Gear Material Selection

There are two important factors in consideration for picking up the suitable material for gear;
wear resistance and bending stress. These two dictates a gear’s lifecycle and strength. In order to
determine these two factors, multiple other factors have to be considered to determine the most
possible risk situation.
These criterions can be categorized onto several factors;

1. Machinability
2. Cost
3. Function ability
4. Operating factor

Taking into account all this probably will make one go crazy as the analysis will be never
ending. But then there are several important factors that we need to consider and fortunately they
have categorized into charts. The selections of the gear material for a big industrial fan have to
consider the performance and life cycle of the gears. Big industrial fans are big and heavy. Once
mounted, it is rarely brought down unless for service or replacement. Therefore, the materials of
the gears have to sustain high life cycle. Even though it is having to have high life cycle, the
gears rotate relatively slow (60 rpm). But that does not mean the gears should not be high
performing. The performance of the gears has to be parallel to the gear’s life cycle.

Therefore, picking up the material is tricky business. Considering the charts and available
materials in market, we have several process factors to ponder upon. Most of the gear materials
are carburized. For special high-performance gears, they are nitridited (or carbon nitriding). For
the purpose of being corrosion resistive, alloy based or nickel-based steels are used. There also
through hardened steels which are widely used due to the increased capability of toughness and
strength (which also known as quenching and tempering).
Due to the fact that strength and bending is the two most important factors in gear, we pick
through hardened steel as our main materials.
Steel Grade 1 AISI 1095 Hot-Rolled
We picked the material; Steel, Grade 1, Through-hardened. The reason why steel is that its
yield strength is big enough to sustain the strength acting upon it. The through hardening
process is able to increase the yield capability. The reason of picking Grade 1 is that; steel is
high performing materials and has two grades; 1 and 2. Grade 2 is the highest but costlier
compared to Grade 1. Since Grade 1 is compatible, we set Steel Grade 1. And also for the pinion
gear, we set the material to be able sustain 240 HB (Brinell Hardness) and for gear, its 200 HB.
AISI 1095 Hot-Rolled is able to sustain up till 248 HB.

Pinion 1 Gear 1
AISI 1095 HR Grade 1 AISI 1095 HR Grade 1
Through Hardener Through Hardened
H b =240 H b =200
N P=19 teeth N G =114 teeth
n=1200 rpm n=200 rpm
m=5 mm m=5 mm
10 10
N cycles =10 cycles 10
N cycles = cycles
9

pitch line velocity, v

πdn π (0.095)(1200)
v= = =6 m/s
60 60
Overload factor, Ko
Ko=1.00
Dynamic Factor, K v
Dynamic factors are used to account for inaccuracies in the manufacture and meshing of
gear teeth in action. The equations for dynamic factor are:

Kv= ( A +√A200 V ) B
v∈m/s

Where
 A=50+56(1−B)
B=0.25 ¿
To evaluate Kv with AGMA transmission accuracy level Qv=4 as for most commercial quality
years are in the range of 3 to 7 and pitch line velocity v=6 m/s

B=0.25 ¿
¿1
A=50+56(1−1)
¿ 50

( )
1
50+ √ 200(6)
Kv= Factor , Ks
50
¿ 1.693
The ¿ 1.693 Factor reflects non uniformity of material properties due ¿ ¿
K s =0.904 ¿

Figure 2.2.3: Size factor Ks

To determine the size factor, Ks , the Lewis form are needed. From Figure 2.2.3, with N p=19
teeth, Y P=0.314 . Interpolation for the gear with N G =114teeth, Y G =0.45064 .
Thus, with the face width, F ¿ 95 mm∧module m=5 mm .

K sp =0.904 ¿

¿ 1.118

K sG =0.904 ¿

¿ 1. 243

Face load distribution factor:

K m =Cmf =1+C mc (C pf C pm +C ma C e )

Where,

{
C mc 1 for uncrowned teeth
0.8 for crowned teeth

{
F
−0.025
10 d
F
C pf = −0.0375+ 4.92 ( 10−4 ) F
10 d
F −4 2
−0.1109+ 8.15(10 ) F
10 d

F F
Note for the value of <0.05, = 0.05 is used.
10 d 10 d

C mc =1

F
−0.0375+4.92 ( 10 )F is used.
−4
Since face width, F=95mm, hence C pf =
10 d
 95
For pinion 1, (C pf ) P= −0.0375+ 4.92 ( 10−4 ) 95
10(95)

¿ 0.10924

F 95
For gear 1, =
10 d 10(570)

¿ 0.0 17<0.05

¿¿

¿ 0.05924

C pm
{ 1 for straddle−mounted pinion withS 1 /S <0.175
1.1 for straddle −mounted pinion with S1 / S ≥ 0.175

Figure 2.2.3 (a): definition of distance S and S1 used in evaluating C pm

For pinion 1
C pm=1

For gear 1
C pm=1
Table 2.2.3: Empire Constant A, B, and C For Face Width F in inches
 2
C ma= A+ BF+C F
Face width, F=95mm=3.740 in

−4
C ma=0.127+ 0.0158 ( 3.740 ) +(−0.930 ×10 )¿

{
C e = 0.8 for gearing adjusted at assembly ,∨¿ compatibility is improved by lapping ,∨both
1 for all other conditions

Therefore, K m :
K m =Cmf =1+C mc (C pf C pm +C ma C e )
C e =1
For pinion 1, ¿
¿ 1.429

For gear 1, (K ¿¿ m)G=1+1 [ 0.05924 ( 1 ) +0.3194(1) ] ¿

¿ 1.379

Rim – Thickness Factor, K B

Rim thickness factor adjust the estimated bending stress for the thin-rimmed gear.

{
2.242
K B= 1.6 ln mb mb <1.2
1 mb ≥ 1.2

tR
Where mB is the backup ratio, mB =
ht
t R = rim thickness ratio
ht = the tooth height

For pinion 1, assuming shaft diameter of ∅=35 mm

t R (Dded −Dshaft )/2
mB = =
ht a+ b
(82.5−35)/2
¿
11.25
¿ 2.11>1.2
K B=1
For gear 1, assuming shaft diameter of∅=55 mm
t R (Dded −Dshaft )/2
mB = =
ht a+ b
(557.5−55)/2
¿
11.25
¿ 22.33>1.2
K B=1
Bending Strength Geometry Factor, Y J

For pinion 1 with N p=19 teeth Y J =0.32

Figure 2.2.3(b)(i): Spur Gear Geometry Factor, J

For gear 1 with N G =114 teeth Y J =0.4 2

0.42

Figure 2.2.3(b)(ii): Spur Gear Geometry Factor,

Surface Strength Geometry Factor ( I )

The factor Zt is also called the pitting-resistance geometry factor by AGMA. The equations are:

{
cos ∅ t sin ∅ t mG
external gas
2m mG +1
Zt = N

cos ∅ t sin ∅ t mG
internal gear
2m N
mG−1

Where tooth load-sharing ratio mn= 6 for spur gears

Since external gear are used and gear ratio is mG= 5. So,

Gear set 1

II =
1
2m n
(
cos ∅ I sin ∅ I m G
mG + 1 )
¿
cos 20 sin 20 5
2(6) 5+1( )
¿ 0. 0223
Surface Condition Factor, I R
Standard surface condition for gear teeth have established. Hence, I R =1
Stress Cycle Factor Y N and I N
The purpose of the load cycle factor Y N and I N is to modify the gear strength for lives other than
95
10 load cycles. Values for these factors are given. The speed ratio is mG= 19 =5 .
7

The load cycle factor ¿ cycles and ¿ cycle are

Y N =1.3558 N −0.0178
−0.023
Z N =1.4488 N

Figure 2.2.3(c)(i): Repeatedly applied bending strength stress-cycle factor Y N

¿
¿ 0.90
Figure 2.2.3(c)(ii): Repeatedly applied bending strength stress-cycle factor Y N
¿

( )
−0.0178
1010
¿ 1.3558
9
¿ 0.936

Figure 2.2.3(d)(i): Pitting resistance stress-cycle factor, Z N

¿
¿ 1.4488 ¿
¿ 0.853
 Figure 2.2.3(d)(ii): Pitting resistance stress-cycle factor, Z N
¿

( )
10 −0.023
10
¿ 1.4488
9
¿ 0.897
Temperature Factor, Y θ
Working temperature¿ 3 0℃ C
For temperature ≤ 120℃ ,Y θ =1.0
Hence,Y θ=1.0
Reliability = 0.99 (1 failure occur in 100)
Y Z =1.00

Table 2.2.3(d): Reliability Factor, Y Z

Hardness- Ratio Factor ZW (C H )

The hardness-ratio factor is used only for the gear. Its purpose is to adjust the surface strength for
this effect

Table 2.2.3(e): Hardness-Ratio Factor, ZW ( C H )

Since both pinion and gear are through hardened, ZW =1+ A '( mG −1) is used.
H B ( p) 240
= =1.2
H B (G) 200
HB ( p)
=1.2≥ 1.2
HB (G)

A =8.98 ( 1 0 ) ( 1.2 ) −8.29 ( 10 )=2.489(10 )

' −3 −3 −3

ZW =1+2.486 ( 1 0−3 ) ( 5−1 ) =1.010

1
Allowable Bending Stress Number, St (σ FP ,MPa)

Figure 2.2.3(e): Allowable bending stress number for through-hardened steels.

Pinion 1
Grade 1, through hardened stress, 240 HB
St =0.533 HB+ 88.3 MPa
¿ 0.533 ( 240 ) +88.3
σ FP=216.22 MPa

Gear 1
Grade 1, through hardened stress, 200 HB
St =0.533 HB+ 88.3 MPa
¿ 0.533 ( 200 ) +88.3 MPa
σ FP=194.9 MPa
Allowable Contact Stress Number, St (σ FP ,MPa )

Figure 2.2.3(f): Contact-fatigue strength at cycles and 0.99 reliability for through-hardened steel
gears.
Pinion 1
Grade 1, through hardened stress, 240 HB
SC =2.22 HB +200 MPa
¿ 2.22 ( 240 )+ 200 MPa
σ HP=732.80 MPa
Gear 1
Grade 1, through hardened stress, 200 HB
SC =2.22 HB +200 MPa
¿ 2.22 ( 200 )+ 200 MPa
σ HP=644.00 MPa
The Elastic Coefficient, Z E

Table 2.2.3(f): Poisson ratio of different type materials

From the table above, the poison ratio of steel is at 0.3, hence I E can be determined from table
 Table 2.2.3(g): Gear Material and Modulus Of Elasticity

Hence, I E =191 √ MPa

AGMA Stress Equation
Spur Gear Bending
Gear bending stress equation
t 1 km kB
σ =w k 0 k v k s
Fmt Y J
For pinion 1,

σ P=(16750)(1)(1.693)(1.118)
( 1
95(5))(
(1.429)(1)
0.32 )
¿ 298.06 MPa
For gear 1,

σ G=(16750)(1)(1.693)(1.243)
( 1
95(5))(
(1.379)(1)
0.4 2 )
¿ 2 43.65 MPa
Bending factor of safety
¿¿
For pinion 1,
(216.22)(0.90)/ ( 1 ) (1)
( S F )P =
298.06
¿ 1 ≥1
(safe from bending failure)
For gear 1,
¿¿
¿ 1 ≥1
(safe from bending failure)
Spur Gear Wear
Gear contact stress equation

√
σ c =Z F W t k 0 k v k s
km ZR
d p ZI
F

For pinion 1,

√
σ c =191 ( 16750 ) ( 1 )( 1.693 ) ( 1.118 )
( 1.429 ) ( 1)
( 95 )( 95 ) ( 0. 0223 )
¿ 2865.70 MPa
For gear 1,

√
σ c =191 ( 16750 ) ( 1 )( 1.693 ) ( 1.2 43 )
( 1.379 ) ( 1)
( 5 70 ) ( 95 ) ( 0. 0223 )
¿ 1233.59 MPa
Wear factor of safety
¿
(732.80)(0.853)(1.0 10)/(1)(1)
¿
2865.70
¿ 1 ≥1
(safe from wear failure)
¿
(644.00)(0.897)(1.0 10)/(1)(1)
¿
1233.59
¿ 1 ≥1
(safe from wear failure)

Gear set 2
Pinion 2 Gear 2
 AISI 1095 HR Grade 1 AISI 1095 HR Grade 1
Through hardened Through hardened
H B = 240 H B =200
N P=20 teeth N G =60 teeth
n = 200 rpm n = 66.67 rpm
m=5 m = 5.5
F=110 mm F=110 mm
1010 1010
N cycle = cycle N cycle = cycle
9 9 (3)
Pitch Line Velocity,
π (d )(n)
V=
60
π (0.110)(200)
V=
60
¿ 1.152 m/s
Overload Factor,

Table 2.2.3(h): Overload factor, k o

k 0 ← alphabet net zero
In application of induction lifting crane, our power source is uniform.

Hence,k o=1.00

Dynamic factor, k v
To evaluate k v with AGMA transmission accuracy-level number QV =4 as for most commercial-
quality gears are in the range of 3 to 7 and pitch-line velocity v = 1.152m/s.

( )
B
A+ √ 200 V
k v=
A
B=0.25 ¿
¿1
A=50+56(1−1)
¿ 50

( )
1
50+ √ 200(1. 152)
k v=
50
¿ 1.3 04
Size Factor, k S
The size factor reflects non-uniformity of material properties due to size.
k S=0.904 ¿

Table 2.2.3(i): Values of Lewis Form Factor, Y

To determine, k S the Lewis form factor is needed. N P = 20 teeth Y P=0.322 interpolation for the
gear with N G =60teeth yields Y G =0.4 22. Thus, with face width F =110 mm and module m = 5.5
mm.
¿
¿ 1.235
¿
= 1.244
Load Distribution Factor, k m
k m=C mf =1+C mf (C pf C pm +C ma C e )

{
where C mc= 1 uncrowned teeth
0.8 crowned teeth
C mc =1
C pf =¿
b b
Note that for value of <0.05 , =0.05 is used
10 d 10 d

F
−0.0375+4.92 ( 1 0 ) F is used
−4
Since face width, F=110 mm, hence
10 d
For pinion 2,
F 110
= =0.1
10 d 10(110)
110
(C pf ) P= −0.0375+ 4.92 ( 10−4 ) 110
10(110)
 ¿ 0.117

For gear 2,
F 110
= =0.0 33
10 d 10(330)
¿
¿ 0.0 50

{
s1
1 for stroddle proven with < 0.175
C pm= s
s
1.11 for stoddle mounted proven with 1 ≥0.175
s

Figure 2.2.3(g): Definition of distance S and S1 used in evaluating C pm

For pinion 2,
C pm=1.1
For gear 2,
C pm=1.1

C ma= A+ BF+C F 2
Face width, F = 110 mm =4.3307 inch
−4
C ma=0.127+ 0.0158 ( 4.3307 ) +(−0.930)( 10 )¿
¿ 0.1937

For pinion 2,
¿
¿ 1+1( ( 0.117 ) ( 1.1 ) +0.1937 ( 1 ))
¿ 1.3224
For gear 2,
¿
¿ 1+1( ( 0.0 50 ) ( 1.1 )+ 0.1937 (1 ))
¿ 1.2 49

Rim Thickness Factor, k b

{
2.242
1.6 ln mb <1.2
k b= mb
1 mb ≥ 1.2
Where mb is the backup ratio
tR
mB =
ht
t R =¿ rim thickness ratio
ht =¿ the teeth height
Where t R =¿ rim thickness ratio and ht =¿ the tooth height
For pinion 2, assuming shaft diameter of 55 mm
D ded−D shaft
t R=
2
96.24−55
¿
2
¿ 20 .62
30.62
mB =
a+b
30.62
¿
5.5+ 6.88
¿ 2.473
Hence, k B=1

Bending Strength Geometry Factor, Y J

For pinion 2 with N p=20teeth Y J =0.34

Figure 2.2.3(h)(i): Spur Gear Geometry Factor, J

For gear 2 with N p=60teeth Y J =0.4 0

0.40

Figure 2.2.3(h)(ii): Spur Gear Geometry Factor, J

Surface Strength Geometry Factor, I
The factor I is also referred to by AGMA as the pitting-resistance geometry factor. The equations
are:

{
cos ∅ t sin ∅ t mG
external gears
2 mN mG +1
I=
cos ∅ t sin ∅ t mG
external gears
2 mN mG−1

Where teeth load sharing ratio, mN =3 for spur gear

Since external gear are used and gear ratio is 3.0, so

II =
2
2(3) (
cos 20 sin 20 5.5
5.5+1 )
¿ 0. 0453

Surface Condition Factor, I R

Standard surface condition for gear teeth have not yet been established.

Hence, I R =1.0
Stress Cycle Factor, Y N and I N
The purpose of the load cycle factor Y N and I N is to modify the gear strength for lives other than
60
10 load cycles. Values for these factors given. The speed ration is mG= =3 .0 The load cycle
7
20
factor ¿cycles and ¿ cycles are
−0.0178
Y N =1.355 N
Z N =1.4488 N −0.023

Figure 2.2.3(i)(i): repeatedly applied bending strength stress-cycle factor,Y N

¿
¿ 0.935
Figure 2.2.3(i)(ii): Repeatedly applied bending strength stress-cycle factor, Y N
¿

( )
10 −0.0178
10
¿ 1.3558
9 ×3
¿ 0.95 4
Figure 2.2.3(j)(i): Pitting resistance stress-cycle factor, Z N
¿

( )
−0.023
1010
¿ 1.4488
9
¿ 0.897
 Figure 2.2.3(j)(ii): Pitting resistance stress-cycle factor, Z N
¿

( )
10 −0.023
10
¿ 1.4488
9 ×3
¿ 0.92 0
Temperature Factor, Y θ
Working temperature = 30º C
For temperature ≤ 120º C, Y θ = 1.0
Hence, Y θ = 1.0
Reliability Factor, Y Z
The reliability factor accounts for the effect of the statistical distributions of material fatigue
failures.
Y Z =1.00

Table 2.2.3(k): Reliability Factor, Y Z

Hardness-Ratio Factor, ZW (C H )

Table 2.2.3(l): Hardness-Ratio Factor, ZW (C H )

Since both pinion and gear are through hardened, ZW =1+ A ( mG−1 ) is used.
H B( p) 240
= =1.2
H B (G ) 200
H B( p)
=1.2≥ 1.2
H B (G )

A' =8.98 ( 1 0−3 ) ( 1.2 ) −8.29 ( 10−2 )=2.489(1 0−3)

Z w =1+2.486 ( 1 0 ) ( 5.5−1 )=1. 011
−3
2

Allowable Bending Stress Number, St (σ FP , MPa)

Figure 2.2.3(k): Allowable bending stress number for through-hardened steels.

Pinion 2
Grade 1, through hardened stress, 240 HB
St =0.533 HB+ 88.3 MPa
¿ 0.533 ( 200 ) +88.3 MPa
¿ 216.22 MPa
 σ FP=216.22 MPa
Gear 2
Grade 1, through hardened stress, 200 HB
St =0.533 HB+ 88.3 MPa
¿ 0.533 ( 200 ) +88.3 MPa
¿ 194.9 MPa
σ FP=194.9 MPa
Allowable Contact Stress Number, SC (σ HP , MPa)

Figure 2.2.3(l): Contact-fatigue strength at cycles and 0.99 reliability for through-hardened steel
gears,
Pinion 2
Grade 1, through hardened steel, 240 HB
SC =2.22 HB +200 MPa
¿ 2.22 ( 240 )+ 200 MPa
¿ 732.80 MPa
σ HP=732.80 MPa
Gear 2
Grade 1, through hardened steel, 200 HB
SC =2.22 HB +200 MPa
¿ 2.22 ( 200 )+ 200 MPa
¿ 644.00 MPa
 σ HP=644.00 MPa
The elastic coefficient, Z E

Table 2.2.3(m): Poison ratio of different type of material.

From the table above, the poison ratio of steel is at 0.3, hence Z E can be determined from the
table.

Table 2.2.3(n): Gear Material and Modulus of Elasticity

Hence, I E =191 √ MPa
AGMA Stress Equation
Spur Gear Bending

Gear bending stress equation

1 km k B
σ =w t k o k v k s
Fmt Y J
For pinion 2,

σ P=(18930)(1)(1.3 04 )(1.235)
( 1
)(
110(5.5)
(1.322)(1)
0.34 )
¿ 1 95.93 MPa
For gear 2,

σ G=(18930)(1)(1.3 04)(1.2 4 4)
( 110(5.5)
1
)( (1.20.44 9)(1)
0 )
¿ 15 8.49 MPa
Bending factor of safety
YN
σ FP
YθYZ
S F=
σ
For pinion 2,
¿¿
¿ 1. 032> 1
(safe from bending failure)
For gear 2,
¿¿
¿ 1.1 842> 1
(safe from bending failure)
Spur Gear Wear
Gear contact stress equation

√
QC =Z E W t k o k v k s
km ZR
d p ZI
f

For pinion 2,

√
σ c =191 ( 18930 ) ( 1 )( 1.304 )( 1. 235 )
( 1.322 ) (1)
( 110 ) ( 110 ) ( 0. 0453 )
¿ 1637.78 MPa
For gear 2,

√
σ c =191 ( 18930 ) ( 1 )( 1.304 )( 1.24 4 )
(1. 249 ) (1)
(330 )( 110 ) ( 0. 0453 )
¿ 922.44 MPa
Wear factor of safety
For pinion 2,
¿¿
¿¿
¿ 1.00 0>1
(safe from wear failure)
For gear 2,
¿¿
¿ 1.0 0 0>1
(safe from wear failure)

Summary of Gear Failure Analysis

Pinion 1 Gear 1 Pinion 2 Gear 2
 Overload Factor, 𝐾𝑜 1

Dynamic Factor, 𝐾𝑣 1.693 1.304

Size Factor, 𝐾𝑠 1.118 1.243 1. 235 1.24 4

Load Distribution Factor, 𝐾𝑚 1.429 1.379 1.322 1.249

Rim-Thickness Factor, 𝐾𝐵 1 1 1 1

Bending-Strength Geometry 0.32 0.42 0.34 0.40

Factor, 𝑌𝐽
Surface-Strength Geometry 0.0223 0.0453
Factor, 𝑍𝐼
Surface Condition Factor, 𝑍𝑅 1

Bending Strength Stress-Cycle 0.90 0.936 0.935 0.954

Factor, 𝑌𝑁
Pitting Resistance Stress-Cycle 0.853 0.897 0.897 0.920
Factor, 𝑍𝑁
Temperature Factor, 𝑌𝜃 1

Reliability Factor, 𝑌𝑍 1

Hardness-Ratio Factor, 𝑍𝑊 1.010 1.010 1.011 1.011

Allowable Bending Stress 216.22 194.90 216.22 194.90

Number, 𝜎𝐹𝑃
Allowable Contact Stress 732.80 644.00 732.80 644.00
Number, 𝜎𝐻𝑃
The Elastic Coefficient, 191 191
𝑍𝐸(√𝑀𝑃𝑎)
Tangential Transmitted 16750 18930
Load,𝑊𝑡(𝑁)
Bending Stress, 𝜎(𝑀𝑃𝑎) 298.06 243.65 195.93 158.49

Contact Stress, 𝜎𝑐(𝑀𝑃𝑎) 2865.70 1233.59 1637.78 922.44

Compare S F with S2H when trying to identify the treat to loss of function with confidence. From
the comparison, we could identify the gear sets prone to either bending failure or wear failure.
Gear Set 1

Pinion 1 Gear 1
Bending Factor of Safety, S F 0.6529 0.7487
Wear Factor of Safety, S H 0.2203 0.4730
2
SH 0.0485 0.2237

Gear Set 2

Pinion 2 Gear 2
Bending Factor of Safety, S F 1. 032 1.1 842
Wear Factor of Safety, S H 0.4058 0.6571
2
SH 0.1647 0.4318

From the comparison tables above, by examining factor of safety, the threat in opinion and gear
for both sets of gear is from wear.