GEAR DESIGN (IS-4460)(SPUR OR HELICAL)

No. of
Teeth Module Pressure Helix Face RPM Running
Angle Angle Width Time

Z m a b b(mm) n H(hours)

Pinion 19 16 20 20.67 320 260.37 12

Gear 58 16 20 20.67 320 85.29 12

Speed Speed Strenth Zone Bending Surface Pitch

Factor(Str Factor(W Factor Factor Stress Stress Factor
enth) ear) (n=30) (n=30) Factor Factor

Xb Xc Y Yz Sb Sc K For Sc & Sb
See Sheet 2
Pinion 0.355 0.3 0.69 1.9 24.6 2.47 1.45
Gear 0.43 0.365 0.585 1.9 19.7 1.9 1.45 For Xb,Xc,Y&Yz
See Graph

HP(Strength) HP (Wear) HP (Strength) HP (Wear)

Helix (Helix) Spur Spur
HP KW HP KW HP KW HP KW
Pinion 1985.756 1461.517 374.475 275.6136 1705.55975 1255.292 437.0881 321.6968
Gear 1633.067 1201.937 350.4702 257.9461 1402.63585 1032.34 409.0696 301.0752
 TABLE :-1
Relation between depth of case, case-hardening prosses and module,m

Case hardening process Depth of hardness (mm)

Case carburising 0.25 m for m = 1.5 to 4

0.5*(m)1/2 for m = 4 to 30
Induction and flame hardening 0.3 m
Nitriding 0.1 to 0.6
Soft nitriding 0.015
cyaniding up to 0.4

TABLE :-2
Standard value of center distance

50 56 63 71 80 100 112 125 140

160 180 200 224 250 280 315 355 400
450 500 560 630 710 800 900 1000 1120
1250 1400 1600 1800 2000

First Preference
Second Preference

TABLE :-3
Standard Gear Ratio, I

Single Double stage Tripple Single Double stage Tripple

1.25 8 40 3.55 20 112

1.4 9 45 4 22.4 125
1.6 10 50 4.5 25 140

1.8 11 56 5 28 160
2 12 63 5.6 31.5 180
2.24 12.5 71 6.3 35.5 200

2.5 14 80 7.1 40 250

2.8 16 90 8 45 280
3.15 18 100 9 50 315
355
400

TABLE :-4
Recommended series of Modules (mm) IS: 2535

Preferred Choice 2 Choice 3

 1
1.25 1.125
1.5 1.375
2 1.75
2.5 2.25
3 2.75
4 3.5 3.25
5 4.5 3.75
6 5.5
8 7 6.5
10 9
12 11
16 14
20 18
 GEAR DESIGN
Helical gears without correction

Normal Normal Helix

Pressure Module Gear No.of teeth angle
angle ratio

Degree (mm) Degree

an mn I z b

Pinion 20 8 5 17 7.99
Gear 20 8 5 85 7.99

Pitch Base Outside Root Centre

diameter circle diameter diameter distance
diameter
(mm) (mm) (mm) (mm) (mm)
d db da df a

Pinion 137.33 128.90 153.33 117.33 412.00

Gear 686.67 644.51 702.67 666.67 412.00

Transvers
e Transeverse Lead Virtual
module pressure number of
angle teeth
(mm) (Degree) (mm) (mm)
mt at pz zv

Pinion 8.0784 20.18 3073.8 17.50

Gear 8.0784 20.18 15368.9 87.52

Helical gears with correction

Working Addendum Addendum
centre modification modification
distance for pinion for gear

(mm) (mm) (mm)

a' x1 x2
For x1 &x2 see graph in figs. 52,53,54
415 -0.2 0.2 of book M/c Tool Design in chap Gear

Average Centre dis. Working Sum of Addendum

virtual modification normal addendum reduction
number of coefficient pressure modification coefficient
teeth angle
(mm) (rad) (mm) (mm)
zvm y an' x1+x2 k
Pinion 52.51 0.375 0.368 0.385 0.010
Gear 52.51 0.375 0.368 0.385 0.010

Outside Root
Addendum Deddendum. diametre diameter

(mm) (mm) (mm) (mm)

ha hf da df

Pinion 6.321 7.25 149.98 122.83

Gear 9.521 5.25 705.71 676.17
2 see graph in figs. 52,53,54
/c Tool Design in chap Gear
 Basic surface stress and bending stress factor

Basic Basic
Material Condition Min.tensile Brinell surface bending
(Finished strength hardness stress stress
gear) kgf/mm2 HB(kgf/mm2) factor Sc factor Sb
Forged Steels (IS : 1570-1962)
Carbon Steel
C 30 Normalised 50 143 0.985 11.95
60 152 1.125 14.8
C 30 Hardened &
Tempered 58 152 1.125 14.05
C 40 Normalised 60 179 1.44 14.8
Hardened &
C 40 Tempered 70 201 1.63 16.9
C 55 Mn 75 Normalised 72 223 1.83 17.6
Hardened &
C 55 Mn 75 Tempered 80 248 2.11 19.7

Carbon Cromium Steel

Hardened &
55 Cr 70 Tempered 90 225(min.) 2.105 22.2
Hardened &
55 Cr 70 Tempered 100 285(min) 2.47 24.6
Hardened &
40 Cr 1 Tempered 80 229(min) 1.9 19.7

Carbon Manganese Steel

27 Mn 2 Normalised 55 ** ** 13.4
27 Mn 2 Har & Temp 60 170 1.41 14.8
27 Mn 2 Har & Temp 70 201 1.69 16.9
37 Mn 2 ** 70 201 1.69 16.9
37 Mn 2 ** 80 229 1.9 19.7

Manganese Molybdenum Steel

35 Mn 2 Mo 28 Har & Temp 70 201 1.69 16.9

36 Mn 2 Mo 28 Har & Temp 80 229 1.9 19.7
37 Mn 2 Mo45 Har & Temp 80 229 1.9 19.7
38 Mn 2 Mo 45 Har & Temp 90 255 2.105 23.2

Cromium Molybdenum Steel

40 Cr 1 Mo 28 Har & Temp 70 201 1.69 16.9
40 Cr 1 Mo 28 Har & Temp 80 229 1.9 19.7
40 Cr 1 Mo 28 Har & Temp 90 255 2.105 23.2
40 Cr 1 Mo 28 Har & Temp 100 285 2.47 24.6
40 Cr 1 Mo 60 Har & Temp 90 248 1.75 23.2
40 Cr 1 Mo 60 Har & Temp 100 293 2.06 24.6
 15 Cr 1 Mo 55&
25 Cr 3 Mo 55 Har & Temp 90 255 2.105 23.2
15 Cr 1 Mo 55&
25 Cr 3 Mo 55 Har & Temp 155 144 1.16 36.6

Nickel Steel
40 Ni 3 Har & Temp 80 229 1.9 19.7
41 Ni 3 Har & Temp 90 255 2.105 23.2

Nickel Cromium Steel

30 Ni 4 Cr 1 154 444 3.87 35.9
Nickel Cromium Molybdenum
Steel

40 Ni 2 Cr 1 Mo 28 Har & Temp 90 255 2.11 23.2

41 Ni 2 Cr 1 Mo 28 Har & Temp 155 444 3.87 37.3
31 Ni 3 Cr 65 Mo 55 Har & Temp 90 255 2.11 23.2
31 Ni 3 Cr 65 Mo 55 Har & Temp 155 444 3.87 36.6
31 Ni 3 Cr 65 Mo 55 Har & Temp 110 331 2.6 26.7
40 Ni 3 Cr 65 Mo 55 Har & Temp 100 285 2.47 24.6
40 Ni 3 Cr 65 Mo 55 Har & Temp 155 444 3.81 37.3
40 Ni 3 Cr 65 Mo 55 Har & Temp 120 341 3.82 28.8

Surface Hardened Steels (IS : 1570

Carbon Steel
145(core)
C 40 ** 55.2 460(case) 1.97 8.35
200(core)
C 55 Mn 75 ** 70.86 520(case) 2.8 10.55

Carbon Cromium Steel

250(core)
55 Cr 70 ** 86.61 500(case) 3.58 12.91
1% Cr Steel ** 70.86 500(case) 2.8 10.55

Nickel Steel
200(core)
3 1/2% nickel steel ** 70.86 300(case) 3.57 12.91
250(core)
3 1/2% nickel steel ** 86.61 500(case) 3.58 12.91
250(core)
1 1/2% Ni, 1% Cr ste** 86.61 3.58 12.91

Case Hardened Steels (IS : 1570-1

Carbon Steel

0.12 to 0.22% C-Steel 50.39 650(case) 7 28

0.15% C-Steel 50.39 140(core) 7 28
140(core)
0.20% C-Steel 50.39 640(case) 7 28
 Nickel Steel

3% Ni Steel 70.86 200(case) 7.17 28.12

200(core)
3 1/2% Ni Steel 70.86 620(case) 7.17 28.12
250(core)
5% Ni Steel 86.61 600(case) 7.87 33.07
 GEAR DESIGN (IS-4460)(SPUR OR HELICAL)
No. of
Teeth Module Pressure Helix Face RPM Running
Angle Angle Width Time

Z m a b b(mm) n H(hours)

Pinion 23 6 20 9.696 75 1500 24

Gear 38 6 20 9.696 75 907.89 24

Speed Speed Strenth Zone Bending Surface Pitch

Factor(Str Factor(W Factor Factor Stress Stress Factor
enth) ear) (n=30) (n=30) Factor Factor

Xb Xc Y Yz Sb Sc K

Pinion 0.223 0.19 0.66 2.6 37.3 3.87 3.17

Gear 0.245 0.217 0.59 2.6 37.3 3.87 3.17

HP(Strength) HP (Wear) HP (Strength)

Helix (Helix) Spur
HP KW HP KW HP KW
Pinion 461.546 339.6978 128.1255 94.30035 357.158005 262.8683
Gear 453.2985 333.6277 146.3328 107.7009 350.77585 258.171
For Sc & Sb
See Sheet 2

For Xb,Xc,Y&Yz
See Graph

HP (Wear)
Spur
HP KW
165.9882 122.1673
189.576 139.5279
 GEAR DESIGN
Spur gears without correction

Pressure Module Gear No.of teeth

angle ratio

Degree (mm)
a m I z

Pinion 20 8 5 17
Gear 20 8 5 85

Pitch Base Outside Root Centre

diameter circle diameter diameter distance
diameter
(mm) (mm) (mm) (mm) (mm)
d db da df a

Pinion 136 127.80 152 116 408

Gear 680 277.50 696 660 408

Modified spur gears

Working Addendum Addendum

centre modification modification
distance for pinion for gear

(mm) (mm) (mm)

a' x1 x2
For x1 &x2 see graph in figs. 52,53,54
412 -0.2 0.2 of book M/c Tool Design in chap Gear

Average Centre dis. Working Sum of Addendum

number of modification pressure addendum reduction
teeth coefficient angle modification coefficient

(mm) (Degree) (mm) (mm)

zm y a' x1+x2 k

Pinion 51 0.5 21.476 0.01015487 -0.48984513

Gear 51 0.5 21.476 0.01015487 -0.48984513

Tip Outside Root

Addendum Deddendum. clearance diametre diameter

(mm) (mm) (Degree) (mm) (mm)

ha hf c da df
Pinion 10.318761 7.25 2 156.637522 112.8
Gear 13.518761 5.25 2 707.037522 663.2
2 see graph in figs. 52,53,54
/c Tool Design in chap Gear