A motor shaft rotating at 1440 rpm has to transmit 15 kW to a low speed shaft rotating at 500

rpm. The teeth are 200 involute with 25 teeth on the pinion. Both the pinion and gear are made
of cast iron with a maximum safe strees of 56 MPa. A safe stress of 35 MPa may be taken for the
shaft on which the gear is mounted. Design and sketch the spur gear drive to suit the above
conditions. The starting torque may be assumed as 1,25 times the running torque.
Material : Cast iron, ordinary (table 28.4)

Assuming The distances between the centre line of bearings and gear are 100 mm each.
The starting torque may be assumed as 1,25 times the running torque.
Np = 1440 rpm
P = 15 kW
𝑁2 = 500 rpm
Ф = 200
𝑇𝑝 = 25
𝜎0𝐺 = 56 MPa = 56 𝑁⁄𝑚𝑚2
𝜎0𝑝 = 56 MPa = 56 𝑁⁄𝑚𝑚2

𝜏 = 35 MPa = 35 𝑁⁄𝑚𝑚2

module :
M = module ( mm )
Dp = pitch circle diameter of the pinion in mm
We know velocity :
𝜋 . 𝐷𝑝 . 𝑁𝑝 𝜋𝑚 . 𝑇𝑝 . 𝑁𝑝 𝜋𝑚 .25 .1440
V= = =
60 60 60

= 1884,95 𝑚 . 𝑚𝑚⁄𝑠
 = 1,884 𝑚 . 𝑚⁄𝑠
Assuming steady load conditious and 8 – 10 hours of service per day, the service factor ( 𝐶𝑠 )
from table 28.10 given by 𝐶𝑠 = 1

We know that the design tangential tooth load,

𝑃 15 𝑥 103 7,96 𝑥 103
W T = 𝑉 𝑥 𝐶𝑠 = 𝑥1= 𝑁
1,884 𝑚 𝑚

3
And velocity factor = C V = 3+1,884 𝑚 = 0,614

We know that tooth form factor for pinion :

0,912 0,912
𝑦𝑝 = 0,154 − = 0,154 − = 0,117
𝑇𝑝 25

𝜎0𝑝 x 𝑦𝑝 = 56 × 0,117 = 6,52

And tooth form factor for gear

0,912 0,912
𝑦𝐺 = 0,154 − = 0,154 − = 0,141
𝑇𝐺 2,88 𝑥 25

𝜎0𝐺 x 𝑦𝐺 = 56 x 0,141 = 7,89

Since ( 𝜎0𝐺 x 𝑦𝐺 ) , therefore the gear is meaker. Now using the lewis equation to the gear, we
have
Since is 𝜎0𝑝 x 𝑦𝑝 less than 𝜎0𝐺 x 𝑦𝐺 therefore the pinion is weaker. Now using the Lewis
equation to the pinion, we have
assuming face width is 14 times the module.
W T = (𝜎0𝑝 x CV ) . G . π m . 𝑦𝑝
7,96 𝑥 103 3 864,51 𝑚2
= [ 56 𝑥 (3+1,884 𝑚) ] x 14 m x π m x 0,117 = 3𝑥 1,884 𝑚
𝑚

864,51 𝑚3 = ( 3 + 1,884 m ) x 7,96 x 103

0,108 𝑚3 = 3 + 1,884 m
 0,108 𝑚3 – 1,884 m – 3 = 0
m = 4,81 mm ≈ 5 mm

Design for spur gear

We know that the gear reduction ratio ( 28.2), Assumsing the gear reduction ratio (TG / TP) is 3.
𝑇𝐺 = 3 x 𝑇𝑝 = 3 x 25 = 75

Since the starting torque is 1,25 times the running torque, there fore the spur gear should
be designed for power :
𝑃1 = 1,25 P = 1,25 x 15 x 103 = 18750 N
Let us assume that the module ( m ) for the pinion and gear is 5 mm :
Pitch circle diameter of the pinion :
𝐷𝑝 = m . 𝑇𝑝 = 5 x 25 = 125 mm = 0,125 m = 125 mm

and pitch circle diameter of gear

𝐷𝐺 = m . 𝑇𝐺 = 5 x 75 = 375 mm = 0,375 m= 360 mm

𝜋 . 𝐷𝑝 . 𝑁𝑝 𝜋 𝑥 0,125 𝑥 1440
V= = = 9,42 𝑚⁄𝑠
60 60
𝑃1 18750
Wt= x 𝐶𝑠 = 𝑥1 = 1990,445 𝑁
𝑉 9,42
We know that ordinary cut gears and operating at velocities lees to 12,5 m/s the velocity factors
3
Cv =3+9,42 = 0,24

Since both the pinion and the gear are made of the same material therefore
0,912
Y=0,154 − 𝑇
0,912
=0,154 − = 0,117
25

Let G = face width for both the pinion and gear , we know that the design tangensial tooth load
𝑊𝑇 𝑊𝑇 = (𝜏𝑜 𝑮 𝑪𝒗 𝞹 𝒎 𝒚𝒑)

1990,445 N = (56 0,24) G ×𝝿×5×0,117

1990,45 N = 24,70 G
1990,45
G= = 80,58 ~ 81 𝑚𝑚
24,70

b = 6×m = 6×5= 30 mm

From table 28.1 for the pinion and the gear having 20˚ Involute teeth :

1. Addendum =1m = 1×5 = 5mm

2. Dedendum = 1,25m = 1,25×5 = 6,25mm
3. Working depth = 2m = 2×5 = 10 mm
4. Tooth thickness = 1,5708m = 1,5708×5 = 7,854 mm
5. Maksimum clearance = 0,25m = 0,25×5 = 1,25 mm
6. Fillet Radius at root = 0,4 m = 0,4 × 5 = 2 mm
7. Minimum total depth = 2,25 m = 2,25×5 = 11,25 mm
Design of the shaft
d = Diameter of the shaft.
We know that torque transmitted by the shaft,
𝑃×60 15000×60
T= 2𝜋×𝑁 = = 99,47 𝑁𝑚 = 99,47 ×10³ Nmm
2𝜋×1440

We also know that torque transmitted by the shaft ( T )

𝜋 𝜋
99,47 ×10³ = 16 × 𝜏 × 𝑑³ = 16 × 35 × 𝑑³

6,87 d³ = 99,47 × 10³

D = 24,37 mm ~ 25 mm
Design for the pinion shaft
Assumsing The distances between the centre line of bearings and gear are 150 mm each.
We know that the normal load acting between the tooth surfaces,
𝑊𝑇 1990,45
WN = cos 𝜃 = = 2118,19 𝑁
cos 20

and weight of the pinion,

WP = 0.00118 TP.b m2 = 0.001 18 × 25 × 30 × 52 = 22,125 N
Resultant load acting on the pinion,

Wr = √(𝑊𝑁2 ) + (𝑊𝑃2 ) + 2𝑊𝑁 𝑊𝑃 𝐶𝑜𝑠Ø

= √2118,19² + 22,125² + (2 × 2118,19 × 22,125 × cos 20)
= 2138,994 N

Assuming that the pinion is overhung on the shaft and taking overhang as 150 mm, therefore
Bending moment on the shaft due to the resultant load :
M = 𝑊𝑅 × 150 = 320849,1 Nm
and twisting moment on the shaft,
𝐷𝑃 0,125
T = 𝑊𝑇 × = 1990,445 × = 124,402 𝑁𝑚
2 2

T = 124402N-mm
Equivalent twisting moment,

Te = √𝑀² + 𝑇² = √320849,1² + 124402² = 344122,075 Nmm

We know that equivalent twisting moment (Te),

𝜋 𝜋
344122,075 = 16 × 𝞽 × 𝒅𝒑 = 16×35×𝑑𝑝 ³ = 6,872 𝑑𝑝 ³
 344122,075
𝑑𝑝 ³ = 6,872

3
𝑑𝑝 = √50075,97 = 36,85 ~ 38 mm

We know that the diameter of the pinion hub

=1,8 𝑑𝑝 = 1,8 × 38 = 68,4 mm

and length of the hub 1,25× 𝑑𝑝 = 1,25 × 38 = 47,5 mm

Since the length of the hub should not be less than that of the face width i.e. 36 mm, therefore let
us take length of the hub as 36 mm. Ans.
Thickness of the web = 1.8 m = 1.8 × 5 = 9 mm

Design for the gear shaft

Assumsing The distances between the centre line of bearings and gear are 150 mm each.
We have calculated above that the normal load acting between the tooth surfaces,
WN = 2118,19N
We know that weight of the gear,
WG = 0.001 18 TG.b.m² = 0.001 18 × 75 × 30 × 5² = 66 ,375 N
Resulting load acting on the gear

Wr = √(𝑊𝑁2 ) + (𝑊𝑔2 ) + 2𝑊𝑁 𝑊𝑔 𝐶𝑜𝑠Ø

= √2118,19² + 66,375² + (2 × 2118,19 × 66,375 × cos 20)

= 2180,68N
Assuming that the gear is overhung on the shaft and taking the overhang as 150 mm, therefore
bending moment on the shaft due to the resultant load,
M = WR × 150 = 2280,68 × 150 = 342102 N-mm
and twisting moment on the shaft,
𝐷𝑔 360
T = 𝑊𝑇 × = 1990,445 × = 358280,1 𝑁𝑚𝑚
2 2

Dg = diameter of the gear shaft

Equivalent twisting moment,
Te = √𝑀² + 𝑇² = √342102² + 358280,1² = 495377,036 Nm
We know that equivalent twisting moment (Te),
𝜋 𝜋
495377,036 = 16 × 𝞽 × 𝒅𝒈 = 16×35×𝑑𝑔 ³ = 6,872 𝑑𝑝 ³
495377,036
𝑑𝑔 ³ = 6,872

𝑑𝑔 = 3√72086,29 = 41,61 ~ 42 mm

We know that diameter of the gear hub

1,8 𝑑𝑔 = 1,8 × 42 = 75,6 𝑚𝑚

and length of the hub

1,25 𝑑𝑔 = 1,25 × 42 = 52,5 𝑚𝑚
Design for the gear arms
Since the pitch circle diameter of the gear is 450 mm, therefore the gear should be
provided with four arms. Let us assume the cross-section of the arms as elliptical with major axis
(a1) equal to twice the minor axis (b1).
 Section modulus of arms
𝜋 . 𝑏1 .(𝑎1 )2 𝜋 . (𝑎1 )3
Z= = = 0,05 (𝑎1 )3 ^(b1 = a1/2)
32 64

Since the arms are designed for the stalling load and it is taken as the design tangential
load divided by the velocity factor, therefore

𝑊𝑇 1990,445
Stalling load, 𝑊𝑠 = = ( )
𝐶𝑣 0,24
= 8293,52 𝑁
Maximum bending moment on each arm,
n=number of arms (table 28.11)

𝑊 𝐷 8293,52 360
𝑀 = 𝑛𝑠 𝑥 2𝐺 = 𝑥 2 = 373208,4 𝑁-mm
4
We know that bending stress (𝞃b), 𝞃b= 40 MPa
𝑀 373208,4 7464168
40= 𝑍 = 0,05 (𝑎 )3 = (𝑎 )3 Type equation here.
1 1

(𝑎1 )3 = 7464168/40 = or 𝑎1 = 57,114𝑠𝑎𝑦 57 𝑚𝑚

𝑎𝑛𝑑 𝑏1 = 𝑎1 / 2 = 57 / 2 = 28,5 mm
Since the arms are tapered towards the rim and the taper is 1/16 mm per mm length of the
arm (or radius of the gear), therefore

Major axis of the arm at the rim end,

1 𝐷𝐺
𝑎2 = 𝑎1 − 𝑇𝑎𝑝𝑒𝑟 = 𝑎1 − 𝑥
16 2
1 360
= 57 − 16 𝑥 = 45,75 𝑚𝑚
2

and minor axis of the arm at the rim end,

𝑏2 = 𝑎2 /2 = 45,75/2 = 22,875 𝑚𝑚
Design for the rim
The thickness of the rim for the pinion may be taken as 1.6 m to 1.9 m, where m is the
module.

Let us take thickness of the rim for pinion,

𝑡𝑅𝑃 = 1.6 𝑚 = 1.6 𝑥 5 = 8 𝑚𝑚
The thickness of the rim for the gear (𝑡𝑅𝐺 ) is given by

𝑇𝑔 75
𝑡𝑅𝐺 = 𝑚 √ 𝑛 = 5 √ 4 = 21,65 𝑠𝑎𝑦 22 𝑚𝑚
 Desain bantalan pada poros pinion dan gear
Didesain tekanan pelumas pada motor adalah 1, N/mm², Jenis minyak
pelumas SAE 10 dengan viskositas absolut pada 55˚c= 0,017 kg/m-s`, suhu awal
16 ˚c.
Kenaikan suhu dibatasi 15˚c dengan koefisien penyaluran panas pada
bantalan jurnal 1400 W/m²/˚C.
Panas spesifik pelumas = 2000 J/kg/˚C

Pada bantalan gear

A motor shaft rotating 𝑑𝑙 = 1 𝑠𝑎𝑚𝑝𝑎𝑖 2 , diketahui Diameter pada poros 38
𝑙
mm, sedangkan l= 50, diambil 𝑑 = 1,31

2. Tekanan bantalan :
𝑊 2180,68
𝑝 = 𝑙𝑑 = = 1,14 𝑁/𝑚𝑚²
50 ×38

Karena tekanan pelumas pada motor 1,5 N/mm², maka tekanan pada bantalan aman dan
ukuran .
𝑍𝑁 0,017 ×1440
3. Bilangan karakteristik bilangan = = 21,47
𝑝 1,14

Dari table 15.1 diperoleh nilai operasi

𝑍𝑁
= 28
𝑝
Telah dipelajari bahwa nilai minimum modulus bantalan agar lapisan pelumas tidak
pecah ditentukan dengan persamaan

𝑍𝑁
3K= ,
𝑝

1
K= 3 × 28 = 9,33
𝑍𝑁
Karena karakteristik hitung bantalan = 21,47, besar dari 9,33 maka bantalan bekerja
𝑝
pada kondisi hidrodinamis
4. Dari table 15.1 diperoleh untuk motor perbandingan
𝑐
= 0,0013
𝑑
5. Koefisien gesek
33 𝑍𝑁 𝑑
𝜇= ( )( ) + 𝑘
108 𝑝 𝑐
33 1
= 108 (21,47) (0,0013) + 0,002 = 0,00745

6. Panas Terbentuk
𝜋𝑑𝑁
𝑄𝑔 = 𝜇 𝑊 𝑣 = 𝜇 𝑊 ( )
60
𝜋×0,038×1440
= 0,0051×2180,68×( ) = 31,86 W
60

7. Panas disalurkan
𝑄𝑑 = 𝐶 𝐴 (𝑡𝑏 − 𝑡𝑎 ) = 𝐶 𝑙 𝑑 (𝑡𝑏 − 𝑡𝑎 )
Telah dipelajari bahwa

𝑡𝑏 − 𝑡𝑎=1(55−16)=19,5 ˚𝐶
2

Maka didapat

𝑄𝑑 = 1400× 0,05 × 0,038 × 19,5 = 51,87 𝑊

Panas yang harus dibuang melalui pendingin buatan
𝑄𝑡 = 𝑄𝑔 − 𝑄𝑑 = 51,87 − 31,86 = 20,01 𝑊

𝑄𝑡 = 𝑚 𝐶 ∆𝑡
= m ×2000×10
20,01 = 20000 m
m = 20,01/20000
m =0,001 k/s = 0,06 kg/min
 Pada bantalan pinion
A motor shaft rotating 𝑑𝑙 = 1 𝑠𝑎𝑚𝑝𝑎𝑖 2 , diketahui Diameter pada poros 30
𝑙
mm, sedangkan l= 50, diambil 𝑑 = 1,67

2. Tekanan bantalan :
𝑊 2138,994
𝑝 = 𝑙𝑑 = = 1,42 𝑁/𝑚𝑚²
50 ×30

Karena tekanan pelumas pada motor 1,5 N/mm², maka tekanan pada bantalan aman dan
ukuran .
𝑍𝑁 0,017 ×1440
3. Bilangan karakteristik bilangan = = 17,23
𝑝 1,42

Dari table 15.1 diperoleh nilai operasi

𝑍𝑁
= 28
𝑝
Telah dipelajari bahwa nilai minimum modulus bantalan agar lapisan pelumas tidak
pecah ditentukan dengan persamaan

𝑍𝑁
3K= ,
𝑝

1
K= 3 × 28 = 9,33
𝑍𝑁
Karena karakteristik hitung bantalan = 17,23, besar dari 9,33 maka bantalan bekerja
𝑝
pada kondisi hidrodinamis
4. Dari table 15.1 diperoleh untuk motor perbandingan
𝑐
= 0,0013
𝑑
5. Koefisien gesek
33 𝑍𝑁 𝑑
𝜇= ( )( ) + 𝑘
108 𝑝 𝑐
33 1
= 108 (17,23) (0,0013) + 0,002 = 0,00637

6. Panas Terbentuk
 𝜋𝑑𝑁
𝑄𝑔 = 𝜇 𝑊 𝑣 = 𝜇 𝑊 ( )
60
𝜋×0,030×1440
= 0,0051×2138,994×( ) = 24,67 W
60

8. Panas disalurkan
𝑄𝑑 = 𝐶 𝐴 (𝑡𝑏 − 𝑡𝑎 ) = 𝐶 𝑙 𝑑 (𝑡𝑏 − 𝑡𝑎 )
Telah dipelajari bahwa

𝑡𝑏 − 𝑡𝑎=1(55−16)=19,5 ˚𝐶
2

Maka didapat

𝑄𝑑 = 1400× 0,05 × 0,030 × 19,5 = 40,95 𝑊

Panas yang harus dibuang melalui pendingin buatan
𝑄𝑡 = 𝑄𝑔 − 𝑄𝑑 = 40,95 − 24,67 = 16,28 𝑊

𝑄𝑡 = 𝑚 𝐶 ∆𝑡
= m ×2000×10
16,28 = 20000 m
m = 16,28/20000
m =0,0008 k/s = 0,04 kg/min