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COLLEGE OF ENGINEERING
Legazpi City
S U B M I T T E D T O:
ENGR. MANUEL RUSTRIA,MME
Professor
S U B M I T T E D B Y:
RUSSEL JAMES ALAMER
BSME4B
LETTER OF TRANSMITTAL
February 11 ,2010
Sincerely yours,
ii
ACKNOWLEDGEMENT
those who inspired and helped him in the realization of this design project.
To His professor Engr. Manuel Rustria for his valuable advices and
To his parents Rodolfo and Jonibeth Alamer for their encouragement and
financial support.
Above all to the Lord Jesus Christ, his God and Savior Who enables the
TITLE PAGE………………………………………………………………………………i
LETTER OF TRANSMITTAL……………………………………………………………ii
ACKNOWLEDGEMENT ………………………………………………………………...iii
TABLE OF CONTENTS………………………………………………………………....iv
COMPUTATIONS………………………………………………………………………..2
SKETCHES……………………………………………………………………………….
BIBLIOGRAPHY………………………………………………………………………….13
APPENDICES……………………………………………………………………………..14
iv
STATEMENT OF THE PROBLEM
PROBLEM 676]
A gear reduction unit is to be designed according to the data in the table and the
following specifications.
The Velocity ratio may be varied by an amount necessary to have whole tooth
numbers. The given center distance is the permissible maximum. The teeth are to be
20˚FD with Np≥ 18 teeth, with 17 as the minimum acceptable. The service is
continuous, with indefinite life. Use Buckingham’s dynamic-load for average gears.
a) Decide upon the material with its treatment, pitch, and face width. Start out
being orderly with your calculations so that you do not need to copy all of
them for your report. The report should show calculations for the final decision
first, but all significant calculations should be in the appendix. These latter
calculations should show: that a cheap material cannot be used; that through
b) To complete the design of the gears. A shaft size is needed. At the option of
the instructor (i) compute shaft diameters for pure torsion only using a
minor bending, on the assumption that the bearings will be quite close to the
for the input and output to be via flexible couplings. Let the shaft material be
cold finished AISI 1137. Design the keys for cold-drawn AISI C1118. Use better
c) Determine the dimensions of the hub, arms or webs, and rims and beads of
both gears.
d) Make a sketch of each gear (on separate sheets of paper) including on it all
e) At the instructor’s option (i) choose rolling type bearings, or (ii) design sleeve
bearings.
f) Decide upon all details of the housing to enclose the gears, with sketches
depicting them.
g) Your final report should be arranged (1) Title Page; (2) a summary of the final
1
COMPUTATIONS]
GIVEN: Power = P = 80 hp
Gear Ratio=Mg=2
Center distance= Cd=5 ¼
Pinion Revolution = N = 720 rpm
Kind of Loading = Minor Pulsations
Nsf = 1.2
Pressure Angle = Ф = 20 ˚FD
Design the gears based on endurance strength
SOLUTION:
Mw = Mg = 2, since the pinion is the driver.
◘ Dg=(10.5)-Dp ……..eq.1
◘ Dg=10.5 - 3.5
Dg=7 in.
Pd = Np/Dp = 17/3.5
= 4.85, use 5
with Pd = 5 and,
For Ng:
Ng= Pd(Dg)
= (7)(5)
=35
Dp= Np/Pd
= 17/5
= 3.4
with Pd=5, Ng= 35,
Dg= Ng/Pd
= 35/5
=7
the new Gear ratio,since it can be adjusted, Mg’,
Mw’=Mg’= Ng/Np=35/17
=2.0588
the new center distance Cd’,
Cd’ = (Dg + Dp)/2
= (7 + 3.5)/2
= 5.25 in.
Solving for the Pitch line Speed, Vm,
Vm= πDpn
2
= [π(3.4 in.)(720 rpm)]/(12 in/ ft.)
= 640.8849013 fpm
For transmitted Load Ft:
Ft = 80hp/Vm
= [(80hp)(33000 ft.-lb/min-hp)]/ 646.5397681 fpm
= 4119.304409 lb.
assume face width, b =1.75,
Fd = Ft + I
= Ft + [o.o5Vm(bc + Ft) ]/[0.05Vm + (bc + Ft)1/2]….eq. 2
Q = (2 Mg) / (Mg + 1)
= (2x2.055)/(2.055+1)
= 1.346
since Fw = Fd= 5792.810194,
Kg = Fw / (DpbQ)
= 5792.810194/(1.346x3.4x1.75)
= 726.5533919
From AT26,
With Kg = 726.5533919
…out of range!
Choose Kg = 400, ∑BHN=600,
3
For gear, At BHN = 269
Choose C1137, at table AT9, Design of Machine Elements by V.M. Faires
˚F BHN
700 277
t˚F 269
1000 229
Use kf as 1.5,
Fs = Sn’yp (b)/[(Kf)(Pd)
= (1.75)(42,368)/(1.5 x 5)
= 9885.8667 lb. ≤
Fs ≥ Fd,
9,885.8667 ≥ 5,759.986, satisfied
For Gear:
• Dedendum Diameter
= Dg – 2d
= 7 – 2(0.25)
= 6.5 in.
• Addendum Diameter
= Dg + 2a
= 7 + 2(0.2)
= 7.4 in.
• Rim Diameter
= Dedendum Diameter – 2(rimT)
= 6.5 – 2(0.3518)
= 5.7694 in.
For Pinion:
• Dedendum Diameter
= DP – 2d
= 3.4 – 2(0.25)
= 3.9 in.
• Addendum Diameter
= DP + 2a
= 3.4 + 2(.2)
= 3 in.
P = 2πTN
T = P/ 2πN
= [80 hp x (33000 ft. lb x 12 in)/ (min-hp-ft)]/ (2π)(720 rpm)
= 7002.817 lb.-in.
For tolerance,
Assuming class RC 1, from table 3.1,Design of Machine Elements, by Faires
At given Shaft diameter
-0.004 in.
-0.007 in.
For hub,
Solve for the Hub Diameter. Dh,
for pinion,
use 2 ½ in. since Dp = 3.43
Sdc = (75ksi)/2.125
= 35.29ksi
Using Sdc,
L = 4T / (Sdc)(t)(Ds)
= 4(7002.817496 lb. in.)/[(35,291 psi)(1 11/16 in.)(1/4 in.)]
= 1.88 in.
Using Sds,
L = 2T/ (Sds)(b)(Ds)
= (2 x 7002.817496 lb. in.)/ [(1 11/16 in.)(3/8 in.)(21,176.47psi)]
= 1.045 in
…..
T = P/ 2πN
= [80 hp x (33000 ft. lb x 12 in)/ (min-hp-ft)]/ (2π)( 349.72 rpm)
= 14,417.32 lb.-in.
For tolerance,
Assuming class RC 1, from table 3.1,Design of Machine Elements, by Faires
At given Shaft diameter:
-0.004 in.
-0.007 in.
Sdc = (75ksi)/2.125
= 35.29ksi
Using Sdc,
L = 4T / (Sdc)(t)(Ds)
= 4(14,417.32lb. in.)/[(35,291 psi)(1 15/16 in.)(3/8 in.)]
= 2.25 in.
Using Sds,
L = 2T/ (Sds)(b)(Ds)
= (2 x 14417.32 lb. in.)/ [(1 15/16 in.)(1/2 in.)(21,176.47psi)]
= 1.41 in
by BUCKINGHAM’S EQ.
Fd = Ft + I
= Ft + [o.o5Vm(bc + Ft) ]/[0.05Vm + (bc + Ft)1/2]
Solving for c, assume steel and steel, at table AT 25 p. 601 T.B.
c = 1660e (1000)
Permissible error, e, from Figure AF 20
e = .0005(for precision cut)
Therefore,
c = (.0005) (830) (1000)
= 415
Fd = 4119.304+[0.05(640.88)(1.75 x415+4119.304)]/[0.05(640.88)+(1.75x415+
4119.304)1/2]
= 5646.75 lbf
Limiting Load for Wear (Fw)
Fw = DpbQKg
Solving for Q,
Q = (2 Mg) / (Mg + 1)
= (2x2.055)/(2.055+1)
= 1.346
From p. 57 T.B. Cast Iron in general sense includes white cast iron, malleable iron,
and nodular iron, but when cast iron is used without a qualifying adjective, gray cast
iron, spoken of as gray iron is meant. From that definition we can use table AT 6 p.
570 T.B., and we can notice from that given type, if we select two materials
and get their ∑BHN it is smaller compare to our computed ∑BHN. For
example if we take the two material with the highest BHN, ASTM60 with ∑BHN= 302
and nodular cast iron 100-70-03(heat treated) (ASTM A396-58) with BHN= 270, their
∑BHN= 572, since 600>572 therefore we cannot use that materials.
~END
DESIGN SUMMARY
BEARING
~GEAR
Rolling Bearing
Material: BRG. 304
AISI C1137 with tempering temperature 750˚F
Bore Diameter
Type of cut: 20mm or .7874
Precision cut in.
Outside
BHN: Diameter 52mm or 2692.04 in.
No. of Teeth 35
Gear Diameter 7 in.
HUB
Material GEAR AND PINIONAISI C1137 with tempering temperature 750˚F
DIMENSIONS
Hub Diameter 3 ½ in.
Center distance 5.2 in.
Hub length 3.15 in.
Velocity
KEY ratio 2.0558
Material AISI C1118 cold drawn
Gear ratio 2.0558
thickness 3/8 in.
Diametral
base pitch 51/2 in. (tolerance: -0.0025 in.)
Length 3.15 in.
Face width 1.75in
RIM
Addendum:
Material 1/5 in with tempering temperature 750˚F
AISI C1137
Thickness:
Dedendum 1.25/5 in. .3518in.
WEB
Working
Materialdepth 2/5 in. with tempering temperature 750˚F
AISI C1137
Thickness
whole depth 2.25/5 in. .3455in.
ARM N.A.
Fillet radius 0.3/5
SHAFT
clearance
Material 0.35/5AISI 1137 cold finished
Shaft Diameter 1 15/16 in (Tolerance: -0.0004 in. -0.0007 in.)
~PINION
Material: AISI 4150 with tempering temperature 1200˚F
BHN: 331
HOUSING
Type of Cut Precision cut
Material
No. of Teeth SAE17 1045
Height
Pinion Diameter 10. 2 inches
3.4 in.
Length
HUB 10 inches
Depth
Material 14 inches
AISI 4150 with tempering temperature 1200F
Hub Diameter ```For Detail dimensions, see at
2½ sketches
in.
Hub length 2.74 in.
KEY
Material AISI C1118
Thickness 1/4 in.
Base 3/8 in. (Tolerance: -0.004 in. -0.007 in.)
Length 2.74 in
SHAFT
Material AISI 1137 cold finished
Shaft Diameter 1 11/16 in. (Tolerance: -0.003 in. -0.016 in.)
BEARING
Rolling Bearing BRG. 308
Bore Diameter 40mm or 1.5748 in.
Outside Diameter 90mm or 3.5433 in.
BIBLIOGRAPHY
9
APPENDICES
Addendum. The radial distance between the Pitch Circle and the top of the teeth.
Base Circle. The circle from which is generated the involute curve upon which the
Circular Thickness. The thickness of the tooth measured along an arc following the
Pitch Circle
Clearance. The distance between the top of a tooth and the bottom of the space into
Contact Ratio. The ratio of the length of the Arc of Action to the Circular Pitch.
Dedendum. The radial distance between the bottom of the tooth to pitch circle.
Face. The working surface of a gear tooth, located between the pitch diameter and
Face Width. The width of the tooth measured parallel to the gear axis.
Flank. The working surface of a gear tooth, located between the pitch diameter and
Gear. The larger of two meshed gears. If both gears are the same size, they are both
called "gears".
Line of Action. That line along which the point of contact between gear teeth
Pitch Circle. The circle, the radius of which is equal to the distance from the center
Pitch Point. The point of tangency of the pitch circles of two meshing gears, where
pitch circles.
Pressure Angle. Angle between the Line of Action and a line perpendicular to the
Line of Centers.
Ratio. Ratio of the numbers of teeth on mating gears.
Root Circle. The circle that passes through the bottom of the tooth spaces.
Working Depth. The depth to which a tooth extends into the space between teeth
block of platinumiridium
alloy) of the kilogram, kept at the International Bureau of Weights and Measures at
Second. The second is defined as the duration of 9 192 631 770 periods of the
radiation corresponding
to the transition between the two hyperfine levels of the ground state of the caesium
– 133 atom.
Strength. It is the ability of a material to resist the externally applied forces without
breaking
called *stress.
modulus of
deformation when
the external forces are removed. This property is desirable for materials used in tools
and machines.
load
in ornamental work.
Ductility. It is the property of a material enabling it to be drawn into wire with the
application
of a tensile force. A ductile material must be both strong and plastic. The ductility is
usually
commonly used in engineering practice (in order of diminishing ductility) are mild
steel, copper,
cast iron. is obtained by re-melting pig iron with coke and limestone in a furnace
known as cupola.
It is primarily an alloy of iron and carbon. The carbon contents in cast iron varies from
1.7 per cent to 4.5 per cent. It also contains small amounts of silicon, manganese,
cast iron is present in either of the following two forms: 1. Free carbon or graphite,
11
Involute. the curve formed by path of a point on a straight line, called the
generatrix, as it rolls along a convex base curve. (The base curve is usually a circle.)