Ch14 Gear Theory

Chapter 14
Just stare at the machine. There is

nothing wrong with that. Just live
with it for a while. Watch it the way
you watch a line when fishing and
before long, as sure as you live,
you’ll get a little nibble, a little fact
asking in a timid, humble way if
you’re interested in it. That’s the way
the world keeps on happening. Be
interested in it.
Robert Pirsig, Zen and the Art of

Motorcycle Maintenance
Hamrock • Fundamentals of Machine Elements

Thursday April 12, 2012
• Qz#3 – 25 minutes
• Test 3 – Thursday April 26?
• Design mtgs-
• Lecture – Ch 14 –
• Reading- sections 1-4, 6, 7 (exclude 14.7.4),10,11
• Practice problems Ch 14- 3, 5, 8, 16, 18, 20, 23.

Spur Gears
Figure 14.1 Spur gear drive. (a) Schematic illustration of meshing

spur gears; (b) a collection of spur gears.

Helical Gears
Figure 14.2 Helical gear drive. (a) Schematic illustration of meshing

helical gears; (b) a collection of helical gears.

Bevel Gears
Figure 14.3 Bevel gear drive. (a) Schematic illustration of meshing

bevel gears; (b) a collection of bevel gears.

Worm Gears
Figure 14.4 Worm gear drive. (a) Cylindrical teeth; (b) double
enveloping; (c) a collection of worm gears.

Spur Gear Geometry
Figure 14.5 Basic spur

gear geometry.

Gear Teeth
Figure 14.6 Nomenclature of gear teeth.

Standard Tooth Size
Table 14.1 Preferred diametral

Figure 14.7 Standard diametral pitches for four tooth classes
pitches compared with tooth size.

Power vs. Pinion Speed
Figure 14.8 Transmitted

power as a function of pinion
speed for a number of
diametral pitches.

Gear Geometry Formulas
Table 14.2 Formulas for addendum, dedendum, and clearance (pressure

angle, 20°; full-depth involute).

Pitch and Base Circles
Pressure angle 
What is best pressure

angle for torque
transmission?
Standard pressure
angles = ?
Figure 14.9 Pitch and base circles

for pinion and gear as well as line
of action and pressure angle.

Involute Curve
Figure 14.10 Construction of the involute curve.

Construction of the Involute Curve
1. Divide the base circle into a number of equal distances, thus

constructing A0, A1, A2,...
2. Beginning at A1, construct the straight line A1B1, perpendicular
with 0A1, and likewise beginning at A2 and A3.
3. Along A1B1, lay off the distance A1A0, thus establishing C1. Along
A2B2, lay off twice A1A0, thus establishing C2, etc.
4. Establish the involute curve by using points A0, C1, C2, C3,...
Gears made from the involute curve have at least one pair of teeth
in contact with each other.

Contact Parameters
Figure 14.11 Illustration of parameters important in defining contact.

Line of Action
Length of line of action:
Contact ratio:
Figure 14.12 Details of line of

action, showing angles of
approach and recess for both
pinion and gear.
Backlash
Figure 14.13 Illustration of Table 14.3 Recommended

backlash in gears. minimum backlash for coarse-
pitched gears.

Meshing Gears
Figure 14.14 Externally Figure 14.15 Internally

meshing gears. meshing gears.

Gear Trains
Figure 14.16 Simple

gear train.
Figure 14.17 Compound

gear train.

Example 14.7
Figure 14.18 Gear train

used in Example 14.7.

Planetary Gear Trains
Important planet gear equations:
Figure 14.19 Illustration of planetary

gear train. (a) With three planets; (b)
with one planet (for analysis only).

Gear Design Formulae
Design for Bending Stress - next.

Spur Gear Design
(Modified from Design Data, PSG Tech,1995)
DESIGN OF SPUR GEAR
3 (or so) steps:
1. Determine Horse Power based on Lewis Formula

Metallic Spur Gears:
(Tangential)Tooth Load (force)
Wt = S*bw*Y*600 / (Pd. [600 + V])
Where,
Wt = Tooth Load, Lbs
S = Safe Material Stress (static) psi.
bw = Face Width, In.
Y = Tooth Form Factor (Lewis Form Factor See Table 14.7 p-648)
Pd = Diametral Pitch
D = Pitch Diameter
N = speed RPM
V = Pitch Line Velocity, (FPM). = 0.2618 * D* N

Gear Design (contd.)
2. Horse Power Rating

(HP_L) = Wt *D* N / 126051
3. Calculate Design Horse Power

Design HP = HP_L * Service Load factor
4. Select the Gear / pinion with horse power capacity

equal to or more than Design HP.
Given Design HP, we can find tooth load for a given

tooth face width. Then can find, Pd … etc.
For Non-Metallic (e.g. polymer) Gears, tooth load:
W = S*F*Y* {(150 /[200 + V]) + 0.25} / Pd

Gear Quality
Figure 14.20 Gear cost as a function of gear quality.

The numbers along the vertical lines indicate
tolerances. Table 14.4 Quality index Qv for various
applications.

Form Cutting
Figure 14.21 Form cutting of teeth. (a) A form cutter. Notice that the
tooth profile is defined by the cutter profile. (b) Schematic illustration
of the form cutting process. (c) Form cutting of teeth on a bevel gear.

Pinion-Shaped Cutter
Figure 14.22 Production of gear teeth with a pinion-shaped cutter. (a)

Schematic illustration of the process; (b) photograph of the process
with gear and cutter motions indicated.

Gear Hobbing
Figure 14.23 Production of gears through the hobbing process. (a) A

hob, along with a schematic illustration of the process; (b) production
of a worm gear through hobbing.
Allowable Bending Stress
Figure 14.24 Effect of Brinell hardness on allowable bending stress

number for steel gears. (a) Through-hardened steels. Note that the
Brinell hardness refers to the case hardness for these gears.
Allowable Bending and Contact Stress
Table 14.5 Allowable bending and contact stresses for selected gear
materials.
Allowable Bending Stress
Figure 14.24 Effect of Brinell hardness on allowable bending stress

number for steel gears. (b) Flame or induction-hardened nitriding
steels. Note that the Brinell hardness refers to the case hardness for
these gears.
Allowable Contact Stress
Figure 14.25 Effect of Brinell hardness on allowable contact stress

number for two grades of through-hardened steel.

Stress Cycle Factor
Figure 14.26 Stress cycle factor. (a) Bending stress cycle factor YN.

Stress Cycle Factor
Figure 14.26 Stress cycle factor. (a) pitting resistance cycle factor ZN.

Reliability Factor
Table 14.6 Reliability factor, KR.

Hardness Ratio Factor
Figure 14.27 Hardness ratio

factor CH for surface
hardened pinions and
through-hardened gears.

Loads on Gear Tooth
Figure 14.24 Loads acting on an individual gear tooth.

Loads and Dimensions of Gear Tooth
Figure 14.29 Loads and length dimensions used in determining tooth

bending stress. (a) Tooth; (b) cantilevered beam.

Bending and Contact Stress Equations
Lewis Equation
AGMA Bending Stress

Equation
Hertz Stress
AGMA Contact Stress

Equation

Lewis Form Factor
Table 14.7 Lewis form factor for various numbers of teeth (pressure
angle, 20°; full-depth involute).

Spur Gear Geometry Factors
Figure 14.30 Spur gear geometry factors for pressure angle of 20° and
full-depth involute profile.

Application and Size Factors
Table 14.8 Application factor as function of driving power source and

driven machine.
Table 14.9 Size factor as a function of diametral pitch or module.

Load Distribution Factor
where

Pinion Proportion Factor
Figure 14.31 Pinion

proportion factor Cpf.

Pinion Proportion Modifier
Figure 14.32 Evaluation of S and S1.

Mesh Alignment Factor
Figure 14.33 Mesh alignment factor.

Dynamic Factor
Figure 14.34 Dynamic factor as a function of pitch-line velocity and

transmission accuracy level number.

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Chapter 14

Just stare at the machine. There is

Robert Pirsig, Zen and the Art of

Hamrock • Fundamentals of Machine Elements

• Test 3 – Thursday April 26?

• Reading- sections 1-4, 6, 7 (exclude 14.7.4),10,11

• Practice problems Ch 14- 3, 5, 8, 16, 18, 20, 23.

Hamrock • Fundamentals of Machine Elements

Figure 14.1 Spur gear drive. (a) Schematic illustration of meshing

Hamrock • Fundamentals of Machine Elements

Figure 14.2 Helical gear drive. (a) Schematic illustration of meshing

Hamrock • Fundamentals of Machine Elements

Figure 14.3 Bevel gear drive. (a) Schematic illustration of meshing

Hamrock • Fundamentals of Machine Elements

Hamrock • Fundamentals of Machine Elements

Figure 14.5 Basic spur

Hamrock • Fundamentals of Machine Elements

Figure 14.6 Nomenclature of gear teeth.

Hamrock • Fundamentals of Machine Elements

Table 14.1 Preferred diametral

Hamrock • Fundamentals of Machine Elements

Figure 14.8 Transmitted

Hamrock • Fundamentals of Machine Elements

Table 14.2 Formulas for addendum, dedendum, and clearance (pressure

Hamrock • Fundamentals of Machine Elements

What is best pressure

Figure 14.9 Pitch and base circles

Hamrock • Fundamentals of Machine Elements

Figure 14.10 Construction of the involute curve.

Hamrock • Fundamentals of Machine Elements

1. Divide the base circle into a number of equal distances, thus

Hamrock • Fundamentals of Machine Elements

Figure 14.11 Illustration of parameters important in defining contact.

Hamrock • Fundamentals of Machine Elements

Length of line of action:

Figure 14.12 Details of line of

Figure 14.13 Illustration of Table 14.3 Recommended

Hamrock • Fundamentals of Machine Elements

Figure 14.14 Externally Figure 14.15 Internally

Hamrock • Fundamentals of Machine Elements

Figure 14.16 Simple

Figure 14.17 Compound

Hamrock • Fundamentals of Machine Elements

Figure 14.18 Gear train

Hamrock • Fundamentals of Machine Elements

Important planet gear equations:

Figure 14.19 Illustration of planetary

Hamrock • Fundamentals of Machine Elements

Hamrock • Fundamentals of Machine Elements

3 (or so) steps:

1. Determine Horse Power based on Lewis Formula

Wt = S*bw*Y*600 / (Pd. [600 + V])

Hamrock • Fundamentals of Machine Elements

2. Horse Power Rating

3. Calculate Design Horse Power

4. Select the Gear / pinion with horse power capacity

Given Design HP, we can find tooth load for a given

For Non-Metallic (e.g. polymer) Gears, tooth load:

W = S*F*Y* {(150 /[200 + V]) + 0.25} / Pd

Hamrock • Fundamentals of Machine Elements

Wt = SbwY*600 / (Pd. [600 + V])

W = SFY* {(150 /[200 + V]) + 0.25} / Pd