UNIT-I GEAR BOXES Procedure for typical gear box design. Step I: Selection of spindle speeds: 1. Determine the progression ratio= 9 "' = (where n= number of speed) 2. Find step ratio series and speed of gears (PSG Data book pg no. 7.20) 3. Write the structural formulae Z. = pi (%) * pols) *ps(%s) * Pals) Xi =1, Xp, X3= pip2, Xa= PiP2 Ps Preferred Structural Formulas 6 speeds (2x3 (or) 3x2 Sspeeds [2x4 (or) 4x2 (or) 2x2x2 9 speeds [3x3 12 speeds |3x2x2 (or) 2x2x3 (or) 2x3x2 16 speeds |4x2x2 (or) 2x4x2 (or) 2x2x4 Draw the ray diagram or speed diagram Shatt-tNoput Shatt-2/ntrmediate shat. /iarmedions Shat-4 Oupet 34Step Calculate the number of teeth. Step 5: Select the suitable materials Materials constant PSG.1.15, Materials Materials constant (M) C45 30 15 Ni2Cr 1 Mo 15 | 80 40 Ni 2Cr 1 Mo 28 | 100 Permissible shear stress(Z) N/mm” S.No | Shait materials ©) Nimm™ 1. | C14 (as supplied) 25 2. | C45 (case hardened) 30 3. | Low carbon alloyed steel (case hardened) 40 4. | 40 Ni2Cr 1 Mo 28 (hardened and tempered) | 55 Step 6:.caleulation of module Calculate the torque for the gear which has the lowest speed using the relation, ex6o 2a Calculate the tangential force on the gear in terms of module using the relation BK ‘Now calculate the module using the relation m= JF /0,)° 35@m = Ratio between the face width and module Ble " S M-= Material constant Standard module in PSG data book pg no: 8.2 Step 7:Calculation of centre distance in all stages: Calculate the centre distance in cach stage by using the relation gh i zim asl Z,andZ,, = Number of tecth on the gear pair in engagement in cach stage Step 8: cateulation of face width: b=10%m Step 9:calculation of distance between the bearings ie., length of shafts: Calculate the distance between the bearings by using the following assumptions ASSUMPTIONS: Give 10mm clearance between the gear and the bearings on both sides, Take the distance between the adjacent groups of gears as 20 mm, Take the total length for two pairs gear group as 4b and for three pairs gear group as 7b as shown in figure. ‘Assume the width of the bearings as 25mm_ Distance between the bearings is given by L=25+1 044 (or 7b) + 20 (or 4b) + 10 +25 + al _fjA - — oH 56‘Step 10:Design of shafts: () Design of spindleic.,ouiput shaft: Design the ourput shaft for maximum bending moment by considering the shaft as simply supported on bearings: Step 11 Calculate the maximum bending moment due to normal load (F,) using the relation Where F,-Normal load on gear = cose Step 12 Caleulate the equivalent torque using the relation ir x60 2X ‘Where T=Torque on the spindle Step 13 Caleulate the diameter of the spindle using the relation 1 e-tan ‘Where [r] = Permissible shear stress, Step 14 Design of other shafis: Determine the diameter of the input and intermediate shafts using the relation. T= 0.2 ds? [7] 37UNIT- IV: GEAR BOXES (PART - A) T. What ix step ratio? Name the series in which speeds of multispeed gear box are arranged. (May/June 2014) Soin. Step ratio is the ratio of one speed of the shaft to iis previous lower speed Since the spindle speeds are arranged in geometric progression, the ratios adjacent speeds (ie., step ratios) are constant, IfNr is;the maximum speed and N, is the minimum speed, then, SS (Step ratio) = r-1 Basic series ‘Step ratio(g) RS Va0=158 RIO R20 26 RO R80 J 12 4 V v 03 2, Sketch the kinematic layout of gears for 3 speeds between two shafis. (May/June 2014) Soln. Shut Noput iid Fj A tH [|] on Shut /inwrmesiste fl. lef |, Shat-4 Oupat 3. What are preferred numbers? (May/June 2013) ‘Soln, The series of preferred number is obtained by multiplying a step ratio with the first ‘umber to get the second number. The third number is obtained by multiplying a step ratio with the second number, similarly the procedure is continued until the series is competed. (fiom data book page no,7.20) 4, List four applications where constant mesh gear box is used. (Nov/Dec 2012) ‘Soln, 1. Automobile 2. Rolling mill 3. Machine tools 4. Crane 58UNIT- IV: GEAR BOXES (PART - Ay 5. Which type of gear is used in constant mesh gear hox? Justify. (Nov/Dec 2012) Sotn, Helical gears are used in constant mesh gear boxes to provide quieter and smooth operation 6 What are the possible arrangements to achieve 12 speeds from a gear box? (AprivMay2015) Soln. S.No Number Of Speeds Preferred Structural Formula i Pspeed @. 3D 23) 20 Gi). 21) 32) 26) ili). 20) 2(2) 3(4) 7, Define the term progression ratio? (April /May2015) Soin, When the spindle speeds are arranged in geometric progression, the ratio between the two adjacent spceds is known as step ratio or progression ratio, 8. What are the points fo be considered while designing a sliding mesh type of multi speed gear box? (April /May2010) Soin. i) The transmission ratio in a gear box is limited by 4 - Internal radius of friction surface. ‘Area of the elemental ring = 2 mr.de Normal or axial force on the ring,SW r.dr=px2 mrde Friction torque acting on the ring, t,=2 typr".dr 62(® Considering uniform pressure: a ae Ae a? —12) a Ra (ii) Considering uniform wear pas Aa (r\—7) T-H WR RT] Design ofa Multiplate clutch (Torque transmitted on multiplate cluteh) Friction rings (eplined) n, = Number of discs on the driving shaft, and nz = Number of dises on the driven shaft. Number of pair of contact surfaces, 63n=nytn ‘Total frictional torque on the clutch is given by T=mWR [For uniform pressure] J[ [For uniform wear] Design of a cone clutch Cone surface ‘Torque transmitted on the cone clutch is given by T= HWR cosec @ |] [For uniform pressure] R=[ =": ][For uniform wear] ‘Axial force required at the engagement of cluteh is given by *W, And axial force required at the disengagement of clutch is given by Wa (sinac+yte0sa) We= Wn (sina-peosa)BRAKE SINGLE BLOCK OR SHOE BRAKE The friction between the block and the brake drum causes the retarding of the drum. This type of Brake is commonly used on railway trains and tram cars. Fig. 11.2. Clockwise rotation of brake drum The block is pressed against the drum by a force applied on one end of the lever. The ather end of the lever Is pivoted on a fixed fulerum O. Let r= Radius of the drum Ry= Normal reaction of the block a (clockwise) {anti -clockwise) Taree = Force applied at the lever end = Coefficient of friction HRv= Frictional force ‘Tp = Braking torque Rn. (clockwise) Far {anti clockwise) ara 65DOUBLE BLOCK OR DOUBLE SHOE BRAKE Ifonly one block is used for brakig, then there will be side thrust on the bearing of wheel shaft, This drawback can be removed by providing two blocks on the two sides of the drum, as shown in fig 11.7, This also doubles the braking torque. The double shoes on the drum reduce the unbalanced force on the shaft, The blocks or shoes are held on the drum by means of spring force. Let $= Spring force required to set the blocks on the drum, R= Radius of drum. Ryi and» Ry, = Normal Reaction and the braking force on the left hand side shoe, and Ryz and jt Ryo = Normal Reaction and the bracking foroe on the right hand side shoe. Fig. 11.7. Double shoe brake DESIGN PROCEDURE FOR BLOCK BRAKE Step 1: calculate the total energy absorbed by the brake Ep-$mv?.Z1W7,WX Step 2: calculate the torque capacity by using the relation a Tp- N,- Initial speed of brake drum and ime of application of brakeStep 3: calculate the initial braking power by using the relation Step 4:Select the brake drum diameter Step 5:Select the suitable brake drum and shoe materials. For the chosen materials, consulting Table 11.1, the coefficient of friction is obtained, Table 11.1 properties of brake lining materials ‘Material x Allowable pressure (Pysx } Mpa ‘Max.Temp. (°C) Wood on metal 025 O48 6 Metal on metal 0.25 14 315 Leather on metal 0.35 O17 6 Asbestos on metalin_| 0.40 034 260 emia metal 015 28 260 lining on C.1in oil Step 6: Consulting table 11.2, calculate the induced bearing pressure (p) Table 11.2 Limiting values of pv (from PSG 7.130) ‘Operating conditions ‘Pv (mpa) (mis Continuous service, poor heat dissipation | 1.03 Intermittent service, poor heat dissipation | 2.1 Conlinuous service, good heat dissipation as | 3.0 in oil bath Step 7: calculate the projected area of the shoe by using the relation, A~"* Step 8:Finalty calculate the breath and width of the shoe by using the relation projected area of the shoe, A= Breadth X Width SIMPLE BAND BRAKES ‘The band or rope is wrapped round the cylindrical drum. When a force F is applied to the lever at B, the level turns about the fulcrum pin O and tightens the band on the drum and hence the brakes are applied. The friction between the band and the drum provides the braking torque. o7Drum (8) Clockwise rotation of drum {(b) Anticlockwise rotation of drum Fig. 11.11. Simple band brake Let F = Force applied on the lever, R= Radius of the drum, ‘T=Thickness of the band, Ry= Riffective radius of the band = r+5 a= Length of lever = OB b= Distance between the fulerum O and point A, For clockwise rotation of drum Fa=Ty.b For anticlockwise rotation of drum FasTs.b Braking torque Ty = (T1-T2). Fx$(t-sr DIFFERENTIAL BAND BRAKE Ina differential band brake the ends of the band are joined to the lever DOB at points D and A. Point D is the fulcrum, It may be noted that for the band to tighten, the length OD must be greater than the length OA.ckwise rotation of drum (@) Clockwise rotation of drum Fig. 11.14. Differential band brake (i) Downward force on lever for clockwise rotation of drum: This type of arrangement is shown in fig. 11.14(a). Taking moments about O, we get Fa=Ty.c-Ty.b Thus T;.c >T).b (or) 2> ‘Thus > for the system to work satisfactorily. ite %, the external applied force F = 0, which is the condition for self-locking. Downward force on lever for anticlockwise rotation of drum: ‘Taking moments about O, we get F.a=T).b-Tr.¢ Thus T).b>Ts.¢ (o> £ Condition for self-locking: IfT).b 2 -€, then external applied force F = 0 moe (iii)Upward froce on lever for anticlockwise rotation of drum: ‘This type of arrangement is shown in fig.11.14(b). Taking moments about O, we get F.a=T,.b-Tic Thus T; b>T2¢ het ne (iv)Upwards froce on lever for clockwise rotatio of drum: ‘Taking Moment about O, we get, F.a=Ta.c-Ti.b 69Thus T2.¢> Ti.b (or) Condition for self-lockin; if B= sthen F=0 me In this case, ¢ must be less then b for proper braking. DESIGN PROCEDURE FOR BAND BRAKES Step 1:Calculate the braking torque required from the data given. Step 2: If not given, select the suitable diameter (D) of the brake drum, consulting table 11.3 Table 11.3 Dimensions of brake drum (from PSG 7.98) Power of the motor, KW | Brake drum diameter, mm | Brake drum width, mm 7.36 160 50 H08 200 65 14.72 250 80 23.76 320 100 44.16 400 2s 73.6 500 160 04 630 200 184 800 250 Step 3: Determine the tight and stack side tensions. Step 4: Calculate the thickness (t) of hand: Take thickness of band as 0.005XDiameter of brake drum. Step 5: calculate the band width (w) Induced tensile stress, & ,= 7% T, =Tight side tension in the band, W = width of the band t= Thickness of the band = 0,005 D , = permissible tensile stress = 5010 80 /,.9,2 Step 6: check for bearing pressure Step 7: calculate the force to be applied at the end of the lever 70Table 11.4 Safe bearing pressure in band brakes (from PSG. 7.98) Materials of the rubbing, surfaces ‘Steel band on | Asbestos brake | Rolledpress | Wood on CI Cor steel | bund on steel or | formed and dram Types of brake dram Cldrum | shaped frietion material on ‘metal drum Holding 1S 06 08 0.6 Lowering 10 0.3 04 Od AND AND BLOCK BRAKE This arrangement is a combination of both the band and the block brakes, as shown. ‘The band is lined with a number of wooden blocks, each of which is in contact with the rim of the brake drum, When the brake is applied, the blocks are pressed against the drum, The advantage of using wooden blocks is that they provide higher coefficient of friction and they can be easily and economically replaced after being worn out Let Ty=Tension in the band on tight side, T. = Tension in the band on slack side, T, = Tension in band between the first and secon block, ‘ension in band between second and third block, T; = Tension in band between third and fourth blocks. n= Number of wooden blocks, = Coefficient of friction between block and drum, 28 = Angle subtended by cach block at the drum centre, Ry = Normal reaction on the block. 1Fig, 11.19. Band and block brake Resolving the forces radially, we get (T, + Ty) sind =R, Resolving the forces tangentialy, we get (Ty =To) cos = LR Dividing equation (i) by (ii), we get nutnd (HER) _ 2m etn 1 (TER) am or Ty _ dtutane 7) i-ytand Similarly, it can be proved for each of the blocks that Tp _teutand Ty _ aw tae SS, Me 1, d-utont 7, i-ptand qa hb —- hn 2+ntano Therefore, hes x tte zh Tue = vtand 2So the ratio of tensions forall ‘n' block is given by Te Te i, 38. Te Tt T1 Te 1+ nian ay = pean Braking torque on the drum is given by Ta =(T1—T) r +2, Tp =(T, —T?) DESIGN OF INTERNAL EXPANDING SHOE BRAKE Moment of normal force, My spub.no0r[ 8 »)+ Ysin20 , sin20 », $(COS20 >.COS20 \), Moment of frictional force, Mr=E per. [r(cos 8 \ 8 >)+ Braking torque in Block or shoe brake is given by fie A A ‘T, <= pwhen the rotation of drum is clockwise] “Ke oe. —— {when the rotation of drum is anticlockwise] where T, - Braking torque, r= Radius of drum, F = Force applied at lever end, u-Coeflicient of friction, and a,c & 1=Dimensions of lever. Equivalent coefficient of friction (4) used when 28 > 40° is given by where 2@ = Angle of contact Braking torque in Double block or double shoe braki Terur(Rx: + xz) where 1 RN) & RN; adius of drum, formal reaction on the left & right hand side shoes In Band brake system, BTension ratio, += e# and Braking torque,7,= (T1-T2)r T, and T, = Tension in the band on tight and slack sides respectively 6 = Angle of lap r= Radius of dram, Force applied on the lever in Simple band brake is given by @F=7; (2). [Ror clockwise rotation of the drum] =T2(5; [For anticlockwise rotation ofthe dram] Tension ratio in Band and block brake is given by ty _ Pius] a pcane where T, = Tension in the band on tight side (maximum tension), T, = Tension in the band on slack side (minimum tension), 26 - Angle sub tended by each block at the drum centre, and n= Number of wooden blocks. Actuating force on leading (or left hand) shoe. FI Actuating force on Trailing (or right hand) shoe. F2 Energy considerations; (i) Total energy absorbed by brake: Er = (ii) Heat generated in brakes: Hy =m x Ry xV= 4p A.V (iii) Heat dissipated in brakes: Hi=C x Ax At=Cx Ax (lets) ‘Temperature rise: At 74