SECTION 13 BEVEL GEARS

DESIGN PROBLEMS
751.

Decide upon the pitch, face, N g , material, and heat treatment of a pair of straight
bevel gears to transmit continuously and indefinitely a uniform loading of 5 hp at
900 rpm of the pinion, reasonable operating temperature, high reliability;
mg 1.75 ; D p 3.333 in . Pinion overhangs, gear is straddle mounted.

Solution:

L = rp2 + rg2

tan p =

1
2

1
1
=
mg 1.75

p = 29.75o
L sin p = rp
L sin 29.75 =

3.333
2

L = 3.358 in
33,000hp
Ft =
lb
vm
D p n p (3.333)(900)
vm =
=
= 785.4 fpm
12
12
33,000(5)
Ft =
= 210 lb
785.4
Fd = (VF )N sf K m Ft
1

50 + vm2 50 + (785.4 ) 2
VF =
=
= 1.56
50
50
One gear straddle, one not
K m = 1.2
Table 15.2, uniform
N sf = 1.0

Fd = (1.56)(1.0)(1.2 )(210) = 393 lb

Wear load
s2 C
Fw = D pbI cd2 l
C e K t Cr

D p = 3.333 in

b = 0.3L = 0.3(3.358) = 1.0 in

Temperature factor
K t = 1.0 , reasonable operating temperature
Life factor for wear

Page 1 of 17

SECTION 13 BEVEL GEARS

Cl = 1.0 for indefinite life
Reliability factor for wear
Cr = 1.25 high reliability
Geometry factor for wear, Fig. 15.7
Assume I = 0.080
Elastic coefficient (Table 15.4)
Steel on steel , Ce = 2800
Fw = Fd
2
(3.333)(1.0)(0.08) (scd ) 2 1.0
(2800) (1.0)(1.25)

= 393

scd = 134,370 psi

Table 15.3, use Steel, (300)
scd = 135 ksi
Strength of bevel gears
s bJ K l
Fs = d
Pd K s K t K r
Size factor, assume K s = 0.71
Life factor for strength
K l = 1 for indefinite life
Temperature factor,
K t = 1 good operating condition
Reliability factor
K r = 1.5 high reliability
Geometry factor for strength (Fig. 15.5)
Assume J = 0.240
b = 1.0 in
sd = design flexural stress
Min. BHN = 300
sd = 19 ksi

Fs = F d

(19,000)(1.0)(0.240)
Pd

1
(0.71)(1)(1.5) = 393

Pd = 11
say Pd = 10
10 10
so that b =
=
= 1.0 in
Pd 10
Dg = D p mg = (3.333)(1.75) = 5.833 in

Page 2 of 17

SECTION 13 BEVEL GEARS

N g = Pd Dg = (10 )(5.833) = 58.33

say N g = 58
Use Pd = 10 , b = 1.0 in , N g = 58
Material = steel, min. Bhn = 300
752.

A pair of steel Zerol bevel gears to transmit 25 hp at 600 rpm of the pinion;
mg = 3 ; let N p 20 teeth; highest reliability; the pinion is overhung, the gear
straddle mounted. An electric motor drives a multi-cylinder pump. (a) Decide
upon the pitch, face width, diameters, and steel (with treatment) for intermittent
service. (b) The same as (a) except that indefinite life is desired.

Solution:
N
20
Dp = p =
Pd
Pd
20
(600)
D p n p
Pd
1000

vm =
=
=
fpm
12
12
Pd
10
Let b =
Pd
Dynamic load
Fd = (VF )N sf K m Ft

33,000hp
lb
vm
33,000(25)
Ft =
= 262.6 Pd
1000

Pd
Ft =

1000

50 +
1
2
Pd
50 + vm
1.121
1.121

VF =
=
= 1 + 12 = 1 +
50
50
Pd
Pd
Table 15.2, electric motor drives a multi-cylinder pump
Service factor, N sf = 1.25
2

One gear straddle, one not, K m = 1.2

1.121

(1.25)(1.2 )(262.6 )Pd = 394 Pd 1 + 1.121

Fd = 1 +

Pd
Pd

(a) Strength of Bevel Gears

s bJ K l
Fs = d
Pd K s K t K r
Size factor, assume K s = 0.71

Page 3 of 17

SECTION 13 BEVEL GEARS

Life factor for strength
Intermittent service, use K l = 4.6
Temperature factor, say K t = 1.0
Reliability factor, highest reliability
K r = 3.0
Geometry factor for strength
N
mg = g
Np
N p = 20
N p = 3(20 ) = 60

Fig. 15.5, J = 0.205

10
b=
Pd
Design flexural stress, steel
Assume sd = 15 ksi
Fs = Fd

(15,000) 10 (0.205)(4.6)

1.121

= 394 Pd 1 +

P
d

1.121
66,408

=
394
P
d 1 +

Pd2
P
d

Pd = 4.814
say Pd = 5
10 10
b=
=
= 2.0 in
Pd
5
Pd
Pd (0.71)(1.0 )(3)

Wear load for bevel gears

s2 C
Fw = D pbI cd2 l
C e K t Cr

N p 20
=
= 4 in
Pd
5
K t = 1.0

Dp =

Life factor for wear, intermittent service

Cl = 1.5
Reliability factor for wear, highest reliability
Cr = 1.25
Geometry factor for wear, Fig. 15.7

Page 4 of 17

SECTION 13 BEVEL GEARS

N p = 20 , N g = 60
I = 0.083
Elastic coefficient, steel on steel (Table 15.4)
Ce = 2800

Pd = 5
Fw = Fd
2

2
(4)(2)(0.083) scd 2 1.5 = 394(5)1 + 1.121
(2800) (1.0)(1.25)
5

scd = 155,730 psi

Table 15.3
Use steel, min. BHN = 360, scd = 160 ksi
Pd = 5
b = 2 in
D p = 4 in

Dg = mg D p = (3)(4 ) = 12 in
steel, min. BHN = 360

(b) For indefinite life,

K l = 1.0 , life factor for strength
Cl = 1.0 , life factor for wear
Strength:
s bJ K l
Fs = d
Pd K s K t K r
Fs = Fd

(15,000) 10 (0.205)(1.0)

1.121

= 394 Pd 1 +

P
d

1.121
14,437

= 394 Pd 1 +
2

Pd
P
d

Pd = 2.799
say Pd = 3
10 10
b=
=
= 3.33 in
Pd
3
Pd
Pd (0.71)(1.0)(3)

Wear load

Page 5 of 17

SECTION 13 BEVEL GEARS

scd2 Cl

Fw = D pbI 2
C e K t Cr

N p 20
=
= 6.67 in
Pd
3
Fw = Fd

Dp =

2
(6.67 )(3.33)(0.083) scd 2 1.0 = 394(3)1 + 1.121
(2800) (1.0)(1.25)
3

scd = 113,744 psi

Table 15.3
Use steel, min. BHN = 240, scd = 115 ksi
Pd = 3
b = 3.33 in
D p = 6.67 in

Dg = mg D p = (3)(6.67 ) = 20 in
steel, min. BHN = 240

753.

Decide upon the pitch, face, and number of teeth for two spiral-bevel gears for a
speed reducer. The input to the pinion is 20 hp at 1750 rpm; mg 1.9 ; pinion
overhung, gear-straddle mounted. It is hoped not to exceed a maximum D p of 4
3/8-in.; steel gears with minimum 245 BHN on pinion and 210 BHN on gear.
The gear is motor-driven, subject to miscellaneous drives involving moderate
shock; indefinite life against breakage and wear with high reliability. If the gears
designed for the foregoing data are to be subjected to intermittent service only,
how much power could they be expected to transmit?

Solution:
(a) vm =

D p n p

(4.375)(1750)

= 2000 fpm
12
12
33,000hp 33,000(20 )
Ft =
=
= 330 lb
vm
2000
Dynamic load
Fd = (VF )N sf K m Ft
One gear straddle, one not
K m = 1.2
Table 15.2
Motor-driven, moderate shock

Page 6 of 17

SECTION 13 BEVEL GEARS

N sf = 1.25
1

70 + vm2 2
VF =
, spiral
70
1

70 + (2000) 2
VF =
= 1.254
70

Fd = (1.254)(1.25)(1.2)(330) = 621 lb
1

Wear load
s2 C
Fw = D pbI cd2 l
C e K t Cr

D p = 4.375 in

Temperature Factor, K t = 1.0

Design contact stresses,
BHN = 245 , pinion
scd = 116 ksi
Life factor for wear
Cl = 1.0 , indefinite life
Reliability factor for wear
Cr = 1.25 , high reliability
Geometry factor for wear, Fig. 15.8
Assume I = 0.12
Elastic coefficient, steel on steel (Table 15.4)
Ce = 2800

(116,000)2 1.0
Fw = (4.375)(b )(0.12)
(2800)2 (1.0)(1.25)
Fw = Fd
721b = 621
b = 0.8613 in
7
say b = in = 0.875 in
8

Strength of gear
s bJ K l
Fs = d
Pd K s K t K r
sd = design flexural stress
min. BHN = 210
sd = 15.4 ksi
Size factor, assume K s = 0.71

Page 7 of 17

= 721b

SECTION 13 BEVEL GEARS

Life factor for strength
K l = 1 for indefinite life
Temperature factor,
Kt = 1
Reliability factor
K r = 1.5 high reliability
Geometry factor Fig. 15.6
Assume J = 0.28
3543
(15,400)(0.875)(0.28)
1
Fs =

= P
Pd
(0.71)(1)(1.5)
d
Fs = Fd
3543
= 621
Pd
Pd = 5.7
say Pd = 6
7
Then, Pd = 6 , b = in , N p = D p Pd = (4.375)(6 ) = 26
8
N g = mw N p = (1.9 )(26 ) = 50
(b) Intermittent service only
Strength
s bJ K l
Fs = d
Pd K s K t K r
sd = 15,400 psi (Gear)
For Pd = 6 , K s = 0.64
For indefinite service, K l = 4.6
K t = 1.0 , K r = 1.5
Geometry factor, Fig. 15.6, N p = 26 , N g = 50
J = 0.292
(15,400)(0.875)(0.292) 4.6 = 3142 lb
Fs =
(0.71)(1)(1.5)
6

Wear load
s2 C
Fw = D pbI cd2 l
C e K t Cr
D p = 4.375 in

K t = 1.0
scd = 116 ksi
Ce = 2800

Page 8 of 17

SECTION 13 BEVEL GEARS

Cl = 1.5 intermittent service
Cr = 1.25
Geometry factor for wear, Fig. 15.8
N p = 26 , N g = 50
I = 0.116

(116,000)2 1.5
Fw = (4.375)(0.875)(0.116 )
(2800)2 (1.0)(1.25)

= 1098 lb

use Fw = Fd
Fd = (VF )N sf K m Ft
1098 = (1.254)(125)(1.2)Ft
Ft = 584 lb
Fv
(584)(2000) = 35 hp
hp = t m =
33,000
33,000
CHECK PROBLEMS
755.

A pair of straight-bevel gears are to transmit a smooth load of 45 hp at 500 rpm

3
of the pinion; mg = 3 . A proposed design is Dg = 15 in. , b = 2 in. , Pd = 4 .
8
Teeth are carburized AISI 8620, SOQT 450 F. The pinion overhangs, the gear is
straddle-mounted. Would these gears be expected to perform with high reliability
in continuous service? If not would you expect more than 1 failure in 100?

Solution:
D 15
D p = g = = 5 in
mg
3
D p n p (5)(500)
vm =
=
= 655 fpm
12
12
33,000hp 33,000(45)
Ft =
=
= 2267 lb
vm
655
Dynamic load
Fd = (VF )N sf K m Ft
1

50 + vm2 50 + (655) 2
VF =
=
= 1.512
50
50
One gear straddle, one not
K m = 1.2

Smooth load, N sf = 1.0

Fd = (1.512)(1.0)(1.2 )(2267 ) = 4113 lb

Page 9 of 17

SECTION 13 BEVEL GEARS

Strength of bevel gears
s bJ K l
Fs = d
Pd K s K t K r
Size factor, for Pd = 4 ,
K s = 0.71
Life factor for strength
Kl = 1
Temperature factor,
Kt = 1
Geometry factor for strength (Fig. 15.5)
N p = Pd D p = (4 )(5) = 20
N g = Pd Dg = (4 )(15) = 60
J = 0.205

sd = 30 ksi (55 63 Rc) for carburized teeth

Fs =

(30,000)(2.375)(0.205)

5143
1
(0.71)(1)(K ) = K
r
r

Fs = Fd
5143
= 4113
Kr
K r = 1.25 < 1.5 will not perform high reliability.
Wear load
s2 C
Fw = D pbI cd2 l
C e K t Cr

D p = 5 in
b = 2.375 in
Table 15.3, scd = 225 ksi

Table 15.4, Ce = 2800

Geometry factor for wear, Figure 15.7
N p = 20 , N g = 60
I = 0.083
Kt = 1
life factor for wear Cl = 1

(225,000)2 1
Fw = (5)(2.375)(0.083)
(2800)2 (1)(Cr )
Fw = Fd

Page 10 of 17

6364
Cr2

SECTION 13 BEVEL GEARS

6364
= 4113
Cr2
Cr = 1.244 1.25 , high reliability

Since K r < 1.5 ,this will not perform high reliability but 1 in 100, K r 1.12 < 1.25
756.

A gear catalog rates a pair of cast-iron, straight-bevel gears at 15.26 hp at 800

rpm of the 16-tooth pinion; mg = 3.5 , b = 3 in. , Pd = 3 ; pinion overhangs,
straddle-mounted gear. Assume the cast iron to be class 30. If the load is smooth
is this rating satisfactory, judging by the design approach of the Text for good
reliability (a) when strength alone is considered, (b) when long continuous
service is desired?

Solution:
N
16
Dp = p =
= 5.333 in
Pd
3
D p n p (5.333)(800)
vm =
=
= 1117 fpm
12
12
33,000hp 33,000(15.26 )
Ft =
=
= 451 lb
vm
1117
Dynamic load
Fd = (VF )N sf K m Ft
1

50 + vm2 50 + (1117 ) 2
VF =
=
= 1.668
50
50
One gear straddle, one not
K m = 1.2

Smooth load, N sf = 1.0

Fd = (1.668)(1.0)(1.2)(451) = 903 lb
(a) Strength
s bJ K l
Fs = d
Pd K s K t K r
Pd = 3 ,
K s = 0.76
Kl = 1
Kt = 1
K r = 1.5
sd = 4.6 ksi , cast-iron class 30
N p = 16

Page 11 of 17

SECTION 13 BEVEL GEARS

N g = mw N p = (3.5)(16 ) = 56
J = 0.184

(4,600)(3)(0.184)
1
Fs =

= 742 lb < 903 lb(= Fd )

3
(0.76)(1)(1.5)
with
K l = 1.4 for 106 cycles

Fs = (1.4)(742) = 1040 lb > 903 lb(= Fd )

Therefore satisfactory for 106 cycles.
(b) Continuous service
Wear load
s2 C
Fw = D pbI cd2 l
C e K t Cr

D p = 5.333 in
b = 3 in
Table 15.3, scd = 50 ksi , cast-iron class 30

Table 15.4, cast-iron and cast-iron Ce = 2250

Cl = 1
Kt = 1
Cr = 1.25
Geometry factor for wear, Figure 15.7
N p = 16 , N g = 56
I = 0.077

(50,000)2 1
Fw = (5.333)(3)(0.077 )
(2250)2 (1)(1.25)

= 389 lb < Fd (= 903 lb )

Therefore, not satisfactory for long continuous service.

757.

An 870-rpm motor drives a belt conveyor through bevel gears having 18 and 72
3
teeth; Pd = 6 , b = 1 in . Both gears are straddle-mounted. What horsepower may
4
these gears transmit for an indefinite life with high reliability if both gears are (a)
cast-iron, class 40; (b) AISI 5140, OQT 1000 F; (c) AISI 5140, OQT 1000 F,
flame hardened (d) AISI 8620, SOQT 450 F?

Solution:
N
18
D p = p = = 3 in
Pd
6
D p n p (3)(870)
vm =
=
= 683 fpm
12
12
Dynamic load
Page 12 of 17

SECTION 13 BEVEL GEARS

Fd = (VF )N sf K m Ft
Both gears straddle mounted
K m = 1.0

Table 15.2, N sf = 1.0

1

50 + vm2 50 + (683) 2
=
= 1.523
50
50
Fd = (1.523)(1.0)(1.0)Ft = 1.523Ft

VF =

(a) Cast-iron, class 40

Strength
s bJ K l
Fs = d
Pd K s K t K r
sd = 7 ksi , cast-iron class 40
3
b = 1 in
4
K l = 1 , indefinite life
Pd = 6
K s = 0.64
Kt = 1
K r = 1.5 , high reliability
Figure 15.5, N p = 18 , N g = 72
J = 0.204

(7000)(1.75)(0.204)
1
Fs =

= 434 lb
6
(0.64)(1)(1.5)
Wear:
s2 C
Fw = D pbI cd2 l
C e K t Cr

D p = 3 in
3
b = 1 in
4
Table 15.3, scd = 65 ksi , cast-iron class 40

Table 15.4, cast-iron and cast-iron Ce = 2250

Cl = 1 , indefinite life
Kt = 1
Cr = 1.25 , high reliability
Geometry factor for wear, Figure 15.7
N p = 18 , N g = 72
I = 0.082
Page 13 of 17

SECTION 13 BEVEL GEARS

2
(
65,000) 1
Fw = (3)(1.75)(0.082 )
(2250)2 (1)(1.25)

= 230 lb

Fd = Fw
1.523Ft = 230
Ft = 151 lb
Fv
(151)(683) = 3 hp
hp = t m =
33,000
33,000
(b) AISI 5140, OQT 1000 F, BHN = 300
Strength
sd = 19,000 psi
Fs =

(19,000)(1.75)(0.204)

1
(0.64)(1)(1.5) = 1178 lb

Wear:
s2 C
Fw = D pbI cd2 l
C e K t Cr

Table 15.3, scd = 135 ksi

Table 15.4, steel and steel, Ce = 2800
2
(
135,000) 1
Fw = (3)(1.75)(0.082)
(2800)2 (1)(1.25)

= 640 lb

Fd = Fw
1.523Ft = 640
Ft = 420 lb
Fv
(420)(683) = 8.7 hp
hp = t m =
33,000
33,000
(c) AISI 5140, OQT 1000 F, Flame Hardened
Strength
sd = 13.5 ksi
Fs =

(13,500)(1.75)(0.204)

1
(0.64 )(1)(1.5) = 837 lb

Wear:
s2 C
Fw = D pbI cd2 l
C e K t Cr

Table 15.3, scd = 190 ksi

Table 15.4, steel and steel, Ce = 2800

Page 14 of 17

SECTION 13 BEVEL GEARS

2
(
190,000) 1
Fw = (3)(1.75)(0.082)
(2800)2 (1)(1.25)

= 1269 lb

Fd = Fs
1.523Ft = 837
Ft = 550 lb
Fv
(550)(683) = 11.4 hp
hp = t m =
33,000
33,000
(d) AISI 86200, SOQT 450 F, carburized
Strength
sd = 30 ksi (55 63 Rc)
Fs =

(30,000)(1.75)(0.204)

1
(0.64)(1)(1.5) = 1859 lb

Wear:
s2 C
Fw = D pbI cd2 l
C e K t Cr

Table 15.3, scd = 225 ksi

Table 15.4, steel and steel, Ce = 2800
2
(
225,000) 1
Fw = (3)(1.75)(0.082)
(2800)2 (1)(1.25)

= 1779 lb

Fd = Fw
1.523Ft = 1779
Ft = 1168 lb
Fv
(1168)(683) = 24.2 hp
hp = t m =
33,000
33,000
758.

A pair of straight-bevel gears transmits 15 hp at a pinion speed of 800 rpm;

Pd = 5 , N p = 20 , N p = 60 , b = 2 in . Both gears are made of AISI 4140 steel,
OQT 800 F. What reliability factor is indicated for these gears for strength and
for wear (a) for smooth loads, (b) for light shock load from the power source and
heavy shock on the driven machine?

Solution:
N
20
Dp = p =
= 4 in
Pd
5
D p n p (4)(800)
vm =
=
= 838 fpm
12
12

Page 15 of 17

SECTION 13 BEVEL GEARS

33,000hp 33,000(15)
=
= 591 lb
vm
838
Fd = (VF )N sf K m Ft

Ft =

50 + vm2 50 + (838) 2
VF =
=
= 1.579
50
50
assume K m = 1.0
Fd = (1.579 )(N sf )(1.0 )(591) = 933 N sf
Strength of bevel gear
s bJ K l
Fs = d
Pd K s K t K r
For AISI 4140, OQT 800 F, BHN = 429
sd = 24 ksi

assume K l = 1
Kt = 1
Pd = 5
K s = 0.675
Figure 15.5, N p = 20 , N g = 60
J = 0.205
2916
1
(24,000)(2)(0.205)
Fs =

= K
5
r
(0.675)(1)(K r )
Fs = Fd
2916
= 933 N sf
Kr
3.1254
Kr =
N sf
Wear load:
s2 C
Fw = D pbI cd2 l
C e K t Cr

BHN = 429
Table 15.3, scd = 190 ksi
Table 15.4, steel and steel, Ce = 2800
D p = 4 in
b = 2 in
Assume Cl = 1.0 , K t = 1.0
Fig. 15.7, N p = 20 , N g = 60
I = 0.083

Page 16 of 17

SECTION 13 BEVEL GEARS

2
(
190,000 ) 1
(
)(
)(
)
Fw = 4 2 0.083
(2800 )2 (1)(Cr )

3058
Cr2

Fd = Fw
3058
Cr2
1.810
Cr =
N sf
933 N sf =

(a) Table 15.2, smooth load

N sf = 1.0

For strength, K r =
For wear, Cr =

3.1254 3.1254
=
= 3.1254
N sf
1

1.810 1.810
=
= 1.810
N sf
1

(b) Table 15.2, light shock source, heavy shock driven

N sf = 2.0

3.1254 3.1254
=
= 1.5627
N sf
2
1.810 1.810
For wear, Cr =
=
= 1.2799
N sf
2
For strength, K r =

- end -

Page 17 of 17