CONTENTS

Abstract
List of Figures
List of Tables
Nomenclature
1. INTRODUCTION
2. LITERATURE SURVEY
2.1Introduction to HMT
2.2Establishment of Companys Branches
2.3Companys Milestones
2.4About Praga Division
3. Power transmission
3.1Types of drives
3.2Advantage of gear drives
3.3Disadvantages of gear drives

i
ii
ii
iii
1
3
3
3
4
5
7
7
7
8

4. INTRODUCTION TO GEAR DRIVES

4.1Introduction
4.2General classification of gears
4.3Gear terminology
4.4Spur gear
4.5Characteristics of helical gears

9
9
10
14
17
18

5. PROBLEM DEFINITION
5.1Design procedure for helical gears
5.2calculations

22
23
25

6.
7.
8.
9.

FINITE ELEMENT METHOD

ANALYSIS
RESULTS AND CONCLUTION
REFERENCES

54
56

ABSTRACT

This project involves the design of a set of helical gears for gearbox of a thread rolling
machine at HMT. Thread rolling is a cold forming process in which different types of threads
are formed by rolling action.
In this project problems posed by spur gears like noise, lack of free movement
during power transmission and high impact stresses at the time of engagement of gears
are eliminated by replacing them with helical gears.
The design constraints in this project work are centre distance between the gears,
tranmission ratio and the gearbox dimensions.
First, set of helical gears to be designed theoretically using LEWIS EQUATION.
Stresses induced in those gears are to be evaluated and they should be within the safe limits.
Later, Finite element package ANSYS will be used for analysis. Aim of the analysis is to
determine the maximum deflection and stresses induced in the helical gear. Tangential, radial
and axial loads are analyzed using ANSYS software. The stresses produced in the gears
should be with in the limits, if not the process would be repeated accordingly and the stress
produced in the gear which is within the limits should be achived.

LIST OF FIGURES
Figure 1 : Thread rolling machine

Figure 2 : Spur gear

Figure 3 : Helical gear
Figure 4 : Herring bone gear
Figure 5 : Straight bevel gear
Figure 6 : Hypoid gear
Figure 7 : Crossed gear
Figure 8 : Worm gear
Figure 9 : Gear terminology
Figure 10 : Meshed gear
Figure 11 : Compressive stress diagram
Figure 12 : Deformed shape of helical gear

LIST OF TABLES
Table 1 : Spur gear results
Table 2 : Helical gear results

ii

NOMENCLATURE

Pressure angle, degrees

Normal pressure angle, degrees

Helix angle, degrees

ad

Design stress, N/mm2

Endurance limit stress, N/mm2

es

Surface endurance limit of a gear pair, N/mm2

Center distance, mm

Face width, mm

Dynamic factor depending upon machining errors

Cs

Service factor

Cw

Wear and lubrication factor

Cv

Velocity factor

Pitch circle diameter, mm

Fa

Axial thrust, N

Fd

Dynamic load on gear tooth, N

Ft

Tangential load at pitch line, N

Fs

Dynamic strength of the gear, N

Fw

Limiting load for wear, N

Load stress factor

Module, mm

mn

Normal module, mm

Speed, rpm

Pc

Circular pitch

Pd

Diametral pitch

Circular pitch, mm
iii

pn

Normal circular pitch, mm

Ratio factor

Pitch line velocity, m/s

Form factor

Lewis form factor

Ze

No. Of teeth on gear

Equivalent no. of teeth

iv

CHAPTER 1
INTRODUCTION
The thread rolling is a cold forming process in which different types of threads are
formed by means of rolling action. The thread rolling machine can produce threads, worms,
knurls, serrations, annular forms, roll finishing and straightening. There are different types of
thred rolling machines like:

axial rolling,

radial rolling,

tangential rolling.
In the thread rolling machine rolls are pressed into the component,stressing the

material beyond its yield point. This causes the component material to be deformed
plastically, and thus, permanently. Unike thread cutting, the grain structure of the material is
displaced not removed. As the material will be plastically deformed by pressure, it should
have a minimum elongation of 5% and a maximum tensile strength of 246,000 PSI. Materials
that have less than 5% elongation or a significant hardness greater than 40 HRc, such as cast
iron, hard brass alloys and other hardened materials are not suitable candidates for thread
rolling process. The only requirement for the rolling process is that either the component or
the rolling head, or both, are rotating towards one another. Thread rolling tools can be used
on a wide variety of standard and special machine tools.
Threads are produced in second and in only one pass, whereas CNC single point
thread cutting requires numerous passes and a much longer cycle time. Long roll-life
eliminates costly down time for tool changes.
Cold forming operations, extremely short cycle times are not just a welcome attribute,
but rather a condition of the process. In plastic forming, the material must be caused to flow.
Therefore, higher speeds are better than low speeds.

Fig 1 Thread rolling machine and thread rolling process

Chapter 2
Literature survey
2.1 Introduction to HMT
HMT Ltd is a public limited commercial organisation involved in the manufacture
and sales of engineering goods as well as project consultancy. The company is engaged in the
business of manufacturing and selling tractors and food processing machines. Their segments
include machine tools, watches, tractors, bearings and exports.
The company's products include printing machine, bearings, food processing
machine, machine tools, watches and tractors. They have five subsidiaries namely HMT
Machine Tools Ltd, HMT Watches Ltd, HMT Chinar Watches Ltd, HMT (International) Ltd
and HMT Bearings Ltd. HMT Ltd was incorporated in the year 1953 by the Government of
India as a Machine Tool manufacturing company with the name Hindustan Machine Tools
Ltd.
The company was incorporated with the objective of producing a limited range of
machine tools, required for building an industrial edifice for the country. Over the years, the

company diversified into Watches, Tractors, Printing Machinery, Metal Forming Presses, Die
Casting & Plastic Processing Machinery, CNC Systems & Bearings. In 1960s, the company
set up new units at Pinjore, Kalamassery and Hyderabad. In 1970s, they set up HMT
International Ltd as a subsidiary company to channel HMT's products and technical services
abroad.

2.2 Establishment of Companys branches :

They set up two units for manufacture of watches, one at Srinagar and another at
Tumkur. Also, they took over Machine Tool Corporation at Ajmer as their sixth machine tool
unit. In May 13, 1977, the company was converted into a public limited company and in
September 12, 1978, the name of the company was changed from Hindustan Machine Tools
Ltd to HMT Ltd. In 1980s, the company as a part of vertical integration efforts, launched
units to manufacture Watches at Ranibagh, Watch Cases at Bangalore, Stepper Motors at
Tumkur, CNC Systems at Bangalore and Ball screws for use on CNC machines at Bangalore.
They took over Indo-Nippon Precision Bearings Ltd, a state owned unit as a subsidiary,
which was renamed HMT-Bearings Ltd.
Also, they took over Praga Tools Ltd as another subsidiary. In 1990s, the company
restructured themselves into five Business Groups viz., Machine Tools, Watches, Tractors,
Industrial Machinery and Engineering Components as part of Business Reorganization. In the
year 1993, they launched two new brands, namely 'Ramani' for gents and 'Utsav' for ladies. In
the year 1997, the tractors group launched a 45 HP Coastal Special model tractor for
application in coastal areas on Commercial basis. Also, they launched 59 HP model tractors
with Power Steering. In the year 1998, the company introduced 350 range of Citizen watches
in Mumbai along with their latest Eco-Drive models, which absorb power thorough any
source of light.

2.3 Companys Milestones :

They entered into manufacturing and marketing alliance with Tennmax Industrial Ltd.
of Hong Kong. In August 1, 2000, the company received the approval of the Government of
India for the turnaround plan submitted by the company. Consequently, the company signed a
Memorandum of Understanding with the Government of India on August 11, 2000 detailing
various actions to be taken on a time bound manner both by the Government and the
company. As per the restructuring plan, two separate subsidiary companies, namely HMT

Machine Tools Ltd and HMT Watches Ltd have been incorporated and these subsidiaries will
take over the business of Machine Tools and Watches of the company.
In the year 2004, the company signed agreement with UK-based Trantor for high
power tractors. Also, they signed MoU with State Bank of India (SBI) for tractor finance.
During the year 2004-05, an Emission Testing Lab with an investment of 4 crore was set up
to upgrade each of the engines to conform to emission norms. During the year 2004-05, they
increased the installed capacity of Machine Tools to 1479 Nos with the increase of 90 Nos. In
the year 2006, the company established a high tech Engine Emission Testing Laboratory in
R&D Centre at their Tractor Division, Pinjore with an investment of Rs 50 million.
During the year 2007-08, Praga Tools Ltd, a subsidiary company was amalgamated
with HMT Machine Tools Ltd, another subsidiary company. During the year 2008-09, the
company initiated a number of operational measures such as improvement in their products,
rationalization of product mix, operational methods, capital investments, new strategies for
marketing and distribution and introduction of productivity improvement schemes. The
Tractor Group of the company has initiated a host of measures towards performance
improvement in right earnest, by appointment of new distributors and dealers in select
potential areas/ territories, engine upgradation for compliance of new emission norms for all
models of tractors, setting up of a new paint plant, entering into MoUs with Banks/ Financing
Agencies for priority loan sanction for the purchase of HMT Tractors, dynamic business
strategies, etc.

2.4 About PRAGA Division :

PRAGA is one of the leading machine tool manufacturing units in india. Established
in 1943, Pragas products are well known in the field of Machine Tools. The company is
organised in four divisions viz the machine tools, forge, foundry and CNC Division which
pulsates with the activities of 565 employees, turning out a wide range of products.
The four divisions, equipped with modern facilities for design, development and
manufacture of machine tools, are manned by qualified personnel with proven record of
technical knowledge and exquisite craftsmanship acquired over a period of 60 years.
PRAGA is proud of its diverse range of machine tools the cutter and tool grinders,
milling machines, copy lathes, thread rolling machines and praga CNC machines which keep

pace with the ever changing technology. In addition, the company also manufactures a wide
range of industrial forgings for railway, automotive and ordnance applications.
PRAGAS wisest investment has been in it excellent collaboration with cutter and tool
grinders, gambian of france for milling machines, escofier of france for thread rolling
machines, george fisher of switzerland for copying lathes,mitsubishi heavy industries of
japan for machining centres and keiyo seiki of japan for CNC lathes. The collaborations have
culminated in Praga producing machine tools of the highest quality conforming to
international standards. By virtue of their dependability, precision engineering and proven
performance , praga machine tools are penetrating larger segments of foreign markets
including UK, CIS, Canada, Bulgaria,Indonesia, Germany, Japan, etc., praga is even more
proud of the fact that it has contributed to the development of the machine tool industry in the
country and the creation of a vast band of skilled technicians. Thus, Praga today, is a nam to
reckon within the machine tool industry.
HMT Limited has 18 manufacturing units.The constituent subsidiaries are given
below while the holding company retains the tractors business group.HMTs tractor business
commenced

its

operations

in

1971

in

technical

collaboration

with

MOTOKOV, Czechoslovakia. HMT started the operation with the manufacture of

25 HP tractor at the manufacturing plant in Pinjore, Haryana state. Over the years, it has
developed tractors ranging from 25 HP to 75 HP.
HMT Limited took over Praga Tools Limited as one of its subsidiaries 1988. Praga
Tools Limited was established in May, 1943 as Praga Tools Corporation Limited to
manufacture machine tools with its head quarters at Secunderabad. It was renamed as Praga
Tools Limited in 1963. It is mainly involved in manufacture of machine tools including CNC
machines.

CHAPTER 3
POWER TRANSMISSION
Power transmission is transfer of rotary motion and power from one shaft to another. The
transmission of power can be done in different ways like belt drives, rope drives, chain drives
and gear drives.

3.1 Types of drives

3.1.1Belt and Rope drives:
These drives are used to transmit power between two parallel shafts by means of friction.
In this drive an endless belt or rope envelopes the pulleys of two shafts. These drives are used
for long distance transmission. But there is a demerit of using these drives is that there is a
slipping between the belt and pulley.

3.1.2 Chain drives:

In this drive an endless chain is wrapped around sprockets/ toothed wheels thereby
constraining the motion of the chain and the wheels thus eliminating the slipping of belt and
ropes around pulleys.

3.1.3 Gear drives:

Gears are toothed wheels or multilobed cams, which transmits power and motion fro one
shaft to another by means of progressive engagement of teeth. Although belt drives have the
inherent advantages of shock, load reaction and vibration absorption capacities, greater space
requirements, exposure to surrounding and vulnerability to slippage make the gearing
systems more preferable because these systems are positively driven, can be totally enclosed,
require less space and are compact driving arrangements.

3.2 Advantages of gear drive:

Gears offer positive power transmission.

Gear drives are compact in construction due to relatively small centre distance.

Gears provide power transmission with high angular or linear accuracy.

Gear drives can avail a wide range of power transmission beyond the range of belt
drives or chain drives.

Gears can change the rate of rotation of a machinery shaft.

Gears can change the direction of the axis of rotation.

Gears can change rotary motion to linear motion.

Gear drives have a provision for gear shifting thus changed the transmission ratio over
a wide range.

3.3 Disadvantages of Gear drives:

Their manufacturing is complex as special tools and equipment is needed.

The error in cutting teeth may cause vibrations and noise during operation.
Gears are of several categories and can be combined in a multitude of ways some of

which are explained below those transmitting power and motion between

Parallel shafts, namely spur and helical.

Intersecting shafts where the angle is nearly 90 degrees namely between bevel gears.

Neither parallel nor intersecting shafts where angle being 90 degrees, namely worm
and worm wheel, crossed helical gears and hypoid gears.

Many modern gears use a special tooth profile called an involute profile. This profile
has the very important property of maintaining a constant speed ratio between the two
gears. But the shape of the involute gear tooth compensates for this movement.

CHAPTER 4
INTRODUCTION TO GEARS
Gears are most common means of transmitting power in modern mechanical world.
They vary from a tiny size used in watches to the larger gears used in marine speed reducers,
bridge lifting mechanisms and rail road turn table drives. They form vital elements of main
and auxilary machanisms in many machines such as automobiles, tractors, metal cutting
machine tools, rolling mills, hoisting and transmitting machinery, marine engines etc.
Toothed are used to change the speed or power ratio as well as direction between input and
output.

4.1 Definition:
Gear is defined as a toothed wheel or multilobed cam which transmits power and
motion from one shaft to another by means of successive engagement of teeth.

4.1 a)Advantages of gears :

Gear drives offer the following advantages compared with chain or belt drives.

It is a positive drive and the velosity ratio remains constant.

The center distance between the shafts is relatively small, which results in compact
construction.

It can transmit very large power, which is beyond the range of belt or chain drives.

It can transmit motion at very low velosity, which is not possible with the belt drives.

The efficiency of geardrives is very high even up to 99% in case of spur gears.

A provision can be made in the gear shifting, thus changing the velosity ratio over a
wide range i.e. from 0.1kw to 1000s kW.

4.1 b) Disadvantages of gears :

Manufacturing of gears is complex, since special tools and equipment are necessary to
manufacture.

Due to errors and inaccuracy in their manufacture, the drive may become noisy
accompained by vibration and high speed.

They are not suitable for large center distances because the drive becomes bulky.

4.2 GENERAL CLASSIFICATION OF GEARS:

Depending upon the relation between the axes, shape of the solid on which the teeth
are developed, curvature of the tooth trace and any other special features, gears are
categorized into the following types.
4.2.1 Spur gears:
In a pair of mating spur gears the axes of the component gears are parallel, that is they
are mounted on shafts which are parallel to each other. The gear teeth are straight along the
length and parallel to the axes.

Fig 2

4.2.2 Helical gears:

In these gears also the axes are parallel and the pitch solid is cylindrical. The traces or
the elements of teeth are helices and these may be left handed or right handed.

Fig 3
4.2.3 Herringbone gears:
They are also known as double helical gears, these gears are actually two helical gears
of opposite hands, placed side by side and cut on the same blank to obtain a composite unit.

Fig 4
4.2.4 Straight bevel gears:
In this type of gearing, the axes are intersecting. The angle between the tooth axes,
known as shaft angle is usually 90 degrees. The gear blan is a cone on which teeth are
generated. The teeth are straight, but the height of the teeth gradually decreases and sides of
the teeth are tapered so that all lines, when extended meet at a common point called cone
apex. Bevel gears having straight teeth but mounted on non-intersecting axes are known as
skew gears.

Fig 5
4.2.5 Hypoid gears:
These are similar to spiral bevel gears, but have non-intersecting axes i.e. the axis of
the pinion is offset relative to the gear axes. However, the planes containing the two axes are
usually at right angles to each other.

Fig 6
4.2.6 Crossed gears:
These are cylindrical helical gears, but their axes are at the angle when in mesh and
do not intersect. Crossed helical gears are also sometimes termited as spiral gears and screw
gears.

Fig 7
4.2.7 Worm and worm wheel:
In this system of gearing the axes are non-intersecting and the planes are containing
the axes are normally at right angles to each other. The tooth elements of both the
components are helices. The system can be single enveloping or double enveloping types.

Fig 8

4.3 GEAR TERMINOLOGY:

Fig 9
a) Pitch circle:
Pitch circle is an imaginary circle, which by pure rolling motions would give same
motion as the actual gear.

b) Pitch circle diameter:

It is the diameter of the pitch circle. The size of gear usually specified by the pitch
circle diameter. It is also called pitch diameter.
c) Pitch point:
It is a common point of contact between two pitch circles.
d) Pitch surface:
It is the surface of the rolling discs, which meshing gears have replaced at the pitch
circle.
e) Pressure angle or angle of obliquity:
It is the angle between the common normal to two gear teeth at the pitch point. It is
usually denoted by .
f) Addendum:
It is the radial distance of a tooth from pitch circle to the top tooth.

g) Deddendum:
It is a radial distance of a tooth from pitch circle to the bottom of tooth.
h) Addendum circle:
It is the circle drawn through the top of tooth and is concentric with the pitch circle.
i) Dedendum circle:
It is the circle drawn through the bottom of tooth and is concentric with the pitch
circle.
j) Circular pitch :
It is the distance measured to the circumference of the pitch circle from a point of one
tooth the corresponding point on next tooth. It is denoted by Pc .
Pc=D*N
Where Pc= circular pitch
D= diameter of pitch circle
N= no. Of teeth on wheel
k) Diametral pitch : it is the ratio of no. Of teeth to the pitch circle diameter in mm, it is
denoted by Pd.
Pd = N*D = Pc
l) Module:
It is the ratio of the pitch circle diameter in mm to the no. Of teeth. It is denoted by m.

m) Clearance:
It is the radial distance from the top of the teeth to the bottom of teeth in a meshing
gear. A circle passing through top the meshing gear is known as clearance circle.
n) Tooth depth :

It is the radial distance from addendum and the dedendum circle of a gear. It is equal
to the sum of addendum to the dedendum.
o) Working depth :
It is the radial distance from the addendum circle to the clearance circle. It is equal to
the sum of addendum of the two meshing gears.
p) Tooth thickness :
It is the width of tooth measured along pitch circle.
q) Tooth space :
It is the space between the two adjacent teeth measured along pitch circle.
r) Backlash :
It is the difference between the tooth space & tooth thickness, as measured along the
pitch circle. Theoretically, back lash is zero, but some back lash must be allowed back lash
must be allowed to prevent jamming of the teeth due to tooth errors & thermal expansion.
s) Face of the tooth :
It is the surface of the gear tooth above pitch surface.
t) Flank of tooth :
It is the surface of gear tooth below pitch surface.
u) Top land:
It is the surface of top of tooth.
v) Face width :
It is the width of gear tooth measured parallel to its axis.
w) Profile :
It is the curve formed by the face & flank of the tooth.
x) Fillet radius :

It is the radius that connects the circle to the profile of the teeth.
y) Path of contact :
It is the path traced by the point of contact two teeth from the beginning to the end of
engagement.
z) Length of path of contact :
It is the length of common normal cut of addendum circles of wheel & pinion.
aa) Arc of contact :
It is the path traced by point on the pitch circle from beginning of engagement of a
given pair of teeth.
ab) Arc of approach :
It is the portion of path of contact from the beginning of engagement to the pitch
point.
ac) Arc of recess :
It is the portion of path of contact from pitch point to the end of engagement of a pair
of teeth.

4.4 Spur Gears :

Spur gears are the ost common type of gears. They have straight teeth and are
mounted on parallel shafts. Sometimes, many spur gears are used wheels with teeth that mesh
together. Spur gears are used to change the speed and force of a rotating axle. Because spur
gears are easier to design & manufacture, engineers usually prefer these gears when power is
transmitted btween parallel shafts. There are, however, some design considerations like
greater contact ratios, greater strength and some design operational requirements such as
noiselessness, smoother engagement of meshing of teeth, for which the use of helical gears is
preferred.
4.4.1 Gear noise :
Due to the change in pitch and bending of teeth, the pair of teeth, which comes in
mesh, next is subjected to an impact at the beginning of the contact. The ensuing noise is

proportional to the magnitude of the pitch error. This can be some what alleviated by
providing tip relief of teeth and lapping the teeth to have a crowning.
Longer duration of meshing period generally reduces noise level. Helical gears are
better than spur gears in this respect, because the engagement of teeth is gradual and more
teeth are mesh simultaneously which helps to cancel out the bad effects of tooth error
resulting in smoother operation.
Gears may become more prone to vibration due to resonance. Therefore, natural
frequency of the system must lie away from the critical zone or the inclination towards co
vibration should be corrected by providing appropriate shape and providing vibration
damping methods.
Gear box housing should be so designed that the resonance effect is avoided by
damping. Webs and ribs should be appropriate placed to attain this objective.

4.5 CHARACTERISTICS OF HELICAL GEARS :

Helical gears are analogous to a set of stepped gears which consist of a number of
identical spur gears so arranged that the teeth of each individual member are slightly out of
phase relative to each other. In such an arrangement there is an mesh at the pitch line, other
mating pairs of teeth are in different phases of contact including approach and recess
contacts. A helical gear construction is approximated if a composite body is made up of an
infinite number of such stepped gears, each of which is a lamination of infinitesimal
thickness, placed side by side successively with a slight phase difference.
4.5.1 Thrust characteristics of a helical gear:
When the tooth force acting on the surface of a helical gear is resolved one of the
components is the thrust, which acts along the axis of the gear. Determination of a magnitude
and the direction of the thrust forces are fundamental criteria of helical gear design. The
directions of helix, that is left hand or right hand, of the members comprising the gear set will
be fixed only after the direction of thrust has been determined and position of the driven gear
is known.
The direction of thrust in a helical gear drive is a function of several factors. These are
directions of helix, the relative positions of two components of gearing and the direction of

rotation of individual gears. Since the axial force or thrust is created due to the helical
orientation of the teeth, there by altering the direction of main tooth force (normal force).
The helix angle should be chosen carefully. For single helical gear running on parallel
shafts it is prudent to confine the helix angle within 20 degrees.
4.5.2 Force analysis for helical gears :
In helical gears tooth force Fn acts normal to the surface at an angle equal to the
pressure angle. This tooth force is resolved into three components, which act at right angles to
one another.

Circumferential force, Ft = 2000 T/d

Axial force Fa = Ft*tan

Radial force Fr = Ft tan/cos

Where D is the pitch circle diameter and T is the driving torque.

It is important that the designer begin by identifying exactly how he /she will
recognize a satisfactory alternatives, and how to distinguish between two satisfactory
alternatives in order to identify the better. From this kernel, optimization strategies can be
formed or selected. Then , the following tasks unfold :

Invent alternative solutions

Through analysis and test, simulate and predict the performance of each alternative,
retain satisfactory altenatives, and discard unsatisfactory ones.

Choose the best satisfactory alternative discovered as an approximation to optimality.

Implement the design.

4.5.3 Gear materials :

Material used for gears is an alloy of steel. The designation given to the alloy steel 40
Ni2 Cr1 Mo28.
The properties of the material are :

Youngs modulus = 2* E5 N/mm2.

Poissons ratio = 0.3

Maximum bending stress = 400 N/mm2

Maximum design compressive stress = 1100 N/mm2

Density = 7.89*E-6 Kg/mm3.

4.6 Gear box design considerations :

Same module (m) of the gear set must be used.

For sliding the gears, the central distance between two shafts must remain constant. In
other words the sum of no. Of teeth of mating gears must be constant.

Only one set of gear should be in mesh at one time in other words,one set of gears
must be completely disengaged before the other set begins to come into mesh.

The transformation ratio ( between a pair of gears) in a gear should be less than or
equal to 2:1 and greater than or equal to 1:4.

Gear box dimentions remain constant.

For helical gears same helix angle of gears should be used.

The gear teeth of each member must have opposite helices, that is, one gear must have
right handed helical teeth while the other must have left handed teeth.

CHAPTER 5
PROBLEM DEFINITION
The objective of this project is to give a design of helical gear drive, which has
interchangability with the existing spur gear drive. There are constraints to be taken care of
i.e, centre distance and transmission ratios. The existing gear box has a single gear drive,
which restricts its user to have variable speeds at a time, so a gear train is to be designed for a
minimum of 4 speeds.
The given data of the existing gear drive is as follows:
Power (P)

= 3728.5 W

Speed (N)

= 1430 rpm

Centre distance (a) = 110 mm

Face width (b)

=25 mm

Pairs (Z2/Z1)

76/34

71/39

65/45

58/52

34/76

39/71

45/65

52/58

Transmission 2.235

1.821

1.444

1.115

0.447

0.549

0.692

0.897

ratio (i)
Speed (N1)

1430

1430

1430

1430

1430

1430

1430

1430

Speed (N2)

640

785

990

1283

3200

2605

2067

1595

Torque (T1)

24.88

24.88

24.88

24.88

24.88

24.88

24.88

24.88

Torque (T2)

55.6

45.34

35.95

27.74

11.12

13.67

17.22

22.32

Roll rpm

84

70

54

42

16

20

34

No. of teeth

34

39

45

52

58

65

71

76

Module

78

90

104

116

130

142

152

72

82

94

108

120

134

146

156

20

20

20

20

20

20

20

20

Addendum

Whole depth

4.5

4.5

4.5

4.5

4.5

4.5

4.5

4.5

Backlash

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.036

0.036

0.040

0.040

0.040

0.040

0.040

Pitch

circle 68

diameter
Outer
diameter
Pressure
angle

Base tangent 4
length

over

teeth
Radial

0.036

runout
Table no 1

5.1 DESIGN PROCEDURE FOR HELICAL GEARS :

5.1 a) Determination of module :
M = mn/cos

Mn = [(Ft*Cw)/(d*Cv*K*Y)]1/2
Where

Ft = P*Cs/V

Cw = 1.15

d = 56.4 N/mm2

Cv= 6.1/(6.1+V)

V = *Dp*Np

Dp = (Zp*mn/cos)

a = [(Zp+Zg)*mn/2 Cos]

K = b/mn

b= [(1.15**mn)/sin]

Y = *y

y= 0.122

5.1 b) Design of Gear :

a= [(Z1+Z2)*mn/2cos]
D = Z*m/cos
P = Z/Dp
Pn = P/cos
Dr = D cosn
Tann = Tan*cos = 0.35, n = 19.3
Do = D + 2mn
Fa = Ft*Tan

b= 1.15**mn/Sin
Ze = Z/Cos3
5.1 c) Strength of gear :
For a safe design Fs> Fd , Fw> Fd
Fd = Ft+{[K3V(CbCos2+Ft)Cos]/[K3V+(CbCos2 + Ft)1/2]}
Where

K3 = 20.67 in S.I units

Fs = e*b*Y*mn

e = B.H.N.*1.75

Fw = Dp*b*Q*K/Cos2

Q = 2Z2/(Z1+Z2)

K = [(es2*Sin/1.4)*[(E1 + E2 )/ E1 E2]

5.2CALCULATIONS :
5.2.1 Module determination :
Given data :
P = 3728.5 W
i= 2.235
a= 110 mm
= 160
= 200
N1 = 1430 rpm

N2 = 640 rpm
mn = [(Ft*Cw)/(Sd*Cv*K*Y)]1/2
Ft = P*1000/V
Cs = 1
V = *Dp*Np
= (*Zp*mn*Np)/(60000*Cos)
Zp = [2a*Cos]/[mn*(i+1)]
= (2*110*0.96)/3.235*mn)
= 65.37/mn
V = (3.14*65.37*1430)/(0.96*60000)
= 5.09 m/s
= 3728.5*1/5.09
= 732.5 N
d = 56.4 N/mm2
Cv = 6.1/(6.1+V)
= 6.1/(6.1+5.09)
= 0.545
K = b/mn
b = [(1.15**mn)/Sin]
= [(1.15*3.14*mn)/0.28]
= 13.11
Y = *y
= (0.154- 0.912/Te)

y = 0.122
= 3.14*0.122
= 0.38308
mn = [(732.5*1.15)/(56.4*0.545*13.11*0.383)]1/2
=2.34
m = mn/cos
= 2.34/0.96
= 2.43 = 2.5 (approx)
2.5 mm is selected as the standard module for all the gears as it is calculated for the highest
transmission ratio.
Since standard modules are 2 , 2.5 , 3 , 3.5 ......
1st pair :
a = [(Z1+Z2)*mn/2cos]
110 = (3.235*Z1*2.4)/(2*0.96)
There for Z1 = 88/3.235
Z1 = 27
Z1 = 27, Z2 = 61
D = Z*m
Dp = 27*2.5 = 67.5 mm
Dg = 61*2.5 = 152.5 mm
P = Z/ Dp
= 27/67.5
= 0.4

since Z2 = 2.235 Z1

Pn = P/Cos
= 0.4/0.96
= 0.42
Root diameter (Dr )= D Cosn
Drp = 67.5*0.944 = 63.73 ~ 64 mm ( for pinion)
Drg = 152.5*0.944 = 143.99 ~ 144 ( for gear )
Outer diameter (Do )= D+2mn
Dop = 65.5+4.8 = 72.3 ~ 72 mm
Dog = 152.5+4.8 = 157.3 ~ 157 mm
Fa = Ft* Tan
Ft = P*Cs/V
V = * Dp*Np
= (3.14*65.5*1430)/(60000)
= 5.05 m/s
Ft = 3728.5*1/5.09
= 738.38 N
Fa = 738.38*0.287
= 211.7 N
Fr = Ft*tan/cos
= 738.38*tan20/cos16
= 279.58 N
b = 1.15**mn/sin
= 13.11*mn

= 31.5 mm
Ze = Z/cos3
Zep = 31
Zeg = 69
Fd = Ft+{[K3V(CbCos2+Ft)Cos]/[K3V+(CbCos2 + Ft)1/2]}
C = 286.35
=738.38+
{[20.67*5.05(286.35*31.5*0.924+738.38)]*0.96/20.67*5.05+(286.35*31.5*0.924+738.38)1/2
]}
= 5012.2 N
Fs = e*b*Y*mn
e = B.H.N*1.75 = 200*1.75 =385 N/mm2
Fs = 385*31.5*0.358*2.4
Fs = 10424.1 N
Fw = Dp*b*Q*k/cos2
Q = 2Z2/(Z1+Z2)
= 1.39
K = [es 2*sin/1.4]*[(E1+E2)/E1E2]
= 1.864
=67.5*31.5*1.39*1.864/0.924
= 5962 N
2nd pair :
a = [(Z1+Z2)*mn/2cos]

110 = (2.821*Z1*2.4)/(2*0.96)
There for Z1 = 88/2.821
Z1 = 31
Z1 = 31, Z2 = 57
D = Z*m
Dp = 31*2.5 = 77.5 mm
Dg = 57*2.5 = 142.5 mm
P = Z/ Dp
= 31/77.5
= 0.4
Pn = P/Cos
= 0.4/0.96
= 0.42
Dr = D Cosn
Drp = 77.5*0.944 = 73.16 ~ 73 mm
Drg = 142.5*0.944 = 134.52~ 135 mm
Do = D+2mn
Dop = 77.5+4.8 = 82.3 ~ 82 mm
Dog = 142.5+4.8 = 147.3 ~ 147 mm
Fa = Ft* Tan
Ft = P*Cs/V
V = * Dp*Np
= (3.14*77.5*1430)/(60000)

since i = 1.821

= 5.8 m/s
Ft = 3728.5*1/5.8
= 642.85 N
Fa = 642.85*0.287
= 184.5 N
Fr = Ft*tan/cos
= 642.85*tan20/cos16
= 243.40 N
b

= 1.15**mn/sin
= 13.11*mn
= 31.5 mm

Ze = Z/cos3
Zep = 35
Zeg = 64
Fd = Ft+{[K3V(CbCos2+Ft)Cos]/[K3V+(CbCos2 + Ft)1/2]}
C = 343.6
=

642.85+

{[20.67*5.8(343.6*31.5*0.924+642.85)]*0.96/20.67*5.8+(343.6*31.5*0.924+642.85)1/2]}
= 6141.95 N
Fs = e*b*Y*mn
e = B.H.N*1.75 = 200*1.75 =385 N/mm2
Fs = 385*31.5*0.371*2.4
Fs = 10798.33 N

Fw = Dp*b*Q*k/cos2
Q = 2Z2/(Z1+Z2)
= 1.29
K = [es 2*sin/1.4]*[(E1+E2)/E1E2]
= 1.864
=77.5*31.5*1.29*1.864/0.924
= 6352.8 N
3rd pair :
a = [(Z1+Z2)*mn/2cos]
= (2.44*Z1*2.4)/(2*0.96)
There for Z1 = 88/2.44
Z1 = 36
Z1 = 36, Z2 = 52
D = Z*m
Dp = 36*2.5 = 90 mm
Dg = 52*2.5 = 130 mm
P = Z/ Dp
= 36/90
= 0.4
Pn = P/Cos
= 0.4/0.96
= 0.42
Dr = D Cosn

since Z2= 1.44Z1

Drp = 90*0.944 = 84.96 ~ 85 mm

Drg = 130*0.944 = 122.72~ 123 mm
Do = D+2mn
Dop = 90+4.8 = 94.8 ~ 95 mm
Dog = 130+4.8 = 134.8 ~ 135 mm
Fa = Ft* Tan
Ft = P*Cs/V
V = * Dp*Np
= (3.14*90*1430)/(60000)
= 6.74m/s
Ft = 3728.5*1/6.74
= 533.19 N
Fa = 533.19*0.287
= 153.1 N
Fr = Ft*tan/cos
= 533.19*tan20/cos16
= 201.88 N
b = 1.15**mn/sin
= 13.11*mn
= 31.5 mm
Ze = Z/cos3
Zep = 41
Zeg = 59

Fd = Ft+{[K3V(CbCos2+Ft)Cos]/[K3V+(CbCos2 + Ft)1/2]}
C = 343.6
=

533.19+

{[20.67*6.74(343.6*31.5*0.924+533.19)]*0.96/20.67*6.74+(343.6*31.5*0.924+533.19)1/2]}
= 6363.72 N
Fs = e*b*Y*mn
e = B.H.N*1.75 = 200*1.75 =385 N/mm2
Fs = 385*31.5*0.396*2.4
Fs = 11525.97 N
Fw = Dp*b*Q*k/cos2
Q = 2Z2/(Z1+Z2)
= 1.18
K = [es 2*sin/1.4]*[(E1+E2)/E1E2]
= 1.864
=90*31.5*1.18*1.864/0.924
= 6748.52 N
4th pair :
a = [(Z1+Z2)*mn/2cos]
= (2.12*Z1*2.4)/(2*0.96)
There for Z1 = 88/2.12
Z1 = 42
Z1 = 42, Z2 = 46
D = Z*m

since Z2= 1.12Z1

Dp = 42*2.5 = 105 mm
Dg = 46*2.5 = 115 mm
P = Z/ Dp
= 42/105
= 0.4
Pn = P/Cos
= 0.4/0.96
= 0.42
Dr = D Cosn
Drp = 105*0.944 = 99 mm
Drg = 115*0.944 = 109 mm
Do = D+2mn
Dop = 105+4.8 = 110 mm
Dog = 115+4.8 = 120 mm
Fa = Ft* Tan
Ft = P*Cs/V
V = * Dp*Np
= (3.14*105*1430)/(60000)
= 7.86m/s
Ft = 3728.5*1/7.86
= 474.36 N
Fa = 474.36*0.287
= 136 N

Fr = Ft*tan/cos
= 474.36*tan20/cos16
= 179.61 N
b = 1.15**mn/sin
= 13.11*mn
= 31.5 mm
Ze = Z/cos3
Zep = 48
Zeg = 52
Fd = Ft+{[K3V(CbCos2+Ft)Cos]/[K3V+(CbCos2 + Ft)1/2]}
C = 286.35
=
474.36+
{[20.67*7.86(286.36*31.5*0.924+474.36)]*0.96/20.67*7.86+(286.36*31.5*0.924+474.36)1/2
]}
= 5834.55 N
Fs = e*b*Y*mn
e = B.H.N*1.75 = 200*1.75 =385 N/mm2
Fs = 385*31.5*0.408*2.4
Fs = 11875.25 N
Fw = Dp*b*Q*k/cos2
Q = 2Z2/(Z1+Z2)
= 1.05
K = [es 2*sin/1.4]*[(E1+E2)/E1E2]
= 1.864
=105*31.5*1.05*1.864/0.924
= 7005.88 N
For helical gears:

Material = steel 40 ni2 cr1 mo28

Power = 3728.5 W

Speed (N1) = 1430 rpm

Center distance (a) = 110 mm

Face width (b) = 31.5 mm

No of teeth

27

31

36

42

46

52

57

61

Module

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

77.5

90

105

115

130

142.5

152.5

64

73

85

99

109

123

135

144

72

85

95

110

120

135

147

157

20

20

20

20

20

20

20

20

Addendum

2.4

2.4

2.4

2.4

2.4

2.4

2.4

2.4

Whole depth

5.4

5.4

5.4

5.4

5.4

5.4

5.4

5.4

Pairs (Z2/Z1)

61/27

57/31

52/36

46/42

27/61

31/57

36/52

42/46

Transmission 2.259

1.839

1.444

1.095

0.443

0.544

0.692

0.913

Speed(N1)

1430

1430

1430

1430

1430

1430

1430

1430

Speed(N2)

633

778

990

1306

3228

2629

2067

1566

Torque(T1)

24.88

24.88

24.88

24.88

24.88

24.88

24.88

24.88

Torque(T2)

56.3

45.8

36.0

27.3

11.3

13.5

17.23

22.74

Pitch

circle 67.5

diameter
Root
diameter
Outer
diameter
Pressure
angle

Table no 2