Design of Spur Gears

The design of spur gears is based on ensuring the gear doesn’t fail according to one of the following
three modes:

1. Bending of gear teeth (Lewis Equation)

2. Surface endurance of gear teeth (Buckingham Equation)
3. Wear of gear teeth

The pinion is always smaller than the gear. The output power is equal to the input power multiplied
by a mechanical efficiency ratio. The size of the gears, however, influence the output torque and
speed.
 If the pinion drives the gear, the speed is reduced and the torque is increased.
 If the gear drives the pinion, the speed is increased and the torque is reduced.
 ‘1’ is the drive gear while ‘2’ is the driven gear
𝑵𝟏 𝑻𝟐 𝑫𝟐
𝑽𝑹 = = =
𝑵𝟐 𝑻𝟏 𝑫𝟏
𝑉𝑅: Velocity Ratio
𝑁: Speed (rpm)
𝑇: Number of teeth
𝐷: Gear Diameter (m)

Lewis Equation (Failure in Bending)

𝑾𝑻
𝝈𝒘 = = 𝝈𝒐 × 𝑪 𝒗
𝒃𝝅𝒎𝒚
𝜎𝑤 : Maximum bending stress on the gear (MPa)
𝑊𝑇 : Tangential Load (N)
𝑏: Width of gear face (mm)
𝑚: Gear module (mm)
𝑦: Lewis tooth form factor
𝜎𝑜 : Allowable static stress (MPa)
𝐶𝑣 : Velocity factor

 The Lewis equation calculates if the gear will fail due to tooth bending
 The Lewis equation is applied only to the weaker of the two gears
 The pinion is always weaker if the gear and pinion are made of the same material
 To determine if the pinion or gear are weaker, use the following equation:
 𝜎𝑤 × 𝑦 or 𝜎𝑜 × 𝑦

Lewis Tooth Form Factor

𝟎.𝟔𝟖𝟒
𝒚 = 𝟎. 𝟏𝟐𝟒 − 𝑻
(for 14.5° composite and full depth involute system)
𝟎.𝟗𝟏𝟐
𝒚 = 𝟎. 𝟏𝟓𝟒 − (for 20° full depth involute system)
𝑻
𝟎.𝟖𝟒𝟏
𝒚 = 𝟎. 𝟏𝟕𝟓 − 𝑻
(for 20° stub system)

𝑦: Lewis tooth form factor

𝑇: Number of teeth
Tangential Tooth Load
𝑷
𝑾𝑻 = × 𝑪𝒔
𝒗
𝑊𝑇 : Tangential Load (N)
𝑃: Transmitted power (Watts)
𝑣: Pitch line velocity (m/s)
𝐶𝑠 : Service factor

Power/torque/velocity/module/ conversions
𝝅𝑫𝑵
𝒗=
𝟔𝟎
𝝅𝑫
𝑷𝒄 = = 𝝅𝒎
𝑻
𝑫 = 𝒎𝑻
𝑣: Pitch line velocity (m/s)
𝐷: Pitch circle diameter (m)
𝑁: Speed (rpm)
𝑃𝑐 : Circular pitch (m)
𝑇: Number of teeth
𝑚: Gear module (m)

Recommended series of modules are: 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16, 20, 25, 32, 40 and
50.

If the calculated module does not match a standard module, round up to the nearest standard
module.

Velocity Factor
𝟑
𝑪𝒗 = 𝟑+𝒗 (Ordinary gears, 𝑣 ≤ 12.5 𝑚/𝑠)
𝟎.𝟕𝟓
𝑪𝒗 = 𝟎.𝟕𝟓+ (Precision gears, 𝑣 ≤ 20 𝑚/𝑠)
√𝒗

𝐶𝑣 : Velocity Factor
𝑣: Velocity (m/s)

Dynamic Load using Buckingham Equation (Surface Durability Stress)

𝟐𝟏𝒗(𝒃𝑪 + 𝑾𝑻 )
𝑾𝑫 = 𝑾𝑻 + 𝑾𝑰 = 𝑾𝑻 +
𝟐𝟏𝒗 + √𝒃𝑪 + 𝑾𝑻

𝑊𝐷 : Total Dynamic Load (N)

𝑊𝑇 : Tangential/Transmitted Load (N)
𝑊𝐼 : Increment Dynamic Load (N)
𝐶: Deformation or dynamic factor (N/mm)
𝑣: Pitch line Velocity (m/s)
b: Gear Face Width (mm)
Deformation or Dynamic Factor
𝑲×𝒆
𝑪=
𝟏 𝟏
𝑬𝑷 + 𝑬𝑮
𝐶: Deformation or Dynamic Factor (MPa)
𝐸𝑃 : Young’s Modulus of the pinion (MPa)
𝐸𝐺 : Young’s Modulus of the gear (MPa)
𝑒: Tooth error action (mm)
𝐾: Factor depending on the form of the teeth
 0.107 for 14.5° full depth involute system
 0.111 for 20° full depth involute system
 0.115 for 20° stub system

Static tooth Factor (Endurance Strength limiting load)

𝑾𝒔 = 𝝈𝒆 𝒃𝝅𝒎𝒚 = 𝝈𝒆 𝒃𝒑𝒄 𝒚
𝑊𝑠 : Static tooth load (N)
𝜎𝑒 : Flexural Strength Limit / Elastic limit stress (MPa) (For steel, 𝜎𝑒 = 1.75 𝐵. 𝐻. 𝑁. (𝑀𝑃𝑎))
𝑏: Width of gear face (mm)
𝑚: Gear module (mm)
𝑦: Lewis tooth form factor
𝑝𝑐 : Circular pitch (mm)

In order to ensure no breakage, the following should hold true:

𝑾𝒔 ≥ 𝑾𝑫

Tooth Wear Load (Wear strength limiting load)

𝑾𝑾 = 𝑫𝑷 𝒃𝑸𝑲
𝑊𝑊 : Max load for wear (N)
𝐷𝑃 : Pitch circle diameter of pinion (mm)
𝑏: Face width (mm)
𝑄: Ratio factor
𝐾: Load-stress combination factor

In order to ensure no breakage, the following should hold true:

𝑾𝒘 ≥ 𝑾𝑫
Ratio Factor
𝟐×(𝑽.𝑹) 𝟐𝑻𝑮
𝑸 = (𝑽.𝑹)+𝟏 = 𝑻 For external gears
𝑮 +𝑻𝑷

𝟐×(𝑽𝑹) 𝟐𝑻𝑮
𝑸= = For internal gears
(𝑽.𝑹)−𝟏 𝑻𝑮 −𝑻𝑷

𝑄: Ratio Factor
𝑉. 𝑅: Velocity Ratio
𝑇𝑔 : Teeth on gear
𝑇𝑝 : Teeth on pinion

Load-stress Combination Factor

(𝝈𝒆𝒔 )𝟐 𝐬𝐢𝐧 𝝓 𝟏 𝟏
𝑲= ( + )
𝟏. 𝟒 𝑬𝒑 𝑬𝒈

𝜎𝑒𝑠 : Surface endurance limit (MPa)

𝜙: Pressure angle
𝐸𝑝 : Young’s Modulus for the pinion (Mpa)
𝐸𝑔 : Young’s Modulus for the gear (MPa)

Tutorial
Part 1: Literature Research

1. Sketch a labelled diagram of a spur gears.

2. List and explain common ways for spur gears to fail.
3. Provide three applications of spur gears.
4. Provide a benefit of helical gears over spur gears.

Part 2: Calculations

1. A bronze spur pinion rotating at 600 rpm drives a cast iron spur gear at a transmission ratio
of 4:1. The allowable static stresses for the bronze pinion and cast iron gear are 84MPa and
105MPa respectively. The pinion has 16 standard 20° full depth involute teeth of module
8mm. The face width of both gears is 90mm. Find the power that can be transmitted from
the stand point of strength.
𝑚
[Ans: 𝑣 = 4.02 𝑠
; 𝑊𝑇 = 7870𝑁; 𝑃 = 31.64𝑘𝑊]

2. A pair of spur gears with 20° full depth teeth are to transmit 5 hp at 1800 rpm of the pinion
speed. The velocity ration is VR = 2.5 and the number of teeth on the pinion is 18. The pinion
and gear are made of a material with max allowable static stress equal to 260 MPa.
Assuming that the load is steady and continuous, design the gear and pinion set based on
bending stress with a service factor of 2. The gear module is equal to 3.5.
Note: 1 hp = 745.7 Watts
𝑚
[Ans: 𝐷𝑝 = 63𝑚𝑚; 𝐷𝑔 = 157𝑚𝑚; 𝑣 = 5.94 𝑠
; 𝑊𝑇 = 1255.895𝑁; 𝑏 = 12.66𝑚𝑚]
3. A pair of ordinary, straight teeth, 20° full depth involute system, spur gears is to transmit 20
kW when the pinion rotates at 300 r.p.m. The velocity ratio is 1 : 3. The allowable static
stresses for the pinion and gear materials are 120 MPa and 100 MPa respectively. The pinion
has 15 teeth and its face width is 14 times the module. The service factor is equal to 1.

Determine: 1. module
2. face width
3. pitch circle diameters of both the pinion and the gear from the standpoint
of strength only, taking into consideration the effect of the dynamic loading.

[Ans: 𝑚 = 6.4 𝑚𝑚 𝑟𝑜𝑢𝑛𝑑𝑒𝑑 𝑢𝑝 𝑡𝑜 8 𝑚𝑚; 𝑏 = 112 𝑚𝑚; 𝐷𝑝 = 120 𝑚𝑚; 𝐷𝑔 = 360 𝑚𝑚]

4. A gear drive is required to transmit a maximum power of 22.5 kW. The velocity ratio is 1:2
and speed of the pinion is 200 rpm. The approximate centre distance between the shafts
may be taken as 600 mm. The teeth have 20° stub involute profiles. The static stress for the
gear material (which is cast iron) may be taken as 60 MPa and face width as 10 times the
module. Find the module, face width and number of teeth on each gear.

Check the design for dynamic and wear loads. The deformation or dynamic factor in the
Buckingham equation may be taken as 80 and the material load/stress combination factor
for the wear as 1.4. Due to steady working conditions, assume a service factor equal to 1.
The flexural endurance limit (𝜎𝑒 ) for cast iron is 84 MPa.
𝐷𝑃 𝐷𝐺
𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑐𝑒𝑛𝑡𝑒𝑟𝑠 = 600 = +
2 2

[Ans: 𝑚 = 6.5 𝑚𝑚 𝑟𝑜𝑢𝑛𝑑𝑒𝑑 𝑢𝑝 𝑡𝑜 8 𝑚𝑚; 𝑏 = 112 𝑚𝑚; 𝑇𝑝 = 50; 𝑇𝑔 = 100]

[Ans: 𝑊𝐷 = 10630 𝑁; 𝑊𝑠 = 26722 𝑁; 𝑊𝑤 = 59584 𝑁]