Solution:

A. Materials for pinion and gear

For diameter of pinion (Dp) and diameter of gear (Dg)

Dg
Mg= =4
Dp

Dg=4Dp ---------- equation1

Also;

Dg+Dp
C= = 9in
2

Dp=18-Dg ----------- equation 2

Substitute Equation 1 to equation 2

Dp=18-4Dp

Dp=3.6 in

Dg=4Dp

Dg=4 ( 3.6 )

Dg=14.4 in

For the pitch line velocity (Vm):

Vm= πDpNp ;fpm

where pinion speed (Np)=720 rpm

3.6
Vm=π( )(720)
12

Vm=678.58 fpm

For the transmitted force (Ft):

33,000 hp
Ft=
Vm

33,000(80)
Ft=
678.58

Ft=3,890.48 lbs

From Figure AF 19 , for Vm = 678.58 fpm , the maximum permissible error (e) in
Gear Tooth profile; Design of Machine Elements by V.M. Faires:

For Vm = 678.58 ft/min; Maximum permissible error (e) = 0.0035 in.

From Figure AF 20, for maximum permissible error (e) = 0.0035, it falls within the
limit of First Class Commercial Gear with expected error (e) = 0.002, assume Pd =
6 and using First Class Commercial Gear the expected error (e) = 0.002 in.

From Table AT 25 with e = 0.002, for a material of steel and steel 20 0 Full Depth,

the value of C is;

0.002
C= x 1660
0.001

C=3320
TRIAL NO.1

From Text, p. 367, in the absence of special consideration, the following

proportions are considered good:

8 < bPd < 12.5

Solving for face width (b):

Let bPd = 12.5, since Pd = 5, therefore:

bPd
b=
Pd

12.5
b=
5

b=2.5

For dynamic load, using Buckingham’s equation:

0.05(Vm)(bC+Ft)
Fd=Ft+
0.05 ( Vm ) + √ bC+Ft

0.05 ( 678.58 ) [ ( 2.5 )( 3320 ) +3890.48]

Fd=3,890.48+
0.05 ( 678.58 ) + √ ( 2.5 ) (3320 ) +3890.48

Fd=6756.02 lbs

For limiting load for wear (Fw):

Fw=DpbQKg

Fw=Fd=6756.02 lbs

Where:

2mg
Q=
mg+1
 2(4)
Q=
4+1

Q=1.6

Therefore solving for the value of limiting wear load factor (kg):

Fw
kg=
DpbQ

6756.02
kg=
3.6(2.5)(1.6)

kg=469.17

For BHN, from Kent’s Mechanical Engineers Handbook

Load Carrying Capacity of Gearing

MATERIALS BHNp BHNp K

Steel 600 400 417

Steel BHNp BHNp 469.17

Steel 450 450 470

For BHN (Pinion), by interpolation:

600-BHN 417-469.17
=
600-450 417-470

BHNp=452.35

For BHN (Gear), by interpolation:

400-BHN 417-469.17
=
400-450 417-470

BHNg=449.22
For the material of pinion and gear, use selection at Table AT9 Typical Properties

of heat-treated steels, Design of Machine Elements by Faires.

MATERIALS BHN SU

PINION AISI 8742 Ni-Cr-Mo (oil) 455 226,000

GEAR AISI 4150 Cr-Mo (oil) 444 228,000

For the number of teeth of pinion and gear;

For pinion:

Np=DpPd

Np=3.6 x 5

Np=18 teeth

For gear:

Ng=DgPd

Ng=14.4 x 5

Ng=72 teeth
For the values of form factor (y) in Lewis equation (Table AT24)

LOAD NEAR THE MIDDLE 20°FD

Np = 18 teeth 0.522

Ng = 72 teeth 0.7308

Checking the material for its factor of safety estimation of endurance strength;

For pinion:

S' n=0.5Su

S' n=0.5(226,000)

S' n=113,000 psi

For gear:

S' n=0.5Su

S' n=0.5(228,000)

S' n=114,000 psi

To determine which one has the weaker value of the (Fs);

For pinion:

( Ys ) p=0.522 x 113,000

( Ys ) p=58,986 psi
For gear: ( Ys ) g=0.7308 x 114,000

( Ys ) g=83,311.2 psi

Therefore: Pinion is weaker than the gear.

For the factor of safety (use Kf=2.0 for load near the middle)

( Sy ) b
Fs=
KfPd

(58,986)(2.5)
Fs=
(1.75)(5)

Fs=14,746.5 lbs

For the service factor

Fs
Nsf=
Fd

14,746.5
Nsf=
6,756.02

Nsf=2.18

From the result, it shows that the service factor Nsf = 2.02 > 1.9 (the
recommended value), therefore breakage is expected.

TRIAL NO. 2
From Text, p. 367, in the absence of special consideration, the following
proportions are considered good:

8 < bPd < 12.5

Solving for face width (b):

Let bPd = 11.5, since Pd = 6, therefore:

bPd
b=
Pd

11.5
b=
6

b=1.9

For dynamic load, using Buckingham’s equation:

0.05(Vm)(bC+Ft)
Fd=Ft+
0.05 ( Vm ) + √ bC+Ft

0.05 ( 678.58 ) [ (1.9 )( 3320 ) +3890.48]

Fd=3,890.48+
0.05 ( 678.58 ) + √ ( 1.9 )( 3320 ) +3890.48

Fd=6455.21 lbs

For limiting load for wear (Fw):

Fw=DpbQKg

Fw=Fd=6455.21

Where:

2mg
Q=
mg+1

2(4)
Q=
4+1

Q=1.6
Therefore solving for the value of limiting wear load factor (kg):

Fw
kg=
DpbQ

6455
kg=
3.6(1.9)(1.6)

kg=589.84

For BHN, from Kent’s Mechanical Engineers Handbook

Load Carrying Capacity of Gearing

MATERIALS BHNp BHNp K

Steel 500 500 588

Steel BHNp BHNp 589.54

Steel 6950 600 861

For BHN (Pinion), by interpolation:

500-BHN 588-589.84
=
500-600 588-861

BHNp=500

For BHN (Gear), by interpolation:

500-BHN 588-589.84
=
500-600 588-861

BHNg=500

For the material of pinion and gear, use selection at Table AT9 Typical Properties
of heat-treated steels, Design of Machine Elements by Faires.
 MATERIALS BHN SU

PINION AISI 8742 Ni-Cr-Mo (oil) 514 259,000

GEAR AISI 8742 Ni-Cr-Mo (oil) 514 259,000

For the number of teeth of pinion and gear;

For pinion:

Np=DpPd

Np=3.6 x 6

Np=22 teeth

For gear:

Ng=DgPd

Ng=14.4 x 6

Ng=87 teeth

For the values of form factor (y) in Lewis equation (Table AT24)
 LOAD NEAR THE MIDDLE 20°FD

Np = 22 teeth 0.559

Ng = 87 teeth 0.7446

Checking the material for its factor of safety estimation of endurance strength;

For pinion:

'
S n=0.5Su

S' n=0.5(259,000)

S' n=129,000 psi

For gear:

S' n=0.5Su

S' n=0.5(259,000)

S' n=129,000 psi

To determine which one has the weaker value of the (Fs);

For pinion:

( Ys ) p=0.559 x 129,000

( Ys ) p=72,111 psi

For gear: ( Ys ) g=0.7446 x 129,000

( Ys ) g=96,053.4 psi

Therefore: Pinion is weaker than the gear.

For the factor of safety (use Kf=2.0 for load near the middle)

( Sy ) b
Fs=
KfPd

(72,111)(1.9)
Fs=
(1.75)(6)

Fs=13,048.66 lbs

For the service factor

Fs
Nsf=
Fd

13,048.66
Nsf=
6,455.21

Nsf=2.02

From the result, it shows that the service factor Nsf = 2.02 > 1.9 (the
recommended value), therefore breakage is far expected.

SOLVING FOR RECOMMENDED DIMENSIONS

ADDENDUM = 1/Pd = 1/6

= 0.167 in.

DEDENDUM = 1.25/Pd. = 1.25/6

= 0.208 in.

CLEARANCE = 0.25/Pd = 0.25/6

= 0.042 in.

WORKING DEPTH = 2/Pd = 2/6

= 0.33 in.

Outside Diameter of Pinion = Dp + 2a

= 3.6 + 2(0.167)

= 3.934 in.

Root Diameter of Pinion = Dp – 2d

= 3.6 - 2(0.208)

= 3.184 in.

Outside Diameter of Gear = Dg + 2a

= 14.4 + 2(0.167)

= 14.734 in.

Root Diameter of Gear = Dg – 2d

= 14.4 - 2(0.208)

= 13.984 in.

Basic Tooth Thickness on the Pitch line:

Circular pitch (Pc):

Pc = π/Pd =π/6

Pc = 0.524 in.

Tooth Thickness:

= Pc/2 = 0.524/2

= 0.262 in

Clearance:

= 0.25/Pd = 0.25/6

= 0.042 in

Fillet radius:

= 1.5 x clearance

= 1.5 x 0.042

= 0.063 in

B. REQUIRED SHAFTS AND KEYS FOR PINION AND GEAR

FOR THE SOLID ROUND SHAFT:

16KsT
Ssd 3 =
π D3

Where:

Sds – Design stress

D – Diameter of a solid circular shaft

 T – Transmitted toque

Ks – Numerical combined shock and fatigue factor applied in every

case to the computed torsional moment of horsepower.

For the Design Stress (Shaft Design by Code)

(Page 278, Design of Machine Elements by V. M. Faires)

Ssd = 0.3 Sy (for the shear)

Ssd = 0.18 Su (for the stress)

For the Transmitted Torque (T):

For Pinion:

63,000hp
T=
Np

63,000(80)
T=
720

T=7,000 in-lb

For the Gear:

Np Dg
=
Ng Dp

NpDp (720)(3.6)
Ng= =
Dg 14.4
 Ng=14.4 rpm

By substitution:

63,000(80)
T=
180

T=28,000 in-lb

For the Shaft Diameter (D):

16ksT
Ssd=
π D3

From Table 9.1, (pp. 279)

Ks ranges from 1.0 to 1.5 (suddenly applied minor shock)

Use: ks = 1.3

For the Pinion Shaft Diameter:

1/3
16ksT
D= [ πSsd ]
1/3
16(1.3)(7,000)
D= [ π(18,540) ]
D=1.3572 in

For the Gear Shaft Diameter:

 1/3
16ksT
D= [
πSsd ]
1/3
16(1.3)(28,000)
D= [
π(18,540) ]
D=2.1544 in

Based from the Pinion and Gear diameter we can find the corresponding
tolerance and allowances for both materials, assume a precision running fits.

From Table 3.1, Running and Sliding Fits (pp. 82 by Faires)

For the Pinion: Class RC1

Pinion shaft diameter: 1.3572 in

Between: 0.19 - 1.97

HOLE SHAFT

+ 0.4 - 0.4

0 - 0.7

HOLE = 0.0004 - 0 = 0.0004 in

SHAFT = -0.0004 - (-0.0007)

= 0.0003 in

ALLOWANCE = 0 - (-0.0004) = 0.0004

 Therefore:

For the Gear: Class RC1

Gear shaft diameter: 2.1544 in

Between: 1.97 - 3.17

HOLE SHAFT

+ 0.5 - 0.4

0 - 0.7

HOLE = 0.0005 - 0 = 0.0005 in

SHAFT = -0.0005 - (-0.0007)

= 0.0003 in

ALLOWANCE = 0 - (-0.0004) = 0.0004

Therefore:
C. FOR THE REQUIRED KEYS OF PINION AND GEAR.

FOR THE KEY DESIGN:

Use: COLD DRAWN AISI C1118 (Table AT 7)

Where: Sn = 80,000 psi

Ss = 60,000 psi

Sy = 75,000 psi

BHN = 180

Using the Formulas:

SsbLd
1. ¿ T= → Shear
2

SsbLd
2. ¿ T= → Compression
4

The stress in Eq. 1 may be obtained from the shearing yield strength of the
material and (1) is taken according to the weakest of the three parts involved;
the shaft, key of the Hub.
It is suggested that the design factor on the yield strength be about 2.0 to 2.5 for
the minor shock loading for the shaft material.

For the Shaft Material: C1137 COLD DRAWN

Sy = 93,000 psi

Su = 103,000 psi

For the Pinion:

Pinion shaft diameter = 1.3572 in

Tp = 7,000 in-lb

From the Table AT 19, Key Dimensions (pp. 594, Text by Faires)

SHAFT DIAMETER b t TOLERANCE on b, in

1 5/16 - 1 3/8 5/16 1/4 -0.0020

Choose a Flat Key:

In solving for (b); use Sy = 93,000 psi; by a factor of safety:

Use Shaft Material for (b):

Solving for (1.) in Shear:

2T
L=
SsbD
 Where: Ss = Sy/N

Use: N = 2.25(for mild shock)

0.5(75,000)
Ss=
2.25

Ss = 16,666.67 psi

Therefore:

2 x 7,000
L=
5
16,666.67 x x 1.3572
16

L = 1.9805 in

For Compression: (Sc)

From

SctLD
T=
4

Where: Sc = Sy/N

93,000
Sc =
2.25

Sc = 41,333.3 psi

Therefore:
 4 x 7,000
L=
1
41,333.33 x x 1.3572
4

L = 1.9965 in

Use L = 1.9965 in for the length of the key for the Pinion.

For the GEAR:

Where: Gear shaft diameter = 2.1544 in

Tg = 28,000 in - lb

From the Table AT 19, Key Dimensions (pp. 594, Text by Faires)

SHAFT DIAMETER b t TOLERANCE on b, in

1 13/16 – 2 1/4 1/2 3/8 -0.0025

For the Shear:

2T
L=
SsbD

2 x 28,000
L=
16,666.67 x 0.5 x 2.1544

L = 3.1192 inches say 3 inches

For the Compression:

 4T
L=
SctD

4 x 28,000
L=
3
41,333.33 x x 2.1544
8

L = 3.3539 in

Use L = 1.35 inches for the length of key for Gear

KEY DIMENSION FOR PINION AND GEAR

PINION GEAR

L 1.99 in 3.35 in

B 5/16 in ½ in

T ¼ in 3/8 in

FOR THE HUBS DIMENSIONS:

The Length of the Hub should not in general be made less than the face of the
gear. Hub length usually vary from about 1.25 Ds, to 2 Ds where Ds is the Bore
(p. 358, Text)

Assume steel material for the Hub.

For steel, Diameter of Hub = 1.8 Ds

Diameter of the Hub for the Pinion (DHP):

 DHP = 1.8(1.3572)

= 2.4430 in

Diameter of the Hub for the Gear (DHG):

DHG = 1.8(2.1544)

= 3.8779 in

FOR THE LENGTH OF THE HUB:

For Steel, Length of Hub:

LH = 1.25 D shaft

For the PINION:

LHP = 1.25 x 1.3572

= 1.6965 in

For the GEAR:

LHG = 1.25 x 2.1554

= 2.693 in

Since the Length of the Hub is shorter than the length of the Key use the value
for the length of key = length of the Hub.

Therefore:
 Length of the Hub = 2.693 in

FOR WEBS DIMENSION:

FdL
Ssz=
Na

Let section modulus z a rectangular shape:

Z = bh2 / 6 (Table AT 1 pp. 563)

Where: b = Web Thickness

From page 390, Text: b = 0.5; Pc = 0.6 Pc

Use b = 0.6 Pc

From Equation 13.3 page 358 (Text by Faires)

Pc =  / Pd ; b = 0.6  / Pd

b = 0.6  / 6 ; b = 0.3142 in

2
Fd ( Dg
Dsg )
S' s (6bh ) =2Na
Where: Dg = 14.4 in Fd = 6,240.7 lbs

Dsg = 2.1544 in b = 0.3142 in

Na = 6 arms Ss = 75,000 Psi

Then substituting the values:

h=
√[
3 6Fd (Dg
2bNaS's
Dsg )
]
6(6,240.7) ( 2.1544 )
h=
√[
3

75,000(2)(6)(0.3142) ]
h = 0.9408 in

From Figure 13.16 (page 389 Text by Faires)

Moment area = 0.7h

= 0.7 (0.9408)

M’ = 0.6585 in

FOR THE RIMS AND BEADS DIMENSIONS:

Rim Thickness = 0.56 Pc (page 390, Text by Faires)

But Pc = /Pd; Pd = 6

Rim Thickness = 0.56(/6)

Rim Thickness = 0.2932 in

Depth of Beads = Rim Thickness

Depth of Beads = 0.2932 in

FOR THE NECESSARY ROLLING BEARINGS:

Let radial load Fx = Ft (Transmitted load) since two bearing are required on its
shaft, the radial load on its bearing will be equal to Ft / 2 (equally distributed),
therefore for the corresponding radial load for both Pinion and Gear.

Fx = Ft/2

Fx = 3,890.45/2

Fx = 1,945.225 lbs

Assume: BORE - SHAFT DIAMETER

INNER RACE - ROTATED

ROLLER BEARING

For:

Br = 1 mr

Fe = CrFx

(Fz/CrFx < Q)

Fe = 0.56 CrFx + CtFz

(Fz/CrFx > Q)

Use: Fe = CrFx ; Cr = 1.0 (inner race rotating)

Fe = 1.0 (1,945.225)
 Fe = 1,945.225 lb

k = 10/3 (Roller Bearing)

FOR THE BEARING OF THE PINION:

From Table 9-2 page (Design of Machine Member by Doughtie and Vallance)

Shaft Diameter of Pinion = 1.3572 in

SAE and is Bore all series Light (200) series

Number OD Width

07 1.3780 2.8346 0.669

From Table 12.3 Single Row, Deep Groove Ball Bearing

Also from Table 12.3 (pp. 341 text)

Single Row, Deep Groove Ball Bearing

BRG. No. No. of Ball Diameter (FR) / Br

07 09 7/16 4,440 / 1mr

For the desired 90% Life of desired number of revolution before 10% failures
have occurred.
k
Fr
B10 = [ ]
Fe
Br
Then:

3
4,440
B10 = [ 1,945.225 ]
(1)

B10 = 11.8916 mr

Converting to number of hours:

Hr = B10 (mr/Np)(60 x 106)

Hr = 11.8916/720 (60 x 106)

990966.67
Hr =
3600

Hr = 275.27 hours = 11.47 days = 0.3823 months

FOR THE BEARING OF THE GEAR:

From Table 9-2 page (Design of Machine Member by Doughtie and Vallance)

Shaft Diameter of Gear = 2.1544 in

SAE and is Bore all series Light (200) series

Number OD Width

11 2.1654 3.9370 in 0.827 in

From Table 12.3 Single Row, Deep Groove Ball Bearing

BRG. No. No. of Ball Diameter (FR) / Br

 11 10 9/16 7,500 / 1mr

For the desired 90% Life of desired number of revolution before 10% failures
have occurred.
k
Fr
B10 = [ ]
Fe
Br

Then:

3
7,500
B10 = [ 1,945.225](1)

B10 = 57.3158 mr

Converting to number of hours:

Hr = B10 (mr/Np) (60 x 106)

Hr = 57.3158/720 (60 x 106)

44776315.613
Hr =
3600

Hr = 1326.754 hours = 55.281 days = 1.8427 months

FOR THE SHAFT LENGTH:

For the Pinion:

0.33
SLP = [140 (Dsp) 2 ]

0.33
SLP = [140 (1.3572)2 ]
SLP = 6.2484 in

For the Gear:

0.33
SLG = [ 140 (Ds g ) 2 ]

0.33
SLG = [ 140 (2.1544) 2 ]

SLG = 8.4765 in
 SUMMARY OF COMPUTED AND ADJUSTED VALUES:

Computed Computed Adjusted

FOR THE PINION MATERIALS Values Values Values
( in ) ( mm ) ( mm )
AISI 8724 (Ni-Cr-Mo oil)
Number of Teeth: 22
Outside Diameter 3.934 99.923 100
Pitch Diameter 3.6 91.44 92
Face Width 1.5 38 38
Shaft Diameter 1.3572 34.47 35
Shaft Material ( C1137 Cold Drawn )
Key Material (AISI C1118 Cold
Drawn)
b of Key 5/16 7.93 8
t of Key 1/4 6.35 7
L of key 1.9965 50.7 51
Hub Diameter 2.4430 62.05 63
Hub Length 1.6965 43.09 44
Bearing No.: 07
Type of Bearing: Roller
Computed Computed Adjusted
FOR THE GEAR MATERIALS Values Values Values
( in ) ( mm ) ( mm )
AISI 8724 (Ni-Cr-Mo oil)
Number of Teeth: 87
Outside Diameter 14.734 374.2436 378
Pitch Diameter 14.4 365.76 366
Face Width 1.5 38 38
Shaft Diameter 2.1544 54.72 55
Shaft Material ( C1137 Cold Drawn )
Key Material (AISI C1118 Cold
Drawn)
b of Key 0.5 12.7 13
t of Key 0.375 9.525 10
L of key 3.35 85.09 86
Hub Diameter 3.8779 98.49 99
 Hub Length 2.693 68.4 69
Bearing No.: 11
Type of Bearing: Roller

GLOSSARY

Addendum – is the radial distance between the pitch circle and the addendum
circle.
Addendum Circle – is the circle that bounds the outer ends of the teeth.

Angle of Action – is the angle through which the turns from the time a particular
pair of teeth come into contact until they go out of contact

Angle of Approach – is the angle through which the gear turns from the time a
particular pair of teeth is in contact at the pitch point.

Angle of recess – is the angle through which the gear turns from the time a given
pair of teeth are in contact at the pitch point until they pass out of the
mesh.

Axle – it is a stationary member carrying rotating wheels, pulleys, etc.

Backlash – is the tooth space minus the circular thickness.

Base Pitch – it is the distance in inches measured along the base circle from a
point on one tooth to the corresponding point on an adjacent tooth.

Bearing – a part of a machine that bears the friction of a moving part.

Bottom Land - is the surface of the bottom of the tooth space.

Chordal Thickness – is the total width measured along the chord at the pitch
circle.

Circular Pitch – is the distance in inches measured along the pitch circle from a
point on one tooth to the corresponding point on an adjacent tooth.
Circular Thickness – also called tooth thickness which is the width of tooth
measured along the pitch circle.

Clearance – is the radial distance between the working depth circle and the root
circle.

Dedendum – is the radial distance from the pitch circle to the root circle.

Dedendum Circle – is the circle that bounds the bottoms of the teeth.

Face Width – is the length of teeth in axial direction.

Flank – is the surface of the tooth between the pitch and root cylinders.

Gear – the larger gear when two gears are in mesh.

Gear Ratio – is the number of teeth in the gear divided by the number of teeth
in the pinion.

Pinion – the smaller gear when two gears are in mesh.

Pitch Angle – it is the angle subtended by an arc on the pitch circle equal in
length to the circular pitch

Pitch circle – is the basis of measurements of gears.

Pitch Diameter – is the size of a gear

Pitch Point – is the point of tangency of the pitch circles.

Shaft – is a rotating member transmitting power.

Spur Gears – are toothed wheels whose tooth elements are straight and parallel
to the shaft axis; they are used to transmit motion and power between
parallel shafts.

Top land – is the surface of the top of the tooth.

Velocity Ratio – is the angular velocity of the driver divided by the angular
velocity of the driven.

Width of space – or tooth space between teeth measured along the pitch circle.

Whole Depth – is equal to the addendum plus the dedendum.

Working Depth – is the radial distance from the addendum circle to the working
depth circle.

BIBLIOGRAPHY

Doughtie, Venton Levy, Vallance, Alex, "Design of Machine Members"

4th Edition, Mc Graw Hill Book Company Inc., New York, Copyright
1964.

Parker Sybil P., " Mc Graw Hill Dictionary of Engineering ", Mc Graw Hill
Book Company Inc, New York, Copyright 19

Faires, Virgil Moring, & Wingfred, “Problems on the Design of Machine

Elements”, 4th Edition; The Macmillan Co., New York, Copyright
1969.

Faires, Virgil Moring, “Design of Machine Elements”, 4th edition,

The Macmillan Book Company Inc., New York, Copyright 1969.