Project Progress Report

Mechanical Design II
MCE 322
Dr. Mohammad Nazzal
Due: April 24, 2014

Group members:
Nibras Nassar 42626
Omar Ahmed 43550
Usman Ndanusa 42431

Assumptions

All values to be used in the English Units

Diametral Pitch 8 (P=6 makes diameter too larger and P=10 fails under stress.)
Helix angle = 30 degrees
Pressure angle = 20 degrees
Safety factor assumed to be 2
9
14
Face width =
<
F
<
P
P
( 1.125 < F < 1.750

We have chosen F to be 1.6 to minimize the face width, which in turn minimizes the gear
box width
QV =
Quality,
6

Choose material as grade 1 steel therefore the elastic coefficient factor is 2300

We assumed the temperature factor to be, 1 (

We assumed the reliability to be 0.99 and based on the table 14-10 (

We assumed surface finish to be greater than 64 and based on Figure 14-13(

equal 1
We assumed our gear to have a uniform and light shock. Therefore our overload factor (
Ko
) equal 1.25 (Figure 14-17)

We assumed rim thickness to be (

We assumed surface conditioning factor (

We assumed an under cut for the teeth to minimize interference, however there will be
interference
We assume the pinion to be case hardened with the material for Material designation to
be 4320, with a condition of SOQT 450 with a core hardness of 415 HB and case
hardening of 59 HRC (628 HB)
We assumed a through hardened gear with the material to be Material designation 3140,
with a condition of OQT 700 with Brinell hardness of 461 HB
We assumed empirical constants to be that of commercial enclosed units from Table 14-9
Based on Figure 14-7 & 14-8, we rounded our J value to 0.539 for gear and 0.372 for
pinion

KB

KT

Psi

= 1)
KR

= 1.00)
CH

) equal 1
Cf

) equal 1

For the load distribution factor (

position (

C pm

Km

), we assumed non-crowned teeth, Mounting

) equals to 1 and Extra adjustment value (

Ce

) equals to 1

Initial Calculations
1) Calculate

number of teeth:

Gear Train, e =

N2
N3

N3 =

N4
N5

= 4.123 x

N3

17 = 4.123

N 5 = 16

N2 = N4
= 65.986 teeth,

Therefore we use 66 teeth

To check the percentage error:

e=

66 x 66
=17.016
16 x 16

% error =

17.01617
x 100=0.094
17

Our % error is less than 1% therefore the number of teeth calculated are valid. However the teeth
will be undercut to reduce interference

2) Calculating the diameters using:

P=

N
d cos

d p=d2

d g =d 3

d4 =

16
=2.31
8 cos 30

d 5=

66
=9.53
8 cos 30

* Diametral pitch is acceptable because the gear is not very larger and it is less than 10 in

3) Find

the gear box height:

Y =d 2+

d3 d 4
2
+
+d 5+
2
2
P + Clearance + Thickness of casing

Y =d 2+

d3 d 4
2 0.25
+
+d 5+ +
+ 0.25
2
2
P
P

Y= 9.523 + 1.155 + 4.765 + 2.309 + 0.250 + 0.0313 + 0.250 = 18.283

Contact stress( pittingresistance)

c =C p

K VK SK m
C f
d pF
t
W K O
(USunits)
I

C p : AGMA elastic coefficient , psi

Cf

: Surface condition factor

dp

: Pitch diameter of the pinion in (mm)

I : Geometry factor for pitting resistance

Allowable (limiting) contact stress

c , all

S cZ N C H
S HK K
T

S c : AGMA contact strength, psi

z N : Stress cycle life factor for pitting
C H : Hardness ratio factor for pitting resistance
S H : AGMA factor of safety

Load-sharing ratio
mN =

PN
0.95Z

Normal base pitch

PN =Pncos n

Length of line of action in transverse plane

Z=

[(r

2
2
p + a ) r bp ]

[(r

+ a ) r bG

1
2 2

] ( r

+ r G )sin n

r b=rcos t
Material used for pinion AISI 4320 conditioned as SOQT 450 with Brinell hardness of
628 HB (59 HRC) and material for gear is AISI 3140 and condition is OQT 700 with
Brinell hardness of 461 HB

For Contact Pinion Case Hardened

c , all= 1.287 * 105 psi
c =1.0601105 psi
For Gear Through hardened
c , all=1.069105 psi
c =

1.0653* 10 psi

Stress Calculation procedures

Pinion Allowable Contact Stress:
SH =

KT

=1

KR

=1

Z N = 0.787
CH = 1
S c =332H B +29100 psi=231316 psi
c , all

2313160.7871
5
=1.287310 psi
2 11

Pinion Contact Stress:

C p =2300 psi
v=

dn 2.3091200
=
=725.39 ft /min
12
12

W=

3300016.623
=756.22 lbf
725.39

K O =1.25

KV =

A + v
= 1.658
A

A=50+ 56 (1B ) = 59.773

B=0.25( 12QV )= 1.3594
Y=0.296

K s =1.192

( F PY )=

1.0586

Dp= 2.309 in
F=1.6
C f =1

K m=1+C mc ( C pf C pm +C maC e ) =1+1 ( 0.05181+0.1531 )=1.203 8

c =C p

K VK SK m
C f
d pF
t
W K O
I

= 8 cos 20=0.369

pN = pncos n

Z=

[ ( 1.155+0.125 )21.064 2 ]

[ ( 4.763+ 0.125 )24.3912 ] 2 ( 1.155+ 4.763 )sin 20

0.5634

mN =

0.369
=0.6896
0.950.5634

I = 0.2085

c =

1.0601105 psi

Pinion Allowable Bending Stress:

all

S tY N
S FK K
T

N=7.2 x 108
YN= 1.61831N-0.0323 =0.8710
HB=628
HB= 415
S t =77.3H B +12800 psi
St= 44 879.5 psi
St =6.1344e+04
SF =2
Kt =1
Kr =1
all = 26 715

19 545 psi

Pinion Bending Stress:

K V K SPdK m
K B
F
t
=W K O
J
The values of

Wt , KO , KV , KS , F , Km

Stress was calculated

Pd =Pcos 30 =8 * cos 30 = 6.928
J= 0.375 from figures 14-7 and 14-8
KB=1
=

19049 psi

Can be taken from above when Contact

Gear allowable Stress:

c , all

S cZ N C H
S HK K

S c = 322H B +29100 psi=177542 psi

SH =

KT

=1

KR

=1

Z N = 0.8520
CH = 1
c , all=106961.06 ps i

Gear Contact Stress:

c =C p

K VK SK m
C f
d pF
t
W K O
I

C p =2300 psi
v=

dn
=725.39 ft / min
12

Wt=

3300016.623
=756.22 lbf
725.39

K O =1.25

A + v
KV =
=
A

1.3595

A=50+ 56 (1B ) = 59.773

B=0.25( 12QV )= 1.3594
Y= 0.4270
K s =1.192

( F PY )=

1.0690

Dg= 9.53 in
F=1.6

C f =1
K m=1+C mc ( C pf C pm +C maC e ) =1+1 ( 0.05181+0.15201 )= 1.2038
pN = pncos n

Z=

= 8 cos 20=0.369

[ ( 1.155+0.125 )21.064 2 ]

0.5634
mN =

0.369
=0.6896
0.950.5634

I =0.2085
c =

5
1.0653 10 psi

[ ( 4.763+ 0.125 )24.3912 ] 2 ( 1.155+ 4.763 )sin 20

Gear Allowable Bending Stress:

all

S tY N
S FK K

N=7.2 x 108
YN= 1.61831N-0.0323 =0.9118
HB= 461
S t =77.3H B +12800 psi
St= 4435
SF =2
Kt =1
Kr =1
all =

Gear

22081 psi

Bending Stress:

K V K SPdK m
K B
F
t
=W K O
J
The values of

Wt , KO , KV , KS , F , Km

Can be taken from above when Contact

Stress was calculated

Pd =Pcos 30 =8 * cos 30 = 6.928
J= 0.53929 from figures 14-7 and 14-8
KB=1
=

1326 psi

Meeting Minutes
Members attended: Nibras, Omar , Usman
Date: Wednesday, 16th April 2014
Meeting commences at 4:00 pm in the library study room 6

Read given project carefully and identified the given inputs and the
desired outputs.
Calculated the number of gear teeth
Assumed 10 to be the diametral pitch
Calculated the height of the gear box
Made initial assumption to calculate bending for the pinion:
o Material: 1340 OQT 700
o Face width of 1.3 in
o Safety factor of 2
Calculated the life of the pinion
Calculated the Bending stress and allowable bending stress
First trail failed

Meeting ended at 8:00pm

Next meeting set for Friday the 18th at 3:00pm

Meeting Minutes
Members attended: Nibras, Omar, Usman
Date: Friday, 18th April 2014
Meeting commences at 3:00 pm in the library study room 6

Began Matlab code

Group decided to work with the pitting stresses because they are more
critical
Changed diametral pitch to 8 and face with of 1.7in, assuming same
material as previous meeting
Contact stress was higher than allowable contact stress failed attempt
Assumed a diametral pitch of 12 and a face width of 1 in same material
Contact stress was higher than allowable contact stress failed attempt
Review of calculations lead to a miss calculation which affected the
results
Calculations were redone
For both new diametral pitches the contact stress was higher than
allowable contact stress, failed attempt

Meeting ended at 8:00pm

Next meeting scheduled for Sunday at 2:00 pm

Meeting Minutes
Members attended: Nibras, Omar, Usman
Date: Sunday 20th April 2014
Meeting commences at 3:00 pm in the library study room 6

Matlab file was continued

Group members agreed to use case hardened material for the pinion
Material 4118 DOQT 450 was initially chosen as the new material
however after observing the through hardening Brinel hardness value a
material with a higher value was selected. Material 4320 DOQT 450
The diametral pitch was selected to be 10 with a face width of 1.3 in
The pinion failed under these circumstances
The diametral pitch was decreased to 8 as a diametral pitch of 6 would
lead to a very large gear diameter.
The pitting stress was calculated for the new value of diametral pitch 8
and a face width of 1.7
The pinions allowable pitting stress was higher than the pitting stress,
pinion passed
The pitting stress and bending stress Matlab codes were complete and
were checked with the hand calculated values

Meeting ended at 6:30 pm

Next meeting set for Monday 21st of April 2014

Meeting Minutes
Members attended: Nibras, Omar, Usman
Date: Monday 21th April 2014
Meeting commences at 4:00 pm in the library study room 6

Matlab was finished

Calculated pitting stress for gear with material 1340 OQT 700
Gear failed
Material was changed to 3140 OQT 700
The gear passed
The Matlab file was tested both answers done by hand and on Matlab
were identical
Matlab was used to minimize the face width from 1.7in to 1.6 in and
the gear and pinion both passed successfully
Began writing progress report
Work was divided to be typed up

Meeting ended 7:00 Pm