Gear Design

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Design of Spur and Helical Gears

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Ratna Kumar Annabattula
208, Machine Design section

Department of Mechanical Engineering
IIT Madras
Office hours: Wednesday, 3:00 p.m. - 4:00 p.m.

email: ratna@iitm.ac.in
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Ratna Kumar (IIT Madras) Design of Gears July-Nov 2018 1 / 88
Outline I
1.The Lewis Bending Equation
2.Surface Durability
3.AGMA Stress Equations
4.AGMA Strength Equations
5.Correction Factors
6.Finding St and Sc
Finding St
Finding Sc
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7 ALL THE FACTORS
Dynamic factor Kv
Kv factor
GEOMETRY FACTORS (I and J) or (ZI and Y J )
J(Y J )
I(ZI )
Overload factors (Ko )
Load-Distribution factor (Km (KH )) .
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Outline II
Finding Cp f
Finding Cpm
Finding Cma
Finding Ce
Size factor Ks
Rim thickness factor KB
Elastic Coefficient Cp (ZE )
Surface condition factor C f (ZR )
Temperature factor KT (Yθ )
Safety factors (SF and SH )
Reliability factor (KR (YZ ))
Stress cycle factors (YN (ZN ))
Hardness ratio factor (CH (Zw ))
Flowchart of spur gear design for dending
Flowchart for spur gear design for wear
8. Spur gear Problem. 1 . . . . . . . . . . . . . . . . . . . .

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Outline III
9. Spur gear Problem 2
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10 Guidelines for design of a gear mesh
Parallel Helical Gears
Force Analysis - Helical Gears
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11 Bevel Gear - Force Analysis
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The Lewis Bending Equation
The Lewis Bending Equation I
Wilfred Lewis intorduced an equation in 1892, for estimating the

bending stresses in gear teeth which still remains the basis for
most of the gear design today.
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The Lewis Bending Equation II
From similar triangles,
t/2 ℓ t2
= =⇒ ℓ =
x t/2 4x
Using the concept of a rectangular cantilever beam
M 6W t ℓ
σ= = ,
I/c Ft2
where I/c is the section modulus.

By rearranging the above equation,
6W t ℓ Wt 1
σ= =
Ft2 F t2 /6ℓ
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The Lewis Bending Equation III

Substituting for the value of ℓ and using y = 2x/(3p), with p being
circular pitch, the above equation can be written as
Wt
σ=
Fpy
Here, y is called Lewis form factor

In the above equation, some times, it is preferred to have
diametral pitch instead of circular pitch. Hence, by replacing
p = π/P and y = πY
WtP 2xP
σ= , where Y = .
FY 3
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The Lewis Bending Equation IV
Figure 1 : Values of the Lewis Form Factor Y for a normal pressure angle
20◦ and full-depth teeth.
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Dynamic Effects I
Dynamic factor Kv has been defined as the reciprocal of that used

in previous AGMA standards. It is now greater than 1.0. In
earleir, AGMA standards it was less than 1.0.
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Velocity factor in terms of the current AGMA standards is given

by C. G. Barth as (V is the pitch-line velocity in ft/min)
600 + V
Kv = (cast iron, cast profile)
600
1200 + V
Kv = (cut or milled profile).
1200
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Dynamic Effects II
AGMA equation for velocity factor

√
50 + V
Kv = (hobbed or shaped profile)
√ 50
√
78 + V
Kv = (shaved or ground profile)
78
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Dynamic Effects III
The above equations for velocity factor in SI units (V is in m/sec)

are given by
3.05 + V
Kv = (cast iron, cast profile)
3.05
6.1 + V
Kv = (cut or milled profile)
6.1 √
3.56 + V
Kv = (hobbed or shaped profile)
√ 3.56
√
5.56 + V
Kv = (shaved or ground profile)
5.56
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Dynamic Effects IV
Effect of velocity factor on Lewis equation
σ=
Kv W t P
FY
J
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The metric version of the Lewis equation with velocity factor is given
by
σ=
Kv W t
FmY
, J
.
where face width F and module m are in mm, W t is in N leading to
stress units of MPa.
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Dynamic Effects V
The above two equations form the basis for AGMA

approach to bending strength of the gear teeth.
For spur gears, F should be 3 to 4 times the circular pitch as
a general rule.
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Example-1
A stock spur gear is available having a module of 4 mm, a 44 mm face,

16 teeth, and a pressure angle of 20◦ with full-depth teeth. The
material is AISI 1020 steel in as-rolled condition. Use a design factor
nd = 3.5 to rate the horse power output of the gear corresponding to a
speed of 25 rev/s and moderate applications.
Note: For AISI-1020 steel, the tensile strength (Sut ) is 379 MPa
and the yield strength (S y ) is 206 MPa.
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Solution-1
Allowable stress σall = S y /nd = 206/3.5 = 58.86 MPa
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Solution-1

The pitch diameter d = Zm = 16(4) = 64 mm
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Solution-1

The pitch-line velocity is V = πdN = π(64/1000)(25) = 5.0265 m/s
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Solution-1

The velocity factor Kv = (6.1 + V)/6.1 = (6.1 + 5.0265)/6.1 = 1.824
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Solution-1

Form factor Y for 16 teeth is 0.296
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Solution-1

Lewis equation
FmYσall (44)(4)(0.296)(58.86)
Wt = = = 1681 N.
Kv 1.824
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Solution-1

Lewis equation
FmYσall (44)(4)(0.296)(58.86)
Wt = = = 1681 N.
Kv 1.824
The transmittable power is H = W t V = 1681(5.0265) = 8450 W
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Example-2
Estimate the horse power rating of the gear in the previous example
based on obtaining infinite life in bending.
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Surface Durability
Surface Failure I
Failure of surafces of gear teeth is called wear.

Pitting (fatigue of high contact stresses), scoring (lubrication
failure) and abrasion (foreign material)
Hertz theory to obtain the surface contact stress between two
cylinders
2F
pmax = ,
πbℓ
where pmax is the largest surface pressure, F is the force pressing
the two cylinders together, ℓ is the length of the cylinders and b is
the half-width given by
[ ]1/2
2F (1 − ν1 )/E1 + (1 − ν2 )/E2
2 2
b=
πℓ 1/d1 + 1/d2
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Surface Durability
Surface Failure II
The above equations for the notion used in gears may be obtained
by replacing the quantities as follows
F → W t / cos ϕ
d → 2r
ℓ → face width F
pmax → σC (surface compressive stress)
Therefore, we get
Wt 1/r1 + 1/r2
σ2C = , (1)
πF cos ϕ (1 − ν1 )/E1 + (1 − ν22 )/E2
2
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where r1 and r2 are the instantaneous radii of curvature of pinion
and gear tooth profiles, respectively. .
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Surface Durability
Surface Failure III

The equation for Hertzian stress doesn’t account for sliding but
only for rolling.
In the gear contact only the contact at pitch point is under pure
rolling. Elsewhere, the motion is a combination of rolling and
sliding.
The radii of curvature of the tooth profiles at the pitch point are
dP sin ϕ dG sin ϕ
r1 = , r2 =
2 2
To smplify the equation for compressive stress (Eq. 1), we define
an elastic coefficient CP as
 1/2
 
 1 
CP =  ( 2 ) 

 1−ν 1−ν2G  
π EP
P
+ EG . . . . . . . . . . . . . . . . . . . .
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Surface Durability
Surface Failure IV
Hence,
[ ( )]1/2
Kv W t 1 1
σC = −CP + (2)
F cos ϕ r1 r2
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Negative sign is to indicate compressive stress.
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Surface Durability
Example-3
The pinion in Example-1 and Example-2 is to be mated with a

50-tooth gear manufactured of ASTM No. 50 cast iron. Using the
tangential load of 1700 N, estimate the factor of safety of the drive
based on the possibility of surface failure.
Material Properties
EP = 207 GPa
νP = 0.292
EG = 100 GPa
νG = 0.211
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Surface Durability
Solution-3 I
The elastic coefficient CP

 1/2
 
 1 
CP =  ( )  = 150927.3
 π 1−0.2922 + 1−0.2112  
207(109 ) 100(109 )
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Surface Durability
Solution-3 II
Face width F = 44 mm and using Kv = 1.824 from Example-1,

[ ( )]1/2
Kv W t 1 1
σC = −CP +
F cos ϕ r1 r2
[ ( )]1/2
1.824(1700) 1 1
σC = −150927.3 +
0.044 cos 20◦ 0.01094 0.0342
σC = −454 MPa.
The surface endurance strength of cast iron for 108 cycles is given
by
SC = 2.206HB MPa
The value of HB for ASTM no. 50 cast iron is 262. Hence,
SC = 2.206(262) = 578 MPa.
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Surface Durability
Solution-3 III
Note that the contact stress is not a linear function of transmitted

load. Hence, the factor of safety is defined as
( )2 ( )2
SC 578
nd = = ≈ 1.62
σC 454
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AGMA Stress Equations
AGMA I
Many assumptions and simplification go into the Lewis equation.
It has to be corrected for various factors. Standards are set by
AGMA
For bending
For pitting resistance or contact stress
FOR BENDING:
Pd Km KB
σ = W t Ko Kv Ks [US units] (3)
F J
.
1 KH KB
σ = W t Ko Kv Ks [SI units] (4)
bm Y J
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AGMA II
W t tangential load lbf(N)

Ko is the overload factor
Kv is called the dynamic factor [Norton has 1
where Kv < 1. New

Kv
standards have Kv > 1]
Ks is called the size factor
Pd is the transverse diametral pitch
m is the module
F(b) is the face width in(mm)
Km (KH ) is the load-distribution factor
KB is the rim thickness factor
J(Y J ) is the geometric factor for bending strength (includes the
root fillet stress concentration factor)
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AGMA III
FOR PITTING:
√
Km C f
σ c = Cp W t Ko Kv Ks [US units] (5)
dP F I
.
√
KH ZR
σc = ZE W t Ko Kv Ks [SI units] (6)
dw1 b ZI
.
√ √
Cp (ZE ) is an elastic coefficient, lb f /in2 ( N/mm2 )
C f (ZR ) is the surface condition factor
dP (dw1 ) is the pitch diameter of the pinion in(mm)
I(ZI ) is the geometry factor for pitting resistance . . . . . . . . . . . . . . . . . . . .
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AGMA Strength Equations
AGMA Strength Equations I
Allowable bending stress
St YN
σall = [US units] (7)
SF KT KR
.
St YN
σall = [SI units] (8)
SF Yθ TZ
.
St is the bending strength or allowable bending stress number,

lbf/in2 (N/mm2 )
YN is the stress cycle factor for bending stress
KT (Yθ ) are temperature factors
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AGMA Strength Equations
AGMA Strength Equations II

KR (YZ ) are the reliability factors
SF is the AGMA factor of safety, which is a stress ratio
Allowable contact stress, σc,all
Sc ZH CH
σc,all = [US units] (9)
SH KT KR
.
Sc ZN ZW
σc,all = [SI units] (10)
SH Yθ YZ
.
Sc is the allowable contact stress,lbf/in2 (N/mm2 )
ZN is the stress cycle life factor
CH (ZW ) are the hardness ratio factors for pitting resistance
SH is the AGMA factor of safety. . . . . . . . . . . . . . . . . . . . .
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Correction Factors
Correction factors
15 factors need to be found to design a gear!
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Finding St and Sc Finding St
Finding St I
Depends on
1. Material
2. Material Hardness
3. Surface treatment
4. Grade. Higher grades are more expensive, have higher strengths.
We find these using a combination of tables, equations and charts.
FINDING St
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Finding St II
Figure 2 : Allowable bending strength for nitrided through hardened steel

gears (i.e. AISI 4140, 4340), St . The SI equations are St = 0.568HB + 83.8MPa
for grade 1 and 0.749HB + 110MPa for grade 2
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Finding St III
Figure 3 : Allowable bending fatigue strength. Norton uses S′f b for St

.. Go to AGMA Process
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Finding St and Sc Finding Sc
Finding Sc
Figure 4 : Allowable surface fatigue strength. Norton uses S′f c for Sc

.. AGMA Wear
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ALL THE FACTORS Dynamic factor Kv
Dynamic factor Kv I
Is present both in the bending stress and the surface stress

equations equations 3,4,5,6. Note that Norton uses K1v for
this.
Accounts for the transmission error
1. Inaccuracies in tooth profile
2. Vibration of the tooth during meshing
3. magnitude of the pitch-line velocity
4. dynamic unbalance
5. wear and permanent deformation of contacting portions of the teeth
6. Tooth friction, Gear shaft misalignment and the linear and angular
deflection of the shaft
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Dynamic factor Kv II
√
A+ V ft
Kv = V in (11)
A min
√
A + 200V m
Kv = V in (12)
A s
2
A = 50 + 56(1 − B); B = 0.25(12 − Qv ) 3 (13)
πdp np
V is the pitch-line velocity 12 , if dp (pitch diameter) .
Qv is called the quality factor, of the least quality gear in mesh.
Will be given to you.
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Kv factor
Figure 5 : Kv factor. Maximum velocity at the end point of the Qv curve is

ft [A+(Qv −3)]2 m
Vtmax = [A + (Qv − 3)]2 [ min ] and Vtmax = 200 [s]
.. AGMA Wear . . . . . . . . . . . . . . . . . . . .
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ALL THE FACTORS GEOMETRY FACTORS (I and J) or (ZI and Y J )
Geometry Factors I and J J Useful in a data sheet
Are present both in the bending stress (J(Y J )) and the surface
stress(I(ZI )) equations equations 3,4,5,6.
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Bending Strength Geometry FactorJ(Y J ) I
Like the Lewis form factor, it accounts for the tooth form and the
geometry of the tooth profile. Includes the filleting at the root tip,
which may change the Lewis form factor.
Depends on where the loading is, the depth of the tooth (Full or
stub) and the pressure angle
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Bending Strength Geometry FactorJ(Y J ) II
Figure 6 : Geometry factor (J(Y J )). For 20◦ pressure angle, full depth
teeth. The loading is at the highest point of single tooth contact.
.. Go to AGMA Process . . . . . . . . . . . . . . . . . . . .
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Surface Strength Geometry Factor I(Z(I) I
We use equations (+ for external and - for internal)

( ) ( )
cos ϕt sin ϕt mG
I= (14)
2mN mG ± 1
Load sharing factor mN is given by
mN =
pN
0.95Z
; Z Jis not the number of teeth (15)
mN = 1 for spur gears

pN = pn cos ϕn (16)
Z in Eq.15 is given by
[ ]1/2 [ ]1/2
Z = (rP + a)2 − r2bP + (rG + a)2 − r2bG − (rP + rG ) sin ϕt (17)
rP and rG are pitch radii. rbG and rbP are base circle radii.
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Surface Strength Geometry Factor I(Z(I) II
Surface strength geometry factor. Use + for external gears and −

for internal gears
.. AGMA Wear
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ALL THE FACTORS Overload factors (Ko )
Overload factor (Ko )

Are present both in the bending stress and the surface stress
equations equations 3,4,5,6. we make allowance for all externally
applied loads in excess of the load W t in a specific kind of
application.
Called application factor in NORTON
There is a table.
Figure 7 : Overload factor Ko . Called Application factor in NORTON(Ka )
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.. Go to AGMA Wear
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ALL THE FACTORS Load-Distribution factor (Km (KH ))
Load distribution factor (Km (KH )) I
equations equations 3,4,5,6.
Corrects for the fact that the loads are not distributed uniformly
across the line of contact.
Depends on the face width F. Larger this is more chances of non
uniformity in the load.
Km = 1 + Cmc (Cp f Cpm + Cma Ce ) (18)
Cmc = 1 for uncrowned teeth and 0.8 for crowned teeth
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Load distribution factor (Km (KH )) II
Figure 8 : A crowned gear tooth
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Finding Cp f I
F(b) Cp f
F ≤ 1in F
10d− 0.025
1 < F ≤ 17in F
10d− 0.0375 + 0.0125F
17 < F ≤ 40in F
10d− 0.119 + 0.0207F − 0.000228F2
b ≤ 25mm b
10d− 0.025
25 < b ≤ 425mm b
10d− 0.0375 + 4.92(10−4 )b
425 < b ≤ 1000mm b
10d− 0.1109 + 8.15(10−4 )b−
3.53(10−7 )b2
Table 1 : Values of Cp f . If F
10d < 0.05 then use F
10d = 0.05. d is the pinion
pitch diameter
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Finding Cpm
S1
For straddle mounted pinion with S < 0.175 use Cpm = 1
S1
straddle mounted pinion with S ≥ 0.175 use Cpm = 1.1
Figure 9 : Definitions of S1 and S to find Cpm
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Finding Cma
Cma = A + BF + CF2 (F is face width in inches)
Figure 10 : Constants to calculate Cma . Note that F is in inches
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Finding Ce
Ce is 0.8 for gearing adjusted at the assembly, or when the

compatibility is improved by lapping or both. Ce = 1 for all other
conditions.
.. Go to AGMA Process
.. Go to AGMA Wear
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ALL THE FACTORS Size factor Ks
Size factor Ks
equations equations 3,4,5,6.
Takes into account the non uniformity of material properties due
to the size. ( √ )0.0535
F Y
Ks = 1.192 US units (19)
P
( √ )0.0535
Ks = 0.904 bm Y SI units (20)
If Ks < 1 set Ks = 1
.. Go to AGMA Wear
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ALL THE FACTORS Rim thickness factor KB
Rim thickness factor KB I
Are present in the bending stress equations 3,4

When the rim thickness is not large enough to provide support to
the tooth root, faille occurs in the rim rather than at the tooth
root fillet.
( )
2.242
KB = 1.6 ln [For mB < 1.2] (21)
mB
KB = 1 For mB ≥ 1.2 (22)
tR
mB = (23)
ht
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ALL THE FACTORS Rim thickness factor KB
Rim thickness factor KB II
Figure 11 : Backup ratio and KB determination
.. Go to AGMA Process . . . . . . . . . . . . . . . . . . . .
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ALL THE FACTORS Elastic Coefficient Cp (ZE )
Elastic Coefficient Cp (ZE )
Are present in the surface stress equations equations 5,6

Accounts for the fact that the materials of the pinion and the gear
can be different
Equation
v
u
t 1
Cp = ( ) (24)
1−ν2P 1−ν2G
π EP + EG
Where νP and νG are the Poisson’s ratio of the pinion and the
gear, respectively
Where EP and EG are the Young’s modulus of the pinion and the
gear, respectively
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Surface condition factor C f (ZR )
Surface condition factor C f (ZR )
Not established
When detrimental surface finish is known to exist then C f > 1, say
about 1.5.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Temperature factor KT (Yθ )
Temperature factor KT (Yθ )
Accounts for higher operating temperatures

Occurs in Equations 7, 8, 9,10
If oil or gear blank temperature up to 250◦ F (120◦ )C use
KT (Yθ ) = 1. For higher temperatures, use a value > 1.
.. Go to AGMA Process .. AGMa Wear
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Safety factors (SF and SH )
Safety factors (SF and SH ) I

St YN /(KT KR ) fully corrected bending strength
SF = = (25)
σall bending stress
Sc ZN CH /(KT KR ) fully corrected contact strength
SH = = (26)
σc contact stress
NOTE: SF ∝ W t (proportional to load, since stress is proportional

to the load (σbending ∝ W t ))
√ √
It so happens that σc ∝ W t . So, SH ∝ W t
So Compare SF to S2H while deciding the cause of failure (Bending
or Pitting)
If SF = 3 and SH = 2, then SF < S2H , this means there is a threat of
failure of the gear tooth from bending . . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Safety factors (SF and SH )
Safety factors (SF and SH ) II
If SF = 5.73 and SH = 1.69, then SF > S2H , this means is a threat of

failure of the gear tooth from wear or pitting
√
This relation ship σc ∝ W t is valid for when the contact is linear
or helical (Spur gear or helical gear)
1
Crowned teeth then σc ∝ (W t ) 3 which means that we should
compare SF to S3H
.. Go to AGMA Process .. AGMA Wear
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Reliability factor (KR (YZ ))
Reliability factor (KR (YZ )) I

Accounts for statistical distributions of material fatigue failure
KR = 0.658 − 0.0759ln(1 − R) if 0.5 < R < 0.99
KR = 0.5 − 0.109ln(1 − R) if 0.99 < R ≤ 0.9999
Reliability KR (YZ )
0.9999 1.5
0.999 1.25
0.99 1.00
0.9 0.85
0.5 0.7
Table 2 : Reliability factors. Use this only for the values of reliability in the
table. For other reliability use the equation
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Reliability factor (KR (YZ ))
Reliability factor (KR (YZ )) II
.. Go to AGMA Process .. AGMA Wear
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Stress cycle factors (YN (ZN ))
YN (ZN ) I
Occurs in Equations 7, 8(YN ), 9,10(ZN ) .. Go to AGMA Process
The St and Sc choices are for a life of 107 cycles
We need YN (ZN ) to modify for other values of life .. AGMA Wear
Note that if the cycles is slightly > 107 then the mating gear may be experiencing slightly fewer
than 107 cycles
Figure 12 : The Strength-Cycle factors YN and ZN for bending and pitting

respectively
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Hardness ratio factor (CH (Zw ))
Hardness ratio factor (CH (Zw )) I
Occurs in Equations 9,10

Pinion is generally subjected to more cycles than the gear since it
has fewer teeth
If both are hardened by the same process, then one can actually
harden the pinion alone a little more so that the pinion will work
harden the gear as it makes contact with it
Applies only to the GEAR not the pinion.
If both gear and pinion are through hardened
CH = 1.0 + A′ (mG − 1) (27)
HBP HBP
A′ = 8.98 × 10−3 − 8.29 × 10−3 [1.2 ≤ ≤ 1.7] (28)
HBG HBG
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Hardness ratio factor (CH (Zw ))
Hardness ratio factor (CH (Zw )) II

HBP and HBG are the Brinell Hardness numbers of the pinion and
the gears, respectively. (10mm ball at 3000kg load)
mG is the gear ratio
HBP
HBG < 1.2, A′ = 0
HBP
HBG > 1.7, A′ = 0.00698
If surface hardened pinions with hardness of 48 HRC or harder are
run with through hardened then,
CH = 1 + B′ (450 − HBG ) (29)
B′ = 0.00075e−0.0112 fp , where fp is the surface finish of the pinion

expressed as root mean square roughness Ra in µin
CHARTS ARE ALSO AVAILABLE
.. AGMA Wear
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Flowchart of spur gear design for dending
Spur Gear Bending based on ANSI/AGMA

2001-D04
ZP πdN P Km KB
dP = , V= , σ = W t Ko Kv Ks d
Pd 12 F J
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
33000H
Wt =
V
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
√
A+ V
Kv = V in ft/min
A
√
A + 200V
Kv = V in m/sec
A
2
A = 50 + 56(1 − B); B = 0.25(12 − Qv ) 3
V is the pitch-line velocity πdp Np /12.

Qv is called the quality factor, of the least quality gear in mesh.. Will be given to you.
. . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
 ( √ )0.0535 
 F Y 
Ks = max 1.192 , 1
P
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
Load distribution factor (Km )
Km = Cm f = 1 + Cmc (Cp f Cpm + Cma Ce )
.. Go To Km
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
Rim thickness Factor (KB ) .. Go to KB
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
Geometry Factor (J) .. Go to J
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
Bending endurance strength
St YN
σall =
SF KT KR
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
St YN
σall =
SF KT KR
.
Gear bending strength or allowable bending stress number St
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
St YN
σall =
SF KT KR
.
Stress Cycle Factor YN
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
St YN
σall =
SF KT KR
.
Temperature Factor KT
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
St YN
σall =
SF KT KR
.
Reliability Factor KR
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
ZP πdN P Km KB
Pd 12 F J
.
St YN
σall =
SF KT KR
.
Safety Factor SF
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
ALL THE FACTORS Flowchart for spur gear design for wear
Spur Gear Wear based on ANSI/AGMA

2001-D04
( )1/2
ZP πdN Km C f
dP = , V= , σC = CP W Ko Kv Ks
t
Pd 12 dP F I
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
Tangential Load
33000H
Wt =
V
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
Overload Factor Ko
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
Dynamic Factor Kv
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
Size Factor Ks
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
Load Distribution Factor Km
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
Surface condition Factor C f is taken as 1
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
Geometry Factor I
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
Contact endurance strength
SC ZN CH
σC,all =
SH KT KR
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
SC ZN CH
σC,all =
SH KT KR
.
Gear contact strength or allowable contact stress number SC
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
SC ZN CH
σC,all =
SH KT KR
.
Stress Cycle Factor ZN
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
SC ZN CH
σC,all =
SH KT KR
.
Temperature Factor KT
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
SC ZN CH
σC,all =
SH KT KR
.
Reliability Factor KR
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
SC ZN CH
σC,all =
SH KT KR
.
Safety Factor SH
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

2001-D04
( )1/2
ZP πdN Km C f
t
Pd 12 dP F I
.
SC ZN CH
σC,all =
SH KT KR
.
Hardness Ratio Factor CH
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Spur gear Problem. 1
Spur gear Problem 1
A 17-tooth 20◦ pressure angle spur pinion rotates at 1800 rev/min and
transmits 4hp to 52 tooth disk gear. The diametral pitch is 10
teeth/in, the face width 1.5 in and the quality standard is No. 6. The
gears are straddle mounted with bearings immediately
adjacent (Cpm = 1). The pinion is a grade 1 steel with a hardness of
240 HB tooth surface and a through hardened core. The gear is steel,
through hardened also, grade 1 material, with a HB of 200, tooth
surface and core. Poisson’s ratio is 0.3, JP = 0.3, JG = 0.4, and Young’s
Modulus is 30Mpsi. The loading is smooth because of motor and the
load. Assume a pinion life of 108 cycles and a reliability of 0.9, and
use YN = 1.3558N−0.0178 , ZN = 1.4488N−0.023 . The tooth profile is
uncrowned. This is a commercial enclosed unit gear. Find Factor of
safety in bending, contact and examine the safety factors to comment
on possible failure mode.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Spur gear Problem. 1
Spur gear Problem 1 - Data
Number of teeth on pinion ZP = 17

Pressure angle ϕ = 20◦
Speed of rotation NP = 1800 rev/min
Power transmitted H = 4 hp
Number of teeth on gear ZG = 52
Diametral pitch P = 10 teeth/in
Face width F = 1.5 in
Quality standard number Qv = 6
Gears are straddle mounted with bearing immediately adjacent
Pinion material: Grade 1 steel with HB = 240 with through and surface hardened
Gear material: Grade 1 steel with HB = 200
Poisson’s ratio ν = 0.3
JP = 0.3, JG = 0.4, E = 30(106 ) psi.
Smooth loading because of motor and load
Pinion life: 108 cycles and a reliability of 0.9
The load cycle factors: YN = 1.3558N−0.0178 and ZN = 1.4488N−0.023
Tooth profile is uncrowned
The gear set is a commercial enclosed unit.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Spur gear Problem 2
Spur gear problem 2
A speed reducer has 20◦ full-depth teeth. The gear set has 22 and 60
teeth with a diametral pitch of 4 and a face width of 3 14 in. The pinion
shaft speed is 1145 rev/min. The expected life is for 5 years at 24 hour
per day service. The transmission accuracy is 6.The gears are through
hardened and nitrided and are of grade 1.The nitriding results in the
pinion and gear core hardness of 250 HB and 390 HB for the pinion
and gear case. Estimate the power rating. The source of power is
smooth and there could be some moderate shock in the gear. Assume
that the reliability is 0.99. [1hp=33, 000 lbf ft
min ]
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Spur gear Problem 2
Problem 3 I
A pair of open gears having pressure angle 20◦ is designed to transmit 180hp [1hp=33,000 lbf ft ] with a
rev . The distance between the two shafts is known to be 12.5min
pinion speed of exactly 1000 min inches. The
rev
gear is supposed to rotate at a speed of exactly 500 min in a direction that is opposite to that of the
pinion. The gear is made of grade 1, through hardened steel, while that of pinion is made of grade 2
nitrided through hardened steel. The hardness of the gear and the pinion is 300 HB and 325 HB,
respectively. The quality of mesh is 6. The face width of a tooth in the gear and the pinion is 4.17 in.
The reliability of the design is 0.99 for a billion revolutions of the gear.
If the following is known about the gear set, is it a good design? Is it a good design, if the life expected is
two orders of magnitude smaller?
The total number of teeth in the pinion must be greater than 27 and less than 95
The pinion must be straddle mounted at the center of a simply supported shaft.
The overload factor is 1.5
The rim thickness factor is 1.0
The Ce = 1
The Cma = 0.3153
The elastic coefficient, Cp = 2300
The surface finish factor, C f = 1
The geometry factor for pitting resistance, I = 0.1071
The Strength life factors for bending is given by, YN = 1.6831N−0.0323 and is 0.8618 for the gear
The Strength life factor for contact is, ZN = 2.466N−0.0566 and is 0.7727 for the gear
The temperature factor, KT = 1
The theoretical allowable bending strength for the gear is 35990 psi
The theoretical allowable contact strength for the pinion is 147725 psi
HINT: It would help if you calculated Kv , Ks , Km , J, YN for pinion, ZN for pinion, Allowable bending strength
. . . . . . . . . . . . . . . . . . . .
for pinion, allowable contact strength for gear to organize your thoughts.
. .
. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Guidelines for design of a gear mesh
Design of a Gear Mesh I
A priori decisions
Function: load, speed, reliability, life, Ko

Unquantifiable risk: design factor nd
Tooth system: ϕ, ψ, addendum, dedendum, root fillet radius
Gear ratio mG , ZP , ZG
Quality number Qv
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Design of a Gear Mesh II
Desgin decisions
Diametral pitch Pd
Face width F
Pinion material, core hardness, case hardness
Gear material, core hardness, case hardness
.
Four design decision categories

Total 8 decisions to make
More number of decisions compared to other m/c elements
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Design of a Gear Mesh III
Steps for Design
Choose a diametral pitch.

Examine implications on face width, pitch diameters and
material properties. If not satisfactory, return to pitch
decision for change.
Choose a pinion material and the associated core and case
hardness. If not satisfactory, return to pitch decision and
iterate until no decisions are changed.
Choose a gear material and the associated core and case
hardness. If not satisfactory, return to pitch decision and
iterate until no decisions are changed.
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Problem-4
Design a 4:1 spur-gear reduction for a 100-hp, theree phase

squirrel-cage induction motor running at 1120 rev/min. The load
is smooth , providing a reliability of 0.95 at 109 revolutions of the
pinion. Gearing space is meager. Use Nitralloy 135M, grade 1
material to keep the gear size small. The gears are heat-treated
first and then nitraded.
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Guidelines for design of a gear mesh Parallel Helical Gears
Helical Gears I
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Helical Gears II
Nomenclature
ψ: Helix angle
pt : Transverse circular pitch
pn : Normal circular pitch pn = pt cos ψ
pt
px : Axial pitch px = tan ψ
Pt
Pn : Normal diametral pitch Pn = cos ψ
ϕn , ϕt : normal and tangential pressure angle
tan ϕn
cos ψ =
tan ϕt
.
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Helical Gears III
Condition to avoid interference

Smallest number of teeth ZP for mG = ZG /ZP = 1
( √ )
2k cos ψ
ZP = 1 + 1 + 3 sin2 ϕt
3 sin2 ϕt
For a given gear ratio m = NG /NP , the smallest pinion
2k cos ψ [ √ ]
ZP = mG + m2 + (1 + 2mG ) sin2 ϕt
(1 + 2mG ) sin2 ϕt G
Largest gear teeth number

Z2
P
sin2 ϕt − 4k2 cos2 ψ
ZG =
4k cos ψ − 2NP sin2 ϕt
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Problem-1
A stock helical gear has a normal pressure angle of 20◦ , a helix angle of
25◦ and a transverse diametral pitch of 6 teeth/in and has 18 teeth.
Find:
1. The pitch diameter
2. The transverse, the normal and the axial pitches

3. The normal diametral pitch
4. The transverse pressure angle
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Guidelines for design of a gear mesh Force Analysis - Helical Gears
Force Analysis-Helcial Gears I
Figure 13 : Tooth faces acting on a right-hand helical gear

. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Force Analysis-Helcial Gears II
The forces are applied on pitch plane and in the center of

the gear face.
The theree components of the total toothe force:
Radial component: Wr = W sin ϕn (30)

Tangential component: Wt = W cos ϕn cos ψ (31)
Axial components: Wa = W cos ϕn sin ψ (32)
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Force Analysis-Helcial Gears III

.
Problem-2
.
In the Figure, a 1-hp motor runs at 1800 rev/min in the clockwise direction, as viewed from the positive x
axis. Keyedto to the motor shaft is an 18-tooth helical pinion having a normal pressure angle of 20◦ , a
helix angle of 30◦ , and a normal diametral pitch of 12 teeth/in. The hand of helix is shown to be right
handed. Make a three-dimensional sketch of the motor shaft and pinion, and show the forces acting on
.
the pinion and the bearing reactions at A and B. The thrust to be taken out at A.
tan ϕn tan 20◦

ϕt = tan−1 = tan−1 = 22.8◦ (33)
cos ψ cos 30◦ . . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Force Analysis-Helcial Gears IV
Pt = Pn cos ψ = 12 cos 30◦ = 10.39 teeth/in (34)

Hence,
dP = 18/10.39 = 1.732 in
Pitch line velocity:
πdN π(1.732)(1800)
V= = = 816 ft/min
12 12
Transmitted load:
33000H 33000(1)
Wt = = = 40.4 lbf
V 816
. . . . . . . . . . . . . . . . . . . .
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Force Analysis-Helcial Gears V

Solution
Wr = Wt tan ϕt = (40.4) tan 22.8◦ = 17.0 lbf

Wa = Wt tan ψ = (40.4) tan 30◦ = 23.3 lbf
Wt 40.4
W = = = 49.6 lbf
cos ϕn cos ψ cos 20◦ cos 30◦
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Force Analysis-Helcial Gears VI
The forces Wt , Wr and Wa act in the −y, z and −x directions,

respectively at point C.
Given that the thrust load to be taken by A and hence,
FA = Wa = 23.3 lbf
Considering moment equilibrium about z axis at support A
y
Wa (dP /2) − Wr (13) + FB (10) = 0
y 17(13) − 23.3(1.732/2)
=⇒ FB = = 20.1 lbf
10
Taking force equilibrium in y direction, we get
y y
−FA + FB − Wr = 0
y
=⇒ FA = 20.1 − 17.0 = 3.1 lbf
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.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Force Analysis-Helcial Gears VII
Now considering moment equilibrium about y axis at A, we get
FzB (10) − Wt (13) = 0

=⇒ FzB = 40.4(13)/10 = 52.5 lbf
Considering the force equilibrium in z direction leads to
FzA = 2.1 lbf
Torque applied would be T = Wt dP /2 = (40.4)(1.732/2) = 35 lbf.in
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Bevel Gear - Force Analysis
Bevel Gears I
Figure 14 : Forces acting on a bevel gear tooth

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Bevel Gears II
Transmitted load is given by
T
Wt = ,
rav
where T is the torque and rav is the pitch radius at the midpoint of
the tooth.
Radial force is given by
Wr = Wt tan ϕ cos γ
Axial force is given by
Wa = Wt tan ϕ sin γ
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.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
Bevel Gears III
The bevel pinion shown in the figure rotates at 600 rev/min in the
direction shown and transmits 5 hp to the gear. the mounting
distances, the locations of all bearings, and the average pitch radii of
the pinion and gear are shown in teh figure. For simplicity, the teeth
have been replaced by pitch cones. Bearings A and C should take the
thrust loads. Find the bearing forces on the gear shaft.
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Bevel Gears IV
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Bevel Gears V
Free body diagram
.
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Gear Design

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Gear Design

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Design of Spur and Helical Gears

Ratna Kumar Annabattula

208, Machine Design section

Oﬃce hours: Wednesday, 3:00 p.m. - 4:00 p.m.

Ratna Kumar (IIT Madras) Design of Gears July-Nov 2018 2 / 88

8. Spur gear Problem. 1 . . . . . . . . . . . . . . . . . . . .

The Lewis Bending Equation I

Wilfred Lewis intorduced an equation in 1892, for estimating the

The Lewis Bending Equation II

From similar triangles,

Using the concept of a rectangular cantilever beam

where I/c is the section modulus.

The Lewis Bending Equation III

Here, y is called Lewis form factor

The Lewis Bending Equation IV

Dynamic factor Kv has been deﬁned as the reciprocal of that used

Velocity factor in terms of the current AGMA standards is given

AGMA equation for velocity factor

Dynamic Eﬀects III

The above equations for velocity factor in SI units (V is in m/sec)

Eﬀect of velocity factor on Lewis equation

The above two equations form the basis for AGMA

A stock spur gear is available having a module of 4 mm, a 44 mm face,

Allowable stress σall = S y /nd = 206/3.5 = 58.86 MPa

Allowable stress σall = S y /nd = 206/3.5 = 58.86 MPa

Allowable stress σall = S y /nd = 206/3.5 = 58.86 MPa

Allowable stress σall = S y /nd = 206/3.5 = 58.86 MPa

Allowable stress σall = S y /nd = 206/3.5 = 58.86 MPa

Allowable stress σall = S y /nd = 206/3.5 = 58.86 MPa

Allowable stress σall = S y /nd = 206/3.5 = 58.86 MPa

The transmittable power is H = W t V = 1681(5.0265) = 8450 W

Failure of surafces of gear teeth is called wear.

Ratna Kumar (IIT Madras) Design of Gears July-Nov 2018 18 / 88

Surface Failure III

The pinion in Example-1 and Example-2 is to be mated with a

The elastic coeﬃcient CP

Face width F = 44 mm and using Kv = 1.824 from Example-1,

Note that the contact stress is not a linear function of transmitted

W t tangential load lbf(N)

AGMA Strength Equations I

Allowable bending stress

St is the bending strength or allowable bending stress number,

AGMA Strength Equations II

15 factors need to be found to design a gear!

Figure 2 : Allowable bending strength for nitrided through hardened steel

Figure 3 : Allowable bending fatigue strength. Norton uses S′f b for St 

Figure 4 : Allowable surface fatigue strength. Norton uses S′f c for Sc 

Is present both in the bending stress and the surface stress

Figure 5 : Kv factor. Maximum velocity at the end point of the Qv curve is

Geometry Factors I and J J Useful in a data sheet

Bending Strength Geometry FactorJ(Y J ) I

Bending Strength Geometry FactorJ(Y J ) II

Surface Strength Geometry Factor I(Z(I) I

We use equations (+ for external and - for internal)

mN = 1 for spur gears

Ratna Kumar (IIT Madras) Design of Gears July-Nov 2018 41 / 88

Surface Strength Geometry Factor I(Z(I) II

Surface strength geometry factor. Use + for external gears and −

Overload factor (Ko )

Figure 7 : Overload factor Ko . Called Application factor in NORTON(Ka )

Load distribution factor (Km (KH )) I

Cmc = 1 for uncrowned teeth and 0.8 for crowned teeth

Figure 3 : Allowable bending fatigue strength. Norton uses S′f b for St

Figure 4 : Allowable surface fatigue strength. Norton uses S′f c for Sc