FME3 Ch14

Fundamentals of Machine Elements, 3
rd
ed.
Schmid, Hamrock and Jacobson
2014 CRC Press
Chaler 14: GeneraI Gear Theory,
Sur Gears
We are vhal ve reealedIy do.
IxceIIence, lherefore, is nol an acl,
bul a habil.
ArislolIe
An assorlmenl of gears. !"#$%&' Courlesy of
QuaIily Transmission Comonenls.
rd
ed.
2014 CRC Press
Sur Gears
Iigure 14.1: Sur gear drive. (a) Schemalic iIIuslralion of meshing sur gears, (b) a
coIIeclion of sur gears. !"#$%&' Courlesy of oslon Gear Works, Inc.
Face view
Edge view
(a)
(b)
rd
ed.
2014 CRC Press
HeIicaI Gears
Iigure 14.2: HeIicaI gear drive. (a) Schemalic iIIuslralion of meshing heIicaI gears, (b) a
coIIeclion of heIicaI gears. !"#$%&' Courlesy of oslon Gear Works, Inc.
(a) (b)
rd
ed.
2014 CRC Press
eveI Gears
Iigure 14.3: eveI gear drive. (a) Schemalic iIIuslralion of meshing beveI gears vilh
slraighl leelh, (b) a coIIeclion of beveI gears. !"#$%&' Courlesy of oslon Gear Works, Inc.
(a) (b)
rd
ed.
2014 CRC Press
Worm Gears
Iigure 14.4: Worm gear drive. (a) CyIindricaI leelh, (b) doubIe enveIoing, (c) a
coIIeclion of vorm gears. !"#$%&' Courlesy of oslon Gear Works, Inc.
(a) (b) (c)
rd
ed.
2014 CRC Press
Sur Gear
Geomelry
Iigure 14.5: asic sur gear
geomelry.
Tooth profile
Pitch circle
Whole depth, h
t
Addendum, a
Dedendum, b
Root (tooth)
Fillet
Top
land
Pitch circle
Base circle
Pressure
angle,
Line of
action
Circular pitch, p
c
Working
depth, h
k
Clearance, c
r
Circular tooth
thickness
Chordal tooth
thickness
Gear
Pinion
Center
distance, c
d
P
i
t
c
h

d
i
a
m
e
t
e
r
,

d
g

R
o
o
t

d
i
a
m
e
t
e
r
r b
p
r p
r
op
O
u
t
s
id
e

d
ia
m
e
t
e
r
,

d
o
p
r b
g
r
g
r
og
Base diameter, d
bg
rd
ed.
2014 CRC Press
Gear Toolh NomencIalure
Iigure 14.6: NomencIalure of gear leelh.
F
l
a
n
k
F
a
c
e
Tooth
thickness
P
itc
h
c
ir
c
le
Width
of space
Circular pitch
B
o
t
t
o
m

l
a
n
d
T
o
p

l
a
n
d
F
a
c
e

w
i
d
t
h
Clearance
Fillet
radius
Clearance
circle
Dedendum
circle
Addendum
Dedendum
Outside
circle
rd
ed.
2014 CRC Press
Toolh Size
Iigure 14.7: Slandard diamelraI ilches comared vilh loolh size. IuII size is assumed.
2 3 4 5
6 7 8 9 10 12 14 16
2
2
1
rd
ed.
2014 CRC Press
Ireferred Iilches
TabIe 14.1: Ireferred diamelraI ilches for four loolh cIasses.
Diametral pitch,
Class p
d
, in
1
Coarse 1/2, 1, 2, 4, 6, 8, 10
Medium coarse 12, 14, 16, 18
Fine 20, 24, 32, 48, 64
72, 80, 96, 120, 128
e 150, 180, 200
rd
ed.
2014 CRC Press
Iover Caacily
Iigure 14.8: Transmiued over as a funclion of inion seed for a number of diamelraI
ilches. Ior aII cases shovn, )
$
4, *
+
24, ,
o
1.0, -20. !"#$%&' Irom Mou |2003j.
0 600 1200 1800 2400 3000 3600
Pinion speed, rpm
100
50
30
20
10.0
5.0
2.0
1.0
0.5
P
o
w
e
r

t
r
a
n
s
m
i
t
t
e
d
,

k
W
150
2
4

p
itc
h
; d
=
1
.0
0
in. (m
= 1; d = 25 mm)
1
2

p
itc
h
; d
=
2
.00 in. (m
= 2; d = 50 mm)
6

p
itc
h
; d
= 4.00 in. (m = 4; d = 100 mm)
3 pitch; d = 8.00 in.
(m = 8; d = 200 mm)
rd
ed.
2014 CRC Press
Iilch and ase CircIes, Line of
Aclion
Iigure 14.9: (a) Iilch and base circIes for inion and gear as veII as Iine of aclion and
ressure angIe. (b) DelaiI of aclive rohIe, shoving delaiI of Iine of aclion and Ienglh of
aclion, L
./
.
Base circle
Pitch circle
Pitch circle
Pitch point, p
p
Gear
Base circle
Pinion
A
B
r
p
r
g
r
bg
r
bp
p
Line of centers
Base circle (gear)
Base circle (pinion)
A
B
Outside circle
(pinion)
Outside circle
(gear)
L
ab
(Length of action)
Line of action
Pitch point
(a) (b)
L
1
L
2
rd
ed.
2014 CRC Press
Addendum, Dedendum &
CIearance
TabIe 14.2: IormuIas for addendum, dedendum and cIearance (-20, fuII-delh
invoIule).
Metric
Coarse pitch Fine pitch module
Parameter Symbol (p
d
< 20 in.
1
) ( p
d
20 in.
1
) system
Addendum a 1/p
d
1/p
d
1.00 m
Dedendum b 1.25/p
d
1.200/p
d
+ 0 .002 1.25 m
Clearance c 0.25/p
d
0.200/p
d
+ 0 .002 0.25 m
rd
ed.
2014 CRC Press
InvoIule Curve
Iigure 14.10: Conslruclion of invoIule curve.
A
4
A
3
A
2
A
1
C
1
C
2
B
1
B
2
B
3
B
4
C
4
C
3
A
o
Base circle
0
Involute
rd
ed.
2014 CRC Press
Arc of Aroach
Iigure 14.11: IIIuslralion of arc of aroach, arc of recess and Ienglh of aclion.
P
b
a
L
in
e
o
f a
c
tio
n
Arc of approach
a
Arc of recess
r
O
u
t
s
id
e

c
ir
c
le
P
i
t
c
h

c
i
r
c
l
e Outside circle
Motion
L
a
b
rd
ed.
2014 CRC Press
ackIash
Iigure 14.12: IIIuslralion of backIash
in gears.
B
a
s
e

Base
P
itc
h
c
irc
le
P
itc
h

0
Backlash
Pressure line
Backlash
TabIe 14.3: Recommended minimum backIash

for coarse-ilched gears.
Diametral
pitch Center distance, c
d
, in.
p
d
, in.
1
2 4 8 16 32
18 0.005 0.006
12 0.006 0.007 0.009
8 0.007 0.008 0.010 0.014
5 0.010 0.012 0.016
3 0.014 0.016 0.020 0.028
2 0.021 0.025 0.033
1.25 0.034 0.042
rd
ed.
2014 CRC Press
Meshing Gears
Iigure 14.13: IxlernaIIy meshing
sur gears.
r
2
Gear 1
(N
1
teeth)
Gear 2
(N
2
teeth)
(+)
()
1

2
r
1
r
1
2
Gear 1
(N
1
)
Gear 2
(N
2
)
r
2
r
1
Iigure 14.14: InlernaIIy meshing
sur gears.
rd
ed.
2014 CRC Press
Gear Trains
Iigure 14.15: SimIe gear lrain.
N
2
N
1
N
1
N
2
N
5
N
6
N
7 N
8
N
3
N
4
Shaft 1
Shaft 2
Shaft 3
Shaft 4
Shaft 5
Iigure 14.16: Comound gear lrain.
rd
ed.
2014 CRC Press
IxamIe 14.6
Iigure 14.17: Gear lrain used in IxamIe 14.6.
Only pitch
circles of
gears shown
Shaft 1
Input
Shaft 2
Shaft 3
Shaft 4
Output
A
B
N
A
= 20
N
B
= 70
N
C
= 18
N
D
= 22
N
E
= 54
A
B
C
D
E
C
D
E
rd
ed.
2014 CRC Press
IIanelary Gear Train
Iigure 14.18: IIIuslralion of Ianelary gear lrain. (a) Wilh lhree Ianels, (b) vilh one
Ianel (for anaIysis onIy).
Ring
R
P
P
S
A
P
Planet
Arm
Sun
(a)
R
P
S
(b)
rd
ed.
2014 CRC Press
Gear Cosl vs. QuaIily
Iigure 14.19: Gear cosl as a funclion of gear quaIily. Nole lhal lhe ovder melaIIurgy
aroaches of ressing and sinlering and melaI in|eclion moIding can roduce gears u
lo a quaIily index of 8 vilhoul addilionaI machining. Recenl research has suggesled lhal
simiIar quaIily IeveIs can be achieved from coId forging as veII.
16
AGMA quality index
R
e
l
a
t
i
v
e

c
o
s
t
10
100
1
0.5
4 6 8 10 12 14
Special methods
Production
grinding
Shaving
Dimensional tolerance (in.)
Powder
Metal
Shaping &
Hobbing
10
-4
10
-2
10
-3
10
-5
rd
ed.
2014 CRC Press
QuaIily Index
TabIe 14.4: QuaIily index 0
1
for various aIicalions. !"#$%&' Courlesy of lhe American
Gear Manufaclurers Associalion.
Application Quality index, Q
v
Cement mixer drum driver 3-5
6 - 5 n l i k t n e m e C
Steel mill drives 5-6
7 - 5 s r e k c i p n r o C
7 - 5 s s e r p h c n u P
Mining conveyor 5-7
Clothes washing machine 8-10
1 1 - 9 s s e r p g n i t n i r P
Automotive transmission 10-11
Marine propulsion drive 10-12
Aircraft engine drive 10-13
4 1 - 2 1 e p o c s o r y G
Pitch velocity Quality index, Q
v
ft/min m/s
0-800 0-4 6-8
800-2000 4-10 8-10
2000-4000 10-20 10-12
> 4000 > 20 12-14
rd
ed.
2014 CRC Press
Iorm Cuuing of Gears
Iigure 14.20: Iorm cuuing of gear leelh. (a) A form cuuer. Nolice lhal lhe loolh rohIe is
dehned by lhe cuuer rohIe, (b) schemalic iIIuslralion of lhe form cuuing rocess, (c)
form cuuing of leelh on a beveI gear. !"#$%&' (a) and (b) Irom KaIak|ian and Schmid
|2010j, (c) Courlesy Schafer Gear Works, Inc.
Gear
blank
Form
cutter
(a) (b)
(c)
rd
ed.
2014 CRC Press
Shaing
Iigure 14.21: Iroduclion of gear leelh vilh a inion-shaed cuuer. (a) Schemalic
iIIuslralion of lhe rocess. !"#$%&' Irom KaIak|ian and Schmid |2010j, (b) holograh of
lhe rocess vilh gear and cuuer molions indicaled. !"#$%&' Courlesy Schafer Gear
Works, Inc.
rd
ed.
2014 CRC Press
Hobbing
Iigure 14.22: Iroduclion of gears lhrough lhe hobbing rocess. (a) A hob, aIong vilh a
schemalic iIIuslralion of lhe rocess. !"#$%&' Irom KaIak|ian and Schmid |2010j, (b)
roduclion of a vorm gear lhrough hobbing. !"#$%&' Courlesy Schafer Gear Works, Inc.
(a)
Hob
Helical gear
Hob rotation
(b)
(b)
Gear
blank
Gear
blank
Hob
Top view
rd
ed.
2014 CRC Press
Gear
Iinishing
Iigure 14.23: Iinishing gears by grinding: (a) form grinding vilh shaed grinding
vheeIs, (b) grinding by generaling, using lvo vheeIs. !"#$%&' Irom KaIak|ian and
Schmid |2010j.
(a)
(b)
15 or 20 position 0 position
Grinding wheels
Gear
Gear
Single-ribbed
grinding wheel
Multiribbed
grinding wheel
Two grinding
wheels
Grinding
wheel
Worm
gear
rd
ed.
2014 CRC Press
Hardness Iecls on ending
Slrenglh
Iigure 14.24: Iecl of rineII hardness on aIIovabIe bending slress for sleeI gears. (a)
Through-hardened sleeIs, (b) IIame or induclion hardened nilriding sleeIs. Nole lhal
rineII hardness refers lo case hardness for lhese gears. !"#$%&' ANSI/AGMA Slandard
2101-D04 |2004j.
10
150 120 200 250 300 350 400 450
20
100
150
200
250
300
350
400
30
40
50
60
B
e
n
d
i
n
g

s
t
r
e
n
g
t
h
,

S
b
,

M
P
a
k
s
i
Brinell hardness, HB
Grade 1
T
h
r
o
u
g
h
-
h
a
rd
e
n
e
d
T
h
r
o
u
g
h
-
h
a
r
d
e
n
e
d
Grade 2
N
itr
id
e
d
N
itrid
e
d
Grade 1 - Nitralloy
250 300
350 275 325
100
200
300
400
500
B
e
n
d
i
n
g

s
t
r
e
n
g
t
h
,

S
b
,

M
P
a
Grade 3 - 2.5% Chrome
G
rade 2 - N
itralloy
70
20
30
40
50
60
k
s
i
rd
ed.
2014 CRC Press
Hardness Iecls on Conlacl
Slrenglh
Iigure 14.25: Iecl of rineII hardness on aIIovabIe conlacl slress number for lvo
grades of lhrough-hardened sleeI. !"#$%&' ANSI/AGMA Slandard 2101-D04 |2004j
75
150 200 250 300 350 400 450
100
600
700
800
900
1000
1100
1200
1300
125
150
175
C
o
n
t
a
c
t

s
t
r
e
n
g
t
h
,

S
c
,

M
P
a
k
s
i
G
r
a
d
e

1
G
r
a
d
e

2
1400
2.22 HB +200 (MPa)
0.322 HB + 29.1 (ksi)
S
c
=
{
Grade 2:
2.41 HB +237 (MPa)
0.349 HB + 34.3 (ksi)
S
c
=
{
Grade 1:
rd
ed.
2014 CRC Press
Slrenglh of Gear MaleriaIs
TabIe 14.5: ending and conlacl slrenglh for seIecled gear maleriaIs. !"#$%&' Adaled
from ANSI/AGMA 2101-D04 |2004j and MIII Slandard 35 |2009j.
Material designation Grade Typical Bending strength, Sb Contact strength, Sc
Hardness
a
lb/in.
2
MPa ksi MPa
Steel
Through-hardened
b
1 180-400 HB 0.0773 HB + 12.8 0.533 HB + 88.3 0.349 HB + 34.3 2.41 HB + 237
2 180-400 HB 0.102 HB + 16.4 0.703 HB + 11.3 0.322 HB + 29.1 2.22 HB + 200
Carburized & hardened 1 55-64 HRC 55.0 380 180.0 1240
2 58-64 HRC 65.0
c
450
c
225.0 1550
3 58-64 HRC 75.0 515 275.0 1895
Nitrided and through- 1 83.5 HR15N 0.0823 HB +12.15 0.568 HB + 83.8 150,000 1035
hardened
b
2 0.1086 HB + 15.89 0.749 HB + 110 163,000 1125
Nitralloy 135M and 1 87.5 HR15N 0.0862 HB + 12.73 0.594 HB + 87.76 170,000 1170
Nitralloy N, nitrided
b
2 87.5 HR15N 0.1138 HB + 16.65 0.784 HB + 114.81 183,000 1260
2.5% Chrome, nitrided
b
1 87.5 HR15N 0.1052 HB + 9.28 0.7255 HB + 63.89 155,000 1070
2 87.5 HR15N 0.1052 HB + 22.28 0.7255 HB + 153.63 172,000 1185
3 87.5 HR15N 0.1052 HB + 29.28 0.7255 HB + 201.81 189,000 1305
Cast Iron
ASTM A48 gray cast Class 20 5.00 34.5 50.0-60.0 345-415
iron, as-cast Class 30 174 HB 8.50 59 65.0-75.0 450-520
Class 40 201 HB 13.0 90 75.0-85.0 520-585
ASTM A536 ductile 60-40-18 140 HB 22.0-33. 150-230 77.0-92.0 530-635
(nodular) iron 80-55-06 179 HB 22.0-33.0 150-230 77.0-92.0 530-635
100-70-03 229 HB 27.0-40.0 185-275 92.0-112.0 635-770
120-90-02 269 HB 31.0-44.0 215-305 103.0-126.0 710-870
Bronze
Sut > 40, 000 5 0 2 0 . 0 3 5 . 9 3 0 7 . 5 i s p
(Sut > 275 GPa)
Sut > 90, 000 0 5 4 0 . 5 6 5 6 1 6 . 3 2 i s p
(Sut > 620 GPa)
Powder Metal
FL-4405, = 7 .30 g/cm
3
80 HRB 49.0 340 282.0 1945
FLN2-4405, = 7 .35 g/cm
3
90 HRB 60.0 410 180.0 1240
FLC-4608, = 7 .30 g/cm
3
65 HRB 95.72 660 210.0 1450
FN-0205, = 7 .10 g/cm
3
69 HRB 30.0 210 180.0 1240
a
Hardness refers to case hardness unless through-hardened.
b
See Figs. 14.24 and/or 14.25.
c
70,000 psi (485 MPa) may be used if bainite and microcracks are limited to grade 3 levels.
rd
ed.
2014 CRC Press
Gear Slrenglh Modihcalion Iaclors
and ReIiabiIily Iaclor
TabIe 14.6: ReIiabiIily faclor, ,
$
.
!"#$%&' Irom ANSI/AGMA 2101-
D04 |2004j.
Probability of
survival, percent
Reliability factor
a
K
r
50
90
99
99.9
99.99
0.70
b
0.85
b
1.00
1.25
1.50
a
Based on surface pitting. If tooth breakage is
considered a greater hazard, a larger value may
be required.
b
At this value, plastic flow may occur rather
than pitting.
AIIovabIe bending slress:
AIIovabIe conlacl slress:
b,all
=
S
b
n
s
Y
N
K
t
K
r
c,all
=
S
c
n
s
Z
N
C
H
K
t
K
r
rd
ed.
2014 CRC Press
ending Slress CycIe Iaclor
Iigure 14.26: Slress cycIe faclor. (a) ending slrenglh slress cycIe faclor 2
*
, !"#$%&'
ANSI/AGMA Slandard 2101-D04 |2004j.
Number of load cycles, N
10
2
10
3
10
4
10
5
10
6
10
7
10
8
10
9
10
10
S
t
r
e
s
s

c
y
c
l
e

f
a
c
t
o
r
,

Y
n
2.0
1.0
0.9
0.8
0.7
0.6
0.5
3.0
4.0
400 HB: Y
N
= 9.4518 N
-0.148
Case Carb.: Y
N
= 6.1514N
-0.1192
250 HB: Y
N
= 4.9404 N
-0.1045
Nitrided: Y
N
= 3.517 N
-0.0817
160 HB: Y
N
= 2.3194 N
-0.0538
Y
N
= 1.3558 N
-0.0178
Y
N
= 1.6831 N
-0.0323
rd
ed.
2014 CRC Press
Iiuing Resislance CycIe Iaclor
S
t
r
e
s
s

c
y
c
l
e

f
a
c
t
o
r
,

Z
n
2.0
1.1
1.0
0.9
0.8
0.7
0.6
0.5
Number of load cycles, N
10
2
10
3
10
4
10
5
10
6
10
7
10
8
10
9
10
10
Z
n
= 1.249 N
-0.0138
Hydrodynamic: Z
n
= 2.466 N
-0.056
Z
n
= 1.4488 N
-0.023
1.5
M
i
x
e
d
:

Z
n
=

3
.
8
3
4

N

-
0
.
0
9
4
,

N

>

1
0 5
Boundary: Z
n
= 7.821 N
-0.156
, N > 10
5
Z
n
= 1.47, N < 10
4
Z
n
= 1.10, N < 10
4
Grade 1 & 2
Nitrided
Iigure 14.26: Slress cycIe faclor. (b) Iiuing resislance slress cycIe faclor 3
*
. !"#$%&'
ANSI/AGMA Slandard 2101-D04 |2004j.
rd
ed.
2014 CRC Press
Loads on Gear Toolh
Iigure 14.27: Loads acling on an individuaI gear
loolh.
Pitch circle
W
r
W
t
W
TangenliaI Ioad:
If 4
+
is in horseover:
NormaI Ioad:
RadiaI Ioad:
W
t
=
h
p
u
=
60h
p
dN
a
W
t
=
126, 050h
p
dN
a
W =
W
t
cos
W
r
= W
t
tan
rd
ed.
2014 CRC Press
ending of Gear
Teelh
Iigure 14.28: A crack lhal has deveIoed al
lhe rool of a gear loolh due lo excessive
bending slresses. !"#$%&' Courlesy of lhe
American Gear Manufaclurers Associalion.
(a)
(b)
W
t
b
w
t
l
r
f
t
x
W
t
W
r
W
Iigure 14.29: Loads and Ienglh dimensions

used in delermining loolh bending slress.
(a) Toolh, (b) canliIevered beam.
rd
ed.
2014 CRC Press
Levis Iorm Iaclor
!"#$% !"#$%
&'()"* +,*( &'()"* +,*(
,+ -""-. +/0-,* ,+ -""-. +/0-,*
!" "#!$% &' "#&()
!! "#!*( &% "#&(*
!( "#(!" &+ "#&&(
!& "#((& '" "#&&%
!' "#(&% ') "#&'"
!) "#(') )" "#&'%
!% "#()% )) "#&)(
!$ "#(%' %" "#&))
!+ "#($" %) "#&)+
!* "#($$ $" "#&%"
(" "#(+& $) "#&%!
(( "#(*( +" "#&%&
(' "#&"( *" "#&%%
(% "#&"+ !"" "#&%+
(+ "#&!' !)" "#&$)
&" "#&!+ ("" "#&$+
&( "#&(( &"" "#&+(
TabIe 14.7: Levis form faclor for various numbers of leelh
(ressure angIe, 14.5, fuII-delh invoIule).
rd
ed.
2014 CRC Press
Sur Gear Geomelry Iaclors
Iigure 14.30: Sur gear geomelry faclors for fuII-delh invoIule rohIe. (a) -20, (b)
-25. !"#$%&' AGMA Slandard 908-89 |1989j.
0
15 12 20 25 30 40 60 80 275
0.10
0.20
0.30
0.40
0.50
G
e
o
m
e
t
r
y

f
a
c
t
o
r
,

Y
j
Number of teeth, N
Number of
teeth in
mating gear.
Load considered
applied at
highest point
of single-tooth
contact.
125
1000
170
85
50
35
25
17
Load applied at
tip of tooth
15 12 20 25 30 40 60 80 275
G
e
o
m
e
t
r
y

f
a
c
t
o
r
,

Y
j
Number of teeth, N
125
0.20
0.30
0.40
0.50
0.60
Load applied at
tip of tooth
Number of
teeth in
mating gear.
Load considered
applied at
highest point
of single-tooth
contact.
1000
85
50
25
17
(a)
(b)
rd
ed.
2014 CRC Press
AGMA ending Slress Iqualion
b
=
W
t
p
d
K
o
K
s
K
m
K
v
K
b
b
w
Y
j
vhere
5
6
lransmiued Ioad, N
+
7
diamelraI ilch, m
-1
,
o
overIoad faclor
,
8
size faclor
,
9
Ioad dislribulion faclor
,
1
dynamic faclor
,
/
rim lhickness faclor
rd
ed.
2014 CRC Press
OverIoad and Size Iaclors
Iigure 14.8: OverIoad faclor, ,
"
, as
funclion of driving over source and
driven machine.
!"#$%& '()*#&%+
,#-*. '/0%"(.% 1%($2
3/4%" +/5")% 6&#7/"8 +*/)9 +*/)9 +*/)9
!"#$%&' ()** ()+, (),* ()-,
.#/01 20%34 ()+* ()5* ()-, +)+,
6%78&918 20%34 ():* ()-* +)** +)-,
Diametral pitch, p
d
, Module, m,
in.
1
mm Size factor, K
s
5 5 1.00
4 6 1.05
3 8 1.15
3 12 1.25
1.25 20 1.40
TabIe 14.9: Recommended vaIues
of size faclor, ,
8
.
rd
ed.
2014 CRC Press
Load dislribilion faclor:
vhere
:
9%
Iead correclion faclor
:
+;
inion roorlion faclor
:
+9
inion roorlion modiher
:
9.
mesh aIignmenl faclor
:
&
mesh aIignmenl correclion faclor
Lead correclion faclor:

Load Dislribulion Iaclor
K
m
= 1.0 +C
mc
(C
pf
C
pm
+C
ma
C
e
)
C
mc
=
1.0 for uncrowned teeth

0.8 for crowned teeth
rd
ed.
2014 CRC Press
Iinion Iroorlion Iaclor
Iigure 14.31: Iinion roorlion faclor, :
+;
.
!"#$%&' ANSI/AGMA Slandard 2101-D04 |2004j.
0.60
0.50
0.40
0.30
0.20
0.10
0.00
b
w
/
d
p

=

2
.
0
0
1
.
5
0
1
.
0
0
0
.
5
0
For b
w
/d
p
< 0.5 use
curve for b
w
/d
p
= 0.5
P
i
n
i
o
n

p
r
o
p
o
r
t
i
o
n

f
a
c
t
o
r
,

C
p
f
0.70
0 200 400 600 800 1000
Face width, b
w
(mm)
40 0 10 20 30
Face width, b
w
(in.)
Iinion roorlion faclor:
If /
<
< 25 mm,
Ior 25 mm < bv < 432 mm,
Ior 432 mm < bv s 1020 mm,
(see lexl if /
<
is in inches)
C
pf
=
b
w
10d
p
0.025
C
pf
=
b
w
10d
p
0.0375 + 0.000492b
w
C
pf
=
b
w
10d
p
0.1109 + 0.000815b
w
(3.53 10
7
)b
2
w
rd
ed.
2014 CRC Press
Mesh AIignmenl Iaclor
Iigure 14.33: Mesh aIignmenl faclor. !"#$%&' ANSI/AGMA Slandard 2101-D04 |2004j.
C
ma
= A + Bb
w
+ Cb
2
w
If b
w
is in inches:
Condition A B C
Open gearing 0.247 0.0167 0.765 ! 10
4
Commercial enclosed gears 0.127 0.158 1.095 ! 10
4
Precision enclosed gears 0.0675 0.0128 0.926 ! 10
4
Extraprecision enclosed gears 0.000380 0.0102 0.822 ! 10
4
If b
w
is in mm:
Condition A B C
Open gearing 0.247 6.57 ! 10
4
1.186 ! 10
7
Commercial enclosed gears 0.127 6.22 ! 10
4
1.69 ! 10
7
Precision enclosed gears 0.0675 5.04 ! 10
4
1.44 ! 10
7
Extraprecision enclosed gears 0.000380 4.02 ! 10
4
1.27 ! 10
7
0 200 400 600 800 1000
Face width, b
w
(mm)
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
M
e
s
h

a
l
i
g
n
m
e
n
t

f
a
c
t
o
r
,

C
m
a
Face width, b
w
(in)
40 30 20 10 0
O
p
e
n

g
e
a
r
i
n
g
C
o
m
m
e
r
c
ia
l
e
n
c
lo
s
e
d
g
e
a
r
u
n
its
P
r
e
c
is
io
n
e
n
c
lo
s
e
d
g
e
a
r u
n
its
E
x
tra
-p
re
c
is
io
n
e
n
c
lo
s
e
d
g
ear units
rd
ed.
2014 CRC Press
Iinion Iroorlion and Mesh AIignmenl
Modihers
Iigure 14.32: IvaIualion of ! and !
1
.
!"#$%&' ANSI/AGMA Slandard 2101-D04
|2004j.
S
S/2 S
1
Iinion roorlion modiher:
Mesh aIignmenl correclion faclor:

C
pm
=
1.0, (S
1
/S) < 0.175
1.1, (S
1
/S) 0.175
C
e
=
0.80 when gearing is adjusted at assembly

0.80 when compatibility between gear teeth is
improved by lapping
1.0 for all other conditions
rd
ed.
2014 CRC Press
Dynamic faclor:
Where
Maximum recommended ilch Iine

veIocily:
Dynamic Iaclor
Iigure 14.34: Dynamic faclor as a funclion of
ilch-Iine veIocily and lransmission accuracy
IeveI number. !"#$%&' ANSI/AGMA Slandard
2101-D04 |2004j.
D
y
n
a
m
i
c

f
a
c
t
o
r
,

K
v
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
Pitch line velocity, m/s
0 10 20 30 40 50
Q
v
= 5 Q
v
= 6
Q
v
= 7
Q
v
= 8
Q
v
= 9
Q
v
= 10
Q
v
= 11
"Very accurate" gearing
0
Pitch line velocity, ft/min
7500 5000 2500
K
v
=
A+C
v
t
A
B
A = 50 + 56(1.0 B)
B = 0.25(12 Q
v
)
0.667
C = 1 for v
t
in ft/min
C =
200 = 14.14 for v

t
in m/s
v
t,max
=
1
C
2
[A+ (Q
v
3)]
2
rd
ed.
2014 CRC Press
Design Irocedure 14.2: Melhods lo
Increase ending Ierformance of Gears
If a gear does nol roduce a salisfaclory design based on bending
requiremenls, a design aIleralion may be needed. This is nol aIvays
slraighlforvard, since such aIleralions may heI in one area and hurl in
anolher, and may aecl associaled machine eIemenls such as bearings.
Hovever, some faclors lhal imrove bending erformance are lhe foIIoving:
1. Reduclion in lhe Ioad, such as by increasing conlacl ralio, or aIlering
olher asecls of lhe syslem.
2. Increase lhe cenler dislance.
3. AIy gears vilh a coarser ilch.
4. Use a higher ressure angIe.
5. Use a heIicaI gear inslead of a sur gear.
6. Use a carburized maleriaI.
7. Imrove lhe gear accuracy lhrough manufacluring rocess seIeclion.
8. SeIecl a beuer (slronger) gear maleriaI.
9. Use a vider eeclive face vidlh.
10. AIy shol eening lo lhe leelh.
rd
ed.
2014 CRC Press
Iiuing
Iigure 14.35: A gear shoving exlreme iuing or saIIing. !"#$%&' Courlesy of lhe
American Gear Manufacluring Associalion.
rd
ed.
2014 CRC Press
AGMA Conlacl Slress Iqualion
c
= E
K
o
K
s
K
m
K
v
2
1
2
= p
H
(K
o
K
s
K
m
K
v
)
1
2
Maximum HerL ressure:
Where
Ko, Ks, Km, and Kv are dehned as vilh lhe AGMA ending Slress
Iqualion.
p
H
= E
2
1
2
E
= eective elastic modulus =

2
1
2
a
E
a
+
1
2
b
E
b
W
= dimensionless load =
w
R
x
=
W
E
R
x
b
w
1
R
x
=
1
r
p
+
1
r
g
1
sin
=
1
d
p
+
1
d
g
2
sin
b
= R
x
8W
1/2
rd
ed.
2014 CRC Press
Design Irocedure 14.3: Melhods lo
Increase Iiuing Resislance
If a gear does nol roduce a salisfaclory design based on surface iuing
requiremenls, a design aIleralion may be needed. This is nol aIvays
slraighlforvard, since such aIleralions may heI in one area and hurl in
anolher, and may aecl associaled machine eIemenls such as bearings.
Hovever, some faclors lhal imrove iuing erformance are lhe foIIoving:
1. Reduclion in lhe Ioad, such as by increasing conlacl ralio, or aIlering
olher asecls of lhe syslem.
2. Increase lhe cenler dislance.
3. AIy gears vilh a hner ilch.
4. Use a higher ressure angIe.
5. Use a heIicaI gear inslead of a sur gear.
6. Use a carburized maleriaI.
7. Increase lhe surface hardness by maleriaI seIeclion, or by erforming a
surface hardening oeralion.
8. Imrove lhe gear accuracy lhrough manufacluring rocess seIeclion.
9. Use a vider eeclive face vidlh.
10. Increase lhe Iubricanl hIm lhickness.
rd
ed.
2014 CRC Press
Design Irocedure 14.4: Lubricanl
IiIm Thickness
Il viII be assumed lhal lhe over lransmiued, gear and inion anguIar veIocily, number
of leelh in inion and gear, gear maleriaIs, Iubricanl roerlies, and geomelry of lhe
inion and gear are knovn or can be delermined from design conslrainls. Of lhese, lhe
Iubricanl roerlies, eseciaIIy lhe ressure exonenl of viscosily, are mosl IikeIy lo be
unknovn or viII have lhe Iargesl uncerlainly. RegardIess, lhese roerlies shouId be
auainabIe from lhe Iubricanl suIier.
The normaI force acling on lhe gear leelh can be oblained from Iq. (14.50) as:
The Iubricalion veIocily for lhe inion and gears is oblained from Iqs. (14.29) and (14.30)
as
The eeclive radius is oblained from Iq. (14.74) as
u =
u
p
+ u
g
2
=

p
r
p
sin +
g
r
g
sin
2
W =
W
t
cos
1
R
x
=
1
r
p
+
1
r
g
1
sin
rd
ed.
2014 CRC Press
Design Irocedure 14.4 (concIuded)
5. The eeclive moduIus of eIaslicily is oblained from Iq. (8.16):
6. Ior sleeI-on-sleeI, =' 227.5$ GIa (32.97 Msi).

7. Iqualions (13.68), (13.69), and (13.72) yieId lhe dimensionIess Ioad, seed,
and maleriaIs aramelers as:
8. The Iubricanl hIm lhickness is lhen oblained from lhe Hamrock-Dovson
equalion for reclanguIar conlacls given by Iq.-(13.71):
E
=
2
(1
2
a
)
E
a
+
(1
2
b
)
E
b
W
=
W
b
w
E
R
z
; U =

o
u
E
R
x
; G = E
H
min
=
h
min
R
x
= 1.714(W
)
0.128
U
0.694
G
0.568
rd
ed.
2014 CRC Press
Design Irocedure 14.5: Gear
Design Synlhesis
1. Irom design requiremenls, delermine lhe over lransfer, lolaI Iife
required, and inion and gear seed.
2. The gear ralio, )
$
, musl be knovn from design requiremenls. If lhis vaIue is
near or in excess of 6:1, a second slage is advisabIe.
3. If lhe inion face-lo-diameler ralio is nol a design requiremenl, il can be
eslimaled from lhe foIIoving equalion for sur gears:
Where )
$
*
)
/*
+
is lhe gear ralio.
4. Islimale ,
o
from TabIe 14.8.
b
w
d
p
=
g
r
g
r
+1
,
rd
ed.
2014 CRC Press
Design Irocedure 14.5 (conlinued)
5. The Ioad dislribulion faclor, ,
9
, cannol be delermined unliI knovIedge of
lhe design, manufacluring aroach, and mounling is eslabIished. A
rough aroximalion based on inion lorque can be made according lo
Hovever, if lhe ilch diameler is knovn (from design requiremenls or
seIecled based on exerience), lhen lhe Ioad dislribulion faclor can be
more accuraleIy eslimaled from
RecaII lhal lhe lorque is reIaled lo lhe over by 4
+
>?.
6. The dynamic faclor, ,
1
, deends on gear seed and quaIily. Ior simIicily,
a vaIue of ,
1
1.43 can be assumed, vhich is conservalive for mosl
aIicalions.
K
m
= 1 +
b
w
d
p
0.2 + 0.0112
T
p
K
o
b
w
/d
p
0.33
K
m
= 1 +
b
w
d
p
(0.2 + 0.0012d
p
)
rd
ed.
2014 CRC Press
7. The ressure angIe, @, is generaIIy chosen as 20, since lhese gears are videIy
avaiIabIe. Hovever, lhe ressure angIe can be reduced lo oblain higher
conlacl ralios, or increased vhen recision and noise are nol issues.
RegardIess, il is recommended lhal slandard vaIues of 14.5, 17.5, 22.5, or
25 be used.
8. A geomelry faclor for sur gears is given by:
Where )
$
is lhe gear ralio. Nole lhal lhe Ius sign in lhe denominalor of Iq.-
(14.79) aIies for exlernaI gearsels, lhe negalive sign for inlernaI gearsels.
AB 2
C
can be conservaliveIy eslimaled as aroximaleIy 0.45 (see Iig. 14.30).
10. The Iife faclors 2
D
and 3
D
can be eslimaled from Iig. 14.26.
11. Oblain lhe bending (o
/
) and conlacl (o
%
) slrenglhs for lhe gear maleriaI
according lo Iqs.-(14.45) or (14.46), resecliveIy.
I =
sincos
2
g
r
g
r
1
rd
ed.
2014 CRC Press
12. An eslimale for lhe referred number of inion leelh is lhen:
Ior lhe seciaI case of sleeI gears (I' 227 GIa) a ressure angIe of @20,
,
/
1, D
8%
D
8/
D
8
, and 2
C
0.45, lhe referred number of inion leelh becomes
13. Oblain lhe iuing resislance conslanl:
14. The inion ilch diameler is lhen eslimaled as
N
p
=
1
K
b
Y
j
I
2
c
E
2
n
2
sc
n
sb
N
p
= (101.17 GPa)
g
r
+ 1
g
r
2
c
n
s
K
c
=
0.3183E
h
p
K
o
K
m
K
v
I
p
n
sc
2
d
p
=
K
c
b
w
/d
p
1/3
rd
ed.
2014 CRC Press
Design Irocedure 14.5 (concIuded)
15. The face vidlh can be caIcuIaled from lhe ralio of /
<
/7
+
eslabIished in
sle 3 if a secihc vaIue vas nol secihed as a design requiremenl.
16. When lhe gear rohIe is seIecled from lhis design rocedure, il is
necessary lo anaIyze lhe design more cIoseIy in accordance vilh lhe
aroaches described in Seclions 14.11 and 14.12. This is cIearIy required
since a number of aroximale vaIues vere used.
17. Il shouId aIso be noled lhal an essenliaI arl of lhe gear design synlhesis
is caIcuIaling Iubricanl hIm lhickness as described in Seclion 14.13.
rd
ed.
2014 CRC Press
IM Sur Gear
Manufaclure
Iigure 14.36: Iroduclion of gears lhrough lhe ovder comaclion rocess. (a) Sles
required lo roduce a arl, (b) iIIuslralion of looIing required for a simIe sur gear.
!"#$%&' Afler KaIak|ian and Schmid |2010j.
Compacted
shape
(green)
Upper punch
Lower punch
Powder
Feed
Shoe
(b)
Ejector
Lower punch
PM spur gear
(green)
Core rod
Upper punch
(a)
Die
1. 2. 3. 4.
Die
rd
ed.
2014 CRC Press
Surface Densihed IM Gears
Iigure 14.37: Image of a
IM maleriaI afler roII
densihcalion. Nole lhe
Iov orosily near lhe
surface, resuIling in high
aIIovabIe conlacl slresses.
!"#$%&' Courlesy Caslan
AlIanlic Cor.
Subsurface porosity
Densified surface
100 m
Iigure 14.38: A sleed
gear roduced lhrough
lhe melaI in|eclion
moIding rocess. !"#$%&'
Courlesy Ierry TooI &
Research, Inc.
Iigure 14.39: A coIIeclion
of IM gears used in
aulomolive aIicalions.
!"#$%&' Courlesy Caslan
AlIanlic Cor.

FME3 Ch14

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Fundamentals of Machine Elements, 3

TabIe 14.3: Recommended minimum backIash

AIIovabIe conlacl slress:

Iigure 14.29: Loads and Ienglh dimensions

Lead correclion faclor:

1.0 for uncrowned teeth

Ior 25 mm < bv < 432 mm,

Ior 432 mm < bv s 1020 mm,

Mesh aIignmenl correclion faclor:

0.80 when gearing is adjusted at assembly

Maximum recommended ilch Iine

200 = 14.14 for v

= eective elastic modulus =

The eeclive radius is oblained from Iq. (14.74) as

6. Ior sleeI-on-sleeI, =' 227.5$ GIa (32.97 Msi).

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