DESIGN AND FABRICATION FABRICATION OF PARKINSON PARKINSON GEAR TESTER
A PROJECT REPORT
Submitted by J.KIRUBASON EDWIN A.KANNAN
S.JAYAPRAKASH S.IYYAPPAN
In partial fulfillment for the award of the degree Of MECHANICAL ENGINEERING GOERNMEN! COLLEGE O" ENGINEERING !IR#NELELI$%&
ACKNOWLEDGEMENT
Our fir't fir't and foremo' foremo'tt than(' than(' to THE ALMIGHT ALMIGHTY Y for pre'enting thi' opportunity to )omplete thi' pro*e)t+ ,e al'o wi'h to e-pre'' our 'in)ere than(' to our belo.ed prin)ipal for her her (ind ind Dr.D.SHALINI Dr.D.SHALINIPUNITHAV PUNITHAVA ATHANI,M.E.,Ph.D.,MISTE., THANI,M.E.,Ph.D. ,MISTE., for patronage+ ,ith great great pride and plea'ure we e-pre'' our our deep 'en'e of gratitude and profound than(' to Dr.T.CHRISTOPHER,M.E.,Ph.D., /rofe''or 0 Head of the 1epartment2 Me)hani)al Engineering2 Go.ernment College of Engineering2 !irunel.eli !irunel.eli for en)ouraging u' to underta(e thi' pro*e)t+ ,e ar e indebted to our pro*e)t 'uper.i'or2 ''i'tan antt /rofe /rofe'' ''or or in Me)h Me)han ani) i)al al Dr.T.CHRISTOPHER,M.E.,Ph.D., A''i't Engineering 1epartment for her (ind guidan)e2 ad.i)e and en)ouragement throughout the pro*e)t+ Our
'pe)ial
than('
to
our our
fa)ulty
ad.i'er2
''i'ta tant nt /rofe /rofe''o ''orr in Mr. T. PREM REM SING INGH INB INBARA ARAJ. ME. E.,, A''i' Me)h Me)han ani) i)al al Engi Engine neer erin ing g for for hi' hi' prof profou ound nd and and .alu .aluab able le in'i in'igh ghtt and and )omment' on our pro*e)t+ ,e e-pre'' our 'in)ere than(' to all the fa)ulty 0 'taff member' of the 1epartment of Me)hani)al Engineering for helping and guiding u' to )omplete thi' pro*e)t with great 'u))e''+ ,e al'o e-pre'' our 'pe)ial than(' to our parent' who ha.e 'a)rifi)ed greatly in our edu)ation and welfare+ ,e than( all tho'e who ha.e helped dire)tly and indire)tly in thi' doing pro*e)t and bringing out thi' 'u))e''ful report+
ABSTRACT /ar(in'on gear te'ter i' u'ed to te't the error in the gear+ Here the )arriage ha' two 'pindle+ One main gear i' fi-ed in one 'pindle and another te'ting gear i' fi-ed in the 'e)ond 'pindle+ !he )an 'lide both 'ide and the'e gear' are mounted in me'h by 'pring pre''ure+ ,hen the gear are
rotated rotat ed22 th thee mo mome ment nt of 'l 'lid idin ing g )a )arri rriag agee )a )an n be me mea' a'ur ured ed by th thee di dial al indi)ator+ !hi' .alue' are re)orded in the re)order+ !he 'pindle' )an be ad*u'ted 'o that a-ial di'tan)e i' e3ual and ')ale i' atta)hed to one 'ide and .ernier to the other 'ide for mea'ure the )entre di'tan)e+ If error' o))ur in the tooth form moment of )arriage due to the error in the pit)h and tooth thi)(ne''+ !hi' moment i' indi)ated in the dial gauge+ !he ma-imum gear diameter 45% mm )an be te'ted+
CONTENTS Chaptr !" I#tr$%&'t($# 4+4
/ar(in'on gear te'ter
4+6
Gear
4+7
Shaft
4+8
9all bearing
Chaptr )" C$#*tr&'t($# + $r-(#
6+4
Con'tru)tion
6+ 6+6 ,or(ing Chaptr /" D*(# + Ca0'&0at($#* 7+4 7+6
Heli)al gear )al)ulation 9e.el gear )al)ulation
7+7
Spring )al)ulation
7+8
9earing )al)ulation
Chaptr 1" Fa2r('at($# pr$'** 8+4
9e.el gear
8+6
Heli)al gear
8+ 8+7
Shaft
8+8
9all bearing
8+5
Rail 'etup and a''embly
Chaptr 3" C$*t E*t(4at($# Chaptr 5" C$#'0&*($#
CHAPTER ! INTRODUCTION !.! PARKINSON GEAR TESTER
/ar(in'on gear te'ter i' u'ed to te't the error in the gear+ prin)iple of thi' gear te'ter i' to mount a 'tandard gear on a fi-ed .erti)al 'pindle and gear to be te'ted on another 'imilar 'imilar 'pindle mounted on a 'liding 'liding )arriage2 maintaining the gear' in me'h by 'pring pre''ure+ Mo.ement of the 'liding )arriage a' the gear rotated are indi)ated by a dial indi)ator+ !hi' !hi' dial indi)ator gi.e' the reading of mo.ement of gear' or it may be 'aid that dial gauge gi.e' the mea'urement of gear .ariation'+ !he'e .ariation' are a mea'ure of any irregularitie' in the gear under te't+ Here the )arriage ha' two 'pindle+ One main gear i' fi-ed in one 'pindle and another te'ting gear i' fi-ed in the 'e)ond 'pindle+!he )an 'lide both 'ide and the'e gear' gear' are maintained in me'h by 'pring 'pring pre''ure+ ,hen the gear are rotated2 the moment of 'liding )arriage )an be mea'ured by the dial indi)ator+ !hi' !hi' .alue' are re)orded in the re)order+ r e)order+ !he 'pindle' )an be ad*u'ted 'o that a-ial di'tan)e i' e3ual and ')ale i' atta)hed to one 'ide and .ernier to the other 'ide for mea'ure the )entre di'tan)e+ If error' o))ur in the tooth form moment of )arriage due to the error in the pit)h and tooth thi)(ne''+ !hi' moment i' indi)ated in the dial gauge+ !he ma-imum gear diameter 45%mm )an be te'ted
!.) GEAR :
/ower tran'm /ower tran'mi'' i''ion ion i' i' the mo.e mo.emen mentt of energ energy y from it' it' pla)e pla)e of generation to a lo)ation where it i' applied to performing u'eful wor(
:
A gear i' a )ompo )omponent nent with within in a tran'm tran'mi''ion i''ion de.i de.i)e )e that that tran'mi tran'mit' t' rotational for)e to another gear or de.i)e +
!.).! TYPES OF GEAR
4+ A))ording A))ording to the po'ition of a-e' of the 'haft'+ :
/arallel 4+Spur Gear 6+Heli)al Gear 7+Ra)( and /inion
b+ Inter'e)ting 9e.el Gear )+ Non$inter'e)ting and Non$parallel worm and worm gear'
!.).) Sp&r
Spur gear' or 'traight$)ut gear' are the 'imple't type of gear+ !hey )on'i't of a )ylinder or di'( with the teeth pro*e)ting radi)ally2 and although they are not 'traight$'ided in form;they are u'ually of 'pe)ial form to a)hie.e )on'tant dri.e ratio2 mainly in.olute<2 the edge of ea)h tooth i' 'traight and aligned parallel to the a-i' of rotation+
!.)./ H0('a0 Heli)al or =dry =dry fi-ed> gear' offer offer a refinement o.er o.er 'pur gear'+ !he !he leading edge' of the teeth are not parallel to the a-i' of rotation2 but are 'et at an angle+ :
!he teet teeth h on heli) heli)al al gear' gear' are are )ut at at an angle angle to to the fa)e fa)e of the the gear gear
:
!hi' gradual !hi' gradual enga engagem gement ent ma(e ma(e'' heli)a heli)all gear' gear' opera operate te mu)h mu)h more more 'moothly and 3uietly than 'pur gear'
:
ne intere't intere'ting ing thing thing abou aboutt heli)al heli)al gear' i' that that if the angle' angle' of the the gear gear teeth are )orre)t2 they )an be mounted on perpendi)ular 'haft'2 ad*u'ting the rotation angle by ?% degree'
!.).1 D$&20 h0('a0 1ouble heli)al gear'2 or herringbone gears2 gears 2 o.er)ome the problem of a-ial thru't pre'ented by @'ingle@ heli)al gear'2 by ha.ing two 'et' of teeth that are 'et in a 'hape+ A double heli)al gear )an be thought of a' two mirrored heli)al gear' *oined together+ !hi' arrangement )an)el' out the net a-ial thru't2 'in)e ea)h half of the gear thru't' in the oppo'ite dire)tion re'ulting in a net a-ial for)e of ero+ !hi' arrangement )an remo.e the need for thru't
bearing'+ Howe.er2 double heli)al gear' gear' are more diffi)ult to manufa)ture manufa)ture due to their more )ompli)ated 'hape+
"or both po''ible rotational dire)tion'2 there e-i't two po''ible arrangement' for the oppo'itely$oriented heli)al gear' or gear fa)e'+ One arrangement i' 'table2 and the other i' un'table+ In a 'table orientation2 the heli)al gear fa)e' are oriented 'o that ea)h a-ial for)e i' dire)ted toward the )enter of the gear+ In an un'table orientation2 both a-ial for)e' are dire)ted away from the )enter of the gear+ In both arrangement'2 the total ;or net < a-ial for)e on ea)h gear i' ero when the gear' are aligned )orre)tly+ If the gear' be)ome mi'aligned in the a-ial dire)tion2 the un'table arrangement generate' a net for)e that may lead to di'a''embly of the gear train2 while the 'table arrangement generate' a net )orre)ti.e for)e+ If the dire)tion of rotation i' re.er'ed2 the dire)tion of the a-ial
thru't' i' al'o re.er'ed2 'o a 'table )onfiguration be)ome' un'table2 and vice versa++ versa Stable double heli)al gear' )an be dire)tly inter)hanged with 'pur gear' without any need for different bearing'+
!.).3 B60 ar A be.el be.el gear i' 'haped li(e a right )ir)ular )one with mo't of it' tip )ut off+ ,hen two be.el gear' me'h2 their imaginary .erti)e' mu't o))upy the 'ame point+ !heir 'haft a-e' al'o inter'e)t at thi' point2 forming an arbitrary non$'traight angle between the 'haft'+ !he angle between the 'haft' )an be anything e-)ept ero or 4B% degree'+ 9e.el gear' with e3ual number' of teeth and 'haft a-e' at ?% degree' are )alled miter gear'+ T7p* $8 B60 Gar*
9e.el gear' are )la''ified in different type' a))ording to geometry
Stra(ht 260 ar* ha.e )oni)al pit)h 'urfa)e and teeth are 'traight and tapering toward' ape-+ Straight be.el gear' are 'hown in "igure 4+D+
"igure 4+D+ Straight 9e.el gear' Sp(ra0 260 ar* ha.e )ur.ed teeth at an angle allowing tooth )onta)t to be gradual and 'mooth+ Spiral be.el gear' are illu'trated in "igure 4+&+
"igure+ Spiral 9e.el gear' 9r$ 260 ar* are .ery 'imilar to a be.el gear only e-)eption i' the teeth are )ur.ed the end' of ea)h tooth are )oplanar with the a-i'2 but the middle of ea)h tooth i' 'wept )ir)umferentially around the gear+ ero be.el gear' )an be thought thought of a' 'piral be.el gear' gear' ;whi)h al'o ha.e )ur.ed teeth< but with a 'piral angle of ero ;'o the end' of the teeth align with the a-i'<+ H7p$(% 260 ar* are 'imilar to 'piral be.el but the pit)h 'urfa)e' are hyperboli) and not )oni)al+ /inion )an be off'et abo.e2 or below2 the gear )entre2 thu' allowing larger pinion diameter2 and longer life and 'moother me'h2 with additional ratio'
!.).: W$r4 ar !he worm gear' are widely u'ed for tran'mitting power at high .elo)ity ratio' between non$inter'e)ting 'haft' that are generally2 but not ne)e''arily2 at right angle'+ It )an gi.e .elo)ity ratio' a' high a' 7%%4 or more in a 'ingle 'tep in a minimum of 'pa)e2 but it ha' lower effi)ien)y+ !he worm gear i' widely u'ed to 'peed redu)er and a worm wheel or gear+ gear+ !he worm;whi)h i' the dri.ing member< i' u'ually of a )ylindri)al form ha.ing thread' of the 'ame 'hape a' that of an in.olute ra)(+ !he thread' of the worm may be left handed or right handed and 'ingle or multiple thread'+ ,orm wheel or gear ;whi)h i' the dri.en member< i' 'imilar to a ,orm heli)al gear with a fa)e )ur.ed )ur.ed to )onform to the 'hape of the worm gear i' made of brone or )a't iron for light 'er.i)e+ !he worm gearing i' )la''ified a' non$inter)hangeable2 be)au'e a worm wheel )ut with a hop of one diameter will not operate 'ati'fa)torily with a worm of different diameter2 e.en if the thread pit)h i' 'ame+
TYPES OF WORMS !he following are the two type' of worm' :
Cyli Cy lind nder er or or 'tra 'traig ight ht wor worm2 m2 and and
:
Cone Co ne or do doub uble le en en.e .elo lopi ping ng wo worm+ rm+
!he '70(#%r $r *tra(ht $r4 i' mo't )ommonly u'ed+ !he 'hape of the thread i' in.olute heli)oid of pre''ure angle 48 % for 'ingle and double threaded worm' and 6% % for 'ingle and double threaded worm' and 6% % for triple and 3uadruple threaded worm'+ !he worm thread are )ut by a 'traight 'ided milling )utter ha.ing it' diameter not le'' then the out'ide diameter of worm or greater than 4+65 time' the out'ide diameter of worm+ !he '$# $r %$&20 #60$p(# $r4 i' u'ed to 'ome e-tent2 but it re3uire' e-tremely a))urate alignment+
TYPES OF WORM GEARS !he following three type' of worm gear' are important from the
'ub*e)t point of .iew :
Stra St raig ight ht fa fa)e )e wo worm rm ge gear ar22
:
Hobb Ho bbeed 'tr 'trai aig ght fa fa)e )e22
:
Con Co n)a )a.e .e fa fa)e )e wor orm m gea gearr+
!he Stra(ht 8a' $r4 ar i' li(e a heli)al gear in whi)h the 'traight teeth are )ut with a form for m )utter+ Sin)e it ha' only point )onta)t with the worm thread2 therefore it i' u'ed for light 'er.i)e+ !he H$22% *tra(htt 8a' $r4 ar i' al'o u'ed for light 'er.i)e but it' teeth are )ut with with a hob2 after whi)h the outer 'urfa)e i' turned+
!he C$#'a6 8a' $r4 ar i' the a))epted 'tandard form and i' u'ed for all hea.y 'er.i)e and general indu'trial u'e'+ !he teeth of thi' gear are )ut
"igworm gear
!.).; Ra'- a#% p(#($# A ra)( i' a toothed bar or rod that )an be thought of a' a 'e)tor gear with an infinitely large radiu' of )ur.ature+ !or3ue )an be )on.erted to linear for)e by me'hing a ra)( with a pinion the pinion pinion turn'F the ra)( mo.e' in a 'traight line+ Su)h a me)hani'm i' u'ed in automobile' to )on.ert the rotation of the 'teering wheel into the left$to$right motion of the tie rod;'<+ Ra)(' al'o feature in the theory of gear geometry2 where2 for in'tan)e2 the tooth 'hape of an inter)hangeable 'et of gear' may be 'pe)ified for the ra)( ;infinite radiu'<2 and the tooth 'hape' for gear' of parti)ular a)tual radii are then deri.ed from that+ !he ra)( and pinion gear type i' employed in a ra)( railway++ railway
!./ Tr4(#$0$7
!.).< NOMENCLATURE :
A%%#%&4 '(r'0 A )ir)le bounding the end' of the teeth2 in a right 'e)tion of the gear+
:
R$$t =$r %%#%&4> '(r'0 !he )ir)le bounding the 'pa)e' between the teeth2 in a right 'e)tion of the gear+
:
A%%#%&4 !he radial di'tan)e between the pit)h )ir)le and the addendum )ir)le+
:
D%#%&4 !he radial di'tan)e between the pit)h )ir)le and the root )ir)le+
:
C0ara#' !he differen)e between the dedendum of one gear and the addendum of the mating gear+
:
Fa' $8 a t$$th !hat part of the tooth 'urfa)e lying out'ide the pit)h 'urfa)e+
:
F0a#- $8 a t$$th !he part of the tooth 'urfa)e lying in'ide the pit)h 'urfa)e+
:
C(r'&0ar th('-#** ;al'o )alled the t$$th th('-#** < !he thi)(ne'' of the tooth mea'ured on the pit)h )ir)le+ It i' the length of an ar) and not the length of a 'traight line+
:
C(r'&0ar p(t'h ;/)< !he width of a tooth and a 'pa)e2 mea'ured on the pit)h )ir)le+
:
D(a4tra0 p(t'h = /d< !he number of teeth of a gear unit pit)h diameter+ !he !he diametral pit)h i'2 by definition2 the number of teeth di.ided by the pit)h diameter+ !hat i'2
,here
/d diametral pit)h N number of teeth 1 pit)h diameter :
M$%&0 ;m< /it)h diameter di.ided by number of teeth+ !he pit)h diameter i' u'ually 'pe)ified in in)he' or millimeter'F in the former )a'e the module i' the in.er'e of diametral pit)h+
m 1N
!./ SHAFT A 'haft i' a rotating ma)hine element whi)h i' u'ed to tran'mit power from one pla)e to other pla)e+ Carbon 'teel' of grade 8%CB2 85CB2 5%C82 5%C46 are normally u'ed a' 'haft material'+ Material propertie' :
It 'ho 'houl uld d ha. ha.ee hig high h 'tr 'tren engt gth h
:
It 'hou 'hould ld ha. ha.ee good good ma)h ma)hin inab abil ilit ity y+
:
It 'hou 'hould ld ha.e ha.e low low not)h not)h 'en' 'en'it iti. i.it ity y fa)tor fa)tor++ (6. It 'hould ha.e good heat treatment propertie'+
6. It 'hould ha.e high wear re'i'tan)e+
!./.! TYPES OF SHAFT :
Tra#*4(**($# *ha8t"
!he'e 'haft' tran'mit power between the 'our)e and ma)hine' ab'orbing power+ !he !he )ounter 'haft'2 line 'haft'2 o.erhead 'haft' all 'haft' are tran'mi''ion 'haft'+ :
Ma'h(# *ha8t*"
!he'e 'haft' from an integral part of the ma)hine it'elf+
!.1 BALL BEARING !he purpo'e of a ball bearing i' to redu)e rotational fri)tion and 'upport radial radial and and a-ial a-ial load'+ load'+ It a)hie.e' thi' by u'ing at lea't two ra)e' to )ontain the ball' and tran'mit the load' through the ball'+ In mo't appli)ation'2 one ra)e i' 'tationary and the other i' atta)hed to the rotating a''embly ;e+g+2 a hub or 'haft<+ A' one of the bearing ra)e' rotate' it )au'e' the ball' to rotate a' well+ 9e)au'e the ball' are rolling they ha.e a mu)h lower )oe )oeffi) ffi)ient ient of fri)tion fri)tion than than if two flat 'urfa)e' were 'liding again't ea)h other+ 9all bearing' tend to ha.e lower load )apa)ity for their 'ie than other (ind' of rolling$element bearing' due to the 'maller )onta)t area between the ball' and ra)e'+ Howe.er2 they )an tolerate 'ome mi'alignment of the inner and outer ra)e'+
Single$dire)tion thru't ball bearing' are 'eparable and the mounting i' 'imple a' the )omponent' )an be mounted indi.idually+ indi.idually+ !here are three 'eparable part' of thi' bearing (nown a' 'haft wa'her2 a hou'ing wa'her and the ball and )age a''embly+ !he !he mounting of thru't bearing i' 'hown in the "igure 4+B+
"igure 4+B+ !hru't 9earing !he inner diameter of the 'haft wa'her i' pre'' fitted in the ')rew body++ !he body !he outer diameter of the hou'ing hou'ing wa'her i' pre'' fitted in the the )up+ !he'e two )omponent' are 'eparately mounted before final a''embly+ !he life of thru't bearing i' a''umed to be 7%%% hour'+
CHAPTER )
CONSTRUCTION AND WORKING
).! PRINCIPLE"
!he prin)iple of thi' i' to mount a 'tandard gear on a fi-ed .erti)al 'pindle and the gear to be te'ted on another 'imilar 'pindle mounted on a 'liding )arriage2maintaining the gear' in me'h by 'pring pre''ure+ ).) PARTS"
4<
Ma'ter gear
6<
Gear under te't
7<
"i-ed part
8<
Mo.able pa part
5<
Rai aili ling ng arr rran ange gem men entt
D<
Hub
&<
9earing
B<
Spur gear
?<
9e.el gear
4%< 'pring
44<< di 44 dial al in indi di)a )ato tor r
)./ CONSTRUCTION OF PARKINSON"
It )on'i't' of gear'2 dial indi)ator2 fi-ed and mo.able part2 bearing and 'pring+ !he gear' are mounted on the two mandrel' 'o that they are free to rotate without mea'urable )learan)e+ !he left 'pindle )an be mo.ed along the table )lamped in any de'ired po'ition+ !he right mandrel 'lide i' free to mo.e running on 'teel ball' 2again't 'pring pre''ure and it ha' a limited mo.ement+!he two mandrel' )an be ad*u'ted 'o that their a-ial di'tan)e i' e3ual to the de'igned gear )enter di'tan)e+ !he 'pring pre''ure )an be regulated+!here are al'o ')rew' for limiting the mo.ement of the 'liding )arriage+ A ')ale i' atta)hed to one )arriage and a .ernier to the othor+!hi' enable )enter di'tan)e to be mea'ured to with in %+%65 mm+ !he dial indi)ator on the right )onta)t' the right end of the 'liding and therefore indi)ate' any radial .iriation' of the gear under te't a' the gear' are rotated+!he wa-ed paper re)order i' fitted 2the )hart ma(e' a re.olution for ea)h one of the gear' mounted on the 'liding )arriage+A' the )hart mo.e' or rotate'2the line tra)ed re)ord' the mo.ement of the floating )arriage a )ir)le i' drawn at the 'ame time a' the re)ord+ !he fig i' reprodu)tion reprodu)tion of a few typi)al )hart' with with a redu)ed ')ale and radial error' magnified about 5% time'+!he gear 'hown by No+4 re)ord i' a fully 'ati'fa)tory one2that at No+6 i' a moderate gear at No+7 i' an un'ati'fa)tory one+
).1 WORKING OF A PARKINSON" PARKINSON"
!he wor(ing of the /ar(in'on gear te'ter i' the mo.ement of the 'liding )arriage a' the gear' are rotated are indi)ated by a dial indi)ator and the'e .ariation' are are a mea'ure of any irregularitie' in the gear under te'tFalternati.ely a re)order )an be fitted in the form for m of a wa-ed )ir)ular )hart' and re)ord' made of the gear .ariation in a))ura)y of me'h+ !he )orre)t method of te'ting i' 'ingle$flan( method in whi)h in'tead of mea'uring )enter di'tan)e .ariation the angular .ariation i' mea'ured+!he te'ter i' a )omple- 'y'tem and more )o'tly+ An indi)ator i' u'ed to mea'ure angular .ariation between the gear and di') on thi' 'haft+In u'e 2the two di')' are brought into fri)tional )onta)t 'o that one )an dri.e the other without 'lip+ !hi' method i' not popular be)au'e it re3uire' r e3uire' the manufa)ture of two .ery a))urate pit)h di')' for e.ery gear pair of different'ie
CHAPTER /
DESIGN CALCULATION"
/.!. HELICAL GEAR CALCULATION
:
1E!ERM 1E!ERMINA INA! !ION O" O" MA! MA!ERIAL ERIAL /RO/E /RO/ER! R!IES IES
"rom de'ign data boo( for material C85 Steel #ltimate yield 'tre'' Allowable yield 'tre''
y
7D%% (g)m7
J yK 4B%% (g)m7
Allowable 'hear 'tre''
JK
4%B% (g)m 7
Allowable bending 'tre'' J bK 64D% (g)m7
:
1E!ERM 1E!ERMINA INA! !ION O" O" MINIM#M MINIM#M CEN!RE CEN!RE 1IS! 1IS!A ANCE NCE
Minimum )enter di'tan)e a min Speed ratio oungP' ungP' Modulu Modulu'' 1e'ign tor3ue
Nominal tor3ue 1e'ign tor3ue
;i4< i 4+5B
%+4
E
6+45 6+45 4% D (gf)m6
JM tK Mt Q d Q
Mt
?&86% ?&86% 7D+57 7D+57 (gf)m JM tK Mt Q d Q 7D+574+7 8? (gf)m
Allowable )ompre''i.e 'tre'' J)K C b H9 Q Cl Cl 6566?%+? 5456+5 (gf)m 6
Compare the abo.e .alue with allowable J )K .alue in 'tep 4 .alue
and ta(e the lea't .alue for further further )al)ulation'+ )al)ulation'+ J)K
64D% (gf)m6
Minimum )entre di'tan)e ;44< amin 5+?5D )m :
1E!E 1E!ERM RMIN INA A!ION ION O" MO1 MO1#L #LE E Module Ma. 4+45 )o' β
Minimum No+ of teeth to a.oid interferen)e 4
6%
irtual irtual no+ of teeth
.
68
"orm fa)tor B+4B
. %+847 from /SG 119 /g no+
Life fa)tor for bending Q bl
%+&
Enduran)e 'tre''
$4
%+66;u y<5%%
%+66;7D%%4D%%<5%% 4868 (gf)m6 "a)tor of 'afety
n
6
"illet fa)tor
Q
4+6
Allowable bending 'tre'' J bK 8&?+5 (gf)m 6 Compare the abo.e .alue with J bK .alue in 'tep 4 and ta(e the lea't .alue for further ma.4+45 )o'65
'tandard module
:
ma.
%+6??)m
m a.
%+7 )m
1E!ERM 1E!ERMINA INA! !ION O" AC!# AC!#AL AL CEN! CEN!RE RE 1IS! 1IS!ANCE NCE
A)tual )entre di'tan)e
a
a
B+D )m
Compare the abo.e .alue with a .alue in 'tep 6 and ta(e the greater .alue for further )al)ulation' A)tual )entre di'tan)e a :
1E!ERM 1E!ERMINA INA! !ION O" O" AC!# AC!#AL AL N#M9ER N#M9ER O" O" !EE!H !EE!H No+ of teeth on pinion pinion
:
B+D )m
4
65+48 6?
6
4+8B6? 87
1E!E 1E!ERM RMIN INA A!ION ION O" 1IAM 1IAME! E!ER ER O" O" GEARS GEARS /it)h )ir)le diameter of pinion
d 4 4
D+D6 )m
/it)h )ir)le diameter of wheel
:
d 6 6
48+67 )m
1E!E 1E!ERM RMIN INA A!ION ION O" ,I ,I1! 1!H H O" GEA GEARS RS
%+4 %+BD )m
,idth b
4+47 )m
m ,idth b b
%+74% 7 )m
Compare the abo.e .alue' and ta(e the greater .alue a' width for further )al)ulation' b
7 )m
CHECKING
:
CHEC CHECQ Q "OR "OR IN1# IN1#CE CE1 1 COM/ COM/RE RESSI SSIE E S!R S!RESS ESS %+4?
Load )on)entration fa)tor elo)ity elo)ity of dri.e
Q
4+47 from /SG 119 /g no+ B+45 %+445? m'
/ref /refer erre red d IS IS 3ua 3uali lity ty
D from from /SG /SG 119 119 /g no+ no+ B+7 B+7
1ynami) load fa)tor
( d 4+7
JMtK 8?4+474+7 &4+?B (gf)m 6
Compre''i.e 'tre''
) 6%&4+?& (gf)m 6
"or 'afe de'ign )
T
J)K
6%&4+?&
T
64D%
1e'ign I' Safe :
CHEC CHECQ Q "OR "OR IN1# IN1#CE CE1 1 9EN 9EN1I 1ING NG S!RES S!RESS S
J bK
7?+48D (gf)m 6 "or de'ign 'afe b
T
J bK 1e'ign I' Safe
/.). BEVEL GEAR CALCULATION
:
1E!ERM 1E!ERMINA INA! !ION O" O" MA! MA!ERIAL ERIAL /RO/E /RO/ER! R!IES IES "rom de'ign data boo( for material C85 Steel
#ltimate yield 'tre''
7D%% (g)m7
y
J yK 4B%% (g)m7
Allowable yield 'tre'' Allowable 'hear 'tre''
4%B% (g)m 7
JK
Allowable bending 'tre'' J bK 64D% (g)m7
:
1E!ERM 1E!ERMINA INA! !ION O" MINIM#M MINIM#M CONE CONE RA1 RA1I#S I#S Radiu' of )one
R
y
Speed ratio
i
4
oungP' ungP' Modulu Modulu'' 1e'ign tor3ue Nominal tor3ue (gf)m6 1e'ign tor3ue
y
7
E
6+45 6+45 4% D (gf)m6
JM tK Mt Q d Q Mt
?& ?&86%
7D 7D+57
JM tK Mt Q d Q 7D+574+5 58+&? (gf)m 6
Allowable )ompre''i.e 'tre'' J)K C b H9 Q Cl Cl 6566?%+? 5456+5 (gf)m 6
Compare the abo.e .alue with allowable J )K .alue in 'tep 4 .alue and ta(e the lea't .alue for further further )al)ulation'+ )al)ulation'+ J)K
64D% (gf)m6
Minimum )one )one radiu' R 7 R min min 7+%8 )m :
1E!E 1E!ERM RMIN INA A!ION ION O" MO1 MO1#L #LE E Module Ma. 4+6B
Minimum No+ of teeth to a.oid interferen)e 4
6% U 48 o
Referen)e angle irtual irtual no+ of teeth
.
64
"orm fa)tor B+4B
. %+7?D from /SG 119 /g no+
Life fa)tor for bending Q bl
%+&
Enduran)e 'tre''
$4
%+66;u y<5%%
%+66;7D%%4D%%<5%% 4868 (gf)m6 "a)tor of 'afety
n
6
"illet fa)tor
Q
4+6
Allowable bending 'tre'' J bK 8&?+5 (gf)m 6 Compare the abo.e .alue with J bK .alue in 'tep 4 and ta(e the lea't .alue for further Ma.4+6B
'tandard module :
ma.
%+45B)m
m a.
%+6 )m
1E!ERM 1E!ERMINA INA! !ION O" AC!#AL C!#AL CONE CONE RA1I# RA1I#S S
!ran'.er'e module
A)tual )one radiu'
=
mt mt
%+68 )m
R
%+5 R
R
%+5%+686% 7+8 )m
Compare the abo.e .alue with R .alue in 'tep 6 and ta(e the greater .alue for further )al)ulation'
A)tual )one radiu' :
R
1E!ERM 1E!ERMINA INA! !ION O" O" AC!# AC!#AL AL N#M9ER N#M9ER O" O" !EE!H !EE!H No+ of teeth on pinion pinion
:
:
7+8 )m
4
4D+5B 4D
6
44D 4D
1E!E 1E!ERM RMIN INA A!ION ION O" 1IAM 1IAME! E!ER ER O" O" GEARS GEARS /it)h )ir)le diameter of pinion
d 4 mt4 %+7D4D 5+&D )m
/it)h )ir)le diameter of wheel
d 6 mt6 %+7D8B 5+&D )m
1E!E 1E!ERM RMIN INA A!ION ION O" ,I ,I1! 1!H H O" GEA GEARS RS y
,idth b
4+47 )m
m ,idth b b
%+64% 6 )m
Compare the abo.e .alue' and ta(e the greater .alue a' width for further )al)ulation' b
6 )m
CHECKING
:
CHEC CHECQ Q "OR "OR IN1# IN1#CE CE1 1 COM/ COM/RE RESSI SSIE E S!R S!RESS ESS
%+4? Load )on)entration fa)tor elo)ity elo)ity of dri.e
Q
4 from /SG 119 /g no+ B+45
%+46 m'
/ref /refer erre red d IS IS 3ua 3uali lity ty
4% 4% fro from m /SG /SG 119 119 /g /g no+ no+ B+7 B+7
1ynami) load fa)tor
( d 4 JMtK 7D+5744 7D+57 (gf)m 6
Compre''i.e 'tre''
)
) 64%&+B (gf)m 6 "or 'afe de'ign ) 64%&+B
T
J)K
T
64D%
1e'ign I' Safe :
CHEC CHECQ Q "OR "OR IN1# IN1#CE CE1 1 9EN 9EN1I 1ING NG S!RES S!RESS S
J bK
68&+?8 (gf)m 6 "or de'ign 'afe b
T
J bK 1e'ign I' Safe
/./. SPRING CALCULATION
:
C
%+6 Q,
/
&N
1E!ERM 1E!ERMINA INA! !ION O" MA! MA!ERIAL ERIAL /RO/ER /RO/ER!I !IES ES !he )ho'en 'haft material i' ;C45 'teel<
:
#ltimate ield ield 'tre''
y
5%% Nmm 6
Allowable ield ield 'tre''
J yK
65% Nmm 6
Allowable Shear 'tre'' JK
45% Nmm 6
A''ume fa)tor of 'afety
6
1E!ERM 1E!ERMINA INA! !ION O" 1IMENS 1IMENSION ION O" S/RING S/RING Shear 'tre'' ,hal 'tre'' fa)tor Q ' 4+488B 45% )oil diameter 4+48 mm 4mm Mean wire diameter 4% mm
:
1E!E 1E!ERM RMIN INA A!ION ION O" N#M N#M9E 9ER R O" !#R !#RNS NS
1efle)tion of 'pring y 7D Number of )oil' 5B :
1E!E 1E!ERM RMIN INA A!ION ION O" SOLI SOLI1 1 HEIG HEIGH! H!22 "REE "REE LEN! LEN!H H AN1 /I!CH "ree length pnd
Solid length dnd 45B4 5? mm
"ree length length 'olid length ma-imum ma-imum e-pan'ion e-pan'ion
5? 7D ?5 mm
"ree length pnd ?5
/it)h 4+D mm
/.1. BEARING CALCULATION
Radial load
4%% N 4% (gf
A-ial load
&5 N &+5 (gf
Life
6 year'
Speed
8% rpm
I+ 1E!ERMINA!ION O" EV#IALEN! LOA1 A''ume the bearing a' deep groo.e ball bearing /SG 119 /g No+ 8+6 E3ui.alent Load
/ J;W" r <;" <;"a
Ser.i)e fa)tor
S
4+7
"rom /SG 119 /g+No+ 8+8 W %+5D / E3ui.alent Load
X ;%+66$%+88< 4
J;%+5D4%%<;4&5
II+ 1E!ERMINA!ION O" 1NAMIC LOA1 1ynami) Load C / "rom /SG 119 pg no+ 8+6 L 4% 4 mr
Q
7 for ball bearing'
Life
L
67D546D%8%
C
64+%68 mr
1ynami) load C
8&%+%6 N 8& (gf
III+SELEC!ION O" 9EARING
"or e3ui.alent
Shaft diameter 66 mm 1ynami )apa)ity 8& (gf
SQ" D%%8 )an be 'ele)ted from /SG 119 /g+No+ 8+6 Shaft diameter
d
66 mm
9earing diameter 1
86 mm
,idth of bearing 9
46 mm
1ynami) load
&75 (gf
Stati) load C% I+!OLERANCE ANALSIS
C
85% (gf
from /SG 119 /g+No+ 8+B for 'haft2 type of )ondition i' light and .ariable load *D for hou'ing2 type of )ondition i' normal and light load Y& from /SG 119 /g+No+ 7+B Shaft diameter 66 mm 9earing out'ide diameter 86 ;< mm
Chaptr 1 " FA FABRICAT BRICATION ION 1.!. BEVEL GEAR
9e.el gear' are u'ed for ?%Z power tran'mi''ion+ Some material' )ho'en for be.el gear are Ca't Iron2 Steel2 Ca't Steel2 Carbon Steel2 Alloy Alloy Steel and Non$Metalli) Material'+ 9e.el gear' are manufa)tured on pre)i'ion generating ma)hine' ma)hine' by inde-ing method method en'uring that the teeth teeth 'hould be of tapered depth and thi)(ne''+ !eeth !eeth are )ut on the out'ide of the )one+ !hey ha.e a 'traight tooth geometry2 whi)h if e-tend'2 pa''e' through the inter'e)tion of their a-e'+ 9e.el gear' are generally (nown a' 'traight be.el gear'+ Straight be.el angle' angle' )an al'o be with with one gear flat with a pit)h pit)h angle of ?%Z+ !hey ha.e )oni)al pit)h 'urfa)e' that operate on inter'e)ting a-e'+ !hey )an be de'igned and )ut to operate on any 'haft angle+ In be.el gear' when ea)h tooth engage' it impa)t' the )orre'ponding tooth and 'imply )ur.ing the gear teeth )an 'ol.e the problem+ pr oblem+ !he'e gear' are re)ommended at le'' 'peed and when load' are ar e light+ At At higher 'peed they ma(e' noi'e+ !he mo't preeminent fun)tion of the'e gear' i' in a be.el gear differential+ 9e.el gear' are al'o u'ed in 'teel plant2 material handling 'y'tem and )ooling tower' et)+
1.). HELICAL GEAR
Heli)al or dry fi-ed gear' offer' a refinement o.er 'pur gear'+ !hey are generally made up of Carbon Steel2 Ca't Iron2 Alloy 'teel and Non$ Metalli) Material'+ !he'e gear' are manufa)tured by .ariou' pro)e''e'+ !he'e are2 )a'ting2 'tamping2 rolling2 e-truding2 and ma)hining+ Gear' )an al'o be produ)ed by powder metallurgy+ metallurgy+ Among Among the abo.e 'aid pro)e''2 ma)hining pro)e'' in mo't )ommonly u'ed+ It i' an a))urate method+ 9a'i)ally gear' are produ)ed by ma)hining by a< "orming method+ b< Generating method+ 1.).!. GEAR FORMING
In thi' method a form )utter i' u'ed+ !he formed )utter may be 'ingle point )utting tool or a multipoint milling milling )utter+ !he )utting edge' formed formed )utter ha' been fini'hed to the 'hape between the gear teeth being )ut+ "orming method method i' u'ed for produ)ing .ery .ery 'mall number of gear'+ Gear' produ)ed by forming are le'' a))urate+ "orming pro)e'' i' 'imple and )heaper+ !hi' method i' ta(e' more time+ 1.).). Gar G#rat(#
!hi' method of gear manufa)turing i' ba'ed on the fa)t that any two in.olute gear' of the 'ame module will me'h together together++ Here one of the me'hing gear' i' made a' the )utter+ !he other gear rotate' and al'o re)ipro)ate' along the width of the gear blan(+ 9e)au'e of the relati.e rolling motion between )utter and the blan(2 gear teeth are generated on the gear blan(+ !he gear may be be generated by ra)( )utter2 )utter2 pinion pinion )utter or a hob+ #'ing the generated method2 profile of the gear teeth )an be .ery a))urately produ)ed+ !he following following generating method' method' u'ed for gear produ)tion are are Gear 'haping2 Gear planning2 Gear hobbing+ 1.).).!. Gar H$22(# It i' a pro)e'' of generating a gear by mean' of a rotating )utter )alled hob+ !he hob ha' heli)al thread'+ Groo.e' are )ut in the thread' parallel to the a-i'+ !hi' will pro.ide the edge'+ /roper ra(e and )learan)e angle are ground on the'e )utting edge'+ !he rotating hob a)t' li(e a )ontinuou'ly
mo.ing ra)( a' it )ut'+ !he blan( i' mounted on a .erti)al arbour+ !he hob i' mounted in a
rotating arbour+ !he hob a-i' i' tilted the hob lead angle 'o that it' teeth are parallel to the a-i' of the the gear blan(+
1./. SHAFTS
Shaft' are u'ually made up of Ca't Iron+ A higher diameter rod i' redu)ed into re3uired dimen'ion' by )ondu)ting fa)ing and turning operation' on lathe ma)hine+ "a)ing i' the operation whi)h i' u'ed to redu)e the length of the 'haft+ "a)ing u'ually )arried out on both 'ide' of the 'haft'+ !urning i' one of the mo't )ommon of metal )utting operation'+ In turning2 a wor(pie)e i' rotated about it' a-i' a' 'ingle$point )utting tool' are f ed into it2 'hearing away unwanted material and )reating the de'ired part+ !u !urning rning )an o))ur on both e-ternal and internal 'urfa)e' to produ)e an a-ially$ 'ymmetri)al )ontoured part+ 1.1 Ba00 Bar(#*
9all bearing' are at the heart of almo't e.ery produ)t with a rotating 'haft+ 9all bearing' are generally made up of high )arbon 'teel+ !he .ario' pro)e''e' in.ol.e' in the fabri)ation fabri)ation of ball bearing' are are turning operation2 )enterle'' grinding2 heat treatment2 hardne'' te'ting rough grinding2 fini'h
grinding2 honing and 'uper fini'hing+ !he ring'2 ball' and )age' are manufa)tured in different 'e)tion' and finally a''embled together+
1.3 Ra(0 St&p a#% A**4207
!he rail 'etup i' u'ed for the to and fro motion of the mo.able gear a''embly+ ,e ,elding lding and drilling operation' are u'ed for the a''embly of rail 'etup and the whole 'etup+ !here are many welding pro)e''e' u'ed in
modern metal fabri)ation and repair+ !he !he primary differen)e' between the .ariou' welding pro)e''e' are the method' by whi)h heat i' generated to melt the metal+ !he mo't )ommon type' of welding are o-y$fuel ga' welding ;O",<2 ar) welding ;A,<2 ;A,<2 and re'i'tan)e welding ;R,<+ ;R,<+ Here O", and A, are u'ed+ One of the mo't popular welding method' u'e' a ga' flame a' a 'our)e of heat+ In the o-y$fuel ga' welding pro)e'' heat i' produ)ed by burning a )ombu'tible ga'2 'u)h a' a)etylene2 mi-ed with o-ygen+ Ga' welding i' widely u'ed in maintenan)e and repair wor( be)au'e of the ea'e in tran'porting o-ygen and fuel )ylinder'+ #'ing ga' welding metal plate of nearly 4%mm )an be )ut+ Ar) welding welding i' a pro)e'' that u'e' an an le)tri) ar) to *oin the metal' being welded+ welded+ A di'tin)t ad.antage ad.antage of ar) welding o.er ga' welding i' the )on)entration of heat+ Ar) welding i' generally u'ed for *oin two metal part'+ 1rilling i' the operation u'ed for produ)ing a 'mall hole for the a''embly of whole part' u'ing bolt and nut+ !hi' operation i' 'imply )arried out by drilling ma)hine and drill bit+ 1ue to high 'peed of rotation of the drill bit a hole )an be generated on the metal plete+ #'ually the drill bit i' made up of high )arbon 'teel+
