HELICAL GEARS

Helical gear nomenclature:

Relation of Angles:
DPc Pc
1. DPn = 2. Pcn = 3. tann = tan cos 4. Tv =
cos  cos 
T
cos3 

Relation of Forces:
5. Power = Ft V 6. Fa = Ft tan 7. Fr = Ft tan 8.
2 2 2
Fn  Fr  Fa  Ft
Where: Fr = radial load Fa = axial load Ft = tangential load Fn =
total load

Sw f Y  78 
9. Strength of Helical Gears Ft =  
P  78  V 
F = 2 Pa where: Pa = axial pitch = Pcn / sin
0.05V(C f cos2   Ft ) cos 
10. Dynamic Load on Helical Gears Fd = Ft +
0.5V  C f cos2   Ft

where: V = pitch line velocity = DN, fpm

 = helix angle Pc = circular pitch Pcn = normal
circular pitch
 = pressure angle n = normal pressure angle f = face width,
in
DP = diametral pitch DPn = normal diametral pitch T = number
of teeth
Tv = virtual number of teeth Y = form factor based on the virtual
number of teeth Sw = safe working stress, psi C = a factor dependent
upon machining errors
V = pitch line velocity, fpm
 WORM GEARS

Worm gears are used where high speed ratios(10:1) and above are desired.

Worm Gear Nomenclature

1. Linear pitch, p = distance between adjacent threads
Dg
2. Pc = circular pitch of the gear Pc = 
Tg
Dg
3. Pitch of worm = Circular pitch of gear p = Pc =
Tg
Nw Tg
4. Speed ratio = 
Ng Number of threads on worm
Note: No. of threads on the worm is equal to 1 for single threaded and 2 for
double threaded.

5. Tangential velocity of worm, vwt = π Dw Nw

6. Linear velocity of worm, vwL = Nw L

7. Tangential velocity of gear, vg = π Dg Ng

8. But: vwL = vg , therefore Nw L = π Dg Ng

9. Lead, L - the distance from any point on one thread to the corresponding point on
the next turn of
the same thread.
Lead angle - the angle between the tangent to the pitch helix and the plane of
rotation.
Lead L = p (for single thread) = 2p ( for double thread) = 3p (for triple thread)
Dw  Dg
10. Center Distance, C C
2
 Where: Dw = pitch diameter of the worm Dg = pitch diameter of the gear

Ng = speed of gear Nw = speed of worm Tw = number of teeth

of worm
Tg = number of teeth of gear vw = tangential velocity of worm
Vg = tangential velocity of gear vwL = linear velocity of worm

Lead  Dw
11. Relation of angles: tan x = tan = where:  =
Dw Lead
90o - x
   tan n
tann = tan (cos x) tan  
 2  tan x
where: x = lead angle of worm  = pressure angle
o
  face angle (usually60 )
n = normal pressure angle = 14.5o if not given  = helix
angle of worm
Note: lead angle of worm = helix angle of gear
tan x(cos n  f tan x )
12. Efficiency of Worm gear: e =
cos n tan x  f

To maximize efficiency, tan x  1 f 2  f

13. Power transmitted: Pw = power of worm = 2 π Tw Nw = W t vw

Pg = power of gear = 2 π Tg Ng = Pw e = Ft vg

2 Tw
14. Tangential force on worm, W t: Tw  Wt (Dw / 2) or Wt 
Dw
2Tg
15. Tangential load on gear, Ft: Tg  Ft (Dg / 2) or Ft 
Dg
e cos  cos x  f sin x
or Ft  Wt  Wt
tan x cos  sin x  f cos x
Ft (sinn )
16. Separation Load, S: S 
cos n cos x  f sin x
2 2
17. Total Force of resultant force: Fn  Ft  Wt  S2
18. Strength of Worm Gear
Note: The worm gear is weaker than the worm, therefore the design for strength is
based on the
worm gear.
S w f Y  1200 
Tangential Load on the gear: Ft =  
DP  1200  V 
where: Ft = tangential pitch line load on the gear Sw = safe stress, Table
12-2
f = face width Y = form factor, Table 11-2
 V = pitch line velocity of the gear, fpm DP = diametral pitch
D w  2 add
f = face width =
2
where: add = addendum = 1/DP
BEVEL GEAR

Bevel gears - are used to connect intersecting shafts, usually at

right angle.

1. Number of teeth and Speed relation T1 N1 = T2 N2

2. Speed and Diameter relation: D1 N1 = D2 N2
3. Angle between shafts, θ   p   g
where:  p = pitch angle of the pinion  g = pitch angle of the gear
4. Speed and Angle relation: Ng sin  g = Np sin  p

sin  sin 
5. Angle of Gear: tan g  6. Angle of Pinion: tan p 
Ng Np
 cos   cos 
Np Ng

6. If the shafts are right angle (90o) or θ = 90o if not given

Np Ng
A. tan g  B. tan p 
Ng Np

7. Face Angle
A. Face angle of Gear,  g : g =  g +  a where:
Addendum (2 sin g )
tan a 
Dg
B. Face angle of Pinion p : p =  p +  a where:
Addendum (2 sin p )
tan a 
Dp
8. Cutting Angle:
A. Cutting angle of Gear  g :  g =  g -  d where:
Dedendum (2 sin g )
tan d 
Dg
 B. Cutting angle of Pinion p : p =  p -  d where:
Dedendum (2 sin p )
tan d 
Dp
9. Power Transmitted: P = 2 π T N

10. Torque transmitted by bevel gear: T  Ft (R)  Ft (Dp / 2)

11. Dynamic Load on Gear:

2T
A. Tangential Force, Ft Ft  B. Radial Force, Fr
Dp
Fr  Ft tan n cos p
C. Axial Force, Fa Fa  Ft tan n sin p D. Resultant Force, Fn

Fn  Fr 2  Fa2  Ft 2

12. Strength of Gear Teeth

S fY f f 2   78 
Ft  w 1   2   
DP  L 3L   78  V 
Where: Sw = working stress f = face width DP diametral pitch Y =
form factor
V = pitch line velocity L = distance from the point of shafts axis
intersection to the outermost point of contact of gears.

MACHINE DESIGN – DAY 5

ROLLER CHAIN AND SPROCKET

Are used in transmitting power from one shaft to another shaft that are parallel. It could
be single or multiple strand.
A. Roller Chain Designation: RCXY ---- RC means Roller Chain. X means one or
two-digit no. that shows the number 1/8” in the chain pitch. Y means (Y = 0 for chains
of usual proportion, Y = 1 for lightweight chain, Y = 5 for roller-less bushing chins.
Example RC40 has X = 4, therefore the pitch p = 4/8 = ½ inch.
2/3
 900 
B. Estimation Formula for the Chain Pitch. p   
 , inch
 N1 
where: p = pitch, N = speed
C. Sprocket Teeth in terms of Sprocket Bore:
4d
1. For RC with pitches up to 1 inch: Tmin  5
p
d  bore
4d
2. For RC with pitches 1 ¼” to 2 ½” Tmin  4
p
4d
3. For a silent chain Tmin  6
p
Where: d = bore, inches p = pitch

FORMULAS:
1. θ = angle between two adjacent teeth of sprocket θ = 360O / T
P
2. Pitch diameter , D D 
 180 
sin  
 T 
3. Pitch line velocity, v v = π D N = p (t)(N)
Where: p = pitch N = speed
d = pitch diameter of smaller sprocket D = pitch diameter of larger
sprocket
T = number of teeth of larger sprocket t = number of teeth of smaller
sprocket
θ = angle between two adjacent teeth of sprocket
4. Power transmitted, P P = Fv P = 2πTN
Where: F = force v = velocity T = torque N = speed
T  t (T  t ) 2
5. Length of Chain, L in pitches L  2C   Where: C = center
2 40 C
distance, in pitches
p 
6. Center Distance, C C 2 L  T  t  (2 L  T  t )3  0.81(T  t )2 
8  
7. Average good center distance (Standard)
d
C  D  , inches 
D  d / 2 , pitches
2 p
9. Horsepower Capacity of Roller Chain:
A. Based on link plate fatigue strength.
hp / strand  0.004 (T1)1.08 (N1)0.9 (p)(30.07p)
 pV  V 
B. Silent Chain hp / inch of width  1  
53  425(T1  8) 
Design hp
Width of chain, b =
hp / inch of width

BELTS
FLAT BELT
1. For Open Belt Connection:
A. Pulley diameter and speed relation:
D1 N1 = D2 N2
(D2  D1)2
B. Belt length: L = 1.57(D2  D1)  2C 
4C
C. Angle of contact:
 R  R1 
 =   2sin-1  2  , radians
 C 
D2  D1
 =   , radians
C
Note: Use + sign for larger pulley Use - sign for smaller pulley

2. For Crossed Belt Connection

A. Pulley diameter and speed relation: D1 N1 = D2
N2
B. Belt Length: L = 1.57 (D2 + D1) + 2C +
D2  D12
4C
where: L = length of belt D1 = diameter of smaller
pulley
D2 = diameter of larger pulley R = radius of larger pulley r = radius of
smaller pulley  = arc of contact, radians C = center distance
C. Angle of contact:
 R  R1  D2  D1
 =  + 2sin-1  2  , radians  =  + , radians
 C  C

3. Belt Tension
F1
A. If Centrifugal Tension is Neglected = ef 
F2
where: F1 = tension in tight side F2 = tension in slack side f = coefficient
of friction
 = arc of contact, rad
The maximum tension on belt is: F1 = Fmax = Sd (b t)
where Sd = belt’s design stress = 400 e, psi
e = joint efficiency (1.0 for cemented joint, 0.88 for wirelace ends, 0.35 ends joined
by metal hooked)
F1  Fc
B. If Centrifugal Tension is Considered = ef 
F2  Fc
where: Fc = centrifugal tension = 12wbtv2/g w = belt weight, lb/in3
b = belt width, in t = belt thickness, in v = belt velocity, ft/sec
C. Net belt pull (tangential force on pulley), F F = F1 - F2
F
D. Stress in Belt: Sw = 1 where: Sw = working stress = 300 psi for
bt
leather belts
E. Power Transmitted and Torque Relation by Belt:
T = (F1 - F2) r = F x r P = 2TN, Kw
where: P = power, KW T = torque, KN-m N = speed, rps
F. Horsepower transmitted and stress relation
(F1  F2 )v  550 (Hp)   ef  
P = , hp bt =    f 
 v(Sw  12wv / g)   e  1
550 2

V-BELT
(D  d)2
A. Belt Length L = 1.57(D + d) + 2C + B. Center Distance C =
4C

b  b2  32(D  d)2
16
(D  d)60
C. Arc of contact on small sheave  = 180 
C
where: L = pitch length of belt C = center distance D = pitch diameter
d = pitch diameter of large sheave b = 4L - 6.28(D + d)
BEARING
lb  sec
A. Units of Viscosity: 1 reyn = 1 1 poise = 1
in2
dyne  sec
cm2
B. Sliding Bearings:
Dd
Cd = diametral clearance = D - d Cr = radial clearance =
2
Cd D  d
C. Diametral Clearance Ratio = 
D D
where: p = unit loading or bearing pressure = F/LD e = eccentricity
e = radial distance between center of bearing and the displaced center of the
journal
D = diameter (bore) of the bearing d = diameter of the journal
L = axial length of the journal inside the bearing F = radial load
 un
Bearing Modulus = where: u = viscosity in reyns n = speed in rps p = unit
p
loading, psi
D. Frictional torque in bearings (Vallance p 231) Tb = F fb D/2
4u 2 r 3 Ln s
Petroff’s equation for frictional torque (Faires p 302) Tf =
Cr
where: Tf = frictional torque, in-lb u = viscosity, reyns (Fig. AF 16, p 595)
r = journal radius, in L = axial length of bearing, in
ns = journal speed, rps Cr = radial clearance, in
ChLD
Heat dissipation in journal bearings (Valiance p 240) H
778
where: H = heat dissipated in Btu/min
Ch = heat dissipation coefficient, of projected area, ft-lbs/min-in2
L = length of bearing, in D = diameter of bearing, in
E. Ball and Roller Bearings
1. Bearing Sizes and Designation
Example of bearing designation: SAE or IS 314 is 300 series, No.14
2. Tabulated data on ball and roller bearings: Vallance: Table 9-2 p 206
3. Bearing Capacity based on stresses (Vallance p 205)
k1nD2 k nLD
Fr = ( for ballbearings) Fr = 2 (for roller bearings)
5 5
where: Fr = total radial load, lbs n = number of balls or rollers
D = ball diameter or roller diameter, in L = length of rollers, in
k1 = 550 for unhardened steel = 700 for hardened carbon steel
= 1000 for hardened alloy steel on flat races = 1500 for hardened
carbon steel
= 2000 for hardened alloy steel on grooved races
k2 = 7000 for hardened carbon steel = 10,000 for hardened alloy steel
4. Radial Load Catalog Capacities of Ball and Roller Bearings (Vallance: pp 207-213)
5. Tabulated catalog capacities of ball and roller bearings: Table 9-7, p 212 and Table
9-8, p 213
Fc = (ka k1)ko kp ks kt Fr
where: Fc = Catalog rating of bearing, lb (tables 9-7 and 9-8)
Fr = actual radial load on the bearing, lb Ha = desired life of bearing, hrs
of use
Hc = catalog rated life of bearing, hr
ka = application factor taking into account the amount of shock (Table 9-4)
Ha
k1 = 3 , the life factor where: ko = oscillation factor = 1.0 for
HcK rel
constant rotational speed of the races = 0.67 for sinusoidal oscillations of
the races
kp = preloading factor = 1.0 for non-preloaded ball bearings and straight
roller bearings
kr = rotational factor = 1.0 for bearings with fixed outer races and rotating
inner races
 K r Na
krel = reliability factor, Table 9-3 ks = 3 , the speed factor
Nc
kt = thrust factor = 1.0 if there is no thrust-load component

MACHINE DESIGN – DAY 6

BRAKES
Brake - is a device which is used to regulate or stop the
motion of a body.
A. Simple Band Brake: Tension in the band =
F1
 e f
F2
where: F1 = force on tight side F2 = force on slack
side f = coefficient of friction  = angle of contact,
rad
B. Brake Torque Developed: T = (F1 - F2)r
where: T = brake torque r = radius of friction surface on the
drum
C. Actuating Force Required: (by taking moment about the pivot point)
Fa = a F 2 / L
F1 2 F1
D. Maximum Unit Pressure: Pmax = 
wr wD
where: w = width of the band D = diameter of drum =
2r
F
E. Stress in band: S = 1
wt
where: t = thickness of the band
F. Differential Band Brake
By taking moment about the pivot point: Fa =
F2 (a )  F1(b )
L
G. Self-Locking Differential Band Brake:
A differential band brake is self-locking when Fa is zero or
negative.
H. Block Brake (Valiance p 364)
1. Single Block
 4fFr r sin( / 2) Pmax wr
T = f Fr h T = Fr = (  sin )
  sin  2
where:
T = braking torque Fr = radial force between the drum and each shoe
f = coefficient of friction h = effective moment arm of the friction force
r = radius of the friction surface of the drum  = angle of contact
Pmax = maximum normal pressure between block and drum
w = axial width of block
2. Double Block
Principles of Double Block Brake:
A, Torque, T = (FL + FR) (D/2)
 4 sin L 
B. FL = PL fL  

 2L  sin 2L  2L 2R
 4 sin R 
C. FR = PR fR  

 2R  sin 2R 
D. Power, P = 2 π T N
Where: PL and PR = normal forces , FL and FR = frictional forces, θL and θR = angle
of contact
I. Heat Dissipated in Brakes (Valiance p 374) H = f Fr V
where: H = heat dissipated f = coefficient of friction Fr = radial force V =
surface velocity
J. For Brake used in lowering of a weight: H = Wh
where: W = weight lowered h = total distance traveled

CLUTCH
Clutch - is a machine member which is used to connect
shafts so that the driven shaft will rotate with
the driving shaft, and to disconnect them at will.
Single Plate of Disc Clutch
A. Power transmitted: P = 2 T N T = n
f F a rf
I
B. Clutch Starting Torque, T T
g
where: I = inertia T = torque transmitted
n = number of pairs of mating friction surfaces =
(np – 1)
f = coefficient of friction Fa = axial load
rf = mean friction radius np = number of plates
or disc
C. Mean frictional Radius, rf
For uniform pressure disc clutch:
 2  R3  r 3  1  D3  d3 
rf =    
3  R2  r 2  3  D2  d2 
Fa
Pmax 
 2
(D  d2 )
4
For uniform wear clutch worm clutch:
Rr Dd Fa
rf =  Pmax 
2 4 (d / 2)(D  d)
D. Bearing Pressure on the jaw faces: Pb = Fb / Ab
Where: Fb = bearing force = 2T/Dm
Ab = bearing area = t h nj
Where: t = axial length h = jaw height nj = no. of jaws

Cone clutch:
A. Power: P = 2TN
F fr
B. Torque: T = a f
sin 
C. Fe = force needed to engage cone clutch
Fe = Fn ( sin  + f cos  )
Fa
D Fn = normal Force =
sin 
E. Pn = Fn / An where: An = normal area = π Dm b
Dd
Where: Dm = mean diameter =
2
Dd
b
2 sin 
WIRE ROPES
A. Wire Rope Designation:
For 6 x 7 wire rope - 6 stands for the number of strands; 7 stands for the number of
wires

B. Approximate wire diameters and areas:

ROPE dw A
6x7 0.106 d 0.38 d2
6 x 19 0.063 d 0.38 d2
6 x 37 0.045 d 0.38 d2
8 x 19 0.050 d 0.35 d2
d = rope diameter, in A = rope area, in2
E d
C. Bending Stress, Sb: Sb = r w
D
Where: Sb = bending stress, psi
 Er = modulus of elasticity of wire rope, psi = 12,000,000 psi (for steel)
dw = wire diameter, in D = drum or sheave diameter, in
D. Bending Load
A Er d w
Fb =  Sb A
D
Where: A = wire area
E. The ultimate strengths (Fu) of plow steel is approximately:
Fu = 76,000 d2, lb (for 6 x 7 and 6 x 19 ropes)
Fu = 75,000 d2, lb (for 6 x 37 ropes)
Where: d = rope diameter, in
F. The weight of wire rope is approximately: W = 1.58 d2, lb/ft

FL
E. Approximate wire elongation: y = , in
A Er
FACTOR OF SAFETY, FS
Fu  Fb
FS = where: Ft = tensile load
Ft

A. If moving upward: Ft = WL  WR 1  a 

 g

B. If moving downward: Ft = WL  WR 1  a 

 g
Where: WL = weight attached on the rope
WR = weight of the rope
From DESIGN OF MACHINE ELEMENTS by: Faires
For 6 x 7 wire ropes: For 6 x 19 wire ropes: For 6 x 37 wire ropes:
w = 1.52 Dr2, ft/lb w = 1.6 Dr2, ft/lb w = 1.55 Dr2, ft/lb
Dw = 0.111 Dr, in Dw = 0.067 Dr, in Dw = 0.048 Dr, in
Am = 0.38 Dr2, in2 Am = 0.40 Dr2, in2 Am = 0.40 Dr2, in2
Er = 13 x 106, psi Er = 12 x 106, psi Er = 13 x 106, psi
Min. Ds = 42 Dr, in Min. Ds = 30 Dr, in Min. Ds = 18 Dr, in

WELDED JOINTS:
Welding - a process of joining the metal by heating the metal to a state fusion
permitting it to flow into a solid joints.

A. Strength of BUTT weld: St = F / t L

where: F = tensile force
t = plate thickness
L = length of weld

B. Strength of Fillet weld: St = F/2A

Where: A = t L
t = throat thickness = b sin45o
So, A = (b sin 45o)
 F
Therefore: St 
2( b sin 45) L

RIVETED JOINTS
Application - use for pressure vessels, building structures, tanks, bridges, etc.

Size of Rivets: A. Before driving, rivet diameter is 1/16 inch less than the rivet hole.
B. After driving, the rivet diameter is equal to the rivet hole.
Strength of Rivets
1. Fu = force that can be carried by unpunched plate
Fu = St (t L)
Where: St = tensile stress
t = plate thickness L = plate length

2. Ft = force that can cause tensile stress on plate

between rivets
Ft = St A
where: A = t [ L – n D ] n = no. of rivets

D = hole diameter
3. Fs = force that cause shearing stress on rivets

Fs = Ss n D 2
4
Where: Ss = shearing stress A = π/4 D2

4. Fb = force that can cause bearing stress in the rivets

Fb = Sb ( n t D)
Where: Sb = bearing stress