Lecture 1. Design of a Helical-Bevel Gear Box Part-I. For. Students

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1 Lecture 1 (20 March, 2017) Design of a Helical-Bevel Gear Box Part-I For Design of Machine Elements Practice (ME39602) Students 1

2 Design of Machine Elements Practice (ME39602) 3 rd. Design Assignment : Design of an Industrial General Purpose Reduction Gear Unit (Monday Group : Spring Semester 2017) [Duration (5 days) x 3 hours between Mar 20 to Apr 17, 2017] March 16 : PPT Demonstration Nalanda Complex March 23 : 1st. Layout Drawing- Drawing Hall MED (Plan view of all Gears in their respective positions. Follow the plan view as in problem sheet. IMP-Do not put any dimension unless instructed.) March 30 : PPT Demonstration Nalanda Complex April 06 : Drawing Continuation - Drawing Hall MED (Plan view of the whole gear box. As in problem sheet. Dimensions which are not determined by design or selection of components, are to be taken proportionally following the view in problem sheet.) April 13 : Drawing Continuation/Class Test/Viva - Drawing Hall MED Department of Mechanical Engineering IIT, Kharagpur 2

3 Design of an Industrial General Purpose Reduction Gear Unit : Tasks : Design all gears and pinions of a two stage general purpose industrial gear box. Verify the design of the intermediate gear shaft with the helical & bevel - pinion & gear with the following data. Photographic view (Example) Two Stage Bevel-Helical Horizontal Input-Output. Select the bearings and draw plan, elevation and side views of the assembled gear sets placed in lower housing Make a bill of material. 2 Assembled plan view (Top cover removed) (Not of the same one as above) 3

4 Design of an Industrial General Purpose Reduction Gear Unit : Tasks (contd.) : Data: TheTWO- TWO stage (1 st stage Bevel and 2 nd. Stage helical) reduction gear box has the following specifications. (20 to 22 different problems). GROUP POWER INPUT OUTPUT DUTY OVERHAUL (kw) RPM RPM Sub Description TIME Group I A,E,I,M, Precision, A, B, C, D, Q, U Intermittent, 2 years No shock II E, F,G,H III I, J, K, L IV M,N,O,P B,F,J,N,R General, Continuous, Medium shock C,G,K,O, S, V General, Intermittent, Heavy Shock D,H,L,P,T Precision, Continuous, Medium Shock LUBRICATION Forced Oil Sump Oil Sump Forced V Q,R,S,T VI Horizontal o input and vertical output (Forced Lubrication) U, V In general non co-axial horizontal input and output (except otherwise mentioned) Assembled plan view (Top cover removed) (Not of the same one as below) For helical gear (pinion) number of teeth may be taken as low as 15 & for straight bevel it is 17. Photographic view (Example) Two Stage Bevel-Helical Horizontal Input-Output. 4

5 (Monday Group : Spring Semester 2017) [Duration (5 days) x 3 hours between Mar 20 to Apr 17, 2017] Formation of Group & Problem Distribution. Each Group to be of 4Students(Not less than 3 & Not more than 4). You would write name & roll number of all members (one of them to be mentioned as group leader) in a piece of paper and drop in my locker (No. 32, MED) by 22 nd. March, 2017 (Wednesday). A listmentioning problem code against the name of group leader will be send to you THROUGH ERP by 23 th.march. You would complete gear calculations before coming to the class on 27 th. March. (Also, you have to submit a free hand sketch (as in problem sheet- Fig.-3), one copy per group, of plan view of the whole gear box, as in the problem sheet. Dimensions which are not determined by design or selection of components, are to be taken proportionally p following the view in problem sheet 5

6 Design of an Industrial General Purpose Reduction Gear Unit : Gear Design: Module (m, in meter) can be estimated as: For helical gear: m helical 3 2T cos Sd Y cc For straight tooth bevel gear: m bevel 3 Sd cc v w v w 2T Y (1 ) o Photographic view (Example) Two Stage Bevel-Helical li l Horizontal Input-Output. t t c w c v = Velocity factor, = 1 for precision gears & no shock, 12f 1.2 for general purpose gear. = Wear load / Lubrication factor, = 1 for force lubrication & 1.5 for sump/splash lubrication Where: T = Torque (Nm), = Number of teeth, S d = Allowable design strength (Pas), S Yield strength to 3 d For selecting material and other information follow any machine design book. 6

7 Design of an Industrial General Purpose Reduction Gear Unit : Gear Design: (contd.) Module (m, in meter) can be estimated as: For helical l gear: m helical Fig.- 3 2T cos S d Y cc v w 1: Helical Gear. For helical gear formative number of teeth, For straight tooth bevel gear: m bevel ' 3 / cos Pitch Circle Diameter, PCD (Helical) = m /cos helical 3 Sd cc v w 2T Y (1 ) Where: o o Fig.- Helix angle (degree), 2: Straight Bevel. = Width factor [active width (b) of gear/module], bl for bevel gear (See Fig. -2), usually 1/3 or less, Modified Lewis form factor Y ( / and for straight bevel gear, ' /cos Mean PCD (Straight Bevel) 2 mean r mbevel ' ) pitch cone angle (see Fig.- 2) ). 7

8 Design of an Industrial General Purpose Reduction Gear Unit : Tasks (contd.) : GROUP POWER INPUT OUTPUT DUTY OVERHAUL (kw) RPM RPM Sub Group Description TIME LUBRICATION I A,E,I,M,Q, Precision, Forced A, B, C, D, U Intermittent, No shock 2 years II B,F,J,N,R General, Oil Sump E, F,G,H Continuous, Medium shock III C,G,K,O,S, General, Oil Sump I, J, K, L V Intermittent, Heavy Shock IV D,H,L,P,T Precision, Forced M,N,O,P Continuous, Medium Shock V Q,R,S,T VI U, V Horizontal input and vertical output (Forced Lubrication) IMPORTANT NOTICE: (i) A group should be of 3/4students(Strictly not more than 4). (ii) One of the group members should act as group leader. (iii) Form your own group and write your name & roll number in a small piece of paper and drop in my locker (No. 32, MED) by tomorrow (March 22, 2017). 8

9 A Typical General Purpose Industrial Gear Box (Speed Reducer): 2 nd. Stage Intermediate, Helical Gear (stage) One Input Shaft One Output Shaft Two Intermediate Shafts 1 st. Stage Input, Bevel Gear(Stage) Fig. G02-1: A Typical 3-stage Gear Box 3 rd. Stage Output, Helical Gear 9

10 Typical General Purpose Industrial Gear Box (Speed Reducer) Contd : How it looks like? GEAR BOX REDUREX 10

11 Typical General Purpose Industrial Gear Box (Speed Reducer) Contd : GEAR BOX FG Cast Housing Fabricated (Welded) Housing 11

12 Typical General Purpose Industrial Gear Box (Speed Reducer) Contd : 12

13 Welded Housing- (Single Piece) GB Exploded View (3 Stage- Bevel & Helical) 13

14 Welded Housing- (Single Piece) GB Exploded View (2 Stage Helical) Click to see Fabrication and Assembly Sequences. 14

15 15

Preliminary Layout of Gear Box : 1 2 Step-1 3 4 Knowing the direction of Input & Output Selection of ratios, type of Gears & teeth numbers.

Let total transmission ratio is 18. Then possible stage ratios are:- 3x6= 18.

16 Preliminary Layout of Gear Box : 1 2 Step Knowing the direction of Input & Output Selection of ratios, type of Gears & teeth numbers. Rules and Limitations: Example: Stage ratio should not be more than 6. (Formative) Number of teeth, cr-min 2/sin 2 (Pressure Angle). Let total transmission ratio is 18. Then possible stage ratios are:- 3x6= 18. Possible teeth numbers are: As cr-min 17 for 20 o Pressure Angle (Involute straight spur Teeth). Ideally such Numbers of teeth should not have any problem. However, there are several considerations. 16

17 Preliminary Layout of Gear Box (Contd.) : Step-1 (Contd.) i) Is, however, not an 1 optimum (size) selection. 2 ii) Tooth Haunting. Say, optimum (size) teeth numbers are: = This is acceptable as variation in output speed is negligibly small. Note: Normally helical gears are chosen rather than straight t tooth spur gears. ' 3 Therefore, we consider formative number of teeth: = / cos β Where, β is helix angle which is commonly between 12 o to 20 o for single helical gear. ' For which considering =17, may be taken as 16 to 14 respectively. Considering cutter geometry, speed of gears and manufacturing 17 methods this number my further be lowered.

Preliminary Layout of Gear Box (Contd.) : Step-2 After selecting teeth numbers i.e., 1 2 3 4 2 4 1 3 Gears are designed.

Step-5 Step-6 Step-7 Step-8 Bearings are selected preliminarily. After putting the bearings in layout load calculations become possible.

18 Preliminary Layout of Gear Box (Contd.) : Step-2 After selecting teeth numbers i.e., Gears are designed Step-3 Then first layout is made. Step-4 Rough shape to the shafts are given. Step-5 Step-6 Step-7 Step-8 Bearings are selected preliminarily. After putting the bearings in layout load calculations become possible. Lives of all bearings are estimated. If estimated lives are not satisfactory then a new set of bearings are chosen. If necessary shaft(s) dimensions are also altered and lives are re-estimated. 18 Further, gear design may need to be altered.

What are the functions of gears? What is gear?

8//0 hapter seven Laith atarseh are very important in power transmission between a drive rotor and driven rotor What are the functions of gears? - Transmit motion and torque (power) between shafts - Maintain