Spur and Helical Gears
© McGraw Hill 1
Cantilever Beam Model of Bending Stress in Gear Tooth
M 6W t l
= =
I c Ft 2
t 2 l t2 t2
= or x = or l =
x t 2 4l 4x
6W t l W t 1 Wt 1 1
= 2
= 2
=
Ft F t 6l F t 2 4l 64
Wt p
=
F ( 23 ) xp
y = 2 x (3 p )
Wt
= (14 - 1) Fig. 14–1
Fpy
Access the text alternative for slide images.
© McGraw Hill 2
Lewis Equation 1
Wt
= (14 - 1)
Fpy
p= P y =Y
W tP
Lewis Equation = (14 - 2)
FY
2 xP
Lewis Form Factor Y= (14 - 3)
3
© McGraw Hill 3
Values of Lewis Form Factor Y
Number of Teeth Y Number of Teeth Y
12 0.245 28 0.353
13 0.261 30 0.359
14 0.277 34 0.371
15 0.290 38 0.384
16 0.296 43 0.397
17 0.303 50 0.409
18 0.309 60 0.422
19 0.314 75 0.435
20 0.322 100 0.447
21 0.328 150 0.460
22 0.331 300 0.472
24 0.337 400 0.480
26 0.346 Rack 0.485
Table 14–2
© McGraw Hill 4
Dynamic Effects 1
Effective load increases as velocity increases.
Velocity factor Kv accounts for this.
With pitch-line velocity V in feet per minute,
600 + V
Kv = (cast iron, cast profile) (14 - 4a )
600
1200 + V
Kv = (cut or milled profile) (14 - 4b)
1200
50 + V
Kv = (hobbed or shaped profile) (14 - 5a )
50
78 + V
Kv = (shaved or ground profile) (14 - 5b )
78
© McGraw Hill 5
Dynamic Effects 2
With pitch-line velocity V in meters per second,
3.05 + V
Kv = (cast iron, cast profile) (14 - 6a )
3.05
6.1 + V
Kv = (cut or milled profile) (14 - 6b)
6.1
3.56 + V
Kv = (hobbed or shaped profile) (14 - 6c )
3.56
5.56 + V
Kv = (shaved or ground profile) (14 - 6d )
5.56
© McGraw Hill 6
Lewis Equation 2
The Lewis equation including velocity factor.
• U.S. Customary version.
K vW t P
= (14 - 7)
• Metric version. FY
K vW t
= (14 - 8)
FmY
where the face width F and the module m are both in millimeters (mm). Expressing the
tangential component of load Wt in newtons (N) then results in stress units of
megapascals (MPa).
Acceptable for general estimation of stresses in gear teeth.
© McGraw Hill 7
© McGraw Hill 8
© McGraw Hill 9
Example 14–1 (1)
A stock spur gear is available having a diametral pitch of 8 teeth/in, a 1 12 -in face,
16 teeth, and a pressure angle of 20° with full-depth teeth. The material is AISI 1020 steel
in as-rolled condition. Use a design factor of nd = 3 to rate the horsepower output of the
gear corresponding to a speed of 1200 rev/m and moderate applications.
Solution
The term moderate applications seems to imply that the gear can be rated by using the
yield strength as a criterion of failure. From Table A–20, we find Sut = 55 kpsi and Sy = 30
kpsi. A design factor of 3 means that the allowable bending stress is 30/3 = 10 kpsi. The
pitch diameter is d = N/P = 16/8 = 2 in, so the pitch-line velocity is.
dn (2)1200
V= = = 628ft min
12 12
The velocity factor from Equation (14–4b) is found to be.
1200 + V 1200 + 628
Kv = = = 1.52
1200 1200
© McGraw Hill 10
Example 14–1 (2)
Table 14–2 gives the form factor as Y = 0.296 for 16 teeth. We now
arrange and substitute in Equation (14–7) as follows:
FY all 1.5(0.296)10 000
W =
t
= = 365lbf
Kv P 1.52(8)
The horsepower that can be transmitted is.
W tV 365(628)
hp = = = 6.95hp Answer
33 000 33 000
It is important to emphasize that this is a rough estimate, and
that this approach must not be used for important applications. The
example is intended to help you understand some of the
fundamentals that will be involved in the AGMA approach.
© McGraw Hill 11
Example 14–2 (1)
Estimate the horsepower rating of the gear in the previous example based on
obtaining an infinite life in bending.
Solution
The rotating-beam endurance limit is estimated from Equation (6–10),
Se = 0.5Sut = 0.5(55) = 27.5 kpsi
To obtain the surface finish Marin factor ka we refer to Table 6–3 for machined
surface, finding a = 2.00 and b = −0.217. Then Eq. (6–18) gives the surface
finish Marin factor ka as.
ka = aSutb = 2.00(55) −0.217 = 0.838
The next step is to estimate the size factor kb. From Table 13–1, the sum of the
addendum and dedendum is.
1 1.25 1 1.25
l= + = + = 0.281 in
P P 8 8
© McGraw Hill 12
Example 14–2 (2)
The tooth thickness t in Figure 14–1b is given in Sec. 14–1 [Equation (b)] as t =
(4lx)1/2 when x = 3Y/(2P) from Equation (14–3). Therefore, since from Example
14–1 Y = 0.296 and P = 8,
3Y 3(0.296)
x= = = 0.0555 in
2P 2(8)
then
t = (4lx)1 2 = [4(0.281)0.0555]1 2 = 0.250 in
We have recognized the tooth as a cantilever beam of rectangular cross section, so
the equivalent rotating-beam diameter must be obtained from Equation (6–24):
d e = 0.808(hb)1 2 = 0.808( Ft )1 2 = 0.808[1.5(0.250)]1 2 = 0.495 in
Then, Equation (6–19) gives kb as.
− 0.107 − 0.107
de 0.495
kb = = = 0.948
0.30 0.30
The load factor kc from Equation (6–25) is unity. With no information given
concerning temperature and reliability we will set kd = ke = 1.
© McGraw Hill 13
Example 14–2 (3)
In general, a gear tooth is subjected only to one-way bending. Exceptions include
idler gears and gears used in reversing mechanisms. We will account for one-way
bending by establishing a miscellaneous-effects Marin factor kf .
For one-way bending the steady and alternating stress components are σa = σm = σ/2
where σ is the largest repeatedly applied bending stress as given in Equation (14–7). If a
material exhibited a Goodman failure locus,
a m
+ =1
Se Sut
Since σa and σm are equal for one-way bending, we substitute σa for σm and solve the
preceding equation for σa, giving.
SeSut
a =
Se + Sut
Now replace σa with σ/2, and in the denominator replace S′e with 0.5Sut to obtain.
2 SeSut 2 Se
= = = 1.33Se
0.5Sut + Sut 0.5 + 1
© McGraw Hill 14
Example 14–2 (4)
Now defining a miscellaneous Marin factor kf = σ/S′e = 1.33S′e/S′e = 1.33.
Similarly, if we were to use a Gerber fatigue locus,
2
a
+ m =1
Se Sut
Setting σa = σm and solving the quadratic in σa gives.
Sut2 4 Se 2
a = −1 + 1 + 2
2 Se Sut
Setting σa = σ/2, Sut = S′e/0.5 gives.
Se
= 2
−1 + 1 + 4(0.5) 2 = 1.66 Se
0.5
and kf = σ/S′e = 1.66. Since a Gerber locus runs in and among fatigue data and
Goodman does not, we will use kf = 1.66. The Marin equation for the fully
corrected endurance strength is.
Se = ka kb kc kd ke k f Se
= 0.838(0.948)(1)(1)(1)1.66(27.5) = 36.3 kpsi
© McGraw Hill 15
Example 14–2 (5)
For stress, we will first determine the fatigue stress-concentration factor Kf. For a 20° full-
depth tooth the radius of the root fillet is denoted rf, with a typically proportioned value of
0.300 0.300
rf = = = 0.0375 in
P 8
From Figure A–15–6
r rf 0.0375
= = = 0.15
d t 0.250
Since D/d = ∞, we approximate with D/d = 3, giving Kt = 1.68. From Figure 6–26, q =
0.62. From Equation (6–32),
Kf = 1 + (0.62)(1.68 − 1) = 1.42
For a design factor of nd = 3, as used in Example 14–1, applied to the load or strength, the
maximum bending stress is.
S
max = K f all = e
nd
Se 36.3
all = = = 8.52 kpsi
K f nd 1.42(3)
© McGraw Hill 16
Example 14–2 (6)
The transmitted load Wt is.
FY all 1.5(0.296)8520
W =
t
= = 311 lbf
Kv P 1.52(8)
and the power is, with V = 628 ft/min from Example 14–1,
W tV 311(628)
hp = = = 5.9 hp
33 000 33 000
Again, it should be emphasized that these results should be
accepted only as preliminary estimates to alert you to the nature of
bending in gear teeth.
© McGraw Hill 17
Surface Durability 1
Another failure mode is wear due to contact stress.
Modeling gear tooth mesh with contact stress between two
cylinders, from Equation (3–74),
2F
pmax =
bl
where pmax = largest surface pressure
F = force pressing the two cylinders together
l = length of cylinders
12
2 F (1 − v ) E1 + (1 − v ) E2
2 2
b= 1 2
(14 - 10)
l 1 d1 + 1 d 2
© McGraw Hill 18
Surface Durability 2
Converting to terms of gear tooth, the surface compressive stress
(Hertzian stress) is found.
12
W t
1 r +1 r
C = − 1 2
(14 - 11)
F cos (1 − v1
2
) E1 + (1 − v2
2
) E 2
Critical location is usually at the pitch line, where
d P sin dG sin
r1 = r2 = (14 - 12)
2 2
Define elastic coefficient from denominator of Equation (14–11),
12
1
Cp = (14 - 13)
1 − vP2 1 − vG2
+
E P E G
© McGraw Hill 19
Surface Durability 3
Incorporating elastic coefficient and velocity factor, the contact
stress equation is.
12
K vW 1 1
t
C = −C p + (14 - 14)
F cos r1 r2
© McGraw Hill 20
Example 14–3 (1)
The pinion of Examples 14–1 and 14–2 is to be mated with a 50-tooth gear manufactured
of ASTM No. 50 cast iron. Using the tangential load of 382 lbf, estimate the factor of
safety of the drive based on the possibility of a surface fatigue failure. The surface
endurance strength of cast iron can be estimated from Sc = 0.32 HB kpsi for 108 cycles.
Solution
From Table A–5 we find the elastic constants to be EP = 30 Mpsi, νP = 0.292, EG = 14.5
Mpsi, νG = 0.211. We substitute these in Equation (14–13) to get the elastic coefficient as.
− (1 2)
1 − (0.292) 1 − (0.211)
2 2
C p = 6
+ 6 = 1817(psi)1 2
30(10 ) 14.5(10 )
From Example 14–1, the pinion pitch diameter is dP = 2 in. The value for the gear is dG =
50/8 = 6.25 in. Then Equation (14–12) is used to obtain the radii of curvature at the pitch
points. Thus.
2sin 20 6.25sin 20
r1 = = 0.342 in r2 = = 1.069 in
2 2
© McGraw Hill 21
Example 14–3 (2)
The face width is given as F = 1.5 in. Use Kv = 1.52 from Example 14–1.
Substituting all these values in Equation (14–14) with ϕ = 20° gives the contact
stress as.
12
1.52(380) 1 1
C = −1817 + = −72 400 psi
1.5 cos 20 0.342 1.069
Table A–24 gives HB = 262 for ASTM No. 50 cast iron. Therefore SC = 0.32(262)
= 83.8 kpsi. Contact stress is not linear with respect to the transmitted load [see
Equation (14–14)]. If the factor of safety is defined as the loss-of-function load
divided by the imposed load, then the ratio of loads is the ratio of stresses
squared. In other words,
2
loss-of-function load SC2 83.8
n= = 2 = = 1.34 Answer
imposed load C 72.4
© McGraw Hill 22
