Gears - General: Shigley's Mechanical Engineering Design

Gears - General
Machine Design II
Chapter 13
Shigley’s Mechanical Engineering Design
Gears: Introduction Pinion (2)
• Gears are toothed, cylindrical wheels used for

transmitting motion and power from one rotating
shaft to another.
• The teeth of a driving gear mesh accurately in the
spaces between teeth on the driven gear as shown
in Figure
• The driving teeth push on the driven teeth, exerting
a force perpendicular to the radius of the gear.
Thus, a torque is transmitted, and because the gear
is rotating, power is also transmitted
• Normally, gears are employed to produce a change
in the speed of rotation of the driven gear (n3)
relative to the driving gear (n2). If the smaller top
gear (a pinion) is driving the larger lower gear, (a
gear) the larger gear will rotate more slowly.
• The amount of speed reduction is dependent on
the ratio of the number of teeth in the pinion (N2) Gear (3)
to the number of teeth in the gear (N3) according
to this relationship:
Objectives
After completing this chapter, you will be able to:
• Recognize and describe the types of gears, namely, spur
gears, helical gears, bevel gears, and worm/worm gear sets,
and their main features.
• Describe the important operating characteristics of these
various types of gears with regard to the similarities and
differences among them and their general advantages and
disadvantages.
• Describe the involute-tooth form and discuss it relationship
to the law of gearing.
• 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.
• Define train value as it pertains to the overall speed ratio
between the input and output shafts of a gear-type speed
reducer (or speed increaser) that uses more than two gears.
Perspectives of Gear System Design
Assume that you are responsible for the design of a speed reducer that will take
the power from the shaft of an electric motor rotating at n1 rpm and deliver it to a
machine that is to operate at n3 rpm. You have decided to use gears to transmit
the power, and you are proposing a double-reduction speed reducer like the
concept sketch shown here:
• What design decisions must you make to complete the specification of the
gears needed?
Perspectives of Gear System Design
Here is the list of parameters that may give you some of the important
aspects:
• The number of teeth.
• The form of the teeth.
• The size of the teeth as indicated by the pitch.
• The width of the face of the teeth.
• The style and dimensions of the gear blank into which the gear teeth
are to be machined.
• The design of the hub for the gear that facilitates its mounting to the
shaft.
• The degree of precision of the gear teeth and the corresponding
method of manufacture that can produce that precision.
• The means of attaching the gear to its shaft.
• The means of locating the gear axially on the shaft.
• Additionally, you may need to analyze the forces on these various kinds
of gears including the stress analysis of the gear teeth and make
recommendations on material selection to ensure safe operation with
long life.
Types of Gears
Spur gears have teeth parallel to the Helical gears have teeth inclined to
axis of rotation. They are used to the axis of rotation. Sometimes
transmit motion from one shaft to helical gears are used to transmit
another, parallel, shaft. motion between nonparallel shafts
Types of Gears
Bevel gears have teeth formed on

Worm (Hypoid) gears: worm gear
conical surfaces and are used
are used to transmit motion between
mostly for transmitting motion
nonparallel, nonintersecting shafts.
between intersecting shafts.
Nomenclature of Spur Gears
Nomenclature of Spur-Gear Teeth
Nomenclature and Definitions
 Pair of Spur Gears – Equivalent to a pair of cylindrical discs,
keyed to parallel shafts and having line contact used to transmit
torque.
 Pitch Circle – The circle which by pure rolling would transmit
the same motion as the actual gear wheel. This is the
theoretical circle upon which all calculations are based. Its
diameter is called the “Pitch Circle Diameter” or PCD.
 The pitch circles are tangent to each other.
 The large wheel is called the gear and the small one is called
the pinion
 Circular Pitch: The circular pitch is the distance from a point on
one tooth to the corresponding point on the adjacent tooth
measured along the pitch circle.
 Circular pitch = Tooth thickness + Width of Space
 Module – Ratio of the pitch diameter to the number of teeth (in
millimeter). The module is the index of tooth size in SI units.
 Diametral Pitch – Ratio of the number of teeth to the pitch circle
diameter. This is the inverse of Module. Used only in US units
 Addendum – Distance between the Top Land and the pitch circle.
 Dedendum – Distance between the bottom land and the pitch
circle.
 Whole Depth: The sum of addendum and dedendum is called the
whole depth of the tooth.
 Clearance Circle – Circle tangent to the addendum circle of the
mating gear.
 Clearance – Clearance is the amount by which the dedendum of a
given gear exceeds the addendum of its mating gear.
 Backlash – The backlash is the amount by which the width of a
tooth space exceeds the thickness of the engaging tooth measured
along the pitch circle.
Tooth size:
N
P (13 - 1) For USC Units
d
d Approximate. ref.
m table next slide (13 - 2) For SI Units
N
d in “inches”
p m (13 - 3)
N
pP   (13 - 4)
where P = diametral pitch, teeth per inch

N = number of teeth
d = pitch diameter, in or mm
m = module, mm
p = circular pitch, in or mm
Tooth Sizes in General Use
Diametral Pitch, P (teeth/in)
Coarse 2,2 14 , 2 12 , 3, 4, 6, 8, 10, 12, 16
Fine 20, 24, 32, 40, 48, 64, 80, 96, 120, 150, 200
Module, m (mm/tooth)
Preferred 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16, 20, 25, 32, 40, 50
Next Choice 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5, 5.5, 7, 9, 11, 14, 18, 22, 28,
36, 45
Standardized Tooth Systems (Spur Gears)
Tooth System Pressure Angle ϕ, deg Addendum a Dedendum b
Full depth 20 1/P or m 1.25/P or 1.25m
1.35/P or 1.35m
22 12 1/P or m 1.25/P or 1.25m

1.35/P or 1.35m
25 1/P or m 1.25/P or 1.25m
1.35/P or 1.35m
Stub 20 0.8/P or 0.8m 1/P or m
Common pressure angle f : 20° and 25°

Old pressure angle: 14 ½°
Common face width: 
3p  F  5p Where, p 
P
3 5
F
P P
The Involute Profile
 Needed for smooth engaging and disengaging of the gear teeth
 Involute is the path traced by a point on a straight line as the line rolls
without slipping on the circumference of a circle. OR, the path traced
by the end of a string which is originally wrapped on a circle when
the string is unwrapped taut from the circle.
 The circle on which the involute is traced is called the base circle
Conjugate Action
 When the tooth profiles are
designed so as to produce
constant angular velocity
ratio during meshing, these
are said to have conjugate
action.
 When contacting surfaces of
cam A and follower B are
involute profiles, conjugate
action produces constant
angular velocity ratio.
Line of Action
 When one curved surface
pushes against another the
point of contact occurs where
the two surfaces are tangent to
each other (point C).
 The forces at any instant are
directed along the common
normal ab to the two curves.
The line ab, representing the
direction of action of the forces,
is called the line of action.
Pitch Point and Pitch Circle
 The line of action will intersect the line
of centres O-O at some point P. The
angular-velocity ratio between the two
arms is inversely proportional to their
radii to the point P.
 Circles drawn through point P from each

centre are called pitch circles, and the
radius of each circle is called the pitch
radius. Point P is called the pitch point
 To transmit motion at a constant
angular-velocity ratio, the pitch point
must remain fixed.
 That is, all the lines of action for every
instantaneous point of contact must
pass through the same point P.
Circles of Gear Layout
Sequence of Gear Layout
• Pitch circles in contact.

• Pressure line at desired
pressure angle.
• Base circles tangent to pressure
line.
• Involute profile from base circle.
• Top of teeth at addendum circle
at 1/P from pitch circle.
• Root of teeth at dedendum
circle at 1.25/P from pitch circle.
• Tooth spacing from circular
pitch, p = π / P
Relation of Base Circle to Pressure Angle
rbi  ri cos f i  1, 2 (13 - 6)
Tooth Action
First point of contact at a
where flank of pinion
touches tip of gear.
Last point of contact at b

where tip of pinion touches
flank of gear
Line ab is line of action.

Angle of action is sum of
angle of approach and
angle of recess.
Rack
• A rack is a spur gear with an pitch diameter of infinity.
• The sides of the teeth are straight lines making an angle to the
line of centers equal to the pressure angle.
• The base pitch and circular pitch, shown in Fig. 13–9, are related
by
pb  pc cosf (13 – 7)
Fig. 13–9
• Access the text alternative for slide images.

Internal Gear

Fig. 13–10
Example 13–1 (1)
A gearset consists of a 16-tooth pinion driving a 40-tooth gear. The diametral
pitch is 2, and the addendum and dedendum are 1m and 1.25m, respectively.
The gears are cut using a pressure angle of 20°.
(a) Compute the circular pitch, the center distance, and the radii of the base
circles.
(b) In mounting these gears, the center distance was incorrectly made 6.35mm
larger. Compute the new values of the pressure angle and the pitch-circle
diameters.
Solution
We will use Metric units. So, the first thing is determine the module
m Take m = 12 (Refer to table on slide 13)
(a) Answer p  
Example 13–1 (2)
The pitch diameters of the pinion and gear are, respectively,
d p  m x N p  12(16)  192mm dG  m x N G  12(40)  480mm
Therefore the center distance is
d P  dG 192+480
Answer   336mm
2 2
The radii of the base circles.
From Equation (13–6), with a 20° pressure angle, the base radii are
192
Answer (rb ) pinion  cos 20  85.24mm
2
480
Answer (rb ) gear  cos 20  225.53mm
2
Example 13–1 (3)
(b) Designating d′P and d′G as the new pitch-circle diameters, the 6.35 mm
increase in the center distance requires that
d P  dG
 342.35 (1)
2
Also, the velocity ratio does not change, and hence

d p 16
 (2)
dG 40
Solving Equations (1) and (2) simultaneously yields
Answer d p  195.63mm d G  489.07mm
Since rb = r cos ϕ, using either the pinion or gear, the new pressure angle is
(rb ) pinion 85.24
f   cos
1
 cos 1  22.59
Answer 
dP 2 95.63 2
Contact Ratio
Arc of action qt is the sum of the arc of approach qa and the arc of recess qr.,
that is
qt  qa  qr
The contact ratio, mc, is the ratio of the arc of action and the circular pitch.
qt
mc  (13 - 8)
p
The contact ratio is the average number of pairs of teeth in contact.
Fig. 13–11
Contact Ratio
Contact ratio can also be found from the length of the line of
action.
Lab
mc  (13 - 9)
p cos f
The contact ratio should be at least 1.2
Fig. 13–11
Interference
• Contact of portions of
tooth profiles that are not
conjugate is called
interference.
• Occurs when contact
occurs below the base
circle.
• If teeth were produced by
generating process
(rather than stamping),
then the generating
process removes the
interfering portion;
known as undercutting.

Fig. 13–12
Interference of Spur Gears
On spur and gear with one-to-one gear ratio, smallest number of
teeth which will not have interference is
NP 
2k
3sin f
2 
1  1  3sin 2
f  (13 - 10)
k =1 for full depth teeth. k = 0.8 for stub teeth.

On spur meshed with larger gear with gear ratio mG = NG/NP = m,
the smallest number of teeth which will not have interference is
NP 
2k
1  2m  sin f
2
m 
 m 2
 (1  2 m )sin 2
f  (13 - 11)
Interference of Spur Gears
Largest gear with a specified pinion that is interference-free is
N P2 sin 2 f  4k 2
NG  (13 -12)
4k  2 N P sin 2 f
Smallest spur pinion that is interference-free with a rack is
2(k )
NP  (13 - 13)
sin 2 f
Force analysis of Spur Gears
Notations for Force Analysis
 Numbering: Beginning from the frame of the machine as 1
In put gear is 2, and the successive gears are 2, 3, 4 - - -
 Shafts: Shafts are numbered as a, b, c - - -
 Force exerted by a gear on the other:
F23 – Force exerted by 2 on 3
F2a – Force exerted by 2 on shaft a
 Directions of the force as superscripts:
Force Analysis – Spur Gearing
FREE BODY DIAGRAMS
Fig. 13–28
Force Analysis – Spur Gearing
Transmitted load Wt is the
tangential load.
Wt  F32t
It is the useful component of

force, transmitting the torque.
d
T Wt
2

• Fig. 13–
29
Power in Spur Gearing
Transmitted power H.
H  T   (Wt d 2) (13 - 33)
Pitch-line velocity is the linear velocity of a point on the gear at the

radius of the pitch circle. It is a common term in tabulating gear
data.
V   dn 12 (13 - 34)
where V = pitch-line velocity, ft/min.
d = gear diameter, in.
n = gear speed, rev/min.
Power in Spur Gearing
Useful power relation in customary units,
H
Wt  33000 (13 - 35)
V
where Wt = transmitted load, lbf.
H = power, hp. V = pitch-line velocity, ft/min.
In SI units,
60000 H
Wt  (13 - 36)
 dn
where Wt = transmitted load, kN.
H = power, kW.
d = gear diameter, mm.
n = speed, rev/min.
Example 13–7
Pinion 2 in Figure 13–30a runs at 1750 rev/min and transmits 2.5
kW to idler gear 3. The teeth are cut on the 20° full-depth system
and have a module of m = 2.5 mm. Draw a free-body diagram of
gear 3 and show all the forces that act upon it.
Fig. 13–30
Example 13–7 (2)
Solution
The pitch diameters of gears 2 and 3 are
d 2  N 2 m  20(2.5)  50 mm
d3  N 3m  50(2.5)  125mm
From Equation (13–36) we find the transmitted load to be
60000 H 60000(2.5)
Wt    0.546 kN
 d2n  (50)(1750)
Thus, the tangential force of gear 2 on gear 3 is Ft23 = 0.546 kN, as shown in Figure 13–
30b. Therefore
F23r  F23t tan 20  (0.546) tan 20  0.199 kN
and so F23t 0.546
F23    0.581 kN
cos 20 cos 20
Since gear 3 is an idler, it transmits no power (torque) to its shaft, and so the tangential
reaction of gear 4 on gear 3 is also equal to Wt. Therefore
F43t  0.546 kN F43r  0.199 kN F43  0.581kN
and the directions are shown in Figure 13–30b.
Example 13–7 (3)
The shaft reactions in the x and y directions are
Fbx3  ( F23t  F43r )  ( 0.546  0.199)  0.347 kN
Fby3  ( F23r  F43t )  (0.199 ─ 0.546)  0.347 kN
The resultant shaft reaction is

Fb3  (0.347) 2  (0.347)2  0.491kN
These are shown on the figure 13-30b

Gears - General
Machine Design II
Chapter 13
Lecture outline
• Straight Bevel Gears
• Force Analysis of Bevel Gears
• Parallel Helical Gears
• Force Analysis of Helical Gears
• Worm Gears
• Force Analysis of Worm gears
• Gear Manufacturing
• Forming
• Milling
• Shaping
• Hobbing
• Finishing
Straight Bevel Gears
• A Bevel gear is a gear
having teeth cut into a
conical surface, usually
meshing with a similar
gear set at right angles
• Bevel Gears transfer
motion between
nonparallel shafts
Nomenclature of Bevel Gears
 Pitch Cone: Pitch surface of the bevel gear represented by
OP.
 Back cone.- The complementary cone generated by a line at
right angles to the pitch cone generator at the pitch
diameter and intersecting the axis.
 Cone Centre: The apex of the pitch cone where the axes
mating gears intersect
 Pitch Diameter d: The pitch of bevel gears is measured at
the large end of the tooth, and both the circular pitch and
the pitch diameter are calculated in the same manner as for
spur gears.
 Pitch cone Angle, , : The pitch angles are defined by the
pitch cones meeting at the apex.
 Face Width F: Length of one tooth
 Cone Distance Ao: Distance from pitch circle to intersection of
shaft axes.
NP NG
tan   tan   (13 -14)
NG NP
 Back-Cone Radius rb
 The shape of teeth, projected on back cone, is same as in a
spur gear with radius rb.
 Virtual number of teeth in this virtual spur gear is
2 rb
N  (13 - 15)
p
 Shaft angle.- The angle between the intersecting shaft axes

Tooth Proportions for 20° Straight Bevel-Gear
Teeth
Item Formula
Working depth hk = 2.0/P
Clearance c = (0.188∕P) + 0.002 in
Addendum of gear 0.54 0.460
aG  
P P(m90 ) 2
Gear ratio mG = NG∕NP

Equivalent 90° ratio m90 = mG when Γ = 90°
cos 
m90  mG when   90
cos 
10
Face width F = 0.3A0 or F
P
,whichever is smaller
Minimum number of teeth Pinion 16 15 14 13
Gear 16 17 20 30
Table 13–3
Force analysis of Bevel Gears
T
Wt  (13 - 37)
rav
Wr  Wt tan  cos 
(13 - 38)
Wa  Wt tan  sin 
Example
The bevel pinion in the Figure rotates at 600 rev/min in the direction shown and
transmits 5 hp to the gear. The mounting distances, the location of all bearings, and
the average pitch radii of the pinion and gear are shown in the figure. The pinion
has 15 teeth and P = 5 teeth/in. For simplicity, the teeth have been replaced by
pitch cones. Bearings A and C should take the thrust loads. Find the bearing forces
on the gear shaft.
Solution
The pitch angles are
The pitch-line velocity corresponding to the average pitch radius is
Therefore the transmitted load is
and from Equation (13–38), with Γ replacing γ, we have
where Wt acts in the positive z direction, Wr in the −x direction, and Wa in the −y

direction, as illustrated in the isometric sketch of Figure 13–32b.
Solution
In preparing to take a sum of the moments about bearing D, define the position vector
from D to G as
We shall also require a vector from D to C:

Solution
Then, summing moments about D gives
(1)
When we place the details in Equation (1), we get
After the two cross products are taken, the equation becomes
(2)
from which
(3)
Solution
Now sum the forces to zero. Thus
FD  FC  W  0 (4)
When the details are inserted, Equation (4) becomes
(5)
First we see that FyC = 140 lbf, and so
Answer
Then, from Equation (5),

Answer
These are all shown in Figure 13–32b in the proper directions. The analysis for
the pinion shaft is quite similar.
Helical Gears
• Similar to spur gears, but with
teeth making a helix angle with
respect to the gear centerline.
• Adds axial force component to
shaft and bearings.
• Smoother transition of force
between mating teeth due to
gradual engagement and
disengagement.
Parallel Helical Gears
Tooth shape is involute helicoid
• If a piece of paper cut in the
shape of a parallelogram is
wrapped around a cylinder,
the angular edge of the
paper becomes a helix.
• If we unwind this paper, each
point on the angular edge
generates an involute
curve.
• The surface obtained when
every point on the edge
generates an involute is
called an involute helicoid
Right hand and Left hand Helical Gears
• The teeth of a LEFT HAND Helical Gear lean to the left when
the gear is placed flat on a horizontal surface.
• The teeth of a RIGHT HAND Helical Gear lean to the right
when the gear is placed flat on a horizontal surface.
Helical gears basic Geometry
plane of rotation
the plane
perpendicular to
the teeth.
Transverse circular pitch pt is in the plane of
rotation.
Normal circular pitch pn is in the plane
perpendicular to the teeth.
pn  pt cos (13 - 16)
Axial pitch px is along the direction of the
shaft axis.
pt
px  (13 - 17)
tan
Normal diametral pitch.
Pt
Pn 
cos  (13 -18)
pn Pn  
Relationship between angles.
tan n
cos  (13 - 19)
tan t Fig. 13–18
Normal diametral pitch. (for USC units)
Pt
Pn 
cos  (13 -18)
pn Pn  
For Metric gears, module (m) is specified.

Equation (13-18) for module becomes:
Relationship between angles.
tan n
cos  (13 - 19)
tan t
 The parameters on the normal plane are the
standard values.
 To use the formulae for spur gear Transverse
plane parameters should be used.
• Viewing along the teeth, the apparent pitch
radius is greater than when viewed along the
shaft.
• The greater virtual R has a greater virtual
number of teeth N‘.
N
N  (13 - 20)
cos3 
Allows fewer teeth on helical gears without

undercutting.
Fig. 13–19
Properties of helical gears
 Transmit motion between Parallel shafts
 The helix angle is the same for each gear but the direction is different; One is
right hand and the other is left.
 The shape of the tooth is an involute helicoid
 .Unlike the spur gears the line of contact is diagonal across the face of the
teeth.
 This gradual engagement of teeth makes it possible for smooth transfer of
high speeds and torques.
 The contact ratio therefore becomes less important and the contact area
which is the face area that becomes important.
Properties of helical gears
 Helical gears produce both axial and radial loads on the shaft.
 When the thrust loads become objectionably high double helical or
herringbone gears are used.
 A double helical or herringbone is equivalent to two helical gears of
opposite hands mounted side by side on the same shaft.
 They develop opposite thrusts and cancels each other.
 When two or more helical gears are mounted on the same shaft the hands
of the gears should be chosen to minimize the thrust load.
Example
A stock helical gear has a normal pressure angle of 20°, a helix
angle of 25°, and a transverse diametral pitch of 6 teeth/in, and has
18 teeth. Find:
(a) The pitch diameter.
(b) The transverse, the normal, and the axial pitches.
(c) The normal diametral pitch.
(d) The transverse pressure angle.
Solution
Interference with Helical Gears
On helical gear with one-to-one gear ratio, smallest
number of teeth which will not have interference is
NP 
2k cos
3sin t
2
1 
 1  3sin 2
t  (13 - 21)
k =1 for full depth teeth. k = 0.8 for stub teeth.

On helical gear meshed with larger gear with gear ratio
mG = NG/NP = m, the smallest number of teeth which will
not have interference is
2k cos  m  m2  (1  2m)sin 2  
NP  (13 - 22)
(1  2m)sin 2 t  
t
Interference with Helical Gears
Largest gear with a specified pinion that is interference-
free is
N P2 sin 2 t  4k 2 cos 2 
NG  (13 - 23)
4k cos  2 N P sin 2 t
Smallest helical pinion that is interference-free with a

rack is
2k cos
NP  (13 - 24)
sin 2 t
Standard Tooth Proportions for Helical Gears
Quantity* Formula Quantity* Formula
1.00
Addendum External gears:
Pn
Dedendum 1.25
Standard center Dd
Pn 2
distance
NP
Pinion pitch diameter Pn cos Gear outside diameter D + 2a
NG
Gear pitch diameter Pn cos Pinion outside diameter d + 2a
 Bn

Normal arc tooth thickness† 2 Pn 2 Gear root diameter D − 2b
Pinion base diameter d cos ϕt Pinion root diameter d − 2b

Internal gears:
Dd
Gear base diameter D cos ϕt Center distance 2
Base helix angle tan−1 (tan ψ cos ϕt) Inside diameter D − 2a

Root diameter D + 2b
*All dimensions are in inches, and angles are in degrees.
†Bn is the normal backlash.
Table 13–4
Force Analysis of Helical Gears
FORCE ON COUNTER CLOCKWISE DRIVER
FORCE AND THE PLANE
NORMAL AND TANGENTIAL PLANES
PRESSURE AND HELIX ANGLE
RESOLVING IN NORMAL PLANE
RESOLUTION IN THE TANGENTIAL PLANE
TRANSVERSE PLANE AND PRESSURE ANGLE
AXIAL PLANE AND FORCE
Summary - Forces and Directions
 Where: Forces will act on the Pitch Cylinder
 Normally represented at the middle of the tooth
 Four planes
o Tangential Plane
o Frontal Plane
o Axial Plane
o Normal Plane
 Direction
o For the Driver: Against the Direction of the motion
o For the Driven: Along the Direction of motion
 Components: Axial, Radial and Tangential
 Expressions
Wr  W sin n
Wt  W cos n cos  (13 - 39)
Wa  W cos n sin 
Wr  Wt tan t
Wa  Wt tan (13 - 40)
Wt
W
cos n cos
Fig. 13–33
Example
A 0.75 kw electric motor runs at
1800 rev/min in the clockwise
direction, as viewed from the
positive x axis. Keyed to the motor
shaft is an 18-tooth helical pinion
having a normal pressure angle of
20◦, a helix angle of 30◦, and a
normal module of 2 mm. The hand
of the helix is shown in the figure.
Make a three-dimensional sketch of
the motor shaft and pinion, and
76.2mm
show the forces acting on the pinion 254mm
and the bearing reactions at A and B.
The thrust should be taken out at A
 The pinion transmits the forces it experiences to
bearings A and B.
 Bearing B cannot take axial loads and hence bearing A
takes up the Axial loads.
 Hence the forces in the bearings A and B are as follows:
Free-body diagram of motor shaft
254mm 76.2mm dp/2 = 41.6/2 = 20.08 mm

Example
Solution Gear Forces
Determination of reaction forces at A and B can be achieved by
considering the equilibrium of the motor shaft and pinion assembly
254mm 76.2mm dp/2 = 41.6/2 = 20.08 mm
Taking moments about the z axis: ( )=0

Summing forces in the y direction then gives: - FyA – Wr + FyB = 0
Taking moments about the y axis: =0

Summing forces in the z direction: FzA + Wt F zB = 0
Gears - General
Machine Design II
Chapter 13
(Part 3)
Lecture outline
• Worm Gears
• General features and properties
• Force Analysis of Worm gears
• Gear Manufacturing
• Forming
• Milling
• Shaping
• Hobbing
• Finishing
Worm and Worm Gears
 A worm gear is a device consisting of a
threaded shaft (a worm) that meshes
with a gearwheel (the worm wheel), so
that rotary motion can be transferred
between two shafts at right angles to
each other, and their axes do not meet.
 Worm gears are used to transmit
motion or power between right-angled
shafts when a high-ratio reduction is
necessary. https://youtu.be/ozy7gdiCTY8
 When the worm rotates against the
wheel, the screw face pushes on the https://www.youtube.com/
watch?v=S3XAeMCeZr0
teeth of the wheel.
 The wheel is connected to the load and
thus is pushed against the load.
Worm and Worm Gears
Why the gear reduction is large?
 When the worm makes a full rotation, the gear advances by a
distance of a single lead.
 For a single start thread, the distance travelled by the worm is
the pitch (Distance between two corresponding points in a
screw)
 This means if the wheel has 20 teeth, the worm has to make 20
rotations for the wheel to make one full rotation.
https://www.youtube.com/watch?v=aKwWvlhqes0
Worm and Worm Gears
Common to specify lead
angle λ for worm and helix
angle G for gear.
Common to specify axial
pitch px for worm and
transverse circular pitch pt
for gear.
Pitch diameter of gear is
measured on plane
containing worm axis.
N G pt
dG  (13 - 25)

Fig. 13–20
Worm and Worm Gears
Warm Gear Pairs
(N1, n1) (N1, n1)
(N2, n2) (N2, n2)

Terminologies
 Axial pitch: Axial pitch or linear pitch is the distance between two
adjacent corresponding points in a thread on the worm.
 The axial pitch of a worm is equal to the circular pitch of the
mating worm gear.
 Lead: Lead is the distance through which a point on a thread
moves ahead, in a single revolution of the worm.
 For a single start thread, Lead is equal to the Axial pitch.
 For multiple start threads Lead = Axial pitch times number of
starts.
Terminologies
 Lead Angle: It is the angle between the tangent to the thread
helix on the pitch cylinder and the plane normal to the axis of the
worm.
L
Relation between lead L and lead angle λ,

L  px NW (13 - 27) Nw = 1 for single start
L Nw = 2 for double start
tan   (13 - 28) Nw = n for n start
 dW
Recommended range for worm pitch diameter as a function of center
distance C,
C 0.875 C 0.875
 dW  (13 - 26)
3.0 1.7
Terminologies
 Normal pitch: Normal pitch is the distance measured along the
normal to the threads between two corresponding points on two
adjacent threads.

 Helix Angle: The worm helix angle is the complement of the
worm lead angle.

Velocity ratio =
=
Worm and Worm gears
Recommended Pressure Angles and Tooth Depths
for Worm Gearing
Lead Angle λ, deg Pressure Angle ϕn, deg Addendum a Dedendum bG
0–15 0.3683px 0.3683px
15–30 20 0.3683px 0.3683px
30–35 25 0.2865px 0.3314px
35–40 25 0.2546px 0.2947px
40–45 30 0.2228px 0.2578px
Table 13–5
Face Width of Worm Gear

Face width FG of a worm gear should be
equal to the length of a tangent to the worm
pitch circle between its points of
intersection with the addendum circle.
Worm and Worm gears
Example:
A single threaded worm has pitch circle diameter of 50 mm. If the worm
gear has 30 teeth and a module of 6 mm find the following:
a. Lead angle of the worm
b. Velocity ratio
c. Centre distance
Solution:
Answer: 
Answer:
Answer: Centre distance

Force Analysis of Worm Gears
W x  W cos n sin  WWt  WGa  W x

W y  W sin n (13-41) WWr 
(13 WGr  W y
- 41) (13 - 42)
(13-42)
W z  W cos n cos  WWa  WGt  W z
Relative motion in worm gearing is sliding action.
Friction is much more significant than in other types of gears.
Including friction components, Eq. (13–41) can be expanded to
W x  W (cos n sin   f cos  )

W y  W sin n (13 - 43)
W z  W (cos n cos   f sin  )
Combining with Eqs. (13–42) and (13–43),

f WGt
Wf  f W  (13 - 44)
f sin   cos n cos 
cos n sin   f cos 

WWt  WGt (13 - 45)
© McGraw Hill 13
Worm Gearing Efficiency
Efficiency is defined as
WWt (without friction)

 (a )
WWt (with friction)
From Eq. (13–45) with f = 0 in the numerator,
cos n  f tan 
 (13 - 46)
cos n  f cot 
© McGraw Hill 14
With typical value of f = 0.05, and ϕn = 20º, efficiency as a function
of lead angle is given in the table.
Lead Angle λ, deg Efficiency η, %
1.0 25.2
2.5 45.7
5.0 62.6
7.5 71.3
10.0 76.6
15.0 82.7
20.0 85.6
30.0 88.7
Table 13–6
© McGraw Hill 15
Coefficient of friction is
dependent on relative or sliding
velocity VS.
VG is pitch line velocity of gear.
VW is pitch line velocity of worm.
VW  VG  VS
VW
VS  (13 - 47)
cos 
Fig. 13–37
Access the text alternative for slide images.
© McGraw Hill 16
Coefficient of Friction for Worm Gearing
Graph shows representative values.
Curve A is for when more friction is expected, such as when gears are cast iron.
Curve B is for high-quality materials.
Fig. 13–38
Access the text alternative for slide images.
© McGraw Hill 17
Example
A worm drive transmits 15 kW at 2000 rpm to a machine carriage at 75 rpm. The
worm is triple threaded and has 65 mm pitch diameter. The worm gear has 90
teeth and 6 mm module. The tooth form is to be 200 involute. Calculate
a. The tangential force on the worm
b. Axial thrust on the worm
c. Separating force on the worm
Solution: × ×
Torque on the worm, T
×
× × . ×
Answer: Tangential force on the worm
Answer:

Answer: Axial thrust on the worm,

.
Answer: Radial force on the worm, . .

Example 13–10
A 2-tooth right-hand worm transmits 1 hp at 1200 rev/min to a 30-tooth worm gear.
The gear has a transverse diametral pitch of 6 teeth/in and a face width of 1 in. The
worm has a pitch diameter of 2 in and a face width of 2 in. The normal pressure
angle is 14°. The materials and quality of the gearing to be used are such that curve
B of Figure 13–38 should be used to obtain the coefficient of friction.
(a) Find the axial pitch, the center distance, the lead, and the lead angle.
(b) Figure 13–39 is a drawing of the
worm gear oriented with respect to the
coordinate system described earlier in
this section; the gear is supported by
bearings A and B. Find the forces exerted
by the bearings against the worm-gear
shaft, and the output torque.
Fig. 13–39
© McGraw Hill 19
Solution:
(a) The axial pitch is the same as the transverse circular pitch of the gear, which is
Answer
The pitch diameter of the gear is dG = NG/P = 30∕6 = 5 in. Therefore, the center
distance is
Answer
From Equation (13–27), the lead is
Answer
Also using Equation (13–28), we find
Answer
© McGraw Hill 20
Solution:
(b) Using the right-hand rule for the rotation of the worm, you
will see that your thumb points in the positive z direction. Now
use the bolt-and-nut analogy (the worm is right-handed, as is the
Wwa
screw thread of a bolt), and turn the bolt clockwise with the
right hand while preventing nut rotation with the left. The nut Wwr Wwt
will move axially along the bolt toward your right hand.
Therefore the surface of the gear (Figure 13–39) in contact with WGa WGr
the worm will move in the negative z direction as shown in the
figure. WGt
The pitch-line velocity of the worm is:
The speed and velocity of the gear can be determined. Direction of rotation
The speed of the gear can be determined: nG = Fig. 13–39b
Therefore the pitch-line velocity of the gear is
t
© McGraw Hill 21
Solution:
Then, from Equation (13–47), the sliding velocity VS is found to be
Getting to the forces now, we begin with the horsepower formula
This force acts in the negative x direction, as shown in the Fig. 13-39b. Using Figure 13–38,
we find f = 0.03. Then, the first equation of Equation (13–43) gives
Also, from Equation (13–43),
© McGraw Hill 22
Solution:
‘ now identify the components
We
acting on the gear as
A free-body diagram showing the

forces and torsion acting on the gear
shaft is shown in Figure 13–40.
We can make B a thrust bearing in

order to place the gearshaft in
compression.
Summing forces in the x direction

gives:
Fig. 13–40 Fig. 13–40
© McGraw Hill 23
Force
Solution:
Analysis of Worm Gears
Taking moments about the z axis, we have:
Answer
Taking moments about the y axis,

Answer
Summing forces in the y direction,

Answer
Similarly, summing forces in the z direction,

Answer
Summing moments about x,

Answer
It is because of the frictional loss that this output torque is less than
the product of the gear ratio and the input torque.
© McGraw Hill 24
Gear Manufacturing
Forming of Gear Teeth
Common ways of forming gear teeth.
• Sand casting.
• Shell molding.
• Investment casting.
• Permanent-mold casting.
• Die casting.
• Centrifugal casting.
• Powder-metallurgy.
• Extrusion.
• Injection molding (for thermoplastics).
• Cold forming.
Gear Manufacturing
Cutting of Gear Teeth
Common ways of cutting gear teeth.

• Form Milling.
 Milling cutter that has shape of tooth space is used
 Each space is cut completely before gear blank is indexed to the position
of next adjacent space
• Shaping.
 Cutter reciprocates, usually on vertical spindle
• Hobbing.
 Workpiece (gear blank) and cutter (hob) rotate in coordinated fashion.
• Finishing
Gear Manufacturing
Gear Cutting Tools
Form Milling cutter Spur gear shaper cutter
Hob for small pitch gears Hob for high pitch gears
having large teeth having small teeth
Gear Manufacturing
Finishing
Different methods of gear finishing:
• Shaving
• a minute amount of metal is cut bringing the accuracy of the tooth
profile within the limits of 250 μin.
• Burnishing,
• hardened gears with slightly oversize teeth are run in mesh with the
gear until the surfaces become smooth.
• Grinding
• used for hardened gear teeth after heat treatment.
• Employs the generating principle and produces very accurate teeth.
• Lapping
• Also used for hardened gear teeth after heat treatment.
• The teeth of the gear and lap slide axially so that the whole surface
of the teeth is abraded equally.
Gear Manufacturing
Generating a Spur Gear with a Pinion Cutter
Fig. 13–13
• Courtesy of Boston Gear—Altra Industrial Motion

Gear Manufacturing
Shaping with a Rack
Fig. 13–14
Gear Manufacturing
Hobbing a Spur Gear
Fig. 13–15
Gear Manufacturing
Videos for Gear Manufacturing
https://youtu.be/B0XSsa79Y1w
https://youtu.be/XZgsV0AZJJ0
Gears - General
Machine Design II
Chapter 13
(Part 4)
Lecture outline
• Gear Trains
• Definition
• Types of Gear Trains
• Simple gear Train
• Compound gear Train
• Compound Reverted Gear Train
• Epicyclic or Planetary gear Train
• Planetary Gear Analysis
Gear Trains
 A gear train consists of a combination of two or more gears
mounted on rotating shafts to transmit power from one to the
other and act as speed reducer or speed increaser.
 Driver gives power and the driven receives power.

Gear Trains
For a pinion 2 driving a gear 3, the speed of the driven gear is
N2 d
n3  n2  2 n2 (13 - 29)
N3 d3
where n = revolutions or rev/min
N = number of teeth
d = pitch diameter
For spur and parallel helical gears, the directions in the viewing plane
ordinarily correspond to the right-hand rule—positive for counterclockwise
rotation and negative for clockwise rotation.
Gear Trains
Rotational directions are somewhat difficult to deduce for worm
and crossed helical gearsets. Figure below will be of help in these
situations
Fig. 13–22
Gear Trains
Note: The speed ratio is independent of the size of

intermediate gear
Gear Trains
For longer gear trains:
Fig. 13–23
Gear Trains
 Velocity Ratio: Ratio of rotational speed of input gear to
output gear for single pair of gears
 Train Value (e): Product values of VR for all pairs of gear in

train
product of driving tooth numbers
e (13 - 30)
product of driven tooth numbers
Example, for Fig. 13-23 above:
N 2 N3 N5
n6   n2
N3 N 4 N 6
nL  enF (13 - 31)
where nL is the speed of the last gear in the train and nF is the speed of the first.
Gear Trains
External and Internal Meshing
 External meshing produces rotation in opposite directions.
 Internal meshing produces rotation in the same direction
Types of the Gear Trains
 Simple gear Train – One gear mounted in one shaft
 Compound gear – Two gears are placed in the same shaft
 Compound Reverted Gears – Input and output shafts are
collinear
 Epicyclic or planetary gears – At least one of the gears is
rotating with the axis of another gear. (Epi means axis cyclic
means rotating)
Simple Gear Train
Simple gear Train – One gear mounted in one shaft
Driver Driven
gear gear
Intermediate
(idler) gears
Simple Gear Trains
• Note that when the number of intermediate gears is odd,
driver and driven gears rotate on the same direction; but
if the number of intermediate gears is even, driver and
driven gears rotate on opposite directions.
• Train value is independent of the size and the number of
intermediate gears.
• Intermediate gears are called idle gears, as they do not
effect the speed ratio of the system.
• The idle gears are used for the following two purposes :
1. To connect gears where a large distance is required, and
2. To obtain the desired direction of motion of the driven
gear(i.e. clockwise or anticlockwise).
Compound Gear Train
• Definition: When there are more than one gear a shaft as shown
in the figure, it is known as compound gear train.
• Compound gear trains are useful in bridging over the space
between the driver and the driven.
• The advantage of compound train over a simple train is that a
much longer speed reduction from one shaft to the last shaft can
be obtained with small gears
Compound Reverted Gear Trains
 It is sometimes desirable for the input shaft and the output shaft
of a two-stage compound gear train to be in-line, as shown in
Figure 13–25. This configuration is called a compound reverted
gear train.
 Requires the distances between the shafts to be the same for both
stages of the train.
 The distance constraint is: d 2 2  d3 2  d 4 2  d5 2
Diametral pitch is P  N d
Therefore, N 2 (2 P)  N 3 (2 P)  N 4 (2 P)  N 5 (2 P) N 2  N3  N 4  N5
Fig. 13–25
Gear Trains
Guidance for Gear Train design:
• Rough guideline: a train value of up to 10 to 1 can be obtained
with one pair of gears.
• Greater ratios can be obtained in less space and with fewer
dynamic problems by compounding additional pairs of gears.
• A two-stage compound gear train can obtain a train value of up to
100 to 1.
• Since numbers of teeth on gears must be integers, it is better to
determine them first, and then obtain pitch diameters second.
• Determine the number of stages necessary to obtain the overall
ratio, then divide the overall ratio into portions to be
accomplished in each stage
• To minimize package size, keep the portions as evenly divided
between the stages as possible. For example, if the overall train
value need only be approximated, each stage can be identical.
Gear Trains
Example 13-3:
A gearbox is needed to provide a 30:1 (±1 percent) increase in speed,
while minimizing the overall gearbox size. Specify appropriate tooth
numbers.
Solution
° [Use Equation (13–11)]

Gear Trains
Gear box from Example 13-3:
Gear Trains
Example 13-4:
A gearbox is needed to provide an exact 30:1 increase in speed,
while minimizing the overall gearbox size. Specify appropriate teeth
numbers.
Solution
Factor the overall ratio into two integer stages
i.e., and hence and
With two equations and four unknown numbers

of teeth, two free choices are available.
Assuming a pressure angle of minimum

number of teeth required is 16. [Use Equation (13–11)]
Assign
Assign then
Planetary Gear Trains
 Definition: If one or more shafts rotate around another shaft
as well as spinning about their own axes, the gear train is called
a planetary or epicyclic gear train.
/Arm
 Planetary gear train overcome the restriction of both simple

and compound gear trains in which their gear shafts must
rotate in bearings fixed to the frame.
https://youtu.be/ARd-Om2VyiE
https://youtu.be/kmJADKX5yaw
 Planetary gear trains are used extensively for compact gear
reducers. Also, because they are basically devices with multiple
degrees of freedom, they are used in automatic transmissions for
automobiles and trucks
 A planetary gear train has the following advantages over ordinary
gear trains:
1. It has compact space requirements, particularly when the
input and output axes are collinear
2. Both static and dynamic forces are balanced when multiple
planets are equally spaced about the central axes of the gear
train
3. High torque capacity is possible, by using multiple planets.
4. It can provide a wide range of speed ratios.
• Planetary (Epicyclic) Gear Box
A simple planetary gear trains are typically made up of the
following:
1. Sun gear (which may or may not be fixed) - has fixed center
axis.
2. Planet carrier or Arm - carries planet axis relative to sun axis.
3. Planet gears (one or more) - has moving center axis).
4. Internal ring gear (not used in all planetary gear trains).
Planetary
2/9/2022 gear train Side view Skeleton representation
Planetary Gear Analysis
• The motion of a planetary gear train is not always as
intuitive as fixed-center trains.
• As gears and carriers rotate, the motion can appear
rather complex.
• To analyze the motion of a planetary gear train, Two
methods are usually employed:
1. Formula method
2. Superposition method (Tabular method)
Formula Method
 To develop the formula method, the motion of the mating gears
is examined relative to the arm or carrier. Thus, kinematic
inversion is used to view the train as if the carrier were fixed.
 One gear on the end of the train is designated the first gear. The
gear on the opposite end of the train is designated the last gear
 The first gear is designated as a driver gear and the last gear is
a driven gear. The intermediate gears are appropriately
identified depending on whether they drive or are driven.
 The first gear has a velocity designated nF and the last gear has
a velocity designated nL. The arm (carrier) has a velocity nA.
Formula Method
 The angular velocity of the first gear relative to the arm in rev/min
is: nF/A = nF – nA (a)
 Also, the angular velocity of the last gear relative to the arm in
rev/min is: nL/A = nL – nA (c)
 Dividing Equation (c) by Equation (b) gives:
/
(13-32)
/
 The relationship between the angular velocities and number of

teeth in the train is given as follows:
/
 The above equation can be solved for any of the angular velocity
terms, knowing the other two. Often, either the first gear, last gear,
or the carrier is fixed and a zero is substituted for that term.
Formula Method
Example 13–6
In Figure 13–26 the sun gear is the input, and it is driven clockwise at 100
rev/min. The ring gear is held stationary by being fastened to the frame. Find the
rev/min and direction of rotation of the arm and gear 4.
Solution
1. Specify the first and last gear: The sun (gear
2) will be designated the first gear and the
ring gear (gear 5) will be designated as the
last gear
2. Substitute Gear Ratios into the Planetary
Train Formula: Gear 2 (first) mates with gear
4, which in turn mates with gear 5 (last).
Substituting into the equation gives:
3. Identify the Velocity Terms: nF = 100

rev/min. nL = n5 = 0. The velocity of the arm
must be determined, thus nA = ? Fig. 13–26
Formula Method
Solution (continued):
4. Substitute Values into the Planetary Train Formula and Solve:
Substituting values into the equation gives:
Solving;
nA = 0 rpm = 20 rpm CW
To obtain the speed of gear 4, we follow the procedure of Planetary Train

Formula once again
/
Solving, we get: n4 = 33.33 rpm - CCW

Formula Method
Example:
For a planetary gear train shown, the
arm (link 2) serves as the input to the
train. The sun (gear 1) is the fixed
gear and has 30 teeth. The planet
gear (gear 3) has 35 teeth. The ring
gear serves as the output from the
train and has 100 teeth. Determine
the rotational velocity of all members
of this gear train when the input shaft
rotates at 1200 rpm clockwise.
Formula Method
Solution:
1. Specify the first and last gear: The sun (gear 1) will be designated
the first gear. Being on the other end of the train, the ring gear (gear 4)
will be designated as the last gear
2. Substitute Gear Ratios into the Planetary Train Formula: Gear 1

(first) mates with gear 3, which in turn mates with gear 4 (last).
Substituting into the equation gives:
3. Identify the Velocity Terms: The sun is fixed, giving nF = 0. The

carrier rotates at 1200 rpm clockwise. Taking clockwise to be a
negative direction, nA = - 1200 rpm. The ring gear must be determined,
thus nL = ?
Formula Method
4. Substitute Values into the Planetary Train Formula and Solve:
Substituting values into the equation gives:
Solving;
nL = n4 1560 = 1560 rpm CW
Similarly;
/
Solving, we get: n3 = 2228.6 rpm = 2228.6 CW

Superposition Method
The method of superposition consists of the following:
Step One: Relax the constraint on the fixed link and temporarily
assume that the carrier is locked. Then turn the previously fixed
gear one revolution and calculate the effect on the entire train.
Step Two: Free all constraints and record the movement of rotating
each link one revolution in the opposite direction of the rotation in
step one.
Step Three: The motion of all links is determined by combining the
rotations from the first two steps. As the motion in step two is
combined with the motion in the step one, the superimposed motion
of the fixed gear equals zero.
Step Four. Determine Velocities of All Links: The velocities can be
determined by using the ratios of angular displacements of any pair.
The reference can be made with the item with known speed.
Example:
For a planetary gear train shown,
the carrier (link 2) serves as the
input to the train. The sun (gear 1)
is the fixed gear and has 30 teeth.
The planet gear (gear 3) has 35
teeth. The ring gear serves as the
output from the train and has 100
teeth. Determine the rotational
velocity of all members of this
gear train when the input shaft
rotates at 1200 rpm clockwise.
Solution:
Step 1: Temporarily fix the carrier then compute the motions of all
gears as the previously fixed gear (sun gear) rotates one revolution.
Thus, the following can be determined:
Gear 1 rotates one revolution: θ1 = + 1 rev.
 N   30 
Gear 3 rotates w.r.t gear 1:  3    N 1  1     35   1 rev.  0.857 rev.
 3   
  
Gear 4 rotates w.r.t gear 1:  4    N1    N 3 1     30    35 
 1 rev.
 N3   N4   35   100 
 0.3 rev.
Step 2: Rotates all links –1 revolution. This returns the sun gear to its
original position, yielding a net movement of zero.
Step 3: Combine the two motions, resulting in the actual planetary gear
train motion. Thus the rotations from both steps are algebraically
added together
Step 4: Determine Velocities of All Links: The velocities can be
The reference can be made with the item with known speed. In this
case, it is the arm (no. 2)
Example 13–6 (using superposition method)
In Figure 13–26 the sun gear is the input, and it is driven clockwise at 100
rev/min. The ring gear is held stationary by being fastened to the frame. Find the
rev/min and direction of rotation of the arm and gear 4.
Solution
Step 1: Temporarily fix the carrier then compute
the motions of all gears as the previously fixed
gear (ring gear) rotates one revolution. Thus, the
following can be determined:
Gear 5 rotates one revolution: θ5 = + 1 rev.
Gear 4 rotates w.r.t. gear 5:
Gear 2 rotates w.r.t. gear 5:
 Fig. 13–26
Solution (continue..):
Step 2: Rotates all links –1 revolution. This returns the ring gear to its
original position, yielding a net movement of zero.
Step 3: Combine the two motions above resulting in the actual planetary
gear train motion. Thus the rotations from both steps are algebraically
added together
Link Ring (5) Planet (4) Arm (3) Sun (2)
Step 1: +1 +2.667 0 4
Rotate with fixed arm
Step 2: 1 1 1 1
Rotate all links 1 rev opposite direction
Step 3: 0 1.667 1 5
Total rotations
Step 4. Determine Velocities of All Links: The velocities can be
The reference can be made with the item with known speed. In this
case, it is the sun gear (no. 2)
Some Useful Links
Planetary Gear Simulator (thecatalystis.com)
Epicyclic Gear Trains – Marples Gears
Planetary Gears: Principles Of Operation |

Lancereal
Design of Gears for
Strength
(Spur and Helical Gears)
Machine Design II
Chapter 14
Lecture outline
• Introduction
• Cantilever Beam Model of Bending Stress in Gear
Tooth
• Lewis Equation
• Dynamic factor
• Fatigue Stress-Concentration Factor
• Surface Durability
• AGMA Method
• Various factors used in gear design
Introduction
Stress Distribution On Gear Tooth:
Stress distribution on the gear
tooth in operation can be
observed by considering the
Photoelastic Model of the tooth:
 Here, concentrated lines show
high concentration of stresses
at two areas:
 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
ii. Bearing (contact) stress at the surface of the tooth.
Introduction
• For the analysis and design of spur and helical gears the
main focus is the strength to resist bending failure of the
teeth as well as pitting failure of tooth surfaces.
• Failure by bending will occur when the significant tooth
stress equals or exceeds either the yield strength or the
bending endurance strength.
• A surface failure occurs when the significant contact
stress equals or exceeds the surface endurance strength.
Cantilever Beam Model of Bending Stress in
Gear Tooth
A cantilever of cross-sectional
dimensions F and t, having a length l
and a load Wt uniformly distributed
across the face width F.
Gear Tooth
 Considering the cantilever
M 6W t l
s  (a)
I c Ft 2
where s is the bending stress at the root of

the gear tooth a.
 From Similar Triangles

t 2 l t2 t2
 or x  or l  (b)
x t 2 4l 4x
 Rearranging the stress equation gives
6W t l W t 1 Wt 1 1
s 2
 2
 (c)
Ft F t 6l F t 2 4l 64
Gear Tooth
 If we now substitute the value of l from
Equation (b) in Equation (c) and multiply the
numerator and denominator by the circular
pitch p, we find
Wt p
s (d)
F  3  xp
2
 Letting y =2x/3p gives

Wt
s (14 - 1)
Fpy
 Substituting P = p/p and Y= py gives

W tP
Lewis Equation s  (14 - 2)
FY
2 xP
Lewis Form Factor Y (14 - 3)
3
Values of Lewis Form Factor Y
Number of Teeth Y Number of Teeth Y
12 0.245 28 0.353
13 0.261 30 0.359
14 0.277 34 0.371
15 0.290 38 0.384
16 0.296 43 0.397
17 0.303 50 0.409
18 0.309 60 0.422
19 0.314 75 0.435
20 0.322 100 0.447
21 0.328 150 0.460
22 0.331 300 0.472
24 0.337 400 0.480
26 0.346 Rack 0.485
Dynamic Effects
Effective load increases as velocity increases.
Velocity factor Kv accounts for this.
With pitch-line velocity V in feet per minute,
600  V
Kv  (cast iron, cast profile) (14 - 4a )
600
1200  V
Kv  (cut or milled profile) (14 - 4b )
1200
50  V
Kv  (hobbed or shaped profile) (14 - 5a )
50
78  V
Kv  (shaved or ground profile) (14 - 5b )
78
Dynamic Effects
With pitch-line velocity V in meters per second,
3.05  V
Kv  (cast iron, cast profile) (14 - 6a )
3.05
6.1  V
Kv  (cut or milled profile) (14 - 6b )
6.1
3.56  V
Kv  (hobbed or shaped profile) (14 - 6c )
3.56
5.56  V
Kv  (shaved or ground profile) (14 - 6d )
5.56
Lewis Equation
The Lewis equation including velocity factor.
U.S. Customary version.
K vW t P
s (14 - 7)
FY
Metric version.
K vW t
s (14 - 8)
FmY
Acceptable for general estimation of stresses in gear
teeth.
Forms basis for AGMA method, which is preferred
approach.
Lewis Equation
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 20° 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.
Solution
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:
V
Lewis Equation
Example 14–1 (continues…)
The velocity factor from Equation (14–4b) is found to be
Table 14–2 gives the form factor as Y = 0.296 for 16 teeth.
We now bring Equation (14–8):

Surface Durability
Another failure mode is wear due
to contact stress.
Contact Stress - Two Cylinders in
Compression:
Modeling gear tooth mesh with
contact stress between two
cylinders:
2F
pmax 
p bl
where
pmax  largest surface pressure
F  force pressing the two cylinders together
l  length of cylinders
12
 2 F (1  v ) E1  (1  v ) E2 
2 2
b 1 2
 (14 -10)
 p l 1 d1  1 d 2 
Surface Durability
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
12
 W t
1 r 1 r 
sC    1 2
 (14 - 11)
 p F cos f (1  v1 ) E1  (1  v2 ) E2 
2 2
Critical location is usually at the pitch line, where

d P sin f dG sin f
r1  r2  (14 - 12)
2 2
Define elastic coefficient from denominator of Equation (14–11),
12
 
 
1
Cp    (14 - 13)
  1  vP2 1  vG2  
p    
  E P E G 
Surface Durability
Incorporating elastic coefficient and velocity factor, the
contact stress equation is.
12
 K vW  1 1  
t
s C  C p     (14 -14)
 F cos f  r1 r2  
where the sign is negative because σC is a compressive stress.
Again, this is useful for estimating, and as the basis for the
preferred AGMA approach.
AGMA Stress Equations
AGMA stands for the American Gear Manufacturers
Association.
• AGMA provides a recommended method for gear
design.
• Includes bending stress and contact stress as two failure
modes.
• Incorporates modifying factors to account for various
situations.
• Imbeds much of the detail in tables and figures.
AGMA Bending Stress
 t Pd K m K B
 W K K
o v s K (U.S. customary units)
F J
s  (14 - 15)
1 KH KB
W t K o K v K s (SI units)
 bmt YJ
where for U.S. customary units (SI units),

Wt is the tangential transmitted load, lbf (N).
Ko is the overload factor.
Kv is the dynamic factor.
Ks is the size factor.
Pd is the transverse diametral pitch.
F (b) is the face width of the narrower member, in (mm).
Km (KH) is the load-distribution factor.
KB is the rim-thickness factor.
J (YJ) is the geometry factor for bending strength (which includes root fillet stress-
concentration factor Kf).
(mt) is the transverse metric module.
AGMA Contact Stress
 t Km C f
C p W K o K v K s (U.S. customary units)
 dP F I
sc   (14 - 16)
 t KH ZR
Z
 E W Ko Kv K s (SI units)
 d w1b Z I
where W t, Ko, Kv, Ks, Km, F, and b are the same terms as defined for
Equation (14–15). For U.S. customary units (SI units), the
additional terms are.
2 2
Cp (ZE) is an elastic coefficient, lbf in ( N mm )
Cf (ZR) is the surface condition factor.
dP (dw1) is the pitch diameter of the pinion, in (mm).
I (ZI) is the geometry factor for pitting resistance.
AGMA Strengths
AGMA uses allowable stress numbers rather than strengths.
These are referred to as strengths for consistency within the
textbook.
The gear strength values are only for use with the AGMA stress
values, and should not be compared with other true material
strengths.
Representative values of typically available bending strengths are
given in Table 14–3 for steel gears and Table 14–4 for iron and
bronze gears (See textbook)
Figures 14–2, 14–3, and 14–4 are used as indicated in the tables.
(See textbook)
Tables assume repeatedly applied loads at 107 cycles and 0.99
reliability.
Allowable Bending Stress
 St YN
S K K (U.S. customary units)

s all   F T R (14 - 17)
 St YN (SI units)
 S F Y YZ
where for U.S. customary units (SI units),

St is the gear bending strength, lbf/in2 (N/mm2).
YN is the stress-cycle factor for bending stress.
KT (Yθ) are the temperature factors.
KR (YZ) are the reliability factors.
SF is the AGMA factor of safety, a stress ratio.
Allowable Contact Stress
 Sc Z N CH
S (U.S. customary units)
 H KT K R
s c ,all  (14 -18)
 Sc Z N ZW
(SI units)
 S H Y YZ
Sc is the gear contact strength, lbf/in2 (N/mm2).

ZN is the stress-cycle factor.
CH (ZW) are the hardness ratio factors for pitting resistance.
KT (Yθ) are the temperature factors.
KR (YZ) are the reliability factors.
SH is the AGMA factor of safety, a stress ratio.
Bending-Strength Geometry Factor J (YJ in
metric)
Accounts for shape of tooth in bending stress equation.
Includes.
A modification of the Lewis form factor Y.
Fatigue stress-concentration factor Kf.
Tooth load-sharing ratio mN.
AGMA equation for geometry factor is
Y
J (14 - 20)
K f mN
pN
mN  (14 - 21)
0.95Z
Values for Y and Z are found in the AGMA standards.
For most common case of spur gear with 20° pressure angle, J can be read
directly from Figure 14–6.
For helical gears with 20° normal pressure angle, use Figures 14–7 and 14–8.
Surface Strength Geometry Factor I (ZI in metric)
Called pitting resistance geometry factor by AGMA.
 cosft sinft mG
 2m external gears
 N mG  1
I  (14 - 23)
 cosft sinft mG internal gears
 2mN mG  1
NG dG
mG   (14 - 22)
NP dP
pN
mN  (14 - 21)
0.95Z
pN  pn cosfn (14 - 24)
Z  [(rp  a ) 2  rbP2 ]1 2  [( rG  a ) 2  rbG ]  ( rP  rG ) sinft

2 12
(14 - 25)
rb  r cos ft (14 - 26)

Factors
Several factors are defined that are used with AGMA method.
These are:
Dynamic Facto, Kv
Overload Factor, Ko
Surface Condition Factor, Cf (ZR)
Size Factor Ks
Load-Distribution Factor Km (KH)
Hardness-Ratio Factor CH (ZW)
Stress-Cycle Factors YN and ZN
Reliability Factor KR (YZ)
Temperature Factor KT (Yθ)
Rim-Thickness Factor KB
Safety Factors SF and SH
 Please refer to the relevant passages, formulas, tables and graphs in the
textbook for these factors:
Summary for Bending of Gear Teeth
Su
Fig. 14–17
Summary for Surface Wear of Gear Teeth
s
Fig. 14–18
Gear Mesh Analysis
Example 14-4
A 17-tooth 20° pressure angle spur pinion rotates at 1800 rev/min and
transmits 4 hp to a 52-tooth disk gear. The diametral pitch is 10 teeth/in,
the face width 1.5 in, and the quality standard is No. 6. The gears are
straddle-mounted with bearings immediately adjacent. The pinion is a
grade 1 steel with a hardness of 240 Brinell tooth surface and through-
hardened core. The gear is steel, through-hardened also, grade 1 material,
with a Brinell hardness of 200, tooth surface and core. Poisson’s ratio is
0.30, JP = 0.30, JG = 0.40, and Young’s modulus is 30(106) psi. The loading is
smooth because of motor and load. Assume a pinion life of 108 cycles and a
reliability of 0.90, and use YN = 1.3558N−0.0178, ZN = 1.4488N−0.023. The tooth
profile is uncrowned. This is a commercial enclosed gear unit.
(a) Find the factor of safety of the gears in bending.
(b) Find the factor of safety of the gears in wear.
(c) By examining the factors of safety, identify the threat to each gear and
to the mesh.
Gear Mesh Analysis
Solution:
Gear Mesh Analysis
Solution (Continues..)
To determine the size factor, Ks, the Lewis form factor is needed. From Table 14–2,
with NP = 17 teeth, YP = 0.303. Interpolation for the gear with NG = 52 teeth yields
YG = 0.412. Thus from Eq. (a) of Sec. 14–10, with F = 1.5 in,
The load distribution factor Km is determined from Eq. (14–30), where five terms
are needed. They are, where F = 1.5 in when needed:
Gear Mesh Analysis
Gear Mesh Analysis
Gear Mesh Analysis
Gear Mesh Analysis
(c) For the pinion, we compare (SF)P with (SH)2P, or 5.73 with 1.692 = 2.86, so
the threat in the pinion is from wear. For the gear, we compare (SF)G with
(SH)2G, or 6.96 with 1.522 = 2.31, so the threat in the gear is also from wear.
Design of Gears for
Strength
(Bevel and Worm Gears)
Machine Design II
Chapter 15
Lecture outline
Bevel Gearing—General
Bevel-Gear Stresses and Strengths
AGMA Equation Factors
Straight-Bevel Gear Analysis
Design of a Straight Bevel Gear Mesh
Worm Gearing—AGMA Equation
Worm-Gear Analysis
Designing a Worm Gear Mesh
Buckingham Wear Load
Bevel Gearing - General
Bevel gear classifications.
• Straight bevel gears
• Spiral bevel gears
• Zerol bevel gears.
• Hypoid gears.
• Spiroid gears.
Consists of curved teeth but with a
zero spiral angle. Axial thrust loads
are less than spiral bevel gear.
Often used instead of straight bevel
gears.
Perpendicular shafts lying in a plane.

Usually used for pitch line velocities
up to 1000 ft/min (5 m/s).
Sprial and hypoid bevel gears
Recommended for higher speeds.

Recommended for lower noise
levels.
Allows for offset in shaft center-

lines.
Pitch surfaces are hyperboloids of
revolution.
Spiroid bevel gear
Greater offset of center-

lines than hypoid gears.
Hypoid and Spiroid gears
are progressions from
spiral gear to worm gear.
Fig. 15–4
Due to complexity of other forms of bevel gears, only a portion of
the applicable standards that refer to straight-bevel gears is
presented here. Table 15–1 gives the symbols used in ANSI/AGMA
2003-B97.
Fundamental Contact Stress Equation
1/2
 W t 
sc  σ c  C p  K o K υ K m Cs C xc  (U.S. customary units)
 Fd p I 
(15 - 1)
1/ 2
 1000W t 
σH  ZE  K A K υ K Hβ Z x Z xc  (SI units)
 bd Z 1 
Permissible Contact Stress Number (Strength) Equation

sacCLCH
swc  (σ c )all  (U.S. customary units)
S H KT C R
(15 - 2)
σ H lim Z NT ZW
σH P  (SI units)
S H Kθ Z Z
Bending Stress
Wt KK
st  Pd K o K υ s m (U.S. customary units)
F Kx J
(15 - 3)
1000W K A K υ Yx K Hβ
t
σF  (SI units)
b met Yβ YJ
Permissible Bending Stress Equation
sat K L
swt  (U.S. customary units)
S F KT K R
(15 - 4)
σ F lim YNT
σF P  (SI units)
S F K θYZ
AGMA Equation Factors
Many factors are defined as in the case of Spur gears. Students are
asked to refer to textbook for detail coverage of these factors.
Allowable Stresses
Refer to the relevant tables and graphs in the textbook for
allowable contact stresses and allowable bending stresses
Summary for Straight-Bevel Gear Wear
Continues next side

Summary for Straight-Bevel Gear Wear
Continues from previous side
Fig. 15–14
Summary for Straight-Bevel Gear Bending
Continues
next side
Summary for Straight-Bevel Gear Bending
Continues from previous side
Fig. 15–15
Example 15–1
A pair of identical straight-tooth miter gears listed in a catalog has a
diametral pitch of 5 at the large end, 25 teeth, a 1.10-in face width,
and a 20° normal pressure angle; the gears are grade 1 steel through-
hardened with a core and case hardness of 180 Brinell. The gears are
uncrowned and intended for general industrial use. They have a
quality number of Qv = 7. It is likely that the application intended will
require outboard mounting of the gears. Use a safety factor of 1, a
107 cycle life, and a 0.99 reliability.
(a) For a speed of 600 rev/min find the power rating of this gearset
based on AGMA bending strength.
(b) For the same conditions as in part (a) find the power rating of this
gearset based on AGMA wear strength.
(c) For a reliability of 0.995, a gear life of 109 revolutions, and a safety
factor of SF = SH = 1.5, find the power rating for this gearset using
AGMA strengths.
Solution Continues…
Design of Straight-Bevel Gear Mesh
A useful decision set for straight-bevel gear design is
Function: power, speed, mG, R
Design factor: nd
Tooth system A priori decisions
Tooth count: NP, NG
Pitch and face width: Pd, F
Quality number: Qv Design decisions
Gear material, core and case hardness
Pinion material, core and case hardness
Recommended Face Width
Bending strength is not linear with face width.
Added material is placed at the small end of the teeth.
Recommended face width,
F  min(0.3 A0, 10 Pd ) (15 - 24)
dP dG
A0   (15 - 24)
2 sin γ 2 sin 
Worm Gearing - AGMA Equation
Worm gears are used to transmit rotary
motion between non-parallel and non-
intersecting shafts. Usually perpendicular
Relation between shaft angle and helix angles
is.
  ψ P  ψG (15 - 26)
Crossed helical gears can be considered as

non-enveloping worm gears.
Fig. 15–16
Worm Gear Dimensions
With center-to-center distance C, good proportions indicate the
pitch worm diameter d should be in the range.
C 0.875 C 0.875
d (15 - 27)
3 1.6
Cylindrical worm dimensions common to both worm and gear,

ϕn
14.5° 20° 25°
Quantity Symbol NW ≤ 2 NW ≤ 2 NW > 2
Addendum a 0.3183px 0.3183px 0.286px

Dedendum b 0.3683px 0.3683px 0.349px
Table 15–8
Whole depth ht 0.6866px 0.6866px 0.635px
*The table entries are for a tangential diametral pitch of the gear of
Pt = 1.
Friction Force
fW t
Wf  (15 - 29)
cos  cos n
where f = coefficient of friction

λ = lead angle at mean worm diameter
ϕn = normal pressure angle
Sliding Velocity and Torque

 nW d m
Vs  (15 - 30)
12 cos 
W t Dm
TG  (15 - 31)
2
Worm Gearing Equations for Allowable Tangential Force
 
Wt
all
 Cs Dm0.8 FeCmCv (15 - 28)
where Cs = materials factor

Dm = mean gear diameter, in
Fe = effective face width of the gear (actual face width,
but not to exceed 0.67dm, the mean worm diameter), in
Cm = ratio correction factor
Cv = velocity factor
Cs  720  10.37C 3 C  3 in (15 - 32)
For sand-cast gears,

1000 C  3 Dm  2.5 in
Cs   (15 - 33)
1190  477 log Dm C  3 Dm  2.5 in
For chilled-cast gears,

1000 C  3 Dm  8 in
Cs   (15 - 34)
1412  456 log Dm C  3 Dm  8 in
For centrifugally cast gears,

1000 C  3 Dm  25 in
Cs   (15 - 35)
1251  180 log Dm C  3 Dm  25 in
The ratio correction factor Cm for is given by
0.02  m 2  40m  76  0.46 3  m  20

 G G G

Cm  0.0107  mG2  56mG  5145 20  mG  76 (15 - 36)
1.1483  0.006 58m mG  76
 G
The velocity factor Cv is given by
0.659 exp  0.001 1Vs  Vs  700 ft/min


Cv  13.31 Vs 0.571 700  Vs  3000 ft/min (15 - 37)
65.52 V 0.774 Vs  3000 ft/min
 s
Coefficient of Friction f
0.15 Vs  0


f  0.124 exp 0.074Vs0.645  0  Vs  10 ft/min (15 - 38)

 0.103 
exp  0.110Vs 
0.450
 0.012 Vs  10 ft/min
Worm-Gear Geometry
px
a  0.3183 px (15 - 39)
π
1.157 px
b  0.3683 px (15 - 40)
π
 2.157 px
 π  0.6866 px px  0.16 in
ht   (15 - 41)
 2.200 px  0.002  0.7003 p  0.002 p < 0.16 in
 π x x
d o  d  2a (15 - 42)
d r  d  2b (15 - 43)
Dt  D  2a (15 - 44)
Dr  D  2b (15 - 45)
c ba (15 - 46)
Face Width
2 2
D  D 
( FW ) max  2  t     a  2 2 Da (15 - 47)
 2 2 
2d m 3 p x  0.16 in
FG   (15 - 48)
1.125  d o  2c  2
  d o  4 a  2
px  0.16 in
Energy Issues
Heat loss rate from worm-gear case in ft·lbf/min,
H loss  33 000(1  e)H in (15 - 49)
Overall coefficient for combined convective and radiative heat

transfer from the worm-gear case,
 nW
 6494  0.13 no fan on worm shaft
 CR  (15 - 50)
 nW  0.13 fan on worm shaft
 3939
With case lateral area A, the oil sump temperature,
H loss 33 000 1  e H  in
t s  ta    ta (15 - 51)
 CR A  CR A
AGMA recommended minimum lateral area in in2

Amin  43.20C1.7 (15 - 52)
Buckingham Stress Equation
Worm teeth are inherently much stronger than worm-gear teeth.
Worm-gear teeth are short and thick on the edges of the face.
Midplane they are thinner as well as curved.
Buckingham adapted the Lewis equation for this case,
WGt
σa  (15 - 53)
pn Fe y
y is the Lewis form factor.

Worm-Gear Analysis
Mechanical efficiency with worm driving,
cos n  f tan 
eW  (15 - 54)
cos n  f cot 
Mechanical efficiency with gear driving,

cos n  f cot 
eG  (15 - 55)
cos n  f tan 
To ensure worm gear will drive the worm,
f stat  cos n tan  (15 - 56)

Worm-Gear Analysis
Relation of tangential worm force and tangential gear force,
cos  n sin   f cos 
WWt  WGt  (15 - 57)
cos n cos   f sin 
Due to low efficiency of worm gearing, output power is not

considered equivalent to input power.
Relating tangential gear force to output power and efficiency,
33 000nd H 0 K a
WGt  (15 - 58)
VG e
To ensure worm gear will drive the worm,
WWt VW πdW nW WWt
HW   hp (15 - 59)
33 000 12  33 000
WGtVG πdG nGWGt
HG   hp (15 - 60)
33 000 12  33 000
Worm-Gear Analysis
Friction force,
fWGt
Wf  (15 - 61)
Sliding velocity of worm at pitch cylinder,

 dnW
Vs  (15 - 62)
12 cos 
Friction power,
W f Vs
Hf  hp (15 - 63)
33 000
Maximum Lead Angle for Worm Gearing
Table 15–9 Largest Lead Angle Associated with a
Normal Pressure Angle ϕ n for Worm Gearing
ϕn Maximum Lead Angle λmax
14.5° 16°
20° 25°
25° 35°
30° 45°
Design of Worm Gear Mesh
A useble decision set for worm gear mesh includes:
Function: power, speed, mG, Ka
Design factor: nd
Tooth system A priori decisions
Material and process
Number of threads on the worm: NW
Axial pitch of worm: px
Pitch diameter of the worm: dW
Design decisions
Face width of gear: FG .
Lateral area of case: A
The worm-gear materials in the experience base are principally
bronzes:
• Tin- and nickel-bronzes (chilled-casting produces hardest surfaces)
• Lead-bronze (high-speed applications)
• Aluminum- and silicon-bronze (heavy load, slow-speed application)
Axial pitches for the worm are usually integers, and quotients of
integers are common. Typical pitches are:
Dimensions common to both worm gear and cylindrical worm for

proportions often used are given in Table 15–8
Minimum Number
of Gear Teeth for Can choose a trial axial pitch px.
Normal Pressure Having NW and a trial worm
Angle ϕn diameter d,
Then,
. .
Table 15–10 Reading Assignment:

Review of EXAMPLE 15–4

Gears - General: Shigley's Mechanical Engineering Design

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Gears - General

• Gears are toothed, cylindrical wheels used for

Bevel gears have teeth formed on

where P = diametral pitch, teeth per inch

22 12 1/P or m 1.25/P or 1.25m

Common pressure angle f : 20° and 25°

 Circles drawn through point P from each

• Pitch circles in contact.

Last point of contact at b

Line ab is line of action.

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The radii of the base circles.

Also, the velocity ratio does not change, and hence

Answer d p  195.63mm d G  489.07mm

The contact ratio should be at least 1.2

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k =1 for full depth teeth. k = 0.8 for stub teeth.

Smallest spur pinion that is interference-free with a rack is

It is the useful component of

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H  T   (Wt d 2) (13 - 33)

Pitch-line velocity is the linear velocity of a point on the gear at the

Fby3  ( F23r  F43t )  (0.199 ─ 0.546)  0.347 kN

The resultant shaft reaction is

These are shown on the figure 13-30b

 Shaft angle.- The angle between the intersecting shaft axes

Gear ratio mG = NG∕NP

The pitch-line velocity corresponding to the average pitch radius is

Therefore the transmitted load is

and from Equation (13–38), with Γ replacing γ, we have

where Wt acts in the positive z direction, Wr in the −x direction, and Wa in the −y

We shall also require a vector from D to C:

First we see that FyC = 140 lbf, and so

Then, from Equation (5),

For Metric gears, module (m) is specified.

Relationship between angles.

Allows fewer teeth on helical gears without

k =1 for full depth teeth. k = 0.8 for stub teeth.

Smallest helical pinion that is interference-free with a

Pinion base diameter d cos ϕt Pinion root diameter d − 2b

Base helix angle tan−1 (tan ψ cos ϕt) Inside diameter D − 2a

Free-body diagram of motor shaft

254mm 76.2mm dp/2 = 41.6/2 = 20.08 mm

254mm 76.2mm dp/2 = 41.6/2 = 20.08 mm

Taking moments about the z axis: ( )=0

Taking moments about the y axis: =0

(N1, n1) (N1, n1)

(N2, n2) (N2, n2)

Relation between lead L and lead angle λ,

Face Width of Worm Gear

Answer: Centre distance

W x  W cos n sin  WWt  WGa  W x

W x  W (cos n sin   f cos  )

Combining with Eqs. (13–42) and (13–43),

cos n sin   f cos 

WWt (without friction)

From Eq. (13–45) with f = 0 in the numerator,