Identification of need

Problem formulation

Design is an iterative process Analysis requires mathematical model of system/component.

Mechanism/Synthesis

Analysis

Verification

Presentation
11/2/2011 1

Can we increase speed of Jute Flyer ??

Flyer Spinning Machine

Current speed 4000 rpm Target speed 6000 rpm

11/2/2011

Bobbin
2

Can we increase speed of Jute Flyer ??

Flyer Spinning Machine Increase rotational speed p Constraints: Stress < ?? Deflection < ???

11/2/2011

Increase operating speed wharve assembly

Bearing life must be at least 3 years The wharves must be lighter than the current wharves Temperature rise must be within 5C. Cost of new wharve assembly 1.5 times cost of existing assembly

11/2/2011

Total Product Development

Stress concentration factor, surface finish factor, size factor, etc.

Design Factors: Factor of Safety

FOS is a ratio of two quantities that have same units:
Strength/stress ; Critical load/applied load Load to fail part/expected service load Maximum cycles/applied cycles Maximum safe speed/operating speed.

Necessary to calculate one or more factors of safety to estimate likelihood of failure.

Stress Deformation Wear
11/2/2011 6

Design Factors: Factor of Safety

Material properties (FSM ) 1.0,1.1,1.3 St ess (FS Stress ( SS ) 1.0, 1.2, 3.0 0, ,30 Geometry (FSG ) 1.0, 1.2 Failure analysis (FSFA ) 1 0 1 2 1 5 1.0, 1.2, 1.5 Environmental factors (FSE ) 1.0, 1.3, 1.6 Danger to Personnel (FSD ) 1.0, 1 6 1 0 1.6 FOS is deterministic. Often data are statistical and there is a need to use Probabilistic approach.
11/2/2011 7

Analysis of Steam y Turbine Coupling

Shrinkage stresses and power transmission capacity with a short circuit factor of 4.4 at rated speed of 3000 rpm

11/2/2011

Press Fit

Baseline

rs

rs

Pressure pf is caused by interference between shaft & hub. Pressure h ft h b P increases radius of hole and decreases radius of shaft.
pf

rh rf

rh

rf

rf
pf
11/2/2011

rf

Circumferential strain =

(r + r )d r d = r = ( r )
r d r E

Radial t i R di l strain r =

r +

r dr r ( ) r = r = r dr E r

d Force balance = ( r + d r )(r + dr ) d dz r rd dz 2 sin dr dz = 0 2

11/2/2011 10

pi ri2 po ro2 (ri ro r )2 ( po pi ) Circumferential stress = ro2 ri2 pi ri2 po ro2 + (ri ro r )2 ( po pi ) Radial stress r = ro2 ri2

rf

CASE I: Internally Pressurized (Hub)Circumferential stress = Radial stress r = p f r f2 1 + (ro r ) ro2

p f r f2 1 (ro r )2 ro2 r f2

r f2

,max =

p f r f2 + ro2 ro2 r f2

r ,max = p f

Circumferential strain =

rh
rf

( h r ) =
E

,max

r p f r f2 + ro2 = + = h rf E ro2 r f2
11

11/2/2011

CASE II: Externally Pressurized (shaft)pi ri2 po ro2 (ri ro r )2 ( po pi ) Circumferential stress = ro2 ri2 Radial stress r = pi ri
2

po ro2

+ (ri ro r ) ( po pi ) ro2 ri2

2

,max =

p f r f2

2 2 2 r f ri

r ,max = p f

1 + (r r )2 Circumferential stress = p f r f2 2 i 2 r f ri Radial stress r = 1 r r p f r f2 2 i 2 r f ri

rf

)2
r p f ri2 + r f2 = s = s Es r f2 ri2 rf
12

Circumferential strain =
11/2/2011

rs
rf

( s r ) =
E

,max

Total interference r = rh rs h
2 2 ro2 + r f2 ri + r f h s or r = r f p f + + 2 2 2 2 Eh Es r f ri Es Eh ro r f

Ex: A wheel hub is press fitted on a 105 mm diameter solid shaft. The hub and shaft material is AISI 1080 steel (E = 207 GPa). The hubs outer diameter is 160mm The radial interference between shaft and 160mm. hub is 65 microns. Determine the pressure exercised on the interface of shaft and wheel hub.

rf p f ro2 + rf2 ri 2 + rf2 If hub and shaft are made of same materials : r = 2 2 + 2 2 E ro rf rf ri rf p f 2 ro2 ANS: pf =73 MPa If shaft is solid : r = 2 2 E ro rf Iterations !!!! I i

) (

11/2/2011

13

4.59,4.34,4.5796,4.50, 4 582 4 5847 4 59 4 34 4 5796 4 50 4.582,4.58474.5948 4 5948

EX. NOMINAL SHAFT DIA. NUMBER OF SPECIMEN

d

d i2 ( d i )2 / N d = N 1 4.5mm 6 34 4.5294 4.58mm 0.0987 0 0987 0.0097 0 0097

11/2/2011

14

Probabilistic Approach to Design

Ex: Tensile tests on 9 pieces of hot rolled steel. Measured ultimate tensile strength data are: 433, 444, 454, 457, 470, 476, 481, 493 481 493, and 510 MPa. MPa Find the values of mean, and std. dev. Assuming normal di t ib ti l distribution fi d find the probability density function.

s = 468.67 MPa s = 24.34 MPa

1 f (x ) = e 24.34 2
+ 1 x 468.67 2 24.34
2

f (x ) dx = 1

NOTE: Reliability is probability that machine element will perform y intended function satisfactorily.
11/2/2011 15

Ex: Consider a structural member subjected to a static load that develops a stress
Variation in load !!!!! Variation in Area !!! Margin
NOTE: Addition or subtraction of normal distribution provides normal distribution.
F , F , SF

,, s

Probabilit of failurePf = P(Q < 0) y Reliabilit R =1 Pf y

Q = S

11/2/2011

16

f (Q ) =

1 SQ 2

1 Q Q 2 SQ

Let normal variable Z = R= 1 + 2 Z 2 dZ e 2 Z 0 where Z 0 =

1

Q Q SQ

Q = 40 30 = 10 sQ = 6 + 8 = 10
2 2

Q SQ

1 z0 2 z 2 F= dZ e 2
ALGEBRAIC FUNCTIONS
Q=C Q = Cx Q=C+x
Q = x y Q = xy Q=x y Q =1 x

MEAN Q

STD. DEVIATION
0 C x

C Cx C+x xy xy x y 1x

at Q = 0 0 10 Z = = 1 10 11/2/2011

x x2 + y2
y 2 x + x 2 y
2 2

y 2 x + x 2 y
2

y2

x x2

Z-Table provides probability of failure

11/2/2011

18

Value of normal variable provide the probability of failure. f il

In the I th present case t Probability of failure is 0.1587 & reliability is .8413.

0

Selecting stronger material (mean value of strength = ) 50 units!!!!)

Material properties (FSM ) 1.0,1.1,1.3 ( Stress (FSS ) 1.0, 1.2, 3.0 Geometry (FSG ) 1.0, 1.2 Failure analysis (FSFA ) 1.0, 1.2, 1.5
11/2/2011

1.9 19
19

Ex : Strength and Stress of a tensile bar are : S y = (270, 32 ) MPa &

= (184,15) MPa

Reliability of design R

2.43 = 1

1 z2 2 e dz 2

R = 1-0.0075 ????

Ref: Probabilistic Mechanical Design, Edward B. Haugen, 1980.

Prob: A steel bar is subjected to compressive load. Statistics of load are (6500, 420) N. Statistics of area are (0.64, 0.06) m2. Estimate the statistics of stress. Ans: (10156, 1156.4) Pa. (10156 1156 4) Pa
11/2/2011 20

Example: Stress developed in a machine element is given by:

= P / 4kd 3

)(

2 4 L1 + 3L2 2

Given P = (1500, 50) N, Strength = (129, 3) MPa, L1=(150, 3) mm, L2=(100, 2) mm. Assume std. dev. of d is 1.5% mean value of d. k = 0.003811. Determine distribution of d if the maximum probability of machine-element-failure is 0.001
ALGEBRAIC FUNCTIONS
Q=C Q = Cx

MEAN Q

STD. DEVIATION
0 C x

C Cx C+x xy xy x y 1x

Standard deviation of a complex St d d d i ti f l function is expressed by :

Q=C+x Q = x y Q = xy y Q=x y Q =1 x

x x2 + y2
y 2 x + x 2 y
2 2

i =1 x i
n

2 xi

y 2 x + x 2 y
2

y2

x x2
21

Example: Stress developed in a machine element is given by:

= P / 4kd 3

)(

2 4 L1 + 3L2 2

Given P = (1500, 50) N, Strength = (129, 3) MPa, L1=(150, 3) mm, L2=(100, 2) mm. Assume std. dev. of d is 1.5% mean value of d. k = 0.003811. Determine distribution of d if the maximum probability of machine-element-failure is 0.001
2 n xi Standard deviation of a complex function is expressed by : = i =1 xi
2 2 2 2 2 2 2 2 = P + d + L L1 + L L2 P d 1 2 1/ 2

Statistically independent
1/ 2

2 2 2 22724 2 2 170430 2 13635e 4 2 85216 2 (50) + (0.002) = (0.015 d ) + (0.003) + 3 4 3 3 d d d d 1 = 3 [1.291e12 + 41830 + 261420 + 29047]1 / 2 d 1136200 = 22 d3

 = P / 4kd 3

)(

2 2 4 L1 + 3L2

Strength = (129, 3) Std. dev. of d is 1.5% mean value of d

34087000 = d3

Z = 3.09 =

0 129e6 34087000 d 3 2 1136200 3e6 + 3 d

2 2

11031 1136.2 (3000) + 3 = 41748 3 d d d = 0.6686 m ; = 0.001 m

2
11/2/2011

23

GEARS
Elements required to t a s t po e between transmit power bet ee rotating shafts. ~ Different rotational speeds. Often gears are treated as Rotates about axis axis. Consists of gearwheel and teeth.
pitch cylinder which roll together without slip.
Positive drive by meshing teeth.

Torque Ratio
Generally gear pair acts as a speed reducer aiming torque amplification q p at output shaft.
p Torque ratio, m A = g
Gear Pair: Smaller PINION Larger -- Gear

Internal & External gearing

Tooth Profile

p mA = g
Involute tooth form: Locus of a point on a line rolling on its base circle. Velocity ratio does y not change due to inaccuracies in center distance. t di t

Tooth curves of the mating Teeth need to be tangent to each other. Line of action is tangent to Both pinion & gear base Circles. On changing center distance Line of action still remains Tangent to both base circles But slope changes.

Pressure angle ??
Rb I = cos R I
1

Backlash: Difference between tooth space and tooth thickness.

Prevents jamming of teeth. Compensates for thermal expansion of teeth.

Any limit on Torque ratio ?????

Velocity ratio
Normally speed reduction for a single p of spur g g pair p gear < 7:1.
Size of gear wheel increases Gear box size.

For high speed reduction. Two stage or three stage T h construction are preferred. Compound Gear Train: At least one shaft carries two gears. g

Helical 10:1 Internal 4-8 Bevel 1-8 Cylindrical worm 3 80 3-80

Velocity ratio in Spur Gear

Ex: Motor speed 1440 rpm. Required speed to transmit a R i d dt t it load of 10 kN is 100 rpm.

Stage reduction ratio =

(Overall reduction ratio )1 n

1440 = 3.795 100
11/2/2011

Pinion 18 teeth (20)

30

Spur Gears:

Teeth parallel to axis of rotation. Suitable to transmit motion b t ti between parallel ll l shafts.

11/2/2011

Spur Gear Drive

31

Spur Gears S G
Basic gear. Pressure angle is measure of inclination of each teeth teeth.
Larger greater strength & wear resistance.

Diametrical Pitch: N in each inch of gears pitch diameter.

11/2/2011 32

Classification of Gears based on Position of Shaft Axes

Rolling Gears. 1. Parallel axes.
2. Intersecting axes

Quieter operation. Axial force. Herrringbone gears. Manufacturing complexity. l it

Rolling Cross Axis Gears

Mixture of rolling & Sliding at contact surfaces.
Lubrication requires ub a o qu attention.
Relatively low efficiency Worm Gears

Hypoid bevel gears Helical crossed axis gears

Rolling Vs sliding

Rolling

Sliding

Rolling Vs sliding
As contact moves towards or away from pitch point, sliding occurs. lidi With involute profile of gears, fil f only one contact position experience pure g rolling.

After few degrees rotation

Gear

Parallel shaft

Intersecting shaft h ft

Non intersecting non parallel shaft

Spur Gear

Helical Gear

Crossed Helical Gear

Hypoid Gear

Worm Gear

Single Helical Gear

11/2/2011

Double Helical Gear BevelGear

37

Spur Gear Nomenclature Nomen l t e

Pitch circles: Imaginary tangent circles. Pinion: Smaller. Circular pitch: Sum of tooth thickness & width of space space. Addendum: Radial distance between top land and pitch i l circle. Backlash: Difference between tooth space and p tooth thickness. Module: m=Dp/ZP=DG/ZG
11/2/2011

Basic spur gear Geometry.

38

Pitch and Base Circles Cross belt

Tooth , system deg

Adde Dede ndum ndum

Full depth

20 22.5 25

1m 1m 1m

1.25m 1.35m 1.25m 1.35m 1.25m 1.35m 1m

Stub
c

20

.8m

Modules
Preferred
1,1.25,1.5,2,2.5,3,4,5,6,8,10,12,16,20,25,32,40 1 1 25 1 5 2 2 5 3 4 5 6 8 10 12 16 20 25 32 40
39 11/2/2011 Second choice 1.125,1.375,1.75,2.25,2.75,3.5,4.5,5.5,7,9,11,14,18,22,28,36,45

Catalogue B
Module MM
HBIGM01 HBIGM01.25 HBIGM01.5 HBIGM01.75 HBIGM02 HBIGM02.25 HBIGM02.5 HBIGM02.75 HBIGM02 75 HBIGM03 HBIGM3.25 HBIGM03.5 HBIGM03.75 HBIGM04

Bore diameter of cutter 27mm or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1 27 or 1

Pounds 95.20 95.20 98.00 100.80 103.60 103.60 107.80 110.60 110 60 119.00 123.20 120.40 120 40 123.20 124.60 147.00 142.80 152.60
HBIGM05 HBIGM05.5 HBIGM06 HBIGM07 HBIGM08 HBIGM09 HBIGM10 HBIGM11 HBIGM12 HBIGM14 HBIGM16 HBIGM18 HBIGM20

Module MM 5 5.5 6 7 8 9 10 11 12 14 16 18 20

Bore diameter of cutter 27 or 1 27 or 1 27 or 1 32 or 1-1/4 32 or 1-1/4 1 1/4 32 32 40 40 40 40 50 50

Pounds 155.40 172.20 193.20 329.00 392.00 456.40 512.40 560.00 560 00 616.00 665.00 980.00 980 00 1190.00 1358.00

1mm 1.25 1.5 1.75 2 2.25 2.5 2.75 2 75 3 3.25 3.5 35 3.75 4 4.25 4.5

HBIGM04.25

HBIGM04.5

HBIGM04.75

11/2/20114.75

40

All sizes shown above are in 20o PA =Presure Angle (Note: 14.1/2o PA is also supplied)

Catalogue B
BSS Cutter Number 1 2 3 4 5 6 7 Cuts Teeth 135 - RACK 55 - 134 35 - 54 26 - 34 21 - 25 17 - 20 14 - 16 (European p Cutter No) 8 7 6 5 4 3 2

11/2/2011

41

Contact Ratio
Length of action = Base_p pitch Length of approach + Length of recess rbg g (2 ) Zg

11/2/2011

42

Contact Ratio
Length Length Length a * c = r p sin a *b =
2 rop rb2 bp

cb = a * b a * c

2 2 or, cb = rop rbp rp sin

2 2 Similarly Si il l ac = rog rbg rg sin i 2 2 2 2 Length of action, ab = rop rbp + rog rbg (rp + rg ) sin 2 2 2 2 rop rbp + rog rbg C sin

Contact ratio =
11/2/2011

2 rbg / Z g
43

For =20, ZP=19, Zg=37, and m=4; Find Gear Ratio, , , , ; , circular pitch, base pitch, pitch diameters, center distance, addendum, dedendum, whole depth, outside diameters, and contact ratio If center distance is increased by 2% what will ratio. be new pressure angle and new contact ratio. Gear Ratio = 37 19 dg Circular pitch = or, p c = m Zg r cos
Base pitch p b = pc cos ; Pitch dia d g = m Z g Nominal center dist, C = (rg + rp ) Addendum, a = 1 0 m a = 4 mm Add d 1.0 Dedendum, b = 1.25 m b = 5 mm d op = d p + 2 a

Ex:

new

= cos 1.02 r p
1 p

New rp

Contact ratio =
11/2/2011

2 2 2 2 rop rbp + rog rbg C sin

pb

44

Ex:

A gear pair (ZP=23, =20, Zg =24, m=1.75, F=10.0 mm) has h center distance equal to 42 mm. Find nominal and running d l 2 d l d contact ratios.
Gear Ratio = 24 ; Circular pitch p c = m pc = 5.5 mm 23 Base pitch p b = pc cos 5.1662 mm ; Pitch dia d g = m Z g d g = 42 mm No Nominal center dist, C = (rg + rp ) 41.125 ce e d s , ( 5 Addendum, a = 1.0 m a = 1.75 mm ; Dedendum, b = 1.25 m b = 2.1875 mm d op = d p + 2 a d op = 43.75

CR =

2 rop

2 rbp

2 rog

2 rbg

C sin

new = cos

pb 1 41.125 cos
42

new = 23.06o
45

Nominal contact ratio = 1 6 1.6, Contact ratio after assembly = 1.14

Design of Spur Gear

b , static Elastic strength b , dynamic B di endurance strength Bending d t th

contact Surface endurance strength

Core Case

Hardness; Strength > 1 GPa ; g

Related to wear. Indirectly Lubrication.

11/2/2011 46

Stresses in Spur Gears

Two modes of failures:
Fatigue: fluctuating bending stresses at root of tooth.
Keep stress state within modified Goodman line for material.. Infinite life
Tooth , system deg Adde Dede ndum ndum

Full depth

20 22.5 25

1m 1m 1m

1.25m 1.35m 1.25m 1.35m 1.25m 1.35m 1m

Surface fatigue (Pitting)

Repeated surface contact stresses materials do not exhibits endurance limit

In the present course Only p y two pressure angle and Full depth teeth.
11/2/2011

Stub

20

.8m

47

Bending Stresses g
b = b =
Moment Section Modulus Wt l F t2 / 6

Wr Wt

Assumptions

Compression due to radial tooth f t th force Wt , Wr component of force is negligible. and W a Teeth do not share load. Uniformly distributed load across the face Circumference width. mN = Greatest force is exerted at tip m N = (Tooth thickness + Spacing )N Wt l 2m b = Lewis Eq. = (Tooth thickness + Tooth thickness ) F Y m t 2 2 m2 m= 4 m Tooth thickness = 11/2/2011 Y = 0.2056 2

Components of gear

No. of Teeth
12 13 14 15 16 17 18 19 20

Form No. of factor Y Teeth

0.245 0.261 0 261 0.277 0.290 0 290 0.296 0.303 0.309 0.314 0.322 21 22 24 26 28 30 34 38 43

Form No. of factor Y Teeth

0.328 0.331 0 331 0.337 0.346 0 346 0.353 0.359 0.371 0.384 0.397 50 60 75 100 150 300 400 Rack

Form factor Y
0.409 0.422 0 422 0.435 0.447 0 447 0.460 0.472 0.480 0.485
Wt FY m

Ex: A gear set is connected to 5 H.P. motor, 1440 rpm. Pinion H P motor rpm (m=3mm, F=38 mm, number of teeth =16, pressure angle 20 degrees) is made of AISI 1020 steel (yield strength = 206 MPa) on milling machine Find factor of safety machine. safety.

b =

V = 3.6191 m/s ; Wt = 1031 N; Stress = 30.6 MPa

49

Load L d variation d i ti due to contact ratio t t t ti

11/2/2011

50

Pinion shaft passes 15kW at 2500 rpm. For =25, ZP=14, m=4, and Gear Ratio=3.5, determine transmitted , , , loads on gear teeth. Find pitch diameters, mean and alternative components of transmitted load.

Ex:

Z g = 3.5 14 = 49 T p = 15000 /(2 2500 / 60) = 57.3 Tg = 3.5 57.3 = 200.55 N .m Tangential load ,Wt = T p / (d p / 2 ) = 2046 N Radial load R di l l d ,Wr = Wt t = 954 N tan W Mean load = t 2 W Alternative load = t 2
11/2/2011

d p = m Z p = 4 14 = 56 mm

47% load

51

Homework: What will the pressure angle be if the center

distance of a 20 pressure angle gear pair is increased by 7%. 7%

Homework: Find out the mean and alternating load

components of a gear-set that transmits 50 kW at 1600 gear set pinion rpm. =25, ZP=23, Zg=57, and m=4.

Fatigue Bending F il F ti B di Failure of S f Spur Gear G Surface Finish Gear size Reliability R li bili Stress concentration S i Rotation in one direction or both Temperature
11/2/2011 52

AGMA introduced velocity factor in terms of pitch line velocity (m/s) in Lewis equation. AGMA Lewis Eq Eq. 3.05 + V (cast iron, cast profile ) Kv = K v Wt 3.05 b = FY m 6.01 + V
Kv = 6.01 3.56 + V Kv = 3.56

(Cut or milled profile )

(Hobbed or shaped profile ) (Shaved or ground profile )

5.56 + V Kv = 5.56

Useful for preliminary estimation of gear size.

For V = 15 m/s , Kv Cast iron, cast profile Cut or milled profile Sh Shaved or ground d d
11/2/2011

= 5.2 =35 3.5 = 1.3 13

53

Hobbed or shaped profile = 2.1

Ex: Find out the power rating of milled profiled spur

gear (AISI material, yield strength = 210MPa) for data: =20, ZP=16, F=36mm, m=3.0, N = 20 rps. Assume factor of safety = 3.0.

No. of Form Teeth factor Y

14 15 16 0.277 0.290 0.296

Ans:

Allowable bending stress = 70 MPa. Pitch line velocity V=3.0 m/s. Kv = 1.5 , Form factor Y = 0.296 Tangential load = 1492 N. Power rating = 4.475 kW P ti 4 475 kW.

Kv =

6.01 + V 6.01

(Cut or milled profile )

K v Wt b = FY m
11/2/2011 54

AGMA Bending Stress Equation

J = AGMA bending Geometry Factor

K v Wt b = Ka K B Km FmJ
depends on pressure angle, point of loading

11/2/2011

55

11/2/2011

56

K v Wt b = Ka K B Km FmJ
Power Source Uniform (Electric motor, turbine) Light shock (Multicylinder) Moderate shock (single cylinder) Uniform Driven Machines Light shock Moderate shock Heavy shock Application factor, Ka factor

1.00 1.20 1.30

1.25 1.40 1.70

1.50 1.75 2.00

1.75 2.25 2.75

Character of operation
Uniform Medium M di Heavy
11/2/2011

Driven machines
Generator, conveyor, electric hoist, Machine tool, mixer, pump, M hi t l i Press, shear, mill, drilling,
57

Load di ib i d distribution f factor Km Face width, mm Km

K v Wt b = Ka K B Km FmJ

< 50 150 250 >500

1.6 1.7 1.8 2.0

Rim thickness factor K B = 2 m B + 3 . 4 K B = 1 .0

11/2/2011

0.5 m B < 1 . 2 where tR mB = ht

58

m B 1 .2

Summary of Previous Lecture

Lewis Eq.
b =
Wt FY m

AGMA Bending Stress Eq. K v Wt b = Ka K B Km FmJ

11/2/2011

59

Ex:

K W b = Ka K B Km FmJ
Power Source Uniform (Electric motor, turbine) Light shock (Multicylinder) Moderate shock
11/2/2011

A gear pair (ZP=23, =20, Zg =24, m=1.75, F=10.0 mm) transmits 8 N.m torque from crankshaft (rotational speed 8000 rpm) of single cylinder IC engine to wheels. Bore diameter of pinion is 17 mm, and bore dia of gear is 20 mm. Use AGMA bending stress formula to determine the maximum bending stress. Assume gears are grounded. Given: F = 10 mm, m = mm 1.75, Wt = 8000/(23*1.75*0.5) v t

Driven Machines Uniform 1.00 Light shock 1.25 Moderate shock Heavy shock Application factor, Ka 1.50 1.75

Load distribution factor Km Face Km width, width mm

1.20 1.30

1.40 1.70

1.75 2.00

2.25 2.75

< 50

1.6

60

K a = 2.0
d p = 23 *1.75 = 40.25 mm V=

K m = 1.6
60 16.86 m / s

Kv =

5.56 + V 5.56

(ground gears )

dp N
60

(40.25) 8000

5.56 + V Kv = = 1.3185 5.56

d proot = d p 2 *1.25 *1.75 = 35.875 ht = 2.25 *1.75 = 3.9375 mm

t R = 0.5 (d proot Bore p ) = 9.4375 m B > 1. 2 K B = 1

K v Wt b = Ka K B Km FmJ
11/2/2011 61

J = 0.35

J = 0.26

K v Wt b = Ka K B Km FmJ b = 368.6 MPa b = 273.8 MPa 11/2/2011 for tip loading for HPSTC loading

K a K B K m K v = 4.22
Lewis b = Wt = 75 MPa FY m
62

AISI 1020 steel (yield strength = 206 MPa) FoS = 0.75

K finish = a(Sut in MPa )b

Endurance Strength
Se = S k L
' e

Finishing method Ground

a 1.58 4.51 57.7

b -0.085 -0.265 -0.718 0.718

ks
0.107 e

kr

kT

Machined or finish cold drawn Hot rolled

=1.0 0 for b bending load g

= 1.24 d

if d e 51 mm if d e > 51 mm

Probability of survival, % 50 90 95 99 99.9 99.99 99.999 99 999 99.9999

= 1.51 d e0.157

Reliability factor, kr 1.0 0.897 0 897 0.868 0.814 0.753 0.702 0.659 0 659 0.620

d e = 0.808 t l

Temperature Factor
Temperature KT 20C 50C 100C 150C 200C 250C 1.00 1.01 1.02 1.025 1.02 1 02 1.0 Temperature KT 300C 350C 400C 450C 500C 550C 0.975 0.943 0.900 0.843 0.768 0 768 0.672

NOTE: Initially increase in temperature causes the redistribution of stress-strain profiles at notches or stress concentration features, hence increases the fatigue strength.
11/2/2011 64

Endurance Strength
Se = S k L
' e

K finish = a(Sut in MPa )b 0.265 K finish = 4.51(380 )

K finish = 0.934
Finishing method Machined or cold drawn a 4.51 b -0.265

ks

kr

kT

k finish

S e = (0 . 5 380 MPa

=1.0 0 for b bending load g

= 1.24 d e0.107 if 2.79 d e 51 mm

d e = 0.808 t l d e = 0.808 (1.5708 m )(2 m ) d e = 2.65 mm

Probability of survival, % 50 90 95 99

Reliability factor, kr 1.0 0.897 0 897 0.868 0.814 0 814

k s = 1.0

)(1 )(1 )(0 . 897 )(1 )(0 . 934 ) = 159

MPa

Fatigue failure criteria for fluctuating stresses

m
1 + = S ut S e FoS

+ m =1 S e Sut

a tan = =1 m

a =

2 274 a = = 137 MPa 2

137 137 1 + = 380 159 FoS

K v Wt Ka KB Km 2F m J

a
Se

m
S yt

=1

0.82

AGMA Strength Equation

Through Hardened Steel

b = 273.8 MPa
Grade 2 all ,b = 0.703 H B + 113 MPa Grade1 all ,b = 0.533 H B + 88.3 MPa
Grade 2 required H B = 228.7 Grade1 required H B = 348
11/2/2011 67

Nitrided through hardened steel gears (AISI 4140, 4340): Max hardness 340 HB.
Grade 2 all ,b = 0.749 H B + 110 MPa Grade1 all ,b = 0.568 H B + 83.8 MPa
Material Designation

corrected ,all , b =

all , b YN
S F KT K R

Strength at 107 cycles and 0 99 Reliability. 0.99 Reliability

Heat Treatment Allowable Bending Stress Number (MPa) 35 58 90 39 163

ASTM A48 Gray cast iron Bronze ASTM A536 ductile

11/2/2011

Class 20 Class 30 Class 40

As Cast As Cast As Cast Sand cast Heat T e ted He t Treated

Grade Grade Grade Grade

60 80 100 120

Annealed 151-227 Quenched & Temp 151-227 Quenched & Temp 186-275 Quenched & Temp 213-275

68

 corrected ,all , b =

all , b YN ll
S F KT K R

Material properties (FSM ) 1.0,1.1,1.3 St ess (FS Stress ( SS ) 1.0, 1.2, 3.0 0, ,30 Geometry (FSG ) 1.0, 1.2 Failure analysis (FSFA ) 1 0 1 2 1 5 X 1.0, 1.2, 1.5 Environmental factors (FSE ) 1.0, 1.3, 1.6 Danger to Personnel (FSD ) 1.0, 1 6 X 1 0 1.6

11/2/2011

69

Correction Factors
0.658 0.0759 log e (1 R ) 0.5 < R < 0.99 KR = log 0.5 0.109 l e (1 R ) 0.99 R 0.9999
corrected ,all , b = all , b YN
S F KT K R

Contact Stresses
Two rolling surfaces under compressive load experience contact stresses . contact stresses. Ball and roller bearings Cams with roller follower Spur or helical gear tooth contact S h l l h
Pinion

Gear
11/2/2011 71

Contact (Elastic) Stresses

Compressive load elastic deformation of surfaces over a region surrounding the initial point of contact. p Stresses are highly dependent on geometry of Stress concentration the surfaces in contact as well as loading and material near contact region g is very high Stress high. properties. concentration factor ????
11/2/2011 72

R1

Cylindrical

R1 R2

Spherical R2

On varying radii of curvature: sphereplane, sphere-in-cup, cylinder-onplane, plane and cylinder in trough cylinder-in-trough. Zero areas Infinite stress. Material y will elastically deform and contact geometry will change.

Contact stresses
b << d1 b << d 2
Deformation b will be small compared to dimensions of two bodies. bodies

High stress g concentration

11/2/2011

74

Spherical contact h l
p = pmax r 2 1 b

Total applied load on contact patch is F = p rd dr

0 0

b 2

Total applied load on contact patch is F = 2 pmax

0

r 2 1 r dr b

or on assuming b r = t i
2 2 2

2 pmax F= b
2 pmax F= b

[b
b 0
0 b

r 2 r dr

dt t ( t d )

or or

2 pmax b 3 F= b 3 2 F = b 2 pmax 3

K t = 1.5

Cylindrical Contact
p = pmax x 2 y 2 1 b a

R1

Pressure variation along Y-axis is negligible, li ibl

p = pmax x 2 1 b
patch is
Y

R2

Total applied load on contact F = 2L

p max

2 x 1 dx b

X
76

11/2/2011

Cylindrical Contact
F = 2 L pmax
0 b

x 2 1 dx b

let l x = b sin i or

F = 2 pmax b cos 2 d
0

F=

b L pmax

Stress concentration factor = 4/

Fspherical contact

2 = b 2 pmax 3

Fcylindrical contact =
11/2/2011

b L pmax

How to determine b ???

77

How to determine b
Assume pmax = y and find value of b.
1.5 Fspherical contact b= pmax 2 Fcylindrical contact b= L pmax

Criterion b << d1 needs to be checked.

11/2/2011 78

For axi-symmetric point load axi symmetric Timoshenko & Goodier suggested:
= x2 + y2 + z2
G= E 2 (1 + ) F z 2 (1 ) z = 3+ 4 G

1 =

F 4 E 2(1 + )
2

(1 ) 0+ x2 + y2

Z 2 E r Ref: S. Timoshenko and J.N.Goodier, Theory of elasticity, 2nd Edition, McGraw Hill.
79

(1 ) F =

11/2/2011

Deflection of sphere 1 1 12 1 (r , ) = 2 E1 0
b 2

pmax 1 (r / b ) rd d d dr r
2 2

b p 1 (r / b ) 1 12 or 1 = 2 max rd dr 2 E1 r 0

or 1 =

(1 ) p
2 1

E1

max

1 (r / b ) dr
2

on assuming r = b sin

1 =

(1 ) p
2 1

max

E1

cos (b cos d )
0

or

b 1 1 = 2 E1 b 1 1 = 2 E1

( ( (

2 1

)p )p )

max

(cos 2 + 1) d
0

or or
11/2/2011

2 1

sin 2 2 + max 2 0

b 1 12 1 = pmax 2 E1 2

2 2 F = b pmax 3 80

b 1 12 1 = pmax 2 E1 2
3 1 12 1 = F 8 b E1
1 = OB OC
or, 1 = R1 OA2 AC 2 or, or 1 = R1 R12 b 2

2 2 F = b pmax 3
O

2 b or, 1 = R1 1 1 , R 1 1 b 2 or, 1 = R1 1 1 + negligible terms 2 R1

C B

b or, 1 = R1 2 R12
2

1 12 b 3 = 0.75 R1 F E1

A
81

Two spherical contacting surface

Deflection f h D fl ti of sphere 1 b 1 12 1 = pmax 2 E1 2
b2 b2 + = pmax 2 R1 2 R2 4

2 b 1 2 2 = pmax 4 E2

pmax

2 1 12 1 2 b + E1 E2

) (

b2 b2 Total deflection can be p presented in terms of g geometric radii, = + 2 R1 2 R2 or or

2 1 12 1 2 + b E1 E2

) (

2 1 12 1 2 + b= 4 1 E2 1 E1 2R + 2R 2 1

pmax

) (

2 2 F = b pmax 3

2 1 12 1.5 F 1 2 b3 = + 4 1 E2 E1 1 For cylindrical contacts + 2R 2R 2 1 1 2 4F

) (

b=

11/2/2011

L 1 R + 1 R E1 1 2

2 1 2 + E2

Surface/Contact Stresses in Spur Gears

Surface failure of gear tooth occurs due to very high local y g contact stresses. Maximum contact pressure at the contact point between two cylinders is given by:
pmax = 2F bL

2 2 F 1 12 / E1 + 1 2 / E2 where b = L 1 + 1 d2 d1
11/2/2011

[(

) ]

As per nomenclature of gear design: F = W, L=F, W = Wt /cos , d1=dp*sin d sin

83

pmax

2F = bL

2 2 F 1 12 / E1 + 1 2 / E2 where b = L 1 + 1 d d2 1

[(

) ]

As per nomenclature of gear design: F = W L=F, W = Wt / d i W, L F cos , d1=dp*sin

pmax =

2W bF

2 2 2 W 1 p / E p + 1 g / E g where b = h F 1 1 + 1 d d g sin p

[(

) ]

pmax

2 Wt / cos = bF

pmax =

2 Wt / cos

2 2 1 p / E p + 1 g / E g 2 Wt F F cos 1 1 1 d + d p g sin i

[(

]
84

2 pmax

c2

2Wt = F sin cos 1

2 Wt = F sin cos 1 2 p

2 p

dp + dg d d p g 2 / E p + 1 g / E g

d p + dg d p dg 2 / E p + 1 g / E g

Surface contact compressive stress

Wt = F dp
2 c

1 2 2 1 p / E p + 1 g / E g

[(

dg + d p 2 sin cos d g

Let C P =

1
2 1 2 1 g p + E P E g

sin cos Zg I= 2 Zp + Z g
c = CP Wt F I dp
85

11/2/2011

AGMApitting resistance equation c = C P p g q

Wt C a C m Cv F I dp
Load di ib i L d distribution factor Cm

Driven M hi D i Machines Power Source Unifor m 1.00 Light shock

Uniform (Electric motor, turbine) g Light shock (Multicylinder) Moderate shock

Moderate Heavy Face width, Cm idth shock shock F Application factor, Ca mm 1.25 1.50 1.75

1.20 1.30

1.40 1.70

1.75 2.00

2.25 2.75

< 50 150 250 >500

1.6 16 1.7 1.8 2.0

A + 200V Cv = A 11/2/2011

whe e where A = 50 + 56 (1 B ) ; B = 0.25 (12 Qv ) 5

2/3
86

Calculation of Factor Cv
A + 200 V Cv = A
B

A = 50 + 56 (1 B )

and

B = 0.25 (12 Qv )

2/3

AGMA Tolerance Cv Qv
9 10 11 12
11/2/2011

for 16.86 m/s velocity

15 m 10 m 7 m 5 m

1.34 1.23 1.13 1

87

Ex:

A gear pair (ZP=23, =20, Zg =24, m=1.75, F=10.0 mm) transmits 8 N.m torque from crankshaft (rotational speed 8000 rpm) of single cylinder IC engine to wheels. Bore diameter of pinion is 17 mm, and bore dia of gear is 20 mm. Using AGMA pitting resistance formula to determine the maximum contact stress. Assume gears quality = 9, E = 2.e5 MPa, =0.3
AGMApitting resistance equation c = C P CP = 1 Wt C a C m Cv F I dp 2.0 1.6 1.34

1 1 + E E P g sin cos Zg I= I = 0.0821 2 Zp + Z g

2 p

2 g

C p = 187000

Ans: 1334 MPa

A + 200 V Cv = A 11/2/2011

A = 50 + 56 (1 B )

and

B = 0.25 (12 Qv )

88

2/3

Contact Stress vs. Brinell Hardness

corrected ,all , c = all , c Z N
S F KT K R

all , c = 2.22 HB + 200 MPa Grade1 all ,,c = 2.41 HB + 237 MPa Grade 2 c
Stess: 1334 MPa

Effect of Brinell Hardness on allowable contact stress for through-hardened steel. g

11/2/2011 89

Alternatives
Reliability < 0.99

0.658 0.0759 log e (1 R ) 0.5 < R < 0.99 KR = 0.5 0.109 log e (1 R ) 0.99 R 0.9999
1334 1 < K R < 0.8996 1200 K R
corrected ,all , c = all , c Z N
S F KT K R

R < 0.9585
11/2/2011 90

Pitting resistance stress cycle g y is based 10 factor, ZN Allowable contact stressreliability on 0.99. million load cycles with of
Heat Treatment Induction I d ti Carburized Nitrided Grade 1 (MPa) 1172 1206 1240 Grade 2 1310 1344 1551 Grade 3 1896

Strength of Steel
Increase in module. Increase in face width.

1334 = 2.466 N 0.056 N = 1.51 106 cycles l 1200

corrected ,all , c =
11/2/2011

all , c Z N
S F KT K R
91

Ex: Motor speed 1440 rpm. Required speed to transmit a load of 10 kW is 100 rpm Design rpm. gears.

Stage reduction ratio =

(Overall reduction ratio )1 n

1440 = 3.795 100
Pinion 18 teeth (20) (20 )

75 MPa if starting with Lewis equation 9m F 15m Wt

b =

FY m

10000 W Wt = (m Tp )(1440 60) m / s

92

No. of Teeth
12 13 14 15 16 17 18 19 20

Form No. of factor Y Teeth

0.245 0.261 0 261 0.277 0.290 0 290 0.296 0.303 0.309 0.314 0.322 21 22 24 26 28 30 34 38 43

Form No. of factor Y Teeth

0.328 0.331 0 331 0.337 0.346 0 346 0.353 0.359 0.371 0.384 0.397 50 60 75 100 150 300 400 Rack

Form factor Y
0.409 0.422 0 422 0.435 0.447 0 447 0.460 0.472 0.480 0.485

Wt 7.37 m 6 b = 75 *10 = (12 m )(0.309)m FY m Modules

Preferred

m=3.0 mm
Select m = 3.0 mm PCD = 54 mm
93

1,1.25,1.5,2,2.5,3,4,5,6,8,10,12,16,20,25,32,40

Is dp = 54 mm justifiable ?
Easily available bearings 10, 12, 15 mm. Gears to be on stepped shaft 15 mm mm. Tooth height = 2.25*3mm. Minimum rim thickness =1.2*ht Mi i i hi k 1 2*h dp 4 6.7 mm dp = 54 mm is justifiable. V = 4 m/s

11/2/2011

94

AGMA Bending Stress Equation

K v Wt b = Ka K B Km FmJ
Teeth on Gear = 68

J = 0.3 F= F 36 mm

11/2/2011

K a = 1.5 ; b = 310 MPa

10000 = 2500 N 4 Cut or milled profile 6.01 +V +V Kv = = 1.67 6.01 Wt =

Checking contact stress

AGMApitting resistance equation c = C P CP = 1 1 EP
2 p

Wt C a C m Cv F I dp 1.5 1.6 1.123

1 + E g

2 g

C p = 187000

sin cos Zg I= 2 Zp + Z g
A + 200 V Cv = A
11/2/2011

I = 0.1271

Ans: 977 MPa

B = 0.25 (12 Qv )

; A = 50 + 56 (1 B ) assuming Qv = 10

and d

2/3

96

281 HB
Grade 2 all ,b = 0.703 H B + 113 MPa

307 HB

b = 310 MPa

all , c = 2.41 HB + 237 MPa Grade 2

Ans: 977 MPa

11/2/2011

97

Helical Gears
Teeth are angled (15, 23, 30, 45 )w. r. t. axis of rotation
High contact ratio
Smooth engagement Less noise

Axial load

Increase in helix angle increases smoothness.

Z Virtual teeth, Z = cos3

98

Helical Gears H li l G
Axial load
Wn = Contact Force Wr = Radial Force = Wn sin n Wt = Tangential Force = Wn cos n cos Wa = Thurst Force = Wn cos n sin
Two pressure angles
Transverse pressure angle () Normal pressure angle (n)
11/2/2011 99

tan n cos = tan

For parallel axes, p , Meshing of opposite hand Helical Gears is essential. Axial force = Separation force p

Wa = Wn cos n sin

pn = pc cos pa = pc tan F > pa

100

2Re 2 (0.5 d / cos2 ) Z = = pc mn Z = d Z mn / cos = 2 mn cos mn cos2

d Semi - major axis of ellipse, a = 2 cos d Semi - minor axis of ellipse, b = 2 a2 Radius of curvature, Effective radius R e = b

Z Virtual teeth, Z = cos3

101

Ex: A pair of helical gears (=25, Zp=22, Zg=44) have normal pressure angle=20 and normal module = 3mm. Find nominal center distance & transverse 3 Fi d i l t di t t pressure angle, . Compare with spur gear.
Geometric entity in Helical gear transverse plane Module (mm) M d l ( ) Dp (mm) Dg (mm) 3/cos(25)=3.31 3/ (25) 3 31 3*22/cos(25)=72.823 3*44/cos(25)=145.646 tan(20)/cos(25)=21.88 0.5*(Dp+Dg)=109.234 Spur gear 3 66 132 20 99

()
C (mm)

Z Virtual teeth, Z = cos3

11/2/2011 102

Axial Thrust Force

Wn = Contact Force Wr = Radial Force = Wn sin n Wt = Tangential Force = Wn cos n cos = Power to be transmitted (W ) Wa = Thurst Force = Wn cos n sin
Wt Bending B di stress, b = F Yz m Lewis Eq. L i E
( rad / s ) rp ( m)

Z Z = cos 3
103

K v Wt b = Ka K B Km 11/2/2011 m J F z

AGMA Eq.

Pinion teeth = 18, Gear teeth = 68, helix angle = 20 20. 0.35 Virtual teeth = 21.6, 81.6 Ratio = = 1.17
J

0. 3

11/2/2011

104

BEARINGS
Mechanical elements which
1. allow relative motion between two elements (i t l t (i.e. shaft & housing). 2. 2 Bear load Thrust load Radial load Combined load

11/2/2011

105

1. Dry Contacts

2. Chemical Films

3. Lamellar Solids

5. Elastomers 4 Pressurized Lubricant Film i d L b i t Fil 4. P

6. Flexible Strips

7. Rolling Elements
11/2/2011

8. Magnetic Field
106

Comparison in three types of bearing

11/2/2011 107

Rolling Element Bearing

Rotation is always easier than linear motion.
Low Lo friction & moderate l bricant req irements lubricant requirements are two important advantages of rolling bearing.

If you can buy it, dont make it!

Bearing l ti B i selection.
~ 20,000 Varieties of bearings. Conventional bearing steel to ceramics, with (out) cage (brass/polymers). Pin. Smallest bearings few grams. Largest 70 Tonnes

Frequent questions
~ 20,000 Varieties of bearings c ass cat o classification. How do I select a bearing for given application. application How do I treat combined load. Bearing lif (106 cycles ?? 3000 rpm). B i life l ) Mathematical formulation ? Any requirement of lubrication (How to we incorporate) p )
11/2/2011 109

Bearing Classification

11/2/2011

110

http://www.skf.com/portal/skf/home/products?newlink=first&lang=en

11/2/2011

111

Deep Groove Ball Bearing (DGBB): Both rings

possess deep grooves. Bearing can support high radial forces as well as axial forces. There are single-row & double row DGBB. Widely d bl G d l used in industry.

Cage/Separator: Ensures

Angular Contact Ball Bearing (ACBB):

uniform spacing and prevents mutual contact of rolling elements.

Raceways are so arranged that forces are transmitted from one raceway to other under certain contact angleangle between line of action of the force & radial plane. Due to CA, ACBB are better suited to sustain h h axial d high l loads than DGBB.

Ball

Cylindrical roller

Angular contact ball

Tapered roller

Spherical roller

Ball
11/2/2011

Cylindrical roller
113

Cylindrical Roller Bearing

Higher coefficient of friction because of small diameter rollers and rubbing action against each other
11/2/2011 114

Cylindrical roller bearings

11/2/2011

115

Shield: Profiles sheet steel discs pressed into the

grooves of outer ring and forming gap-type seals gap type with the inner-ring shoulders. Nomenclature with Z

Seals: Often S l Oft made of elastic rubber. Bearings sealed on d f l ti bb B i l d

both sides are grease filled and in normal working conditions the grease filling lasts the entire service life of g g the bearings. Nomenclature with R

117

Selection of bearing type t pe

Cylindrical & Needle roller Pure Radial Load Cylindrical roller thrust, ball thrust, four point y , , p angular contact ball bearings Pure Axial load Taper roller, spherical roller, angular contact p , p , g bearings Combined load Cylindrical roller, angular contact ball bearing y , g g High speed Deep groove, angular contact, and cylindrical eep g oo e, a gu a co tact, a d cy d ca roller bearing High running accuracy
11/2/2011 118

Designation

International Organization for Standardization

Each rolling bearing is designed by a code that clearly indicates construction, dimensions, tolerances and bearing clearance. , , g
618 05 2Z

11/2/2011

Multiply by 5 to get bore in mm d<10mm d<10mm 618/8 (d=8mm) d>500 mm 511/530 (d=530mm)

00 = 10mm 01= 12mm 02 = 15mm 03 = 17mm

119

0 Double row angular contact ball bearings 1 Self aligning ball bearings Self-aligning 2 Spherical roller bearings 3 Taper roller bearings p g 4 Double row deep groove ball bearings 5 Thrust ball bearings Series S i Bore B 6 Single row deep groove ball bearings 7 Single row angular contact ball bearings 8 Cylindrical roller thrust bearings HK needle roller bearings with open ends K Needle roller and cage thrust assemblies g N Cylindrical roller bearings A second and sometimes a third letter are used to identify the configuration of the flanges e.g. NJ, NU, NUP; double or flanges, e g NJ NU multi-row cylindrical roller bearing designations always start with NN. QJ Four-point contact ball bearings
11/2/2011 120

SRB ACBB SABB TRB DGBB

TBB DGBB ACBB CRTB

In increasing order

11/2/2011

In order of increasing outside bearing 121 diameter

Examples of basic codes

11/2/2011

122

Rolling Element Bearings

Load Direction Radial
Deep groove ball Cylindrical Roller Needle Taper Roller Self Aligning Ball Self Aligning Spherical Roller Angular contact ball Thrust ball y y y y y y y y y y y y y y y y y
123

Misalignment Capacity Both

y Some types

Axial

High

Med
y

Low
y y y

Suffix

61804

61804-2Z

61804-2RS1

11/2/2011

124

Basic Dynamic Load Rating: C Radial load (thrust load for thrust bearings) which a group of identical bearings with stationary outer rings can theoretically endure one million revolutions of inner ring. y g Static Load Rating: C0 Radial load causing permanent deflection greater than 0.01% of ball dia. ------ > 0.3 m 2320 N
11/2/2011 125

Equivalent load E i l tl d
P = V X Fr + Y Fa V X Rotation factor Radial factor

Fr Applied radial load Y Thrust factor Fa Applied thrust load

11/2/2011 126

Bearing type Deep groove ball bearing Fa/C0

.014 .028 .056 .084 .11 .17 .28 .42 .56 20 25 30 35 40

Inner ring
Rotating Stationary

Single row Fa/VFr > e X

0.56

Double row
Fa/VFr e X
1

Fa/VFr > e X
0.56

V
1

V
1.2

Y
2.30 1.99 1.71 1.55 1.45 1.31 1.15 1.04 1.00 1.0 .87 .76 66 .66 .57

Y
0

Y
2.30 1.99 1.71 1.55 1.45 1.31 1.15 1.04 1.00 1.63 1.44 1.24 1.07 1 07 .93 .19 .22 .26 .28 .3 .34 .38 .42 .44 .57 .68 .80 95 .95 1.14

Angular contact ball bearing

Self aligning ball bearing

1.2

.43 .41 .39 37 .37 .35

1.09 .92 .78 66 .66 .55

.70 .67 .63 60 .60 .57

.4

.4 cot

.42 cot

.65

.65 cot

1.5 tan

Deep Groove Ball Bearing

RSH Sheet steel reinforced contact seal of acrylonitrile-butadiene rubber (NBR) on one side of the bearing. L stand for low friction.

Example: Assume radial and axial loads on a bearing

p y g are 7500N and 4500N respectively. Rotating shaft dia = 70 mm. Select a single row deep groove ball bearing.
Bearing type Inner ring
Rotating R t ti

Single row Fa/ r > e /VF X

0.56 0 56

Fa/C0 Deep groove .014 014 ball .028 bearing

.056 .084 084 .11 .17 .28 .42 .56

V
1

Y
2.30 2 30 1.99 1.71 1.55 1 55 1.45 1.31 1.15 1.04 1.00 .19 19 .22 .26 28 .28 .3 .34 .38 .42 .44
129

Fa/Fr = 0.6; Fa/C0=4500/31000 Fa/C0=4500/68000

X = 0.56, Y= 1.37; P=10365 X = 0.56, Y= 1.65; P=11625

Rolling Element BearingsBearings Load Calculation: Tabular Approach Load rating C > P x fn x fL x fd
Where C = radial dynamic rating P = calculated effective radial load fn = speed (rpm) factor fl = Life (hours) factor fd = dynamic or service factor
Load classification
Uniform f Light shock Moderate shock Heavy shock
11/2/2011

Factor
1.0 1.5 2.0 3.0
130

11/2/2011

131

Example 1: Radial load = 4448 N, p Speed = 1000 rpm, p p Shaft dia. 30 mm; Desired life= 30 000 hours, No Shock loading.

C
=> C

> P x fn x fL x fd > 42 290 N 42,

fd = 1.0; P = 4 448 N, fn= 2.78; fl= 3.42

11/2/2011

132

Revisiting example discussed in slide 129

Example: Assume radial and axial loads on a bearing are 7500N and 4500N respectively Shaft dia = 70 mm Select a deep groove ball bearing. respectively. mm. bearing

Consider shaft rotates at 1000 rpm and expected bearing life = 30000 hours
Fa/Fr = 0.6; Fa/C0=4500/31000 Fa/C0=4500/68000 P=10365 P=11625

> P x fn x fl
C = 98.55 kN C = 110. 53 kN 110
133

fn= 2.78; fl= 3.42

Case 1: Case 2: C 2
11/2/2011

May be a good option for life = 1300 hr M b d ti f lif h

Summarizing previous lecture

Rolling element bearings/Rolling bearings
Ball bearing Roller bearing Antifriction bearings Starting ~Running friction.
Exception for Taper roller bearing Cone Cup Finite Life of bearing Cost of dis-assembling Maintenance free bearings f Finite Life. b i for Fi it Lif
134

Five Components

Inner ring Outer ring Rolling elements Cage/Retainer/Separator Seal/Shield S l/Shi ld

11/2/2011

Equivalent Dynamic L d E i l tD i Load

Equivalent load: P = V X Fr + Y Fa

Assuming rotation of inner ring P = Fr when Fa / Fr e P = X Fr + Y Fa when Fa / Fr > e

e is a dimensionless ratio, indicating axial load lower than a certain limit does not affect total load

Value f depends on arrangement & static load V l of e d d t t ti l d capacity (CO ) of bearing

11/2/2011 135

Fa/C0 Fa/VFr > e X

.014 .028 .056 .084 .11 11 .17 .28 .42 .56 0.56

e
.19 .22 .26 .28 .3 3 .34 .38 .42 .44

Y
2.30 1.99 1.71 1.55 1.45 1 45 1.31 1.15 1.04 1.00

Single/Double row Deep groove ball bearing

P V Fr
1

Fa V Fr

X & Y Factors depend upon bearing geo., number of balls and size of balls balls.
11/2/2011 136

Fixed (Ball) vs Floating (Roller) Bearings

Predominately Used as Floating Bearing

Variations of shaft due to the thermal expansion are accommodated between the inner ring & the roller set.

Summarizing previous lecture lecture

Considered an example: speed of inner ring = 1000 rpm, expected bearing life = 30000 t db i lif hours 1.8e09 cycles. 13000 hours 7.8e08 cycles. 7 8e08 cycles Life should be infinite after 1.0e6 cycle ?
Rating life corresponding to 10% failure probability (Reliability ??) Dynamic load rating (catalogue C reading) is the load hi h l d which 90% (reliability=0.9) of a group of ( li bilit 0 9) f f identical bearings will sustain for minimum of 106 cycles. cycles
11/2/2011 138

L-10 Life

L 10 L-10 Life

(C ) 10
a

= P a L1 = P2a L2 = P3a L3 1
Load Rating Factors

a=3 10 a= 3

for ball bearings for roller bearings

a

C Bearing life in hours = P

1000,000 60 Speed p

C = 110530 N, P = 11625 N, Speed = 1000 rpm Life = 14,326 hours. C=39700 N, P=10365 N, Speed = 1000 rpm Life = 936.5 hours
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Load Rating Factors

1 a1 = 4.48 log e R

2 3

(C ) 10
a

= P a L1 = P2a L2 = P3a L3 1
a

Application

Factor

C in 10 6 cycles L = a1 Pa f a = 3 for ball bearings 10 for roller bearings a= 3

Electric El t i motor, t b t turbo- 1 0 1 4 1.0-1.4 compressor Reciprocating machines 1.5-2.0

Impact machines like 2.5-3.5 hammer V-belt drive Single ply belt drive Multi ply belt drive Chain drives 2.0 3.0 3.5 1.5
140

11/2/2011

Example 2:

Radial load = 2 224 N,

Speed = 1500 rpm

Desired life= h D i d lif 8 hours/day, 5 day/weeks for 5 years, Li h Shock /d d / k f Light Sh k loading. For shaft dia of 25 mm.

C C C

> 2224*1 5*(10400*1500*60/106)1/ 2224*1.5*(10400*1500*60/10 1/a > 32, 633 N for BALL BEARINGS > 25, 978 N for ROLLER BEARINGS

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141

Types

Bearing Selection
Radial + Thrust
Deep groove ball bearing

Conrad type Filling notch type

Single row angular contact ball bearing can resist thrust l d i one direction i t th t load in di ti only.

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142

Example 3: A radial load of 3000N combined with thrust load of 2500N is to be carried on a 6214 ball bearing for 70 mm dia rotating shaft at 1000 rpm. Determine equivalent radial load to be used for calculating fatigue life. Compare life of 6214 bearing with that for a 7214 (nominal contact angle 30)

Step 1: C0 for 6214 is 45kN and 7214 is 60 kN. C for 6214 is 63.7 kN and 7214 is 71.5 kN Step 2:
Bearing type g yp Deep groove ball bearing Fa/C0 .056
Angular contact ball bearing 30

Single row, Fa/VFr > e g , X 0.56 .39 Y 1.71 .76

e
.26 0.8

Step 3: Equivalent radial load for 6214 bearing is 5955N & for 7214 bearing radial load is 3070.
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Step 4: Life for 6214 will be 20,400 hours and for 7214, p , , life=210,550 Hours

C 1000,000 Bearing life in hours = P 60 Speed

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144

W = Wmax (cos ) Fr =

W cos
=
1

= 1

Fr

Fr Fr

ball

= ( Z / 4.37).Wmax = ( Z / 4.06).Wmax
Deflection of rolling element under load W = K n ; n = 1.5 for ball bearing, n = 1 11 f roller b i 1.11 for ll bearing

roller ll

50% of angular extent of load zone

1 = cos 1 (Cd 2 r ) ; r = radial shift of ring

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146

Failure of Four Row Cylindrical Roller Bearing

Two large roller bearings (ID = 865 mm, OD = 1180 mm) failed in a cold rolling mill. R 35 00 000 each lli ill Rs. 35,00,000 h
one bearing failed within 105 hours (installed on 05/01/03 and failed completely on 10/01/03) and ), other failed within 300 hours of operation (installed on 05/01/03 and removed on 24/01/03 due to detection of excessive vibration and metal particles). Expected life of bearings was approximately 40,000 operating hours Survival rate 0.5% and 1.0%.

Failed Bearing

Bearing subjected to normal load

Constant direction load.

Quarter of the outer race is under load.
Outer i O t ring with marking I t IV. ith ki to IV

First time mounting

zone I along the direction of the load.

After a period of approximately 1000 operating h ti hours ( 2 ( months), outer ring is turned 90. 90

Co c us o Conclusion: Rated bearing life = 4.* Life of one load zone. a ed bea g e e o o e oad o e Expected life of each load zone = 10,000 operating hours

Hole in line of maximum load. Four holes of 3/8 10 UNC 3B of 45mm depth were drilled and tapped to facilitate the handling of outer race.

Hole

new arrangement, no complaint was received.

With

III

III

IV

W
II

II

IV

I I

(a) Earlier arrangement

(b) New arrangement

Homework: A single row cylindrical roller bearing N 205 ECP

is subjected to pure radial load of 2800 N and rotational speed = 1500 rpm. Estimate the bearing life for reliability = 0.99.

Homework: Select a suitable deep groove ball bearing for a

shaft of 30 mm dia rotating at 2000 rpm. Bearing needs to support a radial load of 2000 N and axial load of 400 N.
Drawback of Angular contact bearings ?? g g
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Tandem arrangement T d t

Back to b k B k t back

Face to face F t f

g g primary factor). y ) Back to back for rigid shaft mounting ( p Requires inner rings to be clamped. Face to face for shaft misalignment (primary concern). Requires outer rings to be clamped.

Bearing type

Single row

Double row

()
Angular contact ball bearing
Self aligning ball bearing 20 25 30 35 40

Fa/VFr > e Fa/VFr e Fa/VFr > e X Y X Y X Y

.43 .41 .39 .37 .35 35 .4 1.0 .87 .76 .66 .57 57 .4 cot 1 1.09 .92 .78 .66 .55 55 .42 cot .70 .67 .63 .60 .57 57 .65 1.63 1.44 1.24 1.07 .93 93 .65 cot

.57 .68 .80 .95 1.14 1 14 1.5 tan

Representative Bearing Design Lives

Type of Application T f A li ti Design Life D i Lif (thousands of hours) 0.1-0.5 8-14 14-20 20-30 20 30 50-60 100-200

Instruments and apparatus for infrequent use Machine used intermittently, but reliability is of great importance Machine for 8-hours service, but not every day Machines for 8 hour service, every working day 8-hour service Machine for continuous 24-hour service Machine for continuous 24-hour service where reliability is of extreme importance.

NOTE: SKF recommends min load of 0.02 C to be imposed on roller 0 02

11/2/2011 bearings, while 0.01 C to be applied on ball bearing. 157

Variable Loading
Often bearings are subject to variable loading:
P a L1 1 P2a L2 P3a L3

In such situation it is advisable t fi d an d i bl to find equivalent load using g

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Bearing operates at 1000 rpm and applied load of 500 N for 100 hours, then bearing operates at 1200 rpm and 250 N for 250 hours.

+ + + ... a P= L1 + L2 + L3 + ... a = 3 f b ll b i for ball bearings 10 a= for roller bearings 3 L1, L2 , L3 ,... Number of rotations IF L = expected life then life, P= P=

P a L1 1

+ + + ... L (L1 + L2 + L3 + ...) L P2a L2 P3a L3 + P2a f 2 + P3a f 3 + ...

P a f1 1

a
158

Example: A ball bearing is run at four piecewise load and speed conditions. conditions Find equivalent load load.

Time fraction
0.1 0.2 0.3 0.4

Speed, rpm
1000 2000 3000 4000

Product, Rotation column 1*2 fraction

100 400 900 1600 0.0333 0.1333 0.3 0.5333

Applied load, kN
4 3 2 1

P=

P = (8.6636 10 )
9
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P 3 f1 1

P23 f 2

P33 f 3
1

+
3

P43 f 4

= 2054 N
159

Homework
A ball bearing (C = 85 kN) supports a shaft that rotates at 1000 rpm. A radial load varies in such a way that 50, 30 and 20 percent of the time the load is 3, 5, and 7 kN respectively. Estimate L-10 life. life

P=

P 3 f1 1

P23 f 2

P33 f 3

P43 f 4

2
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(P1max sin 2 )3 d i
0

160

Bearing Clearance

Bearing Mounting
Bearings are mounted on shaft and housing with transition to Interference fit. If interference fits exceed the internal radial clearance, the rolling elements become preloaded.
C2, C3, C4 as bearing suffix.

High operating temperature environment requires larger bearing clearance.

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162

IT Grade Lapping Honing Super finishing Cylindrical i di C li d i l grinding Diamond turning Plan grinding Broaching Reaming Boring, Boring Turning Sawing Milling Planing, Shaping Extruding Cold Rolling Drawing Rolling, Drilling Die Casting Forging Sand Casting Hot rolling, Flame cutting

10

11

12

13

14

15

16

Nominal Sizes (mm)

over inc. IT Grade

1 3

3 6

6 10

10 18

18 30

30 50

50 80

80 120

120 180

180 250

250 315

International tolerance grade of industrial processes.

0.8 08 1.2 2 3 4 6 10 14 25 40 60 100 140 250 1 1.5 2.5 4 5 8 12 18 30 48 75 120 180 300 1 1.5 2.5 4 6 9 15 22 36 58 90 150 220 360 1.2 12 2 3 5 8 11 18 27 43 70 110 180 270 430 1.5 15 2.5 4 6 9 13 21 33 52 84 130 210 330 520 1.5 15 2.5 4 7 11 16 25 39 62 100 160 250 390 620 2 3 5 8 13 19 30 46 74 120 190 300 460 740 2.5 25 4 6 10 15 22 35 54 87 140 220 350 540 870 3.5 35 5 8 12 18 25 40 63 100 160 250 400 630 1000 4.5 45 7 10 14 20 29 46 72 115 185 290 460 720 1150 6 8 12 16 23 32 52 81 130 210 320 520 810 1300

1 2 3 4 5 6 7 8 9 10 11 12 13 14

A company X, decided to design air-circulators for paint p y , g p shops. Length of 2-m and diameter of 0.6-m was designed for rotor of air-circulator. Company X wanted to design suitable b i it bl bearings t reduce th power consumption on 2/3 to d the ti 2/3.

On studying the air-circulator it was found that rotor length could be reduced from 2-m to 1.4 m by relocating the drive2 m 1.4-m drive motor. Reduction in length of rotor itself fulfilled the requirements.