50998335YG1M - Design of Machine Elements - II - Solution Manual

1
Spur Gears
Important Solved Examples
Example 1.21
Given data : P = 18 kW = 18 10 3 W, n P = 720 rpm, n G = 300 rpm,
Solution :
(S ut ) P = 780 N mm 2 , (S ut ) G = 680 N mm 2 , K a = 1.5,

FOS = 1.35, b = 12 m, K m = 1.4, f = 20
(BHN) P = 450, (BHN) G = 350
To find :
Design a gear pair.
Step - 1 : Calculate the number of teeth on pinion and gear

Gear ratio, G =
nP
720
=
= 2.4
nG
300
The number of teeth on gear and pinion should be selected such that the gear ratio must
be exactly 2.4. For 20 full-depth involute system, the minimum number of teeth on pinion
should be 18.
Gear ratio is,
or
G=
ZG
ZP
\ Z G = G Z P
Z G = 2.4 Z P
ZP
ZG
Remark
18
2.4 18 = 43.2
Not possible
19
2.4 19 = 45.6
Not possible
20
2.4 20 = 48
Possible
\ Selecting Z P = 20 and Z G = 48
Step - 2 : Check whether gear is weaker or pinion is weaker
We know that,
s bP =
(S ut ) P
780
=
= 260 N mm 2
3
3
1 - 1
Design of Machine Elements - II
Spur Gears
and
s bG =
(S ut ) G
680
=
= 226.6666 N mm 2
3
3
Lewis form factor is,
and
YP = 0.484 -
2.87
2.87
= 0.484 = 0.3405
ZP
20
YG = 0.484 -
2.87
2.87
= 0.484 = 0.4242
ZG
48
Now,
s bP YP = 260 0.3405 = 88.53 N mm 2
and
s bG YG = 226.666 0.4242 = 96.1519 N mm 2
... (Given)
As
s bP YP < s bG YG , pinion is weaker than the gear in bending. Therefore, it is
required to design a pinion for bending.
Step - 3 : Calculate the beam strength of pinion
Fb = s bP b m YP = 260 12 m m 0.3405
\
Fb = 1062.36 m 2 , N
... (i)
Step - 4 : Calculate the wear strength of gear pair

Fw = d P b Q K
But,
... (ii)
d P = m Z P = 20 m, mm
Q =
2 ZG
2 48
=
= 1.4117
ZG + ZP
48 + 20
BHN
K = 0.16
100
... (Given)
Considering smaller value of BHN.

\
350
K = 0.16
= 1.96 N mm 2
100
and
b = 12 m
Substituting all these values in equation (ii),
\
Fw = 20 m 12 m 1.4117 1.96
\
Fw = 664.0636 m 2 , N
... (iii)
As
Fw < Fb , gear pair is weaker in pitting. Hence, it is required to design a gear
pair against the pitting failure.
Step - 5 : Calculate the effective load on gear pair
K a K m Ft
Feff =
Kv
p dPnP
p 20 m 720
But,
V =
=
60
60
V = 0.7539 m 103 mm sec = 0.7539 m , m sec
\
1 - 2
... (iv)
Spur Gears
Ft =
Kv =
23.8732 103
P
18 103
=
=
,N
V
0.7539 m
m
6
6
=
6 + V 6 + 0.7539 m
... (Given)
K a = 1.5 and K m = 1.4

Substituting all these values in equation (iv),
23.8732 103
1.5 1.4
Feff =

m
6
6+ 0.7539 m
... (Given)
Feff
8355.6345 (6 + 0.7539 m)
m
Feff
50.1338 103 + 6.2993 103 m

m
Step - 6 :
Calculate the value of module and other dimensions
... (v)
For safety against pitting failure,

Fw = FOS Feff
Substituting the values of equation (ii) and (v),
50.1338 103 + 6.2993 103 m
\ 664.0636 m 2 = 1.35
491.8989 m 3 = 50.1338 103 + 6.2993 103 m
Solving the above cubic equation, we get

m = 5.5754 mm
Selecting standard value of module from the given data,
m = 6 mm
\
Other dimensions
b = 12 m = 12 6 = 72 mm
... Ans.
d P = m Z P = 6 20 = 120 mm
dG = m Z G = 6 48 = 288 mm
C. D. =
dP + dG
120 + 288
=
= 204 mm
2
2
h a = 1m = 1 6 = 6 mm
hf
= 1.25 m = 1.25 6 = 7.5 mm
... Ans.
Step - 7 : Calculate the dynamic load by using Buckingham's equation

Buckingham's equation for dynamic load is,
21 V (bC + Ft max )
Fd =
21 V + bC + Ft max
1 - 3
... (Given) ... (vi)

Spur Gears
V = 0.7539 m = 0.7539 6 = 4.5234 m sec
But,
b = 72 mm
Ft =
23.8732 103
23.8732 103
=
= 3978.8666 N
m
6
Ft max = K a K m Ft = 1.5 1.4 3978.8666 = 8355.6198 N

Now, pitch error for grade 7,
e = 11+ 0.9 [m + 0.25 d ]
\
... (Given)
For pinion,
e P = 11 + 0.9 [m + 0.25 d P ]
e P = 11+ 0.9 [6 + 0.25 120] = 18.8647 mm
For gear,
e G = 11+ 0.9 [m + 0.25 d G ]
e G = 11+ 0.9 [6 + 0.25 288] = 20.2183 mm
But,
e = e P + e G = 18.8647 + 20.2183
e = 39.083 mm = 39.083 10- 3 mm
E E
Deformation factor, C = 0.111 e P G
EP + EG
\
... (Given)
207 103 207 103

C = 0.111 39.083 10-3
207 103 + 207 103
C = 449 N mm
\
Substituting all these values in equation (vi),
21 4.5234 (72 449 + 8355.6198)
\
Fd =
21 4.5234 + 72 449 + 8355.6198
\
Fd
= 13.0255 103 N
Step - 8 : Calculate the available factor of safety

Effective load for precise estimation is,
Feff = Ft max + Fd = 8355.6198 + 13.0255 10 3
\
Feff
= 21.3811 103 N
As gear pair is weaker in pitting,

Fw = FOS Feff
\
FOS =
Fw
664.0636 (6) 2
=
Feff
21.3811 103
FOS = 1.1180 < 1.35

As the available factor of safety of gear pair is lower than the required factor of safety, the design of
gear pair is unsafe.
1 - 4
Spur Gears
Step - 9 : Calculate the modified dimensions of gear pair
As the design of gear pair is unsafe, selecting next standard value of module from the
given data i.e. 8 mm.
Modified dimensions
m = 8 mm
b = 12 m = 12 8 = 96 mm
d P = m Z P = 8 20 = 160 mm
dG = m Z G = 8 48 = 384 mm
C.D. =
d P +d G
160 + 384
=
= 272 mm
2
2
h a = 1 m = 1 8 = 8 mm
hf
Step - 10 :
= 1.25 m = 1.25 8 = 10 mm
... Ans.
Calculate the dynamic load by using Buckingham's equation

21 V (bC + Ft max )
Fd =
21 V + bC + Ft max
... (Given) ... (vii)
V = 0.7539 m = 0.7539 8 = 6.0312 m sec
But,
b = 96 mm
Ft =
23.8732 103
23.8732 103
=
= 2984.15 N
m
8
Ft max = K a K m Ft = 1.5 1.4 2984.15 = 6266.715 N

Now, pitch error for grade 7,
e = 11+ 0.9 [m + 0.25 d ]
... (Given)
For pinion,
e P = 11 + 0.9 [m + 0.25 d P ]
e P = 11+ 0.9 [8 + 0.25 160] = 21.046 mm
For gear,
e G = 11+ 0.9 [m + 0.25 d G ]
e G = 11+ 0.9 [8 + 0.25 384 ] = 22.609 mm
But,
e = e P + e G = 21.046 + 22.609
e = 43.655 mm = 43.655 10-3 mm
E E
Deformation factor, C = 0.111e P G
EP + EG
... (Given)
1 - 5
Spur Gears
\
207 103 207 103

C = 0.111 43.655 10-3
207 103 + 207 103
C = 501.5304 N mm
Substituting all these values in equation (vii),

\
\
Step - 11 :
Fd =
Fd
21 6.0312 (96 501.5304 + 6266.715)

21 6.0312 + 96 501.5304 + 6266.715
= 19.1479 103 N
Calculate the available factor of safety

Feff = Ft max + Fd = 6266.715 + 19.1479 10 3
\
Feff
= 25.4146 103 N
As gear pair is weaker in pitting,

Fw = FOS Feff
Fw
664.0636 (8) 2
=
Feff
25.4146 103
FOS =
FOS = 1.6722 > 1.35
As the available factor of safety of gear pair is higher than the required factor of safety, the design
of gear pair is safe.
Example 1.22
Solution : Given data : f = 20 , Z P = 24, Z G = 50, m = 4 mm

b = 50 mm, (S ut ) P = (S ut ) G = 600 N mm 2 , BHN = 450
n P = 1440 rpm, K a = 1, FOS = 1.5
To find : Power (P)
Step - 1 : Calculate the beam strength for pinion
When pinion and gear are made of same material, at that time pinion is weaker than the
gear in bending. Hence, it is necessary to find beam strength of pinion.
Fb = s bP b m YP
But,
s bP =
... (i)
(S ut ) P
600
=
= 200 N mm 2
3
3
b = 50 mm, m = 4 mm
YP = 0.484 -
2.87
2.87
= 0.484 = 0.3644
ZP
24
1 - 6
... (Given)
Spur Gears
Substituting all these values in equation (i),
\
Fb = 200 50 4 0.3644 = 14576.6666 N

Fw = d P b Q K
... (ii)
d P = m Z P = 4 24 = 96 mm, b = 50 mm
But,
Q =
2 ZG
2 50
=
= 1.3513
ZG + ZP
50 + 24
2
BHN
450
K = 0.16
= 0.16
= 3.24 N mm 2
100
100
... (Given)

Fw = 96 50 1.3513 3.24 = 21015.4176 N
Step - 3 : Calculate the rated power transmitted by gear pair

As Fb < Fw , the gear pair is weaker in bending.
For safety against bending failure,
Fb = FOS Feff
\
14576.6666 = 1.5 Feff
Feff
= 9717.7777 N
Now,
Feff
K a K m Ft
Kv
... (iii)
p dPnP
p m ZP n P
p 4 24 1440
=
=
60
60
60
But,
V =
V = 7.2382 103 mm sec = 7.2382 m sec

Kv =
3
3
=
= 0.2930
3 + V 3 + 7.2382
... (Given)
K a = 1 and assuming K m = 1
Substituting all these values in equation (iii),
\
\
9717.7777 =
1 1 Ft
0.2930
Ft = 2847.4975 N
Power transmitted by gear pair is,

P = Ft V = 1235.9177 4.5553
\
P = 20610.7565 W = 20.6107 kW
1 - 7
... Ans.
Spur Gears
Example 1.23
Solution : Given data :

f = 20 , Z P = 25, Z G = 60, m = 5 mm
b = 45 mm, n P = 500 rpm, (S ut ) P = (S ut ) G = 600 N mm 2
BHN = 220, K a = 1.75, FOS = 2, K m = 1
To find : i) Fb
ii) Fw
iii) Ft
iv) P
Step - 1 : Calculate the beam strength for pinion

... (i)
Fb = s bP b m YP
But,
s bP =
(S ut ) P
600
=
= 200 N mm 2
3
3
b = 45 mm, m = 5 mm
YP = 0.484 -
2.87
2.87
= 0.484 = 0.3692
ZP
25
... (Given)

\
Fb = 200 45 5 0.3692
Fb = 16.614 10 3 N
... Ans.

Fw = d P b Q K
But,
... (ii)
d P = m Z P = 5 25 = 125 mm, b = 45 mm
Q =
2 ZG
2 60
=
= 1.4117
ZG + ZP
60 + 25
BHN 2
220 2
K = 0.16
= 0.16
= 0.7744 N mm 2
100
100
... (Given)

\
Fw = 125 45 1.4117 0.7744
Fw = 6149.3652 N
... Ans.
Step - 3 : Calculate the rated power transmitted by gear pair

As Fw < Fb , the gear pair is weaker in pitting failure,
Fw = FOS Feff
1 - 8
Spur Gears
\
6149.3652 = 2 Feff
Feff
= 3074.6826 N
Now,
Feff
K a K m Ft
Kv
... (iii)
p dPnP
p m ZP n P
p 5 25 500
=
=
60
60
60
But,
V =
V = 3.2724 103 mm sec = 3.2724 m sec

Kv =
6
6
=
= 0.6470
6 + V 6 + 3.2724
... (Given)
K a = 1.75 and K m = 1
\
\
3074.6826 =
1.75 1 Ft
0.6470
Ft = 1136.8975 N
... Ans.

P = Ft V = 1136.8975 3.2724
\
P = 3720.3835 W = 3.7203 kW
... Ans.
Example 1.24

Z P = 22, Z G = 48, (S ut ) P = 800 MPa
(S ut ) G = 530 MPa, P = 7 kW = 7 103 W, n P = 1440 rpm
K a = 1.5,
BHN = 350, FOS = 2
b = 10 m, Assume K m = 1, K v =
6
6+ V
To find : Design a gear pair.

We know that,
and
s bP =
(S ut ) P
800
= 266.6666 MPa
=
3
3
s bG =
(S ut ) G
530
= 176.6666 MPa
=
3
3
Assuming 20 full-depth involute system,

\
YP = 0.484
2.865
ZP
1 - 9
Spur Gears
\
YP = 0.484
2.865
= 0.3537
22
Similarly,
YG = 0.484
2.865
ZG
YG = 0.484
2.865
= 0.4243
48
Now,
s bP YP = 266.6666 0.3537 = 94.32 MPa
and
s bG YG = 176.6666 0.4243 = 74.96 MPa
As s bG YG < s bP YP , gear is weaker than the pinion in bending. Therefore, it is required

to design a gear for bending.
Step - 2 : Calculate the beam strength of gear
Fb = s bG b m YG = 176.6666 10 m m 0.4243
\
Fb = 749.596 m 2 , N
... (i)

Fw = d P b Q K
But,
... (ii)
d P = m Z p = 22 m, mm
Q =
2 ZG
2 48
= 1.3714
=
ZG + Zp
48 + 22
For steel pinion and steel gear,

BHN
K = 0.16
100
\
K = 1.96 N mm 2
and
b = 10 m, mm
350
= 0.16
100

\
Fw = 22 m 10 m 1.3714 1.96
Fw = 591.3476 m 2 , N
(iii)
As Fw < Fb , gear pair is weaker in pitting. Hence, it is required to design a gear pair
against the pitting failure.
K a K m Ft
Feff =
Kv
(iv)
p dP nP
p 22 m 1440
=
60
60
But,
V =
V = 1.658 m 103 mm/sec. = 1.658 m, m/sec.

1 - 10
Spur Gears
Ft =
Kv =
P
7 103
4221.9541
,N
=
=
V
1.658 m
m
6
6
=
6 + V 6 + 1.658 m
K a = 1.5 and K m = 1
(Given)

1.5 1
4221.9541

m
6
6 + 1.658 m
Feff
Feff
1055.4885 (6 + 1.658 m)
m
Feff
6332.9312 + 1750 m
m
(v)
Step - 5 : Calculate the value of module and other dimensions

Fb = FOS Feff
Substituting the values of equation (i) and (v),
6332.9312 + 1750 m
\ 749.5963 m 2 = 2
m
\
379.7981 m 3 = 6332.9312 + 1750 m

m = 3.1472 mm
(Neglecting negative values)
The standard value of module under first choice is 5 mm.

m = 4 mm
\
Other dimensions :
b = 10 m = 10 4 = 40 mm
Ans.
d P = m Z p = 4 22 = 88 mm
dG = m Z G = 4 48 = 192 mm
C. D. =
dP + dG
88 + 192
= 140 mm
=
2
2
h a = 1 m = 1 4 = 4 mm
hf
= 1.25 m = 1.25 4 = 5 mm
Ans.
Example 1.25
Solution : Given data : n G = 200 rpm, P = 7 kW = 7 10 3 W, n P = 800 rpm,

1 - 11
Spur Gears
C.D. = 300 mm, K a = 1.5, (S ut ) P = (S ut ) G = 700 N mm 2 ,
f = 20, FOS = 2
To find : i) Design a gear pair
iii) Feff and (FOS) bending
ii) Fd
iv) Surface hardness

Beam strength of pinion is,
Fb = s bP b m YP
But,
Assume,
s bP =
d P +d G
2
\ 300 =
d P +d G
2
600 = d P + d G
G =
(S ut ) P
700
=
= 233.333 N mm 2
3
3
b = 10 m
C.D. =
... (i)
... (a)
nP
d
= G
nG
dP
800 d G
=
200 d P
dG = 4 dP
... (b)
Solving equations (a) and (b),

d P = 120 mm
Now, Lewis form factor is,
YP = 0.484 -
and
d G = 480 mm
d
... Q m = P
ZP
2.87
2.87
= 0.484 ZP
(120 m)
2.87 m
120
2.87 m
\
Fb = 233.333 10 m m 0.484
120
\
YP = 0.484 -
Fb = 1129.3317 m 2 - 55.8054 m 3
... (ii)
As hardness of gear pair is unknown, we can't find wear strength of gear.

K a K m Ft
Feff =
Kv
1 - 12
... (iii)
Spur Gears
p dP nP
p 100 800
=
60
60
But,
V =
V = 5.0265 103 mm sec = 5.0265 m sec

Ft =
P 7 103
=
= 1392.6057 N
V 5.0265
Kv =
3
3
=
= 0.3737
3 + V 3 + 5.0265
... (Q K v = Cv )
K a = 1.5 and Assume K m = 1

\
Feff
1.5 1 1392.6057
= 5589.8007 N
0.3737

F b = FOS Feff
(1129.3317 m 2 - 55.8054 m 3 ) = 2 5589.8007
(1129.3317 m 2 - 55.8054 m 3 ) = 11.179 10 3
m = 3.5573 mm
... (Selecting smaller positive value)
Selecting standard value of module from the Table 6.1,
m = 4 mm
... Ans.
\
Other dimensions
b = 10 m = 10 4 = 40 mm
d P = 120 mm and dG = 240 mm
ZP =
dP
120
=
= 30
m
4
ZG =
dG
480
=
= 120
m
4
h a = 1m = 1 4 = 4 mm
hf
= 1.25 m = 1.25 4 = 5 mm
... Ans.
Step - 4 : Calculate the value of dynamic load by using Buckingham's equation

Buckingham's dynamic load is,
21 V (bC + Ft )
Fd =
21 V + bC + Ft
But,
... (iv)
b = 40 mm, Ft = 1392.6057 N, V = 5.0265 m sec

1 - 13
Spur Gears
Pitch error for grade 6,
e = 8 + 0.63 [m + 0.25 d ]
... (Given)
For pinion,
e p = 8 + 0.63 [m + 0.25 d P ]
e p = 8 + 0.63 [4 + 0.25 120] = 12.2453 mm
For gear,
e G = 8 + 0.63 [m + 0.25 d G ]
e G = 8 + 0.63 [4 + 0.25 480] = 13.9706 mm
But,
e = e P + e G = 12.2453 + 13.9706
e = 26.2249 mm = 26.2249 10-3 mm
Deformation factor, C = 11400 e

\
C = 11400 26.2249 10-3 = 298.9644 N mm

21 5.0265 (40 298.9644 + 1392.6057)
21 5.0265 + 40 298.9644 + 1392.6057
Fd =
Fd = 6374.2505 N
... Ans.
Step - 5 : Calculate the effective load by precise estimation

Feff = Ft max + Fd = K a K m Ft + Fd
\
Feff
= 1.5 1 1392.6057 + 6374.2505
\
Feff = 8463.1591 N
Fb = FOS Feff
\
FOS =
... Ans.
Fb
Feff
But,
Fb = 1129.3317 m 2 - 55.8054 m 3
Fb = 1129.3317 (4) 2 - 55.8054 (4) 3 = 14.4977 103 N
... [From equation (ii)]
14.4977 103
8463.1591
FOS =
FOS = 2.0295
... Ans.
Step - 6 : Calculate the surface hardness for gears

Wear strength is given by,
Fw = d P b Q K
But,
... (v)
d P = 120 mm, b = 40 mm
1 - 14
Spur Gears
Q =
2 ZG
2 120
=
= 1.6
ZG + ZP
120 + 30
BHN 2
K = 0.16
100
... (Given)
Substituting all these value in equation (v),

\
BHN 2
Fw = 120 40 1.6 0.16
100
BHN 2
Fw = 1228.8
,N
100

Fw = FOS Feff
BHN
\ 1228.8
100
= 2.0295 8463.1591
BHN = 373.8696
BHN 375
... Ans.
qqq
1 - 15
Helical Gears
Example 2.13

Z P = 20,
Z G = 40,
f n = 20,
a = 25,
m n = 3 mm
To find : i) m t and f t
ii) d P and d G iii) p a
Step - 1 : Calculate the transverse module and transverse pressure angle

We know that,
mt =
mn
3
= 3.3101 mm
=
cos a
cos (25)
tan f n = cos a tan f t

\
tan f t =
Ans.
[From equation (2.5)]
tan f n
tan (20)
= 0.4015
=
cos a
cos (25)
f t = 21.8802
Ans.
Step - 2 : Calculate the PCD of pinion and gear

Now,
d P = m t Z P = 3.3101 20
\
d P = 66.202 mm
Ans.
d G = m t Z G = 3.3101 40
\
dG = 132.404 mm
Step - 3 : Calculate the axial pitch

pt
p m t
p 3.3101
=
=
pa =
tan a
tan a
tan (25)
\
pa = 22.3006 mm
Ans.
Example 2.14
Solution :
Given data :
Z P = 20, Z G = 100, (S ut ) P = (S ut ) G = 600 MPa, f n = 20, m n = 4
2 - 1
Helical Gears
(BHN) P = (BHN) G = 300,
K a = 1.5,
FOS = 2,
a = 25
b = 40 mm, n P = 720 rpm,

To find : Power P
When the pinion and gear are made of same material, at that time always pinion is
weaker than the gear in bending.
Fb = s bP b m n YP
s bP =
Z P =
(i)
(S ut ) P
600
= 200 MPa
=
3
3
ZP
cos 3 a
YP = 0.484
20
(cos 25) 3
= 26.8659
2.87
2.87
= 0.3771
= 0.484 26.8659
Z P

\
Fb = 200 40 4 0.3771
\
Fb = 12.0672 103 N
(ii)

dP b Q K
Fw =
cos 2 a
But,
d P = mt Z P =
(iii)
mn
4
ZP =
20 = 88.2702 mm
cos a
cos (25)
b = 40 mm
Q =
2 ZG
2 100
= 1.6667
=
ZG + ZP
100 + 20
BHN
K = 0.16
100
\
... (Given)
300
K = 0.16
= 1.44 N / mm 2
100
... (Selecting smaller value of BHN)

\
Fw =
88.2702 40 1.667 1.44

(cos 25) 2
= 10.3167 103 N
As Fw < Fb , gear pair is weaker in pitting than the bending. Therefore, it should be
designed for safety against pitting failure.
2 - 2
Helical Gears
Step - 3 : Calculate the power transmitting capacity of gear pair
Effective tooth load is,
K a K m Ft
Feff =
Kv
(ii)
p dP nP
p 88.2702 720
=
60
60
But,
V =
V = 3.3277 103 mm/sec = 3.3277 m/sec

Kv =
5.6
5.6
= 0.7542
=
5.6 + V
5.6 + 3.3277
K a = 1.5 and assuming, K m = 1

\
Feff
1.5 1 Ft
= 1.9888 Ft
0.7542

Fw = FOS Feff
10.3167 103 = 2 1.9888 Ft
\
Ft = 2593.7104 N
Power transmitting capacity of gear pair is,

P = Ft V = 2593.7104 3.3277
\
P = 8.6310 10 3 W = 8.6310 kW
... Ans.
Example 2.15
Solution : Given data : P = 10 kW = 10 10 3 W, n P = 1000 rpm, n G = 500 rpm,

Z P = 18, C.D. = 180 mm, a = 26, b = 12 m n ,
f n = 20, s bP = s bG = 100 N / mm 2 , K a = 1.25,
K m = 1.1,
e = 40 mm = 40 10 -3 mm,
C = 11600 e N/mm
To find : i) (FOS) bending ii) (FOS) pitting

Step - 1 : Calculate the normal module of gear pair
nP
Z
Gear ratio
G =
= G
nG
ZP
\
ZG
1000
=
18
500
Z G = 36
2 - 3
Helical Gears
Centre distance is given by,
mn
C.D. =
(Z P + Z G )
2 cos a
mn
(18 + 36)
2 cos (26)
180 =
m n = 5.991 mm
mn
= 6 mm
Other dimensions
mt =
mn
6
= 6.6756 mm
=
cos a
cos (26)
d P = m t Z P = 6.6756 18 = 120.161 mm
dG = m t Z G = 6.6756 36 = 240.322 mm
b = 12 m n = 12 6 = 72 mm
h a = 1 m n = 1 6 = 6 mm
hf
= 1.25 m n = 1.25 6 = 7.5 mm

Fd =
21 V [bC cos 2 a + Ft max ]

21 V + bC cos 2 a + Ft max
cosa
(Given) ... (i)
p dP nP
p 120.161 1000
=
60
60
But,
V =
V = 4.5299 103 mm/sec = 6.2916 m/sec

C = 11600 e = 11600 40 10 -3
... (Given)
C = 464 N/mm
Ft =
P
10 103
= 1589.4169 N
=
V
6.2916
Ft max = K a K m Ft = 1.25 1.1 1589.4169 = 2185.4483 N

21 6.2916 [72 464 (cos 26) 2 + 2185.4483]
Fd =
cos (26)
21 6.2916 + 72 464 (cos 26) 2 + 2185.4483
\
Fd = 12.7242 10 3 N

\
Feff
= Ft max + Fd = 2185.4483 + 12.7242 10 3
Feff
= 14.9096 103 N
2 - 4
Helical Gears
Step - 3 : Calculate the beam strength and wear strength of gear pair
weaker in bending.
Fb = s bP b m n YP
But,
... (ii)
s bP = 100 N / mm 2 , b = 72 mm, m n = 6 mm
Z P =
ZP
cos 3 a
YP = 0.484 -
18
(cos 26) 3
= 24.7908
2.87
2.87
= 0.3682
= 0.484 24.7908
Z P

\
Fb = 100 72 6 0.3682 = 15.9062 103 N
Wear strength of gear pair is,

d b Q K
Fw = P
cos 2 a
But,
d P = 120.161 mm,
Q =
... (iii)
b = 72 mm
2 ZG
2 36
= 1.333
=
ZG + ZP
36 + 18
2
BHN 2
350
K = 0.16
= 0.16
100
100
... (Assume)
K = 1.96 N / mm 2
\
\
Fw =
120.161 72 1.333 1.96

(cos 26) 2
= 27.9809 103 N
Step - 4 : Calculate the factor of safety against bending and pitting failure
Fb = (FOS) bending Feff
\ 15.9062 103 = (FOS) bending 14.4413 103
\ (FOS) bending = 1.0668
... Ans.

Fw = (FOS) pitting Feff
\ 27.9809 103 = (FOS) pitting 14.9096 103
\
(FOS) pitting = 1.8767
... Ans.
2 - 5
Helical Gears
Example 2.16
Solution : Given data : P = 15 kW = 15 10 3 W, n P = 700 rpm, Z P = 35, Z G = 70,

f n = 20, a = 23, b = 35 mm, (S ut ) P = (S ut ) G = 650 N / mm 2
K a = 1.25,
FOS = 2.5,
C = 11400 e N/mm
To find : i) Normal module and other dimensions ii) Fb

iii) Fd
iv) Surface hardness

weaker in bending.
Fb = s bP b m n YP
(S ut ) P
650
But,
s bP =
=
= 216.666 N / mm 2
3
3
Z P =
ZP
cos 3 a
35
(cos 23) 3
... (i)
= 44.8734
Assume, Lewis form factor is,

YP = 0.484 -
2.87
2.87
= 0.42
= 0.484 44.8734
Z P

... (ii)
Fb = 200 40 m n 0.42 = 3185 m n , N
As surface hardness of gear pair is unknown, we cannot find the wear strength of gear
pair.

K a K m Ft
Feff =
Kv
... (iii)
But,
V =
p d P NP
p mt Z P n P
p mn Z P n P
=
=
60
60
cos a 60
V =
p m n 35 700
= 1.3936 m n 103 , mm/sec
cos (23) 60
V = 1.3936 m n , m/sec
Ft =
Kv =
P
15 103
10.7634 103
,N
=
=
V 1.3936 m n
mn
5.6
5.6
=
5.6 + V 5.6 + 1.3936 m n
2 - 6
Helical Gears
K a = 1.5 and assuming K m = 1
10.7634 103
1.5 1

mn
5.6
5.6 + 1.3936 m n
Feff
Feff
2883.0535(5.6 + 1.3936 m n )
mn
Feff
16.1451 103 + 4.0178 103 m n

mn

Fb = FOS Feff
\
16.1451 103 + 4.0178 103 m n

3185 m n = 2.5
mn
1274 m 2n = 16.1451 103 + 4.0178 103 m n
Solving the above quadratic equation, we get

m n = 5.4703 mm
Selecting the standard value of module,
\
mn
= 6 mm
... Ans.
Other dimensions
mt =
mn
6
= 6.5181 mm
=
cos a
cos (23)
d P = m t Z P = 6.5181 35 = 228.1356 mm
dG = m t Z G = 6.5181 70 = 456.2713 mm
C.D. =
d P +d G
228.1356 + 456.2713
= 342.2034 mm
=
2
2
h a = 1 m n = 1 6 = 6 mm
hf
= 1.25 m n = 1.25 6 = 7.5 mm
... Ans.
Substituting these values in equation (ii),

\
Fb = 3185 m n = 3185 6
Fb = 19.11 10 3 N
... Ans.
2 - 7
Helical Gears
Fd =
cosa
21 V+ bC cos 2 a + Ft max
... (iv)
V = 1.3936 m n = 1.3936 6 = 8.36 m/sec
But,
b = 35 mm
Ft =
10.7634 103
10.7634 103
= 1793.9 N
=
mn
6
Ft max = K a K m Ft = 1.5 1 1793.9 = 2690.85 N

Now, pitch error for grade 6, e = 8 + 0.63 [m n + 0.25 d ]
For pinion,
e P = 8 + 0.63 [m n + 0.25 d P ]
e P = 8 + 0.63 [6 + 0.25 228.1356] = 14.1589 mm
For gear,
e G = 8 + 0.63 [m n + 0.25
e G = 8 + 0.63 [6 + 0.25 456.2713] = 15.14428 mm
dG ]
But,
e = e P + e G = 14.1589 + 15.14428
e = 29.3031 mm = 29.3031 10-3 mm
Deformation factor, C = 11400 e

\
... (Given)
C = 11400 29.3031 10-3 = 334.0553 N/mm

21 8.6 [35 334.0553 (cos 23) 2 + 2690.85]
Fd =
Fd = 7684.7320 N
21 8.6 + 35 334.0553 (cos 23) 2 + 2690.85
cos (23)
... Ans.
Step - 5 : Calculate the surface hardness of gear pair

d b Q K
Fw = P
cos 2 a
But,
... (v)
d P = 228.1356 mm, b = 35 mm
Q =
2 ZG
2 70
= 1.333
=
ZG + ZP
70 + 35
BHN 2
K = 0.16
100
... (Assume)
2 - 8
Helical Gears
Substituting all these values in equation (v),
BHN
228.1356 35 1.333 0.16
100
Fw =
BHN
Fw = 2009.8288
,N
100
(cos 23) 2
2

Fw = FOS Feff
BHN
2009.8288
100
... (Q Feff = Ft max + Fd )
= 2.5 (2690.85 + 7684.7320)
BHN = 359.2499
BHN 360
... Ans.
Example 2.17
Solution : Given data : P = 150 kW = 150 10 3 W, n P = 1440 rpm, n G = 360 rpm,

C.D. 435 mm, a = 24, b = 14 m n ,
s bP = 152 N / mm 2 ,
K a = 1.53,
Z P = 20,
s bG = 125 N / mm 2 ,
e = 0.0406 mm,
f n = 20,
C = 11600 e N/mm
To find : (i) (FOS) bending (ii) Surface hardness, if FOS = 1.5

Step - 1 : Calculate the normal module of gear pair
nP
Z
Gear ratio
G =
= G
nG
ZP
\
ZG
1440
=
20
360
Z G = 80
Approximate centre distance is given by,

C.D.
\
435
mn
mn
(Z P + Z G )
2 cos a
mn
(20 + 80)
2 cos (24)
7.9478 mm
Considering the nearest standard value i.e.

m n = 8 mm
2 - 9
Helical Gears
Now, the exact centre distance is,
C.D. =
\
mn
8
(Z P + Z G ) =
(20 + 80)
2 cos a
2 cos (24)
C.D. = 437.8545 mm

Feff = Ft max + Fd = K a K m Ft + Fd ... (i)
But,
V =
p dP nP
p mt Z P n P
p mn Z P n P
=
=
60
60
cos a 60
V =
p 8 20 1440
= 13.2053 103 mm/sec
cos (24) 60
= 13.2053 m/sec
Ft =
P
150 103
=
= 11.359 103 N
V
13.2053
Ft max = K a K m Ft = 1.53 1 11.359 103

\
Ft max = 17.3793 103 N
... (Assuming K m = 1)
Dynamic load is given by,

Fd =

21 V+ bC cos 2 a + Ft max
cos a
But,
C = 11600 e
C = 11600 0.0406 = 470.96 N/mm
and
b = 14 m n = 14 8 = 112 mm
... (a = y)
... (Given)
21 13.2053 [112 470.96 (cos 24) 2 + 17.3793 103 ]
Fd =
Fd = 29.6227 103 N
21 13.2053 + 112 470.96 (cos 24) 2 + 17.3793 103
cos ( 24)

Feff
= 17.3793 103 + 29.6227 103 = 47 103 N

ZP
20
= 26.2342
=
Z P =
3
cos a
(cos 24) 3
and
ZG
=
ZG
cos 3 a
80
(cos 24) 3
= 104.9299
2 - 10
Helical Gears
By interpolation for 26.2342,
YP = 0.3456 +
\
(0.3487 - 0.3456) (26.2342 - 26)

(27 - 26)
YP = 0.3463
Similarly, by interpolation for 104.9299,

YG = 0.4461 +
\
(0.4587 - 0.4461) (104.9299 - 100)

(150 - 100)
YG = 0.4473
Now, s bP YP = 152 0.3463 = 52.6376 N / mm 2

and
s bG YG = 125 0.4473 = 55.9177 N / mm 2
As s bP YP < s bG YG , pinion is weaker than the gear in bending. Therefore, it is

required to design a pinion for bending.
Beam strength for pinion is,
Fb = s bP b m n YP = 152 112 8 0.3463
\
Fb = 47.1632 103 N
Step - 4 : Calculate the factor of safety against bending failure

Fb = (FOS) bending Feff
\
(FOS) bending =
Fb
47.1632 103
=
Feff
47 103
\ (FOS) bending = 1.0034
... Ans.
Step - 5 : Calculate the surface hardness of gear pair

d b Q K
Fw = P
cos 2 a
But,
d P = mt Z P =
... (ii)
mn
8
ZP =
20 = 175.1418 mm
cos a
cos (24)
b = 112 mm
Q =
2 ZG
2 80
= 1.6
=
ZG + ZP
80 + 20
BHN
K = 0.16
100
... (Given)

2 - 11
Helical Gears
BHN
175.1418 112 1.6 0.16
100
Fw =
BHN
Fw = 6017.1034
100
(cos 24) 2
2

Fw
BHN
6017.1034
100
= FOS Feff
= 1.5 47 103
BHN
= 342.2952
or
BHN
345
... Ans.
qqq
2 - 12
Bevel Gears
Example 3.14
Solution : Given data : Z P = 36 , Z G = 80, (S ut ) P = 700 N mm 2 ,
q = 90
(S ut ) G = 660 N mm 2 , P =10 kW = 10 103 W, n P = 1000 rpm

K a = 2, (BHN) P = (BHN) G = 300, FOS = 1.5
To find : Design the gear pair
We know that,
and
s bP =
(S ut ) P
700
=
= 233.3333 N mm 2
3
3
s bG =
(S ut ) G
660
=
= 220 N mm 2
3
3
ZP
36
=
ZG
80
tan g P =
\ g P = 24.2277
g G = q - g P = 90 - 24.2277 = 65.7723
Now,
Z P =
ZP
36
=
= 39.4770
cos g P
cos (24.2277)
and
Z G =
ZG
80
=
= 103.6431
cos g G
cos (65.7723)
Lewis form factor is,
and
New,
YP = 0.484 -
2.87
2.87
= 0.484 = 0.4112
39.4770
Z P
YG = 0.484 -
2.87
2.87
= 0.484 = 0.4563
103.6431
Z G
s bP YP = 233.3333 0.4112 = 95.9466 N mm 2

3 - 1
Bevel Gears
and
s bG YG = 220 0.4563 = 100.386 N mm 2
As s bP YP < s bG YG , pinion is weaker than the gear in bending. Therefore, it is required

to design a gear for bending.
b
Fb = s bP b m YP 1 AO
But,
... (i)
s bP = 233.3333 N mm 2 , YP = 0.4112
d P = m Z P = 36 m, mm
d G = m Z G = 80 m, mm
AO =
(d P 2) 2 + (d G 2) 2 =
(36 m 2) 2 + (80 m 2) 2 = 43.8634 m, mm
b =
AO
or 10 m } whichever is smaller
3
b =
43.8634 m
or 10 m } whichever is smaller
3
b = 14.6211 m or 10 m } whichever is smaller
b 10 m, mm
\
\
10 m
Fb = 233.3333 10m m 0.4112 1 43.8634 m
Fb = 740.7268 m 2 , N
... (ii)

0.75 d P b Q K
Fw =
cos g P
But,
... (iii)
d P = 36 m, mm, b = 10 m, mm
Q =
2 Z G
2 103.6431
=
= 1.4483
103.6431 + 39.4770
Z G + Z P
BHN 2
300 2
K = 0.16
= 0.16
= 1.44 N mm 2
100
100
... (Given)

0.75 36 m 10 m 1.4483 1.44
\
Fw =
cos (24.2277)
Fw = 617.1860 m 2 , N
... (iv)
As Fw < Fb , gear pair is weaker in pitting. Hence, it is required to design a gear pair
against the pitting failure.
3 - 2
Bevel Gears
Step - 4 : Calculate the effective load the gear pair can transmit
K a K m Ft
Feff =
Kv
But,
K a = 2 and Assuming
V =
... (v)
Km = 1
p dP np
p 36 m 1000
=
60
60
V = 1.8849 m 103 , mm sec = 1.8849m, m sec

Ft =
10 103
P
5.3051 103
=
=
,N
V 1.8849 m
m
As the gear pair is manufactured by generation, assuming

Kv =
6
6
=
6 + V 6 + 1.8849 m
Substituting all these values in equation (v),

21
5.3051 103
\
Feff =
m
6
6 + 1.8849m
Feff
1768.3666(6 + 1.8849m)
m
Feff
10.6102 103 + 3.3331 103 m

m
... (vi)

Fw = FOS Feff
\
\
10.6102 103 + 3.3331 103 m

617.1860 m 2 = 1.5
3
3
3
925.779 m = 31.8306 10 + 10.0048 10 m
Solving the above equation by using trial and error method, we get
m = 4.32 mm
Selecting standard value of module from the given data,
m 5 mm
\
Other dimensions
b = 10 m = 10 5 = 50 mm
... Ans.
d P = m Z P = 5 36 = 180 mm
dG = m Z G = 5 80 = 400 mm
AO = 43.8634 m = 43.8634 5 = 219.317 mm
3 - 3
Bevel Gears
h a = 1 m = 1 5 = 5 mm
hf
= 1.25 m = 1.25 5 = 6.25 mm
... Ans.
Example 3.15
Solution : Given data : Z P = 30, Z G = 45, m = 6 mm, b = 50 mm,

(S ut ) P = (S ut ) G = 600 MPa
To find : i) Fb
When both the pinion and gear are made of same material, pinion is always weaker than
the gear in bending. Hence, it is necessary to design the pinion for bending,
b
But,
s bP =
... (i)
(S ut ) P
600
=
= 200 MPa
3
3
b = 50 mm, m = 6 mm
d P = m Z P = 6 30 = 180 mm
d G = m Z G = 6 45 = 270 mm
AO =
tan g P =
(d P 2) 2 + (d G 2) 2 =
ZP
30
=
ZG
45
(180 2) 2 + (270 2) 2 = 162.2498 mm
\ g P = 33.6900
g G = q - g P = 90 - 33.6900 = 56.3099
Now,
Z P =
ZP
30
=
= 36.0554
cos g P
cos (33.69)
and
Z G =
ZG
50
=
= 90.1387
cos g G cos (56.3099)
... (Assume q = 90)
Assume,
Y = 0.484 -
2.87
Z
YP = 0.484 -
2.87
2.87
= 0.484 = 0.4044
36.0554
Z P

50
\
Fb = 200 50 6 0.4044 1 162.2498
\
Fb = 16786.6410 N
... Ans.
3 - 4
Bevel Gears
Example 3.16
Solution : Given data : Z P = 24, Z G = 48, m = 6 mm, b = 50 mm,

(S ut ) P = (S ut ) G = 220 MPa, f = 20, n P = 300 rpm, K a = 1.5
(BHN) P = (BHN) G = 250, (FOS) bending = 2
To find : i) Fb
ii) Fw
iii) Ft
iv) P

When both the pinion and gear are made of same material, pinion is always weaker than
the gear in bending. Hence, it is necessary to design the pinion for bending,
b
But,
s bP =
... (i)
(S ut ) P
220
=
= 73.333 MPa
3
3
b = 50 mm, m = 6 mm
d P = m Z P = 6 24 = 144 mm
d G = m Z G = 6 48 = 288 mm
AO =
tan g P =
(d P 2) 2 + (d G 2) 2 =
ZP
24
=
ZG
48
(144 2) 2 + (288 2) 2 = 161 mm
\ g P = 26.565
g G = q - g P = 90 - 26.565 = 63.435
... (Assume q = 90)
Now,
Z P =
ZP
24
=
= 26.8328
cos g P
cos (26.565)
and
Z G =
ZG
48
=
= 107.3314
cos g G cos (63.435)
Assume,
Y = 0.484 -
2.87
Z
YP = 0.484 -
2.87
2.87
= 0.484 = 0.377
26.8328
Z P

50
\
Fb = 73.333 50 6 0.377 1 161
3 - 5
Bevel Gears
\
Fb = 5718.1976 N
... Ans.

0.75 d P b Q K
Fw =
cos g P
d P = 144 mm,
But,
Q =
... (ii)
b = 50 mm
2 Z G
2 107.3314
=
= 1.6
107.3314 + 26.8328
Z G + Z P
Assume,
BHN 2
K = 0.21
100
250 2
K = 0.21
= 1.3125 N mm 2
100
...(Gear pair is made of cast iron)

0.75 144 50 1.6 1.3125
cos (26.565)
Fw =
Fw = 12.6784 10 3 N
... Ans.
Step - 3 : Calculate the maximum static load the gear can transmit
Effective load on gear pair is,
Feff
But,
K a = 1.5
V =
K a K m Ft
Kv
and
... (iii)
Km = 1
Assuming
p dP nP
p 144 300
=
60
60
V = 2.2619 103 mm sec = 2.2619 m sec
As the gear pair is manufactured by generation,

Kv =
5.6
5.6
=
= 0.7882
5.6 + V 5.6 + 2.2619

Feff
1.5 1 Ft
= 1.903 Ft , N
0.7882

Fb = FOS Feff
\
\
5718.1976 = 2 1.903 Ft
Ft = 1502.4167 N
... Ans.
3 - 6
Bevel Gears
Step - 4 : Calculate the rated power the gear pair can transmit
P = Ft V = 1502.4167 2.2619
\
P = 3.3983 10 3 W = 3.3983 kW
... Ans.
Example 3.17
Solution : Given data : q = 90, Z P = 40, Z G = 65, f = 20 ,

(S ut ) P = (S ut ) G = 600 N mm 2
m = 3 mm, b = 35 mm
To find : i) Fb
ii) Fw
Step - 1 : Calculate the beam strength and wear strength of gear pair
When pinion and gear are made of same material, pinion is always weaker than the gear
in bending. Hence it is required to design the pinion for bending.
b
Fb = s bP b m YP 1
AO
... (ii)
d P = m Z P = 3 40 = 120 mm
d G = m Z G = 3 65 = 195 mm
But,
s bP =
(S ut ) P
600
=
= 200 N mm 2
3
3
b = 35 mm, m = 3 mm
AO =
tan g P =
(d P 2) 2 + (d G 2) 2 =
ZP
40
=
ZG
65
(120 2) 2 + (195 2) 2 = 114.4825 mm

\ g P = 31.6075
g G = q - g P = 90 - 31.6075 = 58.3925
Z P =
ZP
40
=
= 46.9671
cos g P
cos (31.6075)
Z G =
ZG
65
=
= 124.0227
cos g G
cos (58.3925)
YP = 0.484 -
2.87
2.87
= 0.484 = 0.4228
46.9671
Z P
3 - 7
Bevel Gears
35
\
Fb = 200 35 3 0.4228 1 114.4825
Fb = 6164.3141 N
Ans.

Fw =
But,
0.75 d P b Q K
cos g P
... (iii)
d P = 120 mm, b = 35 mm
Q =
2 Z G
2 124.0227
=
= 1.4506
124.0227 + 46.9671
Z G + Z P
BHN 2
300 2
K = 0.16
= 0.16
= 1.44 N mm 2
100
100
... (Given)

0.75 120 35 1.4506 1.44
\
Fw =
cos (31.6075)
\
Fw = 7726.0109 N
Ans.
Example 3.18
Solution : Given data : q = 20 , Z P = 18, Z G = 36, q = 90

m = 8 mm, b = 40 mm, s bP = s bG = 73.33 MPa,
K a = 1.5, FOS = 2, n P = 500 rpm, (BHN) P = (BHN) G = 230
To find : i) Fb
ii) Fw
iii) Ft iv) P

When both pinion and gear are made of same material, pinion is always weaker than the
gear in bending, hence, it is necessary to design the pinion for bending.
b
Fb = s bP b m YP 1
AO
But,
... (i)
s bP = 73.33 MPa, b = 40 mm, m = 8 mm

d P = m Z P = 8 18 = 144 mm
d G = m Z G = 8 36 = 288 mm
AO =
tan g P =
(d P 2) 2 + (d G 2) 2 =
ZP
18
=
ZG
36
(144 2) 2 + (288 2) 2 = 160.9968 mm

\ g P = 26.565
3 - 8
Bevel Gears
g G = q - g P = 90 - 26.565 = 63.435
\
Z P =
ZP
18
=
= 20.7246
cos g P
cos (26.565)
Z G =
ZG
36
=
= 80.4985
cos g G
cos (63.435)
YP = 0.484 -
2.87
2.87
= 0.484 = 0.3455
20.7246
Z P

40
\
Fb = 73.33 40 8 0.3455 1 160.9968
\
Fb = 6093.3765 N
... Ans.

0.75 d P b Q K
Fw =
cos g P
But,
d P = 144 mm,
Q =
... (ii)
b = 40 mm
2 Z G
2 80.4985
=
= 1.5905
80.4985 + 20.7246
Z G + Z P
Assume,
BHN 2
K = 0.21
100
230
K = 0.21
= 1.1109 N mm 2
100
... (Gear pair is made of cast iron)

0.75 144 40 1.5905 1.1109
\
Fw =
cos (26.565)
\
Fw = 8.5338 10 3 N
... Ans.
As Fb < Fw , gear pair is weaker in bending than the pitting. Therefore it is necessary to
design a gear pair against bending.
Step - 3 : Calculate the maximum static load the gear can transmit
Effective load on gear pair is,
K a K m Ft
Feff =
Kv
But,
K a = 1.5
V =
and
... (iii)
Assuming
Km = 1
p dP nP
p 144 500
=
60
60
V = 3.7699 103 mm sec = 3.7699 m sec

3 - 9
Bevel Gears
Kv =
5.6
5.6
=
= 0.7425
5.6 + V
5.6 + 3.7699

1.5 1 Ft
= 2.0200 Ft
\
Feff =
0.7425
Fb = FOS Feff
\
8.5338 = 2 2.0200 Ft
Ft = 1508.2029 N
... Ans.
Step 4 : Calculate the rated power the gear pair can transmit
P = Ft V = 1508.2029 3.7699
\
P = 5.6857 10 3 W = 5.6857 kW
... Ans.
qqq
3 - 10
Rolling Contact Bearings

Example 4.34
Solution : Given data : Type of bearing = Single-row-deep groove ball bearing

L 05h = Rating life of bearing = 10000 hours
Sr. No.
Fraction of cycle
Radial load (Fr ) N
R.P.M.
1.
25%
3000 N
1440
2.
50%
5000 N
720
3.
25%
2500 N
1440
To find : i) Basic dynamic load capacity, C

Step - 1 : Equivalent dynamic (radial) load during first element, (Pe1 )
Pe = Fr 1 = 3000 N
1
Step - 2 : Revolutions of bearing during first element, (N1 )

L
60 n 1
N1 = 0.25 10h
106
= 0.25
or
L10h 60 1440
106
N1 = 0.0216 L10h million revolutions
Step - 3 : Equivalent dynamic (radial) load during second element, (Pe 2 )

Pe = Fr 2 = 5000 N
2
Step - 4 : Revolutions of bearing during second element, (N 2 )

L
60 n 2
N2 = 0.5 10h
106
= 0.5
or
L10h 60 720
106

4 - 1

Step - 5 : Equivalent dynamic (radial) load during third element, (Pe 3 )
Pe = Fr 3 = 2500 N
3
Step - 6 : Revolutions of bearing during third element, (N 3 )

L
60 n 3
L
60 1440
= 0.25 10h
N3 = 0.25 10h
6
10
106
or
N3 = 0.0216 L10h million revolutions.
Step - 7 : Equivalent dynamic (radial) load during entire work cycle, (Pe )
Pe
N1 (Pe ) a + N2 (Pe ) a + N3 (Pe ) a

1
2
3
=
N1 + N2 + N3
1a
0.0216 L10h (3000) 3 + 0.0216 L10h (5000) 3 + 0.0216 L10h (2500) 3

=
0.0216L10h + 0.0216 L10h + 0.0216 L10h
or
13
Pe = 3823.0136 N
Step - 8 : Rating life of bearing, (L10 )

i) Rating life of bearing for 90% reliability, (L10h )
L10 = N1 + N2 + N3
= 0.0216 L10h + 0.0216 L10h + 0.0216 L10h
or
L10 = 0.0648 L10h
ii) Rating life of bearing for 90% reliability (L10h )
L 05h
L10h
1 1.17
log e (1 R 95 )
=
log e (1 R 90 )
1 1.17
10000
log e (1 0.95)
=
L10h
log e (1 0.90)
or
L10h = 18500.96 hours

L10 = 0.0648 L10h
= 0.0648 18500.96
or
L10 = 1198.8622 million revolutions
Step - 9 : Basic dynamic load capacity, (C)

a
C
L10 =
Pe
3
C
1198.8622 =
3823.0136
or
C = 40612.7376 N
... Ans.
4 - 2

Example 4.35

Type of bearing = Single-row deep-groove ball bearing
L = Center distance between bearings = 100 mm
P = Power transmitted by shaft = 5 10 3 W
n = Speed of shaft = 3000 r.p.m.
Dg = Pitch diameter of gear pinion = 80 mm
f n = Normal pressure angle of gear pinion = 20
y = Helix angle of gear pinion = 19
L 05h = Rating lift of bearing at 95% reliability = 8000 hours
K a = Load application factor = 1.25
X = Radial load factor = 0.56
Y = Axial load factor = 1.2
To find :
i)
Basic dynamic load capacity at 90% reliability, C
Consider the power transmission through helical gear as shown in Fig. 4.1.
FtG
FrG
Bearing 'A'
FaG
Helical gear 'G'

Bearing 'B'
(a)
FtG
FrG
RAH
RAV
50 m
FaG
m
50 m
(b)
RBH
RBV
Fig. 4.1
4 - 3

Step - 1 : Radial load, (FrA and FrB )
i) Pitch line velocity of gear, (VG )
VG =
=
or
p Dg n
60 1000
p 80 3000
60 1000
VG = 12.5663 m/s
ii) Power transmitted by the gear, (P)

P = FtG VG
5 10 3 = FtG 12.5663
FtG = 397.8873 N
or
iii) Radial force by the gear, (FrG )

tan f n
FrG = FtG
cos y
tan 20
= 397.8873
cos 19
FrG = 153.1637 N
or
iv) Axial force by the gear, (FaG )

FaG = FtG tan y
= 393.8873 tan 19
or
FaG = 137.0035 N
v) Resultant load on the bearings, (R A and R B )
Refer Fig. 4.1 (b), considering moments about bearing 'A' in the vertical plane,
FtG 50 R BV 100 = 0
397.8873 50 - R BV 100 = 0
R BV = 198.9436 N
Refer Fig. 4.1 (b), considering moments about bearing 'B' in the vertical plane,
R AV 100 - FtG 50 = 0
R AV 100 - 397.8873 50 = 0
R AV = 198.9436 N
4 - 4
Refer Fig. 4.1 (b), considering moments about bearing 'A' in the horizontal plane,
FrG 50 - FaG 40 - R BH 100 = 0
153.1637 50 - 137.0035 40 - R BH 100 = 0
R BH = 21.7804 N
Refer Fig. 4.1 (b), considering moments about bearing 'B' in the horizontal plane,
R AH 100 - FrG 50 - FaG 40 = 0
R AH 100 - 153.1637 50 - 137.0035 40 = 0
R AH = 131.3832 N
Resultant radial load at bearing 'A'

RA =
=
(R AV ) 2 + (R AH ) 2
(198.9436) 2 + (131.3832) 2
R A = 238.4116 N
or
Resultant radial load at bearing 'B'

RB =
=
or
(R BV ) 2 + (R BH ) 2
(198.9436) 2 + (21.7804) 2
R B = 200.1323 N
Radial load on bearing 'A' = R A = FrA = 238.4116 N
Radial load on bearing 'B' = R B = FrB = 200.1323 N
Thrust (axial) load on bearing 'A' and 'B' = FaA = FaB = FaG = 137.0035 N
Step - 2 : Equivalent dynamic load, (Pe )
Bearing 'A' has more radial load as compared to bearing 'B', hence, selecting the
bearing based on load at 'A'.
Pe = (X V FrA + Y FaA ) K a
= (0.56 1 238.4116 + 1.2 137.0035) 1.25
or
Pe = 372.3933 N
Ans.

i) Life of bearing for 95% reliability, (L 05 )
L 05 =
L 05h 60 n
106
4 - 5

=
or
8000 60 3000
10 6
L 05 = 1440 million revolutions
ii) Life of bearing for 90% reliability, (L10 )

1 1.17
L 05
log e (1 R 95 )
=
L10
log e (1 R 90 )
1 1.17
1440
log e (1 0.95)
=
L10
log e (1 0.90)

C
L10 =
Pe
3
C
2664.1382 =
372.3933
or
C = 5162.4292 N
Ans.
Example 4.36

Types of bearing = Single-row deep-groove ball bearing
n = Speed of shaft rotation = 1750 r.p.m.
Co = Basic static load capacity = 11600 N
C = Basic dynamic load capacity = 17600 N
L h = Life of bearing = 4000 hours
To find : i) Reliability of the bearing, (R)
Step - 1 : Radial and axial load factor, (X and Y)
The radial and axial load factor are obtained from the given information
Radial Axial load
load (Fr )
(Fa )
Fa Fr
Fa Co
Gear
4000 N
3250 N
0.8125
0.2801
0.3784
0.56
1.18
First gear
2750 N
500 N
0.1818
0.0431
0.2448
Second gear
2750 N
50 N
0.01818
4.31 10-3
< 0.22
Third gear
nil
nil
Fourth gear
4 - 6

Step - 2 : Equivalent dynamic (radial) load during first gear, (Pe1 )
Pe1 = (X1 V1 Fr1 + Y1 Fa1 ) K a
1
= (0.56 1 4000 + 1.18 3250) 1

or
Pe1 = 6075 N
Step - 3 : Revolutions of bearing during first gear, (N1 )

L
60 n 1
N1 = 0.01 10h
106
= 0.01
or
L10h 60 1750
106
N1 = 1.05 10-3 L10h million revolutions
Step - 4 : Equivalent dynamic (radial) load during second gear, (Pe 2 )

Pe = (X 2 V2 Fr2 + Y2 Fa 2 ) K a
2
= (1 1 2750 + 0) 1
or
Pe
= 2750 N
Step - 5 : Revolutions of bearing during second gear, (N 2 )

L
60 n 2
N2 = 0.03 10h
106
L
60 1750
= 0.03 10h
106
or
N2 = 3.15 10-3 L10h million revolutions
Step - 6 : Equivalent dynamic (radial) load during third gear, (Pe 3 )

Pe 3 = (X 3 V3 Fr3 + Y3 Fa 3 ) K a
= (1 1 2750 + 0) 1
or
Pe 3 = 2750 N
Step - 7 : Revolutions of bearing during third gear, (N 3 )

L
60 n 3
N3 = 0.21 10h
106
= 0.21
or
L10h 60 1750
106
Step - 8 : Equivalent dynamic (radial) load during fourth gear, (Pe 4 )

Pe = (X 4 V4 Fr4 + Y4 Fa 4 ) K a
4
or
Pe
= 0 N
4 - 7

Step - 9 : Revolutions of bearing during fourth gear, (N 4 )
L
60 n 4
N4 = 0.75 10h
106
= 0.75
L10h 60 1750
106
or
Step - 10 : Equivalent dynamic (radial) load during entire work cycle, (Pe )
Pe
N1 (Pe ) a + N 2 (Pe ) a + N 3 (Pe ) a + N 4 (Pe ) a

1
2
3
4
=
+
N
+
N
+
N
N
1
2
3
4
1a
=
1.05 10 -3 L 10h (6075) 3 + 3.15 10 -3 L 10h (2750) 3 + 0.02205 L 10h
(2750) 3 + 0.07875 L 10h (0) 3
1.05 10 -3 L
3
10h + 3.15 10 L 10h + 0.02205 L 10h + 0.07875 L 10h
or
13
Pe = 1933.9481 N

i) Rating life of bearing, (L10 )
C
L10 =
Pe
17600 3
=
1933.9481
or
ii) Actual revolutions completed by bearing during entire workcycle, (L a )
L h 60 n
4000 60 1750
=
La =
6
10
106
or
L a = 420 million revolutions
Step - 12 : Reliability of bearing, (R a )

1 1.17
La
log e (1 R a )
=
L10
log e (1 R 90 )
1 1.17
420
log e (1 R a )
=
753.7086
log e (1 0.90)
R a = 0.9380
or
R a = 93.80 %
... Ans.
4 - 8

Example 4.37

Type of bearing = Single row deep groove ball bearing
L10h = Rating life of bearing = 10000 hours
X = Radial load factor = 1
Y = Axial load factor = 1.5
V = 1 (assumed)
To find :
i) Basic dynamic load capacity, C
Step - 1 : Equivalent dynamic (radial) load during first element, (Pe1 )
Pe1 = (X V Fr1 + Y Fa1 ) K a1 = (1 1 3500 + 1.5 1500) 3
or
Pe1 = 17250 N
Step - 2 : Revolutions of bearing during first element, (N1 )

L
60 n 1
0.35 10,000 60 550
=
N1 = 0.35 10h
6
106
10
or
N1 = 115.5 million revolutions
Step - 3 : Equivalent dynamic (radial) load during second element, (Pe 2 )
Pe2 = (X V Fr2 + Y Fa2 ) K a2 = (1 1 3300 + 1.5 1000) 2
or
Pe2 = 9600 N
Step - 4 : Revolutions of bearing during second element, (N 2 )

L
60 n 2
10,000 60 650
= 0.35
N2 = 0.35 10h
6
10
106
or
N2 = 136.5 million revolutions
Step - 5 : Equivalent dynamic (radial) load during third element, (Pe 3 )
Pe3 = (X V Fr3 + Y Fa3 ) K a3 = (1 1 2400 + 1.5 1000) 1.5
or
Pe3 = 5850 N
Step - 6 : Revolutions of bearing during third element, (N 3 )

L
60 n 3
N3 = 0.3 10h
106
10,000 60 750
= 0.3
106
or
N3 = 135 million revolutions
Step - 7 : Equivalent dynamic (radial) load for the entire work cycle, (Pe )
N (Pe1 ) a + N2 (Pe2 ) a + N3 (Pe3 ) a
Pe = 1
N1 + N2 + N3
4 - 9
1/a
or
Pe
115.5 (17250) 3 + 136.5 (9600) 3 + 135 (5850) 3

=
115.5 + 136.5 + 135
= 12415.5884 N
1/3
Step - 8 : Rating life of the bearing during the entire work cycle, (L10 )
L10 = N = N1 + N2 + N3
= 115.5 + 136.5 + 135
or
L10 = 387 million revolutions
Step - 9 : Basic dynamic capacity of the bearing, (C)

a
C
L10 =
Pe
3
C
387 =
12415.5884
or
C = 90476.8825 N
... Ans.
Example 4.38

Types of bearing = Single-row deep-groove ball bearing
L = Length of shaft = 180 mm
n = Speed of shaft rotation = 4000 r.p.m.
L 05h = Rating life of bearing = 8000 hours
To find : i) Basic dynamic load capacity, (C)
Refer Fig. 4.2 for the various loads acting on the bearings
400 N
RAH
450 N
RAV
60 m
m
50 m
m
70 m
RBH
RBV
Fig. 4.2
Step - 1 : Radial load (FrA and FrB ) acting on the bearings
Refer Fig. 4.2, considering moments about bearing 'A' in the vertical plane,
400 60 - R BV 180 = 0
or
R BV = 133.3334 N
4 - 10
Refer Fig. 4.2, considering moments about bearing 'B' in the vertical plane,
R AV 180 - 400 120 = 0
or
R AV = 266.6667 N
Refer Fig. 4.2, considering moments about bearing 'A' in the horizontal plane,
450 110 - R BH 180 = 0
or
R BH = 275 N
Refer Fig. 4.2, considering moments about bearing 'B' in the horizontal plane,
R AH 180 - 450 70 = 0
or
R AH = 175 N
Resultant radial loud at bearing 'A'
FrA = R A =
=
or
(R AV ) 2 + (R AH ) 2
(266.6667) 2 + (175) 2
FrA = 318.9610 N
Resultant radial load of bearing 'B'

FrB = R B =
=
or
(R BV ) 2 + (R BH ) 2
(133.3334) 2 + (275) 2
FrB = 305.6187 N
Axial load on bearings 'A' and 'B' is zero.
Step - 2 : Load application factor, (K a )

K a = 1.5
(assumed)
Step - 3 : Equivalent dynamic load, (Pe )

At bearing 'A',
PeA = (X V FrA + Y FaA ) K a = (1 1 318.9610 + 0) 1.5
or
PeA = 478.4415 N
At bearing 'B'
PeB = (X V FrB + Y FaB ) K a = (1 1 305.6187 + 0) 1.5
or
PeB = 458.4280 N
We will consider designing the bearing 'B' as it has higher equvalent dynamic load.
4 - 11

i) Life of bearing for 95% reliability, (L 05 )
L 05 =
=
or
L 05h 60 n
106
8000 60 4000
10 6
L 05 = 1920 million revolutions
ii) Life of bearing for 90% reliability, (L10 )

1 1.17
L 05
log e (1 R 95 )
=
L10
log e (1 R 90 )
1 1.17
1920
log e (1 0.95)
=
L10
log e (1 0.90)
or

C
L10 =
Pe
3
C
3552.1843 =
458.4280
or
C = 6994.7087 N
Ans.
qqq
4 - 12
Worm Gears
Example 5.21
Solution : Given data : As per designation of worm gear drive,

Z W = 2, Z G = 52, q = 10, m = 4 mm
Pi = 10 kW = 10 103 W, n W = 720 rpm, m = 0.04, f n = 20
To find : i) Components of tooth force
Step - 1 : Calculate the component of tooth force acting on the worm gear pair
d W = m q = 4 10 = 40 mm
d G = m Z G = 4 52 = 208 mm
ZW
2
tan l =
\ tan l =
q
10
\
l = 11.31
p dW nW
p 40 720
VW =
=
60
60
= 1.5079 10 3 mm sec = 1.5079 m sec
tan f v = m v =
m
cos f n
\ tan f v =
0.04
cos (20)
\
f v = 2.4374
Tangential force acting on the worm is,
Pi
10 103
FWt =
=
VW
1.5079
\
FWt = 6631.7395 N = FGa
Axial force acting on the worm is,
FWa =
\
... Ans.
FWt
6631.7395
=
tan (2.4374 + 11.31)
tan ( f v + l )
FWa = 27107.0102 N = FGt
... Ans.
5 - 1
Worm Gears
Radial force acting on the worm is,
tan l
tan f n
FWr = FWt
sin l
f
+
l
tan
tan
v
\
tan (11.31)
tan (20)
FWr = 6631.7395
tan (2.4374) + tan (11.31) sin (11.31)
FWr = 10147.9279 N = FGr
... Ans.
Example 5.22
Solution : Given data : As per designation of worm gear pair,

Z w = 1, Z G = 40, q = 10, m = 4 mm, (S ut ) G = 245 N mm 2
(S ut ) W = 700 N mm 2 , m = 0.04, f n = 20 , K = 0.825 N mm 2 , Ka = 1.25
To find : i) Pib
ii) Piw
Step-1 : Calculate the beam strength of worm gear

d W = m q = 4 10 = 40 mm
d G = m Z G = 4 40 = 160 mm
b = 2 m q + 1 or 0.73 d W } whichever is larger
\
\
\
Now,
But,
b = 2 4 10 + 1 or 0.73 40 } whichever is larger

b = 26.5329 or 29.2 } whichever is larger
b = 29.2 mm
d + dG
40 + 160
C.D. = W
=
= 100 mm
2
2
ZW
1
\ tan l =
tan l =
q
10
l = 5.7105
nW
Z
G =
= G
nG
ZW
1000 40
=
nG
1
n G = 25 rpm
(S ut ) G
245
s bG =
=
= 81.667 N mm 2
3
3
Fb = s bG b m Y cos l
2.87
2.87
Y = 0.484 = 0.484 = 0.4122
ZG
40
Fb = 81.667 29.2 4 0.4122 cos (5.7105)
Fb = 3.9128 103 N
5 - 2
Worm Gears
Step - 2 : Calculate the wear strength of worm gear
Fw = d G b K = 160 29.2 0.825
\
Fw = 3.8544 103 N
... (ii)
Step - 3 : Calculate the input power rating based on beam strength

K F
Feff = a Gt
Kv
VG =
p dG nG
p 160 25
=
= 0.2094 103 mm sec = 0.2094 m sec
60
60
Kv =
6
6
=
= 0.9662
6 + VG
6 + 0.2094
Feff =
1.25 FGt
= 1.2936 FGt
0.9662
But,
... (iii)

Fb = FOS Feff
\
3.9128 103 = 1 1.2936 FGt

FGt = 3.0246 103 N
Now, output power based on beam strength (Pob ) is,

Pob = FGt VG = 3.0246 103 0.2094 = 633. 3636W
cos a - m tan g
cos a + m cot g
Now,
h =
h =
h = 0.6984 = 69.84 %
... (Given) ... (a = f n and g = l )
cos (20) - 0.04 tan (5.7105)

cos f n - m tan l
=
1
cos f n + m cot l
cos (20) + 0.04
tan (5.7105)
... (iv)
Input power based on beam strength (Pib ) is,

\
\
h =
Pob
Pib
\ 0.6984 =
633.3636
Pib
Pib = 0.9068 10 3 W = 0.9068 kW
... Ans.
Step - 4 : Calculate the input power rating based on wear strength

Fw = FOS Feff
\
\
3.8544 103 = 1 1.2936 FGt
... [From equation (ii) and (iii)]
FGt = 2979.5918N
5 - 3
Worm Gears
Now, output power based on wear strength (Pow ) is,
Pow = FGt VG = 2979.5918 0.2094 = 623.9265 W
Input power based on wear strength (Piw ) is,
Pow
Piw
623.9265
Piw
... [From equation (iv)]
Piw = 0.8933 10 3 W = 0.8933 kW
... Ans.
h =
\ 0.6984 =
Example 5.23
Solution : Given data : A = 0.25 m 2 , h = 25 W/m 2 C, DT = 45 C, Z w = 1, Z G = 40,

q = 10, m = 4 mm, n w = 1000 rpm, f n = 20 , m = 0.035.
To find : Pit
Step - 1 : Calculate the input power based on thermal consideration
tan l =
Zw
1
=
q
10
tan f v = m v =
\ l = 5.7105
m
cos f n
\ tan f v =
0.035
cos( 20)
\
f v = 2..1330
Efficiency of worm gear pair is,
h =
\
tan (5.7105)
tan l
=
tan( f v + l) tan (2.1330 + 5.7105)
h = 0.7259 = 72.59 %
Input power based on thermal consideration is,

Pit =
\
hADT 25 0.25 45
=
(1 h )
(1 0.7259)
Pit = 1.0260 10 3 W = 1.0260 kW
Ans.
Example 5.24
Solution : Given data : d W = 48 mm, d G = 190 mm, p a = 18 mm, f n = 20 ,

L = 18 mm, b = 40 mm, n W = 3700 rpm, s bG = 85 N mm 2 ,
K = 0.63N mm 2 , m = 0.03, h = 18 W m 2 C.
To find : i) Dimensions of worm gear pair
iii) Temperature rise
ii) Input power

iv) Is fan necessary ?
5 - 4
Worm Gears
Step - 1 : Calculate the dimensions of worm gear pair
L = p a ZW
18 = 18 Z W
\
\
ZW
= 1
... Ans.
pa = p m
\
18 = p m
m = 5.7295 mm 6 mm
... Ans.
d W = m q
\
48 = 6 q
q = 8
Ans.
d G = m Z G
190 = 6 Z G
ZG = 31.666 mm 32 mm
G =
\
... Ans.
nW
Z
= G
n G ZW
3700 32
=
nG
1
tan l =
n G = 115.625 rpm
tan l =
ZW
q
1
8
l = 7.125
... Ans.
Designation of worm gear pair, 1 32 8 6
... Ans.
C. D. =
LW
dW + dG
48 + 192
=
= 119 mm
2
2
... Ans.
Z
32
= p m 4.5 + G = p 6 4.5 + = 96.8867 mm
50
50
... Ans.
For l < 15,

h a = 1m = 1 6 = 6 mm
hf
mn
... Ans.
= 1.25 m = 1.25 6 = 7.5 mm
... Ans.
= m cos l = 6 cos (7.125) = 5.9536 mm
... Ans.
Step - 2 : Calculate the beam strength and wear strength of gear tooth
Fb = s bG b m Y cos l
But,
Y = 0.484 -
2.8
2.8
= 0.484 = 0.3965
ZG
32
Fb = 85 40 6 0.3965 cos (7.125)
Fb = 8026.1391 N
Similarly,
Fw = d G b K = 190 40 0.63
\
Fw = 6308 N
As Fw < Fb , gear pair is weaker in pitting. Hence, pitting failure is the design criterion.
5 - 5
Worm Gears
Step - 3 : Calculate the static load the worm gear can transmit
K a FGt
Feff =
Kv
p d G n G p 190 115.625
=
60
60
But,
VG =
VG = 1.1502 103 mm sec = 1.1502 m sec

Kv =
Feff
6
6
=
= 0.8391
6 + VG 6 + 1.1502
1 FGt
= 1.1917 FGt
0.8451
... (i)

Fw = FOS Feff
\
6308 = 1 1.1917 FGt
FGt = 5293.2185 N
Step - 4 : Calculate the input power rating based on strength

Po = FGt VG = 5293.2185 1.1502 = 6088.2599 W
cos a - m tan g
... (Given) ... (a = f n and g = l )
cos a + m cot g
cos f n - m tan l cos (20) - 0.03 tan (7.125)
=
h =
1
cos f n + m cot l
cos (20) + 0.03
tan (7.125)
h =
\
\
But,
\
h = 0.7933 = 79.33 %
P
6088.2599
h = o
\ 0.8218 =
Pi
Pi
Pi
= 7673.8449 10 3 W = 7673.8449 kW
... Ans.
Step - 5 : Calculate the temperature rise of lubricating oil

Effective area of housing,
A = 9 10-5 (a)1.88
\
... (Given) (a = C. D. )
A = 9 10-5 (119)1.88 = 0.7182m 2
Total power loss in friction is,

Pf
= Power lost due to friction in teeth
Pf
= (Pi - Po )
Pf
= (6.4871 103 - 5.3311 103 )
Pf
= 1585.585 W
5 - 6
Worm Gears
This power loss in friction is equal to the rate of heat generated i.e.
Hg = Pf = 1585.585W
... (ii)
Temperature rise of lubricating oil with fan

Overall heat transfer coefficient with fan is,
h = 15.2 + 8.25 10- 3 n W
... (Given)
h = 15.2 + 8.25 10-3 3700 = 45.725 W m 2 C
Rate of heat dissipation is,

Hd = h A ( DT) = 45.725 0.7182 ( DT)
\
Hd = 32.8396 ( DT), W
But
Hg = Hd
\
\
... (iii)
1585.585 = 32.8396 ( DT)

( DT) with fan
... [From equations (ii) and (iii)]
= 48.2825 C
... Ans.
Temperature rise of lubricating oil without fan

Overall heat transfer coefficient without fan is,
h = 18 W m 2 C
... (Given)
Rate of heat dissipation is,

Hd = h A ( DT) = 18 0.7182 ( DT)
\
Hd = 12.9276 ( DT), W
But,
Hg = Hd
... (iv)
1585.855 = 12.9276 ( DT)
\ ( DT) without fan = 122.6511 C

As ( DT) without fan > 50 C, fan is necessary for effective dissipation of heat.
... Ans.
... Ans.
qqq
5 - 7
Belt, Rope and Chain Drives

Example 6.26

Type of drive = open type flat belt drive
P = power to be transmitted by belt = 30 103 W
n = speed of driving (small) pulley or electric motor = 1000 r.p.m.
N = speed of driven (big) pulley or pump = 500 r.p.m.
C = center distance between the shafts = 6000 mm
Refer an open type flat belt drive as shown in Fig. 6.1.
Step 1 :
(i)
Assume belt speed as V B = 17.8 m/s
(ii) Diameter of pulley (d)

Driving
pulley
For driving (small) pulley,

VB =
\
\
17.8 =
pd n
60 1000
p d 1000
60 1000
d = 339.9549 mm
Step 2 :
Fig. 6.1 : Open-type Flat Belt Drive
(i) Select nearest standard diameter of

pulleys
From the given standard pulley diameters,
selecting
d = 355 mm
Now,
Driven
pulley
Ans.
N
d
=
n
D
6 - 1

\
500
355
=
1000
D
D = 710 mm
\
(ii) Actual belt speed (V B )
p 355 1000
p d n
=
= 18.58 m s
VB =
60 1000
60 1000
Step 3 : Load correction factor Fa = 1.2
Ans.
given
Step 4 : Design power (Pd )

Design power is given by,
Pd = Fa P
= 1.2 30 103
or
Pd = 36 103 W
Step 5 :
(i) Calculate angle of contact (q s )
D - d
- 1 710 - 355 = 1.6952
a = sin - 1
= sin
2 6000
2C
a = 1.6952 or a = 0.0295 rad
For open type flat belt,

q s = p - 2a = p - (2 0.0278) = 3.0824 rad
\
q s = 3.0824 rad or 176.6095
(ii) Angle of contact correction factor (Fd )
The angle of contact correction factor is obtained by interpolation from given data
Fd = 1.04 -
(1.04 - 1.00) (170 - 176.6095 )

(170 - 180 )
= 1.0135
Step 6 : Power Rating of belt (P.R.)
The power rating of belt per ply per mm width is,
P.R. = 0.023 103 W ply mm
This power rating is at angle of contact of 180 and belt speed of 10 m/s.
Step 7 : Modified power rating (P. R. ) M
Modified power rating is given by,
(P.R.) M =
6 - 2
V
(P.R)
B
Fd
10
0.023 10 3
18.58
1.0135
10
= 0.04216 10 3 W ply mm
Step 8 : Product (Belt width Number of plies)
Belt width Number of plies =
Pd
(P.R.) M
36 10 3
0.04216 10 3
= 853.7932 ply-mm
Step 9 : Select standard width (b) and number of plies
We have, (Belt width Number of plies) = 853.7932
853.7932
= 213.44 mm
4
853.7932
belt width =
= 170.75 mm
5
For 4 plies,
belt width =
For 5 plies,
From the data given, selecting,
number of plies = 6
... Ans.
width of belt (b) = 180 mm
Ans.
Step 10 : Length of belt (L)

For open type flat belt drive,
p (D + d)
(D - d) 2
L = 2C +
+
2
4C
= 2 6000 +
p (710 + 355 )
(710 - 355 ) 2
+
2
4 4500
= 13678.45 mm
or
L = 13679 mm
Ans.
Example 6.27

Type of drive = open type V-belt
PT = total power to be transmitted = 10 103 W
6 - 3

n = speed of driving (small) pulley = 1440 r.p.m.
d = pitch diameter of driving (small) pulley = 200 mm
2f = groove angle of pulley = 34
m = coefficient of friction between belt and pulley = 0.2
m = mass of belt = 0.5 kg/m
Tmax = maximum allowable tension in belt = 500 N
q s = angle of contact for small pulley = 157 = 2.7401 rad
To find :
Driving
pulley
(i) Number of belts required (z)

Consider an open type V-belt drive as
shown in Fig. 6.2.
Driven
pulley
D
(i) Number of belts required (z)
The total power to be transmitted by

the belt system is given.
To calculate, number of belts

required, we need to calculate power
transmission capacity of each belt.
(1) Pitch line velocity of belt (V B )
p d n
VB =
60 100
=
Fig. 6.2 : Open-type V-Belt Drive
p 200 1440
= 15.0796 m s
60 1000
(2) Centrifugal tension (Tc )

Tc = m (VB ) 2
= 0.5 (16.96) 2
or
Tc = 113.6978 N
(3) Limited tension ratio
m q
Tft
= e sin
Tfs
0.2 2.7401
sin 17
= e
or
Tft
= 6.5168
Tfs
... (a)
6 - 4

(4) Belt tension in tight side due to frictional effect (Tft )
We have
Tmax = Tft + Tc
500 = Tft + 113.6978
or
Tft = 386.3022 N
... (b)
(5) Belt tension in slack side due to frictional effect (Tfs )

Substituting equation (b) in equation (a), we get
Tft
= 6.5168
Tfs
or
or
386.3022
= 6.5168
Tfs
Tfs = 59.2778 N
(6) Power transmission capacity of each belt (P)

P belt = (Tft - Tfs ) VB
= (386.3022 - 59. 3778 ) 15.0796
= 4931.3956 W
(7) Number of belt required (z)
z =
=
or
Total power to be transmitted (PT )

Power transmission capacity of each belt (P)
10 103
= 2.02
4931.3956
z = 2
... Ans.
Example 6.28

Type of drive = open type V-belt
z = number of belts = 1
d = pitch diameter of driving (small) pulley = 300 mm
D = pitch diameter of driven (big) pulley = 700 mm
n = speed of driving (small) pulley = 1000 r.p.m.
C = center distance between pulleys = 1000 mm
M = mass of belt per unit length = 0.5 kg/m
6 - 5

Tmax = maximum allowable tension in belt = 900 N
To find :
(i) Power transmitting capacity of belt (P)
(ii) Initial tension in the belt (Ti )
Consider an open type V-belt drive as shown in Fig. 6.3.
Driving
pulley
Driven
pulley
D
Fig. 6.3 : Open type V-belt drive

(i) Power transmitting capacity of belt (P)
(1) Angle of contact (q )
D - d
-1 700 - 300
a = sin -1
= sin
2 1000
2
C
\
For driving (small) V-belt :
a = 11.5369
qS
m q S
e sin f
Product
For driven (big) flat-belt :
or a = 0.2014 rad
= p - 2a = p - (2 0.2014) = 2.7388 rad

0.3 2.7388
sin 19
= e
= 12.4748
q B = p + 2a = p + (2 0.2014) = 3.5444 rad

em q B = e 0.3
Product
3.5444
= 2.8959
m qs
Since product e sin f
(em q B ) flat
V- belt
Hence design of belt is governed by flat pulley.
(2) Limiting tension ratio
Tft
= em q B
Tfs
= e 0.3
or
3.544
Tft
= 2.8959
Tfs
... (a)
6 - 6

(3) Pitch line velocity of belt (V B )
p 300 1000
p d n
=
= 15.70 m s
VB =
60 1000
60 1000
(4) Centrifugal tension (Tc )
Tc = m (VB ) 2
= 0.5 (15.70) 2
or
Tc = 123.3700 N
(5) Belt tension in tight side due to frictional effect (Tft )

We have, Tmax = Tft + Tc
900 = Tft + 123.37
or
Tft = 776.6299 N
... (b)
(6) Belt tension in slack side due to frictional effect (Tfs )

Substituting equation (b) in equation (a), we get,
Tft
= 2.8959
Tfs
\
or
776.6299
= 2.8959
Tfs
Tfs = 268.1825 N
(7) Power transmitting capacity of belt (P)

P = (Tft - Tfs ) VB
= (776.6299 - 268.1825) 15.70
= 7982.6228 W
or
P = 7.982 kW
... Ans.
(ii) Initial tension in belt (Ti )

Ti =
=
Tft + Tfs + 2Tc

2
776.6299 + 268.1825 + (2 123.3700)
2
Ti = 645.7762 N
... Ans.
6 - 7

Example 6.29

q = angle of contact = 160 or 2.7925 rad
To find : i) Percentage increase in power transmission
(i) Increase in power transmission by V-belt over flat belt
(1) Power transmission by flat belt (Pf )
Since the material, cross-sectional area and speed of both the belts are same, hence the
maximum tension (Ttt ) in both the drives will also be equal.
This implies that maximum tension on tight side due to frictional effect in both drives
will be equal.
For flat belt,
Limiting tension ratio,
Tft
= emq = e 0.3 2.7925
Tfs
or
Tft
= 2.3111
Tfs
or
Tfs = 0.4326 Tft
Power transmission capacity of flat belt, (Pf )
Pf = (Tft - Tfs ) VB
= (Tft - 0.4326 Tft ) VB
or
Pf
= 0.5673 Tft VB
(a)
(2) Power transmission by V-belt (Pv )

For V-belt drive,
Limiting tension ratio,
m q
f
Tft
= e sin
Tfs
or
0. 3 2.7925
e sin 35
Tft
= 4.3084
Tfs
or
Tfs = 0.2321 Tft
Power transmission capacity of V-belt drive (Pv )
Pv = (Tft - Tfs ) VB
= (Tft - 0.2321 Tft ) VB
or
Pv = 0.7678 Tft VB
6 - 8

(3) Percentage increase in power transmission of V-belt over flat belt drive
P - Pf
% increase in power = v
100
Pf
=
0.7678 Tft VB - 0.4326 Tft VB

0.4326 Tft VB
= 0.7748
or
% increase in power = 77.48 %
... Ans.
Example 6.30
Solution : Given data : t = 12 mm, b = 300 mm, Ratio of friction tensions = 2.4,
2
3
3
g/mm
s t per = 2 MPa = 2 N/mm , r = 1.1 10
To find : Maximum power to be transmitted (Pmax)

Step - 1 : The maximum tension in tight side of belt should equal belt strength
\
Tmax = Ttt = s t
per
b t = 2 300 12
Ttt = 7200 N
Step - 2 : Calculate the velocity of belt (VB)

i) Centrifugal tension (Tc )
T
7200
= 2400 N
Tc = tt =
3
3
ii) Tension in tight side of belt due to belt friction (Tft )
\
Ttt = Tft + Tc
Tft = 4800 N
We have,
Tc = m (VB ) 2 = (Density Volume) (VB ) 2
Tc =
\
\
(r
7200 = Tft + 2400
b t) (VB ) 2
2400 = (1100
300
12
) (VB ) 2
1000 1000
VB = 24.6182 m/s
Step 3 : Calculate maximum power transmitted by belt (Pmax)

i) Tension in slack side of belt due to belt friction (Tfs )
We have,
Tft
= em q
Tfs
4800
= 2.4
Tfs
Tfs = 2000 N
ii) Maximum power transmitted by belt (Pmax )

Pmax = (Tft - Tfs ) (VB ) = (4800 - 2000) (24.6182)
\
Pmax = 68930.96 W = 68.930 kW

6 - 9
Ans.

Example 6.31
Solution : Given data : N = 90 r.p.m., P = 10.5 kW = 10.5 103 W,

b = 11.5 cm = 115 mm, t = 12 mm, n = 225 r.p.m., d = 60 cm = 600 mm,
C = 2.75 m = 2750 mm, m = 0.25
To find : Stress in belt (s t per )

Step - 1 : Calculate speed ratio (S.R)
N d
90
600
=
=
S.R =
\
n
D
225
D
\
D = 1500 mm
Step - 2 : Calculate the actual belt speed (VB)

pd n
p 600 225
=
= 7.0685 m/s
VB =
60 1000
60 1000
Step - 3 : Calculate power transmitted by the belt
P = (Tft Tfs ) VB \ 10.5 103 = (Tft Tfs ) 7.0685
\
Tft Tfs = 1485.4461 N
(a)
Step - 4 : Calculate the angle of contact

D- d
1500 - 600
a = sin -1
= sin -1
= 9.4180 = 0.1643 rad
2C
2 2750
q s = p - 2 a = p - ( 2 0 . 1463) = 2.8128 rad
Step - 5 : Calculate limiting tension ratio
Tft
= em q = e 0 . 25 2 . 8128 = 2.0202
Tfs
\
Tft = 2.0202 Tfs
(b)
Step - 6 : Calculate tensions in belt due to belt friction (Tft) an (Tfs)

Substituting equation (b) in equation (a)
Tft + Tfs = 1485.4461 \ 2.0202 Tfs + Tfs = 1485.4461
\
\
3.0202 Tfs = 1485.4461
Tfs = 491.8324 N
Tft = 2.0202 Tfs = 993.5998 N
Step - 7 : Calculate Stress in the belt

i) Centrifugal tension (Tc)
Assuming density of the belt r = 0 (As belt is weightless)
Tc = 0
ii) Total tension in tight side of belt (Ttt)
Ttt = Tft + Tc = 993.5998 + 0 = 993.5998 N
6 - 10

iii) Maximum tensile stress in the belt (s t per )
s t per =
993 5998
Ttt
= 0.7199
=
115 12
bt
2
s t per = 0.7199 N/mm
Ans.
Example 6.32

Type of drive = Open type flat belt, n = 600 r.p.m., N = 220 r.p.m.,
P = 10 kW = 10000 W, C = 1.25 m = 1250 mm, d = 250 mm, m = 0.25,
2
s t per = 2.5 N/mm , r = 0.001 gm/mm = 1000 kg/m , t = 12 mm
To find : Width of the belt (b)

Step - 1 : Speed ratio (S.R)
S.R =
\
N d
=
n
D
220 250
=
600
D
D = 681.8181 mm
Step - 2 : Calculate the width of belt (b)

i) Actual belt speed (VB)
p 250 600
p d n
= 7.8539 m/s
=
VB =
60 1000
60 1000
ii) Power to be transmitted by belt (P)
P = (Tft Tfs) VB
10,000 = (Tft Tfs) 7.8539
\
Tft Tfs = 1273.2527
\
iii) Angle of contact (q s )
D- d
681 . 8181 - 250
a = sin -1
= sin -1
2 1250
2C
(a)
\
a = 9.9464 or a = 0.1735 rad
For open type belt drive,
q s = p - 2 a = p 2(0.1735) = 2.7945 rad
iv) Limiting tension ratio
Tft
= em q = e 0 . 25 2 .7945 = 2.0109
Tfs
Tft = 2.0109 Tfs N
\
v) Tension in belt due to belt friction (Tft) and (Tfs)
(b)
Substituting equation (b) in equation (a),

Tft Tfs = 1273.2527
2.0109 Tfs Tfs = 1273.2527

6 - 11

Tfs = 1259.5238 N
and
Tft = 2.0109 Tfs = 2.0109 1259.5238 = 2532.7764 N
vi) Centrifugal tension (Tc)

Tc = m (VB)
= (Density Volume) VB2
b
t
= r
1 VB2
1000 1000
b
12
2
Tc = 1000
1 7.8539 = 0.7402 (b) N

1000 1000
vii) Total tension in tight side of belt (Ttt)

Ttt = Tft + Tc
Ttt = 2532.7764 + 0.7402 (b)
viii) Maximum tensile stress in the belt (s t per )
s t per =
\
\
\
Ttt
b t
2.5 =
2532 . 7764 + 0.7402 ( b)

(b) 12
30 (b) = 2532.7764 + 0.7402 (b)

29.2598 (b) = 2532.7764
b = 86.5616 mm = 87 mm
Ans.
qqq
6 - 12
Sliding Contact Bearing

Example 7.16

d = Diameter of shaft (journal) = 60 mm
l = Length of bearing = 30 mm
n s = Speed of journal = 1000/60 r.p.s.
e = Eccentricity = 30 10-3 mm
c = Radial clearance between journal and bearing = 40 10 -3 mm
m = Absolute or dynamic viscosity of fluid = 0.030 10-6 N -s mm 2
Step - 1 : Velocity at surface of journal, (U)
U = p d n s
= p 60
or
1000
60
U = 3141.5926 mm s
Step - 2 : Eccentricity ratio, ()

e
=
c
=
or
30 10-3
40 10-3
= 0.75
Step - 3 : Type of bearing

Length to diameter ratio,
l
30
=
= 0.5
d
60
Since (l/d) ratio is equal to 0.5, the journal bearing is considered as infinitely short
hydrodynamic journal bearing.
7 - 1

Step - 4 : Load carrying capacity, (W)
W =
p m U l3
4c 2
(1- 2 ) 2
16
2
- 1 + 1
2
p
p 0.030 10 -6 3141.5926 (30) 3

4 (40
10 -3 ) 2
0.75
(1 -
0.75 2 ) 2
16
0.75 2
- 1 + 1
p2
= 5925.9136 N
or W = 5.9259 kN
.. Ans.
Step - 5 : Flow rate of lubricant, (Q s )

Qs = U c l
= 3141.5926 (40 10-3 ) 0.75 30
= 2827.4333 mm 3 s
= 2827.4333 10-9 103 60 l min
Q s = 0.1696 l min
or
... Ans.
Example 7.17
Solution : Given data : W = 50 10 3 N, n s = 1440/60 r.p.s., d = 100 mm, l = 100 mm,
c = 0.12 mm, m = 16 10 - 9 N-s mm 2

To find :
(i)
Coefficient of friction, (f)
(ii) Power lost in friction, (Pf )
(iii) Minimum oil-film thickness, (h o )

Step - 1 : Load per unit projected area, (p)
50 103
W
=
p =
l d
100 100
or
p = 5 N mm 2
Step - 2 : Sommerfeld number, (S)

r 2 m n s 50 2
1440
1
S =

16 10- 9
=
c p 0.12
60
5
or
S = 0.0133
Step - 3 : Dimensionless parameters
Refer Table 7.4, we get the following information :
7 - 2

S
l
d

(ho c)
r
c f

0.0133
0.0726
0.8403
Step - 4 : Co-efficient of fluid friction, (f)

For (l/d) = 1 and For (l/d) = 1 and
S = 0.0188
S = 0.00474
For (l/d) = 1 and S = 0.0133
ho
c
0.1
0.03
(h o c) 0.1
0.1 0.3
=
0.01333 0.00474
0.0188 0.00474
ho
= 0.0726
c
r
f
c
1.05
1.70
(r c) 1.70
1.05 1.70
=
0.00133 0.00474
0.0188 0.00474
r
f = 0.8403
c
r f = 0.8403
c
\
50 f = 0.8403
0.12
f = 2.0167 10 3
or
Ans.
Step - 5 : Power lost in friction, (Pf )

2.0167 10 3 50 10 3 50
(2 p n s ) (f W r)
1440
= 2p
Pf =
60
106
10 6
or
Pf
= 0.76 kW
Ans.
Step - 6 : Minimum oil-film thickness, (h o )

h o = 0.0726
c
ho
= 0.0726
0.12
h o = 0.008712 mm
or
Ans.
Exmaple 7.18
Solution : Given data : m = 50 mm, d = 50 mm, W = 7.5 kN = 7.5 10 3 N,
h s = 4500/60 r.p.s., c = 0.1 mm, m = 30 10 9 N - s mm 2 , r = 0.86, Cp = 2.09 kJ/kgC

To find :
(i) h o , (ii) f, (iii) Pf , (iv) Q, (v) Q s , (vi) Tavg

W
p =
l d
7 - 3

=
7.5 103
50 50
p = 3 N / mm 2
or
Step - 2 : Sommerfeld number, (S)

r 2 mn s
S =
c p
25
=
0.1
or
4500
1
30 10- 9

60
3
S = 0.046

We have,
l
50
=
=1
d
50
and
S = 0.046
Refer Table 7.4, we get the following information

For ( l / d) = 1 and
For ( l / d) = 1 and
S = 0.121
S = 0.0446
For ( l / d) = 1 and S = 0.046
ho

c
0.4
0.2
(h0 / c) - 0.2
0.4 - 0.2
=
0.046 - 0.0446 0.121 - 0.0446
ho
= 0.2036
c
r
f
c
3.22
1.70
r
c f - 1.70

3.22 - 1.70
=
0.046 - 0.0446 0.121- 0.0446
r
f = 1.7278
c
r c ns l
4.33
4.62
- 4.33
r c ns l
4.62 - 4.33
=
0.121- 0.0446
0.121- 0.046
Q
= 4.6146
r Cnsl
Qs
Q
0.680
0.842
(Qs / Q) - 0.680
0.842 - 0.680
=
0.121- 0.0446
0.121- 0.0446
Qs
= 0.8390
Q

ho
= 0.2036
c
7 - 4

ho
= 0.2036
0.1
h o = 0.02036 mm
or
h o = 20.36 microns
... Ans.
Step - 5 : Coefficient of fluid friction, (f)

r f = 1.7278
c
25 f = 1.7278
0.1
or
f = 0.006911
... Ans.

(2 p n s ) (f W r)
Pf =
106
=
or
Pf
2 p 4500
0.006911 75 103 25
60
10 6
= 0.6165 kW
... Ans.
Step - 7 : Total flow rate of lubricating oil, (Q)

Q
= 0.8390
r c ns l
Q
= 0.8390
4500
25 0.1
50
60
Q = 43261.875 mm 3 / s
= 43261.875 10-9 60 m 3 / min
= 43261.875 10-9 60 103 lit/min
or
Q = 2.5957 lit/min
... Ans.
Step - 8 : Side leakage of lubricating oil, (Q s )

Qs
= 0.8390
Q
Qs
= 0.8390
2.5957
Q s = 2.1778 lit/min
... Ans.
Step - 9 : Temperature rise of lubricant, ( DT)

Neglecting effect of side leakage,
DT =
(2 p n s ) (f W r)
103
r Q Cp
7 - 5

4500
0.00691 7.5 103 25
= 2 p
103

60
860 43261.875 2.09
DT = 7.85 C
or
Ans.
Step - 10 : Average temperature of lubricant, (Tavg )

DT
Tavg = T1 +
2
= 30 +
7.85
2
Tavg = 33.92 C
or
... Ans.
Example 7.19
Solution : Given data : W = 15 10 3 N, n s = 1000/60 r.p.s., l d = 1, e = 0.03 mm,

c = 0.04 mm, l = 100 mm, r = 0.86, C p = 2.09 kJ/kgC
To find :
(i)
Minimum oil-film thickness, ( h o )
(ii) Coefficient of friction, (f)

(iii) Power lost in friction, (Pf )
(iv) Absolute viscosity of lubricating oil, (m )
(v) Total flow rate of lubricating oil, (Q)
(vi) Side leakage of lubricating oil, (Q s )
(vii) Average temperature of lubricating oil, (Tavg )
Step - 1 : Eccentricity ratio, ()
e 0.03
=
= 0.75
=
c 0.04
l
We have,
= 1
d
and
ho

c
= 0.75
For (l d ) = 1
For (l d ) = 1
and = 0.6
and = 0.8
0.4
0.2
7 - 6
For (l d ) = 1
and = 0.75
(ho c) - 0.2 0.4 - 0.2
=
0.8 - 0.75
0.8 - 0.6
ho
= 0.25
c

r
c f

3.22
1.70
r
c f - 1.70

3.22 - 1.70
=
0.8 - 0.75
0.8 - 0.6
r
f = 2.08
c
0.121
0.0446
S - 0.0446
0.121 - 0.0446
=
0.8 - 0.75
0.8 - 0.6
S = 0.0637
Q
r c ns l
4.33
4.62
Q
- 4.33
r c ns l
4.62 - 4.33
=
0.75 - 0.6
0.8 - 0.6
Q
r c n l = 4.5475
Qs
Q
0.680
0.842
(Qs Q) - 0.680
0.842 - 0.680
=
0.75 - 0.6
0.8 - 0.6
Qs
= 0.8015
Q

ho
= 0.25
c
ho
= 0.25
0.04
h o = 0.01 mm
or
h o = 10 microns
Ans.
Step - 4 : Coefficient of fluid friction, (f)

r f = 2.08
c
100 2
f = 2.08
0.04
or
f = 0.001664
Ans.

0.001664 15 103 (100 2)
(2 p n s ) (f W r)
= (2 p 1000 60)
Pf =
106
106
or
Pf
= 0.1306 kW
Ans.

W
15 103
=
p =
l d 100 100
or
p = 1.5 N mm 2
7 - 7

Step - 7 : Absolute viscosity of lubricating oil, (m)
We have Sommerfeld number as,
r
S =
c
m n s
100 2
0.0637 =
0.04
1000
1
m
60
1.5
m = 3.6691 10- 9 N-s mm 2

m = 3.6691 cP
or
Ans.
Step - 8 : Total flow rate of lubricating oil, (Q)
= 4.5475
l
r
c
n
s
Q
= 4.5475
(100 2) 0.04 (1000 60) 100
Q = 15158.3333 mm 3 s
= 15158.3333 10 - 9 60 m 3 min
= 15158.3333 10 - 9 60 10 3 lit/min
or
Q = 0.9095 lit/min
Ans.
Step - 9 : Side leakage of lubricating oil, (Q s )

Qs
= 0.8015
Q
Qs
= 0.8015
0.9095
Q s = 0.7289 lit/min
Ans.
Step - 10 : Temperature rise of lubricant, ( DT)

Neglecting effect of side leakage,
DT =
=
or
(2 p n s ) (f W r)
103
r Q Cp
2p (1000 60) 0.001664 15 103 (100 2)
103
860 15158.3333 2.09
DT = 4.7967 C
Step - 11 : Average temperature of lubricating oil, (Tavg )

4.7967
DT
= 30 +
Tavg = T1 +
2
2
or
Tavg = 32.3983 C
Ans.
7 - 8

Example 7.20

d = Journal diameter = 60 mm
n s = Journal speed = 1000/60 r.p.s.
l = Bearing length = 60 mm
m = 20 10- 9 N-s mm 2
To find :
(i)
Radial load on bearing, (W)
(ii) Total flow rate of lubricating oil, (Q)

The minimum oil-film thickness in this case is given by,
h o = 5 (1.6 + 0.8) = 12 microns
or
h o = 0.012 mm
Step - 2 : Radial clearance, (c)
Refer BIS standards, for the class of fit H8d8, the limits for the hole and shaft
are :
Hole limits : (60 + 0.000) and (60 + 0.039) mm
Shaft limits : (60 0.119) and (60 0.080) mm
When the process of manufacturing is centered,

0.000 + 0.039
Average diameter of bearing, (Davg ) = 60 +
= 60.0195 mm
2
- 0.119 - 0.080
Average diameter of journal, (d avg ) = 60 +
= 59.9005 mm
2
Davg - d avg
60.0195 - 59.9005
=
2
2
c = 0.0595 mm
Radial clearance, c =
or
and
We have,
l
60
=
=1
d
60
ho
0.012
=
= 0.2017
c
0.0595
7 - 9
Refer Table 7.4, we get the following information :

For (l d) = 1
For (l d) = 1
and (ho c) = 0.2
and (ho c) = 0.4
0.0446
0.121
For (l d) = 1
and (ho c) = 0.2017
S - 0.0446
0.121 - 0.0446
=
0.2017 - 0.2
0.4 - 0.2
S = 0.04525
r c ns l
4.62
4.33
- 4.33
r c ns l
4.62 - 4.33
=
0.4 - 0.2
0.4 - 0.2017
Q
= 4.6175
r c ns l

We have Sommerfeld number as,
r
S =
c
m n s
30 2
1000
1
0.04525 =

20 10- 9
0.0595
60
p
p = 1.8727 N mm 2
Step - 5 : Radial load on bearing, (W)
We have load per unit projected area as,
W
p =
l d
1.8727 =
or
W
60 60
W = 6741.7282 N
Ans.
Step - 6 : Total flow rate of lubricant, (Q)

Q
= 4.6175
r c n s l
Q
30 0.0595
1000
60
60
Q
= 4.6175
= 8242.24 mm 3 s = 8242.24 10- 9 60 m 3 min
= 8242.24 10- 9 60 103 lit/min
or
Q = 0.4945 lit/min
Ans.
qqq
7 - 10

50998335YG1M - Design of Machine Elements - II - Solution Manual

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1

Given data : P = 18 kW = 18 10 3 W, n P = 720 rpm, n G = 300 rpm,

(S ut ) P = 780 N mm 2 , (S ut ) G = 680 N mm 2 , K a = 1.5,

Design a gear pair.

Step - 1 : Calculate the number of teeth on pinion and gear

Design of Machine Elements - II

Lewis form factor is,

s bP YP = 260 0.3405 = 88.53 N mm 2

s bG YG = 226.666 0.4242 = 96.1519 N mm 2

Step - 4 : Calculate the wear strength of gear pair

Considering smaller value of BHN.

Design of Machine Elements - II

K a = 1.5 and K m = 1.4

50.1338 103 + 6.2993 103 m

Calculate the value of module and other dimensions

For safety against pitting failure,

491.8989 m 3 = 50.1338 103 + 6.2993 103 m

Solving the above cubic equation, we get

= 1.25 m = 1.25 6 = 7.5 mm

Step - 7 : Calculate the dynamic load by using Buckingham's equation

... (Given) ... (vi)

Ft max = K a K m Ft = 1.5 1.4 3978.8666 = 8355.6198 N

e P = 11+ 0.9 [6 + 0.25 120] = 18.8647 mm

e G = 11+ 0.9 [m + 0.25 d G ]

e G = 11+ 0.9 [6 + 0.25 288] = 20.2183 mm

e = 39.083 mm = 39.083 10- 3 mm

207 103 207 103

207 103 + 207 103

Step - 8 : Calculate the available factor of safety

As gear pair is weaker in pitting,

FOS = 1.1180 < 1.35

Design of Machine Elements - II

Calculate the dynamic load by using Buckingham's equation

Buckingham's equation for dynamic load is,

... (Given) ... (vii)

V = 0.7539 m = 0.7539 8 = 6.0312 m sec

Ft max = K a K m Ft = 1.5 1.4 2984.15 = 6266.715 N

e P = 11+ 0.9 [8 + 0.25 160] = 21.046 mm

e G = 11+ 0.9 [m + 0.25 d G ]

e G = 11+ 0.9 [8 + 0.25 384 ] = 22.609 mm

e = 43.655 mm = 43.655 10-3 mm

Design of Machine Elements - II

207 103 207 103

207 103 + 207 103

Substituting all these values in equation (vii),

21 6.0312 (96 501.5304 + 6266.715)

Calculate the available factor of safety

Effective load for precise estimation is,

As gear pair is weaker in pitting,

FOS = 1.6722 > 1.35

Solution : Given data : f = 20 , Z P = 24, Z G = 50, m = 4 mm

Design of Machine Elements - II

Fb = 200 50 4 0.3644 = 14576.6666 N

Step - 2 : Calculate the wear strength of gear pair

Substituting all these values in equation (ii),

Step - 3 : Calculate the rated power transmitted by gear pair

14576.6666 = 1.5 Feff

V = 7.2382 103 mm sec = 7.2382 m sec

Power transmitted by gear pair is,

Design of Machine Elements - II

Solution : Given data :

Step - 1 : Calculate the beam strength for pinion