Chapter 10 Design of gears

Key points: Failures, materials and design criteria;

Force analysis;
The factors affecting the gear strength;
The procedure of gearing design.
Difficulties: Strength calculation for spur gearing;
Force analysis for helical gearing.
10-1 Introduction
1. Advantages and disadvantages of gears
High efficiency
High reliability
High service life
i=c
Take small room
Can transmit a large range of power and speed (ten thousand
KW150m/s)
Special machine tools are needed
High precision is required
Cost is high
2. Types of gears
Classify by the relative position of gear shafts
1 Gear pair with parallel axes;
2 Gear pair with intersecting axes;
3 Gear pair with nonparallel and nonintersecting axes that can be
called skew axes.
Classify by tooth elements relation to the gear shaft
1 Spur gears;
2 Helical gears;
3 Herringbone gears.
Classification by work conditions
1 Encased gearing;
2 Open gearing;
3 Semi-open gearing
Classification by tooth profiles
1 Involute gear;
2 Cycloi gear;
3 Circular tooth gear.
1

 Classification by the shapes of gear

1 Cylindrical gear;
2 Bevel gear;
3 Worm gear.
Classification by the case hardness of gear tooth
1 Soft tooth surface (case hardness350HBS);
2 Hard tooth surface (case hardness >350HBS).
10-2 Gear failures and design criteria
1. gear failures
1) Breakage
Overload breakage
Fatigue breakage
2) Pitting
(1) Three features
Begins at pitch line, develops on flank and operates in grease.
3) Gluing
Gluing is a kind of lubrication failure.
4) Abrasive wear
Open and semi-open gearing.
5) Ridging
Driving gear: notch
Driven gear: Crown
2. Design criteria
Design Criteria
Main failures
Enclosed
F[F]
Pitting breakage
H[H]
gearing
Open or semiWearing
F 0.7[F]
open
breakage
10-3 Gear materials
1. Requirements:
Gear teeth core: Sufficient toughness
Gear teeth surface: Sufficient hardness
2. Materials most in use
Typical materials include forged steel, cast steel, cast iron, plain
carbon steel, alloy steel and non-metal.
1 Forged steel
High strength and low cost
The forged steel most in use is medium carbon steel or alloy steel,

low carbon steel or alloy steel.

Medium carbon steel: quenching and tempering
Low carbon steel: case-hardening, carburizing, and nitriding
2 Cast steel for big size gears
Good wear resistance, good strength
Normalizing, annealing, quenching and tempering
3 Cast iron such as gray cast iron and nodular iron
Good wear resistance, gluing resistance, pitting resistance, lower
noise, but low tensile strength
It is easy to cast and to machine.
It can be used in gears with smooth operation, low speed, light-duty,
low precision.
4 Non-metal
Good corrosion resistance, good wear resistance, low weight, low
friction, quite operation, but low hardness, low contact strength, low
bending strength.
Pinion can be made from non-metal
Gear can be made from metal
3. Choice of gear materials
HBS1 HBS2 = 30 50
Small size: bar steel
Medium size: forged steel
Large size: cast steel or cast iron
Most of steels: case-hardening
Low-carbon steel or low-carbon alloy steel: carburizing
Quenched and tempered steel or Nitrided steel: Nitriding
Normalizing: steady load or light impact
Quenching and tempering: Medium impact
Alloy steel: high speed, heavy-duty, impact
10.4 Design of spur gears

1. Forces acting on gear teeth

Ft

2T1
Ft 2
d1

Fr Ft tg Fr 2
Fn

Ft
Fn 2 constant
cos

2. Calculated load
Calculated load

Fnc KFn
Ftc KFt

Where: K Load factor

K K A K v K K

1 Application factor K A

Table 10-2

2 Dynamic factor KV
Caused by the deformation of the gear teeth and the base pitch error
1.05 ~ 1.4
1.02 ~ 1.2

for spur gears

for helical gears

KV

ImprovementModifying the tooth face profile

3 Load partition factor

Caused by the load partition between teeth.

1 ~ 1 .2
1 ~ 1 .4

4 Load distribution factor

for spur gears

for helical gears

Caused by the deformation of the shafts and the pinion body.

1 ~ 1.2
1.1 ~ 1.35

soft suface
both are hard surface

ImprovementCrowning the gear teeth.

3. Contact fatigue strength of spur gear teeth

Hertz formula

1
1

Fn
1 2
H
L 1 12 1 2 2

E1
E2
b

Where L contact length, L Z 2

Set

ZE

coefficient of contact ratio,

Z 0.85 ~ 0.92

1
1 1 1 22

E2
E1
2

Z E Elastic

coefficient,
KFn
b

H Z E Z

1
1

1 2

d ' sin '

2

1
1
2
2
2
1

1
1 2 d1 ' sin ' d 2 ' sin ' d1 ' sin '
u

d '

2
2
u 1
u 1

d1 cos
u d1 cos tan ' u

sin '
cos '
z

Gear ratio u d2 ' d2 z2 1

1
1
1

Transmission ratio i 1
2
H Z E Z

set

ZH

KFn
2
u 1

Z E Z
b d1 cos tan ' u

2
cos tan '
2

Z H Zone

factor, see Fig. 10.

KFt
2
u 1

bd1 cos 2 tan ' u

2 KT1 u 1
H
2
bd1 u

H Z H Z E Z

Set d

checking formula

b
d1

Z H Z E Z
H

d1 3

2 KT1 u 1

d u

design formula

4. Bending fatigue strength of spur gear teeth

Strength equation
F

Fn

M KFn cos h 6 KFn cos h

bS 2
W
bS 2
6

For spur gears, 30 tangent method

h Kh m , S K s m
S

m module, mm

6 KFt cos ( K h m ) KFt 6 K h cos KFt

YFa
cos b( K S m )2
bm K S 2 cos bm

YFa Tooth form factor

YFa is independent of module. It depends on the tooth form, the shape

and size of the fillet at the root of the tooth, and the point of application of
the force on the tooth.
1. tooth form

ha*

c*

( fillet )

2. pt e, pt a
3. z, x
Strength concentration factor YSa
F
Y

KFt
2 KT1
YFa YSa
YFa YSa Y F check
bm
d1bm

coefficient of contact ratio,

calculation

Y 0.65 ~ 0.85 ,when a 2

Set d

b
, d 1 mz1
d1

F2

F1

2 KT1

d m 3 z1

YFa1YSa1Y F 1

2 KT1
YFa 2YSa 2Y F 2
d m 3 z1

2 KT1

d m 3 z1

m3

YFa YSa Y F

2 KT1 YFa YSa Y

2
F
d z1

Check calculation
Design calculation

d face width factor

4. Notes
Design
Enclosed drive

Soft surface
Hard surface

Exposed drive

Check

d1

F F

H H

Soft surface: Normalizing, quenching and tempering

Hard surface: Quenching, case-hardening, cementation, nitrizing, carbonitrizing

Contact strength calculation

H 1 H 2 H min H 1 , H 2

Bending strength calculation

F 1 F 1
F 2 F 2

In design calculation
Because KV

Y Y
YFa YSa
Y Y
max Fa1 Sa1 , Fa 2 Sa 2
F
F 2
F 1

K K depend on the size of gearsso we can select a

trial K t , then calculate K . If K is not closed to K t , d1 or mn can be

corrected.

d 1 d 1t 3

K
Kt

mn mnt 3

K
Kt

10.5 Allowable stresses and design parameters

1. Allowable stresses

K N lim
S

Safety factor S
SH SF

Table 10.5

Life factor K N
Expected number of load cycles

N 60njLh

Where n rotational speed of the gear, rpm

j number of load applications at one tooth profile per

revolution
Lh design life, h

Endurance limit Fig. 10.14 Fig 10.15

Three lines: MEhigh quality
MQmedium quality
MLlow quality
Generally, the value between MQ and MQ is suitable.
Pulsation cycle loading
Symmetrical cycle loading or open gear drive 0.7 lim
Interpolation method
2. Design parameters
Pressure angle
Number of pinion z1
Z operate smoothly.
Enclosed gear drive: z1 20 ~ 40

Open gear drive: z1 17 ~ 20

Face width factor d Table10-7
3. Precision/ quality classes of gears
Fig 10.22 Select of gear precision.
Example:
The meshing gears (see figure)
have same module, same number of
teeth, same face width, same
material and same heat-treatment.
Find out which gear has worst
bending fatigue strength, which gear
has worst contact fatigue strength.
bending fatigue strength from
best to worst: 2,2 1 3,3
contact fatigue strength from best

driving

1
2

2
3

to worst: 1 2,3,3

3
driven

10.6 Design of helical gears

1. Forces acting on gear teeth

Three component forces:
Tangential force

Ft1

2T1
Ft 2
d1
Ft tan n
Fr 2
cos

Radial force

Fr1 F tan n

Axial force

Fa1 Ft tan Fa 2

composite force
Normal force

Fn1

Ft
Ft
F

Fn 2
cos n cos n cos cos t cos b

Direction of forces:
Ft in opposite direction of turn round for driving gear;
in same direction of turn round for driven gear.
FrPoint to gears own center

Fa Left or Right-hand rule for driving gear

When driving gear is L-up (or R-up) , we hold up it by four fingers of
our left hand (or right hand), the hold direction is in the same direction of
driving turn round motion, then the thumb direction is axial forces
direction of driving gear.
2. Contact fatigue strength of helical gears
L

cos b

Transverse contact ratio a

n

t
d ' sin t '
; t
cos b
2

2 cos b
2 cos b
2 cos b
1
1
1

1
n1 n 2 d1 ' sin t ' d 2 ' sin t ' d1 ' sin t '
u

2 cos b u 1
2 cos b
2 cos b
u 1
u 1

d1 cos t
d1 ' sin t ' u
u
d1 cos t tan t ' u
sin t '
cos t '
1
KFt
2 cos b
1
u 1
Z E
H Z E p ca

2
b d 1 cos t tan t ' u
n1 n 2
Z E Z H Z Z

KFt u 1

H
bd1 u

H Z H Z E Z Z

2 KT1 u 1
H
2
bd 1 u

Z E Z H Z Z
d1 3
H

2 KT1 u 1

d u

3. Bending fatigue strength of helical gears

F

KFt
KFt1
YFa YSa
YFaYSa
b
bm
mn
cos b
KFt1
2 KT1
YFa YSa Y Y
YFa YSa Y Y F
bmn
bd 1mn

b d d1

Ft

2T1
d1

d1

10

mn Z 1
cos

2 KT1Y Y cos 2 YFa YSa

mn 3

F
d z1 2
m n Normal

module, that is standard module

Transverse module

mt

Helix angle factor Y

d mt Z 1tg
0.318 d Z 1tg
mt

btg

Overlap contact ratio m

t

Tooth form factor YFa zv table10-5

z
cos 3

zv

Equivalent number of teeth

Strength concentration factor

YSa

10.7 Design of straight bevel gears

1. Design parameters
Gear ratio
z2 d2

cot 1 tan 2
z1 d 1

Cone distance
d1

d2

d1
1 u2
2

d m1 d m2
R 0.5b

1 0.5 R
d1
d2
R

Face width factor: R

R 0.25 ~ 0.35 ; Generally, R

Mean reference diameter d m

d m d 1 0.5 R

11

1
3

 Mean module

mm

mm m 1 0.5 R

Module of large end m is standard module.

Equivalent reference radius
rv

Equivalent number of teeth

zv

dm
2 cos

dv
2r
z
v
mm mm cos

Equivalent gear ratio

uv

zv 2 z 2 cos 1

u2
zv1 z1 cos 2

2. Forces acting on gear teeth

Three component forces:
Tangential force

Ft1

2T1
Ft 2
d m1

Radial force

Fr 1 F cos 1 Ft tg cos 1 Fa 2

Axial force

Fa1 F sin 1 Ft tg sin 1 Fr 2

One composite force:

Normal force

Fn1

Ft
Fn 2
cos

Force direction:
FtIn opposite direction of turn round for driving gear.
In same direction of turn round for driven gear.
FrPoint to gears own center.
FaForm Small end to large end.

3. Contact fatigue strength

v

d v sin
2

12


1
1
2
2
2
1
1

v1 v 2 d v1 sin
d v 2 sin
d v1 sin
uv
u2 1
2

mm z v1 sin u 2
=

H ZE

KFt
b

m1 0.5 R

z1
sin
cos 1

u 2 1

2
u

u 2 1
2 cos 1

mz1 1 0.5 R sin u 2

cos 1
d1 1 0.5 R sin

1
1

v1 v 2

Z E

u 2 1

2
u

Z v1

mm m(1 0.5 R )

d v1 m m Z v1

Z1
cos 1

uv u 2

Fn

Ft
cos

u 2 1
KFt
2 cos 1

b cos mz1 1 0.5 R sin u 2

u

u 1
KFt
cos 1

ZEZH

b mz1 1 0.5 R u 2
2

= ZEZH

set

ZH

2
cos sin

= ZEZH

= ZEZH
ZEZH

ZEZH

cos 1

2 KT1
1
bd m1 d 1 1 0.5 R

2 KT1

bd 1 1 0.5 R
2

r2
r22 r12

d1
2
2
u 2 1d1 1 0.5 R
2
4 KT1

R d1 1 0.5 R 2 u
3

b R R

u2 1

2 KT1

u2 1
u

u2 1
u

u 2 1
KFt
u2 1

b mz1 1 0.5 R u 2

u2 1

H ZH ZE

4.7 KT1

R d1 1 0.5 R u
3

13

Equ.10.19

 Z Z
d1 3 H E
H

4.7 KT1

R 1 0.5 R 2 u

Equ.10.20

4. Bending fatigue strength

F

KFt
KFt YFa YSa
YFa YSa
F Equ. 10-23
bmm
bm 1 0.5 R

KFt YFa YSa

R Rm 1 0.5 R

R d1

KFt YFa YSa

d1 2
u 1 m 1 0.5 R
2
2 KYFa YSa
2T
4 KT1YFa YSa
1
2
2
u 2 1 m 1 0.5 R d m1 R d 1 u 2 1 m 1 0.5 R

4 KT1YFa YSa

R z1

u 1 m 1 0.5 R
2

Ft

m3

d m1 d (1 0.5 R )

mm m(1 0.5 R )
d m1 mm Z 1

b R R

2T1
d m1

4 KT1

R z1 2 u 2 1 1 0.5 R

YFa YSa
F

Equ.10.23

10.8 Gear blank design

1. Gear shafts
1) When

e 2 mt

for spur and helical gear

2) When e 1.6m for bevel gear

2. Gear with solid hub d a 160mm
3. Gears with thinned web d a 500mm
4. Spoked gears d a 400 ~ 1000mm

14

d1
u2 1
2

10.9 Efficiency and lubrication in gear sets

1. Efficiencty of gear set
1 23

2. Lubrication
Bath lubrication v 12m / s
Splash lubrication v 12m / s
Atomized lubrication v 12m / s
When v 25m / s , the oil infection nozzle may be on either side of
meshing in or side of meshing out; when v 25m / s , the oil infection nozzle
must be on the side of meshing out in order to cool the meshing gear teeth
simultaneously.

SURFACE ENGINEERING

LTPC

OBJECTIVES: To impart knowledge on surface engineering and surface

modification methods that will come in handy to solve the industrial problems. This will
also serve as a precursor for future
UNIT I ELEMENTS OF SOLID MECHANICS 9
The geometry of stress and strain, elastic deformation, plastic and elasto-plastic
deformation limit analysis Airy s function field equation for stress intensity factor.
UNIT I STATIONARY CRACK UNDER STATIC LOADING
Two dimensional elastic fields Analytical solutions yielding near a crack front
Irwins approximation - plastic zone size Dugdaale model determination of J
integral and its relation to crack opening displacement.
UNIT I ENERGY BALANCE AND CRACK GROWTH
Griffith analysis stable and unstable crack growth Dynamic energy balance

15

crack arrest mechanism K1c test methods - R curves - determination of collapse load.
UNIT IV FATIGUE CRACK GROWTH CURVE 9
Empircal relation describing crack growth law life calculations for a given load
amplitude efects of changing the load spectrum - rain flow method external factors
afecting the K1c values.- leak before break analysis.
UNIT V ENGINEERING MATERIALS 10
Introduction Advanced alloys Super alloys, Titanium alloys, Magnesium alloys,
Aluminum alloys, and Nickel based alloys Ceramics Polymers Biomaterials
Applications Bio Tribology Nano Tribology.
1. G.W.Stachowiak & A.W .Batchelor , Enginering Tribology, ButerworthHeineman, UK,
2. Rabinowicz.E, Friction and Wear of materials, John Wiley &Sons ,UK,195
3. Haling, J. (Editor) Principles of Tribology , Macmilian 1984.
4. Wiliams J.A. Enginering Tribology, Oxford Univ. Pres, 194.
5. S.K.Basu, S.N.Sengupta & B.B.Ahuja ,Fundamentals of Tribology, Prentice
Hal of India Pvt
6. Fontana G., Corosion Enginering, McGraw Hil, 1985

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