MACHINE DESIGN II

Dr Sangarappillai Sivaloganathan
February 2021

Analysis and Strength of Gears

LECTURE 6.2
 STRESS DISTRIBUTION ON GEAR TOOTH
PHOTOELASTIC MODEL

▪ Concentrated lines show high concentration of stresses

▪ At the point of contact and at the root of the tooth
▪ Main causes of gear failure are (i) bending stresses at the
root of the tooth and (ii) bearing stress at the surface of the
tooth.
 THEORETICAL APPROACH - CANTILEVER

▪ A cantilever of cross-sectional dimensions F and t, having a

length l and a load Wt, uniformly distributed across the face
width F.
 STRESS AS A CANTILEVER
▪ Assume that the maximum
stress occurs at the narrowest
cross section in the Filleted
region at section represented
by ‘a’.
▪ The normal through this
section meets the central
radial line at a distance ‘x’ from
the horizontal through ‘a’.

▪ Looking at the cantilever the maximum stress can be said as

follows:
 LEWIS’S BENDING EQUATION

▪ Lewis Bending Equation is given by

where s is the bending stress at the root of the gear tooth a, Wt

is the tangential load, F is the face width, P is the Diametral pitch
and Y is the Lewis Factor.
 DERIVATION OF LEWIS’S BENDING EQUATION
▪ Considering the cantilever

where s is the bending stress at the root of the gear tooth a,

Wt is the tangential load, F is the face width, and l is the
height of the tooth.
▪ From Similar Triangles

▪ Rearranging the stress equation in terms of x gives

▪ Multiplying the denominator and numerator by the circular

pitch p gives
 DERIVATION OF LEWIS’S BENDING EQUATION
▪ Multiplying the denominator and numerator by the circular
pitch p gives

▪ Letting y =2x/3p gives

▪ Substituting P = p/p and Y= py gives

and

Where Y is called the Lewis Factor.

Lewis Factor
 DYNAMIC FACTOR INCLUSION
▪ Lewis Factor considers the static loading only. For dynamic
load Dynamic Factor was introduced.
▪ Dynamic load was first introduced by Barth.

▪ The equation becomes in FPS unit system and

in SI
▪ Several equations define Kv
 Example 14.1
▪ A stock spur gear is available having a module of 3 mm, a 38
mm face, 16 teeth and a pressure angle of 200 with full
depth. The material is AISI1020 steel in a as rolled condition.
Use a design factor of nd = 3 to rate the power output of the
gear corresponding to a speed of 1200 rpm and moderate
applications.

The term moderate applications seems to imply that the gear

can be rated by using the yield strength as a criterion of failure.
From Table A–20, Sut = 379 MPa and Sy = 206 MPa.
A design factor of 3 means that the allowable bending stress is
206/3 MPa
The pitch diameter is 3 x 16 = 48 mm, so the pitch-line velocity is
Example 14.1
CONTACT STRESS - TWO CYLINDERS IN COMPRESSION
▪ The area of contact is a narrow rectangle of width 2b and
length l.

▪ Maximum pressure
 CONTACT BETWEEN GEARS
▪ To adapt these relations to the notation used in gearing,
replace F by Wt/cos f, d by 2r, and l by the face width F. With
these changes substitute the value of b. Replacing pmax by sC,
the surface compressive stress (Hertzian stress) is found from
the equation

▪ Where

▪ Let

▪ Then
 CONTACT BETWEEN GEARS
▪ To adapt these relations to the notation used in gearing,
replace F by Wt/cos f, d by 2r, and l by the face width F. With
these changes substitute the value of b. Replacing pmax by sC,
the surface compressive stress (Hertzian stress) is found from
the equation

▪ Where

▪ Let

▪ Then