Design of bevel Gear

Pair
Prof Sumit Suresh Malusare
Finolex Academy Of Management and Technology, Ratnagiri

Prof Sumit S Malusare,FAMT,Ratnagiri

Design Bevel gear pair for following Particular's
• Power to be transmitted -: 10 KW
• Input speed -: 960 rpm
• Output speed (approximate) -: 250 rpm

Prof Sumit S Malusare,FAMT,Ratnagiri

Designed Power
• Assuming application as Rotary air
Compressor with 8 to 10 hours duty per
day
• Hence Service Factor = 1.1 -----PSG 7.69
• [P] = P X SF
[P] = 10 X 1.1
= 11 KW

Prof Sumit S Malusare,FAMT,Ratnagiri

General Assumptions
• Gear tooth Profile-: Involute/Cycloidal → • Involute
1° • 20° Full Depth
• Pressure angle ( α )-:
142 , 15° ,20° ,25° →
• Gear Grades-: Grade 1 to 12 → • Carefully Cut
Gears(5-6)
• Sn Gearing( a = m)
• Type of Gearing-: S, Sn, So →
• Straight
• Type of Bevel Gear → Straight, Spiral

Prof Sumit S Malusare,FAMT,Ratnagiri

Reduction Ratio and Number of stages
𝑁𝑖
• 𝑖𝑜𝑣𝑒𝑟𝑎𝑙𝑙 =
𝑁0
• Reduction ratio per stage is
limited up to 5 for Straight Bevel
gear pair
960
• = = 3.84
250
• 3.84 < 5
• Hence we go for single stage
reduction unit

Prof Sumit S Malusare,FAMT,Ratnagiri

Determination of semi cone angles
• 𝜃𝑠 = 𝜃𝑃1 + 𝜃𝑃2 • Since shaft angle not given we
−1 sin 𝜃𝑆 assume as 90°
• 𝜃𝑃1 = tan
𝑖 +cos 𝜃𝑆 • i = 3.84
• 𝜃𝑆 - : Shaft Angle • 𝜃𝑃1 = 14.5965°
• 𝜃𝑃1 −: Pitch Angle of Pinion
• 𝜃𝑃2 = 75.4035°
• 𝜃𝑃2 −: Pitch Angle of Gear wheel

Prof Sumit S Malusare,FAMT,Ratnagiri

Number of Teeth to avoid Interference
2
• As per AGMA • 𝑍𝑉 = = 17.09 ≈ 18
2𝑎Τ𝑚 sin2 20
• 𝑍𝑉 = 2 • But these are nothing but teeth on spur
sin 𝛼
• We have consider Sn gear
𝑍
gearing( a = m) • 18 =
2 𝑐𝑜𝑠 14.5965
𝑍𝑉 = • Z = 17.41 ≈ 18
sin2 𝛼 • It means For Bevel Gear 18 teeth are
𝒁
• 𝒁𝑽 = 𝒄𝒐𝒔 𝜽 sufficient on pinion.
𝑷 𝑍2
• 3.84 = 18 → 𝑍2 =69.12 ≈70
𝑍2 • Hence 𝑖𝑒𝑥𝑎𝑐𝑡 = 3.89 for further
•𝑖= 𝑍1 calculations

Prof Sumit S Malusare,FAMT,Ratnagiri

Recalculation of Exact semi cone angles
• 𝜃𝑠 = 𝜃𝑃1 + 𝜃𝑃2 • Since shaft angle not given we
−1 sin 𝜃𝑆 assume as 90°
• 𝜃𝑃1 = tan
𝑖 +cos 𝜃𝑆 • 𝑖𝑒𝑥𝑎𝑐𝑡 = 3.89
• 𝜃𝑆 - : Shaft Angle • 𝜃𝑃1 = 14.4168°
• 𝜃𝑃1 −: Pitch Angle of Pinion
• 𝜃𝑃2 = 75.5832°
• 𝜃𝑃2 −: Pitch Angle of Gear wheel

Prof Sumit S Malusare,FAMT,Ratnagiri

Designed Torque
• 𝑃 =
2𝜋𝑁 𝑀𝑡 • 𝑀𝑡1 = 109419.0234 N.mm
60
• 𝑀𝑡2 = 425640.0009 N.mm
• Where
• 𝑃 -: Designed power = 11 KW
• 𝑁1 = 960 rpm
𝑁1 960
• 𝑁2 = = = 246.78 rpm
𝑖𝑒𝑥𝑎𝑐𝑡 3.89

Prof Sumit S Malusare,FAMT,Ratnagiri

Determination of Virtual Number of teeth
• 𝒁𝑽 =
𝒁 • 𝑍𝑉1 =18.5852
𝒄𝒐𝒔 𝜽𝑷
• 𝑍𝑉2 =281.1539
• 𝑍1 = 18
• 𝑍2 = 70
• 𝜃𝑃1 = 14.4168°
• 𝜃𝑃2 = 75.5832°

Prof Sumit S Malusare,FAMT,Ratnagiri

Lewis Form factor
• 𝑌𝑉 = 𝜋 0.154 −
0.912
--PSG 8.50 • 𝑌𝑉1 = 0.3296
𝑍𝑉
• 𝑌𝑉2 = 0.4736
For 20° full depth involute teeth

• 𝑍𝑉1 = 18.5852
• 𝑍𝑉2 = 281.1539

Prof Sumit S Malusare,FAMT,Ratnagiri

 Material Selection Material [𝝈𝒃 ] [𝝈𝒄 ]
• This time we go with material (N/𝒎𝒎𝟐 ) (N/𝒎𝒎𝟐 )

pairs given on PSG 8.04 as

Pinion 40Ni2Cr1Mo28 400 1100
• Pinion -:40Ni2Cr1Mo28
• Gear wheel-:15Ni2Cr1Mo15 Gear 15Ni2Cr1Mo15 320 950
• Now with Reference to PSG 1.05 Wheel

Prof Sumit S Malusare,FAMT,Ratnagiri

Determination of Weaker Element
• Beam Strength 𝐹𝑏 = 𝜎𝑏 b𝑌𝑣 1 − 𝑏Τ𝑅 𝑚𝑡 ---PSG 8.52
• For meshing gears module, face width and cone radius should remain
same hence Strength factor is
• 𝐹 = 𝜎𝑏 × 𝑌𝑣
• 𝜎𝑏1 = 400 𝑁Τ𝑚𝑚2 𝜎𝑏2 = 320 𝑁Τ𝑚𝑚2
• 𝑌𝑉1 = 0.3296 𝑌𝑉2 = 0.4736
• 𝐹1 = 131.84 𝐹2 = 151.552
𝐹1 < 𝐹2
Hence pinion is weaker and we go for design of Pinion
Prof Sumit S Malusare,FAMT,Ratnagiri
Module Estimation
• We go for design for bending and check against wear, Average module
is given by
3 𝑀𝑡
• 𝑚𝑎𝑣 ≥ 1.28 ---PSG 8.13
𝑌𝑣 𝜎𝑏 𝜑𝑚 𝑍1
Where
• 𝑀𝑡1 = 109419.0234 N.mm
• 𝑌𝑉1 = 0.3296
• 𝜎𝑏 = 400 𝑁Τ𝑚𝑚2
• 𝑍1 = 18
• 𝜑�𝑚 = 𝑏Τ𝑚𝑡= 10 Assume as per PSG Guidelines
𝒎𝒂𝒗 ≥ 2.1304 ≈ 3 ---PSG 8.2
Consideration of Dynamic load at high speed. We consider higher
module for safe design
𝒎𝒏 = 3 mm
Prof Sumit S Malusare,FAMT,Ratnagiri
Checking For Wear failure
3
0.72 𝑖 2 +1 ൗ2
• 𝜎𝑐 = × 𝐸 × 𝑀𝑡 < 𝜎𝑐 ---PSG 8.13
𝑅−0.5𝑏 𝑖𝑏
• Where
• i = 3.89
• + sign for external gearing
10𝑚𝑡
• 𝑚𝑡 = 𝑚𝑎𝑣 + sin 𝜃𝑃 = 3.4816 mm
𝑍1
𝑚𝑡 ×𝑍1
• 𝑅= = 125.6426mm
2 sin 𝜃𝑃
• b = Face Width = 10 x 𝑚𝑡 OR 0.3R whichever Higher
b = 34.816mm OR 37.6927mm We go with b = 37.6927 mm
• E= 2.1 x 105 𝑁Τ𝑚𝑚2 ---PSG 1.1
• 𝑀𝑡1 = 109419.0234 N.mm

𝜎𝑐 = 679.3558 𝑁Τ𝑚𝑚2 < 𝜎𝑐 = 1100 𝑵Τ𝒎𝒎𝟐

Hence we can say that design is safe against wear failure
Prof Sumit S Malusare,FAMT,Ratnagiri
Determination of Beam Strength
• Beam Strength 𝐹𝑏 = 𝜎𝑏 b𝑌𝑣 1 − 𝑏Τ𝑅 𝑚𝑡 ---PSG 8.52

Where
• 𝜎𝑏 = 400 𝑁Τ𝑚𝑚2
• b =37.6927 mm
• 𝑌𝑉1 = 0.3296
• 𝑚𝑡 = 3.4816 mm
• 𝑅 = 125.6426
𝑭𝒃 = 11927.6101 N
Prof Sumit S Malusare,FAMT,Ratnagiri
 Check Against Lewis Dynamic Load
• 𝐹𝑑 = 𝐹𝑡 × 𝐶𝑣 × 𝑁𝑆𝐹 × 𝐾𝑚 ---PSG 8.52
• Where
• 𝐹𝑡 = Tangential Force acting on Gear
= 𝑀𝑡1 ൗ𝐷1𝑎𝑣𝑔Τ2
𝑀𝑡1 = 109419.0234 N.mm
𝐷1 = 𝑚𝑎𝑣𝑔 × 𝑍1 = 54 mm
𝐹𝑡 = 4052.5564 N
6+𝑉𝑚
• 𝐶𝑣 = 𝐵𝑎𝑟𝑡ℎ 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = For carefully Cut Gears ---PSG 8.51
6
𝜋𝐷𝑎𝑣𝑔 𝑁
𝑉𝑚 = Pitch Line Velocity = = 2714.3361 𝑚𝑚Τ𝑠𝑒𝑐 = 2.7143 𝑚Τ𝑠𝑒𝑐
60
𝐶𝑣 = 1.4523
• 𝑁𝑆𝐹 -: Service factor– We already considered hence consider as 1
• 𝐾𝑚 -: Load Distribution factor -: We assume one gear straddle mounted hence = 1.2
𝑭𝒅 = 7062.6332 N < 𝑭𝒃 = 11927.6101 N
Hence we can say that Deign is safe against Lewis Dynamic Load
Prof Sumit S Malusare,FAMT,Ratnagiri
 Check Against Buckingham's Dynamic Load
0.164𝑉𝑚 𝑐𝑏 +𝐹𝑡
• 𝐹𝑏𝑑 = 𝐹𝑡 + ---PSG 8.51
0.164𝑉𝑚 +1.485 𝑐𝑏 +𝐹𝑡
Where
• 𝐹𝑡 = 4052.5564 N = 405.25kgf
𝜋𝐷𝑡 𝑁
• 𝑉𝑚 = Consider for maximum Pitch circle diameter= 60
𝐷𝑡 = 𝑚𝑡 × 𝑍1 = 3.4816 X 18 = 62.6688 mm
𝑉𝑚 = 3150.0775 mm/sec = 3.15 m/sec
• b = Face Width = 37.6927 mm = 3.6793 cm
• c = 11860e ( For 20° Pressure angle, Steel with Steel Pair) ---PSG 8.53 T 41
e = 0.025 For carefully cut gear and 4 mm module ---PSG 8.53 T 42
c = 296.5
𝐹𝑏𝑑 = 418.5861kgf = 4185.861 N < 𝑭𝒃 = 11927.6101 N
Hence We can say that design is safe against Buckingham's Dynamic load
Prof Sumit S Malusare,FAMT,Ratnagiri
Summery of Design
• 𝑚𝑎𝑣𝑔 = 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑀𝑜𝑑𝑢𝑙𝑒 = 3 𝑚𝑚
• 𝑚𝑡 = Transverse Module = 3.4816 mm
• 𝑍1 = 18 𝑍2 = 70
• Addendum = 1𝑚𝑡 = 3.4816 mm
• Dedendum = 1.25 𝑚𝑡 = 4.352 mm
• 𝑅 = Cone Radius = 125.6426 mm
𝐴𝑑𝑑
• Addendum Angle α = tan−1 = 1.5873°
𝑅
𝐷𝑒𝑑
• Dedendum Angle β = tan−1 = 1.9838°
𝑅

Prof Sumit S Malusare,FAMT,Ratnagiri

Parameter Formula Pinion Gear Wheel
Semi cone angle 𝜃𝑃 14.4168° 75.5832°
Face cone Angle 𝜃𝑓 𝜃𝑃 + 𝜃𝑓 16.0041° 77.1705°
Root Cone Angle 𝜃𝑅 𝜃𝑃 - 𝜃𝑅 12.433° 73.5994°
Pitch Circle Diameter D 𝑚𝑡 × 𝑍 62.6688 mm 243.712mm
Addendum circle D + 2(Add× cos α) 69.6293 mm 250.6725 mm
diameter
Root Circle Diameter D - 2(Ded× cos 𝛽) 53.97 mm 235.0132 mm

Prof Sumit S Malusare,FAMT,Ratnagiri

Thank You….

Prof Sumit S Malusare,FAMT,Ratnagiri