ME 4175
Machine Design

Gear Design
(Chapters 12 & 13)

Dr. The Nguyen

University of Minnesota Duluth

ME 4175, Spring 2011 - 1

 

Gear Trains
Fundamental law of gearing

A n g u l a r v e l o c i t y r a t io  between the gears

 between
io  
of a gear set must remain constant:
External and internal
gear sets mV     out    r in
  r 
in out 

Use negative sign for

external sets

Tor q ue r at io or m ec hanic al adv ant age is

reciprocal to the velocity ratio:

m A  1    in   r out 

mV   out  r in

ME 4175, Spring 2011 - 2

 

Gear Trains
Simple gear trains

mV    ou
out t 
   r in    N in
 in r out   N out 

Number of teeth

Train velocity ratio:

mV    
   N 2  
 N 
   N 3   
 N 
   N 4  
 N 
   N 5     N 2
 N   N 
  3   4   5   6  6
 ME 4175, Spring 2011 3
 

Gear Trains
Compound gear trains

Train velocity ratio:

mV    
  N 2    N 4 
  N     N  
  3   5 
 ME 4175, Spring 2011 4
 

Gear Trains
Planetary gear trains
 ME 4175, Spring 2011 5
 

Gear Trains
Planetary gear trains: review Example 12-3
First gear:   Fi rst     Arm
 First   Ar m     Fi
 First 
rst / arm
Velocity
Velocity difference-equation
difference-equations:
s:
Last gear:   Last     Arm     Last / arm
      arm
Velocity ratio: mV    Last / arm   Last 
  Fir st / arm   Fin al    arm
 Final 
Number of teeth: mV    refer to previous
  slides (mV  for simple gear trains)
 N ring    N    n  2 N  pl
   sun
 su  plan
anet 
et 
 ME 4175, Spring 2011 6
 

Gear
Tooth
Shape
 ME 4175, Spring 2011 7
 

Spur gears
Nomenclature
  d   pd     N 
Circular pitch:  pc 
Diametral pitch:
 N  d d 
Base pitch:  pb   p  c cos  Module: m   

 N 
( d 
d is
 is pitch diameter, and  N  is
 is number of teeth)

Defines
diametral
 pitch
 ME 4175, Spring 2011 - 8
 

Spur gears
 AGMA specifications
 ME 4175, Spring 2011 - 9
 

Spur gears
 AGMA specifications

Standard full-depth gears (pinion and gear) have equal addendum

and larger dedendum for clearance

 Addendum Note
the radius
tooth at
base

Dedendum
 ME 4175, Spring 2011 - 10
 

Spur gears
Contact geometry: involute gear-teeth

Figure 12-4
 ME 4175, Spring 2011 - 11
 

Interference and Undercutting

 ME 4175, Spring 2011 - 12
 

Profile-Shifted Teeth
To avoid interference
 ME 4175, Spring 2011 - 13
 

Spur gears
Length of action: involute gear-teeth

Normals at leaving contact and beginning contact points are the

t he same

Length of action:  Z   ( r  p  a p )  (r  p cos

  )     (r  g   a g )2  (r g  cos)2  C cos
2 2

 Z 
Contact ratio: m p    p
b
(Number of teeth in
contact at one time)

Figure 12-5
 ME 4175, Spring 2011 - 14
 

Spur gears
Center distance: affects pressure angle and pitch diameter
Changing center distance affects pressure angle and pitch diameter
 ME 4175, Spring 2011 - 15
 

Spur gears
 AGMA specifications
 ME 4175, Spring 2011 - 16
 

Gears
Main Classification
Spur
Helical

Worm and worm gear pair

Straight bevel Spiral bevel
 ME 4175, Spring 2011 - 17
 

Spur Gears

 Teeth are parallel to axis

 Least expensive type
 Noisier than others
 High efficiency (99% / set)

 Can be disengaged
 Backlash can be a problem
 ME 4175, Spring 2011 - 18
 

Helical Gears
Parallel axes
(e = 96 - 98%)
 Teeth not parallel to axis
 More expensive than spur
 Quieter than others
 Axial force component

 Parallel or crossed axes

Crossed axes  Stronger tooth section
(e = 50 - 90% )  Harder to disengage
 ME 4175, Spring 2011 - 19
 

Herringbone Gears

 Two opposite-hand helicals back to back

 Cancels axial force component
 As quiet as helicals
 Very expensive to make
 ME 4175, Spring 2011 - 20
 

Worm and Wheel

 Worm has single tooth or “thread”

 Ratio = no. of teeth on wheel
 Worm is “helical” with big helix angle 
angle 
 Teeth are not involutes
 Made and installed as matched pairs
 Very expensive to make
 Poor efficiency (40 - 85%)
 High torque capacity
 ME 4175, Spring 2011 - 21
 

Rack and Pinion

 Rotary to linear motion

 Can be spur, helical, or herringbone
 Involute becomes a straight line –
line – trapezoidal
 trapezoidal teeth
 Used in “rack and pinion” steering 
steering 
 Used as a cutter to make circular gears
 ME 4175, Spring 2011 - 22
 

Bevel Gears

Straight  Based on rolling cones

Bevel  Cone apices must intersect
 So, axes intersect also
 Can turn any corner angle
 Low power capacity
 Teeth are not involutes
Spiral  Straight bevels are “spur” 
“spur” 
Bevel  Spiral bevels are “helical” 
“helical” 
 ME 4175, Spring 2011 - 23
 

Hypoid Gears

 Based on rolling
hyperboloids
 Non-intersecting axes
 Non-involute teeth
 High torque capacity
 Used in automotive
differentials
 ME 4175, Spring 2011 - 24
 

Stresses in Spur Gears

 ME 4175, Spring 2011 - 25
 

Spur Gears
Forces on pinion and gear sets –
sets – time-varying
 time-varying forces
T  p   2T  p 2 pd T  p
Tangential force component: W t   r  p  d  p   N  p

Radial force component: W r     t  tan 

  W 

Resultant force: W    W r 2   W t 2

Note: for contact ratios > 1, there exists a HIGHEST POINT OF SINGLE-TOOTH CONTACT
CONTACT (HPSTC)
 ME 4175, Spring 2011 - 26
 

• Gear teeth see both bending and

Gear Teeth surface stresses

Always • Gears can be designed for infinite

life against bending failure

Have • Gears cannot be designed for

infinite life against surface failure
•

There
surfaceisstress
no endurance limit for
Dynamic
Loading • They will eventually fail in surface
fatigue by pitting and spalling
Even if • Inadequate or dirty lubrication can
cause premature failure by

adhesion or abrasion.
Applied
Load is •  Automobile gears very rarely fail in
the life of the vehicle unless
abused in service.
Constant
 ME 4175, Spring 2011 - 27
 

Spur Gears
Bending stresses
(note that contact stresses are also generated )

Tooth is modeled as a Cantilever beam in bending:

W 
t 
 F 

t 

l 
Bending stresses:  b     6W 2t l 
  Mc
 I   Ft 
 ME 4175, Spring 2011 - 28
 

Spur Gears
Bending stresses
W r  W 

Gear tooth in
bending: W t 

Bending stresses (Lewis’ equation):

equation):  

 b   Mc( x)   W t   pd 

 I ( x )  F  Y 
l  •  W t t is the tangential force
 

•   pd  is the diametral pitch

•   F  is
 is the face width
•  Y  is
 is the geometric factor (Lewis
a dimensionless geometric factor)
r  f    x
y

t 
 ME 4175, Spring 2011 - 29
 

Spur Gears
Bending stresses

A G M A b e n d i n g s t r es
es s eq u a t i o n :
W t  pd   K a K m
 b      K  s K  B K  I  U.S. specifications
 FJ   K  

W t   K a K m
 b      K  s K  B K  I  SI specifications - m is the
 FmJ 
 Fm J   K   metric module

•   F  is
 is face width (minimum face width is 3 to 5 times  pc )
•   J  is
 is bending strength geometric factor (AGMA; Tables 12-8 through 12-15; p. 712)
•   K v is dynamic factor (depends on tangential velocity -- Figure 12-22; p. 711)
711)
•   K m is load distribution factor (to account for misalignments -- Table
Table 12-16; p. 715)
•   K a is application factor (application dependent; “Shocks” -- Table 12-17; p. 715)
•   K  s is size factor (similar
(simil ar concept as Equation 6.7b -- AGMA recommends value of 1)
•   K  B is rim thickness factor (for gears made of rims and spokes -- Figure 12-23; p. 716)
•   K  I  is idler factor (set to 1.42 for an idler gear and 1 for a non-idler gear)
•  m is metric module: m = d  p (in mm) / N
 ME 4175, Spring 2011 - 30
 

Spur Gears
Bending stresses
(note that contact stresses are also generated)

A GMA s tandard 20 200101-- B88

i s s u b j ec
e c t t o f o l l o w i n g g e n er
e r al
a l c o n s t r a in
in t s :

•  Contact ratio between 1 and 2 (# of teeth in contact at a given time)

 Z 
m p   ;    pb  pc co
coss  
 pb
•  No interference between tips and roots
•  No teeth are pointed

•
 There is nonzero backlash
•  Root fillets are standard
•  Friction forces are neglected (assumed good lubrication)
 ME 4175, Spring 2011 - 31
 

Load
Sharing
 ME 4175, Spring 2011 - 32
 

AGMA W t  pd   K a K m

Dynamic Factor  b      K  s K  B K  I 
 FJ   K  
 ME 4175, Spring 2011 - 33
 

W t  pd   K a K m
AGMA Geometry Factor J  b  
 FJ   K  
   K  s K  B K  I 
 ME 4175, Spring 2011 - 34
 

Other AGMA Factors

W t  pd   K a K m
 b      K  s K  B K  I 
 FJ   K  
 ME 4175, Spring 2011 - 35
 

More AGMA Factors

t  pd   K 
 b   W   a K m  K  s K  B K  I 
 FJ   K   

 K s  = Size factor

- Set to 1
 K B  = Rim thickness factor
- Set to 1 for a solid gear (no rim)
- See text for other cases
 K I  =
 = Idler factor
- Set
Set toto 1 fo
forr a no
non-
n-id
idle
lerr gea
gearr
- Se
Sett tto
o 1.4
1.42
2 for
for an id
idle
lerr gea
gearr
 Idler sees fully reversed stress
of twice the range of non-idler
 ME 4175, Spring 2011 - 36
 

Surface Stress in Gear Teeth

 Can design teeth to never fail in bending

 But they will eventually fail in surface fatigue
 ME 4175, Spring 2011 - 37
 

Elastic Coefficient Cp
(Table 12-18)
 ME 4175, Spring 2011 - 38
 

Surface Geometry Factor I

 ME 4175, Spring 2011 - 39
 

Gear Material Strengths

 AGMA has done extensive testing to establish
fatigue strengths for gear materials in both
bending and surface fatigue.
 Cast Iron
 These data were generated with proper size,
 Steel geometry,, surface finish, etc., and so are partially
geometry
corrected fatigue strengths.

Bronze  They are stated at 1E7 cycles (unlike other data at
 Nonmetallic 1E6 or 5E8) and are at 99% reliability level.
l evel.
- Nylon
 The test load was fluctuating, containing the
- Delrin
mean stress component, so these data can be
- Phenolic
Phenolic   compared
tooth. directly to the alternating stress on the

 A Goodman line analysis is not needed here as

the strength data already are in the Goodman
domain.
 ME 4175, Spring 2011 - 40
 

Gear Bending Fatigue Strength

 Formulae are defined based on Brinell hardness

 Tabular data are also published (see Tab le 12-20)

 ME 4175, Spring 2011 - 41
 

Correcting Gear Bending Fatigue

Reliability Factor
Note that these are different factors
than in Chapter 6 because these data
are based on 99% reliability not 50%
 ME 4175, Spring 2011 - 42
 

Bending Strength Life Factor K L

 Modifies strength based on your cycle life
 ME 4175, Spring 2011 - 43
 

Gear Surface Fatigue Strength

 AGMA has done extensive testing on gears
 Formulae are defined based on Brinell hardness

 Tabular data are also published (see Tab le 12-21)

 ME 4175, Spring 2011 - 44
 

Correcting Gear Surface Fatigue

 C  is the same as K T  defined

 is
T 
T   defined earlier
 C 
R 
R  is the same as K R  defined
 is  defined earlier
 ME 4175, Spring 2011 - 45
 

Surface Strength Life Factor C L

 Modifies strength based on your cycle life

 ME 4175, Spring 2011 - 46
 

Hardness Ratio Factor C H

 ME 4175, Spring 2011 - 47
 

Lubrication

 Gears need lubrication

 Oil bath is best

 Grease lubrication is a poor substitute


Hypoid
velocityoils are needed where sliding component of
is high
- Hyperboloidal (hypoid) gears
- Wormsets
 ME 4175, Spring 2011 - 48
 

Stresses in Helical Gears

 ME 4175, Spring 2011 - 49
 

Helical Gears
Forces on pinion and gear sets –
sets – time-varying
 time-varying forces

Tangential: Radial:  Axial: Resultant force:

T  p   2T  p 2 pd T  p W t 
W t     W r     t  tan 
  W  W a  
  W t  tan ψ W    
r  p d  p  N  p   n
cos ψ cos

Pressure angles:

tan t  tan    tan n

cos ψ
 ME 4175, Spring 2011 - 50
 

Helical Gears
Other quantities

Transverse pitch: Axial pitch: Dimetral pitch: Normal dimetral pitch:

 pn  pn  N         pd 
 pt     pc   p x    pd      pnd   
cos ψ sin ψ d   pc  pt  cos ψ

Virtual number of teeth:

 N e  2 r e    d   2

    d 3   N 3
 pn  pn cos ψ  pt  cos ψ cos ψ

Transverse contact ratio:

 Z 
m   

 p
 pb
 Axial contact ratio:
 F   Fpd  tan ψ
m F    
 p  
 x
Should be at least 1.15
 Should be at least 1.15

ME 4175, Spring 2011 - 51

 

Helical Gears
Stresses

Geometry factor J:
A G M A b e n d i n g s t r eses s eq u a t i o n :
W t  pd   K a K m tables 13.1 –
13.1 – 13.6
 13.6 or AGMA standards
 b      K  s K  B K  I 
 FJ   K  
AGMA su rface stress equation: Geometry factor I:
W t  C aC m c os
 c  C  p  FI d  C v C  sC  f  
 FId   I    
       d  p m N 
   p    g  
   

Load sharing ratio:

m N     F 
 Lm in

Base helix angle:

  c osn  
ψb  c  os1  c  osψ 
  c os  
 ME 4175, Spring 2011 - 52
 

Spur and Helical Gears

Surface geometrical factor I
 cos t  s in t  mG
 2m N  mG  1 external gears
 I   
 cos t  s in t  mG internal gears
 2m N  mG  1
m N   1 for spur gears

Gear ratio:
 N G d G
mG   
 N  P  d  P 

cos t  s in t   N G

 I  
2m N   N G  N  P