SECTION 12 HELICAL GEARS

DESIGN PROBLEMS
701.

For continuous duty in a speed reducer, two helical gears are to be rated at 7.4 hp
at a pinion speed of 1750 rpm; m w 2.75 ; the helix angle 15o ; 20o F.D. teeth in
the normal plane; let N p = 21 teeth, and keep b < 2 D p . Determine the pitch, face,
N g , and the material and heat treatment. Use through-hardened teeth with a
maximum of 250 BHM (teeth may be cut after heat treatment).

Solution:
= 15o
n = 20o
D p n p
vm =
12
N p 21
Dp =
=
Pd
Pd
n p = 1750 rpm
21
(1750)
Pd
9621

vm =
=
12
Pd
33,000hp (33,000 )(7.4 )
Ft =
=
= 25.38 Pd
vm
9621

P
d

b 2 Dp

21 42
b = 2 =
Pd Pd
0.05vm (Ft + Cb cos 2 )cos
Fd = Ft +
lb
1
2
2
0.05vm + (Ft + Cb cos )
Table AT 25
Assume C = 1660
= 15o

Fd = 25.38Pd +

9621
42
25.38Pd + 1660 cos 2 15 cos15
0.05
Pd
Pd

9621
42
+ 25.38Pd + 1660 cos 2 15
0.05
Pd
Pd

Page 1 of 14

1
2

lb

SECTION 12 HELICAL GEARS

Fd = 25.38 Pd +

465
65050
25.38 Pd +

Pd
Pd
481
65050

+ 25.38 Pd +
Pd
Pd

For continuous service: Fw Fd

bD pQK g
Fw =
cos 2
2mg
2(2.75)
Q=
=
= 1.467
mg + 1 2.75 + 1
Table At 26, Bhn = 250
Sum of BHN = 500, n = 20o
K g = 131

42 21 (1.467 )(131) 181,670

Fw =
=
2
Pd2
Pd Pd cos 15
Fw Fd
By trial and error method
Pd
7
6

Fd
3967
4758

Fw
3708
5046

use Pd = 6
21 21
Dp =
=
= 3.5 in
Pd
6
42 42
b=
=
= 7 in
Pd
6
9621 9621
vm =
=
= 1604 fpm
Pd
6
Fig. AF 19, permissible error = 0.0018 in
Fig. AF 20
Use carefully cut gears, Pd = 6
Error = 0.001 in is o.k.
For material
Strength
sbY cos
Fs =
K f Pd

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1
2

lb

SECTION 12 HELICAL GEARS

Np

21
= 23
cos cos3 15
Table AT 24, Load near middle
N ep = 23 , n = 20o FD
N ep =

Y = 0.565
assume K f = 2.0
Fs = N sf Fd

assume N sf = 2.0
s (7 )(0.565) cos15
= (4758)(2)
(2 )(6)
s = 29,892 psi
s
use sn = u
3
su = 3(29,892) = 89,676 psi
Use C1050, OQT 1100 F,
su = 122 ksi , BHN = 248 < 250
Ans.
Pd = 6
b = 7 in
N g = mw N p = (2.75)(21) = 58
Material. C1050, OQT 1100 F
703.

A pair of helical gears, subjected to heavy shock loading, is to transmit 50 hp at

3
1750 rpm of the pinion.; mg = 4.25 ; = 15o ; minimum D p = 4 in. ; continuous
4
o
service, 24 hr/day; 20 F.D. teeth in the normal plane, carefully cut; throughhardened to a maximum BHN = 350. Decide upon the pitch, face width, material
and its treatment.

Solution:
(4.75)(1750)
vm =
= 2176 fpm
12
33,000hp (33,000 )(50 )
Ft =
=
= 758 lb
vm
(2176)
Dynamic load:
0.05vm Ft + Cb cos 2 cos
Fd = Ft +
lb
1
2
2
0.05vm + Ft + Cb cos
Fig. AF 19, vm = 2176 fpm
Permissible error = 0.0014 in

Page 3 of 14

SECTION 12 HELICAL GEARS

Use carefully cut gears, e = 0.001 in , Pd = 5 as standard
Table AT 25,
Steel and steel, 20o FD
C = 1660
Fd = 758 +

0.05(2176) 758 + 1660b cos 2 15 cos15

0.05(2176) + 758 + 1660b cos 15

105.1(758 + 1548.8b )
Fd = 758 +
1 lb
108.8 + (758 + 1548.8b )2
Wear load:
bD pQK g
Fw =
cos 2
2mg
2(4.25)
Q=
=
= 1.619
mg + 1 4.25 + 1
Table At 26, 20o FD,
Sum of BHN =2(350)=700
K g = 270
2

b(4.75)(1.619 )(270 )
= 2225b
cos 2 15
2
Fw Fd , bmin = 2 Pa =
= 4.69 in.
Pd tan
By trial and error method
Fw =

b
5
6

Fd
5203
5811

Fw
11125
13350

use b = 5 in
Material:
Strength:
sbY
sbY cos
Fs =
=
K f Pdn
K f Pd
Np
N ep =
cos3
N p = Pd D p = (5)(4.375) = 22
22
= 25
cos3 15
Table AT 24, Load near middle
N ep =

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1
2

lb

SECTION 12 HELICAL GEARS

N ep = 25 , n = 20o FD
Y = 0.580
assume K f = 1.7

s (5)(0.580) cos15
= 0.32955s
(1.7 )(5)
Fs = N sf Fd
for 24 hr/day service, heavy shock loading
N sf = 1.75
Fs =

0.32955s = (1.75)(5203)
s = 27,629 psi
s
use sn = u
3
su = 3(27,629) = 82,887 psi
Table AT 9
Use 4150, OQT 1200 F,
su = 159ksi , BHN = 331 < 350
Ans.
Pd = 5
b = 5 in
Material. 4150, OQT 1200 F
705.

Design the teeth for two herringbone gears for a single-reduction speed reducer
with mw = 3.80 . The capacity is 36 hp at 3000 rpm of the pinion; = 30o ; F.D.
teeth with n = 20o . Since space is at a premium, the initial design is for N p = 15
teeth and carburized teeth of AISI 8620; preferably b < 2 D p .

Solution:
N
15
Dp = p =
Pd
Pd
b 2Dp
b = 2 Dp =
vm =

30
Pd

D p n p

12
15
(3000)
P
11,781
vm = d
=
12
Pd

Page 5 of 14

SECTION 12 HELICAL GEARS

33,000hp (33,000 )(36 )
=
= 101Pd
vm
11,781

Pd
Dynamic load
0.05vm Ft + Cb cos 2 cos
Fd = Ft +
lb
1
2
0.05vm + Ft + Cb cos 2
Ft =

n = 20

= 30 o
Assume C = 1660 , Table AT 25, 20o FD

11,781
30
101Pd + 1660 cos 2 30 cos 30
0.05
Pd
Pd

Fd = 101Pd +
lb
1
2

11,781
30
+ 101Pd + 1660 cos 2 30
0.05
Pd
Pd

510
37,350
101Pd +

Pd
Pd
Fd = 101Pd +
lb
1
2
589
37,350

+ 101Pd +
Pd
Pd
Wear load
bD pQK g
Fw =
cos 2
2 mg
2(3.80)
Q=
=
= 1.583
mg + 1 3.80 + 1
For AISI 8620, carburized, 20o FD
K g = 750 for 1010 cycles
30 15 (1.583)(750) 712,350
Fw =
=
2
Pd2
Pd Pd cos 30
By trial and error, Fw Fd
Pd
Fd
Fw
5
4433
28,494
4
5454
44,522
6
3817
19,788
8
3173
11,130
9
3008
8794

For carefully cut gears, e = 0.001

vmax = 1400 fpm (Fig. AF 9)

Page 6 of 14

SECTION 12 HELICAL GEARS

Pd
5
4
6
8
9

11,781
Pd
2356.2
1963.5
1683
1473
1309 fpm
vm =

use Pd = 9
Fd = 3008 lb
Fw = 5794 lb > Fd
30 30
b=
=
= 3.3 in
Pd
9
use b = 3.0 in
To check for strength
sbY
sbY cos
Fs =
=
K f Pdn
K f Pd
Np
N ep =
cos3
N p = 15
15
= 23
cos3 30
Table AT 24, Load near middle
N ep = 23 , n = 20o FD
N ep =

Y = 0.565
assume K f = 1.7

8620, SOQT 450, su = 167 ksi

s
sn = u
3
su 167
sn = =
= 83.5
2
2
(83,500)(3.0)(0.565)cos 30 = 8011 lb > F (= 3008 lb )
Fs =
d
(1.7)(9)
Designed Data:
Pd = 9
b = 3.0 in
N p = 15
N g = mw N p = (3.8)(15) = 57

Page 7 of 14

SECTION 12 HELICAL GEARS

N p 15
= = 1.67 in
Pd
9
N
57
Dg = g =
= 6.33 in
Pd
9
Dp =

CHECK PROBLEMS
707.

The data for a pair of carefully cut gears are: Pdn = 5 , n = 20o , = 12o ,
b = 3.5 in. , N p = 18 , N g = 108 teeth; pinion turns 1750 rpm. Materials: pinion,
SAE 4150, OQT to BHN = 350; gear, SAE 3150, OQT to BHN = 300. Operation
is with moderate shock for 8 to 10 hr./day. What horsepower may be transmitted
continuously?

Solution:
N
Dp = p
Pd
Pd = Pdn cos = (5)cos15 = 4.89
18
Dp =
= 3.681 in
4.89
Wear load
bD pQK g
Fw =
cos 2
b = 3.5 in.
2Ng
2(108)
Q=
=
= 1.7143
N p + N g 18 + 108
Table AT 26, n = 20o
Sum of BHN = 350 + 300 = 650
K g = 233
Fw =

(3.5)(3.681)(1.7143)(233) = 5379 lb

cos 2 12
Strength of gear
sbY
Fs =
lb
K f Pdn
For gear: SAE 3150, OQT to BHN = 300
su = 151 ksi

sn = 0.5su = 0.5(151) = 75.5 ksi

Ng
108
N eg =
=
= 116
3
cos cos3 12

Page 8 of 14

SECTION 12 HELICAL GEARS

Table AT 24, Load near middle, n = 20o
Y = 0.763
snY = (75.5)(0.763) = 57.6
For pinion: SAE 4150, OQT to BHN = 350
su = 0.5BHN = 0.5(350) = 175 ksi
sn = 0.5su = 0.5(175) = 87.5 ksi
Np
18
N ep =
=
= 19
3
cos cos3 12
Table AT 24, Load near middle, n = 20o
Y = 0.534
snY = (87.5)(0.534) = 46.7
Therefore use pinion as weak
Assume K f = 1.7
Fs =

(87,500)(3.5)(0.534) = 19,240 lb
(1.7 )(5)

For moderate shock, 8 to 10 hr./day

Use N sf = 1.5
Fs N sf Fd

19,240 = 1.5Fd
Fd 12,827 lb
Therefore use Fd = Fw = 5379 lb
Fd = Ft +

0.05vm (Ft + Cb cos 2 )cos

lb
1
0.05vm + (Ft + Cb cos 2 )2
Fig. AF 20, carefully cut gears, Pdn = 5 , e = 0.001 in
Table AT 25, steel and steel, 20o FD
C = 1660
D p n p (3.681)(1750)
vm =
=
= 1686 fpm
12
12
0.05(1686) Ft + 1660(3.5) cos 2 12 cos12
Fd = Ft +
lb
1
2
0.05(1686) + Ft + 1660(3.5) cos 12 2
82.46[Ft + 5559]
Fd = Ft +
= 5379 lb
1
84.3 + [Ft + 5559]2
Trial and error
Ft = 1800 lb
Fv
(1800)(1686) = 92 hp
hp = t m =
33,000
33,000

Page 9 of 14

SECTION 12 HELICAL GEARS

708.

Two helical gears are used in a single reduction speed reducer rated at 27.4 hp at
a motor speed of 1750 rpm; continuous duty. The rating allows an occasional 100
% momentary overload. The pinion has 33 teeth. Pdn = 10 , b = 2 in. , n = 20o ,

= 20o , mw = 2.82 . For both gears, the teeth are carefully cut from SAE 1045
with BHN = 180. Compute (a) the dynamic load, (b) the endurance strength;
estimate K f = 1.7 . Also decide whether or not the 100 % overload is damaging.
(c) Are these teeth suitable for continuous service? If they are not suitable
suggest a cure. (The gears are already cut.)
Solution:
N
Dp = p
Pd
Pd = Pdn cos = (10) cos15 = 9.66
33
Dp =
= 3.42 in
9.66
D p n p (3.42)(1750)
vm =
=
= 1567 fpm
12
12
33,000hp 33,000(27.4 )
Ft =
=
= 577 lb
vm
1567
(a) Dynamic load
0.05vm (Ft + Cb cos 2 )cos
Fd = Ft +
lb
1
0.05vm + (Ft + Cb cos 2 )2
Fig. AF 20, carefully cut gears, Pdn = 10 , e = 0.001 in
Table AT 25, steel and steel, 20o FD
C = 1660
b = 2 in
Fd = 577 +

0.05(1567 ) 577 + 1660(2)cos 2 15 cos15

(b) Endurance strength

sbY
Fs =
lb
K f Pdn
For SAE 1045, BHN = 180
su = 0.5BHN = 0.5(180) = 90 ksi
sn = 0.5su = 0.5(90) = 45 ksi
Np
33
N ep =
=
= 37
3
cos cos3 15
Table AT 24, Load near middle, n = 20o

Page 10 of 14

1
2

0.05(1567 ) + 577 + 1660(2)cos 15

2

= 2578 lb

SECTION 12 HELICAL GEARS

Y = 0.645
K f = 1 .7

sbY
(45,000)(2)(0.645) = 3415 lb
=
(1.7 )(10)
K f Pdn
For 100 % overload
Ft = 2(577 ) = 1154 lb
Fs =

Fd = Ft +

0.05vm (Ft + Cb cos 2 )cos

1
2

lb

0.05vm + (Ft + Cb cos )

2

Fd = 1154 +

0.05(1567 ) 1154 + 1660(2)cos 2 15 cos15

(c) Fw =

1
2

0.05(1567 ) + 1154 + 1660(2) cos 15

Since Fs Fd , 100 % overload is not damaging
2

= 3475 lb

bD pQK g
cos 2

b = 2 in.
2mw
2(2.82 )
Q=
=
= 1.476
mw + 1 2.82 + 1

Table AT 26, n = 20o

Sum of BHN = 2(180) = 360
K g = 62.5
Fw =

(2)(3.42)(1.476)(62.5) = 676 lb < F (= 2578 lb )

d

cos 2 15
Therefore not suitable for continuous service.
Cure: Through hardened teeth
For Bhn
2578
Kg =
(62.5) = 238
676
min Bhn = 0.5(650) = 325

709.

Two helical gears are used in a speed reducer whose input is 100 hp at 1200 rpm,
from an internal combustion engine. Both gears are made of SAE 4140, with the
pinion heat treated to a BHN 363 415, and the gear to 321 363; let the teeth
be F.D.; 20o pressure angle in the normal plane; carefully cut; helix angle
= 15o ; N p = 22 , N g = 68 teeth; Pd = 5 , b = 4 in . Calculate the dynamic load,
the endurance strength load, and the limiting wear load for the teeth. Should these
gears have long life if they operate continuously? (Data courtesy of the Twin
Disc Clutch Co.)

Solution:

Page 11 of 14

SECTION 12 HELICAL GEARS

N p 22
=
= 4.4 in
Pd
5
D p n p (4.4)(1200)
vm =
=
= 1382 fpm
12
12
33,000hp 33,000(100 )
Ft =
=
= 2388 lb
vm
1382
Dynamic load
0.05vm (Ft + Cb cos 2 )cos
Fd = Ft +
lb
1
2
0.05vm + (Ft + Cb cos )2
Fig. AF 20, carefully cut gears, Pdn = 5 , e = 0.001 in
Table AT 25, steel and steel, 20o FD
C = 1660
b = 4 in
Dp =

Fd = 2388 +

0.05(1382) 2388 + 1660(4) cos 2 15 cos15

1
2

0.05(1382 ) + 2388 + 1660(4)cos 15

Endurance strength load
sbY cos
Fs =
lb
K f Pd
2

= 5930 lb

Assume K f = 1.7
Pinion
sn = 0.25BHN = 0.25(363) = 90.75 ksi
Np
22
N ep =
=
= 25
3
cos cos3 15
Table AT 24, Load near middle, n = 20o
Y = 0.580
sbY cos (90,750)(4 )(0.580) cos15
Fs =
=
= 23,925 lb
(1.7 )(5)
K f Pd
Gear
sn = 0.25BHN = 0.25(321) = 80.25 ksi
Np
68
N ep =
=
= 75
3
cos cos3 15
Table AT 24, Load near middle, n = 20o
Y = 0.735
sbY cos (80,250 )(4)(0.735)cos15
Fs =
=
= 26,811 lb
(1.7 )(5)
K f Pd
use Fs = 23,925 lb

Page 12 of 14

SECTION 12 HELICAL GEARS

Limiting Wear Load
bD pQK g
Fw =
cos 2
Table AT 26, n = 20o
Sum of BHN = 684 to 778 use 700
K g = 270
Q=

2Ng
2(68)
=
= 1.511
N p + N g 22 + 68

Fw =

(4)(4.4)(1.511)(270) = 7696 lb

cos 2 15
Since Fw (= 7696 lb ) > Fd (= 5930 lb ) these gears have long life if they operate
continuously.

CROSSED HELICAL
710.

Helical gears are to connect two shafts that are at right angles
( N1 = 20 , N 2 = 40 , Pdn = 10 , 1 = 2 = 45o ). Determine the center distance.

Solution:
D cos 1
N1 = 1
= Pdn D1 cos 1
Pcn
20 = (10)(D1 )cos 45
D1 = 2.83 in
N 2 = Pdn D2 cos 2
40 = (10)(D2 )cos 45
D2 = 5.66 in
C = 12 (D1 + D2 ) = 12 (2.83 + 5.66) = 4.25 in
712.

Two shafts that are at right angles are to be connected by helical gears. A
tentative design is to use N1 = 20 , N 2 = 60 , Pdn = 10 , and a center distance of 6
in. What must be the helix angles?

Solution:
= 1 + 2 = 90o
N1
D1 =
Pdn cos 1
N2
D2 =
Pdn cos 2
1
C = 2 (D1 + D2 )

Page 13 of 14

SECTION 12 HELICAL GEARS

N1
N2
+
Pdn cos 1 Pdn cos 2
20
60
+
2(6 ) =
10 cos 1 10 cos 2
2
6
12 =
+
cos 1 cos 2
1
3
6=
+
cos 1 cos 2
By trial and error method
1
3
+
6=
cos 1 sin 1
2C =

1 = 39.5o
2 = 50.5o
- end -

Page 14 of 14