IBL (Ch 14-covered using problem based learning method) ME 302/Machine Design II Fall semester Gear Design Chapters 13 and 14, from textbook Problem Statement Utilize AGMA standard full-depth teeth to design a spur gearset for the compressor gearbox, as shown in Figure 1 below. The output shaft experiences a maximum (operational) torque of 66 N.m, with a required gear ratio of 2.5:1 reduction in velocity from input to output shaft. The output shaft operates at 1,500 rpm, and the gearset should have a 10-year lifespan with 1-shift operation. During operations, the gearbox temperature could reach a maximum of 350°F. You are required to select suitable material and full-depth teeth parameters to ensure a minimum safety factor of 2 and √2 against bending and pitting failure, respectively. Figure 1 illustrates the setup, where a two-stroke engine with a flywheel is the source of power to run the reciprocating compressor. engine fo flywheel gear engine cross section U engine clutch top view output sh 凶凶 clutch front view gearbox gear bearings 1 gearbox gear MX IXI pin- ion coup- ling compressor base coup- ling bear- ings compressor input shaft out valves compressor cross section (schematic) Figure 1: Air compressor engine, gearbox, couplings, shafts and bearings The following assumptions and limitations must be applied during the design process. 1. The gear train is made of spur gears of commercial quality level (the designer should take into consideration operating speed). 2. The gear train output and input nature of load should be carfuly considered based on operation. Machine Design II ME 302 IBL-231 in 3. Assume 20° pressure angle. 4. The geometrical space requires having center distance of 150 ± 5 mm between the input and output shafts. 5. Both pinion and gear are made from the same material and hardness. 6. Interference must be avoided. 7. The minimum safety factor against bending and pitting should be 2 and √2, respectively. 8. The minimum reliability is 0.99, and the gearset should have a 10-year lifespan with 1-shift operation. a. List the design constraints provided: b. List all assumptions or relevant information that must be identified to start the solution: c. Locate and indicate the input and output shaft gears in Figure 1. d. Estimate the pinion and gear diameters: e. Determine the no. of teeth on the pinion/gear to achieve the required gear ratio, with no interferance. Double check if the diameters obtained in (d) need to be modified to meet the design requirements. f. Calculate the angular velocity of the pinion using the gear ratio: g. Calculate the maximum tangential loads and max. power to be transmitted from the engine to compressor: h. Develop an excel sheet containing all design relations and parameters needed for the calculation of bending and pitting Stresses. i. Select a suitable material for the gear and pinion ensuring that the minimum safety factor against pitting and bending is satisfied. Also, in case of anticipated failure scenario, identify the source of the threat. j. According to your findings in i, would you recommend subjecting the gear sets to further heat treatment before assembly and usage? Provide details. 2 Machine Design II ME 302 IBL-231

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IBL (Ch 14-covered using problem based learning method) ME 302/Machine Design II Fall semester Gear Design Chapters 13 and 14, from textbook Problem Statement Utilize AGMA standard full-depth teeth to design a spur gearset for the compressor gearbox, as shown in Figure 1 below. The output shaft experiences a maximum (