Gears (cont.

)
Overview
Week 4
Gear General
Involute gears
Spur, helical, bevel, worm gears
Forces Analysis on gears
Gear Trains
Week 5 (this week)
Modes of Gear Failure
AGMA Method for Bending Stress in Spur Gears
AGMA Method for Surface Stress in Spur Gears

1
 The Lewis Bending Eq.
In 1892, Wilfred Lewis developed an equation for estimating the bending
stress in gear teeth.

His method for analyzing a tooth as a cantilever beam accounts for the
form of the tooth, as well as the size of the tooth.

M
W t
b =
I /c

Ft 3 t
t M = W tl I= c=
12 2
l

F 6W t l
b =
Ft 2
2

2
 The Lewis Bending Eq.
W Wt l

6W t l
b =
Ft 2
t
Wr
t 2 x t2 x
= = 4x
l t 2 l

Wt
b = 2 rf

3 Fx

Wt Wt Wt W tP
b = 2 = = =
( 3 x p ) Fp Fpy F (y ) p FY 3

3
 The Lewis Bending Eq.
U.S. customary units SI units
W Wt l
t t
W P W
b = b =
FY FmY

b , bending stress
Wt , tangential component of the force on the gear
P , diametral pitch of the gear t
F , face width Wr
Y , LEWIS FORM FACTOR (dimensionless)
x
U.S. customary units SI units

K W tP K vW t
b = v b =
FY FmY
Kv , DYNAMIC FACTOR (dimensionless) rf

See equations 14-4a to 14-6d

Note:
The Lewis Equation is not commonly used anymore in its original form.
Lewis does not account for dynamic effects
Carl G. Barth added a velocity factor, known as the Lewis Formula Barth Revision 4

4
 The AGMA Stress Eqs.
Bending Stress:

P KmKBKI
b = W tKoKvKs (U.S. customary units)
F J

1 KmKBKI
b = W tKoKvKs (SI units)
bm t YJ

W t: tangential transmitted load

Ko: overload factor
Kv: dynamic factor
Ks: size factor
P: transverse diameteral pitch
Km (KH): load-distribution factor
Kb: rim-thickness factor
J(YJ): geometry factor (includes root fillet stress-concentration factor Kf)
KI: Idler factor
Mt: transverse metric module
5

5
 The Lewis Bending Eq.

AGMA Standard 2001-B88 is valid only when some

assumptions are made:

1) The contact ratio is between 1 and 2 (external teeth ONLY)

2) There is no interference between the tip and root fillets of
mating teeth, and no undercutting of teeth above the
theoretical start of the active profile
3) No teeth are pointed
4) There is non-zero backlash
5) The root fillets are standard, assumed smooth, and produced
by a generating process
6) The friction forces are neglected

6
 Overload Factor
Factors
KoK :Overload
overloadfactor (Application Factor in Norton)
factor
o

To
Kvdeal with time
: dynamic varying or shock loading
factor
Depends on driving and driven machinery
Ks: size factor
Can be looked up in Norton Table 11-17
Km (KH): load-distribution factor
Kb: rim-thickness factor
J(YJ): geometry factor
Cp (ZE): elastic coefficient
Cf (ZR): surface condition factor
I(ZI): geometry factor for contact stress
7

7
 Dynamic Factor
Factors
Kv Dynamic factor
Ko: overload factor
Accounts for internal
Kv: dynamic factorvibration (called transmission errors)
due to errors in Gear Profile
Ks: size factor
Can be looked up in Shigley Figure 14-9
Km (KH): load-distribution factor
B
A+ V
KKb=: rim-thickness
v A
Vfactor
in ft/min

J(YJ): geometry B factor
A + 200V
K = V in m/s
coefficient
Cvp (Z
E): elastic
A

AC=f50
(Z+R): 1 B)
56(surface condition
Qv factor
Quality index number
or
= 0I.):
BI(Z (12 Qv ) 3
25geometry factor fortransmission
contact stress
2

accuracy-level number
8

8
 Dynamic Factor
Qv Transmission accuracy-level number (Quality Index Numbers)
Determined by manufacturing technique

Table 11-6
Recommended AGMA Gear Quality Index Numbers
for Various Applications
Application Qv
Cement mixer drum
3-5 Gas meter mechanism 7-9
driver
Cement kiln 5-6 Small power drill 7-9
Clothes washing
Steel mill drivers 5-6 8-10
machine
Corn picker 5-7 Printing press 9-11
Cranes 5-7 Computing mechanism 10-11
Punch press 5-7 Radar antenna drive 10-12
Marin propulsion
Mining conveyor 5-7 10-12
drive Norton 2nd Edition
Paper-box making
6-8 Aircraft engine drive 10-13
machine

9
Dynamic Factor

Shigley
Figure 14-9

10

10
 Size Factor
Factors
KKso: Size
overload
factorfactor
Kv: dynamic factor
KTo: account for the test specimen being smaller than the
s size factor
designed gear
Km (KH): load-distribution factor
AGMA has not yet dealt with this
Kb: rim-thickness factor
KS = 1
J(YJ): geometry factor
If your gear is very large, KS = 1.25 or 1.5
Cp (ZE): elastic coefficient
Cf (ZR): surface condition factor
I(ZI): geometry factor for contact stress
11

11
Load Distribution
Factors Factor
KKmo(K
: overload factor
H) Load distribution factor

KAccounts
v: dynamic factorload distribution over face width
for uneven
KNorton
: sizeTable 11-16
factor
s

Km (KH): load-distribution factor

NOTE: Recommended
Kb: rim-thickness factor
8/pd < F <16/pd
J(YJ): geometry factor
Cp (ZE): elastic coefficient
Cf (ZR): surface condition factor
I(ZI): geometry factor for contact stress
12

12
 Rim-Thickness
Factors Factor
KB Rim-Thickness
Ko: overloadfactor
factor
Kv: for
Accounts dynamic
Gear notfactor
being a solid disc
Back-up ratio, (must be at least 0.5)
Ks: size factor
tR
mB =
htm (KH): load-distribution factor
K
2.242
K : rim-thickness
K B = 1.b6 ln mB <factor
1 .2
m
J(YJ): geometry
B factor
B 1 .2
K B = 1C.0 (Z ): elasticmcoefficient
p E

Cf (ZR): surface condition factor

I(ZI): geometry factor for contact stress
13

13
Rim-Thickness Factor

Figure 14-16
14

14
 Geometry Factor
Factors
J (YJ)
KoBending-Strength
: overload factorGeometry factor
(AGMA Standard 908-B89)
Kv: dynamic factor
HPSTC (Highest Point of Single Tooth Contact)
Ks: sizeGears,
High Precision factorCan assume load sharing between teeth
K (K ): load-distribution factor
Single m
ToothH carries load at tooth tip worst possible case
Kb: rim-thickness factor
J can be
J(Ylooked up in Figure 14-6 (spur gears, a=20o, full-depth)
J): geometry factor

Cp (ZE): elastic coefficient

Cf (ZR): surface condition factor
I(ZI): geometry factor for contact stress
15

15
 Geometry Factor
Factors
J (YJ) Bending-Strength Geometry factor
(AGMA Standard 908-B89)

16

16
 Idler Factor
KI Idler Factor (Not included in Shigley)
(for bending stress)

Idler Gears experience larger stress amplitudes,

and usually 2x more cycles

KI = 1.42, when gear is an idler or meshes with more than one gear

KI = 1.0 otherwise

17

17