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Chapter 15
15-1 Given: Uncrowned, through-hardened 300 Brinell core and case, Grade 1, NC = 109 rev of
pinion at R = 0.999, N P = 20 teeth, NG = 60 teeth, Q v = 6, Pd = 6 teeth/in, shaft angle
90°, n p = 900 rev/min, J P = 0.249 and JG = 0.216 (Fig. 15-7), F = 1.25 in, S F =
S H = 1, K o = 1.
Mesh d P = 20/6 = 3.333 in
dG = 60/6 = 10.000 in
Eq. (15-7): vt = π(3.333)(900/12) = 785.3 ft/min
Eq. (15-6): B = 0.25(12 − 6) 2/3 = 0.8255
A = 50 + 56(1 − 0.8255) = 59.77
√ 0.8255
59.77 + 785.3
Eq. (15-5): Kv = = 1.374
59.77
Eq. (15-8): vt, max = [59.77 + (6 − 3)]2 = 3940 ft/min
Since 785.3 < 3904, K v = 1.374 is valid. The size factor for bending is:
Eq. (15-10): K s = 0.4867 + 0.2132/6 = 0.5222
For one gear straddle-mounted, the load-distribution factor is:
Eq. (15-11): K m = 1.10 + 0.0036(1.25) 2 = 1.106
Eq. (15-15): (K L ) P = 1.6831(109 ) −0.0323 = 0.862
(K L ) G = 1.6831(109 /3) −0.0323 = 0.893
Eq. (15-14): (C L ) P = 3.4822(109 ) −0.0602 = 1
(C L ) G = 3.4822(109 /3) −0.0602 = 1.069
Eq. (15-19): K R = 0.50 − 0.25 log(1 − 0.999) = 1.25 (or Table 15-3)
√
C R = K R = 1.25 = 1.118
Bending
Fig. 15-13: 0.99 St = sat = 44(300) + 2100 = 15 300 psi
sat K L 15 300(0.862)
Eq. (15-4): (σall ) P = swt = = = 10 551 psi
SF K T K R 1(1)(1.25)
(σall ) P F K x J P
Eq. (15-3): W Pt =
Pd K o K v K s K m
10 551(1.25)(1)(0.249)
= = 690 lbf
6(1)(1.374)(0.5222)(1.106)
690(785.3)
H1 = = 16.4 hp
33 000
15 300(0.893)
Eq. (15-4): (σall ) G = = 10 930 psi
1(1)(1.25)
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10 930(1.25)(1)(0.216)
WGt = = 620 lbf
6(1)(1.374)(0.5222)(1.106)
620(785.3)
H2 = = 14.8 hp Ans.
33 000
The gear controls the bending rating.
Chapter 15 381
15-3 AGMA 2003-B97 does not fully address cast iron gears, however, approximate compar-
isons can be useful. This problem is similar to Prob. 15-1, but not identical. We will orga-
nize the method. A follow-up could consist of completing Probs. 15-1 and 15-2 with
identical pinions, and cast iron gears.
Given: Uncrowned, straight teeth, Pd = 6 teeth/in, N P = 30 teeth, NG = 60 teeth, ASTM
30 cast iron, material Grade 1, shaft angle 90°, F = 1.25, n P = 900 rev/min, ◦
√ φn = 20 ,
one gear straddle-mounted, K o = 1, J P = 0.268, JG = 0.228, S F = 2, S H = 2.
M Kv W t P
σ = =
I /c FY
Then
14.7
(K v ) CI = (K v ) steel = 0.7(K v ) steel
30
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Our modeling is rough, but it convinces us that (K v ) CI < (K v ) steel , but we are not sure of
the value of (K v ) CI . We will use K v for steel as a basis for a conservative rating.
Eq. (15-6): B = 0.25(12 − 6) 2/3 = 0.8255
A = 50 + 56(1 − 0.8255) = 59.77
√ 0.8255
59.77 + 1178
Eq. (15-5): Kv = = 1.454
59.77
(σall ) P F K x J P
Eq. (15-3): W Pt =
Pd K o K v K s K m
2250(1.25)(1)(0.268)
= = 149.6 lbf
6(1)(1.454)(0.5222)(1.106)
149.6(1178)
H1 = = 5.34 hp
33 000
Gear bending
JG 0.228
WGt = W Pt = 149.6 = 127.3 lbf
JP 0.268
127.3(1178)
H2 = = 4.54 hp
33 000
The gear controls in bending fatigue.
H = 4.54 hp Ans.
Chapter 15 383
2
35 355 1.25(5.000)(0.086)
Thus, W =
t
= 91.6 lbf
1960 1(1.454)(1.106)(0.59375)(2)
91.6(1178)
H3 = H4 = = 3.27 hp Ans.
33 000
Rating Based on results of Probs. 15-3 and 15-4,
H = min(5.34, 4.54, 3.27, 3.27) = 3.27 hp Ans.
The mesh is weakest in wear fatigue.
15-5 Uncrowned, through-hardened to 180 Brinell (core and case), Grade 1, 109 rev of pinion at
R = 0.999, N P = z 1 = 22 teeth, NG = z 2 = √ Q v = 5, m et = 4 mm, shaft angle
24 teeth,
90°, n 1 = 1800 rev/min, S F = 1, S H = S F = 1, J P = Y J 1 √ = 0.23, JG = Y J 2 =
0.205, F = b = 25 mm, K o = K A = K T = K θ = 1 and C p = 190 MPa .
Mesh d P = de1 = mz 1 = 4(22) = 88 mm
dG = m et z 2 = 4(24) = 96 mm
Eq. (15-7): vet = 5.236(10−5 )(88)(1800) = 8.29 m/s
Eq. (15-6): B = 0.25(12 − 5) 2/3 = 0.9148
A = 50 + 56(1 − 0.9148) = 54.77
√ 0.9148
54.77 + 200(8.29)
Eq. (15-5): Kv = = 1.663
54.77
Eq. (15-10): K s = Yx = 0.4867 + 0.008 339(4) = 0.520
Eq. (15-11) with K mb = 1 (both straddle-mounted),
K m = K Hβ = 1 + 5.6(10−6 )(252 ) = 1.0035
From Fig. 15-8,
(C L ) P = ( Z N T ) P = 3.4822(109 ) −0.0602 = 1.00
(C L ) G = ( Z N T ) G = 3.4822[109 (22/24)]−0.0602 = 1.0054
Eq. (15-12): C xc = Z xc = 2 (uncrowned)
Eq. (15-19): K R = Y Z = 0.50 − 0.25 log (1 − 0.999) = 1.25
√
C R = Z Z = Y Z = 1.25 = 1.118
From Fig. 15-10, C H = Zw = 1
Eq. (15-9): Z x = 0.004 92(25) + 0.4375 = 0.560
Wear of Pinion
Fig. 15-12: σ H lim = 2.35H B + 162.89
= 2.35(180) + 162.89 = 585.9 MPa
Fig. 15-6: I = Z I = 0.066
(σ H lim ) P ( Z N T ) P Z W
Eq. (15-2): (σ H ) P =
SH K θ Z Z
585.9(1)(1)
=√ = 524.1 MPa
1(1)(1.118)
2
σH bde1 Z I
Eq. (15-1): WP =t
Cp 1000K A K v K Hβ Z x Z xc
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Chapter 15 385
Rating of mesh is
Hrating = min(10.37, 9.29, 4.90, 4.93) = 4.90 kW Ans.
with pinion wear controlling.
15-7
σ
σ
all all
(a) (S F ) P = = (S F ) G =
σ P σ G
(sat K L /K T K R ) P (sat K L /K T K R ) G
=
(W Pd K o K v K s K m /F K x J ) P
t (W Pd K o K v K s K m /F K x J ) G
t
In wear
1/2
sac C L CU W t K o K v K m Cs C xc
= Cp
SH K T C R 22 Fd P I 22
t
Squaring and solving for W gives
2 2 2
sac C L C H Fd P I
W =
t
2
(2)
SH K T2 C 2R C 2P 22 K o K v K m Cs C xc 22
Equating the
right-hand sides of Eqs. (1) and (2) and canceling terms, and recognizing
that C R = K R and Pd d P = N P ,
we obtain
2
Cp SH (sat ) 11 (K L ) 11 K x J11 K T Cs C xc
(sac ) 22 = 2
(C L ) 22 SF CH N P Ks I
For equal W t in bending and wear
2
√
2
SH SF
= =1
SF SF
So we get
Cp (sat ) P (K L ) P J P K x K T Cs C xc
(sac ) G = Ans.
(C L ) G C H N P I Ks
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(c)
σc, all σc, all
(S H ) P = (S H ) G = =
σc P σc G
Substituting in the right-hand equality gives
[sac C L /(C R K T )] P [sac C L C H /(C R K T )]G
=
C p W t K o K v K m Cs C xc /( Fd P I ) C p W t K o K v K m Cs C xc /( Fd P I )
P G
Denominators cancel leaving
(sac ) P (C L ) P = (sac ) G (C L ) G C H
Solving for (sac ) P gives,
(C L ) G
(sac ) P = (sac ) G
CH (1)
(C L ) P
From Eq. (15-14), (C L ) P = 3.4822N L−0.0602 , (C L ) G = 3.4822( N L /m G ) −0.0602 . Thus,
(sac ) P = (sac ) G (1/m G ) −0.0602 C H = (sac ) G m 0G.0602 C H Ans.
This equation is the transpose of Eq. (14-45).
15-8
Core Case
Pinion ( H B ) 11 ( H B ) 12
Gear ( H B ) 21 ( H B ) 22
Given ( H B ) 11 = 300 Brinell
Eq. (15-23): (sat ) P = 44(300) + 2100 = 15 300 psi
From Prob. 15-7,
J P −0.0323 0.249 −0.0323
(sat ) G = (sat ) P m G = 15 300 3 = 17 023 psi
JG 0.216
17 023 − 2100
( H B ) 21 = = 339 Brinell Ans.
44
2290 15 300(0.862)(0.249)(1)(0.593 25)(2)
(sac ) G = = 141 160 psi
1.0685(1) 20(0.086)(0.5222)
141 160 − 23 600
( H B ) 22 = = 345 Brinell Ans.
341
.
(sac ) P = (sac ) G m 0G.0602 C H = 141 160(30.0602 )(1) = 150 811 psi
Chapter 15 387
388 Solutions Manual • Instructor’s Solution Manual to Accompany Mechanical Engineering Design
Pinion case
(sac ) P = 341(373) + 23 620 = 150 813 psi
150 813(1)
(σc, all ) P = = 134 895 psi
1(1)(1.118)
134 895 2 1.25(3.333)(0.086)
W =
t
= 689.0 lbf
2290 1(1.374)(1.106)(0.593 75)(2)
Gear case
(sac ) G = 341(345) + 23 620 = 141 265 psi
141 265(1.0685)(1)
(σc, all ) G = = 135 010 psi
1(1)(1.118)
135 010 2 1.25(3.333)(0.086)
W =
t
= 690.1 lbf
2290 1(1.1374)(1.106)(0.593 75)(2)
15-10 The catalog rating is 5.2 hp at 1200 rev/min for a straight bevel gearset. Also given:
N P = 20 teeth, NG = 40 teeth, φn = 20◦ , F = 0.71 in, J P = 0.241, JG = 0.201,
Pd = 10 teeth/in, through-hardened to 300 Brinell-General Industrial Service, and
Q v = 5 uncrowned.
Mesh
d P = 20/10 = 2.000 in, dG = 40/10 = 4.000 in
πd P n P π(2)(1200)
vt = = = 628.3 ft/min
12 12
K o = 1, S F = 1, SH = 1
2/3
Eq. (15-6): B = 0.25(12 − 5) = 0.9148
A = 50 + 56(1 − 0.9148) = 54.77
√ 0.9148
54.77 + 628.3
Eq. (15-5): Kv = = 1.412
54.77
Eq. (15-10): K s = 0.4867 + 0.2132/10 = 0.508
Eq. (15-11): K m = 1.25 + 0.0036(0.71) 2 = 1.252
where K mb = 1.25
Eq. (15-15): (K L ) P = 1.6831(109 ) −0.0323 = 0.862
(K L ) G = 1.6831(109 /2) −0.0323 = 0.881
Eq. (15-14): (C L ) P = 3.4822(109 ) −0.0602 = 1.000
(C L ) G = 3.4822(109 /2) −0.0602 = 1.043
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Gear:
(sac ) G = 125 920 psi
125 920(1.043)(1)
(σc, all ) = = 117 473 psi
1(1)(1.118)
117 473 2 0.71(2.000)(0.078)
W =
t
= 156.6 lbf
2290 1(1.412)(1.252)(0.526 25)(2)
156.6(628.3)
H4 = = 3.0 hp
33 000
Rating:
H = min(3.8, 3.3, 2.7, 3.0) = 2.7 hp
Pinion wear controls the power rating. While the basis of the catalog rating is unknown,
it is overly optimistic (by a factor of 1.9).
15-11 From Ex. 15-1, the core hardness of both the pinion and gear is 180 Brinell. So ( H B ) 11
and ( H B ) 21 are 180 Brinell and the bending stress numbers are:
(sat ) P = 44(180) + 2100 = 10 020 psi
(sat ) G = 10 020 psi
The contact strength of the gear case, based upon the equation derived in Prob. 15-7, is
2
Cp SH (sat ) P (K L ) P K x J P K T Cs C xc
(sac ) G =
(C L ) G C H S F N P I Ks
Substituting (sat ) P from above and the values of the remaining terms from Ex. 15-1,
2290 1.52 10 020(1)(1)(0.216)(1)(0.575)(2)
= 114 331 psi
1.32(1) 1.5 25(0.065)(0.529)
114 331 − 23 620
( H B ) 22 = = 266 Brinell
341
The pinion contact strength is found using the relation from Prob. 15-7:
(sac ) P = (sac ) G m 0G.0602 C H = 114 331(1) 0.0602 (1) = 114 331 psi
114 331 − 23 600
( H B ) 12 = = 266 Brinell
341
Core Case
Pinion 180 266
Gear 180 266
Realization of hardnesses
The response of students to this part of the question would be a function of the extent
to which heat-treatment procedures were covered in their materials and manufacturing
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Chapter 15 391
prerequisites, and how quantitative it was. The most important thing is to have the stu-
dent think about it.
The instructor can comment in class when students curiosity is heightened. Options
that will surface may include:
• Select a through-hardening steel which will meet or exceed core hardness in the hot-
rolled condition, then heat-treating to gain the additional 86 points of Brinell hardness
by bath-quenching, then tempering, then generating the teeth in the blank.
• Flame or induction hardening are possibilities.
• The hardness goal for the case is sufficiently modest that carburizing and case harden-
ing may be too costly. In this case the material selection will be different.
• The initial step in a nitriding process brings the core hardness to 33–38 Rockwell
C-scale (about 300–350 Brinell) which is too much.
Emphasize that development procedures are necessary in order to tune the “Black Art”
to the occasion. Manufacturing personnel know what to do and the direction of adjust-
ments, but how much is obtained by asking the gear (or gear blank). Refer your students
to D. W. Dudley, Gear Handbook, library reference section, for descriptions of heat-
treating processes.
15-13 A design program would ask the user to make the a priori decisions, as indicated in
Sec. 15-5, p. 786, SMED8. The decision set can be organized as follows:
A priori decisions
• Function: H, K o , rpm, mG , temp., N L , R
√
• Design factor: n d (S F = n d , S H = n d )
• Tooth system: Involute, Straight Teeth, Crowning, φn
• Straddling: K mb
• Tooth count: N P ( NG = m G N P )
Design decisions
• Pitch and Face: Pd , F
• Quality number: Q v
• Pinion hardness: ( H B ) 1 , ( H B ) 3
• Gear hardness: ( H B ) 2 , ( H B ) 4
First gather all of the equations one needs, then arrange them before coding. Find the required hardnesses, express the consequences of the
392
chosen hardnesses, and allow for revisions as appropriate.
budynas_SM_ch15.qxd
stress)
17:42
Associated Bhn = 44 Bhn = 44 Bhn = 341 Bhn = 341 1
(sat ) P − 5980
(sat ) G − 5980
(sac ) P − 29 560
(sac ) G − 29 560
hardness
48 48 363.6 363.6
Chosen ( HB ) 11 ( HB ) 21 ( HB ) 12 ( HB ) 22
hardness
44( HB ) 11 + 2100 44( HB ) 21 + 2100 341( HB ) 12 + 23 620 341( HB ) 22 + 23 620
New tabulated (sat1 ) P = (sat1 ) G = (sac1 ) P = (sac1 ) G =
strength 48( HB ) 11 + 5980 48( HB ) 21 + 5980 363.6( HB ) 12 + 29 560 363.6( HB ) 22 + 29 560
2 2
σall (sat1 ) P (K L ) P (sat1 ) G (K L ) G (sac1 ) P (C L ) P (C H ) P (sac1 ) G (C L ) G (C H ) G
Factor of n 11 = = n 21 = n 12 = n 22 =
safety σ s11 K T K R s21 K T K R s12 K T C R s22 K T C R
Note: SF = n d , S H = SF
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Chapter 15 393
Eq. (15-47): ( FW ) max = 2 2(7)0.125 = 2.646 in
394 Solutions Manual • Instructor’s Solution Manual to Accompany Mechanical Engineering Design
(d) Eq. (15-52): Amin = 43.2(8.5) 1.7 = 1642 in2 < 1700 in2
Eq. (15-49): Hloss = 33 000(1 − 0.7563)(2.18) = 17 530 ft · lbf/min
Assuming a fan exists on the worm shaft,
1725
Eq. (15-50): h̄ C R = + 0.13 = 0.568 ft · lbf/(min · in2 · ◦ F)
3939
17 530
Eq. (15-51): ts = 70 + = 88.2◦ F Ans.
0.568(1700)
budynas_SM_ch15.qxd
15-15 to 15-22
Problem statement values of 25 hp, 1125 rev/min, m G = 10, K a = 1.25, n d = 1.1, φn = 20°, ta = 70°F are not referenced in the table.
Parameters
12/05/2006
FAN FAN
HW 38.2 38.2 38.2 38.2 38.2 38.0 41.2 41.2
HG 36.2 36.2 36.2 36.2 36.2 36.1 37.7 37.7
Hf 1.87 1.47 1.97 1.97 1.97 1.85 3.59 3.59
NW 3 3 3 3 3 3 3 3
NG 30 30 30 30 30 30 30 30
KW 125 80 50 115 185
Cs 607 854 1000
Cm 0.759 0.759 0.759
Cv 0.236 0.236 0.236
VG 492 492 492 492 492 563 492 492
WGt 2430 2430 2430 2430 2430 2120 2524 2524
t
WW 1189 1189 1189 1189 1189 1038 1284 1284
f 0.0193 0.0193 0.0193 0.0193 0.0193 0.0183 0.034 0.034
e 0.948 0.948 0.948 0.948 0.948 0.951 0.913 0.913
( Pt ) G 1.795 1.795 1.795 1.795 1.795 1.571 1.795 1.795
Pn 1.979 1.979 1.979 1.979 1.979 1.732 1.979 1.979
C-to-C 10.156 10.156 10.156 10.156 10.156 11.6 10.156 10.156
ts 177 177 177 177 177 171 179.6 179.6
L 5.25 5.25 5.25 5.25 5.25 6.0 5.25 5.25
λ 24.9 24.9 24.9 24.9 24.9 24.98 24.9 24.9
σG 5103 7290 8565 7247 5103 4158 5301 5301
dG 16.71 16.71 16.71 16.71 16.71 19.099 16.7 16.71
395
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