Gearing

Topics:
• Spur, bevel, helical and worm gears
• Kinematics
• Force analysis
• Bending and contact stress analyses

1
 Spur gears

 p np rg
Angular velocity ratio:  
 g ng rp
Pitch-line velocity: V  rp p  rg  g

For conjugate gear-tooth action,

the common normal to the
surfaces at the point of contact
must always intersect at point P
Juvinall and Marshek
on the line of centers. This is
achieved using involute profiles
for the teeth.
2
 Spur gears

Juvinall and Marshek

• pinion: the smaller of two gears

• P : diametral pitch [teeth/in]
• m : module [mm/tooth] N d
P m
• N : number of teeth d N
• d : pitch diameter d p  dg
c  rp  rg
• c : center distance 2
pP  
• p : circular pitch
3
Spur gears dimensions

Juvinall and Marshek

4
Spur gears dimensions

Juvinall and Marshek

5
 Check for teeth interference!

With k  1 for full-depth teeth and 0.8 for stub teeth,

Ng
 the pressure angle, and R  :
Np
Smallest number of teeth on pinion without interference:

Np 
2k
(1  2 R) sin 
2
R  R 2
 (1  2 R ) sin 2
 
For spur pinion and rack (or any gear) without interference:
2k
Np 
sin 2 
Largest number of teeth on gear without interference:
N p2 sin 2   4k 2
Ng 
4k  2 N p sin 2 
Shigley, Eqns. 13-11 to 13-13

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 Spur gears kinematics
N
d : pitch diameter (d p , d g )
P
N : number of teeth (N p , N g )
P : diametral pitch (teeth per inch)

p : circular pitch
P
p
t  : tooth thickness (not face width b!)
2
 : pressure angle
d
r  : pitch circle radius (rp , rg )
2
rb  r cos  : base circle radius (rbp , rbg )
pb  p cos  : base pitch
CR : contact ratio; keep CR  1.2
(rp  a ) 2  rp2 cos 2   (rg  a ) 2  rg2 cos 2   (rp  rg ) sin 
CR 
pb
1 1
a : addendum (e.g. for spur gears, for helical gears)
P Pn

7
*
 Helical gears kinematics

Juvinall and Marshek

N pn  p cos
d
P p
pa 
Pn 
P cos
cos N
tan n  tan  cos Ne 
cos3 
 : helix angle, typically between 15o and 30o
 : pressure angle in direction of rotation
n : pressure angle in normal direction, typically 20o
p : circular pitch in direction of rotation
pn : normal circular pitch
pa : axial pitch
N : actual number of teeth 8
N e : virtual (or formative) number of teeth
Check for teeth interference!

With k  1 for full-depth teeth and 0.8 for stub teeth,

 the pressure angle, and  the helix angle:
Smallest number of teeth on pinion to mate without
interference with any gear:
2k cos
Np 
sin 2 
Myszka, Eqn. 10.28

9
Bevel gears kinematics

Juvinall and Marshek

 p np N g d g 1
Gear ratio:     tan  g 
 g ng N p d p tan  p
2 rb
N' : virtual number of teeth
p
rb : back cone radius
10 L 10
Face width b: smaller of and ( L as in Fig. 16.9)
P 3
 Worm gears kinematics

Juvinall and Marshek

p : axial pitch c 0.875 c 0.875

 dw  : worm pitch diameter
N w : number of worm threads 3.0 1.7
w nw N g c : center distance
 
 g ng N w L  pN w : lead
N g  N w  40 tan  
L
Ng p  dw
dg  : gear pitch diameter Worm lead angle   gear helix angle
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

 Gear trains

Shigley, Fig. 13-27

no k product of driving tooth numbers

e  (1)
ni product of driven tooth numbers
e : train value
n : rev/min; i : input gear; o : output gear
N : number of teeth
k : number of external contacts between gears

12
Planetary (epicyclic) gear trains

Shigley, Fig. 13-31

Juvinall and Marshek

2 degrees of freedom
2 input velocities required
no  na
e
ni  na
no : rev/min of output gear in planetary train
ni : rev/min of input gear in planetary train
na : rev/min of arm
In complex trains, note that different members
can be input, output and arm. 13
*
Spur gears force analysis
Convention:
frame (1), input gear (2),...
a, b, c...: shafts
F23 : force exerted by gear 2 on gear 3
Forces in 2 dimensions, along pressure line
Radial and tangential components from total
Fr  Ft tan  : radial load
Ft : transmitted load 0.98 < efficiency < 0.99
33000 H (hp)  d (in)n(rpm)
Ft (lbf)  V
V (ft/min) 12
H (kW)  d (m)n(rpm)
Ft (kN)  V
V (m/s) 60
d
T  Ft : torque, constant along one shaft
2
Juvinall and Marshek

14
Helical gears force analysis

Juvinall and Marshek

H
Ft  or some form of it
V
Fr  Ft tan 
Fa  Ft tan
Ft
F
cos cos n
tan n  cos tan  15
 Bevel gears force analysis

H
Juvinall and Marshek
Ft  or some form of it
Vav
Vav calculated at midpoint of tooth, i.e.
d av  d  b sin 
Fr  Ft tan  cos 
Fa  Ft tan  sin 
Ft
F
cos 
16
Worm gears force analysis
Significant effect of friction, loss of efficiency
Fgt  Fwa
Fwt  Fga
Fgr  Fwr
tan n  cos tan 
Fgt cos n cos   f sin 

Fwt cos n sin   f cos 
sin n
Fgr  Fwr  Fgt
cos n cos   f sin 
cos n  f tan 
e efficiency
cos n  f cot 
Vw Vg
Vs   sliding velocity
cos  sin 
f  cos n tan  for self-locking

Juvinall and Marshek

17
 Stress and strength analyses:
history
Bending stress and contact stress issues
• Lewis bending equation: old
• Hertzian contact stress : old
• American Gear Manufacturer’s Association: new

Lewis equation
o models the gear tooth as cantilever beam
o no load sharing (CR = 1)
o assumes greatest applied force at tip of tooth
(worst case; in fact mid-tooth since no load sharing)
Ft P
 , with Y Lewis form factor
bY

Juvinall and Marshek

18
 Stress and strength analyses:
history

Early wear considerations (pitting)

based on Hertzian stresses

Ft  1 1 
 H  Cp   
b cos   rp sin  rg sin  

1
Cp 
 1  p2 1  g2 
   
 Ep Eg 

Cp : elastic coefficient

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 Stress and strength analyses:
AGMA-inspired equations
for spur gears
• Bending fatigue
Ft P
 K v K o K m , bending stress
bJ
S n  S nCLCG CS kr kt kms , bending fatigue strength

• Surface fatigue
Ft
 H  Cp K v K o K m , surface stress
bd p I
S H  S feCLi CR , surface fatigue strength

Applied stress must be < strength

A safety factor of 1.5 for bending fatigue, and safety
factors of 1.1 to 1.5 for surface fatigue are appropriate
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• Geometry factor J – Fig. 15.23, p 643
• Dynamic factor Kv – Fig. 15.24, p 644
• Overload factor Ko – Table 15.1, p 645
• Mounting correction factor Km – Table 15.2, p 645
• Endurance limit S n
• Load factor CL – p 645
• Gradient factor CG – p 645
• Surface factor CS – Fig. 8.13, p 323
• Reliability factor kr – Table 15.3, p 645
• Temperature factor kt – p 646
• Mean stress factor kms – p 646

• Elastic coefficient Cp – Eqn. 15-22, Table 15.4, p 651

• Geometry factor I – Eqn. 15-23, p 651

• Surface fatigue strength Sfe – Table 15.5, p 653

• Life factor CLi – Fig. 15.27, p 653
• Reliability factor CR – Table 15.6, p 654

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 25
kms : mean stress factor  1 for idler gears, 1.4 for input and output gears
 sin  cos  R
I with R 
dg

2 R 1 dp

2.8
2.8

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* 27
 Stress and strength analyses:
AGMA-inspired equations
for helical gears
• Bending fatigue
Ft P Geometry factor J
 K v K o (0.93K m ) – Fig. 16.8, p 685
bJ
S n  S nCLCG CS kr kt kms

• Surface fatigue
Ft  cos 
 H  Cp   K v K o (0.93K m )
bd p I  0.95CR 
S H  S feCLi CR
Applied stress must be < strength
A safety factor of 1.5 for bending fatigue, and safety
factors of 1.1 to 1.5 for surface fatigue are appropriate
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* 29
 Stress and strength analyses:
AGMA-inspired equations
for bevel gears
• Bending fatigue
Geometry factor J
Ft P – Fig. 16.13, p 690
 Kv Ko Km Mounting factor Km
bJ – Table 16.1, p 690
S n  S nCLCG CS kr kt kms

• Surface fatigue

Ft
 H  Cp Kv Ko Km Elastic coefficient Cp
– 1.23 times value from
bd p I Table 15.4, p 651
Geometry factor I
S H  S feCLi CR – Fig. 16.15, p 692

Applied stress must be < strength

A safety factor of 1.5 for bending fatigue, and safety
factors of 1.1 to 1.5 for surface fatigue are appropriate
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 Stress and strength analyses:
worm gears (p 701-705)
Worm teeth are much stronger than gear teeth.
Since friction is high, a cooling system must be
included in the design (p 703-705).
• Load equation

1200  Vg
Fd  Fgt K v  Fgt Pitch line velocity Vg
in feet per minute
1200

• Strength equations
Zero-to-max. bending
fatigue strength Sn
Fs  S nbpy – usually 24 ksi for
gear bronze
Fw  d g bK w Lewis form factor y
– Table 16.2, p 696
Wear factor Kw
One needs to have: – Table 16.3, p 703

Fs  Fd
Fw  Fd
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