UNIVERSITY TRANSILVANIA OF BRAOV

FACULTY OF TECHNOLOGICAL ENGINEERING

MACHINE ELEMENTS DEPARTMENT

Vehicle Dynamics Project

SUV Vehicle (160 km/hr)

3. Dimensioning calculus
Nr.
Parameters

Calculus equations. Results.

0
3.1.

1
Selection of coefficients

The pressure angle in frontal

plane t, degrees
The real angle of gearing, wt
in frontal plane, and wn in
normal plane

t = a tan(

tan n
tan 20
) = a tan(
) = 20.28356
cos
cos 10

wt = a cos(

a
99.38488
cos t ) = a cos(
cos 20.28356 ) = 21.21665
aw
110

wn = a sin(

sin n
sin 20
sin wt ) = a sin(
sin 22.21665 ) = 20.91883

sin t
sin 20.28356

The total profile displacement

coefficient, Xsn,Xs

X sn = X 2 + X 1 =

Selection of the displacement

coefficients Xn1,Xt1

X n 1 = 0.4

inv wt inv t
0.01791 0.01557
(z 2 + z1 ) =
(18 + 70) = 0.28288
2 tan n
2 tan 20

X t 1 = X n 1 cos = 0.4 cos 10 = 0.39392

Selection of the displacement

coefficients Xn2,Xt2

X n 2 = X sn X n 1 = 0.28288 0.4 = 0.11712

X t 2 = X n 2 cos = 0.11712 cos 10 = 0.11534

The geometrical elements of

the gears
o The division circle
diameters d1, d2, mm

mn
2.25
z1 =
18 = 41.124778mm
cos( )
cos( 10 )
mn
2 .5
d2 =
z2 =
70 = 159.92969mm
cos( )
cos( 10 )
d1 =

o The base circle

diameters db1, db2, mm

o The pitch circle

diameters dw1, dw2, mm

db 1 = d1 cos( t ) = 41.124778 cos( 20.28356 ) = 38.574566mm

db 2 = d2 cos( t ) = 159.92969 cos( 20.28356 ) = 150.0122 mm

2 aw
2 100
=
= 40.8997955mm
u + 1 3.89 + 1
2 aw
2 110
dw 2 =
u =
3.89 = 159.10020mm
u+1
3.89 + 1
dw 1 + dw 2 40.8997955 + 159.10020
=
= 100mm OK
2
2
dw 1 =

o The addendum circle

diameters da1,2, mm

o The dedendum circle

diameters df1,2, mm

da1 = 2 aw m n (

z2
70
*
2 han
+ 2 X n 2 ) = 2 100 2.25
2 + 2 ( 0.11712 ) =

cos
cos 10

= 45.097348mm
da2 = 2 aw m n (
= 161.57522 mm

o The pressure angle on

the addendum circle

z1
18
*
2 han
+ 2 X n 1 ) = 2 100 2.25(
2 + 2 0.4 ) =
cos
cos 10

z1
18
*
2( han
+ cn* X n 1 )] = 2.25[
2( 1 + 0.25 0.4 )] =
cos
cos 10
= 37.29977 mm
d f 1 = mn [

o The inclination angle of

the teeth on the base
circle b

z2
70
*
2( han
+ cn* X n 2 )] = 2.25[
2( 1 + 0.25 + 0.11712 )] =
cos
cos 10
= 153.77765mm
d f 2 = mn [

o The inclination angle of

d
41.124778
at 1 = arccos( 1 cos t ) = arccos(
cos 20.28356) = 31.200228
the teeth on the
d a1
45.097348
addendum circle a1,2
d
159.92969
at 2 = arccos( 2 cos t ) = arccos(
cos 20.28356 ) = 21.80773
da2
161.57522
o The base pitch pbt, mm
b = a tan(cos t tan ) = a tan(cos 20.28356 tan 10) = 9.39128

The arch of the tooth in normal

(n) and frontal (t) plane
o On the division circle sn1,2,
st1,2

d a1
tan ) = arctan(
d1
d
= arctan( a2 tan ) = arctan(
d2

a1 = arctan(
a2

45.097348
tan 10 ) = 10.943647
41.124778
161.57522
tan 10 ) = 10.10078
159.92969

pbt = pt cos t = 7.17762 cos 20.28356 = 6.73253mm

pt = m t = 2.53 = 7.17762 mm
mt =

o On the addendum circle

sat1,2, san1,2, mm

mn
2.25
=
= 2.28471mm
cos cos 10

sn = (0.5 + 2 X n 1 tan n ) m n = ( 0.5 + 2 0.4 tan 20 ) 2.25 = 4.189438mm

sn 2 = ( 0.5 + 2 X n 2 tan n ) m n = ( 0.5 2 0.11712 tan 20) 2.25 = 3.34246mm
st 1 = ( 0.5 + 2 X t 1 tan t )

mn
2.25
= (0.5 + 2 0.39392 tan 20.28356 )
=
cos
cos 10

= 4.25406mm
st 2 = (0.5 + 2 X t 2 tan t )

mn
2.25
= ( 0.5 2 0.11534 tan 20.28356 )
=
cos
cos 10

= 3.39403mm

mn z1
cos t
2.25 18
+ st 1 ]
= [(0.01557 0.06044)
+
cos
cos at 1
cos 10
cos 20.28356
+ 4.25406 ]
= 2.63869mm
cos 31.100228
m z
cos t
2.25 70
s at 2 = [(inv t inv at 2 ) n 2 + st 2 ]
= [(0.01557 0.019511)
+
cos
cos at 2
cos 10
cos 20.28356
+ 3.39403]
= 2.79218mm
cos 21.80773
s an 1 = s at 1 cos a1 = 2.63869 cos 10.943647 = 2.59070mm
s at 1 = [(inv t inv at 1 )

Elements of the equivalent

gears and equivalent gear
o The number of the
equivalent gears teeth

o The diameters of the

division circles of the
equivalent gears, dn1,2,
mm
o The diameters of the
base circles of the
equivalent gears, dbn1,2,
mm

s an 2 = s at 2 cos a2 = 2.79218 cos 10.10078 = 2.74890mm

z1
18
=
= 18.77766
2
cos b cos cos 9.39128 cos 10
z2
70
=
=
= 73.02423
2
2
cos b cos cos 9.39128 cos 10

zn1 =
o The diameters of the
pitch circles of the
equivalent gears, dan1,2,
mm
o The distance between
the axes of the
equivalent circle, awn,
mm

zn 2

dn 1 = m n z n 1 = 2.25 18.77766 = 42.249735mm

dn 2 = m n z n 2 = 2.25 73.02423 = 164.3045175mm

dbn 1 = dn 1 cos n = 42.249735 cos 20 = 39.70176mm

dbn 2 = dn 2 cos n = 164.3045175 cos 20 = 154.39574mm

o The contact ratio of the

equivalent gear, n
d an 1 = dn 1 + d a1 d1 = 42.249735 + 45.097348 41.124778 = 46.222305mm
d an 2 = dn 2 + d a2 d2 = 164.3045175 + 161.57522 159.92969 = 165.95005mm

The functional-constructive
conditions check
o The contact ratio of the
gearing

fontal plane
additional
total

awn =

cos n
a
99.384880
cos 20

= 102.71624mm
2
2
cos b cos wn cos 9.39128 cos 20.91883

o The condition to avoid

sharpening of the tooth

n =

2
2
2
2
d an
d an
1 dbn 1 +
2 dbn 2 2 awn sin wn
=
2m n cos n

46.222305 2 39.70176 2 + 165.95005 2 154.39574 2 2 102.71624 sin 20.91883

=
2 2.25 cos 20.91883
= 1.90181
=

o The condition to avoid

interference
=

d a21 db21 + d a22 db22 2 aw sin wt

cos =
2m n cos t

45.097348 2 38.574566 2 + 161.57522 2 150.0122 2 2 100 sin 21.21665

cos 10 =
2 2.25 cos 20.28356
= 1.317433
=

b sin 31 sin 10
=
= 0.76155
m n
2.25
= + = 0.76155 + 1.317433 = 2.07898

s an 1 0.4 m n 2.59070 0.4 2.25 0.9

s an 2 0.4 m n 2.74890 0.4 2.25 0.9

X n 1 X n 1 min = 0.4 0.28104

3.3
3.4
3.5
3.5.1
3.5.2
3.5.3

External velocity
v, m/s
Selection of the lubricant
Technological elements
Precision class selection
Technological process
Tooth side roughness and fillet
area roughness, Ra1,2, m

X n 2 X n 2 min = 0.11712 3.47201

z
z n 1 14 18.77766
X n 1 min = min
=
= 0.28104
17
17
z z n 2 14 73.02423
X n 2 min = min
=
= 3.47201
17
17
z min = 14
d1 n 1 41.124778 554
v=
=
= 1.2 m/s
60 1000
60 1000
200 EP, =180cSt(mm2/s) at 50oC

9 (A14)
Milling and grinding
Fine milling
Ra1=0.8 m
Ra2=1.6 m

3.6
3.6.1

Contact factors
Contact factor
ZH

ZH =

2 cos b
1
1
2 cos 9.39128

= 2.404
cos t
tan wt
cos 20.28356 tan 21.21665

3.6.2

Contact ratio factor

Z

Z=

4
(1 ) + =
3

3.7
3.7.1

Bending calculus factors

Shape factor
YFa1,2

Y Fa1 = Y Fa ( z n 1 , x n 1 ) = 2.3( 18.77766 ,0.4 )

3.7.2
3.7.3

Factors for correcting stresses

at the tooth base
YSa1,2
Tooth inclination factor
Y

42
0.62
(1 2 ) +
= 0.89
3
2

Y Fa2 = Y Fa ( z n 2 , x n 2 ) = 2.27(73.02423,0.11712 )
Y Sa 1 = Y Sa ( z n 1 , x n 1 ) = 1.74(18.77766 ,0.4 )
Y Sa 2 = Y Sa ( z n 2 , x n 2 ) = 1.74(73.02423 ,0.11712 )
Y = 1

10
= 1 0.76155
= 0.937
120
120

3.7.4
3.8
3.8.1

Contact ratio factor

Y
Load correcting factors
Dynamic factor Kv

Y = 0.25 +

0.75

= 0.25 +

0.75
= 0.644
1.90181

K
z
u2
47
3.89 2

1.2 18
1
1
Kv = 1 +
+ K2

=
1
+
+
0
.
0087

1+u2
1 + 3.89 2
K Ft
100
0.0087 3372.682
100
A

= 1.337
K 1 = 47 , K 2 = 0.0087
K A = 1 .6
Ft
M 2 68971 2
= tI
=
= 3372.682
b
dw1
40.89979

3.8.2

Non-uniform load distribution,

KH for contact and KF for
bending

K H = 1.23 + 0.18 d2 + 0.61 10 3 b = 1.23 + 0.18 0.802 2 + 0.61 10 3 33 = 1.366

d =

u +1
b
33
a =
=
= 0.802
2
d1 41.12477

K F = K HNF = 1.366 0.883 = 1.291

1
1
=
= 0.883
h
h 2
3.899
3.899 2
1 + +( )
1+
+(
)
b
b
33
33
da d f
45.09734 37.29977
h=
=
= 3.899
2
2
K H = 1 .4
K F = 1 .4
NF =

3.8.3
3.8.4
3.8.5
3.9

Non-uniform load distribution

in frontal plane, KH for contact
and KF for bending
ZB =1
Gearing factor for the pinion,
ZB
Z D = 1.0 , u = 3.89
Gearing factor for the driven
wheel, ZD
Allowable stresses, HP for contact, FP1,2 for bending, MPa

3.9.1

Allowable stresses for contact

Lubrication factor, ZL

Speed factor, Z

Active teeth sides roughness

factor, ZR
Material factor, Zw
Size factor, Zx

3.9.2

Wear resistance factor, ZN1

and ZN2
Admissible resistances for
bending stress

H lim Z N 1
1500 1.03557
Z LZ Z R Z w Z x =
1.043 0.941 0.966 1.041 1.0 = 1334 MPa
S H min
1.15

Z
1500 0.977
HP 2 = H lim N 2 Z L Z Z R Z w Z x =
1.043 0.941 0.966 1.041 1.0 = 1258 MPa
S H min
1.15
HP = min( HP 1 , HP 2 ) = 1258 MPa
HP 1 =

4( 1.0 C ZL )
4( 1.0 0.91)
= 0.91 +
= 1.043
80
80 2
( 1.2 +
)
(1.2 +
)
50
180
C ZL = 0.91, if H lim > 1200 MPa
C ZL = 0.91, because H lim = 1500 MPa
2(1.0 C Z )
2(1.0 0.93)
Z = C Z +
= 0.93 +
= 0.957
32
32
0.8 +
0.8 +

1.2
C Z = C ZL + 0.02 = 0.91 + 0.02 = 0.93
Z R = 0.966 , for H lim > 1200 MPa
Z L = C ZL +

if 130 HB 470, than

HB 130
350 130
Z W = 1.2
= 1.2
= 1.07
1700
1700
Z x =1.0
Z N 1 = Z N 2 = Z N = 1.4

F lim 1Y ST Y N 1
1500 2 1
Y 1Y R 1Y x =
0.99 1.04334 1 = 757 MPa
S F min
1. 5

Y Y
1500 2 1
= F lim 2 ST N 2 Y 2Y R 2Y x =
0.98 1.04334 1 = 749 MPa
S F min
1. 5

FP1 =
FP2

Bending correcting factor, YST

High-stress area factor, Y1 and
Y2
Fillet area factor, YR1 and YR2
Size factor Yx
Wear resistance factor, YN1 and
YN2
Minimum coefficient of safety
SFmin for bending
3.10
Gearing verification
3.10.1 Effective stresses for contact
load, HB and HD , MPa

Y ST 1 = 1.04589
Y ST 2 = 0.992366
Y 1 = 0.99

Y 2 = 0.98
Y R 1 , 2 = 1.04334
Yx = 1
YN 1 = YN 2 = YN = 1
S F min = 1.5

HB =

Z BZ E Z H Z Z
aw

T1
( u + 1) 3 cos t
K A K v K H K H
=
2b
u
cos wt

( 4 + 1) 3 cos 20.28356
1.78675 189.8 2.43 0.39 3.16 119375

1.35 1.166 1.318 7.4

=
112
2 37
4
cos 21.69899
= 818.9 MPa < HP
=

3.10.2 Effective stresses for bending

load, F 1 and F 2 , MPa

HD =

ZD
1
HB =
818.9 = 458 MPa < HB
ZB
1.78675

F1 =

T 1 z 1 ( u + 1) 2
cos 2 t
K A K v K F K F Y Y Y Fa1Y Sa 1
=
2 baw cos
cos 2 wt

119375 16 ( 4 + 1)2
cos 2 20.28356
1
.
35

1
.
166

1
.
253

1
.
58

0
.
94

0
.
74

2
.
35

1
.
73
=
2 37 112 2 cos 10
cos 2 20.69899
= 167 MPa < FP1
b Y Y
37 2.45 1.63
F 2 = F 1 1 Fa2 Sa 2 = 167
= 174 MPa < FP 2
b2 Y Fa1 Y Sa 1
35 2.34 1.73
=