1

Power transmission

Components used to transmit power: gears, belt, clutch and

brakes.

Gear
Objective:
Student must be able to force analysis, stress analysis using basic
formula (Lewis) and AGMA (bending stress and surface stress)

Type of gear:
Spur gear only

Types of Gear

a) Spur Gear

Teeth is parallel to axis of rotation

Can transmit power from one shaft to another
parallel shaft

b) Helical gear

Teeth is inclined to the axis of rotation

Smoother than spur
Develop thrust load (helix angle)
Can transmit power from one shaft to a
parallel and non-parallel shaft
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c) Bevel gear

Teeth on conical surfaces

Transmit power between two intersecting
shafts

d) Worm gear

Transmit power between two

intersecting shafts

Terminologies

A pair of gears can represented as 2 circles

d1 = Nm
d2 = Nm

2 3

where: N : number of teeth

m : module
note: mating gear must have same m
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Module: is the ratio if diametral pitch and number of teeth m = d/N [mm]
Face Width (F) : width of the tooth
Addendum [a] : distance between top face of the tooth to pitch circle
Dedendum [b] : distance between pitch diameter to bottom of the gear

In the following : we only concentrates on full depth gear

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Full depth tooth

When the offset occurs between pitch. not full-depth tooth, which is called stub

Undercut: resulted from number of tooth is less than the minimum number of
tooth suggested. Results: higher stresses at the root of the tooth. (Refer to
section 13-7 interference)

Backlash : gap between mating tooth. The gap can be used for lubrication
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Contact Ratio: the number of tooth in contact during meshing. Roughly spur
gear (1.4 to 1.8 )

Pinion and Gear : pinion is driver and gear is driven

Gear Parameters

Metric Module m = d/N

Imperial Diametral Pitch P= N/d (inverse to module)

One pair of gear must have the same module

Pressure Angle: 200, 22.5o, 250

Table 13-1: relationship between addendum (a) and dedundum (b) pp

696

Table 13-2: Available pitch diametral and module.

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Gear Train

2 3

dn
V2 = V3 Known that V
60
where : n : revolution / min it

d 2 n2 d 3 n3
Equation 1
d 2 n2 d 3 n3

For a pair of gear m2 = m3

d2 d3
Equation 2
N2 N3

From Eq 1 and 2

d 2 N 2 n3

d 3 N 3 n2
Significance:
d increases N increase
d increases n reduces to reduce rpm requires small
pinion and larger gear and vice versa.
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Gear Train (continued)

3
2
4

V2 = V3 and V3 = V4

Therefore V2 = V3 = V4
N2 n3

From previous formula: N3 n2
N2 n2 N3 n3

Gear 2 and 3
N2
n3 n2 (1)
N3
Gear 3 and 4
N3
n4 n3 (2)
N4
Eq (1) in eq (2)
N3 N2
n4 n2
N4 N3

product of driving tooth numbers

nL nF
product of driven tooth numbers
where: nL : rotational speed of last gear (output)
nF : rotational speed of first gear (input)

product of driving tooth numbers

Train value e
product of driven tooth numbers
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Planetary Gear

5 Gear 2: Sun gear

4 Gear 3: Arm
2 Gear 4: Planet Gear
3 Gear 5: Ring Gear

Assumption Arm Fixed:

4 5
2
3

N 2 N 4 N5
Train value e
N 4 N 5 N6
 9

3 MAGIC FORMULAE FOR FBD ANALYSIS ON GEAR

d
Torque T Wt [ Nm ]
2
Wt: tangential force

dn
Speed V [ m / s]
60
D: pitch diameter in [m]
n: rotational speed [rpm]

Power H WtV [ watts ]

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Force Analysis (Free Body Diagram)

Input rpm direction: cw

To transfer power, T must exist.

When the pinion rotates, tooth from gear against the movement direction W t32
must against the direction of rotation
Wt32 = H / V
T2 = Wt32. d2/2
Due to pressure angle, W r32 (radial force) is generated
Wr32 = Wt32 tan

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On Gear 3,

Wt23 and W r23 must in the opposite direction.

To be statically analytical, T3 is against Wt23

T3 = Wt23. d3/2

Note: Wt23 can be calculated using Wt32= H/ V, please remember that all the
parameters must be based on gear 3.

Discuss example 13-7

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Example

You are responsible to design a gear system for speed reducer. The
speed reducer is a two stage reduction which each pinion has 18T
(Gear 2 and 4 in Figure 1). One of the constraints is that the
maximum allowable reduction is 10 at each stage.
Based on this, answer the following questions.
a. Suggest the two possible number of teeth for Gear 3 and 5 if
the speed has to be reduced by 24 times. Note: if Gear 3 has X teeth
and Gear 5 has Y teeth and vice versa, the answer is considered as
one)
Number of Tooth Gear 3 Gear 5
Combination 1 ________ ________
Combination 2 ________ ________

Assume gear 3 and 5 have 72 and 90 teeth respectively and

comprises of m = 4 and 200 pressure angle gears. The motor is 8kW
at 1000 rpm clockwise.
b. Calculate the rpm of the output shaft.
c. Draw and calculate all the resultant forces on all of the gears.
d. Based on the above calculation, discuss the relationship
between torque and gear ratio.

18T 18T
2
4
Syaf masukan Syaf Keluaran
dari motor 3
5

Figure 1
 13

Example

The figure below shows a dual output power transmission system. A

8kW motor with 1000 rpm in clockwise direction is attached to shaft
1 at A. 40% of the power is delivered to shaft 2 using gear 2 and 4
and the remaining 60% of the power is delivered to shaft 3 via gear
3 and 5. All the gear module is 2 mm (m = 2mm) with pressure
angle of 200.
Based on this information, answer the following questions
a) Draw the FBD for every gear and also calculate all the forces
and torques if the speed of both output shafts have been
reduced by 3.
b) Calculate N5 if torque on shaft 2 and 3 is equal and N4 is 72.
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Failure Types

Bending: resulted from bending stress.

Wt act on the tooth
Lewis formula and AGMA

Pitting: resulted from surface stress

Repetition of high contact stresses

Scoring: resulted from insufficiency of lubrication

Bending Stresses

Wt
Basic Formula:
FmY
*take note that there are two formulae in pair in the textbook (imperial and metric)
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Assumption Basic Formula

Cantilever Beam Problem
Ft is carried by one tooth only.

However, dynamic effects are present when a pair of gear at

moderate and high speed. ( KV)

KV' W t
eq 14-1 pp738
FmY

Y: Lewis form factor Table 14-2 pp 718. (interpolation if it is required)

Dynamic Effect

3.05 V
KV' (cast iron, cast profile)
3.05

6.1 V
KV' (cut or milled profile)
6.1
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3.56 V
KV' (hobbed or shaped profile)
3.56

5.56 V
K 'V (finishing process on gears:
5.56
shaved or ground profile)
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Fatigue Strength

Endurance Limit Se ka kb kc kd keS'e

Se 0.5Sut
'

For steel

For cast iron

AGMA
 18

Surface Factor ka

k a aSut
b

0.265
Machining process k a 4.51S ut
 19

Size Factor kb

1.24 d e 0.107 2.79 d 51mm

kb 0.157
1.51d e 51 d 254mm

In the case of gear tooth d = de

d e 0.808 Ft

3Ym
x
2 (Eq 14-3)
t 4 xl (Eq b)
l = add + dedd (refer to Table 13-1)

Stress Concentration Factor

K f K f 1K f 2

Stress concentration factor due to load (Kf1)

kf1 = 1.66 (one way bending)

kf1 = 1 (two way bending)
1
K f1
k f1

Stress concentration 2 (Kf2)

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Refer to Table A-15-6

r = 0.3m
d=t
D = infinite

Based on r/d and D/d = infinite, uses the largest D/d,

get the value of Kt

Kf2= 1 + q (Kt 1)

Definition of one and two way bending

One way bending: tooth subjected one direction rev.

Two way: tooth subjected to both direction rev (forward
and reverse)

Fatigue failure theories

K fm K fa 1
Goodman Line
Sut Se n

nK f m nK f a
2

1
Gerber Failure
Sut Se

Determine the mean and alternating stress

One way bending

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m a
2

Two way bending

a
m 0

KV W t
Where
FmY

Project
You have to set m, F, NP, NG
The constraint
Min no of tooth for pinion: Eq 13-11
Max no of tooth for gear: Eq 13-12
Face width 2p < F < 5p
Material : Figure 14-2, 14-3
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SURFACE DURABILITY

Surface Stresses (compressive ve)

1
K W 1 1 2
C CP V t
F cos r1 r 2

= pressure angle
P = pinion
G = gear
Cp = elastic coefficient
1
2

1
CP
1 P2 1 G2

EP EG

= Poisson Ration (Table A-5 )

E = Modulus of Elasticity (Table A-5)

Radius of curvature of the tooth profile

dp sin
r1
2
d sin
r2 G
2
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Example

A 19-TOOTH 300 Bhn HOBBED STEEL SPUR GEAR PINION

TRANSMITS 15 Kw AT A PINION SPEED OF 360 rev/min TO A 77
TOOTH OF THE SAME MATERIAL GEAR. THE FACE WIDTH IS 75
mm, = 200 AND m = 6mm.
a) USING LEWIS FORMULA CALCULATE THE STRESSES DUE
TO BENDING AND THE CONTACT STRESSES?
b) CALCULATE THE F.S OF THE BENDING STRESS AGAINST
ITS FATIGUE STRENGTH USING GERBER THEORY?
c) CALCULATE THE F.S OF THE CONTACT STRESSES
AGAINST CONTACT STRESS ENDUCRANCE LIMIT (Sc)?
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Soln

a) Bending Stresses
Pinion

KvWt

FmY
d = Nm = (19)(6) = 114 mm = 0.114 m

dn (0.114)(360)
V [m / s] = 2.149 m/s
60 60

H 15,000
Wt = 6980 N
V 2.149

3.56 V
Hobbed KV' = 1.402
3.56

Y = 0.314 (Table 14-2)

KvWt
= 69.8 MPa
FmY
GEAR

K v W t (1.412)( 6980)

FmY (75)( 6)Y

Y interpolation (77 tooth)Y = 0.436

K v W t (1.412)( 6980)

FmY (75)( 6)Y = 50.23 MPa
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b) Surface Stresses

1
K W 1 1 2
C CP V t
F cos r1 r 2

Kv = 1.40
Wt = 6980 N
F = 75mm

dp = Nm = (19)(6) = 114 mm
dg = Nm = (77)(6) = 462 mm

dp sin
r1 = 19.5 mm
2
dG sin
r2 = 79 mm
2

1
2

1
CP
1 P2 1 G2

EP EG

Carbon Steel:
V = 0.292
E = 207 GPa = 207 x 103 MPa
Cp = 189.780 MPa
1
K W 1 1 2
C CP V t
F cos r1 r 2
1
(1.402)( 6980) 1 1 2
(189,780)
( 75 ) cos( 20 ) 19 . 5 79
= -565.5 MPa
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Safety factor

S
n c
c
Sc 6.89(0.4HB 10) MPa

Sc = 757.9

n = 1.15
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Limits

Se k a k b k c k d k e Se'
all
F .S F .S
It is advisable to have F.S > 3

Contact Stress
1
K vW t 1 1 2
c C p
F cos r1 r2
Eq 14-14 pp 732

Negative: because it is always in compression

Cp . Eq 14.13
E : Modulus of elasticity Table A-5
u : Poissons Ratio Table A-5
r1 , r2 : Eq 14-12
 28

Example

You are responsible to design a gear system for speed reducer. The
speed reducer is a two stage reduction which each pinion has 18T
(Gear 2 and 4 in Figure 1). One of the constraints is that the
maximum allowable reduction is 10 at each stage.
Based on this, answer the following questions.
a. Suggest the two possible number of teeth for Gear 3 and 5 if
the speed has to be reduced by 24 times. Note: if Gear 3 has X teeth
and Gear 5 has Y teeth and vice versa, the answer is considered as
one)
Number of Tooth Gear 3 Gear 5
Combination 1 ________ ________
Combination 2 ________ ________

Assume gear 3 and 5 have 72 and 90 teeth respectively and

comprises of m = 4 and 200 pressure angle gears. The motor is 8kW
at 1000 rpm clockwise.
b. Calculate the rpm of the output shaft.
c. Draw and calculate all the resultant
forces on all of the gears.
d. Based on the above calculation,
discuss the relationship between
torque and gear ratio.

18T 18T
2
4
Syaf masukan Syaf Keluaran
dari motor 3
5

Figure 1
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a) G3 G5
Comb 1 144 (8 x 18) 54 ( 3 x 18)
Comb 2 108 (6 x 18) 72 ( 4 x 18)

N 2N 4
e
N 4N5
18 x18
b)
72x90
0.05

nL = e.nF
= (0.05)(1000)
= 50 rpm

c) FBD at Gear 2

Diameter pinion d = Nm
d = (18)(4x10-3)
= 0.072 m
Calculating the tangential for
60H
Ft
dn
60(8,000)

(0.072)(1000)
2,122N
2.122kN
Direction of Ft: when gear 2 pushes gear 3, gear 3 will resist and therefore
the direction is UP

Fr= Ft tan 200 = 0.773kN

T2= Ft d/2 = (2,122)(0.072/2) = 76.4 Nm

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FBD at Gear 3

Reaction at gear 3 is equal in magnitude and opposite direction to gear 2

Diameter d3 = Nm
= (72) (4x10-3) m
= 0.288 m

T3 = Fr d3/2
= 2122 (0.288/2)
= 305.6 Nm

Rotation direction ccw

FBD at Gear 4

T3 must be equal to T4 with opposite direction. This is because the G3 and G4 is

on the same shaft, therefore, the total Torque = 0. Rotation direction ccw
T3 = T4 = 305.6 Nm

Gear 4 (ccw) pushes gear 3: dirction of Ft is DOWN.

Ft = 2 T/d
d = 0,072 m
Ft = 8.48 kN
Fr = 3.09 kN

60H
Ft
dn
60(8,000)

Or (0.072)( 250)
8.48kN
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Gear 5