12.

Spur Gear Design and

selection

Standard proportions

Objectives

Apply principles learned in Chapter 11 to actual design and selection of spur

gear systems.

Calculate forces on teeth of spur gears, including impact forces associated with
velocity and clearances.

Determine allowable force on gear teeth, including the factors necessary due to
angle of involute of tooth shape and materials selected for gears.

Design actual gear systems, including specifying materials, manufacturing

accuracy, and other factors necessary for complete spur gear design.

Understand and determine necessary surface hardness of gears to minimize or

prevent surface wear.

Understand how lubrication can cushion the impact on gearing systems and cool
them.

Select standard gears available from stocking manufacturers or distributors.

P N RAO

Specifications for standard gear

teeth
Item

Full depth & pitches

coarser than 20

Pressure
angle

Full depth &

pitches finer
than 20

14 full
depth

20

25

20

14

Addendum
(in.)

1.0/P

1.0/P

1.0/P

1/P

Dedendum
(in.)

1.250/P

1.250/P

1.2/P + 0.002

1.157/P

P N RAO

Fn = Ft tan
F
Fr = t
cos
3

P N RAO

Example Problem 12-1: Forces on Spur Gear Teeth

20-tooth, 8 pitch, 1-inch-wide, 20 pinion

transmits 5 hp at 1725 rpm to a 60-tooth gear.

Torque, T = Ft r and r = Dp /2
Combining the above we can write

Determine driving force, separating force, and

maximum force that would act on mounting
shafts.

2T
Dp
P N RAO

Ft = Transmitted force
Fn = Normal force or separating
force
Fr = Resultant force
= pressure angle

Tn
or T = 63,000 P
63,000
n

Ft =

P N RAO

Forces on spur gear teeth

Forces on spur gear teeth

Power, P; P =

American Standard Association (ASA)

American Gear Manufacturers Association
(AGMA)
Brown and Sharp
14 deg; 20 deg; 25 deg pressure angle
Full depth and stub tooth systems

P N RAO

Example Problem 12-1: Forces on Spur Gear Teeth (contd.)

Example Problem 12-1: Forces on Spur Gear Teeth

Find transmitted force:

(12-3)

20-tooth, 8 pitch, 1-inch-wide, 20 pinion transmits 5 hp at 1725 rpm to a 60-tooth gear.

Determine driving force, separating force, and maximum force that would act on
mounting shafts.
(2-6)
P =

T =

2T
Dp

Ft =

Ft =

Tn
63,000

(2)183 in-lb
= 146 lb
2.5 in

Find separating force:

63,000P
n

(12-1)
Fn = Ft tan

(63,000)5
= 183 in-lb
T =
1725

Fn = 146 lb tan 20
Fn = 53 lb

Find pitch circle:

Find maximum force:

(12-2)

(11-4)
Dp =

Dp =

Fr =

Np
Pd

Fr =

20 teeth
= 2.5 in
8 teeth/in diameter

Ft
cos
146 lb
cos 20

Fr = 155 lb

P N RAO

P N RAO

Example Problem 12-2: Surface Speed

Surface Speed

In previous problem, determine the surface speed:

Surface speed (Vm) is often referred to as

pitch-line speed
Vm =
Vm =

Dp n
12
Dp n
1000

(12-7)
Vm = D n
or

ft/min

(12-5)
Vm =

m/min -- Metric units

Dp n
12

Vm = 2.5 in 1725 rpm

ft
12 in

Vm = 1129 ft/min
P N RAO

P N RAO

10

Forces on Gear Tooth

Strength of Gear Teeth

Lewis form factor method

Figure 14.20 Forces acting

on individual gear tooth.

P N RAO

11

P N RAO

1998 McGraw-Hill, Hamrock,

Jacobson and Schmid

12

Lewis equation

Table 12.1 Lewis form factors (Y)

Sn Y b
Pd

Fs =

Fs = Allowable dynamic bending force (lb)

Sn = Allowable stress (lb/in2). Use
endurance limit and account for the fillet as
the stress concentration factor
b = Face width (in.)
Y = Lewis form factor (Table 12.1)
Pd = Diametral pitch
P N RAO

13

Example Problem 12-3: Strength of Gear Teeth

P N RAO

14

Example Problem 12-3: Strength of Gear Teeth (contd.)

In Example Problem 12-1, determine the force allowable (Fs) on these teeth if the
pinion is made from an AISI 4140 annealed steel, the mating gear is made from AISI
1137 hot-rolled steel, and long life is desired.

Gear:
Sn = .5 (88 ksi) = 44 ksi

Pinion:

(Table 12-1)
Sn = .5 Su = .5 (95 ksi) = 47.5 ksi

Y = .421
(12-9)

Fs =

Sn b Y
Fs =
Pd

44,000 (1) .421

8

Fs = 2316 lb

Find Lewis form factor (Y) from Table 12-1, assuming full-depth teeth:
Y = .320
Fs =

Use Fs = 1900 lb for design purposes.

47,500 (1) .320

8

Fs = 1900 lb
P N RAO

15

Classes of Gears

P N RAO

Force Transmitted

Transmitted load depends on the accuracy of the

gears
Gear Manufacture

Transmitted load depends on the accuracy of the

gears
A dynamic load factor is added to take care of
this.
Ft = Transmitted force
Fd = Dynamic force
Commercial
600 + Vm

Casting
Machining
Forming
Hobbing
Shaping and Planing

Forming
stamping

Fd =

P N RAO

16

17

600
P N RAO

Ft

18

Classes of Gears
Carefully cut Fd =
Precision

Fd =

Design Methods

1200 + Vm
Ft
1200

Strength of gear tooth should be greater

than the dynamic force; Fs Fd
You should also include the factor of safety,
Nsf
Fs
Fd
N sf

78 + Vm0.5
Ft
78

Hobbed or shaved Fd =

50 + Vm0.5
Ft
50

P N RAO

19

Relation between the width of gears and the

diametral pitch

Uniform load without shock

8
12.5
<b<
Pd
Pd

1.25 < Nsf < 1.5 Medium shock, frequent starts

1.5 < Nsf < 1.75 Moderately heavy shock
1.75 < Nsf < 2

20

Face width of Gears

Table 12.2 Service Factors

1 < Nsf < 1.25

P N RAO

Heavy shock

P N RAO

21

P N RAO

22

Example Problem 12-5: Design Methods

Example Problem 12-4: Design Methods

If, in Example Problem 12-1, the gears are commercial grade, determine dynamic load
and, based on force allowable from Example Problem 12-3, would this be an acceptable
design if a factor of safety of 2 were desired?
Use surface speed and force transmitted from Example Problems 12-2 and 12-3.
Dynamic load:
600 + Vm
(12-10)
Fd =
Ft
600
600 + 1129
Fd =
(146 lb)
600
Fd = 421 lb

Spur gears from the catalog page shown in Figure 12-3 are made from a .2% carbon
steel with no special heat treatment.
What factor of safety do they appear to use in this catalog?
Try a 24-tooth at 1800 rpm gear for example purposes.
From Appendix 4, an AISI 1020 hot-rolled steel would have .2% carbon with an Sy = 30
ksi and Su = 55 ksi.
Therefore:
Sn = .5 Su
Sn = .5 (55 ksi) = 27.5 ksi

Comparing to force allowable:

Find Dp :

Fs
Fd
N sf

(11-4)

1900 lb
421
2
950 lb > 421 lb

Dp =

Dp =

This design meets the criteria.

P N RAO

23

Np
Pd

24
= 2 in
12

P N RAO

24

Example Problem 12-5: Design Methods (contd)

Example Problem 12-5: Design Methods (contd)

Find Vm :

Set Fs = Fd and solve for Ft :

600 + Vm
Fd = Fs =
Ft
600

(12-5)

Vm =

Dp n
12

Vm = 2 in (1800 rpm)

600 + 942
519 lb =
Ft
600

ft
12 in

Ft = 202 lb
(12-3)

Vm = 942 ft/min
Dp
T = F

Find Fs :
(12-9)

Fs =

2 in
T = 202 lb

Sn b Y
Pd

T = 202 in-lb
(from Table 12-1)

(2-6)

Tn
202 (1800)
P =
=
= 5.8 hp
63,000
63,000

Y = .302
Fs =

27,500 () .302
12

or
(12-6)

Fs = 519 lb

P N RAO

25

Example Problem 12-5: Design Methods (contd)

Pair of commercial-grade spur gears is to transmit 2 hp at a speed of 900 rpm of the

pinion and 300 rpm for gear.
If class 30 cast iron is to be used, specify a possible design for this problem.
The following variables are unknown: Pd, Dp, b, Nt, Nsf, .
As it is impossible to solve for all simultaneously, try the following:
Pd = 12, Nt = 48, = 14, Nsf = 2
Solve for face width b.

hp - calculated
hp - catalog

Nsf =

26

Example Problem 12-6: Design Methods

Compared to catalog:

Nsf =

Ft Vm
202 (942)
P =
= P N RAO = 5.8 hp
33,000
33,000

5.8
= 1.4
4.14

Miscellaneous properties:
(11-4)

Appears to be reasonable value.

Np
48
=
= 4 in
Dp =
Pd
12

Manufacturer may also have reduced its rating for wear purposes as these
are not hardened gears.

Ng = Np Vr = 48(3) = 144 teeth

P N RAO

27

P N RAO

Example Problem 12-6: Design Methods (contd.)

Example Problem 12-6: Design Methods (contd.)

600 + Vm
Fd =
Ft
600
600 + 943
Fd =
70
600
Fd = 180 lb

Dynamic force
Surface speed:
(12-5)

Vm =

Dp n

Fs
Fd
N sf
and

Vm = 943 ft/min

Fs =

Finding force on teeth:

Sn b Y
Pd

(12-8)

Sn b Y
= Fd
N sf Pd

(12-6)

33,000 hp
Ft =
Vm

Class 30 CI; Su = 30 ksi; Sn = .4 Su (.4 is used because cast iron):

33,000 (2)
943

Sn = 12 ksi
Y = .344

Ft = 70 lb

P N RAO

(12-10)

Since width b is the unkown:

12

4 in 900 rpm
Vm =
12 in/ft

Ft =

28

29

(Table 12-1)

P N RAO

30

Example Problem 12-6: Design Methods (contd.)

To increase the dynamic beam strength of

the gear

Substituting:
(12-9)

Increase tooth size by decreasing the

diametral pitch
Increase face width upto the pitch diameter
of the pinion
Select material of greater endurance limit
Machine tooth profiles more precisely
Mount gears more precisely
Use proper lubricant and reduce
contamination

Sn b Y
= Fd
Nsf Pd
12,000 b .344
= 180
2 (12)
b = 1.0 inches
Check ratio of width to pitch:
(12-14)

12.5
8
< b <
Pd
Pd
12.5
8
< 1 <
12
12
.66 < 1 < 1.04

This is an acceptable design.

Many other designs are also possible.
P N RAO

31

Buckingham Method of Gear Design

P N RAO

32

Fig. 12.4 Expected error in tooth profiles

It offers greater flexibility

Expected error is based on different-pitch
teeth
More conservative design

P N RAO

33

14 deg 20 deg

Gray iron and Gray iron

Gray iron and steel
Steel and steel

800
1,100
1,600

P N RAO

34

Buckingham Method of Gear Design

Table 12.3 Values of C for e = 0.001 inch

Material

P N RAO

830
1,140
1,660

Fd = Ft +

35

0.05 Vm (b C + Ft )
0.05 Vm + (b C + Ft )0.5

P N RAO

36

Example Problem 12-7: Buckingham Method of Gear

Design and Expected Error

Fig. 12.5 Recommended maximum error in gear teeth

A pair of steel gears is made from annealed AISI 3140.

Each gear has a surface hardness of BHN = 350.
The pinion is a precision, 16 pitch, 20 involute, with 24 teeth 1 inch wide.
The gear has 42 teeth.
To transmit 3 hp at a speed of 3450 rpm for a safety factor of 1.4, is this a
suitable design?
(Appendix 4)

Su = 95 ksi
Sn = .5 Su = .5(95 ksi) = 47.5 ksi
(11-4)

Dp =

P N RAO

Np
24
=
= 1.5 in
16
Pd

37

Example Problem 12-7: Buckingham Method of Gear

Design and Expected Error (contd.)

P N RAO

38

Example Problem 12-7: Buckingham Method of Gear

Design and Expected Error (contd.)
Find surface speed:

Find torque:

(12-5)

(2-6)

P =

Tn
63,000

T =

P (63,000)
n

T =

3 (63,000)
3450

Vm =

Dp n
12

1.5 in 3450 rpm

Vm =

12 ft/in

Vm = 1355 ft/min
Find force allowable (Fs):

T = 55 in-lb

(12-9)

Find force transmitted:

Fs =
(12-3)

Ft =

Ft =

Sn b Y
Pd
(from Table 12-1)

2T
Dp

Y = .337

2(55 in-lb)
1.5 in

Fs =

Ft = 73 lb
P N RAO

39

Example Problem 12-7: Buckingham Method of Gear

Design and Expected Error (contd.)

47,500 (1) .337

16
Fs = 1000

P N RAO

40

Wear strength (Buckingham)

Expected error from Figure 12-4:

e = .0005

The value of C from Table 12-3 for steel and steel and 20 involute angle gears is 1660:
C = .0005 (1000) 1660
C = 830

Solve for dynamic load using Buckinghams equation:

Fd = Ft +

.05Vm (bC + Ft )
(12-15)

.05 Vm + (bC + Ft )1/ 2

Fd = 73 +

.05 (1355) (1 830 + 73)

.05 (1355) + (1 830 + 73)

Fd = 699 lb

2 Dg

FW = D P b K g
D + D
g
p
Fw = tooth wear strength (lb)

1/ 2

Dp = diametral pitch of pinion (in.)

Fs
Fd
N sf

Dg = diametral pitch of gear (in.)

1000
699
1.4
714 > 699

b = face width (in.)

Kg = load stress factor (Appendix 13)

This meets the criteria.

P N RAO

41

P N RAO

42

Example Problem 12-8: Wear of Gears

Example Problem 12-8: Wear of Gears (contd.)

In prior example problem, verify the surface is suitable for wear considerations.
For wear use Nss = 1.2

Substituting into equation 12-16:

Fw = 1.5 (1) 1.27 (270)

Wear formula:

Fw = 514

(12-16)

Fw = Dp b Q Kg

This would not be suitable. Try if surfaces each had a BHN = 450.
Find Q :

K g = 470
Fw = 1.5 (1) (1.27) ( 470)

(12-17)

Q =

2 Ng
Ng + Np

Fw = 895

Q =

2 (42)
42 + 24

Fw
Fd
N sf

(from Appendix 13)

895
> 699
1 .2
746 > 699

Q = 1.27
(from Appendix 13)

Kg = 270

This would now be acceptable if the gear teeth were hardened to a BHN of 450.
P N RAO

43

P N RAO

44