
v=
m/sec
STEP: 2 Calculate the Width of the Pulley( ):
Where
(T1-T2) v
Tc
mv2
m
=
Mass of the belt per meter length
m
=
Density X Volume
Density of leather belt is 1000Kg/m3
T
=
X Area of belt
(Area = b X t)
T1
=
T Tc
After finding the width of the Pulley find out the thickness of the Pulley
rim also Ref PSG DDB Page No: 7.57.
STEP: 3 Calculate the Dimensions of arms:
Number of arms (n) Ref PSG DDB Page No: 7.56.
Cross section of the arm Ref PSG DDB Page No: 7.56.
Arms taper Ref PSG DDB Page No: 7.56.
Radius of the cross section of arms
STEP: 4 Calculate the Dimensions of Hub:
Diameter of the Hub (d1)
d1
1.7 To 2.0 times of Diameter of the Shaft (d2)
Length of the Hub ( )
Where
= Width of the Pulley
Ref PSG DDB Page No: 7.56.

Crown of the Pulley Ref PSG DDB Page No: 7.55.
DESIGN PROCEDURES

UNIT
DESIGN PROCEDURE FOR V - BELT DRIVE:-
STEP: 1 Selection of belt section:

Select the belt cross section depending on the power to be transmitted.
Ref PSG DDB Page No: 7.58
STEP: 2 Selection of pulley diameters (d and D)
Select the small pulley diameter (d) from Ref PSG DDB Page No: 7.56.
Using speed ratio (i) find the larger diameter (D) for std Diameter
Ref PSG DDB Page No: 7.54.
STEP: 3 Selection of Center distance (C):
Using speed ratio (i) find the (C) Ref PSG DDB Page No: 7.61
STEP: 4 Determine the nominal pitch length:
Referring from PSG DDB Page No: 7.53. Which type of drive given
corresponding Drive formula used (Ex. Open belt drive)
STEP: 5 Selection of various modification factors:

1. Length correction factor (Fc)
Referring from PSG DDB Page No: 7.58 7.60
2. Correction factor for arc of contact (Fd)
= 180
) X 60
Referring from PSG DDB Page No: 7.68.
3. Service factor (Fa)

Referring from PSG DDB Page No: 7.69. Its taken from load transmitted
which depends upon the characteristics of the driving and driven units.
4
DESIGN PROCEDURES
STEP: 6 Determination of Maximum power capacity:
Referring from PSG DDB Page No: 7.62. Its taken from belt cross section symbol
S = Belt speed, m/sec.
de = dp X Fb
dp = Pitch diameter of the smaller pulley, mm.
Fb = Small diameter factor to account for variation of arc contact, Ref
Page No. 7.62.
STEP: 7 Determination of No. of Belt (nb)
STEP: 8 Calculation of actual centre distance:

DESIGN PROCEDURES

UNIT
DESIGN PROCEDURE FOR CHAIN DRIVE:-
STEP: 1 Selection oF Transmission Ration
STEP: 2 Selection of No. of Teeth on the Drivers Sprocket (Z1)

Assume the z value based on the transmission ratio (i)
STEP: 3 Determine No. of Teeth on the Driven Sprocket (Z2)
Z1, Z2 ODD Number for uniform wear

STEP: 4 Selection of Standard Pitch (P)
Centre distance a = (30 50) P
Ref PSGDDB Page No: 7.74.
STEP: 5 Selection of Chain

STEP: 6 Calculation of total load on the driving side of the chain (PT)
(i)
Tangential Force (PT)

Ref PSGDDB Page No: 7.78
(ii)
Centrifugal tension (PC)
PC = mv2
Where, m = mass per length Ref PSGDDB Page No: 7.71 7.73
6
DESIGN PROCEDURES
(iii)
Tension due to sagging (PS):

PS = k.w.a
Where, k = Co-efficient of Sag, Ref PSGDDB Page No: 7.78

w = Weight of the chain per metre = m. g Ref PSGDDB Page No: 7.71 7.73
a = Centre distance in metre.
STEP: 7 Calculation of service factor (ks)
ks = k1, k2, k3, k4, k5, k6
Load factor k1 Ref PSGDDB Page No: 7.76
Factor for distance regulation k2 Ref PSGDDB Page No: 7.76
Factor for centre distance of sprockets k3 Ref PSGDDB Page No: 7.76
Factor for the position of the sprockets, k4 Ref PSGDDB Page No: 7.77
Lubrication factor, k5 Ref PSGDDB Page No: 7.77
Rating factor k6 Ref PSGDDB Page No: 7.77
STEP: 8 Calculation of design load:
Design load = PT X ks
STEP: 9 Calculation of working factor of safety (FSw)
FSw =
Breaking load (Q) -- Ref PSGDDB Page No: 7.71 7.73
STEP: 10 Check for factor of safety:
Recommended value (FSw) check to n.
For n Ref PSGDDB Page No: 7.77
If the design is not safe means 1) Increase the Pitch of chain. 2) Choose Duplex or
Triplex chain.
DESIGN PROCEDURES
STEP: 11 Check for Bending stress in the roller (
Where, A Area of the roller, Ref PSGDDB Page No: 7.71 7.73
By using smaller sprocket speed and pitch the allowable bearing stress is
compared to induced stress. The induced stress is less than allowable bearing stress
hence the design is safe.
To find allowable stress Ref PSGDDB Page No: 7.77
STEP: 12 Calculation of actual length of chain (L):
Ref PSGDDB Page No: 7.75, using those formulas to calculate the (L).
STEP: 13 Calculation of exact centre distance (a):
Ref PSGDDB Page No: 7.75, using those formulas to calculate the (a).
STEP: 14 Calculation of sprocket diameters:
Ref PSGDDB Page No: 7.78, using those formulas to calculate the (d1 & d01)
DESIGN PROCEDURES

UNIT
DESIGN PROCEDURE FOR WIRE ROPE:STEP: 1 Selection of suitable wire rope:

STEP: 2 Calculations of design load:
Design Load: Load to be lifted X Assumed factor of safety
Assume factor of safety 2 to 2.5 times, the factor of safety Ref PSGDDB Page No: 9.1
STEP: 3 Selection of wire rope diameter (d):
Ref PSGDDB Page No: 9.5 9.6. From the pages select the wire rope
diameter and breaking strength.
STEP: 4 Calculating of shave diameter (D):
(For velocity upto 50m/min)
Ref PSGDDB Page No: 9.1
STEP: 5 Selection of the area of useful cross-section of the rope (A):
Type of
construction
Metallic area of
rope A, mm2
6X7
0.38 d2
6 X 19
0.4 d2
6 X 37
0.4 d2
STEP: 6 Calculation of wire diameter (dw)
STEP: 7 Selection of weight of rope (Wr)

Ref PSGDDB Page No: 9.5 9.6
9
DESIGN PROCEDURES
STEP: 8 Calculation of various loads:
1. Direct load
Wd
=
W + Wr
2. Bending load
Wb
=
XA
3. Acceleration load due to change in the speed of hoisting,
Wa
a=
4. Starting or stopping load:

a) Starting load, Wst = 2 X Wd
b) When there is slack in the rope
Wst =
XA
STEP: 9 Calculation of effective loads:

1. Effective load on the rope during normal working, Wen = Wd + Wb
2. Effective load on the rope during acceleration of the load Wea = Wd + Wb + Wa
3. Effective load on the rope during starting, West = Wb + Wst

STEP: 10 Calculation of working factor of safety (FSw)
FSw =
for Breaking load Ref PSGDDB Page No: 9.5 9.6
STEP: 11 Check for safe design.

Compare the calculate working factor of safety (FSw) with the recommended
factor safety n.
i.e., (FSw) > n then the design is safe.
(FSw) < n the the design is not safe. So choose some other rope
with greater breaking strength or increase the number of ropes.
STEP: 12 Calculation of number of ropes:
Number of ropes =
10
DESIGN PROCEDURES

UNIT
II
DESIGN PROCEDURE FOR SPUR GEARBASED ON LEWIS EQUATION METHOD

STEP: 1 Selection of materials:
If not given, select
Ref PSGDDB Page No: 1.40 and 8.4
suitable
pinion
and
gear
materials
STEP: 2 Calculations of Z1 and Z2:

If not given, assume number of teeth on pinion Z1 18 (Prefer 20)
Z2 = i X Z1, where i gear ratio.
STEP: 3 Calculations of Tangential load on tooth (Ft):
Ft =
Ko in Newton
V = Pitch Velocity = dN / 60, in m/sec

Ko = Service / Shock factor
Types of load
Steady
1.0
Light shock
1.25
Medium shock
1.5
Heavy shock
2.0
STEP: 4 Calculations of Initial dynamic load (Fd):

Fd =
in Newton
Cv = Velocity factor assume value 10 20 m/sec

Cv =
11
Ko
DESIGN PROCEDURES
STEP: 5 Calculations of beam Strength (Fs):
Fs = . m. b . [b] . y
Where,
m
B
[b]
y
= Module in mm,
= Face width in mm, initially assume b = 10 X module.
= Design bending stress or allowable static stress.
= Form factor, Ref PSGDDB Page No. 8.53.
STEP: 6 Calculations of module (m):

Equating Fs Fd. find the module.
STEP: 7 Calculations of b, d and v.:
Find the face width (b)
Find the pitch circle diameter (d1)
Find the pitch line velocity (v)
=
=
=
10m
z.m
d1 N1/60
STEP: 8 Recalculations of the beam strength (Fs) :

Fs = . m. b . [b] . y
Using the above step b,m values find the new beam strength.
STEP: 9 Calculations of accurate dynamic load (Fd):
Fd
Ft + F I
Ft +
Where, c = deformation factor, Ref PSGDDB Page No. 8.53

Ft = P/v (neglecting service factor K0)
STEP: 10 Checking of beam strength:
Compare Fd and Fs
If Fd Fs, hence the design is safe.
If Fd Fs, hence the design is not safe, 1. Reduce the deformation factor, 2.
Select the precision gear 3.Increase the face width.
12
DESIGN PROCEDURES
STEP: 11 Calculations of Maximum wear load (Fw):
Fw
Ratio factor (Q)
Kw
d1 X b X Q X Kw
=
load stress factor
STEP: 12 Check for wear:

Fd < Fw , then the design is safe and satisfactory.
STEP: 13 Calculation of basic dimensions of pinion and gear:
Ref PSGDDB Page No: 8.82 and find the following parameters
Module, centre distance, height factor, bottom clearance, tooth depth, pitch
circle diameter, tip diameter and root diameter.
13
DESIGN PROCEDURES

UNIT
II
DESIGN PROCEDURE FOR SPUR GEARSTEP: 1 Calculation of gear ratio (i):
=
If not given the gear materials, Ref PSGDDB Page No: 8.2 8.5
STEP: 3 Calculation of gear life:
N = N1 .T. 60
Where, N1 = Pinion speed in rpm.
T = Working life hours. If not given the gear life, assume (20,000hrs)
STEP: 4 Calculation of Initial torque [Mt]:
[Mt] = Mt . K. Kd. other details Ref PSGDDB Page No: 8.15
STEP: 5 Calculation of Eeq, [b] and [c]:
For Eeq Ref PSGDDB Page No: 8.14
For [b] Ref PSGDDB Page No: 8.19
For [c] Ref PSGDDB Page No: 8.16
STEP: 6 Calculation of Centre distance (a)
For (a) Ref PSGDDB Page No: 8.13
For Ref PSGDDB Page No: 8.14
STEP: 7 Selection of number of teeth on Pinion (Z1) and Gear (Z2)
Assume Z1 18;
Z2 = i X Z1
14
DESIGN PROCEDURES
STEP: 8 Calculations of module (m)
for standard module. Ref PSGDDB Page No 8.2 selects choice I
STEP: 9 Revision of centre distance (a)
a
STEP: 10 Calculations of b,d,v, and p

Calculate face width
(b)
Calculate the pitch diameter of the pinion (d1)
Calculate the pitch line velocity
(v)
=
=
=
Calculate the value of
(p)
a
m. Z1
d1 N1 / 60
STEP: 11 Selection of quality of gears:

Using pitch line velocities select the quality of the gear.
Ref PSGDDB Page No.8.3
STEP: 12 Revision of design torque [Mt]:
Revise K: Using the calculated value of p, revise the load concentration
factor. Ref PSGDDB Page No. 8.15.
Revise Kd: Using the selected quality of gear and calculated pitch line
velocity, revise of dynamic load factor (Kd) Ref PSGDDB Page No. 8.16.
Revise [Mt]: Using the revised value of K and Kd, find the revised design
torque.
STEP: 13 Check for bending stress b:
Ref PSGDDB Page No. 8.13.
STEP: 14 Check for Wear strength c:
15
DESIGN PROCEDURES
STEP: 14 Calculation of basic dimensions of pinion and gear.
If the design is not satisfactory b > [b] and c > [c], then increase the
module or face width value or change the gear material.
16
DESIGN PROCEDURES

UNIT
III
DESIGN PROCEDURE FOR HECIAL GEARBASED ON LEWIS EQUATION METHOD

If not given, select
Ref PSGDDB Page No: 1.40 and 8.4
suitable
pinion
and
gear
materials
STEP: 2 Calculations of Z1 and Z2:

If not given, assume number of teeth on pinion Z1 18 (Prefer 20)
Z2 = i X Z1, where i gear ratio.
STEP: 3 Calculations of Tangential load on tooth (Ft):
Ft =
Ko in Newton
V = Pitch Velocity = dN / 60, in m/sec

Ko = Service / Shock factor
Types of load
Steady
1.0
Light shock
1.25
Medium shock
1.5
Heavy shock
2.0
STEP: 4 Calculations of Initial dynamic load (Fd):

Fd =
in Newton
Cv = Velocity factor assume value 10 20 m/sec

Cv =
17
Ko
DESIGN PROCEDURES
STEP: 5 Calculations of beam Strength (Fs):
Fs = . m. b . [b] . y
Where,
m
B
[b]
y
= Module in mm,
= Face width in mm, initially assume b = 10 X module.
= Design bending stress or allowable static stress.
= Form factor, Ref PSGDDB Page No. 8.53.
STEP: 6 Calculations of normal module (mn):

Equating Fs Fd. find the module.
STEP: 7 Calculations of b, d and v.:
Find the face width (b)
Find the pitch circle diameter (d1)
Find the pitch line velocity (v)
10 mn
d1 N1/60
STEP: 8 Recalculations of the beam strength (Fs) :

Fs = . m. b . [b] . y
Using the above step b,m values find the new beam strength.
STEP: 9 Calculations of accurate dynamic load (Fd): cos2
Fd
Ft + F I
Ft +
Where, c = deformation factor, Ref PSGDDB Page No. 8.53

Ft = P/v (neglecting service factor K0)
STEP: 10 Checking of beam strength:
Compare Fd and Fs
If Fd Fs, hence the design is safe.
If Fd Fs, hence the design is not safe, 1. Reduce the deformation factor, 2.
Select the precision gear 3.Increase the face width.
18
DESIGN PROCEDURES
STEP: 11 Calculations of Maximum wear load (Fw):

Fw
Ratio factor (Q)
Kw
=
load stress factor
STEP: 12 Check for wear:

Fd < Fw , then the design is safe and satisfactory.
STEP: 13 Calculation of basic dimensions of pinion and gear:
19
DESIGN PROCEDURES

UNIT
II
DESIGN PROCEDURE FOR HELICAL GEARSTEP: 1 Calculation of gear ratio (i):
=
N = N1 .T. 60
Assume Z1 18;
Z2 = i X Z1
20
DESIGN PROCEDURES
STEP: 8 Calculations of normal module (mn)
For standard module. Ref PSGDDB Page No 8.2 selects choice I
cos
mn =
STEP: 9 Revision of centre distance (a)
a
mn
STEP: 10 Calculations of b,d1,v, and p
(b)
(v)
(p)
a
Z1

torque.
21
DESIGN PROCEDURES

22
DESIGN PROCEDURES

UNIT
III
DESIGN PROCEDURE FOR BEVEL GEARSTEP: 1 Calculation of gear ratio (i) pitch angles.:
=
Pitch angle:

N = N1 .T. 60
STEP: 6 Calculation of Cone distance (R)
23
DESIGN PROCEDURES
Assume Z1 18;
Z2 = i X Z1
Virtual number of teeth:
STEP: 8 Calculations of module (mt)

STEP: 9 Revision of cone distance (R)
R =0.5 mt
STEP: 10 Calculations of b,mav, d1av and y

(b)
Calculate average module
(mav)
mt
Calculate the pitch diameter of the pinion (d1av)

(v)
=
=
mav. Z1
d1av N1 / 60
(y)

torque.
24
DESIGN PROCEDURES

25
DESIGN PROCEDURES

UNIT
III
DESIGN PROCEDURE FOR WORM GEARSTEP: 1 Selection of materials:

If not given the gear materials.
Sl. No
Condition
1.
Light loads and low speed
2.
Medium service conditions
3.
High speeds, heavy loads with

shock conditions
Materials
Worm
Worm Wheel
Steel
Cast Iron
Case hardened
Phosphor Bronze
steel of BHN 250
Hardened
molybdenum steel
Phosphor bronze
or chrome
(chilled)
vanadium steel
STEP: 2 Calculation of Initial design wheel torque [Mt]

STEP: 3 Selection of Z1 & Z2
For
= 80% If Z1 is not given Ref PSGDDB Page No:8.46

Z2 = i X Z1,
STEP: 4 Selection of [b] and [c]:

Assume q = 11 (its q can vary from 8 to 13)
26
DESIGN PROCEDURES
STEP: 6 Calculate the axial module (mx)
mx =
STEP: 7 Revise centre distance (a)
a = 0.5 mx (q + Z2)
STEP: 8 Calculations of d1, v,
and vs
(v)
( )
Calculate Sliding velocity
(vs)
q x mx & d2 = Z2 X mx
STEP: 9 Recalculate the design contact stress [c]

Using Sliding velocity select the quality of the gear.
Ref PSGDDB Page No.8.45.
For v2 < 3 m/sec, Kd = 1
b =
yv
= Form factor based
on
Zv =
yv = Ref PSGDDB Page No. 8.52.
27
virtual
number
of
teeth,
DESIGN PROCEDURES
STEP: 13 Check for efficiency:
actual =
Ex:
0.95 X
0.05 vs = 1.432 m/sec and bronze wheel, from Graph.
STEP: 14 Calculation of cooling area required (A)

( 1 ) X Input power
Kt X A (to ta)
STEP: 15 Calculation of basic dimensions of the worm and worm gear
Axis module, Number of stars, Number of teeth on worm wheel,
Length of worm, Centre distance, Face width, Height factor, Bottom clearance,
Pitch diameter, Tip diameter & Root diameter.
28
DESIGN PROCEDURES

UNIT
IV
DESIGN PROCEDURE FOR GEARBOXSTEP: 1 Selection of spindle speeds:

=
STEP: 2 Draw the Ray diagram
STEP: 3 Draw the Kinematic arrangement
STEP: 4 Calculation of number of teeth on all gears.
STEP: 5 Selection of material.
STEP: 6 Calculation of module.
STEP: 7 Calculation of centre distance
Ex:
a1 =
X m ; a2 =
STEP: 8 Calculation of face width:
Xm
b =
Xm
STEP: 9 Calculation of Length of shaft.

STEP: 10 Design of shaft.
29
;;
a3 =
Xm

Design Transmission Systems

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DESIGN PROCEDURES

DESIGN OF TRANSMISSION SYSTEMS

DESIGN PROCEDURE FOR FLAT BELT DRIVE:-

STEP: 1 Calculation of pulley diameters:

Where N1 = Driver pulley speed in rpm.

Rated Kw is given in the problem.

If C is not Given Assume 1 meter ( 1000mm)

From DDB Page No: 7.54.

DESIGN OF TRANSMISSION SYSTEMS

STEP: 2 Calculate the Width of the Pulley( ):

1.7 To 2.0 times of Diameter of the Shaft (d2)

Length of the Hub ( )

= Width of the Pulley

Ref PSG DDB Page No: 7.56.

DESIGN OF TRANSMISSION SYSTEMS

DESIGN PROCEDURE FOR V - BELT DRIVE:-

STEP: 1 Selection of belt section:

STEP: 5 Selection of various modification factors:

Referring from PSG DDB Page No: 7.68.

3. Service factor (Fa)

STEP: 8 Calculation of actual centre distance:

DESIGN OF TRANSMISSION SYSTEMS

DESIGN PROCEDURE FOR CHAIN DRIVE:-

STEP: 1 Selection oF Transmission Ration

STEP: 2 Selection of No. of Teeth on the Drivers Sprocket (Z1)

Z1, Z2 ODD Number for uniform wear

Ref PSGDDB Page No: 7.74.

STEP: 5 Selection of Chain

Tangential Force (PT)

Centrifugal tension (PC)

Tension due to sagging (PS):

Where, k = Co-efficient of Sag, Ref PSGDDB Page No: 7.78

For n Ref PSGDDB Page No: 7.77

DESIGN OF TRANSMISSION SYSTEMS

DESIGN PROCEDURE FOR WIRE ROPE:STEP: 1 Selection of suitable wire rope:

STEP: 6 Calculation of wire diameter (dw)

STEP: 7 Selection of weight of rope (Wr)

4. Starting or stopping load:

STEP: 9 Calculation of effective loads:

3. Effective load on the rope during starting, West = Wb + Wst

for Breaking load Ref PSGDDB Page No: 9.5 9.6

STEP: 11 Check for safe design.

DESIGN OF TRANSMISSION SYSTEMS

DESIGN PROCEDURE FOR SPUR GEARBASED ON LEWIS EQUATION METHOD

STEP: 2 Calculations of Z1 and Z2:

V = Pitch Velocity = dN / 60, in m/sec

STEP: 4 Calculations of Initial dynamic load (Fd):

Cv = Velocity factor assume value 10 20 m/sec

STEP: 6 Calculations of module (m):

STEP: 8 Recalculations of the beam strength (Fs) :

Where, c = deformation factor, Ref PSGDDB Page No. 8.53

Ratio factor (Q)

STEP: 12 Check for wear:

DESIGN OF TRANSMISSION SYSTEMS

DESIGN PROCEDURE FOR SPUR GEARSTEP: 1 Calculation of gear ratio (i):

STEP: 10 Calculations of b,d,v, and p

Calculate the value of

STEP: 11 Selection of quality of gears:

DESIGN OF TRANSMISSION SYSTEMS

DESIGN PROCEDURE FOR HECIAL GEARBASED ON LEWIS EQUATION METHOD

STEP: 2 Calculations of Z1 and Z2:

V = Pitch Velocity = dN / 60, in m/sec