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MechanicalDesignDataBook

Design Data Hand Book


Contents:1 Friction Clutches

Single plate clutches05


Multi plate clutches05
Cone clutches06
Centrifugal clutches06

2 Brakes

External Contracting Brakes08


Internal Expanding Brake09
Band Brakes10
Thermal Considerations11

3 Belt Drives

Geometrical Relationships12
Analysis of Belt Tensions13
Condition for Maximum Power13
Selection of Flat Belts from the Manufactures
Catalogue13
Selection of V-Belts15

4 Chain Drives

Roller Chains20
Geometrical Relationships20
Power Rating of Roller Chains21
Sprocket Wheels24

5 Rolling Contact Bearings

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Stribecks Equation25
Equivalent Bearing Load26

Shinto Mathew

Load Life Relationship26


Selection of Bearing from the Manufactures
Catalogue27
Selection of Taper Roller Bearings32
Design for Cyclic Load and Speed38
Bearing With a Probability of Survival Other Than
90 Percent38

6 Sliding Contact Bearings

Effect of Temperature on Viscosity39


Hydrostatic Step Bearing40
Energy Losses in Hydrostatic Bearing40
Reynolds Equation41
Raimondi and Boyd Method41
Temperature Rise43
Bearing Design Selection of Parameters44

7 Spur Gears

Standard System of Gear Tooth45


Force Analysis50
Beam Strength of Gear Tooth47
Effective Load on Gear Tooth48
Estimation of Module Based on Beam Strength50
Wear Strength of Gear Tooth50
Estimation of Module Based on Wear Strength51
Gear Design for Maximum Power Transmitting
Capacity51

8 Helical Gears

Virtual Number of Tooth52


Tooth Proportions53
Beam Strength of Helical Gears54
Effective Load on Gear Tooth54
Wear Strength of Helical Gears55

9 Bevel Gears

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Force Analysis57

Shinto Mathew

Beam Strength of Bevel Gears58


Wear Strength of Bevel Gears59
Effective Load on Gear Tooth60

10 Worm Gears

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Proportions of Worm Gears62


Force Analysis64
Friction in Worm Gears64
Strength Rating of Worm Gears65
Wear rating of worm gears67

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FRICTION CLUTCHES
Notations:D = outer diameter of friction disk.
d = inner diameter of friction disk.
p = intensity of pressure.
P = total operating force.
(M t ) f = torque transmitted by friction.
z = number of pairs of contacting surfaces, for single plate
clutch z=one. (z = number of plates 1).
= coefficient of friction.

p a = intensity of pressure at the inner edge.


= semi cone angle.

rd
rg

= radius of the drum.

= radius of the centre of gravity of the shoe in engaged


position.
m = mass of each shoe.

Pcf = centrifugal force.


Ps = Spring force

= running speed. (Rad/sec)


= speed at which engagement starts. (Rad/sec)

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Single Plate & Multi Plate Clutches


Uniform pressure theory

P=

(M t ) f

4
=

(D 2 d 2 )
Pz (D3 d 3 )
3 (D 2 d 2 )

Uniform wear theory


pa d
P =
(D d )
2

(M t ) f

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Pz
4

(D + d )

Shinto Mathew

Cone Clutches
Uniform pressure theory

P=

(Mt ) f

(D 2 d 2 )

Pz (D3 d 3 )
=
3sin (D2 d 2 )

Uniform wear theory


p a d
P =
(D d )
2

(M t ) f

Pz
(D + d )
4 sin

Centrifugal Clutches
Ps =

m 12 rg
1000
mr g rd z ( 22 12 )

(M t ) f

1000

Note: - here z = number of shoes.

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Brakes
Notations:E = total energy absorbed by the brake.
K.E = kinetic energy absorbed by the brake.
P.E = potential energy absorbed by the brake.
m = mass of the system.
I = mass moment of inertia of the rotating body.
k = radius of gyration.
v1 , v 2 = Initial and final velocities of the system

1 , 2 = Initial and final angular velocities of the body


M t = braking torque.

= angle through which the brake drum rotates during the


braking period.
1
m(v12 v 22 )
2
1
K .E = I ( 12 22 )
2
1
K .E = mk 2 ( 12 22 )
2
P.E = mgh
K .E =

E = M t

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External Contracting Brakes


Block brake with short shoe

M t = NR
Where
= Braking Torque
R = Radius of the Brake Drum
= Coefficient of Friction
N = Normal reaction
Mt

N = plw
Where
p = Permissible pressure between the block and
the brake drum
l = length of the block
w = width of the block

R X = N
RY = ( N P )

(a c)
P=
N
b
Pivoted block brake with long shoe

P = Pmax cos
h=

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4 R sin
2 + sin 2

Shinto Mathew

M t = 2 R 2 wp max sin
1
Rwp max ( 2 + sin 2 )
2
1
RY = Rwp max (2 + sin 2 )
2
RX =

Internal expanding brake


p max Rw[4 R(cos 1 cos 2 ) h(cos 2 1 cos 2 2 )]
4 sin max
p Rwh[2( 2 1 ) (sin 2 2 sin 21 )]
M n = max
4 sin max

Mf =

R 2 p max w(cos 1 cos 2 )


Mt =
sin max
P=
P=

Mn M f
C

Mn + M f
C

(Clock wise rotation of the brake drum)

(Anti clock wise rotation of the brake drum)

max = 90 0 when 2 > 90 0


max = 2 when 2 < 90 0
Where
p max = maximum intensity of pressure.
= coefficient of friction.

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10

M f = moment due to friction.


M n = moment due to normal force.
M t = elemental torque due to frictional force.

R = radius of the brake lining.


w = face width of frictional lining.

Band Brakes
P1 = tension on the tight side of the band.
P2 = tension on the loose side of the band.

= angle of wrap (rad).

M t = torque capacity of the brake.


R = radius of the brake drum.
M t = ( P1 P2 ) R

p=

P
Rw

pmax =

P1
Rw

p = intensity of pressure.
w = width of the frictional lining.
Differential band brake.
P2 (a b e )
p=
l

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11

Thermal Considerations

t =

E
mc

Where t = temperature rise of the brake drum assembly


(0C )
E = total energy absorbed by the brake
m = mass of the brake drum assembly
c = specific heat of the brake drum material

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12

Belt Drives

GEOMETRICAL RELATIONSHIPS
Open belt drive

Dd
)
2C
1 D d
b = 180 + 2 sin (
)
2C

s = 180 2 sin 1 (

L = 2C +

(D + d )
2

(D d ) 2
+
4C

Cross belt drive

s = b = 180 + 2 sin 1 (
L = 2C +

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(D + d )
2

D+d
)
2C

( D + d )2
+
4C

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13

Analysis of belt tension

P1 mv 2
f
=
e
P2 mv 2

f
P1 mv 2
=e
2
P2 mv

(For flat belts)

sin(

Power transmitted= ( P1

1
)
2

(For V-belts)

P2 )v

Condition for maximum power transmission

v =

Pi
3m

SELECTION OF FLAT BELT FROM THE


MANUFACTURES CATALOGUE
(kW ) max = Fa (kW )

Where (kW ) max = power transmitted by the belt for the


design purpose
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14

(kW ) = actual power transmitted by the belt

Fa = load correction factor


Type of load
(i) Normal load

Fa
1.0

(ii) Steady load, e.g. centrifugal pumps-fans-light


machine tools-conveyors
(iii) Intermittent load, e.g. heavy duty fansblowers-compressors- reciprocating pumps-line
shafts-heavy duty machines
(iv) Shock load, e.g. vacuum pumps-rolling millshammers-grinders

1.2
1.3

1.5

Arc of contact factor

s (degrees)

120 130 140 150 160 170 180 190 200

Fd

1.33 1.26 1.19 1.13 1.08 1.04 1.00 0.97 0.94

HI-SPEED
FORT

A MEADinfo Publication

0.0118 kW per mm width per ply


0.0147 kW per mm width per ply

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15

Standard widths of the belt are as


follows
3-Ply 25
4-Ply 40
5-Ply 76
6-Ply 112

40 50 63 76
44 50 63 76
100 112 125 152
125 152 180 200

90

100 112 125 152

(kW ) corrected = (kW ) max Fd


For HI-SPEED belt,
Corrected kW rating=

0.0118v
(5.08)

For FORT belt,


Corrected kW rating=

0.0147v
(5.08)

SELECTION OF V-BELTS
Dimensions of standard cross-sections
Belt Section
Width
Thickness
Minimum pitch
W(mm)
T(mm)
diameter of pulley(mm)
A
13
8
125
B
17
11
200
C
22
14
300
D
32
19
500
E
38
23
630

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16

Conversion of inside length to pitch length of the belt


Belt section
A B C D E
Difference between pitch length and
inside length (mm)
36 43 56 79 92

125
236
475
1000

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Preferred values for pitch diameters (mm)


132 140 150 160 170 180 190 200 212 224
250 265 280 300 315 355 375 400 425 450
500 530 560 600 630 670 710 750 800 900

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17

Number _ of _ belts =
Where

(transmitted _ power _ in _ kW ) Fa
kW _ rating _ of _ belt Fd Fl

Fa = correction factor for industrial service

Fd = correction factor for arc of contact


Fl = correction factor for belt length

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18

A MEADinfo Publication

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19

Li
3658
4013
4115
4394
4572
4953
5334
6045
6807
7569

A
-

B
1.11
1.13
1.14
1.15
1.16
1.18
1.19
-

Belt section
C
1.00
1.02
1.03
1.04
1.05
1.07
1.08
1.11
1.14
1.16

D
0.90
0.92
0.92
0.93
0.94
0.96
0.96
1.00
1.03
1.05

E
0.94
0.96
0.99
1.01

0.9
0.8

Fd

0.7
0.6
0.5
120

150

180

s (Degrees)

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20

Chain Drives
Roller Chains
Dimensions and breaking loads of roller chains
ISO chain
number

Pitch p
(mm)

Roller
diameter
d1 (mm)

06 B
08 B
10 B
12 B
16 B
20 B
24 B
28 B
32 B
40 B

9.525
12.70
15.875
19.05
25.40
31.75
38.10
44.45
50.80
63.50

6.35
8.51
10.16
12.07
15.88
19.05
25.40
27.94
29.21
39.37

Width b1
(mm)

5.72
7.75
9.65
11.68
17.02
19.56
25.40
30.99
30.99
38.10

Transverse Breaking load for


pitch pt
single strand
chain (kN)
(mm)

10.24
13.92
16.59
19.46
31.88
36.45
48.36
59.56
58.55
72.29

10.7
18.2
22.7
29.5
65.0
98.1
108.9
131.5
172.4
272.2

Geometric Relationships
n1
z
= 2
n2
z1
zpn
v
=
Average velocity,
60 10 3

Velocity ratio, i =

Length of the chain, L = Ln p


Number of links in the

a z1 + z 2 z 2 z1 p
+

chain, L n = 2 +
p
2
2


a

2

Where a = centre distance between the axis of the


driving and driven sprockets.

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Shinto Mathew

21
2
2

p
z2 z1
z1 + z2
z1 + z2
a = Ln
8
+ Ln

4
2
2
2

POWER RATING OF ROLLER CHAINS


kW =

P1v
1000

Where

P1 = allowable tension in the chain (N)


v = average velocity of chain

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22

kW rating of chain =
Where

(kW _ to _ be _ transmitted ) K s
K1 K 2

K s = service factor

Multiple strand factors ( K1 )


Number of strands

K1

1
2
3
4
5
6

A MEADinfo Publication

1.0
1.7
2.5
3.3
3.9
4.6

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23

Tooth correction factor ( K 2 )


Number of teeth on the K
2
driving sprocket
15
0.85
16
0.92
17
1.00
18
1.05
19
1.11
20
1.18
21
1.26
22
1.29
23
1.35
24
1.41
25
1.46
30
1.73

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24

SPROCKET WHEELS

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25

Rolling Contact Bearing


Stribecks Equation
C 0 = P1 + 2 P2 cos + 2 P3 cos (2 ) + .......... .....

2
= cos
1
2 P2
=
1 P1

23

C 0 = P1 M
Where,
M = 1 + 2 (cos

)5 2

+ 2 (cos 2

)5 2 ]

C0 = Static load
1 , 2 ... = radial deflections at the respective balls.

360
z

Where
z is number of balls
z
is practically
M
z
5 for
M

constant and Stribeck suggested a value of

1
C 0 = zP1
5

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Shinto Mathew

26

P1 = kd 2

Where d is, the ball diameter and factor k


depends upon radii of curvature at the point of contact and
on the modulii of elasticity of the materials.
Stribecks Equation

kd 2 z
C0 =
5
Equivalent Bearing Load
P = XFr + YFa

Where, P= equivalent dynamic load


Fr = radial load
Fa = axial or thrust load
X and Y are radial and thrust factors respectively and
there values are given in the manufactures catalogue.

Load Life Relationship


p

C
L=
P
Where L = bearing life (in million revolutions)
C = dynamic load capacity (N)
p=3
(for ball bearing)
p = 10/3 (for roller bearing)

A MEADinfo Publication

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27

Relationship between life in million revolutions and and life in


working hours is given by
60nLh
L=
10 6
Where Lh =bearing life (hours)
n = speed of rotation (rpm)

Selection of bearing from manufactures


catalogue
X and Y factors for single-row deep groove ball bearings

Fa

C0

0.025
0.040
0.070
0.130
0.250
0.500

Fa

Fr

Fa

Fr

> e

1
1
1
1
1
1

0
0
0
0
0
0

0.56
0.56
0.56
0.56
0.56
0.56

2.0
1.8
1.6
1.4
1.2
1.0

0.22
0.24
0.27
0.31
0.37
0.44

P = XFr + YFa
A MEADinfo Publication

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28

Dimensions and static and dynamic load


capabilities of singlerow deep groove ball
bearings.
Principal
dimensions
(mm)
d
D
B
10
19
5
26
8
30
9
35
11
12
21
5
28
8
32
10
37
12
15
24
5
32
9
35
11
42
13
17
26
5
35
10
40
12
47
14
62
17
20
32
7
42
8
42
12
47
14
52
15
72
19
25
37
7
47
8
47
12
A MEADinfo Publication

Basic load
ratings(N)
C
1480
4620
5070
8060
1430
5070
6890
9750
1560
5590
7800
11400
1680
6050
9560
13500
22900
2700
7020
9360
12700
15900
30700
3120
7610
11200

Designation

C0

630
1960
2240
3750
695
2240
3100
4650
815
2500
3550
5400
930
2800
4500
6550
11800
1500
3400
4500
6200
7800
16600
1960
4000
5600

61800
6000
6200
6300
61801
6001
6201
6301
61802
6002
6202
6302
61803
6003
6202
6303
6403
61804
16400
6004
6204
6304
6404
61805
16005
6005
Shinto Mathew

29

30

35

40

45

50

55

A MEADinfo Publication

52
62
80
42
55
55
62
72
90
47
62
62
72
80
100
52
68
68
80
90
110
58
75
75
85
100
120
65
80
80
90
110
130
72

15
17
21
7
9
13
16
19
23
7
9
14
17
21
25
7
9
15
18
23
27
7
10
16
19
25
29
7
10
16
20
27
31
9

14000
22500
35800
3120
11200
13300
19500
28100
43600
4030
12400
15900
25500
33200
55300
4160
13300
16800
30700
41000
63700
6050
15600
21200
33200
52700
76100
6240
16300
21600
35100
61800
87100
8320

6950
11400
19600
2080
5850
6800
10000
14600
24000
3000
6950
8500
13700
18000
31000
3350
7800
9300
16600
22400
36500
3800
9300
12200
18600
30000
45500
4250
10000
12300
19600
36000
52000
5600

6205
6305
6405
61806
16006
6006
6206
6306
6406
61800
16007
6007
6207
6307
6407
61808
16008
6008
6208
6308
6408
61809
16009
6009
6209
6309
6409
61810
16010
6010
6210
6310
6410
61811

Shinto Mathew

30

60

65

70

75

A MEADinfo Publication

90
90
100
120
140
78
95
95
110
130
150
85
100
100
120
140
160
90
110
110
125
150
180
95
115
115
130
160
190

11
18
21
29
33
10
11
18
22
31
35
10
11
18
23
33
37
10
13
20
24
35
42
10
13
20
25
37
45

19500 12200
28100 17000
43600 25000
71500 41500
99500 63000
8710
6100
19900 13200
29600 18300
47500 28000
81900 48000
108000 69500
11700
8300
21200 14600
30700 19600
55900 34000
92300 56000
119000 78000
12100
9150
28100 19000
37700 24500
61800 37500
104000 63000
143000 104000
12500
9800
28600 20000
39700 26000
66300 40500
112000 72000
153000 114000

16011
6011
6211
6311
6411
61812
16012
6012
6212
6312
6412
61813
16013
6013
6213
6313
6413
61814
16014
6014
6214
6314
6414
61815
10615
6015
6215
6315
6415

Shinto Mathew

31

Dynamic load capacity


C
L =
P

A MEADinfo Publication

Shinto Mathew

32

Selection of Taper Roller Bearings

Fa =

0.5Fr
Y

Where Y is the thrust factor


Equivalent dynamic load for single row taper roller bearings
is given by

P = Fr when(Fa Fr ) e

P = 0.4 Fr + YFa when(Fa Fr ) > e

Dimensions, Dynamic capabilities and calculation factors for


single row taper roller bearing
d
D
B
C
Designation
e
Y
20
42
15
22900
32004X
0.37
1.6
47
15.25 26000
30204
0.35
1.7
52
16.25 31900
30304
0.30
2.0
52
72.25 41300
32304
0.30
2.0
25
47
15
25500
32005X
0.43
1.4
52
16.25 29200
30205
0.37
1.6
52
19.25 34100
32205B
0.57 1.05
52
22
44000
33205
0.35
1.7
62
18.25 41800
30305
0.30
2
62
18.25 35800
31305
0.83 0.72
62
25.25 56100
32305
0.30
2
30
55
17
33600
32006X
0.43
1.4
62
17.25 38000
30206
0.37
1.6
62
21.25 47300
32206
0.37
1.6
62
21.25 45700
32206B
0.57 1.05

A MEADinfo Publication

Shinto Mathew

33

30

35

40

45

50

A MEADinfo Publication

62
72
72
72
62
72
72
72
72
80
80
80
80
68
75
80
80
80
85
90
90
90
75
80
85
85
85
95
95
100
100
100
100
80

25
20.75
20.75
28.75
18
18.25
24.25
24.25
28
22.75
22.75
32.75
32.75
19
26
19.75
24.75
32
33
25.25
25.25
35.25
20
26
20.75
24.75
32
29
36
27.25
27.25
38.25
38.25
20

60500
52800
44600
72100
40200
48400
61600
57200
79200
68200
57200
89700
88000
49500
74800
58300
70400
96800
114000
80900
69300
110000
55000
79200
62700
74800
101000
84200
140000
101000
85800
132000
128000
57200

33206
30306
31306
32306
32007X
30207
32207
32207B
33207
30307
31307
32307
32307B
32008X
33108
30208
32208
33208
T2EE040
30308
31308
32308
32009X
33109
30209
32209
33209
T7FC045
T2ED045
30309
31309
32309
32309B
32010X

0.35
0.31
0.83
0.31
0.46
0.37
0.37
0.57
0.35
0.31
0.83
0.31
0.54
0.37
0.35
0.37
0.37
0.35
0.35
0.35
0.83
0.35
0.40
0.37
0.40
0.40
0.40
0.88
0.33
0.35
0.83
0.35
0.54
0.43

1.7
1.9
0.72
1.9
1.3
1.6
1.6
1.05
1.7
1.9
0.72
1.9
1.1
1.6
1.7
1.6
1.6
1.7
1.7
1.7
1.72
1.7
1.5
1.6
1.5
1.5
1.5
0.68
1.8
1.7
0.72
1.7
1.1
1.4

Shinto Mathew

34

50

60

70

A MEADinfo Publication

80
85
90
90
90
100
105
110
110
110
110
95
95
100
110
110
110
115
115
125
130
130
130
130
110
110
120
125
125
125
130
140
140
150

24
26
21.75
24.75
32
36
32
29.25
29.25
42.25
42.25
23
27
30
23.75
29.75
38
39
40
37
33.5
33.5
48.5
48.5
25
31
37
26.25
33.25
41
43
39
32
38

64400
80900
70400
76500
108000
145000
102000
117000
99000
161000
151000
76500
85800
110000
91300
119000
157000
157000
183000
145000
161000
134000
216000
205000
95200
121000
161000
119000
147000
190000
220000
168000
264000
209000

33010
33110
30210
32210
33210
T2ED050
T7FC050
30310
31310
32310
32310B
32012X
33012
33112
30212
32212
33212
T5ED060
T2EE060
T7FC060
30312
31312
32312
32312B
32014X
33014
33114
30214
32214
33214
T2ED070
T7FC070
T4FE070
3014

0.31
0.40
0.43
0.43
0.40
0.35
0.88
0.35
0.83
0.35
0.54
0.43
0.33
0.40
0.40
0.40
0.40
0.54
0.33
0.83
0.35
0.83
0.35
0.54
0.43
0.28
0.37
0.43
0.43
0.40
0.33
0.88
0.44
0.35

1.9
1.5
1.4
1.4
1.5
1.7
0.68
1.7
0.72
1.7
1.1
1.4
1.8
1.5
1.5
1.5
1.5
1.1
1.8
0.72
1.7
0.72
1.7
1.1
1.4
2.1
1.6
1.4
1.4
1.5
1.8
0.68
1.35
1.7

Shinto Mathew

35

70

80

90

100

150

A MEADinfo Publication

150
150
150
125
125
130
140
140
140
145
170
170
170
170
140
140
150
155
160
160
190
190
190
145
150
150
165
180
180
180
215
215
215
225

38
54
54
29
36
37
28.25
35.25
46
46
42.5
42.5
61.5
61.5
32
39
45
46
32.5
42.5
46.5
46.5
67.5
24
32
39
47
37
49
63
51.5
56.5
77.5
48

176000
275000
264000
128000
157000
168000
140000
176000
233000
264000
255000
212000
358000
336000
157000
205000
238000
270000
183000
238000
308000
251000
429000
119000
161000
212000
292000
233000
297000
402000
380000
352000
539000
347000

31314
32314
32314B
32016X
33016
33116
30216
32216
33216
T2ED080
30316
31316
32316
32316B
32018X
33018
33118
T2ED090
30218
32218
30318
31318
32318
T4CB100
32020X
33020
T2EE100
30220
32220
33220
30320
31320X
32320
32030X

0.83
0.35
0.54
0.43
0.28
0.43
0.43
0.43
0.43
0.31
0.35
0.83
0.35
0.54
0.43
0.27
0.40
0.33
0.43
0.43
0.35
0.83
0.35
0.48
0.46
0.28
0.31
0.43
0.43
0.40
0.35
0.83
0.35
0.46

0.72
1.7
1.1
1.4
2.1
1.4
1.4
1.4
1.4
1.9
1.7
0.72
1.7
1.1
1.4
2.2
1.5
1.8
1.4
1.4
1.7
0.72
1.7
1.25
1.3
2.1
1.9
1.4
1.4
1.5
1.7
0.72
1.7
1.3

Shinto Mathew

36

150

200

300

A MEADinfo Publication

270
270
320
320
280
310
360
360
420

49
77
72
82
51
70
64
104
76

402000
682000
765000
837000
446000
704000
737000
1140000
990000

30230
32230
30330
31330X
32940
32040X
30240
32240
32960

0.43
0.43
0.35
0.83
0.40
0.43
0.43
0.40
0.40

1.4
1.4
1.7
0.72
1.5
1.4
1.4
1.5
1.5

Shinto Mathew

37

A MEADinfo Publication

Shinto Mathew

38

Design for Cyclic Load and Speeds

BP 3
Pe = 3

Bearing With a Probability of Survival Other


Than 90 Percent

1
log


e
L
R

=
L
90 log 1
e

R90
Where b = 1.17

A MEADinfo Publication

1b

Shinto Mathew

39

Sliding Contact Bearing


Effect of Temperature on Viscosity

A MEADinfo Publication

Shinto Mathew

40

Hydrostatic Step Bearing


The following notations are used in the analysis,
W = Trust load

R0 = outer radius of the shaft

Ri = inner radius of the shaft


Pi = supply of inlet pressure

Po = outlet or atmospheric pressure

h0 = fluid film thickness


Q = flow of the lubricant
= viscosity of the lubricant
Q=

Pi h03
R
6 log e 0
Ri

Pi R 02 R i2
W =
2
R0

log e

R i

Energy Losses in Hydrostatic Thrust


Bearing
(kW ) p = Q( Pi P0 )(10 6 )
( kW ) p = power loss in pumping
2
4
4
1

n ( R0 Ri )
(kW ) f =
6
h0
58.05 10
( kW ) f = power loss due to friction

A MEADinfo Publication

Shinto Mathew

41

( kW ) t = ( kW ) p + ( kW ) f
( kW ) t = total power loss

Reynolds Equation
3 p 3 p
h
h
+ h
= 6 U

x x z z
x

Raimondi and Boyd Method


Dimensionless performance parameters for full
journal bearings with side flow

l

d

h0

c

0
1.0
0.1
0.9
0.2
0.8
0.4
0.6
0.6
0.4
0.8
0.2
0.9
0.1
0.97 0.03
1.0
0
0
1.0
0.1
0.9
0.2
0.8
0.4
0.6
0.6
0.4
0.8
0.2
0.9
0.1

A MEADinfo Publication

0.240
0.123
0.0626
0.0389
0.021
0.0115
_
0

1.33
0.631
0.264
0.121
0.0446
0.0188

r
f
c

70.92

69.10 4.80
67.26 2.57
61.94 1.52
54.31 1.20
42.22 0.961
31.62 0.756
_
_
0
0
85

79.5
26.4
74.02 12.8
63.10 5.79
50.58 3.22
36.24 1.70
26.45 1.05

Qs

p max

0
3.03
0
2.83
0
2.26
0
1.56
0
0.760
0
0.411
0
_
0
0
0

0
3.37 0.150
3.59 0.280
3.99 0.497
4.33 0.680
4.62 0.842
4.74 0.919

_
0.826
0.814
0.764
0.667
0.495
0.358
_
0
_
0.540
0.529
0.484
0.415
0.313
0.247

rcn
l
s

Shinto Mathew

42

0.97 0.03 0.00474 15.47


1.0
0
0
0
0
1.0
88.5

0.1
0.9
4.31
81.62
0.2
0.8
2.03
74.94
0.4
0.6
0.779 61.45
0.6
0.4
0.319 48.14
0.8
0.2
0.0923 33.31
0.9
0.1
0.0313 23.66
0.97 0.03 0.00609 13.75
1.0
0
0
0
0
1.0
89.5

0.1
0.9
16.2
82.31
0.2
0.8
7.57
75.18
0.4
0.6
2.83
60.86
0.6
0.4
1.07
46.72
0.8
0.2
0.261 31.04
0.9
0.1
0.0736 21.85
0.97 0.03 0.0101 12.22
1.0
0
0
0

0.514
0

4.82
0

85.6
40.9
17.0
8.10
3.26
1.60
0.610
0

3.43
3.72
4.29
4.85
5.41
5.69
5.88
_

322.0
153.0
61.1
26.7
8.8
3.50
0.922
0

3.45
3.76
4.37
4.99
5.60
5.91
6.12
_

0.973
1.0
0
0.173
0.318
0.552
0.730
0.874
0.939
0.980
1.0
0
0.180
0.330
0.567
0.746
0.884
0.945
0.984
1.0

0.152
_
_
0.523
0.506
0.441
0.365
0.267
0.206
0.126
0
_
0.515
0.489
0.415
0.334
0.240
0.180
0.108
0

c = R-r
Where c = radial clearance (mm)
R = radius of bearing
r = radius of journal

e
c

Where e =eccentricity ratio,


= eccentricity ratio
h0

= 1

Where h0 =film thickness

A MEADinfo Publication

Shinto Mathew

43

h0
is called the minimum film thickness variable
c
The Sommerfed number is given by

r n s
S =
c p
2

Where ns =journal speed


p = unit bearing pressure
The Coefficient of Friction Variable (CFV) is given by
r
(CFV ) = f
c
Where f is the coefficient of friction
Frictional power (kW ) f =

2n s fWr
10 6

The Flow Variable (FV) is given by


Q
( FV ) =
rcn s l
Where l = length of the bearing
Q= flow of the lubricant

Temperature Rise
8.3 p (CFV )
( FV )
t
= Ti +
2

t =

Tav

A MEADinfo Publication

Shinto Mathew

44

Bearing Design Selection of


Parameters

A MEADinfo Publication

Shinto Mathew

45

Spur Gears
The pitch circle diameter is given by

d 1 = mz
Centre to centre distance,

a=

mn ( z p + z g )
2

Here transmission ratio i =

zg
zp

np
ng

Standard System of Gear Tooth


Choice 1
1.00 1.25
(preferred) 5.00 6.0
Choice2
1.12 1.375
5.5 7.00

1.50
8.00
1.75
9.00

2.00
10.00
2.25
11.00

2.5
12.00
2.75
14.0

3.00 4.0
16.00 20.00
3.50 4.5
18.00

Addendum (ha ) =(m)


Dedendum (h f ) =1.25m
Clearance(c) =0.25m
Tooth thickness = 1.5708m
Fillet radius = 0.4m

A MEADinfo Publication

Shinto Mathew

46

Force Analysis
60 10 6 (kW )
Mt =
2n

pt =

2 mt
d1

Pr = Pt tan

Pt
cos
Number of Teeth
PN =

2
sin 2
Pressure angle ( )
z min =

z min (Theoretical)
z min (Practical)

14.5 0

20 0

25 0

32

17

11

27

14

Face Width
(3m)<b< (12m)
In preliminary stages of gear design, the face width assumed
as ten times of module.

A MEADinfo Publication

Shinto Mathew

47

Beam Strength of Gear Tooth

S b = mb bY
Values of the Lewis form factor Y for 20 0 full depth involute
system
z
Y
z
Y
z
Y

A MEADinfo Publication

15

0.289

27

0.348

55

0.415

16

0.295

28

0.352

60

0.421

17

0.302

29

0.355

65

0.425

18

0.308

30

0.358

70

0.429

19

0.314

32

0.364

75

0.433

20

0.320

33

0.367

80

0.436

21

0.326

35

0.373

90

0.442

22

0.330

37

0.380

100

0.446

23

0.333

39

0.386

150

0.458

24

0.337

40

0.389

200

0.463

25

0.340

45

0.399

300

0.471

26

0.344

50

0.408

Rack

0.484

Shinto Mathew

48

Effective Load on Gear Tooth


(1)For ordinary and commercially cut gears made with form
cutters with v<10m/s

Cv =

3
3+v

(2) For actually hobbled and generated gears with v<20m/s,

Cv =

6
6+v

(3) For precision gears with shaving, grinding and lapping


operations and with v>20m/s,
Cv =

5 .6
5 .6 + v

The pitch line velocity is given by


d ' n
v=
60 10 3
The effective load between two meshing teeth is given by

Peff =

C s Pt
Cv

n the final stages of gear design, when the gear dimensions


are known, the errors specified and the quality of gears
determined, the dynamic load is calculated by the equations
derived by Prof. Spotts. The effective load is given by

Peff = (C s Pt + Pd )

where Pd is the dynamic load


Depending upon the materials of the pinion and the gear,
there are three equations for the dynamic load.
(1) Steel Pinion with steel gear:
en p z p br1 r2
Pd =
2530 (r12 + r22 )

A MEADinfo Publication

Shinto Mathew

49

(2) C.I Pinion with C.I gear:


en p z p br1r2
Pd =
3785 (r12 + r22 )
(3) Steel Pinion with C.I Gear
en p z p br1r2
Pd =
3260 (r12 + 0.92r22 )
e = sum of errors between two meshing teeth (mm)
e = e p + eg

where e p =error for pinion


e g =error for gear
Source of power
Type of driven
machines

Electric
motor

Turbine/Multi
cylinder engine

Single-cylinder
engine

1.10

1.25

1.50

Machine tools-hoist and


cranes-rotary drives-piston
pumps-distribution pumps

1.25

1.50

1.75

Blanking and shearing presses


-rolling mills-centrifuges-steel
work machinery

1.75

2.00

2.25

Generators-feeding
mechanisms-belt conveyorsblowers-compressors-agitators
and mixers

A MEADinfo Publication

Shinto Mathew

50

Estimation of Module Based on Beam


Strength

60 10 6

m=

13

(kW )C ( fs )

znCv b S ut Y

m 3

Wear Strength of Gear Tooth


K=

c2 sin cos (1 E1 + 1 E 2 )

A MEADinfo Publication

1.4

Shinto Mathew

51

S w = bQd 1p K
Q=

2z g
zg z p

Expression for the load stress factor K can be simplified


when all the gears are made of steel with a 20 0 pressure
angle . in this special case,

E1 = E 2 = 207000 N mm 2
= 20 0
c = 0.27(9.81)( BHN ) N mm 2
where BHN=Brinell Hardness Number.
Therefore,
BHN
K = 0.16

100

Estimation of Module Based on


Wear Strength

60 10 6

m=

13

(kW )C ( fs )

z 2p n p Cv b QK

Gear Design for Maximum Power


Transmitting Capacity
S w = 2 Pd
Pt = Pd =

A MEADinfo Publication

Sw
2

Shinto Mathew

52

Helical gears
P
cos
mn = m cos
Pn =

m n = normal module
m = transverse module

pa =

p
tan

tan n
tan
zmn
d=
cos

cos =

a=

m n ( z1 + z 2 )
2 cos

p zg
=
g zp
Where i=speed ratio for helical gear
Suffixes p and g refer to the pinion and gear respectively
a is the centre to centre distance between two helical gears
having z1 and z 2 as the number of teeth.
The normal pressure angle is usually 20 0 .
i=

Virtual number of teeth


z1 =

z
cos 3

A MEADinfo Publication

Shinto Mathew

53

Tooth proportions
In helical gears, the normal module mn should be selected
from standards. The first preference values of the normal
module are m n (mm) 1, 1.25, 1.5, 2, 2.5,3,4,5,6,8 and10.
The standard proportions of the addendum and dedendum
are,
Addendum (ha ) = mn
Dedendum (h f ) = 1.25mn
Clearance (c) = 0.25mn
Addendum circle diameter d a is given by
z

+ 2
d a = mn
cos

Dedendum circle diameter d f is given by


z

2 .5
d f = mn
cos

sin

This is the minimum face width.


Force Analysis

p t = Tangential component
p r = Radial component
p a = Axial or thrust component
pt = p cos n cos
p a = pt tan

A MEADinfo Publication

Shinto Mathew

54

tan n
p r = pt

cos

2 mt
pt =
d
Beam strength of helical gears
S b = m n b Y

Effective load on gear tooth


60 10 6 (kW )
Mt =
2n

Pt =

2M t
d

C s Pt
Peff =
Cv
C s = service factor (from table)
C v = velocity factor
The velocity factor ,
Cv =

5.6
5.6 + v

Dynamic load is given by

A MEADinfo Publication

Shinto Mathew

55

en p z p br1r2

Pd =

2530 r12 + r22

Peff = (Cs Pt + Pd cos n cos )


S b = Peff ( fs )

Wear strength of helical gears


bQd p K

Sw =

cos 2

Q=
Q=

2 z1g
z1g + z1p
2 zg

zg + z p

for internal helical gear

Q=

K=

2 zg

zg z p
1
1
+
E1 E2

c2 sin n cos n

A MEADinfo Publication

1.4

Shinto Mathew

56

n = Normal

pressure angle

BHN
K = 0.16

100

(20 0 )

S w = Peff ( fs )

A MEADinfo Publication

Shinto Mathew

57

Bevel Gears
D
2 cos
z
z1 =
cos
zp
tan =
zg
zg
tan =
zp

rb =

+ =

The cone distance

Dp
A0 =
2

A0 is given by

Dg
+

Force Analysis
D p b sin

rm =

2
2

Where rm = radius of the pinion at the mid point along the


face width
b = face width of the tooth

A MEADinfo Publication

Shinto Mathew

58

Mt
Pt =
rm
Ps = Pt tan

Where Pt = tangential or useful component which is


perpendicular to the plane of the paper.

Ps = the separating force between the two meshing


teeth
Pr = Pt tan cos

Pa = Pt tan sin

Beam Strength of Bevel Gears

b
S b = mb bY 1
A0
Where S b beam strength of the tooth
m = module at the large end of the tooth
b = face width

b = permissible bending stress ( S ut

3)
Y = Lewis form factor based on formative number of

teeth

A0 = cone distance
Pt =

2M t
D

face width of the bevel gear is generally taken as (10 m) or


( A0 3 ) whichever is smaller

A MEADinfo Publication

Shinto Mathew

59

b = (10 m) or ( A

3)

(Whichever is smaller)

WEAR STRENGTH OF BEVEL GEARS


Buckinghams equation

S w = bQd 1p K

S w = wear strength

Where

b = face width of gears


Q = ratio factors
d 1p = pitch circle diameter of the formative pinion
K = material constant

d 1p = 2rb

Sw =
Q=

0.75bQD p K
cos

(Buckinghams equation)

2z g

z g + z p tan

1
1
sin cos
+

E
E

g
p
K=
1. 4
When pinion as well as the gear is made of steel with 20 0
pressure angle, the value of K is given by
2
c

BHN
K = 0.16

100

A MEADinfo Publication

Shinto Mathew

60

EFFECTIVE LOAD ON GEAR TOOTH


60 10 6 (kW )
Mt =
2n

Pt =

2M t
D

Peff =

C s Pt
Cv

C s = service factor (from table)


Source of power
Type of driven
machines

Electric
motor

Turbine/Multi
cylinder engine

Single-cylinder
engine

1.10

1.25

1.50

Machine tools-hoist and


cranes-rotary drives-piston
pumps-distribution pumps

1.25

1.50

1.75

Blanking and shearing presses


-rolling mills-centrifuges-steel
work machinery

1.75

2.00

2.25

Generators-feeding
mechanisms-belt conveyorsblowers-compressors-agitators
and mixers

C v = velocity factor
The velocity factor for cut teeth is given by

A MEADinfo Publication

Shinto Mathew

61

Cv =

6
6+v

For general teeth,


Cv =

5.6
5.6 + v

Dynamic load is given by


en p z p b1 r1 r2
Pd
2530 r12 + r22

r1 , r2 Radii of the pinion and gear respectively


b1 Axial width of the gear blank
D p b sin

r1 =

2
2

D g b cos

r2 =

2
2

Peff = (C s Pt + Pd )
Stress in gear tooth due to bending
S b = Peff ( fs )
Stress in gear tooth due to pitting

S w = Peff ( fs )

A MEADinfo Publication

Shinto Mathew

62

Worm Gears
Notations:z1 = number of starts on the worm
z2 = number of teeth on the worm wheel
q = diametral quotient
m = module
d1 = pitch circle diameter of the worm

d a1 = outer diameter of the worm


d a 2 = outer diameter of the worm wheel
d 2 = pitch circle diameter of the worm wheel
l = lead of the worm

p x = axial pitch of the worm


a = the centre distance
i = the speed ratio.
F = the effective face width
lr = the length of the root of the worm gear teeth.

Proportions of Worm Gears

A MEADinfo Publication

Shinto Mathew

63

d1
m
l = p x z1
q=

d 2 = mz 2
p x = m

l = mz 1
a=

1
m( q + z 2 )
2

A MEADinfo Publication

Shinto Mathew

64

i =

z2
z1

F = 2m (q + 1)

l r = (d a1 + 2c) sin 1
+
d
2
c
a1

Force Analysis
( P1 ) t = tangential component on the worm
( P1 ) a = axial component on the worm
( P1 ) r = radial component on the worm
( P1 ) t =

2M t
d1

( P1 ) a = ( P1 ) t
( P1 ) r = ( P1 ) t

(cos cos sin )


(cos sin + cos )

sin
(cos sin + cos )

Friction in worm gears


v s = rubbing velocity
v1 = pitch line velocity of the worm

v2 = pitch line velocity of the worm wheel

vs =

n 1
( 60 )( 1000
1

d 1 n1

(60000 ) cos
(cos tan )
=
(cas + cot )

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Shinto Mathew

65

Strength Rating Of Worm Gears


( M t )1 = 17.65 X b1 S b1 ml r d 2 cos
( M t ) 2 = 17.65 X b 2 S b 2 ml r d 2 cos

( M t )1 , ( M t ) 2 = permissible torque on the worm wheel

b1

, X b 2 = speed factors for the strength of worm and


worm wheel

b1

Sb2

= bending stress factors for worm and worm

wheel

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Shinto Mathew

66

m = module

l r = the length of the root of the worm gear teeth.


d 2 = pitch circle diameter of the worm wheel

= lead angle of the worm


Power transmitting capacity of the worm gear based on the
beam strength is given by

2 nM t
kW =
60 10 6

Where

A MEADinfo Publication

( M t)

is the lower value between ( M t)1 and ( M t) 2 .

Shinto Mathew

67

Wear Rating of Worm Gears


( M t ) 3 = 18.64 X c1 S c1YZ (d 2 )1.8 m
( M t ) 4 = 18.64 X c 2 S c 2YZ (d 2 )1.8 m

( M t )3 , ( M t ) 4 = permissible torque on the worm wheel

X c1 , X c 2

= speed factors for the strength of worm and

worm wheel

S c1 , S c 2 = surface stress factors of the worm and worm


wheel

Yz = zone factor
Thermal Considerations
H g = 1000(1 )kW
Where H g = rate heat generation

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Shinto Mathew

68

= efficiency of the of the worm gear (fraction)


kW = power transmitted by the gears

H d = k (t t 0 ) A
Where H d = rate of heat dissipation
k = overall heat transfer coefficient of housing
20
walls W m C
t = temperature of the lubrication oil. ( 0C )

t 0 = temperature of the surrounding air ( C )


0

A = effective surface area of housing

k (t t 0 ) A
1000(1 )
1000(1 )kW
t = t0 +
kA
kW =

A MEADinfo Publication

Shinto Mathew

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