Design of Gears

Module-2
Mechanical drives
Mechanical drive is defined as a mechanism,
which is intended to transmit mechanical
power over a certain distance, usually
involving a change in speed and torque.
These can be classified into two groups
according to their principle of operation.

Mechanical drives that transmit power by

means of friction
eg: belt drive and rope drive

Mechanical drives that transmit power by

means of engagement
e.g., chain drives and gear drives
 GEAR DRIVES
Gears are defined as toothed wheels or
multilobed cams, which transmit power and
motion from one shaft to another by means of
successive engagement of teeth

Gears are broadly classified into four groups,

viz.,
• Spur
• Helical
• Bevel and
• Worm gears
 Spur gears
In case of spur gears, the teeth are cut parallel
to the axis of the shaft. As the teeth are
parallel to the axis of the shaft, spur gears are
used only when the shafts are parallel
 Helical gears
The teeth of these gears are cut at an angle with the
axis of the shaft.
 Bevel gears
Bevel gears, as shown in, have the shape of a
truncated cone. The size of the gear tooth, including
the thickness and height, decreases towards the apex
of the cone. Bevel gears are normally used for shafts,
which are at right angles to each other
 Worm gears
The worm gears, as shown in Fig., consist of a worm and a
worm wheel. The worm is in the form of a threaded screw,
which meshes with the matching wheel.
Worm gear drives are used for shafts, the axes of which do
not intersect and are perpendicular to each other.
Classification depending upon peripheral
speed
• Low velocity gear (V < 3m/s)
• Medium velocity gear (3m/s < V < 15 m/s)
• High velocity gear (V > 15 m/s)
 Manufacturing method
• Metal removal method
– Profiling (milling cutter)
– Generation (Hobbing)
• Casting – die casting
• Forming – Roll forming

Gear finishing operation

Grinding, Lapping and honning
Types of gear tooth failure
• Tooth fracture
The teeth in contact are under bending action.
The bending stresses are maximum at the root of
tooth. Periodical effects causes fatigue crack near
the tooth face and result in ultimate failure of
tooth.
• Abrasion and run-in-wear
The metal particles, dust or dirt between
contacting teeth are responsible for abrasive wear.
Wear due to insufficient smooth surface is called
run-in-wear.
• Pitting
Due to large contact pressure between two
surfaces pitting wears. Cracks are setup due to
repeated contact stresses. These cracks develop
into pits resulting in ultimate failure of tooth.

• Seizure
Due to high loads applied to 2 surfaces, lubricating
oil film is forced out of contacting faces. Due to
relative motion between them material surfaces
are under dry lubrication.
Nomenclature of Spur gears
Law of Gearing
The fundamental law of gearing
states ‘The common normal to
the tooth profile at the point of
contact should always pass
through a fixed point, called the
pitch point, in order to obtain a
constant velocity ratio’
Lewis beam strength equation
Since the tooth subjected to bending we have,

Where, depends on shape and size of the tooth and is designated by ‘yp’.

According to Lewis where ‘y’ is called Lewis form factor and ‘p’ is circular pitch = m.

therefore,
………………… data hand book (12.5(a) / 204)
Problem 1: Design a pair of spur gears to transmit
15 kW from a shaft rotating at 1000 rpm to a
parallel shaft which is to rotate at 310 rpm. Assume
the number of teeth on pinion 31 and 20˚ full depth
involute form. The material of the pinion is C40
steel untreated and for gears cast steel 0.2% carbon
untreated.
Data:
P = 15 kW
n1 = 1000 rpm
n2 = 310 rpm
Z1 = 31
α = 20˚
𝑛1
i= = 3.22
𝑛2
𝑍2
i = 𝑍 = 𝑍2 = 100
1
Weaker gear
To decide weaker gear, take the product of σd and y for both pinion and gear

Pinion - 𝜎𝑑1 y1 = 25.66

Gear - 𝜎𝑑2 y2 = 19.91 - weaker (product of σd y is less for gear,

hence gear is weaker)

Since the gear is weaker further design is based on gear.

 4.58
Velocity factor, Cv = 4.58+𝑣 …………T(12.6(b)/205)
4.58
Cv = 4.58+1.68𝑚

module,
 13.88 × 103
𝐹𝑡 = = 3.47 × 103 𝑁
Ft 𝑚
b=𝜎 4.58
𝑑 𝐶𝑣 πym Cv = 4.58+1.68𝑚 = 0.419

3.47 × 103
b= = 33.45 mm
138.3 ×0.419 ×0.144 × 𝜋 ×4

Pitch circle diameters (d)

Check for dynamic load (Fd):

𝐾3 𝑉 (𝐶𝑏+ 𝐹𝑡 )
Fd = Ft + ………… T(12.12/207)
𝐾3 𝑉+ 𝐶𝑏+ 𝐹𝑡

V= 6.48 m/s, k3 = 20.67, 𝐹𝑡 = 3.47 × 103 N, b= 34 mm

For ‘c’ dynamic factor

From T (12.13/237), for accurate or carefully cut gears and for module m = 4
error, e = 0.0254
From T (12.12/236), for the material steel and steel, tooth form α = 20˚ deg.
full depth involute and for error e = 0.0254

Dynamic factor, c = 286.1

3 20.67 ×6.48 ×((286.1 ×34)+3.47 × 103 )
Fd = 3.47 × 10 +
20.67 ×6.48+ (286.1 ×34)+3.47 × 103

Fd = 10.57 × 103 N
Endurance Load (Fen):
Fen = σen bYm …………… T(12.13(a)/207)

Fen = σen bπym σen = 1.75 (BHN)

= 1.75× 180 = 315

Fen = 315 × 34 × 𝜋 × 0.144 × 4

Fen = 19.368 × 103 N

Fen > Fd gears are safe under dynamic load

 Wear Load (Fw)
Fw = d1bQK ……………..T(12.15(a)/208)

d1 = 124 mm, b = 34mm

2 𝑍2
Q=𝑍 = 1.52 ………………T(12.15(c)/208)
1 + 𝑍2

𝜎𝑒𝑠2 𝑆𝑖𝑛𝛼 1 1
K= + ……..…T (12.15(b)/208)
1.4 𝐸1 𝐸2

383.752 ×𝑆𝑖𝑛 20 1 1
K= + = 0.34
1.4 210×103 210×103

Fw = 124 × 34 × 1.52 × 0.34

Fw = 2.17 × 103 N

Fw < Fd

Gears are not safe under wear load

 i.e Fw > Fd

d1bQK > Fd

10.54 ×103
K> 122 ×34 ×1.52

K > 1.67

From table (12.16/239), check for nearest ‘K’ (=1.746) value for α = 20˚ and material steel
and steel. Hardness values for pinion and gear are 400 BHN and 300 BHN respectively

400+300
Avg. Hardness = = 350 BHN
2

For the gears to be safe under wear load, both pinion and gears must be heat treated to
hardness of 350 BHN
Note: When different materials are used, the
product of σd and y decides the weaker between
pinion and gear. The Lewis form factor ‘y’ is
always less for pinion compared with gear. When
the same material is used for both pinion and
gear the pinion is always weaker than the gear.
Problem 2: Design a pair of spur gears to
transmit a power of 20 kW from a shaft running
at 1000 rpm to another shaft to be runs at 400
rpm. The number of teeth on pinion is 18 and are
of 20° full depth involute form. Check the design
for dynamic and wear load.
 Selection of material:
Data:
From Design data hand book T (12.7/234)
P = 20 kW
n1 = 1000 rpm Selecting 0.2% C untreated as a material for both
pinion and gear 𝜎𝑑1 =𝜎𝑑2 = 138.3 MPa
n2 = 400 rpm
Z1 = 18 Lewis form factor(y):
α = 20˚ For 20˚ full depth involute form teeth
𝑛1
i= = 2.5 0.912
𝑛2 y = 0.154 - …………………. T (12.5(d)/204)
𝑍
𝑍2
i = 𝑍 = 𝑍2 = 45 y1 = 0.1033, y2 = 0.1337
1

Weaker gear
Since material is same and y less for pinion, pinion is
weaker. Further design is based on pinion.
 𝜋𝑑 𝑛
1 1 𝜋𝑚𝑧 𝑛
1 1
Where, V = 60×1000 = 60×1000 (d1 = mZ1)
1000 ×20 ×1.5 31.85 × 103
Ft = = 𝜋×𝑚 ×18 ×1000
0.942𝑚 𝑚 V= 60×1000

V = 0.942 m
 4.58
Velocity factor, Cv = 4.58+𝑣 …………T(12.6(b)/205)
4.58
Cv = 4.58+0.942𝑚

𝜎𝑑1 = 138.3 MPa, y1 = 0.1033

31.85 × 103 4.58

𝑚
= 138.3 × 4.58+0.942𝑚 × 10m × π × 0.1033 × m

module, m = 5. 𝟐𝟗 ≈ 𝟔 mm
 Assumed face width, b = 10 m = 50 mm

31.85 × 103
𝐹𝑡 = = 5.30 × 103 𝑁
Ft 𝑚
b=𝜎 4.58
𝑑 𝐶𝑣 πym Cv = 4.58+0.942𝑚 = 0.447

5.30 × 103
b= = 44.02 mm
138.3 ×0.447 ×0.1033 × 𝜋 ×6

b = 45 mm

Pitch circle diameters (d):

d1 = mZ1 = 108 mm
d2 = mZ2 = 270 mm
Check for dynamic load (Fd):

𝐾3 𝑉 (𝐶𝑏+ 𝐹𝑡 )
Fd = Ft + ………… T(12.12/207)
𝐾3 𝑉+ 𝐶𝑏+ 𝐹𝑡

V= 5.65 m/s, k3 = 20.67, 𝐹𝑡 = 5.30 × 103 N, b= 45 mm

For ‘c’ dynamic factor

From T (12.13/237), for accurate or carefully cut gears and for module m = 4
error, e = 0.0316
From T (12.12/236), for the material steel and steel, tooth form α = 20˚ deg.
full depth involute and for error e = 0.0316

Dynamic factor, c = 361.6

3 20.67 ×5.65×((361.6×45)+5.30 × 103 )
Fd = 5.30 × 10 +
20.67 ×5.65+ (361.6×45)+5.30 × 103

Fd = 14.85 × 103 N
Endurance Load (Fen):
Fen = σen bYm …………… T(12.13(a)/207)

Fen = σen bπym σen = 1.75 (BHN)

= 1.75× 180 = 315

Fen = 315 × 45 × 𝜋 × 0.1033 × 6

Fen = 27.6 × 103 N

Fen > Fd gears are safe under dynamic load

 Wear Load (Fw)
Fw = d1bQK ……………..T(12.15(a)/208)

d1 = 108 mm, b = 45mm

2 𝑍2
Q=𝑍 = 1.42 ………………T(12.15(c)/208)
1 + 𝑍2

𝜎𝑒𝑠2 𝑆𝑖𝑛𝛼 1 1
K= + ……..…T (12.15(b)/208)
1.4 𝐸1 𝐸2

4252 ×𝑆𝑖𝑛 20 1 1 𝜎𝑒𝑠 = 2.75 𝐵𝐻𝑁 𝑎𝑣𝑔 − 70

K= + = 0.42
1.4 210×103 210×103
BHNavg = 180

Fw = 108 × 45 × 1.42 ×0.42 𝜎𝑒𝑠 = 425 MPa

Fw = 2.90 × 103 N

Fw < Fd

Gears are not safe under wear load

 i.e Fw > Fd

d1bQK > Fd

14.85×103
K> 108 ×45 ×1.42

K > 2.15

From table (12.16/239), check for nearest ‘K’ (=2.189) value for α = 20˚ and material steel
and steel. Hardness values for pinion and gear are 400 BHN and 350 BHN respectively

400+350
Avg. Hardness = = 375 BHN
2

For the gears to be safe under wear load, both pinion and gears must be heat treated to
hardness of 375 BHN
Homework problem
Design a pair of spur gears to transmit a power of 18 kW
from a shaft running at 1000 rpm to another shaft to be run
at 400 rpm. Check the design for dynamic and wear load.

Since the number of teeth are not given,

Data:
P = 28 kW assuming that the teeth are of 20° full depth
n1 = 1000 rpm involute form
n2 = 4000 rpm
𝑛1
From T(12.4(b)/230) smallest number of teeth on
i= = 2.5
𝑛2 pinion without interference is 18
Assume 𝑍1 = 20
𝑍2
i= = 𝑍2 = 50
𝑍1
Problem 3: Design a pair of spur gears to transmit a power
of 27 kW from an oil pump with velocity ratio 3:1. The
speed of pinion is 1200 rpm and the centre distance is 400
mm. The gears are to be of forged steel untreated with
14½° involute form. Check the design for dynamic and
wear consideration.
 Selection of material:
Data:
From Design data hand book T (12.7/234)
P = 27 kW
n1 = 1200 rpm Selecting forged steel untreated as a material for both
pinion and gear 𝜎𝑑1 =𝜎𝑑2 = 172.6 MPa
α = 14½°
𝑑2 Lewis form factor(y):
i=3=
𝑑1
a = 400 mm For 14½° involute form teeth
𝑑1 + 𝑑2 0.684
a= y = 0.124 - …………………. T (12.5(d)/204)
2 𝑍

𝑑1 + 3𝑑1 y1 = 0.124 – (3.42 × 10−3 )m

400 = 2
y1 = 0.124 – (1.14 × 10−3 )m
𝑑1 = 200 𝑚𝑚
𝑑2 = 600 𝑚𝑚 Weaker gear
Since material is same and y less for pinion, pinion is
weaker. Further design is based on pinion.
 𝜋𝑑 𝑛
1 1
Where, V = 60×1000
1000 ×27 ×1.5
Ft =
12.56 V=
𝜋×200 ×1200
60×1000

Ft = 3.224 × 103 V = 12.56 m/s

 4.58
Velocity factor, Cv = 4.58+𝑣 …………T(12.6(b)/205)
4.58
Cv = 4.58+12.56 = 0.267

𝜎𝑑1 = 172.6 MPa, y1 = 0.124 – (3.42 × 10−3 )m

3.224 × 103 = 172.6 × 0.267 × 10m × π × (0.124 – (3.42 × 10−3 )m) × m

module, m = 4. 𝟓𝟏 ≈ 𝟓 mm
 Assumed face width, b = 10 m = 50 mm

Ft
b= 𝜎𝑑 𝐶𝑣 πym

Ft = 3.224 × 103 , Cv = 0.267,

y1 = 0.124 – (3.42 × 10−3 )m = 0.107

3.224 × 103
b= 172.6 ×0.267 ×0.107 × 𝜋 ×5
= 41.42 mm
b = 42 mm
Number of teeth (Z):
𝑑1
Z1 = = 40 teeth
𝑚
𝑑2
Z2 = = 120 teeth
𝑚
Check for dynamic load (Fd):

𝐾3 𝑉 (𝐶𝑏+ 𝐹𝑡 )
Fd = Ft + ………… T(12.12/207)
𝐾3 𝑉+ 𝐶𝑏+ 𝐹𝑡

V= 12.56 m/s, k3 = 20.67, 𝐹𝑡 = 3.224 × 103 N, b= 42 mm

For ‘c’ dynamic factor

From T (12.13/237), for accurate or carefully cut gears and for module m = 5
error, e = 0.0277
From T (12.12/236), for the material steel and steel, tooth form α = 14½° deg.
full depth involute and for error e = 0.0277

Dynamic factor, c = 305.53

3 20.67 ×12.56×((305.53×42)+3.224 × 103 )
Fd = 3.224 × 10 +
20.67 ×12.56+ (305.5∗42)+3.224 × 103

Fd = 14.01 × 103 N
Endurance Load (Fen):
Fen = σen bYm …………… T(12.13(a)/207)

Fen = σen bπym σen = 1.75 (BHN)

= 1.75× 180 = 315

Fen = 315 × 42 × 𝜋 × 0.107 × 5

Fen = 22.236 × 103 N

Fen > Fd gears are safe under dynamic load

 Wear Load (Fw)
Fw = d1bQK ……………..T(12.15(a)/208)

d1 = 200 mm, b = 45 mm
2 𝑍2
Q=𝑍 = 1.5 ………………T(12.15(c)/208)
1 + 𝑍2

𝜎𝑒𝑠2 𝑆𝑖𝑛𝛼 1 1
K= + ……..…T (12.15(b)/208)
1.4 𝐸1 𝐸2

342.52 ×𝑆𝑖𝑛 20 1 1 𝜎𝑒𝑠 = 2.75 𝐵𝐻𝑁 𝑎𝑣𝑔 − 70

K= + = 0.199
1.4 210×103 210×103
BHNavg = 150

Fw = 200 × 42× 1.5 ×0.199 𝜎𝑒𝑠 = 342.5 MPa

Fw = 2.50 × 103 N

Fw < Fd

Gears are not safe under wear load

 i.e Fw > Fd

d1bQK > Fd

14.016×103
K> 200 ×42 ×1.5

K > 1.112

From table (12.16/239), check for nearest ‘K’ (= 1.177 ) value for α = 14½° and material
steel and steel. Hardness values for pinion and gear are 350 BHN and 300 BHN respectively

350+300
Avg. Hardness = = 325 BHN
2

For the gears to be safe under wear load, both pinion and gears must be heat treated to
hardness of 325 BHN
Homework problem
A compressor running at 300 rpm is driven by 15 kW, 1200 rpm
motor. The teeth are of 14½° involute form. The centre distance
is 375 mm. The motor pinion is to be of C30 forged steel,
hardened and tempered and driven is to be cast steel. Assuming
medium shock condition. Design the gear.
Design of Helical gear
HW:
Problem2
Problem 3: The following data refers to a
helical gear drive, power= 34 kW,
n1=2800 rpm, i=4.5,β=25o , material for both is
medium carbon steel, whose allowable
bending stress is 230 MPa. Pinion gear
diameter is limited to 125 mm. Determine the
module and face width. Also find axial thrust
on the shaft.
Given: Velocity ratio,
P  34kW n1
i
n1  2800rpm n2
i  622.22rpm
i  4.5
d1  125mm Pitch dia,
 d 1   d 2  230MPa let , d1  120mm
  25o d2
Also, i   d2  540mm
d1

d cos 
Z
mn
 108.76 489.41
Z1  Z2 
mn mn
146.09 657.42
Z e1  Ze2 
mn mn

𝑦 = 0.175 − 0.0065𝑚 , 𝑦 = 0.175 − 0.00145𝑚

Pinion is weaker, since both are of same material and further

design based on pinion
 Ft  2897.73N
 d1n1
V  17.6m / s
60000

CV  0.464
On substituting all values in Lewis eq. mn  2.11mm
Standard size T12.2 (page 229) mn  2.5mm

b  27.23mm
Axial thrust, Eq.12.21 (page 211)

Fa  Ft tan   1351.23N
Home work problem:4
Design a pair of helical gear with 20o stub
involute form to transmit 40kW with
moderate shocks, pinion speed is 1200 rpm,
with velocity ratio 3:1. Two shafts are parallel
and 440 mm apart both gears are made of
cast steel of allowable stress 138 MPa. Check
for dynamic and wear load.
Problem:5
A 55kW motor is running at 450 rpm
is geared to a pump by means of double
helical gear (Herringbone gear). A forged
steel pinion on the motor shaft as pitch
circle diameter of 200 mm and it drives a
gray cast Iron gear over the pump shaft at
120 rpm, the allowable stress for the forged
steel pinion and CI gear are 224 MPa and 56
MPa. Find the module for the gear
• Given Velocity ratio,

P  55kW n1
i   3.75
n1  450rpm n2

d1  200mm Pitch dia,

n2  120rpm d2
Also, i   d2  750mm
 d 1  224MPa d1
 d 2  56MPa

d cos 
Z
mn
 181.26 679.73
Z1  Z2 
mn mn
243.49 913.08
Z e1  Ze2 
mn mn

y1  0.175  (3.902  10 )mn 3 , y2  0.175  (1.04 10 )mn

3

Since  d 2 y2 is less gear is weaker, and further design based

on gear
 Ft  17515.92 N
 d 2 n2
V  4.17m / s
60000

CV  0.493
Face width ‘b’ , from Eq.12.23(g)/pg 213 for herringbone gear
b  20mn  30mn
Assume, b  25mn

On substituting all values in Lewis eq. mn  6.21mm

Standard size T12.2 (page 229) mn  8mm
 Home work problem:6
A pair of herringbone gears are used to
transmit 50kW power. Pinion rotates at 2800 rpm,
teeth on pinion and gear are 21 and 109
respectively. Tooth form is 20o FDI and β=25o.
The material for the gear is cast steel with
hardness 250BHN and for pinion is steel. Wear
and lubrication factor may be taken as 1.15. The
normal module employed for gear is 4mm and
face width of gear is 20 mn . Determine the
hardness of pinion for continuous operation of
drive.