ALCORCON ENGINEERING REVIEW CENTER

Cebu Main: 4th floor Coast Pacific Downtown Center, Sanciangko St, Cebu City Tel #(032) 254-33-84
Manila: 3rd floor JPD Bldg 1955, C M Recto corner N. Reyes St, Sampaloc, Manila Tel # (02) 736-4438

MACHINE DESIGN – DAY 4

I. HELICAL GEARS
HELICAL GEAR NOMENCLATURE:

Relation of Angles:

Pcn Pc DP DP
1. cosψ = Pcn = 2. DPn = cosψ =
Pc cos Y cos Y DPn

T
3. tanfn = tanf cosY 4. Tv =
cos3 y

Relation of Forces:
Where: Fr = radial load Fa = axial load
Ft = tangential load Fn = total load

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 5. Power = Ft V 6. Fa = Ft tanY

7. Fr = Ft tanf 8. Fn = Fr 2 + Fa2 + Ft 2

Sw f Y é 78 ù
Strength of Helical Gears Ft = ê ú
P ë 78 + V û
F = 2 Pa where: Pa = axial pitch = Pcn ( sinY)

Dynamic Load on Helical Gears

2
Fd = Ft + 0.05V(C f cos y + Ft ) cos y
0.5V + C f cos2 y + Ft

where: V = pitch line velocity = pDN, fpm

Y = helix angle
Pc = circular pitch
Pcn = normal circular pitch
f = pressure angle
fn = normal pressure angle
f = face width, in
DP = diametral pitch
DPn = normal diametral pitch
T = number of teeth
Tv = virtual number of teeth
Y = form factor based on the virtual number of teeth
Sw = safe working stress, psi
C = a factor dependent upon machining errors
V = pitch line velocity, fpm

II. WORM GEARS

e
d angl
X = lea Where:
p = pitch X = lead angle of the worm
p = linear pitch of the worm
P = circular pitch of the gear
c
D = pitch diameter of the worm
w
D = pitch diameter of the gear
g

P
c

Worm gears are used where high-speed ratios (10:1) and above are desired.

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WORM GEAR NOMENCLATURE

1. Linear pitch, p = distance between adjacent threads

pDg
2. Pc = circular pitch of the gear Pc = =
Tg
pDg
3. Pitch of worm = Circular pitch of gear p = Pc =
Tg

Nw Tg
4. Speed ratio = =
Ng Number of threads on worm

Note: No. of threads on the worm is equal to 1 for single threaded and 2 for double threaded.

5. Tangential velocity of worm, vwt = π Dw Nw

6. Linear velocity of worm, vwL = Nw L

7. Tangential velocity of gear, vg = π Dg Ng

8. But: vwL = vg , therefore Nw L = π Dg Ng

9. Lead, L - the distance from any point on one thread to the corresponding point on the next turn of the same thread.
Lead angle - the angle between the tangent to the pitch helix and the plane of rotation.
Lead, L = p (for single thread) = 2p ( for double thread) = 3p (for triple thread)

Dw + Dg
10. Center Distance, C C=
2
Where: Dw = pitch diameter of the worm Dg = pitch diameter of the gear
Ng = speed of gear Nw = speed of worm
Tw = number of teeth of worm Tg = number of teeth of gear
vw = tangential velocity of worm Vg = tangential velocity of gear
vwL = linear velocity of worm

11. Relation of angles:

For one revolution of the worm:

Lead angle(x):
L

Axis of
rotation
Y

πD o
X w where: Y = 90 - x
N tanf = tanf (cos x)
w
n

Note: lead angle of worm = helix angle of gear

where: x = lead angle of worm

f = pressure angle b = face angle (usually 60o )
fn = normal pressure angle = 14.5o if not given Y = helix angle of worm

Note: lead angle of worm = helix angle of gear

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 tan x(cos fn - f tan x )
12. Efficiency of Worm gear: e =
cos fn tan x + f

To maximize efficiency, tan x = 1+ f 2 - f

13. Power transmitted: Free body diagram:

Pw = power of worm = 2 π Tw Nw = Wt vw
Pg = power of gear = 2 π Tg Ng = Pw e = Ft vg D
w

F W
14. Tangential force on worm, Wt: t
t
S S
2 Tw F
Tw = Wt (Dw / 2) or Wt = t W
t
Dw
D
g
15. Tangential load on gear, Ft:

2Tg e cos f cos x - f sin x

Tg = Ft (Dg / 2) or Ft = or Ft = Wt = Wt
Dg tan x cos f sin x + f cos x

Ft (sin fn )
16. Separation Load, S: S =
cos fn cos x - f sin x

17. Total Force of resultant force: Fn = Ft 2 + Wt 2 + S2

18. Strength of Worm Gear

Note: The worm gear is weaker than the worm, therefore the design for strength is based on the worm gear.

Sw f Y æ 1200 ö
Tangential Load on the gear: Ft = ç ÷
DP è 1200 + V ø

where: Ft = tangential pitch line load on the gear

Sw = safe stress, Table 12-2
f = face width
Y = form factor, Table 11-2
V = pitch line velocity of the gear, fpm
DP = diametral pitch
f = face width = Dw + 2 add
2

Note: add = addendum = 1/DP

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III. BEVEL GEAR

Bevel Gears - are used to connect intersecting shafts, usually at right angle.

1. Number of teeth and Speed relation T1 N1 = T2 N2

2. Speed and Diameter relation: D1 N1 = D2 N2
3. Angle between shafts, θ q = ap + a g

where: ap = pitch angle of the pinion

a g = pitch angle of the gear

4. Speed and Angle relation: Ng sin a g = Np sin ap

sin q
5. Angle of Gear: tan a g =
Ng
+ cos q
Np

sin q
6. Angle of Pinion: tan ap =
Np
+ cos q
Ng

Note: If the shafts are right angle (90o) or θ = 90o if not given

Np Ng
A. tan ag = B. tan ap =
Ng Np

7. Face Angle

A. Face angle of Gear, bg :

bg = a g + a a

Addendum (2 sin ag )
where: tan aa =
Dg

B. Face angle of Pinion bp : bp = ap + aa

Addendum (2 sin ap )
where: tan aa =
Dp

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8. Cutting Angle:

A. Cutting angle of Gear bg : bg = a g - a d

Dedendum (2 sin ag )
where: tan ad =
Dg

B. Cutting angle of Pinion bp : bp = ap - a d

Dedendum (2 sin ap )
where: tan ad =
Dp

9. Power Transmitted: P = 2 π T N

10. Torque transmitted by bevel gear: T = Ft (R) = Ft (Dp / 2)

11. Dynamic Load on Gear:

2T
A. Tangential Force, Ft Ft =
Dp

B. Radial Force, Fr Fr = Ft tan fn cos ap

C. Axial Force, Fa Fa = Ft tan fn sin ap

D. Resultant Force, Fn Fn = Fr 2 + Fa2 + Ft 2

12. Strength of Gear Teeth

Sw f Y é f f 2 ù é 78 ù
Ft = ê1 - + 2 ú ê ú
DP ëê L 3L ûú ë 78 + V û

Where: Sw = working stress

f = face width
DP diametral pitch
Y = form factor
V = pitch line velocity
L = distance from the point of shafts axis intersection to the outermost point of contact of gears.

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PROBLEMS:

WORM GEAR, HELICAL AND BEVEL GEAR

1. A helical gear a 14 ½ deg normal pressure angle and transverse diameter pitch of 2.3622 per cm. The helix
angle is at 45o and has 8 teeth. Compute the transverse pressure angle in degrees.
A. 22.2o B. 19.3o C. 18.9o D. 20.1o

2. A parallel helical gear-set consists of a 19-tooth pinion driving a 57-tooth gear. The pinion has a left-hand helix of
20o, a normal pressure angle of 14 ½ deg and a normal diametral pitch of 10 tooth/inch. If the pinion is to transmit
50 Hp at a speed of 1750 rpm, determine the center distance of the two gears.
A. 2.02 inches B. 6.06 inches C. 4.04 inches D. 2.06 inches

3. A triple thread worm has a pitch diameter of 3 inches. The wheel has 25 teeth and a pitch diameter of 5 inches.
Material for both the worm and the wheel is of phosphor bronze. Compute the helix angle.
A. 0.20 B. 0.30 C. 0.40 D. 14

4. A double threaded right-handed worm gear transmits 15 HP at 1150 rpm. The pitch of the worm is 0.75 the
coefficient of friction is 0.12. Find the separating force in pounds.
A. 504 lbs B. 501 lbs C. 407 lbs D. 5091 lbs

5. A 20o straight-tooth bevel pinion having 14 teeth and a diametral pitch of 6 tooth/inch drives a 42-tooth gear. The
two shafts are at right angles and in the same plane. Find the pitch angle of the pinion.
A. 18.4o B. 20o C. 14.5o D. 20.5o

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