SECTION 11 SPUR GEARS

INTERMITTENT SERVICE

DESIGN PROBLEMS

631. A pair of gears with 20o full-depth teeth are to transmit 10 hp at 1750 rpm of the
3-in. pinion; velocity ratio desired is about 3.8; intermittent service. Use a
strength reduction factor of about 1.4, with theload at the tip and teeth
commercially cut. Determine the pitch, face width, and tooth numbers if the
material is cast iron, class 20.

Solution:
D p n p (3)(1750)
vm = = = 1374 fpm < 2000 fpm
12 12
10 hp < 20 hp
Commercially cut gears, vm < 2000 fpm
600 + vm
Fd = Ft
600
33,000hp 33,000(10 )
Ft = = = 240 lb
vm 1374
600 + 1374
Fd = (240) = 790 lb
600

sbY
Fs =
K f Pd
For cast-iron, class 20, sn = 0.4 su
s = 0.4(20 ) = 8 ksi = 8000 psi

K f = 1 .4
10
assume b =
Pd
Table AT 24, Load at tip, 20o F.D.
Assume Y = 0.33

Fs = Fd
(8000)(10)(0.33) = 790
(1.4)Pd2
Pd = 4.89
use Pd = 5
N p = Pd D p = (5)(3) = 15
Y = 0.289

Page 1 of 57
 SECTION 11 SPUR GEARS

Fs = Fd
(8000)(b )(0.33) = 790
(1.4)(5)
b = 2.4 in
8 12.5
<b<
Pd Pd
use
12.5 12.5
b= = = 2.5 in
Pd 5
1
b = 2 in
2

Summary of answers:
Pd = 5
1
b = 2 in
2
N p = 15
N g = 3.8(15) = 57

633. A pair of gears with 20o full-depth teeth are to transmit 5 hp at 1800 rpm of the
pinion; mw = 2.5 ; N p = 18 teeth; commercially cut teeth; intermittent service;
K f 1.45 . (a) Determine the pitch, face width, and tooth numbers if the material
is cast iron, class 25. (b) The same as (a) except that the pinion is to be made of
phosphor gear bronze (SAE 65, Table AT 3).

Solution:

Load at tip, Table AT 24, 20o F.D.

N p = 18 , Y = 0.308
N g = (2.5)(18) = 45 , Y = 0.399

D p n p
vm =
12
N p 18
Dp = =
Pd Pd
n p = 1800 rpm
(18)(1800 )
2700
vm = =
12 Pd Pd
Commercially cut teeth

Page 2 of 57
 SECTION 11 SPUR GEARS

600 + vm
Fd = Ft
600
33,000(5) 550 Pd
Ft = =
2700 9
Pd
2700 8482.3
600 + 600 +
Pd 550 Pd Pd
Fd = = (19.4523Pd )
600 9 600

14.1372
Fd = 19.4523Pd 1 +
Pd
sbY
Fs =
K f Pd
10
assume b =
Pd
(a) Cast iron, class 25,
sn = 0.4su = 0.4(25) = 10 ksi = 10,000 psi
Fs = Fd
Pinion is weaker
(10,000)(10)(0.308) = 19.4523P 1 + 14.1372
d
(1.45)(Pd )2 Pd
21,241 14.1372
2
= 19.4523Pd 1 +
Pd Pd
Pd = 7.16
use Pd = 7

Face width b
(10,000 )(b )(0.308) = 19.4523(7 ) 1 + 14.1372
(1.45)(7 ) 7
b = 1.355 in
8 12.5
<b<
Pd Pd
1.143 < b < 1.786
say b = 1.5 in
Summary of answers:
Pd = 7
1
b = 1 in
2

Page 3 of 57
 SECTION 11 SPUR GEARS

N p = 18
N g = 45

(b) Phosphor gear bronze , (SAE 65, Table AT 3)

su = 80 ksi
sn = 0.4su = 0.4(80) = 32 ksi
or sn = 31 ksi (Table AT 3)
use sn = 31 ksi

Pinion, bronze
sY = (31,000)(0.308) = 9548
Gear, cast iron
sY = (10,000)(0.399) = 3990

Therefore gear is weaker

(10,000)(10)(0.399) = 19.4523P 1 + 14.1372
d
(1.45)(Pd )2 Pd
27,517 14.1372
2
= 19.4523Pd 1 +
Pd Pd
Pd = 8
use Pd = 8

Face width b
(10,000 )(b )(0.399) = 19.4523(8) 1 + 14.1372
(1.45)(8) 8
b = 1.252 in
8 12.5
<b<
Pd Pd
1 < b < 1.5625
1
say b = 1.25 in = 1 in
4
Summary of answers:
Pd = 8
1
b = 1 in
4
N p = 18
N g = 45

Page 4 of 57
 SECTION 11 SPUR GEARS

634. It is desired to transmit 120 hp at 1800 rpm of the pinion; intermittent service;
with light shock (13.18); preferably not less than 18, 20o-full-depth teeth on the
pinion; K f = 1.5 should be conservative; mw = 1.5 . Decisions must be made
concerning the material and quality of cutting the teeth. Since the design is for
strength only, it will be convenient to express Ft , Fd , vm , b in terms of Pd and
arrange an equation containing s and Pd convenient for iteration. Weak material
results in a relatively large pinion with high peripheral speed. A very strong
material may be unnecessarily expensive. On a production basesm carefully cut
teeth should have a reasonable cost. Specify material, accuracy of cutting, pitch,
face width, and tooth numbers.

Solution:
N 18
Dp = p =
Pd Pd
18
(1800)
D p n p Pd 8482.3
vm = = =
12 12 Pd
33,000hp 33,000(120 )
Ft = = = 466.85Pd
vm 8482.3
Pd
120 hp > 20 hp
use Buckinghams equation
0.05vm (Cb + Ft )
Fd = Ft + 1
0.05vm + (Cb + Ft )2
Assume a material of steel, as rolled AISI 1050,
su = 102 ksi
For carefully cut teeth, Fig. AF 20, e = 0.001 in (min.)
Table AT 25, steel on steel, 20o F.D.
C = 1660

10
Try b =
Pd
8482.3 10
0.05 1660 + 466.85 Pd
Pd Pd
Fd = 466.85Pd + 1
2
8482.3 10
0.05 + 1660 + 466.85Pd
Pd Pd

Page 5 of 57
 SECTION 11 SPUR GEARS

424 16,600
+ 466.85Pd
Pd Pd
Fd = 466.85Pd + 1
2
424 16,600
+ + 466.85Pd
Pd Pd
sbY
Fs =
K f Pd
Weak pinion
Table AT 24, N p = 18 , Y = 0.522 (Load near middle, 20o F.D.)
s = 0.5su = 0.5(102) = 51 ksi = 51,000 psi
K f = 1 .5
10
(51,000) (0.522)
Pd 177,480
Fs = =
(1.5)Pd Pd2
Fs = N sf Fd
(13.18), light shock, N sf = 1.25

Iteration:
Pd Fd Fs N sf ( 1.25)
5 5331 7099 1.33
4 5342 11093 2.08

Use Pd = 5
10 10
b= = = 2 in
Pd 5
N p = 18
Ng
= mw
Np
N g = (1.5)(18) = 27
Summary of first computation
Material, AISI 1050, as rolled
Accurately cut gears
Pd = 5
b = 2.0 in
N p = 18
N g = 27

Page 6 of 57
 SECTION 11 SPUR GEARS

CHECK PROBLEMS

636. A pair of carefully cut, full depth, 20o involute gears, made of cast iron, ASTM
30, is transmitting 5 hp at 1150 rpm of the pinion; N p = 24 , N g = 32 , Pd = 8 ,
1
b = 1 in . For the teeth, determine (a) the endurance , (b) the dynamic load, (c)
2
the service factor (13.18).

Solution: 5 hp < 20 hp
N p = 24 , 20o F.D.
Y = 0.337 , Load at tip
assume K f = 1.45 average

sbY
(a) Fs =
K f Pd
cast-iron, s = 0.4su = 0.4(30) = 12 ksi = 12,000 psi

Fs =
(12,000)(1.5)(0.337 ) = 523 lb
(1.45)(8)
1200 + vm
(b) Fd = Ft
1200
For carefully cut gears
D p n p
vm =
12
N 24
Dp = p = = 3 in
Pd 8
n p = 1150 rpm
(3)(1150)
vm = = 903.2 fpm
12
33,000hp 33,000(5)
Ft = = = 182.7 lb
vm 903.2
1200 + vm 1200 + 903.2
Fd = Ft = (182.7 ) = 320 lb
1200 1200

Fs 523
(c) N sf = = = 1.63
Fd 320

637. A manufacturers catalog for cut-tooth spur gears rates a 25-tooth, cast-iron
(ASTM 25) pinion with 5-pitch, 20o full-depth involute teeth at 16.5 hp at 900

Page 7 of 57
 SECTION 11 SPUR GEARS

1
rpm; b = 2 in and mg = 2 ; let K f = 1.5 ; intermittent service; smooth load. (a)
2
What horsepower may these gears transmit? Do you consider the catalog rating
too high or too low? (b) The same as (a) except that the teeth are carfully cut. (c)
The same as (a) except that the pinion is to be made of phosphor bronze (SAE 65,
Table AT 3).

Solution:
16.5 hp < 20 hp
D p n p
vm =
12
N p 25
Dp = = = 5 in
Pd 5
n p = 900 rpm
(5)(900)
vm = = 1178 fpm
12

(a) Using commercially cut.

600 + vm
Fd = Ft , vm 2000 fpm
600

Table AT 24, Load at tip, 20o F.D.

N p = 25 , Y = 0.340
N g = mg N p = 2(25) = 50 , Y = 0.408
use Y = 0.340 , weaker pinion

Cast iron, s = 0.4su = 0.4(30) = 12 ksi = 12,000 psi

K f = 1 .5
Pd = 5
1
b = 2 in
2
sbY
Fs =
K f Pd

Fs =
(12,000)(2.5)(0.340) = 1360 lb
(1.5)(5)
Fs = N sf Fd
smooth load, N sf = 1
600 + 1178
1360 = (1) Ft
600
Ft = 459 lb

Page 8 of 57
 SECTION 11 SPUR GEARS

hp =
Ft vm
=
(459)(1178) = 16.4 hp
33,000 33,000
The rating is not too low or too high.

(b) Carefully cut, [1000 fpm < vm < 4000 fpm]

1200 + vm
Fd = Ft
1200
Fs = N sf Fd
1200 + 1178
1360 = (1) Ft
1200
Ft = 686 lb

hp =
Ft vm
=
(686)(1178) = 24.5 hp
33,000 33,000

(c) Phosphor bronze, (SAE 65, Table AT 3)

sn = 24 ksi = 24,000 psi

Pinion
sY = (24,000 )(0.340) = 8160
Gear
sY = (12,000)(0.408) = 4896
Therefore , gear is weaker
sbY
Fs =
K f Pd

Fs =
(12,000)(2.5)(0.408) = 1632 lb
(1.5)(5)
Fs = N sf Fd
600 + 1178
1632 = (1) Ft
600
Ft = 551 lb

hp =
Ft vm
=
(551)(1178) = 19.7 hp
33,000 33,000

638. A pair of commercially cut spur gears transmits 10 hp at 1750 rpm of the 25-
tooth pinion. The teeth are 20o full depth with 6 pitch; material , cast iron, class
9
30; face width is 1 in .; N g = 40 . Allow for stress concentration. (a) Compute
16

Page 9 of 57
 SECTION 11 SPUR GEARS

the service factor for the teeth (13.18). (b) If the drive is for a single-cylinder
compressor, would carefully cut teeth be advisable? Show calculations.

Solution:
10 hp < 20 hp

Np 25
Dp = = = 4.167 in
Pd 6
D p n p
vm =
12
(4.167 )(1750)
vm = = 1909 fpm
12

For commercially cut gears

600 + vm
Fd = Ft
600
33,000hp 33,000(10 )
Ft = = = 173 lb
vm 1909
600 + 1909
Fd = (173) = 723.4 lb
600
sbY
Fs =
K f Pd
Assume K f = 1.45 , average, load near tip
Table AT 24, 20o F.D.
N p = 25 , Y = 0.340

Cast iron, s = 0.4su = 0.4(30) = 12 ksi = 12,000 psi

(12,000) 1 9 (0.340)
16
Fs = = 732.8 lb
(1.45)(6)
Fs 732.8
(a) N sf = = 1 .0
Fd 723.4
(b) Carefully cut gears
1200 + vm 1200 + 1909
Fd = Ft = (173) = 448.2 lb
1200 1200
F 732.8
N sf = s = = 1.635
Fd 448.2
(13.18) Single-cylinder compressore
1.5 < N sf < 1.75

Page 10 of 57
 SECTION 11 SPUR GEARS

1.5 < 1.635 < 1.75

Therefore advisable.

CONTINUOUS SERVICE

DESIGN PROBLEMS

NOTE: When using Buckinghams Fd equation and a K f is used, as intended in design

for continuous service, use Y for load near middle.

639. The pinion of a pair of steel gears, transmitting 110 hp at 2300 rpm, is to have a
1
diameter of about 4 in .; mg 2.3 ; 20o full-depth teeth; the drive is to a
3
centrifugal pump, continuous service. (a) Decide upon Pd , b , N p , N g , and the
material to be used. Consider the strength with the load near the middle of the
profile. (b) The same as (a) except that it is not expected that the maximum
loading will occur for more than 107 cycles, can you justify changes in your
previous answers?

Solution:
110 hp > 20 hp
1
D p = 4 in
3
n p = 2300 rpm
1
D p n p
4 (2300)
3
vm = = = 2609 fpm
12 12
33,000hp 33,000(110 )
Ft = = = 1391 lb
vm 2609
0.05vm (Cb + Ft )
Fd = Ft + 1
0.05vm + (Cb + Ft )2
Fig. AF 19, vm = 2609 fpm
Maximum permissible error = 0.0012 in
Fig. AF 20
Use carefully cut gears
Expected errors = 0.001 in
Table AT 25, steel on steel, 20o F.D.
C = 1660
10
Try b =
Pd

Page 11 of 57
 SECTION 11 SPUR GEARS

10
0.05(2609) 1660 + 1391
Pd
Fd = 1391 + 1
2
10
0.05(2609) + 1660 + 1391
Pd
16600
130.45 + 1391
Pd
Fd = 1391 + 1
2
16600
130.45 + + 1391
Pd
Wear Load
Fw = D pbQK g
2m g 2(2.3)
Q= = = 1.394
mg + 1 2 .3 + 1
with Pd = 5 , Fd = 4478 lb
Pd = 4 , Fd = 4919 lb

1 10
Pd = 5 , Fw = 4 (1.394)K g = 4478
3 5
K g = 371

1 10
Pd = 4 , Fw = 4 (1.394)K g = 4919
3 4
K g = 326

Table AT 26, 20o F.D.

Use sum of BHN = 800. K g = 366

1 10
Fw = 4 (1.394)(366) = 22,109
3 Pd Pd
Iteration: Fw Fd
Pd Fd Fw
5 4478 4422
4 4919 5527

8 12.5
Use Pd = 5 , <b<
Pd Pd
1.6 in < b < 2.5 in
use b = 2.5 in

Page 12 of 57
 SECTION 11 SPUR GEARS

To check for strength

sbY
Fs =
K f Pd
1
Load near middle, N p = Pd D p = (5) 4 = 21.67
3
N g = mg N p = (2.3)(21.67 ) = 49.84
use N g = 50 , N p = 22
D p = 4.4 in
50
Dg = = 10 in
5
For s , average BHN = 400

Use 8630 WQT 800 F, BHN = 375 gear

2330 WQT 600 F, BHN = 429 pinion

Sum of BHN = 375 + 429 = 804 800

Table AT 24, Load near middle, 20o F.D.

N p = 22 Y = 0.559
N g = 50 Y = 0.694

Pinion: s = 250(429) = 107,250 psi

sY = (107,250)(0.559) = 59,953 psi
Gear: s = 250(375) = 93,750 psi
sY = (93,750)(0.694) = 65,062 psi

Pinion is weaker
Fs =
sbY
=
(59,953)(2.5) = 17,633 lb > F
d
K f Pd (1.7)(5)
Summary of answer:
Pd = 5
b = 2.5 in
N p = 22
N g = 50
Material:
Pinion: 2330 WQT 600 F, BHN = 429
Gear: 8630 WQT 800 F, BHN = 375

(b) For 107 cycles

Page 13 of 57
 SECTION 11 SPUR GEARS

Tables AT 26, K g =< 306 for the less stronger material available, therefore cant be
justify to change the previous answer. ( N p will become less than minimum). Using
stronger material is expensive.

640. A pinion with 20o full-depth teeth, transmitting 60 hp at 2400 rpm, is part of a
gear reduction for a lobeblower. It is to be about 3.2 in. in diameter; mg 1.56 .
(a) Decide upon a material for the mating gears (and its treatment), Pd , b , N p ,
and N g . Determine the strength with the load near the middle of the profile. (b)
The same as (a), except that the maximum loading will occur for no more than
107 cycles.

Solution:
D p = 3.2 in
n p = 2400 rpm
D p n p (3.2)(2400)
vm = = = 2011 fpm
12 12
33,000hp 33,000(160 )
Ft = = = 2626 lb
vm 2011
160 hp > 20 hp
0.05vm (Cb + Ft )
Fd = Ft + 1
0.05vm + (Cb + Ft )2
Fig. AF 19, vm = 2011 fpm
Maximum permissible error = 0.0015 in
Fig. AF 20
carefully cut gears
Expected errors = 0.001 in
Table AT 25, steel on steel, 20o F.D.
C = 1660
10
Try b =
Pd
10
0.05(2011) 1660 + 2626
Pd
Fd = 2626 + 1
2
10
0.05(2011) + 1660 + 2626
Pd

Page 14 of 57
 SECTION 11 SPUR GEARS

16600
100.55 + 2626
Pd
Fd = 2626 + 1
2
16600
100.55 + + 2626
Pd
Fw = D pbQK g
2m g 2(1.56 )
Q= = = 1.22
m g + 1 1.56 + 1
10 39.04 K g
Fw = (3.2) (1.22)K g =
Pd Pd

Fw = Fd
For Pd = 5
Fd = 5991 lb
39.04 K g
Fw = = 5991
5
K g = 767
For Pd = 4
Fd = 6532 lb
39.04 K g
Fw = = 6532
4
K g = 651

Table AT 26,
Use Steel (600), carburized case hardened, and same 1010 cycles, 20o F.D.
K g = 750

10
Using Pd = 5 , b = = 2 in
5
1
Say b = 2 in
2

To check for strength

sn = 250 BHN = 250(600) = 150,000 psi

Table AT 24, Load near middle

N p = Pd D p = (5)(3.2 ) = 16 Y = 0.503
N g = mg N p = (1.56 )(16 ) = 25 Y = 0.580

Page 15 of 57
 SECTION 11 SPUR GEARS

assume K f = 1.7

Fs =
sbY
=
(150,000)(2.5)(0.503) = 22,191 lb > F
d
K f Pd (1.7)(5)
Summary of answer:
Pd = 5
b = 2.5 in
N p = 16
N g = 25

(b) 107 cycles

Table AT 26, K g = 1680

39.04(1680 ) 65,587
Fw = =
Pd Pd

Iteration: Fw Fd
Pd Fd Fw
7 5560 9370
8 5421 8198
9 5311 7287
10 5222 6559
11 5148 5962
12 5086 5466
13 5033 5045

Use Pd = 13
10
b = in
13
N p = D p Pd = (3.2 )(13) = 42 , Y = 0.667

To check for strength

Fs =
sbY
=
(150,000)(10)(0.667) = 3482 lb < F
d
K f Pd (1.7)(13)2
Therefore use Fs N sf Fd
For lobe blower, 1.25 < N sf < 1.5
Assume Y = 0.50

Page 16 of 57
 SECTION 11 SPUR GEARS

Fs =
sbY
=
(150,000)(10)(0.50) = 441,177
K f Pd (1.7 )(Pd )2 Pd2
Iteration:
Pd Fs Fd N sf
7 9004 5560 1.619
8 6894 5421 1.272>1.25

Use Pd = 8
10 10
b= = = 1.25 in
Pd 8
N p = Pd D p = (8)(3.2 ) = 25.6 say 26
N g = mg N p = (1.56 )(25.6 ) = 40
Summary of answer:
Pd = 8
1
b = 1 in
4
N p = 26
N g = 40

641. Gears with 20o full-depth teeth are to transmit 100 hp continuously at 5000 rpm
with mg = 4 ; pinion D p = 3 in. ; the drive is subjected to minor shocks with
frequent starts. First calculations are to be made for carburized pinion teeth of
AISI E3310, SOQT 450F, and the gear of cast steel, SAE 0175, WQT. Decide
upon Pd , b , N p , and N g .

Solution:
D p n p (3)(5000)
vm = = = 3927 fpm
12 12
Fig. AF 19, max. per/ error. e = 0.00075 in
Use precision gears, error, e = 0.0005 in
Table AT 25, steel on steel, 20o F.D.
C = 0.5(1660) = 830
33,000hp 33,000(100 )
Ft = = = 840 lb
vm 3927
10
b=
Pd
0.05vm (Cb + Ft )
Fd = Ft + 1
0.05vm + (Cb + Ft )2

Page 17 of 57
 SECTION 11 SPUR GEARS

10
0.05(3927 ) 830 + 840
Pd
Fd = 840 + 1
2
10
0.05(3927 ) + 830 + 840
Pd
8300
196.35 + 840
Pd
Fd = 840 + 1
2
8300
196.35 + + 840
Pd
For minor shock with frequent start
1.25 < N sf < 1.5

sbY
Fs =
K f Pd
Pinion: AISI E3310, SOQT 450 F, Rc = C 57.5 , BHN = 600
sn = 250(600) = 150,000 psi
Gear: Cast Steel, SAE 0175, WQT
sn = 77 ksi = 77,000 psi (Table AT 6)

use s = sn = 77,000 psi

Fs =
sbY
=
(77,000)(10)(0.50) = 226,471
K f Pd (1.7 )(Pd )2 Pd2
F
Iteration: N sf = s , 1.25 < N sf < 1.5
Fd
Pd Fd Fs N sf
5 2833 9059 3.2
6 2633 6291 2.4
7 2488 4622 1.9
8 2378 3539 1.49

Use Pd = 8

Check for wear

Fw = Fd
Fw = D pbQK g
2m g 2(4 )
Q= = = 1 .6
mg + 1 4 +1

Page 18 of 57
 SECTION 11 SPUR GEARS

10
b= = 1.25 in
8
Fw = (3)(1.25)(1.6 )K g = 2378
K g = 396
K g = 396 < for carburized teeth
Therefore
Pd = 8
1
b = 1 in
4
N p = D p Pd = (3)(8) = 24
N g = mg N p = (4 )(24 ) = 96

Summary of answer:
Pd = 8
1
b = 1 in
4
N p = 24
N g = 96

642. A 20-tooth (20o F.D.) pinion is to transmit 50 hp at 600 rpm, the service being
indefinitely continuous in a conveyor drive; mw = 2.5 . The original pplan is to
use a nodular-iron casting, 80-60-03, for each gear. Determine suitable values for
the pitch, face width, and diameters. (Warning: compute C .)

Solution:
N p = 20
Np 20
Dp = =
Pd Pd
20
(600)
D p n p Pd 3142
vm = = =
12 12 Pd
33,000hp 33,000(50)
Ft = = = 525Pd
vm 3142
Pd
10
b=
Pd
0.05vm (Cb + Ft )
Fd = Ft + 1
0.05vm + (Cb + Ft )2

Page 19 of 57
 SECTION 11 SPUR GEARS

3142 10
0.05 C + 525Pd
Pd Pd
Fd = 525Pd + 1
2
3142 10
0.05 + C + 525Pd
Pd Pd
157.1 10C
+ 525Pd
Pd Pd
Fd = 525Pd + 1
2
157.1 10C
+ + 525Pd
Pd Pd
Fs N sf Fd
Conveyor drive, 1 < N sf < 1.25
sbY
Fs
K f Pd
assume Y = 0.50 load near middle
K f = 1 .7
For nodular-iron, 80-60-03
sn = 40,000 psi
E = 23 106 psi

C=
kE p E g
=
(
k 23 106 )
2

(
= k 11.5 106 )
Eg + E p (
2 23 10 6
)
k = 0.111e for 20o full depth

Fs =
(40,000)(10)(0.50) = 117,647
(1.7 )Pd2 Pd2
Fs
N sf =
Fd
Iteration: Use Fig. AF 19 and Fig AF 20.
3142 Fs
Pd vm = e C Fd Fs N sf =
Pd Fd
5 628.4 0.00225 2872 4765 4706 0.99
4 785.5 0.002625 3351 5005 7353 1.46

Use Pd = 4 , commercially cut

8 12.5
<b<
Pd Pd
2 < b < 3.125
use b = 3.0 in

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