Bending! Ra ge kott-T3 ( in Bevel y Gear TeethCopyright 1981 F Gleason Machine Division Gleason Works 1000 University Avenue Rochester, N. Y. 14692, USA. ‘ZEROL and CONIFLEX are trademarks of the Gleason WorksBENDING STRESSES IN BEVEL GEAR TEETH Under ideal conditions of operation, bevel gears have a tooth contact which utilizes the {ull working profile of the tooth without load concentration in any area and with gradual fading of the tooth contact at the tips and ends of the teeth. Under these conditions, the gears have the greatest load capacity and will function most smoothly and quietly. In practice, however, it is not feasible to obtain this ideal tooth contact under all operating conditions. If the gears operate within a very narrow range of conditions of load, speed, temperature, etc,, it is possible to approacit this ideal, Usually the gears are called upon to operate over a wide range of conditions, and the design and manufacture of the mountings and gears must be a compromise. Working and assembly tolerances limit the usable length and width of contact. Considerations of weight, cost and space often influence the design of both the gears and mountings. Because of the smaller bearing loads in the straddle mounting, the overall design may be somewhat smaller and lighter for equal rigidity. Frequently, space limitations dictate the type of mounting for a particular installation. Usually one member of the pair can be straddle mounted, but it is not always feasible to use a straddle mounting for both members. Generally speaking, an overhung mounting may be just as good as or better than a straddle mounting arrangement. However, rigid supports as well as adequate capacity are required for both types of mountings. The recommendations and rating formulas given here are designed specifically for bevel gears in which the tooth contact has been developed to give the correct pattern in the final mountings under full load. Application of these recommendations and rating formulas to bevel gears in which this condition is not fulfilled requires a modification in the ratings. The extent of this modification is defined below for certain conditions. The section entitled “Fundamental Bending Stress Formulas” below is intended for the calculation of bending stresses in a pair of gears when the power or torque is known. The section entitled “Fundamental Power Formulas” is intended for determining the power capacity of the pair of gears based on an assumed allowable bending stress. The designer will choose the section appropriate to his needs: § Fundamental Bending Stress Formulas The basic equation for the bending stress in a bevel gear is given as follows: WK, Py Ki Kr KF SK a where s, = calculated tensile stress in pounds per square inch at the root of the tooth. {e = transmitted tangential load in pounds. Load Ke = overload factor. kK, = dynamic factor. Tooth P, = diametral pitch at large end of the tooth Size F = face width in inches, Ks = size factor. Stress K,, = load distribution factor. Distribution )J” = geometry factor. Kx = cutter radius factor.The basic equation for working stress in a bevel gear is given as follows: su Ky PaRaKe (2) where oy = working strees in pounds por equaro inch 54 = allowable bending stress in pounds per square inch. K, = life factor, Ky = temperature factor. Kp = factor of safety. The calculated bending stress must be equal to or less than the working stress. (3) § Fundamental Power Formulas The basic equation for the rated power of a pair of bevel gears is given by the following equation. This equation is for rating stock gears or for determining the capacity of an existing pair of gears. Med Ff SK (eg (4) 126.050 PF,’ Ke rated power in horsepower at np rpm of pinion, = allowable bending stress in pounds per square inch, rpm of pinion, large end pitch diameter of pinion in inches. face width in inches. diametral pitch at large end of tooth. geometry factor. cutter radius factor. size factor. The above rated capacity of a pair of bevel gears operating at a specified speed (Ns) must be modified to suit the application. The resulting allowable power ie given by the following equation: PKK “Ko Kr Kr Kn where P= allowable power in horsepower which may be safely transmitted at ne rpm of pinion rated power at ne rpm given by equation (4). ite tactor. dynamic factor. overload factor. Kr= temperature factor. Ka= factor of safety. K,.= load distribution factor. P (6)DETAILED EXPLANATION OF THE BENDING STRESS AND POWER FORMULAS ™ Calculated Tensile Stress—s, ‘The formula (1) above for s; gives the calculated value of the tensile stress in pounds per square inch at the root of the tooth due to bending, @ Transmitted Tangential Load—W, The transmitted tangential load in pounds is calculated directly from the power or torque transmitted and is given by the following equation: 126,050 P_ 2T. dnd where P= power transmitted in horsepower. The maximum tangential load will depend upon the maximum torque rather than the maximum power. Therefore, consideration should be given to the torque characteristics of the driving motor. d= large end pitch diameter of the pinion in inches. Adjustment has been madein the geometry factor to correct the tangen- tial load for the mean pitch diameter. ne pinion speed in rpm corresponding to the power, P. = pinion torque in pound inches. In general, the calculated stress should be based on the maximum operating torque 1 Overload Factor—K,, The overload factor makes allowance for the roughness or smoothness of operation of both the driving and driven units. In determining the overload factor consideration should be given to the fact that many prime movers develop momentary overload torques which are very much greater than those determined by the rated output of the prime mover. Uniess experience dictates otherwise (see section on Service Factors), the values given in Table 1 may be used as a guide TABLE 1 Overload Factors—K., Character of Load on Driven Machine Prime Mover Medium Heavy aoa Shock Shock Uniform 1.00 1.25 1.75 Light Shock 1.25 1.50 2.00 Medium Shock 1.50 1.75 2.25Service Factor Service factors are special factors which have been established by an industry for specific applications, where field data is available for determining more positively what factor should be used. The service factor incluries not only the overhead factor, but also tho life factor and factor of safety. Service factors should be used whenever available. It a spe- cific service is used in place of the overload factor, Ke, use a value of 1.0 for the life factor, K, and the factor of safety Ka @ Dynamic Factor The dynamic factor reflects the effect of inaccuracies in profile, tooth spacing and runout, Here is a practical guide for using the curves given in Figure 1 below: Curve No. 1—Spiral bevel gears cut to good commercial quality with accurate spacing and concentricity and ‘quenched in a manner that maintains such accuracy Curve No. 1A—Large spiral bevel gears of the same accuracy as in No.1 but free quenched. Curve No. 2—Spiral bevel gears of lower accuracy than in No. 1A, or large planed spiral bevel gears. ‘Curve No. 24—Straiaht bevel aears of ood commercial quality. ‘Curve No, 3—Straight bevel gears of lower accuracy than in NO. 2A, oF large planed straight bevel gears. Onstraight bevel or Zerol bevel gears when the profile contact ratio m, is less than one, the value from the graph should then be multiplied by the quantity [mp/(2.0 — ma)]. Pune tes (Curve NoA Sena Dynamic Factor - K+ Pitch Line Velocity - V (Feet Per Minute) FIGURE 1Size Factor - Ks @ Diametral Pitch—P, This value is taken at the outer end of the tooth. In the stress formula, however, adjustment has been made in the geometry factor to correct for the mean diametral pitch Diamewral puch - Pa FIGURE 2 - Size Factor for Bevel Gears Face Width—F The face width is given in inches. In general, the face width will be equal on gear and mating pinion. If, however, the face width is greater on one member than on the mating member, it will be conservative to use the smaller value. If maximum capacity is required, it will be necessary to make a tooth layout to check gear strength when n22r and pinion face widths are unequal, or to use the formulas on page 21 i Size Factor—K, For gears coarser than 16 DP the size factor K, = P°*, and for gears finer than 16 DP the size factor K, = 0.5. See Figure 2. Load Distribution Factor—K,, Because the performance of bevel gears is dependent to a considerable degree upon > &E : é 3 i z i = E : 3 3 a g & 5 i their alignment under operating conditions, this load distribution factor is used. This factor is based on the magnitude of the displacements of the gear and pinion from their theoretically correct locations. When assumed or known deflections or displacements are available, the load distribu- tivn factor can be obtained from the graph, Figure 3. As mentioned in the introduction, it is assumed that the tooth contact has been developed to give a suitable pattern in the final mountings under normal operating load. If deflections are large, however, the tooth contact may not be favorable under other operating loads such as light load or overloads. The deflections at these other loads may increase the stresses in the gear teeth. When using Figure 3, use the value of displacement from the position for which the tooth contact is developed together with the corresponding load, Vertical displacement refers to a change in the perpendicular distance between the gear and pinion axes. Axial displacement refers to movement of the gear or pinion along its axis. In order to obtain the amount of displacement along the cone element, it is Necessary to multiply the axial displacement by the cosine of the pitch angle. When the estimated or actual displacements are not known, an estimate of this factor may be obtained from Table 2. Where mountings are carefully designed for maximum rigidity, use the smaller factor from the Table. Where mounting rigidity is questionable, use the larger factor. While the table indicates that lower factors are obtained with straddle mountings, it is often true that overhung mountings are just as good as or better than straddle mountings. Because of the lower bearing loads in the straddle mounting, the over-all design may be somewhat smaller and lighter. Regardless of the type of mounting, the size and type of bearings and their supports should provide rigidity as well as adequate life. 016] on 1912 Tn ar ar ee Load Distribution Factor - Km FIGURE 3 - Load Distribution Factor for Bevel GearsTABLE 2 Load Distribution Factors—Km 1 Both Members One Member | Neither Member oo reen Straddle Mounted | Straddle Mounted | Straddle Mounted General Industrial 1,00 to 1.10 1.1010 1.25 1.25 to 1.40 Automotive 1.00 to 1:10 1.10 to 1.25 —_— Aircraft 1.00 to 1.25 1.10 to 1.40 1.25 to 1.50 Cutter Radius Factor—K. This factor reflects the effect of the cutter radius (lengthwise curvature of the tooth) on the calculated bending stress. See appendix E. Using Ks in the bending stress formula decreases the calculated stress as the cutter diameter is decreased. Recommended design practice is to select the cutter radius on the basis of the following equation: fe= 1.1 Aasin yo te = cutter radius (choose the next larger nominal size) Ac = gear mean cone distance Yo = gear mean spiral angle @ Geometry Factor—J Within this factor are incorporated the tooth form factor. the load location. the load sharing, the effective face width, the stress correction factor, and the inertia factor. The series of graphs listed below give the geometry factors for some of the more common applications. Generated Coniflex® Straight Bevel Gears and Zerol® Bevel Gears with 20° Pressure Angle—Figure 44 This araph gives values for gear and mating pinion for generated (crowned) Coniflex straight bevel gears and Zerol bevel gears with 20° pressure angle, 90° shaft angle, and a 0.120 tool edge radius of ~5: the Gleason 20° Straight Bevel Gear System or Gleason Zero! Bevel Gear System, provided the face width does not exceed one-third of the cone distance (on Zerols 10 “p, - Values given by this graph are based on symmetrical rack tooth thickness proportions wherever tooth top lands do not exceed a ratio of 1.5t0 1 on gear and mating pinion. Note that J is different for gear and mating pinion. when designed according to the tooth proportions given by one-fourth of the cone distance) or Generated Coniflex Straight Bevel Gears and Zerol Bevel Gears with 25° Pressure Angle—Figure 48 This graph gives values for gear and mating pinion for generated (crowned) Coniflex straight bevel gears and Zerol bevel gears with 25° pressure angle and 90° shaft angle When designed according to the tooth proportions given by the Gleason 20” Straight Bevel Gear System or the Gleason Zerol Bevel Gear System, provided the face width does ot exceed one-third of the cone distance (on Zerols one-fourth of the cone distance) or 10 "p, - Values given by this graph are based on symmetrical rack tooth thickness - 7} Proportions wherever tooth top lands do not exceed aratio of 1.5t0 1 on gear and mating Pinion. Note that J is different for gear and mating pinion. ‘Number of Teeth in Mate Number of Teeth in Gear for which Geometry Factor is desired Geometry Factor - J FIGURE 4A - Geometry Factor for Conitlex Straight Bevel Gears with 20° Pressure Angle and 90° Shaft Angle Generated Conitlex Straight Bevel Differential Gears with 22/.° Pressure Angle— Figure 4C, This graph gives values for generated (crowned) Coniflex straight bevel gears for automotive rear axle differentials with 22° pressure angle, 90° shaft angle, and a tool 240 edge radius of ao when designed according to the Gleason publication “Straight "s Bevel Gear Design,” provided the face width does not exceed one-third of the Cone distance. Values of J should be multiplied by 0.89 if tools with standard edge radius are employed. (Edge racius =2 eo ‘approximately.) Values given by this graph are based on tooth thickness proportions which will give equal stress in gear and mating pinion. This graph is only for statically loaded gears. (The J-factors have been modified by the factor kK),‘Number of Teeth in Gear for which Geometry Factor is desired g 3 Number of Teeth in Gear for which Geometry Factor is desired. 8 8 0.200 0240 0.280 0.320 0.360 Geomeiry Factor - J FIGURE 4B - Geometry Factor for Coniflex Straight Bovel Gears with 25° Pressure Angle and 90° Shaft Angle Number of Teeth in Mate 10 2 fig eerie ta age a 25; 2al al al a 19 a} ” 16 8 “ 13 1 1 240, 250 (260 270 280 290 “300 10 ‘Geometry Factor -J FIGURE 4C - Geometry Factor for Conitlex Straight Bevel Differential Gears with 22%° Pressure Angle and 90° Shaft Angle °Generated Spiral Bevel Gears with 20° Pressure Angle and 35° Spiral Angle—Figure 4D This graph gives values for generated (crowned) spiral bevel gears with 20° pressure 0.120 angle, 35° spiral angle, 90° shaft angle, and a cutter edge radius of ~~ when desianed according to the Gleason Spiral Bevel Gear System, provided the face width does not 10 exceed three-tenths of the cone distance or 5 ands not less than one-fourth of the cone 4 distance. Values given by this graph are based on tooth thickness proportions which will give equal stress in gear and mating pinion. This will give optimum life when the stress is below the endurance limit. Number of Teeth in Mate Number of Teeth in Gear to: which Geometry Factoris desired Geometry Factor - J FIGURE 4D - Geometry Factor for Spiral Bevel Gears with 20° Pressure Angle, 35° Spiral Angle and 90° Shaft Angle Generated Spiral Bevel Gears with 20° Pressure Angle, 25° Spiral Angle, and 90° Shaft Angle—Figure 4E. This graph gives values for generated (crowned) spiral bevel gears with 20° pressure angle, 25° spiral angle, Yo" shatt angle and a cutter edge radius of oe when designed according to the tooth proportions given by the Gleason Spiral evel Gear System, provided the face width does not exceed three-tenths of the cone distance or joless than one-fourth of the cone distance. Values given by this graph are based on tooth thickness proportions which will give equal stress in gear and mating pinion. This will give optimum life when the stress is below the endurance limit Number of Teeth in Mate 1 Ee Number of Teeth in Gear for which Geometry Facior is desired Geometry Factor - J FIGURE 4E - Geometry Factor for Spiral Bevel Gears with 20° Pressure Angle, 25° Spiral Angle and 90° Shaft Angle Generated Spiral Bevel Gears with 20° Pressure Angle, 15° Spiral Angle, and 90° Shaft Angle—Figure 4F. This graph gives values for generated (crowned) spiral bevel gears with 20° pressure 0.120 angle, 15° spiral angle, 90° shaft angle, and a cutter edge radius of 5 when designed according to the tooth proportions given by the Gleason Spiral Bevel Gear System, provided the face width does not exceed three-tenths of the cone distance or not less than one-fourth of the cone distance. Values given by this graph are based on tooth thickness proportions which will give equal stress in gear and mating pinion wherever tooth top lands do not exceed a ratio of 1.5 to 1 on gear and mating pinion. This will give ‘optimum life when the stress is below the endurance limit. Generated Spiral Bevel Gears with 25° Pressure Angle, 35° Spiral Angle, and 90° Shaft Angle—Figure 4G. This graph gives values for generated (crowned) spiral bevel gears with 25° pressure - 4"‘Number of Teeth in Mate 204 ETE Number of Teeth in Gear for which Geometry Factor Is desired Geometry Factor - J FIGURE 4F - Geometry Factor for Spiral Bevel Gears with 20° Pressure Angle, 15° Spiral Angle and 90° Shaft Angle 0.120 angle, 35° spiral angle, 90° shaft angle, and a cutter edge radius of 5 — when designed according to the tooth proportions given by the Gleason Spiral Bevel Gear System, 10 Provided the face width does not exceed three-tenths of the cone distance or = andis not less than one-fourth of the cone distance. Values given by this graph are based on tooth thickness proportions which will give equal stress in gear and mating pinion. This will give optimum life when the stress is below the endurance limit. Generated Spiral Bevel Gears with 20° Pressure Angle, 35° Spiral Angle, and 60° Shaft Angle—Figure 4H. This graph gives values for generated (crowned) spiral bevel gears with 20° pressure 0.120 angle, 35° spiral angle, 60° shaft angle, and a cutter edge radius of “5 ~ when designed y according to the tooth proportions given by the Gleason Spiral Bevel Gear System, 10 Provided the face width does not exceed three-tenths ofthe cone distance or =; andis not less than one-fifth of the cone distance. Values given by this graph are based on tooth thickness proportions which will give equal stress in gear and mating pinion. This will give optimum life when the stress is below the endurance limit, a :ar for which Geometry Factor is desired é : 5 } 5 2 Number of Teeth in Mate 50 12 45 403515 30 Us 200 240 280 320 360) “400 440 480 ‘Geometry Factor - J FIGURE 4G - Geometry Factor for Spiral Bevel Gears with 25° Pressure Angle, 35° Spiral Angle and 90° Shaft Angle Number of Teeth in Mate 2 2 30 40 80 a Number of Teeth in Gear for which Geometry Factor is desired 8 10! 160 200 240 “320 260 Geometry Factor - J FIGURE 4H - Geometry Factor for Spiral Bevel Gears with 20° Pressure Angle, ‘35° Spiral Angle and 60° Shaft Angle isi .Generated Spiral Bevel Gears with 20° Pressure Angle, 35° Spiral Angle, and 120° Shaft Angle—Figure 41. This graph gives values for generated (crowned) spiral bevel gears with 20° pressure 0190, angle, 35° spiral angle, 120° shaft angle, and a cutter edge radius of — 5 when designed according to the tooth proportions given by the Gleason Spiral Bevel Gear System, 10 provided the face width does not exceed three-tenths of the cone distance or 5 andis not less than one-fourth of the cone distance. Values given by this graph are based on tooth thickness proportions which will give equal stress in gear and mating pinion. This will give optimum life when the stress is below the endurance limit. Number of Teeth in Mate Number of Teeth In Gear fer which Geometry Factor Ie desired m4 180 260 300 “340 “380 Geometry Factor - J FIGURE 41 - Geometry Factor for Spiral Bevel Gears with 20° Pressure Angle, ‘35° Spiral Angle and 120° Shaft Angle Automotive Spiral Bevel Gears with 20° Pressure Angle, 35° Spiral Angle, and 90° Shaft Angle—Figure 4u. This graph gives values for automotive (crowned) spiral bevel gears and pinions with 0.240 Po ion when designed according to the special tooth proportions 20° pressure angle, 36° spiral angle, 90° shaft angle, and a cutter edge radius of —>—on 0.120 the gearand~5—on the pi given by the Gleason Spiral Bevel Gear System for pinions with fewer than 12 teeth, 10 provided the face width does not exceed three-tenths of the cone distance or and is not 4 48for which Geometry Factor Is Number of Teeth in Gi less than one-fourth of the cone distance. Values given by this graph are based on tooth thickness proportions which will give as nearly equal fatigue life above the endurance limit as possible consistent with a reasonable balance in tooth top lands. Because of narrow point width cutters on the finer pitches, it may not be practical to use this tooth thickness balance in all cases. Note that J is different for gear and mating pinion. For other tooth proportions, other spiral angles, other pressure angles, other shaft angles, or unequal face widths on the two members, the formulas on page 2| may be used for calculating the geometry factor, J ‘Number of Teeth in Mate 5s 7 ° oo 120~—1OSCTGOSSCBOSSCO]SSCRSti 2800 Geometry Factor - J FIGURE 4J - Geometry Factor for Spiral Bevel Gears with 20° Pressure Angle, ‘95° Spiral Angle and 90° Shaft Angle 1 Working Stress—s,, The formula (2) above for s, gives the allowable working stress in pounds per square inch. The calculated tensile stress, s,, must not exceed the allowable working stress. Allowable Bending Stress—s.. The maximum allowable bending stress in pounds per square inch is based upon the properties of the material. It varies with the material, heat treatment, and surface treat- ment. Table 3 gives nominal values for allowable bending stress in gear teeth for com- monly used gear materials and heat treatments. It should be emphasized that these are only approximate values subject to considerable variation as discussed below. It should likewise be emphasized that the bending stresses listed below are not directly related to the tensile strength of the material, but are based on the fatigue properties of actual gear teeth The allowable bending stresses given in the Table are nominal values intended for general applications. Higher stresses may be permitted in some cases by careful gear design, manufacturing procedures, choice of steels and the use of the best heat treating procedure. Likewise, lower values may be required if the steel composition and heat treatment are poorly suited to the application . 18Carburized case-hardened gears require a core hardness in the range of 260-350 BHN (26-37 Rc) and a total case depth in the range shown by the graph Figure 5 to develop the greatest strength. The case must also be free of surface decarburization or grinding cracks and burns (if ground), and must have a carbon content near the eutectoid composition. Flame and induction hardening have given excellent results in instances where there is. sufficient control over the process. However, these processes require close control for satisfactory results, and can be detrimental if employed improperly. Nitrided steels usually have strengths very similar to through-hardened steels of the same hardness as the core hardness. In fine pitches it is sometimes possible to obtain higher strength with nitriding. Use 70 per cent of the Table values for idler gears and other gears where the teeth are loaded in both directions. TABLES Allowable Bending Stress—3y Bonding Surface Hardness ras |g srr Brinell Rockwell | (Endurance limit) Steel Carburizea (Case- Hardened) — 55 Minimum | 30,000 Stee! Flame or Induc- tion hardened (Unhardened root fillet) __ 50 Minimum | 13,500 Steel Hardened and Tempered 450 Minimum a 25,000 Stee! Hardened and Tempered 300 Minimum — 19,000 Stee! Hardened and Tempered 180 Minimum ee 13,500 Stee! Normalized 140 Minimum __ 11,000 Steel Nitrided a — 22,000 Nodular | Hardened and tron Tempered 450 Minimum __ 18.500 Nodular | Hardened and tron Tempered 300 Minimum a 14,000 Nodular | Hardened and iron Tempered 180 Minimum __ 10,000 Nodular Iron Normalized 440 Minimum __ 8,000 Cast Iron | As Cast 200 Minimum 7.000 Cast iron | As Cast 175 Minimum —_ 4,600 Cast Iron | As Cast — 2,700 16010 DIAMETRAL PITCH VS. TOTAL CASE DEPTH In case of choice, use the greater case depth on ground gears or.on short face widths. On fine-pitch gears (25 DP and finer) consult metallurgical department. 030040050080 070080 08000110 Approximate Total Depth of Case FIGURE 5 - Diametral Pitch vs. Total Case Depth 7 20it Factor—Ki ife Factor—K, The life factor is obtained from the graph, Figure 6. Thisis dependent upon the required life in cycles. For a single mesh the number of revolutions and the number of cycles are the same. For a gear which has mare than one mating member the life must be equal to the required number of revolutions multiplied by the number of mating gears. When the required life is less than 6,000,000 cycles on the pinion, the life factors will be different on gear and mating pinion. In cases where the load varies, the designer may wish to determine the equivalent life at maximum torque. One suggested method is as follows: where Lop = required equivaient life in pinion cycles at maximum torque. required total life in hours. ky, ko, Kg « . . Ky = proportion of time at torque loads T;, T2, Ts. . . Ts respectively. Lo py, Mp2, Np » . » Npq = Pinion rpm corresponding to torque loads Ty, Tz, Ts... Ty respectively. Ty, Ta, To. . . Ty = torque loads where T; is maximum torque and T, is minimum torque which will produce a stress above the endurance limit. The required equivalent life in gear cycles at maximum torque may be obtained by multiplying the life in pinion cycles by the gear ratio: 10 10" 10° 10° 107 10 (cycles for Rupture FIGURE 6 - Life Factor for Bevel Gears @ Temperature Factor—K; Under normal conditions use a temperature factor of 1.0. For conditions involving case-hardened steel and oil discharge temperatures between 160° F and 300° F, one accepted basis for correction is the following 460+ Te 620 where T; is the peak operating oil temperature in degrees Fahrenheit. Kr 18 # ? Conidence Level 3Factor of Safety—Ka, The factor of safety is introduced in this equation to offer the designer an opportunity to design for maximum safety or, in some instances, to design for a calculated risk. In the present instance the factor of safety is applied lo the faligue strerigtt of lhe material rather than to the tensile strength. For this reason, the values are much smaller than customarily used in other branches of machine design. Failure in the table below does not mean an immediate failure under the applied load, but rather a shorter life than the minimum, specified. TABLE 4 Factors of Safety Requirements of Application Factor of Safety—Ky Maximum safety 2.0 Fewer than 1 failure in 100 1.0 Fewer than 1 failure in 3 08APPENDIX A FORMULAS FOR GEOMETRY FACTOR, J The geometry factor, J, discussed previously may be obtained fromone of the graphs 44 through 4J for many of the common bevel gear designs. It may be possible in some cases to interpolate between graphs, if one does not require a very precise value. However, when the geometry factor, J, cannot be taken from one of the graphs, it may be necessary to calculate the J-factor using the following formula: Ye. Fe. Pa “mK RF Py In order to solve the above equation, the following data must be available for both gear and mating pinion: ‘A, = outer cone distance, a, = large end addendum, b, = large end dedendum, D_ = large end pitch diameter. F = actual face width. This may be different on the two members. F’ = net face width. If face widths of gear and pinion are not equal, use the smaller value. N_ = Number of teeth P,, = large end diametral pitch. (transverse) = tool edge radius t, = large end transverse circular tooth thickness. (standard convention) 6 = dedendum angle. T= pitch angle. T, = face angle. @ = normal pressure angle. Y= mean spiral angle. In addition to the above given data the following calculated quantities will be required for both gear and pinion. Subscripts » and g refer to pinion and gear respectively. Subscript yyare refers to the value for the mating member. A =A, —0.5F’ = mean cone distance. a =1,—F =addendum angle. a = a,—0.5F" tan a = mean addendum. b= b,— 0.5F' tan 8 = mean dedendum. k= 32No +40 Np No — Np. p, =p, di 'm = 4. Pa = mean diametral pitch. (transverse) P= 5. = large end transverse circular pitch A Px =/q_P COS w= mean normal circular pitch cos @ (cos? w + tan’ @) atA a <= mean transverse pitch radius. 2cosr A, Py =e = | pitch radi wv = Gogay * Mean normal pitch radius. Ray = Ry 60s = mean normal base radius. Roy = Ry + a = mean normal outside radius. A t= 4 t, cos w= mean normal circular tooth thickness. A Ap = V Rae — Rant — Ry sin o. Zy =A pe + Apa = length of action in mean normal section. Zn = transverse (profile) contact ratio. For straight bevel and Zerol bevel gears Pe this value must be greater than 1.0. Otherwise, these formulas cannot be used. tan® y) Ay Ps = face contact ratio, m, = Ving me = moditied contact ratio me) * Py Map met Pinion when m, Is less pom: (ie) [- Sioa eae a | Gear than 2.0 0 2 tom, + kms mp)? [mg 4. mpm”) Pinion =p, (My [me If Me a (Gea) eS + = ] es when m, is greater than 2.0 = distance in mean normal section from the beginning of action to the point of load application. Fim Pinion when m is less 1 oF me [2 mp so Emme vm ("e—1)] BS mi Emp = cmt when m, is greater than 2.0 = distance from mean section to center of pressure measured in the lengthwise direction along the tooth. ZR, = Rye + Rug a *ERy sin @ — V (Ron? — Rn’) war tan dy =2: see (Ron’ ) ware = pressure angle at point of load application ost — inv by+ inv 0.017453 and tooth center line. = rotation angle between point of load applicationx = @n — 8 = angle which the normal force makes with a line perpendicular to the tooth center line. - Pow ~ C08 Oy tooth center line, AR, = Rx — Ry = distance from pitch circle to point of load application on tooth center line, b= rr)? (b= 1h) ,, fillet radius at root of tooth Rut b— ry Fim, [2 Fe =e 2 > imp 1 | when m, is less than 2.0 = radius in mean normal section to point of load application on the Fim, * a, when m, is greater than 2.0 = projected length of the line of contact contained within the ellipse of tooth contact in the lengthwise direction of the tooth, Ye = boty Xe =bebtan 6 +r (sec @ — tan 6) With the values available it is now possible to determine each quantty in the equation for J. Tooth Form Factor—Yx Within this form factor Is incorporated the components for boll: the radial and tangential loads and the combined stress concentration and stress correction factor. Since the tooth form factor must be determined for the weakest section, an initial assumption must be made, and by trial a final solution obtained. X, = assumed value. For an initial value, make Xe = x. + Yo _ Xe : Xe = Xp— Xo Z, =ypcos@—x sing Z — =yosin +x, cos @ 41 tang = ty =X, — By (8— sin 8) — ry cos ¢ — z = one-half the tooth thickness at the weakest section hy = ARy + Ry (1 —cos 4) + ry sin ¢ + 2, = distance along the tooth center line from the weakest section to the point of load application. Change X, until nae © . 2.0. when this condition has been satisfied proceed as follows: “ Xy = R= tooth strength factor. aiy\2 (2% \b kK =H+ (FE =i)" = combined stress concentration factor and stress ft y correction factor (Dolan and Broghamer). Coefficients are obtained from Table 5 on the following page: 23TABLE 5 Pressure Angle H J L 14°" 0.22 0.20 0.40 20°0" 0.18 0.15 0.45 3 (i_ and) = tooth form factor. "xy Sty Load Sharing Ratio—my This factor determines what proportion of the total load is carried on the most heavily loaded tooth My, = 1.0 when ma is less than 20. mm > == when m, is greater than 2.0. mo +2 /(mg ay a = load sharing ratio, 1 Inertia Factor—K, This factor allows for the lack of smoothness of rotation in gears with a low contact ratio. 20 K, =—— when m, is less than 2.0 = 1.0 when m, is greater than 2.0 = inertia factor. § Mean Transverse Radius to Point of Load Application—R, A+x," R=R 4 ~). ARy = mean transverse radius to point of load application Mean Transverse Pitch Radius—R Formula for this quantity is given on page 22 i Effective Face Width—F, This quantity evaluates the effectiveness of the tooth in distributing the load over the root cross section ary -FaFe 8" oy = Faas Gee ~ 108 Increment = : AF — = heel increment “2eosy cosy 24AF, = AF,’ when AF,’ and AF,’ are both positive. FoF« “cos =o when AF,’ is negative and AF,,’ is positive. AF, = AF,’ when AF;' and AF;,' are both positive. when AF,’ is positive and AF,’ is negative when AF,’ is positive and AF," is negative cosy =o when AFy' is negative and AF,’ positive. - TAFT stan AFH) 4 Fy = F. = hycos y(tan” SFT + tan 41H) + F« = effective face width Face Width—F This is the actual face width on the particular member. Its value may be different on gear and pinion. & Diametral Pitch—P, This value is one of the given quantities on page 21 1 Mean Diametral Pitch—P,,, Formula for this quantity is given on page 21 APPENDIX B FORMULAS FOR STRENGTH FACTOR, Q The strength factor, Q, given on Gleason dimension sheets is given by the following formula: Pa_Ks FDJ In the above equation the following data must be available for both gear and mating pinion. P, = large end diametral pitch (transverse) K, = size factor. See Fig. 2. F = actual face width in inches for corresponding member. This may be different on the two members. D_ = large end pitch diameter in inches for corresponding member. J = gcometry factor for corresponding momber. See Figs. 4A through 4J or Appendix A, The final equation for bending stress will be: _TQK Kn SKK, where T = torque in pound inches for corresponding member. Q = strength factor for corresponding member. K, = overload factor. See Table 1 K,, = load distribution factor. See Table 2 or Fig. 3 K, = dynamic factor. See Fig. 1. K, = cutter radius factor. See Chart Appendix E. 28APPENDIX C NUMERICAL EXAMPLE OF BENDING STRESS CALCULATION Example Gears: Type - Generated Spiral Bevel Combination . 14/43 Diametral Pitch . pace Face Width 1.625" Shaft Angle . 90° Pressure Angle + 20° Spiral Angle 35° Cutter Radius . 3.750" Load Data: Horsepower (electric motor drive) +e 170 Pinion Rpm «0.0.2.2... ee 1800 Left hand pinion drives clockwise. Mountings—both members straddle mounted. Application—centrifugal pump drive. Material—case-hardened steel Operating Data: Lubricating oil peak operating temperature +. 160°F Specified minimum gear service lite 1000 hs. (10° cycles) Fundamental Bending Stress Formula (rom Page 1) Wike | Pa | Ks Km nn a na Load Factors Transmitted Tangential Load (W,) 126,050 w= Ss (from Page 3) _ 126,050 (170) (500) (1800) ~ 2-400 pounds Overload Factor (K,) Ko = 1.00 (from Table 1, Page 3, assuming uniform prime mover and uniform driven load) Dynamic Factor (K,) K, = 1.00 (from Curve No. 1, Figure 1, Page 4) @ Tooth Size Factors Diametral Pitch (P.) P,=4 (from given data) Face Width (F) F = 1.625 (from given data) 26§ Stress Distribution Factors Size Factor (K.) K, = .708 (from Figure 2, Page 5, for P..= 4, as given) Load Distribution Factor (K.,) K, = 1.00 (from Table 2, page 7, for both members straddle mounted in general industrial use) Geometry Factor (J) J =.23 (from Figure 4D, page 10, for spiral bevel gears having 20° pressure angle, 35° spiral angle and 90° shaft angle.) Cutter Radius Factor (K,) 3.750 4.840 K, = 1.072 (from Chart Appendix E. r./A 778) 1 Bending Stress Calculation og, = (8-400) (1.00) _(4) (708) (1.00) . (1.00) (1.625) * (23) (1.072) = 24,032 pounds per square inch (at the root of the tooth) 1 Working Stress Evaluation Basic equation for working stress (from page 2) = Sake SK Kn Determination of Working Stress Factors Allowable Bending Stress—s,. ‘Sq = 30,000 pounds per square inch (from Table 3, page 16, for case-nardened steel) Life Factor—K, K, = 1 (from Figure 6, Page 18, based on the specified 1000 hours minimum gear service life requirement) Minimum Service Life Cycles = 1000 hours = 60 minutes/hour * 1800 cycles/minute = 1.08 x 10° cycles Temperature Factor—K; x, ~ 460+ (160) T 620 = 1.0 (from equation on page 18, for Tr = 160°F). Factor of Safety—K,, Ka = 1.0 (from Table 4. page 19. for fewer than one failure in 100 pairs) § Working Stress Calculation (30,000) (1) (1.0) (110) ~ 39:000 pounds per square inch bak!@ Comparison of Working Stress with Calculated Bending Stress 30,000 pounds per square inch S, = 22,600 pounds per square inch This is a conservative comparison since (from page 2) the calculated bending stress (s,) must be equal to or less than the working stress (sy) In this example, the gears have a design Factor of Safety (Kp) of 1.0 but an actual operating safety factor of 30,000 psi/22,600 psi = 1.33 (approximately). While this might at, first suggest that the gears are slightly oversized for the application, careful reference should be made to the Gleason pamphlet “Surface Durability Pitting Formulas for Bevel Gear Teeth” before drawing a final conclusion APPENDIX D Numerical Example of Power Capacity Calculation Example Gears (Same as used in Appendix C) 1 Calculation of Rated Power—P’ Rated Power Formula (from Page 2) nod Fd Kx "726,050, Ke (Note: The factors used in this equation were previously determined during the work outlined in Appendix C.) : (1800) (3.500) (1.625) (23) (1.072) ceo 126,050, 4 (708) 212 HP (at 1800 pinion RPM) | Calculation of Allowable Power Capacity—P. Allowable Power Capacity Formula (from Page 2) PKK K Kr Kn Ky (Note: The factors used in this equation were previously determined during the work outlined in Appendix C.) (212) (1) (1.00) ~ (1,00) (1.0) (1.0) (1.00) = 212 HP (1800 pinion RPM) Based on this evaluation, the 170HP load imposed on the example gears lies well within their allowable power capacity. Pp 28oats (' APPENDIX E 27s gang fe 0.7880 Cutter Radius Factor - K. vs Ratio of Cutter Radius to Mean Cone Distance Note A= Gear Mean Cone Distance Gear Mean Spiral Angle Cutter RadiusSO8103E/Apri 1965, GLEASON MACHINE DIVISION 1000 University Avenue Rochester, New York 14692 USA