Subject : Machine Design

Presentation on
Spur Gear Design
Mechanical 7th - B2

Prepared By:
Kartik Pandya :- 130120119126

Guided By:
Prof. Amit Patel

SPUR GEAR DESIGN

TOOTH FORCE ANALYSIS

SPUR GEAR TOOTH FORCE ANALYSIS

As shown in Fig
The normal force F can be resolved into two components; a tangential
force Ft which does transmit the power and radial component Fr which
does no work but tends to push the gears apart.
They can hence be written as,
Ft = F cos
(7. 1)
Fr = F sin
(7.2)
From eqn. (7.2),
Fr = Ft tan
(7.3)

TOOTH FORCE ANALYSIS

The pitch line velocity V, in meters per second, is given as

where d is the pitch diameter of the gear in millimeters and n is the rotating
speed in rpm and W power in kW.

GEAR - TOOTH STRESSES

Photo-elastic Model of gear tooth

Stresses developed by Normal force in a photo-elastic model of gear tooth as
per Dolan and Broghammer are shown in the Fig. The highest stresses exist at
regions where the lines are bunched closest together. The highest stress
occurs at two locations:
A. At contact point where the force F acts
B. At the fillet region near the base of the tooth.

BEAM STRENGTH OF GEAR TOOTH

The accurate stress analysis of a gear tooth for a particular application is a

complex problem because of the following reasons:

There is continuous change in the point of application of load on the tooth

profile.
The magnitude and direction of applied load also change.
In addition to static load, the dynamic load due to inaccuracy of the tooth
profile, error in machining and mounting, tooth deflection, acceleration and
stress concentration also act on the tooth which are all difficult to model
mathematically.

The analysis of bending stresses in gear tooth was done by WILFRES

LEWIS. The lewis equation is considered as the basic equation in the
design of gears.
In the lewis analysis, the gear tooth is consider as a cantilever beam

BEAM STRENGTH OF GEAR TOOTH

Wilfred Lewis, in a paper titled, The investigation of the strength of gear
tooth published in 1892, derived an equation for determining the
approximate stress in a gear tooth by treating it as a cantilever beam of
uniform strength. The beam strength calculation is based upon the
following assumptions:

Gear tooth as cantilever beam

BEAM STRENGTH OF GEAR TOOTH

Lewis considered gear tooth as a cantilever beam with static normal force F
applied at the tip.
Assumptions made in the derivation are:
1.
2.
3.
4.
5.

The full load is applied to the tip of a single tooth in static condition.
The radial component is negligible.
The load is distributed uniformly across the full face width.
Forces due to tooth sliding friction are negligible.
Stress concentration in the tooth fillet is negligible.

Here force is denoted my

P

BEAM STRENGTH OF GEAR TOOTH

The cross-section of the tooth varies from free end to the fixed end.
Therefore , A parabola is constructed within the tooth profile. Parabola is
beam of uniform strength. The stress at any cross-section of beam is
uniform or same.

The weakest section of the gear tooth is at the section XX, where parabola
is tangent to the tooth profile.

BEAM STRENGTH OF GEAR TOOTH

At the section XX,
Mb= Pt h
I= (1/12) b x t3
Y= t / 2
The bending stresses are given by,
b = Mb y / I
= (pt h)(t/2) / [(1/12)bt3]
Rearranging the terms,
Pt = b b (t2/6h)
Multiplying the numerator and denominator of the right-hand side by m,
Pt = m b b (t2/6hm)

BEAM STRENGTH OF GEAR TOOTH

Defining a factor Y,
Y=(t2/6hm)

The equation is rewritten as,

Pt= mb b Y

Y is called the lewis form factor.

................ (i)

Eq.(i) gives relationship between the tangential force(Pt) and the corresponding
stress b.
When stresses reaches the permissible magnitude of bending stresses, the
corresponding force(Pt) is called the beam strength.

Therefore the beam strength(Sb) is maximum value of the tangential force that the
tooth can transmit without bending failure.
Replacing Pt by Sb,

Sb = mb bY
................ (ii)

Sb = beam strength of gear tooth(N)

BEAM STRENGTH OF GEAR TOOTH

Eq.(Ii) is known as lewis
equation. Table for values of
lewis form factor is given
below

In order to avoid the

breakage of gear tooth
due to bending, the
bending strength
should be more than
the effective force
between the meshing
teeth.

BEAM STRENGTH OF GEAR TOOTH

BEAM STRENGTH OF GEAR TOOTH

The Lewis equation indicates that tooth bending stress varies with the
following:
(1) Directly with load,
(2) Inversely with tooth width b,
(3) Inversely with tooth size p or m,
(4) Inversely with tooth shape factor y or Y.
Drawbacks of Lewis equation are:
The tooth load in practice is not static. It is dynamic and is influenced by
pitch line velocity.
The whole load is carried by single tooth is not correct. Normally load is
shared by teeth since contact ratio is near to 1.5.
The greatest force exerted at the tip of the tooth is not true as the load is
shared by teeth. It is exerted much below the tip when single pair contact
occurs.
The stress concentration effect at the fillet is not considered.

BEAM STRENGTH OF GEAR TOOTH

The modified Lewis equation for bending stress is,
Pt= Kvmb b Y

..(iii)

Where Kv is known as velocity factor and is given by Barths equation below for
known pitch line velocity V in m/s and is given by,
(iv)
Eqn. (4) is used for cut or milled teeth or for gears not carefully generated.
(v)
Eqn. (5) is used for hobbed and shaped gears.
.(vi)
Eqn. (6) is used for high-precision shaved or ground teeth.
The modified Lewis equation given in eqn.(3) is used when fatigue failure of the
gear teeth is not a problem and a quick estimate is desired for more detailed

WEAR STRENGTH OF GEAR TOOTH

WEAR STRENGTH
Due to rolling and sliding actions of the gear teeth, the following types of
surface destructions (wear) may occur:

Abrasive wear. Scratching of the tooth surface due to the presence of

foreign materials in the lubricant is called abrasive wear.

Corrosive wear. Chemical reactions on the surface of a gear cause corrosive

wear.

Pitting. Repeated application of the stress cycle, known as pitting, cause

fatigue failure.

Scoring. Inadequate lubrication between metal-to metal contact cause

scoring.
It is observed from the results of various experiments that abrasion,
corrosive, the scoring are caused by improper lubrication, whereas pitting
usually occurs because of repeated application of Hertz contact stress on
the portion of a gear tooth which has relatively little sliding motion
compared to rolling motion. Clearly, the spur gear will have pitting near the
pitch lien where motion is almost all of rolling.

WEAR STRENGTH OF GEAR TOOTH

The failure of the gear tooth due to pitting occurs when the contact stress
between two meshing teeth exceed the surface endurance strength of the
material.
Pitting is a surface fatigue failure, characterized by small pits on the surface
of the gear tooth.
To avoid this type of failure, properties of gear tooth and surface properties
should be selected such a way that the wear strength of the gear tooth is
more than the effective load between the meshing teeth.
The analysis of wear strength of gear tooth is done by Earle Buckingham.
Buckingham s equation gives the wear strength of the gear tooth. which is
based on Hertz theory of contact stresses.

WEAR STRENGTH OF GEAR TOOTH

When two cylinders are pressed together as shown in fig.(a), the contact stress
is given by,
c= 2*P/*b*l

................(1.1)

and
b= { [ 2P(1-2)(1/E1 + 1/E2)] / l(1/d1 + 1/d2) }1/2
................(1.2)
where,
= maximum value of compressive stress (N/mm2)
P=force pressing the two cylinders together (N)
b= half width of deformation (mm)
l= axial length of the cylinder (mm)
d1,d2= diameter of two cylinders (mm)
E1,E2= moduli of elasticity of 2 cylinders (N/mm2)
= Poissons ratio
fig. contact stresses

WEAR STRENGTH OF GEAR TOOTH

Due to deformation under the action of load P, a rectangular surface of width
(2b) and length (l) is formed between the two cylinders. The elliptical stress
distribution across the width (2b) is shown in fig.
Substituting eq.(ii) into(i) and squaring both sides,
c2 =[1/(1-2)]* (P/l)* {(1/r1+ 1/r2) / (1/E1+ 1/E2)}

................(1.3)

Where, r1,r2= radii of two cylinders

c2 =0.35*(P/l)* {(1/r1+ 1/r2) / (1/E1+ 1/E2)}

................(1.4)

The above equation of the contact stress is based on the following

assumptions:
The cylinders are made of isotropic materials.
The elastic limit of the material is not exceeded.
The dimensions r1,r2 are very large when compared to the width (2b) of the
deformation.

WEAR STRENGTH OF GEAR TOOTH

Fig. shows the contact

between two meshing teeth
at the pitch point

Fig. contact between two meshing teeth at pitch

WEAR STRENGTH OF GEAR TOOTH

r1,r2 are to be replaced by radii of curvature at the pitch point. Therefore,

r1= dp * sin /2

r2= dg * sin /2

There are some reasons for taking the radii of curvature at the pitch point.
The wear on the gear tooth generally occurs at or near the pitch line.
When only one pair of teeth carries the entire load, contact occurs at
the pitch point.
The dynamic load is imposed on the gear tooth near the pitch line area.
(1/r1 + 1/r2)= 2/sin [1/dp + 1/dg]

............(1.5)

A ratio factor Q is defined as,

Q= 2*zg/(zg+zp)

..............(1.6)

WEAR STRENGTH OF GEAR TOOTH

Substituting, dp=m zp and dg= m zg,
Q= 2 dg/(dg + dp)
Therefore,
[1/dp + 1/dg] = (dg + dp)/dg * dp
= 2/ Q*dp

...............(1.7)

From eq.(v) and (vii),

(1/r1 + 1/r2)= 2/sin*Q*dp

..............(1.8)

The force acting along the pitch line in fig.(b) is P N,

P=PN= Pt / cos
The axial length of the gears is the face width b,i.e.

.............(1.9)
l=b

Therefore,
c2= 1.4*Pt / b*Q*dp*sin*cos* (1/E1+ 1/E2)

............(1.10)

WEAR STRENGTH OF GEAR TOOTH

a load stress factor K is defined as,

K= c2* sin*cos* (1/E1+ 1/E2) /1.4
...............(1.11)
Substituting the above eq. Into (1.1),
Pt= b*Q*dp*k

...............

(1.12)
This equation gives a relationship between the tangential force Pt and the
corresponding contact stress c .
The tangential force is increase with the increasing contact stress. Pitting
occurs when the contact stress reaches the magnitude of the surface
endurance strength. The corresponding value of Pt is called wear strength.

WEAR STRENGTH OF GEAR TOOTH

Wear strength is maximum value of the tangential force that tooth can
transmit without pitting failure.
Replacing Pt by Sw,
Sw= b*Q*dp*k
(1.13)
Where,
Sw= wear strength of the gear tooth (N)
c= surface endurance strength of the material (N/mm2)
equation (1.13) is known as Buckinghams equation for wear

.............