Week 3 Lecture Material PDF

Module-03
Design of a General Purpose

Industrial Helical Gear Reduction Unit- Part I
Lecture-11
Gear Unit Design –
Selection of Stage Ratios,
Pinion & Gear Teeth Numbers
Prof. Rathindranath Maiti

Mechanical Engineering Department 1
Outline of the Lecture
 Description of a Gear Reduction Unit
 A typical Design Problem
 Constructional features of Gear Units
 Steps in Design
 Selection of Stage Ratios, Pinion and Gear Teeth Numbers

A Typical General Purpose Industrial Gear Box (Speed Reducer):
Intermediate Shafts Output Shaft
One Input Shaft
One Output Shaft
One Intermediate
Shafts
Bottom Housing
1st. Stage Input Shaft 2nd. Stage
Input , Helical Gear Stage Output, Helical Gear Stage

Welded Housing- (Single Piece) – GB Exploded View
(3-Stage- Bevel & Helical)
Source a leaflet.

A Typical Gear Box Design Problem
Assembled plan view is of 2-stage gear box.

(Top Cover removed).
Photographic plan view is of 4-stage gear box
(Top cover removed).
Problem : A helical gear reduction unit has to transmit 30 Nm input torque
at 1500 rpm with a total reduction of about 37 to 40.

A Typical Gear Box Design Problem (Contd….) :
At starting the torque may go as high as 200%
and also there is medium shock loads during
operation.
The material for pinion is EN 19A and for gear
wheel it is EN 18A.
The gear box may be an ordinary industrial class
unit preferably with uncorrected gears.
It is of continuous duty (with medium shock)
Assembled plan view is of Two-stage gear box.
and overhauling time is Two years.
(Alternatively -the bearing life should not be
below 10,000 hours).

Essential Steps in Designing a Gear Box :
Step-1
Selection of stages, Gear Ratios
& Teeth numbers.
Step-2 Design of Gears.
Step-3 First layout is made.
Step-4 Rough shape to the shafts

are given.
Assembled plan view is of
a Two stage gear box.

Essential Steps in Designing a Gear Box (Contd…):
Step-5 Bearings are selected preliminarily.
Step-6 After putting the bearings in layout

load calculations become possible.
Step-7 Lives of all bearings are estimated.
Step-8 If estimated lives are not satisfactory then a new set of bearings are chosen.
Last Step If necessary shaft(s) dimensions are also altered .
Further, gear design may need to be altered.

Design Steps:
Step-1 Knowing the direction of Input &
Output Transmission ratios, type of
Gears & teeth numbers are selected.
Rules and Limitations:
Stage ratio not more than 6.
Number of teeth, Zcr-min ≥
a Two stage gear box. 2/sin2 (Pressure Angle).
Note: Normally helical gears are chosen rather than straight tooth spur gears.
Therefore, we consider formative number of teeth: Z ′ = Z / cos β ,
3
Z being actual number of teeth.

Where, β is helix angle which is commonly between 1 2 to 2 0 for single helical gear .
o o
For which considering Z ′ = 17, Z may be taken as 16 to 14 respectively.

Considering cutter geometry, speed of gears and manufacturing
methods this number may further be lowered.

A Typical General Purpose Industrial Gear Box (Speed Reducer):
Z1 - Number of Teeth of 1st. Stage Pinion.

Z 2 - Number of Teeth of 1st. Stage Gear.
Z 3 - Number of Teeth of 2nd. Stage Pinion.
Z 4 - Number of Teeth of 2nd. Stage Gear.

Design Steps:
1st. Step (Contd). Selection of number of stages for a
Total Transmission Ratio
 i
t = 37 to 40.
In choosing the numbers of

teeth and stage ratios, not only
the size optimization is
considered, but also the
roundness in
centre distances with
uncorrected gears is taken
care* of:


Design Steps:
1st. Step (Contd). Selection of number of stages for a Total
Transmission Ratio t i
= 37 to 40.
Considering two stage reduction the numbers of teeth of pinions and
gears were selected as follows:
Z 81
1st. Stage: i1 = 2 = = 4.76
Z 1 17
2nd. Stage: i = Z 4 = 131 = 8.19

2
Z 3 16
Therefore, total ratio becomes:
Z 2 Z 4 81 131
i t = i1 × i 2 = × = × = 4.76 × 8.19 = 39.01
Z1 Z 3 17 16
Assembled plan view is of This is acceptable.

Thank You

Module-03
Lecture-12
First Stage Pinion & Gear Design- I
(Module on Beam Strength Basis)

Selection of Stage Ratios , Gear and Pinion Teeth Numbers

Determination of Design Torque
Material properties and material selection
In a gear and pinion set which one is weaker and to be designed
Choosing other parameters of Lewis formula
Module Selection (Preliminary / 1st Attempt).

Design Steps:
Selection of number of stages for a Total
1st. Step (Recapitulation).
= 37 to 40.
Considering two stage reduction the numbers of teeth of pinions and
gears were selected as follows:
Z 81
1st. Stage: i1 = 2 = = 4.76
Z 1 17
2nd. Stage: i = Z 4 = 131 = 8.19

2
Z 3 16
Z 2 Z 4 81 131
i t = i1 × i 2 = × = × = 4.76 × 8.19 = 39.01
Z1 Z 3 17 16

Gear Design (1st. Stage):
Step-2 In next step gears are designed:
1st. Stage
Module Estimation on Strength Basis:
2Tcosβ
mn =
So cv
ψYZ
3
cw
Input Torque (Nominal):
Power
Ti =
2πωi
Step-2 In next step gears are designed:
1st. Stage
In this problem input continuous torque = 30 Nm.
i.e. Ti = 30 Nm
As starting torque is 200%
the design torque may be taken as:
Tid =2 × Ti =60 Nm

Step-2 • Suggested Materials for Pinion , Gear & Shaft
Pinion Gear Shaft
EN 19 EN 18A EN 8
Ultimate Strength : Su = 940 MPa Su = 860 MPa Su = 570 MPa
Yield Strength : S y = 600 MPa S y = 550 MPa S y = 280 MPa
BHN (Hardened 300-340 250-300
and Tempered) :

Alloy Steel Equivalent Grades
International
BS DIN IS EN SAE/AISI
Standard
EN18A 530A40 37Cr4 40Cr1 EN18 5140

EN18 530A40 37Cr4 40Cr1 EN18A 5140
EN19 709M40 42Cr4Mo2 40Cr4Mo3 EN19 4140,4142
EN19C 709M40 - 40Cr4Mo3 EN19C 4140,4142
EN24 817M40 34CrNiMo6 40NiCr4Mo3 EN24 4340
Carbon Steel
EN8 080A40 CK45 45C8 EN8 1040,1045

Step-2 Materials &- Chemical Composition
0.35～ 0.50～
C(％) Si(％) 0.10～0.35 Mn(％) P(％) ≤0.035
EN 19 0.45 0.80
0.20～
S(％) ≤0.050 Cr(％) 0.90～1.50 Mo(％)
0.40
C Mn Si S P Cr Ni
EN18 .35 – .60 – .10 – .050 .050 - -
.45 1.00 .35 MAX MAX
Standard Grade C Mn P S Si
EN8/08 0.36- 0.60- 0.10-
BS 970 0.05 0.005
0M40 0.44 1.00 0.40

Step-2 Materials Heat Treatment
Consider EN19
which is equivalent material with AISI 4140, DIN 42CrMo4, IS 42CrMo4,
EN 1.7225, GB 42CrMo, JIS SCM440C alloy engineering steel
Thermal processing temperature / ℃|Forging: 1050 ~ 850
The heat treatment temperature / ℃ | Annealing: 680 to 720
The heat treatment temperature / ℃ | normalizing: 840 to 880
The heat treatment temperature / ℃ | quenching: 820 ~ 850 830 ~ 860 oil water
The heat treatment temperature / ℃ | Tempering: 540 to 680
Hardness after annealing ≤HBS: 241

Step-2 Design of Gears – Module estimation (Contd.):
1st. Stage (Cont.)
In a gear pair which one to be designed?
2Tcosβ
mn =
So cv
ψYZ
3
cw
Compare (SoY)gear with (SoY)pinion

Z Pinion = 17 Z Gear = 81

Step-2 Allowable strength of selected material in gear design.
It is to be noted that in the following Lewis formula for bending strength of gear tooth.
2Tcosβ
mn =
So cv
ψYZ
3
cw
S o cv
Is the ultimate allowable strength for the particular gear considering its
cw dynamic and lubrication conditions in operations,
Now S o is taken as certain proportion of either ultimate strength or yield

strength of the selected material.
S o = Yield strength/2.5 for gear design is often considered.
Step-2 (So )pinion = (S y )E N 1 9 A / 2.5 = 240 MPa = 240 × 106 Pa
(So )gear = (S y )E N 1 8 A / 2.5 = 220 MPa = 220 × 106 Pa
Considering nominal helix angle β = 12

o
0.484 − 3.28 / Z ′ =
YPinion = 0.484 − 3.28 / (17 / cos3 12o ) =
0.303
0.484 − 3.28 / Z ′ =
YGear = 0.484 − 3.28 / (81/ cos3 12o ) =
0.446
(SoY)gear = 220 × 0.446 = 98.12 (SoY)pinion = 240 × 0.303 = 72.72
(SoY)pinion < (SoY)gear means pinion is weaker and it is to be designed.

Step-2 Design of Gears – Module estimation (Contd.):
1st. Stage (Cont.)
Pinion shaft is the input shaft. Therefore:
T = 60 Nm β = 12o ψ = 20
Considering accurately cut gear and
assuming module may be 2.5 mm.
π (17 × 2.5) ×1500

Assembled plan view is of 2-stage gear box. V= = 3.41 m / sec
cos12 ×1000 × 60
0
4.5 4.5
cv = = = 0.57
4.5 + V 4.5 + 3.41

Step-2
2Tcosβ
Substituting the values in- mn =
So cv
ψYZ
3
cw
cw Being 1.25 for oil lubrication with regular inspection.
2 × 60 × 0.978 −2
= = 0 .218 × 10 m = 2.18 mm
3 240 ×10 × 0.57
6
× 20 × 0.303 ×17
1.25
Therefore, 1st stage normal module (in 1st Attempt / round) may be taken as 2.5 mm
.
Thank You

Module-03
Lecture-13
Failure of Gear Tooth
(Probable Dynamic Load and Wear Load Capacity)

 Failure of gear tooth.

 Wear load capacity at tooth contacts.
 Estimation of Probable Dynamic Load .
Comparison of Wear load capacity with probable
dynamic load for infinite life of gears.

Design Steps:
1st. Step (Recapitulation).Selection of number of stages for a Total
= 37 to 40.
Considering two stage reduction, with input rpm 1500, the numbers of
teeth of pinions and gears were selected as follows:
Z 81
1st. Stage: i1 = 2 = = 4.76
Z 1 17
2nd. Stage: i = Z 4 = 131 = 8.19

2
Z 3 16
Z 2 Z 4 81 131
i t = i1 × i 2 = × = × = 4.76 × 8.19 = 39.01
Z1 Z 3 17 16

Step-2 Suggested Materials for Pinion & Gear (Recapitulation)
For General Purpose Industrial Gear unit recommended materials are:

Pinion Gear Shaft
EN 19A EN 18A EN 8
S y = 550 MPa Su = 280 MPa

Yield Strength : S y = 600 MPa
BHN (Hardened 300-340 250-300

and Tempered) :

Failure of Gear Teeth
Failure- Contact Gear Tooth may fail at root due to excessive bending stress.
Surface
The bending stress is exaggerated due to dynamic load.
Ultimately fatigue failure may occur.
Next tooth surface may fail due to wear and pitting.

Therefore, surface hardness usually increased to
withstand at high contact pressure.
In designing gear tooth, all these issues are considered carefully.

Depending on loads, loading pattern and severity in operation
Failure- Crack
‘through hardening’ or ‘case carburizing’ steel is selected.

Wear Load Capacity of Teeth Pair
When two cylindrical bodies are in contact with force Fn
contact deformation (δ c ) occurs:
Fn
According to Hertz Contact theory, R1
Developed contact stress (σ c) is expressed as:
δc
b
1 1 
Fn  + 
σc =  R1 R2  R2 Fn
 1 1 
( )
π 1 −ν 2 b  + 
 E1 E2 
Where, ν Poison’s ratio, And E1 & E2 Modulus of Elasticity.

Considering 1 1 1
= + Fn
R R1 R2
And as both materials are steel R1
1 1 1 δc
= + b
E E1 E 2
Also, Poison’s ratio ( ν ) for steel = 0.3
R2
1 1 
Fn  +  Fn
σc =  R1 R2 
Fn E
( )  1
π 1 −ν 2 b  + 
1  σ = 0.35
2
c
 E1 E2  bR
Wear Load Capacity of Teeth Pair O1
In involute tooth pair contact d1

2
α N1
d1 d2 Fn
R1 = ρ1 = sin α and R2 = ρ 2 = sin α
2 2 P α
Fn ρ1
Therefore,
ρ1 ρ 2 d1 sinα N2
90o ρ 2
R= = ×i
ρ1 + ρ 2 2(1 + i ) d2
α
Where, i = d 2 d1 = Z 2 Z1 or, = Zg Z p , 2
the ‘Transmission Ratio’, Gear ratio in simple gear train. O2

1 1 
Fn  + 
Substituting in
σc =  R1 R2  and rearranging,
 1 1 
( )
π 1 −ν b  + 
2
 E1 E2 
σ c2 sin α  1 1   2 i 
Fn =   +    d1 b
 1.4  E1 E2  1 + i 
Expressing in terms of ‘Wear load carrying capacity ( Fw )’ in relation to allowable
compressive endurance limit (S es ) of the gear and pinion materials-
σ c2 sin α  1 1   2 i 
Fn =  
 +    d1 b
 1.4  E1 E2  1 + i 
is expressed as: Fw = K Qg d pp b
Where
 S es2 sin α  1 1   2 i  , function of relative
K =  +  and Qg = 
 1.4  E1 E2  1 + i  size of gears.
d pp = d1 being the pitch circle diameter of pinion.
K Is available in tabular form (against surface hardness) in machine design
and gear data books.

 2 Zg 
In Fw = K Qg d pp b , Q g can also be expressed as: Qg =  
 p
Z + Z g 

Now as d pp = Z p mn and d pg = Z g mn then Fw can also be expressed as:
 2 Zp 
Fw = K Q p d pg b Where, Qp =  
 p
Z + Z 
g 
d pg = d 2 being the pitch circle diameter of gear.
K Q p d pg b K Qg d pp b
In case of helical gear, Fw = =
cos β cos β
Where, d pg and d pp are pcd of helical gear and pinion respectively.

Probable Dynamic Load at Tooth Contact
Probable Dynamic Load Fd = Fn + Fi

Where, Fi is increase in load over the normal load.
Buckingham proposed a detail expression for Fi

considering the accuracy and manufacturing errors in gear.
Fn
However, Fd = and1.15 Fd ≤ Fw are in common practice for designing
cv ordinary purpose industrial gear unit considering
infinite life of gears.

Thank You

Module-03
Lecture-14
1st. Stage Pinion & Gear Design-II
(Probable Dynamic Load and Wear Load Capacity
and Finalizing 1st. Stage Pinion & Gear set)
 Design of 1st. Stage pinion and gear- Estimation of Wear Load Capacity
Estimation of Probable Dynamic Load at Tooth Contact.
Comparison of Wear Load Capacity and Probable Dynamic Load
Finalizing 1st. Stage Module- (Considering Bearing ID)
2nd. Stage Module Calculation

Finalizing Gear Dimensions/Data

Design Steps:
Selection of number of stages for a Total
1st. Step (Recapitulation). Transmission Ratio t i
= 37 to 40.
Considering two stage reduction, with 1500 rpm input speed, the
numbers of teeth of pinions and gears were selected as follows:
Z 2 81
1st. Stage: i1 = = = 4.76
Z 1 17
2nd. Stage: i = Z 4 = 131 = 8.19

2
Z 3 16
Z 2 Z 4 81 131
i t = i1 × i 2 = × = × = 4.76 × 8.19 = 39.01
Z1 Z 3 17 16
Assembled plan view is of Which is accepted.

Step-2 Suggested Materials for Pinion & Gear (Recapitulation)
Pinion Gear Shaft
EN 19A EN 18A EN 8
S y = 550 MPa Su = 280 MPa

Yield Strength : S y = 600 MPa
BHN (Hardened 300-340 250-300

and Tempered) :

Step-2 Design of Gears (Contd.): 1st. Stage (Cont.) Verification for wear load:
Selected normal module (on beam strength

basis) for 1st. Stage is 2.5 mm.
Fw = K Qg d pp b
 2 Z g  2 × 81
Qg =  = = 1.653
 Z p + Z g  81 + 17

b = 2.5 × 20 × 10-3 = 5 × 10-2 m

Step-2 Wear load capacity at tooth contact- 1st. stage:
17 × 2.5
=dpp = × 10 -3 43.456 × 10 -3 m
0.978
For 300 BHN in gear and 350 BHN in
pinion K=1.8x106 Pas for 20o Involute.
Fw = K Qg d pp b
Fw = 1.8 ×106 ×1.653 × 43.456 ×10 −3 × 50 ×10 −3 = 6465 N

Step-2 Design of Gears (Contd.): 1st. Stage (Cont.)
Probable dynamic load:
Fd = Fn cv
2T 2 × 60
Ft = = ×103 = 2761.4 N
d pp 43.456
Fn = Ft sec β sec α = 2761.4 × sec120 × sec 20o
= 2761.4 ×1.0223 ×1.064 = 3004.15 N

Step-2 Design of Gears (Contd.): 1st. Stage (Cont.)
Probable dynamic load:
Substituting the values of Fn and cv (=0.57) :
Fd = Fn cv = 3004.15 / 0.57 = 5270.4 N

Wear load capacity should be higher than probable
dynamic load. i.e., 1.15 Fd ≤ Fw
1.15 Fd = 1.15 × 5270.4 = 6061 N
It is less than Fw (=6465 N)
Therefore, 1st stage module 2.5 mm is safe.

Gear Nomenclature : A = rpp + rpg
11.2980
rbp , rbg Base Circle Radii

pcfcf
p
rdp , rdg Root or Dedendum Circle Radii
20°
rpg
rpp , rpg Pitch Circle Radii rag
rpp rbp rbg
rap , rag Tip or Addendum Circle Radii rap rdg
rdp
P
A = rpp + rpg Centre Distance PITCH POINT
PINION GEAR
α Pressure Angle
p cf Circular Face Pitch
P Pitch Point α
p&g
31°
As subscript at second place stand

for pinion & gear respectively.

2nd. Step (Contd.): It is found that 1st stage module 2.5 mm is safe.
Pinion dimensions (nominal/not final):
Z p × mn 17 × 2.5
PCD of Pinion : d pp = = = 43.45 mm
cos β cos12 o
Root diameter of Pinion :

d dp = d pp − 2 × (mn × d f )
= (43.45 − 2 × 2.5 ×1.25) = 35.25 mm
Inner Diameter (ID) of Bearing close to the Pinion :
In normal course of design it should not be more
than 25 mm.
As recommended bearing life is 10,000 hrs. (higher
than normal), considering bearing ID at least 30 mm,
Bearings on input shaft. 1st. Stage normal module is taken as 3 mm.

Gears for 2nd. Stage and Centre Distances :
2nd. Step (Contd.):
Estimated 1st. Stage module is mn1 = 3 mm
Gear Design for 2nd. Stage
Torque= Design torque for first stage x

(Reduction) Ratio of 1st. Stage.
T2 d =
Tid × ( Z g1 Z p1 ) =
Tid × ( Z 2 Z1 )
=60 × (81 17) =60 × 4.76 =285.6 Nm
Following the same procedure as in 1st stage
the 2nd. Stage module is selected as: mn 2 = 4 mm
Dimensions of Gears and Gear data Table :
2nd. Step (Contd.):
With a suitable selection of helix angle, β=
1 β=2 11o 28' 42′′, for which
=
cos β1 cos
= β 2 0.98 and centre distances become:
A1
( Z1 + Z 2 ) × mn1 (17 + 81) × 3 98 × 3

=A1 = = = 150 mm*
2 × cos β1 2 × 0.98 2 × 0.98
and
( Z 3 + Z 4 ) × mn 2 (16 + 131) × 4 147 × 4
=A2 = = = 300 mm*
2 × cos β 2 2 × 0.98 2 × 0.98
A2

Dimensions of Gears and Gear data Table : 2nd. Step (Contd.):
Sl. Description 1st. Stage 2nd. Stage

No.
Pinion Gear Pinion Gear
1. Number of Teeth ( Z ) 17 81 16 131
2. Tooth Profile 20O Full Depth Involute, Uncorrected
3. Normal Module ( mn ) 3 mm 4 mm
4. Helix Angle ( β ) 11o 28′42′′ 11o 28′42′′
RH LH LH RH
5. Addendum Height, ( a f × mn = 1× mn ) 3 mm 4 mm
6. Dedendum Height, ( d f × mn = 1.25 × mn ) 3.75 mm 5 mm


No.
7. Pitch Circle Diameter (mm) 52.04 247.96 65.306 534.694
8. Centre Distance (mm) 150 300
9. Addendum or Tip Circle Diameter (mm) 58.04 253.96 73.306 542.694
10. Dedendum or Root Circle Diameter (mm) 44.54 240.46 55.306 524.694
11. Face width (b) 63 mm 58 mm 68 mm 63 mm
12. Material EN 19A EN 18A EN 19A EN 18A
13. Hardness , Through Hardened (BHN) 350 300 350 300
End of Step 2. Now the 1st. Layout of pinions and gears in mesh is done (Step 3)
and Rough shape to the shafts are given (Step 4).

Thank You

Module-03
Lecture-15
Gear Unit Design – 1st. Layout
(After Gear Design)

Pinion and Gear Nomenclature
Design Problem and Gear Data & Dimensions
Lay out of Centre Lines – AutoCAD Input & Drawing
Lay out of Gears – AutoCAD Input & Drawing
Lay out of Intermediate Shaft (Draft) – AutoCAD Input & Drawing

Gear Nomenclature : A = rpp + rpg
11.2980
rbp , rbg Base Circle Radii

pcfcf
p
p&g As subscript at second place stand 20°
for pinion & gear respectively. rpg

rag
rdp , rdg Root or Dedendum Circle Radii rpp rbp rbg
rpp , rpg Pitch Circle Radii rap rdg
rdp
P
rap , rag Tip or Addendum Circle Radii
PINION
PITCH POINT
GEAR
A = rpp + rpg Centre Distance

α Pressure Angle
α
p cf Circular Face Pitch
31°
P Pitch Point

The Gear Unit design problem is same as already considered. All data remain same except the
Second stage reduction ratio is reduced to 5.125. Overall transmission ratio is now 24.42.

No.
1. Number of Teeth ( Z ) 17 81 16 82
2. Tooth Profile 20O Full Depth Involute, Uncorrected
3. Normal Module ( mn ) 3 mm 4 mm
4. Helix Angle ( β ) and Direction of Helix 11o 28′42′′ 11o 28′42′′
RH LH LH RH
5. Addendum Height, ( a f × mn = 1× mn ) 3 mm 4 mm
6. Dedendum Height, ( d f × mn = 1.25 × mn ) 3.75 mm 5 mm


No.
12. Material EN 19A EN 18A EN 19A EN 18A
13. Hardness , Through Hardened (BHN) 350 300 350 300
End of Step 2. Now the 1st. Layout of pinions and gears in mesh is done (Step 3)
and Rough shape to the shafts are given (Step 4).

1st. Layout of Centre Lines - AutoCAD Input:

No. Pinion Gear Pinion Gear
4. Helix Angle ( ) and Direction of Helix
RH LH LH RH
5. Addendum Height, ( ) 3 mm 4 mm
6. Dedendum Height, ( ) 3.75 mm 5 mm
200
Dimensions are in mm,
Except otherwise mentioned

1st. Layout of Centre Lines - AutoCAD Input (Contd…) :

RH LH LH RH
200.00 150.00
Dimensions are in mm,

( )

Layout of 2nd. Stage Pinion - AutoCAD Input : Dimensions are in mm,
Intermediate Shaft Axis Input Shaft Axis

RH LH LH RH

1st. Layout- Centre Lines and Gears:
Centre Lines
Intermediate
Shaft i.e., 2nd.
Stage Pinion
- Pitch Lines
-Boundary or
Envelope
-Root
(Dedendum
Lines)
-Scrap view
to show 5. Addendum Height, ( )

RH LH
3 mm
LH RH
4 mm
tooth mesh 6.
7.
Dedendum Height, (
Pitch Circle Diameter (mm)
)
52.04
3.75 mm
247.96 65.306
5 mm
334.694
-Corner 9.
10.
Addendum or Tip Circle Diameter (mm)
Dedendum or Root Circle Diameter (mm)
58.04
44.54
253.96
240.46
73.306
55.306
342.694
324.694
Finishing
(Chamfer)

Layout of Centre Lines & Gears - AutoCAD Input (Contd…) :

RH LH LH RH
200.00 150.00

1st. Layout- Centre Lines and Gears (Contd…) :
Centre Lines &
2nd. Stage Pinion
Pitch Line of
1st. Stage Gear (on
Intermediate Shaft)
Envelope & Root of
1st. Stage Gear
10
2nd.Stage Gear
(Keyed to Output Shaft)
1st. Stage Pinion 200.00 150.00
(Integral on Input Shaft) Sl. Description 1st. Stage 2nd. Stage
Scrap view on input

pinion to show
RH LH LH RH
tooth mesh 7.
8.
Pitch Circle Diameter (mm)
Centre Distance (mm)
52.04 247.96
150
65.306 334.694
200
Direction of Helix (& Angle) 10.

11.
Dedendum or Root Circle Diameter (mm)
Face width (b)
44.54
63 mm
240.46
58 mm
55.306
68 mm
324.694
63 mm

1st. Layout- Centre Lines and Gears (Contd…) : Ø54
Ø45
Centre Lines &
All pinion & Gears
35
Intermediate shaft
53
Between Pinion
and Gear
1st. Stage Gear End
178
2nd. Stage Pinion End Ø54
50
25
35
Ø45
Ø47
200.00 150.00

11 F idth (b) 63 58 68 63

Layout & Preliminary
(Not taper roller
Bearing Selection (Contd…..) in this case).
Step 3 to 5:
}
Roller Bearings:
Considering
bearing widths,
15 to 25 mm 15 to 25 mm
(Typical) 10 to 15 mm (Typical) (Typical)
53 50 finally distances
are marked.
178
Layout of Intermediate Shaft (Referring to Design Problem)
Mechanical Engineering Department
13
Thank You


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Module-03

Design of a General Purpose

Prof. Rathindranath Maiti

 Description of a Gear Reduction Unit

 A typical Design Problem

 Constructional features of Gear Units

 Selection of Stage Ratios, Pinion and Gear Teeth Numbers

Prof. Rathindranath Maiti

One Input Shaft

One Output Shaft

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

Assembled plan view is of 2-stage gear box.

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

Step-3 First layout is made.

Step-4 Rough shape to the shafts

Prof. Rathindranath Maiti

Step-5 Bearings are selected preliminarily.

Step-6 After putting the bearings in layout

Further, gear design may need to be altered.

Prof. Rathindranath Maiti

Z being actual number of teeth.

For which considering Z ′ = 17, Z may be taken as 16 to 14 respectively.

Prof. Rathindranath Maiti

Z1 - Number of Teeth of 1st. Stage Pinion.

Prof. Rathindranath Maiti

In choosing the numbers of

Assembled plan view is of

Prof. Rathindranath Maiti

2nd. Stage: i = Z 4 = 131 = 8.19

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

Selection of Stage Ratios , Gear and Pinion Teeth Numbers

Prof. Rathindranath Maiti

2nd. Stage: i = Z 4 = 131 = 8.19

Prof. Rathindranath Maiti

In this problem input continuous torque = 30 Nm.

Assembled plan view is of 2-stage gear box.

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

EN18A 530A40 37Cr4 40Cr1 EN18 5140

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

Compare (SoY)gear with (SoY)pinion

Prof. Rathindranath Maiti

Now S o is taken as certain proportion of either ultimate strength or yield

Considering nominal helix angle β = 12

(SoY)gear = 220 × 0.446 = 98.12 (SoY)pinion = 240 × 0.303 = 72.72

(SoY)pinion < (SoY)gear means pinion is weaker and it is to be designed.

Prof. Rathindranath Maiti

π (17 × 2.5) ×1500

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

Prof. Rathindranath Maiti

 Failure of gear tooth.

Prof. Rathindranath Maiti

2nd. Stage: i = Z 4 = 131 = 8.19

Prof. Rathindranath Maiti

For General Purpose Industrial Gear unit recommended materials are:

Ultimate Strength : Su = 940 MPa Su = 860 MPa Su = 570 MPa