Design II MDE 221 Mott CH 8 and CH 9 Spur Gears

MACHINE ELEMENTS IN
MECHANICAL DESIGN
• Chapter 8: Mott p300
• Kinematics of Gears
• Chapter 9: Mott p363
• Spur Gear Design
Design II - Kinematics of Gears Ch 8 p 300 – 323 (Mott)
- Spur Gear Design Ch 9 p 365 – 414 (Mott)
Gears are toothed, cylindrical wheels used
for transmitting motion and power from one
rotating shaft to another.
Spur gears
Spur gears ("straight-cut gears") are the
simplest and most common type of gear
Helical gears
Helical gears offer a refinement over
spur gears. The leading edges of the
teeth are not parallel to the axis of
rotation, but are set at an angle
Rack and pinion

A rack is a toothed bar or rod that can be
thought of as a sector gear with an
infinitely large radius of curvature.
Bevel gears
Bevel gears are essentially conically
shaped,
Crown gear
A crown gear or contrate gear is a
particular form of bevel gear whose teeth
project at right angles to the plane of the
wheel; in their orientation the teeth
resemble the points on a crown.
Worm gear
A worm is a gear that resembles a screw.
Objectives – Design 2: Kinematics of Gears

Ref: Mott Ch 8 p300 – 323
• Recognize the main features of spur gears,

helical gears, bevel gears and worm/wormgear
sets.
• Understand the important operating
characteristics of SPUR gears.
• Understand the involute-tooth form and discuss
its relationship to the law of gearing.
4
Objectives (Concluded)
• Understand the basic functions of the American Gear
Manufacturers Association (AGMA) and identify
pertinent standards developed and published by this
organization.
• No official standard for RSA, therefore use this
textbook for subject purposes, but there are ISO
standards that must be used for actual gear design.
• Define velocity ratio as it pertains to two gears
operating together.
• Specify appropriate numbers of teeth for a mating
pair of gears to produce a given velocity ratio.
• Design 3 – Gear Trains, bevel, helical etc p 323 to
5
357
Contents
1. Spur Gears
2. Helical Gears – Design 3
3. Bevel Gears – Design 3
4. Worm Gears – Design 3
5. Gear trains – Design 3
6. The AGMA
6
1. Spur gears
• Gears that have teeth that are straight
and arranged parallel to the axis of the shaft
that carries the gear.
• Teeth have involute curves to maintain a constant angular velocity
ratio when two working gears mate.
– Angular velocity can be achieved when a line drawn
perpendicular to the surfaces of two rotating bodies at their point
of contact always crosses the center-line between the two
bodies at the same place.
– The above statement is also known as the law of gearing.
• Speed Reduction Ratio: Produce a change in the speed of rotation
of the driven gear (Gear) relative to the driving (Pinion) gear.
nP N G
 where n  rpm and N  no of teeth
nG N P
7
Above: the involute tooth form
Above: diagram illustrating the

law of gearing.
8
• Spur gear teeth features: Ref: Mott p309

– Circular pitch:
• Diametral Pitch Ref: Mott p310

(in inches):
( to convert to mm x by 25.4)
– Module (in SI units):
– To convert to module (m) Ref: Mott

p312
m  25.4
Pd
(Module is in mm)
where N and D are the number of teeth and the
pitch diameters of the gears.
-In the USA Diametrical Pitch is mainly used and is the number of
teeth per inch of pitch diameter.
-Metric System (S.I.) uses the module: See Table 8-3 p313
11
• Addendum: Ref: Mott p312

• The radial distance from the pitch circle to the outside of a
tooth.
– Dedendum: Ref: Mott p312

• The radial distance from the pitch circle to the bottom of the
tooth space.
addendum  mod ule

Ref: Mott p314
dedendum  1.25  addendum
– Backlash: Ref: Mott p315
Gears are made with the tooth spaces
slightly larger than the tooth thickness,
See p315, the difference is call backlash.
– Centre Distance: Ref: Mott p316
DG DP mNG  mN P
C  
2 2 2
12
– Pressure angle
• The pressure angle is the angle between the tangent to the pitch
circles and the line drawn normal to the surfaces of the gear
tooth.
Db  D cos 
13
• Contact ratio – for info. Ref: Mott p317
– Indicates the average number of teeth in contact during the
transmission of power.
– Recommended: 1.2 minimum.
Note: See Example Problem 8-1 Mott p318
14
• Interference between mating spur gear teeth: Ref: Mott p320
– Important that there is NO interference between teeth.
– See table 8-6 for values.
– Undercutting, cutting away of the material at the base (fillet or root) of the tooth
relieve interference, BUT does weaken the tooth design. Ref: Mott p321
– NOTE: Ref: Mott p321
For 20º, full-depth, involute system, using no few than 18 teeth will
ensure that no interference occurs.
Therefore, for most Design 2 assumptions use 18 or 19 teeth (18 Preferable)
• Velocity Ratio: The ratio of rotational speed of the input gear to that
of the output gear for a single set of gears.
 n N D speed P sizeG
VR  P  P  G  G  
G nG N P DP speed G sizeP
• Pitch Line Speed: of the gear and pinion are the same.
Dn
Vt 
60
15
Objectives – Design 2: Spur Gear Design

Ref: Mott p365 – 414 Ch 9
• Compute the forces exerted on gear teeth as they rotate

and transmit power.
• Understand various methods for manufacturing gears
and levels of precision and quality to which they can be
produced.
• Design 3 - Specify a suitable level of quality for gears according to the use to which
they are to be put.
• Design 3 - Describe suitable metallic materials from which to make the gears, in order
to provide adequate performance for both strength and pitting resistance.
16
Objectives for Ch 9 (Continued)

• Use the standards of the American Gear
Manufacturers Association (AGMA) as the basis
for completing the design of the gears.
• Use appropriate stress analyses to determine
the relationships among the applied forces, the
geometry of the gear teeth, the precision of the
gear teeth and other factors specific to a given
application, in order to make final decisions
about those variables.
17
Objectives for Ch 9 (Concluded)

• Design 3 - Perform the analysis of the tendency for the
contact stresses exerted on the surfaces of the teeth to
cause pitting of the teeth, in order to determine the
adequate hardness of the gear material that will provide
an acceptable level of pitting resistance for the reducer.
• Design 3 - Complete the design of the gears, taking into
consideration both the stress analysis and the analysis
of pitting resistance. The result will be a complete
specification of the gear geometry, the material fro the
gear and the heat treatment of the material.
Pitting: Small particles removed from the surface of the tooth face because of the high
contact stresses.
18
Contents
1. Gear Manufacture
2. Materials Used
3. Force and Stress Analysis
4. Design of Spur Gears
19
1. Gear Manufacture Ref: Mott p370 (INFO)
• Small gears
– frequently made from wrought plate and bar.
– Dimensions are machined to precision.
• Large gears
– Frequently fabricated from components.
20
• Gear teeth: Ref: Mott p371 (INFO)

– Machined by various methods.
– Most popular methods –
• Form milling: mainly used for large gears. A milling cutter that
has the shape of the tooth space is used.
• Shaping: usually used for internal gears. Cutter used
reciprocates on a vertical spindle.
• Hobbing: similar process to milling except that both the
workpiece and the cutter rotate in a coordinated manner.
Hobbing
Milling cutter Shaping for small gears
21
• Gear quality Ref: Mott p373

• Composite variation: allowable amounts of variations of the
actual tooth form from the actual tooth form
– Specified by AGMA as quality numbers.
– Quality numbers range from 5 to 15 with increasing
precision.
Above: Schematic diagram of a

typical gear rolling fixture
Right: Chart of gear-tooth errors

of a typical gear when run with a
specific gear in a rolling fixture.
22
– Table below shows the tolerance of composite variation
23
• Recommended quality numbers by AGMA.
• ISO standards 1328-1-1995 has own quality

numbers. See Mott p 375 for comparison.
24
2. Materials Used – Info: Design 3

• Main consideration when selecting
materials:
1. Producibility of the gear
2. Strength and pitting resistance
3. Weight
4. Appearance
5. Corrosion resistance
6. Noise
7. Cost
25
• Steel gear material:

– Through-hardened steels
– Case-hardened steels
• Flame hardened/ induction hardening
• Carburizing
• Nitriding
• Iron and bronze gear materials
– Cast irons
– Bronze
• Phosphor or tin, manganese bronze, aluminum
bronze, silicon bronze.
26
3. Force and Stress Analysis – NB

Design 2
• Forces in gear teeth
Forces on gear teeth.

Wt = force exerted by the pinion teeth on the gear teeth.
Wn = total force transferred from one tooth to the mating tooth.
Wr = vertical component of the total force acting radially on the gear
tooth. 27
- Tangential force
2P
Wt  60 P
D Therefore : Wt 
P Dn
Wt 
vt
where P = power provided
2n
ω = angular velocity 
60
vt = pitch line velocity
- Radial force
Wr  Wt tan 
- Normal force
Wt
Wn 
cos 
28
• Stresses Ref: Mott p385

– Lewis equation – to calculate stress at the base of the
involute profile.
Wt Pd Wt
– Acts like a cantileaver t  .KV .K O  .KV .K O
FY FYm
where Wt = tangential force
Pd = diametral pitch of the tooth where Pd=1/m (module in meters)
F = face width of the tooth
Y = Lewis form factor (dependent on the tooth form, the
pressure angle, the diametral pitch, the number of teeth in the
gear, and the place where Wt acts.
m=Module in meters
Design 2: Lewis including Kv: Velocity Factor p392 with Figure 9-21
Ko: Overload Factor p388/9 with Table 9-5
Nominal Face Width F=12 x m p408
Design Power p409 with Figure 9-27
NOTE: only for Design 2 because Lewis does not take into account stress
concentration that exists in the fillet of the tooth
– Bending stress – DESIGN 3 (Info)

Wt Pd
st  Ko K s Km K B Kv
FJ
where Ko = overload factor for bending strength

Ks = size factor for bending strength
Km = load distribution factor for bending strength
KB = rim thickness factor
Kv = dynamic factor for bending strength
J = geometry factor
 Selection of gear material based on bending stress

 Necessary to keep bending stress < allowable stress.
 Valid only if temperature < 121.1°C, 107 cycles of tooth
loading, reliability of 99% and safety factor of 1.00.
30
4. Design of Spur Gears

• Overall objectives:
– Be compact and small
– Operate smoothly and quietly
– Long life
– Low cost
– Easy to manufacture
– Be compatible with other elements in the
machines.
31
• General guideline:
– Identify input speed of pinion and the desired
output.
– Choose the type of material –Design 3
– Specify the overload factor.
– Specify a trial value for the diametral pitch.
– Specify face width
– Compute/ specify the factors needed to
determine the bending stress and contact
stress.
– Iterate design process to seek for more optimal
designs – Design 3
32
• Example Problem 9-5 Mott p 410

• Example Problem 9-6 Mott p 413
• Exercises p444 no 1,2,3,36,37 and 38
33
Spur Gears:
Gear Terminology
1-Pitch Circle Diameter (PCD or D)
The diameter of the pitch circle or the diameter of
the discs, if driven by friction alone, would have
the same ratio as the pair of gears
PCD
(D)
2-Module (m): Diameter in mm / no. of teeth = D/t

(t = no. of teeth)
3-Circular Pitch (Pc): Distance from any point on
the one tooth to the corresponding point on the
adjacent tooth, measured on the pitch circle.
.D D
PC  but m
no of teeth no of teeth
PC
 PC  .m and m 

4-Addendum: The pitch of the tooth above
(outside) the pitch circle
Addendum = Module
5-Dedendum: The portion of tooth BELOW the
pitch circle.
Dedendum = 1.157 x Module
6-Whole Depth:
(1 x Module) + (1.175 x Module) = 2.157 x Module
7- Clearance = 0.157 x M
8- Working Depth = Whole Depth – Clearance
= 2.157m – 0.157m = 2 x M
9-Pitch Point: Where the gear touch
Pitch point
Line of action
Ø300mm PITCH
Circle
10-Base Circle: Circle from which A
Base Circle
the involute curve is drawn.
Involute Curve – Gear tooth profile R Ψ
11-Line of Action: the line normal Rb 20°
(perpendicular ┴) to a pair of mating
profiles at their point of contact.
12-Pressure angle (θ): The angle
Pitch Point NOTE: Ft
between the line of action and the
B 90° is tangent
common tangent to the base to the
circles. Basic Geometry : PCD
70° 70° P
Ft
Consider 2 meshinggears of Common
o 90° Tangent to
200 and 300 PCD' s with 20
base
PressureAngle circles
Pressure
Consider Triangle ABP : Angle 20° LINE OF
ACTION
AP  pitch circle radius
=PLL
AB  Base circle radius rb
cos 20 
AP r 20°
Ψ
Driver
AB
AB  AP cos 20 Ø200mm PITCH Base Circle
R b  R cos  Circle NOTE: PLL is tangent
to the Base Circle
Construction of an involute curve:

e.g. construct an involute curve for gear teeth of 20° pressure angle on a 300mm PCD gear:
PCR = 150mm = R 1-Divide base circle into segments –
Base Rad = 150 cos 20 = 140.95 = Rb the smaller the angle, the greater the
accuracy – in this example 10°.
2-Draw tangents as shown.
3-Calculate distance from A to B
measured along the base circle:
10 10
2R b   2  140.95   24.6mm
360 360
10
L b  140.95  24.6
180
4-Mark off B1 = 24.6mm

C1= 2(24.6) = 49.2mm
D3 = 3(24.6) = 73.8mm
E4 = 4(24.6) = 98.4mm
Tooth
Thickness
t  no. of teeth
360

2t
reason: the space between the teeth is the
same as the teeth themselves - to allow meshing.
Pinion – the smaller of the two meshing gears
(small letters)
Gear – the larger of the two meshing gears
(capital letters)
Addendum – the height from the pitch circle
to the tip of the tooth.
Dedendum – the height from the pitch circle to
the root of the tooth
Standard proportions for 20° full depth involute Rbase

teeth are:
addendum = module
dedendum = 1.157 x module
Standard modules: 1; 1.25; 1.5; 2; 2.5; 3; 4; 5; 6;

8; 10; 12; 16; 20; 25; 32; 40; 50.
Circular pitch: D
PC 
T
the distance from a point on one tooth to the D
same point on the next tooth measured along a but D  mT or m
pitch circle: T
PC  m
Strength of Gear Teeth:

Cantilever Method: this method considers the gear tooth to be as a cantilever with 2/3 of the pitch
line load acting on the tip of the tooth.
Ft = Tangential force
h  height of tooth
b  breadth of tooth
PLL  pitch line load
  pressureangle Fs = Separating force
  bending stress Ft
Torque  Ft  radius
cos  
PLL
If values for " h" and " t" are not available the followingapproximations can be used: PLL  Ft
h  0.7P and t  0.48P cos 
C C
2 t
(  PLL  h)  ( )
My
  3 3
2
I AA bt
12
2 6
  PLL  h  2
3 bt
PLL  h  4

bt 2
(note : somereferences use Ft in place of PLL in calculations)
Pitch line load PLL may be found from:
Ft Tangent
Power = Force x V to PCR
= Ft x V
Or Power = PLL x V (depending on which radius you are using)
Where power is in Watts and velocity (V) (Ft Velocity) is: PCR
DN PLL
V
60 Tangent
Where : D  PCD in metres to Base
Base Circle
N  Rev/Min Radius Circle
Example: Calculate the DN  140 10 3  600 Alternatively :
load at the tip of a gear V   4.398m / s
60 60 Base Circle  PCD  cos 20
tooth given the following: Power  FT  V  140  cos 20  131.56mm
Power Transmitted = 10 kW
N = 600 rpm  FT 
Power 10000
 DN  131.56 10 3  600
V   4.133m / s
V 4.398 60 60
PCD of gear = 140mm  FT  2273.64 N (Tangentia l Load) Power  PLL  V
Power 10000
 PLL  
FT V 4.133
But : PLL   2419.56 N
cos   PLL  2419.55 N (Pitch Line Load)
2 2
 Load at tip  .PLL  1613.08 N  Load at tip  .PLL  1613.08 N
3 3
Lewis Formula:
Ft  k V ..b.PC .y
  Bending stressinduced in tooth y  Lewis factor (tooth factor)
b  face width of tooth T  number of teeth on gear being designed
D
PC  Circular pitch  or m k V  velocity factor
T
Tooth Factors: (y)
14.5o teeth : 20 o teeth :

0.648 0.912
y  0.124  ( ) y  0.154  ( )
T T
Velocity Factors: (kV) Pitch Circle Velocity:
kV 
3
V  10 m/s
DN
V
3V 60
6 NOTE : V is common to both gears :
kV  10 - 20 m/s
6V
N  Speed (rev/min)
5 .6
kV  V  20 m/s D  Pitch Circle Diameter
5 .6  V
Note: The Lewis formula must be applied to the weaker of the two meshing gears. The
weaker of the two is the one with the smaller σ x y product and the basis for the design.

Design II MDE 221 Mott CH 8 and CH 9 Spur Gears

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Design II MDE 221 Mott CH 8 and CH 9 Spur Gears

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MACHINE ELEMENTS IN

Rack and pinion

Objectives – Design 2: Kinematics of Gears

• Recognize the main features of spur gears,

Above: the involute tooth form

Above: diagram illustrating the

• Spur gear teeth features: Ref: Mott p309

• Diametral Pitch Ref: Mott p310

– Module (in SI units):

– To convert to module (m) Ref: Mott

• Addendum: Ref: Mott p312

– Dedendum: Ref: Mott p312

addendum  mod ule

Note: See Example Problem 8-1 Mott p318

Objectives – Design 2: Spur Gear Design

• Compute the forces exerted on gear teeth as they rotate

Objectives for Ch 9 (Continued)

Objectives for Ch 9 (Concluded)

1. Gear Manufacture Ref: Mott p370 (INFO)

• Gear teeth: Ref: Mott p371 (INFO)

• Gear quality Ref: Mott p373

Above: Schematic diagram of a

Right: Chart of gear-tooth errors

– Table below shows the tolerance of composite variation

• Recommended quality numbers by AGMA.

• ISO standards 1328-1-1995 has own quality

2. Materials Used – Info: Design 3

• Steel gear material:

3. Force and Stress Analysis – NB

Forces on gear teeth.

• Stresses Ref: Mott p385

– Bending stress – DESIGN 3 (Info)

where Ko = overload factor for bending strength

 Selection of gear material based on bending stress

4. Design of Spur Gears

• Example Problem 9-5 Mott p 410

• Exercises p444 no 1,2,3,36,37 and 38

2-Module (m): Diameter in mm / no. of teeth = D/t

Construction of an involute curve:

4-Mark off B1 = 24.6mm

Standard proportions for 20° full depth involute Rbase

Standard modules: 1; 1.25; 1.5; 2; 2.5; 3; 4; 5; 6;

Strength of Gear Teeth:

14.5o teeth : 20 o teeth :

Velocity Factors: (kV) Pitch Circle Velocity:

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