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Describes different kinds of spur gears
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0% found this document useful (0 votes)
132 views28 pagesChapter 15 Spur Gears: Figure 15.1 (P. 591)
Describes different kinds of spur gears
Uploaded by
zeek77Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 28
Chapter 15 Spur Gears
15.1 Introduction
Gears are defined as toothed members transmitting rotary motion from one shaft to
another, and are among the oldest devices and inventions of man.
In about 2600 B.C. the Chinese used a chariot incorporating a complex series of
gears, see Fig, 15.1.
Right angle gearing
Parallel gearing
Figure 15.1 (p. 591)
Primitive gears.
Function: To transmit power, motion and position.
Advantage: High power transmission efficiency, 98%, compact, high speed,
precise timing.
Disadvantage: Gears are more costly than belts and chains. Gear manufacturing
costs increase sharply with increased precision including high speeds, heavy loads,
and low noise.
Spur gears, see Fig. 15.2, are the simplest and most common type of gears with
teeth parallel to the shaft axes and transmitting motion between parallel shafts. Figure 15.2 (p. 592)
Sour gears.
15.2 Geometry and Nomenclature
The basic requirement of gear-tooth geometry is the ability to transmit motion in a
constant angular velocity ratio at all times. For example, the angular velocity ratio
between a 20-tooth and a 40-tooth gear must be precisely 2 in every position.
The action of a pair of gear teeth satisfying this requirement is termed conjugate
gear tooth action, see fig. 15.3. The basic law of conjugate gear-tooth action is:
As the gear rotate, the common normal to the surfaces at the point of contact must
always intersect the line of centers at the same point P, called the pitch point.
Figure 15.3 (p. 593)
Conjugate gear-tooth action
The law of conjugate gear-tooth action can be satisfied by various tooth shapes, but
the most important one is the involute of the circle. An involute of the circle is the
curve generated by any point on a taut thread as it unwinds from a circle, see Fig. 15.4, Correspondingly, involutes generated by unwinding a thread wrapped
counterclockwise around the base circle would form the outer portion of the left
sides of the teeth. Note that at every point, the involute is perpendicular to the taut
thread. An involute cannot exist inside its base circle.
Fig. 15.5 shows two pitch circles. If there is no slippage, rotation of one cylinder
will cause rotation of the other at an angular velocity ratio inversely proportional to
their diameters. The smaller is called pinion and the larger one the gear. We have,
alo, =~ dyldg (15.1)
Where w is the angular velocity, d is the pitch diameter, and the minus sign
indicates that the two cylinders rotate in opposite directions. The center distance is
c=(d,+d,)/2 =1, + 1, (15.1a)
where r is the pitch circle ra
Base pitch, p, iT /
/
lius.
Involute curves
Base circle
Figure 15.4 (p. 593)
Generation of an involute from its base circle. . | *,
Figure 15 (ps9) aTN
Sp
o
Sy
\ | we
\ fircle
—
As in Fig. 15.6, in gear parlance, angle ¢ is called the pressure angle. Neglecting
sliding friction, the force of one involute tooth pushing against the other is always
at an angle equal to the pressure angle.
Seeing in Fig. 15.7 that the involute profiles do indeed satisfy the fundamental law
of conjugate gear-tooth action. Incidentally, the involute is the only geometric
profile satisfying this law that maintains a constant-pressure angle as the gears
rotate.
Fig. 15.8 shows the continued development of the gear teeth. The involute profiles
are extended outward beyond the pitch circle by a distance called the addendum,
and the outer circle is addendum circle. Similarly, the tooth profiles are extended
inward from the pitch circle a distance called the dedendum and also dedendum
circle. Fig. 15.8 shows the position of a pair of a mating teeth as they enter contact
(approach angle) and they go out of contact (recess angle).
Line nn is called the line of action.
The path of contact is the line segment ac. Figure 15.6 (p.594) pinion
Bel cive ade to ton pase
re
Figure 15.7 (p. 595)
Bel cut at cto generate conjugate involut profes.
Nomenclature of a complete gear tooth is in Fig. 15.9.
Circular pitch, p, measured in inches or mm. If N is the number of teeth and d is
the pitch diameter, then
p=ndiN, p= 7d/N, p= nd /Ne (15.2) Figure 15.8 (p. 596)
Further evelopment and
nomenclature of involute gear
teeth. Note:The cagram shows
the special case of maximum
possible gear addendum
tnthout interference: pinion
addendum s far short of the
theoretical mit
vwstine ule
‘Steph
Figure 15.9 (p. 597)
Nomenclature of gear tee
Diametral pitch, P, is defined as the number of teeth per inch of pitch diameter
(used only with English units):
P=Ni, P=N/fdy P=NJd, (15.3)
Module m, which is essentially the reciprocal of P, is defined as the pitch diameter
in millimeters divided by the number of teeth: m=d/N, m=d/Np m=dJN, (15.4)
It can be seen that,
pP=x — (pininches and P in teeth per inch) (15.5)
and
p/m=7 — (pinmillimeters and m in millimeters per tooth) (15.6)
m= 25.4/P (15.7)
In English units the “pitch” means diametral pitch P, a “12-pitch gear” refers to a
gear with 12 teeth per inch of pitch diameter, whereas in SI units “pitch” means
circular pitch p, a “gear of pitch = 3.14 mm” refers to a gear having a circular pitch
of 3.14 mm.
a
Oh, j os
Figure 15.10 (p. 598)
Actual sizes of gear teeth of various diametra pitches. Note: In general, fine-
Pitch gears have P2 20; coarse-pitch gears have P< 20. (Courtesy Bourn &
‘Koch Machine Tool Company.)
Gear are commonly made to an integral value of diametral pitch P (English units)
or standard value of module m (SI units). Fig. 15.10 shows the actual size of gear
teeth of several standard diametral pitches. With SI units, commonly used standard
values of module are:
0.2 to 1.0 by increments of 0.1
1.0 to 4.0 by increments of 0.25,
4.0 to 5.0 by increments of 0.5
, The most commonly used pressure angle, 4, with both English and SI units
is 20°.
For all systems, the standard addendum i
millimeters, and the standard dedendum is 1.25 * a.
/P, in inches, or a =m, in ‘The fillet radius at the base of the tooth, is 0.35/P (English units) or m/3 (SI
units).
Face width, b is generally,
9IP 5, and 0.85 for P <= 5
Cy = Surface factor from Fig. 8.13
k,= reliability factor from Fig. 6.19 or Table 15.3.
k,= temperature factor. For steel gears k, = 1.0 if temp. < 160 F, if temp. > 160 F,
k,= 620/(460 + T).
kyu = mean stress factor. Use 1.0 for idler gears, use 1.4 for input and output gears "Tony 15.8 Reliability Corretion
tit Sete Standard
Table 15.3 (p. 616)
15.10 Gear-Tooth Surface Fatigue Analysis- Recommended Procedure
Surface fatigue stress
(15.24)
singcosp R
2 Rel
Tame 1540 Val Cocfiient G, for Spur Gears, in Vip
ed OM
Gear Materia
Cat Alsminom Tin
Stet trom iroe”ronze
Sie = s0e00 2080
‘Alumioun bronze, = 17S00Ksi 198018001780, T00
Table 15.4a (p. 621)
(alae: Reade Of)
19, 5th Values of Ela
VMPa (Values ¢
{ficient G, for Spur Gears, in
Gear Material
Pinion Material Cast Alominom Tin
(a in All Cases) tet trom Brome Bronze
Sec = 207 i we
Contin, £ = 131604 Wows
‘Aluminum benz, = 121 GPa ew) Sa
Table 15.4b (p. 621)
Values of Elastic Coefficient G, for Spur Gears in
VBP (Values Converted from Table 15.40)
Surface fatigue strength compared with stress (15.24) i:
Su=Sre CuCr (15.25)
Tame 15.5
Materiat i)
Sel 04 (Bbm)10 As 2 hay 40 MPA
larva (9510.1 (Bhn)-104s) 0.928 Ba} -99 |
Csiro, grate 20 3s
fate 30 Xo
pee
‘Ania bronze “s us
(ASTM 16
Suace Fatigue Strength Sor Use wth Metal Spur Gears (107-Cycle
Lite, 99 Percent Reliabliy, Temperature < 250°)
rr a a a TT
Figure 15.27 (p. 624)
‘Values of, forsee! gear (genera shape of surface fatigue S-V eu)
20 TABLE 1
6 Reliability Factor Cr
Reliability (%) Cr
50 1.25
99 1.00
99.9 0.80
Table 15.6 (p. 625)
Felabaty Factor On
21 SAMPLE Proniem 15.5D Design of a Single Reduetion
Spur Gear Train
Using a standard gear system, design a pair of spur gears to connect a
100-hp, 3600-rpm motor to a 900-rpm load shaft. Shock loading from the
motor and driven machine is negligible. The center distance is to be as
small as reasonably possible. A life of 5 years of 2000 hours/year operation
is desired, but full power will be transmitted only about 10 percent of the
time, with half power the other 90 percent. Likelihood of failure during
the 5 years should not exceed 10 percent.
Souunion
Known: A spur gear pair is to transmit power from a motor of known
horsepower and speed to a driven machine shaft rotating at 900 rpm. Full
power is transmitted 10 percent of the time, half power the other 90
percent. The likelihood of failure should not exceed 10 percent when the
gears are operated at 2000 hours/year for 5 years. Center distance is to
be as small as reasonably possible, (See Figure 15.28.)
Find: Determine the geometry of the gearset.
Schematic and Given Data:
Nestle shock ooding
Lite 5 years, 2000 hour
Fall power 10 percent of time
Half power: 90 percent of time
kay
Vig = 100 np
3600 1pm,
Failure in 5 years: 10 perc
900 rpm
ne 15.28
Single-reduction spur gear train,
Decisions:
1. Choose hardened-steel gears corresponding to the spur gear curve in
Figure 9.21, which shows a 10 percent probability of failure. Steel gear
material will be selected to provide relatively high strength at relatively
low cost. The pinion and gear will be machined and then ground. In
accordance with good practice, specify a case-hardening procedure
that will leave compressive residual stresses in the gear-tooth surfaces.
2. Specify high surface hardness of 660 Bhn and 600 Bhn, respectively,
for pinion and gear to obtain the minimum center distance and the
pinion-tooth hardness that will exceed the gear-tooth hardness by
10 percent.
22 3, For these hardnesses (which are too hard for normal machining),
specify a ground finish and precision manufacture corresponding to
the average of curves A and B in Figure 15.24
4. Choose the more common 20° full-depth involute tooth form.
5. Choose 18 teeth, the minimum number of pinion teeth possible to
avoid interference.
For minimum center distance (i.e., minimum gear diameters), tenta-
tively choose width 6 at the maximum of the normal range, 14/P.
7. Choose a safety factor of 1.25 for failure by surface fatigue.
8. A nominal value for face width will be used.
9. A standard diametral pitch will be selected.
Assumptions:
1. The Palmgren—Miner cumulative-damage rule applies.
2, The ground-surface finish will correspond to the average of curves A
and B in Figure 15.24, and K, = 14.
. The characteristics of support are accurate mountings, small bearing
clearances, minimum deflection, and precision gears.
4. The spur gear curve in Figure 9.21 represents about the highest contact
strength that is obtainable for steel gears, and this curve is a plot of
Si = SCisCp for a 10 percent probability of failure versus the number
of cycles constituting the life of the spur gear.
5, There is no load sharing between gear teeth.
6. In the limiting case, the fatigue strength of the core material must be
equal to the bending fatigue stresses at the surface. Under the surface
Cis 1.
7. For the steel core material, 5,
250 (Bhn).
Design Analy
1, Total life required = 3600 rev/min x 60 min/h x 2000 hiyr x
5 yr = 2.16 X 10° revolutions of the pinion. Only 2.16 x 10° cycles
are at full power. Looking at the spur gear curve in Figure 9.21, we
note that if the stresses for 2 x 10° cycles of full power are on the
curve, stresses for 50 percent power would correspond to over
10"-cycle life. Considering the Palmgren-Miner cumulative-damage
rule (Section 8.12), and recognizing the approximate nature of our
solution, we appear justified in designing for the full-load cycles only
and in ignoring the alf-load cycles.
2, Anticipating that surface fatigue will likely be more critical than bend-
ing fatigue, we solve for the value of P that will balance oj and Sy
with a small safety factor, SF, of say 1.25:
on (from Eq. 15.24 = Sy (from Eq. 15.25)
23 A few auxiliary calculations are required:
V = nd,(3600 rpm)/12 = 942d, = 942(18/P) = 16,960/ P
K, ~ 14. (This value is a rough estimate from Figure 15.24,
and must be confirmed or modified after P is determined.)
Ky, = 13 (This value must be increased if b > 2 in.)
F, = 100 hp (33,000)/V = 195P
T= [(sin 20° cos 20°)/2\(4/5) = 0.128
SteCLiCr = 165,000 psi (directly from Figure 9.21)
Substituting gives
from which
P=7.21 teeth/in,
3. Tentatively choose a standard pitch of 7, compute the corresponding
value of V, refine the estimate of Ky, and compute the value of b
required to balance y and Sy. (Note that if P = 8 were chosen, b
would have to exceed 14/P to balance oy and Sj.)
a ‘i am 1813600) = 2424 fpm
From Figure 15.24, K, = 1.5, and
k :
[A195