Force Analysis – Spur Gears

Transmitted load, lb. Power, hp

The equation in SI units
Wt = F32t in-lb rpm
Applied Torque, in-lb. hp = T n / 63000
T = 2d Wt
Pitch line velocity, ft/min. Wt = 33000 hp / V
V = π d n / 12
 DYNAMIC EFFECTS
The tangential force Wt, this is not the entire force that acts between
the gear and teeth. Tooth inaccuracies and deflections, misalignments,
and the like produce dynamic effects that also act on the teeth. The
dynamic load Fd or total gear-tooth load, in U.S. customary units, is
estimated using one of the following formulas:

V is the pitch line velocity in fpm. To convert to m/s divide the given
values in these equations by 196.8.
Force Analysis – Helical Gears
φn = normal pressure angle
φt = tangential pressure angle
ψ = helix angle
tan φn = tan φt cos ψ

Wr = W sin φn
Wt = W cos φn cos ψ
Wa = W cos φn sin ψ
Where W = total force
Wr = radial component
Wt = tangential component (transmitted load)
Wa = axial component (thrust load)

Wr = Wt tan φt φt = pressure angle (20o or 25o)

Wa = Wt tan ψ ψ= helix angle (10, 20, 30, or 40o)

Force Analysis – Bevel Gears

φ= Pressure angle (20o)

 Force Analysis – Worm Gear Sets
Three orthogonal components of
W without considering friction

considering friction

Relations between forces acting on

the worm and the gear
 Force Analysis – Worm Gear Sets
Two useful relations, friction force and transmitted loads.

Efficiency of worm gear sets

φη (pressure angle) = 20o, 25o, 30o λ (max. pressure angle) = 25o, 35o, 45o
f is dependent on the relative or
sliding velocity

VG and VW are the pitch-line

velocity of the gear and the worm
rsp and Vs the sliding velocity
 Stress Analysis – Spur Gears
Bending Strength
Lewis’ equation (1892 Wilfred Lewis, Philadelphia Engineers Club)
Using similar triangles,
Wt
Bending stress is maximum at the root of the tooth,
F

Substituting for x and introducing p (circular pitch),

The form factor y is called Lewis form factor.

Substituting P = π / p and Y = π y

Lewis’ equation, where

 Modification of Lewis’ Equation
Assumptions made in deriving Lewis’ equation

1. The load is applied to the tip of a single tooth.

2. The radial component of the load, Wr , is negligible.

3. The load is distributed uniformly across the full face width.

4. Stress concentration in the tooth fillet is negligible.

Lewis’ equation, where

 Let bending stress σ be designated by the
allowable static bending stress σ0 and so
tangential load Ft, by the allowable bending
load Fb. Then, this equation becomes

For satisfactory gear peiformance, it is necessary that:

 Modification of Lewis’ Equation
Modifications according to AGMA standards (American Gear
Manufacturers Association)

Lewis’ equation

Wt tangential transmitted load

Ko overload factor
KV dynamic factor
KS size factor
Pd transverse diameteral pitch
F face width of the narrower member
Km load-distribution factor
KB rim-thickness factor
J geometry factor for bending strength
which includes root fillet stress concentration factor Kf
 Bending Stress Modifying Factors
Geometry factor J

For 250
The size factor Ks = 1 for helical gears
 Bending Stress Modifying Factors
Dynamic factor Kv

Application factor,(Overload factor) Ka , (Ko )

 Bending Stress Modifying Factors
Size factor Ks
AGMA has not established standards for size factor and recommends that
Ks be set to 1. Load Distribution factor K m

Rim thickness factor KB

Backup ratio

Km = 1.6 may be used as a conservative

value for face width less than 2 in.

KB = -2mB + 3.4 0.5 ≤ mB ≤ 1.2

KB = 1.0 mB > 1.2
 AGMA Bending Strength Equation
Allowable Stress

Sfb’ is the allowable fatigue bending stress, psi

KL is life factor
KT is the temperature factor
KR is the reliability factor

Reliability factor KR
Temperature factor KT
AGMA recommends using temperature factor
of 1 for operating temperatures up to 250 oF.

KT = (460 + T)/620.
for higher temp.
The life Factor KL rectifies the allowable stress for the
required number of stress cycles other than 107
 AGMA Bending Strength Equation

Stress cycle factor KL

AGMA Bending-Fatigue Strength, Sfb’
 THE WEAR STRENGTH OF A GEAR TOOTH:
THE BUCKNGHAM FORMULA
The maximum contact pressure Po between the
two cylinders, for v = 0.3, may be computed from
:
Po ~ Se

Multiplying both sides by b, and replacing the

total load Fab denoted by Fw:
the allowable wear load Fw

For helical gear

For satisfactory gear performance, the usual
requirement is that:
Fw > Fd
 AGMA Surface Stress Equation

OR

Cp elastic coefficient, (lb/in2)0.5

Wt transmitted tangential load
Ca overload factor (same as Ka)
Cv dynamic factor (same as Kv)
Cs size factor (same as Ks)
Cm load-distribution factor (same as Km)
Cf surface condition factor
d pitch diameter of the pinion
F face width of the narrowest member
I geometry factor
Geometry factor
cosφt sinφt mG
external gears mN = 1 for spur gears
2mN mG + 1
I =
cosφt sinφt mG internal gears mG = speed ratio = NG /NP
2mN mG - 1
 AGMA Surface Stress Equation
AGMA Elastic coefficient CP

Surface finish factor Cf

The surface condition factor Cf is used to account for such considerations as surface
finish, residual stress, and plasticity effects.
effects
The Cf =1 for a smooth surface finish.
When rough finishes are present , 1.25 is reasonable.
If both rough finish and residual stress exist, 1.5 is the suggested value.
 AGMA Surface Strength Equation

Sfc’ is the allowable contact stress, psi

CL is the surface-life factor
CT is the temperature factor (same as KT)
CR is the reliability factor (same as KR)
CH is the hardness ratio factor
Hardness ratio factor, CH
CH should only be used for the gear design, for pinion design set CH equal to 1.0.
 AGMA Surface Strength Equation
Pitting resistance stress cycle factor ZN
 AGMA Surface Strength Equation
AGMA allowable surface fatigue strength
Design specification, the contact stress must not
exceed the design stress value:

σc,all ≥ σc
 AGMA Spur Gear Design Equations
Surface strength design equation, Stress = strength

Design steps
• Calculate the transmitted load
• Select material, start with grade 1 with low hardness.
• Select standard full depth gears with pressure angle of 20o or 25o.
• Choose a face width, ½ dP ≤ F ≤ dP
• Decide on: load type (uniform, non-uniform),
mounting accuracy, # of cycles to failure,
gear quality and reliability. Outcome is
• Solve the design equation for the diameter. Diameter and material
• Or, select diameter and solve for material.
 AGMA Spur Gear Design Equations
Bending strength design equation

Design steps
• Assume a value for J (geometry factor), 0.35 to 0.45
• Solve the design equation to obtain the diametral pitch, Pd
• Calculate the number of teeth for pinion and gear, determine the actual
J and check against the assumed one, iterate if needed.
• The number of teeth on the pinion should be over 18 to avoid interference.
• For power transmission, 2 < Pd (diametral pitch) < 16
• Iterate until optimum design is achieved.
Outcome is
Diametral pitch, P
 Design Example
Design a pair of spur gears to transfer power from a 25 hp motor to a fan.
The motor turns at 1000 rpm and the desired fan speed is 500 rpm. Specify
the material, diameter, and number of teeth for both gears.
Selections and assumptions

1. Standard full depth gears with pressure angle, φ = 20o, will be used.
2. Assume good quality gear with, Qv= 10, will be used.
3. Select face width F = dP (pinion diameter) , dP/2 ≤ F ≤ dP
4. Assume uniform load Ka= 1
Select 99% reliability KR = CR= 1
Design for
107 life cycle
KL = CL = 1

5. Assume operating temp. less than 250o (KT=CT = 1), new gear (Cf = 1),
and a small size gear (Ks=Cs = 1).
 Design Example
Surface failure

From assumptions and selections list;

Ca= 1 , CR = 1 , CL = 1 , Cs = 1 , Cf = 1 , CH = 1 (pinion) ,
Select material: use A-3 steel (hardness HB = 300), surface strength range
from 120,000 to 135,000 psi. Use Sc = 125,000 psi in calculation.

Look up CP (elastic coefficient) = 2300

cosφt sinφt mG
I = = 0.107
2mN mG + 1
mN = 1 for spur gears , φt = 20o
mG = speed ratio = ωP / ωG = 1000/500 = 2
 Design Example
Transmitted load
hp = Wt V / 33000 Wt = (1.26 x 105) hp / dP ωP
Pitch line velocity, ft/min.
Wt = (1.26 x 105) 25 / dP 1000
V = π d ω / 12
Wt = 3150 / dP

Assume dynamic factor C v = .9 and load distribution factor Cm = 1.6

Both assumptions have to be checked later.

2300[(3150/dP)(1/.9)(1.6)(1/.107)(1/dp)2]1/2 = 125,000

dP = 2.6 inch
 Design Example
Check assumptions for Cv and Cm
F = dP = 2.6 Cm = 1.61
(1.6 was assumed)
V = (π dP ωP)/12 = π x 2.6 x 1000/12
V = 680 ft/min
Cv = .9 (.9 was assumed)
Qv = 10

With these corrections, dP = 2.6

Select dP = 2.75 and A-3

steel as the material
 Design Example
Bending failure
Wt = (33000) hp / V
Wt = (33000) 25 / 680
Wt = 1213 lb
For A-3 material, St = 36,000 – 47,000 psi
Use 36,000 psi in calculation

Assume J = .4, check later

1213(1/.9)(P /2.75)(1.6)(1/.4) = 36,000 P = 18.3

For power transmission, 2 ≤ P ≤ 16, so select P = 16

 Design Example
Check assumption for J

NP = P dP = 16 x 2.75 = 44
NG = P dG = 16 x (2.75x2) = 88

J = .43 P = 19.7

So P = 16 is valid

Spur gears specifications

Material: A-3 steel
Diametral pitch: P = 16
Diameter: 2.75 (pinion), 5.5 inch (gear)
Number of teeth: 44 (pinion), 88 (gear)
Face width: F = 2.75 inch