Machine Tool Design 1

Topic 1
Gears: Design

Mostafa ElBahloul
Assistant Professor
Department of Production and Mechanical Design
Spring 2022

Mansoura University
Contents
• Introduction
• Design based on tooth beam strength
• Lewis formula
• Modified Lewis formula
• Buckingham equation
• AGMA bending stress equation
• Design based on surface failure
• Contact stress – Hertz
• AGMA contact stress equations

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 2

Introduction
• The two most likely failure modes to govern a typical gearset design are bending fatigue
failure at the root fillet of a tooth, or surface fatigue (pitting) failure generated by the
cyclic Hertz contact stresses produced by repeatedly meshing gear teeth.
• In principle, gear-tooth design procedure is no different from the design procedure for any other
machine element; loading severity parameters (e.g., stresses) are calculated and compared with
critical capacities (e.g., strengths corresponding to governing failure modes), adjusting materials and
geometry until an appropriate safety factor or reliability level is achieved.
• In practice, the results obtained by applying fundamental principles are typically refined by using a
series of experience-based modifying factors to account for manufacturing variabilities, operational
dynamics, strength variabilities, environmental variabilities, and mounting and assembly variabilities.
• Gear design is classified into two approaches:
1. Design based on tooth beam strength
2. Design based on surface failure

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 3

Design Based on Tooth Beam Strength
Lewis Formula
• A gear tooth may be idealized as a cantilever beam subjected to an end load.
• For a tooth of face width b, the nominal tensile bending stress at critical point a due to
transmitted force Ft is:
𝐹𝑡
For spur gears: 𝜎𝑏 =
𝑚𝑏𝑌
𝐹𝑡
For helical gears: 𝜎𝑏 =
𝑚𝑛 𝑏𝑌
𝐹𝑡
For straight bevel gears: 𝜎𝑏 = 1−𝑏
𝑚𝑏𝑌
𝐴𝑜

Where Y is a Lewis form factor; it is a function

of the number of teeth in the gears.

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 4

Design Based on Tooth Beam Strength
Modified Lewis Formula
• A fatigue stress concentration factor kf should be applied to obtain the estimated actual
stress at the tensile critical point a.
• The limiting load carrying capacity is found as:
𝑏𝑚𝑌𝐾2 𝐶𝑉
For spur gears: 𝐹𝑡 𝑚𝑎𝑥 = 𝜎𝑒
𝐾𝑓 𝐾1
𝑏𝑚𝑌𝐶𝑉
For helical gears: 𝐹𝑡 𝑚𝑎𝑥 = 𝜎
𝐾𝑓 𝐾1 𝐶𝑅𝑡 𝑒
1−𝑏
𝑏𝑚𝑌𝐾2 𝐶𝑉
𝐴𝑜
For straight bevel gears: 𝐹𝑡 𝑚𝑎𝑥 = 𝜎𝑒
𝐾𝑓 𝐾1
Where CV is the dynamic factor accounting for
gear tooth impact.

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 5

Design Based on Tooth Beam Strength
Buckingham Formula
• This equation is introduced to account for the dynamic loads on gear teeth (cyclic loads).
• The dynamic load is found as:
𝐹𝑑 = 𝐹𝑡 + 𝑊𝑎 2𝑊2 − 𝑊𝑎
𝑊1 𝑊2
𝑊𝑎 =
𝑊1 + 𝑊2
𝐶1 𝑚𝑝 𝑚𝑔 1 1 𝑏𝑒
For spur gears: 𝑊1 = + 𝑉2 𝑊2 = + 𝐹𝑡
𝑚𝑝 +𝑚𝑔 𝑟𝑝 𝑟𝑔 1 1
𝐶2 +
𝐸𝑝 𝐸𝑔
𝐶1 𝑚𝑝 𝑚𝑔 1 1 𝑏𝑒
For helical gears: 𝑊1 = + 𝑉 2 𝑐𝑜𝑠 2 𝜓 𝑊2 = 𝑐𝑜𝑠 2 𝜓 + 𝐹𝑡
𝑚𝑝 +𝑚𝑔 𝑟𝑝 𝑟𝑔 1 1
𝐶2 +
𝐸𝑝 𝐸𝑔
𝐶1 𝑚𝑝 𝑚𝑔 1 1 𝑏𝑒
For straight bevel gears: 𝑊1 = + 𝑉2 𝑊2 = + 𝐹𝑡
𝑚𝑝 +𝑚𝑔 𝑟𝑣 𝑝 𝑟𝑣 𝑔 1 1
𝐶2 +
𝐸𝑝 𝐸𝑔

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 6

Design Based on Tooth Beam Strength
AGMA Bending Stress Equation
• The AGMA approach to designing gear teeth to resist bending fatigue failure, while
based on the idealized Lewis equation, involves an extensive list of empirical adjustment
factors to account for the influence of various manufacturing, assembly, geometric,
loading, and material variabilities.
• The basic AGMA bending stress equation may be written as:
1 𝐾𝐻 𝐾𝐵 𝑆𝑏 𝑌𝑁
For spur and helical gears: 𝜎𝑏 = 𝐹𝑡 𝐾𝑜 𝐾𝑣 𝐾𝑠 ≤ 𝜎𝑎𝑙𝑙 =
𝑏𝑚𝑡 𝑌𝐽 𝑆𝐹 𝑌𝜃 𝑌𝑍
1000𝐹𝑡 𝐾𝐴 𝐾𝑣 𝑌𝑋 𝐾𝐻𝛽 𝜎𝐹 𝑙𝑖𝑚 𝑌𝑁𝑇
For bevel gears: 𝜎𝐹 = ≤ 𝜎𝐹 𝑃 =
𝑏 𝑚𝑡 𝑌𝛽 𝑌𝐽 𝑆𝐹 𝐾𝜃 𝑌𝑍
where many pages of charts and graphs of supporting data are published by the
AGMA to provide values for all included factors.

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 7

Design Based on Surface Failure
• There are three main forms of surface failure, namely: wear, pitting, and scoring.
• Wear is the general term to cover sliding of metal against metal or abrasion by lapping or
scratching.
• This failure mode occurs due to excessive surface roughness, vibration, shock
loading, and excessive tooth loads in combination with low sliding speeds.
• Pitting is a fatigue failure that results from a combination of too much stress and too
many loading cycles which exceeds the fatigue strength of the gear metal.
• Scoring is a form of wear in which a gross damage to tooth surfaces occur.
• This results from heavy loads and high sliding speeds which causes a large number of
contacts in a given area, hence generating high temperatures that can’t be dissipated
fast enough and the surface runs hot.

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 8

Design Based on Surface Failure
• The diagram below shows the different failure modes for gear teeth.
• There are five different regions bounded by the failure modes as shown.

Torque capacity of gear-set

Wear

Breakage

Pitting

Safe zone Scoring

Pitch line speed

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 9

Design Based on Surface Failure
Contact Stress – Hertz

• When curved surfaces, such as meshing gear teeth, are pressed together, the triaxial
stress distributions at and below the surfaces of the contacting bodies may be described
by their pertinent Hertz contact stress equations.
• The governing contact stress equation is found as:
0.7 𝐹𝑡 𝑚𝐺 +1
For spur gears: 𝜎𝐶 = ×
𝑏𝑑 𝑚𝐺
cos  sin 
1 1
+
𝐸𝑝 𝐸𝑔

0.7 cos2 ψ 𝐹𝑡 𝑚𝐺 +1
For helical gears: 𝜎𝐶 = ×
𝑏𝑑 𝑚𝐺
cos 𝑛 sin 𝑛 𝐶𝑅𝑡
1 1
+
𝐸𝑝 𝐸𝑔

𝐹𝑡
For straight bevel gears: 𝜎𝐶 = 𝐶𝑝 𝐶
𝑉 𝑏𝑑𝑝 𝐼

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 10

Design Based on Surface Failure
AGMA Contact Stress Equation
• The AGMA approach to designing gear teeth to resist surface fatigue (pitting) failure is
based on the idealized Hertz contact stress equation modified by a list of adjustment
factors to account for the influence of various manufacturing, assembly, geometric,
loading, and material variabilities.
• The basic AGMA surface-pitting-resistance equation is written as:
𝐾𝐻 𝑍𝑅 𝑆𝑐 𝑍𝑁 𝑍𝑊
For spur and helical gears: 𝜎𝑐 = 𝑍𝐸 𝐹𝑡 𝐾𝑜 𝐾𝑣 𝐾𝑠
𝑑𝑤1 𝑏 𝑍𝐼
≤ 𝜎𝑐 𝑎𝑙𝑙 =
𝑆 𝐻 𝐾𝑇 𝐾𝑅

1000𝐹𝑡 𝜎𝐻 𝑙𝑖𝑚 𝑍𝑁𝑇 𝑍𝑊

For bevel gears: 𝜎𝐻 = 𝑍𝐸 𝐾 𝐾𝐾 𝑍 𝑍
𝑏𝑑𝑍1 𝐴 𝑣 𝐻𝛽 𝑋 𝑋𝐶
≤ 𝜎𝐻 𝑃 =
𝑆𝐻 𝐾𝜃 𝑍𝑍

where the approach is basically comparing the surface fatigue contact stress with
the allowable surface fatigue strength.

Spring 2022 – PRE 5322 Topic 1 – Gears: Design 11

 engfac.mans.edu.eg

Mostafa ElBahloul
Assistant Professor
mostafaelbahloul@mans.edu.eg