SOLUTION (16.1) Known: A helical spur gear with specified number of teeth, helix angle, y, and pressure angle, 9, is given. Find: Determine: (a) the normal pressure angle, On, and the equivalent number of teeth, Ne, (b) the pressure angle and number of teeth on a spur gear of equivalent strength. Schematic and Given Data: Assumptions: 1. The helical gear teeth have standard tooth profiles. 2. The profile of the helical gear tooth in the plane normal to the tooth can be approximated by the standard profile of a spur gear tooth. Analysis: (a) From Eq. (16.2) : on = tan (tan 9 cos w) = tan“(tan 20° cos 25°), On = 18.2° Ne = Nicos? y = 27/cos 25° : Ne = 36.27 teeth (b) A spur gear of equal strength would have 36.27 teeth and @ = 18.2° 16-1Comment: The increase in the number of teeth of the equivalent spur gear suggests that for the same pitch diameter, number of teeth and material, the helical gear teeth would have greater bending strength than spur gear teeth. SOLUTION (16.2) Known: The normal range of spur gear face widths is given as a function of P. It is desired that the helical gear face width be greater than or equal to twice the axial circular pitch. Find: (a) Determine the helix angle required to have a face width equal to 12/P and also equal to 2.0pa, (b) Compare the helix angle found in (a) with the common range of helix angles, viz. 15 to 30 degrees. Schematic and Given Data: ANE Lp +| Assumption: The helical gear teeth have standard tooth profiles. Analysi: (a) Given that b = 2.0pa = 2 hence 522% = 12 a -Pmy ene? P tan W Pp? (b) The helix angle is within the 15° to 30° "commonly used range" / and pa = or w= 27.64° . Comment: The range of helix angles possible under the conditions, b = 2.0pa , 9/P < b < 14/P and 15° < w < 30’ is 24.2° << 30°. 16-2SOLUTION (16.3) Known: For a pair of meshing helical gears mounted on parallel shafts, the normal circular pitch, gear center distance, speed ratio and the number of teeth on the pinion are given. Find: Determine the helix angle. Schematic and Given Data: Pa= 0.5236 in. 35 Teeth Assumptions: 1. The helical gears are aligned and mounted to mesh along the pitch circles. 2. The gear teeth have standard involute profiles. Analysis: 1. The speed ratio = 2:1, and Np= 35. Hence, Ng = 70. 2. my = py/R = 0.167 in. 3. Center distance, c= (dy + dp)/2 = m(Np + Ng)2 = = 0.16785 +70) _ 19 19 in 2-cos 30° Comment: The helix angle of 30° is at the edge of the recommended range of 15 to 30 degrees.SOLUTION (16.4) Known: A helical spur gear with specified number of teeth, helix angle, y, and pressure angle, 0, is given. Find: Determine (a) the normal pressure angle, Qo, and the equivalent number of teeth, Ne, (b)_ the pressure angle and number of teeth on a spur gear of equivalent strength. Schematic and Given Data: Assumptions: 1, The helical gear teeth have standard tooth profiles. 2. The profile of the helical gear tooth in the plane normal to the tooth can be approximated by the standard profile of a spur gear tooth. Analysis: (a) From Eq. (16.2) n= tan'(tan 9 cos y) = tan” (tan 20° cos 25°), gn = 18.2° Ne = Nicos? y = 30/cos? 25° : Ne = 40.29 teeth (b) A spur gear of equal strength would have 40.29 teeth and 6 = 18.2° 16-4Comment: The increase in the number of teeth of the equivalent spur gear also reflects the fact that for the same pitch diameter and number of teeth, helical gear teeth can have greater bending strength than spur gear teeth. SOLUTION (16.5) Known: The normal range of spur gear face widths is given as a function of P. Itis desired that the helical gear face width be greater than or equal to twice the axial circular pitch. Find: (a) Determine the helix angle required to have a face width equal to 13/P and also equal to 2.2pa, (b) Compare the helix angle found in (a) with the common range of helix angles, viz. 15 to 30 degrees. Schematic and Given Data: rh VME Assumption: The helical gear teeth have standard tooth profiles. Analysis: (a) Given that b = 2.2pa= 8 poor. 22m 13 _ and Pa= tan y = Ptanw * BM? P tan y = P+ OF W = 28° . (b) The helix angle is within the 15° to 30° "commonly used range” . Comment: The range of helix angles possible under the conditions, b = 2.2pa , 9/P < b< 14/P and 15° < y < 30° is 26.3° < w< 30° 16-5SOLUTION (16.6) Known: For a pair of meshing helical gears mounted on parallel shafts, the normal circular pitch, gear center distance, speed ratio and the number of teeth on the pinion are given, Find: Determine the helix angle. Schematic and en Data: 35 Teeth Assumptions: 1. The helical gears are aligned and mounted to mesh along the pitch circles. 2. The gear teeth have standard involute profiles. Analysis: 1. The speed ratio = 2:1, and Np = 35. Hence, Ng = 70. 2. m, = py/t = 0.167 in. 3. Center distance, m(Np + Ny) © (dg + dp/2 = m(Np + Np)/2 =o 0.167(35 + 70) eos W 5. Hence, cos w = 0.974; y = 13.05° = 1303" Comment: The helix angle of 13°32’ is not in the recommended range of 15 to 30 degrees. 16-6SOLUTION (16.7) Known: For a simple planetary gear train the number of teeth on the sun and ring helical gears is given. Module of teeth and helix angle are also specified. Find: Determine the helix angle of the optional helical gearing using the same arm and gear helix angle, but with a 27 tooth sun and 111 tooth ring Schematic and Given Data: Number of Teeth | Normal ] Helix Sun | Ring | Module | Angle Original set:| 24 | 120 | 4mm |042rad Optional set:| 27 | 111 | 4mm/ ? Assumptions: 1. The sun, planet and ring gears are aligned and mounted to mesh along their pitch circles 2. All the gears have standard involute tooth profiles. Analysis: 1. Since the sun, planets, and ring gear all mesh together, all must have the same module and helix angle. 2. From the planetary gear arrangement, dring = dsun + 2dpianet, OF Nring = Neun + 2Nplanet 3. Hence, for the original gears, planet = 48 teeth, and for the replacement gears, Nplanet = 42 teeth. 16-7From Eq. (16.1), p = py/cos y. From Eq. (15.6), m = p/m (and mn = po/t), hence m = ma/cos y 5. From Eq, (15.4), d= mN In order to use the same arm, dsun + dplanet must have the same value for the two gear sets. Hence, m(Nplanet + Nsun) must be equal for the two sets. For the original set, m = jae and for the replacement set, m = cru : ect 48 + 24) = eos yl #27. y = 0.5053 rad = m9 . 6. Therefore, the helix angle for optional gears must be 0.5053 rad or 28.95° Comments: (2) In this problem the helix angle was fixed to conform with the requirement of keeping the same arm and normal module for the optional gearing as well as the original gearing. If instead, the module m was required to be kept the same, there would be a choice in the values for normal module and helix angle, since, m = mp/cos y. (2) Itis possible to check if the same arm could be used when, there are three equidistant planets on the arm. For the original gearing the number of teeth on the ring between planets is 120/3 = 40, and on the sun it is 24/3 = 8. Thus three equidistant planets can mesh with the sun and ring if the planet has an even number of teeth (see section 15.13). This is indeed the case since the number of teeth on the planet is equal to 48. Using a similar argument for the optional gearing, three equidistant planets can be checked and be found to mesh properly. SOLUTION (16.8) Known: double reduction helical gear arrangement is given. Number of teeth and module in the normal plane are specified. The helix angle of the high speed gears is specified. Find: Determine: (a) (b) (c) the total speed reduction provided by the four gears, the helix angle of the low speed gears, the helix angle of the low speed gears if the low speed gears had 24 and 34 teeth respectively but with the same module in the normal plane. 16-8Schematic and Given Data: 24 Teeth Input 60 Teeth Note: The helix angles are different for the gear sets. Assumptions: 1. The helical gears are aligned and mounted to mesh along the pitch circles. 2. The gear teeth have standard involute profiles Analysis: (@)_ Speed ratio = $0. $9: speed ratio = 5 . 60 24° 3 (b) For equal center distance, ¢ = 22 : ds = my(Np + Ng) = wy (Np + Ng) must be the same for the two gear pairs. Therefore, 3.955 (24 + 60) = {5 y20-+ 40); and the helix angle of the low speed gears, y = 0.3944 rad. . oe paaG (©) Similarly, sey (24 +34) = Se ag (24 + 60) y = 0.4680 rad a Comments: (1) The helix angle for the low speed gears is within the common range of helix angles (15° to 30°). 34 (2) The total speed ratio of the unit changes in part (c) to $¢. 34 = 3.54 16-9(3) Unlike spur gears, in part (c) it is possible to change the number of teeth on the helical gears while keeping the center distance and normal plane module the same because in helical gears the module is a function of the normal plane module as well as the helix angle. (4) To assure that each gear tooth in each gear pair meshes with every other tooth in that pair, an odd number of gear teeth could be used for the larger gears in both gear sets, SOLUTION (16.5D) Known: A pair of spur gears of specified numbers of teeth, face width and module is to be replaced with helical gears of the same module in the normal plane. Find: Determine a suitable combination of numbers of teeth and helix angle for the helical gears. Schematic and Given Data: Spur Gears: Helical Gears: Np =20 Ng = 60 b=50mm m=4.0mm w=0 Decisions: 1. The ratio Np/Np must remain 60/20 = 3, but with mp remaining 4.0 mm, fewer teeth will be required to preserve the same center distance. 2. Try Np= 18, Ng = 54. Assumptions: 1. Spur and helical gear sets are aligned and mounted to mesh along their pitch circles 2. All gears have teeth of standard involute tooth profile. Design Anal, m, 1. For equal center distance, © = m(Np + Ng) = <5c4 {Np + Ng) must be the same for irs; 4:9, = 40, rl = the spur and helical gear pairs: 55%5(20 + 60) = = (18 + 54). Therefore, y 25.84° = 0.4510 rad and lies in the commonly used range 15° to 30°. 16-104.0 p= ay = ee = 28.83 mm. Thus, b = 50 mm = 1.73pa which should be okay. 3. Therefore, one possible solution: Np = 18, Ne = 54, y = 0.4510 rad . Comment: Choice of a fewer number of teeth for the helical pinion and helical gear (with the same speed ratio) requires a larger helix angle for the same center distance and normal plane module. SOLUTION (16.10D) Known: A pair of spur gears of specified numbers of teeth, face width and module is to be replaced with helical gears of the same module in the normal plane, Find: Determine a suitable combination of numbers of teeth and helix angle for the helical gears. Schematic and Given Data: ns: 1, The ratio Ng/Np must remain 50/25 = 2, but with ma remaining 10.0 mm, fewer teeth will be required to preserve the same center distance 2. Try Np= 23, Ng = 46. Assumptions: 1. Spur and helical gear sets are aligned and mounted to mesh along their pitch circles. 2. All gears have teeth of standard involute tooth profile Design Analysis: 1. For equal center distance. c = m(Np + Ng) = oa NP + Ng) must be the same for 100 = 10.0 = the spur and helical gear pairs: 2 °(5(25 + 50) = JO4Z(23 + 46). Therefore, y = 23.07° = 0.4026 rad and lies in the commonly used range 15° to 30°. 16-11(10.0) 2. Pa= Sin y= sin 04026 = 80-17 mm. Thus, b = 115 mm = 1.43p, which should be okay, 3. Therefore, one possible solution: Np = 25, Ng = 50, y = 0.4026 rad. a Comment: The choice of a fewer number of teeth for the helical pinion and helical gear (with the same speed ratio) requires a larger helix angle for the same center distance and normal plane module. SOLUTION (16.11) Known: A helical gear pair has several geometric parameter values specified. Also, the rpm of the pinion and the horsepower transmitted are specified. Find: Determine (a) the gear dimensions @, P, dp, dg, Ng; (b) the pitch line velocity, V; (©). the gear forces Fi, Fr and Fy; (d)_ the gear face width b for b = 1.Spa. Schematic and Given Data: (7, 1250 pm Helical Gears: Np =20 ° = 20 16-12Assumptions: The tooth profiles are standard involutes. 2. The gears mesh along their pitch circles. 3 eu the tooth loads are transmitted at the pitch point and in the midplane of the ears 4, Friction losses can be neglected. Analysis: 1. Pressure angle, = tan"? (tan 20° /cos 25°) = 21.88° . 2. Diametral pitch, P = 12cos 25°: P = 10.88 teeth/in. 3. Pinion diameter, dp = 20/10.88: dp = 1.8382 in. 4. Ng = 20(2500 rpm/1250 rpm): Ng = 40 teeth a Ng/P = 40/10.88: dy = 3.6765 in. a dg 5. Pitch line velocity, V = ridgng/12 V = n(3.6765)(1250)/12 = 1203 fpm 6. Fr= 33,000(1)/1203: Fr = 27.4 Ib 7. Fy = 274 tan 21.88°: F, = 11.0 1b 8. Fa= 274 tan 25°: Fy = 12.8 Ib 9. pa= n/(10.88 tan 30°) = 0.500 in . 10. b= 1.5(0.500) : b = 0.75 in 7 Comments: (1) The axial Joad on the helical gears is less than in SAMPLE PROBLEM 16.1 because the helix angle is 25° and hence lower than the helix angle of 30° in the sample problem. (2) The ratio of the radial force and the tangential force is also lower than the ratio in the SAMPLE PROBLEM due to the lower helix angle (since Fr = F; tan 9 = Fi tan ga/tan ). 16-13SOLUTION (16.12) Known: A helical gear reducer transmits a given horsepower at a given speed ratio. Geometry and rpm of the gear are specified. Find: Determine Np, Wp (and hand of helix), 6, P, dp, dg, V, ratio b/pa and forces Fi, F, and F,. Sketch the forces acting on the pinion Schematic and Given Data: pop be bon 300 rpm Helical Gears: P=12 Electric no Motor, 2 hp Ve =25° RH ° %a=20 Speed ratio = 3.0 Pinion RK Assumptions: 1. The gears are mounted and aligned to mesh at the pitch circles. 2. The tooth profiles are standard involutes. 3. All the tooth loads are transmitted at the pitch point and in the midplane of the gears. Analysis: 1. For a 3.0 reduction ratio, Ne = 3Np: Np = 75/3 = 25 teeth . 2. Wp = 25° (left hand) a 3. tan dn=tan 6 cos ; hence, tan o = ™22,. 4 = 21.889 . cos 25°" 16-144. P=Pnacos wy = 12cos 25°, P = 10.88 teeth/in. a 25 5. dp= 7p pgs dp = 2.30 in,, dy = 3dp = 6.90 in 7 Tn, _ 6.90 SUL —_—C. . 7 33,000-W _ 33.0002) _ 15179 1 . V 341.9 21.79 tan 21.88° = 48.91 Ib 7 121.79 tan 25° = 56.79 Ib 7 8. pa=pltan y = 70P tan y = 7/10.88 tan 25° = 0.62 bile 9. Hence, 5 = 965 = 161 / Comments: (1) For helical gears, the diametral pitch, pressure angle as well as the helix angle of one gear fixes the corresponding values for the mating helical gear. (2) With sufficient helix angle, number of teeth and manufacturing accuracy, the actual loads on a tooth will be lower than those calculated here because of load sharing between adjacent teeth. 16-15SOLUTION (16.13) Known: A helical gear speed reducer is driven by a motor of specified speed and horsepower. Helix angle, normal pressure angle and pitch diameters of pinion and gear are given. Find: Determine the magnitude of Fi, Fr and Fy. Show the directions of the tooth loads on the pinion and gear. Schematic and Given Data: = 0.35 rad 140-65 on 7 1000 mpm y= 0.50 rad Motor, 1} hoe 1SkW MAO c 2109 PD cf} Output wu LU Load _ “th F t Fa Fy Helical Gears: Fr vy =0.50 rad F, 9q= 0.35 rad Fa 16-16Assumptions: 1. The gear teeth have a standard involute tooth profile. 2. The gears are aligned and mesh along their pitch circles. 3. All tooth loads are transferred at the pitch point and in the midplane of the gears. Analysis: 9549(W) _ 9549(15) 1. From Eq, (1.2): motor torque, T = "FS? = —Fog5— = 143.23 Nam ~ _ T _ 143.23 ° 2. Rag = Goas m= 4092 N . ano, tan 0.35 Fro Frtan 0 = Fe cos yy = 4092 0s 0.50 =1702N F, = Frtan y = 4092 tan 0.50 = 2235 N . Comment: Actual loads on a tooth will be lower due to load sharing between adjacent teeth if the gears have sufficient number of teeth and good manufacturing quality. SOLUTION (16.14) Known: A double reduction helical gear train has specified numbers of teeth, helix angles, normal plane module and normal plane pressure angle. Input shaft speed and transmitted horsepower are also specified. Find: Determine: (a) the speed ratio between input and output shafts, (b) all force components applied by the high speed pinion on the mating gear along with a sketch showing the forces, (©) all force components applied by the low speed gear on the mating gear along with a sketch showing the forces. Schematic and Given Data: 125 | 200 | 100) 25 Teeth R50 Tees w= 0.35 rad a 20 Teeth B Al y=0.50rad 50 Teeth ra Outpat-f 4g + iar Note: m= 4 mm for all gears 16-17Assumptions: ‘The gear teeth have standard involute tooth profiles. 2. The gears are aligned and mounted to mesh along their pitch circles, 3. All the tooth loads are transmitted at the pitch point in the midplane of the gears 4. Shaft bending deflections are negligible. Analysis: jo = 50.50 _ 1. Speed ratio = 39 52 = 5.0 2. From Eq. (1.2), motor torque, T = S5490W) 5 $5800) = 347.24 Nam Se ence enmtan enacts iene Vv hence motor pinion diameter, d = Nma/cos y = 20(4V/cos 0.50 = 91.16 mm pr, = = 347.24 N: : G2 = 0.09116/2 m= 7618 N . RH helix to mate y =0.50 rad with LH helix of ooo motor pinion A EY a Fy tan oy _ =Fuan =F oe =F, tan y = 7618 tan 0.50 = 4162 N a 5. Pinion torque = 347.24 N-m 55 ou 868.10 Nm 20 pinion diameter, d = Nmp/cos y = 25(4)/cos 0.35 = 106.45 mm. eesTe ee SG810E i Fiz ap Diogisp: Fis 16310N 7 16-18Fa 16,310 420.35 ~ 6338 N os Fr = Frtang = Rowe EE Fy = Fy tan y = 16,310 tan 0.35 = 5954.N Comments: (1) The axial loads on the high speed gear and low speed pinion are in opposite directions because of the opposite hands of the helix. Thus, the axial loads are somewhat balanced and the resultant axial load on the countershaft is 5954 N - 4162 N = 1792 N. The portion of the countershaft between the pinion and gear is ‘under tension. (2) The radial loads on both the pinion and gear on the countershaft tend to bend the shaft in the same direction. In practical cases the bending deflection of the countershaft must be checked to see if the deflection is small enough not to affect the alignment and meshing of the gears. SOLUTION (16.15D) Known: A web site address is given as http://www.bisongear.com, Find: Select a speed reducer for a 1/8 horsepower motor. List (a) available speed reducer ratios, (b) corresponding output torques for each gear ratio, and (c) maximum gearbox torque for each ratio. (d) Determine the maximum gear ratio for a 1/8 hp motor at 1725 rpm for an overload torque of three times the output torque. Analysis: The web site provides the following information: (a) available speed reducer ratios: Ratio: 1 to 12.7 19.1 22.7 28.8 35.8 42.9 50.8 60.2 64.6 16-19(b) corresponding output torque for each gear ratio: 12.7 53 in Ib 19.1 81in Ib 22.7 96 in Ib 28.8 121 in Ib 35.8 148 in Ib 42.9 178 in Ib 50.8 209 in Ib 60.2 245 in Ib 64.6 260 in Ib (©) maximum gearbox torque for each ratio: ie 176 in Ib 19.1 226 in Ib 22.7 190 in Ib 28.8 242 in Ib 35.8 295 in Ib 42.9 275 in Ib 50.8 209 in Ib 60.2 270 in Ib 64.6 260 in Ib d@) maximum gear ratios for 0.125 hp motor at 1725 rpm: Only the 12.7:1 ratio reducer would handle the output torque increase of 3 without overloading since (53 in Ib X 3) = 159 in Ib which is less than the manufacturers maximum rating of 176 in Ib. Comment: The manufacturer should be consulted to determine the expected life of the speed reducer. Speed reducers are normally expected to operate for 10,000 to 15,000 hours at rated load and speed before failure but if life is important, it would be best to obtain this information in writing from the manufacturer. SOLUTION (16.16) Known: A helical gear pair transmits power from a motor of specified rpm to a load of specified rpm involving moderate shock. Geometry, material and manufacturing precision of the gears are specified. Find: Estimate the horsepower rating of the gear pair for 10” pinion revolutions with 99% reliability and a safety factor of 2 based on bending and surface fatigue of the teeth. 16-20Schematic and Given Data: 1500 rpm (=) Helical Gears: ¢ Np =25 Ng=? b= 18in. 4, = 20° AISI 8620 steel, surface Pi,=8 carburized (Appendix C-7) =26° Manufacturing precision ve corresponding to curve B of Fig. 15.24 Assumptions: ‘The gears have teeth of standard involute profile 3. The degrees of accuracy in mounting and alignment ofthe gears corresponds to a mounting factor Km = 1.6 (from Table 15.2). 3. Fatigue failure will originate under the carburized surface of the gear teeth (to justify a surface factor, Cs = 4. The gears operate at a temperature less than 160° F. 5. The degree of manufacturing precision permits consideration of load sharing between adjacent gear teeth 6. Manufacturing precision justifies the use of curve C in Fig. 15.24 to estimate velocity factor Ky. 7. For the uniform source of power and moderate shock load, Ko = 1.25. 8. The surface stress can be estimated by approximating the contact surfaces by cylinders. 9. The surface stress is unaffected by the presence of a lubricant or by the sliding friction in the contact region. Analysis: 1. For bending fatigue, from Eq. (15.18): Sn = Sa’ CLCGCs kr kt kms a = SESH yayay(o. 814)(1)(1.4) = 74 ksi with Sy 130 ksi from Appendix C-7, ky = 0.814 for 99% reliability and kms = 1.4 for one way bending. 2. P=Pacos y=8 cos 26° = 7.190 3. Pinion pitch diameter, dp = 3 = 775 = 3.48 in 4. Pitch line velocity, Vv = 3:48 48311500) = 1366.6 fpm 16-21FP From Eq. (16.12): +r Ky Ko (0.93 Km) Let o = Sn = 74 ksi, and introduce SF = 2. From Fig. 16.8, and considering the pinion, J = (0.47)(1.000) = 0.47 From Fig. 15.24, Ky = 1.47 for curve B. For the uniform source of power and moderate shock load, Ko = 1.25 substituting: 74,000 = eee 2 (147)(1.25)(0.93 X 1.6); therefore, F= 1592 Ib for bending fatigue For surface fatigue, from Eq. (15 Su = Ste CLi Ce = Ste (VD) case hardne: 61 Re = 660 Bhn hence, Ste = (0.4)650 - 10 = 250 ksi = Su From Eq. (15.9): Aig tog? + ling? tpg? ~ c sin Po CR= tay = 38 + addendum = 1.74 + 5 tg = 1:879in nag = 1.743) +745 5 36 in. tan @ = tan On /cos = tan 20% cos 26° hence, $ = 22.0° 74 cos 22° = 1.6133 in. 1.74 x 3)cos 22° = 4,840 in = (n/7.19) cos 22° = 0.405 in. 1.74(1 + 3) = 6.96 in. wana miaiaade sac eaeaee — ¥1.879° - 1.6133° + V5.36* - 4.840° - 6.96 sin 22° _ Re ee Sin P= 1.627 sin cos | _R sin 22° cos 22° va \R+1 From Eq, (15.23): T= 7 (3 = 0.1302 substituting, with SF = 2 applied to x cos 26° Ot = Si = 250,000 = 2300 V (7-8-48)(0.1302) |0.95 x 1 Tal x V(1.47)(1.25).93 x 1.6) from which Fy = 3330 Ib 16-2210. Bending fatigue limits the horsepower rating in this case: F,V__ 1592(1366.6) ,000 = 33,000 = 69.93 hp a Ww Comments: (1) In this case the carburized surfaces of the gear teeth give it a high surface durability while leaving the core material with a relatively smaller endurance strength to resist bending fatigue. Thus, the bending fatigue consideration limits the horsepower rating of the gear pair. If the manufacturing accuracy were of less precision, the bending strength will be reduced because of a lower surface factor, C; and bending stress will be increased because of a lower geometry factor, J (since the load sharing assumption cannot be justified) and a high velocity factor Ky @Q SOLUTION (16.17) Known: A pair of helical gears are mounted on parallel shafts with the pinion driven by an electrical motor involving light shock at specified rpm and the gear driving a load involving moderate shock. Geometry, material and manufacturing precision of gears are specified Find: (a) Determine the helix angle, (b) Estimate the horsepower that can be transmitted for 107 revolutions with 99% reliability and a safety factor of 2.5 based on bending and surface fatigue Schematic and Given Data: 1200 rpm Helical Gears: N,=32 P c=7.5 in. Ng=48 b= 4in, 0, = 20° Pinion Material: Steel, 400 Bhn a Gear Material: Steel, 350 Bbn ye? Manufacturing precision corresponding to curve C of Fig. 15.24 Assumptions: 1. The gears are mounted at the theoretical center distance and have standard involute teeth. 2. The teeth have machined surfaces (for use in estimating the surface factor, Cs). 16-233. The mountings are less rigid than the best possible; the gears are not precision gears but tooth contact can be expected to be full face. This gives a mounting factor Km = 1.7 from Table 15.2 4. The endurance limit for the gear and pinion materials can be estimated as S, = (Ba) W ksi The gears operate at a temperature below 160° F. The surface stress can be estimated by approximating the contact surfaces by cylinders. 7. The surface stress is unaffected by the presence of a lubricant or by the sliding friction in the contact region. au Analysis: 1, Fora7.5 in, center distance and Np = 32, Ng = 48: dp + dg = 15 in. and dp/dg = 32/48 ; hence dy =9 in, dp = 6 in. N 2. From Eq. (16.4): d= proog yi 9 Soe, For P = Pa cos y = 6cos 27.27° = 5.33 We estimate Sp from Eq. (15.18). With Sp’ = Sy/2, Cy = 1, Ca = 1, kr = 0.814, ky =I, kms = 1.4 and Cs = 0.62 (gear), 0.66 (pinion), from Fig. 8.13 (assuming a machined surface). hence, y = 27.27° / Re Sn (pinion) = (299)¢1)(1)(0.62)(0.814)(1)(1.4) = 70.6 ksi Sa (gear) = 423 (1)(1)(0.66)(0.814)(1)(1.4) = 65.8 ksi. ndn_ x(6.0)(1200) —ULULUL—L—~——T 6. To equate Sp to 6 (from Eq. 16.12), and using SF = 2.5: For the pinion, J = (0.48)(0.98) = 0.47, and for the gear, J = (0.49)(0.96) = 0. From curve C of Fig. 15.24, Ky = 1.87 and from Table 15.1, Ko = 1.5 5. Pitch line velocity, V = F,(5.33) pinion: 6 = 70,600 = (1.87)(1.5)(.93 x 1.7) (4)(0.47) = 2246 Ib . 33) gear: 6 = 65,800 = Fa 1-BTUS)(93 x 1.7) F; = 2093 Ib / 16-247. To check surface fatigue capacity, we estimate Sy from Eq. (15.25): Ste = 0.4 (2504400) 19 = 140 ksi Su = Ste CLi Cr = 140(1)(1) = 140 ksi 8. We determine CR from Eq. (15.9) rap = QP + addendum = 3.0 + hy = 3.1876 in. tag = 3.0198) + hy = 4.6876 in tan o = tan Op/cos y = tan 20° /cos 27.27° hence, @ = 22.27° Top = 3.0 cos 22.27° = 2.6666 in. | cos 22.279 = 4.1643 in, Pb = pcos >= _ cos 22.27° = 0.5454 cR = 43.1876" - 2.6666" + V4.6876" - 4.1643” - 7.5sin 22. 0.5454 sin 22.2' 9. We determine oy; from Eq. (16.13) and equate to Siz with 15 3:3] = 0.1052 - ____{_cos 27.27° ou = 140,000 = 2300 4/ (4Y(6.03(0.1053) (0.95 x 1.9369 x ¥(1.87)(1.5)(0.93 x 1.7) from which F; = 1747 Ib. 7 10. We find that surface fatigue is the limiting factor with F; = 1747 Ib. FyV__ (1747)(1885) Therefore the horsepower rating, W = 33.599 = 33,000 = The horsepower that can be transmitted by the gear set is approximately 100 hp. Comments: (1) In estimating the forces transmittable by the teeth, both the pinion and gear were analyzed separately with respect to bending fatigue because the pinion and gear material hardness were different. However, in the case of surface fatigue, the strength of the pinion and gear materials were averaged and compared to the corrected Hertz stress because the maximum surface strength depends on the hardness of the pair of surfaces in contact and averaging the hardness has been empirically found to be acceptable for Bhn < 500. (2) The use of spur gears instead of helical gears for this application would have resulted in a lower horsepower rating because of a lower J, a higher mounting factor and a lower contact ratio resulting in lesser load sharing between teeth. 16-25SOLUTION (16.18D) Known: A pair of helical gears is used to transmit a specified horsepower between an electric motor and a load which is free of shock. The rpm of the motor and the load are specified, Find: Determine a design of the gears specifying pitch, numbers of teeth, helix angle, pressure angle, face width, manufacturing accuracy, material and hardness. Schematic and Given Data: Input, 100 hp Helical Gears: 2400 rpm. + 800 rpm, 40 hr/week operation we? 100% efficiency Material ? Decisions: 1, The pinion should normally have at least 18 teeth. Choose Np = 20. 2. Choose AISI 4320 steel for both gears, carburized to give properties listed in Appendix C-7. Select SF = 2.2 and 90% reliability for bending fatigue. Select y= 25°, On = 20° standard full depth teeth. Choose a manufacturing accuracy giving velocity factor, Ky = 1.5 Choose mounting accuracy to give Km = 1.4. Choose surface fatigue failure safety factor lower than for bending fatigue (as failure is not catastrophic). Select SF = 2 with 99% reliability (Cr = 1). Select b = 12/P. A diametral pitch P value > 5 will be selected thus giving a gradient factor Co=l RORY eo Assumptions: Fatigue failure will originate under the surface justifying use of Cs = 1 The gears operate at a temperature below 160° F. Friction forces on the teeth can be neglected. Surface stresses are unaffected by presence of lubricant. The tooth profile at the contact region can be approximated by cylindrical surfaces to estimate surface stress. Uaone 16-26Design Analysis: 2 2 w With Np = 20, Ne = 20500 = From Eq. (15.18): Sn = Sa’ CL Co Cs kr kt kms Ss aie = 5t= [usc =1,c6=1,Cs=1, = 0.897, Cede (888 ncyayoasnee.n 91.7 ksi ndyn where V = “8” = RG0P)2400) _ 19 seoyp 12 12 33,000(100) 12566/P (2.2) = 578P i= - FP From Eq, (16.12): 6 = bp Ky Ko (0.93Km) Setting, 6 = Sp = 91.7 ksi Since we selected wy = 25° , J = 0.46 with Ky = 1.5, Ko=1, Km= 1.4 and b = 42 (S78P)P 91,100 = T39py(0.46) (1-5KIN.93 x 14) P=765 oe eem 6s COSW cos 25 We choose Pn = 8 (which will give increased SF, and also justify the earlier assumption of Cg =1). Also, P = 7.25 and V = 12,566/7.25 = 1733 fpm. From. Fig. 15.24, curve B precision is required. To check for surface fatigue, with On = 20°, 6 = tan(tan gp/cos wp) = tan"1(tan 20%/cos 25°) = 21.88° 16-27_sioese RR | IR+1) sin 21.88° cos 21 97 we find CR from Eq. (15.9) dp PR = 2.7586 in. rp = 1.38 in P ron tabegss 17 fag = 1.38) + hg = 4.278 in. Top = Tp COs @ = 1.38 cos 21.88° = 1.281 in The = 3 Mop = 3.842 in, =p cos @ = 535g cos 21.88° = 0.402 381 + 3) = 5.52 in. = L. 71.281" +¥4.2787 ~ 3.842" > - 5.52sin 21.88° 0.402 = 1.585 Re 33,000 W 33,000(100) _ 1904 15 for SF = 1.8, and substituting in Eq. (16.13): on= x V(LS\(1(93 X14) = 191,186 psi with OH = Su, solve Eq.(15.25) for Cii, From Appendix C-7, case hardness = 59 Rc ~ 610 Bhn and so Ste = (0.4)(610) - 10 = 234 ksi Setting ou = Ste CLi CR 191 = 234 Cyi (1): Cri = 0.816 From Fig. 15.27, life ~ 10? cycles 9 weeks wosks 800 rpm x 60 "8 x 49 BE = 108 cycles/year Hence, life ~ 10 years. Since, SF = 1.8 and 99% reliability were used, this answer is probably okay. Specifications for the helical gear pair are: Ph = 8, Np = 20, Nz = 60, W = 25°, On = 20°, b= 1-5/8 in., curve B manufacturing accuracy, AISI steel, carburized per ‘Appendix C-7. xs: 16-28Comments: (1) Choice of a larger number of teeth for the pinion, say 25, would have increased the pitch line velocity, V to 15707/P while decreasing F; to 462/P and increasing J to 0.475. With the same estimate of Ky, P can be calculated as 7.18. We find that P is not very sensitive to changes in Np in this range because o is a function of P?/Np. Thus. choice of a small number of teeth has the additional advantage of producing smaller gear diameters and hence a smaller center distance. (2) Choice of a different helix angle affects the geometry factor J. A helix angle of about 20° gives the maximum J for the pair of gears with 20 teeth and 60 teeth and will result in the lowest bending stress. But decreasing the helix angle from 25° to 20° reduces I from 0.1297 to 0.1263 thus producing a higher surface stress. SOLUTION (16.19) Known: A pair of straight tooth bevel gears mounted on perpendicular shafts transmit a specified horsepower at specified pinion and gear rpm. Geometry of the gears are specified Find: With a sketch of the pinion and gear, determine: (a) the direction of rotation (assumed), (b) the direction and magnitude of torque applied by their shafts, (c)_ the direction and magnitude of tooth force components. Schematic and Given Data: Bevel Gears: Pinion = iP jy) } Gear 1000 rpm E400 pm 16-29T = 450 Ib ft Assumptions: 1, The gears are mounted to mesh along their pitch cones. 2. Friction losses can be neglected. 3. All the tooth loads are transmitted at the pitch point midway along the tooth face. 4. The tooth profiles are standard involutes. Analysis: N 000 rpm) 1 dp=sP= 86 in; Ol =15in Yp = 90° - 3 par = oh - sin Yp 6 - 2 sin 21.8° = 5.26 in 4. Vay = Rday n/12 = 2(5.26)1000/12 = 1377 fpm 5. F = 33,000 W _ 33,000(35) a a BIT Vay For the pinion, Fa = F, tan @ sin ¥, For the pinion, Fr =F; tan © C08 Yp = 839 Ib a 839%(tan 20°)(sin 21.8°): Fy=1131b 839(tan 20°)(cos 21.89): Fr = 283 1b _ 33,000 W _ 33,000(35) 2nny ~ 2x (1000) 184 Ib ft op = 33100089) _ sey et Te= On 400) = 46016 Comments: (1) Consideration of friction losses between the teeth will reduce the tangential load transmitted to the gear and hence the torque output. 16-30(2) Unlike helical gears, in bevel gears the axial load of one gear contributes to the radial load on the other gear. (3) The relationships between the pinion and the gear tooth forces will be more complex for non-perpendicular rotation axes SOLUTION (16.20) Known: A pair of straight tooth bevel gears mounted on perpendicular shafts transmit a specified horsepower at a specified pinion rpm. Geometry of the gears and the mounting arrangements for the gear shaft are specified. Find: Make a sketch of the gear and shaft assembly as a free body diagram in equilibrium Schematic and Given Data: 1500 rpm ae, Bevel Gears: [Pinion — 50 bp A |B Np =30 Flexible Coupling Ng= 60 to Machine Gear b=3in. @ =20° P=6 3in 3 in. 1148 3in. 3 in. Horizontal plane Assumptions: 1. The gears are mounted to mesh along their pitch cones and have standard involute tooth profiles. 16-31wpe re Friction losses can be neglected. All the tooth loads are transmitted at the pitch point midway along the tooth face Shaft deflection is negligible. Only torque is transferred from the gearshaft to the machine by the flexible coupling, = @=10in dp = 6 in d Yp = tan! ae = tan! 2 = 68.2° p dg.ay = dg - bsin Yp = 10 - 3 sin 63.4° = 7.32 in. Vay = Mday n/12 = n(7.32)(750)/12 = 1437 fpm Re sme We 2380060) = 1148 Ib Fa=Frtan 6 sin = 1148 tan 20° sin 63.4° = 374 Ib F; =F; tan 6 cos 7 = 1148 tan 20° cos 63.4 = 187 Ib Torque = Fi day/2 = 1148(7.32/2) = 4202 Ib in. = 350 Ib ft For the vertical plane (see schematic) SMA =0: By G1AG.69 - 1873) _ 135% Ey =0: Ay = 187 + 135 = 322 Ib For the horizontal plane (see schematic) An= Bu = 574 lb 187 1b 374 135 1148 Ib 350 Ib ft (from flexible coupling) 374 Ib (thrust Comments: (1). The flexible coupling from the gear shaft to the machine allows us to assume that no additional forces are applied from the machine to the shaft (which can impose additional bearing loads). 16-32(2) In this problem, the radial load, Fr, is about 16% of F; and the thrust load is about %o of Fy. For the given shaft angle, these percentages are determined entirely by the pitch cone angle and the pressure angle and the pitch cone angle in turn depends only on the speed ratio. Thus, the percentages of radial and thrust loads is fixed for a given shaft angle, pressure angle and speed ratio when standard straight tooth bevel gears are used. SOLUTION (16.21) Known: An electric motor of specified rpm drives a load involving moderate shock through a straight tooth bevel gear pair. Geometry, material and manufacturing accuracy of the gears are specified and mounting is fairly rigid with the gear straddle mounted and the pinion overhung. Find: Estimate the horsepower that can be transmitted for a specified design life and reliability Schematic and Given Data: Pinion \) = Gear 1200 rpm 4 Bevel Gears: Steel pinion and gear Np =20 with hardness of 300 Bhn, Ng=50 Manufacturing accuracy -- Curve B, Fig. 15.23 b=1in. Design Life: 7 years, o =20° 1500 hr/yr operation, p=10 99% reliability : Assumptions: The gears are mounted to mesh along their pitch cones and the teeth have standard involute profiles. Tredgold’s approximation is valid. Surface stresses are unaffected by the presence of lubricant and sliding friction in the contact region. The gear teeth have a machined finish ‘The gears operate at a temperature below 160° F. wh wp 16-33Analysis: 1. Surface fatigue is usually the limiting factor with through-hardened steel gears, so we check that first. 2 From Eq. (15:24): on = Cpa/ gh Ko Km with Cp= 1.25(2300) = 2829 in. (given) a =Np/P = 20/10 = 2 in. 1 = 0.082 (Fig. 16.15 for Np = 20, Ng = 50) V=nDn= 1f2.9| 9) 1200 = 6283 fpm v= 132 (cutve B of Fig. 15.24) 1.25 = 1.2 (estimated from Table 16.1) We have oy = 9830 /F, 3. From Eq, (15.25): SH = See CLi CR Ste = 0.4300) - 10 = 110 ksi (from Table 15.5) For a life of 1200 rpm X 60 X 1500 X 7 = 7.56 X 108, Fig. 15.26 shows Ci = 0.82 For 99% reliability, Cr = 1 Hence, Su = 110(0,82)(1) = 90.2 ksi Equating: 9830 YF, = 90,200; hence, F, = 84.2 Ib ‘Therefore, horsepower transmittable is W = (84.2 1b)(628.3 fpm)/33,000 = 1.6 hp 4. To be sure, we check bending fatigue strength: From Eg. (15.17): oath BT Pky Ko Km J=0.245 (from Fig. 16.13) F, (10) 1(0.243) Hence, o = = 80.8 5. From Eq. (15.18): Sn = Sn’ CLCGCs kr ke kms Sn’ = (250)Bhn = 250(300) = 75,000 psi 5 (bending load) (for P > 5) 0.7 {by assumption of machined finish in Fig. 8.13) (1.32)(1.25)(1.2); Kms = 1.4 hence, Sn = 59,829 psi Equating: 80.8 F; = 59,829 F,=740 Ib Hence the teeth have about 9 times as much capacity in bending fatigue as in surface fatigue 6. Therefore, horsepower that can be transmitted by the gear pair is 1.6 hp. i 16-34Comments: a) To produce a balanced design of the gears, the horsepower rating for the gears based on bending fatigue and surface fatigue must be approximately equal. However, as the bending fatigue failure is catastrophic in comparison to surface fatigue failure, the factor of safety for bending fatigue failure is kept higher than that for surface fatigue failure as in this problem. Operation of the gear set for 2000 hr/yr instead of 1500 hr/yr reduces the horsepower capacity of the gear set to 1.52 hp from the original 1.6 hp. This represents only a 5% decrease in rating for a 33% increase in operating cycles. The reason for this is the characteristically low slope of the Ci versus log (cycles) graph in Fig. 15.27 beyond 10° cycles. SOLUTION (16.22D) Known: A pair of straight tooth bevel gears mounted on perpendicular shafts transmit a specified horsepower at a specified pinion and gear rpm. The geometry of the gears is specified. Find: Select appropriate materials, hardness and manufacturing precision for the gears Schematic and Given Data: Pinion Bevel Gears: i= =e 35 hp Decisions: 1. Choose steel gears with Curve B (Fig. 15.24) manufacturing precision. (tentatively) 2. Specify mounting type, accuracy and rigidity corresponding to Km = 1.2 in Table 16.1 3. The face width, b, will be chosen as per Eq. 16.17 to be less than 10/P and L/3, where L is the pitch cone length. 4. Select a safety factor of 1.5 for both bending and surface fatigue failure. 5. Design life is 40 hr/wk, 50 wk/yr for 10 yrs with 99% reliability. Assumptions: af Friction losses can be neglected. 16-35¢) 2 4 5 Tredgold’s approximation is valid Surface stresses are unaffected by the presence of lubricant and sliding friction in the contact region. The gears operate at a temperature below 160 °F. There is no shock loading for the gears, so the overload factor, Ko = 1.0. Design Analysis: From Problem 16, 14, Vay = 1377 fpm. By selecting Curve B manufacturing precision in Fig. 15.24, Kv with Np = 36, Ng = 364200| = 1 = 0.105 (from Fig. 16.15) From Problem 16.14, dg = 15 in. , Yg = 68.2°, therefore, (from Fig. 16.9), dJ2 p=! 215 - go8in, 90, We select bs = 2.69, and b < 12 = 1.67; say, b = 1-5/8 in. Substituting in Eq. (15.24), and applying SF = 1.5 to check for surface fatigue (with Fy = 839 Ib from Problem 16.19): _ (1.5 x 839) 5 oH = 1.23(2300)/ T6315} A7SHL2) = 131,962 psi Pinion life required = 1000 rpm x 60 min/hr x 40 hr/week x 50 week/year x 10 years = 1.2 x 10° cycles, and 99% reliability. Therefore, from Fig. 15.27, Cri = 0.79 From Eq. (15.25): SH = Ste Cii Cr. On = 131.96 ksi = Ste (0.79)(1): Ste = 167 ksi, is required. From Table 15.5: Sfe = 167 = 0.4 Bhn - 10 Hence, 442 Bhn surface hardness (approximately 46R,) is required. Zo check the bending fatieue requirement: From Fig. 16.13: J= Using SF = 1.5 and 99% Teliabilty and substituting in Eq. (15.17) _ 15x 839)6) ~(1625)0.31) From Eq. (15.18): Sn = Sn’ CLCGCs kr kt kms 6 = 26.5 = So’ (1)(1)Cs (0.814)(1)(1.4) Sn! Cs = 23.2 ksi (1.475)(1)(1.2) = 26,531 psi 16-3610. The value of Sy’ Cs is low enough that any steel (with "curve B" manufacturing surface finish) satisfying the surface fatigue requirement is satisfactory for bending fatigue. Therefore, the material and manufacturing specification is: Any carburized steel from Appendix C-7; "Curve B” manufacturing precision. Comments: () @) Since any carburized steel in Appendix C-7 would more than satisfy both surface and bending strength requirements, this suggests that b could be less than 1-5/8 in, and manufacturing precision could be less than "Curve B". Alternatively, the assumption of no shock loading and Km = 1.2 could be relaxed. ‘The selection of a material based on surface fatigue considerations results in a very low value for the product Sq’ Cs for bending fatigue. This implies that the actual safety factor for bending fatigue failure is substantially larger than the assumed value of 1.5. SOLUTION (16.23D) Known: A pair of straight tooth bevel gears mounted on perpendicular shafts transmit a specified horsepower at specified pinion rpm. Geometry of the gears and the mounting arrangement for the gear shaft are specified. Find: Select appropriate materials, hardnesses and manufacturing precision for the gears. Schematic and Given Data: Bevel Gears: 50 hp Flexible Coupling toMachine ‘~ Gear 3 in. 3 in. 16-371148 Ib 350 Ib ft (from flexible 314 coupling) Decisions: 1. Tentatively choose steel gears with curve B (Fig. 15.24) manufacturing precision 2. Specify mounting (Table 16.1) corresponding to Km = 1.2. 3. The face width, b, will be chosen as per Eq. 16.17 to be less than 10/P and L/3, where L is the pitch cone length. 4. Select a safety factor of 1.5 for bending fatigue failure and 1.3 for surface fatigue failure. 5. Design life is 40 hr/wk, 50 wk/yr for 10 yrs with 99% reliability. Assumptions: Friction losses can be neglected. 3 ‘Tredgold's approximation is valid. 3. Surface stresses are unaffected by the presence of lubricant and sliding friction in the contact region. 4. The gears operate at a temperature below 160 °F. 5. There is medium shock loading in the driven machinery corresponding to an overload factor, Ko = 1.5 in Table 15.1. Design Analysis: From Problem 16.14, Vay = 1437 fpm, therefore from curve B in Fig. 15.24, Ky = 1.48, also I = 0.087 (from Fig. 16.15). 2. From Problem 16.14, dg = 10 in., yg = 63.49. — siny, ~ sin 63.4 Therefore, L (from Fig. 16.9) 3 = 5.59 in. L 3. Weselect b < 1.86 in,, and b <4 = 1.67 in say, b = 4. To satisfy the surface fatigue requirement, from Eq. (15.24), with Ft = 1148 Ib, dp ='5 in. (from Problem 16.15) / 3x 1148) = 2 awe i on = 1.23023004/ 7 Eaayo-oET TE ABML-SU-2) = 212,164 psi 5. Pinion life required = 1500 rpm x 60 min/hr x 40 hr/week x 50 weeks/year x 10 years = 1.8 x 10° cycles, and 99% reliability. 16-38 -5/8 in.From Eq. (15.25): Su = Ste Cui Cr. Equating stress and strength gives 212.1 ksi = Sre (0.78)(1); hence, Ste = 272 ksi is required. From Table 15.5: Sfe = 272 = 0.4 Bhn - 10. Hence, 705 Bhn surface hardness (approximately 61R.) is required. . 6. To check the bending fatigue requirement: from Fig. 16.13, J = 0.27 With the use of SF = 1.5 and 99% reliability and substituting in Eq. (15.17) with F; = 1148 Ib: (1.5.x 1148)(6) “TesSVO TT (1-48)C1-5)C.2) = 62,734 psi From Eq. (15.18): Sn = Sn’ CLCGCs kr ke kins 62.7 = Sn’ (1)(1)Cs (0.814)(1)(1 4): Sn’ Cs = 55.0 ksi 7. Acase hardened steel with 61R¢ case and Sy = 110 ksi is minimally required (assuming C; = 1 because of failure originating below the surface.) 8. AISI 1118, carburized (Appendix C-7) and "Curve B" manufacturing precision are chosen. o= Comment: The choice of gear material from standard steel materials in Appendix C- 7 was limited to AISI 1118 because it was the only steel satisfying the high hardness and strength requirements (61 Re case hardness and 110 ksi ultimate strength). If we want more flexibility in the choice of gear material or a higher safety factor, we must change either the face width, manufacturing accuracy or the mounting accuracy and Tigidity of the gears, if other geometric parameters are to remain the same. The other possibility is to reduce the design life of the gears. SOLUTION (16.24D) Known: A web site address is given as http://www.andantex.com. Find: (a) Select a right angle drive that provides a 2:1 ratio for a 1250 rpm output speed at 100 in. Ib of output torque () Select a right angle drive producing less than an 80 db noise level. Analysis: The web site provides the following information: (a) Only the Size 4 AngiGear 2:1 right-angle drive would match. (b) Only the Size 1 (73 dB) and Size 2 (74 dB) AnglGear right-angle drives have a 4B rating below 80 dB. 16-39SOLUTION (16.25D) Known: A web site address is given as http://www.grainger.com. Find: Select a spiral bevel gear set with 14 pitch gears and a 2:1 ratio. List the manufacturer, description, and price of the gear set. Analysis: The following unit has a 2:1 ratio and 14 pitch gears. Mfg. Name: Boston Gear Description: Spiral Bevel Gear Set, Hardened, 14 Pitch 2:1 Ratio Price: $89.35 SOLUTION (16.26) Known: An automobile with a standard differential is stuck on an icy road so that the car does not move. The speedometer reads 75 mph. Find: Determine the normal car speed corresponding to the rotation of the spinning wheel Assumptions: 1. The speedometer reads the input arm speed of the differential gear train. 2. When the automobile is stuck on the icy road, one wheel is stationary while the other wheel is spinning. 3. "Normal" speed corresponds to rotation of the wheels without stip on the ground. Analysi: 1. With slip on the icy road, input arm speed = average wheel speed = 0 + slipping wheel speed 2 2. Under normal conditions, normal speed corresponds to slipping wheel speed = 2(input arm speed) = 2(75) = 150 mph Comment: This problem illustrates that the design of the differential involves consideration of the situation when the rotation speed of the gears are twice their rotation speed under normal operation. Higher rotation speeds imply that a higher velocity factor, Ky has to be used in the design of the gears; however, the torque transmitted will be very low since the wheel is slipping. 16-40SOLUTION (16.27) Known: An automobile with a standard differential turns sharply left. Driving radius of left wheel and distance between wheels is specified. Find: Determine the rotating speeds of each driving wheel as fractions of drive shaft speed. Schematic and Given Data: dr shaft Differential Assumptions: 1. The wheels roll on the ground without slip. 2. The width of the wheels is substantially smaller than the distance between the wheels. Analysis: 1. With @ and @ being the rotation speeds of the left and right wheel respectively, © _ 20m 2 0, = B15 mi HENCE, 1 = 0.9360 2. Since the driveshaft speed wdrsh is the average of the speeds of the wheels, 0} + @ = 2dérsh; and 0.93 wr + We = 2 Warsn Hence, @r = 1.0363@arsh, and . 1 = 0.9637 @arsh . Comment: — The torques transmitted to the left and right wheels are equal since the planets in the standard differential transmit equal forces to the gears connected to the left and right axle (assuming the turning radius is constant and neglecting friction in planet bearings) 1641SOLUTION (16.28) Known: A standard differential has the torque applied to the arm defined as T and the radius from the axis of the axle shafts to the resultant gear tooth force defined as r. Find: Draw a free body diagram in equilibrium with load magnitudes and directions shown for: (a) the assembly composed of the arm, two pinions and shafts, (b) the portion of the right axle with attached gear, (c)_ the portion of the left axle with attached gear. Schematic and Given Data: 6 Arm (input member) Differential train FBD (planctary bevel gear set) (With arm fixed, wp/ Ws =~ 1 exactly.) Assumption: Friction losses in the gears and bearings are negligible. Analysis: © U= upward (out-of-paper) forces = T/4r © D = downward (into-paper) forces = T/4r 16-42Comment: Consideration of friction forces in the gears and bearings will reduce the output torques to the wheels. The torque to each wheel will still remain equal provided the total friction losses are divided symmetrically about the pinions. SOLUTION (16.25) Known: A worm and mating gear of specified diametral pitch and numbers of teeth are given. Find: Determine: (a) the gear ratio, (b) the gear diameter, (c) lead of worm, (@)_ minimum normally recommended diameter of shell worm, (e) corresponding lead angle of worm, (f) corresponding shaft center distance. Schematic and Given Data: Assumption: The worm and worm gear axes are mutually perpendicular and have standard tooth profiles. Analysis: (a) Gear ratio = Ng/Nw = 50/2: Gear ratio = 25 (b) Gear diameter, dg = Np/P = 50/10: dg = 5 in © p= pi Lead, L = 25 = 275: L = 0.6283 in (@) Minimum worm diameter, min dw = 2.4p + 1.1 = 2.75 + 1.1: min dw = 1.854 in, (e) For the corresponding lead angle, A, tan 4 = Litdw = 0.6283/n(1.854): 2 = 6.16° 16-43dp +d, (The corresponding center distance, ¢ = = LSShs5.0 O. 6 = 3,427 in Comment: In this case, the minimum diameter of the worm, dy = 1.854 in. is not within the range recommended by Eq. (16.28) of c9875/3.0 = 0.979 and c°875/1.7 = 1.728 SOLUTION (16.30) Known: A worm and mating gear of specified numbers of teeth are mounted at a given center distance. Find: Determine P, dg, dw, and A such that the worm diameter is as small as Eq. (16.28) will permit and still use an integral gear diametral pitch. Schematic and Given Data: Assumption: The worm and worm gear axes are mutually perpendicular and have standard tooth profiles Analysis: 1. From Eg. (16.28), min dw = c9875/3 = 89-875/3 = 2.0563 in., say 2 in. 2. dg=2c-dw = 16-2=14in. For Ng =55, this requires P = 93 = 3.92 teeth/inch. For integral P, select P= 4. Then dp = 55/4; dg = 13.75 in.; dw = 2c - dg ; dw = 2.25 in, s 3. From Eq, (10.1, modified), tan 4 = Lindy where L = p = 1/4