Chapter 10 Design of Gears

§10-1 Introduction
§10-2 Gear Failures and Design Criteria
§10-3 Gear Materials
§10-4 Design of Spur Gears
§10-5 Allowable Stresses and Design Parameters
§10-6 Design of Helical Gears
§10-7 Gear Blank Design
Basic requirements:

 Gear failures and design criteria

 Force condition of spur gears and helical gears

 Contact fatigue and bending fatigue strength

 Choice of materials and parameters

 Structure, lubrication and efficiency of gear

§10-1 Introduction
Gears are used to transmit
torque and angular velocity

Toothed gearing is the most

widely used and most
important mechanical drive.

Gear reducer:
pinion is driving part
Speed increaser:
gear is driving part Gear reducer
 Spur gear Helical gear

Straight bevel gear Worm and worm wheel

Nomenclature
Addendum circle － da、ra B
pk
Dedendum circle － df、rf p
Tooth thickness－ sk ek
e sk pn
Spacewidth－ ek s
ha pb
Pitch－ pk= sk +ek hf
h
Normal pitch － pn
rf
Base pitch － pb r ra
Parameters on reference circle：
d, r, s, e, p= s+e
Addendum ha
Dedendum hf
O
Tooth depth h= ha+hf
Face width－ B
Advantages
(a) Small overall size (compactness)

(b) High efficiency (98%)

(c) Long service life and high reliability

(d) Constant speed ratio

(e) A wide range of torque, speeds and speed ratios.

Disadvantages
(a) Noise, vibration, concussion, and dynamic load.

(b) High precision is required in manufacture and assembly.

(c) Not suitable for long distance transmission.

§10-2 Gear failures and design criteria
1. Gear failures

Tooth root: Breakage

Failures
Pitting（contact fatigue）
Gluing
Tooth surface
Abrasive wear
Ridging
Tooth root breakage

潘存云教授研制

Fatigue crack Overload breakage of part tooth

Reason:
1) Overload: High overloads of either impact or static action
2) Fatigue crack: Repeated overloads causing low endurance
fatigue, or multiple repeated loads leading to fatigue of the
material.（Hard tooth surface）
 Failure location
A gear tooth is somewhat similar to a
cantilever beam. Thus breakage generally
occurs at the root of the tooth on the side
of the stretched fibers where the highest
tensile stress occurs.

Approaches to prevent tooth breakage

1）Enlarge fillet radius；
2）Gears can be machined with greater precision
3）Increase the rigidities of shaft and bearings that carry the gear
for the sake of more uniformly distributed load
4）Use proper heat treatment to obtain sufficient toughness
5）Strengthen the layout of the fillet by blaster or rolling method
Pitting

潘存云教授研制

Pitting is the phenomenon in which small fractures

are lost from the surface of the tooth because of the
high contact stresses causing fatigue.
 Failure location
Crack initiation appears on
the tooth flanks near the line
along the tooth passing
through the pitch point (i.e.
the pitch line). Then it
spreads to the whole surface
of the flank.

Approaches to prevent pitting

1) Proper heat treatment to improve case hardness of gear teeth
2) Select materials with greater hardness
3) Select lubricants with higher viscosity
Gluing
Gears rotating at very high speed on heavy-duty load will cause a
momentary welding. Subsequently, pulling apart will occur
between the two meshing teeth.

Gluing

Approaches to prevent gluing

1）Supply sufficient lubricants
2）Add extreme pressure additive into lubricants
3）Select a lubricant with gluing resistance
Abrasive wear (open gearing)
Foreign material→materials
wear →tooth thickness is
thinner → tooth root breakage

Approaches to prevent tooth breakage

1) Select materials with high hardness；

2) Use encased gearing ； 潘存云教授研制

3) Use appropriate lubricating

Ridging (soft tooth under heavy load)
The surface materials of the
Driving
gear tooth flow along the
direction of the frictional force. 潘存云教授研制

Notch on driving gear, and the Driven

crown on driven gear.

Notch Crown
Common failure type for gears
Tooth root breakage
Failure type for encased gears
Pitting

Tooth root breakage

Failure type for open gears
Abrasive wear

Notice：In open gearing, pitting is rarely observed. The surface

layers are worn away before fatigue cracks appear.

Failure type Design criteria

 2. Design criteria
▲ No appropriate design criterion for abrasive wear
1) Soft gear surface (HBS≤350)
Pitting — contact strength design
— check bending strength
Encased gearing
2) Hard gear surface (HBS≥350)
Breakage — bending strength design
— check contact strength

Open gearing 3) Breakage\Abrasive wear

— Bending strength design
— Enlarge the module appropriately
§10-3 Gear Materials
In many cases, the core of gear tooth requires toughness to
resist tooth-stripping, but its surface should have sufficient
hardness to resist wear, pitting and gluing.
1. Commonly used materials
Forged steel Carbon-steel or alloy steel containing
(0.15~0.6)% carbon；
Good wear resistance and good strength,
Cast steel
usually for big size gear

Good wear, glue and pitting resistances

Cast Iron
Usually for low speed, light-duty and low quality
Good corrosion, wear resistance
Non-metal Usually for high speed, light-duty transmission
and low precision, low noisy
2. Heat treatment method
Heat treating is a group of industrial and metalworking
processes used to alter the physical, and sometimes
chemical, properties of a material
Quenched
Tempered
Normalizing
Heat treatment
Casehardening
Carburizing
Nitriding
Table 10-1 Gear materials and their mechanical properties

Materials Tensile strength Yield strength Hardness

Heat treatment
designations σB / MPa σS / Mpa Core Case

HT250 250 170~241

HT300 300 187~255

HT350 350 197~269

QT500-5 500 147~241

Normalized
QT600-2 600 229~302

ZG310-570 580 320 156~217

ZG340-640 650 350 169~229

45 580 290 162~217

Table 10-1 Gear materials and their mechanical properties

Materials Tensile strength Yield strength Hardness

Heat treatment
designations σB / MPa σS / Mpa Core Case

ZG340-640 700 380 241~269

45 650 360 217~255

30CrMnSi Quenched and 1100 900 310~360

35SiMn tempered 750 450 217~269

38SiMnMo 700 550 217~269

40Cr 700 500 241~286

Case-hardened 40~50
45 217~255
after being HRC
quenched and 48~55
40Cr tempered 241~286
HRC
Table 10-1 Gear materials and their mechanical properties

Materials Tensile strength Yield strength Hardness

Heat treatment
designations σB / MPa σS / Mpa Core Case

20Cr 650

18CrMnTi 1000 300

Hardened after
20CrMnTi 1100 58~62HRC
being carburized
12Cr2Ni4 1100 320

20Cr2Ni4 1200 350

35CrAlA Nitrided after 950 750

being quenched >850HV
38CrMoAlA and tempered 1000 850
The materials selection is generally thought about
a) The loads
b) The tangential velocity
c) The scale of manufacture ( mass production / single)
d) Basic technology of the manufacture
e) Pinion hardness is greater than gear (20~25HBS spur gears)
(40~50HBS helical gears) when the gear hardness is less than
350HBS (soft tooth surface).
f) Or equal to each other when their hardness is great than
350HBS. (hard tooth surface)

For example:
Alloy steel for high speed, high load and impact
Hardened Alloy steel after being carburized for airplane gear
The heat-treatment is assigned on the basis of the
following considerations:

1) Surface hardening (carburizing nitriding, carbonitriding).

After this the gear hardness is about HBS>=350

1) Quenching used for medium- or high-carbon steel

3) Quenching and tempering.

After this the gear hardness is about HBS<=350

4) Annealing.
After this, the gear hardness is about HBS<=350
§10-4 Design of spur gears
1. Forces on spur gear teeth
Direction of each force is shown in Figure

Tangential force： Ft 
2T1 O2
O2
d1
α ω2 α
Radial force： F  F tan  （driven）
r t
d2
Normal force：F  Ft  2T1 2 N2 Fn N2
Fr
cos d1cos Fn α
n
α t
t t t
d1-reference circle diameter c c Ft
Fn d1
α-pressure angle N1 N1 d1
T1 2 T1 2
T1-nominal torque
α ω1 α ω1
P1-power of driving gear (driving)
（driving）
O1 O1
n1-rotate speed of driving gear
 Direction
Ft on driving gear is the opposite to
rotating direction
Ft on driven gear is the same as
rotating direction
Fr on both gears point to wheel
centre (external meshing）
T1-nominal torque transmitted by
the driving gear
P1 P1
T1  106  9.55  106 N  mm
1 n1

P1---- power of the driving gear（kW）ω1----angular speed of driving gear

n1----rotate speed of driving gear (rpm）
d1----reference circle of driving gear
 driving
Fr1 n1
Ft1
Fr1
Fr1 n1
Ft1 Ft2 Ft1 ⊙
○× F
t2
Ft2 Fr2 Fr2
n2 n2
Fr2
driven
2. Calculated Load
2T1
Ft 
d1
The normal force is calculated under the assumption that it is
uniformly distributed along the face wide of the teeth.
Actually there are load concentration and dynamic load due to
errors in manufacture or teeth deflection.

Calculated load：Ftc  KFt

K: Load factor，K＝KA Kv Kα Kβ
Notice：KA ─Application factor Kα─Load partition factor
Kv ─Dynamic factor Kβ─Load distribution factor
3. Contact fatigue strength of spur gear teeth
Check contact stress To avoid significant pitting on tooth form
 H  [ H ] O2
ω2
Hertz theory
α （driven）
1 1
 d2
Fn 1  2 2
H   N2
 L 1  12 1  22 α

潘存云教授研制
t t
E1 E2 C d1
N1
“+” external meshing，“-” internal meshing T1 2
Fn—normal load μ —Poisson’s ratio α ω1
L —contact length （driving）
O
E —Elastic modulus 1
ρ —radius of curvature
Radius of curvature at contact point：
d1 sin  d 2 sin 
1  N1C   2  N 2C 
2 2
O2
Ratio of tooth number: u=z2/z1=d2/d1 ω2
α （driven）
1 1  2  1
  d2
1  2 1 2 2 N2
ρ2
潘存云教授研制 α
2(d 2  d1 ) u  1 2 t
C
t
   ρ1 d1
d1d 2 sin  u d1 sin  N1
T1 2
α ω1
Ft 2 KT1
Fn   （driving）
cos  d1 cos  O1
 1 1 u 1 2 Ft 2T1
   Fn  
1  2 u d1 sin  cos  d1 cos 

1 1 2 KT1 2 u 1

Fn 1  2 d1 cos  d1 sin  u
H   =
 L 1  12 1  22  1  12 1  22 
  L  
E1 E2  1 E E2 
Effective length of contact line relates to contact ratio

Zε is coefficient of contact ratio. Zε = 0.85~0.92

b
L 2
Z Use higher value for less number of teeth.
b is the width of tooth
 2 KT1 2 u 1
d1 cos  d1 sin  u 2 KT1 b u 1
 Z L 2 
1 2
H=  
 1  1 1  2 
2 2
bd1 Z  1  1 1  2  cos  sin  u
2 2 2
 L      
 1 E E2   1
E E 2 

1
ZE = 2
 1  1  
2 2
ZH =  2.5
 1
 
2
sin  cos 
 1E E2 
Elastic coefficient Zone factor

2 KT1 u  1
 H  Z H Z E Z 2
MPa
bd1 u
Check Formula for contact fatigue strength

2 KT1 u  1
 H  Z H Z E Z 2
 [ H ] MPa
bd1 u
[σH] is the smaller value of the two gears
Design Formula for contact fatigue strength

Define a flank face width ratio d  b d1

to calculate the diameter d1 of the pinion.

2 KT1   1 Z H Z E Z 2
d1  3  ( ) mm
d  [ H ]
 2 KT1 u  1
 H  Z H Z E Z 2
 [ H ] MPa
bd1 u

2 KT   1 Z Z Z
d1  3 1
 ( H E  2
) mm
d  [ H ]

Note:
1) Pay attention to the units of d1, T1, [σH]: mm, N·mm , MPa.
2) Substitute the less value of the [σH1] , [σH2] to the design formula.
3) Plus sign (+) refers to external, and minus (-) to internal gearing.
4) Only one gear should be checked out.
4. Bending fatigue strength of spur gear teeth
We assume that the friction forces on the teeth are small.
Then the force of interaction can be taken as being normal
to the tooth profiles, （i.e. along the line of action which is
tangent to the base circle ） Fn
Under this condition, tooth can be seemed as αF
F1
a cantilever. The dangerous cross section is at
the root of the tooth in the zone of maximum Fn F2
stress concentration. (The dangerous cross h
30˚ 30˚
section is determined by 30°tangential lines
method) s
Normal force at addendum circle：Fn
rb B
F1 = Fn cosαF ---induce bending stress； A σF

F2 = Fn sinαF ---induce Press stress, small and ignore σC

O
Normal force at addendum circle：Fn
F1 = Fn cosαF ---induce bending stress；
F2 = Fn sinαF ---induce Press stress，small and ignore Fn
F1 αF
Bending moment： M=F1·h=Fn·cosαF·h
Fn F2
2 h
Section modulus in bending：W  bs 30˚ 30˚
6 s
Bending stress：
rb B
M 6 Fn h cos  F 2 KT1 A
F   2
Fn 
d1 cos 
W bs σF

2 KT1 6h cos  F O
  2
bd1 s cos 
 2 KT1 6h cos  F
Bending stress：  F   2
bd1 s cos 
hh
6( )cos
6( )cos  2 KT1
2 KT1 FF
  m
m   YFa
bd1m (( ss ))22cos
cos bd1m
m m
h
6( )cos  F
Tooth form factor: YFa  m
s
( ) 2 cos 
m
YFa is independent of module but dependent on tooth number

2 KT1
Bending stress： F   YFa
bd1m
 Considering stress concentration and contact ratio
we introduce two factors to modify the equation.
YSa stress concentration factor. Refer to Table 10.4
Yε contact ratio factor Yε =0.65~0.85

2 KT1 Check Formula 2 KT1

F   YFa F  YFaYSaY  [ F ]
bd1m bd1m

Define a flank face width ratio d  b d1

3
2 KT1 YFaYSaY
Design Formula m   mm
d z1 [ F ]
2
 2 KT1 3
2 KT1 YFaYSaY
F  YFaYSaY  [ F ] m  mm
bd1m d z1 [ F ]
2

Note
1) Pay attention to the units of d1, T1, [σF]: mm, N·mm , MPa.
2) For two gear materials, YFa1YSa1 /[σF1] , YFa2YSa2 /[σF2]
are different, and the greater value of them to design formula
should be substitute.
3) Result m from design formula should be chosen from standard
value.
4) σF1≤[σF1], σF2≤[σF2] should be checked out respectively.
§ 10-5 Allowable stress and design parameters
1. Allowable stress
K HN  H lim K FN  Flim
 H    F    YST
SH SF

σHlim --endurance limit for contact strength (MPa) See Fig. 10.14
σFlim --endurance limit for bending strength (MPa) See Fig. 10.15
KHN -- life factor for contact strength See Fig. 10.16
KFN -- life factor for bending strength See Fig. 10.17
SH -- safety factor for contact strength See Table 10.5
SF -- safety factor for bending strength See Table 10.5
YST -- stress correction factor of the test gear. YST=2.0
2. Design parameters
1) Face width factor φd=b/d1
Contact 2 KT1   1 Z H Z E Z 2 Bending 3
2 KT1 YFaYSaY
d1  3  ( ) m 
design d  [ ] Hdesign d z1 [ F ]
2

Table 10.7 Face width factor φd for cylindrical gears

Gear position relative to Case hardness of Case hardness of both
the bearings the gear ≤350HBS gears ＞350HBS
Centered between
0.8~1.4 0.4~0.9
bearings
Straddle-mounted but not
0.6~1.2 0.3~0.6
centered
Cantilever 0.3~0.4 0.2~0.5

d1 or m obtain b=φdd1 Make b2=b; b1=b+5~10mm

φd=b/d1
2) Pinion tooth number z1.
3
2 KT1 YFaYSaY
m 
d z1
2
[ F ]
If center distance is fixed
Bending strength decrease
m↓
h ↓ → materials cutting decrease
z1 ↑
Contact ratioε↑ →More smooth
For encased soft surface gearing 20-40

For encased hard surface gearing or open gearing 17-20

z1 is chosen, z2= z1 ×u，but z2 sometimes is non-integer
If make z2 integer, actual i12≠u, the difference in 3~5% is OK
3. Quality class of tooth gearing (Precision of gear)
 There are twelve grades (1-12) of tooth gearing accuracy (the less
number represents the higher grade).
 The greater the quality class, the less the dynamic load, the smoother
the engagement, but the more the cost.
 Most commonly used in the engineering industries are grades 6, 7,
8, 9.
Table 10.8 Recommended quality classes for gears in universal machines
Machine Quality classes Machine Quality classes
Steam turbine 3~6 Light vehicle 5~8
Metal-cutting machine
3~8 Cargo vehicle 7~9
tool
Aircraft engine 4~8 Tractor 6~8
General purpose
6~8 Crane 7~10
reducer
Forging press 6~9 Agriculture machine 8~11
Fig. 10.18 Selected values for gear quality classes
Design Example
A pair of spur gears has a gear ratio u=3.2
It transmits power P1=10 kW
while the pinion rotates at n1=960 rpm
The design life is two shifts per day, 250 days per
year, for 10 years. The input power is from an
electric motor, and the drive is for a packing
machine. The drive is encased gearing. Design the
spur gears.
Solution
1. Specify quality classes, materials and the numbers of
teeth z1, z2 for gears
1) The packing machine is a kind of general machine. Its speed is
not high. So we select quality class 8

Table 10.8 Recommended quality classes for gears in universal machines

Machine Quality classes Machine Quality classes
Steam turbine 3~6 Light vehicle 5~8
Metal-cutting machine
3~8 Cargo vehicle 7~9
tool
Aircraft engine 4~8 Tractor 6~8
General purpose
6~8 Crane 7~10
reducer
Forging press 6~9 Agriculture machine 8~11
2) Specify gear materials and their heat treatment from table 10.1
For the pinion: 45, quenched and tempered, 250HBS
For the gear: 45, normalized, 210HBS

Table10.1 Gear materials and their mechanical properties

Tensile Yield
Material Hardness (HBS)
Heat treatment strength strength
designations
(MPa) (MPa) Core Case
QT500-5 500 147~241
ZG340-640 Normalized 650 350 169~229
45 580 290 162~217
45 650 360 217~255
quenched and
30CrMnSi 1100 900 310~360
tempered
40Cr 700 500 241~286
3) For encased gearing, determine the number of teeth in the pinion

For encased soft surface gearing 20-40.

For encased hard surface gearing or open gearing 17-20.

z1 = 24
z2 = uz1 = 3.2× 24=76.8

Because z2 must be an integer, so we let z2 = 77

2. Design gears based on contact fatigue strength
1) Compute the load factor K=KAKVKαKβ
KA-application factor
Table 10.2 Application factor KA
Power source
Driven machine Medium
Uniform Light shock Heavy shock
shock
Uniform 1.00 1.10 1.25 1.50
Light shock 1.25 1.35 1.50 1.75
Moderate shock 1.50 1.60 1.75 2.00
Heavy shock 1.75 1.85 2.00 ≥2.25

With a uniform power source (an electric motor) and

a uniform load (a packing machine)
Kv- dynamic factor
For spur gears Kv=1.05~1.4
For helical gears Kv=1.02~1.2

The higher values for lower precision and higher pitch-line speed.

Kv=1.23

K - load partition factor

For spur gears Kα=1.0~1.2

For helical gears Kα=1.0~1.4

The higher values for lower quality class

Kα=1.1
 Kβ -Load-distribution

When one of the mating gears is soft surface

Kβ=1~1.2
When both gears are hard surface
Kβ=1.1~1.35

Kβ=1.1

Then, load factor K=KAKVKαKβ

=1.0×1.23×1.1×1.1=1.488
2) Calculate the nominal torque exerted on the pinion

P 6 10
T1  9.55  10 6
 9.55  10  9.948  104 N  mm
n1 960

3) Specify φd from Table 10.7, face width factor using the

nominal value
Gear position relative to Case hardness of Case hardness of both
the bearings the gear ≤350HBS gears ＞350HBS
Centered between
0.8~1.4 0.4~0.9
bearings
Straddle-mounted but not
0.6~1.2 0.3~0.6
centered
Cantilever 0.3~0.4 0.2~0.5

φd = 1.1
4) From Fig. 10.12, we have zone factor
for standard spur gear ZH=2.5

5) From Table 10.3, we find elastic factor

ZE=189.8

Gear material
Pinion material Nodular Grey cast
Forged steel Cast steel
cast iron iron
Forged steel 189.8 188.9 186.4 162.0
Cast steel 188.0 180.5 161.4
Nodular cast iron 173.9 156.6
Grey cast iron 143.7
6) Specify the coefficient of contact ratio Zε from P191
Zε = 0.85~0.92
Zε = 0.89
use higher value for less number of teeth.

7) From Equation (10.11), we obtain number of load cycles

N1 = 60n1jLh = 60×960×1×(10×250×2×8)=2.304×109

N2 = N1/u = 2.304×109/3.2 = 7.2×108

8) From Fig. 10.16, we obtain contact strength life factors
without pitting

N1 = 2.304×109 KHN1 = 1
N2 = 7.2×108 KHN2 = 1
9)From Fig. 10.14(b), we obtain contact endurance limits

For the pinion: 45, quenched and

tempered, 250HBS

For the gear: 45, normalized,

210HBS

σHlim1 = 605 MPa

σ Hlim2 = 570 MPa
10) Specify the factor of safety for contact fatigue strength from
Table 10.5
Table 10.5 The minimum values for factor of safety

Factors of safety Static strength Fatigue strength

SH 1.0~1.3 1.0~1.6
SF 1.4~1.8 1.4~3.0

SH = 1.3
11) Substituting above values to Equation (10.9), we obtain
allowable contact stresses
K HN 1 H lim1 1 605
 H1     465 MPa
SH 1.3
K HN 2 H lim 2 1 570
 H2     438 MPa
SH 1.3
12)Compute the reference diameter in the pinion using Equation
(10.6), substituting the smaller allowable contact stress
2 KT1 u  1 Z H Z E Z 2
d1  3  ( )
d u [ H ]

2 1.488  9.948 104 3.2  1 2.5 189.8  0.89 2

 3
 ( )
1.1 3.2 438
 68.99 mm
13） Calculate the key parameters features for the gears
mmin  d1 / z1  68.99 / 24  2.87 mm

First
1 1.25 1.5 2 2.5 3 4 5 6 8 10 12 16 20 25 32 40
series
Second
1.75 2.25 2.75 3.5 3.75 4.5 5.5 7 9 14 18 22 28 36 45
series

Set m  3 mm

Face width b=ϕdd1=1.1×68.99=75.889 mm

3. Checking bending fatigue strength
1) From Table 10.4, the tooth form factor YFa
and the stress concentration factor YSa
Can be easily obtained in term of the number of teeth

Table 10.4 Tooth form factor YFa, and stress concentration factor YSa

z(zv) 17 18 19 20 21 22 23 24 25 26 27 28 29
YFa 2.97 2.91 2.85 2.80 2.76 2.72 2.69 2.65 2.62 2.60 2.57 2.55 2.53
YSa 1.52 1.53 1.54 1.55 1.56 1.57 1.575 1.58 1.59 1.595 1.60 1.61 1.62
z(zv) 30 35 40 45 50 60 70 80 90 100 150 200
YFa 2.52 2.45 2.40 2.35 2.32 2.28 2.24 2.22 2.20 2.18 2.14 2.12 2.06
YSa 1.63 1.65 1.67 1.68 1.70 1.73 1.75 1.77 1.78 1.79 1.83 1.87 1.97

linear interpolation
For the pinion: z1 = 24 YFa1 = 2.65 YSa1 = 1.58
For the gear: z2 = 77
2.22  2.24
YFa 2   (77  70)  2.24  2.226
80  70
1.77  1.75
YSa 2   (77  70)  1.75  1.764
80  70

2) From P195, we specify the coefficient of contact ratio Yε

Y ε = 0.65~0.85
Y ε = 0.67
3) From Fig. 10.17, we obtain bending strength life factors

N1 = 2.304×109 KFN1 = 1
N2 = 7.2×108 KFN2 = 1
4) From Fig. 10.15(b), we obtain bending fatigue endurance limits

For the pinion: 45,

quenched and tempered,
250HBS

For the gear: 45,

normalized, 210HBS

σFlim1 = 230 MPa

σFlim2 = 220 MPa
5) Specify the factor of safety for bending fatigue strength from
Table 10.5
Table 10.5 The minimum values for factor of safety

Factors of safety Static strength Fatigue strength

SH 1.0~1.3 1.0~1.6
SF 1.4~1.8 1.4~3.0

SF = 2.2
6) Compute allowable bending stresses using Equation
(10.10)
K FN 1 Flim1 1 230
 F1    YST   2  209 MPa
SF 2.2

K FN 2 Flim 2 1 220
 F2    YST   2  200 MPa
SF 2.2

YST = stress correction factor of test gear. In term

of national standard (P195)

YST = 2.0
(7) Check bending strength of gears

2 KT 1YFa1YSa1 2  1.488  9.948  104  2.65  1.58

 F1    75.62 MPa<[ F 1 ]
2
bm z1 75.889  3  24
2

YFa 2YSa 2 2.226  1.764

 F 2   F1  75.62  8  71.83 MPa<[ F 2 ]
YFa1YSa 1 2.65  1.56

 d1n1   72  960
v   3.62m / s
60  1000 60000
4. Calculate the dimensions of key features for the gears

d1  mz1  3  24  72 mm

d2  mz2  3  77  231 mm

1 1
a  (d1  d 2 )  (72  231)  151.5 mm
2 2
b  d d1  1.1 72  77 mm

Setting b1  82 mm
b2  77 mm
Engineering drawing
 KA-application factor
Application factor considers the probability that load variations,
vibrations, shock, speed changes and other application-specific
conditions result in peak loads greater than nominal load. It is
determined by the types of the driving power source and the
driven machine.
Table 10.2 Application factor KA
Power source
Driven machine Medium
Uniform Light shock Heavy shock
shock
Uniform 1.00 1.10 1.25 1.50
Light shock 1.25 1.35 1.50 1.75
Moderate shock 1.50 1.60 1.75 2.00
Heavy shock 1.75 1.85 2.00 ≥2.25

Type of machine is on page 187-188

 Kv-dynamic factor
Inevasible errors in manufacture and assembly of gears as well
as elastic deflections under load of the teeth, are prone to result
in non-uniform rotation of the gear when the pinion is rotating
at uniform speed. The dynamic load occurs.
For spur gears Kv=1.05~1.4 The higher values for
lower precision and
For helical gears Kv=1.02~1.2 higher pitch-line speed.
1.8
10
1.6 9

8
Kv 1.4
7
1.2 6

More precise
潘存云教授研制gear mechanism
1.0
0 10 20 30 40 50 m/s
 Kα-load partition factor
K reflects the non-uniformity of tooth loading among two
pairs of teeth due to manufacture error and teeth deformation.

K depends on the gearing rigidity, base pitch error, modifying

magnitude, etc.

For spur gears Kα=1.0~1.2

For helical gears Kα=1.0~1.4

The higher values for lower quality class

 Kβ-load distribution factor
The load is distributed uniformly along the flank width only for
ideally accurate manufacture.
However, Kβ accounts for many variables of gears and shafts,
bearings, housing, and the structure in which the gears are
installed. These variables may cause the gears in misalignment
which results in load concentration along the flank width.

Load concentration occurs owing to

1) Elastic deformation of the shafts.
2) Elastic displacement of the bearing and the gear.
3) Wear of bearings.
4) Errors in manufacturing the mating gear.
 load concentration caused load concentration caused
by bending deformation by twisting deformation

When one of the mating gears is soft surface Kβ=1~1.2.

When both gears are hard surface Kβ=1.1~1.35.
 Table 10.3 Elastic coefficient ZE ( MPa )

Gear material
Pinion material Nodular Grey cast
Forged steel Cast steel
cast iron iron
Forged steel 189.8 188.9 186.4 162.0
Cast steel 188.0 180.5 161.4
Nodular cast iron 173.9 156.6
Grey cast iron 143.7
 Zone factor

2
ZH =
sin  cos 

for standard spur gear

ZH=2.5

Helix angleβ (°)

Fig. 10.12 Zone factor
 Table 10.4 Tooth form factor YFa, and stress concentration factor YSa

z(zv) 17 18 19 20 21 22 23 24 25 26 27 28 29
YFa 2.97 2.91 2.85 2.80 2.76 2.72 2.69 2.65 2.62 2.60 2.57 2.55 2.53
YSa 1.52 1.53 1.54 1.55 1.56 1.57 1.575 1.58 1.59 1.595 1.60 1.61 1.62
z(zv) 30 35 40 45 50 60 70 80 90 100 150 200
YFa 2.52 2.45 2.40 2.35 2.32 2.28 2.24 2.22 2.20 2.18 2.14 2.12 2.06
YSa 1.63 1.65 1.67 1.68 1.70 1.73 1.75 1.77 1.78 1.79 1.83 1.87 1.97
 Fig. 10.14 Endurance limits σH lim for contact strength
The ML, MQ, and ME lines represent low, medium, and high requirements,
respectively. We generally choose the MQ line for the value of endurance limits.

When materials of two gears are different, smaller σHlim should be chosen
 Fig. 10.15 Endurance limits σF lim for bending strength

The limits in figure is based on pulsation cycle loading

For symmetrical cycle loading, the limits should be multiplied by 0.7
N---- expected number of load cycles: N=60njLh
n ---- rotational speed of the gear, rpm
j ---- number of load applications at one tooth profile per revolution
Lh ---- design life for the gears (h)
N---- expected number of load cycles: N=60njLh
n ---- rotational speed of the gear, rpm
j ---- number of load applications at one tooth profile per revolution
Lh ---- design life for the gears (h)
 Table 10.5 The minimum values for factor of safety

Factors of safety Static strength Fatigue strength

SH 1.0~1.3 1.0~1.6
SF 1.4~1.8 1.4~3.0