Gear Design

Solution of Problem
(Helical, Bevel & Worm Gear)

Prof.Md.Khaled khalil
 Helical Gear design
Prob. # A pair of helical gears, subjected to heavy shock loading
is to transmit 37kW at 1750 rpm of the pinion, mg=4.25,
ψ=200, ,minimum dp=120mm, continuous service, 24hr/day, 200
FD teeth in the normal plane, precision cut, through hardened
BHN 350. Decide upon the module, face width and material.
Take Nsf=2.00

Solution: Given H=37kW, np=1750rpm, mg=4.25,dP=120mm

  200   200
, & material hardness-350 BHN
We know flexural strength of teeth WS  σ d bm n Y

& Endurance strength  d  S e  K a K b K c K d K e K f S e'

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 Helical Gear design

For 350 BHN let us take material as BS708M40. H & T

From Table A –35, Page-109

 1225  1075 
Sut  1075   350  311  1166 MPa
 375  311 

S'e  0.504Sut  0.504 1166  588MPa

Sut  1166 MPa1400MPa

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 Helical Gear design

K a  0.65 for Sut  1.166GPa from figure13  25 , Page - 136

Let N P  13 from Table13.1 , page - 149

d P 120
m    9.23  10 (Standard module)
N P 13
From page no.-45

t  1.5708m  15.708mm r  0.4m  0.4  10  4.00mm

From page no.-15
d e  0.808tb   0.80815.708  120  35.08mm
1/2 1/2

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 Helical Gear design
According to Mischke for 2.79≤d≤51mm from page-
14
0.1133 0.1133
 d   35.08 
Kb       0.85
 7.62   7.62 
K C  1 for bending & K d  1 for T350 0 C
Now K f  1  q ( K t  1)
For D/d  d P / t  120 / 15.708  7.64

& r/d  r / t  4.00 / 15.708  0.25

K t  1.5 from figure A  15.6

Fig A-15.6 Page-87
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 Helical Gear design

For Sut  1.166 GPa

and r  4.00mm
from fig 5.16 q  0.95

Fig.5-16 page no.-112

 K f  1  q ( K t  1)  1  0.95(1.5  1)  1.475

Miscellaneous effect factor

K f  1.33 for Sut  1.166GPa 1.4GPa from figure 13 - 26

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 Helical Gear design

 d  S e  0.65  0.85 111 / 1.475 1.33  588  293MPa

We know WS  S ebmnY and mn  m cos ψ from pag e  43

N 13
Equivalent teeth N     15.67, page  45
cos  cos 20
3 3

2.87 2.87
Form factor Y  0.484   0.484   0.3, page  47
N 15.67

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 Helical Gear design
Let b  12m from page  45 ,3.6m  b  20m( S Helical)
WS  293  12m  m cos  0.3  991.19m 2

d p n p  120 1750
V    11m / s
60 60  1000

H 37 103
Transmitte d load WT    3364 N
V 11
1/ 2
 5.56  V   5.56  11 
WD    WT     3364  4250 N
 5.56   5.56 

For Precision cut from page -44

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 Helical Gear design

WS  N sf WD  991.19m 2  2  4250  m  2.93  3.00mm

d P 120
NP    40 N g  m g N P  4.25  40  170
m 3.00

40 2.87 2.87
Since N    63.87 Y  0.484    0.44
cos 
3
N  63.87

Check 293  b  m cos  0.44  2  4250  b  19  6.33m

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 Helical Gear design
d p bQK
Again wear strength of tooth Ww 
cos 2 
2m g 2  4.25
Ratio factor Q    1.62
mg  1 4.25  1
S ce2 sin   1 1 
Material Combination factor K    
1.4  E p E g 
Now surface endurance strength from page-45
S ce  2.75BHN  70  2.75  350  70  892.5MPa
E g  E p  207GPa for carbon steel from Table A  5
S ce2 sin   1 1  (892.5) 2 sin 20  1 1 
K      3
 1.88
1.4  E p E g  1.4  207  10 207 10 
3
 

10
 Helical Gear design
d p bQK
Now puttin g the values in Ww 
cos 2 ψ

120  19  1.62  1.88

WW  2
 6038N
cos 20

Now N sf WD  2  4250  8500

WW  N sf WD  Design is not correct

So we have to redesign by changing the

parameters, such as material and face width

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 P Bevel Gear design
A pair of bevel gear with 200 pressure angles consists of 20
teeth pinion meshing with a 30 teeth gear. The module is 4mm
while the face width is 20mm.The material for the pinion and
gear is cold drawn steel AISI1045. The pinion rotates at
500rpm and receives power from the electric motor. Determine
the rated power that the gear can transmit for indefinite life.
The service is such that a service factor of N sf = 1.2 applies,
operating temperature is normal.

Solution:

Given   200 , N p  20, N g  30, m  4, b  20mm, n p  500rpm,

N sf  1.2, Material : AISI 1045 Cold Drawn Steel, N sf  1.2,
Operating temperature normalFind H for indefinite life.

1
 Bevel Gear design
Since same material is used for both pinion and gear,
the pinion is weaker than the gear

From Table A-20a for AISI 1045 cold drawn steel

Sut  630MPa & BHN - 179

S'e  0.504Sut  0.504  630  318MPa Sut  1400MPa

We know Se  σ d  K a K b K c K d K e K f S'e

K a  0.735 for Sut  0.63GPa from figure - 13.25

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 Bevel Gear design
d e  0.808(bh)1/ 2  0.808(bt )1/ 2  0.808(20 1.5078  4)1/ 2  9.06

According to Mischke for 2.79≤d≤51mm from page-

14 0.1133 0.1133
 d   9.06 
Kb   e     0.98
 7.62   7 . 62 

K C  1 for bending & K d  1 for T350 0 C

D dP dP 80
From figure A-15-6 for     12.74
d t 1.5708  m 6.28

r r 0.4m
&    0.25 We get K t  1.5
d t 1.5708m

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 Bevel Gear design
Again for r  0.4m  1.6mm & Sut  0.63GPa
from figure - 5.16 q  0.75

K f  1  q ( K t  1)  1  0.75(1.5  1)  1.375
Miscellaneous effect factor
K f  1.33 for Sut  0.630GPa1.4GPa from figure  13.26

Se  K a K b K c K d K e K f S'e
 0.735  0.98  1 1 1/1.375  1.33  318  247.18MPa

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 Bevel Gear design

N P 20
tanν    ν  33.69 0 , where ν  Pitch angle
N g 30
Np 20
Equivalent no. of teeth N eq    24.04
cosν cos33.69
2.87 2.87
Y  0.484   0.484   0.365
N 24.04

d p  mN p  4  20  80mm d g  mN g  4  30  120mm

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 Bevel Gear design

2 2
 d p   dg 
Cone distance L      
 2   2 

 402  602  72.11mm

L b
Ws  S ebmY  
 L 
 72.11  20 
 247.18  20  4  0.365   5215.81N
 72.11 

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 Bevel Gear design

d p bQK
We know wear strength Ww 
cosγ

30Ng
Equivalent no of teeth N eg    54.08
cosγ 56.3

2 N eg 2  54.08
Contact strength Q    1.38
N eg  N ep 54.08  24.04

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 Bevel Gear design
S ce2 sin   1 1 
Material Combination factor K    
1.4  E p E g 

Now surface endurance strength

S ce  2.75BHN  70  2.75 179  70  422.25

E g  E p  207GPa for carbon steel from Table A  5

K 
422.25  sin 20 
2
1 1 
1.4  207 103  207 103   0.42

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 Bevel Gear design

80  20 1.38  0.42
Ww   1118 .2 N
cos 33.69
Since WW (1118 .2 N )WS (5215.18N)

So wear governs for indefinite life

3.57  V
W D KV WT  WT from page - 44 for straight teeth
3.57

V   d p n p / 60    80  500  2.09m / sec

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 Bevel Gear design

3.57  2.09
WD  WT  1.68WT
3.57

WW  N sf WD  1118 .27  1.2  1.68WT  WT  665.64 N

 Rated Power H  WT V  665.64  2.09  1391.19W

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 Worm Gear design
A high efficiency worm gear speed reducer is desired to accept
15kW from a 1750 rpm motor. The diameter of the integral
worm has been estimated to be 45mm the next computation is
to be for a steel worm, with a maxm. BHN–250, bronze gear,
mw = 11. Probably the worm should not have less than 4
threads,(a) considering wear & strength only decide upon
module and face width that satisfies these requirement, specify
the pressure angle, diameters and center distance (b) compute
the efficiency

Solution: Given H = 15kW, nw = 1750 rpm, dw =45mm,

mw = 11, Nt=Nw≥4, Steel worm Maxm BHN -250, Bronze gear
Ng dg
Let Nt = Nw= 4 We know that m w  
Nw d w tanλ w
Λ-lead angle , page - 46
22
 Worm Gear design

 Number of teeth of gear N g  mw N w  11  4  44

π  45  1750 d w 45
Vw  πd w n w   4.12 m/s m    12
1000  60 Nw 4
1750
Now Vw  Vg  4.12  πd g n g  πd g  d g  495mm
, 11
dg 495
Speed ratio m w  11    λ w  450
d w tanλ w 45 tanλ w
H 15  1000
Transmitte d load Wt    3640.7 N
V 4.12

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 Worm Gear design
6 V 6  4.12
WD  WT   3640.7  6140.78 N Page  46
6 6

We know Ws  σ d bm n Y  Se bmcosY

From table A-35 we select material BS945M38 H&T

for BHN–201 S ut  690 MPa

 S e  0.504  690  347.76 MPa
Since Sut  690MPa 1400MPa

Endurance strength Se  K a K b K c K d K e K f S'e

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 Worm Gear design

K a  0.71 for Sut  0.69GPa from figure  13.25/Page 136

Let b=0.5dw from page-45 b≤0.5dw

d e  0.808bh   0.808bt 
1/ 2 1/ 2

 0.8080.5  45 1.5708 12 

1/ 2
 16.11
.1133 .1133
 d   16.11 
Kb   e     0.92
 7.62   7.62 
By Mischke for diameter range 2.79  d  51mm

K C  1 for bending & K d  1 for T 350 0 C

25
 Worm Gear design
D dw dw 45
For     2.55
d t 1.5708  m 1.5708  12

r r 0.4m
&    0.25 We get K t  1.5
d t 1.5708m

Fig.-A15.6 Page No.-87

26
 Worm Gear design
Again for r  0.4m  4.8mm & Sut  0.69GPa
from figure - 5.16, page no. - 112 q  0.8

K f  1  q(K t  1)  1  0.8(1.5  1)  1.4

K f  1.33 for Sut  0.69GPa 1.4GPa from figure  13.26

27
 Worm Gear design
1
 S e  0.71 0.92  1 1  1.33  347.70  215.76 MPa
1. 4
From table  13.4 for lead angle λ  450 and
pressure angle   300 Y  0.55
For continous service & heavy shock
let N sf  2.00 from table - 13.7 page no. - 51
We know Ws  σ d bm n Y  Se bmcosY
215.76X0.5X45XmXcos450X0.55 = 2X6140.78
 m  6.5  7.0 (standard module)

1
 Worm Gear design

dg d w 495 45
Centre distance C      270mm
2 2 2 2
C 0.875 C 0.875
 d w  from page no.  45
3 1.7
270 0.875 270 0.875
 44.70  d w (45)   78
3 1.7

28
 Worm Gear design
Wear factor K w  0.829 for  n  300 & steel worm
and bronze gear from Table no. - 13.3 , page no. - 50

Ww  d g bK w  495  0.5  45  0.829  9233N

Now N sf WD  2  6140.78  12281.56N

Ww  N sf WD  Design is not correct

Design might be correct if we redesign by changing

material,face width b and number of thread N t

29
 Worm Gear design
cos  n   tan w
(b) Efficiency   page no. - 49
cos  n   tan w
Vw 4.12
Vs    5.83m / sec page no. - 49
cos w cos 45 0

Page-136

From graph - 13.42 for Vs  5.83m/sec μ  0.028

cos 30 0  0.028 tan 450
  94%
cos 30  0.028 tan 45
0 0

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 Thank you

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