SECTION 13 BEVEL GEARS

DESIGN PROBLEMS
751.

Decide upon the pitch, face, N g , material, and heat treatment of a pair of straight
bevel gears to transmit continuously and indefinitely a uniform loading of 5 hp at
900 rpm of the pinion, reasonable operating temperature, high reliability;
mg 1.75 ; D p 3.333 in . Pinion overhangs, gear is straddle mounted.

Solution:

L rp2 rg2 2
1

tan p

1
1

mg 1.75

p 29.75
L sin p rp

L sin 29.75
L 3.358 in

Ft

3.333
2

33,000hp
lb
vm

D p n p 3.333 900

785.4 fpm
12
12
33,000 5
Ft
210 lb
785.4

vm

Fd VF N sf K m Ft

50 vm2 50 785.4 2
VF

1.56
50
50
1

One gear straddle, one not

K m 1. 2

Table 15.2, uniform

N sf 1.0

Fd 1.56 1.0 1.2 210 393 lb

Wear load
s 2 Cl
Fw D pbI cd2
C e K t Cr

D p 3.333 in

b 0.3L 0.3 3.358 1.0 in

Temperature factor
K t 1.0 , reasonable operating temperature
Life factor for wear
Cl 1.0 for indefinite life
Reliability factor for wear
Cr 1.25 high reliability
Page 1 of 16

SECTION 13 BEVEL GEARS

Geometry factor for wear, Fig. 15.7
Assume I 0.080
Elastic coefficient (Table 15.4)
Steel on steel , Ce 2800
Fw Fd
2

scd
1 .0
3.3331.0 0.08
2
2800 1.01.25

393

scd 134,370 psi

Table 15.3, use Steel, (300)

scd 135 ksi

Strength of bevel gears

s bJ
Kl
Fs d
Pd K s K t K r
Size factor, assume K s 0.71
Life factor for strength
K l 1 for indefinite life
Temperature factor,
K t 1 good operating condition
Reliability factor
K r 1.5 high reliability
Geometry factor for strength (Fig. 15.5)
Assume J 0.240
b 1.0 in

sd = design flexural stress

Min. BHN = 300

sd 19 ksi
Fs F d

19,0001.0 0.240

1
0.7111.5 393

Pd
Pd 11

say Pd 10
10

10

so that b P 10 1.0 in
d
Dg D p mg 3.3331.75 5.833 in
N g Pd Dg 10 5.833 58.33

say N g 58
Use Pd 10 , b 1.0 in , N g 58
Material = steel, min. Bhn = 300

Page 2 of 16

SECTION 13 BEVEL GEARS

752.

A pair of steel Zerol bevel gears to transmit 25 hp at 600 rpm of the pinion;
mg 3 ; let N p 20 teeth; highest reliability; the pinion is overhung, the gear
straddle mounted. An electric motor drives a multi-cylinder pump. (a) Decide
upon the pitch, face width, diameters, and steel (with treatment) for intermittent
service. (b) The same as (a) except that indefinite life is desired.

Solution:
N
20
Dp p
Pd
Pd
vm

D p n p

12

20
600
1000
Pd

fpm
12
Pd

10

Let b P
d
Dynamic load

Fd VF N sf K m Ft

Ft

Ft

33,000hp
lb
vm

33,000 25
262.6 Pd
1000

P
d

1000
50
1
50 vm2
Pd
VF

50
50

1.121
1.121
1
1
2
Pd
Pd
Table 15.2, electric motor drives a multi-cylinder pump
Service factor, N sf 1.25
One gear straddle, one not, K m 1.2

1.121
1.251.2 262.6 Pd 394 Pd 1 1.121
Fd 1

Pd
Pd

(a) Strength of Bevel Gears

s bJ
Kl
Fs d
Pd K s K t K r
Size factor, assume K s 0.71
Life factor for strength
Intermittent service, use K l 4.6
Temperature factor, say K t 1.0
Reliability factor, highest reliability
K r 3.0

Geometry factor for strength

Page 3 of 16

SECTION 13 BEVEL GEARS

mg

Ng
Np

N p 20

N p 3 20 60

Fig. 15.5, J 0.205

b

10
Pd

Design flexural stress, steel

Assume sd 15 ksi
Fs Fd

10
0.205 4.6

1.121
Pd
394 Pd 1

Pd 0.711.0 3
Pd

15,000

66,408
1.121
394 Pd 1
2

Pd
Pd

Pd 4.814
say Pd 5
10 10
b

2.0 in
Pd
5

Wear load for bevel gears

2
2
Cl
scd

Fw D pbI 2
C Kt Cr
e

Dp

Np
Pd

20
4 in
5

K t 1.0

Life factor for wear, intermittent service

Cl 1.5

Reliability factor for wear, highest reliability

Cr 1.25

Geometry factor for wear, Fig. 15.7

N p 20 , N g 60
I 0.083

Elastic coefficient, steel on steel (Table 15.4)

Ce 2800

Pd 5
Fw Fd

Page 4 of 16

SECTION 13 BEVEL GEARS

2

1.5
4 2 0.083 scd 2
2800 1.0 1.25
scd 155,730 psi

1.121

394 5 1

Table 15.3
Use steel, min. BHN = 360, scd 160 ksi
Pd 5
b 2 in
D p 4 in

Dg mg D p 3 4 12 in

steel, min. BHN = 360

(b) For indefinite life,
K l 1.0 , life factor for strength
Cl 1.0 , life factor for wear
Strength:
s bJ
Kl
Fs d
Pd K s K t K r
Fs Fd

10
0.2051.0

1.121
Pd
394 Pd 1

Pd 0.711.0 3
Pd

15,000

14,437
1.121
394 Pd 1
2

Pd
Pd

Pd 2.799
say Pd 3
10 10
b

3.33 in
Pd
3

Wear load
s 2 Cl
Fw D pbI cd2
C e K t Cr
Dp

Np
Pd

20
6.67 in
3

Fw Fd
2

1.0
6.67 3.33 0.083 scd 2
2800 1.0 1.25
scd 113,744 psi

Table 15.3
Use steel, min. BHN = 240, scd 115 ksi
Page 5 of 16

1.121

394 3 1

SECTION 13 BEVEL GEARS

Pd 3
b 3.33 in
D p 6.67 in

Dg mg D p 3 6.67 20 in

steel, min. BHN = 240

753.

Decide upon the pitch, face, and number of teeth for two spiral-bevel gears for a
speed reducer. The input to the pinion is 20 hp at 1750 rpm; mg 1.9 ; pinion
overhung, gear-straddle mounted. It is hoped not to exceed a maximum D p of 4
3/8-in.; steel gears with minimum 245 BHN on pinion and 210 BHN on gear. The
gear is motor-driven, subject to miscellaneous drives involving moderate shock;
indefinite life against breakage and wear with high reliability. If the gears
designed for the foregoing data are to be subjected to intermittent service only,
how much power could they be expected to transmit?

Solution:
D p n p 4.3751750

2000 fpm
(a) vm
12
12
33,000hp 33,000 20
Ft

330 lb
vm
2000
Dynamic load
Fd VF N sf K m Ft

One gear straddle, one not

K m 1.2

Table 15.2
Motor-driven, moderate shock

Page 6 of 16

SECTION 13 BEVEL GEARS

N sf 1.25

70 vm2
VF

70
1

, spiral

70 2000 2
VF

70

1.254

Fd 1.254 1.251.2 330 621 lb

Wear load
s 2 Cl
Fw D pbI cd2
C e K t Cr

D p 4.375 in

Temperature Factor, K t 1.0

Design contact stresses,
BHN 245 , pinion
scd 116 ksi

Life factor for wear

Cl 1.0 , indefinite life
Reliability factor for wear
Cr 1.25 , high reliability
Geometry factor for wear, Fig. 15.8
Assume I 0.12
Elastic coefficient, steel on steel (Table 15.4)
Ce 2800

116,000 2
1 .0
Fw 4.375 b 0.12
2

2800 1.0 1.25

Fw Fd

721b 621

b 0.8613 in

say b

7
in 0.875 in
8

Strength of gear
s bJ
Kl
Fs d
Pd K s K t K r
sd = design flexural stress
min. BHN = 210
sd 15.4 ksi

Size factor, assume K s 0.71

Life factor for strength
K l 1 for indefinite life

Page 7 of 16

721b

SECTION 13 BEVEL GEARS

Temperature factor,
Kt 1

Reliability factor
K r 1.5 high reliability
Geometry factor Fig. 15.6
Assume J 0.28
Fs

15,400 0.875 0.28

1
3543
0.7111.5 P

Pd

Fs Fd
3543
621
Pd
Pd 5.7

say Pd 6
7
in , N p D p Pd 4.375 6 26
8
N g mw N p 1.9 26 50

Then, Pd 6 , b

(b) Intermittent service only

Strength
s bJ
Kl
Fs d
Pd K s K t K r
sd 15,400 psi (Gear)
For Pd 6 , K s 0.64
For indefinite service, K l 4.6
K t 1.0 , K r 1.5
Geometry factor, Fig. 15.6, N p 26 , N g 50
J 0.292

15,400 0.875 0.292

4.6
Fs
0.7111.5 3142 lb
6

Wear load
s 2 Cl
Fw D pbI cd2
C e K t Cr

D p 4.375 in

K t 1.0

scd 116 ksi

Ce 2800
Cl 1.5 intermittent service

Cr 1.25

Geometry factor for wear, Fig. 15.8

N p 26 , N g 50
I 0.116

Page 8 of 16

SECTION 13 BEVEL GEARS

116,000 2
1.5
Fw 4.375 0.875 0.116
2

2800 1.0 1.25

1098 lb

use Fw Fd

Fd VF N sf K m Ft

1098 1.254 1251.2 Ft

Ft 584 lb
584 2000 35 hp
Fv
hp t m
33,000
33,000

CHECK PROBLEMS
755.

A pair of straight-bevel gears are to transmit a smooth load of 45 hp at 500 rpm of

3
the pinion; mg 3 . A proposed design is Dg 15 in. , b 2 in. , Pd 4 .
8

Teeth are carburized AISI 8620, SOQT 450 F. The pinion overhangs, the gear is
straddle-mounted. Would these gears be expected to perform with high reliability
in continuous service? If not would you expect more than 1 failure in 100?
Solution:
Dp

vm
Ft

Dg 15

5 in
mg
3

D p n p 5 500

655 fpm
12
12

33,000hp 33,000 45

2267 lb
vm
655

Dynamic load

Fd VF N sf K m Ft

50 vm2 50 655 2
VF

1.512
50
50
1

One gear straddle, one not

K m 1.2

Smooth load, N sf 1.0

Fd 1.512 1.0 1.2 2267 4113 lb

Strength of bevel gears

s bJ
Kl
Fs d
Pd K s K t K r
Size factor, for Pd 4 ,
K s 0.71

Life factor for strength

Kl 1

Page 9 of 16

SECTION 13 BEVEL GEARS

Temperature factor,
Kt 1

Geometry factor for strength (Fig. 15.5)

N p Pd D p 4 5 20

N g Pd Dg 4 15 60

J 0.205
sd 30 ksi (55 63 Rc) for carburized teeth

Fs

30,000 2.375 0.205

1
5143
0.711 K K

r
r

Fs Fd
5143
4113
Kr

K r 1.25 1.5 will not perform high reliability.

Wear load
s 2 Cl
Fw D pbI cd2
C e K t Cr

D p 5 in
b 2.375 in

Table 15.3, scd 225 ksi

Table 15.4, Ce 2800
Geometry factor for wear, Figure 15.7
N p 20 , N g 60
I 0.083
Kt 1

life factor for wear Cl 1

225,000 2 1
Fw 5 2.375 0.083
2800 2 1 Cr

6364
Cr2

Fw Fd

6364
4113
Cr2
Cr 1.244 1.25 , high reliability

Since K r 1.5 ,this will not perform high reliability but 1 in 100, K r 1.12 1.25
756.

A gear catalog rates a pair of cast-iron, straight-bevel gears at 15.26 hp at 800 rpm
of the 16-tooth pinion; mg 3.5 , b 3 in. , Pd 3 ; pinion overhangs, straddlemounted gear. Assume the cast iron to be class 30. If the load is smooth is this
rating satisfactory, judging by the design approach of the Text for good reliability

Page 10 of 16

SECTION 13 BEVEL GEARS

(a) when strength alone is considered, (b) when long continuous service is
desired?
Solution:
N
16
Dp p
5.333 in
Pd
3
D p n p 5.333 800
vm

1117 fpm
12
12
33,000hp 33,00015.26
Ft

451 lb
vm
1117
Dynamic load
Fd VF N sf K m Ft

50 vm2 50 1117 2
VF

1.668
50
50
1

One gear straddle, one not

K m 1.2

Smooth load, N sf 1.0

Fd 1.6681.0 1.2 451 903 lb

(a) Strength
s bJ
Kl
Fs d
Pd K s K t K r
Pd 3 ,
K s 0.76
Kl 1
Kt 1

K r 1. 5
sd 4.6 ksi , cast-iron class 30
N p 16

N g mw N p 3.516 56

J 0.184

4,600 3 0.184
1
Fs

742 lb 903 lb Fd
3
0.76 11.5

with

K l 1.4 for 106 cycles

Fs 1.4 742 1040 lb 903 lb Fd

Therefore satisfactory for 106 cycles.

(b) Continuous service

Wear load

Page 11 of 16

SECTION 13 BEVEL GEARS

s 2 Cl
Fw D pbI cd2
C e K t Cr

D p 5.333 in
b 3 in

Table 15.3, scd 50 ksi , cast-iron class 30

Table 15.4, cast-iron and cast-iron Ce 2250
Cl 1

Kt 1

Cr 1.25

Geometry factor for wear, Figure 15.7

N p 16 , N g 56
I 0.077
Fw 5.333 3 0.077

50,000 2
1
2
2250 11.25

389 lb Fd 903 lb

Therefore, not satisfactory for long continuous service.

757.

An 870-rpm motor drives a belt conveyor through bevel gears having 18 and 72
teeth; Pd 6 , b 1

3
in . Both gears are straddle-mounted. What horsepower
4

may these gears transmit for an indefinite life with high reliability if both gears
are (a) cast-iron, class 40; (b) AISI 5140, OQT 1000 F; (c) AISI 5140, OQT 1000
F, flame hardened (d) AISI 8620, SOQT 450 F?
Solution:
N
18
Dp p
3 in
Pd
6
D p n p 3 870
vm

683 fpm
12
12
Dynamic load
Fd VF N sf K m Ft

Both gears straddle mounted

K m 1.0

Table 15.2, N sf 1.0

50 vm2 50 683 2
VF

1.523
50
50
1

Fd 1.5231.0 1.0 Ft 1.523Ft

(a) Cast-iron, class 40

Strength
s bJ
Kl
Fs d
Pd K s K t K r

Page 12 of 16

SECTION 13 BEVEL GEARS

sd 7 ksi , cast-iron class 40
3
b 1 in
4
K l 1 , indefinite life
Pd 6
K s 0.64
Kt 1

K r 1.5 , high reliability

Figure 15.5, N p 18 , N g 72
J 0.204

70001.75 0.204
1
Fs

434 lb
6
0.64 11.5

Wear:
s 2 Cl
Fw D pbI cd2
C e K t Cr

D p 3 in

b 1

3
in
4

Table 15.3, scd 65 ksi , cast-iron class 40

Table 15.4, cast-iron and cast-iron Ce 2250
Cl 1 , indefinite life
Kt 1

Cr 1.25 , high reliability

Geometry factor for wear, Figure 15.7

N p 18 , N g 72
I 0.082

65,000 2
1
Fw 31.75 0.082
2
2250 11.25

230 lb

Fd Fw
1.523Ft 230
Ft 151 lb

hp

151 683 3 hp
Ft vm

33,000
33,000

(b) AISI 5140, OQT 1000 F, BHN = 300

Strength
sd 19,000 psi

Fs

19,0001.75 0.204

Wear:

Page 13 of 16

1
0.64 11.5 1178 lb

SECTION 13 BEVEL GEARS

s 2 Cl
Fw D pbI cd2
C e K t Cr

Table 15.3, scd 135 ksi

Table 15.4, steel and steel, Ce 2800

135,000 2
1
Fw 31.75 0.082
2

2800 11.25

640 lb

Fd Fw

1.523Ft 640
Ft 420 lb

hp

Ft vm
420 683 8.7 hp

33,000
33,000

(c) AISI 5140, OQT 1000 F, Flame Hardened

Strength
sd 13.5 ksi

Fs

13,500 1.75 0.204

1
0.64 11.5 837 lb

Wear:
Fw D pbI

2
Cl
scd

2
C e K t Cr

Table 15.3, scd 190 ksi

Table 15.4, steel and steel, Ce 2800

190,000 2
1
Fw 31.75 0.082
2

2800 11.25

1269 lb

Fd Fs
1.523Ft 837
Ft 550 lb

hp

550 683 11.4 hp

Ft vm

33,000
33,000

(d) AISI 86200, SOQT 450 F, carburized

Strength
sd 30 ksi (55 63 Rc)
Fs

30,0001.75 0.204

1
0.6411.5 1859 lb

Wear:
s 2 Cl
Fw D pbI cd2
C e K t Cr

Table 15.3, scd 225 ksi

Page 14 of 16

SECTION 13 BEVEL GEARS

Table 15.4, steel and steel, Ce 2800

225,000 2
1
Fw 31.75 0.082
2
11.25
2800

1779 lb

Fd Fw
1.523Ft 1779
Ft 1168 lb

hp

758.

1168 683 24.2 hp

Ft vm

33,000
33,000
A pair of straight-bevel gears transmits 15 hp at a pinion speed of 800 rpm;
Pd 5 , N p 20 , N p 60 , b 2 in . Both gears are made of AISI 4140 steel,
OQT 800 F. What reliability factor is indicated for these gears for strength and
for wear (a) for smooth loads, (b) for light shock load from the power source and
heavy shock on the driven machine?

Solution:
N
20
Dp p
4 in
Pd
5
D p n p 4 800
vm

838 fpm
12
12
33,000hp 33,00015
Ft

591 lb
vm
838
Fd VF N sf K m Ft

50 vm2 50 838 2
VF

1.579
50
50
1

assume K m 1.0

Fd 1.579 N sf 1.0 591 933 N sf

Strength of bevel gear

s bJ
Kl
Fs d
Pd K s K t K r
For AISI 4140, OQT 800 F, BHN = 429
sd 24 ksi
assume K l 1
Kt 1
Pd 5
K s 0.675

Figure 15.5, N p 20 , N g 60
J 0.205

24,000 2 0.205
1
2916
Fs

5
Kr
0.6751 K r

Page 15 of 16

SECTION 13 BEVEL GEARS

Fs Fd
2916
933 N sf
Kr
3.1254
Kr
N sf

Wear load:
s 2 Cl
Fw D pbI cd2
C e K t Cr

BHN = 429
Table 15.3, scd 190 ksi
Table 15.4, steel and steel, Ce 2800
D p 4 in
b 2 in

Assume Cl 1.0 , K t 1.0

Fig. 15.7, N p 20 , N g 60
I 0.083

190,000 2 1
Fw 4 2 0.083
2800 2 1 Cr

3058
Cr2

Fd Fw

933 N sf
Cr

3058
Cr2

1.810
N sf

(a) Table 15.2, smooth load

N sf 1.0

3.1254 3.1254

3.1254
N sf
1
1.810 1.810
1.810
For wear, Cr N
1
sf

For strength, K r

(b) Table 15.2, light shock source, heavy shock driven

N sf 2.0

3.1254 3.1254

1.5627
N sf
2
1.810 1.810
1.2799
For wear, Cr N
2
sf

For strength, K r

- end -

Page 16 of 16