2 10 PDF

Machine Design II
Prof. K.Gopinath & Prof. M.M.Mayuram
Module 2 - GEARS
Lecture 10 - SPUR GEAR DESIGN
Contents
10.1 Problem 3 Spur gear design
10.1.1 Buckingham Approach
10.1.2 AGMA Approach
10.1 Problem 3 - Design of Spur gear

A pair of gears is to be designed to transmit 30kW power from a pinion running at
960rpm to a gear running at 320rpm. Design the gears so that they can last for 108
cycles. Assume 20o full depth involute spur gear for the system. Motor shaft diameter is
30mm.
Data given:
W = 30 kW; n 1 = 960 rpm; n 2 = 320 rpm; Life = 108 cycles; 20o full depth involute spur
gear.
Solution:
i = n 1 / n 2 = 960 / 320 = 3
In order to keep the size small and meet the centre distance, Z 1 = 17 chosen
Z 2 = i Z 1 = 3 x 17 = 51
2n1 2 x x 960
100.48 rad/s
60
60
Torque is given by,
T1
w 30x1000
298.57 Nm
100.48
Indian Institute of Technology Madras
Machine Design II
From Lewis equation for pinion we have,

p
Ft
2T1
[]p
b Y m bYZ1m 2
(10.1)
SAE 1050 hardened by OQT with permissible bending strength of 532 and hardness of
223Bhn is selected for pinion and SAE 1045 hardened by WQT with permissible
bending strength of 487 and hardness of 215 Bhn is selected for the gear from Table
10.1. Face width b = 10m is chosen for both wheels.
Table 10.1 Safe static stresses for use in the Lewis equation
Material
[ ] MPa
BHN
Gray cast iron

ASTM 25
ASTM 35
ASTM 50
122
183
228
174
212
223
Cast steel(low carbon)

0.2% C not heat treated
0.2% C WQT
304
380
180
250
Forged carbon steel

SAE 1020 case hardened and WQT
SAE 1030 not heat treated
SAE 1045 hardened by WQT
SAE 1045 hardened by WQT
SAE 1050 hardened by OQT
274
304
350
380
456
487
532
156
180
190
202
205
215
223
Alloy steel
SAE 2320 case hardened and WQT
SAE 3115 case hardened and OQT
761
761
563
806
989
989
837
1019
225
475
212
475
475
475
475
475
Machine Design II
10.1.1 Buckingham approach:

The preliminary dimensions are found from Lewis equation and then they are checked
for dynamic loads by Buckingham equation.
From equation (10.1) substituting the value of b = 10m, we have,
T1
[]p
5YZ1m3
(10.2)
From Table 10.2, for the pinion Y = 0.25808 for Z 1 = 17

For the gear, Y = 0.39872, for Z 2 = 51
For gear, Y[] g = 0.39872x 487 = 194.17
For pinion, Y[] p = 0.25808 x 542 = 139.87
Table 10.2 Values of the Lewis form factor Y

Number of
teeth
12
13
14
15
16
17
18
19
20
21
22
24
26
28
30
34
38
45
50
60
75
100
=20
a=0.8m*
b=m
0.335 12
0.348 27
0.359 85
0.370 13
0.379 31
0.387 57
0.395 02
0.401 79
0.407 97
0.413 63
0.418 83
0.428 06
0.436 01
0.442 94
0.449 20
0.459 20
0.467 40
0.478 46
0.484 58
0.493 91
0.503 45
0.513 21
=20
a=m
b=1.25m
0.229 60
0.243 17
0.255 30
0.266 22
0.276 10
0.285 08
0.293 27
0.300 78
0.307 69
0.314 06
.0319 97
0.330 56
0.339 79
0.347 90
0.355 10
0.367 31
0.377 27
0.390 93
0.398 60
0.410 47
0.422 83
0.435 74
=25
a=m
b=1.25m
0.276 77
0.292 81
0.307 17
0.320 09
0.331 78
0.342 40
0.352 10
0.360 99
0.369 16
0.376 71
0.383 70
0.396 24
0.407 17
0.416 78
0.425 30
0.439 76
0.451 56
0.467 74
0.476 81
0.490 86
0.505 46
0.520 71
Machine Design II
Hence, for the same face width pinion will be weaker and consideration for the design
is,
T
298.57 x1000
13610
3
3
5YZ1m 5x0.25808 x17m
m3
532 MPa
(10.3)
m = 2.93 mm. Since motor shaft diameter is 30 mm, to get sufficiently large pinion m = 4
mm is taken.
Table 10.3 Data for pinion and gear

Wheel
b=10m
Pinion 17 4mm 40 mm
Gear
d
68mm
V =wrv
Material
Hardness
3.42 m/s SAE1050
223
51 4mm 40 mm 204mm 3.42 m/s SAE1045
215
We will now use Buckingham dynamic load approach for the design.
F t = T 1 /r 1 = 298.57/0.034 = 8781 N
Buckingham dynamic load is given by,
9.84V (Cb + Ft )
Fi
9.84V +0.4696 Cb+ Ft
(10.4)
For V=3.42 m/s permissible error is e= 0.088 mm from Fig.10.1. From Table 10.4, if we
choose I class commercial cut gears, expected error is 0.050 for m=4mm. In order to
keep the dynamic load low precision cut gears are chosen. So, e = 0.0125
Machine Design II
Fig. 10.1 Permissible error

Table 10.4 Expected error in tooth profile
Gear quality and expected error e
Module
First class commercial
Carefully cut gears
Precision gears
gears
Up to 4
5
6
7
8
9
10
0.050
0.056
0.064
0.072
0.080
0.085
0.090
0.025
0.025
0.030
0.035
0.038
0.041
0.044
Table 10.5 Value of C

Material of pinion and
Tooth form
gear
14.5o
0.0125
0.0125
0.0150
0.0170
0.0190
0.0205
0.0220
Cast iron and cast iron

steel and cast iron
steel and steel
5720 e
7850 e
11440 e
20o Full depth Cast iron and cast iron

steel and cast iron
steel and steel
5930 e
8150 e
11860 e
20o Stub
tooth
6150 e
8450 e
12300 e
Cast iron and cast iron

steel and cast iron
steel and steel
From Table 10.5, if material for both gear and pinion are steel, then,
Machine Design II
C = 11860e = 11860 x 0.0125 = 148.25

Substituting the values F t = 8781 N, C = 148 .25, V=3.42 m/s, b= 40mm in eqn. (10.4),
Buckingham dynamic load is given by,
9.84x3.42(148.25x40 +8781)
Fi
5464N
9.84x3.42+0.4696 148.25x40+8781
(10.5)
F d = F t + F i = 8781 + 5464 = 14245 N

Beam strength of the pinion is given by,
F tp = bYm [] p = 40x0.25808 x4x542 = 22381 N
Since F tp (22381)> F d (14245) the design is safe from tooth bending failure
consideration.
Wear strength of the pinion is given by,
[ ]
Fts bd1 I H
Cp
(10.6)
From Table 10.6 for steel vs steel, pinion and gear C p = 191 MPa0.5 and substituting i
=3, =200 we
I
sin cos i
sin 20o cos 20o 3
0.1205
2
i 1
2
3 1
Table 10.6 Elastic coefficient C p for spur gears in MPa0.5

Pinion Material
(=0.3 in all cases)
Gear Material
Steel
Cast iron
Al Bronze
Tin Bronze
Steel, E=207 GPa
191
166
162
158
Cast iron, E=131 GPa
166
149
149
145
Al Bronze, E=121 GPa
162
149
145
141
Tin Bronze, E=110

GPa
158
145
141
137
Machine Design II
Surface fatigue strength of the pinion material is sf = sf K L K R K T

sf = 2.8(Bhn) 69MPa
= 2.8 x 223-69 = 555.4MPa
K L = 0.9 for 108 cycles life from graph1
K R = 1.0 taken for 99 reliability
K T = 1.0 for operating temperature <120oC (assumed)
Table 10.7 Surface fatigue strength sf (MPa) for metallic spur gears (107 cycle
life 99% reliability and temperature <120oC)
Material
sf (MPa)
Steel
2.8 (Bhn)-69MPa
Nodular iron
0.95(2.8(Bhn)-69MPa)
Cast iron, grade 20
379
Cast iron, grade 30
482
Cast iron, grade 40
551
Tin Bronze, AGMA 2C (11% Sn)
207
Aluminium Bronze (ASTM 148 52) (Alloy 9C H.T.)
448
Fig.10.2 Life factor K L
Machine Design II
Table 10.8 Reliability factor K R
Reliability (%)
KR
50
1.25
99
1.00
99.9
0.80

= 555.4x0.9x1x1 = 500MPa
Assuming, factor of safety, s = 1.1
[ H ] = sf /s = 500/1.1 = 455MPa
Wear strength of the pinion is:
2
2
[ ]
455
Fts = bd1 I H = 40x68x0.1205
=1860 N
Cp
191
Since F ts (1860) << F d (14245), the design is not safe. Revision is necessary.
As the SAE1050 can attain a hardness of 800 VPN(~750 Bhn) after oil quenching,
increase the hardness to 475 Bhn and increase the b to 13m
= 13 x 4 = 52 mm.
From Table 10.7, we know that,

sf = 2.8(Bhn) 69MPa
= 2.8 x 475-69 = 1261MPa
K L = 0.9 for 108 cycles life from Fig.10.1
K R = 1.0 taken for 99 reliability
K T = 1.0 for operating temperature <120oC Assumed.
= 1261x0.9x1x1 = 1135MPa
Machine Design II
Fig.10.3 Effect of carbon content on the hardness of fully hardened steel

Assuming factor of safety, s = 1.1
[ H ] = sf /s = 1135 /1.1 = 1032MPa
2
2
[ ]
1032
Fts = bd1 I H = 52x68x0.1205
=12439 N
C
191
Since F ts (12439)< F d (14245), still it is not safe. Hence increase the module to 5mm.
Table 10.9 Properties of pinion and gear
Wheel
b=13m
V =wrv
85mm
4.27 m/s
C 50
475
51 5mm 65 mm 255mm 4.27 m/s
C 45
450
Pinion 17 5mm 65 mm
Gear
Material Hardness
Machine Design II
With new dimensions F d = 16098 N

F ts = 19436 N. Since F ts > F d , the revised design is safe from surface fatigue (pitting)
considerations.
If b = 50 mm, F d = 13186 N
F ts = 14951 N , Face width of 50 mm is adequate
10.1.2 AGMA Approach

Data given:
W = 30 kW; n 1 = 960 rpm; n 2 = 320 rpm; Life = 108 cycles; 20o full depth involute spur
gear.
Solution:
i = n 1 / n 2 = 960 / 320 = 3
In order to keep the size of gears small and avoid interference, Z 1 = 17 is chosen.
Z 2 = i Z 1 = 3 x 17 = 51
1 =
T1
2n1 2x960
100.48rad / s
=
60
60
1000W 1000x30
298.57 Nm
1
100.48
AGMA equation for tooth bending stress is,
Ft
K K K
bmJ v o m
d1 = m Z1
2T1
K K K [ ]
b Z1 m 2 J v o m
Face width, b= 10 to 13 m.
Machine Design II
b = 10 m is assumed for the first trial.
J = 0.34404 for pinion Z 1 = 17 mating with gear Z 2 =51
For gear J = 0.40808
These values are obtained from the table
Table 10.10 AGMA geometry factor J for teeth having = 20o, a=1m, b=1.25m and
r f =0.300m
Number
of teeth
Number of teeth in mating gear

1
17
25
35
50
85
300
1000
18
0.244 86 0.324 04 0.332 12 0.338 40 0.344 04 0.350 50 0.355 94 0.361 12
19
0.247 94 0.330 29 0.338 78 0.345 37 0.351 34 0.358 22 0.364 05 0.369 63
20
0.250 72 0.336 00 0.344 85 0.351 76 0.358 04 0.365 32 0.371 51 0.377 49
21
0.253 23 0.341 24 0.350 44 0.357 64 0.364 22 0.371 86 0.378 41 0.384 75
22
0.255 52 0.346 07 0.355 59 0.363 06 0.369 92 0.377 92 0.384 79 0.391 48
24
0.259 51 0.354 68 0.364 77 0.372 75 0.380 12 0.388 77 0.396 26 0.403 60
26
0.262 89 0.362 11 0.372 72 0.381 15 0.388 97 0.398 21 0.406 25 0.414 18
28
0.265 80 0.368 60 0.379 67 0.388 51 0.396 73 0.406 50 0.415 04 0.423 51
30
0.268 31 0.374 62 0.385 80 0.395 00 0.403 59 0.413 83 0.422 83 0.431 79
34
0.272 47 0.383 94 0.396 71 0.405 94 0.415 17 0.426 24 0.436 04 0.445 86
38
0.275 75 0.391 70 0.404 46 0.414 80 0.424 56 0.436 33 0.446 80 0.457 35
45
0.280 13 0.402 23 0.415 79 0.426 85 0.437 35 0.450 10 0.461 52 0.473 10
50
0.282 52 0.408 08 0.422 08 0.435 55 0.444 48 0.457 78 0.469 75 0.481 93
60
0.286 13 0.417 02 0.431 73 0.443 83 0.455 40 0.469 60 0.482 43 0.495 57
75
0.289 79 0.426 20 0.441 63 0.454 40 0.466 68 0.481 79 0.495 54 0.509 70
100
0.293 13 0.435 61 0.451 80 0.465 27 0.478 27 0.494 37 0.509 09 0.524 35
150
0.297 38 0.445 30 0.462 26 0.476 45 0.490 23 0.507 36 0.523 12 0.539 54
300
0.301 41 0.455 26 0.473 04 0.487 98 0.502 78 0.520 78 0.537 65 0.555 33
Rack
0.305 75 0.465 54 0.484 15 0.499 88 0.534 67 0.534 67 0.552 72 0.571 73
The tooth bending stress is given by,

78 (200V) 0.5
Kv
78
0.5
1.15
is assumed.
Machine Design II
K o = 1.25 is taken assuming uniform power source and moderate shock load from the
table 7
K m = 1.3 assuming accurate mounting and precision cut gears for face width of about
50mm.
Table 10.11 -Overload factor K o
Driven Machinery
Source of power 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 10.12 Load distribution factor K m

Face width ( mm)
Characteristics of Support
Accurate mountings, small bearing
0 - 50
150
225
400 up
1.3
1.4
1.5
1.8
1.6
1.7
1.8
2.2
Over
Over
Over
Over
2.2
2.2
2.2
2.2
clearances, minimum deflection, precision

gears
Less rigid mountings, less accurate gears,
contact across the full face
Accuracy and mounting such that less than
full-face contact exists
Substituting these values in the equation,

1
2T1
298570 x1.15 x1.25 x1.3
Kv Ko Km
2
10m x17xm 2 x 0.34404
b Z1 m J
9539
m3
Machine Design II
e = e kL kv ks kr kT kf km
The pinion is of steel C50 OQT with 223Bhn hardness and tensile strength of 660MPa
and the gear is of C45 OQT with hardness 210Bhn and tensile strength of 465MPa.
For pinion e = 0.5 ut = 0.5 x 660 = 330MPa
k L = 1 for bending, k V = 1 assumed expecting m to be <5mm; k S = 0.73 from the
Fig.10.4 for ut = 660MPa, k r = 0.897 for 90% reliability
Fig. 10. 4 Surface factor k s
Table 10.13 Reliability factor K r

Reliability factor R
0.50
0.90
0.95
0.99
0.999
0.9999
Factor Kr
1.000
0.897
0.868
0.814
0.753
0.702
kT =1 assumed based on operating temperature <120oC

kf = 1.- and km = 1.33 for ut= 660MPa
( Ultimate tensile strength = 660 MPa for
SAE 1050 OQT condition)

e
= e kL kv ks kr kT kf km
= 330x1x1x0.73x0.897x1x1x1.33 = 287.4MPa
Factor of safety on bending of 1.5 assumed
Machine Design II
[] = e / s = 287.4 / 1.5 =191.6MPa
Fig.10.5 - Miscellaneous effects factor km

From tooth bending fatigue considerations,
9539
[ ] 191.6
m3
Solving the equation we get m = 3.68mm

Now take m=4 mm as the next standard value. From this module, the dimensions
calculated are given in Table 10.14.
Table 10.14 Dimensions of pinion and gear

Wheel
b=10m
V =wrv
68mm
3.42 m/s
C 50
223
51 4mm 40 mm 204mm 3.42 m/s
C 45
205
Pinion 17 4mm 40 mm
Gear
Material Hardness
Ft = T1 / r1 = 29857/34 = 8781N
The tooth has to be checked from surface durability considerations now.
The contact stress equation of AGMA is given below:
H Cp
Ft
KV Ko Km
bd1 I
Cp = 191 MPa0.5 from the table for steel vs steel
Machine Design II
Substituting i =3, =200 we get I= 0.1205
sin cos i
sin 20o cos 20o 3
I
0.1205
2
i 1
2
3 1
78 (200V) 0.5
Kv
78
0.5
78 (200x3.42) 0.5
78
0.5
1.15
From Table 10.11 and 10.12,

Ko = 1.25 and Km = 1.3 assumed as in the case of bending stress calculation
H Cp
Ft
8781x1.15x1.25x1.3
K V K o K m 191
bd1 I
40x68x0.1205
H = 1209MPa
The surface fatigue strength of the pinion material is given by,

sf = sf KL KR KT
Where sf = 2.8(Bhn) 69MPa
= 2.8 x 223-69 = 555.4MPa
KL= 0.9 for 108 cycles life from graph1
KR = 1.0 taken for 99% reliability
KT = 1.0 for operating temperature <120oC assumed.
Substituting the values in the equation,
sf = sf KL KR KT
= 555.4x0.9x1x1 = 500MPa
Assuming a factor of safety, s = 1.1
From Fig. 10.2 and Table 10.8, we get,
[H] = sf /s = 500/1.1 = 455MPa
H = 1209MPa
Machine Design II
Since H (1209) >> [H] (455), the design is not safe and surface fatigue failure will
occur.
Solution:
Increase the surface hardness of the material to 475Bhn and also increase the b to 13m
= 13 x 4 = 52 mm
From Fig. 3 we get,
Surface fatigue strength of the pinion material as
sf = sf KL KR KT
where sf = 2.8(Bhn) 69MPa = 2.8 x 475-69 = 1261MPa
KL= 0.9 for 108 cycles life from graph1

KR = 1.0 taken for 99% reliability
KT = 1.0 for operating temperature <120oC Assumed.
Substituting these values we get,

sf = sf KL KR KT
= 1261x0.9x1x1 = 1135MPa
Assuming a factor of safety s = 1.1
[H] = sf /s = 1135 /1.1 = 1032MPa
H Cp
Ft
8781x1.15x1.25x1.3
K V K o K m 191
b d1 I
52x68x0.1205
As H (1185) > [H] (1032) the design is not safe from surface durability considerations.
Hence increase the module to 5mm and take b=10m
H Cp
Ft
7025x1.17x1.25x1.3
K V K o K m 191
bd1 I
50x85x0.1205
Machine Design II
H =975MPa < [H ] (1032MPa). Hence the design is safe from surface durability
consideration. Final specification of the pinion and gear are given in the Table 10.20
and 10.21.
Table 10.20 Values for gear and pinion

Wheel
b=10m
Pinion
17
5mm
50 mm
85mm
Gear
51
5mm
50 mm
255mm
Table 10.21 Specification of gear and pinion

Wheel
Material Steel
Hardness Manufacturing quality
Pinion
SAE1050 OQT
475Bhn
Precision cut
Gear
SAE 1045 OQT
450Bhn
Precision cut
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Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

10.1 Problem 3 - Design of Spur gear

Torque is given by,

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

From Lewis equation for pinion we have,

Gray cast iron

Cast steel(low carbon)

Forged carbon steel

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

10.1.1 Buckingham approach:

From Table 10.2, for the pinion Y = 0.25808 for Z 1 = 17

Table 10.2 Values of the Lewis form factor Y

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

Table 10.3 Data for pinion and gear

3.42 m/s SAE1050

51 4mm 40 mm 204mm 3.42 m/s SAE1045

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

Fig. 10.1 Permissible error

Table 10.5 Value of C

Cast iron and cast iron

20o Full depth Cast iron and cast iron

Cast iron and cast iron

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

C = 11860e = 11860 x 0.0125 = 148.25

F d = F t + F i = 8781 + 5464 = 14245 N

Table 10.6 Elastic coefficient C p for spur gears in MPa0.5

Steel, E=207 GPa

Cast iron, E=131 GPa

Al Bronze, E=121 GPa

Tin Bronze, E=110

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

Surface fatigue strength of the pinion material is sf = sf K L K R K T

Cast iron, grade 20

Cast iron, grade 30

Cast iron, grade 40

Tin Bronze, AGMA 2C (11% Sn)

Aluminium Bronze (ASTM 148 52) (Alloy 9C H.T.)

Fig.10.2 Life factor K L

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

Table 10.8 Reliability factor K R

Surface fatigue strength of the pinion material is sf = sf K L K R K T

From Table 10.7, we know that,

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

Fig.10.3 Effect of carbon content on the hardness of fully hardened steel

51 5mm 65 mm 255mm 4.27 m/s

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

With new dimensions F d = 16098 N

10.1.2 AGMA Approach

AGMA equation for tooth bending stress is,

Indian Institute of Technology Madras

Prof. K.Gopinath & Prof. M.M.Mayuram

b = 10 m is assumed for the first trial.

J = 0.34404 for pinion Z 1 = 17 mating with gear Z 2 =51