Design of Helical Gear

Helical Gears REV 00
Design of Helical Gears
Amit Belvekar-Patil
Prof. Amit B. Belvekar-Patil Machine Design

REV 00
John Deere 3350 tractor cut in Technikmuseum Speyer Museum

MECHANICAL DRIVES REV 00
What is Mechanical Drives?
Need of mechanical drives ?
A) To reduce speed (Ex. Overhead crane)
B) To get variable speed (Ex. Lathe machine)
Types of mechanical drives
1. Transmitting power by means of friction.
e.g. Belt drives and Rope drives
2. Transmitting power by means of engagement.
e.g. Chain drives and Gear drives
Selection of Mechanical Drive.

INTRODUCTION REV 00
Let the wheel A be keyed to the rotating shaft and the wheel B to the shaft, to be rotated.
A little consideration will show, that when the wheel A is rotated by a rotating shaft, it will rotate the wheel B in
the opposite direction as shown in Fig. (a).
The wheel B will be rotated (by the wheel A) so long as the tangential force exerted by the wheel A does not exceed
the maximum frictional resistance between the two wheels.
But when the tangential force (P) exceeds the frictional resistance (F), slipping will take place between the two
wheels. Thus the friction drive is not a positive drive.
In order to avoid the slipping, a number of projections (called teeth) as shown in Fig. (b), are provided on the
periphery of the wheel A, which will fit into the corresponding recesses on the periphery of the wheel B.
 A friction wheel with the teeth cut on it is known as toothed wheel or gear.

GEARS REV 00
1.Gears are toothed wheels which can transmit power & motion from one shaft to another shaft
by means of successive engagement of teeth.
2.Gear drive is provided when distance between two shaft is small
3.Gear drive is positive drive. i.e. No slipping.
4.Gear drive consists of two wheels small one called pinion while larger one is called gear.

Gear Drive – Significance REV 00
1. Positive drive
2. Compact construction
3. Large power transmission
4. Power transmission at very low speed
5. Very high efficiency
6. Wide range of velocity ratio

CLASSIFICATION OF GEARS REV 00
GEARS
NONINTERSECTING NONINTERSECTING
PARALLEL AXES INTERSECTING
AXES GEARS & PERPENDICULAR & NONPARALLEL
GEARS AXES AXES
Spur Gear Bevel Gear  worm and worm gears  Spiral Gears
Helical Gear
 Herringbone Gear
Rack and Pinion

SPUR GEAR: SYLLABUS REV 00
Parallel shaft Axes Gears

1. Spur Gear
2. Herringbone Gears
3. Helical Gear
4. Rack and Pinion

SPUR GEAR REV 00
Teeth are parallel to axis of rotation

Transmit power from one shaft to another parallel shaft
Used in Electric screwdriver, windup alarm clock, washing machine
and clothes dryer
Advantages-
1. Easy to manufacture
2. Less expensive
3. Efficiency is up to 98%
Disadvantages-
1. Not used for high speed applications due to noisy operation.

SPUR GEAR: EXTERNAL & INTERNAL REV 00
EXTERNAL SPUR GEAR INTERNAL SPUR GEAR

RACK & PINION REV 00
Rack and pinion gears are used to convert rotary motion (From the pinion) into linear motion (of the rack)
 Rack Has no curvature having infinite radius
 Lathe Machine, Drilling Machine
RACK

HELICAL GEAR REV 00
The teeth on helical gears are cut at an angle to the face of the gear (Helix)
Two mating gears have same helix angle but opposite hands
This gradual engagement makes helical gears operate much more smoothly and quietly than spur gears.
Used at high velocity & load capacity applications
Subjected to both radial & tangential load ALONG WITH AXIAL LOAD
Machine tool gearbox,
Automobile gear box
Advantages-
1. Operation is smooth and quietly
2. Efficiency is up to 99%
3. Suitable for high speed applications
Disadvantages-
1. Difficult to manufacture.
2. Exerts end thrust

HERRINGBONE GEAR REV 00
To avoid axial thrust, two helical gears of opposite hand can be mounted side by side, to cancel resulting
thrust forces
Double helical gear
Herringbone gears are mostly used on heavy machinery.

BEVEL GEAR REV 00
Bevel gears are used for transmitting motion between two intersecting shafts at desired angle.
Surface of bevel gear is like frustum of cone.
The teeth on bevel gears can be straight, spiral
locomotives, marine applications, automobiles, printing presses, cooling towers, power plants, steel
plants, railway track inspection machines, etc.

WORM GEAR REV 00
Worm gears are used when large gear reductions are needed. It is common for worm gears to have reductions of 20:1, and
even up to 300:1 or greater.
Self locking or Non reversible.
Many worm gears have an interesting property that no other gear set has: the worm can easily turn the gear, but the gear
cannot turn the worm.
Worm gears are used widely in material handling ,machine tools, automobiles steering Mechanisms, Lifts, Cranes

Terms in Spur & Helical Gears REV 00
SPUR Gear Helical Gear Equivalent Spur Gear
b
b 
'
Face Width
b cos 
d
Pitch circle Diameter d d 
'
cos 2 
z
Number of Teeth Z z 
'
cos 
3
mt  TangentialModule
Module m
mn  NormalModule
Terms in Spur & Helical Gears REV 00
SPUR Gear Helical Gear Equivalent Spur Gear
'
Lewis Form Factor
Y Y

REV 00

Steps in Design of Helical Gears REV 00
STEP 1 Beam Strength of Helical gear tooth
STEP 2 Wear Strength of Helical gear tooth
STEP 3 Check for Beam strength & Wear Strength
STEP 4 Preliminary estimation by velocity factor Kv
STEP 5 Precise estimation by Buckingham's equation
STEP 6 Check Safety of Gear

Beam Strength of a Helical Gear Tooth (Bending Failure) REV 00
LEWIS EQUATION FOR BEAM STRENGTH

 Beam Strength :
Maximum tangential load the gear tooth can take without tooth breakage (bending failure).
Fb  m.b. b .Y
Fb
For Spur Gear
Fbn
b

b' 
cos 
Fbn  mn .b ' . b .Y ' Fb

Fbn 
cos
b
b' 
Fb  mn .b . b .Y ' cos 

Beam Strength of a Helical Gear Tooth (Bending Failure) REV 00
Lewis Equation
Fb  mn .b . b .Y '
Where,
mn= Normal Module in mm
b= Face width in mm 9mn  b  15mn In the preliminary stage generally face width is taken as 10m
( S ut )
Ϭb = Bending Stress in N/mm2 b 
3
Y= Lewis form factor 2.87

Y  0.484  '
_____( 20 0
full depth)
Z

Wear Strength of a Helical Gear Tooth (Pitting Failure) REV 00
For Spur Gear Fw

Fw  d p b.Q.K Fwn
b 
b  '
cos 
Fwn  d p b .Q .K
' ' '

Fw d
Fwn  d 
'
cos cos2  b
b' 
d p b.Q.K cos 
Fw 
cos 2  z 
z ' d p  mt .Z p
cos3  b
'
Q=Ratio factor for external gear pair 2Z g
Q' 
(Z g  Z p )
' '

Steps to Design of Helical Gear REV 00
Step 1: Beam Strength of teeth using Lewis equation Weaker of Gear & Pinion in bending
Pinion Fb  mn .b . b .Y '
Gear
( S ut ) p ( S ut ) g
 bp   bg 
3 3
2.87 2.87
 0.484   0.484 
' '
Yp '
Yg '
Zp Zg
 bp .Yp '
 bg .Yg '
 bp .Yp '
<  bg .Yg '
Pinion is weaker in bending Fb  mn .b. bp .Y p
'
 bp .Y p '
>  bg .Yg ' Gear is weaker in bending Fb  mn .b. bg .Yg
'

Wear Strength of a Spur Gear Tooth REV 00
Step 2: Wear strength Maximum tangential load gear tooth can take without wear/pitting failure
d p b.Q.K
Fw 
cos2 
dp= Pitch Circle Diameter of pinion d p  mt .Z p
in mm
2Z g
Q=Ratio factor for external gear pair Q
(Z g  Z p )
2
K= load stress factor N/mm2  BHN  When Pinion & Gear made with Steel- Steel
K  0.16  
 100 
2
 BHN 
K  0.18  When Pinion & Gear made with Steel- Cast Iron
 100 
2
 BHN  When Pinion & Gear made with Cast Iron- Cast Iron
K  0.21 
 100 

Design of Helical Gear REV 00
STEP 3 Beam Strength V/s Wear Strength
Fb  mn .b . b .Y ' d p b.Q.K
Fw 
cos2 
Fb < Fw Gear Pair is weaker in Bending
Fb > Fw Gear Pair is weaker in Pitting

STEP 4  Effective Load on Gear Tooth
Ft Tangential Force
Ft max Max Tangential Force
Feff Total Max Tangential Force

STEP 4 1. Fluctuation of torque because of prime

movers and driven machine
 Maximum Tangential Load F tmax :
2. Non uniform distribution of load
 Maximum Tangential Load (Ftmax ) is given by across the face width
3. Tooth error and pitch line velocity

Ft max  k a K m Ft (Dynamic load)
Where Ka is Service / Application / Overload factor Compressor
Ka Depends upon application

Driving and Driven elements
Max Torque
Ka 
Rated Torque Motor

REV 00
Ka is Service / Application / Overload factor

REV 00
Km Load Distribution Factor/ Load concentration Factor
Accounts Non uniform distribution of load across the face width

Dynamic load on gear Tooth REV 00
 Ka and Km does not account for inertia forces arising due to tooth errors.
 Gear tooth are NEVER perfect due to inaccuracy in tooth profile, error in tooth spacing run out of gear and
deflection of tooth under load results in Transmission Error.
 Transmission error causes cyclic fluctuation of speed ratio.
 So during meshing each tooth undergoes short period of acceleration and deceleration
 This acceleration and deceleration combined with mass of pinion and gear results in inertia forces.
 So this Additional Forces arises due to inertia forces are Dynamic Load
 Dynamic load depends on
1. Tooth error
2. Pitch Line velocity

Dynamic load on gear Tooth REV 00
Estimations of Dynamic load
Preliminary Estimation Precise Estimation
STEP 4 STEP 5
1. Fluctuation of torque because of prime movers and 3. Tooth error and pitch line velocity (Dynamic
driven machine load)
2. Non uniform distribution of load across the face
width
Feff 
Ft max

K a Ft K m Feff  Ftmax  Fd
kV KV
Barth Factor/Velocity Factor REV 00
STEP 4
Preliminary Estimation By Velocity factor Kv:
Ft max K a Ft K m
Feff  
kV KV
3 m 6 m
KV  V  10 KV  V  20
3 V s 6 V s
3 .6 m 5 .6 m
KV  20  V  25 KV  25  V  30
3 .6  V s 5 .6  V s

Beam Strength of a Spur Gear Tooth (Bending Failure) REV 00
Feff  Ftmax  Fd
STEP 5 Precise Estimation By Buckinghams Equation Fd:
• According to Buckingham Approach Fd is given by
Fd 

21V bC . cos 2   Ft max  X cos 
21V  bC. cos 2
  Ft max 
K is constant, depends on tooth
 E p Eg
ke 
C   ke   form
 1  E E 
  1  p g  K=0.107 -14.50
E E  K=0.111 - 200 Full depth
 p g 
K=0.115 - 200 stub
E =modulus of Elasticity C =Deformation factor
C =11500e N/mm
K =tooth Form factor e = Combined Tooth Error

STEP 5 C =Deformation factor
 E p Eg
ke 
C   ke   e = Combined Tooth Error
 1   E p  Eg 
1
    
E E  e = ep + eg
 p g 

STEP 5
e = ep + eg

STEP 5 Beam Strength of a Spur Gear Tooth (Bending Failure) REV 00
 Effective Load on Gear Tooth

 Actual Load on gear tooth to transmit power
 Tangential Load + Dynamic Load
Effective Load Feff
Tangential Load Dynamic Load

Ftmax Fd
REV 00
STEP 6 Design Check Check the Safety of gear Pair
Check the Safety Against bending failure
In order to avoid the bending failure Fb > Feff

By Considering the FOS Fb  N f Feff
In order to avoid the Pitting failure Fw > Feff

By Considering the FOS Fw  N f Feff
REV 00
Thank You!!
Helical Gears REV 00
Amit Belvekar-Patil
Sachin Dhavane
Dr. A. M Malge

REV 00
Problem 1 : A helical pinion having teeth to be made of alloy steel (Sut= 800 N/mm2) is to mesh with a
gear made of plain carbon steel (Sut=720 N/mm2). The gear pair is required to transmit 30kW power from
an electric motor running at 720 r. p.m.. to a machine running at 225 rpm. The application factor and load
concentration factors are 1.3 and 1.1 resp. The required FOS is 2. The face width is ten times the normal
module. The tooth system is 20 full depth involute, while the helix angle is 25. The gear pair is machined
to meet the specifications of grade 7. The deformation factor for gear pair is 11000e N/mm.
Design the gear pair by using velocity factor and Buckingham
S equation for dynamic load. Suggest surface hardness for gear pair.
Use following data.
5.6
Kv 
5.6  V
Grade 7 e  11.00  0.9 [mn  0.25 d ]m
C  11000e N/mm

REV 00
Problem 1 : A helical pinion having teeth to be made of alloy steel (Sut= 800 N/mm2) is to mesh with a gear made of plain carbon steel (Sut=720 N/mm2).
The gear pair is required to transmit 30kW power from an electric motor running at 720 r. p.m.. to a machine running at 225 rpm. The application factor and
load concentration factors are 1.3 and 1.1 resp. The required FOS is 2. The face width is ten times the normal module. The tooth system is 20 full depth
involute, while the helix angle is 25. The gear pair is machined to meet the specifications of grade 7. The deformation factor for gear pair is 11000e n/mm.
Design the gear pair by using velocity factor and Buckinghams equation for dynamic load. Suggest surface hardness for gear pair.
Use following data.
Pinion Gear
Given Data : Zp  14
  250
Sutp  800 N/mm 2
Sutg  720 N/mm 2
P  30kW  30x103W
Np  720 rpm Ng  225 rpm
Ka  1.3 5.6
Kv 
5.6  V
Km  1.1
C  11000 e N/mm Grade 7 e  11.00  0.9 [mn  0.25 d ]m
Type of standard Tooth System  20 Full Depth b  10 m n FOS  2

STEP 1 Beam Strength REV 00
Fb  mn .b . b .Y ' z
z 
'
cos 3 
Pinion Gear
zp
z p  18.8
'
zp 
'
Pinion Is Weaker In Bending  bp .Yp '
< bg .Yg
'
cos 3 
Gear Is Weaker In Bending  bp .Y p '
> bg .Yg
' zg
z g  60.45
zg 
' '
cos 
3
( S ut ) p ( S ut ) g
 bp   bg 
3 3
2.87 2.87
Y p  0.484  ' Yg  0.484  '
Zp Zg
Zp  14 Np  720 rpm
NP d Z Z 720 ZG
Zg  44.8  45
NP
G  G  G  G 
Ng  225 rpm NG dp Zp NG Zp 225 14

STEP 1 Beam Strength Fb  mn .b . b .Y ' REV 00
Pinion Gear
2.87 ( S ut ) g 2.87
 bp 
( Sut ) p
Y p  0.484  '  bg  Yg  0.484  '
3 Zp 3 Zg
800 2.87 720
 bp  Y p  0.484   bg  Yg  0.484 
2.87
3 18.8061 3 60.4484
σ bp  266.667 N/mm 2 Yp '  0.3313 σ bg  240 N/mm 2 Yg '  0.4365
 bp .Yp '
<  bg .Yg '
Pinion is weaker in bending Fb  mn .b. bp .Y p
'
 bp .Y p '
>  bg .Yg ' Gear is weaker in bending Fb  mn .b. bg .Yg
'
σ bp .Y p  88.3467 N/mm 2 <  bg .Yg '  104.76 N/mm 2

Fb  mn .b. bp .Y p Fb  mn .10mn .266.667 X .0.3313 Fb  883.4677 mn N
' 2

Step 2: Wear strength As surface hardness is unknown, we cannot find wear strength of gear pair
d p b.Q.K
Fw 
cos2 
dp= Pitch Circle Diameter of pinion d p  mt .Z p
in mm
2Z g
Q=Ratio factor for external gear pair Q
(Z g  Z p )
2
K  0.16  
 100 
2
 BHN 
K  0.18  When Pinion & Gear made with Steel- Cast Iron
 100 
2
 BHN  When Pinion & Gear made with Cast Iron- Cast Iron
K  0.21 
 100 

STEP 3 Beam Strength V/s Wear Strength
Fb  mn .b . b .Y ' d p b.Q.K
Fw 
cos2 
Fb < Fw Gear Pair is weaker in Bending
Fb > Fw Gear Pair is weaker in Pitting

STEP 4 Preliminary Estimation By Velocity factor Kv: REV 00
Ft max K a Ft K m Module  m n
Feff  
kV KV
In order to avoid the Bending failure Fb  N f Feff

Ft max  k a K m Ft Ka  1.3 Km  1.1 Kv  5.6
5.6  V
P d p n p
Ft  V
V 60 x 1000

REV 00
d p n p d g n g
V V
60 x 1000 60 x 1000
d p n p  mt z pnp
 mn z pnp
V V V
60 x 1000 60 x 1000 cos  .60 x 1000
Z p  14 Np  720 rpm   250
V  0.5823mn ( m / sec)
P 30X10 3 5.6 5.6 5.6

Ft  Ft  Kv  Kv 
5.6  0.5823mn
Kv 
5.6  0.763 m n
V 0.5823m n 5.6  V

REV 00
K a Ft K m
Feff 
KV
1.3X1.1  30X10 3 
Feff  X 
5.6  0.5823m n 
5.6  0.763 m n
73.6733 X 103  10.0379 X 103 mn

Feff 
mn

REV 00
In order to avoid the Bending failure
Fb  N f Feff Fb  883.4677 mn N
2 FOS  2
 73.6733 X 103  10.0379 X 103 mn 

 (2)x 
2
883.4677 mn 
 mn 
441.7338m n  73.6733 X 103  10.0379X10 3 m n

3
m n  6.0616mm m n  6.1mm
Normal Module m n  8 mm

Dimensions of Gear pair REV 00
mn 8
m n  8mm mt  mt  m t  8.827 mm
cos  cos 25
Z p  14
dp  mt z p d p  123.58mm
Zg  45
dg  mt zg d g  397.21mm
b  10m n b  10x8  80mm
h f  1.25m n h f  10mm
h a  1m n h a  8mm
Fb  883.4677mn N
2
Fb  883.4677 X (8) 2 N Fb  56542.53 N

Precise Estimation By Buckinghams Equation Fd: REV 00
STEP 5 Feff  Ftmax  Fd

V  0.5823mn (m / sec)
Ftmax  K a Ft K m Ft 
30X103
Ft 
30X103
V  4.6584( m / sec)
0.5823mn 4.6584
Ftmax  1.3X1.1X6439.975 Ft  6439.975 N
Ftmax  9209.1642N
b  80mm
Fd 

21V bC. cos2   Ft max  X cos C  11000e N/mm
21V  bC. cos 2
  Ft max    250

REV 00
STEP 5 Precise Estimation By Buckinghams Equation Fd:
C  11000e N/mm
Grade 7 e  11.00  0.9 [mn  0.25 d ]m
e  ep  eg
e p  11.00  0.9 [mn  0.25 d p ]m e g  11.00  0.9 [mn  0.25 d g ]m
e p  20.7012μ0 e g  22.6843 μm
e  ep  eg e  20.7012  22.6843  43.3855 μm e  43.3855 x 10 -3 mm
C  11500 x e N/mm C  477.2405 N/mm

REV 00
Fd 

21 X 4.6584 80 X 477.2405 X (cos 25) 2  9209.1642  X cos 25
21 X 4.6584  80 X 477.2405 X (cos 25) 2
 9209.1642 
Fd  12.0199 X 103 N
Feff  9209.1642  12.0199 X 103
Feff  21.2291X 10 3

REV 00
STEP 6 Design Check Check the Safety of gear Pair
In order to avoid the bending failure Fb > Feff Feff  21.2291X 10 3
Fb  56542.53N
By Considering the FOS Fb  N f Feff
N f  2.6634 > 2
(N f ) calculated > (N f )Given
Design of Gear Pair is safe

Step 2: Wear strength
d p b.Q.K
Fw 
cos 2 
dp= Pitch Circle Diameter of pinion d p  mt .Z p d p  123.58mm Z p  14 Zg  45
in mm
2Z g
Q=Ratio factor for external gear pair Q Q  1.5254
(Z g  Z p )
2
K  0.16  
 100 
2 2
123.5783 X 80 X 1.5254 X 0.16  BHN   BHN 
Fw    Fw  2937.5448 
 100   100 
2
(cos 25)

REV 00
By Considering the FOS Fw > Feff Feff  21.2291X 103
In order to avoid the Pitting failure Fw  N f Feff

2
 BHN 
2937.5448   ( N f ) given X21.2291X10
3
 100 
BHN  380.1793  385

REV 00
Thank You!!
REV 00

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Helical Gears REV 00

Design of Helical Gears

Prof. Amit B. Belvekar-Patil Machine Design

John Deere 3350 tractor cut in Technikmuseum Speyer Museum

Prof. Amit B. Belvekar-Patil Machine Design

What is Mechanical Drives?

Need of mechanical drives ?

A) To reduce speed (Ex. Overhead crane)

B) To get variable speed (Ex. Lathe machine)

Types of mechanical drives

1. Transmitting power by means of friction.

e.g. Belt drives and Rope drives

2. Transmitting power by means of engagement.

e.g. Chain drives and Gear drives

Selection of Mechanical Drive.

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

3. Large power transmission

4. Power transmission at very low speed

5. Very high efficiency

6. Wide range of velocity ratio

Prof. Amit B. Belvekar-Patil Machine Design

Rack and Pinion

Prof. Amit B. Belvekar-Patil Machine Design

Parallel shaft Axes Gears

Prof. Amit B. Belvekar-Patil Machine Design

Teeth are parallel to axis of rotation

Prof. Amit B. Belvekar-Patil Machine Design

EXTERNAL SPUR GEAR INTERNAL SPUR GEAR

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

SPUR Gear Helical Gear Equivalent Spur Gear

SPUR Gear Helical Gear Equivalent Spur Gear

Prof. Amit B. Belvekar-Patil Machine Design

Design of Helical Gears

Prof. Amit B. Belvekar-Patil Machine Design

STEP 1 Beam Strength of Helical gear tooth

STEP 2 Wear Strength of Helical gear tooth

STEP 3 Check for Beam strength & Wear Strength

STEP 4 Preliminary estimation by velocity factor Kv

STEP 5 Precise estimation by Buckingham's equation

STEP 6 Check Safety of Gear

Prof. Amit B. Belvekar-Patil Machine Design

LEWIS EQUATION FOR BEAM STRENGTH

Prof. Amit B. Belvekar-Patil Machine Design

mn= Normal Module in mm

Y= Lewis form factor 2.87

Prof. Amit B. Belvekar-Patil Machine Design

For Spur Gear Fw

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

STEP 3 Beam Strength V/s Wear Strength

Fb < Fw Gear Pair is weaker in Bending

Fb > Fw Gear Pair is weaker in Pitting