Machine Design II Prof. K.Gopinath & Prof. M.M.

Mayuram

Module 2 - GEARS

Lecture 10 - SPUR GEAR DESIGN

Contents

10.1 Problem 3 Spur gear design

10.1.1 Buckingham Approach

10.1.2 AGMA Approach

10.1 Problem 3 - Design of Spur gear

A pair of gears is to be designed to transmit 30kW power from a pinion running at

960rpm to a gear running at 320rpm. Design the gears so that they can last for 108

cycles. Assume 20o full depth involute spur gear for the system. Motor shaft diameter is

30mm.

Data given:

W = 30 kW; n 1 = 960 rpm; n 2 = 320 rpm; Life = 108 cycles; 20o full depth involute spur

gear.

Solution:

i = n 1 / n 2 = 960 / 320 = 3

In order to keep the size small and meet the centre distance, Z 1 = 17 chosen

Z 2 = i Z 1 = 3 x 17 = 51

2n1 2 x  x 960
  100.48 rad/s
60 60

Torque is given by,

w 30x1000
T1    298.57 Nm
 100.48

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

From Lewis equation for pinion we have,

Ft 2T1 (10.1)
p    []p
b Y m bYZ1m 2

SAE 1050 hardened by OQT with permissible bending strength of 532 and hardness of

223Bhn is selected for pinion and SAE 1045 hardened by WQT with permissible

bending strength of 487 and hardness of 215 Bhn is selected for the gear from Table

10.1. Face width b = 10m is chosen for both wheels.

Table 10.1 Safe static stresses for use in the Lewis equation

Material [σ ] MPa BHN

Gray cast iron

ASTM 25 122 174
ASTM 35 183 212
ASTM 50 228 223

Cast steel(low carbon)

0.2% C not heat treated 304 180
0.2% C WQT 380 250

Forged carbon steel

SAE 1020 case hardened and WQT 274 156
SAE 1030 not heat treated 304 180
SAE 1035 not heat treated 350 190
SAE 1040 not heat treated 380 202
SAE 1045 hardened by WQT 456 205
SAE 1045 hardened by WQT 487 215
SAE 1050 hardened by OQT 532 223

Alloy steel
SAE 2320 case hardened and WQT 761 225
SAE 2345 hardened by OQT 761 475
SAE 3115 case hardened and OQT 563 212
SAE 3145 hardened by OQT 806 475
SAE 3245 hardened by OQT 989 475
SAE 4340 hardened by OQT 989 475
SAE 4640 hardened by OQT 837 475
SAE 6145 hardened by OQT 1019 475

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

10.1.1 Buckingham approach:

The preliminary dimensions are found from Lewis equation and then they are checked

for dynamic loads by Buckingham equation.

From equation (10.1) substituting the value of b = 10m, we have,

T1
p   []p (
5YZ1m3 (10.2)

From Table 10.2, for the pinion Y = 0.25808 for Z 1 = 17

For the gear, Y = 0.39872, for Z 2 = 51

For gear, Y[σ] g = 0.39872x 487 = 194.17

For pinion, Y[σ] p = 0.25808 x 542 = 139.87

Table 10.2 Values of the Lewis form factor Y

Number of Φ=20 Φ=20 Φ=25

teeth a=0.8m* a=m a=m
b=m b=1.25m b=1.25m
12 0.335 12 0.229 60 0.276 77
13 0.348 27 0.243 17 0.292 81
14 0.359 85 0.255 30 0.307 17
15 0.370 13 0.266 22 0.320 09
16 0.379 31 0.276 10 0.331 78
17 0.387 57 0.285 08 0.342 40
18 0.395 02 0.293 27 0.352 10
19 0.401 79 0.300 78 0.360 99
20 0.407 97 0.307 69 0.369 16
21 0.413 63 0.314 06 0.376 71
22 0.418 83 .0319 97 0.383 70
24 0.428 06 0.330 56 0.396 24
26 0.436 01 0.339 79 0.407 17
28 0.442 94 0.347 90 0.416 78
30 0.449 20 0.355 10 0.425 30
34 0.459 20 0.367 31 0.439 76
38 0.467 40 0.377 27 0.451 56
45 0.478 46 0.390 93 0.467 74
50 0.484 58 0.398 60 0.476 81
60 0.493 91 0.410 47 0.490 86
75 0.503 45 0.422 83 0.505 46
100 0.513 21 0.435 74 0.520 71

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Hence, for the same face width pinion will be weaker and consideration for the design

is,

T 298.57 x1000 13610

p  3
 3

5YZ1m 5x0.25808 x17m m3
 532 MPa
(10.3)

m = 2.93 mm. Since motor shaft diameter is 30 mm, to get sufficiently large pinion m = 4

mm is taken.

Table 10.3 Data for pinion and gear

Wheel Z m b=10m d V =wrv Material Hardness

Pinion 17 4mm 40 mm 68mm 3.42 m/s SAE1050 223

Gear 51 4mm 40 mm 204mm 3.42 m/s SAE1045 215

We will now use Buckingham dynamic load approach for the design.

F t = T 1 /r 1 = 298.57/0.034 = 8781 N

Buckingham dynamic load is given by,

 9.84V (Cb + Ft ) 
Fi    (10.4)
 9.84V +0.4696 Cb+ Ft 

For V=3.42 m/s permissible error is e= 0.088 mm from Fig.10.1. From Table 10.4, if we

choose I class commercial cut gears, expected error is 0.050 for m=4mm. In order to

keep the dynamic load low precision cut gears are chosen. So, e = 0.0125

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig. 10.1 Permissible error

Table 10.4 Expected error in tooth profile

Gear quality and expected error e
Module First class commercial Carefully cut gears Precision gears
gears
Up to 4 0.050 0.025 0.0125
5 0.056 0.025 0.0125
6 0.064 0.030 0.0150
7 0.072 0.035 0.0170
8 0.080 0.038 0.0190
9 0.085 0.041 0.0205
10 0.090 0.044 0.0220

Table 10.5 Value of C

Tooth form Material of pinion and C
gear
14.5o Cast iron and cast iron 5720 e
steel and cast iron 7850 e
steel and steel 11440 e
20o Full depth Cast iron and cast iron 5930 e
steel and cast iron 8150 e
steel and steel 11860 e
20o Stub Cast iron and cast iron 6150 e
tooth steel and cast iron 8450 e
steel and steel 12300 e

From Table 10.5, if material for both gear and pinion are steel, then,

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

C = 11860e = 11860 x 0.0125 = 148.25

Substituting the values F t = 8781 N, C = 148 .25, V=3.42 m/s, b= 40mm in eqn. (10.4),

Buckingham dynamic load is given by,

 9.84x3.42(148.25x40 +8781) 
Fi     5464N
 9.84x3.42+0.4696 148.25x40+8781  (10.5)

F d = F t + F i = 8781 + 5464 = 14245 N

Beam strength of the pinion is given by,

F tp = bYm [σ] p = 40x0.25808 x4x542 = 22381 N

Since F tp (22381)> F d (14245) the design is safe from tooth bending failure

consideration.

Wear strength of the pinion is given by,

2
 [ ] 
Fts  bd1 I  H  (10.6)
 
 Cp 

From Table 10.6 for steel vs steel, pinion and gear C p = 191 MPa0.5 and substituting i

=3, Ф=200 we

sin  cos  i sin 20o cos 20o 3

I   0.1205
2 i 1 2 3 1

Table 10.6 Elastic coefficient C p for spur gears in MPa0.5

Pinion Material Gear Material

(µ=0.3 in all cases)
Steel Cast iron Al Bronze Tin Bronze

Steel, E=207 GPa 191 166 162 158

Cast iron, E=131 GPa 166 149 149 145

Al Bronze, E=121 GPa 162 149 145 141

Tin Bronze, E=110 158 145 141 137

GPa

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Surface fatigue strength of the pinion material is σ sf = σ sf ’ K L K R K T

σ sf ’ = 2.8(Bhn) – 69MPa

= 2.8 x 223-69 = 555.4MPa

K L = 0.9 for 108 cycles life from graph1

K R = 1.0 taken for 99 reliability

K T = 1.0 for operating temperature <120oC (assumed)

Table 10.7 Surface fatigue strength σ sf ’ (MPa) for metallic spur gears (107 cycle
life 99% reliability and temperature <120oC)

Material σ sf ’(MPa)

Steel 2.8 (Bhn)-69MPa

Nodular iron 0.95(2.8(Bhn)-69MPa)

Cast iron, grade 20 379

Cast iron, grade 30 482

Cast iron, grade 40 551

Tin Bronze, AGMA 2C (11% Sn) 207

Aluminium Bronze (ASTM 148 – 52) (Alloy 9C – H.T.) 448

Fig.10.2 Life factor K L

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Table 10.8 Reliability factor K R

Reliability (%) KR

50 1.25

99 1.00

99.9 0.80

Surface fatigue strength of the pinion material is σ sf = σ sf ’ K L K R K T

= 555.4x0.9x1x1 = 500MPa

Assuming, factor of safety, s = 1.1

[σ H ] = σ sf /s = 500/1.1 = 455MPa

Wear strength of the pinion is:

2
 [σ ]   455 
2

Fts = bd1 I  H  = 40x68x0.1205   =1860 N

 Cp   191 
 

Since F ts (1860) << F d (14245), the design is not safe. Revision is necessary.

As the SAE1050 can attain a hardness of 800 VPN(~750 Bhn) after oil quenching,

increase the hardness to 475 Bhn and increase the b to 13m = 13 x 4 = 52 mm.

From Table 10.7, we know that,

σ sf ’ = 2.8(Bhn) – 69MPa

= 2.8 x 475-69 = 1261MPa

K L = 0.9 for 108 cycles life from Fig.10.1

K R = 1.0 taken for 99 reliability

K T = 1.0 for operating temperature <120oC Assumed.

Surface fatigue strength of the pinion material is σ sf = σ sf ’ K L K R K T

= 1261x0.9x1x1 = 1135MPa

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig.10.3 Effect of carbon content on the hardness of fully hardened steel

Assuming factor of safety, s = 1.1

[σ H ] = σ sf /s = 1135 /1.1 = 1032MPa

2
 [σ ]   1032 
2

Fts = bd1 I  H  = 52x68x0.1205   =12439 N

 C   191 
 p 

Since F ts (12439)< F d (14245), still it is not safe. Hence increase the module to 5mm.

Table 10.9 Properties of pinion and gear

Wheel Z m b=13m d V =wrv Material Hardness

Pinion 17 5mm 65 mm 85mm 4.27 m/s C 50 475

Gear 51 5mm 65 mm 255mm 4.27 m/s C 45 450

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

With new dimensions F d = 16098 N

F ts = 19436 N. Since F ts > F d , the revised design is safe from surface fatigue (pitting)

considerations.

If b = 50 mm, F d = 13186 N

F ts = 14951 N , Face width of 50 mm is adequate

10.1.2 AGMA Approach

Data given:

W = 30 kW; n 1 = 960 rpm; n 2 = 320 rpm; Life = 108 cycles; 20o full depth involute spur

gear.

Solution:

i = n 1 / n 2 = 960 / 320 = 3

In order to keep the size of gears small and avoid interference, Z 1 = 17 is chosen.

Z 2 = i Z 1 = 3 x 17 = 51
2n1 2x960
1 = = 100.48rad / s
60 60

1000W 1000x30
T1    298.57 Nm
1 100.48
AGMA equation for tooth bending stress is,

Ft
 K K K
bmJ v o m

d1 = m Z1
2T1
 K K K  [ ]
b Z1 m 2 J v o m

Face width, b= 10 to 13 m.

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

b = 10 m is assumed for the first trial.

 J = 0.34404 for pinion Z 1 = 17 mating with gear Z 2 =51

 For gear J = 0.40808

 These values are obtained from the table

Table 10.10 AGMA geometry factor J for teeth having Ø = 20o, a=1m, b=1.25m and

r f =0.300m

Number Number of teeth in mating gear

of teeth
1 17 25 35 50 85 300 1000
18 0.244 86 0.324 04 0.332 12 0.338 40 0.344 04 0.350 50 0.355 94 0.361 12
19 0.247 94 0.330 29 0.338 78 0.345 37 0.351 34 0.358 22 0.364 05 0.369 63
20 0.250 72 0.336 00 0.344 85 0.351 76 0.358 04 0.365 32 0.371 51 0.377 49
21 0.253 23 0.341 24 0.350 44 0.357 64 0.364 22 0.371 86 0.378 41 0.384 75
22 0.255 52 0.346 07 0.355 59 0.363 06 0.369 92 0.377 92 0.384 79 0.391 48
24 0.259 51 0.354 68 0.364 77 0.372 75 0.380 12 0.388 77 0.396 26 0.403 60
26 0.262 89 0.362 11 0.372 72 0.381 15 0.388 97 0.398 21 0.406 25 0.414 18
28 0.265 80 0.368 60 0.379 67 0.388 51 0.396 73 0.406 50 0.415 04 0.423 51
30 0.268 31 0.374 62 0.385 80 0.395 00 0.403 59 0.413 83 0.422 83 0.431 79
34 0.272 47 0.383 94 0.396 71 0.405 94 0.415 17 0.426 24 0.436 04 0.445 86
38 0.275 75 0.391 70 0.404 46 0.414 80 0.424 56 0.436 33 0.446 80 0.457 35
45 0.280 13 0.402 23 0.415 79 0.426 85 0.437 35 0.450 10 0.461 52 0.473 10
50 0.282 52 0.408 08 0.422 08 0.435 55 0.444 48 0.457 78 0.469 75 0.481 93
60 0.286 13 0.417 02 0.431 73 0.443 83 0.455 40 0.469 60 0.482 43 0.495 57
75 0.289 79 0.426 20 0.441 63 0.454 40 0.466 68 0.481 79 0.495 54 0.509 70
100 0.293 13 0.435 61 0.451 80 0.465 27 0.478 27 0.494 37 0.509 09 0.524 35
150 0.297 38 0.445 30 0.462 26 0.476 45 0.490 23 0.507 36 0.523 12 0.539 54
300 0.301 41 0.455 26 0.473 04 0.487 98 0.502 78 0.520 78 0.537 65 0.555 33
Rack 0.305 75 0.465 54 0.484 15 0.499 88 0.534 67 0.534 67 0.552 72 0.571 73

The tooth bending stress is given by,

0.5
 78  (200V) 0.5 
Kv    1.15 is assumed.
 78 

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

K o = 1.25 is taken assuming uniform power source and moderate shock load from the

table 7

K m = 1.3 assuming accurate mounting and precision cut gears for face width of about

50mm.

Table 10.11 -Overload factor K o

Driven Machinery

Source of power Uniform Moderate Shock Heavy Shock

Uniform 1.00 1.25 1.75

Light shock 1.25 1.50 2.00

Medium shock 1.50 1.75 2.25

Table 10.12 Load distribution factor K m

Face width ( mm)

Characteristics of Support 0 - 50 150 225 400 up

Accurate mountings, small bearing 1.3 1.4 1.5 1.8

clearances, minimum deflection, precision

gears

Less rigid mountings, less accurate gears, 1.6 1.7 1.8 2.2

contact across the full face

Accuracy and mounting such that less than Over Over Over Over

full-face contact exists 2.2 2.2 2.2 2.2

Substituting these values in the equation,

2T1 298570 x1.15 x1.25 x1.3

1  2
Kv Ko Km 
b Z1 m J 10m x17xm 2 x 0.34404

9539

m3

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

σe = σe’ kL kv ks kr kT kf km

The pinion is of steel C50 OQT with 223Bhn hardness and tensile strength of 660MPa

and the gear is of C45 OQT with hardness 210Bhn and tensile strength of 465MPa.

For pinion σ e ’ = 0.5 σ ut = 0.5 x 660 = 330MPa

k L = 1 for bending, k V = 1 assumed expecting m to be <5mm; k S = 0.73 from the

Fig.10.4 for σ ut = 660MPa, k r = 0.897 for 90% reliability

Fig. 10. 4 Surface factor k s

Table 10.13 Reliability factor K r

Reliability factor R 0.50 0.90 0.95 0.99 0.999 0.9999

Factor Kr 1.000 0.897 0.868 0.814 0.753 0.702

kT =1 assumed based on operating temperature <120oC

kf = 1.- and km = 1.33 for σut= 660MPa ( Ultimate tensile strength = 660 MPa for

SAE 1050 OQT condition)

σe = σe’ kL kv ks kr kT kf km

= 330x1x1x0.73x0.897x1x1x1.33 = 287.4MPa

Factor of safety on bending of 1.5 assumed

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

[σ] = σe / s = 287.4 / 1.5 =191.6MPa

Fig.10.5 - Miscellaneous effects factor km

From tooth bending fatigue considerations,

9539
1   [ ] 191.6
m3

Solving the equation we get m = 3.68mm

Now take m=4 mm as the next standard value. From this module, the dimensions

calculated are given in Table 10.14.

Table 10.14 Dimensions of pinion and gear

Wheel Z m b=10m d V =wrv Material Hardness

Pinion 17 4mm 40 mm 68mm 3.42 m/s C 50 223

Gear 51 4mm 40 mm 204mm 3.42 m/s C 45 205

Ft = T1 / r1 = 29857/34 = 8781N

The tooth has to be checked from surface durability considerations now.

The contact stress equation of AGMA is given below:

Ft
H  Cp KV Ko Km
bd1 I

Cp = 191 MPa0.5 from the table for steel vs steel

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Substituting i =3, Ф=200 we get I= 0.1205

sin  cos  i sin 20o cos 20o 3

I   0.1205
2 i 1 2 3 1

0.5 0.5
 78  (200V) 0.5   78  (200x3.42) 0.5 
Kv       1.15
 78   78 

From Table 10.11 and 10.12,

Ko = 1.25 and Km = 1.3 assumed as in the case of bending stress calculation

Ft 8781x1.15x1.25x1.3
H  Cp K V K o K m 191
bd1 I 40x68x0.1205

σH = 1209MPa

The surface fatigue strength of the pinion material is given by,

σsf = σsf’ KL KR KT

Where σsf’ = 2.8(Bhn) – 69MPa

= 2.8 x 223-69 = 555.4MPa

KL= 0.9 for 108 cycles life from graph1

KR = 1.0 taken for 99% reliability

KT = 1.0 for operating temperature <120oC assumed.

Substituting the values in the equation,

σsf = σsf’ KL KR KT

= 555.4x0.9x1x1 = 500MPa

Assuming a factor of safety, s = 1.1

From Fig. 10.2 and Table 10.8, we get,

[σH] = σsf /s = 500/1.1 = 455MPa

σH = 1209MPa

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Since σH (1209) >> [σH] (455), the design is not safe and surface fatigue failure will

occur.

Solution:

Increase the surface hardness of the material to 475Bhn and also increase the b to 13m

= 13 x 4 = 52 mm

From Fig. 3 we get,

Surface fatigue strength of the pinion material as

σsf = σsf’ KL KR KT

where σsf’ = 2.8(Bhn) – 69MPa = 2.8 x 475-69 = 1261MPa

KL= 0.9 for 108 cycles life from graph1

KR = 1.0 taken for 99% reliability

KT = 1.0 for operating temperature <120oC Assumed.

Substituting these values we get,

σsf = σsf’ KL KR KT

= 1261x0.9x1x1 = 1135MPa

Assuming a factor of safety s = 1.1

[σH] = σsf /s = 1135 /1.1 = 1032MPa

Ft 8781x1.15x1.25x1.3
H  Cp K V K o K m 191
b d1 I 52x68x0.1205

As σH (1185) > [σH] (1032) the design is not safe from surface durability considerations.

Hence increase the module to 5mm and take b=10m

Ft 7025x1.17x1.25x1.3
H  Cp K V K o K m 191
bd1 I 50x85x0.1205

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

σH =975MPa < [σH ] (1032MPa). Hence the design is safe from surface durability

consideration. Final specification of the pinion and gear are given in the Table 10.20

and 10.21.

Table 10.20 Values for gear and pinion

Wheel Z m b=10m d

Pinion 17 5mm 50 mm 85mm

Gear 51 5mm 50 mm 255mm

Table 10.21 Specification of gear and pinion

Wheel Material Steel Hardness Manufacturing quality

Pinion SAE1050 OQT 475Bhn Precision cut

Gear SAE 1045 OQT 450Bhn Precision cut

-------------------

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