1.

GEAR
1.1. First stage
1.1.1. Geometry of gear:
Selecting material and allowable stress
We pick the 40XH steel normalizing
HB 1=300 , HB2 =280

1.1.2. Contact fatigue limit

σ 0 Hlim 1=2 HB 1+ 70=670 ( MPa)

σ 0 Hlim2=2 HB 2 +70=630 (MPa)

σ 0 Flim 1=1.8 HB 1=540(MPa)

σ 0 Flim 2=1.8 HB 2=504 (MPa)

1.1.3. Number of cycles

2.4 7
N HO 1=30 HB 1 =2.64 ∙ 10 (cycles)
2.4 7
N HO 2=30 HB 2 =2.24 ∙ 10 (cycles)

1.1.4. Equivalent number of loading cycles

c=1
1.1.5. Total working hour
Lh=L ∙285 ∙ 2 ∙8=31920(h)

1.1.6. Safety factor

s H =1.1

s F=1.75

1.1.7. Allowable contact stress

( )
3
T1 t i
N HE=60 cn t Σ Σ
T max t Σ

( )
3
N HE 1=60 cn Σ
T1
T max
ti
tΣ (
=60 ∙ 1∙ 1425 ∙31920 ∙
51
51+52
3
+ 0.6 ∙
52
51+52) 9
=1.6 ∙ 10 (cycles)

( )
3
N HE 2=60 cn Σ
T1 t i
T max t Σ
=60 ∙ 1∙ 329.9 ∙31920 ∙
51
51+52 ( 3
+ 0.6 ∙
52
51+52 ) 9
=0.38 ∙ 10 ( cycles)
Because NHE > NHO, K HL1=K HL2=1

σ 0 Hlim ∙ 0.9
[ σ H ]= sH
∙ K HL

σ 0 Hlim1 ∙ 0.9 670 ∙0.9

[ σ H 1 ]= sH
∙ K HL1=
1.1
∙1=548.2(MPa)

σ 0 Hlim2 ∙ 0.9 630 ∙ 0.9

[ σ H 2 ]= sH
∙ K HL2=
1.1
∙1=515.45(MPa)

[ σ H 1 ]+ [ σ H 2 ] 548.2+515.45
[ σ H ]= 2
=
2
=531.83(MPa)

Checking the condition for [ σ H ]

[ σ Hmin ] ≤ [ σ H ] ≤ 1.25 [ σ Hmin ]=¿515.45 MPa ≤ [ σ H ] ≤ 644.31 MPa
[ σ H ] satisfies the condition
So [ σ H ]=531.83 MPa
[ σ H ]max =2.8 σ ch =2.8 ∙600=1680 MPa
1.1.8. Allowable bending stress
N FE=60 cn t Σ Σ ( )
T 1 6 ti
T max t Σ

N FE 1=60 cn Σ
T 1 6 ti
T max t Σ( )
=60 ∙ 1∙ 1425 ∙31920 ∙
51
51+52 (
+ 0.66 ∙
52
51+52 )
=1.42 ∙ 109 (cycles)

N FE 2=60 cn Σ
T 1 6 ti
T max t Σ( )
=60 ∙ 1∙ 329.9 ∙31920 ∙
51
51+52 (
+ 0.66 ∙
52
51+52 )
=0.33∙ 109 (cycles)

Because NFE > NFO, K FL1=K FL2=1

σ 0 Flim ∙ K FC
[ σ F ]= sF
∙ K FL

K FC =1 because this is a one-way rotation system

 σ 0 Flim 1 ∙ K FC 540 ∙1
[σ F1]= sF
∙ K FL1=
1.75
∙1=308.6 MPa

σ 0 Flim 1 ∙ K FC 504 ∙ 1
[ σ F 2 ]= sF
∙ K FL2=
1.75
∙ 1=288 MPa

[ σ F 1 ]max =0.8 σ ch1=0.8 ∙ 630=504

[ σ F 2 ]max =0.8 σ ch2=0.8 ∙ 600=480
1.1.9. Gear width factor and load concentration factor
Because the gears are parallel, according to table 6.6, we choose ѱ ba=0.25
ѱ bd =0.53 ѱ ba ( u+1 )=0.53 ∙ 0.25 ∙ ( 4.32+1 )=0.71

According to table 6.7, figure 3, we’ll choose

K H =K Hβ=1.1

K F=K Fβ=1.2

1.1.10. Center distance:

Choose
Ka =43 (table 6.5)
[σH] = 476.3 MPa
ѱba = 0.31
KH = KHβ = 1.1
KF = KFβ = 1.2

√ √
T 1 . K Hβ 33370 ∙ 1.1
aw =43 ∙ ( u+1 ) ∙ 3 2
=43∙ ( 4.32+1 ) ∙ 3 2
ѱ ba ∙ [ σ H ] ∙ u 0.25 ∙ 531.83 ∙ 4.32

¿ 112.89 mm

Due to standard, choose aw =125 mm

1.1.11. Modulus m:
m = (0.01 ÷ 0.02) ∙ aw = (0.01 ÷ 0.02) ∙ 125=1.25 ÷ 2.5
Choose m = 2.5 mm.
 1.1.12. Number of teeth:
According to this equation: 8˚≤ β ≤ 20˚
Choose β = 10˚
2 aw cos 10 ° 2 ∙125 ∙ cos 10 °
z1 = = =18.51
m(u± 1) 2.5∙(4.32+1)

Choose z1 = 19 teeth => Driven gear has z2 = z1∙ u = 19 ∙ 4.32 = 82.08 teeth
Choose z2 = 80 teeth
m(z1 + z 2 ) 2.5∙ (19+80)
Helix angle: β= arccos 2 aw
= arccos = 8.1˚
2 ∙125

1 2 m(z + z ) 2.5 ∙(19+80)

Redetermine aw = 2cos ⁡(β ) = 2∙ cos ⁡(8.1) =124.99 125 mm

Transmission ratio after choosing teeth:

z2 80
um = z = 19 = 4.21
1

Transmitter relative error:

Δu = | | 100% = |
um−u
u
∙
4.21−4.32
4.32 |
∙100% = 2.54% < 4%

Recalculate the stress:

√
3
2. 10 T 1 K H (u ± 1)
[ σ H ]=Z M Z H Z ε 2
bw u d w 1

Which:
+ The material of gears is steel => Elasticity factor: Z M = 274 ( MPa3 ¿
+ ZH is the factor taking into account the shape of the contact surface:

ZH =
√ 4 cos β b
sin 2 α tw

atw = arctan ( tanα nw

cosβ ) (
tan 20°
)
= arctan cos 8.1 ° = 20.19˚

tan β b =cos α tw ∙ tan β=cos 20.19 ° ∙ tan 8.1 °

=> β b=7.61 ˚
=> ZH =
√ 4 ∙ cos ⁡(7.61 °)
sin ⁡(2 ∙20.19 ° )
=2.47

+ Zε is a factor taking into account the effect of total contact length:

Zε =
√ √ 1
εα
= 1 = 0.78
1.65

with

[ 1 1
( )] 1 1
[ ( )]
εα = 1.88−3.2 z 1 + z 2 cosβ = 1.88−3.2 19 + 80 cos ( 8.1 ° )=1.65

bw sin β 0.25 ∙125 ∙ sin ( 8.1 ° )

ε β= = =0.56
π .m π ∙ 2.5

Determine the working diameter

2αw 2∙ 125
d w 1= = =47.98(mm)
um +1 4.21+1

1.1.13. Determine the speed of the driving gear

π d w 1 n1 π ∙ 47.98 ∙1425
v= = =3.58 (m/s)
60000 60000

With v=3.58 m/s, from table (6.13), select the degree of accuracy is 9
From table (6.14), with the degree of accuracy is 9 and v ≈ 2.5 m/s
=> K Hα =1.13
=> K Fα=1.37

V H =δ H g o v
√ aw
u
=0.002∙ 73 ∙3.58 ∙
125
4.32 √
=2.81

With δ H =0.002 ( table 6.15 ) ; g o=73(table 6.16)

V H b w d w1 2.81 ∙ 0.25∙ 125 ∙ 47.98
K Hv =1+ =1+ =¿ 1.05
2 T 1 K Hβ K Hα 2∙ 33370 ∙1.1 ∙ 1.13

+ KH: the load distribution between the teeth

KH = KHv.KHβ.KHα = 1.05 ∙ 1.1 ∙1.13 = 1.3
Therefore,
σ H =Z M Z H Z ε
√ 2 T 1 K H (u+1)
bw u d w1
2
=274 ∙2.47 ∙ 0.78 ∙
√ 2 ∙33370 ∙ 1.3 ( 4.32+1 )
0.25 ∙125 ∙ 4.32 ∙ 47.98
2
=644.8(MPa)

K HL Z R Z V K l K xH
[σ H ] = σ 0 Hlim
sH

Which:
+ ZR: affected factor of surface roughness. ZR = 1
+ Zv: factor of velocity. ZV = 0.85v0,1 = 0.85∙ 3.580.1 = 0.97
+ Kl: factor taking into account the condition of lubrication. Kl = 1
+ KHx: factor taking into account the size of the gear. KHx =1
1 ∙1 ∙ 0.97 ∙1 ∙1
[σ H ¿ = 531.83 ∙ 1.1
= 466.86 MPa

So, σ H = 644.8 MPa > [σ H ¿ = 466.86MPa

= > We need to reselect aw
With aw = 160 mm, we got the following parameters
Module m (mm) 2.5
Z1 (teeth) 23
Z2 (teeth) 100
β 16.07
um 4.35
ZH 2.41
Zε 0.78
d w 1 (mm) 59.8
V (m/s) 4.46
K Hα 1.09 K Fα 1.27
V H (m/s) 3.04
KH 1.3
= > σ H =446 MPa
1 ∙1 ∙ 0.987 ∙1 ∙ 1
[ σ H ]=531.83 ∙ 1.1
=477.27 MPa

So, σ H = < [σ H ¿ = > The calculation is satisfied

 1.1.14. Check calculation of bending stress:
2T 1 K F Y F Y ε Y β
σF =
bw d w 1 m

Which:
KFβ = 1.2
K Fα=1.27

V F=δ F g o v
√ aw
u √
=0.006 ∙56 ∙ 4.46 ∙
160
4.32
=9.12

δ F =0.006 , go =56(selected from table 6.15 and 6.16 respectively)

V F b w d w1 9.12 ∙ 40 ∙ 59.8
K Fv =1+ =1+ =1.21
2 T 1 K Fβ K Fα 2∙ 33370 ∙ 1.2∙ 1.27

KF = KFv ∙ KFβ ∙ KFα = 1.21 ∙ 1.2∙1.27 = 1.85

1 1
Yε = ε = 1.64 = 0.61
α

β=8.1 °
β 16.07
Yβ ¿ 1− 140 =1− 140 =0.89

z1 23
zv1 = 3 = 3 =25.92
cos β cos 16.07 °
z2 100
zv2 = 3 = 3 = 112.7
cos β cos 16.07 °

We choose: zv1 = 26, zv2 = 113

Driving gear: YF1 = 3.9

Driven gear: YF2 = 3.60
*[σF] = [σF] ∙ 𝑌𝑅𝑌𝑆𝐾𝑥F
Which:
m=3
YR: the factor taking into account the roughness. We choose YR = 1
YS = 1.08- 0.0625ln (2.5) = 1.02~1
𝐾𝑥F = 1
[σF1] = [σF1] ∙ 𝑌𝑅𝑌𝑆𝐾𝑥F = 288∙ 1∙ 1∙ 1= 288 MPa
[σF2] = [σF2] ∙ 𝑌𝑅𝑌𝑆𝐾𝑥F = 236.57∙ 1∙ 1∙ 1= 236.57 MPa
Therefore,
2 T 1 Y F K F Y ε Y β 2 ∙33370 ∙ 3.9∙ 1.85 ∙ 0.61∙ 0.89
σ F1=
b w d w1 m
=
40 ∙ 59.8∙ 2.5
= 43.5 MPa ¿ [σ F 1] = 288 MPa

YF2
σ F 2 =σ F 1 ∙ =40.1 MPa <[σ F 2 ] =236.57 MPa
YF1

 Bending strength guaranteed.

1.1.15. Checking the overloading
T max
K qt = =2.2
T2

σ H max =σ H √ K qt =447 ∙ √ 2.2=663 MPa<[ σ H ]max =1680 MPa

σ F 1max =σ F 2 K qt =43.5 ∙ 2.2=95.7 MPa< [ σ F 1 ]max =504 MPa

σ F 2max =σ F 2 K qt =40.1 ∙2.2=88.22 MPa< [ σ F 2 ]max =480 MPa

1.1.16. Pitch diameter:

m z1 2.5 ∙ 23
d1= = cos16.07 ˚ = 59.84 mm
cos ⁡β
m z2 2.5∙ 100
d2= = cos16.07 ˚ = 260.17 mm
cos ⁡β

1.1.17. Tip diameters:

da1 = d1 + 2m = 59.84+ 2 ∙2.5 = 64.84 mm
`da2 = d2 + 2m = 260.17 + 2∙ 2.5= 265.17 mm
1.1.18. Root diameters:
df1 = d1 – 2.5m = 59.84 – 2.5 ∙2.5 = 53.59 mm
df2 = d2 – 2.5m = 260.17 – 2.5 ∙2.5 = 253.92 mm
 1.1.19. Summary of the helical gear transmission:
Center distance: aw = 160 mm

Module 𝑚 = 2.5

Gear width 𝑏𝑤1 = 64.8( mm) 𝑏𝑤2 = 59.8( mm)

Transmission ratio 𝑢1 = 4.32

Original profile angle α = 20°
Messing angle α tw= 20.75°
Helical angle 𝛽 = 16.07°

Number of teeth 𝑧1 = 23 𝑧2 = 100

Profile pitch 𝑥1 = 0 𝑥2 = 0
Pitch diameter 𝑑1 = 59.84 (𝑚𝑚) 𝑑2 = 260.17 (𝑚𝑚)

Tip diameter 𝑑𝑎1 = 64.84 (𝑚𝑚) 𝑑𝑎2 = 265.17 (𝑚𝑚)

Root diameter 𝑑𝑓1 = 53.59 (𝑚𝑚) 𝑑𝑓2 = 253.92 (𝑚𝑚)