M E C H A N I C A L E Q U I P M E N T D E S I G N

G E A R S
Classification:
1) According to the position of axis of shafts :
a)Parallel:
Spur gears
Helical gears (teeth are inclined to the axis)
b) Non parallel or intersecting(coplanar): Bevel gears
c) Non parallel and non intersecting(spatial):
Ske bevel gears or spiral gears
!or" gears are also classified as spiral gears in hich shafts are usuall#
perpendicular$
%) According to the peripheral velocit#:
a) &o velocit#: &ess than ' "(s
b) )ediu" velocit#: Beteen '"(s and 1* "(s
c) High velocit#: +reater than 1* "(s
') According to t#pe of gears:
a) ,xternal gears: +ears "esh externall#
b) -nternal gears: +ears "esh internall#
c) .ack and Pinion: +ear "esh internall# and externall# in a straight line
/) According to the position of teeth on the gear surface:
a) Straight: Spur
b) -nclined: Helical
c) 0urved: Spiral
Beam strent! of ear toot!" Le#is e$%ation:
1he strength of gear is deter"ined b# &eis b# taking the tooth as a bea"2 shon
in the figure$1$ 1he e3uation given b# &eis is used for deter"ining the si4e and
proportions of gears$


,ach tooth is considered as a cantilever bea" loaded b# a nor"al load !N$ -t is
resolved in to tangential load !1 and radial load !. perpendicular and parallel to the
central line of the tooth$

&eis e3uation to calculate the "axi"u" bending stress or per"issible orking stress at
critical section B0 is given b#

I
My
w
=
) 5 )axi"u" bending "o"ent at critical section B0
5 !1h
!1 5 1angential load
h 5 length of tooth
# 5 t(%
t 5 thickness of tooth
- 5 )o"ent of inertia about the central line of tooth
5 bt
'
(1%
b 5 face idth
No 6 5 7!1h(bt
%
!1 5 6 bt
%
( 7h
1hickness and length depend on the si4e and profile of tooth$ i$e$2 circular pitch$
t 5 xpc and h 5 kpc
T
W
5 6 bpc x
%
( 7k

# 5

x
%
( 7k

Here # is knon as &eis for" factor or tooth for" factor$ 8 and k are constants$
# depends on nu"ber of teeth and s#ste" of teeth$
# 5 9$1%/ : 9$7;/(1 ( for 1/ <
9
co"posite and full depth involute s#ste")
5 9$1*/ : 9$=1%(1 ( for %9
9
full depth involute s#ste")
5 9$1>* : 9$;/1(1

( for %9
9
stub s#ste")
BARTH &'RMULA: 1he per"issible orking stress in the &eis e3uation depends
upon the "aterial for hich an alloable stress "a# be deter"ined$ 1he alloable stress
is the stress at the elastic li"it of the "aterial$ -t is also called basic stress$ -n order to
account for the d#na"ic effects2 hich beco"e "ore severe as the pitch line velocit#
increases2 the value of orking stress is reduced$
According to Barth for"ula2 the per"issible orking stress2

v o w
C =
!here 6o 5 Alloable static stress
0v 5 ?elocit# factor
5
v + '
'
2 for ordinar# cut gears operating at velocities up to 1%$* "(s

5
v + * $ /
* $ /
$ @or carefull# cut gears operating at velocities up to 1%$* "(s
1he above factor depends on precision and accurac# of gears and velocit#$ 1he alloable
static stress depends on the "aterial of gears$ -t is approxi"atel# oneAthird of the ulti"ate
tensile strength for steel gears$
D(NAMIC T''TH L'AD"BUC)INGHAM EQUATI'N:
1he d#na"ic loads are also due to the folloing reasons2 in addition to velocit#:
1$ -naccuracies of tooth spacing2
%$ -rregularities in tooth profiles2 and
'$ Beflections of teeth under load
1he d#na"ic load is the su" of stead# load due to trans"itted tor3ue and incre"ental
load due to d#na"ic action i$e$2
!B 5 !1 C !-
!- 5
T
T
W bC v
W bC v
+ +
+
%1
) ( %1
!here !B 5 1otal d#na"ic load in Netons$
!15 Stead# trans"itted load in Netons
v5 Pich line velocit# in "(s
b5 face idth in ""2 and
05Befor"ation or d#na"ic factor in N(""
1he defor"ation factor depends on error in action beteen teeth2 the class of cut of the
gears2 the tooth for" and the "aterial of gears$
1he value of 0 depends upon the error "a# be deter"ined b# the relation:

G P
E E
e K
C
1 1
$
+
=
,P 5 )odulus of elasticit# for the "aterial of pinion in Pa
,+ 5 )odulus of elasticit# for the "aterial of gear in Pa
e 5 1ooth error in action
k 5load stress factor
1he "axi"u" alloable tooth error in action depends upon the pitch line velocit# and
the class of cut of the gears$
STATIC T''TH L'AD:
1he static tooth load2 hich is also called bea" strength or endurance strength is obtained
b# &eis for"ula b# substituting flexural endurance li"it or elastic li"it stress 6c in
place of per"issible orking stress 6$
Static tooth load !S 5 6e b pc #

@or safet# against tooth breakage2 the static tooth load should be grater than the d#na"ic
load$
*EAR T''TH L'AD:
1he "axi"u" load that gear teeth can carr# ithout pre"ature ear depends upon the
radii of curvature of tooth profiles and on the elastic and surface fatigue li"its of the
"aterials$ 1he "axi"u" or the li"iting load for satisfactor# ear of gear tooth is
obtained b# the e3uation2
bQK D W
P w
=
! 5 )axi"u" or li"iting load for ear in Netons
BP 5 Pitch circle dia"eter of the pinion in ""
b 5 face idth of the pinion in ""
D 5 .atio factor
5
1
%

VR
VR
5
P G
G
T T
T

%
2 C for external gears
E for internal gears
F 5 &oad stress factor
+
)
1 1
(
/ $ 1
sin ) (
%
G P
es
E E
+

6es 5 Surface endurance li"it in )Pa or N(""
%
$

5 Pressure angle
,P 5 GoungHs "odulus for the "aterial of the pinion in N(""
%
,+ 5 GoungHs "odulus for the "aterial of the gear in N(""
%
Note:
1$
1he surface endurance li"it for the steel "a# be obtained fro" the folloing
e3uation: 6es 5 (%$; B$H$N$A>9) N(""
%
%$
1he "axi"u" li"iting ear load "ust be greater than the d#na"ic load$
Ca%ses of Gear Toot! &ail%re:
S$NI$ 1#pe of failure Possible re"edies
1$ Ben,in fail%re: As ever# tooth acts as a
cantilever$ -f the total repetitive load acting on the
gear tooth is greater than the bea" strength of the
gear tooth2 then the gear tooth ill fail in bending2
i$e$2 gear tooth ill break
1he "odule and face idth
of gear "ust be adJusted so
that the bea" strength of
gear tooth is greater than
the d#na"ic load$
%$ Pittin: -t is the surface fatigue failure hich
occurs due to repetition of contact stresses$ 1he
failure occurs hen the surface contact stresses are
higher than the endurance li"it of the "aterial$ 1he
failure starts ith the for"ation of pits hich
continue to gro resulting in the rupture of the
tooth surface$
1he d#na"ic load should
be less than the ear load$
'$ Scorin: 1he excessive heat is generated hen
there is a excessive surface pressure2 high speed or
suppl# of lubricant fails$ -t is a stickAslip
pheno"enon in hich alternate shearing and
elding takes place rapidl# at high spots$
1he lubricant suppl#
para"eters such as speed2
pressure and flo "ust be
properl# designed so that
the te"perature at the
rubbing faces is ithin the
per"issible li"its$
/$ A-rasi.e #ear: 1he foreign particles in the
lubricants such as dirt2 dust or burr enter beteen
the tooth and da"age the for" of tooth$
@ilters for the lubricating
oil or high viscosit#
lubricant should be used
hich enables for"ation of
thick oil fil" and hence
per"its eas# passage of
dirt ithout da"aging the
gear surface$
*$ Corrosi.e #ear: 1he corrosion of the tooth
surface is "ainl# caused due to the presence of
corrosive ele"ents such as additives present in
lubricating oils$
Proper antiAcorrosive
additives should be used$
P R ' B L E M S
1$ A bron4e spur pinion rotating at 799 rp" drives a cast iron spur gear at a
trans"ission ratio of /:1$ 1he alloable static stresses for the bron4e pinion and
cast iron gear are ;/ )Pa and 19* )Pa respectivel#$ 1he pinion has 17 standard
%9
9
full depth involute teeth of "odule ; ""$ 1he face idth of both the gears is
=9 ""$
@ind the poer that can be trans"itted fro" the stand point of strength$
1he service factor is e3ual to one$ 1he tooth for" factor can be taken as
# 5 9$1*/ : 9$=1%(1
and the velocit# factor as
0v 5
v + '
'
%$ A pair of straight teeth spur gears is to trans"it %= F hen the pinion rotates at
'99 rp"$ 1he velocit# ratio is 1:'$ 1he alloable static stresses for the pinion and
gear "aterials are 1%9 )Pa and 199 )Pa respectivel#$ 1he pinion has 1* teeth
and its face idth is 1/ ti"es the "odule$ Beter"ine "odule2 face idth and pitch
circle dia"eters fro" the stand point of strength onl#2 taking into consideration
the effect of d#na"ic loading$
1he service factor is e3ual to one$ 1he tooth for" factor can be taken as
# 5 9$1*/ : 9$=1%(1
and the velocit# factor as
0v 5
v + '
'
'$ A gear drive is re3uired to trans"it a "axi"u" poer of %%$* F$ 1he velocit#
ratio is 1:% and speed of pinion is %99 rp"$ 1he approxi"ate centre distance
beteen the shafts "a# be taken as 799 ""$ 1he teeth has %9
9
stub involute
profiles$ 1he static stress for the gear "aterial2 hich is cast iron "a# be taken as
799 )Pa and face idth as 19 ti"es the "odule$ @ind the "odule2 face idth and
nu"ber of teeth on each gear$
0heck the design for d#na"ic and ear loads$ 1he defor"ation factor and load
stress factors "a# be taken as ;9 and 1$/ respectivel#$
/$ 0alculate the poer that can be trans"itted safel# b# a pair of spur gears ith the
data given belo: /Ta0e 1elocit2 factor + 34/35.66
Nu"ber of teeth on pinion 5 %9
Nu"ber of teeth on gear 5 ;9
)odule 5 / ""
@ace idth 5 79 ""
1ooth profile 5 %9
9
involute
Alloable bending strength of the "aterial
5 %99 )Pa2 for pinion
5 179 )Pa2 for gear
Speed of the pinion 5 /99 rp"
Service factor 5 9$;
&eis for" factor 5 9$1*/A 9$=1%(1

Desin Proce,%re for S7%r Gears
Ste7 8: @ist of all2 the design tangential tooth load is obtained fro" the poer trans"itted
and the pitch line velocit# b# using the relation:

v
PC
W
s
T
=
!1 5 Per"issible tangential tooth load in Netons$
P 5 Poer trans"itted in !atts$
? 5 Pitch line velocit# in "(s$
0S 5 Service factor$
1al%es of Ser.ice factor
T27e of loa, 3 !rs4,a2 9"8: !rs4,a2 ;< !rs4,a2
Stead# 9$; 1$99 8=;>
&ight shock 1$99 1$%* 8=><
)ediu" shock 1$%* 1$*/ 8=9:
Hea.2 s!oc0 8=>< 8=9: ;=::
Note: 1he above values are for enclosed and ell lubricated gears$ -n case of nonAclosed
and grease lubricated gears2 the above values should be divided b# 9$7*$
Ste7 ;: Appl# the &eis e3uation as follos:

y bp W
c w T
=
Note:
1$ 1he &eis e3uation is applied onl# to the eakest of the to heels$
%$ !hen both the heels are "ade of the sa"e "aterial2 the pinion is the eakest$
'$ !hen the# are "ade of different "aterials2 calculate the strength factor of both
the heels$
/$ Strength factor is e3ual to the product of ?# and for" factor 2=
*$ &eis e3uation is used to that heel for hich strength factor is less$
7$ @ace idth "a# be taken as %pc to 'pc for cast teeth and 'pc to /pc for cut teeth$
Ste7 3: 0alculate the d#na"ic load on the tooth b# using Buckingha" e3uation2 i$e$2
!B 5 !1 C !-
!- 5
T
T
W bC v
W bC v
+ +
+
%1
) ( %1
!1 5 P(v
Ste7 <: @ind the static tooth load (bea" strength or the endurance strength) b# using the
relation
!S 5 6e b pc #
Note: @or safet# against breakage2 !S should be greater than !B$
Ste7 >: @inall#2 find the ear tooth load b# using the relation2

bQK D W
P w
=
Note: ! should not be less than !B$