Projeto de Máquinas 4 Ed. Norton (SOLUCIONÁRIO) - CAP 12

MACHINE DESIGN - An Integrated Approach, 4th Ed.
12-1-1
PROBLEM 12-1
Statement: A 20-deg pressure angle, 27-tooth spur gear has a diametral pitch of 5. Find the pitch diameter,
addendum, dedendum, outside diameter, and circular pitch.
1
Given: Diametral pitch p d  5  in Number of teeth N  27
Pressure angle ϕ  20 deg
Solution: See Mathcad file P1201.
N
Pitch diameter d  d  5.400  in
pd
1.0
Addendum a  a  0.200  in
pd
1.25
Dedendum b  b  0.250  in
pd
Outside diameter Do  d  2  a Do  5.800  in
π
Circular pitch p c  p c  0.628  in
pd
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MACHINE DESIGN - An Integrated Approach, 4th Ed. 12-2-1
PROBLEM 12-2
1
Given: Diametral pitch p d  8  in Number of teeth N  43
N
pd
1.0
pd
1.25
pd
π
pd
PROBLEM 12-3
Statement: A 57-tooth spur gear is in mesh with a 23-tooth pinion. For the diametral pitch and pressure angle
given below, find the contact ratio.
Given: Tooth numbers:

1
pinion Np  23 Diametral pitch p d  6  in
gear Ng  57 Pressure angle ϕ  25 deg
π
pd
Base pitch p b  p c  cos( ϕ) p b  0.475  in
Pinion:
Np
Pitch dia d p  d p  3.833  in
pd
Pitch rad rp  0.5 d p rp  1.917  in
Gear:
Ng
Pitch dia d g  d g  9.500  in
pd
Pitch rad rg  0.5 d g rg  4.750  in
1.0
pd
Np  Ng
Center distance C  C  6.667  in
2 pd
Length of action
Z  rp  a 2  rp cos( ϕ)  2   rg  a 2  rg cos( ϕ)  2  C sin( ϕ)

Z  0.708  in
Z
Contact ratio mp  mp  1.491
pb
PROBLEM 12-4
Statement: A 78-tooth spur gear is in mesh with a 27-tooth pinion. For the diametral pitch and pressure angle
given below, find the contact ratio.

1
pinion Np  27 Diametral pitch p d  6  in
gear Ng  78 Pressure angle ϕ  20 deg
π
pd
Pinion:
Np
pd
Gear:
Ng
Pitch dia d g  d g  13.000 in
pd
1.0
pd
Np  Ng
2 pd
Length of action

Z  0.849  in
Z
pb
MACHINE DESIGN - An 12-5-1
PROBLEM 12-5
Statement: What will the pressure angle be if the center distance of the spur gearset in Problem 12-3 is
increased by 5%?
Given: Tooth numbers: new Base Circle
pinion Np  23 Old Pitch Circle
New Pitch Circle
gear Ng  57
1
Diametral pitch p d  6  in fc rp
rbp
C + C
Solution: See Figure 12-5 and Mathcad fc r g rbg
file P1205.
1. Define the factor by which the center
distance changes.
C  ΔC
Let = fc
C
Dividing numerator and denominator of the left
side by C,
FIGURE 12-5
ΔC
fc = 1  Diagram Showing Center Change for Problem 12-5
C
2. In this case, fc  1  0.05 fc  1.05

3. Determine the pitch diameter and pitch radius of the pinion.
Np
Pitch diameter d p  d p  3.833  in
pd
Pitch radius rp  0.5 d p rp  1.917  in
4. When the centers are moved apart the base circle diameters don't change but new pitch circle diameters are
defined by the intersection of the new line of action, which is always tangent to the two base circles, with the
line of centers. The new pitch radii are proportional to fc. Thus, from Figure 12-5, the new pressure angle is
rbp
cos ϕnew =
fc  rp
Substituting rp cos( ϕ) for rbp and solving for

 rp cos( ϕ) 
ϕnew  acos  ϕnew  30.33  deg
 fc  rp 
new,
MACHINE DESIGN - An 12-6-1
PROBLEM 12-6
increased by 7%?
Given: Tooth numbers: new Base Circle
pinion Np  27 Old Pitch Circle
New Pitch Circle
gear Ng  78
1
Diametral pitch p d  6  in fc rp
rbp
C + C
Solution: See Figure 12-6 and Mathcad fc r g rbg
file P1206.
distance changes.
C  ΔC
Let = fc
C
side by C,
FIGURE 12-6
ΔC
fc = 1  Diagram Showing Center Change for Problem 12-6
C
2. In this case, fc  1  0.07 fc  1.07

3. Determine the pitch diameter and pitch radius of the pinion.
Np
Pitch diameter d p  d p  4.500  in
pd
Pitch radius rp  0.5 d p rp  2.250  in
line of centers. The new pitch radii are proportional to fc. Thus, from Figure 12-5, the new pressure angle is
rbp
cos ϕnew =
fc  rp

 fc  rp 
new,
PROBLEM 12-7
Statement: If the spur gearsets in Problems 12-3 and 12-4 are compounded as shown in Figure 12-14, what wil
the overall train ratio be?
Given: Tooth numbers N2  57 N3  23
N4  78 N5  27
1. Using equation 12.9b and assuming that gears 2 and 4 are the driver gears, the train (velocity) ratio is
N2 N4
mv  mv  7.159
N3 N5
2. On the other hand, if gears 3 and 5 are the driver gears then the train ratio is
N3 N5
mv  mv  0.1397
N2 N4
PROBLEM 12-8
Statement: A paper mill processes rolls of paper having a density of 984 kg/m3. The paper roll is 1.50-m
outside diameter (OD) x 0.22-m inside diameter (ID) x 3.23-m long and is on a simple supported,
hollow, steel shaft with S ut = 400 MPa. Design a 2.5:1 reduction spur gearset to drive this roll
shaft to obtain a minimum dynamic safety factor of 2 for 10-year life if the roll turns at 50 rpm
with 1.2 hp absorbed.
Units: yr  2080 hr
Given: Bending factor of safety Nfb  2 Life (years) Life  10 yr
Surface factor of safety Nfs  2 Gear speed n g  50 rpm
Power to be transmitted H  1.2 hp Gear ratio mg  2.5
Assumptions: 1. If both pinion and gear are the same material, it will only be necessary to determine the pinion
size as it will be governing for the set.
2. If the gears are not surface hardened, it will only be necessary to design to the surface
requirement as it will be governing for both bending and surface stresses.

Design Choices:
Pressure angle ϕ  25 deg AGMA Quality level Qv  7
Number of pinion teeth Np  26 Reliability R  0.99
Material: AGMA Grade 2 steel for both pinion and gear, through hardened to
HB  350 S ac  ( 27000  364  HB)  psi S ac  154400 psi
1. Determine the number of gear teeth, the pinion speed, and the cycle life.
Number of gear teeth Ng  Np mg Ng  65
Rotational speed of pinion (rpm) n p  n g mg n p  125  rpm
np 8
Cycle life: N  Life N  1.56  10
2 π
2. Determine the surface geometry factor, I.
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1368
 2  p g
3. Write the equations for pitch diameter, pitch-line velocity, and transmitted load in terms of the unknown
diametral pitch, pd. Note that, in Mathcad, unit conversion factors are not included.
Np Ng
Pitch diameter of pinion (in) d p p d   d g p d  
pd pd
d p p d   n p
Pitch-line velocity (fpm) Vt p d  
2
Wt p d  
H
Transmitted load (lbf)
Vt  p d 
4. Set the application factor, Ca Ca  1
B  0.25  12  Qv
0.6667
5. Write the equation for the dynamic load factor, C B  0.731
v
A  50  56 ( 1  B) A  65.062
B
Cv p d    A 
 
 A  Vt  p d  
min

 ft 
6. Tentatively choose the mounting factor, Cm (Assume 0 < F < 2 in Cm  1.6

0.5
7. Choose an elastic coefficient from Table 12-18 (steel on steel). Cp  2300 psi
C a W t  p d   C m
8. The surface stress equation for the pinion is σcp p d F   Cp
Cv p d   F  d p p d   I
9. Determine the endurance strength of the pinion.

 0.056
Life factor CL  2.466  N CL  0.857
Reliability CR  0.7  0.15 log( 1  R) CR  1
Temperature factor CT  1
Material surface strength (psi)
S ac  154400 psi
Grade 2, 350 HB
S ac CL
Endurance strength S fcp  S fcp  132381 psi
CT  CR
10. Write the design equations using the range of face-width to diametral-pitch ratio given in the text, and the
bending stress equation, solved for the unknown face width.
2
Limits and safety factor FU  p d  
 Sfc 
FL  p d  
16 8
Nfc =  
pd pd  σc 
C a W t  p d   C m
2
 Cp 
Face width F  p d      Nfs
Cv p d   d p p d   I  S fcp 
6 6.5 16
11. Plot F(P) vs p over the range p d   
d in in in
3
12. From the graph, choose a standard value of p d
from Table 12-2.  
F pd
1 in
p d  10 in 2
 
FL pd
13. The calculated value of F is
in
F  p d   1.393  in
 
FU pd 1
14. Round this up to the decimal equivalent of a in
common fractional value.
F  1.375  in
0
6 8 10 12 14 16
15. Then, the parameters that depend on p d and F are:
pd  in
d p p d   2.600  in d g p d   6.500  in FIGURE 12-8

Graph of Face Width and Limits for the Pinion
(surface) in Problem 12-8
Vt p d   85 Wt p d   465  lbf σcp p d F   94207  psi

ft
min
16. There is a wide range of choice for the number of teeth on the pinion. The total weight of the gears goes down
very slightly with increasing pinion tooth number. The choice of Np  26 was somewhat arbitrary but was
arrived at after trying values from 18 to 26.
PROBLEM 12-9
Statement: Design a two-stage compound spur gear train for an overall ratio of approximately 47:1. Specify
tooth numbers for each gear in the train.
Given: Approximate ratio mG  47 Number of stages n  2
Assumptions: The gears will be cut with a hob and the pressure angle will be ϕ  25 deg

1
n
1. For equal stages, the stage ratio is mGs  mG mGs  6.856
2. The minimum number of teeth that we can have without interference on a 25-deg gear cut with a hob is 14. Try
pinions with 14, 15, 16, etc. teeth to see if the mating gear will have close to an integral number of teeth.
14 mGs  95.979
15 mGs  102.835
16 mGs  109.69

n
mG   96  mG  47.02
3. The first trial is very close to an integer so try 96 teeth:  14 
 
4. We can get slightly closer by using two 14-tooth pinions with 95 and 97-tooth gears
95 97
mG  mG  47.015
14 14
5. However, it may be harder to find the 97-tooth gear and, it may be less expensive to have two gears with the
same number of teeth than to have different numbers of teeth.
PROBLEM 12-10
Statement: Design a three-stage compound spur gear train for an overall ratio of approximately 656:1. Specify
Given: Gear ratio mG  656 Number of stages s  3

1
s
1. The average stage ratio is ravg  mG ravg  8.689
2. If the minimum number of teeth is (20 deg pa) Nmin  18

then the number of teeth on the driven gear for each stage is
NG1  floor  ravg Nmin NG1  156
or NG2  ceil ravg Nmin NG2  157
3. But, the prime factors of 656 are 2 4 and 41. This suggests that one of the gears have a number of teeth that is a
multiple of 41, say 164
164
 18.875 Let N2  18 N3  164
ravg
N2
Then, the remaing 2-stage ratio is mG2  mG mG2  72
N3
N5 N7
Thus, = 72 if N4  18 and N6  18
N4 N6
5 6
then N5 N7 = 72 18 18 = 2  3
4 2 1 4
Try N5  2  3 N7  2  3 then N5 N7  23328
Summarizing, N2  18 N3  164
N4  18 N5  144
N6  18 N7  162
4. Since the driven gears all have less than 180 teeth, no stage ratio is greater than 10.
5. Checking the overall gear ratio
N 3 N 5 N 7
mG  mG  656.00
N 2 N 4 N 6
PROBLEM 12-11
Statement: An epicycle spur gear train as shown in Figure 12-16 has a sun gear of 33 teeth and a planet gear
of 21 teeth. Find the required number of teeth in the ring gear and determine the ratio between
the arm and the sun gear if the ring gear is held stationary.
Given: Sun tooth number Ns  33 Arm speed ωa  1  rpm

Planet tooth number Np  21 Ring speed ωr  0  rpm

1. From Figure 12-16 we see that the diameter of the ring gear is equal to the sum of the diameter of the sun gear
and two times the diameter of the planet gear. Since sun, planets, and ring gear must have the same diametral
pitch,
Number of teeth on ring: Nr  Ns  2  Np Nr  75
2. Choose the sun gear as the first gear and the ring gear as the last. Then, write equation (12.11c).
ωra ωr  ωa Ns
= =
ωsa ωs  ωa Nr
Nr ωa  Ns ωa  Nr ωr

Solving for the sun speed, ωs  ωs  3.273  rpm
Ns
ωa
3. The ratio between the arm and sun gear is  0.306
ωs
PROBLEM 12-12
the arm and the ring gear if the sun gear is held stationary.

Planet tooth number Np  31 Sun speed ωs  0  rpm

pitch,
= =
ωsa ωs  ωa Nr
Nr ωa  Ns ωa  Ns ωs

Solving for the ring speed, ωr  ωr  1.271  rpm
Nr
ωa
3. The ratio between the arm and ring gear is  0.787
ωr
PROBLEM 12-13
the sun and the ring gear if the arm is held stationary.

Planet tooth number Np  31 Sun speed ωs  1  rpm
pitch,
= =
ωsa ωs  ωa Nr

Solving for the ring speed, ωr  ωr  0.271  rpm
Nr
ωs
3. The ratio between the sun and ring gear is  3.696
ωr
PROBLEM 12-14
Statement: If the gearset in Problem 12-3 transmits 125 HP at 1000 pinion rpm, find the torque on each shaft.

pinion Np  23 Pinion speed ωp  1000 rpm
gear Ng  57 Transmitted power P  125  hp
Assumptions: There is no loss of power in the gear mesh (100% efficiency).

P
1. For the pinion shaft Tp  Tp  7878 in lbf
ωp
Tp  656.5  ft  lbf
2. The gear shaft will rotate at a lower speed, which is determined by the gear ratio. (The speed will be
decreased in proportion to the ratio and the torque will be increased by the reciprocal of the ratio).
Np
3. For the gear shaft ωg   ωp ωg  403.509  rpm
Ng
P
Tg  Tg  19524  in lbf
ωg
Tg  1627 ft  lbf
4. We could have calculated the torque on the gear shaft directly without finding the gear shaft speed,
Ng
Tg   Tp Tg  19524  in lbf
Np
Tg  1627 ft  lbf
PROBLEM 12-15
Statement: If the gearset in Problem 12-4 transmits 33 kW at 1600 pinion rpm, find the torque on each shaft.

pinion Np  27 Pinion speed ωp  1600 rpm
gear Ng  78 Transmitted power P  33 kW

P
1. For the pinion shaft Tp  Tp  197  N  m
ωp
2. The gear shaft will rotate at a lower speed, which is determined by the gear ratio. (The speed will be decreased i
proportion to the ratio and the torque will be increased by the reciprocal of the ratio).
Np
3. For the gear shaft ωg   ωp ωg  553.846  rpm
Ng
P
Tg  Tg  569  N  m
ωg
4. We could have calculated the torque on the gear shaft directly without finding the gear shaft speed,
Ng
Tg   Tp Tg  569  N  m
Np
PROBLEM 12-16
Statement: Size the spur gears in problem 12-14 for a bending factor of safety of at least 2 assuming a steady
torque, 25 deg pressure angle, full depth teeth, quality index of 9, an AISI 4140 steel pinion, and a
class 40 cast iron gear.
Given: Factor of safety Nfb  2 Number of gear teeth Ng  57

Power to be transmitted (hp) H  125  hp Reliability R  0.99
Rotational speed of pinion n  1000 rpm AGMA Quality level Qv  9
7
Number of pinion teeth Np  23 Life (cycles) N  10

Pinion
1. Determine the bending geometry factor, J (Table 12-13) Jp  0.42
Np
Pitch diameter of pinion (in) d  p d  
pd
dpd  n
2
Wt p d  
H
Vt  p d 
3. Set the application factor, Ka Ka  1

B  0.25  12  Qv
0.6667
4. Write the equation for the dynamic load factor, K B  0.52
v
A  50  56 ( 1  B) A  76.878
B
Kv p d    
A

 A  Vt  p d  
min

 ft 
5. Tentatively choose the mounting factor, Km (Assume 2 < F < 6 in) Km  1.7
Ka Wt p d   p d  Km
6. The bending stress equation for the pinion is σbp p d F  
Kv p d   F  Jp

 0.0323
Life factor KL  1.6831 N KL  1
Reliability KR  0.7  0.15 log( 1  R) KR  1
Temperature factor KT  1
Material bending strength (psi)
S atp  40000  psi
AISI 4140 Nitrided steel
S atp KL
Endurance strength S fbp  S fbp  40001  psi
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb
Ka Wt p d   p d  Km Nfb

Face width F  p d  
Kv p d   Jp S fbp
1 1.5 6
9. Plot F(P) vs. p over the range p d   
d in in in
4
 
from Table 12-2.
F pd
1 3
p d  4  in in
11. The calculated value of F is  

FL pd
2
F  p d   2.743  in
in
 
FU pd
12. Round this up to the decimal equivalent of a
in 1
F  2.750  in
13. Then, the parameters that depend on p d and F are: 0
2 2.5 3 3.5 4 4.5 5 5.5 6
d  p d   5.750  in Kv p d   0.809 pd  in
Vt p d   1505 Wt p d   2740 lbf

ft FIGURE 12-16A
min Graph of Face Width and Limits for the Pinion in
Problem 12-16
σbp p d F   19952  psi
The assumption made in step 5 is correct so no further iteration is required.
Gear
14. Determine the bending geometry factor, J (Table 12-13) Jg  0.49
15. The bending stress equation for the gear is σbg p d F  
Kv p d   F  Jg

S atg  13000  psi
Class 40 cast iron
S atg KL
Endurance strength S fbg  S fbg  13000  psi
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

Kv p d   Jg S fbg
1 1.5 6
d in in in

from Table 12-2. 6
1
p d  3  in
 
F pd
4.5
20. The calculated value of F is in
F  p d   4.178  in  
FL pd
3
common fractional value.  
FU pd
F  4.250  in in 1.5
22. Then, the parameters that depend on P and F are:
d  p d   7.667  in Kv p d   0.788 0
2 2.5 3 3.5 4 4.5 5 5.5 6
pd  in
Vt p d   2007 Wt p d   2055 lbf
ft
min FIGURE 12-16B
Graph of Face Width and Limits for the Gear in
σbg p d F   6391 psi Problem 12-16
23. The gear dimensions are larger (smaller diametral pitch means bigger teeth) than for the pinion. This means
that we will accept the gear requirements for the pinion, thus, for the set
1
Diametral pitch p d  3  in
Face width F  4.250  in

24. Determine the realized factor of safety for the gear using the above values for F and p d.
S fbg
Gear factor of safety Nfbg  Nfbg  2.0
σbg p d F 
25. Check the factor of safety on the pinion:

S fbp
Pinion factor of safety Nfbp  Nfbp  5.4
σbp p d F 
PROBLEM 12-17
Statement: Size the spur gears in problem 12-15 for a bending factor of safety of at least 2.5 assuming a
steady torque, 20 deg pressure angle, full depth teeth, quality index of 11, an AISI 4340 steel
pinion, and an A-7-d nodular iron gear.
Given: Factor of safety Nfb  2.5 Number of gear teeth Ng  78

Power to be transmitted (hp) H  33 kW Reliability R  0.99
7

Pinion
diametral pitch, p d. Note that, in Mathcad, unit conversion factors are not included.
Np
pd
dpd  n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
v
A  50  56 ( 1  B) A  92
B
Kv p d    
A

 A  Vt  p d  
min

 ft 
Kv p d   F  Jp

 0.0323
S atp  42000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

1 1.5 10
d in in in
4
 
from Table 12-2.
F pd
1 3
p d  6  in in

FL pd
2
F  p d   1.318  in
in
 
FU pd
in 1
F  1.375  in
4 5 6 7 8 9 10
d  p d   4.500  in Kv p d   0.908 pd  in
Vt p d   1885 Wt p d   775  lbf

ft FIGURE 12-17A
Problem 12-17
σbp p d F   16103  psi
Gear
Kv p d   F  Jg

S atg  34000  psi
A-7-d nodular iron
S atg KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

1 1.5 10
d in in in

from Table 12-2. 6
1
p d  6  in
 
F pd
4.5
F  p d   1.434  in  
FL pd
3
FU pd
F  1.500  in in 1.5
d  p d   4.500  in Kv p d   0.908 0
4 5 6 7 8 9 10
pd  in
Vt p d   1885 Wt p d   775  lbf
ft
min FIGURE 12-17B
σbg p d F   13004  psi Problem 12-17
23. The gear dimensions are larger than those for the pinion. This means that we will accept the gear requirements
for the pinion, thus, for the set
1

S fbg

S fbp
PROBLEM 12-18
Statement: Size the spur gears in problem 12-14 for a surface factor of safety of at least 2 assuming a steady
torque, 25 deg pressure angle, full depth teeth, quality index of 9, an AISI 4140 steel pinion, and
a class 40 cast iron gear.
Given: Factor of safety Nfs  2 Number of gear teeth Ng  57

Power to be transmitted (hp) H  125  hp Reliability R  0.99
7
Pinion
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1365
 2  p g
Np
Pitch diameter of pinion (in) d p p d  
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
v
A  50  56 ( 1  B) A  76.878
B
Cv p d    
A

 A  Vt  p d  
min

 ft 

0.5
6. Choose an elastic coefficient from Table 12-18. (Steel on cast-iron) Cp  2100 psi
C a W t  p d   C m
Cv p d   F  d p p d   I

 0.056
Life factor CL  2.466  N CL  1

S acp  165000 psi
S acp CL
CT  CR
surface stress equation, solved for the unknown face width.
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
Safety factor Nfc = σ 
 c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
1 1.5 6
d in in in
10. From the graph, choose a standard value of p d 4

from Table 12-2.
1 F pd 
p d  4  in 3
in
FL pd
F  p d   2.379  in in 2
12. Round this up to the decimal equivalent of a  

FU pd
common fractional value. in 1
F  2.375  in
2 2.5 3 3.5 4 4.5 5 5.5 6
d p p d   5.750  in Cv p d   0.809
pd  in
Vt p d   1505 Wt p d   2740 lbf

ft
FIGURE 12-18A
σcp p d F   116767 psi Problem 12-18
Gear
Ng
14. Write the equation for the gear pitch diameter d g p d  
pd
C a W t  p d   C m
15. The surface stress equation for the gear is σcg p d F   Cp
Cv p d   F  d g p d   I

Material bending strength (psi) S acg  80000  psi
Class 40 cast iron
Hp
Hardness factor Hp  230 Hg  200  1.2
Hg
From equation 12.26, A  0

Ng
Gear ratio mg  mg  2.478
Np
Hardness ratio factor CH  1  A   mg  1  CH  1
S acg CL  CH
Endurance strength S fcg  S fcg  79999  psi
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
Safety factor Nfc =  
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d g p d   I  S fcg 
1 1.5 6
d in in in
6
 
from Table 12-2.
F pd
1 4.5
p d  4  in in
20. The calculated value of F is FL pd 

3
F  p d   4.083  in
in
FU pd 
in 1.5
F  4.125  in
2 2.5 3 3.5 4 4.5 5 5.5 6
d g p d   14.250 in Cv p d   0.809 pd  in
FIGURE 12-18B
Vt p d   1505 Wt p d   2740 lbf
ft
min Problem 12-18
σcg p d F   56282  psi
23. The gear face width is larger than for the pinion. This means that we will accept the gear requirements for the
pinion thus, for the set
1

2
 Sfcg 
Gear factor of safety Nfsg   σ p F  Nfsg  2.0
 cg d  
2
 Sfcp 
Pinion factor of safety Nfsp    Nfsp  3.5
 σcp pd F  
PROBLEM 12-19
Statement: Size the spur gears in problem 12-15 for a surface factor of safety of at least 1.2 assuming a
Given: Factor of safety Nfs  1.2 Number of gear teeth Ng  78

Power to be transmitted (hp) H  33 kW Reliability R  0.99
7
Pinion
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1194
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
v
A  50  56 ( 1  B) A  92
B
Cv p d    A 
 
 A  Vt  p d  
min

 ft 

0.5
6. Choose an elastic coefficient from Table 12-18. (Steel on nodular-iron) Cp  2160 psi
C a W t  p d   C m
Cv p d   F  d p p d   I

 0.056

S acp  162000 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
6 6.5 16
d in in in
10. From the graph, choose a standard value of p d 2

from Table 12-2.
1 F pd 
p d  10 in 1.5
in
FL pd
F  p d   1.478  in in 1

FU pd
common fractional value. in 0.5
F  1.500  in
6 8 10 12 14 16
d p p d   2.700  in Cv p d   0.925
pd  in
Vt p d   1131 Wt p d   1291 lbf

ft
FIGURE 12-19A
σcp p d F   146808 psi Problem 12-19
Gear
Ng
pd
C a W t  p d   C m
Cv p d   F  d g p d   I

Material bending strength (psi) S acg  97000  psi
A-7-d nodular iron
Hp
Hg

Ng
Np
S acg CL  CH
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d g p d   I  S fcg 
6 6.5 16
d in in in
3
 
from Table 12-2.
F pd
1
p d  10 in in
2
20. The calculated value of F is FL pd 
F  p d   1.427  in
in
 
FU pd 1
common fractional value. in
F  1.500  in
6 8 10 12 14 16
d g p d   7.800  in Cv p d   0.925 pd  in
FIGURE 12-19B
Vt p d   1131 Wt p d   1291 lbf
ft
min Problem 12-19
σcg p d F   86374  psi

23. The gear face width is the same as that for the pinion. This means that we will accept the gear requirements for
the set
1
Diametral pitch p d  10 in

2
 Sfcg 
 cg d  
2
 Sfcp 
 σcp pd F  
PROBLEM 12-20
Statement: If the gearset in Problem 12-11 transmits 83 kW at 1200 arm rpm, find the torque on each shaft.
Given: Sun tooth number Ns  33 Transmitted power P  83 kW

Planet tooth number Np  21 Arm speed ωa  1200 rpm
Ring gear speed ωr  0  rpm
1. Determine the number of teeth on the ring: Nr  Ns  2  Np Nr  75
= =
ωsa ωs  ωa Nr
Nr ωa  Ns ωa  Nr ωr

Solving for the planet speed, ωs  ωs  3927 rpm
Ns
3. Calculate the torque on the sun and arm shafts.

P
Arm shaft Ta  Ta  660  N  m
ωa
P
Sun shaft Ts  Ts  202  N  m
ωs
PROBLEM 12-21
Statement: If the gearset in Problem 12-12 transmits 39 HP at 2600 arm rpm, find the torque on each shaft.
Given: Tooth numbers: sun Ns  23 planet Np  31

Arm speed ωa  2600 rpm Sun speed ωs  0  rpm
Transmitted power P  39 hp

P
1. For the arm shaft Ta  Ta  945  in lbf
ωa
2. The ring gear will rotate at a higher speed, which is determined by the gear ratio.
3. For the ring gear (see Problem 12-12)

ωr  ωr  3303.529 rpm
Nr
P
Tr  Tr  744  in lbf
ωr
PROBLEM 12-22
Statement: If the gearset in Problem 12-13 transmits 23 kW at 4800 sun rpm, find the torque on each shaft.

sun Ns  23 Arm speed ωa  0  rpm
planet Np  31 Sun speed ωs  4800 rpm
Transmitted power P  23 kW

P
1. For the sun shaft Ts  Ts  45.8 N  m
ωs
2. The ring gear will rotate at a lower speed, which is determined by the gear ratio.
3. For the ring gear (see Problem 12-13)

ωr  ωr  1298.8 rpm
Nr
P
Tr  Tr  169  N  m
ωr
PROBLEM 12-23
Statement: Size the spur gears in problem 12-20 for a bending factor of safety of at least 2.8 assuming a
pinion, and a class 40 cast iron gear.
Given: Factor of safety Nfb  2.8 Number of gear teeth Ng  33

Power to be transmitted H  83 kW Reliability R  0.99
7

Pinion
Np Ng
Pitch diameter of pinion and gear (in) d p p d   d g p d  
pd pd
d g p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
v
A  50  56 ( 1  B) A  76.878
B
Kv p d    A 
 
 A  Vt  p d  
min

 ft 
Kv p d   F  Jp

 0.0323
S atp  40000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

1 1.5 6
d in in in
6
 
from Table 12-2. 5
F pd
1
p d  4  in in
4
FL pd
3
F  p d   2.196  in
in
 
FU pd 2
1
F  2.375  in
2 3 4 5 6
d p p d   5.250  in Kv p d   0.768 pd  in
Vt p d   2592 Wt p d   1417 lbf

ft FIGURE 12-23A
Problem 12-23
σbp p d F   13212  psi
Gear
Kv p d   F  Jg

S atg  13000  psi
Class 40 cast iron
S atg KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

1 1.25 6
d in in in

from Table 12-2. 6
1
p d  3  in
 
F pd
5
F  p d   3.486  in  
FL pd
4
FU pd
F  3.500  in in 3
d g p d   11.000 in Kv p d   0.744 2
2 3 4
pd  in
Vt p d   3456 Wt p d   1063 lbf
ft
min FIGURE 12-23B
σbg p d F   4624 psi Problem 12-23
23. The gear dimensions are larger (smaller diametral pitch means bigger teeth) than for the pinion. This means that
we will accept the gear requirements for the pinion, thus, for the set
1

S fbg
S fbp
PROBLEM 12-24
Statement: Size the spur gears in Problem 12-21 for a bending factor of safety of at least 2.4 assuming a
Given: Factor of safety Nfb  2.4

Power to be transmitted (hp) H  39 hp Reliability R  0.99
Number of pinion (sun) teeth Np  23 AGMA Quality level Qv  11
7
Number of gear (planet) teeth Ng  31 Life (cycles) N  10

Take the sun as the pinion and the planet as the gear, which is also an idler. With a stationary sun, the planet
gear will have one point (where it meshes with the sun) that has an instantaneous zero velocity. All other
points on the planet will have a linear velocity that is proportional to its distance from this instant center. The
point that meshes with the ring gear has maximum velocity. The pitchline velocity at the ring gear is a
function of the tooth numbers and the diametral pitch of the set. But the absolute planet velocity depends
only on the tooth numbers and the arm velocity. For the data of Problem 12-21, the absolute planet (gear)
rotational velocity is
For ωa  2600 rpm ωr  3303.53  rpm
Np  2  Ng
ωg   ωr ωg  9058.1 rpm
Ng
The sun (pinion) is stationary and, therefore, has a zero pitchline velocity. However, the planet (gear) mesh
point rotates about the pitch circle of the sun at the rotational velocity of the arm. Therefore, take the pinion
pitchline velocity to be
Np
Vtp = rp ωa =  ωa
2 pd
The maximum pitchline velocity of the planet (gear) is at the point where it meshes with the ring gear, which is
also the pitchline velocity of the ring gear. Thus, for the gear, the pitchline velocity is
Np  2  Ng
Vtg = rr ωr =  ωr
2 pd
The torques on the arm and ring were determined in Problem 12-21 to be Ta  945.38 in lbf and
Tr  744.05 in lbf . Load analysis of the gearset reveals that the transmitted load on the sun, planet, and ring
gear teeth is
2  p d  Tr
Wt =
Np  2  Ng
Pinion
Np
pd
Np
Pitch-line velocity (fpm) Vtp p d    ωa
2 pd
2  p d  Tr
Transmitted load (lbf) Wt p d  
Np  2  Ng
B  0.25  12  Qv
0.6667
v
A  50  56 ( 1  B) A  92
B
Kvp p d    A 
 
 A  Vtp pd  
min

 ft 
Kvp p d   F  Jp

 0.0323
S atp  42000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

Kvp p d   Jp S fbp
10 11.5 20
d in in in
10. From the graph, choose a standard value of p d from Table 12-2.
1
p d  14 in 2

 
F pd
F  p d   0.997  in 1.5
in
FL pd
common fractional value. 1
in
F  1.000  in
 
FU pd
in 0.5
d  p d   1.643  in Kvp p d   0.925
Vtp p d   1118 Wt p d   245  lbf

ft
0
min 10 12 14 16 18 20
pd  in
σbp p d F   17449  psi
FIGURE 12-24A
The assumption made in step 5 is correct so no Graph of Face Width and Limits for the Pinion in
further iteration is required. Problem 12-24
Gear
15. Write the equations for pitch diameter and pitchline velocity for the gear in terms of the unknown diametral pitc
p d. Note that, in Mathcad, unit conversion factors are not included.
Ng
Pitch diameter of pinion (in) dg p d  
pd
Np  Ng
Pitchline velocity (fpm) Vtg p d    ωr
2 pd
B
Kvg p d    A 
16. Write the equation for the dynamic load factor, K  
 A  Vtg pd  
min
v

 ft 
17. Account for the fact that the gear is an idler by setting the idler factor KI  1.42
Ka Wt p d   p d  Km KI

Kvg p d   F  Jg

A-7-d nodular iron S atg  34000  psi
S atg KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb
Ka Wt p d   p d  Km KI  Nfb

Kvg p d   Jg S fbg
6 6.5 16
17. Plot F(P) vs. p d over the range p d   
in in in
2
18. From the graph, choose a standard value of
p d from Table 12-2. F pd 
1.5
1 in
p d  12 in
 
FL pd
19. The calculated value of F is 1
in
F  p d   1.244  in
FU pd 
20. Round this up to the decimal equivalent of a in 0.5
F  1.250  in
0
6 8 10 12 14 16
pd  in
FIGURE 12-24B
dg p d   2.583  in Kvg p d   0.879 Graph of Face Width and Limits for the Gear in
Problem 12-24
Vtg p d   3892 Wt p d   210  lbf

ft
min
σbg p d F   14095  psi
22. The gear dimensions are larger (smaller diametral pitch means bigger teeth) than for the pinion. This means that
we will accept the gear requirements for the pinion, thus, for the set
1

S fbg
S fbp
PROBLEM 12-25
Statement: Size the spur gears in problem 12-20 for a surface factor of safety of at least 1.7 assuming a
pinion, and a class 40 cast iron gear.
Given: Factor of safety Nfs  1.7 Number of gear teeth Ng  33

Power to be transmitted H  83 kW Reliability R  0.99
Rotational speed of pinion n g  1200 rpm AGMA Quality level Qv  9
7
Pinion
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1170
 2  p g
2. Write the equations for pitch diameter, pitchline velocity, and transmitted load in terms of the unknown
Np Ng
Pitch diameters of pinion and gear (in) d p p d   d g p d  
pd pd
d g p d   n g
pitchline velocity (fpm) Vt p d  
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
v
A  50  56 ( 1  B) A  76.878
B
Cv p d    A 
 
 A  Vt  p d  
min

 ft 

0.5
6. Choose an elastic coefficient from Table 12-18. (Steel on cast iron). Cp  2100 psi
C a W t  p d   C m
Cv p d   F  d p p d   I

 0.056
S acp  165000 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
1 1.5 6
10. Plot F(P) vs. p d over the p d   
range in in in
4

p d from Table 12-2.  
F pd
3
in
1
p d  5  in
 
FL pd
in
F  p d   2.149  in  
FU pd
in 1
F  2.250  in 0
2 3 4 5 6
14. Then, the parameters that depend on p d and F are: pd  in
FIGURE 12-25A
d p p d   4.200  in Cv p d   0.785
Graph of Face Width and Limits for the Pinion in
Problem 12-25
Vt p d   2073 Wt p d   1771 lbf

ft
min
σcp p d F   123671 psi
Gear
Ng
pd
C a W t  p d   C m
Cv p d   F  d g p d   I

Class 40 cast iron S acg  80000  psi
Hp
Hg
Ng
Np
S acg CL  CH
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d g p d   I  S fcg 
1 1.5 6
range in in in
6
F pd
4.5
1 in
p d  4  in
 
FL pd
in
F  p d   3.807  in
FU pd 
22. Round this up to the decimal equivalent of a in 1.5
F  4.000  in
0
2 2.5 3 3.5 4 4.5 5 5.5 6
pd  in
FIGURE 12-25B
d g p d   8.250  in Cv p d   0.768 Graph of Face Width and Limits for the Gear in
Problem 12-25
Vt p d   2592 Wt p d   1417 lbf σcg p d F   59858  psi

ft
min
24. The gear dimensions are larger (smaller diametral pitch means bigger teeth) than for the pinion. This means
that we will accept the gear requirements for the pinion, thus for the set
1

2
 Sfcg 
 cg d  
2
 Sfcp 
 σcp pd F  
PROBLEM 12-26
Statement: Size the spur gears in Problem 12-21 for a surface factor of safety of at least 1.3 assuming a
Given: Factor of safety Nfs  1.3 Pressure angle ϕ  20 deg

Power to be transmitted (hp) H  39 hp Reliability R  0.99
Number of pinion (sun) teeth Np  23 AGMA Quality level Qv  11
7
Number of gear (planet) teeth Ng  31 Life (cycles) N  10

Take the sun as the pinion and the planet as the gear, which is also an idler. With a stationary sun, the planet
gear will have one point (where it meshes with the sun) that has an instantaneous zero velocity. All other
points on the planet will have a linear velocity that is proportional to its distance from this instant center. The
point that meshes with the ring gear has maximum velocity. The pitchline velocity at the ring gear is a
function of the tooth numbers and the diametral pitch of the set. But the absolute planet velocity depends
only on the tooth numbers and the arm velocity. For the data of Problem 12-21, the absolute planet (gear)
rotational velocity is
For ωa  2600 rpm ωr  3303.53  rpm
Np  2  Ng
ωg   ωr ωg  9058.1 rpm
Ng
The sun (pinion) is stationary and, therefore, has a zero pitchline velocity. However, the planet (gear) mesh
point rotates about the pitch circle of the sun at the rotational velocity of the arm. Therefore, take the pinion
pitchline velocity to be
Np
Vtp = rp ωa =  ωa
2 pd
The maximum pitchline velocity of the planet (gear) is at the point where it meshes with the ring gear, which is
also the pitchline velocity of the ring gear. Thus, for the gear, the pitchline velocity is
Np  2  Ng
Vtg = rr ωr =  ωr
2 pd
The torques on the arm and ring were determined in Problem 12-21 to be Ta  945.38 in lbf and
Tr  744.05 in lbf . Load analysis of the gearset reveals that the transmitted load on the sun, planet, and ring
gear teeth is
2  p d  Tr
Wt =
Np  2  Ng
Pinion
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.0923
 2  p g
2. Write the equations for pitch diameter, pitchline velocity, and transmitted load in terms of the unknown diametr
pitch, p d. Note that, in Mathcad, unit conversion factors are not included.
Np
pd
Np
pitchline velocity (fpm) Vtp p d    ωa
2 pd
2  p d  Tr
Np  2  Ng
B  0.25  12  Qv
0.6667
v
A  50  56 ( 1  B) A  92
B
Cvp p d    A 
 
 A  Vtp pd  
min

 ft 
5. Tentatively choose the mounting factor, Cm (Assume 0 < F < 2 in) Cm  1.6
0.5
6. Choose an elastic coefficient from Table 12-18. Cp  2100 psi
Ca Wt p d   Cm
Cvp p d   F  d p p d   I

 0.056
S acp  162000 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 c
C a W t  p d   C m
2
 Cp 
Cvp p d   d p p d   I  S fcp 
6 6.5 16
d in in in
11. From the graph, choose a standard value of 2

p d from Table 12-2.
p d  14 in
1  
F pd
1.5
in
 
FL pd
F  p d   0.611  in 1
in
FU pd
in 0.5
F  0.625  in

6 8 10 12 14 16
d p p d   1.643  in Cvp p d   0.925 pd  in
FIGURE 12-26A
Graph of Face Width and Limits for the Pinion in
Vtp p d   1118 Wt p d   245  lbf
ft
Problem 12-26
min
σcp p d F   140460 psi

Gear
15. Write the equations for pitch diameter and pitchline velocity for the gear in terms of the unknown diametral pitc
p d. Note that, in Mathcad, unit conversion factors are not included.
Ng
Pitch diameter of pinion (in) d g p d  
pd
Np  Ng
pitchline velocity (fpm) Vtg p d    ωr
2 pd
B
Cvg p d    
A
16. Write the equation for the dynamic load factor, C 
 A  Vtg pd  
min
v

 ft 
Ca Wt p d   Cm
Cvg p d   F  d g p d   I
A-7-d nodular iron S acg  97000  psi
Hp
Hg
Ng
Np
S acg CL  CH
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cvg p d   d g p d   I  S fcg 
6 6.5 16
range in in in

1  
F pd 2.5
p d  12 in
in
2
FL pd
F  p d   0.978  in in 1.5

FU pd 1
0.5
F  1.000  in
24. Then, the parameters that depend on P and F are: 0

6 8 10 12 14 16
d g p d   2.583  in Cvg p d   0.879 pd  in
Vtg p d   3892 Wt p d   210  lbf

ft FIGURE 12-26B
min Graph of Face Width and Limits for the Gear in
Problem 12-26
σcg p d F   84140  psi
25. The gear dimensions are larger than that for the pinion. Thus, for the set
1
2
 Sfcg 
 cg d  
2
 Sfcp 
 σcp pd F  
PROBLEM 12-27
Statement: If the gearset in Problem 12-10 transmits 190 kW at 1800 input pinion rpm, find the torque on each
of the four shafts.
Given: Transmitted power P  190  kW Input speed ωp1  1800 rpm
Assumptions: Tooth numbers:

Stage 1 Np1  18 Ng1  164
Stage 2 Np2  18 Ng2  144
Stage 3 Np3  18 Ng3  162
1. Confirm that the gear ratio is correct.
Ng1 Ng2 Ng3

mG  mG  656.000
Np1 Np2 Np3
2. Calculate the gear speeds.
Np1
Stage 1 ωp1  1800 rpm ωg1   ωp1 ωg1  197.561  rpm
Ng1
Np2
Stage 2 ωp2  ωg1 ωg2   ωp2 ωg2  24.695 rpm
Ng2
Np3
Stage 3 ωp3  ωg2 ωg3   ωp3 ωg3  2.744  rpm
Ng3
3. Calculate the shaft torque.

P
Shaft 1 T1  T1  1008 N  m Input
ωp1
P
Shaft 2 T2  T2  9184 N  m
ωg1
P
Shaft 3 T3  T3  73471  N  m
ωg2
P
Shaft 4 T4  T4  661236 N  m Output
ωg3
PROBLEM 12-28
Statement: Size the first-stage spur gears in problem 12-27 for a bending factor of safety of at least 3.2 and
a surface factor of safety of at least 1.7 assuming a steady torque, 25 deg pressure angle, full
depth teeth, Qv = 8, and AISI 4140 steel for all gears.
Given: Pressure angle ϕ  25 deg

Bending factor of safety Nfb  3.2 Reliability R  0.99
Surface factor of safety Nfs  1.7 AGMA Quality level Qv  8
7
Power to be transmitted (hp) H  190  kW Life (cycles) N  10
Number of pinion teeth Np  18 Number of gear teeth Ng  164
Rotational speed of pinion (rpm) n  1800 rpm
Assumptions: Since both pinion and gear from each stage are the same material, it will only be necessary to
determine the pinion size as it will be governing for the set.
Stage 1 Pinion - Bending

Np Ng
pd pd
d p p d   n
2
Wt p d  
H
Vt  p d 
4. Write the equation for the dynamic load factor, Kv
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  70.721
B
B  0.63
Kv p d    A 
 
 A  Vt  p d  
min

 ft 
6. The bending stress equation for the pinion is
σbp p d F  
Kv p d   F  Jp

 0.0323

S atp  40000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

1 1.1 5
d in in in

p d  3  in
1  
F pd
6
in
 
FL pd
F  p d   4.546  in 4
in
12. Round this up to the decimal equivalent of  
FU pd
a common fractional value.
in 2
F  4.500  in

2 2.5 3 3.5 4
pd  in
d p p d   6.000  in d g p d   54.667 in
FIGURE 12-28A
Vt p d   2827 Wt p d   2974 lbf
ft Graph of Face Width and Limits for the Stage 1
min Pinion (bending) in Problem 12-28
σbp p d F   12627  psi Kv p d   0.702
Stage 1 Pinion - Surface Fatigue

 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1726
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
4. Write the equation for the dynamic load factor, Cv
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  70.721
B
Cv p d    
B  0.63 A

 A  Vt  p d  
min

 ft 
0.5
6. Choose an elastic coefficient from Table 12-18. (Steel on steel). Cp  2300 psi
7. The surface stress equation for the pinion is
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S acp  165000 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
1 1.1 6
d in in in
6
 
F pd
1
p d  4  in in
4
FL pd
F  p d   3.933  in
in
 
FU pd 2
13. Round this up to the decimal equivalent of
a common fractional value. in
F  4.000  in
0
14. The bending requirement is governing in 2 3 4 5 6
this case. The diametral pitch and face pd  in
width for the stage 2 gearset are:
FIGURE 12-28B
1
p d  3  in F  4.500  in Graph of Face Width and Limits for the Stage 1
Pinion (surface) in Problem 12-28
PROBLEM 12-29
Statement: Size the second-stage spur gears in problem 12-27 for a bending factor of safety of at least 3.2
and a surface factor of safety of at least 1.7 assuming a steady torque, 25 deg pressure angle,
full depth teeth, quality index of 8, and AISI 4140 steel for all gears.

7
Power to be transmitted H  190  kW Life (cycles) N  10
Rotational speed of pinion (rpm) n  197.561  rpm
Np Ng
pd pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  70.721
B
B  0.63
Kv p d    A 
 
 A  Vt  p d  
min

 ft 
σbp p d F  
Kv p d   F  Jp
 0.0323

S atp  40000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

1 1.1 3
d in in in

20
1
p d  1.5 in
 
F pd
in
F  p d   9.313  in
 
FL pd
12. Round this up to the decimal equivalent of 10
in
 
FU pd
F  9.375  in
in 5
0
d p p d   12.000 in d g p d   96.000 in 1 1.5 2 2.5
pd  in
Vt p d   621  Wt p d   13547  lbf

ft
FIGURE 12-29A
min Graph of Face Width and Limits for the Stage 2
σbp p d F   12417  psi Kv p d   0.827 Pinion (bending) in Problem 12-29

 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1702
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  70.721
B
Cv p d    
B  0.63 A

 A  Vt  p d  
min

 ft 
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S acp  165000 psi
S acp CL
CT  CR
9. Write the design equations using the range of face-width to diametral-pitch ratio given on page 740 of the text,
and the bending stress equation, solved for the unknown face width.
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
1 1.1 3
d in in in
20
 
F pd
1 15
p d  2  in in

FL pd
10
F  p d   8.290  in
in
 
FU pd
in 5
F  8.250  in
0
14. The bending requirement is governing in 1 1.5 2 2.5 3
width for the stage 2 gearset are:
FIGURE 12-29B
1 Graph of Face Width and Limits for the Stage 2
p d  1.5 in F  9.375  in Pinion (surface) in Problem 12-29
PROBLEM 12-30
Statement: Size the third-stage spur gears in problem 12-27 for a bending factor of safety of at least 3.2 and a
surface factor of safety of at least 1.7 assuming a steady torque, 25 deg pressure angle, full depth
teeth, quality index of 8, and AISI 4140 steel for all gears.

7
Power to be transmitted H  190  kW Life (cycles) N  10
Rotational speed of pinion n  24.695 rpm
Np Ng
pd pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  70.721
B
B  0.63
Kv p d    A 
 
 A  Vt  p d  
min

 ft 
σbp p d F  
Kv p d   F  Jp

 0.0323

S atp  40000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

0.5 0.6 2
d in in in

p d  0.75 in
1  
F pd
30
in
 
FL pd
F  p d   18.954 in 20
in
FU pd
in 10
F  19.000 in

0.5 0.75 1 1.25 1.5 1.75 2
pd  in
d p p d   24.000 in d g p d   216.000  in
FIGURE 12-30A
Vt p d   155  Wt p d   54189  lbf
ft Graph of Face Width and Limits for the Stage 3
min Pinion (bending) in Problem 12-30
σbp p d F   12470  psi Kv p d   0.903

 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1724
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  70.721
B
B  0.63
Cv p d    A 
 
 A  Vt  p d  
min

 ft 
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S acp  165000 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
0.5 0.6 2
d in in in
40
 
F pd
1 30
p d  1  in in

FL pd
20
F  p d   16.825 in
in
FU pd 
in 10
F  16.875 in
0
14. The bending requirement is governing in 0.5 0.75 1 1.25 1.5 1.75 2
width for the stage 2 gearset are: FIGURE 12-30B
Graph of Face Width and Limits for the Stage 3
1
p d  0.75 in F  19.000 in Pinion (surface) in Problem 12-30
PROBLEM 12-31
1. For equal stages, the stage ratio is
1
n
mGs  mG mGs  8.832
12 mGs  105.981 15 mGs  132.476
13 mGs  114.813 16 mGs  141.308
14 mGs  123.645 17 mGs  150.14
3. The first trial is very close to an integer so try 106 teeth:

n
 106 
mG   12  mG  78.028
 
4. We can get the exact ratio by using 12-tooth and 16-tooth pinions with 104- and 144-tooth gears
Let Stage 1 Np1  12 Ng1  104
Stage 2 Np2  16 Ng2  144
Ng1 Ng2
Then, the gear ratio is mG  mG  78.000
Np1 Np2
PROBLEM 12-32
Statement: Figure P12-1 shows the same paper machine that was analyzed in Problem 6-46 and in other
problems in previous chapters. Using the data of Problem 4-46, design a suitable spur-gear set
for this application for a 10-yr life against surface failure. State all assumptions.
Units: yr  2080 hr
Given: Gear ratio mg  2 Life (years) Life  10 yr

Torque on gear Tg  74240  in lbf
Assumptions: 1. If both pinion and gear are the same material, it will only be necessary to determine the pinion
size as it will be governing for the set.
3. Pinion speed is n p  3  rpm (5 seconds for a 90-deg rotation).
Design Choices:
Number of pinion teeth Np  26 Reliability R  0.99
Material: AGMA Grade 2 steel for both pinion and gear, through hardened to
Surface factor of safety Nfs  2 Number of shifts shifts  3

1. Determine the number of gear teeth and the cycle life.
Number of gear teeth Ng  Np mg Ng  52
np 7
Cycle life: N  Life shifts N  1.123  10
2 π
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1277
 2  p g
Np Ng
pd pd
d p p d   n p
2
2  Tg
d g p d 

B  0.25  12  Qv
0.6667
v
A  50  56 ( 1  B) A  70.721
B
Cv p d    
A

 A  Vt  p d  
min

 ft 
0.5
7. Choose an elastic coefficient from Table 12-18 (steel on steel). Cp  2300 psi
C a W t  p d   C m
Cv p d   F  d p p d   I
 0.056
Life factor CL  2.466  N CL  0.993
S ac  136200 psi
Grade 2, 300 HB
S ac CL
CT  CR
2
Limits and safety factor FU  p d  
 Sfc 
FL  p d  
16 8
Nfc = σ 
pd pd  c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
1 1.5 10
range in in in
8

F pd
6
in
1
p d  2.5 in
 
FL pd
in
F  p d   5.414  in  
FU pd
in 2
F  5.500  in 0
1 1.5 2 2.5 3 3.5 4
pd  in
d p p d   10.400 in d g p d   20.800 in FIGURE 12-32

Graph of Face Width and Limits for the Pinion
(surface) in Problem 12-32
Vt  p d   8  Wt p d   7138 lbf σcp p d F   94935  psi

ft
min
14. There is a wide range of choice for the number of teeth on the pinion. The total weight of the gears goes down
very slightly with increasing pinion tooth number. The choice of Np  26 was somewhat arbitrary but was
arrived at after trying values from 18 to 26.
PROBLEM 12-33
Statement: Design a non reverted compound transmission based on the arrangement shown in Figure
12-14a for an overall train ratio of approximately 90:1. It should be capable of transmitting 50
hp at 1000 rpm input shaft speed. State all assumptions.
Given: Power to be transmitted H  50 hp Approximate gear ratio mv  90

Input speed (rpm) n in  1000 rpm Number of stages n  2
Assumptions: 1. If both pinion and gear from each stage are the same material, it will only be necessary to
Design Choices:
Surface factor of safety Nfs  1.7 Reliability R  0.99
7
Life (cycles) N  10
Material: AGMA Grade 2 steel for both pinion and gear, both stages, through hardened to
1. For equal stage ratios, the stage ratio is
1
n
mvs  mv mvs  9.487
14 mvs  132.816 20 mvs  189.737 26 mvs  246.658 32 mvs  303.579
15 mvs  142.302 21 mvs  199.223 27 mvs  256.144 33 mvs  313.065
16 mvs  151.789 22 mvs  208.71 28 mvs  265.631 34 mvs  322.552
17 mvs  161.276 23 mvs  218.197 29 mvs  275.118 35 mvs  332.039
18 mvs  170.763 24 mvs  227.684 30 mvs  284.605 36 mvs  341.526
19 mvs  180.25 25 mvs  237.171 31 mvs  294.092 37 mvs  351.013
3. The last trial is very close to an integer so try 351 teeth:

n
 351 
mv   37  mv  89.993
 
4. For each stage let Np  37 Ng  351

Stage 1 Pinion
Given: Rotational speed of pinion (rpm) n 1  n in n 1  1000 rpm
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1732
 2  p g
Np Ng
pd pd
d p p d   n 1
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  70.721
B
B  0.63 Cv p d    A 
 
 A  Vt  p d  
min

 ft 
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S ac  136200 psi
S ac CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
6 6.5 16
d in in in
11. From the graph, choose a standard

value of p d from Table 12-2.
3
1
p d  8  in
 
F pd
in
F  p d   1.697  in
2
 
FL pd
13. Round this up to the decimal in
equivalent of a common fractional value.
 
FU pd 1
F  1.750  in
in
d p p d   4.625  in d g p d   43.875 in 0
6 8 10 12 14 16
pd  in
Vt p d   1211 Wt p d   1363 lbf

ft
min FIGURE 12-33A
σcp p d F   102877 psi Pinion (surface) in Problem 12-33
Stage 2 Pinion
Np
Given: Rotational speed of pinion (rpm) n 2   n in n 2  105.413  rpm
Ng
Np
pd
d p p d   n 2
2
Wt p d  
H
Vt  p d 

B
Cv p d    
A

 A  Vt  p d  
min

 ft 
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
2 2.5 12
d in in in
8
F pd
1 in
p d  4  in 5.333
 
FL pd
in
F  p d   3.779  in
 
FU pd 2.667
9. Round this up to the decimal equivalent of in
F  3.750  in
0
10. Then, the parameters that depend on p d and F are: 2 3 4 5 6 7 8
pd  in
d p p d   9.250  in d g p d   87.750 in
FIGURE 12-33B
Vt p d   255  Wt p d   6464 lbf
ft
min
σcp p d F   104866 psi
PROBLEM 12-34
Statement: Design a reverted compound transmission based on the arrangement shown in Figure 12-14b
for an overall train ratio of approximately 80:1. It should be capable of transmitting 30 hp at
1500 rpm input shaft speed. State all assumptions.
Given: Power to be transmitted H  30 hp Approximate gear ratio mv  80

Input speed (rpm) n in  1500 rpm Number of stages n  2
Assumptions: 1. If both pinion and gear from each stage are the same material, it will only be necessary to
3. If both stages have the same tooth numbers, then both must have the same diametral pitch in
order that the center distances be the same. In this case, the dimensions of the second stage will
govern the design.
Design Choices:
Surface factor of safety Nfs  1.7 Reliability R  0.99
7
Life (cycles) N  10
Material: AGMA Grade 2 steel for both pinion and gear, both stages, through hardened to

1. For equal stage ratios, the stage ratio is
1
n
mvs  mv mvs  8.944
2. The minimum number of teeth that we can have without interference on a 25-deg gear cut with a hob is 14.
Try pinions with 14, 15, 16, etc. teeth to see if the mating gear will have close to an integral number of teeth.
14 mvs  125.22 20 mvs  178.885 26 mvs  232.551 32 mvs  286.217
15 mvs  134.164 21 mvs  187.83 27 mvs  241.495 33 mvs  295.161
16 mvs  143.108 22 mvs  196.774 28 mvs  250.44 34 mvs  304.105
17 mvs  152.053 23 mvs  205.718 29 mvs  259.384 35 mvs  313.05
18 mvs  160.997 24 mvs  214.663 30 mvs  268.328 36 mvs  321.994
19 mvs  169.941 25 mvs  223.607 31 mvs  277.272 37 mvs  330.938
3. The next to last trial is very close to an integer so try 322 teeth:
n
 322 
mv   36  mv  80.003
 
4. For each stage let Np  36 Ng  322
Stage 2 Pinion
Np
Given: Rotational speed of pinion (rpm) n 2   n in n 2  167.702  rpm
Ng
I   sin( ϕ)  cos( ϕ)   Ng I  0.1723

  N N
 2  p g
Np Ng
pd pd
d p p d   n 2
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  70.721
B
B  0.63 Cv p d    A 
 
 A  Vt  p d  
min

 ft 
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S ac  136200 psi
S ac CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
2 2.1 12
d in in in

1  
F pd
p d  5  in 3
in
FL pd
F  p d   2.397  in in 2
13. Round this up to the decimal equivalent of FU pd 

a common fractional value. in 1
F  2.375  in

2 3 4 5 6 7 8 9 10 11 12
pd  in
d p p d   7.200  in d g p d   64.400 in
FIGURE 12-34A
Vt p d   316  Wt p d   3132 lbf
ft
min
σcp p d F   104942 psi
15. This diametral pitch and face width should be used for both stages in the gearset.
PROBLEM 12-35 _____
Statement: If the 23-tooth pinion in the gearset in Problem 12-3 is on the input shaft, find the velocity ratio,
torque ratio, and gear ratio for the gearset.
Given: Input tooth number Nin  23 Output tooth number Nout  57
1. Calculate the velocity ratio using equation 12.1a. Note that, for a given diametral pitch, the pitch radius of a
gear is directly proportional to the number of teeth on the gear.
Nin
mV   mV  0.404
Nout
2. Calculate the torque ratio using equation 12.1b.
1
mA  mA  2.478
mV
3. Calculate the gear ratio using equation 12.1c.
mG  mA mG  2.478
PROBLEM 12-36 _____
Statement: If the 78-tooth gear in the gearset in Problem 12-4 is on the input shaft, find the velocity ratio,
torque ratio, and gear ratio for the gearset.
Given: Input tooth number Nin  78 Output tooth number Nout  27
1. Calculate the velocity ratio using equation 12.1a. Note that, for a given diametral pitch, the pitch radius of a
gear is directly proportional to the number of teeth on the gear.
Nin
mV   mV  2.889
Nout
2. Calculate the torque ratio using equation 12.1b.
1
mA  mA  0.346
mV
3. Calculate the gear ratio using equation 12.1c.
mG  mV mG  2.889
PROBLEM 12-37 _____
Statement: Figure P12-2 shows an involute of a circle that starts at point A(0, rb) and continues to point P(x,y)
The angle  is known as the roll angle and  is the involute pressure angle. Derive expressions for
the x,y coordinates of P in terms of the base circle radius rb and the involute pressure angle only.
Plot y vs. x over the range 0 <  < 40 deg for rb = 2 in.
Given: Base circle radius rb  2.00 in
Solution: See Figure P12-2 and Mathcad file P1237.
1. From the definition of the involute, the distance from P to Q is the arc-length along the base circle subtended
by the angle . Thus,
PQ  rb θ
2. The distance OP = rp is then
2 2 2 2
rp  rb  rb  θ rp  rb 1  θ
3. Looking at triangle OPQ, we see that
rb θ
tan ( ϕ)  θ  tan( ϕ)
rb
4. Writing the x and y coordinates of P in terms of the above relationships, we have
2
x( ϕ)  rb 1  tan ( ϕ)  sin( tan ( ϕ)  ϕ)
2
y ( ϕ)  rb 1  tan( ϕ)  cos( tan( ϕ)  ϕ)
5. Plot y vs. x over the range ϕ  0  deg 1  deg  40 deg
2.6
2.4
y ( ϕ)
in
2.2
2
0 0.1 0.2 0.3 0.4
x( ϕ)
in
PROBLEM 12-38 _____
Statement: Derive equation 12.2 using Figure 12-5.
Solution: See Figure 12-5 and Mathcad file P1238.
1. Label points on Figure 12-5 as follows:
Center of pinion, Op
Center of gear, Og
Beginning of contact, E
Pitch point, P
Leaving contact, F
Extend line of action to tangency with pinion base circle, A (not shown on figure)
Extend line of action to tangency with gear base circle, B (not shown on figure).
2. The length of action, Z, is equal to the distance EF = EP + PF.
3. The distance PF = AF - AP and EP = BE - BP. Thus, Z = AF + BE - (AP + BP).
4. The distance OpF = rp + a p, and OgE = rg + a g, where a p is the pinion addendum and a g is the gear addendum .
5. Since the line of action is tangent to both base circles, angle AOpP = angle BOgP = , the gear pressure angle.
Also, the distance OpA = rbp = rpcos() and OgB = rbg = rgcos().
6. From the relationships above,
AF  rp  ap2   rp cos( ϕ) 2 BE   rg  ag2   rg cos( ϕ) 2
AP  rp sin( ϕ) BP  rg sin( ϕ)
7. Substituting the equations in step 6 into the equation for Z in step 3,
Z  rp  ap2   rp cos( ϕ) 2  rg  ag 2  rg cos( ϕ)  2  rp  rg  sin( ϕ)
But, rp + rg = C, the center distance. So,
Z  rp  ap2   rp cos( ϕ) 2  rg  ag 2  rg cos( ϕ)  2  C sin( ϕ)

which is equations 12-2.
PROBLEM 12-39 _____
Statement: A 39-tooth spur gear is in mesh with an 18-tooth pinion. The p d = 8 and  = 25 deg. Find the
contact ratio.
Given: Tooth numbers: Pinion Np  18 Gear Ng  39

1
Diametral pitch p d  8  in Pressure angle ϕ  25 deg
π
pd
Pinion:
Np
pd
Gear:
Ng
pd
1.0
pd
Np  Ng
2 pd
Length of action
Z  0.516  in
Z
pb
PROBLEM 12-40 _____
Statement: A 79-tooth spur gear is in mesh with a 20-tooth pinion. The p d = 8 and  = 20 deg. Find the
contact ratio.

1
π
pd
Pinion:
Np
pd
Gear:
Ng
pd
1.0
pd
Np  Ng
2 pd
Length of action
Z  0.624  in
Z
pb
PROBLEM 12-41 _____

increased by 6%?

1

distance changes.
new Base Circle
C  ΔC Old Pitch Circle
Let = fc
C New Pitch Circle
side by C, rbp
fc rp
ΔC
fc = 1 
C
C + C
2. In this case, fc  1  0.06 fc  1.060 fc r g rbg
3. Determine the pitch diameter and pitch radius of

the pinion.
Np
Pitch diameter d p 
pd
d p  2.250  in
FIGURE 12-41
Pitch radius rp  0.5 d p Diagram Showing Center Change for Problem 12-41
rp  1.125  in
line of centers. The new pitch radii are proportional to f c. Thus, from Figure 12-41, the new pressure angle is
rbp
cos ϕnew =
fc  rp
new,
 fc  rp 
PROBLEM 12-42 _____

increased by 5%?

1

distance changes. new Base Circle
Old Pitch Circle
C  ΔC New Pitch Circle
Let = fc
C
Dividing numerator and denominator of the left rbp
fc rp
side by C,
ΔC
fc = 1  C + C
C
fc r g rbg
2. In this case, fc  1  0.05 fc  1.050
3. Determine the pitch diameter and pitch radius of

the pinion.
Np
Pitch diameter d p 
pd
d p  2.500  in FIGURE 12-42

Diagram Showing Center Change for Problem 12-42
Pitch radius rp  0.5 d p
rp  1.250  in
line of centers. The new pitch radii are proportional to f c. Thus, from Figure 12-41, the new pressure angle is
rbp
cos ϕnew =
fc  rp
new,
 fc  rp 
PROBLEM 12-43
Statement: If the spur gearsets in Problems 12-39 and 12-40 are compounded as shown in Figure 12-14,
what will the overall train ratio be?
Given: Tooth numbers N2  18 N3  39
N4  20 N5  79
1. Using equation 12.9b and assuming that gears 2 and 4 are the driver gears, the train (velocity) ratio is
N2 N4
mv  mv  0.117
N3 N5
2. On the other hand, if gears 3 and 5 are the driver gears then the train ratio is
N3 N5
mv  mv  8.5583
N2 N4
PROBLEM 12-44 _____

Given: Number of teeth N  23 Pressure angle ϕ  20 deg
1
Diametral pitch p d  6  in
N
pd
1.0
pd
1.25
pd
π
pd
PROBLEM 12-45 _____

Given: Number of teeth N  32 Pressure angle ϕ  20 deg
1
N
pd
1.0
pd
1.25
pd
π
pd
PROBLEM 12-46 _____
1. For equal stage ratios, the stage ratio is approximately

1
n
mGs  mG mGs  7.280
2. The minimum number of teeth that we can have without interference on a 25-deg gear cut with a hob is 14.
Try pinions with 14, 15, 16, etc. teeth to see if the mating gear will have close to an integral number of teeth.
14 mGs  101.922
15 mGs  109.202
16 mGs  116.482
3. The first trial is very close to an integer so try 102 teeth:

n
 102 
mG   14  mG  53.082
 
4. We can get slightly closer by using two 14-tooth pinions with 101 and 103-tooth gears
101  103
mG  mG  53.077
14 14
5. However, it may be harder to find the 101 and 103-tooth gears and, it may be less expensive to have two gears
with the same number of teeth than to have different numbers of teeth.
PROBLEM 12-47 _____
Statement: Design a three-stage compound spur gear train for an overall ratio of approximately 592:1.
Specify tooth numbers for each gear in the train.
Given: Approximate ratio mG  592 Number of stages s  3

1
s
1. The average stage ratio is ravg  mG ravg  8.397
2. If the minimum number of teeth is (for a 20 deg pressure angle) Nmin  18 then the number of teeth on the
driven gear for each stage is
NG1  floor  ravg Nmin NG1  151
or NG2  ceil ravg Nmin NG2  152
3. But, the prime factors of 592 are 2 4 and 37. This suggests that one of the gears have a number of teeth that is
a multiple of 37, say 148.
148
 17.626 Let N2  18 N3  148
ravg
N5 N7
Thus, = 72 if N4  18 and N6  18
N4 N6
5 6
then N5 N7 = 72 18 18 = 2  3
4 2 1 4
Try N5  2  3 N7  2  3 then N5 N7  23328
Summarizing, N2  18 N3  148
N4  18 N5  144
N6  18 N7  162
4. Since the driven gears all have less than 180 teeth, no stage ratio is greater than 10.
5. Checking the overall gear ratio
N 3 N 5 N 7
mG  mG  592.00
N 2 N 4 N 6
PROBLEM 12-48 _____
Statement: Design a planetary gear train similar to that shown in Figure 12-16 for an overall velocity ratio of
exactly 0.2 if the sun gear is the input, the arm is the output, and the ring gear is stationary.
Given: Exact ratio mv  0.2
1. Let the first gear be the sun gear (gear 2) and the last be the ring gear (gear 4). Then, equation 12.11c can be
written as
ω4  ωarm N2
 
ω2  ωarm N4
2. Taking 4 = 0 and solving for out/in, we have
ωout ωarm N2
= = = mv
ωin ω2 N2  N4
3. Let the sun gear have tooth number N2  20 , then the number of teeth required for the ring gear is
1  mv
N4   N2 N4  80
mv
4. In order to mesh properly, the number of teeth on the ring gear must be equal to the sum of the number of
teeth on the sun gear plus two times the number of teeth on the planet gear(s). Thus,
N4  N2
N3  N3  30
2
5. Check the overall velocity ratio and summarize the tooth numbers.
N2
Overall velocity ratio mv  mv  0.200
N2  N4
Sun gear N2  20
Planet gear(s) N3  30
Ring gear N4  80
PROBLEM 12-49 _____
Statement: Design a planetary gear train similar to that shown in Figure 12-16 for an overall velocity ratio
of exactly 4/3 if the sun gear is stationary, the arm is the input, and the ring gear is the output.
4
Given: Exact ratio mv 
3
written as
ω4  ωarm N2
 
ω2  ωarm N4
ωout ω4 N4  N2
= = = mv
ωin ωarm N4
N2
N4  N4  60
mv  1
N4  N2
N3  N3  20
2
N4  N2
Overall velocity ratio mv  mv  1.333
N4
Sun gear N2  20
Ring gear N4  60
PROBLEM 12-50 _____

Statement: A 21-tooth pinion rotating at 1800 rpm meshes with a 33-tooth gear in a spur gear reducer. Both
pinion and gear are manufactured to a quality level of 9. A reliability of 0.9 has been specified,
and the transmitted tangential load is 2800 lb. Conditions are such that Km = 1.7. It is proposed
that standard 25-degree, full-depth teeth be used, with both pinion and gear hobbed from an
AISI 4140 nitrided steel. The diametral pitch is 6, and the face width 2.000 in. Estimate the
number of cycles of bending stress (using the AGMA equations) that the gearset can
withstand.
Given: Tooth numbers Np  21 Ng  33

Pinion speed n  1800 rpm Mounting factor Km  1.7
1
Diametral pitch p d  6  in Quality index Qv  9
Face width F  2.000  in Pressure angle ϕ  25 deg
Tangential load Wt  2800 lbf Reliability R  0.90
Assumptions: The life of the pinion will be less than that of the gear.
1. Calculate the pitch diameter of the pinion using equation 12.4a and the pitch-line velocity of the gearset.
Np d n ft
d  d  3.500  in V  V  1649
pd 2 min
2. Calculate the dynamic factor Kv using equations 12.16 and 12.17.
B  0.25  12  Qv
0.6667
B  0.520 A  50  56 ( 1  B) A  76.878
B
Kv   A  Kv  0.802
 V  min 

 A   
  ft  
3. Determine the bending geometry factor, J (Table 12-13) J  0.40
4. Assume an application factor, Ka Ka  1
5. Calculate the bending stress using equation 12.15.

Ka Wt p d  Km
σb  σb  44.51  ksi
Kv F  J
6. Determine the material bending fatigue strength from Table 12-20 using the average value. S'fb  39.5 ksi
7. Determine the reliability factor for R  0.90 from Table 12-19. KR  0.85
8. Assume a temperature factor, KT KT  1
9. Set the bending stress equal to the corrected bending-fatigue strength in equation 12.24 and solve for the life
factor, KL .
KT  KR σb
KL  KL  0.958
S'fb
10. Assume that the fatigue life is over 10 6 cycles and use the lower curve in Figure 12-24 to solve for the cycle life
1
 0.0323 0.0323
KL = 1.6831 N
N   1.6831  N  3.80  10
7
 K 
 L 
PROBLEM 12-51 _____

Statement: A 21-tooth pinion rotating at 1800 rpm meshes with a 33-tooth gear in a spur gear reducer.
Both pinion and gear are manufactured to a quality level of 9. A reliability of 0.9 has been
specified, and the transmitted tangential load is 2800 lb. Conditions are such that Km = 1.7. It
is proposed that standard 25-degree, full-depth teeth be used, with both pinion and gear
hobbed from an AISI 4140 nitrided steel. The diametral pitch is 6, and the face width 2.000 in.
Estimate the number of cycles of contact (surface) stress (using the AGMA equations) that the
gearset can withstand.

Pinion speed n  1800 rpm Mounting factor Cm  1.7
1
Np d n ft
d  d  3.500  in V  V  1649
pd 2 min
B  0.25  12  Qv
0.6667
B  0.520 A  50  56 ( 1  B) A  76.878
B
Cv   A  Cv  0.802
 

 A   
V min

  ft  
3. Calculate the geometry factor, I
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.117
 2  p g
0.5
4. Determine the elastic coefficient from Table 12-18. Cp  2300 psi
5. Assume an application factor, Ca Ca  1
6. Calculate the contact stress using equation 12.21.

1
2
 Ca Wt 1 Cm 
σc  Cp     σc  195.76 ksi
 Cv F  d I 
7. Determine the material surface-fatigue strength from Table 12-21 using the average value. S'fc  167.5  ksi
8. Determine the reliability factor for R  0.90 from Table 12-19. CR  0.85
9. Assume a temperature factor, CT CT  1
10. Set the contact stress equal to the corrected surface-fatigue strength in equation 12.25 and solve for the life
factor, CL .
CT  CR σc
CL  CL  0.993
S'fc
11. Use the lower curve in Figure 12-26 to solve for the cycle life.
1
0.056
CL = 2.466  N
 0.056
N   2.466  N  1.13  10
7
 C 
 L 
PROBLEM 12-52
Statement: If the gearset in Problem 12-46 transmits 7.5 kW at 1750 input pinion rpm, find the torque on
each of the three shafts.
Given: Transmitted power P  7.5 kW Input speed ωp1  1750 rpm

Stage 1 Np1  14 Ng1  101
Stage 2 Np2  14 Ng2  103
Ng1 Ng2
mG  mG  53.077
Np1 Np2
Np1
Stage 1 ωp1  1750 rpm ωg1   ωp1 ωg1  242.574  rpm
Ng1
Np2
Stage 2 ωp2  ωg1 ωg2   ωp2 ωg2  32.971 rpm
Ng2
3. Calculate the shaft torque

P
Shaft 1 T1  T1  40.9 N  m Input
ωp1
P
Shaft 2 T2  T2  295  N  m
ωg1
P
Shaft 3 T3  T3  2172 N  m Output
ωg2
PROBLEM 12-53
a surface factor of safety of at least 1.8 assuming a steady torque, 25-deg pressure angle, full

7
Power to be transmitted (hp) H  10 hp Life (cycles) N  10
Np Ng
pd pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  76.878
B
B  0.52
Kv p d    A 
 
 A  Vt  p d  
min

 ft 

σbp p d F  
Kv p d   F  Jp

 0.0323
S atp  41500  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

5 5.1 10
d in in in

p d  8  in
1  
F pd
3
in
 
FL pd
F  p d   1.195  in 2
in
FU pd
in 1
F  1.250  in

5 6 7 8 9 10
pd  in
d p p d   1.750  in d g p d   12.625 in
FIGURE 12-53A
Vt p d   802  Wt p d   412  lbf
ft
Pinion (bending) in Problem 12-53
σbp p d F   14175  psi Kv p d   0.850

I   sin( ϕ)  cos( ϕ)   Ng I  0.1682

  N N
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  76.878
B
Cv p d    
B  0.52 A

 A  Vt  p d  
min

 ft 
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S acp  162500 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
5 5.1 10
d in in in

1  
F pd
p d  8  in 3
in
FL pd
F  p d   0.950  in in 2

FU pd
F  1.000  in
14. The bending requirement is governing in 0

5 6 7 8 9 10
this case. The diametral pitch and face
width for the stage 1 gearset are: pd  in
FIGURE 12-53B
1
p d  8  in F  1.250  in
PROBLEM 12-54
and a surface factor of safety of at least 1.8 assuming a steady torque, 25-deg pressure angle,
full depth teeth, Qv = 9, and AISI 4340 steel for all gears.

7
Rotational speed of pinion (rpm) n  242.574  rpm

Np Ng
pd pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  76.878
B
B  0.52
Kv p d    A 
 
 A  Vt  p d  
min

 ft 
5. Tentatively choose the mounting factor, Km (Assume 1.99 < F < 6 in) Km  1.7
σbp p d F  
Kv p d   F  Jp

 0.0323

S atp  41500  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

2 2.1 6
d in in in

p d  4  in
1  
F pd
in
 
FL pd
F  p d   2.134  in
in
FU pd 2
in
F  2.250  in

1 2 3 4 5 6
pd  in
d p p d   3.500  in d g p d   25.750 in
FIGURE 12-54A
Vt p d   222  Wt p d   1485 lbf
ft
σbp p d F   14058  psi Kv p d   0.912

 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1686
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  76.878
B
Cv p d    
B  0.52 A

 A  Vt  p d  
min

 ft 
5. Tentatively choose the mounting factor, Cm (Assume 1.99 < F < 6 in) Cm  1.7
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S acp  162500 psi
S acp CL
CT  CR
9. Write the design equations using the range of face-width to diametral-pitch ratio given in of the text, and the
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
2 2.1 6
d in in in

1  
F pd
p d  4  in 3
in
FL pd
F  p d   1.691  in in 2

F  1.750  in

1 2 3 4 5 6
FIGURE 12-54B
1
p d  4  in F  2.250  in
PROBLEM 12-55
Statement: If the gearset in Problem 12-47 transmits 18.5 kW at 1184 input pinion rpm, find the torque on
each of the four shafts.
Given: Transmitted power P  18.5 kW Input speed ωp1  1184 rpm

Stage 1 Np1  18 Ng1  148
Stage 2 Np2  18 Ng2  144
Stage 3 Np3  18 Ng3  162
Ng1 Ng2 Ng3

mG  mG  592.000
Np1 Np2 Np3
Np1
Stage 1 ωp1  1184 rpm ωg1   ωp1 ωg1  144  rpm
Ng1
Np2
Stage 2 ωp2  ωg1 ωg2   ωp2 ωg2  18 rpm
Ng2
Np3
Stage 3 ωp3  ωg2 ωg3   ωp3 ωg3  2  rpm
Ng3
3. Calculate the shaft torque.

P
Shaft 1 T1  T1  149.2  N  m Input
ωp1
P
Shaft 2 T2  T2  1227 N  m
ωg1
P
Shaft 3 T3  T3  9815 N  m
ωg2
P
Shaft 4 T4  T4  88331  N  m Output
ωg3
PROBLEM 12-56

7

Np Ng
pd pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  83.776
B
B  0.397
Kv p d    A 
 
 A  Vt  p d  
min

 ft 
σbp p d F  
Kv p d   F  Jp

 0.0323

S atp  40000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

5 5.1 10
d in in in

p d  6  in
1  
F pd
3
in
 
FL pd
F  p d   1.575  in 2
in
FU pd
in 1
F  1.750  in

5 6 7 8 9 10
pd  in
d p p d   3.000  in d g p d   24.667 in
FIGURE 12-56A
Vt p d   930  Wt p d   887  lbf
ft
σbp p d F   14997  psi Kv p d   0.884

 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1707
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  83.776
B
Cv p d    
B  0.397 A

 A  Vt  p d  
min

 ft 
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S acp  165000 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 c
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
5 5.1 10
d in in in

1  
F pd
p d  6  in 3
in
FL pd
F  p d   1.294  in in 2

F  1.375  in

5 6 7 8 9 10
FIGURE 12-56B
1
p d  6  in F  1.750  in
PROBLEM 12-57
and a surface factor of safety of at least 2.0 assuming a steady torque, 25-deg pressure angle,
full depth teeth, Qv = 10, and AISI 4140 steel for all gears.

7
Rotational speed of pinion (rpm) n  144  rpm
Np Ng
pd pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  83.776
B
B  0.397
Kv p d    A 
 
 A  Vt  p d  
min

 ft 
σbp p d F  
Kv p d   F  Jp

 0.0323
S atp  40000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

1 1.1 6
d in in in

p d  3  in
1  
F pd
in
 
FL pd
F  p d   3.055  in
in
FU pd 2
in
F  3.250  in

1 2 3 4 5 6
pd  in
d p p d   6.000  in d g p d   48.000 in
FIGURE 12-57A
Vt p d   226  Wt p d   3647 lbf
ft
min Graph of Face Width and Limits for the Stage
2 Pinion (bending) in Problem 12-57
σbp p d F   15669  psi Kv p d   0.937

 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1702
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  83.776
B
B  0.397
Cv p d    A 
 
 A  Vt  p d  
min

 ft 
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S acp  165000 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
1 1.1 6
d in in in

1  
F pd
p d  3  in
in
4
FL pd
F  p d   2.519  in in

FU pd 2
F  2.750  in

1 2 3 4 5 6
FIGURE 12-57B
1
p d  3  in F  3.250  in
PROBLEM 12-58
Statement: Size the third-stage spur gears in problem 12-55 for a bending factor of safety of at least 2.4 and

7

Np Ng
pd pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  83.776
B
B  0.397
Kv p d    A 
 
 A  Vt  p d  
min

 ft 
σbp p d F  
Kv p d   F  Jp

 0.0323

S atp  40000  psi
S atp KL
KT  KR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
S fb
Safety factor Nfb =
σb

1 1.1 6
d in in in

p d  1.5 in
1  
F pd 8
in
 
FL pd 6
F  p d   6.27 in
in
 
4
12. Round this up to the decimal equivalent of FU pd
in
2
F  6.500  in

1 1.25 1.5 1.75 2 2.25 2.5 2.75 3
pd  in
d p p d   12.000 in d g p d   108.000  in
FIGURE 12-58A
Vt p d   57 Wt p d   14589  lbf
ft
σbp p d F   16078  psi Kv p d   0.966

 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.1724
 2  p g
Np
pd
d p p d   n
2
Wt p d  
H
Vt  p d 
B  0.25  12  Qv
0.6667
A  50  56 ( 1  B) A  83.776
B
Cv p d    
B  0.397 A

 A  Vt  p d  
min

 ft 
0.5
C a W t  p d   C m
σcp p d F   Cp
Cv p d   F  d p p d   I

 0.056
S acp  165000 psi
S acp CL
CT  CR
FU  p d  
16
Upper limit
pd
FL  p d  
8
Lower limit
pd
2
 Sfc 
 σc 
C a W t  p d   C m
2
 Cp 
Cv p d   d p p d   I  S fcp 
1 1.1 6
d in in in

1  
F pd 8
p d  1.5 in
in
FL pd 6
F  p d   5.105  in in
 
4
13. Round this up to the decimal equivalent of FU pd
2
F  5.250  in

1 1.25 1.5 1.75 2 2.25 2.5 2.75 3
FIGURE 12-58B
1
p d  1.5 in F  6.500  in
PROBLEM 12-59
Statement: The pinion of an external gearset has pitch radius rp = 40 mm and the gear has pitch radius rg =
160 mm. If the pinion is the input member of the set, determine the velocity ratio, the torque
ratio, and the gear ratio of the set.
Given: Pitch radii rp  40 mm rg  160  mm
1. Equate the pinion pitch radius to rin and the gear pitch radius to rout (in this case).
rin  rp rin  40 mm rout  rg rout  160 mm
2. Using equation 12.1a, calculate the velocity ratio using the minus sign because this is an external set.
 rin 
Velocity ratio mV    mV  0.25
 rout 
3. Using equation 12.1b, calculate the torque ratio using the minus sign because this is an external set.
1
Torque ratio mA  mA  4
mV
4. Using equation 12.1c, calculate the gear ratio using the torque ratio since it is greater than 1.
Gear ratio mG  mA mG  4
This is usually stated as being 4:1.
P1259.xmcd
PROBLEM 12-60
Statement: A pinion having 20 teeth and a diametral pitch of 8 (in -1) is in mesh with a rack. If the pinion
rotates one revolution, how far will the rack move?
1
Given: Number of teeth Np  20 Diametral pitch p d  8  in
1. Calculate the pitch diameter using equation 12-4a.
Np
pd
2. The rack and pinion can be modeled as a cylinder, with diameter equal to the pitch diameter of the gear, in
contact with a plane along the pitch line of the rack. When the gear is rotated one revolution, the rack will
move a distance equal to the circumference of the cylinder.
Distance moved s  π d s  7.854 in
P1260.xmcd
PROBLEM 12-61
Statement: A gearset with full-depth teeth is designed to have a pinion with 24 teeth, a gear with 54 teeth,
and a diametral pitch of 6. Compare the contact ratio for this set for pressure angles of 14.5, 20,
and 25 degrees.
Given: Number of teeth Np  24 Ng  54

1
1. Calculate the pitch radus and addendum for each gear, and the nominal center distamce.
1 Np
Pitch radius: rp   rp  2.000 in
2 pd
1 Ng
rg   rg  4.500 in
2 pd
1
Addendum: a p  a p  0.167 in
pd
a g  a p a g  0.167 in
Center distance C  rp  rg C  6.500 in
2. Write the equation for the length of action as a function of pressure angle using equation 12.2.
Z ( ϕ)  rp  ap 2  rp cos( ϕ)  2   rg  ag2   rg cos( ϕ) 2  C sin( ϕ)

3. Write the equation for the contact ratio as a function of pressure angle using equation 12.7b.
p d  Z ( ϕ)
mp( ϕ) 
π cos( ϕ)
4. Evaluate the contact ratio for the three pressure angles.
14.5 degrees mp( 14.5 deg)  2.007
20 degrees mp( 20 deg)  1.685
25 degrees mp( 25 deg)  1.492
P1261.xmcd
PROBLEM 12-62 _____
of exactly 5 if the ring gear is stationary, the arm is the input, and the sun gear is the output.
Given: Exact ratio mV  5

written as
ω4  ωarm N2
=
ω2  ωarm N4
ωout ω2 N4
= =  1 = mv
ωin ωa N2
N4  N2  mV  1  N4  80
N4  N2
N3  N3  30
2
N4
Overall velocity ratio mV  1 mV  5.000
N2
Sun gear N2  20
Ring gear N4  80
PROBLEM 12-63 _____

Statement: A 22-tooth pinion rotating at 1650 rpm meshes with a 66-tooth gear in a spur gear reducer. Both
pinion and gear are manufactured to a quality level of 10. A reliability of 0.9 has been specified,
and the transmitted tangential load is 5000 lb. Conditions are such that Km = 1.7. It is proposed
that standard 25-degree, full-depth teeth be used, with both pinion and gear hobbed from an
AISI 4340 nitrided steel. The diametral pitch is 5, and the face width 2.500 in. Estimate the
number of cycles of bending stress (using the AGMA equations) that the gearset can
withstand.

Pinion speed n  1650 rpm Mounting factor Km  1.7
1
Np d n ft
d  d  4.400  in V  V  1901
pd 2 min
B  0.25  12  Qv
0.6667
B  0.397 A  50  56 ( 1  B) A  83.776
B
Kv   A  Kv  0.847
 V  min 

 A   
  ft  
3. Determine the bending geometry factor, J (Table 12-13) J  0.42
4. Assume an application factor, Ka Ka  1
5. Calculate the bending stress using equation 12.15.

Ka Wt p d  Km
σb  σb  47.80  ksi
Kv F  J
6. Determine the material bending fatigue strength from Table 12-20 using the average value. S'fb  41.5 ksi
7. Determine the reliability factor for R  0.90 from Table 12-19. KR  0.85
8. Assume a temperature factor, KT KT  1
9. Set the bending stress equal to the corrected bending-fatigue strength in equation 12.24 and solve for the life
factor, KL .
KT  KR σb
KL  KL  0.979
S'fb
10. Assume that the fatigue life is over 10 6 cycles and use the lower curve in Figure 12-24 to solve for the cycle life
1
 0.0323 0.0323
KL = 1.6831 N
N   1.6831  N  1.93  10
7
 K 
 L 
PROBLEM 12-64 _____

Statement: A 22-tooth pinion rotating at 1650 rpm meshes with a 66-tooth gear in a spur gear reducer.
Both pinion and gear are manufactured to a quality level of 10. A reliability of 0.9 has been
specified, and the transmitted tangential load is 5000 lb. Conditions are such that Km = 1.7. It
is proposed that standard 25-degree, full-depth teeth be used, with both pinion and gear
hobbed from an AISI 4340 nitrided steel. The diametral pitch is 5, and the face width 2.500 in.
Estimate the number of cycles of contact (surface) stress (using the AGMA equations) that the
gearset can withstand.

Pinion speed n  1650 rpm Mounting factor Cm  1.7
1
Np d n ft
d  d  4.400  in V  V  1901
pd 2 min
B  0.25  12  Qv
0.6667
B  0.397 A  50  56 ( 1  B) A  83.776
B
Cv   A  Cv  0.847
 

 A   
V min

  ft  
3. Calculate the geometry factor, I
 sin( ϕ)  cos( ϕ)   Ng
I    N N I  0.144
 2  p g
0.5
4. Determine the elastic coefficient from Table 12-18. Cp  2300 psi
5. Assume an application factor, Ca Ca  1
6. Calculate the contact stress using equation 12.21.

1
2
 Ca Wt 1 Cm 
σc  Cp     σc  183.32 ksi
 Cv F  d I 
7. Determine the material surface-fatigue strength from Table 12-21 using the average value. S'fc  162.5  ksi
8. Determine the reliability factor for R  0.90 from Table 12-19. CR  0.85
9. Assume a temperature factor, CT CT  1
10. Set the contact stress equal to the corrected surface-fatigue strength in equation 12.25 and solve for the life
factor, CL .
CT  CR σc
CL  CL  0.959
S'fc
11. Use the lower curve in Figure 12-26 to solve for the cycle life.
1
0.056
CL = 2.466  N
 0.056
N   2.466  N  2.11  10
7
 C 
 L 
PROBLEM 12-65
Statement: The pinion of an internal gearset has pitch radius rp = 30 mm and the gear has pitch radius rg =
150 mm. If the pinion is the input member of the set, determine the velocity ratio, the torque
ratio, and the gear ratio of the set.
Given: Pitch radii rp  30 mm rg  150  mm
1. Equate the pinion pitch radius to rin and the gear pitch radius to rout (in this case).
rin  rp rin  30 mm rout  rg rout  150 mm
2. Using equation 12.1a, calculate the velocity ratio using the plus sign because this is an internal set.
 rin 
Velocity ratio mV  r  mV  0.2
 out 
3. Using equation 12.1b, calculate the torque ratio using the minus sign because this is an external set.
1
Torque ratio mA  mA  5
mV
4. Using equation 12.1c, calculate the gear ratio using the torque ratio since it is greater than 1.
Gear ratio mG  mA mG  5
This is usually stated as being 5:1.
P1265.xmcd
PROBLEM 12-66
Statement: A pinion having 18 teeth and a diametral pitch of 10 (in -1) is in mesh with a rack. If the rack
moves 1 in, how many degrees will the pinion rotate?
1
Given: Number of teeth Np  18 Diametral pitch p d  10 in
1. Calculate the pitch diameter using equation 12-4a.
Np
pd
2. The rack and pinion can be modeled as a cylinder, with diameter equal to the pitch diameter of the gear, in
contact with a plane along the pitch line of the rack. When the rack is moved 1 in, the pinion will rotate
through an angle θ = d/2s, where d is the diameter of the cylinder and s is the distance that the rack moves.
Distance moved s  1  in
d
Pinion rotation θ  θ  51.566 deg
2 s
P1266.xmcd
PROBLEM 12-67
Statement: A gearset with 25 deg, full-depth teeth is designed to have a pinion with 24 teeth, a gear with 54
teeth, and a diametral pitch of 6. Compare the contact ratio for this set for a range of center
distances from 0.90C to 1.10C.
Given: Number of teeth Np  24 Ng  54

1
1. Calculate the pitch radus, base radius, and addendum for each gear, and the nominal center distamce.
1 Np
Pitch radius: rp   rp  2.000 in
2 pd
1 Ng
rg   rg  4.500 in
2 pd
Base circle radius: rbp  rp cos( ϕ) rbp  1.813 in
1
Addendum: a p  a p  0.167 in
pd
a g  a p a g  0.167 in
Center distance C  rp  rg C  6.500 in
2. Write the equation for the pressure angle as a function of variation in center distance. Let f be a factor which,
when multiplied by C gives the actual center distance C'. Then, the actual pitch radius of the pinion will be rp'
frp and the actual pressure angle will be ϕ = acos(rbp/frp).
 rbp  Note that ϕ'( 1 )  25 deg

ϕ'( f )  acos 
 f  rp 
3. Write the equation for the length of action as a function of actual pressure angle and center distance using
equation 12.2.
Z ( f )  rp  ap2   rp cos( ϕ'( f ) )  2   rg  ag2   rg cos( ϕ'( f ) )  2  f  C sin( ϕ'( f ) )
4. Write the equation for the contact ratio as a function of pressure angle using equation 12.7b.
pd  Z ( f )
mp( f ) 
π cos( ϕ'( f ) )
5. Evaluate the contact ratio for the range of center distance. Let f  0.90 0.905  1.10
See the graph on the next page.
P1267.xmcd
CONTACT RATIO vs CHANGE IN CENTER DISANCE

4
3
Contact Ratio
m p( f ) 2
0
0.9 0.95 1 1.05 1.1
f
Change in Center Distance Factor
P1267.xmcd
PROBLEM 12-68 _____
of exactly 1.25 if the sun gear is stationary, the arm is the input, and the ring gear is the output.
Given: Exact ratio mV  1.25

written as
ω4  ωarm N2
=
ω2  ωarm N4
ωout ω4 N2
= =  1 = mv
ωin ωa N4
N2
N4  N4  80
mV  1
N4  N2
N3  N3  30
2
N2
Overall velocity ratio mV  1 mV  1.250
N4
Sun gear N2  20
Ring gear N4  80

Projeto de Máquinas 4 Ed. Norton (SOLUCIONÁRIO) - CAP 12

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MACHINE DESIGN - An Integrated Approach, 4th Ed.

Outside diameter Do  d  2  a Do  5.800  in

Solution: See Mathcad file P1202.

Outside diameter Do  d  2  a Do  5.625  in

Given: Tooth numbers:

Solution: See Mathcad file P1203.

Base pitch p b  p c  cos( ϕ) p b  0.475  in

Pitch rad rp  0.5 d p rp  1.917  in

Pitch rad rg  0.5 d g rg  4.750  in

Z  rp  a 2  rp cos( ϕ)  2   rg  a 2  rg cos( ϕ)  2  C sin( ϕ)

Given: Tooth numbers:

Solution: See Mathcad file P1203.

Base pitch p b  p c  cos( ϕ) p b  0.492  in

Pitch rad rp  0.5 d p rp  2.250  in

Pitch rad rg  0.5 d g rg  6.500  in

Z  rp  a 2  rp cos( ϕ)  2   rg  a 2  rg cos( ϕ)  2  C sin( ϕ)

2. In this case, fc  1  0.05 fc  1.05

Pitch radius rp  0.5 d p rp  1.917  in

Substituting rp cos( ϕ) for rbp and solving for

2. In this case, fc  1  0.07 fc  1.07

Pitch radius rp  0.5 d p rp  2.250  in

Substituting rp cos( ϕ) for rbp and solving for

Solution: See Mathcad file P1207.

Solution: See Mathcad file P1208.

Number of gear teeth Ng  Np mg Ng  65

Rotational speed of pinion (rpm) n p  n g mg n p  125  rpm

4. Set the application factor, Ca Ca  1

6. Tentatively choose the mounting factor, Cm (Assume 0 < F < 2 in Cm  1.6

9. Determine the endurance strength of the pinion.

d p p d   2.600  in d g p d   6.500  in FIGURE 12-8

Vt p d   85 Wt p d   465  lbf σcp p d F   94207  psi

Solution: See Mathcad file P1209.

14 mGs  95.979

15 mGs  102.835

16 mGs  109.69

Solution: See Mathcad file P1210.

2. If the minimum number of teeth is (20 deg pa) Nmin  18

or NG2  ceil ravg Nmin NG2  157

Given: Sun tooth number Ns  33 Arm speed ωa  1  rpm

Solution: See Mathcad file P1211.

Number of teeth on ring: Nr  Ns  2  Np Nr  75

Nr ωa  Ns ωa  Nr ωr

Given: Sun tooth number Ns  23 Arm speed ωa  1  rpm

Solution: See Mathcad file P1212.

Number of teeth on ring: Nr  Ns  2  Np Nr  85

Nr ωa  Ns ωa  Ns ωs

Given: Sun tooth number Ns  23 Arm speed ωa  0  rpm

Number of teeth on ring: Nr  Ns  2  Np Nr  85

Nr ωa  Ns ωa  Ns ωs

Given: Tooth numbers:

Assumptions: There is no loss of power in the gear mesh (100% efficiency).

Given: Tooth numbers:

Assumptions: There is no loss of power in the gear mesh (100% efficiency).

Given: Factor of safety Nfb  2 Number of gear teeth Ng  57

Solution: See Mathcad file P1216.

3. Set the application factor, Ka Ka  1

7. Determine the endurance strength of the pinion.

Ka Wt p d   p d  Km Nfb

11. The calculated value of F is  

Vt p d   1505 Wt p d   2740 lbf

The assumption made in step 5 is correct so no further iteration is required.

16. Determine the endurance strength of the pinion.

Ka Wt p d   p d  Km Nfb