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qxd
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Chapter 15
15-1
Given: Uncrowned, through-hardened 300 Brinell core and case, Grade 1, NC = 109 rev of
pinion at R = 0.999, N P = 20 teeth, NG = 60 teeth, Q v = 6, Pd = 6 teeth/in, shaft angle
90, n p = 900 rev/min, J P = 0.249 and JG = 0.216 (Fig. 15-7), F = 1.25 in, S F =
S H = 1, K o = 1.
d P = 20/6 = 3.333 in
Mesh
dG = 60/6 = 10.000 in
Eq. (15-7):
Eq. (15-6):
59.77 + 785.3
Kv =
= 1.374
59.77
Eq. (15-5):
Eq. (15-8):
Since 785.3 < 3904, K v = 1.374 is valid. The size factor for bending is:
K s = 0.4867 + 0.2132/6 = 0.5222
Eq. (15-10):
Eq. (15-11):
Eq. (15-15):
Eq. (15-14):
(C L ) P = 3.4822(109 ) 0.0602 = 1
(C L ) G = 3.4822(109 /3) 0.0602 = 1.069
K R = 0.50 0.25 log(1 0.999) = 1.25
C R = K R = 1.25 = 1.118
Eq. (15-19):
Bending
Fig. 15-13:
Eq. (15-4):
Eq. (15-3):
0.99 St
(all ) P = swt =
W Pt =
=
H1 =
Eq. (15-4):
(all ) G =
sat K L
15 300(0.862)
= 10 551 psi
=
SF K T K R
1(1)(1.25)
(all ) P F K x J P
Pd K o K v K s K m
10 551(1.25)(1)(0.249)
= 690 lbf
6(1)(1.374)(0.5222)(1.106)
690(785.3)
= 16.4 hp
33 000
15 300(0.893)
= 10 930 psi
1(1)(1.25)
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Chapter 15
WGt =
10 930(1.25)(1)(0.216)
= 620 lbf
6(1)(1.374)(0.5222)(1.106)
620(785.3)
= 14.8 hp Ans.
33 000
The gear controls the bending rating.
H2 =
15-2
sac (C L ) P C H
SH K T C R
(c, all ) P =
125 920(1)(1)
= 112 630 psi
1(1)(1.118)
sac (C L ) G C H
SH K T C R
(c, all ) G =
For steel:
Eq. (15-9):
Fig. 15-6:
Eq. (15-12):
Cp
Cs
I
C xc
Eq. (15-1):
W Pt
= 464 lbf
464(785.3)
= 11.0 hp
33 000
1.25(3.333)(0.083)
120 511 2
t
WG =
2290
1(1.374)(1.106)(0.593 75)(2)
H3 =
= 531 lbf
H4 =
531(785.3)
= 12.6 hp
33 000
391
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H = 11.0 hp Ans.
The pinion controls wear:
The power rating of the mesh, considering the power ratings found in Prob. 15-1, is
H = min(16.4, 14.8, 11.0, 12.6) = 11.0 hp Ans.
15-3
AGMA 2003-B97 does not fully address cast iron gears, however, approximate comparisons can be useful. This problem is similar to Prob. 15-1, but not identical. We will organize the method. A follow-up could consist of completing Probs. 15-1 and 15-2 with
identical pinions, and cast iron gears.
Given: Uncrowned, straight teeth, Pd = 6 teeth/in, N P = 30 teeth, NG = 60 teeth, ASTM
30 cast iron, material Grade 1, shaft angle 90, F = 1.25, n P = 900 rev/min,
n = 20 ,
one gear straddle-mounted, K o = 1, J P = 0.268, JG = 0.228, S F = 2, S H = 2.
Mesh
d P = 30/6 = 5.000 in
dG = 60/6 = 10.000 in
vt = (5)(900/12) = 1178 ft/min
Table 15-5:
Eq. (15-4):
swt =
sat K L
4500(1)
= 2250 psi
=
SF K T K R
2(1)(1)
The velocity factor K v represents stress augmentation due to mislocation of tooth profiles
along the pitch surface and the resulting falling of teeth into engagement. Equation
(5-67)
shows that the induced bending moment in a cantilever (tooth) varies directly with E of the
tooth material. If only the material varies (cast iron vs. steel) in the same geometry, I is the
same. From the Lewis equation of Section 14-1,
=
Kv W t P
M
=
I /c
FY
E CI
E steel
(K v ) CI =
14.7
(K v ) steel = 0.7(K v ) steel
30
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393
Chapter 15
Our modeling is rough, but it convinces us that (K v ) CI < (K v ) steel , but we are not sure of
the value of (K v ) CI . We will use K v for steel as a basis for a conservative rating.
B = 0.25(12 6) 2/3 = 0.8255
A = 50 + 56(1 0.8255) = 59.77
0.8255
59.77 + 1178
Kv =
= 1.454
59.77
Eq. (15-6):
Eq. (15-5):
Pinion bending
K x = 1,
Eq. (15-3):
W Pt =
=
H1 =
K m = 1.106, K s = 0.5222
(all ) P F K x J P
Pd K o K v K s K m
2250(1.25)(1)(0.268)
= 149.6 lbf
6(1)(1.454)(0.5222)(1.106)
149.6(1178)
= 5.34 hp
33 000
Gear bending
WGt
H2 =
JG
W Pt
JP
0.228
= 149.6
0.268
= 127.3 lbf
127.3(1178)
= 4.54 hp
33 000
Eq. (15-1):
Fig. 15-6:
K s = 0.5222, K m = 1.106, C xc = 2
C p = 1960 psi
From Table 14-8:
1.25(5.000)(0.086)
35 355 2
t
W =
= 91.6 lbf
Thus,
1960
1(1.454)(1.106)(0.59375)(2)
H3 = H4 =
91.6(1178)
= 3.27 hp
33 000
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Rating
Uncrowned, through-hardened to 180 Brinell (core and case), Grade 1, 109 rev of pinion at
R = 0.999, N p = z 1 = 22 teeth, Na = z 2 =24 teeth,
Q v = 5, m et = 4 mm, shaft angle
90, n 1 = 1800 rev/min, S F = 1, S H = S F = 1, J P = Y J 1
= 0.23, JG = Y J 2 =
0.205, F = b = 25 mm, K o = K A = K T = K = 1 and C p = 190 MPa .
Mesh
Eq. (15-7):
Eq. (15-6):
Eq. (15-5):
Eq. (15-10):
Eq. (15-11) with
= de1 = mz 1 = 4(22) = 88 mm
= m et z 2 = 4(24) = 96 mm
= 5.236(105 )(88)(1800) = 8.29 m/s
= 0.25(12 5) 2/3 = 0.9148
A = 50 + 56(1 0.9148) = 54.77
0.9148
54.77 + 200(8.29)
= 1.663
Kv =
54.77
dP
dG
vet
B
(both straddle-mounted),
Eq. (15-12):
Eq. (15-19):
From Fig. 15-10,
Eq. (15-9):
Wear of Pinion
Fig. 15-12:
Fig. 15-6:
Eq. (15-2):
C R = Z Z = Y Z = 1.25 = 1.118
(C L ) P
(C L ) G
C xc
KR
C H = Zw = 1
Z x = 0.004 92(25) + 0.4375 = 0.560
H lim = 2.35H B + 162.89
= 2.35(180) + 162.89 = 585.9 MPa
I = Z I = 0.066
( H lim ) P ( Z N T ) P Z W
( H ) P =
SH K Z Z
585.9(1)(1)
= 524.1 MPa
=
1(1)(1.118)
2
bde1 Z I
H
t
WP =
Cp
1000K A K v K H Z x Z xc
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Chapter 15
395
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Rating of mesh is
Hrating = min(9.62, 8.62, 4.90, 4.93) = 4.90 kW
Ans.
(a)
all
= (S F ) G =
(sat K L /K T K R ) P
t
(W Pd K o K v K s K m /F K x J ) P
all
(sat K L /K T K R ) G
t
(W Pd K o K v K s K m /F K x J ) G
(sat ) P (K L ) P J P
JP
= (sat ) P m G
(K L ) G JG
JG
W =
t
In wear
F Kx J
all
S F Pd K o K v K s K m
sac C L CU
SH K T C R
=
11
= Cp
22
F Kx J
sat K L
S F K T K R Pd K o K v K s K m
W t K o K v K m Cs C xc
Fd P I
(1)
11
1/2
22
(2)
Equating the
right-hand sides of Eqs. (1) and (2) and canceling terms, and recognizing
that C R = K R and Pd d P = N P ,
we obtain
(sac ) 22 =
Cp
(C L ) 22
2
SH
(sat ) 11 (K L ) 11 K x J11 K T Cs C xc
2
SF
CH
N P Ks I
So we get
SF
SF
2
=1
Cp
(sac ) G =
(C L ) G C H
(sat ) P (K L ) P J P K x K T Cs C xc
N P I Ks
Ans.
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397
Chapter 15
(c)
(S H ) P = (S H ) G =
c, all
c
=
P
c, all
c
G
Core
( H B ) 11
( H B ) 21
Case
( H B ) 12
( H B ) 22
Eq. (15-23):
( H B ) 21 =
17 023 2100
= 339 Brinell
44
Ans.
15 300(0.862)(0.249)(1)(0.593 25)(2)
= 141 160 psi
20(0.086)(0.5222)
(sac ) G =
2290
1.0685(1)
( H B ) 22 =
(sac ) P = (sac ) G m G
( H B ) 12 =
Ans.
1 .
1
0.0602
= 150 811 psi
)
= 141 160(3
CH
1
Care
300
399
Ans.
Case
373
345
Ans.
(1)
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15-9
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Page 398
Pinion core
(sat ) P = 44(300) + 2100 = 15 300 psi
15 300(0.862)
(all ) P =
= 10 551 psi
1(1)(1.25)
10 551(1.25)(0.249)
Wt =
= 689.7 lbf
6(1)(1.374)(0.5222)(1.106)
Gear core
(sat ) G = 44(352) + 2100 = 17 588 psi
17 588(0.893)
(all ) G =
= 12 565 psi
1(1)(1.25)
12 565(1.25)(0.216)
Wt =
= 712.5 lbf
6(1)(1.374)(0.5222)(1.106)
Pinion case
(sac ) P = 341(372) + 23 620 = 150 472 psi
150 472(1)
= 134 590 psi
(c, all ) P =
1(1)(1.118)
1.25(3.333)(0.086)
134 590 2
t
= 685.8 lbf
W =
2290
1(1.374)(1.106)(0.593 75)(2)
Gear case
(sac ) G = 341(344) + 23 620 = 140 924 psi
140 924(1.0685)(1)
= 134 685 psi
(c, all ) G =
1(1)(1.118)
1.25(3.333)(0.086)
134 685 2
t
= 686.8 lbf
W =
2290
1(1.374)(1.106)(0.593 75)(2)
The rating load would be
t
Wrated
= min(689.7, 712.5, 685.8, 686.8) = 685.8 lbf
(as before)
(as before)
(as before)
Gear core
(sat ) G = 44(339) + 2100 = 17 016 psi
17 016(0.893)
= 12 156 psi
(all ) G =
1(1)(1.25)
12 156(1.25)(0.216)
Wt =
= 689.3 lbf
6(1)(1.374)(0.5222)(1.106)
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399
Chapter 15
Pinion case
(sac ) P = 341(373) + 23 620 = 150 813 psi
150 813(1)
= 134 895 psi
1(1)(1.118)
1.25(3.333)(0.086)
134 895 2
t
= 689.0 lbf
W =
2290
1(1.374)(1.106)(0.593 75)(2)
(c, all ) P =
Gear case
(sac ) G = 341(345) + 23 620 = 141 265 psi
141 265(1.0685)(1)
= 135 010 psi
1(1)(1.118)
1.25(3.333)(0.086)
135 010 2
t
W =
= 690.1 lbf
2290
1(1.1374)(1.106)(0.593 75)(2)
(c, all ) G =
The equations developed within Prob. 15-7 are effective. In bevel gears, the gear tooth
is weaker than the pinion so (C H ) G = 1. (See p. 784.) Thus the approximations in
Prob. 15-7 with C H = 1 are really still exact.
15-10
The catalog rating is 5.2 hp at 1200 rev/min for a straight bevel gearset. Also given:
N P = 20 teeth, NG = 40 teeth, n = 20 , F = 0.71 in, J P = 0.241, JG = 0.201,
Pd = 10 teeth/in, through-hardened to 300 Brinell-General Industrial Service, and
Q v = 5 uncrowned.
Mesh
d P = 20/10 = 2.000 in,
vt =
(2)(1200)
d P n P
=
= 628.3 ft/min
12
12
K o = 1,
Eq. (15-6):
Eq. (15-5):
Eq. (15-10):
dG = 40/10 = 4.000 in
S F = 1,
SH = 1
54.77 + 628.3
= 1.412
Kv =
54.77
K s = 0.4867 + 0.2132/10 = 0.508
K mb = 1.25
Eq. (15-11):
Eq. (15-15):
Eq. (15-14):
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Bending
Pinion:
Eq. (15-23):
C R = K R = 1.25 = 1.118
Eq. (15-4):
(all ) P =
Eq. (15-3):
Wt =
=
H1 =
15 300(0.862)
= 10 551 psi
1(1)(1.25)
(all ) P F K x J P
Pd K o K v K s K m
10 551(0.71)(1)(0.241)
= 201 lbf
10(1)(1.412)(0.508)(1.252)
201(628.3)
= 3.8 hp
33 000
Gear:
(sat ) G = 15 300 psi
15 300(0.881)
= 10 783 psi
1(1)(1.25)
Eq. (15-4):
(all ) G =
Eq. (15-3):
Wt =
10 783(0.71)(1)(0.201)
= 171.4 lbf
10(1)(1.412)(0.508)(1.252)
H2 =
171.4(628.3)
= 3.3 hp
33 000
Wear
Pinion:
(C H ) G = 1,
I = 0.078, C p = 2290 psi, C xc = 2
(c, all ) P =
Eq. (15-1):
= 144.0 lbf
H3 =
144(628.3)
= 2.7 hp
33 000
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Chapter 15
401
Gear:
(sac ) G = 125 920 psi
125 920(1.043)(1)
= 117 473 psi
1(1)(1.118)
0.71(2.000)(0.078)
117 473 2
t
W =
= 156.6 lbf
2290
1(1.412)(1.252)(0.526 25)(2)
(c, all ) =
H4 =
Rating:
156.6(628.3)
= 3.0 hp
33 000
H = min(3.8, 3.3, 2.7, 3.0) = 2.7 hp
Pinion wear controls the power rating. While the basis of the catalog rating is unknown,
it is overly optimistic (by a factor of 1.9).
15-11
From Ex. 15-1, the core hardness of both the pinion and gear is 180 Brinell. So ( H B ) 11
and ( H B ) 21 are 180 Brinell and the bending stress numbers are:
(sat ) P = 44(180) + 2100 = 10 020 psi
(sat ) G = 10 020 psi
The contact strength of the gear case, based upon the equation derived in Prob. 15-7, is
2
SH
Cp
(sat ) P (K L ) P K x J P K T Cs C xc
(sac ) G =
(C L ) G C H S F
N P I Ks
Substituting (sat ) P from above and the values of the remaining terms from Ex. 15-1,
1.52 10 020(1)(1)(0.216)(1)(0.575)(2)
2290
= 114 331 psi
1.32(1) 1.5
25(0.065)(0.529)
( H B ) 22 =
The pinion contact strength is found using the relation from Prob. 15-7:
(sac ) P = (sac ) G m 0G.0602 C H = 114 331(1) 0.0602 (1) = 114 331 psi
114 331 23 600
= 266 Brinell
341
Core Case
Pinion
180
266
Gear
180
266
Realization of hardnesses
The response of students to this part of the question would be a function of the extent
to which heat-treatment procedures were covered in their materials and manufacturing
( H B ) 12 =
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Page 402
prerequisites, and how quantitative it was. The most important thing is to have the student think about it.
The instructor can comment in class when students curiosity is heightened. Options
that will surface may include:
Select a through-hardening steel which will meet or exceed core hardness in the hotrolled condition, then heat-treating to gain the additional 86 points of Brinell hardness
by bath-quenching, then tempering, then generating the teeth in the blank.
Flame or induction hardening are possibilities.
The hardness goal for the case is sufficiently modest that carburizing and case hardening may be too costly. In this case the material selection will be different.
The initial step in a nitriding process brings the core hardness to 3338 Rockwell
C-scale (about 300350 Brinell) which is too much.
Emphasize that development procedures are necessary in order to tune the Black Art
to the occasion. Manufacturing personnel know what to do and the direction of adjustments, but how much is obtained by asking the gear (or gear blank). Refer your students
to D. W. Dudley, Gear Handbook, library reference section, for descriptions of heat-treating processes.
15-12
15-13
A design program would ask the user to make the a priori decisions, as indicated in
Sec. 15-5, p. 794, MED7. The decision set can be organized as follows:
A priori decisions
Design factor: n d (S F = n d , S H = n d )
Tooth system: Involute, Straight Teeth, Crowning, n
Straddling: K mb
Tooth count: N P ( NG = m G N P )
Design decisions
n 11
44( HB ) 11 + 2100
48( HB ) 11 + 5980
SF
all
(sat1 ) P (K L ) P
=
=
s11 K T K R
n 21
44( HB ) 21 + 2100
48( HB ) 21 + 5980
(sat1 ) G (K L ) G
=
s21 K T K R
(sat1 ) G =
( HB ) 21
s21 SF K T K R
(K L ) G
( HB ) 11
(sat1 ) P =
Note: SF = n d , S H =
Factor of
safety
New tabulated
strength
Chosen
hardness
Associated
hardness
(sat ) G =
(sat ) G 2100
44
bhn =
(s
)
5980
at
G
48
s11 SF K T K R
(K L ) P
(sat ) P 2100
44
bhn =
(s
)
5980
at
P
48
(sat ) P =
W t P Ko Kv Km Ks
=
= s21
F K x JG
W t P Ko Kv Km Ks
=
= s11
F K x JP
1/2
n 12
= s12
2
341( HB ) 12 + 23 620
363.6( HB ) 12 + 29 560
(sac1 ) P (C L ) P (C H ) P
=
s12 K T C R
(sac1 ) P =
( HB ) 12
(s ) 23 620
ac P
341
bhn =
(s
)
29 560
ac
P
363.6
s12 S H K T C R
(C L ) P (C H ) P
W t K o K v Cs C xc
Fd P I
(sac ) P =
c = C p
Pinion Wear
s22 S H K T C R
(C L ) G (C H ) G
n 22
2
341( HB ) 22 + 23 620
363.6( HB ) 22 + 29 560
(sac1 ) G (C L ) G (C H ) G
=
s22 K T C R
(sac1 ) G =
( HB ) 22
(s ) 23 620
ac G
341
bhn =
(s
)
29 560
ac
G
363.6
(sac ) G =
s22 = s12
Gear Wear
3:25 PM
Tabulated
strength
Load-induced
stress (Allowable
stress)
Gear Bending
8/28/03
Pinion Bending
First gather all of the equations one needs, then arrange them before coding. Find the required hardnesses, express the consequences of the
chosen hardnesses, and allow for revisions as appropriate.
shi20396_ch15.qxd
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403
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15-14
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Page 404
(a)
px = /8 = 0.3927 in,
Eq. (15-39):
a = px / = 0.3927/ = 0.125 in
Eq. (15-40):
h = 0.3683 px = 0.1446 in
Eq. (15-41):
h t = 0.6866 px = 0.2696 in
Eq. (15-42):
Eq. (15-43):
dr = 3 2(0.1446) = 2.711 in
Eq. (15-44):
Dt = 7 + 2(0.125) = 7.25 in
Eq. (15-45):
Dr = 7 2(0.1446) = 6.711 in
c = 0.1446 0.125 = 0.0196 in
2
7.25 2
7
0.125 = 2.646 in
( FW ) max = 2
2
2
Eq. (15-46):
Eq. (15-47):
Eq. (13-28):
Eq. (15-62):
Pn =
8
Pt
=
= 8.028
cos
cos 4.764
pn =
= 0.3913 in
Pn
(1.5)(1725)
= 679.8 ft/min
12 cos 4.764
f = 0.103 exp 0.110(679.8) 0.450 + 0.012 = 0.0250
Vs =
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Page 405
Chapter 15
Eq. (15-36):
Eq. (15-37):
Eq. (15-38):
Since WGt < (W t ) all , the mesh will survive at least 25 000 h.
Eq. (15-61): W f =
0.025(966)
= 29.5 lbf
0.025 sin 4.764 cos 20 cos 4.764
Eq. (15-63): H f =
29.5(679.8)
= 0.608 hp
33 000
HW =
106.4(677.4)
= 2.18 hp
33 000
HG =
966(56.45)
= 1.65 hp
33 000
966
= 39 500 psi
0.3913(0.5)(0.125)
1
39 500 = 23 940 psi acceptable
1.65
(d) Eq. (15-52): Amin = 43.2(8.5) 1.7 = 1642 in2 < 1700 in2
Eq. (15-49): Hloss = 33 000(1 0.7563)(2.18) = 17 530 ft lbf/min
Assuming a fan exists on the worm shaft,
Eq. (15-50):
Eq. (15-51):
h C R =
1725
+ 0.13 = 0.568 ft lbf/(min in2 F)
3939
ts = 70 +
17 530
= 88.2 F Ans.
0.568(1700)
405
406
38.2
36.2
1.47
3
30
854
0.759
0.236
492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
7290
16.71
38.2
36.2
1.87
3
30
607
0.759
0.236
492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
5103
16.71
HW
HG
Hf
NW
NG
KW
Cs
Cm
Cv
VG
WGt
t
WW
f
e
( Pt ) G
Pn
C-to-C
ts
L
G
dG
1.75
3.60
1.68
2000
1.75
3.60
2.40
2000
15-16
px
dW
FG
A
15-15
1000
0.759
0.236
492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
8565
16.71
492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
7247
16.71
38.2
36.2
1.97
3
30
125
1.75
3.60
1.69
2000
15-18
492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
5103
16.71
38.2
36.2
1.97
3
30
80
1.75
3.60
2.40
2000
15-19
563
2120
1038
0.0183
0.951
1.571
1.732
11.6
171
6.0
24.98
4158
19.099
38.0
36.1
1.85
3
30
50
1.75
4.10
2.25
2000
15-20
492
2524
1284
0.034A
0.913A
1.795
1.979
10.156
179.6
5.25
24.9
5301
16.7
1.75
3.60
2.4
2500
FAN
41.2
37.7
3.59
3
30
115
15-21
492
2524
1284
0.034A
0.913A
1.795
1.979
10.156
179.6
5.25
24.9
5301
16.71
1.75
3.60
2.4
2600
FAN
41.2
37.7
3.59
3
30
185
15-22
3:25 PM
38.2
36.2
1.97
3
30
1.75
3.60
1.43
2000
15-17
8/28/03
#1
#2
#3
#4
Parameters
Selected
15-15 to 15-22
Problem statement values of 25 hp, 1125 rev/min, m G = 10, K a = 1.25, n d = 1.1, n = 20, ta = 70F are not referenced in the table.
shi20396_ch15.qxd
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