MES-POWER TRANSMISSION Final (Read-Only) PDF

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MECHANICAL ENGG. SCEINCE
PARTA ( PROPERTIES OF STEAM, STEAM TURBINES, REFRIGERATION, IC ENGINES) PARTB 1) 2) 3) 4) 5) POWER TRANSMISSION CASTING FORGING MACHINE TOOLS WELDING
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TRANSMISSION OF POWER
Dept. of Mech & Mfg. Engg. 3
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What is a transmission system?

The rotational motion can be transmitted from one mechanical element to the other with the help of certain systems known as transmission system (Drives). These systems is employed to drive a device directly or transmit the rotational motion to various parts of the machine within itself.
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The one that drives is called the driving system and the other which is driven is called the driven system. Round rods called shafts are used to transmit the rotational motion.
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Methods of Drive
Machines may be driven by any one of the following two methods:
1. Individual Drive 2. Group Drive
Dept. of Mech & Mfg. Engg.
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Individual Drive (Self-contained Drive)

Each machine has its own electric motor and starter. The motor may drive the machine shaft through belt, chain, gears etc.. It is used on machines that require considerable power, operating at a full load.
Group Drive (Common Drive)

If several machine tools receive power from a common powerful motor which runs a main shaft or overhead shaft is called group or common drive. The main shaft runs from one end to the other end of the shop. The Main shaft drives another shaft called countershaft, which in turn drives the machine drive shaft. It is most suitable where power consumption of individual machines is extremely variable.
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Classification of transmission systems is done depending on, distance between them, speed & power as,
Types of drives
Flat belt.---- 1.open 2.crossed
i.
Belt drive.
V - belt
ii. Chain drive. iii. Gear drive. iv. Rope drive.
1 1
Belt Drive
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Belt Drive (Friction Drive)

It is one of the most common and effective devices of transmitting power or rotary motion between two parallel shafts. It consists of two pulleys over which a thin inextensible (endless) band is passed encircling both of them. Uses :Mills & Factories,specially when the distance between them is not very great.
In a belt drive arrangement, there is a driver pulley mounted on the driving shaft, and the driven pulley(follower) to which the power has to be transmitted is mounted on the driven shaft. The pull or the tension on one of the sides of the belt should be more than the other side for the belt to move.
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The portion of the belt which is having less tension is called the slack side and the one which is having more(higher) tension is called the tight side. This depends on the direction of rotation of the driving pulley .i.e. clockwise rotation- lowerside tight & upperside slack. This arrangement increases the angle of contact of the belt on the driven side and therefore the capacity of the drive. Due to slip the pulley rotate at a lesser speed which reduces the power transmission, hence belt drives are said to be not a positive type of power transmission system. The effective pulling power of the belt that causes the rotation of the driven pulley is the difference in tensions on the slack 15 and tight sides.
Flat Belt
Types of Flat belt drives:

1. Open belt drive 2. Crossed-belt drive
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Open belt drive

It is employed when the two parallel shafts have to rotate in the same direction.
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Open belt drive
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Open belt drives

When the shafts are placed far apart, the lower side of the belt should be the tight side and the upper side must be the slack side.
When the upper side becomes the slack side, it will sag due to its own weight and thus increases the arc of contact.
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Flat belt drives of the open system can have: Their shaft axes either horizontal or inclined. They should never be vertical (:.the centrifugal force developed in the belt combined with the force of gravity causes the belt to stretch and tend to leave the rim).
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Crossed belt drive
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CROSSED BELT DRIVE

It is employed when:
Two parallel shafts have to rotate in the opposite direction. At the junction where the belt crosses, it rubs against itself and wears off. To avoid excessive wear, the shafts must be placed at a maximum distance from each other Operated at very low speeds.
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Pulley
Pulleys are used to transmit power from one shaft to the other at a moderate distance away by means of a belt or strap running over them. They may be made of cast iron, wrought iron, pressed steel, wood. What is crowning in a pulley? It is the process of keeping the diameter of the rim greater at the center than at the edges. The effect of crowning is to keep the belt in a central position.
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What is crowning in a pulley?
When the flat belt on cylindrical pulley is offcenter and the pulley rotating, the belt quickly moves up to the largest radius at the top of the crown and stays there. The crown is important to keep the belt "tracking" stable, preventing the belt from "walking off" the edge of the pulley. A crowned pulley eliminates the need for pulley flanges and belt guide rollers.
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About Crowning
When a flat belt runs over two pulleys, only one of them needs to be crowned to achieve lateral stability. The amount of curvature required in actual machinery is small. The method works for belts of leather or rubberized fabric that have some elasticity.
Benefits of Crowning the pulley

Crowning of pulleys provides an automatic correction to mis-tracking caused by transient forces that are applied to the belt. Without crowning these transient forces cause the belt to be displaced without consistent means of returning to its normal path. This can cause belt edge cupping and wear. For this reason it is wise to select a conveyor with pulley crowned.
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Pulley crowning *
Critical dimensions: Crowning of pulleys should not exceed 25mm on the dia. / mtr of width Width of the pulley should be 1/4th greater than width of the belt.
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Types of pulleys
Stepped cone pulley (Speed cone) Fast and loose pulleys Guide pulley (Right angled drive) Jockey pulley Grooved pulley Wrought-iron pulley
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Stepped cone pulley
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Stepped cone pulley
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Speed cone pulleys or stepped cone pulleys are cast iron pulleys having several steps of different diameters on which a belt may run. They are used for varying the velocity ratio between a pair of parallel shafts by simply shifting the belt from one step of the pulley to the other i.e, When speed of the driven shaft is to be changed very frequently
Used in lathe, drilling m/c etc.. Integral casting One set of stepped cone pulley is mounted in reverse on the driven shaft
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Fast and Loose pulley When many machines obtain the drive from a main driving shaft, Run some machines intermittently without having to Start and stop the main driving shaft
Fast pulley Securely keyed or fixed firmly to the machine shaft Loose pulley (with brass bush) Mounted freely on the machine shaft Rotates/revolve freely
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Fast and Loose pulley
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Working
When the belt is on the fast pulley,
Power transmitted to the machine shaft
When machine shaft is to be brought to rest,

Belt is shifted from fast pulley to loose pulley
Note: 1. Axial movement of the loose pulley towards fast pulley is prevented . 2. Axial movement of the loose pulley away fast pulley is also prevented.
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Jockey Pulley (rider pulley): * Are used to Increase the arc of contact, the tension & the power transmission.
If Center distance is small One pulley is very small Arc of contact small/less The idler pulleys are mounted near the smaller pulley and always ride on the slack side of the belt
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Jockey Pulley
k f
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Guide pulley (Right angled drive)

Use:
To connect non-parallel shafts those which intersect and those which do not intersect to guide the belt in to the proper plane When two shafts to be connected are close together
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Guide pulley (Right angled drive)
Guide Pulley
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Grooved Pulley
The effect of groove is to increase the frictional grip of the rope on the pulley & thus reduce the tendency to slip. The groves are V-shaped. Angle between 2 faces: 400 600 Uses: Used in V-belts, rope. Transmission of large powers over great distances
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Wrought-iron pulley
Light, strong and durable Entirely free from initial strains To facilitate the errection of pulleys on the main shaft, they are usually made in halves and parts are securely bolted together.
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Length of a belt (*)

Open belt drive:
h (r1 - r2)2 (r + r ) + 2 L= 1 2 +
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Let the two pulleys P and Q are connected by an open belt. From the centre C2 of the smaller pulley draw a line C2G parallel to CD. Let r1 ,r2 be the radii of larger and smaller pulleys P and Q. Let X=Distance between the centers of the two pulleys. From the geometry of the belt drive shown in fig., the length of the belt is given by, L=Arc Length ABC + Length CD + Arc Length DEF + Length FA =2[Arc Length BC+ Length CD + Arc Length DE] =2[{/2 + } r1 + Length CD + {/2 - } r2] = 2 [{/2 + } r1 + Length GC2+ {/2 - } r2] ---(:CD=GC2) =2[{/2 + }r1+X Cos + {/2- } r2 ]--- GC2/X=Cos 47
=2[ /2 (r1+ r2 )+ (r1- r2) + X Cos](1). = (r1+ r2 )+2 (r1- r2 )+2 X Cos From the triangle GC1C2 Sin = (r1- r2 ) / X =Sin-1 r1- r2/ X = r1- r2 / X (: is small).2. 2 1/2 Cos= [1- Sin ] = [1-1/2 Sin2 ] (By Binomial theorem and neglecting higher powers) = [1-1/2{(r1- r2) / X }2 ] ..3. Substituting(2) and (3) in (1) L= (r1+ r2 )+2 (r1- r2) / X (r1- r2) +2X [1- (r1- r2) 2 /2X2 ] = (r1+ r2 )+2 (r1- r2)2 / X + 2X- (r1- r2) 2 / X L= (r1+ r2 )+ (r1- r2)2 / X + 2X *
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Length of a belt (*)

Crossed belt drive:
e (r + r )2 L = (r1+ r2)+ 2 + 1 2
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Let the two pulleys P and Q are connected by an open belt. From the centre C2 of the smaller pulley draw a line C2G parallel to CD. Let r1 ,r2 be the radii of larger and smaller pulleys P and Q. Let X=Distance between the centers of the two pulleys. From the geometry of the belt drive shown in fig., the length of the belt is given by, L=Arc Length ABC + Length CD + Arc Length DEF + Length FA =2[Arc Length BC+ Length CD + Arc Length DE] =2[{/2 + } r1 + Length CD + {/2 + } r2] = 2 [{/2 + }( r1 + r2) + Length CD] = 2 [{/2 + }( r1 + r2) + Length GC2 ---- ---(:CD=GC2) =
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= 2 [{/2 + } ( r1 + r2) + X Cos ] ..(:.GC2/2= Cos ) = [( +2 ) ( r1 + r2) + 2X Cos ] ..1 From the triangle GC1C2 Sin = (r1 + r2 ) / X -1 =Sin r1 + r2/ X Cos= [1- Sin ] 2 = [1-1/2 Sin ]
2 1/2
= r1 + r2 / X
(: is small).2.
(By Binomial theorem and neglecting higher powers)

2
= [1-1/2{(r1 + r2) / X } ] ..3. Substituting(2) and (3) in (1) 2 L = [ + 2{ (r1+ r2 ) / X } ] (r1+ r2 ) +2X [1- (r1+ r2)2 / 2X ] = (r1+ r2 )+2 (r1+ r2)2 / X + 2X- (r1+ r2) / X
2
L = (r1+ r2 )+ (r1+ r2)2 / X + 2X.*

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Define Velocity Ratio of Belt Drive. (Speed Ratio)

The velocity ratio of a belt drive is defined as the ratio of the speed of the driven pulley to the speed of the driving pulley.
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Obtain the expression for velocity ratio of belt drive. Let d1= Diameter of the driving pulley (mm) d2= Diameter of the driven pulley (mm) N1= Speed of the driving pulley (Revolutions/min OR RPM) N2= Speed of the driven pulley (Revolutions/min or RPM)
If there is no relative slip between the pulleys and the portions of the belt which are in contact with them,
the speed at every point on the belt will be same

The circumferential speeds of the driving and driven pulleys and the linear speed of the belt are equal.
Circumfere ntial speed Circumferential speed Linearspeed of the driving pulley = = of the belt of driven pulley
= d1N1 = d1N1
= d2N2 = d2N2
Velocity Ratio = N2 / N1 = d1 / d2 Velocity Speed of the driven pulley = Ratio Speedof the driving pulley
Diameter of the driving pulley Diameterof the driven pulley

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Effect of Thickness of belt on the velocity ratio:
If THICKNESS OF THE BELT IS CONSIDERED,then

The circumferential speed should be the mean speed at the centre of the belt thickness.
[Linear speed of the belt]= [Mean Circumferential speed of the driving pulley] =[Mean circumferential speed of the Driven pulley] .
= [(d1+t)N1]
= [(d2+t)N2]
(d1+t)N1 = (d2+t)N2
Velocity ratio =N2/N1= d1+t /d2+t
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Initial tension in belt drive

Definition
It is a uniform tension that exists initially when the drive is not in motion. It is designated as To.
Formula:
To =
T1 + T2
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Derive the expression for the ratio of tensions in belt drive.

The driving pulley drives the driven pulley only if one side of the belt has higher tension than the other side. The figure shows a driven pulley rotating in clockwise direction.
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The polygon of forces acting on the element is represented by the closed quadrilateral as shown in figure. Consider a small element AB of belt, T1= Higher tension, T2= Lower tension, = angle subtended by the element of AB T =tension on the slack side of the belt. = co-efficient of friction between the belt surface and pulley rim
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Let the tension in the tight side of the belt element AB be greater than the slack side by T. Therefore the tension in the tight side of the belt element is T +T. If R is the normal reaction exerted by the pulley on the element of the belt. Then, The force of friction R acts perpendicular to the normal reaction R in the direction opposite to the direction of motion as shown in figure.
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Element AB will be in equilibrium only when following forces act on it 1. Tension T on the slack side at A 2. Tension T +T on the tight side at B 3. Normal reaction R 4. Frictional force R acting perpendicular to R
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Resolving all the forces in the direction of R.

R = T Sin
2
(T +T ) Sin 2
= 2T Sin + T Sin 2 2 For small angles the following assumptions can be made.
Sin /2 = /2
&
Tx /2 is neglected.
R= 2T
R =T
2
------------------------------ (1)
Resolving all the forces perpendicular to R

R = (T + T ) Cos 2 - T Cos 2
= T Cos + 2 =
T Cos 2
T Cos 2
- T Cos 2
For small angles Cos /2 = 1 R = T ---------------------- (2)
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Substituting equation (1) in (2) T = T

T = T
Integrating between 0 and and tension T between T2 and T1
T = T2 T 0
log e
T1
T1 = T2
= e
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T1 T2
Where = Angle of contact in radians =Coefficient of friction. Taking log of the previous eqn., logT1/T2 = log e
Where, e=2.718 Base of Napierian Logarithms
logT1/T2 = log 2.718 =0.4343
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Slip
What is slip?
The sliding motion of the belt which causes a relative motion between the pulley and the belt. This occurs when the force to be transmitted by the driver is greater than the force of friction. (The difference between the actual speed of the driven pulley and that calculated by the velocity ratio equation).
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The driver pulley rotates along with the belt due to a firm frictional grip between its surface and the belt. Sometimes this frictional grip is not sufficient so it causes some forward motion of the driver pulley without carrying the belt with it. Sometimes the belt moves faster in the forward direction, without carrying the driven pulley with it. The difference between the linear speeds of the pulley rim and the belt is a measure of slip, this slip is expressed as a percentage.
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Effect of Slip on Velocity Ratio The slip is expressed as percentage of the speed Let S1,S2 be the % of slip between driving & driven pulley and the belt So total % of slip S = S1+S2 Circumferential speed of the driving pulley=d1N1
Considering the % Slip S1 between the driving

pulley and the belt passing over it, Reduced Linear Speed of the belt because of the slip
S1 = d1N1 X [100-S1/100
]
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The circumferential speed of the belt on the driven pulley when slip S2 occurs between the belt and its rim is given by, d2N2 =[speed of the belt on the Driven Pulley ] x [100-S2/100 ] N2/N1=d1/d2 x [100-S /100 ] If the thickness of the belt is considered, then N2/N1=(d1+t)/(d2+t) / x [100-S /100 ]
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Creep in Flat belt drive The two tensions T2 &T1are not equal in magnitude(T1>T2).Hence the stretch will be different in different sides. The phenomena of alternate stretching and contraction of the belt results in a relative motion between the belt and the pulley surface. This relative motion is called creep.
Creep in Flat belt drive This results in: Loss of power Decrease in the velocity ratio
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Power transmitted in a belt drive

P = (T1-T2) * v 1,000 kW
v = d N in m/sec 60*1000 T1, T2 in Newtons
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Horse-power transmitted by a belt *

The effective pull of the belt is equal to T1-T2=P where P is called the driving force/driving tension In kg. If v is the linear velocity in metre per minute,then Work transmitted per minute=Pxv kgfm. Therefore, hp=Pxv/4500 If the belt passes over a pulley having the diameter d in metre & which makes n revolutions per minute then Speed of belt,v=circumference x rev.per minute, v=dn Therefore hp=P x dn/4500 72
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Disadvantages of flat belts

Power transmitted is less Exact velocity ratio cannot be maintained Slip & creep causes loss of power Large power cannot be transmitted effectively
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V-Belt Drive
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V-Belt Drive
Widely used form of belt drives in power transmission. (0.5kW up to 150 kW) They are made out of rubber & fibrous material. They run in the V-grooves made in the pulleys & Power transmission can be increased by using several belts placed side by side The wedging action of the belts in the V-grooves enable them to transmit high torques.
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V-Belt Drive Advantages over flat belt drive
Transmit greater power Permit large speed ratios No slipping of the belt from the pulley Maintenance is low
Problems on belt drive
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L = (r1+ r2 )+ (r1- r2)2 / X + 2X---- (Open drive) L = (r1+ r2 )+ (r1- r2)2 / X + 2X---- (Cross drive) logT1/T2 =0.4343 ( Ratio of Tension in belt =Radians=X *
( /180 ) , = Coefficient of friction)

=Sin-1 r1- r2/ X
Sin = (r1- r2 ) / X
=180-2 = * ( /180 ) INITIAL TENSION To = (T1 + T2 ) / 2 Velocity Ratio = N2 / N1 = d1 / d2 Velocity ratio =N2/N1= d1+t /d2+t Linear speed of the belt = d1N1
= d2N2
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1) Simple problems like r1, r2 and center distance X will be given, find out Length of open drive and cross rive melts) 2) The sum of diameters of two pulley is 1000mm and the pulleys are connected by belt. If the pulleys rotate at 600 rpm and 1800 rpm, det. The diameters of each pulley 3) In cross drive belt diff in tension between tight side and slack side is 1200N, if the angle of contact () is 160 degree, and = 0.28, find tension in tight and slack side 4) The driven pulley of 400mm dia of a belt drive runs at 200rpm, the anle of lap is 165 deg, co-efficient of friction is 0.25, find the power transmitted , if the initial tension is not to exceed 10 kN.
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1) An electric motor provides 6 KW power to an open belt drive. The diameter of the motor pulley is 200mm and it rotates at 900 rpm. Calculate tight and slack side tension in the belt if the ratio of tension is 2.
Solution: P = 6kW d1 = 200 mm n1 = 900 rpm
T1 = 2. T2
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P = 6kW, d1 = 200 mm, n1 = 900 rpm , Linear velocity of belt v =
T1 = 2. T2
d1 N1
60 . 1000
. 200 . 900
60 . 1000
9.425 m/sec
= Power P=
(T1 T2 ) v 1000
T1 T2 =
1000 . P 1000 . 6 = v 9 .425
636.6 N
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By data,
T1 = 2. T2
We get, 2T2 T2 = 636.6N Slack side tension Tight side tension T2 =
636.6 N
T1= 2T2 = 1273.2 N
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2) A leather belt transmits 20kW power from a pulley of

750mm diameter which runs at 500 rpm. The belt is in contact with the pulley over an arc of 1600 and the coefficient of friction between the belt and the pulley is 0.3. Find the tension on each side of the open belt drive.
Solution: P = 20 k W d = 750 mm n = 500 rpm = 1600 = 0.3
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Linear velocity of belt
v =
dn
60 . 1000
= .750 . 500
60 . 1000
= 19.635 m / sec
(T1 T2 ) v
Power P=
1000
T1 T2 = =
1000 . p v
.(1)
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1000 . 20 = 1018.6 N 19.635
By data,
T1 = e T2
= e ((0.3 ) (160) * ( /180 ))= 2.311 From equations (1) and (2) 2.311 T2 T2 = 1018.6 Slack side tension T2 = 776.96 N Tight side tension T1 = 776.96 (2.311) = 1795.6 N
.(2)
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3) Power is transmitted by an open belt drive from a pulley 300 mm. diameter running at 600rpm. to a pulley 500 mm. in diameter. The distance between the centre lines of the shaft is 1m. and the coefficient of friction in the belt drive is 0.25. If the safe pull in the belt is not to exceed 500 N, determine the power transmitted by the belt drive.
Solution: d1 = 300 mm. n1 = 600 rpm d2 = 500mm c= 1m. = 1000 mm = 0.25
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T1 = 500 N
Problems on slip in belt:The engine shaft running at 200 rpm, is required to drive a generator at 300 rpm, by means of a flat belt drive. Pulley on the driving shaft has 500mm diameter, det. The diameter of the pulley on the generator shaft if the belt thickness is 8mm and slip is 4%.
Back 88
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Disadvantages of flat belts

Power transmitted is less Exact velocity ratio cannot be maintained Slip & creep causes loss of power Large power cannot be transmitted effectively
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V-Belt Drive
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V-Belt Drive
Widely used form of belt drives in power transmission. (0.5kW up to 150 kW) They are made out of rubber & fibrous material. They run in the V-grooves made in the pulleys & Power transmission can be increased by using several belts placed side by side The wedging action of the belts in the V-grooves enable them to transmit high torques.
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V-Belt Drive Advantages over flat belt drive
Transmit greater power Permit large speed ratios No slipping of the belt from the pulley Maintenance is low
Chain Drives
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Chain Drives
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Chain Drives
Over comes the disadvantages of the belt drive Can be used from 3m to upto 8m centre distances (transmits upto 100kW) Used in agricultural machinery, bicycles, motor cycles etc..
Two types of chains used in power transmission:

1. Roller Chain 2. Silent Chain
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Roller Chain
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Silent Chain
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Roller Chain
A chain drive consisting of a chain and two sprockets Widely used in low or medium speed power transmission systems This type of chain is employed in bicycles, motorcycles, machine tools etc..
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Silent Chain (Inverted Tooth Chain)

Consists of a series of toothed plates pinned together in rows across the width of the chain
Advantage:
- Smooth and noiseless operation at high velocities
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Chain Drive Advantages

Positive non-slip drives Efficiency is high Employed for small as well as large centre distances up to. 8m Permit high velocity ratio Transmit more power than belt drives They produce less load on shafts compared to belt drives Maintenance is low
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Chain Drive Disadvantages

Driving and driven shafts should be in perfect alignment Requires good lubrication High initial cost
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Rope Drive
When centre distances are greater than 10 m Power to be transmitted is more than 200 HP Used in lifts, hoists etc
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Gear Drives
Gear
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When considerable power has to be transmitted over a short centre positively with a constant velocity ratio gear drives are preferred. Gear drives possess a very prominent role in mechanical power transmission. A gear is a toothed wheel with the teeth cut on the periphery of a cylinder or a cone, or on elliptical discs. They are mounted on the axles or shafts and keyed to them. Two gears are mounted on the individual shafts
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What are the different types of gears used in gear drives? 1. Spur Gears - For Parallel Axes shafts. 2. Helical Gears 3. Spiral Gears 4. Bevel Gears 5. Worm Gears - For both Parallel and Non-parallel
and non-intersecting axes shafts.
- For Non-parallel and Non-intersecting

axes shafts.
- For Intersecting Axes shafts. - For Non-Parallel and Non-co-planar

axes shafts.
6. Rack and Pinion - Rotary motion For converting into

linear motion.
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Spur Gears
When the axes of the driving and driven shafts are parallel and co-planar. The teeth of the gear wheels are parallel to the axes The contact between the mating gears will be along a line ,Can transmit higher power. Noise will be very high. Applications: o Machine tools, o Automobile gear boxes and in o All general cases of power transmission where gear drives are preferred.
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Spiral Gears
Used to connect only two non-parallel, nonintersecting shafts There is a point contact in spiral gears Because of the point contact the spiral gears are more suitable for transmitting less power.
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Helical Gears
Similar to the spur gears But teeth are cut in the form of the helix around the gear Used for transmitting power between two parallel shafts and also between non -parallel, non-intersecting shafts. Contact between the mating gears will be along a curvilinear path. Helical gears are preferred to spur gears when smooth and quiet running at higher speeds are necessary. Generally they are used in automobile power transmission.
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Bevel gears
Used when the axes of the two shafts are inclined to one another, and intersect when produced. Teeth are cut on the conical surfaces. The most common examples of power transmission are those in which the axes of the two shafts are at right angles to each other. When two bevel gears have their axes at right angles and are of equal sizes, they are called Miter gears.
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Rack and Pinion

Used when a rotary motion is to be converted into a linear motion. Rack is a rectangular bar with a series of straight teeth cut on it. Theoretically rack is considered to be a spur gear of infinite diameter. Application: Machine tools, such as, lathe, drilling, planing machines, Some steep rail tracks, where the teeth of the locomotive wheel mesh with a rack embedded in the ground, offering the locomotive improved traction. 118
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Worm Gear Worm gearing is a Special form of screw gearing,i.e Its action is like screw and nut. This type of gearing is used for transmitting power between non-intersecting and non- paraIlel shafts. This is a gearing in which teeth have a line contact. Axes of driving and driven shafts are at right angles. A simple worm gear combination consists of a screw meshing with a helical gear. Velocity ratio does not depend upon the diameters of the worm and gear but upon the ratio of no. of teeth on the worm gear to the no. of threads on the worm. Worm gearing is used to provide high angular velocity reduction. Used in machine tools like Lathe, Drill, Milling to get large velocity ratio.
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What are the Advantages and Disadvantages of Gear Drives?

Advantages; 1. They are positive non-slip drives. 2. Most convenient for very small centre distances. 3. By using different types of gears, it will be possible to transmit the power when the axes of the shafts are not only parallel, but even when non-parallel, intersecting, non-intersecting and co-planar or non-coplanar. 4. The velocity ratio will remain constant throughout. ' 5. They can be employed conveniently for low, medium and high power transmission.
6. Any velocity ratio as high as, even upto 60 : 1 can be obtained. 7. They have very high transmission efficiency. 8. Gears can be cast in a wide range of both metallic and non-metallic materials. 9. If required gears may be cast integral with the shafts. 10. Gears are employed for wide range of applications like in watches, precision measuring instruments, machine tools, gear boxes fitted in automobiles, aero engines, etc.
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Disadvantages
1. They are not suitable for shafts of very large centre distances. 2. They always require some kind of lubrication. 3. At very high speeds noise and vibrations will be more. 4. They are not economical because of the increased cost of production of precision gears. 5. Use of large number of gear wheels in gear trains increases the weight of the machine.
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Gear Tooth Profile
Figure:
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Spur Gear elements
Figure:
Spur gear elements

Circular pitch (p): It is the distance from a point on one teeth to the corresponding point on the next tooth measured along the pitch circle. If T is the number of teeth on a gear and d is the diameter of the pitch circle, Circular pitch, pc= d / T, where T is the no.of teeth on gear. Module(m): It is the ratio of the pitch circle diameter of a gear to the number of teeth on a gear m=d/T Diametral pitch (Pd)= Ratio of module ie., 1/m is the Pd. Pd= T/d
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Define velocity ratio of Gear drive
The velocity ratio of a gear drive is defined as the ratio of the speed of the driven gear to the speed of the driving gear.
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Obtain an expression for gear drive. Let d1 = pitch circle diameter of the driving gear d2 = pitch circle diameter of the driven gear T1 = Number of teeth on the driving gear T2 = Number of teeth on the driven gear. N1 =speed of the driving gear in revolutions per minute. N2 = speed of the driven gear in revolutions per minute.
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Since there is no slip between the pitch cylinders of the two gear wheels, The linear speed of the two pitch cylinders must be equal.
Linear speed of the pitch Linear speed of the pitch cylinder representing the Driving gear = cylinder representi ng driven gear
d1N1
= d2N2 (1)
d1 N2 = d2 N1
The circular pitch for both the meshing gears remains same. i.e. pc =
d1
T1
d2
T2
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i.e.,
T1 ..(2) d1 = T2 d2
From equations (1) and (2) Velocity Ratio of a Gear Drive =
N2 T d = 1 = 1 N1 T2 d2
Velocity ratio of the worm and worm wheel is expressed as: Velocity = ratio Speed of the Worm Speed of the Worm Wheel Number of Teeth on Worm Wheel Number of Threads on the Worm
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What do understand by a gear train?
A gear train is an arrangement of number of successively meshing gear wheels through which the power can be transmitted between the driving and driven shafts.
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The different types of gear trains are: 1. Simple gear train. 2. Compound gear train. 3. Reverted gear train. 4. Epicyclic Gear train. The gear wheels used in gear train may be spur , bevel or helical etc.
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Simple Gear Train
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The idler gears act as the intermediate gears to establish the drive between the driver and the driven gears , but they change the direction of rotation of the driven gear. Even number of idler gears will rotate the driven gear in the opposite direction to that of the driving gear. Odd number of idler gears will rotate the driven gear in the same direction as that of the driving gear.
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z z
Simple Gear Train
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Gear meshing
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Draw a neat sketch of a simple gear train and derive an expression for the velocity ratio of the same.
In a simple gear train a series of gear wheels are mounted on different shafts between the driving and driven shafts each shaft carrying only one gear.
A Driving gear B - Intermediate gear (idler gear) C- Intermediate gear(idler gear) D Driven gear
C D
Let NA = speed in RPM of gear A NB = speed in RPM of gear B NC = speed in RPM of gear C ND = speed in RPM of gear D
C
TA = Number of teeth of gear A TB = Number of teeth of gear B TC = Number of teeth of gear C TD = Number of teeth of gear D
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i.
A drives B
NB = NA TA TB
ii. B drives C
NC = NB ND = NC TB TC
C D
iii. C drives D
TC TD
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Velocity ratio between the driving and driven gears is given by, Velocity Ratio =
ND NA
ND NC
. NC . N B
NB
NA
. . Substituting from (i), (ii) and (iii)
Velocity Ratio = . .
ND NA T T T = A . B . C TB TC TD
TA ND = N A Dept.T ofD Mech & Mfg. Engg.
C D
Velocity Ratio
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Draw a neat sketch of a compound gear train and derive an expression for the velocity ratio of the same.
A compound gear train is one in which each shaft carries two or more gears and keyed to it. When Velocity Ratio is very high simple gear train found difficult because of small center distance.
Gear B,C Compound gear
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Gear A drives B,
N B TA = N A TB
.(1)
Since gears B and C are keyed to the same shaft, Both of them rotate at the same speed NB = Nc but TB Tc Gear C drives D,
c
D
N D TC = N C TD
(2)
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Velocity ratio between driving and driven gear
A
=
ND ND = N A NC
. NC
NA
Substituting from (1) and (2)
Velocity ratio =
N D TC TA . = N A TD TB
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Advantages of Gear Drives 1. It is a positive drive and is used to connect closely spaced shafts. 2. High efficiency, compactness, reliable service, more life, simple operation and low maintenance. 3. It can transmit heavier loads than other drives and can be used where precise timing is desired.
145 Dept. of Mech & Mfg. Engg.
Disadvantages: 1. They are not suitable for large centre distance because the drive becomes bulky. 2. High production cost. 3. Due to errors and inaccuracies in their manufacture, the drive may become noisy accompanied by vibrations at high speeds.
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A counter shaft has a pulley 1200 mm. diameter keyed to it and it is to have a speed of200 rpm. It is to be driven by an electric motor which has a speed of 1000 rpm. What diameter pulley should be fitted to the electric motor? Find the velocity ratio and the speed of the belt
Solution: d2= 1200 mm, n2= 200 rpm, n1= 1000 rpm.
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Gear Drive Problems
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FORMULAS TO BE USED
SIMPLE GEAR TRAIN:Velocity Ratio
ND = NA
TA TD
COMPOUND GEAR TRAIN Module m = d mm

T
Velocity ratio =
N D TC TA . = N A TD TB
Circular pitch, pc= d / T, where T is the no.of teeth on gear, d= Pitch circle diameter Train value = 1/ velocity ratio
CONDITIONS TO SOLVE PROBLEM

1. To get maximum velocity ratio Select the driving gear with maximum number of teeth & diven gear with minimum number of teeth 2.To get minimum velocity ratio Select the driving gear with minimum number of teeth & diven gear with maximum number of teeth 3.Mesh two gears with same diametral pitch 4. spur gear has to be meshed with spur gear and helical gear has to be meshed with helical gears
But spur gear can be compounded with helical gear with
Same shaft. Maximum velocity ratio will be obtained only in compound Gear ratio.
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1) A gear wheel has 50 teeth of module 5mm. Find the pitch circle diameter and the circular pitch. Given: module, m= 5mm T or z= 50 Pc=? d =? 5= Solution: Module m= d
T
d
50
d=250 mm
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Circular pitch, pc= d

T
pc= 250 50
pc=15.7 mm
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2) Two gear wheels having 80 teeth and 30 teeth mesh with each other. If the smaller gear wheel runs at 480 rpm, find the speed of the larger wheel.
Given: Larger Gear wheel T1= 80 N1=? Smaller Gear Wheel T2= 30 N2=480 rpm
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Solution: Velocity ratio of a gear drive,
N2 N1
T1
X
T2 N1 = T2 T1 30 = 80
N2 480
= 180 rpm
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3) A gear wheel of 20 teeth drives another gear wheel having 36 teeth running at 200 rpm. Find the speed of the driving wheel and the velocity ratio.
Given: Driving wheel T1= 20 N1=? velocity Ratio = ?
Driven Wheel T2= 36 N2=200 rpm
Solution:
N2 N1
T1 T2
X
N1 = T2 T1
N2
Velocity Ratio =
= 360 rpm N2 N1 = 1:1.8

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4) In a simple train of gears, A has 30 teeth, B has 40 teeth, C has 60 teeth and D has 40 teeth. If A makes 36 rpm, find the rpm of the gear C and D.
Given: TA= 30, TB= 40, TC= 60, TD= 40, NA=36 rpm
NC=? ND=?
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Given: TA= 30, TB= 40, TC= 60, TD= 40, NA=36 rpm
NC=? ND=?
Solution:
NC NA ND NA
TA TC
NC = TA TC ND = TA TD
NA
= 18 rpm
TA TD
NA
= 27 rpm
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5) A compound gear consists of 4 gears A,B,C and D and they have 20, 30, 40 and 60 teeth respectively. A is fitted on the driver shaft, and D is fitted on the driven shaft , B and C are compound gears, B meshes with A, and C meshes with D. If A rotates at 180 rpm, find the rpm of D.
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Given: TA= 20, ND=? TB= 30, TC= 40, TD= 60, NA=180 rpm
ND NA
TC TD
TA TB TA TB
ND = TC TD
NA
= 80 rpm
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6) A compound gear train consists of 6 gears A,B,C,D,E and F, they have 20, 30, 40, 50, 60, 70 teeth respectively. A is fitted to the first shaft and meshed with B. B and C are fitted to the second shaft and C is meshed with D. D and E are fitted to the third shaft and E is meshed with F which is fixed to another shaft. A rotatates at 210 rpm, find speed of F.
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Given: TA= 20, NF=? Gear F Gear B,C Gear A TB= 30, TC= 40, TD= 50, TE=60, TF=70,
NA=210 rpm
c
Gear D,E
Compound train of wheels

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Given: TA= 20, NF=? TB= 30, TC= 40, TD= 50, TE=60, TF=70,
NA=210 rpm
Solution:
N F TA . TC . TE = N A TB TF TD N F 20 40 . 60 . = N A 30 50 70
NF = 96 rpm
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7) A compound gear train is formed by 4 gears P,Q,R and S. Gear P meshes with gear Q and gear R meshes with gear S. Gears Q and R are compounded. P is connected to driving shaft and S connected to the driven shaft and power is transmitted. The details of the gear are,
Gears P No. of Teeth 30 Q 60 R 40 S 80
If the gear S were to rotate at 60 rpm. Calculate the speed of P. Represent the gear arrangement schematically. 164
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SOLUTION:
Velocity ratio =
N S TR T P . = N P TS TQ
Gear P,TP=30
60 40 . 30 = NP 80 60
Speed of P, NP = 240 rpm
Gear Q,TQ=60 Gear R,TR=40 Gear S,TS=80
Gear arrangement
8) A gear train consists of six gears A,B,C,D,E,F and they contain 20,30,40,50,80,100 teeth respectively. Show the arrangement of the gears to obtain i. ii.
D
Maximum velocity ratio Speed reduction of 6.

C A
N Dept. of Mech & Mfg. Engg.
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Solution: i. Maximum velocity ratio
Given: A= 20 B= 30 C= 40 D= 50
N A TD TE TF = N D TB TC TA N A 50 80 100 = N D 40 30 20
D(driver)
= 16.66
E= 80 F= 100
F A(driven)
E
ii. Speed reduction of 6.

Given: A= 20 B= 30 C= 40 D= 50 E= 80 F= 100
Driven
Driver
N F TA TC TD = N A TB TE TF N A 20 40 50 = N D 30 80 100
= 1/6
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9)Five spur gears of 20,30,50,80 and 120 teeth are available along with 3 helical gears of 30, 60 and 80 teeth of all having same diametral pitch. Show the arrangement of gears to get maximum possible velocity ratio using maximum numbers of wheels from the above set of gears.
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Given:
S1= 20 S2= 30 S3= 50 S4= 80 S5= 120
H1= 30 H2= 60 H3= 80
Maximum possible velocity ratio = ?
V.R.(Max) =
120 80 80 20 30 30
= 42.6
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10) There are 5 wheels having 20, 40, 60, 80 and 100 teeth with a diametral pitch of 3 and another set of 4 wheels of diametral pitch of 2 having 20, 40, 60 and 70 teeth. Sketch an arrangement to get maximum velocity ratio using maximum number of wheels from the above lot. Also mention the conditions used.
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V.R.(Max) =
100 20
60 40
= 52.5 Maximum number of wheels used = 8 Conditions:

1. Select the driving gear with maximum number of teeth & driven gear with minimum number of teeth 2. Mesh two gears with same diametral pitch
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11) Two parallel shafts are to be connected by a gear drive. They are very nearly 1m apart and their velocity ratio is to be exactly 9:2. If the pitch of the gears is 57 mm, find the number of teeth in each of the two wheels and distance between the shafts.
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Let d1 and d2 be the pitch diameter of the 2 gears Distance between the gears = Given N2 N1 d1 d2 9 2 d1 = 9 2 d2=363.6 mm d1=1636 mm
d1+d2
2
= 1m
.1
d2
.2
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d1=1636 mm
d2=363.6 mm
T1
Circular pitch, Pc= d1
=d2
T2
=57 mm =90.18 =20.04
T1 = T2 =
d 1 57 d 2 57
Take T1 and T2 as 90 and 20 respectively. d1= d2=

PcT1 PcT2
=1633 mm =363 mm d1+d2 2 =998 mm = 0.998m

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Exact centre distance =
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Gears with following parameters are available Gear A has a module of 2 and 50 teeth, Gear B has a diameter of 201mm and 67 teeth, Gear C has a module of 4 and 152mm diameter, Gear D has a diameter of 50mm and 25 teeth, Gear E has a module of 3 and 100 teeth, Gear F has a (Gear B has a diameter of 201mm and 67 teeth) module of 4 and is 350mm in diameter, Gear G has a module of 3 and diameter of 126mm, Gear H has a diameter of 60mm and 30 teeth, Gear J has 55teeth and a diameter of 110mm.Determine an arrangement to obtain the lowest speed possible for the driven shaft , if the power is transmitted with four shafts? If the driver gear rotates at 225rpm, determine the speed of the driven shaft.
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GEARS A&B, C & D are integral & concentric wheels. The number of teeth are Ta=80, Tb=66, Tc=55, Td=108, the wheel B & C mesh with each other. Wheel D drives wheel E having Te=60 teeths. If wheel A runs at 400 rpm, det. Speed of E.
Ans:Ne=864 rpm
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Wrought-iron pulley
Light, strong and durable Entirely free from initial strains To facilitate the errection of pulleys on the main shaft, they are usually made in halves and parts are securely bolted together.
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10/27/2013

MECHANICAL ENGG. SCEINCE

Dept. of Mech & Mfg. Engg. 3

What is a transmission system?

Dept. of Mech & Mfg. Engg.

Individual Drive (Self-contained Drive)

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Group Drive (Common Drive)

ii. Chain drive. iii. Gear drive. iv. Rope drive.

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Belt Drive (Friction Drive)

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Types of Flat belt drives:

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Open belt drive

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Open belt drive

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Open belt drives

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Crossed belt drive

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CROSSED BELT DRIVE

What is crowning in a pulley?

Benefits of Crowning the pulley

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Stepped cone pulley

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Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

Stepped cone pulley

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Fast and Loose pulley

When machine shaft is to be brought to rest,

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Guide pulley (Right angled drive)

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Guide pulley (Right angled drive)

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Dept. of Mech & Mfg. Engg.

Length of a belt (*)

Length of a belt (*)

(By Binomial theorem and neglecting higher powers)

L = (r1+ r2 )+ (r1+ r2)2 / X + 2X.*

Define Velocity Ratio of Belt Drive. (Speed Ratio)

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the speed at every point on the belt will be same

Diameter of the driving pulley Diameterof the driven pulley

Effect of Thickness of belt on the velocity ratio:

If THICKNESS OF THE BELT IS CONSIDERED,then

Initial tension in belt drive

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Derive the expression for the ratio of tensions in belt drive.

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Resolving all the forces in the direction of R.

Resolving all the forces perpendicular to R

For small angles Cos /2 = 1 R = T ---------------------- (2)

Substituting equation (1) in (2) T = T

Integrating between 0 and and tension T between T2 and T1

logT1/T2 = log 2.718 =0.4343

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Considering the % Slip S1 between the driving

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