Useful Formulas for Helical Gears

• Axial Pitch (Pa)

• Speed Ratio (mw)
𝑷𝒄 𝝅
𝑵𝒈 𝑫𝒈 𝒏𝒑 Pa = =
mw = = = 𝒕𝒂𝒏  𝑷𝒅 𝒕𝒂𝒏 
𝑵𝒑 𝑫𝒑 𝒏𝒈

• Pressure Angle in Normal Plane (n)

• Gear Ratio (mg)
tan n = tan  cos
𝑻𝒈 𝑫𝒈
mg = =
𝑻𝒑 𝑫𝒑

Note: • Pressure Angle ()

𝑫𝒈 𝑫𝒈
since; mw = , and mg = 𝐭𝐚𝐧 
𝑫𝒑 𝑫𝒑  = 𝒕𝒂𝒏−𝟏 ( )
𝐜𝐨𝐬

therefor; mw = mg Where:

n = pressure angle in the normal plane.

• Normal Pitch Circle (Pcn)  = pressure angle in the diametral plane.
Pcn = Pc cos  = helix angle
𝝅
Pcn =
𝑷𝒅𝒏
• Mean Velocity (vm)
• Pitch Circle (Pc)
vm = 𝜋𝐷𝑝 𝑁𝑝
𝝅𝑫𝒑
For Pinion: Pc =
𝑻𝒑

𝝅𝑫𝒈
For Gear: Pc =
𝑻𝒈
• Transmitted Load (Ft)
𝑓𝑡−𝑙𝑏
𝝅 𝑪 (33000 𝐻𝑃−𝑚𝑖𝑛)(𝐻𝑃)
Pc = 𝝅𝑴 = = Ft =
𝑷𝒅 𝑻 𝑣𝑚

• Normal Diametral Pitch (Pdn) • Dynamic Load (Fd)

𝑷𝒅
Pdn = 𝟎.𝟎𝟓𝒗𝒎 (𝑭𝒕 + 𝑪 𝒃 𝒄𝒐𝒔𝟐 ) 𝒄𝒐𝒔
𝐜𝐨𝐬  Fd = Ft + 𝟏
𝟎.𝟎𝟓𝒗𝒎 +(𝑭𝒕 + 𝑪 𝒃 𝒄𝒐𝒔𝟐 )𝟐

• Diametral Pitch (Pd)

• Strength of Helical Teeth (Fs)
𝑻𝒑
For Pinion: Pd = 𝑺𝒏 𝒃𝒀 𝑺𝒏 𝒃 𝒀 𝒄𝒐𝒔
𝑫𝒑 Fs = =
𝒌𝒇 𝑷𝒅𝒏 𝒌𝒇 𝑷𝒅
𝑻𝒈
For Gear: Pd =
𝑫𝒈

• Equivalent Number of Teeth (Te)

• Face Contact Ratio (mf) For Pinion: Ne =

𝑵𝒑
𝒄𝒐𝒔𝟑 
𝒃 𝐭𝐚𝐧  𝒃
mf = = 𝑵𝒈
𝑷𝒄 𝑷𝒂 For Gear: Ne =
𝒄𝒐𝒔𝟑 

• Face Width (b) • Axial Load (Fa)

b ≥ 2Pa, bmin = 1.15pa Fa = Ft tan
b = 2Pa
 • Limiting Wear Load (Fw) Tp =
𝝅𝑫𝒑 𝒄𝒐𝒔𝝍𝟏
𝒃 𝑫𝒑 𝑸 𝒌𝒈 𝑷𝒄𝒏
Fw =
𝒄𝒐𝒔𝟐  𝝅𝑫𝒈 𝒄𝒐𝒔𝝍𝟐
Tg =
𝟐𝑫𝒈 𝟐𝑻𝒈 𝟐𝒎𝒈 𝑷𝒄𝒏
Where: Q = = =
𝑫𝒈 + 𝑫𝒑 𝑻𝒈 + 𝑻 𝒑 𝒎𝒈 + 𝟏 𝑵𝒑 𝝎𝒑 𝑻𝒈 𝑫𝒈 𝒄𝒐𝒔𝝍𝟏
mw = = = =
𝑵𝒈 𝝎𝒈 𝑻𝒑 𝑫𝒑 𝒄𝒐𝒔𝝍𝟐

• Center Distance (C) For Σ=90°

𝑫𝒑 + 𝑫𝒈
C= cos 𝜓2 = cos (90-𝜓1 ) = sin𝜓1
𝟐
cos 𝜓1 = cos (90-𝜓2 ) = sin𝜓2
𝝎𝒑 𝑫𝒈 𝒔𝒊𝒏𝝍𝟏 𝑫𝒈 𝒕𝒂𝒏𝝍𝟏 𝑫𝒈
• Efficiency (e) mw =
𝝎𝒈
=
𝑫𝒑 𝒄𝒐𝒔𝝍𝟏
=
𝑫𝒑
=
𝑫𝒑 𝒕𝒂𝒏𝝍𝟐

𝒄𝒐𝒔∅𝒏 − 𝒇 𝒄𝒐𝒕𝟏
e= Conditions for Solving Helical Gear Problems
𝒄𝒐𝒔∅𝒏 + 𝒇 𝒕𝒂𝒏𝟏

• For Pitches
Where:
𝟎.𝟏𝟓𝟓 1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16
f=
𝒗𝒓 𝟎.𝟐
Note:
(3< 𝑣𝑟 <70 fpm)
for pitches in helical gear use 1 increment.

For iterations always start with 5.

𝟎.𝟑𝟐
f=
𝒗𝒓 𝟎.𝟑𝟓

(70< 𝑣𝑟 <3000 fpm) • For the standard market size of gear teeth

4,5,6,7,8,9,10,11,12,14,16,18,20,22,24,26,28,30
𝜋𝐷𝑁
vr = 32,36,40,48,64,80
𝑐𝑜𝑠𝝍

• For face width

2𝜋 • To test the gear
b=
𝑃𝑑 tan 𝝍
Note:
• For diameter of pinion
For the same material, the pinion is the weakest
𝑁𝑝
Dp=
𝑃𝑑 For not the same material, test the both gears
• Others
2𝑚𝑔 2𝐷𝑔 2𝑁𝑔
Q= = =
𝑚𝑔+1 𝐷𝑔+𝐷𝑝 𝑁𝑔+𝑁𝑝 • For Face Width

𝑒′ B = 2Pa, bmin = 1.15pa

C=C’( )
𝑒

• For the Horsepower (HP), (Market Standard)

• Crossed helical gears. HP = 1.0,1.25,1.5,1.75,2.0,2.25,2.5,2.75,3.0,3.5,

The shafts can be at any angle Σ, but 90° is the 4.0,4.5,5.0,5.5,6.0

most common. Note:

For same hands, Σ=𝜓1+𝜓2 From 1-3 HP, add 0.25

For opposite hands, Σ=𝜓1−𝜓2 From 3-above, add 0.5

and
• For kf: 1. 𝟓 < 𝑵𝒔𝒇 <1.75; moderately heavy shock;
dredging machinery, road machinery, railway
Load at the tip, assume kf = 1.45
motor cars, single-cylinder compressors, ore or
Load near middle, assume kf = 1.7 stone crushers, punch press, tumbling barrels.

Note:

If no given value or condition for kf, assume; 1. 𝟕𝟓 < 𝑵𝒔𝒇 <2; heavy shock; use higher
load near middle, assume kf = 1.7 service factor; rolling mill, rock crusher.

• To solve for Y, from Table AT 24 @ Te Note:

For smooth load, 𝑵𝒔𝒇 = 1.0

• For kg, from Table AT 26 @n (For both gears For uniform load, 𝑵𝒔𝒇 = 1.25
steel)
For medium shock or frequent shock, 𝑵𝒔𝒇 = 1.5

For moderately heavy shock, 𝑵𝒔𝒇 = 1.75

• To solve for su
For heavy shock, 𝑵𝒔𝒇 = 1.75
𝒔𝒖
For steel use, sn =
𝟑
If no give condition for 𝑵𝒔𝒇 , assume smooth
Therefore, su = (sn)(3) load, 𝑵𝒔𝒇 = 1.0

• To solve for the Corrective factor, C • Maximum Permissible Error

From Table AT 25 e = 0.002; 1st class commercial gear

e = 0.001; carefully cut

• For Intermittent Service e = 0.0005; precision cut

Fs ≥ Fd
Fs = Nsf Fd
• Both Material, Pinion is weaker.
• Different Material, test SnY which is
• For Continuous Service weaker.
Fw ≥ Fd • Use maximum life (1010 ) in Design Problem
Fw = Nsf Fd and Check Problem.
• In iteration if not specified make Nsf=1.0 as
• For Safety Factor (Nsf) basis.

1< 𝑵𝒔𝒇 <1.25; uniform load without shock;

centrifugal machines, hoisting machinery, belt-
driven machine tools, textile machinery, and
smoothly running conveyors.

1. 𝟐𝟓 < 𝑵𝒔𝒇 <1.5; medium shock; frequent

start; reciprocating compressor and pumps,
pneumatic tools, well-drilling machinery, wire-
drawing machinery, portable electric tools, lobe
blowers, heavy-duty conveyors, machine tools,
kilns.