Tutorial: GEARS III

• Bending Fatigue
• Surface Fatigue

Prof. J. Uziak
Problem – Bending Fatigue
A pair of 4:1 reduction gears is designed for 75 kW motor, whose full load speed is
1120 rev/min.
The gears are to be cut at pressure angle of 20o full-depth system and made of
BS640M40 alloy steel, heat-treated and tempered to
Sut=800 MPa and
Syt=500 MPa

The size of gears was estimated to have a face width of 92 mm, corresponding to
module of 6 mm, with 18 and 72 teeth respectively. Teeth are generated with a rack
cutter.

Based on the following assumptions:

• Less rigid mountings and less accurate gears,
• Uniform power source and moderate shocks in the driven machinery,
• Reliability of 95%,
Find:
The factor of safety guarding against bending fatigue failure.
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Bending Stress Equations

Modified Lewis tooth bending stress:

Used:
Wt
 Fatigue failure is not a problem,  Kv
 Quick estimate of gear size is needed, F mY
 For later use of these results in
detailed analysis.

AGMA equation for tooth bending stress

Used: Wt
• For important applications, or  Kv Ko Km
FmJ
• When the possibility of fatigue failure
must be considered and analyzed.
 Previously determined:
V=6.33 m/s; Wt=11843 N; F=92 mm; Np=18 teeth

Determine the velocity factor, KV

Since bending fatigue is a failure possibility then AGMA equation applies for
gears finished by hobbing, shaping, or rack cutting:

50  200V 50  200  6.33

KV    1.71174  1.712
50 50

Selecting the AGMA geometry factor, J

AGMA geometry factor from Table
Data:
 =20o
Np=18 teeth
NG=72 teeth
4
Geometry Factor: Teeth =20o, a = 1m, b=1.25m & r f=0.300m

5
Selecting the AGMA geometry factor, J
Data:  =20o, Np=18 teeth, NG=72 teeth

J values - either for N3=NG=50 teeth or for N3= NG=85 teeth of the meshing gear.
interpolate - to find the correct value for J corresponding to N3=72 :

For → N3=50 teeth → J50=0.34404;

For → N3=85 teeth→ J85=0.35050.

J value corresponding to 1 tooth within the appropriate range:

𝐽85 − 𝐽50 0.35050 − 0.34404

𝐽1 = = = 0.000184571
85 − 50 35
J72 - can be calculated in two ways

J 72  J 50  (72  50) J1  0.34404  (22  0.000184571)  0.348100571

J 72  J 85  (85  72) J1  0.35050  (13  0.000184571)  0.348100572
J 72  0.34810 6
Uniform power source & moderate shocks in the driven machinery: Ko = 1.25

Less rigid mountings and less accurate gears, face width 92 mm: Km = 1.7
AGMA tooth bending stress equation:

Wt
 Kv Ko Km
FmJ
Data:
Wt = 11,843 N
F = 92 mm
m = 6 mm
J72 = 0.34810
KV = 1.712
Ko = 1.25
Km = 1.7

Wt 11,843
 Ko Km Kv  1.25 1.7 1.712  224.3 N/mm 2  224 MPa
FmJ 92  6  0.34810
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Estimating the tooth endurance limit, Se

Endurance limit of a machine element:

S e  k a kb k c k d k e k f S e'
where:
 Se - endurance limit of the gear tooth,
 S‫׳‬e - endurance limit of a rotating-beam specimen
 ka - surface factor,
 kb - size factor,
 kc - reliability factor,
 kd - temperature factor,
 ke - modifying factor for stress concentration
 kf - miscellanies effects factor
a) Surface modification factor, ka
From chart for gears made of steel with Sut=0.8 GPa, with teeth cut, shaved or
ground:
ka = 0.70

b) Size modification factor, kb

From Table for module of 6 mm:
kb = 0.894

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c) Reliability factor, kc
Factor is obtained from Table for reliability of 95%:
kc = 0.868

d) Temperature modification factor, kd

Assuming an operating temperature below 120oC to prevent the lubricant failure:
kd = 1.0

Temperature ≤ 350oC kd = 1
350oC < Temperature ≤ 500oC kd = = 0.5

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e) Modifying factor for stress concentration, ke

Fatigue stress-concentration factor Kf has been incorporated into the

AGMA geometry factor J, hence for gears ke=1

f) Miscellaneous effect factor, kf

Factor is obtained from Figure; Sut=0.8 GPa < 1.4 GPa kf = 1.33

For Sut < 1.4 GPa  kf = 1.33

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Endurance limit - rotating beam specimen:

When Sut ≤ 1400 MPa

S e'  0.5S ut  0.5  800  400 MPa

Endurance limit of the pinion tooth

S e  k a kb k c k d k e k f S '
e

S e  0.70  0.894  0.868 1 1 1.33  400  288.98 MPa  289 MPa

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Tooth bending Stress:

Wt 11,843
 Ko Km Kv  1.25 1.7 1.712  224.3 N/mm 2  224 MPa
FmJ 92  6  0.34810

Endurance limit of the pinion tooth

S e  k a kb kc k d ke k f S e'

Se  0.70  0.894  0.868 111.33  400  288.98 MPa  289 MPa

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 S tYN / K T K R 
Bending Factor of Safety SF 


SF - safety factor against bending fatigue failure

 - bending stress
YN - the stress-cycle factor
KR - the reliability factor
KT - the temperature factor
St - the allowable bending stress [N/mm2]

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Bending Factor of Safety

SF - safety factor against bending fatigue failure

 - bending stress 224 MPa
YN - the stress-cycle factor 1
KR - the reliability factor 0.8853
KT - the temperature factor 1.0
St - the allowable bending stress 289 [N/mm2]

S tYN / K T K R  289 1 / 1  0.8853

SF    1.14
 224

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Problem – Bending Fatigue
A pair of 4:1 reduction gears is designed for 75 kW motor, whose full load speed is
1120 rev/min.
The gears are to be cut at pressure angle of 20o full-depth system and made of
BS640M40 alloy steel, heat-treated and tempered to
Sut=800 MPa and Syt=500 MPa with hardness 340Bhn.

The size of gears was estimated to have a face width of 92 mm, corresponding to
module of 6 mm, with 18 and 72 teeth respectively. Teeth are generated with a rack
cutter.
Based on the following assumptions:
• Less rigid mountings and less accurate gears,
• Uniform power source and moderate shocks in the driven machinery,
• Reliability of 95%,
Find:
From surface durability consideration, using contact stress AGMA equation and
AGMA contact fatigue strength, with a general factor of safety 1.2 for a life of 108
cycles, find the factor of safety guarding against surface fatigue.
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Surface-Contact Stress – Hertzian contact stresses.

Wt
 H   Cp Kv Ko Km
Fd p I

where:
Previously determined:
Wt - the transmitted load,
Cp - elastic coefficient
Kv - velocity factor = 1.712
Kv - velocity factor,
Ko - overload factor = 1.25
Ko - overload factor
Km - load distribution factor = 1.7
Km - load distribution factor
F - face width = 92 mm
F - face width,
dp - pinion pitch diameter = 108 mm
I - surface geometry factor,
dp - pinion pitch diameter.

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 Elastic coefficient, CP

From the table:

For steel on steel: CP = 191 Mpa-1

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 Geometry Factor, I

cos  sin  mG cos  sin  mG

I  External mesh I 
mG  1
Internal mesh
2 mG  1 2

mG - gear ratio
 - pressure angle

External mesh
cos  sin  mG cos 20 sin 20 4
I     0.1286
2 mG  1 2 4 1

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Surface-Contact Stress – Hertzian contact stresses.

Wt Wt
 H   Cp K v K o K m  191 1.712 1.25 1.7  10.18 Wt MPa
Fd p I 92 108  0.129

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AGMA equation for contact fatigue strength:

CLCH
SH  Sc
CT CR

where:
SH - the fully corrected contact fatigue strength
CL - the life modification factor
CH - the hardness-ratio factor
CT - the temperature modification factor
CR - the reliability factor
Sc - the surface fatigue strength
 Surface fatigue strength, SC

For steel with 108 cycles:

Sc  2.76  HB   70 MPa where, HB is the Brinell hardness of the softer

of the two contacting surfaces.

Material for the gears BS640M40 alloy steel:

Syt=580 MPa and Sut=800 MPa and hardness 340 Bhn

S c  2.76  HB   70  2.76  340  70  868 MPa

 Life modification factor, CL

108 cycles: CL = 1.0

Reliability factor, CR
Reliability 95%: CR = 0.8

Temperature correction factor, CT

for T<120oC: CT = 1.0

Hardness ratio factor, CH

Always unity for spur gears because the pinion and the gear are usually made
of the same material : CH = 1.0
AGMA equation for contact fatigue strength:
SH - the fully corrected contact fatigue strength

𝐶𝐿 𝐶𝐻 1∙1
𝑆𝐻 = 𝑆𝐶 = 868 = 1085𝑀𝑃𝑎
𝐶𝑇 𝐶𝑅 1 ∙ 0.8

Using factor of safety 1.2 the value of fully corrected contact fatigue strength
changes:
𝑆𝐻 1085
𝑆𝐻′ = = = 904𝑀𝑃𝑎
𝐹𝑆 1.2

Comparing with surface-contact stress:

10.18 𝑊𝑡 𝑀𝑃𝑎 = 904𝑀𝑃𝑎

Permissible transmitted load: 7,889 N = 7.89 kN

Compare with the required transmitted load : Wt=11843 N
Permissible transmitted load: Wt=7,889 N = 7.89 kN
Required transmitted load : Wt=11,843 N = 11.8 kN

Factor of safety guarding against surface fatigue:

7.89
𝑛𝐺 = = 0.66
11.8

Acceptable?

Possible solutions:
 Change material - increase the surface hardness material
 Increase the face width