Question 2.9: For the power transmission system (as shown in Figure 2.10),...
For the power transmission system (as shown in Figure 2.10), power flows from input gear A to the output gear D. If the pitch diameters of the gears B and C are in the ratio 1:2, what is the proper ratio of the shaft diameters d_1: d_2 if both the shafts have same maximum stress.

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Let P be the power which is being transmitted through the system and ω be the angular speed. Then torque acting on the input shaft is
T_{\text {in }}=\frac{P}{\omega_{\text {in }}}
Now, let us draw the free-body diagrams of the shafts
If we consider the free-body diagram shown in Figures 2.11(a) and (b), we can write
F_{ t } \times \frac{d_{ b }}{2}=T_{\text {in }} \quad \text { and } \quad T_{\text {out }}=F_{ t } \times \frac{d_{ c }}{2}
Therefore,
\frac{T_{ out }}{T_{ in }}=\frac{d_{ c }}{d_{ b }} (1)
This can be verified considering no power loss in the transmission system and writing
\frac{T_{\text {out }}}{T_{\text {in }}}=\frac{\omega_{\text {in }}}{\omega_{\text {out }}}=\frac{\omega_{ B }}{\omega_{ C }}=\frac{d_{ c }}{d_{ b }}
This equality \left(\omega_{ B } / \omega_{ C }\right)=\left(d_{ c } / d_{ b }\right) holds goods as the tangential pitch line velocity is same for both B and C. If we assume shear stress developed in the shafts to be same, we can write
\frac{T_{\text {out }}}{T_{\text {in }}}=\frac{\frac{\pi}{16} d_2^3}{\frac{\pi}{16} d_1^3}=\frac{d_2^3}{d_1^3} (2)
From Eqs. (1) and (2),
\frac{d_2^3}{d_1^3}=\frac{d_{ c }}{d_{ b }}
or \left\lgroup \frac{d_2}{d_1} \right\rgroup =\sqrt[3]{\frac{d_{ c }}{d_{ b }}}=\sqrt[3]{2} \quad\left\lgroup \text { as } \frac{d_{ c }}{d_{ b }}=\frac{2}{1} \right\rgroup
Therefore,
\frac{d_1}{d_2}=\frac{1}{\sqrt[3]{2}}=0.7936
Thus, the ratio of shaft diameters is 0.7936 : 1.
