Indian Journal of Science and Technology

Supplementary Article

Evolution of Dynamic Loads in Steel Spur Gears

S. Amaldhasan1* and S. PonPaul2
1,2

Department of Mechanical Engineering, Bharath Institute of Science and Technology, Bharath University,
Chennai-600073, Tamilnadu; amal_as@rediffmail.com1, ponpaul_ranjith@yahoo.com2

Abstract
The Complete study of Literature and reporting on how Spur gears are designed using steel-steel alloys and dynamic load
is calculated for the spur gears. The analytical model is developed to simulate the load sharing characteristics through
a mesh cycle. The model takes into account the main internal factors of dynamic load as time-varying mesh stiffness and
composite tooth profile errors. Comparative different types of dynamic load processors study are included, which shows
the different processors of the dynamic load. Pro Eis an interactive CAD/CAM system, a fully 3-D double precession system
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to create and edit complex solid models interactively. MSC Nastran is a powerful general purpose, Finite element analysis
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provides a wide range of analysis capabilities including linear, statics, dynamic, displacement, strain, stress, vibration,
heat transfer and more. Nastran can handle any material type from plastic and metal to composites and hyper elastic
materials.

Keywords: Pro E, MSC Nastran, Spur Gears.

1. Introduction
Any toothed member designed to transmit motion to
another one, or received motion from it, by means of successively engaging tooth is called a (toothed) gear. Gears
are a means of changing the rate of rotation of a machinery
shaft. They can also change the direction of the axis of rotation and can change rotary motion to linear motion. Gears
are of several categories and can be combined in a multitude of ways, some of which are meshing circular spur
gears, rack and pinion spur gears, and worm gears. Helical
and herringbone gears utilize curved teeth for efficient,
high-capacity power transmission. Worm gears, driven by
worms transmit motion between non-intersecting rightangle axes. Gears mate or mesh via teeth with a very specific

geometry. Gears are used for two basic purposes; increase

or decrease of rotation speed and increase or decrease of
power or torque. Torque is a measure of a force to produce
torsion and rotation about an axis. To increase speed and
reduce torque a large drive gear is coupled to a smaller
driven gear.

1.1 Gear Manufacturing Materials

Mild steel is a poor material for gears as it has poor resistance to surface loading. The carbon content for unhardened
gears is generally 0.4 %(min) with 0.55 %(min) carbon for
the pinions. Dissimilar materials should be used for the
meshing gears - this particularly applies to alloy steels. Alloy
steels have superior fatigue properties compared to carbon

*Corresponding author:
S. Amaldhasan (amal_as@rediffmail.com)

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Evolution of Dynamic Loads in Steel Spur Gears

steels for comparable strengths. For extremely high gear

loading case hardened steels are used the surface hardening
method employed should be such to provide sufficient case
depth for the final grinding process used. While selecting a
gear material depends on its cost, strength, wear resistance,
noise level etc. has to be compromised. Materials such as
ferrous metals Non-Ferrous metals, Non metals.

1.2 Law of Gearing

In order for two meshing gearing to maintain a constant
angular velocity ratio, they must satisfy the fundamental law of gearing. The shape of the teeth of a gear must
be such that the common normal at the point of contact
between two teeth must always pass through a fixed point
on the line of centers. Conjugate action on spur gears: - The
gear-tooth profile that will transmit through each other
uniform rotary motion. The action between such teeth is
called conjugate gear-tooth action

2. Literature Review
The principal advances in the engineering of gears have
been in measurement, inspection and manufacturing
techniques. These, and a new lubrication theory, have
contributed to the improved performance required from
modern high-speed transmissions. Unfortunately, gear case
design has not kept up with the design of gears themselves
[1]. In a theoretical analysis of a single pair of high-class
gears three internal sources of vibration are considered.
Dynamic tooth forces and amplitudes of vibration were
found from photo-elastic stress patterns of model gears
with both small and large errors [2]. Spur gear tooth force
analysis, Spur gear - tooth stresses, Tooth bending stress
Lewis equation, Tooth bending stress AGMA procedure,
Bending fatigue strength AGMA procedure, Permissible
bending stress, Buckingham equation for dynamic load on
gears [3]. The model takes into account the main internal
factors of dynamic load as time- varying mesh stiffness and
composite tooth profile errors. The complicated phenomenon of contact tooth pairs alternation during mesh cycle
is integrated in this dynamic load modeling [4].

3. Spur Gear Design

The formulae and parameters are used from a Hand Book
of Gear Design by G.M.Maitra and Machine Design Data
Book P.S.G. College of Technology.

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3.1 Dimensions for Standard Spur Gear

Pitch circle diameter for pinion, d1 = m*z1 mm
Pitch circle diameter for Gear, d2 = m*z2 mm
Base circle diameter for Pinion, db1 = d1*cos mm
Base circle diameter for Gear, db2 = d2*cos mm
Tip circle diameter for pinion, da1 = d1 + 2m mm
Tip circle diameter for gear, da2 = d2 + 2m mm
Root circle diameter for pinion, df1 = d1 2*1.25 mm
Root circle diameter for gear, df2 = d2 2*1.25 mm
Tooth thickness on pitch circle, S = m/2 mm
Clearance c = 0.25mm
Centre distance, a = (d1 + d2)/2 or m (z1+z2)/2
Total Depth, h = 2.25*m mm
Circular pitch, p = m mm
Face width, b = 3**m mm
Ratio of gear width to center distance y = b/a
Gear ratio i = z1/z2 = n1/n2 = 1/2
Module m = d/z mm
Diametral pitch pd = z/d or 1/m
Power P = 2 n1 Mt/60 KW
Gear life L = 60n1LH revolutions
Pinion Torque Mt = P*60/(2 n1) N mm

3.2 Design Bending Stress

b
b
kbl
k
-1
n

= (1.4 kbl -1) /(n k).for rotation in one direction

= (kbl -1) /(n k).for rotation in both directions
= life factor
= fillet stress concentration factor
= endurance limit in reversed bending
= factor of safety,

3.3 Induced Bending Stress

b =
[Mt]
Y is form factor taken from Ref

3.4 Design Torque

[Mt] = k0* k * kd * Mt
k0 = shock loading condition
k = load concentration factor
kd = dynamic load factor
Mt = pinion Torque

3.5 Design Contact Stress

[c]=CB*HB*Kcl
[c]=CR*HRC*Kcl

N/mm2
N/mm2

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S. Amaldhasan and S. PonPaul

where, CB or CR coefficient depending on the surface hardness, Table 3.1

HB or HRC-Brinell or Rockwell hardness number.
Kcl life factor,

3.6 Induced Contact Stress

c = 0.74
E Equivalent Youngs modulus = 2 E1 E2/(E1 + E2)
Pitch line velocity V = d1 n1/60

200 Full Depth Involute

200 Stub Involute

M
1.25m

0.8m
M

2.25m
0.25m

1.8m
0.2m

Table 3.2. Stress Concentration Factor for Fillet, K

Material and Heat Treatment

steel, normalised, surface hardened

steel, case hardened (low carbon steels)

1.5
1.2

cast iron

1.2

Mode of
Manufacture

Heat Treatment

Steel Cast
Iron

Cast

Steel

Cast or forged
Forged

No heat treatment
tempered or
normalised
Case hardened
Surface hardened
Normalised

Factor of
Safety, n
2.5
2.0
2.0
2.5
2.0

Table 3.4. Life Factor For Surface (Contact Compressive)

Strength, Kcl
Material

Surface
Hardness
HB

Life In
Number Of
Cycles, N

Life Factor
Kcl

Steel

350

10 7
<10 7

1
6
(107/N)

Carbon

>350

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25*107
<25*107

0.585
6
(107/N)
(107/N)

K0

Steady
Light shock
Medium shock
Heavy shock

1.0
1.25
1.5
2.0

yp = b/d1

0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6

Bearing Close
Asymmetrical
Over
To Gear And
Hung
Very Rigid Less Rigid
Symmetrical
Pinion
Shaft
Shaft
1
1
1.03
1.06
1.1
1.14
1.19
1.25

1
1.04
1.08
1.13
1.18
1.23
1.29
1.35

1.05
1.1
1.16
1.22
1.29
1.36
1.45
1.55

1.15
1.22
1.32
1.45
_
_
_
_

Table 3.7. Form Factor, y

Table 3.3. Factor of Safety, N

Material

Type of load

Table 3.6. Load Concentration Factor, k for

Cylindrical Gears

Table 3.1. Proportions of Standard Gear Teeth

Addendum
Minimum
dedendum
Whole depth
Clearance

Table 3.5. Shock Factor, K0

12
14
16
18
20
22
24
26
28
30

0.308
0.330
0.355
0.377
0.389
0.402
0.414
0.427
0.434
0.440

35
40
45
50
60
80
100
150
300
Rack

0.452
0.465
0.471
0.477
0.490
0.499
0.505
0.515
0.521
0.550

Table 3.8. Width to Centre Distance Ratio

Type of gear transmission
Open type of gearing
Speed reducers (closed type)
a) High speed 8 to 25 m/s
b) Medium speed 3 to 8 m/s
c) Low speed 1 to 3 m/s
Gear boxes with sliding gears

y =b/a
0.1 to 0.3
up to 0.3
up to 0.6
up to 1.0
0.12 to 0.15

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Evolution of Dynamic Loads in Steel Spur Gears

Table 3.9. Allowable Peripheral Speed of Gears

IS quality Preferred
quality

High
precision
Precision
Medium
Coarse

Speed of gears in m/s

Cylindrical
gears

Straight bevel
gears

3&4

Above 15

Upto 9

5&6
7,8,& 9
10 & 12

6
8
10,12

8-15
1-8
Upto 1

Upto 6
Upto 3
Upto 2

4. Design Calculation
Standard gear teeth-200 stub involute
Material
= Steel
Poissons Ratio
= 0.27 to 0.30
Youngs Modulus E = 2.1*105 N/mm2
Module
m = 10
Speed of pinion n1 = 1800 rpm
Gear ratio
i = 1:3
Pinion no. of teeth Z1 = 16
Life of teeth
LH= 20000 hr
Pressure angle () = 200
Power
P = 18 KW

Calculation :Speed of gear n2 = 1800/3= 600 rpm

Gear no. of teeth Z2 = 12*3 = 36
Pitch circle diameter for pinion,
d1 = m*z1 = 10*12 = 120 mm
Pitch circle diameter for Gear,
d2 = m*z2 =10*36 = 360 mm
Center distance of gear & pinion
a = (z2+z1)m/2 = (36+12)10/2 = 240 mm
Base circle diameter for Pinion,
db1 = d1*cos =120*cos200 =112.76 mm
Base circle diameter for Gear,
db2 = d2*cos = 360*cos200 = 338.3 mm
Tip circle diameter for pinion,
da1 = d1 + 2m =120+2*10 = 140 mm
Tip circle diameter for gear,
da2 = d2 + 2m=360+2*10 = 380 mm
Root circle diameter for pinion,
df1 = d1 2*1.25m = 120-2*1.25*10 = 95 mm
Root circle diameter for gear,
df2 = d2 2*1.25m = 360-2*1.25*10 = 335 mm

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Tooth thickness on pitch circle,

S = m/2=*10/2=15.71 mm
Clearance c = 0.25m =0.25*10=2.5 mm
Total Depth, h = 2.25*m=2.25*10=22.5 mm
Circular pitch, p = m= *10=3.14*10=31.4 mm
Face width, b = 3**m =3**10=94.25 mm
Diametrical pitch pd = z/d or 1/m =1/10=0.1
Pitch line velocity
V = *d1*n1/(60*1000)=11.31 m/sec
Ratio of gear width to center distance y = b/a =0.3
Face width b = y*a=0.3*240=72 mm
Pinion life L = 60 n1LH = 60*1800*20000

= 2160000000 revolutions

= 216*107 rev.
Pinion Torque
Mt = P*60 / (2 n1) = 10000*60/(2*3.14*1800)
= 95.5 N m

a) Pinion
1. Material : Case hardening steel is used. Assume surface
hardness 55 RC and core hardness greater than 350 BHN.
(Table 3.6, Table 3.9)
Design stresses
Design bending stress b =
-1
-1 = 0.25( u+y)+50 (for cast steel)
y=879 N/mm2
-1=0.25 (1050+879)+50=532.25 N/mm2
n = 2.5 (for surface hardened steel)
K=1.5 (for surface hardened steel)
For steel, surface hardness >350 BHN, core hardness > 350
BHN and life
N is 25*10 7, Kbl=0.7
b =
-1
= (1.4*0.7*532.25) / (2.5*1.5) = 139.1N/mm2
Design Contact Stress [c]
[c] =CR*HRC*Kcl N/mm2
For surface hardened alloy steel CR=23
For steel with surface hardness > 350 BHN and N 25 * 107,
Kcl = 0.585
Therefore,
[c] = 23*55*0.585 = 740.025 N/mm2
Design Torque [Mt]
[Mt] = k0* k * kd * Mt
where,
K0= 1.5 for medium shock
yP= b/d1 = 72/120 = 0.6

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S. Amaldhasan and S. PonPaul

Assume IS quality 6 gears (Table 3.2), for pitch line velocity 11.31 m/s.
k = 1.03
kd = 1.3
[Mt]=1.5*1.03*1.3*53.08=191.79Nm
To Calculate The Induced Stresses
b =
[Mt]
Form factor for z1 = 16, y=0.355 (Table). For stud tooth,
Y = 0.355/0.6 =0.592)
b = [(3+1)(191.79*1000)]/(240*10*72*0.592)=7.5 N/mm2
b = 7.5 N/mm2 < [b] =139.1 N/mm2
c = 0.74
c = 0.74 ((3+1)/240)[((3+1)/(3*72))(2.1*105 *191.79*103)]
c = 336.83N/mm2
c = 336.83 N/mm2 < [c] = 740.025 N/mm2
The design is satisfactory.

b) Gear
Gear life L = 60*600*20000 = 720000000 rev.

= 72*107 rev.
Gear Torque Mt = P*60/(2 n2) = 286.48 Nm
Material : CS 85, case hardness 55 RC and core hardness
greater than 350 BHN.
Design stresses
Design bending stress b =
-1
-1= 0.22( u+ y)+50 (for cast steel)
u = 850 N/mm2
y = 710 N/mm2
-1 = 0.22 (850+710)+50=393.2 N/mm2
n = 2.0 (for case hardened steel)
K = 1.2 (for case hardened steel)
For steel, surface hardness >350 BHN, core hardness > 350
BHN and life
N is 25*10 7, Kbl=0.7
b =
-1
= (1.4*0.7*393.2) / (2.0*1.2) = 160.556 N/mm2
Design Contact Stress [c]
[c] = CR*HRC*Kcl N/mm2
For case hardened alloy steel CR=28
For steel with surface hardness > 350 BHN and N 25*107,
Kcl = 0.585
Therefore,
[c] = 28*55*0.585 = 900.9 N/mm2
Design Torque [Mt]
[Mt] = k0* k * kd * Mt
Where,
K0= 1.5 for medium shock

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yP = b/d1 = 72/360 = 0.2

assume IS quality 6 gears (Table 1.21), for pitch line velocity 11.31 m/s.
k = 1.0
kd = 1.3
[Mt]=1.5*1.0*1.3*286.48=558.636 Nm
To Calculate The Induced Stresses
b =
[Mt]
(Form factor for z1 = 48, y=0.475 (Table For stud tooth,
Y= 0.475/0.2 =2.375)
b = [(3+1)(558.636*1000)]/(240*10*72*2.375)

= 5.445 N/mm2
b = 5.445 N/mm2 < [b] =160.556 N/mm2
c = 0.74
c = 0.74 ((3+1)/240)[((3+1)/(3*72)) (2.1*105 *558.636*103)]
c = 574.854 N/mm2
c = 574.854 N/mm2 < [c] = 901 N/mm2
The design is satisfactory.

5. Dynamic Load
The level of vibration and noise of the gear pairs is in correlation with the characteristics of dynamic load. Calculation
of dynamic loads and determination of their variation during a mesh cycle for spur gears pairs has been considered a
major aspect of gear design. An analytical model that covers the main influence factors with sufficient accuracy is
not currently available.
This paper presents an analytical approach used in
order to predict the characteristics of dynamic loads by
considering the time-varying mesh stiffness and variable
tooth profile errors. The calculus procedure of the mesh
stiffness is found by using an exact analytical model.

5.1 Dynamic Load Procedure

Dynamic load
Fd =

)...

eq.1

Here e is the sum of the errors, inches, of the two mating

teeth, t is the time, seconds, during which the error is acting, k is the spring constant, pounds per inch, of the two
mating teeth, and me is the effective mass, lb sec2/in., of the
two gears.
Time t for the passage of a single pitch, then is
t = 60/(n1N1) sec
eq.2
Spring Constant and Effective Mass

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Evolution of Dynamic Loads in Steel Spur Gears

K = b/9 [(E1E2)/(E1+E2)].
eq.3
Where E1 and E2 are the module of elasticity for the materials of the two gears.
When both gear & pinion are steel, E1 = E2 =30,000,000 psi,
= 2.1*105 N/mm2 the value of k for a meshing pair becomes
K=1,670,000b lb/in. = 11500b N/mm
When one gear is steel, E1=30,000,000 psi and the other gear
is cast iron or bronze, E2 = 16,000,000 psi, = 1.1*105 N/mm2
K =1,160,000b lb/in. = 8000b N/mm
b = width of face of the gears.
The moment of inertia of a gear can be found by approximating it as a solid circular cylinder of diameter equal to
the pitch diameter of the gear, and axial length equal to the
face width of the teeth. The mass moment of inertia I, fig.31(a), then is
I = m (r2/2)
Where m is the mass, with dimensions of lb sec2 /in. as
found from Newtons second law of motion,
mass = force/acceleration. Mass is thus equal to the weight
divided by the gravitational constant g .
A concentrated mass m, located at the pitch circle, has a
moment of inertia I about the axis of
I = m r2
Suppose m were of such size as to make I and I equal.
Then
m = m*1/2
The dynamical system of the two gears is considered as the
masses m1 and m2
Concentrated at the pitch circles connected by a spring
comprising the two teeth. For Such a system, the effective
mass me is given by the following equation.
1/me = 1/m1 + 1/m2.
eq. 4
Mass m1 of the pinion is equal to
m1 = m1(1/2) = ( r12 b 1)/ (2g) ..
eq.5
where 1 is the weight per cubic inch of the material.
Mass m2 of the gear is given by a similar equation.
m2 = m2(1/2) = ( r22 b 2)/ (2g)
eq.6
where 2 is the weight per cubic inch of the material composing the gear.
Substitution into Eq.1 gives
1/me = 2g/( b) [(1/ (r12 1))+(1/( r22 b 2))]

eq.7

5.2 Design Equations for Dynamic Load

steel pinion steel gear .here 1 = 2 =0.283 lb/in.3 =
0.0000768 N/mm3 and acceleration g due to gravity is taken
as 386 in./sec2. = 9806.6 mm/sec2 Equation (7) becomes

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1/me =

((1/r12) + (1/r22) )

=
((r12 + r22)/(r12 r22)) mm/N sec2
At all values substitute in eq.1
Fd =
)
e
= (e*n1*N1*b*r1*r2)/(2520(r12 + r22)) Newtons
Steel pinion cast iron gear . hear 1 = 0.283 lb/in3, and 2 =
0.256 lb/in.3 or 0.0000695 N/mm3
1/me = (2g / b2) ((r12 + (2 / 1) r22)/(r12 r22))
=
((r12 + 0.9r22)/(r12 r22) )
At all values substitute in eq.1
Fd =
)
e
= (e*n1*N1*b*r1*r2)/( 3180(r12 + 0.9r22)) N

5.3 Dynamic Load

a) Process 1
Dynamic Load
Fd =
)
e
= (e*n1*N1*b*r1*r2 )/(2520(r12 + r22)) (N=z no. of teeth)
e = 0.0048+0.0050=0.0098 in. = 0.2489mm
(1 in = 25.4 mm)
Fd = 0.2489*1800*16*72*60*180/ (2520 (602 *+1802))
= 11657.9 N
Fw = d1bQK
Where, d1 = 120mm, b = 72mm
Q = 2z2 / (z1 +z2)
= 2*48 / (16+48) = 1.5
K = 651psi = 4.48842N/mm2
Fw = 120*72*1.5*4.48842
= 58.1699 KN
Ft = Fw- Fd
= 58.1699-11.679
= 46.4909 KN

b) Process 2
Buckinghams Dynamic Load
Fd = Ft +[0.164 Vm (c*b + Ft)/[0.164 Vm + 1.486(c*b+Ft)]]
Where, vm = pitch line velocity, =11.31m/s or 678.6 m/min
Vm = 678.6 m/min
b = face width = 72mm = 0.072 m
c = factor depending on machining error = 12300e
= 12300*0.03 = 369
Ft = transmitted load, kgf
Ft = HP*75/vm
= 24.14*75/11.31

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S. Amaldhasan and S. PonPaul

P = 24.14 HP
= 160.08 kgf or 1570.4 N
Fd = 160.08 + [0.164*678.6 [369*0.072+160.08]/[0.164*
678.6 + 1.486[369*0.072 + 160.08]]]
= 160.08+[20988.5/131.6]
= 319 kgf or 3134.95 N
= 3.135 KN

c) Process 3

6. Conclusions
Design of spur gears using steel-steel alloys is done and the
dynamic loads on spur gears are calculated by using complete study of literature and reporting.

6_5_30.indd 4595

In phase -2 the design of spur gears using Sintered

materials is yet to be done. The dynamic load characteristic
is to be calculated manually then the model is created in
CAD softwares.
An analytical investigation of the dynamic loads fluctuation in spur gears is presented. The dynamic model
permits to predict the individual tooth load characteristics
during the meshing cycle.

7. References

Lewis Equation of dynamic load

Fd = Ft* Cv
Ft = HP*75/ vm
vm = 11.31 m/s
P = 24.14 hp
Cv =(6+vm)/6
= (6+11.31)/6 = 2.885
Ft = 24.14*75/11.31
= 160.08 kgf
Fd = 160.08*2.885
= 461.831 kgf
= 4530.6 N or 4.531 KN

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4595

1. Winter H. (1961). Gear Tooth Strength of Spur Gears, British

Gear Manufacturers Association.
2. A.S.M.E (1931). Dynamic Loads on Gear Teeth.
3. http://nptel.iitm.ac.in/courses/IIT-MADRAS/Machine_
Design_II/pdf/2_7.pdf
4. Vedmar L, Henriksson B (1998). A general approach for
determining dynamic forces in Spur gears, Journal of Mechanical
Design, Transaction of the ASME, 593598.
5. Prabhu T J (2005). Design of Transmission Elements,
6. Maitra G M (1989). Handbook of Gear Design,140
7. Lingaiah K (2007). Machine Design Data Handbook, vol 1.
8. P.S.G. College of Technology (1988). Design Data Book.
9. Merrit H E (1992). Gear Engineering, 15-53,90 Dr. Ulrich
Kissling, Effects of Profile corrections on peak to peak
transmission error, Gear Technology.
10.Kiss Soft (2008). Gear Optimizing with advanced calculation method. www.kisssoft.ch/english/downloads/pdf/Gear_
Optimizing

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