Gears 437

(a) Straight tooth bevel gear (b) Spiral bevel gear

Figure 12.16 Types of bevel gears.

of intersection of the gear axes. Involute profile straight bevel gears are used for relatively low-
speed applications with pitch line velocity up to 10 m/s. When smooth tooth engagement,
quiet operation, greater strength, and high pitch line velocity are the major requirements, spiral
bevel gears with curved teeth are used.
Bevel gears are not interchangeable. Hence these gears are designed in pair. In the
majority of applications, the angle between the axes of two intersecting shafts is 90°, however,
the intersecting angle may be acute, or obtuse angle. These gears are manufactured either by
have
casting, machining, or generating process. Gears manufactured by the generating process
Smooth tooth profile and they can be used for transmitting power at high pitch line velocity.

12.8.1 Kinematics of Bevel Gears

Ine definitions and dimensions relating to bevel gear are shown in Figure 12.17. In a bevel
of the gear, it
Ear t pitch line distance L called cone distance is revolved about the axis
the
formed between the pitch line
ales an imaginary pitch cone with the apex at O. The angle and
tne axís is called the pitch angle 8. The angles 6 and 0 are called addendum
dede (8 + O) is known as
angles, respectively. The sum of the pitch and addendum angles
addendum
h ha. dedendum h and pitch
ace angle. Dimensions of the bevel gear such as
specified at the B andend of the tooth. A line drawn perpendicular to the pitch
lineCTSECts the axis at pointlarger
rdare nt forms a cone called the back cone. The length of the
back element is called the back cone radius rh: The distance
C is called the crown height.
Tone
The distance.
S backing distance and M is known as mounting in a plane perpendicular
Devel gear, for the purpose of design, an imaginary spurisgear considered for finding the
at the larger end having rh pitch circle radius
foTma: n
mative or virtual
numbe: of teeth, i.e.

Formative number of teeth, Z o s

Z (12.34)
cos o
 Machine Elements
438 Design of
ha
h

Axis of gear
B

angle
Face

-C-
M

12.17 Dimensions of bevel gear.

Figure

between two intersecting zes

for any pair of bevel gears is an angle
The shaft angle of two mating gears. i2
at an apex. It is equal
to the sum of the pitch angles
which meet #z
from geometry, shown in Figure 12.18, for shaft angle
. The relationships gear
6= 0 +

given below:

OL

- . - -

S
**********

d/2
Pa

Acute angle bevel gear.

Figure 12.18

. Pitch angle ()
(a) For acute angle bevel gear (0°< 6< 90°)
sin
i) For pinion, tan 0) =

cos 6
 Gars 439

sin &
) For gear, tan d

+cos 8
For right-angled bevel gear, = 90

For pinion, tan =

() For gear, tan d =

(c)Forobtuse angle bevel gear (90° < 8S 180°)

) For pinion, tan à sin (1809-8)

Z-cos (180°-8)
sin (180-)
i) For gear,tan &=S
c o s (S0° - 8)

Pitch diameter at the larger end

) For pinion. d = mz
For gear, d = mz^
(i)
3. Outer diameter at the larger end
)For pinion, doi =dj+2h, cos d
(i) For gear, d = d2+ 2h, cos d
4. Length of the cone distance

L 0.5(4)
12.8.2 Force Analysis
d is N a d Ni
n a bevel gear, the resultant forceacting between two meshiny totd wdile the ihtual
the tace width of the tvth.
Cconcentrated force acting at the mid-point along
end of the axnd. Thas thenv is a
acts somewhere between the mid-point and the larger
Orce tdonee has two maneNS 4anNNNd
Smal error in making this assumption. The resultant shwn
as shown in Figure
1219, The tangential fivY
a n d separating force F, the driving tone. ls maunmtue
van N NNIRNd
pendicular to the plane of rotation is
the following relation:

F
where
18 the torque transmitted by gear a
t dd &nd
consideration at the mat int
d 18 the pitch radius of the gear under

dbsino
2
 Elements
Machine
440 Design of

F
Fs
- Fa
F (perpendicular

to paper)

bevel gear.
Components of forces
on
Figure 12.19

The separating force which acts perpendicular to the pitch line is determined bythe

relation
F, =
F tan a (12.36)
where a is the pressure angle.
further resolved into two components, namely along the axis
The separating force can be
to the axis of the gear called the radial
of the gear called the axial force Fa and perpendicular
force F. Therefore,
F= F, sin d = F tan a sin o (12.31a)
F= F, cos o = F, tan a cos o (12.37b)

in magnitude but opposite in direction.

The forces acting on the mating gear are equal

12.8.3 Beam strength of Bevel Gear Tooth

As mentioned earlier, the size of the bevel gear tooth varies across the face width such that ie
largest tooth height is at the pitch circle and it continuously reduces towards the cone ceu
Further these gears are so mounted that the portion of the gear tooth near the pitch circle
the larger end shares the maximum force compared to the portion of the tooth near the sna ler
end. Therefore, the beam strength of the bevel gear is computed for the elemental portion
then
the equivalent formative spur gear in a plane perpendicular to the tooth element and
integrated over its face width.
a small tooth element of width dx at ch the
Consider
force oad is assumed to be uniformly
distance x from the apex over to
distributed, as shown in Figure 12.20. ACCo g
Lewis, the beam strength of the elemental section is expressed as
(12.38)
where
oFbeam= m,Yoadx
m is the module of the section
dx is the face width of the
elemental section
Yis the Lewis form factor.
 Gears 441

-dX

---

Figure 12.20 Strength determination of a bevel gear tooth.

By integrating Eq. (12.38) within limits (L - b) to L and neglecting the higher order

S5. the modified Lewis beam strength equation of the bevel gear tooth can be written as

-bmYou1 (12.39)

where
bis the face width (= 15m or L/3 whichever is smaller)
L is the cone distance
m is the module.
the maximum value of the
In the design of the bevel gear, the beam strength indicates
transmitted without failure. Therefore
tangential force at the larger end of the gear that can be
the tangential force at the larger end should be computed
instead of that at the mid-point as
is computed by the equation
calculated in force analysis. The maximum tangential force

2T Cs
max
d C
where
Tis the torque to be transmitted
Cs iS the service factor (refer to Table 12.3)
C, is the velocity factor

3.05 form cutter

for teeth cut by
3.05+v

6.1
= for generated teeth
6.1+v
torce o n the gear.
maximum
than the
For safe design, should be greater
the beam strength values: 1, 1.25, 1.5, 2, 2.5, 3,
gn, selected from the
Sva
Slandard gear can
be listed in Table 12.7.
ule m for the bevel
4.5,6,8, 10, 1 and 50. The tooth proportions are
12, 16, 20, 25, 32, 40,
 Elemenls
Machine
442 Design of
Tooth proportions of bevel gear
Table 12.7
Symbol Gear or pini
Element

Addendum
ha m

Dedendum 1.157m
Whole depth 2.157m
Addendum angle m/L
Dedendum angle 1.157m/L
Gear
12.8.4 Dynamic Load on Bevel
tooth is caused due to profile error of the tood
The dynamic load on a bevel gear that the velocity at the laroees which can
be computed on the lines of the spur gear except
must be computed and tangential force should then be based on this velocit
largest pitch Circle

Kv (cb +F
FdynF+ (12.40
Kgv+ cb+F
For safe design against dynamic load, the endurance beam strength of the bevel gearshould
greater than the applied dynamic load. The endurance beam strength can be computed by he
equation

Fen bmYo 1- (12.41

12.8.5 Wear Strength of Bevel Cear

The wear strength of bevel gear is the maximum force at the larger end of the tooth that can De

transmitted without pitting failure. In the bevel gear, the type of contact and Hertz suresiés
between two meshing teeth are similar to those in the spur gear. Therefore, limiting wear loa
is computed on the assumption that the bevel
gear is treated as an equivalent fomauve spur
gear in a plane perpendicular to the tooth at the larger end.
The modified Buckingham equation of wear load for the bevel gea is expressed s

Fwe
Wear
dbOK (1242
cos o
where

Qis the ratio factor 2

K is the
Z,+Z)
load-stress factor.
m i c l o a d for

According to
Buckingham, the limiting wear load should be
satisfactory design. greater than the
uy
a
from

Example 12.5 Apair of bevel gears is required to transmit 10 kW 0

rpm

motor shaft to a machine shaft. The speed reduction is 3:1 power a clinedat
and the shatts a
 Gears 443
to have 24
tecth with
o

he pinio5
The p i n i o n
pressure angle 20° and is to
strength of 75
NImm2.
N/mm2, The gear is to be made of
cast iron with
be made of cast steel
having
is mounted midway on the shaft which is static stress of 55
N/mm*. The
pinion
supported between two
of.00 mm. Design the gear pair and the pinion shaft. bearings having span
Let 8 and o be the pitch angles of the
Solution
pinion and the gear,
Shaft respectively.
angle, 0= 8, +
8 =
60°
Pitch angle of the pinion, tan sin
6 =
6

sin 60
, tan S =13.9
3+ cos 6013.90
Pich angle of the gear, & = 60° - 13.9° = 46.1°

Number of teeth on the pinion, Z = 24

Number of teeth on the gear, Z = speed reduction ratio x Z =3 x 24 = 72

Formative number of teeth, 2' = Z/cos 6. Therefore,

24 = 24.72
cos 8 cos 13.9°

C 2 = 2

COs d
72=103.84
cos 46.1°

Lewis form factor, Y= r |0.154-.14

Z

0.912=0.3679
Forpinion, Y 7|0.154- 24.72
=

|0.154- 0.912
= 0.4562
r
For gear, Yh =
103.84

0.3679 x 75 = 27.59
rength factor for pinion
=
YOa =

0.4562 x 55 = 25.09
Strength factor for gear = Y2O2 weaker.
he gear is
Since the urcngth
streng less than that of the pinion,
factor of the gear is

Px 1000
10x 1000 15,915.5 N
m
Tangential force, F, = T xmx24x500
60 x 1000
 Machine Elements
444 Design of
factor C, = 0.35 (a trial val
alue). Therefo
Cs = 1.0 and velocity
We assume service factor
CsF 10x15,915.5-45,472.8
FrEs Cy
0.35x mn m

Lewis beam strength, Fbeam bmo

mZ = 49.46m
L= slant height 2 sin 13.9°
2 sin o
not be larger than L3, say, L4 (= 12.5m
b = face width, which should
Therefore,
0.4562 x 55 x 0.75 = 235.23m2
12.5m x m x
Fveam
For safe design, the beam strength should be greater than or equal to the tangential fore ie.

Fbeam Pmax
or
45,472.8
235.23m2=

or
m 5.782 mm

We adopt the standard module m = 6 mm as per IS: 5037-1969.

pod of pinion, d =
mZ = 144 mm
pcd of gear, d2 = mZ2 = 432 mm

Pitch line velocity, y= "4 N1 Tx0.144x 500 = 3.77 m/s

60 60

3.05
Velocity factor, C,= 0 5 - = 0.4472
3.05+v
Face width, b = 12.5m = 75 mm
Slant height, L = 4b = 300 mm

Tangential force, F, =
15,915.5_15,915.9=2652.6 N
m 6

F= 1.0x2652.6
max
0.4472 5931.5N
Beam strength, Fbeam 75 x 6 x 0.4562 x 55 x 0.75 =8468.2 N
the design.

Since beam
strength is approximately 1.43 times the maximum
safe under static
loading. tangential
 Gears 445
Dymamic load

Ruckingham
equation for dynamic load is
Buck
Fdyn = Ky (cb+F
FKv+ cb+ F
K 26.67, a constant

C dynamic load factor =

For the 6 mm module, pitch ine velocity up to 4 m/s, class I gears have e = 0.0652. Therefore

0.0652x 0.2 x.10 x 0.2 x 10 724.4

9.0x0.2x 10 x2
cb + FF 724.4 x 75 + 2652.6 56,982.6

ycb+F = 238.71

Thus
Fayn 2652.6 + 20.67x3.77x56,982.6=
20.67 x 3.77+238.711 16.676.3 N = 16,676.33N

We assume that for light shock load, endurance strength Fen =

1.5Fa Therefore,

1.5Fdyn bmYo(L-b
L

Of
0.4562 x Oen X 0.75
1.5x 16,676.3 = 75 x 6 x

Oen 162.5 N/mm2

reasonable for the CI
162.5 BHN, which is quite
Core BHN required 92.8, say, 100
required
=
DiN =

1.75
material
Wear load
The limiting value of the ar load

FwE4bOK

Fweas cos O
2x103.84 =1.615
222
factor=+Z 24.72+ 103.84
Q ratio
 Machine Elements
446 Design of
than the dynami
wear load should be greater load, ie. F
For safe design, the limiting
Faya 16,676.3 x cos 13.9°
om COs = 0.928
Load stress factor, K bod 75x1.615x 144

s i na
where,K
where,K
14 E +.
Thus,
2x0.2x 106
0.928
0.928 = % sin 20
1.4 0.2x10 x0.2x 10

or
es 616.3 N/mm2

Required surface hardness = t 7 0 616.3+700 = 249.6 BHN, say, 250 BHN

2.75 2.75
Pinion shaft design
The radial load on the pinion
F= Fe tan a cos

F = tooth oad acting somewhere between the mid-point and the larger end.

FxL 2652.6x300 3031.5 N

L-0.5b 300 0.5x75
Therefore
F 3031.5 xtan 20°x cos 13.9° = 1071 N
Axial thrust, F, =
Fe an a x sin &
3031.5x tan 20° x sin 13.9° = 265 N
Maximum BM due to radial force

M, = 1071x0.2=53.55 Nm
4
Maximum BM due to
tangential force

M 3031.5x0.2 151.57 N-m

4

Resultant BM, M =
{M? +M
y53.552 +151.572 = 160.75 N m
 Gears 447

T=
10x 1000d
transmitted. = 191 N m
er aqur 27x 500
60

Equivalent torque, Te= M+T?

=
160.75+191 = 249.6 N m

ssune that the shaft is made of cold-rolled steel for which the allowable shear strength,
ding the effect of
the keyway, T = 75 N/mm2.

Shaft diameter, ds=

(16x 249.6 x1000 25.7 mm, say, 28 mm

Tx 75 (standard size)

Ai sress induced,
4x 265
=0.43 N/mm
TTx 282
rds
Anal torsional shear stress

16 16x 249.6 x
100057.9N/mm
Tx 283
nds
Since axial stress is very small compared to torsional shear stress, the maximum shear stress is
OXImaiely equal to torsional shear stress, which is less than the allowable strength of the
atmaterial. Hence the design of the shaft is satisfactory. Proportions of gear tooth may be
mputed from Table 12.7.

12.9 WORM GEAR SET

wo transmit power between two non-parallel, non-
n gear set (Figure 12.21) is used to
threaded screw, and
a
is very much similar to a
n g shafts. It consists of a worm, which
automobiles, material handling equipment, and
BEar. It is widely used in machine tools, has the following
reducer in cement plants for rotating the kiln. The worm gear
i
iortant features:
Reduction of high speeds in the smallest possible space.
without shock, hence operation is quieter.
ooth engagement occurs
be made.
The provision for self-locking can alsolow to spur and helical gears and
4 TD e transmission efficiency is very compared
generates considerable amount of heat.
 Elements
Machine
448 Design of

Worm gear

d2
a

Worm
Px

Figure 12.21 Schematic diagram of a worm gear set.

or double enveloping type. In the sinele

Worm may be of either single
gearing
its width cut into a concave surface, thus, partially encloSing
enveloping set, the worm gear has
the worm in a mesh. In the double enveloping
set, the worm tooth and the worm gear tooth are
and worm gear are partially enclosed. The single
both cut concavely. Thus, both wormn
contact and thus has line contact. In
the double enveloping
enveloping set has fewer teeth in load.
therefore has area contact and can transmit a greater
set, more teeth come in contact; it

12.9.1 Kinematics of Worm

useu
therefore, the terms
is very much similar to the power screw,
In a worm gear set, the wornm
for power screw are also applicable to the worm. A worm gear set is designatea by
quantities as given below:
(12.:43)
Z/ Z2lq/m
where
Z is the number of starts on the worm
Z is the number of teeth on the worm gear
9 is the diametral quotient (= d/m)
(generally its value varies between 6 and 13)
d is the pitch circle diameter of the worm
m is the module.
forr higher
For higher mechanical advantage, the worm is cut with single thread. However
clature o fthe

efficiency, the mulistart worm is generally used. Figure 12.22 shows the nomencia
worm and the worm gear.
on
poinis

Axial pitch (p,). It is the distance measured

axially between two correspo
adjacent teeth. This is equal to transverse circular
pitch (Peir) Of the
ng worm gear.
maling *
( 1 2 . 4 4 )

PxPcir
where
Z2
d is the pitch circle diameter of the worm gear.
 Gears 449

Lw

d
dat
ha2

Worm ha1
hf2

dg2

- Worm

wheel

Figure 12.22 Dimensions of worm gear set.

ad h. It is the axial distance by which a worm advances during its one revolution. The
s equal to the product o f the number of starts and axial pitch of the worm, 1.e.

(12.45)
l= Zp; =
tmZ
Lead angle (7) the and the
is between the tangent
the angle to the helix on
pitch circle
Pane l
normal
t
to the worm axis. It is
equal to
7=-helixangle
For a shaft with 90° shaft angle, the the helix angle.
lead angle is equal to

tan7 z d , 4 (12.46)
Ttd
The lead angle of a worm may vary from 7° to 45°. Past experience
has shown that lead angle
ss th
less than gie lts in rapid wear, therefore, a safe value is 13°. For a
9 resultu compact design, the lead
 Elements
Machine
450 Design of relation
by the
approximately
be computed /3
angle may

tanYN,
made greater than
angle is made
angle
(12.1
shock, the lead
safeguard the
drive against
the w o r m drive
reversible. the frictrn
In order to contact. This makes
surface in
angle of the number of teeth
of the worm gear and the
of the ber «
Velocity ratio. It is the ratio
of the worm.

VRZ the velocity

(12.4M
number of threads
on the worm is based on
ratio
rot:
as
given in
The selection of the
Table 12.8.

Table 12.8 Number of threads on worm

Velocity ratio No. of threads on worm

20 and above single

double
12-16
8-12 triple
6-12 quadruple
4-10 sextuple

to the lead angle of the worm. The

The pressure angle a of the gear is related
recommended pressure angles for the worm gear are given
in Table 12.9.

for set
Table 12.9 Recommended pressure angles worm gear

Lead angle Pressure angle

0-16 14.5°
16-25 20°
25-35 25
35-40° 30

y the
Centre-distance (a). The centre-distance between the worm and the worm gear is giveu
relation
(1249)
a =
0.5(d + da) the
which is
The AGMA has recommended an equation for mean pitch diameter of the wo
orm, *
function of the centre distance, i.e.

(12.50)
a 8 7 s

1.466 worm axis

The ends of the gear teeth either parallel to the axis or radially
are cut
with a lace
angle (28) of 60-75°. This shape is used for towa lead angk
lead an
worms with sn
 Gears 451
r e c o m m e n d e d face angle is given by
The
tan 6sana
tan Y (12.51)
al or
llel or strai
straight teeth cut with a form cutter are not effjcient and are used only for
nd transmission of small powers. Standard
service and
mittent
interm
srecommended by AGMA for industrial use are given in
proportions
Table
of worm and worm
12.10.
gear as recomme

Table 12.10 Standard proportions of worm gear set

Dimensions
Single and double threads Triple and quadruple threads

Worm
Pitch diameter, d 7.54m + 28 7.54m+ 28
(for bored shaft)
Pitch diameter, d 7.39m+10 7.39m+ 10
for integral shaft)
Face length, Lw 14.14m+0.063Zm 14.14m+ 0.063Zm

Tooth depth, h 2.16m 1.96m

Addendum. h m 0.9m

Worm gear
14.5 20
Normal pressure angle
Outside diameter, do2 d +3.1854m da+2.7982m
Throat diameter, dh d2 + 2m dz +1.7978m
7.48m + 6.35 6.758m+ 5.08
Face width, b

set
12.9.2 Force Analysis of Worm Gear
The resultant force F acting8
shown in Figure 12.23(6).
Forces acting on the worm gear pair are
on the worm has two components:
F cos a
(12.52a)
Normal force, F, =

(12.52b)
Radial force, F, = F sin a

Fe Fa2
Fret
Fa
Fat F F

Pitch cylinder
of worm gear
forces on worm and worm

Components of
(b)
a) Components of forces on worm and worm gear.
of worm

Figure 12.23 Force analysis

 Elements
Machine

452 Design of components.

Hence
the

The normal force

can be further
resolved

as
shown
into two

in Figure
12.23(a): following thres
act on
the w o r m gear
forces sin 7
ypes of F cos a
F, =

Tangential
force,
F cos a cos (1253a
Fa
(12.53b)
=
Axial force,
F sin a
F,
(12.53e)
=
Radial force,
forces, the frictional force is
besides the above uite signito
significan
In the worm gear drive
the w o r m and
the worm tional for
gear. The frictional force juF acts
due to sliding motion between
of motion as in
shown in Figure 12.24. along
Figure 1alon
to the direction
the pitch helix and opposite his
uF cos

F sin y

Figure 12.24 Components of frictional forces on worm.

frictional force has two components:

Along the tangential direction, uF cos
Along the axial direction, uF sin 7
Therefore, the total forces
acting along the tangential and axial directions are:
F= F(cos a sin 7+ cos ) (12.54a)
Fal F(cos a cos y-H sin ) (12.54b)
Fr = F sin a (12.54c)
For the
purpose of finding the direction of forces on
thumb rule ht-hand
can be worm and worm gear, nc
applied.
AS menuoned earlier, the action between
Therefore, the worm and the worm ature.

at par with
due to friction the transmission efficiency of the gear is slidin "re
nsidered
the spur or helical worm cannot
gear set
Efficiency of the worm setgear.
is defined as

output power at worm

Input power supplied to gear
worm g * (4,/2)
Fx(d /2) x
 Cears 453
Substituting the value of the tangential force w e get

n = cos6- tan y
cos e+ l cot y (12.55)
tan 0 tan a cos Y
where

the worm gear, the coefficient of friction is

T
generally expressed in terms of rubbing or
ocity, which
sliding velocity, which is defined as the velocity along the direction of
sliding of the worm
worm gear teeth. Thus,
and

rubbing
td,N
cos (12.56)
The coefficient of friction in terms of the rubbing velocity is given by the relations

0.0422
for 0.2 S Vnubbing 2.8 m/s
0.28 (12.57a)
(Vrubbing
3.281
0.025 +
1000 for Vrubbing 2.8 m/s
1000 Vrubbing (12.57b)

12.9.3 Design of Worm Gear

The engagement tooth in the worm set is through the worm thread sliding into contact with the
worm gear teeth. Thus the dynamic force on the worm gear is not so severe. The high sliding
velocity between the worm and the worm gear causes excessive wear and produces heat due to
friction. Therefore, besides strength considerations, the wear and heat dissipation are the major
criteria for the design of the worm gear.

Beam strength
From the layout of the worm gear set, it is quite clear that the teeth of the worm gear are
weaker than the threads on the worm. Therefore, the design criterion should be the worm gear.
lhe Lewis cquation for beam strength of worm gear is used to compute the load carrying
capacity. The equation is
Fbeam bmYoa (12.58)
ne above equation is based upon the assumption that the entire load is taken by one tooth.
Lewis form factor Y may be computed on the basis of spur gear. However, if the number of
unin the worm gear plus the number of teeth (threads) in 25 mm length of worm is greater
an 40, the Lewis form factor Y can be determined from the equation
Y = 0.314+ 0.015(a - 14.5°)
(12.59)
For safe design, the beam strength of the tooth computed by Eq. (12.58) should be
54CT than the maximum tangential force on the worm gear, which may be conmputed by the
relation

Fmax (12.60)

where
CTe C, (dynamic load correction velocity
6.1
or
ractor)6.1+y
 Elements
454 Design of Machine

Wear strength
gear is estimated by the Ruc
The limiting wear load capacity of the worm

wear dhbK
Buckingham's ecuation
where
12.61
the pcd of the worm gear
d2 is
b is the face width
a constant which depends upon the material
Kis the load stress factor, for t he
worm and worm gear (see
Table 12.11).

Load stress factor for wear load

Table 12.11
Material
Load stress factor, K
Y 0-10 Y 10-25
Worm Gear Y> 250
Phosphor bronze 0.412 0.517 0.618
Steel
Hardened steel Phosphor bronze 0.549 0.687 0.824
Hardened stel Chilled bronze 0.824 1.03 1.236
Hardened steel Antimony bronze 0.824 1.03 1.236
CI Phosphor bronze 1.03 1.285 1.746

Thermal capacity
The efficiency of the worm gear set is quite low. Therefore, considerable amount of power s
lOst in fncion which in turn is converted into heat due to frictional resistance. 1o preve
overheating of the drive, heat generated should not exceed the rate of heat transfer.
The rate of heat generated is given by
Q 1000(1 - n) x P (12.62)
where
is the efficiency of the worm gear set
P is the input power
The heat
This heat is dissipated by the housing through convection and
dissipation capacity of the housing depends upon its area, temperature differenc conducti the
radiaio
of the material, and
velocity of air, etc. The rate of C be estimated by
heatt dissipation
dissipation can
can
cs
equation

0.407 (1263)

1 0 Agear + Awom2 - 1)
where
Awom is the projected area of the worm (
womd)
Agar is the area of the

I2 is the gear
gear

temperature
(4)
is the room
temperature
 Gears 455
mnerature I2 must not exceed 80C, otherwise the
The gear

The
lubricating oil may become thin
loose
its properties and the worm gear may fail due to seizure.
and

Example 12.612.6 Design a worm gear speed reducer to transmit 22.5 kW at 1440
24:1 and rpm. The
desired speed ratio
ratio is
is. efficiency 85%. Assume that the worm is made of hardened steel
of phosphor bronze.
and gear
For efficiency of the order of 85%, a triple-
We assume a quadruple start worm. Therefore, Z quadruple-threaded
ion or
Solution worm should be
ed
selectec
= 4.
We also assume that the normal pressure angle a is 20° and the lead angle yis 25°, which
allowed for the 20° pressure angle.
is the maximum
Number of teeth on gear, Z2 = speed ratio x Zj = 24 x 4 = 96

Speed of the worm gear, N, =

N
1-1440 = 60
60 rpm
24 rpmn

Td,N_TmZ, x N2
Pitch line velocity, v=
60x 1000 60x 1000

TXmx96x60 = 0.3016m m/s

60 x 1000
Tangential force

Px1000_22.5x 1000 74,602.1

F V 0.3016m m

Maximum tangential force, Fmax

C
Let Cs = service factor = 1.0

Cy= velocity factor = 0.5 (assumed)

Therefore,
1.0x 74,602.1 149,204.2N
Fmax
0.5x m m

Lewis beam strength, Fbeam= bm¥ Oa

For phosphor bronze, Oj = 80 N/mm2
Lewis form factor, Y =TX y = Tx 0.125 = 0.3927

Face width, b = (6.758m +5.08) (refer Table 12.10)

Therefore,
(6.758m 5.08)m x 0.3927 x 80
Fbeam +

= (6.758m + 5.08) x 31.416m

For safe design, 1
design, the beam strength should be greater than the maximum tangential force. Thus,

149,204.2
(6.758m+ 5.08) x 31.416m =

m
 Muchine Plemenls
456 Dsgn of

199.km 149,24.2 z 0
212.3m -

trial and ermn, we get m - %t 9 men, say, I mm

By
Therefore,
Tangential fonce, ,74,42.=
9
K20 N
Pitch diameter, dh =mln= 9z 9% = hA mn

Pitch line velocity, v=

69
0,647 2.714 ms
6
3.05
Actual velocity factor, C, =
062.7140.529
3.05+2.714
which is greater than the assumed value (0.5). Thus,

PRy 98290 = 15,671 N

O.529
Fhean=(6.758 9 + 56) 31A16 9 = 13,6334 N
As Fbeam > Fmax, the design is safe under statíc load conditíons.
Pitch of the worm = Tm =
23.27 mm

Lead Z pitch = 4 28.27 = 113 m

Face width, b =
6.758 9
x + 5.98 =
65.9 mm
Diameter of worm, dy =
7.54m 28
+ =
95.&6 mm
Face length of worm, Iorm= (14.14 +0.063 Z) % m =
129.52 mm
Lead angle, 7= tan 113
T >95,86 20.56

Rubbing velocity, vpbbing td,N, T95.86z 1440

60 %1000% cos y 60 1000x cos
= 7.72 ms
20.56°
Coefficient of friction, p =0.025+ 3.281
I000
0.025 2,281
1O00 7.12 = 0.05
Efficiency of the drive when worm is the driver
cos-4 tan7
where co% 6 + cot7
an 9= tan o c%
7
 Gears 457

tan (tan 20° x cos 20.56°) =18.81°

Therefore,

cos 18.81°-0.05 x tan 20.56°

cos 18.81° +0.05 x cot 20.56° 85.91%, which is satisfactory
Heat generated = (1 - ) x input power

=
(1 -

0.8591) x 22.5 =
3.17 kW
0.407
Heat dissipaled=o Agear+ Aworm) (2 - )
Agear area of the gear =x 864 586,296.6 mm=
=

AwomWorm projected area worm d 129.5 x 95.86 12,413.87 = =

mm
heat generated
Temperature rise, Al= 0.407
+
-

103
x
(Agear Aworm
3.17x 1000
13°C
0.407(586.296.6
10
+12,413.87)
which is quite low compared the
to permissible temperature rise.
Wear load.
The limiting wear load

wenrdgenr bK
K load stress factor = 0.687 for hardened steel and bronze

Fwent864 x 65.9 x 0.687 = 39,116.1 N

Which is
larger than Fauk Hence the design is saule.

12.10 COMPUTER-AIDED DESIGN OF GEAR TOOTH

O r m 12.1 named "ngeur.cpp" is a Ct+ progranm lor the design ot a spur ger pair. This
n requires the following input data: (i) power. (i) pinion speed, (iii) gear speed,
nunber of teetlh on plnion, (v) rutto of face width to module, (vi) strength ot gear and
l terial and thelr elustie modulus, (vii) core hardness, and (viii) service tactor according
operating conditlons.
COu h lalie donign is porlormed uving tle l ewis bonn strength equation. For dynamie lad
n , the data tor prolile eror given in 'Tlbles 12.5 and 12.0 was bonverted into
the g the loast Njuaro eurve liting nethol of Mierosott ixeel 200. The indication
y ul the eurve lit iw letomined by the so callod quared value, whieh is detinet as
SSI/SST)