Gears Presentation Bubu

Gears
What we need to Know about them.

1. Type of gears
2. Terminologies or nomenclatures
3. Forces transmitted
4. Design of a gear box
Type of Gears
• Spurs
• Helical
• Bevel
• And Worm Gears
Spur Gears
Are used in transmitting torque between parallel shafts

Helical Gears
Are used in transmitting torques between parallel or non

parallel shafts, they are not as noisy as spur gears
Fig. 13.2
Bevel Gears
• Are used to transmit
rotary motion
between intersecting
shafts
Teeth are formed on conical

surfaces, the teeth could be
straight or spiral.
Worm Gears
Are used for transmitting motion between non parallel

and non transmitting shafts, Depending on the number of
teeth engaged called single or double. Worm gear
mostly used when speed ratio is quiet high, 3 or more
Nomenclature
Smaller Gear is Pinion and Larger one is the gear

In most application the pinion is the driver, This reduces
speed but it increases torque.
Internal Spur Gear System
pitch circle, theoretical circle upon which all calculation is based
p, Circular pitch, p the distance from one teeth to the next, along
the pitch circle. p=πd/N
m, module=d/N pitch circle/number of teeth
p= πm
P, Diametral Pitch P=N/d
pP= π
Angle Φ has the values of 20 or 25 degrees. Angle 14.5
have been also used.
Gear profile is constructed from the base circle. Then
additional clearance are given.
How Gear Profile is constructed
A1B1=A1A0, A2B2=2 A1A0 , etc

Standard Gear Teeth
Item 20o full depth 20o Stub 25o full depth
Addendum a 1/P 0.8/P 1/P
Dedendum 1.25/P 1/P 1.25/P
Clearance f 0.25/P 0.2/P 0.25/P
Working depth 2/P 1.6/P 2/P
Whole depth 2.25/P 1.8/P 2.25/P
Tooth thickness 1.571/P 1.571/P 1.571/P
Face width 9/P<b<13/P 9/P<b<13/P 9/P<b<13/P
Gear Trains
n5 N1 N3 N4
 ( )( )( )
n1 N2 N4 N5
Planetary Gear train
You can get high torque ratio in a smaller space
There are two inputs to the planetary gears, RPM of sun and Ring,
The out put is the speed of the arm.
Example of planetary Gear train
Gear 1, sun , RPM 1200, Number of teeth 20,

Planet Gear , Number of teeth 30
Ring Gear, Rotates RPM 120, and teeth of 80,
¼ horse power, find the speed of the arm and torque on the ring.
Alternatively you may have Certain Out put Torque
requirements
Transmitted Load
• With a pair of gears or gear sets, Power is
transmitted by the force developed between
contacting Teeth
Ft  Fn cos 
Fr  Fn sin  These forces
2RPM have to be
V  d / 2  d * d in, RPM rev./min, V
60
in/sec corrected for
dn dynamic effects ,
V  d in, n rpm, V fpm
12 we discuss later,
Tn considering
hp 
63000 Toque lb-in AGMA factors
33000hp
Ft 
V V fpm
FV Tn
KW  t 
1000 9549 T= N.m, V m/s, F Newton
• the phenomenon when the tip of a tooth undercuts the root on its
mating gear is known as interference. interference may only be
prevented, if the addendum circles of the two mating gears cut the
common tangent to the base circles between the points of tangency.
Beam Strength of Gear Teeth – Lewis Equation
• Consider each tooth as a cantilever beam loaded by a normal load (WN) as shown in
Fig below. It is resolved into two components i.e. tangential component (WT) and
radial component (WR) acting perpendicular and parallel to the Centre line of the
tooth respectively. The tangential component (WT) induces a bending stress which
tends to break the tooth. The radial component (WR) induces a compressive stress of
relatively small magnitude; therefore its effect on the tooth may be neglected. Hence,
the bending stress is used as the basis for design calculations. The critical section or
the section of maximum bending stress may be obtained
• The maximum value of the bending stress (or the permissible working
stress), at the section BC is given by
• The value of y in terms of the number of teeth may be expressed as
follows :
Bending Strength of the a Gear Tooth
Mc ( Ft L)t / 2 6 Ft
  3  2
I bt / 12 bt
Earlier Stress Analysis of the Gear Tooth was based on

A full load is applied to the tip of a single tooth
The radial load is negligible
The load is uniform across the width
Neglect frictional forces
The stress concentration is negligible
This equation does not consider stress concentration,

dynamic effects, etc.
Design for the Bending Strength of a Gear
Tooth: The AGMA Method
P Ks Km
  Ft K 0 K v U.S. Customary
b J
1.0 K s K m
  Ft K 0 K v SI units
bm J
 Bending stress at the root of the tooth
Ft  Transmitted tangential load
K0  Overload factor
Kv  Velocity factor
P Diameteral pitch, P
b Face width
m Metric modue
Ks  Size factor
Km  Mounting factor
J Geometry factor
Your stress should not exceed
allowable stress
St K L
 all 
KT K R
 all  Allowable bending stress
S t  Bending Strength
KL  Life factor
KT  Temperature factor
KR  Reliability factor
Overload Factor - Ko
Dynamic Factor - Kv
-Even with steady loads tooth impact can cause shock loading
-Impact strength depends on quality of the gear and the speed of
gear teeth (pitch line velocity)
-Gears are classified with respect to manufacturing tolerances:
-Qv 3 – 7, commercial quality
-Qv 8 – 12, precision
-Graphs are available which chart Kv for different quality factors
Load Distribution Factor - Km
-Failure greatly depends on how load is distributed across face

-Accurate mounting helps ensure even distribution
-For larger face widths even distribution is difficult to attain
-Note formula depends on face width which has to be estimated for initial iteration
-Form goal: b < Dp; 6 < b*P < 16
Reliability Factor - KR
-Adjusts for reliability other than 99%

- KR = 0.658 – 0.0759 ln (1-R) 0.5 < R <0.99
- KR = 0.50 – 0.109 ln (1-R) 0.99 < R < 0.9999
AGMA Geometry Factor - J
-Updated Lewis Form Factor includes effect of stress concentration at fillet

-Different charts for different pressure angles
-Available for Precision Gears where we can assume load sharing (upper curves)
-HPSTC – highest point of single tooth contact
-Account for meshing gear and load sharing (contact ratio > 1)
-Single tooth contact conservative assumption (bottom curve)
-J = 0.311 ln N + 0.15 (20 degree)
-J = 0.367 ln N + 0.2016 (25 degree)
Bending Strength No. – St,
Fatigue bending strength
-Tabulated Data similar to fatigue strength

-Range given because value depends on Grade
-Based on life of 107 cycles and 99% reliability
St – Analytical Estimate
-Through hardened steel gears

-Different charts for different manufacturing methods
-Grade 1 – good quality
St = 77.3 HB + 12,800
-Grade 2 – premium quality
St = 102 HB + 16,400
Bending Strength Life Factor- KL
-Adjusts for life goals other

than 107 cycles
-Fatigue effects vary with
material properties and surface
finishes
-KL = 1.6831 N -0.0323 N>3E6
Note: @ 2000 rpm reach 3

million cycles in 1 day of
service
Example:
A conveyor drive involving heavy-shock torsional loading is operated by an
electric motor, the speed ratio is 1:2 and the pinion has Diameteral pitch P=10
in-1, and number of teeth N=18 and face width of b=1.5 in. The gear has Brinnel
hardness of 300 Bhn. Find the maximum horspower that can be transmitted,
using AGMA formula.
Gear Box Design

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Gears

What we need to Know about them.

Are used in transmitting torque between parallel shafts

Are used in transmitting torques between parallel or non

Teeth are formed on conical

Are used for transmitting motion between non parallel

Smaller Gear is Pinion and Larger one is the gear

A1B1=A1A0, A2B2=2 A1A0 , etc

Gear 1, sun , RPM 1200, Number of teeth 20,

Earlier Stress Analysis of the Gear Tooth was based on

This equation does not consider stress concentration,

-Failure greatly depends on how load is distributed across face

-Adjusts for reliability other than 99%

-Updated Lewis Form Factor includes effect of stress concentration at fillet

-Tabulated Data similar to fatigue strength

-Through hardened steel gears

-Adjusts for life goals other

Note: @ 2000 rpm reach 3

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