Gear Design Lecture MCL211 Course RKP 28-10-2022

Design of Gears
R. K. Pandey, Ph.D.
Professor
Department of Mechanical Engineering
I.I.T. Delhi, New Delhi-110 106, India
Email: [email protected]
1
Gears appear in works traced back to the mechanics of
the Alexandrian school in 3rd-century BC Ptolemaic
Egypt, and were greatly developed by the Greek
polymath Archimedes (287–212 BC).
Dr. R. K. Pandey, Professor, Dept. of Mech.
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Engg., IIT Delhi
Gear: Machine element
which has teeth cut around a
cylindrical or cone-shaped
surface with equal spacing.
Meshed gearsets are used to
transmit rotations and torques
from the driving shaft to the
driven shaft. There are
different types of gears.
Velocity ratio (VR): The ratio of the number of

revolutions of the driving (or input) gear to the
number of revolutions of the driven (or output)
gear. Dr. R. K. Pandey, Professor, Dept. of Mech.
Engg., IIT Delhi
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Difference between gear and gearing
Gears are rotating mechanical devices employing
'teeth' in order to transmit torque between
separate axes.
Gearing is task done with gears.

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Variety of Gears
Helical gears: teeth are

Spur gears : teeth inclined to the axis of
profiles are parallel to rotation, the angle provides
the axis of rotation, more gradual engagement
transmits motion of the teeth during
between parallel shafts. meshing, transmits motion
between parallel shafts.
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Bevel Gear: teeth are
formed on a conical Straight Bevel Gear
surface, used to transfer
motion between non-
parallel and intersecting
shafts.
Spiral Bevel Gear

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Worm gear set: consists Worm (Screw)
of a helical gear and a
power screw (worm),
used to transfer motion
between non-parallel and
Worm wheel or Gear
non-intersecting shafts.

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Fodder cutting machine

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Fodder cutting machine

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Rack and Pinion set: a Pinion
special case of spur gears
with the gear having an
infinitely large diameter,
the teeth are laid flat. Rack
In 1650s, from French pignon "pinion“.

Engg., IIT Delhi
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Gearset: Two
gears in mesh
Pinion: Smaller
of two gears

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Nomenclature /Terminology

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Law of Gearing
(Constant velocity ratio of gears)
Two teeth come in contact at point Q,

and the wheels rotate in the directions
as shown. TT be the common tangent
and MN be the common normal to the
curves at point of contact Q.
Drawing perpendicular from centres (of

rotation) to MN. Point Q moves in the
direction QC, when considered as a point on
body-1 and in the direction QD when
considered as a point on body-2.

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Assuming v1 and v2 as velocities of
the point Q on the body-1 and
body-2, respectively. If the teeth
have to remain in contact, then
the components of these velocities
along the common normal MN
must be equal.
v1 cos (α) = v2 cos (β)
ω1/ ω2 = O2 N/ O1 M = O2 P/ O1 P
Law of gearing: The common normal at the point of

contact between a pair of teeth must always pass through
the pitch point. Dr. R. K. Pandey, Professor, Dept. of Mech.
Engg., IIT Delhi
15
Fundamental law of gearing
Angular velocity ratio between
gears of a gearset must remain
constant throughout the mesh
mV  out / in  rin / rout
VR (velocity ratio) =
(ωp / ωg) = (dg / dp) = (Ng / Np)
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-Involute profile
-Cycloidal profile Dr. R. K. Pandey, Professor, Dept. of Mech.
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Involute
profile

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Torque ratio or Mechanical
advantage ( mA )
mA  1/ mV  in / out  rout / rin

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Circular pitch : pc   d / N
Diametral pitch : p d  N / d
Module : m  d / N

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Module and
corresponding
tooth size
Standard diametric pitch and corresponding tooth size

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Pressure angle ()
Angle between the line of action (common
tangent) and the direction of velocity at the
pitch point.

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Pressure angle ()
1. Standard values are 14.50 ,

200 and 250 .
2. 200 most commonly used.
3. 14.50 is now obsolete.
14.50 200 250

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Note-
Two mating gears must have the
same diametric pitch or module
(m) and pressure angle ().

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Interference and undercutting
The involute tooth

form is only defined
outside of the base
circle. Portion of
tooth below the base
circle will not be
involute and will
interfere with tip of
the tooth on the
mating gear.
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Difference between base circle, root circle and
dedendum circle.

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1. Minimum number of teeth needed on pinion
to avoid interference
2. Profile shifted gears to avoid interference

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Gear manufacturing:
1. Forming (casting, molding,
drawing, extrusion etc.)
2. Machining (milling, shaping,
hobbing etc.)

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Gear finishing processes:
1. Shaving
2. Grinding
3. Burnishing
4. Lapping
5. Honing
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Gear materials:
1. Grey cast iron
2. Steels [medium to high
carbon (C35 to C60), alloy
steel]
3. Bronzes [Copper alloys]
4. Thermoplastics
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For gear design, the following
steps are essential:
1.Kinematics of gear teeth and gear trains
2.Force analysis
3.Design based on tooth bending strength
4.Design based on tooth surface strength

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Pair of meshed pinion and gear teeth

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Free body diagrams of pinion and gear

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Force analysis (Helical gear)
n = normal pressure angle
t = tangential pressure angle
ψ= helix angle
tan n = tan t cos ψ
Wr = W sin n
Wt = W cos  n cos ψ
Wa = W cos n sin ψ
Where W = total force
Wr = radial component
Wt = tangential component (transmitted load)
Wa = axial component (thrust load)
t = pressure angle (20o or 25o)
Wr = Wt tan t
Wa = Wt tan ψ  = helix angle (10, 20, 30, or 40o)
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American Gear Manufacturers Association
(AGMA) has for many years been the responsible
authority for the dissemination of knowledge pertaining
to the analysis and design of gears and gearing.
AGMA has helped to set national gearing
standards since 1916. The association
also serves the focal point within the
United States for the development of ISO
gearing standards. Today, this work is
carried out by 23 Active Technical
Committees. AGMA standards address
nearly all the critical gearing topics, from
load capacity and lubrication to accuracy
andDr.inspection.
R. K. Pandey, Professor, Dept. of Mech.
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Engg., IIT Delhi
Tooth bending strength
Lewis Formula:
W. Lewis (1892)
was the first to
present a formula
for computing the
bending stress in
gear tooth.

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Assumptions made in deriving Lewis’
equation
1. The load is applied to the tip of a single tooth

i.e. one pair of teeth takes the entire load.
2. The radial component of the load, Wr , is
negligible (it induces compressive load).
3. The load is uniformly distributed across the
full face width.
4. Stress concentration at the tooth fillet is
negligible.
5. Tooth sliding friction forces are negligible.
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1. Highest point of single-tooth contact (HPSTC)
2. Tip loading

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Bending stress
Lewis’ equation,
where
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Modifications in Lewis equation according to
AGMA standards (American Gear Manufacturers
Association)
Modified Lewis
equation
Wt tangential transmitted load

Ka application factor (accounts shocks)
KV dynamic factor (account for internally generated vibration)
KS size factor (refer fatigue concept)
KI Idler factor
Pd transverse diametral pitch
F face width of the narrower member
Km load-distribution factor (accounts axial misalignment)
KB rim-thickness factor (gear has rim and spokes)
J geometry factor for bending strength
which includes root fillet stress concentration factor Kf
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Bending Stress Modifying Factors
Geometry factor J

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Dynamic factor (Kv )

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Application factor, Ka

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Size factor, Ks
AGMA has not established

standards for size factor and
recommends that Ks be set to 1.

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Rim thickness factor, KB
Backup ratio (mB)
KB = -2mB + 3.4 0.5  mB  1.2

KB = 1.0 mB  1.2

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Load Distribution factor, Km

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AGMA Bending Fatigue Strengths
for Gear Materials
Sfb is the corrected strength
KL is life factor
KT is the temperature factor
KR is the reliability factor

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Reliability factor, KR

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Temperature factor, KT
AGMA recommends using temperature factor
of 1 for operating temperatures (lubricant
temperature) up to 250oF. For higher
temperatures it can be estimated from:
KT=(460+TF)/620
This equation is valid for steel made gears.

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KL is life factor

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AGMA Bending Fatigue
Strength for the Steels
may be read from Book
by Norton.

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Surface Durability Analysis
Surface fatigue failure due to

many repetitions of high contact
stresses may be evaluated using
the expression for the surface
contact stress.
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Contact Stresses
Two bodies having curved
surfaces are pressed together then
point/line contact changes to area
contact and the stresses
developed in the two bodies will
be 3-D.
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(a) Two spheres held in (b) Contact stress at
contact by force F face of width 2a
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Stress
components
below the
surface of
contacting
spheres

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(a) Two cylinders held in contact by force F;
(b) Contact stress at face
Dr. R. K. Pandey, Professor,of
Dept.contact
of Mech. of width 2b 61
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Stress
components
below the
surface of
contacting
cylinders

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Plot of
shear
stresses
below the
surfaces
for point
and line
contacts
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Surface Durability Analysis
pmax = 2W/(  b l)
Where,
pmax = largest surface pressure
W = force pressing the two cylinders
l = length of cylinders

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pmax = 2W/(  b l)
1/ 2
 2W (1  ) / E1   (1  ) / E1  
2 2
b
1 1

  l 1/ d1   1/ d 2  
 W 1/ d1   1/ d 2  
c  
2 t

  F cos  (1  1 ) / E1   (1  1 ) / E1  
2 2


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Engg., IIT Delhi
Proper lubricating system
can minimize the surface
damage due to wear and
corrosion. But, surface
fatigue can occur even with
proper lubrication and it’s
the most common mode of
gear failure and is
characterized by pitting and
spalling of the tooth
surface. The damage is
caused by repeated contact
stresses. Dr. R. K. Pandey, Professor, Dept. of Mech.
Engg., IIT Delhi
66
Stress at concentrated line contact
(Buckingham equation)
1/ 2
 W 1/ d1   1/ d 2  
c   t

  F cos  (1  1 ) / E1   (1  1 ) / E1  
2 2


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AGMA Surface Stress Equation
Cp elastic coefficient, (lb/in2)0.5

Wt transmitted tangential load
Ca overload factor (same as Ka)
Cv dynamic factor (same as Kv)
Cs size factor (same as Ks)
Cm load-distribution factor (same as Km)
Cf surface condition factor
d pitch diameter of the pinion
F face width of the narrowest member
I geometry factor
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Engg., IIT Delhi
Surface Geometry Factor (I)
This factor takes into account the radii

of curvature of the pinion/gear teeth
and the pressure angle. AGMS provides
equations for ‘I’ for different type of
gears. Please refer pages 724/725 and
761/764 of the main text book for
procedures of calculation of ‘I’ for spur
and helical gears, respectively.
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AGMA Elastic coefficient, CP

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Surface finish factor Cf
AGMA recommends using

surface finish factor of 1 for gears
made by conventional methods.

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AGMA Surface Fatigue Strength Equation
Refer Table 11-21 for Sfc’

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For CH refer Machine
Design book by
Norton.

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Safety factors against bending failure:
Nb pinion = Sfb/b pinion

Nb gear = Sfb/b gear

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Safety factor against surface failure:
Nc pinion-gear = (Sfc/c pinion ) 2
The safety factor against surface failure is found by

comparing the actual load to the load that would produce a
stress equal to the material’s corrected surface strength.
Because surface stress is related to the square root of the
load, the surface fatigue safety factor can be calculated as
the quotient of the square of the corrected surface strength
divided by the square of the surface stress for each gear in
the mesh. Dr. R. K. Pandey, Professor, Dept. of Mech.
Engg., IIT Delhi
78
Please go through the
case study-7C printed on pages
741-747 of the text book
(Machine Design –An Integrated
Approach written by R. L.
Norton. This will bring clarity
related to the gear design.

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Exercise:
Following figure shows photographic and
schematic views of a reducer (a helical
gear set). The reducer connects a steam
turbine and an alternator in a power plant.
Shafts of the turbine (corresponds to
pinion shaft) and alternator (corresponds
to gear shaft) rotate at 8350 rpm and 1500
rpm, respectively.
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…continued
A need arises to determine the fatigue
safety factors of the pinion and gear teeth
for the data mentioned below:
Centre distance = 432 mm
Power to be transmitted = 3 MW
Plant operation= 3 shifts of 8 hours
Expected life of the reducer= 20 years

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Engg., IIT Delhi
…continued
Assume involute teeth profiles and
number of teeth on the pinion and gear 20
and 111, respectively. AGMA standard
full depth teeth may be used in design.
Both pinion and gear are made of same
material and the mating teeth surfaces
have equal hardness 60 HRC.

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…continued

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Design steps
Step-1:
Number of teeth on gear and pinion:
(Ng)=111, Np=20
Velocity ratio:
mG= Ng/Np=111/20=5.55
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Step-2:
Torque on the pinion shaft:
Tp = P/p
= 3.0 x 106 / (2 x x8350 / 60)
= 3430 N-m

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Step-3:
Output torque:
Tg = mG x Tp = 5.55 x 3430
= 19036.5 N-m

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Step-4:
Transmitted load will be same on

pinion and gear.
Wt = Tp/(dp/2) = 3430/(0.1319/2)
= 52 x 103 N

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Step-5:
Velocity factor (Kv):
Pitch line velocity (Vt)

= (dp/2)p
= (0.1319/2) x (2 x x 8350/60)
= 57.66 m/s
Kv = { 78/ [78+ (200 x Vt)0.5]}0.5

=0.648 Dr. R. K. Pandey, Professor, Dept. of Mech.
Engg., IIT Delhi
88
Step-6:
Various factors:
Size factor Ks = 1.0

Rim thickness factor KB = 1.0 (solid-disk gears)
Load distribution factor Km= 1.8
Application factor Ka = 1.25 (Moderate shock)
Idler factor KI = 1.0 (non idler case)
Bending geometry factor Jpinion = 0.428
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Step-7:
Pinion-tooth bending stress:
bp = {(Wt x pd)/ (F x J)} x ( Ka.Km.Ks.KB.KI/Kv)
= {(52050 x 151.63)/(.190 x 0.428)}

x (2.25/0.65)
= 335.95 MPa
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Step-8: Gear tooth bending stress:
bg = {(Wt x pd)/ (F x J)} x ( Ka.Km.Ks.KB.KI/Kv)
={(52050 x 151.63)/(.190 x 0.61)} x

(2.25/0.65)
=235.71 MPa

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Step-9: Length of action:
Zpg = {(rp+ap)2 – (rp cos )2}0.5 +{(rg+ag)2 –

(rg cos )2}0.5 - Cpg sin 
= { (0.0723)2 – (0.06595 x cos(20.7))2}0.5 +
{ (0.3723)2 – (0.366 x cos(20.7))2}0.5 -0.432

x sin (20.7)
=0.0377 + 0.1462 – 0.1527 = 0.0311 m

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Step-10:
Transverse contact ratio:
mpg =pd x Zpg / (3.14 x cos (20.7)) =1.6
Step-11: Axial contact ratio:
mF = F x pd x tan/3.14 = 0.190 x 151.63 x

0.28/3.14 =2.57
px = pt cot  = 0.0207 x cot 15.67 = 0.0737 m
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Step-12: Normal pressure angle and
helix angle:
n = 200 , b = 14.70

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Step-13: Minimum length of the lines of contact
for mesh:
nrpg = Fractional part of mppg = 0.6
na=Fractional part of mF = 0.57
Lmin pg = {mp pg F – (1-na)(1-nr pg) px}/ cos b
={1.6 x 0.19 - (1- 0.57) (1- 0.6) x 0.0737}/cos 14.7

= 0.301 m
m N pg = F/ Lmin pg = .190/.301 = 0.63
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Step-14:
Radii of curvature of teeth:
p = {{ 0.5 [(rp+ap)+(Cpg-rg-ag)]}2 -(rp cos )2}0.5
={0.00435 - .003805} 0.5 = 0.0233 m
g = Cpg sin  - p = 0.432 sin (20.7)- 0.0233

= 0.129 m

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Step-15: Pitting geometry factor:
Ipg = cos /{ (1/p +1/g) dp mN pg}
= .935/(50.67 x .1319 x 0.63)

= 0.222

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Step-16: The elastic coefficient:
Cp = {3.14 x [(1-2p)/ Ep +(1-2g)/ Eg]}-0.5
= 191.63
Material of pinion and gear is same.

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Step-17: Surface stress at mesh:
c p = Cp { (Wt Ca Cm Cs Cf)/ (F Ipg dp Cv)}0.5
= 191.63 {(52050 x1.25 x1.8x1.0x1.0)/

(0.19x.222x0.1319x.65)}0.5
=1090.5 MPa

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Step-18: Corrected bending-fatigue strength:
Sfb’ = 6235 + 174 HB – 0.126 HB2

=6235 + 174 x 600 – 0.126 x (600) 2
= 65275 x 6890= 450 MPa
This value needs to be corrected for certain

factors. Service life = 20 years continuous
run.

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Operating temperature= 700C
No. of cycles during service =8350 x 20 x 365 x 24 x60

=8.77 x1010
Life factor KL= 1.3558 (8.77 x1010) -0.0178 = 0.86

Temperature factor KT= 1.0
Reliability factor KR = 1.0
Corrected bending fatigue strength:

Sfb = (KLx Sfb’)/ (KTx KR)
=(0.86 x 450)/(1x1) =387 MPa
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Step-19: Corrected surface-fatigue strength:
Sfc’ = 27 000 + 364 x HB= 27000 + 364 x

600 =245400x6890= 1690 MPa
CL = Life factor = 1.44(8.77 x1010) -0.023 =0.81
CT=1.0
CR=1.0
CH=1.0
Sfc = CL x CH x Sfc’ /(CTxCR) = 0.81 x 1690
= 1369 MPa
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Step-20:
Safety factor against bending failure:
Nb pinion = 387/335.95= 1.15 O.K.

Nb gear = 387/ 235.71 = 1.64 O.K.

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Step-21:
Safety factor against surface failure:
Nc Pinion = (1369/ 1090.5) 2 = 1.57

O.K.

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Thank you for your
kind attention
R. K. Pandey, Ph.D.
Professor
Department of Mechanical Engineering
I.I.T. Delhi, New Delhi-110 106, India
Email: [email protected]
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Design of Gears

Velocity ratio (VR): The ratio of the number of

Gearing is task done with gears.

Helical gears: teeth are

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

In 1650s, from French pignon "pinion“.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Two teeth come in contact at point Q,

Drawing perpendicular from centres (of

Dr. R. K. Pandey, Professor, Dept. of Mech.

v1 cos (α) = v2 cos (β)

Law of gearing: The common normal at the point of

Dr. R. K. Pandey, Professor, Dept. of Mech.

mA  1/ mV  in / out  rout / rin

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Standard diametric pitch and corresponding tooth size

Dr. R. K. Pandey, Professor, Dept. of Mech.

1. Standard values are 14.50 ,

14.50 200 250

Dr. R. K. Pandey, Professor, Dept. of Mech.

The involute tooth

Dr. R. K. Pandey, Professor, Dept. of Mech.

2. Profile shifted gears to avoid interference

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

1. The load is applied to the tip of a single tooth

Dr. R. K. Pandey, Professor, Dept. of Mech.

Wt tangential transmitted load

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

AGMA has not established

Dr. R. K. Pandey, Professor, Dept. of Mech.

Backup ratio (mB)

KB = -2mB + 3.4 0.5  mB  1.2

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Sfb is the corrected strength

KT is the temperature factor

KR is the reliability factor

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Surface fatigue failure due to

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.

Dr. R. K. Pandey, Professor, Dept. of Mech.