BENHA UNIVERSITY BANHA FACULTY OF ENGINEERING MECHANICAL ENGINEERING DEPARTMENT

M471 MACHINE DESIGN 4 YEAR MECHANICAL ENGINEERING DR. AL-ASSAL | ENG. AMRO | ENG. ABDALLA
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SHEET5: DESIGN OF GEAR DRIVES

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KNOWLEDGE & UNDERSTANDING QUESTIONS

1. Classify gears based on: a) The position of axes of the shafts. b) The type of gearing mesh. c) The gear tooth geometry Discuss what is meant by a) Contact ratio b) Backlash c) Pressure angle d) Involute e) Module f) Pitting resistance formula g) Dynamic factor h) Load distribution factor i) Geometry factor List some of basic advantages, disadvantages, and applications for using gear drives. List the basic types of gear manufacturing process. Compare the basic types of gears based on: a) Motion axes b) Applied load direction What are the differences between module and diametral pitch? Specify the basic gear nomenclature as shown in the figure below (a-o).

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KINEMATICS
1. 2. A spur gearing system has a module of 3 mm, and pressure angle of 20, full depth teeth, calculate all pinion and gear dimensions. Consider the compound gear train shown; indicate the speed magnitude and direction of each gear. The driver gear is no.6 and the final driven gear is no.1. Take the rotational speed of the driver is 1400 rpm in clockwise direction.

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A pair of meshing spur gears has a module of 1.5 mm is considered. The pinion has a speed of 900 rpm and 22 teeth. Calculate the pitch line velocity and hence the angular velocity of the gear while the gear has 38 teeth. A pair of spur gears has a module of 6 mm and pressure angle of 14.5, the pinion diameter is equal to 150 mm. Determine the contact ratio if the transmission ratio is 2.5. A spur gear drive used for make a reduction ratio of 3; it has a module of 5 mm, and a pressure angle of 20 full-depth. The pinion drives in a clockwise direction and has 18 teeth. Compute (a) the circular pitch, (b) base pitch, (c) pitch-circle radii, (d) base-circle radii, (e) length of path of contact, (f) contact ratio, (g) addendum circle diameter, (h) dedendum circle diameter.

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DESIGN PROBLEMS
Solve the following problems, assume any missing data, and use the tables for selecting standard Roller Chain dimensions (according to DIN standards): 1. A pair of gears with 20, full-depth, involute teeth transmits 40 hp while the pinion rotates at 1150 rpm. The diametral pitch is 6, and the quality number is 6. The pinion has 20 teeth, and the gear has 48 teeth. The face width is 2.25 in. The input power is from an electric motor, and the drive is for a cement kiln. The drive is a commercial enclosed gear unit. Compute the bending strength number to give a safety factor closed to 1.2 and the corresponding Brinell hardness number. 2. A pair of spur gears is to be designed to transmit 3.0 hp while the pinion rotates at 1200 rpm. The gear must rotate between 383 and 390 rpm. The gear drives a reciprocating compressor. Design the gear drive. 3. A water turbine transmits 75 kW of power to a pair of gears at 3000 rpm. The output of the gear pair must drive an electric power generator at 2200 rpm. The center distance for the gear pair must not exceed 150 mm. Design the gear drive. 4. Design a pair of spur gear for a special-purpose, dedicated machine tool is being

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designed to mill a surface on a rough steel casting. The drive must transmit 20 hp with a pinion speed of 650 rpm and an output speed between 110 and 115 rpm. The mill is to be used continuously, two shifts per day, six days per week, for at least five years. Design the drive to be as small as practical to permit its being mounted close to the milling head. Design the gear drive for the wheels of an industrial lift truck. Its top speed is to be 2000 fpm. It has been decided that the wheel will have a diameter of 12.0 in. A DC motor supplies 20 hp at a speed of 3000 rpm. The design life is 16 hours per day, six days per week, for 20 years. A gear pair is to be designed to transmit 15 KW of power to a large meat grinder in a commercial meat processing plant. The pinion is attached to the shaft of an electric motor rotating at 575 rpm. The gear must operate at 270 to 280 rpm. The gear unit will be enclosed and of commercial quality. A quality number 5, 20 , full depth involute gears are to be used in the mesh. The maximum center distance is to be 200 mm. Work an acceptable safe design of the gears.

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ANALYTICAL PROBLEMS
1. A gear set has a diametral pitch of 5 teeth/in, a 20 pinion driving a 48-tooth cast-iron gear. The pinion is to rotate at 50 rev/min. What horsepower input can be used with this gear set if the contact? A steel spur pinion and gear have a diametral pitch of 12 teeth/in, milled tee respectively. A 20 pressure angle and a pinion speed of 525 rev/min. 107 loading cycles to work in a simple compressor. Brinell hardness is 190. For a bending and wear safety of 7/8 in, what is the power rating of the gear? A 20 full-depth steel spur pinion rotates at 1145 rev/min. It has a module of 6 mm, a face width of 75 mm, and 16 milled teeth. The ultimate tensile strength at the involute is 900 MPa exhibiting Brinell hardness of 260. The gear is steel with 30 design factor of 1.3, find the power rating of the gear bending and wear fatigue.

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REMARKS
For contact stress, the allowable value at 10 7 cycles can be found from the figure below:

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