2.1
Force and Power
Gears transmit force from tooth of the driving gear on to the
meshing driven tooth as shown in Fig- 2.1. The tooth of the
driving gear 1 pushes the meshing tooth on gear 2 along the
line of action. The force is normal to the teeth profiles and has
been designated as Fn. At the pitch point, normal force Fn may
be resolved into two components, the tangential component
Ft and the radial component Fr.
(2.1)
where
v = pitch line velocity, m/s
d1 = pitch diameter of pinion, mm
n1 = speed of pinion, rpm
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2.2
Gear Tooth Failures
Gear teeth fail due to fatigue. Failure is exhibited either as a
facture of one or more teeth at the root or failure due to
excessive wear of contact surfaces due to pitting, scoring and
wear.
Fatigue Fracture due to Bending
Fatigue fracture due to bending starts with a small crack at
the fillet in the tensile stress zone at the root of the teeth. Fig
2.2a.
The crack slowly progresses inward and downward, Fig. 2.2b,
and finally (c) when the tooth becomes too weak because of
the reduced cross-section, It breaks suddenly as at Fig. 2.2c.
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2.3
Lewis Tooth Bending Stress
Lewis considered tooth as a cantilever subjected to a static
normal force F applied at the tip. Force F is resolved in two
components, tangential Ft and radial Fr. The bending stress at
the point where tooth force meets the middle section is zero;
and then it increase parabolically as shown in Fig 2.3. The
constant strength parabola is inscribed in the tooth profile.
Since the parabola is inside the tooth profile except for the
section at a where parabola and tooth profile are tangential
to each other. Hence section as a critical and the bending
stress is:
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(a)
From two similar triangles formed at point a
(b)
Substituting (b) into (a)
(c)
is called the Lewis form factor
Since
(2.3)
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Since,
(2.4)
(2.5)
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1.
2.
3.
4.
5.
6.
7.
8.
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12
(2.8)
However, the stress at the root depends on the geometry of
both the driving and driven gears and the same are indicated
by geometry factors J. AGMA Standard 908-B89 provides
tables of J factors as well as the algorithm to calculate them.
Several text books and data book also give these values.
In the derivation of Lewis equations; only one tooth carries
the whole load at the tip, which is not true in practice. As the
contact ratio is generally of the order of 1.5, the greatest load
is not exerted at the tip but it is much below the tip where a
single pair is in contact. However, we shall use full Ft at the tip
to be on the safe side.
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where,
d = dynamic stress at the root of the tooth (or design stress)
J = spur geometry factor
Ko = overload factor ( or load application factor)
Kv = velocity factor ( a dynamic factor)
Km = load distribution factor
15
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Driven Machinery
Uniform1
1.00
1.25
1.75
1.25
1.50
2.00
1.50
1.75
2.25
1.
2.
3.
Generator, belt conveyor, platform conveyor, light elevator, electric hoist, feed gears of
machine tools, ventilators, turbo blower, mixer for constant density material.
Main drive to machine tool, heavy elevator, turning gears of crane, mine ventilator,
mixer for variable density material, multi-cylinder piston pump, feed pump.
Press, shear, rubber dough mill, rolling mill drive, power shovel, heavy centrifuge, heavy
feed pump, rotary drilling apparatus, briquette press, pug mill.
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18
(2.13)
(2.14)
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0-50
1.3
1.4
1.5
1.8
1.6
1.7
1.8
2.2
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23
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2.8
Hence
(2.17)
Thus the maximum tangential force Ft transmitted by a pair of
gears is minimum of the following two:
(2.18 a)
(2.18 b)
If the gear and pinion are manufactured from the same
material and to the same accuracies, gear teeth are stronger;
hence design the pinion only.
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26
(2.20)
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Gear
14.5o
full depth teeth
20o
full depth teeth
20o
stub teeth
Grey CI
Grey CI
5600
5800
6000
Steel
Grey CI
7800
8000
8200
Steel
Steel
11000
11400
12000
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2.10
(2.16)
(2.21)
where
(2.22)
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