Spur gears
Spur gears have teeth that are straight and arranged parallel to the axis of the shaft
that carries the gear. The curved shape of the faces of the spur gear teeth has a
special geometry called an involute curve. This shape makes it possible for two gears
to operate together with smooth, positive transmission of power. The shafts carrying
gears are parallel.
Spur gear design
Actual output speed (gear)
np
nG
VR
n P = rotational speed of the pinion
VR = gear ratio
N
VR G
NP
N G , N P = number of gear, pinion teeth.
The spreadsheet computes the approximate number of gear teeth to produce the
nGd
desired speed from N G NP ( nGd = desired output speed). But, of course, the
nP
number of teeth on any gear must be an integer, and the actual value of NG is
selected by the designer.
Spur gear geometry For full depth involute teeth in the diametral pitch system
Pitch diameter
N
D
Pd
Diametral Pitch
N
Pd
D
Outside diameter
N 2
Do
Pd
Addendum
1
a
Pd
Dedendum
if Pd 20
1.25
b
Pd
if Pd 20
1.2
b 0.002
Pd
Clearance
if Pd 20
0.25
c
Pd
if Pd 20
0.2
c 0.002
Pd
Root diameter
DR D 2b
Base circle diameter
Db D cos
Circular pitch
D
p
N
Whole depth
ht a b
Working depth
hk 2a
Tooth thickness
t
2Pd
Center distance
D DP
C G
2
Bending geometry factor, J, is dependent on the number of teeth of gear for which
geometry factor is desired and on the number of teeth in mating gear. Values can be
found from AGMA 908-B89(R1995).
Pitting geometry factor, I, is dependent on the tooth geometry and on gear ratio.
Values can be found from AGMA Standard 218.01.
Force and speed factors
Pitch line speed
DP nP
Vt
12
Tangential force
33000 (P )
Wt
Vt
or
126000 (P )
Wt
nD
where:
P = transmitted power
Radial force
Wr Wt tan
Normal force
Wt
Wn
cos
Expected bending stress
Wt Pd
St K o K s K m K B Kv
F J
where:
J = bending geometry factor
Ko = overload factor
Ks = size factor
Km = load-distribution factor
KB = rim thickness factor
Kv = dynamic factor.
Expected bending stress formula for SI units is given by
σb = (Wt / F.m.J) (KO.KS.Km.KB.KV)
Where;
σb = bending stress [MPa],
m = module [mm],
F = face width [mm],
Wt = transmitted load [N]
The AGMA indicates that the size factor KS can be taken to be 1.00 for most
gears. But for gears with large-size teeth or large face widths, a value greater than
1.00 recommended. Gear design programs compute the size factor automatically.
The determination of load-distribution factor Km is based on many variables in
the design of the gears themselves as well as in the shafts, bearings,
housings, and the structure in which the gear drive is installed. Therefore, it is
one of the most difficult factors to specify. Much analytical and experimental work is
continuing on the determination of values for K m . We will use the following equation
for computing the value of the load-distribution factor:
K m 1.0 C pf C ma
where:
C pf = pinion proportion factor is dependent on face width and pitch diameter
C ma = mesh alignment factor.
The dynamic factor, Kv , accounts for the fact that the load is assumed by a
tooth with some degree of impact and that the actual load subjected to the tooth
is higher than the transmitted load alone. The value of Kv depends on the
accuracy of tooth profile, the elastic properties of tooth, and the speed with
which the teeth come into contact.
AGMA Standard 2001-C95 gives recommended values for Kv based on the
AGMA quality number, Qv , and the pitch line velocity.
Gears in typical machine design would have AGMA quality ratings of 5 through
7, which are for gears made by hobbing or shaping with average to good
tooling.
If the teeth are finish-ground or shaved to improve the accuracy of the tooth
profile and spacing, quality numbers in the 8 - 11 range should be used. Under
very special conditions where teeth of high precision are used in applications
where there is little chance of developing external dynamic loads, higher
quality numbers can be used.
If the teeth are cut by form milling, factors lower than those found from QV = 5
should be used.
Note that the quality 5 gears should not be used at pitch line speed above 12.7
m/s (2500 ft/min). Note that the dynamic factors are approximate.
Expected contact stress
Wt K o K s K m Kv
Sc C p
FD p I
where:
C P = elastic coefficient that depends on the material of both the pinion and the gear.
C P = 2300 for two steel gears. The design program automatically selects the
appropriate value after the user specifies the materials.
Procedure for selecting materials for bending stress
K R SF
St S at
YN
where:
KR = reliability factor
SF = factor of safety
YN = stress cycle factor for bending.
AGMA Standard 2001-C95 allows the determination of the life adjustment factor, Y N ,
if the teeth of the gear being analyzed are expected to experience a number of cycles
of loading much different from 10 7 . Note that the general type of material is a factor
for the lower number of cycles. For the higher number of cycles, a range is indicated
by a shaded area.
Expected number of cycles of loading
Nc (60)(L )(n )(q )
where:
L = design life in hours
n = rotational speed in rpm
q = number of load applications per revolution.
Procedure for selecting materials for contact stress
K R SF
S c S ac
ZN
where:
ZN = pitting resistance stress cycle factor.
AGMA Standard 2001-C95 specifies the determination of the stress cycle factor, Z N .
If the teeth of the gear being analyzed are expected to experience a number of
cycles of loading much different from 10 7 , a factor should be used. The user specifies
the desired life for the system in hours and the program computes the values for YN
and Z N .
After computing the values for allowable bending stress number, S at , and for
allowable contact stress number, S ac , you should go to the data in AGMA Standard
2001-C95, to select a suitable material. Consider first whether the material should be
steel, cast iron, bronze, or plastic. Then consult the related tables of data.
