MACHINE DESIGN (2171909)

1.1 Introduction
 Any toothed member designed to transmit motion to another one, or receive
motion from it, by means of successively engaging tooth is called a (toothed)
gear.
 A gear is a toothed wheel with teeth cut on the periphery of a cylinder or a
cone.
 Teeth of one gear meshes with teeth of the other gear, hence it is called a
mesh drive or positive drive.
 It is preferred when medium or larger power is to be transmitted.
 Rotation of one gear will cause rotation of the other in the opposite direction.
 Fig. 1.1 shows two spur gears in mesh, the smaller gear is called the pinion and

the bigger one the gear wheel.

Fig. 1.1 Spur Gears in Mesh

1.1.1 ADVANTAGES OF GEARS
Gears offer the following advantages:
I. Compact drive on account of small centre distance.
II. High efficiency, reliable service and simple operation.
III. Positive drive due to negligible slip between contacting surfaces.
IV. Give higher speed ratio and can transmit higher power.
V. It is possible to transmit power between parallel, non-parallel, intersecting,
and nonintersecting shafts.
VI. Power can be transmitted at higher speeds.
1.1.2 LIMITATIONS OF GEARS
The limitations of gear drive are:
I. The error in tooth meshing may cause undesirable vibrations and noise
during operation.
II. Costlier than belts and chain drives.

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 III. Power cannot be transmitted over long distances.
IV. Precise alignment of shafts is required.
V. Require continuous lubrication.
1.1.3 APPLICATIONS OF GEARS
The gear drive has wide applications in the following fields:
I. Metal cutting machine tools
II. Automobiles
III. Tractors
IV. Hoisting and transporting machinery
V. Rolling mills
VI. Marine engines, etc.
Table 1.1 indicates the most useful fields of application of the main classes of
gears.
Table 1.1 Choice of Type of Gear

1.1.4 CLASSIFICATION OF GEARS

Fig.1.2 CLASSIFICATION OF GEARS

Gears may be classified as shown in Fig. 1.2.
 A spur gear is a cylindrical gear whose tooth traces are straight line
generators of the reference cylinder.

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  In helical gears the tooth traces are helices.
 A cylindrical gear in which a part of the face width is right hand and the other
left hand, with or without a gap between them is called a double helical or
herring-bone gear.
 The various types of gears are shown in Fig. 1.3.

(i) Spur Gears (ii) Helical Gears

(iii) Double Helical (Herringbone) Gears (iv) Spur Rack and Pinion (v) Crossed Helical Gears

(a) Bevel Gears (b) Spiral Bevel Gears (c) Zerol Bevel Gears
(vi) Bevel Gears

(vi) Worm Gears (viii) Hypoid Gears

Fig. 1.3 Types of gears

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 1. GEAR DESIGN

 In spiral gears the tooth traces are curved lines other than helices.
 A gear pair (or train comprising such gears) one of whose axes, instead of
being fixed in position in the mechanism of which the gear pair is a part,
moves around the other is called planetary gear train.
 In bevel gears the reference surface is a cone. The bevel gears may be
straight, spiral, zerol and face gears. In zerol bevel gears the teeth are
curved in the lengthwise direction and are arranged in such a manner that
the effective spiral angle is zero. In face gears, the teeth are cut on the flat
face of the blank. They mesh at right angles with spur or helical pinions.
 A crown gear is a bevel gear with a reference cone angle of 90⁰.
 The hypoid gears are similar to the spiral bevel gears with the difference that
the axes of the shafts do not intersect.
 In worm gears, one gear has screw threads. They are used on non-parallel
non-intersecting shafts.
1.1.5 GEAR MATERIALS
The desirable properties of gear materials are:
1. The gear material should have sufficient static strength (ultimate or yield)
and endurance strength against fluctuating loads to resist failure due to the
breakage of tooth.
2. It should have sufficient surface endurance strength to avoid failure due to
destructive pitting caused by excessive wear.
3. The material should have a low coefficient of friction to avoid failure due to
scoring caused by high sliding velocities during high speed power
transmission.
4. The coefficient of thermal expansion of material should be low to limit the
thermal stresses causing distortion and warping.
The Bureau of Indian Standards (BIS) has recommended numerous materials for
gears as per IS: 4460-1967. These materials are: Malleable cast iron, cast steel,
forged steel, surface hardened steels, case hardened steels, and phosphor bronze.
1.2 SPUR GEAR TERMINOLOGY
 Spur gears are used to transmit power and rotary motion between parallel
shafts.
 If teeth of the gear wheels are parallel to the axis of wheel, the gears are called
spur gears.
 It is used when axes of the driving and driven shafts are parallel and co-planar.
 The smaller of the two gears in mesh is called the pinion, and the larger is
designated as the gear.
 The terminology of a spur gear is shown in Fig. 1.4.
The important definitions are explained below:
Gear ratio (i): The ratio of the number of teeth of the wheel (gear) to that of the
pinion is called gear ratio.

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1. GEAR DESIGN

Fig. 1.4 Terminology of spur gears

Transmission ratio (i): The ratio of the angular speed of the first driving gear of a train
of gears to that of the last driven gear is called transmission ratio.
Cycloid: A plane curve described by a point on a circle (generating circle), which rolls
without slip on a fixed line (base line) is known as cycloid.
Involute: A plane curve described by a point on a straight line which rolls without slip
on a fixed circle is known as involute.
Face width: The width over the toothed part of a gear, measured along a straight line
generator of the reference cylinder is known as face width.
Base circle: In an involute cylindrical gear, the base circle of the involutes of the tooth
profiles is known as base circle.
Circular pitch (p): The distance on the pitch circle from a point on a tooth to the
corresponding point of the adjacent tooth.
d
Thus, p 
z
Diametral pitch (P): It is defined as the number of teeth of the gear divided by the
pitch circle diameter.
z
P
d
Thus, pP  
Module (m): It is defined as the pitch circle diameter per unit number of teeth, i.e,
d 1
m 
z P

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 1. GEAR DESIGN

Pressure angle (ɸ): The angle between the line of action (a line through the pitch
point and tangential to the base circles) and a line perpendicular to the line of centers at the
pitch point is known as pressure angle.
Centre distance (C): The distance between the centers of the two gears in mesh is
known as centre distance.
1 m
Thus, C   d1  d 2    z1  z2 
2 2
Backlash: The difference between tooth space and tooth width is known as backlash.
Clearance: The difference between the dedendum of one gear and the addendum of
the mating gear is known as clearance.
Fundamental Law of Gearing: This law may be stated as "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”.
1.3 BEAM STRENGTH OF SPUR GEAR TEETH (Design for Static Load)

Fig. 1.5(a) Gear tooth as a cantilever beam Fig. 1.5 (b) Loading on a gear tooth
 The determination of the proper gears to use in a particular application is a
complex problem because of the many factors involved.
 First, the gears must operate together without tooth interference, with a
proper length of contact and without undue noise.
 Second, the gear teeth must have the ability to transmit the applied loads
without failure and with a certain margin of safety. This involves the ability of
the teeth to resist not only the load resulting from the power transmitted but
also the increases in load due to impact and shock caused by inaccuracy of
tooth contour, tooth deflection tooth acceleration and stress-concentration at
the root of the tooth or fatigue strength. The total resulting load is commonly
referred to as the dynamic load.
 Third, the wearing qualities of teeth must be considered. This is known as the
wear load.
Determination of Lewis equation:
 The static strength of the tooth is determined by assuming the tooth to be a
cantilever beam (Fig. 1.5(a)) acted upon by the moment resulting from the

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1. GEAR DESIGN

transmitted load obtained from the power transmitted. The design stress is
based upon the ultimate strength of the material with a factor of safety of
about 3. This analysis was given by Wilfred Lewis in 1892 and the design
equation is known as the Lewis Equation.
 In order to take into account the effects of tooth fabrication and additional
loads due to impact, the design is further modified by a velocity factor. These
modifications in design were presented by Earle Buckingham in 1932, after
which the gear design has been based upon the dynamic load and the
endurance limit of the material and the wear load.
The Lewis equation is based on the following assumptions:
1. The gear tooth is treated as a cantilever beam.
2. The effect of the radial component, which induces compressive stresses,
is neglected.
3. It is assumed that the tangential component is uniformly distributed over
the face width of the gear. This is possible when the gears are rigid and
accurately machined.
4. The effect of stress concentration is neglected.
5. It is assumed that at any time, only one pair of teeth is in contact and
takes the total load.
 Fig. 1.5 (b) shows a gear tooth with the force acting at the tip of the tooth. The
normal force Fn, is resolved into its components Fr and Ft acting at point A, the
intersection of the line of action of the normal tooth load and the centre of the
tooth.
 The radial component Fr produces compressive stress in the tooth and the
tangential component Ft causes bending stresses. The direct compressive stress
is small enough as compared to the bending stress and is ignored in
determining the strength of the tooth.
 The maximum bending stress may be located and computed as follows:
Through the point A in Fig. 1.5 (b), draw a parabola (shown in dash line)
tangent to the tooth curves at B and D. This parabola represents the outline of
a beam of uniform strength, and therefore the maximum stress in the actual
tooth will be the point of tangency B or D. This stress is:
M c 6 Ft h
b  
I bt 2
 bt 2
 Ft  b
6h
Both t and h are based upon the size of the tooth and its profile; hence the equation
may be written in the form,
 b 
h   b  t 2  constant  t 2
 6 Ft 

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 1. GEAR DESIGN

Clearly this is the equation of a parabola. Triangles ABE and BCE are similar, thus
x

 t / 2  or h  t 2
t / 2 h 4x
 bbt 2 4x
 Ft  2
 4 x   bb
6t 6
If we define a factor y  2 x / 3 p , called the Lewis form factor, based on circular pitch
then, we get
 b bY
Ft   b b y p    b bY m   b b  y m
P
Where, y = Lewis form factor based upon circular pitch
Y = Lewis form factor based upon diametral pitch
b =face width, mm = 3 π m to 4 π m
p = circular pitch, mm
σ b = Permissible bending stress, N/mm2
The permissible bending stress in the Lewis equation is taken as ⅓ of the
ultimate tensile strength
1
 b   ut
3
The values of y may be obtained from the following relations:
0.684
y  0.124  , for 14.5⁰ involute
z
0.912
y  0.154  , for 20⁰ involute full depth (FD)
z
0.95
y  0.170  , for 20⁰ involute stub
z
1.3.1 Velocity Factor
Slight inaccuracies in profile and tooth spacing both, teeth being not
absolutely rigid, variations in the applied load and repetitions of the loading cause
impact and fatigue stresses that become more severe as the pitch line velocity
increase. To allow for these additional stresses, a velocity factor C v is introduced into
the Lewis equation. This factor is given by:
3.05
Cv  , for ordinary industrial gears operating at velocity upto 10 m/s
3.05  vm
6.1
Cv  , for accurately cut gears operating at velocity upto 20 m/s
6.1  vm
5.56
Cv  , for precision gears cut with a high degree of accuracy and
5.56  vm
operating at velocity of 20 m/s and over
where vm is the mean speed in m/s.

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1. GEAR DESIGN

1.3.2 Tangential Load on Gear Tooth

The tangential load acting on the gear tooth is the load perpendicular to the
pitch circle radius. The tangential load on the tooth at the pitch line is given by,
P
Ft  103  , N
v
where P = power transmitting in kW
d n
v = mean pitch line velocity = m/s
60 103
d = pitch circle diameter, mm
n = speed in rpm.
1.3.3 Service Factor, Cs
The service factor accounts for increase in the tangential force due to
fluctuation of the torque developed by the prime mover and the torque required to
run the machine. It depends upon the prime mover and the driven machine.
maximum torque
Cs 
rated torque
1.3.4 Load Distribution Factor, Cm For Spur Gears
The load on the gear tooth is not same along the face width. The variation of
the load on the gear tooth is called the load distribution. The load distribution factor
accounts for the non-uniform distribution of load across the face width of the gear. It
depends upon the following factors.
1. Accuracy of alignment of gears and bearing mountings.
2. Bearing clearances.
3. Elastic rigidity of shafts, gears, bearings and housings, etc.
4. Manufacturing accuracy of gear tooth.
The values of load distribution factors are given in Table 1.2
Table 1.2 Load Distribution Factor for Spur Gears, Cm

1.3.5 Maximum Tangential Load, (Ft)

It is the tangential load which the gear tooth is required to sustain after
accounting for service factor and load distribution factor.
 Ft   Cs Cm Ft
1.4 DESIGN FOR DYNAMIC LOAD
The dynamic force is introduced in the gear teeth due to the following factors:
1. Inaccuracies of the tooth profile,

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 1. GEAR DESIGN

2. Errors in tooth spacing,

3. Misalignment between bearings
4. Elasticity of parts, and
5. Inertia of rotating masses
1.4.1 Buckingham’s Dynamic Load Equation
21v  b  C  Ft 
Fd   Ft  
21v  b  C  Ft
where Fd = Total load on gear including load due to dynamic action,
k e
C = Load stress factor,  in N/mm,
 1 1 
  
 E p Eg 
k = 0.107 for 14.5⁰ involute Full Depth
= 0.111 for 20⁰ involute Full depth
= 0.115 for 20⁰ involute Stub,
Ep & Eg = modulus of elasticity of pinion and gear materials respectively,
e = Sum of errors between two meshing teeth, mm
= ep + eg
ep = error for pinion
eg =error for gear
1.5 DESIGN FOR WEAR
 The failure of the gear tooth due to pitting occurs when the Hertz's contact
stresses between two meshing teeth exceed the surface endurance strength
of the material.
 Pitting is a surface fatigue failure which is characterized by small pits on the
surface of the gear tooth. In order to avoid this type of failure, the
proportions of gear tooth and surface hardness should be selected in such a
way that the wear strength of the gear tooth is more than the effective load
between the meshing teeth.
 The analysis of wear strength was done by Earle Buckingham, which gives the
wear strength of gear tooth. This equation is based on Hertz's theory of
contact stresses.
 The wear load is determined by the surface endurance limit of the material,
curvature of the surface, and relative hardness of the surfaces.
 The pinion should always be harder to allow for work hardening of the gear
to preserve the involute profile and to allow for greater abrasive wear on the
pinion, and to decrease the possibility of seizing.
 es 2  b sin   2 d p d g   1 1 
Fw     
1.4  d p  d g   E p Eg 
where σ es = Surface endurance limit,
b = Face width

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1. GEAR DESIGN

ɸ = Pressure angle
Ep & Eg = Modulus of elasticity of pinion and gear materials respectively,
dp & dg = Pitch circle diameter of pinion and gear respectively,
For a safe design, Fw  Fd
If pinion and gear are of steel,  es   2.76  BHN  70  , N / mm2
1.6 GEAR TOOTH FAILURES
The two basic modes for gear tooth failure are:
1. Breakage of the tooth due to static and dynamic loads,
2. Surface destruction.
1.6.1. Breakage of Tooth
 The complete breakage of the tooth can be avoided by adjusting module and
face width so that the beam strength of the gear tooth is more than the sum
of static and dynamic loads.
 The static beam strength of a gear tooth was suggested by Wilfred Lewis. The
dynamic load is caused due to small machining errors resulting into inertia
and impact loads on the gear tooth.
1.6.2. Surface Destruction
 The wear of gear tooth takes place due to the combined action of rolling and
sliding. Rolling causes contact stresses and sliding causes rubbing action.
Pinion is subjected to more rubbing action as it rotates faster than the gear.
 The principal types of gear tooth wear are: abrasive wear, corrosive wear,
pitting, and scoring.
i. Abrasive wear: The tooth surface is scratched by foreign particles in the
lubricant, such as dirt, rust and weld spatter of metallic debris. This can be
reduced by oil filter, using high viscosity lubricants, and surface hardness.
ii. Corrosive wear: The corrosion of the tooth surface is caused by corrosive
elements, such as extreme pressure (EP) additives present in the lubricating
oils and foreign materials due to external contamination.
 These elements attack the tooth surface, resulting in fine wear uniformly
distributed over the entire surface.
 The corrosive wear can be controlled by complete enclosure of the gears,
selecting proper additives and replacing the lubricant at regular intervals of
use.
iii. Pitting: It is a type of fatigue failure caused by repeated applications of stress
cycles. Pitting phenomenon is of two types: initial pitting and destructive
pitting.
 Initial (or corrective) pitting is a localized phenomenon, characterized by
small pits at high spots.

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 1. GEAR DESIGN

 Such high spots are progressively worn out and the load is redistributed.
Initial pitting is caused by the errors in tooth profile, surface irregularities and
misalignment.
 This controlled by precise- machining of gears and their correct alignment so
that the load is uniformly distributed across the full face width and the
dynamic load is reduced.
 Destructive pitting is a surface fatigue failure which occurs when the load on
the gear tooth exceeds the surface endurance strength of the gear material.
 This type of failure is characterized by pits, which continue to grow resulting
in complete destruction of the tooth surface. In some cases, this may even
break the tooth permanently.
 This type of failure can be avoided by ensuring that the wear strength of
entire gear tooth is more than the sum of static and dynamic loads.
 The surface endurance strength is a function of the hardness and can be
increased by improving the surface hardness of the gear tooth surface by
using an appropriate heat treatment process.
iv. Scoring: The oil film between the gear teeth may breakdown under excessive
surface pressure, high sliding velocity and inadequate supply of lubricant.
This results in generation of excessive frictional heat and overheating of the
contacting surfaces of gear teeth. This may lead to metal-to-metal contact.
Scoring is a stick-slip phenomenon, in which alternate welding and shearing
takes place rapidly at the high spots. This increases the wear rate faster.
 Scoring can be controlled by selecting proper surface speed, surface pressure
and flow rate of lubricant to keep the temperature of contacting surfaces
within permissible limits. The bulk temperature of lubricant can be reduced
by providing fins on the gear box, air cooling by a fan or circulating cold
water.

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1. GEAR DESIGN

EXAMPLE 1.1
Design a pair of spur gear with 20⁰ FD involute teeth to transmit 10 kW at 1440 rpm of the
pinion. The speed ratio is 4: 1. The pinion is made of plain carbon steel Fe 410 (Sut = 410
MPa) and the gear is made of grey cast iron FG 200(S ut = 200 MPa). The factor of safety
desired is 3 and the load is steady with medium shocks running for 8 to 10 hours per day.
The gears are commercial gears.
Solution:
Data given:
Pressure angle, ɸ =20⁰ FD involute,
P = 10 kW,
np = 1440 rpm,
i = 4:1,
n = 3,
(σ ut)p = 410 MPa,
(σ ut)g = 200 MPa.
 Design for Static Beam Strength
Minimum number of teeth on pinion to avoid interference, zp = 18 for ɸ =20⁰ involute.
Assume, module, m =5 mm.
σ p = 410/3 MPa
σ g = 200/3 MPa

Number of teeth on the gear zg= i zp = 4 x 18 = 72

Pitch diameters of pinion and gear,

dp= m zp= 5 x 18 = 90 mm
dg= m zg=5 x 72 = 360 mm

Lewis form factors:

0.912
y  0.154  , for 20⁰ involute full depth (FD)
z
0.912 0.912
y p  0.154   0.154   0.1033
zp 18
0.912 0.912
yg  0.154   0.154   0.1431
zg 72
 p y p  410  0.1033  42.35
 g yg  200  0.1431  28.26
Hence gear is the weaker and shall be considered for design.
Pitch line velocity,
 d p n p  90 1440
v   6.79 m / s
60 103 60 103

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 1. GEAR DESIGN

Tangential load,
P 103 10
Ft  103    1472.75 N
v 6.79

For given conditions, value of C s = 1.5 and C m = 1.3

Maximum load, Ft  Cs Cm Ft 1.5 1.3 1472.75  2871.87 N

3.05 3.05
Velocity factor for (v < 8 m/s), Cv    0.31
3.05  v 3.05  6.79
Ft 2871.87
Effective load, Feff    9264 N
Cv 0.31

Lewis equation for beam strength of gear tooth,

 200 
Fb   g yg b  m     0.1413    b  5  147.96 b N
 3 

Now, Fb  Feff
147.96 b  9264
 b  62.6 mm
The limits for face width are:
9.5 m = 9.5 x 5 = 47.5 mm and 12.5 x 5 = 62 mm
Adopt b=62 mm and m=5 mm
 Design for Wear

Wear load, Fw  d p bQ K
Here, dp = 90 mm, b =62 mm
2 zg 2  72
Q   1.6
z g  z p 72  18
2
 BHN 
For given condition, load stress factor, K  0.2413  
 100 
Pinion material is given as Fe 410, hence hardness = 300 BHN
2
 300 
K  0.2413    2.172
 100 
Fw  d p bQ K  90  62 1.6  2.172  19391.6 N

Fw 19391.6
FOS    1.69
Fd 11461.2
Hence design is safe.

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1. GEAR DESIGN

EXAMPLE 1.2
A compressor running at 250 rpm is driven by a 15 kW 750 rpm electric motor through a
pair of 20⁰ full depth spur gears. The pinion is made of 45C8 steel (heat treated) and gear
of 40C8 steel (untreated). Estimate the module, face width, and number of teeth on each
gear. Check for dynamic and wear loads.
Solution:

Data given:
np = 750 rpm,
ng = 250 rpm,
Pressure angle, ɸ =20⁰ FD involute,
P = 15 kW,

For 45C8 steel pinion, (σ ut) p = 630 MPa,

For 40C8 steel gear, (σ ut) g = 580 MPa.

Minimum number of teeth on pinion to avoid interference, zp = 18 for ɸ =20⁰ involute.

Assume, module, m =5 mm.
σ p = 410/3 MPa
σ g = 200/3 MPa

np 750
Speed ratio, i   3
ng 250
Number of teeth on the gear zg= i zp = 3 x 18 = 54

Pitch diameters of pinion and gear,

dp= m zp= 5 x 18 = 90 mm
dg= m zg= 5 x 54 = 270 mm

Lewis form factors:

0.912
y  0.154  , for 20⁰ involute full depth (FD)
z
0.912 0.912
y p  0.154   0.154   0.1033
zp 18
0.912 0.912
yg  0.154   0.154   0.1371
zg 54

For pinion, ep  32.0  2.50(5  0.25 90)  50.42  m

For gear, eg  32.0  2.50(5  0.25 270)  54.70  m

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 1. GEAR DESIGN

e  ep  eg  50.42  54.70  105.18  m  105.18 103 m

Pitch line velocity,

 d p n p  90  750
v   3.53 m / s
60 103 60 103

Tangential load,
P 103 10
Ft  103    2829.42 N
v 3.53

For given conditions, value of C s = 1.5 and C m = 1.3

Maximum load, Ft  Cs Cm Ft 1.5 1.3  2829.42  5517.37 N
k e 0.111105.18 103
C   787.2 N / mm
 1 1   1 1 
     3 
 207 10 100 10 
3
 E p Eg 

21v  b  C  Ft 
Fd   Ft  
21v  b  C  Ft
21 3.53  50  787.2  5517.37 
Fd  5517.37   17150.7 N
21 3.53  50  787.2  5517.37

Wear load, Fw  d p bQ K
Here, dp = 90 mm, b =50 mm
2 zg 2  54
Q   1.5
z g  z p 54  18
2
 BHN 
For given condition, load stress factor, K  0.1536  
 100 
Pinion material is given as 45C8, hence hardness = 500 BHN
2
 500 
K  0.1536    3.84
 100 

Fw  d p bQ K  90  50 1.5  3.84  25920 N

Fw > Fd
Hence design is safe.

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1. GEAR DESIGN

1.7 HELICAL GEARS

 A helical gear has teeth in the form of a helix around the gear. The helix may
be right handed on one gear and left handed on the other gear.
 The pitch surfaces are cylindrical like spur gears but the teeth wind around
the cylinder helically like screw threads. Helical gears are used to transmit
power between parallel shafts.
1.7.1 COMPARISON BETWEEN SPUR AND HELICAL GEARS
Table 1.3 Comparison Between Spur and Helical Gears
Spur Gears Helical Gears
1. Teeth are cut parallel to the axis of 1. Teeth are cut in the form of a helix on the
the shaft. pitch cylinder between meshing gears.
2. Contact between meshing teeth 2. Contact between meshing gears begins
occurs along the entire face width of with a point on the leading edge of the
the tooth. tooth and gradually extends along the
diagonal line across the tooth.
3. Load application is sudden resulting 3. Pick up of load by the tooth is gradual,
into impact conditions and generating resulting in smooth engagement and quiet
noise in high speed applications. operation even at high speeds.
4. Used for parallel shafts only. 4. Crossed helical ears are used on shafts
with crossed axes.
5. Speed is limited to about 20 m/s. 5. Used in automobiles, turbines and high
speed applications upto 50 m/s.
6. Imposes radial load only. 6. Imposes radial and axial thrust loads.
7. Contact ratio is low. 7. Contact ratio is high.
1.8 HELICAL GEARS TERMINOLOGY

Fig. 1.6 Helical Gear Terminology

Helix angle: It is the angle between a line drawn through one of the teeth and the
centre line of the shaft on which the gear is mounted. It is denoted by Ψ. It varies
from 15⁰ to 30⁰.

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 1. GEAR DESIGN

Normal circular pitch, pn: It is the distance between corresponding points of

adjacent teeth as measured in a plane perpendicular to the teeth elements. This is
shown by plane y-y in Fig. 1.7, which is perpendicular to teeth elements. AC
represents normal circular pitch.
Transverse circular pitch, pt: It is measured in a plane perpendicular to the shaft
axis, as shown by plane x-x in Fig. 1.7. AB represents the transverse circular pitch.
Transverse diameter pitch, P t: It is the diametral pitch measured in the plane of
rotation, i.e. transverse to the axis of rotation.
Normal diametral pitch, P n: It is the diametral pitch measured in the plane normal to
the helix. It is equal to diametral pitch of the hob.
Transverse pressure angle, ɸt: It is the pressure angle measured in the transverse
plane or plane of rotation.
Normal pressure angle, ɸn: It is the pressure angle measured in the normal plane or
plane perpendicular to the teeth.
Axial pitch px: It is the distance measured parallel to the shaft axis, AD represents
the axial pitch.

Fig. 1.7 Tooth Relationships

1.8.1 Angle Relationships in Helical Gears
Consider the cross-sections of the helical gear in the axial plane x-x and normal plane
y-y, as shown in Fig 1.7.
In ∆ABC, we have

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1. GEAR DESIGN

AC pn
  cos
AB pt
 Normal circular pitch, pn  pt cos
d
Transverse circular pitch, pt 
z
z
Transverse diametral pitch, Pt 
d
1 d
Transverse module, mt  
Pt z
pt Pt    pn Pn
Pt z
Normal diametral pitch, Pn  
cos d cos
Normal module, mn  mt cos
pt d 
From ∆ABD, px    cot
tan  z 
tan n
Also, cos 
tan t
zpt z mn
d  z mt 
 cos
1 mn
Centre distance, C     d1  d 2    z1  z2 
2 2cos
1.8.2 VIRTUAL (or FORMATIVE) NUMBER Of TEETH

Fig. 1.8 Concept of virtual number of teeth

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 1. GEAR DESIGN

 In helical gears, the plane x-x normal to the gear teeth intersects the pitch
cylinder to form an ellipse, as shown in Fig. 1.8.
 The gear tooth profile generated in this plane, using the radius of curvature of
the ellipse, would be a spur gear having the same properties as the actual helical
gear.
 The semi-major and semi-minor axes of this ellipse are:
d d
a and b= respectively.
2cos 2
 The radius of curvature rc at point A is,
a2 d
rc  
b 2 cos 2 
where d  pitch circle diameter.
 In the design of helical gears, an imaginary spur gear is considered in the plane x-
x with a pitch circle radius rc and module mn. It is called a "formative" or "virtual"
spur gear.
 Pitch circle diameter of virtual gear,
d
dc 
cos 2 
 The numbers of teeth of the equivalent (or virtual) spur gear in the normal plane
are called the virtual number of teeth, zv.
 dc d 1
zv   
pn cos   mn
2

d

mn cos 2 
z

cos3 
 The design of helical gears is based on virtual number of teeth.
 Design equations will also change accordingly, considering helix angle and other
parameters.

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1. GEAR DESIGN

EXAMPLE 1.3

A pair of parallel helical gears is having 20 teeth pinion and 80 teeth on the gear. The
pinion rotates at 750 rpm. The normal pressure angle is 20⁰ and the helix angle is 30⁰. The
face width is 50 mm and the normal module is 5 mm. Both the pinion and the gear are
made of 40 C8 steel (S ut = 600 MPa) and heat treated to a surface hardness of 300 BHN.
The service factor, load distribution factor and wear and lubrication factor are 1.5, 1.2 and
1.15 respectively. Calculate the power transmitting capacity of the gear pair assuming that
velocity factor accounts for the dynamic load. Factor of safety is 3.0.
Solution:
Data given:
zp = 20, zg = 80, Np, = 750 rpm, ɸn=20⁰, Ψ = 30⁰, b = 50 mm, mn = 5 mm, Sut = 600 MPa,
BHN= 300, C s = 1.5, C m = 1.2, C w = 1.15, FOS=3.0
Virtual number of teeth
zp 20
z pv    30.792
cos  cos3 30
3

zg 80
z gv    123.168
cos 
3
cos3 30

Pinion and gear are made of the same material; therefore, pinion is the weaker and shall be
considered for design.
s 600
 p  ut  200 MPa
FOS 3
Lewis form factor
0.912 0.912
y p  0.154   0.154   0.1157
z pv 30.792

Static Beam strength

Fb  mn b   p y p  5  50    0.1157  200  18174 N

Pitch line velocity

z m 20  5
dp  p n   115.47 mm
cos cos 30
 d p np 115.47  750
vp    4.53 m / s
60 10 3
60 103

Velocity factor
For v  5 m / s,
4.58 4.58
Cv    0.503
4.58  v p 4.58  4.53

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 1. GEAR DESIGN

Wear load,
bQ dpK
Fw 
cos 2 
b = 50 mm, dp = 115.47 mm

2 zg 2  80
Q   1.6
zg  z p 80  20
2 2
 BHN   300 
K  0.16    0.16    1.44
 100   100 

50 1.6 115.47 1.44

Fw   17736 N
cos 2 30

Effective load
c c c F 1.5 1.2 1.15  Ft
Feff  s m w t   4.1153 Ft N
cv 0.503

Safe tangential load

Feff  FOS  Fw
4.1153 Ft  3  17736
 Ft  1436.6 N

Torque transmitted
Fd 1436.6 115.47
T t p   82941.5 N  mm
2 2

Power transmitting capacity

2  N pT 2   750  82941.5
P   6.51 kW
60 106 60 106

EXAMPLE 1.4
Design a pair of helical gears to transmit 50 kW. The pinion revolves at 4800 rpm and the
speed ratio is 3. Consider the following data.
Material foe pinion: 45C8 (S ut = 630 MPa, BHN = 229 core and 520 case),
Material for gear: 30C8 (Sut = 500 MPa, BHN = 179),
Normal pressure angle, ɸn = 20⁰,
Helix angle, Ψ = 25⁰,
Number of teeth on pinion, zp =20,
Normal module, mn=3 mm,
FOS = 3.

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1. GEAR DESIGN

Solution:
Virtual number of teeth
zp 20
z pv    26.86
cos  cos3 25
3

zg 60
z gv    80.6
cos 
3
cos3 25

Lewis form factors

0.912 0.912
y p  0.154   0.154   0.120
z pv 26.86
0.912 0.912
yg  0.154   0.154   0.142
z gv 80.6

630
 p yp   0.120  25.2
3
500
 g yg   0.142  23.7
3
 g yg <  p y p . Hence, pinion is the weaker and shall be considered for design.

Pitch diameters of gears,

z m 20  3
dp  p n   66.2 mm
cos cos 25
z g mn 60  3
dg    198.6 mm
cos cos 25

Pitch line velocity,

 d p n p  66.2  4800
vp    16.64 m / s
60 103 60 103

Velocity factor
For 10  v  20 m / s,
15.25 15.25
Cv    0.478
15.25  v p 15.25  16.64

For given condition conditions, C s = 1.5, Cm = 1 and Cw = 1.5.

Tangential load,
P 103  50
Ft  103    3004.8 N
v 16.64

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 1. GEAR DESIGN

Effective load
c c c F 1.5 11.15  3004.8
Feff  s m w t   10843.7 N
cv 0.478

Static Beam strength

Fb  mn b   p y p  3  b    0.142 167  223.5 N

Fb  Feff
223.5 b 10843.7
b  48.5 mm
1.15   mn 1.15    3
bmin    25.64 mm
sin sin 25
12.5 mn  b  20mn
Also,
 37.5 mm  b  60 mm
We observe that the estimated value of face width is within the specified limits.
Hence we adopt, b = 50 mm and mn = 3 mm

Dynamic load,
21v  C  b  cos 2   Ft  cos
Fd   Ft  
21v  C  b  cos 2   Ft

Assuming, accuracy of Grade 8

The error is,
ep  16.00  1.25(2  0.25 66.2)  21.04  m
eg  16.00  1.25(2  0.25 198.6)  22.9  m
e  ep  eg  21.04  22.9  43.94  m

k e 0.111 43.94 103

C   505.31 N / mm
 1 1   1 1 
     3 
 207 10 207 10 
3
 E p Eg 
2116.64  505.31 50  cos 2 25  5183.3 cos 25
Fd  5183.3   16009.9 N
2116.64  505.31 50  cos 2 25  5183.3

Endurance strength of gear,

Fe   e b  y p mn
where,  e  1.75 BHN  1.75 179  313.25 MPa
 Fe  313.25  50    0.142  3  20961.4 N

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1. GEAR DESIGN

Fe 20961.4
FOS    1.57
Fd 13340.5
Hence, design is safe.

Wear load,
bQ dpK
Fw 
cos 2 
b = 50 mm, dp = 66.2 mm
2 zg 2  60
Q   1.5
zg  z p 60  20
2 2
 BHN   520 
K  0.16    0.16    4.3264
 100   100 
50 1.5  66.2  4.3264
Fw   26151 N
cos 2 25

Fw 26151
FOS    1.96
Fd 13340.5
Hence, design is safe.
 1.9 Introduction to Bevel Gears
 Bevel gears are cut on conical blanks whose pitch surfaces are frustrum of cones.
 The bevel gears are used for transmitting power at a constant velocity ratio between
two shafts whose axes intersect at a certain angle.
 The elements of the cones intersect at the point of intersection of the axes of rotation.
Since the radii of both the gears are proportional to their distance from the apex of the
cones, therefore the cones may roll together without sliding. This is the main advantage
of bevel gears over other type of gears.
1.9.1 CLASSIFICATION OF BEVEL GEARS
The bevel gears may be classified in two ways as follows:
a) Based on profile of tooth: The various types of bevel gears based on tooth
profile are shown in Fig. 1.9.

Fig. 1.9 Types of bevel gears based on tooth profile.

1) Straight tooth bevel gears: The straight tooth bevel gears are shown in Fig.
1.9 (a). Their axes generally intersect at right angles. The elements of the
teeth are straight lines that converge at the apex of the pitch cone.
2) Spiral tooth bevel gears: The spiral tooth bevel gears are shown in Fig. 1.9
(b). They are made with curved teeth. They have smoother tooth
engagement, quiet operation, greater strength and higher permissible
velocities.
3) Zerol bevel gears: The axes of the zerol bevel gears, as shown in Fig. 1.9 (c),
intersect and the teeth are curved and can be ground.
4) Face bevel gears: The face bevel gears, shown in Fig. 1.9 (d), consist of a spur
or helical pinion in combination with a conjugate gear of disc form.
5) Skew bevel gears: The skew bevel gears shown in Fig. 1.9 (e) are non-parallel
and non-intersecting having straight teeth.
6) Hypoid bevel gears: The axes of hypoid gears shown in Fig. 1.9 (f) are non-
parallel and non-intersecting, and the teeth are curved.
1. GEAR DESIGN

b) Based on angle between the axes: The various types of bevel gears based on
angle between the axes are shown in Fig. 1.10.

Fig. 1.10 Types of bevel gears based on angle between shafts.

1) External bevel gears: The angle between the axes of these bevel gears is 0:
as shown in Fig. 1.10 (a). The contact between the teeth of these gears is
external.
2) Acute angle bevel gears: The angle between the axes of these gears is less
than 90:, as shown in Fig. 1.10 (b).
3) Right angle bevel gears: The angle between the axes of these gears is 90: as
shown in Fig. 1.10 (c).
4) Miter bevel gears: The angle between the axes of these gears is 90: and the
gears are of the same size, as shown in Fig. 1.10 (d). The pitch angle of each
gear is 45:.
5) Obtuse angle bevel gears: The angle between the axes of these gears is more
than 90: as shown in Fig. 1.10 (e).
6) Crown gears: Gears having a pitch angle of 90: are known as crown gears as
shown in Fig. 1.10 (f). The angle between the shaft axes shall be more than
90:.
7) Internal gears: The bevel gears having pitch angle more than 90: are called
internal gears. The angle between the axes of the shafts is 180: as shown in
Fig. 1.10 (g).
 We shall study the design procedure for straight bevel gears in which the angle
between the shaft axes is 90:. Involute profile is assumed for these gears with
pressure angle of 20:.
1.10 BEVEL GEAR TERMINOLOGY
The terminology of a straight bevel gear is shown in Fig. 1.11.
Some of the important terms are:

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 1. GEAR DESIGN

Fig. 1.11 Terminology of straight tooth bevel gears

 Pitch cone: It is the pitch surface of the bevel gear as represented by OP.
 Back cone: It is an imaginary cone the elements of which are perpendicular to the
elements of the pitch cone at the larger end of the tooth.
 Cone centre: It is the apex of the pitch cone where the axes of the two mating gears
intersect each other.
 Pitch circle diameter, d: It is the diameter of the pitch circle at the large end of the
teeth.
 Pitch cone angle δ: It is the angle made by the pitch cone element with the axis of
the gear.
 Pitch cone distance: It is the length of the pitch cone element.
L  r12  r2 2
where r1, r2 = pitch circle radius of pinion and gear respectively.
 Back cone radius: It is the length of the back cone element.
r r
rb1  1 , rb 2  2
cos 1 cos  2
 Mean radius (rm): It is the pitch radius at the midpoint along the face width of the
teeth.
b sin 1 b sin  2
rm1  r1  , rm 2  r2 
2 2
1.11 VIRTUAL NUMBER OF TEETH
 The tooth prolife at the large end of the gear should theoretically be laid out on a
sphere. The profile laid out on the surface of the back cone differs only slightly from
the spherical profile.

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1. GEAR DESIGN MACHINE DESIGN (2171909)

Fig. 1.12 (a) Back cone Fig. 1.12 (b) Development of back cone
 The cone can be developed into a plane surface on which to study the tooth form
and the tooth action. This approximation is based upon the fact that a cone tangent
to the sphere at the pitch point will closely approximate the surface of the sphere for
a short distance on either side of the pitch point, as shown in Fig. 1.12 (a).
 The back cone may be developed as a plane surface and spur gear teeth
corresponding to the pitch and pressure angle of the bevel gear and the radius of the
developed cone can be drawn, as shown in Fig. 1.12 (b).
 The profile of the teeth of a bevel gear at the large end is the same as the profile of a
spur gear laid out on a pitch radius equal to the back cone radius, rb. The number of
teeth on this imaginary gear is called the virtual or formative number of teeth.
 Let δ = pitch angle or half of the cone angle
r = pitch circle radius of the bevel pinion or gear
rb = back cone radius or equivalent pitch circle radius of spur pinion or gear
From Fig. 1.12 (a), we find that
rb  r sec 
Equivalent or formative number of teeth is given by,
PitchCircle Diameter 2 rb 2 r sec 
zv   
Module m m
where m = module at the large end of teeth.
d
Actual number of teeth on bevel gear, z 
m
where d = pitch circle diameter at the large end.
zv 2 rb

z d
AP
In ∆ABP, sin ABP 
BP
 sin  90    
d
2rb
d
 rb 
2 cos 
z
 zv 
cos 
 Design equations will modify by considering the above factors.

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 1. GEAR DESIGN

Example 1.5
A pair of straight bevel gears is mounted on shafts intersecting at right angles. The
number of teeth on pinion and gear are 24 and 40 respectively. The pressure angle is 20⁰.
The input power to the pinion is 15 kW at 1440 rpm. The pinion and gear are made of
50C4 (Sut = 660 MPa) steel and heat treated to a surface hardness of 300 BHN and core
hardness of 250 BHN. The gears are machined accurately by a hobbing process to Grade 6.
Determine the module and the face width of gears. The service is with light shocks
working daily from 8 to 10 hours.
Solution:
Data given:
θ = 90:, z1 = 24, z2=40, ɸ = 20:, P=15 kW, n1 = 1440 rpm,
Sut = 660 MPa, (BHN) surface = 300, (BHN) core = 250

Assume m = 4 mm for the initial calculations

s 660
Allowable bending stress,  b  ut   220 MPa
3 3
Pitch circle diameters of pinion and gear,
d1  m z1  4  24  96 mm
d2  m z2  4  40  160 mm
Pitch cone length,
2 2 2 2
d  d   96   160 
L  r12  r2 2   1    2         98.3 mm
2  2  2   2 
Pitch angles of pinion and gear,
z 24
tan 1  1   0.6
z2 40
1  30.96
&  2  90  30.96  59.04
Virtual number of teeth,
z 24
z1v  1   28
cos 1 cos 30.96
z2 40
z2 v    77.75
cos  2 cos 59.04
Lewis form factors based on circular pitch,
0.912
y  0.154  , for 20: involute FD
zv
0.912
y1  0.154   0.1214
28
0.912
y2  0.154   0.1423
77.75

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1. GEAR DESIGN

The material of pinion and gear is same and y1 < y2. Therefore, pinion is the weaker and shall
be considered for design.
Pitch line velocity,
 d1 n1   96 1440
v   7.24 m / s
60 103 60 103
Tangential load,
P 103 15
Ft  103    2072.33 N
v 7.24
6.1 6.1
Velocity factor for (v < 8 m/s), Cv    0.457
6.1  v 6.1  7.24
For given conditions, value of C s = 1.25 and C m = 1.25
Maximum tangential load, Ft  Cs Cm Ft 1.25 1.25  2072.33  3238 N
Ft 3238
Effective load, Feff    7085 N
Cv 0.457

Static beam strength,

 b
Fb   b b  y m 1  
 L
Now, Fb  Feff
 b
 b b  y m 1    Feff
 L
 b 
 220    0.1214  4  b 1    7085
 98.3 
b2  98.3 b  2075  0
It gives b = 30.7 mm or 67.6 mm.
Now L = 98.3 mm < (30 m =30 (4) = 120 mm)
Therefore, b = 6 m to 7 m or 24 mm to 28 mm.
L
Also, b   33 mm
3
We adopt, b = 26 mm, m = 4 mm.
For accuracy Grade 6, tolerance for adjacent pitch error,
e  8.0  0.63(m  0.25 dm )
dm  d  b sin 
d1m  96  26sin 30.96  82.62 mm
d2m  160  26sin 59.04  137.70 mm
e1  8.0  0.63(4  0.25 82.62)  11.950  m
e2  8.0  0.63(4  0.25 137.70)  12.368  m
e  e1  e2  11.950  12.368  24.318  m

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 1. GEAR DESIGN

For steel pinion and gear,

C  11500e  11500  24.318 103  279.66 N / mm

Dynamic load,
21v  b  C  Ft 
Fd   Ft  
21v  b  C  Ft
21 7.24  279.66  26  3238 
Fd  3238   9474.8 N
21 7.24  279.66  26  3238
Endurance strength of pinion teeth,
 b
Fe   e b  y m 1  
 L
For core, BHN = 250 of steel
σ e = 1.75 BHN = 1.75(250) = 437.5 MPa
 26 
Fe  437.5  26    0.1214  4 1    12763.4 N
 98.3 
F 12763.4
FOS  e   1.347
Fd 9474.8
Hence, design is safe.
Wear load,
d bQ K
Fw  1
cos 1
For steel pinion and gear,
2 2
 BHN   300 
Load stress factor, K  0.16    0.16    1.44
 100   100 
2 z2 v 2  77.75
Q   1.47
z2v  z1v 77.75  28
96  26 1.47 1.44
Fw   6161.4 N
cos30.96
Fw < Feff, therefore hardness of pinion has to be increased.
For Fw =1.5 Feff
= 1.5 x 7085 = 10627.5
96  26 1.47  K
 10627.5
cos 30.96
So, K = 2.484
2
 BHN 
K  0.16    2.484
 100 
 BHN  394
Adopting BHN = 400
Therefore, hardness of pinion should be raised to 400 BHN.

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1. GEAR DESIGN

1.12 Worm gears

 The worm gear drive consists of a worm and a worm wheel as shown in Fig. 1.13.
 The worm is a threaded screw which can have single, double, triple or multi-start
threads.
 Worm is generally the driver. The worm is usually of cylindrical form having threads
of the same shape as that of an involute rack.
 The worm gear is similar to a helical gear with a face curved to conform to the shape
of the worm.
 The worm is generally made of steel and worm gear of phosphor bronze or cast iron.
 Worm gears are used to transmit power at high velocity ratios between two non-
intersecting shafts. The speed ratio may be as high as 300:1.
 The shafts are generally at right angles to each other. Worm gears are used in
mechanical handling equipment, machine tools and automobiles.

Fig. 1.13 Worm and Worm Gear

1.12.1 TYPES OF WORMS
The worms are of the following two types;
1. Cylindrical or straight worm, and
2. Cone or double enveloping worm.

Fig. 1.14 Types of Worms

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 1. GEAR DESIGN

1. Cylindrical worm: It is most commonly used worm as shown in Fig. 1.14 (a)
and (b). The shape of the thread is involute helicoids of 14.5: pressure angle
for single and double start worms and 20: for triple and quadruple threaded
worms. The worm threads are cut by a straight sided milling cutter.
2. Conical worm: The conical worm shown in Fig. 1.14 (c) is not used generally.
1.12.2 TYPES OF WORM GEARS
The worm gears are classified according to the type of face. The three types of faces
are:
1. Straight face
2. Hobbed straight face
3. Concave face
1. Straight face worm gear: This type of worm gear is shown in Fig. 1.15 (a). It is
like a helical gear in which the straight teeth are cut with a form cutter. It has
only a point contact with the worm thread and is used for light service.
2. Hobbed straight face worm gear: Its teeth are cut with a hob and the surface
is turned afterwards. Such a worm gear is shown in Fig. 1.15 (b). It is also
used for light service.
3. Concave face worm gear: It is the standard form of worm gear as shown in
Fig. 1.15 (c). It is used for heavy service and general industrial use. The teeth
of this worm gear are cut with a hob of the same pitch diameter as the
mating worm to increase the contact area.

Fig. 1.15 Types of Worm Gears

1.12.3 ADVANTAGES AND DISADVANTAGES OF WORM GEARS
Advantages:
1. High speed ratio from 60 : 1 to 100 : 1 with a single pair is possible.
2. Compact drive with small overall dimensions.
3. Smooth and silent operation.
4. Self-locking operation provision possible.
Disadvantages:
1. Low efficiency due to excessive heat generation.
2. Costly worm made of phosphor bronze.
3. Excessive heat generation requires large amount of lubricating oil to dissipate
heat.
4. Low power transmission capacity upto 100 kW only.

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1. GEAR DESIGN

1.13 Worm gears Terminology

The terminology of worm and gear is shown in Fig. 1.16.

Fig 1.16 Dimensions of worm

 Helix angle, α: It is the angle which the centre line of the thread makes with a line
perpendicular to the worm axis. It is defined in case of a single start threaded worm.
The worm and worm gear have same hand of helix angle,
 w   g  90
 Lead angle of worm, ϒ: It is the angle which the centre line of the thread makes with
a line perpendicular to the worm axis. It is defined in case of multi-start threaded
worm,
 w    90
From the above both equations, we can say that    g
 Number of starts (or threads on worm), zw: It is the number of thread helices cut
around the cylindrical body of the worm along the length of the worm.
The number of starts on the worm should not normally exceed 6. The recommended
values of number of starts are given in Table 1.4.
Table 1.4 Number of Starts on Worm
Speed ratio, i Number of starts on worm, zw
20 and over 1
12 – 16 2
8 – 12 3
6 – 12 4
4 - 10 6

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 1. GEAR DESIGN

 Axial pitch of worm, px: It is the distance measured parallel to the axis of worm from
a point on one thread to the corresponding point on the adjacent thread,
px   mx
dg
where mx = axial module of worm  transverse module of worm gear =
zg
 Transverse circular pitch of worm gear, pt: It is the circular pitch measured in the
transverse plane (or plane of rotation) of the worm gear.
The axial pitch, px of a worm is equal to the transverse circular pitch pt of the mating
worm gear when the shafts are at right angles,
px  pt   mx
 Normal circular pitch of worm gear, pn: It is the circular pitch measured in the
normal plane (or plane perpendicular to the teeth) of the worm gear.
As worm gear is similar to the helical gear,
pn  pt cos  g  px cos 
where  g  helix angle of worm gear.
Now,  mn   mx cos  g
mn  mx cos  g  mx cos 
where mn  normal module.
 Diametral quotient, q: It is the ratio of pitch circle diameter to axial module of
worm.
d
q w
mx
 Lead, pz: It is the distance measured between two consecutive intersections of a
helix and a straight generator of the cylinder on which it lies. It is defined as the
distance of a point on one tooth to the corresponding point on the same helix,
measured on the pitch surface in an axial direction.
pz  z w p x
where z w  number of threads  or starts  on worm
pz z p  mx zw mx zw zw
tan    w x   
 dw  dw  dw dw q
 Speed ratio, i: It is ratio of the speed of worn to that of the gear,
n z
i w  g
ng z w
 Centre distance, a: It is the distance between the axis of the worm and the axis of
the gear,
dw  d g mx q  mx z g mx  q  z g 
a  
2 2 2

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1. GEAR DESIGN

 Axial module, mx: It is the module measured parallel to the worm axis,
d m
mx = g  n
z g cos 
 Width (or face) angle,  : It is the angle at the centre included between the points of
intersection of the generating circle with the lateral faces of the teeth,
tan n
tan 
tan 
 Transverse pressure angle, ɸt: It is angle measured in the transverse plane (or plane
of rotation) of worm gear.
 Normal pressure angle, ɸn: It is the angle measured in the normal plane (or plane
perpendicular to the teeth).
 Normal module, mn: mn = mx Cos ϒ.
 Designation of worm drive: z1 / z2 / q / mx
where, z1 = No. of starts of worm, usually = 1.2,4,6
z2 = No. of teeth on gear wheel,
q = Diametral quotient,
mx = axial module.
Design equations will modify by considering the above factors.
1.14 EFFICIENCY OF WORM AND WORM GEAR DRIVE
The efficiency of worm and worm gear drive is the ratio of power output by worm gear to
the power input to the worm.
Power output by the gear Pg
Efficiency,  
Power input to the worm Pw

 Because F  Faw 
Faw vg
 tg
Ftw vw
Faw   d g ng Faw d g ng
   
Ftw   d w nw Ftw d w nw
dg mx z g zg zg zw
Now,      i tan 
dw mx q q zw q
ng 1
Also, 
nw i
 Faw

Therefore,    tan 
 Ftw

Ftw
Now, Faw 
tan v   
  
where v = tan 1 v = tan 1    virtuat angle of friction
 cos n 
μ = coefficient of friction between worm and worm wheel

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 1. GEAR DESIGN

ɸn = normal pressure angle.

tan 
Hence , 
tan n   
cos n   tan 
, when worm is the driver
cos n   cot 
cos n   cot 
, when worm gear is the driver
cos n   tan 
Therefore, we can say that the efficiency of the worm gear pair depends upon the following
factors: Lead angle (ϒ), Coefficient of friction between the worm and worm gear (μ) and
Normal pressure angle (ɸn).
1.15 THERMAL CAPACITY OF WORM GEARS
 The speed ratio in worm and worm drives is very high. The worm has to rotate many
cycles for one revolution of the worm gear.
 In this process, lot of heat is generated due to the work lost in friction. This heat must be
dissipated in order to avoid overheating of the drive and the lubricating oil.
 Heat capacity is the heat absorbing capacity of the worm and worm gear along with the
housing and the lubricating oil.
 For a reasonable temperature rise of the lubricating oil, the power transmitting capacity
of the worm drive may be estimated. The heat generated must be dissipated through
the lubricating oil to the gear box housing and then to the atmosphere.
 The heat dissipating capacity depends upon the following factors:
1. Area of housing,
2. Temperature difference between the housing surface and surrounding air, and
3. Thermal conductivity of the material.
 Heat generated,
H g  1   P kW
Ftw vw
 H g  1    kW
103
 Heat dissipated,
t
H d  hcr Ac kW
103
where P  input power, kW ,
η = efficiency of worm gear drive,
h cr  combined heat transfer coefficient, W / m 2 C
= 10 to 18 W / m 2 C with natural air circulation
= 20 to 28 W / m 2 C with forced circulation with a fan
A c  effective surface area of housing, m 2
= 1.14  104  a1.7 m 2
a = centre distance, mm

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1. GEAR DESIGN

∆t = rise in temperature of lubricant, :C ≤ 50 :C

 For a safe design, Hd > Hg
 For Hd = Hg, we have
t
1   P  hcr Ac
103
hcr Ac t
P  kW
1    103 
Example 1.6
Design a worm and worm gear to transmit 2 kW from an electric motor revolving at 1440
rpm to a machine running at 72 rpm. Load is intermittent and steady. Gear is made of
phosphor bronze and the worm of hardened steel. The gears are manufactured by
hobbing process.
Solution:
Data given:
P = 2 kW, nw = 1440 rpm, ng = 72 rpm,

1440
Speed ratio, i   20
72
For a compact design,
1 1
 n  3  72  3
tan    g      0.368
 nw   1440 
Lead angle,   20

For i = 15 to 30, zw = 2.
For ϒ = 15: to 30:, Normal pressure angle, ɸn = 20:

Number of teeth on the gear,

zg  i zw  20  2  40
Select mn = 5 mm for the initial design,
mn 5
mx =   5.32 mm
cos  cos 20
d g  mx zg  5.32  40  212.8 mm
mx zw 5.32  2
dw =   29.23 mm
tan  tan 20

Pitch line velocities,

 d w nw   29.23 1440
vw    2.2 m / s
60 103 60 103

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 1. GEAR DESIGN

 d g ng   212.8  72
vg    0.8 m / s
60 10 3
60 103

Velocity factor for gears manufactured by hobbing process,

6.1 6.1
Cv    0.884
6.1  vg 6.1  0.8
zg 40
zvg    48.2
cos  3
cos3 20

Lewis form factor for gear,

0.912 0.912
y  0.154   0.154   0.135
zg 48.2

Tangential load,
P 103  2
Ft  10  
3
 2500 N
vg 0.8

For given conditions, value of C s = 1.5

C F 1.5  2500
Effective load, Feff  s t   4242 N
Cv 0.884

Static beam strength,

Fb   dg b  yg mn
245
For phosphor bronze gear,  dg   81.67 MPa
3
 Fb  81.67  b   0.135  5  173.18 b

Now, Fb  Feff
173.18 b  4242
4242
b   24.5 mm
173.18

d w 29.23
q   5.5
mx 5.32
b  2 mx  
q  1  2  5.32  5.5  1  27 mm
or b  0.73 d w  0.73  29.23  21.34 mm
We adopt b =25 mm and mn = 5 mm.

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1. GEAR DESIGN

Wear load, Fw  d g b K
Load stress factor, K = 0.685 for hardened steel on phosphor bronze and lead angle between
10: to 25:
 Fw  212.8  25  0.685=3644.2 N < Feff
Therefore, hardness of the gear has to be increased.

Rubbing velocity,
v 2.2
vr  w   2.34 m / s
cos  cos 20

Coefficient of friction,
0.0422 0.0422
   0.033
 vr   2.34 
0.28 0.28

tan n = tan  cos  = tan 20 cos 20 = 0.342

n  18.9

Efficiency,
cos n   tan 

cos n   cot 
cos18.9  0.033tan 20
   0.9 or 90%
cos18.9  0.033cot 20

Heat generated,
H g  1   P  1  0.9  2  0.2 kW

Heat dissipated,
t
H d  hcr Ac 3 kW
10
Taking h cr  10 W / m2 C and t=50 C
Now, Hg = Hd
50
 0.2  10  Ac 
103
0.2 103
 Ac   0.4 m2
10  50

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