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gear systems.
Calculate forces on teeth of spur gears, including impact forces associated with
• American Gear Manufacturers Association
velocity and clearances. (AGMA)
• Determine allowable force on gear teeth, including the factors necessary due to
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angle of involute of tooth shape and materials selected for gears.
Design actual gear systems, including specifying materials, manufacturing
• Brown and Sharp
•
accuracy, and other factors necessary for complete spur gear design.
Understand and determine necessary surface hardness of gears to minimize or
• 14 ½ deg; 20 deg; 25 deg pressure angle
prevent surface wear.
• Understand how lubrication can cushion the impact on gearing systems and cool • Full depth and stub tooth systems
them.
• Select standard gears available from stocking manufacturers or distributors.
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Example Problem 12-1: Forces on Spur Gear Teeth Example Problem 12-1: Forces on Spur Gear Teeth (cont’d.)
− Find transmitted force:
• 20-tooth, 8 pitch, 1-inch-wide, 20° pinion transmits 5 hp at 1725 rpm to a 60-tooth gear. (12-3)
2T
• Determine driving force, separating force, and maximum force that would act on Ft =
Dp
mounting shafts.
(2-6) (2)183 in-lb
Tn Ft = = 146 lb
P = 2.5 in
63,000
− Find separating force:
63,000P (12-1)
T =
n
Fn = Ft tan θ
(63,000)5
T = = 183 in-lb
1725 Fn = 146 lb tan 20°
Fn = 53 lb
or
π Dp n
• Vm = ft/min (12-5)
12 Vm =
π Dp n
12
π Dp n
• Vm = m/min -- Metric units Vm = π 2.5 in 1725 rpm
ft
12 in
1000 Vm = 1129 ft/min
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Lewis equation Table 12.1 Lewis form factors (Y)
Sn Y b
Fs =
Pd
• Fs = Allowable dynamic bending force (lb)
• Sn = Allowable stress (lb/in2). Use
endurance limit and account for the fillet as
the stress concentration factor
• b = Face width (in.)
• Y = Lewis form factor (Table 12.1)
• Pd = Diametral pitch
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Example Problem 12-3: Strength of Gear Teeth Example Problem 12-3: Strength of Gear Teeth (cont’d.)
• In Example Problem 12-1, determine the force allowable (Fs) on these teeth if the
− Gear:
pinion is made from an AISI 4140 annealed steel, the mating gear is made from AISI
1137 hot-rolled steel, and long life is desired. Sn = .5 (88 ksi) = 44 ksi
− Pinion:
(Table 12-1)
Sn = .5 Su = .5 (95 ksi) = 47.5 ksi
Y = .421
(12-9)
44,000 (1) .421
Sn b Y Fs =
Fs = 8
Pd
Fs = 2316 lb
− Find Lewis form factor (Y) from Table 12-1, assuming full-depth teeth:
Y = .320
Fs = 1900 lb
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Classes of Gears Design Methods
1200 + Vm
• Carefully cut Fd = Ft • Strength of gear tooth should be greater
1200 than the dynamic force; Fs ≥ Fd
• Precision 78 + Vm0.5 • You should also include the factor of safety,
Fd = Ft
78 Nsf
Fs
≥ Fd
50 + Vm0.5 N sf
• Hobbed or shaved Fd = Ft
50
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Example Problem 12-4: Design Methods Example Problem 12-5: Design Methods
• If, in Example Problem 12-1, the gears are commercial grade, determine dynamic load
and, based on force allowable from Example Problem 12-3, would this be an acceptable • Spur gears from the catalog page shown in Figure 12-3 are made from a .2% carbon
design if a factor of safety of 2 were desired? steel with no special heat treatment.
• Use surface speed and force transmitted from Example Problems 12-2 and 12-3. • What factor of safety do they appear to use in this catalog?
– Dynamic load: • Try a 24-tooth at 1800 rpm gear for example purposes.
600 + Vm
Fd = Ft (12-10) • From Appendix 4, an AISI 1020 hot-rolled steel would have .2% carbon with an Sy = 30
600 ksi and Su = 55 ksi.
600 + 1129 − Therefore:
Fd = (146 lb)
600
Fd = 421 lb Sn = .5 Su
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Example Problem 12-5: Design Methods (cont’d) Example Problem 12-5: Design Methods (cont’d)
− Find Vm : − Set Fs = Fd and solve for Ft :
(12-5) ⎛ 600 + Vm ⎞
Fd = Fs = ⎜ ⎟ Ft
π Dp n ⎝ 600 ⎠
Vm =
12
⎛ 600 + 942 ⎞
519 lb = ⎜ ⎟ Ft
⎝ 600 ⎠
ft
Vm = π 2 in (1800 rpm)
12 in Ft = 202 lb
(12-3)
Vm = 942 ft/min
⎛ Dp ⎞
− Find Fs : T = F ⎜ ⎟
⎝ 2 ⎠
(12-9)
⎛ 2 in ⎞
T = 202 lb ⎜ ⎟
Sn b Y ⎝ 2 ⎠
Fs =
Pd
T = 202 in-lb
(from Table 12-1)
(2-6)
Tn 202 (1800)
Y = .302 P = = = 5.8 hp
63,000 63,000
Example Problem 12-5: Design Methods (cont’d) Example Problem 12-6: Design Methods
(11-4)
• Appears to be reasonable value.
Np 48
• Manufacturer may also have reduced its rating for wear purposes as these Dp = = = 4 in
Pd 12
are not hardened gears.
Ng = Np Vr = 48(3) = 144 teeth
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Example Problem 12-6: Design Methods (cont’d.) Example Problem 12-6: Design Methods (cont’d.)
⎛ 600 + Vm ⎞
– Dynamic force Fd = ⎜ ⎟ Ft (12-10)
⎝ 600 ⎠
− Surface speed: ⎛ 600 + 943 ⎞
Fd = ⎜ ⎟ 70
(12-5) ⎝ 600 ⎠
π Dp n Fd = 180 lb
Vm = – Since width b is the unkown:
12
Fs
Vm = π
4 in 900 rpm ≥ Fd
12 in/ft N sf
and
Vm = 943 ft/min
Sn b Y
− Finding force on teeth:
Fs =
Pd (12-8)
(12-6) Sn b Y
= Fd
33,000 hp N sf Pd
Ft =
Vm
33,000 (2) –Class 30 CI; Su = 30 ksi; Sn = .4 Su (.4 is used because cast iron):
Ft =
943 –Sn = 12 ksi
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Example Problem 12-6: Design Methods (cont’d.)
− Substituting: • To increase the dynamic beam strength of
(12-9) the gear
Sn b Y
Nsf Pd
= Fd – Increase tooth size by decreasing the
12,000 b .344 diametral pitch
= 180
2 (12)
– Increase face width upto the pitch diameter
b = 1.0 inches
of the pinion
− Check ratio of width to pitch:
(12-14)
– Select material of greater endurance limit
8
< b <
12.5 – Machine tooth profiles more precisely
Pd Pd
8 12.5
– Mount gears more precisely
< 1 <
12 12
– Use proper lubricant and reduce
.66 < 1 < 1.04
contamination
• This is an acceptable design.
• Many other designs are also possible.
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Buckingham Method of Gear Design Fig. 12.4 Expected error in tooth profiles
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Table 12.3 Values of C for e = 0.001 inch Buckingham Method of Gear Design
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Example Problem 12-7: Buckingham Method of Gear
Fig. 12.5 Recommended maximum error in gear teeth Design and Expected Error
Su = 95 ksi
(11-4)
Np 24
Dp = = = 1.5 in
Pd 16
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Example Problem 12-7: Buckingham Method of Gear Example Problem 12-7: Buckingham Method of Gear
Design and Expected Error (cont’d.) Design and Expected Error (cont’d.)
− Find torque: − Find surface speed:
(2-6) (12-5)
Tn π Dp n
P = Vm =
63,000 12
Ft = 73 lb Fs = 1000
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Example Problem 12-8: Wear of Gears Example Problem 12-8: Wear of Gears (cont’d.)
• In prior example problem, verify the surface is suitable for wear considerations. – Substituting into equation 12-16:
For wear use Nss = 1.2
Fw = 1.5 (1) 1.27 (270)
− Wear formula:
(12-16) Fw = 514
Fw = Dp b Q Kg
• This would not be suitable. Try if surfaces each had a BHN = 450.
− Find Q : K g = 470
(from Appendix 13)
(12-17)
Fw = 1.5 (1) (1.27) ( 470)
2 Ng
Q =
Ng + Np
Fw = 895
Fw
2 (42) ≥ Fd
Q =
42 + 24 N sf
895
Q = 1.27 > 699
1 .2
Kg = 270
(from Appendix 13)
746 > 699
• This would now be acceptable if the gear teeth were hardened to a BHN of 450.
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