BudynasNisbett: Shigleys Mechanical Engineering Design, Eighth Edition

III. Design of Mechanical Elements

13. Gears General

The McGrawHill Companies, 2008

655

656

Mechanical Engineering Design

Top land
id th Fa ce w

Figure 135
Nomenclature of spur-gear teeth.

Addendum circle

Face

Addendum

Circular pitch

Flank
Pitch ci rcle
lan d Bo tto m

Dedendum

Tooth thickness

Width of space

Clearance

Fillet radius

Dedendum circle

Clearance circle

The module m is the ratio of the pitch diameter to the number of teeth. The customary unit of length used is the millimeter. The module is the index of tooth size in SI. The diametral pitch P is the ratio of the number of teeth on the gear to the pitch

re 1333
n2

Fr 32 F t32 Ta 2 F ta 2 a Fr a2 Fa2 d2 2

F32

on of gear forces.

While any units can be used in this equation, the units of

Wa = axial component, also called thrust load

Wr
t

Wa

Wt

Tooth element y

Pitch cylinder

factor of safety Eq. (1442)

SH =

Sc Z N CH (KT KR)
c

Remember to compare SF with S 2 when deciding whether bending H or wear is the threat to function. For crowned gears compare SF with S 3 . H Table of Overload Factors, Ko Driven Machine Power source Uniform Light shock Medium shock Uniform Moderate shock Heavy shock 1.00 1.25 1.50 1.25 1.50 1.75 1.75 2.00 2.25

ure 1418

map of gear wear equations based on AGMA standards. (ANSI/AGMA 2001-D04.)

Mechanical Engineering Design

ble 142

ues of the Lewis Form tor Y (These Values for a Normal ssure Angle of 20, Depth Teeth, and a metral Pitch of Unity he Plane of Rotation)

Number of Teeth 12 13 14 15 16 17 18 19 20 21 22 24
26

Y 0.245 0.261 0.277 0.290 0.296 0.303 0.309 0.314 0.322 0.328 0.331 0.337
0.346

Number of Teeth 28 30 34 38 43 50 60 75 100 150 300 400

Rack

Y 0.353 0.359 0.371 0.384 0.397 0.409 0.422 0.435 0.447 0.460 0.472 0.480
0.485

The use of Eq. (143) also implies that the teeth do not share the load and that the greatest force is exerted at the tip of the tooth. But we have already learned that the con tact ratio should be somewhat greater than unity, say about 1.5, to achieve a quality

Preferred
Next Choice

1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16, 20, 25, 32, 40, 5
1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5, 5.5, 7, 9, 11, 14, 18, 22, 28, 36, 45

Item Working depth Clearance Addendum of gear Gear ratio Equivalent 90 ratio

Formula hk = 2.0/P

ear

c = (0.188/P) + 0.002 in 0.54 0.460 + P P(m90 )2

aG =

mG = N G/N P

m90 = mG when = 90 m90 = cos when = 90 cos 10 F = 0.3A 0 or F = , whichever is smaller P mG Pinion
Gear

Face width Minimum number of teeth

16
16

15
17

14
20

13
30

angle and full-depth teeth. Use Figs. 147 and 148 for helical gears having a 20 normal pressure angle and face-contact ratios of m F = 2 or greater. For other gears, consult the AGMA standard.

Pinion addendum 1.000 Addendum 1.000 Gear addendum 1.000 0.60 Load applied at highest point of single-tooth contact 2.400 Whole depth

0.60

0.55

0.50 0.35 rT Geometry factor J 0.45

20

1000 170 85 50 35 25 17

0.55

0.50

0.45

Generating rack 1 pitch 0.40

Number of teeth in mating gear

0.40

0.35

0.35

0.30

0.30

0.25

Load applied at tip of tooth

0.25

0.20

0.20

12

15

17

20

24

30

35

40 45 50

60

80

125

275

Number of teeth for which geometry factor is desired

Figure 146

MPa 2.5% chrome, grade 3 (Source: ANSI/AGMA 2001D04,2101-D04.)

St = 86.2HB + 12 730 psi 30 250 275 300 Core hardness, HB 325 350

Table 143 Repeatedly Applied Bending Strength St at 107 Cycles and 0.99 Reliability for Steel Gears
Source: ANSI/AGMA 2001-D04.

Material Designation Steel3

Heat Treatment Through-hardened Flame4 or induction hardened4 with type A pattern5 Flame4 or induction hardened4 with type B pattern5 Carburized and hardened Nitrided (throughhardened steels)
4,7

Minimum Surface Hardness1 See Fig. 142 See Table 8*

Allowable Bending Stress Number St,2 psi Grade 1 See Fig. 142 45 000 Grade 2 See Fig. 142 55 000 Grade 3

See Table 8*

22 000

22 000

See Table 9* 83.5 HR15N 87.5 HR15N

55 000 See Fig. 143 See Fig. 144

65 000 or 70 0006 See Fig. 143 See Fig. 144

75 000 See Fig. 144

Nitralloy 135M, Nitralloy N, and 2.5% chrome

(no aluminum)

Nitrided

4,7

Notes: See ANSI/AGMA 2001-D04 for references cited in notes 17. 1 Hardness to be equivalent to that at the root diameter in the center of the tooth space and face width. 2 See tables 7 through 10 for major metallurgical factors for each stress grade of steel gears. 3 The steel selected must be compatible with the heat treatment process selected and hardness required. 4 The allowable stress numbers indicated may be used with the case depths prescribed in 16.1. 5 See gure 12 for type A and type B hardness patterns. 6 If bainite and microcracks are limited to grade 3 levels, 70,000 psi may be used. 7 The overload capacity of nitrided gears is low. Since the shape of the effective S-N curve is at, the sensitivity to shock should be investigated before proceeding with the design. [7]

Spur and Helical Gears

729

Table 144 Repeatedly Applied Bending Strength St for Iron and Bronze Gears at 107 Cycles and 0.99 Reliability
Source: ANSI/AGMA 2001-D04.

Material ASTM A48 gray cast iron ASTM A536 ductile (nodular) Iron

Material Designation1 Class 20 Class 30 Class 40 Grade 604018 Grade 805506 Grade 1007003 Grade 1209002

Heat Treatment As cast As cast As cast Annealed Quenched and tempered Quenched and tempered Quenched and tempered Sand cast

Typical Minimum Surface Hardness2 174 HB 201 HB 140 HB 179 HB 229 HB 269 HB Minimum tensile strength 40 000 psi Minimum tensile strength
90 000 psi

Allowable Bending Stress Number, St,3 psi 5000 8500 13 000 22 00033 000 22 00033 000 27 00040 000 31 00044 000 5700 23 600

Bronze ASTM B148

Alloy 954

Heat treated

Notes: 1 See ANSI/AGMA 2004-B89, Gear Materials and Heat Treatment Manual. 2 Measured hardness to be equivalent to that which would be measured at the root diameter in the center of the tooth space and face width. 3 The lower values should be used for general design purposes. The upper values may be used when: High quality material is used. Section size and design allow maximum response to heat treatment. Proper quality control is effected by adequate inspection. Operating experience justies their use.

Spur and Helical Gears

5.0 4.0 400 HB YN = 9.4518 N 0.148 YN = 6.1514 N 0.1192 YN = 4.9404 N 0.1045

ng YN. .)
Stress cycle factor, YN

NOTE: The choice of YN in the shaded area is influenced by: Pitchline velocity Gear material cleanliness Residual stress Material ductility and fracture toughness

3.0 Case carb. 250 HB Nitrided 2.0 160 HB

YN = 3.517 N 0.0817 YN = 1.3558 N 0.0178 1.0 0.9 0.8 0.7 0.6 0.5 10 10

YN = 2.3194 N 0.0538 1.0 0.9 0.8 0.7 0.6 0.5 10 2 10 3 10 4 10 5 10 6 10 7

YN = 1.6831 N 0.0323

10 8

10 9

Number of load cycles, N

5.0

NOTE: The choice of Z in the shaded

Mechanical Engineering Design, Eighth Edition

Elements

44

Mechanical Engineering Design

Table 1410 Reliability Factors KR (YZ )

Source: ANSI/AGMA 2001-D04.

Reliability 0.9999 0.999 0.99 0.90

0.50

KR (YZ) 1.50 1.25 1.00 0.85

0.70

1415

Temperature Factor KT (Y)

For oil or gear-blank temperatures up to 250F (120C), use K temperatures, the factor should be greater than unity. Heat e ensure that operating temperatures are considerably below th

Table 148 Elastic Coefcient Cp (ZE),

psi ( MPa)
Source: AGMA 218.01

Gear Material and Modulus of Elasticity EG, lbf/in2 (MPa)* Pinion Modulus of Elasticity Ep psi (MPa)* 30 106 (2 105) Steel 30 106 (2 105) 2300 (191) 2180 (181) 2160 (179) 2100 (174) 1950 (162) 1900
(158)

Pinion Material Steel Malleable iron Nodular iron Cast iron Aluminum bronze Tin bronze

Malleable Iron 25 106 (1.7 105) 2180 (181) 2090 (174) 2070 (172) 2020 (168) 1900 (158) 1850
(154)

Nodular Iron 24 106 (1.7 105) 2160 (179) 2070 (172) 2050 (170) 2000 (166) 1880 (156) 1830
(152)

Cast Iron 22 106 (1.5 105) 2100 (174) 2020 (168) 2000 (166) 1960 (163) 1850 (154) 1800
(149)

Aluminum Bronze 17.5 106 (1.2 105) 1950 (162) 1900 (158) 1880 (156) 1850 (154) 1750 (145) 1700
(141)

Tin Bronze 16 106 (1.1 105) 1900 (158) 1850 (154) 1830 (152) 1800 (149) 1700 (141) 1650
(137)

25 106 (1.7 105)

6

24 10 (1.7 105)

17.5 106 (1.2 105)

(1.1 105)

22 106 (1.5 105) 16 106

Poissons ratio 0.30. When more exact values for modulus of elasticity are obtained from roller contact tests, they may be used.

737

Spur and Helical Gears

731

Table 146 Repeatedly Applied Contact Strength Sc at 107 Cycles and 0.99 Reliability for Steel Gears
Source: ANSI/AGMA 2001-D04.

Material Designation Steel3

Heat Treatment Through hardened4 Flame5 or induction hardened5 Carburized and hardened5 Nitrided5 (through hardened steels)

Minimum Surface Hardness1 See Fig. 145 50 HRC 54 HRC See Table 9 83.5 HR15N 84.5 HR15N 87.5 HR15N 90.0 HR15N 90.0 HR15N 90.0 HR15N

Allowable Contact Stress Number,2 Sc, psi Grade 1 See Fig. 145 170 000 175 000 180 000 150 000 155 000 155 000 170 000 172 000 176 000 Grade 2 See Fig. 145 190 000 195 000 225 000 163 000 168 000 172 000 183 000 188 000 196 000 Grade 3 275 000 175 000 180 000 189 000 195 000 205 000 216 000

2.5% chrome (no aluminum) Nitralloy 135M Nitralloy N 2.5% chrome

(no aluminum)

Nitrided5 Nitrided5 Nitrided5 Nitrided5

Notes: See ANSI/AGMA 2001-D04 for references cited in notes 15. 1 Hardness to be equivalent to that at the start of active prole in the center of the face width. 2 See Tables 7 through 10 for major metallurgical factors for each stress grade of steel gears. 3 The steel selected must be compatible with the heat treatment process selected and hardness required. 4 These materials must be annealed or normalized as a minimum. 5 The allowable stress numbers indicated may be used with the case depths prescribed in 16.1. *Table 9 of ANSI/AGMA 2001-D04 is a comprehensive tabulation of the major metallurgical factors affecting St and Sc of carburized and hardened steel gears.

732

Mechanical Engineering Design

Table 147 Repeatedly Applied Contact Strength Sc 107 Cycles and 0.99 Reliability for Iron and Bronze Gears
Source: ANSI/AGMA 2001-D04.

Material ASTM A48 gray cast iron ASTM A536 ductile (nodular) iron

Material Designation1 Class 20 Class 30 Class 40 Grade 604018 Grade 805506 Grade 1007003 Grade 1209002

Heat Treatment As cast As cast As cast Annealed Quenched and tempered Quenched and tempered Quenched and tempered Sand cast Heat treated

Typical Minimum Surface Hardness2 174 HB 201 HB 140 HB 179 HB 229 HB 269 HB Minimum tensile strength 40 000 psi Minimum tensile
strength 90 000 psi

Allowable Contact Stress Number,3 Sc, psi 50 00060 000 65 00075 000 75 00085 000 77 00092 000 77 00092 000 92 000112 000 103 000126 000 30 000 65 000

Bronze

ASTM B-148
Alloy 954

Notes: 1 See ANSI/AGMA 2004-B89, Gear Materials and Heat Treatment Manual. 2 Hardness to be equivalent to that at the start of active prole in the center of the face width. 3 The lower values should be used for general design purposes. The upper values may be used when: High-quality material is used. Section size and design allow maximum response to heat treatment. Proper quality control is effected by adequate inspection.

In this approach the strengths are modied by various factors that produce l values of the bending stress and the contact stress.

Allowable bending stress number, St kpsi

ess rdened s

Metallurgical and quality control procedure required 50 Grade 2 St = 102 HB + 16 400 psi

and MPa,

40

30 Grade 1 St = 77.3 HB + 12 800 psi 20

1-D04.)

10 150

200

250

300 Brinell hardness, HB

350

400

450

 Unidirectional loading 10 million stress cycles 99 percent reliability

1000 lb in2

Allowable contact stress number, Sc

ngth Sc 0.99 hrs. The SI

Metallurgical and quality control procedures required

175 Grade 2 Sc = 349 HB + 34 300psi

00 MPa,

150

7 MPa,

125 Grade 1 Sc = 322 HB + 29 100psi

1-D04 and

100

75 150

200

250

300 Brinell hardness, HB

350

400

450

Hardn

10 2

10 3

10 4

10 5

10 6

10 7

10 8

10 9

10 10

Number of load cycles, N

5.0 4.0 3.0 Stress cycle factor, Z N

cle

NOTE: The choice of Z N in the shaded zone is influenced by: Lubrication regime Failure criteria Smoothness of operation required Pitchline velocity Gear material cleanliness Material ductility and fracture toughness Residual stress ZN = 1.4488 N 0.023

2.0 ZN = 2.466 N 0.056

1.1 1.0 0.9 0.8 0.7 0.6 0.5 102 103

Nitrided ZN = 1.249 N 0.0138

104

105

106

107

108

109

1010

Number of load cycles, N

al Engineering Design
1.14 1.7 1.6 1.5 1.4 1.3 1.2 1.04 When HBP < 1.2, HBG Use CH = 1 0 2 4 6 8 10 12 14 16 18 20 Single reduction gear ratio mG HBP HBG Calculated hardness ratio, 1.12

12

tor CH steel). 001-D04.)

Hardness ratio factor, CH

1.10

1.08

1.06

1.02

1.00

13