GEAR DESIGN (IS-4460)(SPUR OR HELICAL)

No. of
Teeth

Pinion
Gear

Module

Pressure
Angle

Pinion
Gear

Face
Width

RPM

b(mm)

19
58

16
16

20
20

20.67
20.67

320
320

260.37
85.29

Speed
Speed
Strenth
Factor(Str Factor(W Factor
enth)
ear)
(n=30)

Pinion
Gear

Helix
Angle

Zone
Factor
(n=30)

Bending
Stress
Factor

Surface
Stress
Factor

Running
Time
H(hours)
12
12
Pitch
Factor

Xb

Xc

Yz

Sb

Sc

0.355
0.43

0.3
0.365

0.69
0.585

1.9
1.9

24.6
19.7

2.47
1.9

1.45
1.45

HP(Strength)
HP (Wear)
Helix
(Helix)
HP
KW
HP
KW
1985.756 1461.517 374.475 275.6136
1633.067 1201.937 350.4702 257.9461

For Sc & Sb
See Sheet 2
For Xb,Xc,Y&Yz
See Graph

HP (Strength)
HP (Wear)
Spur
Spur
HP
KW
HP
KW
1705.55975 1255.292 437.0881 321.6968
1402.63585 1032.34 409.0696 301.0752

TABLE :-1
Relation between depth of case, case-hardening prosses and module,m
Case hardening process

Depth of hardness (mm)

Case carburising

0.25 m for m = 1.5 to 4

0.5*(m)1/2 for m = 4 to 30
0.3 m
0.1 to 0.6
0.015
up to 0.4

Induction and flame hardening

Nitriding
Soft nitriding
cyaniding

TABLE :-2
Standard value of center distance
50
160
450
1250

56
180
500
1400

63
200
560
1600

71
224
630
1800

80
250
710
2000

100
280
800

112
315
900

125
355
1000

First Preference
Second Preference
TABLE :-3
Standard Gear Ratio, I
Single

Double stage Tripple

Single

Double stage Tripple

1.25
1.4
1.6

8
9
10

40
45
50

3.55
4
4.5

20
22.4
25

112
125
140

1.8
2
2.24

11
12
12.5

56
63
71

5
5.6
6.3

28
31.5
35.5

160
180
200

2.5
2.8
3.15

14
16
18

80
90
100

7.1
8
9

40
45
50

250
280
315
355
400

TABLE :-4
Recommended series of Modules (mm) IS: 2535
Preferred

Choice 2

Choice 3

140
400
1120

1
1.25
1.5
2
2.5
3
4
5
6
8
10
12
16
20

1.125
1.375
1.75
2.25
2.75
3.5
4.5
5.5
7
9
11
14
18

3.25
3.75
6.5

GEAR DESIGN
Helical gears without correction

Pinion
Gear

Normal
Pressure
angle

Normal
Module

No.of teeth

Helix
angle

Degree
n

(mm)
mn

Degree

20
20

8
8

5
5

17
85

7.99
7.99

Pitch
diameter

Outside
diameter

Root
diameter

Centre
distance

(mm)
da

(mm)
df

(mm)

Base
circle
diameter
(mm)
db

137.33
686.67

128.90
644.51

153.33
702.67

117.33
666.67

412.00
412.00

Lead
(mm)
pz

Virtual
number of
teeth
(mm)
zv

3073.8
15368.9

17.50
87.52

(mm)

Pinion
Gear

Transverse Transeverse
module
pressure
angle
(mm)
(Degree)
mt
t
Pinion
Gear

8.0784
8.0784

20.18
20.18

Gear
ratio

Helical gears with correction

Working
centre
distance
(mm)

Addendum Addendum
modification modification
for pinion
for gear

a'

(mm)
x1

(mm)
x2

415

-0.2

0.2

Average
Centre dis.
virtual
modification
number of coefficient
teeth
(mm)
zvm
y

Working
normal
pressure
angle
(rad)
n'

For x1 &x2 see graph in figs. 52,53,54

of book M/c Tool Design in chap Gear

Sum of
addendum
modification

Addendum
reduction
coefficient

(mm)
x1+x2

(mm)
k

Pinion
Gear

52.51
52.51

0.375
0.375

Addendum Deddendum.
(mm)
ha
Pinion
Gear

6.321
9.521

(mm)
hf
7.25
5.25

0.368
0.368

0.385
0.385

Outside
diametre

Root
diameter

(mm)
da

(mm)
df

149.98
705.71

122.83
676.17

0.010
0.010

2 see graph in figs. 52,53,54

/c Tool Design in chap Gear

Basic surface stress and bending stress factor

Material

Condition
(Finished
gear)
Forged Steels (IS : 1570-1962)
Carbon Steel
C 30
Normalised
C 30
C 40
C 40
C 55 Mn 75
C 55 Mn 75

Hardened &
Tempered
Normalised
Hardened &
Tempered
Normalised
Hardened &
Tempered

Min.tensile
strength
kgf/mm2

Basic
surface
stress
factor Sc

Brinell
hardness
HB(kgf/mm2)

Basic
bending
stress
factor Sb

50
60

143
152

0.985
1.125

11.95
14.8

58
60

152
179

1.125
1.44

14.05
14.8

70
72

201
223

1.63
1.83

16.9
17.6

80

248

2.11

19.7

90

225(min.)

2.105

22.2

100

285(min)

2.47

24.6

80

229(min)

1.9

19.7

Carbon Cromium Steel

55 Cr 70
55 Cr 70
40 Cr 1

Hardened &
Tempered
Hardened &
Tempered
Hardened &
Tempered

Carbon Manganese Steel

27 Mn 2
Normalised
27 Mn 2
Har & Temp
27 Mn 2
Har & Temp
37 Mn 2
**
37 Mn 2
**

55 **
60
70
70
80

170
201
201
229

**
1.41
1.69
1.69
1.9

13.4
14.8
16.9
16.9
19.7

Har & Temp

Har & Temp
Har & Temp
Har & Temp

70
80
80
90

201
229
229
255

1.69
1.9
1.9
2.105

16.9
19.7
19.7
23.2

Cromium Molybdenum Steel

40 Cr 1 Mo 28
Har & Temp
40 Cr 1 Mo 28
Har & Temp
40 Cr 1 Mo 28
Har & Temp
40 Cr 1 Mo 28
Har & Temp
40 Cr 1 Mo 60
Har & Temp
40 Cr 1 Mo 60
Har & Temp

70
80
90
100
90
100

201
229
255
285
248
293

1.69
1.9
2.105
2.47
1.75
2.06

16.9
19.7
23.2
24.6
23.2
24.6

Manganese Molybdenum Steel

35 Mn 2 Mo 28
36 Mn 2 Mo 28
37 Mn 2 Mo45
38 Mn 2 Mo 45

15 Cr 1 Mo 55&
25 Cr 3 Mo 55
15 Cr 1 Mo 55&
25 Cr 3 Mo 55

Har & Temp

90

255

2.105

23.2

Har & Temp

155

144

1.16

36.6

Nickel Steel
40 Ni 3
Har & Temp
41 Ni 3
Har & Temp

80
90

229
255

1.9
2.105

19.7
23.2

154

444

3.87

35.9

90
155
90
155
110
100
155
120

255
444
255
444
331
285
444
341

2.11
3.87
2.11
3.87
2.6
2.47
3.81
3.82

23.2
37.3
23.2
36.6
26.7
24.6
37.3
28.8

1.97

8.35

2.8

10.55

3.58
2.8

12.91
10.55

3.57

12.91

3.58

12.91

3.58

12.91

7
7

28
28

28

Nickel Cromium Steel

30 Ni 4 Cr 1
Nickel Cromium Molybdenum
Steel
40 Ni 2 Cr 1 Mo 28
41 Ni 2 Cr 1 Mo 28
31 Ni 3 Cr 65 Mo 55
31 Ni 3 Cr 65 Mo 55
31 Ni 3 Cr 65 Mo 55
40 Ni 3 Cr 65 Mo 55
40 Ni 3 Cr 65 Mo 55
40 Ni 3 Cr 65 Mo 55

Har & Temp

Har & Temp
Har & Temp
Har & Temp
Har & Temp
Har & Temp
Har & Temp
Har & Temp

Surface Hardened Steels (IS : 1570

Carbon Steel
C 40

**

C 55 Mn 75

**

145(core)
55.2 460(case)
200(core)
70.86 520(case)

Carbon Cromium Steel

55 Cr 70
1% Cr Steel

**
**

250(core)
86.61 500(case)
70.86 500(case)

Nickel Steel
3 1/2% nickel steel

**

3 1/2% nickel steel

**

1 1/2% Ni, 1% Cr ste**

200(core)
70.86 300(case)
250(core)
86.61 500(case)
250(core)
86.61

Case Hardened Steels (IS : 1570-1

Carbon Steel
0.12 to 0.22% C-Steel
0.15% C-Steel
0.20% C-Steel

50.39 650(case)
50.39 140(core)
140(core)
50.39 640(case)

Nickel Steel
3% Ni Steel
3 1/2% Ni Steel
5% Ni Steel

70.86 200(case)
200(core)
70.86 620(case)
250(core)
86.61 600(case)

7.17

28.12

7.17

28.12

7.87

33.07

GEAR DESIGN (IS-4460)(SPUR OR HELICAL)

No. of
Teeth

Pinion
Gear

Module

Pressure
Angle

Pinion
Gear

Face
Width

RPM

b(mm)

23
38

6
6

20
20

9.696
9.696

75
75

1500
907.89

Speed
Speed
Strenth
Factor(Str Factor(W Factor
enth)
ear)
(n=30)

Pinion
Gear

Helix
Angle

Zone
Factor
(n=30)

Bending
Stress
Factor

Surface
Stress
Factor

Running
Time
H(hours)
24
24
Pitch
Factor

Xb

Xc

Yz

Sb

Sc

0.223
0.245

0.19
0.217

0.66
0.59

2.6
2.6

37.3
37.3

3.87
3.87

3.17
3.17

HP(Strength)
HP (Wear)
Helix
(Helix)
HP
KW
HP
KW
461.546 339.6978 128.1255 94.30035
453.2985 333.6277 146.3328 107.7009

HP (Strength)
Spur
HP
KW
357.158005 262.8683
350.77585 258.171

For Sc & Sb
See Sheet 2
For Xb,Xc,Y&Yz
See Graph
HP (Wear)
Spur
HP
KW
165.9882 122.1673
189.576 139.5279

GEAR DESIGN
Spur gears without correction

Pinion
Gear

Pressure
angle

Module

Gear
ratio

No.of teeth

Degree

(mm)
m

20
20

8
8

5
5

17
85

Pitch
diameter

Outside
diameter

Root
diameter

Centre
distance

(mm)
da

(mm)
df

(mm)

Base
circle
diameter
(mm)
db

136
680

127.80
277.50

152
696

116
660

408
408

(mm)

Pinion
Gear

Modified spur gears

Working
centre
distance
(mm)

Addendum Addendum
modification modification
for pinion
for gear

a'

(mm)
x1

(mm)
x2

412

-0.2

0.2

Average
Centre dis.
number of modification
teeth
coefficient
(mm)

Pinion
Gear

Working
pressure
angle

Sum of
addendum
modification

Addendum
reduction
coefficient

(mm)
x1+x2

(mm)

zm

(Degree)
'

51
51

0.5
0.5

21.476
21.476

Addendum Deddendum.
(mm)
ha

(mm)
hf

For x1 &x2 see graph in figs. 52,53,54

of book M/c Tool Design in chap Gear

0.01015487 -0.48984513
0.01015487 -0.48984513

Tip
clearance

Outside
diametre

Root
diameter

(Degree)

(mm)
da

(mm)
df

Pinion
Gear

10.318761
13.518761

7.25
5.25

2 156.637522
2 707.037522

112.8
663.2

2 see graph in figs. 52,53,54

/c Tool Design in chap Gear