7 Spur Gears

Design of Gears (Page 201, DDHB)
Gears are used to transmit motion or power from one shaft

to another shaft if the center distance between the
shafts is small. It is a positive & smooth drive.
Gears are classified as follows:
(i) According to relative position of shaft axes:
Parallel axes : Spur gear, helical gear
Intersecting axes : Bevel gears
Non parallel, Non intersecting: Worm gears
(ii) According to peripheral velocity (v) of gears:
V< 3 m/sec: Low velocity gears
3<V< 15 m/sec: Medium velocity gears
V>15 m/sec: High velocity gears
P R Venkatesh Mech Dept RVCE Bangalore
(iii) According to type of gearing:
Gears mesh externally & hence rotate in opposite
directions : External gearing
Gears mesh internally & hence rotate in same
directions: Internal gearing
(iv) According to position of the teeth on gear surface:
Straight teeth: Spur gears
Inclined teeth: Helical gears
Skewed (curved) teeth: Spiral gear
P R Venkatesh Mech Dept RVCE Bangalore

Spur gear pair (External & Internal)
P R Venkatesh Mech Dept RVCE
Bangalore
Spur gear animation
Rack & pinion Animation

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Helical gear Herringbone gear

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Bevel gears (Straight teeth & Skewed teeth)

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Worm Shaft & worm gear
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Gear tooth profiles
• Gears are mainly used for transmission of
motion & power and must be of accurate profile
to obtain exact velocity ratio.
• Two commonly used profiles of gear teeth are
the Involute profile & the Cycloidal profile
• Involute is defined as the path described by a
point on an inextensible cord which is unwound
from a stationary cylinder.
• Cycloid is defined as the curve traced by a point
on the rim of a circle which rolls without slipping
on a fixed straight line.
GEAR TOOTH NOMENCLATURE
• Base circle: It is the circle from which gear teeth
profiles are generated.
• Pitch circle: It is an imaginary circle which by pure
rolling action, would produce the same motion as
the toothed wheel. The size of the gear is usually
specified by the pitch circle diameter.
• Pitch point: It is a common point of contact between
two pitch circles of two meshing gear wheels.
• Pressure angle: It is the angle between the common
normal to two gear teeth at the point of contact and
the common tangent at the pitch point.
• Addendum: It is the radial distance from the pitch
circle to the tip of the tooth.
• Dedendum: It is the radial distance from the pitch
circle to the root of the tooth.
• Face : It is the part of the tooth surface which is
above the pitch surface.
• Flank : It is the part of the tooth surface which is
below the pitch surface.
• Circular pitch : It is the distance measured on the
circumference of the pitch circle from a point on one
tooth to the corresponding point on the adjacent
tooth.
• Module: It is the ratio of the pitch circle diameter in
millimeters to the number of teeth.
• Face width: It is the width of the gear tooth
measured parallel to its axis.
Pitch cylinders with
pure rolling friction
Line of action & Pressure angle
Actual gears (Toothed wheels) P R Venkatesh Mech Dept

Bangalore
RVCE
SYSTEMS OF GEAR TEETH
Three systems of gear teeth listed below are
commonly used :
(i) 141/2o involute system; The number of teeth
required to avoid interference is high because of the
low pressure angle.
(ii) 20o full depth involute system; The number of teeth
required to avoid interference is less because of high
pressure angle. These teeth are broader at the root
& stronger.
(iii) 20o stub involute system; In this system the working
depth is usually 20% less than the FDI as the
addendum is made shorter. Its advantages are
• Low production cost
• Stronger teeth
• Less interference due to shorter addendum
Beam Strength of Spur gear teeth (Lewis Equation)
Lewis analysis (Wilfred Lewis, Philadelphia, 1892)
considers the gear tooth as a cantilever beam loaded by
a normal load Fn (along the line of action) which can be
resolved into :
(i) Tangential component Ft
(ii) Radial component Fr
Assumptions made:
• The effect of radial component which induces
compressive stress is neglected.
• The tangential component is uniformly distributed
over the face width of the gear.
• The effect of stress concentration is neglected.
• At any instant, only one pair of teeth is in contact &
takes the entire load.
Fr
Fn
b
A Parabola
Ft
Tangent to base circle
B C Tooth profile
t
Forces acting on gear tooth

Chain link
Bangalore
Ft
A
t
b
C
h

Bangalore
The bending stress due to Ft is taken as the basis for design.
The critical section may be obtained by drawing a parabola
through point A & tangentia l to the tooth profile at B & C.
This parabola (shown by dotted lines) outlines a beam of uniform strength.
The critical section will be BC where bending moment is maximum.
The bending stress due to tangential component Ft
Mc
where Bending moment M Ft h
I
t
Distance of BC from neutral axis c ,t thickness of tooth
2
bt 3
Moment of inertia I , b face width of tooth
12
t
Ft h
2 Ft h 6 t2
Ft b
bt 3
bt 2 6h
12 P R Venkatesh Mech Dept RVCE
Bangalore
Since t & h are dependent on the shape of tooth & circular pitch,
t2
the quantity may be replaced by p y where ' y' is known as
6h
Lewis form factor or Tooth form factor, & p circular pitch
Also the bending stress d Cv
where d allowable static stress
& Cv Velocity factor.Substituti ng in equation of Ft , we get
Ft σ d C v byp Equation 12.5 (a) Page 204.
NOTE : The Lewis form factor ' y' is a function of the pressure angle
(tooth system) & the number of teeth on the gear.
For values of y refer equation nos 12.15 (c) to 12.15(e) Page 204
For velocity factor C v refer equation nos 12.6 a to 12.6 e Page 205
For d refer Table 12.7 Page 234.
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Dynamic Tooth Load
The dynamic tooth load is due to:
(i) Errors in tooth spacing.
(ii) Elements of face may not be perfectly parallel to axis.
(iii) Inaccuracies in the tooth profile.
(iv) Uneven distribution of load on the face of gear tooth.
(v) Deflection of tooth under load
(vi) Deflection of shaft & mountings.
Due to the above inaccuracies, there will be dynamic

load due to shock & impact.
It will be greater than the steady load and consists of
the tangential tooth load Ft required for power
transmission and an increment Fi due to irregularities.
Fd Ft Fi where Fi is the additional (increment) load due to
the dynamic action. According to Buckingham ' s equation,
K 3 v(Cb Ft )
Fd Ft  Eq 12.12 Page 207
K3 Cb Ft
where C dynamic factor which depends on the materials,
pressure angle and error in tooth action.
Fd
The ratio is called dynamic load factor.
Ft
It is a function of peripheral velocity, tooth surface hardness &
degree of accuracy.
If a gear tooth is not strong enough dynamically, then
(i) The module can be increased
(ii) Face width can be increased
(iii) The hardness mayPbe increased by proper heat treatment.
R Venkatesh Mech Dept RVCE
Bangalore
Wear Load
There are two main reasons for gear tooth failures:
• Breakage of tooth due to static & dynamic loads. (Failure
in bending)
• Surface destruction. (Wear)
The surface destruction or Wear occurs due to rolling &
sliding action of the gear teeth. The tooth wear may be of
following types:
(i) Abrasive wear: It is failure due to presence of foreign
particles in the lubricant that can scratch the tooth
surface
(ii) Corrosive wear: Failure due to chemical reaction on the
tooth surface.
(iii) Pitting: A fatigue failure due to repeated application of
stress cycles.
(iv) Scoring: A failure due to metal to metal contact which
occurs when there is breakdown of lubricant oil film
because of excessive surface pressure or heat generation.
The failure of the gear tooth due to pitting occurs when the contact stresses
between the meshing teeth exceed the surface endurance strength of the
material.
It is a surface fatigue failure and is analyzed by Buckingham whose
equation for wear strength is given by;
Fw d 1bQK  Eq 12.15(a) Page 208
where d1 Pitch circle diameter of the gear,
2z 2
Q Ratio factor 12.15 (c) Page 208
z 2 z1
K Load stress factor (Refer Table 12.16 & 12.17 Page 239 & 240)
2
sin 1 1
Also K es
12.15 (b) Page 208
1 .4 E1 E2
where es surface endurance strength of gear pair
and es 2.75( BHN ) 70 12.15 (d ) page 208
b Face width of gear P R Venkatesh Mech Dept RVCE
Bangalore
Design Procedure for Spur Gears :
Step 1 : To identify the weaker member :
Load carrying capacity of the teeth is a function of the
product d y. The one which has least value of d y is the
weaker of the gear pair.
For pinion (Driver) d1 y1 , For gear (Driven) d2 y2
If d1 1 y d2 y2 , the pinion is weaker.
If d2 y2 d1 1y , the gear is weaker.
For allowable static stress d refer Table 12.7, Page 234.
For Lewis form factor ' y' refer
equations 12.5(c) to 12.5 (e), Page 204
Note * If both gear & pinion are of same material,Pinionis always weaker
Design must be based on the weaker member.
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Step 2 : Tangential tooth load Ft
(a) Using Power transmitted & rpm,
1000 P Cs
Ft  Eq 12.7 (a) Page 205
v
where P Power transmitted in KW,
Cs Service factor (from Table 12.8, Page 235)
d 1 N1 d2 N2
v Peripheral velocity
60000 60000

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(b) Using Lewis equation of beam strength
Ft d C v byp  Eq 12.5(a), Page 204
where Cv velocity factor
( from Eq 12.6 (a) to 12.6 (e) page 205)
p Circular pitch πm where m module
b face width 9.5m b 12.5m
(Equation 12.5 (f), p 205)
Equating (a) & (b) module m can be obtained.
Select standard module from Table 12.2 Page 229

Bangalore
Step 3 : Dimensions of the gear & pinion
(a) Pitch diameter of pinion d 1 mz 1
Pitch diameter of gear d 2 mz 2
d1 d 2
(b) Center distance between shafts a
2
(c) Face width b 10m where m module
(d) Addendum diameter of pinion d a1 d1 2ha
Addendum diameter of gear d a2 d2 2ha
(e) Dedendum diameter of pinion d f1 d 1 2h f
Dedendum diameter of gear d f2 d2 2h f
For addendum (h a ) & Dedendum (h f ), refer T 12.4, P 230.
Bangalore
Step 4 : Check for dynamic & wear load :
K 3v(Cb Ft )
(a) Dynamic load Fd Ft  Eq12.12, Page 207
K 3v Cb Ft
where C Dynamic load factor from T12.12 Page 236
K 3 20.67 (for SI units, Page 207)
(b)Wear load Fw d1bQK  Eq12.15 (a) Page 208
K load stress factor from T12.16/17, Page 239
Q Ratio factor from Eq 12.15c, Page 208
If Fw Fd , the design is safe.

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Problem 1
(Type I :where number of teeth are assumed/given)
Design a pair of spur gears to

transmit 9KW at 2000 rpm of cast
steel(untreated) pinion. The gear
is made of high grade Cast iron
(heat treated) and is to rotate at
500 rpm. The pinion has 20 teeth
of 141/2o involute form.
Bangalore
Gear
Pinion
N2
N1
d2
d1
1 2 z2
z1
a
Data:
P=9KW, N1=2000 rpm, N2=500 rpm.
Speed ratio i=(N1/N2)=(2000/500)=4
141/2o , z1=20,
Hence z2=iz1=4x20=80 teeth
Bangalore
Design Procedure :
From Table 12.7, Page 234, for Cast steel 0.2% (untreated)
pinion, allowable static stress d1 138.3Mpa( N / mm 2 )
For High grade CI (heat treated) gear, d2 78.5Mpa
o
1
From Eq 12.5c P 204, Lewis form factor ' y' for 14 system
2
0.684 0.684
y1 0.124 0.124 0.0898 (for pinion)
z1 20
0.684 0.684
y2 0.124 0.124 0.1154 (for gear)
z2 80
y
d1 1 138.3 0.0898 12.42, d2 y2 78.5 0.1154 9.0598
As d2 y2 y , the gear is weaker.
d1 1
Design must be based on theMechgear.

P R Venkatesh Dept RVCE
Bangalore
1000 P C s
Ft  Eq 12.7a Page 205
v
where P Power transmitted in KW 9 KW
Assuming medium shock loads, 8 - 10 hrs service/day, Cs 1.5
d2 N2 mz 2 N 2
60000 60000
m 80 500
v (2.094m ) m / sec
60000
Substituti ng the above in equation of Ft , we get
1000 9 1.5 6444.9
Ft (1)
2.094m m
Bangalore
Tangential tooth load
Ft d C v byp  Eq 12.5 (a), Page 204
where Cv velocity factor, d d2 78.5Mpa
b 10m (Equation 12.5(f) , p 205), y y2 0.1154, p πm
Substituti ng, we get Ft 78.5 C v 10m 0.1154 πm
Ft 284.6m 2Cv (2)
6444.9
Equating(1) & (2), 284.6m 2Cv
m
m 3C v 22.65 (3)
Find module ' m' by trial & error.Assume C v 0.5
3 3
Such that m 2 RHS i.eMech
P R Venkatesh . mDept RVCE
2 22.65 3.54 mm
Bangalore
From T 12.2, P 229, the preferred values are 3 mm & 4 mm
Trial 1 :
Let m 3mm, Then pitch line velocity v 2.094m
v 2.094 3 6.282 m/sec
4.58
Assuming carefully cut gears, C v 12.6 (b), P205
4.58 v
4.58
Cv 0.421
4.58 6.282
m 3Cv 33 0.421 11.38 22.65 ( RHS ).
Trial 2 :
Let m 4 mm, Then pitch line velocity v 2.094m
v 2.094 4 8.376 m/sec
4.58
Cv 0.353
4.58 8.376
m 3Cv 43 0.353 22.62 22.65 ( RHS ).
Select m 4 mm as it yields m 3C v value very close to the required value.
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(a) Pitch diameter of pinion d 1 mz 1 4 20 80mm
Pitch diameter of gear d 2 mz 2 4 80 320mm
d 1 d 2 80 320
(b) Center distance between shafts a 200mm
2 2
(c) Face width b 10m 10 4 40 mm
(d) Circular pitch p πm 4 12.566 mm
6444.9 6444.9
(e) Tangential tooth load Ft 1611.2 N
m 4
o
(f) For 14 1 system, from T12.4(a), Page 230, addendum h a 1m 1 4 4mm
2
dedendum h f 1.157m 1.157 4 4.628 mm (where m module 4 mm)
Addendum diameter of pinion d a1 d1 2ha 80 (2 4) 88mm
Addendum diameter of gear d a2 d2 2ha 320 (2 4) 328mm
Dedendum diameter of pinion d f1 d 1 2h f 80 (2 4.628) 70.74mm
Dedendum diameter of gear d f2 d2 2h f 320 (2 4.628) 310.74mm
Bangalore
K 3v(Cb Ft )
(a) Dynamic load Fd Ft  Eq12.12 Page 207
K 3v Cb Ft
Here v 8.36m/sec,From Table 12.14 Page 237,
for v 8m/sec, tooth error e 0.05mm
By interpolation, for v 8.36m/sec,e 0.048
0
From T 12.12, page 236, for CI & steel combination, 14 1 system
2
for e 0.04, C 303.2 N/mm
303.2
for e 0.048, C 0.048 363.84 N / mm (Linear variation)
0.04
K3 20.67 (Always for SI system of units), Page 207
20.67 8.36 (363.84 40) 1611.2)
Dynamic load Fd 1611.2
(20.67 8.36) (363.84 40) 1611.2
2.793 10 6
Fd 1611.2 10924 N
299.94
Bangalore
C
e=0.05
E
x
D
B
A
e=0.0386
V=8.0 V=8.36 V=10
From the similar triangles, ABC & CDE,

AB AC (10 8) (0.05 0.0386)
DE CD (8.36 8) x
x 0.002 and hence for V 8.36 m/sec,
tooth error e (0.05 - 0.002) 0.048
Bangalore
(b) Wear load Fw d1bQK  Eq 12.15 (a)Page 208
K load stress factor from T12.16, Page 239
2 z2 2 80
Q 1.6, b 10m 10 4 40 mm, d1 80 mm
z1 z2 20 80
Fw 80 40 1.6 K 5120 K . For safe design, Fw Fd
i.e. 5120 K 10924 K 2.133
0
1
From T 12.16, P 239, For 14 system, K=2.363 (>2.133)
2
BHNof gear pinion = 450, BHN of gear = 450 .

Bangalore
K3v(Cb Ft )
(a) Dynamic load Fd Ft  Eq12.33
K 3v Cb Ft
K3 20.67
(b) Wear load Fw d1bQK  Eq12.36a Page 167
If Fw Fd , the design is safe.

Bangalore
Problem 2
(Type I :where number of teeth are assumed/given)
Design a pair of spur gears to

transmit 12KW at 1000 rpm of
pinion with a velocity ratio 2.5.
The design should be as
compact as possible.

Bangalore
Gear
Pinion
N2
N1
d2
d1
1 2 z2
z1
a
Bangalore
Data:
P=12KW, N1=1000 rpm,
Speed ratio i=(N1/N2)=2.5
Hence N2=1000/2.5= 400rpm.
Assume full depth involute, z1=20.
(From Table 12.4(b), Page 230)
Hence z2=iz1=2.5x20=50 teeth
For compact design, size of gears should be
as minimum as possible. Hence select
strongest material for both the pinion & gear.
Hence select chrome vanadium steel,
0.45%C heat treated, static stress =516.8
Mpa (Table 12.7, page 234)
Bangalore
Design Procedure :
From Table 12.7, Page 234,
for chrome vanadium steel (heat treated) material
allowable static stress d1 d2 516.8Mpa
Here as both pinion & gear are assumed
to be of same material, the pinion is weaker.
Design must be based on the pinion.
Lewis form factor for 200 FDI tooth system,
0.912
for pinion y1 0.154 0.1084
20
0.912
for gear y 2 0.154 0.1358 (Eq 12.5(d) P204)
50Bangalore
1000 P C s
Ft  Eq 12.7a Page 205
v
d 1 N1 mz1 N1
60000 60000
m 20 1000
v (1.047m ) m / sec
60000
1000 12 1.5 17191.97
Ft (1)
1.047m m
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where Cv velocity factor, d d1 516.8Mpa
b 10m (Equation 12.5(d), p 205), y y1 0.1084, p πm
Substituti ng, we get Ft 516.8 C v 10m 0.1084 πm
Ft 1759.955m 2Cv (2)
17191.97
Equating(1) & (2), 1759.95m 2Cv
m
m 3C v 9.768 (3)
3
Find module ' m' by trial & error.Assume m 2 RHS
3
i.e. m 2 9.768 2.69 mm
From Table 12.2, page 229 the preferred values are
m 2.5 mm & m 3 mmBangalore
Trial 1 :
Let m 2.5mm, Then pitch line velocity v 1.047m
v 1.047 2.5 2.6175 m/sec
3.05
For v upto 8m/sec, C v
3.05 v
3.05
Cv 0.538
3.05 2.6175
m 3Cv 2.53 0.538 8.408 9.768 ( RHS ).
Hence module of 2.5 is not suitable.
Trial 2 :
Let m 3 mm, Then pitch line velocity v 1.047m
v 1.047 3 3.141 m/sec
3.05
Cv 0.493
3.05 3.141
m 3Cv 33 0.493 13.3 9.768( RHS ).
Select m 3 mm as it yields m 3C v value greater than the required value.
Bangalore
(a) Pitch diameter of pinion d 1 mz 1 3 20 60mm
Pitch diameter of gear d 2 mz 2 3 50 150mm
d1 d2 60 150
2 2
17191.97 17191.97
(e) Tangential tooth load Ft 5730.6 N
m 3
(f) For 20 o FDI system, from T12.4, Page 230, addendum h a 1m 1 3 3mm
Dedendum diameter of gear d f2 d2 2h f 150 (2 3.75) 142.5mm
Bangalore
K 3v(Cb Ft )
K 3v Cb Ft
Here v 3.141m/sec 3m/sec, From Table 12.14 Page 237,
tooth error e 0.0785mm
From T 12.12, page 236, for Steel & Steel combination, 200 FDI system
for e 0.01, C 114.4 N/mm
114.4
for e 0.0785, C 0.0785 892.3N / mm (Linear variation)
0.01
20.67 3.141 (892.3 30) 5730.6)
Dynamic load Fd 5730.6
(20.67 3.141) (892.3 30) 5730.6
2.11 10 6
Fd 5730.6 14336N
245.2
Bangalore
(b)Wear load Fw d1bQK  Eq12.15 (a ) Page 208
2 z2 2 50
Q 1.428, b 30mm, d1 60 mm
z1 z 2 20 50
Fw 60 30 1.428 K 2571.43K
For safe design, Fw Fd 2571.43K 14336
or K 5.575, For K 5.913( 5.575), & 200 tooth system,
From Table 12.16, page 239,
BHN for pinion 600
BHN for gear 600
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Problem 3
(Type II: where velocity/center distance/diameters are known)
A pair of carefully cut spur gears transmit 20
KW at 230 rpm of the gear. Reduction ratio is
5:1. The pinion is made of cast steel (heat
treated) with allowable stress of 197 MN/m2.
Gear is made of Cast iron with allowable stress
of 56 MN/m2.
Determine the module, face width and number
of teeth on pinion & gear. Also suggest suitable
surface hardness for the gear pair. Pitch line
velocity of the pinion is not to exceed 7.5
m/sec. P R Venkatesh Mech Dept RVCE
Bangalore
Gear
Pinion
N2
N1
d2
d1
1 2 z2
z1
a
Bangalore
Data: P=20KW, N2=230 rpm,
Speed ratio i=(N1/N2)=5
Hence N1=230x5= 1150rpm.
Pitch line velocity v=7.5m/sec
Assume pressure angle FDI
d1=197 Mpa, d2=56
Mpa,
πd1 N1
As pitch line velocity of pinion m/sec,
60000
Given that the value is not to exceed 7.5 m/sec,
π d1 1150
7.5 d1 124.5mm.
60000
Select pitch circle diameter of pinion d1 120mm
Pitch circle dia of gear d 2 id1 5 120 600mm.
Bangalore
Design Procedure :
Here the number of teeth are to be found out (not assumed).
But to decide the weaker member assume tentatively,
z1 20 teeth z2 iz1 5 20 100 teeth (Not the final value)
0.912
Lewis form factor for pinion y1 0.154 0.1084
20
0.912
for gear y 2 0.154 0.145 (Eq 12.5(d) P163)
100
For pinion, d1 y1 197 0.1084 21.35
For gear, d2 y2 56 0.145 8.11 y
d1 1
Gear is weaker,hence design must be based on gear.

(Note : The above values of y should
P R Venkatesh not be used for design)
Mech Dept RVCE
Bangalore
1000 P Cs
Ft  Eq 12.7(a) Page 205
v
d2 N2 600 230
v Peripheral velocity 7.23m / sec
60000 60000
1000 20 1.5
Ft 4150N (1)
7.23
Bangalore
4.58 4.58
where Cv velocity factor 0.388
4.58 v 4.58 7.23
(for carefully cut gears, eq 12.6b, page 205, for v 13m/sec)
d d2 56Mpa
b 10m (Equation 12.5(d), p 205), p πm
0.912 0.912m
y y2 0.154 0.154 (0.154 - 1.52 10-3 m)
d2 600
m
Substituti ng, we get Ft 56 0.388 10m (0.154 - 1.52 10-3 m) πm
Ft (105.12m 2 1.0376m 3 ) (2)
Equating(1) & (2), 4150 (105.12m 2 1.0376m 3 )
Solving, module m 6.5 mm.
From table 12.2, page 182, the preferred values are 6 & 8mm.
m 6 mm gives Ft 3560N required value of 4150 N.
Select m 8mm. Bangalore
(a) Pitch diameter of pinion d 1 mz 1 120 8 z1 z1 15
Number of teeth on pinion 15 teeth
Pitch diameter of gear d 2 mz 2 600 8 z 2 z2 75
Number of teeth on gear 75 teeth
d1 d 2 120 600
2 2
(e) Tangential tooth load Ft 4150N
(f) For 20 o FDI system, from T12.4(a), Page 230, addendum h a 1m 1 8 8mm
dedendum h f 1.25m 1.25 8 10 mm (where m module 8 mm)
Dedendum diameter of pinion d f1 d 1 2h f 120 (2 10) 80mm
Dedendum diameter of gear d f2 d2 2h f 600 (2 10) 580mm
Bangalore
K 3v(Cb Ft )
(a) Dynamic load Fd Ft  Eq12.12, Page 207
K 3v Cb Ft
Here v 7.23m/sec.From Table 12.14 Page 237,
By interpolation, for v 7.23 m/sec, e 0.0535
From T 12.12, page 236, for Steel & Cast iron combination, 200 FDI system
for e 0.01, C 78.6 N/mm
78.6
0.01
K 3 20.67 (Always for SI system of units), Page 207
20.67 7.23 (420.5 80) 4150)
Dynamic load Fd 4150
(20.67 7.23) (420.5 80) 4150)
Fd 4150 16424.7 20575N
Bangalore
C
e=0.059
E
x
D
B
A
e=0.05
V=6.0 V=7.23 V=8
AB AC
From similar triangles ABC & CDE,
DE CD
(8 - 6) (0.059 - 0.05)
i.e. x 0.0055
(7.23 - 6) x
For v 7.23 m/sec, tooth error e (0.059 - 0.0055) 0.0535
Bangalore
(b)Wear load Fw d1bQK  Eq12.15a Page 208
2 z2 2 75
Q 1.667, b 80mm, d1 120 mm
z1 z 2 15 75
Fw 120 80 1.667 K 16000K
For safe design, Fw Fd 16000K 20575
or K 1.286
For K 1.344( 1.286), & 200 tooth system,
From Table 12.16, page 239,
BHN for pinion 350
BHN for gear 250
Bangalore
Problem 4
(Type II: where velocity/center distance/diameters are known)
A compressor running at 400 rpm is driven by a
25 KW, 1200 rpm motor through a pair of
141/2o involute spur gear. The centre distance is
around 400 mm. The pinion is made of forged
steel of static allowable 190 MN/m2 and 350
BHN. Gear is to be made of cast steel of
allowable stress 180 MN/m2 and 300 BHN.
Design the gear for safe continuous operation.
Check the gear for endurance, wear & dynamic
strength.
Bangalore
Data: P=25KW, N1=1200 rpm,
N2=400 rpm,
Speed ratio i=(N1/N2)=(1200/400)=3
Center distance a=400 mm
pressure angle
d1=190 Mpa, d2=180 Mpa,
BHN (pinion)=350, BHN(gear)=300
N1 d2 d2
As velocity ratio i 3
N2 d1 d1
d1 d 2 d1 3d1
d 2 3d1 Also center distance ' a' 400
2 2
Pitch diameter of pinion d1 200mm
Pitch diameter of gear d 2 3 200 600mm
Bangalore
Gear
Pinion
N2
N1
d2
d1
1 2 z2
z1
a
Bangalore
Design Procedure :
Here the number of teeth are to be found out (not assumed).
But to decide the weaker member assume tentatively,
z1 20 teeth z 2 iz1 3 20 60 teeth (Not the final value)
0.684
Lewis form factor for pinion y1 0.124 0.0898
20
0.684
for gear y 2 0.124 0.1126 (Eq 12.5(c) P204)
60
For pinion, d1 y1 190 0.0898 17.06
For gear, d2 y2 180 0.1126 20.27
y
d1 1 d2 y2
Pinion is weaker,hence design must be based on pinion.
(Note : The above values of Bangalore
y should
P R Venkatesh not be used for design)
Mech Dept RVCE
1000 P C s
Ft  Eq 12.7(a) Page 164
v
Assuming medium shock loads, continuous service, Cs 1 .8
d 1 N1 200 1200
v Peripheral velocity 12.57m / sec
60000 60000
1000 25 1.8
Ft 3581N (1)
12.57
Bangalore
Ft d C v byp  Eq 12.5(a) Page 204
6.1 6.1
where Cv velocity factor 0.327
6.1 v 6.1 12.57
(Assume accurately cut & ground gears, eq 12.6(c),page 205, for 6 v 20m/sec)
d d1 190 Mpa
b 10m (Equation 12.5(f), p 205), p πm
0.684 0.684m
y y1 0.124 0.124 (0.124-3.42 10-3 m)
d1 200
m
Substituting, we get Ft 190 0.327 10 m (0.124-3.42 10-3 m) πm
Ft (242.03m 2 6.675m3 ) (2)
Equating (1) & (2), 3581 (242.03m 2 6.675m3 )
Solving, module m 4.25 mm.
From table 12.2, page 229, the preferred values are 4 & 5mm.
m 4 mm gives Ft 3445 N required value of 3581 N.
Select m 5mm. Bangalore
(a) Pitch diameter of pinion d 1 mz 1 200 5 z1 z1 40
Number of teeth on pinion 40 teeth
Pitch diameter of gear d 2 mz 2 600 5 z 2 z2 120
Number of teeth on gear 120 teeth
d1 d2 200 600
2 2
(e) Tangential tooth load Ft 3581N
o
(f) For 14 1 tooth system, from T12.4, Page 230, addendum h a 1m 1 5 5mm
2
Dedendum diameter of gear dP f2R Venkatesh
d 2 2h 600
Mech Dept
f
RVCE ( 2 5.785) 588.43mm
Bangalore
Step 4 : Check for dynamic load :
K 3v(Cb Ft )
K 3v Cb Ft
Here v 12.57m/sec.From Table 12.14 Page 237,
By interpolation, for v 12.57 m/sec, e 0.0311
From T 12.12, page 236, for Steel & Steel combination, 14.50 involute system
for e 0.01, C 110.3 N/mm
110.3
0.01
20.67 12.57 (343.3 50) 3581)
Dynamic load Fd 3581
(20.67 12.57) (343.3 50) 3581)
5390.26 10 3
Fd 3581 16928 N
403.86
Bangalore
C
e=0.033
E
x
D
B
A
e=0.023
V=12 V=12.57 V=15
AB AC
From similar triangles ABC & CDE,
DE CD
(15 - 12) (0.033- 0.023)
i.e. x 0.0019
(12.57 - 12) x
For v 7.23 m/sec, tooth error e (0.033- 0.0019) 0.0311
Bangalore
(b) Check for wear load :
Fw d1bQK  Eq12.15a Page 208
where d1 Pitch circle diameter of the gear 200 mm
2z 2 2 120
Q Ratio factor 1.512.15c Page 208
z 2 z1 120 40
2
sin 1 1
Also K es
12.15b Page 208
1.4 E1 E2
where es surface endurance strength of gear pair
and es 2.75( BHN ) 7012.15 d page 208
350 300
where BHN avearge value for pinion & gear 325
2
es 2.75(325) 70 823.75Mpa, Pressure angle 14.50
b Face width of gear 50 mm, E1 E2 207Gpa 207 103 N / mm 2
823.752 sin(14.5) 1 1
Load stress factor K 3
1.173
1.4 10 207 207
Wear load Fw d 1bQK 200 50 1.5 1.173 17588N
As Fw Fd , the designP is safe.
R Venkatesh Mech Dept RVCE
Bangalore

7 Spur Gears

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7 Spur Gears

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Design of Gears (Page 201, DDHB)

Gears are used to transmit motion or power from one shaft

P R Venkatesh Mech Dept RVCE Bangalore

P R Venkatesh Mech Dept RVCE

P R Venkatesh Mech Dept RVCE

P R Venkatesh Mech Dept RVCE

Line of action & Pressure angle

Actual gears (Toothed wheels) P R Venkatesh Mech Dept

Forces acting on gear tooth

P R Venkatesh Mech Dept RVCE

Due to the above inaccuracies, there will be dynamic

P R Venkatesh Mech Dept RVCE

P R Venkatesh Mech Dept RVCE

P R Venkatesh Mech Dept RVCE

Design a pair of spur gears to

Design must be based on theMechgear.

V=8.0 V=8.36 V=10

From the similar triangles, ABC & CDE,

P R Venkatesh Mech Dept RVCE

P R Venkatesh Mech Dept RVCE

Design a pair of spur gears to

P R Venkatesh Mech Dept RVCE

Gear is weaker,hence design must be based on gear.

V=6.0 V=7.23 V=8

V=12 V=12.57 V=15

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