Anup Goel - Spur Gear

Design of Machine
Elements-I|
Fundamentals and Applications)
Anup goEl
Technical Publications
DESIGN OF MACHINE ELEMENTS - II
First Edition : January 2021
@ Copyright with Author

All publishing rights (printed and ebook version) reserved with Technical Publications. No part of this book
should be reproduced in any torm, Electronic, Mechanical, Photocopy or any intormation storage and
retrieval system without prior permission in writing, from Technical Publications, Pune.
Published by :
TERHNIRA Amit Residency, Office No. 1,412, Shoniwar Peth, Pune- 411030, M.S. INDIA
TEGHNIGAL Ph.: +91-020-24495496/97, Email : sales@technicalpublications.org
PUBLICATTONS Website: www.technicalpublications.org
An Up-Thruaf or Knowiedge
ISBN 978-93-332-2180-1
JU
(ii)
Copyriglod matoral
TABLE OF CONTENTS
1.11.4 Face Width.. 19
Unit I: Spur Gears 1-
1.12 Wear Strength of Spur Gear Tooth. .. . 1-20
1-20
Chapter 1 Spur Gears (1-1) to (1 70) 1.12.1 Load-Stress Factor.
1.13 Effective Load on Spur Gear Tooth.. 1-22

1.1 Introduction. 1-2
1.2 Advantages and Disadvantages of Gear Drive. 1-2
1.13.1 Maximum Tangential
Force.. 1-22
1.13.2 Dynamic Load on Gear Tooth... 1-23
1.3 Classification of Gears . -5 1.14 Methods of Estimation of Dynamic 1-23
Load..
1.3.1 Parallel Shaft Axes Gears 1-3
1.14.1 Preliminary Estimation of Dynamic Load by
1.3.2Intersecting Shaft Axes Gears... ... 1-4
1.3.3 Non-intersecting and Perpendicular Shaft Axes
Velocity Factor. . . 25
Gears * 1.14.2 Precise Estimation of Dynamic Load by

Buckingham's Equation.. . 1-24
1.3.4 Non-intersecting and Non-perpendicular Shaft
Safety of Gear
AxesGears. . -4 1.15
Pair.. 26
Selection of Types of Gears..
1.4 IP 1.16 List of Formulae. ***************
-26
1.5 Terminology of Spur Gears... 1-6 1.17 Solved Examples.
1.6 Minimum Number of Teeth to Avoid 1.18 Gear Lubrication. .. 064
..
Interterence. -8 1.18.1 Types of Lubricants used in Gears.. 1-64
1.7 Standard Tooth Profile. . 1-9
1.7.1
1.7.2
Angle.. .
Advantages and Limitations of Smaller Pressure
Advantages and Limitations of Larger Pressure

1 10
1.18.2 Heat Dissipation..
1.19 Construction of Spur Gear Blank.

****** I-
1-65
05
Angie ... . 1-10

1.20 University Questions with Answers. 168
1.7.3 Addendum Modification in Gears 1-10 Unit II : Helical and Bevel Gears
1.8 Force Analysis of Spur Gears.. -11
1.9 Gear Tooth Failure. ****** **
** -13 Chapter 2 Helical Gears (2-1) to (2-40)
1.9.1 Bending Failure (Breakage of Tooth). 1- 13 2.1 Introduction ******** * .2-2
1.9.2 Wear Failure (Surface Destruction). 1- 13 2.1.1 Herringbone Gears..
1.10 Gear Materials 15
1- 2.2 Terminology for Helical Gear.... 2-3
1.10.1 Types of Gear Materials.. ***
-15 2.3 Virtual Number of Teth on Equivalent Spur
1.11 Beam Strength of Spur Gear Tooth. 1-17 Uear *******ss*n**s*ss******sore:
2.4 Minimum Number of Teeth on Helical Pinion 2-7
1.11.1 Lewis Equation for Beam Strength of Spur Gear
2.5 Force Analysis of Helical Gears.. 2-8
1.11.2 Lewis Form Factor.. .. T-18 2.5.I Relation between Transverse and Normal
Pressure Angle... 2-10
1.11.3 Permissible Bending Stress. .. 1- 19
2.6 Beam Strength of Helical Gear Tooth . 2-10
Copyightod matorial
UNIT 1
1
Spur Gears
Syilabus
Introduction to gears : Gear Selection, material selection, Basic modes of tooth failure, Gear Lubrication Methods
Spur Gears: Number of teeth and face width, Force analysis, Beam strength (Lewis) equation, Velocity factor, Service factor,
Load concentration factor, Efective load on gear, Wear strength (Buckingham s) equation, Estimation of module based on beam
and wear strength, Estimation of dhynamic tootih load by velocity factor and Buckingham's equation..
Contents 1.10 Gear Materials. 1-15

1.1 Introduction 1 -2 1.11 Beam Strength of Spur Gear Tooth. . 1-17
Dec.-12, 15, May-10, Marks 6
1.2 Advantages and Disadvantages of Gear Drive
1.12 Wear Strength of Spur Gear Tooth . 1-20
Dec.-12, Marks 4
1.3 Classification of Gears. ***
1
-3
1.13 Effective Load on Spur Gear Tooth.. . 1-22
1.4 Selection of Types of Gears. 1-5 April-16, May-15, April-15, Marks 4
1.5 Terminology of Spur Gears. . 1-b 1.14 Methods of Estimation of Dynamic Load... 1-23
Dec.-10 May-16, Marks 6
1.6 Minimum Number of Teeth to

Avoid Interference.
1.15 Safety of Gear Pair... 1-26
T-8
Dec-10, Marks 2 1.16 List of Formulae ... 1-265
1.7 Standard Tooth Profile. .. .. 1-9
. 1.17 Solved Examples. .
1- 28
Dec.-10, 15, May-14, Marks 6
1.18Gear Lubrication . 1 64
1.8 Force Analysis of Spur Gears Dec.-09, Dec.-10, Marks 3
Aprml-l7, Marks 3
1.19Construction of Spur Gear Blank.. . 1-65
1.9 Gear Tooth Failure. . . 1-13
Dec.-09, 16, May-12, 16, April-17, Marks 6 1.20 University Questions with Answers. 1 68
(1-1)
yg0 haten
Design of Machine Elements- II
1-2 Spur Gears
1.1 Introduction
Gear drive is a positive drive and it is provided when the distance between the driver and follower is very
small.
.Gears are defined as toothed wheels which can transmit power and motion from one shaft to another shaft by
means of successive engagement of teeth.
It is important to note that, both the gears which are engaged, always rotate in opposite direction.
.The gear drive consists of two wheels. The small wheel is called as pinion and larger wheel is called as gear.
1.2 Advantages and Disadvantages of Gear Drive
Advantages
Gear drive is a positive drive (no slipping) and it transmits exact velocity ratio.
It can transmit large power with low velocity.
It has high efficiency.
It is compact in SIZe.
It is more reliable than other drives.
It can be used to transmit power between two shaft which are parallel, intersecting or non-parallel and
non-intersecting
It can be used for changing the speed ratio over a wide range.
Disadvantages
As special tools or cutters are required for manufacturing of gears, the manufacturing cost of gear is high.
The manufacturing process of gears is also complicated.
It requires precise alignment of shafts.
It requires lubrication system for smooth operation and long life of gear teeth.
Gears
Non-intersecting and Non-intersecting and

Parallel shaft Intersecting shaft
axes gearss axes gears perpendicular shaft Non-perpendicular shaft
axes gears axes gears
Spur gears Bevel gears Worm gears Spiral geas

2Helical gears
3. Herringbone gears
4. Rack and pinion
5. Internal gears
Fig. 1.1: Types of gears

1-3 SpurGears
1.3 Classification of Gears

The gears or toothed wheel are generally classified as per the position of axes of the two shafts between which the m
otion is to be transmitted. They are grouped as follows
1. Parallel shaft axes gears

2. Intersccting shait axes gears
Non-intersecting and perpendicular shaft axes gears
Non-intersecting and non-perpendicular shaft axes gears
1.3.1 Paralel Shaft Axes Gears

For the transmitting the motion, two parallel shatts are connected by following types of gears
a) Spur gears b) Helical gears c) Herringbone gears

|d) Rack and pinion e) Internal gears
a) Spur gears
Spur pinion
Spur gears are used to transmit motion between two
parallel axes shafts. Refer Fig. 1.2.
They are the simplest of all the gears and easiest in
production.
The teeth of spur gears are cut along the periphery and
parallel to the axis of gear. Spur
b) Helical gears
Helical gears are similar to spur gears but its teeth are Fig. 1.2: Spur gears
cut at an angle with the axis of rotation of the gear. Left hand pinion
Refer Fig. 1.3.
Helical gears can transmit motion from one shaft
another shaft which are parallel to each other.
The helix angles of gear and pinion are same in
magnitude but of different hands. For example, right
hand pinion meshes with left hand gear.
Right hand gear
c) Herringbone gears
Herringbone gears looks like two single helical Fig. 13: Helical gears
gears, one right hand and other left hand, placed Herningbone
pinion
side by side. Refer Fig. 1.4. Let Right
nand hand
These gears reduces the end thrust acting on the
thrust bearings.
These gears are used to transmit motion from one
shaft to another shaft which are parallel to each
other.
Herringbone gears are also called as double helical Right- Let
nand hand
gears. Herringbone
9ear
Fig. 1.4: Herringbone gears
opyrightod materinl
Design of Machine Elements- I1 1-4 Spur Gears
d) Rack and pinion

Rack is a straight gear which has no curvature and it
represents a gear of infinite radius. Refer Fig. 1.5.
Rack gears may have either straight or helical teeth.
During the operation, a rack gear meshes with a pinion
and converts rotary motion of pinion into reciprocating
motion of rack or reverse.
Bevel- Bevel
pinion gear
AA - Pinion
Fig. 1.7: Bevel gears

Rack
The teeth of bevel gears are cut so that they radiate from
Fig. 1.5: Rack and pinion the apex of a cone and lie on the conical surface.
e) Internal gears
Generally bevel gears are used when two shafts are at
All the above gears carry teeth on their peripheries or
right angle to each other; but it can be used for any
external surfaces.
desired shaft angle.
But, internal gears have teeth on their inner surface Bevel gears are available with straight, helical and spiral
which may be spur, helical, ete. Refer Fig. 1.6. teeth.
It is important to note that, in internal gears both the
wheels rotate in the same direction. 1.3.3 Non-intersecting and Perpendicular Shaft
Axes Gears
Internal
gear For transmitting the motion between two non-intersecting
FTtA and perpendicular shafts, worm and worm gears are
External used.
pinion
In worm and worm gears, worm is more or less similar
to serew having single or multiple start threads which
HE
forms the teeth of the wom. Refer Fig. 1.8.
Refer Fig. 1.8 on next page.
.Worm gear is a helical gear with concave face to
AnA accommodate a portion of worm periphery.

This wom drives a worm gear or worm wheel while
transmitting the motion.
Fig. 1.6: nternal gears
1.3.2 Intersecting Shaft Axes Gears 1.3.4 Non-intersecting

Shaft Axes Gears
and Non-perpendicular
For transmitting the motion between two intersecting For transmitting the motion between two non-intersecting
shafts or shafts at desired angle, bevel gears are and non-perpendicular shafts, spiral gears are commonly
commonly used. used.
The surface of the bevel gear is like a frustrum of a cone Spiral gears are also called as skew gears or crossed
and its size decreases towards the apex of cone. Refer helical gears.
Fig. 1.7.
Coyrghtod matona
Design of Machine Elements- l 1-5 Spur Gears
Right hand When the axes of shafts are perpendicular and

worm gear
non-intersecting, worm gears are used.
If the axes of the two shafts are neither perpendicular

nor intersecting, erossed helical gears are used.
(ii) Speed reduction
Right hand
The speed reduction or velocity ratio for a single pair
Worm of spur or helical gears is generally 6:1 and in some
cases it can be raised upto 10:1
But when the velocity ratio inereases, the size of gear
increases which results in increase in the size of
gearbox and cost of the material. For high speed
Fig. 1.8: Worm and worm gears reduction, two stage or three stage ypes of gearbox are
In these gears, pure rolling contact is not possible. These used.
gears have a line contact, the rotation of which about the For a pair of bevel gears the normal velocity ratio is
axes generates the two pitch surfaces called as 1:1 which can be increased upto 3:1 under a particular
hyperboloids.
condition.
As the velocity ratio of worm gears is 60:1, it is the
best choice for high speed reduetion. This velocity ratio
can be increased upto 100:1, therefore worm gears are
widely used in material handling equipments.
(ii) Power to be transmitted and input speed

In case of spur gears, for high speed applications, due
to sudden contact over the entire face width between
two meshing teeth large noise is generated. But, in
Fig. 1.9: Hyperboloid gear helical gears, the contact between the two meshing
teeth starts with a point and it extends along the tooth.
1.4 Selection of Types of Gears
This results in quiet operation.
The first step in the design of the gear drive is the Therefore, helical gears are commonly used for high
selection of an appropriate type of gear for a given speed power transmission.
application.
Worm gears produces low noise and vibration than any
The factors that are to be considered while selecting the
other type of gear drives.
type of gear are as follows:
(iv) Efficiency
i) Layout of shafts ii) Speed reduction
ii1) Power to be transmitted
The etficiency of a pair of spur or helical gear is in
iv) Input specd
v) Efficiency vi) Cost between 95 to 99 % whereas, for bevel gears it is 94
to 98 % but for worm gears it is 45 to 95 %.
(i) Layout of shafts The efficiency of worm gear drive reduces with
When the axes of two shalts are parallel, spur, helical increase in velocity ratio.
or herringbone gears are used. But, if the shaft axes (v) Cost
intersect at right angle then straight bevel gears or From the cost point of view, spur gears are less costly
spiral bevel gears are used. than the other types of gears because they are easy to
thted malorial
Design of Machine Elements- II 1-6 Spur Gears
2. Pitch Circle Diameter (PCD): It is the diameterof

manufacture and various methods can be used to
produce them. the pitch circle. Generally, the size of gear is specified by
the PCD. It is denoted by d.
The manufacturing of helical, bevel and worm gears
require special arrangement, hence these gears are more 3. Pitch surface: It is the surface of the rolling disc
costly. which the toothed gear has replaced at the pitch cirele.
4. Pitch point: It is the point of contact or the point of

1.5 Terminology of Spur Gears SPPU: Dec.-10 tangency between the two pitch circles of the mating
The basic terminology or basic terms used in gears are as gears.
follows (Refer Fig. 1.10):
It is the ratio of the PCD in mm to the
5. Module:
1. Pitch circle: It an imaginary circle on gear which number of teeth of gear. It is denoted by m.
by pure rolling action would produce the same motion as Mathematically,nm
PCD of gear mm
the actual gear.
No. oftecth on gear
.. (1.1)
Addendum circle.
Top land
Face width
Pitch surface element
Working depth
OK
F1a
Addendum
Dedendum Pitch circle
depth Tooth space Root or
Total dedendum
Circie
Clearance Circular ptch Tooth

thickness
Clearance or
Working depth circle
a)
Addendum
Dedendum
Gear
Pinion Pitch point
(b)
Fig. 1.10: Terminology used in gears

Design of Machine Elements- I1 1-7 Geas
Spur
12. Dedendum circle: It is the circle drawn through the
The module specifies the size of the gear tooth. As the
module increases, the size of the gear tooth also increases. bottom of the gear teeth. It is concentric with the pitch
standard values of module recommended by ISO (in circle. It is also called as root circle. Diameter of
mm) are given in Table 1.1. The module given under first dedendum circle is given by,
choice is always preferred but in some cases it is not Dedendum circle diameter = PCD -2x Dedendum... (1.5)
possible, at that time second choice can be used.
Table 1.1:Standard values of module 13. Clearance: It is the radial height difference between
the addendum and dedendum of a teeth. The standard
First choice 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12,
16, 20, 25 mm, etc. teeth clearance value is 0.157 m. It is denoted by CL and
given as,
Second choice 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 45,
S.5, 7, 9, 1, 14, 18, 22, 28 mm, etc. CL hr-h, (1.6)
6.Circular pitch: It is the distance measured along the 14. Total depth: It is the radial distance between the
circumference of the pitch circle from a point on one addendum and dedendum of a gear. Also, it is equal to the
tooth to the corresponding point on the next tooth. sum of addendum and dedendum.
Generally, it is denoted by, Pe Total depth = Addendum + Dedendum
Ttd m
It is given by, Pe
zTm (1.2) 15. Working depth: lt is the radial distance between the
addendum circle to the clearance cirele.
7. Diametral pitch: It is the ratio of number of teeth on 16. Tooth thickness: It is the thickness or width of the
gear to the PCD in mm. It is denoted by pd
tooth measured along the pitch circle.
It is given by, pa = m- Pc
m-2(03) 17. Tooth space: It is the gap or width
of space
between the two adjacent teeth measured along pitch
8. Pressure angle : It is the angle between the common circle.
normal drawn at the point of contact of the mating gears 18. Face of the tooth: It is the part of the tooth surface
and the common tangent at the pitch point. It 1s also which is above the pitch surface.
called as angle of obliquity and denoted by The
19. Flank of the tooth: It is the part of the tooth surface
standard values of pressure angles are 14.5° and 20.
which is below the pitch surface.
9. Addendum: It is the radial distance of a gear tooth
from the pitch circle to the top of the gear tooth. It is also
20. Top land: It is the surface of the top of the tooth.
defined as the radial height of the gear tooth above the 21. Face width: It is the width of the gear tooth
pitch circle. It is generally denoted by ha measured parallel to its axis. It is denoted by b.
10. Addendum circle : It is the circle drawn through the 22. Fillet radius It is the
radius which connects the root
top of the gear teeth. It is concentric with the pitch circle. circle to the profile of the tooth.
Diameter of addendum circle is given by, 23. Backlash: It is the difference between the tooth
Addendum circle diameter PCD + 2x Addendum space and the tooth thickness which is measured along the
pitch circle. Theoretically, it should be zero but practically
(1.4)
some backlash must be allowed to prevent jamming of the
11. Dedendum: It is the radial distance of a gear tooth leeth due to tooth errors and thermal expansion during the
from the pitch circle to the bottom of the gear tooth. It is manufacturing
also defined as the radial depth of the gear tooth below
the pitch circle. It is generally denoted by hp.
Design of Machine Elements- 11 1-8 Spur Gears
24. Speed ratio or velocity ratio or gear ratio (G):
r Pitch circle radius of pinion in mm
Speed ratio or gear ratio is defined as the ratio of pinion
speed to the gear speed. It is also defined as the ratio of m-Zp
number of teeth on gear to the number of teeth on pinion
or it is the ratio of diameter of gear to the diameter of m Module in mm
pinion.
Lel, nG and np Gear and pinion speeds in rpm
dg and dp = Diameter of gear and pinion in mm
Zg and Zp = Number of teeth on gear and pinion

Pitch circle
Gear ratio or speed ratio= "P =da Zg
Zp .(1.7)
of pinion
ngdp
25. Centre distance : It is the distance between the axes Pitch line
of the two mating gears. It is given by, f rack
C.D. = p *uG _mZp t m ZG

Fig. 1.11 : Interference in rack and pinion
m(Zp + ZG) Pressure angle

C.D. (1.8)
ha Addendum of meshing rack in mm
=m(ZptGZp)
C.D.
G 2 As the rack is a part of toothed wheel of infinite
diameter, its base circle diameter and profiles of the
involute teeth are straight lines.
C.D. = p (1+ G)
(1.9)
These straight profiles are tangential to the pinion
profiles at the piont of contact, hence they are
1.6 Interference
Minimum Number of Teeth to Avoid
SPPU: Dec.-10
perpendicular to the tangent PF. The point F is the
interference point.
The mating of two non-involute or non-conjugate tooth Addendum for rack is given by,
profiles is called as interference.
h BH = PB.sin
All standard system prefers the involute profile for gear
tooth because of the following reasons
ha (OP-sin )-sin o(PB = OP-sino)
Involute profile satisfies the fundamental law of
gearing.
ha OP.sin o = r.sin o
o All involute gears of a given module and pressure
angle are interchangeable.
.OP r=mp
The basic rack of an involute profile has straight m-Z
sides which comparatively easy to machine. a sin0
If there is a slight change in centre distance due to
incorrect mounting then it has no effect on the shape 2 a
m-sin oo
.(1.10)
of involute. Also, the pitch point is fixed and the
law of gearing is satisfied hence the velocity ratio
remains constant.
o Fig. 1.11 shows a rack and pinion in mesh.
Let, Zp = Number of teeth on pinion
Design of Machine Elements -11 1-9 Spur Gears
1.7 Standard Tooth Profile SPPO: Dec.-10

The following four types of tooth profiles have been standardised for interchangeability.
Each of the four systems has gear teeth which are conjugate to a basic rack.
i) 14.5° composite system:
The sides of the basic rack are made up of circular arc at the top and bottom whereas straight line in the
middle portion. Refer Fig. 1.12.
i) 14.5 composite system ii) 14.5 full depth involute system
111) 20° full depth involute system 1v) 20 stub involute system
The circular arc portion represents cycloidal section whereas straight portion represents involute section.
i) 14.5 ful depth involute system

In this system, the basic rack is composed of straight sides except for the fillet arcs. Refer Fig. 1.13.
14.50
m
14.50
m
Tm
1 m
1m
1.157 m 1.157 m
Radius-
Fig. 1.12: 14.5° Composite system Fig. 1.13 14.5° Full depth involute system
The whole profile represents involute profile but they have an interference problem hence generally they are
not used.
This type of tooth system gives good result for large number of teeth on the gear wheel.
ii) 20° ful depth involute system
In this system, the basic rack is similar to 14.5° system, except for the pressure angle. Refer Fig. 1.14.
This tooth system is best suited for small tooth number gears. Also, this system is the best of the four
ypes.
iv) 20° stub involute
In this tooth system, the interference problem is minimitsed by removing the extra addendum of tooth which
causes interference. Refer Fig. 1.15.
200
0.8 m
---
2 m 1 m
1.157 m
Radius
Fig. 1.14: 20" Full depth involute system Fig. 1.15: 20° Stub involute system
Design of Machine Elements - 11 1-10 Spur Gears
.This modified tooth profile is called as stub involute profile which is suitable for heavy loads.
1.7.1 Advantages and Limitations of Smaller Pressure Angle SPPU : May-14

Advantages:
Radial or separating force is low.
High contact ratio due to which operation is silent.
It gives good result for large number of teeth.

Limitations:
To avoid interference, relatively large number of teeth are required.
High bending stresses and contact stresses.
1.7.2 Advantages and Limitations of Larger Pressure Angle

Advantages
To avoid interference, lesser number of teeth are required.
Due to large tooth thickness at the base, bending stresses are low.
Due to larger radius of curvature, contact stresses are also low.
Limitations :
Radial or separating force is high.

Contact ratio is low, hence operation is noisy.
1.7.3 Addendum Modification in Gears SPPU: Dec.-15

If the length of action EF is within the points of tangency A and B, then there is no interference.
But, if the length of path of contact EF is larger than AB, then interference will occur, Refer Fig. 1.16 (a)
see Fig. 1.16 (a) on next page).
The main reason of interference is that, the addendum circle of the gear crosses the point of tangency at A i.e.
the point E crosses the line AB.
Now, the addendum of the pinion is enlarged until the addendum circle of pinion passes through the point of
tangency i.e. B. Refer Fig. 1.16 (6)
(see Fig. 1.16 (6) on next page).
To retain the same full depth, dedendum of the pinion is reduced by the same amount as that the addendum is
increased.
At the same time, he addendum of gear is reduced and dedendum of gear is increased for suitable arrangement.
Due to this, the length of path of contact EF is within the points of tangeney.
In this way, by modifying the addendum of pinion and gear, interference and undercutting is avoided.
It is important to note that, in this method there is no change in the pitch circles, pressure angle and centre
distance.
Design of Machine Elements- II 1-11 pur Gears
Gear Dedendum circle
Dedendum
Base circle
circle
gear Pitch
Addendum
of gear
Addendum circle
Addendum circle
Pitch circle
Base circle
Addendum-
O Dedendum circle
Dedendumm.
Pinion
(a) Gears with interference
Gea
Increasedaddendum- Dedendum circle
Reduced dedendum Base circle
Pitch circle
Addendum circle
Addendum circle
Pitch circle
-Base circle
Dedendum circle
Increasedaddendum O
Reduced dedendum Pinion
(b) Gears without interference
Fig. 1.16 : Modified addendum of pinion and wheel
1.8 Force Analysis of Spur Gears SPPU: April-17
In case of gears, power is transmitted by means of a force exerted by the tooth of the driving gear on the
meshing tooth of the driven gea.
According to the law of gearing, the resultant force F always act along the pressure line. Refer Fig. 1.17 (a).
The resultant forceF acting on the driving and driven gear are same in magnitude but opposite in direction.
Refer Fig. 1.17 (6).
The resultant force F can be resolved into two components:
1. Tangential component (F) 2. Radial component (F
Copyrightod matonia
1-12 Spur Gears
Pinion
riving)
-Pitch point
Gear
(Driven)
a)
Pinion Pinion
(Driving) (Driving)
--
Gear Gear
(Driven) (Driven) j
b) (C)
Fig. 1.17: Force analysis of spur gears

1. Tangential component (F)
2t npTp
The tangential force (F) is a usetul component of 60 Tp Te
resultant force F and it is responsible for the Tdpnp
transmission of torque or power. 60
It is always tangent to the pitch circle at pitch point.

I aways opposes the rotation of driving gear and P-60(L12)
assists the rotation f driven gear. (2 T ngle
The magnitude of tangential force is given by, 60 To G (1.15)
TtdGhG TG
Tdp np TdgnG 60
60 Where, P= Power to be transmitted in W
.(1.11) ng and np Gear and pinion speed in rpm
Design of Machine Elements II 1-13 Spur Gears
dg and dP = Diameter of gear and pinion in m This failure can be avoided by adjusting the parameters
TG and rp Radius of gear and pinion in m such as module and face width in the gear design, so
that the beam strength of gear tooth is more than the
TG and Tp Torque acting on gear and pinion in N-m
total repetitive load.
V = Pitch line velocity in m/sec.
1.9.2 Wear Failure (Surface Destruction)
2. Radial component (F)
Wear or surface destruction is a phenomenon which
The radial force always tends to separate the two gears. removes the complete layer of the surface or it make
lt acts along the radial line through the pitch point craters or seratches on the surface.
and directed towards the centre. Wear failure is classified on the basis of their primary
From
F F tan ,
Fig. 1.17 (¢), it is given by,
N (1.14)
causes. The principal types of gear tooth wear are as
follows:
where, Pressure angle 1

Pitting
(a) Initial pitting (b) Destructive pitting
Resultant force (F) 2. Scoring
The resultant force on the gear tooth is given by,
3. Abrasive wear
F- +F (1.15) 4. Corrosive wear
F .(1.16) 1. Pitting
cos Sin o
Pitting is a surface fatigue failure due to repetitive
contact stresses.
1.9 Gear Tooth Failure
SPPU: Dec.09, 16, May-12, 16, April-17 The pitting can be divided into twO groups i.e.
The various modes of gear tooth failures are classificd in
(a) Initial pitting (b) Destructive pitting
two basic categories (Refer Fig. 1.18):
Refer Fig. 1.18 on next page. (a) Initial pitting
To avoid gear tooth failure, the gear designer should The initial or corrective pitting is a localised
have a sufficient knowledge of possible causes of gear phenomenon which 1S characterised by small pits at
tooth failure and corresponding remedies. high spots.
These high spots are progressively worn out and the
1.2. Bending failure or breakage of tooth
Wear failure or surface destruction load is redistributed.
The causes of initial pitting are the errors in tooth
1.9.1 Bending Failure (Breakage of Tooth) profile, surtace irregularities and misalignment of gears.
Every gear tooth acts like a cantilever beam which is The initial pitting can be minimized by the precise
subjected to a repetitive bending stress. Due to this machining of gears, adjusting the correct alignment of
stress, the gear tooth may break. gears so that the load is uniformly distributed across
The continuous repetition of bending stress (of varying the face width and by reducing the dynamic loads
magnitude) leads to fatigue which may results in crackk
(b) Destructive pitting
and hence the gear tooth breaks away.
It is a second phase of pitting. It is the surface fatigue
f the total repetitive load (sum of static load and dynamic failure due to repetitive contact stresses.
load) on the gear tooth is greater than the
It occurs when the load on the gear tooth exceeds the
beam strength of gear tooth, then the gear tooth will fail in
bending surface endurance strength of the material. It means,
the destructive piting starts when the total load (sum
hted maleral
Design of Machine Elements -l 1-14 Spur Gears
Gear tooth failure
ending tailure or Wear failure or

Breakage of tooth surface destruction
Pitting Scoring Abrasive wear Corrosive wear
Destructive
Initialpiting
pitting
Fig. 1.18 : Modes of gear tooth failure
of static load and dynamic load) acting on the gear Due to this, there is rapid alternate welding and tearing
tooth exceeds the wear strength of the tooth. at high spots which is called as stick-slip
This type of failure is characterised by pits which phenomenon. In this case rate of wear is faster.
continue to grow resulting in complete destruction of Scoring can be avoided by selecting the parameters like
tooth surface. surface pressure, surface specd and the quantity and
It depends upon the magnitude of Hertz contact stress, quality of lubricant in such a way that the resulting
surface endurance strength and the number of cycles. temperature at the contact surfaces is within the
Destructive pitting begins a a micro-crack on the permissible limits.
surface of gear and progressively develops into a big .The bulk temperature of gearbox can be minimised by
pit on the surface. providing tins on the outer surface of gearbox and
This failure can be minimised by increasing the surface fan for forced circulation of air over the fins surfäce.
hardness of the gears. 3. Abrasive wear
Another type of surface fatigue failure is spalling, in It a damage or surtace injury caused by the particles
is
which due to sub-surface stresses the crack starts below trapped between the mating teeth surfaces.
the gear tooth surface. This crack makes the surface The foreign particles in the lubricant like dirt, rust,
weak and ultimately leads to the surface failure. weld spatter or metallic debris enter between the tooth
2. Scoring surface and damage the form of tooth.
Scoring or galling or scuffing is a lubrication failure. This type of failure can be avoided by providing oil
Insufficient lubrication along with excessive surface ilters, using high viscosity oils and by increasing the
pressure and high surface speed results in the surface hardness of gear.
breakdown of oil film. Due to thick film of oil, the fine particles can pass
This results in excessive frictional heat and overheating easily without scratching the gear surface.
of the meshing teeth.
Copyrighled ritalett
Design of Machine Elements - II 1-15 Spur Gears
4. Corrosive wear 1. Cast iron

It is caused by the corrosive elements like extreme The gears of large size and complicated shape are
pressure additives present in lubricants and foreign generally made of cast iron.
materials due to extermal contamination. The different types of cast iron used for the
These elements attack the tooth surface which results manufacturing of gears are gray cast iron, malleable cast
in fine wear iron, nodular cast iron, ete.
of entire surface.
This type of failure can be avoided by providing the Advantages of cast iron as gear material
complete enclosure for the gears free from external They can be cast into complicated shapes.
contamination, selecting proper additives and by They have excellent machinability.
replacing the lubricant at regular intervals. They can provide good damping capacity and high
compressive strength
1.10 Gear Materials They have high hardness, high resistance to wear and
One of the important factor for the satisfactory abrasion.
performance of gear pair is, the material of gears and Cast iron is the cheapest amongst all the commercial
their heat treatment. alloys.
The material used for the manufacturing of gears depend Disadvantages of cast iron as gear material
upon the strength and service conditions like noise, wear,
They are brittle and their mechanical properties like
etc.
toughness, stiffness, etc. are poor.
Desirable properties of gear material They have low bending strength.
The desirable properties of gear material are as follows: The mechanical properties of different grades of cast iron
When the gear tooth is subjected to fluctuating loads, the are given in the following Table 1.2:
endurance strength of the tooth is important factor. The Table 1.2 : Mechanical properties of different grades of
cast iron
gear material should have sufficient endurance strength
to avoid failure due to bending
Ultimate tensile.
Types of cast Hardness
The gear material should have suficient surface Sr. strength (Su) in Brinell
No. iron number (BHN)
endurance strength to avoid failure due to destructive N /mm2
pitting.
For high speed power transmission, the sliding velocities I. Gray cast iron
are very high. At that time, the gear material should4 (a) FG 200 200 180 225
have low coefficient of friction to avoid failure due to
Scoring. (6) FG 260 260 200 - 240
The amount of thermal distortion or warping during the (C) FG 350 350 205- 240
heat treatment process is a major problem in gears.
2. Malleable cast iron
Hence, the gear material should have low and consistent
thermal distortion during the heat treatment. (a) MCI A 360-420 Maximum 150
1.10.1 Types of Gear Materials (b) MCI B 320-350 Maximum 150
The different materials used for the manufacturing of gears

3. Nodular cast iron (Spheroidal graphite cast iron)
are as follows
(a) SG 600 600 190 260
1. Cast iron 2. Steel 3. Non-ferrous metal (b) SG 700 700 230 300
4. Sintered metal 5. Non-metal
(c) SG 800 800 240 350
Design of Machine Elements -
I 1-16 Spur Gears
2. Steel 3. Non-ferrous metals

There are various types of stecls used for the The non-ferrous metals like copper, aluminium, zinc,
manufacturing of gears which ranges from low carbon tin, manganese, etc. are used in different combinations
steel to high carbon steel and plain carbon steel to as gear materials.
alloy steel. The most commonly used alloy is bronze. The different
Advantages of steel as gear material types of bronzes are used as gear materials because
They have high bending strength and surface strength. they have ability to withstand heavy sliding loads as in
They are ductile, hence their mechanical properties like case of worm gears.
toughness, stitfness, etc. are very good. Advantages of bronze as gear material
They have higher load carrying capacity. It has low coefficient of friction.
Disadvantages of steel as gear material It has excellent conformability.
They generate more noise. It has good resistance to corTosion and wear.
They provide poor damping property. It has ability to cast into complicated shapes.
During heat treatment, they are subjected to thermal Disadvantages of bronze as gear material
distortion or warping It is very costly.
They are expensive. lt has low strength as compared to steels.
A
good combination of gear pair is, a steel pinion and a
4. Sintered metals
cast iron gear. The mechanical properties of the plain and
Now-a-days the sintered iron gears made by powder
alloy steels used as gear materials are given in the
metallurgical processes are used as low cost gears
following Table 1.3 :
Table 1.3: Mechanical properties of different vhere strength is not a prime criteria.
types of steel These gears are used in toys, washing machines, food
mixers, etc. These gears are easy to lubricate and they
Ultimate
Brinell have good resistance to wear.
tensile
ype ot
Heat-treatment strength Hardness
NO steel Number Generally, the base materials for sintered gears are iron
(Sut)
(BHN) or copper powder.
N mm
5. Non-metals
40C8 Hardened and 580 218
Tempered
Non-metallic gears are used under the following
conditions 2
45C8 Hardened and 630 230 o When the load is light and pitch line velocity is
tempered low.
. 55C8 Hardened and 720 265 o When a long life of gears is expected.
tempered o When the operation is free from noise and
50C4 Hardened and 660 240 vibrations.
tempered OWhen the gears are likely to be affected by water
and oil.
40Crl Hardened and 700 200 250
Tempered In case of non-metallie gear drives, only
1
pinion 1S
made of non-metals like molded nylon, laminated

6. 30Ni4Crl Hardened and 1500 Minimum
tempered 450 phenolics (bakelite or celoron), etc.
The non-metallic pinion run with cast iron gears.
7. 40Ni3Cr65 Hardened and 1000 280 350
MoSS tempered Non-metallic gears do not have sufticient strength,
hence they are used for light duty applications.
1.11 Beam Strength of Spur Gear Tooth At a time, only one pair of teeth is in contact and
SPPU: Dec.-12, 15 the full load is acting at the tip of a single tooth.
Beam strength of gear tooth is defined as the maximum
tangential load the gear tooth can take without failure. |1.11.1 Lewis Equation for Beam Strength of Spur
Gear Tooth
The analysis of bending stresses in gear tooth was done The gear tooth is considered as cantilever beam as shown
by Wilfred Lewis in 1892. Today also, the Lewis in Fig. 1.19 (b).
cquation is considered as the basic cquation in the design
It is observed that the cross-section of the tooth varies
of gears.
from the firee end to the fixed end. Hence, a parabola is
In the Lewis analysis, the gear tooth is treated as a constructed within the tooth profile and shown by dotted
cantilever beam as shown in Fig. 1.19. line in Fig. 1.19 (a).
The main advantage of parabolic outline is that, it is a
lensile beam of uniform strength and the stress at any
Stress cross-section is uniform.
The normal force F acting at the tip of gear tooth is
resolved into two components
Tee 1. Radial component of force (F,)
Compressive C end
stress Fixed 2. Tangential component of force (F)
end (a)
i) Radial force (F)

This component induces a direct compressive stress of
relatively small amount and hence its effect is
neglected.
i) Tangential force (F)

This component induces a bending stress which tends
to break the tooth.
Let M = Maximum bending moment at section
BC in N-mm F 1
F Tangential force acting on gear tooth in N
T= Length of gear tooth in mm
(b) I = Area moment of inertia of tooth section BC
Fig. 1.19 : Gear tooth acting as cantilever beam about the neutral axis in mm" bt12
The Lewis equation is based on the following
b Face width of gear tooth in mm
assumptions
The effect of radial component (F, ) of force which t Thickness of gear tooth at section BC
produces compressive stresses IS neglected. n mm
The tangential component (F) of force is uniformly
The maximum bending stress at point B is,
distributed over the face width of the gear. (lt is
x 1)x (/2)
possible when the gears are rigid and accurately
machined). Ob
M-y F (bts/12)
The effect of stress concentration is neglected.
Design of Machine Elements- II 1-18 SpurGears
Table 1.4: Values of Lewis form factor (Y)
6F
bt
Number of teeth 14.5 full depth 20° full depth
involute involute
bt67
0.2545 0.2890
Now, multiplying and dividing the numerator and 16 0.2592 0.2953

denominator of right-hand side by 'm',
17 0.2639 0.3016
Obox
61 m O bm 6/m
18 0.2702 0.3079
19 0.2765 0.3142
F =Ob bmY (11)
20 0.2827 0.3204
where, Y Lewis form tactor
6/m 21 0.2890 0.3267
In the above equation (i), as angential force (F) is 22 0.2922 0.3299

increased, the bending stress O also increases
23 0.2953 0.3330
When the bending stress reaches its limiting value, the
corresponding tangential force is called as beam 24 0.2985 0.3362
strength.
25 0.3047 0.3393
It means, the beam strength is the maximum value of
tangential force that the gear tooth can transmit without 26 0.3079 0.3456
bending failure. Hence, replacing F by Fb in

27 0.3110 0.3487
equation (ii) we get,
28 0.3142 0.3519
b bb m- Y (1.17)
30 0.3173 0.3581
Where, Fb = Beam strength of gear tooth in N
34 0.3267 0.3707
Ob Permissible bending stress in N/mm*
38 0.3330 0.3833
m = Module of tooth in mm
43 0.3393 0.3958
Y Lewis form factor
The above equation (1.17) is called as Lewis equation for 50 0.3456 0.4084
beam strength of spur gear tooth. 60 0.3550 0.4210
1.11.2 Lewis Form Factor 75 0.3613 0.4335

The Lewis form factor (Y) is the function of gear tooth
100 0.3676 0.4461
shape, number of teeth on gear and the point of
application of load. 150 0.3738 0.4587
The values of Lewis form factor (Y) for 14.5° and 20° 300 0.3833 0.4712
full depth involute system are given in the following
Table 1.4 Rack 0.3895 0.4838
When the table for Lewis fornmfactor is not available

then use the following standard relations
Design of Machine Elements-11 1-1 Spur Gears
= 2.642
Y 0.55 for 20 stub system
Z
2.865
Y = 0.484 for 20° full depth involute system (1.18)
Z
Y =
0.39- for 14.5° full depth involute system
1.11.3 Permissible Bending Stress SPPU: May-10

The gear tooth subjected to fluctuating or repeated bending stress as it comes in contact with the meshing tooth.
The permissible bending stress or bending endurance strength for gear or pinion is given by,
K K Ke Ka- K K, S
b K Kp Ke Ka Ke Kg x 0.5 Sut (Se = 0.5 Su)
For gears, K, Kp* Ke* Ka Ke Kg0.666

Gb0.666 x 0.5 Sut 0.333 Sut
. ut (1.19)
Where e Endurance limit of specimen in N/mm
Sut Ultimate tensile strength of gear material in Nmm
1.11.4 Face Width
While designing the gears, it is necessary to express the face width in terms of module of gears.
If the face width of gear is to0 small, the module and hence the diameter of gear will increase.
Similary, if the face width is too large, then there is possibility of non-uniform distribution of load across the
face width of gear tooth. Due to this, there is misalignment or deflection of gears occur.
.Generally, the face width is taken as 9 times to 15 times of module i.e.
m bs 15 m
9 (1.20)
Note
While designing a gear pair, it is necessary to find the weaker member between the gear and pinion
in bending
The Lewis equation of beam strength for gear or pinion is,

F m Y
b
But, the values of 'b and 'm' are same for gear and pinion. Hence, the product of (b X Y) decides
the weaker member between the gear and pinion in bending.
If the products of (Gh X Y) pinion ( X Y) gear then the gear is weaker in bending. If the
product of (G, Y pinion <
X (
X Ygear then the pinion is weaker in bending.
In some applications, the gear and pinion are made of same material, then 'o,' is same for both of
them. At that time Y (Lewis form factor) is a deciding parameter. In such cases, pinion is always
weaker, because Ypinion
is always less than Ygear
Copyrghtod matoria
Design of Machine Elements - I1 1-20 Spur Gears
1.12 Wear Strength of Spur Gear Tooth

SPPU : Dec.-12
Wear strength of gear tooth is defined as he maximum tangential load the gear toolh can take without piting
failure.
It is already discussed that, pitting is a surface fatigue failure characterised by small pits on the surface of gear
tooth.
The analysis of wear strength was done by Earle Buckingham in 1926 which is based on Hertz theory of
contact stresses.
When two cylinders (Curved surtaces) are pressed against each other, the point or line contact changes to area
contact and the stress developed in the contact zone is called as Hertz contact stress.
In case of a gear pair, when the tangential force (F) is increased, the contact stress (e) also increases.
.When the contact stress reaches its limiting value, the corresponding tangential stress in called as wear
strength.
The wear strength of spur gear tooth is,
b:Q .
F dp K (1.21)
where, Fw Wear strength of gear tooth in N
dp PCD of pinion in mm
b Face width of tooth in mm
Q Ratio factor for gear pair
For external gear pair, z 2Z6

+Z (1.22)
For internal gear paut, 2Lo (1.23)

Za Zp
K Load-stress factor in N mm
osinor cos o (-4)(1-4

1.2732 Ep EG
Pressure angle
Hp and HG Poisson's ratio for pinion and gear material
Ep and EG Modulus of elasticity for pinion and gear material in mm
The equation (1.21) is called as Buckingham's equation for wear strength of gear tooth.
1.12.1 Load-Stress Factor

Load-stress factor (K) is given by,
K- sin o- cos o(4)(1- (1.24)

1.2732 Ep EG
Copyrighted materin
Design ot Machine Elements- I Spur Gears
The surface endurance strength (o.) can be expressed in terms of Brinell Hardness Number (BHN) as,
2.6487 BHN (1)
The equation for load-stress factor for different pinion and gear material combinations with 20" pressure angle
are as follows
1. Steel gear and steel pinion

In this case, p HG 0.292
and Ep = EG = 206 x 10 N/mm (11)
Substituting the value of equation (1) and (1i) in equation (1.24),
K
(2.6487 BHN x sin (20)x cos (20) [1- (0.292) i. [1- (0.292) 1
1.2732 206 x 10 206 x 103
.(0= 20°)
BHN)
K = 0.1572
100
BHN
K 0.10 100 mm .(1.25)
2. Cast iron gear and cast iron pinion

In this case, Hp HG 0.211
and Ep = EG = 160 x 10 Nmm (11)
Substituting the values of equation (1) and (1ii) in equation (1.24),
K
(2.6487 BHN x sin (20)x cos (20) J[- (0.211)-1 [1- (0.211) 1
1.2732 160x 103 160 x 10
K 0.211 1BHN aBHN Nmm (1.26)

100
3. Cast iron gear and steel pinion

In this case, Hp0.292, G 0.211
and Ep 206 x 10 Nmm, EG = 160 x 10 N/mm (1v)
Substituting the values of equation () and (iv) in equation (1.24)

(2.6487 BHN) x sin (20) x cos (20)[1-(0.292)1 [1- (0.211)]|
1.2732 206 x 10 160x103
K 0.184100
0.184 = 0.18
100 mm (1.27)
Design of Machine Elements- II 1-22 pur Gears
1.13 Effective Load on Spur Gear Tooth Table 1.5: Different values of application or service
factor
SPPU: April-16
Effective load on spur gear tooth is defined as the total Driven machine
maximum tangential load (force) acting on the gear Prime-mover
tooth. No. (Driving machine) Oderate Heavy
Uniform
shock shock
The theoretical tangential force acting on the gear tooth
for power transmission is, Electric motor, steam 1.00 1.25 1.75
Power P= F X V
or gas turbine
Multi-cylinder 1.C. 1.25 1.50 2.00

engine
of (i)
Single cylinder 1.C. L.5 1.75 2.25
engine
O
(27npTp /60)(27nG Ta/60)
(T dp np/60) (T dG nG/60) The type of load for various applications are given in the
following Table 1.6:
Tp Table 1.6: Type of load for various applications
F (ii)
dp/2) dG/2
Sr. No. 1ype of load Driven machines
1.13.1 Maximum Tangential Force
From the above equation (ii) it is clear that, the Uniform Conveyors, generators, Iight
elevators, electric hoist,
theoretical tangential force depends upon the rated power
ventilators, blowers, mixers,
or torque and rated speed. erc.
But in actual practice, the tangential force or torque

2 Moderate shock Machine tool, heavy elevators,
fluctuates due to running of prime mover and driven feed pump, multi-cylinder
piston pump, mine ventilators,
machine. Also the distribution of load may not be
uniform across the face width.
3. Heavy shock Press machine, shear machine,
This fluctuation in torque and non-uniform distribution of rolling mil, heavy feed pump,
load across the face width are accounted by service crushers, compressors, ete,
factor or application factor (K,) and load distribution

factor or load concentration factor (Km) respectively. Load Distribution Factor or Load Concentration Factor
(Kn)
Therefore, the maximum value of tangential force on the .This factor accounts for the non-uniform distribution of
gear tooth isgiven by, load across the face width.
P
Ft max Ka Km F = K, Km * The non-uniform distribution of load depend on the
tollowing tactors
From equation (i)]. (1.28) Accuracy of gear tooth manufacturing
Accuracy of gear alignment
Service factor or Application Factor (Ka)
This factor accounts for increase in tangential force due Accuracy of bearing mounting and bearing
clearances, etc.
to the fluctuation in torque developed by the prime
mover
The different values of load distribution factor for
different conditions are given in the following Table 1.7
This factor depends upon the prime mover and the driven
machine. This factor is also called as overload factor
.The different values of application factor for different
applicationsare as follows
Design of Machine Elements - 11 1-23 Spur Gears
Table 1.7 : Values of load distribution factor
Face width in mm
Sr. No. Support conditions
Upto 50 Upto 150 Upto 220
. Precision gears, accurate mountings, small bearing clearances. 1.2 1.3 1.4
2 Less accurate gears, less rigid mountings. 1.5 1.6 1.7
Accuracy and mounting is less than the full face. 2.1 2.2 2.3
1.13.2 Dynamic Load on Gear Tooth

SPPU: April-15, May-15
Practically the gear teeth are never perfect. The error in tooth spacing, inaccuracies in tooth profilee and the
deflection of the tooth under the load results in transmission error.
This transmission error results in the cyclic fluctuation of speed ratio.
The application factor (Ka) and load distribution factor (Km does not account the inertia forces arising due to
the tooth errors.
While meshing each tooth undergoes for a short period of acceleration and retardation which combines with the
mass of the pinion and gear and results in inertia forces.
These forces arising due to inertia effects are called as dynamic loads.
In addition to other factors, the dynamic load mainly depends on the tooth error and pitch line velocity
1.14 Methods of Estimation of Dynamic Load

SPPU: May-16
There are two basic methods which are commonly used for the estimation of dynamic load :
. Preliminary estimation by velocity factor.

2. Precise estimation by Buckingham's equation.
1.14.1 Preliminary Estimation of Dynamic Load by

Velocity Factor
In the preliminary stages of gear design the dimensions of gear are unknown, so it is difficult to estimate the
dynamic load.
Therefore dynamic load is accounted by multiplying a factor which is called as velocity factor (Ky).
This factor depends on the pitch line velocity and accuracy of gear tooth. The different values of velocity factor
are given in the following Table 1.8 :
Table 1.8: Velocity factor for spur gear
Allowable pitch line

LS. Grades Accuracy level Method of manufacturing velocity Velocity factor (Ky)
(V in m/sec.)
Very low (E) V <110

12 Gears are made with form
Cutters. 3+ V
and 11 Low(D) Gears are made by V<20 6

hobbing or shaping. 6+V
Copyrighted mRtenial
8 and 9 Medium (C) Gears are made by fine 20 V s25 3.6

hobbing. 3.6 + V
30 5.6
6 and 7
Medium High Gears are finished by
shaving and lapping
25Vs 5.6 + V
4 and 5 High Gears are finished by 30 5.6
shaving and fine grinding. V5.6 + V
,2 and 3 Ultra high Gears are finished by fine 40 S V SI50 0.8 to 0.95
grinding and honing.
The velocity factor is an empirical relationship developed by past experience.

.The first equation of velocity factor was developed by Carl Barth, hence it is also called as Barth factor.
The effective load between the two meshing teeth in tangential direction is,
Km E
Feff t max Ka
. (1.29)
Feff Kam. V
(1.30)
Ky
Depending on the accuracy of gear tooth, Indian Standard (1.S.) has classified the gears into twelve different
grades from
I to 12 in decreasing order of precision.
.Table 1.8 gives the manufacturing methods and allowable pitch line velocities for different grades of gears.
Note: In some exanmple, Ky is also denoted by Cy.
1.14.2 Precise Estimation of Dynamic Load by Buckingham's Equation
In the final stages of gear design, when the dimensions of gear are known and errors are specitied, the dynamic
load can be more accurately found as an incremental load by using Earle Buckingham's equation of dynamic
load.
The Buckingham's cquation for the dynamic load in tangential direction is,
21 V (bC+ Fmax)
Fa (1.31)
21 V+bC + t max
where. Dynamic load in N
Pitch line velocity in m/sec.
C Deformation factor in N/mm
b Face width of tooth in mm
Ft max Maximum tangential force in N K, Km F

The deformation factor or dynamic factor depends upon the modulus of elasticity of pinion and gear
materials and the form of tooth (pressure angle). It is given by,
rmaterial
C K.e - KeE+E .(1.32)
where, Ep and EG Modulus of elasticity of pinion and gear material in N mm*

Sum of errors between two meshing teeth in mm
K Tooth form factor
0.107 for 14.5° full depth involute system
0.111 for 20° full depth involute system
= 0.115 for 20" stub tooth involute system
The incremental dynamic load (a) calculated by equation (1.31) is always more than the load calculated by the
velocity factor method.
In this case, the effective load between two meshing teeth is,
For Fmax + Fa = K, Kn F +Fa . (1.33)

The expression for deformation factor (C) can be simplified for various gear and pinion material with 20°
pressure angle as follows
() Steel gear and steel pinion
In this case, Ep = EG = 206 x 10 Nmm and K =0.111
Substituting these values in equation (1.32)
206 x 10 x 206 x 10
C 0.11l xe 11433 e
206 x 10+206 x 10
C 11500 e N/mm . (1.34)
(i) Cast iron gear and cast iron pinion

In this case, Ep EG =
160 x 10 Nmm and K = 0.111
Substituting these values in equation (1.32),
160 x 10x 160 x

C 0.111x 10=8880 e
160x 103+ 160 x 10
C 8900 e N/mm (1.35)

(ii) Case iron gear and steel pinion
In this case,
EG = 160x 10° Nmm, Ep = 206 x 10 Nmm and K = 0.111
Substituting these values in equation (1.32),
206 x 10 x 160 X
C = 0.111 x 10=9996.065 e
206 x 10+160 x 103
Copyrignted material
Design of Machine Elements -
1-20 Spur Gears
=
C 10000 e N/mm (1.36) 1. Safety against bending failure.
2Satety against wear failure.
Pitch error between meshing teeth
The sum of pitch errors between two meshing teeth is
given by, 1. Safety against bending failure
(1.37) In order to avoid the failure of gear tooth due to
ep G mm
bending or tooth breakage, the beam strength (Fb) must
where, Cp Ptch error tor pinion in mm
be greater than the effective load (Fer) between the
CG Pitch error for gear in mm meshing teeth. It means,
lt depends upon the quality of gear, sIze of gear and the FFet
method of manufacturing. The expected error on the gear
Introducing factor of safety,
or pinion teeth is considered to be equal to tolerance.
Fb FOS x Fer (1.39)
The tolerances for adjacent pitch error (e) for various I.S.
grades are given in the following table: where, FOS Factor of safety
Table 1.9: Tolerances for adjacent pitch error
2. Safety against wear failure
I.S. grades Pitch error in microns (e) In order to avoid the failure of gear tooth due to
12 5
pitting or wear, the wear strength (Fw) must be greater
han the efiective load (Fetr) between the meshing
11 45+ 3.55
teeth. It means,
10 32+2.5
w Feff
22+ 1.8 Introducing factor of safety,
16 + 1.25
F FOSx Fefr (1.40)
11 +0.9 0 where, FOS Factor of safety
8+ 0.63
5+04 0
1.16 List of Formulae
3.2+0.25
1. Module : m =, mm
2+0.160
2. Circular pitch: Pe = Tt-m mn
1.25+0.1
0.8 + 0.06 3. Diametral pitch
Pdm d
G)
where, Op Tolerance factor = m + 0.25 vd 4. Centre distance: C.D= "p +dGm2p (l+ mm
2
(1.38)
5. Gear ratio G 0Zp = dG =
p
Module in mm P G
d = Pitch circle diameter in mm 6. Minimum number of teeth on pnion to avoid

interference:
1.15 Safety of Gear Pair
na
min Zp =
In order to avoid the failure of gear tooth it must be safe m Sin
against the following:
7. Addendum : ha Im , mm
opyronio0 matenal
Design of Machine Elements- II Spur Gears
8. Dedendum :
h = 1.25 m , mm
9. Pitch line velocity:
V -Tdp np t dG "G m/sec.

60 60
10. Forces acting on spur gcar tooth
Ip TG N
V(dp/2) (dG/2)
= F tano, N
=
F
F+ F?
COs Sino
N
I1. Beam strength of spur gear tooth :
Fb
bb m- Y N
, mm
9m s b sI5 m, mm
=
Y 0.55 -
For 20° stub system
= 2.865
Y 0.484 For 20 full depth involute system
2.148
Y = 0.39- For 14.5° full depth involute system
Z
If (Gb X Y)p > (GbX YG then gear is weaker in bending
If (o, X Y)p (b X Y)G then pinion is weaker in bending

12. Wear strength of spur gear tooth
Fwdpb Q.K, N
22G external gear pair
ZgFor
2
internal gear pair
7For
QZG-Zp
K sincos (-4), (1-
1.2732 Ep EG
BHN
K 0.10100 mm For steel gear and steel pinion with o= 20
K N mm For cast iron gear and cast iron pinion with= 20

0.2100
100
Opyrigtod malanal
Design of Machine Elements -II 28
Spur Gears
For cast iron gear and steel pinion with

K
0.1800Nmm
100
20
13. Maximum tangential force
max
F K* Km F = Ka Km N
14. Preliminary estimation of effective (dynamic) load :
Feft
FtmaxKa *Km ,N
Ky
15. Precise estimation of effective load
Fetr-Fmax + Fa = Ka Km F + Fa. N
21 V (bC + Ftmax N
Fa Buckingham's equation
21 V+bC + F max
C
Ke Ep + EGNmm
C 11500 e, N/mm For steel gear and steel pinion with o = 20°
C 8900 e, Nmm For cast iron gear and cast iron pinion with o= 20°
C = 10000 e, N/mm For cast iron gear and steel pinion with o = 20°
16. Pitch error: e ep eG mm
17. Safety of gear pair
b FOS x Feff For safety against bending failure
Fw FOSx Feft For safety against pitting failure
1.17 Solved Examples

Ex. 1.1: A spur pinion having 22 teeth is to mesh wih a gear having 48 mumber
of teeth. Both the pinion and gear are
made up of steel having ultimate tensile strength of 600 MPa and 300 MPa respectively. The pinion is connected to 7.5 kW,
1440 rpm three phase induction motor. The siarting torque of motor is 50 % greater than the rated torque. f the surface
hardness of the gear pair is 350 BHN, design a gear pair with factor of safety 2. Assume face widh is ten times the
module and velocity factor accounts for the dynamic load is given by, K,
6+ V
Sol.: Given data :
Zp 22, ZG = 48, (S ut )p = 600 MPa, (St )G = 330 MPa, P 7.5 kW =7.5 x 10 W,
np 1440 rpm, K, = l.5, BHN = 350, FOS = 2, b= 10 m, Assume Km =1, Ky V

6+
To find Design a gear pair.
Step 1 Check whether gear is weaker or pinion is weaker

Design of Machine Elements- II 1-29 Spur Cears
We know that, GbP

Sut p.= -200 MPa
As Fb < Fw» gear pair is weaker in bending. Hence, itis
3 required to design a gear pair against the bending failure
and bG ut 3 G =
300
100 MPa Step 4: Calculate the effective load on gear pair
Km
Feff = (V)
Assuming 20° full-depth involute system, K
0.484 2.865 = p np TX 22 m x 1440

p
Zp
Bul V 60 60
p 0.484 2.862 - 0.3537 V =1.658 mx 10 mm/sec.

=
1.658 m, m/scC.
Similarly, YG 0.484 .865
4.80
ZG
F 7.5 x 4523.5225.N
2.862 1.658 m
YG 0.484 - 0.4243
48
Now, bP Yp= 200 x 0,3537- 70.74 MPa

6+V 6+ 1.658 m
= 100 x 0.4243 42.43 MPa Ka 15 and Km =I (Given)

and bGYG
As ObG YG < Obp Yp, gear is weaker than the pinion in Substituting all these values in cquation (iv)
bending. Therefore, it 1s required to design a gear for 1
1.5x 4523.5223
bending. Feff
m
6+ 1.658 m
Step 2: Calculate the beam strength of gear
Fb bG bm. YG 1130.8805 (6 + 1.658 m)
FefT
m
100 x 10 m x mx 0.4243
6785.283 + 1875 m
Fb = 424.3 m, N . (1)
FeT
m
()
Step 3: Calculate the wear strength of gear pair Step 5: Calculate the value of module and other
Fw dp b Q K . (ii) dimensions
For safety against bending failure,
But, dp m Zp 22 m, mm
2 F FOS x Fett
Zg
ZG 2X*221.3714
+Zp48+ 1.3714 =
Substituting the values of equation (i) and (v).

For steel pinion and steel gear, + m]
350)2 424.3 m2= 2x 875.283 1875
BHN) 0.16/ m
K 0.16 100
=
100
212.15 m = 6875.283 + 1875 m
K 1.96 N/mm
Solving the above cubic equation, we get
and b= 10 m, mm
m= 4.0933 mm
Substituting all these values in equation (1i),
(Neglecting negative values)
F 22 mx 10 m x 1.3714 x 1.96
From Table 1.1, the standard value of module under first
Fw 591.3476 m, N . (ii) choice is 5 mm.
m 5 mm .A Ans.
Other dimensions Sol.: Given data :
b 10 m = 10x 5= 50 mm Zp 720 N/ mm, (Sut NV mms,

= 21, (Sut )p = G = 580
dp m Zp = 5x 22- 110 mm P 22 kW 22x 10 W.
dG m Zg = 5 x 48= 240 mm =
np = 1000 rpm, ng 300 rpm, FOS = 1.5, Ka 2,
C. D.
dp +
2
dG t = 175 mm Km 1.3, b= 10 m, o= 20°,
(BHN)G =400, (BHN)P =450

=1x 5=
h m 5 mm
I
To find: Design a gear pair.

hr 1.25 m = 1.25x 5= 6.25 mm
Step 1: Check whether gear is weaker or pinion is
Ans.
weaker
Ex. 1.2: A spur pinion having 21 teeth to be made of
plain carbon steel 55C8 (S = 720 N/mmn) is to mesh
We know that, bP Sut
with a gear to be made of plain carbon steel 40C8
(Su580 Nimm). 1The gear pair is required to transmit 720240
3
N mm
22 kW p0wer from an electric motor running af 1000
rp.m. to a machine runming at 300 rp.m. The factor of and ur G
safet required is 1.5. The application factor and load
distribution factor are 2.0 and 1.5 respectively. The face
580= 193.333 N mm
width is ten times the module and tooth system is 20 3
full-depth involute. The gear pair is machined to meet the
specifications of grade 6. The gear and pinion are to be
case hardened to 400 BHN and 450 BHN respectively.
But, Gear ratio G
ZG
nG
Design the gear pair by using the velocity factor and 1000
Buckinghanm's equation for dynamic load. G ZG 70
300 21
Use the following data:
Lewis form factor is,
Velocity factor, K, =
ULewis form Jactor,
2.87
Y = 0.484 - 2.87 0484 Zp
= 0.48
21
Load stress factor, K = 0.16 [BHN/1007 Ninm = 0.3473 (Given)
For grade 6, e = 8.0 + 0.63 [m + 0.25 Vd] um.
Deformation factor, C = 0.111 e N/mm. and YG 0.484 -287 0.484
87
70 0.443
Ep +Eg
Modulus of elasticity for gear, Eg = 207 * 10 N/mm. Now, ObP Yp 240x 0.3473 = 83.352 N/mm
Modulus of elasticity for pinion, Ep= 207 x 10' N/mm
and, BG YG 193.333 x 0.443 85.6465 N/mm
Buckingham's equation for dynamic load in tangential
direction As ObP Yp <ObG YG. pinion is weaker than the gear in
Fa 21V(bC+FrmaxN. bending. Therefore, it is required to design a pinion for

21V+bC+Ftmax bending.
Standard modules (mm): 1, 1.25, 1.5, 2.0, 2.5, 3.0. 4.0,
Step -2: Caleulate the beam strength of pinion
5.0, 6.0, 8.0, 10.0, 12.0 and 16.0.
SPPU: May:06, Dec.-07, Marks 17
F bP b m. Yp
240 x 10 mx mx 0.3473
F 833.52 m, N ()
Copyrighted material
Step 3: Calculate the wear strength of gear pair Step 5: Caleulate the value of module and other
F dp b Q K dimensions
For safety against pitting failure,
But, dp m Zp 21 m, mm (11)
F FOSx Fe
Q 2ZG 2x70=1.5384 Substituting the values of cquation (ii) and (v),
Zg+ Zp 21
70 +
60.027 x 10 + 11 x 10 m
827.0438 m = 1.5 x
BHN
D m
K = 0.16 (Given)
100
551.3625 m = 60.027x 10 + 11x 10 m
Considering smaller value of BHN.
K
=
0.16
100 = 2.56 N/mm
m= 6.1388 mm
Selecting standard value of module from the given data,
and b 10 mn
Substituting all these values in equation (1i), m 8 mm Ans.
F 21 mx 10mx 1.5384 x 2.56 Other dimensions
Fw 827.0438 m, N ii)
b 10 m = 10 x 8 = 80 mm
dp m-Zp = 8 x 21 =
168 mm
As <Fb gear pair is weaker in pitting. Hence, it is
Fw
dG
m
ZG = 8 x 70 = 560 mm
required to design a gear pair against the pitting failure.
Step 4: Calculate the effective load on gear pair C.D. = p t dg 168 + 560
364 mm
2 2
Fef (iv) 1x 8 =8 mm
haI m =
hr 1.25m = 1.25x 8 = 10 mm Ans.

Bul, V = p p TX 21 mx 1000
60 60 Step 6: Calculate the dynamic load by using
V = 1.0995 mx 10 mm/sec. Buckingham's equation
Buckingham's equation for dynamic load is,
= 1.0995 m, m/sec.
21 V(bC + F max
x (Given).. (V1)
22
V 1.0995 m
10 20.009 x
m
10
N fa21 V +bC+
Fmax
But, V= 1.0995 m = 1.0995 x8 = 8.796 m/see

Kv 1.0995 m
(Given)
6+ V 6+
b =
80 mm
and Km .. (Given)
Ka
2 1.5
20.009x 103 20.009x 103
F m 8
Substituting all these values in equation (iv),
103 N
Feff X1.5 20.009x 10
m
= 2.5011x
6
F max KaKm
6+ 1.0995 m
= 2x 1.5 x 2.5011 x 103
10.0045 x 10 (6+ 1.0995 m)
Feff
m - 7.5033 x 10 ,N
60.027x 10 + 11x 10 m Now, pitch error for grade 6,
Feff
m
.. ()
e 8+0.63 [m +0.25 Vd] (Given)
Design of Machine Elements- 11
1-32 Spur Gears
For pinion, ep 8 +0.63 [m +0.25 Jdp]
ep 8+ 0.63 [8 + 0.25 V168] = 15.0814 um
For gear, CG 8+ 0.63 [m +0.25 dG]
CG 8+0.63 [8 +0.25 V560]=16.7671 um
But eCp +eG = 15.0814+ 16.7671
31.8485um 31.8485 x 10 mm
Deformation factor,C
=
0.111 el Ep EG (Given)
|Ep +EGJ
C = 0.111x 31.8485x 10-3207x

10" x 207x 103
207x 10 +207x 10
C 365. 8914 N/mm
Substituting all these values in equation (vi),
Fa 21x 8.796 (80x 365.8914 +7.5033x 10

21x 8.796 +80x 365.8914+ 7.5033x 103
Fa 18.0429x 103 N
Step 7: Calculate the available factor of safety

Effective load for precise estimation is,
Feff F max +Fa=7.5033x I10 + 18.0429 x 103
Feft25.5462x 10' N
As gear pair is weaker in pitting,
Fw FOS x Fef
827.0438 x (8)
FOS
FFw 25.5462 x 103
FOS 2.0719> 1.5 Ans.

As the available factor of safety of gear pair is higher than tihe required factor of safety, the design of gear pair
safe.
Note: favailable factor of safety is less than the required factor of safety (design is not safe). then
the design is modified by increasing the module to the next standard value and it is checked again for
safetyby precise estimation of dynamic load.
Copynighted rmaterial
Design of Machine Elements- I 1-33 Spur Gears
Ex. 13: The following data refers to a steel spur gear 10

5x
F 11.3097 442.0983 N
pair transmitting 5 kW power from an 1.C.engine running
at 3000 rp.m. to a machine running at 1500 r.p.m.
Module = 4 mm, Number of pinion teeth = 18. NoW, t max Ka *Km *F = Ix 1x 442.0983
Ultimate tensile strength for gear and pinion material =
630 N/mm.
Ft max 442.0983 N
Face width = 10 * module,
Surface hardness=400 BHN. (Assuming, Ka =Km)
Tooth system= 20° full-depth involute,
Dynamic load is given by,
Deformation factor, C = 171 N/mm.
Assuming the dynanmic load is accounted by the 21 V
(bC+tmax) (Given)
Buckingham's equation, calculate: 21 V+bC+ Ftmax
i) Factor of safety against wear failure: and
i) Factor of safety against bending failure.
Use following data Fa -21x 11.3097 (40x 171171+ 442.0983
+
87 21x 11.3097+V40x 442.0983
Lewis form factor, Y = 0.484- Load stress factor,
K 0.16 [BHN/100} N/mmt 5.3572x 10 N

Buckingham's equatiom for dynamic load tangential
direction 21V(bC+FrmaxN. Substituting all these values in equation (i),
Td
21V +
bC +Frmax Fefr 442.0983 +5.3572 x 10
SPPU: May-06, Marks 8, Dec.-15, May-16, Marks 6
5.7992 x 10 N
Sol.: Given data :
P 5 kW 5x 10 W, np =
3000 rpm, ng = 1500 rpm, Step 2: Calculate the beam strength and wear
strength of gear pair
m =4 mm, Zp = 18,
When pinion and gear are made of same material, at that
(Sur )p =(ut )a =630 N/mm time pinion is weaker than the gear in bending. Hence, it
is necessary to find beam strength of pinion.
b 10 m =10x 4=40 mm, BHN = 400, o= 20,
C 171 N/mm Beam strength for pinion is,
To find: i) (FOS) wear n (FOS)sending Fb bP b-m- Yp (ii)
Step 1: Calculate the effective load on gear pair

Effective load for precise estimation is, But, bP -uP630 = 210 N mm
Feff Fmax + Fa
N Tdpnp TTmZpnp
b 40 mm, m=4 mm
Bul
60 60
... (: dp =m-Zp) and Yp = 0.484 0.484 2.8

p 18
TX 4X 18x 3000
V
60
= 0.3245 .(Given)
11.3097x 10 mm/see (11),
Substituting all these values in equation
V 11.3097 m/sec
Fb 210x 40x 4x 0.3245
10.9032x 105 N Ex. 1.4:A spur gear pair is to be used to transmit

20 kW power Jrom an electric motor running a
Wear strength is given by, 1440 r.p.m. to the machine tool expected to run exactly at
600 r.p.m. The pinion and gear are to be made of alloy
F dp-b-Q K . (iin)
steel (Sur 800 N/mm) and plain carbon steel
(S 700 N/mm) respectively. The service factor and
But, dp mZp = 4x 18 72 mm Jactor of safety are 1.5 and 1.35 respectively, The Jace
width is 12 times module Jor which load distribution
b = 40 mm
Jactor is 1.4. The tooth system is 20" full-depth involute.
The gears are to be machined to meet the specifications
G The pinion and gear are to be case hardened
7.
Z nG of grade
to 400 BHN and 350 BHN respectively. Design the gear
pair by using the velocity factor and Buckingham's
3000
G36 equation for dynamic load.
1500
Use the following data
2 ZG 2x 36 Velocity factor, K,
NoW .333 V
QZG+ZP 36+ 18
6+V
Lewis form factor, Y =0484-
K 0.16 DN=0.16400 Load stress factor, K = 0.16 [BHN/ 1007. Nmm

100 100 For grade 7, e = 1.0 + 0.9 fm + 0.25 vd), um
Deformation factor, C 0.11leEp +EG Nmm

2.56 N/mm .. (Given)
Modulus of elasticity for pinion, Ep = 207 x 10 Nimm
Substituting all these values in equation (ii).
Modhulus of elasticity for gear, Eg = 207 x 10' Nimm
Fw 72x 40x 1.333x 2.56 Buckingham's equation for dynamic load in tangential
direction
9.8279x 10 N 2/V(bC +Ftmax
Fa N. FimasKa Am.Fi
21V+bC+Ftmax
Step 3: Calculate the factor of safety against wear
Standard modulues (mm): 1, 1.25, 1.5, 2.0, 2.5, 3.0, 4.0,
and bending failure
5.0, 6.0, 8.0 10.0, 12.0, and 16.0.
Factor of safety against wear failure is,
SPPU: Dec.-06. Marks 18; May-09 Dec.-11, Marks 17.
9.8279x 103 April-16, Marks 6
(FOS) wear F
Feff 5.7992 x 10*
1.6946
Sol.: Given data
. Ans. P 20 kW 20x 10" W, np = 1440 rpm, ng =600 rpm,
Factor of safety against bending failure is, (Sut p = 800 N/mm
10.9032 x 10 (ut G 700 N/mm, K, = 1.5, FOS=1.35, b = 12 m,

(FOS) bending 1.8801
Feff 5.7992 x 10 Km1.4, o= 20°,
Ans. (BHN)P =400 (BHN)G = 350
Tofind: Design a gear pair.
Step 1: Calculate the number of teeth on pinion and

gear
Design of Machine Elements - 11
1-35 Spur Gears
1440 As ObP Yp YG pinion is weaker than the gear in

Gear ratio, G
=
"P =
600
2.4 bG
nG bending. Therefore, it is required to design a pinion for
bending.
The number of teeth on gear and pinion should be selected
such that the gear ratio must be exactly 2.4. For 20° Step 3: Caleulate the beam strength of pinion
full-depth involute system, the minimum number of teeth Fb ObP-b-m-Yp
on pinion should be 18.
= 266.667 x 12 mx mx 0.3405
LG =G.Zp 2.4x Zp
Gear ratio is, G
Lp
ZG =
Fb - 1089.6013 m, NN
(1)
Z Remark Step 4 Calculate the wear strength of gear pair

18 2.4 x 1843.2 Not possible
F dp b0 K (11)
19 2.4x 19-45.6 Not possible But, dp m-Zp = 20 m, mm

20 2.4 x20 48 Possible 2ZG 2x4 =1.4117
Zg +
Zp 48 + 20
Selecting Zp =20 and Zg =48
Check whether gear is weaker or pinionis =0.16 BHN

Step 2: K
100
(Given)
weaker
We knowW that,
bP
ut p 800 Considering smaller value of BHN.
K 0.16|
350 1.96 N/mm and
266.667 N mm* 100
and bG utG 700 b 12 m

3
Substituting all these values in equation (ii),
233.333 Nmm
F 20 mx 12 mx 14117x 1.96
664.0636 m,N (11)
2.87
0.484- As Fw is weaker in pitting. Hence, it is
Zp Fb gear pair
2.87
0.48420 0.3405 Step-5: Calculate the effective load on gear pair
2.87
. (Given) Fenr
am E Ky
(iv)
and YG - 0,484
ZG plp TX 20 mx 1440
But, V=
2.8/ 0.4242
60 60
=
0,484- 48 V 1.5079 mx 10 mm/secc
NoW, Yp 266.667x 0.3405 = 1.5079 m,m/sec

bP
90.8 N/mm P 20x 10- 13.2634x 10 N
1.5079 m
and bG YG 233.333x 0.4242
6 6
(Given)
98.9798 N mm Ky6+V6+ 1.5079 m
Copynighted maeial
Design of Machine Elements- II 1-36 Spur Cears
and Km 21 V (bC+ max

a1.5 =14 .. (Given)
a l
) (Given). (V1)
21 V+/bC+ Ftmax
Substituting all these values in equation (iv)
1.5x1.4 13.2634x 10 Bu, V 1.5079 m= 1.5079 x 6

Felff X
6 =
9.0474 m/sec, b = 72 mm
6+1.5079 m
13.2634x1013.2634x 10
4642.19 (6+1.5079 m) m 6
Feff
= 2210.5667 N
Feff
27.8531x 10+ 7x 10 m
(v =1.5x 1.4x 2210.5667
m t max Ka*Km h
= 4642.19N
Step 6 : Calculate the value of module and other
dimensions Now, pitch error for grade 7,
e l1+0.9 [m+0.25 Vd] (Given)
Fw FOSx Fefr
For pinion, ep 11+0.9 [m+0.25 Jdp]
Substituting the values of equation (ii) and (V),
ep 11+0.9 [6+0.25 120]= 18.8647 um
= 1.35x278531 x 10 +7x 10 m
664.0636 m2 For ear, eG 11+0.9 [m+0.25dGl
eG 11+0.9 [6+ 0.25 V288]= 20.2183um

491.8989 m* 27.8531x 10 + 7x 10 m
Solving the above eubic equation, we get Bus eep +eG =

18.8647+ 20.2183
e 39.083 jum= 39.083 x 10 mm

5.0451 mm
Selecting standard value of module from the given data, Deformation factor, C-0.111 ep-Eg (Given)
m=6 mm Ans.
**
0.11lx 39.083x 10-3207X

10 x 207x 103
Other dimensions
:C =
207x 10+207x 10
b 12 m =12 x6 =72 mm C = 449 N/mm
dp m Zp = 6x 20= 120 mm Substituting all these values in equation (vi),

dG m-Zg =6x 48= 288 mm 21x 9.0474 (72x 449 + 4642.19)
21x9.0474+V72x 449+ 4642.19
C.D. = p t dg _ 120 + 288
204 mmn
= 18.3747x 10 N
ha Im = 1x6 =6 mm
Step 8: Calculate the available factor of safety
hr 1.25 m = 1.25 x6=7.5 mm Ans. Effective load for precise estimation is,
max t Fa =4642.19 + 18.3747x 103

Step 7: the
Calculate dynamic load by using Feff
Buckingham's equation
Buckinghanm's equation for dynamic load is, Feff23.0168x 10N
As gear pair is weaker in pitting, Now, pitch error for grade 7,
Fw = FOS x Fefr e 11+0.9 [m+ 0.25 vd] .(Given)
FOS
w 664.0636x (6) For pinion, ep 11+0.9 [m+0.25 dp1
Fefr 23.0168x 103
Cp 11+0.9 [8+0.25 W160]=21.046 um
1.0386 <1.35
For ear, eG 11+0.9 [m+0,25 ydG]
As the available factor of safety of gear pair is lower than
the required factor of safety, the design of gear pair is
eg = 11+0.9 [8+0.25 384]=22.609um
Unsaye.
But, eep +eG =21.046+ 22.609
Step 9 Caleulate the modified dimensions of gear
pair e = 43.655 um=43.655 x 10 mm
As the design of gear pair is unsafe, selecting next
standard value of module from the given data i.e. 8 mm. Deformation factor, C - 0.11le Ep+EG (Given)
Modified dimensions
.C= 0.11lx 43.655x 10-3 207X 10 x 207x 103
m 8 mm 207x 10 +207x 10
b= 12 m = 12x 8=96 mm C 501.5304 N/mm
dp m-Zp =8x 20=160 mm
Substituting all these values in equation (vii),
dG m-Zg = 8x 48 = 384 mm
dp tdg 160+384 21x12.0632 (96x 501.5304 +3481.6425)

C.D 272 mm 21x 21x 12.0632+ 96x 501.5304 + 3481.6425
ha Im=1x8=8 mm Fa 27.2167x 10 N
hr= 1.25 m = 1.25 x 8 =10 mm Ans.

Step 11 : Caleulate the available factor of safety
Step 10 Calculate the dynamie load
: by using Effective load for precise estimation is,
FeffFmax + Fa
3481.6425 +27.2167x 10
21 V (bC+ F max)
Fa .. (Given)
21 V+ ybC+ F max Feff30.6983x103 N
. (vii) As gear pair is weaker in pitting,
=
But. V 1.5079 m = 1.5079 x 8
FFOSx Feft
12.0632 m/sec 564.0636x (8)
FOS
Feft 30.6983x 10
b 96 mm
13.2634x 10 13.2634x 10 FOS = 1.3844 > 1.35
As the available factor of safety of gear pair is higher

1657.925 N than the required factor of safety, the design of gear pair
1.5x 1.4x 1657.925 safe.
t max Ka Km F =
3481.6425 N
Ex. 1.5 pair of spur gears with 20° full-depth

A 103
imvolute teeth consists of 21 teeth pinion meshing with 60 F.35x 4.75
= 1547.3684 N
teeth internal gear. The pinion shaft is directly coupled to

7.35 RW electric motor running at 1440 r:p.m. The gear
Now, max Ka Km F = 1.5x 1
x 1547.36844
shaft is ransmitting a power to a machine. The F max2521.0526 N. (Assuming, Km =)

applicatio factor is 1.5. The pinion as well as gear are
made of alloy steel (Su 1500 Nmm'). The nmodule and Dynamic load is given by,
face width of gears are 3 mm and 35 mm respectiveb
The gears are machined to the specifications of grade 8
21 V (bC+
Fmax) (Given)
and heat treated to a surface hardness of 400 BHN. The d21 V+/bC+ Fimax
deformation factor is 11500 e, Nimm. Assuming the
Pitch error for grade 8,
dynamic load is accounted by Buckingham's equation,
calculate 16+1.25[m+ 0.25 vd]
) The factor of safety against bending failure: and
i) The factor of safety against pitting failure
Use the following daa: Lewis form factor,
For pinion, Cp16+ 1.25 [m+0.25 Jdp ]
Y= 0.484-4.87 (:dp 3x 21 = 63mm)
Load stress factor, K = 0.16 [BHN7 100/, Nmm ep 16+ 1.25 [3+ 0.25 V63]= 22.2303 jum
For grade 8, e = 16 1.25 [m + 0.25 vd), um
+
Buckingham's equation for dynamic load in tangential For gear, CG 16+1.25 [m+ 0.25 Jd G]
direction
2V(bC+lrmax N, Fma Ka Km * (dG 3x 60 = 180mm)
Fa
2V+bC +Frmax eG 16+1.25 [3+ 0.25V180]=23.9426um
SPPU: Dec.-06, Dec.-08, Marks 12, May-17, Marks 6
Bul, Cp +eG = 22.2303+ 23.9426
Sol.: Given data :
e 46.1729 um = 46.1729x 10 mm
20, Zp =21, ZG =
60, P 7.35 kW 7.35 x 10 W,
np = 1440 rpm K = 1.5 Delormation factor, C = 11500e (Given)
(Sut )p =(St G = 1500 N/mm, m =3 mm, b=35 mm, B .C= 11500x 46.1729x 10 = 530.9883 Nmm
HN=400, C =11500 e N/mm
.Fa 21x4.75 (35x 530.9883+ 2321.0526
-+
To find: 1) (FOS) bending ii) (FOS)piting 21x 4.75+35x 530.9883 2321.0526
Step 1: Caleulate the effective load on gear pair Fa=8534.6496 N

Substituting all these values in equation (i),
Feff t max + Fa .)
Fefr 2321.0526+ 8534.6496= 10.8557x 10 N
But, V Tdpnp T:m Zp np
60 60
Step 2 : Calculate the beam strength and wear
. (: dp =m: Zp) strength of gear pair
V
TX 3x 21x 1440
4750 mm/sec time pinion is weaker than the gear in bending. Hence, it
60
4.75 m/sec
Copyrlahted mmaloria
Design of Machine Elements- 11 1-3 pur Gears
Beam strength for pinion is, Ex 1.6: spur gear pair is used to transmit 7.5 kW
A
power Jrom an eleciric motor running at 1440 rpm to a

(1i)
Fb bP bm- Yp machine runming at 360 rpm. The pinion and gear are
(Sut )p_ 1500 made of plain carbon steel 55 C8 (S- 720 N/mm). The
But ObP 5001 mm
tooth system is 20° full depth involute and umber of
feeth on pinion as minimum as possible. The service
b= 35 mm, m = 3 mm factor and load concentration factor are 1.25 and 1.2
respectively. The face width is 12 times module. The gear
and Yp 0.484 = 0,484-.821
Zp are machined to meet the specification of grade 7. Design
the gear pair by using velocity factor and Buckinghami's
0.3473 . (Given)
equation for dynamic load. Assume factor of safety 1.2.
Substituting all these values in equation (ii), Also, suggest the case hardness for gear pair. Use the
following data :
Fb 500x 35x 3x 0.3473
Velocity factor
18.2332x 10 N
C3+ V *
Y =
2.87
Lewis form factor 0484 -
Wear strength is given by, Z

Load stress factor K = 0.16 [BHN/1007
Fwdp-b:0-K (iii) For grade 7, e=11.0 +
0.9 [m + 0.25 Vd] um
But, dp = m- Zp =3x 21 =63 mm, b= 35 mm Deformation factor C 0.111 ePtG|Nmm
2 ZG 2x 60 Modulus of elasticity for pinion and gear = 210 x 10
QZGZp 60-21
B.0769
N/mm
21V (bC + Ftmax
.. (Internal gear) Buckingham's equation Fa= N
21V+bC+lt max
=0.16 400 Stamdard modules (mm) -1, 1.25, 1.5, 2.0, 2.5, 3.0, 4.0,
K 0.16 01010
100 5.0, 6.0, 8.0, 10.0, 12.0 and 16.0.
SPPU: May-07, Marks 17
2.56 N/mm
Sol. : Given data:
P 7.5 kW 7.5 x 10 W,
Fw 63x 35x 3.0769x 2.56
np =1440 rpm, ng 360 rpm, Ka =1.25, Km =1.2
17.3684x 10 N
(Sut )p =(Sut G = 720 N/ mm ,0=20, b = 12 m,
Step 3: Calculate the factor of safety against

Zp =2min FOS= 1.2
bending and pitting failure
Factor of safety against bending failure is, To find: Design a gear pair and their hardness.
(FOS) bending Fb18.2332x105 1.6795

Step 1: Check whether gear is weaker or pinion is
Feff 10.8557x 10 weaker
We know that,
* Ans.
bP bG 240 N/mm
Factor of safety against pitting failure is,
FOS) pitting F17.3684x 10

Feff 10.8557x 10
1.6 . Ans. For 20 full depth involute system, the minimum number
of teeth on pinion 1s,
(u )p =(Sut )al
Design of Machine Elements- 1l 1-40 Spur Gears
Zp Lmin = 18 Substituting all these values in equation (i),
np 1.25x 1.2 5526.4903

Gear ratio, G Feff
nG PP m
3+1.3571m
1440
360 1 ZG 72
Feff
2763.2451 3+1.3571 m)
8289.7354+3750 m (ii)
Yp 0.484 2.87 m
Zp
Step 4: Calculate the value of module and other
= 0.484 0.3245 .. (Given) dimensions
18
and YG 0.484
LG
0484 72
0.4441
FFOSx Fr
As YpYG. pinion is weaker than the gear in bending. 934.56 m2 = 1.2x289.7354 + 3750 m]
m
Therefore, it is required to design a pinion for bending.
778.8 m= 8289.7354 + 3750 m

Step- 2: Calculate the beam strength of pinion Solving the above cubic equation, we get
Fb bPb-m-Yp m = 2.9106 mm
240x 12 mx mx 0.3245 Selecting standard value of module from the given data,
Fb 934.56 m, N () m= 3 mm ns.
As hardness of gear pair is unknown, we can't find wear Other dimensions
strength of gear pair. b 12 m =

12x3 = 36 mm
Step 3: Calculate the effective load on gear pair dp m-Zp = 3x 18 = 54 mm
Fef a KmF . (11) d m-ZG=3x 72 =216 mm

dp +dG54+ 216= 135 mm
C.D.
But, V = Ttd pnp TT-mZP np
60 ha lm =1x 3=3 mm
V =
mx I8X 1440
** = 1.3571 mx 10 mm/sec hr 1.25 m = 1.25x 3=3.75 mm
0
Step 5: Calculate the dynamic load by using
1.3571 m, m/sec Buckingham's equation
F .3X 105526.4903N Buckingham's equation for dynamic load is,
21 V(bC + Ftmax
(Given) (1V)
Ky
3+V 3+1.3571 m
21 V+bC+ Fimax
But, V 1.3571 m =
1.3571x3
=
4.0713 m/sec,
.(Ky =Cv) (Given)
Ka 1.25 and Km=

1.2
and b 36mm
5526.4903 5526.4903
F m
Copynighted mialeriel
Design of Machine Elements - II Spur Gears
1842.1634 N Step 7: Caleulate the modified dimensions of gear

pair
t max K Km F = 1.25x 1.2x 1842.1634 As the design of gear pair is unsafe, selecting next
2763.2451 N standard value of module from the given data i.e. 4 mm.
Now, pitch error for grade 7, Modified dimensions
e = l1+0.9 [m+ 0.25 vd] . (Given)

m
4 mm
b 12 m = 12x 4=48 mm
For pinion, pl1+ 0.9 [m+ 0.25 dp]
dp mZp =4x 18=72 mm
ep 11+0.9 [3+0.25 v54]=15.3534 um
dG m- Zg =4x 72 = 288 mm
For gear, CG 11+0.9 [m+0.25,dG]
dp taG =
180 mm
CG 11+0.9 [3+ 0.25 V216]= 17um
h 1 m =
1x4=4 mm
But, c cp tcG = 15.3534+ 17
hr 1.25 m = 1.25x4 =5 mm Ans.
= 32.3534 um 32.3534 x 10 mm
Step 8: Calculate the dynamic load using
Deformation factor, C= 0.111 eP tG
Ep +EG Buckingham's equation
Buckingham's cquation for dynamic load is,
C= 0.111x32.3534 x 10-3210x10 x 210x 103

21 V(bC+i max. (Given)
103 ()
210x 10+ 210x 21 V+bC+ Ft max
C 377.0788 N/mm But, V 1.3571 m = 1.3571 x 4 5.4284 m/sec,
Substituting all these values in equation (iv), b 48 mm
21x 4.0713 (36 x377.0788 + 2763.2451) 5526.49035526.4903

F
21x4.0713+ 36x 377.0788+ 2763.2451 m
=1381.6225 N
Fa 6548.2667 N
ftmax Ka Km P =1.25x 1.2x 1381.6225
Step -6: Calculate the available factor of safety
Effective load for precise estimation is = 2072.4338 N
Feff max t Fd = 2763.2451 + 6548.2667 Now, pitch error for grade 7,
Feff 9311.5118 N e 11+0.9 [m+ 0.25 vd] (Given)
Available factor of safety is, For pinion, Cp11+0.9 [m+ 0.25 d p]

FOS Fb934.56x (3) ep 11+0.9 [4+0.25V72]= 16.5091 um
Feff 9311.5118
For gear, eG 1+0.9 [m+ 0.25 d G]
FOS 0.9032 < 1.2
eGI1+0.9 [4+0.25 288] 18.4183 um
=
As the available factor of safety of gear pair is lower than

the required factor of safety the design of gear pair is But, eCp teG = 16.5091 + 18.4183
unsafe. e 34.9274 um 34.9274 x 10 mm
Copyrightod matoriat
Deformation factor, C Ep EG .. (Given)

For safcty against pitting failure,
0.111E +Ec
Fw FOS x Feft
C= 0.11lx 34.9274 x 10-3210x 10° x 210x 103 Considering the given factor of safety i.e. l.2.
210x 10 +210x 10J
884.736 = 1.2x 11.5116x 10°
C 407.0788 N/mm 100
Substituting all these values in equation (v), BHN = 395.1405 = 400 ns.
Fa 21x5.4284 (48 x 407.0788 + 2072.4338) Ex. 1.7 Following data given for steel gear pair
21x 5.4284+ y48 x 407.0788 +2072.4338
ransnitting 7.5 kW power from an electric motor
Fa 9439.255 N running at 1440 rpm to a machine runing at 480 rpm.
Number of teeth on pinion-18
Step 9: Calculate the available factor of safety Centre distance 216 mm, Face width 10 m -
Effective load for precise estimation is, Allowable bending stress for pinion and gear
= 2072.4338+ 9439.255 160 Nimm
Feff max + Fa
Surface hardness 300 B.H.N, Tooth system 20° full
= 11.5116 x 10 N depth involute
Combine teeth error 0.012 mm, Defornmation factor
Available factor of safety is, 11500 error N/mm
x
Assuming dynamic load accounted by Buckingham's

Fb 934.56 x (4
FOS equation. Calculate,
Feff 11.5116 x 103
) Factor of safety against bending failure, 2) Factor f
FOS= 1.2989 2 Ans. Safety against pitting failure
Use following data:
As the available factor of safety of gear pair is higher 2.87
Lewis form factor - Y = 0484-
than the required factor of safety, the design f gear pair
saje. Load stress fuctor
K - 0.16 (BHN/100 -
21V (bC + Frmax

Step 10 : Calculate the surface hardness of gear pair Buckingham's equation Fa
21V+bC+Fmax
Wear strength is given by,
SPPU: May-07, Marks 10
Fw-dp b:Q:K (vi)
But, dp m-Zp =4x 18 =72 mm b = 48 mm Sol.: Given data
2x12 P= 7.5 kW = 7.5x 10 W,

Zg +Zp72+ 18 1.6
np 1440 rpm, ng = 480 rpm, Zp = 18, C.D. = 216 mm,
BHN
K 0.16100 . (Given) bP ObG =160 N/mm-, BHN= 300, e = 0.012 mm,
Substituting all these values in equation (vi).

- 20°, b = 10 m,
C= 11500, e = 11500x 0.012= 138 N/mm

BHN
Fw 72x 48 x 1.6 x 0.16
100 Tofind: 1) (FOS)bending ii) (FOS)piting
Step 1: Calculate the effective load in gear pair

Fw884.736D
100
,N Effective load for precise estimation is,
11
Design of Machine Elements- Spur Gears
Feff t max
+ Fa .() Beam strength for pinion is,
But. G
=
"P =Lg 14402G Fb ObP-b-m- Yp (1i)
G Z 480 18
But, b=60 mm, m=6 mm
GbP 160 N mm*,
LG54 2.87
Yp
p *dG = mZp tm-ZG and =
0484-
C.D. =
m (Zp +ZgG) 0.484

18 0.3245 (Given)
Substituting all these values in equation (11),
216
m (18 + 54)
:F = 160x 60x 6x 0.3245= 18.6912x 10 N
mm
b = 10 m = 10x 6=60 mm
F dpb:Q K ii)
Ttdp npTX mZp Xnp
N But, dpm:Zp =6x 18= 108 mm, b = 60 mm
60 60
6x 18x 1440 2ZG 2x 54 1.5

TX
60
9Z+ Zp 54+18
V 8.143x 10 mm/sec = 8.143 m/see DN=0.16 300

K 0.16|
100 100
P_ 7.5X 10= 921.0364 N
8.143 =1.44 N mms (Given)
T't max Ka Km F = 1x1x 921.0364 Substituting all these values in equation (ii),
921.0364 N
F108x 60x 1.5x 144 13.9968x 10 N
. (Assuming, Ka = Km )
Step 3: Caleulate the factor of safety against
Dynamic load is given by, bending and pitting failure
Factor of safety against bending failure is,
21 V (bC+ Ft max
Fa (Given)
21 V+bC+ Fmax (FOS) bending b 18.6912x l10
=22.7424
Teff 6815.5934
21 x 8.143 (60x 138+921.0364)
21x 8.143 +60x 138 + 921.0364 ns.
S894.557 N Factor of safety against pitting failure is,
Substituting all these values in equation (1), W 13.9968x 10

(FOS)pitting 2.0536
6815.5934 N
Fcff 6815.5934
Feff 921.0364 + 5894.557
Ans.
Step 2: Calculate the beam strength and wear
strength of gear pair
time pinion is weaker than the gear in bending. Hence, it
Design of Machine Elements - II Spur Gears
Ex. 1.8: A spur gear pair with 20° full depth imvolute
Q 2 ZG *41+20 = 1.3442
teeth consist of 20 teeth pinion meshing ith 41 teeth Zg tZp
gear. The module is 3 mm while the face width is 40 mm.
Material for pinion as wel as gear is steel with an K 0.16-BHN
100
=0.16 400
100
ultimate tensile strength 600 Nmm. The gears are heat
treated to a surface hardness of 400 BHN. The pinion
= 2.56 N/ mm (Given)
rotates at 1450 rpm and service factor 1.75. Assume
velocity factor accounts for dynamic load. Determine the Substituting all these values in equation (i),
rated power that the gears can transmit. Assume factor of
safety 1.5. F 60x 40x 1.3442x 2.56= 8258.7648 N
Use following data:
Step 3: Caleulate the rated power transmitted by
Lewis form factor Y = 0.484 .0 gear pair
Velocity factor Cr 3 As F <Fw, the gear pair weaker in bending.
3+V
BHN
K = Load stress factor = 0.16 Nmm
100 Fs = FOS x Feff 8172 = 1.5x Fr
SPPU: Dec.-07, Marks 10; May-09, Marks 12
Fefr5448N
Sol.: Given data:
=20°, Zp =
20, ZG =41, m=3 mm b = 40 mm, Now, Feff KaKm .(11i)
(Sut )p = (St G = 600N/ mm*,
BHN 400, np = 1450 rpm, K =1.75, FOS=1.5 Bul
Ttdpp T:m2p np
b0 60
To find: Power (P) TX 3x 20x 1450
Step 1: Calculate the beam strength for pinion
. V 4.5553x 10 mm/sec = 4.5553 m/sec
0.397... (Given)
Fb =
bP -b m-Yp (1)
3+V 3+4.5553
Ka 1.75 and assuming Km
But, bP ut P= 200 N mm
3
b =
40 mm, m3 mm
5448
1.75xIx F
Yp 0.484- 2.87
0.397
Zp
F = 1235. 9177 N
0.484 = 0.3405 (Given) Power transmitted by gear pair is,

20
Substituting all these values in equation (i), P FxV= 1235.9177x 4.5553
Fb 200x 40x 3x 0.3405 8172N P 5629.9758 W=5.6297 kW ns.
Step 2: Calculate the wear strength of gear pair
F dp b-Q K (ii)
But, dp m-Zp = 3x 20=60 mm, b = 40 mm
Copyrighitod materia
Design of Machine Elements -II 1-45 Spur Gears
Ex. 1.9:A pair of spur gear with 20° pressure angle But, dp m:Zp =5x 25 = 125 mm, b =45 mm
consist of 25 teeth pinion meshing with 60 teeth gear.
The module is 5 mm while the face width is 45 mm. The
2Zg 2x6 F 1.4117
60+25
pinion rotates at 500 r.p.m. The gear pair is made of
steel (S =
600 N
/mn-) and heat treated to a surface BHN 220
hardness of 220 BHN. Assume dynamic load accounted
K 0.16 100 0.10100
by velocity factor. The service factor and factor of safety
are 1.75 and 2.0 respectively while load deformation = 0.7744 N/mm (Given)
Jactor is unity. Calculate:
Substituting all these values in cquation (i1),
) Beam srength 2) Wear strength
) Static load that the gear can transmit. F 125x 45x 14117x 0.7744
4) Rated power that can be transmitted by gear
287 6149.3652 N ns.
Usefollowing data : Lewis form factor Y = 0484-
Z
Step 3 Calculate the rated power transmitted
: by
Load stress factor K= 0.16 D| N/mm gear pair
100
As Fw <Fb. the gear pair is weaker in pitting failure,
Velocity factor C, =
3+V For safety against pitting failure,
SPPU: May-08, Marks 11, April-15, Marks 6 Fw FOS x Feff 6149.3652 2x Fefr
Sol.: Given data
Feff 3074.6826 N
20, Zp =25, Zg =60, m=5 mm, b= 45 mm,
(Su p=(S )g =600 N/mm, BHN = 220, Now, Feff aKm

Ky
(11)
K =1.75, FOS=2, Km =1
_
But, V =dphp T mZp np
To find: i) Fb i) F i) E iv) P 60 60
Step 1 Calculate the beam strength for pinion TX5x 25x 500
When pinion and gear are made of same material, at that 60
time pinion is weaker than the gear in bending. Hence, it 10 mm/sec 3.2724 m/sec
V 3.2724x =
iS necessary to find beam strength of pinion.
Fb= ObP m- Yp (i)

Ky3+V 0.4782
b
3+3.2724
Sut P= 600
Bu, bP 3
200 N mm
(Given)
b 45 mm, m = 5 mm
K 1.75 and K =1
2.87 2.87
Yp 0.484 0.484-5
.
1.75x Ix F
0.3692 . (Given) 3074.6826 =
0.4782
Substituting all these values in equation (i),
F 840.1789 N Ans.
F 200x 45x 5x 0.3692
16.614x 103N Power transmitted by gear pair is,
Ans.
P FXV=840.1789>x 3.2724
Fdp b-0K (11) P 2749.401 W = 2.7494 kW ns.
Copyriginted matena
Design of Machine Elements - II 6 Spur Gears
Ex. 1.10: A spur gear pair is used to transmit 7.5 kW power from an electric motor running at 1440 r.p.n. to a machine
tool at 370 rp.m. The pinion and gear are made of plain carbon steel (S u 720 N /mm) and steel (Sa 600N /mm)
respectivel: The tooth system is 20° full depth involute and mumber of teeth on pinion are 18. The service factor and load
concentration factor are 1.25 amd 1.2 respectively. The factor of safety is 1.2 while the face width is 12 x module
respectively. The gears are machine to meet the specification of grade 7. Design the gea" pair by using Velocity factor
y4y nd Buckingham's equation for dynamic load.

Also, suggest the surface hardness of gear pair. Use following data -
Lewis form factor Y = 0.484
Load stress factor K =0.16 (BHN 100) N

/mm
For grade 7, e = l1.0+ 0.9[m+ 0.25 Vd],um
= 0.11le
+EG SN
Deformation factor C /mm
Modulus of elasticity for pinion and gear =

210x 10 N
/ mn
21V (bC+ Fr max
Buckingham's
equalo d
)
21V+ bC+ Fmax
Standard module in mm 1, 1.25, 2.0, 2.5, 3.0, 4.0, 5.0, 6.0, 8.0, 10.0, 12.0, and 16.0. SPPU: May-08, Marks 18
Sol.: The above example is similar to example 16, so refer Example 1.6. The answers of the above example are,
m 4 mm, FOS = 1.31 > 1.25, BHN = 445
Ex. 1.11: A spur gear pair with 20° full depth involute teeth consist of 21 teeth pinion meshing with 40 teeth gear. Pinion
and gear are made of steel with 600 N /mm and 400 N /mm ulimate tensile strength respectively.
The pinion shafi is connected to 5 kW at 720 r:p.m. electric motor The starting orque of motor is approximately 1.25 the
rated torque and jactor of safety is 2. Assume load concentration jactor as 1.6. Calculate
) Module based on velocity factor Cy Assume form factor for pinion 0.326 and form factor jor gear 0.389.
6+
2) Select the standard module and calculate gear dimensions
3) Specify the surface hardness of gear. Use following data
i) Load stress factor K =0.16

100
mm
ii)
-
Standard module in mm 1, 1.25, 2.0, 2.5, 3.0, 4.0, 5.0, 6.0, 8.0. 10.0
ii) Assume V= Pitch line velocity = 5 m/s, for module calculation. SPPU: Dec-08, Marks 13
Sol.: Given data :
=20, Zp =21, Zg= 40, (Sut )p =600 N/mm
(utG=400 N mm, P 5 kW 5x 10 W, np
= 720 rpm
Ka =1.25, FOS = 2, Km = 1.6, Yp = 0.326 Yg =0.389, V= 5 m/sec
To find: i) Module ii) Other dimensions of gear ii) Hardness of gear
Step 1 Check whether gear is weaker or pinion is weaker
We know that, O bP
(Sut)P o00 200 N/mm*
Copyrlghtecd ralerial
Sut G0 =133.333 N/mm Selecting the standard value from the given data,
bG 3
m 4 mm . Ans.
Now, bP Yp 200x 0.326=65.2 N/mm
Other dimensions
bG YG= 133.333x 0.389= 51.8667 N/mm =
b=10 m =
10x 4
40 mmn
As ObG YG bp Yp, gear is weaker than the pinion in =

dp m-Zp 4x 21= 84 mm
bending. Therefore, it is required to design a gear for
bending. dG m-ZG=4x 40=160 mm
dp tdg84+ 160
Step 2: Calculate the beam strength of gear C.D. 22 mm
Fb =
ObGb.m Yg
ha Im=Ix4=4 mm
Assume, b = 10 m
hr 1.25 m=1.25x 4=5 mm * ns.
Fb = 133.333x 10 mx mx 0.389
Step 5: Calculate the surface hardness of gear
= 518.6653 m,N . (i) Wear strength is given by,
step 3: Calculate the effective load on gear pair Fwdpb.Q-K . (iv)

As hardness of gear is unknown, we can't find wear
But, dp 84 mm, b = 40 mm
strength of gear.
2LG 2x40
Feff a m
Ky
(11)
ZG+Zp 40 +21
1.3114
But V = 5 m/sec (Given) KK 0.16 BHN)

0.10 (Given)
100
6
Kv =0.5454
6+V 6+5
=
. CCy =Ky)
84x 40x 1.3114x 0.16 BHN

100
Ka1.25, Km 1.6
BHN
F 1000 N 705 100 N
Substituting all these values in equation (ii), For safety against pitting failure,
eff
1.25x 1.6x 1000
0.5454
3667.0333 N FwFOS x Fefr
Considering the given factor of safety i.e. 2.
(iii)
BHN )
Step 4 Calculate the value of module and other 705 100 2x3667.0333
dimensions
For safety against bending failure, BHN= 322.5357 325 Ans.
Fb = FOS x Feff
Substituting the value of equation (i) and (ii),
518.6653 m2
2x 3667.0333 m 3.7603 mm
Ex. 1.12 For a gear pair, mumber of teeth on pinion is

: As OhG YG Obp Yp, gear is weaker than the pinion in
18 and that on gear is 36. Using the following data bending. Therefore, it is required to design a gear for
calculate beam and wear strength of gear teeth, rated bending.
power the pair can transmit and maximum static load on
gear. Step 2: Calculate the beam strength of gear
Ultimate tensile strength of pinion material 660 MPa. F bG-b m- Yg
Ulimate tensile strength gear material 510 MPa.
= 170x 50x 5x 0.4042
Module 5 nmm, Face width is ten times the module,
Surface hardness of pinion 330 BHN, Surface hardness = 17.1785x 10 N Ans.
Jor gear 280 BHN,
Velocity factor is gven by
.6
Service factor 1.5,
5.0 +v F dp b-Q-K .. i)
Factor of safety 2,
Bu, dp m:Zp =5x 18 = 90 mm, b= 50 mm
Pinion speed 1440 rpm, Lewis form factor
Y= 0.484-48 (Given)
LSPP0: Dec.-09, Marks 14, May-15, Marks 6
2 ZG 2x361.333
Sol.: Given data :
Zp= 18, Zg = 36, (Sut )p
QZg+Zp 36+1
= 660 MPa,
(SutG=510 MPa, m =5 mm, K 0.16 100 (Given)
b 10m = 10x 5=50 mm,

Selecting smaller value of BHN.
(BHN)p = 330
(BHN)G=280, K, = 1.5, FOS= 2, np = 1440 rpm 280
K 0.16 100 1.2544 N/ mm
To find: i) Fb i) Fw ii) P iv) F
Check whether gear is weaker or pinion is

F 90x 50x 1.333x 1.2544
Step 1
Weaker = 7.5245x 10 N Ans.
We know (SutP ooU=220 MPa power transmitted

that, ObP Step 4: Calculate the rated by
gear pair
and d bG
Sut G =170MPa As FwFb, the gear pair is weaker in pitting. For safety
3 against pitting failure,
F FOSx Feft
Yp 0.484. 7.5245x10=2x Fef
Fefr3.7622x10 N
R40=
0.484-
8
0.3245 .(Given)
= 0.4842.87
NOW, Feff KK (1)
and YG
ZG
But, v =Tap np X 90X 1440
60 60
87
0.484 = 0.4042
36 V 6.7858x 10 mm/sec = 6.7858 m/scc
Now, GbP Yp 220x 0.3245= 71.39 MPa 5.6 5.6
Ky 0.6825
170x 0.4042 68.714 MPa 5.6+V 5.6+6.7858
and bG YG =
htod matenat
Ka = 1.5 and Assume Kn =1 and bG

(SutG - 30= 100 MPa
3
Substituting all these values in equation (1i),
Lewis fornm factor is,
1.5x Ix F
3.7622x 10
0.6825 2.87
Yp = 0.484
F = 1711.801 N ADs.
Power transmitted by gear pair is, = 0.484-

0.484 = 0.3535 (Given)
22
=
P
FxV 1711.801x 6.7858 and YG 0.484 -
2.87
ZG
P 11.6159x 103 W=11.6159 kW
2.87
Ans. = 0.484- 60
= 0.4361
Ex. 1.13: A pinion having 22 mumber of teeth is o

mesh with a gear having 60 mumber of teeth. Both the
Now, bP Yp 200 x 0.3535 =70.7 MPa
pinion and the gear made up of steel having ultimate bG YG = 100x 0.4361 =43.61 MPa
tensile strength of 600 MPa and 300 MPa respectivel
As GbG YG <ObP Yp. gear is weaker than the pinion in
The pinion is connected to a 10 kW, 1440 rpm three
bending. Therefore, it is required to design a gear for
phase induction motor. Design the gear pair and specify
bending.
the surface hardness reguired on gear teeth using
Jollowing data. Step 2: Caleulate the beam strength of gear
Starting torque of motor is 56 % greater than the rated
torque. Face width is ten times the module. Deformation
Fb ObG b m-YG
factor C is T1000 N/mnr. Sum of the errors between = 100x 10mx mx 0.4361
meshing teeth e= 7.3 microns, Factor of safety 1.75,
Fb=436.1m, N (1)
Y = 0.484 ,
Velocity factor is given by
2.87
Z
Lewis form factor
Buckingham's equation Jor dynamic

As hardness of gear pair is unknown, we cant find wear
strength of gear.
load is Fa 21V(Ceb+F) Stamdard module series

21 V+Ceb + F
3, 4, 5, 6, 8, 10, 12. SPPU: Dec.-09, Marks 14 Feff Km Ky
(ii)
Sol.: Given data :

-7t dp npTmZp np
Zp = 22, ZG=60, (Sut p = 600 MPa, (Sut )G= 300 MPa, But, V
50 60
P= 10 kW = 10x 10* W,
V = mx22x 1440
np =1440 rpm, K = 1.56 60
b
=
10 m, C=11000 N mm, e=7.3jum= 7.3x 10 mm
=1.6587 mx 10 mm/sec
FOS= 1.75
= 1.6587 m, m/sec
To Find: Design a gear pair and their hardness.
10 6028.8177 N
gear is weaker or pinion is F =P10x
y 1.6587 m
Step 1: Check whether m
weaker
We know that, Sut p 6U0 200 MPa

y6+V 6+1.6587m
bP
Ka 1.56 and Assume KmI
righto
Substituting all these values in equation (ii), C = 11000 N/mm, e= 7.3x107 mm
Feff
1.56x1 6028.8177
.(Given)
m
6+ 1.6587 m F
6028.8177 6028.8177
m
1567.4926 (1.6587 m)
Feft = 1205.7635 N
m
9404.9556+ 2600 m Substituting all these values in equation (iv).

Feff .. (ii)
21x8.2935 (11000x 7.3x 10x 50+ 1205.7635)
Step 4 : Calculate the value of module and other 21x 8.2935+Vi1000x 7.3x 10 x 50+ 1205.7635
dimensions
For safety against bending failure, Fa3689.9299 N
Fb = FOS x Feff Step 6: Calculate the available factor of safety
436.1 m = 1.75x04.9556+ 2600 m max +
m
FerFi Fa =K, Km F +Fa
249.2 m = 9404.9556 + 2600 m Fff1.56x Ix 1205.7635+ 3689.9299

= 5498.575 1N
Available factor of safety is,
m = 4.3674 mm
Selecting standard value of module from the given data, 436.1x (5)
FOS
E
Teff 5498.5751
m 5 mm ** AnS.
FOS 1.9827> 1.75
Other dimensions
As the available factor of safety of gear pair is higher
b = 10 m = 10x 5=50 mm than the required factor of safety, the design gear pair
is safe.
f
dp m-Zp = 5x 22=110 mm
dG m
Zg = 5x 60 =300 mm Step 7: Calculate the surface hardness of gear pair
Wear strength 1s given by,
C.D. dp +da 0 205 mm
w dp b Q-K (V)
ha m =1x5=5 mm Bul. dp110 mm, b = 50 mm

hr 1.25 m = 1.25x 5=6.25 mm Ans. 2 ZG
2x60 = 1.4634
ZG+Zp 60+ 22
Step 5: Calculate the dynamic load by using
K
BHN
Assume, 0.16| 100
100
21 V (Ceb+ f) (Given) Substituting all these values in equation (V),

(V)
21 V+(Ceb+ F)
3HN
But, V = 1.6587 m= 1.6587x 5 Fw110x 50x 1.4634x 0.16 100
8.2935m/sec, b=50 mm
Copyrighted matenal
Design of Machine Elements -1I1
Spur Gears
Beam strength of pinion is,

w 1287.792 BHN
100
b bPb m-Yp
For safety against pitting failure, 600
But, bP uP 3 200 N/mm
FwFOSx Feff
Considering the given factor of safety i.e. 1.75

Assume, b 10 m
2.87
1287.792 BHN )
p 0.484
1.75x 5498.5751 Zp
100
0.484 = 0.3245 .(Given)
BHN 273.3513 275 *** AnS.
Ex. 1.14:I is required to design a pair of spur gears Substituting all these values in equation (),
with 20 full-depth ivolute teeth based on Lewis
Fb 200x 10 mx mx 0.3245
equation. The velocity factor is to be used to account for
dynamic load. The pinion shaft is connected to a 10 kW, Fb = 649 m (ii)
1440 rpm motor 1he starting torque of the motor is
150 % of the rated torque. The speed reduction is 4 :1 As the hardness of gear pair is unknown, we cant find
The pinion as well as the gear is made of plain carbon wear strength of gear
steel 40C8(S =600N /mm* ). The factor of safety can
Step 2: Caleulate the effective load on gear pair
be taken as 1.5. Design the gears, specify their
dimensions and suggest suitable surface hardness for the Fef am F ii)
gears.
Use following data:
But, V
Tdpp T-m-Zp np
2.87 60
60
) Lewis form factor, Y = 0.484-
TEX mx 18xX 1440
3
2) Velocity factor
Cy3+V
3) Load stress factor, K 0.16 = V 1.3571 mx 10 mm/sec
4) Assume number of teeth on pinion 18.
= 1.3571 m, m/sec
SPPU: May-10, Marks 10, May-14. Marks 12, May-15, Marks 6
7368.655
Sol.: Given data F 10x1.357110 ,N
:
V m m
-20, P = 10 kW = 10x 10° W, np = 1440 rpm,
3
K, = 1.5, G=4, Ky34v 3+1.3571m
(Stp =(Suu G =600 N/mm, FOS = 1.5, Zp = 18
Ka= 1.5 and assume Km =
To find: i) Design a gear pair ii) Other dimensions of Substituting all these values in equation (ii),
gear ii) Surface hardness of gear 1.5xI 7368.6537
T3+
Feff
m
Step 1: Calculate the beam strength of pinion. 1.3571 m
3684.3268(3+1.3571 m)
Feff
m
Feff =
11.05298x 10 +5000m
(iv)
Copyrighed iatira
Design of Machine Elements- I1 1-52 pur Gears
Step 3: Calculate the value of module and other For safety against pitting failure,
dimensions
For safety against bending failure, F FOSx Fefr . (vi)
FOS x Feft Considering, FOS = 1.5

F =
11.05298x 10° +5000 m I1.05298x 10 + 5000m

649m= 1.5x
Feff
m
11.05298x 10 + 5000x 5
432.667 m = 11.05298 x 103 +5000 m
Solving the above cubic equation, we get Fefr7210.596 N

m 4.2 mm Substituting these values in equation (vi),
Substituting the standard value of module from Table 1.1 BHN

115100 1.5x 7210.596
m mm Ans.
Other dimensions BHN 306.4114 310 ns.
b = 10 m = 10x 5=50 mm Ex. 1.15: is required to design a spur gear

reducer Jor a compressor running at 250 rpm driven by a
dp m-Zp = 5x 18=90 mm
7.5 kW, T000 rpm electric motor. The centre distance
between the axes of the gear shafts should be exactly 250
=
18 = 72
G 4- Zg 4x mm. The starting torque of the motor can be assumed to
be 150 % of the rated torque. The gears are made f
dG m-ZG = 5X 72=360 mm carbon steel 50C4(Su = 700N /mm) The pressure
C.D. = dp tdg 90+ 360 225 mm angle is 20 The factor of safety is 2 for preliminary
2 design based on the use of velocity factor
) Design the gears and specify their dimensions.
ha I
m = 1x 5=5 mm
ii) Assume that the gears are maufactured to meet the
h 1.25m=1.25 x 5=6.25 mm Ans. requirements of grade-6 and calculate the dynamic load
by using Buckingham's equation.
Step 4: Calculate the surface hardness of gear pair ii) Calculate the efective load and factor of safety
Wear strength is given by, against bending failure.
iv) Using the same jactor o fety against pitting failure,
F dp b-Q-K . (V)
specify suitable surface hardness for the gears
But. dp 90 mm, b = 50 mm Use following data :
87
Q 2 Zg 1.6 Lewis fornm factor = Y = 0.484-
Zg +Zp 72+ 18
Velocity factor C, Load stress factor
BHN
K =
0.10 100
BHN
K 0.16 100 /mm, For grade - 6,
Substituting all these values in equation (v),
8.00 +0.63(m+0,25 Vd) microns.
50x 1.6x 0.16 Deformation factor C 11400 e, N/mm
Fw90x =
Buckinghanm's equation Fa = 21V (b-C+F)
BHN 21 V+b-C+F,
Fw1152 100
N
SPPU: May-10, Marks 16, April-16, Marks 10
Design of Machine Elements-I1 1-55 Spur Gears
Sol.: Given data : As hardness of gear pair is unknown, we can't find wear
strength of gear.
nG 250 rpm, P=7.5 kW 7.5x 10* W, np =1000 rpm
C.D. = 250 mm, Ka = 1.5, (Sut )p =(Sut G=700 N/mm, Step 2: Calculate the effective load on gear pair
20, FOS = 2
Feff Km (11)
K
To find: i) Design a gear pair in)Fa
ii) Feft and (FOS) bending iv) Surface hardness But, =Tdp nP TX 100 x 1000
60 60
Step 1: Caleulate the beam strength of pinion
. V 5.2359x 10° mm/sec = 5.2359 m/seec
is necessary to find beam strength of pinion. F P7.5X 0

5.2359
= 1432.4184 N

Ky34V3+5.2359 = 0.3642
b bP b m-Yp )
.( Ky =Cy )
But, bP
(Su) 700
233.333 N/ mm
K .5 and Assume Km =1
Assume, b 10 m Substituting all these values in equation (i),
= dp tdG
C.D. 250 +dg
2
P
Feff 1.5xIx 1432.4184
0.3642
5899.5815N
500 dp +dG (a)

npdG 1000 dimensions
G dG
hG dp 250 For safety against bending failure,
dG 4 dp . (6) Fb- FOSx Fefr
Solving equations (a) and (6), (1129.3317 m 66.9665 m)= 2x 5899.5815
dp100 mm and dg=400 mm (1129.3317 m -66.9665 m')= 11.7991x 103
Now, Lewis form factor is,

2.87
0.484- 2.8 0.484 m =3.6517 mm
(100/m)
Selecting smaller positive value)
Selecting standard value of module from the Table 1.1,
m mm . ns.
Ip 0.484 .6/100m 4
Other dimensions
Substituting all these values in equation (),
b = 10 m 10x 4= 40 mm
2.87 m
Fb233.333x 10 mx mx 0.484 dp = 100 mm and dG =400 mm
100
Fb 1129.3317 m-66.9665 m3 Z = p =
= 25
(11) 4
Copyrighted material
G 400 For safety against bending failure,

00
m 4 00
Fb FOSx Feff FOS -
haIm= Ix4=4mm Feff
hr = 1.25 m = 1.25x 4=5 mmn

Bul, Fb 1129.3317 m-66.9665 m
Step 4 : Calculate the value of dynamic load by
From equation (ii)]
using Buckingham's equation
Buckingham's dynamic load is, Fb 1129.3317x (4) -66.9665x (4)
21V (bC+ F) (iv)

= 13.7834x 10 N
21 V+ybC+ F
13.7834x10=1.603
FOS Ans.
But, b = 40 mm, F = 1432.4184 N, 8596.8737
V=5.2359 m/scc Step 6: Caleulate the surface hardness for gears

Wear strength is given by
Pitch error for grade 6,
e = 8+0.63 [m+ 0.25 vd] .. (Given)

Fwdp-b.Q K . (V)
Bul, dp 100 mm, b = 40 mm

For pinion, ep 8+0.63 [m+0.25 dp
Q 2ZG 2x100=1.6
ZG +Zp 100+ 25
p8+0.63 [4 +0.25/100] = 12.095 m
For gear, 8+0.63 [m+0.25,dGl BHN
eG K =
0.16100 .(Given)
eG 8+0.63 [4 +0.25400] 13.67 um

Substituting all these value in equation (v),
But, ep t eG = 12.095+ 13.67
100x 40x 1.6x 0.16 BHN
e - 25.765 um= 25.765x 10 mm 100
Deformation factor, C 11400 «

1024 BHN)
=
C 11400x 25.765x 10 100

293.721 N/mm

Fw FOSx Fefr
. Fd
21x 5.2359 (40x 293.721+ 1432.4184) 1024 BHN
100
1.603x8596.8737
21x 5.2359+V40x 293.721+ 1432.4184
Fa = 6448.2461 N *** Ans. BHN= 366.8487 370 ** Ans.
Step 5: alculate the effective load by precise

estimation
Fett Fmax + Fa =Ka Km E +Fa
Feft 1.5x 1x 1432.4184+6448.2461
8596.8737 N *** Ans.
Copyriahted matorial
Ex. 1.16: A pinion having 22 mumber of teeth is to Sol.: Given data:

mesh with a gear having 60 mumber of teeth. Both the = 10* W.
20, Zp 25, Zg =60, P=7.5 kW 7.5x
pinion and the gear are made up of steel having ultinmate
np =1440 rpm,
tensile strength 600 MPa and 300 MPa respectively. The
pinion is connected to a 10 kW, 1440 rpm three phase (Sut )p = (Sut )a =420 N/mm, b =10 m
induction motor. Design the gear pair and specify the Yp =0.34, Yg =0.421, K, =1.75, FOS=2
surface hardness required on gear teeth using following
data To find: i) Module and other dimensions i) Fp
Starting torque ofthe motor is 30 % greater than the ii) F iv) Surface hardness
rated torque.
Face width is ten times the module. Load distribution Step 1: Calculate the beam strength of pinion
factor is l1.2. Deformation fuctor is 80 Nimm. Factor of When pinion and gcar are made of same material, at that
safety 1.75. Velocity factor is given by Lewis form
6+ V is necessary to design a pinion for bending.
2.87
factor Y =
0.484- Z
Buckingham 's equation for Beam strength of pinion is,
dynamic load is,
21 V (bC+P max
Fb
=bP-b m-Yp . (1)
PFa and Pmax Fy max d 21V+ bC+Pt max 420

Bu, bP =ut P
3
= 140 N/mm,
Standardmodules are 3, 4, 3, 6, 8, 10, 12,
SPPU: Dec-10, Marks 14 b 10 m
Sol. : The above example is similar to example 1.13 so Substituting these values in equation (),
refer Example 1.13.
Fb140x 10 mx m x 0.34-476 m2, N
Ex. 1.17: pair of spur gears with a 20° full depth
A
(11)
involute teeth consists of 25 teeth pinion meshing with 60
teeth gear An electric motor transmis 7.5 kW power at AS hardness of gear pair is unknown, ve cant find wear
1440 rpm connected to the pinion shafi. Both pinion and strength of gear.
gear are made of plain carbom steem C-40 wilh an
ultimate tensile strength Su 420 N/mm. Step 2: Calculate the effective load on gear pair
Use the following data for the design of gears based on Feff (11)
Lewis equation.
i) Face width = 10 m i) Velocity factor = 6/ (6+Vp )
ii) Lewis form factor, Yp 0.340 YG = 0.421 But, v =tdP Dp - mLp *np
60
i) Service factor= 1.75 v) Factor of safety- 2
vi) Deformation factor, C = 11400 e vii) Finished grade TXmx 25x 1440
60
8, e 16.00 + 1.25 where o=m+0.25 (d)
here, m-module in mm. V =1.8849 mx 10 mm/sec
Estimate
a)the module and dimensions of pinion and gear = 1.8849 m, m/sec
b) the beam strength
c)the dynamic load using Buckingham's equation Ky 6+ V 6+ 1.8849 m
dthe surface hardness for the gears and check the wear
srength of the gear.
F
7.5x1033978.899
1.8849m N
SPPU: May-11, Marks 17, April-15, Marks 10
Ka 1.75 and Assume Km =1
Copyrighted matenat
Design of Machine Elements- I1
1-5 Spur Geas
Substituting all these values in equation (ii), Bul, V 1.8849 m= 1.8849x 5
Feff 1.75xI 3978.899 =9.4245 m/see, b= 50 mm
6+1.8849 m 3978.899_3978.899 795.7798 N

F
1160.539 (6+1.8849 m)
Feff max Ka Km F = 1.75x 1x 795.7798
6963.2341+ 2187.5 m 1392.6146N

Feff (iv)
m
Now, pitch error for grade 8,
e = 16 + 1.25 [m +0.25vd] (Given)
dimensions
For safety against bending failure, For pinion, ep 16+ 1.25 [m +0.25 Jdp]
Fb FOS x Feff Cp 16 + 1.25 [5 +0.25 V125]
963.2341 + 2187.5 m]
476 m2 2x m =25.7438 um
283 m 6963.2341 + 2187.5 m For gear, cG = 16 + 1.25 [m +0.25 dl
Solving the above cubic equation, we get G 16 + 1.25 [5 + 0.25 V300]
m = 4.0512 mm
27.6626 jum
Selecting standard value of module from the Table 1.1. =
But, Cp tcG 25.7438 + 27.6626
mm . AIS.
e 53.4064 um = 53.4064 x 10 mm
Other dimensions
Deformation factor for steel, C = 11400 e
b= 10 m = 10x5 =50 mm C 11400 x 53.4064x 103
dp m-Zp =5x 25 = 125 mm
608.8329 N/mm
dG m-Zg=3X 60= 300 mm Substituting all these values in equation (v),
125+
C.D. dpt 300212.5 mm 21x94245(50x 608.8329+ 1392.6146
2
21x 94245+V50x 608.8329+ 1392.6146
ha
1
m= Ix5=5 mm
Fa 16.7415x 10 N Ans.
hr 1.25 m=1.25x 5=6.25 mnm Ans.
Step 5 : Calculate the surface hardness of gear
Substituting the value of module in equation (ii),
Wear strength of gear is,
Fs-476m = 476x (5) Fw dp b:Q K (V1)
11.9 x 10N Ans.

Bul, dp= 125 mm, b = 50 mm
Step - 4: Calculate he dynamic load x60=
QZ+ 2
using ZG 2
14117
Buckingham's equation Zp 60 + 25
K BHN
21 V (bC+ Fimax) Assume, 0.16 100
Fa
21 V+bC+ Ft max
Design of Machine Elements- I1 -57 Spur Gears
Substituting all these values in equation (vi),
Fw 125 x 50 x 1.4117 x 0.16 BHN

100
Fw1411.7 100 N (V11)
For safety against wear failure,
F FOSx Fef
But, FOS 2
max 103 N
and Feff + Fa = 1392.6146+ 16.7415x 10= 18.1341x
BHN
1411.7 BN
100
2x 18.1341x 10
BHN 506.8646 =510 ** ANS.

Substituting this value of BHN in equation (vii).
Fw1411. 510=
T00
36.7183x 10° N
To check the wear strength of gear,
Fw FOSx Feff
36.7183x 105
Fw
FOS
Feff 18.1341x 10
FOS 2.0248 >2
As the available factor of safety is higher 1han the required factor of safety, the design ogear pair is safe in wear.
* Ans.
Ex. 1.18: A spur pinion having 20 teeth to be made of plain carbon steel 40C8 (S = 580N /mm ) is to be mesh with a
gear having 85 teeth to be made of grey cast iron FG260. The gear pair is required to transmnit 15 kW power j an
eleciric motor runing at 1440 rp.m. to a machine. The starting torque required is 200 % of rated torque while the load
distribution factor is 1.4. The Jace width is 12 times the module and the tooth system is 20 full depth involute. The gears
are to be machined to meet the specifications of grade 7. The deformation factor C for gear pair is 240 N /mm.
i) f the factor of safety against the bending failure is 1.5, design the gear pair by using the dynamic factor C, =6/(6+V),
(assume V=10 m/s Jor initial stages ) and Buckingham's equation for dynamic load.
i) f the factor of safety against the pitting failure is 2.0, Specify the surface hardness.
Use fotlowing data
Lewis form factor Y = 0.484-2.87/Z Load-stres factor, K =

0.180n mn
For grade -7, e = 11.00 + 0.9 (m + 0.25 VD) um, Pa =21 V (bC+ Pmax )/(21V+ (bC+ Pmax))
First preference module (mm) 1, 1.25, 1.5, 2, 3, 4. 5, 6, 8, 10, 12, 16. SPPU: May-12, Marks 12
Sol.: The above example is similar to example 1.13, so refer Example 1.13.
opyriahited mmalen
Design ot Machine Elements-11 1-58 Spur
Gears
Ex. 1.19: An electric hoist is being designed for lifing As the gear ratio of the reduction drive is 36 and reduction
capacity of 30 kN at 80 m/min. The rope drum diameter ratio of each stage is 6, it means 2 stages are required
will be approximately 640 mm and it will be driven by an
1S.
electric motor runing at 1440 rpm through a pairs of
spur gears only. The pinion and gear are made of plain Step 2: Calculate the capacity of electrie motor
carbon steel 55 C8 (Su 720 N /mn*). The tooth
Power required to raise the loadis,
system is 20" full depth involute and number of teeth on
pinion as minimum as possible. The service factor and =
(Po= WHX V 30 x10 x1.3333
factor of safety are taken as 1.25 and 1.5 respectively.
The face width 12 times module. Suggest suitable mumber = 40 x 10 W
of stages for the reduction drive. The velocity ratio in
each stage should not exceed 6:l. Design the first stage Efficiency of hoist is,
gear pair by using velocity factor Also, suggest suitable 105
capacity of electric motor. Use following data : H 0.95 = 40x
Velocity factor Cy
3+V =
(PH 42.1052 x 10*W 42.1052 kW
Lewis form factor Y =0484- 2.8/
It means, input power for the motor is 42.1052 kW. But,
BHN from standard kW rating of electric motors,
Load stress factor K
=0.10100 mm
Stage efficiency = 95 % im 45 kW Ans.
Standard module in mm 1, 1.25, 2, 3, 4, 5, 6, 8, 10, 12, Step 3 : Calculate the beam strength and wear
16 Standard kW rating of electric motors 5, 10, 15, 20. strength of gear pair
25, 30, 35, 40, 45, 50, 60. SPPU: Dec.-12, Marks 12
Sol.: Given data :
W=30 kN =30x 10 N, VA = 80 m/min= 1.3333 m/sec. Beam strength for pinion is,
dH 640 1mm, np =1440 rpm, (Sut )p = (Sut )G
Fb
bP b.m-Yp (i)
720 N/mm, Ka = 1.25, FOS = 1.5, b = 12 m, Gcnch6
To find : i) Number of stages ii) Design of first stage iii) bP SutP = = 240 N/ mm
Capacity of electric motor
2.87
But, b 12 m and Yp= 0.484
Step I: Calculate the number of stages for the Zp
reduetion drive
.. (Assume Zp = 18)
Refer Fig. 1.19.
Yp
7 = 0.3245
Velocity of rope drum is,
=0.484
I8
TtdHN1.3333 x 10 TX 640x N Substituting all these values in equation (),

60
Fb 240x 12 mx mx 0.3245
N =
39.778 rpm = 40 rpm
934.56 m-, N (ii)
Gear ratio of the reduction drive is,
P 1440
G 36 b-Q.K
N 40 Fwdp
Gear 1
Shaft
Motor
Gear
Shaft
B
Drum ermediate shaft

Gear 2
Gear
Pulley
Load
Fig. 1.20
But, dp m-Zp 18 m, mm ii) Step 4:Calculate the effective load on gear pair
Gear ratio G LG 6 G Fefr

-K, Km
Ky
.(V)
nG
ZG = 108 Bul. V =
TtdphpTX 18 mx 1440
60 60
ZG+2ZG 2x
108 1.7142 V = 1.3571 mx 10 mm/seec.
Zp 108+ 18
= 1.3571 m, m/seC.
BHN)
K 0.16
16
100 (Given)
45x 10
1.3571 m
Assuming surface hardness of gear pair as 300 BHN.
(Refer Table 1.3). 33.1589 x 10 N
m
S00 3
K =
0.16| 1.44 N/mm
100
Kv34V 3+ 1.3571 m
Substituting all these values in equation (ii), Ka 1.25 and assume Km =1
Fw18 mx 12 mx 1.7142 x 144 Substituting all these values in equation (v),
m, 55.1589 x 103
533.1847 N (iv) 1.25x 1x
m
As Fw < Fb. gear pair is weaker in pitting. Hence it is Feff
3+ 1.3571 m)
Tmatonal
Design of Machine Elements- I 1-60 Spur GearS
13.8162 x 10 (3+ 1.3571 m) Ex. 1.20: Design a pair of gear used for ruming a
Feff
m compressor at 300 rpm driven by a 7.5 kW, 1200 rpm
electric motor. The center distance benween the needs to
be 250 mm. The gears are made of 50C4 having ultimate
Feff
41.4486 x 10 + 18.7499x 10 m
m strength 700 MPa. Take service factor as 1.5, Jactor of
safety as 2. Initially using velocity factor,
(vi) i) Design the gear and specify 1heir dimensions.
ii) Assume Grade 6 of mamufacture and find exact
dimensions dynamic load using Buckingham's equation.
i) Find available factor of safety for the designed pair
For safety against pitting failure, in bending
iv) Using the obtained factor ofsafety the required
F FOSx Fefr surface hardness.
Substituting the values of equation (iv) and (vi), Use following data :
m Pressure angle 20, Lewis from factor Y = 0484- 87

.533.1847 m?
=
1.5x41.4486 x10+18.7499x10
For Grade 6, e = 8+0.63/m+0.252r).
Velocity factor Cy
355.4564 m*=41.4486 x 10 + 18.7499 x 10 m 6+V
Pa=- 2/VbCe+
Pmax
Dynamic load
2/V+bCe+Pmar
8.185 mm Deformation factor = 11400 Nimm
Standard module, mm, I. 1.25, 1.5, 2.0, 2.5, 3.0, 4.0, 5.0,
(Neglecting negative values) 6.0, 8.0, 10, 12, 16, 20
Selecting standard value of module from the given data, Determine the module based on beanm strength.
SPPU:May-13, Marks 12, Similar in Dec.-13, Marks 16
mm AnS.
Sol. The above example i similar to example 1.15, So
Other dimensions :
refer Example 1.15.
b= 12 m = 12x 10 120 mm Ex. 1.21 A steel pinion with 20° full depth imvolute
teeth is transmitting 7.5 kW power at 1000 rpm fronm an

dp mZp =
10 x 18= 180 mm electric motor. The starting torque of motor is twice the
rated torque. The mumber of teeth on the pinion is 25,
dG m-Zg = 10 x 108= 1080 mm while the module 4 mm. The face width is 45 mm.
Assuming that the velocity factor account for dynamic
C.D. dp t dg 180+ 1080 630 mm
load, calculate .
2.87
i) The effective load on gear tooth Y = 0.487-
Z
1x 10 = 10 mm
1
ha m =
ii) The bending stress in gear oom
3+V
h = 1.25 m 1.25 x 10 12.5 mm :

SPPU Dec.-16, Marks 6
Ans.
Sol.:
20,
K, 2,
Given data:
P
Zp =
7.5 kW
25, m=4
=7.5x10
mm,
, np
b= 45
=
mm,
1000 rpm,
To find i) Fetf ii) Ob

Design of Machine Elements-11 1-61 Spur Gears
Step 1:Caleulate the effective load on gear pair Sol.: Given data :
-20", Zp=20, np= 1440 rpm, Zg = 80,
Fef
K (Sut p (Sut G 660 N/ mmn,
Ttdpnp TX mp Xnp
Bul,
60 60 P 10 kW = 10x10 W,
TX 4x 25x 1000
(BHN)P = (BHN)G = 350, K = 1.5, FOS= 1.75
60
V 5.235x 10 mm/s = 5.235 m/s To find: i) Module of gears

ii) Dimensions of the gears
P7.5x10
5.235 .4326x 10 3N
5.235 ii) (FOS) bending and (FOS)wear
Ky 0.3642 Step 1: Calculate the beam strength for pinion

3+V 3+5.235
When pinion and gear are made of same material, the
2x1x1.4326x 103
Feff pinion is weaker in bending. Hence, it is necessary to find
0.3642
beam strength of pinion.
(Assume Km 1)
Feff 7.867 x103 N Ans.
Step 2: Calculate the bending stress in gear tooth

Fb bP-b-m-Yp . (1)
For safety against bending failure, Assume b= 10 m

FOSx Fefft= 1.5x7.867 x 10 and O bP (SutP
3
O0 220 N/ mm*
F 11.80x 10 N ...(Assume FOS = 1.5)

NoW, b Ob-m-Y
= =
Y 0.487- = 0.487- 0.3435
Zp
Bul. Y 0.487-0= 0.487-
Z 25
0.3722
Substituting all these values in equation (i).

11.80x103 =
o x45x 4x 0.3722 .F 200 x 10m X m x0.3435 = 755.7 m, N
b176.129 MPa Ans.
Ex. 1.22: A pair of 20"full depth involute gears consist Step 2: Calculate wear strength of gear pair
of 20 teeth pinion rotating at 1440 rpm transmiting Fwdp b-Q.K (ii)

power to S0 teeth gear. Both gears are made of steel
with an ultimate tensile strength of 660 N /mm. Power
But, dp mZp 20 m, mm
transmitted is 10 kW. They are heat reated to surface

hardness of 350 BHN. Assuming velocity Jactor accounts
and Q 22 2x
QZg+Zp 80
80+220
1.6
for the dynamic load. For steel pinion and stecl gear,
i) Estimate the module of the gears using beam strength
or wear strength. i) Caleulate all dimensions of the
K 0.16 0.16
gears. 1i) Factor o safety Jor beam strength or wear 100 1000
strength.
Assume service factor 1.5, factor of safety .75 and Lewis K = 1.96 N/mm
Jorm Jactor is given by. Y =

0.487-40 Substituting all these values in equation (in).
Z
SPPU: April-17, Marks Fw 20 m x 10 m x 1.6 x 1.96
Fw 627.2 m*, N dp mZp = 4* 20 80 mm
As Fh >Fw gear pair is weaker in pitting. dG mZG =4x 80=320 mm

Hence, it is required to design a gear pair against the pitting C.D.
dp +dGS0+ 320 200 mm
2
failure.
I
m= 1
x44 mm
x 4 = 5 mm
Feff K,KnF . (11)
hr 1.25 m = 1.25 .Ans.
Step 5: Calculate FOS against wear and bending failure

But, V TdpnpTX 20m x 1440
Feff
9.9474x 10 +2.4999x 10° m
60 60
= 1.507 m x 10° mm/sec 9.9474x 10" +2.4999x 10 x 4

4
V = 1.5079 m, m/sec
x Feff 4.986x 10 N
P10 106.6317x 10
N
1.5079 m Fw 627.2x
FOS) wear 2.012 Ans.
ASsume, 6 Fef 4.986x 10
6+ V 6+ 1.5079m
Fb 755.7x 4-2.425
FOS) bending Ans.
Ka 1.5 and Km 1
= Feff 4.986x 10
Substituting all these values in equation (111)

Ex. 1.23 t is required to design a pair of spur gears
with 20° full depth involute teeth. The input shaft rotates at
Fefr 1.5x1 6.6317 x 10
T000 rpm and receives 7.5 kW power through a coupling
6 + 1.5079 m The speed of output shaft is S00 rpm. Both the gears are
made of steel having ultimate tensile strength of 410
1.6579x 10° (6+ 1.5079 m) N/mns. The servicefactor is 1.25 and factor of safety is
Feff
1.75. The gears are machined to grade of 6 Assume
suitable number of teeth on pinion. Lewis form factor is
Feff
9.9474x 10 +2.4999x 10° m = 0.487 2.87
Y
Step 4: Calculate value of module and other dimension Calculate:

) Module of gears assuming 5 m/s pitch line velocity to
Factor of safety against pitting failure,
calculate velocity factor.
Fw FOS x Feff i) Calculate Buckingham dynanmic load and factor of safety
Substituting the values of cquations (ii) and (ii), for it. For grade 6 and o=
m+0.25vd e - 8.0+ 0.63
Deformation factor is 11400e N
/nm.
9.9474 x 10+2.4999 x 10 m SPPU: April-17, Marks 7
627.2 m 1.75x
Sol.: Given data :
358.4 m- 9.9474 x 10 +2.4999 x 10 m P 7.5 kW, = 7.5x 10 W, = 20°, np = 1000 rpm
3.781 mm 4 mm .Ans.
ng S00 rpm, FOS =1.75, Ka = 1.25, V = 5 m/sec,
Other dimensions
C 11400 e N/mm
b 10 m = 10 * 4 =40 mm
(Sut p=(SutG= 410 N mm, Assume number of teeth Ka 1.25 and assume Km =
1
on pinion Zp = 18
To find: i) Module of gears Feff

1.25x17957.7471
ii) Dynamic load and its FOS (0.375) m
Step 1: Calculate the beam strength of pinion Fefr

26525.82
= N
1S necessary to find beam strength of pinion.
dimensions
Beam strength ot pinion is, For safety against bending failure,
Fb b m- Yp (i)
bp Fb FOSx Fetf
But,
(Sut p=41- 136.666 N mm* 447.65 m
= 1.75x0525.82
bP 3 3 m
Assume b= 10 m 447.65m 46420.185

2.87 = 0.487 2.887
Yp0.487- 18
m
4.698 mm
P
Selecting the standard value of module from given value
0.3275 . (Given) i.e. m =5 mm Ans.
Substituting all these values in equation (i), Other dimensions
Fb = 136.66 x 10 mx mx 0.3275 b = 10 m = 10 x5 = 50 mm
F = 447.65 m*, N (11)

dp = mxZp =5 x 18 = 90 mm
As the hardness of gear pair 1s unknown, we cant find

G = P 10002 - ZG ZG
wear strength of gear. nG 500 Zp 18
Step 2: Caleulate the effective load on gear pair ZG 18 * 2 = 36
Feff K, Km (iii) dG mZG = 5 x 36 = 180 mm

Ky
C.D. = P * dG _ 90 + 180
135 mm
But.
Ky34V 3+50.375 2
h m 5 mm
1
= 1x5 =
V=5 m/s)
hr 1.25 m= 1.25x5 = 6.25 mm.. Ans.
V
Tdpp Tm-Zp np
60 60 Step 4: Calculate the value of dynamic load by
using Buckingham's equation
TX mx l8 x 1000
Buckingham's dynamic load is,
60
21 V (bC+
F)
N 942.47 m, mm/sec (iv)
21 V+bC+ F
0.94247 m, m/sec
Pitch error for grade 6
103 7957.7471N
P- 7.5x
V 0.94247 m e 8+0.63 [m+ 0.25 Vd]
1ten
For pinion ep 8+0.63 [m+ 0.25 dp] 1.18 Gear Lubrication SPPU: Dec.-09, Dec.-10
For the satisfactory performance and durability of the
ep 8+0.63 [5+ 0.25 V90] = 12.64 um gears, proper lubrication of the gear teeth is necessary.
For gear eG= 8+0.63 [m+ 0.25 yda] Proper lubrication means adequate quality and quantity of
lubricant with proper mode of lubrication.
eG 8+0.63 [5+ 0.25 Vi80] = 13.26 um
Purpose of gear lubrication
To reduce the power loss due to friction.
But Cp t CG12.64 + 13.26
To reduce wear of the gear teeth.
25.9030 jum = 25.9030x 10 mm
To carry away the worn-out particles, dust, etc.
Deformation factor, C = 11400 e To act ike a coolant by dissipating the heat generated
due to friction.
C = 11400x 25.9030x 10
.To minimize noise and vibrations.
295.2942 N/mm
1.18.1 Types of Lubricants used in Gears
Also, b 0 mm, The type of lubricant used in gears should have suficient
7957.7471 7957.7471= 1591.54 viscosity to develop a suitable oil film between the tooth
N surfaces.
m
It is necessary to ensure that the lubricant has suflicient
and V 0.94247 m =
0.94247 x 5 oiliness property.
4.7123 m/sec The various types of lubricants used in gears are as
follows:
1. Grease 2. Straight mineral oils
21x4.7123 (50x 295.294 + 1591.54) 3. Extrerme pressure (EP) Jubricants 4. Motor oils
21x 4.7123+V50x 295.294+ 1591.54
Fa 7135.05 N Ans. 1. Grease

Grease is used as a lubricant for the gears of
Step 5: Calculate the effective load by precise hand-operated mechanisms, where the pitch line velocity is
estimation and required FOS low (less than 0.8 m/sec) and the operation is intermittent.
Fett F max + FaK, Km + Fa
2. Straight mineral oils :
Fofr1.25x Ix 1591.54+ 7135.05 This type of lubricant is used for the operation where the
pitch line velocity medium. During lubrication, the gears
is
9124.47 N Ans.
are enclosed in a box and dipped in a bath of mineral oil
For safety against bending failure, which is called as splash lubrication. The mineral oils of
grades SAE 80, SAE 90 or SAE 140 are commonly used.
Fb FoSx Fefr FOS =b
Feff 3. Extreme Pressure (EP) lubricants
EP lubricants are used for heavy duty applications EP
But, Fb 447.65 m = 447.65x 5 Tubricants are mineral oils with additives for improving the
pertormance of oil. They are commonly used in
11.19x 103 N
automobile gearbox and heavy industrial gearboxes.
103
FOS = 1.19x 1.2265 AnS. 4. Motor oils:
9124.47
The transmission gears which are used to change the speed
are generally lubricated with motor oils. The SAE grades
pyrente ataral
Design of Machine Elements- l 1-65 Spur Gears
of different motor oils are SAE 5W, SAE 1OW, SAE 20, Large gears (more than 500 mm in diameter) are
SAE 30, SAE 40, etc. provided with arms to join the hub and rim. The number
40 of arms depends upon the PCD of the gear. Such gears
1.18.2 Heat Dissipation
are light in weight as compared to the solid gears. Refer
Due to relative sliding motion between the meshing Fig. 1.20 (d).
teeth, high amount of heat is generated. This heat is
Review Questions
either carried away by the lubricating oil or dissipated to
State the advantages, disadvantages and applications
the surrounding through the casing.
gear drive
Due to high amount of heat, the temperature of the
Give the classification of gears
lubricating oil also increases. The amount of lubricating 3. State and explain parameters to be considered while
oil should be sufficient so as to maintain the temperature selecting the bype of gear for the given application.
of lubricant within the limits. 4. With neat sketch explain the terminology of spur gears.
When the temperature of lubricating oil exceeds the 5. Explain the different ypes of standard gear tooth
limit, it may loose its important properties. Therefore, in systems.
some applications, the casing of gearbox is provided with What are the etfects of increasing or decreasing the
fins so as to increase the heat transfer from the casing to pressure angle ?
the atmosphere. Explain he force analysis of spur gears with neat
sketch.
High capacity gearbOxes are usually provided with spray
8. Give the classification of gear tooth failures.
lubrication and oil seals for the shafts, gaskets for the
Write short note on ) Bending failure i) Wear
cover, plug for inserting oil, drain plug at the bottom,
failure
etc.
0. State the causes and remedies of the following
The pressurized lubricant supplied by the pump is
) Piting failure i) Scoring failure
sprayed through the nozzle on the gear teeth. The heated
oil which drains back to the sump (reservoir) is ii) Abrasive wear iv) Corrosive wear
recirculated through the external oil cooler, where it is T1. What are the desirable properties of gear material 2
cooled and supplied back through the pump State the different ypes of gear materials
12. Derive an expression for beam strength of spur gear
1.19 Construction of Spur Gear Blank tooth. Also state the assumptions made.
The construction of gear may have different design 13. Show hat the permissible bending stress for gear
depending upon the size, material, application and cost of tooth is taken as one third of ultimate tensile strength.
the gear. 14. Explain:
When the dedendum circle diameter is slightly greater i) Lewis form factor ) Load-stress factor
then the diameter of shaft, the pinion teeth are cut
ii) Service factor iv) Load-distribution factor
integral with the shaft. Refer Fig. 1.20 (a). It reduces the
15. Whatis dynamic load ? Explain the methods of
manufacturing cost of the pinion.
estimation of dynamic load an gear tooth.
(See Fig. 1.20 on next page).
16. What do you understand by gear lubrication ? State
If the PCD of pinion is upto 250 mm, then the pinion is
made solid with uniform thickness equal to the face
the purpose of gear lubrication.
width. Refer Fig. 1.20 (b). 17. What are the types of lubricants used in gears?
Sometimes, small gears upto 500 mm in diameter are 18. Explain the concept of heat dissipation
built with a web which joints the hub and rim. The web 19. Explain the construction of spur gear blank.
may be made solid or may have recesses in order to
reduce its weight. Refer Fig. 1.20 (c)
Design of Machine Elements- I1
1-66 Spur Gears
Dedend m Shaft-
Keyway
Shaft-
(a) Hub
(b) Web Rimm
(c)
Hub
Keyway
Shaft-
Rim
Arms
Fig. 1.21: Construction of spur gear blank

Examples for Practice
hardened to 450 BHN and 350 BHN
Ex. 1.24 :A spur gear pair is to be used to transmit respectively. Design the gear pair by using
18 kW power from an electric motor the velocity factor and Buckingham's
running at 720 rp.m. to the machine tool
equation for dynamic load.
expected to run exactly at 300 rp.m. The
[Ans.: m= 6 mm, FOS= 1.67221.35]
pinion and gear are to be made of alloy
Ex. 1.25 :A spur gear pair with 20° full depth imvolute
steel (Sa 780 Nmm) and plain carbon
teeth consist of 24 teeth pinion meshing with
steel (S = 680 Nmnt) respectively. The
50 teeth gear. The module is 4 mm while
service factor and factor of safety are 1.5
the face width is 50 mm. Material for pinion
and 1.35 respectively The face width is 12
as well as gear is steel with an ultimate
times module for which load distribution
tensile strength 600 Nmm. The gears are
jactor is 14. The tooth system is 20
heat treated 1o a surface hardness of 450
full-depth involute. The gears are to be
BHN. The pinion rotates at 1440 rpm and
machined to meet the specifications of grade
service factor 1.75. Assume velocity factor
7. The pinion and gear are to be case
accounts for dynamie load. Determine the
Design of Machine Elements- 1-67 Spur Gears
raled power that The gearS can transmil. induction motor. The starting torque of |
Assume factor of safety 1.5. motor is 50 % greater than the rated
Use following data forque. the surface hardness of the gear
f
2.87 pair is 350 BHN, design a gear pair with
Lewis form factor Y = 0.484 -0
Z factor of safety 2. Assume face width is ten
Velocity factor Cy times the module and velocity factor
accounts for the dynamic load is given by,
BHN
K =
Load stress Jactor U.10100 Ky6+V [Ans. : m=4 mm]
N/mn Ex. 1.28: Ii is required to design a spur gear speed
[Ans.: P 20.6107 kW reducer compressor running at
jor a
Ex. 1.26: A pair of spur gear with 20° pressure angle 200 rpm driven by a 7 k", 800 rpm electric
consist of 25 teeth pinion meshing with 60 motor. The centre distance between the axes
teeth gear. The module is 5 mm while the of the gear shafts should be exactly
face width is 45 mm. The pinion rotates a 300 mm. The starting torque of the motor
O0 r.p.m. The gear pair is made of steel can be assumed to be 150 o of the rated
torque. The gears are made of carbon steel
(Su600 N /mm*) and heat treated to a
50C4(Su 700N /mnm) The pressure
surfuce hardness of 220 BHN. Assume
angle is 20% The factor of safety is 2 for
dynamic load accounted by velocity factor
preliminary design based on the use of
The service factor and Jactor of safety are
velocity factor.
1.75 and 2.0 respectively while load
)Design the gears and specify their
deformation factor is unity. Calculate dimension.
) Beam srength 2) Wear sirength
ii) Assume that the gears are maufactured
3) Static load that the gear can transmit. fo meet the requirements of grade-6 and
4) Rated power that can be transmitted by calculate the dynamic load by using
gear. Buckingham's equation.
Use following daa Lewis form factor ii) Calculate the effective load and factor of
Y = 0484-287 safety against bending failure
iv) Using the same factor of safety ugainst
Load stress Jactor piting Jailure, specify suitable surface
BHN hardness Jor the gears,
K =0.16100N/mm Use following data
Velocity factor Cy Lewisform factor Y=0.484

+V
6+
Velocity factor C,
[Ans.: Fb 16.614x 10 N, F = 6149.3652N, F= 1136.8975 N, 3+V
P 3.7203 kW]
Load stress factor 0.16
Ex. 1.27 :A spur pinion having 22 teeth is to mesh
with a gear having 48 mumber
BHN mm
of teeth. Both 100
the pinion and gear are made up of steel
For grade-6, e = 8.00 +0.63 (m+0.25Vd)
having ulinmate tensile strength of 800 MPa
microns.
and 530 MPa respectively. The pinion is
Deformation factor C= 11400 e, N/mm
connected to 7 kW, 1440 rpm three phase
Design of Machine Elements -11 1-6 pur Gears
d
21V(b-C+F;))y i) Hunting tooth: This concept is used for uniform
21V+b:C+F distribution of tooth wear. In the gear ratio (Zg/Zp),
let the Zp-22 and ZG = 44. It means, after every
[Ans.:m=4 mm, Fa 6374.2505 N, Feft 8463.1591 N, FOS
2.0295, BHN= 375] Two revolutions of the pinion, the same pair of gear
teeth will engage. If we modify as Zp = 22 and Zg =
1.20 University Questions with Answers 45 then the pinion will rotate 45 times betore the same
pair of teeth will engage again. This extra tooth on the
Dec. 2009 gear called as hunting tooth which results in more
even distribution of wear. But, due to hunting tooth
Q.1 Discuss ditferent pes of gear tooth jailure. there is small variation in the gear ratio.
(Section 1.) 1)Crowning of gear tooth : It is one of the
Q.2 Discuss lubrication of gears. (Section 1.18) method of strengthening the gear tooth. During the
3] operation of gear, there is uneven distribution of
pressure along the face width of the tooth. This results
May 2010 in shifting the maximum pressure to the end of the
tooth along the face width. By crowning the tooth, this
Q.3 Why permissible bending stress for gear tooth
load can be shifted towards the middle of the face
taken as one third of ultimate tensile strength
width. In crowning process, the ends of the tooth are
(Section 1.11.3) 6)
made slightly thinner. It is done by using shaving
Dec. 2010 cutters. It is very small and depends upon the elastic
deformation of teeth.
Q.4 Discuss standard system of gear tooth.
May 2014
(Section 1.7)
Q.5 Explain why involute profile is preferred over Q.10 Discuss standard system of gear tooth
cyeloidal profile for gear tooth. (Section 1.6) 121 (Section 1.7)
Q.6 Discuss uubrication o gears. (Section 1.18) B]
May2015
May 2012
Q.11 What are the causes of consideration of the
Q.7 State and explain different types of gear tooth dynamic load in design of gears ?
jailures, their causes and remedies. (Section 1.9) (Section 1.13.2)
4
April 2015 (In Sem)
Dec. 2012
Q.12 What are the causes of consideration of the
Q.8 Define beam and wear strength of spurs gear. dynamic load in design of gears ?
(Sections 1.11 and 1.12) (Refer section 1.13.2)
May 2013 Dec. 2015 (End Sem)
Q.9 Explain the following terms: ) Hunting tooth Q.13 What is the beam strength of spur gear ? Derive
i) Crowning of gear tooth. the expression for it. (Refer section 1.11) 61
Ans. :
April 2016 (In Sem)
Q.14 Explain the term effective load with reference of

spur gear. How to estimate the effective load of
spur gear tooth. (Refer section 1.13) 14
Copyrighted.maenia
Design of Machine Elements -I1 I-6 Spur Gears
May 2016 (End Sem) April 2017 (In Sem)

Q.15 Explain Q.17 State and explain various modes of Jailures of
i) Methods of estimation of dynamic load for gear tooth. (Refer section 1.9) 4
spur gear. (Refer section 1.14)
Q.18 What are the diferent forces acting on a gear
) Gear tooth failures (Refer section 1.9) 6]
tooth. Explain with the help of a force diagram.
(Refer section 1.8) 31
Dec.2016 End Sem)
Q.16 State and explain diferent vpes of gear tooth
Jailures, 1heir causes and remedies.
(Refer section 1.9)
Copyngnted matOfial

Anup Goel - Spur Gear

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Anup Goel - Spur Gear

Uploaded by

Copyright:

Available Formats

Design of Machine

@ Copyright with Author

1.13 Effective Load on Spur Gear Tooth.. 1-22

Gears * 1.14.2 Precise Estimation of Dynamic Load by

Advantages and Limitations of Larger Pressure

1.19 Construction of Spur Gear Blank.

Angie ... . 1-10

Contents 1.10 Gear Materials. 1-15

1.6 Minimum Number of Teeth to

1.2 Advantages and Disadvantages of Gear Drive

It is more reliable than other drives.

Non-intersecting and Non-intersecting and

Spur gears Bevel gears Worm gears Spiral geas

Fig. 1.1: Types of gears

1.3 Classification of Gears

1. Parallel shaft axes gears

1.3.1 Paralel Shaft Axes Gears

a) Spur gears b) Helical gears c) Herringbone gears

Fig. 1.4: Herringbone gears

d) Rack and pinion

Fig. 1.7: Bevel gears

AnA accommodate a portion of worm periphery.

1.3.2 Intersecting Shaft Axes Gears 1.3.4 Non-intersecting

Right hand When the axes of shafts are perpendicular and

If the axes of the two shafts are neither perpendicular

(ii) Power to be transmitted and input speed

2. Pitch Circle Diameter (PCD): It is the diameterof

4. Pitch point: It is the point of contact or the point of

Clearance Circular ptch Tooth

Pinion Pitch point

Fig. 1.10: Terminology used in gears

Lel, nG and np Gear and pinion speeds in rpm

dg and dp = Diameter of gear and pinion in mm

Zg and Zp = Number of teeth on gear and pinion

C.D. = p *uG _mZp t m ZG

m(Zp + ZG) Pressure angle

1.7 Standard Tooth Profile SPPO: Dec.-10

i) 14.5 ful depth involute system

1.7.1 Advantages and Limitations of Smaller Pressure Angle SPPU : May-14

High contact ratio due to which operation is silent.

It gives good result for large number of teeth.

1.7.2 Advantages and Limitations of Larger Pressure Angle

Radial or separating force is high.

1.7.3 Addendum Modification in Gears SPPU: Dec.-15

Gear Dedendum circle

(a) Gears with interference

(b) Gears without interference

Fig. 1.16 : Modified addendum of pinion and wheel

1.8 Force Analysis of Spur Gears SPPU: April-17

1. Tangential component (F) 2. Radial component (F

Fig. 1.17: Force analysis of spur gears

It is always tangent to the pitch circle at pitch point.

where, Pressure angle 1

F- +F (1.15) 4. Corrosive wear

Gear tooth failure

ending tailure or Wear failure or

Pitting Scoring Abrasive wear Corrosive wear

Fig. 1.18 : Modes of gear tooth failure

Destructive pitting begins a a micro-crack on the permissible limits.

hardness of the gears. 3. Abrasive wear

4. Corrosive wear 1. Cast iron

1.10.1 Types of Gear Materials (b) MCI B 320-350 Maximum 150

The different materials used for the manufacturing of gears