1. Choose a diametral pitch.

Smaller pitch implies large gears and low transmitted forces. Larger pitch
implies smaller gears but high transmitted forces.

2. Once the pitch is chosen, you can make a choice of Face width based on
the recommended guideline

3. Calculate bending and contact stress for the Pinion and Gear

4. If the stress are high compared to St and Sc of the common materials, than
go back to step 1 and restart by choosing a different diametral pitch.

5. Once satisfactory pitch is determined, choose material for Pinion. It is

possible to have surface treatment to improve the surface hardness. So
you could possibly choose a material with low core hardness (bending
strength) and high case hardness (surface contact strength)

6. Make sure that required factor of safety are satisfied for both bending and
surface contact strength.
If not, either increase the face width but still stay within optimum limits or
go back to step 1 and start with a smaller diametral pitch.

7. Choose a material for Gear and verify that factors of safety corresponding
to bending and contact resistance are satisfied. If not, either increase the
face width but still stay within optimum limits or go back to step 1 and start
with a smaller diametral pitch. 1
 Gear Design
Requirements:
• Functional Requirements: Load or power transmitted, speed ratio, reliability,
life and loading requirements (power source and applications)
• Depending on applications or risk involved: Design Factor will also be
specified
Choices:
• Tooth system (fixes pressure angle, and geometric characteristics of gear teeth)
• Number of teeth on the pinion ( Check that number of teeth is larger than
interference limit)
• Quality factor based on the application and precision required. Most commercial
gears between 3 to 7 and precision quality between 8 to 12.

Design Decisions ( Pd , F and material of the Pinion and Gears)

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Example 14-8: Design a 4:1 spur gear reduction for a 100 hp motor running at 1120
rev/min. The load is smooth, provide reliability of 0.95 and life of 109 revolutions for the
pinion. Gearing space is meager. Use Nitralloy 135M, grade 1 material to keep the gear
size small. The gears are heat-treated first and then nitrided

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