EXAMPLE

Design a pair of helical gears to transit 30 KW power at a speed reduction ratio of 4:1.The input
shaft rotates at 2000 rpm. Take helix and normal pressure angles equal to 25 and 20,
respectively. Both pinion and gear are made of steel. (The following data is given.)

Name of the part

pinion
gear

Permissible stress
55 MPa
40 MPa

BHN
340
300

The number of teeth on the pinion may be taken as 30.

SOLUTION: Number of teeth on gear, z 2= speed reduction ratio

z 1 = 4 30 = 120

Lewis form factor on the basis of formative number of teeth

Y = (0.154 -

1='

'
2

z1
3

cos
z

30
cos3 25

z2
=

cos

120
3
cos 25

30
0.744

= 40.3, say,41

120
0.744

Lewis form factor, Y 1 = (0.154Y 2 = (0.154

0.912
162

0.912
)
z'

= 161.2, say, 162

0.912
41 )= 0.414

) = 0.4661

Strength factor of the pinion = d 1 Y 1

= 55 0.414 = 22.77
Strength factor of the gear = 40 0.4661 = 18.64
Since the strength of the gear is less than that of the pinion, the gear is the weaker element.
Tangential force on the gear,

Ft =

P 1000
v

(V=pitch line velocity)

=

d2N
60 1000 =
2

3.14 m 120 500

= 3.14m m/s
60 1000

Tangential force,

Maximum tangential force,

30 1000
3.141 m =

Ft =

C wear F
Cv

Fmax =

9551
m N

C wear = wear and lubrication factor

=1.25 for scant lubrication with frequent inspection
C v = 0.35 (assumed trial value)
Fmax =

1.25 9551
=
0.35 m

34,110.7
N
m
Since ma = m cos

Fmax =

34,110.7
cos 25 =
ma

30,914.8
N
ma

Fbeam = b m a Y d

Lewis beam strength,

Let us adopt face width, b= 15 ma , Therefore,

Fbeam = 15 ma ma 0.4661 40
2

= 279.66 m a
For safe design, the beam strength should be greater than or equal to maximum force.
Therefore,
30914.8
ma

= 279.66 ma

OR
ma = 4.8 mm, say, 5 mm
Pitch diameter of the pinion, d 1 =

Pcd of the gear,

d2

120 5
cos 25

Z1m
cos

600
0.906

30 5.0
cos 25

= 662 mm

150
0.906 = 165.5 mm

Pcd line velocity, v=

dN
60

3.14 0.662 500

60

Tangential force,

Ft =

9551.0
=
m

= 17.33m/s
9551.0 cos 25
=
5

9551.0 0.906
=
5

1731.23 N
Velocity factor, C v =

Maximum tangential force,

15.25
15.25+17.33 = 0.468

Fmax =

1.25 1731.23
= 4624 N
0.468

Lewis beam strength

Fmax = b m a Y d
=15550.466140=6991.5 N
The beam strength is greater than the maximum tangential force (1.512 times). Hence the design
is safe under static load conditions.
Dynamic load
Buckingham equation for dynamic load
Ft +

Fdyn =

K 3 v ( cb cos2 + Ft )cos
K 3 v + cb cos2 + F t

K 3 = constant = 20.67

c = dynamic load factor =

e
1 1
K 1( + )
1 2

A permissible profile error for 17 m/s velocity is 0.01925. This order of error can be obtained
in class 3 gears with 5 mm module, which gives e =0.015 mm. Thus,
C=

0.015 0.2 106 0.2 106

9.0 2 0.2 10 6

cb cos 2 + F t = 166.67 15 5 cos 2 25 + 1731.23 = 166.67 15 5 0.821 +

1731.23= 11,998.85
And

cb cos

+ Ft

= 109.54

Hence dynamic load,

Fdyn

= 1731.23

+20.67 17.33 11,998.85 0.821

=
20.67 17.33+109.54
1731.23 +

3528757.55
467.75

=1731.23 +

8327.97= 10,059.2 N
For safe design, the endurance strength of the gear should be equal to 1.25 times the dynamic
load for steady load conditions, i.e.
Fen = b m n Y en

1.25 Fdyn

Or
en

1.25 10,059.2
15 5 5 0.4661

2
= 71.93 N/ mm

Therefore,
Core BHN required =

en
1.75

71.93
1.75

= 41.1

Which is less than the core BHN of steel.

Wear load
The limiting wear load
F wear =

d 1 bQK
2

cos

F dyn
'

Q=

2 Z2
'
'
Z 2+ Z 1

2 162
162+ 41

= 1.596

F dyn cos
d 1 bQ
2

Load stress factor, K =

10,059.2 cos 25
165.5 75 1.596

10,059.2 0.821
165.5 75 1.596

= 0.417
Also,
K=

2es sin E1+ E

1.4
E1 E2
2

Therefore,
2

K=

6
es sin 20
2 0.2 10

6
6
1.4
0.2 10 0.2 10

8258.60
19810.25

2
es

0.417 1.4 0.2 10 6

0.342 2

0.0411 106
0.684

es

106
=0.060

2
= 413.15 N/ mm

Required surface hardness

BHN =

es +70
2.75

==

413.15+70
2.75

= 175.7

Which is less than the core hardness. Hence there is no need for surface hardening.

A pair of parallel helical gear consists of a 20 teeth pinion of the velocity ratio is 3:1. The
helix angle is 15 and the normal module is 5 mm. Calculate
The pitch circle diameter of the pinion and gear and
The centre distance
ANS :
Zp =20
Helix angle=15
m=5
Zg =3 Zp
=320
=60
1: The pitch circle diameter
For pinion dp =mtzp
Where mt =transverse module
Mt=mn/cos=5/cos15
=5.176mm
Now
dp =mtzp
=5.17620
( dp =103.52 mm)
For gear
dg =mtzg
=5.17660
dg = 310.56 mm
2)Centre distance
a= (dp + d g)/2

= (103.52+310.56)/2
a=207.04 mm

Helical Gears
Example: A pair of helical gears consists of 24 teeth pinion meshing with 72 teeth gear. Normal
pressure angle is 20, and helix angle is 24. The pinion rotates at 720 RPM. Normal module of
gear is 5 mm and face width is 50 mm. Both, pinion and gear are made of steel with ut =
600MPa. Gears are heat treated to a surface hardness of 360 BHN.
What power can be transmitted by gears if service factor is 1.4 and factor of safety is 2? Assume
that velocity factor accounts for the dynamic load.
Solution:
Normal Module, mn = 5mm
Face width, b= 50mm
Helix angle, = 24, cos

= 0.9135

Beam strength, S b = b mn b Y
Allowable bending stress, b

ut
3

= 600/3 = 200MPa

Virtual Number of teeth on pinion:

'

Zp

Zp
3

cos

24
cos3 24

24
0. 7624

= 31.48

Y= Lewis form factor for 31.48 teeth

= 0.3624
S b = b m n b Y = 5 0.362420050 = 18,120 N
( in transverse direction)
Sw

= wearing strength =

b d p QK
cos2

( in transverse direction)
d p = pitch circle diameter of pinion

mn
cos

Zp =
2Zg
Z p +Z g

Q = ratio factor =

5 24
cos 24

2 72
72+24

= 120/0.9135 = 131.36 mm

= 1.5

BHN
360
K = 0.16 ( 100 ) = 0.16 ( 100 ) = 2.0736
Sw

50 131 . 36 1 .5 2. 0736
cos 2 24

= 24,478.8 N
Sb < Sw
Power transmission will depend upon beam strength, S b .
Service factor C s = 1.5
Factor of safety, FOS = 2
5.6
5 . 6+ v

Velocity factor, C v =

Pitch line velocity v =

2 720
60

2 N
60

131 . 36
2

dp
2

1
1000

1
1000

= 4.95m/s
Cv =

5.6
5 . 6+ 4 . 95

Peff = Pt

Cs
Cv
Sb =

5. 6
5 . 6+2 . 22

Pt

Peff

= 4.19 Pt
Pt

= tangential tooth load

1. 5
0. 716

FOS

= 2.095 Pt 2

5.6
7 . 82

= 0.716

= 2.095 Pt

= 20,429/0.8345

=
Power =

18 , 120
4 .19

= 4,324.6N

Pt v Nm

= 4,324.64.95 W
= 21406.7 = 21,406 kW
HELICAL GEAR
A single stage helical gear receiver is to receive is to receive power from a 1440 rpm 25 KW
induction motor. The gear tooth profile is involute full depth width. 20Normal pressure angle
the helix angle is 23.No of teeth on pinion is 20 and the gear ratio is 3.Both the gears are made
of steel with allowable beam stresses of 90Mpa and hardness 250Mpa.
Design the gears for 20% overload carrying capacity from stand point of bending strength and
wear.
If the increment dynamic load of 8 KN is estimate in tangential plane. What will be the safe
power transmitted by the pair at the same speed.
Solution:
Given data:
Power (P) = 25 KW
Hardness = 250Mpa
Zp

= 20

Z g = 60
b

= 90Mpa

= 20

= 23

K = 1.2
BEAM STRENGTH:
Z 'p

Z 'g =

Zp
3

cos
Zg
cos3

= 25.64

= 76.92

For 20 full depth involute tooth

Y 'p = 0.484

2 . 87
Z 'p

= 0.372

Y 'g

2 . 87
'
Zg

= 0.447

= 0.484
'

b Y p = 900.372 = 33.48

Now,

b Y 'g = 900.447 = 40.23

b Y 'p < b Y 'g So that gear design is based on pinion take b = 10 mm

Now,
Fb

b Y 'p b m n = 33.4810 m2n = 334.8 m2n N

EFFECTIVE LOAD
mn Z p
dp = m Zp =
cos
d p np
60 ,000

V=
Ft

P
v

25
1 . 638 mn

Cv =

Now

K a = 1.2,
Peff

Fb

mn

3 . 14 1 . 72 1440 mn
60 ,000

Velocity factor,
Again

= 21.72

= 1.638 mn m/sec

15 . 261
KN
mn

5.6
5 . 6+ v

5 .6
5 . 6+ 1 .33 mn

Km = 1

K aK F
Cv
m

15261
1 . 2 1
5 .6+ 1 . 33 mn
(
mn
5.6

= FOS Peff
2
334.8 mn = 2 Peff

3
18312. 86+3771 . 32 mn
334.8 mn = 2
)

(18312. 86+3771. 32 mn )
mn

Take m n = 4.7but standard value is m n = 5mm

Dimension b = 105 = 50mm
mt =
Zp

5
0. 9 2

= 5.435mm

= 20

dp =

mt Z p = 5.435 20 =109 mm

Z g = 60
dg

= mt Z g = 5.43560 = 326mm

ha

= 5 mm

hf

= 1.255 = 6.25 mm

a = + d g )/2 = 217.5mm

e p = 8.0 + 0.63( mn + 0.25

d p

) = 12.79 m

e g = 8.0 + 0.63( mn + 0.25

dg

) = 13.99

3
e = e p + e g = 26.78 10 mm

Ft

Ftmax =

15.261
KN = 3052N
mn
Ka Km Ft

= 3662.6N

V=

1.638 mn = 8.19m/s
C = 11500e=307.97N/mm
Fd

21 v( cb cos 2 + F t max) cos

2650575.55
301.41

21 v + cb cos + F tmax
2

=8793.92N

21 8.19 ( 307.97 50 0.85+3662.6 ) .92

21 8.19+ 307.97 50 0.85+3662.6

Peff

Ka Km Ft

Fd

= 3662.6+8793.92 = 12456.52N

WEAR STRENGTH
Fw =

d p bQK

cos

F w = FOS

109 50 2 60
0.85 80

250
0.16 ( 100 )

Peff

16193.47= FOS 12456.52

FOS=1.299
FOS=1.3
Our design is safe
Case:- 2
Power required for dynamic load of 8 KN
P

eff

Ka Km Ft

P=19495.74
P=19 KW

Fd

P
12456.52 =1.21 V

+ 8000

=16193.47 N