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Gears
Toothedcylindricalorconicalwheelsusedforpower
transmissionwithorwithoutspeedreduction
Spurgears
Teethareparalleltotheaxisofrotation
Usedfortransmittingpowerbetween
parallelshafts
Helical gears
Helicalgears
Teethareinclinedtotheaxisofrotation
Relativelyquieterinoperation
Canbeusedfortransmittingpowerbetween
nonparallelshaftsalso
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Bevelgears
Teethareformedonaconicalsurface
Teethcanbestraightorspiral
Usedfortransmittingpowerbetween
perpendicularintersectingshafts
Hypoidgears
Similartobevelgearbutshaftscanbe
offset,perpendiculartoeachother
WormandWormwheel
Shaftsperpendicular,nonintersecting
Largespeedreductionpossible
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Pitchcircle
Theoreticalcircleuponwhichallcalculationsaremade.Itsdiameteriscalledpitch
circlediameter d.Pitchcirclesoftwomatinggearsaretangenttoeachother
Addendum,a
Radialdistancebetween
toplandandpitchcircle
Dedendum,b
Radialdistancebetween
bottomlandandpitch
circle
Circularpitch(p)
Distancemeasuredonthepitchcirclefromapointonthetoothtothe
correspondingpointonanadjacenttooth
p =tooththickness+widthofspace(measuredonPC)
p =d/N,Nisnumberofteeth
Pinion:thesmallerofthetwomatinggears
Gear:thelargeramongthetwomatinggears
Idler:usedforchangingdirection
Module
m = d/N
d/ (standardvaluesgivenindatabook)
(
d d l
d b k)
Clearancecircle:Thecirclewhichistangenttothe
addendumcircleofmatinggear,c = b-a
Wholeteethdepth,ht = a + b
Backlash
A
Amountbywhichthewidthofthetoothspace
t b hi h th idth f th t th
exceedsthethicknessoftheengagingtooth,both
measuredonPC
a andb havedefiniteproportionwithmina
standardgear
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VA rA A ;
OA
VA
rA
VB
VB rBB
rB
A rB cos OB N OB P
B rA cos OA M OA P
Piscalledthepitchpoint(isalso
instantaneouscenterofAandB)
B
OB
IfLOAintersectsLOCatthesamepoint,
thenvelocityratioremainsconstant
Involute profile
Thecircleon whichtheinvolute
isgeneratediscalledBasecircle
LOAisthecommontangenttothebase circleofthetwogears
LOAisalsothenormaltothetoothprofilesatthecontactpoint
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isthepressure angle
rB1 r1 cos
rB2 r2 cos
rB 2
Whentwogearsareinmesh,theirpitchcirclesrollon
eachotherwithoutslipping
Standardpressureangles
1 r2 d 2 mN 2 N 2
20o,25o, 14.5o
2 r1 d1 mN1 N1
14.5o
20o
25o
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Interference
Contactoftoothportionsthatarenotinvolute (conjugate)
iscalledinterference
Inagearmanufacturedbygenerationprocess,
undercuttinghappensandthiseliminatesinterference
Undercuttingweakensthetooth
Avoidinginterference:spurgears
Thesmallestnumberofteethonaspurpinionandgearwhichcan
existwithoutinterferenceis
Np
NG
2k
2
2
m
(1
2
m
)
sin
;
m
G
G
G
G
(1 2mG ) sin 2
Np
Thelargestgearforaspecifiedpiniontoavoidinterference
NG
N p2 sin 2 4k 2
Forrackandpinion
Np
2k
sin 2
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Helicalgears
Shapeofthetoothisaninvolute helicoid
Parallelshafts,pinionandgearhasleftand
p
g
righthandteeth
Perpendicularshafts,bothgearandpinionhas
sametype
Inspurgearsthecontactisoveralinewhichisacross
thefaceofthegear
Contactissimultaneousalongthefacewidth
Thelinecontactstartsfromaddendumcircletobase
circle
Inahelicalgear,theinitialcontactisatapointandthen
itextendsintoalineastheteethcomeintoengagement
Thelinecontactextendsdiagonallyacrossthetooth
facegoingfromtiptotheroot
Engagementisthereforemoregradualforapairof
Engagement is therefore more gradual for a pair of
toothwithsmoothloadtransfer
Contactratioisnotaconcern,rathersufficientface
widthshouldbeprovided
Generatesanaxialloadontheshaft
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PCD (d)ismeasuredin
thetransverseplane
Transversecircularpitch
pt
d
N
Transversemodule
mt
d
N
Normalcircularpitch
pn pt cos
Normalmodule
mn mt cos
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Helixangleismeasuredonthecylindricalpitchsurface
Normalpressureangle n
Transversepressureangle
W
Wa
tan n
cos
t tan 1
Wr
t
Wt
cos
tan n
tan t
Wr W sin
i n
Wt W cos n cos
Wa W cos n sin
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Commonlyusedstandardtoothsystemsforspurgear
Commonlyusedstandardtoothsystemsforhelicalgear
addendum, a mn
Base diameter :
d cos t for pinion
dedendum, b 1.25mn
PCD : d
N p mn
cos
, D
N G mn
cos
Avoidinginterference:helicalgears
Thesmallestnumberofteethonahelicalpinionandhelicalgear
whichcanexistwithoutinterferenceis
Np
NG
2k cos
2
2
m
(1
2
m
)
sin
;
m
G
G
G
t
G
(1 2mG ) sin 2 t
Np
Thelargestgearforaspecifiedpiniontoavoidinterference
NG
N p2 sin 2 t 4k 2 cos 2
Forrackandpinion
Np
2k cos
sin 2 t
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Toothfailuremodes
Bendingstressattherootofthetooth
Yielding
Fatiguefailure
Contactstressatpointofcontact
Pittingorsurfacefatiguefailure
Bendingstress
AnalysisbyWilfredLewis in1892
Treatthetoothasacantileverofspanl, deptht andwidthF
W
Wr
Wt
l
6Wt l
Ft 2
Wp
W
t2
x, 2t t
4l
F 3 xp FpY
p is circular pitch
Y
2x
; is called Lewis form factor
3p
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Yincreaseswithincreasingnumberofteethor
increasingpressureangle
Theworstconditionistaken;i.e.theloadappliedattipof
thetooth
Onlyonepairofteethisassumedtoengageatatime
Loadsharing(whencontactratiois>1)isnotconsidered
d h i ( h
i i
)i
id d
Stressconcentrationattherootisnotconsidered
Alloftheabovedependsontoothgeometry,numberof
teethetc.
Hencetheformfactorismodifiedfurthertoaccountfor
theseeffects
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AGMA DesignEquations
Tooth bending
Wt K O KV K S
1 KH KB
(SI units)
Fmt YJ
YJ (orJ)geometryfactor
Capturestheeffectoftoothformonbendingstresses
Willbedifferentforpinionandgear
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Forhelicalgear,determine
YJ (J)fromthefirstfigure
andmultiplythatwiththe
modifyingfactorfromthe
secondfigure
KO overloadfactor
AccountsforallexternalloadsinexcessofWt
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KV dynamicfactor
Thisaccountsforinaccuraciesinmanufacturingand
meshingofagearteethdueto
Vibrationduringmachining
Dynamic unbalance of rotating members
Dynamicunbalanceofrotatingmembers
Wearandpermanentdeformationoftooth
Shaftmisalignmentduetolinearandangulardeflection
Toothfriction
Allofthesecausestransmissionerror(departurefrom
constantangularvelocityratio)
Theseleadtoanincreaseinloadonthetooth
These lead to an increase in load on the tooth
KV dependsonpitchlinevelocity
A 200V
KV
; V in m/sec
A
A 50 56(1 B )
B 0.25(12
( QV ) 2 / 3
These
Thesecurvesarefromtestdataonlargenumberofgears
curves are from test data on large number of gears
QV isAGMA qualitynumber
3to7:Commercialquality
8to12:Precisionquality
KV increasesasVincreasesorQV decreases
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KS Sizefactor
Accountsfornonuniformityinmaterialpropertiesdueto
size seepage29ofdatabook
KH Loaddistributionfactor
Accountsfornonuniformityofloadacrossthelineofcontact
(seepage29ofdatabook)
Facewidth(mm)
upto50 150
225
>400
KB Rim thicknessfactor
Thebendingstresscalculationassumesthatthe
toothislikeacantileverwithrootofitfixed.
Largegearshavearimandiftherimisnot
sufficientlythick,thenitcaninducerootflexibility
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Allowablebendingstress
all
St YN
S F Y YZ
2
St Bending
B di strengthh (N/mm
(N/
),
) S F AGMA safety
f ffactor
Gearteetharesubjectedtorepeatedloading
Theteethinanidlergearwillundergotwowaybending,
henceuse0.75St inaboveequation
Gearmaterials
Canbemadeofsteel,bronze,graycastiron,evenplastics
Strengthandpittingresistanceareimportantfactors
g
Throughhardenedsteels
180<HB <400recommended
e.g AISI 3140,4140,4340,6150,8150etc.aregood
%elongationof12%ofmoreisdesired
Casehardenedsteels
HB >400
Inductionhardening,Flamehardening,Ntriding etc.
produceahardsurfacelayerandtoughcore
Thehardeningdepthhastobeensured
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RepeatedlyAppliedBendingstrength:St
107 cyclesand0.99reliability
Grade1isbasicstandard
Grade2requireshighdegree
of microstructure control
ofmicrostructurecontrol
YN isusedwhenlifeisnot107 cycles
Inagearset,thenumberofloadcyclesforpinionandgear
aredifferent.Sothisfactorwillbedifferentforpinionand
gear
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Surfacedurability
Inagearteethpair,perfectrollinghappensonlywhen
thecontactisatthepitchcircle(P)
Atothercontactpoints,thereisrollingwithsliding
Relativevelocityalongthe
directionperpendicularto
LOAisnotzero
Thesliding velocityreverses
directionasthecontact
direction as the contact
crossesthepitchpoint
Themagnitudeofrelative
velocityisalso notconstant
Surfacedurability
Theslidingcauses
Abrasivewearduetotrappedforeignparticles
Scoring
Highervelocityintheabsenceofproperlubrication(elasto
Higher velocity in the absence of proper lubrication (elasto
hydrodynamic)resultsinhighfriction
Thehighcontactpressureandhighfrictionleadtolocalized
heating
Thisheatingresultsinlocalweldingofsurfaceparticlesand
theirsubsequenttearing
Lubricationandcoolingcanminimizethis
Pittingandspalling
Surfaceandsubsurfacefatiguefailureundercontactstress
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Hertzcontactstress
Considertwocylindersarecontactunderloadasshown
Thecontactisoveranarrowrectangularpatchofwidth
2b andlengthL
1/ 2
4 P (1 12 ) / E1 (1 22 ) / E2
1/ 1 1/ 2
L
p0
2P
P 1
1
ZE
bL
L 1 2
ZE
1
1 12 1 22
E2
E1
Contactstressesinmeshinggearteeth
Pittingdamageismostlyobservedaroundthepitchline
Slidingvelocityisverysmallbecauseofwhichhydrodynamic
actionisabsent(nooilfilm)
p
p
Thereforethecontactstressesareevaluatedatthepitchpoint
1 rP sin ; 2 rG sin ; P
rP
c ZE
ZI
Wt
cos
Wt
Fd P Z I
sin cos mG
2
mG 1
ZI isthegeometryfactorforsurfacestrength
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ZI forhelicalgear
n1
rP sin t
cos b
n 2
rG sin t
cos b
ZI forhelicalgear
Inahelicalgear,thecontactloadactsoveralarger
distancethanthefacewidthduetohelixangle
Thereisloadsharing
sin
i t cos t mG
ZI
2 mN
mG 1
pn cos n
is load sharing ratio
0.95Z
pn is normal circular pitch
mN
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AGMA DesignEquations
Tooth pitting
c Z E Wt K O KV K S
KH ZR
(SI units)
dP F ZI
1
1
1 G2
E
EG
P
2
P
Allowablecontactstress
c ,all
S c Z N ZW
S H Y YZ
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Repeatedlyappliedcontactstrength,Sc
107 cyclesand0.99reliability
Hardnessratiofactor,ZW
Goodgeardesignpracticesuggests
Makingpinionteethmoreharderthangearteeth
Gearteetharesmoothenedandworkhardenedduring
service and this improves pitting resistance
serviceandthisimprovespittingresistance
Bothpinionandgeararethroughhardened
Pinionissurfacehardened
andgearisthroughhardened
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SafetyfactorsSF andSH
all
St YN
1 KH KB
; Wt K O KV K S
S F Y YZ
Fmt YJ
SF
St YN
; stress
t
( ) scales
l linearly
li
l with
ith W t
Y YZ
c , all
SH
Sc Z N ZW
K Z
; c Z E Wt K O KV K S H R
S H Y YZ
dP F ZI
Sc Z N ZW
; stress ( c ) scales with W t
c Y YZ
Safetyfactorforpinionandgear
Thesafetyfactorsforpinionandgearneednotbethesame
(YJ )P (YJ )G ,(YN )P (YN )G ,(ZN)P (ZN)G
Whataretheimplications?
p
Oneofthemwillfailfirst(theonewithlowersafetyfactor)
Replacingoneelementinasetisnotgoodastheother
element(alreadyweaker)canfailresultinginshutdown
Matchingthefactorofsafetyofpinionandgearistherefore
desirable
S F P S F G S t G S t P
YN P YJ P S S S S Z N P
H G c G c P
Z N G
YN G YJ G H P
1
ZW
Canbeachievedby
Havingdifferenthardnessforpinionandgear
Usingdifferentmaterialsforpinionandgear
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