Dr P R Venkatesh Mech Dept RVCE

23-Feb-18 8:37 PM 1
Bangalore
 Bevel Gears
• Bevel gears are used to transmit power between
two intersecting shafts, angle between the axis can
be less than, equal to or more than 900.
• The pitch surfaces of the bevel gears are rolling
cones. The teeth of bevel gears are tapered, the
outer larger part is called ‘heel’ & the inner part is
called the ‘toe’.
• The bevel gear has many diverse applications such
as locomotives, marine applications, automobiles,
printing presses, cooling towers, power plants, steel
plants, railway track inspection machines, etc.
Dr P R Venkatesh Mech Dept RVCE
2
Bangalore
 Bevel gear lifts floodgate by means of central screw.
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 3
Bangalore
 Bevel gear on
roller shutter door

Dr P R Venkatesh Mech Dept RVCE

23-Feb-18 8:37 PM 4
Bangalore
 Terminology Of Bevel Gears
Pitch Cone: It is an imaginary cone, the surface of
which contains the pitch lines of all teeth in the
bevel gear.
Cone distance: It is the length of the pitch cone
element. It is denoted by ‘L’.
Pitch angle: It is the angle which the pitch line
makes with the axis of the gear. It is denoted by ‘d’.
Back cone: It is an imaginary cone whose elements
are perpendicular to the elements of the pitch cone.
Back cone distance: It is the length of the back cone
element. It is also called back cone radius and is
denoted by ‘rb’.
23-Feb-18 8:37 PM
Dr P R Venkatesh Mech Dept RVCE
Bangalore
5
 ha hf

L
nce
ta
dis
ne
Co

Axis of Gear

O d B

d rb
i us
ad
ner
k co
c
Ba

Face width
b
23-Feb-18 8:37 PM
Terminology of Bevel Gears
Dr P R Venkatesh Mech Dept RVCE
6
Bangalore
 d

d 

Two bevel gears in mesh showing Shaft angle

& pitch angle
23-Feb-18 8:37 PM
Dr P R Venkatesh Mech Dept RVCE
Bangalore
7
 

Right Angled Bevel gear

Obtuse angled bevel gear



Acute angled bevel gear

Dr P R Venkatesh Mech Dept RVCE

23-Feb-18 8:37 PM 8
Bangalore
 Formative number of teeth in Bevel Gears
• Formative number of teeth or equivalent
number of teeth in a bevel gear is equal to
the number of teeth in an equivalent spur
gear having pitch radius equal to back cone
radius.
Let z= number of teeth on bevel gear
ze= Equivalent number of teeth
rb=Back cone radius
r=Pitch radius at the larger end
m= module, d=Pitch cone angle
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 9
Bangalore
 d rb

r
d
d

Virtual Or Equivalent
number of teeth on
Bevel gear
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 10
Bangalore
 d 2r
Number of teeth on pitch circle z= =
m m
2rb
Number of teeth on back cone radius z e =
m
ze 2rb m r
From the above equations, =  =
z m 2r cos d  r
ze 1  r 
 =  From the geometry of bevel gear,rb = 
z cos d  cos d 
z
 ze = Eqn 12.35 Page 218
cosδ
Note : The equivalent number of teeth must be used
in computation of Lewis form factor.
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 11
Bangalore
 Terms used in Bevel Gears
l = Cone distance (Slant height of cone)
b= Face width
d =Semi pitch cone angle or Pitch angle
d=Pitch diameter gear/pinion=mz
h a = Addendum height, h f = Dedendum height
 a &  d =Addendum & dedendum angle
 c = cutting angle = (d   d )
 f = Face angle = (d   d )
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 12
Bangalore
 Pitch Cone angle ( d )
For Acute angle between shaft axes,
sin 
tand1 = Eqn12.29(a) Page 215
i  cos 
sin 
tand 2 = Eqn12.29(b) Page 215
1
   cos 
i
For right angle bevel gears,
1
tand1 = Eqn 12.32 (a) Page 217, tand 2 = i Eqn 12.32 (b) Page 217
i
For Obtuse angle between shaft axes,
sin(180   )
tand1 = Eqn 12.31 (a ) Page 217
i  cos(180   )
sin(180   )
tand 2 = Eqn 12.31 (b) Page 217
1
   cos(180   ) Dr P R Venkatesh Mech Dept RVCE
i Bangalore
13
 Design Procedure for Bevel Gears :
Step 1 : To identify the weaker member
Find  d 1 y1 for Pinion &  d 2 y2 for Gear
where y1 & y2 are the Lewis form factors for pinion & gear
calculated on the basis of equivalent number of teeth z e
Step 2 : Beam strength or Load carrying capacity
(a) Tangential tooth load
1000  P  Cs
Ft = 12.7(a), Page 205, Cs from T 12.8, P 235
v
(b) Lewis equation
 Lb 
Ft =  d Cv bYm   Eqn 12.37, Page 218
 L 
where  d = allowable stress Table 12.7, Page 234
C from equations 12.38
v 8:37 PM
23-Feb-18
a & 12.38
Dr P R Venkatesh b, Page 219
Mech Dept RVCE
14
Bangalore
Face width b = 10m Eqn 12.36a, Page 218
L
Also b  Eqn 12.36b, Page 218. Take whichever is least.
3
1
Cone distance L= d12  d 2 2 Eqn 12.33, Page 217
2
 m 2 
 As d = mz, L may be written as = z1  z2 
2

 2 
Equating the values of Ft from (a) & (b), module m can be
obtained.
For standard value of module, refer T12.24, Page 242

Dr P R Venkatesh Mech Dept RVCE

15
Bangalore
 Step 3 : Dimensions of Gears :
(1) Pitch diameter of pinion d1 = mz1 , of gear d 2 = mz2
(2) Face width of gear b=6m to 10 m Eqn 12.36(a), page 218
(3) Cone distance L=3b 12.36 b, P 218
(4) Addendum h a , Dedendum h f from Table 12.23, page 242.
(5) Outer dia of pinion d o1 = d1  2ha cos d1 Eqn12.30a, P 215
Outer dia of gear d o 2 = d 2  2ha cos d 2 Eqn12.30b, P 215
 2h sin d1 
(6) Addendum angle  a = tan 1  a  Eqn12.29c, Page215
 d1 
1 
2h f sin d1 
(7) Dedendum angle  d = tan   Eqn12.29d , Page215
 d1 
(8) Lateral or Radial load:
Fr = Fte tan  cos d1 Eqn 12.45 d , Page 219, where
Ft L
Fte = Effective tooth load= 12.45 ( a), page 219
L  0.5b
(9) Axial load or thrust:
a =
23-Feb-18F8:37 F
PM te tan  sin d 1
Dr P R Venkatesh Mech Dept RVCE
Eqn 12.45(Bangalore
e), Page 219 16
Step 4: Check for dynamic & wear load :
K 3v(Cb  Ft )
(a) Dynamic load Fd = Ft  Eq12.40, Page 219
K 3v  Cb  Ft
where C = Dynamic load factor from T12.12 Page 236
K 3 = 20.67
 d1bQe K 
(b) Wear load Fw =   Eq12.41 Page 219
 cos d1 
K = load stress factor from T12.16, Page 239
2 ze 2
Qe = Ratio factor = Eq12.41 Page 219
ze 2  ze1
If Fw  Fd , the design is safe.

Dr P R Venkatesh Mech Dept RVCE

23-Feb-18 8:37 PM 17
Bangalore
 PROBLEM 1
Type 1 (Where number of teeth are given/Assumed)
A cast steel (Untreated) pinion having 24
teeth transmits a power of 9 KW through a
high grade CI (heat treated) gear at a
velocity ratio 3. Pinion rotates at 720 rpm.
The angle between the shaft axes is 600.
The teeth are 141/20 system . Design the
gears completely.

Dr P R Venkatesh Mech Dept RVCE

23-Feb-18 8:37 PM 18
Bangalore
 Pitch Cone angle( δ)
For Acute angle between shaft axes,
sin 
tand1 = Eqn12.67 Page 171
i  cos 
0
sin 60
Here  = 600 , i = 3  tand1 =  d = 13.9 o

3  cos 600
1

sin 
tand 2 = Eqn12.68 Page 171
1
   cos 
i
sin 600
tan d 2 =  d 2 = 46.10
1
   cos 60 0

3
Here z1 = 24, z2 = iz1 = 3  24 = 72 teeth
z1 24
Equivalent number of teeth on pinion z e1 = = = 24.73
cos d1 cos13.9
z2 72
Equivalent number of teeth on gear z e 2 = = = 103.86
23-Feb-18 8:37 PM cos d 2 cos 46.1
Dr P R Venkatesh Mech Dept RVCE
19
Bangalore
Step 1 : To identify the weaker member :
From T 12.7/ P 234, for cast steel pinion (untreated),
 d 1 = 138.3Mpa
For high grade Cast iron (grade 35) (heat treated),
 d 2 = 78.5Mpa
Lewis form factor for pinion & gear based on equivalent teeth
0
0.684 1
y1 = 0.124  Eqn12.5 (c), page 204 ( For 14 system)
ze1 2
0.684 0.684
y1 = 0.124  = 0.0963, Also y 2 = 0.124  = 0.1174
24.73 103.83
 d 1 y1 (for Pinion)=78.5  0.0963=13.318
&  d 2 y2 (for Gear)=138.3  0.1174=9.22 (< d 1 y1 )
Gear is weaker. Hence design must be based on gear
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 20
Bangalore
Step 2 : Beam strength or Load carrying capacity
(a) Tangential tooth load
1000  P  Cs
Ft = 12.7(a), Page 205
v
 d 2 N 2   m  z2  N 2
Here, P=9 KW, v= =
60000 60000
  m  72  240
v = = 0.905m
60000
C s = 1.5, (Assuming medium shocks, 8-10 hrs service/day)
1000  9 1.5 14917
Substituting the above, Ft = = (1)
0.905m m
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 21
Bangalore
(b) Lewis equation :
 Lb 
Ft =  d Cv bYm   Eqn 12.37, Page 218
 L 
Here  d =  d 2 =78.5 Mpa, Y= y 2 =   0.1174 = 0.3688
1 m m
Cone distance L= d1  d 2 =
2 2
z1  z2 =
2 2
242  722
2 2 2
L 37.94m
L = 37.94m , Face width b   12.65m(> 10m)
3 3
Taking the least value b = 10m
L  b 37.94m  10m
Also = = 0.7364.
L 37.94m
Substituting ,the above values,
Ft = 78.5  Cv  10m  0.3688  m  0.7634
23-Feb-18
Ft = 8:37221.15
PM
m 2
Cv (2)Dr P R Venkatesh Mech Dept RVCE 22
Bangalore
Equating (1) & (2),
14917
= 221m 2Cv  m 3Cv = 67.49 (3)
m
As the value of Cv is around 0.5, initial trial value of module is
m = 3 2  RHS = 3 2  67.49 = 5.13  5mm (standard value)
Now, velocity v=0.905  m =0.905  5=4.525 m/sec
6.1
Velocity factor Cv = Eqn12.38b, Page219
6.1  v
(Assuming generated teeth)
6.1
Cv = = 0.574
6.1  4.525
 m 3Cv = 53  0.574 = 71.76 > 67.49 (required value)
 Selected module of 5Drmm is satisfactory.
P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 23
Bangalore
 Step 3 : Dimensions of Gears :
(1) Pitch diameter of pinion d1 = mz1 = 5  24 = 120mm
(2) Pitch diameter of gear d 2 = mz2 = 5  72 = 360mm
(2) Face width of gear b=10  m = 10  5 = 50mm
(3) Cone distance L=37.94m =37.94  5=189.7 mm
14917
(4) Tangential tooth load Ft = = 2983.4 N
5
(4) Addendum h a , Dedendum h f from Table 12.23, page 242
For 14.50 system, h a = 1m = 1 5 = 5mm,
h f = 1.157 m = 1.157  5 = 5.785mm
(5) Outer dia of pinion d o1 = d1  2ha cos d1 Eqn12.30a, P 218
d o1 = 120  (2  5  cos13.9) = 129.7 mm
Outer dia of gear d o 2 = d 2  2ha cos d 2 Eqn12.30b, P 218
d = 360  (2  5 Drcos
o 2PM
23-Feb-18 8:37
46.1)Mech
P R Venkatesh = 366.93
Dept RVCE mm
24
Bangalore
 Continued
 2ha sin d1 
(6) Addendum angle  a = tan  1
 Eqn12.29c, Page 218
 d1 
 2  5  sin13.9 
 a = tan 1   = 1.15 0

 120 
 2h f sin d1 
(7) Dedendum angle  d = tan  1
 Eqn12.29d , Page 218
 d1 
 2  5.785  sin13.9 
 d = tan 1   = 1.330

 120 
(8) Radial load on gear & end thrust (axial load) on pinion
Fr = Fte tan  cos d1 Eqn 12.45d , Page 219, where
Ft L 2983.42 189.7
Fte = Effective tooth load= = = 3580 N
L  0.5b 189.7  0.5  63.2
 Fr = 3580  tan14.5  cos13.9 = 899 N
(9) Axial thrust on gear & radial load on pinion
Fa = Fte tan  sin d1 Eqn12.45e, Page 219
F = 3580  tan14.5 Drsin13.9
23-Feb-18 8:37 PM
a = 222.4
P R Venkatesh NRVCE
Mech Dept
25
Bangalore
Step 4: Check for dynamic & wear load :
K 3v(Cb  Ft )
(a) Dynamic load Fd = Ft  Eq12.40, Page 219
K 3v  Cb  Ft
where C = Dynamic load factor from T12.12 Page 236
For v=4.525m/sec, From Table 12.14, page 237,
tooth error e  0.0675 (Average value for v=4 & 5 m/sec)
From T 12.12, Page 236, for 14.50 system CI & Steel combination,
454.8
Dynamic load factor C=  0.0675 = 511.65 N / mm
0.06
K 3 = 20.67 for SI system of units (always), Here,b=63.2 mm
20.67  4.525  (511.65  50  2983.4)
 Fd = 2983.4 
20.67  4.525  (511.65  50  2983.4)
Dynamic load Fd = 2983.4 +10176.6 = 13160N
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 26
Bangalore
  d1bQe K 
(b) Wear load Fw =   Eq12.41 Page 219
 cos d1 
2 ze 2
Qe = Ratio factor = Eq12.41 Page 219
ze 2  ze1
2 103.83
Q = = 1.61, Also b=50 mm, d1 = 13.90
103.83  24.73
 120  50 1.61 K 
Fw =   = 9951.4K Newton
 cos13.9 
For safe design, Fw  Fd
i.e 9951.4K 13160  K 1.322
From T 12.16, Page 239, for 14.5 system & K=1.383(  1.17),
0

BHN for Pinion = 350, BHN for gear = 350

Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 27
Bangalore
 PROBLEM 2
Type 1 (Where number of teeth are given/Assumed)
Design a pair of bevel gears to transmit 12
KW at 300 rpm of the gear & 1470 rpm of
the pinion. The angle between the shaft
axes is 900. The pinion has 20 teeth and
the material for gears is cast steel
(d=183.33 N/mm2), BHN 320. Take service
factor as 1.25 and check the gears for wear
& dynamic load.
suggest suitable surface hardness for the
gear pair.
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 28
Bangalore
 Pitch Cone angle ( d )
For right angle between shaft axes,
1
tand1 = Eqn12.32a Page 217,
i
1470
Here i= = 4.9  z2 = iz1 = 4.9  20 = 98 teeth
300
1  1  1  1 
 Pitch angle of pinion δ1 = tan   = tan   =11.53 0

 
i  4. 9 
Also tand 2 = i Eqn12.32b Page 217
i.e. Pitch angle of gear=δ 2 = tan 1 (4.9) = 78.46 0
z1 20
Equivalent number of teeth on pinion z e1 = = = 20.4
cos d1 cos11.53
z2 98
Equivalent number of teeth on gear z e2 = = = 490
cos d 2 cos 78.46
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 29
Bangalore
Step 1 : To identify the weaker member :
As both the pinion & gear are made of same material,
the pinion is the weaker member.
 d 1 =  d 2 = 183.33Mpa
Lewis form factor for pinion & gear based on equivalent teeth
0.912
y1 = 0.154  Eqn12.5(d ), page 205 ( For 200 FDI system)
ze1
0.912 0.912
y1 = 0.154  = 0.1093 , Also y 2 = 0.154  = 0.152
20.4 490
 d 1 y1 (for Pinion)=183.33  0.1093=20.03
&  d 2 y2 (for Gear)=183.33  0.152=27.89
As  d 1 y1   d 2 y2 ,
Pinion is weaker. Hence Drdesign must be based on pinion.
P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 30
Bangalore
Step 2 : Beam strength or Load carrying capacity
(a) Tangential tooth load
1000  P  Cs
Ft = 12.7(a), Page 205
v
 d1 N1   m  z1  N1
Here, P=12 KW, v= =
60000 60000
  m  20 1470
v = = 1.5394m
60000
C s = 1.25, (given in the problem statement)
1000 12 1.25 9744
Substituting the above, Ft = = (1)
1.5394m m
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 31
Bangalore
 (b) Lewis equation :
 Lb 
Ft =  d Cv bYm   Eqn 12.37, Page 218
 L 
Here  d =  d 1 =183.33 Mpa, Y= y1 =   0.1094 = 0.3437
1 m m
Cone distance L= d1  d 2 =
2 2
z1  z2 =
2 2
202  982
2 2 2
L 50m
L = 50m , Face width b   16.67m
3 3
From eqn 12.3 6(d)page 173, b = 10m if L > 30m
Take b = 10m
L  b 50m  10m
Also = = 0.8.
L 50m
Substituting ,the above values,
Ft = 183.33  Cv 10m  0.3437  m  0.8
 F =
23-Feb-18 8:37t PM
504.08m 2
Cv (2)
Dr P R Venkatesh Mech Dept RVCE
32
Bangalore
Equating (1) & (2),
9744
= 504.08m 2Cv  m 3Cv =19.33 (3)
m
As the value of Cv is around 0.5, initial trial value of module is
m = 3 2  RHS = 3 2  19.33 = 3.38mm
From Table 12.24, page 242 (OR Table 12.2, page 229),
the preferred values are 3 mm & 4mm.
Taking m = 3mm , velocity v=1.5394  m =1.5394  3 =4.62 m/sec
6.1
Velocity factor Cv = Eqn12.38(b), Page 219 (Assuming generated teeth)
6.1  v
6.1
Cv = = 0.57  m 3Cv = 33  0.57 =15. 36 < 19.33 (required value)
6.1  4.62
 module of 3 mm is not satisfactory.
For m=4mm, v=1.5394  4=6.16m/sec, Cv = 0.498
 m 3Cv = 43  0.498 = 31.87 > 19.33 (required value)
Hence Selected module of 4 mm is satisfactory.
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 33
Bangalore
 Step 3 : Specification of Gears :
(1) Pitch diameter of pinion d1 = mz1 = 4  20 = 80mm
(2) Pitch diameter of gear d 2 = mz2 = 4  98 = 392mm
(2) Face width of gear b=10  m = 10  4 = 40mm
(3) Cone distance L=50m =50  4=200 mm
9744
(4) Tangential tooth load Ft = = 2436N
4
(4) Addendum h a , Dedendum h f
For 200 involute system, h a = 1m = 1 4 = 4 mm,
h f = 1.25 m = 1.25  4 = 5mm
(5) Outer dia of pinion d o1 = d1  2ha cos d1
d o1 = 80  (2  4  cos11.53) = 87.84mm
Outer dia of gear d o 2 = d 2  2ha cos d 2
d
23-Feb-18 8:37 PM o 2
= 392  (2 Dr4PR Venkatesh Mech Dept =
cos 78.46) 393.6 mm
RVCE
34
Bangalore
 Step 3 Continued
 2h sin d1 
(6) Addendum angle  a = tan 1  a  Eqn12.29(c), Page 215
 d 1 
1  2  4  sin11.53 
 a = tan   = 1.145 0

 80 
1 
2h f sin d1 
(7) Dedendum angle  d = tan   Eqn12.29( d ), Page 215
 d1 
 2  5  sin11.53 
 d = tan 1   = 1.430

 80 
(8) Radial load on gear & end thrust (axial load) on pinion
Fr = Fte tan  cos d1 Eqn12.45( d ), Page 219, where
Ft L 2436  200
Fte = Effective tooth load= = = 2707 N
L  0.5b 200  0.5  40
 Fr = 2707  tan 200  cos11.530 = 965.3 N
(9) Axial thrust on gear & radial load on pinion
Fa = Fte tan  sin d1 Eqn12.45(e), Page 219.
F = 2707  tan 200  sin11.53
23-Feb-18 8:37a PM = 197 N
0 Mech Dept RVCE
Dr P R Venkatesh
Bangalore
35
Step 4: Check for dynamic & wear load :
K 3v(Cb  Ft )
(a) Dynamic load Fd = Ft  Eq12.40, Page 219
K 3v  Cb  Ft
where C = Dynamic load factor from T 12.12 Page 236
For v = 6.16 m / sec , From Table 12.14, page 237,
tooth error e  0.059 (As 6.16m/sec  6m/sec)
From T 12.12, Page 236, for 200 FDI system Steel & Steel combination,
Dynamic load factor C= 686.7 N / mm (for e=0.06)
K 3 = 20.67 for SI system of units (always), Here,b=40 mm
20.67  6.16  (686.7  40  2436)
 Fd = 2436 
20.67  6.16  (686.7  40  2436)
Dynamic load Fd = 2436 +12681 = 15117N

Dr P R Venkatesh Mech Dept RVCE

23-Feb-18 8:37 PM 36
Bangalore
  d bQ K 
(b) Wear load Fw =  1 e  Eq 12.41 Page 219
 cos d1 
2 ze 2
Qe = Ratio factor = Eq12.41 Page 219
ze 2  ze1
2  490  es 2 sin  1 1 
Q = = 1.92, Also b=40 mm, d1 = 11.53 . K =
0
   12.15b, page208
490  20.4 1.4  E1 E2 
 es = 2.75( BHN )  70 12.15 d , page 208, Given BHN=320,
Surface endurance limit  es = 2.75(320)  70 = 810Mpa,
Elastic modulus E1 = E2 = 207Gpa = 207  103 Mpa (As both pinion & gear are of Steel)
810 
2
sin 200  1 1 
Load stress factor K=    = 1.55
1.4 10 3
 207 207 
 80  40 1.92  1.55 
Fw =   = 9719 Newton<Fd .
 
0
cos11.53
Hence design will be unsatisfactory from stand point of wear. Hence find 'K'
For safe design, Fw  Fd
i.e 6270.5K 15 117  K  2.4
From T 12.16, Page 239, for 200 system & K=3.226(  2.4),
BHN for Pinion = 450, BHN for gear Dr P R=Venkatesh
450 Mech Dept RVCE
23-Feb-18 8:37 PM 37
Bangalore
 PROBLEM 3
Type 2 (Where pitch diameter/velocity are given)
A pair of straight tooth bevel gears at right
angles is to transmit 5 KW at 1200 rpm of
the pinion. The diameter of the pinion is
80 mm & the velocity ratio is 3.5. The teeth
are 14.50 involute form. Both the pinion &
gear are made of Cast iron with an
allowable stress of 55 Mpa.
Determine the module, face width from
the standpoint of strength & also check the
design for dynamic & wear load.
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 38
Bangalore
 Pitch Cone angle ( d )
For right angle between shaft axes,
1
tand1 = Eqn12.32a Page 217,
i
Here i=3.5, d1 = 80mm  d 2 = i  d1 = 3.5  80 = 280mm
 1 
 Pitch angle of pinion δ1 = tan 1   =15.95 0

 3.5 
Also tand 2 = i Eqn12.32b Page 217,
i.e. Pitch angle of gear=δ 2 = tan 1 (3.5) = 74.05 0
z1 80 83.2
Equivalent number of teeth on pinion z e1 = = =
cos d1 m cos15.95 m
z2 280 1399.6
Equivalent number of teeth on gear z e2 = = =
cos d 2 m cos 78.46 m
 d
 z= 
 8:37 PM m 
23-Feb-18
Dr P R Venkatesh Mech Dept RVCE
Bangalore
39
Step 1 : To identify the weaker member :
As both the pinion & gear are made of same material,
the pinion is the weaker member.
Hence design must be based on pinion.
For 14.50 involute system, the Lewis form factor
for pinion based on equivalent number of teeth is
0.684
y1 = 0.124 
83.2 
m 
y1 = (0.124  8.22 103 m)
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 40
Bangalore
Step 2 : Beam strength or Load carrying capacity
(a) Tangential tooth load
1000  P  Cs
Ft = 12.7( a), Page 205
v
 d1 N1   80 1200
Here, P=5 KW, v= =
60000 60000
 Pitch line velocity v = 5.027 m / sec
C s = 1.0, (Assuming steady loads, 8-10 hrs/day service)
1000  5 1
Substituting the above, Ft = = 995 N (1)
5.027
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 41
Bangalore
(b) Lewis equation :
 Lb 
Ft =  d Cv bYm   Eqn 12.37, Page 218
 L 
Here  d =  d 1 =55 Mpa, Y= y1 =  y1 =  (0.124  8.22  103 m)
 Y=(0.3896-0.026m )
1 1
Cone distance L= d1  d 2 =
2 2
802  2802 = 145.6mm
2 2
L 145.6
Let face width b    48.3mm,say 48mm.
3 3
 L  b   145.6  48 
 =  = 0.67
 L   145.6 
6.1 6.1
Velocity factor C v = = = 0.548
6.1  v 6.1  5.027
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 42
Bangalore
Substituting ,the above values,
Ft = 55  0.548  48  (0.3896-0.026m )  m  0.67
 Ft = 377.64m  25.2m 2 (2)
Equating (1) & (2),
995 = 377.64m  25.2m 2
Solving, module m =3.41mm
From Table 12.24, page 242
(OR Table 12.2, page 229), the preferred value is 4 mm.
Take m = 4mm.

Dr P R Venkatesh Mech Dept RVCE

23-Feb-18 8:37 PM 43
Bangalore
Step 3 : Specification of Gears :
(1) Pitch diameter of pinion d1 = mz1
80  4  z1  Number of teeth on pinion= 20 teeth
(2) Pitch diameter of gear d 2 = mz2
 280 = 4  z2  Number of teeth on gear=70 teeth
(3) Addendum h a , Dedendum h f from Table 12.23, page 242
For 14.50 involute system, h a = 1m = 1 4 = 4 mm,
h f = 1.157 m = 1.157  4 = 4.63mm
(5) Outer dia of pinion d o1 = d1  2ha cos d1
d o1 = 80  (2  4  cos15.93) = 87.7 mm
Outer dia of gear d o 2 = d 2  2ha cos d 2
d o 2 = 280  (2  4  cos 74.05) = 282.2mm
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 44
Bangalore
 Step 3 Continued
 2h sin d1 
(6) Addendum angle  a = tan 1  a  Eqn 12.29 (c), Page 215
 d 1 
1  2  4  sin15.95 
 a = tan   = 1.57 0

 80 
1 
2h f sin d1 
(7) Dedendum angle  d = tan   Eqn 12.29 ( d ), Page 215
 d1 
 2  4.63  sin15.95 
 d = tan 1   = 1.82 0

 80 
(8) Radial load on gear & end thrust (axial load) on pinion
Fr = Fte tan  cos d1 Eqn 12.45( d ), Page 219, where
Ft L 995 145.6
Fte = Effective tooth load= = = 1191.4 N
L  0.5b 145.6  0.5  48
 Fr = 1191.4  tan14.50  cos15.950 = 296.25 N
(9) Axial thrust on gear & radial load on pinion
Fa = Fte tan  sin d1 Eqn 12.45(e), Page 219
F = 1191.4  tan14.50 Drsin15.95
23-Feb-18 8:37
a PM =
P R Venkatesh0Mech
Bangalore
Dept RVCE
84.67 N 45
Step 4: Check for dynamic & wear load :
K 3v(Cb  Ft )
(a) Dynamic load Fd = Ft  Eq 12.40, Page 219
K 3v  Cb  Ft
where C = Dynamic load factor from T12.12 Page 236
For v=5.027  5m/sec, From Table 12.14, page 235,
tooth error e  0.064
From T 12.12, Page 236, for 14.50 system CI & CI combination,
331.3
Dynamic load factor C=  0.064 = 353.4 N / mm
0.06
K 3 = 20.67 for SI system of units (always), Here,b=48 mm
20.67  5.027  (353.4  48  995)
 Fd = 995 
20.67  5.027  (353.4  48  995)
Dynamic load Fd = 995 + 7843.1 = 8838.1N

Dr P R Venkatesh Mech Dept RVCE

23-Feb-18 8:37 PM 46
Bangalore
  d1bQe K 
(b) Wear load Fw =   Eq12.41 Page 219
 cos d1 
2 ze 2
Qe = Ratio factor = Eq12.41 Page 219
ze 2  ze1
z1 20 z2 70
z e1 = = = 20.8, z e 2 = = = 254.73
cos d1 cos15.950
cos d 2 cos 74.05 0

2  254.73
Q = = 1.85, Also b=48 mm, d1 = 15.950.
254.73  20.8
 80  48 1.85  K 
Fw =   = 7388 K Newton
 
0
cos15.95
Hence design will be unsatisfactory from stand point of wear. Hence find 'K'
For safe design, Fw  Fd
i.e 7388 K  8838.1  K 1.2
From T12.16, Page 239, for 14.50 system & K=1.275(  1.2),
BHN for Pinion = 400, BHN for gear = 300
Dr P R Venkatesh Mech Dept RVCE
23-Feb-18 8:37 PM 47
Bangalore