Gear Design

50T
4

Problem: Pinion 2 is shown in the figure

3

Output
(gear)

runs at 1750 rpm and transmits 2.5 kW to

60T

idler gear 3. The teeth are cut on the 200

20T

full-depth system and have a module of

2
Input
(pinion)

m = 2.5 mm.

a) Draw a free-body diagram of gear 3 and show all the forces and compute the torques on
the output gear 4
dp

T = Wt

Wt : tangential force

dp : pitch diameter

H = T *

H = Wt *

H: Power
: angular rotation

d p 2

*
*2
2 60

(rev/min) =

H =

(rev/sec)

60

d p *

= 2

*W

60

(rad/sec)

where,

60 * 10

H : (kN)

2 : (rev/min)
dp : (mm)
Wt : (kN)

60 * 10

* H

dp= N*m:
2

N: number of teeth
m: module (mm)

60 * 10

* H

(N * m )*

60 * 10

* ( 2 .5 )

= 0.546 kN

( 20 * 2 . 5 ) * 1750

Thus, the tangential force of gear 2 on gear 3 is 0.546 kN. The radial force is;
W

= W t * tan 20

= 0 . 546 * tan 20

= 0 . 199 kN

The tangential reaction of gear 4 on gear 3 is also equal to Wt

Wt
Gear
3

Fx
Fy

Wr

Wt
Wr

Forces on shaft of gear 3;

FX = - ( - 0.546 + 0.199) = 0.347 kN
FY = - ( 0.199-0.546 ) = 0.347 kN
The output Torque:

4 r2 N 2
= =
2 r4 N 4
N
N

= (

N
N

2
3

) * (

N
N

T2 = Wt * r2
T4 = Wt * r4
2

3
4

) =

20
60

T4 =

r4
N
* T2 = 4 * T2
r2
N2

T4 =

60
50
* T2 = 3 * (0.546 * )
20
2

T2 =13.65 Nm
T4 =40.95 Nm

b) Compute the mean and alternating loads on 1) pinion, 2) gear and, 3) idler.

The repeated loads on pinion and gear:

R=0=

min
max

(since min = 0 )

Wt 0.546
=
= 0.273 kN
2
2
W 0.546
Wtalternating = t =
= 0.273 kN
2
2
Wtmean =

The fully-reversed loads on the idler:

min
max
= max

R = -1 =

min

Wtalternating = Wt = 0.546 kN
Wtmean = 0 kN

c) Determine a suitable face width and the bending stresses in the idler gear (3)

b =

Wt * Pd K a * K m
*
* KS * KB * KI
F*J
Kv

Recommended face-width range is

Pd

<F<

Take

16
Pd

F=

Pd = diametral pitch = 25.4/m

12
Pd

8m
16m
<F<
25.4
25.4

( SI units )

The relation between Pd (U.S. specification) and the module m (S.I. unit) is

25.4
= 2.5 mm/teeth
Pd
Hence, Pd = 10.16 teeth/inches.
m=

The face width (F):

12
F=
= 1.81 inches = 3 cm = 30 mm
10.16

The load distribution factor (Km)

4

Using Table 11 16
Km=1.6

(for F=1.81 inches = 30 mm)

The application factor:

(assume uniform loading; table 11 -17)
Ka = 1
The velocity factor:

A
KV =
A + 200 * V
t

Vt : pitch-line velocity
dp
d
Vt =
* = 3 * 3
2
2
Gear 3:
d3 = m N3 = 2.5*50 = 125 mm
N
3 = 2 * 2
N3
20
3 = * 1750
50
rev
3 = 700rpm *
min
2
3 = 700 *
= 73.266 rad/sec
60

Vt = 4.58 m/s = 274.76 m/min

Note that Vt ( ft / min) = Vt (m / sec) *196.85
Vt = 901.5 ft/min

since 1 ft = 12 inches = 30.48 cm

The quality index (Qv)

Using Table 11-7 (page 710)
Vt
Qv
0- 800
6-8
901.5 ft/min ?
800-2000
8-10

Take Qv = 8

(12 8) 2 / 3
= 0.63
4
A = 50 +56(1-B) =7 0.72
B=

70.72
KV =

70.72 + 200 * 4.58

0.63

= 0.8

The size factor KS=1 for all gears

The rim thickness factor KB= 1

(assume no rim)

The idler factor KI = 1 for gears 2 and 4, KI = 1.42 for the gear 3.
The bending geometry factor J for 200 presume angle (full depth teeth with HPSTC
loading)
pinion : 20 T (200)
gear : 60 T (200)
idler : 50 T (200)

First, calculate the Jpinion, and Jgear based on pinion (gear 2 in the figure) and idler (gear 3
in the figure) interactions:

idler
(gear)

50T

20T

pinion

Using Table 11- 9 (p.716)

Jpinion 0.34
Jgear(idler) 0.39

b =

Wt * Pd K a * K m
*
* KS * KB * KI
F*J
Kv

since F=

b =

12
Pd

Wt * Pd2 K a * K m
*
* KS * KB * KI
12 J
Kv

also,
Pd =

25.4
m

25.4
Wt *

m * Ka * Km * K * K * K
b =
S
B
I
12 J
Kv

b =

Wt * (53.76) K a * K m
*
* KS * KB * KI
Kv
m2 * J

m = 2.5 mm
then

b is in MPa

Wt = 0.546 kN

pinion

b
b

gear

0.546 * (53.76) 1 * 1.6

*1 *1 *1
*
0. 8
( 2.5) 2 * (0.34)

= 27.63

pinion

pinion

MPa

0.546 * (53.76) 1 * 1.6

*
* 1 * 1 * 1.42
( 2.5) 2 * (0.39)
0 .8

= 34.2

MPa

Second, calculate the Jpinion, and Jgear based on idler (3) and gear (4) interactions:

60T

Using Table 11- 9 (p.716)

50T

Jpinion(idler) 0.42
Jgear 0.43

gear

idler

Note: The idler has a slightly different J factor when considered to be the gear in mesh with
the smaller pinion (0.42) than when considered to be the pinion in mesh with the larger gear
(0.43).

idler

0.546 * (53.76) 1 * 1.6

*
* 1 * 1 * 1.42
2
0.8
(2.5) * (0.42)

= 31.75 MPa

gear

0.546 * (53.76) 1 * 1.6

*
*1 *1 *1
2
0 .8
(2.5) * (0.43)

= 21. 84 MPa

d) All gears are made of steel (AGMA grade 2 with Brinell Hardness number of 250 HB).
The service life required is 5 years of one-shift operation. Operating temperature is 2000 F.
Calculate the safety factor for bending stress (Assume 99 % reliability).

Sf b=

KL
* S f b
KT * K R

S f b = 280 MPa

(from the Figure 11-25, pp.733 for HB = 250)

piniom =1750 rpm

idler =700 rpm
gear =583.3 rpm

60 min
2080hr
*
* 5 yr
hr
shift year
=1.092*109 cycles

N pinion = 1750rpm
N pinion

Nidler = 0.4368*109 cycles

8

Ngear = 0.364*109 cycles

The life factor:
KL(pinion)= 1.3558*N-0.0178

(Fig. 11-24, N>108 commercial app)

= 0.936
KL(idler) = 0.951
KL(gear) = 0.955
The temperature factor:
KT=1

(T<2500)

The reliability factor:

KR=1

(%99 reliability)

262
= 9.48
27.63

S f b pinion = 262 MPa

N b pinion =

S f b idler = 266 MPa

N b idler =

266
= 7.77
34.2

S f b gear = 267.4 MPa

N b gear =

267.4
= 12.24
21.84

Hence, idler is the most critical (it is exposed to fully reversed stresses).

e) Determine the surface stresses for

1) pinion- idler mesh
2) idler-gear mesh
and the safety factor for surface stresses.

c = cp

Ca * Cm * Cs * C f

F *I *d

Cv

Ca = Ka = 1
Cm = Km = 1.6

Cv = Kv = 0.8
F = 30 mm
Notes:
d (pitch diameter) is the smaller of mating gears
I is the smaller of mating gears
Be careful with the +/- signs in equations 11.22a and 11.22b.
Eq. 11.22a (+ : external, -: internal)
Eq. 11.22b (- : external, +: internal)

Cs= 1 (size factor)

Cf = 1 (surface finish factor)
The elastic coefficient:
Cp =

1
1 v

2
p

E p

1 v g2
)+(
)
E g
v =0.3

All gears are made of steel

(Table 11-18 assumes that v = 0.3)

Ep = 30*106 psi = 2*105 MPa

Instead of calculating the Cp using the equation; you can directly get the value from the table if
the material is available.
UNIT
pinion
steel
gear

Cp=2300

psi

Cp=191

MPa

steel

Surface Geometry Factor (I)

I=

cos
1
1

*d

p
p g

p = (rp +

1+ xp
pd

use + sign for external gears and - for internal gears

) 2 (rp * cos ) 2

g = c sin m p

pd

* cos

-: external gears

10

+ : internal gears

pinion-idler mesh
rp=

dp
2

ridler=

m * N pinion
2

2.5 * 20
= 25 mm
2

d idler 2.5 * 50 125

=
=
mm
2
2
2

= 20 0
m=

25.4
pd

Pd =

25.4
= 10.16
m

The pinion addendum coefficient xp= 0

(xp= 0 for full-depth teeth and xp= 0.25 for 25 % long-addendum teeth)

p = (25 +

1
10.16

) 2 (25 * cos 20 0 ) 2

10.16

p = 8.54 mm
gear = c sin 1 = (25 +
gear =21.39 mm
I=

cos
1
1

*d
+
p

p g

125
) * sin 20 0 8.54
2

= 0.115

Idler gear mesh

idler
125
rp=
m
2
150
rp=
mm
2
= 20 0

11

* cos 20 0

 p = (62.5 +

1
10.16

) 2 (62.5 * cos 20 0 ) 2

10.16

* cos 20 0

p =21.37 mm
g = c sin m p = (62.5 + 75) * sin 20 0 21.37
g = 25.7 mm
Iidler(pinion) =

cos
= 0.175
1
1
+

* 62.5
21.37 25.7

The surface stress for pinion-idler mesh:

cp = c p

Ca * Cm * C s * C f

F * I pinion * d p

Cv

0.546 *10 3 N 1 * 1.6 * 1 *1

30 * 0.115 * 50
0.8
cp = 480.56 MPa
= 191 *

The surface stress for idler-gear mesh:

cidler = 191 *

0.546 * 10 3 1 *1.6 *1 *1
30 * 0.175 * 62.5
0.8

cidler = 348.4 MPa

Sfc=

CL * CH
* S'f c
CT * C R

S ' f c 820MPa

(for HB= 250 and Grade II ) Table 11-27, page 737

CT=1

(T< 2500 F)

CR=1

(%99 reliability)

CH=1

(Hardness Ratio factor)

12

C L pinion = 1.4488 N 0.023 = 1.4488(1.092 *10 9 ) 0.023

(Fig. 11-26, pp.734)

=0.898
C L idler = 0.917
C L gear = 0.92

= 820 * 0.898 = 736MPa

Sfc

pinion

Sfc

idler

Sfc

gear

=752 MPa
= 754 MPa

N c pinion idler

736
=
= 2.4
480.56
2

N c idler gear

752
=
= 4.7
348.4

Hence; pinion-idler surface is more critical.

Note: we take the square of the safety factor because the surface stress is related to the
square root of the load.

13