(bevel gear solution)

EXAMPLE:0 1
A pair of bevel gears is required to transmit 10 kw power at 500 rpm from a motor shaft
to a machine shaft the speed reduction is 3:1 and the pinion have 24 teeth with pressure
angle

20

and to be made of cast steel having strength of 75 N/ mm

be made of cast iron with static stress of 55 N/ mm

.the gear is to

.pinion is mounted midway on the

shaft which is supported between two bearings having span of 200mm .design the gear
pair and the pinion shaft.
Solution :
Shaft angle = 1+ 2
Pitch angle of pinion
tan 1 =

sin
Z1
+ cos
Z2

1 sin 60
1 = tan
3+ cos 60

1 = 13.9
Pitch angle of gear 2 = 60 -13.9 = 46.1
Z1 = 24
Z2 = Speed reduction ratio Z1
= 3 24 = 72
Z1 =

Z1
cos 1

24.72
cos 13.9 = 24.72

Z2 =

Z2
cos 2

72
cos 46.1

= 103.84

0.912
For pinion Y1 = (0.154 109.84 ) = 0.4562
Strength factor for pinion Y1 d 1=0.3679 75 = 27.59
For gear Y2 d 2

= 0.4562 55 = 25.09
P 1000
V

Tangential force Ft =

10 1000
m 24 500

15915.5
m

,N

Assume service factor Cs = 1.0 and Cv = 0.35

Cs Ft
Cv

Fmax =

1.0 15915.5
=
0.35 m

45472.8
m

,N

2
Fbeam= 12.5m m 0.4562 55 0.75 = 235.23 m

Fbeam Fmax
2

235.23 m =

45472.8
m

m = 5.782 mm

m = 6 mm as per IS:S037-1969
d1 = m.Z1 = 144 mm
d2 = m.Z2 = 432 mm
V=

d1N 1
=
60

Cv =

0.144 500
= 3.77 m/sec
60

3.05
3.05+V = 0.4472

b = 12.5 mm
Ft =

L = 4b = 300 mm

15915.5
=
m

15315.5
= 2652.6 N
6

1.0 2652.6
= 5931.5 N
0.4472

Fmax =

Fbeam = 75 6 0.4562 55 0.75 = 8468.2 N

Dynamic load Fdyn = Ft

+ K 3 V (Cb+ Ft )
K 3 V Cb+ Ft

K3 = 26.67
E2

1 1
+
E1
K 1
e

Dynamic load factor =

C=

0.0652 0.210 2 0.2 106

6
= 724.4
9.0 0.2 10 2

Cb + Ft = 724.4 75 + 2652.6 = 56,982.6

Cb+ Ft = 238.7
F dyn =

2652.6+ 20.46 3.77 56982

= 16676.3 N
20.67 3.77+238.71

Endurance strength Fen = 1.5 fd

1.5 fdyn = bm y m

Lb
L

2
1.5 16676.3 = 75 6 0.4562 en 0.75 = en = 162.5 N / mm

BHN requried =

162.5
1.75

= 92.8

d1bqk
cos 1

Fwear =

Q =Ratio Factor =

2 z12
z 2+ z 1

2 103.84
2472+103.84

= 1.625

Load stress Fector:

(k) =

fdyn cos 1
bqd 1

(k) =

0.928 =

2 es sin
1.4

16676.3 cos 13.9

75 1.625 144

= 0.928

1
1
+
= ( E1 E2 )

2 es sin 2
1.4

2 0.2 106
2
= 0.210 6 0.2 106 = 616.3 N / mm
Radial load on pinion :
Ft = ft tan cos 1
Fte =

ft L
L0.5 b

2652.6 300
= 3000.5 75
Ft = 3031.5

= 3031.5 N
2

tan

cos 13.9

= 1071 N

Fa = ft e tan sin 1
= 3031.5 tan 20 sin 13.9=265 N
Max BM due to radial force :

F L
4

MT =

1071 2
4

= 53.55 N

Tangential force :
Mte =

Ft e L
4
3031.5 0.2
4

= 151.57

2
2
M = Mt + Mte

T=

53.552+151.57 2
10 1000
2 500
(
)
60

P
W =

Ted = M +T

= 191 N m

= 160.75 +191

Take t = 75 N / mm

Ds =(

=160.75 Nm

= 249.6 Nm

16 Ted 1

t
3

16 249.6 1000 1

75
3

Axial stress induced :

a=

4 fa 4 265
2
=
=0.43
N / mm
ds2 282

16 Teq 16 249.6 1000

=
ds2
282
=57.9 N / mm2

EXAMPLE: 02

2
= 25.7 N / mm

A pair of bevel gears with 20

pressure angle consist of a 20 teeth pinion meshing

with a 30 teeth gear. The module is 4mm wile the face width is 20mm. the material for
the pinion and gear is steel 50c4 the gear teeth are lapped and ground and the surface
hardness is 400 BHN. The pinion rotate at 500rpm and receives 2.5 kw power from
electric motor the starting torque of motor is 150 % of the rated torque determine the
factor of safety against bending failure and against pitting failure.
Solution :
Given Data :
kw = 25
np = 500 rpm
zp
= 20
zg
=30
m
= 4 mm
b
= 20mm
Sut = 750 N / mm

BHN =400
=20
Starting torque = 150
maching garde = class 3
Step : 01 ( Beam strenth )
tan

zp
zg

20
30

=33.69

Z p =

zp
cos

20
cos 33.69

= 24.04

0.337+ ( 0.3400.337 ) (24.0424 )

=0.33712
(2524)

Sb = Sut / 3 =750 3 = 250 c

Dp =m zp 4 20 = 80mm
Dg = m zg = 4 30 = 120mm

Ao =

Dp 2 Dg 2
) +(
)
2
2
80 2 120 2
) +(
)
2
2

=72.11mm
Sb = m b b y (1C)
=

4 20 250 0.3712(1(

20
))
72.11

= 4872.37 N
Step : 02 ( Beam strength)
Q=

2 Zg
2 30
)
(
)
=
Zg+ Zp tan
30+ 20 tan 33.69 = 1.385 mm
2

BHN
K = 0.16 ( 100 )
2

400
=0.16 ( 100 )

2
= 2.56 N / mm

Sw =

Sw =

Dp K
( 0.75 b Q
)
cos
80 2.56
( 0.75 20 1.385
)=5113.53 N
cos 33.69

Step : 03 (Tangential force )

MT =

Pt =

)(

60 10 (kw)
60 10 (2.5)
=
=47786.48 N
2 np
2 500

)
2( 47746.48)
=(
( 2(MT
)
)=1193.6 N
Dp
80

Step : 04 (Dynamic load )

500
=2.094 m/s
( 60Dp10np )=( 6080
10 )

V=

2
C = 11400 N / mm

b = 20mm

Pt = 1193.66 N
21 V (Ceb+ Pt )
21V + ( Ceb+ Pt )

Pd =

21(2.094) ( ( 11400 ) ( 0.0125 ) ( 20 ) +1193.66 )

21 ( 2.094 )+ ( ( 11400 ) ( 0.0125 ) ( 20 ) +1193.66 )

= 1653.25 N
Step : 05 (Effective load )
Peff = (Cs Pt + Pd)
= (1.5 1193.66 + 1653.25)
= 3443.75 N
Step : 06 (Factor of safety)
(Fs) =

Sb
=1.41 N
( Peff
)=( 4872.53
3443.75 )

Patting failure =

Sw
5113.3
( Peff
)=( 3443.75
)=1.48 N

EXAMPLE:03
A pair of straight bevel gears is mounted on a shaft which is intersecting at right angles.
The gear are made of steel and surface hardness is 300 BHN number of teeth on pinion
and gear are 40 $&65 module at the outside diameter 3mm face width 35 mm calculate
the wear strength.
Solution :
Given Data :
Zp = 40

Zg = 65
BHN = 300
m = 3mm
b = 35mm

Beam strength
BHN 2
(
)
(k) = 0.16
100
zp
tan = zg

300 2
(
=0.16 100 )

2
1.44 N / mm

40
65

=31.60

2 Zg
2 65
Q = ( Zg+ Zp tan ) = ( 65+40 tan31.60 ) = 1.45 mm
Dp = m Zp=3 40

dp =

= 120

Dp
( cos
)

120=

( cosDp31.60 )

= Dp = 102.20

Dp K
( 0.75 b Q
)
cos

Sw =

Sw =

102.20 1.44
( 0.75 35 1.45
)
cos 31.60

= 6576.73 N

EXAMPLE:04
A pair of bevel gear is required to transmit 10 kw at 500 rpm from the motor shaft to
0

the another shaft at 250 rpm. The pinion has 24 teeth the pressure angle 20

if the

shaft axis are at right angle to each other find the module, face width, addendum ,out
side diameter and slant height the gear are capable of withstanding static stress of 60
Mpa the tooth form factor as 4.5/4.5+v the pitch line speed in m/s the face width may be
taken as of the slant height of the pitch cone.
Solution :
Given data :
3
P = 10kw = 10 10 WALT

Np = 500 rpm
Ng = 250 rpm
Zp = 24 ,
dp = 24 m ,
=20
Finding teeth on gear :
:

( npng )=( ZgZp )

Zg
=( )
( 500
)
250
24
Zg = 48

Beam strength (Sb) :

Sb =

( Aob ))

m b b y (1

= (Sut) D/3 = 60 N / mm
b =10 m

287
p 0.484
Zp '

Zp
, Zp cos p

( )

p=

( ZgZp )= ( 2448 )

p=tan1

1
2

( 12 )

Zp = 26.83
p = 0.3770
0

Hear 20

Ao =

full depth involute :

Dp 2 Dg 2
) +(
)
2
2
24 2 48 2
) +( )
2
2

=26.83 mm
m
Sb = 60 10m 0.3770 (1- ( 26.83 ) )
2
Sb = 141.89 N / mm

Wear strength :
Q=

2 Zg
2 107.31
)
(
)
=
Zg ' + Zp '
107.31+26.83 = 1.599 mm

BHN = 350
BHN 2
(
)
(k) = 0.16
100

350 2
(
=0.16 100 )

2
1.96 N / mm

Q Dp K
( 0.75 bcosp
)

Sw =

m 1.599 1.96
( 0.75 24 m 10
)
cos 63.43

Sw =

= 1261.20 N
Effective load :
c Dp np 24 m500
=
=0.628 m/s
60 103
60 103

V=

P
V

Pt =

Peff =

=
Cs
Cv

10000
0.628

= 15915.49 N/m

Pt

1.5
)
4.5
=
4.5+0.628

15915.48
m

1.5
)
4.5
15915.48

4.5+ 0.628
m

( 4.5+0.628 ) 5305.16
m

Estimation module :
Sw = Nf Peff
3
1261.20 m =5305.16 ( 45+6.625 m )

1261.20 m =23873.22+3331.64 m

m = 7.4 mm

m = 8 mm