C = 200 mm n1 = 550rpm

Angular velocity of the gear: 1 1

2𝑎𝑤 𝑃 2(5)( )(0.2)
𝑇2 𝑑 60
2𝜋𝑛1 2𝜋(550) 𝑇1 ≥ → 1 1
= 2.39633
𝑤1 = = = 57.595 = 57.95 𝑟𝑎𝑑/𝑠 1 1 1+ ( )+2 𝑠𝑖𝑛2 20−1
60 60 1+ +2 𝑠𝑖𝑛2 ∅−1 60 60
𝑇2 𝑇2

Assumptions based from the standard of American Gear Manufacturer Association (AGMA) and
Available standard Hob (cutters). 20 ≥ 2.39633 
T1 = 20 D1 = 100mm ∅ = 20°
Parameters
T2 = 60 D2 = 300mm Working depth, hs 2.00 2.00
= = 10𝑚𝑚
𝑃𝑑 0.2
So, the angular velocity of the driven gear is: Total depth, ht 2.250 2.250
= = 11.25𝑚𝑚
𝑃𝑑 0.2
𝑤2 𝑇1 𝑤2 20 20
= → = = → 𝑤2 = (57.595) → 𝑤2 = 19.198 𝑟𝑎𝑑/𝑠 Fillet radius of basic rack, rf 0.300 0.300
𝑤1 𝑇2 57.595 60 60 = = 1.5𝑚𝑚
𝑃𝑑 0.2
1.5708 1.5708
Tooth thickness, t = = 7.85𝑚𝑚
𝑃𝑑 0.2
Design for space limitation: 0.250 0.350
Clearance = = 1.25𝑚𝑚
𝑃𝑑 0.2
D1 + D2 = Allowance width → 100mm + 300mm = 400mm

𝐷1 𝑛2 100 𝑛2 100 Parameters Diver Gear/ Pinion Driven Gear

= → = = → 𝑛2 = (550) → 𝑛2 = 183𝑟𝑝𝑚 Number of teeth, T 20 60
𝐷2 𝑛1 300 550 300
Pitch circle diameter, D 100 300
Determination of number of teeth: Diametral pitch, 𝑃𝑑 𝑇1 20 𝑇2 60
𝑃𝑑 = = = 0.2 𝑃𝑑 = = = 0.2
𝐷1 100 𝐷2 300
Since, T1 = 20 and T2 = 40 Circular pitch, , 𝑃𝑐 𝑃𝑐 = 𝜋𝑚 = 𝜋(5) = 15.71𝑚𝑚 𝑃𝑐 = 𝜋𝑚 = 𝜋(5) = 15.71𝑚𝑚
Module, m 𝐷 100 𝐷 300
𝑇1 𝑇2 20 60 = = 5𝑚𝑚 = = 5𝑚𝑚
= = 𝑃𝑑 → = = 0.2 𝑇 20 𝑇 60
𝐷1 𝐷2 100 300 Addendum, aw 1m = 1(5) = 5mm 1m = 1(5) = 5mm
Dedendum, dw 1.25 1.25 1.25 1.25
= = 6.25𝑚𝑚 = = 6.25𝑚𝑚
𝑃𝑑 0.2 𝑃𝑑 0.2
Check for interference: Angular velocity, w 57.6 𝑟𝑎𝑑/𝑠 19.198 𝑟𝑎𝑑/𝑠
Addendum Circle Diameter D + 2aw = 100+2(5) = 110mm D + 2aw = 200+2(5) = 310mm
Dedendum Circle Diameter D - dw = 100- 2(6.25) = D - dw = 200- 2(6.25) =
87.5mm 287.5mm
𝐷𝑝 100 Base Circle Diameter 𝐷𝑐𝑜𝑠∅ = 100𝑐𝑜𝑠20° = 𝐷𝑐𝑜𝑠∅ = 200𝑐𝑜𝑠20° =
𝑚= → = 5 → 𝑚 = 𝑎𝑤 → 𝑎𝑤 = 5 93.97𝑚𝑚 281.91𝑚𝑚
𝑇 20
P = 20 hp Transmitted load

np = 550rpm 𝑃 14920𝑊
𝑊𝑙 = → 𝑚 = 102.99 𝑁
𝑣𝑙 144.875 𝑠
ng = 183(180-190)rpm
746𝑊 Gear quality
𝑃 = 20ℎ𝑝( ) → 𝑃 = 14920𝑊
1ℎ𝑝 𝑄=6
𝑂𝑣𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝐾𝑜 = 1.50 Face to Pinion
The Design Power Transmitted 𝐹 60 𝑚𝑚
= = 0.6
𝐷𝑝 100 𝑚𝑚
𝐾𝑑𝑒𝑠 = 𝐾𝑜 𝑃 = 1.50(14920𝑊)

𝐾𝑑𝑒𝑠 = 22371𝑊
Design for a life L=20,000 h
Diametrical Pitch

𝑃𝑑 = 0.2 183 𝑟𝑒𝑣 𝑙𝑜𝑎𝑑 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑡𝑖𝑜𝑛

𝑁𝑐 = 𝑛𝐿𝑞 = (20,000 ℎ)( )
𝑛𝑝 550 𝑚𝑖𝑛 𝑟𝑒𝑣
𝑉𝑅 = = =3
𝑛𝑔 183

Face Width (Lower,Upper,Nominal) 183 𝑟𝑒𝑣 60𝑚𝑖𝑛

𝑁𝑐𝑝 = (20,000 ℎ) = 2.19 𝑋 108 𝑙𝑜𝑎𝑑 𝑐𝑦𝑐𝑙𝑒𝑠
8 8 𝑚𝑖𝑛 ℎ
𝐹𝑙𝑜𝑤𝑒𝑟 𝑙𝑖𝑚𝑖𝑡 = = = 40𝑚𝑚
𝑃𝑑 0.2
16 16 550 𝑟𝑒𝑣 60𝑚𝑖𝑛
𝐹𝑢𝑝𝑝𝑒𝑟 𝑙𝑖𝑚𝑖𝑡 = = = 80𝑚𝑚 𝑁𝑐𝑔 = (20,000 ℎ) = 6.6 𝑋 108 𝑙𝑜𝑎𝑑 𝑐𝑦𝑐𝑙𝑒𝑠
𝑃𝑑 0.2 𝑚𝑖𝑛 ℎ
12 12
𝐹𝑛𝑜𝑚𝑖𝑛𝑎𝑙 = = = 60𝑚𝑚
𝑃𝑑 0.2
𝑌𝑁𝑝 = 0.93 𝑌𝑁𝑔 = 0.95 𝑍𝑁𝑝 = 0.89 𝑍𝑔 = 0.92
Material used in gear: STEEL thus,

𝐶𝑝 = 191 𝑀𝑃𝑎
𝐽𝑝 = 0.32 𝐽𝑔 = 0.41 𝐼 = 0.108 𝐶𝑝𝑓 = 0.048 𝐶𝑚𝑎 = 0.147
Pitch Line Velocity

𝑇𝑝 20 𝑟𝑎𝑑 𝑟𝑎𝑑 𝑚
𝑣𝑙 = 𝑤𝑝 → 57.95 = 2897.5 , 𝑓𝑜𝑟 𝑟𝑎𝑑𝑢𝑖𝑠 = 0.05𝑚 → 144.875
2𝑃𝑑 2(0.2) 𝑠 𝑠 𝑠 𝐾𝑚 = 1.0 + 𝐶𝑝𝑓 + 𝐶𝑚𝑎 = 1 + 0.048 + 0.147 = 1.2
 𝐾𝑝 = 1 𝐾𝑆 = 1 𝑆𝐹 = 1 𝐾𝑅 = 1 𝐶𝐻 = 1

𝑊𝑙 𝑃𝑑 (102.99 𝑁)(0.2)
𝑠𝑡𝐺 = 𝐾𝑜 𝐾𝑠 𝐾𝑚 𝐾𝐵 𝐾𝑣 = (1.5)(1)(1.2)(1)(1.32) = 2.54 𝑀𝑃𝑎
𝐹𝐽𝑔 (60𝑚𝑚)(0.32)

𝑊𝑙 𝑃𝑑 (102.99 𝑁)(0.2)
𝑠𝑡𝑃 = 𝐾𝑜 𝐾𝑠 𝐾𝑚 𝐾𝐵 𝐾𝑣 = (1.5)(1)(1.2)(1)(1.32) = 2.04 𝑀𝑃𝑎
𝐹𝐽𝐺 (60𝑚𝑚)(0.4)

𝐾𝑅 (𝑆𝐹) 1(1)
𝑠𝑤𝐺 > 𝑠𝑡𝐺 → (2.54 𝑀𝑃𝑎) = 2.67 𝑀𝑃𝑎
𝑌𝑁𝑔 0.95

𝐾𝑅 (𝑆𝐹) 1(1)
𝑠𝑤𝑝 > 𝑠𝑡𝐺 → (2.04 𝑀𝑃𝑎) = 2.19 𝑀𝑃𝑎
𝑌𝑁𝑝 0.93

𝑊𝑙 𝐾𝑜 𝐾𝑠 𝐾𝐵 𝐾𝑣 102.99 𝑁(1.5)(1)(1.2)(1.32)
𝑆𝑐 = 𝐶𝑝 = 191 𝑀𝑃𝑎 = 121.98 𝑀𝑃𝑎
𝐹𝐷𝑝 𝐼 60 𝑚𝑚 (100 𝑚𝑚)(0.1)

𝐾𝑅 (𝑆𝐹) 1(1)
𝑃𝑖𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑤𝐺 = 𝑆𝑐 𝑍𝑁 𝐶𝐻
= 121.98 𝑀𝑃𝑎 (0.92)(1) = 132.59 𝑀𝑃𝑎
𝐺

𝐾𝑅 (𝑆𝐹) 1(1)
𝑃𝑖𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑤𝑝 = 𝑆𝑐 𝑍𝑁 𝐶𝐻
=121.98 𝑀𝑃𝑎 (0.89)(1)
= 137.06 𝑀𝑃𝑎
𝐺