stresses and deformations in involute spur gears by finite element ...
4: WORKED OUT PROBLEMS ON INVOLUTE SPUR …nptel.ac.in/courses/112106137/pdf/2_4.pdf · Lecture –...
Transcript of 4: WORKED OUT PROBLEMS ON INVOLUTE SPUR …nptel.ac.in/courses/112106137/pdf/2_4.pdf · Lecture –...
Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras
Module 2 - GEARS
Lecture – 4: WORKED OUT PROBLEMS ON INVOLUTE SPUR GEARS Content 4.1 Introduction
4.2 Gear Calculation -Worked example 1
4.3 Gear Calculation -Worked example 2
4.1 INTRODUCTION
In the earlier lectures, the definition of gear, gear terminology, interference, methods of
eliminating interference, standard tooth systems for spur gears, profile shifted gears,
involutometry and design of gear blanks were dealt in detail. With the background of the
above knowledge, solving of simple gear problems will be dealt in this lecture.
4.2 GEAR CALCULATION – Worked out example 1 In a drive, a velocity ratio of 2.5 with a centre distance of 70 mm is desired. (a) Determine
the pitch diameter of the gears with 20o full depth involute teeth; (b) Is there any
interference in the system? If so, how will you avoid it? (c) Determine the contact ratio, (d)
Find the dedendum, addendum, root diameters and the tip clearance, (e) If the centre
distance is increased by 1.5%, what will be the new pressure angle?
• Given Data: i = 2.5; C = 70 mm; φ = 20o;
• It is an involute full depth tooth system ;
• To be found: m = ?; Z1 = ? ; d1 = ?; Interference exists or not ?;
Z2 = ?; d2 = ?; CR = ?
We know that,
C = (r1 +r2) = 0.5 m ( Z1 + Z2) = 0.5 m (Z1 + i Z1) = 70 mm
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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras
From the above, i.e., m x Z1 = 40
• Possible solutions for standard modules as can be seen from the table:
Solution I:
• m = 2mm, Z1 = 20, Z2 = i. Z1 = 2.5 x 20 = 50
• d1 = m Z1 = 2 x 20 = 40 mm
• d2 =i d1 = 2.5 x 40 = 100 mm
STANDARD MODULES IN mm:
0.3 0.4 0.5 0.6 0.7 0.8 1.0
1.25 1.5 1.75 2.0 2.25 2.5 3.0
3.5 4.0 4.5 5.0 5.5 6.0 6.5
7 8 9 10 11 12 13
14 15 16 18 20 22 24
26 28 30 33 36 39 42
45 50 Further increase is in terms of 5 mm
• Minimum number of teeth that can engage with the gear of 50 teeth without
interference is given by,
2 21 1 2 2
4k(z + k)z + 2 z z =
sin φ
• For full depth gears, k = 1. Substituting the values Z2 = 50, φ = 20o in the above
equation,
2
1 1 2 o
4 x 1(50 1)z 2 z x50
sin 20
2z + 100 z 1744 0
1 1
• i.e., Z1min = 15 is the minimum permissible number of teeth without interference.
Since from the above it is seen that, Z1 > Z1min no interference will occur.
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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras
Fig 4.1. Path of Contact
Contact ratio, CR:
Referring to fig. 4.1, the path of contact:
La = ua + ur
2 2 2 2 2 2
1 1 2 2 1 2 L ( r a ) r cos ( r a ) r cos ( r r ) sin
a
Substituting the values,
o oL ( ) cos ( ) cos ( )sina
. mm
2 2 2 2 2 220 2 20 20 50 2 50 20 20 50 20
9 798
o
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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras
Now CR can be calculated with the formulae below,
L L . .a aCR .
opcos m cos .x x cos
9 798 9 7981 660
5 9012 20 For full depth tooth, the various values calculated are as shown below:
Addendum: a = 1m = 1x2 = 2mm Dedendum: b = 1.25m = 1.25x2 = 2.5 mm Clearance: c = 0.25 m = 0.25x2 = 0.5 mm Pinion root circle diameter: dr1 = d1- 2b = 40 – 2x2.5 = 35 mm Pinion addendum diameter: da1 = d1+ 2a = 40 + 2x2 = 44 mm Gear root circle diameter: dr2 = d2- 2b = 100 – 2x2.5 = 95 mm Gear addendum diameter: da2 = d2+ 2a = 100 + 2x2 = 104 mm
Solution II:
The centre distance is given by, C = (r1 +r2) = 0.5 m ( Z1 + Z2) = 0.5 m (Z1 + i Z1)
= 70 mm
• Simplifying, m x Z1 = 40
• Another possible solution for standard module from the table is,
m = 2.5 mm, Z1 = 16, Z2 = i x Z1 = 40,
d1 = m Z1 = 2.5x16=40 mm,
d2 = m Z2 = 2.5 x 40 =100 mm
• Minimum number of teeth that can engage the gear of 40 teeth without interference
is given by,
2 21 1 2 2
4 k (z +k)z + 2 z z =
sin φ
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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras
• For full depth gears k = 1. Substituting Z2 = 40, φ = 20o, in the above equation,
4(40 + )2z + z x =1 1 2 osin
12 40
20
2z + 80 z 1402 01 1
• i.e., Z1min = 15 is the minimum permissible without interference. Since Z1 > Z1min, no interference will occur. Contact ratio, CR :
Referring to the fig. 4.1, the path of contact is given by,
La = ua + ur
2 2 2 2 2 2
1 1 2 2 1 2 L ( r a ) r cos ( r a ) r cos ( r r ) sin
a
Substituting the values,
2 2 2 o 2 2 2 o oL (20 2.5 ) 20 cos 20 (50 2.5 ) 50 cos 20 (20 50 ) sin 20a
11.854 mm
Now CR can be calculated as,
11 854 11 854
1 6075 9012 5 20
L L . .a aCR .opcos m cos .x . x cos
For full depth tooth the values are,
Addendum : a =1m = 1x2.5 =2.5mm
Dedendum : b =1.25m =1.25x2.5 = 3.125 mm
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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras
Clearance: c = 0.25 m = 0.25x2.5 = 0.625 mm
[Pinion root circle diameter: dr1= d1- 2b = 40 – 2x3.125 = 33.75 mm
Pinion addendum diameter: da1= d1+ 2a = 40+2x2.5 = 45 mm
Gear root circle diameter: dr2= d2- 2b = 100 – 2x3.125 = 93.75 mm
Pinion addendum diameter: da2= d2+ 2a = 100 + 2x2.5 = 105 mm
New Pressure angle Ø when the centre distance C is increased by 1.5% is given by:
Ø = cos-1( r1 cos20o / r1 1.015) = 22.21o
4.3 GEAR CALCULATIONS- Worked out example 2
A 21 teeth gear has 20o full depth involute teeth with a module of 12mm. (a) Calculate the
radii of pitch circle, base circle and addendum circle (b) Determine the tooth thickness at
base circle, pitch circle and addendum circle. Comment on the top land thickness.
brrcos
inv tan
t1t 2 r ( inv inv
2 r1
) Fig 4.2 Involutometry The terminologies used in the problem are explained in earlier chapters. Hence the figures
referred are self explanatory.
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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras
Fig. 4.3 Layout for tooth thickness determination at any point on tooth profile
Given Data: Pressure angle, Ø =20o = 0.349 rad., Z1 = 21, m= 12mm.
Solution:
r1 = 0.5.m.Z1 = 0.5 x 12 x 21=126 mm
rb = r1.CosØ = 126 x cos 20o = 118.4 mm
a = 1m = 1 x 12 = 12 mm
ra = r1 + a = 126 + 12 = 138 mm
p1 = π.m = π. 12 = 37.14 mm
t1 = 0.5 p1 = 0.5 x 37.14 = 18.57 mm
inv Ø = tan Ø - Ø = tan 0.349 – 0.349 = 0.015 rad
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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras
At the base circle Øb= 0, Hence tooth thickness tb at the base circle is:
t1t 2 r ( inv inv )
b b b2 r1
18.572x 118.4 x( 0.015 0 ) 21.0 mm
2x126
At the addendum circle the pressure angle is given by,
Øa=cos-1(rb/ra) =cos-1(118.4 /138) =0.54 rad
inv Øa = tan 0.54 – 0.54 = 0.059
Hence tooth thickness ta can be calculated as,
t1t 2 r inv inv
a a 2 r1
a
Substituting the values,
.t x x . . . ma x
18 57
2 138 0 015 0 059 8 202 126
m
Minimum recommended top land thickness is,
tamin = 0.25 m = 0.25 x 12 = 3 mm
From the above, we know that, ta > tamin, hence the tip thickness is adequate and
permissible.
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