DESIGN OF SPUR GEAR AND HELICAL Week # 05-06

Fall 2021
GEAR Haseeb Ahmed
LEWIS BENDING EQUATION
• It is an equation for estimating the bending stress in gear tooth in which the tooth
form entered into formulation F is Face Width along
with other cross sectional
dimension t. Wt is the
Load.

Assumption that maximum

stress occours at point “a”

y is Lewis Form Factor

and the equation is Lewis
Eq.
LEWIS BENDING EQUATION
p = π/P and y = πY

Y means that only the bending of the

tooth is considered and that the
compression due to the radial component
of the force is neglected.
DYNAMIC EFFECTS
When a pair of gears is driven at moderate or high speed and noise is generated, it
is certain that dynamic effects are present.
In the nineteenth century, Carl G. Barth first expressed the velocity factor, and
in terms of the current AGMA standards:
Barth
Cycloidal teeth Equation

V is the pitch-line velocity in fpm.

CYCLOID PROFILE
INVOLUTE PROFILE
DYNAMIC EFFECTS Velocity
Safety Factor
Added

Later AGMA modified the Barth Equation

V is in m/s

Metric
Version; m is
module
EXAMPLE

 Assume Sut = 55 kpsi, Sy = 30 kpsi. Since the design factor is 3, it means that allowable bending
stress it 10 kpsi. Also, d = N/P = 16/8 = 2in.

Step 1: Finding Pitch-Line Velocity Step 2: Finding Velocity Factor

Step 3: Finding Tangential Load Step 4: Finding the Power

 AGMA uses μ for
SURFACE DURABILITY Poisson’s Ratio

 The Surface Compressive Stress (Hertzian Stress) can be written as:

 The radii of curvature of the tooth profiles at the pitch point are written as:

 An elastic coefficient Cp is introduced into the existing equation:

 The final equation takes the form:

EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
SPUR AND HELICAL GEAR DESIGN
There are two type of failure in Gears
1. Bending Failure: Failure by bending will occur when the significant tooth stress equals or exceeds
either the yield strength or the bending endurance strength.

2. Pitting failure : A surface failure occurs when the significant contact stress equals or exceeds the
surface endurance strength

Contact Stresses

Bending Stresses
SPUR GEAR BENDING BASED ON AGMA/ANSI STANDARDS
Gear Bending Stress equation
SPUR GEAR BENDING BASED ON AGMA/ANSI STANDARDS
Gear Bending Endurance Strength Equation
SPUR GEAR BENDING BASED ON AGMA/ANSI STANDARDS
Bending Factor of Safety: The ANSI/AGMA standards contain a safety factor SF guarding against
bending fatigue failure and safety factor SH guarding against pitting failure.
SPUR GEAR WEAR BASED ON AGMA/ANSI
Gear Contact Endurance Strength Equation: The fundamental equation for pitting resistance (contact
stress) is
SPUR GEAR WEAR BASED ON AGMA/ANSI
Gear Contact Endurance Strength Equation

Proper lubricating system can minimize the surface

damage due to wear and corrosion. But, surface
fatigue can occur even with proper lubrication; it’s the
most common mode of gear failure and is
characterized by pitting of the tooth surface. The
damage is caused by repeated contact stresses.
SPUR GEAR WEAR BASED ON AGMA/ANSI
Wear Factor of Safety Equation
EXAMPLE: All the terms used in above set of equations and methodology of analyzing a spur
gear system will be explained with following example:
Key Formulas

Gear Bending Stress equation Bending Factor of Safety

Taken
as 1

Gear Contact Endurance Strength Equation Gear Contact Endurance Strength Equation
1 2 3 4 5 6 7
1 1 1 1 1
8 9 0 1 2 3 4

Wear Factor of Safety Equation

 Step 1:

Finding the pitch diameter, pitch-line velocity and load:

Example: Conti…..
Step 2: Overload Factor, Ko
The overload factor Ko is intended to make allowance for all externally applied loads
in excess of the nominal tangential load Wt in a particular application

Example: Conti….
Step 3: Dynamic Factor, Kv
Dynamic factors are used to account for inaccuracies in the manufacture and meshing of
gear teeth in action. AGMA has define a set of quality numbers.

• Quality number 3 to 7 will include most commercial quality gears

• Quality number 8 to 12 are for precision quality

Quality

Example: Conti…..
 Step 4: Size Factor, Ks
The size factor reflects non-uniformity of material properties due to size. You may select Ks =
1 or may elect to use the following equation.

Where F = face width of the tooth

Y = Lewis Form Factor
P = diametral Pitch
Lewis Form Factor for 20o pressure angle

Example: Conti…..
 Step 5: Load Distribution Factor, Km
The load-distribution factor modified the stress equations to reflect non-uniform distribution of
load across the line of contact

Definition of distance S and S1

 Load Distribution Factor, Km
The load-distribution factor modified the stress equations to reflect non-uniform distribution of
load across the line of contact

Example: Conti…..
 Step 6: Rim-Thickness Factor, KB
When the rim thickness is not sufficient to provide full support for the tooth
root, the location of bending fatigue failure may be through the gear rim
rather than at the tooth fillet. In such cases, the use of a stress-modifying
factor KB or (tR) is recommended

Example: Conti….
Step 7: Reliability Factors, KR
The reliability factor accounts for the effect of the statistical distributions of material fatigue
failures. Load variation is not addressed here. The gear strengths St and Sc are based on a
reliability of 99 percent.

Example: Conti…..
 Step 8: Stress cycle Factors, YN and ZN
The AGMA strengths as given and for contact-stress fatigue discussed above are based on
107 load cycles applied. The purpose of the load cycle factors YN and ZN is to modify the
gear strength for lives other than 107

Repeatedly applied bending strength stress-cycle factor YN.

Example: Conti…..
Step 13: Stress cycle Factors, YN and ZN
The AGMA strengths as given and for contact-stress fatigue discussed above are based on
107 load cycles applied. The purpose of the load cycle factors YN and ZN is to modify the
gear strength for lives other than 107

Pitting resistance stress-cycle factor ZN

Example: Conti…..
 Step 9: Temperature Factors, KT
For oil or gear-blank temperatures up to 250°F (120°C), use KT = Yθ = 1.0. For higher
temperatures, the factor should be greater than unity. Heat exchangers may be used to
ensure that operating temperatures are considerably below this value, as is desirable for
the lubricant.

Example: Conti….. The temperature and surface condition factors are KT = 1,

if the temperature is less than 250oF
Step 10: Surface-Strength Geometry Factor I (ZI)
The factor I is also called the pitting-resistance geometry factor by AGMA

For Spur Gear:

The Load sharing ratio MN = 1
Φt = Φ=Pressure angle
Speed ratio = mG = NG /Np

Example: Conti….
Step 11: Elastic- Coefficient Cp

Example: Conti….
Step 12: Gear Bending Strength, St
We shall use the term gear strength as a replacement for the phrase allowable stress
numbers as used by AGMA

St =0.749HB + 110 Mpa, grade 2.

St =0.533HB + 88.3 MPa, grade 1

Allowable bending stress number for through- Allowable bending stress number for nitrided through-hardened
hardened steels steel gears
Gear Bending Strength, St
Gear Bending Strength, St
 Gear Contact Strength, Sc

Example: Conti…..
Step 14: Hardness Ratio Factor, CH
The hardness-ratio factor CH is used only for the gear. Its purpose is to adjust the surface strengths

Where the terms HBP and HBG are the Brinell hardness (10-mm ball at 3000-kg load) of the pinion
and gear, respectively. The term mG is the speed ratio

Example: Conti….
Step 15: Pinion and Gear Tooth Bending

Example: Conti….
Step 16: Pinion and Gear Tooth Wear

Example: Conti…..
Example: Conti…..
Nomenclature for Helical Gear
Relation b/w Transverse and Normal Circular Pitch
The angle ψ is the helix angle. The distance ac is the
transverse circular pitch pt in the plane of rotation (usually
called the circular pitch). The distance ae is the normal
circular pitch pn

Axial Pitch px
The distance ad is called the axial pitch px and is related
by the expression

47
Nomenclature for Helical Gear
Relation b/w Transverse and Normal Diametrial pitch
Since pn Pn = π, the normal diametral pitch is

Relation b/w Transverse and Normal Pressure Angles

The pressure angle φn in the normal direction is different from the
pressure angle φt in the direction of rotation, because of the
angularity of the teeth
EXAMPLE: All the terms used in above set of equations and methodology of
analyzing a helical gear system will be explained with following example:
 Step 1: Finding the pitch diameter, pitch-line velocity and load:

Example conti….
Step 2: Overload Factor, Ko
The overload factor Ko is intended to make allowance for all externally applied loads
in excess of the nominal tangential load Wt in a particular application

Example: Conti…..
Step 3: Dynamic Factor, Kv
Dynamic factors are used to account for inaccuracies in the manufacture and meshing of gear teeth in
action. AGMA has define a set of quality numbers.

• Quality number 3 to 7 will include most commercial quality gears

• Quality number 8 to 12 are for precision quality

Quality

Example: Conti….
 Step 4: Size Factor, Ks
The size factor reflects non-uniformity of material properties due to size. You may select Ks =
1 or may elect to use the following equation.

Where F = face width of the tooth

Y = Lewis Form Factor
P = diametral Pitch
Lewis Form Factor for 20o pressure angle

Example: Conti…..
Step 5: Load Distribution Factor, Km
The load-distribution factor modified the stress equations to reflect non-uniform distribution of load
across the line of contact
 Load Distribution Factor, Km
The load-distribution factor modified the stress equations to reflect non-uniform distribution of load
across the line of contact

Example conti….
 Step 6: Rim-Thickness Factor, KB
When the rim thickness is not sufficient to provide full support for the tooth
root, the location of bending fatigue failure may be through the gear rim
rather than at the tooth fillet. In such cases, the use of a stress-modifying
factor KB or (tR) is recommended

Example: Conti….
Step 7: Reliability Factors, KR
The reliability factor accounts for the effect of the statistical distributions of material fatigue
failures. Load variation is not addressed here. The gear strengths St and Sc are based on a
reliability of 99 percent.

Example: Conti…..
 Step 8: Stress cycle Factors, YN and ZN
The AGMA strengths as given and for contact-stress fatigue discussed above are based on
107 load cycles applied. The purpose of the load cycle factors YN and ZN is to modify the
gear strength for lives other than 107

Repeatedly applied bending strength stress-cycle factor YN.

Example: Conti…..
Step 13: Stress cycle Factors, YN and ZN
The AGMA strengths as given and for contact-stress fatigue discussed above are based on
107 load cycles applied. The purpose of the load cycle factors YN and ZN is to modify the
gear strength for lives other than 107

Pitting resistance stress-cycle factor ZN

Example: Conti…..
 Step 9: Temperature Factors, KT
For oil or gear-blank temperatures up to 250°F (120°C), use KT = Yθ = 1.0. For higher
temperatures, the factor should be greater than unity. Heat exchangers may be used to
ensure that operating temperatures are considerably below this value, as is desirable for
the lubricant.

Example: Conti….. The temperature and surface condition factors are KT = 1,

if the temperature is less than 250oC
Step 10: Surface-Strength Geometry Factor I (ZI)

A conservative approximation for load sharing factor is given by the equation

The quantity Z and pN for use in above Eq. can be obtained from the equation

Where
rP and rG are the pitch radii the pinion and gear
rbP and rbG the base-circle radii of the pinion and gear, respectively

rbP and rbG the base-circle radii of the pinion and gear
 Surface-Strength Geometry Factor I (ZI)
The factor I is also called the pitting-resistance geometry factor by AGMA

rb is the base circle radius Speed Ratio

Example: Conti….
 Surface-Strength Geometry Factor I (ZI)

Example conti….
Step 11: Elastic- Coefficient Cp

Example: Conti….
Step 12: Gear Bending Strength, St
We shall use the term gear strength as a replacement for the phrase allowable stress numbers as used
by AGMA

St =0.749HB + 110 Mpa, grade 2.

St =0.533HB + 88.3 MPa, grade 1

Allowable bending stress number for through- Allowable bending stress number for nitrided through-hardened
hardened steels steel gears
Gear Bending Strength, St
Gear Bending Strength, St
Gear Contact Strength, Sc

Example: Conti…..
Step 14: Hardness Ratio Factor, CH
The hardness-ratio factor CH is used only for the gear. Its purpose is to adjust the surface strengths

Where the terms HBP and HBG are the Brinell hardness (10-mm ball at 3000-kg load) of the pinion
and gear, respectively. The term mG is the speed ratio

Example: Conti….
Step 15: Bending Strength Geometry Factor, J’
For helical gears having a 20◦ normal pressure angle
 Modifying Factor for J’

Example conti….
 Step 16: Pinion and Gear Tooth Bending

Example conti….
 Step 17: Pinion and Gear Tooth Wear

Example conti….
Example conti….

Reading Assignment:
14–19 Design of a Gear Mesh

Assignment #01:
Example 14.8 with Diametral pitch of your choice
ranging from 4 to 20 teeth/in & Should be different for
each student.