m3 Machine Design Gear

Course in Machine Design
Gears and mechanical transmissions
Udvekslinger og mekaniske
transmissioner
Machine Design
Computational Mechanics, AAU, Esbjerg
Outline
1. Product design and development [Ch. 1]
2. Steel design [Ch. 3, App. D]
3. Gears and mechanical transmissions [Ch. 11, 12, App. C]
4. Mechanism and dynamics [Ch. 3, notes]
5. Shafts, keys, and couplings [Ch. 9, App. B, C]
6. Shafts, keys, and couplings [Ch. 9, App. B, C]
7. Tolerances [Notes]
8. Fatigue I [Ch. 4, 5, App. E]
9. Fatigue II [Ch. 5, 6, App. E]
10. Fasteners – fatigue [Ch. 14]
Machine Design Gears and mechanical transmissions 2

Case study
• Life saving system for beaches
– Mobility: terrain, offroad
– Non buoyant
– Load: 2 persons + rescue equipment

Program
• Case study
• Project management
– Vision
– Mission
– Objective/goal
– Strategy
• Power considerations
• Discussion of Gears
• Gears
• Spur Gears
• Bevel gears
Gears
• Mechanical power transmission devices
between two rotating shafts
Friction Gears
Friction ensures contact. Since contact point
velocity is constant
ω1R1 = ω 2 R2
ω1 R2
= Speed ratio
ω 2 R1
Gears
Spur Bevel
Helical Worm

Gears: Constant Speed Ratio
Two arbitrary profiles in contact.
ω2
O1 C O2
ω1
Desired: We want the ratio of angular velocity to be

constant as different points come in contact.

ω2
O1 C O2
ω1
v2 = ω1O1C
v1 = ω1O1C

θ2
v2
θ1
O1 v1 Note: The tangential
ω1 components of the velocities
O
need not be equal … they2 ω2
C
can slip relative to each other
Key: The component of the velocities along the common

normal must be equal … else the parts will lose contact or
interfere
v1 cosθ1 = v2 cosθ 2
ω1O1C cos θ1 = ω2O2C cos θ 2
D1 θ1
D
θ2 2
O1
θ1
C θ2
90 − θ1
From previous: ω1O1C cosθ1 = ω 2O2C cosθ 2
But O1C cosθ1 = O1D1
ω1 O2 D2
ω1O1D1 = ω 2O2 D2 =
ω 2 O1D1
D2
O1 P
D1
C
ω1 O2 D2
From previous: =
ω 2 O1D1
By similarity triangles
ω1 O2 D2 O2 P
= = P: Pitch point.
ω 2 O1D1 O1P
P ω2
O1
ω1
O2
P: Pitch point. Intersection of normal at contact and line joining centers.
Law of conjugate action

• The ratio of angular velocities remains constant only if the pitch point
remains fixed!!
• There are many ways to ensure conjugate action
ω1 R2
Spur gears
=
ω 2 R1
• Spur gears achieve
constant speed ratio
through involute teeth.
See animation at:
http://auto.howstuffworks.co
m/gear7.html
• Pitch point does not move

Pressure angle
for two involute-profile
also remains
teeth gears in contact
constant!
Spur Gears
rb
2πrb
N=
pb

Spur Gears
Pressure angle governed

by intended pitch circle
rpb
cos ϕ =
rp
Gears behave like two

friction gears in contact
except high power transmission

Spur Gears: Definitions
Involute for rack
is a straight line!
Tool
Gear being
manufactured



Spur Gears: Meshing
• For two gears to
mesh, they must
have the same:
– Nominal pressure
angle
– Nominal circular pitch
• But can have
different
– Number of teeth
ω1 N 2
= – Pitch diameter dp, dg
ω 2 N1
Spur Gears
• Actual center distance
determines
– Actual pressure angle
– Actual circular pitch
– Actual tooth thickness
– Back-lash
– Interference
• Smaller = Pinion
– Contact ratio
• Larger = Gear

Spur Gears

Gears: Forces
Two components of force:
Ft: Useful tangential force
Fr: Radial force
Fr = Ft tan ϕ
Torque = rFt
Power = ωrFt
The tangential force is

determined from the power
being transmitted.

Gears: Stresses
Contact Stresses
Need to design gear

against both types
of stresses.
Bending stresses
Fatigue stresses!
Gears: Bending Stress

Gears: Bending Stresses
Two approaches: • Lewis assumptions:
– Simplistic Lewis – Neglect radial force
Equation – Force acts at tip
– Modern AGMA – Uniform force
method distribution
– No stress
concentration
– No sliding force
– Zero contact velocity

Mc
σ (bending ) =
I
M = Ft h
c =t/2
3
bt
I=
12
6 Ft h
σ= 2
bt

6 Ft h
Ft ⎛ 6h ⎞ Function of diametral pitch
σ= 2 = ⎜⎜ ⎟⎟
bt b ⎝ t2 ⎠
Ft ⎛ P ⎞
6 Ft h
σ= 2 = ⎜ ⎟
bt b ⎝Y ⎠
Y : Lewis Factor

Example :
Ft = 100lbf
b = 0.1" ;
P = 4; ϕ = 20; N = 28
Y = 0.35
Ft ⎛ P⎞
σ= ⎜ ⎟ = 11.45ksi
b ⎝Y ⎠

AGMA model:
• Neglect radial force Ft ⎛ P ⎞
σ = ⎜ ⎟Kv Ko Km
• Force acts at tip b ⎝J⎠
• No sliding force J : geometry factor
• Non-uniform force K v : velocity factor
distribution K o : overload factor
• Stress concentration K m : mounting factor
• Non-zero contact
velocity
Geometry factor J: allows for 2 different assumptions

Velocity factor Kv: also depends on how gear is manufactured

• Overload factor Ko: depends on power
source and driven machinery Table 15.1
• Light shock power and moderate shock
machinery, Ko = 1.5
• Mounting factor Km: depends on accuracy

of mounting and face width Table 15.2
very accurate and width of 4”, Km = 1.4
σm σa 1
+ =
Sut S n n
σ σ 1
+ =
2 Sut 2 S n n
0.4σ σ 1
S n = (Other factors) * CG C LCS 0.5Sut + =
2S n 2S n n
S n ≈ 0.4 Sut
...
σ 1
=
1.4 S n n
For the idler
σm σa
1
+ =
Sut S n n
σ 1
=
Sn n
Include 1.4 for regular gears

as a factor in Sn

S n = kt k r k ms CG C LCS 0.5Sut Conclusion
kt : temperature factor σ : AGMA
k r : reliability factor S n : From above
1 for idler σ 1
k ms :} =
1.4 for other Sn n
or design ' b' for a
given safety factor

Gears: Bending Strength - Example
Problem info:
• Pinion: 20 teeth, gear: 40 teeth
• 20 degrees pressure angle; P = 8
• Accurate mounting
• Material: Steel, heat treated to 350 Bhn.
• Standard full depth teeth
• Required life: 5 years, 60 hours/week, 50 week/year, 1100 rpm (pinion)
• Find: max horsepower that can be transmitted with a safety factor of 1.5,
and 99% reliability, based only on bending strength.
Assumptions:
• AGMA method of analysis
• Gear tooth loads transmitted at pitch point
• No load sharing
• Assume top quality hobbing operation

Ft ⎛ P ⎞
σ = ⎜ ⎟Kv Ko Km σ 1
b ⎝J⎠
=
V : 720rpm(pitch line velocity) Sn n
From Curve C (Fig.15.24) K v = 1.54
From Fig.15.23a J = 0.24 (pinion is weaker)
K m = 1.6(assumption)
K o = 1.0(assumption)
σ = 82.1Ft

S n = kt k r k ms CG C LCS 0.5Sut σ 1
=
kt : 1 Sn n
k r : 0.814
k ms : 1.4
CG : 1; C L : 1.0; CS : 0.66
S n = 65812 psi

σ 1
82.1Ft = 65812 / 1.5 =
Ft = 534lb Sn n
HP = 11.7 hp

Gears: Hertzian Contact Stress
As before
Find :
Eeq
Req
Area of contact
Max stress...
But also include the various factors

Gears: Hertzian Contact Stress
Buckingham model
Ft
σ H = Cp Kv Ko Km
bd p I
C p : E and ν dependent (Table 15.4)
d p : Pinion pitch diameter
I : Geometry factor (Eqn 15.23)

Gears: Contact Strength
Recall contact stress problems have only finite life.
Table 15.5 provides typical contact strength values Sfe for 107 cycles,
99 percent reliability and temp < 250 F
To find strength at a different number of cycles and temperature

use eqn. 15.25
S H = S feC Li C R

Bevel Gears
Note:
b: Face width
L: Pitch cone length
γ: Pitch cone angle
d: pitch dia
Bevel gears are not interchangeable!

Gears: Forces
Fr Determined from
Ft power requirements
Fr = Ft tan ϕ cos γ
Fa
Fa = Ft tan ϕ sin γ
Note: What is axial force for one bevel gear is radial force for the other.

Gears: Stresses
Both bending and contact stresses
Bending stress and strength
Ft ⎛ P⎞
σ= ⎜ ⎟Kv Ko Km
b ⎝J⎠
S n = kt k r k ms CG C LCS 0.5Sut
Factors similar or slightly different for Bevel gears
Contact stress and strength
Ft
σ H = Cp Kv Ko Km S H = S feC Li C R
bd p I
Factors similar or slightly different for Bevel gears

m3 Machine Design Gear

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Course in Machine Design

Gears and mechanical transmissions

Machine Design Gears and mechanical transmissions 2

Machine Design Gears and mechanical transmissions 3

Machine Design Gears and mechanical transmissions 6

Desired: We want the ratio of angular velocity to be

Machine Design Gears and mechanical transmissions 7

Machine Design Gears and mechanical transmissions 8

Key: The component of the velocities along the common

P: Pitch point. Intersection of normal at contact and line joining centers.

Law of conjugate action

• Pitch point does not move

Machine Design Gears and mechanical transmissions 14

Pressure angle governed

Gears behave like two

Machine Design Gears and mechanical transmissions 15

Machine Design Gears and mechanical transmissions 16

Machine Design Gears and mechanical transmissions 17

Machine Design Gears and mechanical transmissions 18

Machine Design Gears and mechanical transmissions 20

Machine Design Gears and mechanical transmissions 21

The tangential force is

Machine Design Gears and mechanical transmissions 22

Need to design gear

Machine Design Gears and mechanical transmissions 24

Machine Design Gears and mechanical transmissions 25

Machine Design Gears and mechanical transmissions 26

Machine Design Gears and mechanical transmissions 27

Machine Design Gears and mechanical transmissions 28

Machine Design Gears and mechanical transmissions 30

Machine Design Gears and mechanical transmissions 31

• Mounting factor Km: depends on accuracy

Include 1.4 for regular gears

Machine Design Gears and mechanical transmissions 34

Machine Design Gears and mechanical transmissions 35

Machine Design Gears and mechanical transmissions 36

Machine Design Gears and mechanical transmissions 37

Machine Design Gears and mechanical transmissions 38

Machine Design Gears and mechanical transmissions 39

But also include the various factors

Machine Design Gears and mechanical transmissions 40

Machine Design Gears and mechanical transmissions 41

Recall contact stress problems have only finite life.

To find strength at a different number of cycles and temperature

Machine Design Gears and mechanical transmissions 42

Bevel gears are not interchangeable!

Machine Design Gears and mechanical transmissions 44

Contact stress and strength

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