MecE 360 Winter 2022 SMath Group Competition
Code for Gear Analysis by Group 2
General Assumptions
- All gears are standard AGMA gears with no undercutting or interference.
- Design is for multi-cylinder engines driving moderate shock applications.
- Gears are of high quality and are solid and non-idling, with a face width of at least 1 inch.
- Both gears are composed of an identical steel alloy.
- Reliability of 90% and no miscellaneous factors are required.
- Gear ratio will not exceed 5.
List of Variables
List of Variables
H Brinell hardness
pd Diametral pitch
Tin Input torque
m Module
ωin Input rotational velocity
ϕ Pressure angle
TF The operating temperature of steel
ϕt Transverse pressure angle
N Number of cycles
ϕn Normal angle
F Face width
Ψ Helix angle
nbg Gear bending safety factor
ag Gear addendum
nbp Pinion bending safety factor
ap Pinion addendum
ncg Gear contact safety factor
dg Gear pitch diameter
ncp Pinion contact safety factor
dp Pinion pitch diameter
nbc Critical bending safety factor
rg Gear pitch radius
ncc Critical contact safety factor
rp Pinion pitch radius
n Critical safety factor
C Centre to centre distance
Qv Quality of the gears
Ng Gear number of teeth
Wt Tangential force
Np Pinion number of teeth
Wr Radial force
Jg Gear geometry factor
Wa Axial force
Jp Pinion geometry factor
W Net force
S'fb Uncorrected bending Strength
tR Tire thickness
S'fc Uncorrected contact Strength
Sfb Bending strength
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Sfc Contact strength
σbg Bending stress for the gear
σbp Bending stress of pinion
σcg Contact stress for the gear
σcp Contact stress for the pinion
Input Variables
A. Input of Variables
Number of teeth in pinion
N1 30
N2 66 Number of teeth in Gear
ϕ 20 ° Pressure angle
ωin 6500 rpm Input shaft speed
P 24.4 kW
P
Tin 35.8466 N m Input shaft torque
ωin
S'fb 50 ksi Uncorrected bending strength
S'fc 155 ksi Uncorrect contact strength
TF 430 °F The operating temperature of steel for high T.
6
N 1.4 10 Input shaft cycles
R 90 % 90 Percent reliability as per the module
B. User input variables
H 400 Brinell hardness
Qv 10 Quality of the gears,
tR 225 in The rim thickness,
Ψ 0° Helix angle, put zero is not present
F 20 mm Face Width assumed
dp1 60 mm
dp1 2.3622 in Assumed diameter of pitch for gear 1
Gear Geometry Calculation
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MecE 360 Winter 2022 SMath Group Competition
Gear geometry calculation
dp1
m1 2 mm Module of the system (module is the same for both gears when they are
N1 in mesh)
m m1
ag m Gear addendum - same as module if standard gear
ap m Pinion addendum - same as module if standard gear
dg N2 m
Gear pitch diameter
N1
dp Pinion pitch diameter
pd
dg
rg Gear pitch radius
2
dp
rp Pinion pitch radius
2
tan ϕ
ϕt atan
cos Ψ Transverse pressure angle
C rg rp Centre to centre distance between gear and pinion
1
pd Diametrical Pitch
m
N2
11 Gear ratio
egr
N1 5
CC dp1 dg 7.5591 in
centre to centre distance
Lenght of action:
2 2 2 2
Z rp ap rp cos ϕt rg ag rg cos ϕt C sin ϕt 0.0102 m
Force Calculation
Calculation Forces
Tin
Wt 268.6211 lbf Tangential force
rp
Wa Wt tan Ψ 0 lbf Axial force - for helical gears
Wr Wt tan ϕt 97.7701 lbf Radial force
2 2
W Wt Wr 285.8606 lbf Net force
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Factors
Application factor:
Ka 1.5
Ca Ka
Load distribution factor:
8 16
if F F 1.6
pd pd
if F 2 in
Km 1.6
else
if F 6 in
F 2 in
Km 1.7 1.6 1.6
6 in 2 in
else
if F 9 in
F 6 in
Km 1.8 1.7 1.7
9 in 6 in
else
if F 20 in
F 9 in
Km 2.0 1.8 1.8
20 in 9 in
else
Km 2.0
else
"Not possible"
Cm Km
Reliability factor:
Reliability factor for reliability of 90%
KR 0.85
CR KR
Elastic Coefficient:
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MecE 360 Winter 2022 SMath Group Competition
Assuming that the gear and pinion are made of steel.
0.5
CP 2300 psi
Size factor:
As an accepted value has not been determined the Size Factor is 1.
Ks 1
Cs 1
Surface life factor:
Npin N
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7
if Npin 10
0.0323
KLp 1.6831 Npin
else
if H 400
0.148
KLp 9.4518 Npin
else
if H 250
0.1045
KLp 4.9404 Npin
else
if H 160
0.0538
KLp 2.3194 Npin
else
KLp 1
0.056
CLp 2.466 Npin
Life factor:
N1 5
Ngear N 6.3636 10
N2
7
if Ngear 10
0.0323
KLg 1.6831 Ngear
else
if H 400
0.148
KLg 9.4518 Ngear
else
if H 250
0.1045
KLg 4.9404 Ngear
else
if H 160
0.0538
KLg 2.3194 Ngear
else
KLg 1
0.056
CLg 2.466 Ngear
Surface finish factor:
Cf 1 Assume surface finish factor as 1, according to slide MecE360 Spur Gear Design - L15 and L16 - Feb 11.
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MecE 360 Winter 2022 SMath Group Competition
Hardness factor:
CH 1 Both the gear and pinion are made of the same material so Hardness factor is 1.
Dynamic Factor:
Qv is obtained from the recomended AGMA gear quality numbers for
ωin dp
ft various applications Table 11 6
Vt 4019.7544
2 min
From Input Variables Section:
2
3
12 Qv
B for 6 ≤ Qv ≤ 11
4
A 50 56 1 B
B
A
Kv
min
A Vt
ft
Cv Kv
Output Factors:
Kv 0.7996 or Cv 0.7996
Rim thickness Factor:
Does the gear have rim and spokes?(Yes or No)
Choice "No"
KB if Choice "Yes"
if 0.5 mb mb 1.2
2 mb 3.4
else
if mb 1.2
1
else
"error: Value for Kb is not possible"
else
mb 1
Calculation of backup ratio:
Value of Kb thats determined.
tR
mb
KB 1 ht
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MecE 360 Winter 2022 SMath Group Competition
Idler factor:
Is the Gear an idler gear? ans "no"
KI if ans "no"
1
else
1.42
Contact geeometry factor(I) : Tempreture factor:
π TF
β ϕ 0.3491 rad 9
180 ° Tunitless 273.15 32 430
K 5
KT if Tunitless 250
460 Tunitless
620
else
1
sin β cos β N2
I 0.1105 CT KT 1.4355
2 N2 N1
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MecE 360 Winter 2022 SMath Group Competition
Geometry Factor J:
Assumed for full depth teeth and tip loading. Values were obtained from Table 12 8
JP if N1 17 N1 26
JG if N2 17 N2 26
0.24
0.24
else
else
if N1 26 N1 35
if N2 26 N2 35
N1 26
N2 26 JP 1 0.25 0.26 0.25
JG 1 0.25 0.26 0.25 35 26
35 26
else
else
if N1 35 N1 55
if N2 35 N2 55
N1 35
N2 35 JP 1 0.26 0.28 0.26
JG 1 0.26 0.28 0.26 55 35
55 35
else
else
if N1 55 N1 135
if N2 55 N2 135
N1 55
N2 55 JP 1 0.28 0.29 0.28
JG 1 0.28 0.29 0.28 135 55
135 55
else
else
if N1 17
if N2 17
"There is undercutting"
"There is undercutting"
else
else
"Not Possible"
"Not Possible"
JP 0.2544
JG 0.2814
Contact and Bending stress
Contact Stress:
Pinon contact stress:
Wt Ca Cm 5
σcp CP Cs Cf 1.4407 10 psi
F I dp Cv
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MecE 360 Winter 2022 SMath Group Competition
Gear contact stress:
Wt Ca Cm
σcg CP Cs Cf 97130.1369 psi
F I dg Cv
Pinon contact strenght of same material:
The uncorrected contact strength factors were obtained from
CLp CH Table 7 10 and the material was assumed as Grade 1
5
Sfcp S'fc 1.4182 10 psi steel with 360 HB.
CT CR
Gear contact strenght of same material:
CLg CH 5
Sfcg S'fc 1.4822 10 psi
CT CR
Pinon contact safety factor:
2
Sfcp
ncp 0.969
σcp
Gear contact safety factor:
2
Sfcg
ncg 2.3286
σcg JP 0.2544
Bending Stress: JG 0.2814
Pinon bending stress:
Wt pd Ka Km
σbp Ks KB KI 51107.3661 psi
F JP Kv
Gear bending stress:
Wt pd Ka Km
σbg Ks KB KI 46215.8521 psi
F JG Kv
Pinon bending strenght of same material:
The uncorrected bending strenth factors were
KLp
Sfbp S'fb obtained from Table 7 7 and the material
47691.429 psi
KT KR was assumed as Grade 1 steel with 360 HB
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MecE 360 Winter 2022 SMath Group Competition
Gear bending strenght of same material:
KLg
Sfbg S'fb 53594.3357 psi
KT KR
Pinon bending safety factor:
Sfbp
nbp 0.9332
σbp
Gear bending safety factor:
Sfbg
nbg 1.1597
σbg
Output for the critical Failure mode
CFMg if nbg ncg
CFMp if nbp ncp
"The gear will fail in contact"
"The pinion will fail in contact"
else
else
"The gear will fail in bending"
"The pinion will fail in bending"
CFMg "The gear will fail in bending" Output produced for the critical failure mode for the gear
CFMp "The pinion will fail in bending" Output produced for the critical failure mode for the pinion
Face width Calculation
Face width due to bending: Face width due to contact:
Wt Ka Km Ks KB KI KT KR pd 2
Fbg 0.0172 m CP CT CR Wt Ca Cm Cs Cf
JG Kv KLg S'fb Fcg 0.0189 m
CLg CH S'fc I dp Cv
2
Wt Ka Km Ks KB KI KT KR pd CP CT CR Wt Ca Cm Cs Cf
Fbp 0.0214 m Fcp 0.0206 m
JP Kv KLp S'fb CLp CH S'fc I dp Cv
Determining minimum Facewidth:
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Fnew if Fbg Fbp Fbg Fcg Fbg Fcp 0.0214 m
Fbg
else
if Fbp Fbg Fbp Fcg Fbp Fcp
Fbp
else
if Fcp Fbp Fcp Fbg Fcp Fcg
Fcp
else
Fcg
Validating present Facewidth:
8 16
Validating_present_facewidth if F F
pd pd
"Present Facewidth is in the standard range"
else
"Present Facewidth is not in the standard range"
Verdict:
Validating_present_facewidth "Present Facewidth is in the standard range"
Validating New Facewidth:
8 16
Validating_new_facewidth if Fnew Fnew
pd pd
"New Facewidth is in the standard range"
else
"New Facewidth is not in the standard range"
Verdict:
Validating_new_facewidth "New Facewidth is in the standard range"
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