6/3/2017

Chapter Outline

Shigleys Mechanical Engineering Design

Types of Gears

Spur Helical

Bevel Worm
Figs. 131 to 134 Shigleys Mechanical Engineering Design

1
 6/3/2017

Nomenclature of Spur-Gear Teeth

Fig. 135 Shigleys Mechanical Engineering Design

Tooth Size

Shigleys Mechanical Engineering Design

2
 6/3/2017

Tooth Sizes in General Use

Table 132

Shigleys Mechanical Engineering Design

Standardized Tooth Systems (Spur Gears)

Table 131

Shigleys Mechanical Engineering Design

3
 6/3/2017

Standardized Tooth Systems

Common pressure angle f : 20 and 25
Old pressure angle: 14
Common face width:
3p F 5p
p
p
P
3p 5p
F
P P

Shigleys Mechanical Engineering Design

Conjugate Action
When surfaces roll/slide
against each other and
produce constant angular
velocity ratio, they are said
to have conjugate action.
Can be accomplished if
instant center of velocity
between the two bodies
remains stationary between
the grounded instant centers.

Fig. 136
Shigleys Mechanical Engineering Design

4
 6/3/2017

Conjugate Action
Forces are transmitted on
line of action which is
normal to the contacting
surfaces.
Angular velocity ratio is
inversely proportional to the
radii to point P, the pitch
point.

Circles drawn through P

from each fixed pivot are
pitch circles, each with a
pitch radius.
Fig. 136
Shigleys Mechanical Engineering Design

Involute Profile
The most common conjugate profile is the involute profile.
Can be generated by unwrapping a string from a cylinder, keeping
the string taut and tangent to the cylinder.
Circle is called base circle.

Fig. 138 Shigleys Mechanical Engineering Design

5
 6/3/2017

Involute Profile Producing Conjugate Action

Fig. 137 Shigleys Mechanical Engineering Design

Circles of a Gear Layout

Fig. 139 Shigleys Mechanical Engineering Design

6
 6/3/2017

Sequence of Gear Layout

Pitch circles in contact
Pressure line at desired
pressure angle
Base circles tangent to
pressure line
Involute profile from
base circle
Cap teeth at addendum
circle at 1/P from pitch
circle
Root of teeth at
dedendum
circle at 1.25/P from Fig. 139
pitch circle
Tooth spacing from
circular pitch, p = p / P

Shigleys Mechanical Engineering Design

Tooth Action
First point of
contact at a
where flank of
pinion touches
tip of gear
Last point of
contact at b
where tip of
pinion touches
flank of gear
Line ab is line of
action
Angle of action
is sum of angle
of approach and
angle of recess
Fig. 1312 Shigleys Mechanical Engineering Design

7
 6/3/2017

Rack
A rack is a spur gear with an pitch diameter of infinity.
The sides of the teeth are straight lines making an angle to the line
of centers equal to the pressure angle.
The base pitch and circular pitch, shown in Fig. 1313, are related
by

Fig. 1313
Shigleys Mechanical Engineering Design

Internal Gear

Fig. 1314

Shigleys Mechanical Engineering Design

8
 6/3/2017

Contact Ratio
Arc of action qt is the sum of the arc of approach qa and the arc of
recess qr., that is qt = qa + qr
The contact ratio mc is the ratio of the arc of action and the circular
pitch.

The contact ratio is the average number of pairs of teeth in contact.

Shigleys Mechanical Engineering Design

Contact Ratio
Contact ratio can also be found from the length of the line of action

The contact ratio should be at least 1.2

Fig. 1315 Shigleys Mechanical Engineering Design

9
 6/3/2017

Interference(Giriim)
Contact of portions of
tooth profiles that are not
conjugate is called
interference.
Occurs when contact
occurs below the base
circle
If teeth were produced by
generating process (rather
than stamping), then the
generating process
removes the interfering
portion; known as
undercutting.

Fig. 1316 Shigleys Mechanical Engineering Design

Interference
For 20 pressure angle, the most useful values from Eqs. (1311)
and (1312) are calculated and shown in the table below.

Minimum NP Max NG Integer Max NG Max Gear Ratio

mG= NG/NP
13 16.45 16 1.23
14 26.12 26 1.86
15 45.49 45 3
16 101.07 101 6.31
17 1309.86 1309 77

Shigleys Mechanical Engineering Design

10
 6/3/2017

Interference
Increasing the pressure angle to 25 allows smaller numbers of
teeth

Minimum NP Max NG Integer Max NG Max Gear Ratio

mG= NG/NP
9 13.33 13 1.44
10 32.39 32 3.2
11 249.23 249 22.64

Shigleys Mechanical Engineering Design

Interference
Interference can be eliminated by using more teeth on the pinion.
However, if tooth size (that is diametral pitch P) is to be
maintained, then an increase in teeth means an increase in
diameter, since P = N/d.
Interference can also be eliminated by using a larger pressure
angle. This results in a smaller base circle, so more of the tooth
profile is involute.
This is the primary reason for larger pressure angle.
Note that the disadvantage of a larger pressure angle is an increase
in radial force for the same amount of transmitted force.

Shigleys Mechanical Engineering Design

11
 6/3/2017

Forming of Gear Teeth

Common ways of forming gear teeth
Sand casting
Shell molding
Investment casting
Permanent-mold casting
Die casting
Centrifugal casting
Powder-metallurgy
Extrusion
Injection molding (for thermoplastics)
Cold forming

Shigleys Mechanical Engineering Design

Cutting of Gear Teeth

Common ways of cutting gear teeth
Milling
Shaping
Hobbing

Shigleys Mechanical Engineering Design

12
 6/3/2017

Shaping with Pinion Cutter

Fig. 1317
Shigleys Mechanical Engineering Design

Shaping with a Rack

Fig. 1318
Shigleys Mechanical Engineering Design

13
 6/3/2017

Hobbing a Worm Gear

Fig. 1319 Shigleys Mechanical Engineering Design

Calculation Torque and Revolution

D1 S pitch
diameter

D2 is pitch
diameter

RESULT:Torque of gear in a gear

pair works together with changes in
proportion to the number of teeth

Fig. 1319 Shigleys Mechanical Engineering Design

14
 6/3/2017

Calculation Torque and Revolution

D1 is pitch
diameter

RESULT:Torque of gear
in a gear pair works
together with changes in
proportion to the
number of teeth
D2 s pitch
diameter

RESULT: Cycles of gears in a pair of gear

which works together changes with
inversely proportional

Fig. 1319 Shigleys Mechanical Engineering Design

Example

P=10 Kw
N=3000 rpm
T=?
N=?

Fig. 1319 Shigleys Mechanical Engineering Design

15
 6/3/2017

Example

Calculating Torque

1) P= T1*N1/9550 First find the enter Torque

T1=9550*P/N1 => T1=9550*10/3000 =>

T1=31.8 N-m
2) T1/T2=Z1/Z2 => T2=T1*Z2/Z1 =>
T2=31.8*40/10 => T2=127.2 N-m

3) Due to Z2 and Z3 Gears are on same

shaft T2=T3=127.2N-m

4) T3/T4=Z3/Z4 => T4=T3*Z4/Z3 =>

T4=127.2*50/16 => T4=397.5 N-m

Out Shaft Tork T=397.5N-m

Fig. 1319 Shigleys Mechanical Engineering Design

Example

Calculating Revolution
1) N1/N2=Z2/Z1 => N2=N1*Z1/Z2 =>
N2=3000*10/40 => N2=750rpm

2) Due to Z2 ve Z3 Gears are on same shaft

N2=N3=750rpm

3) N3/N4=Z4/Z3 => N4=N3*Z3/Z4 =>

N4=750*16/50 => N4=240rpm

Out Shaft Revolution N=240 rpm

Ratio of Reduction
i=Input Revolution/OutputRevolution
i=3000/240 => i=12.5

Fig. 1319 Shigleys Mechanical Engineering Design

16
 6/3/2017

Example

Pratic Solving

i=i1*i2
i=(Z2/Z1)*(Z4/Z3)
i=(40/10)*(50/16)
i=12,5
Noutput=Ninput/ i
NIKI=3000/12.5=240 rpm
Toutput=Tinput*i
P= Tinput*Ninput/9550 => Tinput=9550*P/Ninput
=> Tinput=9550*10/3000 => Tinput=31.8 N-m
Toutput=31.8*12.5
Toutput=397.5 N-m

Fig. 1319 Shigleys Mechanical Engineering Design

Calculations

You must estimate some values.These are

Pinion thooth number(Zp)

Main Gear thooth number(Zg)
Presure Angle(f)
Module is main paremater which is variable in
equation, try to find best value in calculations

Shigleys Mechanical Engineering Design

17
 6/3/2017

Calculations
Slay Makers Equation(interferance control)

k =1 for full depth teeth. k = 0.8 for stub teeth

Slay Makers Equation for Full Sized Gears

Gear Width

b=10*M

Shigleys Mechanical Engineering Design

Calculation of Force

P= FS*V(power)
V= *D*N/60
P=FS* *D*N/60

Module in terms of:

M=D/Z => D=M*Z

Shigleys Mechanical Engineering Design

18
 6/3/2017

Calculation of Force
SERVICE FACTOR Cs
Maximum Force From Load (FY) GEAR WORKING TIME
LOADING 3 Hours/Day 8-10 24 Hours/Day
CASE Hour/Da
Fy =FS *CS y
Continous 0.8 1 1.25
working
to light shock 1 1.25 1.5

to moderate 1.25 1.5 1.8

shock
to severe shock 1.5 1.8 2.0

Lewis Equation(Diin dayanabilecei teetsel kuvvet)

Ft =s *b*Y*M Ft: Maximum Strenght of Teeth(N)

s : Strenght of the Tooth(N/mm2)
b: Lenght of the Teeth(mm)
Y: Lewis Foctor of Form(Look Table)
M:Module(mm)

Shigleys Mechanical Engineering Design

Calculation of Force

Lewis Equation(Diin dayanabilecei teetsel kuvvet)

Ft =s *b*Y*M
Number of
theeth
Ft: Maximum Strenght of Teeth(N)
s : Strenght of the Tooth(N/mm2)
b: Lenght of the Teeth(mm)
Y: Lewis Foctor of Form(Look Table)
M:Module(mm)

Shigleys Mechanical Engineering Design

19
 6/3/2017

Calculation of Force

Maximum Force From Load (FY)

Lewis Equation

Ft =s *b*Y*M

Number of Teeth

Barth Equation (Coming from Lewis)

You can add Fatique to Lewis Equation
Ft max =Ft * Cv

=>Ft max =s *b*Y*M*Cv Cv : : Speed Coefficient

Shigleys Mechanical Engineering Design

Speed Coefficient (CV) Determination

Shigleys Mechanical Engineering Design

20
 6/3/2017

Iteration

Must be
We must find module under this
condition

Shigleys Mechanical Engineering Design

Affect of Dynamic Forces From Tooth

Buckinghm Equation

Under the condution of low speed just load forces exist

But If the tangential speed more than limits, You must consider dynamic forces
Buckinghm equtions is used to find dynamic forces.

FY: maximum tangential force

generated by the load
Fi: dynamic forces generated by
the speed
C: Some mistakes coming from
manufacturing

k=0.107*e => =14.50 Full teeth

k=0.111*e => =20 Full teeth

k=0.115*e => =20 Bask (Stub)

Shigleys Mechanical Engineering Design

21
 6/3/2017

Affect of Dynamic Forces From Tooth

Buckingham Equation

If the pinion and main gear is to be made

of the same material of which the elastic
module (E) is equal to each other. Thus,
from the same steel material and steel
gears = 20 full-length "c" coefficients
occurs as follows.

FY: maximum tangential force

generated by the load
Fi: dynamic forces generated by the
speed

Shigleys Mechanical Engineering Design

Affect of Dynamic Forces From Tooth

Buckingham Equation

k=0.107*e => =14.50 Full teeth

k=0.111*e => =20 Full teeth
k=0.115*e => =20 Bask (Stub)

Shigleys Mechanical Engineering Design

22
 6/3/2017

Affect of Dynamic Forces From Tooth

Buckingham Equation

Acording to e(mm), manifacturing precision must be

select from table which is given below

The maximum amount of error that may occur in the processing

(mm)
Module Commercial Gears Elaborated Gears Precision machining
M Grinding Gears
4 0.05 0.025 0.0125
5 0.056 0.025 0.0125

6 0.064 0.030 0.0150

7 0.072 0.035 0.0170
8 0.080 0.038 0.0190
9 0.085 0.041 0.0205
10 0.090 0.044 0.0220

Shigleys Mechanical Engineering Design

Affect of Dynamic Forces From Tooth

Buckingham Equation

If the pinion and main gear is to be made of the same material of which
the elastic module (E) is equal to each other. Thus, from the same steel
material and for steel gears = 20 full-length "c" coefficients occurs as
follows.

Shigleys Mechanical Engineering Design

23
 6/3/2017

In Tooth Corrosion Strength

FW: Abrasion force (N)

DP: pinion gear section circle diameter
(mm)
b: Gear width (mm)
Q: Ratio factor
K: load stress factor (N / mm2)
A: Surface strength resistance (N / mm2)
: Gear pressure angle
E: Material elastic modulus (N / mm2)

The surface abrasion resistance is directly

related to the surface hardness and BHN
is 2.6487 times the surface hardness.

Shigleys Mechanical Engineering Design

Example

Coupling
Main gear
Die rolls
N=310
rpm

Electrical motor
P=20KW

Pinion gear

System works every day between 8 or 10 hour

Shigleys Mechanical Engineering Design

24
 6/3/2017

Gear reduction ratio:i= NP/NG = 1000/310 => i=3.226:1

Main gear teeth count:ZG =i*ZP = 3.226*31 => ZG =100

ZG /ZP =100/31 =3.226

Slay makers equation:

3453.6<7167 No nterferance
SERVICE FACTOR Cs
Force of Turning the Gears (FY) b=10*M
GEAR WORKING TIME
LOADING 3 Hours/Day 8-10 24 Hours/Day
CASE Hour/Day

Continous 0.8 1 1.25

working
to light shock 1 1.25 1.5

to moderate 1.25 1.5 1.8

shock
to severe shock 1.5 1.8 2.0
Shigleys Mechanical Engineering Design

Tangential Force in Lewis Equation (Ft)

Ft =s *b*Y*M
s : 138.3 N/mm2 (Table 1) STRENGTH (s) AND HARDNESS OF GEAR MATERIAL WHICH

b= 10*M WILL USED IN LEWIS FORMULA

MATERIAL STRENGT HARDNES

H OF S (BHN)
ZP =31, =200 GEAR
(N/mm^2)

To get a full gear; 20 Grade Iron casting 47.1 200

Y= 0.358 Table 3 25 Grade Iron casting 56.4 220

35 Grade Iron casting 56.4 225

Ft =138.3*10*M*0.36*M 35 Grade Iron casting (heat treated) 78.5 300
Ft =498*M2 0.2% Carboniferous steel 138.3 100

0.2% Carboniferous steel (heat treated) 193.2 250

Bronze 68.7 80

Phosphorous Bronze 82.4 100

Manganese Bronze 138.3 100

Aluminous Bronze 152.0 180

0.3% Carboniferous wrought steel 172.6 150

0.3% Carboniferous wrought steel (heat 220.0 200

treated)

C30 Steel (heat treated) 220.6 300

C40 Steel 207.0 150

C45 Steel 233.4 200

Alloy Steel-surface hardeness 345.2 650

Cr-Ni alloy 0.45% carboniferous steel 462.0 400

Cr-Va alloy 0.45% carboniferous steel 516.8 450

Plastic 58.8

Shigleys Mechanical Engineering Design

25
 6/3/2017

Tangential velocity (Vt)

Tangent velocity of pinion and

gear are same
Np=1000 rpm
ZP=31 gear

Cv=Hz
constant

Shigleys Mechanical Engineering Design

Barth Equation

Ft max =Ft*Cv Barth Equation Fatique Calculation

For iteration:

M=6

Shigleys Mechanical Engineering Design

26
 6/3/2017

Gear width (b):

b= 10*M=10*6=> b=60mm.

Pinion section circle diameter: (DP)

Dp=M*ZP = 6*31 => Dp=186 mm.

The main gear section circle diameter: (DG)

DG=M*ZG = 6*100 => Dp=600 mm.

Gear distance between axes: C(mm)

C(mm)= (Dp +DG )/2
C=(186+600)/2=393 mm.

Shigleys Mechanical Engineering Design

CONTROL OF CORROSION STRENGTH

SERVICE FACTOR Cs
GEAR WORKING TIME
LOADING 3 Hours/Day 8-10 24 Hours/Day
CASE Hour/Day

Continous 0.8 1 1.25

working
to light shock 1 1.25 1.5

to moderate 1.25 1.5 1.8

shock
to severe shock 1.5 1.8 2.0

Shigleys Mechanical Engineering Design

27
 6/3/2017

=200 For full-sized gears: k=0.111*e

c=11655*e

e: for error factor Graphics1.

V=9.7 m/ sn => e=0.04mm.

=> c=11655*0.04=466 N/mm

Shigleys Mechanical Engineering Design

Affect of Dynamic Forces From Tooth

Buckingham Equation

Shigleys Mechanical Engineering Design

28
 6/3/2017

In Tooth Corrosion Strength

FW: Abrasion force (N)

DP: pinion gear section circle diameter
(mm)
b: Gear width (mm)
Q: Ratio factor
K: load stress factor (N / mm2)
A: Surface strength resistance (N / mm2)
: Gear pressure angle
E: Material elastic modulus (N / mm2)

Shigleys Mechanical Engineering Design

In Tooth Corrosion Strength

f Ep=EG
Same Material STRENGTH (s) AND HARDNESS OF GEAR MATERIAL WHICH WILL USED IN LEWIS
FORMULA

The surface abrasion resistance is directly MATERIAL STRENGTH

OF GEAR
HARDNESS
(BHN)

related to the surface hardness and BHN (N/mm^2)

20 Grade Iron casting 47.1 200

is 2.6487 times the surface hardness. 25 Grade Iron casting 56.4 220
35 Grade Iron casting 56.4 225
35 Grade Iron casting (heat treated) 78.5 300
0.2% Carboniferous steel 138.3 100
Selected material is 0,2 C Steel 0.2% Carboniferous steel (heat treated) 193.2 250
Bronze 68.7 80
Phosphorous Bronze 82.4 100
Manganese Bronze 138.3 100
Aluminous Bronze 152.0 180
0.3% Carboniferous wrought steel 172.6 150
0.3% Carboniferous wrought steel (heat 220.0 200
treated)
C30 Steel (heat treated) 220.6 300
C40 Steel 207.0 150
C45 Steel 233.4 200
Alloy Steel-surface hardeness 345.2 650
Cr-Ni alloy 0.45% carboniferous steel 462.0 400
Cr-Va alloy 0.45% carboniferous steel 516.8 450
Plastic 58.8
Shigleys Mechanical Engineering Design

29
 6/3/2017

In Tooth Corrosion Strength

FW=DP*b*Q*K
Dp=186 mm.
B=60 mm.
Q=1.52
K=0.5
FW=186*60*1.52*0.5
FW=8,481 N
Must be required to corrosion:

FD =19,719 N > FW=8,481 N Corrosion Strength is not enough

We must change the metarial

Shigleys Mechanical Engineering Design

STRENGTH (s) AND HARDNESS OF GEAR MATERIAL WHICH WILL USED IN

LEWIS FORMULA

We select new material MATERIAL STRENGTH HARDNESS

OF GEAR (BHN)
We must select a harder material (N/mm^2)

For 300BHN 20 Grade Iron casting 47.1 200

25 Grade Iron casting 56.4 220
35 Grade Iron casting 56.4 225
35 Grade Iron casting (heat treated) 78.5 300
0.2% Carboniferous steel 138.3 100
0.2% Carboniferous steel (heat treated) 193.2 250
Bronze 68.7 80
Phosphorous Bronze 82.4 100
Manganese Bronze 138.3 100
Aluminous Bronze 152.0 180
0.3% Carboniferous wrought steel 172.6 150
0.3% Carboniferous wrought steel (heat 220.0 200
treated)
FW=DP*b*Q*K C30 Steel (heat treated) 220.6 300
C40 Steel 207.0 150

FW=186*60*1.52*1.4 C45 Steel 233.4 200

Alloy Steel-surface hardeness 345.2 650
FW=23,816 N Cr-Ni alloy 0.45% carboniferous steel 462.0 400
Cr-Va alloy 0.45% carboniferous steel 516.8 450
FD =19,719 N < FW=23,816 N Plastic 58.8

Corrosion Strengt is Suitable

Shigleys Mechanical Engineering Design

30