Analysis and Design Optimization of Transmission system of

Rotavator
(PROJECT PHASE I)
By

Aravind P
(2013214002)
Guided by
Dr. K. ShanmugaSundaram

N. Dasari

Associate Professor

Senior Manager

Engg. Design Division

Tube Investments of India

MASTER OF ENGINEERING
in
ENGINEERING DESIGN

DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING, GUINDY

ANNA UNIVERSITY
Chennai 600 025
November 2014

Calculations for Bevel Gear:

1.
2.
3.

Power in Take off shaft

Speed Of Shaft
Material Chosen

=
=
=

45 hp
540 rpm
C45 Steel

4.

5.

Material Properties:
Hardeness
=
380BHN
Ultimate Strength
=
1240MPa
Corrected
Bending Strength of Pinion :

e e Kl K s K r Kt K f K m
e 0.5 ut 0.5 1240 620 MPa
K l K v 1.0 for bending
K s 0.645 for ut 1240 MPa
K r 0.897 for 90 percent reliability
K t 1.0

K m 1.33 for ut 1240 MPa

e 620 11 0.645 11 0.897 1.33 477 MPa

6.

Corrected
Fatigue strength of gear material:

e e Kl K s K r Kt K f K m

e 0.35 ut 0.35 974 340.9 MPa

K l K v 1.0 for bending
K s 0.673 for ut 974 MPa
K r 0.897 for 90 percent reliability
K t 1.0

K m 1.33 for ut 974MPa

e 340.9 11 0.673 0.897 111.33 273.7 MPa

7.

Surface Fatigue
Strength of pinion:

sf sf K l K h K r K t
sf 2.8( BHN ) 69 2.8(380) 69 995MPa
K l 0.9 for 108 cycles

K h 1.005
K r 1.0 for 99% reliablity

K t 1.0

 sf 1 sf K l K h K r K t 995 0.9 11.005 1 900MPa

8.

Surface
fatigue Strength of Gear:

sf 0.95 2.8 BHN 69

sf 0.95 2.8 331 69 815MPa
K l 0.97 for 0.39 108 cycles
K h 1.005

K r 1.0 for 99% reliablity

K t 1.0
sf 2 815 0.97 1.005 11 795MPa

9.

Permissible stresses in bending Fatigue:

477
Pinion
e
Material

218MPa
1b

1.5
e 273.7
Gear
2b material:

182.5MPa
s
1.5

10. Permissible stresses in Contact Fatigue:

sf 1 900
Pinion
Material:

750 MPa
1H

1.2 1.2
sf 2 795
Gear
2 H material:

663MPa
1.2 1.2

11.

The teeth on pinion is assumed to be 20. Since the gear

ratio is taken as 1 the teeth on driven bevel gear will also
be 20.
1 2 45
2NT 2shaft:
540 T
Torque
P on the

45 745
60
60

T 592.8 Nm
F
2T
12. Bending
Pinion :3
b t Stress
K v Kin
Kv Ko Km
oKm
bmJ
8m Z1 J
Assuming,

b 8m

Ft

2T
d

d mZZ1 1

20
28.3
cos 1 cos 45
J 0.23 for Z v1 28.3
K v 1.25 assumed expecting the V to be 8m/s

Z v1

K o 1.75 for heavy shock

K m 12.75
for .overhang
592
8 103 bevel setup
b
1.25 1.75 1.25
3
3
65
.
71

10
8 m 20 0.23
b
b
m3

m 7.7 8 mm
13. Bevel Gear Contact Stress:
b 8592
m .881083 64mm
Ft
8914.2 N
0.5 F133
t
H CP
Kv Ko K m
bdl
C p 0.93 166 154.38

I 0.107

K v 1.11
H 154.38

H H

9814.2
1.11 1.75 1.25 752.59 MPa
64 133 0.107

Therefore the design is safe.

Calculations For Splines:

Splines can be thought of as a series of axial keyways with mating
keys machined onto a shaft. Splines provide a more uniform
circumferential transfer of torque to the shaft than a key.
D2 d 2

8
34
2 282
3

592.8 10 1000.N
8

T 1000.N

N 112.7 13 34 28
h (D d )
3mm
2
2

Matlab Usage:
Flowchart used as basis for writing the matlab program:
Matlab Program:
d=input('input diameter d>>>');
N=input('input number of teeth>>>');
gr=1
phi=20 %degree
Pd=N/d
if Pd>20
disp('warning Pd>20');
end
%======
a= 1/Pd
b=1.25/Pd
c=.25/Pd
%========
rp=d/2
Pc=(pi*d)/N
dO=d+2*a
dr=d-2*b
ht=a+b
hk=2*a
dhk=dO-2*(a)
rbp=(rp)*cos(phi*pi/180)
Pb=Pc*cos(phi*pi/180)
rpplusa=rp+a;
rpcos=rp*cos(phi*pi/180);

AO=sqrt(rpplusa^2-rpcos^2)-rp*sin(phi*pi/180)
Cr=(2*AO)/(Pc*cos(phi*pi/pi))
thickness=Pc/2
backlash=input('input backlash>>>');
actualthickness=thickness-backlash
d
dhk=dr+c
dO
dr
diameter_rbp=rbp*2