Proceedings of the ASME 2009 International Mechanical Proceedings

Engineering of IMECE 2009

Congress & Exposition
2009 ASME International Mechanical Engineering Congress and Exposition IMECE2009
November 13 19, 2009 Lake Buena
November Vista,Buena
13-19, Lake Florida, USA Florida, USA
Vista,

IMECE 200910172
IMECE2009-10172
DETERMINING THE LEWIS FACTOR FOR PLASTIC SPUR GEARS WITH ASYMMETRIC
TEETH.

J.L. Moya, A.S. Machado A.M. Becerra

Department of Applied Mechanics. Central University of Las Villas.
Carretera a Camajuan, Km. 3 1/2, CP 54830. Santa. Clara. Villa Clara. Cuba.
* jorgemoyar@gmail.com

J.A. Velzquez
Mechanical and Electrical Engineering Faculty. Universidad Veracruzana. Xalapa. Mxico.
**javp521222@hotmail.com

R. Goytisolo
Mechanical Engineering Faculty. University of Cienfuegos.
Cuatro Caminos, CP 59430. Cienfuegos, Cuba.
ragoyti@ucf.edu.cu

Abstract

The basic weakness of plastic spur gear teeth is tooth fracture brought on by the accumulation of stress at the
root of the tooth and by the geometry of the tooth. Tooth width and height play a major role in failure, as does
the Lewis factor, which has a direct effect on the expression to calculate tooth strength. This study describes a
theoretical analysis of a procedure to determine the Lewis factor for asymmetric teeth.
Keywords: Lewis factor, asymmetric profiles, plastic spur gears.

Nomenclature
critmen Critical radius of curvature at the root of
the asymmetric tooth.
afmen Load angle in asymmetric gear tooth.
rmay
Radius of curvature at the root of the

amen Outside angle for asymmetric spur gear drive for
tooth for driving involute profile.
coast side profile.

rmen Radius of curvature at the root of the
tooth for coast involute profile.
cmay
Pressure angle for asymmetric spur gear drive for
driving side profile. y
Inverse shift profile coefficient.

cmen b
Pressure angle for asymmetric spur gear drive for Face width
coast side profile.
C Coefficient of asymmetry.

Fan Load angle in spur and helical gear teeth c Radial clearance.

n d a Outside circle diameter.
Pressure angle for spur and helical gear teeth.
d
Angle at top of the tooth.
bmen Base circle diameter for asymmetric spur
gear drive for coast side profile.
dp
Pitch diameter.
e Eccentricity.

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 E , G, H fracture, when stress originating at the root of the tooth and
Geometric factors. tooth geometry play decisive roles. [1]. The Lewis Factor

ha* Tooth height coefficient. is decisive for calculating the bending strength of gears,
and most traditional texts in the literature on gears employ
hcrit Distance from critical section to intersection of graphs and tables to calculate it [2-11]. However, since
asymmetric plastic teeth are still somewhat recent
the tooth centerline and the line of action for load at tip of inventions, their Lewis factor values are nowhere to be
tooth, in the asymmetric tooth. found in the above-cited papers despite them being a sine
h qua non to calculate bending strength.
Fa Distance from critical section to intersection of
This paper analyses the procedure to calculate the Lewis
the tooth centerline and the line of action for load at tip of factor for asymmetric teeth and describes the values of this
tooth and the curvature radius of the root trochoid for spur parameter in terms of the coefficient of asymmetry and
and helical gear teeth. teeth number [12-13].
m Module.
2. Determining the Lewis factor in symmetric gears
Mf
Bending moment produced by the horizontal There is a range of procedures for calculating the Lewis
component of transmitted force. Factor for symmetric gears. According to Black [14], the
starting point to calculate this factor is the constant

Pn Normal resultant force in the tooth. strength parabola in the tooth, as shown in Fig. 1, which
establishes that the Lewis factor is determined by the

Pt Tangential force.
t2
expression: y= ; t and h are obtained from the

Pv Vertical force. 6h p
figure and p is diametral pitch.

S a Top land thickness.
Faires [15] proposes the procedure illustrated in Fig. 2. It

S crit Critical tooth thickness in the asymmetric tooth. t2
can be deduced from the figure that: h = and
S 4 h
critmay
Critical tooth thickness for driving side
3 Pt 2 h
profile. = , where the expression is termed the
S 2 b h 3
critmen Critical tooth thickness for coast side Lewis factor ( y ). Other standards, such as DIN 3990 [16],
profile. calculate the most critical section by extending a line at an
Sp angle of 30 from the tooth axis of symmetry, tangent to
Tooth thickness on pitch diameter. the tooth-root profile in points a-a.

S Fn Tooth thickness at critical section for spur and
3. Determining the Lewis factor for asymmetric gears
helical gear teeth. The authors calculations of the Lewis factor were based
Variable angle to determine Lewis factor. on Figs. 3-4. The stress produced at the root of the tooth
due to flexion can be calculated using the following

W x Section module. expression:
X Shift profile coefficient.
Mf ( )
Pn cos afmen hcrit Pv e
= = (1)
Wx Wx
YF Lewis factor for asymmetric gear teeth.
where:

YFa Lewis factor for spur and helical gear teeth. (
M f = Pn cos afmen hcrit Pn sen afmen e ; )
YFsg b S crit
2
Lewis factor for asymmetric teeth from the regression Wx = ;
equations obtained by the Statgraphics software. 6
Z Pt
Number of teeth. Pn =
cos cmen
1. Introduction then:
Pt 6 (hcrit cos afmen e sen afmen )
The most common failure of well lubricated metallic =
gears is caused by pitting at the flank of the tooth. b 2
S crit cos cmen
Volumetric fatigue is of secondary importance. However,
the most frequent failure in plastic spur gears teeth is tooth Multiplying and dividing by the module:

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 For 40 Z 70 (with 99,13% reliability level and
hcrit cos afmen e sen afmen absolute error of 0,00058)
6 YFsg = -0,0543935 + 0,011263 Z + 0,0685655 C -
Pt m m
= (2)
bm 0,0000845454 Z + 0,0404041 C
2 2
S crit
2
2 cos cmen For 75 Z 100 (with 99,13% reliability level and

m absolute error of 0,00058)
From the expression (2), YF is designated as: YFsg = -0,0599137 + 0,00834091 Z + 0,028519 C -
S crit
2
0,0000413636 Z + 0,0581197 C
2 2

2 cos cmen
YF = m Table 2 provides a comparison of Lewis Factor values
hcrit cos afmen e sen afmen
6 developed by author and the regression equations from the
m m
then the expression (2) can be rewritten as follows:
Pt
= (4)
b m YF
YF is the Lewis Factor for asymmetric gear teeth.
Observe the difference between the expression (3) and
the expression (5) for symmetric gear teeth [16]:
S Fn
2
2 cos Fan
=
m
YFa
hFa cos n
6
m References
After considering the DIN 3990 Standard [16], the
algorithm proposed by Gonzlez [17], and the
characteristics of asymmetric teeth, the authors propose the
algorithm in Fig. 5 to calculate YF . The concept of the
asymmetry coefficient was incorporated to cater for
asymmetry. It is the relation between the driving side
cmay
profile and the coast side profile angles: C = . Fig.
cmen
6 illustrates how the Lewis Factor varies for different
numbers of teeth and asymmetry coefficients, and its
differing values are described in Table 1.
Using Statgraphics software, the authors found the
regression equations to obtain the values of the Lewis
Factor for asymmetric teeth depending on the number of
teeth and the asymmetry coefficients. Three expressions
were established considering the range of number of teeth
so that values were precisely calculated:
For 10 Z 35 (with 98,9% reliability level and
absolute error of 0,0053)
YFsg = -0,0315949 + 0,0269414 Z + 0,405287 C -
0,000462649 Z - 0,103118 C
2 2
(3)
for asymmetric teeth calculated using the algorithm
Statgraphics software.
4 Conclusions
New expressions for calculating the Lewis Factor are
obtained. The principal failures and the calculation
methods are analyzed and compared with the Finite
Elements Method. The limitations of present calculation
expressions and new coefficients and formulas for the
particular case of asymmetric gears are offered. All
information was obtained by employing the most advanced
methods of graphic design, geometric modeling and
simulation. The positive influence of asymmetric profiles
combined with tooth profile modification on the bending
(5) strength of teeth is demonstrated.
[1] K. Cavdar, F. Karpat, F.C. Babalik, Computer aided
analysis of bending strength of involute spur gears
with asymmetric profile Journal of Mechanical Design
127 (3) (2005) 477-484.
[2] W. Lewis, Investigation of strength of gear teeth,
Proceedings of Engineers Club, Philadelphia, P.A.
(1892) 16-23.
[3] E. Buckingham, Manual of gear design. Editorial
Industrial Press Inc., New York, 1971.
[4] D.W. Dudley, Gear Handbook: Design, Manufacture
and Application of Gears, Editorial Continental, S.A.,
Mxico, 1980 (in Spanish).
[5] G. Henriot, Trait Thorique et Pratique des
Engrenajes, Villars, Paris, 1991 (in French).
[6] V. N. Kudriatzev, Design Machine Elements,
Mashinostroienie, Leningrad, 1980 (in Russian).
[7] F. L. Litvin, Gear Theory, Nauka, Moscow, 1968 (in
Russian).
[8] H. Merrit, Gear Engineering, Pitman Publishing,
England, 1990.
[9] D. Reshetov, Machine Elements, La Habana, Pueblo y
Educacin, 1985 (in Spanish).
[10] M. F. Spotts, T. E. Shoup, Mechanical Design,
McGraw-Hill, New York, 1999.
[11] K. Zirpke, Zahnrader, Veb Fachbuch Verlag, Leipzig
1980 (in German).
[12] A. L. Kapelevich, Geometry and Design of Involute
Spur Gears with Asymmetric Teeth, Mechanism and
Machine Theory 35 (2000) 117130.

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 [13] J. I. Pedrero, A. Rueda, A. Fuentes, Determination of
the ISO Tooth Form Factor for Involute Spur and
Helical Gears, Mechanism and Machine Theory 34
(1999) 89103.
[14] P. Black, Machine Design, McGraw-Hill, New York,
1948.
[15] V. M. Faires, Machine Design, Limusa, 1998 (in
Spanish).
[16] DIN 3990, Calculation of Load Capacity of
Cylindrical Gears: Calculation of Tooth Strength,
1987-12 (in German).
[17] G. Gonzlez, P. Frechilla, R. Garca, The Finite
Element Method as alternative to design gears,
Ingeniera Mecnica 1 (2001) (in Spanish).

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 Fig. 1. Determination of Lewis factor according to Black.

Fig. 2. Determination of the Lewis factor for symmetric gears.

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 Fig. 3. Asymmetric tooth profiles.

Fig. 4. Stress at the root of the asymmetric gear tooth.

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 Fig. 5. Algorithm to determine Lewis Factor values (YF)

Start
1

Data: m, Z, c, ha*, cmen, cmay, X, rmen, rmay

Driving side profile :

rmay
(
hr = ha * + c m ) E=
4
( )
m hr tan cmay 1 sen cmay
cos cmay
rmay
h
G= r +X
m m
Coast side profile :
2 E
rmen H =
E= m hr tan c men (1 sen c men ) Z 2 m 3
4 cos cmen
rmen
h
G= r +X
m m
2 E = /6
H =
Z 2 m 3

2G
1 = tan H
= /6 Z

2G
1 = tan H No
Z ( - 0.001 =

Yes
No
( - 0.001 =
=

Yes
S critmay G rmay
= = Z sen + 3
m 3 cos m

S critmen G
= Z sen + 3 rmen e S critmay S critmen
m 3 cos m =
Critical radius hcrit m 2m 2m

critmen rmen 2G 2
= +
m m (
cos Z cos 2 2G ) S critmay S critmen
2

d bmen 2m + 2m cos cmen
amen = cos 1 , afmen = amen
YF =
da hcrit e
cos afmen sen afmen
d bmen (
= d p cos cmen , d a = m Z + 2ha + 2 X 2 y ) 6
m m
0,5 + 2 X tan amen
= + inv cmen inv amen
Z
hcrit cos cmen G End
= 0,5Z cos + 0,5 men
m cos amen 3 m cos

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 Fig. 6. Variation of the Lewis Factor according to the number of teeth and the asymmetry coefficient

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 Table 1 Values of the Lewis Factor for asymmetric teeth

Values of Lewis factor according to the number of teeth Z and the coefficients of asymmetry C
C
Z=10 Z=12 Z=15 Z=20 Z=30 Z=40 Z=50 Z=60 Z=70 Z=80 Z=90 Z=100
1,00 0,201 0,245 0,289 0,320 0,358 0,389 0,408 0,421 0,429 0,429 0,442 0,446
1,05 0,228 0,267 0,308 0,351 0,392 0,396 0,415 0,435 0,437 0,438 0,450 0,454
1,10 0,232 0,272 0,314 0,354 0,399 0,403 0,422 0,442 0,444 0,445 0,458 0,462
1,15 0,242 0,277 0,320 0,358 0,406 0,410 0,430 0,450 0,452 0,453 0,466 0,470
1,20 0,237 0,282 0,326 0,371 0,413 0,417 0,438 0,458 0,460 0,461 0,474 0,478
1,25 0,247 0,288 0,332 0,378 0,421 0,424 0,446 0,466 0,468 0,469 0,482 0,487
1,30 0,252 0,294 0,339 0,385 0,429 0,432 0,454 0,475 0,477 0,478 0,490 0,496
1,35 0,257 0,300 0,345 0,392 0,437 0,440 0,463 0,483 0,486 0,487 0,498 0,505
1,40 0,263 0,306 0,352 0,400 0,445 0,448 0,472 0,492 0,495 0,496 0,510 0,515
1,45 0,268 0,312 0,359 0,408 0,454 0,457 0,481 0,502 0,504 0,505 0,520 0,525
1,50 0,274 0,319 0,366 0,416 0,463 0,466 0,491 0,512 0,514 0,515 0,530 0,535

Table 2 Comparison of Lewis Factor values for asymmetric teeth calculated using the algorithm developed by
author and the regression equations from the Statgraphics software

Z =30 Z =40 Z =50 Z =90

C =1,35

C =1,50

C =1,00

C =1,35

C =1,50

C =1,00

C =1,35

C =1,50

C =1,00

C =1,35

C =1,50
C =1,00

YF 0,358 0,437 0,463 0,389 0,446 0,471 0,408 0,463 0,491 0,442 0,498 0,530
YFsg 0,378 0,435 0,451 0,370 0,427 0,454 0,406 0,463 0,491 0,445 0,503 0,532

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