FME3 Ch15 PDF

Chapter 15: Helical, Bevel, and
Worm Gears
A combined helical and worm gearset speed

reducer. Source: Courtesy of Boston Gear.
Fundamentals of Machine Elements, 3rd ed.

Schmid, Hamrock and Jacobson
Just stare at the machine. There is

nothing wrong with that. Just live
with it for a while. Watch it the way
you watch a line when shing and
before long, as sure as you live, you'll
get a liFle nibble, a liFle fact asking in
a timid, humble way if you're
interested in it. That's the way the
world keeps on happening. Be
interested in it.

Robert Pirsig,
Zen and the Art of
Motorcycle Maintenance
2014 CRC Press
Helical Gear
Tangent to helical tooth
Element of pitch
cylinder (or
gear's axis)
(a)
Pitch cylinder
Helix
angle, s
(b)
(c)
Figure 15.1: Helical gear. (a) Illustration of meshing helical gears; (b) front view; (c) side
view.

2014 CRC Press
Gear Design Considerations

Gear type
Spur
Helical
Bevel
Worm
Advantages
Inexpensive, simple to design, no thrust load is developed by the gearing, wide variety of manufacturing options.
Useful for high speed and high power applications,
quiet at high speeds. Often used instead of spur
gears for high speed applications.
High efFLHQFy (can be 98% or higher), can transfer
power across nonintersecting shafts. Spiral bevel
gears transmit loads evenly and are quieter than
straight bevel.
Compact and cost effective designs for large gear
ratios. EfFLHQFy can be as high as 90% or as low as
50%, and is lower than for other gear sets.
Disadvantages
Can generate VLJQLFDQt noise, especially at high
speeds, and are usually restricted to pitch-line velocities below 20 m/s (4000 ft/min).
Generate a thrust load on a single face, more expensive than spur gears.
Shaft alignment is critical, rolling element bearings
are therefore often used with bevel gears. This
limits power transfer for high speed applications
(where a journal bearing is preferable). Can be expensive.
Wear by abrasion is of higher concern than other
gear types, can be expensive. Generate very high
thrust loads. Worm cannot be driven by gear; worm
must drive gear.
Table 15.1: Design considerations for gears.

2014 CRC Press
cn
Helical Gear Pitches
pc
(a)
pa
(b)
Figure 15.2: Pitches of helical gears. (a) Circular; (b) axial.

2014 CRC Press
AGMA Equations for Helical Gears

t =
W t pd K o K s K m K v K b
bw Yh
c = pH (Ko Ks Km Kv )
1
2
Correction factors are determined as in Chapter 14, except for geometry

factor. This can be approximated from
Yh = Ya Ym

2014 CRC Press
Helical Gear Geometry Factor

0.70
500
Geometry factor, Ya
0.65
150
0.60
60
0.55
30
0.50
20
Number of teeth
in mating gear
0.45
0.40
0
10
15
20
25
Helix angle, s ()
30
35
Figure 15.3: Helical gear geometry factor as a function of helix angle when mating with
a 75-tooth gear. Source: Courtesy of the American Gear Manufacturers Association.

2014 CRC Press
Correction Factor vs. Helix Angle

1.05
Geometry factor modifier, Ym
500
150
1.00
75
50
30
0.95
20
Number of teeth in mating gear
0.90
0
10
15
20
25
30
35
Helix angle, s ()
Figure 15.4: Helical gear geometry correction factor as a function of helix angle. Source:
Courtesy of the American Gear Manufacturers Association.

2014 CRC Press
Types of Bevel Gears
(a)
(b)
(c)
(d)
Figure 15.5: Types of bevel gears; (a) a straight bevel gear set; (b) a Zerol gear set; (c)
spiral bevel gear set; (d) hypoid bevel gear set. Source: Courtesy of ATI Precision
Gearing.

2014 CRC Press
Pitch apex to back
ce )
n
h
a
ist widt
d
e e
ne
on fac r co e
c
c
ter cted Innestan
u
O roje
di Dedendum
(p e
c
Face angle
Fa idth
angle
w
Back
angle
Pitch
angle
Front
angle
Crown to back
Pitch apex
to crown
Crown
Pitch
apex
Bevel Gear
Terminology
Pinion
Shaft
angle
Root angle
Gear
Pitch diameter
Outside diameter
Back
cone
angle
Back cone
distance
Figure 15.6: Terminology for bevel gears.

2014 CRC Press
Gear Mounting
(a)
(b)
Figure 15.7: Schematic illustration of the two basic forms of gear mounting. (a) Straddle
mounting, where the gear is located between bearings; (b) overhang mounting. Note
that deep groove rolling element bearings are shown, but often a bearing beFer suited
for thrust load support is required in at least one location.

2014 CRC Press
Bevel Gear Forces

Straight bevel gears:

Wt
T
W
=
=

cos
rave cos

Wa = Wt tan sin

Wr = Wt tan cos

Spiral bevel gears:

Wt
W
=
a cos (tan sin sin cos )
Wt

Wr =
(tan cos + sin sin )

cos
Figure 15.8: Forces acting on a bevel gear.
where the refers to dierent rotation
directions or spiral direction.
2014 CRC Press
AGMA Equations for Bevel Gears

2Tp pd Ko Kv Ks Km
t =
bw d p
Kx Yb
c =
Tp E
Ko Kv Km Ks Kx
bw d2p Ib
Ko and Kv are dened as for spur gears.

The load distribution factor is:
2

Kmb + 0.0036b
for bw in inches
w
K
=
m

Kmb + 5.6 106 b2w for bw in mm

The crowning factor is, for contact stress:

1.5 for properly crowned teeth
K
=
x

2.0 (or larger) for non-crowned teeth
And for bending:
q
rc

Kx = 0.211
+ 0.789
Am
0.279
q=
log(sin )
2014 CRC Press
Size Factor
Face width, bw, mm
Outer transverse module, met

1.0
1.6 5
10
20
30
40
25
50
0.8
Size factor, Ks
Size factor, Ks
Ks = 0.4867 + 0.2133/pd
= 0.4867 + 0.008399 met
0.7
0.6
0.5
75
100
125
Ks = 1.0 for bw > 114.3 mm (4.5 in.)
1.00
0.9
50
0.75
Ks = 0.00492 bw + 0.4375 (bw in mm)

= 0.125 bw + 0.4375 (bw in in.)
0.50
Ks = 0.5 for bw < 12.7 mm (0.5 in.)
Ks = 0.5 for met < 1.6 (pd < 16 in.-1)

0.25
0.4
16
2.5
1.25
0.8
0.6
Outer transverse pitch, pd,
0.5
in.-1
(a)
1.0
2.0
3.0
4.0
5.0
Face width, bw, in.

(b)
Figure 15.9: Size factor for bevel gears. (a) Size factor for bending stress; (b) size factor
for contact stress or piFing resistance. Source: From AGMA [2010].

2014 CRC Press
Geometry Factor for Contact Stress

(Straight Bevel Gears)
Number of gear teeth
60
50
50
70
80
90
100
Number of pinion teeth
45
40
40
35
30
30
25
20
20
15
10
0.05
0.06
0.07
0.08
0.09
0.10
0.11
Geometry factor, Ib
Figure 15.10: Geometry factors for straight bevel gears, with pressure angle =20 and
shaft angle = 90. (a) Geometry factor for contact stress Ib. Source: From AGMA [2010].

2014 CRC Press
Geometry Factor for Bending

Number of teeth on gear for which geometry factor is desired
Number of teeth in mate

100
13 15
20
25 30 35 40 45 50
100
90
90
80
80
70
70
60
60
50
40
30
20
10
0.16
0.20
0.24
0.28
0.32
0.36
0.40
Geometry factor, Yb
Figure 15.10: Geometry factors for straight bevel gears, with pressure angle =20 and
shaft angle = 90. (b) geometry factor for bending Yb. Source: From AGMA [2010].

2014 CRC Press

(SpiralBevel Gears)
Number of teeth in gear
50
50
60
70 80 90 100
45
40
40
35
30
30
25
20
20
15
10
0.04
0.06
0.08
0.10
0.12
0.14
0.16
Geometry factor, Ib
Figure 15.11: Geometry factors for spiral bevel gears, with pressure angle =20, spiral
angle = 25 and shaft angle = 90. (a) Geometry factor for contact stress Ib. Source: From
AGMA [2010].

2014 CRC Press
Geometry Factor for Bending Stress

100
12
20
30 40 50
Number of teeth on gear for which

geometry factor is desired
90
80
70
60
60
50
80
100
40
30
20
10
0.12
0.16
0.20
0.24
Geometry factor, Yb
0.28
0.32
0.36
Figure 15.11: Geometry factors for spiral bevel gears, with pressure angle =20, spiral
angle = 25 and shaft angle = 90. (b) geometry factor for bending Yb. Source: From
AGMA [2010].

2014 CRC Press

(Zerol Bevel Gears)
Number of gear teeth
50
50
60
70
80
90 100
45
40
40
35
30
30
25
20
20
15
10
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
Geometry factor, Ib
Figure 15.12: Geometry factors for Zerol bevel gears, with pressure angle =20, spiral
angle = 25 and shaft angle = 90. (a) Geometry factor for contact stress Ib. Source:
From AGMA [2010].

2014 CRC Press
Geometry Factor for Bending Stress

(Zerol Bevel Gears)
100
13 15
20
25 30
40
50
Number of teeth in gear for which

geometry factor is desired
90
80
70
60
60
50
70
80 90 100
40
30
20
10
0.16
0.20
0.24
0.28
0.32
0.36
0.40
Geometry factor, Yb
Figure 15.12: Geometry factors for Zerol bevel gears, with pressure angle =20, spiral
angle = 25 and shaft angle = 90. (b) geometry factor for bending Yb. Source: From
AGMA [2010].

2014 CRC Press
Design Procedure 15.1: Bevel Gear

Synthesis
This design procedure will assist in the selection of preliminary bevel gear
geometries where the application's load, speed, and desired gear ratios are
known. The discussion will be limited to spiral bevel gears. The approach
is also restricted to 90 shaft angles.
1. An estimate for the required pinion diameter can be obtained from the
pinion torque and gear ratio using Fig. 15.14 for surface piFing and Fig.
15.13 for bending strength. For precision nished gears (which have a
cost penalty), the pinion diameter from piFing resistance can be
multiplied by 0.80. From the two pinion diameter estimates, the larger
value should be selected for further evaluation.
2. The pinion diameter selected in Step 1 is based on using case hardened
steel with a hardness of 55 HRC, and other materials will require a
modication in the pinion diameter. Table 15.2 lists material
modication factors for selected materials. An updated pinion diameter
can be obtained by multiplying the estimate obtained from Step 1 by
the materials factor from Table 15.2.
2014 CRC Press
Design Procedure 15.1 (continued)

3. Figure 15.15 provides an estimate for the number of teeth that should
be machined into the pinion. Spiral bevel gears can maintain a higher
contact ratio than straight or Zerol bevel gears, so departure from the
recommendation in Fig. 15.15 is not uncommon. Also, note that Fig.
15.15 is for a 35spiral angle, so that a high contact ratio can be
preserved for fewer teeth (see Step 6).
4. The outer transverse diametral pitch, pdo, can be obtained from Eq.
(14.5) as the ratio of the number of teeth in the pinion to the pinion
diameter.
5. The face width of the spiral bevel gear can be obtained from Fig. 15.16
as a function of pinion pitch diameter and gear ratio. The face width
should not exceed 10/pdo, however.

2014 CRC Press

6. The spiral angle should be selected based on a face contact ratio of 2.0.
AGMA [2003] recommends higher values for smooth and quiet
operation, or high speed applications. Face contact ratios below 2.0 can
be tolerated for some applications, but this is a reasonable value for
preliminary design synthesis. The face contact ratio is given by
so that
Crf
Ao pdo bw tan
=
Am
Crf Am
tan =
pdo bw Ao
where\
Ao = outer cone distance (see Fig. 15.6).
Am = mean cone distance
pdo = other transverse diametral pitch
bw = net face width
= mean spiral angle at the pitch surface.
2014 CRC Press
Design Procedure 15.1 (concluded)

7. The most common pressure angle for bevel gears is 20, and is
recommended for initial design synthesis. However, higher or lower
pressure angles can be used. Lower pressure angles increase the contact
ratio, reduce axial and separating forces, and increase the tooth slot
widths. However, lower pressure angles increase the risk of undercut
gear teeth and associated high stress concentrations.

The results from this Design Procedure generally are a reasonable starting
point for gear design. As is usually the case, results from this approach
must be modied slightly to produce a useful result. For example, if Fig.
15.15 suggests 32.2 teeth should be used, clearly one should specify 32 or
33 teeth. Also, it is good practice to use blanks that are of standard size, etc.

2014 CRC Press
Pinion Diameter vs. Torque

Pinion torque, Nm
11.3
113
1130
Pinion pitch diameter, in
Gear ratio =
11,300
113,000
2500
Ng
Np
1
2
4
10
10
250
25
0.1
10
102
103
104
105
Pinion pitch diameter, mm
1.13
100
2.5
106
Pinion torque, lb in
Figure 15.17: Estimated pinion pitch diameter as a function of pinion torque for a
number of gear ratios, and based on piFing resistance. Source: From AGMA [2003].

2014 CRC Press
Materials Factor
Gear
Material
Case hardened steel
Case hardened steel
Flame hardened steel
Oil hardened steel
Heat treated steel
Cast iron
Cast iron
Cast iron
Cast iron
Hardness
58 HRC
55 HRC
50 HRC
50 HRC
375-425 HB
210-300 HB
Pinion
Material
Case hardened steel
Case hardened steel
Case hardened steel
Oil hardened steel
Case hardened steel
Case hardened steel
Annealed steel
Cast iron
Hardness
60 HRC
55 HRC
55 HRC
50 HRC
375-425 HB
55 HRC
55 HRC
55 HRC
160-200 HB
Material factor
0.85
1.00
1.05
1.05
1.20
1.45
1.95
2.00
2.10
3.10
Table 15.2: Material factor for pinion diameter estimate for selected gearset materials.
Source: From AGMA [2003].

2014 CRC Press
Pinion Pitch Diameter vs. Torque

Pinion torque, Nm
11.3
113
1130
Pinion pitch diameter, in
Gear ratio =
11,300
113,000
2500
Ng
Np
10
1
2
4
10
250
25
Pinion pitch diameter, mm
1.13
100
2.5
0.1
10
102
103
10
105
106
Pinion torque, lb in
Figure 15.18: Estimated pinion pitch diameter as a function of pinion torque for a
number of gear ratios, and based on bending strength. Source: From AGMA [2003].

2014 CRC Press
Number of Teeth vs. Pinion Pitch

Diameter
Pinion pitch diameter dp, mm
0
50
100
150
200
Approximate number of pinion teeth, Np
40
Gear ratio =
250
Ng
Ng
Np
Np
300
=1
2
3
4
30
6
20
10
10
0
0
10
12
Pinion pitch diameter dp, in.
Figure 15.19: Approximate number of teeth for a spiral bevel gear as a function of
pinion pitch diameter for various gear ratios. Source: From AGMA [2003].

2014 CRC Press
Spiral Bevel Gear Face Width

Pinion pitch diameter dp, mm
0
Face width bw, in
50
Gear ratio =
100
150
Ng
10
200
250
6
300
225
5
200
Np
4 175
150
3
125
2 100
75
1
2
1
Face width bw, mm
50
25
0
0
10
0
12
Pinion pitch diameter dp, in.
Figure 15.20: Face width of spiral bevel gears operating at a 90 shaft angle. Source:
From AGMA [2003].

2014 CRC Press
Number of Wormgear Teeth

Pressure angle
, deg
Minimum number of
wormgear teeth
14.5
17.5
20
22.5
25
27.5
30
40
27
21
17
14
12
10
Table 15.3: Suggested minimum number of wormgear teeth for customary designs.
Source: From ANSI/AGMA [1993].

2014 CRC Press
Worm Gear Contact
Figure 15.21: Illustration of worm contact with a worm gear, showing multiple teeth in
contact.

2014 CRC Press
Worm Forces
Wsw
Wtw into paper

y
Wsg
Wag out of paper
Waw
W
Wtw
Wtg
Waw
Wsw
(a)
(b)
Figure 15.22: Forces acting on a worm. (a) Side view, showing forces acting on worm
and worm gear. (b) Three-dimensional view of worm, showing worm forces. The worm
gear has been removed for clarity.

2014 CRC Press
AGMA Equations for Wormgears

Wt dg
Wf dwm
=
+
2Z
2 cos
Input power rating: hpi

where
0.8
C
d
English units
s
gm bw Cm Cv

0.8
Wt =
C
d
s

gm bw Cm Cv
SI units

75.948

See the text for Cm and Cv. Wf is given by:

Wt
W
=
f

cos cos n

and

vt = 0 ft/min
0.150

0.124 exp 0.074vt0.645
0 < vt 10 ft/min
=
0.103 exp 0.110vt0.450 + 0.012 10 ft/min < vt

2014 CRC Press
Materials Factor
Manufacturing
Process
Sand casting
Static chill cast
or forged
Centrifugally cast
Pitch
diameter
d 64 mm (2.5 in.)
d 64 mm
d 200 mm (8 in.)
d > 200 mm
d 625 mm (25 in.)
d > 625 mm
Units for pitch diameter

in.
mm
1000
1000
1190 476.5 log d
1859 476.5 log d
1000
1000
1412 455.8 log d
2052 455.8 log d
1000
1000
1251 179.8 log d
1504 179.8 log d
Table 15.4: Materials factor, Cs, for bronze worm gears with the worm having surface
hardness of 58 HRC. Source: From AGMA [2010a]

2014 CRC Press
Materials Parameter
Center distance, cd (mm)
30
40
50
60
Mean gear pitch diameter, d (mm)

127
254
508 720
St
at
ic
900
800
20
1016 1524 2286
Ce n
trifu
gall
y
ch
ill
c
as
s
ca
to
rf
700
or
g
ed
70
75
1000
Materials factor, Cs
63.5
nd
Sa
Materials factor, Cs
1000
900
800
600
500
2.5
10
20
30
40 60
90
Mean gear pitch diameter, d (in.)

(a)
700
0.5
1.0
1.5
2.0
Center distance, cd (in.)
2.5
3.0
(b)
Figure 15.23: Materials parameter Cs for bronze worm gears and worm minimum
surface hardness of 58 HRC. (a) Materials factor for center distances cd greater than 76
mm (3 in.); (b) Materials factor for center distances cd less than 76 mm (3 in.). When
using part (b), the value from part (a) should be checked, and the lower value used. See
also Table 15.4. Source: From AGMA [2010a].

2014 CRC Press
Design Procedure 15.2: Worm Gear

Synthesis
The approach is restricted to coarse pitch cylindrical worm gears operated at
right angles. It is recognized that high power transmission at high speeds
will require ne-pitch teeth. It is assumed that the worm and worm gear
speeds are known, as is the input power.

1. A pressure angle needs to be selected based on the design application.
Higher pressure angles lead to higher tooth strength, but have the
drawback of higher bearing reaction loads and worm bending stress, as
well as resulting in fewer teeth in contact. Lower pressure angles are
beFer suited for high speed and quiet operation. Table 15.3 lists the
customary pressure angles for worm gears.
2. The minimum number of teeth in the worm gear is given in Table 15.3.
More teeth can be selected if the center distance is not a design constraint.
3. The number of teeth in the worm is then obtained from Eq. (15.36).

2014 CRC Press

4. The worm pitch diameter usually falls between the following ranges:
c0.875
c0.875
d
dw d
3.0
1.6
c0.875
c0.875
d
dw d
2.0
1.07
English units
SI units
Where cd is the the center distance between the axes of the worm and
worm gear.
5. The worm gear pitch diameter is calculated as
dg = 2cd dw
6. The axial pitch of the worm gear is
dg
px =
Ng

2014 CRC Press

7. Fig. 15.20 illustrates the required face width of the worm, which is given
as
2
2
dgt
dg
bww = 2
a
2
2
A slightly larger face width should be used to allow for manufacturing
and assembly tolerances. However, most worm gears have between two
and three teeth in contact at all times, so using bww = 5px gives a
reasonable face width, allowing an extra axial pitch before and after
contact.
8. If px 0.160 in. ~ (4.06 mm), the worm gear face width can be determined
from
2
bwg = dw
3
9. and if px < 0.160 in. ~ (4.06 mm),
2
2
bwg = 1.125 (do + 2c) (do 4a)
2014 CRC Press
Worm Face Width
dg
2
dgt
-a
bww
Figure 15.24: Worm face width.

2014 CRC Press
Mixer Gears
Speed
Torque
Tmax=
20 ft-lbf
Maximum
current
Motor current, A
Figure 15.25: The gears used to transmit

power from an electric motor to the
agitators of a commercial mixer. Source:
Courtesy of Hobart, Inc.

Figure 15.26: Torque and speed of motor

as a function of current for the industrial
mixer used in the case study.
2014 CRC Press

FME3 Ch15 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

FME3 Ch15 PDF

Uploaded by

Copyright:

Available Formats

Chapter 15: Helical, Bevel, and

A combined helical and worm gearset speed

Fundamentals of Machine Elements, 3rd ed.

Just stare at the machine. There is

2014 CRC Press

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Gear Design Considerations

Table 15.1: Design considerations for gears.

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Helical Gear Pitches

Figure 15.2: Pitches of helical gears. (a) Circular; (b) axial.

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

AGMA Equations for Helical Gears

Correction factors are determined as in Chapter 14, except for geometry

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Helical Gear Geometry Factor

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Correction Factor vs. Helix Angle

Geometry factor modifier, Ym

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Types of Bevel Gears

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Pitch apex to back

Figure 15.6: Terminology for bevel gears.

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Bevel Gear Forces

2014 CRC Press

AGMA Equations for Bevel Gears

Ko and Kv are dened as for spur gears.

2014 CRC Press

Outer transverse module, met

Ks = 1.0 for bw > 114.3 mm (4.5 in.)

Ks = 0.00492 bw + 0.4375 (bw in mm)

Ks = 0.5 for bw < 12.7 mm (0.5 in.)

Ks = 0.5 for met < 1.6 (pd < 16 in.-1)

Outer transverse pitch, pd,

Face width, bw, in.

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Geometry Factor for Contact Stress

Number of pinion teeth

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Geometry Factor for Bending

Number of teeth in mate

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Geometry Factor for Contact Stress

Number of pinion teeth

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press

Geometry Factor for Bending Stress

Number of teeth on gear for which