22-08-2016

S .
.
Design of Gears

R
Prepared by :Rehan Siddiqui

 Power transmission
Power transmission is the movement of energy from its place of
generation to a location where it is applied to perform useful work.

Useful Work Machine Useful work

Power transmission elements

1
 22-08-2016

.
 Functions of power transmission elements

S
 Connect/Disconnect the prime mover to the machine.

 Vary the leverage between the prime mover and the machine.

.
 To turn the drive through required angle.

 To provide connection between the machine and the prime mover

without shock.
 Types of power transmission elements

R
 Belts ,Ropes & Chains Flexible connectors
 Gears
 Clutches Rigid connectors
 Cams

 What are Gears?

Gears are toothed members which transmit power / motion between
two shafts by meshing without any slip. Hence, gear drives are also
called positive drives.

Friction Wheels Gears

Pinion :Driver Step down drive (Speed Torque )

Gear :Driver Step up drive(Speed Torque )

2
 22-08-2016

.
 Types of Gears

S
 Spur Gears  Helical Gears

R.
 Double Helical Gears /Herringbone  Bevel Gears

3
 22-08-2016

.
 Worm & Worm Wheel  Rack & Pinion

. S
R
 Gear Tooth Terminology
Pc 

Pd 
d
z
1
m odule

4
 22-08-2016

.
 Fundamental Law of Gearing
V1  V2

S
1  O1 P  2  O2 P
1 D2


.
2 D1

I13
I12
I23

mesh.
R
The fundamental law of gearing states that the angular velocity ratio
between the gears of a gear set must remain constant throughout the

Also the common normal at the point of contact must always pass
through the pitch point.

5
 22-08-2016

.
 Gear tooth profiles

S
 Involute
 Cyclodial

R.
Involute Profile

Cyclodial Profile

6
 22-08-2016

S .
 Interference in Gears
R.

7
 22-08-2016

.
 Methods to avoid interference

S
 Increase centre to centre distance
 Minimum number of teeths to avoid interference
 Use of profile corrected gears
 Increase pressure angle.

.
 Corrected gears
Profile correction means modifying the addendum keeping the pitch circle
radius base circle radius and circular pitch same.

X  xm Addendum  m  X
 Types of Gearing

R
S n  X1  X 2  0
S0  X1 +X 2  0
S  X1 +X 2  0

 What is Gearbox ? (Multi Stage Speed Reducer)

Speed of Driver
Velocity Ratio i 
Prime Speed of Driven
mover

M/C

Single Gear Set

8
 22-08-2016

Prime
mover

S . Stage-I

.
Stage-II

M/C

R
Multi-Stage Gear Reducer

Used when V.R is greater than 5. Speed of 1st Driver

io / a 
Speed of last Driven

io / a  i1  i2  i3  i4  i5 .......in
Assume i1  i2  i3  i4  i5  .......in  istage
n For overall V.R of 60
io / a   istage 
istage  3 60  3.9
istage  n io / a i1  3
3  i2  i3  60
i2  4 i3  5
 Choices for speed reduction

i1  3 i1  5
i1 i2 i3 3.9 i2  4 i2  4
i3  5 i3  3

9
 22-08-2016

.
 Gear tooth failures

S
Mechanical Failure Wear Failure

.
Abrasive Wear
Corrosive Wear
Static condition Dynamic condition
Pitting
Scoring

 Mechanical Failure
R
Failure or breakage of tooth due to static and dynamic loads on the
tooth.
 Lewis Theory of Bending
 Assumptions in Lewis Equation:

 Effect of Radial force which causes

compressive stress is neglected.
 Effect of Shear due to tangential force
is neglected.
 Effect of stress concentration is
neglected.
 The tooth is assumed to be a parabolic
profile of uniform strength.
 Tangential force is assumed to be
uniformly distributed over the tooth
width.

10
 22-08-2016

.
 Lewis Bending Equation

S
Bending Stress

M B b MB  y
 ; b 
I y I

.
MB
b 
I
y

bt 3 t I bt 2 ;
I ; y ;  M b  Ft  h

R
12 2 y 6
Induced Tangential Force
Lewis
2
Ft  6h  b  bt 2  t  Form
b  ; Ft  ; Ft   b  b  m   factor
bt 2 6h  6hm  (Y)

Ft   b  b  m  Y

Replacing  b by  b 
Tooth strength in Bending or
Fs   b   b  m  Y
Static strength
Tooth strength is the maximum value of tangential force that a gear
tooth can withstand without bending failure.
 Design based on weaker element

 0.912  Lewis form factor based on

Y   0.154 
 Z  number of teeths ……… PSG 8.50

 b Y  Strength factor

Design of the tooth should be done for the weaker element based on
the strength factor

11
 22-08-2016

.
For Safe Design, Replacing b by  m  m

S
Fs  Ft 2M t
m3 
d  b   m  z  Y
M t  Ft 

.
2
Mt Mt
 b   b  m  Y  m  1.26 3
d /2  b   m  z  Y
2M t
 b   b  m  Y 
mz Module based upon

R
static strength
2M t
m2 
 b   b  z  Y
As per AGMA,
b
m 
m

 Dynamic Load on Gear tooth

Causes of Dynamic Load on gear tooth:
 Inaccuracies in tooth profile
 Errors in tooth spacing
 Misalignment between bearings
 Elasticity of the parts.
 Inertia of rotating parts

Barth's approximation by Buckingham's Dynamic Load

Velocity factor

12
 22-08-2016

.
 Barth's approximation for Dynamic Load

S
FD  Ft  Cv
Depends upon Velocity of the
Cv  Barth Velocity Factor
gear and Gear Quality

.
As per AGMA following grades of Gears are there

 GRADE –1,2 High Precision gears (Master Gears)

 GRADE-3,4 Precision Cut gears (Lapped Gears)

 GRADE-5,6 Carefully Cut gears (Grinded or Shaved Gears)

R
 GRADE-7,8,9,10,11,12 Commercially Cut gears (Machined Gears)
3  Vm
Cv  ..........for comercially cut gears
3
 DN
Vm 
60

 Effect of Surface Finish

Cost

Error, Dynamic load, Noise &Vibration

Surface Finish

13
 22-08-2016

.
 Buckingham's Dynamic Load

S
 Why Buckingham's dynamic Load is to be considered ??
 Dynamic load depends upon number of factors such as mass of gears,
mass of gear shaft and material properties like modulus of elasticity.
 Use of velocity factor is limited to range of velocities.

.
FD  Ft  Fi
Fi = Incremental Load
0.164Vm (Cb  Ft )
Fi = ................(kgf )
0.164Vm  1.485 Cb  Ft

 Wear Failure
R
Abrasive Wear

Corrosive Wear

14
 22-08-2016

S .
.
Scoring

R
Pitting

 Wear Strength of the gear tooth

FN  d1Qkb Maximum normal force to avoid wear

FW  d1Qkb
d1  PCD of Pinion k  Load stress factor

2i 2  1 1 
Q  Ratio factor =  c  sin    
i 1 k=  E1 E2 
1.4
 c   2.8BHN avg  70 N/mm 2 As per AGMA

HB1 +HB2
BHN avg 
2
For Safe Design,
FW  FD

15
 22-08-2016

.
 Effects of Pressure angle

S
 Increasing pressure angle reduces the base circle diameters which
avoids interference

 Increasing pressure angle increases the Radius of curvature of

.
gear tooth, which improves the strength of gear tooth in bending.

 Increasing the pressure angle increases the contact ratio which

improves power transmission.

 Increasing the pressure angle increases the contact stresses which

leads to wear failure.

R
 Material selection for Gears
 Different materials for Gear and pinion

 Pinion should be of higher strength material.

 Load carrying capacity depends upon the endurance limit.

 Bending stress is taken as approximately equal to endurance limit.

1
Endurance limit = Ultimate Tensile strength
3
Ultimate Tensile strength
 b  =
F .O.S

 Cast iron, Steel, Alloy steel & nonmetals like Bakelite laminated
phenolics are used as materials for gears

16
 22-08-2016

.
Design of Spur Gears
Q. A 2-stage spur& Helical gearbox is used to transmit 10KW power

S
from an electric motor running at 1440rpm to a machine with an
approximate overall reduction ratio of 10.

Design the spur gear based on bending and wear strength

.
considerations. Check the gears for dynamic load using Buckingham's
equation.

Describe & sketch constructional details for Pinion & Gear showing
main dimensions.
Given :
Power P =10KW

R
Input Speed Ni= 1440rpm

Overall velocity ratio io / a  10

Stage velocity ratio istage  n io / a istage  10  3.162

 Speed reducer configuration

Prime Stage-I (Helical)

mover

Stage-II (Spur)

M/C

Multi-Stage Gear Reducer

 N 2 I   N1 II

17
 22-08-2016

.
 Speeds at each stage

S
1440
;  
N
 N1  I  1440rpm 1 I
 i1 ;  N2 I
 3.162 ;  N 2 I  455rpm
 N2 I
 N1  II 455
 3.162

.
 N 2  I   N1  II  455rpm ;  N 2  II
 i2 ; N 2 II

 N 2 II  144rpm

 Data for Design of Spur Gear pair

Power P= 10KW

R
Input speed N1 = 455rpm

Output speed N2 = 144rpm

 Service Factor
Based on application from PSG 7.69
SF : 1.2

 Calculate Design Power [P]

[P]  SF  Power  12KW
 General Assumptions
 Tooth profile : Involute
 Pressure angle: 20 degree full depth
 Gear quality: Commercially cut Gears
 Type of Gearing : Standard Sn gearing X1=X2=0

 Selection of Minimum number of teeths on Pinion

2  ha / m 
Zc 
sin 2 
Z2
Using 18 teeths on pinion  3.162 Z 2  57teeths
Z1

18
 22-08-2016

.
 Calculate the Lewis Form Factor

S
0.912 -----For 20 degree involute tooth ……PSG 8.50
y  0.154 
Z
 0.912 
Y    0.154  
Z 

.

For Pinion
 0.912 
Y1    0.154  
 Z1 

 0.912 
Y1    0.154    0.3246
 18 

R
For Gear
 0.912 
Y2    0.154  
 Z2 

 0.912 
Y2    0.154    0.4335
 57 

 Material Selection & Allowable stresses

For Pinion : 40Cr1 For Gear : C-50
 ut  975 N/mm 2
 ut  720 N/mm 2
 yt = 700 N/mm 2  yt = 380 N/mm 2
HB1  283 HB2  241
Assuming FOS of 5
 ut  ut
 b1    195 N/mm 2  b 2    144 N/mm 2
FOS FOS

 Determination of Weaker Element

Strength Factor for pinion
 b1 Y1  195  0.3246  63.297  b 2 Y2   b1 Y1
Strength Factor for Gear Gear is the weaker element
Hence designing based on gear
 b 2 Y2  144  0.4335  62.42 tooth

19
 22-08-2016

.
 Determination of Module

S
Criterion: Finding module based upon bending failure using Lewis
equation and dynamic load using Barth's velocity factor. Then check for
dynamic load and wear.

.
 Tooth strength Fs
Fs   b 2   b  m  Y2 …….. PSG 8.50
b
Let,  m   10
m
Fs  62.42  10m  m
Fs  624.2m 2 …….. (1)

R
 Dynamic Load FD
By Barth's approximation

FD  Ft  Cv

 Calculate the tangential force Ft on the gear tooth

Mt   P
Ft  ;  P   M t  ;  M t    P ; Ft 
d
d  
2 2

Ft 
 PKW  103
Vm

 D1 N1 Pitch Line velocity m/sec

Vm 
60, 000
Vm  0.4288m
12  103 27985.7
Ft  Ft  N
0.4228m m

20
 22-08-2016

.
3  Vm
Cv  ..........for comercially cut gears.......PSG 8.51

S
3
 27985.07   3  0.4288m 
FD    
 m   3 

.
 27985.07   0.4288m 
FD     1  
 m   3 

 27985.07 
FD     4000...........(2)
 m 

R
For Safe Design,
Fs  FD
m  4.149
 27985.07 
624.2m2     4000 Select standard module from
 m  PSG 8.2

 Tooth strength Fs

Fs  624.2m 2
Fs  15606 N
 Dynamic Load FD
By Barth's approximation
 27985.07 
FD     4000
 m 
FD  9597 N

Fs  FD Hence Safe.

 Buckingham's Dynamic Load

0.164Vm (Cb  Ft )
FD = Ft  ................(kgf )....PSG 8.51
0.164Vm  1.485 Cb  Ft

21
 22-08-2016

.
Ft .....kgf

S
Vm .....m / min
b.....cm

.
 D1 N1 Vm  2.144m / sec
Vm 
60000 Vm  128.64m / min

Ft 
 P  103  12 103  5597.01N
Vm 2.144

R
Ft  559.701 kgf
c  constant from T-41 ...PSG 8.53

c  11860e ....for 200 full depth and steel steel combination

e  constant based on gear quality T-42 ...PSG 8.53

c  11860  0.056
c  664.16
0.164 128.64(664.16  5  559.7)
FD = 559.7  ................(kgf )
0.164 128.64  1.485 664.16  5  559.7

FD = 1280.3 kgf
FD = 12803 N
Fs  FD Hence Safe.
 Wear Strength of the gear tooth
FW  d1Qkb
2i 2  3.167
Q   1.52
i  1 3.167  1

22
 22-08-2016

.
2  1 1 
 c 

S
sin    
k  E1 E2 
1.4
 c   2.8BHN avg  70 N/mm 2

.
HB1  HB2 283  241
BHN avg    262
2 2
 c   663.6 N/mm 2

R
E1  E2  2.1105 N/mm 2

 1 1 
663.62  sin 20  5
 5 
k  2.110 2.110   1.024
1.4

FW  d1Qkb
FW  90  1.52  1.024  50
FW  7004.16 N

FW  FD Hence not Safe.

 Remedies to make tooth safe in wear

 Increase Face width
 Increase Module
 Increase Hardness
 Increase quality of the tooth (Improve surface finish)

 Increasing the module

 Using m=6mm
 Increasing the facewidth
 Using  m  12

23
 22-08-2016

.
 Recalculate the values of Tooth strength and dynamic load

S
Vm  2.57 m / sec
Vm  154.37 m / min
Ft  466.92 kgf

.
FD  1541.97 kgf......... Buckhinghams dynamic load
FW  12103.18 N
FW  FD Hence not Safe.

 Increasing the hardness

FW  FD ............for safe design

R
d1Qkb  15419.7
108 1.52  k  72  15419.7
k  1.304

2  1 1 
 c  sin    
k  E1 E2   1.304
1.4
2  1 1 
 c  sin 20  5
 5 
 2.110 2.110   1.304
1.4

 c   748.80 N/mm 2
2.8BHN avg  70  748.8
BHN avg  292.4
Using, BHNavg =300
HB1  321 Hence gears should be
HB1 -HB 2  42
HB2  279 heat treated to improve
the surface quality

24
 22-08-2016

.
 Gear tooth proportions (Spur Gear pair)

S
Item Pinion Gear
Material 40Cr1 HB=321 C-50 HB=279
No. of teeths Z1  18 Z 2  57

.
Face Width b=72mm b=72mm
Module m=6mm m=6mm
Pressure angle   200   200
Pitch circle Dia d1= 108mm d2= 342mm
Tip Dia d a1   z1  2 f 0  m d a 2   z2  2 f 0  m

R
Root Dia d f 1   z1  2 f 0  m  2c d f 2   z2  2 f 0  m  2c

 Constructional details
 Integral with Shaft construction

used for d f  60 to 75 mm

25
 22-08-2016

.
 Solid Disc construction

. S
R
used for d  75 to 150 mm

 Web construction
used for d  150 to 400 mm
trim  2.25m

t web  0.3b
No of holes
d rim  d h
 70........ No holes
2
d rim  d h
 70 but <100........ 4 holes
2
d rim  d h
 100........ 6 holes
2
d  dh
PCD of hole = rim
2

d h  1.6d s

26
 22-08-2016

.
 Arm construction

. S
R
used for d > 450 mm

 Pinion construction
Since PCD is 108mm , Hence using Solid Disc construction.
 Input Shaft Design
Material : C-45
 Allowable stresses

Yield Stress  yt  360 N / mm2 …………………….. PSG 1.9

F.O.S : assuming 4 since neglecting bending

Keyway factor :0.7 to 0.8 assuming 0.75

[ ]  ( yt  0.5)  Kw / F.O.S  33.75N / mm2

 Calculate Design Torque [Mt]

9.55106  [Pkw ] 9.55106  12
[Mt ]  [Mt ]   252 103 N  mm
Nshaft 455

27
 22-08-2016

.
 Calculate Shaft diameter

S
16  M t 
d s1  3
  

.
16  252 103
d s1  3
  33.75
d s1  33.62mm

R
using d s1  35mm

 Gear construction
Since PCD is 342mm , Hence using Web construction.
 Input Shaft Design
Material : C-45
 Allowable stresses

Yield Stress  yt  360 N / mm2 …………………….. PSG 1.9

F.O.S : assuming 4 since neglecting bending

Keyway factor :0.7 to 0.8 assuming 0.75

[ ]  ( yt  0.5)  Kw / F.O.S  33.75N / mm2

28
 22-08-2016

.
 Calculate Shaft diameter

S
16  M t1 
d s1
3
   d s1  M t1 
3

.
 
ds2 16  M t 2 
ds2  t2 
3 M

3
  

9.55 106  [ Pkw ]

3

R
d s1 N1 ds2 N1 ds2 3
  3  i
ds2 9.55 106  [ Pkw ] d s1 N2 d s1
3
N2

 Web construction
d h  1.6d s 2 ..............PSG 8.62
D0  d a  10m ...........PSG 8.62
d f 2  D0
trim 
2
tweb  0.3b
No of holes
D0  d h
 70
2
Using 4 holes

d0  d h
PCD of hole =
2

D0  d h 2
d hole 
5

29
 22-08-2016

.
Q2. It is required to design a two-stage spur- spur gear reduction unit
with 20degree full depth involute teeth.

S
The input shaft is connected to a 10KW 1440rpm motor through a
flexible coupling. The speed of the output shaft shall be approximately
180rpm. The starting torque of the motor is 150% of the rated torque.

.
The gears are made up of plain carbon steel with ultimate tensile
strength of 700 N/mm2 and heat treated to a surface hardness of
340BHN.
Design the gears and specify their dimensions.

Given :
Power P =10KW

R
Input Speed Ni= 1440rpm
1440
Overall velocity ratio
io / a  8
180
Stage velocity ratio istage  n io / a istage  8  2.828

 Speed reducer configuration

Prime Stage-I (Spur)

mover

Stage-II (Spur)

M/C

Multi-Stage Gear Reducer

 N 2 I   N1 II

30
 22-08-2016

.
 Speeds at each stage

S
1440
;  
N
 N1  I  1440rpm 1 I
 i1 ;  N2 I
 2.828 ;  N 2 I  509.1rpm
 N2 I
 N1  II 455
 2.828

.
 N 2  I   N1  II  509.1rpm ;  N 2  II
 i2 ; N 2 II

 N 2 II  180rpm

 Designing for II stage Spur Gear pair

Power P= 10KW

R
Input speed N1 = 509.1rpm

Output speed N2 = 180rpm

Service factor =1.5 …(given)

 Calculate Design Power [P]

[P]  SF  Power  15KW
 General Assumptions
 Tooth profile : Involute
 Pressure angle: 20 degree full depth
 Gear quality: Carefully cut Gears
 Type of Gearing : Standard Sn gearing X1=X2=0

 Selection of Minimum number of teeths on Pinion

2  ha / m 
Zc 
sin 2 
Z2
Using 18 teeths on pinion  2.828 Z 2  51teeths
Z1

Z2
iexact   2.833
Z1

31
 22-08-2016

.
 Calculate the Lewis Form Factor

S
0.912 -----For 20 degree involute tooth ……PSG 8.50
y  0.154 
Z
 0.912 
Y    0.154  
Z 

.

For Pinion
 0.912 
Y1    0.154  
 Z1 

 0.912 
Y1    0.154    0.3246
 18 

R
For Gear
 0.912 
Y2    0.154  
 Z2 

 0.912 
Y2    0.154    0.4276
 51 

 Material Selection & Allowable stresses

For Pinion : Plain carbon steel For Gear : Plain Carbon Steel
2
 ut  700 N/mm
 ut  700 N/mm 2
HB1  340
HB2  340
Assuming FOS of 5
 ut
 ut  b 2    140 N/mm 2
 b1    140 N/mm 2
FOS
FOS
 c   2.8BHN avg  70 N/mm 2  c   882 N/mm
2

 Determination of Weaker Element

Strength Factor for pinion
 b1 Y1  140  0.3246  45.444  b 2 Y2   b1 Y1
Strength Factor for Gear Pinion is the weaker element
Hence designing based on Pinion
 b 2  Y2  140  0.4276  59.864 tooth

32
 22-08-2016

.
 Determination of Module

S
Criterion: Finding module based upon bending failure. Then checking
for dynamic load and wear.

m  1.26
Mt  ...........PSG 8.13 eq 2.1
3

.
 b1   m  z1  Y1

 Calculate Design Torque [Mt]

9.55106  [Pkw ] 9.55106 15

[Mt ]  [Mt ]   281.379 103 N  mm
N1 509.1
 Calculate module

R
281.379  103
m  1.26 3 assuming  m  10
140  10  18  0.3246

m  4.097mm Selecting standard module 5mm from PSG 8.2 T-1

 Check for Bending strength

 Tooth strength Fs
Fs   b1   b  m  Y1 …….. PSG 8.50
Fs  140  50  5  0.3246
Fs  11361 N
 Dynamic Load FD
By Barth's approximation
FD  Ft  Cv

Ft 
 PKW  103
Vm
 D1 N1 Pitch Line velocity m/sec
Vm 
60, 000
  5 18   509.1
Vm  Vm  2.399 m/sec
60, 000

33
 22-08-2016

.
15  103

S
Ft 
2.399
Ft  6252.4 N

.
Ft  625.24 kgf
6  Vm
Cv  ..........for carefully cut gears.......PSG 8.51
6
6  2.399 Cv  1.399
Cv 
6
FD  6252.4 1.399

R
FD  8752.4 N

Fs  FD Hence Safe.

 Buckingham's Dynamic Load

0.164Vm (Cb  Ft )
FD = Ft  ................(kgf )....PSG 8.51
0.164Vm  1.485 Cb  Ft
Ft .....kgf
Vm .....m / min
b.....cm
Ft  625.24 kgf

c  constant from T-41 ...PSG 8.53

c  11860e ....for 200 full depth and steel steel combination

e  constant based on gear quality T-42 ...PSG 8.53
c  11860  0.025
c  296.5

34
 22-08-2016

.
0.164 143.94(296.5  5  625.24)

S
FD = 625.24  ................(kgf )
0.164  143.94  1.485 296.5  5  625.24
FD = 1166.95 kgf

.
FD = 11669.5 N

Fs  FD Hence not Safe.

 Increasing the facewidth

 Using  m  12

 Recalculate the values of Tooth strength and dynamic load

R
Fs  13632 N

FD = 1213.45 kgf
FD = 12134.5 N
Fs  FD Hence Safe.

 Wear Strength of the gear tooth

FW  d1Qkb .......PSG 8.51
2i 2  2.833
Q   1.48 .......PSG 8.51
i  1 2.833  1
2  1 1 
 c 
sin    
k  E1 E2  ......PSG 8.51
1.4
2  1 1 
882  sin 20  5
 5 
k  2.110 2.110   1.81
1.4
FW  90  1.48  1.81 60
FW  14466 N
FW  FD Hence Safe.

35
 22-08-2016

.
 Gear tooth proportions (Spur Gear pair) ….PSG 8.22

S
Item Pinion Gear
Material Plain carbon steel Plain carbon steel
No. of teeths Z1  18 Z 2  51

.
Face Width b=60mm b=60mm
Module m=5mm m=5mm
Pressure angle   200   200
Pitch circle Dia d1= 90mm d2= 255mm
Tip Dia d a1   z1  2 f 0  m d a 2   z2  2 f 0  m

R
Root Dia d f 1   z1  2 f 0  m  2c d f 2   z2  2 f 0  m  2c

 Module for I stage

Assuming same material & same stresses with equal number of teeths in
II stage and for same VR

m  3 Torque

mI  M t1  mI N2 mI 1
mII
 3
Mt2  ; mII
 3
N1 ; mII
3
istage

36
 22-08-2016

.
Helical Gears

S
pt  Transverse pitch
pn  Normal pitch

.
am
In amc cos =
ac
pn
cos  
pt

pn  pt cos 
n

R
pc  pd  
m

pc 
pd
 
 pc t 
 pd t  pc n   pd n

  1 cos 
 pc n   pt n cos  ; 
 pd n  pd t
cos  ; 
 pd n  pd t

mn
mn  mt cos  ; d  mt z ; d
cos 
z

 Virtual Number of teeths

d
2 cos 
b

d
d
2 cos   2


d
2 cos 

37
 22-08-2016

.
2
 d 

S
a2  2 cos   d
rv  ; rv    ; rv 
2 cos 2 
b d
rv
2

.
d 2 rv 2 rv
d v  2rv ; dv 
cos 2  ; p  c n 
Zv ; Zv 
 pc n
d
2 rv 2 rv 2
Zv  ; Zv  ; 2 cos 2  ; Zv 
d

R
  mn Zv  mn cos 2 
 mn
 pd n
mn
z Virtual
Zv 
d
mn cos 2 
; Zv 
cos  ; Zv 
Z
number of
cos3 
mn cos 2  teeths

 Face Advance 
 pc t   pc t   mt
 pd t
FA  btan
pt b
FA  Transverse Circular pitch
FA btan
FAC = FAC =
FA Circular pitch  mt

sin  As per AGMA,

b
cos  FAC  1.15
FAC =
mn
 b sin 
cos   1.15
 mn
b sin  1.15 m n
FAC = b 
 mn sin 

38
 22-08-2016

.
 Force Analysis (Helical Gears)

S
In Vertical plane

.


Px  P cos 

Py  P sin 
Pr  Py  P sin 

In plane BDC,

R
Pt  P cos  cos 
Pa  P cos  sin 
tan 
Pa  Pt tan  Pr  Pt
cos 

Design of Helical Gears

Q1. It is required to design a pair of helical gears to transmit power
from an electric motor rated 30KW, 960rpm to machine rotating at
approximately 250rpm.

The Helix angle is 17degrees and the gears are made with 20
degrees pressure angle and full depth involute profile.

Design the gears by:

a. Choosing suitable materials and design stresses,
b. Determining the module and face width to satisfy strength and
wear criteria,
c. Checking the gears for dynamic load using Buckingham's
analysis,
d. Specifying the complete dimensional details of the pinion and
gear.

39
 22-08-2016

.
Given :
Power P =30KW

S
Input Speed Ni= 960rpm
Output Speed No= 250rpm
Helix angle   170
Pressure angle   200

.
Application : Electric motor to machine
Tooth Profile: Involute

 Velocity ratio i
N1 960
i   3.84
N 2 250

R
 Service Factor
Based on application from PSG 7.69
SF : 1.2

 Calculate Design Power [P]

[P]  SF×Power  36 KW

 General Assumptions
 Tooth profile : Involute
 Pressure angle: 20 degree full depth
 Gear quality: Precision cut Gears
 Type of Gearing : Standard Sn gearing X1=X2=0

 Selection of Minimum number of teeths on Pinion

2  ha / m 
Zc 
sin 2 
Using 18 teeths on pinion
Z2 Z2
 3.84 Z 2  70 teeths iexact   3.88
Z1 Z1
 Virtual number of teeths ….. PSG8.22
On Pinion On Gear
Z1 18 Z2 70
Z v1    20.58 Zv2    80.04
cos  cos3 17
3 cos  cos3 17
3

40
 22-08-2016

.
 Calculate the Lewis Form Factor based on virtual number of
teeths

S
0.912 -----For 20 degree involute tooth ……PSG 8.50
y  0.154 
Z
 0.912 
Y    0.154  
Z 

.

For Pinion
 0.912 
Yv1    0.154  
 Z v1 
 0.912 
Yv1    0.154    0.3445
 20.58 

R
For Gear
 0.912 
Yv 2    0.154  
 Zv2 
 0.912 
Yv 2    0.154    0.4880
 80.04 

 Material Selection & Allowable stresses …….PSG 8.5

For Pinion : 40Ni2Cr1Mo28 For Gear : 15Ni2Cr1Mo15
 ut1  1550 N/mm 2  ut 2  900 N/mm 2
HB1  600 HB1  600

 b1   380 N/mm2  b 2   300 N/mm2

 c1   1100 N/mm2  c 2   950 N/mm2

 Determination of Weaker Element

Strength Factor for pinion

 b1 Yv1  380  0.3445  130.91

Strength Factor for Gear
 b 2 Yv 2   b1 Yv1
Pinion is the weaker element
 b 2  Yv 2  300  0.4480  134.4 Hence designing based on Pinion
tooth

41
 22-08-2016

.
 Determination of Module

S
Criterion: Finding module based upon bending failure. Then checking
for dynamic load and wear.

mn  1.15cos
Mt  ...........PSG 8.13 eq 2.2

.
3
 b1   m  z1  Yv1

 Calculate Design Torque [Mt]

9.55106  [Pkw ] 9.55106  36
[Mt ]  [Mt ]   358.125103 N  mm
N1 960
 Calculate module

R
358.125  103
mn  1.15cos 3 assuming  m  10
380 10  18  0.3445

mn  2.72 mm Selecting standard module 3mm from PSG 8.2 T-1

 Check for Face width

 As per AGMA
1.15  π  m n
b
sin 

1.15  π  3
b
sin17
using  m  15
b  49.42 mm Increasing mn to 4mm
 Check for Bending strength
 Tooth strength Fs

Fs 
 b1   b  Yv1 …….. PSG 8.51 Fs   b1   b  Yv1  mn
Pdn
Fs  380  60  4  0.3445
Fs  31418.4 N Fs  3141.84 kgf

42
 22-08-2016

.
 Dynamic Load FD

S
By Barth's approximation

FD  Ft  Cv

 PKW  103

.
Ft 
Vm
 D1 N1 Pitch Line velocity m/sec
Vm 
60, 000
mZ
D1  n 1 .........PSG 8.22
cos 

R
4 18
D1   75.29mm
cos18
  75.29  960 Vm  3.784 m/sec
Vm 
60, 000 Vm  227.06 m/min

Ft 
 PKW   103 36 103
  9513.74 N
Vm 3.784
5.5  Vm
Cv  ..........for Precision cut gears.......PSG 8.51
5.5

5.5  3.784 Cv  1.353

Cv 
5.5
FD  Ft  Cv

FD  9513.74 1.353

FD  12878.57 N
Fs  FD Hence Safe.

43
 22-08-2016

.
 Buckingham's Dynamic Load

S
0.164Vm (Cb cos 2   Ft ) cos 
FD = Ft  ........PSG 8.51
2
0.164Vm  1.485 Cb cos   Ft
Ft  951.374 kgf

.
Vm  227.06 m / min
b  6 cm c  constant from T-41 ...PSG 8.53
c  11860e ....for 200 full depth and steel steel combination
e  constant based on gear quality T-42 ...PSG 8.53

R
c  11860  0.0125  148.25
0.164  227.06(148.25  6 cos 2 17  951.374) cos17
FD = 951.374 
0.164  227.06  1.485 148.25  6 cos 2 17  951.374

FD  1582.22 kgf Fs  FD Hence Safe.

 Wear Strength of the gear tooth

d1Qkb
FW  .......PSG 8.51
cos 2 
2i 2  3.88
Q   1.59 .......PSG 8.51
i  1 3.88  1
2  1 1 
 c 
sin    
k  E1 E2  ......PSG 8.51
1.4
 1 1 
1100 2  sin 20  5
 5 
k  2.1 10 2.110   2.815
1.4
75.29 1.59  2.815  60
FW 
cos 2 17
FW  22109.11 N FW  FD Hence Safe.

44
 22-08-2016

.
 Gear tooth proportions (Helical Gear pair) ..PSG 8.22

S
Item Pinion Gear
Material 40Ni2Cr1Mo28 15Ni2Cr1Mo28
No. of teeths Z1  18 Z 2  70

.
Face Width b=60mm b=60mm
Module mn  4mm mn  4mm
Pressure angle   200   200
Helix angle   17 0 R.H .   17 0 L.H .
Pitch circle Dia d1= 75.29mm d2= 300.79mm

R
Tip Dia  z   z 
d a1   1  2 f 0  mn d a 2   2  2 f 0  mn
 cos    cos  
Root Dia  z 
d f 1   1  2 f 0  mn  2c d f 2   z1  2 f 0  mn  2c
 cos    cos  

 Pinion construction
Since PCD is 75.29 , Hence using Integral with shaft construction.
 Input Shaft Design
Material : 40Ni2Cr1Mo28
 Allowable stresses

Ultimate Stress  yt  360 N / mm2 …………………….. PSG 8.5

F.O.S : assuming 5

Keyway factor :1 since no keyway for integral construction

[ ]  ( yt  0.5)  Kw / F.O.S  155N / mm2

 Calculate Design Torque [Mt]

9.55106  [Pkw ] 9.55106  36
[Mt1 ]  [Mt1 ]   358.125103 N  mm
N1 960

45
 22-08-2016

.
 Calculate Shaft diameter

S
16  M t 
d s1  3
  

.
16  358.125 103
d s1  3
  45
d s1  22.74mm

R
using d s1  25mm

 Gear construction
Since PCD is 300mm , Hence using Web construction.
 Input Shaft Design
Material : C-45
 Allowable stresses

Yield Stress  yt  360 N / mm2 …………………….. PSG 1.9

F.O.S : assuming 4 since neglecting bending

Keyway factor :0.7 to 0.8 assuming 0.75

[ ]  ( yt  0.5)  Kw / F.O.S  33.75N / mm2

 Calculate Design Torque [Mt]
[Mt 2 ]  [Mt1 ] i

[Mt 2 ]  358.125103  3.88  13.895105 N  mm

46
 22-08-2016

.
 Calculate Shaft diameter

S
16[ M t 2 ]
ds2  3
  

.
5
16  13.895  10
ds2  3
  33.75
d s1  59.40 mm

R
using d s1  60 mm

 Web construction ….PSG 8.62

d h 2  1.6d s 2
D0  d a  10m

d f 2  D0
trim 
2
t web  0.3b
No of holes
D0  d h
 70
2
Using 4 holes

D0  d h 2
PCD of hole =
2

D0  d h 2
d hole 
5

47
 22-08-2016

.
Q.2 A Helical gear pair has following specifications:
Normal Module =3mm

S
Face Width =30mm
Pressure angle = 20 degrees
Helix angle= 17 degrees
Speed of output shaft = 200rpm

.
Number of teeths on pinion=20
Material for pinion is 40Cr1 with ultimate tensile strength 950 N/mm2
& BHN 460
Number of teeths on gear=56
Material for gear is steel C-50 with ultimate tensile strength 800 N/mm2
& BHN380

R
Gears are commercially cut with grade A.
Gear mounting is symmetric

Estimate power rating of pair based on

i. Beam Strength
ii. Wear Strength

 Calculate Velocity ratio i

N1 Z 2 56
i    2.8
N 2 Z1 20
 Calculate Input Speed
N1
i
N2
; N1  iN 2 ; N1  2.8  200 ;N 1  560 rpm

 Calculate Virtual number of teeths ….. PSG8.22

On Pinion On Gear
Z1 20 Z2 56
Z v1    22.8686 Zv2    64.0322
cos  cos3 17
3
cos  cos3 17
3

 Calculate the Lewis Form Factor based on virtual number of

teeths…PSG 8.50
For Pinion For Gear

 0.912   0.912 
Yv1    0.154    0.3585 Yv 2    0.154    0.4390
 22.8686   64.0322 

48
 22-08-2016

.
 Calculate Allowable Bending stresses …….PSG 8.5

S
For Pinion : 40Cr1 For Gear : C-50
 ut1  9550 N/mm 2  ut 2  800 N/mm 2
HB1  460 HB1  380

.
Assuming FOS of 5
 ut 800
 b1  
 ut

950
 190 N/mm 2
 b 2     160 N/mm 2
FOS 5
FOS 5
460  380 
 c   2.8BHN avg  70 N/mm 2  c   2.8    70
 2 
 c   1106 N/mm 2

R
 Determination of Weaker Element
Strength Factor for pinion
 b1 Yv1  190  0.3585  68.115  b 2 Yv 2   b1 Yv1
Strength Factor for Gear Pinion is the weaker element
Hence design should be based on
 b 2 Yv 2  160  0.4390  70.24 Pinion tooth

 Power rating based upon Bending strength

 Calculate Tooth strength Fs
Fs   b1   b  Yv1  mn
Fs  190  30  0.3585  3
Fs  6130.35 N ..........eq.(1)
 Calculate the Dynamic Load FD
By Barth's approximation
FD  Ft  Cv

Ft 
 PKW   103
Vm
 D1 N1
Vm  Pitch Line velocity m/sec
60, 000
mZ 3  20
D1  n 1 .........PSG 8.22 D1   62.79mm
cos  cos17

49
 22-08-2016

.
  75.29  960
Vm  Vm  1.839 m/sec

S
60, 000
3  Vm
Cv  ..........for comercially cut gears.......PSG 8.51
3

.
3  1.839
Cv  Cv  1.613
3

Ft 
 PKW  103
FD 
 PKW  103
1.613 ......eq.(2)
1.839 1.839
For Safe Design,

R
Fs  FD

6130.35 
 PKW  103 1.613
1.839
 PKW   6.989 KW Power based upon Bending strength

 Power rating based upon Wear strength

 Calculate Wear strength Fw
d1Qkb
FW  .......PSG 8.51
cos 2 
2i 2  2.8
Q   1.47 .......PSG 8.51
i  1 2.8  1
2  1 1 
 c  sin    
k  E1 E2  ......PSG 8.51
1.4
 1 1 
11062  sin 20  5
 5 
k  2.1 10 2.1 10   2.846
1.4
62.79  1.47  2.846  30
FW  FW  8617.5 N ......eq.(3)
cos 2 17

50
 22-08-2016

.
For Safe Design,

S
FW  FD
8617.5 
 PKW  103 1.613
1.839

.
 KW 
P  9.82 KW Power based upon Wear strength

Based upon the Bending and Wear criteria, For safe Design the power
rating of the gear pair can be taken as 6.989KW
 P   6.989KW .....Design Power
 P   Pm ×Service Factor

R
P 
 P
m
Service Factor
Assuming Service factor of 1.3
6.989
Pm  Pm  5.376 KW
1.3

Bevel Gears

 1
2

  1   2

51
 22-08-2016

.
 Virtual Spur Gear
r
sin  90    

S
rv
r
rv 
cos 

.
d d
mt 
z
; zm t

r
 2rv
zv 
mt
rv
zv 2rv mt
 

R
z mt d
zv 2r 1
 
z cos  2r
z Virtual
zv  number of
cos  teeths

 Velocity ratio i
N1 d 2 2 R sin  2 sin  2
i 
N 2 d1
; i  dd 2

2 R sin 1
; i 
1 sin  1
 Cone angles
  1   2

i
sin  2 ; sin  2  i sin 1 ; sin  2  i sin    2 
sin 1
sin  2  i  sin  cos  2  sin  2 cos  
Replacing  2 by 1 ; i=1/i
Dividing by cos 2
sin  / i
tan  2  i sin  i tan  2 cos  tan 1 
tan  2  i tan  2 cos   i sin  1   cos  / i 
i sin  sin 
tan  2  tan 1 
1  i cos  i  cos 

52
 22-08-2016

.
 Force Analysis (Bevel Gears)

S
Pt  P cos 
P

 

.

 Ps  P sin 

R
Ps P sin  Pr  Pt tan  cos 

Pt P cos  Pa  Pt tan  sin  
Ps  Pt tan 
Ps  Pt tan 

 Pr  gear Ps cos 

Ps 
 Pr  pinion  Ps cos  Ps sin    Pa  gear

Ps
Ps sin    Pa  pinion



Dp b sin 
rm  
2 2
 M t   Ft  rm  Pr  gear   Pa  pinion  Pa  gear   Pr  pinion

53
 22-08-2016

.
Design of Bevel Gears

S
Q1. A pair of 90degree, straight bevel gears is used to transmit
power to a bucket elevator shaft rotating at 36rpm.

The reduction ratio is 4.5:1.

.
Power to be transmitted is 11KW and duty is 10-12 hours per day.

i. Assuming suitable materials and stresses design the gears

considering strength and wear.

ii. Check the gears for Dynamic load using Buckingham's analysis.

R
iii. Sketch the constructional details of the gears along with the
leading dimensions.

Given :
Power P =11KW
Duty Hrs : 10-12hrs/day
Output Speed N2= 36rpm
Type of Bevel Gear : 90degree Bevel arrangement
Application : Electric motor Bucket Elevator
Reduction ratio i: 4.5

 Input speed N1
N1  i  N 2  4.5  36
N1  162rpm
 Service Factor
Based on application from PSG 7.69
SF : 1.3
 Calculate Design Power [P]
[P]  SF×Power  14.3 KW

54
 22-08-2016

.
 General Assumptions

S
 Tooth profile : Involute
 Pressure angle: 20 degree full depth
 Gear quality: Carefully cut Gears
 Type of Gearing : Standard Sn gearing X1=X2=0

.
 Selection of Minimum number of teeths on Pinion
2  ha / m 
Zc 
sin 2 
Using 18 teeths on pinion
Z2

R
Z2 Z 2  81 teeths iexact   4.5
 4.5 Z1
Z1
 Calculate the pitch cone angles
 For Gear 1
 For Pinion
0  2  tan  i  1  90   2
 =90
tan  2  i  2  tan 1  4.5   2  77.470   12.530
1

 Virtual number of teeths ….. PSG8.39

On Pinion On Gear
Z1 18 Z2 81
Z v1    18.44 Zv2    373.35
cos 1 cos12.53 cos  2 cos 77.47

 Calculate the Lewis Form Factor based on virtual number of

teeths….. PSG 8.50
 0.912 
Y    0.154  
 Z 
For Pinion For Gear

 0.912   0.912 
Yv1    0.154   Yv 2    0.154  
 Z v1   Zv 2 

 0.912   0.912 
Yv1    0.154    0.3284 Yv 2    0.154    0.4761
 18.44   373.35 

55
 22-08-2016

.
 Material Selection & Allowable stresses …….PSG 8.5

S
For Pinion : 40Ni2Cr1Mo28 For Gear : 15Ni2Cr1Mo15
 ut1  1550 N/mm 2  ut 2  900 N/mm 2
HB1  600 HB1  600

.
 b1   380 N/mm2  b 2   300 N/mm2
 c1   1100 N/mm2  c 2   950 N/mm2

 Determination of Weaker Element

Strength Factor for pinion

R
 b1 Yv1  380  0.3284  124.6
Strength Factor for Gear  b 2 Yv 2   b1 Yv1
 b 2 Yv 2  300  0.4761  142.83 Pinion is the weaker element
Hence designing based on Pinion
tooth

 Determination of Module
Criterion: Finding module based upon bending failure using Lewis
equation and dynamic load using Barth's velocity factor. Then check for
Buckingham's dynamic load and wear.
 Tooth strength Fs
b
 b 2   b  Yv 2  1  
 R  …….. PSG 8.51
Fs 
Pd
mt Z1
 b R ..............PSG 8.38
Fs   b 2   b  Yv 2  1    mt 2sin 1
 R
mt Z1
b  0.3 
b 1 1 2sin 1
 to
R 3 4 mt 18
b  0.3 
b  0.3R ............PSG 8.38 2sin12.53
b  12.44mt

56
 22-08-2016

.
Fs  380  12.44mt  0.3284  1  0.3  mt

S
Fs  1085.02mt 2 …….. (1)
 Dynamic Load FD
By Barth's approximation

.
FD  Ft  Cv  N sf  K m …….. PSG 8.52
 Calculate the tangential force Ft on the gear tooth

Ft 
 PKW  10 3

Vm

R
 D1 N1  18mt 162
Vm  Vm  Vm  0.1527 mt m / sec
60, 000 60, 000

14.3  103 93.6476 103

Ft  Ft 
0.1527 mt mt

3.5  Vm
Cv  ..........for straight bevel.......PSG 8.52
3.5
3.5  0.1527 mt
Cv 
3.5
 93.65  103   0.1527mt 
FD     1  
 mt   3.5 

 93.65  103   93.65 103 0.1527 mt 
FD       
 mt   mt 3.5 


93.65  103 10455.84

FD   ..........(2)
mt mt

57
 22-08-2016

.
For Safe Design,

S
Fs  FD
93.65 103 10455.84
1085.02mt 2   ..........(2)

.
mt mt
mt  4.752 mm
Selecting standard module of 5mm from PSG 8.2
 Face Width & Cone Distance
b  12.44mt b  62.2mm

R
b  0.3R R  207.33mm
 Tooth strength Fs
Fs  1085.02mt 2 from eq1

Fs  27134 N

 Dynamic Load FD
93.65  103 10455.84
FD   ..........frm eq.2
mt mt
93.65 103 10455.84
FD  
5 5
Fs  FD Hence Safe.

 Buckingham's Dynamic Load

0.164Vm (Cb  Ft )
FD = Ft  ................(kgf )....PSG 8.51
0.164Vm  1.485 Cb  Ft
93.6476 103 Ft  18729.53 N
93.6476  103
Ft  ; Ft 
5
; Ft  1872.953 kgf
mt
Vm  0.7635 m/sec
Vm  0.1527 mt m / sec ; Vm  0.1527  5 ;
Vm  45.81 m/min

58
 22-08-2016

.
c  11860e ....for 200 full depth and steel steel combination

S
e  constant based on gear quality T-42 ...PSG 8.53
c  11860  0.025  296.5

.
0.164  45.81(296.5  6.22  1872.95)
FD = 1872.95 
0.164  45.81  1.485 296.5  6.22  1872.95
FD = 2240.935 kgf
FD = 22409.35 N
Fs  FD Hence Safe.

R
 Wear Strength of the gear tooth
d1Qkb
FW   0.75
cos 1
2Z v 2 2  373.35
Q Q Q  1.905
Z v 2  Z v1 373.35  18.44

2  1 1 
 c 
sin    
k  E1 E2  ......PSG 8.51
1.4
 1 1 
11002  sin 20  5
 5 
k  2.1 10 2.1 10   2.815
1.4
90  1.905  2.815  62.2
FW   0.75
cos12.53

FW  23023.11 N FW  FD Hence Safe.

59
 22-08-2016

.
 Gear tooth proportions (Bevel Gear pair) ..PSG 8.38,8.39

S
Item Pinion Gear
Material 40Ni2Cr1Mo28 15Ni2Cr1Mo28
No. of teeths Z1  18 Z 2  81

.
Face Width b=62.2mm b=62.2mm
Module mt  5mm mt  5mm
Pressure angle   200   200
Cone Distance R=207.3mm R=207.3mm
Pitch circle Dia d1= 90mm d2= 405mm

R
Tip Dia d a1  mt  z1  2 cos 1  d a 2  mt  z2  2 cos 1 

Root Dia d f 1  d1  2h f cos 1 d f 2  d 2  2h f cos  2

 mt f 0 
Addendum angle  a1  tan 1    a1   a 2
 R 

 Gear tooth proportions (Bevel Gear pair) ..PSG 8.38,8.39

Item Pinion Gear

Tip angle  a1   1   a1  a1   2   a 2
Root angle  f 1  1   f 1  f 2  2  f 2

 Pinion construction
Since PCD is 90mm , Hence using Solid Disc construction.
 Input Shaft Design
Material : C-45
 Allowable stresses

Yield Stress  yt  360 N / mm2 …………………….. PSG 1.9

F.O.S : assuming 4 since neglecting bending

Keyway factor :0.7 to 0.8 assuming 0.75

[ ]  ( yt  0.5)  Kw / F.O.S  33.75N / mm2

60
 22-08-2016

.
 Calculate Design Torque [Mt]
9.55106  [Pkw ] 9.55106 14.3

S
[Mt ]  [Mt ]   8.43105 N  mm
Nshaft 162
 Calculate Shaft diameter

.
16  M t 
d s1  3 d a1
  
df1
5
16  8.43 10
d s1  3
d s1
  33.75 d h1

R
d s1  50.29mm
using d s1  55mm

 Gear construction
Using Web construction.
 Input Shaft Design
For same material and same design stresses as that of input shaft
ds2 3
 i
d s1

d s 2  d s1 3 i

d s 2  55  3 4.5
d s 2  90.85 mm
using d s 2  95 mm

61
 22-08-2016

.
 Gear proportions …… PSG 8.62

S
Hub Dia d h 2  1.6d s 2
Hub length l  1.1 d s 2
trim  a  h f

.
a  0.2 R
Web thickness c  0.3d s 2

R
Q.2 A commercially cut Bevel gear pair is used to transmit 5KW of power
from pinion shaft rotating at 400rpm with reduction ratio of 3.4

Shaft angle is 80 degrees and drive is subjected to moderate shock and

operating for 10hrs/day.

Selecting suitable material and design stresses design the gears.

Given :
Power P =5KW
Duty Hrs : 10hrs/day
Input Speed N1= 400rpm
Type of Bevel Gear : 80degree Bevel arrangement
Reduction ratio i: 3.4
Drive is subjected to moderate shock
Gear Quality : Commercially cut
 Output speed N2
N1 400
N2  
i 3.4
N 2  117.65 rpm

62
 22-08-2016

.
 Service Factor
Based on application for moderate shock and 10hrs duty/day

S
SF : 1.1 ………PSG7.69
 Calculate Design Power [P]
[P]  SF×Power  5.5 KW

.
 General Assumptions
 Tooth profile : Involute
 Pressure angle: 20 degree full depth
 Gear quality: Commercially cut Gears
 Type of Gearing : Standard Sn gearing X1=X2=0
 Selection of Minimum number of teeths on Pinion

R
2  ha / m 
Zc 
sin 2 
Using 18 teeths on pinion

Z2 Z2
 3.4 Z 2  62 teeths iexact   3.444
Z1 Z1

 Calculate the pitch cone angles

 For Pinion
 sin   ; sin 80
1  tan 1   1

 tan 1 

 ; 1  15.230
 i  cos    3.444  cos80 
 For Gear
 i sin    3.444sin 80  ;   64.77 0
 2  tan 1   ; 2  tan 1   1
 1  i cos    1  3.444 cos80 
 Virtual number of teeths ….. PSG8.39
On Pinion On Gear
Z1 Z2
Z v1  Zv2 
cos 1 cos  2
18 62
Z v1   18.654 Zv2   145.507
cos15.23 cos 64.77

63
 22-08-2016

.
 Calculate the Lewis Form Factor based on virtual number of
teeths….. PSG 8.50

S
 0.912 
Y    0.154  
 Z 
For Pinion For Gear

.
 0.912   0.912 
Yv1    0.154   Yv 2    0.154  
 Z v1   Zv 2 
 0.912   0.912 
Yv1    0.154    0.3302 Yv 2    0.154    0.4641
 18.654   145.507 
 Material Selection & Allowable stresses …….PSG 8.5
For Pinion : 40Ni2Cr1Mo28 For Gear : 15Ni2Cr1Mo15

R
 ut1  1550 N/mm 2  ut 2  900 N/mm 2
HB1  600 HB1  600

 b1   380 N/mm2  b 2   300 N/mm 2

 c1   1100 N/mm2  c 2   950 N/mm2

 Determination of Weaker Element

Strength Factor for pinion
 b 2 Yv 2   b1 Yv1
 b1 Yv1  380  0.3284  124.6 Pinion is the weaker element
Strength Factor for Gear Hence designing based on Pinion
tooth
 b 2 Yv 2  300  0.4761  142.83
 Determination of Module
Criterion: Finding module based upon bending failure using Lewis
equation and dynamic load using Barth's velocity factor. Then check for
Buckingham's dynamic load and wear.

mav  1.28
M t  ...........PSG 8.13 eq 2.3
3
 b1   m  z1  Yv1

b
mt  mav + sin ...........PSG 8.13 eq 2.3
Z

64
 22-08-2016

.
 Calculate Design Torque [Mt]

S
9.55106  [Pkw ] 9.55106  5.5
[Mt1 ]  [Mt1 ]   131.31103 N  mm
N1 400
 Calculate Module

.
131.31103
mav  1.28 3 assuming  m  10
380  10  18  0.3302
mav  2.30 mm
b
mt  mav + sin1 ...........PSG 8.13 eq 2.3
Z1

R
m 10
mt  2.30+ t sin15.22
18
mt  2.692 mm
Selecting standard module of 3mm from PSG 8.2

 Face Width  Cone Distance

b = 10mt b=0.3R
b = 30 mm R= 100 mm
 Tooth strength Fs
b
 b1   b  Yv1  1   …….. PSG 8.52
 R
Fs 
Pd
 b
Fs   b1   b  Yv1  1    mt
 R
 30 
Fs  380  30  0.3302   1  3
 100 
Fs  7904.98 N
 Dynamic Load FD
FD  Ft  Cv  N sf  K m …….. PSG 8.52

65
 22-08-2016

.
Assuming N sf  1.3

S
km  1.25
 Calculate the tangential force Ft on the gear tooth

.
Ft 
 PKW  103
Vm
 D1 N1   18  3  400
Vm 
60, 000
; Vm 
60, 000
;V m  1.131 m / sec

5.5  103 ;

R
Ft  Ft  4862.95 N
1.131
3.5  Vm
Cv  ..........for straight bevel.......PSG 8.52
3.5
3.5  1.131
Cv 
3.5
; Cv  1.303

FD  4862.95  1.303 1.3  1.25

FD  10296.688 N Fs  FD Hence not Safe.

 Increasing the facewidth  m  12

 Increasing the module m=4mm
 Recalculate Fs & Fd Vm  1.51 m / sec
b  48 ; R  b / 0.3 ; R  160
3.5  1.51 Cv  1.35
Cv 
 b 3.5
Fs   b1   b  Yv1  1    mt
 R 5.5  103 F  3642.38 N
30  Ft  t
 1.51
Fs  380  48  0.3302   1   4
 100 
FD  3642.38  1.35  1.3  1.25
Fs  16864 N
  18  4   400 FD  7990.47 N
Vm 
60, 000 Fs  FD Hence Safe.

66
 22-08-2016

.
 Buckingham's Dynamic Load

S
0.164Vm (Cb  Ft )
FD = Ft  ................(kgf )....PSG 8.51
0.164Vm  1.485 Cb  Ft

.
Ft  364.238 kgf Vm  90.48 m/min

c  11860e ....for 200 full depth and steel steel combination

e  constant based on gear quality T-42 ...PSG 8.53
c  11860  0.05  593
0.164  90.48(593  4.8  364.238)

R
FD = 364.238 
0.164  90.48  1.485 593  4.8  364.238
FD  845.51 kgf FD  8455.1 N

Fs  FD Hence Safe.

 Check for Wear Strength of the gear tooth

 Induced contact stress
3
0.72 i 2
 1
c    E   M t1  ...........PSG 8.13 Eq.1.6
R  0.5b ib
R :16cm
R, b : cm
b : 4.8cm
 M t  : Kgf  cm ;  M t  :1313.1Kgf  cm
E : Kgf / cm 2
E : 2.1 106 Kgf / cm 2
3
0.72  3.444 2
 1
c    2.1106  1313.1
16  0.5  4.8 3.444  4.8
 c  4639.98 kgf/cm 2
 c   c1  Hence Safe.

67
 22-08-2016

.
 Gear tooth proportions (Bevel Gear pair) ..PSG 8.38,8.39

S
Item Pinion Gear
Material 40Ni2Cr1Mo28 15Ni2Cr1Mo28
No. of teeths Z1  18 Z 2  62

.
Face Width b=48mm b=48mm
Module mt  4mm mt  4mm
Pressure angle   200   200
Cone Distance R=160mm R=160mm
Pitch circle Dia d1= 72mm d2=248mm

R
Tip Dia d a1  mt  z1  2 cos 1  d a 2  mt  z2  2 cos  2 

Root Dia d f 1  d1  2h f cos 1 d f 2  d 2  2h f cos  2

 mt f 0 
Addendum angle  a1  tan 1    a1   a 2
 R 

Worm & Worm-Wheel Drive

 Designation of Worm gears

Z / z/q/m
Z : Number of starts on Worm
z : Number of teeths on W.W
q: Diameter quotient q  d1
m
D
p
z
; p   mt

p x   mx ; mx  mt

68
 22-08-2016

.
l  px  Z ; l   mx Z

S
 l 
   tan 1  
  d1 

.
  mx Z 
  tan 1  
  qmx 
Z
  tan 1  
q

R
    900


 Force Analysis (Worm Gears)

In Vertical plane
Px  P cos 
Py  P sin 
Pr  P sin 

In plane BDC,
Pt  P cos  sin 
Pa  P cos  cos 

69
 22-08-2016

.
 Frictional Force
Pt  P cos  sin    P cos 

S
Pa  P cos  cos    P sin 

Pa P cos  cos    P sin 

.

Pt P cos  sin    P cos 

cos  cos    sin 

Pa  Pt 
cos  sin    cos 

sin 
Pr  Pt 

R
cos  sin    cos 

 Direction of Forces

 Pr ww

 Pt ww
 Pa ww
 Pr w
 Pt w  Pa w
 Pa w   Pt ww
 Pt w   Pa ww

70
 22-08-2016

.
 Efficiency of Worm Drive

S
tan   

tan     

.
 Sliding Velocity
Vm1
cos  
Vs
Vm1
Vs 
cos 

R
 D1 N1
Vs 
60000  cos 

Design of Worm & Worm-Wheel Drive

Q1. A worm and worm wheel drive is required to transmit
power from an electric motor rated at 11KW and 1440rpm
with a reduction ratio of 15. The power is supplied to a belt
conveyor which operates for 12-14hrs/day.

i. Select suitable material and design stresses.

ii. Design the worm and worm wheel to satisfy the strength
and wear criteria.

iii. Indicate the constructional details of worm and worm

wheel.

iv. Check the unit for heat dissipation capacity and modify the
design if required.

71
 22-08-2016

.
Given :
Power P =5KW

S
Worm speed N1=1440 rpm
Duty Hrs : 10hrs/day
Reduction ratio i: 15

.
 Service Factor
Based on application for moderate shock and 10hrs duty/day
SF : 1.2 ………PSG7.69

 Calculate Design Power [P]

[P]  SF×Power  13.2 KW

R
 Worm: Cylindrical
 Worm Wheel: Concave globoidal
 Tooth profile : Involute
 Pressure Angle : 20 degrees
 Type of Gearing : Standard Sn gearing X1=X2=0
 Layout : Overrunning Worm

 Selection of Minimum number of starts on worm

As per AGMA
Z  z  40
z 40 40 40
1
Z

Z ; 1 i 
Z ; Z
i 1
For i=15
40
Z ;Z 2.5 ; using Z = 3 starts
15  1
 Number of teeths on Worm Wheel

z  iZ ; z  15  3 ; z  45
 Selection of Diameter Quotient
q = 8 to 13
Initially assuming q =11 ……….PSG 8.44

72
 22-08-2016

.
 Calculate the lead angle on worm ….PSG8.44

S
Z Z
tan  1  ;  1  tan 1 
q q
 Calculate the Helix Angle

.
On Worm On Worm Wheel
1  90   1 2   1
1  90  15.25  2  15.25
1  74.750
 Calculate the Virtual number of teeths ….. PSG8.39

R
On Worm On Worm Wheel
Z z
Z v1  Zv2 
cos3 1 cos3  2
3 45
Z v1  3
 164.85 Zv2  3
 50.10
cos 74.75 cos 15.25

 Calculate the Lewis Form Factor based on virtual number of

teeths….. PSG 8.50
 0.912 
Y    0.154  
 Z 
For Worm For Worm Wheel
 0.912 
Yv1    0.154    0.912 
 Z v1 
Y v 2    0.154  
 Zv 2 

 0.912   0.912 
Yv1    0.154    0.4664 Yv 2    0.154 
 164.85    0.4266
 50.10 

 Material Selection & Allowable stresses …….PSG 8.5,8.45

For Worm : C-45 For Worm wheel: Chilled Phosphor Bronze

 ut1  630 N/mm 2  ut 2  390 N/mm 2

 b1   135 N/mm 2  b 2   110N/mm2

73
 22-08-2016

.
 Determination of Weaker Element

S
Strength Factor for Worm
 b 2 Yv 2   b1 Yv1
 b1 Yv1  135  0.4664  62.9 Worm wheel is the weaker
Strength Factor for W.W element

.
Hence designing based on worm
 b 2 Yv 2  110  0.4266  46.926 wheel tooth
 Determination of Module
Criterion: Finding module based upon Contact stresses,
Then checking for Bending and wear.
2

R
 
 z   540 
a    1 3    M t  .......P S G 8 .4 4
 q z
    
c
 q 
a  0.5mx  ( q  z ) ........PSG 8.43 T-35

 Calculate Design Torque [Mt]

9.55106  [Pkw ]0
[Mt 2 ] 
N2
[Pkw ]o  Power at worm wheel shaft

[ Pkw ]o
 Efficiency of Worm Wheel Drive
[ Pkw ]i

  0.8 to 0.92 ......PSG 8.46

Assuming   0.92
[ Pkw ]o  [ Pkw ]i ; [ Pkw ]o  0.92  13.2 ; [ Pkw ]o  12.144 KW

9.55106  12.144 [Mt 2 ]  1.208106 N-mm

[Mt 2 ] 
96
[Mt 2 ]  1.208104 kgf-cm

74
 22-08-2016

.
 Calculate module

S
2
 
 45   540  4
a   1 3  45   1 .2 0 8  1 0
 11    1490 

.
 11 
a  23.213 cm

a  0.5mx  (q  z )
23.213  0.5mx  (11  45)

R
mx  0.829 cm
mx  8.29 mm
Selecting standard module of 10mm from PSG 8.2
mx  mx  10 mm

 Tooth strength Fs
 b 2   b  Y2
Fs 
Pdn
…….. PSG 8.52 ; F     b  Y  m
s b2 2 n

mn  mt cos  2 ;m n  mt cos  1 ; mn  mx cos  1

Fs   b 2   b  Y2  mx cos  1
Y2  Lewis form factor based upon actual number of teeths
 0.912 
Y2    0.154    0.4201
 45 
b  0.75d1 ........PSG 8.48 T-38
d1 = qm x ; d = 1110 ; d = 110 mm
1 1

Fs  110  82.5  0.420110 cos15.25

Fs  36781.62 N

75
 22-08-2016

.
 Calculate the Actual Efficiency of the drive
tan  1

S
 ........PSG 8.49
tan   1   
  tan 1 

.
 D1 N1  110 1440
Vs  ;V s  ; Vs  8.59 m / sec
60, 000  cos  1 60, 000  cos15.25

Assuming   0.3 .......PSG 8.49

  tan 1 0.3 ;   1.720

R
tan15.25

tan 15.25  1.72 

  0.8934

 Dynamic Load
6  Vmg
FD   Ft …….. PSG 8.52
6
 D2 N 2 Pitch line velocity of Worm Wheel
Vmg 
60, 000
D2  PCD of Worm Wheel ; D2  m x z ; D2  10  45  450mm

  450  96
Vmg  ; Vmg  2.26 m/sec
60, 000
 Calculate the tangential force Ft on the gear tooth

Ft 
 PKW   103
Vm
[ Pkw ]o  [ Pkw ]i ; [ Pkw ]o  0.8934  13.2 ; [ Pkw ]o  11.79 KW
11.79  103
Ft 
2.26
; Ft  5198 N

76
 22-08-2016

.
6  2.26
FD   5198

S
6
FD  7156 N

Fs  FD

.
Hence Safe.

 Wear Strength of the gear tooth

FW  Dg  b  kw .......PSG 8.52
k w = Wear Factor .......PSG 8.54 T-43
k w = 3.5 kgf/cm 2

R
FW  450  82.5  0.35
FW  12993.75 N
FW  FD Hence Safe.

 Thermal Check
Convection +Radiation
Power loss = Heat generated
H g   PKW i   PKW o Housing

H g   PKW i    PKW i
H
H g  (1   )   PKW i
a
H g  (1  0.8934)  13.2
H g  1.45 KW or 1450 W
Heat generated  Heat Dissipiated W
H g  HC  H R L
H g  hA  Th -Ta   σ s A  Th 4 -Ta 4 
A- Free surface area required
H.T by convection H.T by radiation for Heat dissipation

77
 22-08-2016

.
h- Convective heat transfer co-efficient

S
h = 11 W/m 2 K ....still air
h = 15 W/m 2 K ....Normal breezing air
h = 35 W/m 2 K ....Forced convection

.
Th : Housing temperature 60-700C
Th : 600 C  333K
Ta : Ambient Temperature =300C
 s : stefan boltzmann constant
 s : 5.67 108 W/m 2 0 K

R
H g  15A  333-303  5.67  108 A  3334 -3034 
1450  15A  333-303   5.67  108 A  3334 -3034 
A  2.166 m 2 Minimum Area required for Heat
Dissipation

 Available Area [A]

Using AGMA relation
 A  57.2  a1.7 cm 2 .......PSG 8.52

D1  D2 450  110
a
2 ; a
2 ; a  28cm
1.7
 A  57.2   28 
 A  1650.3 cm 2 ;  A  1.65 m 2
 A  A Hence Drive is not Safe.
 Remedies to make drive safe
 Increase Heat transfer co-efficient by using forced convection
 Increase Available using fins

78
 22-08-2016

.
 Increasing the Heat Transfer area by providing fins on the housing

S
a f  Area of one Fin Housing
a f  2   25H   4  25  2  H  4 Wall

H  Height of Housing

.
d d
H  a + a1 a 2  Clearance+ Thousing
2
H
d a1  d1  2 f 0 mx d a 2   z  2 f 0  2 x  mx 20-25

d a1  110  2  110 d   45  2  1  2 110

a2

d a1  130 mm d a 2  470 mm

R
Fin
130  470
H  280 +  20+ 20
2
H  620 mm
a f  2   25  620   4  25  2  620  4 ; ;
a f  33680mm 2 a f  0.03368m
2

Total Fin Area required =Arequired - Aavailable

Af  Areqd  [ A]
Af  2.166  1.65
Af  0.516 m 2
Total are of fin required
No. of fins required =
Area of one fin
Af 0.516
No. of fins required =
af ; No. of fins required =
0.03368
 15.32

Hence using 16 fins to make the drive safe against thermal failure
 Alternate method to make the drive safe
 Inducing forced convection with the help of blowers/fans.
Taking higher value of h recalculate the area required
A  1.142 m 2
H g  35A  333-303   5.67 10 A  333 -303
8 4 4
  A  A
1450  35A  333-303  5.67  10 A  333 -3034 
8 4
Hence Drive is Safe.

79
 22-08-2016

.
 Gear tooth proportions (Worm & Worm Wheel pair) ..PSG 8.43 T-34

S
 Worm  Worm Wheel
Pitch circle Dia d1= 72mm Pitch circle Dia d1= 450mm
Tip Dia d a1  130 mm Tip Dia d a 2  470 mm

.
Root Dia d f 1  d1  2 f 0 mx  2c Root Dia d f 1   z  2 f 0  mx  2c
d f 1  110  2 1 10  2  0.25 10 d f 1   45  2  110  0.25 10
d f 1  85 mm d f 1  425.5 mm
Length of Worm PSG 8.48 Face Width b=82.5mm
For 3 starts, X=0
L  12.5+0.09z  mx

R
L  12.5+0.09  45 10
L  165.5 mm
Using L  166 mm

 Worm construction

d s1

m/2 L m/2
 Input Shaft Design
Material : Phosphor Bronze
 Allowable stresses
Yield Stress  yt  360 N / mm2…………………….. PSG 1.9
F.O.S : assuming 4 Keyway factor :1
[ ]  ( yt  0.5)  Kw / F.O.S  45N / mm2

80
 22-08-2016

.
 Calculate Design Torque [Mt]

S
9.55106  [Pkw ]
[Mt1] 
N1
9.55106 13.2
[Mt1]   87.54 103 N  mm

.
1440
 Calculate Shaft diameter
16  M t 
d s1  3
  
16  87.54 103

R
d s1  3
  45
d s1  20.91mm
using d s1  25mm

 Worm-Wheel construction
 Calculate Design Torque [Mt]
9.55106  [Pkw ]
[Mt1] 
N2
6
9.5510 11.79
[Mt1]   1.173106 N  mm
96
 Calculate Shaft diameter
16  M t 2 
ds2  3

da2 ds2 dh2   

16  1.173 106
ds2  3
  45
d s 2  58.39mm
using d s 2  60mm d h 2  1.6d s 2

81
 22-08-2016

S .
.
End of Module -I

R Assignment No :1
Q1. List the various methods to reduce Interference in gears?

Q2. Write short note on Gear Teeth Modification?

Q3. Explain the types of errors in Gear Drives ?

Q4. What do you mean by Pressure angle ? Explain the effects of pressure
angle?

Q5. State the advantages of Involute tooth profile over Cycloidal tooth
profile?

Q6. What is a Hunting tooth?

Q7. Derive the Lewis equation for design of a gear tooth, stating clearly the
assumptions made ?

Q8. Write a brief note on “Types of Wear failures in Gears”?

82