Spur gear design

SPUR GEAR
DESIGN PROCEDURE
1.

Determine the speed ratio.

i

Z2
= ----Z1

No. of teeth in gear

-------------------------No. of teeth in pinion

Speed of pinion
------------------Speed of gear

If no value is given assume unity.

2.

Choose suitable material(s) for the gear and pinion [Pg 8.4].
Note ultimate stress, u and yield stress, y for the selected material(s) [Pg 1.9].

3.

Select the tooth profile and pressure angle.

Generally involute profile with pressure angle 14 or 20 is used.

4.

Calculate the design torque (twisting moment).

[Mt]

Mt.k.kd

[Pg 8.15]

Mt Nominal twisting moment transmitted by pinion in kgf.cm

k - Load concentration factor [Pg 8.15, T 14]
kd - Dynamic load factor [Pg 8.15, T 15]
Initially assume k.kd = 1.3.
5.

Calculate the equivalent Youngs modulus. [Pg 8.4, T 9]

2E1.E2
E = -------- kgf/cm2
E1 + E2
E1 & E2 Youngs modulus of pinion and gear materials respectively

6.

Use
b
face width
= -- = -----------------a
centre distance
Initially take between 0.2 and 0.4.

7.

Calculate the design surface contact compressive stress depending on hardness number.
[c] = CB.HB.kcl kgf/cm2

(OR) [c] = CR.HRC.kcl kgf/cm2 [Pg 8.16]

CB or CR factor depending on surface hardness [Pg 8.16, T 16]

HB or HRC Brinell or Rockwell C hardness number [Pg 8.16, T 16]
kcl Life factor [Pg 8.17, T 17]
Pg & T Page & Table numbers respectively in PSG Design Data Book

Spur gear design

8.

Calculate the centre distance.

a (i 1)

0.74 E.[Mt]
------ -------[c]
i.

[Pg 8.13, T8]

+ for external and - for internal

9.

Calculate the design bending stress (tension).

1.4 kbl
[b] = ------- -1
n.k

[Pg 8.18]

kbl Life factor for bending [Pg 8.20, T22]

k - Fillet stress concentration factor [Pg 8.19, T21]
-1 Endurance limit stress in bending for complete reversal of stress [Pg 8.19, T19]
10. Determine the minimum value of the module.
[Mt]
m 1.26 --------------[b].Y.m.Z1

[Pg 8.13, T 8]

Y Form factor [Pg 8.18, T18]

m = (b/m) = 10 initially
Z1 Minimum number of teeth for pinion
Take the nearest standard module [Pg 8.2, T1]

11. Determine the number of teeth for pinion.

2a
Z1 = -----------(i + 1) m

[Pg 8.22]

12. Calculate the number of teeth on gear.

Z2 = i.Z1
13. Calculate the (pitch circle) diameters and determine the centre distance.
d1 + d2
a = --------2

d1(pinion) = m.Z1
d2(gear) = m.Z2

14. Determine face width.

Select the higher value of b given by expressions: b = .a ; b = m.m.

Pg & T Page & Table numbers respectively in PSG Design Data Book

Spur gear design

15. Calculate the pitch line velocity.

.d1.n1
v = ---------- m/s
60x100

(d1 in cm)

16. Determine the design torque.

[Mt] = k.kd
k [Pg 8.15, T14] ; kd [Pg 8.16, T15]
17. Check for compressive stress [Pg 8.13, T8].
i1
i1
c = 0.74 ------- -------- E.[Mt]
a
i.b

[c]

18. Check for bending stress [Pg 8.13, T8].

i1
b = ----------- [Mt]
a.m.b.y

[b]

19. Check for plastic deformation or brittle crushing.

(Mt)max instantaneous maximum due to

starting, sudden stopping, etc.

Under surface contact stress

c max = c

(Mt)max
----------

[Pg 8.21]

[c]max

[c]max

max allowable surface contact

stress to avoid plastic
deformation or brittle crushing
[T 24]

[b]max -

max allowable bending stress

to avoid plastic deformation or
brittle crushing [T 25]

Mt
Under bending
b max = b

(Mt)max
----------

[b]max

Mt
20. Calculate the teeth dimensions.
fo = 1 for full depth
fo = 0.8 for stub teeth

Addendum = fo.m

Height factor

Dedendum = fo + c

c = 0.25m for full depth

Clearance factor c = 0.3m for stub teeth

Total height = addendum + dedendum

Top circle diameter = Pitch circle diameter + 2(addendum)

Pg & T Page & Table numbers respectively in PSG Design Data Book