PROBLEM 10 – 0284: The normal diametral pitch of a helical gear is 2 and the helix

angle is 25 degrees. Evaluate the transverse diametral pitch,

the axial and normal circular pitch and the face width.

Solution: The transverse diametral pitch, PT, is given by the relation,

PT = PN cos(ψh) (1)

where PN = normal diametral pitch

ψh = helix angle, degrees.

Substituting values of PN and in (1),

PT = 2cos(25°) = 1.81

transverse circular pitch, PC, is given by,

PC = (π / PT) (2)

Substituting values of PT in (2),

PC = [π / (1.81)] = 1.735 in.

The normal circular pitch, PCN, is related to PC by,

PCN = PC cos(ψh) (3)

Substituting values of PC, and ψh in (3) and solving for PCN,

PCN = 1.735 cos(25°) = 1.57 in. (4)

The face width of the gear, bg, is given by,

bg = [PC / {(tan (ψh)}] (5)

Substituting values of PC and ψh in (5),

bg = [(1.735) / {tan (25°)}] = 3.72 in. (6)

PROBLEM 10 – 0285: A set of helical gears have a center distance of 5 in. The

diametral pitch and the diametral pitch normal to the teeth of

the pinion are 5 and 6 respectively. The pinion carries 25°

full depth teeth. Evaluate the number of teeth on the gear

 and the pinion and the pressure angle normal to the teeth, if

the velocity of the pinion is thrice the velocity of the gear.

Solution: Since it is given that the velocity of the pinion is thrice the velocity

of the gear,

(Ng / Np) = (1/3) (1)

where, N = gear speed, rpm

and subscripts p and g are for the pinion and the gear respectively.

Also the velocity ratio is inversely proportional to the teeth ratio,

hence

(Ng / Np) = (tp / tg) = (1/3) (2)

where, t = number of teeth.

From (2),

tg = 3tp (3)

The transverse circular pitch, PC, is related to the diametral pitch in

transverse plane, PD, by,

PC = (π / PD) (4)

Substituting the value of PD = 5 in (4),

PC = (π/5) = 0.62831 in.

The center distance, Cd, is given by the relation,

Cd = (PC / 2π) (tp + tg) (5)

Solving (5) for (tp + tg),

(tp + tg) = [(2πCd) / PC] (6)

From (3) since tg = 3tp, thus (6) reduces to

4tp = [(2πCd) / PC] (7)

or,

tp = (π/2) (Cd / PC) (8)

Substituting values of Cd and PC in (8),

 tp = (π/2) [5 / (0.62831)] (9)

or,

tp = 12.5

or,

tp ≅ 13 teeth.

The number of teeth on the gear are,

tp = 3 × 13 = 39 teeth.

The helix angle for the gear or the pinion is given by the relation,

cos (ψh) = (PD / PN) (10)

where, PN = diametral pitch normal to the pinion teeth.

Substituting values of PD and PN in (10),

cos (ψh) = (5/6) = 0.83333

or,

ψh = cos–1 (0.83333)

∴ ψh = 33.55 deg.

The pressure angle normal to the pinion teeth is given by the

relation,

tan (ɸN) = tan (ɸ) cos (ψh) (11)

where, ɸ = pressure angle of the teeth = 25°.

Substituting values of ɸ and in (11),

tan (ɸN) = tan (25°) cos (33.55°) (12)

or,

ɸN = tan–1 (0.3886226)

∴ ɸN = 21.24 deg.

PROBLEM 10 – 0286: Mechanical power is delivered from one shaft parallel to

another by a pair of helical gears of pressure angle 14(1/2)°.

 Both the pinion and the gear are made of steel of BHN value

235 and contain 30 and 43 teeth, respectively. The normal

diametral pitch is 3.5 and the face thickness is 3 in. Pinion

runs at 900 rpm, and the shaft centers are separated by 12

in. The gears conform to AGMA standard No. 9. Evaluate

the helix angle of the pinion and the horsepower capacity of

the gear set.

Solution: The pitch diameter of the pinion, Dp, is given by,

Dp = [(2tpCd) / (tp + tg)] (1)

where, t = number of teeth

Cd = center distance

and subscripts p and g are for pinion and gear, respectively.

Substituting values of tp, tg and Cd in (1),

Dp = [(2 × 30 × 20) / (30 + 43)] = 9.86 in. (2)

Similarly, the pitch diameter of the gear, Dg, is given by,

Dg = [(2tpCd) / (tp + tg)] (3)

Substituting values in (2),

Dg = [(2 × 43 × 12) / (30 + 43)] = 14.37 in. (4)

The helix angle for the pinion, ɸp, is given by,

cos (ɸp) = [tp / (PDNDp)] (5)

where, PDN = normal diametral pitch.

Substituting values of tp, PDN and Dp in (5),

cos (ɸp) = [30 / (3.5 × 9.86)] (6)

or,

ɸp = cos–1 (0.86931) = 29.62° (7)

The formative number of teeth on the pinion, tp', is given by the

relation,

tp' = [tp / {cos (ɸp)}] (8)

 Substituting values of tp and ɸp in (8),

tp' = [30 / {cos3 (29.62°)}] = 45.66 (9)

or, tp' ≅ 46

The bending strength of the teeth is given by,

FB = SbbyPN (10)

where, Sb = allowable stress in bending

b = face thickness of the pinion

y = form factor

PN = normal circular pitch.

From Table 10.5 (see prep) for steel of BHN value = 235.

Sb = 22,000 psi

for helical gears. From Table 10.7 (see prep) for number of teeth on the

pinion ≅ 46, and for 14(1/2)° pressure angle

y = 0.109.

PN is given by,

PN = [π / (PDN)] (11)

Substituting value of PDN in (11),

PN = [π / (3.5)] = 0.89759

Substituting values of Sb, b, y and PN in (10),

FB = 22,000 × 3 × 0.109 × 0.89759 lb.

∴ FB = 6457.26 lbs.

From Table 10.5 (see prep) for steel of BHN value = 235, and

pressure angle 14(1/2)°,

factor k = 58.

The teeth strength in wear is given by,

FW = 2Dpb [tg / (tp + tg)] [k / {cos2 (ɸp)}] (12)

Substituting values of all the known quantities in (12),

FW = 2 × 9.86 × 3 [43 / (30 + 43)] [58 / {cos2 (19.62°)}] (13)

or,

FW = 2674.5 lbs.

Since FW < FB, hence FW will determine the horsepower capacity of

the gear set.

The dynamic load for helical gears is given by,

FD = [(1.46 × ε × Np × tp × b × Rp × Rg) / √(Rp2 + Rg2)] (14)

where, ε = tooth profile error, inches

Np = pinion speed, rpm

Rp = pitch radius of the pinion, inches

Rg = pitch radius of the gear, inches.

From table 10.10 (see prep), for AGMA standard No. 9, diametral

pitch = 3.5 and pitch diameter of the pinion ≅ 10 in. , ε = 0.0024 in.

Substituting values of all known quantities in (14),

FD = [(1.46 × 0.0024 × 900 × 30 × 3 × 4.93 × 7.0685)

/ √{(4.93)2 + (7.0685)2}]

or,

FD = 1147.68 lbs.

The transmitted load, FT, is given by,

FT = FW – FD (15)

Substituting values of FW and FD in (15),

FT = (2674.5 – 1147.68) lb.

or,

FT = 1526.8 lbs.

The pitch line velocity of the pinion is given by,

Vp = [(πDpNp) / 12] (16)

Substituting values of Dp and Np in (16),

Vp = [(π × 9.86 × 900) / 12] (17)

or,
 Vp = 2323.2 fpm

The horsepower capacity of the gear set is given by,

H.P. = [(FTVp) / (33,000)] (18)

Substituting values of FT and Vp in (18),

H.P. = [(1526.8 × 2323.2) / (33,000)] (19)

or,

H.P. = 107.5

PROBLEM 10 – 0287: A centrifugal water pump is driven by a 120 hp electric motor

rotating at 1200 rpm through two helical gears. The gears

have a face thickness of 2 in. , diametral pitch and pressure

angle in the normal plane of 3 and 22° respectively. The

pinion, which is the driver, is right–handed and contains 20

teeth. The helix angle is 25° and gear ration is 3. The

material of the gear and the pinion is AISI 3150 steel with a

durability of 90%. The gears are installed with average

accuracy and the driven gear may experience light shock.

Determine the safety factor by considering,

(1) bending strength of the teeth

(2) wear strength of the teeth.

Table 1: Deviation multiplication factor table

Percentage reliability df

90.00 1.28

95.00 1.64

98.00 2.05

99.00 2.33
 99.90 3.08

99.99 3.62

Table 2: Reliability factor, Cr

reliability Cr

High reliability 1.50 or higher

Fewer than 1 failure in 100 1.00

Fewer than 1 failure in 3 0.70

Table 3: Elastic coefficient, CE, psi for spur, helical and herringbone gears.

Gear material and modulus of elasticity

Pinion Material and Steel Cast Iron Aluminum Bronze Tin Bronze
modulus of Elasticity, E 30 × 106 19 × 106 17.5 × 106 16 × 106

Steel 30 × 106 2300 2000 1950 1900

Cast iron 19 × 106 2000 1800 1800 1750

Aluminum 17.5 × 106 1950 1800 1750 1700

Tin bronze 16 × 106 1900 1750 1700 1650

Solution: (1) The transverse diametral pitch for the pinion is given by the

relation,

PT = PN cosψ (1)

where, PN = normal diametral pitch

ψh = helix angle, degrees.

Substituting values of PN and ψh in (1),

PT = 3 cos(25°) = 2.72 (2)

The pinion pitch–diameter, Dp, is given by,

Dp = (tp / PT) (3)

where, tp = number of teeth on the pinion.

Substituting values of tp and PT in (3),

Dp = [20 (2.72)] = 7.35 in.

The pitch line velocity of the pinion is given by,

Vp = [(πDpNp) / 12] fpm (4)

where, Np = pinion speed, rpm.

Substituting values of Dp and Np in (4),

 Vp = [(π × 7.35 × 1200) / 12] = 2309 fpm (5)

The velocity factor, Kv, for the helical pinion is given by,

Kv = [78 / (78 + √Vp)](1/2) (6)

Substituting value of Vp in (6),

Kv = [78 / {78 + √(2309)}](1/2) = 0.786

The delivered or transmitted load, FT, is given by,

FT = [(33,000 × H.P.) / Vp] (7)

where, H.P. = transmitted horsepower.

Substituting values of H.P. and Vp in (7),

FT = [(33,000 × 120) / (2309)] = 1715 lbs.

The number of teeth on the gear, tg, is,

tg = r × tp (8)

where, r = gear ratio.

Substituting values of r and tp in (8),

tg = 3 × 20 = 60 teeth.

The calculated strength of the teeth in bending is,

(Sb)cal = [(FT × PT) / (Kv × b × j)] (9)

where, b = face width of the gear

j = geometry factor for bending.

From Fig. 1, for number of teeth on the pinion = 20 and for a helix

angle of 25°, j = 0.49.

Substituting values of all the known quantities in (9),

(Sb)cal = [(1715 × 2.72) / (0.787 × 2 × 049)] = 6056 psi (10)

The endurance limit of the teeth is given by,

SE = KRKSKF (1 / Kf) SE' (11)

where, KR = reliability factor

KS = size correction factor

KF = surface finish correction factor

 Kf = fatigue stress concentration factor

SE' = endurance limit of the material.

The reliability factor, KR, is given by,

KR = 1 – 0.08 × df (12)

where, df = deviation multiplication factor.

From Table 1, for reliability of 90% the value of df =1.28.

Substituting value of df in (12),

KR = 1 – 0.08 × 1.28 = 0.8976

The fatigue strength reduction factor, KS, is generally taken as 0.85.

The ultimate tensile strength for AISI 3150 steel, 0QT1000 is 151

Ksi and the BHN no. = 300. From Fig. 2, for machined parts with ultimate

tensile strength = 150 ksi, factor CF = 0.70. The factor Kf from Table (10.1)

for 20° pressure angle, quenched and drawn steel is 2.0.

The endurance limit of steel with ultimate tensile strength < 200 ksi

and BHN < 400 is given by,

SE' = 0.5 Sult (13)

where, Sult = ultimate tensile strength.

Substituting value of Sult in (13),

SE' = 0.5 × 150 = 75 ksi

Substituting values of all the known quantities in (11),

SE = 0.8976 × 0.85 × 0.70 × [1 / (2.0)] × 75,000

or,

SE = 20,028 psi.

The factor of safety, fs, based on bending strength of the teeth is

given by,

fs = [SE / {(Sb)cal}] (14)

Substituting values of SE and (Sb)cal, in (14),

fs = [(20,028) / (6056)] = 3.3

(2) The calculated contact stress, (Sc)cal, is given by,

 (Sc)cal = [(ClCh) / (CtCr)] Sac (15)

where, Cl = life factor

Ch = hardness ratio factor

Ct = temperature factor

Cr = factor of safety

Sac = allowable contact stress.

Now, Cl = 1, Ch = 1.

∴ [(BHN of pinion material) / (BHN of gear material)] = 1 < 1.2

Since the operating temperature will be less than 600°F, Ct = 1.0.

From Table 2, Cr = 1.25 for high reliability. From Table 10.3

(see prep), for steel of BHN = 300, Sac = 127.5 kpsi.

Substituting values of all the known quantities in (15),

(Sc)cal = [(1 × 1) / (1 × 1.25)] × 127.5 × 103 psi

or,

(Sc)cal = 102,000 psi

The maximum permissible transmitted load, F(T)p, is given by,

F(T)p = [{(Sc)cal} / CE]2 (CvbDpi) (16)

where,

Cv = Kv = 0.786

i = geometry factor for wear

CE = elastic coefficient.

From Table 3, for both the gear and the pinion made of steel,

CE = 2300 psi.

The factor i is given by,

i = [(cosɸT × sinɸT) / (2MN)] [r / (r + 1)] (17)

where, ɸT = transverse pressure angle, deg.

MN = load sharing ratio.

ɸT can be obtained from the following relation,

ɸT = tan–1 [(tanɸT) / (cosψh)] (18)

where, ɸN = normal pressure angle, degrees.

Substituting values of ɸN and ψh in (18),

ɸT = tan–1 [{tan (22°)} / {cos (25°)}] (19)

or,

ɸT = 24 degrees.

The load sharing ratio, MN, is given by,

MN = [(Pbc) / (0.9z)] (20)

where, Pbc = normal base pitch

z = length of contact.

Pbc is given by,

Pbc = PCN cosɸN (21)

where, PCN = normal circular pitch.

PCN = (π / PN) (22)

Substituting value of PN in (22),

PCN = (π/3)

Substituting values of PCN and ɸN in (21),

Pbc = (π/3) cos (22°) (23)

or,

Pbc = 0.971 in.

The contact length, z, is given by,

z = √[(Rp + A)2 – Rbp2] + √[(Rg + A)2 – Rbg2] – (Rp + Rg) sinɸT (24)

where,

R = pitch radius

A = addendum

Rb = base radius

and subscripts p and g stand for the pinion and gear, respectively.

The addendum, A, is given by,

A = (1/ PN) = (1/3) (25)

 The base radius is related to the pitch radius by

Rb = RcosɸT (26)

Applying (26) to pinion and gear,

Rbp = RbcosɸT

or,

Rbp = 3.657cos (24°) = 3.36 in.

and since Rg = PN × Rp, therefore,

Rbg = (3 × 3.675) cos (24°) = 10.1 in.

Substituting values of all the known quantities in (24),

z = √[{3.657 + (1/3)}2 – (3.36)2] + √[{11 + (1/3)}2 – (10.1)2]

– (3.675 + 11) sin (24°) (27)

or,

z = 2.1856 + 5.141 – 5.9688

∴ z = 1.3577

From (20),

MN = [(0.971) / {0.95 × 1.3577)] = 0.7528

Substituting values of all known quantities in (17)

i = [{cos (24°) sin (24°)} / (2 × 0.7528)] [3 / (3 + 1)] = 0.185

Substituting values of known quantities in (16),

F(T)p = [(102,000) / (2300)]2 (0.786 × 2 × 7.35 × 0.185)

or,

F(T)p = 4204 lbs.

The factor of safety fs is,

fs = [(F(T)p) / FT] (28)

Substituting values in (28),

fs = [(4204) / (1715)] = 2.45

PROBLEM 10 – 0288: A helical gear and pinion combination is driven by a 2 hp,

2000 rpm electric motor as shown in Fig. 1 below. The pinion

has 20 teeth, a diametral pitch normal to the teeth, of 10,

a 25° pressure angle and a 35° helix angle. Evaluate the

forces to which the pinion and the bearings 1 and 2 are

subjected.

Solution: The relation between the normal pressure angle, ɸN, transverse

pressure angle, ɸT, and the helix angle, is

tanɸN = tanɸT × cosψh (1)

Rearranging (1) for ɸT,

ɸT = tan–1 [{tanɸN) / (cosψh)] (2)

Substituting values of ɸN and ψh in (2),

ɸT = tan–1 [{tan–1 (25°)} / {cos (35°)}] (3)

or,

ɸT = 29.65°

The relation between the transverse diametral pitch, PT, and the
normal diametral pitch, PN, is,

PT = PNcosψh (4)

Substituting values of PN and ψh in (4),

PT = 10cos (35°) = 8.19 teeth/in.

The pitch diameter of the pinion, Dp, is given by,

Dp = (tp / PT) (5)

where, tp = number of teeth on the pinion.

Substituting values of tp and PT, in (5),

Dp = [20 / (8.19)] = 2.44 in.

The pitch–line velocity of the pinion, Vp, is given by,

Vp = [(πDpNp) / 12] (6)

where, Np = speed of the pinion, rpm.

Substituting values of Dp and Np in (6),

Vp = [(π × 2.44 × 2000) / 12] = 1277.58 fpm

The load delivered by the pinoin to the gear is given by,

FT = [(33,000 × hp) / Vp] (7)

where, hp = horsepower transmitted.

Substituting values of hp and Vp in (7),

FT = [(33,000 × 2) / (1277.58)]2 = 51.66 lbs.

The radial load, FR, acting on the pinion is given by,

FR = FTtanɸT (8)

Substituting values of FT and ɸT in (8),

FR = 51.66tan (29.54°) = 29.4 lbs.

The thrust or axial load, FA, acting on the pinion is given by,

FA = FTtanψh (9)

Substituting values of FT and ψh in (9),

FA = 51.66tan (35°) = 36.17 lbs.

The normal load, FN, acting on the pinion is given by,

 FN = [FT / (cosɸNcosψh)] (10)

Substituting values of FT, ɸN and ψh in (10),

FN = [(51.66) / {cos (25°) cos (35°)}] = 69.58 lbs. (11)

Forces FT, FA and FR are shown to act on point 3 in Fig. 2. In Fig. 2,

the bearing forces are also shown.

Applying force balance along the x–axis,

F1X = FA = 36.17 lbs. (12)

Considering moments produced about the z–axis at point 1,

clockwise moments = anti–clockwise moments

or,

FA × (Dp / 2) + F2Y × 12 = FR × (4 + 12) (13)

Substituting values of Dp, FA and FR in (13) and solving for F2Y,

F2Y = [{29.4 × 16 – 36.17 × [(2.44) / 2]} / 12] (14)

or,

F2Y = 35.522 lbs.

Applying force balance in the Y direction,

FR + F1Y = F2Y (15)

Substituting values of FR and F2Y in (15) and solving for F1Y,

F1Y = (35.522 – 36.17) lb. (16)

or,
 F1Y = – 0.648 lb.

The negative sign shows that F1Y acts in the–y direction.

Consideration of moments about the Y axis at point 1 gives,

FT × 16 = F2Z × 12 (17)

Substitution of values for FT in (17) and solving for F2Z leads to,

F2Z = [(51.66 × 16) / 12] = 68.88 lbs. (18)

Applying force balance in the Z direction,

FT + F1Z = F2Z (19)

Substituting values of FT and F2Z in (19) and solving for F1Z,

F1Z = (68.88 – 51.66) = 17.22 lbs.