Department of Mechanical Engineering

B.E. Mechanical (SW), SEM II [2022-23]

Assignment : 1
SUBJECT: Design of Transmission Elements [Sub. Code: 402066]
Assume suitable data , if necessary Last Submission Date : 10/03/2023

CO 1 (402066.1) : APPLY the principle of Spur & Helical gear design for industrial application
and PREPARE a manufacturing drawing with the concepts of GD&T.
CO 2 (402066.2) : EXPLAIN and DESIGN Bevel & Worm gear considering design parameters as
per design standards.

Unit 1
Design of Spur and helical Gear
Q1. A pair of spur gears with 20 degree full depth involute teeth consists of 19 teeth pinion
meshing with 40 teeth gear. The pinion is mounted on a crankshaft of 7.5 KW single cylinder
disel engine running at 1500 rpm. Assume service factor 1.5. Both the gears are made of
40C8 (Sut = 600 N/mm2). The module and face width is 4 and 40 mm respectively.
respectively. The gars are finished to meet the accuracy of Grade 4.
Apply the concept of design and do the following :
1. Using velocity factor to account for dynamic load, Determine the factor of safety.
2. IF the factor of safety is 2 for pitting failure Recommend Surface hardness of the
gears.
3. If the gears are machined to meet the specification of grade 8. Determine the factor of
safety for bending using Buckingham’s equation.
4. Is the gear design satisfactory? If not what is the method to satisfy the design
conditions? How will you modify the design?

[Ans key : FOS bending = 1.78, BHN : 420, Design fail in Dynamic condition using
Buckingham’s equation So 1 – Increase module (Not possible because module is given)
hence reduce grade from grade 8 to grade 6 and redesign FOS =1.19)

Q2. A pair of Parallel helical gears consists of 24 teeth pinion rotates at 5000 rpm and
supplying 2.5KW power to the gear. The speed reductions ration 4:1. The normal pressure
angle and helix angle is 200 and 230respectively. Both the gears are made of hardened steel
(Sut = 750 N/mm2). The service factor and factor of safety is 1.5 and 2 respectively. The gars
are finished to meet the accuracy of Grade 4.
 Apply the concept of design and do the following:
1. In the initial design assume velocity factor accounts for the dynamic load and face
width in 10 times the normal module .Assume the pitch line velocity to be 10 m/s.
Determine the normal module.
2. Select the first preference value of the normal module and calculate the main
dimensions of the gears.
3. Calculate the dynamic load using Buckingham’s equation and find out the effective
load for the above dimensions. What is the correct factor of safety for bending?
4. Specify the surface hardness for the gears assume a Factor of safety of 2 for wear
consideration.
Q3. A pair of spur gears with 20 degree full depth involute teeth consists of 25 teeth pinion
meshing with 60 teeth gear. The module and face width is 5 and 45 mm respectively. The
pinion is rotating at 500 rpm. The gears are made of steel and heat treated to a surface
hardness of 220 BHN. Assume dynamic load accounted by velocity factor. The service factor
and factor of safety is 1.75 and 2 respectively
Apply the concept of design and do the following:
1. Calculate Wear strength of gear
2. Static load that the gear can transmit without pitting , and
3. Rated power that can be transmitted by gears

[ Ans : 1--- 6149.8 N, 2---840.41 N 3----2.75 KW )

Q4. It is required to design a pair of spur gear with 200 full depth involute system. The input
shaft rotates at 720 rpm and receives 5 KW power through flexible coupling. The speed of
the output shaft is 144 rpm. The pinion as well as gear are made of steel Fe410 Sut = 410
N/mm2). The service factor and factor of safety is 1.25. The gars are finished to meet the
accuracy of Grade 6.
Apply the concept of design and do the following :
1. Assume suitable number of teeth for the pinion and the gears.
2. For preliminary design, assume the pitch line velocity as 5 m/s and the factor of safety
as 2. Estimate the module and select the first preference value of the module.
3. Using value of module, calculate the pitch circle diameters of pinion and gear and
face width.
4. Determine static load and dynamic load by Buckingham’s equation. Also calculate the
beam strength and correct value of FOS based on beam strength.
5. Using FOS 2 for wear strength. Specify the surface hardness for gears.

{Ans : 1. 18 & 90 teeth, 2 : 5 mm 3. 90,450 and 50 mm 4. 1473.66 N and 10523.33 N

5. FOS = 1.34 and BHN : 361.33 or Approx 370 BHN

Q5. Derive the expression for

1. Beam strength of a spur gear
2. Formative number of teeth in helical gear.
 Unit 2
Design of Bevel and Worm Gear

Q1. A pair of straight Bevel gears, mounted on shafts which are intersecting at right angles,
consists of 24 teeth pinion meshing with 32 teeth gear. The pinion shaft is connected with an
electric motor developing 12.5 KW rated power at 1440 rpm. The starting torque of the motor
is 150% of the rated torque. The pressure angle is 200. Both the gears are made of case
hardened steel (Sut = 750 N/mm2). FOS = 2. The gears are finished to meet the accuracy of
Grade 3.
Apply the concept of design and do the following:
1. In the initial design assume velocity factor accounts for the dynamic load and face
width in 10 times the normal module .Assume the pitch line velocity to be 7.5 m/s.
Determine the module.
2. Select the first preference value of the normal module and calculate the main
dimensions of the gears.
3. Calculate the dynamic load using Buckingham’s equation and find out the effective
load for the above dimensions. What is the correct factor of safety for bending?
4. Specify the surface hardness for the gears assume a Factor of safety of 2 for wear
consideration.

[ Ans : 1--- m = 3.73 =approx =5mm, FOS =1.55,BHN =410]

Q2. A pair of straight Bevel gears, mounted on shafts which are intersecting at right angles,
consists of 21 teeth pinion meshing with 28 teeth gear. The pinion shaft is connected with an
electric motor developing 5 KW rated power at 1440 rpm. The starting torque of the motor is
150% of the rated torque. The pressure angle is 200. Both the gears are made of case
hardened steel (Sut = 750 N/mm2). BHN =380. The gears are machined by a manufacturing
process, which limits the error between meshing teeth to 10 microns. The module and face
width is 4mm and 20 mm respectively.
Apply the concept of design and determine the factor of safety against bending and pitting
failure .

[ Ans : FOS 9Bending = 1.47, FOS (Wear)=1.39]

Q3. A pair of worm gear and worm wheel is designated as 3/60/10/6. The work is
transmitting 5 KW power at 1440 rpm to the worm wheel. The coefficient of friction is 0.1
and normal pressure angle is 200. Determine the components of the gear tootl force acting on
the worm and worm wheel.

[ Ans : Ptg =2332.55, Pag=1105 and Prg = 1033.5 N)]

Q4. It is required to design a worm gear speed reducer with worm wheel made of phosphor
bronz and worm made of case made of steel 10C4. The central distance is 250mm and
transmission ration is 40:1. The worm speed is 1500 rpm. Design the drive and find out
power transmitting capacity based on wear rating.

[ Ans : 16.28 KW]

Q5. Explain with the help of neat sketch different types of worm gear reducer?
Q6. Following data is given for worm gear pair:
 PCD of worm r : 48mm
 PCD of worm gear : 192mm
 Axial pitch of worm : 18.85 mm
 Pressure angle : 200
 Lead of worm : 18.85 mm
 Effective width of the worm gear teeth : 36 mm
 Worm speed : 3500 rpm
 Permissible bending stress for worm gear ; 90 MPa
 Worm gear wear factor : 830 KN/m2
 Coefficient of friction : 0.025
 Overall heat transfer coefficient without fan : 15 W/m2 0C
 Overall heat transfer coefficient with fan : 15.2 +8.28 x 10-3 Nw ---- W/m2 0C
 Effective are of housing : 9 x 10-5 x (a)1.88 --- m2
 Frictional losses in bearing : 4% of total input power
Where,
Nw = Worm speed rpm and a = central distance
Determine:
1. The dimensions of worm gear pair
2. The input power rating on the basis of strength
3. The temperature rise of lubricating oil with fan, Is fan necessary ? Justify

[ Ans : Pi = 6.487 KW ( based on strength) & temp rise : 43.91 0C , Fan is necessary]

Dr. Mangesh R. Phate

Subject Teacher