DTS QB Watermark

ME 6601 DESIGN OF TRANSMISSION SYSTEMS
ME-6601 DESIGN OF TRANSMISSION SYSTEMS
UNIT-I DESIGN OF TRANSMISSION SYSTEMS FOR FLEXIBLE

ELEMENTS
(PART-A)
1. What do you understand by 6×19 construction in wire ropes?
A 6 × 19 wire rope means a rope is made from 6 strands with 19 wires

in each strand.
2. Mention the losses in belt drives?

❖ The losses in a belt drive are due to:
❖ Slip and creep of the belt on the pulleys
❖ Air resistance to the movement of belt and pulleys
❖ Bending of the belt over the pulleys
❖ Friction in the bearings of the pulley
3. In what ways the timing belts are superior to ordinary V – belts?
Flat belt and V – belt drives cannot provide a precise speed ratio, because
slippage occurs at the sheaves. But certain applications required an exact output
and input speed ratio. In such situations, timing belts are used.
4. What is meant by ‘Chordal action of chain’? Also name a company that produces
driving chains?
❖ When chain passes over a sprocket, it moves as a series of chords instead of a
continuous arc as in the case of a belt drive. It results in varying speed of the
chain drive. This phenomenon is known as chordal action.
❖ Roto mechanical equipment, Chennai; Monal Chains Limited; Innotech
Engineers Limited., New Delhi.
5. What is centrifugal effect on belts?
In operation, as the belt passes over the pulley the centrifugal effect due to its Self
Weight tends to lift the belt from the pulley surface. This reduces the normal
reaction and hence the frictional resistance.
The centrifugal force produces an additional tension in the belt.
6. What is Chordal action in chain drives?
When chain passes over a sprocket, it moves as a series of chords instead of a

continuous are as in the case of a belt drive. It results in varying speed of the chain
drive. This phenomenon is known as chordal action.
7. Name the few material for belt drives?

❖ Leather
❖ Fabric and cotton
❖ Rubber
❖ Balata
❖ Nylon
8. Under what circumstances chain drives are preferred over V belt drives?
❖ To transmit more power
AMSCE/MECH/DTS Page 1
9. Define the term ‘crowning of pulley’?
❖ The pulley rims are tapped slightly towards the edges. This slight convexity is
known as crowning.
10. What factors will affect the working conditions of the chain drive?
❖ Lubrication
❖ Wear
❖ Strength
11. What are the types of belts?

❖ (a) Flat Belts
❖ (b) V Belts.
(ii) Multiple V belt. (iii) Ribbed Belt.
❖ (c) Toothed or Timing
❖ (d), Round, Belts.
12. Indicate some merits and demerits of belt-drive;
Merits
❖ Belt drives are used for long distance power transmission.
❖ Their operations are smooth and flexible.
❖ Simple in design and their manufacturing cost is lower.
Demerits
❖ They need large space.
❖ Loss of power due to friction is more.
13. What is meant by the ply of belt?
Flat belts are made of thin strips and laminated one over the other in
order to get thick belt. These thin strips or sheets are called as plies of belt.
Usually flat belts are made of 11 ply, 4 ply, 5 ply, 6 ply and 8 ply belt etc And 4
ply belt is thicker than 3 ply belt and so-on.
14. Specify the application of round belt.
Round-belt is applied, in sewing machine.
15. Specify the purpose of crowning of bets.

To prevent slipping from pulley due to centrifugal force
16. What factors should be considered during the selection of a belt drive?
a) Amount of power to be transmitted, b) Peripheral and angular speeds. c)
Speed ratio. d) Efficiency. e) Centre distance between shafts f) Space available. g)
Working environment
17. What are the advantages of chain drives?

Advantages of chain drives
❖ Are having more power transmitting capacity.
❖ Have higher efficiency and compact size.
❖ 3- Exert -less load on shafts since no initial tension is applied on the
sprocket shafts.
❖ Require easy maintenance
18. Specify some drawbacks of chain drives.
❖ The design of chain drive is more complicated.
❖ The operation is noisy and production cost is high.
❖ They require more accurate assembly bf shafts than for belts.
19. What are the types of ropes?
They are two type namely
a) Fibre ropes
b) Wire ropes.
20. In what ways wire ropes are superior to fibre ropes?

a) Wire ropes are stronger, more durable than fibre ropes.
b) Wire ropes can withstand' shock loads.
c) Their 'efficiency in high.
d) They can be operated for Very long centre distance even up to 1000 m.
Hence wire-ropes are superior in most of occasions.
21. A longer belt will last more than a shorter belt. Why? (April/May 2017)
The life of a belt is a function of the center distance between the driver
and driven shafts. The shorter belt is more often it will be subjected to
additional bending stresses while running around the pulleys at a given
speed, and quicker it will be destroyed due to fatigue. Hence a longer belt
will last more than a shorter belt.
22. List the advantages of wire ropes compared to chains. (April/May 2017)
❖ Lighter weight and high strength to weight ratio
❖ More reliable in operation
❖ Silent operation even at high working speeds
23. Write the advantages of V belts over the Flat belts? (Nov/Dec 2017)
❖ Power transmitted is more due to wedging action in the grooved
pulley
❖ Higher velocity ratio (upto 10) can be obtained
❖ V belt is more compact , quiet and shock absorbing
❖ The drive positive because the slip is negligible
24. List the chain drive failures? (Nov/Dec 2017)
The four basic modes of chain failures are
❖ Near
❖ Fatigue
❖ Impact
❖ Galling
25. Define Coefficient of friction? (April/May 2018)
The Coefficient of friction is the ratio of the frictional force to the force
acting perpendicular to the two surfaces in contact. This coefficient is a
measure of the difficulty with which the surface of one material will slide over
another material.
26. What are the advantages of Chain Drives? (April/May 2018)

i. Chain Drive can be used for long as well as short centre distances
ii. They are more compact than belt or gear drives
iii. There is no slip between chain and sprocket, so they provide positive
drive
iv. Higher efficiency (upto 98%) of the drive.
27. Name the four types of belts used for transmission of power (Nov/Dec
2018)
i. Flat belts
ii. V belts
iii. Ribbed belts
iv. Toothed or timing belts
28. When do use stepped pulley drive? (Nov/Dec 2018)
A stepped or cone pulley drive is used when the driven or machine
shaft is to be started or stopped whenever desired without interfacing with
the driving shaft.
29. Which side of the belt should be on the bottom side of the pulley and why?
(April/May 2019)
i. The tight side of the belt should be on the bottom side of the pulley
ii. Because the driving pulley pulls the belt from the bottom side and
delivers it to the upper side. So it is obvious that the bottom side of the
belt is tight
30. What are the various stresses induced in wire ropes? (April/May 2019)
i. Direct stress due to the weight of the load to be lifted and weight of the
rope
ii. Bending stress when the rope passes over the sheave
iii. Stress due to acceleration
iv. Stress during starting and stopping
PART-B)
1. A compressor is to run by a motor pulley running at 1440rpm, Speed

ratio 2.5. Choose a flat belt crossed drive. Centre distance between
pulleys is 3.6m. Take belt speed as 16 m/s. Load factor is 1.3. Take a 5-
ply, flat Dunlop belt. Power to be transmitted is 12 KW. High speed load
rating is 0.0118 KW/ply/mm, width at v = 5 m/s. Determine the width
and length of the belt.
Given data:
N 1 = 1440rpm
 = 2.5
c = 3.6m
 = 16 m
s
K s = 1.3
Belt = 5 Ply, flat dunlop belt.
P = 12KW
Load rating at 5 m = 0.0118 KW Ply mm
s
Step 1: Calculation of Pulley diameters:
Assume the driven pulley diameter D = 1000 mm.
D N1
W.K.T  = =
d N2
Case (i): To find the driven pulley speed. (N2).
Case (ii): To find the driver pulley diameter (d):
N1
N2 =

1440
=
2.5
N 2 = 576rpm
Case (iii): To find the driver pulley diameter (d):
D
d=

1000
=
2.5
d = 400mm
From PSGDB 7.54, from recommended series of pulley diameters and

tolerances.
The standard diameter for 

 d = 400mm
the driver pulley 
Step 2: Calculation of design power in KW.
Rated power ( K w )  Load correction factor ( K s )

Design power =
Arc of contact factor ( K  )  Small pulley factor ( Kd )
Case (i): To find the arc of contact factor (K)
From PSGDB 7.54
 D −d 
Arc of contact = 180 −    60
 c 
 1000 − 400 
= 180 −    60
 3600 
= 170
From PSGDB 7.54, take the value of K  = 1.04 . Corresponding to the arc of
contact 170°
K  = 1.04
Case (ii): To find the small pulley factor (Kd)
Table: Small pulley factor ‘Kd’
Small Pulley Kd
diameter
Upto 100mm 0.5
100 – 200mm 0.6
200 – 300mm 0.7
300 – 400mm 0.8
400 – 750mm 0.9
Over 750mm 1.0
From the above table. We take the Kd value 0.8
 K d = 0.8
Case (iii):
To find the design power, KW:
P  Ks
W. K. T. Design power =
Ka  Kd
12  1.3
=
1.04  0.8
= 18.75KW
Step 3: Selection of belt:
Given: 5 Ply, flat Dunlop belt. Its capacity is given by 0.0118

KW/ply/mm.
Step 4: Load rating correction:
From PSGDB 7.54.
v
Load rating at ‘V’ m /s = Load rating at 10 m /s 
10
16
Load rating at 16 m /s = ( 0.0118  2 ) 
10
= 0.03776KW /Ply /mm
Step 5: Determination of belt width:
Design Power
Width of the belt =
Load rating  No. of plies.
18.75
=
0.03776  5
= 99.31mm
From PSGDB 7.52 Specification of transmission belting standard

widths.
The standard belt width for 5 Ply belt = 100mm.
Step 6: Determination of Pulley width:
From PSGDB 7.54, Pulley width is given by
Pulley width = Belt width + 18 mm
= 100 + 13 mm
= 113 mm
From PSGDB 7.54, recommended series of width of flat pulleys, mm.
The standard pulley width = 125 mm.
Step 7: Calculation of length of the belt (L):
From PSGDB 7.61,
(D − d)
2

L = 2C + ( D + d ) +
2 4C
( 1000 − 400 )
2
= 2  3600 + 
2(
1000 + 400 ) +
4  3600
= 7200 + 2199.11 + 25
L = 9424.11mm
2. At the construction site, 1 tonne of steel is to be lifted upto a height of

20m with the help of 2 wire ropes of 6 × 19 size, nominal diameter 12
mm and breaking load 78 KN. Determine the factor of safety if the
sheave diameter is 56 d and if wire rope is suddenly stopped is 1
second when travelling at a speed of 1.2 m/s. What is the factor of
safety if bending load is neglected?
Given data:
h − = 20m
W = 1 tonne = 1000Kg = 9810N
n=2
Wire rope size = 6  19
d = 12mm
Breaking load Wbreak = 78KN
D = 56d
t = 1sec
v = 1.2 m s = 72 m min
Step 1: Selection of suitable Wire rope:
Given: 6 × 19 size wire rope.
Step 2: Calculation of design load:
Assuming a larger factor of safety of 15, the design load is calculated.
Design load = Load to be lifted × Assumed FOS
= 9810 × 15
= 147150 N
= 147.15 KN
Step 3: Selection of Wire rope diameter (d):
From PSGDB 9.5. For the breaking strength (Wbreak) 78 KN (7.8

tonnes). take the diameter of the rope is 12mm.
d = 12mm
u = 1600 to 1750 N mm 2
Step 4: Calculation of sheave diameter (D):
Given:
Sheave diameter D = 56 d
= 56 × 12
= 672 mm
Step 5: Selection of the area of useful cross section of the rope (A):
From PSGDB 9.1
A = 0.4    d 2
4
= 0.4    12 2
4
A = 45.24mm 2
Step 6: Calculation of Wire diameter (dw):
d
dw =
1.5 i
i = Number of strands × Number of wires in each strand
= 6 × 19
i = 114
12
dw =
1.5 114
 dw = 0.75mm
Step 7: Selection of Weight of rope (Wr):
From PSGDB 9.5. Corresponding to the diameter of the rope

12mm, take
Approximate weight = 0.54 Kgf m
= 5.3 N m
 Weight of rope Wr = Approximate Weight  h
= 5.3  20
Wr = 106N
Step 8: Calculation of various loads:
Case (i): To find the direct load (Wd):
Wd = W + Wr
= 9810N + 106N
Wd = 9916N
Case (ii): To find the acceleration load (Wa):
 W + Wr 
Wa =  a
 g 
a = acceleration of the load
V2 − V1
=
t1
1.2 − 0
=
1
a = 1.2 m s2
 9810 + 106 
 Wa =   1.2
 9.81 
Wa = 1212.97N
Step 9: Calculation of effective loads on the rope:
Effective load during acceleration of the load
Wea = Wd + Wb + Wa
= 9916 + 0 + 1212.97
 Wb = 0, From the Question 
 Bending load is neglected 
 
= 11128.97N
Step 10: Calculation of working factor of safety (FSw):
Working factor   Breaking load

=
of Safety ( Fsw ) 
 Effective load
during acceleration ( Wea )
78  10 3
=
11128.97
Fsw = 7
Step 11: Check for design:
From PSGDB 9.1, for hoists and class 2, the recommended factor of
safety = 5.
Since the working factor of safety is greater than the recommended

factor of safety. Therefore the design is safe.
3. Design a V belt drive and calculate the actual belt tensions and
average stress for the following data. Power to be transmitted = 7.5 KW,
speed of driving wheel = 1000 rpm, speed of driven wheel = 300 rpm,
diameter of the driven pulley = 500 mm, diameter of the driver pulley =
150 mm and centre distance = 925 mm
Given data:
P = 7.5 KW
N1 = 1000 rpm
N2 = 300 rpm
D = 500 mm
d = 150 mm
C = 925 mm
Step 1: Selection of belt
From PSGDB 7.58,
For 7.5 KW, B section is selected
Step 2: Selection of pulley diameters. d & D:
d = 150 mm, D = 500 mm given.
Step 3: Selection of centre distance (c) :
C= 925 mm given.
Step 4: Calculation of nominal pitch length (L).
From PSGDB 7.61,
 (D − d) 2
L = 2C + (D + d) +
2 4C
 (500 − 150) 2
= 2  925 + (500 + 150) +
2 4  925
= 2904.12mm.
From PSGDB 7.60, For B section.
The next standard length L = 3091 mm.
Step 5: Selection of various modification factors.
Case 1: Length correction factor (Fc)
From PSGDB 7.60 for B section corresponding to ‘L’
Fc = 1.07
Case 2: Correction factor for arc of contact (Fα)
From PSGDB 7.68
D−d
Arc of contact angle = 180 − ( )  60
C
500 − 150
= 180 − ( )  60
925
= 157.29
Corresponding to the angle 1579.29° 160°
Fd = 0.95.
Case 3: Service factor (Fa).
From PSGDB 7.69
Fa = 1.3
Step 6: Calculation of Maximum power capacity (KW).
50.8
KW = (0.79S−0.09 − − 1.32 10 −4 S2 )S
de
dN1
Where, S = Belt speed =
60
 0.150 1000
=
60
= 7.854m / s
D 500
d e = equivalent pitch diameter; From PSGDB 7.62 = = 3.33 Take
d 150
Fb=1.14
= d p  Fb
= 150 1.14
= 171 mm.
50.8
 KW = (0.79  7.854−0.09 − − 1.32 10−4  7.84 2 )7.84
171
= 2.757KW
Step 7: Calculation of number of belts (nb)
From PSGDB 7.70
P  Fa
nb =
K w  Fc  Fd
7.5 1.3
=
2.757 1.07  0.95
= 3.48
n b = 4belts.
Step 8: Calculation of actual centre distance. (Cactual).
From PSGDB 7.61
Cactual = A + A 2 − B
L D + d
A= −
4  8 
3091  500 + 150 

= − 
4  8
A = 517.5mm
(D− d) 2 (500 − 150) 2

B= =
8 8
= 15312.5 mm 2
 Cactual = 517.5 + 517.52 − 15312.5
= 1020 mm.
Step 9: Calculation of belt tensions (T1 and T2).
Power transmitted per belt = (T1 − T2 ) v
7.5 103
= (T1 − T2 )7.854
4
T1 − T2 = 238.73 ------1
From PSGDB 7.58  m = 0.189 Kg/m.
7.70  2B =34°

From step 5:   = 157.29
180
= 2.745 rad.
T1 − mv 2
Tension ratio  = e cos ec
T2 − mv 2
T1 − 0.189(7.854) 2
= e0.32.745cos ec17
T2 − 0.189(7.854) 2
T1 − 16.72T2 = −184.3 ------2
Solving equation 1 and 2
T2 = 26.9 N , T1 = 265.64 N
Step 10: Calculation of Stress induced.
Maximum tension
Stress induced =
Cross sectional area
From PSGDB 7.58 Area of B section = 140 mm2
265.64
 Stress induced =
140
= 1.897 N / mm 2
4. A 7.5 KW electric motor running at 1400rpm is used to drive the input

shaft of the gear box of a machine. Design a suitable roller chain to
connect the motor shaft to the gearbox shaft to give an exact speed
ration of 10:1. The center to center distance of the shaft is to be
approximately 600mm.
Given data:
N = P = 7.5 KW
N1 = 1400 rpm
i = 10
a0=600 mm
Step 1: Selection of transmission ratio. (i)
N1
i= = 10 given.
N2
Then,
N1
= N2
10
1400
N2 =
10
N 2 = 140rpm
Step 2: Selection of no. of teeth on the driver sprocket (z1).
From PSGDB 7.74
Z1 = 7
Step 3: Calculation of no. of teeth on the driven sprocket (Z2).
From PSGDB 7.74
Z2 = i  Z1
= 10  7
Z 2 = 70
Z 2max = 100 to 120
Recommended value of Z2 should be less than the above value or else the
chain may run off the sprocket for a small pull.
Z2 = 70 is satisfactory.
Step 4: Selection of standard pitch (P).
From PSGDB 7.74
Centre distance a = ( 30 to 50 ) P
a 600
Maximum Pitch, Pmax = = = 20 mm
30 30
a 600
Minimum Pitch, Pmin = = = 12 mm
50 50
Any standard pitch between 12 mm and 20 mm can be chosen. But to get a

quicker solution, it is always preferred to take the standard pitch closer to Pmax.
From PSGDB 7.72, Standard Pitch P = 15.875 mm.
Step 5: Selection of the chain:
From PSGDB 7.72, assume the chain to be duplex.
 10 A - 2 / DR50 Chain number is selected.
Step 6: Calculation of total load on the driving side of the chain (PT):
From PSGDB 7.78,
PT = Pt + Pc + Pa
Case 1: To find the tangential force (Pt)
From PSGDB 7.78
1020N
Pt =
V
Z1  P  N1
Where, v = chain velocity =
60 1000
7  15.875 1400
=
60 1000
= 2.59 m / s
1020  7.5
 Pt =
2.59
Pt = 2950.35 N
Case 2: To find the centrifugal tension (Pc).
Wv 2
From PSGDB 7.78. Pc = = mv 2
g
Where, m= mass of the chain
From PSGDB 7.72, For the selected chain,
m = 1.78 Kg/m [1Kg m/s2=1N]
 Pc = 1.78 (2.59) 2
Pc = 11.94 N
Case 3: To find the tension due to sagging (Ps).
From PSGDB 7.78,
Ps = K. W. a
Where, K = 6 (for horizontal) From PSGDB 7.78
W = m x g = 1.78 x 9.81 = 17.46 N
A = 600 mm = 0.6 m.
 Ps = 6 x 17.46 x 0.6
= 62.82 N
 PT = 2950.35 + 11.94 + 6282
PT = 3025.11 N
Step 7: Calculation of Service factor (Ks).
From PSGDB 7.76
Ks = K1 K2 K3 K4 K5 K6
From PSGDB 7.76 and 7.77.
❖ K1 = 1.25 for load with mild shocks

❖ K2 = 1 for adjustable supports.
❖ K3 = 1 we have used ap = ( 30 to 50 ) P
❖ K4 = 1 for horizontal drive.
❖ K5 = 1 for drop lubrication
❖ K6 = 1.25 for 16 hrs/day running
 Ks = 1.25 × 1 × 1× 1× 1× 1.25
= 1.5625
Step 8: Calculation of design load.
Design load = PT × Ks
= 3025.11 × 1.5625
= 4726.73 N
Step 9: Calculation of working factor of safety (FSw)
Q
FSw =
Design load
Where, Q = Breaking load = 44400 N. From PGSDB 7.72 for the selected chain
44400
 FSW =
4726.73
FSW = 9.4
Step 10: Check for factor of safety.
From PSGDB 7.77, Recommended factor of safety = 12.45
We find FSW  12.45 , the design is not safe.
In order to overcome this issue we have to increase the pitch = 19.05 mm.
 The chain number 12 A -2 / DR 60 is selected.
For this chain, M= 2.90 Kg/m, Q = 63600 N
By the recalculation of step 6 and step 8, step 9.
PT = 2590.28 N.
Design load = 4047.31 N
FSw = 15.71
We find FSw > 12.45 , the design is safe.
Step 11: Check for the bearing stress in the roller.
Pt  K s
 roller =
A
Where, A = 210 mm 2 From PSGDB 7.72 for selected chain
2459.81*1.5625
  roller =
210
= 18.30 N/mm2
From PSGDB 7.77, the allowable bearing stress for the given speed 1400rpm, is
19.75 N/mm2.
Induced stress is less than the allowable stress i.e 18.30 < 19.75 N/mm2.
 The design is safe.
Step 12: Calculation of length of chain (L).
From PSGDB 7.75

L = lp  P
 Z + Z2  [(Z2 − Z1 ) / 2]
2
Where no.of links lp = 2a p +  1 +
 2  ap
a0 600
Approximate center distance in multiples of pitches a p = = = 31.50
P 19.05
 7 + 70  [(70 − 7) / 2]
2
 lp = 2  31.50 +  +
 2  31.50
= 63 + 38.5 + 3.19
lp = 104.69
lp =106 links
Actual length 
  L = 106 19.05
of chain 
L = 2019.3 mm
Step 13: Calculation of exact centre distance (a):
From PSGDB 7.75.
e + e2 − 8m
m = 100.54 a= P
4
Case 2: To find m:
Case 1: To find e:
 Z − Z1 
2
 Z + Z2  * m= 2 
* e = lp −  1   2 
 2 
 70 − 7 
2
 7 + 70  = 
= 106 −    2 
 2 
m = 100.54
e = 67.5
67.5 + 67.52 − 8 100.54

 a= 19.05
4
a = 613.18 mm
From PSGDB 7.75, Decrement in centre distance for an initial sag = 0.01a
= 6.132 mm
 Exact centre distance = 613.18 − 6.132
= 607.05 mm.
Step 14: Calculation of sprocket diameters.
Case 1: Smaller sprocket.
P
PCD of smaller sprocket d1 = From PSGDB 7.78
 180 
sin  
 Z1 
19.05
=
 180 
sin  
 7 
d1 = 43.91 mm.
Sprocket outside diameter d 01 = d1 + 0.8d r
d r = diameter of roller = 11.90 mm. From PSGDB 7.72 for selected chain.
 d 01 = 43.91 + 0.8 11.90
d 01 = 53.43 mm
Case 2: Larger sprocket:
P
d2 = From PSGDB 7.78
 180 
sin  
 Z2 
19.05
=
 180 
sin  
 70 
d 2 = 424.61 mm
Sprocket outside 
 d 02 = d 2 + 0.8d r
diameter 
= 424.61 + 0.8 + 11.90
d 02 = 434.13 mm
5. Select a suitable v belt and design the drive for a wet grinder. Power is
available from a 0.5KN motor running at 750rpm. Drum speed is to be
about 100rpm. Drive is to be compact.
Given data:
P = 0.5KW
N 1 = 750rpm
N 2 = 100rpm
From PSGDB 7.58, for power 0.5KW.
As per data book the usual load of drive starts from, 0.75KW
only. So choose A section, and P=0.75KW.
Step 2: Selection of Pulley diameters (d and D).
D N 1 750
Speed ratio = = = = 7.5
d N 2 100
Smaller pulley diameter d = 75mm .
From PSGDB 7.54,
The standard diameter d = 80mm .
D = 7.5d
Larger Pulley diameter = 7.5  80
D = 600mm
From PSGDB 7.54,
The standard D = 630mm .
Step 3: Selection of centre distance. (C)
From PSGDB 7.61, For i = 7.5 , take C = 0.85

D
 C = 0.85  D
= 0.85  630
C = 535.5mm
Step 4: Calculation of nominal pitch length: (L)
From PSGDB 7.61,
(D − d)
2
L = 2C + ( 2 ) (D + d) +
4C
( 630 − 80 )
2
( 2 ) ( 630 + 80 )
= 2 ( 535.5 ) +  +
4  535.5
= 1071 + 1115.27 + 141.22
L = 2327.49mm
From PSGDB 7.59, From A section.
The next standard nominal pitch length
L = 2474mm.
Case 1: Length correction factor. (Fc)
For A section , Fc = 1.08 From PSGDB 7.59
Case 2: Correction factor for arc of contact (Fd)
 D −d 
Arc of contact = 180 −    60 From PSGDB 7.68
 C 
 630 − 80 
= 180 −    60
 535.5 
= 118.38
 Fd = 0.82 From PSGDB 7.68
Case 3: Service factor (Fa)
For light duty 16 hours continuous service , for driving machines of

type II , service factor is selected as Fa = 1.3 From PSGDB 7.69
Step 6: Calculation of maximum power capacity.
 19.62 
KW =  0.45S −0.09 − − 0.765  10 −4 S 2  S From PSGDB 7.62 for A
 de 
section.
dN 1
S=
60
 80  750
=
60  1000
= 3.14 m
s
d e = d p  Fb
d p = d = 80mm
Fb = 1.14 From PSGDB 7.62
 de = 80  1.14
= 91.2mm.
 19.62 2 
 KW =  0.45  ( 3.14 ) − 0.765  10 −4 ( 3.14 )  3.14
−0.09
−
 91.2 
= 0.6KW.
Step 7: Determination of number of belts (nb)
P  Fa
nb =
K w  Fc  Fd
0.5  1.3
=
0.6  1.08  0.82
n b = 1.223
nb 2 belts.
Step 8: Calculation of actual centre distance:
CActual = A + A2 − B From PSGDB 7.61
L D+d
A= −  
4  8 
2474  630 + 80 
= −  
4  8 
A = 339.68mm
(D − d) ( 630 − 80 )
2 2
B= = = 37812.5mm 2
8 8
( 339.69 )
2
 C actual = 339.69 + − 37812.5
= 618.22mm
6. Select a wire rope for a vertical mine hoist to lift a load of 20KN from a
depth of 60 metres. A rope speed of 4 m/sec is to attained on 10
seconds.
Given data:
Weight to be lifted = 20 KN
Depth = 60m
v2 = v = 4 m sec = 240 m min
t = 10sec
Step 1: Selection of suitable wire rope.
For hoisting purpose, 6  19 rope is selected. From PSGDB 9.1
Step 2: Calculation of Design load.
Assuming the factor of safety of 15, the design load is calculated.
Design load = 20  15
= 300KN
Step 3: To find wire rope diameter (d).
From PSGDB 9.5 For design load 300KN, The next standard value.
d = 25mm
m = 2.41Kg m
 u = 1600 to 1750 N mm 2
Breaking strength = 340KN
Step 4: Sheave diameter (D)
Dmin
From PSGDB 9.1. We find = 27 for class 4, for velocity upto
d
50m min . But the actual speed is
 240  D
240m min  i.e 5 times 50 m min  . Therefore min has to be modified.
 50  d
D min
= 27  ( 1.08 ) = 36.73
5−1
37mm.
d
Sheave diameter D = 37  d
= 37  25
D = 925mm
Step 5:Calculation of Area of cross section of the rope (A).
From PSGDB 9.1
A = 0.4    d 2
4
= 0.4    25 2
4
A = 196.35mm 2
Step 6: To find Wire diameter. (dw).
d
dw =
1.5 i
25
=
1.5 6  19
= 1.56
d w = 2mm
Step 7: Weight of the rope. (Wr).
Wr per meter = 2.41  9.81 = 23.64 N m.
Wr = 23.64  60 = 1418.53N
= 1418.53N
Step 8: Load calculations
Case 1: Direct load (Wd)
Wd = W + Wr = 20 + 1418.53  10−3 = 21.42KN
Case 2: Bending load (Wb)
Er  dw
Wb =  b  A = A
D
0.84  10 5  2
=  196.35  Er = 0.84  105 N mm2 
925
= 35661.41N
= 35.66KN.
Case 3: Acceleration load (Wa)
 W + Wr  v2 − v1
Wa =  a a=
 g  t
 20 + 1418.53  10 −3  4−0
=   0.4 =
 9.81  10
= 0.87 KN = 0.4 m s 2
 Effective load on the rope 

 W = Wd + Wb + Wa
during acceleration  ea
= 21.42 + 35.66 + 0.87
= 57.95
Wea = 58KN
Step 9:Working factor of Safety (FSw).
Breaking load
FS w =
Wea
340
=
58
FS w = 5.86
Step 10: Check for Safe design
 We find Fsw  n ' ( 6 ) .  The design is not safe.

 The safe design can be achieved either by selecting the rope
with greater breaking strength.
From PSGDB 9.5, for d=25, take breaking strength = 376 KN and
u = 1750 to 1900N mm2
376
 Fsw =
58
= 6.48
Now we find Fsw  n ' ( 6 ) . The design is safe.
7. Design a flat belt drive to transmit 110kW for a system consisting of

two pulleys of diameter 0.9m and 1.2m respectively, for a center
distance of 3.6m. Belt speed of 20m/s and coefficient of friction=0.3.
There is a slip of 1.2% at each pulley and 5% friction loss at each shaft
with 20% over load.
Given: P = 110kW = 150 HP, d1 = 0.9m = 90cm,
 r1 = 0.45 m, d2 = 1.2 m = 120 cm, r2 = 0.6 m ;
x = 3.6m; v = 20m /s;  = 0.3; S 1 = S 2 = 1.2%
Let N1 = Speed of the smaller or driving pulley in rpm
N2 = Speed of the larger or driven pulley in rpm
We know that speed of the belt (v)
d 1N 1  S1 
v= 1− 
60  100 
 0.9N 1  1.2 
20 = 1− 
60  100 
 N1 =430 rpm
And peripheral velocity of driven pulley
d 2 N 2  S 
= v1 − 2 
60  100 
  1.2N 2  1.2 
= 20  1 − 
60  100 
 N 2 =315 rpm
We know that the torque acting on the driven shaft
Power transmitted 4500

=
2 N 2
150  4500
=
2  315
= 341 Kgf − m
Since there is a 5% friction loss at each shaft, therefore the torque acting on the
belt
= 1.05  341
= 358 Kgf − m
Since belt is to be designed for 20% overload, therefore the design torque,
= 1.2  358
= 430 Kgf − m
Let T1 = Tension on the tight side of the belt
T2 = Tension on the slack side of the belt
We know that the torque exerted on the driven pulley.
= ( T1 − T2 ) r2 = ( T1 − T2 ) 0.6
= 0.6 ( T1 − T2 ) Kgf − m
Equating this to the design torque, we have
= 0.6 ( T1 − T2 ) =430
430
 ( T1 − T2 ) = = 717 Kgf
0.6
 T1 − T2 = 717 Kgf
Now let us find out the angle of contact of the belt on the smaller or driving pulley.
From the geometry of the figure, we find that
O 2 M r2 − r1 60 − 45
sin  = = = = 0.0417
O 1O 2 x 360
  = 2.4
  = 180 − 2 = 180 − 2  2.4 = 175.2

= 175.2  = 3.06rad
180
We know that
T 
2.3 log  1  = 
 T2 
= 0.3  3.06
= 0.918
 T  0.918
 log  1  = = 0.3991
 T2  2.3
T1
Or = 2.51 2
T2
From equation (1) & (2) , we have
T1 = 1192Kgf and T2 = 475Kgf
Assuming f =safe stress for the belt = 25 Kgf/cm2
t = thickness of the belt = 1.5 cm
b = Width of the belt.
Since the belt speed is more than 10 m/s, therefore centrifugal tension must be
taken into consideration.
Assuming a leather belt for which the density may be taken as 1 gm/cm 2
 Weight of the belt per meter length
w = Area  length  density
= b  1.5  1000  1
= 0.15bKg /m
and centrifugal tension
w
Tc =  v2
g
0.15b
( 20 )
2
=
9.81
= 6.12bKgf
We know that maximum tension in the belt,
T = T1 + Tc = f.b.t
1192  6.12b = 25  b  1.5 = 37.5b
37.5b − 6.12b = 1192
b = 37.98cm.
From design data book, the standard width of the belt (b) is 40 cm.
From design data book, Pg.No. 7.53 for open drive
( d − d1 )
2

L = 2x  ( d 2 − d 1 )  2
2 4x
( 120 − 90 )
2

= 2  360  ( 120 − 90 ) 
2 4  360
= 1050.6cm
L = 10.506m

shaft of the gear box of a special purpose machine. Design a suitable
roller chain to connect the motor shaft to the gear box shaft to give an
exact speed ratio of 10 to 1. Assume the minimum centre distance
between driver and driven shaft as 600 rpm.
Given data:
N = P = 7.5 KW
N1 = 1400 rpm
i = 10
a0=600 mm
N1
i= = 10 given.
N2
Then,
N1
= N2
10
1400
N2 =
10
N 2 = 140rpm
From PSGDB 7.74
Z1 = 7
From PSGDB 7.74
Z2 = i  Z1
= 10  7
Z 2 = 70
Z 2max = 100 to 120
From PSGDB 7.74
a 600
30 30
a 600
50 50

From PSGDB 7.72, Assume the chain to be duplex.
 10 A - 2 / DR50 chain number is selected.
Step 6: Calculation of total load on the driving side of the chain (P T):
From PSGDB 7.78,
PT = Pt + Pc + Pa
From PSGDB 7.78
1020N
Pt =
V
Z1  P  N1
60 1000
7  15.875 1400
=
60 1000
= 2.59 m / s
1020  7.5
 Pt =
2.59
Pt = 2950.35 N
Wv 2
g
m = 1.78 Kg/m [1Kg m/s2=1N]
 Pc = 1.78 (2.59) 2
Pc = 11.94 N
From PSGDB 7.78,
Ps = K. W. a
W = m x g = 1.78 x 9.81 = 17.46 N
A = 600 mm = 0.6 m.
 Ps = 6 x 17.46 x 0.6
= 62.82 N
 PT = 2950.35 + 11.94 + 6282
PT = 3025.11 N
From PSGDB 7.76
Ks = K1 K2 K3 K4 K5 K6

 Ks = 1.25 × 1 × 1× 1× 1× 1.25
= 1.5625
= 3025.11 × 1.5625
= 4726.73 N
Q
FSw =
Design load
44400
 FSW =
4726.73
FSW = 9.4
PT = 2590.28 N.
FSw = 15.71
Pt  K s
 roller =
A
Where, A = 210 mm From PSGDB 7.72 for selected chain

2
2459.81*1.5625
  roller =
210
= 18.30 N/mm2
From PSGDB 7.77, the allowable bearing stress for the given speed 1400rpm , is
19.75 N/mm2.
Induced stress is less than the allowable stress i.e 18.30 < 19.75 N/mm2. 
the design is safe.
From PSGDB 7.75
L = lp  P
 Z + Z2  [(Z2 − Z1 ) / 2]
2
lp = 2a p +  1 +
 2  ap
a0 600
ap = = = 31.50
P 19.05
 7 + 70  [(70 − 7) / 2]
2
 lp = 2  31.50 +  +
 2  31.50
= 63 + 38.5 + 3.19
lp = 104.69
lp 106 links
Actual length 
  L = 106 19.05
of chain 
L = 2019.3 mm
Step 13:
Calculation of exact centre distance (a): From PSGDB 7.75.
e + e2 − 8m
a= P
4
 Z + Z2 
* e = lp −  1 
 2 
 7 + 70 
= 106 −  
 2 
e = 67.5
 Z − Z1 
2
* m= 2 
 2 
 70 − 7 
2
= 
 2 
m = 100.54
67.5 + 67.52 − 8 100.54

 a= 19.05
4
a = 613.18 mm
Decrement in centre distance for an initial sag = 0.01a
= 6.132 mm
= 607.05 mm.
P
 180 
sin  
 Z1 
19.05
=
 180 
sin  
 7 
d1 = 43.91 mm.
 d 01 = 43.91 + 0.8 11.90
d 01 = 53.43 mm
Case 2:
Larger sprocket:
P
 180 
sin  
 Z2 
19.05
=
 180 
sin  
 70 
d 2 = 424.61 mm
 d 02 = d 2 + 0.8d r
diameter 
= 424.61 + 0.8 + 11.90
d 02 = 434.13 mm
9. Design a flat belt drive to transmit 110kn for a system. Consisting of

two pulleys of diameter 0.9m and 1.2m for a cuter distance of 3.6m,
belt speed of 20 m/s and co – efficient of friction is O.S. There is a slip
of 1.2 % at each pulley and 5% friction loss at each shaft with 20%,
overload.
Given: P = 110kW = 150 HP, d1 = 0.9m = 90cm,
 r1 = 0.45 m, d2 = 1.2 m = 120 cm, r2 = 0.6 m ;
x = 3.6m; v = 20m /s;  = 0.3; S 1 = S 2 = 1.2%
Let N1 = Speed of the smaller or driving pulley in rpm
N2 = Speed of the larger or driven pulley in rpm
We know that speed of the belt (v)
d 1N 1  S1 
v= 1− 
60  100 
 0.9N 1  1.2 
20 = 1− 
60  100 
 N1 =430 rpm
and peripheral velocity of driven pulley
d 2 N 2  S 
= v1 − 2 
60  100 
  1.2N 2  1.2 
= 20  1 − 
60  100 
 N 2 =315 rpm
We know that the torque acting on the driven shaft
Power transmitted 4500

=
2 N 2
150  4500
=
2  315
= 341 Kgf − m
Since there is a 5% friction loss at each shaft, therefore the torque acting on the
belt
= 1.05  341
= 358 Kgf − m
Since belt is to be designed for 20% overload, therefore the design torque,
= 1.2  358
= 430 Kgf − m
Let T1 = Tension on the tight side of the belt
T2 = Tension on the slack side of the belt
We know that the torque exerted on the driven pulley.
= ( T1 − T2 ) r2 = ( T1 − T2 ) 0.6
= 0.6 ( T1 − T2 ) Kgf − m
Equating this to the design torque, we have
= 0.6 ( T1 − T2 ) =430
430
 ( T1 − T2 ) = = 717 Kgf
0.6
 T1 − T2 = 717 Kgf
Now let us find out the angle of contact of the belt on the smaller or driving pulley.
From the geometry of the figure, we find that
O 2 M r2 − r1 60 − 45
sin  = = = = 0.0417
O 1O 2 x 360
  = 2.4
  = 180 − 2 = 180 − 2  2.4 = 175.2

= 175.2  = 3.06rad
180
We know that
T 
2.3 log  1  = 
 T2 
= 0.3  3.06
= 0.918
 T  0.918
 log  1  = = 0.3991
 T2  2.3
T1
Or = 2.51 2
T2
From equation (1) & (2) , we have
T1 = 1192Kgf and T2 = 475Kgf
Assuming f =safe stress for the belt = 25 Kgf/cm2
t = thickness of the belt = 1.5 cm
b = Width of the belt.
Since the belt speed is more than 10 m/s, therefore centrifugal tension must be
taken into consideration.
Assuming a leather belt for which the density may be taken as 1 gm/cm 2
Weight of the belt permetre length
w = Area  length  density
= b  1.5  1000  1
= 0.15bKg /m
and centrifugal tension
w
Tc =  v2
g
0.15b
( 20 )
2
=
9.81
= 6.12bKgf
We know that maximum tension in the belt,
T = T1 + Tc = f.b.t
1192  6.12b = 25  b  1.5 = 37.5b
37.5b − 6.12b = 1192
b = 37.98cm.
From design data book, the standard width of the belt (b) is 40 cm.
From design data book, Pg.No. 7.53 for open drive
( d − d1 )
2

L = 2x  ( d 2 − d 1 )  2
2 4x
( 120 − 90 )
2

= 2  360  ( 120 − 90 ) 
2 4  360
= 1050.6cm
L = 10.506m
10. A bucket elevator is to be driven by geared motor and a roller chain

drive with the information given below.
Motor out – put – 3KW, speed of motor shaft – 100 rpm, elevator drive shaft
speed – 42rpm, load – even. Distance between centres of sprockets
approximately = 1.2 m, period of operation 16 hour / day. Geared motor is
mounted on an auxiliary bed for centre distance adjustments. Design the
chain drive.
Given data:-
N =  = 3kw
N1 = 100rpm
N 2 = 42rpm
a 0 = a = 1.2m
Step 1:- Selection of transmission ratio (i)
N1 100
i= = = 2.38 3
N 2 42
Step 2:- Selection of no. of teeth on driver sprocket (z1)
Z1=25
Step 3:- Calculation of no. of teeth on driven sprocket (z2)
z 2 = ixz1
= 3  25
z 2 = 75
z max = 100 to120
Recommended value of z2 should be less than the above value or else the chain
may run off the sprocket for a small pull, z2 = 75 is satisfactory.
Step 4:- Selection of standard pitch (P)
Centre distance q = (30 to 50)P
a 1200
Maximum pitch, Pmax = 30 = 30 = 40mm
a 1200
Minimum pitch Pmin = 50 = 50 = 24mm
Any standard pitch between 24 mm and 40 mm can be chosen, but to get a quicker
solution, it is always preferred to take the standard pitch closer to Pmax.
Standard pitch P = 38.10 mm
Step 5:- Selection of the chain:
Assume the chain to be duplex,
∴ 24 B2 / DR 3825 chain number is selected.
Step 6: Calculation of total load on the diving side of the chain (P T)
Pt = Pt + Pc + Pa
Case 1:- To find the tangential force (Pt)
1020N
Pt =
v
z P N 25  10  100
Where v = chain velocity = 60  1000 = 60  1000 = 1.59m / 2
1 1
1020  3
 Pt = = 19.24.53N
1.59
Case 2:- To find the centrifugal tension (Pc)
Wv 2
pc = = mv 2
2
m = 14.50kg / m
p c = 14.50  (1.59) 2
= 36.66N
Case 3:- To find the tension due to sagging (Ps)
ps = K.W.a
K = 6 (for horizontal)
W = m  g = 14.50  9.81 = 142.25N
a = 1200mm = 1.2m
 ps = 6  142.25  1.2
= 1024.16N
PT = 1924.53 + 36.66 + 1024.16
= 2985.35N
Step 7:- Calculation of service factor (Ks)
Ks = K1. K 2 . K3. K 4 . K5. K 6
Where, K1 = 1.25 for load with mid shocks
K2 = 1 for adjustable supports
K3 = 1 We have used ap = (30 to 50) P
K4 = 1 for horizontal drive
K5 = 1 for drop lubrication
K6 = 1.25 for 16/ hurs / day running
K s = 1.25  1  1  1  1  1.25
= 1.5625
Step 8:- Calculation of design load
Design load
DL = PT  K s
= 2985.35  1.5625
= 4664.62N
Step 9:- Calculation of working factor of safety (Fsw)
Q
Fsw =
Design Load
Q = 199600N
199600
Fsw =
4664.62
= 42.8
Step 10:- Check for factor of safety.
We find Fsw > 7.4, the design is safe.
Step 11:- Check for the bearing stress in the safe.
Pt  K s
rouer =
A
A = 11.09cm 2 = 1109mm 2
1924.53  1.5625
rouer =
1109
= 2.71 / mm 2
The allowable bearing stress for the given speed 100 rpm, is 33.3 N/mm 2.
Induced stress is less than the allowable stress i.e, 2.71 < 33.33 Nmm2. The design
is safe.
Step 12:- Calculation of length of chain (L)
L= p P
 z + z   (z − z ) / 2
2
p = 2a p   1 2  + 2 1
 6  ap
a 0 1200
ap = = = 31.50
p 38.10
 25 + 75   (75 − 25) / 2
2
p = (2  31.50)   +
 2  31.50
p = 3152 links
Actual length 
 L = 3152  38.10
of chain 
= 120m
Step 13:- Calculation of exact centre distance (a)
e + e 2 − 8m
a= P
4
z +z 
e = p − 1 2 
 2 
 25 + 75 
= 3152 −  
 2 
e = 3102
z −z 
m= 2 1
 2 
 75 − 25 
2
= 
 2 
= 63.33
3102 + 3102 2 − 8  63.33
a=  38.10
4
a = 59092.32 mm
Decrement in centre distance for an initial sag = 0.01 a ; = 590.92 mm
Exact centre distance = = 59092.32 − 59092 = 58501.4 mm
Step 14:- Calculation of sprocket diameters
Case 1: smaller sprocket
PCD of smaller sprocket
P
d1 =
(
sin 180
z1 )
38.10
= = 304 mm
(
sin 180
25 )
Sprocket outside diameter d01 = d1 + 0.8d r
Where,
dr = diameter of rouer = 25.40 mm
d 01 = 304 + 0.8  25.40

= 324.32 mm
Case 2:- Layer sprocket:-
P
d2 =
 180 
sin  
 z2 
38.10
=
 180 
sin  
 75 
d 2 = 909.84 mm
Sprocket outside diameter = d02 = 909.87 + 0.8(25.40) = 930.16 mm
11. Two shafts whose center distance are 1m apart are connected by a V
belt drive. The driving pulley is supplied with 100kW and has an
effective diameter of 300mm. it runs at 1000rpm, while the driven
pulley runs at 375rpm. The angle of groove on the pulleys is 40º. The
permissible tension in 400mm2 cross sectional area of belt is 2.1MPa.
The density of the belt is 1100 kg/m3. Taking µ=0.28. Estimate the
number of belts required. Also calculate the length of each belt.
(April/May 2017)
Given data:
C=1m=1000mm
P=100kW
d=300mm
N1=1000rpm
N2=375rpm
2ß=40º
A=400 mm2
2.1MPa
µ=0.28.
Step 1: To find the velocity of the belt ‘v’:
Step 2: To find the larger pulley diameter ‘D’
D=0.8m
Step 3: To find the number of belts required
For an open belt drive
Case i: To find α:
α=14.48°
Case ii: To find θ:
Case iii: To find T1& T2:
----1
Mass of the belt per meter length
m=density x area x Length
=1100x400x10-6x1
=0.44kg/m
Centrifugal tension
Maximum tension in the belt
T=840N
We know that the tension in the tight side of the belt
From equation 1
Case iv: To find the power transmitted
Case v: To find the number of belts
= 16.22
=17 belts
Step 4: To find the length of the each belt:
(D − d)
2
L = 2C + ( 2 ) (D + d) +
4C
= 3.852m
shaft of the gear box of a machine. Design a suitable roller chain to
connect the motor shaft to the gearbox shaft to give an exact speed ration
of 10:1. The center to center distance of the shaft is to be approximately
600mm. (April/May 2017)
Given data:
N = P = 7.5 KW
N1 = 1400 rpm
i = 10
a0=600 mm
***similar to this problem, Change the power to be 7.5 kW and the speeds 900 and 400
rpm.
N1
i= = 10 given.
N2
Then,
N1
= N2
10
1400
N2 =
10
N 2 = 140rpm
From PSGDB 7.74
Z1 = 7
From PSGDB 7.74
Z2 = i  Z1
= 10  7
Z 2 = 70
Z 2max = 100 to 120
From PSGDB 7.74
a 600
30 30
a 600
50 50

From PSGDB 7.78,
PT = Pt + Pc + Pa
From PSGDB 7.78
1020N
Pt =
V
Z1  P  N1
60 1000
7  15.875 1400
=
60 1000
= 2.59 m / s
1020  7.5
 Pt =
2.59
Pt = 2950.35 N
Wv 2
g
m = 1.78 Kg/m [1Kg m/s2=1N]
 Pc = 1.78 (2.59) 2
Pc = 11.94 N
From PSGDB 7.78,
Ps = K. W. a
W = m x g = 1.78 x 9.81 = 17.46 N
A = 600 mm = 0.6 m.
 Ps = 6 x 17.46 x 0.6
= 62.82 N
 PT = 2950.35 + 11.94 + 6282
PT = 3025.11 N
From PSGDB 7.76
Ks = K1 K2 K3 K4 K5 K6

 Ks = 1.25 × 1 × 1× 1× 1× 1.25
= 1.5625
= 3025.11 × 1.5625
= 4726.73 N
Q
FSw =
Design load
44400
 FSW =
4726.73
FSW = 9.4
PT = 2590.28 N.
FSw = 15.71
Pt  K s
 roller =
A
2459.81*1.5625
  roller =
210
= 18.30 N/mm2
From PSGDB 7.77, the allowable bearing stress for the given speed
1400rpm , is 19.75 N/mm2.
Induced stress is less than the allowable stress i.e 18.30 < 19.75
N/mm2.  the design is safe.
From PSGDB 7.75
L = lp  P
 Z + Z2  [(Z2 − Z1 ) / 2]
2
lp = 2a p +  1 +
 2  ap
a0 600
ap = = = 31.50
P 19.05
 7 + 70  [(70 − 7) / 2]
2
 lp = 2  31.50 +  +
 2  31.50
= 63 + 38.5 + 3.19
lp = 104.69
lp 106 links
Actual length 
  L = 106 19.05
of chain 
L = 2019.3 mm
Step 13: Calculation of exact centre distance (a): From PSGDB 7.75.
e + e2 − 8m
a= P
4
 Z + Z2 
* e = lp −  1 
 2 
 7 + 70 
= 106 −  
 2 
e = 67.5
 Z − Z1 
2
* m= 2 
 2 
 70 − 7 
2
= 
 2 
m = 100.54
67.5 + 67.52 − 8 100.54

 a= 19.05
4
a = 613.18 mm
= 6.132 mm
= 607.05 mm.
P
 180 
sin  
 Z1 
19.05
=
 180 
sin  
 7 
d1 = 43.91 mm.
 d 01 = 43.91 + 0.8 11.90
d 01 = 53.43 mm
Case 2:Larger sprocket:
P
 180 
sin  
 Z2 
19.05
=
 180 
sin  
 70 
d 2 = 424.61 mm
 d 02 = d 2 + 0.8d r
diameter 
= 424.61 + 0.8 + 11.90
d 02 = 434.13 mm
13. Design a V belt drive and calculate the actual belt tensions and average
stress for the following data. Power to be transmitted = 7.5 KW, speed of
driving wheel = 1000 rpm, speed of driven wheel = 300 rpm, diameter of
the driven pulley = 500 mm, diameter of the driver pulley = 150 mm and
centre distance = 925 mm
Given data:
P = 7.5 KW
N1 = 1000 rpm
N2 = 300 rpm
D = 500 mm
d = 150 mm
C = 925 mm
***Similar to this problem change the center distance as C=2500mm and slight changes in
speeds
From PSGDB 7.58,
d = 150 mm, D = 500 mm given.
C= 925 mm given.
From PSGDB 7.61,
 (D − d) 2
L = 2C + (D + d) +
2 4C
 (500 − 150) 2
= 2  925 + (500 + 150) +
2 4  925
= 2904.12mm.
Fc = 1.07
From PSGDB 7.68
D−d
C
500 − 150
= 180 − ( )  60
925
= 157.29
Fd = 0.95.
From PSGDB 7.69 Fa = 1.3
50.8
KW = (0.79S−0.09 − − 1.32 10 −4 S2 )S
de
dN1
60
 0.150 1000
=
60
= 7.854m / s
D 500
d 150
Fb=1.14
= d p  Fb
= 150 1.14
= 171 mm.
50.8
 KW = (0.79  7.854−0.09 − − 1.32 10−4  7.84 2 )7.84
171
= 2.757KW
From PSGDB 7.70
P  Fa
nb =
K w  Fc  Fd
7.5 1.3
=
2.757 1.07  0.95
= 3.48
n b = 4belts.
From PSGDB 7.61
L D + d
A= −
4  8 
3091  500 + 150 

= − 
4  8
A = 517.5mm
(D− d) 2 (500 − 150) 2

B= =
8 8
= 15312.5 mm 2
 Cactual = 517.5 + 517.52 − 15312.5
= 1020 mm.
7.5 103
= (T1 − T2 )7.854
4
T1 − T2 = 238.73 ------1
From PSGDB 7.58  m = 0.189 Kg/m.
7.70  2B =34°

From step 5:   = 157.29
180
= 2.745 rad.
T1 − mv 2
T2 − mv 2
T1 − 0.189(7.854) 2
= e0.32.745cos ec17
T2 − 0.189(7.854) 2
T1 − 16.72T2 = −184.3 ------2
T2 = 26.9 N , T1 = 265.64 N
Maximum tension
Stress induced =
265.64
From PSGDB 7.58 Area of B section = 140 mm2  Stress induced =
140
= 1.897 N / mm 2
14. Select a wire rope for a vertical mine hoist to lift a load of 20KN from a
depth of 60 metres. A rope speed of 4 m/sec is to attained on 10
seconds.
Given data:
Depth = 60m
v2 = v = 4 m sec = 240 m min
t = 10sec
= 300KN
d = 25mm
m = 2.41Kg m
 u = 1600 to 1750 N mm 2
Dmin
d
 240  D
 50  d
D min
= 27  ( 1.08 ) = 36.73
5−1
37mm.
d
= 37  25
D = 925mm
From PSGDB 9.1
A = 0.4    d 2
4
= 0.4    25 2
4
A = 196.35mm 2
d
dw =
1.5 i
25
=
1.5 6  19
= 1.56
d w = 2mm
Wr per meter = 2.41  9.81 = 23.64 N m.
Wr = 23.64  60 = 1418.53N
= 1418.53N
Wd = W + Wr = 20 + 1418.53  10−3 = 21.42KN
Er  dw
Wb =  b  A = A
D
0.84  10 5  2
=  196.35  Er = 0.84  105 N mm2 
925
= 35661.41N
= 35.66KN.
 W + Wr  v2 − v1
Wa =  a a=
 g  t
 20 + 1418.53  10 −3  4−0
=   0.4 =
 9.81  10
= 0.87 KN = 0.4 m s 2

 W = Wd + Wb + Wa
= 21.42 + 35.66 + 0.87
= 57.95
Wea = 58KN
Breaking load
FS w =
Wea
340
=
58
FS w = 5.86
 We find Fsw  n' ( 6 ) .  The design is not safe.

u = 1750 to 1900N mm2
376
 Fsw =
58
= 6.48
15. Select a flat belt to drive a mill at 250 rpm from a 10 kW, 730 rpm
motor. Centre distance is to be around 2000 mm. The mill shaft pulley
is of 1000 mm diameter. (April/May 2018)
Given data:
N1=730 rpm
N2= 360 rpm
P= 10 kW
C= 2000 mm
D=1000 mm
***similar to this problem, Change the power to be 10 kW and the speeds 730 and 360
rpm.
The driven pulley diameter D = 1000 mm.
D N1
W.K.T  = =
d N2
N1
N2 =

1440
=
2.5
N 2 = 576rpm
D
d=

1000
=
2.5
d = 400mm
tolerances.

 d = 400mm

Design power =
From PSGDB 7.54
 D −d 
Arc of contact = 180 −    60
 c 
 1000 − 400 
= 180 −    60
 3600 
= 170
contact 170°
K  = 1.04
Small Pulley Kd
diameter
Upto 100mm 0.5
100 – 200mm 0.6
200 – 300mm 0.7
300 – 400mm 0.8
400 – 750mm 0.9
Over 750mm 1.0
 Kd = 0.8
Case (iii):
P  Ks
Ka  Kd
12  1.3
=
1.04  0.8
= 18.75KW

KW/ply/mm.
From PSGDB 7.54.
v
10
16
Load rating at 16 m /s = ( 0.0118  2 ) 
10
= 0.03776KW /Ply /mm
Design Power
Width of the belt =
18.75
=
0.03776  5
= 99.31mm
widths.
= 100 + 13 mm
= 113 mm
From PSGDB 7.61,
(D − d)
2

L = 2C + ( D + d ) +
2 4C
( 1000 − 400 )
2
= 2  3600 + 
2(
1000 + 400 ) +
4  3600
= 7200 + 2199.11 + 25
L = 9424.11mm
16. Design a chain drive to accurate a compressor from a 10 Kw electric

motor at 960 rpm. The compressor speed is to be 350 rpm. Minimum
centre to center should be 500 mm. Motor is mounted on an auxiliary
bed. Compressor is to work for 8 hours/day. (April/May 2018)
Given data:
N1=960rpm
N2= 350 rpm
P= 10 kW
a= 500 mm
***similar to this problem, Change the power to be 10 kW and the speeds 960 and 350
rpm.
N1
i= = 10 given.
N2
Then,
N1
= N2
10
1400
N2 =
10
N 2 = 140rpm
From PSGDB 7.74
Z1 = 7
From PSGDB 7.74
Z2 = i  Z1
= 10  7
Z2 = 70
Z2max = 100 to 120
From PSGDB 7.74
a 600
30 30
a 600
50 50


From PSGDB 7.78,
PT = Pt + Pc + Pa
From PSGDB 7.78
1020N
Pt =
V
Z1  P  N1
60  1000
7  15.875 1400
=
60  1000
= 2.59 m / s
1020  7.5
 Pt =
2.59
Pt = 2950.35 N
Wv 2
From PSGDB 7.78. Pc = = mv2
g
m = 1.78 Kg/m [1Kg m/s2=1N]
 Pc = 1.78 (2.59) 2
Pc = 11.94 N
From PSGDB 7.78,
Ps = K. W. a
W = m x g = 1.78 x 9.81 = 17.46 N
A = 600 mm = 0.6 m.
 Ps = 6 x 17.46 x 0.6
= 62.82 N
 PT = 2950.35 + 11.94 + 6282
PT = 3025.11 N
From PSGDB 7.76
Ks = K1 K2 K3 K4 K5 K6

 Ks = 1.25 × 1 × 1× 1× 1× 1.25
= 1.5625
= 3025.11 × 1.5625
= 4726.73 N
Q
FSw =
Design load
44400
 FSW =
4726.73
FSW = 9.4
PT = 2590.28 N.
FSw = 15.71
Pt  K s
 roller =
A
2459.81*1.5625
  roller =
210
= 18.30 N/mm2
From PSGDB 7.77, the allowable bearing stress for the given speed
1400rpm , is 19.75 N/mm2.
Induced stress is less than the allowable stress i.e 18.30 < 19.75
N/mm2.  the design is safe.
From PSGDB 7.75
L = lp  P
 Z + Z2  [(Z2 − Z1 ) / 2]
2
lp = 2a p +  1 +
 2  ap
a0 600
ap = = = 31.50
P 19.05
 7 + 70  [(70 − 7) / 2]
2
 lp = 2  31.50 +  +
 2  31.50
= 63 + 38.5 + 3.19
lp = 104.69
lp 106 links
Actual length 
  L = 106 19.05
of chain 
L = 2019.3 mm
Step 13: Calculation of exact centre distance (a): From PSGDB 7.75.
e + e2 − 8m
a= P
4
 Z + Z2 
* e = lp −  1 
 2 
 7 + 70 
= 106 −  
 2 
e = 67.5
 Z − Z1 
2
* m= 2 
 2 
 70 − 7 
2
= 
 2 
m = 100.54
67.5 + 67.52 − 8 100.54

 a= 19.05
4
a = 613.18 mm
= 6.132 mm
= 607.05 mm.
P
 180 
sin  
 Z1 
19.05
=
 180 
sin  
 7 
d1 = 43.91 mm.
 d 01 = 43.91 + 0.8 11.90
d 01 = 53.43 mm
Case 2:Larger sprocket:
P
 180 
sin  
 Z2 
19.05
=
 180 
sin  
 70 
d 2 = 424.61 mm
 d 02 = d 2 + 0.8d r
diameter 
= 424.61 + 0.8 +11.90
d 02 = 434.13 mm
17. Select a V belt drive for 15kW, 1440 rpm motor, which drives a centrifugal
pump running at a speed of 576 rpm for a service of 8-10 hours per day. The
distance between the driver and the driven shaft is approximately 1.2 m.
Service factor Ks=1.1, design factor Na=1.0 , VR=2.5 (April/May 2018)
Given data:
P = 7.5 KW
N1 = 1000 rpm
N2 = 300 rpm
D = 500 mm
d = 150 mm
C = 925 mm
***similar to this problem, Change Given data as per the given question and solve the
problem with same procedure.
From PSGDB 7.58,
d = 150 mm, D = 500 mm given.
C= 925 mm given.
From PSGDB 7.61,
 (D − d) 2
L = 2C + (D + d) +
2 4C
 (500 − 150) 2
= 2  925 + (500 + 150) +
2 4  925
= 2904.12mm.
Fc = 1.07
From PSGDB 7.68
D−d
C
500 − 150
= 180 − ( )  60
925
= 157.29
Fd = 0.95.
From PSGDB 7.69
Fa = 1.3
50.8
KW = (0.79S−0.09 − − 1.32 10 −4 S2 )S
de
dN1
60
 0.150 1000
=
60
= 7.854m / s
D 500
d 150
Fb=1.14
= d p  Fb
= 150 1.14
= 171 mm.
50.8
 KW = (0.79  7.854−0.09 − − 1.32 10−4  7.84 2 )7.84
171
= 2.757KW
From PSGDB 7.70
P  Fa
nb =
K w  Fc  Fd
7.5 1.3
=
2.757 1.07  0.95
= 3.48
n b = 4belts.
From PSGDB 7.61
L D + d
A= −
4  8 
3091  500 + 150 

= − 
4  8
A = 517.5mm
(D− d) 2 (500 − 150) 2

B= =
8 8
= 15312.5 mm 2
 Cactual = 517.5 + 517.52 − 15312.5
= 1020 mm.
7.5 103
= (T1 − T2 )7.854
4
T1 − T2 = 238.73 ------1
From PSGDB 7.58  m = 0.189 Kg/m.
7.70  2B =34°

From step 5:   = 157.29
180
= 2.745 rad.
T1 − mv 2
T2 − mv 2
T1 − 0.189(7.854) 2
= e0.32.745cos ec17
T2 − 0.189(7.854) 2
T1 − 16.72T2 = −184.3 ------2
T2 = 26.9 N , T1 = 265.64 N
Maximum tension
Stress induced =
From PSGDB 7.58 Area of B section = 140 mm2
265.64
 Stress induced =
140
= 1.897 N / mm 2
18. A temporary elevator is assembled at the construction site to raise building

materials, such a cement, to a height of 20m. It is estimated that the
maximum weight of the material to be raised is 5 kN. It is observed that the

acceleration in such applications is 1 m/s2, 10mm diameter, 6x19
construction wire ropes with fibre core are used for this application. The
tensile designation of the wire is 1570 and the factor of safety should be 10
for the preliminary calculations. Determine the number of wire ropes
required for this application. Neglect bending stress. (April/May 2018)
Given data:
h − = 20m
W = 1 tonne = 1000Kg = 9810N
n=2
Wire rope size = 6  19
d = 12mm
Breaking load Wbreak = 78KN
D = 56d
t = 1sec
v = 1.2 m s = 72 m min
***similar to this problem, Change Given data as per the given question and need to find
the number of wire ropes
Step 1: Selection of suitable Wire rope:
Given: 6 × 19 size wire rope.
Step 2: Calculation of design load:
Assuming a larger factor of safety of 15, the design load is calculated.
Design load = Load to be lifted × Assumed FOS
= 9810 × 15
= 147150 N
= 147.15 KN
Step 3: Selection of Wire rope diameter (d):
From PSGDB 9.5. For the breaking strength (Wbreak) 78 KN (7.8

tonnes). take the diameter of the rope is 12mm.
d = 12mm
u = 1600 to 1750 N mm 2
Step 4: Calculation of sheave diameter (D):
Given:
Sheave diameter D = 56 d
= 56 × 12
= 672 mm
Step 5: Selection of the area of useful cross section of the rope (A):
From PSGDB 9.1
A = 0.4    d 2
4
= 0.4    12 2
4
A = 45.24mm 2
Step 6: Calculation of Wire diameter (dw):
d
dw =
1.5 i
i = Number of strands × Number of wires in each strand
= 6 × 19
i = 114
12
dw =
1.5 114
 dw = 0.75mm
Step 7: Selection of Weight of rope (Wr):
From PSGDB 9.5. Corresponding to the diameter of the rope

12mm, take
Approximate weight = 0.54 Kgf m
= 5.3 N m
 Weight of rope Wr = Approximate Weight  h
= 5.3  20
Wr = 106N
Step 8: Calculation of various loads:
Case (i): To find the direct load (Wd):
Wd = W + Wr
= 9810N + 106N
Wd = 9916N
Case (ii): To find the acceleration load (Wa):
 W + Wr 
Wa =  a
 g 
a = acceleration of the load
V2 − V1
=
t1
1.2 − 0
=
1
a = 1.2 m s2
 9810 + 106 
 Wa =   1.2
 9.81 
Wa = 1212.97N
Step 9: Calculation of effective loads on the rope:
Effective load during acceleration of the load
Wea = Wd + Wb + Wa
= 9916 + 0 + 1212.97
 Wb = 0, From the Question 
 Bending load is neglected 
 
= 11128.97N
Step 10: Calculation of working factor of safety (FSw):
Working factor   Breaking load

=
of Safety ( Fsw ) 
 Effective load
during acceleration ( Wea )
78  10 3
=
11128.97
Fsw = 7
Step 11: Check for design:
From PSGDB 9.1, for hoists and class 2, the recommended factor of
safety = 5.
Since the working factor of safety is greater than the recommended

factor of safety. Therefore the design is safe.
19. Select a high-speed duck flat belt drive for a fan running at 360 rpm
which is driven by 10kW, 1440rpm motor. The belt drive is open and
space available for a center distance of 2m approximately. The diameter
of the driven pulley 1000 rpm. (Nov/Dec 2018)
Given data:
N 1 = 1440rpm
 = 2.5
c = 3.6m
 = 16 m
s
K s = 1.3
Belt = 5 Ply, flat dunlop belt.
P = 12KW
Load rating at 5 m = 0.0118 KW Ply mm
s
***Similar to this problem changes in speeds and power
Assume the driven pulley diameter D = 1000 mm.
D N1
W.K.T  = =
d N2
N1
N2 =

1440
=
2.5
N 2 = 576rpm
D
d=

1000
=
2.5
d = 400mm
tolerances.

 d = 400mm

Design power =
From PSGDB 7.54
 D −d 
Arc of contact = 180 −    60
 c 
 1000 − 400 
= 180 −    60
 3600 
= 170
contact 170°
K  = 1.04
Small Pulley Kd
diameter
Upto 100mm 0.5

100 – 200mm 0.6
200 – 300mm 0.7
300 – 400mm 0.8
400 – 750mm 0.9
Over 750mm 1.0
 K d = 0.8
Case (iii):
P  Ks
Ka  Kd
12  1.3
=
1.04  0.8
= 18.75KW

KW/ply/mm.
From PSGDB 7.54.
v
10
16
Load rating at 16 m /s = ( 0.0118  2 ) 
10
= 0.03776KW /Ply /mm
Design Power
Width of the belt =
18.75
=
0.03776  5
= 99.31mm
widths.
= 100 + 13 mm
= 113 mm
From PSGDB 7.61,
(D − d)
2

L = 2C + ( D + d ) +
2 4C
( 1000 − 400 )
2
= 2  3600 + 
2(
1000 + 400 ) +
4  3600
= 7200 + 2199.11 + 25
L = 9424.11mm
20. A centrifugal pump running at 340rpm is to be driven by a 100 kW

motor running at 1440 rpm. The light duty drive is to work for atleast
20 hours every day. The center distance between the motor shaft and
the pump shaft is 1200mm. suggest a suitable multiple v belt drive for
the application. (Nov/Dec 2018)
Given data:
C=1m=1000mm
P=100kW
d=300mm
N1=1000rpm
N2=375rpm
2ß=40º
A=400 mm2
2.1MPa
µ=0.28.
***Similar to this problem change the center distance as C=1200 mm and slight changes in
speeds
Step 1: To find the velocity of the belt ‘v’:
Step 2: To find the larger pulley diameter ‘D’
D=0.8m
Step 3: To find the number of belts required
For an open belt drive
Case i: To find α:
α=14.48°
Case ii: To find θ:
Case iii: To find T1& T2:
----1
Mass of the belt per meter length
m=density x area x Length
=1100x400x10-6x1
=0.44kg/m
Centrifugal tension
Maximum tension in the belt
T=840N
We know that the tension in the tight side of the belt
From equation 1
Case iv: To find the power transmitted
Case v: To find the number of belts
= 16.22
=17 belts
Step 4: To find the length of the each belt:
(D − d)
2
L = 2C + ( 2 ) (D + d) +
4C
= 3.852m
21. The transporter of a heat treatment furnace is driven by a 4.5kW,

1440rpm induction motor through a chain drive with a speed
reduction ratio 2.4. The transmission is horizontal with bath type
of lubrication. Rating is continuous with 3 shifts per day. Design
the complete chain drive. Assume center distance as 500mm and
service factor as 1.5. (Nov/Dec 2018)
Given data:
N = P = 7.5 KW
N1 = 1400 rpm
i = 10
a0=600 mm
*** similar to this problem with different data.
N1
i= = 10 given.
N2
Then,
N1
= N2
10
1400
N2 =
10
N 2 = 140rpm
From PSGDB 7.74
Z1 = 7
From PSGDB 7.74
Z2 = i  Z1
= 10  7
Z 2 = 70
Z 2max = 100 to 120
From PSGDB 7.74
a 600
30 30
a 600
50 50

From PSGDB 7.78,
PT = Pt + Pc + Pa
From PSGDB 7.78
1020N
Pt =
V
Z1  P  N1
60 1000
7  15.875 1400
=
60 1000
= 2.59 m / s
1020  7.5
 Pt =
2.59
Pt = 2950.35 N
Wv 2
g
m = 1.78 Kg/m [1Kg m/s2=1N]
 Pc = 1.78 (2.59) 2
Pc = 11.94 N
From PSGDB 7.78,
Ps = K. W. a
W = m x g = 1.78 x 9.81 = 17.46 N
A = 600 mm = 0.6 m.
 Ps = 6 x 17.46 x 0.6
= 62.82 N
 PT = 2950.35 + 11.94 + 6282
PT = 3025.11 N
From PSGDB 7.76
Ks = K1 K2 K3 K4 K5 K6

 Ks = 1.25 × 1 × 1× 1× 1× 1.25
= 1.5625
= 3025.11 × 1.5625
= 4726.73 N
Q
FSw =
Design load
44400
 FSW =
4726.73
FSW = 9.4

PT = 2590.28 N.
FSw = 15.71
Pt  K s
 roller =
A
Where, A = 210 mm From PSGDB 7.72 for selected

2
2459.81*1.5625
chain  roller =
210
= 18.30 N/mm2
From PSGDB 7.77, the allowable bearing stress for the given speed 1400rpm, is
19.75 N/mm2.
Induced stress is less than the allowable stress i.e 18.30 < 19.75 N/mm2.
From PSGDB 7.75

L = lp  P
 Z + Z2  [(Z2 − Z1 ) / 2]
2
Where no.of links lp = 2a p +  1  +
 2  ap
a0 600
Approximate center distance in multiples of pitches a p = = = 31.50
P 19.05
 7 + 70  [(70 − 7) / 2]
2
 lp = 2  31.50 +   +
 2  31.50
= 63 + 38.5 + 3.19
lp = 104.69
lp =106 links
Actual length 
  L = 106 19.05
of chain 
L = 2019.3 mm
Step 13: Calculation of exact centre distance (a):
From PSGDB 7.75.
e + e2 − 8m
m = 100.54 a= P
4
Case 2: To find m:
Case 1: To find e:
 Z − Z1 
2
 Z + Z2  * m= 2 
* e = lp −  1   2 
 2 
 70 − 7 
2
 7 + 70  = 
= 106 −    2 
 2 
m = 100.54
e = 67.5
67.5 + 67.52 − 8 100.54

 a= 19.05
4
a = 613.18 mm
From PSGDB 7.75, Decrement in centre distance for an initial sag = 0.01a
= 6.132 mm
= 607.05 mm.
P
 180 
sin  
 Z1 
19.05
=
 180 
sin  
 7 
d1 = 43.91 mm.
 d 01 = 43.91 + 0.8 11.90
d 01 = 53.43 mm
Case 2: Larger sprocket:
P
 180 
sin  
 Z2 
19.05
=
 180 
sin  
 70 
d 2 = 424.61 mm
 d 02 = d 2 + 0.8d r
diameter 
= 424.61 + 0.8 + 11.90
d 02 = 434.13 mm
22. A workshop crane is lifting a load

of 25 kN through a wire rope and hook. The weight of the hook etc., is 15 kN.
The rope drum diameter may be taken as 30 times the diameter of the rope.
The load is to be lifted with an acceleration of 1m/s2. Calculate the diameter of
the wire rope. Take a factor of safety of 6 and E for the wire is 80kN/mm2. The
ultimate stress may be taken as 1800 MPa. The cross-sectional area of the wire
rope may be taken as 0.38 times the square of the wire rope diameter.
(Nov/Dec 2018)
Given data:
Depth = 60m
v2 = v = 4 m sec = 240 m min
t = 10sec
***Similar to this problem
= 300KN
d = 25mm
m = 2.41Kg m
 u = 1600 to 1750 N mm 2
Dmin
d
 240  D
 50  d
D min
= 27  ( 1.08 ) = 36.73
5−1
37mm.
d
= 37  25
D = 925mm
From PSGDB 9.1
A = 0.4    d 2
4
= 0.4    25 2
4
A = 196.35mm 2
d
dw =
1.5 i
25
=
1.5 6  19
= 1.56
d w = 2mm
Wr per meter = 2.41  9.81 = 23.64 N m.
Wr = 23.64  60 = 1418.53N
= 1418.53N
Wd = W + Wr = 20 + 1418.53  10−3 = 21.42KN
Er  dw
Wb =  b  A = A
D
0.84  10 5  2
=  196.35  Er = 0.84  105 N mm2 
925
= 35661.41N
= 35.66KN.
 W + Wr  v2 − v1
Wa =  a a=
 g  t
 20 + 1418.53  10 −3  4−0
=   0.4 =
 9.81  10
= 0.87 KN = 0.4 m s 2

 W = Wd + Wb + Wa
= 21.42 + 35.66 + 0.87
= 57.95
Wea = 58KN
Breaking load
FS w =
Wea
340
=
58
FS w = 5.86
 We find Fsw  n ' ( 6 ) .  The design is not safe.

u = 1750 to 1900N mm2
376
 Fsw =
58
= 6.48
23. A motor driven blower is to run at 650rpm driven by an electric motor of 7.5
kW at 1800rpm. Design a suitable V belt drive. (April/May 2019)
Given data:
P = 7.5 KW
N1 = 1000 rpm
N2 = 300 rpm
***Similar to this problem assume the missing data’s and slight changes in speeds
From PSGDB 7.58,
d = 150 mm, D = 500 mm given.
C= 925 mm given.
From PSGDB 7.61,
 (D − d) 2
L = 2C + (D + d) +
2 4C
 (500 − 150) 2
= 2  925 + (500 + 150) +
2 4  925
= 2904.12mm.
Fc = 1.07
From PSGDB 7.68
D−d
C
500 − 150
= 180 − ( )  60
925
= 157.29
Fd = 0.95.
From PSGDB 7.69 Fa = 1.3
50.8
KW = (0.79S−0.09 − − 1.32 10 −4 S2 )S
de
dN1
60
 0.150 1000
=
60
= 7.854m / s
D 500
d 150
Fb=1.14
= d p  Fb
= 150 1.14
= 171 mm.
50.8
 KW = (0.79  7.854−0.09 − − 1.32 10−4  7.84 2 )7.84
171
= 2.757KW
From PSGDB 7.70
P  Fa
nb =
K w  Fc  Fd
7.5 1.3
=
2.757 1.07  0.95
= 3.48
n b = 4belts.
From PSGDB 7.61
Cactual = A + A − B
2
L D + d
A= −
4  8 
3091  500 + 150 

= − 
4  8
A = 517.5mm
(D− d) 2 (500 − 150) 2

B= =
8 8
= 15312.5 mm 2
 Cactual = 517.5 + 517.52 − 15312.5
= 1020 mm.
7.5 103
= (T1 − T2 )7.854
4
T1 − T2 = 238.73 ------1
From PSGDB 7.58  m = 0.189 Kg/m.
7.70  2B =34°

From step 5:   = 157.29
180
= 2.745 rad.
T1 − mv 2
T2 − mv 2
T1 − 0.189(7.854) 2
= e0.32.745cos ec17
T2 − 0.189(7.854) 2
T1 − 16.72T2 = −184.3 ------2
T2 = 26.9 N , T1 = 265.64 N
Maximum tension
Stress induced =
265.64
From PSGDB 7.58 Area of B section = 140 mm2  Stress induced =
140
= 1.897 N / mm 2
24. Design a chain drive to accurate a compressor from a 10kW electric motor
at 960rpm. The compressor speed is to be 350rpm. Minimum center distance
should be 0.5m. motor is mounted on an auxiliary bed. Compressor is to
work for 8 hours/ day. (April/May 2019)
Given data:
N = P = 7.5 KW
N1 = 1400 rpm
i = 10
a0=600 mm
***similar to this problem, change the centre distance and power
N1
i= = 10 given.
N2
Then,
N1
= N2
10
1400
N2 =
10
N 2 = 140rpm
From PSGDB 7.74
Z1 = 7
From PSGDB 7.74
Z2 = i  Z1
= 10  7
Z 2 = 70
Z 2max = 100 to 120
From PSGDB 7.74
a 600
30 30
a 600
50 50

From PSGDB 7.72, Assume the chain to be duplex.
 10 A - 2 / DR50 chain number is selected.
Step 6: Calculation of total load on the driving side of the chain (P T):
From PSGDB 7.78,
PT = Pt + Pc + Pa
From PSGDB 7.78
1020N
Pt =
V
Z1  P  N1
60 1000
7  15.875 1400
=
60 1000
= 2.59 m / s
1020  7.5
 Pt =
2.59
Pt = 2950.35 N
Wv 2
g
m = 1.78 Kg/m [1Kg m/s2=1N]
 Pc = 1.78 (2.59) 2
Pc = 11.94 N
From PSGDB 7.78,
Ps = K. W. a
W = m x g = 1.78 x 9.81 = 17.46 N
A = 600 mm = 0.6 m.
 Ps = 6 x 17.46 x 0.6
= 62.82 N
 PT = 2950.35 + 11.94 + 6282
PT = 3025.11 N
From PSGDB 7.76
Ks = K1 K2 K3 K4 K5 K6

 Ks = 1.25 × 1 × 1× 1× 1× 1.25
= 1.5625
= 3025.11 × 1.5625
= 4726.73 N
Q
FSw =
Design load
44400
 FSW =
4726.73
FSW = 9.4

PT = 2590.28 N.
FSw = 15.71

Pt  K s
 roller =
A
Where, A = 210 mm From PSGDB 7.72 for selected chain

2
2459.81*1.5625
  roller =
210
= 18.30 N/mm2
From PSGDB 7.77, the allowable bearing stress for the given speed 1400rpm , is
19.75 N/mm2.
Induced stress is less than the allowable stress i.e 18.30 < 19.75 N/mm2. 
the design is safe.
From PSGDB 7.75
L = lp  P
 Z + Z2  [(Z2 − Z1 ) / 2]
2
lp = 2a p +  1  +
 2  ap
a0 600
ap = = = 31.50
P 19.05
 7 + 70  [(70 − 7) / 2]
2
 lp = 2  31.50 +  +
 2  31.50
= 63 + 38.5 + 3.19
lp = 104.69
lp 106 links
Actual length 
  L = 106 19.05
of chain 
L = 2019.3 mm
Step 13:
Calculation of exact centre distance (a): From PSGDB 7.75.
e + e2 − 8m
a= P
4

 Z + Z2 
* e = lp −  1 
 2 
 7 + 70 
= 106 −  
 2 
e = 67.5
 Z − Z1 
2
* m= 2 
 2 
 70 − 7 
2
= 
 2 
m = 100.54
67.5 + 67.52 − 8 100.54

 a= 19.05
4
a = 613.18 mm
= 6.132 mm
= 607.05 mm.
P
 180 
sin  
 Z1 
19.05
=
 180 
sin  
 7 
d1 = 43.91 mm.
 d 01 = 43.91 + 0.8 11.90

d 01 = 53.43 mm
Case 2:
Larger sprocket:
P
 180 
sin  
 Z2 
19.05
=
 180 
sin  
 70 
d 2 = 424.61 mm
 d 02 = d 2 + 0.8d r
diameter 
= 424.61 + 0.8 + 11.90
d 02 = 434.13 mm
25. Select a suitable wire rope for a mini hoist carrying a load of 2 tonnes to be
lifted from a depth of 100m. A rope speed of 10m/s must be attained in 10
seconds. Assume minimum factor of safety as 10. (April/ May 2019)
Given data:
Depth = 60m
v2 = v = 4 m sec = 240 m min
t = 10sec
*** Refer this Problem
= 300KN

d = 25mm
m = 2.41Kg m
 u = 1600 to 1750 N mm 2
Dmin
d
 240  D
 50  d
D min
= 27  ( 1.08 ) = 36.73 37mm.
5−1
= 37  25
D = 925mm
From PSGDB 9.1
A = 0.4    d 2
4
= 0.4    25 2
4
A = 196.35mm 2
d
dw =
1.5 i
25
=
1.5 6  19
= 1.56
d w = 2mm

Wr per meter = 2.41  9.81 = 23.64 N m.
Wr = 23.64  60 = 1418.53N
= 1418.53N
Wd = W + Wr = 20 + 1418.53  10−3 = 21.42KN
Er  dw
Wb =  b  A = A
D
0.84  10 5  2
=  196.35  Er = 0.84  105 N mm2 
925
= 35661.41N
= 35.66KN.
 W + Wr  v2 − v1
Wa =  a a=
 g  t
 20 + 1418.53  10 −3  4−0
=   0.4 =
 9.81  10
= 0.87 KN = 0.4 m s 2

 W = Wd + Wb + Wa
= 21.42 + 35.66 + 0.87
= 57.95
Wea = 58KN
Step 9: Working factor of Safety (FSw).

Breaking load
FS w =
Wea
340
=
58
FS w = 5.86
 We find Fsw  n' ( 6 ) .  The design is not safe.

u = 1750 to 1900N mm2
376
 Fsw =
58
= 6.48

ME 6601 - DESIGN OF TRANSMISSION SYSTEMS
QUESTION BANK
UNIT –II
SPUR GEARS AND HELICAL GEARS
PART A
1. Specify the effects of increasing the pressure angle in gear design?
Increasing the pressure angle will increase the beam and surface
strengths of tooth. But gear becomes noisy.
2. Why is gear tooth subjected to dynamic load?
Inaccuracy of tooth spacing
Elasticity of parts
Deflection of teeth under load
Dynamic unbalance of rotating masses
3. State the law of gearing?
The law of gearing states that for obtaining a constant velocity ratio,
at any instant of teeth the common normal at each point of contact
should always pass through a pitch point (fixed point), situated on the
line joining the centres of the rotation of the pair of mating gears.
4. What is pressure angle? What is the effect of increase in pressure angle?

❖ Pressure angle in the angle between the common normal to two
gear teeth at the point of contact and the common tangent at the
pitch point
❖ The increase of the pressure angle results in stronger tooth,
because the tooth acting as a beam is wider at the base.
5. Define module?
It is the ratio of the pitch circle diameter to the number of teeth.
6. Differentiate the double helical and herringbone gears.
❖ When there is groove in between the gears, then the gears are
specifically known as double helical gears.
❖ When there is no groove in between the gears, then the gears is

known as herringbone gears
7. What are the profiles of a spur gear?
❖ Involute tooth profile
❖ Cycloidal tooth profile
8. What is herringbone gear?
When there is no groove in between the gears, then the gears is

known as herringbone gears.
(Or)
The double helical gears are connecting two parallel shafts are known as
herringbone gears. It is used in heavy machinery and gear boxes.
9. Define backlash. What factors influence backlash?
Back lash is the difference between the tooth space and the tooth thickness along
the pitch circle.
The factors influencing in backlash are given below,
Module
Pitch line velocity
10. A helical gear has a normal pressure angle of 20°, a helix angle of 45°,
and normal module of 4mm and has 20 teeth. Find the pith diameter.
Given data:
 = 20
 = 45
m n = 4mm
Z = 20
mn
d= Z
cos 
4
=  20
cos 45
d = 113.14 mm
11. Why are gear drives superior to belt drives or chain drives? The
advantages of gear drives?
❖ The gear drives possess high load carrying capacity, high
compact layout.
❖ They can transmit power from very small values to several
kilowatts.
12. Illustrate the materials for making gears'.
1. Ferrous metals such as carbon steels, alloy steels of nickel,
chromium and vanadium.
2. Cast-iron of different grades.
3. Non-ferrous metals such as brass, bronze, etc.
4. Non-metals like phemolic resins nylon, bakelite etc.
Among them steel with proper heat treatment is extensively, employed
in many of the engineering applications.
13. Specify the types of gears-failures.

❖ a) Tooth breakage. b) Pitting of tooth surface. c) Abrasive-
wears. d) Seizing of teeth etc.
14. At what occasions non-metallic gears are employed.
❖ Non-metallic gears are employed 'where we require silent
operation and low power transmission. For example, in
instruments like pressure gauge and so on.
15. What is meant by spur-gear?
Spur-gear is the gear in which teeth are cut at the circumference of a
slab called as gear-blank such that the teeth are parallel to gear-axis.
16. Define the following terms. a) Tip circle. b), Root circle. c) Pitch circle
a) Tip circle or addendum circle is the circle which coincides crests or tops
of all teeth.
b) Root circle or addendum circle is the circle which coincides with. Roots
or bottoms of all teeth.
c) Pitch circle is the imaginary circle in which the pair of gears rolls one
over the other. This circle can be visible when the pair of gears fast rotating. This
will lie between tip circle and root circle.
17. How are the following terms defined? a) Pressure angle. b) Module.
a) Pressure angle (a) is the angle making by the line of action
common- tangent to the pitch circles of mating parts.
b) Module m is the ratio of pitch circle diameter to the number d of
gear teeth, and is usually represented in millimetres
18. . Write short notes on backlash of gears.
Backlash can be defined as the play between a mating pair of gear
assembled condition
19. Define form factor?
Form factor is a constant, employed in the design of gear which, design
the shape and the number of teeth.
20. Why dedendum Value is more than addendum value?

In order to get clearance between the teeth of one gear and bottom
surface of mating gear so as to avoid interference, dedendum is having more
value than addendum.
21. What are the effects of increasing and decreasing the pressure angle in
gear design? (April/May 2017)
❖ Increasing the pressure angle will increase the beam and

surface strengths of tooth. But gear becomes noisy.
❖ Decreasing the pressure angle will increase the minimum
number of teeth required on the pinion to avoid interference/
undercutting
22. Differentiate the double helical and herringbone gears. (April/May 2017)
❖ When there is groove in between the gears, then the gears are
specifically known as double helical gears.
❖ When there is no groove in between the gears, then the gears is

known as herringbone gears
23. What is meant by stub tooth in gear drives? (Nov/Dec 2017)
Teeth in which the working depth is less than 2.000 divided by the
normal diametral pitch.
24. Define virtual number of teeth in helical gears. (Nov/Dec 2017)

The equivalent number of teeth (also called virtual number of teeth),
Zv, is defined as the number of teeth in a gear of radius.
25. Specify the types of gear failures. (April/May 2018)

i. Tooth breakage (due to static and dynamic loads)
ii. Tooth wear (or surface deterioration)- Abrasion, Pitting and Scoring or
Seizure
26. In what ways helical gears are different from spur gears? (April/May
2018)
Helical gears produce less noise than spur gears. They have a greater
load capacity than equivalent spur gears
27. State the advantages of toothed gears over the other types of
transmission systems. (Nov/Dec 2018)
i. Since there is no slip, so exact velocity ratio is obtained
ii. It is capable of transmitting larger power
iii. It is more efficiency and effective means of power transmission
28. Why pinion is made harder than the gear? (Nov/Dec 2018)
Because the teeth of pinion undergo more number of cycles than those of
gear and hence quicker wear.
29. State the law of gearing (April/May 2019)
The law of gearing states that for obtaining a constant velocity ratio, at any
instant of teeth the common normal at each of contact should always pass
through a pitch point, situated on the line joining the centres of rotation of the
pair of mating gears.
30. What is meant by virtual number of teeth? (April/May 2019)

The number of teeth on virtual spur gear in the normal plane is known as
virtual number of teeth (zeq)
Where, z= actual number of teeth on a helical gear

β= Helix angle
PART B
1. Design a spur gear drive for a stone crusher where the gears are made of
C40 steel. The pinion is transmitting 30 KW at 1200rpm. The gear ratio
is 3. Taking the working life of the gears as 7500hrs.
Given data:
Material = C40 steel
P = 30KW
N 1 = 1200rpm
i=3
Gear life = 7500hrs.
Step 1: To find Gear ratio (i):
i=3 Given.
Step 2: Selection of Material:
Pinion and gear are made of C40 steel
 Assume surface hardness > 350
Step 3: To find the gear life in number of cycles (N):
N = Gear life in mins × N1
= (7500 × 60) mins × 1200
N = 54 × 107 cycles.
Step 4: Calculation of initial design torque [Mt]:
From PSGDB 8.15, table 13.
[M t ] = M t  K  K d
From PSGDB 8.15 , table 13 Initially assume for symmetric scheme,

take K  K d = 1.3
60  P
Mt =
2 N 1
60  30  10 3
=
2   1200
238.73N.m
 M t  = M t  K  K d
= 238.73  1.3
Mt  = 310.34Nm.
Step 5: Calculation of Eeq, , [b] and [C]:
Case (i): To find equivalent young’s Modulus:
From PSGDB 8.14 , table 9 For C40 steel take
Eeq = 2.15 × 105 N/mm2 .
Case (ii): To find design bending stress [b]:
From PSGDB 8.18 , table 18, Rotation in one direction
1.4  K b1
b  =   −1
n  K
 Life factor for bending Kb1
Kb1 = 0.7 for HB > 350 and N  25 × 107 cycles
From PSGDB 8.20 table 22.
 Factor of safety (n):
n = 2, for steel tempered From PSGDB 8.19 , table 20
 Stress concentration factor (K):
K = 1.5 for steel From PSGDB 8.19 , table 21
 Tensile strength (u):
u = 630 N/mm2 for C40 steel From PSGDB 8.19
 Endurance limit stress in bending (-1):
-1 = 0.35 u + 120 , for alloy steel. From PSGDB 8.19 table 19
= (0.35 × 630) + 120
-1 = 340.5 N/mm2
1.4  K b1
W  K  T  b  =   −1
n  K
1.4  0.7
=  340.5
2  1.5
b  = 111.23N mm 2
Case (iii): To find the design contact stress  c  :
c  = CR  HRC  KC1 From PSGDB 8.16

 CR = co efficient depending upon surface hardness.
CR = 265 , for C40 steel hardened and tempered From PSGDB 8.16 ,
table 16
 Rockwell Hardness number (HRC):
HRC = 40 to 55 , for C40 steel From PSGDB 8.16 , table 16
 Life factor (Ku):
Ku = 0.585 , for HB  350 and N  25  107 cycles. From PSGDB 8.17 ,

table 17
c  = 265  55  0.585
= 8526.375 Kgf cm 2
c  = 852.64 N mm 2
Step 6: Calculation of centre distance (a):
 0.74  E eq  M t 
2
a  ( b + 1) 3  −2   From PSGDB 8.13 table 8 for

 c  i
designing.
 = b = 0.3 , for initial calculation From PSGDB 8.14 table 10

a
2
 0.74  2.15  10  310.34  10
5 3
a  ( 3 + 1) 3
 852.64   3  0.3
 152.89mm.
Take a = 155mm
Step 7: Selection of Z1 and Z2:
 Number of teeth on pinion Z1 = 17 (Assume)

 Number of teeth on gear (Z2)
Z2
Z 2 = i  Z 1 From PSGDB 8.1 and table 4(8.3) i = 1
Z1
= 3  17
Z2 = 51
Step 8: Calculationof module (m):
From PSGDB 8.22 table 26
2a
m=
Z1 + Z2
2  155
=
17 + 51
m = 4.56mm
From PSGDB 8.2, table 1. Choice 1. Take the nearest higher standard
module,
m = 5mm.
Step 9: Revision of centre distance:
From PSGDB 8.22 , table 26.
m ( Z1 + Z2 )
a=
2
5 ( 17 + 51 )
=
2
a = 170mm
Step 10: Calculation of b , d1 , v and P
Case 1: To find the face width (b):
b =  a
= 0.3  170
b = 51mm
Case 2: To find the Pitch circle diameter (d1)
From PSGDB 8.22 , table 26
d1 = m  Z 1
= 5  17
d1 = 85mm
Case 3: To find the pitch line velocity (v):
d 1N 1
v=
60
 85  10 −3  1200
=
60
= 5.34 m sec
Case 4: To find P:
b
P =
d1
51
85
P = 0.6
Step 11: Selection of Quality of gear:
For pitch line velocity 5.34 m/sec. Is Quality 8 gears are selected.
Step 12: Revision of design torque [Mt]:
M t  = M t  K  Kd
Revised K = 1.03 , From PSGDB 8.15 , table 14, for p = 0  6 bearings
are close to gears and symmetrical.
Revised K d = 1.4 . From PSGDB 8.16 , table 15, for IS Quality 8 , HB

> 350 , and v = 5.34 m sec
Mt  = 238.73  1.03  1.4

= 344.24Nm .
Step 13: Check for bending:
Calculation of induced bending stress (b):
i1
b =  M t   b  From PSGDB 8.13A table 8
amby
 y = Form factor = 0.366 , for Z1 = 17 , From PSGDB 8.18 table 18
3+1
b =  344.24  10 3
170  5  51  0.366
= 86.78N mm2
We find b   b  ,  the design is safe.
Step 14: Check for wear strength ( c ) :
From PSGDB 8.13 table 8 , for checking.
i+1 i+1
c = 0.74   Eeq  M t 
a ib
3+1 3+1
= 0.74   2.15  10 5  344.24  10 3
170 3  51
= 765.9N mm2
We find c   c  .  The design is safe.
Step 15: Basic dimensions of Pinion and gear:
 Module: m = 5mm
 Number of teeth: Z1 = 17
Z2 = 51
 Pitch circle diameter:
d1 = m  Z1 = 5  17 = 85mm
d2 = m  Z2 = 5  51 = 255mm
 Centre distance:
a = 170mm
 Face width:
b = 51mm
 Height factor:
f0 = 1 , for full depth teeth,
 Bottom clearance:
C = 0.25m = 0.25  5 = 1.25mm .
 Tooth depth:
h = 2.25m = 2.25  5 = 11.25mm
 Tip diameter:
da1 = ( Z1 + 2f0 ) m
= ( 17 + 2  1) 5
= 95mm.
da2 = ( Z2 + 2f0 ) m
= ( 51 + 2  1) 5
= 265mm.
 Root diameter:
df 1 = ( Z1 − 2f0 ) m − 2C
= ( 17 − 2  1) 5 − 2  1.25
= 72.5mm.
df 2 = ( Z2 − 2f0 ) m − 2C
= ( 51 − 2  1) 5 − 2  1.25
= 242.5mm.
2. Design of helical gear drive to connect an electric motor to a

reciprocating pump. Gears are overhanging in their shafts. Motor speed
= 1440rpm. Speed reduction ratio = 5, motor power = 37 KW, pressure
angle = 20° , helix angle = 25°.
Given data:
N 1 = 1440rpm
i=5
P = 37KW
 = 20 =  n
 = 25
Step 1: selection of Material.
Generally we assume C45 steel for both pinion and gear.
b  = 180 N mm2 , 250 BHN.
Step 2: Calculation of number of teeth Z1 & Z2:
No. of teeth on pinion Z1 = 20 (assume)
No. of teeth on gear Z 2 = i  Z 1
= 5  20
= 100
Step 3: Calculation of tangential load on teeth (Ft):
P
Ft =  K0
v
Case 1: To find the Pitch line velocity (v)
d 1N 1
v=
60
From PSGDB 8.22
mn
d1 =  Z1
cos 
mn
=  20
cos 25
mn
d1 =
22.06
 m n  1440
v =
60  22.06  1000
= 1.66m n m
sec
Case 2: To find K0:
K 0 = 1.5 for medium shock conditions.
37  10 3
 Ft =  1.5
1.66m n
33433.73
=
mn
Step 4: Calculation of initial dynamic Load (Fd)
Ft
Fd =
Cv
Case 1: To find velocity factor ( C v )
6
Cv = for carefully cut gears, v  20 m s
6+v
6
=
6 + 15
C v = 0.286
Case 2: To find initial dynamic load (Fd):
33433.73 1
Fd = 
mn 0.286
116901.17
mn
Step 5: Calculation of beam strength (Fs):
Fs = b  by−1Pcn From PSGDB 8.51 Pcn = m n
 Fs = b  by1m n
Where,
b = 10  m n From PSGDB 8.14
y1 = 0.154 −  0.912  From PSGDB 8.50 , 20 full depth


 Z v1 
system.
Z1
Z v1 =
cos 3 
20
=
cos 3 25
Z v1 = 26.86 27
0.912
 y 1 = 0.154 −
26.86
= 0.12
Fs = b  b y1m n
= 180  10  m n  0.1143   m n
= 678.58m2n
Step 6: Calculation of normal module (mn):
From PSGDB 8.51
Fs  Fd
116901.17
678.58m 2n 
mn
m n  5.56mm
From PSGDB 8.2 , table 1. The nearest higher standard module value under
choice 1, is
m n = 6mm
Step 7: Calculation of b , d1, and v:
Case 1: To find the face width (b)
b = 10  m n
= 10  6
= 60mm
Case 2: To find Pitch circle diameter (d1)
mn
d1 =  Z1
cos 
6
=  20
cos 25
d1 = 124.23mm.
Case 3: To find Pitch line velocity (v)
d 1N 1
v=
60
 124.23  10 −3  1440
=
60
= 9.37 m
s
Step 8: Recalculation of Beam strength (Fs)
Fs = b  b y1m n
= 180  60  0.12  6 
Fs = 24429.02N
Step 9: Calculation of Accurate dynamic load (Fd)
From PSGDB 8.51
21v ( 6c.cos 2  + Ft ) cos 

Fd = Ft +
21v + 6c.cos 2  + Ft
Case 1: To find (Ft)
P
Ft =
v
37  10 3
=
9.37
Ft = 3948.77N
Case 2: To find deformation factor (C)
C = 11860 e From PSGDB 8.53 , table 41 , for 20° FD , steel and

steel.
e = 0.030 , for module upto 6 and carefully cut gears – PSGDB 8.53
table 42
 C=11860  0.030
= 355.8 N mm
Case 3: To find (Fd)
21  9.37  10 3 ( 60  355.8  cos 2 25 + 3948.77 ) cos 25

Fd = 3948.77 +
21  9.37  10 3 + 60  355.8  cos 2 25 + 3948.77
Fd = 23398.68 N
Step 10: Check for beam strength or tooth breakage.
We find Fs  Fd .  the design is safe
Step 11: Calculation of Maximum wear load (Fw):
Case 1: To find Ratio factor (Q)
From PSGDB 8.51
2i 25
Q= = = 1.67
i+1 5+1
Case 2: To find Load stress factor (Kw)
From PSGDB 8.51
 fes2  sin dn  1 1
Kw =  + 
1.4  E1 E 2 
Assume fes = 618N mm2
6182 sin 20  1 1 
Kw =  + 5
 2.15  10 2.15  10 
5
1.4
= 0.867 N mm2
Case 3: To find Maximum wear load (Fw).
From PSGDB 8.51
d1  b  Q  K w
Fw =
cos 2 
124.23  60  1.67  0.867

=
cos 2 25
Fw = 13138.98N
Step 12: Check for wear:

We find Fw  Fd .  the design is not safe.

In order to increase the wear load, we have to increase the hardness
(BHN). So now for steel hardened to 400 BHN, KW = 2.41 N/mm2.
 Fw = 36522.44N
 Fw  Fd , Design is safe.
Step 13: Calculation of basic dimensions of Pinion and gear.
 Normal module: m n = 6mm

 No. of teeth: Z1 = 20 , Z 2 = 100
mn
 Pitch circle diameter: d1 = 124.23mm , d2 =  Z2
cos 
6
= = 662.03mm.
cos 25 100
m n  Z1 + Z2 
 Centre distance: a=  
cos   2 
6  20 + 100 
=  
cos 25  2 
a = 397.22mm
 Face width: b = 60mm

 Height factor: f0 = 1 , for 20 full depth teeth.
 Bottom clearance: C = 0.25m n
= 0.25  6
C = 1.5mm
 Z1 
 Tip diameter: d a1 =  + 2f0  m n
 cos  
 20 
= + 2  1 6
 cos 25 
da1 = 144.41mm
 Z 
da2 =  2 + 2f0  m n
 cos  
 100 
= + 2  1 6
 cos 25 
da2 = 674.03mm
 Root diameter:
 Z   Z 
d f 1 =  1 − 2f0  m n − 2C d f 2 =  2 − 2f0  m n − 2C
 cos    cos  
 20   100 
df 1 =  − 2  1  6 − 2  1.5 = − 2  1  6 − 2  1.5
 cos 25    cos 25  
df 1 = 117.41mm df 2 = 647.03mm.
 Virtual number of teeth:
Z v1 = 26.86 = 27
Z2 100
Z v2 = =
cos  cos 3 25
3
Z v2 = 134.33 =135
3. Design a spur gear drive to transmit 8 KW at 720 rpm and the speed
ratio is 2. The pinion and wheel are made of the same surface hardened
carbon steel with 55 RC and core hardness less than 350 BHN. Ultimate
strength is 720 N/mm2 and yield strength is 360 N/mm2.
Given data:
P = 8 KW
N1 = 720 rpm
i=2
Material = Surface hardened carbon steel
 u = 720N / mm 2
y = 360N / mm2
u
 b = 240N / mm 2 (Assume) why Allowable static stress [ b ] =
3
720
=
3
= 240N / mm 2
Step 1: To find Gear ratio (i):
i = 2 given
Step 2: Selection of material.
Both pinion and gear, surface hardened carbon steel
Surface hardness < 350 with 55 RC
Step 3: Calculation of Z1 and Z2
No. of teeth on pinion Z1 = 20 (Assume)
Gear Z 2 = i  Z 1 From PSGDB 8.1 table 8.3
= 2  20
Z 2 = 40
Step 4: Calculation of tangential load (Ft):
P
Ft =  K0
v
Where K 0 = 1.5 , Assume medium shock conditions.
d1 N1
* v=
60
From PSGDB 8.22, table 26
d1 = m  Z1
 m  Z1  N1
 v=
60 1000
 m 20  720
=
60 1000
v = 0.754 mm / sec.
8 103
 Ft = 1.5
0.754m
15915.12
Ft =
m
Step 5: Calculation of initial dynamic load (Fd).
Ft
Fd =
Cv
From PSGDB 8.51, Assume v = 12 m/sec.
6
Cv =
6+v
6
=
6 + 12
Cv = 0.333
15915.12 1
 Fd = 
m 0.333
47793.15
Fd =
m
Step 6: Calculation of beam strength (Fs).
Fs =  m b [b ]  y From PSGDB 8.50
Where, b = 10  m From PSGDB 8.14
y = 0.154 −  0.912  From PSGDB 8.50 , for 20° involute.

 Z1 
 (
y = 0.154 − 0.912
20 )
y = 0.1084
 Fs =  m10  m 240  0.1084
Fs = 817.32  m2
Step 7: Calculation of module ‘m’:
Fs  Fd
47793.15
817.32m 2 
m
m  3.88 mm.
From PSGDB 8.2, table 1. Choice 1.
The next higher standard module m = 4 mm.
Step 8: Calculation of b, d1 and v:
Case 1: To find face width (b):
b = 10  m
= 10  4
b = 40mm
Case 2: To find Pitch circle diameter (d1).
d1 = m  Z1
= 4  20
d1 = 80mm
Case 3: To find Pitch line velocity (v).
v = 0.754 m From step 4
= 0.754  4
v = 3.016 m / s
Step 8: Recalculation of beam strength (Fs).
Fs = 817.32  m2 From step 5
= 817.32  42
Fs = 13077.12 N
Step 9: Calculation of accurate dynamic load (Fd)
21v(bc + Ft )
Fd = Ft + From PSGDB 8.51
21v + b c + Ft
Case 1: To find tangential load (Ft)
P 8 103
Ft = = = 2652.52N
v 3.016
C = 11860 e
e = 0.0125 , for precision gears, module upto 4
 C=11860  0.0125
C = 148.25 N / mm 2
21 3.016 103 (40 148.25 + 2652.52)

 Fd = 2652.52 +
21 3.016 103 + 40 148.25 + 2652.52
Fd = 11222.504 N
Step 11: Check for beam strength.
We find Fd < Fs  the design is safe.
Step 12: Calculation of Maximum wear load (Fw)
From PSGDB 8.51,
Fw = d1  b Q K w
2i 2 2
Where Q = = = 1.33
i +1 2 +1
K w = 0.919 N / mm2
 Fw = 80  40 1.33  0.919
Fw = 3911.264 N
Step 13: Check for wear.
We find Fw < Fd .  the design is unsatisfactory
 Increasing the value of K w = 2.553 N / mm2
 Fw = 10890.08 N .
We find Fw value is closer to Fd , but not in that condition Fw  Fd . 

Moderately safe. mild wear takes place.
Step 14: Calculation of basic dimensions of pinion and gear.
 Module: m = 4mm
 No. of teeth: Z1 = 20, Z2 = 40
 Pitch circle diameter: d1 = 80mm
d 2 = m  Z2 = 4  40 = 160mm
m(Z1 + Z2 ) 4(40 + 40)

 Centre distance: a= = = 120mm
2 2
 Height factor: f 0 = 1 , for 20° full depth
 Bottom clearance: C = 0.25m = 0.25  4 = 1mm
 Tip diameter: d a1 = (Z1 + 2f 0 ) m = (20 + 2(1))4 = 88mm
d a 2 = (Z 2 + 2f 0 ) m = (40 + 2 1)4 = 168mm
 Root diameter: d f 1 = (Z1 − 2f 0 ) m− 2C = (20 − 2 1)4 − 2(1) = 70 mm
d f 2 = (Z2 − 2f 0 ) m− 2C = (40 − 2 1)4 − 2(1) = 150 mm
4. Design of helical gear drive to transmit the power of 14.7 KW , speed ration
6 , pinion speed 1200 rpm , helix angle is 25° select suitable material and
design the gear.
Given data:
P = 14.7KW
i=6
N1 = 1200 rpm
 = 25
Step 1: Selection of Material.
C45 – Steel material is selected for both pinion and gear.
 [b ]=180 N/mm2
Step 2: Calculation of no. of teeth:
Case 1: Calculation of Z1 & Z2.
No. of teeth on pinion Z1 = 20 Assume
Gear Z 2 = i  Z 1
= 6  20 6* 20
= 120
Case 2: Calculation of Zv1 & Zv2:
From PSGDB 8.22 , table 2b
Z1 20
Virtual no. of teeth on pinion Zv1 = =
cos  cos3 25
3
= 26.86 = 27
Z2 120
Gear Zv2 = =
cos  cos3 25
3
= 161.19 = 162
Step 3: Calculation of tangential load on teeth (Ft).
P
Ft =  K0
v
Case 1: To find the pitch line velocity (v).
d1 N1
v=
60
From PSGDB 8.22
mn
d1 =  Z1
cos 
 m n  20  1200
 v=
60  cos 25 100
v = 1.39mn m / sec
Case 2: To find K0
K0 = 1.5 , for medium shock condition.
14.7 103
 Ft = 1.5
1.39  m n
15902.83
Ft = (N)
mn
Step 4: Calculation of initial dynamic load (Fd)
Ft
Fd =
Cv
Case 1: To find the velocity factor (Cv)
6
Cv = for carefully cut gears , v < 20 m/s From BSGDB 8.51 Assume v
6+v
= 15 m/s
6
=
6 + 15
Cv = 0.286
Case 2: To find initial dynamic load (Fd)
15902.83 1
Fd = 
mn 0.286
55604.3
Fd =
mn
Step 5: calculation of beam strength (Fs)
Fs = [b ]by1 mn From PSGDB 8.51
Where,
 b = 10  m n From PSGDB 8.14
 y1 = 0.154 –  0.912 
 From PSGDB 8.50 , 20° Full depth system.
 Z v1 
(
= 0.154 – 0.912
27 )
y1 = 0.12
 Fs = 180 10  m n  0.12   m n
= 678.58 m 2n
Step 6: Calculation of normal module (mn).
From PSGDB 8.51
Fs  Fd
55604.3
678.58m 2n 
mn
mn  4.34 mm.
From PSGDB 8.2, table 1, the nearest higher standard module value
under choice 1 is;
mn = 5 mm.
Step 7: Calculation of b1 d1 and v:
b = 10  mn
= 10  5
= 50 mm.
mn
d1 =  Z1
cos 
5
=  20
cos 25
d1 = 110.34 mm
Case 3: To find the pitch line velocity (v)
d1 N1
v=
60
110.34 10−3 1200

60
v = 6.93 m / s
Step 8: Recalculation of beam strength (Fs)
Fs = [ b ]  b y1  m n
= 180  50  0.12  5
Fs = 16964.6 N
From PSGDB 8.51
21v(bc.cos 2  + Ft ) cos 
Fd = Ft +
21v + (bc.cos 2  + Ft )
Case 1: To find (Ft).
P
Ft =
v
14.7 103
=
6.93
Ft = 2121.21 N
Case 2: To find deformation factor (C).
C = 11860 e From PSGDB 8.53 , table 41 , for 20° FD , steel and steel.
e = 0.025 From PSGDB 8.53 table 42 , for module upto 5 and carefully
cut gears.
 C = 11860  0.025
= 296.5 N/mm 2
Case 3: To find (Fd).
21 6.93 103 (50  296.5  cos 2 25 + 212.21) cos 25

Fd = 2121.21 +
21 6.93 103 + 50  296.5  cos 2 25 + 2121.21
Fd = 15069.29 N
We find Fs > Fd  The design is safe.
From PSGDB 8.51.
d1  b  Q  K w
Fw =
cos 2 
Case 1: To find ratio factor (Q).
From PSGDB 8.51.
2i 26
Q= = = 1.71
i +1 6 +1
Case 2: To find Load stress factor (Kw).
Assume Kw = 0.919 for 20° FD
110.34  50 1.71 0.919

 Fw =
cos 2 25
Fw = 10555.12 N
 We find Fw < Fd .  The design is not safe.

 In order to increase the wear load, we have to increase the hardness (BHN).
So how for steel hardened to 400 BHN, K w = 2.553 N / mm2 .
 Fw = 29322.33 N .
Step 13: Calculation of basic dimension of pinion and gear.

 No. of teeth: Z1 = 20 , Z2 = 120
mn
 Pitch circle diameter: d1 = 110.34mm , d 2 =  Z2
cos 
5
=  120
cos 25
= 662.03mm
m n  Z1 + Z 2 
cos   2 
5  20 + 120 
= * 
cos 25  2 

 Height factor: f 0 = 1 , for 20FD
 Bottom clearance: c = 0.25mn
= 0.25  5
= 1.25 mm
 Z1   Z 
 Tip diameter: d a1 =  + 2 f0  mn da 2 =  2 + 2 f0  mn
 cos    cos  
 20   120 
= + 2  1 5 = + 2  1 5
 cos 25   cos 25 
= 120.33 mm. = 672 mm.
 Z   Z 
 Root diameter: d f 1 =  1 − 2f 0  m n − 2c d f 2 =  2 − 2f 0  m n − 2c
 cos    cos  
 20   120 
= − 2  1 5 − 2  1.25 = − 2  1 5 − 2  1.25
 cos 25   cos 25 
= 97.83mm. = 649.52mm.
5. Design a spur gear drive required to transmit 45 KW at a pinion speed of

800 rpm. The velocity ratio is 3.5:1. The teeth are 20° involute with 18
teeth on the pinion. Both the pinion and gear are made of steel with a
maximum safe static stress of 180 N/mm2. Assume medium shock conditions
Given data:
P = 45KW
N 1 = 800rpm
i = 3.5
 = 20
Z 1 = 18
b  = 180 N mm 2
Material = steel (for both pinion and gear)
Step 1: Selection of Material
Pinion and Gear = Steel
Assume steel is hardened to 200 BHN (BRINELL HARDNESS
NUMBER) from PSGDB 8.16 table 16
Number of Teeth on Pinion Z1 = 18
Number of Teeth on Gear Z 2 = i  Z 1
= 3.5  18
Z2 = 63
Step 3: Calculation of Tangential load (Ft)
d 1N 1 P
v= Ft =  K0
60 v
P = 45KW
mZ 1N 1
v=
60 K 0 = 1.5
 m  18  800 d 1N 1
= v=
60  1000 60
= 0.754m m sec d1 = m  Z 1
Case 2: To find K0 From PSGDB

8.22
K 0 = 1.5 for medium shock conditions
Case 3: To find Ft
P
Ft =  K0
v
45  10 3
Ft =  1.5
0.754m
=89522.5/m
Step 4: Calculation of Initial Dynamic Load (Fd)
Case 1: To find velocity factor (Cv)
6 Ft
Cv = for accurately hobbed and generated Fd =
6+v Cv
gears
6
Cv =
6+v
With v  20 m sec From
PSGDB 8.51
6 Assume
Cv =
6 + 12 v = 12 m sec
89522.5 1
Fd = 
m 0.333
268836.3
Fd =
m
Step 5: Calculation of Beam Strength (Fs)
Case 1: To find form factor (y): From PSGDB 8.50
Fs = b  b y Pc
Where
y = 0.154 − ( 0.912 Z1 )
d
Pc = circular pitch = = m
= 0.154 − ( 0.912 18 ) z
m=d z
= 0.1033
Case 2: To find the beam strength (Fs) Finally we write
Lewis equation, Fs =  b  b y  m
Fs =  b  b y  m Where
= 180  10m  0.1033  m b = Face width 10  m
y = Form Factor
= 584.15m 2
Step 6: Calculation of Module (m): = 0.154 − ( 0.912 Z1 ) for 20°
From PSGDB 8.51 Full depth system
Fs  Fd
268836.3
584.15m 2 
m
m  7.72mm
From PSGDB 8.2 table 1, the nearest higher standard module value under
choice 1 is 8 mm
Step 7: Calculation of b , d and v
Case 1: To find the face width

(b) Case 3: To find Pitch line
velocity (v)
b = 10  m
d 1N 1
= 10  8 v=
60
= 80mm
 144  10 −3  800
=
Case 2: To find pitch circle 60
diameter (d1)
= 6.03 m sec
d1 = m  Z 1
= 8  18
= 144mm
Step 8: Recalculation of Beam Strength
Beam Strength Fs =  b  b y  m
= 180  80  0.1033  8
= 37385.45 N
Step 10: Check for Beam strength or Tooth breakage
Since Fd  Fs ( 50908.19N  37385.45N ) the design is unsatisfactory. The

dynamic load is greater than the beam strength
In order to reduce the dynamic load Fd , Select the precision gears. Therefore
from PSGDB 8.53 , table 42 take e = 0.019 for precision gears
Recalculation of deformation factor:
C = 11860  0.019 = 225.34
Recalculation of dynamic load:
21  6.03  10 3 ( 80  225.34 + 7462.68 )

Fd = 7462.68 +
21  6.03  10 3 + 80  225.34 + 7462.68
= 32920.46N
Now we find Fs  Fd ( 37385.45N  32920.46N ) . It means the gear tooth has

adequate beam strength and it will not fail by breakage. Therefore the design
is safe.
Step 11: Calculation of maximum wear load (Fw)
Case 1: To find ratio factor (Q)

From PSGDB 8.51
2i 2  3.5
Q= = = 1.555 Fw = d1  b  Q  K w
i + 1 3.5 + 1
2i
Q = Ratio factor =
i+1
Case 2: To find maximum wear load
(Fw) Kw = load stress factor = 0.919N mm2 ,
for steel hardened to 250 BHN
Fw = d1  b  Q  K w
= 144  80  1.555  0.919
= 16462.6N
Step 12: Check for wear
Since Fd  Fw ( 32920.46N  16462.6N ) the design is unsatisfactory. That is the

dynamic load is greater than the wear load.
In order to increase the wear load ( Fw ) , we have to increase the hardness

(BHN). So now for steel hardened to 400BHN, Kw = 2.553N mm2
 Fw = d1  b  Q  K w
= 144  80  1.555  2.553
= 45733.42N
Now we find Fw  Fd ( 45733.42N  32920.46N ) . It means the gear tooth is

adequate wear capacity and it will not wear out. Therefore the design is
satisfactory
Step 13: Basic dimensions of Pinion and gear
Module: m = 8mm
Number of teeth: Z1 = 18, Z 2 = 63
Pitch circle diameter: d1 = 144mm
d2 = m  Z 2 = 8  63
d2 = 504mm
Centre distance: a = m ( Z1 + Z 2 ) 2
= 8 ( 18 + 63 ) 2
a = 324mm
Face width: b = 80mm
Height factor: f0 = 1 , for 20 full depth teeth
Bottom clearance: c = 0.25m = 0.25  8
c = 2mm
Tip diameter: da1 = ( Z1 + 2f0 ) m da2 = ( Z2 + 2f0 ) m
= ( 18 + 2  1) 8 = ( 63 + 2  1) 8
= 160mm = 520mm
Root diameter: df 1 = ( Z1 − 2f0 ) m − 2c df 2 = ( Z2 − 2f0 ) m − 2c
= ( 18 − 2  1) 8 − 2  2 = ( 63 − 2  1) 8 − 2  2
= 124mm = 484mm
6. Design a pair of helical gears to transmit 10 KW at pinion speed of

1000rpm. The Reduction ratio is 5. Assume suitable materials and stresses.
Given data:
N 1 = 1000rpm
P = 10KW
i=5
b  = 180 N mm 2 , 400 BHN.
Step 2: Calculation of number of teeth Z1 and Z2:
No. of teeth on pinion gear Z1 = 20 (assume)
Z2 = i  Z1
= 5  20
= 100 .
Virtual no. of teeth Zv1 & Zv2
From PSGDB 8.22 , table 26. Assume  = 25
Z1 Z2
Z v1 = Z v2 =
cos 3  cos 3 
20 100
= =
cos 3 25 cos 3 25
Z v1 = 27 = 134.33mm .
Z v2 135mm
P
Ft =  K0
v
K 0 = 1.5 , for medium shock conditions.
d 1N 1
v=
60
mn
d1 =  Z1
cos 
 m n  20  1000
 v=
60  1000  cos 25
v = 1.16m n m sec
10  10 3
 Ft =  1.5
1.16m n
12931.03
=
mn
Ft
Fd =
Cv
6
Cv = for carefully cut gears v  20 m s . From PSGDB 8.51 Assume
6+v
v = 15 m s .
6
=
6 + 15
C v = 0.286.
12931.03 1
 Fd = 
mn 0.286
45213.41
=
mn
Fs = b   b  y1   m n
Where,
y1 = 0.154 −  0.912 
 From PSGDB 8.50 , 20° FD
 Z v1 
0.912
= 0.154 −
27
= 0.12
 Fs = 180  10  m n  0.12   m n
Fs = 678.58 m 2n
Step 6: Calculation of normal module (mn)
From PSGDB 8.51
Fs  Fd
45213.41
678.58 m 2n 
mn
m n  4.05mm .
From PSGDB 8.2, table 1. The nearest higher standard module

value under choice 1 is m n = 5mm .
Step 7: Calculation of b , d1 , and v:
Case 1: To find face width (b).
b = 10  m n
= 10  5
= 50mm.
mn
d1 =  Z1
cos 
5
=  20
cos 25
d1 = 110.34mm
d 1N 1
v=
60
 110.34  1000
=
60  1000
v = 5.78m s
Fs = 678.58  m2n From step 5
= 678.58  52
Fs = 16964.5N
From PSGDB 8.51
21v ( bc  cos2  + Ft ) cos 

Fd = Ft +
21v + bc  cos2  + Ft
P
Ft =
v
10  10 3
=
5.78
Ft = 1730.1N
C = 11860e From PSGDB 8.53 , table 41 , 20° FD.
e = 0.025 for module upto 5 and carefully cut gears.
 C = 296.5N mm2
21  5.78  10 3 ( 50  296.5  cos 2 25 + 1730.1 ) cos 25

 Fd = 1730.1 +
21  5.78  10 3 + 50  296.5  cos 2 25 + 1730.1
Fd = 1836.98N
We find Fs  Fd ,  The design is safe.
From PSGDB 8.51
2 (i ) 2  5
Q= = = 1.67 .
i+1 5+1
Kw = 2.553N mm2 . For 20° FD , 400BHN.
Case 3: To find maximum wear load.
From PSGDB 8.51
d1  b  Q  K w
Fw =
cos 2 
110.34  50  1.67  2.553

=
cos 2 25
Fw = 23521.78N
We find Fw  Fd ,  Design is safe.
 Normal Module: m n = 5mm

 No. of teeth: Z 1 = 20 , Z 2 = 100
mn
cos 
5
=  100
cos 25
= 551.68mm
m n  Z1 + Z2 
cos   2 
5  20 + 100 
 
cos 25  2 
a = 331.01mm

 Height factor: f0 = 1 , for 20° FD
= 0.25  5
= 1.25mm
 Tip diameter:
 Z   Z 
da1 =  1 + 2f0  m n da2 =  2 + 2f0  m n
 cos    cos  
 20   100 
= + 2 ( 1)  5 = + 2  1 5
 cos 25   cos 25 
da1 = 120.34mm da2 = 561.69mm
 Root diameter:
 Z   Z 
d f 1 =  1 − 2f0  m n − 2C d f 2 =  2 − 2f0  m n − 2C
 cos    cos  
 20   100 
= − 2  1  5 − 2  1.25 = − 2  1  5 − 2  1.25
 cos 25   cos 25 
df 1 = 97.84mm df 2 = 539.19mm
 Virtual no. of teeth: Z v1 = 27 , Z v2 = 135
7.A speed reducing unit using spur gear is to be designed. Power to be transmitted is 60hp and is
continuous with moderate shaft loads. The speeds of the shafts are 720 rpm and 144 rpm,
respectively. The centre distance is kept as small as possible. Select a suitable material and design
the gears. Give the details of the gears.
Given data:
1hp = 0.746KW
 P = 60hp = 60  0.746
= 44.76KW
P 45KW
N1 = 720rpm
N 2 = 144rpm
Step 1: To find Gear ratio (i).
N 1 720
i= = =5
N 2 144
Assume, both pinion and gear = Surface hardened carbon steel.
Surface hardness < 350 BAU with 55 RC.
Step 3: Calculation of Z1 and Z2:
No. of teeth on pinion Z1 = 20 (Assume).
Gear Z2 = i  Z1
= 5  20
=100
Step 4: Calculation tangential Load (Ft)
P
Ft =  K0
v
Where, K 0 = 1.5 Assume medium shock conditions.
d 1N 1
v=
60
d1 = m  Z 1
 m  Z 1  N 1
v =
60  1000
 m  20  720
=
60  1000
v = 0.754m m /s
45  10 3
 Ft =  1.5
0.754m
89522.55
Ft =
m
Ft
Fd =
Cv
From PSGDB 8.51 , Assume v=12 m/sec.
6 6
Cv = = = 0.333
6 + v 6 + 12
89522.55 1
 Fd = 
m 0.333
268836.48
Fd =
m
Fs =  m  b  b   y From PSGDB 8.50
Where, b = 10  m from PSGDB 8.14
y = 0.154 −  0.912  From PSGDB 8.50 , for 20° FD

 Z1 
(
= 0.154 − 0.912
20 )
y = 0.1084.
 b = 240 N /mm 2
 Fs =  m  10  m  240  0.1084
Fs = 817.32  m2
Step 7: Calculation of module ‘m’:
Fs  Fd
268836.48
817.32m 2 
m
m  6.90 mm.
From PSGDB 8.2, table 1, choice 1.
The next higher standard module m=8mm
Step 8: Calculation of b , d1 and v.
Facewidth b = 10  m
= 10  8
= 80mm
Pitch circle diameter d1 = m  Z 1
= 8  20
= 160mm
Pitch line velocity v = 0.754m From step 4
= 0.754  8
v = 6.032 m /s
Fs = 817.32  m2 From step 6
= 817.32  82
Fs = 53308.48 N
Step 10: Calculation of accurate dynamic load (Fd).
21v ( bc + Ft )
Fd + Ft + From PSGDB 8.51
21v + b c + Ft
Case 1: To find tangential load (Ft)
P 45  10 3
Ft = = = 7460.212N.
v 6.032
Case 2: To find deformation factor (c)
c = 11860e
take e = 0.038 . for precision gears.
c = 450.68N /mm 2
21  6.03  10 3 ( 80  450.68 + 7460.21 )

 Fd = 7460.21 +
21  6.03  10 3 + ( 80  450.68 ) + 7460.21
Fd = 50903.26 N
We find Fs  Fd  the design is safe.
Step 12: Calculation of maximum wear load (Fw).
From PSGDB 8.51
Fw = d1  b  Q  K w
2i 25
Where Q = = = 1.67
i+1 5+1
Kw = 2.553 N /mm2
 Fw = 160  80  1.66  2.553
Fw = 54246.14N
We find Fw > Fd  the design is safe.
Step 14: Calculation of basic dimensions of pinion and gear:
 Module: m = 8mm
 No. of teeth: Z1 = 20 , Z 2 = 100
 Pitch circle diameter: d1 = 160mm.
d2 = m  Z 2 = 8  100 = 800mm.
m ( Z1 + Z2 )
 Centre distance: a=
2
8 ( 20 + 100 )
=
2
= 480mm.
 Face width: b = 80mm.

 Height factor: f0 = 1 , for 20 full depth.
 Bottom clearance: c = 0.25m = 0.25  8 = 2mm.
 Tip diameter:
da1 = (Z1 + 2 f0 )m da2 = (Z2 + 2 f0 )m
= ( 20 + 2  1) 8 = ( 100 + ( 2  1) ) 8
= 176mm = 816mm
 Root diameter:
df 1 = (Z1 + 2 f0 )m − 2 c df 2 = (Z 2 + 2 f0 )m − 2 c
= ( 20 − 2  1) 8 − 2  2 = ( 100 − 2  1) 8 − 2  2
= 140mm = 780mm
9.Design a pair of strength spur gear drive for a stone crusher, the pinion and wheel are made of C15
steel and cast iron grade 30b respectively. The pinion is to transmit 22.5 KW power at 900 rpm. The gear
ratio is 2.5. Take pressure angle of 20° and working life of gears as 10, 000 hours.
Given data:
P = 22.5KW; N1 = 900r.p.m; i = 2.5;  = 20;N = 10000hrs
To find: Design a spur gear
Solution: Since the materials for pinion and wheel are different, therefore we have design the pinion first and
check both pinion and wheel.
1. Gear ratio: i = 2.5
2. Material selection:
Pinion: C15 steel, case hardened to 55 RC and core hardness < 350, and
Wheel: C.I grade 30.
3. Gear life: N = 10000 hrs
Gear life in terms of number of cycles is given by
N = 10000  60  900 = 54  10 2 cycles
4. Design torque [Mt]:
 M t  = M t .K.K d
60  P 60  22.5  103
Mt = = = 238.73N − m
2N1 2  900
K.K d = 1.3
Design torque  Mt  = 238.73 1.3 = 310.35N − m
5. Calculation of Eeq,  b and 1 :
To find Eeq: For pinion steel and cast iron (> 280 N/mm 2), equivalent Young’s modulus,
Eeq = 1.7 105 N / mm2
To find  b : The design bending stress   p  is given by
1.4  K b1
b  =  −1 , assuming rotation in one direction only.
n.K 
For steel (HB ≤ 350) and N≥ 107, Kb1 = 1.
For steel case hardened, factor of safety n = 2
For steel case hardened, stress concentration factor, K = 1.2
For forged steel, −1 = 0.25( u +  y ) + 50.
For C15, u = 490N / mm2 and y = 240N / mm2
 −1 = 0.25(490 + 240) + 50 = 232.5N / mm 2

1.4  1
b  =  232.5 = 135.625N / mm 2
2  1.2
(iii) To find c : The design contact stress c is given by
c  = CR .HRC.Kct
Where,
CR =22, for C 15 steel
HRC = 55 to 63, for C 15 steel
K cl = 0.585, for HB > 350, n ≥ 25 × 10 7
c  = 22  63  0.585 = 810.81N / mm2
6. Calculation of centre distance (a):

We know that,
 0.74  E eq  M t 
2
a  (i + 1) 3  
     i
 c 
b
 = = 0.3
a
 0.74  1.7  10  310.35  10
2 3 3
a  (2.5 + 1) 3   
 810.81  2.5  0.3
 135.94mm or a = 136mm
7. To find z1 and z2:
(i) For 20° full depth system, select z1 = 18.
(ii) z2 = i  z1 = 2.5 18 = 45
8. Calculation of module (m):
We know that,
2a 2  136
m= = = 4.32 mm
z1 + z 2 18 + 45
The nearest higher standard module, m = 5 mm
9. Revision of centre distance:
m(z1 + z 2 ) 5(18 + 45)

New centre distance, a = = = 157.5mm
2 2
10. Calculation of b, dp, v and  p :
Face width (b): b = .a = 0.3 157.5 = 47.25 mm

Pitch diameter of pinion (d1): d1 = m.z1 = 5 18 = 90mm
d1N1  90 10−3  900
Pitch line velocity (v): v = = = 4.24m / s
60 60
b 47.25
p = = = 0.525
d1 90
11. Selection of quality of gear:
For v = 4.24 m/s, IS quality 8 gears are selected.
12. Revision of design torque  M t  :
Revise K: For  p = 0.525,K = 1.03

Revise Kd: for IS quality 8 and v = 4.24 m/s, Kd = 1.4,
Revise  Mt  :  Mt  = Mt .K.Kd = 238.73 1.03 1.4 = 344.24N − m
13. Check for bending:
Calculation of induced bending stress,  p :
Where,
(i + 1)
p = Mt 
a.m.b.y
y = Form factor = 0.377, for z1 = 18
(2.5 + 1)  344.24  103
p = = 58.89N / mm 2
157.5  5  47.25  0.377
We find b B  . Therefore the design is satisfactory.
14. Check for wear strength:
Calculation of induced contact stress,  c

i +1 i +1
c = 0.74  E eq  M t 
a ib
 2.5 + 1   2.5 + 1 
= 0.74      1.7  10  344.24  10
5 3
 157.5   2.5  47.25 

= 684.76N / mm 2
We find c  c . Therefore the design is safe and satisfactory.
15. Check of wheel:
(i) Calculation of  b wheel

and c wheel
:
Wheel material: CI grade 30.
N1 900
Wheel speed: N2 = = = 360r.p.m
i 2.5
Life of wheel = 10,000  60  360 = 21.6  107 cycles
To find  b wheel
: The design bending stress for wheel is given by
1.4  K b1
b wheel =  −1 , assuming rotation in one direction only.
n.K a
107 9 107
For cast iron wheel, K b1 = 9 = = 0.918
N 21.6  107
For cast iron, n = 2.
For cast iron, −1 = 0.45u
For cast iron,  u = 290N / mm 2
 −1 = 0.45  290 = 130.5 N / mm 2

1.4  0.918
b wheel =  130.5 = 69.88 N / mm 2
2  1.2
To find  c wheel
: The wheel design contact stress for wheel is given by
c wheel
= CB .HB.K cl
Where,
CB = 2.3, for cast iron grade 30
HB = 200 to 260, for cast iron
107 6 107
K cl = 6 = = 0.879,for cast iron
N 21.6 107
c wheel = 2.3  260  0.879 = 525.64 N / mm 2
(ii) Check for bending:
Calculation of induced bending stress for wheel b2

b1  y1 = b2  y2
Where b1 and b2 = Induced bending stress in the pinion and wheel respectively, and
y1 and y 2 = Form factors for pinion and wheel respectively.
y2 = 0.471, for z2 = 45.
 b1 = 85.89 N / mm 2 and y1 = 0.377

85.89  0.377 =  b2  0.471
 b2 = 68.75 N / mm 2
We find b2  b wheel . Therefore the design is satisfactory.
(iii) Check for wear strength: Since contact area is same, therefore c,wheel = c pinion = 684.76N / mm2 . Here
c wheel  c wheel . It means, wheel does not have the required wear resistance. So, in order to decrease the
induced contact stress, increase the face width (b)value or in order to increase the design contact stress, increase
the surface hardness, say to 340 HB. Increasing the surface hardness will give
c  = 2.3  340  0.879 = 687.34N / mm2 . Now we find c  c . So the design is safe and satisfactory.
16. Calculation of basic dimensions of pinion and wheel:
Module: m = 5mm
Face width: b = 47.25 mm
Height factor: f0 = 1 for full depth teeth.
Bottom clearance: c = 0.25m = 0.25  5 = 1.25 mm
Tooth depth: h = 2.25 m=2.25  5 = 11.25 mm
Pitch circle diameter: d1 = m.z1 = 5 18 = 90 mm and d2 = m.z2 = 5  45 = 225 mm
Tip diameter:
d a1 = (z1 + 2f 0 )m = (18 + 2  1)5 = 100 mm; and
d a 2 = (z 2 + 2f 0 )m = (45 + 2  1)5 = 235mm
Root diameter:
df1 = (z1 − 2f 0 )m − 2c
= (18 − 2  1)5 − 2  1.25 = 77.5 mm; and
df 2 = (z 2 − 2f 0 )m − 2c
= (45 − 2  1)5 − 2  1.25 = 212.5 mm
10.A hardened steel worm rotates at 1440 rpm and transmits 12 kW to a phosphor Bronze gear. The
speed of the worm gear should be 60 rpm. Design the worm gear drive if an efficiency of at least 82% is
desired.
Given data:
Nmax = 1440 rpm, Nmin = 60 rpm p = 12kW desired = 82%
1440
Gear ratio required, i = = 24
60
1. Material selection: Worm – Hardened steel, and
Worm – Phosphor bronze
2. Selection of z1 and z2:
For η = 85%,z1 = 3
Then, z2 = i  z1 = 24  3 = 72.
3. Calculation of q and γ:
d1
Diameter factor: q= = 11
mx
z  3
Lead angle:  = tan −1  1  = tan −1   = 15.25
q  11 
4. Calculation of F1 in terms mx:
P
Tangential load, Ft =  K0
v
Where
d 2 N 2 (z 2  m x )  N 2
v= =
60  1000 60  1000
  72  m x  60
= = 0.226m x m / s
60  1000
K 0 = 1.25, assuming medium shock
12  103 66371.68
Ft =  1.25 =
0.226m x mx
5. Calculation of dynamic load (Fd):
Ft
Dynamic load, Fd =
cv
6
cv = , v = 5m / s is assumed.
6+v
6
= = 0.545
6+5
66371.68 1 121681.4
Fd =  =
mx 0.545 mx
6. Calculation of beam strength (Fs) in terms of axial module:
Beam strength, Fs =  mx  b  b   y
Where
b = 0.75d1
= 0.75  qm x = 0.75  11m x = 8.25m x
b  = 80 N / mm 2
y = 0.125, assuming  = 20
Fx =   m x  8.25m x  80  0.125 = 259.18m 2x
7. Calculation of axial module (mx):
We know that,
121681.4
259.18m 2x 
mx
m x  7.77 mm
The nearest higher standard axial pitch is 8 mm.
8. b = 66 mm, d2 = 576 mm; v = 1.808 m/s
9. Fs = 259.18mx2 = 16587. 52 N
Ft
10. Dynamic load, Fd =
cv
6 6
cv = = = 0.768 and
6 + v 6 + 1.808
66371.68 66371.68
Ft = = = 8296.46N
mx 8
8296.46
Fd = = 10802.68N
0.768
11. Check for beam strength: We find Fd < Fs. It means that the gear tooth has adequate beam strength and will
not fail by breakage. Thus the design is satisfactory.
12. Calculation of maximum wear load (Fw):
Wear load, Fw = d 2  b  K w
Where
K w = 0.56N / mm 2
Fw = 576  66  0.56 = 21288.96N
13. Check for wear: We find Fd < Fw. It means that the gear tooth has adequate wear capacity and will not wear
out. Thus the design is safe and satisfactory.
14. Check for efficiency: We know that,
tan 
actual = 0.95
tan(  + )
Where
 = Frictional angle = tan −1 

= tan −1 (0.03) = 1.7
tan15.25
 = 0.95  = 0.8498 or 84.98%
tan(15.25 + 1.7)
We find that the actual efficiency is greater than the desired efficiency. Thus the design is satisfactory.
15. Calculation of basic dimensions of worm and worm gears:
Axial module: mx = 8 mm
Number of starts: z1 = 3
Number of teeth on worm wheel: z2 = 72
Face width of worm wheel: b = 66 mm
Length of worm: L  (12.5 + 0.09z2 )mx , L  (12.5 + 0.09  72)8 = 151.84mm
Centre distance: a = 0.5mx (q + z 2 ) = 0.5  8(11 + 72) = 332mm
Height factor: f0 = 1
Bottom clearance: c = 0.25mx = 0.25  8 = 2mm
d1 = q  m x = 11  8 = 88mm
Pitch diameter:
d 2 = z 2  m x = 72  8 = 576 mm
d a1 = d1 + 2f 0 .m x = 88 + 2  1  8 =104 mm
Tip diameter:
d a 2 = (z 2 + 2f 0 )m x = (72 + 2  1)8 = 592 mm
d f 1 = d1 − 2f 0 .m x − 2.c = 88 − 2  1  8 − 2  2 = 68mm
Root diameter:
d f 2 = (z 2 − 2f 0 )m x − 2.c = (72 − 2  1)8 − 2  2 = 556 mm
11. Design a spur gear drive required to transmit 45 KW at a pinion speed

of 800 rpm. The velocity ratio is 3.5:1. The teeth are 20° involute with
18 teeth on the pinion. Both the pinion and gear are made of steel with
a maximum safe static stress of 180 N/mm2. Assume medium shock
conditions (April/May 2017)
Given data:
P = 45KW
N 1 = 800rpm
i = 3.5
 = 20
Z 1 = 18
b  = 180 N mm 2
= 3.5  18
Z2 = 63
d 1N 1 P
v= Ft =  K0
60 v
P = 45KW
mZ 1N 1
v=
60 K 0 = 1.5
 m  18  800 d 1N 1
= v=
60  1000 60
= 0.754m m sec d1 = m  Z 1

8.22
Case 3: To find Ft
P
Ft =  K0
v
45  10 3
Ft =  1.5
0.754m
=89522.5/m
6 Ft
Cv = for accurately hobbed and generated Fd =
6+v Cv
gears
6
Cv =
6+v
With v  20 m sec From
PSGDB 8.51
6 Assume
Cv =
6 + 12 v = 12 m sec
89522.5 1
Fd = 
m 0.333
268836.3
Fd =
m
From PSGDB 8.50
Where
d
z
m=d z
Finally we write
Fs =  b  b y  m
Where
Case 1: To find form factor (y): b = Face width 10  m
y = Form Factor
= 0.154 − ( 0.912 Z1 ) for 20°

y = 0.154 − ( 0.912 Z1 )
Full depth system
= 0.154 − ( 0.912 18 )
= 0.1033
Case 2: To find the beam strength (Fs)
Lewis equation,
Fs =  b  b y  m
= 180  10m  0.1033  m
= 584.15m 2
Step 6: Calculation of Module (m):
From PSGDB 8.51
Fs  Fd
268836.3
584.15m 2 
m
m  7.72mm
choice 1 is 8 mm

(b)
b = 10  m
= 10  8
= 80mm
Case 2: To find pitch circle

diameter (d1)
Case 3: To find Pitch line
velocity (v)
ME 6601 DESIGN OF TRANSMISSION

d 1N 1 SYSTEMS
v=
60
d1 = m  Z 1
 144  10 −3  800
=
= 8  18 60
= 144mm = 6.03 m sec
= 180  80  0.1033  8
= 37385.45 N

C = 11860  0.019 = 225.34
21  6.03  10 3 ( 80  225.34 + 7462.68 )

Fd = 7462.68 +
21  6.03  10 3 + 80  225.34 + 7462.68
= 32920.46N

is safe.

From PSGDB 8.51
2i 2  3.5
Q= = = 1.555 Fw = d1  b  Q  K w
i + 1 3.5 + 1
2i
Q = Ratio factor =
i+1
Case 2: To find maximum wear load
(Fw) Kw = load stress factor = 0.919N mm2 ,
Fw = d1  b  Q  K w
= 144  80  1.555  0.919
= 16462.6N


 Fw = d1  b  Q  K w
= 144  80  1.555  2.553
= 45733.42N

satisfactory
Module: m = 8mm
d2 = m  Z 2 = 8  63
d2 = 504mm
= 8 ( 18 + 63 ) 2
a = 324mm
c = 2mm
= ( 18 + 2  1) 8 = ( 63 + 2  1) 8
= 160mm = 520mm
= ( 18 − 2  1) 8 − 2  2 = ( 63 − 2  1) 8 − 2  2
= 124mm = 484mm
12. A general purpose enclosed gear train is based on parallel helical gears,
specified life is 36000 hours. Torque at driven shaft is 411 Nm. Driving
shaft speed is 475 rpm. Velocity ratio is 4. it is desired to have standard
Centre distance. Design a gear drive. (April/May 2017)
Given Data:
Gear life=36000 hours
=411 Nm
N1 =475 rpm
i= 4
***Similar to this problem, gear life and materials has to be changed, refer the question paper
STEP 1: CALCULATION OF GEAR RATIO AND VIRTUAL NUMBER OF TEETH
Gear ratio (i)
i=4 (given)
STEP 2: SELECTION OF MATERIAL
Pinion and Gear = C45 steel
STEP 3: CALCULATION OF GEAR LIFE
Given that the gear is to work 36000 hours
Case 1: To find gear life
Gear life=36000 hours
= 2160000 mins
Case 2: To find life in number of cycles (N)
N=2160000xN1
=2160000x475
=102.6x107 cycles
STEP 4: CALCULATION OF INITIAL DESIGN TORQUE [Mt]
[Mt]=Mt K. Kd
=411x 1.3
[Mt]=534.3 Nm
STEP 5: CALCULATION OF Eeq, [σb], AND [σc]
Case 1: To find equivalent young’s modulus
From PSGDB 8.14,table 9
For C45 steel, take Eeq=2.15x105 N/mm2
Case 2:
1. To find Endurance limit stress in bending (σ-1 )
σ-1 =0.35x670+120
= 354.5 N/mm2
2. To find design bending stress [σb]
1.4  k bl
b  =   −1
n  k
= 115.80 N/mm2
Case 3: To find design contact stress [σc]
=8526.375 kgf/cm2
= 852.64 N/mm2
STEP 6: CALCULATION OF CENTRE DISTANCE (a)
From PSGDB 8.13, table-8- for designing
✓ Where,𝛙=b/a = Width to Centre Distance ratio

✓ Generally assume ψ = 0.3 for Initial Calculation, From PSGDB
8.14, table-10
STEP 7: SELECTION OF z1 AND z2
• Number Of Teeth On Pinion z1 = 20

• Number Of Teeth On Gear z2 = i x z1
= 4 x 20
z2 = 80
STEP 8: CALCULATION OF NORMAL MODULE (mn)
(Assume = )
=3.88mm
✓ The nearest higher standard module From PSGDB 8.2 table 1 choice
1, take =4mm
STEP 9: REVISION OF CENTRE DISTANCE (a)
Centre distance
a= 207.05mm
STEP 10: CALCULATION OF b , d1,v and 𝜳
From PSGDB 8.14, table-10
b= 𝜳 x a
= 0.3 x 207.05
b= 62.12 mm
Case 2: To find pitch circle diameter (d1)
d1= x
= x
d1 = 82.82mm
Case 3: To find pitch line velocity (v)
= 2.06 m/sec
Case 4: To find 𝜳p
𝜳p=b/d1
=62.12/82.82
𝜳p=0.75
STEP 11: SELECTION OF QUALITY OF GEAR
For pitch line velocity 2.06 m/sec, IS quality 8 gears are selected
STEP 12: REVISION OF DESIGN TORQUE [Mt]
[Mt]=Mt . K. Kd
=411x 1.06x1.1
[Mt]=479.23Nm
STEP 13: CHECK FOR BENDING
Calculation of induced bending stress
479.23x103
We find ( ). Therefore the design is safe

and satisfactory
STEP 14: CHECK FOR WEAR STRENGTH (σc)
Calculation of induced contact stress (σc)
From PSGDB 8.13 table 8, For checking
=769.70N/mm2 We find (769.70 N/mm2
STEP 14: BASIC DIMENSIONS OF PINION AND GEAR
✓ From PSGDB 8.22, table 26
➢ Normal Module:m =4mm
➢ Number of teeth: z1=20, z2=80
➢ Virtual Number of teeth:zv1=22 , zv2= =
➢ Pitch circle diameter: d1=82.82mm
d2= x = x 80
d2=331.28mm
➢ Centre distance : a=207.05 mm

➢ Face width: b=62.12 mm
➢ Height factor: f0=1 , for 20° full depth teeth
➢ Bottom clearance: c=0.25mn=0.25x4
c=1mm
➢ Tip diameter:
= x4
=90.82mm
= x4
=339.28mm
➢ Root diameter:
=72.82mm
=321.28mm
13. Design a pair of helical gears to transmit 10 KW at pinion speed of

1000rpm. The Reduction ratio is 5. Assume suitable materials and
stresses. (Nov/Dec 2017)
Given data:
N 1 = 1000rpm
P = 10KW
i=5
Generally we assume C45 steel for both pinion and gear (But in this
problem we have to change the material as40Ni2 Cr1 Mo28 steel and )
b  = 180 N mm2 , 400 BHN.
Z2 = i  Z1
= 5  20
= 100 .
Z1 Z2
Z v1 = Z v2 =
cos 3  cos 3 
20 100
= =
cos 3 25 cos 3 25
Z v1 = 27 = 134.33mm .
Z v2 135mm
P
Ft =  K0
v
d1N 1
v=
60
mn
d1 =  Z1
cos 
 m n  20  1000
 v=
60  1000  cos 25
v = 1.16m n m sec
10  10 3
 Ft =  1.5
1.16m n
12931.03
=
mn
Ft
Fd =
Cv
6
6+v
v = 15 m s .
6
=
6 + 15
C v = 0.286.
12931.03 1
 Fd = 
mn 0.286
45213.41
=
mn
Fs = b   b  y1   m n
Where,
y1 = 0.154 −  0.912  From PSGDB 8.50 , 20° FD

 Z v1 
0.912
= 0.154 −
27
= 0.12
 Fs = 180  10  m n  0.12   m n
Fs = 678.58 m 2n
From PSGDB 8.51
Fs  Fd
45213.41
678.58 m 2n 
mn
m n  4.05mm .

b = 10  m n
= 10  5
= 50mm.
mn
d1 =  Z1
cos 
5
=  20
cos 25
d1 = 110.34mm
d1N 1
v=
60
 110.34  1000
=
60  1000
v = 5.78m s
= 678.58  52
Fs = 16964.5N
From PSGDB 8.51
21v ( bc  cos2  + Ft ) cos 

Fd = Ft +
21v + bc  cos2  + Ft
P
Ft =
v
10  10 3
=
5.78
Ft = 1730.1N
 C = 296.5N mm2
21  5.78  10 3 ( 50  296.5  cos 2 25 + 1730.1 ) cos 25

 Fd = 1730.1 +
21  5.78  10 3 + 50  296.5  cos 2 25 + 1730.1
Fd = 1836.98N
From PSGDB 8.51
2 (i ) 2  5
Q= = = 1.67 .
i+1 5+1
Kw = 2.553N mm2 . For 20° FD , 400BHN.
From PSGDB 8.51
d1  b  Q  K w
Fw =
cos 2 
110.34  50  1.67  2.553

=
cos 2 25
Fw = 23521.78N

 No. of teeth: Z 1 = 20 , Z 2 = 100
mn
cos 
5
=  100
cos 25
= 551.68mm
m n  Z1 + Z2 
cos   2 
5  20 + 100 
 
cos 25  2 
a = 331.01mm

= 0.25  5
= 1.25mm
 Tip diameter:
 Z   Z 
da1 =  1 + 2f0  m n da2 =  2 + 2f0  m n
 cos    cos  
 20   100 
= + 2 ( 1)  5 = + 2  1 5
 cos 25   cos 25 
da1 = 120.34mm da2 = 561.69mm
 Root diameter:
 Z   Z 
d f 1 =  1 − 2f0  m n − 2C d f 2 =  2 − 2f0  m n − 2C
 cos    cos  
 20   100 
= − 2  1  5 − 2  1.25 = − 2  1  5 − 2  1.25
 cos 25   cos 25 
df 1 = 97.84mm df 2 = 539.19mm
14. Design a pair of strength spur gear drive for a stone crusher, the pinion
and wheel are made of C15 steel and cast iron grade 30b respectively.
The pinion is to transmit 22.5 KW power at 900 rpm. The gear ratio is
2.5. Take pressure angle of 20° and working life of gears as 10, 000
hours. (Nov/Dec 2017)
Given data:
P = 22.5KW; N1 = 900r.p.m; i = 2.5;  = 20;N = 10000hrs
Solution: Since the materials for pinion and wheel are different, therefore we have
design the pinion first and check both pinion and wheel.
N = 10000  60  900 = 54  10 2 cycles
 M t  = M t .K.K d
60  P 60  22.5  103
Mt = = = 238.73N − m
2N1 2  900
K.K d = 1.3
Design torque Mt  = 238.73 1.3 = 310.35N − m
To find Eeq: For pinion steel and cast iron (> 280 N/mm2), equivalent
Young’s modulus, Eeq = 1.7 105 N / mm2
1.4  K b1
n.K 
For forged steel, −1 = 0.25(u +  y ) + 50.
 −1 = 0.25(490 + 240) + 50 = 232.5N / mm 2

1.4  1
b  =  232.5 = 135.625N / mm 2
2  1.2
Where,
K cl = 0.585, for HB > 350, n ≥ 25 × 107
c  = 22  63  0.585 = 810.81N / mm2
We know that,
 0.74  E eq  M t 
2
a  (i + 1)  
    
3
 c  i
b
 = = 0.3
a
 0.74  1.7  10  310.35  10
2 3 3
a  (2.5 + 1) 3   
 810.81  2.5  0.3
 135.94mm or a = 136mm
(ii) z2 = i  z1 = 2.5 18 = 45
We know that,
2a 2  136
m= = = 4.32 mm
z1 + z 2 18 + 45
m(z1 + z 2 ) 5(18 + 45)

2 2
Face width (b): b = .a = 0.3 157.5 = 47.25 mm

d1N1  90 10−3  900
60 60
b 47.25
p = = = 0.525
d1 90
Revise K: For  p = 0.525,K = 1.03

Revise  Mt  : Mt  = Mt .K.Kd = 238.73 1.03 1.4 = 344.24N − m
Where,
(i + 1)
p = Mt 
a.m.b.y
(2.5 + 1)  344.24  103
p = = 58.89N / mm 2
157.5  5  47.25  0.377

i +1 i +1
c = 0.74  E eq  M t 
a ib
 2.5 + 1   2.5 + 1 
= 0.74      1.7  10  344.24  10
5 3
 157.5   2.5  47.25 

= 684.76N / mm 2
15. Check of wheel:
(i) Calculation of b wheel and c wheel :
N1 900
i 2.5
To find  b wheel : The design bending stress for wheel is given by
1.4  K b1
n.K a
107 9 107
N 21.6  107
 −1 = 0.45  290 = 130.5 N / mm 2

1.4  0.918
b wheel =  130.5 = 69.88 N / mm 2
2  1.2
To find  c wheel : The wheel design contact stress for wheel is given by
c wheel
= CB .HB.K cl
Where,
107 6 107
N 21.6 107
c wheel = 2.3  260  0.879 = 525.64 N / mm 2

b1  y1 = b2  y2
Where b1 and b2 = Induced bending stress in the pinion and wheel
respectively, and
y2 = 0.471, for z2 = 45.
 b1 = 85.89 N / mm 2 and y1 = 0.377

85.89  0.377 =  b2  0.471
 b2 = 68.75 N / mm 2
(iii) Check for wear strength: Since contact area is same, therefore
c,wheel = c pinion = 684.76N / mm . 2
Here c wheel  c wheel . It means, wheel does not have the
required wear resistance. So, in order to decrease the induced contact stress,
increase the face width (b)value or in order to increase the design contact stress,
increase the surface hardness, say to 340 HB. Increasing the surface hardness will
give c  = 2.3  340  0.879 = 687.34N / mm2 . Now we find c c . So the design is safe and
satisfactory.
Module: m = 5mm
Tooth depth: h = 2.25 m=2.25  5 = 11.25 mm
Tip diameter:
d a1 = (z1 + 2f 0 )m = (18 + 2  1)5 = 100 mm; and
d a 2 = (z 2 + 2f 0 )m = (45 + 2  1)5 = 235mm
Root diameter:
df1 = (z1 − 2f 0 )m − 2c
= (18 − 2  1)5 − 2  1.25 = 77.5 mm; and
df 2 = (z 2 − 2f 0 )m − 2c
= (45 − 2  1)5 − 2  1.25 = 212.5 mm
15. Design a pair of spur gear drive to transmit 20kW at a pinion speed of
1400 rpm. The transmission ratio is 4. Assume 15 Ni2 Cr1 Mo 15 for
pinion and C45 for gear. (April/ May 2018)
Given data:
P= 20 kW
N1=1400 rpm
i= 4
Material = 15 Ni2 Cr1 Mo 15 for pinion and C45 for gear
pinion and gear)
15 Ni2 Cr1 Mo 15 for pinion and C45 for gear

= 3.5  18
Z2 = 63
d 1N 1 P
v= Ft =  K0
60 v
P = 45KW
mZ 1N 1
v=
60 K 0 = 1.5
 m  18  800 d 1N 1
= v=
60  1000 60
= 0.754m m sec d1 = m  Z 1

8.22
Case 3: To find Ft
P
Ft =  K0
v
45  10 3
Ft =  1.5
0.754m
=89522.5/m
Ft
Fd =
Cv
6
Cv =
6+v
From
PSGDB 8.51
Assume
6 v = 12 m sec
Cv = for accurately hobbed and generated
6+v
gears
With v  20 m sec
6
Cv =
6 + 12
89522.5 1
Fd = 
m 0.333
268836.3
Fd =
m
Where
y = 0.154 − ( 0.912 Z1 )
d
= 0.154 − ( 0.912 18 ) z
m=d z
= 0.1033
Finally we write
b = Face width 10  m
= 180  10m  0.1033  m
y = Form Factor
= 584.15m 2

= 0.154 − ( 0.912 Z1 ) for 20°
Fs  Fd
268836.3
584.15m 2 
m
m  7.72mm
choice 1 is 8 mm

(b) Case 3: To find Pitch line
velocity (v)
b = 10  m
d 1N 1
= 10  8 v=
60
= 80mm
 144  10 −3  800
=
Case 2: To find pitch circle 60
diameter (d1)
= 6.03 m sec
d1 = m  Z 1
= 8  18
= 144mm
= 180  80  0.1033  8
= 37385.45 N

C = 11860  0.019 = 225.34

21  6.03  10 3 ( 80  225.34 + 7462.68 )

Fd = 7462.68 +
21  6.03  10 3 + 80  225.34 + 7462.68
= 32920.46N

is safe.
From PSGDB 8.51
Fw = d1  b  Q  K w
Case 1: To find ratio factor (Q) 2i

Q = Ratio factor =
i+1
2i 2  3.5
Q= = = 1.555
i + 1 3.5 + 1 Kw = load stress factor = 0.919N mm2 ,
Case 2: To find maximum wear load (Fw)
Fw = d1  b  Q  K w
= 144  80  1.555  0.919
= 16462.6N


 Fw = d1  b  Q  K w
= 144  80  1.555  2.553
= 45733.42N

satisfactory
Module: m = 8mm
d2 = m  Z 2 = 8  63
d2 = 504mm
= 8 ( 18 + 63 ) 2
a = 324mm
c = 2mm
= ( 18 + 2  1) 8 = ( 63 + 2  1) 8
= 160mm = 520mm
= ( 18 − 2  1) 8 − 2  2 = ( 63 − 2  1) 8 − 2  2
= 124mm = 484mm
16. Design of helical gear drive to

transmit the power of 14.7 KW , speed ratio 6 , pinion speed 1200 rpm ,
helix angle is 25° select suitable material and design the gear. (April/
May 2018)
Given data:
P = 14.7KW
i=6
N1 = 1200 rpm
 = 25
Step 1: Selection of Material.
15 Ni2 Cr1 Mo 15 for pinion and C45 for gear
 [b ]=180 N/mm2
Step 2: Calculation of no. of teeth:
Case 1: Calculation of Z1 & Z2.
No. of teeth on pinion Z1 = 20 Assume
Gear Z 2 = i  Z 1
= 6  20 6* 20
= 120
Case 2: Calculation of Zv1 & Zv2:
From PSGDB 8.22 , table 2b
Z1 20
Virtual no. of teeth on pinion Zv1 = =
cos  cos3 25
3
= 26.86 = 27
Z2 120
Gear Zv2 = =
cos  cos3 25
3
= 161.19 = 162
P
Ft =  K0
v
Case 1: To find the pitch line velocity (v).
d1 N1
v=
60
From PSGDB 8.22
mn
d1 =  Z1
cos 
 m n  20  1200
 v=
60  cos 25 100
v = 1.39mn m / sec
Case 2: To find K0
K0 = 1.5 , for medium shock condition.
14.7 103
 Ft = 1.5
1.39  m n
15902.83
Ft = (N)
mn
Ft
Fd =
Cv
6
Cv = for carefully cut gears , v < 20 m/s From BSGDB 8.51 Assume v
6+v
= 15 m/s
6
=
6 + 15
Cv = 0.286
15902.83 1
Fd = 
mn 0.286
55604.3
Fd =
mn
Step 5: calculation of beam strength (Fs)
Fs = [b ]by1 mn From PSGDB 8.51
Where,
 b = 10  m n From PSGDB 8.14
 y1 = 0.154 –  0.912  From PSGDB 8.50 , 20° Full depth system.

 Z v 1 
(
= 0.154 – 0.912
27 )
y1 = 0.12
 Fs = 180 10  m n  0.12   m n
= 678.58 m 2n
Step 6: Calculation of normal module (mn).
From PSGDB 8.51
Fs  Fd
55604.3
678.58m 2n 
mn
mn  4.34 mm.
From PSGDB 8.2, table 1, the nearest higher standard module value
under choice 1 is;
mn = 5 mm.
b = 10  mn
= 10  5
= 50 mm.
mn
d1 =  Z1
cos 
5
=  20
cos 25
d1 = 110.34 mm
d1 N1
v=
60
110.34 10−3 1200

60
v = 6.93 m / s
Fs = [ b ]  b y1  m n
= 180  50  0.12  5
Fs = 16964.6 N
From PSGDB 8.51
21v(bc.cos 2  + Ft ) cos 
Fd = Ft +
21v + (bc.cos 2  + Ft )
Case 1: To find (Ft).
P
Ft =
v
14.7 103
=
6.93
Ft = 2121.21 N
Case 2: To find deformation factor (C).
C = 11860 e From PSGDB 8.53 , table 41 , for 20° FD , steel and steel.
e = 0.025 From PSGDB 8.53 table 42 , for module upto 5 and carefully
cut gears.
 C = 11860  0.025
= 296.5 N/mm 2
21 6.93 103 (50  296.5  cos 2 25 + 212.21) cos 25

Fd = 2121.21 +
21 6.93 103 + 50  296.5  cos 2 25 + 2121.21
Fd = 15069.29 N
We find Fs > Fd  The design is safe.
From PSGDB 8.51.
d1  b  Q  K w
Fw =
cos 2 
Case 1: To find ratio factor (Q).
From PSGDB 8.51.
2i 26
Q= = = 1.71
i +1 6 +1
Case 2: To find Load stress factor (Kw).
Assume Kw = 0.919 for 20° FD
110.34  50 1.71 0.919

 Fw =
cos 2 25
Fw = 10555.12 N
 We find Fw < Fd .  The design is not safe.

 In order to increase the wear load, we have to increase the hardness (BHN).
So how for steel hardened to 400 BHN, K w = 2.553 N / mm2 .
 Fw = 29322.33 N .

 No. of teeth: Z1 = 20 , Z2 = 120
mn
cos 
5
=  120
cos 25
= 662.03mm
m n  Z1 + Z 2 
cos   2 
5  20 + 120 
= * 
cos 25  2 

 Height factor: f 0 = 1 , for 20FD
 Bottom clearance: c = 0.25mn
= 0.25  5
= 1.25 mm
 Z1   Z 
 Tip diameter: d a1 =  + 2 f0  mn da 2 =  2 + 2 f0  mn
 cos    cos  
 20   120 
= + 2  1 5 = + 2  1 5
 cos 25   cos 25 
= 120.33 mm. = 672 mm.
 Z   Z 
 Root diameter: d f 1 =  1 − 2f 0  m n − 2c d f 2 =  2 − 2f 0  m n − 2c
 cos    cos  
 20   120 
= − 2  1 5 − 2  1.25 = − 2  1 5 − 2  1.25
 cos 25   cos 25 
= 97.83mm. = 649.52mm.
17. A compressor running at 300rpm is driven by a15kW, 1200rpm motor
through a 14 full depth spur gears. The center distance is 375mm.
The motor pinion is to be C30 forged steel hardened (BHN 250) and
tempered, and the driven gear is to be of cast iron. Assuming medium
shock condition and minimum number of teeth as 18. Design the gear
drive completely. (Nov/Dec 2018)
Given data:
P = 45KW
N 1 = 800rpm
i = 3.5
 = 20
Z 1 = 18
b  = 180 N mm 2
***Similar to this problem change the material for pinion and gear, and BHN 200 to 250.
= 3.5  18
Z2 = 63

P
d N Ft =  K0
v= 1 1 v
60
P = 45KW
K 0 = 1.5
mZ 1N 1
v=
60 d 1N 1
v=
 m  18  800 60
=
60  1000 d1 = m  Z 1
= 0.754m m sec
From PSGDB
8.22
Case 2: To find K0
Case 3: To find Ft
P
Ft =  K0
v
45  10 3
Ft =  1.5
0.754m
=89522.5/m
6
Cv = for accurately hobbed and generated
6+v
gears
Ft
Fd =
Cv
With v  20 m sec 6
Cv =
6+v
6
Cv =
6 + 12 From
PSGDB 8.51
Case 2: To find initial dynamic load (Fd) Assume
89522.5 1 v = 12 m sec
Fd = 
m 0.333
268836.3
Fd =
m
Where
y = 0.154 − ( 0.912 Z1 )
d
= 0.154 − ( 0.912 18 ) z
m=d z
= 0.1033
Finally we write
b = Face width 10  m
= 180  10m  0.1033  m
y = Form Factor
= 584.15m 2

= 0.154 − ( 0.912 Z1 ) for 20°
Fs  Fd
268836.3
584.15m 2 
m
m  7.72mm
choice 1 is 8 mm

(b)
b = 10  m
= 10  8
Case 3: To find Pitch line

= 80mm velocity (v)
Case 2: To find pitch circle
d 1N 1
diameter (d1) v=
60
d1 = m  Z 1
= 8  18  144  10 −3  800
=
60
= 144mm
= 6.03 m sec
= 180  80  0.1033  8
= 37385.45 N

C = 11860  0.019 = 225.34

21  6.03  10 3 ( 80  225.34 + 7462.68 )

Fd = 7462.68 +
21  6.03  10 3 + 80  225.34 + 7462.68
= 32920.46N

is safe.

2i 2  3.5 From PSGDB 8.51
Q= = = 1.555
i + 1 3.5 + 1
Fw = d1  b  Q  K w
2i
Q = Ratio factor =
Case 2: To find maximum wear load (Fw) i+1
Fw = d1  b  Q  K w Kw = load stress factor = 0.919N mm2 ,

= 144  80  1.555  0.919
= 16462.6N

(BHN). So now for steel hardened to 400BHN, Kw = 2.553N mm

2
 Fw = d1  b  Q  K w
= 144  80  1.555  2.553 = 45733.42N

satisfactory
Module: m = 8mm
d2 = m  Z 2 = 8  63
d2 = 504mm
= 8 ( 18 + 63 ) 2
a = 324mm
c = 2mm
= ( 18 + 2  1) 8 = ( 63 + 2  1) 8
= 160mm = 520mm
= ( 18 − 2  1) 8 − 2  2 = ( 63 − 2  1) 8 − 2  2
= 124mm = 484mm
18. Design a carefully cut helical gears to transmit 15kW at 1400rpm to

the following specifications. Speed reduction is 3. Pressure angle is 20˚,
Helix angle 15˚. The material for both the gears is C45 steel. Allowable
static stress is 180 N/mm2, endurance limit is 800 N/mm2. Young’s
modulus of the material =2x105 N/mm2. Assume minimum number of
teeth as 20 and medium shock conditions, v= 15m/s. (Nov/Dec 2018)
Given data:
N 1 = 1440rpm
i=5
P = 37KW
 = 20 =  n
 = 25
*** similar to this problem, change the speed as 1400rpm and Helix angle15˚
Step 1: selection of Material.
b  = 180 N mm 2 , 250 BHN.
Step 2: Calculation of number of teeth Z1 & Z2:
No. of teeth on pinion Z1 = 20 (assume)
No. of teeth on gear Z 2 = i  Z 1
= 5  20
= 100
Step 3: Calculation of tangential load on teeth (Ft):
P
Ft =  K0
v
Case 1: To find the Pitch line velocity (v)
d1N 1
v=
60
From PSGDB 8.22
mn
d1 =  Z1
cos 
mn
=  20
cos 25
mn
d1 =
22.06
 m n  1440
v =
60  22.06  1000
= 1.66m n m
sec
Case 2: To find K0:
K 0 = 1.5 for medium shock conditions.
37  10 3
 Ft =  1.5
1.66m n
33433.73
=
mn
Step 4: Calculation of initial dynamic Load (Fd)
Ft
Fd =
Cv
Case 1: To find velocity factor ( C v )
6
Cv = for carefully cut gears, v  20 m s
6+v
6
=
6 + 15
C v = 0.286
Case 2: To find initial dynamic load (Fd):
33433.73 1
Fd = 
mn 0.286
116901.17
mn
Step 5: Calculation of beam strength (Fs):
Fs = b  by−1Pcn From PSGDB 8.51 Pcn = m n
 Fs = b  by1m n
Where,
y1 = 0.154 −  0.912  From PSGDB 8.50 , 20 full depth


 Z v1 
system.
Z1
Z v1 =
cos 3 
20
=
cos 3 25
Z v1 = 26.86 27
0.912
 y 1 = 0.154 −
26.86
= 0.12
Fs = b  b y1m n
= 180  10  m n  0.1143   m n
= 678.58m2n
Step 6: Calculation of normal module (mn):
From PSGDB 8.51
Fs  Fd
116901.17
678.58m 2n 
mn
m n  5.56mm
From PSGDB 8.2 , table 1. The nearest higher standard module value under
choice 1, is

m n = 6mm
Step 7: Calculation of b , d1, and v:
b = 10  m n
= 10  6
= 60mm
Case 2: To find Pitch circle diameter (d1)
mn
d1 =  Z1
cos 
6
=  20
cos 25
d1 = 124.23mm.
d1N 1
v=
60
 124.23  10 −3  1440
=
60
= 9.37 m
s
Step 8: Recalculation of Beam strength (Fs)
Fs = b  b y1m n
= 180  60  0.12  6 
Fs = 24429.02N
From PSGDB 8.51
21v ( 6c.cos 2  + Ft ) cos 

Fd = Ft +
21v + 6c.cos 2  + Ft

P
Ft =
v
37  10 3
=
9.37
Ft = 3948.77N
C = 11860 e From PSGDB 8.53 , table 41 , for 20° FD , steel and

steel.
e = 0.030 , for module upto 6 and carefully cut gears – PSGDB 8.53
table 42
 C=11860  0.030
= 355.8 N mm
Case 3: To find (Fd)
21  9.37  10 3 ( 60  355.8  cos 2 25 + 3948.77 ) cos 25

Fd = 3948.77 +
21  9.37  10 3 + 60  355.8  cos 2 25 + 3948.77
Fd = 23398.68 N
Step 10: Check for beam strength or tooth breakage.
We find Fs  Fd .  the design is safe
From PSGDB 8.51
2i 25
Q= = = 1.67
i+1 5+1
From PSGDB 8.51
 fes2  sin dn  1 1
Kw =  + 
1.4  E1 E 2 
Assume fes = 618N mm2

6182 sin 20  1 1 
Kw =  + 5
 2.15  10 2.15  10 
5
1.4
= 0.867 N mm2
Case 3: To find Maximum wear load (Fw).
From PSGDB 8.51
d1  b  Q  K w
Fw =
cos 2 
124.23  60  1.67  0.867

=
cos 2 25
Fw = 13138.98N

We find Fw  Fd .  the design is not safe.

In order to increase the wear load, we have to increase the hardness
(BHN). So now for steel hardened to 400 BHN, KW = 2.41 N/mm2.
 Fw = 36522.44N
Step 13: Calculation of basic dimensions of Pinion and gear.

 No. of teeth: Z1 = 20 , Z 2 = 100
mn
cos 
6
= = 662.03mm.
cos 25 100
m n  Z1 + Z2 
cos   2 
6  20 + 100 
=  
cos 25  2 
a = 397.22mm

 Height factor: f0 = 1 , for 20 full depth teeth.


= 0.25  6
C = 1.5mm
 Z1 
 Tip diameter: d a1 =  + 2f0  m n
 cos  
 20 
= + 2  1 6
 cos 25 
da1 = 144.41mm
 Z 
da2 =  2 + 2f0  m n
 cos  
 100 
= + 2  1 6
 cos 25 
da2 = 674.03mm
 Root diameter:
 Z   Z 
d f 1 =  1 − 2f0  m n − 2C d f 2 =  2 − 2f0  m n − 2C
 cos    cos  
 20   100 
df 1 =  − 2  1  6 − 2  1.5 = − 2  1  6 − 2  1.5
 cos 25   cos 25 
df 1 = 117.41mm df 2 = 647.03mm.

Z v1 = 26.86 = 27
Z2 100
Z v2 = =
cos  cos 3 25
3
Z v2 = 134.33 =135
19. Design a spur gear drive to transmit 22

kW at 900rpm, speed reduction is 2.5. materials for pinion and wheel are C15 steel
and cast-iron grade 30 respectively. Take pressure angle of 20˚ and working life of
the gears as 10,000 hours. (April/May 2019)
Given data:
P = 22.5KW; N1 = 900r.p.m; i = 2.5;  = 20;N = 10000hrs

Solution: Since the materials for pinion and wheel are different, therefore we have
design the pinion first and check both pinion and wheel.
N = 10000  60  900 = 54  10 2 cycles
 M t  = M t .K.K d
60  P 60  22.5  103
Mt = = = 238.73N − m
2N1 2  900
K.K d = 1.3
Design torque Mt  = 238.73 1.3 = 310.35N − m
To find Eeq: For pinion steel and cast iron (> 280 N/mm2), equivalent
Young’s modulus, Eeq = 1.7 105 N / mm2
1.4  K b1
n.K 
For forged steel, −1 = 0.25(u +  y ) + 50.
 −1 = 0.25(490 + 240) + 50 = 232.5N / mm 2

1.4  1
b  =  232.5 = 135.625N / mm 2
2  1.2

Where,
K cl = 0.585, for HB > 350, n ≥ 25 × 107
c  = 22  63  0.585 = 810.81N / mm2
We know that,
 0.74  E eq  M t 
2
a  (i + 1) 3  
     i
 c 
b
 = = 0.3
a
 0.74  1.7  10  310.35  10
2 3 3
a  (2.5 + 1) 3   
 810.81  2.5  0.3
 135.94mm or a = 136mm
(ii) z2 = i  z1 = 2.5 18 = 45
We know that,
2a 2  136
m= = = 4.32 mm
z1 + z 2 18 + 45
m(z1 + z 2 ) 5(18 + 45)

2 2
Face width (b): b = .a = 0.3 157.5 = 47.25 mm

d1N1  90 10−3  900
60 60

b 47.25
p = = = 0.525
d1 90
Revise K: For  p = 0.525,K = 1.03

Revise  Mt  : Mt  = Mt .K.Kd = 238.73 1.03 1.4 = 344.24N − m
Where,
(i + 1)
p = Mt 
a.m.b.y
(2.5 + 1)  344.24  103
p = = 58.89N / mm 2
157.5  5  47.25  0.377

i +1 i +1
c = 0.74  E eq  M t 
a ib
 2.5 + 1   2.5 + 1 
= 0.74      1.7  10  344.24  10
5 3
 157.5   2.5  47.25 

= 684.76N / mm 2
15. Check of wheel:
(i) Calculation of b wheel and c wheel :
N1 900
i 2.5
To find  b wheel : The design bending stress for wheel is given by

1.4  K b1
n.K a
107 9 107
N 21.6  107
 −1 = 0.45  290 = 130.5 N / mm 2

1.4  0.918
b wheel =  130.5 = 69.88 N / mm 2
2  1.2
To find  c wheel : The wheel design contact stress for wheel is given by
c wheel
= CB .HB.K cl
Where,
107 6 107
N 21.6 107
c wheel = 2.3  260  0.879 = 525.64 N / mm 2

b1  y1 = b2  y2
Where b1 and b2 = Induced bending stress in the pinion and wheel
respectively, and
y2 = 0.471, for z2 = 45.
 b1 = 85.89 N / mm 2 and y1 = 0.377

85.89  0.377 =  b2  0.471
 b2 = 68.75 N / mm 2
(iii) Check for wear strength: Since contact area is same, therefore
c,wheel = c pinion = 684.76N / mm . 2
Here c wheel  c wheel . It means, wheel does not have the

required wear resistance. So, in order to decrease the induced contact stress,
increase the face width (b)value or in order to increase the design contact stress,
increase the surface hardness, say to 340 HB. Increasing the surface hardness will
give c  = 2.3  340  0.879 = 687.34N / mm2 . Now we find c c . So the design is safe and
satisfactory.
Module: m = 5mm
Tooth depth: h = 2.25 m=2.25  5 = 11.25 mm
Tip diameter:
d a1 = (z1 + 2f 0 )m = (18 + 2  1)5 = 100 mm; and
d a 2 = (z 2 + 2f 0 )m = (45 + 2  1)5 = 235mm
Root diameter:
df1 = (z1 − 2f 0 )m − 2c
= (18 − 2  1)5 − 2  1.25 = 77.5 mm; and
df 2 = (z 2 − 2f 0 )m − 2c
= (45 − 2  1)5 − 2  1.25 = 212.5 mm
20. A pair of helical gears is to be designed to transmit 30kWat a pinion speed
of 1500rpm. The velocity ratio is 3. Selecting 15Ni2Cr1Mo15 steel as the
material. Determine the dimensions of the gears. (April/May 2019)
Given data:
N 1 = 1000rpm
P = 10KW
i=5
*** similar to this problem
b  = 180 N mm 2 , 400 BHN.
Z2 = i  Z1
= 5  20

= 100 .
Z1 Z2
Z v1 = Z v2 =
cos 3  cos 3 
20 100
= =
cos 3 25 cos 3 25
Z v1 = 27 = 134.33mm .
Z v2 135mm
P
Ft =  K0
v
d 1N 1
v=
60
mn
d1 =  Z1
cos 
 m n  20  1000
 v=
60  1000  cos 25
v = 1.16m n m sec
10  10 3
 Ft =  1.5
1.16m n
12931.03
=
mn

Ft
Fd =
Cv
6
6+v
v = 15 m s .
6
=
6 + 15
C v = 0.286.
12931.03 1
 Fd = 
mn 0.286
45213.41
=
mn
Fs = b   b  y1   m n
Where,
y1 = 0.154 −  0.912 
 From PSGDB 8.50 , 20° FD
 Z v1 
0.912
= 0.154 −
27
= 0.12
 Fs = 180  10  m n  0.12   m n
Fs = 678.58 m 2n
From PSGDB 8.51
Fs  Fd
45213.41
678.58 m 2n 
mn

m n  4.05mm .

b = 10  m n
= 10  5
= 50mm.
mn
d1 =  Z1
cos 
5
=  20
cos 25
d1 = 110.34mm
d 1N 1
v=
60
 110.34  1000
=
60  1000
v = 5.78m s
= 678.58  52
Fs = 16964.5N
From PSGDB 8.51
21v ( bc  cos2  + Ft ) cos 

Fd = Ft +
21v + bc  cos2  + Ft

P
Ft =
v
10  10 3
=
5.78
Ft = 1730.1N
 C = 296.5N mm2
21  5.78  10 3 ( 50  296.5  cos 2 25 + 1730.1 ) cos 25

 Fd = 1730.1 +
21  5.78  10 3 + 50  296.5  cos 2 25 + 1730.1
Fd = 1836.98N
From PSGDB 8.51
2 (i ) 2  5
Q= = = 1.67 .
i+1 5+1
Kw = 2.553N mm2 . For 20° FD , 400BHN.
From PSGDB 8.51
d1  b  Q  K w
Fw =
cos 2 
110.34  50  1.67  2.553

=
cos 2 25

Fw = 23521.78N

 No. of teeth: Z 1 = 20 , Z 2 = 100
mn
cos 
5
=  100
cos 25
= 551.68mm
m n  Z1 + Z2 
cos   2 
5  20 + 100 
 
cos 25  2 
a = 331.01mm

= 0.25  5
= 1.25mm
 Tip diameter:
 Z   Z 
da1 =  1 + 2f0  m n da2 =  2 + 2f0  m n
 cos    cos  
 20   100 
= + 2 ( 1)  5 = + 2  1 5
 cos 25   cos 25 
da1 = 120.34mm da2 = 561.69mm
 Root diameter:

 Z   Z 
d f 1 =  1 − 2f0  m n − 2C d f 2 =  2 − 2f0  m n − 2C
 cos    cos  
 20   100 
= − 2  1  5 − 2  1.25 = − 2  1  5 − 2  1.25
 cos 25   cos 25 
df 1 = 97.84mm df 2 = 539.19mm

UNIT-III BEVEL GEAR AND WORM GEARS

(PART-A)
1. What is virtual number of teeth in bevel gear?
An imaginary spur gear considered in a plane perpendicular to the
tooth of the bevel gear at the larger end is called as virtual spur gear.
The number of teeth zv on this imaginary spur gear is called virtual

number of teeth in bevel gears.
Where, z= Actual number of teeth on the bevel gear

δ = Pitch angle
2. Mention the advantages of worm gear drive?

❖ The worm gear drives can be used for speed ratios as
high as 300:1
❖ The operation is smooth and silent
3. State the advantages of herringbone gear?
It eliminates the existence of axial thrust load in the helical gears.
Because, in herringbone gears, the thrust force of the right hand is balanced
by that of the left hand helix.
4. What is zerol bevel gear?

Spiral bevel gear with curved teeth but with a zero degree spiral angle
is known as zerol bevel gear.
5. What is the difference between an angular gear and miter gear?
❖ When the bevel gears connect two shafts whose axes intersect at
an angle other than a right angle, then they are known as angular
bevel gears.
❖ When equal bevel gears (having equal teeth and equal pitch angles)
connect two shafts whose axes intersect at right angle, then they
are known as miter gears.
6. What kind contact occurred between worm and wheel? How does it
differs from other gears?
❖ The worm gears are used to transmit power between two non-
intersecting, non-parallel shafts.
❖ The worm gears drives are compact, smooth and silent in
operation.
7. How bevel gears are manufactured?
Bevel gears are not interchangeable. Because they are designed and
manufactured in pairs.
8. What is helical angle of worm?
Helical angle is the angle between the tangent to the thread helix on
the pitch cylinder and axis of the worm. The worm helix angle is the
complement of worm lead angle, that is ß=90º-
9. What is a crown gear?
A bevel gear having a pitch angle 90° and a plane for its pitch surface is known as
crown gear.
10. Write some applications of worm gear drive?
Worm gear drives are widely used as a speed reducer in materials handling
equipment, machine tools and automobiles.
11. When do we use worm-gears?

When we require to transmit power between nonparallel and non-
intersecting shafts and very high velocity ratio, of about 100, worm gears, can
be employed. Also worm-gears provide self-locking facility.
12. Write some applications of worm gear drive.

Worm gear, drive find wide applications like milling machine indexing
head, table fan and steering rod of automobile and so on.
13. What is a bevel gear?
Bevel gear is the type of gear for which the teeth are cut on conical surface in
contrast with spur and helical gears for which the teeth are cut on cylindrical
surfaces. The structure of bevel gear is similar to and uniformly truncated frustum
of a cone.
14. When do we use bevel gears?
When the power is to be transmitted in an angular, direction, i.e., between the
shafts whose axes intersecting at an angle, bevel gears are employed.
15. How are bevel gears classified?
Bevel gears are classified in two ways
1. Based on the shape of teeth.
▪ Straight bevel gears.
▪ Spiral bevel gears
2. Based on the included angle between the shaft axes, called as shaft
angle
▪ External gears < 90 deg)
▪ Internal gears > 90 deg)
▪ Crown gears 90 deg
16. What is a crown gear?

A crown gear is a type of bevel gear whose shaft angle is 90 degree and angle of
pinion is not equal to the pitch angle of gear. Let Shaft angle
17. What is the specific feature of mitre gear?

Mitre gear is the special type of crown gear In which the shaft, 90 deg and the
pitch angles of pinion and gear are equal and each angle to 45 deg.
18. Fill in the blanks of the following

a) Bevel gears having shaft, Angle of, 90deg are known as........
b) When the spiral angle of a.bevel gear is zero, it is called as...
Answers
a) Crown gears. b) Zerol bevel gear.
19. Define the following terms

a) Cone distance or pitch cone radius.
b) Face angle.
a) Cone distance or pitch cone radius is the slant length of pitch cone, i.e.,
distance between the apex and the extreme point of tooth of bevel gear.
b) Face angle is the angle subtended by the face of the teeth at the cone
centre. It is equal to the pitch angle plus addendum angle. It is also called as tip
angle.
20. In which gear-drive, self-locking is available?
Self-locking is available in worm-gear drive.
21. What is known as formative number of teeth on bevel gears? (April/May
2017)
The formative of equivalent number of teeth for a bevel gear may be

defined as the number of teeth that can be generated on the surface of a
cylinder having a radius of curvature at a point at the tip of minor axis of an
ellipse obtained by taking a section of the gear in the normal plane.
22. Write the conditions of self-locking of worm gears in terms of lead and
pressure angles. (April/May 2017)
The conditions of self-locking of worm gears in terms of lead and
pressure angles can be
If
23. What are the disadvantages of worm gear drive? (Nov/Dec 2017)
❖ Manufacturing cost is heavy as compared with manufacturing

cost of bevel gear
❖ Cost of raw material to manufacture the worm and worm gear
set will be quite high
❖ Worm and worm gear set will have heavy power losses.
❖ Efficiency will be low
❖ If speed reduction ratio is large, worm teeth sliding action will
create lots of heat
❖ Lubrication scheduled must be strictly maintained for
healthiness of worm and worm gear as this unit requires much
lubrication for smooth working of gearbox.
24. What is Meant by miter gears? (Nov/Dec 2017)
When equal bevel gears (having equal teeth and equal pitch angles)
connect two shafts whose axes intersect at right angle, then they are known
as miter gears
25. When do we use bevel gears? (April/May 2018)
Bevel gears are used to transmit power between two intersecting shafts
26. In which gear drive, self-locking is available? (April/May 2018)
Worm and Worm Wheel
27. List the forces acting on bevel gears. (Nov/Dec 2018)

i. Tangential force
ii. Axial force
iii. Radial force
28. What is irreversibility in worm gear? (Nov/Dec 2018)
The worm gear drives are irreversible. It means that the motion cannot be
transmitted from worm wheel to the worm. This property of irreversible is
advantageous in load hoisting applications like cranes and lifts.
29. What is crown and miter gear? (April/May 2019)

A bevel gear having a pitch angle 90° and a plane for its pitch surface is
known as crown gear.
When equal bevel gears (having equal teeth and equal pitch angles) connect
two shafts whose axes intersect at right angle, then they are known as miter
gears
30. Define the pitch and lead of worm gears. (April/May 2019)
It is distance measured along the normal to the threads between two

corresponding points on two adjacent threads of the worm.
PART B
1. Derive expressions for determining the forces acting on a bevel gear
with suitable illustrations.
In force analysis of bevel gears, it is assumed that the resultant tooth

force between two meshing gears is concentrated at the midpoint
along the face width of the tooth. The forces acting at the centre of the
tooth are shown in figure.
The components of the resultant force are,
(a) Tangential or useful component (Ft).

(b) Separating Force (Fs): It is resolved into two components. They are
(i) Axial force (Fa) (ii) Radial force (Fr)
(i) Components of the tooth force on the pinion:
To find Ft: The tangential force can be determined using the familiar
relationship.
2M t M t
Ft = =
d 1av rm
60  P
Where, M t = Transmitted torque =
2 N
P = Power transmitted
N = speed of the gear
d1av = Average diameter of the pinion , at midpoint along the face width.
= Z1  m av
 b.Sin  
= Z1  M t − 
 Z1 
 d b Sin1 
rm =  1 − 
 2 2 
= Mean radius of the pinion at midpoint along the face width.

To find Fs: The analysis is similar to that of spur gears and the
separating force can be determined using the relation
Separating force Fs = Ft  tan  (1)
Where,  = Pr essure angle
To find Fr and Fa:
The separating force is further resolved into radial and axial

forces, as shown in figure below.
From the geometry of the figure, we can write
Radial force, Fr = Fs  c os 
Axial force, Fa = Fs  Sin 
Substituting equation (1) in the above equations,
Fr = Ft tan   c os 
Fa = Ft tan   Sin 
The above derived expressions are used to determine the

components of the tooth force on the pinion.
(ii) Components of the tooth force on the gear:
From the figure a and b, the following conclusions can be made for the right
angle bevel gears:
 The radial component on the gear is equal to the axial component on

the pinion but in opposite direction.
( Fr ) gear = − ( Fa ) pinion
 Similarly, the axial component on the gear is equal to the radial
component on the pinion, but in opposite direction.
( Fa ) gear = − ( Fr ) pinion
Note: The three forces Ft, Fr and Fa are perpendicular to each other
and can be used to determine the bearing loads by using the methods of
statics.
2. A hardened steel worm rotates at 1440rpm and transmits 12KW to a

phosphor bronze gear. The speed of the worm wheel should be 60 
3%rpm. Design a worm gear drive if an efficiency of atleast 82% is
desired.
Given data:
N1 = 1440rpm
P = 12KW
N 2 = 60  3%rpm
desired = 82%
Step 1: To find gear ratio ( i ) :
N1
i=  3%
N2
1440
=  3%
60
= 24  0.72
take i = 24
Worm = Hardened steel
Worm wheel = Phosphor bronze
For  = 82% , Z 1 = 3
Z2 = i  Z1
= 24  3
Z2 = 72
Step 4: Calculation of q and H:
Case 1: To find diameter factor (q):
From PSGDB 8.43, table 35, and PSGDB 8.44
q
d1 =
mx
Initially we assume q = 11
Case 2: To find Lead angle (H):
Z1
tanH =
q
 3 
H = tan −1  
 11 
H = 15.25
Step 5: Calculation of ‘Ft’ in terms of ‘mx’:
P
Tangential Load Ft =  K0
v
Case 1: To find the velocity ‘v’:
d 2 N 2
v=
60  1000
d2 = Z2  m x
 Z 2  m x  N 2
 v=
60  1000
 72  m x  60
=
60  1000
v = 0.226m x m
s
Case 2: to find shock factor ( K 0 ) :
Assume medium shock,
K 0 = 1.5
12  10 3
 Ft =  1.5
0.226m x
79646.02
Ft =
mx
Step 6: Calculation of dynamic load: ( Fd )
Ft
Fd =
Cv
Case 1: To find velocity factor ( C v ) :
From PSGDB 8.51 , assume v = 5m s
6
Cv =
6+v
6
=
6+5
C v = 0.545
Case 2: To find ( Fd ) :
79646.02 1
Fd = 
mx 0.545
1460177.70
=
mx
Step 7: Calculation of beam strength ( Fs ) in terms of ( m x )
From PSGDB 8.51
Fs =  m x  b  b   y1
Where ,
b = 0.75d 1 From PSGDB 8.48 , table 38
= 0.75  q  m x
= 0.75  11  m x
= 8.25m x
y1 = 0.125 From PSGDB 8.52 , Assume  = 20
Form factor y = 0.392
y
 y1 =

0.392

=0.125
b  = 80 N mm 2 From PSGDB 8.45 , table 33
 Fs =  m x  8.25m x  80  0.125
= 259.18 m2x
Step 8: Calculation of Axial module (mx )

W.K.T Fs  Fd
146017.70
259.18  m 2x 
mx
m x  8.26mm
From PSGDB 8.2 , Table 1.
The nearest higher standard axial module
m x = 10mm.
b = 8.25m x From step 7
= 82.5mm
Case 2: To find pitch diameter of the worm wheel (d2)
d2 = Z2  m x From step 5 case 1.
= 72  10
= 720mm
Case 3: To find the pitch line velocity of worm wheel (v)
v = 0.226 m x From step 5, case 1.
= 0.226  10
v = 2.26 m s
Step 10: Recalculation of beam strength.
Fs = 259.18m x2 From step 7
= 259.18  10 2
Fs = 25918N
Step 11: Recalculation of dynamic load ( F )
Ft
Fd =
Cv
6 6
Cv = = = 0.726
6 + v 6 + 2.26
79646.02 79646.02
Ft = = = 7964.602N From step 5 case 2
mx 10
7964.602
 Fd =
0.726
Fd = 10970.53N
We find Fd  Fs . the design is safe.
Step 13: Check for Maximum wear load ( FN ) :
From PSGDB 8.52
Fw = d2  b  K w
K w = 0.56 N mm 2 From PSGDB 8.54 , table 43
Fw = 720  82.5  0.56
Fw = 33264N
Step 14: Check for efficiency.
tan H
actual = 0.95  From PSGDB 8.49
tan ( H + e )
Where,  = tan −1 M , Assume M = 0.03 From PSGDB 8.49
 = tan −1 ( 0.03 )
= 1.7
tan 15.25
actual = 0.95 
tan ( 15.25 + 1.7 )
= 0.8498 We find that the actual efficiency is greater than

the desired efficiency.  The design is safe.
actual = 84.98%
Step 15: Calculation of basic dimensions of worm and worm gears.
Axial module: m x = 10mm
No. of starts: Z 1 = 3
No. of teeth on the worm wheel: Z2 = 72
Face width of the worm wheel: b = 82.5mm
Length of the worm: L  ( 12.5 + 0.09Z2 ) m x
= ( 12.5 + 0.09  72 ) 10
= 189.8mm
Take L = 190mm
Centre distance: a = 0.5m x ( q + Z2 )
a = 0.5  10 ( 11 + 72 )
a = 415mm
Bottom clearance: C = 0.25m x = 0.25  10 = 2.5mm.
Pitch diameter: d1 = q  m x = 11  10 = 110mm
d2 = 720mm
Tip diameter: da1 = d1 + 2f0  m x = 110 + 2  1  10 = 130mm
da2 = ( Z2 + 2f0 ) mx = ( 72 + 2  1) 10 = 740mm
Root diameter: df 1 = d1 − 2f0  m x − 2C
= 110 − 2  1 10 − 2  2.5
= 85mm
df 2 = ( Z2 − 2f0 ) mx − 2C
= ( 72 − 2  1)  10 − 2  2.5
= 695mm.
3. Design a pair of strength bevel gears for two shafts whose axis are at
right angles. The power transmitted is 25 KW. The speed of pinion is
300 rpm and the gear is 120 rpm.
Given data:
P = 25KW
N1 = 300rpm
N 2 = 120rpm
From PSGDB Pg No. 1.40. Both pinion and gears C45 steel is selected.
Step 2: Calculation of no. of teeth, virtual number of teeth and pitch angles:
N1 300
= i
N 2 120
i = 2.5.
Case(1): Calculation of no. of teeth Z1 & Z2
Z1 = 20 Assume
Z2 = i  Z1
= 2.5  20
= 50
Case 2: Calculation of virtual no. of teeth Zv1 & Zv2
From PSGDB 8.39 From PSGDB 8.39
z1
z V1 = 1 = 90 − 2
cos 1
20
= = 21.54 22 tan 2 = i
cos 21.8
Z2 50
Z v2 = =  2 = tan −1 2.5 = 68.2
cos  2 cos 68.2
= 134.64 135  1 = 21.8
Step 4: Calculation of tangential load (Ft).
P
Ft =  K0
v
Where
 K 0 = 1.5 for medium shock conditions.

d1 N1
 v=
60
d1 = m t  Z1
 m t  20  300
 v=
60  1000
v = 0.314 m t m/s
25 103
 Ft = 1.5
0.314m t
119366.21
Ft =
mt
Ft
Fd =
Cv
From PSGDB 8.52
5.5
Cv = , assuming v = 5 m/s
5.5 + v
5.5
=
5.5 + 5
Cv = 0.711
119366.21 1
 Fd = 
mt 0.711
167895.48
Fd =
mt
Step 6: Calculation of beam strength (Fs)
From PSGDB 8.52,
R−b
Fs =  m t  [ b ]  b y1  
 R 
Where,
b = 10  m t From PSGDB 8.38, table 31
[b ] = 180 N/mm2 , for C45 steel
0.912
y1 = 0.154 − From PSGDB 8.50, 20 FD
Z v1
0.912
= 0.154 −
22
y1 = 0.112
R = cone radius = 0.5m + Z12 + Z22 From PSGDB 8.38 , table 31
= 0.5  mt 202 + 502
R = 26.93m t
 26.93m t − 10m t 
 Fs = m t  10  m t 180  0.112   
 26.93m t 
= 398.16 m 2t
Step 7: Calculation of transverse module (mt):
From PSGDB 8.51
Fs  Fd
167895.48
398.16 m 2t 
mt
m t  7.5
From PSGDB 8.2 , table 1, choice 1. The next nearest higher standard module
m t = 8mm .
 Face width b = 10  m t
= 10  8
= 80 mm
Pitch circle diameter, d1 = m t  Z1
= 8  20
d1 = 160 mm
d1 N1
Pitch line velocity v =
60
 160  300
=
60 1000
v = 2.51 m / s
Step 9: Recalculation of beam strength:
Fs = 398.16 m 2t From step 6
= 398.16  82
Fs = 25482.24 N
From PSGDB 8.51
21v(bc+ Ft )
Fd = Ft +
21v + bc + Ft
Where,
P
Ft =
 v
25  103
=
2.51
= 9960.16 7961.78
 C = 11860 e From PSGDB 8.53 , table 41, for 20° FD
e = 0.019 , for module upto 8 , precision gears. Table 42
C = 11860  0.019 = 225.34 / mn
21 2.51103 (80  225.34 + 9960.16)

 Fd = 9960.16 +
21 2.51103 + 80  225.34 + 9960.16
Fd = 37858.96 
We find Fd > Fs . Design is not safe.
In order to overcome this issue, increase the module 10mm.
 Fd = 30415.23 
& Fs = 39816
 Fs  Fd . Design is safe.
Step 12: Calculation of maximum wear load. (Fw)
0.75  d1  b  Q1  K w
Fw = From PSGDB 8.51
cos 1
2Z v2
 Q1 = From PSGDB 8.51
Z v1 + Z v2
2  135
=
22 + 135
Q1 = 1.72
 K w = 2.553 N/mm 2 , for steel hardened to 400 BHN,
0.75  200 100 1.72  2.553

 Fw =
cos 21.8
Fw = 70940.66N
Fw > Fd . Design is safe
 Transverse module: m t = 10mm
 Number of teeth: Z1 = 20 , Z2 = 50
 Pitch circle diameters: d1 = 200mm
d 2 = 500mm.
 Cone distance: R = 26.9310 = 269.3mm

 Pitch angles: 1 = 21.8 , 2 = 68.2
d a1 = m t (Z1 + 2cos 1 ) d a 2 = m t (Z2 + 2cos 2 )
 Tip diameter:
= 10(20 + 2 cos 21.8) = 10(50 + 2 cos 68.2)
d a1 = 218.56mm d a 2 = 507.43mm
 Height factor: f0 = 1
 Clearance: c = 0.2
m t  f0
 Addendum angle: tan a1 = tan a2 =
R1
10  1
=
269.3
= 0.037
a1 = a2 = 2.13
 Deddendum angle:
m t (f0 + c)
tan f 1 = tan f 2 =
R1
10(1 + 0.2)
=
269.3
= 0.045
f 1 = f 2 = 2.55
 Tip angle: a1 = 1 + a1 a2 = 2 + a2
= 21.8 + 2.13 = 68.2 + 2.13
a1 = 23.93 a2 = 70.33
 Root angle:  f 1 =  1 + f 1  f 2 =  2 + f 2
= 21.8 + 2.55 = 68.2 + 2.55
f 1 = 19.25 f 2 = 65.65
Zv1 = 22 , Zv2 = 135
4. Design a worm gear drive to transmit 22.5KW at a worm speed of 1440

rpm. velocity ration is 24:1. An efficiency of atleast 85% is desired. The
temperature raise should be restricted to 40°C. Determine the required
cooling area.
Given data:
P = 22.5KW
N1 = 1440 rpm
i = 24
desired = 85%
 t = t 0 − t a = 40c
Step 1: To find gear ration (i):
i = 24 (given)
Assume,
Worm wheel = Phosphor bronze.
N1
For,  = 85% , Z1 =3 =i
N2
1440
 Z2 = i  Z1 = 24
N2
= 24  3 N 2 = 60rpm.
Z 2 = 72.
Case 1: To find diameter factor (q).
From PSGDB 8.43 , table 35, and PSGDB 8.44
q = m x  d1
Initially we assume q = 11.
Case 2: To find Lead angle (H) .
Z1
tan H =
q
 3 
H = tan −1  
 11 
H = 15.25
Step 5: Calculation of ‘Ft’ in terms of ‘mx’
P
Tangential load Ft =  K0
v
d 2 N 2
v=
60  1000
d2 = Z2  m x
 Z 2  m x  N 2
 v=
60  1000
 72  m x  60
=
60  1000
v = 0.226 m x m/s
Case 2: To find tangential load
Assume medium shock
K 0 = 1.5 .
22.5  10 3
 Ft =  1.5
0.226m x
149336.28
mx
Step 6: Calculation of dynamic load (Fd)
Ft
Fd =
Cv
Case 1: To find velocity factor (Cv).
From PSGDB 8.51 , assume v= 5 m/s
6
Cv =
6+v
6
=
6+5
C v = 0.545
149336.28 1
Fd = 
mx 0.545
274011.53
=
mx
Step 7: Calculation of beam strength (Fs) in terms of (mx).
From PSGDB 8.51
Fs =  m x  b  b   y1
Where,
 b = 0.75d 1 From PSGDB 8.48 , table 38
= 0.75  q  m x
= 0.75  11  m x
= 8.25m x
 y1 = 0.125 From PSGDB 8.52 ,

Assume =20°
y
y1 = From PSGDB 8.53 , table 40

0.392
= = 0.125

 b  = 80 N/mm2 From PSGDB 8.45 , table 33
 Fs =  m x  8.25  m x  80  0.125
= 259.18 m2x
Step 8: Calculation of Axial module (mx).
From PSGDB 8.51
Fs  Fd
274011.53
259.18 m 2x 
mx
m x  10.18 mm.
PSGDB 8.2 , table 1.
The next nearest higher standard axial module
m x = 12 mm.
Step 9: calculation of b , de and v:
b = 8.25 m x From step 7
= 8.25  12
b = 99 mm
Case 2: To find Pitch diameter of the worm wheel (d2).
d2 = Z2  m x From step 5 , case 1.
= 72  12
d2 = 864 mm
Case 3: To find the Pitch line velocity of worm wheel (v)
v = 0.226 m x From step 5 , case 1.
= 0.226  12
v = 2.712 m /s
Fs = 259.18 m2x From step 7.
= 259.18  12 2
Fs = 37321.92 N
Step 11: Recalculation of dynamic load (Fd).
Ft
Fd =
Cv
6 6
 Cv = = = 0.688
6 + v 6 + 2.712
149336.28 149336.28
 Ft = = = 12444.69 N From step 5 , case 2.
mx 12
12444.69
 Fd =
0.688
Fd = 18088.21 N
We find Fs  Fd .  the design is safe.
Step 13: Check for maximum wear load (Fw).
From PSGDB 8.52
Fw = d2  6  K w
 K w = 0.56 N/mm 2 From PSGDB 8.54 , table 43.
Fw = 864  99  0.56
Fw = 47900.16 N .
We find Fw  Fd .  the design is safe.
tan H
tan ( H +  )
Where ,  = tan −1 ( H ) Assume H = 0.03From PSGDB 8.49
 = tan −1 ( 0.03 )
= 1.7
tan 15.25
actual = 0.95 
tan ( 15.25 + 1.7 )
= 0.85
actual = 85%
We find that the actual efficiency is equal to the desired efficiency.
Step 15: To find cooling area (A).
In order to avoid overheating, we have to find cooling area.
Heat generated (i.e Power loss) = Heat emitted into the atmosphere.
From PSGDB 8.52 ( 1 − )  Input Power = K tA ( t 0 − t a ) .
Assume Kt = 10w /m2 c
( 1 − 0.85)  22.5  103 = 10  A  40

Required cooling Area , A = 8.44 m
2
Step 16: Calculation of basic dimension of worm and worm wheel.
Axial module: m x = 12 mm
No. of teeth on worm wheel: Z2 = 72
Face width: b = 99 mm.
= ( 12.5 + 0.09  72 ) 12
= 227.76 mm.
L 228 mm.
Centre distance: a = 0.5 m x ( q + Z2 )
= 0.5  12 ( 11 + 72 )
a = 498 mm.
Height factor: f0 = 1.
Bottom clearance: c = 0.25m x = 0.25  12 = 3.0
c = 3 mm.
Pitch diameter: d1 = q  m x = 11  12 = 132 mm.
d2 = 864 mm
Tip diameter: da1 = d1 + 2f0  m x da2 = Z2 + 2f0  m x
= 132 + 2  1 12 = ( 72 + 2 ( 1) ) 12
= 156 mm. = 888 mm.
Root diameter: df 1 = d1 − 2f0  m x − 2c
= 132 − 2  1 12 − 2  3
df 2 = ( Z2 − 2f0 ) m x − 2c
= ( 72 − 2  1) 12 − 2  3
df 2 = 834 mm
5. Design a straight bevel gear drive between two shafts at right angles to
each other. Speed of the pinion shaft is 360 rpm and the speed of the
gear. Wheel shaft is 120 rpm. Pinion is of steel and wheel of cast iron.
Each gear is expected to work 2 hours / day for 10 years. The drive
transmits 9.35 KW.
Given data:  = 90 ; N 1 = 360rpm ; N 2 = 120rpm ;

P = 9.37KW
To find: Design the bevel gear drive.
Solution: Since the materials of pinion and gear are different, we have
to design the pinion first and check the gear.
N 1 360
1. Gear ratio: i= = =3
N 2 120
Pitch angles: tan 2 = i = 3 or 2 = tan −1 ( 3 ) = 71.56 from PSGDB 8.39
Then, 1 = 90 − 2 = 90 − 71.56 = 18.44
2. Material selection: Pinion – C45 Steel, u = 700N mm2 and

 y = 360 N m 2
Gear – CI grade 35, u = 350N mm2
3. Gear life in hours

= ( 2 hours day )  ( 365days year  10years ) = 7300hours
 Gear life in cycles, N = 7300  360  60 = 15.768  107 cycles
4. Calculation of initial design torque [Mt]:
We know that, Mt  = Mt  K  Kd

60  P 60  9.37  10 3
Where Mt = = = 248.6N − m and
2 N 1 2  360
K  K d = 1.3 , initially assumed.
 Mt  = 248.6  1.3 = 323.28N − m

5. Calculation of Eeq ,   b  and  c  :
To find Eeq: Eeq = 1.7  105 N mm 2 From PSGDB 8.14
To find  b1  : We know that the design bending stress for pinion,
1.4K b1
 b1  =   −1 , for rotation in one direction
n  K
Where K b1 = 1 , for HB  350 and N  107 From PSGDB 8.20, table 22
K  = 1.5 , for steel pinion From PSGDB 8.19, table 21
n = 2.5 , steel hardened table 20, PSGDB 8.19
( )
 −1 = 0.25  u +  y + 50 , for forged steel - From PSGDB 8.19, table 19
= 0.25 ( 700 + 360 ) + 50 = 315N mm 2
1.4  1
 b1  =  315 = 117.6 N mm 2
2.5  1.5
To find   c1  : We know that the design contact stress for pinion,
c1  = CR  HRC  Kcl From PSGDB 8.16
Where CR = 23 From PSGDB 8.16, table 16
HRC = 40 to 55 From PSGDB 8.16, table 16
K cl = 1 , for steel pinion, HB  350 and N  107 From PSGDB

8.16, table 17
 c1  = 23  50  1 = 1150 N mm 2
6. Calculation of cone distance (R):
2
 0.72  E M 
i2 + 1 3    eq t
We know that, R   y From PSGDB
( )
  y − 0.5  c  

i
8.13
Where  y = R b = 3 , initially assumed.
2
 0.72  1.7  10 5  323.28  10 3
 R  3 3 +13  2
 
 ( 3 − 0.5 ) 1150  3
 99.36
or R = 100mm .
7. Assume Z1 = 20 ; Then Z 2 = i  Z1 = 3  20 = 60
Z1 20
Virtual number of teeth: Z v1 = = 22 ; and
cos 1 cos 18.44
Z2 60
From PSGDB 8.39 Z v2 = = 190 .
cos  2 cos 71.56
8. Calculation of transverse module (mt):
R
We know that, mt = From PSGDB 8.38, table 31
0.5 Z12 + Z 22
100
= = 3.162mm
0.5 20 2 + 60 2
From PSGDB 8.2 , table 1. Under choice 1. The nearest higher standard
transverse module is 4mm.
9. Revision of cone distance (R):
We know that, R = 0.5m t Z12 + Z 22 = 0.5  4 20 2 + 60 2 = 126.49mm
10. Calculation of b, m av , d1av , v and  y :
R 126.49
Face width (b): b= = = 42.16mm From PSGDB 8.38
y 3
Average module (mav):

b sin 1 42.16  sin 18.44
m av = m t − = 4− PSGDB 8.38
Z1 20
= 3.333
Average pcd of pinion ( d1av ) : d1av = m av  Z1 = 3.333  20 = 66.66mm
Pitch line velocity ( v ) :
 d1av  N 1  66.66  10 −3  360

v= = = 1.256 m s
60 60
b 42.16
y = = = 0.632
d 1av 66.66
11. IS quality 6 bevel gear is assumed From PSGDB 8.3 , table 2


Where K = 1.1
Kd = 1.35
 Mt  = 248.6  1.1  1.35 = 369.28N − m

13. Check for bending of pinion: We know that the induced bending stress,
R i 2 + 1 M t 
b1 = From PSGDB 8.13 [A]
( R − 0.5b )
2
 b  m t  y v1
Where y v1 = 0.402 , for Z v1 = 22
126.49 32 + 1  369.28  10 3
 b = = 196.09 N mm 2
( 126.49 − 0.5  42.16 )
2
 42.16  4  0.402
We find b1  b1  . Thus the design is unsatisfactory.
Trial 2: Now we will try with increased transverse module 5mm. Repeating
from step 9 again, we get
R = 0.5  m t  Z12 + Z 22 = 0.5  5  20 2 + 60 2 = 158.11mm
R 158.11
b= = = 52.7mm
y 3
b sin 1 52.7  sin 18.44

m av = m t − = 5− = 4.166mm
Z1 20
d1av = m av  Z1 = 4.166  20 = 83.33mm
 d1av  N 1  83.33  10 −3  360

v= = = 1.57 m s
60 60
b 52.7
y = = = 0.632
d 1av 83.33
IS quality 6 bevel gear is assumed.
K = 1.1 ; Kd = 1.35
M t = 248.6  1.1  1.35 = 369.28N − m
158.11 32 + 1  369.28  10 3
 b1 = = 100.4 N mm 2
( 158.11 − 0.5  52.7 )
2
 52.7  5  0.402
Now we find b1  b1  , thus the design is satisfactory.
14. Check for wearing of pinion: We know that the induced contact stress,
1
 2
(i + 1)
2 3
 0.72   
c1 =    Eeq   M t  From PSGBD 8.13
 R − 0.5b   ib
 
1
 2
  ( 3 + 1)
2 3
 0.72 
=   1.7  10 5  369.28  10 3 
 158.11 − 0.5  52.7  3  52.7
 
= 612.33N mm2
We find C1  C1  . Thus the design is satisfactory for pinion.
15. Check for gear (i.e., wheel): Gear material: CI grade 30.
First we have to calculate  b2  and  C 2  .
N pinion 15.768  107

Gear life of wheel, N = = = 5.256  107 cycles
3 3
To find  b2  : We know that the design bending stress for gear,
1.4  K b1
 b2  =   −1
n  K
107 9 107
Where K b1 = 9 = = 0.832
N 5.256  107
K  = 1.2
n=2
−1 = 0.45u = 0.45  350 = 157.5N mm2
1.4  0.832
 b2  =  157.5 = 76.44 N mm 2
2  1.2
To find  b2  : We know that the design contact stress for gear,
C2  = CB  HB  Kcl
Where C B = 2.3
HB = 200 to 260
107 6 107
K cl =6 = = 0.758
N 5.256  107
 C2  = 2.3  260  0.758 = 453.284 N mm 2
(a) Check for bending of gear: The induced bending stress for gear can
be calculated using the relation
b1  y v1 = b2  y v2
Where y v1 = 0.402 , for Z v1 = 22
y v2 = 0.520, for Z v2 = 190
 100.4  0.402 = b2  0.520
or  b2 = 77.6 N mm 2
We find  b 2 is almost equal to  b2  . Thus the design is okay and it

can be accepted.
(b) Check for wearing of gear: Since the contact area is same,
c2 = c1 = 612.33N mm2
We find c2  c2  . It means the gear does not have adequate beam
strength. In order to increase the wear strength of the gear, surface
hardness may be raised to 360 BHN. Then we get
b2  = 2.3  360  0.758 = 627.62 N mm 2
Now we find b2   b2  , thus the design is safe and satisfactory.
6. The input to the worm gear shaft is 18KW at 600rpm. Speed ratio is 20.
The worm is to be of hardened steel and the wheel is made of chilled
phosphor bronze. Considering wear and strength, design worm and
worm wheel.
Given data:
N 1 = 600rpm
P = 18KW
i = 20
Step 1: To find gear ratio (i)
N1
i= = 20 ( given )
N2
600
20 =
N2
N 2 = 30rpm.
Step 2: Selection of Materail:
For  = 80% , Z1 = 3
Z 2 = i  Z1 = 20  3
Z2 = 60
Case 1: To find diameter factor (q)
q
d1 =
mx
Initially we assume q= 11.
Case 2: To find Lead angle (H)
Z1
tanH =
q
H = tan −1 3 ( 11)
H = 15.25
Step 5: Calculation of (F7) in terms of (mx).
P
Ft =  K0
v
Case 1: To find the velocity ‘v’
d 2 N 2
v=
60  1000
d2 = Z2  m x
 60  m x  30
 v=
60  1000
v = 0.094m x m s.
Case 2: To find shock factor (K0)
Assume medium shock, K0 = 1.5
18  10 3
 Ft =  1.5
0.094m x
287234.04
Ft =
mx
Step 6: Calculation of dynamic load (Fd).
Ft
Fd =
Cv
Case 1: To find velocity factor (Cv):
From PSGDB 8.51, assume v = 5m s
6
Cv =
6+v
6
=
6+5
C v = 0.545
287234.04 1
 Fd = 
mx 0.545
527034.94
=
mx
From PSGDB8.51,
Fs =  m x  b  b   y1
Where,
b = 0.75d 1 From PSGDB 8.48, table 38
= 0.75  q  m x
= 0.75  11  m x
= 8.25m x
b  = 110 N mm 2 From PSGDB 8.45, table 33
 Fs =  m x  8.25m x  110  0.125
= 356.37m2x
Step 8: Calculation of axial module (mx).
Fs  Fd
527034.94
356.37m 2x 
mx
m x  11.4mm.
From PSGDB 8.2, table 1. The next nearest higher standard module mx =
12mm.
Step 9: Calculation of b , d2 and v:
From step 7  b = 8.25  m x
= 8.25  12
b = 99mm
From step 5, Case 1  d2 = Z2  m x = 60  12
= 720mm
From step 5, Case 1  v = 0.094  m x = 0.094  12
= 1.13m s
Fs = 356.37  m2x From step 7.
= 356.37  12 2
Fs = 51317.28N
Ft
Fd =
Cv
6 6
Cv = = = 0.84
6 + v 6 + 1.13
287234.04 287234.04
Ft = = = 23936.17N
mx 12
 Fd = 28495.44N
We find Fs >Fd . The design is safe.
Step 12: Check for maximum wear load (Fw):
From PSGDB 8.52
Fw = d2  b  K w
K w = 0.88 N mm 2 From PSGDB 8.54 , table 43.
Fw = 720  99  0.88 = 62726.4N
We find Fw  Fd  The design is safe.
tan H
tan ( H + e )
Where, e = tan −1 ( M ) , Assume M = 0.05
e = tan −1 ( 0.05 ) = 2.86
tan 15.25
 actual = 0.95 
tan ( 15.25 + 2.86 )
=0.792
actual = 79.2%
We find that the actual efficiency is greater than the desired efficiency.
Step 14: Calculation of basic dimensions.
 Axial module: M x = 12mm

 No. of starts: Z 1 = 3
 No. of teeth on the worm wheel: Z2 = 60
 Face width of worm wheel: b = 99mm
 Length of the worm: L  ( 12.5 + 0.09Z2 ) m x
= ( 12.5 + 0.09  60 ) 12
= 214.8mm
L 215mm
 Centre distance: a = 0.5m x ( q + Z2 )
= 0.5  12 ( 11 + 60 )
a = 426mm .
 Bottom clearance: C = 0.25m x = 0.25  12 = 3mm
 Pitch diameter: d1 = q  m x = 11  12 = 132mm
d2 = 720mm
 Tip diameter:
da1 = d1 + 2f0  m x da2 = ( Z2 + 2f0 ) m x
= 132 + 2  1 12 = ( 63 + 2 ( 1) ) 12
= 156mm = 744mm
 Root diameter:
df 1 = d1 − 2f0  m x − 2c df 2 = ( Z2 − 2f0 ) m x − 2c
= 132 − 2  1 12 − 2  3 = ( 60 − 2  1) 12 − 2  3
df 1 = 102mm = 690mm
7. Design a bevel gear device to transmit 3.5KW speed ratio =4. Driving
shaft speed =200rpm. The drive is non-reversible. Pinion is of steel and
wheel of CI. Assume a life of 25,000hrs.
Given data:
P = 3.5KW
i=4
N 2 = 200rpm.
Material  Pinion − Steel
Wheel − CI
The materials of pinion and gear are different, we have to design the pinion first
and check the gear.
Step 1: Gear ratio & Pitch angles:
N1
i= =4
N2
N1
=4
200
N 1 = 800rpm.
Pitch angles:
From PSGDB 8.34
tan 2 = i = 4
 2 = tan −1 ( 4 ) = 75.96
1 = 90 − 2 = 90 − 75.96
= 14.04
Step 2: Material selection:
Pinion: Steel,  u = 700N /mm 2  y = 360N /m 2
Gear: CI grad 35 -  u = 350N /mm 2
Step 3: Gear life in cycles:
Gear life in hours = 25000hrs.
Gear life in cycles N = 25000  800  60
= 12  10 8 cycles.
From PSGDB 8.44,
Mt  = Mt  K  Kd
60  P 60  3.5  10 3
Mt = = = 41.778N.m
2 N 1 2   800
K.K d = 1.3 initially assume.
 Mt  = 41.778  1.3

= 54.31 Nm.
Step 5: Calculation of Eeq , [b] and [c]:
To find Eeq.
Eeq = 1.7  105 N /mm 2 From PSGDB8.14
To find [b1] Design bending stress for pinion.
1.4K b1
 b1  =  −1 From PSGDB 8.18 rotation in one direction
n  K
Kb1 = 1 , for HB  350 and N Z107, From PSGDB 8.20, table 22.
K  = 1.5, for steel pinion. From PSGDB 8.19, table 21
n = 2.5 steel hardened From PSGDB 8.19, table 20
( ( ) )
 −1 = 0.25  u +  y + 50 , for forged steel. From PSGDB 8.19, table 19
−1 = 0.25 ( 700 + 360 ) + 50
= 315N /mm 2 .
1.4  1
  b1  =  315 = 117.6N /mm 2 .
2.5  1.5
To find   c1  :
c1  = CR .HRC  KC1

CR = 23
HRC = 40to55
K C1 = 1
c1  = 23  55  1
= 1265N /mm 2
Step 6: Calculation of cone distance (R).
2
 0.72  E M 
i2 + 1 3    eq t
R  y
( )
 y − 0.5  c  

i
y = R = 3
6
2
 0.72   1.7  10 5  54.31  10 3 
R  3 4 +1 2
  
 ( 3 − 0.5 )  1265   4 
 135.29mm.
R = 136mm.
Step 7: Selection of No. of teeth on pinion and gear.
Z1 = 20
Z2 = i  Z1
4  20
= 80
Z1 20
Virtual no. of teeth: Z v1 = = = 20.61 21
cos 1 cos 14.04
Z2 80
From PSGDB 8.22. Z v2 = = = 329.76 330
cos  2 cos 75.96
Step 8: Calculation of transverse module: (mt).
R1
Mt = From PSGDB 8.38 table 31
0.5 Z 21 + Z 22
136
=
0.5 20 2 + 80 2
= 3.29mm
The nearest next higher standard transverse module mt =4mm.
Step 9: Revision of cone distance: (R)
R = 0.5m t Z12 + Z 22
= 0.5  4 202 + 802
= 164.92mm.
Step 10: Calculation of b, mav , d1av, v and y :
R 164.92
(i) To find b: b= = = 54.97 55mm PSGDB 8.38
y 3
b sin 1
(ii) Average module m av = m t − PSGDB 8.38
Z1
55SIN14.04
= 4−
20
= 3.33mm.
(iii) Average PCD of pinion: d1av = m av  Z 1
= 3.33  20
= 66.66mm.
d1av  N 1  66.66  800

(iv) Pitch line velocity v = = = 2.79 m .
60 60  1000 s
b 55
(v) y = = = 0.83
d 1av 66.66
Step 11: Selection of Quality of gears.
Is Quality 8 bevel gear is selected. From PSGDB 8.3 table 2.
Mt  = Mt  K  Kd
K = 1.1 From PSGDB 8.15
Kd = 1.45 From PSGDB 8.16 table 15.
 Mt  = 41.778  1.1  1.45

= 66.64Nm.
Step 13: Check for bending of pinion.
R l 2 + 1 M t 
b1 = From PSGDB 8.13[A].
( R − 0.5b )
2
 b  m t  y v1
y v1 = 0.402 for Z v1 = 21
164.92 4 2 + 1  66.64  10 3
  b1 =
( 164.92 − 0.5  55 )
2
 55  4  0.402
b1 = 27.13N mm2
We find b1  b1  .  the design is safe.
Step 14: Check for wearing of pinion.
1
  2
(i + 1)
2 3
 0.72   
c1 =    Eeq   M t  From PSGDB 8.13
 R − 0.56   ib
 
1
  2
(4 + 1)
2 3
 0.72  3
=   1.7  10  66.64  10 
5
 164.92 − 0.5  55   4  55
 
C1 = 314.77N /mm2
We find C1   C  . Thus the design is satisfactory for pinion.
Step 15: Cheek for gear.
Gear material: CI grade 30.
First we have to calculate  b2  and   c2  .
N pinion
Gear life of wheel N =
3
12  10 8
=
3
= 4  10 8
To find  b2  :
1.4  K b1
 b2  =   −1
h  K
Where,
107 9 107
K b1 = 9 = = 0.66
N 4  108
K  = 1.2
n=2
−1 = 0.45u = 0.45  350 = 157.5N /mm2 .
1.4  0.66
   b2  =  157.5
2  1.2
= 60.64N.mm 2 .
To find   c2  :
c2  = CB  HB  Kcl .
Where C B = 2.3, HB = 200 to 260
107 b 107
K cl = b = = 0.54
N 4  10 8
c2  = 2.3  260  0.54
= 322.92N /mm 2 .
Case 1: Check for bending of gear.
b1  y v1 = b2  y v2
y v1 = 0.402 for Z v1 = 21
y v2 = 0.521 for Z v2 = 330
27.13  0.402 = b2  0.521
b2 = 20.93N /mm2 .
b2  b2  .  design is safe.
Case 2: Check for wearing of gear.
Since the contact area is same.
 c2 = c1 = 314.77N /mm2
We find c2   c2  . It means the gear having the adequate beam strength.
 The design is safe and satisfactory.
8. Design a worm gear drive to transmit 20KW at 1440rpm. Speed of worm

wheel is 60rpm.
Given data:
P = 20KW
N1 = 1440rpm.
N 2 = 60rpm.
Step 1: To find gear ratio (i).
N1
i=
N2
1440
=
60
i = 24
For  = 80% , Z1 = 3
Z 2 = i  Z1 = 24  3
= 72
From PSGDB 8.43 , table 35 and PSGDB 8.44
q
d1 =
mx
Initially we assume q=11
Case 2: To find Lead angle (H).
Z1 3
tan H = =
q 11
H = 15.25
Step 5: Calculation of (Ft) in terms of (mx).
P
Ft =  0
v
d 2 N 2
v=
60  1000
d2 = z2  m x
 z 2  m x  N 2
v=
60  1000
 72  m x  60
=
60  1000
v = 0.226m x m s .
Case 2: To find shock factor (K0).
Assume medium shock , K 0 = 1.5
20  10 3
 Ft =  1.5
0.226m x
132629.12
Ft =
mx
Ft
Fd =
Cv
From PSGDB 8.51, Assume v = 5m s
6 6
Cv = = = 0.545.
6+v 6+5
132629.12 1
 Fd = 
mx 0.545
243356.18
Fd =
mx
From PSGDB 8.51
Fs =  m x  b  b   y1
Where,
 b = 0.75d 1 From PSGDB 8.48 , table 38
= 0.75  q  m x
= 8.25m x
 y1 = 0.125 From PSGDB 8.52 , Assume  = 20

 b  = 110 N mm2 From PSGDB 8.45 , table 33.
 Fs =  m x  8.25  m x  110  0.125
= 356.37m2x
Step 8: Calculation of axial module: (mx)
Fs  Fd
243356.18
356.37m 2x 
mx
m x  8.81mm.
From PSGDB 8.2 , table 1. The next nearest higher standard module mx = 10
mm
From step 7  b = 8.25m x = 8.25  10
From step 5, case 1  d2 = Z2  m x = 72  10
= 720mm.
From step 5, case 1  v = 0.226  m x = 0.226  10
= 2.26 m
s .
Step 10: Recalculation of beam strength (Fs).
Fs = 356.37  m2x From step 7
= 356.37  10 2
Fs = 35637 N
Ft
Fd =
Cv
6 6
 Cv = = = 0.73
6 + v 6 + 2.26
132629.12 132629.12
 Ft = = = 13262.91 N
mx 10
13262.91
 Fd =
0.73
Fd = 18168.37 N
We find Fs  Fd . The design is safe.
Step 12: Check for Maximum wear load (Fw)
From PSGDB 8.52,
Fw = d2  b  K w
 K w = 0.88 N mm 2 From PSGDB 5.54 , table 43.
Fw = 720  82.5  0.88
= 52272 N
We find Fw  Fd .  The design is safe.
tan H
actual = 0.95  From PSGDB 8.49.
tan ( H + e )
Where,
e = tan −1 M , take M = 0.04 From PSGDB 8.49, Graph.
e = tan −1 ( 0.04 ) = 2.29
tan 15.25
actual = 0.95 
tan ( 15.25 + 2.29 )
= 0.82
= 82%
The design is safe.
 Axial module: m x = 10mm.

 Face width of the worm wheel: b = 82.5mm.
 Length of the worm: L  ( 12.5 + 0.09Z2 ) m x.
= ( 12.5 + 0.09  72 ) 10
= 189.8
L 190mm
 Centre distance: a = 0.5mx ( q + Z2 ) .
= 0.5  10 ( 11 + 72 )
a = 415mm
 Bottom clearance: c = 0.25m x = 0.25  10 = 2.5mm.
 Pitch diameter: d1 = q  m x = 11  10 = 110mm.
d2 = 720mm.
 Tip diameter:
da1 = d1 + 2f0  m x da2 = ( Z2 + 2f0 ) m x
= 110 + 2  1 10 ( 72 + 2  1) 10
= 130mm. = 740mm.
 Root diameter:
df 1 = d1 − 2f0  m x − 2 df 2 = ( Z2 − 2f0 ) m x − 2c
= 110 − 2  1 10 − 2  2.5 = ( 72 − 2  1) 10 − 2  2.5
= 85mm. = 715mm.
9. Design a bevel gear drive to transmit 3.5 KW with dividing shaft is 200
rpm. Speed ratio required is 4. The drive is no – reversible pinion is
made of steel and wheel made of steel and wheel made of CI. Assume
lite at 25000 hrs.
Given data:
P = 3.5KW
i=4
N 2 = 200rpm.
Wheel − CI
and check the gear.
N1
i= =4
N2
N1
=4
200
N 1 = 800rpm.
Pitch angles:
From PSGDB 8.34
tan 2 = i = 4
 2 = tan −1 ( 4 ) = 75.96
1 = 90 − 2 = 90 − 75.96
= 14.04
= 12  10 8 cycles.
From PSGDB 8.44,
Mt  = Mt  K  Kd
60  P 60  3.5  10 3
Mt = = = 41.778N.m
2 N 1 2   800
 Mt  = 41.778  1.3

= 54.31 Nm.
To find Eeq.
1.4K b1
n  K
( ( ) )
−1 = 0.25 ( 700 + 360 ) + 50
= 315N /mm 2 .
1.4  1
  b1  =  315 = 117.6N /mm 2 .
2.5  1.5
To find   c1  :
c1  = CR .HRC  KC1

CR = 23
HRC = 40to55
K C1 = 1
c1  = 23  55  1
= 1265N /mm 2
2
 0.72  E M 
i2 + 1 3    eq t
R  y
( )
 y − 0.5  c  

i
y = R = 3
6
2
 0.72   1.7  10 5  54.31  10 3 
R  3 4 +1 
2
  
 ( 3 − 0.5 )  1265   4 
 135.29mm.
R = 136mm.
Z1 = 20
Z2 = i  Z1
4  20
= 80
Z1 20
cos 1 cos 14.04
Z2 80
From PSGDB 8.22. Z v2 = = = 329.76 330
cos  2 cos 75.96
R1
0.5 Z 21 + Z 22
136
=
0.5 20 2 + 80 2
= 3.29mm
R = 0.5m t Z12 + Z 22
= 0.5  4 202 + 802
= 164.92mm.
R 164.92
(i) To find b: b= = = 54.97 55mm PSGDB 8.38
y 3
b sin 1
(ii) Average module m av = m t − PSGDB 8.38
Z1
55SIN14.04
= 4−
20
= 3.33mm.
(iii) Average PCD of pinion: d1av = m av  Z 1
= 3.33  20
= 66.66mm.
d1av  N 1  66.66  800

(iv) Pitch line velocity v = = = 2.79 m .
60 60  1000 s
b 55
(v) y = = = 0.83
d 1av 66.66
Mt  = Mt  K  Kd
 Mt  = 41.778  1.1  1.45

= 66.64Nm.
R l 2 + 1 M t 
( R − 0.5b )
2
 b  m t  y v1
y v1 = 0.402 for Z v1 = 21
164.92 4 2 + 1  66.64  10 3
  b1 =
( 164.92 − 0.5  55 )
2
 55  4  0.402
b1 = 27.13N mm2

1
  2
(i + 1)
2 3
 0.72   
 R − 0.56   ib
 
1
  2
(4 + 1)
2 3
 0.72  3
=   1.7  10  66.64  10 
5
 164.92 − 0.5  55   4  55
 
C1 = 314.77N /mm2
N pinion
3
12  10 8
=
3
= 4  10 8
1.4  K b1
 b2  =   −1
h  K
Where,
107 9 107
K b1 = 9 = = 0.66
N 4  108
K  = 1.2
n=2
−1 = 0.45u = 0.45  350 = 157.5N /mm2 .
1.4  0.66
   b2  =  157.5
2  1.2
= 60.64N.mm 2 .
To find   c2  :
c2  = CB  HB  Kcl .
Where C B = 2.3, HB = 200 to 260
107 107
K cl = b = b = 0.54
N 4  10 8
c2  = 2.3  260  0.54
= 322.92N /mm 2 .
b1  y v1 = b2  y v2
y v1 = 0.402 for Z v1 = 21
y v2 = 0.521 for Z v2 = 330
27.13  0.402 = b2  0.521
b2 = 20.93N /mm2 .
 c2 = c1 = 314.77N /mm2
10. A hardened steel worm rotates at 1440 rpm and transmits 12 kW to

a phosphor Bronze gear. The speed of the worm gear should be 60
rpm. Design the worm gear drive if an efficiency of at least 82% is
desired.
Given data:
Nmax = 1440 rpm, Nmin = 60 rpm p = 12kW desired = 82%
1440
Gear ratio required, i = = 24
60
1. Material selection: Worm – Hardened steel, and
Worm – Phosphor bronze
2. Selection of z1 and z2:
For η = 85%,z1 = 3
Then, z2 = i  z1 = 24  3 = 72.
3. Calculation of q and γ:
d1
Diameter factor: q= = 11
mx
z  3
Lead angle:  = tan −1  1  = tan −1   = 15.25
 
q  11 
4. Calculation of F1 in terms mx:
P
Tangential load, Ft =  K0
v
Where
d 2 N 2 (z 2  m x )  N 2
v= =
60  1000 60  1000
  72  m x  60
= = 0.226m x m / s
60  1000
K 0 = 1.25, assuming medium shock
12  103 66371.68
Ft =  1.25 =
0.226m x mx
5. Calculation of dynamic load (Fd):
Ft
Dynamic load, Fd =
cv
6
cv = , v = 5m / s is assumed.
6+v
6
= = 0.545
6+5
66371.68 1 121681.4
Fd =  =
mx 0.545 mx
6. Calculation of beam strength (Fs) in terms of axial module:
Beam strength, Fs =  mx  b  b   y
Where
b = 0.75d1
= 0.75  qm x = 0.75  11m x = 8.25m x
b  = 80 N / mm 2
y = 0.125, assuming  = 20
Fx =   m x  8.25m x  80  0.125 = 259.18m 2x
7. Calculation of axial module (mx):
We know that,
121681.4
259.18m 2x 
mx
m x  7.77 mm
The nearest higher standard axial pitch is 8 mm.
8. b = 66 mm, d2 = 576 mm; v = 1.808 m/s
9. Fs = 259.18mx2 = 16587. 52 N
Ft
10. Dynamic load, Fd =
cv
6 6
cv = = = 0.768 and
6 + v 6 + 1.808
66371.68 66371.68
Ft = = = 8296.46N
mx 8
8296.46
Fd = = 10802.68N
0.768
11. Check for beam strength: We find Fd < Fs. It means that the gear tooth has
adequate beam strength and will not fail by breakage. Thus the design is
satisfactory.
12. Calculation of maximum wear load (Fw):
Wear load, Fw = d 2  b  K w
Where
K w = 0.56N / mm 2
Fw = 576  66  0.56 = 21288.96N
13. Check for wear: We find Fd < Fw. It means that the gear tooth has adequate
wear capacity and will not wear out. Thus the design is safe and satisfactory.
14. Check for efficiency: We know that,
tan 
actual = 0.95
tan(  + )
Where
 = Frictional angle = tan −1 

= tan −1 (0.03) = 1.7
tan15.25
 = 0.95  = 0.8498 or 84.98%
tan(15.25 + 1.7)
We find that the actual efficiency is greater than the desired efficiency. Thus the
design is satisfactory.
15. Calculation of basic dimensions of worm and worm gears:
Axial module: mx = 8 mm
Number of starts: z1 = 3
Number of teeth on worm wheel: z2 = 72
Face width of worm wheel: b = 66 mm
Length of worm: L  (12.5 + 0.09z2 )mx , L  (12.5 + 0.09  72)8 = 151.84mm
Centre distance: a = 0.5mx (q + z 2 ) = 0.5  8(11 + 72) = 332mm
Bottom clearance: c = 0.25mx = 0.25  8 = 2mm
d1 = q  m x = 11  8 = 88mm
Pitch diameter:
d 2 = z 2  m x = 72  8 = 576 mm
d a1 = d1 + 2f 0 .m x = 88 + 2  1  8 =104 mm
Tip diameter:
d a 2 = (z 2 + 2f 0 )m x = (72 + 2  1)8 = 592 mm
d f 1 = d1 − 2f 0 .m x − 2.c = 88 − 2  1  8 − 2  2 = 68mm
Root diameter:
d f 2 = (z 2 − 2f 0 )m x − 2.c = (72 − 2  1)8 − 2  2 = 556 mm

3%rpm. Design a worm gear drive if an efficiency of at least 82% is
desired. (April/May 2017)
Given data:
N1 = 1440rpm
P = 12KW
N 2 = 60  3%rpm
desired = 82%
***Similar to this problem, power has to be changed to 20HP=15 kW and efficiency is 80%
N1
i=  3%
N2
1440
=  3%
60
= 24  0.72
take i = 24
For  = 82% , Z 1 = 3
Z2 = i  Z1
= 24  3
Z2 = 72
q
d1 =
mx
Z1
tanH =
q
 3 
H = tan −1  
 11 
H = 15.25
P
v
d 2 N 2
v=
60  1000
d2 = Z2  m x
 Z 2  m x  N 2
 v=
60  1000
 72  m x  60
=
60  1000
v = 0.226m x m
s
K 0 = 1.5
12  10 3
 Ft =  1.5
0.226m x
79646.02
Ft =
mx
Ft
Fd =
Cv
6
Cv =
6+v
6
=
6+5
C v = 0.545
79646.02 1
Fd = 
mx 0.545
1460177.70
=
mx
From PSGDB 8.51
Fs =  m x  b  b   y1
Where ,
b = 0.75d1 From PSGDB 8.48 , table 38
= 0.75  q  m x
= 0.75  11  m x
= 8.25m x
y
 y1 =

0.392

=0.125
b  = 80 N mm 2 From PSGDB 8.45 , table 33
 Fs =  m x  8.25m x  80  0.125
= 259.18 m2x

W.K.T Fs  Fd
146017.70
259.18  m 2x 
mx
m x  8.26mm
m x = 10mm.
= 82.5mm
= 72  10
= 720mm
= 0.226  10
v = 2.26 m s
= 259.18  10 2
Fs = 25918N
Ft
Fd =
Cv
6 6
Cv = = = 0.726
6 + v 6 + 2.26
79646.02 79646.02
mx 10
7964.602
 Fd =
0.726
Fd = 10970.53N
From PSGDB 8.52
Fw = d2  b  K w
Fw = 720  82.5  0.56
Fw = 33264N
tan H
tan ( H + e )
 = tan −1 ( 0.03 )
= 1.7
tan 15.25
actual = 0.95 
tan ( 15.25 + 1.7 )

actual = 84.98%
= ( 12.5 + 0.09  72 ) 10
= 189.8mm
Take L = 190mm
a = 0.5  10 ( 11 + 72 )
a = 415mm
d2 = 720mm
da2 = ( Z2 + 2f0 ) mx = ( 72 + 2  1) 10 = 740mm
= 110 − 2  1 10 − 2  2.5
= 85mm
df 2 = ( Z2 − 2f0 ) mx − 2C
= ( 72 − 2  1)  10 − 2  2.5
= 695mm.
12. Design a bevel gear drive to transmit 3.5 KW with dividing shaft is
200 rpm. Speed ratio required is 4. The drive is no – reversible
pinion is made of steel and wheel made of steel and wheel made of
CI. Assume lite at 25000 hrs. (April/May 2017)
Given data:
P = 3.5KW
i=4
N 2 = 200rpm.
Wheel − CI
and check the gear.
N1
i= =4
N2
N1
=4
200
N 1 = 800rpm.
Pitch angles:
From PSGDB 8.34
tan 2 = i = 4
 2 = tan −1 ( 4 ) = 75.96
1 = 90 − 2 = 90 − 75.96
= 14.04
= 12  10 8 cycles.
From PSGDB 8.44,
Mt  = Mt  K  Kd
60  P 60  3.5  10 3
Mt = = = 41.778N.m
2 N 1 2   800
 Mt  = 41.778  1.3

= 54.31 Nm.
To find Eeq.
1.4K b1
n  K
( ( ) )
−1 = 0.25 ( 700 + 360 ) + 50
= 315N /mm 2 .
1.4  1
  b1  =  315 = 117.6N /mm 2 .
2.5  1.5
To find   c1  :
c1  = CR .HRC  KC1
CR = 23
HRC = 40to55
K C1 = 1
c1  = 23  55  1
= 1265N /mm 2
2
 0.72  E M 
R  y i +1
2
   eq t
( )
3
 y − 0.5  c   i
 
y = R = 3
6
2
 0.72   1.7  10 5  54.31  10 3 
R  3 4 +1 
2
  
 ( 3 − 0.5 )  1265   4 
 135.29mm.
R = 136mm.
Z1 = 20
Z2 = i  Z1
4  20
= 80
Z1 20
cos 1 cos 14.04
Z2 80
From PSGDB 8.22. Z v2 = = = 329.76 330
cos  2 cos 75.96
R1
0.5 Z 21 + Z 22
136
=
0.5 20 2 + 80 2
= 3.29mm
R = 0.5m t Z12 + Z 22
= 0.5  4 202 + 802
= 164.92mm.
R 164.92
(vi) To find b: b= = = 54.97 55mm PSGDB 8.38
y 3
b sin 1
(vii) Average module m av = m t − PSGDB 8.38
Z1
55SIN14.04
= 4−
20
= 3.33mm.
(viii) Average PCD of pinion: d1av = m av  Z 1
= 3.33  20
= 66.66mm.
d1av  N 1  66.66  800

(ix) Pitch line velocity v = = = 2.79 m .
60 60  1000 s
b 55
(x) y = = = 0.83
d 1av 66.66
Mt  = Mt  K  Kd
 Mt  = 41.778  1.1  1.45

= 66.64Nm.
R l 2 + 1 M t 
( R − 0.5b )
2
 b  m t  y v1
y v1 = 0.402 for Z v1 = 21
164.92 4 2 + 1  66.64  10 3
  b1 =
( 164.92 − 0.5  55 )
2
 55  4  0.402
b1 = 27.13N mm2

1
  2
( i + 1)
2 3
 0.72   
 R − 0.56   ib
 
1
  2
( 4 + 1)
2 3
 0.72  3
=   1.7  10  66.64  10 
5
 164.92 − 0.5  55   4  55
 
C1 = 314.77N /mm2
N pinion
3
12  10 8
=
3
= 4  10 8
1.4  K b1
 b2  =   −1
h  K
Where,
107 9 107
K b1 = 9 = = 0.66
N 4  108
K  = 1.2
n=2
−1 = 0.45u = 0.45  350 = 157.5N /mm2 .
1.4  0.66
   b2  =  157.5
2  1.2
= 60.64N.mm 2 .
To find   c2  :
c2  = CB  HB  Kcl .
Where C B = 2.3, HB = 200 to 260
107 107
K cl = b = b = 0.54
N 4  10 8
c2  = 2.3  260  0.54
= 322.92N /mm 2 .
b1  y v1 = b2  y v2
y v1 = 0.402 for Z v1 = 21
y v2 = 0.521 for Z v2 = 330
27.13  0.402 = b2  0.521
b2 = 20.93N /mm2 .
 c2 = c1 = 314.77N /mm2

13. Design a worm gear drive to transmit 22.5KW at a worm speed of 1440
rpm. velocity ration is 24:1. An efficiency of at least 85% is desired. The
temperature raise should be restricted to 40°C. Determine the required
cooling area. (Nov/Dec 2017)
Given data:
P = 22.5KW
N1 = 1440 rpm
i = 24
desired = 85%
 t = t 0 − t a = 40c
Step 1: To find gear ration (i):
i = 24 (given)
Assume,
N1
For,  = 85% , Z1 =3 =i
N2
1440
 Z2 = i  Z1 = 24
N2
= 24  3 N 2 = 60rpm.
Z 2 = 72.
Case 1: To find diameter factor (q).
q = m x  d1
Initially we assume q = 11.
Case 2: To find Lead angle (H) .
Z1
tan H =
q
 3 
H = tan −1  
 11 
H = 15.25
Step 5: Calculation of ‘Ft’ in terms of ‘mx’
P
Tangential load Ft =  K0
v
d 2 N 2
v=
60  1000
d2 = Z2  m x
 Z 2  m x  N 2
 v=
60  1000
 72  m x  60
=
60  1000
v = 0.226 m x m/s
Case 2: To find tangential load
Assume medium shock
K 0 = 1.5 .
22.5  10 3
 Ft =  1.5
0.226m x
149336.28
mx
Step 6: Calculation of dynamic load (Fd)
Ft
Fd =
Cv
Case 1: To find velocity factor (Cv).
From PSGDB 8.51 , assume v= 5 m/s
6
Cv =
6+v
6
=
6+5
C v = 0.545
149336.28 1
Fd = 
mx 0.545
274011.53
=
mx
Step 7: Calculation of beam strength (Fs) in terms of (mx).
From PSGDB 8.51
Fs =  m x  b  b   y1
Where,
 b = 0.75d1 From PSGDB 8.48 , table 38
= 0.75  q  m x
= 0.75  11  m x
= 8.25m x
 y1 = 0.125 From PSGDB 8.52 ,

Assume =20°
y
y1 = From PSGDB 8.53 , table 40

0.392
= = 0.125

 b  = 80 N/mm2 From PSGDB 8.45 , table 33
 Fs =  m x  8.25  m x  80  0.125
= 259.18 m2x
Step 8: Calculation of Axial module (mx).
From PSGDB 8.51
Fs  Fd
274011.53
259.18 m 2x 
mx
m x  10.18 mm.
PSGDB 8.2 , table 1.
The next nearest higher standard axial module
m x = 12 mm.
Step 9: calculation of b , de and v:
b = 8.25 m x From step 7
= 8.25  12
b = 99 mm
Case 2: To find Pitch diameter of the worm wheel (d2).
d2 = Z2  m x From step 5 , case 1.
= 72  12
d2 = 864 mm
Case 3: To find the Pitch line velocity of worm wheel (v)
v = 0.226 m x From step 5 , case 1.
= 0.226  12
v = 2.712 m /s
Fs = 259.18 m2x From step 7.
= 259.18  12 2
Fs = 37321.92 N
Ft
Fd =
Cv
6 6
 Cv = = = 0.688
6 + v 6 + 2.712
149336.28 149336.28
 Ft = = = 12444.69 N From step 5 , case 2.
mx 12
12444.69
 Fd =
0.688
Fd = 18088.21 N
We find Fs  Fd .  the design is safe.
Step 13: Check for maximum wear load (Fw).
From PSGDB 8.52
Fw = d2  6  K w
 K w = 0.56 N/mm 2 From PSGDB 8.54 , table 43.
Fw = 864  99  0.56
Fw = 47900.16 N .
We find Fw  Fd .  the design is safe.
tan H
tan ( H +  )
Where ,  = tan −1 ( H ) Assume H = 0.03From PSGDB 8.49
 = tan −1 ( 0.03 )
= 1.7
tan 15.25
actual = 0.95 
tan ( 15.25 + 1.7 )
= 0.85
actual = 85%
We find that the actual efficiency is equal to the desired efficiency.
Step 15: To find cooling area (A).
In order to avoid overheating, we have to find cooling area.
Heat generated (i.e Power loss) = Heat emitted into the atmosphere.
From PSGDB 8.52 ( 1 − )  Input Power = K tA ( t 0 − t a ) .
Assume Kt = 10w /m2 c
( 1 − 0.85)  22.5  103 = 10  A  40

Required cooling Area , A = 8.44 m 2
Step 16: Calculation of basic dimension of worm and worm wheel.
• Axial module: m x = 12 mm
• No. of starts: Z 1 = 3
• No. of teeth on worm wheel: Z2 = 72
• Face width: b = 99 mm.
• Length of the worm: L  ( 12.5 + 0.09Z2 ) m x
= ( 12.5 + 0.09  72 ) 12
= 227.76 mm.
L 228 mm.
• Centre distance: a = 0.5 m x ( q + Z2 )
= 0.5  12 ( 11 + 72 )
a = 498 mm.
• Height factor: f0 = 1.
• Bottom clearance: c = 0.25m x = 0.25  12 = 3.0
c = 3 mm.
• Pitch diameter: d1 = q  m x = 11  12 = 132 mm.
d2 = 864 mm
da1 = d1 + 2f0  m x da2 = Z2 + 2f0  m x

• Tip diameter:
= 132 + 2  1 12 = ( 72 + 2 ( 1) ) 12
= 156 mm. = 888 mm.
• Root diameter: df 1 = d1 − 2f0  m x − 2c
= 132 − 2  1 12 − 2  3
df 2 = ( Z2 − 2f0 ) m x − 2c
= ( 72 − 2  1) 12 − 2  3
df 2 = 834 mm
14. Design a straight bevel gear drive between two shafts at right angles to
each other. Speed of the pinion shaft is 360 rpm and the speed of the gear.
Wheel shaft is 120 rpm. Pinion is of steel and wheel of cast iron. Each gear
is expected to work 2 hours / day for 10 years. The drive transmits 9.35
KW. (Nov/Dec 2017)
Given data:  = 90 ; N 1 = 360rpm ; N 2 = 120rpm ;

P = 9.37KW
N 1 360
N 2 120
Then, 1 = 90 − 2 = 90 − 71.56 = 18.44
2. Material selection: Pinion – C45 Steel, u = 700N mm2 and  y = 360 N m 2
3. Gear life in hours = ( 2 hours day )  ( 365days year  10years ) = 7300hours


60  P 60  9.37  10 3
2 N 1 2  360
 Mt  = 248.6  1.3 = 323.28N − m

1.4K b1
n  K
( )
= 0.25 ( 700 + 360 ) + 50 = 315N mm 2
1.4  1
 b1  =  315 = 117.6 N mm 2
2.5  1.5

8.16, table 17
 c1  = 23  50  1 = 1150 N mm 2
2
 0.72  E M 
i2 + 1 3    eq t
( )
  y − 0.5  c  

i
8.13
2
 0.72  1.7  10 5  323.28  10 3
 R  3 3 +13  2
 
 ( 3 − 0.5 ) 1150  3
 99.36
or R = 100mm .
7. Assume Z1 = 20 ; Then Z 2 = i  Z1 = 3  20 = 60
Z1 20
cos 1 cos 18.44
Z2 60
From PSGDB 8.39 Z v2 = = 190 .
cos  2 cos 71.56
R
0.5 Z12 + Z 22
100
= = 3.162mm
0.5 20 2 + 60 2
We know that, R = 0.5m t Z12 + Z 22 = 0.5  4 20 2 + 60 2 = 126.49mm
R 126.49
y 3

b sin 1 42.16  sin 18.44
m av = m t − = 4− PSGDB 8.38
Z1 20
= 3.333

 d1av  N 1  66.66  10 −3  360
v= = = 1.256 m s
60 60
b 42.16
y = = = 0.632
d 1av 66.66

Where K = 1.1
Kd = 1.35
 Mt  = 248.6  1.1  1.35 = 369.28N − m

R i 2 + 1 M t 
( R − 0.5b )
2
 b  m t  y v1
Where y v1 = 0.402 , for Z v1 = 22
126.49 32 + 1  369.28  10 3
 b = = 196.09 N mm 2
( 126.49 − 0.5  42.16 )
2
 42.16  4  0.402
R = 0.5  m t  Z12 + Z 22 = 0.5  5  20 2 + 60 2 = 158.11mm
R 158.11
b= = = 52.7mm
y 3
b sin 1 52.7  sin 18.44

m av = m t − = 5− = 4.166mm
Z1 20
d1av = m av  Z1 = 4.166  20 = 83.33mm
 d1av  N 1  83.33  10 −3  360

v= = = 1.57 m s
60 60
b 52.7
y = = = 0.632
d 1av 83.33
K = 1.1 ; Kd = 1.35
M t = 248.6  1.1  1.35 = 369.28N − m
158.11 32 + 1  369.28  10 3
 b1 = = 100.4 N mm 2
( 158.11 − 0.5  52.7 )
2
 52.7  5  0.402
1
 2
(i + 1)
2 3
 0.72   
 R − 0.5b   ib
 
1
 2
  ( 3 + 1)
2 3
 0.72 
=   1.7  10 5  369.28  10 3 
 158.11 − 0.5  52.7  3  52.7
 
= 612.33N mm2
First we have to calculate  b2  and  C 2  .
N pinion 15.768  107

3 3
1.4  K b1
 b2  =   −1
n  K
107 9 107
Where K b1 = 9 = = 0.832
N 5.256  107
K  = 1.2
n = 2 & −1 = 0.45u = 0.45  350 = 157.5N mm2
1.4  0.832
 b2  =  157.5 = 76.44 N mm 2
2  1.2
C2  = CB  HB  K cl
Where C B = 2.3
HB = 200 to 260
107 6 107
K cl =6 = = 0.758
N 5.256  107
 C2  = 2.3  260  0.758 = 453.284 N mm 2
(c) Check for bending of gear: The induced bending stress for gear can
b1  y v1 = b2  y v2
Where y v1 = 0.402 , for Z v1 = 22
y v2 = 0.520, for Z v2 = 190
 100.4  0.402 = b2  0.520
or  b2 = 77.6 N mm 2

can be accepted.
(d) Check for wearing of gear: Since the contact area is same,
c2 = c1 = 612.33N mm2
b2  = 2.3  360  0.758 = 627.62 N mm 2
15. Design a bevel gear drive to transmit 7 kW at 1600 rpm for the following
data. Gear ratio= 3, Material for pinion and gear -C45 steel, Life 10,000
Hours. (April/May 2018)
Given data: N 1 = 360rpm ; N 2 = 120rpm ; P = 9.37KW
***similar to this problem, Change the power to be N1=1600 rpm and the Material for
pinion and gear -C45 steel,
N 1 360
N 2 120
Then, 1 = 90 − 2 = 90 − 71.56 = 18.44
17. Material selection: Pinion – C45 Steel, u = 700N mm2 and

 y = 360 N m 2
18. Gear life in hours

= ( 2 hours day )  ( 365days year  10years ) = 7300hours

60  P 60  9.37  10 3
2 N 1 2  360
 Mt  = 248.6  1.3 = 323.28N − m

1.4K b1
n  K
( )
= 0.25 ( 700 + 360 ) + 50 = 315N mm 2
1.4  1
 b1  =  315 = 117.6 N mm 2
2.5  1.5

8.16, table 17
 c1  = 23  50  1 = 1150 N mm 2
2
 0.72  E M 
i2 + 1 3    eq t
( )
  y − 0.5  c  

i
8.13
2
 0.72  1.7  10 5  323.28  10 3
 R  3 32 + 1 3   
 ( 3 − 0.5 ) 1150  3
 99.36
or R = 100mm .
22. Assume Z1 = 20 ; Then Z 2 = i  Z1 = 3  20 = 60
Z1 20
cos 1 cos 18.44
Z2 60
From PSGDB 8.39 Z v2 = = 190 .
cos  2 cos 71.56
R
0.5 Z12 + Z 22
100
= = 3.162mm
0.5 20 2 + 60 2
We know that, R = 0.5m t Z1 + Z 2 = 0.5  4 20 + 60 = 126.49mm

2 2 2 2
R 126.49
y 3

b sin 1 42.16  sin 18.44
m av = m t − = 4− PSGDB 8.38
Z1 20
= 3.333
 d1av  N 1  66.66  10 −3  360

v= = = 1.256 m s
60 60
b 42.16
y = = = 0.632
d 1av 66.66

Where K = 1.1
Kd = 1.35
 Mt  = 248.6  1.1  1.35 = 369.28N − m

R i 2 + 1 M t 
( R − 0.5b )
2
 b  m t  y v1
Where y v1 = 0.402 , for Z v1 = 22
126.49 32 + 1  369.28  10 3
 b = = 196.09 N mm 2
( 126.49 − 0.5  42.16 )
2
 42.16  4  0.402
R = 0.5  m t  Z12 + Z 22 = 0.5  5  20 2 + 60 2 = 158.11mm
R 158.11
b= = = 52.7mm
y 3
b sin 1 52.7  sin 18.44

m av = m t − = 5− = 4.166mm
Z1 20
d1av = m av  Z1 = 4.166  20 = 83.33mm
 d1av  N 1  83.33  10 −3  360

v= = = 1.57 m s
60 60
b 52.7
y = = = 0.632
d 1av 83.33
K = 1.1 ; Kd = 1.35
M t = 248.6  1.1  1.35 = 369.28N − m
158.11 32 + 1  369.28  10 3
 b1 = = 100.4 N mm 2
( 158.11 − 0.5  52.7 )
2
 52.7  5  0.402
1
 2
(i + 1)
2 3
 0.72   
 R − 0.5b   ib
 
1
 2
  ( 3 + 1)
2 3
 0.72 
=   1.7  10 5  369.28  10 3 
 158.11 − 0.5  52.7  3  52.7
 
= 612.33N mm2
First we have to calculate  b2  and  C2  .
N pinion 15.768  107

3 3
1.4  K b1
 b2  =   −1
n  K
107 9 107
Where K b1 =9 = = 0.832
N 5.256  107
K  = 1.2
n=2
−1 = 0.45u = 0.45  350 = 157.5N mm2
1.4  0.832
 b2  =  157.5 = 76.44 N mm 2
2  1.2
C2  = CB  HB  K cl
Where C B = 2.3
HB = 200 to 260
107 6 107
K cl = 6 = = 0.758
N 5.256  107
 C2  = 2.3  260  0.758 = 453.284 N mm 2
(e) Check for bending of gear: The induced bending stress for gear can
b1  y v1 = b2  y v2
Where y v1 = 0.402 , for Z v1 = 22
y v2 = 0.520, for Z v2 = 190
 100.4  0.402 = b2  0.520
or  b2 = 77.6 N mm 2

can be accepted.
(f) Check for wearing of gear: Since the contact area is same,
c2 = c1 = 612.33N mm2
b2  = 2.3  360  0.758 = 627.62 N mm 2
16.Theinput to the worm gear shaft is 18KW at 600rpm. Speed ratio is 20.
The worm is to be of hardened steel and the wheel is made of chilled
phosphor bronze. Considering wear and strength, design worm and worm
wheel. (April/May 2018)
Given data:
N 1 = 600rpm
P = 18KW
i = 20
Step 1: To find gear ratio (i)
N1
i= = 20 ( given )
N2
600
20 =
N2
N 2 = 30rpm.
Step 2: Selection of Materail:
For  = 80% , Z1 = 3
Z 2 = i  Z1 = 20  3
Z2 = 60
Case 1: To find diameter factor (q)
q
d1 =
mx
Initially we assume q= 11.
Case 2: To find Lead angle (H)
Z1
tanH =
q
H = tan −1 3 ( 11)
H = 15.25
Step 5: Calculation of (F7) in terms of (mx).
P
Ft =  K0
v
d 2 N 2
v=
60  1000
d2 = Z2  m x
 60  m x  30
 v=
60  1000
v = 0.094m x m s.
Case 2: To find shock factor (K0)
Assume medium shock, K0 = 1.5
18  10 3
 Ft =  1.5
0.094m x
287234.04
Ft =
mx
Ft
Fd =
Cv
From PSGDB 8.51, assume v = 5m s
6
Cv =
6+v
6
=
6+5
C v = 0.545
287234.04 1
 Fd = 
mx 0.545
527034.94
=
mx
From PSGDB8.51,
Fs =  m x  b  b   y1
Where,
b = 0.75d 1 From PSGDB 8.48, table 38
= 0.75  q  m x
= 0.75  11  m x
= 8.25m x
b  = 110 N mm 2 From PSGDB 8.45, table 33
 Fs =  m x  8.25m x  110  0.125
= 356.37m2x
Step 8: Calculation of axial module (mx).
Fs  Fd
527034.94
356.37m 2x 
mx
m x  11.4mm.
From PSGDB 8.2, table 1. The next nearest higher standard module mx =
12mm.
From step 7  b = 8.25  m x
= 8.25  12
b = 99mm
From step 5, Case 1  d2 = Z2  m x = 60  12
= 720mm
From step 5, Case 1  v = 0.094  m x = 0.094  12
= 1.13 m s
Fs = 356.37  m2x From step 7.
= 356.37  12 2
Fs = 51317.28N
Ft
Fd =
Cv
6 6
Cv = = = 0.84
6 + v 6 + 1.13
287234.04 287234.04
Ft = = = 23936.17N
mx 12
 Fd = 28495.44N
We find Fs >Fd . The design is safe.
Step 12: Check for maximum wear load (Fw):
From PSGDB 8.52
Fw = d2  b  K w
K w = 0.88 N mm 2 From PSGDB 8.54 , table 43.
Fw = 720  99  0.88 = 62726.4N
We find Fw  Fd  The design is safe.
tan H
tan ( H + e )
Where, e = tan −1 ( M ) , Assume M = 0.05
e = tan −1 ( 0.05 ) = 2.86
tan 15.25
 actual = 0.95 
tan ( 15.25 + 2.86 )
=0.792
actual = 79.2%
 Axial module: M x = 12mm

 Face width of worm wheel: b = 99mm
 Length of the worm: L  ( 12.5 + 0.09Z2 ) m x
= ( 12.5 + 0.09  60 ) 12
= 214.8mm
L 215mm
 Centre distance: a = 0.5m x ( q + Z2 )

= 0.5  12 ( 11 + 60 )
a = 426mm .
 Bottom clearance: C = 0.25m x = 0.25  12 = 3mm
 Pitch diameter: d1 = q  m x = 11  12 = 132mm
d2 = 720mm
 Tip diameter:
da1 = d1 + 2f0  m x da2 = ( Z2 + 2f0 ) m x
= 132 + 2  1 12 = ( 63 + 2 ( 1) ) 12
= 156mm = 744mm
 Root diameter:
df 1 = d1 − 2f0  m x − 2c df 2 = ( Z2 − 2f0 ) m x − 2c
= 132 − 2  1 12 − 2  3 = ( 60 − 2  1) 12 − 2  3
df 1 = 102mm = 690mm
17.Design a pair of bevel gears to transmit 10kW at a pinion speed of

1440rpm. Required transmission ratio is 4. Material of gears is 15Ni 2Cr
1Mo 15 steel (BHN 400). The tooth profiles of the gears are of 20˚
composite form. Assume minimum number of teeth as 20, v=5m/s and
medium shock conditions. (Nov/Dec 2018)
Given data:
P = 25KW
N1 = 300rpm
N 2 = 120rpm
*** Similar to this problem, change the power, speeds and material.
From PSGDB Pg No. 1.40. Both pinion and gears C45 steel is selected.
Step 2: Calculation of no. of teeth, virtual number of teeth and pitch angles:
N1 300
= i
N 2 120
i = 2.5.
Case(1): Calculation of no. of teeth Z1 & Z2
Z1 = 20 Assume
Z2 = i  Z1
= 2.5  20
= 50
Case 2: Calculation of virtual no. of teeth Zv1 & Zv2
From PSGDB 8.39 From PSGDB 8.39
z1
z V1 = 1 = 90 − 2
cos 1
20
= = 21.54 22 tan 2 = i
cos 21.8
Z2 50
Z v2 = =  2 = tan −1 2.5 = 68.2
cos  2 cos 68.2
= 134.64 135  1 = 21.8
Step 4: Calculation of tangential load (Ft).
P
Ft =  K0
v
Where
 K 0 = 1.5 for medium shock conditions.

d1 N1
 v=
60
d1 = m t  Z1
 m t  20  300
 v=
60  1000
v = 0.314 m t m/s
25 103
 Ft = 1.5
0.314m t
119366.21
Ft =
mt
Ft
Fd =
Cv
From PSGDB 8.52
5.5
Cv = , assuming v = 5 m/s
5.5 + v
5.5
=
5.5 + 5
Cv = 0.711
119366.21 1
 Fd = 
mt 0.711
167895.48
Fd =
mt
From PSGDB 8.52,
R−b
Fs =  m t  [ b ]  b y1  
 R 
Where,
b = 10  m t From PSGDB 8.38, table 31
[b ] = 180 N/mm2 , for C45 steel
0.912
y1 = 0.154 − From PSGDB 8.50, 20 FD
Z v1
0.912
= 0.154 −
22
y1 = 0.112
R = cone radius = 0.5m + Z12 + Z22 From PSGDB 8.38 , table 31
= 0.5  mt 202 + 502
R = 26.93m t
 26.93m t − 10m t 
 Fs = m t  10  m t 180  0.112   
 26.93m t 
= 398.16 m 2t
Step 7: Calculation of transverse module (mt):
From PSGDB 8.51
Fs  Fd
167895.48
398.16 m 2t 
mt
m t  7.5
From PSGDB 8.2 , table 1, choice 1. The next nearest higher standard module
m t = 8mm .
 Face width b = 10  m t
= 10  8
= 80 mm
Pitch circle diameter, d1 = m t  Z1
= 8  20
d1 = 160 mm
d1 N1
Pitch line velocity v =
60
 160  300
=
60 1000
v = 2.51 m / s
Step 9: Recalculation of beam strength:
Fs = 398.16 m 2t From step 6
= 398.16  82
Fs = 25482.24 N
From PSGDB 8.51
21v(bc+ Ft )
Fd = Ft +
21v + bc + Ft
Where,
P
Ft =
 v
25  103
=
2.51
= 9960.16 7961.78
 C = 11860 e From PSGDB 8.53 , table 41, for 20° FD

e = 0.019 , for module upto 8 , precision gears. Table 42
C = 11860  0.019 = 225.34 / mn
21 2.51103 (80  225.34 + 9960.16)

 Fd = 9960.16 +
21 2.51103 + 80  225.34 + 9960.16
Fd = 37858.96 
We find Fd > Fs . Design is not safe.
In order to overcome this issue, increase the module 10mm.
 Fd = 30415.23 
& Fs = 39816
 Fs  Fd . Design is safe.
Step 12: Calculation of maximum wear load. (Fw)
0.75  d1  b  Q1  K w
Fw = From PSGDB 8.51
cos 1
2Z v2
 Q1 = From PSGDB 8.51
Z v1 + Z v2
2  135
=
22 + 135

Q1 = 1.72
 K w = 2.553 N/mm 2 , for steel hardened to 400 BHN,

0.75  200 100 1.72  2.553
 Fw =
cos 21.8
Fw = 70940.66N
Fw > Fd . Design is safe
 Transverse module: m t = 10mm

 Number of teeth: Z1 = 20 , Z2 = 50
 Pitch circle diameters: d1 = 200mm
d 2 = 500mm.
 Cone distance: R = 26.9310 = 269.3mm

 Pitch angles: 1 = 21.8 , 2 = 68.2
d a1 = m t (Z1 + 2cos 1 ) d a 2 = m t (Z2 + 2 cos 2 )
 Tip diameter:
= 10(20 + 2cos 21.8) = 10(50 + 2 cos 68.2)
d a1 = 218.56mm d a 2 = 507.43mm
 Clearance: c = 0.2
m t  f0
 Addendum angle: tan a1 = tan a2 =
R1
10  1
=
269.3
= 0.037
a1 = a2 = 2.13
 Deddendum angle:
m (f + c)
tan f 1 = tan f 2 = t 0
R1

10(1 + 0.2)
=
269.3
= 0.045
f 1 = f 2 = 2.55
 Tip angle: a1 = 1 + a1 a2 = 2 + a2

= 21.8 + 2.13 = 68.2 + 2.13
a1 = 23.93 a2 = 70.33
 Root angle:  f 1 =  1 + f 1  f 2 =  2 + f 2
= 21.8 + 2.55 = 68.2 + 2.55
f 1 = 19.25 f 2 = 65.65

Zv1 = 22 , Z v2 = 135

phosphor bronze gear. The speed of the worm wheel should be 60  3%rpm.
Design a worm gear drive if an efficiency of at least 82% is desired.
Assume q=1, medium shock conditions, v=5m/s, pressure angle 20˚
(Nov/Dec 2018)
Given data:
N1 = 1440rpm
P = 12KW
N 2 = 60  3%rpm
desired = 82%
N1
i=  3%
N2
1440
=  3%
60
= 24  0.72

take i = 24
For  = 82% , Z 1 = 3
Z2 = i  Z1
= 24  3
Z2 = 72
q
d1 =
mx
Z1
tanH =
q
 3 
H = tan −1  
 11 
H = 15.25
P
v

d 2 N 2
v=
60  1000
d2 = Z2  m x
 Z 2  m x  N 2
 v=
60  1000
 72  m x  60
=
60  1000
v = 0.226m x m
s
K 0 = 1.5
12  10 3
 Ft =  1.5
0.226m x
79646.02
Ft =
mx
Ft
Fd =
Cv
6
Cv =
6+v
6
=
6+5
C v = 0.545

79646.02 1
Fd = 
mx 0.545
1460177.70
=
mx
From PSGDB 8.51
Fs =  m x  b  b   y1
Where ,
= 0.75  q  m x
= 0.75  11  m x
= 8.25m x
y
 y1 =

0.392

=0.125
b  = 80 N mm2 From PSGDB 8.45 , table 33
 Fs =  m x  8.25m x  80  0.125
= 259.18 m2x

W.K.T Fs  Fd
146017.70
259.18  m 2x 
mx

m x  8.26mm
m x = 10mm.
= 82.5mm
= 72  10
= 720mm
= 0.226  10
v = 2.26 m s
= 259.18  10 2
Fs = 25918N
Ft
Fd =
Cv
6 6
Cv = = = 0.726
6 + v 6 + 2.26

79646.02 79646.02
mx 10
7964.602
 Fd =
0.726
Fd = 10970.53N
From PSGDB 8.52
Fw = d2  b  K w
Fw = 720  82.5  0.56
Fw = 33264N
tan H
tan ( H + e )
 = tan −1 ( 0.03 )
= 1.7
tan 15.25
actual = 0.95 
tan ( 15.25 + 1.7 )

actual = 84.98%

= ( 12.5 + 0.09  72 ) 10
= 189.8mm
Take L = 190mm
a = 0.5  10 ( 11 + 72 )
a = 415mm
d2 = 720mm
da2 = ( Z2 + 2f0 ) mx = ( 72 + 2  1) 10 = 740mm
= 110 − 2  1 10 − 2  2.5
= 85mm
df 2 = ( Z2 − 2f0 ) mx − 2C
= ( 72 − 2  1)  10 − 2  2.5
= 695mm.

19.Design a bevel gear drive to transmit 7kW at 1600rpm for the following data.
Gear ratio=3, Material for pinion and gear= C45 steel, Life 10,000 hours.
(April/May 2019)
Given data:
P = 3.5KW
i=4
N 2 = 200rpm.
Wheel − CI
and check the gear.
*** similar to the problem
N1
i= =4
N2
N1
= 4 N 1 = 800rpm.
200
Pitch angles:
From PSGDB 8.34
tan 2 = i = 4
 2 = tan −1 ( 4 ) = 75.96
1 = 90 − 2 = 90 − 75.96
= 14.04

= 12  10 8 cycles.
From PSGDB 8.44,
Mt  = Mt  K  Kd
60  P 60  3.5  10 3
Mt = = = 41.778N.m
2 N 1 2   800
 Mt  = 41.778  1.3

= 54.31 Nm.
To find Eeq.
1.4K b1
b1  =  −1 From PSGDB 8.18 rotation in one direction
n  K
Kb1 = 1 ,for HB  350 and N Z107, From PSGDB 8.20, table 22.
( ( ) )
−1 = 0.25  u +  y + 50 , for forged steel. From PSGDB 8.19, table 19
−1 = 0.25 ( 700 + 360 ) + 50
= 315N /mm 2 .
1.4  1
  b1  =  315 = 117.6N /mm 2 .
2.5  1.5
To find   c1  :
c1  = CR .HRC  KC1

C R = 23
HRC = 40to55
K C1 = 1
c1  = 23  55  1
= 1265N /mm 2
2
 0.72  E M 
R  y i2 + 1 3    eq t
( )
 y − 0.5 c  

i
y = R =3
6
2
 0.72   1.7  10 5  54.31  10 3 
R  3 4 +1 
2
  
 ( 3 − 0.5 )  1265   4 
 135.29mm.
R = 136mm.
Z1 = 20
Z2 = i  Z1
4  20
= 80
Z1 20
cos 1 cos 14.04
Z2 80
From PSGDB 8.22. Z v2 = = = 329.76 330
cos 2 cos 75.96
R1
0.5 Z 21 + Z 22

136
=
0.5 20 2 + 80 2
= 3.29mm
R = 0.5m t Z12 + Z 22
= 0.5  4 202 + 802
= 164.92mm.
R 164.92
(vi) To find b: b= = = 54.97 55mm PSGDB 8.38
y 3
b sin 1
(vii) Average module m av = m t − PSGDB 8.38
Z1
55SIN14.04
= 4−
20
= 3.33mm.
(viii) Average PCD of pinion: d1av = m av  Z 1
= 3.33  20
= 66.66mm.
d1av  N 1  66.66  800
(ix) Pitch line velocity v = = = 2.79 m .
60 60  1000 s
b 55
(x) y = = = 0.83
d 1av 66.66
Mt  = Mt  K  Kd

K d = 1.45 From PSGDB 8.16 table 15.
 M t  = 41.778  1.1  1.45
= 66.64Nm.
R l 2 + 1 M t 
( R − 0.5b )
2
 b  m t  y v1
y v1 = 0.402 for Z v1 = 21
164.92 4 2 + 1  66.64  10 3
 b1 =
( 164.92 − 0.5  55 )
2
 55  4  0.402
b1 = 27.13N mm2

1
  2
(i + 1)
2 3
 0.72   
 R − 0.56   ib
 
1
  2
(4 + 1)
2 3
 0.72  3
=   1.7  10  66.64  10 
5
 164.92 − 0.5  55   4  55
 
C1 = 314.77N/mm2
N pinion
3

12  10 8
=
3
= 4  10 8
1.4  K b1
 b2  =   −1
h  K
Where,
107 107
K b1 = 9 = 9 = 0.66
N 4  108
K  = 1.2
n=2
−1 = 0.45u = 0.45  350 = 157.5N/mm2 .
1.4  0.66
   b2  =  157.5
2  1.2
= 60.64N.mm 2 .
To find   c2  :
c2  = CB  HB  Kcl .
Where C B = 2.3, HB = 200 to 260
107 107
K cl = b = b = 0.54
N 4  10 8
c2  = 2.3  260  0.54
= 322.92N /mm 2 .
b1  y v1 = b2  y v2
y v1 = 0.402 for Z v1 = 21
y v 2 = 0.521 for Z v2 = 330

27.13  0.402 = b2  0.521
b2 = 20.93N /mm2 .
 c2 = c1 = 314.77N/mm2
20.A hardened steel worm rotates at 1440rpm and transmits 12KW to a

3%rpm. Design a worm gear drive if an efficiency of at least 82% is
desired. (April/May 2019)
Given data:
N1 = 1440rpm
P = 12KW
N 2 = 60  3%rpm
desired = 82%
N1
i=  3%
N2
1440
=  3%
60
= 24  0.72
take i = 24

For  = 82% , Z 1 = 3
Z2 = i  Z1
= 24  3
Z2 = 72

q
d1 =
mx

Z1
tanH =
q
 3 
H = tan −1  
 11 
H = 15.25
P
v
d 2 N 2
v=
60  1000
d2 = Z2  m x
 Z 2  m x  N 2
 v=
60  1000
 72  m x  60
=
60  1000

v = 0.226m x m
s
K 0 = 1.5
12  10 3
 Ft =  1.5
0.226m x
79646.02
Ft =
mx
Ft
Fd =
Cv
6
Cv =
6+v
6
=
6+5
C v = 0.545
79646.02 1
Fd = 
mx 0.545
1460177.70
=
mx
From PSGDB 8.51
Fs =  m x  b  b   y1
Where ,

= 0.75  q  m x
= 0.75  11  m x
= 8.25m x
y
 y1 =

0.392

=0.125
b  = 80 N mm2 From PSGDB 8.45 , table 33
 Fs =  m x  8.25m x  80  0.125
= 259.18 m2x

W.K.T Fs  Fd
146017.70
259.18  m 2x 
mx
m x  8.26mm

m x = 10mm.

= 82.5mm

= 72  10
= 720mm
= 0.226  10
v = 2.26 m s
= 259.18  10 2
Fs = 25918N
Ft
Fd =
Cv
6 6
Cv = = = 0.726
6 + v 6 + 2.26
79646.02 79646.02
mx 10
7964.602
 Fd =
0.726
Fd = 10970.53N
From PSGDB 8.52
Fw = d2  b  K w
Fw = 720  82.5  0.56

Fw = 33264N
tan H
tan ( H + e )
 = tan −1 ( 0.03 )
= 1.7
tan 15.25
actual = 0.95 
tan ( 15.25 + 1.7 )

actual = 84.98%

= ( 12.5 + 0.09  72 ) 10
= 189.8mm
Take L = 190mm
a = 0.5  10 ( 11 + 72 )
a = 415mm

d2 = 720mm
da2 = ( Z2 + 2f0 ) mx = ( 72 + 2  1) 10 = 740mm
= 110 − 2  1 10 − 2  2.5
= 85mm
df 2 = ( Z2 − 2f0 ) mx − 2C
= ( 72 − 2  1)  10 − 2  2.5
= 695mm.

UNIT-IV DESIGN OF GEAR BOXES

(PART-A)
1. What are the preferred numbers?
Preferred numbers are conventionally rounded of values derived from
geometric series. There are five basic series, denoted as R5, R10, R20, R40
and R80 series.
2. Specify four types of gear boxes?

❖ Sliding mesh gear box
❖ Constant mesh gear box
❖ Synchromesh gear box
❖ Planetary gear box
3. Draw the ray diagram for a six speed gear box?
A typical ray diagram for a 6 speed gear box, for the preferred
structural formula 3(1) 2(3), is shown in figure below.
4. In which gear drive, self-locking is available?

Self-locking is available in worm gear drive.
5. Define progression ratio?

When the spindle speeds are arranged in geometric progression, then
the ratio between the two adjacent speeds is known as step ratio or
progression ratio.
6. Write the significance of structural formula.
❖ STRUCTURAL FORMULAE:
No.of Stages: {(p1 (X1) . p2 (X2). P3 (X3) }
1st stage. 2nd stage 3rd stage
Note:Where X1 =1 X2= p1 X3= p1 p2
7. What is multispeed gear box?
The gear box containing variable spindle speeds are known as

multispeed gear box
8. What is R20 series?

R20 is one of the series of five basic geometric series. The symbol ‘R’ is
used as a tribute to French engineer Charles Renard, whom introduced the
preferred number first.
9. Differentiate ray diagram and structural diagram.
The structural diagram is a kinematic layout that shows the arrangement of

gears in a gear box
The speed diagram, also known as ray diagram, is a graphical representation
of the structural formula.
10. List out two methods used for changing speeds in gear boxes?
Sliding mesh gear box

Constant mesh gear box
11. What purpose does the housing of gear-box serve?

Gear-box -housing or casing is used as container inside which, the gears, shafts,
bearings and other components are "mounted.' Also it prevents the entry of dust
inside the housing and reduces noise of operation.
That is, the housing Safe-guard the inner components.
12. What is the function of spacers in a gear-box?(or) What are

spacers as applied to a gear-box?
Spacers are sleeve like components, which are mounted, in shafts in-between gears
and bearings or one gear and another gear in order to maintain the distance
between them so as to avoid interruption between them.
13. Fill in the blanks of the following.

(a) The number of gears employed in a gear-box is kept to the minimum
by arranging the Speed of the spindle is ................................. series.
(b) In a gear- box, -for a set of gears, if the centre distance and module are same,
then the sum of teeth of engaging pair will be .....
Answers
a) Geometric series.
b) Equal.
14. What is a speed diagram? (or) What is the structural diagram-of -

&.gear-box
Speed diagram or structural diagram is the graphical representation different
speeds of output shaft, motor shaft and intermediate shafts.
15. For what purpose we are using gear-box?

Since the gear-box is provided with number of gears of different size arranged is
different forms, we can get number of output speeds by operated motor at single
speed.
16. Name the types of speed reducers.

a) Single reduction speed reduces.
b) Multi reduction speed reducers.
17. What does the ray-diagram of gear-box indicate?

The ray-diagram or kinematic arrangement of a gear box indicates arrangement of
various gears in various shafts of the gear box in order to obtain the different
output speeds from the single speed of the motor.
18. What is step ratio?,
Step ratio is the ratio of one speed of the shaft to its previous lower speed Since the
spindle speeds are arranged in geometric progression, the ratios adjacent speeds
(i.e., step ratios) are constant.
19. What is the functions of spacers in gear box?

The functions of spacers in gear box is to provide the necessary distance
between the gears and the bearings
20. What are the methods of lubrications in speed reducers?

❖ Splash or spray lubricating methods
❖ Pressure lubricating methods
21. Why geometric progression is selected for arranging the

speeds in gear box? (April/May 2017)
❖ The speed loss is minimum , if geometric progression is used
❖ The number of gears to be employed is minimum, if geometric
progression is used
❖ Geometric progression provides more even the range of spindle speeds
at each step
❖ The layout is comparatively very compact, if geometric progression is

used
22. What does the ray diagram of gear box indicate? (April/May 2017)
The ray diagram is a graphical representation of the drive

arrangement in general form. It serves to determine the specific values of all
the transmission ratios and speeds of all the shafts in the drive.
23. Draw the ray diagram of 12 speed gear box. (Nov/Dec 2017)
24. Write any two principles to be followed to obtain optimum design in gear
box. (Nov/Dec 2017)
❖ Reliability of the system (Gear box)
❖ Component reliability (Gear pair)
25. For what purpose we are using gear box? (April/May 2018)
Gear boxes are required wherever the variable spindle speeds is necessary
26. What is speed diagram? (April/ May 2018)
The speed diagram is also known as ray diagram, is a graphical

representation of the drive arrangement in general form. It serves to determine
the specific values of all the transmission ratios and speeds of all the shafts in
the drive.
27. Define progression ratio. (Nov/Dec 2018)

When the spindle speeds are arranged in geometric progression, the
the ratio between the two adjacent speeds is known as step ratio or
progression ratio.
28. List out the all possible arrangements to achieve 16 speed gear box.
(Nov/Dec 2018)
i. 4X 2 X 2 Scheme
ii. 2X 4 X 2 Scheme
iii. 2X 2 X 4 Scheme
29. What is torque converter? (April/May 2019)
(i) A torque converter is a type of fluid coupling which transfers
rotating power from a prime mover, like an internal combustion
engine, to a rotating driven load.
(ii) In a vehicle with an automatic transmission, the torque converter
connects the power source to the load.
30. Draw the kinematic layout for the 6-speed gear box. (April/May 2019)
PART B
1. A sixteen speed gear box is required to furnish output speeds in the
range of 100 to 560rpm. Sketch the kinematic arrangement and draw
the speed diagram.
Given data:
M = 16
N min = 100rpm
N max = 560rpm
Step 1: Selection of spindle speeds.
N max
= 16 − 1
N min
560
= 15
100
1
 = ( 5.6 ) 15
 = 1.12
We find  = 1.12 is the standard ratio, it satisfies the requirement.

Select the spindle speeds using the series of preferred numbers.
PSGDB 7.20
Basic series R20 (  = 1.12 )
Spindle speeds are 100, 112, 125, 140, 160, 180, 200, 224,
250, 280, 315, 355, 400, 450, 500, 560 rpm.
Step 2: To find the structural formulae.
16 Speeds = 4 ( 1) 2 ( 4 ) 2 ( 8 )
Step 3: Construct the speed diagram for 16 speed gear box.

 Structural formula = 4 ( 1) 2 ( 4 ) 2 ( 8 )
  
No. of stages = 3 P1 ( X 1 )  P2 ( X 2 )  P3 ( X 3 )
P1 = 4 , P2 = 2 , P3 = 2
Note: X 1 = 1 , X 2 = P1 = 4 , X 3 = P1  P2 = 4  2 = 8.
 No. of shafts = No. of stages +1
= 3+1
= 4 ( Draw 4 vertical lines )
 No. of speeds = 16 ( Draw 16 horizontal lines ) .
Stage 3:
N min 1 N max
 2
N input 4 N input
100 250
= 0.714  1 = 1.78  2
140 4 140
 Ninput = 140rpm.
Stage 2:
N min 1 N max
 2
N input 4 N input
140 224
= 0.7  1 = 1.12  2
200 4 200
Stage 1:
200 280
= 0.44  1 = 0.622  2
450 4 450
 N input = 450rpm.
Step 4: Kinematic Layout - 16 Speed gear box

No. of shafts = 4
No. of Gears = 2 ( 4 + 2 + 2 ) = 16
2. Design a nine speed gear box for a machine to provide speeds ranging
from 100rpm to 1500rpm. The input is from a motor of 5KW at
1440rpm. Assume any alloy steel for the gears.
Given data:
=9
N min = 100rpm.
N max = 1500 rpm .
P = 5 KW
N input = 1440rpm.
Note: In this problem the given max speed is 1500rpm. But as per R 20 series am
taken the 9th speed 1400rpm. If you want to take 1500rpm as the 9th speed also
correct. No issues. Anyhow maximum cases we should follow the standard values.
Step 1: Selection of spindle speeds:
N max
= n − 1
N min
1500
= 9 − 1
100
15 = 8
 = 1.403.
 We find  = 1.403 is not a standard ratio. So let us find out whether multiples
of standard ratio 1.12 or 1.06 come close to 1.403.
1.12  1.12  1.12 = 1.405 Skip 2 speeds.
  = 1.12 Satisfies the requirement. Therefore the spindle speeds from R 20

series skipping 2 speeds, are.
From PSGDB 7.20,
100, 140, 200, 280, 400, 560, 800, 1000, 1400 rpm.
Step 2: To find the structural formula:
9 speeds = 3(1) 3(3)
Step 3: Kinematic diagram for 9 speeds.
Structural formula =3(1) 3(3).
No. of shafts = No. of stages +1 = 3 (3 horizontal lines).
No. of gears = 2(P1+P2) = 2(3+3) = 12 gears.
Step 3: Ray diagram for 9 speed.
Structural formula = 9 speeds = 3(1) 3(3).
No. of shafts =3 (3 vertical lines)
Speeds = 9 (9 horizontal lines)
For stage 2
N min 1 N max
 2
N I/p 4 N I/p
100 1 N N max 800

  min = 1  1 = =22
400 4 N I/p 4 4 N I/p 400
NI/p = 400rpm.
For stage 1
N min 1 N max
 2
N I/p 4 N I/p
N min 400 N max 800

= = 0.29  1 = = 0.57  2
N I/p 1400 4 N I/p 1400
 N I/p = 1400rpm.
Step 4: Calculation of no. of teeth on all the gears.
Let Z1, Z2, Z3… Z12 = No. of teeth of the gears 1, 2, 3…. 12 respectively.
N1, N2, N3… N12 = No. of speed of the gears 1, 2, 3…. 12 respectively.
Z1 N 2
We know that , =
Z2 N1
Case 1: consider stage 2.
First pair:
 Gears 11 and 12
 From the ray diagram consider Ray DA.
 Maximum speed reduction from 400 rpm to 1000 rpm .
Z11 = 20 ( driver ) .
Z 11 N 12
 =
Z 12 N 11
20 100
=
Z 12 400
Z12 = 80
Z11 = 20 , Z12 = 80
Second Pair:
 Gears 7, 8 & Ray DB

 Minimum speed reduction 400 to 280 rpm.
Z7 N 8
=
Z8 N7
Z7 280
=
Z 8 400
Z7 = 0.7Z8 1
Note: The centre distance between the shafts are fixed and same.  The sum of
number of teeth of mating gears should be equal.
 Z11 + Z12 = Z7 + Z8 = 100
0.7Z8 + Z8 = 100
Z8 = 58.82 59
 Z7 = 41 , Z8 = 59
Third Pair:
 Gears 9 & 10, Ray DC

 Speed increase from 400 to 800 rpm.
Z 9 N 10
=
Z 10 N 9
Z 9 800
=
Z 10 400
Z9 = 2Z10
W.K.T Z11 + Z12 = 100 = Z9 + Z10
2Z10 + Z10 = 100
Z10 = 33.33 34
 Z9 = 66
Z10 = 34
Case 2: Consider stage 1:
First Pair:
 Gears 5 and 6 , Ray GD.

 Maximum speed reduction from 1400 to 400 rpm.
Z5 N6
=
Z6 N 5
Z5 = 20 ( driver )
20 400
=
Z 6 1400
Z6 = 70
Z5 = 20, Z6 = 70.
Second Pair:
 Gears 1 and 2 , Ray GE

 Speed reduction from 1400 to 560 rpm.
Z1 N 2
=
Z2 N1
Z1 560
=
Z 2 1400
Z1 = 0.4Z 2
We know that Z5 + Z6 = 90 = Z1 + Z 2
0.4Z2 + Z2 = 90
Z 2 = 64.28 65
Z1 = 25
Third Pair
 Gears 3 and 4, Ray GF

Z3 N 4
=
Z4 N3
Z3 800
=  Z 3 = 0.57Z 4
Z 4 1400
W.K.T  Z5 + Z6 = 90 = Z 3 + Z 4
0.57Z 4 + Z 4 = 90
Z 4 = 57.32 58
Z3 = 32
Step 5: Select suitable material.
Take, 40 Ni 2 Cr 1M028 (Hardened and tempered).
Material constant M=100 , [i]=55 N/mm2 .
Step 6: Calculation of module (m).
Case 1: To find the torque (T)
Calculate the torque for the gear (12) has the lowest speed of 100 rpm using
the relation.
60P
T12 =
2 N
60  5  10 3
=
2   100
T12 = 477.46 Nm.
Case 2: To find the tangential force on gear 12.
T 2T12
Ft12 = =
r Z 12 m
2  477.46  103
=
80  m
11944
Ft12 =
m
Case 3: To find the module (m).
Ft12
m=
( m .M )
Where m = b = 10 From PSGDB 8.1 and 8.14 , (table 12).

m
M=100
11944
m= m
10  100
11944
m=
1000  m
11.944
m2 =
m
m = 2.28 mm.
From PSGDB 8.2 , table 1. Choice 1.
The next nearest higher standard module m= 2.5 mm
Step 7: Calculation of centre distance in all stages.
 Zx + Zy 
a=  m.
 2 
Zx and Zy = No. of teeth on the gear pair in engagement in each stage.
Case 1:
Centre distance for stage 1.
 Z + Z4 
a1 =  3  m.
 2 
 32 + 58 
=  2.5
 2 
a1 = 112.5 mm
Case 2:
Centre distance for stage 2.
 Z + Z 10 
a2 =  9 m
 2 
 66 + 34 
=  2.5
 2 
a 2 = 125 mm
Step 8: Calculation of face width. (b)
W.K.T. b = 10  m
= 10  2.5
b = 25 mm
Step 9: Calculation of Length of the shafts.
L = 25 + 10 + 7b + 20 + 7b + 10 + 25
= 90 + 14b
= 90 + 14  25
L = 440mm
 Bearing width = 25 mm.

 Gear & Bearing clearance = 10 mm.
 Adjacent group distance = 20 mm
 If two pair gear group = 4b
 Three pair gear group = 7b
Step 10: Design of shafts.
Case 1: Design of spindle (or) output shafts.
(i) To find normal load on gear 12 (Fn)
Ft12
Fn =
cos 
4777.6
Fn =   = 20FD
cos 20
Fn = 5084.22 N.
(ii) To find maximum bending moment (M).
M=
( Fn .L )
4
5084.22  440
=
4
M = 5.59  10 5 Nmm.
(iii) To find the equivalent torque.
Teq = M 2 + T122
= ( 5.59  10 ) + ( 477.46  10 )
5 2 3 2
Teq = 7.35  105 Nmm
(iv) To find the diameter of the spindle.
16Teq
ds = 3
. 
16  7.35  10 5
= 3
 55
ds = 40.82 mm
From R20 series, the standard diameter
ds = 45 mm .
Case 2: Design of other shafts.
(a) Diameter of shaft 1.
Input speed = 1400 rpm.
60P
Torque T =
2 N
60  5  10 3
=
2   1400
T = 34.10 Nm
W.K.T T = 0.2ds1
3
 
34.10  103 = 0.2  ds1
3
 55
ds1 = 14.58 mm .
ds1 = 16 mm .
(b) Diameter of shaft 2.
60P
Torque T =
2 N
60  5  10 3
=
2   400
T = 119.37 Nm
W.K.T T = 0.2ds2
3
 
119.37  103 = 0.2  ds2
3
 55
ds2 = 22.14 mm .
ds2 = 25 mm .
3. Design of 12 speed gear box for a lathe. The minimum and maximum
speeds are 100 and 1200 rpm. Power is 5 KW from 1440 rpm induction
motor.
Given data:
n = 12 speeds
N min = 100rpm.
N max = 1200 rpm .
P = 5 KW
N input = 1440rpm.
N max
= n − 1
N min
1200
= 12 −1
100
 = 1.25 .
Therefore the spindle speeds from R10 series.
From PSGDB 7.20.
100, 125, 160, 200, 250, 315, 400, 500, 630, 800, 1000 and 1200rpm.
Step 2: To find the structural formula.
12 speeds = 3(1) 2(3) 2(6)
Structural formula = 3(1) 2(3) 2(6)
No. of shafts = No. of stages +1 = 3+1=4 (4 horizontal lines)
No. of gears = 2(P1+P2+P3) =2(3+2+2) = 14 gears.
No. of shafts = 4 (4 vertical lines)
For stage 3:
N min 1 N max
 2
NI 4 NI
P P
100 400
= 0.4  1 = 1.6  2
250 4 250
N I = 250 rpm .
P
For stage 2:
N min 1 N max
 2
NI 4 NI
P P
250 500
= 0.625  1 = 1.25  2
400 4 400
N I = 400 rpm .
P
For stage 1:
N min 1 N max
 2
NI 4 NI
P P
400 630
= 0.4  1 = 0.63  2
1000 4 1000
 N I = 1000 rpm .
P
Z1 N 2
We know that, =
Z2 N1
Case 1: Consider stage 3
First Pair:
 Gears 13 and 14 , Ray CA

Z 13 N 14
= , Z13 = 20 ( driver )
Z 14 N 13
20 100
=
Z 14 250
Z14 = 50
Z13 = 20 , Z14 = 50
Second Pair:
 Gears 11 and 12 , Ray CB

Z 11 N 12
 =
Z 12 N 11
Z 11 400
=
Z 12 250
Z11 = 1.6 Z12
W.K.T. Z13 + Z14 = 70 = Z11 + Z12
 1.6Z12 + Z12 = 70
Z12 = 26.92 27
Z11 = 43
Z12 = 27 , Z11 = 43
Case 2: consider stage 2:
First Pair:
 Gears 9 and 10, Ray EC
Z 9 N 10
= Z9 = 20 ( driver )
Z 10 N 9
20 250
=
40 400
Z10 = 32
Z9 = 20 , Z10 = 32
Second Pair:
 Gears 7 and 8, Ray ED

 Speed increase 400 to 500 rpm.
Z7 N 8
=
Z8 N7
Z7 500
=
Z 8 400
Z7 = 1.25Z 8
W.K.T. Z9 + Z10 = 52 = Z7 + Z8
1.25Z8 + Z9 = 52
Z8 = 23.11 24
Z7 = 28
Z7 = 28 , Z8 = 24
First Pair:
 Gears 5 and 6, Ray HE

 Speed reduction 1000 to 400 rpm.
Z5 N6
=
Z6 N 5
20 400
= Z5 = 20 ( driver )
Z 6 1000
Z6 = 50
Z5 = 20 , Z6 = 50
Second Pair:
 Gears 1 and 2, Ray HF

Z1 N 2
=
Z2 N1
Z1 500
=
Z 2 1000
Z1 = 0.5Z2
W. K. T. Z5 + Z6 = 70 = Z1 + Z 2
1.5Z2 = 70
Z2 = 46.7 47
Z1 = 23
Z1 = 23 , Z 2 = 47
Third Pair:
 Gears 3 and 4, Ray HG

Z3 N 4
=
Z4 N3
Z3 630
=
Z 4 1000
Z 3 = 0.63Z 4
W. K. T. Z3 + Z 4 = Z 5 + Z6 = 70
1.63Z 4 = 70
Z 4 = 42.94 43
Z 3 = 27.
Z 3 = 27 , Z 4 = 43
Step 5: Selection of material,
40N: 2cr 1MO 28 (Hardened and tempered) material is selected.
Material constant M=100 ,   = 55N /mm2

Step 6: Calculation of module (m)
Calculate the torque for the gear (14) has the lowest speed of 100 rpm, using
the relation.
60P
T14 =
2 N
60  5  10 3
=
2   100
T14 = 477.46 Nm.
T 2T14
Ft14 = =
r Z 14  m
2  477.46  103
=
50  m
19098.4
Ft14 =
m
Ft14
m=
m.m
Where , m = b = 10 From PSGDB 8.1 , and 8.14 (table 12).

m
19098.4
m= m
10  100
19.098
m2 =
m
m = 2.67 mm.
From PSGDB 8.2 , table 1, choice 1.
The next nearest higher standard module
m = 3mm .
Step 7: Calculation of centre distance in all stages. From PSGDB 8.22 ,

table 26.
 Zx + Zy 
a= m
 2 
Zx and Z y No. of teeth on the gear pair in engagement is each stage.
Case 1: Centre distance for stage 1.
 Z + Z4 
a1 =  3 m
 2 
 27 + 43 
= 3
 2 
a1 = 105mm .
 Z + Z8 
a2 =  9 m
 2 
 28 + 24 
= 3
 2 
a 2 = 78mm .
 Z + Z 12 
a 3 =  11 m
 2 
 43 + 27 
= 3
 2 
a1 = 105mm .
Step 8: Calculation of Face width (b).
W.K.T  b = 10  m
= 10  3
b = 30mm
L = 25 + 10 + 7b + 20 + 4b + 20 + 4b + 10 + 25
= 110 + 15b
= 110 + 15  30
L = 450 mm
(i) To find normal load on gear 14 (Fn)
Ft14
Fn =  = 20FD
cos 
6366.13
=
cos 20
Fn = 6774.7 N
(ii) To find maximum bending moment (M).
M=
( Fn .L )
4
6774.7  450
=
4
M = 7.62  10 5 Nmm.
(iii) To find the equivalent torque. (Teq)
Teq = M 2 + T42
= ( 7.62  10 ) + ( 477.46  10 )
5 2 3 2
= 8.99  10 5 Nmm
(iv) To find the diameter of the spindle (ds)
16Teq
ds = 3
  
16  8.99  10 5
= 3
 55
ds = 43.66 mm
From R10 series, The standard diameter.
ds = 50mm .
(a) Diameter of shaft 1.
60P
Torque T =
2 N
60  5  10 3
=
2   1000
= 47.75 Nm .
W.K.T T = 0.2d13   .
47.75  103 = 0.2  ds1

3
 55
ds1 = 16.31 mm.
From R10 series., The standard diameter ds1=20 mm.
(b) Diameter of shaft 2.
60  5  10 3
 T=
2   400
= 119.36 Nm .
W.K.T  T = 0.2d32   .
119.36  103 = 0.2  ds2

3
55
ds2 = 22.14 mm.
(c) Diameter of shaft 3.
60  5  10 3
 T=
2   250
T = 190.98 Nm .
W.K.T  T = 0.2d33   .
190.98  103 = 0.2  ds3

3
55
ds3 = 25.89 mm.
From R10 series. The standard diameter ds3=31.5 mm.
4. A nine speed box, used as a head stock gear box of a turret lathe, is to
provide a speed range of 180 rpm to 1800 rpm. Using standard step
ratio, draw the speed diagram, and the kinematic layout showing
number of teeth in all gears.
Given data:
n =9
N min = 180rpm
N max = 1800rpm
Step 1:- selection of spindle speeds
Determine the progression ratio () using the relation
N max
= n −1
N min
1800
= 9 −1
180
1
 = (10) 8
 = 1.333
✓ We find  =1.333 is not a standard ratio. So let us find out whether

multiplies of standard ratio 1.12 or 1.06 come close to 1.333
✓ For example we can write, 1.12 1.12 = 1.2544 &1.12 1.12 1.12 = 1.405
Then 1.06 1.06 1.06 1.06 = 1.338 skip 4 speeds
So we take ϕ= 1.06, because satisfies the requirement, select the standard spindle
speeds using the series of preferred numbers
Take Step Ratio from R40 series ϕ=1.06
Spindle Speeds are 180, 236, 315, 425, 560, 750, 1000, 1320 and 1800rpm
Step 2: To find the structural formulae
Structural formulae: 3(1) 3(3)
Step 3: Construct the kinematic arrangement for 9 speed gear box
✓ Structural formulae: 3(1) 3(3)

✓ P1 = 3 p2 = 3 Note: where X1 = 1; X2 = p1 = 3
✓ No. of shafts = No. of stages +1 (2+1=3 shafts) (so draw 3 horizontal lines)
✓ To find the no. of gears by using
No. of gears = 2(p1 + p2 ) 2(3 + 3) = 12gears
Step 4:- Construct the ray diagram for 9 speed gear box
➢ Structural formulae: 3(1) 3(3)
No .of stages: 2(p1 ( X1 ).p2 ( X2 )
p1 = 3 p2 = Note: Where X1 = X2 = p1 = 3
✓ No. of shafts = No. of stages +1 (2+1= 3 shafts) (so draw 3 vertical lines)
✓ No. of speeds = 9 (Draw 9 horizontal lines)
Step 5: Calculation of No. of teeth
• Calculation of numbers of teeth on all the gears
Let Z1, Z2, Z3, …..Z12 = Number of teeth of the gears 1, 2, 3, …12 respectively
z1 N 2
Formulae given =
z 2 N1
Take stage – 2
• Consider the first pair of gear 11 and 12

• From ray diagram consider ray DA
• Maximum speed reduction 560rpm to 180rpm
We know that, Zmin ≥ 17, assume Z11 = 20 (driver)
z11 N12
=
z12 N11
20 180
=
z12 560
z12 = 62.22  63
Z11 = 20, Z12 = 63
Take stage – 2
• Consider the second pair of gear 7 and 8

• From ray diagram consider ray DB
We know that,
z 7 N8
=
z8 N 7
z 7 425
=
z8 560
z 7 = 0.76z8 − − (i)
NOTE: The centre distance between the shafts are fixed and same. The sum of
So we can write
z7 + z8 = z11 + z12 = 20 + 63 = 83 (ii)
Solving equations (i) and (ii), we get
z8 = 47.16  48
z 7 = 83 − 48 = 35
z 7 = 35 z8 = 48
Take stage – 2
• Consider the third pair of gear 9 and 10

• From ray diagram consider ray DC
• Speed increase from 560rpm to 1000rpm
We know that,
z 9 N10
=
z10 N9
z 9 1000
=
z10 560
Z9 = 1.786 Z10 − − (iii)
So we can write
Z9 + Z10 = Z11 + Z12 = 20 + 63 = 83 − − (iv)
Solving equation (iii) and (iv), we get
Z10 = 29.79  30
Z9 = 83 − 30 = 53
Z9 = 53 Z10 = 30
Take stage -1

• From ray diagram consider ray GD
We know that, Zmin  17 ∴ assume Z5 = 20 (Driver)
z5 N 6
=
z6 N5
20 1320
=
z12 560
z 6 = 47.14  48
Take stage – 1

We know that,
z1 N 2
=
z 2 N1
z1 750
=
z 2 1320
Z1 = 0.57z 2 − − −(v)
So we can write
z1 + z2 = z5 + z6 = 20 + 48 = 68 − − −(vi)
Solving equations (v) and (vi), we get
z 2 = 43.3  44
z1 = 68.44 = 24
Z1 = 24 Z2 = 44
Take stage – 1

• From ray diagram consider ray GF
• Speed increase from 1320rpm to 1000 rpm
We know that,
z3 N 4
=
z 4 N3
z 3 1000
=
z 4 1320
Z3 = 0.76z 4 − − (vii)
Solving equations (iii) and (iv), we get
Z 4 = 38.64  39
Z3 = 68 − 39 = 29
Z3 = 29 Z 4 = 39
5. A gear box is to give 18 speeds for a spindle of a milling machine.

Maximum and minimum speeds of the spindle are to be around 650 and
35 rpm respectively. Find the speed ratios which will give the desired
speeds and draw the structural diagram and kinematic arrangement of

the drive.
Given data:
n = 18
N min = 35rpm
N max = 650rpm
Step 1: Selection of Spindle speeds
Determine the progression ratio (  ) using the relation
Nmax Nmin =n−1
650 35 = 18 −1
 = ( 18.571)
1 17
 = 1.87
We find  = 1.87 is not a standard ratio. So let us find out whether

multiples of standard ratio 1.12 OR 1.06 come close to 1.87
For example we can write 1.12  1.12 = 1.2544
Then 1.06  ( 1.06  1.06 ) = 1.91 … Skip 2 speeds
So we take  = 1.06 , because satisfies the requirement. Select the

standard spindle speeds using the series of preferred numbers From
PSGDB 7.20, 7.19
Step ratio from R40 series  = 1.06
 Spindle speeds are 35.5, 42.5, 50, 60, 71, 85, 100, 118, 140, 170,
200, 236, 280, 335, 400, 475, 560 and 670 rpm
Step 2: To find the Structural Formulae
Structural formulae: 2 ( 1) 3 ( 2 ) 3 ( 6 )
Step 3: Construct the Kinematic arrangement for 18 speed gear box
No. of shafts = No. of stages + 1 (3 + 1 = 4 shafts) (so draw 4

horizontal lines)
To find the no. of gears by using

No. of gears = 2 ( p 1 + p 2 + p 3 )  2 ( 2 + 3 + 3 )  = 16gears
Step 4: Construct the ray diagram for 18 speed gear box
Note: Where X 1 = 1 X 2 = p1 = 2 X 3 = p1  p 2 = 2  3 = 6
No. of shafts = No. of stages +1 (3 + 1 = 4 shafts) (so draw 4 vertical

lines)
No. of speeds = 18 (Draw 18 horizontal lines)
6. Draw the speed diagram, and the kinematic layout of the head stock
gear box of a turret lathe having arrangement for 9 spindle speeds,
ranging from 31.5rpm to 1050rpm. Calculate the no. of teeth on each
gear. Minimum number of teeth on a gear is 25. Also calculate the
percentage deviation of the obtainable speeds from the calculated ones.
GIVEN DATA:
n=9
N min = 31.5rpm
N max = 1050rpm
Zdriver = 25
Step 1: Selection of Spindle Speeds
Determine the progression ration () using the relation
N max N min = n − 1
1050 31.5 = 9−1
 = ( 33.33 )
18
 = 1.55
✓ We find  = 1.55 is not a standard ratio. So let us find out whether multiples
of standard ratio 1.12 or 1.25 come close to 1.55
✓ For example we can write 1.12 × 1.12 = 1.2544 and 1.12 × 1.12 × 1.12 =
1.405
Then 1.25 × 1.25 = 1.55 ….. skip 1 speed
So we take  = 1.25 , because satisfies the requirement. Select the standard

spindle speeds using the series of preferred numbers – From PSGDB 7.20, 7.19
Take step Ratio from R10 series  = 1.25
 Spindle speeds are 31.5, 50, 80, 100, 160, 250, 400, 630, 1000rpm
Structural Formulae: 3(1) 3(3)
Note: Where X 1 = 1 X 2 = p1 = 3
No. of shafts = No. of stages + 1 (2+1=3 shafts) (so draw 3 horizontal lines)
To find No. of gears = 2(p1 + p2) {[2(3+3)]=12gears}
Step 4: Construct the Ray diagram for 9 speed gear box
Note: Where X1 = 1 X2 = p1 =3
No. of shafts = No. of stages + 1 (2+1=3 shafts) (so draw 3 vertical lines)
Stage 2:
✓ For stage 2 = 3(3) , 3 points with 3 speed gap or 3 speeds on shaft 3, Make
the points A, B & C
✓ Find input speed for the speeds A=31.5 rpm and C=500rpm by using
31.5 1500
= 0.1  = 1.58  2 Ratio requirement satisfied,
31.5 4315
Input speed for stage 2=315rpm
Stage 1:
✓ For stage 1=3(1), 3 points with 1 speed gap or 1 speeds on shaft 2, Make the
points D, E & F
✓ Find input speed for the speeds D=315 rpm and F=800rpm by using
31.5 1 800
= 0.252  = 0.64  2 , Ratio requirement satisfied,
1250 4 1250
 Input speed for stage 1=1250 rpm
Step 5: Calculation of Number of Teeth on all the gears
Let, Z1, Z2, Z3 …Z12 = Number of teeth of the gears 1, 2, 3…12 respectively
N1, N2, N3… N12 = Speeds of the gears 1, 2, 3 …12 respectively
Z1 N 2
Formulae given =
Z2 N1
Take stage-2-Consider the first pair of gear 11, and 12

• Maximum speed reduction 315rpm to 31.5rpm
We know that, Z min  17,  assume Z11 = 25 (Driver)
Z 11 N 12 25 31.5
= = = Z12 = 250
Z 12 N 11 Z 12 315
Take stage-1-Consider the second pair of gear 1 and 2
• From ray diagram consider ray GE

• Speed reduction 1250rpm to 500rpm
Z1 N 2 Z1 500
We know that, = = =
Z 2 N 1 Z 2 1250
Z1 = 0.4Z 2 ….. (v)
Z1 + Z 2 = Z 5 + Z6 = 25 + 80 = 105 …….(vi)
Z 2 = 75
Z 1 = 105 − 75 = 30
Z3 N 4 Z3 800
We know that, = = =
Z 4 N 3 Z 4 1250
Z 3 = 0.64Z 4 ….. (vii)
Z3 + Z 4 = Z 5 + Z6 = 25 + 80 = 105 …….(viii)
Solving equations (viii) and (vii), we get
Z 4 = 64.02 65
Z 3 = 105 − 65 = 40
Step 6: Calculation of Output Speeds
Let N1 and N0 = Input and output speeds of the gears. From the ray diagram input
speed N1 = 1250 rpm
Z 1 Z7 30 78
N 01 = N 1   = 1250   = 197.96rpm
Z2 Z8 75 197
Z1 Z9 30 168
N 02 = N 1   = 1250   = 785.05rpm
Z 2 Z 10 75 107
Z 1 Z 11 30 25
N 03 = N 1   = 1250   = 50rpm
Z 2 Z 12 75 250

Z7 N 8 Z7 125
We know that, = = =
Z 8 N 7 Z 8 315
Z7 = 0.4Z 8 ….(i)
Z7 + Z8 = Z11 + Z12 = 25 + 250 = 275 ….(ii)
Z 8 = 196.42 197
Z7 = 275 − 197 = 78

Z 9 N 10 Z 9 500
We know that, = = =
Z 10 N 9 Z 10 315
Z9 = 1.59Z10 ….(iii)
Z9 + Z10 = Z11 + Z12 = 25 + 250 = 275 ….(iv)
Z 10 = 106.18 107
Z 9 = 275 − 107 = 168

• Maximum Speed reduction 1250rpm to 315rpm
We know that, Zmin  17 ,  assume Z5 = 25 (Driver)
Z5 N6 25 315
= = =
Z 6 N 5 Z 12 1250
Z6 = 79.37 80
Z 3 Z7 40 78
N 04 = N 1   = 1250   = 304.57rpm
Z 4 Z8 65 197
Z3 Z9 40 168
N 05 = N 1   = 1250   = 1207.76rpm
Z 4 Z 10 65 107
Z 3 Z 11 40 25
N 06 = N 1   = 1250   = 76.92rpm
Z 4 Z 12 65 250
Z 5 Z7 25 78
N 07 = N 1   = 1250   = 154.66rpm
Z6 Z8 80 197
Z5 Z9 25 168
N 08 = N 1   = 1250   = 613.32rpm
Z 6 Z 10 80 107
Z 5 Z 11 25 25
N 09 = N 1   = 1250   = 39.06rpm
Z 6 Z 12 80 250
Step 7: Calculation of % Deviation:
7.A 6 speed gear box is required to provide output speeds in the range of 125
to 400 rpm, with a step ratio of 1.25 and transmit a power 5kW at 710 rpm.
Draw the speed diagram and kinematic diagram. Determine the number of
teeth module and face width of all the gears, assuming materials for gears.
Determine he length of the gear box along the axis of the gear shaft.
GIVEN DATA:
n= 6
Nmin=125 rpm
Nmax= 400 rpm
∅=1.25
P=5 kW
Ninput= 710 rpm
STEP 1: SELECTION OF SPINDLE SPEEDS
∅=1.25 (given)
we take ∅=1.25, because satisfies the requirement. Select the

standard spindle speeds using the series of preferred numbers – From PSGDB
7.20, 7.19
TAKE
STEP RATIO from R10 series ∅=1.25
∴SPINDLE SPEEDS ARE 125, 160,200,250,315 and400
STEP 2: TO FIND THE STRUCTURAL FORMULAE
STRUCTURAL FORMULAE: 3(1) 2(3)
STEP 3: CONSTRUCT THE KINEMATIC ARRANGEMENT FOR 6 SPEED GEAR

BOX
No.of Stages: 2, {(p1 (X1) . p2 (X2)}
Note:Where X1 =1 X2= p1 =3
✓ No. of shafts= No. of stages+1 (2+1=3 shafts) (so draw 3 horizontal lines)
✓ No. of gears= 2(p1 + p2) {[2(3+2)]=10 gears}
STEP 4: CONSTRUCT THE RAY DIAGRAM FOR 6 SPEED GEAR BOX
Note: Where X1 =1 X2= p1 =3
✓ No. of shafts= No. of stages+1 (2+1=3 shafts) (so draw 3 vertical lines)
✓ No. of speeds=6 (Draw 6 horizontal lines)
STEP 5: CALCULATION OF NUMBER OF TEETH ON ALL THE GEARS
LET, Z1, Z2,Z3,……Z10= Number of teeth of the gears 1,2,3,…10

respectively
N1,N2,N3,……N10= Speeds of the gears 1,2,3,…10 respectively
Formulae given
Take stage-2-Consider the first pair of gear 9 and 10
• From ray diagram consider ray CA

We know that, Zmin 17, ∴ assume Z9=20 (Driver)
Z10=32
• From ray diagram consider ray CB

• Minimum speed increase 200rpm to 250rpm
We know that,
Z7=1.25 ……(i)
Z7+ Z8 =Z9+ Z10 =20+32=52 ……(ii)
Solving equations (i) and (ii) ,we get
Z8=22.22 ≈23
Z7=52-23=29
Take stage-1-Consider the first pair of gear 5 and 6
• From ray diagram consider ray FC

We know that, Zmin 17, ∴ assume Z5=20 (Driver)
Z6=31.5≈32
• From ray diagram consider ray FD

We know that,
Z1=0.79 ……(v)
Z1+ Z2 =Z5+ Z6 =20+32=52 ……(vi)
Solving equations (v) and (vi) ,we get
Z2= 29
Z1=52-29=23
Take stage-2-Consider the third pair of gear 3 and 4
• From ray diagram consider ray FE

• Speed from 315rpm to 315 rpm
We know that,
Z3=1 ……(vii)
Z3+ Z4 = Z5+ Z6 =20+32=52 ……(viii)
Solving equations (iii) and (iv) ,we get
Z4=26
Z3=52-26=26
STEP 6: SELECTION OF MATERIAL:
➢ Take 40 Ni 2 Cr 1 Mo 28 (Hardened and Tempered) and material

constant M=100
STEP 7: CALCULATION OF MODULE
Case 1: To Find the Torque
✓ Calculate the torque for the gear 10 has the lowest speed of 125
rpm using the relation,
Case 2: To Find the Tangential force on gear 10:
✓ Calculate the tangential force (Ft) on the gear in terms of

module using the relation, From PSGDB 8.57, table 46
Case 3: To Find module:
➢ Now calculate the module (module is defined as the ratio of

pitch circle diameter to number of teeth) using the relation
Where, 𝛙m= Ratio between the face width and module = b/m =10, From
PSGDB 8.1 and 8.14 (table 12)
M= Material constant = 100 from table 1 (step 6-40 Ni 2 Cr 1 Mo 28
➢ Module:
OR
m2=
∴ Module m=2.88mm
From PSGDB 8.2 choice 1 the nearest higher standard module is 3 mm
STEP 8: CALCULATION OF CENTRE DISTANCE IN ALL STAGES
By using the relation
From PSGDB 8.22, Table 26
Zx and Zy = Number of teeth on the gear pair in engagement in each

stage.
✓ Centre distance in stage 1, = 78mm
✓ Centre distance in stage 2, = 78 mm
STEP 9: CALCULATION OF FACE WIDTH
b = 10 x m
We know that module m=3 mm
∴ Face width b= 10 x3 =30 mm
STEP 10: CALCULATION OF LENGTH OF THE SHAFTS
L= 25+10+7b+20+4b+10+25
= 90 + 11b
= 90 + (11x30)
L= 420 mm
8. Design the layout of a 12 speed gear box far a milling machine having an output of speeds
ranging from 25 to 600 rpm. Power is applied to the gear box from a 2.25 KW induction motor at
1440 rpm. Construct the speed diagram using standard speed ratio. Calculate the number of
teeth on each gear and sketch the arrangement of the gear box.
Given data:
n = 12
Nmin = 25rpm
Nmax = 1440 rpm
P = 2.25KW
1. Selection of spindle speeds:
We know that,
N max
n −1 =
N min
600
12 −1 =
25
 = 1.335
We can write, 1.06  (1.6 1.06 1.06 1.06) = 1.338
So, ϕ = 1.06 satisfies the requirement. Therefore the spindle from R 40 series skipping four speeds, are given as
25, 33.5, 45, 60, 80, 106, 140, 190, 250, 250, 335, 450 and 600 rpm.
2. Ray diagram: The ray diagram is constructed, as shown in fig.
Structural formula: 3(1) 2(3) 2(6)
Step 3:
N min 25 1
= = 0.31 and
N input 80 4
N max 140
= = 1.75  2
N input 80
Step 2:
N min 80 1
= = 0.57 
N input 140 4
N max 190
= = 1.36  2
N input 140
Step 1:
N min 140 1
= = 0.311 
N input 450 4
N max 250
= = 0.56  2
N input 450
3. Kinematic arrangement: The kinematic arrangement for the given 12 speed gear box is constructed, as
shown in fig.
4. Calculation of number of teeth on alt gears: The number of teeth on all gears are calculate as below,
following the procedure used
Stage 3:
First pair: Consider the ray that gives, maximum reduction i.e, from 80 r. p. m to 25 r. p. m. The corresponding
gears are 13 and 14 on shaft 4.
We know that, Zmin ≥ 17. Therefore assume z13= 20 (driver)
z13 N14 20 25
= or = ; z14 = 64
z14 N13 z14 80
Second pair: Consider the other ray that gives speed increase form 80 r. p. m. To 140r. p. m. The corresponding
gears are 11 and 12.
z11 N12 140

= = or z11 = 1.75z12 − − (i)
z12 N11 80
We also know that the sun of number of teeth of mating gears should be equal.
z11 + z12 = z13 + z14 = 20 + 64 = 84 − − (ii)
On solving equations (i) and (ii), we get
z12 = 30.5  31 and z11 = 84 − 31 = 53
Stage 2:
First pair: Consider the ray that gives maximum reduction from 140 r.p.m to 8 r.p.m. The corresponding gears
are 9 and 10. Assume z9 = 20 (driver).
z9 N10 20 80
= or = ; z10 = 35
z10 N9 z10 140
Second pair: Consider the other ray that gives speed increase from 140 r.p.m to 190 r.p.m. The corresponding
gears are 7 and 8.
z 7 N8 190
= = or z 7 = 1.357 z8 − − (iii)
z8 N 7 140
z 7 + z8 = z9 + z10 = 20 + 35 = 55 − − (iv)
On solving equation (iii) and (iv), we get
z8 = 23.3 = 24 and z7 = 55 − 24 = 31
Stage 1:
First pair: Consider the ray that gives maximum from 450 r.p.m to 140 r.p.m. The corresponding gears are 5
and 6. Assume z5 = 20 (driver)
z5 N 6 20 140
= or = ; z 6 = 64.28 = 65
z 6 N5 z 6 450
Second pair: Consider the ray that gives speed reduction from r.p.m to 190 r.p.m. The corresponding gears are
3 and 4.
z3 N 4 190
= = or z3 = 0.422z 4 − − (v)
z 4 N3 450
z3 + z 4 = z5 + z 6 = 20 + 65 = 85 − − (vi)
On solving the equations (v) and (vi), we get
z 4 = 59.77  60 and z3 = 85 − 60 = 25
Third pair: Consider the ray that gives speed reduction from 450 r.p.m to 250 r.p.m. The corresponding gears
are 1 and 2.
z1 N 2 250
= = or z1 = 0.555z 2 − − (vii)
z 2 N1 450
z1 + z 2 = z3 + z 4 = 60 + 25 = 85 − − (viii)
On solving the equations (vii) and (viii), we get
z2 = 54.66  55 and z1 = 85 − 55 = 30
9. Sketch the arrangement of six speed gear box for a minimum speed of 460 rpm. Draw the speed
diagram and kinematic arrangement showing number of teeth in all gears. Check whether all the
speeds obtained through the selected gears are within ± 2% of standard speeds. The drive is for
an electric motor giving 2.25kW at 1440rpm.
Given data;
n=6
N min = 460rpm
N max = 1400rpm
p = 2.25kW
N input = 1440rpm
Step 1: Selection of spindle speeds
N max
= n −1
N min
1400
= 6 −1
460
 = 1.25
So we take , because satisfies the requirement . Select the standard spindle speeds using the series of preferred
numbers .
Take , step ratio from R10 series  = 1.25
Standard spindle speeds are 500, 630, 800, 1250 and 1600 rpm
Step 2: Structural Formulae
Structural Formulae 3(1) 2(3)
Step 3: Construct the kinematic arrangement for 6 speed gearbox
Structural formulae 3(1) 2(3)
Note: Where x1 = 1x2 = p1 = 3
✓ To find the no. of gears = 2(p1 + p 2 ) 2(3 + 2)  = 10 gears
Step 4: construct The Ray Diagram for 6 speed Gear box
Structural formulae 3(1) 2(3)
✓ No. of shafts = No. of stages +1 (2+1=3)(so draw 3 vertical lines)

Stage 2:
✓ For stage 2 = 2(3), 2 points with 3 speed gap

✓ Find input speed for the speeds A = 500 rpm and B = 1000rpm by using
630 1 1000
= 0.504  = 0.8  2
1250 4 1250
Ratio requirement satisfied. Input speed for stage 1 = 1250 rpm
Step 5: Calculation of number of teeth on all the gears
Let Z1, Z2, Z3,.....Z10 = Number of teeth of the gears 1, 2, 3, ....10 respectively
N1, N2, N3, .....N10 = Speeds of the gears 1, 2, 3, ....10 respectively
z1 N1
Formulae given =
z2 N2
Take stage – 2 consider the first pair of gear 9 and 10
• From ray diagram consider ray CA

• Maximum speed reduction 630 rpm to 460 rpm
We know that, Zmin ≥ 17, ∴ assume Z9 =20 (Driver)
z9 N10 20 460
= = =
z10 N 9 z10 630
Z10 = 28
Take stage – 2 consider the speed pair of gear 7 and 8
• From ray diagram consider ray CB

• Speed increase 630 rpm to 1000 rpm
We know that,
z 7 N6 20
= =
z 6 N5
Take stage – 1 consider the second pair of gear 1 and 2
• From ray diagram consider ray FD

• Speed reduction 1250 rpm to 800rpm
z1 N 2 z1 800
We know that, = = =
z 2 N1 z 2 1250
z1 = 0.64z 2 − − (v)
z1 + z 2 = z 5 + z 6 = 20 + 40 = 60 − − (vi)
z2 = 36.58  37, zl1 = 60 − 37 = 23
Take stage – 2 – consider the third pair of gear 3 and 4
• From ray diagram consider ray FE

• Speed from 1250 rpm to 100rpm
z3 N 4 z3 1000
We know that, = = =
z 4 N3 z 4 1250
z 3 = 0.8z 4 − − (vii)
z 3 + z 4 = z 5 + z 6 = 20 + 40 = 60 − − (viii)
Solving equations (iii) and (iv) we get
z 4 = 33.33  34
z 3 = 60 − 34 = 26
Step 6:- Calculation of output speeds
Let N1 and N0 = Input and output speeds of the gears. From the ray diagram input speed N 1 = 1250rpm
Z1 Z7 23 29
N 01 = N1  X = 1250   = 1186rpm
Z2 Z8 37 19
Z1 Z9 23 20
N 02 = N1  X = 1250   = 555.02rpm
Z2 Z10 37 28
Z3 Z 7 26 29
N 03 = N1  X = 1250   = 1459rpm
Z4 Z8 34 19
Z3 Z9 26 20
N 04 = N1  X = 1250   = 682.77rpm
Z4 Z10 34 28
Z5 Z 7 20 29
N 05 = N1  X = 1250   = 954rpm
Z6 Z8 40 19
Z5 Z9 20 20
N 06 = N1  X = 1250   = 446.42rpm
Z6 Z10 40 28
10. A sixteen speed gear box is required to furnish output speeds in

the range of 100 to 560rpm. Sketch the kinematic arrangement and
draw the speed diagram.
Given data:
M = 16
N min = 100rpm
N max = 560rpm
N max
= 16 − 1
N min
560
= 15
100
1
 = ( 5.6 ) 15
 = 1.12
We find  = 1.12 is the standard ratio, it satisfies the requirement.

Select the spindle speeds using the series of preferred numbers.
PSGDB 7.20
Basic series R20 (  = 1.12 )
Spindle speeds are 100, 112, 125, 140, 160, 180, 200, 224,
250, 280, 315, 355, 400, 450, 500, 560 rpm.
Step 2: To find the structural formulae.
16 Speeds = 4 ( 1) 2 ( 4 ) 2 ( 8 )
Step 3: Construct the speed diagram for 16 speed gear box.

 Structural formula = 4 ( 1) 2 ( 4 ) 2 ( 8 )
  
No. of stages = 3 P1 ( X 1 )  P2 ( X 2 )  P3 ( X 3 )
P1 = 4 , P2 = 2 , P3 = 2
Note: X 1 = 1 , X 2 = P1 = 4 , X 3 = P1  P2 = 4  2 = 8.
 No. of shafts = No. of stages +1
= 3+1
= 4 ( Draw 4 vertical lines )
 No. of speeds = 16 ( Draw 16 horizontal lines ) .
Stage 3:
N min 1 N max
 2
N input 4 N input
100 250
= 0.714  1 = 1.78  2
140 4 140
Stage 2:
N min 1 N max
 2
N input 4 N input
140 224
= 0.7  1 = 1.12  2
200 4 200
Stage 1:
200 280
= 0.44  1 = 0.622  2
450 4 450
 N input = 450rpm.
Step 4: Kinematic Layout - 16 Speed gear box

No. of shafts = 4
No. of Gears = 2 ( 4 + 2 + 2 ) = 16
11. Design a nine speed gear box for a machine to provide speeds
ranging from 100rpm to 1500rpm. The input is from a motor of 5KW at
1440rpm. Assume any alloy steel for the gears. (April/May 2017)
Given data:
=9
N min = 100rpm.
N max = 1500 rpm .
P = 5 KW
N input = 1440rpm.
Note: In this problem the given max speed is 1500rpm. But as per R 20 series am
taken the 9th speed 1400rpm. If you want to take 1500rpm as the 9th speed also
correct. No issues. Anyhow maximum cases we should follow the standard values.
Step 1: Selection of spindle speeds:
N max
= n − 1
N min
1500
= 9 − 1
100
15 = 8
 = 1.403.
 We find  = 1.403 is not a standard ratio. So let us find out whether multiples
of standard ratio 1.12 or 1.06 come close to 1.403.
1.12  1.12  1.12 = 1.405 Skip 2 speeds.
  = 1.12 Satisfies the requirement. Therefore the spindle speeds from R 20

series skipping 2 speeds, are.
From PSGDB 7.20,
100, 140, 200, 280, 400, 560, 800, 1000, 1400 rpm.
Step 2: To find the structural formula:
9 speeds = 3(1) 3(3)
Structural formula =3(1) 3(3).
No. of shafts = No. of stages +1 = 3 (3 horizontal lines).
No. of gears = 2(P1+P2) = 2(3+3) = 12 gears.
Structural formula = 9 speeds = 3(1) 3(3).
No. of shafts =3 (3 vertical lines)
For stage 2
N min 1 N max
 2
N I/p 4 N I/p
100 1 N N max 800

  min = 1  1 = =22
400 4 N I/p 4 4 N I/p 400
NI/p = 400rpm.
For stage 1
N min 1 N max
 2
N I/p 4 N I/p
N min 400 N max 800

= = 0.29  1 = = 0.57  2
N I/p 1400 4 N I/p 1400
 N I/p = 1400rpm.
Z1 N 2
We know that , =
Z2 N1
Case 1: consider stage 2.
First pair:
 Gears 11 and 12
 From the ray diagram consider Ray DA.
 Maximum speed reduction from 400 rpm to 1000 rpm .
Z11 = 20 ( driver ) .
Z 11 N 12
 =
Z 12 N 11
20 100
=
Z 12 400
Z12 = 80
Z11 = 20 , Z12 = 80
Second Pair:
 Gears 7, 8 & Ray DB

 Minimum speed reduction 400 to 280 rpm.
Z7 N 8
=
Z8 N7
Z7 280
=
Z 8 400
Z7 = 0.7Z8 1
Note: The centre distance between the shafts are fixed and same.  The sum of
 Z11 + Z12 = Z7 + Z8 = 100
0.7Z8 + Z8 = 100
Z8 = 58.82 59
 Z7 = 41 , Z8 = 59
Third Pair:
 Gears 9 & 10, Ray DC

Z 9 N 10
=
Z 10 N 9
Z 9 800
=
Z 10 400
Z9 = 2Z10
W.K.T Z11 + Z12 = 100 = Z9 + Z10
2Z10 + Z10 = 100
Z10 = 33.33 34
 Z9 = 66
Z10 = 34
Case 2: Consider stage 1:
First Pair:
 Gears 5 and 6 , Ray GD.

 Maximum speed reduction from 1400 to 400 rpm.
Z5 N6
=
Z6 N 5
Z5 = 20 ( driver )
20 400
=
Z 6 1400
Z6 = 70
Z5 = 20, Z6 = 70.
Second Pair:
 Gears 1 and 2 , Ray GE
Z1 N 2
=
Z2 N1
Z1 560
=
Z 2 1400
Z1 = 0.4Z 2
We know that Z5 + Z6 = 90 = Z1 + Z 2
0.4Z2 + Z2 = 90
Z 2 = 64.28 65
Z1 = 25
Third Pair
 Gears 3 and 4, Ray GF

Z3 N 4
=
Z4 N3
Z3 800
=  Z 3 = 0.57Z 4
Z 4 1400
W.K.T  Z5 + Z6 = 90 = Z3 + Z 4
0.57Z 4 + Z 4 = 90
Z 4 = 57.32 58
Z3 = 32
12. Design a 12 speed gear box. The required speed range is 100 to
355 rpm. Draw the ray diagram, kinematic arrangement (April/May
2017)
GIVEN DATA:
n= 12
Nmin=100 rpm
Nmax= 355 rpm
Step 1: SELECTION OF SPINDLE SPEEDS
Determine the progression ratio (∅) using the relation
Nmax/Nmin=∅n-1
355/100=∅12-1
∅=(3.55)1/11
∅=1.122
For the calculated ∅=1.122 ,select the standard spindle speeds using
the series of preferred numbers – From PSGDB 7.20, 7.19
TAKE
STEP RATIO from R20 series ∅=1.122
∴SPINDLE SPEEDS ARE 100, 112, 125, 140, 160,180, 200, 224, 250, 280,
315,AND 355
Step 2: CONSTRUCT THE KINEMATIC ARRANGEMENT FOR 12 SPEED GEAR

BOX
➢ STRUCTURAL FORMULAE: 3(1) 2(3) 2(6)

No.of Stages: 3, {(p1 (X1) . p2 (X2) . p3 (X3)}
1st stage. 2nd stage . 3rd stage
p1 =3 p2 =2 p3 =2
Note:Where X1 =1 X2= p1 =3 X3 = p1.p2 =(3.2)=6
✓ No. of shafts= No. of stages+1 (3+1=4 shafts) (so draw FOUR horizontal lines)
No. of gears= 2(p1 + p2+p3) {[2(3+2+2)]=14 gears}
Step 3: CONSTRUCT THE RAY DIAGRAM FOR 12SPEED GEAR BOX
STRUCTURAL FORMULAE: 3(1) 2(3) 2(6)
No.of Stages: 2, {(p1 (X1) . p2 (X2)} . p3 (X3)}
1st stage. 2nd stage . 3rd stage
p1 =3 p2 =2 p3 =2
Note:Where X1 =1 X2= p1 =3 X3 = p1.p2 =(3.2)=6
✓ No. of shafts= No. of stages+1 (3+1=4 shafts) (so draw 4 vertical lines)
✓ No. of speeds=12 (Draw 12 horizontal lines)
13. Draw the speed diagram, and the kinematic layout of the head stock
gear box of a turret lathe having arrangement for 9 spindle speeds, ranging
from 31.5rpm to 1050rpm. Calculate the no. of teeth on each gear.
Minimum number of teeth on a gear is 25. Also calculate the percentage
deviation of the obtainable speeds from the calculated ones.
(Nov/Dec 2017)
GIVEN DATA:
n=9
N min = 31.5rpm
N max = 1050rpm
Zdriver = 25
Step 1: Selection of Spindle Speeds
Determine the progression ration () using the relation
N max N min = n − 1
1050 31.5 = 9−1
 = ( 33.33 )
18
 = 1.55
✓ We find  = 1.55 is not a standard ratio. So let us find out whether multiples
of standard ratio 1.12 or 1.25 come close to 1.55
✓ For example we can write 1.12 × 1.12 = 1.2544 and 1.12 × 1.12 × 1.12 =
1.405
Then 1.25 × 1.25 = 1.55 ….. skip 1 speed
So we take  = 1.25 , because satisfies the requirement. Select the standard

spindle speeds using the series of preferred numbers – From PSGDB 7.20, 7.19
Take step Ratio from R10 series  = 1.25
 Spindle speeds are 31.5, 50, 80, 100, 160, 250, 400, 630, 1000rpm
Note: Where X 1 = 1 X 2 = p1 = 3
No. of shafts = No. of stages + 1 (2+1=3 shafts) (so draw 3 horizontal lines)
To find No. of gears = 2(p1 + p2) {[2(3+3)]=12gears}
Step 4: Construct the Ray diagram for 9 speed gear box
Note: Where X1 = 1 X2 = p1 =3
No. of shafts = No. of stages + 1 (2+1=3 shafts) (so draw 3 vertical lines)
Stage 2:
✓ For stage 2 = 3(3) , 3 points with 3 speed gap or 3 speeds on shaft 3, Make
the points A, B & C
✓ Find input speed for the speeds A=31.5 rpm and C=500rpm by using
31.5 1500
= 0.1  = 1.58  2 Ratio requirement satisfied,
31.5 4315
Input speed for stage 2=315rpm
Stage 1:
✓ For stage 1=3(1), 3 points with 1 speed gap or 1 speeds on shaft 2, Make the
points D, E & F
✓ Find input speed for the speeds D=315 rpm and F=800rpm by using
31.5 1 800
= 0.252  = 0.64  2 , Ratio requirement satisfied,
1250 4 1250
 Input speed for stage 1=1250 rpm
Step 5: Calculation of Number of Teeth on all the gears
Let, Z1, Z2, Z3 …Z12 = Number of teeth of the gears 1, 2, 3…12 respectively
N1, N2, N3… N12 = Speeds of the gears 1, 2, 3 …12 respectively
Z1 N 2
Formulae given =
Z2 N1
Take stage-2-Consider the first pair of gear 11, and 12

• Maximum speed reduction 315rpm to 31.5rpm
We know that, Z min  17,  assume Z11 = 25 (Driver)
Z 11 N 12 25 31.5
= = = Z12 = 250
Z 12 N 11 Z 12 315
• From ray diagram consider ray GE

Z1 N 2 Z1 500
We know that, = = =
Z 2 N 1 Z 2 1250
Z1 = 0.4Z 2 ….. (v)
Z1 + Z 2 = Z 5 + Z6 = 25 + 80 = 105 …….(vi)
Z 2 = 75
Z 1 = 105 − 75 = 30

Z3 N 4 Z3 800
We know that, = = =
Z 4 N 3 Z 4 1250
Z 3 = 0.64Z 4 ….. (vii)
Z3 + Z 4 = Z 5 + Z6 = 25 + 80 = 105 …….(viii)
Solving equations (viii) and (vii), we get
Z 4 = 64.02 65
Z 3 = 105 − 65 = 40
Step 6: Calculation of Output Speeds
Let N1 and N0 = Input and output speeds of the gears. From the ray diagram input
speed N1 = 1250 rpm
Z 1 Z7 30 78
N 01 = N 1   = 1250   = 197.96rpm
Z2 Z8 75 197
Z1 Z9 30 168
N 02 = N 1   = 1250   = 785.05rpm
Z 2 Z 10 75 107
Z 1 Z 11 30 25
N 03 = N 1   = 1250   = 50rpm
Z 2 Z 12 75 250

Z7 N 8 Z7 125
We know that, = = =
Z 8 N 7 Z 8 315
Z7 = 0.4Z 8 ….(i)
Z7 + Z8 = Z11 + Z12 = 25 + 250 = 275 ….(ii)
Z 8 = 196.42 197
Z7 = 275 − 197 = 78

Z 9 N 10 Z 9 500
We know that, = = =
Z 10 N 9 Z 10 315
Z9 = 1.59Z10 ….(iii)
Z9 + Z10 = Z11 + Z12 = 25 + 250 = 275 ….(iv)
Z 10 = 106.18 107
Z 9 = 275 − 107 = 168

• Maximum Speed reduction 1250rpm to 315rpm
We know that, Zmin  17 ,  assume Z5 = 25 (Driver)
Z5 N6 25 315
= = =
Z 6 N 5 Z 12 1250
Z6 = 79.37 80
Z 3 Z7 40 78
N 04 = N 1   = 1250   = 304.57rpm
Z 4 Z8 65 197
Z3 Z9 40 168
N 05 = N 1   = 1250   = 1207.76rpm
Z 4 Z 10 65 107
Z 3 Z 11 40 25
N 06 = N 1   = 1250   = 76.92rpm
Z 4 Z 12 65 250
Z 5 Z7 25 78
N 07 = N 1   = 1250   = 154.66rpm
Z6 Z8 80 197
Z5 Z9 25 168
N 08 = N 1   = 1250   = 613.32rpm
Z 6 Z 10 80 107
Z 5 Z 11 25 25
N 09 = N 1   = 1250   = 39.06rpm
Z 6 Z 12 80 250
Step 7: Calculation of % Deviation:
14. Design of 12 speed gear box for a lathe. The minimum and maximum
speeds are 100 and 1200 rpm. Power is 5 KW from 1440 rpm induction
motor.
(Nov/Dec 2017)
Given data:
n = 12 speeds
N min = 100rpm.
N max = 1200 rpm .
P = 5 KW
N input = 1440rpm.
*** Similar problem. We have to change the speed range of 100 to 355 rpm and also solved in April/May
2017
N max
= n − 1
N min
1200
= 12 −1
100
 = 1.25 .
From PSGDB 7.20.
100, 125, 160, 200, 250, 315, 400, 500, 630, 800, 1000 and 1200rpm.
12 speeds = 3(1) 2(3) 2(6)
For stage 3:
N min 1 N max
 2
NI 4 NI
P P
100 400
= 0.4  1 = 1.6  2
250 4 250
N I = 250 rpm .
P
For stage 2:
N min 1 N max
 2
NI 4 NI
P P
250 500
= 0.625  1 = 1.25  2
400 4 400
N I = 400 rpm .
P
For stage 1:
N min 1 N max
 2
NI 4 NI
P P
400 630
= 0.4  1 = 0.63  2
1000 4 1000
 N I = 1000 rpm .
P
Z1 N 2
We know that, =
Z2 N1
First Pair:

Z 13 N 14
= , Z13 = 20 ( driver )
Z 14 N 13
20 100
=
Z 14 250
Z14 = 50
Z13 = 20 , Z14 = 50
Second Pair:

Z 11 N 12
 =
Z 12 N 11
Z 11 400
=
Z 12 250
Z11 = 1.6 Z12
W.K.T. Z13 + Z14 = 70 = Z11 + Z12
 1.6Z12 + Z12 = 70
Z12 = 26.92 27
Z11 = 43
Z12 = 27 , Z11 = 43
First Pair:

Z 9 N 10
= Z9 = 20 ( driver )
Z 10 N 9
20 250
=
40 400
Z10 = 32
Z9 = 20 , Z10 = 32
Second Pair:

Z7 N 8
=
Z8 N7
Z7 500
=
Z 8 400
Z7 = 1.25Z 8
W.K.T. Z9 + Z10 = 52 = Z7 + Z8
1.25Z8 + Z9 = 52
Z8 = 23.11 24
Z7 = 28
Z7 = 28 , Z8 = 24
First Pair:

Z5 N6
=
Z6 N 5
20 400
= Z5 = 20 ( driver )
Z 6 1000
Z6 = 50
Z5 = 20 , Z6 = 50
Second Pair:

Z1 N 2
=
Z2 N1
Z1 500
=
Z 2 1000
Z1 = 0.5Z2
W. K. T. Z5 + Z6 = 70 = Z1 + Z 2
1.5Z2 = 70
Z2 = 46.7 47
Z1 = 23
Z1 = 23 , Z 2 = 47
Third Pair:

Z3 N 4
=
Z4 N3
Z3 630
=
Z 4 1000
Z 3 = 0.63Z 4
W. K. T. Z3 + Z 4 = Z 5 + Z6 = 70
1.63Z 4 = 70
Z 4 = 42.94 43
Z 3 = 27.
Z 3 = 27 , Z 4 = 43

the relation.
60P
T14 =
2 N
60  5  10 3
=
2   100
T14 = 477.46 Nm.
T 2T14
Ft14 = =
r Z 14  m
2  477.46  10 3
=
50  m
19098.4
Ft14 =
m
Ft14
m=
m.m

m
19098.4
m= m
10  100
19.098
m2 =
m
m = 2.67 mm.
m = 3mm .

table 26.
 Zx + Zy 
a= m
 2 
 Z + Z4 
a1 =  3 m
 2 
 27 + 43 
= 3
 2 
a1 = 105mm .
 Z + Z8 
a2 =  9 m
 2 
 28 + 24 
= 3
 2 
a 2 = 78mm .
 Z + Z 12 
a 3 =  11 m
 2 
 43 + 27 
= 3
 2 
a1 = 105mm .
W.K.T  b = 10  m
= 10  3
b = 30mm
L = 25 + 10 + 7b + 20 + 4b + 20 + 4b + 10 + 25
= 110 + 15b
= 110 + 15  30
L = 450 mm
(v) To find normal load on gear 14 (Fn)
Ft14
Fn =  = 20FD
cos 
6366.13
=
cos 20
Fn = 6774.7 N
(vi) To find maximum bending moment (M).
M=
( Fn .L )
4
6774.7  450
=
4
M = 7.62  10 5 Nmm.
(vii) To find the equivalent torque. (Teq)
Teq = M 2 + T42
= ( 7.62  10 ) + ( 477.46  10 )
5 2 3 2
= 8.99  10 5 Nmm
(viii) To find the diameter of the spindle (ds)
16Teq
ds = 3
  
16  8.99  10 5
= 3
 55
ds = 43.66 mm
ds = 50mm .
(d) Diameter of shaft 1.
60P
Torque T =
2 N
60  5  10 3
=
2   1000
= 47.75 Nm .
W.K.T T = 0.2d13   .
47.75  103 = 0.2  ds1

3
 55
ds1 = 16.31 mm.
(e) Diameter of shaft 2.
60  5  10 3
 T=
2   400
= 119.36 Nm .
W.K.T  T = 0.2d32   .
119.36  103 = 0.2  ds2

3
55
ds2 = 22.14 mm.
(f) Diameter of shaft 3.
60  5  10 3
 T=
2   250
T = 190.98 Nm .
W.K.T  T = 0.2d33   .
190.98  103 = 0.2  ds3

3
55
ds3 = 25.89 mm.
15. Design of 12 speed gear box for a lathe. The minimum and
maximum speeds are 100 and 1200 rpm. Power is 5 KW from 1440 rpm
induction motor. (April/May 2018)
Given data:
n = 12 speeds
N min = 100rpm.
N max = 1200 rpm .
P = 5 KW
N input = 1440rpm.
N max
= n − 1
N min
1200
= 12 −1
100
 = 1.25 .
From PSGDB 7.20.
100, 125, 160, 200, 250, 315, 400, 500, 630, 800, 1000 and 1200rpm.
12 speeds = 3(1) 2(3) 2(6)
For stage 3:
N min 1 N max
 2
NI 4 NI
P P
100 400
= 0.4  1 = 1.6  2
250 4 250
N I = 250 rpm .
P
For stage 2:
N min 1 N max
 2
NI 4 NI
P P
250 500
= 0.625  1 = 1.25  2
400 4 400
N I = 400 rpm .
P
For stage 1:
N min 1 N max
 2
NI 4 NI
P P
400 630
= 0.4  1 = 0.63  2
1000 4 1000
 N I = 1000 rpm .
P
Z1 N 2
We know that, =
Z2 N1
First Pair:

Z 13 N 14
= , Z13 = 20 ( driver )
Z 14 N 13
20 100
=
Z 14 250
Z14 = 50
Z13 = 20 , Z14 = 50
Second Pair:

Z 11 N 12
 =
Z 12 N 11
Z 11 400
=
Z 12 250
Z11 = 1.6 Z12
W.K.T. Z13 + Z14 = 70 = Z11 + Z12
 1.6Z12 + Z12 = 70
Z12 = 26.92 27
Z11 = 43
Z12 = 27 , Z11 = 43
First Pair:

Z 9 N 10
= Z9 = 20 ( driver )
Z 10 N 9
20 250
=
40 400
Z10 = 32
Z9 = 20 , Z10 = 32
Second Pair:

Z7 N 8
=
Z8 N7
Z7 500
=
Z 8 400
Z7 = 1.25Z 8
W.K.T. Z9 + Z10 = 52 = Z7 + Z8
1.25Z8 + Z9 = 52
Z8 = 23.11 24
Z7 = 28
Z7 = 28 , Z8 = 24
First Pair:

Z5 N6
=
Z6 N 5
20 400
= Z5 = 20 ( driver )
Z 6 1000
Z6 = 50
Z5 = 20 , Z6 = 50
Second Pair:

Z1 N 2
=
Z2 N1
Z1 500
=
Z 2 1000
Z1 = 0.5Z 2
W. K. T. Z5 + Z6 = 70 = Z1 + Z 2
1.5Z2 = 70
Z2 = 46.7 47
Z1 = 23
Z1 = 23 , Z 2 = 47
Third Pair:

Z3 N 4
=
Z4 N3
Z3 630
=
Z 4 1000
Z 3 = 0.63Z 4
W. K. T. Z 3 + Z 4 = Z 5 + Z6 = 70
1.63Z 4 = 70
Z 4 = 42.94 43
Z 3 = 27.
Z 3 = 27 , Z 4 = 43

the relation.
60P
T14 =
2 N
60  5  10 3
=
2   100
T14 = 477.46 Nm.
T 2T14
Ft14 = =
r Z 14  m
2  477.46  10 3
=
50  m
19098.4
Ft14 =
m
Ft14
m=
m.m

m
19098.4
m= m
10  100
19.098
m2 =
m
m = 2.67 mm.
m = 3mm .

table 26.
 Zx + Zy 
a= m
 2 
 Z + Z4 
a1 =  3 m
 2 
 27 + 43 
= 3
 2 
a1 = 105mm .
 Z + Z8 
a2 =  9 m
 2 
 28 + 24 
= 3
 2 
a 2 = 78mm .
 Z + Z 12 
a 3 =  11 m
 2 
 43 + 27 
= 3
 2 
a1 = 105mm .
W.K.T  b = 10  m
= 10  3
b = 30mm
L = 25 + 10 + 7b + 20 + 4b + 20 + 4b + 10 + 25
= 110 + 15b
= 110 + 15  30
L = 450 mm
(ix) To find normal load on gear 14 (Fn)
Ft14
Fn =  = 20FD
cos 
6366.13
=
cos 20
Fn = 6774.7 N
(x) To find maximum bending moment (M).
M=
( Fn .L )
4
6774.7  450
=
4
M = 7.62  10 5 Nmm.
(xi) To find the equivalent torque. (Teq)
Teq = M 2 + T42
= ( 7.62  10 ) + ( 477.46  10 )
5 2 3 2
= 8.99  10 5 Nmm
(xii) To find the diameter of the spindle (ds)
16Teq
ds = 3
  
16  8.99  10 5
= 3
 55
ds = 43.66 mm
ds = 50mm .
(g) Diameter of shaft 1.
60P
Torque T =
2 N
60  5  10 3
=
2   1000
= 47.75 Nm .
W.K.T T = 0.2d13   .
47.75  103 = 0.2  ds1

3
 55
ds1 = 16.31 mm.
(h) Diameter of shaft 2.
60  5  10 3
 T=
2   400
= 119.36 Nm .
W.K.T  T = 0.2d32   .
119.36  103 = 0.2  ds2

3
55
ds2 = 22.14 mm.
(i) Diameter of shaft 3.
60  5  10 3
 T=
2   250
T = 190.98 Nm .
W.K.T  T = 0.2d33   .
190.98  103 = 0.2  ds3

3
55
ds3 = 25.89 mm.
16. A gear box is to give 18 speeds for a spindle of a milling machine.

Maximum and minimum speeds of the spindle are to be around 650 and
35 rpm respectively. Find the speed ratios which will give the desired
speeds and draw the structural diagram and kinematic arrangement of
the drive. (April/May 2018)
Given data:
n = 18
N min = 35rpm
N max = 650rpm
Nmax Nmin =n−1
650 35 = 18 −1
 = ( 18.571)
1 17
 = 1.87

Then 1.06  ( 1.06  1.06 ) = 1.91 … Skip 2 speeds

PSGDB 7.20, 7.19
200, 236, 280, 335, 400, 475, 560 and 670 rpm

horizontal lines)


lines)
17. A nine-speed gear box used as a headstock gear box of a turret

lathe is to provide a speed range of 18 rpm to 1800 rpm. Using standard
step ratio draw the speed diagram, and the kinematic layout. Also find
and fix the number of teeth on all the gears. (Nov/Dec 2018)
Given data:
n =9
N min = 180rpm
N max = 1800rpm
N max
= n −1
N min
1800
= 9 −1
180
1
 = (10) 8
 = 1.333

Then 1.06 1.06 1.06 1.06 = 1.338 skip 4 speeds

P1 = 3 p2 = 3 Note: where X1 = 1; X2 = p1 = 3
No. of shafts = No. of stages +1 (2+1=3 shafts) (so draw 3 horizontal lines)
No .of stages: 2(p1 ( X1 ).p2 ( X2 )
p1 = 3 p2 = Note: Where X1 = X2 = p1 = 3
Formulae given z1 = N 2
z2 N1
Take stage – 2

z11 N12
=
z12 N11
20 180
=
z12 560
z12 = 62.22  63
Z11 = 20, Z12 = 63
Take stage – 2

We know that,
z 7 N8
=
z8 N 7
z 7 425
=
z8 560
z 7 = 0.76z8 − − (i)
So we can write
z7 + z8 = z11 + z12 = 20 + 63 = 83 (ii)
z8 = 47.16  48
z 7 = 83 − 48 = 35
z 7 = 35 z8 = 48
Take stage – 2

We know that,
z 9 N10
=
z10 N9
z 9 1000
=
z10 560
Z9 = 1.786 Z10 − − (iii)
So we can write
Z9 + Z10 = Z11 + Z12 = 20 + 63 = 83 − − (iv)
Z10 = 29.79  30
Z9 = 83 − 30 = 53
Z9 = 53 Z10 = 30
Take stage -1

z5 N 6
=
z6 N5
20 1320
=
z12 560
z 6 = 47.14  48
Take stage – 1

We know that,
z1 N 2
=
z 2 N1
z1 750
=
z 2 1320
Z1 = 0.57z 2 − − −(v)
So we can write
z1 + z2 = z5 + z6 = 20 + 48 = 68 − − −(vi)
z 2 = 43.3  44
z1 = 68.44 = 24
Z1 = 24 Z2 = 44
Take stage – 1

We know that,
z3 N 4
=
z 4 N3
z 3 1000
=
z 4 1320
Z3 = 0.76z 4 − − (vii)
Z 4 = 38.64  39
Z3 = 68 − 39 = 29
Z3 = 29 Z 4 = 39
18. Sketch the speed diagram and the kinematic layout for an 18
speed gear box the following data. Motor speed =1440rpm, minimum
output speed 16 rpm, maximum output speed= 800rpm, arrangement
2X3X3. List the speeds of all the shafts when the output speed is 16
rpm. (Nov/Dec 2018)
Given data:
n = 18
N min = 35rpm
N max = 650rpm
*** Similar to this problem, Change the minimum and maximum speed
Nmax Nmin =n−1
650 35 = 18−1
 = ( 18.571)
1 17
 = 1.87

Then 1.06  ( 1.06  1.06 ) = 1.91 … Skip 2 speeds

PSGDB 7.20, 7.19
200, 236, 280, 335, 400, 475, 560 and 670 rpm

horizontal lines)


lines)
19. Design a gear box with 12 speed from a source of motor with a
speed of 1600rpm. The required range is from 160rpm to 2000rpm.
(April/ May 2019)
Given data:
n = 12
Nmin = 25rpm
Nmax = 1440 rpm
P = 2.25KW
*** Change the Speed range
1. Selection of spindle speeds:
We know that,
N max
n −1 =
N min
600
12 −1 =
25
 = 1.335
We can write, 1.06  (1.6 1.06 1.06 1.06) = 1.338
So, ϕ = 1.06 satisfies the requirement. Therefore the spindle from R 40 series skipping four
speeds, are given as
25, 33.5, 45, 60, 80, 106, 140, 190, 250, 250, 335, 450 and 600 rpm.
2. Ray diagram: The ray diagram is constructed, as shown in fig.
Structural formula: 3(1) 2(3) 2(6)
Step 3:
N min 25 1
= = 0.31 and
N input 80 4
N max 140
= = 1.75  2
N input 80
Step 2:
N min 80 1
= = 0.57 
N input 140 4
N max 190
= = 1.36  2
N input 140
Step 1:
N min 140 1
= = 0.311 
N input 450 4
N max 250
= = 0.56  2
N input 450
3. Kinematic arrangement: The kinematic arrangement for the given 12 speed gear box is
constructed, as shown in fig.

4. Calculation of number of teeth on alt gears: The number of teeth on all gears are
calculate as below, following the procedure used
Stage 3:
First pair: Consider the ray that gives, maximum reduction i.e, from 80 r. p. m to 25 r. p. m.
The corresponding gears are 13 and 14 on shaft 4.
We know that, Zmin ≥ 17. Therefore assume z13= 20 (driver)
z13 N14 20 25
= or = ; z14 = 64
z14 N13 z14 80
Second pair: Consider the other ray that gives speed increase form 80 r. p. m. To 140r. p. m.
The corresponding gears are 11 and 12.
z11 N12 140

= = or z11 = 1.75z12 − − (i)
z12 N11 80
We also know that the sun of number of teeth of mating gears should be equal.
z11 + z12 = z13 + z14 = 20 + 64 = 84 − − (ii)
On solving equations (i) and (ii), we get
z12 = 30.5  31 and z11 = 84 − 31 = 53
Stage 2:

First pair: Consider the ray that gives maximum reduction from 140 r.p.m to 8 r.p.m. The
corresponding gears are 9 and 10. Assume z9 = 20 (driver).
z9 N10 20 80
= or = ; z10 = 35
z10 N9 z10 140
Second pair: Consider the other ray that gives speed increase from 140 r.p.m to 190 r.p.m.
The corresponding gears are 7 and 8.
z 7 N8 190
= = or z 7 = 1.357 z8 − − (iii)
z8 N 7 140
z 7 + z8 = z9 + z10 = 20 + 35 = 55 − − (iv)
On solving equation (iii) and (iv), we get
z8 = 23.3 = 24 and z 7 = 55 − 24 = 31
Stage 1:
First pair: Consider the ray that gives maximum from 450 r.p.m to 140 r.p.m. The
corresponding gears are 5 and 6. Assume z5 = 20 (driver)
z5 N 6 20 140
= or = ; z 6 = 64.28 = 65
z 6 N5 z 6 450
Second pair: Consider the ray that gives speed reduction from r.p.m to 190 r.p.m. The
corresponding gears are 3 and 4.
z3 N 4 190
= = or z3 = 0.422z 4 − − (v)
z 4 N3 450
z3 + z 4 = z5 + z 6 = 20 + 65 = 85 − − (vi)
On solving the equations (v) and (vi), we get
z 4 = 59.77  60 and z3 = 85 − 60 = 25
Third pair: Consider the ray that gives speed reduction from 450 r.p.m to 250 r.p.m. The
corresponding gears are 1 and 2.
z1 N 2 250
= = or z1 = 0.555z 2 − − (vii)
z 2 N1 450
z1 + z 2 = z3 + z 4 = 60 + 25 = 85 − − (viii)
On solving the equations (vii) and (viii), we get
z 2 = 54.66  55 and z1 = 85 − 55 = 30

20. A 9-speed box, used as a head stock gear box of a turret lathe, is
to provide a speed range of 180 rpm to 1800 rpm. (April/ May 2019)
Given data:
n =9
N min = 180rpm
N max = 1800rpm
N max
= n −1
N min
1800
= 9 −1
180
1
 = (10) 8
 = 1.333

Then 1.06 1.06 1.06 1.06 = 1.338 skip 4 speeds
✓ Structural formulae: 3(1) 3(3)

✓ P1 = 3 p2 = 3 Note: where X1 = 1; X2 = p1 = 3
✓ No. of shafts = No. of stages +1 (2+1=3 shafts) (so draw 3 horizontal lines)


No .of stages: 2(p1 ( X1 ).p2 ( X2 )
p1 = 3 p2 = Note: Where X1 = X2 = p1 = 3


z1 N 2
Formulae given =
z 2 N1
Take stage – 2

z11 N12
=
z12 N11
20 180
=
z12 560
z12 = 62.22  63
Z11 = 20, Z12 = 63
Take stage – 2

We know that,

z 7 N8
=
z8 N 7
z 7 425
=
z8 560
z 7 = 0.76z8 − − (i)
So we can write
z7 + z8 = z11 + z12 = 20 + 63 = 83 (ii)
z8 = 47.16  48
z 7 = 83 − 48 = 35
z 7 = 35 z8 = 48
Take stage – 2

We know that,
z 9 N10
=
z10 N9
z 9 1000
=
z10 560
Z9 = 1.786 Z10 − − (iii)
So we can write
Z9 + Z10 = Z11 + Z12 = 20 + 63 = 83 − − (iv)
Z10 = 29.79  30
Z9 = 83 − 30 = 53
Z9 = 53 Z10 = 30
Take stage -1


z5 N 6
=
z6 N5
20 1320
=
z12 560
z 6 = 47.14  48
Take stage – 1

We know that,
z1 N 2
=
z 2 N1
z1 750
=
z 2 1320
Z1 = 0.57z 2 − − −(v)
So we can write
z1 + z2 = z5 + z6 = 20 + 48 = 68 − − −(vi)
z 2 = 43.3  44
z1 = 68.44 = 24
Z1 = 24 Z 2 = 44
Take stage – 1

We know that,

z3 N 4
=
z 4 N3
z3 1000
=
z 4 1320
Z3 = 0.76z 4 − − (vii)
Z 4 = 38.64  39
Z3 = 68 − 39 = 29
Z3 = 29 Z 4 = 39
21. Design an 18 speed gear box from a source of 1000 rpm. Maximum and
minimum speeds are to be around 650rpm and 35rpm respectively. (April/
May 2019)
Given data:
n = 18
N min = 35rpm
N max = 650rpm
Nmax Nmin =n−1
650 35 = 18 −1
 = ( 18.571)
1 17
 = 1.87

Then 1.06  ( 1.06  1.06 ) = 1.91 … Skip 2 speeds


PSGDB 7.20, 7.19
200, 236, 280, 335, 400, 475, 560 and 670 rpm

horizontal lines)



lines)

UNIT-V CLUTCHES AND BRAKES

(PART-A)
1. Differentiate between uniform pressure and uniform wear theories
adopted in the design of clutches?
In clutches, the value of normal pressure, axial load for the given
clutch is limited by the rate of wear that can be tolerated in the brake links.
Moreover the assumption of uniform wear rate gives a lower calculated
clutch capacity than assumption of uniform pressure. Hence clutches are
usually designed on the basis of uniform wear.
2. In a hoisting machinery, what are the different energies absorbed by a

brake system?
❖ Kinetic energy of translation:
❖ Kinetic energy of rotation:
❖ Potential or gravitational energy:
Total energy absorbed:
3. If a multidisc clutch has 6 discs in driving shaft and 7 discs in driven

shaft, then how many number of contact surfaces it will have?
Given data:
Number of pair of contact surfaces,
4. Why in automobiles, braking action when travelling in reverse is not as

effective as when moving forward?
When an automobile moves forward, the braking force acting in the
opposite direction to the direction of motion of the vehicle. Whereas in
reverse travelling the braking force acts in the same direction to the direction
of motion of the vehicle. So it requires more braking force to applying brake.
5. Name the profile of cam that gives no jerk?

Circle- arc cam gives no jerk. Because the derivative of acceleration of
cam is zero.
6. What is meant by positive clutch?
Positive clutches means to have interlocking engaging surfaces to

form a rigid mechanical junction.
7. What is the function of clutch in a transmission system?

❖ To connect and disconnect the shafts at will.
❖ To start or stop a machine (or a rotating element) without starting
and stopping the prime mover.
❖ To maintain constant speed, torque and power.
❖ For automatic disconnect, quick start and stop, gradual starts,
non-reversing and over-running functions
8. What is the significance of pressure angle in cam design?
The pressure angle is very important in cam design as it represents
steepness of the cam profile. If the pressure angle is too large, a
reciprocating follower will jam in its bearings
9. Mention few application of cams.
The cam can be a simple tooth, as is used to deliver pulses of power

to a stream hammer, for example, or an eccentric disc or other shape that
produces a smooth reciprocating (back and forth) motion in the follower,
which is a lever making constant with the cam.
Also it is used in IC engines for value opening and closing
10. What do you mean by self-energizing brake?
When the moment of applied force and the moment of the frictional
force are in the same direction, then frictional force helps in applying the
brake. This type of brake is called us self-energizing brake.
11. What is a clutch and where it is used?

Clutch is machine, component used as temporary coupling: and is used
mainly in automobiles for engaging and disengaging the driving shaft where
periodical engagement is required.
12. What is meant by positive clutch?

A positive clutch transmits power from driving shaft to the driven shaft
by jaws or teeth is called positive clutch. No slipping is there.
13. By what means, power is transmitted by clutches?

In clutches, power transmission is achieved through
(a) Interlocking (b) Friction (c) Wedging
14. Why are cone clutches better than disc clutches?
Since the cone discs are having large frictional areas and they can
transmit a larger torque than disc clutches with, the same oil diameter and
actuating force and hence cone clutches are preferred over disk clutches. But
usually cone clutches are mainly used in low peripheral s applications.
15. What factors should be considered when designing friction

clutches?
❖ The friction materials for the clutch should have high co-efficient
of friction and-they should not be affected by moisture and oil.
❖ May be light in weight.
❖ The design is in such a way that the engagement should be made
without shock and fast
❖ Disengagement without drag.
16. Why should the generated heat be dissipated in clutch
operation?
In order to save the friction plates and materials from melting by the
heat produced during operation, the generated heat should be dissipated.
17. Name the two theories applied for the design of friction clutches.
1. Uniform Pressure theory
2. Uniform wear theory
18. Name four materials used for lining of friction surfacing clutches.
❖ Wood
❖ Leather
❖ Asbestos based friction materials
❖ Powdered metal friction materials
19. State the advantages of cam mechanisms.
Cams are used for transmitting desired motion to a follower by direct

contact. Cam mechanisms are used in the operation of IC engine valves.
20. Why should the temperature rise be kept within the permissible
range in brakes?
Otherwise the brake drawn will be overheated and hence the brake shoes
may be damaged due to overheating.
21. Differentiate a brake and a dynamometer. (April/May 2017)
A dynamometer is a brake incorporating a device to measure the

frictional resistance applied.
22. Double shoe brakes are preferred than single shoe brake. Why?
(April/May 2017)
In a single shoe brake normal force introduces transverse loading on

the shaft on which the brake drum is mounted two shoes are often used to
provide braking torque.
23. Write the difference between dry and wet clutch. (Nov/Dec 2017)
❖ When a clutch operates in the absence of a lubricant, then that
the clutch is known as dry clutch. In dry clutch the torque
capacity is high but the heat dissipating capacity is low
❖ When the clutch operates ‘wet’ (i.e., with lubrication), then
torque capacity is low but the heat dissipating capacity is high
24. What is meant by self-energizing brakes? (Nov/Dec 2017
When the moment of applied force and the moment of the frictional
force are in the same direction, then frictional force helps in applying the
brake. This type of brake is called us self-energizing brake.
25. What are the types of brakes used in modern vehicles?
(April/May 2018)
Disc brakes, drum brakes and internally expanding brakes
26. How does the function of a brake differ from that of a clutch?
(April/May 2018)
A clutch connects two moving members of a machine, whereas a brake

connects a moving member to a stationary member.
27. Name few commonly used friction materials. (Nov/Dec 2018)
Wood, Cork, Leather, Asbestos based friction materials, and powdered

metal friction materials.
28. What do you meant by self-locking brake? (Nov/Dec 2018)

When the moment of applied force and the moment of the frictional force
are in the same direction, then frictional force helps in applying the brake.
This type of brake is called us self-energizing brake.
29. How does the function of a brake differ from that of a clutch? (April/May
2019)
Brake is a mechanical device by means of which motion of a body is retarded
for slowing down or to bring it to rest, by applying frictional resistance
30. Why are cone clutches better than disc clutches? (April/May 2019)
i. In disc clutches, friction lined flat plates are used
ii. In cone clutches, friction lined frustum of cone is used
PART B
1. An automobile engine has an output of 80KW at 3000rpm. The mean

diameter of the clutch is 200mm with a permissible pressure of 0.2
N/mm2. Friction lining is of asbestos with M=0.22 . What should be the
inner diameter of the disc? Take both the sides of the plates with
friction lining as effective. There are 8 springs and axial deflection in
spring is limited to 10 mm. Given G=80KN/mm2 spring index may be
taken as b.
Given data:
P = 80KW
N = 3000rpm
d1 = 200mm
P max = 0.2 N mm 2
M = 0.22
No.ofSprings = 8
C=6
G = 80 KN mm 2
Axial deflection = 10mm.
Step 1: To find the inside diameter of the plate.
Case: 1: To find the torque transmitted.
60P
T=
2 N
60  80  10 3
=
2   3000
= 254.65N.m
Case 2: To find the axial force acting on the friction faces.
R
W = AP =4
b
R
= 2Rb  P b=
4
R
= 2  R   0.2 P = Pmax
4
W = 0.314 R 2
Case 3: To find the mean radius of the friction lining (R)
T = M W R  n
254.65  10 3 = 0.22  0.314  R 2  R  2  n = 2
R = 122.61mm
r1 + r2
W  K  T  R1 =
2
100 + r2
122.61 =
2
r2 = 145.22mm
Case 4: To find the inside diameter of the Plate.
d2 = 2  r2
= 2  145.22
d2 = 290.44mm
Step 2: To find the axial force to engage the clutch.
W = 0.314  R 2
= 4720.43N
Step 3: To find the spring wire diameter. (d)
In order to allow for adjustment and for Maximum torque, the spring
is designed for an overload of 25%
 Total load on 
 = 1.25  W
the springs 
= 1.25  4720.43
= 5900.54N
Since there are 8 springs, therefore the maximum load on each

spring.
5900.54
Ws =
8
= 737.56N
We know that Wahl’s stress factor
4C − 1 0.615
K= +
4C − 4 C
4  6 − 1 0.615
= +
46 − 4 6
23 0.615
= +
20 6
K = 1.2525
Maximum stress induced in the wire ( s ) ,
Assume s = 600mpa
8Ws C
s = K 
d 2
8  737.56  6
600 = 1.2525 
 d 2
d 2 = 23.524
d = 4.85mm
From PSGDB 13.1, We shall take a standard wire of size SWG 6 having
diameter. 4.88mm.
2. Derive an expression to determine the braking torque for an internal

expanding shoe brake.
The figure shows an internal shoe automatic brake. It consists of two

semi-circular shoes S1 and S2 which are lined with a frictional material
such as ferrodo. When brakes are applied, can rotates which pushes the
shoes outwards to press the brake lining against the rim of the drum. As
soon as the brakes are off, the shoes are pushed inside by the spring.
It may be noted that for the anticlockwise direction the left side shoe is
known as primary or leading shoe, while the right hand shoe is known as
trailing or secondary shoe.
Determination of pressure and Brake torque:
Consider the forces on the brake when the drum rotates in

anticlockwise direction as shown in figure.
Let P1 = Maximum intensity of normal pressure
PN = Normal pressure
r = Internal radius of the drum
b = width of the brake lining
TB = Braking torque
F1 = Force exerted by the cam on the loading or primary shoe.
F2 = Force exerted by the cam on the trailing or secondary shoe.
RN = Normal force.
F = Frictional force.
M= Co-efficient of friction between shoe and drum.
MN = Moment of normal force
MF = Moment of Frictional force.
Consider a small element AB of brake lining subtending an angle  at the

centre of the drum. Join 01 to 0. It is assumed that the pressure distribution
on the shoe is nearly uniform. However the shoe wears out more at the free
end. The rate of wear of the shoe lining varies directly as the perpendicular
distance from 01 to B ie 01 c.
From the geometry of the figure b.
O1C = 00, sin 
and normal pressure at B,
PN  sin  or PN = P1 sin 
Normal force acting on the element ,
R N = Normal pressure  Area of the element
= PN  ( b  r  ) = P1 sin b  r 
Friction force on the element
F = M  R N = MP1 sin  b  r  
Braking torque due to the element about 0
TB = F  r
= MP1  sin  b  r   r
= MP1 sin  br 2 
Total braking torque for whole shoe about 0

2
TB = MP1 br 2  sin .d

1
= MP1 br 2  − cos 2


1
TB = MP1 br 2  cos 1 − cos 2 
3. A Power of 20 KW is to be transmitted through a cone clutch at 500 rpm. For

uniform wear condition, find the main dimensions of clutch and shaft. Also
determine the axial force required to engage the clutch. Assume co-efficient
of friction as 0.25, the maximum normal pressure on the friction surface is
not to exceed 0.08 Mpa, and take the design stress for the shaft materials as
40 Mpa.
Given data:
P = 20KW
N = 500rpm
M = 0.25
Pmax = 0.08mpa
Pshaft = 40mpa.
Step 1: To find the Torque transmitted.
60P
T=
2 N
60  20  10 3
=
2   500
T = 382 Nm.
Step 2: To find b, R, r1 and r2.
R
b= , semi cone angle =15
2
r1 − r2
For cone clutch = sin 
b
r1 − r2
b=
sin 
r1 + r2
Mean radius R=
2
r1 − r2 r1 + r2
 =
sin  4
r1 − r2 r1 + r2
=
sin 15 4
By solving the above equation r1 = 1.139 r2 1
Design Torque  T  = T  K s
Assume K s = 2.5
 T  = 382  2.5
= 955 Nm.
For uniform wear,
 T  = 2MPmaxP12 b
R
955  10 3 = 2   0.25  0.08  R 2 
2
R = 247.7mm.
r1 + r2
Also, R =
2
r1 + r2
247.7 =
2
r1 + r2 = 495.4 2
Solving 1 and 2
Inner radius r1 = 264mm.
Outer radius r2 = 231.6mm.
R
Face width b=
2
247.7
=
2
b = 123.85mm.
Step 3: To find axial force required to engage the clutch (W).
W = 2 c ( r1 − r2 ) .
= 2  Pmax r2 ( r1 − r2 )  c = Pmax  r2  .
= 2   0.08  106  0.2316(0.264 − 0.2316).
= 3771.84 N.
Step 4: To find the diameter of the shaft:
 T  =  16  ds3  Pshaft
955 =   d s3  40  10 6
16
ds = 0.0495m .
ds = 49.5 mm.
4.Design a differential band brake for a winch lifting a load of 20 KN through a

steel wire rope wound around a barrel of 600mm diameter. The brake drum keyed
to the barrel shaft, is 800mm diameter and the angle of lap of the band over the
drum is about 240° operating arms of the brake are 50mm and 250mm. The length
of operating level is 1.6m.
Given data:
Load = 20 KN
Barreldiameter = 600mm.
 = 240 = 240   = 4.188rad.

180
M = 0.25.
Step 1: Calculation of braking torque. (TB)
TB = Load  Barrel radius.
 0.6 
= 20  10 3   
 2 
= 6000 Nm
Step 2: Brake drum diameter. (D).
D = 800mm (given).
Step 3: Calculation of T1 and T2:
T1
Tension ratio , = e M = e 0.254.188
T2
T1 = 2.849 T2
TB = ( T1 − T2 )  r
 0.8 
6000 = ( T1 − T2 )   
 2 
T1 − T2 = 15000
2.849T2 − T1 = 15000
T2 = 3897.12 N
 T1 = 11102.88 N.
Step 4: Thickness of band. (t).
t = 0.005 D
= 0.005  800
t = 4mm.
Step 5: Calculation of band width. (w).
T1
t =  t 
wt
11102.88
 50 = t  = 50 N/mm2 is assumed .
w 4
w = 55.51
w = 56 mm
Step 6: Check for bearing pressure.
T1
Pmax =
w.r.
11102.88
=
 800 
56   
 2 
= 0.495 N/mm 2
For steel band on steel drum. P  = 1.5N /mm 2

We find Pmax  P  ,  the design is safe.
Step 7: Calculation of the force to be applied at the end of the lever.
Refer figure (b) , taking moments about O , we get.
F  1600 + T1  50 = T2  250
F  1600 + 11102.88  50 = 3897.12  250
F = 261.96 N.
5. Design a cam for operating the exhaust valve of an oil engine. It is

required to give equal uniform acceleration and retardation during
opening and closing or the valve, each of which corresponding to 60° of
cam rotation. The valve should remain in the fully open position for 20°
of cam rotation. The lift valve is 50mm and the least radius of
the cam is 50mm, the follower is provided with a roller of 50mm
diameter and its line of stroke passes through the axis of the cam.
Construction: First of all, the displacement diagram, as shown in Fig.1., is

drawn as discussed in the following steps:
1. Draw a horizontal line ASTP such that AS represents the angular

displacement of the cam during opening (i.e., outstroke) of the valve (equal to
60°) to some suitable scale. The line ST represents the dwell period of 20°
i.e., the period during which the valve remains fully open and TP represents
the angular displacement during closing (i.e., return stroke) of the valve
which is equal to 60°.
2. Divide AS and TP into any number of equal even parts (say six).
3. Draw vertical lines through points 0, 1, 2, 3, etc., and equal to the lift of the
valve (i.e., 50 mm).
4. Divide the vertical lines 3 f and 3 ‘f’ into six equal parts as shown by the
points a, b, c, .. and a’, b’, c’ in Fig.1.
5. Since the valve moves with equal uniform acceleration and retardation,
therefore the displacement diagram for opening and closing of a valve
consists of double parabola.
6. Complete the displacement diagram as shown in Fig.1. Now, the profile of
the cam, with a roller follower when its line of stroke passes through the axis
of the cam, as shown in Fig.2 is drawn in the usual way.
6. Explain with a neat sketch the working of a single plate clutch. Derive
an expression for the torque to be transmitted by clutch assuming
i. Uniform pressure condition and
ii. Uniform wear condition
Consider two friction surfaces held together by an axial thrust W, as shown

in Fig. (A)
Let T = Torque transmitted by the clutch,
P = Intensity of axial pressure acting on contact surfaces,
r 1 = External radius of friction surface,
r 2 = Internal radius of friction surface, and
µ = Coefficient of friction.
Consider an elementary ring of radius r and thickness dr as shown in Fig.

10.3 (b).
Area of the elemental ring = 2r.dr
Normal or axial force on the ring, W = Pr essure  Area = p  2r  dr
and the frictional force on the ring acting tangentially at radius r is given by
Fr =   W = p  2 r  dr
Frictional torque acting on the ring, Tr = Fr  r
Tr = p  2 r  dr  r
= 2pr2dr
The design of friction clutch is done based on any one of the following
assumptions:
(i) When there is a uniform pressure, and

(ii) When there is a uniform wear.
(i) Considering uniform pressure:
Area of the friction surface, A =  r12 − r22 ( )

Uniform intensity of pressure (p) is given by
W W
p= =
A  ( r1 − r22 )
2
Total frictional torque acting on the friction

surface or on the clutch is obtained by integrating the equation of the
frictional torque on the elementary ring within the limits from r 2 to r1.
r1 r1
 r3   r3 − r3 
 T =  2 pr dr = 2 p   = 2 p  1 2 
2
r2  3  r2  3 
Substituting the value of p from equation (1)
W  r13 − r23 
T = 2    
 ( r12 − r22 )  3 
or
2  r3 − r3 
T=  W  12 22  = WR
3  r1 − r2 
where R = Mean radius of friction
surface
2  r13 − r23 
R=  
3  r12 − r22 
(ii) Considering uniform wear: For uniform

wear, the intensity of pressure varies inversely with the distance.
Therefore,
C
p  r = cons tan t = C or p =
r
So
p1  r1 = p2  r2 = C
Where p1 and p2 are intensities of pressure at radii r1 and r2 respectively.
We know that normal or axial force on the elementary ring,
 C
W = p2rdr = 2 ( p  r ) dr = 2Cdr  p =
r 
 Total force acting on the friction surface,
r1
W =  2 Cdr = 2 C  r r1 = 2 C ( r1 − r2 )
r
2
r2
or
W
C=
2  ( r1 − r2 )
We know that the frictional torque acting on the

elementary ring,
C 2  C
Tr = 2 pr 2 dr = 2    r  dr  p = r 
r
= 2   C  r  dr
 Total frictional torque on the friction surface,

r1 r1
 r2   r2 − r2 
T =  2   C  r  dr = 2 C   = 2 C  1 2 
r2  2  r2  2 
T = C r12 − r22 
Substituting the value of C from equation (4)
W
T =    ( r12 − r22 )
2  ( r1 − r2 )
1
T=    W ( r1 + r2 ) = .W.R
2
Where R = Mean radius of the friction
surface
or r1 + r2
R=
2
Note:
1. In general, total frictional torque acting on the friction surface or on

the clutch is given by
T = n   W  R
Where n = Number of pairs of friction or contact surfaces.
2. For single disc plate clutch, n=2. Since both the sides of the disc are
in contact.
7. A multiplate clutch with both sides effective transmits 30KW at

360rpm. Inner and Outer radii of the clutch discs are 100mm and 200
mm respectively. The effective co-efficient of friction is 0.25. An axial
load of 600N is applied. Assuming uniform wear conditions, find the
number of discs required and the maximum intensity of pressure
developed.
Given data:
P = 30KW
N = 360rpm.
r2 = 100mm.
r1 = 200mm
M = 0.25
w = 660N.
Assuming uniform wear, axial force exerted is given by,
w = 2 c ( r1 − r2 ) .
600 = 2   Pmax  r2 ( r1 − r2 )  c = Pmax  r2 
600 = 2   Pmax  100 ( 200 − 100 )
600 = 2   Pmax  0.1 ( 0.2 − 0.1)
Pmax = 9.55  103 N m2
Torque transmitted by a single friction surface is given by.
r +r 
T = Mw 1 2 
 2 
 0.2 + 0.1 
= 0.25  600  
 2 
torque required 
 T = 22.5Nm
per surface 
The total torque is required can be calculated as given below
Power P=2πNT/60
30x103= 2xπx360xT/60
T=795.77 Nm
No.of friction surfaces required= total torque required/ torque required per surface
= 795.77/22.5
=35.36
=36
Total number of plates= no. of pairs of contact surface+1
=36+1=37
8. A 50 Kg wheel , 0.5 m in diameter turning at 150 rpm is stationary bearing is brought to
rest by pressing a brake shoe radially against the rim with a force of 100N. If the radius of
gyration of wheel 0.2m. How many revolutions will the wheel make before coming to rest?
Assume that the co-efficient of friction between shoe and rim has the steady value of 0.25.
Given data:
m = 50Kg
D = 0.5m.
N = 150rpm.
F = 100N.
K = 0.2m.
M = 0.25
Take, l=0.28m
 = 60 From PSGDB 7.129
Step 1: To find Braking torque.

 = 60 
180
 = 1.05rad.
Tension ratio is given by
T1
= e M = e 0.251.05
T2
T1 = 1.3T2 1
Moments about the fulcrum 0,
F  l = T1  a
100  0.28 = T1  0.25
T1 = 112Nm.
From eqn 1 T1 = 1.3T2
112 = 1.3T2
T2 = 86.15Nm.
Braking torque is given by TB = ( T1 − T2 ) r
= ( 112 − 86.15 ) 0.25
= 6.46Nm.
Step 2: No. of turns of flywheel before it comes to rests. (n):
We know that kinetic energy of flywheel.
K.E = 1  mK 2  w 2
2
2
2  2   150 
= 1  50  ( 0.2 )   
2  60 
K.E = 246.74Nm.
This kinetic energy is used to overcome the work done due to braking torque (TB).
K.E = TB  w
246.74 = 6.46  2  n.
n = 6.08 revolutions.
9.A multiple clutch, steel on bronze is to transmit 6KW power at 750 rpm. The inner radius of contact
surface is 4 cm and outer radius is 7cm. The clutch plates operate in oil, so the co – efficient of friction is
0.1. The average pressure is 0.35 N/mm2. Determine (i) The total number of steel and bronze friction
discs. (ii) Actual axial force required. (iii) Actual average pressure (iv)Actual maximum pressure
Given data:
p = 6kW
N = 750rpm
r2 = 4cm = 40mm
r1 = 7cm = 70mm
M = 0.1
Pavg = 0.35N / mm 2
Step 1:- To find P1 and P2.
P1 + P2
Pavg = = 0.35
2
P1 + P2 = 0.7 − − −(1)
P1r1 = p 2 r2 = c
P1 r1 40
= =
P2 r2 70
4
P1 =  P2 − − −(2)
7
Solving (1) and (2)
P2 = 0.4454 N / mm 2 = Pmax
P1 = 0.2545
Step 2:- To find ‘c’
c = Pmax  r2
= 0.4454  40
c = 17.82 N / mm
Step 3:- To find axial force:
W = 2c(r1 − r2 )
= 2    17.82(70 − 40)
W = 3358.99 N
Step 4:- To find the torque transmitted by a single friction surface:
r +r 
T = M W 1 2 
 2 
 70 + 40 
= 0.1  3358.99   
 2 
T = 18474.45 N / mm
Step 5:- To find total torque
2NT
P=
60
2    750  T
6  10 =
3
60
T = 76.39 Nm
Step 6:- To find number of friction surface required
76.39
n= = 4.13  5
18.48
Step 7:- To find total number of plates
Total number of plates = 5+1 =6 surface
Step 8:- To find the actual torque (T1)
T
n=
T1
76.39
5=
T1
T1 = 15.278 Nm
Step 9:- To find the actual axial force (W)
r +r 
T1 = MW  1 2 
 2 
 70 + 40 
15.278  103 = 0.1  W  
 2 
W = 2777.82N
Step 10:- To find actual average pressure:
W = 2c(r1 − r2 )
2777.82 = 2    c(70 − 40)
c = 14.73 N / mm
 c = Pmax  r2
14.73 = Pmax  40
Actual max imum 
 Pmax = 0.368 N / mm
2
pressure 
Step 11:- To find actual average pressure:
4
P1 = P2
7
4
P1 =  0.3684 = 0.2105 N / mm 2
7
P + P 0.2105 + 0.3684
Pavg = 1 2 =
2 2
Pavg = 0.2895 N / mm 2
10. A single shoe brake is shown in figure. The diameter of drum is 250 mm and angle of contact is 90°.
If the operating force of 750 N is applied at the end the of the lever and M = 0.35, Determine the torque
that may be transmitted by the brake.
Given data:
d = 250 mm or r = 125mm
20 = 90 =  rad
2
P = 750N
M = 0.35
Since 20 > 90° therefore equivalent co – efficient of friction
4Msin 
M=
2 + sin 2
4  0.35  sin 45
=
 + sin 90
2
= 0.385
Taking moments about the fulcrum 0, we get,
F
750(250 + 200) + F 500 = R IN  200 =  200
'
F
337500 + F(500) =  200 = 520F
0.385
337500
F=
19.48
F = 17325.46N
Torque transmitted by the 
 TB = F − r
block brake 
= 17325.46 N − 0.125
= 2165.68 NM
11. A multi plate clutch with both sides effective transmits 30KW at 360rpm.
Inner and Outer radii of the clutch discs are 100mm and 200 mm
respectively. The effective co-efficient of friction is 0.25. An axial load of
600N is applied. Assuming uniform wear conditions, find the number of
discs required and the maximum intensity of pressure developed.
(April/May 2017)
Given data:
P = 30KW
N = 360rpm.
r2 = 100mm.
r1 = 200mm
M = 0.25
w = 660N.
Assuming uniform wear, axial force exerted is given by,
w = 2 c ( r1 − r2 ) .
600 = 2   Pmax  r2 ( r1 − r2 )  c = Pmax  r2 
600 = 2   Pmax  100 ( 200 − 100 )
600 = 2   Pmax  0.1 ( 0.2 − 0.1)
Pmax = 9.55  103 N m2
Torque transmitted by a single friction surface is given by.
r +r 
T = Mw 1 2 
 2 
 0.2 + 0.1 
= 0.25  600  
 2 
torque required 
 T = 22.5Nm
per surface 
The total torque is required can be calculated as given below

Power P=2πNT/60
30x103= 2xπx360xT/60
T=795.77 Nm
No.of friction surfaces required= total torque required/ torque required per surface
= 795.77/22.5
=35.36
=36
Total number of plates= no. of pairs of contact surface+1
=36+1=37
12. A single shoe brake is shown in figure. The diameter of drum is 250 mm and
angle of contact is 90°. If the operating force of 750 N is applied at the end that
of the lever and M = 0.35, Determine the torque that may be transmitted by the
brake. (April/May 2017)
Given data:
d = 250 mm or r = 125mm
20 = 90 =  rad
2
P = 750N
M = 0.35
Since 20 > 90° therefore equivalent co – efficient of friction
4Msin 
M=
2 + sin 2
4  0.35  sin 45
=
 + sin 90
2
= 0.385
Taking moments about the fulcrum 0, we get,
F
750(250 + 200) + F 500 = R IN  200 =  200
'
F
337500 + F(500) =  200 = 520F
0.385
337500
F=
19.48
F = 17325.46N
Torque transmitted by the 
 TB = F − r
block brake 
= 17325.46 N − 0.125
= 2165.68 NM
13. A differential band brake is operated by the lever of length 500mm. the
brake drum has a diameter of 500mm and the maximum torque on the
drum is 100Nm. The band brake embraces 2/3rd of the circumference. One
end of the band is attached to a pin 100mm from the fulcrum and the
other end to the pin 80mm from the fulcrum and on the other side of it
when operating force is also acting. Coefficient of friction 0.3. Find the
operating force. Design the steel band, shaft, and key. The permissible
stresses may be taken as 70MPa in tension, 50MPa in shear and 20MPa i9n
bearing. The bearing pressure for the brake lining should not exceed
0.2N/mm2. (Nov/Dec 2017)
Given Data:
d=500mm, TB =1kN-m, µ=0.3, a=OB=500mm, b=OA=80mm, c=OD=100mm,

θ=240°=240xπ/180=4.188 rad
Solution:
To find the operating force
We know that the tension ratio is given by
T1=3.5136 T2 -----1
Braking torque is given by
-------2
Solving the equations 1 & 2
Taking moments about the fulcrum O, we get
Operating force
14. A Power of 20 KW is to be transmitted through a cone clutch at 500

rpm. For uniform wear condition, find the main dimensions of clutch and
shaft. Also determine the axial force required to engage the clutch.
Assume co-efficient of friction as 0.25, the maximum normal pressure on
the friction surface is not to exceed 0.08 Mpa, and take the design stress
for the shaft materials as 40 Mpa. (Nov/Dec 2017)
Given data:
P = 20KW
N = 500rpm
M = 0.25
Pmax = 0.08mpa
Pshaft = 40mpa.
Step 1: To find the Torque transmitted.
60P
T=
2 N
60  20  10 3
=
2   500
T = 382 Nm.
Step 2: To find b, R, r1 and r2.
R r −r
b= , semi cone angle =15 For cone clutch 1 2 = sin 
2 b
r1 − r2
b=
sin 
r1 + r2
Mean radius R=
2
r1 − r2 r1 + r2
 =
sin  4
r1 − r2 r1 + r2
=
sin 15 4
By solving the above equation r1 = 1.139 r2 1
Design Torque  T  = T  K s
Assume K s = 2.5
 T  = 382  2.5
= 955 Nm.
For uniform wear,
 T  = 2MPmaxP12 b
R
955  10 3 = 2   0.25  0.08  R 2 
2
R = 247.7mm.
r1 + r2
Also, R =
2
r1 + r2
247.7 =
2
r1 + r2 = 495.4 2
Solving 1 and 2
Inner radius r1 = 264mm.
Outer radius r2 = 231.6mm.
R
Face width b=
2
247.7
=
2
b = 123.85mm.
Step 3: To find axial force required to engage the clutch (W).
W = 2 c ( r1 − r2 ) .
= 2  Pmax r2 ( r1 − r2 )  c = Pmax  r2  .
= 2   0.08  106  0.2316(0.264 − 0.2316).
= 3771.84 N.
Step 4: To find the diameter of the shaft:
 T  =  16  ds3  Pshaft
955 =   d s3  40  10 6
16
ds = 0.0495m .
ds = 49.5 mm.
15. A single disc clutch having one pair of contacting surface is required to transmit 10kW
at 720 rpm under normal operating condition. Due to space limitation the outer
diameter should be limited to 250 mm. the coefficient of friction is 0.25 and the
permissible intensity of pressure is 0.5 N/mm2 . Use (a) Uniform pressure theory (b)
Uniform wear theory and determine the clutch dimensions. (April/May 2018)
Given Data:
P=10kW
N=720rpm
µ=0.25, , , D=2
For Single plate, z=1
Assumption: Use the hardened steel palte for clutch with single disk
T= 132.64 Nm
1. Uniform Pressure Theory
d=226.18 mm
2. Uniform Wear Theory
Rearranging the terms, we get

d(
-( =0
By solving the above equation d= 224.66= 225 mm
16. A single block brake as shown in Figure, has the drum diameter 250 mm.
The angle of contact is 90˚ and the coefficient of friction between the drum
and lining is 0.35. if the torque transmitted by the brake is 80000 Nmm, find
the force required to operate the brake. (April/May 2018)
17. A single plate clutch transmits 25kW at 900rpm. The maximum

pressure intensity between the plates is 85 kN/m2. The ratio of radii is
1.25. both the sides of the plates are effective and the coefficient of
friction 0.25. Determine (i) The inner diameter of the plate and (ii) The
axial force to engage the clutch. Assume theory of uniform wear.
(Nov/Dec 2018)
18. Determine the capacity and the main dimensions of a double

block brake for the following data. The brake sheave is mounted on the
cast iron drum shaft. The hoist with its load weighs 45kN and moves
downwards with a velocity of 1.15 m/s. the pitch diameter of the hoist
drum is 1.2m. the hoist must be stopped within a distance of 3.25m.
The kinetic energy of the drum maybe neglected. Assume sintered
metal block shoe, equal friction force on each shoe, continuous service
and poor heat condition. (Nov/Dec 2018)
19. A multiple disc clutch is to be designed for a machine tool driven by an electric
motor of 12.5 kW running at 1440 rpm the frequency of clutch engagement is 6/ hr
and the machine tool is to operate continuously 8hrs/day. Determine the
appropriate values for disc inside diameter, outside diameter, total number of
discs and clamping force. (April/May 2019)
20. A double shoe brake as shown in the figure is capable of absorbing a torque of
1500N-m. The diameter of the brake drum is 400mm and the angle of contact for
each shoe is 100˚. If the coefficient of friction between the brake drum and lining
is 0.4, find (i) The spring force necessary to set the brake and (ii) The width of the
brake shoe, if the bearing pressure on the lining material is not exceed 0.3 N/mm2
(April/May 2019)

DTS QB Watermark

Uploaded by

Copyright:

Available Formats

DTS QB Watermark

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DTS QB Watermark

Uploaded by

Copyright:

Available Formats

ME 6601 DESIGN OF TRANSMISSION SYSTEMS

ME-6601 DESIGN OF TRANSMISSION SYSTEMS

UNIT-I DESIGN OF TRANSMISSION SYSTEMS FOR FLEXIBLE

A 6 × 19 wire rope means a rope is made from 6 strands with 19 wires

2. Mention the losses in belt drives?

The centrifugal force produces an additional tension in the belt.

6. What is Chordal action in chain drives?

When chain passes over a sprocket, it moves as a series of chords instead of a

7. Name the few material for belt drives?

9. Define the term ‘crowning of pulley’?

11. What are the types of belts?

15. Specify the purpose of crowning of bets.

17. What are the advantages of chain drives?

20. In what ways wire ropes are superior to fibre ropes?

24. List the chain drive failures? (Nov/Dec 2017)

The four basic modes of chain failures are

26. What are the advantages of Chain Drives? (April/May 2018)

1. A compressor is to run by a motor pulley running at 1440rpm, Speed

Step 1: Calculation of Pulley diameters:

Assume the driven pulley diameter D = 1000 mm.

Case (i): To find the driven pulley speed. (N2).

Case (ii): To find the driver pulley diameter (d):

Case (iii): To find the driver pulley diameter (d):

From PSGDB 7.54, from recommended series of pulley diameters and

The standard diameter for 

Step 2: Calculation of design power in KW.

Rated power ( K w )  Load correction factor ( K s )

Case (i): To find the arc of contact factor (K)

From PSGDB 7.54

Case (ii): To find the small pulley factor (Kd)

Table: Small pulley factor ‘Kd’

From the above table. We take the Kd value 0.8

To find the design power, KW:

Step 3: Selection of belt:

Given: 5 Ply, flat Dunlop belt. Its capacity is given by 0.0118

Step 4: Load rating correction:

From PSGDB 7.54.

= 0.03776KW /Ply /mm

Step 5: Determination of belt width:

From PSGDB 7.52 Specification of transmission belting standard

The standard belt width for 5 Ply belt = 100mm.

Step 6: Determination of Pulley width:

From PSGDB 7.54, Pulley width is given by

Pulley width = Belt width + 18 mm

From PSGDB 7.54, recommended series of width of flat pulleys, mm.

The standard pulley width = 125 mm.

Step 7: Calculation of length of the belt (L):

From PSGDB 7.61,

2. At the construction site, 1 tonne of steel is to be lifted upto a height of

Step 1: Selection of suitable Wire rope:

Given: 6 × 19 size wire rope.

Step 2: Calculation of design load:

Assuming a larger factor of safety of 15, the design load is calculated.

Design load = Load to be lifted × Assumed FOS

Step 3: Selection of Wire rope diameter (d):

From PSGDB 9.5. For the breaking strength (Wbreak) 78 KN (7.8

Step 4: Calculation of sheave diameter (D):

From PSGDB 9.1

Step 6: Calculation of Wire diameter (dw):