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    Gear Analysis

    Uploaded by

    Rob Morien
    This document provides a summary of analysis methods for spur and helical gears, including: 1) Simple beam and contact stress models for loaded gear teeth; factors in the Lewis and AGMA equations for bending and contact stress. 2) Discussion of tooth geometry, load distribution, material properties, and velocity factors used to calculate allowable stresses. 3) Overview of similar AGMA approaches and equations for analyzing bending and surface stresses in helical gears and determining forces in bevel gears.

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    © All Rights Reserved
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    Gear Analysis

    Uploaded by

    Rob Morien
    170 views33 pages
    This document provides a summary of analysis methods for spur and helical gears, including: 1) Simple beam and contact stress models for loaded gear teeth; factors in the Lewis and AGMA equations for bending and contact stress. 2) Discussion of tooth geometry, load distribution, material properties, and velocity factors used to calculate allowable stresses. 3) Overview of similar AGMA approaches and equations for analyzing bending and surface stresses in helical gears and determining forces in bevel gears.

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    Gear Analysis

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    This document provides a summary of analysis methods for spur and helical gears, including: 1) Simple beam and contact stress models for loaded gear teeth; factors in the Lewis and AGMA equations for bending and contact stress. 2) Discussion of tooth geometry, load distribution, material properties, and velocity factors used to calculate allowable stresses. 3) Overview of similar AGMA approaches and equations for analyzing bending and surface stresses in helical gears and determining forces in bevel gears.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    170 views33 pages

    Gear Analysis

    Uploaded by

    Rob Morien
    This document provides a summary of analysis methods for spur and helical gears, including: 1) Simple beam and contact stress models for loaded gear teeth; factors in the Lewis and AGMA equations for bending and contact stress. 2) Discussion of tooth geometry, load distribution, material properties, and velocity factors used to calculate allowable stresses. 3) Overview of similar AGMA approaches and equations for analyzing bending and surface stresses in helical gears and determining forces in bevel gears.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 33

    Analysis of Spur and Helical

    Gears
    prepared by Wayne Book
    based on Norton, Machine Design
    and
    Mischke and Shigley
    Mechanical Engineering Design

    The Gnashing of Teeth

    Simple model for


    loaded gears
    Beam for bending
    stress
    Cylinders in
    contact for surface
    contact stress

    Idealized Shape of a Tooth for Stress Analysis


    Simple model: cantilever
    beam with applied force W
    Tooth thickness t
    Length l
    Face width F
    Max stress at root (a)
    Mc (Wt l )t / 2 6Wt l

    3
    I
    ( Ft / 12 ) Ft 2

    l
    t

    Wt

    Consider the Shape of a Tooth


    Uncertainties include:

    point of load application l


    point of maximum stress
    appropriate load component
    beam thickness

    Depends on pitch P, number of teeth N and


    pressure angle
    Conservative assumptions are made
    Y = Lewis form factor

    Introduce Lewis Shape Factor


    Wr

    x
    t

    Wt

    6Wt l Wt P 12l
    2
    Ft
    F 2 Pt 2
    By similar triangles
    t/2
    l
    t2

    x
    x
    t/2
    4l
    Wt P Wt P

    2
    t P FY
    F
    6l
    2 xP
    Y
    3

    Rather than calculate Y(P,, N), create a table, e.g. 14-2


    Lewis equation has been improved by AGMA

    Velocity Effect
    (Its Barth not Barf)
    Purely empirical adjustment for non-zero velocity
    Barths equation (1800s) has been modified to account for
    current practice and accuracy
    V is velocity in ft/sec at the pitch line
    Kv= 1200/(1200+V) (Modified Barth)
    Metric form Kv= 6.1/(6.1+V), V in m/sec
    Compare to endurance strength (reversing) or use
    Goodman diagram (one direction)
    Apply notch sensitivity, Marin factors. the works

    Wt P

    K v FY

    Surface Durability: Contact Stress


    Analyzed as two cylinders of
    1/ 2
    Wt
    1 1
    length l in rolling contact

    c C p
    with specified force
    CV F cos r1 r2
    1/ 2
    Cylinder radii r1 and r2 vary

    with contact point

    Depends on elastic material C p


    1 2
    2
    1 G
    properties and radii of
    p

    E p
    E
    cylinders
    G

    Translate into gear


    Poisson's ratio
    nomenclature as shown on E Young' s modulus
    right

    G, P subscriptsrefer togear and pinion


    C v velocity factor

    AGMA Approach
    AGMA formula calculates stress for
    Bending
    Contact

    Stress is compared to an allowable stress


    (also called strength by Norton) based on
    strength and conditions

    Bending Stress gear

    tooth
    loading geometry
    form
    K K P K K K
    Many terms are similar to
    Wt I a d s m B
    the Lewis equation
    Kv F
    J

    Additional terms account Wt tangential load


    for the application, load K I idler factor
    sharing and size
    K a applicatio n factor
    K v velocity factor as in Lewis
    Pd diametral pitch
    F face width
    K s size factor
    K m load distribution factor
    K B rim backup factor
    J tooth geometry factor

    J factor sample table


    Tip loading
    (low
    precision)

    Distributed
    loading
    (higher
    precision)

    Kv Velocity Factor (similar to Barth)


    (also provided in equations 11.16 11.19)

    Load Distribution Factor


    Loads are less evenly
    distributed for wide
    face teeth
    Keep F (face width)
    8/pd < F < 16/pd
    Nominally F = 12/pd

    Application Factor
    Created to account for known but
    unquantified shock in load
    Electric motors are smooth while single
    cylinder engines have shock
    Centrifugal pumps are smooth loads while
    rock crushers have shock

    Other Factors
    Size, Rim Thickness, Idler
    Size
    Fatigue tests are done on small specimins and
    indications are that size results in weaker parts
    Very large teeth might warrant Ks=1.25 to 1.5
    Material properties created directly for gears
    account for this

    Rim thickness
    In large diameter gears, the centers are
    connected to a rim by spokes.
    KB reflects failures across the radius

    Idler: use KI = 1.42

    Allowable Bending Stress


    Incorporate material strength St specific to gear
    materials
    St based on Brinell hardness of material
    Environmental and application factors
    KL = life factor
    KT = temperature factor
    KR = reliability factor

    all

    St K L

    KT K R

    Life Factor KL
    (a specialized S-N curve)

    BendingTemperature and Reliability


    Factors
    Strength data is based on 99%
    reliability. Adjust up or down.
    Temperatures up to 250 deg F
    use KT = 1
    Adjust for higher temperatures

    460 TF
    KT
    620

    AGMA Bending Fatigue Strengths


    (uncorrected)

    tooth
    gear
    condition &
    loading geometry geometry
    material
    1/ 2
    Wt Ca Cs CmC f
    c CP

    C
    Fd
    I
    v

    Contact Stress
    Based on rolling
    cylinder model
    Added terms for size,
    load distribution,
    surface condition

    C P elastic coefficient
    Ca applicatio n factor
    Cv velocity (dynamic)factor
    Cs size factor
    d pitch diameter
    Cm load distribution factor
    C f surfacecondition factor
    I tooth geometry factor

    Surface Geometry Factor I


    I

    cos

    1
    1

    dp

    p g
    2

    1 xp

    rp cos 2
    p rp
    cos
    pd
    pd

    g C sin p
    pd diametrial pitch of pinion
    rp pitch radius of pinion

    pressureangle
    p radius of curvaturefor pinion
    g radius of curvaturefor gear
    x p fraction addendum elongation
    (0 for full depth teeth)

    AGMA Elastic Coefficient


    (also from basic material properties and (11.23))

    Other Surface Stress Factors


    Cf = 1 for standard manufacturing methods
    Ca, Cm, Cv, Cs are equal to corresponding K
    values from bending

    Allowable Contact Stress


    (Norton calls Strength)
    Material strength SC is the basis, specific to
    gear materials
    Sc based on Brinell hardness of material or
    on tables in Norton
    S ' fc CLCH
    S fc
    Adjust for conditions

    CT CR

    CL = life factor
    CH = hardness-ratio factor (pinion rel to gear)
    CT = temperature factor
    CR = reliability factor

    Surface Fatigue Strengths

    Surface Fatigue Life Factor

    Hardness Ratio Factor


    Only applied to the gear material (not pinion)
    Accounts for work hardening of the gear during
    run-in
    Depends on previous hardening (through hardened
    vs surface hardened)
    Pinion surface hardened
    C H 1 B(450 HBg )

    Both through hardened


    C H 1 A(mG 1)
    mG gear ratio
    HB p
    HBg

    1.2 then A 0

    1.2

    HB p

    HB p

    1.7 then A 0.00698

    HBg

    HBg

    1.7 then A 0.00898

    HB p
    HBg

    B 0.00075e

    0.0112 Rq

    B 0.00075e

    0.052 Rq

    (U .S .)

    ( S .I .)

    Rq rms surfaceroughnessin microinch


    0.00829

    HB p , HBg Brinnel hardness of pinion, gear

    Helical Gears Brief Overview


    The treatment of tooth stresses for helical
    gears is very similar to spur gears
    Bending and Surface stresses must be
    analyzed
    AGMA formulas are analagous
    Tables also consider helix angle in range
    of 10 to 30 degrees
    For this class, be able to perform force
    analysis but we will not cover tooth stresses

    Forces, Helical
    (Equations 12.3 in Norton)
    n normal pressureangle
    t circular pressureangle (for involute)
    helix angle
    cos

    tan n
    tan t

    W total force
    Wt W cos n

    cos transmitted force

    Wa W cos n

    sin axial force

    Wr W sin n radial force

    Bevel Gears

    Treat force analysis of intersecting, straight


    tooth, bevel gears
    Equations (12.8 in Norton)

    Forces, Bevel Gears


    (Shigley, Fig 13-34)
    Assume forces
    concentrated at average
    radius
    Net force surface
    Decompose into
    transmitted, radial and
    axial forces

    pressure angle
    pitch cone half - angle
    Wt T / rave ; W Wt tan
    Wr Wt tan cos
    Wa Wt tan sin

    Bending Strength from Hardness


    (Fig 14-2 Shigley)

    Contact Strength from Hardness


    (Fig 14-3 Shigley)

    "I've had a wonderful time, but this wasn't it."


    - Groucho Marx (1895-1977)

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