SECTION 12 HELICAL GEARS

Page 1 of 14
DESIGN PROBLEMS

701. For continuous duty in a speed reducer, two helical gears are to be rated at 7.4 hp
at a pinion speed of 1750 rpm; 75 . 2
w
m ; the helix angle 15
o
; 20
o
F.D. teeth in
the normal plane; let 21 =
p
N teeth, and keep
p
D b 2 < . Determine the pitch, face,
g
N , and the material and heat treatment. Use through-hardened teeth with a
maximum of 250 BHM (teeth may be cut after heat treatment).

Solution:
o
15 =
o
n
20 =
12
p p
m
n D
v

=
d d
p
p
P P
N
D
21
= =
rpm n
p
1750 =
( )
d
d
m
P
P
v
9621
12
1750
21
=
|
|

\
|
=

( )( )
d
d
m
t
P
P
v
hp
F 38 . 25
9621
4 . 7 000 , 33 000 , 33
=
|
|

\
|
= =
p
D b 2
d d
P P
b
42 21
2 =
|
|

\
|
=
( )
( )
lb
Cb F v
Cb F v
F F
t m
t m
t d
2
1
2
2
cos 05 . 0
cos cos 05 . 0

+ +
+
+ =
Table AT 25
Assume 1660 = C
o
15 =
lb
P
P
P
P
P
P
P F
d
d
d
d
d
d
d d
2
1
2
2
15 cos
42
1660 38 . 25
9621
05 . 0
15 cos 15 cos
42
1660 38 . 25
9621
05 . 0
38 . 25
(

|
|

\
|
+ +
|
|

\
|
(

|
|

\
|
+
|
|

\
|
+ =
SECTION 12 HELICAL GEARS
Page 2 of 14
lb
P
P
P
P
P
P
P F
d
d
d
d
d
d
d d
2
1
65050
38 . 25
481
65050
38 . 25
465
38 . 25
|
|

\
|
+ +
|
|

\
|
+
+ =
For continuous service:
d w
F F

2
cos
g p
w
QK bD
F =
( )
467 . 1
1 75 . 2
75 . 2 2
1
2
=
+
=
+
=
g
g
m
m
Q
Table At 26, Bhn = 250
Sum of BHN = 500,
o
n
20 =
131 =
g
K
( )( )
2 2
670 , 181
15 cos
131 467 . 1 21 42
d d d
w
P P P
F =
|
|

\
|
|
|

\
|
=
d w
F F
By trial and error method

d
P
d
F
w
F
7 3967 3708
6 4758 5046

use 6 =
d
P
in
P
D
d
p
5 . 3
6
21 21
= = =
in
P
b
d
7
6
42 42
= = =
fpm
P
v
d
m
1604
6
9621 9621
= = =
Fig. AF 19, permissible error = 0.0018 in
Fig. AF 20
Use carefully cut gears, 6 =
d
P
Error = 0.001 in is o.k.

For material
Strength
d f
s
P K
sbY
F
cos
=
SECTION 12 HELICAL GEARS
Page 3 of 14
23
15 cos
21
cos
3 3
= = =

p
ep
N
N
Table AT 24, Load near middle
23 =
ep
N , FD
n
o
20 =
565 . 0 = Y
assume 0 . 2 =
f
K
d sf s
F N F =
assume 0 . 2 =
sf
N
( )( )
( )( )
( )( ) 2 4758
6 2
15 cos 565 . 0 7
=
s

psi s 892 , 29 =
use
3
u
n
s
s =
( ) psi s
u
676 , 89 892 , 29 3 = =
Use C1050, OQT 1100 F,
ksi s
u
122 = , 250 248 < = BHN

Ans.
6 =
d
P
in b 7 =
( )( ) 58 21 75 . 2 = = =
p w g
N m N
Material. C1050, OQT 1100 F

703. A pair of helical gears, subjected to heavy shock loading, is to transmit 50 hp at
1750 rpm of the pinion.; 25 . 4 =
g
m ;
o
15 = ; minimum .
4
3
4 in D
p
= ; continuous
service, 24 hr/day; 20
o
F.D. teeth in the normal plane, carefully cut; through-
hardened to a maximum BHN = 350. Decide upon the pitch, face width, material
and its treatment.

Solution:
( )( )
fpm v
m
2176
12
1750 75 . 4
= =


( )( )
( )
lb
v
hp
F
m
t
758
2176
50 000 , 33 000 , 33
= = =
Dynamic load:
( )
( )
lb
Cb F v
Cb F v
F F
t m
t m
t d
2
1
2
2
cos 05 . 0
cos cos 05 . 0

+ +
+
+ =
Fig. AF 19, fpm v
m
2176 =
Permissible error = 0.0014 in
SECTION 12 HELICAL GEARS
Page 4 of 14
Use carefully cut gears, in e 001 . 0 = , 5 =
d
P as standard

Table AT 25,
Steel and steel, 20
o
FD
1660 = C
( )( )
( ) ( )
lb
b
b
F
d
2
1
2
2
15 cos 1660 758 2176 05 . 0
15 cos 15 cos 1660 758 2176 05 . 0
758
+ +
+
+ =
( )
( )
lb
b
b
F
d
2
1
8 . 1548 758 8 . 108
8 . 1548 758 1 . 105
758
+ +
+
+ =
Wear load:

2
cos
g p
w
QK bD
F =
( )
619 . 1
1 25 . 4
25 . 4 2
1
2
=
+
=
+
=
g
g
m
m
Q
Table At 26, 20
o
FD,
Sum of BHN =2(350)=700
270 =
g
K
( )( )( )
b
b
F
w
2225
15 cos
270 619 . 1 75 . 4
2
= =
d w
F F , . 69 . 4
tan
2
2
min
in
P
P b
d
a
= = =

By trial and error method

b
d
F
w
F
5 5203 11125
6 5811 13350

use in b 5 =

Material:
Strength:
d f dn f
s
P K
sbY
P K
sbY
F
cos
= =

3
cos
p
ep
N
N =
( )( ) 22 375 . 4 5 = = =
p d p
D P N
25
15 cos
22
3
= =
ep
N
Table AT 24, Load near middle
SECTION 12 HELICAL GEARS
Page 5 of 14
25 =
ep
N , FD
n
o
20 =
580 . 0 = Y
assume 7 . 1 =
f
K
( )( )
( )( )
s
s
F
s
32955 . 0
5 7 . 1
15 cos 580 . 0 5
= =
d sf s
F N F =
for 24 hr/day service, heavy shock loading
75 . 1 =
sf
N
( )( ) 5203 75 . 1 32955 . 0 = s
psi s 629 , 27 =
use
3
u
n
s
s =
( ) psi s
u
887 , 82 629 , 27 3 = =
Table AT 9
Use 4150, OQT 1200 F,
ksi s
u
159 = , 350 331< = BHN
Ans.
5 =
d
P
in b 5 =
Material. 4150, OQT 1200 F

705. Design the teeth for two herringbone gears for a single-reduction speed reducer
with 80 . 3 =
w
m . The capacity is 36 hp at 3000 rpm of the pinion;
o
30 = ; F.D.
teeth with
o
20 =
n
. Since space is at a premium, the initial design is for 15 =
p
N
teeth and carburized teeth of AISI 8620; preferably
p
D b 2 < .

Solution:
d d
p
p
P P
N
D
15
= =
p
D b 2
d
p
P
D b
30
2 = =
12
p p
m
n D
v

=
( )
d
d
m
P
P
v
781 , 11
12
3000
15
=
|
|

\
|
=

SECTION 12 HELICAL GEARS
Page 6 of 14
( )( )
d
d
m
t
P
P
v
hp
F 101
781 , 11
36 000 , 33 000 , 33
=
|
|

\
|
= =
Dynamic load
( )
( )
lb
Cb F v
Cb F v
F F
t m
t m
t d
2
1
2
2
cos 05 . 0
cos cos 05 . 0

+ +
+
+ =
o
n
20 =
o
30 =
Assume 1660 = C , Table AT 25, 20
o
FD
lb
P
P
P
P
P
P
P F
d
d
d
d
d
d
d d
2
1
2
2
30 cos
30
1660 101
781 , 11
05 . 0
30 cos 30 cos
30
1660 101
781 , 11
05 . 0
101
(

|
|

\
|
+ +
|
|

\
|
(

|
|

\
|
+
|
|

\
|
+ =
lb
P
P
P
P
P
P
P F
d
d
d
d
d
d
d d
2
1
350 , 37
101
589
350 , 37
101
510
101
|
|

\
|
+ +
|
|

\
|
+
+ =
Wear load

2
cos
g p
w
QK bD
F =
( )
583 . 1
1 80 . 3
80 . 3 2
1
2
=
+
=
+
=
g
g
m
m
Q
For AISI 8620, carburized, 20
o
FD
750 =
g
K for 10
10
cycles
( )( )
2 2
350 , 712
30 cos
750 583 . 1 15 30
d d d
w
P P P
F =
|
|

\
|
|
|

\
|
=
By trial and error,
d w
F F
d
P
d
F
w
F
5 4433 28,494
4 5454 44,522
6 3817 19,788
8 3173 11,130
9 3008 8794

For carefully cut gears, 001 . 0 = e
fpm v 1400
max
= (Fig. AF 9)

SECTION 12 HELICAL GEARS
Page 7 of 14
d
P
d
m
P
v
781 , 11
=
5 2356.2
4 1963.5
6 1683
8 1473
9 1309 fpm

use 9 =
d
P
lb F
d
3008 =
d w
F lb F > = 5794
in
P
b
d
3 . 3
9
30 30
= = =
use in b 0 . 3 =

To check for strength
d f dn f
s
P K
sbY
P K
sbY
F
cos
= =

3
cos
p
ep
N
N =
15 =
p
N
23
30 cos
15
3
= =
ep
N
Table AT 24, Load near middle
23 =
ep
N , FD
n
o
20 =
565 . 0 = Y
assume 7 . 1 =
f
K
8620, SOQT 450, ksi s
u
167 =
3
u
n
s
s =
5 . 83
2
167
2
= = =
u
n
s
s
( )( )( )
( )( )
( ) lb F lb F
d s
3008 8011
9 7 . 1
30 cos 565 . 0 0 . 3 500 , 83
= > = =
Designed Data:
9 =
d
P
in b 0 . 3 =
15 =
p
N
( )( ) 57 15 8 . 3 = = =
p w g
N m N
SECTION 12 HELICAL GEARS
Page 8 of 14
in
P
N
D
d
p
p
67 . 1
9
15
= = =
in
P
N
D
d
g
g
33 . 6
9
57
= = =

CHECK PROBLEMS

707. The data for a pair of carefully cut gears are: 5 =
dn
P ,
o
20 =
n
,
o
12 = ,
. 5 . 3 in b = , 18 =
p
N , 108 =
g
N teeth; pinion turns 1750 rpm. Materials: pinion,
SAE 4150, OQT to BHN = 350; gear, SAE 3150, OQT to BHN = 300. Operation
is with moderate shock for 8 to 10 hr./day. What horsepower may be transmitted
continuously?

Solution:
d
p
p
P
N
D =
( ) 89 . 4 15 cos 5 cos = = =
dn d
P P
in D
p
681 . 3
89 . 4
18
= =

Wear load

2
cos
g p
w
QK bD
F =
. 5 . 3 in b =
( )
7143 . 1
108 18
108 2
2
=
+
=
+
=
g p
g
N N
N
Q
Table AT 26,
o
20 =
n

Sum of BHN = 350 + 300 = 650
233 =
g
K
( )( )( )( )
lb F
w
5379
12 cos
233 7143 . 1 681 . 3 5 . 3
2
= =
Strength of gear
lb
P K
sbY
F
dn f
s
=
For gear: SAE 3150, OQT to BHN = 300
ksi s
u
151 =
( ) ksi s s
u n
5 . 75 151 5 . 0 5 . 0 = = =
116
12 cos
108
cos
3 3
= = =

g
eg
N
N
SECTION 12 HELICAL GEARS
Page 9 of 14
Table AT 24, Load near middle,
o
20 =
n

763 . 0 = Y
( )( ) 6 . 57 763 . 0 5 . 75 = = Y s
n

For pinion: SAE 4150, OQT to BHN = 350
( ) ksi BHN s
u
175 350 5 . 0 5 . 0 = = =
( ) ksi s s
u n
5 . 87 175 5 . 0 5 . 0 = = =
19
12 cos
18
cos
3 3
= = =

p
ep
N
N
Table AT 24, Load near middle,
o
20 =
n

534 . 0 = Y
( )( ) 7 . 46 534 . 0 5 . 87 = = Y s
n


Therefore use pinion as weak
Assume 7 . 1 =
f
K
( )( )( )
( )( )
lb F
s
240 , 19
5 7 . 1
534 . 0 5 . 3 500 , 87
= =
For moderate shock, 8 to 10 hr./day
Use 5 . 1 =
sf
N
d sf s
F N F
d
F 5 . 1 240 , 19 =
lb F
d
827 , 12
Therefore use lb F F
w d
5379 = =
( )
( )
lb
Cb F v
Cb F v
F F
t m
t m
t d
2
1
2
2
cos 05 . 0
cos cos 05 . 0

+ +
+
+ =
Fig. AF 20, carefully cut gears, 5 =
dn
P , in e 001 . 0 =
Table AT 25, steel and steel, 20
o
FD
1660 = C
( )( )
fpm
n D
v
p p
m
1686
12
1750 681 . 3
12
= = =

( ) ( ) [ ]
( ) ( ) [ ]
lb
F
F
F F
t
t
t d
2
1
2
2
12 cos 5 . 3 1660 1686 05 . 0
12 cos 12 cos 5 . 3 1660 1686 05 . 0
+ +
+
+ =
[ ]
[ ]
lb
F
F
F F
t
t
t d
5379
5559 3 . 84
5559 46 . 82
2
1
=
+ +
+
+ =
Trial and error
lb F
t
1800 =
( )( )
hp
v F
hp
m t
92
000 , 33
1686 1800
000 , 33
= = =
SECTION 12 HELICAL GEARS
Page 10 of 14

708. Two helical gears are used in a single reduction speed reducer rated at 27.4 hp at
a motor speed of 1750 rpm; continuous duty. The rating allows an occasional 100
% momentary overload. The pinion has 33 teeth. 10 =
dn
P , . 2 in b = ,
o
20 =
n
,
o
20 = , 82 . 2 =
w
m . For both gears, the teeth are carefully cut from SAE 1045
with BHN = 180. Compute (a) the dynamic load, (b) the endurance strength;
estimate 7 . 1 =
f
K . Also decide whether or not the 100 % overload is damaging.
(c) Are these teeth suitable for continuous service? If they are not suitable
suggest a cure. (The gears are already cut.)

Solution:
d
p
p
P
N
D =
( ) 66 . 9 15 cos 10 cos = = =
dn d
P P
in D
p
42 . 3
66 . 9
33
= =
( )( )
fpm
n D
v
p p
m
1567
12
1750 42 . 3
12
= = =

( )
lb
v
hp
F
m
t
577
1567
4 . 27 000 , 33 000 , 33
= = =
(a) Dynamic load
( )
( )
lb
Cb F v
Cb F v
F F
t m
t m
t d
2
1
2
2
cos 05 . 0
cos cos 05 . 0

+ +
+
+ =
Fig. AF 20, carefully cut gears, 10 =
dn
P , in e 001 . 0 =
Table AT 25, steel and steel, 20
o
FD
1660 = C
in b 2 =
( ) ( ) [ ]
( ) ( ) [ ]
lb F
d
2578
15 cos 2 1660 577 1567 05 . 0
15 cos 15 cos 2 1660 577 1567 05 . 0
577
2
1
2
2
=
+ +
+
+ =

(b) Endurance strength
lb
P K
sbY
F
dn f
s
=
For SAE 1045, BHN = 180
( ) ksi BHN s
u
90 180 5 . 0 5 . 0 = = =
( ) ksi s s
u n
45 90 5 . 0 5 . 0 = = =
37
15 cos
33
cos
3 3
= = =

p
ep
N
N
Table AT 24, Load near middle,
o
20 =
n

SECTION 12 HELICAL GEARS
Page 11 of 14
645 . 0 = Y

7 . 1 =
f
K
( )( )( )
( )( )
lb
P K
sbY
F
dn f
s
3415
10 7 . 1
645 . 0 2 000 , 45
= = =
For 100 % overload
( ) lb F
t
1154 577 2 = =
( )
( )
lb
Cb F v
Cb F v
F F
t m
t m
t d
2
1
2
2
cos 05 . 0
cos cos 05 . 0

+ +
+
+ =
( ) ( ) [ ]
( ) ( ) [ ]
lb F
d
3475
15 cos 2 1660 1154 1567 05 . 0
15 cos 15 cos 2 1660 1154 1567 05 . 0
1154
2
1
2
2
=
+ +
+
+ =
Since
d s
F F , 100 % overload is not damaging

(c)

2
cos
g p
w
QK bD
F =
. 2 in b =
( )
476 . 1
1 82 . 2
82 . 2 2
1
2
=
+
=
+
=
w
w
m
m
Q
Table AT 26,
o
20 =
n

Sum of BHN = 2(180) = 360
5 . 62 =
g
K
( )( )( )( )
( ) lb F lb F
d w
2578 676
15 cos
5 . 62 476 . 1 42 . 3 2
2
= < = =
Therefore not suitable for continuous service.
Cure: Through hardened teeth
For Bhn
( ) 238 5 . 62
676
2578
= =
g
K
min Bhn = 0.5(650) = 325

709. Two helical gears are used in a speed reducer whose input is 100 hp at 1200 rpm,
from an internal combustion engine. Both gears are made of SAE 4140, with the
pinion heat treated to a BHN 363 415, and the gear to 321 363; let the teeth
be F.D.; 20
o
pressure angle in the normal plane; carefully cut; helix angle
o
15 = ; 22 =
p
N , 68 =
g
N teeth; 5 =
d
P , in b 4 = . Calculate the dynamic load,
the endurance strength load, and the limiting wear load for the teeth. Should these
gears have long life if they operate continuously? (Data courtesy of the Twin
Disc Clutch Co.)

Solution:
SECTION 12 HELICAL GEARS
Page 12 of 14
in
P
N
D
d
p
p
4 . 4
5
22
= = =
( )( )
fpm
n D
v
p p
m
1382
12
1200 4 . 4
12
= = =

( )
lb
v
hp
F
m
t
2388
1382
100 000 , 33 000 , 33
= = =
Dynamic load
( )
( )
lb
Cb F v
Cb F v
F F
t m
t m
t d
2
1
2
2
cos 05 . 0
cos cos 05 . 0

+ +
+
+ =
Fig. AF 20, carefully cut gears, 5 =
dn
P , in e 001 . 0 =
Table AT 25, steel and steel, 20
o
FD
1660 = C
in b 4 =
( ) ( ) [ ]
( ) ( ) [ ]
lb F
d
5930
15 cos 4 1660 2388 1382 05 . 0
15 cos 15 cos 4 1660 2388 1382 05 . 0
2388
2
1
2
2
=
+ +
+
+ =
Endurance strength load
lb
P K
sbY
F
d f
s
cos
=
Assume 7 . 1 =
f
K
Pinion
( ) ksi BHN s
n
75 . 90 363 25 . 0 25 . 0 = = =
25
15 cos
22
cos
3 3
= = =

p
ep
N
N
Table AT 24, Load near middle,
o
20 =
n

580 . 0 = Y
( )( )( )
( )( )
lb
P K
sbY
F
d f
s
925 , 23
5 7 . 1
15 cos 580 . 0 4 750 , 90 cos
= = =


Gear
( ) ksi BHN s
n
25 . 80 321 25 . 0 25 . 0 = = =
75
15 cos
68
cos
3 3
= = =

p
ep
N
N
Table AT 24, Load near middle,
o
20 =
n

735 . 0 = Y
( )( )( )
( )( )
lb
P K
sbY
F
d f
s
811 , 26
5 7 . 1
15 cos 735 . 0 4 250 , 80 cos
= = =


use lb F
s
925 , 23 =


SECTION 12 HELICAL GEARS
Page 13 of 14
Limiting Wear Load

2
cos
g p
w
QK bD
F =
Table AT 26,
o
20 =
n

Sum of BHN = 684 to 778 use 700
270 =
g
K
( )
511 . 1
68 22
68 2
2
=
+
=
+
=
g p
g
N N
N
Q
( )( )( )( )
lb F
w
7696
15 cos
270 511 . 1 4 . 4 4
2
= =
Since ( ) ( ) lb F lb F
d w
5930 7696 = > = these gears have long life if they operate
continuously.

CROSSED HELICAL

710. Helical gears are to connect two shafts that are at right angles
( 20
1
= N , 40
2
= N , 10 =
dn
P ,
o
45
2 1
= = ). Determine the center distance.

Solution:
1 1
1 1
1
cos
cos

D P
P
D
N
dn
cn
= =
( )( ) 45 cos 10 20
1
D =
in D 83 . 2
1
=
2 2 2
cos D P N
dn
=
( )( ) 45 cos 10 40
2
D =
in D 66 . 5
2
=
( ) ( ) in D D C 25 . 4 66 . 5 83 . 2
2
1
2 1 2
1
= + = + =

712. Two shafts that are at right angles are to be connected by helical gears. A
tentative design is to use 20
1
= N , 60
2
= N , 10 =
dn
P , and a center distance of 6
in. What must be the helix angles?

Solution:
o
90
2 1
= + =
1
1
1
cos
dn
P
N
D =
2
2
2
cos
dn
P
N
D =
( )
2 1 2
1
D D C + =
SECTION 12 HELICAL GEARS
Page 14 of 14
2
2
1
1
cos cos
2

dn dn
P
N
P
N
C + =
( )
2 1
cos 10
60
cos 10
20
6 2

+ =
2 1
cos
6
cos
2
12

+ =
2 1
cos
3
cos
1
6

+ =
By trial and error method
1 1
sin
3
cos
1
6

+ =
o
5 . 39
1
=
o
5 . 50
2
=

- end -