Pg 23

Miscellaneous Problems

Pbm) Design a worm gear drive to transmit a power of 2kW at 1000 rpm. The speed ratio is 20 &
centre distance is 200 mm. Take pressure angle α = 20o FD & materials for gear – phosphor bronze
whose σd2 = 55 N/ mm2 for worm hardened steel.

Soln: Given Data

P = 2kW ; N1 = 1000 rpm ; I = 20; a = 200 mm; d = 20o FD; σd2 = 55 N/ mm2

I) Dimensions of worm & worm gear -:

𝑁 𝑍2 1000
i = 𝑁1 = 𝑍1
=> 𝑁2 = 20
= 50 𝑟𝑝𝑚
2

a0.875
Pitch Diameter of worm = d1 = 1.466 ------ 12.103/ Pg 176
a = Centre Distance in mm
2000.875
∴ 𝑑1 = = 70.35 𝑚𝑚 ≈ 70 𝑚𝑚
1.466

𝑑1 +𝑑2
Centre Distance = 𝑎 =
2

10 + 𝑑2
200 = 2
=> d2 = 330 mm  1st Estimate
According to AGMA, d1 ≈ 3Px (Px – Axial Pitch = πm)
d1 ≈ 3 x π x m
70 ≈ 3 x π x m
 m = 7.42 = 8 mm.
Pg 24

Also, we have 𝑑2 = 𝑖𝑚𝑍1

330
 𝑍1 = 20 𝑥 8
= 2.0625 = 2
 No of starts = Z1 = 2

If Z1 = 2; Z2 = iz1 = 20 x 2 = 40 teeth

From Table 12.30/page 200; we have for

m = 8 ; ΡX = 25.133 ; Z1 = 2 ; d1 = 80 mm ; q = 10;

γ = 11o19’
𝑑1 + 𝑑2
∴a= 2
80 + 𝑑2
200 = 2
=> d2 = 320 mm
𝑚𝑍1 8𝑥2
Leading edge angle = tan γ = = = 11.30𝑜
𝑑1 80

(i) Dimensions of worm [ from table 12.25 / Pg 198]

a) Z1 = 2; b) d1 = 80 mm; c) Face length of worm : Lw = (4.5 + 0.02Z1) Px (Px = πm)

= (4.5 + 0.02 x 2 ) π x 8

= 114.10 ≈ 115 mm

d) Depth of tooth = h = 0.686 x π x 8 = 17.24 mm

e) Addendum = ha = 0.318 Px = 0.318 x π x 8 = 7.99 ≈ 8 mm

f) Top Radius = r = 0.05 Px = 0.05 x π x 8 = 1.256 mm

g) Hub Diameter = dH = 1.66Px + 25 mm= 1.66 x π x 8 + 25 = 66.70 mm

h) Max bore for shaft = ds = Px + 15.9 mm= π x 8 + 15.9 = 41.03 mm

i) Outside dia of worm = d01 = d1 + 0.636 Px = 80 + 0.636 x π x 8 = 95.98 mm = 96 mm

Pg 26

(b) Tangential tooth load to be transmitted:

1000 𝑥 𝑃 𝜋𝑑2 𝑁2 𝜋 𝑥 320 𝑥 50
𝐹𝑡2 = 𝜃2
− − − −𝑤ℎ𝑒𝑟𝑒 𝑣2 = 60𝑥1000
= 60 𝑥 1000

𝑣2 = 0.837 𝑚/𝑠𝑒𝑐
1000 𝑥 2
= 0.837

= 𝐹𝑡2 = 2387.32 𝑁  tangential tooth load to be transmitted

Therefore, tangential tooth load capacity is higher than transmitted load, Design is satisfactory.

Actual power capacity / permissible power

1000 𝑥 𝑃
𝐹𝑡2 = 𝑣2

𝐹𝑡2 𝑥 𝑣2 9118.67 𝑥 0.837

𝑃= 1000
= 1000
= 7.63 𝑘𝑊

∴ 𝑃𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑝𝑜𝑤𝑒𝑟 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 7.63 𝑘𝑊

IV) Wear Load

Dynamic Strength = 𝐹𝑑 = 𝜎𝑑 𝑏 𝑌𝑚 − −12.110/𝑃𝑔 117

𝐹𝑠 = 𝜎𝑑2 𝑏𝜋𝑦2 𝑚

= 55 𝑥 60 𝑥 𝜋 𝑥 0.1312 𝑥 8
𝐹𝑠 = 10881.47 𝑁
Wear load = 𝐹𝑁 = 𝑑2 𝑏𝐾 − − − 𝑒𝑞𝑛 12.122/ 𝑃𝑔179

From table 12.31 / page 202 for γ = 10o – 25o & phosphor bronze

K = 0.687
Pg 27

∴ 𝐹𝑊 = 320 𝑥 60 𝑥 0.687
𝐹𝑊 = 13190.4 𝑁
𝐹𝑊 > 𝐹𝑆 ; 𝑑𝑒𝑠𝑖𝑔𝑛 𝑖𝑠 𝑠𝑎𝑓𝑒
v) Efficiency
tan 𝛾 ( 1−𝜇 tan 𝛾) 12.117
𝜂= tan 𝛾+𝜇
− − − − − 𝑃𝑔 177

0.0422 12.120𝑎
𝜇 = ( 𝑉 )0.28 𝑓𝑜𝑟 0.2 < 𝑣 < 2.8 𝑚/𝑠 − − − − − 𝑃𝑔 178
𝑟

𝑣 = 0.837 𝑚/𝑠
0.837
∴ 𝑉𝑟 = 𝑉/ cos 𝛾 = cos 11.31
= 0.8535
0.0422
𝜇= (0.8535)0.28
= 0.044

𝜇 = 0.044
tan 11.30 (1−0.044 tan 11.30)
𝜂= tan 11.30+0.044

𝜂 = 0.812 = 81.2%
Pg 28

Heat Dissipation
𝜇𝐹𝑛 𝑉𝑟 12.124𝑎
Heat Generated : Q(Hg) = cos 𝑟
−−− 𝑃𝑔 179

𝐹𝑡2 9118.67
𝐹𝑛 = = = 9895.71𝑁
cos 𝛾 cos 𝛼 cos 11.30 cos 20
0.04 𝑥 9895.71 𝑥 0.8535
𝑄= = 378.96 𝐽/𝑠𝑒𝑐
cos 11.30
0.407 12.124𝑐
Heat dissipated Q(Hd) = 103
(𝐴𝑔 + 𝐴𝑤 )(𝑡2 − 𝑡1 ) − − − 𝑃𝑔 180

𝜋𝑑2 𝜋
𝐴𝑔 = = (320)2 = 80424.77 𝑚𝑚2
4 4
𝐴𝑤 = 𝐿𝑤 𝑑1 = 115 𝑥 80 9200 𝑚𝑚2
Assume t2 = Gear temp = ?

t1 = Ambient Temp = 25oC (Assume)

0.407
379 = (80424.77 + 9200)(𝑡2 − 25)
103
 t2 – 25 = 10.39
 t2 = 35.39 ≈ 36oC  Without any artificial cooling