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=
+ +
+
=
2
2
Teeth) 85 ( 3
2
Teeth 42
mm 20 mm 600
2
2
3
2
) Thickness Wall Clearance (
2 1
N N
H
m
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 4 of 21
Based on the computations of module above, the module employed for the two-stage compound
reverted gear train must not exceed m = 3.85388 mm/Tooth. In addition, according to KHK Gear
Catalog, spur gears with module of 2 have the closest number of teeth (N = 85 Teeth) to the number
of teeth for gears 2 and 4 given in this assignment. As a result, steel spur gears with 85 Teeth and
module 2 has been chosen in the analysis of gear tooth strength and surface durability.
According to KHK Gear Catalog, Steel Spur Gears with 42 and 85 Teeth with module of 2 have
face widths of 20 mm (See KHK Gear Catalog in Appendix):
mm 20
Tooth mm 20
Teeth 42
146) pp. Catalog, Gear (KHK
3 1
=
)
`
=
= =
b
m
N N
mm 20
Tooth mm 20
Teeth 85
156) pp. Catalog, Gear (KHK
4 2
=
)
`
=
= =
b
m
N N
Therefore, b
1
= b
2
= b
3
= b
4
= 20 mm.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 5 of 21
3.3 Analysis of Gear Tooth Strength
3.3.1 Bending Fatigue Analysis by Using Steel Spur Gear with Module 2
For m = 2 mm/Tooth,
( )( )
( )( )
( )( )
( )( ) mm 170 Teeth 5 8 Tooth mm 2
mm 84 Teeth 42 Tooth mm 2
mm 170 Teeth 5 8 Tooth mm 2
mm 84 Teeth 42 Tooth mm 2
4 4
3 3
2 2
1 1
= = =
= = =
= = =
= = =
mN d
mN d
mN d
mN d
The gear ratio for a pair of spur gears (pinion and gear) is given by:
p
g
g
p
d
d
=
where
g
= Angular velocity of gear
p
= Angular velocity of pinion
d
g
= Diameter of gear
d
p
= Diameter of pinion
By using the relation of gear ratio above, the angular velocity of gear 2 can be obtained:
rpm 1136.47 = |
\
|
=
|
|
\
|
= =
mm 170
mm 4 8
rpm 2300
2
1
1 2
1
2
2
1
d
d
d
d
Since gear 2 and gear 3 are located on the same shaft, therefore,
rpm 1136.47 = =
2 3
The speed ratio for double-reduction gear train is given by:
rpm 561.55 = |
\
|
=
|
|
\
|
= =
85 85
42 42
rpm 2300
4 2
3 1
1 4
3 1
4 2
4
1
N N
N N
N N
N N
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 6 of 21
Stage 1 (Gear 1 & Gear 2)
Pitch Line Velocity,
60000
d
V =
s m 10.12 =
= = =
= = =
1 Stage
2 2
2
1 1
1
s m 12 . 0 1
60000
rpm) 7 mm)(1136.4 170 (
60000
: 2 Gear
s m 12 . 0 1
60000
rpm) mm)(2300 84 (
60000
: 1 Gear
V
d
V
d
V
Tangential Forces, F
t
= /V
N 889.33 =
= = =
= = =
1 Stage ,
1 Stage 2
1 Stage 1
N 33 . 889 s m 10.12 W 9000 : 2 Gear
N 33 . 889 s m 10.12 W 9000 : 1 Gear
t
t
t
F
V W F
V W F
Gear Tooth Bending Stress,
m o v
t
K K K
bJm
F
=
From Figure 14-6 (Budynas, R. G. & Nisbett, J. K., pp. 753), the Geometry Factor for spur
gears of 42 Teeth and 85 Teeth are J
1, 3
0.2725 and J
2,4
0.295.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 7 of 21
min ft 1992.13 = = =
m .3043 0
ft 1
min 1
s 60
s
m
12 . 10 s m 12 . 10
1 Stage
V
Velocity (Dynamic) Factor,
78
78 V
K
v
+
= (Highest precision, shaved and ground)
1.2539 =
+
=
+
= =
78
13 . 1992 78
78
78
1 Stage
V
K K
v v
From TABLE 15.1 (Juvinall, R. C. & Marshek, K. M., pp. 615), the Overload Correction
Factor, K
o
= 1 (Uniform source of machinery and power)
From TABLE 15.2 (Juvinall, R. C. & Marshek, K. M., pp. 616), the Mounting Factor,
K
m
= 1.3 (Accurate mounting, small bearing clearance, minimum deflection)
MPa 132.99 = = = ) 3 . 1 )( 1 )( 2539 . 1 (
Tooth) mm )(2 mm)(0.2725 20 (
N 33 . 889
1 1
1 Stage ,
1 m o v
t
K K K
m J b
F
MPa 122.85 = = = ) 3 . 1 )( 1 )( 2539 . 1 (
Tooth) mm (2 mm)(0.295) 20 (
N 33 . 889
2 2
1 Stage ,
2 m o v
t
K K K
m J b
F
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 8 of 21
Stage 2 (Gear 3 & Gear 4)
Pitch Line Velocity,
60000
d
V =
s m 4.8895 =
= = =
= = =
2 Stage
4 4
4
3 3
3
s m 9985 . 4
60000
rpm) mm)(561.55 170 (
60000
: 4 Gear
s m 9985 . 4
60000
rpm) 7 mm)(1136.4 84 (
60000
: 3 Gear
V
d
V
d
V
Tangential Forces, F
t
= /V
N 1800.54 =
= = =
= = =
2 Stage ,
2 Stage 4
2 Stage 3
N 54 . 1800 s m 4.9985 W 9000 : 4 Gear
N 54 . 1800 s m 4.9985 W 9000 : 3 Gear
t
t
t
F
V W F
V W F
Gear Tooth Bending Stress,
m o v
t
K K K
bJm
F
=
From Figure 14-6 (Budynas, R. G. & Nisbett, J. K., pp. 753), the Geometry Factor for spur
gears of 42 Teeth and 85 Teeth are J
1, 3
0.2725 and J
2,4
0.295.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 9 of 21
min ft 983.96 = = =
m .3043 0
ft 1
min 1
s 60
s
m
9985 . 4 s m 9985 . 4
2 Stage
V
Velocity (Dynamic) Factor,
78
78 V
K
v
+
= (Highest precision, shaved and ground)
1.1844 =
+
=
+
= =
78
96 . 983 78
78
78
1 Stage
V
K K
v v
From TABLE 15.1 (Juvinall, R. C. & Marshek, K. M., pp. 615), the Overload Correction
Factor, K
o
= 1 (Uniform source of machinery and power)
From TABLE 15.2 (Juvinall, R. C. & Marshek, K. M., pp. 616), the Mounting Factor,
K
m
= 1.3 (Accurate mounting, small bearing clearance, minimum deflection)
MPa 269.19 = = = ) 3 . 1 )( 1 )( 2539 . 1 (
Tooth) mm )(2 mm)(0.2725 20 (
N 54 . 1800
3 3
2 Stage ,
3 m o v
t
K K K
m J b
F
MPa 248.73 = = = ) 3 . 1 )( 1 )( 2539 . 1 (
Tooth) mm (2 mm)(0.295) 20 (
N 54 . 1800
4 4
2 Stage ,
4 m o v
t
K K K
m J b
F
By comparing the four bending stresses above, the maximum bending stress is
max
=
3
= 269.19
MPa.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 10 of 21
The gear in the gear train which is subjected to the highest tooth bending stresses is the one which
has the largest possibility to fail in advance. Based on the stresses computed above,
max
= 269.19
MPa and therefore the critical gear is Gear 3.
Refined Analysis of Gear-Tooth Bending Strength Endurance Limit
ms
K K K C C C S S
t r S G L n n
=
where
u n
S S 5 . 0 =
Since the Steel Spur Gears are made of S45C Steel with a maximum Brineel Hardness of 194 HB,
therefore, the tensile strength, S
u
, can be determined by using the relation:
S
u
= K
h
(HB) = (3.45)(194) MPa = 669.3 MPa (K
h
= 3.45 in SI Units)
( ) MPa 65 . 334 MPa 3 . 669 5 . 0 5 . 0 = = =
u n
S S
Load Factor, C
L
= 1 (Bending loads)
) 5 ( 1
in. Teeth 7 . 12
mm 25.4
in. 1
mm 170
Teeth 5 8
in. Teeth 7 . 12
mm 25.4
in. 1
mm 84
Teeth 42
in. Teeth 7 . 12
mm 25.4
in. 1
mm 170
Teeth 5 8
in. Teeth 7 . 12
mm 25.4
in. 1
mm 84
Teeth 42
4
4
4
3
3
3
2
2
2
1
1
1
> =
= =
=
= =
=
= =
=
= =
P C
D
N
P
D
N
P
D
N
P
D
N
P
G
From TABLE 15.3 (Juvinall, R. C. & Marshek, K. M., pp. 615), the Reliability Correction
Factor, K
r
= 1 (50% Reliability)
Temperature Factor, K
t
= 1 (Assumed the temperature lower than 160 F)
Mean Stress Factor, K
ms
= 1 (Gear 3 is idler)
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 11 of 21
From FIGURE 8.13 (Juvinall, R. C. & Marshek, K. M., pp. 301), the Surface Factor,
C
S
= 0.76 (Machined or cold-drawn)
Therefore, the endurance limit is computed as follows:
MPa 254.334 =
=
=
1) 76)(1)(1)( MPa)(1)(0. (334.65
ms
K K K C C C S S
t r S G L n n
Safety Factor, 0.9448 = = =
MPa 19 . 269
MPa 334 . 254
SF
max
n
S
Since the safety factor obtained above is less than 2.2 in which the pre-requisites is not
satisfied. Therefore, Steel Spur Gear with module of 2 cannot be employed in the double-
reduction gear train. As a result, Steel Spur Gear with module of 3 has been selected for the
application.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 12 of 21
3.3.2 Bending Fatigue Analysis by Using Steel Spur Gear with Module 3 (N
2
= N
4
= 90)
For m = 3 mm/Tooth,
( )( )
( )( )
( )( )
( )( ) mm 270 Teeth 0 9 Tooth mm 3
mm 126 Teeth 42 Tooth mm 3
mm 270 Teeth 0 9 Tooth mm 3
mm 126 Teeth 42 Tooth mm 3
4 4
3 3
2 2
1 1
= = =
= = =
= = =
= = =
mN d
mN d
mN d
mN d
The gear ratio for a pair of spur gears (pinion and gear) is given by:
p
g
g
p
d
d
=
where
g
= Angular velocity of gear
p
= Angular velocity of pinion
d
g
= Diameter of gear
d
p
= Diameter of pinion
By using the relation of gear ratio above, the angular velocity of gear 2 can be obtained:
rpm 1073.33 = |
\
|
=
|
|
\
|
= =
mm 270
mm 26 1
rpm 2300
2
1
1 2
1
2
2
1
d
d
d
d
Since gear 2 and gear 3 are located on the same shaft, therefore,
rpm 1073.33 = =
2 3
The speed ratio for double-reduction gear train is given by:
rpm 500.89 = |
\
|
=
|
|
\
|
= =
0 9 0 9
42 42
rpm 2300
4 2
3 1
1 4
3 1
4 2
4
1
N N
N N
N N
N N
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 13 of 21
Stage 1 (Gear 1 & Gear 2)
Pitch Line Velocity,
60000
d
V =
s m 15.17 =
= = =
= = =
1 Stage
2 2
2
1 1
1
s m 17 . 15
60000
rpm) 3 mm)(1073.3 270 (
60000
: 2 Gear
s m 17 . 15
60000
rpm) mm)(2300 126 (
60000
: 1 Gear
V
d
V
d
V
Tangential Forces, F
t
= /V
N 593.28 =
= = =
= = =
1 Stage ,
1 Stage 2
1 Stage 1
N 28 . 593 s m 15.17 W 9000 : 2 Gear
N 28 . 593 s m 15.17 W 9000 : 1 Gear
t
t
t
F
V W F
V W F
Gear Tooth Bending Stress,
m o v
t
K K K
bJm
F
=
From Figure 14-6 (Budynas, R. G. & Nisbett, J. K., pp. 753), the Geometry Factor for spur
gears of 42 Teeth and 85 Teeth are J
1, 3
0.2725 and J
2,4
0.2975.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 14 of 21
min ft 2991.13 = = =
m .3043 0
ft 1
min 1
s 60
s
m
17 . 15 s m 17 . 15
1 Stage
V
Velocity (Dynamic) Factor,
78
78 V
K
v
+
= (Highest precision, shaved and ground)
1.3043 =
+
=
+
= =
78
13 . 1992 78
78
78
1 Stage
V
K K
v v
From TABLE 15.1 (Juvinall, R. C. & Marshek, K. M., pp. 615), the Overload Correction
Factor, K
o
= 1 (Uniform source of machinery and power)
From TABLE 15.2 (Juvinall, R. C. & Marshek, K. M., pp. 616), the Mounting Factor,
K
m
= 1.3 (Accurate mounting, small bearing clearance, minimum deflection)
MPa 41.02 = = = ) 3 . 1 )( 1 )( 3043 . 1 (
Tooth) mm )(3 mm)(0.2725 30 (
N 93.28 5
1 1
1 Stage ,
1 m o v
t
K K K
m J b
F
MPa 37.57 = = = ) 3 . 1 )( 1 )( 3043 . 1 (
Tooth) mm )(3 mm)(0.2975 30 (
N 93.28 5
2 2
1 Stage ,
2 m o v
t
K K K
m J b
F
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 15 of 21
Stage 2 (Gear 3 & Gear 4)
Pitch Line Velocity,
60000
d
V =
s m 7.079 =
= = =
= = =
2 Stage
4 4
4
3 3
3
s m 079 . 7
60000
rpm) mm)(500.89 270 (
60000
: 4 Gear
s m 079 . 7
60000
rpm) 3 mm)(1073.3 126 (
60000
: 3 Gear
V
d
V
d
V
Tangential Forces, F
t
= /V
N 1271.37 =
= = =
= = =
2 Stage ,
2 Stage 4
2 Stage 3
N 37 . 1271 s m 7.079 W 9000 : 4 Gear
N 37 . 1271 s m 7.079 W 9000 : 3 Gear
t
t
t
F
V W F
V W F
Gear Tooth Bending Stress,
m o v
t
K K K
bJm
F
=
From Figure 14-6 (Budynas, R. G. & Nisbett, J. K., pp. 753), the Geometry Factor for spur
gears of 42 Teeth and 85 Teeth are J
1, 3
0.2725 and J
2,4
0.295.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 16 of 21
min ft 23.23 = = =
m .3043 0
ft 1
min 1
s 60
s
m
079 . 7 s m 079 . 7
2 Stage
V
Velocity (Dynamic) Factor,
78
78 V
K
v
+
= (Highest precision, shaved and ground)
1.0304 =
+
=
+
= =
78
23 . 23 78
78
78
2 Stage
V
K K
v v
From TABLE 15.1 (Juvinall, R. C. & Marshek, K. M., pp. 615), the Overload Correction
Factor, K
o
= 1 (Uniform source of machinery and power)
From TABLE 15.2 (Juvinall, R. C. & Marshek, K. M., pp. 616), the Mounting Factor,
K
m
= 1.3 (Accurate mounting, small bearing clearance, minimum deflection)
MPa 69.44 = = = ) 3 . 1 )( 1 )( 0304 . 1 (
Tooth) mm )(3 mm)(0.2725 30 (
N 37 . 1271
3 3
2 Stage ,
3 m o v
t
K K K
m J b
F
MPa 63.61 = = = ) 3 . 1 )( 1 )( 0304 . 1 (
Tooth) mm (3 mm)(0.295) 30 (
N 34 . 1271
4 4
2 Stage ,
4 m o v
t
K K K
m J b
F
By comparing the four bending stresses above, the maximum bending stress is
max
=
3
= 69.44
MPa.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 17 of 21
The gear in the gear train which is subjected to the highest tooth bending stresses is the one which
has the largest possibility to fail in advance. Based on the stresses computed above,
max
= 269.19
MPa and therefore the critical gear is Gear 3.
Refined Analysis of Gear-Tooth Bending Strength Endurance Limit
ms
K K K C C C S S
t r S G L n n
=
where
u n
S S 5 . 0 =
Since the Steel Spur Gears are made of S45C Steel with a maximum Brineel Hardness of 194 HB,
therefore, the tensile strength, S
u
, can be determined by using the relation:
S
u
= K
h
(HB) = (3.45)(228) MPa = 786.6 MPa (K
h
= 3.45 in SI Units)
( ) MPa 3 . 393 MPa 86.6 7 5 . 0 5 . 0 = = =
u n
S S
Load Factor, C
L
= 1 (Bending loads)
) 5 ( 1
in. Teeth 4667 . 8
mm 25.4
in. 1
mm 270
Teeth 5 8
in. Teeth 4667 . 8
mm 25.4
in. 1
126mm
Teeth 42
in. Teeth 4667 . 8
mm 25.4
in. 1
mm 270
Teeth 0 9
in. Teeth 4667 . 8
mm 25.4
in. 1
mm 126
Teeth 42
4
4
4
3
3
3
2
2
2
1
1
1
> =
= =
=
= =
=
= =
=
= =
P C
D
N
P
D
N
P
D
N
P
D
N
P
G
From TABLE 15.3 (Juvinall, R. C. & Marshek, K. M., pp. 615), the Reliability Correction
Factor, K
r
= 1 (50% Reliability)
Temperature Factor, K
t
= 1 (Assumed the temperature lower than 160 F)
Mean Stress Factor, K
ms
= 1 (Gear 3 is idler)
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 18 of 21
From FIGURE 8.13 (Juvinall, R. C. & Marshek, K. M., pp. 301), the Surface Factor,
C
S
= 0.74 (Machined or cold-drawn)
Therefore, the endurance limit is computed as follows:
MPa 291.042 =
=
=
1) 74)(1)(1)( MPa)(1)(0. (393.3
ms
K K K C C C S S
t r S G L n n
Safety Factor, 4.19 = = =
MPa 9.44 6
MPa 042 . 291
SF
max
n
S
Since the safety factor is equal 4.19 (SF > 2.2), therefore, the pre-requisite is attained and Steel Spur
Gears with module 3 and face width of 30 mm has been selected from the KHK Gear Catalog for
the double-reduction gear train.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 19 of 21
3.4 Analysis of Surface Durability of Tooth Surface
The critical gear (Gear 3) has been selected for the analysis of surface durability as it is subjected to
maximum bending stress.
Surface Fatigue Stress,
m o v
p
t
p
g
g
p
p
g p
t
H
K K K
I bd
F
C
E
v
E
v
b
d d
F
=
|
|
\
|
+
|
|
\
|
+
=
2 2
1 1
cos
sin
2
sin
2
564 . 0
Gear 3: F
t3
= 1271.37 N, b = 30 mm = 0.03 m, d
p
= d
3
= 126 mm = 0.126, R = d
g
/d
p
= 270/126 =
2.14. From previous calculations, K
v
= 1.0304, K
o
= 1 and K
m
= 1.3.
From TABLE 15.4b (Juvinall, R. C. & Marshek, K. M., pp. 621), the Surface Factor, the Values of
Elastic Coefficient C
p
for Spur Gears is C
p
= 191 ( )Pa 10 191 MPa
3
= .
Geometry Factor, 1024 . 0
1 14 . 2
14 . 2
2
20 cos 20 sin
1 2
cos sin
=
+
=
+
=
R
R
I
Surface Fatigue Stress, MPa 123.8 = = =
m)(0.1024) m)(0.126 (0.03
(1)(1.3) N)(1.0304) 37 . 1271 (
m o v
p
t
H
K K K
I bd
F
Surface Fatigue Strength, S
H
= S
fe
C
Li
C
R
The angular velocity of gear 3,
3
= 1073.33 rpm and given that the expected life for 40 hr/week,
and 50 week/year operation is 3.25 years. Therefore, the Surface Fatigue Life (Cycle) is given by:
Cycle 10 2 . 4
hr 1
min 60
years 25 . 3
year
week
50
week
hr
40
min
rev
1073.33 Life Fatigue Surface
8
=
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 20 of 21
From FIGURE 15.27 (Juvinall, R. C. & Marshek, K. M., pp. 624), the Life Factor, C
Li
= 0.83 for a
surface fatigue life of 4.2(10
8
) Cycle.
From TABLE 15.6 (Juvinall, R. C. & Marshek, K. M., pp. 625), the Reliability Factor, C
R
= 1.25
for a reliability of 50%.
From TABLE 15.5 (Juvinall, R. C. & Marshek, K. M., pp. 624), the relation for the computation of
the Surface Hardness, S
fe
, is S
fe
= 2.8(Bhn) 64 MPa.
Assignment 2 Group 9
HES3350 Machine Design, Semester 1, 2012 Page 21 of 21
Since the maximum Brineel Hardness of the Steel Spur Gear is 228 HB or 228 Bhn, therefore, the
surface hardness can be determined by using the relation above:
S
fe
= 2.8(228 Bhn) 64 MPa = 574.4 MPa
Thus, the Surface Fatigue Strength S
H
can be computed as follows:
S
H
= (574.4 MPa)(0.83)(1.25) = 595.94 MPa
Checking of Safety Factor for Surface Durability:
4.8 = = =
MPa 123.9
MPa 94 . 595
SF Factor, Safety
H
H
S
Since the Safety Factor SF = 4.8 (> 2.2), therefore, the selection and utilization of Steel Spur Gear
with module of 3 from the KHK Gear Catalog will not results in any operating failure. As a verdict,
based on the analysis of bending fatigue and surface durability of gear tooth strength above and as
in previous section, it is ascertain that the Steel Spur Gear with Module 3 from the KHK Gear
Manufacturer can be employed in the compound-reverted gear train. 2 models have been selected
from the KHK Gear Catalog due to the same size of pinions and gears.
Gear 1 & Gear 3 (Pinion):
42 Teeth of Number 3 Module Gear Spur S45C : Steel
42 3 S S
=
Gear 2 & Gear 4 (Gear):
90 Teeth of Number 3 Module Gear Spur S45C : Steel
90 3 S S
=
The material used for the spur gears is Steel S45C with Brineel Hardness of 228 HB or 228 Bhn.