Gear Speed Reducer

NEW ERA UNIVERSITY
COLLEGE OF ENGINEERING AND TECHNOLOGY

MECHANICAL ENGINEERING DEPARTMENT
ME 484
MACHINE DESIGN II
GEAR REDUCER DESIGN
Submitted by:
Vallejos, Dario Jr. C.
IV-BSME
Submitted to:
Engr. Nelio S. Gesmundo, Jr
Course Instructor
ACKNOWLEDGMENT
This work, though amateur at best, would not have been possible without the help of the
people within my immediate surroundings, that is, my family, professors, friends, and
acquaintances. Of special mention are the following individuals/persons:
My parents, without whose support this endeavor would surely fall apart in terms of
logistics and moral support,
My professors and instructors, without whom the knowledge and information taxed by this
task would not have been met,
My classmates/colleagues, without whom the ideas developed here would not have an
environment to thrive, improve, and grow,
My paramour, who kept me going, without whom this project would not have been rebuilt
each time it fell apart,
And to God, without whom all of these are otherwise physically void, intellectually
impossible, and mentally hopeless.
TABLE OF CONTENTS
I. DESIGN PROBLEM AND DESIGN SPECIFICATIONS
A. DESIGN PROBLEM
B. DESIGN SPECIFICATIONS
1. GEAR PAIR
2. SHAFTING
3. RIMS AND ARMS
4. GEAR HOUSING
II. DESIGN SKETCH/ILLUSTRATION
III. COMPUTATIONS
A. GEAR PAIR
1. PRELIMINARY GEAR DIMENSIONS, CONTACT RATIO, AND INTERFERENCE
2. TORQUE AND FORCES
3. BENDING STRENGTH
4. PITTING STRENGTH
5. MATERIAL SELECTION
B. SHAFTING
1. SHAFT
2. GEAR HUB
3. BEARING SELECTION
4. TOLERANCES AND FITS
5. KEYS AND COUPLINGS
C. RIMS AND ARMS
1. INITIAL DIMENSIONS
2. ARM GEOMETRY
D. HOUSING
1. INITIAL ILLUSTRATION
2. GEARBOX DIMENSIONS
IV. RECOMMENDATIONS
V. APPENDIX
I. DESIGN PROBLEM AND DESIGN SPECIFICATIONS

A. DESIGN PROBLEM
A gear-reduction unit is to be designed according to the data in the table and the
following specifications. The velocity ratio may be varied by an amount necessary to have
whole tooth numbers. The given center distance is the permissible maximum (but this
does not preclude asking the engineer in charge if a slightly larger one can be tolerated, in
case it looks impossible to satisfy this condition. The teeth are to be 20 F.D. with Np 18
teeth, with 17 as the minimum acceptable. The service is continuous, with indefinite life.
Use Bucking hams dynamic load for average gears.
(a) Decide upon the material with its treatment, pitch, and face with. Start out being
orderly with your calculations so that you do not need to copy all of them for your report.
The report should show calculations for the final decisions first, but all significant
calculation should be in the appendix. These latter calculations should show: that a cheap
material (as cat iron) cannot be used; that through-hardened steel (minimum permissible
tempering temperature is 880F), flame or induction-hardened steel, and carburized
case-hardened teeth have all been considered in detail.
(b) To complete the design of the gears, a shaft size is needed. At the option of the
instructor: (i) compute shaft diameters for pure torsion only using a conservative design
stress, as Ss= 6 ksi (to cover stress concentration, minor bending, on the assumption that
the bearings will be quite close to the gears, etc.); or (ii) make a tentative assumption of
the distance between bearings, and design the shafts by a rational procedure. It would be
logical for the input and output to be via flexible couplings. Let the shaft material be coldfinished AISI 1137. Design the keys for cold-drawn AISI C1118. Use better materials than
these only for good reason.
(c) Determine the dimensions of the hub, arms or webs, and rims and beads of both
gears.
(d) Make a sketch of each gear (on separate sheets of paper) including on it all
dimensions and information for its manufacture.
(e) At the instructors option (i) choose rolling type bearings, or (ii) design sleeve
bearings.
(f) Decide upon all details of the housing to enclose the gears, with sketches depicting
them.
(g) Your final report should be arranged as follows: (1) title page; (2) a summary of final
design decisions, and material specifications; (3) sketches; (4) final calculation; (5) other
calculations.
B. DESIGN SPECIFICATIONS
1. GEAR PAIR
MATERIAL
TABLE I.B.1-1
MATERIAL
Pinion
AISI 6150 OQT 400
Gear
AISI 6150 OQT 400
YIELD STRENGTH
270 ksi
HARDNESS
Pinion
Approx 634 HB or 59 HRC
Gear
CASE DEPTH
.023 in
ALLOWABLE STRESS NUMBERS:

TABLE I.B.1-2.a
RATING METHOD
ANSI/AGMA 2001-D04
ALLOWABLE BENDING STRESS NUMBER

Pinion
74.79 ksi
Gear
58.51 ksi
STRESS CYCLE FACTOR

Pinion
.94
Gear
.97
TEMPERATURE FACTOR
1.0
RELIABILITY FACTOR
1.0
BENDING STRESS NUMBER

Pinion
81614.24 psi
Gear
65881.37 psi
GEOMETRY FACTOR
Pinion
.335
Gear
.415
OVERLOAD FACTOR
1.75
DYNAMIC FACTOR
1.275
SIZE FACTOR
LOAD DISTRIBUTION FACTOR
RIM FACTOR
1.0
1.181
1.0
TABLE I.B.1-2.b
ALLOWABLE CONTACT STRESS NUMBER
Pinion
264.02 ksi
Gear
252.79 ksi
STRESS CYCLE FACTOR

Pinion
.91
Gear
.94

Pinion
237617.65 psi
Gear
237617.65 psi
GEOMETRY FACTOR
Pinion
.109
Gear
.109
GEOMETRY
TABLE I.B.1-3
PROFILE TYPE
PRESSURE ANGLE
DIAMETRAL PITCH, Pd
INVOLUTE
20
6
FACE WIDTH, F
2.67 in
CENTER DISTANCE, c
9.583 in
GEAR RATIO, mg
NUMBER OF PINION TEETH, Np
5.053
19
NUMBER OF GEAR TEETH, Ng

PINION SPEED, np
GEAR SPEED, ng
91
900 rpm
178.125 rpm
PINION DIAMETER, Dp
3.167 in
GEAR DIAMETER, Dg
8.00 in
PITCH LINE VELOCITY, v
776.44 rpm
DEDENDUM, b
.2083 in
CLEARANCE, c
.0413 in
WHOLE DEPTH, ht
.334 in
WORKING DEPTH, hk
.50 in
TOOTH THICKNESS, t
.262 in
BASE CIRCLE DIAMETER (PINION)
2.976 in
BASE CIRCLE DIAMETER (GEAR)
7.516 in
CIRCULAR PITCH
.5234 in
BACKLASH
.015 in
2. SHAFTING
SHAFT MATERIAL
TABLE I.B.2-1
MATERIAL
AISI 1137 CD
ULTIMATE TENSILE STRENGTH
98 ksi
YIELD STRENGTH
82 ksi
MODULUS OF ELASTICITY
30E6 psi
MODULUS OF RIGIDITY
11.5E6 psi
DESIGN STRESS
6 ksi
SHAFT DIMENSIONS
Pinion
TABLE I.B.2-2.a
D1
DIMENSION
D1s
D2
D3
1.5475 in
1.8504 in
1.80 in
1.5475 in
HOLE
+0
No Adjustment
+0
+0
SHAFT
+.0024 in
No Adjustment
-.0030 in
+.0024 in
Gear
TABLE I.B.2-2.b
D1
DIMENSION
D1s
D2
D3
2.7559 in
3.0709 in
3.00 in
2.7559 in
HOLE
+0
No Adjustment
+0
+0
SHAFT
+.0029 in
No Adjustment
-.0037 in
+.0029 in
GEAR HOB
TABLE I.B.2-3
DIAMETER
LENGTH
PINION
2.70 in
2.25 in
GEAR
4.50 in
3.75 in
BEARINGS
TABLE I.B.2-4
MANUFACTURER/ DYNAMIC LOAD INNER
MODEL NAME
PINION
SKF
CAPACITY
OUTER
DIAMETER DIAMETER
BEARING
WIDTH
18300 lbsf
1.5748 in
3.1496 in
.9055 in
12600 lbsf
2.7559 in
4.3307 in
.7874 in
MANUFACTURER/ TORQUE
MINIMUM
MAXIMUM
COUPLING
MODEL NAME
DIAMETER DIAMETER
NUP 2208 ECP

GEAR
SKF
NU 1014 ML
COUPLINGS
TABLE I.B.2-5
PINION
SKF
CAPACITY
WIDTH
7884 lbs-in
.748 in
2.874 in
2.008 in
37812 lbs-IN
1.4961 in
6.7323 in
3.386 in
KD2-153
GEAR
SKF
KD2-303
KEYS MATERIAL
TABLE I.B.2-6
MATERIAL
AISI 1137 CD
80 ksi
YIELD STRENGTH
75 ksi
30E6 psi
MODULUS OF RIGIDITY
11.5E6 psi
KEYS DIMENSIONS
TABLE I.B.2-7
PINION KEY
GEAR KEY
PINION
GEAR
COUPLER KEY
COUPLER KEY
ORIGINAL
1.12 in
2.26 in
2.084 in
2.46 in
ADJUSTED
2.00 in
3.50 in
2.00 in
3.25 in
3. RIM AND ARMS

Data for the rims and arms are summarized as follows:
TABLE I.B.3-1
MATERIAL
RIM THICKNESS
AISI 6150 OQT 400

.5864 in
RIM BEAD
INCORPORATED IN RIM
HUB BEAD
NONE
NUMBER OF ARMS
ARM LEGNTH
ARM GEOMETRY
5
4.955 in
ELLIPTICAL (h = 1.06 in)
4. HOUSING
Summary of gearbox dimensions is as follows:
TABLE I.B.4-1
MATERIAL
Cast iron
WALL THICKNESS
.45 in
TOP COVER THICKNESS
.36 in
COVER FLANGE THICKNESS
.90 in
COVER FLANGE BOLT DIAMETER
.75 in
COVER FLANGE WIDTH
1.875 in
COVER FLANGE BOLT SPACING
4.5 in
FOUNDATION FLANGE BOLT DIAMETER
.875 in
FOUNDATION FLANGE THICKNESS
1.3125 in
FOUNDATION FLANGE WIDTH
2.1875 in
PINION BEARING HOUSING DIAMETER
3.80 in
GEAR BEARING HOUSING DIAMETER
5.20 in
II. DESIGN SKETCH/ILLUSTRATION
III. CALCULATIONS
A. GEAR PAIR
1. PRELIMINARY GEAR DIMENSIONS, CONTACT RATIO, AND INTERFERENCE
INITIAL CALCULATIONS FROM THE ORIGINAL PROBLEM SPECIFICATIONS
Original specifications given by the problem are as follows:
TABLE III.A.1-1
POWER
GEAR RATIO
MAX CENTER DISTANCE
90 hp
5
9.5 in
PINION RPM
900
LOAD TYPE
Shock load
SAFETY FACTOR
1.4
PRESSURE ANGLE
20
PINION TEETH
18
Using the tabulated values, we may assign initial values to the center distance, number
of gear teeth, diametral pitch, and the pinion and gear diameters using the following
equations and correlations, respectively:
C = (Dp + Dg)/2
Eqn III.A.1-1
mg = Ng/Np Dg/Dp
Eqn III.A.1-2
mg = Dg/Dp
5 = Dg/Dp = Ng/Np
5Dp = Dg
C = (Dp + 5Dp)/2 = (6Dp)/2
9.5 in = (6Dp)/2
Dp = 3.167 in (initial)
Ng = 5Np = 5 18
Ng = 90 (initial)
Dg = 5Dp = 5 3.167
Dg = 15.835 in (initial)
DIAMETRAL PITCH Pd
The diametral pitch is given by the formula:
Pd = N/D
Eqn III.A.1-3
For this design, any value derived from Eqn III.A.1-3 will be rounded up in order to
meet a value for the center distance that is below the minimum. Hence:
Pd = N/D = 18/3.167 = 5.684
Pd = 6
CENTER DISTANCE C
The original maximum center distance C = 9.5 in will have to be adjusted with respect
to the adjusted diametral pitch. Modifying Eqn III.A.1-1:
C = (Dp + Dg)/2 = (Np + Ng)/2Pd = (18 + 90)/(2 6)
C = 9.00 in
DIAMETER ADJUSTMENT
Using Eqn III.A.1-3, the diameters for the gear pair may be derived as follows:
Dp = Np/Pd = 18/6
Dp = 3.00 in
Dg = Ng/Pd = 90/6
Dg = 15.00 in
Since the value for the center distance has not yet reached the maximum, these values
may still be increased without compromising the initial specifications.
The relations below logically follow if adjustments from the original gear pair diameters
are incrementally iterated in terms of the number of teeth:
Dp = (Np + N)/Pd = (18 + N)/(6) = (18 + N)/6
Eqn III.A.1-4
Dg = 5Np = 5(18 + N)/6
Eqn III.A.1-5
Np = (Np + N) = 18 + N
Eqn III.A.1-6
Ng = 5Np = (Ng + N)
Eqn III.A.1-7
C = (Dp+Dg)/2=(Dp+5Dp)/2=6(18+N)/(26)=(18+N)/2
Eqn III.A.1-8
Summarizing the values for N until C 9.50 in

TABLE III.A.1-1
N
Dp (in)
Dg (in)
Np
Ng
C (in)
3.00
15.00
18
90
3.167
15.833
19
95
9.5
Only a single tooth can be added to the pinion, otherwise, the center distance limit will
be exceeded. This value will be checked if the resulting contact ratio has a range of 1.0
mp 2.01, and no interference exists.
CONTACT RATIO
The contact ratio is given by the formula:
CR = AB/Pb
Where:
AB = Line of contact = AP + BP
1
. ANSI/AGMA 2001-D04, Clause 1.2
Eqn III.A.1-9
Pb = (D/N)cos = (/Pd)cos
CR = (AP + PB)/(/Pd)cos
Eqn III.A.1-10
To find the length of lines AP and BP, consider Fig III.A.1-12. An examination of the
figure yields the following relations:
Fig III.A.1-1
= 90 +
Eqn III.A.1-11
3 = arcsin [(PO3sin)/AO3]
Eqn III.A.1-12
3 = 180 - ( - 3)
Eqn III.A.1-13
AP = (AO3sin3)/sin
Eqn III.A.1-14
2 = arcsin [(PO2sin)/BO2]
Eqn III.A.1-15
Kinematics and Dynamics of Machines, Martin, 2 ed., p. 251
2 = 180 - ( 2)
Eqn III.A.1-16
BP = (BO2sin2)/sin
Eqn III.A.1-17
The length of PO3, AO3, PO2, and BO2 can be expressed in term of the radii of the pinion
and the gear, and the addendum circle.
PO3 = Rg
Eqn III.A.1-18
AO3 = Rg + 1/Pd
Eqn III.A.1-19
PO2 = Rp
Eqn III.A.1-20
BO2 = Rp + 1/Pd
Eqn III.A.1-21
Considering the sum of the pinion and gear radii, the center distance, equals 9.00, i.e.
Rg + Rp = 9.50 in
Eqn III.A.1-22
Eqn III.A.1-22 has to be modified in anticipation of a hunting tooth. Considering the

length that a single tooth of the gear adds on the center distance:
(Rg + 1/2Pd) + Rp = 9.5 in +1/2Pd = 9.5 + 1/(26)
(Rg + 1/2Pd) + Rp = 9.583 in
let Rg = (Rg + 1/2Pd)
C = Rg + Rp = 9.583 in
Eqn III.A-1-23
Combining Eqns III.A.1-10~23, the final equation for the contact ratio of the gear pair
in term of the gear radius is given by Eqn III.A.-1-23. For the full derivation, see
Appendix A.
CR = ((Rg+1/6) sin(70-arcsin(xsin110/( Rg+1/6))) +
(9.75-Rg)sin(70-arcsin((9.583-Rg)sin110/(9.75-Rg))))/ ((sin110)(cos20)(/6))
Eqn III.A.1-24
Using Microsoft Mathematics confirms that valid values for Rg include {0 <mp < 9.0}.
Fig III.A.1-2
Plotting the value of the contact ratio (y-axis) with respect to the gear radius (x-axis) =
(Rg + 1/2Pd) = (15.833 + 1/(26)) 8.00 in, a value of contact ratio mp 1.70 is
obtained. Therefore, the diameters of the gear and the pinion are valid values for the
design.
HUNTING TOOTH
The addition of a hunting tooth in the gear modified the gear ratio mg = 95/19 = 5, a
relatively poor distribution of load amongst the teeth, to mg = 96/19 = 5.053. This
means that for the same tooth from the gear and the pinion will mesh again for every 96
revolutions from the gear and 19 revolutions the pinion.
The angular speed of the gear also changes in correspondence with the hunting tooth.
From 180 rpm, the value changes to ng = 178.125 rpm.
ADDENDUM a
The addendum is identified early on because it will be used to find whether or not
interference exists. It is given by the formula:
a = 1/Pd = 1/6
Eqn III.A.1-25
a = .167 in.
INTERFERENCE
Using SolidWorks, interference with Rp = Dp/2 = 3.167/2 = 1.584 in and Rg = 8.00 in is
determined graphically. Looking at Fig III.A.1-3, points A and B do not exceed either
points E and F. Hence, no interference occurs.
Fig III.A.1-4
PITCH LINE VELOCITY

After finalizing both the diameters of the pinion and the gear, the pitch line velocity v
may now be determined.
v = 2Rpnp = 2 1.584 in 900 rpm
v = 8957.31 in/min = 776.44 fpm
Eqn III.A.1-26
FACE WIDTH
After finalizing the diametral pitch, the face width can now be determined. Using the
formula
F = (8 ~ 16)/Pd, say 16/Pd
Eqn III.A.1-27
= 16/6
F = 2.67 in
Other geometric dimensions of particular concern are solved as follows:
DEDENDUM, b
Eqn III.A.1-28
b = 1.25/Pd = 1.25/6
b = .2083 in
CLEARANCE, c
Eqn III.A.1-29
c = b - a = .2083 - .167
c = .0413 in
WHOLE DEPTH, ht
Eqn III.A.1-30
ht = a + b = .167 + .2083
ht = .3753 in
WORKING DEPTH, hk
Eqn III.A.1-31
hk = 2a = 2 .167
hk = .334 in.
TOOTH THICKNESS, t
t = /2 Pd =/(2 6)
t = .262 in
Eqn III.A.1-32
BASE CIRCLE DIAMETER

Db = Dcos
Eqn III.A.1-34
Pinion
Dbp = 3.167cos(20)
Dbp = 2.976 in
Gear
Dbp = 8.00cos(20)
Dbp = 7.516 in
CIRCULAR PITCH
Pc = D/N = /Pd = /6
Eqn III.A.1-35
Pc = .5234 in
BACKLASH
The 26th edition of Machinerys Handbook provides a table to serve as a guide in
determining the amount of backlash of the gear:
TABLE III.A.1-2
For this design, an average between the two limits of the recommended gear backlash
value for gear pairs with diametral pitch Pd = 6~9.99, i.e., backlash bl = .015 in.
SAFETY FACTOR SF
The original specified safety factor SF = 1.4 will be reduced to unity. This is because the
design will use the rating method employed by the American Gear Manufacturers
Association (AGMA), an empirical approach to determine factors to be applied in the
design rating, i.e., uncertainties from which the safety factor was deemed fit to be
employed are now evaluated by empirical means.
UPDATED DIMENSIONAL SUMMARY
Preliminary dimensions for the involute spur gears are re-evaluated as follows:
TABLE III.A.1-3
POWER, P
DIAMETRAL PITCH, Pd
90 hp
6
FACE WIDTH, F
2.67 in
CENTER DISTANCE, c
9.583 in
GEAR RATIO, mg
5.053
NUMBER OF PINION TEETH, Np
19
NUMBER OF GEAR TEETH, Ng
91
PINION SPEED, np
GEAR SPEED, ng
900 rpm
178.125 rpm
PINION DIAMETER, Dp
3.167 in
GEAR DIAMETER, Dg
8.00 in
PITCH LINE VELOCITY, v
776.44 rpm
DEDENDUM, b
.2083 in
CLEARANCE, c
.0413 in
WHOLE DEPTH, ht
.334 in
WORKING DEPTH, hk
.50 in
TOOTH THICKNESS, t
.262 in
BASE CIRCLE DIAMETER (PINION)
2.976 in
BASE CIRCLE DIAMETER (GEAR)
7.516 in
CIRCULAR PITCH
.5234 in
SAFETY FACTOR, SF
DRIVEN LOAD
1.0
Shock load
2. TORQUE AND FORCES

In order to proceed with the design, it will be necessary to find the value of the torque,
tangential force, radial force, and normal force acting on the gear pair assembly. These
are calculated by the following formulae, respectively:
T = 63000P/n; lbs-in
Eqn III.A.2-1
Where
P = power in horsepower
n = angular speed in rpm
Wt = T/R; lbs
Eqn III.A.2-2
Where
R = radius in inches
Wr = Wttan; lbs
Eqn III.A.2-2
Wn = Wt/cos; lbs
Eqn III.A.2-2
Applying the formulas for both the pinion and the gear:
PINION
T = 63000 90/900
T = 6300 lbs-in
Wt = 6300/1.584
Wt = 3977.27 lbs
Wr = 3977.27 tan20
Wr = 1477.61 lbs
Wn = 3977.27/cos20
Wn = 4232.52 lbs
GEAR
T = 63000 90/178.125
T = 31831.58 lbs-in
Value for Wt, Wr, and Wn for the gear is the same with the pinion.
TABULAR SUMMARY
Summarizing the computed values on a table:
TABLE III.A.2-1
PINION
GEAR
TORQUE, T
6300 lbs-in
31809.26 lbs-in
TANGENTIAL FORCE, Wt
3977.27 lbs
3977.27 lbs
RADIAL FORCE, Wr
1477.61 lbs
1477.61 lbs
NORMAL FORCE, Wn
4232.52 lbs
4232.52 lbs
3. BENDING STRENGTH
The bending strength is determined by the allowable bending stress number S at, which,
in turn, is determined by the bending stress number St. The formula for the two are as
follows:
St = WtKOKVKS(Pd/F)(KmKB/J)
Eqn III.A.3-1
Sat St (SFKTKR/YN)
Eqn III.A.3-2
Where
KO = Overload factor
KV = Dynamic factor
KS = Size factor
Km = Load distribution factor
KB = Rim factor
KT = Temperature factor
KR = Reliability factor
YN = Stress cycle factor
To proceed with the design, St is determined first. The factors are calculated next.
OVERLOAD FACTOR KO
The overload factor is determined by the use of the table below:3
TABLE III.A.3-1
th
Machine Elements in Mechanical Design, Mott, 4 ed., p. 389
The given design problem specifi.e.s that the driven load is shock load. However, the
power source is not specified. The design will limit its application to uniform shock
power source, eg, electric motor. Therefore, KO =1.75.
DYNAMIC FACTOR KV
The dynamic factor is determined using the figure below4:
Fig III.A.3-1
Since the transmission grade QV is not specified, assumption will be made according to
the type of load and pitch line velocity. From TABLE III.A.3-25, shock load applications
usually fall under QV = 7 or below; by the pitch line velocity method, it is suggested to
have QV = {6, 7, 8} for pitch line velocity v < 800 fpm.
4
5
ANSI/AGMA 2001-D04, Appendix A

th
TABLE III.A.3-2
For a high grade rating, QV = 8 will be used. Applying the formula for curves 5 QV 11
from Fig III.A.3-1:
KV = ((A + v.5)/A)B
Eqn III.A.3-3
Where
B = .25 (12 - QV).667 = .25 (12 - 8).667
Eqn III.A.3-4
B = .6303
A = 50 + 56(1.0 - B) = 50 + 56(1.0 - .6306)
Eqn III.A.3-4
A = 70.6864
KV = ((70.6864 + 776.44.5)/70.6864).7314
KV = 1.275
SIZE FACTOR, KS
The size factor may be taken as unity for most gears provided that the materials are
properly selected for the size.6 For this design, KS = 1.00.
ANSI/AGMA 2001-D04, clause 20.2
LOAD DISTRIBUTION FACTOR Km

ANSI/AGMA 2001-D04 defines the laod distribution factor as ...the peak load intensity
divided by the average, or uniformly distributed, load intensity; i.e., the ratio of peak to
mean loading. It is affected by two components, namely the face load distribution
factor Cmf, which accounts for the distribution of load along the face width, and the
transverse load distribution factor Cmt, which accounts for the distribution of load
among the teeth that share the transmitted load instantaneously. I.e.,
Km = Cmf + Cmt
Eqn III.A.3-5
Since there is no standard rating method for the transverse load distribution factor, it
can be assumed that Cmt = 1.00.
The empirical method of calculating for the Cmf may be used provided the design meets
certain criteria that are explained in Appendix C. Its formula is given as:
Cmf = Cmc(CpcCpm + CmaCe)
Eqn III.A.3-6
Where
Cmc = lead correction factor
Cpf = pinion proportion factor
Cp = is pinion proportion modifi.e.r
Cma = mesh alignment factor
Ce = mesh alignment correction factor
The value of Cmc is rated either as 1.00 for unmodified loads or .8 for crowned leads. For
this design, with uncrowned leads, Cmc = 1.00.
For Cpf, Fig III.A.3-27 is used.
ANSI/AGMA 2001-D04, Fig 5
Fig III.A.3-2
For face width 1.0 < F 17, the curves from the table is defined by the formula:
Cpf = F/10Dp - .0375 +.0125F = 2.67/(103.167) -.0375 +.0125(2.67)
Cpf = .08
Eqn III.A.3-6
Cpm is based on the location of the gear pair from their respective distances from their
bearing centrelines. Consider the figure8:
Fig III.A.3-3
Cpm is 1.0 for straddle mounted pinions with (S1/S) < 0.175; Cpm is 1.1 for straddle
mounted pinions with (S1/S) 0.175. For this design, the pinions will be located at the
center of the bearing line, hence (S1/S) < 0.175. Cpm = 1.00.
The mesh alignment factor, Cma, can be obtained from the figure9 and table10 below:
Fig III.A.3-4
TABLE III.A.3-3
For this design, precision enclosed gear units will be used. Using the graph and the
empirical values above, the mesh alignment factor is computed with the formula:
Cma = A + BF +CF2 = .675E-1 +. 128E-12.67 - .822E-4 2.672
Cma = .101

ANSI/AGMA 2001-D04, Table 2
10
Eqn III.A.3-7
The mesh alignment correction factor Ce is used to modify the mesh alignment factor. It
is rated as either .8 if alignment is improved upon assembly, etc, or 1.00 if no further
improvement with the alignment is made. For this design, the latter scenario is
assumed, hence Ce = 1.00.
Substituting the obtained values for the factors in Eqn III.A.3-5 yields:
Km =1.0 + 1.0(.081.0+ .1011.0)
Km = 1.181
RIM FACTOR KB
This factor is only modified for thin rimmed gears. Current information is insufficient to
find out whether or not rimmed gear is more appropriate for the design. However, the
graph11 shows that for a certain range of backup ratio mb = ht/tR 1.2 the rim factor is
at unity. Rimmed or not, this limit shall be observed so that KB = 1.0.
Fig III.A.3-5
11
ANSI/AGMA 2001/D04, Fig B.1
GEOMETRY FACTOR J
Calculation for the geometry factor for the bending stress of spur gears is relatively
complex. It is simplified, however, with the aid of the table12 below.
Fig III.A.3-6
It logically follows then that the pinion and the gear will each have a different geometry
factor J. Thru inspection:
Jp .335
Jg .415
Substituting all the calculated values of the factors from Eqn III.A.3-1 for the pinion
yields
Stp = WtKOKVKS(Pd/F)(KmKB/Jp) = 3977.27 1.75 1.275 1.0 (6/2.67)
(1.181 1.0/.335)
Stp = 70303.20 psi
12
th
For the gear, Stp is multiplied to Jp to cancel its value and divide the new value with Jg.
Stg = Stp (Jp/Jg) = 81614.24 (.335/.415)
Eqn III.A.3-7
Stg = 56750.78 psi

RELIABILITY FACTOR KR
The reliability factor accounts for the normal statistical distribution of failure amongst
gear units. Refer to the TABLE III.A.3-213. For this design, a .99 reliability will be used,
i.e., one failure in 10000, hence, KR = 1.00.
TABLE III.A.3-4
TEMPERATURE FACTOR KT
The temperature factor is usually taken as unity for temperature range 32< F <250 (0
< C < 121). For this design, it will be assumed that the normal operating conditions
will observe this limit; hence, KT = 1.00.
STRESS CYCLE FACTOR YN
The bending stress number adjusts the allowable stress numbers for the required
cycles of operation. It is given Fig III.A.3-714:
For number of cycles N exceeding 107, the upper limit of the shaded region in the graph
will be used.
13
14
ANSI/AGMA 2001-D04, clause 18

Fig III.A.3-7
YN = 1.3558Nc-.0178
Eqn III.A.3-8
In which N shall be determined by the formula

Nc = 60Lnq
Eqn III.A.3-9
Where
L = Number of life hours
q = Number of contacts per revolution
From Eqn III.A.3-9, it is obvious that different values of YN For this design, the number
of life hours will be designated as the upper limit of the design life of multi-purpose
gearing application (15000 hrs,
or approx 5 years for 8-hour continuous, daily
operation) given by the TABLE III.A.3-515.

For q, a value of unity is designated because the gear pair only mesh with one another
in each revolution, i.e., q = 1.0
15
th
TABLE III.A.3-5
Evaluating Eqn III.A.3-9 for both the gear and the pinion
Ncp = 60 15000 900 1
Ncp = 8.10E8
Ncg = 60 15000 178.125 1
Ncg = 1.60E8
Substituting the values of Np and Ng to Eqn III.A.3-8
YNp = 1.3558 (8.10E8)-.0178
YNp = .94
YNg = 1.3558 (1.60)-.0178
YNg = .97
Substituting the values of St, SF, KT, KR, and YN to Eqn III.A.3-2 for both the gear and the
pinion yields:
Satp 70303.20 (1.0 1.0 1.00/.94)

Satp 74790.64 psi 74.79 ksi
Satg 56750.78 (1.0 1.0 1.00/.97)
Satg 58505.96 psi 58.51 ksi
TABULAR SUMMARY
Summarizing the values for the bending strength in a table:
TABLE III.A.3-6
ALLOWABLE BENDING STRESS NUMBER
Pinion
74.79 ksi
Gear
58.51 ksi
STRESS CYCLE FACTOR

Pinion
.94
Gear
.97
TEMPERATURE FACTOR
1.0
RELIABILITY FACTOR
1.0

Pinion
81614.24 psi
Gear
65881.37 psi
GEOMETRY FACTOR
Pinion
.335
Gear
.415
OVERLOAD FACTOR
1.75
DYNAMIC FACTOR
1.275
SIZE FACTOR
LOAD DISTRIBUTION FACTOR
RIM FACTOR
1.0
1.181
1.0
4. PITTING STRENGTH
The pitting strength is determined by the allowable contact stress number S ac, which, in
turn, is determined by the contact stress number Sc. The formulae for the two are as
follows:
Sc = CP (WtKOKVKS(Km/DpF)(Cf/I)).5
Eqn III.A.4-1
Sac Sc (SFKTKR)/(ZNCH)
Eqn III.A.4-2
Where
CP = elastic coeffici.e.nt
Cf = surface condition factor
I = pitting geometry factor
ZN = pitting resistance stress cycle factor
CH = hardness ratio factor.
All other variables have been previously identified. The remaining unknown factors
shall be accordingly identified.
ELASTIC COEFFICI.E.NT CP
The elastic coeffici.e.nt is defined by the equation16:
CP = (1/(((1 - p2)/Ep) + ((1 - g2)/Eg))).5
Where
p = Poissons ratio of the pinion
g = Poissons ratio of the gear
Ep = Modulus of elasticity of the pinion
Eg = Modulus of elasticity of the gear
For steel, the design material, = .3 and E = 30000 ksi, CP = 2300.
16
ANSI/AGMA 2001-D04, Eqn 31
Eqn III.A.4-3
SURFACE CONDITION FACTOR Cf

This design assumes that the manufacturing of the gear allows for appropriate surface
finish. Hence, surface condition factor can be taken as Cf = 1.0.
PITTING GEOMETRY FACTOR I
Likewise with the bending geometry factor J, the pitting geometry factor I requires a
relatively complex procedure to identify. For this design, a simplified approach will be
taken based from the pressure angle and the number of teeth of the pinion and the gear
ratio. Consider the figure17:
Fig III.A.4-1
Plotting the corresponding value of I for Np = 20 and gear ratio 4.45, I .109
Substituting the unknown variables from Eqn III.A.4-1 with the values from TABLE
III.A.3-6 and the new calculated values yields:
Sc = 2300 (3733.27 1.75 1.275 1.0 (1.181/2.67 3.167)(1.0/.109)).5
Sc = 237617.65 psi
17
th
STRESS CYCLE FACTOR ZN

The contact stress number also adjusts the allowable stress numbers for the required
cycles of operation. It is given by the graph18:
Fig III.A.4-2
For a number of load cycles greater than 107, the shaded region shall be used to identify
ZN. Using the formula for the upper region:
ZN = 1.4488Nc-.023
Eqn III.A.4-5
The values of Nc for the gear and the pinion have been previously identified, namely Ncp
= 8.10E8, and Ncg = 1.60E8. Substituting these values to Eqn III.A.4-5 yields:
ZNp = 1.4488(8.10E8)-.023
ZNp = .90
ZNg = 1.4488(1.60E8)-.023
ZNg = .94
18
HARDNESS RATIO FACTOR CH

The value of CH for the pinion is set at 1.0. The value of CH for the gear is either set at 1.0
or otherwise depending upon the gear ratio, surface finish of the pinion, and/or
hardness of the pinion and the gear.
For this design, it is initially assumed that the hardness ratio factor for the gear CH = 1.0
until further information regarding the material of the gear is decided.
Substituting the values for the variables in Eqn III.A.4-2:
Sacp 237617.65 (1.0 1.0 1.00)/(.90 1.0)
Sacp 264019.61 264.02 ksi
Sacg 237617.65 (1.0 1.0 1.00)/(.94 1.0)
Sacg 252784.73 psi 252.79 ksi
TABULAR SUMMARY
TABLE III.A.4-1
ALLOWABLE CONTACT STRESS NUMBER
Pinion
264.02 ksi
Gear
252.79 ksi
STRESS CYCLE FACTOR

Pinion
.91
Gear
.94

Pinion
237617.65 psi
Gear
237617.65 psi
GEOMETRY FACTOR
Pinion
.109
Gear
.109
5. MATERIAL SELECTION
Given the allowable contact stress number and the allowable bending stress number
previously calculated, it will be necessary to select a relatively stronger type of steel.
With the contact stress as the governing stress for this design, consider the figure19
below:
Fig III.A.5-1
Required Brinell hardness number is calculated for both the gear and the pinion for
both Grades 1 and 2.
Grade 1
HB = (Sacp - 29100)/322
Pinion
HB = (264019.61 - 29100)/322
HB = 729.56
Gear
HB = (252784.73 - 29100)/322
19
Eqn III.A.5-1
HB = 694.67
Grade 2
HB = (Sacp - 34300)/349
Eqn III.A.5-2
Pinion
HB = (264019.61 - 34300)/349
HB = 658.22
Gear
HB = (252784.73 - 34300)/349
HB = 626.03
The Brinell hardness numbers, all well above 400, suggest that through hardening will
not be sufficient. Heat treatment case hardening will be required. In order to select the
appropriate heat treatment, consider the table20:
TABLE III.A.5-1
Only carburization hardening meets the requirement for the allowable contact stress,
namely Gear 3 for both the pinion and the gear. In this regard, a material with good heat
treatment hardening property and yield strength will be required for the gear pair.
20
ANSI/AGMA 2001-D04, TABLE 3
Upon inspection of the properties of AISI 6150 (tempered at 400 F)21, it is conclusive
that it should serve well as the material for the gear pair.
Fig III.A.5-2
CASE DEPTH
ANSI-AGMA provides suggested case depth for carburized gear teeth. Consider Fig
III.A.5-322. For this design, normal case depth is selected for economy. Using the
equation for the normal case depth curve, the normal case depth is evaluated as
he = .119935Pd -.86105 = .119935 (6 -.86105)
he = .023 in
21
22
th
Machine Elements in Mechanical Design, Mott, 4 ed., p. A-10

Eqn III.A.5-2
Fig III.A.5-3
TABULAR SUMMARY
Tabulating the new data23 for summary:
TABLE III.A.5-2
MATERIAL
Pinion
AISI 6150 OQT 400
Gear
AISI 6150 OQT 400
YIELD STRENGTH
270 ksi
HARDNESS24
Pinion
Gear
CASE DEPTH
23
24
See Appendix C for more details on metallurgical factors

See Appendix D for hardness conversion chart
.023 in
B. SHAFTING
1. SHAFT
ORIGINAL SPECIFICATION FOR THE SHAFTS
The shaft material and the allowable design stress are given by the design problem. The
data are tabulated as follows:
TABLE III.B.1-1
MATERIAL
AISI 1137 CD
98 ksi
YIELD STRENGTH
82 ksi
MODULUS OF RIGIDITY
DESIGN STRESS
30E6 psi
11.5E6 psi
6 ksi
INITIAL SHAFT DIAMETER

The design problem specifies that the design stress be limited to 6 ksi, only for pure
torsion, with the value covering for the stress concentration, minor bending, etc. Using
the torsion equation, initial shaft diameter is evaluated:
d = 16T/(d3)
d = (16T/( d))1/3
Evaluating d for the pinion and the gear:
dp = (16Tp/( d))1/3 = (16 6300/( 6000))1/3
dp = 1.749 in 1.75 in
dg = (16Tg/( d))1/3 = (16 31831.16/( 6000))1/3
dg = 3.00 in
Eqn III.B.1-1
INITIAL SHAFT LENGTH

The problem does not specify the length of the shaft. However, it does suggest keeping
the distance of the gear pair from each of their respective bearing as little as possible.
For this design, the distance of the gear pair from the bearing will be determined by
angular deflection, and synchronous vibration and transverse deflection.
The website roymech.co.uk provides data sheet for engineering application, including
recommended shaft deflection. From the table:25
TABLE III.B.1-2
The design specified the use of roller bearings. For this design, cylindrical roller
bearings will be used for economy, hence, the maximum angular deflection of .06.
TORSIONAL DEFLECTION
Using the torsional deflection formula:
= TL/JG
L = JG/(T)
Where
L = Distance of gear pair from the bearing
J = Polar moment of inertia
25
http://www.roymech.co.uk/Useful_Tables/Drive/Shaft_design.html#Deflections
Eqn III.B.1-2
= angular deflection in rads

Evaluating for the gear and the pinion shafts:
Pinion
L = JG/(T) = (.06 /180)((1.754/32))(30E6))/(6300)
= (.00105)(.9208)(30E6)/6300
L = 4.59 in
Gear
L = JG/(T) = (.06 /180)((3.004/32))(30E6))/(31831.16)
= (.00105)(7.9522)(30E/6)/6300
L = 7.85 in
SYNCHRONOUS VIBRATION
In order to design the shafts against critical speed, they must be designed such that
resonance starts to occur at about each of their fifth harmonics26, in which the impulses
are negligible, i.e.:
ns fn /2n-1
Where
ns = angular speed of the shaft
fn = natural frequency
n = nth harmonic (5th harmonic for this design)
fn ns 25-1
For the pinion
fnp (900) 25-1
fnp 14400 vib/min 240 vib/sec
26
Internal Combustion Engine, Maleev, 2 ed., p. 447
Eqn III.B.1-3
For the gear

fng (178.125) 25-1
fng 2850 vib/min 47.5 vib/sec
The design natural frequencies of the pinion and the gear shafts are substituted to Eqn
III.B.1-4 in order to find the allowable transverse deflection.
fn = (12g/y).5/2
Eqn III.B.1-427
Where
g = 32.2 ft/s2
y = transverse deflection
y = (12g)/(2fn)2
For the pinion
yp = (12 32.2)/(2 240)2
yp = .00017 in
For the gear
yg = (12 32.2)/(2 47.5)2
yg = .00434 in
Using the acquired values of deflection, the distance of the gear pair from the bearings
may be obtained by the beam deflection formula for simply supported beams:
y = WnL3/48EI
E = Modulus of elasticity
I = Moment of inertia
L = (48EIy/Wn)1/3
27
Internal Combustion Engine, Maleev, 2 ed., p. 460
Eqn III.B.1-5
Calculating the moment of inertia for both the pinion and the gear shaft using the
formula:
I = (D4/64)
Eqn III.B.1-6
Pinion
Ip = ( 1.754/64)
Ip = .4604 in4
Gear
Ig = ( 3.004/64)
Ip = 3.9761 in4
Substituting the values to Eqn III.B.1-5
Pinion
Lp = (48 30E6 .4604 .00017/4232.52)1/3
Lp = 2.99 in 3.00 in
Gear
Lg = (48 30E6 3.9761 .00434/4232.52)1/3
Lg = 18.04 in
The evaluated distance of the pinion shaft from the bearing is also safe for the gear
shaft. For housing convenience, the same value will be used for both the pinion and the
gear shafts. Therefore, tentative shaft length = 2L = 6.00 in.
BEARING REACTION
To illustrate the initial set-up of the gear and shaft assembly, consider Fig III.B.1-1. The
combined radial and tangential forces are combined and are represented as the normal
force. The bearing reactions from the gear and the pinion will be the same since the
same amount of force acts on the shafts.
Using static moment equation to evaluate bearing reactions, with clockwise set as
positive:
MA = 3Wn - 6RB = 0
RB = (3 4232.52)/6
Fig III.B.1-1
RB = 2116.26 lbs
MB = 6RA - 3Wn = 0
RA = (3 4232.52)/6
RA = 2116.26 lbs
SHEAR AND MOMENT DIAGRAM
With the forces acting on the shaft already known, the shear and moment diagram may
now be determined. Using the shear and moment equation:
V = Fy
Eqn III.B.1-7
Where
V = Shear force
Fy =Vertical forces
M = M = f(V)
Eqn III.B.1-8
Evaluating the two equations:

V = 2116.26 - (4232.52) + 2116.26
V=0
M = f(V) = ( 2116.26) - ( 4232.52) = 2116.26(6) - 4232.52(6-3)

M=0
Using Microsoft Mathematics, the shear and moment diagram are graphed as follows:
Fig III.B.1-2a
Shear diagram
Fig III.B.1-2b
Moment diagram
ACTUAL ENDURANCE STRENGTH Sn

The actual endurance strength of the material must be evaluated in order to proceed
with the shaft design. Its value is evaluated as:
Sn = SnCmCstCRCs
Eqn III.B.1-9
28
Where
Sn = Endurance strength
Cm = Material factor
Cst = Stress type factor
CR = Reliability factor
Cs = Size factor
These variables are evaluated accordingly.
28
th
ENDURANCE STRENGTH Sn
The endurance strength may be derived from Fig III.B.1-329
Fig III.B.1-330
Plotting the tensile strength of AISI 1137 CD against the surface finish condition,
endurance strength Sn = 38 ksi.
MATERIAL FACTOR Cm
According to its density and general characteristics, AISI 1137 CD can be classified as
wrought steel31. Hence, from TABLE III.B.1-3, its material factor Cm = 1.00.
TABLE III.B.1-3
29
th

30
th
31
http://www.steelforge.com/literature/ferrousnon-ferrous-materials-textbook/ferrous-metals/carbon-steel/
STRESS TYPE FACTOR Cst

Stress type factor is either evaluated 1.0 for bending or .80 for axial tension. For this
design, Cst = 1.0032.
RELIABILITY FACTOR CR
The same reliability from the gear pair shall be applied for the shafts. Hence, from the
table33 below, reliability factor CR = .81.
TABLE III.B.1-4
SIZE FACTOR CS
The size factor of the shaft shall be evaluated using the following range of values34:
TABLE III.B.1-4
Using the equation for .30 < D 2.0 for the pinion shaft and 2.0 < D < 10.0 for the gear
shaft:
Pinion
Eqn III.B.1-10
Cs = (D/0.3) -.11 = (1.75/.3)-.11

32
th

33
th
34
th
Cs = .8237
Gear
Eqn III.B.1-11
Cs = .859 - .02125D = .859 - .02125 3.00

CS = .7953
Substituting the obtained values to Eqn III.B.1-9
Pinion
Sn = 38E3 (1.00)(1.00)(.81)(.8237)
Snp = 25353.49 psi
Gear
Sn = 38E3 (1.00)(1.00)(.81)(.7953)
Sng = 24479.33 psi
READJUSTED SHAFT DIAMETERS
The final shaft diameters left to be determined are those at the section of the bearing.
Considering that neither torque nor bending moment occurs at the bearings from both
the pinion and the gear shaft, the equation for the shaft diameter at these sections is
applied:
D = (2.94KtVN/Sn).5
Where
N = Shaft factor of safety = 3 (shock load, certain data)
Kt = Stress concentration factor = 1.5 (round fillet)
Pinion
D = (2.94 1.5 2116.26 3/25353.49).5
D = 1.0501 in
Eqn III.B.1-12
Gear
D = (2.94 1.5 2116.26 3/24479.33).5
D = 1.0695 in
TABULAR SUMMARY
The acquired values for the shaft diameters, including the preferred basic sizes, are
summarized in a table:
TABLE III.B.1-5
Pinion
D1
D2
D3
Nominal Size
1.05 in
1.75 in
1.05 in
Preferred basic size
1.20 in
1.80 in
1.20 in
Gear
D1
Nominal Size
Preferred basic size
D2
D3
1.0695 in
3.00 in
1.0695 in
1.20 in
3.00 in
1.20 in
2. GEAR HUB
Mott and Faires recommend empirical methods for calculating the hub diameter and
hub length, respectively.
Dh = 1.5Ds
Eqn III.B.2-135
Lh = 1.25 ~ 2Ds
Eqn III.B.2-236
HUB DIAMETER
Substituting values of Ds for both the gear and the pinion to Eqn III.B.2-1
Pinion
Dhp = 1.50 1.80
Dhp = 2.70 in
Gear
Dhg = 1.50 3.00
Dhg = 4.50 in
HUB LENGTH
Substituting values of Ds for both the gear and the pinion to Eqn III.B.2-2
Pinion
Dhp = 1.7 5 1.80
Dhp = 2.25 in
Gear
Dhg = 1.25 3.00
Dhg = 3.75 in
35
36
th

th
Design of Machine Elements, 4 ed., p. 388
3. BEARING SELECTION
Bearings are selected next for the design. Note that bearing selection may affect predetermined shaft dimensions according to size compatibility.
BEARING DYNAMIC LOAD CB
The bearing dynamic load is given by the formula:
CB = V(Nc/1E6)1/k
Eqn III.B.3-137
Where
CB = Rated bearing load
V = Shear force
Nc = Number of life cycle (See III.A.3, STRESS CYCLE FACTOR)
k = life-load ratio
Substituting the values accordingly for both the pinion and the gear, with k = 3.3 for
ball bearings, bearing dynamic load is evaluated as:
Pinion
CBp = 2116.26 (8.1E8/1E6)1/3.3
CBp = 16103.79 lbs
Gear
CBg = 2116.26 (1.6E8/1E6)1/3.3
CBg = 9851.09 lbs
SELECTION FROM BEARING CATALOGUE
For its local availability, this design will use bearings manufactured by Svenska
Kullagerfabriken (SKF). Select products from the catalogue are included in Appendix E.
37
th
The bearings are selected according to their dynamic load capacity and bore diameter
such that stress concentration will be minimized, i.e. the bore should be only slightly
smaller than the diameters at the gear pair section.
The figure38 should serve as a guide in selecting bearings with respect to their bore
diameter:
Fig III.B.3-1
Note that to achieve stress concentration factor Kt = 1.5, the step ratio of the shaft
diameters must not exceed 1.25. Therefore, for the pinion shaft, the minimum bore
diameter:
D1p = D2p/1.25 = 1.80/1.25
Eqn III.B.3-2
D1p = 1.44 in
while for the gear, minimum bore diameter
D1g = D2g/1.25 = 3.00/1.25
Eqn III.B.3-3
D1g = 2.40 in
38
th
Machine Elements in Mechanical Design, Mott, 4 ed., p. A-27
For the pinion shaft, the SKF NUP 2208 ECP roller bearing will be used.
Fig III.B.3-2
For the gear shaft, the SKF NU 1014 ML roller bearing will be used
Fig III.B.3-3
ADJUSTED DIAMETERS
The shaft diameters for both the pinion and the gear shafts are adjusted to
accommodate the selected bearings. The new dimensions are tabulated as follows:
TABLE III.B.3-1
D1
D1s
D2
D3
PINION
1.5475 in
1.8504 in
1.80 in
1.5475 in
GEAR
2.7559 in
3.0709 in
3.00 in
2.7559 in
4. TOLERANCES AND FITS

Tolerances shall be applied to the gear pair sections of the shafts while fits shall be
applied to the bearing sections. Given the design load and speed, a tolerance of RC5 and
a force fit of FN2 will be used. For convenience, only the shaft dimensions will be
adjusted while the dimensions of the holes are maintained.
Using the ANSI/ASME Clearance Fits and Force Fits charts39, the clearances/fits for the
diameter:
Pinion
TABLE III.B.4-1a
D1
Dimension
D1s
D2
D3
1.5475 in
1.8504 in
1.80 in
1.5475 in
Hole
+0
No Adjustment
+0
+0
Shaft
+.0024 in
No Adjustment
-.0030 in
+.0024 in
Gear
TABLE III.B.4-1b
D1
Dimension
39
D1s
D2
D3
2.7559 in
3.0709 in
3.00 in
2.7559 in
Hole
+0
No Adjustment
+0
+0
Shaft
+.0029 in
No Adjustment
-.0037 in
+.0029 in
See Appendix F
5. KEYS AND COUPLINGS

ORIGINAL SPECIFICATION FOR THE KEYS
The problem specifies that the material for the keys is AISI C1118 CD. Summarizing its
properties:
TABLE III.B.5-1
MATERIAL
AISI 1137 CD
80 ksi
YIELD STRENGTH
75 ksi
30E6 psi
MODULUS OF RIGIDITY
11.5E6 psi
For this design, the axial area for the shaft and coupling keys are empirically selected
from the TABLE III.B.5-240 whilst the key length is given by the formula:
Lk = (4TN)/(DsWSy)
Eqn III.B.5-141
Where
W = face width
Value of T, W, and D are different for both the pinion and the gear. Hence, they shall be
solved separately. In all cases, factor of safety N = 3.00
PINION KEY
Upon inspection at TABLE III.B.5-2, nominal face width and height for a square key
configuration for the pinion shaft Ds = 1.80 in is obtained:
Wp = Hp = in
Substituting the variables from Eqn III.B.5-1:
40
41
th

th
TABLE III.B.5-2
Lkp = (4 6300 3)/( 1.80 .5 75000)

Lkp = 1.12 in
GEAR KEY
Upon inspection at TABLE III.B.5-2, nominal face width and height for a square key
configuration for the pinion shaft Ds = 3.00 in is obtained:
Wg = Hg = .75 in
Lkg = (4 31809.26 3)/( 3.00 .75 75000)

Lkg = 2.26 in
PINION COUPLER KEY
For this design, the diameter of the shaft that elongates to the coupling is given the
same diameter as the diameter of the section of the shaft that is adjacent to the bearing.
In this regard, axial dimension of the pinion coupler key for Ds = 1.5475 in is given as:
Wpc = Hpc = .3125 in
Lkpc = (4 6300 3)/( 1.5475 .3125 75000)
Lkpc = 2.084 in
GEAR COUPLER KEY
Axial dimension of the pinion coupler key for Ds = 2.7559 in is given as:
Wgc = Hgc = .75 in
Lkgc = (4 31809.26 3)/( 2.7559 .75 75000)
Lkgc = 2.46 in
COUPLING SELECTION
Manufactured couplings are selected accordingly for this design. See Appendix G for a
select catalogue range from Svenska Kullagerfabriken.
The parameters for the flexible coupling selection are the minimum allowed shaft
diameter, torque capacity, and angular speed capacity. Assigning a value of 4.00 in as
the distance of the elongated portion of the shafts from their respective bearings to
their couplings also limits possible and practical choices. For this design, disc flexible
couplings are employed.
For the pinion, the SKF KD2-153 satisfies all parameters for the pinion coupling.
Fig III.B.5-1
For the gear, the SKF KD2-303 satisfies all parameters for the gear coupling.
Fig III.B.5-2
READJUSTED KEY DIMENSIONS

The key lengths are further adjusted in order to be compatible with their respective
hubs.
TABLE III.B.5-2
PINION KEY
GEAR KEY
PINION
GEAR
COUPLER KEY
COUPLER KEY
ORIGINAL
1.12 in
2.26 in
2.084 in
2.46 in
ADJUSTED
2.00 in
3.50 in
2.00 in
3.25 in
C. RIM AND ARMS

1. PRELIMINARY DIMENSIONS
For this design, only the gear will use rim and arms in order to reduce mass and cost.
Rim thickness and the number of arms are determined empirically. This design will also
incorporate the ring bead to the rim for easier manufacturing and to keep the material
homogenous.
RIM THICKNESS
A suggested empirical value for the rim thickness is given by the formula:
tR = .56Pc = .56/Pd
Eqn III.C.1-142
Since this design incorporates the bead to the rim, and the bead having the same
formula for the rim thickness, Eqn III.C.1-1 is modified to:
tR = 2(.56/Pd) = 2(.56/6)
Eqn III.C.1-2
tR = .5864 in
Note that this value of tR is within the prescribed range for the rim thickness factor
determined earlier. The radial distance will be subtracted from the dedendum line.
NUMBER OF ARMS
The number of arms is also empirically suggested43:
TABLE III.C.1-1
Gear diameter(mm)
42
43
Arms
300-500
4-5
500-1500
th
Design of Machine Elements, Faires, 4 ed., p. 390

th
Design of Machine Elements, Bhandari, 4 ed., p. 670
1500-2400
>2400
10-12
The gear diameter, Dg = 16 in = 403 mm, suggests a recommended number of arms NA

= 4 ~ 5. For this design, NA = 4.
The figure illustrates the preliminary dimensions of the gear pitch diameter, hob, rim,
and shaft bore.
Fig III.C.1-1
2. ARM GEOMETRY
Appropriate arm dimensions are calculated such that the arms, acting as cantilever
beams, will be able to withstand the applied tangential forces. To proceed with the
design, the shape of the cross section must be determined. Faires lists common cross
section shapes for gear arms44. For this design, elliptical arms are selected for their
smaller tendency for stress concentration.
Using the stress formula for beams:
= M/S = Sy/N = M/S
Eqn III.C.1-3
Where
M = Moment
S = Section modulus
N = Factor of safety = 4
S = 4M/(270 ksi)
Solving for the value of the moment evenly distributed to the four arms:
M = WtL/NA = 3977.27 4.955 /5
Eqn III.C.1-4
M = 3941.48 lbs-in
The section modulus of an elliptical cross section in which the major diameter is twice
the minor diameter is given by the formula:
S = h3/64
Eqn III.C.1-545
Substituting the values to Eqn III.C.1-3

h3/64 = 4M/(270 ksi)
h = ((64 4 3941.48)/(270E3 ))1/3
44
45
th

th
h = 1.06 in
TABULAR SUMMARY
TABLE III.C.2-1
RIM THICKNESS
.5864 in
RIM BEAD
INCORPORATED IN RIM
HUB BEAD
NONE
NUMBER OF ARMS
ARM LEGNTH
ARM GEOMETRY
To illustrate the assembly, consider the figure:
Fig III.C.1-2
5
4.955 in
ELLIPTICAL (h = 1.06 in)
D. HOUSING
1. INITIAL ILLUSTRATION
To proceed with the gearbox design, an initial illustration, determined by other
dimensions previously designated, e.g., bearings, is provided in order to have a general
idea of the gearbox configuration. Also note that a .5 in clearance from the gear pair is
provided.
Fig III.D.1-1
Further modifications will be made according to recommended dimensions and

material selection.
2. GEARBOX DIMENSIONS
Actual gearbox dimensions are solved as follows:
GEARBOX THICKNESS
Professors Gopinath and Mayuram of the Indian Institute of Technology, Madras,
provide a rule of thumb in determining gear house thickness. 46
TABLE III.D.1-1
Wall thickness s in mm of the
gearboxes Material
Non-case hardened
gears
Case hardened gears
CI castings
0.007L + 6 mm
0.010 L + 6 mm
Steel castings
0.005L + 4 mm
0.007L + 4 mm
Welded construction
0.004L + 4 mm
0.005L + 4 mm
For this design, cast iron castings will be used. Using the empirical formula for CI
castings and case hardened gear, gearbox thickness s is determined:
s = 0.010 L + 6 mm
Where
L = largest dimension of the housing
L = 20.167 in = 532.18 mm
s = 0.010 (532.18) + 6 mm
s = 11.122 mm = .44 in
s . 45 in
46
Indian Institute of Technology, Machine Design 2, Module 2, Lecture 17
Eqn III.D.1-1
2. OTHER DIMENSIONS
Other necessary dimensions for the gearbox are as follows47:
TOP COVER THICKNESS
sc = .8s = .8 .45 in
Eqn III.D.1-2
sc = .36 in
scf = 2s = 2 .44
Eqn III.D.1-3
scf = .9 in
Eqn III.D.1-4
Dcb = 1.5s = 1.5 .44

Dcb = .675 in
Dcb = .75 in (standard)
COVER FLANGE WIDTH
Eqn III.D.1-5
Wcf = 2.5Dcb = 2.5 .75

Wcf = 1.875 in
wcs = 6Dcb = 6 .75
wcs = 4.5 in
Dfb = (1.38E-5Tg)1/3 = (1.38E-5 31809.26)1/3
Dfb = .7598 in
Dfb = .8750 in (standard)
47
Indian Institute of Technology, Machine Design 2, Module 2, Lecture 17
Eqn III.D.1-6
Eqn III.D.1-7
sff = 1.5Dfb = 1.5 .8750

sff = 1.3125 in
Eqn III.D.1-8
Wff = 2.5Dfb = 2.5 .875

Wfc = 2.1875
BEARING HOUSING DIAMETER
Bearing housing diameter on the gearbox is given by:
Dbh = 1.2Dob
Eqn III.D.1-10
Pinion
Dpbh = 1.2 3.1496
Dpbh = 3.80 in
Gear
Dgbh = 1.2 4.3307
Dgbh = 5.20 in
TABULAR SUMMARY
Summarizing the computed values of gearbox dimensions:
TABLE III.D.1-2
WALL THICKNESS
.45 in
TOP COVER THICKNESS
.36 in
.90 in
.75 in
COVER FLANGE WIDTH
1.875 in
4.5 in
.875 in
1.3125 in
2.1875 in
PINION BEARING HOUSING DIAMETER
3.80 in
GEAR BEARING HOUSING DIAMETER
5.20 in
To illustrate a general idea for the gearbox dimensions, consider the figure below. Note
that the illustration excludes the top cover and the holes.
Fig III.D.1-2
IV. RECOMMENDATIONS
1. Improve alignment upon assembly to avoid stress due to misalignment
2. Operate according to prescribed temperature determined for the temperature factor.
Properly insulate if extreme temperatures are unavoidable.
3. Apply lubricant appropriate with the operating temperature
4. Ensure case hardening is properly conducted.
5. Improve surface finish of shaft.
6. Refer to Fig III.B.3-1 for the appropriate fillet radii.
7. Also apply fillet radii on gear arm joints to avoid stress concentration.
8. Drill horizontal sluice on gearbox cover for ease of lubricant application.
9. Regular, commercially available retaining ring may be used for the unit.
10. Conduct cleaning according to the working environment of the unit.
V. APPENDIX
A. DERIVATION OF THE CONTACT RATIO FORMULA
CR = AB/Pb
AB = AB + PB
Pb = /(Pdcos)
CR = (AB + PB)/ (cos/Pd) = (AOgsin3 + BOpsin2)/(sin cos/Pd)
AOg = Rg + 1/Pd
BOp = Rp + 1/Pd
CR = ((Rg + 1/Pd)sin(180 - ( + 3)) + (rp +1/Pd)sin(180 - ( + 2)))/(sin cos/Pd)
CR = ((Rg + 1/Pd)sin(180 - - sin-1(Rgsin/(Rg + 1/Pd))) + (rp +1/Pd) sin(180- - sin-1
(Rpsin/(Rp + 1/Pd)))/(sin cos/Pd)
Note that:
= 90 +
c = Rg + Rp
Substituting these values yields a function for the contact ratio in terms of either the
pinion or the gear radius.
B. RESTRICTIONS FOR THE EMPIRICAL METHOD FOR Cmf

From ANSI/AGMA 2001-D04, clause 15.3:
The face load distribution factor accounts for the non--uniform distribution of load
across the gearing face width. The magnitude of the face load distribution factor is
defined as the peak load intensity divided by the average load intensity across the face
width.
This factor can be determined empirically or analytically. This standard provides an
empirical method only, but includes a theoretical discussion for analytical analysis in
annex D. Either method can be used, but when using the analytical approach, the
calculated load capacity of the gears should be compared with past experience since it
may be necessary to re--evaluate other rating factors to arrive at a rating consistent with
past experience. Also see AGMA 927--A01.
The empirical method requires a minimum amount of information. This method is
recommended for relatively stiff gear designs which meet the following requirements:
-- Net face width to pinion pitch diameter ratio, F/d, 2.0. (For double helical gears the
gap is not included in the face width).
-- The gear elements are mounted between bearings (see following paragraph for
overhung gears).
-- Face width up to 40 inches.
-- Contact across full face width of narrowest member when loaded.
CAUTION: If F/d > 2.4 -- 0.002Kwhere K = the contact load factor (see equation 6), the
value of Km determined by the empirical method may not be sufficiently conservative.
In this case, it may be necessary to modify the lead or profile of the gears to arrive at a
satisfactory result. The empirical method shall not be used when analyzing the effect of a
momentary overload. See 16.3.
When gear elements are overhung, consideration must be given to shaft deflections and
bearing clearances. Shafts and bearings must be stiff enough to support the bending
moments caused by the gear forces to the extent that resultant deflections do not
adversely affect the gear contact. Bearing clearances affect the gear contact in the same
way as offset straddle mounted pinions. However, gear elements with their overhang to
the same support side can compound the effect. This effect is addressed by the pinion
proportion modifying factor, Cpm. When deflections or bearing clearances exceed
reasonable limits, as determined by test or experience, an analytical method must be
used to establish the face load distribution factor.
When the gap in a double helical gear set is other than the gap required for tooth
manufacture, for example in a nested design, each helix should be treated as a single
helical set.
Designs which have high crowns to centralize tooth contact under deflected conditions
may not use this method.
This method will give results similar to those obtained in previous AGMA standards.
Designs falling outside the above F/d ranges require special consideration.
C. METALLURGICAL FACTORS FOR CARBURIZED CASE HARDENING
D. HARDNESS CONVERSION TABLE48
Hardness Conversion Chart

Rockwell
60kg
Brale
Rockwell Superficial
100kg
100kg
150kg 100kg
1/16"
1/8"
Brale Brale
Ball
Ball
Brinell
Vickers
Shore
15-N
30-N
45-N
30-T
3000 kg
500 kg
136
60kg
1/16"
Ball
15kg
Brale
30kg
Brale
45kg
Brale
30 kg
1/16"
Ball
10mm
Ball
Steel
10mm
Ball Steel
Diamond
Pyramid
Scieroscope
Approx
Tensile
Strength
(psi)
86.5
---
70
78.5
---
---
94.0
86.0
77.6
---
---
---
1076
101
---
86.0
---
69
77.7
---
---
93.5
85.0
76.5
---
---
---
1044
99
---
85.6
---
68
76.9
---
---
93.2
84.4
75.4
---
---
---
940
97
---
85.0
---
67
76.1
---
---
92.9
83.6
74.2
---
---
---
900
95
---
84.5
---
66
75.4
---
---
92.5
82.8
73.2
---
---
---
865
92
---
83.9
---
65
74.5
---
---
92.2
81.9
72.0
---
739
---
832
91
---
83.4
---
64
73.8
---
---
91.8
81.1
71.0
---
722
---
800
88
---
82.8
---
63
73.0
---
---
91.4
80.1
69.9
---
705
---
772
87
---
82.3
---
62
72.2
---
---
91.1
79.3
68.8
---
688
---
746
85
---
81.8
---
61
71.5
---
---
90.7
78.4
67.7
---
670
---
720
83
---
81.2
---
60
70.7
---
---
90.2
77.5
66.6
---
654
---
697
81
320,000
80.7
---
59
69.9
---
---
89.8
76.6
65.5
---
634
---
674
80
310,000
80.1
---
58
69.2
---
---
89.3
75.7
64.3
---
615
---
653
78
300,000
79.6
---
57
68.5
---
---
88.9
74.8
63.2
---
595
---
633
76
290,000
79.0
---
56
67.7
---
---
88.3
73.9
62.0
---
577
---
613
75
282,000
78.5
120
55
66.9
---
---
87.9
73.0
60.9
---
560
---
595
74
274,000
78.0
120
54
66.1
---
---
87.4
72.0
59.8
---
543
---
577
72
266,000
77.4
119
53
65.4
---
---
86.9
71.2
58.6
---
525
---
560
71
257,000
76.8
119
52
64.6
---
---
86.4
70.2
57.4
---
500
---
544
69
245,000
76.3
118
51
63.8
---
---
85.9
69.4
56.1
---
487
---
528
68
239,000
75.9
117
50
63.1
---
---
85.5
68.5
55.0
---
475
---
513
67
233,000
75.2
117
49
62.1
---
---
85.0
67.6
53.8
---
464
---
498
66
227,000
74.7
116
48
61.4
---
---
84.5
66.7
52.5
---
451
---
484
64
221,000
74.1
116
47
60.8
---
---
83.9
65.8
51.4
---
442
---
471
63
217,000
48
Carbide Depot, https://www.carbidedepot.com/formulas-hardness.htm
73.6
115
46
60.0
---
---
83.5
64.8
50.3
---
432
---
458
62
212,000
73.1
115
45
59.2
---
---
83.0
64.0
49.0
---
421
---
446
60
206,000
72.5
114
44
58.5
---
---
82.5
63.1
47.8
---
409
---
434
58
200,000
72.0
113
43
57.7
---
---
82.0
62.2
46.7
---
400
---
423
57
196,000
71.5
113
42
56.9
---
---
81.5
61.3
45.5
---
390
---
412
56
191,000
70.9
112
41
56.2
---
---
80.9
60.4
44.3
---
381
---
402
55
187,000
70.4
112
40
55.4
---
---
80.4
59.5
43.1
---
371
---
392
54
182,000
69.9
111
39
54.6
---
---
79.9
58.6
41.9
---
362
---
382
52
177,000
69.4
110
38
53.8
---
---
79.4
57.7
40.8
---
353
---
372
51
173,000
68.9
110
37
53.1
---
---
78.8
56.8
39.6
---
344
---
363
50
169,000
68.4
109
36
52.3
---
---
78.3
55.9
38.4
---
336
---
354
49
165,000
67.9
109
35
51.5
---
---
77.7
55.0
37.2
---
327
---
345
48
160,000
67.4
108
34
50.8
---
---
77.2
54.2
36.1
---
319
---
336
47
156,000
66.8
108
33
50.0
---
---
76.6
53.3
34.9
---
311
---
327
46
152,000
66.3
107
32
49.2
---
---
76.1
52.1
33.7
---
301
---
318
44
147,000
65.8
106
31
48.4
---
---
75.6
51.3
32.5
---
294
---
310
43
144,000
65.3
105
30
47.7
---
---
75.0
50.4
31.3
---
286
---
302
42
140,000
64.7
104
29
47.0
---
---
74.5
49.5
30.1
---
279
---
294
41
137,000
64.3
104
28
46.1
---
---
73.9
48.6
28.9
---
271
---
286
41
133,000
63.8
103
27
45.2
---
---
73.3
47.7
27.8
---
264
---
279
40
129,000
63.3
103
26
44.6
---
---
72.8
46.8
26.7
---
258
---
272
39
126,000
62.8
102
25
43.8
---
---
72.2
45.9
25.5
---
253
---
266
38
124,000
62.4
101
24
43.1
---
---
71.6
45.0
24.3
---
247
---
260
37
121,000
62.0
100
23
42.1
---
---
71.0
44.0
23.1
82.0
240
201
254
36
118,000
61.5
99
22
41.6
---
---
70.5
43.2
22.0
81.5
234
195
248
35
115,000
61.0
98
21
40.9
---
---
69.9
42.3
20.7
81.0
228
189
243
35
112,000
60.5
97
20
40.1
---
---
69.4
41.5
19.6
80.5
222
184
238
34
109,000
59.0
96
18
---
---
---
---
---
---
80.0
216
179
230
33
106,000
58.0
95
16
---
---
---
---
---
---
79.0
210
175
222
32
103,000
57.5
94
15
---
---
---
---
---
---
78.5
205
171
213
31
100,000
57.0
93
13
---
---
---
---
---
---
78.0
200
167
208
30
98,000
56.5
92
12
---
---
---
---
---
---
77.5
195
163
204
29
96,000
56.0
91
10
---
---
---
---
---
---
77.0
190
160
196
28
93,000
55.5
90
---
---
---
---
---
---
76.0
185
157
192
27
91,000
55.0
89
---
---
---
---
---
---
75.5
180
154
188
26
88,000
54.0
88
---
---
---
---
---
---
75.0
176
151
184
26
86,000
53.5
87
---
---
---
---
---
---
74.5
172
148
180
26
84,000
53.0
86
---
---
---
---
---
---
74.0
169
145
176
25
83,000
52.5
85
---
---
---
---
---
---
73.5
165
142
173
25
81,000
52.0
84
---
---
---
---
---
---
73.0
162
140
170
25
79,000
51.0
83
---
---
---
---
---
---
72.0
159
137
166
24
78,000
50.5
82
---
---
---
---
---
---
71.5
156
135
163
24
76,000
50.0
81
---
---
---
---
---
---
71.0
153
133
160
24
75,000
49.5
80
---
---
---
---
---
---
---
70.0
150
130
---
---
73,000
49.0
79
---
---
---
---
---
---
---
69.5
147
128
---
---
---
48.5
78
---
---
---
---
---
---
---
69.0
144
126
---
---
---
48.0
77
---
---
---
---
---
---
---
68.0
141
124
---
---
---
47.0
76
---
---
---
---
---
---
---
67.5
139
122
---
---
---
46.5
75
---
---
---
99.5
---
---
---
67.0
137
120
---
---
---
46.0
74
---
---
---
99.0
---
---
---
66.0
135
118
---
---
---
45.5
73
---
---
---
98.5
---
---
---
65.5
132
116
---
---
---
45.0
72
---
---
---
98.0
---
---
---
65.0
130
114
---
---
---
44.5
71
---
---
100.0
97.5
---
---
---
64.2
127
112
---
---
---
44.0
70
---
---
99.5
97.0
---
---
---
63.5
125
110
---
---
---
43.5
69
---
---
99.0
96.0
---
---
---
62.8
123
109
---
---
---
43.0
68
---
---
98.0
95.5
---
---
---
62.0
121
107
---
---
---
42.5
67
---
---
97.5
95.0
---
---
---
61.4
119
106
---
---
---
42.0
66
---
---
97.0
94.5
---
---
---
60.5
117
104
---
---
---
41.8
65
---
---
96.0
94.0
---
---
---
60.1
116
102
---
---
---
41.5
64
---
---
95.5
93.5
---
---
---
59.5
114
101
---
---
---
41.0
63
---
---
95.0
93.0
---
---
---
58.7
112
99
---
---
---
40.5
62
---
---
94.5
92.0
---
---
---
58.0
110
98
---
---
---
40.0
61
---
---
93.5
91.5
---
---
---
57.3
108
96
---
---
---
39.5
60
---
---
93.0
91.0
---
---
---
56.5
107
95
---
---
---
39.0
59
---
---
92.5
90.5
---
---
---
55.9
106
94
---
---
---
38.5
58
---
---
92.0
90.0
---
---
---
55.0
104
92
---
---
---
38.0
57
---
---
91.0
89.5
---
---
---
54.6
102
91
---
---
---
37.8
56
---
---
90.5
89.0
---
---
---
54.0
101
90
---
---
---
37.5
55
---
---
90.0
88.0
---
---
---
53.2
99
89
---
---
---
37.0
54
---
---
89.5
87.5
---
---
---
52.5
---
87
---
---
---
36.5
53
---
---
89.0
87.0
---
---
---
51.8
---
86
---
---
---
36.0
52
---
---
88.0
86.5
---
---
---
51.0
---
85
---
---
---
35.5
51
---
---
87.5
86.0
---
---
---
50.4
---
84
---
---
---
35.0
50
---
---
87.0
85.5
---
---
---
49.5
---
83
---
---
---
34.8
49
---
---
86.5
85.0
---
---
---
49.1
---
82
---
---
---
34.5
48
---
---
85.5
84.5
---
---
---
48.5
---
81
---
---
---
34.0
47
---
---
85.0
84.0
---
---
---
47.7
---
80
---
---
---
33.5
46
---
---
84.5
83.0
---
---
---
47.0
---
79
---
---
---
33.0
45
---
---
84.0
82.5
---
---
---
46.2
---
79
---
---
---
32.5
44
---
---
83.5
82.0
---
---
---
45.5
---
78
---
---
---
32.0
43
---
---
82.5
81.5
---
---
---
44.8
---
77
---
---
---
31.5
42
---
---
82.0
81.0
---
---
---
44.0
---
76
---
---
---
31.0
41
---
---
81.5
80.5
---
---
---
43.4
---
75
---
---
---
30.8
40
---
---
81.0
79.5
---
---
---
43.0
---
74
---
---
---
30.5
39
---
---
80.0
79.0
---
---
---
42.1
---
74
---
---
---
30.0
38
---
---
79.5
78.5
---
---
---
41.5
---
73
---
---
---
29.5
37
---
---
79.0
78.0
---
---
---
40.7
---
72
---
---
---
29.0
36
---
---
78.5
77.5
---
---
---
40.0
---
71
---
---
---
28.5
35
---
---
78.0
77.0
---
---
---
39.3
---
71
---
---
---
28.0
34
---
---
77.0
76.5
---
---
---
38.5
---
70
---
---
---
27.8
33
---
---
76.5
75.5
---
---
---
37.9
---
69
---
---
---
27.5
32
---
---
76.0
75.0
---
---
---
37.5
---
68
---
---
---
27.0
31
---
---
75.5
74.5
---
---
---
36.6
---
68
---
---
---
26.5
30
---
---
75.0
74.0
---
---
---
36.0
---
67
---
---
---
26.0
29
---
---
74.0
73.5
---
---
---
35.2
---
66
---
---
---
25.5
28
---
---
73.5
73.0
---
---
---
34.5
---
66
---
---
---
25.0
27
---
---
73.0
72.5
---
---
---
33.8
---
65
---
---
---
24.5
26
---
---
72.5
72.0
---
---
---
33.1
---
65
---
---
---
24.2
25
---
---
72.0
71.0
---
---
---
32.4
---
64
---
---
---
24.0
24
---
---
71.0
70.5
---
---
---
32.0
---
64
---
---
---
23.5
23
---
---
70.5
70.0
---
---
---
31.1
---
63
---
---
---
23.0
22
---
---
70.0
69.5
---
---
---
30.4
---
63
---
---
---
22.5
21
---
---
69.5
69.0
---
---
---
29.7
---
62
---
---
---
22.0
20
---
---
68.5
68.5
---
---
---
29.0
---
62
---
---
---
21.5
19
---
---
68.0
68.0
---
---
---
28.1
---
61
---
---
---
21.2
18
---
---
67.5
67.0
---
---
---
27.4
---
61
---
---
---
21.0
17
---
---
67.0
66.5
---
---
---
26.7
---
60
---
---
---
20.5
16
---
---
66.5
66.0
---
---
---
26.0
---
60
---
---
---
20.0
15
---
---
65.5
65.5
---
---
---
25.3
---
59
---
---
---
---
14
---
---
65.0
65.0
---
---
---
24.6
---
59
---
---
---
---
13
---
---
64.5
64.5
---
---
---
23.9
---
58
---
---
---
---
12
---
---
64.0
64.0
---
---
---
23.5
---
58
---
---
---
---
11
---
---
63.5
63.5
---
---
---
22.6
---
57
---
---
---
---
10
---
---
62.5
63.0
---
---
---
21.9
---
57
---
---
---
---
---
---
62.0
62.0
---
---
---
21.2
---
56
---
---
---
---
---
---
61.5
61.5
---
---
---
20.5
---
56
---
---
---
---
---
---
61.0
61.0
---
---
---
19.8
---
56
---
---
---
---
---
---
60.5
60.5
---
---
---
19.1
---
55
---
---
---
---
---
---
60.0
60.0
---
---
---
18.4
---
55
---
---
---
---
---
---
59.0
59.5
---
---
---
18.0
---
55
---
---
---
---
---
---
58.5
59.0
---
---
---
17.1
---
54
---
---
---
---
---
---
58.0
58.0
---
---
---
16.4
---
54
---
---
---
---
---
---
57.5
57.5
---
---
---
15.7
---
53
---
---
---
---
---
---
57.0
57.0
---
---
---
15.0
---
53
---
---
---
E. SELECTED BEARING CATALOG

Pinion
Gear
F. FITS AND TOLERANCE CHARTS

CLEARANCE FITS
FORCE FITS
F. SELECTED COUPLING CATALOG

Gear Speed Reducer

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NEW ERA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

GEAR REDUCER DESIGN

I. DESIGN PROBLEM AND DESIGN SPECIFICATIONS

AISI 6150 OQT 400

AISI 6150 OQT 400

Approx 634 HB or 59 HRC

Approx 670 HB or 61 HRC

ALLOWABLE STRESS NUMBERS:

ALLOWABLE BENDING STRESS NUMBER

STRESS CYCLE FACTOR

BENDING STRESS NUMBER

STRESS CYCLE FACTOR

BENDING STRESS NUMBER

NUMBER OF GEAR TEETH, Ng

PITCH LINE VELOCITY, v

BASE CIRCLE DIAMETER (PINION)

BASE CIRCLE DIAMETER (GEAR)

ULTIMATE TENSILE STRENGTH

NUP 2208 ECP

ULTIMATE TENSILE STRENGTH

3. RIM AND ARMS

AISI 6150 OQT 400

TOP COVER THICKNESS

COVER FLANGE THICKNESS

COVER FLANGE BOLT DIAMETER

COVER FLANGE WIDTH

COVER FLANGE BOLT SPACING

FOUNDATION FLANGE BOLT DIAMETER

FOUNDATION FLANGE THICKNESS

FOUNDATION FLANGE WIDTH

PINION BEARING HOUSING DIAMETER

GEAR BEARING HOUSING DIAMETER

II. DESIGN SKETCH/ILLUSTRATION

Dg = 5Np = 5(18 + N)/6

Summarizing the values for N until C 9.50 in

. ANSI/AGMA 2001-D04, Clause 1.2

Kinematics and Dynamics of Machines, Martin, 2 ed., p. 251

Eqn III.A.1-22 has to be modified in anticipation of a hunting tooth. Considering the

PITCH LINE VELOCITY

BASE CIRCLE DIAMETER

NUMBER OF PINION TEETH, Np

NUMBER OF GEAR TEETH, Ng

PITCH LINE VELOCITY, v

BASE CIRCLE DIAMETER (PINION)

BASE CIRCLE DIAMETER (GEAR)

2. TORQUE AND FORCES

Machine Elements in Mechanical Design, Mott, 4 ed., p. 389

ANSI/AGMA 2001-D04, Appendix A

ANSI/AGMA 2001-D04, clause 20.2

LOAD DISTRIBUTION FACTOR Km

ANSI/AGMA 2001-D04, Fig 5

ANSI/AGMA 2001-D04, Fig 6

ANSI/AGMA 2001-D04, Fig 7

ANSI/AGMA 2001/D04, Fig B.1

Machine Elements in Mechanical Design, Mott, 4 ed., p. 389

Stg = 56750.78 psi

ANSI/AGMA 2001-D04, clause 18

In which N shall be determined by the formula

or approx 5 years for 8-hour continuous, daily

operation) given by the TABLE III.A.3-515.

Machine Elements in Mechanical Design, Mott, 4 ed., p. 396

Satp 70303.20 (1.0 1.0 1.00/.94)

STRESS CYCLE FACTOR