Theory of Gears r3
Theory of Gears r3
Is equivalent to set of spur gears having same diameter circles as the pitch
circles of the pair.
z
Pd
d
pcPd
For two gears to mesh they must have the same pitch.
RELATIVE SIZES OF STANDARD 200 PRESSURE ANGLE STANDARD,FULL
DEPTH TEETH FOR SEVERAL STANDARD DIAMETRAL PITCHES FROM 4 TO
80
In SI units the size of the teeth is specified by the module “m” measured in mm
d
m
z
Therefore circular pitch pc m
1
m
Pd
With SI units standard values of metric module(mm)
1 n1 z d 2
2
SPEED RATIO ἰ12=
2 n2 z d 1 1
BASE CIRCLE
INVOLUTE GEAR TEETH CONTACT AND PRESSURE ANGLE
Gear teeth are cut to the shape of an involute between the addendum
circle and the base circle
Part of the teeth between the base and dedendum are radial.
Pressure line- Direction in which the resultant force acts between the
gears
r b = rcos Ф
STANDARD GEAR TEETH
Standard pressure angle - 14.50,200 or 250
In this one can have full depth gears and stronger stub tooth gears.
Commonly used involute spur gear teeth in terms of the diametral pitch (Pd)
Tooth proportions for some spur gear teeth in terms of diametral
pitch
FACE WIDTH (b)OF SPUR GEARS
9 13
b
Pd Pd
9.6m b 12.5m
However under certain conditions ,as where there are space
limitations the width “b” may be as narrow as 6.3m or as wide
as 19m.
EX 1: Two parallel shafts with center distance 14 inch are to be
driven by 2 teeth/inch diametral pitch , 200 pressure angle spur
gears providing a velocity ratio of 3 .
For each gear determine:
a) The number of teeth
b) Base circle radius and the outside diameter
c) Clearance
d) Pitch line velocity if the gear (2) rotates at 500 rpm
Addendum circle
Addendum =a = 1/Pd =1/2=0.5 in
Dedendum
bd = 1.25/Pd =1.25/2 = 0.625
Clearance
c = bd-a =0.625-0.5= 0.125 in
Contact between the two gears starts when the addendum circle of the
driven gear (dn)intersects the pressure line and ends when the addendum
circle of the driving gear(dg) intersects the pressure line. Length of contact:
When two gears are in mesh it’s desirable to have at least one pair of teeth in
contact all the time.
How many teeth are in contact is denoted by the contact ratio
L
C
c
Cr=Length of Contact
r
Base Pitch
pb
Contact Ratio in terms of circular pitch by substituting,
pb pc cos
1 cTan
Cr { (rp ap ) 2 (rp cos ) 2 (rg ag ) 2 (rg cos ) 2 }
pc cos pc
Cr=1 One tooth is leaving contact just as the next is beginning contact
For smooth operation minimum Cr=1.2
Higher the contact ratio more the load is shared between the teeth.
Interference
Since the part of the gear tooth below the base circle is not cut as an involute
curve basic law of gearing will not be held.
The contact of these portions of tooth profiles is called interference.
When interference occurs gears will have to be modified by removal of the
portion of the tooth below the base circle and cutting away the interfering
material- Undercutting.
Undercutting can be avoided by
a) Removing a portion of tips of the teeth.
b) Increasing the pressure angle
c) Increasing the center distance
d) Use minimum required teeth numbers
Power is transmitted by the force that the tooth of one gear exerts
on the tooth of the other.
The transmitted load Fn is normal to the tooth surface.
Therefore it acts along the pressure line.
dn
V=Pitch Line Velocity = m/s
60
FtV Tn
KW
1000 9549
1000 KW 745.7 hp
Ft
V V
DYNAMIC EFFECTS & SERVICE CONDITIONS
The tangential force Ft does not account for the entire force that acts between
the gear teeth.
Dynamic effects also act on the teeth due to teeth inaccuracies, deflection and
misalignments.
This is taken into account by the Barth Velocity Factor Kv.
1200 V
Kv (2000 V 4000 fpm) 6.1 V
(10 V 20)
1200 Kv
6.1
78 V 3.56 V
Kv (V 2000 fpm) Kv (V 20)
78 3.56
Fd KvCsFt
Ex : Gear Force Analysis
Three meshing gears have a module of 5mm and 200 pressure angle. Driving
gear1 transmits 40KW at 2000rpm to idler gear 2 on shaft B. Output gear 3
is mounted on shaft C,which drives a machine. Determine
(a) The tangential and radial forces acting on gear 2.
(b) The reaction on shaft B.
z 2 40
z 3 30
z1 20
The pitch diameters of gears 1 and 3:
d1 = m1z1 = 20*5=100mm
d3 = m3z3 = 30*5 = 150mm
9549KW 9549 * 40
T = 191Nm
2000 2000
Ft12
T 1 191
3.82kN Fr12 3.82Tan 20 1.39kN
r1 0.05
Gear 2 is an idler .
Ft32 = 3.82 kN Fr32 =1.39kN
t/2 L t2
L
Using similarity of triangles, x t/2 4x
6 Ft t 2 3 Ft
2
bt 4 x 2 bx
3 Ft Pd Ft Pd
Multiplying by Pd [ ][ ]
2 bx Pd b Y
2x
Y Pd
3
Y= Modified Lewis Form Factor and is a function of the pressure angle and
the number of teeth.
FtPd
-LEWIS FORMULA
bY Y-Modified Lewis Form Factor
Lewis Formula in SI
units
Substituting m=1/Pd
Ft
mbY
VALUES OF MODIFIED LEWIS FORM FACTOR(Y) FOR SOME COMMON FULL DEPTH TEETH
Lewis form factor (y) can be calculated from
0.684
y 0.124 For 14.50 Pressure Angle
z
0.912 For 200 Pressure Angle
y 0.154
z
0.95
y 0.175 For 200 Stub Teeth system
z
(Y y )
EFFECT OF STRESS CONCENTRATION
The stress in a gear tooth is influenced by the fillet radius rf. This is
taken into account by the stress concentration factor Kf.
The Lewis formula is modified to include the effect of the stress
concentration,
KfFtPd
bY
b Y
Ft
Kf Pd
[σb]= Allowable Static Bending Stress
Kf = 1.5
In SI units
[b]mbY
[ Fb ]
Kf
Design Tangential load should not exceed the Allowable Bending Load capacity
Fd [ Fb ]
STRENGTH FACTOR IN LEWIS EQUATION
m,b are the same for pinion as well as for gear in a pair.
When different materials are used the product Y[σb] STRENGTH FACTOR
determines the weaker between the pinion and the gear.
Y for pinion is always less compared to the gear.
When the same material is used for the pinion and the gear pinion is always
weaker.
Therefore pinions should be made approximately 40BHN harder than their
mating wheel to even out the life of the two parts .
Allowable Static Bending Stress-Values for some materials of different
hardnesses
Ex: A 250 pressure angle, 25 teeth spur gear having a module of 2mm and a
face width of 45mm are to operate at 900rpm. The gear is made of SAE1040
steel. Fatigue concentration factor =1.5 , Cs=1
Determine a) Allowable bending load
b) The maximum tangential load and power that the gear can
transmit.
Modified Lewis form factor for 25 teeth, pressure angle
250 Y=0.402
Allowable static bending stress for SAE1040 steel
[σb]=172 Mpa [ ]mbY
Maximum allowable bending load [F b] =
Kf
172 *106 * 2 *10 3 * 45 *10 3 * 0.402
3
4.149kN
1.5 *10
Pitch diameter d =mz = 2*25=50mm
dn m/s=
* 0.05 * 900
V=Pitch Line Velocity = = 2.356 m/s= 463.77fpm
60 60
The design load
[ Fb] Fd
4.149 1.77 Ft
Ft 2.344kN
FtV 2.344 *1000 * 2.356
Power Transmitted by the gear 5.52 KW
1000 1000
WEAR STRENGTH OF A GEAR TEETH –BUCKINGHAM FORMULA
The failure of the surface of gear teeth is called wear. Surface fatigue failure
occurs due to repeated high contact stresses.
Hertz formula for contact stresses of two cylinders of Radii R1 and R2
Maximum contact pressure developed between two cylinders
FaEpEg 1 1 1/ 2
p 0 0.592{ [ ]}
Ep Eg R1 R 2
Fa= Load per axial length pressing the cylinders together
Ep,Eg= Moduli of elasticity of the cylinders
0.3
Considering the two meshing gear teeth as two parallel cylinders in contact
and taking radii of the two cylinders as radii of curvature of the involutes
dp
R1 Sin
2
dg zgdp
R 2 Sin Sin
2 2 zp
Z=Number of teeth
dp dg
zp zg
FaEpEg 2 zp
S 0 0.35
2
[1 ]
Ep Eg dp sin zg
Representing the maximum contact pressure p0 by Surface Endurance
Limit S0
[ Fw] dpbQK
Where S 0 2 sin 1 1
WearLoadFactor K { }
1.4 Ep Eg
2 zg
SpeedFactor Q
zp zg
For satisfactory gear performance ,
Fd [ Fw ]
Ex: A 25 teeth 250 pressure angle spur gear is having a module of 2mm
and a face width 45mm to be operated at 900rpm. The gear is made of
SAE 1040.(Hardness 200BHN) The mating gear is of 60 teeth and cast iron.
Calculate a) Maximum allowable wear load
b) The maximum load that can be transmitted
2 zg 2 * 60 24
Q
zp zg 25 60 17
From the table K=1.014 Mpa
Design a pair of gears to transmit 20KW power while operating for 8-10
hrs/day sustaining medium shock. Both the gear and pinion are made of
Cast Steel (0.2% C).Take fatigue stress concentration factor Kf=1
n1 1000
Speed Ratio i12 3.226
n 2 310
1000 20 12322.86
Ft
1.623m m
Service Factor C s 1 .5
Barth Velocity Factor 3.05 V 3.05 1.623m
Kv
3.05 3.05
[3.05 1.623m]
Fd 6060.423
m
Gear width b=10m
Number of teeth on the gear wheel
[b]mbY
[ Fb]
Kf
Fd [ Fb ]
Strength Condition
PARAMETR FORMULA
PCD d=mz PINION:155MM GEAR: 500MM
WIDTH b=10m 50MM
PITCH LINE
VELOCITY
dn / 60 8.115m/s
dp=0.155 meter
b = 0.050 meter
2 Ng 2 100
SpeedFactor Q 1.527
Np Ng 31 100
Strength Condition
Fd [ Fw ]
13530.49 0.155 0.050 1.527 K
1143333.12 K
1.14( MPa) K
Material should be heat treated to 300 BHN.