Gear Design

Prof.Md.Khaled khalil
 Gear Design
• Function of gears
– Transmit mechanical power
– Change rotational speed
– Change torque
– Maintain constant speed ratio

Generally this functionality is

accomplished by many gears mounted in a
gear box!

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 Five-Speed Gearbox
1 3 5

N7 N8
N5
N3 N11
2 4 R N1

Main
Shaft
Bearing

NI
N8
Counter N6 N12
Shaft N2 N4

Synchronizer Idler Gear

Gear
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 Type of Gears
Spur Gear
Single Helical
Parallel Shaft
Gear
Helical Gear
Double Helical
(Herringbone)
According to the Gear
Intersecting
position of axes Bevel Gear
Shaft
of the shaft

Hypoid Gear
Non-intersecting
and non-parallel Worm Gear
Shaft Cross Helical
Gear

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 Type of Gears
Coniflex
Bevel gear

Zerol Bevel
Gear

Spiral Bevel
Gear
Bevel Gear
Miter Bevel
Gear

Angular Gear

Crown Gear

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 Type of Gears

Spur Gear
Helical Gear

Bevel Gear Worm Gear

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 Spur Gear
• Teeth are parallel to the axis of the gear
• Advantages
– Cost
– Ease of manufacture
– Availability
• Disadvantages
– Only works with mating gear
– Axis of each gear must be parallel

• Used in transmitting torque between parallel shafts

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 Rack & Internal Spur Gear System

Rack & Pinion Ring Gear (Internal)

Rack & Pinion Ring Gear (Internal)

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 Helical Gears
• Teeth are at an angle to the gear axis
(usually 10° to 45°) – called helix angle
• Advantages
– Smooth and quiet due to gradual tooth
engagements. Helical gears good up to
speeds in excess of 5,000 ft/min
– More tooth engagement allows for
greater power transmission for given
gear size.
• Disadvantage
– More expensive
– Resulting axial thrust component

• Used in transmitting torques between

parallel or non parallel shafts, they
are not as noisy as spur gears

Herringbone Gear
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 Bevel Gears
• Gear axis at 90°, based on
rolling cones
• Advantages
– Right angle drives
• Disadvantages
– Get axial loading which
complicates bearings and
housings
• Are used to transmit rotary
motion between
intersecting shafts

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 Types of Bevel Gears

Miter Bevel Gear

Crown Bevel Gears Crown Bevel Gear

Straight Bevel Gear

Spiral Bevel Gear Angular Bevel Gear Hypoid Bevel Gear

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 worm Gears
• Gears that are 90° to each other
• Advantages
– Quiet / smooth drive
– Can transmit torque at right angles
– No back driving
– Good for positioning systems
• Disadvantage
– Most inefficient due to excessive friction
– Needs maintenance
– Slower speed applications

• Used for transmitting motion between

non parallel and non transmitting
shafts. Worm gear mostly used when
speed ratio is quiet high, 3 or more.
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 Different Type of Gear box

Audi car gear box Quick change gear box

Indexing head gear box Differential gear box

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 Nomenclature of Spur-Gear Teeth

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 Involute Profile
• The most common conjugate profile is the involute profile.
• Can be generated by unwrapping a string from a cylinder,
keeping the string taut and tangent to the cylinder.
• Circle is called base circle.

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 Gear Nomenclature

Smaller Gear is Pinion and Larger one is the

gear
In most application the pinion is the driver, This
reduces speed but it increases torque.

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 Gear Nomenclature
• N = Number of teeth
Use subscript for specific gear
• NP=Number of teeth on pinion (driver)
• Ng=Number of teeth on gear (driven)
• NP < Ng (for speed reducer)
• Circular Pitch, Pc is the radial distance from a point on a tooth at
the pitch circle to corresponding point on the next adjacent tooth
d
Pc 
N
Diametral Pitch, (Pd) – Number of teeth per inch of pitch diameter

N
Pd 
d
Ng Np
Two gears in mesh must have equal Pd: Pd  
dg dp
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 Gear Nomenclature
• Gear Train Rule – Pitch of two gears in mesh must
be identical

 dg dp
Pc  
Ng Np

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 Bending Strength of the a Gear Tooth
Flexural Strength of Tooth

Ws  S ebmY
Contact or Wear Strength of Tooth In general, when indefinite, more-
or-less continuous service is
Ww  d p bQK desired it is necessary for both
Ws≥ NsfWD and Ww ≥ NsfWD
Where
Se= Endurance Strength For intermittent or other limited
b= Face width service, it is common to make
m = Module Ws≥ NsfWD
Y = Lewis form factor
dp= Diameter of pitch circle For very short service, fatigue limit
Q = Ratio factor Ws may be smaller than WD
K = Material combination factor

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 Table 13.7 Values of service factor, Nsf

Type of service
Type of
load Intermittent or 8-10 hours Continuous 24
3 hours per day per day hours per day
Steady 0.8 1.00 1.25
Light shock 1.00 1.25 1.54
Medium shock 1.25 1.54 1.80
Heavy shock 1.54 1.80 2.00

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 Spur Gear design
A pair of spur gear with 200 full depth teeth are to transmit 8kW
at 1750rpm of the 75mm pinion; velocity ratio desired is about
3.8; intermittent service. Use strength reduction factor of about
1.4 with the load at the tip and teeth commercially cut.
Determine the module, face width, and tooth numbers if the
material is cast-iron, class 20.
Solution: Given

n P  1750 rpm, d p  75 mm, k f  1.4, m g  3.8, H  8kW

Material : Cast iron Class - 20, Find m, b, N P , N G  ?

For material Cast iron, Class–20 from Table no A-24

Sut  22 kpsi  22  6.89  151.58 MPa

Table A-2 Page No. – 73 Y=AX
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 Spur Gear design =

Number of Teeth of Pinion for Φ=200 FD from page 47

N P  18, then m  d P / N P  75 / 18  4.17  4.5

We know Flextural Strength Ws  N sf WD and Ws  Se bmY

Endurance strength Se  K a K b K c K d K e K f S e'

S e  0.45Sut , Sut  151.58 MPa  600 MPa

 0.45 151.58  68.21 MPa
Page No -13 Equation No. -7.2

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 Spur Gear design

K a  0.8 for Sut  0.152 GPa from figure no.13 - 25

Page N0 136

K b  0.92 for m  4.5 from Table No. - 13.1 Page 48

K c  1 for bending

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 Spur Gear design

K d  1 for T3500 C

K e  1 / K f  1 / 1.4 , K f  1.4 (Given)

K f  1.33 for Sut  0.152 GPa 1.4 GPa from figure no.13  26

Page N0 136

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 Spur Gear design
Se  K a K b K c K d K e K f S e'
Se  0.8  0.92  1 1 1/1.4  1.33  68.21  47.69 MPa

Let face width b  8m for cast gear (6.5m to 9.5m)

Page No. -45

Form factor Y  0.484  2.87 / N Page No. -47

 0.484  2.87 / 18  0.325 for   20 0 FD

WS  S e bmY  47.69  8m  m  0.325  124m 2

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 Spur Gear design
πd P n P π  75 1750
Velocity V    6.87m/s
60 60 1000
H 8 103
Transmitted load WT    1164.48N
V 6.87
From Table 13.7 for heavy shock & intermittent service N sf =1.54

3  V   3  6.87 
WD    WT   1164.48  3831.14N
 3   3 
For Commercially cut and V≤10 m/s Page No -44

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 Spur Gear design
Ws  N sf WD  124m 2  1.54  3831.14  m  4.8  5.5

 K b  0.902 for m  5.5 from Table no. - 13.1

S e  0.8  0.902 111/ 1.4 1.33  68.21  46.76 N

WS  46.76  8m  m  0.325  121.57m 2

Ws  N sf WD  121.57m 2  1.54  3831.14

 m  6.97  7
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 Spur Gear design

Number of Teeth of Pinion

N P  d P / m  75 / 7  10.71  11

Number of Teeth of Gear

N g  m g N p  3.8 11  41.8  42

Face width b  8m  8  7  56mm

Design Value : m  7, N p  11, N g  42, b  56mm

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 Thank you

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