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Analysis of Spur and Helical

Gears
prepared by Wayne Book
based on Norton, Machine Design
and
Mischke and Shigley
Mechanical Engineering Design
The Gnashing of Teeth
Simple model for
loaded gears
Beam for bending
stress
Cylinders in
contact for surface
contact stress
Idealized Shape of a Tooth for Stress Analysis
Simple model: cantilever
beam with applied force W
Tooth thickness t
Length l
Face width F
Max stress at root (a)

l
W
t

F
t
a
2 3
6
) 12 / (
2 / ) (
Ft
l W
Ft
t l W
I
Mc
t t
= = = o
Consider the Shape of a Tooth
Uncertainties include:
point of load application l
point of maximum stress
appropriate load component
beam thickness
Depends on pitch P, number of teeth N and
pressure angle |
Conservative assumptions are made
Y = Lewis form factor
Introduce Lewis Shape Factor
t
l
W
r

W
t

W
x
3
2
6
4 2 /
2 /
iangles similar tr By
2
12 6
2
2
2 2
xP
Y
FY
P W
l
P t
F
P W
l
t
x
t
l
x
t
Pt
l
F
P W
Ft
l W
t t
t t
=
= =
= =
= =
o
o
Rather than calculate Y(P,, N), create a table, e.g. 14-2
Lewis equation has been improved by AGMA
Velocity Effect
(Its Barth not Barf)
Purely empirical adjustment for non-zero velocity
Barths equation (1800s) has been modified to account for
current practice and accuracy
V is velocity in ft/sec at the pitch line
K
v
= 1200/(1200+V) (Modified Barth)
Metric form K
v
= 6.1/(6.1+V), V in m/sec
Compare to endurance strength (reversing) or use
Goodman diagram (one direction)
Apply notch sensitivity, Marin factors. the works


FY K
P W
v
t
= o
Surface Durability: Contact Stress
Analyzed as two cylinders of
length l in rolling contact
with specified force
Cylinder radii r
1
and r
2
vary
with contact point
Depends on elastic material
properties and radii of
cylinders
Translate into gear
nomenclature as shown on
right
factor velocity C
pinion and gear refer to subscripts P G,
modulus s Young' E
ratio s Poisson'
1
1
1
1 1
cos
v
2 / 1
2
2
2 / 1
2 1
=
=
=
(
(
(
(
(

|
|
.
|

\
|

+

=
(

|
|
.
|

\
|
+ =
v
v
v
t
|
o
G
G
p
p
p
V
t
p c
E E
C
r r F C
W
C
AGMA Approach
AGMA formula calculates stress for
Bending
Contact
Stress is compared to an allowable stress
(also called strength by Norton) based on
strength and conditions


Bending Stress
Many terms are similar to
the Lewis equation
Additional terms account
for the application, load
sharing and size
factor geometry tooth
factor backup rim
factor on distributi load
factor size
width face
pitch diametral
Lewis in as factor velocity
factor n applicatio
factor idler
load l tangentia
=
=
=
=
=
=
=
=
=
=
=
J
K
K
K
F
P
K
K
K
W
J
K K K
F
P
K
K K
W
B
m
s
d
v
a
I
t
B m s d
v
a I
t
o
loading
gear
geometry
tooth
form
J factor sample table
Tip loading
(low
precision)
Distributed
loading
(higher
precision)
K
v
Velocity Factor (similar to Barth)
(also provided in equations 11.16 11.19)
Load Distribution Factor
Loads are less evenly
distributed for wide
face teeth
Keep F (face width)
8/p
d
< F < 16/p
d

Nominally F = 12/p
d

Application Factor
Created to account for known but
unquantified shock in load
Electric motors are smooth while single
cylinder engines have shock
Centrifugal pumps are smooth loads while
rock crushers have shock
Other Factors
Size, Rim Thickness, Idler
Size
Fatigue tests are done on small specimins and
indications are that size results in weaker parts
Very large teeth might warrant K
s
=1.25 to 1.5
Material properties created directly for gears
account for this
Rim thickness
In large diameter gears, the centers are
connected to a rim by spokes.
K
B
reflects failures across the radius
Idler: use K
I
= 1.42

Allowable Bending Stress
Incorporate material strength S
t
specific to gear
materials
S
t
based on Brinell hardness of material
Environmental and application factors
K
L
= life factor
K
T
= temperature factor
K
R
= reliability factor
R T
L t
all
K K
K S
= o
Life Factor K
L

(a specialized S-N curve)
BendingTemperature and Reliability
Factors
Strength data is based on 99%
reliability. Adjust up or down.
Temperatures up to 250 deg F
use K
T
= 1
Adjust for higher temperatures

620
460
F
T
T
K
+
=
AGMA Bending Fatigue Strengths
(uncorrected)
Contact Stress
Based on rolling
cylinder model
Added terms for size,
load distribution,
surface condition
factor geometry tooth
factor condition surface
factor on distributi load
diameter pitch
factor size
factor (dynamic) velocity
factor n applicatio
t coefficien elastic
2 / 1
=
=
=
=
=
=
=
=
(

=
I
C
C
d
C
C
C
C
I
C C
Fd
C
C
C W
C
f
m
s
v
a
P
f m
s
v
a t
P c
o
loading
gear
geometry
tooth
condition &
geometry
material
Surface Geometry Factor I
( )
h) depth teet full for (0
elongation addendum fraction
gear for curvature of radius
pinion for curvature of radius
angle pressure
pinion of radius pitch
pinion of pitch diametrial
sin
cos cos
1
1 1
cos
2
2
=
=
=
=
=
=
=

|
|
.
|

\
| +
+ =
|
|
.
|

\
|

=
p
g
p
p
d
p g
d
p
d
p
p p
p
g p
x
r
p
C
p
r
p
x
r
d
I

|
|
|
t
|

|

AGMA Elastic Coefficient


(also from basic material properties and (11.23))
Other Surface Stress Factors
C
f
= 1 for standard manufacturing methods
C
a
, C
m
, C
v
, C
s
are equal to corresponding K
values from bending
Allowable Contact Stress
(Norton calls Strength)
Material strength S
C
is the basis, specific to
gear materials
S
c
based on Brinell hardness of material or
on tables in Norton
Adjust for conditions
C
L
= life factor
C
H
= hardness-ratio factor (pinion rel to gear)
C
T
= temperature factor
C
R
= reliability factor
R T
H L fc
fc
C C
C C S
S
'
=
Surface Fatigue Strengths
Surface Fatigue Life Factor
Hardness Ratio Factor
Only applied to the gear material (not pinion)
Accounts for work hardening of the gear during
run-in
Depends on previous hardening (through hardened
vs surface hardened)
gear pinion, of hardness Brinnel ,
00698 . 0 7 . 1
00829 . 0 00898 . 0 7 . 1 2 . 1
0 2 . 1
ratio gear
) 1 ( 1
=
= >
= < <
= <
=
+ =
g p
g
p
g
p
g
p
g
p
G
G H
HB HB
A then
HB
HB
HB
HB
A then
HB
HB
A then
HB
HB
m
m A C
microinch in roughness surface rms
.) . ( 00075 . 0
.) . ( 00075 . 0
) 450 ( 1
052 . 0
0112 . 0
=
=
=
+ =

q
R
R
g H
R
I S e B
S U e B
HB B C
q
q
Both through hardened
Pinion surface hardened
Helical Gears Brief Overview
The treatment of tooth stresses for helical
gears is very similar to spur gears
Bending and Surface stresses must be
analyzed
AGMA formulas are analagous
Tables also consider helix angle in range
of 10 to 30 degrees
For this class, be able to perform force
analysis but we will not cover tooth stresses
Forces, Helical
(Equations 12.3 in Norton)
t
n
t
n
|
|
|
|
tan
tan
cos
angle helix
involute) (for angle pressure circular
angle pressure normal
= +
= +
=
=
force radial sin
force axial sin cos
force d transmitte cos cos
force total
= =
= + =
= + =
=
n r
n a
n t
W W
W W
W W
W
|
|
|
Bevel Gears
Treat force analysis of intersecting, straight
tooth, bevel gears
Equations (12.8 in Norton)
Forces, Bevel Gears
(Shigley, Fig 13-34)
Assume forces
concentrated at average
radius
Net force surface
Decompose into
transmitted, radial and
axial forces
|
|
|

|
sin tan
cos tan
tan ; /
angle - half cone pitch
angle pressure
t a
t r
t ave t
W W
W W
W W r T W
=
=
= =
=
=
Bending Strength from Hardness
(Fig 14-2 Shigley)
Contact Strength from Hardness
(Fig 14-3 Shigley)
"I've had a wonderful time, but this wasn't it."
- Groucho Marx (1895-1977)

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