Contents

I. Design of Gear pump .................................................................................................................4

1. Introduction ..............................................................................................................................4
1.1 Working Of Gear Pump ...................................................................................................................... 5
1.2 Problem Definition ....................................................................................................................6
1.3 Solution .....................................................................................................................................6
1.4 Assembly of Gear pump .......................................................................................................... 13
II) Analysis of Gear Pump ............................................................................................................ 14
2.1 Comparison of Actual and theoretical values .......................................................................... 15
2.2 Conclusion ............................................................................................................................... 16

References

1
 List of Figures

1 Gear Pump 3
2 Working of gear pump 4
3 Gear pump in machine 5
4 Flexible coupling 6
5 Force analysis 9
6 Bending moment diagram 10
7 Casing design 11
8 Assembly of gear pump 12
9 Displacement analysis 13
10 Stress analysis 13

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 List of Table

Table Title Page no

1) comparison between calculated and original values 14

3
 I. Design of Gear pump

1. Introduction

A gear pump uses the meshing of gears to pump fluid by displacement. They are one of the most
common types of pumps for hydraulic fluid power applications. Gear pumps are also widely used
in chemical industries to pump high viscosity fluids. Gear pumps are positive displacement (or
fixed displacement), meaning they pump a constant amount of fluid for each revolution. Gear
pumps can be found on the following machines:

1. In the car’s oil pump

2. Hydraulically driven lawn care equipment
3. Some hydraulically driven log splitters
4. Hydraulic power units on trucks and construction equipment
5. Metering applications (gear pumps are good at controlling volume flow rate)

Gear pump is a robust and simple positive displacement pump. It has two meshed gears revolving
about their respective axes. These gears are the only moving parts in the pump. They are compact,
relatively inexpensive and have few moving parts. The rigid design of the gears and houses allow
for very high pressures and the ability to pump highly viscous fluids. They are suitable for a wide
range of fluids and offer self-priming performance. Sometimes gear pumps are designed to
function as either a motor or a pump. These pump includes helical and herringbone gear sets
(instead of spur gears), lobe shaped rotors similar to Roots blowers (commonly used as
superchargers), and mechanical designs that allow the stacking of pumps. A gear pump uses the
meshing of gears to pump fluid by displacement. They are one of the most common types of pumps
for hydraulic fluid power applications

Figure 1 Gear pump

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1.1 Working Of Gear Pump

The external gear pump consists of externally meshed two gears housed in a pump case as shown
in figure. One of the gears is coupled with a prime mover and is called as driving gear and another
is called as driven gear. The rotating gear carries the fluid from the tank to the outlet pipe. The
suction side is towards the portion whereas the gear teeth come out of the mesh. When the gears
rotate, volume of the chamber expands leading to pressure drop below atmospheric value.
Therefore the vacuum is created and the fluid is pushed into the void due to atmospheric pressure.
The fluid is trapped between housing and rotating teeth of the gears. The discharge side of pump
is towards the portion where the gear teeth run into the mesh and the volume decreases between
meshing teeth. The pump has a positive internal seal against leakage; therefore, the fluid is forced
into the outlet port. The gear pumps are often equipped with the side wear plate to avoid the
leakage. The clearance between gear teeth and housing and between side plate and gear face is
very important and plays an important role in preventing leakage. In general, the gap distance is
less than 10 micro meters. The amount of fluid discharge is determined by the number of gear
teeth, the volume of fluid between each pair of teeth and the speed of rotation. The important
drawback of external gear pump is the unbalanced side load on its bearings. It is caused due to
high pressure at the outlet and low pressure at the inlet which results in slower speeds and lower
pressure ratings in addition to reducing the bearing life. Gear pumps are most commonly used for
the hydraulic fluid power applications and are widely used in chemical installations to pump fluid
with a certain viscosity.

Figure 2 Working of gear pump

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 1.2 Problem Definition
Design of gear pump for the following specification
Pressure – 20 bar
Discharge 13 LPM

Application: Lubrication of automated hacksaw machine.

1.3 Solution
There are four units in the gear pump.

1. Drive Unit
2. Pump Unit
3. Transmission Unit

Figure 3 Gear Pump in

machine

1)Drive Unit
Standard range of efficiencies (ƞ) are :
Ƞmech – Mechanical Efficiency, Ƞv – Volumetric Efficiency,
Selecting efficiency as ƞm = 0.93, Ƞv = 0.97

13 x10-3 x 20 x 105

Power input = = 478.88W

8 60 x 0.93 x 0.97
Motor Power = Power input * Service Factor (S.F) ……………………S.F from PSG 7.109

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Motor Power = 478.88 * 1.5 = 718.32 W
Selecting Standard motor from PSG 5.124 P = 1.1 KW

2)Transmission Unit:

Selecting flexible bush pin coupling form PSG 7.108

Maximum rating at 100 RPM = Power * S.F *100 /960 = 0.111
Selecting Coupling No. 1 having diameter range of 12 – 16 mm.

Figure 4 Flexible coupling

3)Pump Unit:
There are different component in the pump unit and they are as follows,
Gear Pair, Shaft, Bearing, Casing, Fasteners

i) Gear pair
Assumptions, Profile Selection – Involute, Pressure angle – 200
Quality of gear – Precision cut, Type of meshing – SN gearing (X1 = X2 = 0, Fo = 1)
Since the given pressure is P < 200 bar so selecting Spur Gear
Both the gears are of equal size for uniform discharge, better loading on input and output shaft
and control of bearing load.

Gear material selection …………………………………………… PSG 8.5

Let the gear material selected be 40Ni2Cr1Mo
[σb] = 400 N/mm2 for, m < 6
[σc] = 1100 N/mm 2

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Design criteria

Module selection is based on discharge and checking is done for Bending, Dynamic load

Now Discharge, Q (m3/min) = ƞv * (da2-df2) * b*N

4
da – Addendum Diameter,
df – Root Diameter,
b – Width of the gear ,
N – Speed in rpm
Let z = number of teeth = 10
Φm= b/m = 6 to 8, Where m = module of the gear Let, b/m = 7,
da = Z *m +2*m = 10m + 2m = 12m
df = Z*m – 2*m = 11m – 2m = 8m
Q = ƞv *π (da2-df2) b*N
4
0.013= 0.98 [122- 82] *m2 * 7m * 960
m = 3.89 * 10-3 metre
m = 4 mm
Selecting Standard value of module ……………………………………………..PSG 8.1
m=4
b = 4*7 = 28 mm, b=2

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 Mt1 = ( P/ 2w)
Mt1 = 5000 Nmm

Z= 10 ; Y1 = 0.2513; ø = 4
( sb ) = 8 N /mm2
Hence,
(Sb) < [Sb]
Safe in bending

Checking for dynamic load

Static strength Fs = [σb1]*b*Y1*m ……………….PSG 8.50

where Fs – static strength of the gear tooth
Fs = 400 * 28 * 0.279 * 4 = 6433.28 N

Lewis dynamic force Fd = Ft * Cv ……….............PSG 8.50

Where Fd – dynamic force acting on the gear,

v = π D N / 60
D= 40 mm ; N = 960 rpm
v = 2.010 m/s ; Cv = 1.257
Ft = P/v = 475.96 N

Fd = 475.96 * 1.2578= 600N

Fd < Fs

Hence , Safe

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4)Tooth Proportion:
Centre distance a = m = 4 mm
Addendum diameter da = 12*m = 12*4 = 48 mm
Clearance C = 0.25*m = 0.25*4 = 1mm

Root diameter df = 8*m = 8*4 = 28 mm

Pitch diameter of gear d = m*z = 4*10 = 40 mm

Figure 5 Force analysis

Where Fr – radial force acting on the gear,

Now, Fh = 1.6366 *Ra*b*Pmax
Where Fh – hydraulic force
Ra – Addendum radius = 48/2 =24
b – Width of the gear = 28 mm
Pmax – Maximum pressure acting on the gear = 1.2*P = 2.4 N/mm
Fh = 1.50 KN
a = 20˚
Fr= Ft tan( a)= 173.2 N
Resultant force Fr = [(1506 + 475.9)2 + (173.2)2 ] 0.5 = 1.989 KN

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5) Bearing Design
The suitable types of bearing used in the gear pump are needle type bearing
For Needle Type Bearing , forces acting on bearing are,
Fr=173.2N ; Fa=0
Assuming Lhr = 5000hrs

Lmr = (Lhr x N x 60) / 106

Peq = X *V*Fr*S……………………………………PSG 4.2,

Pq = 1* 1 * 173.2 * 1.1
Pq = 0.19 KN
C = Peq ( Lmr )1/k
C = 0.19 (288)3/10

C = 111.05 KN = 104.17 Kgf

D0-Df ≤ 10 mm
So, D0 ≤ 42mm
Selecting Needle bearing of RNA 69 series (without inner race)
……….PSG 4.35
For Do = 42 mm, Dynamic capacity of bearing: C = 4200 kgf ( > 3428.35
kgf)
Therefore, selecting RNA 6906 ( Df = 32 mm, B = 30 mm, D=42 mm)

6)Shaft Design

Figure 6 Bending moment

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Maximum bending moment, B.M. max = F.l /4 ,

and l – span between the two bearing)

Assuming Shaft Material as C-40 with
[τ] = 45 N/mm2,
Span length, L = B + b + Clearance
L = 28 + 30 + 10 = 68 mm
Maximum bending moment (Bmmax) = W* L /4
(Bmmax ) = 1.989 x 103 x 68 / 4 =33.81x 103 N.mm
[Mt1] = Tmax = 5000 N.mm
Teq = (𝑇2 + 𝑀2)0.5 = 34.172 KNmm

d = 14.69 = 15mm

7) Casing Design

Figure 7 Casing design

Selecting the material of the casing to be GCI-20

σu = 200 N/mm2 , where σu – ultimate strength of
the GCI [σt] = σu /FOS , where σt – tensile stress of
GCI and FOS – factor of safety
[σt] =200/6 = 33 N/mm2
Pmax = 1.2*20 = 24 bar

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By Thick Cylinder theory,

= 4.78 mm=8 mm
From Figure, C = D + Do = 48+ 32 = 80mm
PCD for casing = C + 3 * dbolt=110 mm
Outer diameter of casing = PCD of casing + 3 * dbolt
=110+3*10=140mm

4. Assembly of Gear pump

Figure 8 Assembly of Gear pump

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 II) Analysis of Gear Pump

1. Displacement of Gear tooth

Displacement : 1.067 x 10-5 mm

Figure 10 Displacement in gear tooth

2. Stress analysis of gear tooth

Stress : 1.31 Mpa

Figure 11 Stress ananlysis

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2.1 Comparison of Actual and theoretical values

Criteria Calculated value Actual value

External Diameter 48mm 43mm

Internal Diameter 32mm 27mm

Shaft Diameter 15mm 10.6mm

No. of teeth 10 10

Thickness of Casing 8mm 10mm

Stress 8Mpa 1.31Mpa

Motor power 1.1Kw 0.75Kw

Module 4mm 4.5mm

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 2.2 Conclusion

The dimensions of the actual gear pump were calculated and compared with theoretical values
along with the analysis of the pump which was done using Autodesk inventor . discharge and
pressure for the gear pump were taken as initial specifications based on which power , spur gears,
shaft bearing and casing were designed.

References
1. V B. Bhandari
2. Pump handbook
3. Psg Data Book

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