Force Analysis Spur Gears
Transmitted load, lb.
Wt = F32t
Applied Torque, in-lb.
T = 2d Wt
Pitch line velocity, ft/min.
Power, hp
in-lb
rpm
The equation in SI units
hp = T n / 63000
Wt = 33000 hp / V
V = d n / 12
Ken Youssefi
Mechanical Engineering Dept.
Force Analysis Helical Gears
n = normal pressure angle
t = tangential pressure angle
= helix angle
tan n = tan t cos
Wr = W sin n
Wt = W cos n cos
Wa = W cos n sin
Where W = total force
Wr = radial component
Wt = tangential component (transmitted load)
Wa = axial component (thrust load)
Wr = Wt tan t
t =
pressure angle (20o or 25o)
Wa = Wt tan
helix angle (10, 20, 30, or 40o)
Ken Youssefi
Mechanical Engineering Dept.
Force Analysis Bevel Gears
=
Ken Youssefi
Pressure angle (20o)
Mechanical Engineering Dept.
Force Analysis Worm Gear Sets
Three orthogonal components of
W without considering friction
considering friction
Relations between forces acting on
the worm and the gear
Ken Youssefi
Mechanical Engineering Dept.
Force Analysis Worm Gear Sets
Two useful relations, friction force and transmitted loads.
Efficiency of worm gear sets
(pressure angle) = 20o, 25o, 30o
Ken Youssefi
(max. pressure angle) = 25o, 35o, 45o
Mechanical Engineering Dept.
Stress Analysis Spur Gears
Bending Strength
Lewis equation (1892 Wilfred Lewis, Philadelphia Engineers Club)
Using similar triangles,
Wt
Bending stress is maximum at the root of the tooth,
F
Substituting for x and introducing p (circular pitch),
The form factor y is called Lewis form factor.
Substituting P = / p and Y = y
Lewis equation, where
Ken Youssefi
Mechanical Engineering Dept.
Modification of Lewis Equation
Assumptions made in deriving Lewis equation
1.
The load is applied to the tip of a single tooth.
2.
The radial component of the load, Wr , is negligible.
3.
The load is distributed uniformly across the full face width.
4.
Stress concentration in the tooth fillet is negligible.
Lewis equation, where
Ken Youssefi
Mechanical Engineering Dept.
Modification of Lewis Equation
Modifications according to AGMA standards (American Gear
Manufacturers Association)
Lewis equation
Wt
Ka
KV
KS
KI
Pd
F
Km
KB
J
Ken Youssefi
tangential transmitted load
application factor
dynamic factor
size factor
Idler factor (use 1.42 if designing an idler gear)
transverse diameteral pitch
face width of the narrower member
load-distribution factor
rim-thickness factor
geometry factor for bending strength
which includes root fillet stress concentration factor Kf
Mechanical Engineering Dept.
Bending Stress Modifying Factors
Geometry factor J
Ken Youssefi
Mechanical Engineering Dept.
Bending Stress Modifying Factors
Dynamic factor Kv
Application factor, Ka
Ken Youssefi
Mechanical Engineering Dept.
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Bending Stress Modifying Factors
Size factor Ks
AGMA has not established standards for size factor and recommends that
Ks be set to 1.
Load Distribution factor K
m
Rim thickness factor KB
Backup ratio
Km = 1.6 may be used as a conservative
value for face width less than 2 in.
KB = -2mB + 3.4
KB = 1.0
Ken Youssefi
0.5 mB 1.2
mB 1.2
Mechanical Engineering Dept.
11
AGMA Bending Strength Equation
Allowable Stress
Sfb is the allowable fatigue bending stress, psi
KL is life factor
KT is the temperature factor
KR is the reliability factor
Reliability factor KR
Temperature factor KT
AGMA recommends using temperature factor
of 1 for operating temperatures up to 250 oF.
Consult the standards for higher temp.
Ken Youssefi
Mechanical Engineering Dept.
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AGMA Bending Strength Equation
Stress cycle factor KL
Ken Youssefi
Mechanical Engineering Dept.
13
AGMA Bending-Fatigue Strength, Sfb
Ken Youssefi
Mechanical Engineering Dept.
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Surface Strength Analysis
The basic surface deterioration
Scoring
If the surface asperity welding and tearing cause a transfer of metal
from one surface to the other, the resulting surface damage is called
scoring. If the local welding of asperities becomes so extensive
that the surfaces no longer slide on each other, the resulting failure
is called seizure.
Initial scoring on
4340 steel helical
gear
Moderate scoring
on a 3310 steel
spur gear.
Ken Youssefi
Mechanical Engineering Dept.
15
Surface Strength Analysis
Abrasive wear
Abrasive wear is a surface damage caused by the presence of abrasive
particles in the lubricant. Large particles tend to scratch and gouge the
surface, where small (dust like) particles polish the tooth surface to a
mirror finish.
Corrosion wear
A type of surface deterioration that is caused by chemical
reaction of lubricant, or of contaminants such as water or acids,
with gear tooth surface.
Scoring, abrasive wear and
corrosion wear are due to the
failure of lubrication system.
Ken Youssefi
Mechanical Engineering Dept.
16
Surface Strength Analysis
Surface Fatigue Failure, due
to repeated contact load
Proper lubricating system can minimize the
surface damage due to wear and corrosion.
But, surface fatigue can occur even with
proper lubrication and its the most common
mode of gear failure and is characterized by
pitting and spalling of the tooth surface. The
damage is caused by repeated contact stresses.
Ken Youssefi
Mechanical Engineering Dept.
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AGMA Surface Stress Equation
Cp
Wt
Ca
Cv
Cs
Cm
Cf
d
F
I
Geometry factor
I =
Ken Youssefi
elastic coefficient, (lb/in2)0.5
transmitted tangential load
overload factor (same as Ka)
dynamic factor (same as Kv)
size factor (same as Ks)
load-distribution factor (same as Km)
surface condition factor
pitch diameter of the pinion
face width of the narrowest member
geometry factor
mG
cost sint
external gears
2mN
mG + 1
mG
cost sint
internal gears
2mN
mG - Mechanical
1 Engineering Dept.
mN = 1 for spur gears
mG = speed ratio = NG /
NP
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AGMA Surface Stress Equation
AGMA Elastic coefficient CP
Surface finish factor Cf
AGMA recommends using surface finish factor of 1 for gears made of
conventional methods.
Ken Youssefi
Mechanical Engineering Dept.
19
AGMA Surface Strength Equation
Sfc is the allowable contact stress, psi
CL is the surface-life factor
CT is the temperature factor (same as KT)
CR is the reliability factor (same as KR)
CH is the hardness ratio factor
Hardness ratio factor, CH
CH should only be used for the gear design, for pinion design set CH equal to 1.0.
Ken Youssefi
Mechanical Engineering Dept.
20
AGMA Surface Strength Equation
Pitting resistance stress cycle factor ZN
Ken Youssefi
Mechanical Engineering Dept.
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AGMA Surface Strength Equation
AGMA allowable surface fatigue strength
Ken Youssefi
Mechanical Engineering Dept.
22
AGMA Spur Gear Design Equations
Surface strength design equation, Stress = strength
Design steps
Calculate the transmitted load
Select material, start with grade 1 with low hardness.
Select standard full depth gears with pressure angle of 20o or 25o.
Choose a face width, dP F dP
Decide on: load type (uniform, non-uniform),
mounting accuracy, # of cycles to failure,
gear quality and reliability.
Solve the design equation for the diameter.
Or, select diameter and solve for material.
Ken Youssefi
Mechanical Engineering Dept.
Outcome is
Diameter and material
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AGMA Spur Gear Design Equations
Bending strength design equation
Design steps
Assume a value for J (geometry factor), .35 to .45
Solve the design equation to obtain the diametral pitch, Pd
Calculate the number of teeth for pinion and gear, determine the actual
J and check against the assumed one, iterate if needed.
The number of teeth on the pinion should be over 18 to avoid interference.
For power transmission, 2 < Pd (diametral pitch) < 16
Iterate until optimum design is achieved.
Ken Youssefi
Mechanical Engineering Dept.
Outcome is
Diametral pitch, P
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Design Example
Design a pair of spur gears to transfer power from a 25 hp motor to a fan.
The motor turns at 1000 rpm and the desired fan speed is 500 rpm. Specify
the material, diameter, and number of teeth for both gears.
Selections and assumptions
1.
Standard full depth gears with pressure angle, = 20o, will be used.
2.
Assume good quality gear with, Qv= 10, will be used.
3.
Select face width F = dP (pinion diameter) , dP/2 F dP
4.
Assume uniform load
Select 99% reliability
Ka= 1
KR = CR= 1
Design for
107 life cycle
KL = CL = 1
5.
Assume operating temp. less than 250o (KT=CT = 1), new gear (Cf = 1),
and a small size gear (Ks=Cs = 1).
Ken Youssefi
Mechanical Engineering Dept.
25
Surface failure
Design Example
From assumptions and selections list;
Ca= 1 , CR = 1 ,
CL = 1 , Cs = 1 , Cf = 1 , CH = 1 (pinion) ,
Select material: use A-3 steel (hardness HB = 300), surface strength range
from 120,000 to 135,000 psi. Use Sc = 125,000 psi in calculation.
Look up CP (elastic coefficient) = 2300
I =
mG
cost sint
= 0.107
2mN
mG + 1
mN = 1 for spur gears , t = 20o
mG = speed ratio = P / G = 1000/500 = 2
Ken Youssefi
Mechanical Engineering Dept.
26
Design Example
Transmitted load
hp = Wt V / 33000
Pitch line velocity, ft/min.
V = d / 12
Wt = (1.26 x 105) hp / dP P
Wt = (1.26 x 105) 25 / dP 1000
Wt = 3150 / dP
Assume dynamic factor C v = .9 and load distribution factor Cm = 1.6
Both assumptions have to be checked later.
2300[(3150/dP)(1/.9)(1.6)(1/.107)(1/dp)2]1/2 = 125,000
dP = 2.6 inch
Ken Youssefi
Mechanical Engineering Dept.
27
Design Example
Check assumptions for Cv and Cm
F = dP = 2.6
Cm = 1.61
(1.6 was assumed)
V = ( dP P)/12 = x 2.6 x 1000/12
V = 680 ft/min
Qv = 10
Cv = .9 (.9 was assumed)
With these corrections, dP = 2.6
Select dP = 2.75 and A-3
steel as the material
Ken Youssefi
Mechanical Engineering Dept.
28
Design Example
Bending failure
Wt = (33000) hp / V
Wt = (33000) 25 / 680
Wt = 1213 lb
For A-3 material, St = 36,000 47,000 psi
Use 36,000 psi in calculation
Assume J = .4, check later
1213(1/.9)(P /2.75)(1.6)(1/.4) = 36,000
P = 18.3
For power transmission, 2 P 16, so select P = 16
Ken Youssefi
Mechanical Engineering Dept.
29
Design Example
Check assumption for J
NP = P dP = 16 x 2.75 = 44
NG = P dG = 16 x (2.75x2) = 88
J = .43
P = 19.7
So P = 16 is valid
Spur gears specifications
Material:
Diametral pitch:
Diameter:
Number of teeth:
Face width:
Ken Youssefi
A-3 steel
P = 16
2.75 (pinion), 5.5 inch (gear)
44 (pinion), 88 (gear)
F = 2.75 inch
Mechanical Engineering Dept.
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