SECTION 2

Spur gear design: Problem 1

Dr LK TARTIBU
Mechanical Engineering
 Contents

• Problem 1 Analysis
• Problem 2 Spur gear
PROBLEM 1 – SPUR GEAR DESIGN

• In a conveyor system a step-down gear drive is used. The input pinion

is made of 18 teeth, 2.5 mm module, 20o full depth teeth of hardness
330BHN and runs at 1720 rpm. The driven gear is of hardness 280BHN
and runs with moderate shock at 860 rpm. Face width of wheels is 35
mm. The gears are supported on less rigid mountings, less accurate
gears and contact across full face may be assumed. The ultimate tensile
strength of pinion and gear materials is 420 and 385MPa respectively.
The gears are made by hobbing process. Find the tooth bending strength
of both wheels and the maximum power that can be transmitted by the
drive with a factor of safety 1.5. The layout diagram is shown in the Fig
1.
Fig 1 Conveyor drive layout
Solution:
• The bending fatigue stress is found from AGMA equation as,
Wt
• σ= K K K
bmJ V o m
(1)

N1
• We know that, Z2 = Z1 ×
N2

1720
• Substituting values, Z2 = 18 ×
860
= 36

Table 1 Data given for gear and pinion

N Z m d b

Pinion 1720rpm 18 2.5 mm 45 mm 35 mm

Gear 860 rpm 36 2.5 mm 90 mm 35 mm

• Using the values from Table 1,
πdN 𝜋×45×1720
• V=
60000
=
60000
= 4.051𝑚/𝑠

50+ 200V 0.5

• We know that K V =
50
(2)

Table 2 J values for pinion and gear

Z J (sharing) Kv Ko Km

Pinion 18 0.338 1.569 1.25 1.6

Gear 36 0.385 1.569 1.25 1.6

• The J value is obtained from Fig. 2 for sharing teeth as in practice.

Ko and Km values are obtained from Tables 3 and 4 for the given
conditions.
Fig.2 - Geometric Factor J
 Table 3 - Overload factor Ko

Driven Machinery

Source of power Uniform Moderate Shock Heavy Shock

Uniform 1.00 1.25 1.75

Light shock 1.25 1.50 2.00

Medium shock 1.50 1.75 2.25

Table 4 - Load distribution factor Km

Face width ( mm)

Characteristics of Support 0 - 50 150 225 400 up

Accurate mountings, small bearing 1.3 1.4 1.5 1.8

clearances, minimum deflection, precision

gears

Less rigid mountings, less accurate gears, 1.6 1.7 1.8 2.2
contact across the full face

Accuracy and mounting such that less than Over Over Over Over
full-face contact exists 2.2 2.2 2.2 2.2
SPUR GEAR –TOOTH BENDING STRESS
(AGMA)
Wt Wt
• For pinion: σ= K K K
bmJ V o m
=
35×2.5×0.338
× 1.569 × 1.25 × 1.6 =

0.1061Wt (3)
Wt Wt
• For gear: σ= K K K
bmJ V o m
=
35×2.5×0.385
× 1.569 × 1.25 × 1.6 =

0.0932Wt (4)
SPUR GEAR – PERMISSIBLE TOOTH BENDING
STRESS (AGMA)
• Endurance limit of the material is given by:
• σe = σ′e K L K V K s K R K T K f K m (5)
• Where, σe’ is the endurance limit of rotating-beam specimen
• From Table 5

Table 5 Properties of pinion and gear

Prop. σut MPa σ’e=0.5σut MPa kL Kv ks

Pinion 420 210 1 1 0.8

Gear 385 187.5 1 1 0.8

• kL = load factor = 1.0 for bending loads
• kv = size factor = 1.0 for m < 5 mm and
• = 0.85 for m > 5 mm
• ks = surface factor, is taken from Fig.3 based on the ultimate tensile
strength of the material for cut, shaved, and ground gears.
• kr = reliability factor given in Table 5.
• kT = temperature factor = 1 for T≤ 350oC
= 0.5 for 350 < T ≤ 500oC
• Reliability of 90%, working temperature <150o C and reversible is
assumed.
• kf = 1.0 since it is taken in J factor.
• km = 1.0 for reverse bending assumed here
Fig.3 Surface factor Ks
 Table 6

Table 7
 σe
• [σ] =
S
where s is the factor of safety

• Hence, from tooth bending fatigue considerations, the design

equation is,
• σ (tooth bending stress) ≤ [σ] (strength value of the tooth)
• If the factor of safety s = 1.5
Table 8 Strength values of pinion and gear

Prop. σe MPa [σ]= σe / s MPa σ MPa FT N

Pinion 150.7 100.5 0.1061 Ft 947

Gear 134.6 89.7 0.0932 Ft 962

• Table 8 shows that the pinion is weaker than gear. And maximum
tangential force that can be transmitted is: Wt= 947 N
• So, the maximum power that can be transmitted is:
• P = Wt ×v / 1000 = 947 × 4.051 /1000 = 3.84 kW
PROBLEM 2 – SPUR GEAR DESIGN

• In a conveyor system a step-down gear drive is used. The input pinion is

made of 18 teeth, 2.5 mm module, 20o full depth teeth of hardness
340BHN and runs at 1720rpm. The driven gear is of hardness 280BHN
and runs with moderate shock at 860 rpm. Face width of wheels is
35mm. The gears are supported on less rigid mountings, less accurate
gears and contact across full face may be assumed. The ultimate tensile
strength of pinion and gear materials is 420 and 385MPa respectively.
The gears are made by hobbing process. From surface durability
consideration, find the maximum power that can be transmitted by the
drive with a factor of safety 1.2 for a life of 108 cycles. Drive layout is
shown in the Fig 4.
Fig. 4 Conveyor drive Layout diagram
• V.R. = n1 / n2 = 1720 / 860 = 2
• Z2 = V.R. × Z1 = 2 x 18 = 36
•
Table 9 Data given for pinion and gear

n Z m d = mZ b

Pinion 1720rpm 18 2.5 mm 45 mm 35 mm

Gear 860 rpm 36 2.5 mm 90 mm 35 mm

Table 10 Properties of gear and pinion

Bhn Ø Reliability Life Temp

Pinion 340 20o 99 % 108 <120oC

Gear 280 20o 99 % - <120oC

• Solution:
• The induced dynamic contact stress is given by equation below,
Wt
• σH = Cp √ K K K
bd1 I V o m

• When both pinion and gear material are made up of steel, from
Table 11, Cp =191MPa0.5
• SPUR GEAR – CONTACT STRESS
Table 11
• Substituting the values from table 10,
sin∅cos∅ i sin20o cos20o 2
• I=
2 i+1
=
2 2+1
= 0.1071

• SPUR GEAR – SURFACE DURABILITY

• From table 3 and 4,
πdN 𝜋×45×1720
• V=
60000
=
60000
= 4.051𝑚/𝑠

50+ 200V 0.5

• For hobbed gear, K V =
50
Table 14
• Substituting values from Table 14, we have,

Wt Wt ×1.569×1.25×1.6
• σH = Cp K K K
bd1 I V o m
= 191
35×45×0.1071
= 26.051√Wt MPa

• Surface fatigue strength of the material is given by,

• σsf = σ′sf K L K R K T
• From table 10, for steel life is 107 cycles & reliability 99% and from
Table 15, σsf’ = 2.8(BHN) – 69MPa = 2.8 x 340-69 = 954MPa
• KL = 0.9 for 108 cycles from Fig.2
• KR = 1.0. for 99% reliability from Table 10
• SPUR GEAR – SURFACE FATIGUE STRENGTH
Table 15 Surafce fatigue strength σsf for metallic spur gears (107 cycle life 99%
reliability and temperature <120 0 C)
Material σsf’(MPa)

Steel 2.8 (Bhn)-69MPa

Nodular iron 0.95 (2.8(Bhn)-69MPa)

Cast iron, grade 20 379

Cast iron, grade 30 482

Cast iron, grade 40 551

Tin Bronze, AGMA 2C (11% Sn) 207

Aluminium Bronze (ASTM 148 – 52) 448

(Alloy 9C – H.T.)

Fig. 5 Life factor KL

• SPUR GEAR – ENDURANCE LIMIT
Table 16 Reliability factor KR

Reliability (%) KR

50 1.25

99 1.00

99.9 0.80

• SPUR GEAR – ALLOWABLE SURFACE FATIGUE STRESS

(AGMA)
• We know that,
• [σH] = σSf /s = 954/1.2 = 795MPa
• For factor of safety s = 1.2
• Design equation is, σH ≤ [σH]
• 26.051 √Wt = 795 Wt = 931 N
• Maximum Power that can be transmitted is,
• P = Wt ×V/1000 = 931×4.051/1000 = 3.51kW
One man is working hard, but isn't getting much done.
The other is working smart, and is getting results!