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Pinion
Gear
Lecture Steps:
1. Quick review, gear geometry (Chapter 8) 2. Transmitted loads 3. Review bending stress, bending stress number, St, allowable bending stress number, Sat and adjusted allowable bending stress number, Sat. 4. Review contact stress number, Sc, allowable contact stress number, Sac and adjusted allowable contact stress number Sac. 5. Overview gear design steps. handout 6. Example(s) gear design!!
(overhead)
Quick review:
Compute transmitted load, Wt, pitch line speed, vt, quality number, Qv, and other factors required for calculating bending stress and contact stress. 8. Calculate St and required Sat. Does material in 2 meet Sat #? No then select new material or define new geometry (step 4). If yes, continue to 9. 9. Calculate Sc and required Sac. Does material in 2 meet Sac? No then select new material to meet Sac and Sat or define new geometry (step 4). If yes, continue to 10. 10. Summarize design
Problem # 9.61
A gear pair is to be a part of the drive for a milling machine requiring 20 hp with the pinion speed at 550 rpm and the gear speed to be between 180 and 190 rpm.
Given:
Driven = Milling Machine Power = 20 hp Pinion Speed = 550 rpm Output Speed = 180 -190 rpm 185 rpm Continuous Use = 30,000 hours
Find:
Compact Gear Design
Solution:
Design Power:
Assume: Light Shock Driver and Moderate Shock Driven Ko = 1.75 (Table 9-5, page 389) PDesign = (Ko)(PInput) = (1.75)(20hp) = 35hp
Trial Size
Pick Sizes Pd = 5 T/in Dp = 4.80 in DG = 14.2 in Np = 24 teeth NG = 71 teeth
Center Distance
Tangential Load
Face Width
Assumptions:
Design Decisions Quality Number, Qv = 6 (Table 9-2, Page 378) Steel Pinion Cp = 2300 (Table 9-9, Page 400) Steel Gear
More precision, higher quality number!
Softer material, more relative deformation, therefore contact area increases and stress decreases
Geometry Factors
I = .108
Size Factor
ks = 1.0 since Pd 5
Page 389
For this problem, specify a solid gear blank KB = 1.00 KB = 1.00 for mB = 1.2 or larger
We are assuming a solid gear blank for this problem, but if not then use:
Safety Factor
SF = 1.25 (Mid-Range)
Hardness Ratio
CH =1.00 for early trials until materials have been specified. Then adjust CH if significant differences exist in the hardness of the pinion and the gear.
Reliability
Page 396
Dynamic Factor
Kv
Page 393
Kv
Qv comes from Figure 9-21 Kv can be calculated like in above equations or taken from Figure 9-21. Equations are more accurate.
Design Life
Ncp = (60)(L)(n)(q) L = 30,000 hours from Table 9-7 n = 550 rpm q = 1 contacts Ncp = (60)(30,000 hours)(550 rpm)(1 contact) = 9.9x108 cycles
Page 395
Page 403
Gear:
Gear:
Pinion Bending Satp = 34,324.5 psi = HB 270 Gear Bending SatG = 28,741.9 psi = HB 215
Go to appendix A3 or A4 and spec out material that meets this hardness requirement! Example AISI 1040, Temper at 900 F
Pinion Contact Sacp = 261,178 psi Gear Contact SacG = 245,609 psi
These Stresses are WAY too HIGH! Values are off table!
Summary of Problem
Contact stresses are too High. Must iterate until stress are low enough until a usable material can be found.
NOTE: Contact Stress generally controls. If material cannot be found for bending, contact stress is too high! Iterate! Decrease Pd and increase F Excel is a GREAT tool to use for these Iterations. This problem solved after third iteration using Excel