Machine Design II Prof. K.Gopinath & Prof. M.M.

Mayuram

Module 2 - GEARS
Lecture – 12 HELICAL GEARS-PROBLEMS

Contents

12.1 Helical gears – Problem 1 Force analysis

12.2 Helical gears – Problem 2 Stress analysis
12.3 Helical gears –Problem 3 Reworking of gear dimensions of crossed helical gears
12.4 Helical gears – Problem 4 Design of double helical gears

12.1 HELICAL GEARS – PROBLEM 1

A 75 kW induction motor runs at 740 rpm in clock wise direction as shown in Fig.12.1. A
19 tooth helical pinion with 20o normal pressure angle, 10 mm normal module and a
helix angle of 23o is keyed to the motor shaft. Draw a 3-dimensional sketch of the motor
shaft and the pinion. Show the forces acting on the pinion and the bearing at A and B.
The thrust should be taken out at A.

Fig.12.1 Helical gear layout diagram

Data: W=75kW, n 1 =740rpm, Z 1 = 19, Z2 = 38, Ø n =20o, ψ = 23o, m n = 10 mm.

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Question: Find reactions at A&B.

Solution: Transverse Pressure angle

tan Ø n = tan Ø cos ψ

tan φn
φ  tan1 ( )
cos ψ
tan 20o
 tan1 ( o
)  21.57o
cos 23

m = m n / cos ψ = 10 / cos 23o = 10.864 mm

Pitch diameter of the pinion:

d 1 = mZ 1 = 10.864 x 19 = 206.4 mm

Pitch line velocity:

V = πd 1 n 1 /60 = π x 206.4 x 740 / 60000 = 8 m/s

Tangential force on the pinion: F t

F t = 1000W/V = 1000 x 7 5 / 8 = 9375 N

F r = F t tan Ø = 9375 tan 21.57o = 3706 N

F a = F t tan ψ = 9375 tan 23o = 3980 N

F n = F t / cosØ n cosψ = 9375 / cos20o x cos23o = 10838 N

3 forces, F r in the –y direction, F a in the x direction, and F t in the +z direction are acting

at the pitch point c of the pinion as shown in the sketch.

Bearing at A is made to take the Axial reaction R A X = 3980 N

Taking moments about the z axis

-F r (950) + F a (206.4/2) + R B y (750) = 0, i.e.,

-3706 x 950 + 3980 x 103.2 + R B y (750) = 0

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig. 12.2 Reaction the shaft bearings due to forces at the pinion pitch point

R B y = 4146.7 N

Σ FY = 0, from which R a y = 440.7 N

Taking moment about y axis,

R B z (750) - F t (950) = 0

i.e, 750 R B z - 9375x 950 = 0 R B z = 11875 N

Σ Fz = 0, from which R A z = 2500 N

T = F t (206.4/2) = 9375 x (103.2) = 96750 Nmm = 96.75 Nm

Fig.12.3 Reaction on shaft bearings due to forces at the pinion pitch point from
calculation

----------------

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

12.2 HELICAL GEARS - PROBLEM 2

A helical gear drive shown in Fig.12.4 transmits 20 kW power at 1440 rpm to a machine
input shaft running at 360rpm. The motor shaft pinion has 18 teeth, 20O normal pressure
angle and a normal module of 4mm and 30o right hand helix. Determine all dimensions
of the gear and the pinion. b=1.2 p a . Comment the chosen gears.

Fig.12.4 Helical gear layout diagram

The pinion material is made of C45 steel with hardness 380 Bhn and tensile strength

σ ut = 1240 MPa. The gear is made of ductile iron grade 120/90/02 of hardness 331 Bhn
and tensile strength σ ut = 974 MPa. Both gears are hobbed, HT and OQ&T and ground.

Given data:
W=20 kW, n 1 =1440 rpm, Z 1 = 18, m n = 4mm, Ø n = 20o, b=1.2 p a , n 2 = 360 rpm, Ψ = 30o
RH Helix

The following assumptions are made:

(a) Tooth profiles are std. involutes.
(b) Gears mesh along their pitch circles
(c) All loads are transmitted at the pitch point and mid planes of the gears.
(d) All power losses are neglected.

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Solution:

tan Ø n = tan Ø. Cos ψ

1. Transverse pressure angle Ø = tan-1(tan Øn / Cos ψ) = tan-1(tan20o/cos 30o) = 22.8o
2. Transverse module: m = m n /cos ψ

i.e., m = 4 / cos30o = 4.62 mm

3. Pinion pitch dia.:d 1 = Z 1 m = 18 x 4.62 = 83.2 mm

4. Gear, no. of teeth: Z 2 = Z 1 (n 1 /n 2 ) = 18(1440/360) = 72

5. Gear dia.: d 2 = Z 2 m = 72 x4.62 = 335.7mm

6. p = πm = πx4.62 = 14.51 mm

7. p a = p / tan ψ = 14.51 / tan30o = 25.13 mm

8. b = 1.2p a = 1.2 x 25.13 = 30.16 mm

9. V = πd 1 n 1 /60000= πx83.2x1440 /60000 = 6.27 m/s

10. d b1 = d 1 cosØ = 83.2cos22.8o = 76.7 mm

d b2 = d 2 cosØ = 335.7cos22.8o =309.5 mm

11. Addendum: h a or a=1m n = 4.0 mm

12. Dedendum: h f = 1.25 m n = 1.25 x 4.0 = 5.00 mm

13. F t = 1000 W / V = 1000 x 20/6.27 = 3190 N

14. F r = F t tan Ø = 3190x tan 22.8o = 1341 N

15. F a = F t tan ψ = 3190x tan 30o = 1842 N

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig. 12.5 View of the forces acting on pitch cylinder of the helical drive pinion

Bending stress on the pinion:

Ft
σb1  K v K o (0.93Km )
b mn J

J= 0.45 for Z V1 =Z 1 / cos3 ψ = 18 / cos3 30o = 27.7 or 28 and ψ = 30o from Fig.12.6
J-multiplication factor from Fig.12.7 = 1.013 from Fig.12.7
Z v2 = Z 2 / cos3 ψ = 72/ cos3 30o = 110.9 or 111 teeth mating gear.
J = 0.45 x 1.013 = 0.4559

HELICAL GEAR - TOOTH BENDING STRESS

Fig.12.6 Geometry factor J for helical gear with φ n = 20o and mating with 75 tooth
gear

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig.12.7 J- factor multiplier when the mating gear has tooth other than 75

0.5 0.5
 78  (200V) 0.5   78  (200x 6.27) 0.5 
Kv       1.21
 78   78 

K o = 1.25 assuming uniform source of power and moderate shock from driven
machinery, Table 12.1
K m = 1.5 for b=30.16 mm & less rigid mountings, less accurate gears, contact across full
face, Table 12.2

HELICAL GEAR –TOOTH BENDING STRESS (AGMA)

Table 12.1 -Overload factor K o

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

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Table 12. 2 Load distribution factor K m

Face width ( mm)

Characteristics of Support 0 - 50 150 225 400 up

Accurate mountings, small bearing

clearances, minimum deflection, 1.2 1.3 1.4 1.7
precision gears

Less rigid mountings, less accurate

gears, contact across the full face 1.5 1.6 1.7 2.0

Accuracy and mounting such that less

than full-face contact exists Over 2.0 Over 2.0 Over 2.0 Over 2.0

Bending stress in the pinion is

Ft
σ  K K (0.93 K )
b1 b mn J v o m

3190
 x1.21x 1.25 (0.93 x 1.5)
30.2 x 4.00 x 0.4559

 122.2 MPa

 For the gear J = 0.525, for Z V2 = 111 & ψ=30o from Fig. 12.6
 J-factor multiplier = 0.965 for Zv 1 =28 & ψ=30o from Fig.12.7
For the gear, J = 0.525 x 0.965 = 0.5066

Bending stress for the gear is

Ft
σ  K K (0.93K )
b2 b mn J v o m
3190
 x1.21x 1.25 (0.93 x 1.5)
30.2 x 4.0 x 0.5066
 110 MPa

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Corrected bending fatigue strength of the pinion:

σ e = σ e’ k L k v k s k r k T k f k m

σ e’ = 0.5σ ut =.0.5x1240 =620 MPa

k L = 1.0 for bending

k V = 1.0 for bending for m ≤ 5 module,

k s = 0.645 for σ ut = 1240 MPa from Fig.12.8

k r = 0.897 for 90% reliability from the Table 12.3

k T =1.0 with Temp. < 120oC,

k f = 1.0

k m = 1.33 for σ ut = 1240 MPa from the Fig.12.9

σ e = 620x1x1x0.645x1x1x0.897x1.33 = 477 MPa

SPUR GEAR – PERMISSIBLE TOOTH BENDING STRESS (AGMA)

Fig. 12.8 Surface factor k s

Table 12.3 Reliability factor k r

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

k f = fatigue stress concentration factor. As this factor is included in J factor, kf =1 is

taken.

k m = Factor for miscellaneous effects. For idler gears subjected to two way bending,

= 1. For other gears subjected to one way bending, the value is taken from the
Fig.12.9. Use k m = 1.33 for σ ut less than 1.4 GPa.

Fig.12.9 Miscellaneous effects factor, k m

Corrected fatigue strength of the gear:

σ e = σ e’ k L k v k s k r k T k f k m

σ e ’ = 0.35σ ut =.0.35x974 =340.9 MPa

k L = 1.0 for bending

k V = 1.0 for bending for m ≤ 5 module,

k s = 0.673 for σ ut = 974 MPa from Fig.12.8

k r = 0.897 for 90% reliability from the Table 12.3

k T = 1.0 with Temp. < 120oC,

k f = 1.0

k m = 1.33 for σ ut = 974 MPa from Fig.12.9

σ e = 340.9x1x1x0.673x0.897x1x1x1.33 = 273.7MPa

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Factor of safety for the pinion on bending:

s b1 = σe / σ b1 = 477 / 122.2 = 3.9

Factor of safety for the gear on bending:

s b2 = σ e / σ b2 = 273.7/110 = 2.49

Table 12.4 Guidance on the necessary safety factor

As per Niemen Table 12.4, the minimum factor of safety for infinite life in bending
fatigue is 1.8. Since both the case the factor of safety exceeds this value, the gears will
have infinite life.

Ans: The gear is weaker among the two in bending fatigue as its factor of safety is
lower.

Contact stress on helical gears is given by:

Ft  cos ψ 
σH  Cp   K v K o (0.93Km )
bdI  0.95CR 

Cp = 166 (MPa) 0.5 for steel pinion vs cast iron gear from Table 12.5.

sinφ cosφ i sin22.8o cos22.8o 4

I   0.143
2 i1 2 41

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Table 12.5 Elastic coefficient Cp for spur gears, in MPa

Contact ratio is given by:

 (r  a)2  r 2  (r  a)2  r 2  (r  r ) sinφ 

CR t   1 b1 2 b2 1 2

 πmcosφ 
 

Using standard tooth system with a= 1m n , CR t :

   
( 41.6  4.0 )2  38.352  (167.85  4.0)2 154.752 
CR    
t  π x 4.62 cos22.8 o   π x 4.62 cos 22.8o 
   
 
( 41.6  167.85 ) sin22.8o 
  1.365

 π x4.62cos22.8o 


K v =1.21, K o = 1.25, K m =1.5

Ft  cosψ 
σ C K K (0.93Km )
H p b d I  0.95 CR  v o

3190  cos 30o 

 166   1.21x 1.25 (0.93 x 1.5)
30.2 x 83.2 x 0.143  0.95 x1.365 
 
 587MPa

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Surface fatigue strength of pinion is:

σ sf = σ sf ’ K L K H K R K T
σ sf ’ = surface fatigue strength of the material
= 2.8 (Bhn) – 69 from Table 12.6
= 2.8x 380 -69
= 995 MPa

HELICAL GEAR – SURFACE FATIGUE STRENGTH

K L = 0.9 for 108 cycles from Fig.12.10

K H = 1.005 for K = 380/331 = 1.14 & i= 4 from Fig.12.11
K R = 1.0 for 99% reliability from Table 12.7
K T = 1.0 assuming temp. < 1200C

For the pinion material,

σ sf1 = σ sf ’ K L K H K R K T = 995 x 0.9 x 1 x1.005 x 1 = 900 MPa

Table 12.6 Surface fatigue strength σ sf ’ (MPa) for metallic spur gears
(107 cycle life, 99% reliability and temperature <120oC)

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig.12.10 Life Factor K L

Fig. 12. 11 Hardness ratio factor, K H

K = Brinell hardness ratio of pinion and
gear, K H = 1.0 for values of K below 1.2

Table 12.7 Reliability factor K R

Reliability (%) KR

50 1.25

99 1.00

99.9 0.80

K T (Temperature factor) = 1 for T≤ 120oC based on Lubricant temperature.

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Above 120oC, it is less than 1 to be taken from AGMA standards.

For gear: σ sf ’ = 0.95[2.8(Bhn)-69] = 0.95[2.8x331-69] = 815 MPa

K L = 0.9 for 108 cycles from Fig.12.10
K H = 1.005 for K = 380/331 = 1.14 & i=4 from Fig.12.11
K R = 1.0 for 99% reliability from Table 12.7
K T = 1.0 assuming temp. < 1200C
σ sf 2 = σ sf ’ K L K H K R K T = 815 x 0.9 x 1.005 x1 x 1 = 795 MPa

HELICAL GEAR – ALLOWABLE SURFACE FATIGUE STRESS (AGMA)

Allowable surface fatigue stress for design is given by

[σ H ] = σ Sf / s H
Factor of safety s H = 1.1 to 1.5

Design equation is: σH ≤ [ σH ]

Factor of safety for the pinion against pitting:

s H1 = σ Sf1 / σ H = 900 /587 = 1.53

Factor of safety for gear against pitting:

s H2 = σ Sf2 / σ H = 795 /587 = 1.35

In both case the factor of safety is more than 1.3 against pitting (Table 12.4) and the
design is adequate. Among these, gear is slightly weaker than pinion and is likely to fail
first.

The factor of safety in surface fatigue is proportional to square root of load and that in
bending fatigue is directly proportional to load. Hence, the equivalent bending factor of
safety for corresponding surface fatigue (s H2 )2 =1.352 = 1.81 is compared with (S b2 ) and
is <2.49. So the gears are likely to fail due to surface fatigue and not due to bending
fatigue.
-----------------

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

12.3 HELICAL GEARS - PROBLEM 3

In a crossed helical gear drive, the shaft angle is 90o and the gear ratio is 1:1 with the
helix angle ψ 1 = ψ 2 = 45o. The normal module is 4 mm and the number of teeth in the
gears are Z 1 = Z 2 = 50. The above identical gears are to be so changed that the driven
gear has a pitch diameter of around 200 mm in the new arrangement.

Data: Σ = ψ 1 + ψ 2 = 90o; ψ 1 = ψ 2 = 45o; m n = 4 mm;

Z 1 = Z 2 = 50 and d 2 ~ 200 mm.

Solution:

mn z1 m z m z
d1   n 1 and d2  n 2
cos  1 sin  2 cos  2

Centre distance: C = 0.5 (d 1 +d 2 ) = 0.5m n (Z 1 +Z 2 ) /cosψ

= 0.5 x 4 x (2x50) / cos45o

= 282.84 mm

1 1 m Z m Z  m Z  sin  2  cos  2 
C  (d  d )   n 1  n 2   n  
2 1 2 2  sin  2 cos  2  2  sin  2 cos  2 

d2 cos  2
Also Z 
mn

mn d2 cos  2  sin  2  cos  2  d2

Therefore C  x x   1  cot  2 
2 mn  sin  2 cos  2  2
2C 2 x 282.84
Or cot  2   1  1  1.828,  2  28.675o
d2 200

d2 cos  2 200 x cos 28.675o

Hence, Z 2    43.86
mn 4

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Taking an integral value for Z = 44 and substituting

2C sin  2  cos  2
 or
mn Z sin  2 cos  2

C 282.84 sin  2  cos  2

 
mn Z 4 x 44 2 sin  2 cos  2

1 sin 2 2
Squaring: 2.5826 
sin2 2 2

Solving we get ψ 2 = 28.9o

Final values d 1 = 4 x 44 / sin 28.85o = 364.75 mm

d 2 = 4 X 44 / cos 28.85o = 200.94 mm which is near to 200 mm

C = 0.5 (d 1 + d 2 ) = (364.75 +200.94) = 282.84 mm equal to original centre distance.

-------------------

12.4 HELICAL GEARS - PROBLEM 4

In a turbine drive 300 kW power is transmitted using a pair of double helical gear. The

pinion speed is 2950 rpm and that of the gear is about 816.5 rpm. There are no space

constraints on the gear drive. Selecting suitable materials, design the pinion and the

gear to last for 108 cycles.

Data: W = 300kW; n 1 = 2950rpm; n 2 = 816.5 rpm; Life 108 cycles.

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Solution: Since there are no constraints for the drive design, the number of teeth on the
pinion is assumed as Z 1 = 29. Helix angle of 35o and normal pressure angle φ n = 20o
are taken for the gears and b = 1.2 p a is assumed.

2πn1 2π x 2950
ω1    308.77 rad / s
60 60

i = n 1 / n 2 = 2950 / 816.5 = 3.612

Z 2 = i Z 1 = 3.612 x 29 = 104.8 rounded to 105

Torque:

1000W 1000x300
T1'    971.6Nm
ω 308.77

The double helical gear is considered as two single helical gears coupled together
sharing the torque equally. Torque on each half is T 1 =971.6/2 =485.8 Nm=485800
Nmm.

The AGMA bending stress equation:

Ft
σb  K v K o (0.93Km )
b mn J

p = πm = π m n /cos ψ = π m n /cos 35o = 3.833m n

p a = p / tan ψ.
Assuming b = 1.2p a = 1.2 p /tanψ = 1.2 x 3.833m n / tan35o = 6.569m n
F t = 2T 1 / d 1 = 2T 1 / mZ 1 = 2T 1 cosψ / m n Z 1 = 2 x 485800 x cos35o/ m n x29
= 27444 / m n N
J for the pinion with teeth Z v1 = Z 1 / cos3 ψ =29 / cos335o = 82, ψ=35o is: J=0.47 from
Fig. 12.6
J multiplier for mating with Zv2 = Z 2 /cos3 ψ = 105/cos345o =297, is =1.015 from Fig.
12.7
For pinion J = 0.47 x 1.015 = 0.4771

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

HELICAL GEAR - TOOTH BENDING STRESS

Fig.12.6 Geometry factor J for helical gear with φ n = 20o and mating with 75 tooth
gear.

Fig.12.7 J- factor multiplier when the mating gear has tooth other than 75

J factor for the gear with teeth Z v2 = 297 and ψ =35o is J =0.495 from Fig. 12.6
J multiplier for mating with Z v1 = 82 is = 1.003 from Fig. 12.7

For gear J = 0.495 x 1.003 = 0.4965

0.5
 78  (200V) 0.5

Kv     1.25 assumed sin ce V is not known.
 78 

K o = 1.25 assuming uniform source of power and moderate shock from driven
machinery, Table 12.1.

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

K m = 1.3 expecting b=150 mm Accurate mountings, small bearing clearances, minimum

deflection, precision gears, Table 12.2.

Helical Gear –Tooth Bending Stress (AGMA)

Table 12.1 -Overload factor K o

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 12.2 Load distribution factor K m

Face width ( mm)

Characteristics of Support 0 - 50 150 225 400 up

Accurate mountings, small bearing

clearances, minimum deflection, 1.2 1.3 1.4 1.7
precision gears

Less rigid mountings, less accurate

gears, contact across the full face 1.5 1.6 1.7 2.0

Accuracy and mounting such that less

than full-face contact exists Over Over 2.0 Over 2.0 Over 2.0
2.0

For the pinion:

Ft
σ = K K (0.93K )
b1 bmn J v o m

27444 16542
 x1.25x1.25x(0.93x1.3) 
3
6.569mn x 0.4771 mn3

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

For the gear:

Ft
σ = K K (0.93K )
b2 b mn J v o m
27444
 x1.25x1.25x(0.93x1.3)
3 x 0.4965
6.569mn
15895

mn3

The pinion material is made from C45 steel with hardness 380 Bhn and tensile strength
σ ut = 1240 MPa. The gear is made from ductile iron grade 120/90/02 of hardness 331
Bhn and tensile strength σ ut = 974 MPa. Both gears are hobbed, HT and OQ&T and
ground.

Corrected bending fatigue strength of the pinion:

σe = σe’ kL kv ks kr kT kf km
σ e ’ = 0.5σ ut =.0.5x1240 =620 MPa
k L = 1.0 for bending
k V = 1.0 for bending for m ≤ 5 module,
k s = 0.645 for σ ut = 1240 MPa from Fig.12.8
k r = 0.897 for 90% reliability from the Table 12.3
k T = 1.0 with Temp. < 120oC, k f = 1.0
k m = 1.33 for σ ut = 1240 MPa from the Fig.12.9
σ e = 620x1x1x0.645x1x1x0.897x1.33 = 477 MPa

Corrected bending fatigue strength of the gear:

σe = σe’ kL kv ks kr kT kf km
σ e ’ = 0.35σ ut =.0.35x974 =340.9 MPa
k L = 1.0 for bending
k V = 1.0 for bending for m ≤ 5 module,
k s = 0.673 for σ ut = 974 MPa from Fig.12.8
k r = 0.897 for 90% reliability from the Table 12.3

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

k T = 1.0 with Temp. < 120oC, k f = 1.0

k m = 1.33 for σ ut = 974 MPa from Fig.12.95
σ e = 340.9x1x1x0.673x0.897x1x1x1.33 = 273.7MPa

Permissible stress for the pinion in bending fatigue with factor of safety 1.6 for finite life
gearing from Table 12.4:
[σ b ] 1 = σ e / s b = 477/1.6 = 298 MPa

Permissible stress for the pinion in bending fatigue with factor of safety 1.6,
[σ b ] 2 = σ e / s b = 273.7/1.6 = 171 MPa

For the pinion,

16542
σ   [σ]  298
b2 3 2
mn
m n = 3.81 mm

For the gear,

15895
σ   [σ]  171
b2 3 2
mn
m n = 4.53 mm

Take a standard value of 5 mm as given in Table 12.8.

Table 12.8 Standard modules in mm

0.3 0.4 0.5 0.6 0.7 0.8 1.0

1.25 1.5 1.75 2.0 2.25 2.5 3

3.5 4 4.5 5 5.5 6 6.5

7 8 9 10 11 12 13

14 15 16 18 20 22 24

26 28 30 33 36 39 42

45 50 Further increase is in terms of 5 mm

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

m = m n / cos35o = 5 / cos35o = 6.104 mm

d 1 = mZ 1 = 6.104 x 29 = 177.01 mm
d 2 = mZ 2 = 6.104 x 105 = 640.92 mm
p = 3.833m n = 3.833x 5 = 19.165 mm
p a = p / tan ψ. = 19.165 / tan 35o =27.37 mm
b = 1.2p a = 1.2 x 27.37 = 32.84 mm, take 35 mm
d a1 = d 1 + 2m n = 177.01 + 2x5 = 187.01 mm
d a2 = d 2 + 2m n = 640.92 + 2x5 = 650.92 mm

Transverse pressure angle: tan Ø n = tan Ø cos ψ

tan φn tan 20o

φ  tan1 ( )  tan1 ( )  23.96o
cos ψ cos 35o

d b1 = d 1 cosØ = 177.01 cos23.96o = 161.76 mm

d b2 = d 2 cosØ = 640.92 cos23.96o = 585.69 mm
C = 0.5(d 1 +d 2 ) = 0.5(177.01+ 640.92) = 408.97mm
V = 0.5ωd 1 = 0.5 x 308.77x 177.01x10-3= 27.33 m/s
F t = 2T 1 /d 1 = 2x485800 /177.01 =5489N

Contact stress on the gears is given by:

Ft  cos ψ 
σ C K K (0.93Km )
H p bdI  0.95CR  v o

C p = 166 (MPa)0.5 for steel pinion vs cast iron gear from Table 12.5.

sin φ cos φ i
I
2 i1
sin 23.96o cos 23.96o 3.621
  0.1454
2 3.621 1

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Table 12.5 Elastic coefficient Cp for spur gears, in MPa

Contact ratio is given by:

 
 (r1 a)2  rb12  (r2  a)2 rb22  (r1  r2 ) sinφ 
CR 
t  πmcos φ 
 

Using standard tooth system with a= 1m n , CR:

   
 (93.512  80.882  2
 (325.46  292.85
2

CR  
t  o  π x6.104 cos 23.96o 
 π x6.104 cos 23.96   
 
408.97 sin23.96o 
  1.3044
 π x6.104 cos 23.96o 
 

0.5 0.5
 78  (200V) 0.5
  78  (200x 27.33) 0.5

Kv        1.396
 78   78 

K v =1.396, K o = 1.25, K m =1.

Ft  cos ψ 
σ C K K (0.93Km ) (25)
H p bdI  0.95CR  v o

5489  cos 35o 

 166   1.396 x 1.25 (0.93 x 1.5)
35 x 177.01x 0.1454  0.95 x1.3044 
 
 519.8 MPa

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Contact fatigue strength of pinion is:

σ sf = σ sf ’ K L K H K R K T

σ sf ’ = surface fatigue strength of the material = 2.8 (Bhn) – 69 From Table 12.6
= 2.8x 380 -69
= 995 MPa

HELICAL GEAR – SURFACE FATIGUE STRENGTH

Table 12.6 Surface fatigue strength σ sf ’ (MPa), for metallic spur gears,
(107 cycle life 99% reliability and temperature < 120o C)

K L = 0.9 for 108 cycles from Fig.12.10

K H = 1.005 for K = 380/331 = 1.14 & i=4 from Fig.12.11
K R = 1.0 for 99% reliability from Table 12.7
K T = 1.0 assuming temp. < 1200C

σ sf = σ sf ’ K L K H K R K T = 995 x 0.9 x 1.005 x1 x 1

= 900 MPa

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig.12.10 Life Factor K L

Fig.12.11 Hardness ratio factor, K H K = Brinell hardness

ratio of pinion and gear, K H = 1.0 for values of K below 1.2

Table 12.7 Reliability factor K R

Reliability (%) KR

50 1.25

99 1.00

99.9 0.80

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

K T = temperature factor,
= 1 for T≤ 120oC based on Lubricant temperature.
Above 120oC, it is less than 1 to be taken from AGMA standards.

HELICAL GEAR – ALLOWABLE SURFACE FATIGUE STRESS (AGMA)

Allowable surface fatigue stress for design is given by

[σ H ] = σ Sf / s H
Design equation is: σ H ≤ [σ H ]

For gear: σ sf ’ = 0.95[2.8(Bhn)-69] = 0.95[2.8x331-69] = 815 MPa

K L = 0.97 for 2.5x107 cycles from Fig.12.10
K H = 1.005 for K = 380/331 = 1.14 & i=4 from Fig.12.11
K R = 1.0 for 99% reliability from Table 12.10
K T = 1.0 assuming temp. < 1200C
σ sf = σ sf ’ K L K H K R K T = 815 x 0.97 x 1.005 x1 x 1 = 795 MPa

Factor of safety for the pinion against pitting:

s H1 = σ Sf / σ H = 900 /519.8 = 1.73

Factor of safety for gear against pitting:

s H2 = σ Sf / σ H = 795 /519.8 = 1.53

Table 12.4 Guidance on the necessary factor of safety

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

As per the Niemen guidance for factor of safety given in Table 12.4, for long life gearing
the factor of safety has to be more than 1.3 in pitting. Since for both gear and pinion the
factor of safeties is more than 1.3, the design is adequate.

The final specifications of the pinion and gear are:

20o pressure angle involute teeth with helix angle of 35o, h a = 1m n , h f = 1.25m n

Z mn d da db dr mt
mm mm mm mm mm mm

Pinion 29 5 177.01 187.01 161.76 164.51 6.104

Gear 105 5 640.92 650.92 585.69 628.42 6.104

Φn φt b mm p t mm p a mm

Pinion 20o 23.96o 35 19.165 27.37

Gear 20o 23.96o 35 19.165 27.37

CR t CR a CR FS s b FS s H

Pinion 1.3044 1.2787 2.583 1.99 1.73

Gear 1.3044 1.2787 2.583 1.89 1.53

Indian Institute of Technology Madras

Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

(a) (b)
Fig. 12.12 Dimensional sketch of the pinion and the gear.
(All dimensions are in mm and not to scale.)

Fig. 12.13 Assembly drawing of the double helical gearbox

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Indian Institute of Technology Madras