Gearbox design

Geardesign

Steven Thielemans
Carra Tillon

Introduction.
For the design of the two gears, we have to determine the most critical aspects of
the pair of gears. Those are: the tooth base strength and the contact strength.
When the tooth base strength is exceeded, the teeth will show fractures, when
contact strength is exceeded, pitting will occur. We will now explain our calculations
in different steps.

1. Gear ratio number of teeth.

The first thing that we do, is determine the number of teeth on the small and bigger
gear. We know that the transmission ratio for the gears is 2,659. The number of
teeth of the smallest gear should be between 19 and 24. Next to that, both number
of teeth cannot be divided by the same number. The reason is that one specific
tooth will always match the same hole in the other gear. When that hole is a little
bit smaller than the others (because of a manufacturing error), the tooth that
matches the hole, will experience more pressure than the others. Because of that, it
is possible that the tooth breaks. If the number of teeth cannot be divided by the
number of the other gear, the tooth with the manufacturing error will rotate
between all holes.
We may assume that the gear ratio is equal to the transmission of the number of
teeth on the gears.

i t=u=

z2
=2,659
z1

We choose the number of teeth of the first gear 23. In order for the gear ratio to be
2,659, the number of teeth of the second gear should be 61. Those are both prime
numbers, and when dividing them, they equal the gear ratio, despite a small
correction.

z 2 61
= =2,652
z 1 23

1. Calculating contact strength.

The purpose of the calculation of the contact strength, is to determine the minimum
diameter d1 of the smallest gear. The condition that has to be fulfilled is:

H HP
1) Pressure in the flank of the tooth.
We will first calculate the pressure that occurs in the side of the tooth:

H =K Htot H 0
Where KHtot is the total loadfactor.

K Htot = K AK V K HK H
Explanation of the different factors:
KA = operating factor = 1,9. We got this value from table 3.5b in the book of
Roloff&Matek.
Kv = dynamic factor = 1,1. This is an appropriate value for our gear.
KH = factor of division of load = 1. We got this factor from table 21.19a. We
assumed that the quality of the teeth was ISO 7.
KH = factor of the concentration of the load = 1,5. This is an appropriate value for
our gear.
When using all the values in the formula, we get that

K Htot = 1,91,111,5=1,77

Next to the loadfactor, we have the nominal pressure of the flank of the tooth H0. In
this first case, we assume that the profile shift is zero. (x = 0).

Ft
u+1
b1d 1
H 0=Z HZ EZ Z
u
Explanation of the different factors:
ZH = geometry factor = 2,5. We have straight teeth, so the angle is zero. The
profile shift is zero. (table 21.22a)
ZE = elasticity factor = 189,8. We used table 21.22b for this value.
Z = snatching factor

4 a
. The value for a was found in table 21.2a.
3

a = 1,65, so Z = 0,885
Z = tooth angle factor =

cos

= 1. Because we have straight teeth, the angle

is zero.

Ft =

T1
T1
=
d w 1 /2 d1
cos
2
cos w

= the force that works on the periphery. In this case, both of

the cosines can be deleted. There is no profile shift, so there wont be an angle shift.

= w
Next to that theres a formula for the torque T1.

K AP1 1,91,5103
T1=
=
=29,03 Nm
1
98,175
Where
P1 = the power delivered by the motor = 1,5 kW
1 = the rotational speed of the shaft = 937,5 RPM = 98,175 rad/sec
KA is already given in the first part of the calculations.

Ft =

2T 1 58,06
=
N
d1
d1

58,06
2,659+1
b1d 21
79,895
H 0=2,5189,80,8851
=419
2
2,659
b1d 1

For now, d1 is still unknown. Later on, we have to choose our diameter, so the
condition of the contact strength is fulfilled.
When combining the formulas and the different values, we can find some values for
our main unknown parameters.
Ka
Kv
KH
KH
KHtot

1,9
1,1
1
1,5
1,77

ZE
Z
Z
ZH
H0

H =1,77419

79,895
b 1d 21

189,8
0,885
1
2,5
calculation later on

2) Allowable contact pressure

Another formula for the contact pressure that is allowed. This is a maximum value.

HP=

HlimZ NT
Z LZ vZ RZ W Z X
S Hlim

Explanation of the different factors:

Hlim = fatigue resistance of the material = 1300 For this value, we had to use table
20.1
ZNT = factor of durability =1. There is no remark on a limited lifetime.
SHlim = the minimal required safety = 1,3
ZL*Zv*ZR = viscosity factor = 0,92. This is a given value.
Zw = reinforcement factor = 1 . We had to transform the Rockwell toughness (= 58)
to the Brinell toughness (=600), which was tabled in the book in table 21.23e.
Zx = factor of size = 1

HP=

13501
0,9211=955,38 Pa
1,3

When calculating the allowed contact pressure, we get that HP is 920Pa. With that
value, we can now determine our minimal modulus m 1,min and the minimal diameter
of the smallest gear d1,min. For that, we use table 21.1a and the initial condition.

H HP

741,63

79,895
955,38
b1d 21

We also have to determine the depth of the gears, table 21.14 can help us with that.
We know that the gears have been flame hardened, so the ratio depth/diameter
has to be smaller than 1,1. We assume that this value is 1, this is easy to calculate
and its smaller than 1,1. We assume that b = d.

372,106d

3
2

955,38

3
2

2,568

d 0,533 mm

The minimal diameter is 0,533mm, so the minimal modulus that we could pick is
0,023. This value is actually not in the list of table 21.1a. The minimal modulus we
can pick there is 0,1.
For our actual values, we choose that m is 1,5 and d 1 is 34,5mm. We chose the
modulus value from the table 21.1a, and by using the formula
calculate the diameter.
Here you can see a structured view of the calculated values.
HP
H
Ft

920 Pa
32,71 Pa
1,683 N

Z1
Z2
D1

23
61
34,5 mm

d=zm

we can

1,5

D2

91,5 mm

2. Applying profile shift.

After dimensioning the gears, we can calculate the distance between the axes.

ad =

d 1+ d 2 34,5+ 91,5
=
=63 mm
2
2

Normally, profile shift is used to avoid undercutting or for constructive reasons. We

actually dont need that here, but we will just do these calculations to complete the
report.
The distance between the axis will be corrected by a given factor.

a=ad + correction=63 mm+ 0,5 mm=63,5 mm

Now, we can calculate the corrected pressure angle with equation 21.21. After that,
equation 21.32 can help us to find the total profile shift-factor.

R =arccos

cos 20)=21,2 (eq 21.21)

( aa cos )=arccos( 63,5
63
d

( R)inv( )
0,0178650,014904
inv
( z 1+ z 2 ) =
( 84 ) =0,34
2tan
2tan 20
x=
The values of inv(R) and inv() can be found in table 21.4.
We will now determine the division of the total profile shift-factor into profile shiftfactors of each gear. Table 21.6 shows how to divide it, and we get that x 1 = 0,06
and x2 = 0,28.
With these values, we can calculate the profile shift of each gear.

V 1=mx 1=1,50,06=0,09

V 2=mx 2=1,50,28=0,42

The minimal thickness of the top of the tooth should be checked. To check it
properly, we have to use following condition:

s a 0,4m
Sa is the thickness of the top. We can calculate this value by using formula 21.28

s
s a=d a( +invinv a )
d
Explanation of the different factors:
sa = the corrected thickness of the top of the teeth.
da = the corrected diameter of the gear = 34,5mm
s = the thickness of the top of the teeth, without correction

p
s= =2,726 mm
2

p=

d1
=4,71mm=stake
z1

d = the diameter of the gear = 34,5mm

= the pressure angle = 20
a = the corrected pressure angle = 21,2
After using all the values, we get that sa = 2,85mm. We will check this with the
initial condition:

s a 0,4m

2,85 0,6

We will now calculate the corrected diameters, when taking into account the profile
shift.

d a=d+ 2m+2V

d f =d2,5m+2V

When we do this for both gears, we get following values:

da1 = 37,68 mm
df1 = 30,93 mm
da2 = 95,34 mm
df2 = 88,59 mm
The available tolerance of the pair of gears is calculated a followed:

c=a

d a 1+ d f 2
37,68+ 88,59
=63
=0,137
2
2
c mini=0,25m=0,375 . In this case,

The minimal value of this parameter should be

our value for c is smaller than the minimal tolerated value. Thats why we will have
to implement a change in height of the top of the teeth.

k =aad m( x 1 + x 2 )=63,5631,50,34=0,01
We now can re-calculate the new values for the diameters of the gears by using
following formula:

d a=d+ 2m+2V + 2k
We get that

d a 1=37,66 mm and

d a 2=95,2 mm .

3. Controlling the contact strength.

This calculation is similar to the one in 1. Most of the values stay the same, except
for the one who are influenced by the profile shift. In following table, all the values
are listed up. The values that differ from previous calculations, are explained more
extensively.
1) Pressure in the flank of the tooth.
KA
KV
KH
KH
KHt

1,9
1,1
1
1,5
1,77

ZH
ZE
Z
Z

2,4
189,8
0,885
1

ot

Ft =

T1
T1
=
d w 1 /2 d1
cos =force on the periphery. We must consider the profile shift in
2
cos w

this case.

Ft =

29,03
=1,67 N
34,5
cos 20
2
cos 21,2

The nominal pressure:

Ft
1,67
u+1
2,659+1
b1d 1
34,537,66
H 0=Z HZ EZ Z
=2,4189,80,8851
u
2,659
H 0=16,954 Pa

H = H 0K Htot =16,9541,77=30,01 Pa

2) Allowable contact pressure

Hlim
1350
ZNT
1
ZL*ZV* 0,92
ZR

Zx
Zw
SHlim

1
1
1,3

The allowable pressure:

HP=

HlimZ NT
Z LZ vZ RZ W Z X
S Hlim

HP=

13501
0,9211=955,385 Pa
1,3

The initial condition:

H HP

30,01 955,385

4. Calculating and controlling tooth base strength.

This calculation is similar to the one in 3. The condition that has to be valid is :

F FP
1) Pressure in the foot of the teeth F

F =K Ftot F 0
KFtot is the total factor that influences the load.

K Ftot =K AK VK FK F
Explanation of the different factors (they are the same as in section 3):
KA = 1,9
KV = 1,1
KF = 1
KF = 1,5
So

K Ftot =1,91 ,111,5=3,135

F0 is the nominal pressure in the foot of the teeth.

F 0=

Ft
Y FaY SaY Y
bm

Explanation of the different factors:

Ft = force of the periphery = 1,67 N
YFa = form factor = 2,1. We used table 21.20a to get this value.
YSa = notch factor = 2,6. We used table 21.20b to get this value.

Y =0,25+

0,75
a = snatching factor= 0,705. We used table 21.2b to get a value for

a, that is 1,65.
Y = tooth angle factor = 0,85. We used table 21.20c to get this value.

F 0=

1,67
2,12,60,7050,85=106
34,51031,5

We can now calculate

F =1063 , 135=331

2) Allowed pressure in the foot of the teeth FP

FP=

2 FlimY NT Y X
S Flim

Explanation of the different factors:

Flim = nominal fatigue of the foot of the teeth = 450. We used table 20.1 to get this
value.
SFlim = the required minimal safety factor = 1,5
YNT = durability factor = 1
YX = factor of size = 1. We used table 21.21d to get this value.
So

FP=

245011
=600 Pa
1,5

The initial condition:

F FP
331 600