THE UNIVERSITY OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING

DEPARTMENT OF MACHINE DESIGN


COURSE: DESIGN OF MACHINE ELEMENTS

CHAPTER 6: GEAR DRIVE

ASSOC. PROF: PHAN ĐINH HUAN

 ASSOC. PROF. PHAN DINH HUAN

1. INTRODUCTION

Gear drives transmit rotational motion and

torque between two shafts with small center
distance, based on meshing principle.

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1. INTRODUCTION
Classification:
 By shaft position:

Parallel-axis gears Bevel gears Cross-shaft gears

 By teeth position:

External gears Internal gears 3

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1. INTRODUCTION
 By direction of teeth from axis:

Spur gears Helical gears

Spiral gears Herringbone gears 4

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1. INTRODUCTION
 By teeth profile:

Involute profile
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1. INTRODUCTION

Cycloid profile

Novikov profile 6
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1. INTRODUCTION
 By hand of helical gears:

Right hand gear Left hand gear

 By unit system of measurement: metric gears, inch gears.

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1. INTRODUCTION

• Advantages:
- Small dimensions (compact), high transmission power.
- Constant velocity ratio.
- High efficiency, long life.
• Disadvantages:
- Demanding high technical manufacturing, high accuracy.
- Noise occurs when operating at high speed.

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1. INTRODUCTION

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2. GEOMETRY PARAMETERS OF PARALLEL-AXIS GEAR

2.1 Spur gear

Circular pitch p   .m Module m ( standard on page195)
Preferred: 1 1.25 1.5 2 2.5
3 4 5 6 8 10 12 16 20 25
Next choice: 1.125 1.375 1.75
2.25 2.75 3.5 4.5 5.5 7
9 11 14 18 22
Number of teeth Z (Zmin=17)
Pitch circle d  m.Z
d 1  d 2 m Z 1  Z 2 
Center distance a 
2 2
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 ASSOC. PROF. PHAN DINH HUAN

2. GEOMETRY PARAMETERS OF PARALLEL-AXIS GEAR

2.2 Helical gears

pn
• Normal Circular pitch pn p 
Transverse Circular pitch s cos 
• Normal module mn (standard on page 195).
• Module: mn where  is helix angle
ms 
cos  Helical gear, select 80   200
Herringbone gear, select 300   400
• Pitch circle diameter: mn Z
d  ms Z 
cos 
• Outside circle diameter: d a  d  2mn
• Dedendum circle diameter: d i  d  2.5m n
• Center distance: m s Z 1  Z 2  m n Z 1  Z 2 
a 
2 2 cos 
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 ASSOC. PROF. PHAN DINH HUAN

2. GEOMETRY PARAMETER OF PARALLAL-AXIS GEAR

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ASSOC. PROF. PHAN DINH HUAN

3. FORCE AND CALCULATED LOAD

3.1 Force analysis
The total tooth force Fn consists of three force in three direction .
• Tangential force Ft has its direction normal to shaft (not coincident).
2T1
Ft 
d1
• Radial force Fn has its direction normal to shaft (coincident).
Ft tan  n
Fr 
cos 
• Axial force Fa has its direction parallel to shaft.
Fa  Ft tan 
Beta là góc nghiêng răng

Ft
• The total tooth force Fn 
cos  n cos 
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3. FORCE AND CALCULATED LOAD

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3. FORCE AND CALCULATED LOAD

Direction of force:
• Ft: in reverse on drive gear, in forward on driven gear.
• Fr: toward to shaft center line.
• Fa: toward to contact surface.

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3. FORCE AND CALCULATED LOAD

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4. EFFICIENCY OF GEAR DRIVE

P2

P1

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5. MATERIAL AND HEAT TREATING

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6. ALLOWABLE STRESS

0.9 K HL
 H    0 H lim
sH

N HO
K HL  mH N HO  30HB 2.4 mH  6
N HE

3
 Ti 
N HE  60c    ni t i
 Tmax 

K HL Z R Z V K l K xH
 H    0 H lim
sH 19
ASSOC. PROF. PHAN DINH HUAN

6. ALLOWABLE STRESS

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7. GEAR FAILURE AND DESIGN TARGET

7.1 Gear failure
There are 5 failures in gear drive
Pitting is caused by repeating the contact stress

Pitting

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7. GEAR FAILURE AND DESIGN TARGET

Tooth breakage occurs due to over load or repeating bending stress:

Tooth breakage

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7. GEAR FAILURE AND DESIGN TARGET

• Wear is caused due to metal-to-metal contract

Wear

•Welding due to high temperature and pressure in contact region.

• Scoring due to poor heat treatment.
• Plastic flow due to poor material.
Common failures: pitting and tooth breakage due to fatigue.

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 ASSOC. PROF. PHAN DINH HUAN

7. GEAR FAILURE AND DESIGN TARGET

7.2 Design target

Design for contact stress to avoid pitting.
Design for bending stress to avoid tooth breakage due to fatigue.
When gear drive has cover and good lubrication:
• Design for contact stress.
• Check the design for bending stress.
When gear drive don’t have cover and poor lubrication:
• Design for bending stress.
• Check the design for contact stress.

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 ASSOC. PROF. PHAN DINH HUAN

8. DESIGN SPUR GEAR

8.1 Calculation of contact stress

Calculate contact stress when Fn at the point of contact
Hertzian equation for 2 external mesh cylinders
qn
 H  ZM   H 
2

Material factor
2 E1 E 2
ZM 
 [ E 2 (1  12 )  E1 (1   22 )

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ASSOC. PROF. PHAN DINH HUAN

8. DESIGN SPUR GEAR

The effective radius
1 1 1 2 2 2 u 1
     
 1 2 d w1 sin  d w 2 sin  d w1 u sin 

Load
K H Fn
qn 
where lH
bw 4  
lH  Z 
Z2 3

K H Ft 2 K H T1Z2
 qn  
lH cos  bwd w1 cos 
Substituted into Hertzian equation
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 ASSOC. PROF. PHAN DINH HUAN

8. DESIGN SPUR GEAR

Stress check equation
Z M Z H Z 2 K H T1 (u  1)
H   [ H ]
d w1 bw u

Steel material Z M  275 MPa

2 2 4   4  1 .2
ZH   0
 1.76 Z    0.96
sin 2 w sin(2  20 ) 3 3
d w1 : Pitch circle of drive gear
Design equation (center distance)
K H T1
a w  50(u  1)3
 ba [ H ] 2 u
bw
where  ba  selected in table 6.15
aw
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ASSOC. PROF. PHAN DINH HUAN

8. DESIGN SPUR GEAR

Ft cos  ' Ft sin  '

Ft /  Fn cos  '  Fn/  Fn sin  ' 
cos  cos

  u n

  ( u   n ) K 

 Ft / l Fn/   6 Ft l cos  ' Ft sin  ' 


   . K     .K
 Wu A   b s cos  b s cos  
 w
2
w 
K F Ft  6ml cos  ' m sin  '  K F YF Ft
  2  .K 
m.bw  s cos  s cos   mbw 29
ASSOC. PROF. PHAN DINH HUAN

8. DESIGN SPUR GEAR

 6ml cos  ' m sin  ' 

YF   2  .K
 s cos  s cos  

13.2 27.9 x
YF  3.47    0.092 x 2
Z Z

K F Ft YF
F   [ F ]
bw m

2 K F T1YF
m3
Z 12 bd [ F ]
bw
 bd 
d w1
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 ASSOC. PROF. PHAN DINH HUAN

9. DESIGN HELICAL GEAR

9.1 Characteristic
• Low noisy level.
• Small load value on teeth.
• Contact line is incline on teeth surface .
• Replace helical gear by equivalent spur gear when
calculating.
Equivalent diameter: d
dv 
cos 2 
Equivalent number of teeth:
Z
Zv 
cos3 
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 ASSOC. PROF. PHAN DINH HUAN

9. DESIGN HELICAL GEAR

9.2 Calculation of contact stress

Design equation :
K H T1
a w  43(u  1)3
 ba [ H ] 2 u
Stress check equation:
Z M Z H Z 2 K H T1 (u  1)
H   [ H ]
d w1 bw u
Where
2 cos  1
ZH  Z     1 .6
sin( 2   tw ) 
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9. DESIGN HELICAL GEAR

9.3 Calculation of bending stress

Design equation :
2 K F T1YF Y Y
mn  3
Z12 bd [ F ]
Stress check equation :
K F Ft YF Y Y
F   [ F ]
bw m
13.2 27.9 x
Where YF  3.47    0.092 x 2
Zv Zv
1 0
Y  Y  1 
 140 33
ASSOC. PROF. PHAN DINH HUAN

10. BEVEL GEAR DRIVE

d e  me Z

m m  me (1  0.5 be )

d m  mm Z

b
 be   be  0.25  0.3
Re 34
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10. BEVEL GEAR DRIVE

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ASSOC. PROF. PHAN DINH HUAN

10. BEVEL GEAR DRIVE

me
Re  Z12  Z 22
2
 1   2  90 0
 Z1  1
1  arctan   arctan 
 Z2  u
 Z2 
 2  arctan    arctan u 
 Z1 

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ASSOC. PROF. PHAN DINH HUAN

10. BEVEL GEAR DRIVE

2T1
Ft1  Ft 2 
d m1

Fr1  Fa 2  Ft1 tan  cos  1

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10. BEVEL GEAR DRIVE

Fa1  Fr 2  Ft1 tan  sin  1

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10. BEVEL GEAR DRIVE

dm
dv 
Z cos 
Zv 
cos 

uv  u 2

T1
T1v 
cos 1
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 ASSOC. PROF. PHAN DINH HUAN

10. BEVEL GEAR DRIVE

10.3.2 Calculation of contact stress

Design equation – Pitch cone length (6.116b)

2
K H T1
Re  47.5 u  13
0.85(1  be ) 2 beu[ H ]2

Checking equation (6.114)

2 K H T1 u 2  1
 H  Z M Z H Z 2
 [ H ]
0.85bd m1u

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 ASSOC. PROF. PHAN DINH HUAN

10. BEVEL GEAR DRIVE

10.3.3 Calculation of bending stress

Design equation- outside module (6.119c)
2 K F T1YF1
me  3
0.85 bd Z1[ F ]1  0.5 be 2

b
where bd 
d m1

Checking equation (6.118 )

K F F1YF 1
F   [ F ]
0.85bmm
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 ASSOC. PROF. PHAN DINH HUAN
11. DESIGN PROCEDURE OF GEAR DRIVE
(DESIGN FOR CONTACT STRESS)

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 ASSOC. PROF. PHAN DINH HUAN
11. DESIGN PROCEDURE OF GEAR DRIVE
(DESIGN FOR CONTACT STRESS)

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 ASSOC. PROF. PHAN DINH HUAN
11. DESIGN PROCEDURE OF GEAR DRIVE
(DESIGN FOR CONTACT STRESS)

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References:
[1]. TS. Phan Tấn Tùng, Bài giảng Chi tiết máy, ĐH Bách Khoa,
2012
[2]. PGS TS Nguyễn Hữu Lộc, Cơ sở chi tiết máy, NXB ĐH Quốc
gia, 2011
[3]. TS Bùi Trọng Hiếu, Bài giảng Chi tiết máy, ĐH Bách khoa,
2012
End of chapter 6

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