Chapter 15: Helical, Bevel and Worm Gears

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Hamrock Fundamentals of Machine Elements

Summary of Gear Design

Gear type Spur

Helical

Bevel

Advantages Inexpensive, simple to design, no thrust load is developed by the gearing, wide variety of manufacturing options. Useful for high speed and high power applications, quiet at high speeds. Often used in lieu of spur gears for high speed applications. High eciency (can be 98% or higher), can transfer power across nonintersecting shafts. Spiral bevel gears transmit loads evenly and are quieter than straight bevel. Compact designs for large gear ratios. Eciency can be 90% or higher.

Disadvantages Can generate signicant noise, especially at high speeds, and are usually restricted to pitch-line speeds below 20 m/s (4000 ft/min). Generate a thrust load on a single face, more expensive than spur gears. Shaft alignment is critical, rolling element bearings are therefore often used with bevel gears. This limits power transfer for high speed applications (where a journal bearing is preferable). Can be expensive. Wear by abrasion is of higher concern than other gear types, can be expensive. Generate very high thrust loads. Worm cannot be driven by gear; worm must drive gear.

Worm

Table 15.1 Design considerations for gears.

Hamrock Fundamentals of Machine Elements

Helical Gear

Tangent to helical tooth

Pitch cylinder

Element of pitch cylinder (or gear's axis)

Helix angle,

(a)

(b)

Figure 13.1 Helical gear. (a) Front view; (b) side view.

Hamrock Fundamentals of Machine Elements

Helical Gear Pitches

cn

pc

pa (a) (b)

Figure 15.2 Pitches of helical gears. (a) Circular; (b) axial.

Hamrock Fundamentals of Machine Elements

AGMA Equations for Helical Gears

Bending Stress:
Wt pd KaKsKmKvKiKb !t = bwYh

Pitting Resistance:
!c = pH KaKsKmKv Ih
1 2

Hamrock Fundamentals of Machine Elements

Geometry Factors for Helical Gears

! = 20, " = 10
Gear teeth 12 14 17 21 Ih Yh 26 Ih Yh 35 Ih Yh 55 Ih Yh 135 Ih Yh 12 P Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua G P 14 G P 17 G P 21 G Pinion Teeth 26 35 P G P G 55 P G P 135 G

0.127 0.46 0.46 0.143 0.47 0.49 0.164 0.48 0.52 0.195 0.49 0.55 0.241 0.50 0.60

0.131 0.49 0.49 0.153 0.50 0.53 0.186 0.52 0.56 0.237 0.53 0.61

0.136 0.54 0.54 0.170 0.55 0.57 0.228 0.57 0.62

0.143 0.59 0.59 0.209 0.60 0.63

0.151 0.65 0.65

Table 15.2 Geometry factors Yh and Ih for helical gears loaded at tooth tip.

Hamrock Fundamentals of Machine Elements

Geometry Factors for Helical Gears

! = 20, " = 20
Gear teeth 12 14 17 Ih Yh 21 Ih Yh 26 Ih Yh 35 Ih Yh 55 Ih Yh 135 Ih Yh 12 P Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua 0.125 0.44 0.44 0.140 0.45 0.46 0.156 0.45 0.49 0.177 0.46 0.51 0.205 0.47 0.54 0.245 0.48 0.58 G P 14 G P 17 G P 21 Pinion Teeth 26 G P G 35 P G P 55 G P 135 G

0.129 0.47 0.47 0.145 0.48 0.49 0.167 0.49 0.52 0.197 0.50 0.55 0.242 0.51 0.59

0.133 0.50 0.50 0.155 0.51 0.53 0.188 0.52 0.56 0.238 0.54 0.60

0.138 0.54 0.54 0.172 0.55 0.57 0.229 0.57 0.61

0.144 0.58 0.58 0.209 0.60 0.62

0.151 0.64 0.64

Table 15.2 Geometry factors Yh and Ih for helical gears loaded at tooth tip.

Hamrock Fundamentals of Machine Elements

Geometry Factors for Helical Gears

! = 20, " = 30
Gear 12 14 17 teeth P G P G P G a 12 U 14 Ih Ua 0.125 a Yh U 0.39 0.39 a 17 Ih U 0.139 0.128 Yh Ua 0.39 0.41 0.41 0.41 21 Ih Ua 0.154 0.144 0.132 Yh Ua 0.40 0.42 0.42 0.43 0.44 0.44 26 Ih Ua 0.169 0.159 0.148 Yh Ua 0.41 0.44 0.43 0.45 0.45 0.46 35 Ih Ua 0.189 0.180 0.170 a Yh U 0.41 0.46 0.43 0.47 0.45 0.48 55 Ih Ua 0.215 0.208 0.200 a Yh U 0.42 0.49 0.44 0.49 0.46 0.50 135 Ih Ua 0.250 0.248 0.245 a Yh U 0.43 0.51 0.45 0.52 0.47 0.53 a A U indicates that this geometry would produce an undercut Pinion Teeth 21 26 P G P G 35 P G P 55 G P 135 G

0.135 0.46 0.46 0.158 0.139 0.47 0.48 0.49 0.49 0.190 0.174 0.145 0.48 0.50 0.50 0.51 0.52 0.52 0.240 0.231 0.210 0.49 0.53 0.51 0.54 0.53 0.55 tooth form and should be avoided.

0.151 0.56 0.56

Table 15.2 Geometry factors Yh and Ih for helical gears loaded at tooth tip.

Hamrock Fundamentals of Machine Elements

Geometry Factors for Helical Gears

! = 25, " = 10
Gear teeth 12 14 Ih Yh 17 Ih Yh 21 Ih Yh 26 Ih Yh 35 Ih Yh 55 Ih Yh 135 Ih Yh 12 P Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua Ua 0.129 0.47 0.47 0.144 0.48 0.51 0.159 0.48 0.55 0.175 0.49 0.58 Ua 0.50 0.61 0.221 Ua 0.257 0.52 0.70 G P 14 G P 17 G Pinion Teeth 21 26 P G P G 35 P G P 55 G P 135 G

0.133 0.52 0.52 0.149 0.52 0.55 0.165 0.53 0.58 0.195 0.54 0.62 0.215 0.51 0.65 0.255 0.56 0.71

0.136 0.56 0.56 0.152 0.57 0.59 0.186 0.57 0.63 0.206 0.55 0.66 0.251 0.60 0.72

0.139 0.60 0.60 0.175 0.61 0.64 0.195 0.58 0.67 0.246 0.63 0.73

0.162 0.64 0.64 0.178 0.62 0.68 0.236 0.67 0.74

0.148 0.65 0.69 0.215 0.71 0.75

0.70 0.70 0.154 0.76 0.76

Table 15.2 Geometry factors Yh and Ih for helical gears loaded at tooth tip.

Hamrock Fundamentals of Machine Elements

Geometry Factors for Helical Gears

! = 25, " = 20
Gear teeth 12 Ih Yh 14 Ih Yh 17 Ih Yh 21 Ih Yh 26 Ih Yh 35 Ih Yh 55 Ih Yh 135 Ih Yh 12 G 0.128 0.47 0.47 0.140 0.47 0.50 0.154 0.48 0.53 0.169 0.48 0.56 0.184 0.49 0.59 0.202 0.49 0.62 0.227 0.50 0.66 0.258 0.51 0.70 P P 14 G P 17 G Pinion Teeth 21 26 P G P G 35 P G P 55 G P 135 G

0.131 0.50 0.50 0.145 0.51 0.54 0.161 0.51 0.57 0.176 0.52 0.60 0.196 0.53 0.63 0.222 0.53 0.67 0.257 0.54 0.71

0.134 0.54 0.54 0.150 0.55 0.58 0.166 0.55 0.60 0.187 0.56 0.64 0.215 0.57 0.67 0.255 0.58 0.72

0.137 0.58 0.58 0.153 0.59 0.61 0.176 0.60 0.64 0.206 0.60 0.68 0.251 0.62 0.72

0.140 0.62 0.62 0.163 0.62 0.65 0.196 0.63 0.69 0.246 0.65 0.73

0.144 0.66 0.66 0.178 0.67 0.70 0.236 0.68 0.74

0.148 0.71 0.71 0.214 0.72 0.75

0.153 0.76 0.76

Table 15.2 Geometry factors Yh and Ih for helical gears loaded at tooth tip.

Hamrock Fundamentals of Machine Elements

Geometry Factors for Helical Gears

! = 25, " = 30
Gear teeth 12 Ih Yh 14 Ih Yh 17 Ih Yh 21 Ih Yh 26 Ih Yh 35 Ih Yh 55 Ih Yh 135 Ih Yh 12 P G P 0.130 0.46 0.46 0.142 0.47 0.49 0.156 0.47 0.51 0.171 0.48 0.54 0.186 0.48 0.56 0.204 0.49 0.58 0.228 0.49 0.61 0.259 0.50 0.64 14 G P 17 G Pinion Teeth 21 26 P G P G 35 P G P 55 G P 135 G

0.133 0.49 0.49 0.147 0.50 0.52 0.163 0.50 0.54 0.178 0.51 0.56 0.198 0.51 0.59 0.223 0.52 0.61 0.257 0.53 0.64

0.136 0.52 0.52 0.151 0.53 0.55 0.167 0.53 0.57 0.188 0.54 0.59 0.216 0.54 0.62 0.255 0.55 0.65

0.138 0.55 0.55 0.154 0.56 0.57 0.176 0.56 0.60 0.207 0.57 0.62 0.251 0.58 0.66

0.141 0.58 0.58 0.163 0.58 0.60 0.196 0.59 0.63 0.245 0.60 0.66

0.144 0.61 0.61 0.178 0.62 0.64 0.234 0.62 0.67

0.147 0.64 0.64 0.212 0.65 0.68

0.151 0.68 0.68

Table 15.2 Geometry factors Yh and Ih for helical gears loaded at tooth tip.

Hamrock Fundamentals of Machine Elements

Bevel Gears
Pitch apex to back Crown to back Pitch apex to crown Crown

Pitch apex Face width Face angle Dedendum angle Shaft angle Pitch angle Back angle Front angle Root angle Uniform clearance Gear

Pinion

Pitch diameter Outside diameter Back cone

Ba
an

on

ed

ist

ce

Figure 15.3 Terminology for bevel gears.

Hamrock Fundamentals of Machine Elements

ck c

Bevel Gears

Figure 15.4 Bevel gears with curved teeth. (a) Spiral bevel gears; (b) Zerol. Hamrock Fundamentals of Machine Elements

Bevel Gear Forces

Wt T W= = cos ! r cos ! Wa = Wt tan ! sin " Wr = Wt tan ! cos "

Figure 15.5 Forces acting on a bevel gear Hamrock Fundamentals of Machine Elements

Design of Bevel Gears

Bending Stress:

Pitting Resistance:

2Tp pd KaKvKsKm English units bwd p KxYb !t = 2T K K K K p a v s m SI units bwd p m pKxYb TpE KaKvKmKsKx 2 "bwd pIb English units

!c =

Cp

2TpE KaKvKmKsKx SI units "bwd 2 I p b

Hamrock Fundamentals of Machine Elements

Load Distribution Factor for Bevel Gears

Kmb + 0.0036b2 w English units Km = Kmb + 5.6b2 SI units w

where Kmb = 1.00 for both gear and pinion straddle mounted (bearings on both sides of gear) = 1.10 for only one member straddle mounted = 1.25 for neither member straddle mounted

Hamrock Fundamentals of Machine Elements

Size Factor for Bevel Gears

Outer transverse module, met 20 30 Face width, bw, mm 50 75 100

1.0 0.9 Size factor, Ks 0.8 0.7 0.6 0.5

1.6 5

10

40

50 1.00

25

125

Ks = 1.0 for bw > 114.3 mm (4.5 in.)

Size factor, Ks

Ks = 0.4867 + 0.2133/pd = 0.4867 + 0.008399 met

0.75

0.50

Ks = 0.00492 bw + 0.4375 (bw in mm) = 0.125 bw + 0.4375 (bw in in.) Ks = 0.5 for bw < 12.7 mm (0.5 in.)

Ks = 0.5 for met < 1.6 (pd < 16 in. ) 0.4 16 5 2.5 1.25 0.8 0.6 -1 Outer transverse pitch, pd, in. (a) 0.5

-1

0.25

1.0

2.0 3.0 Face width, bw, in. (b)

4.0

5.0

Figure 15.6 Size factor for bevel gears. (a) Size factor for bending stress; (b) size factor for contact stress or pitting resistance. Hamrock Fundamentals of Machine Elements

Straight Bevel Gear Geometry Factor for Contact Stess

Figure 15.7 Geometry factor for straight bevel gears with pressure angle = 20 and shaft angle 90. (a) Geometry factor for contact stress, Ib. Hamrock Fundamentals of Machine Elements

Straight Bevel Gear Geometry Factor for Bending

100 Number of teeth on gear for which geometry factor is desired 90 80 70 60 50 40 30 20 10 0.16 0.20 0.24 0.28 Geometry factor, Yb 0.32 0.36 0.40 60 70 80 13 15 20 Number of teeth in mate 25 30 35 40 45 50 90 100

Figure 15.7 Geometry factor for straight bevel gears with pressure angle = 20 and shaft angle 90. (b) Geometry factor for bending, Yb. Hamrock Fundamentals of Machine Elements

Spiral Bevel Gears Geometry Factor for Contact Stress

Number of teeth in gear 50 Number of pinion teeth
50 45 60 70 80 90 100

40

40 35

30

30 25

20
15

20

10 0.04

0.06

0.08 0.10 0.12 Geometry factor, Ib

0.14

0.16

Figure 15.8 Geometry factor for spiral bevel gears with pressure angle = 20, spiral angle = 25, and shaft angle 90. (a) Geometry factor for contact stress, Ib. Hamrock Fundamentals of Machine Elements

Spiral Bevel Gears Geometry Factor for Bending

Number of teeth in mate 100 90 Number of teeth on gear for which geometry factor is desired 80 70 60 50 40 30 20 10 0.12 0.16 0.20 0.24 0.28 Geometry factor, Yb 0.32 0.36
60708090 100 12 20 30 40 50

Figure 15.8 Geometry factor for spiral bevel gears with pressure angle = 20, spiral angle = 25, and shaft angle 90. (a) Geometry factor for bending, Yb. Hamrock Fundamentals of Machine Elements

Zerol Bevel Gears Geometry Factor for Contact Stress

Number of gear teeth 50
50 45 60 70 80 90 100

Number of pinion teeth

40

40 35

30
25

30

20
15

20

10

0.04

0.05

0.06 0.07 0.08 Geometry factor, Ib

0.09

0.10

0.11

Figure 15.9 Geometry factor for Zerol bevel gears with pressure angle = 20, spiral angle = 25, and shaft angle 90. (a) Geometry factor for contact stress, Ib. Hamrock Fundamentals of Machine Elements

Zerol Bevel Gears Geometry Factor for Bending

Number of teeth in mate 100 Number of teeth in gear for which geometry factor is desired 90 80 70 60 50 40 30 20 10 0.16 0.20 0.32 0.28 0.24 Geometry factor, Yb 0.36 0.40
60 70 80 90 100 13 15 20 25 30 35 40 45 50

Figure 15.9 Geometry factor for Zerol bevel gears with pressure angle = 20, spiral angle = 25, and shaft angle 90. (a) Geometry factor for bending, Yb. Hamrock Fundamentals of Machine Elements

Worm Gear Contact

Figure 15.10 Illustration of worm contact with a worm gear, showing multiple teeth in contact. Hamrock Fundamentals of Machine Elements

Minimum Number of Worm Gear Teeth

Pressure angle, deg 14.5 17.5 20 22.5 25 27.5 30

Minimum number of wormgear teeth 40 27 21 17 14 12 10

Table 15.3 Suggested minimum number of worm gear teeth for customary designs.

Hamrock Fundamentals of Machine Elements

Forces on a Worm Gear

Figure 15.11 Forces acting on a worm. (a) Side view, showing forces acting on worm and worm gear. (b) Three-dimensional view of worm, showing worm forces. The worm gear has been removed for clarity. Hamrock Fundamentals of Machine Elements

AGMA Equations for Worm Gears

The rated input power is
vtW f NWt dg + English units h pi = (126, 000)Z 33, 000 !Wt dg + vtW f SI units 2Z

where
!Ndwm English units cos " vt = 12 #d wm SI units 2 cos "

Hamrock Fundamentals of Machine Elements

AGMA Equations for Worm Gears (cont.) Tangential Force

0.8 Csdgm bwCmCv English units 0.8 Wt = Csdgm bwCmCv SI units 75.948

where

Hamrock Fundamentals of Machine Elements

0.5 2 + 0.463 Z < 20 0.0200 Z + 40Z 76 Cm = 0.0107 Z 2 + 56Z + 5145 0.5 20 Z < 76 1.1483 0.00658Z 76 Z 0.659 exp (0.0011vt )0 < vt 700 ft/min (0.571) 700 ft/min < vt 3000 ft/min Cv = 13.31vt 65.52v(0.774) 3000 ft/min < vt t

AGMA Equations for Worm Gears (cont.) Friction Force

Wt Wf = cos ! cos "n

where
vt = 0 ft/min 0.150 0 < vt 10 ft/min = 0.124 exp 0.074vt0.645 0.103 exp 0.110vt0.450 + 0.01210 ft/min < vt

Hamrock Fundamentals of Machine Elements

Materials Parameter for Worm Gears

Mean gear pitch diameter, d (mm)
1000II 70 100

111

I 200 I

900

I 500 I I I Ill 1000 I Ce n tr ifu gal ly

I 2500 I

1IO00 1000

12

20 20

Center distance, cd (mm)

30 30

40 40

50 50

60 60

70 70

75 75

cas t

S ta

Materials factor, Cs

Materials factor, Cs

I i i i i 1i i i i i i i i i
900

i i i 3 i in
I I I CALlbN A. .-..a. r*al m-r A ..IlT
1 HIWJ

ti c

ch
ill

Sa

c as

800 800

nd
t cas

ed org rf to

700

IIIIII II
800 800 1-i

I i i i i i i

Y
/

C;HtC;K I-ItiUHt

USE THE LOWER OF THE TWO VALUES

600 600
FACTORFOR CENTER t DISTANCESc 3.00 IN (76 mm) I I 500 500 1 I I I I III ! I I Y I I I I

I I

2.5 3 2.5

90 5 6 7 8910 20 25 30 30 40 40 50 60 60 70 160 90 10 15 20 4 5 MEAN GEAR DIAMETER, Dm -INCHES Mean gear pitch diameter, d (in.)

700 0.5 0.5

1.0 1.0

1.5 2.0 DISTANCET:NCHES Center C::TER distance, cd (in.) (b)

2.5 2.5

3.0 3.0

Figure 15.12 Materials parameter Cs for bronze worm gears and worm minimum surface hardness of 58 Rc. (a) Materials factor for center distances cd greater than 76 mm (3 in); (b) Materials factor for center distances cd less than 76 mm (3 in). When using the figure in (b), the value from part (a) should be checked and the lower value used. See also Table 15.4. Hamrock Fundamentals of Machine Elements

(a)

Materials Factor for Worm Gear

Manufacturing Process Sand casting Static chill cast or forged Centrifugally cast

Pitch diameter d 64 mm (2.5 in.) d 64 mm d 200 mm (8 in.) d > 200 mm d 625 mm (25 in.) d > 625 mm

Units for pitch diameter in. mm 1000 1000 1189.6365 476.5454 log d 1859.104 476.5454 log d 1000 1000 1411.6518 455.8259 log d 2052.012 455.8259 log d 1000 1000 1251.2913 179.7503 log d 1503.811 179.7503 log d

Table 15.4 Materials factor Cs for bronze worm gears with worm having surface hardness of 58 Rc.

Hamrock Fundamentals of Machine Elements

Food Mixer Gear Train Case Study

Speed

Torque

Tmax= 20 ft-lbf Maximum current

Motor current, A

Table 15.13 The gears used to transmit power from an electric motor to the agitators of a commercial mixer. Hamrock Fundamentals

Table 15.14 Torque and speed of motor as a function of current for the industrial mixer used in the Case Study. of Machine Elements