Design of Machine Elements - II Helical Gears

2.1 Introduction Advantages

Helical gears are similar to spur gears but its teeth are .Helical gears operate more quitely and smoothly than the
cut at an angle which is called as helix angle (a) with Spur gears.
the axis of rotation of the gear. Refer Fig. 2.1. Teeth of helical gears are stronger than the spur gear
Helical gears can transmit motion from one shaft another teeth.
shaft which are parallel to each other.
Efficiency of helical gears is high (upto 99 %).
The helix angles of gear and pinion are same in
These gears are suitable for high speed applieations.
magnitude but of diferent hands. For example, right
hand pinion meshes with left hand gear. The contact ratio of these gears is high than the spur
gears.
In spur gear pair, the contact between the two meshing
teeth is theoretically a line contact which results in Disadvantages Limitations
impact, due to which it generates noise and higher Helical gears are difficult to manufacture as compared to
dynamic load at high pitch line velocities. spur gears.
But, in helical gear pair, the contact between the two gears exert an end thrust which is absorbed by
Helical
meshing teeth begins as a point contact and gradually
thrust bearings.
extends along the diagonal line across the tooth. This
results in smoother and quieter operation even at high In helical gears, the friction, heat generation and wear is
pitch line velocities. high.

8
These gears are more expensive than the spur gears.
Left hand pinion Applications
Helical gears are commonly used in high speed
automobile gear box, machine tool gear box, rolling
mills, steam and gas turbines and other high speed
applications.

2.1.1 Heringbone Gears

Herringbone gears looks like two single helical gears,
-Right hand gear
one right hand and other left hand, placed side by side.
Refer Fig. 2.2.

(a) These gears reduces the end thrust acting on the thrust
bearings.
Ler These gears are used to transmit motion from one shaft
hand
pinion to another shaft which are parallel to cach other.
Herringbone gears are also called as double helical
gears.
Advantages
Rignt Herringbone gears operate more quitely and smoothly.
hand
gear Load carrying capacity of these gears is high.
These gears reduces the end thrust on the bearings.
Efficiency of these gears is high (between 98 % and
9 %).

Disadvantages/ Limitations
A Herringbone gears are difficult to manufacture.
(6)
.These gears are more expensive than the spur and helical
Fig. 2.1: Helical gears gears.

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Design of Machine Elements -
I 2-3 Helical Gears

Herringbone Due to helix angle, there more gradual engagement of

is
pinion-
Lert -RIgnt gear pair which makes the operation more smooth. But,
hand nand higher helix angle results in higher axial thrust which is
undesirable.
For single helical gears, the helix angle ranges from 15
to 30", whereas for double helical gears (Herringbone
gears) it ranges from 25° to 30°.

Two meshing parallel helical gears must have the same

helix angle but opposite hands.

Right- Left If the teeth of helical gear are inclined towards the right,
hand hand it is called as right hand gear whereas, if teeth are
Herringbone
gear inclined towards the left, it is called as left hand gear.

Opposite
Note: In some examples, helix angle is also denoted by|
helical teeth

Herringbone ii) Transverse circular pitch (P:) and transverse module

pinion (m)
Transverse circular pitch is the distance between the
Herringbone
gear corresponding points on adjacent teeth measured along
the pitch circle in transverse plane. It is denoted
y Pt
The module corresponding to transverse plane is called
as transverse module. It is denoted by 'm,'".
Transverse circular pitch is given by,

P TX m = TX 7 mm

b)
where, d = Pitch circle diameter in mm,
Fig. 2.2: Herringbone gears
Z =
Number of teeth
Machining of teeth of these gears is very dificult.
Applications ii) Normal circular pitch (Pn) and normal module (m,)
Herringbone gears are used in high speed applications Normal circular pitch is the distance between the
and especially in hearvy duty machinery. corresponding points on adjacent teeth measured along
the pitch circle in normal plane. It is denoted by 'Pn'

2.2 Terminology for Helical Gear S20 Deca13 The module corresponding to normal plane is called as
Fig. 2.5 shows theview of helical gear and
top normal module. It is denoted by 'mn
corresponding normal plane NN and transverse plane T1 Normal circular pitch is given by,
(See Fig. 2.3 on next page.)
Pn X Mn
i) Helix angle («) Consider A ABE in the Fig. 2.3,
.It is an angle made helix or teeth with the axis of
rotation. t is denoted by 'a. It is always measured on cos& AEPo
AB
the cylindrical pitch surface. Pt

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Design of Machine Elements -II 2-4 Helical Gears

Section((NN)

Pt

Transverse
plane

Normal
P
plane P

AAA Section (TT)

Fig. 2.3: Terminology for helical gear

Pn P: X cos , mm (2.2) v) Transverse pressure angle (o)

The pressure angle measured in the transverse plane
Similarly,
The
m
standard values
m, x cos a, mm (2.3) (plane of rotation) is called as transverse pressure
of normal module recommended by angle. It is denoted by '9'.
ISO are given in the following Table 2.1 vi) Normal pressure angle (n)
First choice 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16,
The pressure angle measured in the normal plane (plane
20, 25 mm, etc. perpendicular to the teeth) is called as normal pressure

Second choice 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5, 5.5,
angle. It is denoted by n'
7, 9. 11, 14, 18, 22, 28 mm, etc. The normal pressure angle and transverse pressure angle
are related as,
Table 2.1
iv) Axial pitch (Pa) tan Pn cos & tan (2.5)
It is the distance between the corresponding points on the The standard values of normal pressure angle are 14.5,
adjacent teeth measured on the surface in the axial 20, 22.5 and 25°. The most commonly used normal

direction. It is denoted by 'pa pressure angle is 20.

Consider A ABD in the Fig. 2.3, vii) Gear ratio or velocity ratio (G)
Gear ratio of helical gear is similar to spur gear i.e. the
AB
tan
AD P
Pa
ratio of the number of teeth on gear to the number of
teeth on pinion or the ratio of speed of driver (pinion) to

Pa
= ,
tan o"mm 2.4)
the speed of driven (gear).

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Design of Machine Elements- 11 2-5 Helical Gears

G Zammdpda dgdp
Lp
. (2.6)

G= "p (2.7) Face advance

nG

where, Zg and Zp = Number of teeth on gear and pinion

respectively

dg and dp = PCD of gear and pinion in mm

ng and n p Speed otf gear and pinion in rpm

Fig. 2.4: Face width of helical gear
Face contact ratio or axial contact ratio or overlap
m, Transverse module in mm
ratio is defined as the ratio of face advance to the
vi) Centre Distance (C.D.) transverse circular pitch. It is denoted by 'Mp'.
It is the distance between the axes of the two meshing Mathematically.
helical gears. It is given by,
_ MF Face advance
C.D. =
p t da m, Zp +m ZG Transverse circular pitch
b-tan a
M Pt
(ii)

During rotation of gear for continuous contact in axial

m, (Zp plane, the face contact ratio should be greater than one.
C.D. + ZG)
means,
Mp 21
ma(Zp + Zg) b-tan a
cos a
Pt
21 . [From equation (ii)

C.D. =
a2-cos"ap+Za
a Zp
|

b P
tan d
ma
C.D.
2-cos P (1+ G) of b
tan d

b2 cos
tan cos a &)

ix) Face width (b) b n

Sin a
Face width of the gear tooth is the length measured
Usually, the minimum recommended value of overlap is
along a line parallel to the axis of gear. It is denoted by
15 % hence, the above equation becomes,
'b'.
Face advance of helical gear can be defined as the
b 5Tm,
sina . (2.9)
distance by which the leading edge of the tooth advances
the trailing cdge of the same tooth but measured along 9m, S b s15 m^
The above equation represents the minimum value of
the pitch circle. It is denoted by 'FA'.
face width of helical gear.
From Fig. 2.4 face advance is,
Generally, the face width is selected such that it satisties
FA- b tan a . (i) both the above conditions.

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Design of Machine Elements - I1
2-6 Helical Gears

x) Tooth proportions
The standard tooth proportions for helical gears are as C.D. =dp +da 94.9102 + 189.8204

follows
=142.3653 mm Ans.
Addendum, ha I mn
Dedendum, hr 1.25 mn (2.10) Step 4:
Calculate the addendum and dedendum
circle diameters of pinion
Clearance, CL 0.25 m,
Ex. 2.1 Apair of parallel helical gears consist of a
ha I mn = Ix 4 =4 mmn
22 teeth pinion meshing with a 44 teeth gear. The helix h 1.25 m, = 1.25 x 4= 5 mm
angle is 22 nd norma 2Ssure angle is 20 f the Addendum diameter of pinion 1s,
normal module is 4 mm calculate:
i) Transverse module and transverse pressure angle dPa dp + 2 ha = 94.9102+ 2x 4
i) Pitch circle diameter of pinion and gear = 102.9102 mm .A Ans.
ii) Axial pitch and centre distamce
iv) Addendum and dedendum circle diameters of pinion Dedendum diameter of pinion is,
Sol.: Given data :

= 22°, n
dpadp -2 hp = 94.9102-2x 5
Zp 22, ZG44, 20", m, 4 mm =
84.9102 mm Ans.
o find: i) m, and ii) dp and dg

ii) Pa and C.D. iv) dpa and d pd 2.3 Virtual Number of Teeth on Equivalent Spur
Gear
Step 1: Calculate the transverse module and
SPPU: Dec-09, 10, 13, 15, May-10, 12, 14, 17, Apr.-15
transverse pressure angle
The concept of equivalent spur gear is used in the design
We know that, m n 4
and analysis of helical gears.
cos Cos (22)
If any helical gear is viewed in the normal plane, the
4.3141 mm Ans. helical gear will appear as an equivalent spur gear.
.This imaginary spur gear is kinematically equivalentto
tan Pn Cos tan o helical gear.
. [From equation (2.5)] This transformation of helical gear into equivalent spur
gear helps in the analysis of helical gear. Refer Fig. 2.5.
tan
tan
n tan(20)
0.3925
cos cos (22) Pitch circle diameter of equivalent spur gear (d'):
If the pitch cylinder of the helical gear is cut by the
21.43 Ans.
normal plane NN, the corrresponding section is an ellipse
Step 2: Calculate the PCD of pinion and gear d
with major axis of and minor axis of d.
cos a
Now, dp m, Zp = 4.3141 x 22
The profile of the helical gear tooth in the normal plane
=94.9102 mm ** AnS. is similar to that of a spur gear tooth having the pitch
4.3141 x 44 circle radius (f) equal to the radius of curvature of the
dG Zg =
ellipse at the point P.
189.8204 mm Ans. Mathematically,
Step 3: Calculate the axial pitch and centre distanece
4.3141 Semi-major axis) 2-cosa
Pa Pt T-m Tx
Semi-minor axis (d/2)
tan a tan a tan (20)

37.2369 mm . (2.1)
Ans.
2-cos a cos a

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Design of Machine Elements -11 2-7 Helical Gears

N
2 cOs a

pse
COS

Normal
plane N

Pitch circle of
equivalent spur gear

Section N-N

Fig. 2.5: Equivalent spur gear

Therefore, the helical gear is equivalent to an imaginary 2.4 Minimum Number of Teeth on Helical Pinion
spur gear in the normal plane with pitch cirele radius r
The number of teeth required on a spur pinion to avoid
and normal module m This imaginary spur gear is
interference can be given by,
known as an equivalent spur gear or formative spur
gear or virtual spur gear. Zp 24ha ... [From equation (1.10)]
. Diameter of equivalent spur gear is, m-sin q

Now, the number of teeth required on an equivalent spur

d' 2 2.12) pinion to avoid interference is obtained by modifying the
above equation i.e.
Number of teeth on equivalent spur gear (2Z) Zp 2 2na . (2.14)
The number of teeth on the equivalent spur gear (Z) is m, Sin "n
called as virtual or formative number of teeth.
Substituting the value of Zp from equation (2.13),
Mathematically,
PCD of an cquivalent spur gear Zp_ 2
ha
Module of an cquivalent spur gear Cos mn S Pn

d/coso d coSs
or p4na
Zp
mn m "COs u m, cos a mn
Sin 9n
.. (2.13) Hence, the minimum number of teeth required on helical
cos C
pinion i
Where, Z = Fomative or virtual number of teeth cos a
Zp 2 h, (2.15)
Z Actual number of teeth on helical gear m, sin -o,
=

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Design of Machine Elements -II 2-8 Helical Gears

From the equation (2.15) clear that, the minimum

it is It is always tangent to the pitch circle at pitch point.
number of teeth required on helical pinion decreases with
increase in helix angle. It is given by,
27TtnpTp 277 nglIG
2.5 Force Analysis of Helical Gears 50 60
SPPU:
.The resultant force acting on the helical gear tooth (F)
May 16
FVdp 60
TtdGhG
60
can be resolved into the following three components
(Refer Fig. 2.6): (2.16)
Ip G ..
Tangential force F, 2. Radial foree F, F(aP/2) (da/
(2.17)

3. Axial Force F,
where, dp and dg = PCD of pinion and gear in mm
1. Tangential force (F): np and gear in rpm
and nG Speed of pinion
The tangential force is a useful component of resultant
force and it is responsible for the transmission of Tp and To = Torque acting on pinion and gear
torque or power. N-mm

Pitch cylinder of
helical gear

(a)

-----------------
-
--.

B--- C D
()

Fig. 2.6: Foree analysis of helical gear

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Design of Machine Elements - I1 2-9 Helical Gears

3. Axial force (F)

The tangential conmponent of force acting on the driving
gear oppOses the rotation gear and assists the The axial force is undesirable component of resultant
of driving
force F. Tt acts in an axial direction.
rotation of driven gear.
2. Radial force (F): .Consider ABDC in Fig. 2.6 (b)
The radial force always tends to separate the two gears. BD
na= DC F
It acts along the radial line through the pitch point and
directed towards the centre. . Fa tan . (2.21)
From Fig. 2.6 (b), The magnitude of axial component of force acting on
Consider AEDC two meshing helical gears is equal but opposite in
ED direction.
tan DC
In order to find the direction of axial or thrust
tan component of force acting on any helical gear, use the
F F (2.18)
following hand rule for the driving gear:
From equation (2.5), we can write, o When the driving gear is of right hand type, use the
tan on right hand rule whereas, when the driving gear is of
tan
cOs a left hand type, use left hand rule.
o In the hand rule, keep the fngers in the direction of

=tan ,
Substituting this value in the equation (2.18), we get

(2.19)
rotation of gear and thumb will indicate the
direction of axial or thrust component of jorce
F cos O
acting on the gear.
Also, from AABC The various combinations of parallel helical gears and
F.=F Sin on .(2.20) corresponding directions of axial components are shown
in Fig. 2.7.

Driving Driving Driving Driving

- -

LH L.H. R.H. R.H.

R.H. R.H. L. LH.

Driven Driven Driven Driven

Fig. 2.7: Direction of axial component of force

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Design of Machine Elements - I1 2-10 Helical Gears

4. Resulk tant force (F)

The resultant force acting on the helical gear tooth s bn
determined by using equation (2.20) or it is given by,
+
F- V+E .. (2.22)

2.5.1 Relation
Pressure
between Transverse
Angle
and Normal

The relation between transverse pressure angle (o) and

normal pressure angle (n) can be obtained as follows:
From Fig. 2.6 (a), consider A ABC, Fig. 2.8: Beam strength of helical gear tooth
AB
tan 9n = .AB = BC tan Pn
BC where, Ob Permissible bending stress in N/ mm

But, ED = AB ..ED =
AB = BC tan on b Face width of virtual spur gear in mm

(1)
COs

Now, consider A EDC,

b Face width of helical gear in mm
ED
tan ED =
DC tan o, (i1)
DC a Helix angle

Equating equation (i) and (i), m Normal module in mm

BC. tan on DC tan o Y Lewis form factor based on virtual

number of teeth i.e. Z.
tan BtanOn The above cquation (i) can be written as,
DC
b
kanPn.. DC Fbn mn .
Y
tan P cos RC**
(2.23) cOs &
cos

Obb mnY .. (ii)

2.6 Beam Strength of Helical Gear Tooth cos &

Helical gear is equivalent to an imaginary spur gear i.e. From Fig. 2.10 the component of "Fbn in the plane of

virtual spur gear in a plane perpendicular to the tooth rotation is,

element. b bn cos ii)

To find the beam strength of helical gear tooth, the

Substituting the value of equation (i1) in the equation (ii),
helical gear is replaced by imaginary or virtual spur gear
in a plane perpendicular to the tooth element. bb mn Y
b cOs &
COs &

From Chapter 1, the Lewis equation for beam strength of

spur gear Is given by, (2.24)
Fb
bb mnY
Ob b mY The above equation (2.24) is called as Lewis equation
.. |From equation (1.17)] for beam strength of the helical gear tooth.

Now, the beam strength of the virtual spur gear in the 2.6.1 Lewis Form Factor
plane perpendicular to tooth element (in normal plane) is The standard values of Lewis form factor based on
given virtual number of teeth (Y) for various tooth systems are
given in the Table 1.4 of Chapter 1.
bn b b mn Y ()

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Design of Machine Elements - 11 2-11 Helical Gears

When the table for the standard values in not available then use the following standard relations

Y = 0.55-2.642 for 20 stub system

Z

=
Y 0.484- for 20° full depth involute system . (2.25)
Z
.148
Y = 0.39 -
for 14.5° full depth involute system
Z

2.6.2 Permissible Bending Stress

The permissible bending stress or bending endurance strength for helical gear or pinion is similar to spur gear.
It is given by,
(2.26)

where, Sut Ultimate tensile strength of gear material in N/mm.

Note
While designing a gear pair, it 1s necessary to find the weaker member between the gear and pinion
in bending.

If the product of (X Y)pinion (bX Y )gear then the gear is weaker in bending. If the
product of (Gbx Y) pinion (b X Y)gear then the pinion is weaker in bending.
In some applications the gear and pinion are made of same material, then 'G, is same for both of
them. At that time Y (Lewis form factor) is a designing parameter. In such cases, pinion is always
weaker because Ypinion is always less than the Ygear

2.7 Wear Strength of Helical Gear Tooth

Similar to the beam strength, the wear strength of the helical gear tooth can be
found by replacing the helical gear pair by the virtual or imaginary spur gear in a
plane perpendicular to the tooth element.
From Chapter 1, the Buckingham's equation for wear strength of spur gear is
given by,

Fwdp b Q K [CFrom equation (1.21)]

Now, the wear strength of the virtual spur gear in the plane perpendicular to Fig. 2.9: Wear strength of
tooth element (in normal plane) is given by, helical gear tooth

Fwndp b O K . (1)

where, dp PCD of the virtual spur gear in mm = -

cos a

dp = PCD of the helical pinion in mm

Face width of virtual spur gear m

ncos
b = Face width of helical gear in mm

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Design of Machine Elements - I1 2-12 Helical Gears

a = Helix angle
nNormal pressure angle
- Ratio factor for virtual gear pair The simplified expression for load-stress factor K for
different gear and pinion material combinations with 20
2 ZG pressure angle are as follows (Refer section 1.11.1 of
2 ZG cOS chapter 1)
ZG+ Zp ZG 1. For steel gear and steel pinion
cos a cos a
mm
K 0.16 N
100
ZG + Zp
2. Cast iron gear and cast iron pinion
For external gear pair,
Zg+Zr BHN
(2.30)
... (2.27) K 0.21| 100 N mm
For internal gear pair, Q 2ZoZ
=0ze- 3. Cast iron gear and steel pinion
K = Load-stress factor in N/mm

osin, cosa-), K 0.18 BHN N mm

K
1.2732 L Ep G -K 100

.. (2.25)
Substituting all these values in equation (),
2.8 Effective Load on Helical Gear Tooth
SPPU: May-17

dp D_. Effective load on helical gear tooth is defimed as the

Fwn Q. K
cosa cos a total maximum tangential load (force) acting on the
helical gear tooth.
Fwn
dp b Q.K (ii)
cos The theoretical tangential torce acting on the gear tooth
for power transmission 1s,
From Fig. 2.11 the component of "Fwn in the plane of
Power P Fx V
rotation 1s,

Fw Fwn cOs (iii)

Substituting the value of cquation (ii) in the equation (ii),

(2Tnp Tp/60) (2Tng To/60)
dp b Q K
COS
(T dp np/60) (T d G nG/60)
cos
Tp TG
(2.31)
F dpb Q. K
(2.29)
dp/2) (To/2)
COs The theoretical tangential force depends upon the rated
The above equation (2.29) is called as Buckingham's power and rated speed. In addition to this, the other
equation for wear strength of the helical gear tooth. factors which are considered in the estimation of
where, Surface endurance strength of weaker effective load are as follows
surface in N mm
1. Fluctuation of torque because of prime-mover
p and eG = Poisson's ratio for pinion and gear and driven machine.
material 2. Non-uniform distribution of load across the face width.
3. Tooth error and pitch line velocity (Dynamic load).
Ep and EgG Modulus of clasticity for pinion and
gear material in N/mm

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Design of Machine Elements - II 2-13 Helical Gears

2.8.1 Fluctuation of Torque because Fa

21 V [bC-cos-+ Fmaxx cosa... (2.33)
Prime-mover and Driven Machine 21 V+ybC cosa + max
The fluctuation of torque because of prime-mover and
driven machine is accounted by service factor or where, a Dynamic load in N
application factor i.e. "K,'
V Pitch line velocity in m/sec
The different values of 'K," are given in the Table 1.5 of
Chapter 1. (Refer section 1.12.1). C Deformation factor in N/mm

2.8.2 Non-uniform Distribution of Load Across the b = Face width of tooth in mm

Face Width
F max Maximum tangential force in N
The non-uniform distribution of load across the face
width is accounted by the load distribution factor i.e.
Kam
Km
The deformation factor or dynamic factor depends upon
The different values of Km' are given in the Table 1.7
the gear materials and the form of tooth (pressure angle).
of Chapter 1. (Refer section 1.12.1).
It is given by,

2.8.3 Dynamic Load

C K-e -= K-epEg
KeEp+Eo)
It is already discussed in sections 1.12.2 and 1.13 of
Chapter that, there are two basic methods to account
for the dynamic load.
where, Ep and Eg = Modulus of elasticity of pinion and
1. Preliminary estimation by velocity factor. gear material in Nmm
Precise estimation by Buckingham's cquation.
Sum of errors between two
1. Preliminary estimation of dynamic load by velocity
meshing teeth in mm
factor
Due to the type of contact, the dynamic load on helical K = Tooth form factor
gear is less than that of on spur gears.
= 0.107 for 14.5° full depth involute
The dynamic load is accounted by multiplying a factor
called as velocity factor (K, ) It is similar to as in case system
of spur gears
= 0.111 for 20° full depth involute
The different values of velocity factor are given in Table
1.8 of Chapter 1. (Refer section 1.13.1). system
The effective load between the two meshing teeth in
= 0.115 for 20° stub tooth involute
tangential direction is,
Fefr Ka Km
Ky
-
amKy
The incremental
system
dynamic load (Fa) calculated by
(2.32) equation (2.33) is always more than the load calculated
2. Precise estimation of dynamic load by Buckingham's by the velocity factor method.
equation
In this case, the etfective load between two meshing
In the final stages of gear design, when the dimensions
teeth 11s,
of gear are known and errors are specified, the dynamic
load can be more accurately found as an incremental Fefr Fmax + Fa = K, -Km Fi + Fa
load by using Earle Buckingham's equation of dynamic
(2.34)
load.
The Buckingham's equation for the dynamie load on
helical gear tooth in tangential direction is,

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Design of Machine Elements- II 2-14 Helical Gears

2. Safety against wear failure

The simplified expression for deformation factor (C) for
In order to avoid the failure of gear tooth due to pitting
various gear and pinion material combinations with 20
or wear, the wear strength (F») must be greater than the
pressure angle are as follows
effective load (Feff ) between the meshing teeth. It means,
(i) Steel gear and steel pinion
F Feff

C 11500e Nmm 2.35) Introducing the factor of safety.

(i) Cast iron gear and cast iron pinion Fw FOS x Feff (2.40)
C 8900e N/mm .(2.36) where, FOS= Factor of safety
(i) Cast iron gear and steel pinion
10000 e N/mm .(2.37) 2.10 List of Formulae
Pitch error between meshing teeth 1. Transverse module :
m, =7 mm
The sum of pitch errors between two meshing teeth is
given by,
2. Normal module : m, = m,cosa, mm
Cp t CG mm (2.38) 3. Axial pitch : m
Pa tan a mm
where, CpPitch error for pinion in mm 4. Nornmal pressure angle: tan o, = cos tan o
eG Pitch error for gear in mm . Gear ratio G =G
dp
= "p
G
It depends upon the quality of gear, size of gear and the
method of manufacturing. The expected error on the gear 6. Centre distance
ptdG
cos (Zp Zg), mm
or pinion teeth is considered to be equal to tolerance. CD. - = +
2 &
The tolerance for adjacent pitch error (e) for various I.S.
grades are given in the Table 1.9 of Chapter 1. (Refer .Face width :
b21.1 Sin*n,
a
mmn

section 1.13.2).
9m b S15 mn, mm
In this case, op = mn +0.25 vd
8. Minimum number of teeth on helical pinion :

2.9 Safety of Helical Gear Pair

P min
2-h, cos a
In order to avoid the failure of gear tooth, it must be
m
Sin on
safeagainst the following: 9. Addendum haI mn mm
1. Safety against bending failure. 10. Dedendum: hm 1.25 mg mm
2. Safety against wear failure. 11. Pitch line velocity :

1. Safety against bending failure

v =
Tdp
60
np - aG",
60
m/se

In order to avoid the failure of gear tooth due to bending

12. Formative number of teeth:Z=-
cos
or tooth breakage, the beam strength (Fb) must be greater
13. Forces acting on helical gear tooth:
than the effective load (Fefr ) between the meshing teeth .
lG
d p /2)
da/2).N
,
t means,

FFor F=F tan N

Introducing the factor of safety,
F= F tan o, N
F = FOS x Fefr 2.39)
where FOS = Factor of safety
F
V +(F,+ (F.
F ,N
sin

Copyrghiod rmateria
Design of Machine Elements - II 2-15 Helical Gears

14. Beam strength of helical gear tooth : 21 V [bC cos-a + max

Fa cos a, N
Fb
bb m Y,N 21
V+b C cos + F max
ut (Buckingham's equation)

Y
.642
3 - KeE N N/mm
=
0.55- for 20 stub system
C = 11500 e, N/mm for steel gear and steel
2.865
Y =
0.484- for 20° full depth involute system pinion with on = 20°
2.148 C 8900 e, N/mm for cast iron gear and cast
Y = 0.39- for 14.5° full depth involute system
iron pinion with = 20 o
If (b X Y p < (bX Y G then pinion is weaker in C = 10000 e, N/mm for cast iron gear and
bending steel pinion with o, =20
If (G, X Y )p > (Gb X Y )g then gear is weaker in 19. Pitch error: e = cp G mm

bending 20. Safety of gear pair

15. Wear strength of helical gear tooth: F FOS x Fefr for safety against bending failure

Fw
dpb.Q K, N Fw FOS x Fefr for safety against pitting failure
cos
2 ZG
for external gear pair 2.11 Solved Examples

Ex. 2.2 hand 20 teeth pinion is in mesh with

A lefi
Q Z for internal gear pair
right hand gear of 44 teeth. The pinion and gear are
made of steel having permissible bending stress of 120
cos
K sin on -)
*
(1-4 MPa. The gear pair is heat treated to a surface hardness
1.2752 Ep EG of 300 BHN. The starting torque is 35 % greater than the
rated torque. The require factor of safety is 2 with 20
K 0.16 BHN
T00
N mm for steel gear and
full depth invoute and helix angle is 24% Assume, face
Width is ten times normal module. Ihe pimon rotates at
steel pinion with on = 20 1440 rpm and transmits 20 kW power. Assume,
5.6
Ky Determine the magnitude and direction
K BH
0.21
100
Nmm for cast iron gear 56+ V
of Jorces acting on meshing teeth. Assume the pinion
and cast iron pinion with on = 20°
rotates in clockwise direction when viewed from the lefi
BHN side and it is below the gear.
K 0.18| T00 N mm- for cast iron gear
Sol.: Given data :

and steel pinion with on = 20

16. Maximum tangential force:
Zp 20, Zg = 44, bP ObG= 120 MPa, n 20",
(BHN)P = (BHN)G = 300, Ka = 1.35, FOS = 2,
= Ra PNN
t max Ka Km *
Km
= 24, b = 10 mn, np 440 rpm,

17. Preliminary estimations of effective (dynamic) laod :

P 20 kW 20x 10* W

t max K Km ,N
eff Ky To find: Forces on meshing gears
18. Precise estimation of effective load: Step 1: Calculate the beam strength of pinion
Fa = Ka Km
FefrF max + F + Fa N When the pinion and gear are made of same material, at
that time always pinion is weaker than the gear n bending.

Copyrighted material
Design of Machine Elements - 11 2-16 Helical Gears

Beam strength of pinion is,

b bPb m Yp
But, bP 120 MPa, b= 10 m,n

Zp 20
26.2324
cos a (cos 24)

Yp 0.484-
2.81 2.87
0.48426.2324
Zp
- 0.3745
Substituting all these values in equation (i,
120 x 10 m, x m, x 0.3745

449.4 m, N (11)

Step 2: Calculate the wear strength of gear pair

Fw
dp b QK (ii)
COS (

But, dp *Zp ="cos

COS a
Zp

x 20 21.8927 mn, nm
cos (24)

b = 10 mn

2ZG 44 1.375
Zg + Zp44+ 20
K 0.16| BHN = 300
0.16 100)
T00

= 1.44 N mms .(Assume)

Substituting all these values in equation (ii),
21.8927 m, x m, x 1.375
10 x 1.44
w
(cos 24)

F 519.4026 mg, N iv)

As F, < Fw gear pair is weaker in bending than the pitting failure. Therefore, it is required to design a gear
pair against the bending failure.

Step 3 Calculate the effective load on gear pair

Feff Ka KmF . (V)

Ky

But, v Tdp50np TTX 21.8927

50
m, X 1440

=
V 1.6506 m, x 10°, mm/sec

Copyrighted materinl
Design of Machine Elements - 2-1 Helical Gears

= 1.6506 m,, m/sec

F P_20 x 10 12.1168 x
,N
v1.6506 mn mn

.6 5.6
Ky
5.6+V 5.6+ I.6506 mn

5.6
5.6 + 1.2847 m
Ka 1.35 and assuming Km =1

Substituting all these values in equation (v),

1.35x 1
12.1168 x 10
Feff
mn
5.6
5.6 + 1.2847 m,
2921.0142(5.6 + 1.2847 m,)
Feff

16.3576x 10 +3.7526x 10 Vmn)

Feff
"n

Step 4: Calculate the value of module and other dimensions

For safety against bending failure,

Fb FOS x Feff

16.3576x 10 +3.7526 x 10 ym
449.4 m 2x-
224.7 m 16.3576 x 10 +3.7526 x 10 ym,
Solving the above equation by trial and error method, we get

mn 4.7814 mm
Selecting the standard value of module from the Table 7.1,

n 5 mm
Other dimensions
5
m cos a cos (24)
= 5.4731 mm

b = 10 m, = 10 x 5= 50 mm

dp= m Zp = 5.4731 x 20= 109.4636 mm

d m Zg = 5.4731 x 44 240.8199 mm

Copyrighted materinl
Design of Machine Elements- II 2-18 Helical Gears

t da 109.4636+ 240.8199 Ex. 2.3 helical pinion having 14 teeth to be made

A
C.D. - dp
2
of alloy steel (S = 800 NImm) is to mesh with a gear
175.1417 mm made of plain carbon steel (S 720 Nmm'). The gear
pair is required to transmit 30 kW power from an electric
ha Im, = Ix 5 =5 mm motor running at 720 r:p.m. to a machine running at 225
h 1.25 mn = 1.25 x
5 = 6.25 mm r.p.m. The application Jactor and load concemtration
Ans. factor are 1.3 and 1.I respectively. The required factor of
safety is 2.0. The jace width is ten times the normal
Step 5: Calculate the forces acting on helical gear
module. The tooth system is 20° full-depth involute, while
pair
the helix angle is 25. The gear pair is machined to meet
Tangential component of force 1s,
the specifications of grade 7. The deformation factor for
12.1168 x 1012.1168 x 103 gear pair is 11000 N/mm. Design the gear pair by
F
n using the velocity factor and Buckingham 's equation for

2423.36 N dynamic load. Suggest the surface hardness jor gear pair.
5.6
Use the following data : Velocity factor, K,
F tan o=FcostanPn 5.6+ V
Lewis form factor,
2423.36 x tan(20) 965.503 N 87 Load-stress
cos (24) Y 0.484- factor
Fa - F tan = 2423.36 x tan (24) K 0.16 [BHN/100J N/mm',
1078.9493N ** Ans. Forgrade 7: e = I.0 + 0.9 [mn + 0.25 vd] um
Fig. 2.10 shows the components of forces acting on gear Buckingham's equation for dynamic load in tangential
pair. direction F,
=
0C cOSy + Fmax ] cosy
21V+ybC cos y + Fmax
Standardmodules (mm): 1.0, 1.25, 1.5, 2.0, 2.5, 3.0, 4.0,
5.0, 6.0, 8.0, 10.0, 12.0 and 16.0.
SPPU: May-06, Dec.-08, 11, 12, Marks 166
Sol.: Given data :
Zp = 14, (Sut )p = 800 N/mm, (SutG720 N/mm,
R.H.
P= 30 kW= 30x 10° W, np = 720 rpm, ng = 225 rpm,
,
K = 1.3, Km = 1.1, FOS = 2, b= 10 m, = 20,
a = 25°, C = 11000 e N/mm

To find : Design a gear pair and surface hardness of gear

pair.

- LH.
Step
weaker

We know that,
1: Check whether gear is weaker or pinion is

obp utP = o = 266.667 N/mm

and bG ut G720 - 240 N/nmm

3
Fig. 2.10

opynghted material
Design of Machine Elements - II 2-19 Helical Gears

Gear ratio G V
m, x 14 x 720
=X cos
nG (25) x 60

720 582.349 mn, mm/sec

225 G 44.8
V = 0.5823 mn m/see

ZG 5 P 30x10_S1.5198x 10 ,N
p 14
F V 0.5823 ma
Now, Zp = 18.8061
cos a (cos 25)
Ky = 5.6
5.6+V
and LG 45 = 60.4484
cos (cos 25) 5.6 ... (Given)
S.6+ 0.5823 m
Lewis form factor,

Yp = 0.484 2. 87 Ky 5.6
-
Zp 5.6+0.763ma
Ka 13 and Km = 1.1 . (Given)
=
0.484 2.8/= 0.3315
8. .8061
Substituting all these values in equation (ii),
1.3x1.1 51.5198x 10
and YG 0.484 40ZG Feff
5.6 m
0.484 2.87- 0.4365 5.6+0.763 m,
60.4484
13.1559x 10 (5.6+0.763 m,)
Feff
Now, bp Yp = 266.667 x 0.3313 88.3467 N/mm* mn

and bG YG = 240 x 0.4365 = 104.76 N/mm 73.6733x 10* + 10.0379x10 ym

Feff (111)
mn
As Obp Yp ObGYG, pinion is weaker than the gear in
bending. Therefore, it is required to design a pinion for Step 4: Calculate the value of module and other
bending. dimensions
Step -2: Calculate the beam strength of pinion For safety against bending failure,

Fb bP:b m, Yp Fb FOSx Feff

266.667 X 10 m, X m x 0.3313
883.4677 m
73.6733x10 +10.0379x10 m
. 2x
Fb 883.4677 m. N (1)

As surface hardness of gear is unknown, we cannot find From equations (i) and (ii)]
wear strength of gear pair. m ym
441.7338 = 73.6733x 10 + 10.0379x 10

Step -3: Calculate the effective load on gear pair

Solving the above equation by using trial and error
Fef Ka Km ..(i) method, we get

-
m 6.0616 mm
p np Lp
But, td *np
Selecting the standard value of module from the given
60 60
values i.e.
T m Zp np
cos & X 60 m 8 mm AnS.

Copyrightod materal
Design of Machine Elements - II 2-20 Helical Gears

Other dimensions

n
COS cos (25)
.827 1mm

b 10 m 10x 8 = 80 mm
dp m, Zp = 8.827x 14 = 123.5783 mm
m ZG = 8.827x45 = 397.215 mm
dp +dG 123.5783+ 397.215
C.D. = - 260.3966 mm

ha I m, = 1x8= 8 mm
h = 1.25 m, = 1.25x 8 10 mm ** Ans.

Step 5: Calculate the dynamic load by using Buckingham's equation

Buckingham's equation for dynamic load is,

21 V [bC cos.* Timaxx cos a (C=V) (iv)

d
21 V+ bC cos- a + Fi max
But 0.5823 m, =0.5823 x8
4.6584 m/sec

b 80 mm

51.5198 x 10 51.5198 x 105

n
6439.975N

Tt max Ka Km F =1.3 x 1.l x 6439.975

9209.1642 N
Now, pitch error for grade 7,

e 11+0.9 [m +0.25 vd] .. (Given)

For pinion, ep 11+0.9 [m, +0.25 Jdp]

P 11+0.9 [8+ 0.25 V123.5783]

20.7012 um

For gear, G 11+0.9 [m, +0.25 Jdg

G 11+0.9 [8+0.25 397.215]

22.6843 um

But eCp teg = 20.7012 + 22.6843

e = 43.3855 um = 43.3855x 103 mm

Copynghted materal
Design of Machine Elements - II
2-21 Helical Gears

Deformation factor, C 11000e (Given)

C 1
1000 x 43.3855 x 10
477.2405 N/mm
Substituting all these values in equation (iv),
21 x 4.6584 [80 x 477.2405 x (cos 25)+9209.1642] cos (25)
21x 4.6584 + 80x 477.2405 x (cos 25) +9209.1642

d 12.0199 x 10* N

Step 6 Calculate the available factor of safety

:

Effective load for precise estimation is,

Ft max + Fa = 9209.1642+ 12.0199 x 103
Feff

Fefr 21.2291 x 10 N
As gear pair is weaker in bending,

F FOSx Feft
883.4677x (8)*
FOS
eff 21.2291 x 10

FOS = 2.6634 > 2 . Ans.

As the available factor of safety of gear pair is higher than the required factor of safety, the design of gear pair is safe.

Step 7: Calculate the surface hardness of gear pair

Wear strength of gear pair is,

Fw
dp b-0-K (v)
cosa
But, dp 123.5783 mm, b= 80 mm
Q Zg+Zr
2ZG 2x 45 1.5254
5+14 -
1.5254

K
=
0.16 3HN
100
. N mm .(Given)

Substituting all these values in equation (v),

123.5783 x 80 x 1.5254x 0.16 (BHN
Fw 100
(cos 25)2

Fw 2937.5448 N

For safety against pitting failure

F FOS x Feff
2937.5448 BHN) 2 x 21.2291 x 10
100

BHN 380.1793 =385 ** Ans.

opyngntod matonal
Design of Machine Elements- II 22 Helical Gears

Ex. 2.4 The following data is given for a steel helical Approximate centre distance is given by,
gear pair transmitting 150 kW power from a shaf
rotating at 1440 r.p.m. to another shaft rotating at C.D. = (Zp +ZG)
360 r.p.m.
cosa
Cenire distance approximately 433 mm,
=
435 = n x (20+80)
Helix angle = 24, Face width 14 x normal module 2x cos (24)
Number of teeth on pinion = 20
bending stress for pinion=
m 7.9478 mm
Permissible 152 N
/nm
Permissible bending stress for gear = 125N / mn Considering the nearest standard value i.e.
Tooth system 20" fiull-depth involute, m 8 mm
Service factor = 1.53
Combined teeth error = 0.0406 mm, Now, the exact centre distance is,
Deformation factor = l1600 e, N /mm
Assuming the dynamic load is accounted by the
Buckingham's equation, calculate:
C.D.
.cos
cosa Zp +Z26)
8
) The factor of safety against bending failure; and 80)
i) The surface hardness, if the factor of safety against 2x cos(24)0+
pitting jailure is 1.5. C.D.= 437.8545 mm
Use the following data:
Load stress factor, K = 0.16 [BHN /100]-, N /mn Step 2: Calculate the effective load on gear pair

Lewis form factor, Y Effective load for precise estimation is,

25 27 28 75 100 150 Feff Fmax +Fa = Ka Km F +Fa (1)

Y 0.3393 0.3456 0.3487 0.3519 0.4335 0.4461 0.4587 But, V=

Ttdp np T m Zp np

Buckinghanm's equation for dynamic load in tangentia t m ZP np

direction: COs & X 60
21 V(bC cos y +Fmax )cOsy x 1440
TX 8 X
20
y =
21V+ybC cos +F max V cos (24) x 60

and Fmax KgKmFSPPU: Dec.-06. May-12, Marks 16 13.2053 x 10 mm/sec = 13.2053 m/sec

Sol.: Given data :

x 10
P15013.2053 11.359 x 105 N
F =
P 150 kW = 150 x 10 W, np = 1440 rpm,

nG 360 rpm, C.D. =435 mm, 24°, b = 14 mn a F max Ka "Km F

Zp 20, ObP = 152 N/ mm-, ObG =125 N/mm, = 1.53 x 1x 11.359 x 10
n 20, K, = 1.53, e
=
0.0406 mm, C = 11600 e N/mm . Ft max =
17.3793 x 10° N.(Assuming Km =)
To find: i) (FOS) bending (i) Surface hardness,
Dynamic load is given by,
if FOS = 1.5

Step 1: Caleulate the normal module of gear pair Fa 21V[bC: cos-a+ F max X cOS
21 V+bC: cos a+ Ft max
Gear rati0 G P LG
G Zp ( )
1440 = 80
But, C 11600 e .(Given)
360 Za
20
C = 11600x 0.0406 = 470.96 N/mm

Copyrghted material
Design of Machine Elements - 2-23 Helical Gears

and b 14 m 14 x 8= 112 mm

21 x 13.2053 [112 x 470.96 x (cos 24) +17.3793 x 10°]

Fa Xcos (24)
21 x 13.2053+V112 x 470.96 x (cos 24) + 17.3793 x 10

Fa 29.6227 x 10 N

Substituting all these values in equation (i),

Feff 17.3793x 10 +29.6227 x 10 =47 x 10N

Step 3: Check whether gear is weaker or pinion is weaker

Lp 20
Zp = 26.2342
coS a (cos 24)

and ZG ZLG 80
T04.9299
cos a (cos 24)
By interpolation for 26.2342,
(0.3487-0.3456) (26.2342- 20)
Yp = 0.3463
(27-26)
Similarly, by interpolation for 104.9299,
(0.4587-0.4461)(104.9299-1U=
YG = 0.4461 + 0.4473
(150-100)

NOW
bP Yp 152 x 0.3463 52.6376 N/ mm
and O hG YG 125 x 0.4473 55.9177 N/mm

As Obp Yp <ObG Va pinion is weaker than the gear in bending. Therefore, it is required to design a pinion
for bending.
Beam strength for pinion is,

Fb bP-b-m, Yp = 152 x 112 x 8 x 0.3463

47.1632 x 10 N

Step 4 Calculate the factor of safety against bending failure

For safety against bending failure,
Fb = (FOS) bending Fe
Fb 47.1632X
(FOS) bending 10 = 1.0034 Ans.
Feff 47 x 10

Step 5: Calculate the surface hardness of gear pair

Wear strength of gear pair is,
dp-b-Q-K
Fw (1)
cos
But dp m Zp
cos a
x Lp cos (24) X 20= 175.1418 mm

Copyrghted materal
Design of Machine Elements - 11
2-24 Helical Gears

b = 112 mm, Q= 2ZG To find: Power P

+Zp
Step 1 Check whether gear is weaker or pinion is
2 x 80 weaker
1.6
80+2

K
= 0.16BHN) . (Given)
We know that, Gbp =ut =

100

Substituting all these values in equation (i), and bG ut lGS80 193.333 N/ mm

BHN
175.1418 x 112x 1.6x 0.16|
T00 Now, Zp Lp 20 = 26.8659
F (cos 24) cos a (cos 25)

100
Fw 6017.1034 iN and ZG LG - 134.3299
100 cos a (cos 25)
For safety against pitting failure,
Yp - 0.484- 2.87
w FOS x Feff 0.48426.8659
6017.1034 BHN
6017.103 1.5 x 47 x 105 = 0.3771
100
YG = 0.484 = 0.484-
2.87
BHN 342.2952 =345 and
*** Ans. 134.3
3299

Ex. 2.5: pair of parallel helical gear consist of 20

A
0.4626
teeth pinion meshing with 100 teeth gear. The pinion
rotates at 720 rpm. The normal pressure angle is 20° GbP Yp 240 x 0.3771 = 90.504 N/mm
while the helix angle is 25°. Face width is 40 mm and
and bG YG = 193.333 x 0.4626
normal module 4 mm. The pinion made of plain carbon
steel 55 C8 (S- 720 Nimm') mesh with gear made f = 89.4358 N/ mm*
plain carbon steel 40 C8 (S 580 Nimnm) and hea
treated to a surface hardness 300 BHN and 350 BHN As ObG Yg < Obp Yp, gear is weaker than the pinion in
respectively. The service factor and factor of safety 1.5 bending. Therefore, it is required to design a gear for
and 2.0 respectively. Assume velocity factor accounts for bending.
dynamic load and calculate power transnmitting capacity
Step 2: Calculate the beam strength and wear
ofgear. Use following data: strengti of gear pair
Lewisfornm Jactor Y'
=
0.484 -4.8
Z Fb bG b m, YG

Load stress factor K = 0.16 (BHN /100) 193.333 x 40 x 4 x 0.4626

5.6
Velocity factor Cy
F 14.3097 x 10 N
5.6+V
SPPU: May:07.09, Marks 10, Apr.-16, May-16,17.
Dec.-16, Marks 6 F p-b:Q-K (1)
cos a
Sol.: Given data:
But, dp m
Zp ac p
cos
4
cas (25) X 20
cos & (25)
Zp =20, Zg = 100, np = 720 rpm, ¢n = 20°, a = 25°,
b 40 mm, m, = 4 mm, (Sut )p = 720 N/mm*, 88.2702mm
b 40 mm,
(Sut OG 580 N/ mm-, (BHN)p = 300, (BHN)G = 350,
Q 2 Z2g 2x 100=1.667
FOS = 2, Ka = 1.5 ZG +Zp 100+ 20

Copyrighted materinl
Design of Machine Elements - I1 2-25 Helical Gears

Ex. 6 A pair of helical gear consist of 24 teeth

2

= BHN
K 0.16 ... (Given) pinion rotating at 5000 rpm and supplying 2.5 kW power
100
to a gear. The speed reduction is 4:1. he normal
300 pressure angle and helix angle 20° and 23" respectively.
K 0.16 100 = 1.44 N/ mm*
Both the gears are made of hardended steel
(Su-750 N/um'). The service factor and Jactor of safety
.(Selecting smaller value of BHN) are 1.5 and 2.0 respectively. 7he gears are finish to meet
the specifications of grade - 4.
Substituting all these values in equation (i),
) n initial stage of gear design assume velocity factor
w 88.2702 x 40 x 1.667 x 1.44 accounts dynamic load and face width is 10 x module
(cos 25) and assume pitch line velocity V = 10 m/s for estimating
normal module.
= 10.3185 x 10 N
2) Select first preference module and calculate dimensions
As Fw<Fb, gear pair isweaker in pitting than the of gear
bending. Therefore, it should be designed for safety against 3) Determine the dynamic load byy Buckingham's equation
pitting failure. also calculate factor of safety in bending
4) Specify the surface hardnes at factor of safety 2.0.
Step 3: Caleulate the power transmitting capacity of Use following data :
gear pair
Lewis form factor Y' - 0.484
Effective tooth load is,

Ka Km :F
For grade 4: e = 3.20 + 0.25 [m, + 0.25 vd]
Feff (ii) Buckingham's equation
Ky

x 720
p, =
21V(DC-cOs" y t Pmax *os
= Tdp np_Tx
y 88.2702
But,
60 50
21V+bC-cos V + P max
.0
V =
3.3277 x 10 mm/sec .Velocity factor Cr
5.6+
3.3277 m/sec First preference module (mm) - 1.0, 1.25, 1.5, 2.0, 2.5,
3, 4, 5, 6, 8, 10, 12, 16 and 20.
Ky 5.6 5.6 = 0.7542
SPPU: Dec.07, 13, May-14, Apr.17, Marks 14
5.6+V 5.6 + 3.3277
Ka = 1.5 and assuming, Km = 1 Sol.: Given data :

Zp 24, np = 5000 rpm, P = 2.5 kW = 2.5 x 10 W,

Substituting all these values in equation (i),
G = 4, n =20, a =
23°,

1.5x IX F (Sut p (ut G 750 N/ mm, Ka = 1.5, FOS = 2,

Feff 1.9888 F
0.7542 b= 10 m,n. V= 10 m/sec

For safety against pitting failure, To find: i) Normal module ii) Dimensions of gear pair
in) Dynamic load and (FOS) bending iv) Surtface hardness
F FOSx Feff
Step 1: Calculate the beam strength of pinion
10.3185x 10 2 1.9888 F . F = 2594.07 N
When the pinion and gear are made of same material, at
that time always pinion is weaker in bending.
Power transmitting capacity of gear pair is,
Beam strength of pinion is,
P
Fx V
=
2594.07 x 3.3277 . (1)
Fb bP b-m YP
10
Su p 750
P 8.6322 x W = 8.6322 kW
But, bP = 250 N/ mm
Ans. 3

Copyrighted material
Design of Machine Elements - II 2-26 Helical Gears

Zp Zp
cos a (cos 23
= 30.7703 b 10 mn
m Zp
= 10 x 1.25

1.3579 x 24
12.5 mm

dp =

NoW Yp 0.484
0.484 == 0.484-2.87
0.484-30.7703 =
32.5896 mm

0.3907
G PnG 4-24
Substituting all these values in equation (1), 96

mg x 0.3907
250 x 10 mn X
dG m
Zg = 1.3579 x 96
Fb976.75 m N (11) = 130.3584 mm

Step 2: Calculate the effective load on gear pair

C.D. =dp +dG-32.5896 + 130.3584

Feff
K Km E ii)
Ky 81.474 mm

Bul 5.6 5.6 0.6391 aImn = 1x 1.25 = 1.25 mm

5.6+ V 5.6+ 10
h 1.25 m, = 1.25x 1.25
. (* V = 10 m/s)
1.5625 mm Ans.

P_2.5 x 105
10 td pnp
60
0.25x 10 N TX 32. 5896 x 5000
60
K - 1.5 and Assuming
Km1
= 8.5319 x 10 mm/sec
Substituting all these values in equation (ii),
= 8.5319 m/sec
Feff
1.5 x 1x 0.25x 10 N - 586.7626N
0.6391
Step 4 Calculate the dynamic load by using

Step 3: Calculate the value of normal module and Buckingham's equation

other dimensions Buckingham's equation for dynamic load is,
For safety against bending failure, Fa 21V [bC- cosu+ Fmaxx
max
cos
- FOS x Fer
21 V+ybC:cosfa+ F
F
. (Given)... (iv)
976.75 m = 2x 586.7626
But, V 8.5319 m/sec
m= 1.2014 m 1.09 mm
b= 12.5 mm
Selecting the standard value of module from the given F 250N
values I .C. max = 1.5 x 1x 250
Ka *Km 'F
m 1.25 mm Ans. = 375 N

Other dimensions Pitch error for grade 4, e = 3.2 + 0.25 [m, +0.25 Vd]

mn 1.2 1.3579 mm Cp3.2+0.25 [m, +0.25 dp

cos a cos (25) For pinion,

Copyngtited matorinl
Design of Machine Elements- II 2-27 Helical Gears

CP 3.2+0.25 [1.25+0.25 V32.5896] = 3.8692 um

For gear, eG3.2+ 0.25 [m, +0.25 d aG]

eG 3.2 + 0.25 [1.25 + 0.25 V130.3584] = 4.2661 um

But. e ep +eG 3.8692 + 4.2661

8.1353 um = 8.1353 x 10 mm

As both the pinion and gear are made f steel,

C = 11500 e = 11500x 8.1353 x 10 = 93.5559 N/mm

Substituting all these values in equation (iv),

21x 8.5319 [12.5 x 93.5559 x (cos 23) +375] cos (23)

21x 8.5319+ y12.5 x 93.5559 x (cos 23) +375

Fa 1042.3207 N Ans.

Step - 5: Calculate the factor of safety against bending

Effective load for precise estimation is,

Feff
t max +Fa= 375 + 1042.3207 1417.3027 N

For safety against bending failure,

Fb = (FOS) bending X Feff

(FOS) bending Fb976.75 x (1.25) 1.0768 Ans.

Feff 1417.3027

Step Calculate the surface hardness of gear pair

6:
Wear strength of gear pair is,

Fw
p *b-Q- K .(V)
cos
But. dp 32.5896 mm, b = 12.5 mm

Q 22G
ZG + Zp 96+2
6
16
3HN
K 0.16| (Assume)
100
Substituting all these values in equation (v),

BHN
32.5896 x 12.5x 1.6 x 0.16
100

(cos 23)

BHN)2
F 123.0769
100

pyranG zESTE
Design of Machine Elements - II 2-28 Helical Gears

For safety against pitting failure, Step 1: Calculate the normal module of gear pair
= 2G
F FOSx Fefr Gear ratio0 G="P
GnG Zp
BHN)
123.0769 2x 1417.3027 -36
100
3601:Zg
BHN 479.90 480 *** AnS.
Centre distance is given by,

Ex. 2.7: Following data is given Jor a helical gear C.D.= (Zp +ZG)
cosa
pair transmitting 15 kW power from an electric motor
running at 720 r.p.m. to a machine running at 360 r.p.m. n
2x cos918+36)
180
Number of teeth pinion - 18, Centre distance = 180 mm, (26)
Helix angle 26, Face width = 12 x normal module, m 5.991 mm = 6 mm
Tooth system = 20° full depth involute,
Other dimensions
Permissible bending stress for steel pinion
and gear = 150 N /mm, "n 6.6756 mm
=
cosa cos (26)
Service factor 1.25, Load concentration factor=1.1,
Combine teeth error = 40 microns, dp mZp = 6.6756 x 18B

Deformation factor = I1600 x error N |mn. =120.161 mm

Assuming dynamic load accounted by Buckingham's
dG mZg = 6.6756 x 36
equation. Determine .

) Factor of safety against bending failure 240.322 mm

2) Factor of safety against pitting failure. b= 12 m, = 12x 6=72 mm
Use following data,
ha Im= IX 6=6 mm
2.87
Lewis form factor Y = 0.484- = 1.25 mn = 1.25x 6= 7.5 mm
h
Buckingham's equation Step 2 Calculate the dynamic load by using

P, 21 V(bC cos- a+ Prmax )cos a Buckingham's equation

21V+ybCcos a+ Pmar Buckingham's equation for dynamic load is,

PumaxC, Km P Assuming surface hardness= 350 21 V [bC cosfa+ Fmax

Fa ] X COs
BHN. SPPU: May-08, Marks 10 &
21 V+ybC cosa+ F max

Sol.: Given data :

(Given).. (0)
P= 15 kW = 15 x 10° W, np = 720 rpm,
Tdp npTX 120.161 x 720
Bul, V
26°,
60 60
nG 360 rpm, Zp 18, C.D. = 180 mm, a =

V = 4.5299 x 10° mm/sec

b 12 mn. 9n= 20, GbP = ObG 150 N/ mm*,
4.5299 m/sec
K, = 1.25, Km = 1.1, e =
40 um= 40 x 10mm,
C 11600 e = 11600 x 40x 103
C= 11600 e N/mm
=464 NImm . (Given)
To find: i) (FOS) bending i) (FOS)piting

F 15x 10-3311.3313 N
4.5299

Opyrgntod matorial
 - Helical Gears
Design of Machine Elements I1 2-29
max K, *Km *F = 1.25 x 1.Ix 3311.3313 4553.0806 N
i
Substituting all these values in equation (i),

Fa 21x 4.5299 [72 x 464x (cos 26) +4553.0806] cos (26)

21x 4.5299+ 72 x 464 x (cos 26) +4553.0806

Fa9888.2224 N
Effective load for precise estimation is,
14.4413 x 10 N
FefFmax + Fa 4553.0806 + 9888.2224

Step 3: Calculate the beam strength and wear strength of gear pair
When the pinion and gear are made of same material, at that time always pinion is weaker in bending
Beam strength of pinion is,
(11)
Fb =bP b-m, Yp
But, bP 150 N/ mm, b = 72 mm, mn =6 mm

18
Zp P 24.7908
cos (cos226)

Yp 0.484- 2.87
0.48424.7905 0.3682

Substituting all these values in equation (ii),

Fb= 150x 72 x 6 x 0.3682 = 23.8593 x 10 N

Wear strength of gear pair is,

Fw
dpb-Q-K . (ii)
cos
mm,
But, dp120.161 b=72 mm
2Zg
Zg + Zp
2x 36
36+18
1.333

K 0.16 BHN
100
=0.16 o-
100)
1.96 N/ mm .(Assume)

Substituting all these values in equation (ii),

Fw
120.161x 72 x 1.333 x 1.96 - 27.9809x 10° N
(cos 26)

Step 4: Calculate the factor of safety against bending and pitting failure
For safety against bending failure,

Fb(FOS) bending X Feff

3.8593 x 10" = (FOS)bending X 14.4413 x 10

(FOS) bending 1.6521 Ans.

Copyrighted matorial
 Design of Machine Elements - I1
2-30 Helical Gears

For safety against pitting failure, Selecting the standard value of module from the Table 2.1,

Fw(FOS)pitting Fefr "n 2 mm Ans.

27.9809 x 10 = (FOS)pitting X 14.4413 x 10 Other dimensions

Exact helix angle,

'(FOS) pitting 1.9375 .. Ans.

Ex. 2.8: Helical rack and pinion arrangements is Used

V mna*Zpx 60
COs
*np

to operate a machine tool table. The table speed required

2.1x 103 =
TX 2x 25 x 720
is 2. force required to be applied is
m/s and tangential cos &X 60
600 N. Speed of the pinion is 720 rpm and mumber of
cos a =
0.8975 a = 26.156"
teeth on pinion is 25. Assuming velocity factor accounts
for the dynamic load, design the rack and the pinion and = = 2.2281 mm
calculate the motor power raling cosa Ccos (26.156)

Use the following data b =

12 m, = 12x 2- 24 mm
Ultimate tensile strength for Rack and pinion materialis
630 MPa and 720 MPa respectively.
dp m, Zp = 2.2281 x 25

Surface hardness for rack and pinion is 400 BHN. 55.7042 mm

Starting torque is 35 % greater than the rated torque.
ha I
m, = Ix 2=2 mm
Face widih is twelve times the normal module.
Helix angle is approximately equal to 27, Factor of hr = 1.25 m, = 1.25 x 2 2.5 mm

safety is 1.5. Ans.

5.6
Velocity factor is given by -
5.6 +
Step 2: Calculate the effective load on rack and
pinion
Also find actual factor of safety achieved.
SPPU: Dec.-09, Marks 144 Feff = am *
Ky

Sol.: Given data :

But, Ky
5.6 5.6 = 0.7944
V 2.1 m/s, F = 600 N, np = 720 rpm, Zp 25, 5.6+V 5.6+ 2.1
(Sut R =630 MPa, (Sut )p 720 MPa, (BHN)R (BHN)P
1.35x 1x 600
= =
- 400, K = 1.35, b = 12 m, a = 27", FOS 1.5 Fff 0.7944
To find: i) Design the rack and pinion ii) Power P = 1019.6374 N (Assume, Km =)
ii) Actual factor of safety
Step 3: Check whether rack is weaker or pinion is
Step 1: Calculate the value of normal module and
weaker
other dimensions
Now, Zp 25
= 34.5696
For pinion, pitch line velocity is,
PcOs a (cos 26.156)
v =Tdp 60
npT: m Zp* npP
60 Yp = 0.484 = 0,484- 2.87
Zp 34.5696

cOs&x 60 =
0.401
X 25 720 Note: It is assumed that the mumber of teeth on
2.1 x 103 TX M X

cos (27) x 60 rack i.e. ZR is oo

m 1.9853 mm

Gopyrgntod materna
Design of Machine Elements - II 2-31 Helical Gears

ZR R 2.56 N/ mm .(Assume)
cos o (cos 26.156
Substituting all these values in equation (ii),
YR 0.484- = 0.484- = 0.484
ZR w
55.7042x 24 x 2x 2.56
(cos 26.156)
d bP Sut p 120
=240 MPa
3 3
8495.8376N
and bR ur
3
R =
0- 210 MPa
For safety against pitting failure,
Now, bP Yp = 240 x 0.401 = 96.24 MPa
Fw(FOS)pittingX Feff
and bR YR 210 x 0484 101.64 MPa 8495.8376 - (FOS),pitting X 1019.6374
As ObP Yp <Obr YR. pinion is weaker than the rack in
(FOS)piting 8.3322> 1.5 ii)
bending.
From equation (i) and (ii) it is clear that, the available
Therefore, it is required to design a pinion for bending.
factor of safety is higher than required factor of safety
against bending and piting. Hence, the gear pair is safe.
Step 4: Calculate the beam strength of pinion and
corresponding factor of safety Step 6 : Calculate the motor power rating
FbObP -b-m, Yp Power is given by,
240 x 24 x 2x 0.401= 4619.52 N
PFx V= 600x 2.1
For satety against bending failure, P 1.26x 10° W= 1.26 kW. Ans.
Fb(FOS) bending X Fef Ex. 2.9 pair of parallel helical gears consists of a
A
4619.52 (FOS)bending X 1019.6374 20 teeth pinion meshing with a 100 teelh gear. The
pinion rotates at 720 rpm. The normal pressure angle is
(FOS) bending4.5305> 1.5 (1)
20, while the helix angle is 25, The face width is 40 mm
Step 5: Calculate the wear strength of pinion and and normnal module is 4 mm. The pinion as well as the
corresponding factor of safety gear is made of steel 40C8(5 = 600N /mm* ) and hea

F dpb.0-k
cos
.. (i) treated to a surface hardness of 300 BHN. The service
Jactor and the jactor of safety are 1.5 and 2 respectively.
But, dp 55.7042 mm, b= 24 mm
Assume that the velocity factor accounts for the dynamic
load and calculate the power transmitting capacity of
2ZRZ
QZ+ gears.
Use following data
2.87
) Lewis form factor Y' =0.484-

5.6
2) Velocity Jactor Cy
5.6 +V
Q ) Load stress factor K =
0.164BEN
100
mn
SPPU: May 10, Marks 10
BHN 400 ) Sol.: The above example is similar to example 2.5, so
= 0.16
K 0.16 100 -0.1100
=
refer Example 2.5. The answer of the above example is,
P = 8.6322 kW Ans.

Opyrghed matenia
Design of Machine Elements- II 2-32 Helical Gears

Ex. 2.10: helical pinion having 21 mumber of teeth is

A
Now, Zp Zp 21
made of carbon steel having ultimate tensile strength 720 cos a (cos 25)°
MPa. The gear meshing with the pinion is made of steel
having ultimate tensile strength 580 MPa. The pinio = 28.2092
transmits 0 kW at 1000 rpm. Speed of the gear is 300
rpm. The starting torque is 125 % of rated torque. Factor and LG
cosa (cos
70
25)
of safety required is 1.25. The face width is 10 times the
normal module. Helix angle is 25" The gear and the = 94.0309
pinion are having surface hardness 300 BHN and 350
BHN respectively. Design the gear pair using Lewis form factor,
Buckingham's equaion for dynamic load. Assume 2.87
deformation factor 'C" for gear pair as 11500 e N/mm. Yp0.484
Use Ky 5 .6
5.6+VV = 0.484 2.87 0.3822
e = 8.0+ 0.63 Im +0.25 vd .2092

Y = 0.4842.87
Z
and YG
0.454ZG
0.484- = 87
0.484-
2.87
44.0309
2/V(bC cos a+ Pr max)
Pa Cos C = 0.4534
2/V+bC cosf a+ P max
Now, ObP Yp = 240 x 0.3822-91.728 MPa
Standard values of normal module. 3, 4, 5, 6, 8, 10,..
SPPU: Dec.-10, Marks 14 and bG YG 193.333 x 0.4534 87.6571 MPa

Sol.: Given data: As GbG YG < obp Yp. gear is weaker than the pinion
in bending. Therefore, it is required to design a gear for
Zp 21,(Sut )p =720 MPa, (Sut )a = S80 MPa,
bending.
P=10 kW=10x 10° W, np = 1000 rpm
Step 2 Calculate the beanm strength and wear
nG 300 rpm, Ka = 1.25, FOS = 1.25, b = 10 m strength of gear pair

a - 25°, (BHN)G = 300,

Fb bG b m, YG

193.333 x 10 m, X m, x 04534
(BHN)p = 350, C = 11500 e N/mm

To find : Design the gear pair.

Fb 876.5718 m, N (1)

Step 1: Check whether gear is weaker or pinion is

pb-0 K
weaker F = (1)
coS
We know that, bP
Sut e 720240 MPa
3 But, m = a.Lp
dp Zp -
cOS O

(ut G=o = 193.333 MPa

and bG 3 1 x 21 23.1709 mn, mm
cos (25)

"P LG
Gear ratio G = =
nG Le b 10 mnn
1000
300 21 QZc+Zp 2x
70+21
1.5384

BHN 300
ZG 70 K0.10100 0.16| 00

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