Chapter 15

15-1 Given: Uncrowned, through-hardened 300 Brinell core and case, Grade 1, N C =
109 rev of pinion at R = 0.999, N P = 20 teeth, N G = 60 teeth, Q v = 6, P d = 6
teeth/in, shaft angle = 90°, n p = 900 rev/min, J P = 0.249 and J G = 0.216 (Fig.
15-7), F = 1.25 in, S F = S H = 1, K o = 1.

Mesh d P = 20/6 = 3.333 in, d G = 60/6 = 10.000 in

Eq. (15-7): v t = (3.333)(900/12) = 785.3 ft/min

Eq. (15-6): B = 0.25(12 – 6)2/3 = 0.8255

A = 50 + 56(1 – 0.8255) = 59.77

0.8255
 59.77  785.3 
Eq. (15-5): K v     1.374
 59.77 

Eq. (15-8): v t,max = [59.77 + (6 – 3)]2 = 3940 ft/min

Since 785.3 < 3904, K v = 1.374 is valid. The size factor for bending is:

Eq. (15-10): K s = 0.4867 + 0.2132 / 6 = 0.5222

For one gear straddle-mounted, the load-distribution factor is:

Eq. (15-11): K m = 1.10 + 0.0036 (1.25)2 = 1.106

Eq. (15-15): (K L ) P = 1.6831(109)–0.0323 = 0.862

(K L ) G = 1.6831(109 / 3)–0.0323 = 0.893

Eq. (15-14): (C L ) P = 3.4822(109)–0.0602 = 1

(C L ) G = 3.4822(109 / 3)–0.0602 = 1.069

Eq. (15-19): K R = 0.50 – 0.25 log(1 – 0.999) = 1.25 (or Table 15-3)
CR  K R  1.25  1.118

Bending

Fig. 15-13: 0.99 St  sat  44(300)  2100  15 300 psi

sat K L 15 300(0.862)
Eq. (15-4): ( all ) P  sw t    10 551 psi
S F KT K R 1(1)(1.25)

Chapter 15, Page 1/20

 ( all ) P FK x J P
Eq. (15-3): WPt 
Pd K o K v K s K m
10 551(1.25)(1)(0.249)
  690 lbf
6(1)(1.374)(0.5222)(1.106)
690(785.3)
H1   16.4 hp
33 000

15 300(0.893)
Eq. (15-4): ( all )G   10 930 psi
1(1)(1.25)
10 930(1.25)(1)(0.216)
WGt   620 lbf
6(1)(1.374)(0.5222)(1.106)
620(785.3)
H2   14.8 hp Ans.
33 000

The gear controls the bending rating.

________________________________________________________________________

15-2 Refer to Prob. 15-1 for the gearset specifications.

Wear
Fig. 15-12: s ac = 341(300) + 23 620 = 125 920 psi

For the pinion, C H = 1. From Prob. 15-1, C R = 1.118. Thus, from Eq. (15-2):

sac (CL ) P CH
( c,all ) P 
S H KT C R
125 920(1)(1)
( c,all ) P   112 630 psi
1(1)(1.118)

For the gear, from Eq. (15-16),

B1  0.008 98(300 / 300)  0.008 29  0.000 69

CH  1  0.000 69(3  1)  1.001 38

From Prob. 15-1, (C L ) G = 1.0685. Equation (15-2) thus gives

sac (CL )G CH
( c,all )G 
S H KT C R
125 920(1.0685)(1.001 38)
( c,all )G   120 511 psi
1(1)(1.118)

For steel: C p  2290 psi

Chapter 15, Page 2/20

 Eq. (15-9): Cs  0.125(1.25)  0.4375  0.593 75

Fig. 15-6: I = 0.083

Eq. (15-12): C xc = 2
2
 ( )  Fd P I
Eq. (15-1): W   c,all P 
t
P C p  K o K v K mCsC xc
 
 112 630   
2
1.25(3.333)(0.083)
    
2290 1(1.374)(1.106)(0.5937)(2) 
 464 lbf
464(785.3)
H3   11.0 hp
33 000
 120 511  
2
1.25(3.333)(0.083)
WGt     
2290 1(1.374)(1.106)(0.593 75)(2) 
 531 lbf
531(785.3)
H4   12.6 hp
33 000

The pinion controls wear: H = 11.0 hp Ans.

The power rating of the mesh, considering the power ratings found in Prob. 15-1,
is
H = min(16.4, 14.8, 11.0, 12.6) = 11.0 hp Ans.
________________________________________________________________________

15-3 AGMA 2003-B97 does not fully address cast iron gears. However, approximate
comparisons can be useful. This problem is similar to Prob. 15-1, but not
identical. We will organize the method. A follow-up could consist of completing
Probs. 15-1 and 15-2 with identical pinions, and cast iron gears.

Given: Uncrowned, straight teeth, P d = 6 teeth/in, N P = 30 teeth, N G = 60 teeth,

ASTM 30 cast iron, material Grade 1, shaft angle 90°, F = 1.25, n P = 900
rev/min,  n = 20, one gear straddle-mounted, K o = 1, J P = 0.268, J G = 0.228, S F
= 2, S H  2.

Mesh d P = 30/6 = 5.000 in, d G = 60/6 = 10.000 in

v t =  (5)(900 / 12) = 1178 ft/min

Set N L = 107 cycles for the pinion. For R = 0.99,

Table 15-7: s at = 4500 psi

Chapter 15, Page 3/20

Table 15-5: s ac = 50 000 psi
sat K L 4500(1)
Eq. (15-4): swt    2250 psi
S F KT K R 2(1)(1)

The velocity factor K v represents stress augmentation due to mislocation of tooth

profiles along the pitch surface and the resulting “falling” of teeth into
engagement. Equation (5-67) shows that the induced bending moment in a
cantilever (tooth) varies directly with E of the tooth material. If only the
material varies (cast iron vs. steel) in the same geometry, I is the same. From the
Lewis equation of Section 14-1,
M K W tP
   v
I /c FY
We expect the ratio  CI / steel to be
 CI ( K v )CI ECI
 
 steel ( K v )steel Esteel

In the case of ASTM class 30, from Table A-24(a)

(E CI ) av = (13 + 16.2)/2 = 14.7 kpsi

14.7
Then, ( K v )CI  ( K v )steel  0.7( K v )steel
30

Our modeling is rough, but it convinces us that (K v ) CI < (K v ) steel , but we are not
sure of the value of (K v ) CI . We will use K v for steel as a basis for a conservative
rating.

Eq. (15-6): B = 0.25(12 – 6)2/3 = 0.8255

A = 50 + 56(1 – 0.8255) = 59.77

0.8255
 59.77  1178 
Eq. (15-5): K v     1.454
 59.77 

Pinion bending ( all ) P = s wt = 2250 psi

From Prob. 15-1, K x = 1, K m = 1.106, K s = 0.5222

( all ) P FK x J P
Eq. (15-3): WPt 
Pd K o K v K s K m
2250(1.25)(1)(0.268)
  149.6 lbf
6(1)(1.454)(0.5222)(1.106)

Chapter 15, Page 4/20

 149.6(1178)
H1   5.34 hp
33 000
Gear bending
JG  0.228 
WGt  WPt  149.6   127.3 lbf
JP  0.268 
127.3(1178)
H2   4.54 hp
33 000

The gear controls in bending fatigue. H = 4.54 hp Ans.

________________________________________________________________________

15-4 Continuing Prob. 15-3,

Table 15-5: s ac = 50 000 psi

50 000
sw t   c,all   35 355 psi
2
2
  Fd P I
Eq. (15-1): W   c,all 
t
 C p  K o K v K mCsCxc
 

Fig. 15-6: I = 0.86

From Probs. 15-1 and 15-2: C s = 0.593 75, K s = 0.5222, K m = 1.106, C xc = 2

From Table 14-8: C p  1960 psi

 35 355   
2
1.25(5.000)(0.086)
Wt     91.6 lbf
 1960  1(1.454)(1.106)(0.59375)(2) 

Thus,

91.6(1178)
H3  H 4   3.27 hp
33 000

Rating
Based on results of Probs. 15-3 and 15-4,

H = min(5.34, 4.54, 3.27, 3.27) = 3.27 hp Ans.

The mesh is weakest in wear fatigue.

________________________________________________________________________

15-5 Uncrowned, through-hardened to 180 Brinell (core and case), Grade 1, 109 rev of
pinion at R = 0.999, N P = z 1 = 22 teeth, N G = z 2 = 24 teeth, Q v = 5, m et = 4 mm,
shaft angle 90°, n 1 = 1800 rev/min, S F = 1, S H  S F  1, J P = Y J1 = 0.23,
J G = Y J2 = 0.205, F = b = 25 mm, K o = K A = K T = K  = 1 and C p  190 MPa .

Chapter 15, Page 5/20

Mesh d P = d e1 = mz 1 = 4(22) = 88 mm, d G = m et z 2 = 4(24) = 96 mm

Eq. (15-7): v et = 5.236(10–5)(88)(1800) = 8.29 m/s

Eq. (15-6): B = 0.25(12 – 5)2/3 = 0.9148

A = 50 + 56(1 – 0.9148) = 54.77
0.9148
 54.77  200(8.29) 
Eq. (15-5): Kv     1.663
 54.77
 
Eq. (15-10): K s = Y x = 0.4867 + 0.008 339(4) = 0.520

Eq. (15-11): with K mb = 1 (both straddle-mounted),

K m = K H = 1 + 5.6(10–6)(252) = 1.0035

From Fig. 15-8,

(CL ) P  (Z NT ) P  3.4822(109 ) 0.0602  1.00
(CL )G  (Z NT )G  3.4822[109 (22 / 24)]0.0602  1.0054

Eq. (15-12): C xc = Z xc = 2 (uncrowned)

Eq. (15-19): K R = Y Z = 0.50 – 0.25 log (1 – 0.999) = 1.25

CR  Z Z  YZ  1.25  1.118

From Fig. 15-10, C H = Z w = 1

Eq. (15-9): Z x = 0.004 92(25) + 0.4375 = 0.560

Wear of Pinion

Fig. 15-12:  H lim = 2.35H B + 162.89

= 2.35(180) + 162.89 = 585.9 MPa

Fig. 15-6: I = Z I = 0.066

( H) ( Z NT ) P ZW
Eq. (15-2): ( H ) P  lim P
S H K Z Z
585.9(1)(1)
  524.1 MPa
1(1)(1.118)
2
  bd e1Z I
Eq. (15-1): W  H
t
P C p  1000 K A K v K H  Z x Z xc
 
The constant 1000 expresses Wt in kN.

Chapter 15, Page 6/20

  524.1   
2
25(88)(0.066)
WPt       0.591 kN
 190  1000(1)(1.663)(1.0035)(0.56)(2) 
 dnW t
 (88)(1800)(0.591)
Eq. (13-36): H3  1
  4.90 kW
60 000 60 000

Wear of Gear
 H lim = 585.9 MPa
585.9(1.0054)
( H )G   526.9 MPa
1(1)(1.118)
( H )G  526.9 
WGt  WPt  0.591   0.594 kN
( H ) P  524.1 
 (88)(1800)(0.594)
H4   4.93 kW
60 000

Thus in wear, the pinion controls the power rating; H = 4.90 kW Ans.

We will rate the gear set after solving Prob. 15-6.

________________________________________________________________________

15-6 Refer to Prob. 15-5 for terms not defined below.

Bending of Pinion
( K L ) P  (YNT ) P  1.6831(109 ) 0.0323  0.862
( K L )G  (YNT )G  1.6831[109 (22 / 24)]0.0323  0.864

Fig. 15-13:  F lim = 0.30H B + 14.48

= 0.30(180) + 14.48 = 68.5 MPa

Eq. (15-13): Kx = Y = 1

From Prob. 15-5: Y Z = 1.25, v et = 8.29 m/s,

K A  1, K v  1.663, K  1,
Yx  0.52, K H   1.0035, YJ 1  0.23

 F limYNT 68.5(0.862)
Eq. (5-4): ( F ) P    47.2 MPa
S F K YZ 1(1)(1.25)
( F ) P bmetY YJ 1
Eq. (5-3): WPt 
1000K A K vYx K H 
47.2(25)(4)(1)(0.23)
  1.25 kN
1000(1)(1.663)(0.52)(1.0035)

Chapter 15, Page 7/20

   881800 1.25 
H1   10.37 kW
60 000
Bending of Gear

 F lim  68.5 MPa

68.5(0.864)
( F )G   47.3 MPa
1(1)(1.25)
47.3(25)(4)(1)(0.205)
WGt   1.12 kN
1000(1)(1.663)(0.52)(1.0035)
  88 1800 1.12 
H2   9.29 kW
60 000
Rating of mesh is
H rating = min(10.37, 9.29, 4.90, 4.93) = 4.90 kW Ans.
with pinion wear controlling.
________________________________________________________________________

15-7
   
(a) (S F ) P   all   (S F )G   all 
  P   G
(sat K L / KT K R ) P (sat K L / KT K R )G
t
 t
(W Pd K o K v K s K m / FK x J ) P (W Pd K o K v K s K m / FK x J )G

All terms cancel except for s at , K L , and J,

(s at ) P (K L ) P J P = (s at ) G (K L ) G J G

From which
(sat ) P ( K L ) P J P J
(sat )G   ( sat ) P P mG
( K L )G J G JG

where  = – 0.0178 or  = – 0.0323 as appropriate. This equation is the same as

Eq. (14-44). Ans.

(b) In bending

 FK x J   sat K L FK x J 
W t   all    (1)
 S F Pd K o K v K s K m 11  S F KT K R Pd K o K v K s K m 11
In wear
1/ 2
 sacCLCU   W t K o K v K mCsCxc 
   C p 
 S H KT CR 22  Fd P I 22

Chapter 15, Page 8/20

Squaring and solving for Wt gives

 s 2 C 2C 2   Fd P I 
W t   2 ac 2L 2H 2    (2)
 S H KT CRCP  22  K o K v K mCsCxc  22

Equating the right-hand sides of Eqs. (1) and (2) and canceling terms, and
recognizing that CR  K R and P d d P = N P , we obtain

Cp S H2 (sat )11( K L )11 K x J11KT CsCxc

(sac )22 
(CL )22 SF CH2 N P K s I

For equal Wt in bending and wear

 
2
S H2 SF
 1
SF SF

So we get
Cp (sat ) P ( K L ) P J P K x KT CsCxc
(sac )G  Ans.
(CL )G CH N P IK s
(c)
   
(S H ) P  (S H )G   c,all    c,all 
 c  P  c  G

Substituting in the right-hand equality gives

[ sacC L / (C R KT )]P [ sacCLC H / (C R KT )]G


C W K K K C C / ( Fd I ) 
t C W t K K K C C / ( Fd I ) 
 p o v m s xc P
P  p o v m s xc P
G

Denominators cancel, leaving

(s ac ) P (C L ) P = (s ac ) G (C L ) G C H

Solving for (s ac ) P gives,

(CL )G
( sac ) P  (sac )G CH (1)
(CL ) P
From Eq. (15-14),  C L  P  3.4822 N L0.0602 and  C L G  3.4822  N L / mG 
0.0602
.
Thus,
 sac  P   sac G 1 mG  C H   sac G mG0.0602C H
0.0602
Ans.

This equation is the transpose of Eq. (14-45).

Chapter 15, Page 9/20

________________________________________________________________________

15-8 Core Case

Pinion (H B ) 11 (H B ) 12
Gear (H B ) 21 (H B ) 22

Given (H B ) 11 = 300 Brinell

Eq. (15-23): (s at ) P = 44(300) + 2100 = 15 300 psi

 0.249  0.0323
 3   17 023 psi
J P 0.0323
(sat )G  (sat ) P mG  15 300 
JG  0.216 
17 023  2100
( H B ) 21   339 Brinell Ans.
44
2290 15 300(0.862)(0.249)(1)(0.593 25)(2)
( sac )G 
1.0685(1) 20(0.086)(0.5222)
 141 160 psi
141 160  23 600
( H B ) 22   345 Brinell Ans.
341
(sac ) P  (sac )G mG0.0602CH  141 160(30.0602 ) 1  150 811 psi
150 811  23 600
( H B )12   373 Brinell Ans.
341

Core Case
Pinion 300 373 Ans.
Gear 339 345

________________________________________________________________________

15-9
Pinion core
(sat ) P  44(300)  2100  15 300 psi
15 300(0.862)
( all ) P   10 551 psi
1(1)(1.25)
10 551(1.25)(0.249)
Wt   689.7 lbf
6(1)(1.374)(0.5222)(1.106)
Gear core
(sat )G  44(352)  2100  17 588 psi
17 588(0.893)
( all )G   12 565 psi
1(1)(1.25)
12 565(1.25)(0.216)
Wt   712.5 lbf
6(1)(1.374)(0.5222)(1.106)

Chapter 15, Page 10/20

Pinion case
(sac ) P  341(372)  23 620  150 472 psi
150 472(1)
( c,all ) P   134 590 psi
1(1)(1.118)
 134 590   
2
1.25(3.333)(0.086)
Wt       685.8 lbf
 2290  1(1.374)(1.106)(0.593 75)(2) 
Gear case
(sac )G  341(344)  23 620  140 924 psi
140 924(1.0685)(1)
( c,all )G   134 685 psi
1(1)(1.118)
2
 134 685  1.25(3.333)(0.086)
W 
t
  686.8 lbf
 2290  1(1.374)(1.106)(0.593 75)(2)

The rating load would be

t
Wrated  min(689.7, 712.5, 685.8, 686.8)  685.8 lbf

which is slightly less than intended.

Pinion core
(sat ) P  15 300 psi (as before)
( all ) P  10 551 psi (as before)
W t  689.7 lbf (as before)
Gear core
(sat )G  44(339)  2100  17 016 psi
17 016(0.893)
( all )G   12 156 psi
1(1)(1.25)
12 156(1.25)(0.216)
Wt   689.3 lbf
6(1)(1.374)(0.5222)(1.106)
Pinion case
(sac ) P  341(373)  23 620  150 813 psi
150 813(1)
( c,all ) P   134 895 psi
1(1)(1.118)
 134 895   
2
1.25(3.333)(0.086)
Wt       689.0 lbf
 2290  1(1.374)(1.106)(0.593 75)(2) 
Gear case
(sac )G  341(345)  23 620  141 265 psi
141 265(1.0685)(1)
( c,all )G   135 010 psi
1(1)(1.118)

Chapter 15, Page 11/20

  135 010   
2
1.25(3.333)(0.086)
Wt       690.1 lbf
 2290  1(1.1374)(1.106)(0.593 75)(2) 

The equations developed within Prob. 15-7 are effective.

________________________________________________________________________

15-10 The catalog rating is 5.2 hp at 1200 rev/min for a straight bevel gearset. Also
given: N P = 20 teeth, N G = 40 teeth,  n = 20, F = 0.71 in, J P = 0.241, J G = 0.201,
P d = 10 teeth/in, through-hardened to 300 Brinell-General Industrial Service, and
Q v = 5 uncrowned.

Mesh
d P  20 / 10  2.000 in, dG  40 / 10  4.000 in
 d P nP  (2)(1200)
vt    628.3 ft/min
12 12
K o  1, S F  1, S H  1

Eq. (15-6): B = 0.25(12 – 5)2/3 = 0.9148

A = 50 + 56(1 – 0.9148) = 54.77

0.9148
 54.77  628.3 
Eq. (15-5): K v     1.412
 54.77 
Eq. (15-10): K s = 0.4867 + 0.2132/10 = 0.508

Eq. (15-11): K m = 1.25 + 0.0036(0.71)2 = 1.252, where K mb = 1.25

Eq. (15-15): (K L ) P = 1.6831(109)–0.0323 = 0.862

(K L ) G = 1.6831(109/2)–0.0323 = 0.881

Eq. (15-14): (C L ) P = 3.4822(109)–0.0602 = 1.000

(C L ) G = 3.4822(109/2)–0.0602 = 1.043

Analyze for 109 pinion cycles at 0.999 reliability.

Eq. (15-19): K R = 0.50 – 0.25 log(1 – 0.999) = 1.25

CR  K R  1.25  1.118

Bending
Pinion:
Eq. (15-23): (s at ) P = 44(300) + 2100 = 15 300 psi

Chapter 15, Page 12/20

 15 300(0.862)
Eq. (15-4): (swt ) P   10 551 psi
1(1)(1.25)
(sw t ) P FK x J P
Eq. (15-3): Wt 
Pd K o K v K s K m
10 551(0.71)(1)(0.241)
  201 lbf
10(1)(1.412)(0.508)(1.252)
201(628.3)
H1   3.8 hp
33 000

Gear: (s at ) G = 15 300 psi

15 300(0.881)
Eq. (15-4): ( sw t ) G   10 783 psi
1(1)(1.25)
10 783(0.71)(1)(0.201)
Eq. (15-3): Wt   171.4 lbf
10(1)(1.412)(0.508)(1.252)
171.4(628.3)
H2   3.3 hp
33 000
Wear
Pinion:
(C H )G  1, I  0.078, C p  2290 psi, C xc  2
Cs  0.125(0.71)  0.4375  0.526 25

Eq. (15-22): (s ac ) P = 341(300) + 23 620 = 125 920 psi

125 920(1)(1)
( c,all ) P   112 630 psi
1(1)(1.118)

2
 ( )  Fd P I
Eq. (15-1): W   c,all P 
t

 C p  K o K v K mCsC xc
 112 630   
2
0.71(2.000)(0.078)
   
 2290  1(1.412)(1.252)(0.526 25)(2) 
 144.0 lbf

144(628.3)
H3   2.7 hp
33 000
Gear:
(sac )G  125 920 psi
125 920(1.043)(1)
( c,all )   117 473 psi
1(1)(1.118)
 
2
 117 473  0.71(2.000)(0.078)
Wt    1(1.412)(1.252)(0.526 25)(2)   156.6 lbf
 2290   

Chapter 15, Page 13/20

 156.6(628.3)
H4   3.0 hp
33 000

Rating:
H = min(3.8, 3.3, 2.7, 3.0) = 2.7 hp

Pinion wear controls the power rating. While the basis of the catalog rating is
unknown, it is overly optimistic (by a factor of 1.9).
________________________________________________________________________

15-11 From Ex. 15-1, the core hardness of both the pinion and gear is 180 Brinell. So
(H B ) 11 and (H B ) 21 are 180 Brinell and the bending stress numbers are:

(sat ) P  44(180)  2100  10 020 psi

(sat )G  10 020 psi

The contact strength of the gear case, based upon the equation derived in Prob.
15-7, is
Cp S H2 (sat ) P ( K L ) P K x J P KT CsCxc
(sac )G 
(CL )G CH S F N P IK s

Substituting (s at ) P from above and the values of the remaining terms from
Ex. 15-1,
2290 1.52  10 020(1)(1)(0.216)(1)(0.575)(2) 
(sac )G   
1.32(1) 1.5  25(0.065)(0.529) 
 114 331 psi
114 331  23 620
(H B ) 22   266 Brinell
341

The pinion contact strength is found using the relation from Prob. 15-7:

(sac ) P  (sac )G mG0.0602CH  114 331(1)0.0602 (1)  114 331 psi

114 331  23 600
( H B )12   266 Brinell
341

Core Case
Pinion 180 266
Gear 180 266
Realization of hardnesses

The response of students to this part of the question would be a function of the
extent to which heat-treatment procedures were covered in their materials and
manufacturing prerequisites, and how quantitative it was. The most important

Chapter 15, Page 14/20

 thing is to have the student think about it.

The instructor can comment in class when students’ curiosity is heightened.

Options that will surface may include:

(a) Select a through-hardening steel which will meet or exceed core hardness in
the hot-rolled condition, then heat-treating to gain the additional 86 points of
Brinell hardness by bath-quenching, then tempering, then generating the teeth in
the blank.

(b) Flame or induction hardening are possibilities.

(c) The hardness goal for the case is sufficiently modest that carburizing and case
hardening may be too costly. In this case the material selection will be different.

(d)The initial step in a nitriding process brings the core hardness to 33–38
Rockwell C-scale (about 300–350 Brinell), which is too much.
________________________________________________________________________

15-12 Computer programs will vary.

________________________________________________________________________

15-13 A design program would ask the user to make the a priori decisions, as indicated
in Sec. 15-5, p. 806, of the text. The decision set can be organized as follows:

A priori decisions:
• Function: H, K o , rpm, m G , temp., N L , R
• Design factor: n d (S F = n d , S H  nd )
• Tooth system: Involute, Straight Teeth, Crowning,  n
• Straddling: K mb
• Tooth count: N P (N G = m G N P )

Design decisions:
• Pitch and Face: P d , F
• Quality number: Q v
• Pinion hardness: (H B ) 1 , (H B ) 3
• Gear hardness: (H B ) 2 , (H B ) 4

First, gather all of the equations one needs, then arrange them before coding. Find
the required hardnesses, express the consequences of the chosen hardnesses, and
allow for revisions as appropriate.

Chapter 15, Page 15/20

 Pinion Bending Gear Bending Pinion Wear Gear Wear
1/ 2
 W t K o K vCsC xc 
Load-induced
st 
W t PK o K v K m K s
 s11 st 
W t PK o K v K m K s
 s21 c  Cp    s12
 Fd P I  s 22 = s 12
stress (Allowable FK x J P FK x J G
stress)
Tabulated s11S F KT K R s21S F KT K R s12 S H KT CR s22 S H KT CR
( sat ) P  ( sat )G  (sac ) P  ( sac )G 
strength (K L )P ( K L )G (CL ) P (CH ) P (CL )G (CH )G
 (sat ) P  2100  (sat )G  2100  (sac ) P  23 620  (sac ) P  23 620
Associated  44  44  341  341
Bhn   Bhn   Bhn   Bhn  
hardness  (sat ) P  5980  (sat )G  5980  (sac ) P  29 560  (sac ) P  29 560
 48  48  363.6  363.6
Chosen
(H B ) 11 (H B ) 21 (H B ) 12 (H B ) 22
hardness
New tabulated 44( H B )11  2100  44( H B ) 21  2100 341( H B )12  23 620 341( H B ) 22  23 620
(sat1) P   (sat1)G   (sac1) P   (sac1)G  
strength  48( H B )11  5980  48( H B ) 21  5980 363.6( H B )12  29 560 363.6( H B )22  29 560

2 2
Factor of (s ) ( K ) (s ) ( K )  (s ) (C ) (C )   (s ) (C ) (C ) 
n11  all  at1 P L P n21  at1 G L G n12   ac1 P L P H P  n22   ac1 G L G H G 
safety  s11KT K R s21KT K R  s12 KT CR   s22 KT CR 

Note: S F  nd , S H  SF

Chapter 15, Page 16/20

15-14 N W = 1, N G = 56, P t = 8 teeth/in, d = 1.5 in, H o = 1hp,  n = 20, t a = 70F,
K a = 1.25, n d = 1, F e = 2 in, A = 850 in2

(a) m G = N G /N W = 56, d G = N G /P t = 56/8 = 7.0 in

p x = / 8 = 0.3927 in, C = 1.5 + 7 = 8.5 in

Eq. (15-39): a = p x / = 0.3927 / = 0.125 in

Eq. (15-40): b = 0.3683 p x = 0.1446 in

Eq. (15-41): h t = 0.6866 p x = 0.2696 in

Eq. (15-42): d o = 1.5 + 2(0.125) = 1.75 in

Eq. (15-43): d r = 3 – 2(0.1446) = 2.711 in

Eq. (15-44): D t = 7 + 2(0.125) = 7.25 in

Eq. (15-45): D r = 7 – 2(0.1446) = 6.711 in

Eq. (15-46): c = 0.1446 – 0.125 = 0.0196 in

Eq. (15-47): ( FW ) max  2 2  7  0.125   2.646 in

VW   (1.5)(1725 /12)  677.4 ft/min
 (7)(1725 / 56)
VG   56.45 ft/min
12
Eq. (13-27): L  px NW  0.3927 in
 0.3927 
Eq. (13-28):   tan 1    4.764
o

  (1.5) 
Pt 8
Pn    8.028
cos  cos 4.764

pn   0.3913 in
Pn
 (1.5)(1725)
Eq. (15-62): Vs   679.8 ft/min
12 cos 4.764

(b)
Eq. (15-38): f  0.103exp  0.110(679.8) 0.450   0.012  0.0250

Eq. (15-54):
cos n  f tan  cos 20  0.0250 tan 4.764
e   0.7563 Ans.
cos n  f cot  cos 20  0.0250 cot 4.764

Chapter 15, Page 17/20

 33 000nd H o K a 33 000(1)(1)(1.25)
Eq. (15-58): WGt    966 lbf Ans.
VG e 56.45(0.7563)
cos n sin   f cos 
Eq. (15-57): WWt  WGt
cos n cos   f sin 
 cos 20 sin 4.764  0.025cos 4.764 
 966  
 cos 20 cos 4.764  0.025sin 4.764 
 106.4 lbf Ans.

(c)
Eq. (15-33): C s = 1190 – 477 log 7.0 = 787

Eq. (15-36): Cm  0.0107 562  56(56)  5145  0.767

Eq. (15-37): Cv  0.659 exp[0.0011(679.8)]  0.312

Eq. (15-38): (Wt) all = 787(7)0.8(2)(0.767)(0.312) = 1787 lbf

Since WGt  (W t )all , the mesh will survive at least 25 000 h.

0.025(966)
Eq. (15-61): Wf   29.5 lbf
0.025sin 4.764  cos 20 cos 4.764
29.5(679.8)
Eq. (15-63): Hf   0.608 hp
33 000
106.4(677.4)
HW   2.18 hp
33 000
966(56.45)
HG   1.65 hp
33 000

The mesh is sufficient Ans.

Pn  Pt / cos   8 / cos 4.764o  8.028

pn   / 8.028  0.3913 in
966
G   39 500 psi
0.3913(0.5)(0.125)

The stress is high. At the rated horsepower,

1
G  39 500  23 940 psi acceptable
1.65

(d)

Chapter 15, Page 18/20

 Eq. (15-52): A min = 43.2(8.5)1.7 = 1642 in2 < 1700 in2

Eq. (15-49): H loss = 33 000(1 – 0.7563)(2.18) = 17 530 ft · lbf/min

Assuming a fan exists on the worm shaft,

1725
Eq. (15-50):  CR   0.13  0.568 ft · lbf/(min · in 2 · oF)
3939
17 530
Eq. (15-51): ts  70   88.2o F Ans.
0.568(1700)
________________________________________________________________________

Chapter 15, Page 19/20

15-15 Problem statement values of 25 hp, 1125 rev/min, m G = 10, K a = 1.25, n d = 1.1,
 n = 20°, t a = 70°F are not referenced in the table. The first four parameters listed
in the table were selected as design decisions.

15-15 15-16 15-17 15-18 15-19 15-20 15-21 15-22

px 1.75 1.75 1.75 1.75 1.75 1.75 1.75 1.75
dW 3.60 3.60 3.60 3.60 3.60 4.10 3.60 3.60
FG 2.40 1.68 1.43 1.69 2.40 2.25 2.4 2.4
A 2000 2000 2000 2000 2000 2000 2500 2600
FAN FAN
HW 38.2 38.2 38.2 38.2 38.2 38.0 41.2 41.2
HG 36.2 36.2 36.2 36.2 36.2 36.1 37.7 37.7
Hf 1.87 1.47 1.97 1.97 1.97 1.85 3.59 3.59
NW 3 3 3 3 3 3 3 3
NG 30 30 30 30 30 30 30 30
KW 125 80 50 115 185
Cs 607 854 1000
Cm 0.759 0.759 0.759
Cv 0.236 0.236 0.236
VG 492 492 492 492 492 563 492 492
WGt 2430 2430 2430 2430 2430 2120 2524 2524
t
W W 1189 1189 1189 1189 1189 1038 1284 1284
f 0.0193 0.0193 0.0193 0.0193 0.0193 0.0183 0.034 0.034
e 0.948 0.948 0.948 0.948 0.948 0.951 0.913 0.913
(P t ) G 1.795 1.795 1.795 1.795 1.795 1.571 1.795 1.795
Pn 1.979 1.979 1.979 1.979 1.979 1.732 1.979 1.979
C-to-C 10.156 10.156 10.156 10.156 10.156 11.6 10.156 10.156
ts 177 177 177 177 177 171 179.6 179.6
L 5.25 5.25 5.25 5.25 5.25 6.0 5.25 5.25
 24.9 24.9 24.9 24.9 24.9 24.98 24.9 24.9
G 5103 7290 8565 7247 5103 4158 5301 5301
dG 16.71 16.71 16.71 16.71 16.71 19.099 16.7 16.71

Chapter 15, Page 20/20