Unit 2

Over view Design of Transmission System

Procedure for Design of spur gear

1.
2.
3.
4.

Selection of material(refer PSG data book P.NO.8.4 & 8.5)

Assume life (If not given Assume 20,000 hrs)
Calculate Young Modulus(E) (refer PSG data book P.NO.8.14 and Table 9)
Calculate Design Stress
(a)Permissible value of bending stress [b]
[b] =1.4 ( kbl /k )-1(refer PSG data book P.NO.8.18)
kbl - (refer PSG data book P.NO.8.20 & table 22)
To select Kbl value from table based on Surface hardness & life in number of cycle
*Surface hardness to select based on material (refer PSG data book P.No 8.5)
* Life in number of cycle To calculate based on equation
= RPM of pinion (N1) x required life of bearing (in terms of minutes)
k-(refer PSG data book P.NO.8.19 & table 21)
To select K value from table based on Material and heat treatment & Addendum
modification coefficient
*Material and heat treatment -to select based on material
*Addendum modification coefficient Standard Assumption (x =0. x 0.1)
-1 - (refer PSG data book P.NO.8.19 & table 19)
Where
u - (refer PSG data book P.NO.8.5 & table 7)
y - (refer chapter 1( Materials )from page No 1. To Page No 1.42)
(b)Permissible value of contact stress [c]
[c]=CB HB kcl
*CB To select value in table 16 based on wheel material (refer PSG data book P.NO.8.16)
*HB To select value in table 16 based on wheel material (refer PSG data book P.NO.8.16)
*Kcl To select value in table 17 based on wheel material and surface hardness and life in
number of cycle (refer PSG data book P.NO.8.16)
Surface hardness
- refer PSG data book P.NO.8.5 and Table 7
Life in number of cycle
- refer previous step

5. To calculate torque[Mt] (approximate value)(refer PSG data book P.NO.8.15)

[Mt] =Mtkd k
kd k = 1.3 (assume)
P =2n1Mt/60 => Mt =P*60 /2*3.14*n1
P power in W,n1 speed in RPM
6. To calculate center distance(a) (refer PSG data book P.NO.8.13 and Table 8)

Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Unit 2
Over view Design of Transmission System

c
t
M

a= (i+1)
2

0.74

i Speed ratio
E Equivalent youngs modulus (refer PSG data book P.NO.8.14 and Table 9)
- To select value in table 10 (refer PSG data book P.NO.8.14)
7. Assume No of tooth in pinion (z1)
Z1 17 for 20o full depth
Z1 14 for 20o stub teeth
Z1 32 for 14 1/2o full depth
8. Calculate module (m)(refer PSG data book P.NO.8.22)
m= 2a/ (z1 +z2)
9. Revise
To calculate center distance based on Module (a)(refer PSG data book P.NO.8.22)
a= (m*(z1+z2))/2
To calculate Face width based on Module (b)(Refer PSG data book P.NO.8.15)
=b/a (Take value in table 10 based on types of gear transmission)
If not given Assume open type gearing
To calculate pitch diameter (d1)(refer PSG data book P.NO.8.22)
d1= mn z1
To calculate pitch line velocity (V1)
v1=d1n /60
To calculate (p)
(p) = (b/d1)
10. Revise
To calculate torque [Mt]
To select K value from PSG Data book based on (p) and position of gear fixing
To select Kd value from PSG Data book based on pitch line velocity, Surface Hardness and
IS quality(assume IS quality 8)
11. To calculate induced stresses
Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Unit 2
Over view Design of Transmission System
Induced bending stresses (b)

b=

i +1
[M t ] (Refer PSG data book P.NO.8.13)
amby

Induced contact stress stresses (c)

c =0.74

i +1 i+1
E [M t ] (Refer PSG data book P.NO.8.13)
a
ib

12. To calculate various dimension of Gears

a) To find the bottom clearance (c) (refer PSG data book P.NO.8.22)
C=0.25m (for stub teeth c=1.3 m)
b) To find Tooth depth (h) (refer PSG data book P.NO.8.22)
h=2.25m (for stub teeth h=1.9 m)
c) To find Tip diameter (da)
*Tip diameter of pinion (da1) (refer PSG data book P.NO.8.22)
da1 = (z1 +2f0) m
*Tip diameter of wheel (da2) (refer PSG data book P.NO.8.22)
da2 = (z2 +2f0) m
Where
fo=1 (for sub teeth f0=0.8 )
d) To find Root diameter(df)
*Root diameter of pinion (df1) (refer PSG data book P.NO.8.22)
df1= (z1-2f0) m -2c
*Root diameter of wheel(df2)(refer PSG data book P.NO.8.22)
df2= (z2-2f0) m -2c

Procedure for Design of Helical gear

1.
2.
3.
4.

Selection of material(refer PSG data book P.NO.8.4 & 8.5)

Assume life (If not given Assume 20,000 hrs)
Calculate Young Modulus(E) (refer PSG data book P.NO.8.14 and Table 9)
Calculate Design Stress
(a)Permissible value of bending stress [b]
[b] =1.4 ( kbl /k )-1(refer PSG data book P.NO.8.18)
kbl - (refer PSG data book P.NO.8.20 & table 22)
To select Kbl value from table based on Surface hardness & life in number of cycle
*Surface hardness to select based on material (refer PSG data book P.No 8.5)
* Life in number of cycle To calculate based on equation
= RPM of pinion (N1) x required life of bearing (in terms of minutes)
k-(refer PSG data book P.NO.8.19 & table 21)

Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Unit 2
Over view Design of Transmission System
To select K value from table based on Material and heat treatment & Addendum
modification coefficient
*Material and heat treatment -to select based on material
*Addendum modification coefficient Standard Assumption (x =0. x 0.1)
-1 - (refer PSG data book P.NO.8.19 & table 19)
Where
u - (refer PSG data book P.NO.8.5 & table 7)
y - (refer chapter 1( Materials )from page No 1. To Page No 1.42)
(b)Permissible value of contact stress [c]
[c]=CB HB kcl
*CB To select value in table 16 based on wheel material (refer PSG data book P.NO.8.16)
*HB To select value in table 16 based on wheel material (refer PSG data book P.NO.8.16)
*Kcl To select value in table 17 based on wheel material and surface hardness and life in
number of cycle (refer PSG data book P.NO.8.16)
Surface hardness
- refer PSG data book P.NO.8.5 and Table 7
Life in number of cycle
- refer previous step
5. To calculate torque[Mt] (approximate value)(refer PSG data book P.NO.8.15)
[Mt] =Mtkd k
kd k = 1.3 (assume)
P =2n1Mt/60 => Mt =P*60 /2*3.14*n1
P power in W,n1 speed in RPM
6. To calculate center distance(a) (refer PSG data book P.NO.8.13 and Table 8)

c
t
M

a= (i+1)
2

0.7

i Speed ratio
E Equivalent youngs modulus (refer PSG data book P.NO.8.14 and Table 9)
- To select value in table 10 (refer PSG data book P.NO.8.14)
7. Assume No of tooth in pinion (z1)
Z1 17 for 20o full depth
Z1 14 for 20o stub teeth
Z1 32 for 14 1/2o full depth
8. Calculate module (mn) (refer PSG data book P.NO.8.22)
m= 2acos / (z1 +z2)
9. Revise
To calculate center distance based on Module (a)(refer PSG data book P.NO.8.22)
Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Unit 2
Over view Design of Transmission System
a= (mn/cos ) x ((z1+z2)/2)
To calculate Face width based on Module (b)
=b/a (assume =0.5 for helical hear)
To calculate pitch diameter (d1)(refer PSG data book P.NO.8.22)
d1= (mn z1)/cos
To calculate pitch line velocity (v1)
v1=d1n /60
To calculate (p)
(p)= (b/d1)

10. Revise
To calculate torque [Mt]
[Mt] =Mtkd k
To select K value from PSG Data book based on (p) and position of gear fixing
To select Kd value from PSG Data book based on pitch line velocity, Surface Hardness and
IS quality(assume IS quality 8)
11. To calculate induced stresses
Induced bending stresses (b)

b =0.7

i+1
[M t ] (Refer PSG data book P.NO.8.13)
amby

Induced contact stress stresses (c)

c =0.7

i+1 i+1
E [M t ] (Refer PSG data book P.NO.8.13)
a
ib

12. To calculate various dimension of Gears

e) To find the bottom clearance (c) (refer PSG data book P.NO.8.22)
C=0.25mn(for stub teeth c=1.3 mn)
f) To find Tooth depth (h) (refer PSG data book P.NO.8.22)
h=2.25mn(for stub teeth h=1.9 mn)
g) To find Tip diameter (da)
*Tip diameter of pinion (da1) (refer PSG data book P.NO.8.22)
da1 = ((z1/cos) +2f0) mn
*Tip diameter of wheel (da2) (refer PSG data book P.NO.8.22)
da2 = ((z2/cos) +2f0) mn
Where
fo=1 (for sub teeth f0=0.8 )
h) To find Root diameter(df)
*Root diameter of pinion (df1) (refer PSG data book P.NO.8.22)
Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Unit 2
Over view Design of Transmission System
df1= ((z1/cos) -2f0) m -2c
*Root diameter of wheel(df2) (refer PSG data book P.NO.8.22)
df2= ((z2/cos) -2f0) m -2c

Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology