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MD-12 Spur Gear Design PDF
MD-12 Spur Gear Design PDF
gear systems.
Calculate forces on teeth of spur gears, including impact forces associated with
American Gear Manufacturers Association
velocity and clearances. (AGMA)
Determine allowable force on gear teeth, including the factors necessary due to
accuracy, and other factors necessary for complete spur gear design.
Understand and determine necessary surface hardness of gears to minimize or
14 deg; 20 deg; 25 deg pressure angle
prevent surface wear.
Understand how lubrication can cushion the impact on gearing systems and cool Full depth and stub tooth systems
them.
Select standard gears available from stocking manufacturers or distributors.
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Example Problem 12-1: Forces on Spur Gear Teeth Example Problem 12-1: Forces on Spur Gear Teeth (contd.)
Find transmitted force:
20-tooth, 8 pitch, 1-inch-wide, 20 pinion transmits 5 hp at 1725 rpm to a 60-tooth gear. (12-3)
2T
Determine driving force, separating force, and maximum force that would act on Ft =
Dp
mounting shafts.
(2-6) (2)183 in-lb
Tn Ft = = 146 lb
P = 2.5 in
63,000
Find separating force:
63,000P (12-1)
T =
n
Fn = Ft tan
(63,000)5
T = = 183 in-lb
1725 Fn = 146 lb tan 20
Fn = 53 lb
or
Dp n
Vm = ft/min (12-5)
12 Vm =
Dp n
12
Dp n
Vm = m/min -- Metric units Vm = 2.5 in 1725 rpm
ft
12 in
1000 Vm = 1129 ft/min
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Lewis equation Table 12.1 Lewis form factors (Y)
Sn Y b
Fs =
Pd
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
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Example Problem 12-3: Strength of Gear Teeth Example Problem 12-3: Strength of Gear Teeth (contd.)
In Example Problem 12-1, determine the force allowable (Fs) on these teeth if the
Gear:
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. Sn = .5 (88 ksi) = 44 ksi
Pinion:
(Table 12-1)
Sn = .5 Su = .5 (95 ksi) = 47.5 ksi
Y = .421
(12-9)
44,000 (1) .421
Sn b Y Fs =
Fs = 8
Pd
Fs = 2316 lb
Find Lewis form factor (Y) from Table 12-1, assuming full-depth teeth:
Y = .320
Fs = 1900 lb
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Classes of Gears Design Methods
1200 + Vm
Carefully cut Fd = Ft Strength of gear tooth should be greater
1200 than the dynamic force; Fs Fd
Precision 78 + Vm0.5 You should also include the factor of safety,
Fd = Ft
78 Nsf
Fs
Fd
50 + Vm0.5 N sf
Hobbed or shaved Fd = Ft
50
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Example Problem 12-4: Design Methods Example Problem 12-5: 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 Spur gears from the catalog page shown in Figure 12-3 are made from a .2% carbon
design if a factor of safety of 2 were desired? steel with no special heat treatment.
Use surface speed and force transmitted from Example Problems 12-2 and 12-3. What factor of safety do they appear to use in this catalog?
Dynamic load: Try a 24-tooth at 1800 rpm gear for example purposes.
600 + Vm
Fd = Ft (12-10) From Appendix 4, an AISI 1020 hot-rolled steel would have .2% carbon with an Sy = 30
600 ksi and Su = 55 ksi.
600 + 1129 Therefore:
Fd = (146 lb)
600
Fd = 421 lb Sn = .5 Su
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Example Problem 12-5: Design Methods (contd) Example Problem 12-5: Design Methods (contd)
Find Vm : Set Fs = Fd and solve for Ft :
(12-5) 600 + Vm
Fd = Fs = Ft
Dp n 600
Vm =
12
600 + 942
519 lb = Ft
600
ft
Vm = 2 in (1800 rpm)
12 in Ft = 202 lb
(12-3)
Vm = 942 ft/min
Dp
Find Fs : T = F
2
(12-9)
2 in
T = 202 lb
Sn b Y 2
Fs =
Pd
T = 202 in-lb
(from Table 12-1)
(2-6)
Tn 202 (1800)
Y = .302 P = = = 5.8 hp
63,000 63,000
27,500 () .302 or
Fs =
12
(12-6)
Example Problem 12-5: Design Methods (contd) Example Problem 12-6: Design Methods
(11-4)
Appears to be reasonable value.
Np 48
Manufacturer may also have reduced its rating for wear purposes as these Dp = = = 4 in
Pd 12
are not hardened gears.
Ng = Np Vr = 48(3) = 144 teeth
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Example Problem 12-6: Design Methods (contd.) Example Problem 12-6: Design Methods (contd.)
600 + Vm
Dynamic force Fd = Ft (12-10)
600
Surface speed: 600 + 943
Fd = 70
(12-5) 600
Dp n Fd = 180 lb
Vm = Since width b is the unkown:
12
Fs
Vm =
4 in 900 rpm Fd
12 in/ft N sf
and
Vm = 943 ft/min
Sn b Y
Finding force on teeth:
Fs =
Pd (12-8)
(12-6) Sn b Y
= Fd
33,000 hp N sf Pd
Ft =
Vm
33,000 (2) Class 30 CI; Su = 30 ksi; Sn = .4 Su (.4 is used because cast iron):
Ft =
943 Sn = 12 ksi
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Example Problem 12-6: Design Methods (contd.)
Substituting: To increase the dynamic beam strength of
(12-9) the gear
Sn b Y
Nsf Pd
= Fd Increase tooth size by decreasing the
12,000 b .344 diametral pitch
= 180
2 (12)
Increase face width upto the pitch diameter
b = 1.0 inches
of the pinion
Check ratio of width to pitch:
(12-14)
Select material of greater endurance limit
8
< b <
12.5 Machine tooth profiles more precisely
Pd Pd
8 12.5
Mount gears more precisely
< 1 <
12 12
Use proper lubricant and reduce
.66 < 1 < 1.04
contamination
This is an acceptable design.
Many other designs are also possible.
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Buckingham Method of Gear Design Fig. 12.4 Expected error in tooth profiles
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Table 12.3 Values of C for e = 0.001 inch Buckingham Method of Gear Design
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Example Problem 12-7: Buckingham Method of Gear
Fig. 12.5 Recommended maximum error in gear teeth Design and Expected Error
Su = 95 ksi
(11-4)
Np 24
Dp = = = 1.5 in
Pd 16
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Example Problem 12-7: Buckingham Method of Gear Example Problem 12-7: Buckingham Method of Gear
Design and Expected Error (contd.) Design and Expected Error (contd.)
Find torque: Find surface speed:
(2-6) (12-5)
Tn Dp n
P = Vm =
63,000 12
Ft = 73 lb Fs = 1000
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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. Substituting into equation 12-16:
For wear use Nss = 1.2
Fw = 1.5 (1) 1.27 (270)
Wear formula:
(12-16) Fw = 514
Fw = Dp b Q Kg
This would not be suitable. Try if surfaces each had a BHN = 450.
Find Q : K g = 470
(from Appendix 13)
(12-17)
Fw = 1.5 (1) (1.27) ( 470)
2 Ng
Q =
Ng + Np
Fw = 895
Fw
2 (42) Fd
Q =
42 + 24 N sf
895
Q = 1.27 > 699
1 .2
Kg = 270
(from Appendix 13)
746 > 699
This would now be acceptable if the gear teeth were hardened to a BHN of 450.
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