Spur Gear

2103320 Des Mach Elem

Mech. Eng. Department
Chulalongkorn University
 Introduction
Gear • Transmit power, rotation
• Change torque, rotational speed
• Change direction of rotation

Friction Gear

+ +

Slip

Small gear Large gear

“Pinion” “Gear”
Less slip (usually driving)
 Gear tooth nomenclature (1)
Center distance Center distance

Same
transmission
+ + + +

Pitch circle

Pitch surface
The pitch circle is a theoretical circle
Depend on the types of gears +
upon which all calculations are usually
based; its diameter is the pitch diameter.
Pitch cylinder
 Gear tooth nomenclature (2)
• Circular pitch (CP) = π D/z D = pitch dia.
z = number of teeth
• Diametral pitch (DP) = z/D (inch.)
• Module (m) = D/z (mm)

• m = 25.4/DP
• CP×DP = p
 Module and tooth size

Module Diametral
Pitch
Pressure angle Standard module
For metric For inch
Size gears Size gears 14.5° 20°

st choice โมดูลเลือก โมดูลเลือก

1โมดู ลนิยม 2nd choice st choice
1โมดู ลนิยม 2nd choice
อันดับสอง อันดับสอง
0.1 0.15 1.5 1.75
0.2 0.25 2 2.25
0.3 0.35 2.5 2.75
0.4 0.45 3 3.5
0.5 0.55 4 4.5
0.6 0.7 5 5.5
0.8 0.75 6 7
1 0.9 8 9
1.25 10 11
Module sizes shown are converted
inch sizes
 Gear tooth nomenclature (3)
Pressure angle (deg.)
14.5 (FD) 20 (FD) 20 (Stub)
Addendum a m m 0.8m
Dedendum b 1.157m 1.25m m
FD: Full depth
Stub: Tooth is shorter than FD

Tooth height a+b

Working depth a1+a2
Top diameter Do = D+2a
(Addendum dia.)
Root diameter Dr = D-2b
(Dedendum dia.)
Clearance b-a
 Involute Curve
Gear profile is designed to be involute curve. With this design the velocity ratio of a
gear pair is constant all the time.
Base cylinder is the circle used to construct an involute curve (not a dedendum circle
and cannot be located with the naked eye

Construction of
an involute curve Involute
curve

Involute curve

Base cylinder
 Pressure angle (1)
Line of action • Line of action (pressure line)
(Pressure line) is
perpendicular to line that tangent with the base
φ Contact surface at circles and pass the pitch point
contact point
• During meshing, transmitted
force acts along the line of action

φ rb = rp cos φ
φ
Line tangent
with the
pitch circle

Pitch circle

φ = Pressure angle (14.5°, 20°, 25°)

 Pressure angle (2)
Line of action
(Pressure line) is Base circle
perpendicular to
φ Contact surface at
contact point

Driven

φ
φ
Line tangent
with the
pitch circle

Pitch circle
Driving
 Velocity ratio

ω2(rad/s)
ω1(rad/s) n2(rpm)
n1(rpm) D2
D1 z2
z1

ω1 n1 D2 z 2
mω = = = =
ω2 n2 D1 z1
 Gear ratio & Center distance (1)
Example Center distance 240 mm
R=40
module 3 mm
+
Velocity ratio 5:1
Pressure angle 20°

240
ω1 n1 D2 z 2
mω = = = = 40
ω2 n2 D1 z1
+
5 D2 z 2 Gear dia : Pinion dia
mω = = = 5:1
1 D1 z1
R=200
Divide the center distance into 5+1 = 6 parts
Each part = 240/6 = 40 mm Rpinion = 40, Dia. = 80
 Gear ratio & Center distance (2)
No. of pinion teeth z = D/m = 80/3 = 26.6 choose 27 teeth
No. of gear teeth zgear = 5 × zpinion = 5 × 27 = 135

pinion gear

Dia. Pitch D = m×z 81 405

Center distance = (Dpinion+Dgear)/2 243 (240)

Dia. Addendum = D+2a = D+2m 87 411

Dia. Base = D×cos(PA) = D×cos(20°) 76.115 380.58

Addendum = m 3

Dedendum = 1.25m 3.75

Tooth depth = a+b 6.75

Tooth thickness = πD/2z = πm/2 4.712

 Gear ratio & Center distance (3)
No. of pinion teeth z = D/m = 80/3 = 26.6 choose 26 teeth
No. of gear teeth 134 Velocity ratio = 134/26 = 5.15

pinion gear

Dia. Pitch D = m×z 78 402

Center distance = (Dpinion+Dgear)/2 240

Dia. Addendum = D+2a = D+2m 84 408

Dia. Base = D×cos(PA) = D×cos(20°) 73.30 377.76

Addendum = m 3

Dedendum = 1.25m 3.75

Tooth depth = a+b 6.75

Tooth thickness = πD/2z = πm/2 4.712

 Gear train
Pin
Pout

Increase gear ratio Change direction of rotation

No. of teeth of gear G2 dose not affect
to the ratio
ωi
mω = ωi/ωo
z1 z2

z3 z4 mω = (z2/z1) (z4/z3) (z6/z5)

z5 z6

ωo
 Planetary gear train
Epicyclic gear train, Planetary gear train
Sun gear

Planet carrier

All parts rotate around

the center point
• Sun gear
Each part can be set to be input, Various gear ratio
• Planet carrier
output or fixed can be obtained
• Ring gear
 Planetary gear train
Epicyclic gear train, Planetary gear train

Zp = 20 Input Planet Output

Fixed Ratio
member (rpm) (rpm) (rpm) (ωi/ωo)

Carrier Sun
Ring fix 36 0.375
9 24
Carrier Ring
Sun fix 36 0.625
9 14.4

Carrier sun Ring

27 1.667
fix 9 5.4

ZR = 100 Zs = 60
 Planetary gear train

http://www.diseno-art.com/encyclopedia/terms/automatic_transmission.html
 Gear manufacture
Methods of machining
Form milling : used mostly for large gears. A
milling cutter that has the shape of the tooth
space is used.
Shaping : frequently used for internal gears.
Milling cutter Hobbing
Cutter used reciprocates on a vertical spindle.
Hobbing : similar process to milling except
that both the workpiece and the cutter rotate
in a coordinated manner.
Casting : used most often to make blanks for VDO
gears which will have cut teeth. Possible to
use to make toothed gears with little or no
Shaping
machining
 Gear quality (1)
Quality in gearing is the precision of the individual gear teeth and the precision with
which two gears rotate in relation to one another.
• Runout
• Tooth-to-tooth spacing
• Profile

Schematic diagram of a typical

gear rolling fixture Chart of gear-tooth errors of a typical gear
when run with a specific gear in a rolling
fixture.
 Gear quality (2)
• Gear quality is specified by AGMA as quality numbers.
• Quality numbers range from 5 to 15 with increasing precision (AGMA)
• Besides AGMA standard, there are also other standards (JIS, DIN, ISO-similar to DIN)
Selected values for total composite tolerance Table of Gear Precision Grade
 Gear quality (3)
Recommended AGMA quality numbers

Pitch line speed:

Velocity at the pitch circle
v

pitch circle
 Materials
Steel:
• medium-carbon steel is usually used
• Due to low surface endurance capacity, heat treatment (Flame hardening, Induction
hardening, Carburizing, Nitriding) is required
• Surface finishing (grinding) is probably done after heat treatment to obtain high
precision gear

Cast iron:
Cheap, ASTM grade 20, 30, 40, 50, 60 are normally used
surface fatigue strength is higher than bending fatigue strength
Quieter than steel due to the damping property of cast iron
Ductile or nodular cast-iron is probably used to increase strength of gear
 Gear force analysis (1)
FBD
Gear Gear

Pressure
Fb φ line

F Fr
Pressure φ F
line Fr

Base Pressure φ Fb
circle Pitch circle line

Pinion Pinion

Neglect sliding friction in FBD

 Gear force analysis (2)
From FBD FBD
Fb = F cos φ Gear

Fr = F sin φ

Transmitted torque can be calculated from

Pressure
T = F ⋅ rb = Fb ⋅ r Fb φ line

Transmitted power can be calculated from F Fr

P = Tω = (F ⋅ rb ) ⋅ ω = (Fb ⋅ r ) ⋅ ω
F
Fr

rb = base radius Pressure φ Fb

r = pitch radius line

Pinion
 Gear tooth strength
Max. stress Contact point Tooth root
position
Failure Pitting Crack

Photoelasic pattern of
stresses in a spur gear tooth Design Contact stress Bending stress
principle Hertzian stress Lewis equation
 Gear tooth bending stress (1)
Lewis equation
Assumptions
1. Gear tooth is considered as a cantilever beam
2. All transmitted force acts at the tooth tip of a tooth
pair
3. Fr is neglected
4. Sliding friction is neglected

Mc Fb L(t / 2) 6 Fb L
σ= = 3
=
b
Fb I (bt / 12) bt 2

σbt 2
Fb =
L 6L

t
 Gear tooth bending stress (2)
For constant bending stress
 σb  2
L =  t = (const.)t 2
 6 Fb 
The relation between L and t is parabola.
Tooth tip area has more material than parabola,
hence the failure will occur at the tooth root (BED)
x t/2 t2
From triangle relation = L=
t/2 L 4x
σbt 2  2x 
Hence Fb = Fb = σb  p = σbyp
6L  3p 
p : circularpitch
σbY Fb P y : Lewis form factor
Fb = σ=
P bY Y : Lewis form factor

Fb P : Diametral pitch
Fb = σbYm σ= m : module
bYm
 Load Near Tip of Teeth Load at Near Middle of Teeth

Lewis Form Factor No Teeth

Y
14 1/2 deg
y Y
20 deg FD
y Y
20 deg Stub
y Y
25 deg
y Y
14 1/2 deg
y Y
20 deg FD
y
10 0,176 0,056 0,201 0,064 0,261 0,083 0,238 0,076
Y, y 11
12
0,192
0,21
0,061
0,067
0,226
0,245
0,072
0,078
0,289
0,311
0,092
0,099
0,259
0,277
0,082
0,088 0,355 0,113 0,415 0,132
13 0,223 0,071 0,264 0,084 0,324 0,103 0,293 0,093 0,377 0,12 0,443 0,141
14 0,236 0,075 0,276 0,088 0,339 0,108 0,307 0,098 0,399 0,127 0,468 0,149

Load near tip of teeth 15

16
0,245
0,255
0,078
0,081
0,289
0,295
0,092
0,094
0,349
0,36
0,111
0,115
0,32
0,332
0,102
0,106
0,415
0,43
0,132
0,137
0,49
0,503
0,156
0,16

• Total transmitted force 17

18
0,264
0,27
0,084
0,086
0,302
0,308
0,096
0,098
0,368
0,377
0,117
0,12
0,342
0,352
0,109
0,112
0,446
0,459
0,142
0,146
0,512
0,522
0,163
0,166

acts at the tooth tip 19

20
0,277
0,283
0,088
0,09
0,314
0,32
0,1
0,102
0,386
0,393
0,123
0,125
0,361
0,369
0,115
0,117
0,471
0,481
0,15
0,153
0,534
0,544
0,17
0,173
21 0,289 0,092 0,326 0,104 0,399 0,127 0,377 0,12 0,49 0,156 0,553 0,176
(actually at this point 22 0,292 0,093 0,33 0,105 0,404 0,129 0,384 0,122 0,496 0,158 0,559 0,178
23 0,296 0,094 0,333 0,106 0,408 0,13 0,390 0,124 0,502 0,16 0,565 0,18
double teeth meshing 24 0,302 0,096 0,337 0,107 0,411 0,131 0,396 0,126 0,509 0,162 0,572 0,182
25 0,305 0,097 0,34 0,108 0,416 0,132 0,402 0,128 0,515 0,164 0,58 0,185
occurs, hence the force 26 0,308 0,098 0,344 0,109 0,421 0,134 0,407 0,13 0,522 0,166 0,584 0,186
27 0,311 0,099 0,348 0,111 0,426 0,136 0,412 0,131 0,528 0,168 0,588 0,187
acting on a tooth pair is 28 0,314 0,1 0,352 0,112 0,43 0,137 0,417 0,133 0,534 0,17 0,592 0,188
29 0,316 0,101 0,355 0,113 0,434 0,138 0,421 0,134 0,537 0,171 0,599 0,191
reduced) 30 0,318 0,101 0,358 0,114 0,437 0,139 0,425 0,135 0,54 0,172 0,606 0,193

• Safer design
31 0,32 0,101 0,361 0,115 0,44 0,14 0,429 0,137 0,554 0,176 0,611 0,194
32 0,322 0,101 0,364 0,116 0,443 0,141 0,433 0,138 0,547 0,174 0,617 0,196
33 0,324 0,103 0,367 0,117 0,445 0,142 0,436 0,139 0,55 0,175 0,623 0,198
34 0,326 0,104 0,371 0,118 0,447 0,142 0,44 0,14 0,553 0,176 0,628 0,2
35 0,327 0,104 0,373 0,119 0,449 0,143 0,443 0,141 0,556 0,177 0,633 0,201
Load near middle of teeth 36
37
0,329
0,33
0,105
0,105
0,377
0,38
0,12
0,121
0,451
0,454
0,144
0,145
0,446
0,449
0,142
0,143
0,559
0,563
0,178
0,179
0,639
0,645
0,203
0,205
• Total transmitted force 38
39
0,333
0,335
0,106
0,107
0,384
0,386
0,122
0,123
0,455
0,457
0,145
0,145
0,452
0,454
0,144
0,145
0,565
0,568
0,18
0,181
0,65
0,655
0,207
0,208
acts at the position near 40
43
0,336
0,339
0,107
0,108
0,389
0,397
0,124
0,126
0,459
0,467
0,146
0,149
0,457
0,464
0,145
0,148
0,57
0,574
0,181
0,183
0,659
0,668
0,21
0,213
the middle of teeth (single 45
50
0,34
0,346
0,108
0,11
0,399
0,408
0,127
0,13
0,468
0,474
0,149
0,151
0,468
0,477
0,149
0,152
0,579
0,588
0,184
0,187
0,678
0,694
0,216
0,221
tooth meshing occurs) 55
60
0,352
0,355
0,112
0,113
0,415
0,421
0,132
0,134
0,48
0,484
0,153
0,154
0,484
0,491
0,154
0,156
0,596
0,603
0,19
0,192
0,704
0,713
0,224
0,227
• Close to the actual 65
70
0,358
0,36
0,114
0,115
0,425
0,429
0,135
0,137
0,488
0,493
0,155
0,157
0,496
0,501
0,158
0,159
0,607
0,61
0,193
0,194
0,721
0,728
0,23
0,232
condition 75
80
0,361
0,363
0,115
0,116
0,433
0,436
0,138
0,139
0,496
0,499
0,158
0,159
0,506
0,509
0,161
0,162
0,613
0,615
0,195
0,196
0,735
0,739
0,234
0,235
90 0,366 0,117 0,442 0,141 0,503 0,16 0,516 0,164 0,619 0,197 0,747 0,238
100 0,368 0,117 0,446 0,142 0,506 0,161 0,521 0,166 0,622 0,198 0,755 0,24
150 0,375 0,119 0,458 0,146 0,518 0,165 0,537 0,171 0,635 0,202 0,778 0,248
200 0,378 0,12 0,463 0,147 0,524 0,167 0,545 0,173 0,64 0,204 0,787 0,251
300 0,38 0,122 0,471 0,15 0,534 0,17 0,554 0,176 0,65 0,207 0,801 0,255
Rack 0,39 0,124 0,484 0,154 0,55 0,175 0,566 0,18 0,66 0,21 0,823 0,262
 Gear tooth bending stress (3)
The effect of Fr
1. Compressive stress at B side increase, but tensile stress at
D side decrease.
2. Most material can withstand compressive force more than
tensile force. Fatigue will occur at tensile side.
3. The presence of Fr will increase strength of gear tooth,
since it help to reduce the stress in tensile side

Lewis form factor, Y or y

1. Y and y increase when no. of teeth is increased
2. More Y or y, gear tooth can withstand more Fb
Fb P 3. Pinion has lower no. of gear teeth than gear. Pinion can
σ= withstand low load than gear.
bY 4. Calculation is done at pinion
Fb
σ=
bYm
 AGMA Stress Equation (bending)
American Gear Manufacturers Association (AGMA) proposed the method to design gear
based on the Lewis equation (bending stress consideration)
Lewis Equation AGMA Equation (bending)
Fb Wt
σ= st = KO K s K m K B Kv
bYm FYJ m

σ st KO : Overload factor
Ks : Size factor
Fb Wt Km : Load-distribution factor
b F KB : Rim thickness factor
Kv : Dynamic factor
Y YJ K >= 1.0 (Always)
YJ : Geometry factor
is Y that include the effect of root
fillet stress-concentration factor
 Geometry factor (YJ) st =
Wt
FYJ m
KO K s K m K B Kv

Bending strength geometry factor YJ for full depth teeth spur gears

20° pressure angle 25° pressure angle

 Overload factor (KO) st =
Wt
FYJ m
KO K s K m K B Kv

Suggested overload factors, KO

Driven Machine
Moderate Heavy
Power source Uniform Light shock shock shock
Uniform 1.00 1.25 1.50 1.75
Light shock 1.20 1.40 1.75 2.25
Moderate shock 1.30 1.70 2.00 2.75

Power sources Driven machine

Uniform: Electric motor, Constant-
speed gas turbine
Light shock: Water turbine, variable-
speed drive
Moderate shock: Multicylinder engine
Uniform: Continuous-duty generator
Light shock: Fans and low speed centrifugal pump, variable-duty
generators, uniform loaded conveyors
Moderate shock: High-speed centrifugal pumps, reciprocating pumps
and compressors, heavy duty conveyors, machine tool drives
Heavy shock: Rock crushers, punch press drivers
 Size factor (Ks) st =
Wt
FYJ m
KO K s K m K B Kv

Suggested size factors, Ks

Diametral pitch, Pd Metric module, m Size factor, Ks
>=5 <=5 1.00
4 6 1.05
3 8 1.15
2 12 1.25
1.25 20 1.40
 Load dist. factor (Km) st =
Wt
FYJ m
KO K s K m K B Kv

Used to reflect nonuniform distribution of load across the line of contact.

If load is uniformly distributed Km = 1.0

Causes of nonuniform distribution The method to reduce Km (min = 1.0)

1. Gear tooth error
2. Misalignment, Eccentricity
3. Deformation of gear, shaft, bearing,
housing
4. Clearance between shaft, gear, bearing,
housing
5. Deformation from the temperature
6. Gear tooth modification (crowning, end
relief)
1. Use high quality gear (high quality
number)
2. Narrow face widths
3. Locate gear at the center between two
bearings
4. Short shaft spans between bearing
5. Large shaft diameters (high stiffness)
6. Rigid stiff housings
7. High precision, small clearance on all
drive components
 Load dist. factor (Km) st =
Wt
FYJ m
KO K s K m K B Kv

Load distribution factor (Km) can be Cpf = pinion proportion factor

calculated by F
K m = 1.0 + Cmc (C pf C pm + Cma Ce )
C pf = − 0.025 F ≤ 1 in
10d
F
C pf = − 0.0375 + 0.0125 F 1 < F ≤ 17 in
10d
Cmc = lead correction factor
d, dp = pinion diameter
Cmc = 1 for uncrowned teeth
Cmc = 0.8 for crowned teeth

Cpm = pinion proportion modifier

Cpm = 1 S1/S < 0.175

Cpm = 1.1 S1/S ≥ 0.175
 Load dist. factor (Km) st =
Wt
FYJ m
KO K s K m K B Kv

Load distribution factor (Km) can be

Ce = mesh alignment correction factor
calculated by
K m = 1.0 + Cmc (C pf C pm + Cma Ce )
Ce = 0.8 for gearing adjusted at assembly,
compatibility is improved by lapping
Ce = 1 for all other conditions

Cma = mesh alignment factor

Cma = A + BF + CF 2

Condition A B C
Open gearing 0.247 0.0167 -0.765(10-4)
Commercial, enclosed units 0.127 0.0158 -0.093(10-4)
Precision, enclosed units 0.0675 0.0128 -0.926(10-4)
Extraprecision enclosed gear 0.00360 0.0102 -0.822(10-4)
units
* Face width F in Inches
Rim thickness factor (KB) st =
Wt
FYJ m
KO K s K m K B Kv

Used when the rim thickness is not sufficient to provide full support for the tooth root.

2.242
K b = 1.6 ln mB < 1.2
mB
Kb = 1 mB ≥ 1.2
tR
mB =
ht
 Dynamic factor (Kv) st =
Wt
FYJ m
KO K s K m K B Kv

To compensate the effect of vibration, dynamic unbalance that will increase load that
the gear tooth must withstand especially at high velocity.
B
 A + C vt  A = 50 + 56(1.0 − B)
Kv =   B = 0.25(12 − Qv ) 0.667
 A 
  C =1 for vt in ft/min
C = 200 for vt in m/s
Qv = Gear quality number
vt = Pitch line velocity

Maximum recommended pitch line velocity:

[ A + (Qv − 3)]2
vt ,max =
C2
 Selection of material (bending stress)
Adjusted Allowable Bending
AGMA Equation (bending) Stress Numbers
(Load that the gear must withstand) (Depend on the material property)
Wt YN
st =
FYJ m
KO K s K m K B Kv < sat′ = sat
SF ⋅ K R
sat : Allowable bending stress
YN : Bending strength stress cycle number
KR : Reliability factor
SF : factor of safety (design decision)

KR : Reliability factor SF : factor of safety (design decision)

Reliability KR • To compensate any uncertainty in analysis,
0.90, one failure in 10 0.85 material property, or error in manufacturing
0.99, one failure in 100 1.00 • Most of factors are included in AGMA
equation, hence the recommended SF is
0.999, one failure in 1000 1.25
around 1.00-1.50
0.9999, one failure in 10000 1.50
 Allowable bending stress, Sat

Allowable bending stress number for Allowable bending stress number for
through-hardened steels nitriding steel gears
Bending strength stress cycle number, Yn

N = 60 Lnq N : expected number of cycles of loading

L : design life in hours
n : rotational speed of the gear (rpm)
q : number of load applications per revolution
Bending strength stress cycle number, Yn
Application Design life (h)
Domestic appliances 1,000-2,000
Aircraft engines 1,000-4,000
Automotive 1,500-5,000
Agricultural equipment 3,000-6,000
Elevators, industrial fan, multipurpose gearing 8,000-15,000
Motors, industrial blowers, general industrial machines 20,000-30,000
Pumps and compressors 40,000-60,000
Critical equipment in continuous 24-h operation 100,000-200,000
 Gear tooth contact stress (1)
Driving Driven
W W
r1 r1
r1 +
+
r2
F
r2 + +
r2
Base
circle W W

• The contact of gear teeth can be modeled as the contact of two cylinders
• r is radius of involute curve at the contact point (not the radius of pitch cylinder)
• Radius r is changed along the meshing position
• W is force in the direction of pressure line T = W ⋅ rb = Wt ⋅ r and W cos φ = Wt
• Stress at contact point can be calculated by Hertzian stress equation
 Gear tooth contact stress (1)
Hertzian stress can be calculated from
W
rp  W (1 / r1 + 1 / r2 ) 
1/ 2

+ σ = 
 Fπ [ (1 − ν 2
1 ) E 1 + (1 − ν 2
2 ) E ]
2 
Define Cp (Elastic coefficient)
1/ 2
 1 
Cp =  
 π [(1 −ν 1 ) E1 + (1 −ν 2 ) E2 ] 
2 2
F
+

1/ 2
r1 = (d P sin φ ) 2
rG 2Wt  1 1 
σ = Cp   + 
r2 = (d G sin φ ) 2
W  F cos φ sin φ  d P d G 
W = Wt cos φ

1/ 2
Define I (Geometry factor)
 2Wt  mG + 1  cos φ sin φ mG
σ = Cp    I=
 Fd P cos φ sin φ  mG  2 mG + 1
mG = Z G Z P = d G d P

1/ 2
 W  Basic equation related closely
σ = Cp  t 
 Fd P I  with AGMA for contact stress
 AGMA Stress Equation (contact)
Hertzian stress AGMA Equation (Contact)
1/ 2 1/ 2
 Wt   Wt 
σ = Cp   sc = C p  KO K s K m Kv 
 Fd P I   Fd P I 

โดย KO : Overload factor

Ks : Size factor
1/ 2
 1  Km : Load-distribution factor
Cp =  
 π [ (1 − ν 2
1 ) E1 + (1 − ν 2
2 ) E ]
2 
Kv : Dynamic factor
cos φ sin φ mG Can be found as same as
I=
2 mG + 1
the bending stress cal.
dP : Pitch diameter (pinion)
F : Face width
 1/ 2

Elastic coefficient, Cp  W 
sc = C p  t K O K s K m K v 
 Fd P I 

1/ 2
 1  Subscript: 1 - Pinion
Cp =  
 π [(1 −ν 1 ) E1 + (1 −ν 2 ) E2 ] 
2 2
2- Gear
 Geometry factor, I
1/ 2
 W 
sc = C p  t K O K s K m K v 
 Fd P I 

cos φ sin φ mG mG = Z G Z P = d G d P
I=
2 mG + 1
Selection of material (Contact stress)
Adjusted Allowable Contact
AGMA Equation (contact) Stress Numbers
(Load that the gear must withstand) (Depend on the material property)
1/ 2
 Wt  Z N CH
sc = C p  KO K s K m Kv  < ′ = sac
sac
SF ⋅ K R
 Fd P I 
sac : Allowable contact stress
ZN : Pitting resistance stress cycle number factor
CH : Hardness ratio factor
As same as KR : Reliability factor
bending case
SF : factor of safety (design decision)
KR : Reliability factor
Reliability KR SF : factor of safety (design decision)
0.90, one failure in 10 0.85 • To compensate any uncertainty in analysis,
material property, or error in manufacturing
0.99, one failure in 100 1.00
• Most of factors are included in AGMA
0.999, one failure in 1000 1.25 equation, hence the recommended SF is
0.9999, one failure in 10000 1.50 around 1.00-1.50
 Allowable contact stress, Sac
Contact-fatigue strength Sc at 107 cycles
and 0.99 reliability for through-hardened
steel gears.
ANSI/AGMA 2001-D04 and 2101-D04.

Repeatedly Applied Contact

Strength Sc at 107 Cycles and
0.99 Reliability for Steel Gears
ANSI/AGMA 2001-D04.
Pitting resistance stress cycle number factor, ZN

N = 60 Lnq N : expected number of cycles of loading As same as bending case

L : design life in hours
n : rotational speed of the gear (rpm)
q : number of load applications per revolution
 Hardness ratio factor, CH
• Pinion is smaller and rotate faster
than gear
• If the surface of pinion is harder than
gear, the capacity of pitting
resistance is increase
• HBP : Brinell hardness of pinion
• HBG : Brinell hardness of gear
• CH is used for gear only (does not
use for pinion calculation)
• If the hardness of pinion and gear
are equal, CH = 1
 Design Guidelines
1. Gear ratio should be less than 1:6 (Too much gear ratio will bring about interference
problem and large gear will cause the weight and size problem).
2. If gear ratio more than 1:6 is required, multi-stages gear reduction should be used.
3. Recommended face width is around 8m < F < 16m (commonly use 12m).
4. Very large face width will bring about the alignment and load distribution problem.
5. At the same center distance, the gear pair with small teeth + more no. of teeth is
quieter than the gear pair with large teeth + less no. of teeth.
6. Small no. of teeth make the compact gear pair, but the interference must be checked.
Design Guidelines

Data for all curves:

mG = 4, NP = 24
KO = 1.0, Class 1 service
20° full-depth teeth
 Example
A gear pair is to be designed to transmit 15 kW of power to a large meat grinder in a
commercial meat processing plant. The pinion is attached to the shaft of an electric motor
rotating at 575 rpm. The gear must operate at 270-280 rpm. The gear unit will be enclosed
and of commercial quality. Commercially hobbed (quality number 5), 20°, full depth, involute
gears are to be used in the metric module system. The maximum center distance is to be 200
mm. Specify the design of the gears. [Ex.9-6 Machine Elements in Mechanical Design. Robert L. Mott]