15-1
Eq. (15-7):
Eq. (15-6):
Eq. (15-5):
59.77 785.3
K v
59.77
Eq. (15-8):
0.8255
1.374
Since 785.3 < 3904, K v = 1.374 is valid. The size factor for bending is:
Eq. (15-10):
Eq. (15-15):
(K L ) P = 1.6831(109)0.0323 = 0.862
(K L ) G = 1.6831(109 / 3)0.0323 = 0.893
Eq. (15-14):
(C L ) P = 3.4822(109)0.0602 = 1
(C L ) G = 3.4822(109 / 3)0.0602 = 1.069
Eq. (15-19):
Bending
St sat 44(300) 2100 15 300 psi
Fig. 15-13:
0.99
Eq. (15-4):
( all ) P sw t
sat K L
S F KT K R
15 300(0.862)
10 551 psi
1(1)(1.25)
Eq. (15-3):
Eq. (15-4):
( all ) P FK x J P
Pd K o K v K s K m
10 551(1.25)(1)(0.249)
690 lbf
6(1)(1.374)(0.5222)(1.106)
690(785.3)
H1
16.4 hp
33 000
WPt
15 300(0.893)
10 930 psi
1(1)(1.25)
10 930(1.25)(1)(0.216)
WGt
620 lbf
6(1)(1.374)(0.5222)(1.106)
620(785.3)
H2
14.8 hp Ans.
33 000
( all )G
For the pinion, C H = 1. From Prob. 15-1, C R = 1.118. Thus, from Eq. (15-2):
sac (CL ) P CH
S H KT C R
125 920(1)(1)
( c,all ) P
112 630 psi
1(1)(1.118)
( c,all ) P
For steel:
C p 2290 psi
Eq. (15-9):
Fig. 15-6:
I = 0.083
Eq. (15-12):
C xc = 2
Eq. (15-1):
( )
Fd P I
W c,all P
C p K o K v K mCsC xc
t
P
1.25(3.333)(0.083)
112 630
2290
1(1.374)(1.106)(0.5937)(2)
464 lbf
464(785.3)
11.0 hp
33 000
2
1.25(3.333)(0.083)
120 511
2290
1(1.374)(1.106)(0.593 75)(2)
531 lbf
531(785.3)
12.6 hp
33 000
2
H3
WGt
H4
H = 11.0 hp
Ans.
The power rating of the mesh, considering the power ratings found in Prob. 15-1,
is
H = min(16.4, 14.8, 11.0, 12.6) = 11.0 hp Ans.
________________________________________________________________________
15-3
AGMA 2003-B97 does not fully address cast iron gears. However, approximate
comparisons can be useful. This problem is similar to Prob. 15-1, but not
identical. We will organize the method. A follow-up could consist of completing
Probs. 15-1 and 15-2 with identical pinions, and cast iron gears.
Given: Uncrowned, straight teeth, P d = 6 teeth/in, N P = 30 teeth, N G = 60 teeth,
ASTM 30 cast iron, material Grade 1, shaft angle 90, F = 1.25, n P = 900
rev/min, n = 20, one gear straddle-mounted, K o = 1, J P = 0.268, J G = 0.228, S F
= 2, S H 2.
Mesh
s at = 4500 psi
Table 15-5:
Eq. (15-4):
s ac = 50 000 psi
sat K L
4500(1)
swt
2250 psi
S F KT K R
2(1)(1)
steel ( K v )steel
Esteel
In the case of ASTM class 30, from Table A-24(a)
(E CI ) av = (13 + 16.2)/2 = 14.7 kpsi
Then,
( K v )CI
14.7
( K v )steel 0.7( K v )steel
30
Our modeling is rough, but it convinces us that (K v ) CI < (K v ) steel , but we are not
sure of the value of (K v ) CI . We will use K v for steel as a basis for a conservative
rating.
Eq. (15-6):
Eq. (15-5):
59.77 1178
K v
59.77
Pinion bending
0.8255
1.454
( all ) P FK x J P
Pd K o K v K s K m
2250(1.25)(1)(0.268)
149.6 lbf
6(1)(1.454)(0.5222)(1.106)
WPt
H1
149.6(1178)
5.34 hp
33 000
Gear bending
JG
0.228
149.6
127.3 lbf
0.268
JP
127.3(1178)
H2
4.54 hp
33 000
WGt WPt
s ac = 50 000 psi
50 000
sw t c,all
35 355 psi
2
2
Eq. (15-1):
Fd P I
W c,all
C p K o K v K mCsCxc
Fig. 15-6:
I = 0.86
C p 1960 psi
1.25(5.000)(0.086)
35 355
91.6 lbf
Wt
1960 1(1.454)(1.106)(0.59375)(2)
91.6(1178)
H3 H 4
3.27 hp
33 000
2
Thus,
Rating
Based on results of Probs. 15-3 and 15-4,
H = min(5.34, 4.54, 3.27, 3.27) = 3.27 hp
Ans.
Uncrowned, through-hardened to 180 Brinell (core and case), Grade 1, 109 rev of
pinion at R = 0.999, N P = z 1 = 22 teeth, N G = z 2 = 24 teeth, Q v = 5, m et = 4 mm,
shaft angle 90, n 1 = 1800 rev/min, S F = 1, S H S F 1, J P = Y J1 = 0.23,
J G = Y J2 = 0.205, F = b = 25 mm, K o = K A = K T = K = 1 and C p 190 MPa .
Chapter 15, Page 5/20
Mesh
d P = d e1 = mz 1 = 4(22) = 88 mm,
d G = m et z 2 = 4(24) = 96 mm
Eq. (15-7):
Eq. (15-6):
Eq. (15-5):
Eq. (15-10):
54.77 200(8.29)
Kv
1.663
54.77
C xc = Z xc = 2
Eq. (15-19):
(uncrowned)
Wear of Pinion
Fig. 15-12:
Fig. 15-6:
I = Z I = 0.066
Eq. (15-2):
( H ) P
( H
) ( Z NT ) P ZW
S H K Z Z
585.9(1)(1)
524.1 MPa
1(1)(1.118)
lim P
bd e1Z I
Eq. (15-1):
W H
C p 1000 K A K v K H Z x Z xc
25(88)(0.066)
524.1
WPt
0.591 kN
190 1000(1)(1.663)(1.0035)(0.56)(2)
t
dnW
(88)(1800)(0.591)
1
H3
4.90 kW
60 000
60 000
2
Eq. (13-36):
Wear of Gear
585.9(1.0054)
526.9 MPa
1(1)(1.118)
( H )G
526.9
0.591
0.594 kN
( H ) P
524.1
(88)(1800)(0.594)
H4
4.93 kW
60 000
WGt WPt
Ans.
Eq. (15-13):
Kx = Y = 1
( F ) P
Eq. (5-3):
WPt
F limYNT
68.5(0.862)
47.2 MPa
1(1)(1.25)
S F K YZ
( F ) P bmetY YJ 1
1000K A K vYx K H
47.2(25)(4)(1)(0.23)
1.25 kN
1000(1)(1.663)(0.52)(1.0035)
H1
881800 1.25
60 000
10.37 kW
Bending of Gear
15-7
(a)
(S F ) P all (S F )G all
G
P
(sat K L / KT K R ) P
(sat K L / KT K R )G
t
t
(W Pd K o K v K s K m / FK x J ) P
(W Pd K o K v K s K m / FK x J )G
(sat ) P ( K L ) P J P
J
( sat ) P P mG
( K L )G J G
JG
sat K L
FK x J
FK x J
W t all
S F Pd K o K v K s K m 11 S F KT K R Pd K o K v K s K m 11
(1)
In wear
1/ 2
sacCLCU
W t K o K v K mCsCxc
p
Fd P I
S H KT CR 22
22
s 2 C 2C 2
Fd P I
W t 2 ac 2L 2H 2
S H KT CRCP 22 K o K v K mCsCxc 22
(2)
Equating the right-hand sides of Eqs. (1) and (2) and canceling terms, and
recognizing that CR K R and P d d P = N P , we obtain
(sac )22
Cp
(CL )22
SF
SF
SF
So we get
(sac )G
Cp
(CL )G CH
(sat ) P ( K L ) P J P K x KT CsCxc
N P IK s
Ans.
(c)
(S H ) P (S H )G c,all c,all
c P c G
Substituting in the right-hand equality gives
[ sacC L / (C R KT )]P
C W K K K C C / ( Fd I )
o v m s xc
P
p
P
t
[ sacCLC H / (C R KT )]G
C W t K K K C C / ( Fd I )
o v m s xc
P
p
G
(CL )G
CH
(CL ) P
(1)
0.0602
________________________________________________________________________
Core
Case
Pinion (H B ) 11 (H B ) 12
Gear
(H B ) 21 (H B ) 22
15-8
( H B )12
Core Case
Pinion 300 373
Gear
339 345
Ans.
Ans.
________________________________________________________________________
15-9
Pinion core
(sat ) P 44(300) 2100 15 300 psi
15 300(0.862)
( all ) P
10 551 psi
1(1)(1.25)
10 551(1.25)(0.249)
Wt
689.7 lbf
6(1)(1.374)(0.5222)(1.106)
Gear core
(sat )G 44(352) 2100 17 588 psi
17 588(0.893)
( all )G
12 565 psi
1(1)(1.25)
12 565(1.25)(0.216)
Wt
712.5 lbf
6(1)(1.374)(0.5222)(1.106)
Pinion case
(sac ) P 341(372) 23 620 150 472 psi
150 472(1)
( c,all ) P
134 590 psi
1(1)(1.118)
1.25(3.333)(0.086)
134 590
Wt
685.8 lbf
2290 1(1.374)(1.106)(0.593 75)(2)
2
Gear case
(sac )G 341(344) 23 620 140 924 psi
140 924(1.0685)(1)
( c,all )G
134 685 psi
1(1)(1.118)
2
1.25(3.333)(0.086)
134 685
W
686.8 lbf
(as before)
(as before)
W t 689.7 lbf
(as before)
Gear core
(sat )G 44(339) 2100 17 016 psi
17 016(0.893)
12 156 psi
( all )G
1(1)(1.25)
12 156(1.25)(0.216)
Wt
689.3 lbf
6(1)(1.374)(0.5222)(1.106)
Pinion case
(sac ) P 341(373) 23 620 150 813 psi
150 813(1)
( c,all ) P
134 895 psi
1(1)(1.118)
1.25(3.333)(0.086)
134 895
Wt
689.0 lbf
2290 1(1.374)(1.106)(0.593 75)(2)
2
Gear case
(sac )G 341(345) 23 620 141 265 psi
141 265(1.0685)(1)
( c,all )G
135 010 psi
1(1)(1.118)
1.25(3.333)(0.086)
135 010
Wt
690.1 lbf
2290 1(1.1374)(1.106)(0.593 75)(2)
2
628.3 ft/min
12
12
K o 1, S F 1, S H 1
Eq. (15-6):
Eq. (15-10):
54.77 628.3
K v
1.412
54.77
Eq. (15-11):
Eq. (15-15):
(K L ) P = 1.6831(109)0.0323 = 0.862
(K L ) G = 1.6831(109/2)0.0323 = 0.881
Eq. (15-14):
(C L ) P = 3.4822(109)0.0602 = 1.000
(C L ) G = 3.4822(109/2)0.0602 = 1.043
Eq. (15-5):
Bending
Pinion:
Eq. (15-23):
15 300(0.862)
10 551 psi
1(1)(1.25)
(sw t ) P FK x J P
Eq. (15-4):
(swt ) P
Eq. (15-3):
Wt
Gear:
(s at ) G = 15 300 psi
15 300(0.881)
( sw t ) G
10 783 psi
1(1)(1.25)
10 783(0.71)(1)(0.201)
Wt
171.4 lbf
10(1)(1.412)(0.508)(1.252)
171.4(628.3)
H2
3.3 hp
33 000
Eq. (15-4):
Eq. (15-3):
Pd K o K v K s K m
10 551(0.71)(1)(0.241)
201 lbf
10(1)(1.412)(0.508)(1.252)
201(628.3)
H1
3.8 hp
33 000
Wear
Pinion:
(C H )G 1, I 0.078, C p 2290 psi,
Cs 0.125(0.71) 0.4375 0.526 25
Eq. (15-22):
C xc 2
Eq. (15-1):
( )
Fd P I
W c,all P
C p K o K v K mCsC xc
t
0.71(2.000)(0.078)
112 630
H3
144(628.3)
2.7 hp
33 000
Gear:
(sac )G 125 920 psi
125 920(1.043)(1)
( c,all )
117 473 psi
1(1)(1.118)
117 473
Wt
2290
0.71(2.000)(0.078)
1(1.412)(1.252)(0.526 25)(2) 156.6 lbf
H4
156.6(628.3)
3.0 hp
33 000
Rating:
H = min(3.8, 3.3, 2.7, 3.0) = 2.7 hp
Pinion wear controls the power rating. While the basis of the catalog rating is
unknown, it is overly optimistic (by a factor of 1.9).
________________________________________________________________________
15-11 From Ex. 15-1, the core hardness of both the pinion and gear is 180 Brinell. So
(H B ) 11 and (H B ) 21 are 180 Brinell and the bending stress numbers are:
(sat ) P 44(180) 2100 10 020 psi
(sat )G 10 020 psi
The contact strength of the gear case, based upon the equation derived in Prob.
15-7, is
Cp
S H2 (sat ) P ( K L ) P K x J P KT CsCxc
(sac )G
(CL )G CH S F
N P IK s
Substituting (s at ) P from above and the values of the remaining terms from
Ex. 15-1,
2290 1.52 10 020(1)(1)(0.216)(1)(0.575)(2)
1.32(1) 1.5
25(0.065)(0.529)
(sac )G
The pinion contact strength is found using the relation from Prob. 15-7:
(sac ) P (sac )G mG0.0602CH 114 331(1)0.0602 (1) 114 331 psi
114 331 23 600
( H B )12
266 Brinell
341
Core Case
Pinion 180 266
Gear
180 266
Realization of hardnesses
The response of students to this part of the question would be a function of the
extent to which heat-treatment procedures were covered in their materials and
manufacturing prerequisites, and how quantitative it was. The most important
Pinion Bending
Gear Bending
Pinion Wear
Gear Wear
1/ 2
Load-induced
stress (Allowable
stress)
Tabulated
strength
Associated
hardness
W t PK o K v K m K s
st
s11
FK x J P
( sat ) P
Factor of
safety
( sat )G
s21S F KT K R
( K L )G
W t K o K vCsC xc
Fd P I
c Cp
(sac ) P
s12
s 22 = s 12
s12 S H KT CR
(CL ) P (CH ) P
( sac )G
s22 S H KT CR
(CL )G (CH )G
(sat ) P 2100
44
Bhn
(sat ) P 5980
48
(sat )G 2100
44
Bhn
(sat )G 5980
48
(sac ) P 23 620
341
Bhn
(sac ) P 29 560
363.6
(sac ) P 23 620
341
Bhn
(sac ) P 29 560
363.6
(H B ) 11
(H B ) 21
(H B ) 12
(H B ) 22
44( H B ) 21 2100
(sat1)G
48( H B ) 21 5980
341( H B ) 22 23 620
(sac1)G
363.6( H B )22 29 560
(s ) ( K )
n11 all at1 P L P
s11KT K R
(s ) ( K )
n21 at1 G L G
s21KT K R
(s ) (C ) (C )
n12 ac1 P L P H P
s12 KT CR
Chosen
hardness
New tabulated
strength
s11S F KT K R
(K L )P
W t PK o K v K m K s
st
s21
FK x J G
Note: S F nd , S H
n22
(s ) (C ) (C )
ac1 G L G H G
s22 KT CR
SF
Eq. (15-39):
a = p x / = 0.3927 / = 0.125 in
Eq. (15-40):
b = 0.3683 p x = 0.1446 in
Eq. (15-41):
h t = 0.6866 p x = 0.2696 in
Eq. (15-42):
Eq. (15-43):
d r = 3 2(0.1446) = 2.711 in
Eq. (15-44):
D t = 7 + 2(0.125) = 7.25 in
Eq. (15-45):
D r = 7 2(0.1446) = 6.711 in
Eq. (15-46):
Eq. (15-47):
Eq. (13-27):
Eq. (13-28):
0.3927
o
tan 1
4.764
(1.5)
Pn
pn
Eq. (15-62):
(b)
Eq. (15-38):
Pt
8
8.028
cos
cos 4.764
0.3913 in
Pn
(1.5)(1725)
Vs
679.8 ft/min
12 cos 4.764
f 0.103exp 0.110(679.8) 0.450 0.012 0.0250
Eq. (15-54):
cos n f tan
cos 20 0.0250 tan 4.764
e
0.7563
cos n f cot
cos 20 0.0250 cot 4.764
Ans.
Eq. (15-58):
Eq. (15-57):
33 000nd H o K a
33 000(1)(1)(1.25)
966 lbf
VG e
56.45(0.7563)
cos n sin f cos
WWt WGt
cos n cos f sin
WGt
Ans.
Eq. (15-36):
Eq. (15-37):
Eq. (15-38):
0.025(966)
29.5 lbf
0.025sin 4.764 cos 20 cos 4.764
29.5(679.8)
Hf
0.608 hp
33 000
106.4(677.4)
HW
2.18 hp
33 000
966(56.45)
HG
1.65 hp
33 000
Wf
Ans.
pn / 8.028 0.3913 in
966
G
39 500 psi
0.3913(0.5)(0.125)
The stress is high. At the rated horsepower,
1
39 500 23 940 psi
1.65
acceptable
(d)
Eq. (15-52):
Eq. (15-49):
Eq. (15-50):
CR
15-15 Problem statement values of 25 hp, 1125 rev/min, m G = 10, K a = 1.25, n d = 1.1,
n = 20, t a = 70F are not referenced in the table. The first four parameters listed
in the table were selected as design decisions.
px
dW
FG
A
HW
HG
Hf
NW
NG
KW
Cs
Cm
Cv
VG
WGt
t
W
W
f
e
(P t ) G
Pn
C-to-C
ts
L
G
dG
15-15
1.75
3.60
2.40
2000
15-16
1.75
3.60
1.68
2000
15-17
1.75
3.60
1.43
2000
15-18
1.75
3.60
1.69
2000
15-19
1.75
3.60
2.40
2000
15-20
1.75
4.10
2.25
2000
38.0
36.1
1.85
3
30
50
15-21
1.75
3.60
2.4
2500
FAN
41.2
37.7
3.59
3
30
115
15-22
1.75
3.60
2.4
2600
FAN
41.2
37.7
3.59
3
30
185
38.2
36.2
1.87
3
30
38.2
36.2
1.47
3
30
38.2
36.2
1.97
3
30
38.2
36.2
1.97
3
30
125
38.2
36.2
1.97
3
30
80
607
0.759
0.236
492
854
0.759
0.236
492
1000
0.759
0.236
492
492
492
563
492
492
2430
2430
2430
2430
2430
2120
2524
2524
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
5103
16.71
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
7290
16.71
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
8565
16.71
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
7247
16.71
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
5103
16.71
1038
0.0183
0.951
1.571
1.732
11.6
171
6.0
24.98
4158
19.099
1284
0.034
0.913
1.795
1.979
10.156
179.6
5.25
24.9
5301
16.7
1284
0.034
0.913
1.795
1.979
10.156
179.6
5.25
24.9
5301
16.71