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MECHANICAL DESIGN
Chapter 9:
Spur Gears Design
1
The AGMA has developed a set of allowable bending stress numbers, called St which
are compared to computed bending stress levels in the tooth to rate the acceptability
of a design.
The AGMA has developed a set of allowable contact stress numbers, called Sac which are
compared to computed contact stress levels in the tooth to rate the acceptability of a design
– Bending stress
Wt Pd
st Ko K s Km K B Kv
FJ
where Ko = overload factor for bending strength
Ks = size factor for bending strength
Km = load distribution factor for bending strength
KB = rim thickness factor
Kv = dynamic factor for bending strength
J = geometry factor Selection of gear material based on
bending stress
Necessary to keep bending stress <
allowable stress.
Valid only if temperature < 121.1°C,
Shigley’s Mechanical
Engineering Design
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14
17
19
24
Stress-Cycle Factor YN
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Engineering Design
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35
36
37
42
43
44
45
Quick review:
Required
Allowable Bending
Stress No:
Required
Allowable Contact
Stress No:
47
49
62
63
Stress-Cycle Factor YN
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Engineering Design
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4. Design of Spur Gears
• Overall objectives:
– Be compact and small
– Operate smoothly and quietly
– Long life
– Low cost
– Easy to manufacture
– Be compatible with other elements in the
machines.
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• General guideline:
– Identify input speed of pinion and the
desired output.
– Choose the type of material.
– Specify the overload factor.
– Specify a trial value for the diametral pitch.
– Specify face width
– Compute/ specify the factors needed to
determine the bending stress and contact
stress.
– Iterate design process to seek for more
optimal designs.
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Lecture Steps:
1. Quick review, gear geometry (Chapter 8)
2. Transmitted loads (overhead)
Required
Allowable Bending
Stress No:
Required
Allowable Contact
Stress No:
Steps for Gear Drive Design:
1. From design requirements, identify speed of pinion, nP,
desired output speed of gear, nG, and power to be
transmitted, P.
2. Choose type of material for the gears (steel, cast iron,
bronze, etc.)
3. Determine overload factor, Ko, using table 9-5
4. Calculated Pdes = KoP and calculate a trial value for the
diametral pitch, Pd (for steel use Figure 9-27). Note
diametral pitch must be a standard size (see Table 8-2).
– Note, as Pd decreases, tooth size increases thus bringing down
St and Sc. But….. As Pd increases, # teeth increases and gear
train runs smoother and quiter and the drive gets smaller as
well!
Steps for Gear Drive Design:
6. Specify Np and NG to meet VR requirement. Calculate center
distance, D, OD to make sure there aren’t any interference issues.
7. Specify face width using recommended range: 8/Pd < F < 16/Pd.
– Remember, increasing face width reduces St and Sc but consider
alignment factor. Face width is normally less than 2X Dp.
7. Compute transmitted load, Wt, pitch line speed, vt, quality
number, Qv, and other factors required for calculating bending
stress and contact stress.
8. Calculate St and required Sat. Does material in 2 meet Sat #? No
– then select new material or define new geometry (step 4). If
yes, continue to 9.
9. Calculate Sc and required Sac. Does material in 2 meet Sac? No –
then select new material to meet Sac and Sat or define new
geometry (step 4). If yes, continue to 10.
10. Summarize design
Problem # 9.61
A gear pair is to be a part of the drive for a milling machine requiring 20 hp with
the pinion speed at 550 rpm and the gear speed to be between 180 and 190 rpm.
Given: Find:
Driven = Milling Machine Compact Gear Design
Power = 20 hp
Pinion Speed = 550 rpm
Output Speed = 180 -190 rpm ≈ 185 rpm
Continuous Use = 30,000 hours
Solution:
Design Power:
Assume: Light Shock Driver and Moderate Shock Driven
Ko = 1.75 (Table 9-5, page 389)
PDesign = (Ko)(PInput)
= (1.75)(20hp)
= 35hp
Trial Size
Pick Sizes
Pd = 5 T/in
Dp = 4.80 in
DG = 14.2 in
Np = 24 teeth
NG = 71 teeth
Tangential Load
Face Width
Assumptions:
Design Decisions
More precision, higher quality number!
Quality Number, Qv = 6 (Table 9-2, Page 378)
Steel Pinion
Cp = 2300 (Table 9-9, Page 400)
Steel Gear
Pinion: JP = .36
Gear: JG = .415
Figure 9-17,
Page 387
Geometry Factors Cont…
Page 402
I = .108
Load Distribution Factor
Equation 9-16, Page 390; Equation is solved on next slide
Page
Load Distribution Factor Cont…
ks = 1.0 since Pd ≥ 5
Rim Thickness Factor
Page
Fig. 14–16
Shigley’s Mechanical
Engineering Design
Rim Thickness Factor Cont…
We are assuming a solid gear blank for this problem, but if not then use:
Min Rim Thickness = (1.2)(.45 in) = .54 in
Hardness Ratio
CH =1.00 for early trials until materials have been specified. Then adjust CH if significant
differences exist in the hardness of the pinion and the gear.
Fig. 14–14
Shigley’s Mechanical
Engineering Design
Stress Cycle Factors
Page 395
Stress Cycle Factors Cont…
Page 403
Bending Stress Numbers
Pinion:
Gear:
Required Bending Stress Allowable:
Contact Stress Number
Required Contact Stress Allowable:
Pinion:
Gear:
Hardness Numbers BENDING (Grade 1)
Page 379
Pinion Bending
Satp = 34,324.5 psi = HB 270
Gear Bending
These stresses are OK
SatG = 28,741.9 psi = HB 215
Go to appendix A3 or A4 and spec out material that meets this hardness requirement! Example AISI 1040,
Temper at 900 F
Summary of Problem
Contact stresses are too High. Must iterate until stress are low enough until
a usable material can be found.
NOTE: Contact Stress generally controls. If material cannot be found for bending,
contact stress is too high!
Shigley’s Mechanical
Engineering Design
Surface Condition Factor Cf (ZR)
• To account for detrimental surface finish
• No values currently given by AGMA
• Use value of 1 for normal commercial gears
Shigley’s Mechanical
Engineering Design
Size Factor Ks
• Accounts for fatigue size effect, and non-uniformity of material
properties for large sizes
• AGMA has not established size factors
• Use 1 for normal gear sizes
• Could apply fatigue size factor method from Ch. 6, where this size
factor is the reciprocal of the Marin size factor kb. Applying known
geometry information for the gear tooth,
Shigley’s Mechanical
Engineering Design
Load-Distribution Factor Km (KH)
• Accounts for non-uniform distribution of load
across the line of contact
• Depends on mounting and face width
• Load-distribution factor is currently only defined
for
– Face width to pinion pitch diameter ratio F/d ≤ 2
– Gears mounted between bearings
– Face widths up to 40 in
– Contact across the full width of the narrowest
member
Shigley’s Mechanical
Engineering Design
Surface Condition Factor Cf (ZR)
• To account for detrimental surface finish
• No values currently given by AGMA
• Use value of 1 for normal commercial gears
Shigley’s Mechanical
Engineering Design
Load-Distribution Factor Km (KH)
• Accounts for non-uniform distribution of load
across the line of contact
• Depends on mounting and face width
• Load-distribution factor is currently only defined
for
– Face width to pinion pitch diameter ratio F/d ≤ 2
– Gears mounted between bearings
– Face widths up to 40 in
– Contact across the full width of the narrowest
member
Shigley’s Mechanical
Engineering Design
Comparison of Factors of Safety
• Bending stress is linear with transmitted load.
• Contact stress is not linear with transmitted load
• To compare the factors of safety between the
different failure modes, to determine which is
critical,
– Compare SF with SH2 for linear or helical contact
– Compare SF with SH3 for spherical contact
Shigley’s Mechanical
Engineering Design
Lecture Steps:
1. Quick review, gear geometry (Chapter 8)
2. Transmitted loads (overhead)
• Large gears
– Frequently fabricated from components.
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• Gear teeth
– Machined by various methods.
– Most popular methods –
• Form milling: mainly used for large gears. A milling
cutter that has the shape of the tooth space is used.
• Shaping: usually used for internal gears. Cutter used
reciprocates on a vertical spindle.
• Hobbing: similar process to milling except that both
the workpiece and the cutter rotate in a coordinated
manner.
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• Recommended quality numbers by
AGMA.
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2. Materials Used
• Main consideration when selecting materials:
1. Producibility of the gear
2. Strength and pitting resistance
3. Weight
4. Appearance
5. Corrosion resistance
6. Noise
7. Cost
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• Steel gear material:
– Through-hardened steels
– Case-hardened steels
• Flame hardened/ induction hardening
• Carburizing
• Nitriding
• Iron and bronze gear materials
– Cast irons
– Bronze
• Phosphor or tin, manganese bronze, aluminum bronze,
silicon bronze.
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