Helical Gear Design steps

Equivalent number of teeth 𝑍 = , α = Helix Angle

1) Identify the weaker Gear

a) When both the pinion (smaller gear) and other gear are made of same material, then pinion is
weaker.

b) When the pinion and gear are made of different material than calculate ( σb* Y’)for both the gears.
The less value suggests the weaker gear.

Y’=0.124-0.684/Z’ for 14.5 pressure angle. Y’=0.39-2.148/Z’ for 14.5 pressure angle.

Y’=0.154-0.912/Z’ for 20 Full depth pressure Y’=0.484-2.865/Z’ for 20 Full depth pressure
angle. angle.

Y’=0.175-0.841/Z’ for 20 stub pressure angle Y’=0.55-2.642/Z’ for 20 stub pressure angle

If this is given then multiply by π (3.14) If not given then select as per above

2) Calculate the beam strength (Apply the Lewis equation for weaker gear)

𝐹 = (𝝈 𝑌′) 𝑏 m

b= Face width=If not given then assume 10mn (10 times module)
mn= Normal Module in mm
mn= mtcosα and mt is the transverse module= d/z
3) Calculate the wear strength (Calculate only if load stress factor(k)/hardness-BHN/ wear strength is
mentioned in data)
𝐷 𝑏𝑄𝑘
𝐹 =
cos 𝛼
Dp= Pitch circle diameter of pinion in mm, =mt* Zp b=face width of weaker gear in mm,

Q=ratio factor

Q= for external gear

Q= for internal gear

k= load stress factor

𝟐
𝑩𝑯𝑵
𝒌 = 𝟎. 𝟏𝟔 𝑭𝒐𝒓 𝑺𝒕𝒆𝒆𝒍 𝒈𝒆𝒂𝒓 & 𝑠𝑡𝑒𝑒𝑙 𝑝𝑖𝑛𝑖𝑜𝑛 @ 20 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑛𝑔𝑙𝑒
𝟏𝟎𝟎
Dr. Hardik Chothani, Asst Professor, GEC Bhavnagar Page 1 of 4
Helical Gear Design steps

𝐵𝐻𝑁
𝑘 = 0.21 𝐹𝑜𝑟 𝐶𝑎𝑠𝑡 𝑖𝑟𝑜𝑛 𝑔𝑒𝑎𝑟 & 𝑐𝑎𝑠𝑡 𝑖𝑟𝑜𝑛 𝑝𝑖𝑛𝑖𝑜𝑛 @ 20 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑛𝑔𝑙𝑒
100

𝐵𝐻𝑁
𝑘 = 0.18 𝐹𝑜𝑟 𝑐𝑎𝑠𝑡 𝑖𝑟𝑜𝑛 𝑔𝑒𝑎𝑟 & 𝑠𝑡𝑒𝑒𝑙 𝑝𝑖𝑛𝑖𝑜𝑛 @ 20 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑛𝑔𝑙𝑒
100

(OR)

(𝝈 ) Ø
k=
.

𝝈 = 𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑒𝑛𝑑𝑢𝑟𝑎𝑛𝑐𝑒 𝑙𝑖𝑚𝑖𝑡 in N/mm2

Ep= Young modulus for pinion material in N/mm2

Eg=Young modulus for gear material in N/mm2

4) If Fb < Fw, It is required to design gear pair against the bending load, for safe design effective load
(Feff) should be less than the Fb. And ) If Fb > Fw, It is required to design gear pair against the wear
load, for safe design effective load (Feff) should be less than the Fw.

5) Effective load calculation

𝐾 𝐾 𝐹
𝐹 =
𝐾

Ka= Service factor, It depends on the driving machine and driven machine,

Driving machine Driven machine

pump, multi cylinder Press machine, shear
Conveyors, elevators
piston machine, crusher
Electric motor, turbine 1 1.25 1.75
Multi cylinder IC engine 1.25 1.50 2
Single Cylinder IC
1.5 1.75 2.25
engine

Km= Load distribution factor, it depends on accuracy and face width, if not given then assume 1.

Kv (Cv) = Velocity factor

The value of velocity (m/s) CV

Less than 12.5 for regular gear 𝟑
𝟑+𝒗
Less than 12.5 for Precise gear 4.5
4.5 + 𝑣
Less than 20 for regular gear 6
6+𝑣

Dr. Hardik Chothani, Asst Professor, GEC Bhavnagar Page 2 of 4

Helical Gear Design steps

Less than 20 for Precise gear 0.75

0.75 + √𝑣
(Remember- v is always in meter/second)
Ft= Tangential Load

𝑃
𝐹 =
𝑣

P =Input power in watt, V=Velocity in m/s,

Find out velocity (V)

𝑣=
πDN=m/s

D= Pitch circle diameter of any one gear in meter

N=Speed of the same gear

𝐷1 𝑍1 𝑁2
𝑔= = =
𝐷2 𝑍2 𝑁1

G= speed ratio or gear ratio

Other dimensions

Center distance= Radius of pinion +radius of gear

Z=Number of teeth

6) Check the design is safe/unsafe in bending

6.1) If Fb<Fw, check design for bending

𝐹 < 𝐹 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛

𝐹 ∗ 𝐹𝑂𝑆 = 𝐹

𝐹𝑂𝑆 = 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦

6.2) If Fb>Fw, check design for Wear

𝐹 < 𝐹 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛

𝐹 ∗ 𝐹𝑂𝑆 = 𝐹

𝐹𝑂𝑆 = 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦

Dr. Hardik Chothani, Asst Professor, GEC Bhavnagar Page 3 of 4

Helical Gear Design steps

7) Calculate the dynamic load by using buckingham’s equation

(If dynamic load factor C is given/ mention dynamic load then use only)

21𝑣(𝑏𝐶 + 𝐹𝑒𝑓𝑓 ∗ 𝐾𝑣)

𝐹
21𝑣 + 𝑏𝐶 + 𝐹𝑒𝑓𝑓 ∗ 𝐾𝑣

b =face width in mm

C=dynamic factor in N/mm

Velocity v= M/s

Dynamic factor is based on the tooth error, material and pressure angle. Either select from the table or
calculate based on equation.
𝐾𝑒
𝐶=
1 1
+
𝐸𝑝 𝐸𝑔

K=factor for form of teeth

K=0.107 for 14.5 pressure angle.

K=0.111 for 20 full depth pressure angle.

K=0.115 for 20 stub pressure angle

e=tooth error in mm

Ep= Young modulus for pinion material in N/mm2

Eg=Young modulus for gear material in N/mm2

𝐹 = 𝐹 ∗𝐾 +𝐹

Check design for dynamic load

𝐹 < 𝐹 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛

𝐹 ∗ 𝐹𝑂𝑆 = 𝐹

𝐹𝑂𝑆 = 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦

Dr. Hardik Chothani, Asst Professor, GEC Bhavnagar Page 4 of 4