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Wt
The above photo-elastic analysis of two gear teeth in contact shows that there are
two types of high stress on the teeth. At A and B we see the tensile and compressive
stresses due to bending of the tooth. Note that the compressive stress has a greater
magnitude due to the radially inward component of the tooth force Wt. The bending
stress is cyclic as it occurs once per revolution of the gear and will, thus, lead to a
potential fatigue failure.
At C we have a contact stress situation as the two, approximately cylindrical
surfaces roll and slide on each other during tooth contact. This stress may lead to a
surface fatigue of the tooth.
=
equation:
Wt p
2Fxp / 3
Wt
Fpy
Replacing p with the diametral pitch P ( = /p ) gives the more usual form:
= WtP/FY, where
Wt = tangential tooth load
P = diametral pitch
F = face width of tooth
= bending stress in gear tooth
Y = Lewis form factor
The Lewis form factor is a function of the number of teeth N and the pressure angle
and is given in the following chart. Note that the old 14.5 degree form factor is not
generally used today.
Dynamic effects:
It is found that, if a pair of gears is run under load, the safe load on them
decreases as the running speed increases. Specifically, it is a function of the
pitch line velocity V = dN/12 ft/min where d is the pitch diameter in
inches and N is the rotation speed in rpm.
This is accounted for by the use of a velocity factor Kv.
Values of Kv derived by Barth are used with the Lewis equation:
Kv = (600 + V)/600 for crude gears (typically cast metal)
Kv = (1200 +V)/1200 for cut or milled teeth
Hence we get the gear stress as
K vWt P
FY
We will not use the Lewis equation or the Barth velocity factors in this
course as they have been superseded by the AGMA equations.
= WtPKvKoKmKsKB/FJ
J = AGMA gear geometry factor
Kv = velocity factor
Ko = overload factor
Km = mounting factor
Ks = size factor
KB = rim thickness factor
One important difference is that the AGMA geometry factor J is a function of the numbers
of teeth on both gears.
All of the equations and data in this document applies to design of spur gears using standard
US units (inches, pounds, etc.)
A+ V
K v =
A
where
A = 50 + 56(1 B )
and
B = 0.25(12 Qv )
2/3
The maximum velocity for any given Qv value is: Vmax = [A + (Qv 3)]
ft / min
The following chart and equations give older values for Kv. These are used in the
gear.exe program discussed elsewhere in the ME356 web site notes..
The overload and load distribution factors are highly qualitative in nature as you
will see from sections 14-8 and 14-11 in your text. For the purposes of this
course you should use the values given in the following two tables.
Overload factor KO
Factor Ks
Pitch P
Factor Ks
1.202
1.081
2.5
1.176
1.065
1.156
1.052
1.124
10
1.029
1.100
12
1.010
The rim thickness factor is only needed for large gears with a spoked hub see secton 1416 in your test.
pmax
2F
=
bl
] [
2 F (1 12 ) / E1 + (1 22 ) / E2
b=
(1 / d1 ) + (1 / d 2 )
l
1/ 2
Where 1, E1, 2, E2, d1 and d2 are the elastic constants and diameters of the cylinders.
For two gear teeth we can replace F by Wt/cos , pmax by C, d by 2r and l by the face
width F. This gives the surface contact compressive stress as:
C2 =
(1 / r1 ) + (1 / r2 )
Wt
F cos (1 12 ) / E1 + (1 22 ) / E2
] [
Where r1 and r2 are the radii of curvature of the tooth surfaces at the contact point.
As the first evidence of tooth wear is seen at the pitch point, the curvatures at the
pitch point are used:
d sin
d sin
r1 = P
and r2 = G
2
2
Where dP and dG are the pitch diameters of the pinion and gear respectively.
Note that the denominator in the above contains only the elastic constants for the
materials of the gear and the pinion. We thus define the elastic coefficient Cp:
1/ 2
1
Cp =
2
2
(1 G ) / EG + (1 P ) / EP
] [
This is tabulated below for various common combinations of gear and pinion
materials.
The expression in the contact stress equation that contains only values that are
dependent on the geometry of the gear and pinion can be written as:
I=
1 1
2 1
1
+
+ =
r1 r2 sin d P d G
N G dG
=
NP dP
cos sin mG
for spur gears only.
2
mG + 1
C = C p Wt Ko K v K s
Km C f
dPF I
Wt, Ko, Kv, Ks, Km and F are the same quantities that were defined above for the
bending stress equation. The elastic coefficient Cp and the geometry factor I are
defined above. dP is the pinion diameter.
The surface condition factor Cf has not yet been evaluated by AGMA so its
value is always 1.0.
all =
S t YN
S F KT K R
Where:
The allowable contact strength numbers are given in Figure 14-5 (page
738) and Tables 16-6, 14-7 (pages 739-740) in your text.
These values are modified by a number of factors to arrive at the
allowable bending stress c,all.
c ,all =
SC Z N C H
S H KT K R