18.

1
Step I: Helix angle

From Eq.(18.7),

m n (z 1 + z 2 ) 4 (25 + 50)
a = 2 cos ψ
or 165 = 2 cos ψ

ψ = 24.62 0 (Ans.)

18.2
Step I: Pitch circle diameters

zp mn 20 (5)
dp = cos ψ = = 103.53 mm
cos (150 )

zg mn 60 (5)
dg = cos ψ = = 310.58 mm (i)
cos (150 )

Step II: Centre distance

m n (z 1 + z 2 ) 5 (20 + 60)
a = 2 cos ψ
= = 207.06 mm (ii)
2 cos 150

18.3
Step I: Transverse module

mn 3
m = cos ψ = = 3.26 mm (i)
cos (230 )

Step II: Transverse pressure angle

tan α n tan (200 )

tan α = cos ψ
= or α = 21.57 0 (ii)
cos (230 )

Step III: Axial pitch

p πm π (3.26)
pa = tan ψ
= tan ψ
= = 24.13 mm (iii)
tan (230 )

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 18.4
Step I: Torque

60 × 106 (kW) 60 × 106 (7.5)

(Mt ) = 2πn
= 2 π (2000)
= 35 809.86 N − mm

Step II: Components of force

z mn 18 (6)
d = cos ψ
= = 117.33 mm
cos (230 )

2 (Mt ) 2 (35 809.86)

Pt = d
= 117.33
= 610.41 N

Pa = P t tan Design of Machine

ψ = 610.41 tan (230 ) = 259.10 N
Elements - Chapter 18
Pt [ cos ψ ] 610.41 [ ] =
0
tan α n tan (20 )
Pr = = 241.36 N
cos (230 )

18.5
Step I: Helix angle

m n (z 1 + z 2 ) 5 (35 + 70)
a = 2 cos ψ
285 = 2 cos ψ

ψ = 22.92 0 (i)

Step II: Beam strength

Since both gears are made of the same material, the pinion is weaker than the gear.

zp 35
z′p = cos3 ψ
= = 44.79
cos3 (22.920 )

From Table17.3,

(0.399 − 0.389) (44.79 − 40 )

Y = 0.389 + (45 − 40)
= 0.3986

Su 600
σb = 3
= 3
= 200 N/mm2

Sb = mn b σb Y = 5(50)(200)(0.3986) = 19 930 N (ii)

Step III: Wear strength

2 g
Q = = = 1.333

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 2 zg 2 (70)
Q = zg + zp = 70 + 35
= 1.333

zp mn 35(5)
dp = cos ψ = = 190 mm
cos (22.920 )

0.16 ( BHN
100 )
= 0.16 ( 300
100 )
2 2
K = = 1.44 N/mm2

b Q dp K 50 (1.333) (190)(1.44) (iii)

Sw = cos2
= = 21495.64 N
ψ cos2 (22.920 )

Step IV: Sta[c load

60 × 106 (kW) 60 × 106 (20)

Mt = 2 π np
= 2 π (720)
= 265 258.24 N − mm

2 Mt 2 (265 258.24)
Pt = dp
= 190
= 2792.19 N (iv)

Step V: Dynamic load

From Table 17.8, the error for Grade 6 is given by,

e = 8 + 0.63 ϕ where ϕ = mn + 0.25 √ d

‾

For pinion,

ϕ = mn + 0.25 √ d
‾ p = 5 + 0.25 √190
‾‾‾‾

ep = 8 + 0.63 (5 + 0.25 √ 190

‾‾‾‾ ) = 13.32 μm

For gear,

zg mn 70(5)
dg = cos ψ = = 380 mm
cos (22.920 )

ϕ = mn + 0.25 √ d
‾ g = 5 + 0.25 √380
‾‾‾‾

eg = 8 + 0.63 (5 + 0.25 √ 380

‾‾‾‾ ) = 14.22 μm

e = ep + eg = 13.32 + 14.22 = 27.54 μm or (27.54x10-3 ) mm

Also, C = 11400 N/mm2 b = 50 mm Pt = 2792.19 N

π dp np π (190) (720)
v = 3 = = 7.163 m/s
60 × 10 60 × 103

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 From Eq. (18.21),

21 v ( C e b cos2 ψ + Pt ) cos ψ
Pd =
21 v + √ ( C e b cos2 ψ + Pt )

21 (7.163) [ 11400 (27.54 × 10−3 ) (50) cos2 (22.92) + 2792.19] cos (22.92)
=
21 (7.163) + √ [ 11400 (27.54 × 10−3) (50) cos2 (22.92) + 2792.19]

= 8047.29 N (v)

Step VI: Effec[ve load

From Eq. (18.22),

P ef f = ( C s Pt + P d ) = 1.25(2792.19) + 8047.29 = 11 537.53 N (vi)

Step VII: Factor of safety against bending

Sb 19 930
(f s) = Peff
= 11 537.53
= 1.73 (vii)

Step VIII: Factor of safety against picng,

Sw 21 495.64
(f s) = Peff
= 11 537.53
= 1.86 (viii)

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