3/22/2016

Gears
Toothedcylindricalorconicalwheelsusedforpower
transmissionwithorwithoutspeedreduction

Spurgears
Teethareparalleltotheaxisofrotation
Usedfortransmittingpowerbetween
parallelshafts
Helical gears
Helicalgears
Teethareinclinedtotheaxisofrotation
Relativelyquieterinoperation
Canbeusedfortransmittingpowerbetween
nonparallelshaftsalso

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Bevelgears
Teethareformedonaconicalsurface
Teethcanbestraightorspiral
Usedfortransmittingpowerbetween
perpendicularintersectingshafts

Hypoidgears
Similartobevelgearbutshaftscanbe
offset,perpendiculartoeachother

WormandWormwheel
Shaftsperpendicular,nonintersecting
Largespeedreductionpossible

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Pitchcircle
Theoreticalcircleuponwhichallcalculationsaremade.Itsdiameteriscalledpitch
circlediameter d.Pitchcirclesoftwomatinggearsaretangenttoeachother
Addendum,a
Radialdistancebetween
toplandandpitchcircle

Dedendum,b
Radialdistancebetween
bottomlandandpitch
circle
Circularpitch(p)

Distancemeasuredonthepitchcirclefromapointonthetoothtothe
correspondingpointonanadjacenttooth

p =tooththickness+widthofspace(measuredonPC)

p =d/N,Nisnumberofteeth

Pinion:thesmallerofthetwomatinggears
Gear:thelargeramongthetwomatinggears
Idler:usedforchangingdirection
Module
m = d/N
d/ (standardvaluesgivenindatabook)
(
d d l
d b k)

Clearancecircle:Thecirclewhichistangenttothe
addendumcircleofmatinggear,c = b-a
Wholeteethdepth,ht = a + b
Backlash
A
Amountbywhichthewidthofthetoothspace
t b hi h th idth f th t th
exceedsthethicknessoftheengagingtooth,both
measuredonPC

a andb havedefiniteproportionwithmina
standardgear

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VA rA A ;

OA
VA

rA

VB

VB rBB

Points A and B are moving

together along line a b
VA cos VB cos

rA A cos rBB cos

rB

A rB cos OB N OB P

B rA cos OA M OA P

Piscalledthepitchpoint(isalso
instantaneouscenterofAandB)
B

OB

IfLOAintersectsLOCatthesamepoint,
thenvelocityratioremainsconstant

Involute profile

Thecircleon whichtheinvolute
isgeneratediscalledBasecircle

LOAisthecommontangenttothebase circleofthetwogears
LOAisalsothenormaltothetoothprofilesatthecontactpoint

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isthepressure angle

rB1 r1 cos
rB2 r2 cos
rB 2

Whentwogearsareinmesh,theirpitchcirclesrollon
eachotherwithoutslipping
Standardpressureangles
1 r2 d 2 mN 2 N 2

20o,25o, 14.5o
2 r1 d1 mN1 N1

Theinvolute profile startsatthebasecircleandextends

uptotheaddendumcircle
Thegeartooth(insomecases)extendsbeyondthebase
circleuptothededendum circletohaveclearance
Theportionoftoothbelowthebasecircle isnotan
involute anddoesnotprovideconjugateaction
Contactinthisportionshouldbeavoided

14.5o

20o

25o

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Lab ra21 rB21 ra22 rB22 (r1 r2 ) sin

Lab
; pb p cos is called base pitch
pb
Contactratioofgreaterthan1impliesthatatsometime
duringmeshingmorethanonepairofteethareincontact
Contactratiooflessthan1.2notrecommended
Increasingcentertocenterdistance(r1 +r2 )candecrease
contactratio
Contact ratio: mc

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Interference
Contactoftoothportionsthatarenotinvolute (conjugate)
iscalledinterference

Inagearmanufacturedbygenerationprocess,
undercuttinghappensandthiseliminatesinterference
Undercuttingweakensthetooth

Avoidinginterference:spurgears
Thesmallestnumberofteethonaspurpinionandgearwhichcan
existwithoutinterferenceis

Np

NG
2k
2
2
m

(1

2
m
)
sin

;
m

G
G
G
G
(1 2mG ) sin 2
Np

Thelargestgearforaspecifiedpiniontoavoidinterference

NG

N p2 sin 2 4k 2

1 for full depth

; k
. for
o sstub
ub dep
depth
s
4k 2 N p sin
0.8
2

Forrackandpinion

Np

2k
sin 2

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Helicalgears
Shapeofthetoothisaninvolute helicoid

Parallelshafts,pinionandgearhasleftand
p
g
righthandteeth
Perpendicularshafts,bothgearandpinionhas
sametype

Inspurgearsthecontactisoveralinewhichisacross
thefaceofthegear
Contactissimultaneousalongthefacewidth
Thelinecontactstartsfromaddendumcircletobase
circle
Inahelicalgear,theinitialcontactisatapointandthen
itextendsintoalineastheteethcomeintoengagement
Thelinecontactextendsdiagonallyacrossthetooth
facegoingfromtiptotheroot
Engagementisthereforemoregradualforapairof
Engagement is therefore more gradual for a pair of
toothwithsmoothloadtransfer
Contactratioisnotaconcern,rathersufficientface
widthshouldbeprovided
Generatesanaxialloadontheshaft

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PCD (d)ismeasuredin
thetransverseplane
Transversecircularpitch

pt

d
N

Transversemodule

mt

d
N

Normalcircularpitch

pn pt cos
Normalmodule

mn mt cos

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Helixangleismeasuredonthecylindricalpitchsurface
Normalpressureangle n
Transversepressureangle
W

Wa

tan n

cos

t tan 1

Wr

t
Wt

cos

tan n
tan t

Wr W sin
i n
Wt W cos n cos
Wa W cos n sin

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Commonlyusedstandardtoothsystemsforspurgear

Commonlyusedstandardtoothsystemsforhelicalgear
addendum, a mn

Base diameter :
d cos t for pinion

dedendum, b 1.25mn
PCD : d

N p mn
cos

, D

N G mn
cos

D cos t for gear

Avoidinginterference:helicalgears
Thesmallestnumberofteethonahelicalpinionandhelicalgear
whichcanexistwithoutinterferenceis

Np

NG
2k cos
2
2
m

(1

2
m
)
sin

;
m

G
G
G
t
G
(1 2mG ) sin 2 t
Np

Thelargestgearforaspecifiedpiniontoavoidinterference

NG

N p2 sin 2 t 4k 2 cos 2

1 for full depth

; k
. for
o stub
s ub dep
depth
4k cos 2 N p ssin t
0.8
2

Forrackandpinion

Np

2k cos
sin 2 t

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Toothfailuremodes
Bendingstressattherootofthetooth
Yielding
Fatiguefailure

Contactstressatpointofcontact
Pittingorsurfacefatiguefailure

Bendingstress
AnalysisbyWilfredLewis in1892
Treatthetoothasacantileverofspanl, deptht andwidthF
W

Wr
Wt
l

6Wt l
Ft 2

Bothl and t dependsontoothprofile

From similar triangles

Wp
W
t2
x, 2t t
4l
F 3 xp FpY
p is circular pitch
Y

2x
; is called Lewis form factor
3p

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Yincreaseswithincreasingnumberofteethor
increasingpressureangle

Theworstconditionistaken;i.e.theloadappliedattipof
thetooth
Onlyonepairofteethisassumedtoengageatatime
Loadsharing(whencontactratiois>1)isnotconsidered
d h i ( h
i i
)i
id d
Stressconcentrationattherootisnotconsidered
Alloftheabovedependsontoothgeometry,numberof
teethetc.
Hencetheformfactorismodifiedfurthertoaccountfor
theseeffects

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AGMA DesignEquations
Tooth bending

Wt K O KV K S

1 KH KB
(SI units)
Fmt YJ

F is face width, mt is transverse module

K O is overload factor, KV is dynamic factor
K S is size factor, K H is load distrubution factor
K B is rim thickness factor
YJ is geometry factor for bending strength
(includes the stress concentration factor K F )
F is usually 3 to 5 times circular pitch p

YJ (orJ)geometryfactor

Capturestheeffectoftoothformonbendingstresses
Willbedifferentforpinionandgear

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Forhelicalgear,determine
YJ (J)fromthefirstfigure
andmultiplythatwiththe
modifyingfactorfromthe
secondfigure

KO overloadfactor
AccountsforallexternalloadsinexcessofWt

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KV dynamicfactor
Thisaccountsforinaccuraciesinmanufacturingand
meshingofagearteethdueto

Vibrationduringmachining
Dynamic unbalance of rotating members
Dynamicunbalanceofrotatingmembers
Wearandpermanentdeformationoftooth
Shaftmisalignmentduetolinearandangulardeflection
Toothfriction

Allofthesecausestransmissionerror(departurefrom
constantangularvelocityratio)
Theseleadtoanincreaseinloadonthetooth
These lead to an increase in load on the tooth
KV dependsonpitchlinevelocity

A 200V
KV
; V in m/sec
A

A 50 56(1 B )
B 0.25(12
( QV ) 2 / 3

These
Thesecurvesarefromtestdataonlargenumberofgears
curves are from test data on large number of gears
QV isAGMA qualitynumber
3to7:Commercialquality
8to12:Precisionquality
KV increasesasVincreasesorQV decreases

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KS Sizefactor
Accountsfornonuniformityinmaterialpropertiesdueto
size seepage29ofdatabook

KH Loaddistributionfactor
Accountsfornonuniformityofloadacrossthelineofcontact
(seepage29ofdatabook)
Facewidth(mm)
upto50 150

225

>400

KB Rim thicknessfactor
Thebendingstresscalculationassumesthatthe
toothislikeacantileverwithrootofitfixed.
Largegearshavearimandiftherimisnot
sufficientlythick,thenitcaninducerootflexibility

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Allowablebendingstress
all

St YN
S F Y YZ

2
St Bending
B di strengthh (N/mm
(N/
),
) S F AGMA safety
f ffactor

YN Stress cycle factor for bending, Y Temperature factor = 1

YZ Reliability factor (table 14-10)

Gearteetharesubjectedtorepeatedloading
Theteethinanidlergearwillundergotwowaybending,
henceuse0.75St inaboveequation

Gearmaterials
Canbemadeofsteel,bronze,graycastiron,evenplastics
Strengthandpittingresistanceareimportantfactors
g
Throughhardenedsteels
180<HB <400recommended
e.g AISI 3140,4140,4340,6150,8150etc.aregood
%elongationof12%ofmoreisdesired
Casehardenedsteels
HB >400
Inductionhardening,Flamehardening,Ntriding etc.
produceahardsurfacelayerandtoughcore
Thehardeningdepthhastobeensured

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RepeatedlyAppliedBendingstrength:St
107 cyclesand0.99reliability
Grade1isbasicstandard
Grade2requireshighdegree
of microstructure control
ofmicrostructurecontrol

YN isusedwhenlifeisnot107 cycles
Inagearset,thenumberofloadcyclesforpinionandgear
aredifferent.Sothisfactorwillbedifferentforpinionand
gear

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Surfacedurability
Inagearteethpair,perfectrollinghappensonlywhen
thecontactisatthepitchcircle(P)
Atothercontactpoints,thereisrollingwithsliding
Relativevelocityalongthe
directionperpendicularto
LOAisnotzero
Thesliding velocityreverses
directionasthecontact
direction as the contact
crossesthepitchpoint
Themagnitudeofrelative
velocityisalso notconstant

Surfacedurability
Theslidingcauses
Abrasivewearduetotrappedforeignparticles
Scoring
Highervelocityintheabsenceofproperlubrication(elasto
Higher velocity in the absence of proper lubrication (elasto
hydrodynamic)resultsinhighfriction
Thehighcontactpressureandhighfrictionleadtolocalized
heating
Thisheatingresultsinlocalweldingofsurfaceparticlesand
theirsubsequenttearing
Lubricationandcoolingcanminimizethis
Pittingandspalling
Surfaceandsubsurfacefatiguefailureundercontactstress

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Hertzcontactstress
Considertwocylindersarecontactunderloadasshown
Thecontactisoveranarrowrectangularpatchofwidth
2b andlengthL
1/ 2

4 P (1 12 ) / E1 (1 22 ) / E2

1/ 1 1/ 2
L

p0

2P
P 1
1
ZE

bL
L 1 2

ZE

1
1 12 1 22

E2
E1

Contactstressesinmeshinggearteeth
Pittingdamageismostlyobservedaroundthepitchline
Slidingvelocityisverysmallbecauseofwhichhydrodynamic
actionisabsent(nooilfilm)
p
p
Thereforethecontactstressesareevaluatedatthepitchpoint

1 rP sin ; 2 rG sin ; P

rP

c ZE

ZI

Wt
cos

Wt
Fd P Z I

sin cos mG
2
mG 1

+ for external gear set; - for internal gear set

rG

ZI isthegeometryfactorforsurfacestrength

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ZI forhelicalgear

n1

rP sin t
cos b

n 2

rG sin t
cos b

b Helix angle measured on base circle

ZI forhelicalgear
Inahelicalgear,thecontactloadactsoveralarger
distancethanthefacewidthduetohelixangle
Thereisloadsharing
sin
i t cos t mG
ZI
2 mN
mG 1
pn cos n
is load sharing ratio
0.95Z
pn is normal circular pitch

mN

Z is length of line of action in transverse plane

2
2
rbG
(rP rG ) sin t
Z raP2 rbP2 raG

base circle radius, rb r cos t ; addendum circle radius, ra r a

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AGMA DesignEquations
Tooth pitting

c Z E Wt K O KV K S

KH ZR
(SI units)
dP F ZI

F is face width, d P is PCD of pinion

Z I is geometry factor for pitting resistance
Z R is surface condition factor for accounting effect of
surface finish (=1)
ZE

1
1
1 G2

E
EG
P
2
P

is called the elastic coeffficient

Allowablecontactstress
c ,all

S c Z N ZW
S H Y YZ

SC Contact strength (N/mm 2 )), S H AGMA safety factor

Z N Stress cycle factor for contact strength
Y Temperature factor = 1
YZ Reliability factor (table 14-10)
Z W Hardness ratio factor ((=1 for ppinion))

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Repeatedlyappliedcontactstrength,Sc
107 cyclesand0.99reliability

Hardnessratiofactor,ZW
Goodgeardesignpracticesuggests
Makingpinionteethmoreharderthangearteeth
Gearteetharesmoothenedandworkhardenedduring
service and this improves pitting resistance
serviceandthisimprovespittingresistance

Bothpinionandgeararethroughhardened

Pinionissurfacehardened
andgearisthroughhardened

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SafetyfactorsSF andSH
all

St YN
1 KH KB
; Wt K O KV K S
S F Y YZ
Fmt YJ

SF

St YN
; stress
t
( ) scales
l linearly
li
l with
ith W t
Y YZ

c , all
SH

Sc Z N ZW
K Z
; c Z E Wt K O KV K S H R
S H Y YZ
dP F ZI

Sc Z N ZW
; stress ( c ) scales with W t
c Y YZ

IfagearisdesignedsuchthatSF =SH =2,inwhich

mode(bendingfatigueorsurfacefatigue)itwillfail?
Whichfailuremodeismorecatasrophic?

Safetyfactorforpinionandgear
Thesafetyfactorsforpinionandgearneednotbethesame
(YJ )P (YJ )G ,(YN )P (YN )G ,(ZN)P (ZN)G
Whataretheimplications?
p
Oneofthemwillfailfirst(theonewithlowersafetyfactor)
Replacingoneelementinasetisnotgoodastheother
element(alreadyweaker)canfailresultinginshutdown
Matchingthefactorofsafetyofpinionandgearistherefore
desirable

S F P S F G S t G S t P

YN P YJ P S S S S Z N P
H G c G c P
Z N G
YN G YJ G H P

1
ZW

Canbeachievedby
Havingdifferenthardnessforpinionandgear
Usingdifferentmaterialsforpinionandgear

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