REGULATION: 2013 ACADEMIC YEAR: 2018-2019

ME6601 DESIGN OF TRANSMISSION SYSTEMS LTPC

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OBJECTIVES:

➢ To gain knowledge on the principles and procedure for the design of Mechanical power Transmission
components.
➢ To understand the standard procedure available for Design of Transmission of Mechanical elements.
➢ To learn to use standard data and catalogues.

UNIT I DESIGN OF FLEXIBLE ELEMENTS 9

Design of Flat belts and pulleys - Selection of V belts and pulleys – Selection of hoisting wire ropes and pulleys –
Design of Transmission chains and Sprockets.

UNIT II SPUR GEARS AND PARALLEL AXIS HELICAL GEARS 9

Speed ratios and number of teeth-Force analysis -Tooth stresses - Dynamic effects – Fatigue strength - Factor of
safety - Gear materials – Design of straight tooth spur & helical gears based on strength and wear considerations –
Pressure angle in the normal and transverse plane- Equivalent number of teeth-forces for helical gears.

UNIT III BEVEL, WORM AND CROSS HELICAL GEARS 9

Straight bevel gear: Tooth terminology, tooth forces and stresses, equivalent number of teeth. Estimating the
dimensions of pair of straight bevel gears. Worm Gear: Merits and demerits terminology. Thermal capacity,
materials-forces and stresses, efficiency, estimating the size of the worm gear pair. Cross helical: Terminology-helix
angles-Estimating the size of the pair of cross helical gears.

UNIT IV GEAR BOXES 9

Geometric progression - Standard step ratio - Ray diagram, kinematics layout -Design of sliding mesh gear box -
Design of multi speed gear box for machine tool applications - Constant mesh gear box - Speed reducer unit. –
Variable speed gear box, Fluid Couplings, Torque Converters for automotive applications.

UNIT V CAMS, CLUTCHES AND BRAKES 9

Cam Design: Types-pressure angle and under cutting base circle determination-forces and surface stresses. Design of
plate clutches –axial clutches-cone clutches-internal expanding rim clutches- Electromagnetic clutches. Band and
Block brakes - external shoe brakes – Internal expanding shoe brake.
TOTAL : 45 PERIODS

OUTCOMES:
➢ Upon completion of this course, the students can able to successfully design transmission components used
in Engine and machines

TEXT BOOKS:
1. Bhandari V, “Design of Machine Elements”, 3rd Edition, Tata McGraw-Hill Book Co, 2010.
2. Joseph Shigley, Charles Mischke, Richard Budynas and Keith Nisbett “Mechanical Engineering Design”, 8th
Edition, Tata McGraw-Hill, 2008.

REFERENCES:
1. Sundararajamoorthy T. V, Shanmugam .N, “Machine Design”, Anuradha Publications, Chennai, 2003.
2. Gitin Maitra, L. Prasad “Hand book of Mechanical Design”, 2nd Edition, Tata McGraw-Hill, 2001.
3. Prabhu. T.J., “Design of Transmission Elements”, Mani Offset, Chennai, 2000.
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4. C.S.Sharma, Kamlesh Purohit, “Design of Machine Elements”, Prentice Hall of India, Pvt. Ltd., 2003.
5. Bernard Hamrock, Steven Schmid, Bo Jacobson, “Fundamentals of Machine Elements”, 2nd Edition, Tata
McGraw-Hill Book Co., 2006.
6. Robert C. Juvinall and Kurt M. Marshek, “Fundamentals of Machine Design”, 4th Edition, Wiley, 2005
7. Alfred Hall, Halowenko, A and Laughlin, H., “Machine Design”, Tata McGraw-Hill BookCo.(Schaum’s Outline),
2010
8. Orthwein W, “Machine Component Design”, Jaico Publishing Co, 2003.
9. Ansel Ugural, “Mechanical Design – An Integral Approach", 1st Edition, Tata McGraw-Hill Book Co, 2003.
10. Merhyle F. Spotts, Terry E. Shoup and Lee E. Hornberger, “Design of Machine Elements” 8th Edition, Printice
Hall, 2003.
11. U.C.Jindal : Machine Design, "Design of Transmission System", Dorling Kindersley, 2010

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Subject Code: ME6601 Year/Semester: III /06

Subject Name: DESIGN OF TRANMISSION SYSTEMS Subject Handler: Mr.S.Arun

UNIT I –DESIGN OF FLEXIBLE ELEMENTS

Design of Flat belts and pulleys - Selection of V belts and pulleys – Selection of hoisting wire ropes and
pulleys – Design of Transmission chains and Sprockets.
PART * A

Q.No. Questions

1 Give an expression for ratio of tensions in a flat belt drive. BTL3

𝑇1
= 𝑒 𝜇𝜃
𝑇2
Where, T1=Tension in tight side in N; T2=Tension in slack side in N; µ=Coefficient of friction;
θ=Angle of contact of driving pulley in radians.
2 How is a V-belt specified? BTL2
A typical example of its specification “C2032 IS 2494: 1964”. Here the ‘C’ denotes the section
type of the belt, ‘2032’ represents the nominal inside length of the belt and 1964 is referred to as
year of coding. The power transmitting capacity of section ’C’ type of the belt is 1 kW to 12 kW.
3 What is meant by “Chordal action of chain”? Also name a company that produces driving
chains. (April/May 2015) BTL1
When chain passes over a sprocket, it moves as a series of chords instead of a continuous arc as
in the case of a belt drive. It results in varying speed of the chain drive. This phenomenon is
known as chordal action. Some of the company names producing chains are: Roto mechanical
equipment Chennai: Monal Chains Limited, Mumbai; Innotech Engineers Ltd., New Delhi.
4 Why tight-side of the belt should be at the bottom side of the pulley? BTL4
The positions of input and output pulleys are such that the tight side of the belt must be on the
bottom and slack side on the top of the pulleys. Otherwise, the angle of contact between the belt
and rim of the pulley reduces, decreasing the power transmission capacity of the belt.
5 Define the term “Crowning of pulley”. (Nov/Dec-2016, May/June 2014) BTL1
The pulley rims are tapered slightly towards the edges. This slight convexity is known as
crowning. The crowning tends to keep the belt in centre on a pulley rim while in motion. These
flat belts stayed centered on pulleys without any guides or flanges. The key to keeping them
tracking centered on the pulleys is the use of "crowned pulleys"
6 A longer belt will last more than a shorter belt. Why? (Apr/May 2017) BTL4
The life of a belt is a function of the centre distance between the driver and driven shafts and
diameter of driver and driven pulleys. The shorter the belt, the more often it will be subjected to
additional bending stresses while running around the pulleys at a given speed. And also it will
be destroyed quickly due to fatigue. Hence the increased centre distance and diameter of pulley
will increase the belt life. Hence, a longer belt will last more than a shorter belt.

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7 Mention the losses in belt drives. (Nov/Dec 2014) BTL2
The losses in a belt drive are due to:
➢ Slip and creep of the belt on the pulleys (about 3%)
➢ Bending of the belt over the pulleys (about 1%)
➢ Friction in the bearings of pulley (about 1%) and
➢ Windage or air resistance to the movement of belt and pulleys (usually negligible)
8 In what ways the timing belts are superior to ordinary V-belts? (April/May 2015) BTL4
Flat belt and V-belt drives cannot provide a precise speed ratio, because slippage occurs at the
sheaves. But certain applications require an exact output to input speed ratio. In such situations,
timing belts are used. Since the timing belts (aka. synchronous belts) possess toothed shape in
their -inner side, engagement with toothed pulley will provide positive drive without, belt-slip
where as in the case of ordinary V-belts, chances of slip are and hence positive drive is not
possible at all times. Hence toothed belts (I timing belts) are superior to ordinary V-belts.
9 Why are idler pulleys used in a belt drive? BTL4
Idler pulleys are used to take up slack, change the direction of transmission, or provide
clutching action in any industry, material handling or any other mechanical purpose. But they
don’t provide any mechanical advantage, nor does it transmit power. One such example of its
application is to improve belt drive performances as they reduce vibration by supporting a
segment of belt which is prone to vibration/oscillation. They are also used in car engines for
positive clutching action by running the idler pulley on the slack side of the flat-belt drive from
engine to transmission.
10 Name the few materials for belt drives. (May/June 2016) BTL2
➢ Leather
➢ Fabric and cotton
➢ Rubber
➢ Balata and
➢ Nylon.
11 State the law of belting. BTL1
Law of belting states that the centre line of the belt as it approaches the pulley must lie in a
plane perpendicular to the axis of that pulley or must lie in the plane of the pulley, otherwise
the belt will run off the pulley. “The centre line of the belt when it approaches a pulley must lie
in the midplane of the pulley”.
12 What is wipping? How it can be avoided in belt drives? BTL3
If the centre distances between two pulleys are too long then the belt begins to vibrate in a
direction perpendicular to the direction of motion of belt. This phenomenon is called as
wipping. Wipping can be avoided by using idler pulleys.
13 How are wire ropes designated? Give an example? (Nov/Dec 2012) BTL2
Wire ropes are designated (or specified) by the number of strands and the number of wires in
each strand. Standard Wire Rope, 6x7 Class Wire Rope, Strands: 6, Wires per Strand: 7, Core:
Fiber Core, Standard Grade(s): Improved Plow (IPS), Lay: Regular or Lang, Finish: Bright or
Galvanized

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14 What do you understand by 6 x 19 constructions in wire ropes? (Nov/Dec 2014) BTL2
A 6 x 19 wire rope means a rope is made from 6 strands with 19 wires in each strand.
15 Give any three applications of chain drives. What are they limitations? (April/May 2011)
BTL2
Chain drives are widely used in transportation industry, agricultural machinery, metal and wood
working machines.
Limitations: heavy height, sudden failure, intensive wear of the links in the joints
susceptibility to jerks and overloads.
16 What is the effect of chordal action in chain drives? How can you reduce that effect?
(April/May 2015) BTL4
As the chain enters and exits, it rises and falls as each pitch engages and disengages the
sprockets. This movement, called chordal action, causes chain speed variations (drive
roughness) that may be objectionable in some applications. These speed variations can normally
be minimized by increasing the size of the sprockets. Chordal action results in a pulsating and
jerk motion of a chain. In order to reduce the variation in chain speed, the number of teeth on
the sprocket should be increased.
17 What do you mean by galling of roller chains? (May/June 2012) BTL3
Galling is a stick-slip phenomenon between the pin and the bushing. When the load is
heavy and the speed is high, the high spots (i.e. joints) of the contacting surfaces are
welded together. This phenomenon of welding is called as galling of roller chains. Use high
quality, high pressure lubricants and ensure that the lubricant regime is such that the film of
lubricant is constantly maintained between the surfaces.
18 Under what circumstances chain drives are preferred over V belt drives? (May/June
2016) BTL4
The popularity of chain drives stems from their ability to transmit high torque levels in a small
package, at relatively low cost, while utilizing readily available stock components. While initial
costs of standard roller chain drives can be quite low, the cost of maintaining them can be
substantial. The ability to create any length of chain with connecting links. The availability of a
large selection of chains and sprockets.
19 What factors will affect the working conditions of chain drive? (Nov/Dec-2016) BTL2
➢ Tension in the chains
➢ Sizes of the pulley/gear
➢ Number of pulley/gear
➢ Length of the chain drive
➢ Friction between chains & pulley/gear
➢ Angle of contact.
20 List the advantages of wire ropes compared to chains. (Apr/May-2017) BTL1
➢ More reliable in operation
➢ Silent operation even at high working speeds
➢ Less danger for damage due to jerks.
21 What is centrifugal effect on belts? (Nov/Dec 2015) BTL4

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As the belt moves round the pulley, it would experience a centrifugal force which has a tendency
to separate the belt from the pulley surface. To maintain contact between the pulley and belt, the
centrifugal force produce additional tension in the belt, which is known as centrifugal tension
(TC=mv2).
22 What are the factors upon which the coefficient of friction between the belt and pulley
depends? (May/June 2014, 2012) BTL2
The coefficient of friction between the belt material and pulley surface depends upon the belt
material, material of the pulley surfaces, belt speed and belt slip.
23 Name the types of belts used for transmission of power. (May/June 2013) BTL2
➢ Flat belts
➢ V-belts
➢ Ribbed belts
➢ Toothed or timing belts
24 List out the various stresses induced in the wire ropes. (May/June 2013) BTL1
➢ Direct stress due to the weight of the load to be lifted.
➢ Bending stress when the rope passes over the sheave
➢ Stress due to acceleration
➢ Stress due to starting and stopping
➢ Effective stress.
25 Mention the parts of roller chains. (Nov/Dec 2012) BTL2
➢ Inner (pin link or coupling link) and outer link plates (roller link)
➢ Pin
➢ Bushing and rollers.
PART * B
1 Design a flat belt drive to transmit 110 kW for a system consisting of two pulleys of
diameters 0.9m and 1.2m for a centre distance of 3.6m, belt speed of 20 m/s and coefficient
of friction is 0.3. There is a slip of 1.2% at each pulley and 5% friction loss at each shaft
with 20% overload. (13M) (Nov/Dec 2016) BTL5
Pulley diameters: d = 0.9m, D = 1.2m
Answer: Page: 1.31 – Dr.A.Baskar
Design power: (2M)
𝑅𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 𝑋 𝐿𝑜𝑎𝑑 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = = 135882 𝑊
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑓𝑎𝑐𝑡𝑜𝑟
Type of belt: (2M)
Considering heavy duty and medium belt speed; Dunlop FORT 949 g belt is selected.
Load rating = 0.0578 kW per mm per ply
No. of plies = 8.
Standard belt width: (2M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟
𝐵𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ = = 294 𝑚𝑚
𝑙𝑜𝑎𝑑
Pulley width: (2M)
Pulley width above 250 mm upto including 375 mm is to be wider than belt width by 38 mm.
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Pulley width = 343 mm.
Length of belt: (2M)
𝜋 (𝐷 − 𝑑)
𝐿 = 2𝐶 + (𝐷 + 𝑑) + = 10505 𝑚𝑚
2 4𝐶
Other pulley dimensions: (3M)
Number of arms = 6
Cross section of arms = elliptical
Radius of cross section of arm, r = 52.5 mm (small) & r = 57 mm (large).
Minimum length of bore, l = 230 mm (small) & l = 230 mm (large).
Speed of driver pulley = 430 rpm.
Speed of driven pulley = 319 rpm.
2 A V-belt drive is to transmit 15 kW to a compressor. The motor runs at 115 rpm and the
compressor is to run at 400 rpm. Determine (i) Belt specification, (ii) Number of belts, (iii)
Correct centre distance, (iv) Drive pulley diameters. (13M) (Nov/Dec 2015) BTL5
Answer: Page: 1.69 – Dr.A.Baskar
Belt cross section: (1M)
Nominal top width, W = 17 mm.
Nominal thickness, T = 11 mm.
Pulley diameters: (1M)
𝐷 𝑛1
𝑠𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 = =
𝑑 𝑛2
Standard pulley diameter, D = 400 mm.
Centre distance, C; (1M)
Centre distance is assumed to be equal to 400 mm.
Nominal pitch length: (2M)
𝜋 (𝐷 − 𝑑)
𝐿 = 2𝐶 + (𝐷 + 𝑑) + = 1671.93 𝑚𝑚
2 4𝐶
Minimum power transmitting capacity in kW: (2M)
50.8
𝑘𝑊 = (0.79 × 7.53−0.09 − − 1.32 × 10−4 × 7.532 ) 7.53 = 2.22 𝑘𝑊
142.5
Number of belts: (2M)
𝐷−𝑑
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 = 180° − 60° × = 138.75°
𝐶
𝑃 × 𝐹𝑎
𝑛𝑜. 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 = = 11 𝑏𝑒𝑙𝑡𝑠
𝑘𝑊 × 𝐹𝑐 × 𝐹𝑑
Actual centre distance, C: (2M)
𝐿 𝜋(𝐷 + 𝑑)
𝐴= − = 217.33
4 8
(𝐷 + 𝑑)2
𝐵= = 9453.125
8
𝐶 = 𝐴 + √𝐴2 − 𝐵 = 411.7 𝑚𝑚
Dimensions of V grooved pulley: (2M)
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Pitch width, lp = 14 mm.
Minimum distance down to pitch line, b = 4.2 mm.
Centre to centre distance, e = 19 mm.
Edge of pulley to first groove, f = 12.5 mm.
3 At the construction site, 1 tonne of steel is to be lifted upto a height of 20 m with the help of
2 wire ropes of 6x19 size, nominal diameter 12 mm and breaking load 75 kN. Determine the
factor of safety if the sheave diameter is 56d and wire rope is suddenly stopped in 1 second
while travelling at a speed of 1.2 m/s. What is the factor of safety if bending load is
neglected? (13M) (Nov/Dec 2014) BTL5
Answer: Page: 1.126 – Dr.A.Baskar
Wire rope type: 6 x 19 group. (2M)
Design load: Not required
Wire rope diameter, d and weight of rope, Wr: (2M)
D = 12 mm (given), Wr = 106 N.
Drum diameter, D = 56d = 672 mm.
Useful cross section area, A = 45.24 mm2.
Wire diameter, dw: (3M)
𝑅𝑜𝑝𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑
𝑑𝑤 = = 0.7493 𝑚𝑚
1.5 × √𝑁𝑜. 𝑜𝑓 𝑠𝑡𝑟𝑎𝑛𝑑𝑠 × 𝑁𝑜. 𝑜𝑓 𝑤𝑖𝑟𝑒𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑎𝑛𝑑
Effective load, Weq: (4M)
𝑊𝑑 = 𝑊 + 𝑊𝑟 = 9916 𝑁
𝑑𝑤
𝑊𝑏 = 𝐸 × × 𝐴 = 3959 𝑁
𝐷
𝑊 + 𝑊𝑟
𝑊𝑎 = × 𝑎 = 1213 𝑁
𝑔
𝑊𝑒𝑞 = 𝑊𝑑 + 𝑊𝑏 + 𝑊𝑎
Actual factor of safety: (2M)
𝐵𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑒𝑙𝑒𝑐𝑡𝑒𝑑 𝑟𝑜𝑝𝑒
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = = 10.34
𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑙𝑜𝑎𝑑
4 A bucket elevator is to be driven by a geared motor and a roller chain drive with the
information given below:
Motor output = 3 kW; speed of motor shaft = 100 rpm; elevator drive shaft speed = 42 rpm;
load = even; distance between centres of sprockets approximately = 1.2m; period of
operation = 16 hours/day; geared motor is mounted on an auxiliary bed for centre distance
adjustments. Design the chain drive. (13M) (Nov/Dec 2016) BTL5
Answer: Page: 1.151 – Dr.A.Baskar
Type of chain: Roller chain. (1M)
Preferred transmission ratio, i; (2M)
𝑧2 𝑛1
𝑖= = = 2.38
𝑧1 𝑛2
Number of teeth, z; (1M)
Z1 = 27; Z2 = 100 to 120 satisfied.
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Standard pitch, p: (1M)
𝑎 𝑎
𝑝= 𝑡𝑜 = 40 𝑡𝑜 24 𝑚𝑚
30 50
The standard pitch of 15.875 mm is selected.
Minimum factor of safety, n: (2M)
𝑄. 𝑣
𝑁= 𝑖𝑛 𝑘𝑊
102𝑛𝑘𝑠
Chain velocity, v = 0.7144 m/s.
Service factor, ks = 1.0
𝑁×102×𝑛×𝑘𝑠
B𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑, 𝑄 = = 3341 𝑘𝑔𝑓
𝑣
Selection of chain: (1M)
Chain no.10 A-2 DR 50 is selected; Breaking area, A = 140 mm2
Check for actual factor of safety, [n]: (1M)
𝑄
[𝑛] = = 10.06
∑𝑃
Actual factor of safety is larger than assumed factor of safety. Hence the design is safe.
Check for bearing stress: (1M)
𝑁 × 102 × 𝑘𝑠
𝜎= = 3.15 𝑘𝑔𝑓/𝑚𝑚2
𝐴. 𝑣
Actual bearing stress is less than the allowable bearing stress. Hence the design is safe.
Actual length of chain, l: (1M)
𝑧2 −𝑧1 2
(𝑧1 + 𝑧2 ) ( 2𝜋 )
𝑙𝑝 = 2𝑎𝑝 + + = 198 𝑚𝑚
2 𝑎𝑝
𝑙 = 𝑙𝑝 . 𝑝 = 3143.25 𝑚𝑚
Exact centre distance, a; (1M)
𝑒 + √𝑒 2 − 8𝑚
𝑎= . 𝑝 = 1202.67 𝑚𝑚
4
Chain wheel profile dimensions: (1M)
Pitch diameter of small sprocket, d1 = 136.74 mm.
Tooth side radius, F = 15.88 mm.
Side relief, G = 1.60 mm.
Shroud depth, J = 3.43 mm.
Shroud radius, K = 0.76 mm.
5 A compressor is to run by a motor pulley running at 1440 rpm, speed ratio 2.5. Choose a
flat belt crossed drive. Centre distance between pulleys is 3.6 m. Take belt speed as 16 m/s.
Load factor is 1.3. Take a 5-ply, flat Dunlop belt. Power to be transmitted is 12 kW. High
speed load rating is 0.0118 kW/ply/mm width at v = 5 m/s. Determine the width and length
of the belt. (13M) (Nov/Dec 2014) BTL5
Answer: Page: 1.39 – Dr.A.Baskar
Pulley diameters: (2M)

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𝐷 𝑛
𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = = 2.5
𝑑 𝑁
d = 224 mm, D = 560 mm
Design power: (3M)
𝑅𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 𝑋 𝐿𝑜𝑎𝑑 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = = 16.28 𝑘𝑊
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑓𝑎𝑐𝑡𝑜𝑟
Type of belt: (3M)
For high speeds, Dunlop HI-SPEED 878 g fabric belting is selected.
Load rating = 0.03776 kW/mm/ply
No. of plies = 5 (give).
Standard belt width: (3M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟
𝐵𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ = = 87 𝑚𝑚
𝑙𝑜𝑎𝑑
Length of belt: (2M)
𝜋 (𝐷 + 𝑑)
𝐿 = 2𝐶 + (𝐷 + 𝑑) + = 8474 𝑚𝑚
2 4𝐶
PART * C
1 Design a V-belt drive and calculate the actual belt tensions and average stress for the
following data:
Power to be transmitted = 7.5 kW; Speed of driving wheel = 1000 rpm; Speed of driven
wheel = 300 rpm; Diameter of driven wheel = 500 mm; Diameter of driver pulley = 150 mm
and centre distance = 925 mm. (15M) (April/May 2015) BTL5
Answer: Page: 1.75 – Dr.A.Baskar
Belt cross section: (1M)
Nominal top width, W = 17 mm.
Nominal thickness, T = 11 mm.
Pulley diameters: (1M)
d = 150 mm (given); D = 500 mm (given).
Centre distance, C = 925 mm (given)
Nominal pitch length: (2M)
𝜋 (𝐷 − 𝑑)
𝐿 = 2𝐶 + (𝐷 + 𝑑) + = 2904.13 𝑚𝑚
2 4𝐶
Minimum power transmitting capacity in kW: (3M)
50.8
𝑘𝑊 = (0.79𝑆 −0.09 − − 1.32 × 10−4 𝑠 2 ) 𝑆 = 2.7561 𝑘𝑊
𝑑𝑒
Number of belts: (2M)
𝐷−𝑑
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 = 180° − 60° × = 157.3°
𝐶
𝑃 × 𝐹𝑎
𝑛𝑜. 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 = = 4 𝑏𝑒𝑙𝑡𝑠
𝑘𝑊 × 𝐹𝑐 × 𝐹𝑑
Actual centre distance, C: (3M)
𝐿 𝜋(𝐷 + 𝑑)
𝐴= − = 517.496
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(𝐷 + 𝑑) 2
𝐵= = 15312.5
8
𝐶 = 𝐴 + √𝐴2 − 𝐵 = 1019.98 𝑚𝑚
Actual belt tensions: (3M)
𝑇𝑜𝑡𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑝𝑒𝑟 𝑏𝑒𝑙𝑡 = = 1875 𝑊
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠
𝑇1 (
𝜇𝜃
)
= 𝑒 sin 𝛽
𝑇2
Tension on slack side, T1 = 15.19 N;
Tension on tight side, T2 = 254.04 N.
2 The transporter of a heat treatment furnace is driven by a 4.5 kW, 1440 rpm induction
motor through a chain drive with a speed reduction ratio of 2.4. The transmission is
horizontal with both type of lubrication. Rating is continuous with 3 shifts per day. Design
the complete chain drive. (15M) (Nov/Dec 2013) BTL5
Answer: Page: 1.145 – Dr.A.Baskar
Type of chain: Roller chain. (1M)
Preferred transmission ratio, i = 2.4 (given)
Number of teeth, z: (1M)
Z1 = 27 (assumed); Z2 = 65.
Standard pitch, p: (1M)
𝑎 𝑎
𝑝= 𝑡𝑜 = 16.6667 𝑡𝑜 10 𝑚𝑚
30 50
Available standard pitches are: 9.525 mm, 12.7 mm & 15.875 mm.
The standard pitch of 12.7 mm is selected.
Minimum factor of safety, n: (2M)
𝑄. 𝑣
𝑁= 𝑖𝑛 𝑘𝑊
102𝑛𝑘𝑠
Chain velocity, v = 8.229 m/s.
Service factor, ks = 1.5
𝑁×102×𝑛×𝑘𝑠
B𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑, 𝑄 = = 1104.33 𝑘𝑔𝑓
𝑣
Selection of chain: (1M)
Chain no.08 B-3 R 1278H is selected;
Breaking load, Q = 2100 kgf;
Weight per meter = 0.75 kgf;
Breaking area, A = 54 mm2
Check for actual factor of safety, [n]: (1M)
𝑄
[𝑛] = = 33.23
∑𝑃
Actual factor of safety is larger than assumed factor of safety. Hence the design is safe.
Check for bearing stress: (2M)
𝑁 × 102 × 𝑘𝑠
𝜎= = 1.55 𝑘𝑔𝑓/𝑚𝑚2
𝐴. 𝑣
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Actual bearing stress is less than the allowable bearing stress. Hence the design is safe.
Actual length of chain, l: (2M)
𝑧2 −𝑧1 2
(𝑧1 + 𝑧2 ) ( 2𝜋 )
𝑙𝑝 = 2𝑎𝑝 + + = 125.669 𝑚𝑚
2 𝑎𝑝
𝑙 = 𝑙𝑝 . 𝑝 = 1600.2 𝑚𝑚
Exact centre distance, a: (2M)
𝑒+ √𝑒 2 − 8𝑚
𝑎= . 𝑝 = 502.12 𝑚𝑚
4
Chain wheel profile dimensions: (2M)
Pitch diameter of small sprocket, d1 = 109.4 mm.
Tooth side radius, F = 12.70 mm.
Side relief, G = 1.25 mm.
Shroud depth, J = 2.79 mm.
Shroud radius, K = 0.76 mm.
3 A 7.5 kW electric motor running at 1400 rpm is used to drive the input shaft of the gear box
of a special purpose machine. Design a suitable roller chain to connect the motor shaft to
the gear box shaft to give an exact speed ratio of 10 to 1. Assume the minimum centre
distance between driver and driven shafts as 600 mm. (15M) (May/June 2016) BTL5
Answer: Page: 1.156 – Dr.A.Baskar
Type of chain: Roller chain. (1M)
Preferred transmission ratio, i = 10 (given);
Number of teeth, z: (1M)
Z1 = 11 (assumed); Z2 = 110.
Standard pitch, p: (1M)
𝑎 𝑎
𝑝= 𝑡𝑜 = 20 𝑡𝑜 12 𝑚𝑚
30 50
The standard pitch of 15.875 mm is selected.
Minimum factor of safety, n: (1M)
𝑄. 𝑣
𝑁= 𝑖𝑛 𝑘𝑊
102𝑛𝑘𝑠
Chain velocity, v = 4.07 m/s.
Service factor, ks = 1.5625
𝑁×102×𝑛×𝑘𝑠
B𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑, 𝑄 = = 3877 𝑘𝑔𝑓
𝑣
Selection of chain: (1M)
Chain no.10 B-2 DR 1595 is selected;
Breaking load, Q = 4540 kgf;
Weight per meter = 1.82 kgf;
Breaking area, A = 134 mm2
Check for actual factor of safety, [n]: (2M)
𝑄
[𝑛] = = 10.06
∑𝑃
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Actual factor of safety is larger than assumed factor of safety. Hence the design is safe.
Check for bearing stress: (2M)
𝑁 × 102 × 𝑘𝑠
𝜎= = 3.15 𝑘𝑔𝑓/𝑚𝑚2
𝐴. 𝑣
Actual bearing stress is less than the allowable bearing stress. Hence the design is safe.
Actual length of chain, l: (2M)
𝑧 −𝑧 2
2 1
(𝑧1 + 𝑧2 ) ( 2𝜋 )
𝑙𝑝 = 2𝑎𝑝 + + = 198
2 𝑎𝑝
𝑙 = 𝑙𝑝 . 𝑝 = 3143.25 𝑚𝑚
Exact centre distance, a: (2M)
𝑒 + √𝑒 2 − 8𝑚
𝑎= . 𝑝 = 1202.67 𝑚𝑚
4
Chain wheel profile dimensions: (2M)
Pitch diameter of small sprocket, d1 = 136.74 mm.
Tooth side radius, F = 15.88 mm.
Side relief, G = 1.60 mm.
Shroud depth, J = 3.43 mm.
Shroud radius, K = 0.76 mm.
4 A V-belt drive is to be arranged between two shafts with 1.2 m as centre distance. The
driving pulley is of 250 mm effective diameter and is to be supplied with 20 kW power at
960 rpm. The follower pulley is to run at 460 rpm. Determine the number of belts required
from the following:
Arc of the belt cross section = 143 mm2; Mass density of the belt material = 100 kg/m3;
Permissible tensile stress = 2 N/mm2; Coefficient of friction = 0.3; Groove angle of the
pulley, 2β = 40º. (15M) (Nov/Dec 2015) BTL5
Note: since all the data are available, problem can be solved using basic equations.
Diameter of the driven pulley, D: (2M)
𝐷 𝑛1
𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 = =
𝑑 𝑛2
960 𝑋 0.25
𝐷= = 522 𝑚𝑚
460
Mass of the belt per meter length: (2M)
𝑘𝑔
𝑚 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 × 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 = 0.143
𝑚
Centrifugal tension, Tc: (2M)
2
𝑇𝑐 = 𝑚𝑣 = 22.58 𝑁
Angle contact, θ: (2M)
𝐷−𝑑
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 = 180° − 60° × = 166.4°
𝐶
Maximum tension in the belt, Tmax: (2M)
𝑇𝑚𝑎𝑥 = 𝜎 × 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 = 286 𝑁

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Belt tensions: (2M)
𝑇1 (
𝜇𝜃
)
=𝑒 𝛽 sin
𝑇2
Tension at tight side, T1 = Tmax – Tc = 263.42 N.
Tension at slack side, T2 = 20.63 N.
Number of belts: (3M)
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 = (𝑇1 − 𝑇2 )𝑣 = 3050.9 𝑊

𝑇𝑜𝑡𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 = = 7 𝑏𝑒𝑙𝑡𝑠
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑏𝑦 𝑜𝑛𝑒 𝑏𝑒𝑙𝑡

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UNIT II – SPUR GEARS AND PARALLEL AXIS HELICAL GEARS

Speed ratios and number of teeth-Force analysis -Tooth stresses - Dynamic effects – Fatigue strength -
Factor of safety - Gear materials – Design of straight tooth spur & helical gears based on strength and
wear considerations – Pressure angle in the normal and transverse plane- Equivalent number of teeth-
forces for helical gears.
PART * A

Q.No. Questions

1 Specify the conditions based on which gear cutters are selected. BTL4
➢ The capacity of the machine size and shape of the gear
➢ Proper material selection
➢ The magnitude of production range
➢ The production time
➢ The technical experience of the machinist
➢ The economic viability of the machine
➢ The cutting forces
2 Define backlash. What factors influence backlash in gear drives? (Nov/Dec 2016) BTL1
Shortest distance between the non-contacting surfaces of the adjacent teeth is referred to as
backlash.
➢ Module and
➢ Pitch line velocity influence the backlash in gear drives.
3 What are the advantages of the helical gear over spur gear? BTL2
➢ Helical gears produce less noise than spur gears of equivalent quality because the total
contact ratio is increased.
➢ Helical gears have a greater load carrying capacity than equivalent size of spur gears.
➢ A limited number of standard cutters are used to cut a wide variety of helical gears
simply by varying the helix angle.
➢ Smoother engagement of the gear teeth.
➢ More teeth carry load at a given time so that they are more efficient – carry more load for
a given size.
4 What are the main types of gear tooth failure? (May/June2013, 2012) BTL1
➢ Tooth breakage (due to static and dynamic loads).
➢ Tooth wear (or surface deterioration): (a) Abrasion; (b) Pitting and (c) Scoring or seizure.
5 What are the assumptions made in deriving Lewis equation? BTL3
➢ The effect of radial component, which induces compressive stresses, is negligible.
➢ The tangential component is uniformly distributed across the full face width.
➢ The tangential force is applied to the tip of a single tooth.
➢ Stress concentration in the tooth fillet is negligible.
6 Why is pinion made harder than gear? (Nov/Dec 2012) BTL4

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Since the teeth of pinion undergo more number of cycles than gear and hence quicker wear.
7 List out the various methods of manufacturing a gear. BTL2
➢ Gear milling,
➢ Gear generating,
➢ Gear hobbing,
➢ Gear shaping,
➢ Gear molding,
➢ Injection molding,
➢ Die casting and
➢ Investment casting.
8 What are the common forms of gear tooth profile? (Apr/May 2011) BTL1
➢ Involute tooth profile and
➢ Cycloidal tooth profile.
9 What are the standard interchangeable tooth profiles? BTL2
➢ 14½0 composite system
➢ 14½0 full depth involute system
➢ 200 full depth involute system and
➢ 200 stub involute system.
10 What are the effects of increasing and decreasing the pressure angle in gear design?
(April/May 2015, 2017&2014, Nov/Dec 2014) BTL4
➢ Increasing the pressure angle will increase the beam and surface strengths of tooth. But
gear becomes noisy.
➢ Decreasing the pressure angle will increase the minimum number of teeth required on
the pinion to avoid interference/ undercutting.
11 A helical gear has a normal pressure angle of 20 degrees, a helix angle of 45 degrees,
normal module of 4mm and has 20 teeth. Find the pitch diameter. (Nov/Dec 2016) BTL5
Solution : Pitch circle diameter (d) = (mn x Z)/ cosβ, = (4x20)/cos45 = 113.3 = 114mm
12 Differentiate double helical and herringbone gears. (Nov/Dec 2015, Apr/May 2017) BTL4
When there is groove in between the gears, then the gears are specifically known as double
helical gears. When there is no groove in between the gears, then the gears is known as
herringbone gears.
13 Write short notes on stub tooth system. (May/June2012) BTL1
In this system, the thickness of tooth at top surface and its root is more compare to full depth
tooth system. Also this kind of tooth possesses shorter addendum and larger pressure angle,
usually 200 and thus interference problem may be eliminated. For standard stub tooth system, the
tooth proportion are as Whole depth=1.8*module; Addendum==0.8*module;
Dedendum=1.0*module; Working Depth=1.6*module; Clearance=0.2*module;
14 What are the advantages of helical gears? [(Nov/Dec 2012) BTL2
➢ Transmit more power
➢ Provide smooth and
➢ Soundless operation.

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15 What are the profiles of a spur gear? (May/June 2016) BTL1
Two constant velocity tooth profiles are the most commonly used in modern times:
the cycloid and the involute.
16 What is herringbone gear? (May/June 2016) BTL1
Herringbone gears, also called double helical gears, are gear sets designed to transmit power
through parallel or, less commonly, perpendicular axes. The unique tooth structure of
a herringbone gear consists of two adjoining, opposite helixes that appear in the shape of the
letter 'V'. Double helical gears are used in many applications such as cranes, fluid pumps and
power transmission to the propulsion screws in military ships for a quieter and less vibration
operation.
17 State the advantages of Herringbone gear. (April/May 2015, 2013) BTL1
Herringbone gears eliminate the existence of axial thrust load in the helical gears. Because,
in herringbone gears, the thrust force of the right hand is balanced by that of the left hand helix.
18 Why is a gear tooth subjected to dynamic load? (Nov/Dec 2014) BTL4
Dynamic loads are due to
➢ In accuracies of tooth spacing
➢ Irregularities in tooth profiles
➢ Elasticity of parts
➢ Misalignment between bearings
➢ Deflection of teeth under load
➢ Dynamic unbalance of rotating masses.
19 Compare the features of spur and helical gears. (Nov/Dec 2012) BTL4
Advantages of the spur gear:
➢ Spur gears are simplest, hence easiest to design and manufacture.
➢ A spur gear is more efficient if you compare it with helical gear of same size.
➢ Easy to assemble
Advantages of the helical gear:
➢ Silent operation
➢ Helical gears can be used for transferring power between non-parallel shafts.
➢ For same tooth size (module) and equivalent width, helical gears can handle more load
than spur gears because the helical gear tooth is effectively larger since it is diagonally
positioned.
20 Define the various pitch in a helical gear. (May/June 2012) BTL1
➢ Transverse circular pitch (Pt)
➢ Normal circular pitch (Pn)
➢ Axial Pitch (Pa)
➢ Normal diametral pitch (Pd)
21 State the law of gearing. (or) State the conditions of correct gearing. (Nov/Dec2012, April
/May 2015) (or) What conditions must be satisfied in order that a pair of spur gears may
have constant velocity ratio? (May/June 2014) BTL1
The law of gearing states that for obtaining a constant velocity ratio, at any instant of teeth the

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common normal at each point of contact should always pass through a pitch point (fixed point),
situated on the line joining the centres of rotation of the pair of mating gears.
The angular velocity ratio of the gears of a gear-set must remain constant throughout the mesh.
22 State some materials used for manufacturing of gears. (May/June 2013) BTL1
Metallic gears: steel, cast iron and bronze. Non-metallic gears: wood, compressed paper and
synthetic resins.
23 Define module. (April/May 2011, May/June 2013, Nov/Dec 2015) BTL1
Module, m this indicates the tooth size and is the number of mm of pitch circle diameter (p.c.d.)
per tooth. For gears to mesh, their modules must be equal. Gear ISO standards and design
methods are now normally based on the module. EG a gear of module 3 has 16 teeth, its pitch
circle diameter is: 3 x 16 = 48 mm. In a pair of spur gears, the module is 6 mm.
24 What are the advantages of toothed gears over the other types of transmission systems?
BTL2
Advantages of gear drives over other drives, i.e. belt, rope and chain drives are
➢ It is very compact and need less space.
➢ It has a very high efficiency which is very useful in transmitting motion.
➢ The main advantage of gear drive is that it transmit same velocity ratio.
➢ Again a good advantage is that it is a very good reliable service.
➢ And last is that it can be used to transmit a very large power.
25 What is pressure angle? (April /May 2015 & 2014, Nov/Dec 2014) BTL1
It is the angle which the line of action makes with the common tangent to pitch circles of
mating gears. Simply refers to the angle through which forces are transmitted between
meshing gears. Ideally 20° of pressure angle (involute system) is preferred because the tooth
acting as a beam is wider at the base.
PART * B
1 A speed reducing unit using spur gear is to be designed. Power to be transmitted is 60 hp
and is continuous with moderate shock loads. The speeds of the shafts are 720 rpm and 144
rpm respectively. The centre distance is kept as small as possible. Select a suitable material
and design the gears. Give the details of the gears. (13M) (May/June 2016) BTL5
Answer: Page: 2.59 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= =5
𝑁2
Material: (1M)
C45 is selected for both pinion and wheel.
Design bending stress, [σb] = 13734 X 104 N/m2
Design surface contact stress, [σc] = 49050 X 104 N/m2
Gear life: Not Given
Design torque, [Mt]: (1M)
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 593.648 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 771.742 𝑁 − 𝑚
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Calculation of Eeq, [σb] and [σc]: (1M)
Eeq = 210915 X 106 N/m2
[σb] = 13734 X 104 N/m2
[σc] = 49050 X 104 N/m2
Centre distance, a: (1M)
3 0.74 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
[𝜎𝑐 ] 𝑖×𝜓
𝑏
𝐴𝑠𝑠𝑢𝑚𝑒, = 0.3
𝑎
𝑎𝑚𝑖𝑛 = 376 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 100.
Module, m: (1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √ = 6 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
Revised centre distance, a and number of teeth: (1M)
𝑚(𝑍1 + 𝑍2 )
𝑎=
2
Z1 = 25 teeth; Z2 = 105 teeth; a = 378 mm.
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = ψ . a = 113.4 mm
Pitch circle diameter, d1 = mZ1 = 126 mm.
Pitch line velocity, v = 4.75 m/s.
Quality of gear: (1M)
IS quality 8 is selected.
Revision of design torque:
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 865.539 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
(𝑖 + 1)
𝜎𝑏 = × [𝑀𝑡 ] ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 13734 × 104 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (1M)
(𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = 0.74 × ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 49050 × 104 𝑁/𝑚2
Design is safe.
Basic dimensions of pinion and wheel: (1M)

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Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 126 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = (𝑍1 + 2𝑓0 )𝑚 = 138 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = (𝑍1 + 2𝑓0 )𝑚 − 2𝑐 = 111 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 13.5 𝑚𝑚
Wheel:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 630 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐2 = (𝑍2 + 2𝑓0 )𝑚 = 642 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑍2 + 2𝑓0 )𝑚 − 2𝑐 = 615 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 13.5 𝑚𝑚
2 In a spur gear drive for a stone crusher, the gears are made of C40 steel. The pinion is
transmitting 30 kW at 1200 rpm. The gear ratio is 3. Gear is to work 8 hours per day, six
days a week and for 3 years. Design the drive. (13M) (Nov/Dec 2016) BTL5
Answer: Page: 2.65 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= = 3 (𝑔𝑖𝑣𝑒𝑛)
𝑁2
Material: (1M)
C40 is selected for both pinion and wheel (given).
Gear life: N = 53.9136 X 107 cycles.
Design torque, [Mt]: (1M)
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 238.732 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 310.352 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]: (1M)
6 2
Eeq = 210915 X 10 N/m
1.4𝑘𝑏𝑙 𝜎−1
[𝜎𝑏 ] = = 15525 × 104 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 62697 × 104 𝑁/𝑚2
Centre distance, a: (1M)
3 0.74 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
[𝜎𝑐 ] 𝑖×𝜓
𝑏
𝐴𝑠𝑠𝑢𝑚𝑒, = 0.3
𝑎
𝑎𝑚𝑖𝑛 = 187 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 60.
Module, m: (1M)

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3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √ = 4 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
Revised centre distance, a and number of teeth: (1M)
𝑚(𝑍1 + 𝑍2 )
𝑎=
2
Z1 = 24 teeth; Z2 = 72 teeth; a = 192 mm.
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = ψ . a = 57.6 mm
Pitch circle diameter, d1 = mZ1 = 96 mm.
Pitch line velocity, v = 6.03 m/s.
Quality of gear: (1M)
IS quality 8 is selected.
Revision of design torque:
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 334.416 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
(𝑖 + 1)
𝜎𝑏 = × [𝑀𝑡 ] ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 15525 × 104 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (1M)
(𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = 0.74 × ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 62697 × 104 𝑁/𝑚2
Design is safe.
Basic dimensions of pinion and wheel: (1M)
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 96 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = (𝑍1 + 2𝑓0 )𝑚 = 104 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = (𝑍1 + 2𝑓0 )𝑚 − 2𝑐 = 86 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 9 𝑚𝑚
Wheel:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 288 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐2 = (𝑍2 + 2𝑓0 )𝑚 = 296 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑍2 + 2𝑓0 )𝑚 − 2𝑐 = 278 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 9 𝑚𝑚
3 Design a pair of straight gear drive for a stone crusher, the pinion and wheel are made of
C15 steel and cast iron grade 30 respectively. The pinion is to transmit 22 kW power at 900
rpm. The gear ratio is 2.5. Take pressure angle of 20º and working life of gear as 10000
hours. (13M) (Nov/Dec 2016) BTL5
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Answer: Page: 2.76 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= = 2.5 (𝑔𝑖𝑣𝑒𝑛)
𝑁2
Material: (1M)
Pinion – C15
Wheel – Cast iron, grade 30 (given).
Gear life: N = 10000 hrs (given)
Design torque, [Mt]: (1M)
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 233.427 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 303.4554 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]: (1M)
2𝐸1 𝐸2
𝐸𝑒𝑞 =
𝐸1 + 𝐸2
9 2
Eeq = 143.226 X 10 N/m
1.4𝑘𝑏𝑙 𝜎−1
[𝜎𝑏 ] = = 10379 × 104 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 74487 × 104 𝑁/𝑚2
Centre distance, a: (1M)
3 0.74 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
[𝜎𝑐 ] 𝑖×𝜓
𝑏
𝐴𝑠𝑠𝑢𝑚𝑒, = 0.3
𝑎
𝑎𝑚𝑖𝑛 = 241 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 50.
Module, m: (1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √ = 5 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
Revised centre distance, a and number of teeth: (1M)
𝑚(𝑍1 + 𝑍2 )
𝑎=
2
Z1 = 28 teeth; Z2 = 70 teeth; a = 245 mm.
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = ψ . a = 73.5 mm
Pitch circle diameter, d1 = mZ1 = 140 mm.
Pitch line velocity, v = 6.6 m/s.
Quality of gear: (1M)

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IS quality 8 is selected.
Revision of design torque:
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 329.389 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
(𝑖 + 1)
𝜎𝑏 = × [𝑀𝑡 ] ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 2711 × 104 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (1M)
(𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = 0.74 × ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 30375 × 104 𝑁/𝑚2
Design is safe.
Basic dimensions of pinion and wheel: (1M)
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 140 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = (𝑍1 + 2𝑓0 )𝑚 = 150 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = (𝑍1 + 2𝑓0 )𝑚 − 2𝑐 = 127.5 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 11.25 𝑚𝑚
Wheel:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 350 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐2 = (𝑍2 + 2𝑓0 )𝑚 = 360 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑍2 + 2𝑓0 )𝑚 − 2𝑐 = 337.5 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 11.25 𝑚𝑚
4 A pair of helical gears subjected to moderate shock loading is to transmit 30 kW at 1500
rpm of the pinion. The speed reduction ratio is 4 and the helix angle is 20º. The service is
continuous and the teeth are 20º FD in the normal plane. For gear life of 10,000 hours,
design the gear drive. (13M) (May/June 2016) BTL5
Answer: Page: 2.156 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= = 4 (𝑔𝑖𝑣𝑒𝑛)
𝑁2
Material: (1M)
Assume 40 Ni2 Cr1 Mo 28 for both pinion and wheel (given).
Design bending stress, [σb] = 4000 kgf/cm2
Design surface contact stress, [σc] = 11000 kgf/cm2
Gear life: (1M)
7
Equivalent mean life, N = 60nT = 90 X 10 cycles.
Design torque, [Mt]: (1M)

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60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 190.99 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 248.28 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]: (1M)
Eeq = 210915 X 106 N/m2
1.4𝑘𝑏𝑙 𝜎−1
[𝜎𝑏 ] = = 240.345 × 106 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 1049.64 × 106 𝑁/𝑚2
Centre distance, a: (1M)
3 0.7 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
[𝜎𝑐 ] 𝑖×𝜓
𝑏
𝐴𝑠𝑠𝑢𝑚𝑒, = 0.3
𝑎
𝑎𝑚𝑖𝑛 = 268.7 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 80.
Module, m: (1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.15 cos 𝛽 √ = 3 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
Revised centre distance, a and number of teeth:
𝑚(𝑍1 + 𝑍2 )
𝑎=
2cos 𝛽
Z1 = 34 teeth; Z2 = 136 teeth; a = 271.37 mm.
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = ψ . a = 82 mm
Pitch circle diameter, d1 = mZ1 /Cosβ = 108.55 mm.
Pitch line velocity, v = 8.525 m/s.
Quality of gear: (1M)
IS quality 8 is selected.
Revision of design torque:
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 280.75 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
0.7 × (𝑖 + 1) × [𝑀𝑡 ]
𝜎𝑏 = ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 31.65 × 106 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (1M)

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0.74 × (𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 387.5 × 106 𝑁/𝑚2
Design is safe.
Basic dimensions of pinion and wheel: (1M)
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 108.55 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑍1
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = ( + 2𝑓0 ) 𝑚 = 114.55 𝑚𝑚
cos 𝛽
𝑍1
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = ( + 2𝑓0 ) 𝑚 − 2𝑐 = 101.05 𝑚𝑚
cos 𝛽
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 6.75 𝑚𝑚
Wheel:
𝑚𝑛
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = × 𝑍2 = 434.18 𝑚𝑚
cos 𝛽
𝑍2
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐2 = ( + 2𝑓0 ) 𝑚 = 440.18 𝑚𝑚
cos 𝛽
𝑍2
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = ( + 2𝑓0 ) 𝑚 − 2𝑐 = 426.68 𝑚𝑚
cos 𝛽
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 6.75 𝑚𝑚
5 Design a helical gear drive to transmit a power of 15 kW at 1440 rpm to the following
specifications: Speed reduction is 3, pressure angle is 20º, helix angle is 15º, material of both
gears is C45 steel, allowable static stress is 180 N/mm2, Young’s modulus = 2 X 105 N/mm2.
(13M) (Nov/Dec 2010) BTL5
Answer: Page: 2.175 – Dr.A.Baskar
Material: (1M)
C45 Steel (given)
Number of teeth Z1 and Z2: (1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 60.
Tangential load, Ft: (1M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠 12.488
𝐹𝑡 = =
𝑣𝑚 𝑚

Dynamic Load, Fd: (1M)

𝐹𝑑 = 𝐹𝑡 . 𝐶𝑉
12.488
𝐹𝑑 = × (1 + 260.25𝑚)
𝑚
Beam strength, Fs: (1M)
6 2
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 = 594 × 10 𝑚
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Module, m: (1M)
𝐹𝑠 ≥ 𝐹𝑑 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛
12.488
× (1 + 260.25𝑚) = 594 × 106 𝑚2
𝑚
Module, m = 4 mm.
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = 10 X m = 40 mm
Pitch circle diameter of pinion, d1 = mZ1/cosβ = 82.82 mm.
Pitch circle diameter of wheel, d2 = mZ2/cosβ = 248.47 mm.
Pitch line velocity, v = 6.032 m/s.
Revision of beam strength, Fs: (1M)
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 = 9504 𝑁
Buckingham’s dynamic load, Fd: (1M)
2
0.164𝑉𝑚 (𝑐𝑏𝑐𝑜𝑠 𝛽 + 𝐹𝑡 ) cos 𝛽
𝐹𝑑 = 𝐹𝑡 + [ ] = 7942.96 𝑁
0.164𝑉𝑚 + 1.485√𝑐𝑏𝑐𝑜𝑠 2 𝛽 + 𝐹𝑡
Check for the design:
(Fd = 7942.96 N) < (Fs = 9504 N)
The design is safe.
Check for wear: (2M)
𝑏𝑑1 𝑄𝑘
𝑊𝑒𝑎𝑟 𝑙𝑜𝑎𝑑, 𝐹𝑤 = = 3130.4 𝑁
𝑐𝑜𝑠 2 𝛽
(Fw = 3130.4 N) < (Fd = 7942.96 N)
The design is not safe.
For increasing wear load, it is preferable to increase the [σc] by heat treatment to 9000 kgf/cm2.
Therefore, Fw = 8829 N
Now, (Fw = 8829 N) > (Fd = 7942.96 N)
Hence, the design is safe.
Basic dimensions of pinion and wheel: (2M)
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 82.82 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑍1
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = ( + 2𝑓0 ) 𝑚 = 90.82 𝑚𝑚
cos 𝛽
𝑍1
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = ( + 2𝑓0 ) 𝑚 − 2𝑐 = 72.82 𝑚𝑚
cos 𝛽
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 9 𝑚𝑚
Wheel:
𝑚𝑛
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = × 𝑍2 = 248.47 𝑚𝑚
cos 𝛽
𝑍2
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐2 = ( + 2𝑓0 ) 𝑚 = 256.47 𝑚𝑚
cos 𝛽

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𝑍2
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = ( + 2𝑓0 ) 𝑚 − 2𝑐 = 238.47 𝑚𝑚
cos 𝛽
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 9 𝑚𝑚
PART * C
1 Design a straight spur gear drive to transmit 8 kW. The pinion speed is 720 rpm and the
speed ratio is 2. Both the gears are made of the same surface hardened carbon steel with 55
RC and core hardness less than 350 BHN. Ultimate strength is 720 N/mm2 and yield
strength is360 N/mm2. (15M) (Nov/Dec 2015) BTL5
Answer: Page: 2.71 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= = 2 (𝑔𝑖𝑣𝑒𝑛)
𝑁2
Material: (1M)
Surface hardened carbon steel (given)
Gear life: Not given
Design torque, [Mt]: (1M)
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 106.1 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 137.93 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]: (1M)
6 2
Eeq = 21095 X 10 N/m
1.4𝑘𝑏𝑙 𝜎−1
[𝜎𝑏 ] = = 13802.88 × 104 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 85837.5 × 104 𝑁/𝑚2
Centre distance, a: (1M)
3 0.74 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
[𝜎𝑐 ] 𝑖×𝜓
𝑏
𝐴𝑠𝑠𝑢𝑚𝑒, = 0.3
𝑎
𝑎𝑚𝑖𝑛 = 46 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 12 (assumed)
Z2 = i. Z1 = 24.
Module, m: (1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √ = 4 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
Revised centre distance, a and number of teeth: (1M)
𝑚(𝑍1 + 𝑍2 )
𝑎=
2
Z1 = 12 teeth; Z2 = 24 teeth; a = 72 mm.

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Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = ψ . a = 21.6 mm
Pitch circle diameter, d1 = mZ1 = 48 mm.
Pitch line velocity, v = 1.8096 m/s.
Quality of gear: (1M)
IS quality 8 is selected.
Revision of design torque: (1M)
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 334.41 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
(𝑖 + 1)
𝜎𝑏 = × [𝑀𝑡 ] ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 7012 × 104 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (1M)
(𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = 0.74 × ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 29486 × 104 𝑁/𝑚2
Design is safe.
Basic dimensions of pinion and wheel: (2M)
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 140 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = (𝑍1 + 2𝑓0 )𝑚 = 150 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = (𝑍1 + 2𝑓0 )𝑚 − 2𝑐 = 127.5 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 11.25 𝑚𝑚
Wheel:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 350 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐2 = (𝑍2 + 2𝑓0 )𝑚 = 360 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑍2 + 2𝑓0 )𝑚 − 2𝑐 = 337.5 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 11.25 𝑚𝑚
2 Design a spur gear drive required to transmit 45 kW at a pinion speed of 800 rpm. The
velocity ratio is 3.5:1. The teeth are 20º full depth involute with 18 teeth on the pinion. Both
the pinion and gear are made of steel with a maximum safe static stress of 180 N/mm2.
Assume medium shock conditions. (15M) (Nov/Dec 2015) BTL5
Answer: Page: 2.98 – Dr.A.Baskar
Material: (1M)
Steel for both pinion and wheel (given)
Number of teeth Z1 and Z2: (1M)
Z1 = 18 (given)
Z2 = i. Z1 = 63.

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Tangential load, Ft: (1M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠 77.586
𝐹𝑡 = =
𝑣𝑚 𝑚

Dynamic Load, Fd: (1M)

𝐹𝑑 = 𝐹𝑡 . 𝐶𝑉
77.586
𝐹𝑑 = × (1 + 125.7𝑚)
𝑚
Beam strength, Fs: (1M)
6 2
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 = 584.1 × 10 𝑚
Module, m: (2M)
𝐹𝑠 ≥ 𝐹𝑑 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛
77.586
× (1 + 125.7𝑚) = 584.1 × 106 𝑚2
𝑚
Module, m = 8 mm.
Face width, pitch circle diameter, pitch line velocity: (2M)
Face width, b = 10 X m = 80 mm
Pitch circle diameter, d1 = mZ1 = 144 mm.
Pitch line velocity, v = 6.032 m/s.
Revision of beam strength, Fs: (1M)
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 = 37382 𝑁
Buckingham’s dynamic load, Fd: (1M)
0.164𝑉𝑚 (𝑐𝑏 + 𝐹𝑡 )
𝐹𝑑 = 𝐹𝑡 + [ ] = 26417 𝑁
0.164𝑉𝑚 + 1.485√𝑐𝑏 + 𝐹𝑡
Check for the design:
(Fd = 26417 N) < (Fs = 37382 N)
The design is safe.
Check for wear: (1M)
𝑊𝑒𝑎𝑟 𝑙𝑜𝑎𝑑, 𝐹𝑤 = 𝑑1 𝑄𝑘𝑏 = 36056 𝑁
(Fw = 36056 N) > (Fd = 26417 N)
The design is safe.
Basic dimensions of pinion and wheel: (3M)
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 144 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = (𝑍1 + 2𝑓0 )𝑚 = 160 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = (𝑍1 + 2𝑓0 )𝑚 − 2𝑐 = 124 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 18 𝑚𝑚
Wheel:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 504 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐2 = (𝑍2 + 2𝑓0 )𝑚 = 520 𝑚𝑚

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𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑍2 + 2𝑓0 )𝑚 − 2𝑐 = 484 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 18 𝑚𝑚
3 Design a pair of helical gears to transmit 10 kW at 1000 rpm of the pinion. Reduction ratio
of 5 is required. Pressure angle is 20º and the helix angle is 15º. The material for both the
gears is 40Ni2 Cr1 Mo28. Give the details of the drive in a tabular form. (15M) (Nov/Dec
2016) BTL5
Answer: Page: 2.149 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= = 5 (𝑔𝑖𝑣𝑒𝑛)
𝑁2
Material: (1M)
40 Ni2 Cr1 Mo 28 for both pinion and wheel (given).
Design bending stress, [σb] = 392.4 X 106 N/m2
Design surface contact stress, [σc] = 1079.1X 106 N/m2
Gear life: Not Given
Design torque, [Mt]: (1M)
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 95.493 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 124.141 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]: (1M)
6 2
Eeq = 210915 X 10 N/m
[σb] = 392.4 X 106 N/m2
[σc] = 1079.1 X 106 N/m2
Centre distance, a: (1M)
30.7 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
[𝜎𝑐 ] 𝑖×𝜓
𝑏
𝐴𝑠𝑠𝑢𝑚𝑒, = 0.3
𝑎
𝑎𝑚𝑖𝑛 = 105 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 100.
Module, m: (1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.15 cos 𝛽 √ = 2 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
Revised centre distance, a and number of teeth: (1M)
𝑚(𝑍1 + 𝑍2 )
𝑎=
2cos 𝛽
Z1 = 18 teeth; Z2 = 90 teeth; a = 111.8 mm.
Face width, pitch circle diameter, pitch line velocity: (1M)

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Face width, b = ψ . a = 33.54 mm
Pitch circle diameter, d1 = mZ1 /Cosβ = 37.27 mm.
Pitch line velocity, v = 1.951 m/s.
Quality of gear: (1M)
IS quality 8 is selected.
Revision of design torque: (1M)
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 113.45 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
0.7 × (𝑖 + 1) × [𝑀𝑡 ]
𝜎𝑏 = ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 163.331 × 106 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (1M)

0.74 × (𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 1076 × 106 𝑁/𝑚2
Design is safe.
Basic dimensions of pinion and wheel: (2M)
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 37.27 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑍1
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = ( + 2𝑓0 ) 𝑚 = 41.27 𝑚𝑚
cos 𝛽
𝑍1
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = ( + 2𝑓0 ) 𝑚 − 2𝑐 = 32.27 𝑚𝑚
cos 𝛽
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 4.5 𝑚𝑚
Wheel:
𝑚𝑛
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = × 𝑍2 = 186.35 𝑚𝑚
cos 𝛽
𝑍2
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐2 = ( + 2𝑓0 ) 𝑚 = 190.35 𝑚𝑚
cos 𝛽
𝑍2
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = ( + 2𝑓0 ) 𝑚 − 2𝑐 = 181.35 𝑚𝑚
cos 𝛽
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 4.5 𝑚𝑚

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UNIT III – BEVEL, WORM AND CROSS HELICAL GEARS

Straight bevel gear: Tooth terminology, tooth forces and stresses, equivalent number of teeth. Estimating
the dimensions of pair of straight bevel gears. Worm Gear: Merits and demerits terminology. Thermal
capacity, materials-forces and stresses, efficiency, estimating the size of the worm gear pair. Cross
helical: Terminology-helix angles-Estimating the size of the pair of cross helical gears.
PART * A

Q.No. Questions

1 What is virtual or formative number of teeth in bevel gears? (Nov/Dec 2014, April/May
2017, May/June 2014) BTL1
An imaginary spur gear considered in a plane perpendicular to the tooth of the bevel gear at the
larger end is known as virtual spur gear. The number of teeth zv on this imaginary spur gear
is called virtual number of teeth in bevel gears. z v = z/cos δ where z = actual number of teeth
on the bevel gear and δ = pitch angle.
2 Define the following terms: (a) Cone distance (b) Face angle. (May/June 2014) BTL1
(a) Cone distance: In bevel gears, cone distance is the length of the pitch cone element. (b) Face
angle: It is the angle subtended by the face of the tooth at the cone centre.
3 Why is the efficiency of worm gear drive comparatively low? BTL4
The efficiency of worm gear drive is lower because of power loss due to friction caused
by sliding.
4 In which gear drive, self-locking is available? (April/May 2015, 2013) BTL3
In the worm gear drive, self-locking is available.
5 Write the conditions of self-locking of worm gears in terms of lead and pressure angle in
gear design. And also write the condition for over running drives. (Apr/May 2017) BTL3
➢ The drive is called self-locking, if µ ≥ cos α . tan γ
➢ The drive is called overrunning, if µ < cos γ . tan γ
6 Why is multistart worm more efficient than the single start one? BTL4
The efficiency of the worm depends mainly on pressure angle (also known as pitch angle of
the worm). For a single start worm this pressure angle will be less. In a multi start worm, this
pressure angle can be increased (of the order 45 0). That’s why multi start worm is more
efficient.
7 What is the difference between an angular gear and a miter gear? (Nov/Dec 2015) BTL4
➢ When the bevel gears connect two shafts whose axes intersect at an angle other than
a right angle, then they are known as angular bevel gears.
➢ When equal bevel gears (having equal teeth and equal pitch angles) connect two shafts
whose axes intersect at right angle, then they are known as miter gears.
8 A pair of worm gears is designated as 2/54/10/5. Find the gear ratio. BTL5
Solution: (2/54/10/5): (z1/z2/q/mx)Therefore, Gear ratio, i = z 2/z1 = 54/2 = 27
9 Why phosphor bronze is widely used for worm gears? BTL4

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Phosphor bronze has high antifriction properties to resist seizure. Because in worm gear drive,
the failure due to seizure is more.btl2
10 List out the main types of failure in worm gear drive. (Nov/Dec 2012) BTL2
➢ Seizure
➢ Pitting and rupture.
11 For transmitting large power, worm reduction gears are not generally preferred. Why?
BTL4
In worm drive, meshing occurs with sliding action. Since sliding occurs, the amount of
heat generation and power loss are quite high.
12 In worm gear drive, only the wheel is designed. Why? (Apr/May 2011) BTL4
Since always the strength of the worm is greater than the worm wheel, therefore only the worm
wheel is designed.
13 What are the forces acting on bevel gear? (May/June 2013) BTL2
➢ Tangential force
➢ Separating force: It is resolved into two components, they are axial radial force.
14 Under what situation, bevel gears are used? (Apr/May 2011) BTL3
Bevel gears are used to transmit power between two intersecting shafts.
15 Write some applications of worm gear drive. (Nov-Dec 2016) BTL2
Where do we use worm gears? (May/June2013)
It is commonly used in automotive differentials, Tuning Instruments , Elevators/Lifts, Gates and
Conveyor Belts
16 What are the main types of failures in worm gear drives? (Nov/Dec2012) BTL2
➢ Seizure
➢ Pitting
➢ Surface wear
17 What is the helical angle of worm? (May/June 2016) BTL1
In mechanical engineering, a helix angle is the angle between any helix and an axial line on its
right, circular cylinder or cone. Common applications are screws, helical gears, and worm gears.
The helix angle references the axis of the cylinder, distinguishing it from the lead angle, which
references a line perpendicular to the axis. Naturally, the helix angle is the geometric
complement of the lead angle. The helix angle is measured in degrees.
18 What is a crown gear? (Nov/Dec 2016, May/June 2013) BTL1
A crown gear (or a contrate gear) is a gear which has teeth that project at right angles to the face
of the wheel. In particular, a crown gear is a type of bevel gear where the pitch cone angle is 90
degrees.
19 How bevel gears are manufactured? (May/June 2016) BTL1
Bevel gears can be manufactured through the gear hobbing and machining process.
20 What kind of contact is required between worm and worm wheel? How does this differ
from other gears? (Nov/Dec 2015) BTL4
Sliding contact is required between worm and worm wheel. For other gears Line contact is
required for other gears.

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21 What is a Zero Bevel Gears? (April/May 2015) BTL1
Spiral bevel gears with curved teeth but with a zero degree spiral angle are known as zero bevel
gears.
22 Mention the advantages of worm gear drive. (Nov/Dec 2014) BTL2
Worm gears are used to transmit power between two non-intersecting, non-parallel shafts. Worm
gears can be used for high speed reduction ratios as high as 300:1.
23 When do we employ crossed helical gear? (Nov/Dec 2012) BTL4
Crossed helical gear sets are used to transmit power and motion between non-intersecting and
non-parallel axes. Both of the gears that mesh with each other are involute helical gears, and a
point contact is made between them. They can stand a small change in the center distance and
the shaft angle without any impairment in the accuracy of transmitting motion.
24 List the various types of Bevel gears. (May/June 2012) BTL2
➢ Straight bevel gears
➢ Spiral bevel gears
➢ Zero bevel gears
➢ Hypoid gears
25 What are the various losses in the worm gear drive? (May/June 2012) BTL2
Worm drives have high power losses. A disadvantage is the potential for considerable sliding
action, leading to low efficiency. They produce a lot of heat. High-ratio units have a smaller gear-
tooth lead (helix) angle, which causes more surface contact between them. This higher contact
causes higher friction and lower efficiency. Typical worm-gear efficiencies range from 49% for a
300:1, double-reduction ratio, up to 90% for a 5:1, single-reduction ratio. For this reason, these
units are usually more suitable for low ratios.
PART * B
1 Design a bevel gear drive to transmit 3.5 kW with driving shaft speed is 200 rpm. Speed
ratio required is 4. The drive is non-reversible. Pinion is made of steel and wheel made of
CI. Assume a life of 25,000 hrs. (13M) (Nov/Dec 2016) BTL5
Answer: Page: 3.26 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= = 4 (𝑔𝑖𝑣𝑒𝑛)
𝑁2
tan 𝛿2 = 𝑖
𝛿2 = 75.96°; 𝛿1 = 14.04°
Material: (1M)
Pinion: C45, Hardened steel.
Tensile strength, σu = 700 X 106 N/m2
Yield strength, σy = 360 X 106 N/m2
Wheel: CI Grade 30.
Tensile strength, σu = 300 X 106 N/m2
Gear life, N: (1M)
7
Life in number of cycles, N = 60 X (rpm, n) X (Life in hrs, T) = 30 X 10 cycles

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Design torque, [Mt]: (1M)
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 167.11 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 217.25 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]: (1M)
Eeq = 166.77 X 109 N/m2
1.4𝑘𝑏𝑙 𝜎−1
𝑃𝑖𝑛𝑖𝑜𝑛, [𝜎𝑏 ] = = 836.66 𝑘𝑔𝑓/𝑐𝑚2
𝑛. 𝑘𝜎
𝑃𝑖𝑛𝑖𝑜𝑛, [𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 6054.75 𝑘𝑔𝑓/𝑐𝑚2
1.4𝑘𝑏𝑙 𝜎−1
𝑊ℎ𝑒𝑒𝑙, [𝜎𝑏 ] = = 513.1 𝑘𝑔𝑓/𝑐𝑚2
𝑛. 𝑘𝜎
𝑊ℎ𝑒𝑒𝑙, [𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 3782.35 𝑘𝑔𝑓/𝑐𝑚2

Minimum value is selected.

[σb] = 513.1 kgf/cm2
[σc] = 3782.35 kgf/cm2
Cone distance, R: (1M)
2
3 0.72 𝐸 × [𝑀𝑡 ]
𝑅≥ 𝜓 √𝑖 2 + 1 √( )
(𝜓 − 0.5)[𝜎𝑐 ] 𝑖
𝑅
𝐴𝑠𝑠𝑢𝑚𝑒, 𝜓 = =3
𝑏
𝑅 = 218 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 18 (assumed)
Z2 = i. Z1 = 72.
Transverse Module, mt: (1M)
3 [𝑀𝑡 ]
𝑚𝑎𝑣 ≥ 1.28 √ = 5.096 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
𝑏
𝑚𝑡 = 𝑚𝑎𝑣 + sin 𝛿 = 6 𝑚𝑚
𝑧
Revision of cone distance, R and number of teeth:
𝑅 = 0.5𝑚𝑡 𝑍1 √𝑖 2 + 1 = 222.65 𝑚𝑚
Z1 = 18 teeth; Z2 = 72 teeth;
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = 10.mt = 60 mm
Pitch circle diameter,
𝑅 − 0.5𝑏
𝑑1𝑎𝑣 = 𝑚𝑡 𝑍1 ( ) = 93.45 𝑚𝑚
𝑅
Pitch line velocity, v = 0.98 m/s.
Quality of gear: (1M)

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IS quality 8 is selected.
Revision of design torque:
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 217.25 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
𝑅√𝑖 2 + 1. [𝑀𝑡 ] 1
𝜎𝑏 = 2
. ≤ [𝜎𝑏 ]
(𝑅 − 0.5𝑏) 𝑚𝑏𝑦 cos 𝛼
𝜎𝑏 = 41.8 × 106 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (1M)
0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]
𝜎𝑐 = × √ ≤ [𝜎𝑐 ]
(𝑅 − 0.5𝑏) 𝑖. 𝑏
𝜎𝑐 = 365 × 106 𝑁/𝑚2
Design is safe.
Basic dimensions of pinion and wheel: (1M)
Pinion:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿1 = 14.04°
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 108 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑚𝑡 (𝑍1 + 2𝑐𝑜𝑠𝛿1 ) = 138 𝑚𝑚
Wheel:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿2 = 75.96°
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 432 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = 𝑚𝑡 𝑍2 = 642 𝑚𝑚
2 A pair of cast iron bevel gears connects two shafts at right angles. The pitch diameters of
the pinion and gear are 80 mm and 100 mm respectively. The tooth profiles of the gears are
14½º composite form. The allowable static stress for both gears is 55 MPa. If the pinion
transmits 2.75 kW at 1100 rpm, find the module and number of teeth on each gear and
check the design. Take surface endurance limits as 630 MPa and modulus of elasticity for
cast iron as 84 kN/mm2. (13M) (Nov/Dec 2009) BTL5
Answer: Page: 3.55 – Dr.A.Baskar
Material: (1M)
Cast Iron (given) for both pinion and wheel.
We have to design pinion.
Gear ratio, i: (1M)
𝑁1
𝑖= = 1.25
𝑁2
tan 𝛿2 = 𝑖
𝛿2 = 51.34°; 𝛿1 = 38.66°
Tangential load, Ft: (1M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠 3575
𝐹𝑡 = = = 775.82 𝑁
𝑣𝑚 4.608

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Dynamic Load, Fd: (1M)

𝐹𝑑 = 𝐹𝑡 . 𝑁𝑠𝑓 . 𝑘𝑚 . 𝐶𝑉 = 1251 𝑁
Strength of gear tooth, Fs: (1M)
𝑏
𝐹𝑠 = [𝜎𝑏 ]𝑚𝑡 . 𝑏. 𝑌 (1 − )
𝑅
𝐹𝑠 = 0.294 × 106 × 𝑚𝑡 − 15.86 × 106 × 𝑚𝑡2
Transverse Module, mt: (1M)
𝐹𝑠 ≥ 𝐹𝑑 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛
0.294 × 10 × 𝑚𝑡 − 15.86 × 106 × 𝑚𝑡2 = 1251
6

Module, m = 7 mm.
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = 10 X m = 20 mm
No. of teeth, mZ1 = 12, Z2 = 15.
Pitch circle diameter of pinion, d1 = mZ1 = 80 mm.
Pitch circle diameter of wheel, d2 = mZ2 = 100 mm (given).
Pitch line velocity, v = 4.608 m/s.
Revision of beam strength, Fs: (1M)
𝑏
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 (1 − ) = 1287 𝑁
𝑅
Buckingham’s dynamic load, Fd: (2M)
0.164𝑉𝑚 (𝑐𝑏 + 𝐹𝑡 )
𝐹𝑑 = 𝐹𝑡 + [ ] = 2516.5 𝑁
0.164𝑉𝑚 + 1.485√𝑐𝑏 + 𝐹𝑡
Check for the design:
(Fd = 2616.5 N) > (Fs = 1287 N)
The design is not safe.
➢ d1 and d2 are given, and limited to 80 mm and 100 mm.
➢ No. of teeth Z1to be minimum 12 and hence ‘mt’ cannot be increased.
➢ B cannot be increased much, it will reduce ‘Fs’. ’R’ is also fixed 64 mm given.
➢ It is difficult to re-deign.
Check for wear: (1M)
𝑏𝑑1 𝑄𝑘
𝑊𝑒𝑎𝑟 𝑙𝑜𝑎𝑑, 𝐹𝑤 = = 4225 𝑁
cos 𝛿1
(Fw = 4225N) > (Fd = 2516.5 N)
Basic dimensions of pinion and wheel: (2M)
Pinion:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿1 = 38.66°
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 80 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑚𝑡 (𝑍1 + 2𝑐𝑜𝑠𝛿1 ) = 94.93 𝑚𝑚
Wheel:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿2 = 51.34°

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𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 100 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = 𝑚𝑡 𝑍2 = 113.75 𝑚𝑚
The design is safe.
3 Design a pair of straight bevel gears for two shafts whose axes are at right angle. The power
transmitted is 25 kW. The speed of pinion is 300 rpm and the gear is 120 rpm. Assume 15
Ni2 Cr1 Mo15 steel for both the pinion and wheel. Use Hertz stresses method. (13M) BTL5
Answer: Page: 3.42 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= = 2.5
𝑁2
tan 𝛿2 = 𝑖
𝛿2 = 68.2°; 𝛿1 = 21.8°
Material: (1M)
Assumed: 15 Ni2 Cr1 Mo15 steel for both pinion and wheel.
[σb]= 313.92 X 106 N/m2
[σc]= 931.95 X 106 N/m2
Gear life, N:
Not available.
Design torque, [Mt]: (1M)
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 795.77 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 1034.51 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]: (1M)
9 2
Eeq = 210.915 X 10 N/m
[σb]= 313.92 X 106 N/m2
[σc]= 931.95 X 106 N/m2
Cone distance, R: (1M)
2
3 0.72 𝐸 × [𝑀𝑡 ]
𝑅 ≥ 𝜓√𝑖 2 + 1 √( )
(𝜓 − 0.5)[𝜎𝑐 ] 𝑖
𝑅
𝐴𝑠𝑠𝑢𝑚𝑒, 𝜓 = =3
𝑏
𝑅 = 164 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 50.
Transverse Module, mt: (1M)
3 [𝑀𝑡 ]
𝑚𝑎𝑣 ≥ 1.28 √ = 4.42 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
𝑏
𝑚𝑡 = 𝑚𝑎𝑣 + sin 𝛿 = 6 𝑚𝑚
𝑧

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Revision of cone distance, R and number of teeth:
𝑅 = 0.5𝑚𝑡 𝑍1 √𝑖 2 + 1 = 177.71 𝑚𝑚
Z1 = 22 teeth; Z2 = 55 teeth;
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = 10.mt = 60 mm
Pitch circle diameter,
𝑅 − 0.5𝑏
𝑑1𝑎𝑣 = 𝑚𝑡 𝑍1 ( ) = 129.77 𝑚𝑚
𝑅
Pitch line velocity, v = 2.04 m/s.
Quality of gear: (1M)
IS quality 8 is selected.
Revision of design torque:
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 1782.52 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
𝑅√𝑖 2 + 1. [𝑀𝑡 ] 1
𝜎𝑏 = . ≤ [𝜎𝑏 ]
(𝑅 − 0.5𝑏)2 𝑚𝑏𝑦 cos 𝛼
𝜎𝑏 = 279 × 106 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (2M)

0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]

𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
(𝑅 − 0.5𝑏) 𝑖. 𝑏
𝜎𝑐 = 1077.8 × 106 𝑁/𝑚2
Design is not safe.
Increase face width, b = 1,
∴ [𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 1336.89 𝑁 − 𝑚

0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]

𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
(𝑅 − 0.5𝑏) 𝑖. 𝑏
𝜎𝑐 = 830.9 × 106 𝑁/𝑚2
Hence, design is safe.
Basic dimensions of pinion and wheel: (1M)
Pinion:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿1 = 21.8°
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 132 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑚𝑡 (𝑍1 + 2𝑐𝑜𝑠𝛿1 ) = 143.14 𝑚𝑚
Wheel:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿2 = 68.2°
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 330 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = 𝑚𝑡 𝑍2 = 334.46 𝑚𝑚
4 2 kW power is applied to a worm shaft at 720 rpm. The worm is of quadruple start with 50

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mm as pitch circle diameter. The worm gear has 40 teeth with 5 mm module. The pressure
angle in the diametral plane is 20º. Determine: (i) the lead angle of the worm, (ii) velocity
ratio and, (iii) centre distance. Also calculate efficiency of the worm gear drive and power
lost in friction. (13M) (May/June 2014) BTL5
Answer: Page: 3.94 – Dr.A.Baskar
Lead angle of the worm, γ: (3M)
𝑑1
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑞 = = 10
𝑚𝑥
𝑍
𝛾 = tan−1 = 21.8°
𝑞
Velocity ratio, i: (2M)
𝑧
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = 10
𝑍
Centre distance, a: (2M)
𝑎 = 0.5𝑚𝑥 (𝑞 + 𝑧 + 2𝑥) = 125 𝑚𝑚
Efficiency of the worm drive, η: (2M)
tan 𝛾
𝜂= = 87.11%
tan(𝛾 + 𝜌)
Power lost in friction: (2M)
𝑃𝑜𝑤𝑒𝑟 𝑙𝑜𝑠𝑡 𝑖𝑛 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 = (1 − 𝜂)𝑃 = 257.79 𝑊𝑎𝑡𝑡𝑠
5 Design a worm gear drive to transmit 20 kW at 1440 rpm, speed of worm wheel is 60 rpm.
(13M) (May/June 2016) BTL5
Answer: Page: 3.111 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑛
𝑖= = 24
𝑛1
Material; No. of threads on worm, Z; No. of teeth on worm wheel, z: (1M)
Worm – steel
Worm wheel – bronze (assumed)
Z = 3 (assumed)
Z = i.Z = 72 teeth.
Design of worm wheel torque, [Mt]: (1M)
60 × 𝑃
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = × 𝜂 = 2546.48 𝑁 − 𝑚
2𝜋𝑛1
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 2546.48 𝑁 − 𝑚
Design bending stress, [σb] and surface compressive stress, [σc]: (1M)
For steel and bronze combination, [σc] = 156 X 106 N/m2
For bronze wheel chill casting, [σb] = 53.955 X 106 N/m2
Minimum centre distance, a: (1M)
2
𝑧 3
540
𝑎 = ( + 1) √(𝑧 ) {[𝑀𝑡 ] × 105 }
𝑞 × [𝜎𝑐 ]
𝑞
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𝐴𝑠𝑠𝑢𝑚𝑒, 𝑞 = 11 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)
𝑎 = 312.8 𝑚𝑚
Axial Module, mx: (1M)
3 [𝑀𝑡 ]
𝑚𝑥 = 1.24 √ = 8 𝑚𝑚
𝑦𝑞𝑧[𝜎𝑏 ]

Revision of centre distance, a: (1M)

𝑎 = 0.5𝑚𝑥 (𝑞 + 𝑧 + 2𝑥) = 332 𝑚𝑚
Pitch diameters, pitch line velocity of worm, sliding velocity: (1M)
Pitch diameter-worm,
𝑑1 = 𝑞𝑚𝑥 = 88 𝑚𝑚
Pitch diameter-worm wheel,
𝑑2 = 𝑧𝑚𝑥 = 576 𝑚𝑚
Pitch line velocity, v = 6.635 m/s.
Sliding velocity,
𝑣1
𝑣𝑠 = = 6.877 𝑚/𝑠
cos 𝛾
Revision of [σc]: (1M)
For steel-bronze combination, vs = 6.877 m/s.
Assume [σc] = 146.2 X 106 N/m2
Revision of design torque:
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 2546.5 𝑁 − 𝑚
Check for induced bending stress, σb: (1M)
1.9[𝑀𝑡 ]
𝜎𝑏 = 3 ≤ [𝜎𝑏 ]
𝑚𝑥 𝑞𝑧𝑦
𝜎𝑏 = 23.9 × 106 𝑁/𝑚2
Design is safe.
Check for induced compressive stress, σc: (1M)
𝑧 3
540 +1
𝜎𝑐 = 𝑧 × √[ 𝑏
] {[𝑀𝑡 ] × 105 } ≤ [𝜎𝑐 ]
(𝑏 ) 𝑎

𝜎𝑐 = 146.2 × 106 𝑁/𝑚2

Design is safe.
Check for efficiency, η: (1M)
tan 𝛾
𝜂= = 92.63%
tan(𝛾 + 𝜌)

Basic dimensions of pinion and wheel: (1M)

Worm:
𝑁𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡𝑠, 𝑍 = 3

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𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 88 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑑1 + 2𝑓0 𝑚𝑥 = 104 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = 𝑑1 − 2𝑓0 𝑚𝑥 − 2𝑐 = 68.8 𝑚𝑚
𝑀𝑖𝑛 𝐿𝑒𝑛𝑔𝑡ℎ, 𝐿 = (12.5 + 0.09𝑧)𝑚𝑥 = 154.24 𝑚𝑚
Worm Wheel:
𝑁𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ, 𝑧 = 72
𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 576 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = (𝑧 + 2𝑓0 +2𝑥)𝑚𝑥 = 592 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑧 − 2𝑓0 )𝑚𝑥 − 2𝑐 = 556.8 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 13.5 𝑚𝑚
PART * C
1 Design a pair of right angle bevel gears to transmit 15 kW at 75 rpm to another gear to run
at 250 rpm. Not less than 20 teeth are to be used on either gear. The pressure angle is 20º.
Assume a gear life of 12000 hrs. (15M) (Nov/Dec 2015) BTL5
Answer: Page: 3.35 – Dr.A.Baskar
Gear ratio, i: (1M)
𝑁1
𝑖= =3
𝑁2
tan 𝛿2 = 𝑖
𝛿2 = 75.57°; 𝛿1 = 14.43°
Material: (1M)
C45 steel for both pinion and wheel (assumed).
Tensile strength, σu = 700 X 106 N/m2
Yield strength, σy = 360 X 106 N/m2
Gear life, N: (1M)
7
Life in number of cycles, N = 60 X (rpm, n) X (Life in hrs, T) = 54X 10 cycles
Design torque, [Mt]: (1M)
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 190.99 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 248.28 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]: (1M)
9 2
Eeq = 210.915 X 10 N/m
1.4𝑘𝑏𝑙 𝜎−1
[𝜎𝑏 ] = = 82.076 × 106 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 593.97 × 106 𝑁/𝑚2
Cone distance, R: (1M)
2
3 0.72 𝐸 × [𝑀𝑡 ]
𝑅 ≥ 𝜓√𝑖 2 + 1 √( )
(𝜓 − 0.5)[𝜎𝑐 ] 𝑖
𝑅
𝐴𝑠𝑠𝑢𝑚𝑒, 𝜓 = =3
𝑏
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𝑅 = 152 𝑚𝑚
Number of teeth Z1 and Z2: (1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 60.
Transverse Module, mt: (1M)
3 [𝑀𝑡 ]
𝑚𝑎𝑣 ≥ 1.28 √ = 4.33 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
𝑏
𝑚𝑡 = 𝑚𝑎𝑣 + sin 𝛿 = 6 𝑚𝑚
𝑧
Revision of cone distance, R and number of teeth: (1M)
𝑅 = 0.5𝑚𝑡 𝑍1 √𝑖 2 + 1 = 187.74 𝑚𝑚
Z1 = 20 teeth; Z2 = 60 teeth;
Face width, pitch circle diameter, pitch line velocity: (1M)
Face width, b = 10.mt = 60 mm
Pitch circle diameter,
𝑅 − 0.5𝑏
𝑑1𝑎𝑣 = 𝑚𝑡 𝑍1 ( ) = 101 𝑚𝑚
𝑅
Pitch line velocity, v = 3.966 m/s.
Quality of gear: (1M)
IS quality 6 is selected.
Revision of design torque: (1M)
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 412.54 𝑁 − 𝑚
Check for maximum induced bending stress, σb: (1M)
𝑅√𝑖 2 + 1. [𝑀𝑡 ] 1
𝜎𝑏 = 2
. ≤ [𝜎𝑏 ]
(𝑅 − 0.5𝑏) 𝑚𝑏𝑦 cos 𝛼
𝜎𝑏 = 73.527 × 106 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc: (1M)
0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]
𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
(𝑅 − 0.5𝑏) 𝑖. 𝑏
𝜎𝑐 = 557.27 × 106 𝑁/𝑚2
Design is safe.
Basic dimensions of pinion and wheel: (1M)
Pinion:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿1 = 14.43°
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 120 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑚𝑡 (𝑍1 + 2𝑐𝑜𝑠𝛿1 ) = 131.62 𝑚𝑚
Wheel:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿2 = 75.57°
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 360 𝑚𝑚
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𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = 𝑚𝑡 𝑍2 = 363 𝑚𝑚
2 A hardened steel worm rotates at 1440 rpm and transmits 12 kW to a phosphor bronze
gear. The speed of the worm gear should be 60 rpm. Design the worm gear drive if an
efficiency of atleast 82% is desired. (15M) (Nov/Dec 2016) BTL5
Answer: Page: 3.128 – Dr.A.Baskar
Material: (1M)
Worm-hardened steel (given)
Worm gear-phosphor bronze (given)
No. of threads on worm, Z and teeth on worm wheel, z: (1M)
Z = 3 (assumed)
𝑛
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = 24
𝑛1
No. of teeth on wheel, z = i.Z = 72 teeth.
Diameter factor, q and Lead angle, γ: (1M)
Q = 11 (assumed)
𝑍
𝛾 = tan−1 ( ) = 15.255°
𝑞
Tangential load, Ft: (1M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠 68.967
𝐹𝑡 = = 𝑁
𝑃𝑖𝑡𝑐ℎ 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟 𝑚𝑥

Dynamic Load, Fd: (1M)

6 + 𝑣𝑚𝑔 68.967
𝐹𝑑 = 𝐹𝑡 = + 2600
6 𝑚𝑥
Beam strength, Fs: (1M)
𝐹𝑠 = [𝜎𝑏 ]𝑚𝑥 . 𝑏. 𝑌
𝐹𝑠 = 253.8 × 106 × 𝑚𝑥2 , 𝑁
Axial Module, mx: (1M)
𝐹𝑠 ≥ 𝐹𝑑 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛
68.967
253.8 × 106 × 𝑚𝑥2 = + 2600
𝑚𝑥
Module, mx = 8 mm.
Face width, b; Pitch diameter, d1; pitch line velocity of worm: (2M)
Face width, b = 8.25 X mx = 66 mm
Pitch diameter,
𝑑1 = 𝑞𝑚𝑥 = 88 𝑚𝑚
Pitch line velocity of worm,
𝑣𝑚𝑔 = 226.195𝑚𝑥 = 1.81 𝑚/𝑠
Revision of beam strength, Fs: (1M)
𝐹𝑠 = 253.8 × 106 × 𝑚𝑥2 = 16243.2 𝑁
Revision of dynamic load, Fd: (1M)

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68.967
𝐹𝑑 = [ ] + 2600 = 11220.9 𝑁
𝑚𝑥
Check for the design:
(Fs = 16243.2 N) > (Fd = 11220.9 N)
Wear load, Fw: (1M)
𝐹𝑤 = 𝐷𝑔 . 𝑏. 𝑘𝑤 = 32818.5 𝑁
Check for the design:
(Fw = 32818.5 N) > (Fd = 11220.9 N)
The design is safe.
Check for efficiency, η: (1M)
tan 𝛾
𝜂= = 82%
tan(𝛾 + 𝜌)
Design is satisfactory.
Basic dimensions of pinion and wheel: (2M)
Worm:
𝑁𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡𝑠, 𝑍 = 3
𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 88 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑑1 + 2𝑓0 𝑚𝑥 = 104 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = 𝑑1 − 2𝑓0 𝑚𝑥 − 2𝑐 = 68.8 𝑚𝑚
𝑀𝑖𝑛 𝐿𝑒𝑛𝑔𝑡ℎ, 𝐿 = (12.5 + 0.09𝑧)𝑚𝑥 = 154.24 𝑚𝑚
Worm Wheel:
𝑁𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ, 𝑧 = 72
𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 576 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = (𝑧 + 2𝑓0 +2𝑥)𝑚𝑥 = 592 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑧 − 2𝑓0 )𝑚𝑥 − 2𝑐 = 556.8 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 13.5 𝑚𝑚
3 The input to worm gear shaft is 18 kW at 600 rpm, speed ratio is 20. The worm is to be of
hardened steel and the wheel is made of chilled phosphor bronze. Considering wear and
strength, design worm and worm wheel. (15M) (Nov/Dec 2015) BTL5
Answer: Page: 3.134 – Dr.A.Baskar
Material: (1M)
Worm-hardened steel (given)
Worm wheel – chilled phosphor bronze (given)
Design bending stress (worm wheel) for chilled bronze, [σb] = 98.1 X 106 N/m2
No. of threads on worm, Z and teeth on worm wheel, z: (1M)
Z = 3 (assumed)
𝑛
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = 20 (𝑔𝑖𝑣𝑒𝑛)
𝑛1
No. of teeth on wheel, z = i.Z = 60 teeth.
Diameter factor, q and Lead angle, γ: (1M)

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Q = 11 (assumed)
𝑍
𝛾 = tan−1 ( ) = 15.255°
𝑞
Tangential load, Ft: (1M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠 124.14
𝐹𝑡 = = 𝑁
𝑃𝑖𝑡𝑐ℎ 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟 𝑚𝑥

Dynamic Load Fd: (1M)

6 + 𝑣𝑚𝑔 124.14 + 3900.065𝑚𝑥
𝐹𝑑 = 𝐹𝑡 = ,𝑁
6 𝑚𝑥
Beam strength, Fs: (1M)
𝐹𝑠 = [𝜎𝑏 ]𝑚𝑥 . 𝑏. 𝑌
𝐹𝑠 = 317.25 × 106 × 𝑚𝑥2 , 𝑁
Axial Module, mx: (1M)
𝐹𝑠 ≥ 𝐹𝑑 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛
124.14 + 3900.065𝑚𝑥
317.25 × 106 × 𝑚𝑥2 =
𝑚𝑥
Module, mx = 8 mm.
Face width, b; Pitch diameter, d1; pitch line velocity of worm: (2M)
Face width, b = 8.25 X mx = 66 mm
Pitch diameter,
𝑑1 = 𝑞𝑚𝑥 = 88 𝑚𝑚
Pitch line velocity of worm,
𝑣𝑚𝑔 = 226.195𝑚𝑥 = 1.508 𝑚/𝑠
Revision of beam strength, Fs: (1M)
𝐹𝑠 = 317 × 106 × 𝑚𝑥2 = 20304.32 𝑁
Revision of dynamic load, Fd: (1M)
124.14 + 3900.065𝑚𝑥
𝐹𝑑 = = 19417.565 𝑁
𝑚𝑥
Check for the design:
(Fs = 20304.32 N) > (Fd = 19417.565 N)
Wear load, Fw: (1M)
𝐹𝑤 = 𝐷𝑔 . 𝑏. 𝑘𝑤 = 27348.71 𝑁
Check for the design:
(Fw = 27348.71 N) > (Fd = 19417.565 N)
The design is safe.
Check for efficiency, η: (1M)
tan 𝛾
𝜂= = 87.78%
tan(𝛾 + 𝜌)
Design is satisfactory.
Basic dimensions of pinion and wheel: (2M)

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Worm:
𝑁𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡𝑠, 𝑍 = 3
𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 88 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑑1 + 2𝑓0 𝑚𝑥 = 104 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = 𝑑1 − 2𝑓0 𝑚𝑥 − 2𝑐 = 68.8 𝑚𝑚
𝑀𝑖𝑛 𝐿𝑒𝑛𝑔𝑡ℎ, 𝐿 = (12.5 + 0.09𝑧)𝑚𝑥 = 143.2 𝑚𝑚
Worm Wheel:
𝑁𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ, 𝑧 = 60
𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = 480 𝑚𝑚
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = (𝑧 + 2𝑓0 +2𝑥)𝑚𝑥 = 496 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑧 − 2𝑓0 )𝑚𝑥 − 2𝑐 = 380.8 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 13.5 𝑚𝑚

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UNIT IV – GEAR BOXES

Geometric progression - Standard step ratio - Ray diagram, kinematics layout - Design of sliding mesh
gear box - Design of multi speed gear box for machine tool applications - Constant mesh gear box -
Speed reducer unit – Variable speed gear box, Fluid Couplings, Torque Converters for automotive
applications.
PART * A

Q.No. Questions

1 Calculate standard step ratio for six speed gear box with speed ranging between 100 and
560rpm. BTL5
ɸ = [NMax/NMin]1/n-1
= [560/100]1/6-1
=1.411

2 Comment on the number of gears to be used in the output shaft. (May/June 2012) BTL3
It is practiced in the gear box that output shaft is fixed with maximum of three gears.
3 What are the methods of lubrication in speed reducers? BTL2
➢ Splash or spray lubricating method and
➢ Pressure lubrication method.
4 List any two methods used for changing speeds in gear boxes. (Nov/Dec 2016) BTL2
➢ Sliding mesh gear box and
➢ Constant mesh gear box
5 Write any two requirements of a speed gear box. BTL2
➢ Gear box should provide the designed series of spindle speeds.
➢ Gear box should transmit the required amount of power to the spindle.
6 Differentiate ray diagram and structural diagram. (or) What does the ray diagram of gear
box indicates? (May/June 2012, Nov/Dec 2016) BTL4
The ray diagram is a graphical representation of the drive arrangement in general form. It serves
the specific values of all the transmission ratios and speed of all the shafts in the drive.
The structural diagrams are drawn from the structural formulae which is a graphical tool used to
find the range ratio of transmission groups. The structural diagram gives information about the
number of shafts and the number of gears on each shaft.
7 Write the structural formula for a six speed gear box. BTL3
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A typical ray diagram for a six speed gear box, for the preferred structural formula 3(1) 2(3), is
shown below.
8 Select 3 pairs of gears with total teeth for each pair 60 and speed ratios 1, 1.41, and 2. BTL4
z1+ z2=z3+ z4= z5+ z6=60;
i= z2/ z1=1; i=z4/ z3=1.41; i= z6/ z5=2
z1=30; z2=30; z3=25: z4=36: z5=20: z6=40
9 State any three basic rules to be followed while designing a gear box. BTL1
➢ The transmission ratio in a gear box is limited by ¼ ≤ i ≤ 2.
➢ For stable operation, the speed ratio of any stage should not be greater than 8. i.e., N max/
Nmin ≤ 8.
➢ In all stages except in the first stage, N max ≥ Ninput> Nmin
10 What is the function of spacers in a gear-box? BTL1
The function of spacers is to provide the necessary distance between the gears and the bearings.
11 List out the possible arrangements to achieve 16 speed gear box. BTL2
➢ 4 x 2 x 2 scheme
➢ 2 x 4 x 2 scheme and
➢ 2 x 2 x 4 schemes
12 What are the possible arrangements to achieve 12 speeds from a gear box? (April/May
2011, May/June 2013) BTL3
The possible arrangements are:
➢ 3 x 2 x 2 scheme
➢ 2 x 3 x 2 scheme and
➢ 2 x 2 x 3 scheme.
13 Sketch the kinematics layout of gears for 3 speeds between two shafts. BTL3

14 What are preferred numbers? (Apr/May 2011,2013, Nov/Dec 2014) BTL2

Name the series in which speeds of multi speed gear box are arranged. [May/June 2014]
Preferred numbers are the conventionally rounded off values derived from geometric series.
There are five basic series, denoted as R 5, R 10, R 20, R 40 and R 80 series.
15 What does the ray-diagram of gear box indicates? (May/June 2012, Apr/May 2017) BTL3
The ray diagram is a graphical representation of the drive arrangement in general form. It
serves to determine the specific values of all the transmission ratios and speeds of all the shafts
in the drive.
16 What is step ratio? (or) Define progression ratio. (Nov/Dec 2015, May/June 2014) BTL1
When the spindle speeds are arranged in geometric progression, then the ratio between the two
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adjacent speeds is known as step ratio or progression ratio.
17 Draw the ray diagram for 12 speed gear box. (May/June 2013) BTL3

18 What is a speed reducer? BTL1

Speed reducer is a gear mechanism with a constant speed ratio, to reduce the angular speed of
output shaft as compared with that of input shaft.
19 Specify four types of gear box. (Nov/Dec 2014) BTL2
➢ Sliding mesh gear box,
➢ constant mesh gear box,
➢ synchromesh gearbox,
➢ planetary gearbox.
20 What is multispeed gear box? (May/June 2016) BTL1
A gearbox that converts a high speed input into a number of different speed output it is called a
multi-speed gear box. Multi speed gear box has more than two gears and shafts. A multi speed
gearbox reduces the speed in different stages.
21 Why geometric progression is selected for arranging the speeds in gear box? (Apr/May
2017) BTL2
When the speeds are arranged in G.P, it has the following advantages over the other
progressions.
➢ The speed loss is minimum
➢ No. of gears to be employed is minimum
➢ G.P provides a more even range of spindle speeds at each step.
➢ The lay out is comparatively very compact.
➢ G.P m/c tool spindle speeds can be selected easily from preferred numbers, because
preferred numbers are in geometric progression.
22 What is R20 series? (May/June 2016) BTL1
In industrial design, preferred numbers (also called preferred values, preferred
series or convenient numbers are standard guidelines for choosing exact product dimensions
within a given set of constraints. Product developers must choose numerous lengths, distances,
diameters, volumes, and other characteristic quantities.
Preferred numbers represent preferences of simple numbers (such as 1, 2, and 5) and their
powers of a convenient basis, usually 10. The R5, R10 and R20 series refers to the Renard 5
(first-choice sizes 60 % increments), Renard 10 (second-choice sizes 25 % increments) and
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Renard 20 (third-choice sizes 12 % increments) series of preferred numbers standardized in
ISO3.
23 Write the significance of structural formula. (Nov/Dec 2015) BTL1
Structural formula is used to find the number of speeds (n) available at the spindle and through
no. Stages it can be achieved.
n = p1 (X1) .p2 (X2).p2 (X3)
p= stages in the gear box,
X = Characteristic of the stage.
24 List four application where constant mesh gear box is used. (Nov/Dec 2012) BTL2
Vehicles which use this type of gearboxes are farm trucks, motorcycles, and heavy
machinery. The availability of such mechanisms like constant mesh gearbox which create
less noise and are cost effective.
25 What are the conditions required for interchangeability of toothed Gears?
(Nov/Dec 2012) BTL3
For interchangeability of all gears, the set must have the same circular pitch, module,
diameter pitch, pressure, angle, addendum and dedendum and tooth thickness must be one
half of the circular pitch.
PART * B
1 Sketch three possible ray diagrams for a 6 speed gearbox with 2x3 arrangement. Choose the
best possible ray diagram. Give suitable explanation for the same. (13M) (April/May 2010)
BTL5
Answer: Page: 4.13 – Dr.A.Baskar

(6M)
➢ Three ray diagrams are drawn keeping the input speed same. (6M)
➢ Ray diagram (ii): Two output speeds are same as input speed in stage 2. This is not
preferable.
➢ Ray diagram (i): One speed reduction is very high in stage 1. This is not preferable.
➢ Ray diagram (iii): Do not have any such speeds and hence this is the preferable ray
diagram.
𝑁𝑚𝑖𝑛 1 𝑁𝑚𝑎𝑥
≥ 𝑎𝑛𝑑 ≤ 2 𝑠ℎ𝑜𝑢𝑙𝑑 𝑏𝑒 𝑠𝑎𝑡𝑖𝑠𝑓𝑖𝑒𝑑 𝑎𝑡 𝑒𝑎𝑐ℎ 𝑠𝑡𝑎𝑔𝑒
𝑁𝐼𝑛𝑝𝑢𝑡 4 𝑁𝐼𝑛𝑝𝑢𝑡
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Overlapping speed gearbox: (1M)
➢ Maximum possible speeds = Required number of speeds.
➢ Sometimes: Required number of speeds < Maximum possible speeds.
2 A sliding mesh gearbox is to be used for 4 forward and 1 reverse speeds. First gear speed
ratio is 5.5 and reverse gear ratio is 5.8. Clutch gear on clutch shaft and gear (in constant
mesh) on lay shaft has speed ratio of 2. Calculate the number of teeth on all the gears.
Assume that the minimum number of teeth on any gear should not be less than 18.
Calculate actual gear ratios. Assume that the geometric progression for gear ratios, top gear
(fourth), third gear, second and first gear is 1:x:x2:x3. (13M) (Nov/Dec 2014) BTL5
Answer: Page: 4.33 – Dr.A.Baskar
The GP ratio: (1M)
3
i1 = x = 5.5; x = 1.765.
Gear ratios are:
1:1.765:3.116:5.5
𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑑𝑟𝑖𝑣𝑒𝑟 𝑔𝑒𝑎𝑟
𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 =
𝑆𝑝𝑒𝑎𝑑 𝑜𝑓 𝑙𝑎𝑠𝑡 𝑑𝑟𝑖𝑣𝑒𝑛 𝑔𝑒𝑎𝑟
Max gear ratio, imax: (1M)
𝑍2 𝑍8
𝑖𝑚𝑎𝑥 = ×
𝑍1 𝑍7
Zmin = 18 (given)
Let, Z7 = 18 and Z8 = 50.
Z1 + Z2 = Z7 + Z8 = 69
Z1 = 23 and Z2 = 46
Second gear ratio, i2: (1M)
𝑍2 𝑍6
𝑖2 = × = 3.116
𝑍1 𝑍5
Z1 + Z2 = Z7 + Z8 = Z5 + Z6 = 69
Z5 = 27 and Z6 = 42
Third gear ratio, i3: (1M)
𝑍2 𝑍4
𝑖3 = × = 1.765
𝑍1 𝑍3
Z1 + Z2 = Z7 + Z8 = Z5 + Z6 = Z3 + Z4 = 69
Z3 = 37 and Z4 = 32
Reverse gear ratio, iR: (1M)
𝑍2 𝑍8
𝑖𝑅 = × = 5.8
𝑍1 𝑍9
Z8 = 51 (already found) and Z9 = 18.
Actual gear ratios: (5M)
𝑍2
𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = =2
𝑍1

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𝑍2 𝑍8
𝐹𝑖𝑟𝑠𝑡 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖1 = × = 5.6667
𝑍1 𝑍7

𝑍2 𝑍6
𝑆𝑒𝑐𝑜𝑛𝑑 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖2 = × = 3.1111
𝑍1 𝑍5

𝑍2 𝑍4
𝑇ℎ𝑖𝑟𝑑 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖3 = × = 1.7297
𝑍1 𝑍3

𝑍2 𝑍8
𝑅𝑒𝑣𝑒𝑟𝑠𝑒 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖𝑅 = × = 5.6667
𝑍1 𝑍9
Kinematic Layout: (3M)

3 Design a four speed gearbox to have following speed ratio. First gear is 5:1, second gear is
3:1, third gear is 1.5:1 and the top gear is 1:1. The centre distance between the input and
output shafts is 150 mm. All gears are of 4 mm module, Determine the number of teeth of
all wheels, pitch circle diameter of all wheels and sketch the diagrammatic arrangement of
the gear box. (Assume number of teeth not less than 20 and pressure angle 20º. (13M)
(Nov/Dec 2015) BTL5
Answer: Page: 4.38 – Dr.A.Baskar
𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑑𝑟𝑖𝑣𝑒𝑟 𝑔𝑒𝑎𝑟
𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 =
𝑆𝑝𝑒𝑎𝑑 𝑜𝑓 𝑙𝑎𝑠𝑡 𝑑𝑟𝑖𝑣𝑒𝑛 𝑔𝑒𝑎𝑟
Max gear ratio, imax: (2M)
𝑍2 𝑍8
𝑖𝑚𝑎𝑥 = × =5
𝑍1 𝑍7
Assuming same ratio between any pair of gears;
𝑍2 𝑍8
= = √5
𝑍1 𝑍7
Given centre distance, a: (2M)
𝑚(𝑍1 + 𝑍2 )
𝑎= = 150
2
Z1 + Z2 = 75.
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Z2 = 2.2361Z1 and Z8 = 2.2361Z7
Also, Z1 +Z2 = Z7 + Z8 = Z5 + Z6 = Z3 + Z4 = 75
Z1 = 23 and Z2 = 52.
Also, Z8 = 2.2361Z7 and Z7 + Z8 = 75
Z7 = 23 & Z8 = 52.
Second gear ratio, i2: (1M)
𝑍2 𝑍6
𝑖2 = × =3
𝑍1 𝑍5
Z5 = 32 and Z6 = 43.
Third gear ratio, i3: (1M)
𝑍2 𝑍4
𝑖3 = × = 1.5
𝑍1 𝑍3
Z3 = 45 and Z4 = 30.
Pitch circle diameter of all gears: (4M)
d1 = mZ1 = 92 mm ; d2 = mZ2 = 208 mm; d3 = mZ3 = 180 mm; d4 = mZ4 = 120 mm
d5 = mZ5 = 128 mm; d6 = mZ6 = 172 mm; d7 = mZ7 = 92 mm; d8 = mZ8 = 208 mm
Kinematic layout: (3M)

4 A gear box is to give 18 speeds for a spindle of a milling machine. Maximum and minimum
speeds of the spindle are to be around 650 and 35 rpm respectively. Find the speed ratios
which will give the desired speeds and draw the structural diagram and kinematic
arrangement of the drive. (13M) (Nov/Dec 2015) BTL5
Answer: Page: 4.50 – Dr.A.Baskar
1
𝑁 ( )
𝑛−1
𝑆𝑡𝑒𝑝 𝑟𝑎𝑡𝑖𝑜, ∅ = ( 𝑁𝑚𝑎𝑥 ) = 1.1875 (2M)
𝑚𝑖𝑛
Range of speeds: (1M)
R40 Series:
35.5, 42.5, 50, 60, 71, 85, 100, 118, 140, 170, 200, 236, 280, 335, 400, 475, 560, 670 rpm.
Structural formula: (1M)
1 × 3(1) × 3(3) × 2(9)
Ray Diagram: (2M)
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𝑁𝑚𝑖𝑛 1 𝑁𝑚𝑎𝑥
𝐶𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑡𝑜 𝑏𝑒 𝑠𝑎𝑡𝑖𝑠𝑓𝑖𝑒𝑑, ≥ 𝑎𝑛𝑑 ≤2
𝑁𝐼𝑛𝑝𝑢𝑡 4 𝑁𝐼𝑛𝑝𝑢𝑡
At stage 3:
𝑁𝑚𝑖𝑛 = 35.5 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 142 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 170 𝑟𝑝𝑚
At stage 2:
𝑁𝑚𝑖𝑛 = 85 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 340 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 236 𝑟𝑝𝑚
At stage 1:
𝑁𝑚𝑖𝑛 = 280 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 670 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 400 𝑟𝑝𝑚

Diagram: (5M)
Kinematic arrangement: (2M)

5 A nine speed gear box, used as a head stock gearbox for a turret lathe, is to provide a speed

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range of 180 rpm to 1800 rpm. Using standard step ratio, draw the speed diagram and
kinematic layout. (13M) (May/June 2011) BTL5
Answer: Page: 4.45 – Dr.A.Baskar
1
𝑁 ( )
𝑛−1
𝑆𝑡𝑒𝑝 𝑟𝑎𝑡𝑖𝑜, ∅ = ( 𝑁𝑚𝑎𝑥 ) = 1.3335 (2M)
𝑚𝑖𝑛
Range of speeds: (1M)
R40 Series:
180, 236, 315, 425, 560, 750, 1000, 1320, 1800 rpm.
Structural formula: (1M)
1 × 3(1) × 3(3)
Ray diagram: (2M)
𝑁𝑚𝑖𝑛 1 𝑁𝑚𝑎𝑥
𝐴𝑡 𝑎𝑛𝑦 𝑠𝑡𝑎𝑔𝑒, ≥ 𝑎𝑛𝑑 ≤2
𝑁𝐼𝑛𝑝𝑢𝑡 4 𝑁𝐼𝑛𝑝𝑢𝑡
At stage 2:
𝑁𝑚𝑖𝑛 = 180 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 560 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 1000 𝑟𝑝𝑚
At stage 1:
𝑁𝑚𝑖𝑛 = 560 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 1800 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 1000 𝑟𝑝𝑚

Diagram: (5M)
Kinematic Arrangement: (2M)

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PART * C
1 Draw the kinematic diagram and speed diagram of the head stock gearbox of a turret lathe
arrangement for 9 spindle speeds, ranging from 31.5 rpm to 1050 rpm. Calculate the
number of teeth on each gear. Minimum number of teeth on a gear is 25. Also calculate the
percentage deviation of the obtainable speeds. (15M) (May/June 2016) BTL5
Answer: Page: 4.57 – Dr.A.Baskar
1
𝑁 ( )
𝑛−1
𝑆𝑡𝑒𝑝 𝑟𝑎𝑡𝑖𝑜, ∅ = ( 𝑁𝑚𝑎𝑥 ) = 1.5501 (1M)
𝑚𝑖𝑛
Range of speeds: (1M)
R40 Series:
31.5, 50, 80, 125, 200, 315, 500, 800, 1250 rpm.
Structural formula: (1M)
1 × 3(1) × 3(3)
Ray diagram: (1M)
𝑁𝑚𝑖𝑛 1 𝑁𝑚𝑎𝑥
𝐴𝑡 𝑎𝑛𝑦 𝑠𝑡𝑎𝑔𝑒, ≥ 𝑎𝑛𝑑 ≤2
𝑁𝐼𝑛𝑝𝑢𝑡 4 𝑁𝐼𝑛𝑝𝑢𝑡
At stage 2:
𝑁𝑚𝑖𝑛 = 31.5 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 125 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 500 𝑟𝑝𝑚
At stage 1:
𝑁𝑚𝑖𝑛 = 125 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 800 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 315 𝑟𝑝𝑚
Number of teeth on each gear: (2M)
Z1 = 37; Z2 = 148; Z3 = 52; Z4 = 133
Z5 = 25; Z6 = 160; Z7 = 63; Z8 = 62
Z9 = 100; Z10 = 25; Z11 = 25; Z12 = 100

Diagram: (4M)
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Kinematic Arrangement: (2M)

Obtainable speeds: (2M)

Input speed, N = NG = 800 rpm.
𝑍1 𝑍7 𝑍1 𝑍9
𝑁1 = 𝑁 × × = 203.23 𝑟𝑝𝑚 𝑁2 = 𝑁 × × = 800 𝑟𝑝𝑚
𝑍2 𝑍8 𝑍2 𝑍10

𝑍1 𝑍11 𝑍3 𝑍7
𝑁3 = 𝑁 × × = 50 𝑟𝑝𝑚 𝑁4 = 𝑁 × × = 317.83 𝑟𝑝𝑚
𝑍2 𝑍12 𝑍4 𝑍8

𝑍3 𝑍9 𝑍3 𝑍11
𝑁5 = 𝑁 × × = 1251.13 𝑟𝑝𝑚 𝑁6 = 𝑁 × × = 78.20 𝑟𝑝𝑚
𝑍4 𝑍10 𝑍4 𝑍12

𝑍5 𝑍7 𝑍5 𝑍9
𝑁7 = 𝑁 × × = 127.02 𝑟𝑝𝑚 𝑁8 = 𝑁 × × = 500 𝑟𝑝𝑚
𝑍6 𝑍8 𝑍6 𝑍10

𝑍5 𝑍11
𝑁9 = 𝑁 × × = 31.25 𝑟𝑝𝑚
𝑍6 𝑍12
Arranging in ascending order;
Obtained speeds; 31.25, 50, 78.2, 127.02, 203.23, 317.83, 500, 800, 1251.13 rpm.
Percentage deviation of obtainable speeds from the calculated speeds (1M)
𝑁𝑜𝑏𝑡 − 𝑁𝐶𝑎𝑙
%𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 = × 100
𝑁𝐶𝑎𝑙
Speed No Nobt (rpm) Ncal (rpm) % deviation
1 31.25 31.5 -0.79
2 50 50 0
3 78.2 80 -2.25
4 127.02 125 1.62
5 203.23 200 1.62
6 317.83 315 0.90
7 500 500 0
8 800 800 0
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9 1251.13 1250 0.09
2 Sketch the arrangements of a six speed gearbox. The minimum and maximum speeds
required are around 460 and 1400 rpm. Drive speed is 1440 rpm. Construct speed diagram
of the gearbox and obtain various reduction ratios. Use standard output speeds and
standard step ratio. Calculate number of teeth in each gear and verify whether the actual
output speeds are within ±2% of standard speeds. (15M) (May/June 2014) BTL5
Answer: Page: 4.63 – Dr.A.Baskar
1
𝑁 ( )
𝑛−1
𝑆𝑡𝑒𝑝 𝑟𝑎𝑡𝑖𝑜, ∅ = ( 𝑁𝑚𝑎𝑥 ) = 1.2493 (1M)
𝑚𝑖𝑛
Range of speeds: (1M)
R40 Series:
450, 560, 710, 900, 1120, 1400 rpm.
Structural formula: (1M)
1 × 2(1) × 3(2)
Ray diagram: (1M)
𝑁𝑚𝑖𝑛 1 𝑁𝑚𝑎𝑥
𝐴𝑡 𝑎𝑛𝑦 𝑠𝑡𝑎𝑔𝑒, ≥ 𝑎𝑛𝑑 ≤2
𝑁𝐼𝑛𝑝𝑢𝑡 4 𝑁𝐼𝑛𝑝𝑢𝑡
At stage 2:
𝑁𝑚𝑖𝑛 = 450 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 1800 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 1120 𝑟𝑝𝑚
At stage 1:
𝑁𝑚𝑖𝑛 = 710 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 1400 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 900 𝑟𝑝𝑚

Diagram: (3M)
Number of teeth on each gear: (2M)
Z1 = 37; Z2 = 148; Z3 = 52; Z4 = 133; Z5 = 25;
Z6 = 160; Z7 = 63; Z8 = 62; Z9 = 100; Z10 = 25.
Obtainable speeds: (2M)
Input speed, N = NF = 1440 rpm.
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𝑍1 𝑍5
𝑁1 = 𝑁 × × = 871.58 𝑟𝑝𝑚
𝑍2 𝑍6

𝑍1 𝑍7
𝑁2 = 𝑁 × × = 1394.53 𝑟𝑝𝑚
𝑍2 𝑍8

𝑍1 𝑍9
𝑁3 = 𝑁 × × = 544.74 𝑟𝑝𝑚
𝑍2 𝑍10

𝑍3 𝑍5
𝑁4 = 𝑁 × × = 702.44 𝑟𝑝𝑚
𝑍4 𝑍6

𝑍3 𝑍7
𝑁5 = 𝑁 × × = 1123.90 𝑟𝑝𝑚
𝑍4 𝑍8

𝑍3 𝑍9
𝑁6 = 𝑁 × × = 439.02 𝑟𝑝𝑚
𝑍4 𝑍10
Kinematic Arrangement: (2M)

Arranging in ascending order;

Obtained speeds; 439.02, 544.74, 702.44, 871.58, 1123.90, 1394.53 rpm.
Percentage deviation of obtainable speeds from the calculated speeds (2M)
𝑁𝑜𝑏𝑡 − 𝑁𝐶𝑎𝑙
%𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 = × 100
𝑁𝐶𝑎𝑙
Speed No Nobt (rpm) Ncal (rpm) % deviation
1 439.02 450 -2.44
2 544.74 560 -2.725
3 702.44 710 -1.065
4 871.58 900 -3.158
5 1123.90 1120 0.348

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6 1394.53 1400 -3.907
3 A six speed gearbox is required to provide output speeds in the range of 125 to 400 rpm,
with a step ratio of 1.25 and transmit a power 5 kW at 710 rpm. Draw the speed diagram
and kinematic diagram. Determine the number of teeth, module and face width of all gears,
assuming materials for gears. Determine the length of the gearbox along the axis of the gear
shaft. (15M) (May/June 2016) BTL5
Answer: Page: 4.69 – Dr.A.Baskar
Range of speeds: (1M)
R40 Series:
125, 160, 200, 250, 315, 400 rpm.
Structural formula: (1M)
1 × 2(1) × 3(2)
Ray diagram: (1M)
𝑁𝑚𝑖𝑛 1 𝑁𝑚𝑎𝑥
𝐴𝑡 𝑎𝑛𝑦 𝑠𝑡𝑎𝑔𝑒, ≥ 𝑎𝑛𝑑 ≤2
𝑁𝐼𝑛𝑝𝑢𝑡 4 𝑁𝐼𝑛𝑝𝑢𝑡
At stage 2:
𝑁𝑚𝑖𝑛 = 125 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 500 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 315 𝑟𝑝𝑚
At stage 1:
𝑁𝑚𝑖𝑛 = 200 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 400 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 250 𝑟𝑝𝑚

Diagram: (3M)
Number of teeth on each gear: (2M)
Z1 = 23; Z2 = 37; Z3 = 20; Z4 = 40; Z5 = 26;
Z6 = 26; Z7 = 32; Z8 = 20; Z9 = 20; Z10 = 32.
Minimum module, m: (3M)

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3 [𝑀𝑡 ]
𝑚 ≥ 1.26 × √
𝑦[𝜎𝑏 ]𝜔𝑚 𝑍1
𝐷𝑒𝑠𝑖𝑔𝑛 𝑡𝑜𝑟𝑞𝑢𝑒, [𝑀𝑡 ] = 𝑀𝑡 × 𝑘 × 𝑘2 = 3.10349 × 105 𝑁 − 𝑚𝑚
𝑚 ≥ 3.873 𝑚𝑚
Taking higher standard, m = 5 mm.
Face width, b = 50 mm.
Length of gear box, L: (2M)
𝐿 = 2𝛿 + 4𝑏 + 𝑐 + 7𝑏 + 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑎𝑠𝑠𝑢𝑚𝑒𝑑 = 645 𝑚𝑚
Kinematic Arrangement: (2M)

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UNIT V – CAM, CLUTCHES AND BRAKES

Cam Design: Types-pressure angle and under cutting base circle determination - forces and surface
stresses. Design of plate clutches – axial clutches - cone clutches-internal expanding rim clutches -
Electromagnetic clutches. Band and Block brakes - external shoe brakes - Internal expanding shoe brake.
PART * A

Q.No. Questions

1 What are the desirable properties of friction material to be used for clutches? BTL2
➢ A high and uniform coefficient of friction.
➢ Good resiliency
➢ The ability to withstand high temperatures, together with good heat conductivity.
➢ High resistance to wear, scoring and galling.
➢ Friction materials are basically composite materials made up of strands and fiber
composites.
2 Classify clutches based on the coupling methods. (May/June 2014) BTL2
➢ Positive contact clutches
➢ Frictional clutches
➢ Overrunning clutches
➢ Magnetic clutches and
➢ Fluid couplings.
3 What is fade? (May/June 2012, May/June 2013) BTL1
When the brake is applied continuously over a period of time, the brake becomes overheated
and the coefficient of friction drops. This results in sudden fall of efficiency of the brake. This
phenomenon is known as ‘fade’ of ‘fading’.
4 Distinguish between coupling and a clutch. (Nov/Dec 2012) BTL4
Couplings are used as permanent connecting elements between two power transmitting
elements whereas clutches are used as temporary connecting elements. Thus periodical
engagement is possible in clutch connection.
5 Why in automobiles, braking action when travelling in reverse is not as effective as when
moving forward? (April/May 2015) BTL2
When an automobile moves forward, the braking force acts in the opposite direction to the
direction of motion of the vehicle Whereas in reverse travelling the braking force acts in the
same direction to the direction of motion of the vehicle. So it requires more braking force to
apply brake.
6 What is the axial force required at the engagement and disengagement of cone clutch?
(May/June2013) BTL2
➢ For engagement: We = Wn (1 + µ cot α),
➢ For disengagement: Wd = Wn (1 - µ cot α).
7 What is the function of a clutch in a transmission systems? (May/June 2016) BTL1

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The clutch is a mechanical device which is used to connect or disconnect the source of power at
the operator’s will.
8 What is a self-locking brake? (Apr/May 2011, May/June 2013, Nov/Dec 2012) BTL1
When the frictional force is sufficient enough to apply the brake with no external force, then the
brake is said to be self-locking brake.
9 What you meant by self-energizing brake? (Nov/Dec 2016, May/June 2014, 2013) BTL1
When the moment of applied force (F. l) and the moment of the frictional force (µ . R N . c) are
in the same direction, then frictional force helps in applying the brake. This type of brake is
known as a self-energizing brake.
10 How can pressure angle be reduced in cam design? (May/June 2012) BTL2
It can be reduced by increasing the cam size or by adjusting the offset. Higher the pressure
angle higher the side thrust and higher the chances of jamming the translating follower in its
guide ways.
11 If a multidisc clutch has 8 discs in driving shaft and 9 discs in driven shaft, then how
many number of contact surfaces it will have? (April/May 2015) BTL5
Given data : n1 = 8; n2 = 9
Solution : Number of pair of contact surface, n = n 1 + n2 -1 = 8+9-1 = 16
12 Name different types of clutch. BTL2
➢ Single Plate clutch
➢ Multi plate Clutch
➢ Cone Clutch
➢ Centrifugal Clutch
13 How does the function of a brake differ from that of a clutch? BTL4
Clutch used to engage and disengage the engine from the transmission system when applied.
Brake is used to stop the vehicle when applied due to frictional power.
14 What is the significance of pressure angle in CAM design? (May/June 2016) BTL3
It is the measure of steepness of the cam profile. The angle between the direction of the
follower movement and the normal to the pitch curve at any point is called pressure
angle. Pressure angle varies from maximum to minimum during complete rotation.
15 Mention a few applications of Cams. (Nov/Dec 2016) BTL2
Cam mechanisms are used in various areas of machine building, such as internal-combustion
engines, metal-cutting machines, and machines of the food industry, in which the cam
mechanism performs a programmed operation, as well as in automated machines, in which cam
mechanisms perform control functions, connecting and disconnecting working parts at the
proper moment.
16 Differentiate between uniform pressure and uniform wear theories adopted in the design
of clutches. (Nov/Dec 2014) BTL4
➢ For uniform pressure theory Mean radius of friction surface (R) = 2/3[r 13 – r23/r12-r22]
➢ For uniform wear theory Mean radius of friction surface (R) = [r 1 +r2] /2
r1 = External radius of frictional surface
r2 = Internal radius of frictional surface

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17 Double shoe brakes are preferred than single shoe brakes. Why? (April /May 2017) BTL4
If only one block is used for braking, then there will be side thrust on the bearing of wheel
shaft. This drawback can be removed by providing two blocks on the two sides of the drum.
The double shoes on the drum reduce the unbalanced force on the shaft.
18 What are the effects of temperature rise in clutches? (May/June 2013) BTL2
Because the temperature rise beyond the permissible range in brakes will cause:
➢ Excessive wear
➢ Distortion of the brake linings and
➢ Surface cracks due to thermal stresses.
19 Differentiate a brake and a dynamometer. (April /May 2017) BTL4
➢ Brake is a mechanical device by means of a body is retarded for slowing down or to
bring it to rest, by applying artificial frictional resistance.
➢ A dynamometer is a brake incorporating a device to measure the frictional resistance
applied. This is used for measuring the driving forces or torque transmitted and hence
the power developed by the machine.
20 Name four materials used for lining of friction surfaces in clutches. (or) Name few
commonly used friction materials. BTL2
➢ Wood
➢ Cork
➢ Leather
➢ Asbestos based friction materials and
➢ Powdered metal friction materials.
21 In a hoisting machinery, what are the different energies absorbed by a brake system?
(Nov/Dec 2014) BTL2
In hoists and elevators, the potential energy released by the objects during the braking period is
absorbed by the brake.
22 In cone clutches semi-cone angle should be greater than 12 deg. Why? (May/June 2012)
BTL4
The semi cone angle is kept greater than a certain value to avoid self-engagement; otherwise
disengagement of clutch would be difficult. This is kept around 12.5deg.if the angle is less than
this value than the clutch is liable to jam in engagement
23 Sketch the internal shoe brake and name the various parts. (May/June 2012) BTL3

24 Name the profile of cam that gives no jerk. (Nov/Dec 2015) BTL2

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Cycloidal curve profile of cam that gives no jerk.
25 What is meant by positive clutch? (Nov/Dec 2015) BTL1
Positive-contact clutches have interlocking engaging surfaces to form a rigid mechanical
junction.
PART * B
1 A single shoe brake is shown. The diameter of drum is 250 mm and angle of contact is 90º.
If the operating force of 750 N is applied at the end of the lever and µ = 0.35, determine the
torque that may be transmitted by the brake. (13M) (Nov/Dec 2016) BTL5
Answer: Page: 5.149 – Dr.A.Baskar

i) Drum rotates in anticlockwise direction:

(2M)
𝑃𝑎
𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑜𝑟𝑐𝑒, 𝐹 = 𝑏 = 592.65 𝑁 (2M)
+𝑒
𝜇
𝐷
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = 𝐹 × 2 = 74.08 𝑁 − 𝑚 (2M)
ii) Drum rotates in clockwise direction:

(3M)
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𝑃𝑎
𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑜𝑟𝑐𝑒, 𝐹 = 𝑏 = 718.88 𝑁 (2M)
+𝑒
𝜇
𝐷
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = 𝐹 × 2 = 89.86 𝑁 − 𝑚 (2M)
2 A power of 20 kW is to be transmitted through a cone clutch at 500 rpm. For uniform wear
condition, find the main dimensions of clutch and shaft. Also determine the axial force
required to engage the clutch. Assume coefficient of friction as 0.25, the maximum normal
pressure on the friction surface is not be exceeds 0.08 MPa and take the design stress for the
shaft materials as 40 MPa. (13M) (April/May 2015) BTL5
Answer: Page: 5.115 – Dr.A.Baskar

(2M)

60×𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 382 𝑁 − 𝑚 (2M)
2𝜋𝑛
Clutch shaft diameter, d: (2M)
𝜋
[𝑀𝑡 ] = [𝜏]𝑑3 ; 𝑑 = 37 𝑚𝑚
16
Dimensions of clutch:
Assume semi cone clutch, α = 12º.
Face width, b: (2M)
𝑟𝑚
𝑏=
2
[𝑀𝑡 ] = 2𝜋𝜇𝑝𝑟𝑚2 𝑏; 𝑟𝑚 = 0.183 𝑚
For uniform wear, (2M)
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 =
2
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥 = 0.366 𝑚
From geometry;
𝑟𝑚𝑎𝑥 − 𝑟𝑚𝑖𝑛
sin 𝛼 =
𝑏
Already assumed,
𝑟𝑚
𝑏= = 0.0915 𝑚
2
𝑟𝑚𝑎𝑥 − 𝑟𝑚𝑖𝑛 = 0.019 𝑚
Solving: (1M)
Inner radius of friction surface, rmin = 0.1735 m.
Outer radius of friction surface, rmax = 0.1925 m.
Axial force required to engage the clutch, QE: (2M)
𝑄 = 𝑝 × 2𝜋𝑟𝑚 (𝑏. sin 𝛼)

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𝑄
𝑄𝑛 = = 8417 𝑁
sin 𝛼
𝑄𝐸 = 𝑄𝑛 (𝜇 cos 𝛼 + sin 𝛼) = 3808 𝑁
3 A 50 kg wheel, 0.5 m in diameter turning at 150 rpm in stationary bearings is brought to
rest by pressing a brake shoe radially against the rim with a force of 100 N. If the radius of
gyration of wheel is 0.2 m, how many revolution will the wheel make before coming to rest?
Assume that the coefficient of friction between shoe and rim has the steady value 0.25.
(13M) (May/June 2016)] BTL5
Answer: Page: 5.152 – Dr.A.Baskar
Mass moment of inertia, I: (2M)
2 2
𝐼 = 𝑚𝑘 = 2.0 𝑘𝑔 − 𝑚
Angular velocity, ω: (2M)
2𝜋𝑛 𝑟𝑎𝑑
𝜔= = 15.708
60 𝑠
1
𝐸𝑛𝑒𝑟𝑔𝑦 𝑠𝑡𝑜𝑟𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑟𝑜𝑡𝑎𝑡𝑖𝑛𝑔 𝑤ℎ𝑒𝑒𝑙, 𝐸 = 2 𝐼𝜔2 = 246.74 𝑁 − 𝑚 (2M)
Braking torque, Mt: (4M)
𝑊𝑜𝑟𝑘𝑑𝑜𝑛𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 = 𝐵𝑟𝑎𝑘𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒 × 𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝑑𝑢𝑟𝑖𝑛𝑔 𝑏𝑟𝑎𝑘𝑖𝑛𝑔
𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑜𝑟𝑐𝑒, 𝐹 = 𝜇 × 𝑁 = 25𝑁
𝐷
𝐵𝑟𝑎𝑘𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒, 𝑀𝑡 = 𝐹 × 2 = 6.25𝑁 − 𝑚
𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝑑𝑢𝑟𝑖𝑛𝑔 𝑏𝑟𝑎𝑘𝑖𝑛𝑔, 𝜃 = 𝐴𝑛𝑔𝑙𝑒 𝑡𝑢𝑟𝑛𝑒𝑑 𝑖𝑛 𝑜𝑛𝑒 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛 ×
𝑁𝑜. 𝑜𝑓 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠 𝑚𝑎𝑑𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 𝑏𝑒𝑓𝑜𝑟𝑒 𝑐𝑜𝑚𝑖𝑛𝑔 𝑡𝑜 𝑟𝑒𝑠𝑡 (2M)
𝜃 = 2𝜋𝑛𝑏
𝐸 = 𝑀𝑡 × 𝜃𝑏
No. of revolutions, nb = 6.293. (1M)
4 A radial cam rotates at 1200 rpm with translating flat face follower rising 20 mm with
simple harmonic motion in 150º of cam rotation. The base circle radius is 38 mm. Check
whether undercutting will occur. (13M) (Nov/Dec 2016) BTL5
Answer: Page: 5.40 – Dr.A.Baskar
2𝜋𝑁
𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑐𝑎𝑚, 𝜔 = = 125.664 𝑟𝑎𝑑/𝑠 (2M)
60
For flat follower;
1 𝑑2 𝑦
𝜌𝑐 𝑚𝑖𝑛 = 𝑅𝑏 + (𝑦 + 𝜔2 . 𝑑𝑡 2 ) > 0 (3M)
For SHM;
𝑑2 𝑦 ℎ 𝜋𝜔 2 𝜋𝜃
𝐴𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 𝑎 = = 2 ( 𝛽 ) . cos (3M)
𝑑𝑡 2 𝛽
The min acceleration occurs at θ = β and y = h.
−ℎ 𝜋𝜔 2
𝑎= ( 𝛽 ) … . . cos 𝜋 = cos 180 = −1 (2M)
2
1 −ℎ 𝜋𝜔 2
𝜌𝑐 𝑚𝑖𝑛 = 𝑅𝑏 + [ℎ + 𝜔2 . ( 2 ( 𝛽 ) )] > 0 (2M)
20 × 𝜋 2
= 38 + [20 − ]
2 × (2.618)2
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𝜌𝑐 𝑚𝑖𝑛 = 43.6 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 > 0; (𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒) (1M)
Thus undercutting will not occur.
5 An automobile single plate clutch consists of two pairs of contacting surfaces. The inner and
outer radii of friction are 120 mm and 250 mm respectively. The coefficient of friction is
0.25 and the total axial force is 15 kN. Calculate the power transmitting capacity of the
clutch plate at 500 rpm using: (i) Uniform wear theory and, (ii) Uniform pressure theory.
(13M) (May/June 2013) BTL5
Answer: Page: 5.87 – Dr.A.Baskar
i) Uniform wear theory:
𝑟𝑚𝑖𝑛 +𝑟𝑚𝑎𝑥
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 = = 0.185 𝑚 (2M)
2
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = 2𝜇𝑄𝑟𝑚 = 1387.5 𝑁 − 𝑚 (2M)
2𝜋𝑛𝑀𝑡
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑃 = = 72649 𝑊𝑎𝑡𝑡𝑠 (2M)
60
ii) Uniform pressure theory:
2 𝑟3 −𝑟 3
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 = 3 [𝑟𝑚𝑎𝑥 𝑚𝑖𝑛
] = 0.1926 𝑚 (3M)
2 −𝑟 2
𝑚𝑎𝑥 𝑚𝑖𝑛
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = 2𝜇𝑄𝑟𝑚 = 1444.59 𝑁 − 𝑚 (2M)
2𝜋𝑛𝑀𝑡
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑃 = = 75639 𝑊𝑎𝑡𝑡𝑠 (2M)
60
PART * C
1 A multi plate clutch with both sides effective transmits 30 kW at 360 rpm. Inner and outer
radii of the clutch discs are 100 mm and 200 mm respectively. The effective coefficient of
friction is 0.25. An axial load of 600 N is applied. Assuming uniform wear conditions, find
the number of discs required and the maximum intensity of pressure developed. (15M)
(May/June 2016) BTL5
Answer: Page: 5.98 – Dr.A.Baskar
Torque, Mt: (4M)
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 = = 0.15 𝑚
2
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 795.77 𝑁 − 𝑚
2𝜋𝑛
Design torque, [Mt]:
[Mt] = Mt = 795.77 N-m (assumed) (2M)
Clutch shaft diameter, d – not asked for.
Allowable pressure, Pa: (3M)
𝑄
𝑃𝑎 = = 9549.3 𝑁/𝑚2
2𝜋𝑛 × 𝑟𝑚𝑖𝑛 × (𝑟𝑚𝑎𝑥 − 𝑟𝑚𝑖𝑛 )
Torque transmitted per pair of friction surface, [Mt]1: (2M)
[𝑀𝑡 ]1 = 2𝜇𝑄𝑟𝑚 = 22.5 𝑁 − 𝑚
Number of pairs of friction surfaces, i: (2M)
[𝑀 ]
𝑖 = [𝑀 𝑡] = 36 𝑝𝑎𝑖𝑟𝑠 𝑜𝑓 𝑠𝑢𝑟𝑓𝑎𝑐𝑒𝑠
𝑡 1
Number of plates = Number of friction surfaces + 1 = 37. (2M)

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2 The displacement function of a cam follower mechanism is given by y(θ) = 100(1-cosθ) mm;
0≤θ≤2π, where y is the follower displacement and θ is the cam rotation. The cam speed is
1000 rpm. The spring constant is 20 N/mm and the spring has an initial compression of 10
mm, when the roller follower is int its lowest position. The weight of the mass to be moved
including the follower is 10 N, length of the follower outside the guide A = 40 mm, length of
the guide B = 100 mm, Rb = 50 mm, Rr = 10 mm and the coefficient of friction between the
guide and the follower = 0.05. Compute normal force and the cam shaft torque when the
cam has rotated 60º. (15M) (Nov/Dec 2011) BTL4
Answer: Page: 5.50 – Dr.A.Baskar
2𝜋𝑁
𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑐𝑎𝑚, 𝜔 = = 104.72 𝑟𝑎𝑑/𝑠 (2M)
60
𝑑𝑦 𝑑𝑦 𝑑𝜃 𝑑𝑦
𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑣 = = 𝑑𝜃 . 𝑑𝑡 = 𝑑𝜃 𝜔 (4M)
𝑑𝑡
𝑣 = 100𝜔. 𝑠𝑖𝑛𝜃
𝑑𝑦

tan 𝛼 = 𝑑𝜃
(3M)
𝑅𝑝 +𝑦𝜃
𝛼 = 38.212°
Normal force, Pn; (4M)
𝑃 = 𝑆𝑝𝑟𝑖𝑛𝑔 𝑠𝑡𝑖𝑓𝑓𝑛𝑒𝑠𝑠 × 𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 = 1200 𝑁
𝑃
𝑃𝑛 = 2𝐴+𝐵 = 1644 𝑁
cos 𝛼−𝜇( ).sin 𝛼
𝐵
Cam shaft torque, Mt: (2M)
𝑃. 𝑣
𝑀𝑡 = = 103.93 𝑁 − 𝑚
𝜔
3 A multi plate clutch steel on bronze is to transmit 6 kW power at 750 rpm. The inner radius
of contact surface is 4 cm and outer radius is 7 cm. The clutch plates operate in oil, so the
coefficient of friction is 0.1. The average pressure is 0.5 N/mm2. Determine (i) the total
number of steel and bronze friction discs, (ii) actual axial force required, (iii) actual average
pressure, (iv) actual maximum pressure. (15M) (Nov/Dec 2016) BTL5
Answer: Page: 5.104 – Dr.A.Baskar
Torque transmitted: (2M)
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 = = 0.055
2
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 76.39 𝑁 − 𝑚
2𝜋𝑛
Design torque, [Mt]: (2M)
[Mt] = Mt = 76.39 N-m (assumed)
Clutch shaft diameter, d – not asked for.
Average pressure, Pav = 0.35 N/mm2
Torque transmitted per pair of friction surface, [Mt]1: (2M)
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥
[𝑀𝑡 ]1 = 2𝜇𝜋 [𝑃𝑎𝑣 ( )] (𝑟𝑚𝑎𝑥 + 𝑟𝑚𝑖𝑛 )𝑟𝑚 = 19.96 𝑁 − 𝑚
2
Number of pairs of friction surfaces, i: (3M)

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 REGULATION: 2013 ACADEMIC YEAR: 2018-2019
[𝑀𝑡 ]
𝑖= = 4 𝑝𝑎𝑖𝑟𝑠 𝑜𝑓 𝑠𝑢𝑟𝑓𝑎𝑐𝑒𝑠
[𝑀𝑡 ]1
Number of plates = Number of friction surfaces + 1 = 5.
Actual average pressure, σ: (2M)
[𝑀𝑡 ]
𝜎= = 334927 𝑁/𝑚2
2𝜋 × 4𝑖 × 𝑏 × 𝜇(𝑟𝑚 )2
Axial force required: (2M)
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥
𝑄 = 2𝜋 [𝑃𝑎𝑣 ( )] (𝑟𝑚𝑎𝑥 + 𝑟𝑚𝑖𝑛 ) = 3472 𝑁
2
Actual maximum pressure, Pa: (2M)
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥
𝑃𝑎 . 𝑟𝑚𝑖𝑛 = 𝑃𝑚𝑖𝑛 . 𝑟𝑚𝑎𝑥 = 𝑃𝑎𝑣 ( )
2
𝑃𝑎 = 453750 𝑁/𝑚2

JIT-JEPPIAAR/MECH/Mr.S.ARUN/IIIrdYr/SEM 06 /ME6601/DESIGN OF TRANSMISSION SYSTEMS /UNIT 1-5/QB+Keys/Ver1.0

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