MECHANICAL TRANMISSION SYSTEM DESIGN FOR A MIXER

LOAD DIAGRAM

The mechanical transmission system consists of: 1- Asynchronous three-phase motor; 2- Coupling; 3-
Two-stage spur gears – helical gears reducer; 4- Chain drive; 5- Mixer (one-way rotation, light impact
load, 8 hours per working shift)
Design Parameters

Power applied on mixer’s shaft P, kW 5,2

Mixer’s shaft rotational speed n, rpm 50

Service life L, years 4

Working days per year 𝐾𝑛𝑔 , days 270

Working shifts per day, shift 1

𝑡1 , seconds 31

𝑡2 , seconds 20

T1 T

T2 0,8T
 Chapter 1: Selecting electric motor and speed
ratio distribution

1.1 Electric Motor Selection

Working power of the mixer: 𝑃 = 5,2 𝑘𝑊
System transmission efficiency:
𝜂 = 𝜂𝑐 𝜂𝑏4 𝜂𝑏𝑔 𝜂𝑠𝑔 𝜂𝑐ℎ

In which, the transmission efficiency of each element are selected from table 2.3[1]:

c = 1 : Coupling efficiency.

 b = 0,99 : One couple of roller-bearing efficiency (4 couples).

𝜂𝑏𝑔 = 0,96 : Bevel gear efficiency (fully covered).

𝜂𝑠𝑔 = 0,95 : Spur gear efficiency (fully covered).

ch = 0,92 : Chain drive efficiency (uncovered).

  = 1 × 0,99 4
× 0,96 × 0,95 × 0,92= 0,81
Since the workload is not static, so it is necessary to calculate the equivalent working power of
the mixer

𝑇1 2 𝑇 2
( ) 𝑡1 +( 2 ) 𝑡2 12 ×31+0,82 ×20
𝑃𝑒 = 𝑃√ 𝑇 𝑇
𝑡1 +𝑡2
= 5,2 × √ 31+20
= 4,82 (𝑘𝑊)

Power on the motor shaft:

𝑃𝑒 4,82
𝑃𝑠 = 𝜂
= 0,81 = 5,95 (𝑘𝑊)

From table 3.2 [2], we choose the two-stage spur gear – helical gear reducer transmission ratio
𝑢𝑔 = 16
Preliminary bevel gear transmission ratio in order to assure lubricating condition: 𝑢𝑏𝑔 =
(0,22 ÷ 0,28)𝑢𝑔 = (0,22 ÷ 0,28) × 12 = (3,52 ÷ 4,48)
So we choose 𝑢𝑏𝑔 = 4
𝑢𝑔 16
Spur gear transmission ratio: 𝑢𝑠𝑔 = 𝑢 = 4
=4
𝑏𝑔

Choose the chain drive transmission ratio 𝑢𝑐ℎ = 2,4

 Transmission ratio of the system: 𝑢 = 𝑢𝑔 × 𝑢𝑐ℎ = 12 × 2,4 = 38,4
Required revolution for the motor:
𝑛𝑟𝑞 = 𝑛 × 𝑢 = 50 × 38,4 = 1920 (𝑟𝑝𝑚)

So, we choose the preliminary revolution 𝑛𝑠𝑏 = 3000 (𝑟𝑝𝑚)

Selected motor must have power Pdc and synchronizing revolution ndb satishfy these condition:
𝑃 ≥ 𝑃𝑠
{ 𝑑𝑐
𝑛𝑑𝑏 ≈ 𝑛𝑠𝑏
Thus, from table P1.3[1], we choose motor 4A132S4Y3 which operates at 7,5 kW and 1455 rpm
which these following technical properties:
Table 1: Chosen motor properties

Motor type Power (kW) Revolution cos  Tmax TK

(rpm) Tdn Tdn
%

4A112M2Y3 7,5 2922 0,88 87,5 2,2 2

1.2 Transmission Ratio Distribution

Recalculate the system transmission ratio with the motor power and revolution:
𝑛𝑚𝑜𝑡𝑜𝑟 2922
𝑢= = = 58,44
𝑛 50
Keep the reducer’s transmission ratio constant, recalculate the chain drive transmission ratio:
𝑢 58,44
𝑢𝑐ℎ = = = 3,65
𝑢𝑔 16

1.3 Calculating power, rotational speed and torque on shafts

1.1.1 Power
Power transmitted to working shaft: 𝑃 = 5,2 (𝑘𝑊)
𝑃 5,2
Power transmitted to shaft 3: 𝑃3 = 𝜂 = 0,99×0,92 = 5,71(𝑘𝑊)
𝑏 𝜂𝑐ℎ

𝑃3 5,71
Power transmitted to shaft 2: 𝑃2 = 𝜂 = 0,99×0,95 = 6,07 (𝑘𝑊)
𝑏 𝜂𝑠𝑔

𝑃2 6,07
Power transmitted to shaft 1: 𝑃1 = 𝜂 = 0,99×0,96 = 6,39 (𝑘𝑊)
𝑏 𝜂𝑏𝑔

𝑃 6,39
Power transmitted to motor shaft: 𝑃𝑚 = 𝜂1 = 0,99 = 6,45 (𝑘𝑊)
𝑏

1.1.2 Rotational Speed

 Shaft 1: 𝑛1 = 2922 (𝑟𝑝𝑚)
𝑛 2922
Shaft 2: 𝑛2 = 𝑢 1 = 4
= 730,5(𝑟𝑝𝑚)
𝑏𝑔

𝑛 730,5
Shaft 3: 𝑛3 = 𝑢 2 = 4
= 182,63 (𝑟𝑝𝑚)
𝑠𝑔

𝑛 182,63
Working shaft: 𝑛 = 𝑢 3 = 3,65
= 50 (𝑟𝑝𝑚)
𝑐ℎ

1.1.3 Torque
9,55×106 ×𝑃𝑚 9,55×106 ×6,45
Motor shaft: 𝑇𝑚 = 𝑛𝑚
= 2922
= 21080,6 (𝑁𝑚𝑚)

9,55×106 ×𝑃1 9,55×106 ×6,39

Shaft 1: 𝑇1 = 𝑛1
= 2922
= 20884,5 (𝑁𝑚𝑚)

9,55×106 ×𝑃2 9,55×106 ×6,07

Shaft 2: 𝑇2 = 𝑛2
= 730,5
= 79354,55 (𝑁𝑚𝑚)

9,55×106 ×𝑃3 9,55×106 ×5,71

Shaft 3: 𝑇3 = 𝑛3
= 182,63
= 298584,57 (𝑁𝑚𝑚)

9,55×106 ×𝑃 9,55×106 ×5,2

Working shaft: 𝑇 = 𝑛
= 50
= 993200 (𝑁𝑚𝑚)

1.2 Technical properties of transmission system

Table 2: Technical properties of transmission system

Motor 1 2 3 Working shaft

Power, kW 6,45 6,39 6,07 5,71 5,2

Transmission 1 4 4 3,65
ratio
Torque, Nmm 21080,6 20884,5 79354,55 298584,57 993200

Rotational 2922 2922 730,5 182,63 50

speed, rpm
 Chapter 2: Roller chain transmission design
Initial specification of the roller chain transmission system:
𝑃3 = 5,71 𝑘𝑊
{𝑛3 = 182,63 𝑟𝑝𝑚
𝑢𝑐ℎ = 3,65

2.1 Determine chain and transmission system design parameter

Driving sprocket teeth: 𝑧1 = 29 − 2𝑢𝑐ℎ = 29 − 2 × 3,65 = 21,7 > 19.
Choose 𝑧1 = 21
Driven sprocket teeth: 𝑧2 = 𝑢𝑐ℎ 𝑧1 = 3,65 × 21 = 76,65 < 𝑧𝑚𝑎𝑥 = 120. Choose 𝑧2 = 77.
𝑧 77
Recalculate chain drive transmission ratio: 𝑢𝑐ℎ′ = 𝑧2 = 21 = 3,67
1

𝑢𝑐ℎ′ −𝑢𝑐ℎ 3,67−3,65

Transmission ratio error: 𝐷 = 𝑢𝑐ℎ
× 100 = 3,65
× 100 =0,55%. So, the error is
negligible.
Chain working condition factor: 𝑘 = 𝑘0 𝑘𝑎 𝑘𝑑𝑐 𝑘𝑏𝑡 𝑘𝑑 𝑘𝑐 . In which, based on table 5.6[1]

• Drive positioning factor 𝑘0 = 1

• Center distance and chain’s length factor 𝑘𝑎 = 1
• Chain tension factor 𝑘𝑑𝑐 = 1,25
• Lubricating factor: 𝑘𝑏𝑡 = 1
• Dynamic load factor: 𝑘𝑑 = 1,2
• Working shift factor: 𝑘𝑐 = 1
So, 𝑘 = 1 × 1 × 1,25 × 1 × 1,2 × 1 = 1,5
𝑃𝑘𝑘𝑧 𝑘𝑛
Chain drive wearing capacity assurance factor: 𝑃𝑡 = 𝑘𝑥
≤ [𝑃]. In which

𝑧01 25
• Number of teeth factor: 𝑘𝑧 = 𝑧1
= 21 = 1,19
𝑛01 200
• Rotational speed factor: 𝑘𝑛 = = = 1,1. 𝑛01 is based on table 5.5[1].
𝑛1 182,63

• [P]: Permissible power, based on table 5.5 [1]

• Choose 2 strain chain, so 𝑘𝑥 = 1,7
5,71×1,5×1,19×1,1
So, 𝑃𝑡 = = 6,6 → [𝑃] = 11 (𝑘𝑊)
1,7

From table 5.4[1], we obtain these parameters for the chain drive:

• Chain pitch 𝑝 = 25,4 𝑚𝑚

• Pin diameter 𝑑𝑐 = 7,95 𝑚𝑚
 • Bush length 𝐵 = 22,61 𝑚𝑚
Center distance 𝑎 = (30 ÷ 50)𝑝 = (30 ÷ 50) × 25,4 = 762 ÷ 1270 (𝑚𝑚).
Choose 𝑎 = 992 (𝑚𝑚)
2𝑎 𝑧1 +𝑧2 (𝑧2 −𝑧1 )2 𝑝 2×992 21+77 (77−21)2 ×25,4
Number of chain link 𝑥 = 𝑝
+ 2
+ 4𝜋2 𝑎
= 25,4
+ 2
+ 4𝜋2 ×992
= 129,14. So
choose 𝑥 = 130
Recalculate center distance:

𝑧2 −𝑧1 2
𝑎∗ = 0,25𝑝 {𝑥𝑐 − 0,5(𝑧2 + 𝑧1 ) + √[𝑥𝑐 − 0,5(𝑧2 + 𝑧1 )]2 − 2[ 𝜋
] } = 0,25 × 25,4 {130 −

77−21 2
0,5(77 + 21) + √[130 − 0,5(77 + 32)]2 − 2[ 𝜋
] } = 1003,16 (𝑚𝑚)

In order to alleviate tension on the chain drive, we reduce center distance a an amount of ∆𝑎 =
0,002𝑎 ÷ 0,004𝑎 = 2,01 ÷ 4,01 (𝑚𝑚). So we choose 𝑎 = 1000 (𝑚𝑚)
𝑧1 𝑛1 21×182,63
Chain impact times per second: 𝑖 = 15𝑥
= 15×130
= 1,97 < [𝑖] = 30 Based on table 5.9[1].

2.2 Strength of chain drive analysis

𝑘𝑔
Based on table 5.2[1] damaging load 𝑄 = 113400 (𝑁), mass of chain drive 𝑞𝑙 = 5 ( )
𝑚

1 𝑛𝑧 𝑝 182,63×21×25,4 𝑚
Chain drive velocity: 𝑣 = 60000 = 60000
= 1,62 ( 𝑠 )
𝑃 5,71
Effective peripheral force 𝐹𝑡 = 1000 𝑣 = 1000 × 1,62 = 3524,69 (𝑁)

Tension produced by centrifugal force 𝐹𝑣 = 𝑞𝑣 2 = 5 × 1,622 = 13,12(𝑁)

Tension produced by sagging force 𝐹0 = 9,81𝑘𝑓 𝑞𝑎 = 9,81 × 6 × 5 × 1 = 294,3 (𝑁), in which
𝑘𝑓 = 6 (horizontal transmission)
𝑄 113400
Safety factor: 𝑠 = 𝑘 = 1,7×3524,69+294,3+13,12 = 18, in which dynamic load factor 𝑘𝑑 =
𝑑 𝐹𝑡 +𝐹0 +𝐹𝑣
1,7.
Allowable safety factor [𝑠] = 8,2 < 𝑠. So we can conclude that the chain drive is durable enough.

2.3 Others parameter:

𝑝 25,4
Diameter of driving sprocket: 𝑑1 = 𝜋 = 𝜋 = 170,42 (𝑚𝑚)
sin ( ) sin ( )
𝑧1 21

𝑝 25,4
Diameter of driven sprocket: 𝑑2 = 𝜋 = 𝜋 = 622,72 (𝑚𝑚)
sin ( ) sin ( )
𝑧2 77

Addendum diameter of driving sprocket:

𝜋 𝜋
𝑑𝑎1 = 𝑝 [0,5 + cot (𝑧 )] = 25,4 × [0,5 + cot (21) = 181,22 (𝑚𝑚)
1
 Addendum diameter of driven sprocket:
𝜋 𝜋
𝑑𝑎2 = 𝑝 [0,5 + cot ( )] = 25,4 × [0,5 + cot ( ) = 634,9 (𝑚𝑚)
𝑧2 77

Deddendum diameter of driving sprocket:

𝑑𝑓1 = 𝑑1 − 2(0,5025𝑑𝑙 + 0,05) = 170,42 − 2 × (0,5025 × 15,88 + 0,05) = 154,36 (𝑚𝑚)

Deddendum diameter of driving sprocket:

𝑑𝑓2 = 𝑑2 − 2(0,5025𝑑𝑙 + 0,05) = 622,72 − 2 × (0,5025 × 15,88 + 0,05) = 606,66 (𝑚𝑚)

Chain length 𝐿 = 𝑥𝑝 = 130 × 25,4 = 3302 (𝑚𝑚)

2.4 Stress analysis

𝑚 𝑚
Since 𝑧2 = 77 > 50 and 𝑣 = 1,62 𝑠
<3 𝑠
. Based on table 5.11 [1], the chosen material for the
chain drive is grey cast iron. The heat treatment method is quenching. Allowable contact stress
[𝜎𝐻 ] = 650 𝑀𝑃𝑎. Elastic modulus 𝐸 = 2,1 × 105 (𝑀𝑃𝑎)

Impact force on chain drive

𝐹𝑣𝑑 = 13 × 10−7 𝑛𝑝3 𝑚 = 13 × 10−7 × 182,63 × 25,43 × 2 = 7,78 (𝑁)
Contact stress on the teeth’s chain drive:

𝑘𝑟 (𝐹𝑡 𝐾𝑑 + 𝐹𝑣𝑑 )𝐸 0,48 × (3524,69 × 1,7 + 7,78) × 2,1 × 105

𝜎𝐻 = 0,47√ = 0,47√
𝐴𝑘𝑑 306 × 1,7
= 506,77 (𝑀𝑃𝑎)
In which, projected surface area of the roller’s hinge A is selected from table 5.12[1]. We have
𝜎𝐻 < [𝜎𝐻 ]. So the chain drive satisfy the stress test.

2.5 Force on shaft

Loose side tension force 𝐹2 = 𝐹𝑜 + 𝐹𝑣 = 294,3 + 13,12 = 307,42 (𝑁)
Tight side tension force 𝐹1 = 𝐹𝑡 + 𝐹2 = 3524,69 + 307,42 = 3832,11 (𝑁)
Force on shaft 𝐹𝑟 = 𝑘𝑥 𝐹𝑡 = 1,15 × 3524,69 = 4053,39 (𝑁)
 Table 3: Chain drive technical specification

Technical specification

Parameter Value Parameter Value

Type of chain Roller chain Nominal diameter,
mm
Driving sprocket 𝑑1
Chain pitch 𝑝𝑐 , mm 25,4 170,42
Driven sprocket 𝑑2
622,72

Center distance a, 1000 Addendum diameter,

mm mm

Chain length L, mm 3302 Driving sprocket 𝑑𝑎1

181,22
Driven sprocket 𝑑𝑎2
634,9

Number of links X 130 Deddendum

diameter, mm
Number of teeth
Driving sprocket 𝑑𝑓1
Driving sprocket 𝑧1 21 154,36
Driven sprocket 𝑑𝑓2
Driven sprocket 𝑧2 77 606,66

Effective peripheral 3524,69 Number of strain 2

force 𝐹𝑡 , N

Force on shaft 𝐹𝑟 , N 4053,39 Material Gray cast iron

Validating calculation

Paramater Allowable value Design value Result

Impact times per 30 1,97 Satisfy

second

Safety factor 8,2 18 Satisfy

Contact stress 600 506,77 Satisfy

 Chapter 3: Gearbox transmission design
3.1 Material choice, heat treatment methods, physical properties
In order to obtain synchronization in design, the same material is chosen for both bevel gears and
spur gears.
From table 6.1[1], steel 45 with quenching as the heat treatment method is chosen. Steel 45 has
following properties:

• Maximum length S = 100 mm

• Hardness HB 192 ÷ HB 240
• Ultimate strength 𝜎𝑏 = 750 𝑀𝑃𝑎
• Yield strength 𝜎𝑐ℎ = 450 𝑀𝑃𝑎

3.2 Allowable stress

From table 6.2[1], we can obtain:

• 𝑜
Allowable contact stress corresponding to working cycle 𝜎𝐻𝑙𝑖𝑚 = 2𝐻𝐵 + 70 (𝑀𝑃𝑎)
• Safety factor of contact stress 𝑆𝐻 = 1,1
• 𝑜
Allowable bending stress corresponding to working cycle 𝜎𝐹𝑙𝑖𝑚 = 1,8𝐻𝐵 (𝑀𝑃𝑎)
• Safety factor of bending stress 𝑆𝐹 = 1,75
Choose the hardness for all pinions 𝐻𝐵1 = 230 and the hardness for all driven gears 𝐻𝐵2 = 240.
Allowable contact stress corresponding to working cycle of all pinions:
𝑜
𝜎𝐻𝑙𝑖𝑚1 = 2𝐻𝐵1 + 70 = 2 × 230 + 70 = 530 (𝑀𝑃𝑎)

Allowable contact stress corresponding to working cycle of all driven gears:

𝑜
𝜎𝐻𝑙𝑖𝑚2 = 2𝐻𝐵2 + 70 = 2 × 200 + 70 = 550 (𝑀𝑃𝑎)

Allowable bending stress corresponding to working cycle of all pinions:

𝑜
𝜎𝐹𝑙𝑖𝑚1 = 1,8𝐻𝐵1 = 1,8 × 230 = 414 (𝑀𝑃𝑎)
Allowable bending stress corresponding to working cycle of all driven gears:
𝑜
𝜎𝐹𝑙𝑖𝑚2 = 1,8𝐻𝐵2 = 1,8 × 240 = 432 (𝑀𝑃𝑎)
Cycles of basis stress variation corresponding to contact stress of all pinions:
𝑁𝐻𝑂1 = 30𝐻𝐵12,4 = 30 × 2102,4 = 11,23 × 106
Cycles of basis stress variation corresponding to contact test of all driven gears:
𝑁𝐻𝑂2 = 30𝐻𝐵22,4 = 30 × 2002,4 = 99,91 × 105
Cycles of basis stress variation corresponding to bending test of all gears:
𝑁𝐹𝑂1 = 𝑁𝐹𝑂2 = 4 × 106
Total working hour when working load 𝑇1 = 𝑇
31
𝑡1 = × 8 × 1 × 270 × 4 = 5251,76 (ℎ𝑜𝑢𝑟𝑠)
31 + 20
Total working hour when working load 𝑇2 = 0,8𝑇
20
𝑡2 = × 8 × 1 × 270 × 4 = 3388,24 (ℎ𝑜𝑢𝑟𝑠)
31 + 20
Cycles of equivalent stress variation of bevel pinion:
𝑇1 3 𝑇2 3
𝑁𝐻𝐸1 = 60𝑐 [( ) 𝑛1 𝑡1 + ( ) 𝑛2 𝑡2 ] = 60 × [1455 × 5251,76 + 0,83 × 1455 × 3388,24] = 6,1 × 108 (𝑐𝑦𝑐𝑙𝑒𝑠)
𝑇 𝑇
𝑇1 𝑚𝐹 𝑇2 𝑚𝐹
𝑁𝐹𝐸1 = 60𝑐 [( ) 𝑛1 𝑡1 + ( ) 𝑛2 𝑡2 ] = 60 × [1455 × 5251,76 + 0,86 × 1455 × 3388,24]
𝑇 𝑇
= 5,36 × 108 (𝑐𝑦𝑐𝑙𝑒𝑠)
Cycles of equivalent stress variation of driven bevel gear and spur gear pinion:
𝑇1 3 𝑇2 3
𝑁𝐻𝐸2 = 60𝑐 [( ) 𝑛1 𝑡1 + ( ) 𝑛2 𝑡2 ] = 60 × [485 × 5251,76 + 0,83 × 485 × 3388,24] = 2,03 × 108 (𝑐𝑦𝑐𝑙𝑒𝑠)
𝑇 𝑇
𝑇1 𝑚𝐹 𝑇2 𝑚𝐹
𝑁𝐹𝐸2 = 60𝑐 [( ) 𝑛1 𝑡1 + ( ) 𝑛2 𝑡2 ] = 60 × [485 × 5251,76 + 0,86 × 485 × 3388,24]
𝑇 𝑇
= 1,79 × 108 (𝑐𝑦𝑐𝑙𝑒𝑠)
Cycles of equivalent stress variation of driven spur gear:
𝑇1 3 𝑇2 3
𝑁𝐻𝐸3 = 60𝑐 [( ) 𝑛1 𝑡1 + ( ) 𝑛2 𝑡2 ] = 60 × [121,25 × 5251,76 + 0,83 × 121,25 × 3388,24]
𝑇 𝑇
= 5,08 × 107 (𝑐𝑦𝑐𝑙𝑒𝑠)
𝑇1 𝑚𝐹 𝑇2 𝑚𝐹
𝑁𝐹𝐸3 = 60𝑐 [( ) 𝑛1 𝑡1 + ( ) 𝑛2 𝑡2 ] = 60 × [121,25 × 5251,76 + 0,86 × 121,25 × 3388,24]
𝑇 𝑇
= 4,47 × 107 (𝑐𝑦𝑐𝑙𝑒𝑠)
We have the smallest value of 𝑁𝐻𝐸 is larger than the largest value of 𝑁𝐻𝑂 and the smallest value
of 𝑁𝐹𝐸 is larger than the largest value of 𝑁𝐹𝑂 . So, these value can be obtained:
• Aging factor due to contact stress of all gears 𝐾𝐻𝐿 = 1
• Aging factor due to bending stress of all gears 𝐾𝐹𝐿 = 1
𝑂
𝜎𝐻𝑙𝑖𝑚1 𝐾𝐻𝐿 530×1
Allowable contact stress of all pinions [𝜎𝐻1 ] = 𝑆𝐻
= 1,1
= 481,82 (𝑀𝑃𝑎)
𝑂
𝜎𝐹𝑙𝑖𝑚1 𝐾𝐹𝐿 414×1
Allowable bending stress of all pinions [𝜎𝐹1 ] = = = 236,57 (𝑀𝑃𝑎)
𝑆𝐹 1,75
𝑂
𝜎𝐻𝑙𝑖𝑚2 𝐾𝐻𝐿 550×1
Allowable contact stress of all driven gears [𝜎𝐻2 ] = 𝑆𝐻
= 1,1
= 500 (𝑀𝑃𝑎)
𝑂
𝜎𝐹𝑙𝑖𝑚2 𝐾𝐹𝐿 432×1
Allowable bending stress of all driven gears [𝜎𝐹2 ] = = = 246,86(𝑀𝑃𝑎)
𝑆𝐹 1,75

Allowable contact stress of all gears [𝜎𝐻 ] = 481,82 (𝑀𝑃𝑎)

Allowable bending stress of all gears [𝜎𝐹 ] = 236,57 (𝑀𝑃𝑎)
 Overloaded allowable contact stress [𝜎𝐻 ]𝑚𝑎𝑥 = 2,8𝜎𝑐ℎ = 2,8 × 450 = 1260 (𝑀𝑃𝑎)
Overloaded allowable bending stress [𝜎𝐹 ]𝑚𝑎𝑥 = 0,86𝜎𝑐ℎ = 0,86 × 450 = 387 (𝑀𝑃𝑎)

3.3 Design bevel gear transmission system (Fast Level)

Initial parameter:
• Moment on shaft: 𝑇1 = 20884,5 (𝑁𝑚𝑚)
• Rotational speed: 𝑛1 = 2922 (𝑟𝑝𝑚)
• Transmission ratio: 𝑢𝑏𝑔 = 4
3.3.1 Calculate cone length
Choose bevel gear type is straight bevel gear and the material is steel 45. So, gear type and material
1 1
factor 𝐾𝑑 = 100 (𝑀𝑃𝑎3 ) and 𝐾𝑅 = 0,5𝐾𝑑 = 0,5 × 100 = 50 (𝑀𝑃𝑎3 )
Choose gear teeth face width factor 𝐾𝑏𝑒 = 0,3.
𝐾𝑏𝑒 𝑢 0,3×4
Calculate = = 0,71
2−𝐾𝑏𝑒 2−0,3

From table 6.21[1], we choose the inequivalent distribution on teeth face width factor 𝐾𝐻𝛽 = 1,13.
Outer pitch diameter of pinion:

3 𝑇1 𝐾𝐻𝛽 3 20884,5 × 1,13

𝑑𝑒𝑙 = 𝐾𝑑 √ 2
= 100 × √ = 49,46 (𝑚𝑚)
(1 − 𝐾𝑏𝑒 )𝐾𝑏𝑒 𝑢[𝜎𝐻 ] (1 − 0,3) × 0,3 × 4 × 481,822

Cone length:

2 3 𝑇1 𝐾𝐻𝛽 2 3 20884,5 × 1,13

𝑅𝑒 = 𝐾𝑅 √𝑢2 + 1 √ 2
= 50 × √42 + 1 × √
(1 − 𝐾𝑏𝑒 )𝐾𝑏𝑒 𝑢[𝜎𝐻 ] (1 − 0,3) × 0,3 × 4 × 481,822

= 101,97 (𝑚𝑚)
3.3.2 Meshing parameter
From table 6.22[1], we obtain 𝑧1𝑝 = 16.
Pinion’s number of teeth 𝑧1 = 1,6𝑧1𝑝 = 1,6 × 16 = 25,6. Choose 𝑧1 = 26.
Average diameter 𝑑𝑚𝑙 = (1 − 0,5𝐾𝑏𝑒 )𝑑𝑒𝑙 = (1 − 0,5 × 0,3) × 49,46 = 42,04 (𝑚𝑚)
𝑑𝑚𝑙 42,04
Average module 𝑚𝑡𝑚 = 𝑧1
= 26
= 1,62(𝑚𝑚)
𝑡𝑚 𝑚 1,62
Module 𝑚𝑡𝑒 = 1−0,5𝐾 = 1−0,5×0,3 = 1,91 (𝑚𝑚)
𝑏𝑒

From table 6.8, choose 𝑚𝑡𝑒 = 3,5

𝑚 = 𝑚𝑡𝑒 (1 − 0,5𝐾𝑏𝑒 ) = 3,5 × (1 − 0,5 × 0,3) = 2,98(𝑚𝑚)
Recalculate { 𝑡𝑚
𝑑𝑚𝑙 = 𝑚𝑡𝑚 𝑧1 = 2,98 × 26 = 77,48(𝑚𝑚)
Driven gears number of teeth 𝑧2 = 𝑢𝑧1 = 4 × 26 = 104
 𝑧 104
Recalculate 𝑢𝑏𝑔 = 𝑧2 = 26
= 4. Thus, the deviation is 0%.
1

𝑧 26
𝛿1 = 𝑎𝑟𝑐𝑡𝑔 (𝑧1 ) = 𝑎𝑟𝑐𝑡𝑔 (104) = 14,04𝑜
Cone angle: { 2
𝛿2 = 90𝑜 − 𝛿1 = 90𝑜 − 14,04𝑜 = 75,96𝑜
1 𝑧 26
Calculate 𝑧𝑣𝑛1 = 𝑐𝑜𝑠𝛿 = cos (14,04) = 26,8 > 17. Thus, 𝑧1 satisfy condition that there is no
1

intersection between the root of one gear with the tip of another.
Face width 𝑏 = 𝐾𝑏𝑒 𝑅𝑒 = 0,3 × 101,97 = 30,59 (𝑚𝑚).
𝑏 30,59
We have 10 = 10
= 3,06 < 𝑚𝑡𝑒 = 3,5. The bending endurance of the teeth are assured.

3.3.3 Contact stress analysis

1
From table 6.5[1], material physical property factor 𝑍𝑀 = 274 (𝑀𝑃𝑎)3 .
From table 6.12[1], with 𝑥1 + 𝑥2 = 0 and 𝛽 = 0, contact surface geometry factor 𝑍𝐻 = 1,76.
Horizontal meshing factor:
1 1 1 1
𝜀𝛼 = [1,88 − 3,2( + )] 𝑐𝑜𝑠𝛽 = [1,88 − 3,2( + )] 𝑐𝑜𝑠0 = 1,73.
𝑧1 𝑧2 26 104

4−𝜀𝛼 4−1,73
Meshing factor 𝑍𝜀 = √ 3
=√ 3
= 0,87.

Inequivalent contact stress distribution in meshing teeth factor 𝐾𝐻𝛼 = 1 .

𝜋𝑑𝑚𝑙 𝑛1 𝜋×77,48×2922 𝑚
Longitudinal speed of pinion 𝑣 = = = 11,85 ( ).
60000 60000 𝑠

From table 6.13[1], the precision level is 6

From table 6.15[1], meshing error factor 𝛿𝐻 = 0,006.
From table 6.16[1], module error factor 𝑔𝑜 = 38.

𝑑𝑚𝑙 (𝑢+1) 77,48×(4+1) 𝑚

Calculate 𝑣𝐻 = 𝛿𝐻 𝑔𝑜 𝑣√ 𝑢
= 0,006 × 38 × 11,85 × √ 4
= 26,59( 𝑠 )

𝑚
From table 6.17[1], we obtain 𝑣𝐻𝑚𝑎𝑥 = 160 ( 𝑠 ). Thus 𝑣𝐻 satisfy the condition.

Dynamic contact load in meshing area factor:

𝑣 𝑏𝑑𝑚𝑙 26,59×30,59×77,48
𝐾𝐻𝑣 = 1 + 2𝑇 𝐻𝐾 = 1 + 2×20884,5×1,13×1,04 = 2,28
1 𝐻𝛽 𝐾𝐻𝛼

Contact load factor 𝐾𝐻 = 𝐾𝐻𝛽 𝐾𝐻𝛼 𝐾𝐻𝑣 = 1,13 × 1,04 × 2,28 = 2,68

Contact stress

2𝑇1 𝐾𝐻 √𝑢2 +1 2×20884,5×2,68×√4 2 +1

𝜎𝐻 = 𝑍𝑀 𝑍𝐻 𝑍𝜀 √ 2 𝑢
0,85𝑏𝑑𝑚𝑙
= 274 × 1,76 × 0,87 × √ 0,85×30,59×77,482 ×4
= 360,72 (𝑀𝑃𝑎)
Meanwhile, the allowable contact stress [𝜎𝐻 ] = 481,82 (𝑀𝑃𝑎).So, the bevel gear assure contact
stress endurance.
3.3.4 Bending stress analysis
Helix angle factor 𝑌𝛽 = 1
𝑌𝐹1 = 3,9
From table 6.18 teeth type factor of both gears {
𝑌𝐹2 = 3,6
Inequivalent bending stress distribution factor 𝐾𝐹𝛽 = 1,25

Inequivalent bending stress distribution factor for meshing teeth 𝐾𝐹𝛼 = 1

Meshing error corresponding to bending stress factor 𝛿𝐹 = 0,016

𝑑𝑚𝑙 (𝑢+1) 77,48×(4+1) 𝑚

Calculate 𝑣𝐹 = 𝛿𝐹 𝑔𝑜 𝑣√ 𝑢
= 0,016 × 38 × 11,85 × √ 4
= 70,9 ( 𝑠 )

𝑣𝐹 𝑏𝑑𝑚𝑙 70,9×30,59×77,48
Dynamic load in meshing area factor 𝐾𝐹𝑣 = 1 + =1+ = 4,22
2𝑇1 𝐾𝐹𝛽𝐾𝐹𝛼 2×20884,5×1,25×1

Load factor corresponding to bending stress 𝐾𝐹 = 𝐾𝐹𝛽 𝐾𝐹𝛼 𝐾𝐹𝑣 = 1,25 × 1 × 4,22 = 5,28
1 1
Meshing factor 𝑌𝜖 = = = 0,58
𝜖𝛼 1,73

Bending stress of bevel pinion

2𝑇1 𝐾𝐹 𝑌𝜀 𝑌𝛽 𝑌𝐹1 2 × 20884,5 × 5,28 × 1 × 3,9
𝜎𝐹1 = = = 143,27 < [𝜎𝐹1 ] = 236,57 (𝑀𝑃𝑎)
0,85𝑏𝑚𝑡𝑚 𝑑𝑚𝑙 0,85 × 30,59 × 2,98 × 77,48
Bending stress of bevel driven gear:
𝜎𝐹1 𝑌𝐹2 143,27 × 3,6
𝜎𝐹2 = = = 132,25 < [𝜎𝐹2 ] = 246,56 (𝑀𝑃𝑎)
𝑌𝐹1 3,9
The bevel gears assure bending stress endurance.
3.3.5 Overload analysis
Overload factor 𝐾𝑞𝑡 = 2,2

Maximum contact stress:

𝜎𝐻𝑚𝑎𝑥 = 𝜎𝐻 √𝐾𝑞𝑡 = 360,72 × √2,2 = 535,03 (𝑀𝑃𝑎) < [𝜎𝐻𝑚𝑎𝑥 ] = 1260 (𝑀𝑃𝑎)

Maximum bending stress on bevel pinion:

𝜎𝐹1𝑚𝑎𝑥 = 𝜎𝐹1 𝐾𝑞𝑡 = 143,27 × 2,2 = 315,19(𝑀𝑃𝑎) < [𝜎𝐹𝑚𝑎𝑥 ] = 387 (𝑀𝑃𝑎)

Maximum bending stress on bevel driven gear:

𝜎𝐹2𝑚𝑎𝑥 = 𝜎𝐹2 𝐾𝑞𝑡 = 132,25 × 2,2 = 290,95(𝑀𝑃𝑎) < [𝜎𝐹𝑚𝑎𝑥 ] = 387 (𝑀𝑃𝑎)

The bevel gears assure overload endurance.

3.3.6 Geometry dimensions
Outer cone length

𝑅𝑒 = 0,5𝑚𝑡𝑒 √𝑧12 + 𝑧22 = 0,5 × 3,5 × √262 + 1042 = 187,6 (𝑚𝑚)

Face width
𝑏 = 𝐾𝑏𝑒 𝑅𝑒 = 0,3 × 187,6 = 56,28 (𝑚𝑚)
Average cone length
𝑅𝑚 = 𝑅𝑒 − 0,5𝑏 = 187,6 − 0,5 × 56,28 = 159,46 (𝑚𝑚)
Outer pitch diameter of pinion
𝑑𝑒1 = 𝑚𝑡𝑒 𝑧1 = 3,5 × 26 = 91 (𝑚𝑚)
Outer pitch diameter of driven gear
𝑑𝑒2 = 𝑚𝑡𝑒 𝑧2 = 3,5 × 104 = 364 (𝑚𝑚)
Pitch cone angle of pinion
𝑧 26
𝛿1 = 𝑎𝑟𝑐𝑡𝑔 ( 1 ) = 𝑎𝑟𝑐𝑡𝑔 ( ) = 14,04𝑜
𝑧2 104

Pitch cone angle of driven gear

𝛿2 = 90𝑜 − 𝛿1 = 90𝑜 − 14,04𝑜 = 75,96𝑜
Teeth height
ℎ𝑒 = 2𝑐𝑜𝑠𝛽𝑚𝑡𝑒 + 0,2𝑚𝑡𝑒 = 2 × 1 × 3,5 + 0,2 × 3,5 = 7,7 (𝑚𝑚)
Addendum teeth height of pinion
ℎ𝑎𝑒1 = (𝑐𝑜𝑠𝛽 + 𝑥𝑛1 𝑐𝑜𝑠𝛽)𝑚𝑡𝑒 = (1 + 0,38) × 3,5 = 4,83 (𝑚𝑚)
Addendum teeth height of driven gear
ℎ𝑎𝑒2 = 2ℎ𝑡𝑒 𝑚𝑡𝑒 − ℎ𝑎𝑒1 = 2 × 1 × 3,5 − 4,83 = 2,17 (𝑚𝑚)
Root height of pinion
ℎ𝑓𝑒1 = ℎ𝑒 − ℎ𝑎𝑒1 = 7,7 − 4,83 = 2,87 (𝑚𝑚)

Root height of driven gear

ℎ𝑓𝑒2 = ℎ𝑒 − ℎ𝑎𝑒2 = 7,7 − 2,17 = 5,53 (𝑚𝑚)

Addendum diameter of pinion

𝑑𝑎𝑒1 = 𝑑𝑒1 + 2ℎ𝑎𝑒1 𝑐𝑜𝑠𝛿1 = 91 + 2 × 4,83 × cos(14,04) = 100,37 (𝑚𝑚)
Addendum diameter of driven gear
𝑑𝑎𝑒2 = 𝑑𝑒2 + 2ℎ𝑎𝑒2 𝑐𝑜𝑠𝛿2 = 364 + 2 × 2,17 × cos(75,96) = 365,05 (𝑚𝑚)
Teeth face thickness of pinion
𝑠𝑒1 = (0,5𝜋 + 2𝑥𝑛1 𝑡𝑎𝑛𝛼𝑛 + 𝑥𝜏1 )𝑚𝑡𝑒 = (0,5𝜋 + 2 × 0,38 × 𝑡𝑎𝑛0 + 0,042) × 3,5
= 5,64 (𝑚𝑚)
Teeth face thickness of driven gear
𝑠𝑒2 = 𝜋𝑚𝑡𝑒 − 𝑠𝑒1 = 𝜋 × 3,5 − 5,64 = 5,36 (𝑚𝑚)
Root angle of pinion:

arctan(ℎ𝑓𝑒1 ) arctan(2,87)
𝜃𝑓1 = = = 0,37𝑜
𝑅𝑒 187,6
Root angle of driven gear:

arctan(ℎ𝑓𝑒2 ) arctan(5,53)
𝜃𝑓2 = = = 0,43 𝑜
𝑅𝑒 187,6
Addendum cone angle of pinion
𝛿𝑎1 = 𝛿1 + 𝜃𝑓2 = 14,04 + 0,43 = 14,47𝑜

Addendum cone angle of driven gear

𝛿𝑎2 = 𝛿2 + 𝜃𝑓1 = 75,96 + 0,37 = 76,33𝑜

Deddendum cone angle

𝛿𝑓1 = 𝛿1 − 𝜃𝑓1 = 14,04 − 0,37 = 13,67𝑜

Deddendum cone angle

𝛿𝑓2 = 𝛿2 − 𝜃𝑓2 = 76,96 − 0,43 = 76,53𝑜

Average diameter of pinion

0,5𝑏 0,5 × 56,28
𝑑𝑚1 = (1 − ) 𝑑𝑒1 = (1 − ) × 91 = 77,35 (𝑚𝑚)
𝑅𝑒 187,6
Average diameter of driven gear
0,5𝑏 0,5 × 56,28
𝑑𝑚2 = (1 − ) 𝑑𝑒2 = (1 − ) × 364 = 309,4 (𝑚𝑚)
𝑅𝑒 187,6
Distance from cone peripheral to teeth tip of pinion
𝐵1 = 𝑅𝑒 𝑐𝑜𝑠𝛿1 − ℎ𝑎𝑒1 𝑠𝑖𝑛𝛿1 = 187,6 × cos(14,04) − 4,83 × sin(14,04) = 180,82 (𝑚𝑚)
Distance from cone peripheral to teeth tip of driven gear
𝐵2 = 𝑅𝑒 𝑐𝑜𝑠𝛿2 − ℎ𝑎𝑒2 𝑠𝑖𝑛𝛿2 = 187,6 × cos(76,96) − 2,17 × sin(76,96) = 40,21 (𝑚𝑚)
Average module
𝑚𝑡𝑚 = 𝑚𝑡𝑒 (1 − 0,5𝐾𝑏𝑒 ) = 3,5 × (1 − 0,5 × 0,3) = 2,98 (𝑚𝑚)
 Average normal module
𝑏 56,28
𝑚𝑛𝑚 = (𝑚𝑡𝑒 − ) 𝑐𝑜𝑠𝛽𝑚 = 3,5 − = 3,07 (𝑚𝑚)
𝑧1 + 𝑧2 26 + 104
Eccentric distance
𝑒 = 𝑅𝑠𝑖𝑛𝛽 = 0 (𝑚𝑚)
Tip teeth angle
𝑒
𝛽𝑒 = arcsin ( ) = 𝑎𝑟𝑐𝑠𝑖𝑛0 = 0𝑜
𝑅𝑒

Table 4: Technical Parameter of Bevel Gear Transmission System

Technical specification

Parameter Value Parameter Value

Type of gear Bevel gear Outer pitch diameter,

mm
Outer cone length 𝑅𝑒 ,
Pinion 𝑑𝑒1
mm 187,6 91
Driven gear 𝑑𝑒2
364

Face width b, mm 56,28 Pitch cone angle

Average cone length Pinion 𝛿1 14,04𝑜

𝑅𝑚 , mm
159,46 Driven gear 𝛿2 75,96𝑜

Teeth height ℎ𝑒 , mm 7,7 Addendum teeth height,

mm
Root height, mm
Pinion ℎ𝑎𝑒1
Pinion ℎ𝑓𝑒1 2,87 4,83
Driven gear ℎ𝑎𝑒2
Driven gear ℎ𝑓𝑒2 5,53 2,17

Addendum diameter, Teeth face thickness,

mm mm
Pinion 𝑑𝑎𝑒1 Pinion 𝑠𝑒1
100,37 5,64
Driven gear 𝑑𝑎𝑒2 Driven gear 𝑠𝑒2
365,05 5,36
 Root angle Addendum cone angle
Pinion 𝜃𝑓1 0,37𝑜 Pinion 𝛿𝑎1 14,47𝑜

Driven gear 𝜃𝑓2 0,43𝑜 Driven gear 𝛿𝑎2 76,33𝑜

Average diameter, mm Deddendum cone angle

Pinion 𝑑𝑚1 77,35 Pinion 𝛿𝑓1 13,67𝑜
Driven gear 𝑑𝑚2 309,4 Driven gear 𝛿𝑓2 76,53𝑜

Distance from cone

peripheral to teeth tip,
mm
Number of teeth
Pinion 𝐵1
180,82 Pinion 𝑧1 26
Driven gear 𝐵2
40,21 Driven gear 𝑧2 104

Average module 𝑚𝑡𝑚 , Eccentric distance e, 0

2,98
mm mm

Average normal
3,07 Material Steel 45
module 𝑚𝑛𝑚 , mm

Tip teeth angle 𝛽𝑒 0𝑜

Validating calculation

Paramater Allowable value Design value Result

Contact Stress, MPa 481,82 360,72 Satisfy

Bending Stress on
236,57 143,27 Satisfy
Pinion, MPa

Bending Stress on
246,56 132,25 Satisfy
Driven Gear, MPa

Maximum Contact
1260 535,03 Satisfy
Stress, MPa

Maximum Bending
387 315,19 Satisfy
Stress on Pinion, MPa

Maximum Bending
Stress on Driven Gear, 387 290,95 Satisfy
MPa

3.4 Design spur gear transmission system (Slow Level)

Initial parameter:
 • Moment on shaft: 𝑇2 = 79354,55 (𝑁𝑚𝑚)
• Rotational speed: 𝑛2 = 730,5 (𝑟𝑝𝑚)
• Transmission ratio: 𝑢𝑠𝑔 = 4
3.4.1 Basic parameter of the transmission system
1 1
From table 6.5[1], material and gear type factor 𝐾𝑎 = 49,5 (𝑀𝑃𝑎)3 and 𝐾𝑑 = 77 (𝑀𝑃𝑎)3
From table 6.6[1], which the arrangement of the spur gears is asymmetry corresponding to the
bearing position, choose 𝜓𝑏𝑎 = 0,4 and 𝜓𝑏𝑑𝑚𝑎𝑥 = 1,25
Calculate 𝜓𝑏𝑑 = 0,53𝜓𝑏𝑎 (𝑢 + 1) = 0,53 × 0,4 × (4 + 1) = 1,06
From table 6.7[1], inequivalent contact stress distribution factor 𝐾𝐻𝛽 = 1,07

Center distance

1 𝐻𝛽 (𝑢 + 1)
3 𝑇 𝐾 3 79354,55 × 1,07 × (4 + 1)
𝑎𝑤 = 𝐾𝑎 (𝑢 + 1) √ 2
= 49,5 × (4 + 1) √
[𝜎𝐻 ] 𝑢𝜓𝑏𝑎 481,822 × 4 × 0,4
= 258,77 (𝑚𝑚)
Pinion nominal diameter
3 𝑇1 𝐾𝐻𝛽 (𝑢+1) 3 79354,55×1,07×(4+1)
𝑑𝑤1 = 𝐾𝑑 √ [𝜎 2 = 77 × √ 481,822 ×4×1,06
= 58,18 (mm)
𝐻 ] 𝑢𝜓𝑏𝑑

Face width 𝑏𝑤 = 𝜓𝑏𝑑 𝑑𝑤1 = 1,06 × 58,18 = 61,67 (𝑚𝑚)

3.4.2 Meshing parameter
Module 𝑚 = (0,01 ÷ 0,02)𝑎𝑤 = (0,01 ÷ 0,02) × 258,77 = 2,59 ÷ 5,18.
From table 6.8[1], choose 𝑚 = 4 (𝑚𝑚)
We choose helical angle 𝛽 = 30𝑜
2𝑎𝑤 𝑐𝑜𝑠𝛽 2×258,77×𝑐𝑜𝑠30
Pinion’s number of teeth 𝑧1 = 𝑚(𝑢+1)
= 4×(4+1)
= 22,41. Choose 𝑧1 = 22.

Driven gear’s number of teeth 𝑧2 = 𝑢𝑧1 = 4 × 22 = 88

Total number of teeth 𝑧𝑡 = 𝑧1 + 𝑧2 = 22 + 88 = 110.
𝑚𝑧𝑡 4×110
Recalculate 𝑐𝑜𝑠𝛽 = = = 0,85. So, 𝛽 = 31,77𝑜 .
2𝑎𝑤 2×258,77

𝑧1 > 𝑧𝑚𝑖𝑛 + 2
Since { 𝑢 > 3,5 . So, displacement factor of pinion 𝑥1 = 0,3 and displacement factor of
𝑧1 > 10
driven gear 𝑥2 = −0,3.
Total displacement factor 𝑥𝑡 = 𝑥1 + 𝑥2 = 0,3 − 0,3 = 0
1000𝑥𝑡
Horizontal meshing advancement factor 𝑘𝑥 = 𝑧𝑡
=0
From table 6.10b[1], vertical meshing advancement factor 𝑘𝑦 = 0
𝑦 𝑡 𝑘 𝑧
Teeth addendum reducing factor ∆𝑦 = 1000 =0
𝑚𝑧𝑡 4×110
Recalculate 𝑎𝑤 = 2𝑐𝑜𝑠𝛽 = 2×𝑐𝑜𝑠31,77 = 258,77 (𝑚𝑚)

0,5𝑚(𝑧2 +𝑧1 ) 0,5×4×110

Preliminary center distance 𝑎 = = = 258,82 (𝑚𝑚)
𝑐𝑜𝑠𝛽 0,85

Center distance 𝑎𝑤 = 𝑎 + 𝑦𝑚 = 𝑎 + (𝑥2 + 𝑥1 − ∆𝑦) = 258,82 (𝑚𝑚)

𝑚𝑧 4×22
Nominal diameter of pinion 𝑑1 = 𝑐𝑜𝑠𝛽1 = 0,85
= 103,53 (𝑚𝑚)

𝑚𝑧 4×88
Nominal diameter of driven gear 𝑑2 = 𝑐𝑜𝑠𝛽2 = 0,85
= 414,12 (𝑚𝑚)

Rolling diameter of pinion

2𝑦
𝑑𝑤1 = 𝑑1 + × 𝑑1 = 103,53 (𝑚𝑚)
𝑧1 + 𝑧2
Rolling diameter of driven gear
2𝑦
𝑑𝑤2 = 𝑑2 + × 𝑑2 = 414,12 (𝑚𝑚)
𝑧1 + 𝑧2
Addendum diameter of pinion
𝑑𝑎1 = 𝑑1 + 2(1 + 𝑥1 − ∆𝑦)𝑚 = 103,53 + 2 × (1 + 0,3) × 4 = 113,93 (𝑚𝑚)
Addendum diameter of driven gear
𝑑𝑎2 = 𝑑2 + 2(1 + 𝑥2 − ∆𝑦)𝑚 = 414,12 + 2 × (1 − 0,3) × 4 = 419,72 (𝑚𝑚)
Deddeddum diameter of pinion
𝑑𝑓1 = 𝑑1 − (2,5 − 2𝑥1 )𝑚 = 103,53 − (2,5 − 2 × 0,3) × 4 = 95,93 (𝑚𝑚)

Deddeddum diameter of driven gear

𝑑𝑓2 = 𝑑2 − (2,5 − 2𝑥2 )𝑚 = 414,12 − (2,5 + 2 × 0,3) × 4 = 401,72 (𝑚𝑚)

Base diameter of pinion 𝑑𝑏1 = 𝑑1 𝑐𝑜𝑠𝛼 = 103,53 × 𝑐𝑜𝑠20 = 97,29 (𝑚𝑚)

Base diameter of driven gear 𝑑𝑏2 = 𝑑2 𝑐𝑜𝑠𝛼 = 414,12 × 𝑐𝑜𝑠20 = 389,15 (𝑚𝑚)
𝑡𝑎𝑛𝛼 𝑡𝑎𝑛20
Teeth profile angle 𝛼𝑡 = arctan ( 𝑐𝑜𝑠𝛽 ) = arctan ( 0,85
) = 23,18𝑜

𝑎𝑐𝑜𝑠𝛼𝑡 258,82×𝑐𝑜𝑠23,18
Meshing angle 𝛼𝑡𝑤 = arccos ( 𝑎𝑤
) = arccos ( 297,58
) = 36,91𝑜

Total displacement factor

𝑧𝑡 (𝑖𝑛𝑣𝛼𝑡𝑤 − 𝑖𝑛𝑣𝛼𝑡 ) 110 × (0,10696 − 0,023577)
𝑥𝑡 = = = 12,6
2𝑡𝑎𝑛𝛼 2𝑡𝑎𝑛20
 𝑧1 𝑡𝑎𝑛𝛼1 +𝑧2 𝑡𝑎𝑛𝛼2 +𝑧𝑡 𝑡𝑎𝑛𝛼𝑡𝑤 22×0,36+88×0,34×110×0,75
Horizontal coincident factor 𝜀𝛼 = 2𝜋
= 2𝜋
= 19,15

3.4.3 Contact Stress Analysis

1
From table 6.5, material physical property factor 𝑍𝑀 = 274 (𝑀𝑃𝑎)3
Helical angle on reference cylinder
𝛽𝑏 = arctan(𝑐𝑜𝑠𝛼𝑡 𝑡𝑎𝑛𝛽) = arctan [𝑐𝑜𝑠(23,18𝑜 ) × tan(31,77𝑜 ) = 29,65𝑜

2𝐶𝑂𝑆𝛽𝑏 2×𝐶𝑂𝑆29,65
Contact surface geometry factor 𝑍𝐻 = √𝑠𝑖𝑛2𝛼 = √sin (2×36,91) = 1,35
𝑡𝑤

𝑏𝑤 𝑠𝑖𝑛𝛽 61,67×sin(31,77)
Vertical meshing factor 𝜀𝛽 = 𝑚𝜋
= 4𝜋
= 2,58 > 1.

Horizontal meshing factor

1 1 1 1
𝜀𝛼 = [1,88 − 3,2 × ( + )] 𝑐𝑜𝑠𝛽 = [1,88 − 3,2 × ( + )] × 𝑐𝑜𝑠(31,77) = 1,44
𝑧1 𝑧2 22 88

1 1
Meshing factor 𝑍𝜀 = √𝜀 = √1,44 = 0,83
𝛼

From table 6.7[1], inequivalent contact load distribution on teeth width factor 𝐾𝐻𝛽 = 1,19
𝜋𝑑𝑤1 𝑛1 𝜋×103,53×730,5 𝑚
Longitudinal speed of transmission 𝑣 = = = 3,96 ( )
60000 60000 𝑠

From table 6.13[1], the precision level is 9.

From table 6.14[1], inequivalent contact load distribution on meshing teeth factor 𝐾𝐻𝛼 = 1,16
Frome P2.3[1], dynamic load in meshing area factor 𝐾𝐻𝑣 = 1,05
Load corresponding to contact stress factor 𝐾𝐻 = 𝐾𝐻𝛽 𝐾𝐻𝛼 𝐾𝐻𝑣 = 1,19 × 1,16 × 1,05 = 1,45

Contact stress

2𝑇1 𝐾𝐻 (𝑢 + 1) 2 × 79354,55 × 1,45 × (4 + 1)

𝜎𝐻 = 𝑍𝑀 𝑍𝐻 𝑍𝜀 √ 2 = 274 × 1,35 × 0,83 × √
𝑏𝑤 𝑢𝑑𝑤1 61,67 × 4 × 103,532
= 202,53 (𝑀𝑃𝑎)
Meanwhile [𝜎𝐻 ] = 481,82 (𝑀𝑃𝑎). So this gear transmission satisfy the contact stress analysis.
3.4.4 Bending Stress Analysis
1 1
Meshing factor 𝑌𝜀 = 𝜀 = 1,44 = 0,69
𝛼

𝛽 31,77
Helical factor 𝑌𝛽 = 1 − =1− = 0,77
140 140
𝑧 22
Equivalent teeth of pinion 𝑧𝑣1 = 𝑐𝑜𝑠13 𝛽 = 𝑐𝑜𝑠3 (31,77) = 35,8

𝑧 88
Equivalent teeth of driven gear 𝑧𝑣2 = 𝑐𝑜𝑠23 𝛽 = 𝑐𝑜𝑠3 (31,77) = 143,21
 𝑌𝐹1 = 3,53
From table 6.18[1], teeth type factor of pinion and driven gear {
𝑌𝐹2 = 3,63
From P2.3[1], inequivalent bending load distribution factor 𝐾𝐹𝛽 = 1,04

From table 6.14[1], inequivalent bending load distribution in meshing area 𝐾𝐹𝛼 = 1,4
From table 6.15[1], meshing error corresponding to bending stress 𝛿𝐹 = 0,016
From table 6.16[1], module error factor 𝑔𝑜 = 82

𝑎 258,77
Calculate 𝑣𝐹 = 𝛿𝐹 𝑔𝑜 𝑣√ 𝑢𝑤 = 0,016 × 82 × 3,96 × √ 4
= 41,79

𝑣𝐹 𝑏𝑤 𝑑𝑤1 41,79×61,67×103,53
Dynamic load in meshing area factor 𝐾𝐹𝑣 = 1 + =1+ = 1,15
2𝑇1 𝐾𝐹𝛽 𝐾𝐹𝛼 2×79354,55×1,04×1,4

Load factor corresponding to bending stress 𝐾𝐹 = 𝐾𝐹𝛽 𝐾𝐹𝛼 𝐾𝐹𝑣 = 1,04 × 1,4 × 1,15 = 1,67
2𝑇1 𝐾𝐹 𝑌𝜀 𝑌𝛽 𝑌𝐹1 2×79354,55×1,67×0,69×0,77×3,53
Bending stress on pinion 𝜎𝐹1 = 𝑏𝑤 𝑑𝑤1 𝑚
= 61,67×103,53×4
= 19,46 (𝑀𝑃𝑎)

𝜎𝐹1 𝑌𝐹2 19,46×3,63

Bending stress on driven gear 𝜎𝐹2 = 𝑌𝐹1
= 3,53
= 20,01 (𝑀𝑃𝑎)

Meanwhile, [ 𝜎𝐹1 ] = 236,57 (𝑀𝑃𝑎) and [ 𝜎𝐹2 ] = 246,86 (𝑀𝑃𝑎). So, the gear transmission
satisfy the bending stress analysis.
3.4.5 Overload Analysis
Maximum contact stress 𝜎𝐻𝑚𝑎𝑥 = 𝜎𝐻 √𝐾𝑞𝑡 = 202,53 × √2,2 = 300,4 (𝑀𝑃𝑎)

Maximum bending stress on pinion 𝜎𝐹𝑚𝑎𝑥1 = 𝜎𝐹1 𝐾𝑞𝑡 = 19,46 × 2,2 = 42,81 (𝑀𝑃𝑎)

Maximum bending stress on driven gear 𝜎𝐹𝑚𝑎𝑥2 = 𝜎𝐹2 𝐾𝑞𝑡 = 20,01 × 2,2 = 44,02(𝑀𝑃𝑎)

Meanwhile [𝜎𝐻𝑚𝑎𝑥 ] = 1260 (𝑀𝑃𝑎) and [𝜎𝐹𝑚𝑎𝑥 ] = 387 (𝑀𝑃𝑎). So, the gear transmission
satishfy the overload analysis.
3.4.6 Summary
Table 5: Technical Parameter of Spur Gear Transmission System

Technical specification

Parameter Value Parameter Value

Type of gear Spur gear Nominal diameter, mm

Pinion 𝑑1 103,53
Preliminary center
258,82
distance a, mm Driven gear 𝑑2 414,12

Center distance 𝑎𝑤 , Rolling diameter, mm

mm 258,82
 Pinion 𝑑𝑤1 103,53
Driven gear 𝑑𝑤2 414,12
Face width 𝑏𝑤 , mm 61,67

Base diameter, mm Addendum diameter,

mm
Pinion 𝑑𝑏1 97,29
Pinion 𝑑𝑎1
Driven gear 𝑑𝑏2 389,15 113,93
Driven gear 𝑑𝑎2
Deddendum diameter, 419,72
mm
Pinion 𝑑𝑓1
95,93
Driven gear 𝑑𝑓2
401,72

Teeth profile angle 𝛼𝑡 23,18𝑜 Meshing angle 𝛼𝑡𝑤 36,91𝑜

Total displacement Material Steel 45

12,6
factor 𝑥𝑡

Horizontal coincident
Helical angle 𝛽 31,77𝑜 19,15
factor 𝜀𝛼

Validating calculation

Paramater Allowable value Design value Result

Contact Stress, MPa 481,82 202,53 Satisfy

Bending Stress on
236,57 19,46 Satisfy
Pinion, MPa

Bending Stress on
246,56 20,01 Satisfy
Driven Gear, MPa
Maximum Contact
1260 300,4 Satisfy
Stress, MPa
Maximum Bending
387 42,81 Satisfy
Stress on Pinion, MPa

Maximum Bending
Stress on Driven Gear, 387 44,02 Satisfy
MPa

3.5 Lubricating analysis

Bevel driven gear needs to be dipped in lubrication liquid an amount equal teeth height h
Spur gears need to be dipped in lubrication liquid an amount equal teeth height ℎ𝑟 plus minimum
10 mm.
1
Highest oil level mustn’t pass 𝑅 of spur driven gear.
3

Distance between highest and lowest oil level ℎ𝑚𝑎𝑥 − ℎ𝑚𝑖𝑛 = 10 ÷ 15 (𝑚𝑚)
3.5.1 Consider driven bevel gear
Smallest teeth height that must be dipped into oil
ℎ2𝑚𝑖𝑛 = 2,25𝑚 = 2,25 × 3,5 = 7,88 < 10 (𝑚𝑚)
1 1
Allowable height [𝐻] = 𝑑𝑎4 = × 419,72 =139,91 (mm)
3 3

1 1
𝐻1 = 𝑑𝑎𝑒2 − 10 − 15 = × 365,05 − 10 − 15 = 157,53 (𝑚𝑚) > [𝐻]
2 2
3.5.2 Consider driven spur gear
Smallest teeth height that must be dipped into oil
ℎ4𝑚𝑖𝑛 = 2,25𝑚 = 2,25 × 4 = 10 ≤ 10 (𝑚𝑚)
1 1
𝐻2 = 2 𝑑𝑎4 − 10 − 15 = 2 × 419,72 − 10 − 15 = 184,86(𝑚𝑚) > [𝐻].

So the gearbox satisfies the lubricating condition