This document analyzes the kinematics and sizing of a planetary gear train. It includes:
1) A study of the gear characteristics and meshing including pitch radii, pressure angles, and center distances to avoid interference.
2) Calculations of the total gear ratios for different input/output configurations.
3) A determination that the maximum number of planets is 4 to satisfy the condition that the distance between planet axes must be greater than the tip diameter.
4) A planned calculation of tooth root stress and life duration of the system to size it, though this part is missing details.
This document analyzes the kinematics and sizing of a planetary gear train. It includes:
1) A study of the gear characteristics and meshing including pitch radii, pressure angles, and center distances to avoid interference.
2) Calculations of the total gear ratios for different input/output configurations.
3) A determination that the maximum number of planets is 4 to satisfy the condition that the distance between planet axes must be greater than the tip diameter.
4) A planned calculation of tooth root stress and life duration of the system to size it, though this part is missing details.
This document analyzes the kinematics and sizing of a planetary gear train. It includes:
1) A study of the gear characteristics and meshing including pitch radii, pressure angles, and center distances to avoid interference.
2) Calculations of the total gear ratios for different input/output configurations.
3) A determination that the maximum number of planets is 4 to satisfy the condition that the distance between planet axes must be greater than the tip diameter.
4) A planned calculation of tooth root stress and life duration of the system to size it, though this part is missing details.
This document analyzes the kinematics and sizing of a planetary gear train. It includes:
1) A study of the gear characteristics and meshing including pitch radii, pressure angles, and center distances to avoid interference.
2) Calculations of the total gear ratios for different input/output configurations.
3) A determination that the maximum number of planets is 4 to satisfy the condition that the distance between planet axes must be greater than the tip diameter.
4) A planned calculation of tooth root stress and life duration of the system to size it, though this part is missing details.
Bangkai DU Ben Ayed HABIB Marcos Venicio LEANDRO VIEIRA
Page 1 of 8 Summary Kinematics.............................................................................................................................................. 3 Part A: general study ........................................................................................................................... 3 a) All gear characteristics ........................................................................................................ 3 b) Operating gear characteristics ............................................................................................. 3 c) Meshing interference ........................................................................................................... 4 d) Scheme of the line of action and the calculation of the position of the meshing points ...... 4 e) Calculation specific sliding in A and B meshing ................................................................ 4 Part B: input on sun gear 1; output on sun gear 2 ............................................................................... 5 a) Total gear ratio .................................................................................................................... 5 b) Total gear ratio as a function of ω ....................................................................................... 5 Part C: input on carrier, output on sun gear 1 ..................................................................................... 5 a) Total gear ratio .................................................................................................................... 5 b) Total gear ratio as a function of ω ....................................................................................... 5 Sizing ...................................................................................................................................................... 6 Maximum number of planets .............................................................................................................. 6 Life duration of the system ................................................................................................................. 6 Calculation of the tooth root stress 𝜎𝐹 ........................................................................................... 6 Calculation of the life duration ....................................................................................................... 6
Page 2 of 8 This work is a study of a REDEX planetary gear train, with the main characteristics and the schema of the profile presented in the table and the figure below.
Kinematics
Part A: general study
All gear characteristics were calculated using the Excel spread sheet. The results are in the tables at the section a) and b). a) All gear characteristics Parameters sun gear 1 planet 1 sun gear 2 planet 2 pitch radius 15.8301 23.1363 14.6043 24.3405 base radius 14.8691 21.7318 13.7186 22.8643 addendum 1.1969 1.2133 1.2185 1.2133 addendum radius 17.0270 24.3496 15.8228 25.5538 dedendum 1.5330 1.5166 1.5114 1.5166 dedendum radius 14.2971 21.6197 13.0929 22.8239 normal center distance 38.9664 38.9448 transverse module 1.2177 1.2177 1.2170 1.2170 alpha transversal 20.0668 20.0565 b) Operating gear characteristics Parameters sun gear 1 planet 1 sun gear 2 planet 2 operating pitch radius 15.7662 23.0429 14.5615 24.2692 operating module 1.2128 1.2128 1.2135 1.2135 operating pressure angle 19.9330 20.0210 operating center distance 38.8091 38.8308
Page 3 of 8 c) Meshing interference The center distance chosen to fulfill the conditions below for both set 1 and set 2 so there is no meshing interference.
T2A ≤ T1T2 T1B ≤ T1T2 aw ≤ ra2+rf1 aw ≤ ra1+rf2
d) Scheme of the line of action and the calculation of the position of the meshing points The following values were calculated with excel. We note for the sun gear i and planet i the positions T1i, Ai, … T2i. Bellow are the schemes.
e) Calculation specific sliding in A and B meshing
The specific sliding is calculated with the equation bellow with. All the calculations are done using the excel spread sheet. Vs(k) 𝑟1 Ԑi= 𝑈𝑖(𝑘), with U1(K)=ω10.T1k and U2(K)=ω10.T2k.𝑟2 Missing the comment
Page 4 of 8 Part B: input on sun gear 1; output on sun gear 2 a) Total gear ratio In this case, we have sun gear 1 as input, sun gear 2 as output and the carrier is blocked, then the total gear ratio was calculated as shown below. ω03 ω0 −ω0 ω0 Z Zsungear2 = ω10 −ω30 = ω10 = Z planet1 × , with ω30=0 ω32 2 3 2 sungear1 Zplanet2 ω02 40 × 26 = ≈ 0.684 ω10 38 × 24 b) Total gear ratio as a function of ω In case of a differential application, the carrier has a rotational speed ω, so the total gear ratio as a function of ω is shown below. ω02 − ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 = 0.684 ω10 −ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 ω02 − ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 = 0.684 × ω10 − 0.684 × ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 ω02 − ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 = 0.684 ω10 We need W2/W1 Part C: input on carrier, output on sun gear 1 a) Total gear ratio In this case we have carrier as input, sun gear 1 as output and sun gear 2 is blocked. So, the calculation of the total gear ratio is shown below. ω𝑐𝑎𝑟𝑟𝑖𝑒𝑟 sungear1 ω0𝑠𝑢𝑛𝑔𝑒𝑎𝑟1 − ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 𝑍planet1 𝑍sungear2 = = × ω𝑐𝑎𝑟𝑟𝑖𝑒𝑟 sungear2 ω0𝑠𝑢𝑛𝑔𝑒𝑎𝑟2 − ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 𝑍sungear1 𝑍planet2 ω0sungear1 38 × 24 − 0 +1 = ≈ 0.877 ωcarrier 26 × 40 ω0sungear1 = 0.123 ω0carrier
b) Total gear ratio as a function of ω
In case of a differential application, the sun gear 2 has a rotational speed ω, so the total gear ratio as a function of ω is shown below. ω0𝑠𝑢𝑛𝑔𝑒𝑎𝑟1 − ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 = 0.877 ω0𝑠𝑢𝑛𝑔𝑒𝑎𝑟2 − ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟 ω0𝑠𝑢𝑛𝑔𝑒𝑎𝑟1 − ω0𝑠𝑢𝑛𝑔𝑒𝑎𝑟2 × 0.877 = 0.123 ω0𝑐𝑎𝑟𝑟𝑖𝑒𝑟
Page 5 of 8 Sizing
Maximum number of planets
To calculate the maximum number of the planets, we use the equation below where we should satisfy the condition L > dai. 𝝅 L=2.a.sin(𝑵)
With: L: Distance between tow axis of planets a: Center distance between sun-gear i and planet i N: Number of planets dai : tip diameter of planet i .
As we need L > dai, we will have:
𝜋 𝜋 𝑑𝑎 2.a.sin(𝑁) > dai sin(𝑁) > 2.𝑎𝑖 𝜋 𝑑𝑎 𝜋 𝑁> sin−1 ( 2.𝑎𝑖 ) 𝑁 < 𝑑𝑎𝑖 sin−1 ( ) 2.𝑎 Replacing the values of the “dai” and “a” for both types of planets (1 and 2), we have: 𝑁1 < 4.66 and 𝑁2 < 4.7. Then, the maximum number of the planets in both cases is 4. Life duration of the system Calculation of the tooth root stress 𝜎𝐹
From the formula :
𝒙𝟏+𝒙𝟐 Inv(αw)=inv(α0)+2× ×tan(α0) 𝒁𝟏+𝒁𝟐 For set1 (planet1, sun gear1) −𝟎.𝟎𝟏𝟑𝟓+𝟎 𝝅 Inv(αw)=inv(20)+2× ×tan(20×𝟏𝟖𝟎 ) 𝟐𝟔+𝟑𝟖 Inv(αw)=0.01475 αw=19.933° For set1 (planet2, sun gear2) 𝟎.𝟎𝟎𝟒𝟑+𝟎 𝝅 Inv(αw)=inv(20)+2× ×tan(20×𝟏𝟖𝟎 ) 𝟐𝟒+𝟒𝟎 Inv(αw)=0.014953 αw=20.021°
Calculation of the life duration
To calculate the number of cycles (N) or the life duration in hours (t) we use the relation between the permissible stress 𝜎𝐹𝑃 and the tooth root stress 𝜎𝑓 because we need have 𝜎𝐹 ≤ 𝜎𝐹𝑃 . So, using the equation of the 𝜎𝐹𝑃 we could calculate the life factor for tooth root stress, that is a function (YN) of the N or t. the equations below show this. 𝜎𝐹𝐸 . 𝑌𝑁 . 𝑌𝛿 . 𝑌𝑅 . 𝑌𝑋 𝜎𝐹𝑃 = 𝑆𝐹𝑚𝑖𝑛 As we need 𝜎𝐹 ≤ 𝜎𝐹𝑃 , we have: 𝜎𝐹𝐸 .𝑌𝑁 .𝑌𝛿 .𝑌𝑅 .𝑌𝑋 𝜎𝐹 .𝑆𝐹𝑚𝑖𝑛 𝜎𝐹 ≤ and then 𝑌𝑁 ≥ 𝜎 𝑆𝐹𝑚𝑖𝑛 𝐹𝐸 .𝑌𝛿 .𝑌𝑅 .𝑌𝑋 But we know that:
With: 𝜎𝐹𝐸 : allowable stress number for bending 𝑌𝛿 : relative notch sensitivity factor 𝑌𝑅 : relative surface factor 𝑌𝑋 : size factor relevant to tooth root strength 𝑆𝐹𝑚𝑖𝑛 : minimum required safety factor for tooth root stress 𝑁𝐹 : number of the cycles at the knee of the Woehler curve 𝑚𝑓 : Woehler curve slope j: number of planets To calculate all the other parameters in addition to the 𝜎𝐹 (calculated in the previous section) we use the equations and the given data. In the table below, the values of these parameters were listed and how they were obtained. Parameter Source value 𝜎𝐹𝐸 (𝐴. 𝑥 + 𝐵). 𝑌𝑠𝑡 = (0 + 525). 2 1050 𝑆𝐹𝑚𝑖𝑛 given data 1 𝑌𝛿 given data 1 𝑌𝑅 given data 1 𝑌𝑋 1.05 − 0.01𝑥𝑚𝑛 = 1.05 − 0.01𝑥1.2133 1.037867 𝑁𝐹 book Gears and Gear Drivers 2x106 𝑚𝑓 book Gears and Gear Drivers 8.3 j given data 4 Using these parameters and the values of the 𝜎𝐹 calculated for each type of gear and substituting in the last equation we have the values of the life duration for each gear. In the table below, we can observe the values calculated. Gear Tooth numbers σF N (cycles) t (hours) Sun gear 1 26 261.9516 2.75 x1011 1.43x106 Sun gear 2 38 256.1419 3.32 x1011 1.73 x106 Planet 1 24 378.3304 1.30x1010 6.78x104 Planet 2 40 361.9004 1.88 x1010 9.80x104 As we can see, all the numbers of cycles are big enough for to be considered as infinite life duration. But if we can say that the life duration of the system is 1.30x1010 because this will be the first gear to fail.
