Kono |. Introduction. Terms used in Helical Gears. Face Width of Helical Gears. Formative or Equivalent Number of Teeth for Helical Gears. Proportions for Helical Gears, Strength of Helical Gears. 29.1 Introduction A helical gear has teeth in form of helix around the gear. Two such gears may be used to connect two parallel shafts in place of spur gears. The helixes may be right handed on one gear and left handed on the other. The pitt surfaces are cylindrical as in spur gearing, but the tee instead of being parallel to the axis, wind around the cylinders helically like screw threads. The teeth of helict! gears with parallel axis have line contact, as in spur geal ‘This provides gradual engagement and continuous conta of the engaging teeth, Hence helical gears give smooth df? with a high efficiency of transmission, We have already discussed in Art, 28.4 that the belie! ere Of single helical type or double helical SP" een manele helical gears there is some axial between the teeth, which is a disadvantage. In ord ® minate this axial thrust, double helical gears (*"Helical Gears = 1067 auivalent (0 two single helical gears, in which equal and opposite ‘and the resulting axial thrust is zero, 29.2 Terms used In Helical Gears na ‘The following terms in e¢ hetringbone gears) are used, It is thrusts are provided on each gear onnection with helical Bears, as shown in Hig. 29.1, are important from the subject point ater subject point of view, == 1. Helix angle. Ais u const 1 EA + TLis. a constant angle ma ices wi pe italien isle made by the helices with the V1 ite] i i = - : 2. Axial pitch, lt i the distance, parallel to the ax , between similar ve ea faces of adjacent teeth, Itig th circular pitch and is therefore 4 denoted by p,. The axial pitch may also be defined asthe cies pitch ee in the plane of rotation or the diametral plane, Fig. 29.1. Helical ition or the di ig. 29.1. Helical gear a Normal pite hM isthe distance between similar faces of adjacent wetaclat teeth along a helix on the pitch cylinders normal to the teeth I is denoted : by Py: The normal pitch may 1 Also be defined as the circular pitch in the normal plane which is a plane perpendicular to the teeth. M: lathematically, normal pitch, Px = P08 0 Note: If the gears are cut by standard hobs, then the pitch (or module) and the pressure angle of the hob will eee a Oa i i ee pitch and pressure angle of the cutter will apply to the plane of rotation, The relation between the nomad pressure Anele (by) in the normal plane and the pressure angle (6) inthe diametral plane (or plane of rotation) is given by tan by = tan x cos o 29.3 Face Width of Helical Gears In order to have more than one pair of teeth in contact, the tooth displacement (i.e. the ad- vancement of one end of tooth over the other end) or overlap should be atleast equal to the axial Pitch, such that Overlap = p, = b tan o wali) ‘The normal tooth load (Wy) has two components ; one is tangential component (W,) and the other axial component (WV,), as shown in Fig. 29.2. The axial or end thrust is given by W,y = Wy sin a= W, tan o ie From equation (), we se tha asthe helix angle increases then the Sg tooth overlap increases, But at the same time, the end thrust as given by equation (i), also increases, which is undesirable, It is usually recom- = mended that the oyerlap should be 15 percent of the circular pitch. Wo = Overlap = b tan a= 1.15 p, re 1 LIS pe ASM 4 eS Overlap m tan a tan a Co PRI Pe | PN 7 where b = Minimum face width, and 2 m = Module. : Notes. maximum face width may be taken as 12.5 m to 20 m, where m is ; z, In terms of pinion diameter (D,), the face width should be 1.5 Dy a9 599 pace width of the module, In terms of pi e292. F 2D,, although 2.5 Dy may be used. 1 ‘an lical pear. In case of double helical or herringbone gears, the minimum face wid is given by — 23 p, _23xnm b= ana tan ‘The maximum face width ranges from 20 m to 30m.1068 = A Textbook of Machine Design anges from 20°10 35°, while for double helical gears, it may b, 3.1n single helical gears, the helix angle F made upto 45°, 29.4 Formative or Equivalent Number of Teeth = Nears fs “The formative or equivalent number of teeth for 2 helical i ce ee abe ee teeth that can be generated on the surface of a cylinder having a radiu es ora iste ature ata point at the tip of the minor axis of an ellipse obtained by taking seas ormal plane. Mathematically, formative or equivalent number of teeth on a helical gear, Tz = T/ cos? & ‘Actual number of tee! o: = Helix angle. 1h on a helical gear, and y where 29.5 Proportions for Helical Gears ‘Though the proportions for helical gears are not stands by American Gear Manufacturer's Association (AGMA). Pressure angle in the plane of rotation, ardised, yet the following are recommended 5° to 25° Helix angle, a = 20° t0 45° Addendum 8 m (Maximum) Dedendum Minimum total dept Minimum clearance Thickness of tooth m (Minimum) 8m 2m 5708: m In helical gears, the teeth are inclined fo the axis of the gear,29.6 Strength of Helical In helical gears, the contae . act between mari along the tecth so that at any insane an ieee order to find the strength of hein oe — Helical Gears =» 1069 seth is eradual, staring at one end tee i and moving ‘tcl runs diagonally 4e ji resbenrninn i dgon Hly across the teeth, Therefore in 0,%C) en ation is used, Itis given by ere ‘Mgential tooth joag, So = Allowable static strey Velocity factor, Y= Tooth form factor or Lewis f r 0 S factor corresponding to the i OF Virtual oF equivalent number of tet Ee formative Notes : 1. The value of velocity factor (C,) may be taker 8 Follows : 4 6 C, = Fpp> lor peripheral veto from 5 m/s to 10m/s, 15 , ; = 5 ay7 [OF peripheral velocities from 10m/s1020 m/s. 0.75 = Sasa gy lO" Peripheral velocities great oar br pet Breater than 20 m/s, 0.15 0 aS 0.25, for non-metallic gears. Tty 2. The dynamic tooth load on the helical gears is given by 21 v (bC cos? o + W, a Wo = Wy + BY @Leos Ar 21v + Yb cos? a+ Wy where v, b and C have usual meanings as discussed in spur gears. 3. The static tooth load or endurance strength ofthe tooth is given by Wy = 6,.b.0 my! 4. The maximum or limiting wear tooth load for helical gears is given by Dp-b OK we cos? where Dy, b, Q and K have usual meanings as discussed in spur gears, (@.,)* sin Ov [Ly In this case, k= "4 [Bt Be where 4. = Normal pressure angle. ic it ). The teeth are 20° stub in diametral - ir of helical gears are to transmit 15 kW. b a Example a ee 45°. The pinion runs at 10000 rpan. ad has 80 mm pitch diameter Blane and Pane aor yiomsier Ifthe gears are made of cast steel having allowable static The os fae 4 ak semen eahleniedsicand [face width from static strength considerations strength of i ‘ = and check the gears for wear given 0,, = 618 MPa. =45° ; Np= 10000 rp.m. ; D, = 80mm Bilton Given = HS EW 15 c10W-9 20. 457:0) > pause 2O.= Ooty .08 m ; Dg = 320 mm = 0.32 m ; Ggp= Fog = 100 MPa= Module and face width te m = Module in mm, and b = Face width in mm.1070 = A Textbook of Machine Design Since both the pinion and gear are made of the same material (i.e. cast steel), therefore the pinion is weaker. Thus the design will be based upon the pinion: We know that the torque transmitted by the pinion, Px @ _ 15x10 x 60 IRN, 20x 1000 2. “Tangential tooth load on the pinion, w,- 2 - B® Lasen T> Dpl2 0.08/2 We know that number of teeth on the pinion, Tp = Dpfm=80/m and formative or equivalent number of teeth for the pinion, Tp __80/m__ _80/m__ 2264 Te = cos! a cos? 45° (0.707) sm ¢: Tooth form factor for the pinion for 20° stub teeth, 84 yyy = 0.175 ~ 2841 9.175 - 2841 _ 0.175 0.0037 m ; Te 226.4) m We know that peripheral velocity, ye Bp Np _ 8X 008 % 10000 _ yy sy, @ 0 <. Velocity factor, 075 0.8 = 0.104 vis greater than 20 m/s) *" o1s+ Vv 0.75 + Var Since the maximum face width (b) for helical gears may be taken as 12.5 m to 20 m, where mis the module, therefore let us take b= 125m We know that the tangential tooth load (W;), 358 = (Gop. C,) ba my' = (100 x 0.104) 12.5 m x mm (0.175 — 0.0037 m) = 409 m? (0.175 - 0.0037 m) = 72 m? - 1.5 m> Solving this expression by hit and trial method, we find that m = 2.3 say 2.5 mm Ans. and face width, b = 12.5 m=125 x 2.5 = 31.25 say 32 mm Ans, Checking the gears for wear We know that velocity ratio, VR, = Lote & oe 80 -- Ratio factor, 2xV.R_ 2x4 VR + We know that tan 9 = tan cos a = tan 20° x cos 45° = 0.2573 Oy = 14.42 ‘The tangential tooth load on the pinion may also be obtained by using the relation, Dy.N, where v= © (in m/s)The picture shows double helical gears which are also called herringbone gears. Since both the gears are made of the same material (i.e. cast steel), therefore let us take Ep = Eg = 200 kN/mm? = 200 x 103 N/mm? ~. Load stress factor, = Ges) Si (A 14 Ep Eg Aen _ (618) sin 14.4 ieee al 0678 Nia? 14 20010? — 200 x 10° We know that the maximum or limiting load for wear, Dp bQ.K _ 80x 32x1.6 x 0.678 cos? 0 cos? 45° Since the maximum load for wear is much more than the tangential load on the tooth, therefore the design is satisfactory from consideration of wear. Example 29.2. A helical cast steel gear with 30° helix angle has to transmit 35 kW at 1500 rp.m. If the gear has 24 teeth, determine the necessary module, pitch diameter and face width for 20° full depth teeth, The static stress for cast steel may be taken as 56 MPa. The width of face may be taken as 3 times the normal pitch. What would be the end thrust on the gear? The tooth factor for 20° 0.912 Ww, = =5554.N ‘full depth involute gear may be taken as 0.154 - of teeth. e Solution. Given : o = 30° ; P = 35 kW = 35 x 10) W; N= 1500 rpm. ; Tg = 24; > = 20°; 6, = 56 MPa = 56 N/mm? ; b = 3 x Normal pitch = 3 py Module Let m = Module in mm, and Dg = Pitch circle diameter of the gear in mm. ‘We know that torque transmitted by the gear, 7 Px60 _ 35x10? x 60 “2nN 272x150 , where T, represents the equivalent number = 223 N-m = 223 10° N-mm1072 = A Textbook Formative or equivalent number of teeth, To __ 24 cos’ cos’ 30° (0.866) 0.912 0.912 -—=0.129 0.154 37 ©. Tooth factor, Te ‘We know that the tangential tooth load, Le ao 2T Wy Dgl2 Dg mxTe 2x 223x10° _ 18 600 “s Dg=mz,) (Dg, and m are in mm) = N mx 2d m and peripheral velocity, ye Do N RmTe Ng 60 60 = XM 41500 585 on mm/s = 1.885. tals 60 Letus take velocity factor, 15 Is IS+y 1541.85 m We know that tangential tooth load, Wy = 6, C,) bx my'= (6, x C,) 3py x mx y' = (©, x C,)3 xp, cos xm mx y! 80m? © 1541.85 m or 279 000 + 35 061 m = 2780 m? Solving this equation by hit and trial method, we find that m = 5.5 say 6 mm Ans, Pitch diameter of the gear We know that the pitch diameter of the gear, Dg =mxTy x 24 = 144 mm Ans, Face width Iris given that the face width, 5 = 3p, =3 p,cosa=3xnmcosa = 3% Tx 6 cos 30° = 48.98 say 50 mm Ans, End thrust on the gear We know that end thrust or axial load on the gear, 18 600 Wy = Wp tan a= ee 1a'S0 ibaa Py =P,08 0) we pee mm) 15 6 yo (ts a xm cos 30 x m x 0.129 © 0.577 =1790N Ans.Helical Gears = 1073 | | | pyample 29.3. Design a pair & helical $00 Ep.N. and that of rise ott Sears fo ' J aris f oa Of driven gear is gop emsmiltng 22 kW. The speed of the driver fat sponding 10 2 full depth System. The d 0 rpm. The helix angle is 30° and profile is i SEM, The drive ' and pi ol rable om jwith allowable static stress ag : lar pitch and the overhan, 1g T gear 50 MPa, Agee , ia a teeth. Both the gears are made of cast for each width parallel 10 axis as 4 times th i Ba ea h gear ai Parallel to axis as 4 times the mei may be taken as 50 MPa, The forn ra 's 150 mm, The allowable shear stress for the shaft " . lor may be taken as 0.154 — 0,912 / Tr, where T, is sje equivalent number of teeth. The velocity factor y r may qoeity nm /min. The gears are re vider dynamic condition, under be taken as oo i i Nas 3554, ,* where vis pitch line quired 1 ' ; 0 be designed only against bending failure of the teeth Solution. Given : P = 22 kW = 22x 193 sy, me 9220 :Tp=24 30, =50MPa=50 N/mm? SH1800 1, sb=4p, ; Overhang = m.; Ng = 600 rp.m. ; 0 = 30°; 50 mm’; t= 50 MPa = 50 N/mm? Gears inside a car Desi inion and gear , sign for the pinion and & mitted by the pinion. i torque tran! He ae naan px 60. _ 22X10? 60 = 16.7 Nem = 116 700 N-mm 25nN, 22% 1800 T= 25 Ne nade o tne sare mate (.e: cast steD, therefore the ge — : tive iva Since both the pinion and st Oo a pon the pion. We know tha formative or equivatent Pinion is weaker. Thus the design W? Number of teeth, Dig een 37 -—- Jos 30° (0.866) Te = cos’ & 0.912 _ 9.199 oy O12 2 0.154 — Gz = OI 2 0.154 Fe +. Form factor, >1074 = A Textbook of Machine Design First of all let us find the module of teeth, Let m = Module in mm, and ' Dp. = Pitch circle diameter of the pinion in mm. We know that the tangential tooth load on the pinion, Tr 2r “ "DR mxTp 2x 116 700 = mx 24 m and peripheral velocity, XDpNp=tnTpNp = mmx 24 x 1800 = 135 735 m mm/min = 135.735 m m/min 350 350 3504 v 350 + 135.735 m We also know that the tangential tooth load on the pinion, Wy = (6,.C,) bx my'=(6,.C,) 4p, xmmxy" = (6,0) 4xmmxamxy' 9725 _ 55 350 a2 = 5 ++ Velocity factor, C, : b=4p) p.= hm) 2 4x1? mn? x 0.129 = 89 126 m m —~ (350+ 135.735 350 + 135.735m 3.4 x 10° + 1.32 x 106 mi = 89 126 m? Solving this expression by hit and trial method, we find that m = 4.75 mm say 6 mm Ans, Helical gears, ‘We know that face width, =4 ae P.=4mm=4%x6=75.4 say 76mm Ans, and pitch circle diameter of the Pinion, Dp=mxT,=6 x24 = Since the velocity ratio is 1899 / 699 Ty 23 4nd pitch circle diameter of the Dg = mx Tq = 6X72 = 432 mm Ans,Helical Gears: a 1075 | it. for the pinion shaft pes Let dp, = Diameter of he inion shay We know that the tangential load on ; 3 the Pinion, 725 9725 w= Tg T IL and the axial load of the pini ion, Wy 78 = 162] tan 30° = 1621 0577 = 935 since the overhang for each pear ite tangential Toad, M, = Wy x Ovettang = 1621 ¢ isp « 243 150 N-mm steading moment on the pinion shaft du tote axial load, D, M, = W, xP = 035 Mt Since the bending moment di aval load (ie. M,) are at tight an; 67320 N-mm 'ue to the tangential load (ie. M,) and bending moment due to the gles, therefore resultant bending moment on the pinion shaft, M= WM) +p = (243.150) + (67 320)? = 252293 N-mm The pinion shaft is also subjected toa torque T= 116 700 N-mm, therefore equivalent twisting ‘moment, T= (M+ 7" 2 Gi 909" 4 16700)? We know that equivalent twisting moment (T,, = 277975 N-mm 277915 = Ex (dp) = 2x30 ay) = 982 (dy) 2 (d,)> = 277975 / 9.82 = 28 307 or d, Letus now check for the principal shear stress. We know that the shear stress induced, 16, _16x277975 ee n(dp 5) NA ditect stress due to axial load, = 30,5 say 35 mm Ans, Wy 935 = 0.97 Nimm? = 0.97 Mpa o POR ak Roe par 4 1.) SSRN EATS yor errant bent iNT Hager % | i : } i £ | i q £ ;4076. #_A Textbook of Machine. Doser “s Principal shear stress. 1 (oan +40" = 33 MP: ia _fereel-al om + 405" a issi tress of 50 MPa, the Since the principal shear oes is less than the permissible shear S refore th nce the pt design is satisfactory. , ‘We know that the diameter of the Pinlo® hub = 1,8 dp= 1.8 x35 1,25 dp = 1.25 x3: hub should not be Jess than t 63 mm Ans. 5 = 43.75 say 44 mm he face width, therefore let us take length of and length of the hub ‘Since the length of the the hub as 76 mm. Ans. Note : Since the pitch circle diameter of the pinion web. Let us take the thickness of the web as 1.8 m1, ‘+, Thickness of the web = 1.8m= 18x6= +e 144 mm, therefore the pinion should be provided wit where mt is the module. 10.8 say 12 mm Ans. Design for the gear shaft Let dig = Diameter of the gear shaft. We have already calculated that the tangential load, W, = 1621N and the axial load, W, = 935N . Bending moment due to the tangential load, M, = W, x Overhang = 1621 x 150 = 243 150 N-mm and bending moment due to the axial load, Dy 432 M, = Wy x = 935 x —— = 201 960 N-mm +. Resultant bending moment on the gear shaft, mt = (1, + (1,9 = (243 150) + (201 960)? = 316 000 N-mm Since the velocity ratio is 3, therefore the , torque on the pinion shaft, gear shaft is subjected to a torque equal to 3 times the .- Torque on the gear shaft, T = Torque on the pinion shaft x VR. = 116 700 x 3 = 350 100 N. -mm ‘We know that equivalent twisting moment, ae = JM? 2 = (G16 000)? + G50 100? it? +7 = (16 0005" + (350100 = 472 000 Nem We al: also know that equivalent twisting moment (7-), 42000 = = 3 7 16% ** do)? = x 50 (dg)* = 982 (dg)? * )* = 472.000 ° 19.82 = Let us now check for the principat shea = 48065 or dg = 36.3 say 40 mm Ans. ‘We know that the shear stress induced, co? Aol — 16x 4 = 16% 472009 7 T(dgy (40)? = 37-6 N/mm? = 37.6 MPa= 1077 Helical Gears _ gaint sess de 10 axial load, Wy, o 935 Ae Rigg o® “_ Principal shear stress 4 oY ge 1 2 [or+az] = fy (0.744) +4 70" | = 37.6 MPa since the principal shear stres aeons 8 is less than the permissible shear stress of 50 MP2, therefore the We know that the diameter of the gear hub = 18d, =18x40=72 {= 1.8 x 40= 72 mm Ans. and length of the hub 1.25 dg = 1.25 x 40 = 50 mm We shall take the length of the hub equal to the face width, ie. 76 mm. Ans- Since the pitch circle diameter of the gear is 432 mm, therefore the gear should be provided with four arms. The arms are designed in the similar way as discussed for spur gears. Design for the gear arms Letus assume that the eros-setion of the arms is elliptical with major the minor axis (b,)- These dimensions refer to hub end. = 0.744 Nimm? = 0.744 MPa axis (a,) equal to twice «Section modulus of arms, 2 3 7 Baad? . BO < 005 (a (2% 32 4 since the arms are designed forthe stalling load and itis taken as the design tangential load divided by the velocity factor, therefore Wr 350 + 135.735m i = Wr e1621(->— Stalling load, Ws = 6: ( 350 350 + 135.735 x 6 . 350 + 135.799 2° ) = 5393 N 1621 7 } 1g moment on each a7, Do. = 9393 , 432 = 291 222 N-mm xa 2 ‘>, Maximum bendin} We know that bending stess 991222. _ 5824x 10° eZ ca . (Taking 0, = 42 N/mm?) M 291222, 2-77 005m) (@ yp 25824 « 100/42 = 138.7 «10° or a, = 51.7 say 54mm Ans. ; 7 mm Ans. q 12254! jm and the taper is 1/16 mm per mm length of the arm b= .d towards the Fi and Since the arms are tapers (or radius of the gear)» wherefore Major axis of the arm at the rim end. a a _Taper= 4 - 76% 1 432 og exes AO men ARS 2-60 2 and minor axis by =+ 1078 = A Textbook of Machine Design Design for the rim The thickness of the rim for the pinion may be taken as 1.6 m to 1.9 m, where m is the module, Let us take thickness of the rim for pinion, tap = 1.6m = 1.6 x 6 = 9.6 say 10 mm Ans. The thickness of the rim for the gear (tq) is given by Ts 72 _ fag = nf =6 e = 25.4 say 26mm Ans. EXERCISES