GEOMETRY ANALYSIS

The given overall gear ratio are:

I1; first gear = 3.4
I2; second gear = 2.1
I3; third gear = 1.3
I4; top gear = 1
I5; reverse gear = 3.5
-The first step in calculating the gear ratios is to find the threshold gear ratio (ith) of the gear set between
the input shaft and the lay shaft.
- The ratio ith is always greater than 1, since it is used to reduce the speed coming from the engine.
Error Calculation
3.4 3.4
-𝒊𝟏 = = = 𝟐. 𝟐𝟔𝟕 (i1)new= 2.267*1.5=3.4005
𝑖th 1.5
\3.4−3.4005\
% 𝑒𝑟𝑟𝑜𝑟 = ∗ 100% = 𝟎. 𝟎𝟏𝟒𝟕%
3.4
2.1
𝒊𝟐 = = 𝟏. 𝟒 (I2)new= 1.4*1.5= 2.1
1.5
\1.4−1.4\
-% 𝑒𝑟𝑟𝑜𝑟 = ∗ 100% = 𝟎
1.4
1.3
- -𝒊𝟑 = = 𝟎. 𝟖𝟔𝟕 (i3)new= 0.867*1.5= 2.1
1.5
\1.3005−1.3\
- % 𝑒𝑟𝑟𝑜𝑟 = ∗ 100% = 𝟎. 𝟎𝟑𝟖%
1.3
3.5
-𝒊𝒓 = = 𝟐. 𝟑𝟑𝟑 (ir)new= 2.333*1.5= 3.4995
1.5
\3.5−3.4995\
-% 𝑒𝑟𝑟𝑜𝑟 = ∗ 100% = 𝟎. 𝟎𝟏𝟒𝟑%
3.5
-Lets titrate to find the optimum gear ratios with the least amount of error and optimum ratios of
reduction
ith I1 %error I2 %error I3 %error Ie %error
1.05 3.238 0.00294 2 0 1.238 0.00769 3.333 0.01
1.1 3.091 0.00294 1.909 0.00467 1.182 0.0154 3.182 0.00571
1.15 2.957 0.0161 1.826 0.00467 1.13 0.0384 3.043 0.0571
1.2 2.833 0.0117 1.75 0 1.083 0.0307 2.917 0.0114
1.25 2.72 1.3*10-4 1.68 0 1.04 0 2.8 0
1.3 2.615 0.0147 1.615 0.0238 1 0 2.692 0.0114
1.35 2.514 0.0191 1.556 0.0286 0.963 0.00384 2.593 0.0157
1.4 2.424 0.0196 1.5 0 0.929 0.0461 2.5 0
1.45 2.345 0.00735 1.448 0.0194 0.897 0.05 2.414 0.00857
1.5 2.267 0.0147 1.4 0 0.867 0.0384 2.333 0.0143
1.55 2.194 0.0206 1.355 0.0119 0.839 0.0348 2.258 0.00285
1.6 2.125 0 1.313 0.0381 0.813 0.0615 2.188 0.0229
1.65 2.061 0.0191 1.273 0.0214 0.788 0.0154 2.121 0.01
1.7 2 0 1.235 0.0238 0.765 0.0384 2.059 0.00857
1.75 1.943 0.00735 1.2 0 0.743 0.0192 2 0
1.8 1.889 0.00588 1.267 0.0286 0.722 0.0307 1.944 0.0229
1.85 1.838 0.00882 1.135 0.0119 0.703 0.0437 1.892 0.00571
1.9 1.789 0.0264 1.105 0.0238 0.684 0.0307 1.842 0.00571
1.95 1.744 0.0235 1.007 0.00714 0.667 0.05 1.795 0.00714
2 1.7 0 1.05 0 0.65 0 1.75 0

-The optimum gear ratios for this gear-box are taken to be:
1. ith= 2
2. i1= 1.7
3. i2= 1.05
4. i3= 0.65
5. ir= 1.75
-The minimum number of teeth of the pinion on the threshold gear-set can be calculated as:
2∗𝑘∗cos 𝛹
NP= (1+2𝑚)𝑠𝑖𝑛2 𝛷 [𝑚 + √𝑚2 + (1 + 2𝑚)𝑠𝑖𝑛2 𝛷]
Where, k=1, for full depth teeth
m= gear ratio
Ψ= helix angle
Φ= tangential pressure angle
-1 𝑡𝑎𝑛𝛷𝑛
Φt= tan [ 𝑐𝑜𝑠𝛹 ] , Φn= normal pressure angle
tan 30
= tan-1[cos 30]= 22.80
-Pressure angle: is the angle through which forces are transmitted between the meshing gears. 14.50
pressure angles are standard in gear designs while they are still widely available. The 20o pressure angle
have a wider bases and can transmit greater loads. It also reduces the relative sliding velocity reduce the
contact ratio and overlap. Therefore the 20o pressure angle is chosen.
-Helix angle: is a constant angle made by helices with the axis of rotation. Higher helix angle give
smooth operations but increase the axial load on the teeth. It ranges from 20o to 45o. we have chosen it
to be 30o.
2∗1∗cos 30
NP= (1+2∗2)𝑠𝑖𝑛2 [2 + √22 + (1 + 2 ∗ 2)𝑠𝑖𝑛2 22.8]
22.8
𝑵𝟐
Np= 10 teeth , 𝑵𝟏 = 𝟐 <=> 𝑵𝟐 = 𝟐 ∗ 𝟏𝟎 = 𝟐𝟎 𝒕𝒆𝒆𝒕𝒉
The number of teeth of the first reduction gear-set can be found by using the relation:
𝑁3
N1+N2= N3+N4 , but 𝑁4 = 1.7 = i1 ………. N4 = 1.7 N3
𝑵𝟏+𝑵𝟐
N4= 𝟐.𝟕
Take N1= 10 and N2= 20
𝟑𝟎
N4=𝟐.𝟕 = 𝟏𝟏. 𝟏𝟏 = 𝟏1 𝒕𝒆𝒆𝒕𝒉
N3= 1.7* 11= 19 teeth
𝑵𝟒 𝟏𝟗 \1.7−1.727\
-𝑵𝟑 = 𝟏𝟏 = 1.727 % 𝒆𝒓𝒓𝒐𝒓 = ∗ 100% = 𝟏. 𝟓𝟖𝟖%
1.7
For the second gear reduction:
𝑁6
N1+N2= N5+N6 , but 𝑁5 = 1.05
𝑵𝟏+𝑵𝟐
N6= 𝟐.𝟎𝟓
Take N1= 10 and N2= 20
𝟑𝟎
N6=𝟐.𝟎𝟓 = 𝟏𝟒. 𝟔𝟑𝟒 = 𝟏𝟓 𝒕𝒆𝒆𝒕𝒉
N5= 1.05* 15= 15.67= 16 teeth
𝑵𝟓 𝟏𝟔 \1.05−1.067\
-𝑵𝟔 = 𝟏𝟓 = 1.067 % 𝒆𝒓𝒓𝒐𝒓 = ∗ 100% = 𝟏. 𝟔𝟏𝟗%
1.05
For third reduction gear set
𝑁7
N1+N2= N7+N8 , but 𝑁8 = 0.65
𝑵𝟏+𝑵𝟐
N7= 𝟏.𝟔𝟓
Take N1= 10 and N2= 20
𝟑𝟎
N8=𝟏.𝟔𝟓 = 𝟏𝟖. 𝟏𝟖 = 𝟏𝟖 𝒕𝒆𝒆𝒕𝒉
N7= 1.65* 18= 12 teeth
𝑵𝟕 𝟏𝟐 \0.65−0.667\
-𝑵𝟖 = 𝟏𝟖 = 0.684 % 𝒆𝒓𝒓𝒐𝒓 = ∗ 100% = 𝟐. 𝟔𝟏𝟓%
0.65
Let's titrate the number of teeth on each gear using the method shown above and take the result which
gives the least amount of error.
N1 N2 N3 N4 N5 N6 N7 N8 ERROR
10 20 11 19 13 15 18 12 4.672
11 22 12 21 16 17 20 13 2.941
12 24 13 23 18 18 22 14 4.762
13 26 14 25 19 20 24 15 5.042
14 28 16 26 20 21 25 16 4.762
15 30 17 28 22 23 27 18 3.114
16 32 18 30 23 24 29 19 3.519
17 34 19 32 25 26 31 20 0.952
18 36 20 34 26 28 33 21 2.564
19 38 21 36 28 28 34 22 3.297
20 40 22 38 21 31 36 24 2.564
21 42 23 40 31 32 38 25 2.301
22 44 24 42 32 34 40 26 2.941

At N1 = 17 and N2 = 34, we obtain the smallest % error, therefore we chose the number of teeth
corresponding to these values
Checking the number of teeth obtained in the table for interference.
In order for interference not to occur, the values obtained in the table must be greater than the (NP)min of
the gear.

-First gear , m=1.7

2∗𝑘∗cos 𝛹
(N3)min= (1+2𝑚)𝑠𝑖𝑛2 𝛷 [𝑚 + √𝑚2 + (1 + 2𝑚)𝑠𝑖𝑛2 𝛷]
2∗cos 30
(N3)min= (4.4)𝑠𝑖𝑛2 22.8 [1.7 + √1.72 + (1 + 2 ∗ 1.7)𝑠𝑖𝑛2 22.8]
(NP)min= 9.4≈ 10 teeth
N3 > (N3)min , there is no interference

-Second gear, m= 1.05

2∗𝑘∗cos 𝛹
(N5)min= (1+2𝑚)𝑠𝑖𝑛2 𝛷 [𝑚 + √𝑚2 + (1 + 2𝑚)𝑠𝑖𝑛2 𝛷]
2∗cos 30
(N5)min= (3.1)𝑠𝑖𝑛2 [1.05 + √1.052 + (1 + 3.1)𝑠𝑖𝑛2 22.8]
22.8
(NP)min= 8.56≈ 9 teeth
N5 > (N5)min , there is no interference

-Third gear, m= 0.65

2∗𝑘∗cos 𝛹
(N7)min= (1+2𝑚)𝑠𝑖𝑛2 𝛷 [𝑚 + √𝑚2 + (1 + 2𝑚)𝑠𝑖𝑛2 𝛷]
2∗cos 30
(N7)min= (2.3)𝑠𝑖𝑛2 22.8 [0.65 + √0.652 + (1 + 2.3)𝑠𝑖𝑛2 22.8]
(NP)min= 7.65≈ 8 teeth
N7 > (N7)min , there is no interference
Module: is the ratio of pitch circle diameter to the number of teeth. Module can be calculated by this
formula:
3 𝑇1(𝑢 + 1)4 2𝐶
𝐶 = 𝑘𝑎 √ … … … … … . 𝑚𝑡 =
𝑈 𝑁1 + 𝑁2
Where, T1= Tin*ith= 230*2 = 460
Ka = 0.225 for passenger cars
U = i1 = 3.4
3 460(3.4+1)4
𝐶 = 0.225 √ = 94.4
3.4
M= 3.7 ≈ 4
Take module m = 4
The diameter of the gears can be found using the formula :
𝑚 4
𝑚𝑡 = = = 4.6
𝑐𝑜𝑠𝛹 𝑐𝑜𝑠30
D1 = N1Mt = 17* 4.6 = 78.2 mm
D2 = 156.4 mm
D3= 87.4 mm
D4 = 147.2 mm
D5 = 115 mm
D6 = 119.6 mm
D7 = 142.6 mm
D8 = 92 mm
Center to center distance between the gears
(𝐷1 + 𝐷2) (𝐷3 + 𝐷4) 𝑚(𝐷5 + 𝐷6) (𝐷7 + 𝐷8)
𝐶= = = =
2 2 2 2
C = 117.3 mm
Addendum of the gears
1*m = 4mm
Dedendum of the gear
1.25*m = 5mm
Reverse gear-set
C= 117.8 mm
X= 17.8 mm

𝑑𝑝 𝑑𝑝+𝑑𝑔 𝑑𝑝+𝑑𝑔
-𝑑𝑔 = 1.75 »» = 𝑐 − 𝑥 <=> = 100 𝑚𝑚
2 2
dp + dg= 200 but dp =1.75 dg
200
-𝑑𝑝 = 2.75 = 𝟕𝟑 𝒎𝒎
dg= 1.75 dp = 128 mm
𝑑𝑝 73
number of teeth: 𝑁𝑝 = 𝑚 = 4 = 𝟏𝟖 𝒕𝒆𝒆𝒕𝒉
𝑑𝑝 128
𝑁𝑔 = = = 𝟑𝟐 𝒕𝒆𝒆𝒕𝒉
𝑚 4
Idler gear
128 2 73
C2= (ri+rg)2 + (ri+rp)2 = (ri + ) + (ri + 2 )2
2
128 2 73
ri = (117.8)2 + (73ri)2 - 128ri – [( 2
) + ( 2 )2]
ri = 48mm
Number of teeth:
𝑑 96
-𝑁𝑖 = = = 𝟐𝟒 𝒕𝒆𝒆𝒕𝒉
𝑚 4
 Force Analysis
Force Analysis of Gears
For the pinion attached to the input shaft (threshold gear-set)
1.For the threshold gear-set

Assume the direction of the direction of rotation of the input

torque
to be in the counter clockwise direction.
Ti- input torque
Tc- Torque on countershaft
For helical gear: Φ= 20o
Φt= 22.8o
Ψ= 30o

Force on the pinion

𝐹
From the torque formula T= 𝑟

Where F is the tangential load

T = input torque = 230 KN
2𝑇 230 𝑁𝑚∗2
Fgpt= = = 5.86 𝐾𝑁
𝑑 78.5 𝑚𝑚

Radial load; Fgpr= Fgpt tan Φt = 5.86 KN * tan 22.8

Fgpr= 2.46 KN
Axial load; Fgpa= Fgpt tan Ψ = 5.86 KN * tan 30
Fgpa= 3.38 KN
 Force on the gear

Fpgt = /- Fgpt/ = 5.86 KN

Fpgr = /- Fgpr/ = 2.46 KN
Fpga = /- Fgpa/ = 3.38 KN

The The torque transmitted to the gear

𝑁𝑝
T c = Ti x = 230 x 2 = 460 Nm
𝑁𝑔

Reverse Gear-Set

d9 = 73 mm
d10 = 128 mm
d11 = 73 mm
T9 = 98 mm

From the diameter ratios

2𝑇 460∗2
Gear-9 : Ft = = = 12.78
𝑑9 72

Fr = Ft tan 20o = 4.65Kn

2𝑇 460∗2
Gear-10 : Ft = = = 12.78
𝑑10 128

Fr = Ft tan 20o = 4.65Kn

Idler Gear

Ftgi = 12.78 cos24 i – 12.78 sin 71.2 j

= 11.67 i – 12.1 j

Ftgi = 12.78 cos 71.2 i – 12.78 sin 24 j

= 4.12 i – 5.2 j
/Ft/ = 17.232 KN

Frgi = 4.65 cos 78.7 i – 4.65 sin 68 j

= 0.92 i – 4.31 j

Frgi = 12.78 cos 71.2 i – 12.78 sin 24 j

= 1.74 i – 4.56 j

/Fr/ = 8.673 KN
 Strength Analysis of Gears
Threshold gear-set

Pinion: dP = 78.52 mm Gear: dg = 157.04 mm

Np = 17 teeth Ng = 34 teeth
Wp = 2700 rpm Wg = 1350 rpm
AGMA Stress equation
The gear bending stress is given by:
𝟏 𝒌𝒎 ∗ 𝒌𝒃
𝑱 = 𝑾𝒕 ∗ 𝒌𝒐 ∗ 𝒌𝒗 ∗ 𝒌𝒔 ∗ ∗
𝒎𝑭 𝑱
Where Wt – tangential transmitted load
Ko- overload factor
Kv – dynamic factor
Ks- size factor
F – face width
m- module
km – load distribution
kb – rim thickness factor
J – Geometry factor
Wt (tangential transmitted load ) is given in the force analysis for the threshold gear-set as:
Wt = 5.86 kN/h
Overload factor (ko)
-Assuming uniform loading take ko = 1.5
Dynamic factor (kv)
𝑨+√𝟐𝟎𝟎𝑽 B
Kv =( )
𝑨

where B= 0.25 (12- Qv)2/3 and A = 50+56(1-B)

Qv is the transmission quality number (accuracy level) and for most commercial quality gears, it
ranges from 8-12
Take Qv = 12
B = 0.25(12-12)2/3 = 0 and A = 50+56(1-0) = 106
Tangential speed (v)
∏∗𝒅𝒑∗𝑾𝒑 𝟑.𝟏𝟒∗𝟕𝟖.𝟓𝟐∗𝟐𝟕𝟎𝟎
V= = = 11.095 m/s
𝟔𝟎𝟎𝟎 𝟔𝟎𝟎𝟎𝟎
Therefore
𝟓𝟗.𝟕𝟕𝟑+√𝟐𝟎𝟎∗𝟏𝟏.𝟎𝟗𝟓 0
Kv =( )
𝟓𝟗.𝟕𝟕𝟑
Kv = 1
Size factor (ks)
√𝒚 0.535
Ks =𝟏. 𝟏𝟗𝟐 (𝑭 )
𝑷
Where F is face width = 25 mm
P is diametral pitch = 0.25

Y is the lewis form factor , from shigley ninth edition Table 14-2
The value of Yp(17 teeth) = 0.303
Yg(34 teeth) = 0.371

𝟐𝟓√𝟎.𝟑𝟎𝟑
(ks)p = 1.192 ( ) = 𝟏. 𝟒𝟕𝟒
𝟎.𝟐𝟓
𝟐𝟓√𝟎.𝟑𝟕𝟏
(ks)g = 1.192 ( ) = 𝟏. 𝟒𝟖𝟐
𝟎.𝟐𝟓
Load distribution factor (km)

Km = 1+ Cmc ( Cpf Cpm + Cma Ce )

Where, Cmc = 1 , for uncrowned teeth
𝐹
Cpf = 10𝑑 − 0.0375 + 0.0125𝐹
𝐹
− 0.0375 + 0.0125 ∗ 28 = 0.006642 (for pinion)
10∗78.53
Cpf = 0.025 (for gear)
Cpm = 1.1 , for straddle mounted pinion
Cma = A+BF+CF2
The values of A,B and C are given at shigley 9th ed,
Table 14-9
A = 0.0675
B = 0.0128 for precision, enclosed units
-5
C = -9.3 * 10
25 25
Cma = 0.0675+0.0128∗ 25.4 – 9.26 * 10-5 * (25.4)2
Cma = 0.08
Ce = 1
(km)p = 1+(0.006642+0.08) = 0.927
(km)g = 1+(0.025+0.08) = 0.905
Geometry factor for bending strength
From shigley’s mechanical engineering design, 9th ed, figure 14-6
Jp = 0.29
Jg = 0.369
The bending stresses for gear and pinion are
Pinion

𝟓𝟖𝟔𝟎∗𝟏∗𝟏.𝟒𝟕𝟒∗𝟎.𝟗𝟐𝟕
σp = = 276.10 MPa
𝟐𝟓∗𝟒∗𝟎.𝟐𝟗
Gears

𝟓𝟖𝟔𝟎∗𝟏∗𝟏.𝟒𝟐𝟖∗𝟎.𝟗𝟎𝟓
σg = = 205.233 MPa
𝟐𝟓∗𝟒∗𝟎.𝟑𝟔𝟗

The contact stresses are given by

𝒌𝒎 𝒌
σ = Cp(Wt ko kv ks ∗ )
𝒅𝒑𝑭 𝑰
where, I is the surface strength geometry factor , given as

𝒄𝒐𝒔𝝓𝒕∗𝒔𝒊𝒏𝝓𝒕 𝑴𝒈
I= +( ) , Mg gear ratio = 2
𝟐𝑴𝒏 𝑴𝒈+𝟏

𝑃𝑛
Calculating for Mn , Mn = 0.95𝑍 , Pn = Π m cos Φn
Π*4*cos20 = 1.8025

Quantity, Z= [(rp+a)2-rbp2]1/2+[(rg+ra)2-rbg2]1/2-(rp+rg)sinϕt
Z = 17.679
𝟏𝟏.𝟖𝟎𝟐𝟓
Mn = = 𝟎. 𝟕𝟎𝟑
𝟏𝟕.𝟔𝟕𝟗∗𝟎.𝟗𝟓

𝒄𝒐𝒔𝟐𝟐.𝟖 𝒔𝒊𝒏𝟐𝟐.𝟖 𝟐
I= ( ) = 𝟎. 𝟏𝟔𝟗
𝟐(𝟎.𝟕𝟎𝟑) 𝟐+𝟏

Cp (Elastic coefficient)from the table 14-8 for pinion and gear both made of steel is , Cp = 191Mpa

Pinion
𝟎.𝟗𝟐𝟕 𝟏
σ = 191(5860*1*1.474 * ∗ )
𝟐𝟓∗𝟖.𝟓𝟒 𝟎.𝟏𝟔𝟗

σ =4608.782 Mpa
Gears
𝟎.𝟗𝟓 𝟏
σ = 191(5860*1 *1.482 * ∗ )
𝟐𝟓∗𝟕𝟖.𝟓𝟑 𝟎.𝟏𝟔𝟗

σ = 4792.58 Mpa
 Material Selection

Pinion: AISI 4140 steel with Hb = 510

Gear: AISI 1030 steel with Hb = 495

AGMA strength equations

Solving for the face-width necessary to resist wear and bending

𝒌𝒔 𝒌𝒎 𝒌𝒃 𝒌𝒕 𝒌𝒓
Fb = nd Wt ko kv
𝒎𝑱 𝒔𝒕 𝒀𝒏
𝑪𝒑 𝒁𝒏 𝒌𝒎 𝒌𝒃
FW = ( )𝟐 nd Wt ko kv ks
𝑺𝒄 𝑲𝒕 𝑲𝒓 𝒎𝑱
- St(allowable bending stress)
For grade 2, St = 0.703Hb + 113 Mpa
Pinion, St = 0.703(50) + 113 Mpa
= 471.53 Mpa
Gear, St = 0.703(49.5) + 113 Mpa
= 460.985 Mpa
-YN (stress cycle factor for bending stress) and ZN (stress cycle factor for constant stress)
For number of life cycle (N) taken as 109 cycles.
(YN)P = 0.92 (YN)g = 0.93
-Kt (temperature factor)
For To less than 120oc , Kt = 1
-KR (reliability factor)
We have taken reliability to be R = 0.95
KR = 0.884
-Take design factor of safety
nd = 1.25
𝟏.𝟐𝟓∗𝟓𝟖𝟔𝟎∗𝟏∗𝟏.𝟒𝟕𝟒∗𝟎.𝟗𝟕𝟐∗𝟎.𝟒𝟖𝟒
(Fb)p = = 9.5229 mm
𝟒∗𝟎.𝟐𝟗∗𝟒𝟕𝟏.𝟓𝟑∗𝟏𝟎𝟔 ∗𝟏
𝟏.𝟐𝟓∗𝟓𝟖𝟔𝟎∗𝟏.𝟒𝟖𝟐∗𝟎.𝟗𝟓∗𝟎.𝟒𝟖𝟒
(Fb)g = = 8.8191mm
𝟒∗𝟎.𝟐𝟗∗𝟒𝟔𝟎.𝟗𝟖𝟓∗𝟏𝟎𝟔 ∗𝟏
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟕𝟒∗𝟎.𝟗𝟓
(Fw)p = 𝟏𝟒𝟔𝟔.𝟏∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*5860* = 16.34 mm
𝟕𝟖.𝟓𝟑∗𝟎𝟐𝟗
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟖𝟐∗𝟎.𝟗𝟓
(Fw)g = 𝟏𝟒𝟐𝟗.𝟓∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*5860* = 8.84 mm
𝟕𝟖.𝟓𝟑∗𝟎.𝟑𝟕𝟏

-Sc for grade 2 steel

Sc = 2.22Hb+200Mpa
Pinion=> Sc = 1466.1 Mpa
Gear=> Sc = 1429.95 Mpa
 Strength Analysis of Gears
First gear-set

Pinion: dP = 87.757 mm Gear: dg = 147.8 mm

Np = 19 teeth Ng = 32 teeth
Wp = 1350 rpm Wg = 801.56 rpm
AGMA Stress equation
The gear bending stress is given by:
𝟏 𝒌𝒎 ∗ 𝒌𝒃
𝑱 = 𝑾𝒕 ∗ 𝒌𝒐 ∗ 𝒌𝒗 ∗ 𝒌𝒔 ∗ ∗
𝒎𝑭 𝑱
Where Wt – tangential transmitted load
Ko- overload factor
Kv – dynamic factor
Ks- size factor
F – face width
m- module
km – load distribution
kb – rim thickness factor
J – Geometry factor
Wt (tangential transmitted load) is given in the force analysis for the first gear-set as:
Wt = 10.483 kN/h
Overload factor (ko)
-Assuming uniform loading take ko = 1.5
Dynamic factor (kv)
𝑨+√𝟐𝟎𝟎𝑽 B
Kv =( )
𝑨

where B= 0.25 (12- Qv)2/3 and A = 50+56(1-B)

Qv is the transmission quality number (accuracy level) and for most commercial quality gears, it
ranges from 8-12
Take Qv = 12
B = 0.25(12-12)2/3 = 0 and A = 50+56(1-0) = 106
Tangential speed (v)
∏∗𝒅𝒑∗𝑾𝒑 𝟑.𝟏𝟒∗𝟖𝟕.𝟕𝟓𝟕∗𝟏𝟑𝟓𝟎
V= = = 6.2 m/s
𝟔𝟎𝟎𝟎 𝟔𝟎𝟎𝟎𝟎
Therefore
𝟓𝟗.𝟕𝟕𝟑+√𝟐𝟎𝟎∗𝟏𝟏.𝟎𝟗𝟓 0
Kv =( )
𝟓𝟗.𝟕𝟕𝟑
Kv = 1
Size factor (ks)
√𝒚 0.535
Ks =𝟏. 𝟏𝟗𝟐 (𝑭 )
𝑷
Where F is face width = 45 mm
P is diametral pitch = 0.25

Y is the lewis form factor , from shigley ninth edition Table 14-2
The value of Yp(17 teeth) = 0.314
Yg(34 teeth) = 0.365

𝟒𝟓√𝟎.𝟑𝟎𝟑
(ks)p = 1.92 ( ) = 𝟏. 𝟓𝟐𝟑𝟐
𝟎.𝟐𝟓
𝟒𝟓√𝟎.𝟑𝟕𝟏
(ks)g = 1.192 ( ) = 𝟏. 𝟓𝟐𝟗𝟑
𝟎.𝟐𝟓
Load distribution factor (km)

Km = 1+ Cmc ( Cpf Cpm + Cma Ce )

Where, Cmc = 1 , for uncrowned teeth
𝐹
Cpf = 10𝑑 − 0.0375 + 0.0125𝐹
𝐹
− 0.0375 + 0.0125 ∗ 28 = 0.0359 (for pinion)
10∗78.53
Cpf = 0.025 (for gear)
Cpm = 1.1 for straddle mounted pinion
Cma = A+BF+CF2
The values of A,B and C are given at shigley 9th ed,
Table 14-9
A = 0.0675
B = 0.0128 for precision, enclosed units
-5
C = -9.3 * 10
45 45
Cma = 0.0675+0.0128∗ 25.4 – 9.26 * 10-5 * (25.4)2
Cma = 0.0775
Ce = 1
(km)p = 1+(0.0359+0.0775) = 0.962
(km)g = 1+(0.025+0.08) = 0.95
Geometry factor for bending strength
From shigley’s mechanical engineering design, 9th ed, figure 14-6
Jp = 0.4439
Jg = 0.4725
The bending stresses for gear and pinion are
Pinion

𝟓𝟖𝟔𝟎∗𝟏.∗𝟏.𝟓𝟐𝟑∗𝟎.𝟗𝟔𝟐
σp = = 107.45MPa
𝟒𝟓∗𝟒∗𝟎.𝟒𝟒𝟑𝟗
Gears

𝟓𝟖𝟔𝟎∗𝟏∗𝟏.𝟓𝟐𝟗𝟑∗𝟎.𝟗𝟓
σg = = 101.101 MPa
𝟒𝟓∗𝟒∗𝟎.𝟒𝟕𝟐𝟓

The contact stresses are given by

𝒌𝒎 𝒌
σ = Cp(Wt ko kv ks ∗ )
𝒅𝒑𝑭 𝑰
where, I is the surface strength geometry factor , given as

𝒄𝒐𝒔𝝓𝒕∗𝒔𝒊𝒏𝝓𝒕 𝑴𝒈
I= +( ) , Mg gear ratio = 2
𝟐𝑴𝒏 𝑴𝒈+𝟏

𝑃𝑛
Calculating for Mn , Mn = 0.95𝑍 , Pn = Π m cos Φn
Π*4*cos20 = 1.8025

Quantity, Z= [(rp+a)2-rbp2]1/2+[(rg+ra)2-rbg2]1/2-(rp+rg)sinϕt
Z = 17.679
𝟏𝟏.𝟖𝟎𝟐𝟓
Mn = = 𝟎. 𝟔𝟗𝟗𝟖
𝟏𝟕.𝟔𝟕𝟗∗𝟎.𝟗𝟓

𝒄𝒐𝒔𝟐𝟐.𝟖 𝒔𝒊𝒏𝟐𝟐.𝟖 𝟐
I= ( ) = 𝟎. 𝟏𝟔𝟎𝟐
𝟐(𝟎.𝟕𝟎𝟑) 𝟐+𝟏

Cp (Elastic coefficient)from the table 14-8 for pinion and gear both made of steel is , Cp = 191Mpa

Pinion
𝟎.𝟗𝟔𝟐 𝟏
σ = 191(5860*1*1.5232 * ∗ )
𝟒𝟓∗𝟖𝟕.𝟕𝟓𝟕 𝟎.𝟏𝟔𝟎𝟐

σ =2595.616 Mpa
Gears
𝟎.𝟗𝟓 𝟏
σ = 191(5860*1*1.5293* ∗ )
𝟒𝟓∗𝟏𝟒𝟕.𝟖 𝟎.𝟏𝟔𝟎𝟐

σ = 151.811 Mpa
 Material Selection

Pinion: AISI 4140 steel with Hb = 510

Gear: AISI 1030 steel with Hb = 495

AGMA strength equations

Solving for the face-width necessary to resist wear and bending

𝒌𝒔 𝒌𝒎 𝒌𝒃 𝒌𝒕 𝒌𝒓
Fb = nd Wt ko kv
𝒎𝑱 𝒔𝒕 𝒀𝒏
𝑪𝒑 𝒁𝒏 𝒌𝒎 𝒌𝒃
FW = ( )𝟐 nd Wt ko kv ks
𝑺𝒄 𝑲𝒕 𝑲𝒓 𝒎𝑱
- St(allowable bending stress)
For grade 2, St = 0.703Hb + 113 Mpa
Pinion, St = 0.703(50) + 113 Mpa
= 471.53 Mpa
Gear, St = 0.703(49.5) + 113 Mpa
= 460.985 Mpa
-YN (stress cycle factor for bending stress) and ZN (stress cycle factor for constant stress)
For number of life cycle (N) taken as 109 cycles.
(YN)P = 0.92 (YN)g = 0.93
-Kt (temperature factor)
For To less than 120oc , Kt = 1
-KR (reliability factor)
We have taken reliability to be R = 0.95
KR = 0.884
-Take design factor of safety
nd = 1.25
𝟏.𝟐𝟓∗𝟓𝟖𝟔𝟎∗𝟏.𝟔𝟏𝟔∗𝟏.𝟓𝟐𝟑𝟐∗𝟎.𝟗𝟔𝟐∗𝟎.𝟒𝟖𝟒
(Fb)p = = 17.558 mm
𝟒∗𝟎.𝟐𝟗∗𝟒𝟕𝟏.𝟓𝟑∗𝟏𝟎𝟔 ∗𝟏
𝟏.𝟐𝟓∗𝟓𝟖𝟔𝟎∗𝟏.𝟒𝟓𝟔∗𝟎.𝟗𝟎𝟓∗𝟎.𝟒𝟖𝟒
(Fb)g = = 16.354 mm
𝟒∗𝟎.𝟐𝟗∗𝟒𝟔𝟎.𝟗𝟖𝟓∗𝟏𝟎𝟔 ∗𝟏
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟓𝟐𝟑𝟐∗𝟎.𝟗𝟔𝟐
(Fw)p = 𝟏𝟒𝟔𝟔.𝟏∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*5860* = 29.671 mm
𝟏𝟒𝟕.𝟖∗𝟎𝟐𝟗
𝟏𝟗𝟏∗𝟏 𝟏.𝟔𝟏𝟔∗𝟏.𝟒𝟖𝟒∗𝟎.𝟗𝟎𝟓
(Fw)g = 𝟏𝟒𝟐𝟗.𝟓∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*5860* = 17.467 mm
𝟏𝟒𝟕.𝟖∗𝟎.𝟑𝟕𝟏

-Sc for grade 2 steel

Sc = 2.22Hb+200Mpa
Pinion=> Sc = 1466.1 Mpa
Gear=> Sc = 1429.95 Mpa
Strength Analysis of Gears
Second gear-set

Pinion: dP = 115.47 mm Gear: dg = 120.089 mm

Np = 25 teeth Ng = 26 teeth
Wp = 1350 rpm Wg = 1298.08 rpm
AGMA Stress equation
The gear bending stress is given by:
𝟏 𝒌𝒎 ∗ 𝒌𝒃
𝑱 = 𝑾𝒕 ∗ 𝒌𝒐 ∗ 𝒌𝒗 ∗ 𝒌𝒔 ∗ ∗
𝒎𝑭 𝑱
Where Wt – tangential transmitted load
Ko- overload factor
Kv – dynamic factor
Ks- size factor
F – face width
m- module
km – load distribution
kb – rim thickness factor
J – Geometry factor
Wt (tangential transmitted load ) is given in the force analysis for the threshold gear-set as:
Wt = 7.967 kN/h
Overload factor (ko)
-Assuming uniform loading take ko = 1.5
Dynamic factor (kv)
𝑨+√𝟐𝟎𝟎𝑽 B
Kv =( )
𝑨

where B= 0.25 (12- Qv)2/3 and A = 50+56(1-B)

Qv is the transmission quality number (accuracy level) and for most commercial quality gears, it
ranges from 8-12
Take Qv = 12
B = 0.25(12-12)2/3 = 0 and A = 50+56(1-0) = 106
Tangential speed (v)
∏∗𝒅𝒑∗𝑾𝒑 𝟑.𝟏𝟒∗𝟕𝟏𝟏𝟓.𝟖∗𝟐𝟕𝟎𝟎
V= = = 8.15 m/s
𝟔𝟎𝟎𝟎 𝟔𝟎𝟎𝟎𝟎
Therefore
𝟓𝟗.𝟕𝟕𝟑+√𝟐𝟎𝟎∗𝟏𝟏.𝟎𝟗𝟓 0
Kv =( )
𝟓𝟗.𝟕𝟕𝟑
Kv = 1
Size factor (ks)
√𝒚 0.535
Ks =𝟏. 𝟏𝟗𝟐 (𝑭 )
𝑷
Where F is face width = 30 mm
P is diametral pitch = 115.47

Y is the lewis form factor , from shigley ninth edition Table 14-2
The value of Yp(25 teeth) = 0.3415
Yg(26 teeth) = 0.346

𝟑𝟎√𝟎.𝟑𝟒𝟏𝟓
(ks)p = 1.192 ( ) = 𝟏. 𝟒𝟗3
𝟏𝟓𝟓.𝟒𝟕
𝟑𝟎√𝟎.𝟑𝟕𝟏
(ks)g = 1.192 ( ) = 𝟏. 𝟒𝟗𝟒
𝟏𝟐𝟎.𝟏
Load distribution factor (km)

Km = 1+ Cmc ( Cpf Cpm + Cma Ce )

Where, Cmc = 1 , for uncrowned teeth
𝐹
Cpf = 10𝑑 − 0.0375 + 0.0125𝐹
𝐹
− 0.0375 + 0.0125 ∗ 28 = 0.006642 (for pinion)
10∗78.53
Cpf = 0.025 (for gear)
Cpm = 1.1 , for straddle mounted pinion
Cma = A+BF+CF2
The values of A,B and C are given at shigley 9th ed,
Table 14-9
A = 0.0675
B = 0.0128 for precision, enclosed units
-5
C = -9.3 * 10
25 25
Cma = 0.0675+0.0128∗ 25.4 – 9.26 * 10-5 * (25.4)2
Cma = 0.08
Ce = 1
(km)p = 1+(0.006642+0.08) = 0.92572
(km)g = 1+(0.025+0.08) = 0.92474
Geometry factor for bending strength
From shigley’s mechanical engineering design, 9th ed, figure 14-6
Jp = 0.4655
Jg = 0.4602
The bending stresses for gear and pinion are
Pinion

𝟕𝟗𝟔𝟕∗𝟏∗𝟏.𝟒𝟗𝟑𝟖𝟑∗𝟎.𝟗𝟐𝟓
σp = = 197.1 MPa
𝟑𝟎∗𝟒∗𝟎.𝟒𝟔𝟓𝟓
Gears

𝟕𝟗𝟔𝟕∗𝟏∗𝟏.𝟒𝟒𝟑∗𝟎.𝟗𝟐𝟒
σg = = 199.19 MPa
𝟑𝟎∗𝟒∗𝟎.𝟒𝟔𝟎𝟐

The contact stresses are given by

𝒌𝒎 𝒌
σ = Cp(Wt ko kv ks ∗ )
𝒅𝒑𝑭 𝑰
where, I is the surface strength geometry factor , given as

𝒄𝒐𝒔𝝓𝒕∗𝒔𝒊𝒏𝝓𝒕 𝑴𝒈
I= +( ) , Mg gear ratio = 2
𝟐𝑴𝒏 𝑴𝒈+𝟏

𝑃𝑛
Calculating for Mn , Mn = 0.95𝑍 , Pn = Π m cos Φn
Π*4*cos20 = 1.8025

Quantity, Z= [(rp+a)2-rbp2]1/2+[(rg+ra)2-rbg2]1/2-(rp+rg)sinϕt
Z = 17.853
𝟏𝟏.𝟖𝟎𝟐𝟓
Mn = = 𝟎. 𝟔𝟗𝟓
𝟏𝟕.𝟖𝟓𝟗∗𝟎.𝟗𝟓

𝒄𝒐𝒔𝟐𝟐.𝟖 𝒔𝒊𝒏𝟐𝟐.𝟖 𝟐
I= ( ) = 𝟎. 𝟏𝟑𝟎𝟖𝟓
𝟐(𝟎.𝟕𝟎𝟑) 𝟐+𝟏

Cp (Elastic coefficient)from the table 14-8 for pinion and gear both made of steel is , Cp = 191Mpa

Pinion
𝟎.𝟗𝟐𝟓 𝟏
σ = 191(7967*1*1.493 * ∗ )
𝟑𝟎∗𝟏𝟏𝟓.𝟒𝟕 𝟎.𝟏𝟑𝟎𝟖𝟓

σ =4636.23 Mpa
Gears
𝟎.𝟗𝟐𝟒 𝟏
σ = 191(7967*1 *1.494 * ∗ )
𝟑𝟎∗𝟏𝟐𝟎.𝟏 𝟎.𝟏𝟑𝟎𝟖

σ = 4457.37 Mpa
 Material Selection

Pinion: AISI 4140 steel with Hb = 510

Gear: AISI 1030 steel with Hb = 495

AGMA strength equations

Solving for the face-width necessary to resist wear and bending

𝒌𝒔 𝒌𝒎 𝒌𝒃 𝒌𝒕 𝒌𝒓
Fb = nd Wt ko kv
𝒎𝑱 𝒔𝒕 𝒀𝒏
𝑪𝒑 𝒁𝒏 𝒌𝒎 𝒌𝒃
FW = ( )𝟐 nd Wt ko kv ks
𝑺𝒄 𝑲𝒕 𝑲𝒓 𝒎𝑱
- St(allowable bending stress)
For grade 2, St = 0.703Hb + 113 Mpa
Pinion, St = 0.703(50) + 113 Mpa
= 471.53 Mpa
Gear, St = 0.703(49.5) + 113 Mpa
= 460.985 Mpa
-YN (stress cycle factor for bending stress) and ZN (stress cycle factor for constant stress)
For number of life cycle (N) taken as 109 cycles.
(YN)P = 0.93 (YN)g = 0.93
-Kt (temperature factor)
For To less than 120oc , Kt = 1
-KR (reliability factor)
We have taken reliability to be R = 0.95
KR = 0.884
-Take design factor of safety
nd = 1.25
𝟏.𝟐𝟓∗𝟕𝟗𝟔𝟕∗𝟏∗𝟏.𝟒𝟗𝟑∗𝟎.𝟗𝟐𝟓∗𝟎.𝟒𝟖𝟒
(Fb)p = = 12.0089 mm
𝟒∗𝟎.𝟒𝟔𝟓𝟓∗𝟒𝟕𝟏.𝟓𝟑∗𝟏𝟎𝟔 ∗𝟏
𝟏.𝟐𝟓∗𝟕𝟗𝟔𝟕∗𝟏.𝟒𝟗𝟒∗𝟎.𝟗𝟐𝟒∗𝟎.𝟒𝟖𝟒
(Fb)g = = 12.136 mm
𝟒∗𝟎𝟒𝟔𝟓𝟓∗𝟒𝟔𝟎.𝟗𝟖𝟓∗𝟏𝟎𝟔 ∗𝟏
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟗𝟑∗𝟎.𝟗𝟓
(Fw)p = 𝟏𝟒𝟔𝟔.𝟏∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*5860* = 19.796 mm
𝟕𝟖.𝟓𝟑∗𝟎𝟐𝟗
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟖𝟐∗𝟎.𝟗𝟓
(Fw)g = 𝟏𝟒𝟐𝟗.𝟓∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*5860* = 19.0216 mm
𝟕𝟖.𝟓𝟑∗𝟎.𝟑𝟕𝟏

-Sc for grade 2 steel

Sc = 2.22Hb+200Mpa
Pinion=> Sc = 1466.1 Mpa
Gear=> Sc = 1429.95 Mpa
Strength Analysis of Gears
Third gear-set

Pinion: dP = 143.183 mm Gear: dg = 92.37 mm

Np = 31 teeth Ng = 20 teeth
Wp = 1350 rpm Wg = 1298.08 rpm
AGMA Stress equation
The gear bending stress is given by:
𝟏 𝒌𝒎 ∗ 𝒌𝒃
𝑱 = 𝑾𝒕 ∗ 𝒌𝒐 ∗ 𝒌𝒗 ∗ 𝒌𝒔 ∗ ∗
𝒎𝑭 𝑱
Where Wt – tangential transmitted load
Ko- overload factor
Kv – dynamic factor
Ks- size factor
F – face width
m- module
km – load distribution
kb – rim thickness factor
J – Geometry factor
Wt (tangential transmitted load ) is given in the force analysis for the threshold gear-set as:
Wt = 6.425 kN/h
Overload factor (ko)
-Assuming uniform loading take ko = 1.5
Dynamic factor (kv)
𝑨+√𝟐𝟎𝟎𝑽 B
Kv =( )
𝑨

where B= 0.25 (12- Qv)2/3 and A = 50+56(1-B)

Qv is the transmission quality number (accuracy level) and for most commercial quality gears, it
ranges from 8-12
Take Qv = 12
B = 0.25(12-12)2/3 = 0 and A = 50+56(1-0) = 106
Tangential speed (v)
∏∗𝒅𝒑∗𝑾𝒑 𝟑.𝟏𝟒∗𝟏𝟒𝟑∗𝟐𝟕𝟎𝟎
V= = = 10.11 m/s
𝟔𝟎𝟎𝟎 𝟔𝟎𝟎𝟎𝟎
Therefore
𝟓𝟗.𝟕𝟕𝟑+√𝟐𝟎𝟎∗𝟏𝟏.𝟎𝟗𝟓 0
Kv =( )
𝟓𝟗.𝟕𝟕𝟑
Kv = 1
Size factor (ks)
√𝒚 0.535
Ks =𝟏. 𝟏𝟗𝟐 (𝑭 )
𝑷
Where F is face width = 25 mm
P is diametral pitch = 143.183

Y is the lewis form factor , from shigley ninth edition Table 14-2
The value of Yp(31 teeth) = 0.363
Yg(20 teeth) = 0.322

𝟐𝟓√𝟎.𝟑𝟔𝟑
(ks)p = 1.192 ( 𝟏𝟒𝟑.𝟏𝟖𝟑 ) = 𝟏. 𝟒𝟖𝟏
𝟑𝟎√𝟎.𝟑𝟐𝟐
(ks)g = 1.192 ( ) = 𝟏. 𝟒𝟕𝟕
𝟗𝟐.𝟑𝟕
Load distribution factor (km)

Km = 1+ Cmc ( Cpf Cpm + Cma Ce )

Where, Cmc = 1 , for uncrowned teeth
𝐹
Cpf = 10𝑑 − 0.0375 + 0.0125𝐹
𝐹
− 0.0375 + 0.0125 ∗ 28 = 0.006642 (for pinion)
10∗78.53
Cpf = 0.025 (for gear)
Cpm = 1.1 , for straddle mounted pinion
Cma = A+BF+CF2
The values of A,B and C are given at shigley 9th ed,
Table 14-9
A = 0.0675
B = 0.0128 for precision, enclosed units
-5
C = -9.3 * 10
25 25
Cma = 0.0675+0.0128∗ 25.4 – 9.26 * 10-5 * (25.4)2
Cma = 0.08
Ce = 1
(km)p = 1+(0.006642+0.08) = 0.94748
(km)g = 1+(0.025+0.08) = 0.924542
Geometry factor for bending strength
From shigley’s mechanical engineering design, 9th ed, figure 14-6
Jp = 0.4725
Jg = 0.4501
The bending stresses for gear and pinion are
Pinion

𝟔𝟒𝟐𝟓∗𝟏∗𝟏.𝟒𝟖𝟏𝟕𝟓∗𝟎.𝟗𝟒𝟕𝟒
σp = = 190.88 MPa
𝟐𝟓∗𝟒∗𝟎.𝟒𝟕𝟐𝟓
Gears

𝟔𝟒𝟐𝟓∗𝟏∗𝟏.𝟒𝟕𝟕∗𝟎.𝟗𝟐𝟒𝟓𝟒
σg = = 194.92 MPa
𝟐𝟓∗𝟒∗𝟎.𝟒𝟓𝟎𝟏

The contact stresses are given by

𝒌𝒎 𝒌
σ = Cp(Wt ko kv ks ∗ )
𝒅𝒑𝑭 𝑰
where, I is the surface strength geometry factor , given as

𝒄𝒐𝒔𝝓𝒕∗𝒔𝒊𝒏𝝓𝒕 𝑴𝒈
I= +( ) , Mg gear ratio = 2
𝟐𝑴𝒏 𝑴𝒈+𝟏

𝑃𝑛
Calculating for Mn , Mn = 0.95𝑍 , Pn = Π m cos Φn
Π*4*cos20 = 1.8025

Quantity, Z= [(rp+a)2-rbp2]1/2+[(rg+ra)2-rbg2]1/2-(rp+rg)sinϕt
Z = 17.7831
𝟏𝟏.𝟖𝟎𝟐𝟓
Mn = = 𝟎. 𝟔𝟗𝟖
𝟏𝟕.𝟖𝟓𝟗∗𝟎.𝟗𝟓

𝒄𝒐𝒔𝟐𝟐.𝟖 𝒔𝒊𝒏𝟐𝟐.𝟖 𝟐
I= ( ) = 𝟎. 𝟏𝟓𝟓𝟒
𝟐(𝟎.𝟕𝟎𝟑) 𝟐+𝟏

Cp (Elastic coefficient)from the table 14-8 for pinion and gear both made of steel is , Cp = 191Mpa

Pinion
𝟎.𝟗𝟒𝟕 𝟏
σ = 191(6425*1*1.482 * ∗ )
𝟐𝟓∗𝟏𝟒𝟑.𝟏𝟖𝟑 𝟎.𝟏𝟓𝟓𝟒

σ = 3096.15 Mpa
Gears
𝟎.𝟗𝟐𝟒𝟓𝟒 𝟏
σ = 191(6425*1 *1.477 * ∗ )
𝟐𝟓∗𝟗𝟐.𝟑𝟕 𝟎.𝟏𝟓𝟓𝟒

σ = 4669.72 Mpa
 Material Selection

Pinion: AISI 4140 steel with Hb = 510

Gear: AISI 1030 steel with Hb = 495

AGMA strength equations

Solving for the face-width necessary to resist wear and bending

𝒌𝒔 𝒌𝒎 𝒌𝒃 𝒌𝒕 𝒌𝒓
Fb = nd Wt ko kv
𝒎𝑱 𝒔𝒕 𝒀𝒏
𝑪𝒑 𝒁𝒏 𝒌𝒎 𝒌𝒃
FW = ( )𝟐 nd Wt ko kv ks
𝑺𝒄 𝑲𝒕 𝑲𝒓 𝒎𝑱
- St(allowable bending stress)
For grade 2, St = 0.703Hb + 113 Mpa
Pinion, St = 0.703(50) + 113 Mpa
= 471.53 Mpa
Gear, St = 0.703(49.5) + 113 Mpa
= 460.985 Mpa
-YN (stress cycle factor for bending stress) and ZN (stress cycle factor for constant stress)
For number of life cycle (N) taken as 109 cycles.
(YN)P = 0.93 (YN)g = 0.927
-Kt (temperature factor)
For To less than 120oc , Kt = 1
-KR (reliability factor)
We have taken reliability to be R = 0.95
KR = 0.884
-Take design factor of safety
nd = 1.25
𝟏.𝟐𝟓∗𝟔𝟒𝟐𝟓∗𝟏∗𝟏.𝟒𝟖𝟐∗𝟎.𝟗𝟒𝟕∗𝟎.𝟒𝟖𝟒
(Fb)p = = 9.686 mm
𝟒∗𝟎.𝟒𝟔𝟓𝟓∗𝟒𝟕𝟏.𝟓𝟑∗𝟏𝟎𝟔 ∗𝟏
𝟏.𝟐𝟓∗𝟓𝟖𝟔𝟎∗𝟏.𝟒𝟗𝟒∗𝟎.𝟗𝟐𝟒∗𝟎.𝟒𝟖𝟒
(Fb)g = = 9.890 mm
𝟒∗𝟎𝟒𝟔𝟓𝟓∗𝟒𝟔𝟎.𝟗𝟖𝟓∗𝟏𝟎𝟔 ∗𝟏
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟖𝟐∗𝟎.𝟗𝟓
(Fw)p = 𝟏𝟒𝟔𝟔.𝟏∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*6425* = 11.0058 mm
𝟕𝟖.𝟓𝟑∗𝟎𝟐𝟗
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟒𝟕∗𝟎.𝟗𝟓
(Fw)g = 𝟏𝟒𝟐𝟗.𝟓∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*6425* = 16.592 mm
𝟕𝟖.𝟓𝟑∗𝟎.𝟑𝟕𝟏

-Sc for grade 2 steel

Sc = 2.22Hb+200Mpa
Pinion=> Sc = 1466.1 Mpa
Gear=> Sc = 1429.95 Mpa
Strength Analysis of Gears
Reverse gear-set

Pinion: dP = 72 mm Gear: dg = 128

Np = 18 teeth Ng = 32 teeth
Wp = 1350 rpm Wg = 759.375 rpm
AGMA Stress equation
The gear bending stress is given by:
𝟏 𝒌𝒎 ∗ 𝒌𝒃
𝑱 = 𝑾𝒕 ∗ 𝒌𝒐 ∗ 𝒌𝒗 ∗ 𝒌𝒔 ∗ ∗
𝒎𝑭 𝑱
Where Wt – tangential transmitted load
Ko- overload factor
Kv – dynamic factor
Ks- size factor
F – face width
m- module
km – load distribution
kb – rim thickness factor
J – Geometry factor
Wt (tangential transmitted load ) is given in the force analysis for the threshold gear-set as:
Wt = 12.777 kN/h
Overload factor (ko)
-Assuming uniform loading take ko = 1.5
Dynamic factor (kv)
𝑨+√𝟐𝟎𝟎𝑽 B
Kv =( )
𝑨

where B= 0.25 (12- Qv)2/3 and A = 50+56(1-B)

Qv is the transmission quality number (accuracy level) and for most commercial quality gears, it
ranges from 8-12
Take Qv = 12
B = 0.25(12-12)2/3 = 0 and A = 50+56(1-0) = 106
Tangential speed (v)
∏∗𝒅𝒑∗𝑾𝒑 𝟑.𝟏𝟒∗𝟕𝟏𝟏𝟓.𝟖∗𝟐𝟕𝟎𝟎
V= = = 8.15 m/s
𝟔𝟎𝟎𝟎 𝟔𝟎𝟎𝟎𝟎
Therefore
𝟓𝟗.𝟕𝟕𝟑+√𝟐𝟎𝟎∗𝟏𝟏.𝟎𝟗𝟓 0
Kv =( )
𝟓𝟗.𝟕𝟕𝟑
Kv = 1
Size factor (ks)
√𝒚 0.535
Ks =𝟏. 𝟏𝟗𝟐 (𝑭 )
𝑷
Where F is face width = 60 mm
P is diametral pitch = 72

Y is the lewis form factor , from shigley ninth edition Table 14-2
The value of Yp(18 teeth) = 0.309
Yg(32 teeth) = 0.365

𝟑𝟎√𝟎.𝟑𝟎𝟗
(ks)p = 1.192 ( ) = 𝟏. 𝟓𝟒𝟔
𝟕𝟐
𝟑𝟎√𝟎.𝟑𝟔𝟓
(ks)g = 1.192 ( ) = 𝟏. 𝟓𝟓𝟑
𝟏𝟐𝟖
Load distribution factor (km)

Km = 1+ Cmc ( Cpf Cpm + Cma Ce )

Where, Cmc = 1 , for uncrowned teeth
𝐹
Cpf = 10𝑑 − 0.0375 + 0.0125𝐹
𝐹
− 0.0375 + 0.0125 ∗ 28 = 0.006642 (for pinion)
10∗78.53
Cpf = 0.025 (for gear)
Cpm = 1.1 , for straddle mounted pinion
Cma = A+BF+CF2
The values of A,B and C are given at shigley 9th ed,
Table 14-9
A = 0.0675
B = 0.0128 for precision, enclosed units
-5
C = -9.3 * 10
25 25
Cma = 0.0675+0.0128∗ 25.4 – 9.26 * 10-5 * (25.4)2
Cma = 0.08
Ce = 1
(km)p = 1+(0.006642+0.08) = 1.005376
(km)g = 1+(0.025+0.08) = 0.965272
Geometry factor for bending strength
From shigley’s mechanical engineering design, 9th ed, figure 14-6
Jp = 0.304
Jg = 0.365
The bending stresses for gear and pinion are
Pinion

𝟏𝟐𝟕𝟕𝟕∗𝟏∗𝟏.𝟓𝟒𝟔∗𝟏.𝟎𝟎𝟓𝟑
σp = = 272.017 MPa
𝟔𝟎∗𝟒∗𝟎.𝟑𝟎𝟒
Gears

𝟏𝟐𝟕𝟕𝟕∗𝟏∗𝟏.𝟓𝟓𝟑∗𝟎.𝟗𝟔𝟓
σg = = 218.586 MPa
𝟔𝟎∗𝟒∗𝟎.𝟑𝟔𝟓

The contact stresses are given by

𝒌𝒎 𝒌
σ = Cp(Wt ko kv ks ∗ )
𝒅𝒑𝑭 𝑰
where, I is the surface strength geometry factor , given as

𝒄𝒐𝒔𝝓𝒕∗𝒔𝒊𝒏𝝓𝒕 𝑴𝒈
I= +( ) , Mg gear ratio = 2
𝟐𝑴𝒏 𝑴𝒈+𝟏

𝑃𝑛
Calculating for Mn , Mn = 0.95𝑍 , Pn = Π m cos Φn
Π*4*cos20 = 1.8025

Quantity, Z= [(rp+a)2-rbp2]1/2+[(rg+ra)2-rbg2]1/2-(rp+rg)sinϕt
Z = 63.27
𝟏𝟏.𝟖𝟎𝟐𝟓
Mn = =𝟏
𝟏𝟕.𝟖𝟓𝟗∗𝟎.𝟗𝟓

𝒄𝒐𝒔𝟐𝟐.𝟖 𝒔𝒊𝒏𝟐𝟐.𝟖 𝟐
I= ( ) = 𝟎. 𝟏𝟎𝟐𝟎𝟔𝟖
𝟐(𝟎.𝟕𝟎𝟑) 𝟐+𝟏

Cp (Elastic coefficient)from the table 14-8 for pinion and gear both made of steel is , Cp = 191Mpa

Pinion
𝟏.𝟎𝟎𝟓𝟑 𝟏
σ = 191(12777*1*1.546 * ∗ )
𝟔𝟎∗𝟕𝟐 𝟎.𝟏𝟎𝟐𝟎𝟔𝟖

σ =8601.89 Mpa
Gears
𝟎.𝟗𝟔𝟓 𝟏
σ = 191(12777*1 *1.553 * ∗ )
𝟔𝟎∗𝟏𝟐𝟖 𝟎.𝟏𝟎𝟐𝟎𝟔𝟖

σ = 4665.62 Mpa
 Material Selection

Pinion: AISI 4140 steel with Hb = 510

Gear: AISI 1030 steel with Hb = 495

AGMA strength equations

Solving for the face-width necessary to resist wear and bending

𝒌𝒔 𝒌𝒎 𝒌𝒃 𝒌𝒕 𝒌𝒓
Fb = nd Wt ko kv
𝒎𝑱 𝒔𝒕 𝒀𝒏
𝑪𝒑 𝒁𝒏 𝒌𝒎 𝒌𝒃
FW = ( )𝟐 nd Wt ko kv ks
𝑺𝒄 𝑲𝒕 𝑲𝒓 𝒎𝑱
- St(allowable bending stress)
For grade 2, St = 0.703Hb + 113 Mpa
Pinion, St = 0.703(50) + 113 Mpa
= 471.53 Mpa
Gear, St = 0.703(49.5) + 113 Mpa
= 460.985 Mpa
-YN (stress cycle factor for bending stress) and ZN (stress cycle factor for constant stress)
For number of life cycle (N) taken as 109 cycles.
(YN)P = 0.93 (YN)g = 0.94
-Kt (temperature factor)
For To less than 120oc , Kt = 1
-KR (reliability factor)
We have taken reliability to be R = 0.95
KR = 0.884
-Take design factor of safety
nd = 1.25
𝟏.𝟐𝟓∗𝟏𝟐𝟕𝟕𝟕∗𝟏∗𝟏.𝟓𝟒𝟔∗𝟏.𝟎𝟎𝟓∗𝟎.𝟒𝟖𝟒
(Fb)p = = 38.27 mm
𝟒∗𝟎.𝟒𝟔𝟓𝟓∗𝟒𝟕𝟏.𝟓𝟑∗𝟏𝟎𝟔 ∗𝟏
𝟏.𝟐𝟓∗𝟓𝟖𝟔𝟎∗𝟏.𝟓𝟓𝟑∗𝟎.𝟗𝟔𝟓∗𝟎.𝟒𝟖𝟒
(Fb)g = = 30.745 mm
𝟒∗𝟎𝟒𝟔𝟓𝟓∗𝟒𝟔𝟎.𝟗𝟖𝟓∗𝟏𝟎𝟔 ∗𝟏
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟗𝟑∗𝟎.𝟗𝟓
(Fw)p = 𝟏𝟒𝟔𝟔.𝟏∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*12777* = 73.37 mm
𝟕𝟖.𝟓𝟑∗𝟎𝟐𝟗
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟖𝟐∗𝟎.𝟗𝟓
(Fw)g = 𝟏𝟒𝟐𝟗.𝟓∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*12777* = 39.804 mm
𝟕𝟖.𝟓𝟑∗𝟎.𝟑𝟕𝟏

-Sc for grade 2 steel

Sc = 2.22Hb+200Mpa
Pinion=> Sc = 1466.1 Mpa
Gear=> Sc = 1429.95 Mpa
Strength Analysis of Gears
Idle gear-set

Pinion: dP = 96 mm Gear: dg = 96 mm
Np = 24 teeth Ng = 24 teeth
Wp = 1743.75 Wg = 1012.5 rpm
AGMA Stress equation
The gear bending stress is given by:
𝟏 𝒌𝒎 ∗ 𝒌𝒃
𝑱 = 𝑾𝒕 ∗ 𝒌𝒐 ∗ 𝒌𝒗 ∗ 𝒌𝒔 ∗ ∗
𝒎𝑭 𝑱
Where Wt – tangential transmitted load
Ko- overload factor
Kv – dynamic factor
Ks- size factor
F – face width
m- module
km – load distribution
kb – rim thickness factor
J – Geometry factor
Wt (tangential transmitted load ) is given in the force analysis for the threshold gear-set as:
Wt = 17.232 kN/h
Overload factor (ko)
-Assuming uniform loading take ko = 1.5
Dynamic factor (kv)
𝑨+√𝟐𝟎𝟎𝑽 B
Kv =( )
𝑨

where B= 0.25 (12- Qv)2/3 and A = 50+56(1-B)

Qv is the transmission quality number (accuracy level) and for most commercial quality gears, it
ranges from 8-12
Take Qv = 12
B = 0.25(12-12)2/3 = 0 and A = 50+56(1-0) = 106
Tangential speed (v)
∏∗𝒅𝒑∗𝑾𝒑 𝟑.𝟏𝟒∗𝟕𝟏𝟏𝟓.𝟖∗𝟐𝟕𝟎𝟎
V= = = 8.678 m/s
𝟔𝟎𝟎𝟎 𝟔𝟎𝟎𝟎𝟎
Therefore
𝟓𝟗.𝟕𝟕𝟑+√𝟐𝟎𝟎∗𝟏𝟏.𝟎𝟗𝟓 0
Kv =( )
𝟓𝟗.𝟕𝟕𝟑
Kv = 1
Size factor (ks)
√𝒚 0.535
Ks =𝟏. 𝟏𝟗𝟐 (𝑭 )
𝑷
Where F is face width = 60 mm
P is diametral pitch = 72

Y is the lewis form factor , from shigley ninth edition Table 14-2
The value of Yp(18 teeth) = 0.337
Yg(32 teeth) = 0.3039

𝟔𝟎√𝟎.𝟑𝟑𝟕
(ks)p = 1.192 ( ) = 𝟏. 𝟓𝟒𝟗
𝟗𝟔
𝟔𝟎√𝟎.𝟑𝟎𝟑𝟗
(ks)g = 1.192 ( ) = 𝟏. 𝟓𝟒𝟓
𝟗𝟔
Load distribution factor (km)

Km = 1+ Cmc ( Cpf Cpm + Cma Ce )

Where, Cmc = 1 , for uncrowned teeth
𝐹
Cpf = 10𝑑 − 0.0375 + 0.0125𝐹
𝐹
− 0.0375 + 0.0125 ∗ 28 = 0.006642 (for pinion)
10∗78.53
Cpf = 0.025 (for gear)
Cpm = 1.1 , for straddle mounted pinion
Cma = A+BF+CF2
The values of A,B and C are given at shigley 9th ed,
Table 14-9
A = 0.0675
B = 0.0128 for precision, enclosed units
-5
C = -9.3 * 10
25 25
Cma = 0.0675+0.0128∗ 25.4 – 9.26 * 10-5 * (25.4)2
Cma = 0.08
Ce = 1
(km)p = 1+(0.006642+0.08) = 0.9824
(km)g = 1+(0.025+0.08) = 0.9824
Geometry factor for bending strength
From shigley’s mechanical engineering design, 9th ed, figure 14-6
Jp = 0.335
Jg = 0.346
The bending stresses for gear and pinion are
Pinion

𝟏𝟕𝟐𝟑𝟐∗𝟏∗𝟏.𝟓𝟒𝟗∗𝟎.𝟗𝟖𝟐𝟒
σp = = 326.15 MPa
𝟔𝟎∗𝟒∗𝟎.𝟑𝟑𝟓
Gears

𝟏𝟕𝟐𝟑𝟐∗𝟏∗𝟏.𝟓𝟒𝟓∗𝟎.𝟗𝟖𝟐𝟒
σg = = 314.96 MPa
𝟔𝟎∗𝟒∗𝟎.𝟑𝟒𝟔

The contact stresses are given by

𝒌𝒎 𝒌
σ = Cp(Wt ko kv ks ∗ )
𝒅𝒑𝑭 𝑰
where, I is the surface strength geometry factor , given as

𝒄𝒐𝒔𝝓𝒕∗𝒔𝒊𝒏𝝓𝒕 𝑴𝒈
I= +( ) , Mg gear ratio = 2
𝟐𝑴𝒏 𝑴𝒈+𝟏

𝑃𝑛
Calculating for Mn , Mn = 0.95𝑍 , Pn = Π m cos Φn
Π*4*cos20 = 1.8025

Quantity, Z= [(rp+a)2-rbp2]1/2+[(rg+ra)2-rbg2]1/2-(rp+rg)sinϕt
Z = 120
𝟏𝟏.𝟖𝟎𝟐𝟓
Mn = =𝟏
𝟏𝟕.𝟖𝟓𝟗∗𝟎.𝟗𝟓

𝒄𝒐𝒔𝟐𝟐.𝟖 𝒔𝒊𝒏𝟐𝟐.𝟖 𝟐
I= ( ) = 𝟎. 𝟏𝟎𝟐𝟎𝟔𝟖
𝟐(𝟎.𝟕𝟎𝟑) 𝟐+𝟏

Cp (Elastic coefficient)from the table 14-8 for pinion and gear both made of steel is , Cp = 191Mpa

Pinion
𝟏.𝟎𝟎𝟓𝟑 𝟏
σ = 191(12777*1*1.546 * ∗ )
𝟔𝟎∗𝟕𝟐 𝟎.𝟏𝟎𝟐𝟎𝟔𝟖

σ =8601.89 Mpa
Gears
𝟎.𝟗𝟔𝟓 𝟏
σ = 191(12777*1 *1.553 * ∗ )
𝟔𝟎∗𝟏𝟐𝟖 𝟎.𝟏𝟎𝟐𝟎𝟔𝟖

σ = 4665.62 Mpa
 Material Selection

Pinion: AISI 4140 steel with Hb = 510

Gear: AISI 1030 steel with Hb = 495

AGMA strength equations

Solving for the face-width necessary to resist wear and bending

𝒌𝒔 𝒌𝒎 𝒌𝒃 𝒌𝒕 𝒌𝒓
Fb = nd Wt ko kv
𝒎𝑱 𝒔𝒕 𝒀𝒏
𝑪𝒑 𝒁𝒏 𝒌𝒎 𝒌𝒃
FW = ( )𝟐 nd Wt ko kv ks
𝑺𝒄 𝑲𝒕 𝑲𝒓 𝒎𝑱
- St(allowable bending stress)
For grade 2, St = 0.703Hb + 113 Mpa
Pinion, St = 0.703(50) + 113 Mpa
= 471.53 Mpa
Gear, St = 0.703(49.5) + 113 Mpa
= 460.985 Mpa
-YN (stress cycle factor for bending stress) and ZN (stress cycle factor for constant stress)
For number of life cycle (N) taken as 109 cycles.
(YN)P = 0.93 (YN)g = 0.94
-Kt (temperature factor)
For To less than 120oc , Kt = 1
-KR (reliability factor)
We have taken reliability to be R = 0.95
KR = 0.884
-Take design factor of safety
nd = 1.25
𝟏.𝟐𝟓∗𝟏𝟐𝟕𝟕𝟕∗𝟏∗𝟏.𝟓𝟒𝟔∗𝟏.𝟎𝟎𝟓∗𝟎.𝟒𝟖𝟒
(Fb)p = = 38.27 mm
𝟒∗𝟎.𝟒𝟔𝟓𝟓∗𝟒𝟕𝟏.𝟓𝟑∗𝟏𝟎𝟔 ∗𝟏
𝟏.𝟐𝟓∗𝟓𝟖𝟔𝟎∗𝟏.𝟓𝟓𝟑∗𝟎.𝟗𝟔𝟓∗𝟎.𝟒𝟖𝟒
(Fb)g = = 30.745 mm
𝟒∗𝟎𝟒𝟔𝟓𝟓∗𝟒𝟔𝟎.𝟗𝟖𝟓∗𝟏𝟎𝟔 ∗𝟏
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟗𝟑∗𝟎.𝟗𝟓
(Fw)p = 𝟏𝟒𝟔𝟔.𝟏∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*12777* = 73.37 mm
𝟕𝟖.𝟓𝟑∗𝟎𝟐𝟗
𝟏𝟗𝟏∗𝟏 𝟏∗𝟏.𝟒𝟖𝟐∗𝟎.𝟗𝟓
(Fw)g = 𝟏𝟒𝟐𝟗.𝟓∗𝟏𝟎 𝟔 ∗𝟎.𝟒𝟖𝟒 ∗ 𝟏. 𝟐𝟓*12777* = 39.804 mm
𝟕𝟖.𝟓𝟑∗𝟎.𝟑𝟕𝟏

-Sc for grade 2 steel

Sc = 2.22Hb+200Mpa
Pinion=> Sc = 1466.1 Mpa
Gear=> Sc = 1429.95 Mpa
 Shaft Force Analysis

First Gear Engagement

X-Y Plane
∑ 𝐹 y = Ray + Rby - 2.46 - 4.41 = 0

Ray + Rby = 6.87

(∑ 𝑀a)Z = 0 = (Rby * 305) – (2.46*27.5) – (4.41*265) – (3.38*7.85) + (6.05*43.85) = 0

Rby = 4.14 KN
Ray = 2.729 KN

X-Z Plane
∑ 𝐹 z = Raz + Rbz + 5.86 – 10.98 = 0

Raz + Rbz = 5.12

(∑ 𝑀a)y = 0 = (Rbz * 362) – (5.86*27.5) – (10.98*324.5) = 0

Rby = -8.94KN
Ray = 4.32 KN
X-Y PLANE

SHEAR DIAGRAM
4
2.729959 2.729959
3

2
0.269959
1 0.269959
0
0
0 50 100 150 200 250 300 350 400
-1

-2

-3
-4.140041 -4.14004
-4

-5

MOMENT DIAGRAM
200
155.2515539
150

100 75.0738605

50
0 0
0
0 50 100 150 200 250 300 350 400
-50
-110.0784461
-100

-150 -190.2561395

-200

-250
X- Z PLANE

SHEAR DIAGRAM
10 8.949199

8 8.949199
4.329199
6
4.329199
4

2 0

0
0 50 100 150 200 250 300 350 400
-2
-1.530801 -1.530801
-4

MOMENT DIAGRAM
200
119.0529696
100
0 0
0
0 50 100 150 200 250 300 350 400
-100

-200

-300
-335.5949586
-335.5949586
-400
 COMBINED

X-Y PLANE
400

350

300

250

200

150

100

50

0
0 50 100 150 200 250 300 350 400
 Second Gear Engagement

X-Y Plane
∑ 𝐹 y = Ray + Rby - 2.46 – 3.35 = 0

Ray + Rby = 5.81

(∑ 𝑀a)Z = 0 = (Rby * 362) – (2.46*27.5) – (3.35*159.5) – (3.38*7.85) + (4.6*57.74) = 0

Rby = 1.454 KN
Ray = 4.335 KN

X-Z Plane
∑ 𝐹 z = Raz + Rbz + 5.86 – 7.94 = 0

Raz + Rbz = 2.11

(∑ 𝑀a)y = 0 = (Rbz * 159.5) – (5.86*27.5) – (7.97*150) = 0

Rbz = -2.5711KN
Raz = 0.4611 KN
X-Y PLANE

SHEAR DIAGRAM
5

0
0 50 100 150 200 250 300 350 400
-1

-2

Chart Title
400

300

200

100

0
0 50 100 150 200 250 300 350 400
-100

-200
X-Z PLANE

Chart Title
3

0
0 50 100 150 200 250 300 350 400
-1

-2

-3

-4

-5

-6

Chart Title
100

0
0 50 100 150 200 250 300 350 400
-100

-200

-300

-400

-500

-600

-700
 COMBINED

Chart Title
700

600

500

400

300

200

100

0
0 50 100 150 200 250 300 350 400
 Third Gear Engagement

X-Y Plane
∑ 𝐹 y = Ray + Rby - 2.46 – 2.7 = 0

Ray + Rby = 5.16

(∑ 𝑀a)Z = 0 = (Rby * 362) – (2.46*27.5) – (3.35*159.5) – (3.38*7.85) + (4.6*57.74) = 0

Rby = 0.966298 KN
Ray = 4.1937 KN

X-Z Plane
∑ 𝐹 z = Raz + Rbz + 5.86 – 6.42 = 0

Raz + Rbz = 0.56

(∑ 𝑀a)y = 0 = (Rbz * 159.5) – (5.86*27.5) – (7.97*150) = 0

Rbz = -1.408KN
Raz = 0.84812 KN
X-Y Plane

SHEAR DIAGRAM
5

0
0 50 100 150 200 250 300 350 400
-1

-2

MOMENT DIAGRAM
300
250
200
150
100
50
0
0 50 100 150 200 250 300 350 400
-50
-100
-150
-200
 X-Z PLANE

SHEAR DIAGRAM
2

0
0 50 100 150 200 250 300 350 400
-1

-2

-3

-4

-5

-6

MOMENT DIAGRAM
50

0
0 50 100 150 200 250 300 350 400
-50

-100

-150

-200

-250

-300

-350

-400
 COMBINED

COMBINED
500

450

400

350

300

250

200

150

100

50

0
0 50 100 150 200 250 300 350 400
 Reverse Gear Engagement

X-Y Plane
∑ 𝐹 y = Ray + Rby - 2.46 – 4.65 = 0

Ray + Rby = 7.11

(∑ 𝑀a)Z = 0 = (Rby * 362) – (2.46*27.5) – (3.35*159.5) – (3.38*7.85) + (4.6*57.74) = 0

Rby = 2.0294 KN
Ray = 5.0805 KN

X-Z Plane
∑ 𝐹 z = Raz + Rbz + 12.78 – 5.86 = 0

Raz + Rbz = 6.92

(∑ 𝑀a)y = 0 = (Rbz * 159.5) – (5.86*27.5) – (7.97*150) = 0

Rbz = -6.6332KN
Raz = 0.2867 KN
 X-Y PLANE

SHEAR DIAGRAM
6

0
0 50 100 150 200 250 300 350 400
-1

-2

-3

MOMENT DIAGRAM
400
350
300
250
200
150
100
50
0
-50 0 50 100 150 200 250 300 350 400

-100
-150
 X-Z PLANE

SHEAR DIAGRAM
8

0
0 50 100 150 200 250 300 350 400
-2

-4

-6

-8

MOMENT DIAGRAM
0
0 50 100 150 200 250 300 350 400
-200

-400

-600

-800

-1000

-1200
 COMBINED

Chart Title
1200

1000

800

600

400

200

0
0 50 100 150 200 250 300 350 400
 Shaft Force Analysis

OUTPUT SHAFT

First Gear Engagement

X-Y Plane
∑ 𝐹 y = Ray + Rby = -4.41

(∑ 𝑀a)Z = 0 = (Rby * 275) – (4.41*237.5) + (6.05*43.85) = 0

Rby = -4.704 KN
Ray = 0.2948 KN
X-Z Plane
∑ 𝐹 z = Raz + Rbz = -10.98

(∑ 𝑀a)y = 0 = (Rbz *275) +(10.98*237.5) = 0

Rby = -9.3207 KN
Ray = -1.15929 KN

RA = (R2 AZ + R2 BZ)1/2
= ((-1.5)2 + (-9.48)2)1/2 = 1.19260 KN

RB = (R2 BY + R2 BZ)1/2
= ((-5.43)2 + (-9.48)2)1/2 = 10.4408 KN
 X-Y PLANE

Chart Title
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
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Chart Title
150

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 X-Z PLANE

Chart Title
10

0
0 50 100 150 200 250 300 350 400
-2

Chart Title
0
0 50 100 150 200 250 300 350 400
-50

-100

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-400
 COMBINED

Chart Title
450

400

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150

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0
0 50 100 150 200 250 300 350 400
First Gear Engagement

X-Y Plane
∑ 𝐹 y = Ray + Rby = -3.35

(∑ 𝑀a)Z = 0 = (Rby * 275) – (3.35*237.5) + (4.16*43.85) = 0

Rby = -1.84006 KN
Ray = -1.50994KN
X-Z Plane
∑ 𝐹 z = Raz + Rbz = -10.98

(∑ 𝑀a)y = 0 = (Rbz *275) +(10.98*237.5) = 0

Rbz = 3.1167 KN
Raz = 5.5953 KN
 X-Y PLANE

Chart Title
2.5

1.5

0.5

0
0 50 100 150 200 250 300 350 400
-0.5

-1

-1.5

-2

Chart Title
0
0 50 100 150 200 250 300 350 400
-50

-100

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 X-Z PLANE

Chart Title
3

0
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Chart Title
0
0 50 100 150 200 250 300 350 400
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 COMBINED

Chart Title
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 Third Gear Engagement

X-Y Plane
∑ 𝐹 y = Ray + Rby = -2.7

(∑ 𝑀a)Z = 0 = (Rby * 275) – (2.7*237.5) + (3.71*43.85) = 0

Rby = -1.37605 KN
Ray = -1.32395 KN
X-Z Plane
∑ 𝐹 z = Raz + Rbz = -6.42

(∑ 𝑀a)y = 0 = (Rbz *275) +(6.42*237.5) = 0

Rbz = -1.41088 KN
Raz = -5.00912 KN
 X-Y PLANE

Chart Title
2

1.5

0.5

0
0 50 100 150 200 250 300 350 400
-0.5

-1

-1.5

Chart Title
0
0 50 100 150 200 250 300 350 400
-50

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 X-Z PLANE

Chart Title
2

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0 50 100 150 200 250 300 350 400
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 COMBINED

Chart Title
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 Reverse Gear Engagement

X-Y Plane
∑ 𝐹 y = Ray + Rby = -4.65

(∑ 𝑀a)Z = 0 = (Rby * 275) – (4.65*237.5) = 0

Rby = -2.3387 KN
Ray = -2.3112 KN
X-Z Plane
∑ 𝐹 z = Raz + Rbz = -12.78

(∑ 𝑀a)y = 0 = (Rbz *257) +(12.78*157.5) = 0

Rbz = -6.4277 KN
Raz = -6.3523 KN
 X-Y PLANE

Chart Title
3

0
0 50 100 150 200 250 300 350 400
-1

-2

-3

Chart Title
450
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 X-Z PLANE

Chart Title
8

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-2

-4

-6

-8

Chart Title
0
0 50 100 150 200 250 300 350 400
-200

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 COMBINED

Chart Title
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1200

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 Shaft Strength Analysis
Counter shaft
The critical engagement with a high loading and maximum bending moment on the counter shaft, which
in our case is the reverse gear engagement.

For a rotating shaft the constant bending moment will create a completely reversed bending stress.

Mmax = 935.6 Nm and Mmin = -935.6 Nm

The counter shaft has a steady torque of T = 460 Nm

Endurance limit at the critical location.

Se = ka*kb*kc*kd*ke*kf*(S’e)

- ka :- Surface condition modification factor

ka = a (Sut)b :- from table 6-2, shigley’s machine design, 9th edition

- for machined or cold-drawn surfaces
a = 4.51 and b = -0.265

ka = 4.51 (Sut)-0.265
ka = 4.51 (848)-0.265 :- Sut from material property of AISI 1030 Q&T : Sut = 848 Mpa
ka = 0.755

kb :- size modification factor

Take kb = 0.9, it will be checked once dmin is known
kc :- loading factor
kc = 1 for bending
kd :- temperature factor
kd = 1, since we have taken a temperature corrected tensile strength
ke :- reliability factor
Taking reliability R = 95%, ke = 0.868
kf :- Miscellaneous effects factor
kf = 1 =kfs
 S’e ;- Rotatory beam test specimen endurance limit
For Sut < 1400 Mpa, S’e = 0.5 * Sut
= 0.5*848
S’e =424 Mpa

Se = 0.755*0.9*0.868*424
Se = 250.08 Mpa

-Now let’s find the minimum diameter using DE – Goodman criteria

16𝑛 𝑘𝑓𝑀𝑒 2 𝑘𝑓𝑠𝑇𝑎 2 𝑘𝑓𝑀𝑚𝑖𝑛 2 𝑘𝑓𝑠𝑇𝑚 2 1/2 1/3

dmin = { [4 ( ) + 3( ) + 4( ) + 3( ) ] }
𝜋 𝑆𝑒 𝑆𝑒 𝑆𝑢𝑡 𝑆𝑢𝑡

16𝑛 𝑘𝑓𝑀𝑒 2 𝑘𝑓𝑠𝑇𝑚 2 1/2 1/3

dmin = { [4 ( ) + 3( ) ] } take n = 1.5
𝜋 𝑆𝑒 𝑆𝑢𝑡

16∗1.5 935.6 2 460 2

dmin = {
𝜋
[4 (
250.08
) + 3 (848) ]1/2 }1/3

dmin = 38.62 mm
:- Take d = 40 mm

Check for size modification factor, kb

𝒅 𝟒𝟎 −𝟎.𝟏𝟎𝟕
kb = ( )−𝟎.𝟏𝟎𝟕 = ( ) = 0.836
𝟕.𝟔𝟐 𝟕.𝟔𝟐

Se = 0.755 * 0.836*0.868*424
Se =232.3 Mpa

16∗1.5 935.6 2 460 2

dmin = {
𝜋
[4 (
232.3
) + 3 (848) ]1/2 }1/3

d = 40.96 mm
 𝟑𝟐∗𝒌𝒇∗𝑴𝒂 𝟑𝟐∗𝟗𝟑𝟓.𝟔
σ ’r = =
𝝅𝒅𝟑 𝝅𝟎.𝟎𝟒𝟑

σ’r = 148.91

𝟗𝟑𝟓.𝟔 𝟐 𝟒𝟔𝟎 𝟐
σ’m= [𝟒 ( ) + 𝟑 (𝟖𝟒𝟖) ]𝟏/𝟐
𝟐𝟑𝟐.𝟑

σ’m = 73.91 Mpa

The safety factor using Goodman criterion:-

𝟏 𝛔𝐚 𝛔𝐦’ 𝟏𝟒𝟖. 𝟗𝟏 𝟕𝟑. 𝟗𝟏

= + = +
𝒏𝒇 𝑺𝒆 𝑺𝒖𝒕 𝟐𝟑𝟐. 𝟑 𝟖𝟒𝟖

nf = 1.56
 Shaft Strength Analysis
Output shaft
The critical engagement with a high loading and maximum bending moment on the output shaft,
For a rotating shaft the constant bending moment will create a completely reversed bending stress.

Mmax = 817.78 Nm and Mmin = -817.78 Nm

The output shaft has a steady torque of Tm = 708.8 Nm

Endurance limit at the critical location.

Se = ka*kb*kc*kd*ke*kf*(S’e)

- ka :- Surface condition modification factor

ka = a (Sut)b :- from table 6-2, shigley’s machine design, 9th edition

- for machined or cold-drawn surfaces
a = 4.51 and b = -0.265

ka = 4.51 (Sut)-0.265
ka = 4.51 (848)-0.265 :- Sut from material property of AISI 1030 Q&T : Sut = 848 Mpa
ka = 0.755

kb :- size modification factor

Take kb = 0.84, it will be checked once dmin is known
kc :- loading factor
kc = 1 for bending
kd :- temperature factor
kd = 1, since we have taken a temperature corrected tensile strength
ke :- reliability factor
Taking reliability R = 95%, ke = 0.868
kf :- Miscellaneous effects factor
kf = 1 =kfs
 S’e ;- Rotatory beam test specimen endurance limit
For Sut < 1400 Mpa, S’e = 0.5 * Sut
= 0.5*848
S’e =424 Mpa

Se = 0.755*0.9*0.868*424
Se = 235.6 Mpa

-Now let’s find the minimum diameter using DE – Goodman criteria

16𝑛 𝑘𝑓𝑀𝑒 2 𝑘𝑓𝑠𝑇𝑎 2 𝑘𝑓𝑀𝑚𝑖𝑛 2 𝑘𝑓𝑠𝑇𝑚 2 1/2 1/3

dmin = { [4 ( ) + 3( ) + 4( ) + 3( ) ] }
𝜋 𝑆𝑒 𝑆𝑒 𝑆𝑢𝑡 𝑆𝑢𝑡

16𝑛 𝑘𝑓𝑀𝑒 2 𝑘𝑓𝑠𝑇𝑚 2 1/2 1/3

dmin = { [4 ( ) + 3( ) ] } take n = 1.5
𝜋 𝑆𝑒 𝑆𝑢𝑡

16∗1.5 935.6 2 460 2

dmin = { [4 ( ) + 3 ( ) ]1/2 }1/3
𝜋 250.08 848

dmin = 38.62 mm
:- Take d = 40 mm

Check for size modification factor, kb

𝒅 𝟒𝟎 −𝟎.𝟏𝟎𝟕
kb = ( )−𝟎.𝟏𝟎𝟕 = ( ) = 0.836
𝟕.𝟔𝟐 𝟕.𝟔𝟐

Se = 0.755 * 0.836*0.868*424
Se =232.3 Mpa

16∗1.5 935.6 2 460 2

dmin = {
𝜋
[4 (
232.3
) + 3 (848) ]1/2 }1/3

d = 40.96 mm
 𝟑𝟐∗𝒌𝒇∗𝑴𝒂 𝟑𝟐∗𝟗𝟑𝟓.𝟔
σ ’r = =
𝝅𝒅𝟑 𝝅𝟎.𝟎𝟒𝟑

σ’r = 148.91

𝟗𝟑𝟓.𝟔 𝟐 𝟒𝟔𝟎 𝟐
σ’m= [𝟒 ( ) + 𝟑 (𝟖𝟒𝟖) ]𝟏/𝟐
𝟐𝟑𝟐.𝟑

σ’m = 73.91 Mpa

The safety factor using Goodman criterion:-

𝟏 𝛔𝐚 𝛔𝐦’ 𝟏𝟒𝟖. 𝟗𝟏 𝟕𝟑. 𝟗𝟏

= + = +
𝒏𝒇 𝑺𝒆 𝑺𝒖𝒕 𝟐𝟑𝟐. 𝟑 𝟖𝟒𝟖

nf = 1.56
v