Design of Gears

Factors in selection of type of gears

General layout of shafts
Speed reduction
Power to be transmitted
Input speed
Cost

Spur and Helical gears => for parallel shafts

Bevel gears => for intersecting shafts
Worm gears => for shaft axes perpendicular but non-intersecting
Spiral Helical gears => for shaft axes neither perpendicular nor intersecting
Speed reduction for a single pair of spur/helical gears=> 6:1 normally; maximum 10:1
occasionally
For higher speed reductions=> use 2 or 3 stage constructions
Speed reduction for a single pair of bevel gears=> 1:1 to 3:1
For very high speed reductions => use worm gears
Speed reduction for Worm gears => 60:1 to 100:1
Choose Helical gears for high speed power transmission and to minimize noise
Spur gears => cheapest and easy to manufacture
Helical, bevel and worm gears => costly and difficult to manufacture
20o pressure angle full depth involute teeth system => reduces undercutting, stronger
tooth
14.5o pressure angle involute teeth system => quiet operation
Gear materials => cast iron, steel, bronze, plain carbon steel, alloy steel, Nylon

Design of Gears
Steps in Design of Spur Gears
1.

2.
3.
4.
5.
6.
7.

8.
9.
10.

Select proper tooth profile to meet constraints of space and noise level. Most coomonly
used profile is 20o full depth form. If the space availability is low, 20o stub form is used. If
noise level is to be kept low and there is no constraint on space, 14.5o full depth form is
used.
Select the number of teeth for the smaller gear called pinion, tp as per T-XVI-7. Calculate
the number of teeth on larger gear called tg.
By assuming the module of teeth as m mm (unknown) calculate the pitch diameter of the
pinion Dp.
Calculate the pitch line velocity, Vp, in m/s
Calculate the design power Pd as per T-XVI-1 and T-XVI-2.
Calculate the tangential tooth load, Ft in terms of m
Assume suitable material for pinion and allowable basic stress, So as per T-XVI-10. Low
strength steel and cast iron is preferred for low speeds and medium power while better
grade of steels are used for larger power and higher speeds. For continuous duty which
requires heat treatment of gears, alloy steels are preferred
Calculate the modified Lewis form factors for the pinion and gear yp and yg as per T-XVI-5.
Assume a trial face width, b equal to 10m which is a mean value of the range given in TXVI-7.
Assume a trial value for the velocity factor Cv as given below:
Cv = 0.4 for pinion speeds upto 1000 rpm
= 0.3 for pinion speeds between 1000-2000 rpm
= 0.25 for pinion speeds above 2000 rpm.

Design of Gears
Steps in Design of Spur Gears continued
11. Calculate the bending strength of the gear tooth FB as per the modified Lewis equation TXVI-1.
12. By equating FB to Ft obtained in step 6, calculate the minimum module required for the
drive.
13. Select the nearest standard module, m, as per T-XVI-7.
14. Calculate the actual values of pitch diameters Vp, Ft, Cv.
15. Select the material of the gear and its corresponding basic stresses So as per T-XVI-10.
16. Calculate the product (Soy) for pinion and gear and decide which is weaker.
17. Calculate the actual width required for the by using the actual values of Ft, Cv, m and lower
value of (Soy)
18. Calculate the dynamic load Fd by the Buckinghams equation as per T-XVI-1. For calculating
the probable error from Fig. 16.1 assume the class of gears with the help of Fig. 16.2 which
gives the permissible errors for the given pitch line velocity.
19. Calculate the minimum value of load stress factor K by equating the limiting wear strength,
Fw to the dynamic load Fd. Fw is calculated as per T-XVI-1.
20. Suggest suitable hardness for pinion and gear as per T-XVI-6.
21. Calculate the endurance strength of gear teeth Fen as per T-XVI-1 and T-XVI-9. Check that
Fen < Fd. If not, increase b within the usual range or change the material and the heat
treatment.

Design of Gears
Steps in Design of Helical Gears
The design steps are similar to those of spur gears except that in Step 2 after selecting the
number of teeth on pinion, we calculate the formative number of teeth tf and use tf for
calculation of Lewis form factor y
Use T-XVI-11 for the design formulae for Helical gears

Steps in Design of Worm Gears

1. Select the number of teeth on worm tw as per T-XVI-16. Calculate the number of teeth on
worm gear tg which should be greater than 29.
2. Choose proper lead angle and normal pressure angle n as per T-XVI-16.
3. Assume the module of worm gear teeth as m mm. Calculate the pitch diameter of the
gear and the pitch line velocity of the gear in terms of m.
4. Calculate the design power Pd and the tangential tooth load Ft as per T-XVI-15. This will be
in terms of unknown m.
5. Assume materials of construction for worm and worm gear as per T-XVI-18 and their basic
stress as per T-XVI-10.
6. Assume trial value of b as per T-XVI-19.
7. Calculate the modified Lewis form factor Y as per T-XVI-15.
8. Assume a trial value of Cv = 0.75.
9. Calculate the beam strength FB as per Lewis equation given in T-XVI-15 and the values
assumed in step 5, 6, 7 and 8 in terms of unknown m.
10. Equate FB to Ft and calculate the trial value of m. Choose the nearest standard module as
per T-XVI-7.

Design of Gears
Steps in Design of Worm Gears continued
11. Calculate the pitch diameter of the worm Dw as per T-XVI-19 and see that it is within the
given range as per T-XVI-16.
12. Calculate the actual values of Dg, Vp, Ft and Cv.
13. Calculate the face width b of the gear. Calculate the beam strength FB and check that FB>Ft.
If not, change the module and repeat the procedure.
14. Calculate the dynamic load on the gear by the relation Fd = Ft / Cv.
15. Calculate the limiting wear load Fw as per T-XVI-15. Check that Fw>Fd. If not, change the
module m.
16. Calculate the rubbing velocity VR and coefficient of friction as per T-XVI-16.
17. Calculate the efficiency of the drive as per T-XVI-15.
18. Calculate the heat generated Q1, heat dissipation capacity Q2 in terms of T as per T-XVI-15.
19. Calculate T by equating Q2 to Q1. Check that the maximum oil temperature is within the
given limits.

Steps in Design of Bevel Gears

=> The design procedure for bevel gears is similar to that of Spur gears except that we should
use T-XVI-20 and T-XVI-21 from the design data book and use the formative number of
teeth while calculating the Lewis form factors.