FORCE ANALYSIS

In gears, power is transmitted by means of a force exerted by the tooth of the driving gear on the
meshing tooth of the driven gear.

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Pr is a separating force, which is always directed towards the centre of the gear.

The torque transmitted by the gears is

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 Free-body Diagram of Forces

The pitch circles of a train of spur gears are shown in Fig. Gear A receives 3.5 kW of power
at 700 rpm through its shaft and rotates in the clockwise direction. Gear B is the idler gear while
the gear C is the driven gear. The number of teeth on gears A, B and C are 30, 60 and 40
respectively, while the module is 5 mm. Calculate (i) the torque on each gear shaft; and (ii) the
components of gear tooth forces.

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BEAM STRENGTH OF GEAR TOOTH

In the above equation, Y is called the Lewis form factor. Equation (a) gives the relationship between the
tangential force (Pt ) and the corresponding stress sb. When the tangential force is increased, the stress
also increases. When the stress reaches the permissible magnitude of bending stresses, the corresponding
force (Pt ) is called the beam strength.

Therefore, the beam strength (Sb) is the maximum value of the tangential force that the tooth can
transmit without bending failure. Replacing (Pt ) by (Sb),

, LEWIS EQUATION

In order to avoid the breakage of gear tooth due to bending, the beam strength should be more than the
effective force between the meshing teeth.

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 Values of the Lewis form factor Y for 20° full-depth involute system

Earle Buckingham has suggested that the endurance limit stress of gear tooth is approximately
one-third of the ultimate tensile strength of the material.

In gear design, the maximum force (due to maximum torque) is the criterion. This is accounted
by means of a service factor. The service factor Cs is defined as,

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It is difficult to calculate the exact magnitude of dynamic load in the preliminary stages of
gear design. To overcome this difficulty, a velocity factor Cv developed by Barth is used. The
values of the velocity factor are as follows:

The effective load is given by,

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ESTIMATION OF MODULE BASED ON BEAM STRENGTH

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 The above equation is used in the preliminary stages of gear design.

the wear strength is the maximum value of the tangential force that the
tooth can transmit without pitting failure.
Buckingham’s equation for wear.

The ratio factor for external gears is defined as,

1. It is required to design a pair of spur gears with 20° full-depth involute teeth
based on the Lewis equation. The velocity factor is to be used to account for
dynamic load. The pinion shaft is connected to a 10 kW, 1440 rpm motor.
The starting torque of the motor is 150% of the rated torque. The speed
reduction is 4 : 1. The pinion as well as the gear is made of plain carbon steel
40C8 (Sut = 600 N/mm2). The factor of safety can be taken as 1.5. Design the
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 gears, specify their dimensions and suggest suitable surface hardness for the
gears.

2. It is required to design a pair of spur gears with 20° full-depth involute teeth
consisting of a 20-teeth pinion meshing with a 50 teeth gear. The pinion shaft
is connected to a 22.5 kW, 1450 rpm electric motor. The starting torque of
the motor can be taken as 150% of the rated torque. The material for the
pinion is plain carbon steel Fe 410 (Sut = 410 N/mm2), while the gear is made
of grey cast iron FG 200 (Sut =200 N/mm2). The factor of safety is 1.5. Design
the gears based on the Lewis equation and using velocity factor to account
for the dynamic load.

3. A pair of spur gears with 20° full-depth involute teeth consists of a 20 teeth
pinion meshing with a 41 teeth gear. The module is 3 mm while the face
width is 40 mm. The material for pinion as well as gear is steel with an
ultimate tensile strength of 600 N/mm2. The gears are heattreated to a
surface hardness of 400 BHN. The pinion rotates at 1450 rpm and the service
factor for the application is 1.75. Assume that velocity factor accounts for the
dynamic load and the factor of safety is 1.5. Determine the rated power that
the gears can transmit.

4. A pair of spur gears with 20° pressure angle, consists of a 25 teeth pinion
meshing with a 60 teeth gear. The module is 5 mm, while the face width is
45 mm. The pinion rotates at 500 rpm. The gears are made of steel and heat
treated to a surface hardness of 220 BHN. Assume that dynamic load is
accounted by means of the velocity factor. The service factor and the factor
of safety are 1.75 and 2 respectively. Calculate (i) wear strength of gears; (ii)
the static load that the gears can transmit without pitting; and (iii) rated
power that can be transmitted by gears.

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