Gear Modification

change of the standard geometry of a gear

Face modification

Rack modification (, ha,hf, c0, tip relief, ...)

No modification of the rack
(gear shifting, tooth shortening, ...)

Axial modification
gear axial direction

barrel teeth

crowning

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end relief

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ME&M II- Mech. Trans.

Gear & Gear Set Shifting

x > 0 pozitive shifted gear

x = 0 unshifted gear

x < 0 negative shifted gear

mx
mx

h0
h0f

df
Why do we need ?

What do we get ?

df

df

Restrictions
Improvements
Advantages

Undercutting

Shortcomings
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ME&M II- Mech. Trans.

Gear & Gear Set Shifting

Shifted gear sets

Pozitive

x1 + x2 > 0

a0 < aw

Negative

x1 + x2 < 0

a0 > aw

Zero

x1 + x2 = 0

a0 = aw

How do we select
shifting coefficients ?

Geometry

T.CICONE - 2006

Blocking
contour

Working diameter

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ME&M II- Mech. Trans.

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ME&M II- Mech. Trans.

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ME&M II- Mech. Trans.

Normal Forces

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ME&M II- Mech. Trans.

Normal Forces
n2
Common Tangent of the
Conjugate Profiles
Ff

Fn

Fn
Ff
n1
Pitch Line - Line tangent to Base Circles
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ME&M II- Mech. Trans.

Nominal Forces

Ft

Ft =

2 M t 1, 2
d1, 2

Fr = Ft tan

Fn

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Fr

Fn =

8/

Ft
cos

ME&M II- Mech. Trans.

Normal Forces

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ME&M II- Mech. Trans.

Gear Failures
Tooth fatigue fracture
F

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ME&M II- Mech. Trans.

Bending Stress
Assumptions

Cantilever beam
Normal load concentrated on the tip
One pair in contact
Neglected compression and shear stresses
Critical cross-section: 30 tangent

Stress concentrator neglected

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ME&M II- Mech. Trans.

Bending Stress
Fta

Assumptions

Fn

Fra

Fa
F =

hFa

30

30
sF

db

Fta hFa
b sF2
6

b
c
s
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Corrections

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ME&M II- Mech. Trans.

Bending Stress
O2

d2

Fta
F
= t = Fn
cos Fa cos

db2
Fta
Fn

Fra Fa

Ft

Fn

Fr
db1

d1

O1

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ME&M II- Mech. Trans.

Bending Stress
d2

db2
Fta
Fn

Fra Fa

Fta
F
= t = Fn
cos Fa cos

Ft

Fr

Fn

db1

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d1

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ME&M II- Mech. Trans.

Bending Stress Correction factors

`

F =

f =

Ft
YFa
bm

Line of
contact

YFa - form factor

Ft (K A K v K F K F )
mb

T1

YFaYSaY

C
D E

Fn /2

Y - contact ratio factor

YSa stress correction factor

O1

(=1)F E

Fn

T2

(1<<2)F E

K F transverse load distribution factor

Line of
centers

K F face load distribution factor

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O2
ME&M II- Mech. Trans.

Bending Stress Correction factors

f =

Ft (K A K v K F K F )
mb

YFaYsaY

SF =

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F lim = o lim1, 2Y YR Y X Y N

F lim
> S FP = 1.25
F

YR

Roughness factor

YX

Size factor

YN

Life factor

Contact ratio factor

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ME&M II- Mech. Trans.

Gear Failures
Tooth surface fatigue (pitting)

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ME&M II- Mech. Trans.

Contact Stress

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ME&M II- Mech. Trans.

Contact Stress

HERTZ model
Fn E
2 b

H max =

1 = 1 + 1

2
2
2 = 1 1 + 1 2
E
E1
E2

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ME&M II- Mech. Trans.

Contact Stress
x1 =

d b1
d
tan x1 = 1 cos n tan x1
2
2

x2 =

d2
i d
cos n tan x 2 = 122 1 cos n tan x1
2

x =

x1 x 2
i
d cos n
= 12 1
tan x1 tan x 2
x1 + x 2 1 + i12 2 tan w
E
D
C

H max =

Fn E
2 b

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Fn = Ft cos n
A

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ME&M II- Mech. Trans.

Contact Stress
x1 =

d b1
d
tan x1 = 1 cos tan x1
2
2

x2 =

x =

d2
i d
cos tan x 2 = 122 1 cos tan x 2
2

x1 x 2
i
d
= 12 1 cos tan x1 tan x 2
x1 + x 2 1 + i12 2 tan w
E
D
C

H max =
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C point

Fn E
2 b

x1 = x 2 = w
Fn = Ft cos n

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ME&M II- Mech. Trans.

Contact Stress
Fn E
2 b

H max =

H C = ZH ZE

elasticity factor
ZE =

Ft 1 + i12

b d1 i12

single pair tooth contact factor

1
2

E1

2
E 2

ZH =

1 1 1 2
+

Ft (K A KV K H K H ) 1 + i12

b d1
i12

H C = Z H Z E Z

H lim = H lim b Z L Z V Z R Z W Z X Z N
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II

50

ME&M II- Mech. Trans.

Standard values for modules

II

63

180

71

225

90

280

112
125

1,375

1,75

2,25

10

2,75

12

3,5

16

5,5
7
9

2,5

355
400

140

1,125

315

11

450

14

4
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II
4,5

1,5

250

100

1,25

200

80

II

160
56

2
tan w

H lim
= S H P > 1.15
HC

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Standard values for centers distance

1
cos

18
ME&M II- Mech. Trans.

Spur Gear Dimensioning

Mt, i, materials

GIVEN DATA

CHOSEN DATA

b/d1

BENDING
f =

Ft (K A K v K F K F )
mb

YFaYsaY

Module m

F lim = o lim1,2Y YR Y X YN

SF =

F lim
> S FP = 1.25
F

H C = Z H Z E Z

CONTACT

Ft (K A KV K H K H ) 1 + i12

b d1
i12

Distance between axes a

H lim = H lim b Z L Z V Z R Z W Z X Z N

H lim
= S P > 1.15
HC
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ME&M II- Mech. Trans.

Contact Stress
log ()

Life factor for contact stress

log (H lim st)

ZN

log (H lim x)
log (H lim b)

log (N)
log (Nst)

log (Nx) log (Nb)

ZW

Hardness ratio factor

ZX

Size factor

ZR

Roughness factor

ZV

Velocity factor

ZL

Lubricant factor

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ME&M II- Mech. Trans.