SPUR GEAR

‫ـــــــــــــــــــــــــــــــــــــــ‬

p=d/Nt P=Nt/d m=d/Nt =1/P Pp  

p=circular pitch d=pitch circle diameter
Nt=number of teeth P=diametral pitch
m=module

 1 d2 N t2
r  
 2 d1 N t 1
r =velocity ratio
1=driver angular velocity rad / sec
2=driven angular velocity rad / sec

Ft  Power / V , Fr  Ft tan
Ft = tangential load , Fr =Redial load ,
V= pitch line velocity ,  = pressure angle

SPUR GEAR BENDING

ANSI/AGMA 2001-C95

2C +External gears
d P  ( N P ) ( m) 
mG  1 - Internal gears

 dn
V
1000

1000 H
Ft W t  H: power (KW)
V

AGMA bending stress equation

1 KH KB
  W t KO K 'V K S
bmt YJ

AGMA bending Endurance strength equation

 Y
 all  FP N
S F Y YZ
Bending factor of safety
 FPYN / (Y YZ )
SF 

2-1
K O  Overload factor (Table 1)
K = Size Factor = 1 or
s

Y = Lewis form factor (from Table)

b  Face width
mt  Transverse module

K 'V  Velocity (Dynamic) factor

6.1  V
 cut or milled profile
6.1
3.56  V
 Hobbed Or Shaped profile
3.56
5.56  V
 Shaped or ground profile (V in m/s)
5.56

KH  load distribution factor

 1+ Cmc ( C pf C pm  CmaCe )
C mc 1.0 uncrowned teeth

0.8 crowned teeth

C pf b
  0.025 for b  25 mm
10d
b
 0.0375  4.92(10) 4 b 25  b  425 mm
10d
b
 0.1109  8.15(104 )b  3.53(107 )b 2 425<b  1000 mm
10d
C pm S
 1 straddle – mounted pinion with 1  0 .1 7 5
S
S1
1.1 straddle – mounted pinion with  0 .1 7 5
S
C ma  A + Bb + Cb 2
(Table (2) for values of A, B and C)

Ce  0.8 for gearing adjusted at assembly

1 for other conditions

2-2
K B  Rim thickness factor
 2.242 tR
 1.6 ln mB <1.2 mB =
= mB ht
1 mB  1.2


t R  rim thickness below the tooth, mm

h t  the tooth height, mm

 FP = Repeatedly applied bending strenght at 107 cycles and 0.99 reliability. (Tables 3, 4)
YN = Load cycles factor (Fig. 2)
Y = Temperature fator = 1 if T<120c
YZ = Reliability factor
0.658  0.0759 ln(1  R ) 0.5< R < 0.99 
=  
0.50  0.109 ln (1  R) 0.99  R  0.999 
or (Table 5)
SF = Bending factor of safety

2-3
SPUR GEAR Wear
ANSI/AGMA 2001-C95

AGMA contact stress equation

1/2
 K Z 
 c  Z E W t K O K 'V K S H R 
 d p b Z I 

AGMA contact endurance strength

 HP Z N ZW
 c , all 
S H Y Yz

Wear Factor of Safety

 HP Z N ZW / Y Y 
SH 
c

Z E  Elastic coefficient (Table 6)

1/2
 
 
 1 
or   
  1  vP  1  vG   
2 2

    

E E
  P G  

Z R  Surface condition factor = 1

cos t sint mG
Z I  Geometry factor for pitting resistence =
2 mG  1
dg
mG 
dP

 HP  Repeatedly applied contact strenght at 107 cycles and 0.99 reliability (Tables 7, 8)

Z N  Pitting resistance stress cycle factor (Fig. 3)

ZW  Hardness ratio factor (gear only) (Figs 4, 5)

2-4
 HELICAL GEAR
‫ـــــــــــــــــــــــــــــــــــــــ‬

PARALLEL HELICAL GEARS

Pn  Pt cos 
Pa  Pt / tan 
m n  m t cos 
mt  d / N t
Pt  d / N
where
Pn & Pt = normal and transverse (tangential) circular pitches respectively
mn & mt = normal and transverse modules respectively
 =helix angle (10o - 30o)
Fa  Fn cos  n sin   Ft tan 
Fr  Fn sin  n  Ft tan  t
where
Fn=total normal load
Fa=axial load
Fr=radial load
Ft=tangential load
t=transverse pressure angle
n=normal pressure angle  tan  n  tan  t cos  

To design according to strength (bending) and wear use same equations as in case of spur
gear and change only Y’J Helical-gear geometry factor and ZI Geometry factor for pitting:

Y’J Helical-gear geometry factors from Fig. (1.1) for mating gear of 75 teeth and use correction
factor of Fig (1.2) for mating gear other than 75.

cos t sint mG dg
Z I  Geometry factor for pitting resistence = mG 
2 mN mG  1 dP
Where: mN = load sharing ratio
= pN / 0.95 Z
pN ≡ Pt = transverse pitch = Pn /cos 

Z (Lab) is the length of the line of action in the transverse plane a = addendum
rP and rG = pitch circle radius of the pinion and gear respectively
rbP and rbG = base circle radius of the pinion and gear respectively

2-5
Sympols used in above equations and their definitions

2-6
 BEVEL GEAR
‫ــــــــــــــــــــــــــــــــــ‬

m  d g / N tg  d p / N tp
where
Ntg &Ntp = number of teeth of gear and pinion respectively
dg &dp =pitch diameter of gear and pinion respectively (measured at the large
end of the tooth )
tan  p  d p / d g  N tp / N tg
for   90 o
tan  g  d g / d p  N tg / N tp
where
  shaft angle
 g = gear pitch angle
 P = pinion pitch angle
N g\  N tg / cos g
where
N g\ =formative, virtual or equivalent number of teeth
Forces
  
Ft  Tp / d mp / 2  Tg / d mg / 2 
Tp = torque on pinion
Tg = torque on gear
dmp = mean diameter of pinion
dmg = mean diameter of gear
Ft = tangential force
O
when   90
Frp  Fag Frg  Fap Fr  Ft tan 
Fag  Fr sin  g Fap  Fr sin p
where
Frp = radial force on pinion
Frg = radial force on gear
Fag = axial force on gear
Fr = separation force

2-7
STRAIGHT–BEVEL GEAR BENDING

ANSI / AGMA 2003-B97

Geometry Force Analysis Strength Analysis

dP  NPm 2T 2T
Wt  Wt 
d av dP
NP W r  W t tan  cos  W r  W t tan  cos 
  tan 1
NG
N W a  W t tan  sin  W a  W t tan  sin 
  tan 1 G
NP
d av  d P  b cos 

AGMA bending stress

W t K A KV Yx K H
F 
b met Y YJ

AGMA bending stress

 F lim YNT
 FP 
S F K YZ

Bending factor of safety

 FP
SF  , based on strength
F

n B  FP , based on Wt , same as SF
F

b Face width
K A  Overload factor (Table 9)
K'v  Dynamic (velocity) factor (Fig. 12)

 et  5.236(10 5 )d 1n1

Q v  transm ission accuracy number

2-8
met  outer transverse module
Yx  size factor for bending
0.5 m et < 1.6 mm 
 
0.4867+0.008339 met 1.6  met  50 mm 
K H  load distribution factor
 K mb  5.6 106  b 2
where
1 both members straddle mounted 
 
K mb  1.1 one member straddle mounted 
1.25 neither member straddle mounted 


Y  Lengthwise curvature factor

 1 (for straight bevel gear)
YJ  Bending factor (Fig. 8)
 F lim  Allowable bending stress number (Tables 10, 11)
YNT  Stress cycle factor (Fig. 7) or
2.7 102  nL  103 
 0.1182 
6.1514 nL 103  nL  3(106 ) 
  0.0323 
1.683 nL 3(106 )  nL  1010general 
 0.0323 
1.3558 nL 3(106 )  nL  1010 critical 

K  Temperature factor
1   120 c 
  
 273    / 393   120 c 

YZ  Reliability factor
0.5  0.25 log(1-R) 0.99  R  0.999 
 
0.7  0.15 log(1-R) 0.9  R  0.99 
S F  Bending factor of safety

2-9
STRAIGHT – BEVEL GEAR WEAR

ANSI/AGMA 2003-B97

Geometry Force Analysis Strength Analysis

dP  NPm 2T 2T
Wt  Wt 
d av dP
NP W r  W t tan  cos  W r  W t tan  cos 
  tan 1
NG
N W a  W t tan  sin  W a  W t tan  sin 
  tan 1 G
NP
d av  d p  b cos 

AGMA contact stress

1
 Wt 2
 H  ZE  K A KV K H Z x Z xc 
 bdZ I 

AGMA wear strength

 H lim Z NT ZW
 HP 
S H K K Z

Wear factor of safety

 HP
SH  , based on strenght
H
2
 
nW   HP  , based on w t ; can be compared directly with SF
 H 

 H lim  Allowable contact stress number (Tables 12, 13)

Z NT  Stress- cycle factor for pitting resistance (Fig. 9)
2 103  nL  104
 0.0602
3.4822nL 104  nL  1010
ZW  Hardness ratio factor (gear only) (Figs. 10, 11)
K Z  YZ  Reliability factor.

2-10
Z E  elastic coefficient
1/2
 1 
ZE   
  1  v12  / E1  1  v22  / E2  
  
where
E1 and E 2 : young's moduli for pinion and gear, N / mm 2

Z I  Contact geometry factor (Fig. 6)

Z   Size factor for pitting
0.5 b<12.7mm 
 
 0.00492b  0.4375 12.7mm  b  114.3mm 
1 b>114.3mm 
 
1.5 properly crowned teeth 
Z  c  crowning factor  
2 non crowned teeth 

2-11
 WORM GEAR
‫ــــــــــــــــــــــــــــــــــ‬

L   Pa  W N W L=lead
 Pa  W =axial pitch of worm
N W = number of teeth of worm
 Pt g =  Pa  W
 Pt g =transverse circular pitch of gear
 m t  g =  Pa  W /
 m t  g =transverse module of gear
 m t  g = d g / N tg
N tg =number of teeth of gear
L
tan  W 
d W
d W =pitch diameter of worm
 W =lead angle of worm
W   W   / 2
W =helix angle of worm where g =  W for 90o shaft angle
g =helix angle of gear
g NW L d
r    W tan  W
W N tg d g dg
where
r = velocity ratio
NW = number of threads on word
d g = pitch diameter of gear

Forces
FtW  Fn cos  n sin  W  f cos  W 
FaW  Fn  cos  n cos  W  f sin  W 
1  f sec  n tan  W 
FaW  FtW  
 tan  W  f sec  n 
 sin  n 
Fr  Fn sin  n  FtW  
 cos  n sin  W  f cos  W 
2-12
where
FtW  Fag
FaW  Ftg
Fn=normal force perpendicular to the teeth surface
Fr=radial force
FtW=tangential force on worm
FaW=axial force on worm
Fag=axial force on gear
Ftg=tangential force on gear
n=normal pressure angle of gear
f=coefficient of friction
O. P. Ftg Vg cos  n  f tan  W
=  
I. P. FtW VW cos  n  f cot  W
where
 = efficiency of worm gear drive
VW = pitch line velocity of worm
Vg = pitch line velocity of gear
Vg
 tan  W
VW
Ftg K V

bm n Y
where
 = calculated stress
Y = Lewis form factor from tables according to n
mn = normal module of gear
b = gear face width mm
KV = velocity factor
K V  1  0164
. Vg
Vg=pitch line velocity of gear in m/sec
  Sd Sd=design stress (from table)

Wear load
FW  d g bc
where
FW = allowable wear load N
c = wear constant
FW  Fdynamic
FW  Ftg K V

2-13
THERMAL RATING

H 1 =input power 1  
H 2  KAT
where
H1 = heat developed
H2 = heat dissipated
A = area of housing
6
= 114  10  C 1.7 m
2

2
K= coefficient of heat transfer ( 14 : 17 W/m Co)
C= center distance in (mm)
T =temperature difference between lubricant and ambient air in co
SOME ADDITIONAL DATA FOR WORM GEARS
. C 0..875  d W  0.9C 0.875
05
 
L1  11  0.06N tg m t in mm ( NW = 1 : 2 )

L1  12.5  0.08N tg  m t in mm ( NW = 3 :4 )
b  0.75d W  N W  13
: 
b  0.67d w  N W  4
or b  7.5m t  6 mm  N W  12
: 
b  6.7m t  5 mm  N W  3:4
where
C = center distance
L1 = threaded length of worm
dW = pitch diameter of worm
L32
 Fr2  FtW
2
48EI

I  d 4d / 64
d a  d W  18. mt
where
  deflection of worm > 0.01 mt
L2 = length of worm between bearings
dd = dedendum circle diameter of worm = dw-2.5 mt

2-14
Table (1) Overload Factors, Ko
Driven Machine
Power source Uniform Moderate shock Heavy shock

Uniform 1.00 1.25 1.75

Light shock 1.25 1.50 2.00
Medium shock 1.50 1.75 2.25

Table (2) Empirical Constants A, B, and C

Condition A B C

Open gearing 0.247 6.5748 × 10-4 -1.1858 × 10-7

Commercial, enclosed units 0.127 6.2205 × 10 -0.1442 × 10-7

Precision, enclosed units 0.0675 5.0394 × 10 -1.4353 × 10-7

Extraprecision enclosed gear units 0.00360 4.0157 × 10 -1.2741 × 10-7

Table (3)

2-15
Table (4)

Table (5) Reliability factor, YZ

Table (6)

2-16
Table (7)

Table (8)

Table (9) Overload factor K A for bevel gears

2-17
Table (10)

Table (11)

Table (12)

2-18
Table (13)

Table (14) Design stress for worm gears

Table (15) Lewis form factor for worm gear

Table (16) Wear constant c for worm gear

Table (17) Coeffecient of friction f for worm gear

2-19
Table (18) Recommanded values for pressure angle  n

Table (19) Recommanded values for number of worm threads

2-20
Fig. (1) Spur-gear geometry factors YJ (source: ANSI/AGMA 218.01.)

Fig. (1.1) Helical-gear geometry factors Y’J. For mating gear of 75 teeth

2-21
Fig. 1.2 geometry factors Y’J multiplier for mating gear different than 75 teeth

Fig. (2) Repeatedly applied bending strength stress-cycle factor YN .

2-22
Fig. (3) Pitting resistance stress cycle factor ( ZN )

2-23
2-24
2-25
2-26
Fig 12

2-27