PROBLEM

Itis required to design the Two-Stage spur gear reduction unit with 200 full
depth involute teeth. The input shaft rotates at 1440 RPM and receives 10 kW power
hrough the flexible coupling. The speed of the output shaft should be approximately
180RPM. The gears are made of Plain Carbon Steel 40C8 (S,ut = 700 N/ mm2) and heat
tveatedto a surface hardness of 340 BHN. The gears to be machined to the requirement
of grade 6.
The service factor can be taken as 1.5

i. Assuming that the dynamic load to be proportional to the pitch line velocity,
estimate the required value of the module. The factor of safety is 1.5.
i1. Select the first preference value of the module and determine the correct value of
the factor of safety for ending using Buckingham's equation.
11l. Determine the factor of safety against pitting.
IV. Give alist of gear dimension.

Rer CAL Engg. Regd No.

 NOMENCLATURE

Sr No. Symbol Identification

Speed Reduction Ratio
2
Z Number of teeth on pinion
3
Number of teeth on gear
4 Sh Beam Strength
5 S Wear Strength
6
Ratio Factor
7 111 Module
8 Face Width
Sut Ultimate tensile strength
10 Y Lewis form factor
11 Cs Service factor
12 Co Velocity factor
13 P: Staticload
14
Pef Effective load
15 M;
Torque
16 FS Factor of safety
17 Pa Dynamic load
18 Error
19 P, Radial Force
20 Km Combined shock & fatigue factor for bending
21 KË Combined shock & fatigue factor for twisting
22 T. Equivalent twisting moment
23 Me Equivalent bending moment
24 Diameter of shaft
25 Length of key
26 Width of key
27 d' Pitch circle diameter
28 ha Addendum
29 Deddendum
30 Clearance
31 Fillet radius
32 Tooth thickness
33 Thickness of key
Design Report -TE MECHANICAL Engg. Regd No,
 iactor The
of The
isspeed identical, layout
For (K11)
=10, lGven
unknown machining=6,
Cten Grade of
of The 20
the of pressure
speed While gear 1:
The
Estimation
output
to
nc Ing is :.Zp total
stage.
this n of Zp=18 Gearsshown
ZË=Z3=
angle,
n=1440
= =N4 = shaft
shaft n8 1440 2 = transmission
Angular
Angular
x=X=1440
Z4
are & in 18 the of
is 4 & module rpm,
rpm. are fig.
Assuming
Cv 179.38 508.235 as Z;
minimum
=
velocity
velocity
follows, also for ix Speed C=1.5,
3+V rpm ease ratio based
3= X= 51 18
and
made Z, 2.8284
Vi= of of
that or 51x of number = last first
"i" of
Sut
output
3+5
approximately manufacturing,
identical. 2.2884 drivendriving is on
3 the
=179.38rpm. 508.235 given beam
=700
8 3pitch x(18) of gear gear shaft N/mm²,
rpm, Z2= teeth strength.
by,
line Z= =
180.
=
50.95 to 180 1440
velocity 180 Z= the avoid
=8.
FS=1.5,

rpm. pinion 51.

51 interference
as
5 The 1&
m/velocity
s. 3 BHN=340,
are
is
made 18
 Design
Report
17.3 pair The
Lewis
Tangential
FromStrength
Beam Step Step consisting pair of
Table
3: b=d'3=m The
2: Form at
M,
= Factor Gear the
S; 17.3, 10 first Factor gearof
second
60 force of m=10 x Dimensions
P=
2Ttn 10°
x
due mbo, = The safety preference
Z3=6 60x106 for 1
&
M,2 (6) m 18 2stage
d'3 (kw) to Y Lewis using =60
(18)
tteheterefore
h
-TE
187391.36 2x

108 T
Load
2 torque.
X 60
×
(60)
=
6 Form
Buckingham's
Factor
mm.
mm.
lu8)(508:235)|00.308)
=108 value
of
mim.
5.59 =
J60x106
0.308. pirnionpinion
is
i.e.

X module (1.(10)51.5) (kw)s)

Cs 3
3 and
508.235 10
× (0.308) for d'4 and gear
3479.47 N
= 10 = is
18 equation. m 6 gear4 4,
=
teeth x mm. transmits
torque
more
187891.36
Nmm
258.72 Z4 are
is =6
0.305 to
(51)
N. be
=306 designed
mm.
from than
No. table the
 Dynamic Load,
For Grade 6, e= 8
+0.630
For Pinion, g =m +
0.25,Jd', =6+0.25V108
e, =8 +0.63 =
13.4168 um
For gear, g = m + 0.25,Jd', =6+ 0.25V306

eg = 8+ 0.630 = 14.535 um

e= e, t e, = 13.4168 + 14.535 = 27.9579 um or 27.9579 x 10 'mm

From Table 17.7 the value of deformation factor Cis 11400 N/mm?
TI X 108× 508.235
V= TLd3n3
60 x 103 60 x 103
2.874 m/s

Also b= 60 mm, P=3479.47 N

for dynamic load

From Backingham's Equation
21V (Ceb +P)
P= 21V+ JCeb +P)
3479.47] =
x 27.9579 x 10 x 60)+ 6473.80N
[11400 3479.47]
21 x 2.874 x 27.9579 x 10-3 x 60)+
x/I11400x
21x 2.874

Effective load 11693 N

=
3479.47) + 6473.80
(C + Pa) = (1.5 x
Peff =

Factor of safety, 25872

= 2.21
11693
Peff
satisfactory
design is
The
mm.
shouldbe 6
module
and
Regd No.
-TEMECHANICAL Engg.

r'pn Pepor
 Safetyagainst I'itting
Step 4 Factorof 2x51
2x Zy = 1.4783
51+ 18

2
(10o) =17718.03 AM
108 x0.16 x
Sw bQ,k - 60x 1.4783x
17718.03
Sw = 1.52
11693
Pett

The desgn is satistactorvand the factor of safety is adequate against pittingfailure

GEAR DIMENSIONS

For Pinion 1& 3,

Module (m) = 6 mm

No. of Teth (Zi=Zs=Z) = 18

P.CD. of Pinion (dp-mxZ) = 108 mm

Face width (b-10m) =60 mm

Addendum ( ha=m) = 6 mm

Deddendum (hy =1.25m)

=7.5 mm
Clearance
(h-h) =1.5 mm
Fillet radius
(r =0.4m) = 2,4 mm
Tooth thickness
(s=1.57O8m)
=94248 mm

Design Report
-TE MECHANICAL Engg.
Module
(m)
No. of Teeth =6 mm
(Z1=Z= Z;) =51
PCD. of Gears
(d'm x;) =306 mm
Facewidth
(b=10 m) = 60 mm
Addendum (ha =m) =6 mm
Deddendum (h= 1.25m)
=7.5 mm
Clearance (h-ha) =1.5 mm
Fillet radius (r =0.4m) = 2.4 mm

Tooth thickness
(s=1.5708m) =9.4248 mm

|Design of output shaft with bearing

A) Output Shaft:
Consider vertical force (P) N
tana = 3479.47 x tan 20'= 1266.42
We have radial force(P) = P x
Consider vertical load diagram, Ve1 +V2=P

)Mo,=0

210
Thus, 142.5= V X
Px
1266.42x 142.5
859.35N
=
= Vy
210 1116.40 N
Vc =
2361.06=
=3479.47-
Vc2 Regd No.

-TEMECHANICALEngg.
 From Vertical Load Diagram,

B.M. at C& C = Mc=Ma =0

B.M. at A= MAv=859,35 x 67.5 = 580006. 125 N-mm

From Horizontal Load Diagram,

B.M. at Ci & C= H=Hc2=0
B.M at A= MU= Ha x 67.5 =2361.06X67.5- MAH= 159371.55 N-mm

Resultant at A

M = J(Man) +(Mav")
V(159371.552) + (58606.1252) = Ma = 16599.532 Nmm
Assume combined shock and fatigue factor for bending KM and
tension
Ky= 2.0 & 2.0 respectively.
Also Torque( M)

M,
60 x10°(kw) 60 × 10 x 10
= 530516.48 Nmm
2× I1 X 180

Considering equivalent twisting moment

T, = K,, X MA) + (K, x
M,)?
=/(C %
169599.532)2 +(C, × 530516.48)2
T.= 1087804.645 N-mm

Now T, =

1087804.64
16

:.d50.95 mm

Report TE MECHANICAL Enge. Regd No.

 ding moment
1
M,
1
=;(KM × M) +T]
2

=,|(2 x 169599.532) +
:. M, =
1087804.645|
713501.85 Nmm
Also,M,=xd' x fh
713501.85 X d x 84
32 ....
.assuming fh _84
Mpa
.d= 44.22mm

Sclecting larger value of diameter, : d= 50.90mm 60mm

DESIGN OFBEARING

Totalradial load acting on the bearing C1

(P)c1 = V(859.352) + (2361.062) = 2512.53N

The bearing load acting on bearing C2

V(407.062) + (1118.402)=1190.17N
(P)c2 =
25000 hrs.
Considering life of bearing as
25000 rev.
60x 180 × = 270 Million
60nLn 106
L=
100 0
axial load X =1, Y=
Asthere is
=2
Considering load factor
32421.42 N
(270)'/3 x2=
=(1512.58) x
C;

Regd No.

-TEMECHANICAL Engg.

nroort
 mm
Ford = 60

Bearingnumber

61812 c=8710
Ta
16012 c =19900

6012 c =29600

6012 c=47500

6312 c = 81900

6412 c=108000

At Cj=32421.42 N Bearing Number: 6012

DESIGN OF INTERMEDIATE SHAFT WITH BEARING

Design of Shaft B

Torque on Shaft B is

60 x 10° x (KW) 60 × 10 x 10
Tg =
2 X T X ng 2 x T X 508.235 187891.36 Nmm

2 x TB
(P) = 2(187891.361)
306 = 1228.048 N

Radial load on gear B

(P) = (P) tan a=
1228.048 x tan 20 = 446.97 N
Consider Vertical Load
Diagram,
VB1 t Vg2
Also Vertical B.M. at =446.97 - 1266.42
B=0
Mp1= Mp2 =0, ) My2 = 0
Design Report
-TE MECHANICAL Engg.
Regd No.
 (446.97 x 67.5) -(1266.42 x 142.5)-VX 210 0

V-715.68N &V 103.77 N

Cosder llorizontal load diagran,

l + 1228.048 + 3449.47 4707.51BN

Taking mont about point B,

YM-0

(1228.048 x67.5) +(3477.47x 142.5)- (H x 210) =0

l l =2755.79N& H,, = 1951.71N

Resultant Reactio,

= 2847.20N
Rå =V)' +(Vu)'=/C- 715.85)' +(2755.79)'
1954.46 N
R2 =V)'+ (Vu2)'=/-103.77)+(1951.71)2 =
Now,Vertical bending moment at B; & B 0
Myp2 =Myn1 =0
Nmm
Myk =Vg X 67.5=-103.77 x 67.5 =-7004.475
Nmm
Myc = V X142.5 = -715.68 × 142.5 =-101984.4

Horizotal B.M. at B; & B) =0

Mån =Hp» X 67.5 =1951.71 x 67.5 =131740.425 Nm

M = (1951.71 x 142.5) -(1228.048 x 67.5)=195225.43 N-m

The resultant B.M. at cwill be Maximum

M =/-101984.4)² + (195225.43)= 220258.45 Nmm

T= T=187891.36| N-mm

ipn Report -TE MECHANICAL Engg.

 ConsideringEquivalent Torque,

T, =/(Km XM)² + (K, x T,)2

T.=J(2x 220258.45)2 +(2 x 187891.361) = 579023.13 Nmm

Also,

T, =
16-x d' x f
579023.13 = -x d' x 42 ...assuming fs = 42 Mpa
16

d=41.25 mm

Considering Equivalent bending moment,

1
M, =;[(K* XM) +T]
1
M, =1(2x 220258.45) + (579023.13)]= 509770.015 Nmm
Also,

M, = x d' x fo assuming f = 84 Mpa

32

509770.015 = x d' x 84
32

d=39.53 mm

Selecting the larger value of d= 41.25 mm Say d = 45 mm.

)esign Report -TE MECHANICAL Engg. Re

 DESIGN OFBEARING

Considerthe life cyce of bearing 25000 hrs.

60 x 508.235 x 25000
106
=763.68 Million Rev.

CR1 = 2847.20 x (763.66)7 x 2 = 51934.68 N

CHz =1954.46 x (763.66)3 x 2 = 35721.62 N

For d =45 mm

For Bearing,

BË= Bearing Number = 6308

B, =Bearing Number =6208

BEARING
DESIGN OF INPUT SHAFT WITH
Consider vertical load diagram

V1 + Vaz =-446.97

210) = 0
(446.97 x 67.5)+ (Vp X
VA1 =-303 N
Vap = 143.668 N&

For Horizontal load,

1228.48. SMAI-0,
H1 +H2 =
x 210) = 0
(1228.048 x 67.5) - (H,

394.72 N & H¡p = 833.318 N

H1 =

Now, Vertical B.M. atAj& A2 =0

i.e. Ma1 = MAp2 =0

bMECHANICAL Engg.
Regd No.
 Mua = 394.72 X67.2 == 26643.6 Nmm

Resultant B.M at A

M, =/My)' +(Mua)? = (26643.6)2 +(1532.79)2 = 26688.01 N

Torque (T)
T=60x10x10
2X1440
=66314.55 N-mm

Considering Equivalent Twisting Moment

Tt
T, = V(Km x M)² + (K, x T)2= 16 x d' x fs

V(2 x 26688.01)2 + (2 x 66314.55)2 = x d' x 42 ...assuming fs =42 Mpa

16

d= 25.88 mm

Considering Equivalent Bending Moment,

1
M, =;[(KM XM) + T,l=x d xf

=;(2x 26688.01) +(142966.70)]=Xd' x84

d= 22.88 mm

mm Say d =30 mm.

Taking Larger value, d = 25.88
DESIGN OF BEARING

25000 hrs.
Considering life of bearing as
25000
60nn 60 x 1440 × = 2160 Million rev
L= 106
106
on the bearing A1
Total radial load acting
(394.722) = 497.607N
(P)A1 = /-3032)+

Regd N0.
-TE MECHANICAL Engg.
 The bearing load
acting on bearing A2
(P)A2 =
C=
J-143.668) +
(833.312) =845.61 N
497.607 x (2160)3 x2=
12831.85 N
.C, = 845.61 x
(2160)3 x 2 =21856.14N
for d = 35mm

Bearing No.
61807 4030

16007 12400

6007 15900

6207 25500

6307 23200

55300
6407

For Bearing, 16007

A2= Bearing No
6207,
Aj= Bearing No.

Regd No.

-TEMECHANICALEngg.

Uesign Report
 DESIGN OFKEY
Key For Shaft C:

Equivalent torque,
T. = 108780.645 N-mm

Assume Square key.

Length of key =60 mm,
Width = thickness = 20 mnm.

Considering Shearing of key,

60
108780.645 = (60 x w) x 42 x
2
W=14.43 mm < 20 mm.

So the design of key is safe.

L= 60 mm, w =t= 20 mm.

Key For Shaft B:

We have,

T= 579023.13 N-mm

Assume Square key.

Length of key =60 mm,
Width= thckness =16mmn

Considering Shearing of

-TE MECHANICAL EngE

 T, =(xwxhx5)
579023.13 = (60 x w) x42 x 45
2
W=10.21 < 16mm

ShaftA:
KeyFor
We have,

I=142966.76 N-mm

Assume Square key,

Length of key = 60 mm,

Width = thickness = 10mm

Considering Shearing of key,

30
x 42x
142966.76 = (60 Xw)

mm
W =3.78 < 16
safe.
of keyis
Hencethe designn
mm
W=t= 10
L= 60 mm,

Regd No.

-TEMECHANICALEngg.
 RESULT

Sr.No. Parameter Dimension Dimension

(For Pinion 1«3) (For Gear 2 & 4)
Module (m) 6

No. of Teeth 18 51

Pitch Circle Diameter 108 306

4 Face Width (b) 60 60

5 Addendum (ha) 6

7.5 7.5
Deddendum (h)
1.5 1.5
7 Clearance (C)
2.4 2.4
Fillet Radius (r)
9.4248 9.4248
Tooth Thickness (s)

SHAFT:

1. Diameter of Input shaft (Shaft A) = 60 mm.

45 mm.
2. Diameter of Intermediate Shaft (Shaft B) =
mm.
3. Diameter of Output Shaft (Shaft C) = 30
KEY:

10mm.
1. Key Dimensions for Shaft A =l=60mm, t = w=
60mm, t= w= l6mm.
2. Key Dimensions for Shaft B=|=
Dimensions for Shaft C=|= 60nm, t= w=20mn.
3. Key

BEARING:

(Shaft A) =Bearing No. 6207 & l6007.

1. For lnput Shaft
Shaft B = Bearing Number. 6208 & 6308.
2. For
(Shaft C) = Bearing No. 6012.
3. For Output Shaft