Helical Gear Helical Gear

Important theory questions (For answer refer theory Notes) 4. T h e following data refer to the design of a helical gear drive :
i) Power transmitted 34 kW a t 2800 rpm of pinion
1. List the advantages and disadvantages of helical gears. ii) Speed ratio 4.5, number of teeth on t h e pinion 18
2. Define "formative number of teeth" as applied to helical gears and explain its
iii) Helix angle 25°, pressure angle α = 20° stub
importance in the design of helical gears.
i v ) Material for both pinion and gear is medium carbon steel whose allowable
stress may be taken as 23 0 MPa.
Exam Questions, Type – I, Diameter unknown
v) Pinion diameter is limited to 125 m m .
Determine the axial thrust on the shaft and check the gears for dynamic and
1. A helical cast steel gear with300 helix angle has to transmit 45 kW at 1500 wear loads. (December 2010(AU))(Marks 20)
rpm. If the gear has 24 teeth. Determine the necessary module, face width
and the diameter for 200 full depth teeth. The stress may be taken as 55 MPa;
face width may be taken as 4 times the normal pitch. The tooth factor or 5. Design a pair of helical gears to transmit power of 15 kW at 3200 rpm with
Lewis form factor for 20 full depth teeth is given by,
= 0.154 −
0
.
is speed reduction 4 : 1 pinion is made of cast steel 0.4% C-untreated. Gear
೐
number of teeth on equivalent spur gear. (June / July 2014(06))( Marks 16) made of high grade CI Helix angle is limited to 26° and not less than 20 teeth
are to be used on either gear. Check the gears for dynamic and wear
considerations. (Dec.09/Jan. 10(06))(20 Marks)
2. A pair of helical gears is to transmit 15 KW. The teeth are 20° full depth in
normal plane and have helix angle of 30°. The pinion has 24 teeth and
operates at 10,000 rpm . The velocity ratio is 5 to 1. The pinion is made of 6. Design a single reduction parallel helical gear speed reducer having speed
cast steel [50MPa] and the gear is bronze [40 MPa]. The pinion material is ratio 5 : 1. It is to be capable of transmitting the full load rating of 18.75 kW
hardened to 200 BHN. Design the gear pair. (June 2012(AU))( Marks 14) at 1200 rpm of pinion. Use Nickel Chrome steel for pinion and C45 steel for
gear. Select class III precision gears, the helix angle for the gear wheels is
230. The normal pressure angle of the tooth is 20° and the profile is full depth
3. Design helical gear pair to transmit a power of 15 kW from a shaft rotating at involute. Check the design for dynamic and wear load.
1000 rpm to another shaft to be run at 360 rpm. Assume involute profile with (Dec.08/Jan. 09(02))( 20 Marks)
a pressure angle of 20°. The material for pinion is forged steel SAE 1030
whose  = 172.375  and the material for the gear is cast steel 0.20% 7. Design a steel helical gear form the following data:
C untreated with  = 137.34 . The gears operate under a condition of Power transmitted = 30 kW, Speed of pinion = 1500 rpm, Velocity ratio = 4
medium shocks for a period of 10 hrs per day. Check for dynamic load, if Number of teeth on pinion = 24, Helix angle  = 30

Static stress for steel   =   = 50.7 , BHN = 350. Check the design
load factor C = 580 N/mm and also for wear load.
(December 2010(06))(Marks 16)
from wear point of view also. (June / July 2008(AU))(Marks 20)

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8. Design a pair of helical gears to transmit a power of 20KW from a shaft 13. A pair of carefully cut helical gears for a turbine has a transmission ratio of
running at 1000 rpm to a parallel shaft to be run at 350 rpm. 10%. The teeth are 200 stub involute in the normal plane Pinion has 25 teeth
(June / July 2008(MET))(Marks 20) and rotates at 5000 rpm, Material for pinion and gear is 0.4% carbon steel
untreated with allowable static stress of 69.66 MPa. Helix angle = 300.
Power transmitted = 90 kW. Service factor = 1.25. Wear and lubrication
9. A pair of helical gears with a 230 helix angle is to transmit 2.5 kW at 10000 factor = 1.25. Determine the module in normal plane and face width of the
rpm of the pinion. The velocity ratio is 4 : 1. Both gears are to be made of gears. Suggest suitable surface hardness for the gear pair.
hardened steel with an allowable stress of 100 MPa for each gear. The gears (Dec.06/Jan. 07(AU))( 20 Marks)
are 200 stub and the pinion is to have 24 teeth. Design the gears and
determine the required BHN. (Dec.07/Jan. 08(AU))( 16 Marks)
14. Design a pair of helical gears to transmit 73.5 kW power with a velocity of
10. A pair of double helical gears (herring bone gear) have the following 4.25:1. The pinion rotates at 1750 rpm. Helix angle is 15°. The teeth are 200
specifications: FDI form. The gears are lubricated randomly. Check for beam Strength of
tooth only. Calculate gear forces. (July/Aug 2005(AU))(Marks 20)
Module in the normal plane – 5 mm
Number of teeth on the pinion – 17
15. Design a pair of helical gears t o transmit a power of 20 kW from a shaft
Number of teeth on the gear – 51
running at 1500 rpm to a parallel shaft t o be run at 450 rpm. Suggest suitable
Helix angle - 300 surface hardness for the gear pair. (Jan/Feb 2005(AU))( Marks 20)
Class of gears – precision cut
BHN of gears – 300
Face width of gears-75 mm; determine the load capacity of the gears if they
work under medium shocks 8 to 10 hours per day.
(July 2007(MET))(Marks 14)

11. Design a pair of helical gears t o transmit a power of 30 kW from a shaft

running at 1500 rpm t o a parallel shaft t o be run at 450 rpm.
(Jan/Feb 2006(AU))( 20 Marks)

12. Design a pair of helical gears to transmit a power of 20 kW from a shaft

running at 1000 rpm to parallel shaft to be run at 350 rpm.
(July/Aug 2005(MET))(Marks 20)

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Solved Numerical problems solution, Type – I, Diameter unknown Identifying the weaker member
Because gear & pinion are made of same materials, Design is based on pinion
1. Design a pair of helical gears to transmit to power of 20 kW from a shaft Design should be based on pinion (weaker member).
running at 1000 rpm to a parallel shaft to be running at 350 rpm.

Data:  = 20  ;
 = 1000  ;
 = 350  .
Tangential tooth load#
1000 ×  × 
Solution: Note: - Since the diameters are unknown, it is possible to design for
# = % &'. '( ) (* − &+, ) (
 -
)
$
smallest pitch diameter.
Select following material for pinion & gear From table (T-12.7)(P-186) 1000 ×  × 
#భ = (.
-
)
allowable static stress for $


 −   40 
; భ = 207  Where, P = 20 kW, Power in kW.
  −   40 
; భ = 207   = $/ /  # 0 &'. 1 * − &12
Assume pressure angle in normal plane,  = 20
full depth tooth system.    ℎ/ 
 8 − 10 ℎ 
 

 =  
  ,    = 20
 45
  = 25
;  = 1.5 ;  =
 = 1000 
$ = /ℎ 
 $/
 3  4, ⁄
From table (T-12.19)(P-195) The number of teeth on pinion to avoid interference 
for  = 20
full depth tooth system is not less than 18 teeth for pinion.
6 
6
7
7

Select number of teeth on pinion, ! = 18 ℎ $ = , ⁄ 8∴  = % &'. ,2 * − &+1 9

60000 60000 cos  cos 
=

6 
 6 ×
 7 ×
6 × 1000 18 ×

Velocity ratio (i)

  ! $ = = =
cos 
× ×
 = = =
60000 60000 60000 cos 25

  !
$ = 1.04
⁄


 = =
1000

 ∴ #భ =
= 2.857 1000 × 20 × 1.5
350
1.04

∴ Velocity ratio  = 2.857

#భ = : … … … ;-
(<)
28846.15
! = 18 "ℎ

∴ ! =  ! = 2.857 × 18 = 51.428 ≅ 52 "ℎ

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(ii) Tangential tooth load from lewis equation: To find module ‘

’
  4 =

# = … … % &'. >? (* &+? )
Trial 1:- Let select ‘
=3’

C/
$ = 1.04
= 1.04 × 3
Where,  = 207 
$ = 3.12 ⁄
b = face width 12.5
≤ b ≤ 20
% &'. >1 ) (* &+? )
C/
/ E Dℎ   F  
Select, 4 = 16

 =  $ < 5 ⁄ % &'. +& ) (* &2( ) (
 -
)
4.58
4.58 + $
= = 6

భ = (.
-
)
Lewis form factor, 4.58
To determine ‘y’ the lewis form factor, 0
For 20 FDI profile 4.58 + $

= 0.154 −  20
@
$ 
 . (% − &'. &2A)( * − &+B) భ =
0.912 4.58
7 4.58 + 3.12
7 భ = 0. 5948
 

, 7  = = = 24.18 ℎ
18
cos 
 cos 25 Now from equation ….. (iii)

# 

,
 = 0.154 −
 భ ≥ 29.874 … … … ;-
(<<<)
0.912
7 
3 × 0. 5948 ≥ 29.874

 = 0.154 −
0.912
24.18 16.06 < 29.874 ∴
 4.

 = 0. 116
 =  & 4/
/ 0 &'. '& (* &?+) Trial 2:- Let select ‘
=4’
For scant lubrication but regular, frequent inspection,  = 1.25 C/
$ = 1.04
= 1.04 × 4
 = C/
/ [ Dℎ   ]

$ = 4.16 ⁄
207 × భ × 16 ×
× 6 × 0. 116 ×

#భ = C/
/ E Dℎ   F  

1.25
#భ = 965.58
 భ : … … … ;-
(<<)  =  $ < 5 ⁄ % &'. +& ) (* &2( ) (
 -
)
4.58
4.58 + $
Equating equation (i) & (ii)
భ = (.
-
)
4.58
4.58 + $
965.58
 భ =
28846.15

భ =
4.58

భ = 29.874 … … … ;-
(<<<)

4.58 + 4.16
Governing equation,
 భ ≥ 29.874 … … … ;-
(<<<) భ = 0. 524

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 Helical Gear Helical Gear

Now from equation ….. (iii) Diameter of pinion & gear

 భ ≥ 29.874 … … … ;-
(<<<) 7

 = % &'. ,2 * − &+1
cos 
4 × 0. 524 ≥ 29.874
7
7

33.536 < 29.874 ∴ 4.  = = = 79.44 ,  = =

18 × 4 52 × 4
cos  cos 
= 229.5
cos 25 cos 25
∴ " ,
= 4
∴ Face width ‘b’ b = 16
= 16 x 4 = 64 mm. Dimensions

∴ #భ = =
28846.15 28846.15 Calculate all important geometric parameter of tooth profile by using the

= 7211.5 :
4 equations given in Table
Properties of involutes teeth

Check for the stress Tooth Characteristics *<I<JI KL)M

Allowable stress by the equation Module 
4
 =    (
 -
) Number of teeth z 18 "ℎ 52 "ℎ
 = Gభ భ H (.
-
)

Pitch circle diameter d 79.44 mm 229.5 mm
 = 207 × 0.524
Face width b 64
 = 108.468 
Induced stress Checking for dynamic load
# 

 =   = % &'. >? (* &+? ) (
 -
)
Acc to bucking ham’s equation, Dynamic load#


4 =
N $  4 cos   + # cos 
# = # + … … % &'. +' (* &2( )
#భ  N $ + O 4 cos   + #

 =   = (.
-
)


4 6


 -


 =
7211.5 × 1.25 N $ G 4 cos   + #భ H cos 
64 × 6 × 0.116 × 4 #భ = #భ + .
-

N $ + PG 4 cos   + #భ H


 = 97.5 

 <   97.5 < 108.468  , the design is satisfactory. From Table (T -12.13) (P- 191) for carefully cut gears for
= 4 mm
Machining error, e= 0.0254 mm

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 Helical Gear Helical Gear

From (T-12.12) (P- 190) for e = 0.0254 mm  = 20
#.@ and steel Where ratio factor
material for both pinion & gear
Q = = = % &'. B+ R (* &+2 )
2  2 ! 2 ! 
343.3  +  ! + ! !  + ! 
C =?

Q=
Error ‘e’ C 228.9 0.02 228.9 2 ! 2 × 52
! + ! 52 + 18
0.0254 C
= = 1.486
0.02 228.9

 = 79.44 ; 4 = 64
0.0254 ?
0.03 343.3
0.02 0.0254 0.03
From table (T-12.7)(P-186) for pinion & gear BHN

 × 0.02 = 228.9 × 0.0254 For steel C 40 untreated భ = మ = 207,

 =
228.9 × 0.0254 Brinnal hardness number = 150 BHN
150 + 150
0.02
 = 290  D: = $ / ℎ
  ℎ   =
2
Where,#భ = 7211.5 : ; N = 20.67 ; $ = 4.16 ⁄ ; D: = 150 D:

C = 290 MPa; b = 64 mm; Surface endurance limit

20.67 × 4.16 × 290 × 64 × cos  25 + 7211.5 × cos 25  = 2.75 D: − 70  … … % &'. B+ S (* &+2 )
#భ = 7211.5 +
20.67 × 4.16 + O290 × 64 × cos  25 + 7211.5  = 2.75 × 150 − 70
 = 342.5 
# = 7211.5 +
1750059.94
235.84
# = 7211.5 + 7420.54
Load stress factor

  
∝ 1
# = 14632.04 :  = T + U … … % &'. B+ A (* &+2 )
1
1.4 ; ;
select young’s modulus From table (T – 1.1)(P-7)
Check for wear load # Pinion Steel ; = 202 × 10 
Acc to bucking ham’s equation wear load gear steel ; = 202 × 10 
 4 Q N ∝ = 20

# = ≥ # … … % &'. +, (* &2( ) 
 -

cos  
342.5 
20
 = T U
1 1
 4 Q N +
# = .
-
1.4 202 × 10 202 × 10
cos  
 = 0.2837 

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 Helical Gear Helical Gear

 4 Q N
# = =
79.44 × 64 × 1.486 × 0.2837 2. Design a pair of helical gears to transmit 73.5 kW power with a velocity of
cos  cos 25 
= 2609.43 :
 4.25:1. The pinion rotates at 1750 rpm. Helix angle is 15°. The teeth are 200

# = 2609.43 :
FDI form and not less than 20 teeth are to be used on either gear. The gears
are lubricated randomly. Determine the axial thrust on the shaft and suggest
Since # < #  2609.43 : < 14632.04 : , the design will be suitable hardness number for gear pair. (July/Aug 2005(AU))(Marks 20)

Data: = 73.5  ;
 = 1750  ;  = 4.25 ∶ 1 ;
unsatisfactory from the point of wear or durability.

Lubricated randomly;
= 15
;  = 20
#.@ .

For safer design
Solution: Note: - Since the diameters are unknown, it is possible to design
# ≥ # for smallest pitch diameter.
 4 Q N
≥ #
Select same material for pinion & gear
cos  


&   −   40 
 ;
79.44 × 64 × 1.486 × 
≥ 14632.04
cos 25 
From table (T-12.7)(P-186) allowable stress for



&   భ = మ = 207 
N ≥ 1.59
From the Table (T 12.16)(P- 193) for  = 20

Given in problem to select teeth not less than 20 on gear pair,
Select number of teeth on pinion, ! = 20 ℎ
 ≥ 1.59
Velocity ratio (i)
Surface hardness number for pinion = 350 BHN

 ! 
 = = =

 ! 
Surface hardness number for gear = 300 BHN

! !
= =
!
= 4.25
20
∴ ! =  ! = 4.25 × 20 = 85 "ℎ
Identifying the weaker member
Because gear & pinion are made of same materials, Design is based on pinion
Design should be based on pinion (weaker member).

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Tangential tooth load# Lewis form factor, = = 6


1000 ×  × 
# = % &'. '( ) (* − &+, ) (
 -
)
To determine ‘y’ the lewis form factor
$ For 200 FDI profile
1000 ×  × 
#భ = (.
-
)
= 0.154 −  20
@
$ 
 . (% − &'. &2A)( * − &+B)
$
0.912
7
7
7 = C
 4  ℎ = (% − &'. >' ))( * − &+?)
Where, P = 73.5 kW Power in kW.

 = $/ /  # 0 &'. 1 * − &12 cos 

   ℎ/ 

 8 − 10 ℎ 
 
 =  
  , $
 = 15

7
 = 1.5 ;  =
 = 1750  ℎ,  

, 7  = = = 22.19 ℎ
20
cos 
 cos 15
7
 , 7  = =
85
$ = /ℎ 
 $/
 3  4, ⁄ cos 


= 94.316 ℎ
cos 15
6 
6
7
⁄ V∴  = 7
W (
 -
)
$ = , # 

,
 = 0.154 −
0.912
=
60000 60000 cos
 cos

1

6 
 6 ×
 7 ×
6 × 1750 20 ×

 = 0.154 −
0.912
$ = = × = × 22.19
60000 60000 cos
60000 cos 15

 = 0. 1129
$ = 1.897
⁄

∴ #భ =
1000 × 73.5 × 1.5

 =  & 4/
/ 0 &'. '& (* &?+)
 = 1.35 EXYZ[\]^_`a [^bacdef F
#భ = : … … … ;-
(<)
58118.08

207 × భ × 16 ×
× 6 × 0.1129 ×

#భ =
1.35
#భ = 870.16
 భ : … … … ;-
(<<)
(ii) Tangential tooth load from lewis equation:
  4 =

Equating equation (i) & (ii)
# = … … % &'. >? (* &+? )
 870.16
 భ =
58118.08

Where,
ௗభ = 207 

 భ = 66.79 … … … ;-
(<<<)
b = face width 12.5
≤ b ≤ 20
% &'. >1 ) (* &+? )
Governing equation,
 భ ≥ 66.79 … … … ;-
()
Select, 4 = 16

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 Helical Gear Helical Gear

To find module ‘
’ Now from equation ….. (iii)

Trial 1:- Let select ‘

=4’
 భ ≥ 66.79 … … … ;-
(<<<)
C/
$ = 1.897
= 1.897 × 4 5 × 0.3914 ≥ 66.79
$ = 7.588 ⁄ 48.9 < 66.79 ∴
 4.
C/
/ E Dℎ   F  

 =  $ ≤ 5 ⁄  10 ⁄ % &'. +& A (* &2( )

.
Trial 3:- Let select ‘
=6’
.
C/
$ = 1.897
= 1.897 × 6
భ = (.
-
)
6.1
6.1 + $ $ = 11.383 ⁄

భ =
6.1 C/
/ E Dℎ   F  
6.1 + 7.588
భ = 0.4456  =  $ ≤ 10 ⁄  20 ⁄ % &'. +& R (* &2( )
15.25
15.25 + $

భ = (.
-
)
Now from equation ….. (iii) 15.25

 భ ≥ 66.79 … … … ;-
(<<<) 15.25 + $

4 × 0.4456 ≥ 66.79 భ =
15.25
15.25 + 11.383
28.51 < 66.79 ∴
 4. భ = 0.5726

Now from equation ….. (iii)

 భ ≥ 66.79 … … … ;-
(<<<)
Trial 2:- Let select ‘
=5’
C/
$ = 1.897
= 1.897 × 5
6 × 0.5726 ≥ 66.79
$ = 9.485 ⁄
123.68 < 66.79 ∴ 4.
 =  $ ≤ 5 ⁄  10 ⁄ % &'. +& A (* &2( )
∴ "
= 6
.
.

భ = (.
-
)
6.1
6.1 + $
∴ Face width ‘b’ b = 16
= 16 x 6= 96 mm.
భ =
6.1
∴ #భ = =
58118.08 58118.08

6.1 + 9.485 = 9686.34 :

భ = 0.3914
6

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Check for the stress Dimensions

Allowable stress by the equation Calculate all important geometric parameter of tooth profile by using the
 =    (
 -
)
equations given in Table

 = Gభ భ H (.

-
)
Properties of involutes teeth

*<I<JI KL)M


 = 207 × 0.5726

Tooth Characteristics

 = 118.5282 

Module 6 6

Number of teeth z 20 85
Induced stress
#  Pitch circle diameter d 124.23 527.99

 =   = % &'. >? (* &+? )(
 -
)


4 =

#భ 

 =   = (.
-
)
Checking for dynamic load


4 6

Acc to bucking ham’s equation, Dynamic load


 =
9686.34 × 1.35 N $  4 cos 2
+ # cos

96 × 6 × 0.1129 × 6 # = # + … … % &'. +' (* &2( )
N $ + O 4 cos 2
+ #

 = 64 
 
   
Since 
 <  64  < 118.5282 
N $ G 4 cos 2
+ #భ H cos

, the design is
satisfactory. #భ = #భ + .
-

N $ + PG 4 cos 2
+ #భ H

Diameter of pinion & gear

7
From Table (T 12.13) (P- 191) for carefully cut gears for
= 6 mm
 = % &'. ,2 * − &+1
cos  Machining error, e= 0.0316 mm
7
From (T 12.12) (P- 190) for e = 0.0316 mm  = 20
#.@ and pinion steel –gear
 = =
20 × 6
cos 
= 124.233
cos 15 steel
7

 = =
85 × 6 457.8
cos 
= 527.99 C =?
cos 15
Error ‘e’ C 343.3 0.03 343.3

0.03 343.3 0.0316 C

0.0316 ?
0.04 457.8
0.03 0.0316 0.04

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 Helical Gear Helical Gear

 × 0.03 = 343.3 × 0.0316 For safer design

# ≥ #
 =
343.3 × 0.0316
0.03  4 Q N
 = 361.6  ≥ #
cos 2

Where,#భ = 9686.34 : ; N = 20.67 ; $ = 11.383 ⁄ ; 124.23 × 96 × 1.619 × N
≥ 31398.67
cos 15 2
C = 361.6 MPa; b = 16 ×
= 16 × 6 = 96 mm;
N ≥
31398.67
20.67 × 11.383 × 361.6 × 96 × cos  15 + 9686.34  × cos 15 = 1.5079
భ = 9686.34 + 20694.6
20.67 × 11.383 + 361.6 × 96 × cos  15 + 9686.34 
From the Table (T 12.16)(P- 193) for  = 20
, pinion − steel, gear − steeel
# = 9686.34 +
9562262.772
440.407  ≥ 1.5079
# = 31398.67 : Surface hardness number for pinion = 350 BHN
Axial thrust Surface hardness number for gear = 300 BHN
# = # tan
… … % &'. >& (* &+? )
# = 9686.34 × tan45 = 2595.45 :

Check for wear load #

Acc to bucking ham’s equation, wear load
 4 Q N
# = ≥ # … … % &'. +, (* &2( ) 
 -

cos 2

 4 Q N
# = .
-

cos 2

 = 124.23 ; 4 = 96

Q = = = … … % &'. +> (* &2( )

2  2 ! 2 ! 
 +  ! + ! !  + ! 

Q=
2 ! 2 × 85
! + ! 85 + 20
=

Q = 1.619

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Exam Questions, Type – II, Diameter known Solved Numerical problems solution, Type – II, Diameter known
1. A pair of mating helical gears have 20 0 pressure angle in the normal 1. Design a pair of helical gear to transmit 12 kW at 2400 rpm of pinion, the
plane. The normal module is 5 mm and the module in the diametral velocity ratio required is 4 :1. Helix angle is 23
. The center distance is to
plane is 5.7735 mm, The pitch diameter of the smaller gear is 115.47 

be around 300 mm. pressure angle in the normal plane is 14 involutes.
mm. If the transmission ratio is 4:1, calculate i.) Helix angle. ii) 

Normal pitch iii) Transverse pitch iv) Number of teeth for each gear Pinion material is cast steel & gear material is cast iron. The allowable
v) Addendum- vi) Dedendum vii) Whole depth viii) Clearance static stress for a gear & pinion are 31 & 51.7 MPa respectively.
ix) Tooth thickness x) Working depth xi) Outside diameters xii) Data: = 12  ;
 = 2400  ;  = 300 ;  = 4 ∶ 1 ;
భ = 51.7  ; మ = 31  ;  = 23
;  = 14.5
.
Centre distance xiii) Root circle diameters xiv) Base circle diameters.
(December 2012(06))( Marks 10)
Solution:

2. A pair of helical gears is to transmit 15 kW at 10000 rpm of the pinion with Following material for pinion & gear
PCD 80 mm. The transmission ratio is 3 : 1. Pressure angle  = 20°, helix 

 −   ; భ = 51.7 
angle  = 45°,   =   = 193.2 , BHN = 250 for both pinion and
gear, service factor = 1. Find the Module.   −  
; మ = 31 
(Dec.09/Jan. 10(02))( 15 Marks) Velocity ratio (i)

 ! 
3. A pair of helical gears is to transmit 16 kW. The teeth are 200 stub in  = = =
diametral plane and have a helix angle of 450. The pinion runs at 10000 rpm
 ! 


 =
and has 80 mm pitch diameter. The gear has 320 mm pitch diameter. If the
gears are made of cast steel having allowable static strength of 100 MPa.

Determine module and face width from static strength considerations and
4 =
2400


check the gears for wear, given  = 618.
(July 2007(AU))(Marks 15)
∴ Speed of gear,
 = 600 
 +   +  1 + 
 = = =  × V W
2 2 2

300 =  × V W
1 + 4
2
 = 120
 =  = 4 × 120 = 480

AIT/Mech/CKM/9964676521 23 AIT/Mech/CKM/9964676521 24
 Helical Gear Helical Gear

Identifying the weaker member Tangential tooth load#

1000 ×  × 
# = % &'. '( ) (* − &+, ) (
 -
)
Since teethes are unknown, to identify the weaker member
Temporarily, assume ! = 20 ℎ $
1000 ×  × 
∴ ! =  ! = 4 × 20 = 80 "ℎ #మ = (.
-
)
$
Where, P = 12 kW Power in kW.
To determine ‘y’ the lewis form factor, For 200 FDI profile
 = $/ /  # 0 &'. 1 * − &12

= 0.124 −  14 @
$ 
 . (% − &'. &2))( * − &+B)
0.684 1

7 2    ℎ/ 
 8 − 10 ℎ 
 

7  = 1.5 ;  =
 = 600 
7 = C
 4  ℎ = (% − &'. >' ))( * − &+?)
cos  ⁄
$ = /ℎ 
 $/
 3  4, 
 

, 7  = = 6 

భ 

= 25.64 ℎ
$ = 
 -
;
Where,
య  య 

7 60000
 , 7  = = = 102.56 ℎ
80
cos  6 
 6 × 480 × 600
$ = = = 15.08 ⁄
 cos 23
60000 60000
# 

,
 = 0.124 −
$ = 15.08 ⁄
0.684
7 

 = 0.124 − ∴ #మ =
0.684 1000 × 12 × 1.5
25.64 15.08

 = 0. 0973 #భ = 1193.634 : … … … ;-
(<)

# ,
 = 0.124 −
0.684
7 
(ii) Tangential tooth load from lewis equation:

 = 0.124 −
0.
  4 =

# = … … % &'. >? (* &+? )
102.56

 = 0.1173 

Particulars g h g h Remarks Where,

ௗ =  
  
  ℎ


 

  
 . (  )
Pinion 51.7 0.0973 5.03
gear 31 0.1173 3.63 Weaker b = face width 12.5
≤ b ≤ 20
% &'. >1 ) (* &+? )

Since భ
 > మ
 ,   3  4. Select, 4 = 16

Design should be based on Gear (weaker member). Lewis form factor, = = 6


AIT/Mech/CKM/9964676521 25 AIT/Mech/CKM/9964676521 26
 Helical Gear Helical Gear

 =  & 4/

/ 0 &'. '& (* &?+) Now from equation ….. (iii)
 = 1.25

 ≥ 1.9044 … … … ;-
(<<<)
 = C/
/ [ Dℎ   ] 3 × 0.120377 ≥ 1.9044

 =  $ ≤ 10 ⁄  20 ⁄ % &'. +& R (* &2( ) 1.0834 < 1.9044 ∴ : 4.

15.25
15.25 + $

 =
15.25 15.25
15.25 + $ 15.25 + 15.08
= = 0.5028
Trial 2:- Let select ‘
=4’
31 × 0.5028 × 16 ×
× 6 ×
 ×
7
 cos 
#మ = ∴  = % &'. ,2 (* &+1 ) 7 = % &'. ,+ (* &+1 )
1.25 cos 

#మ = 626.78

 : … … … ;-
(<<)  cos 
7 = =
480 × cos 23

= 110.46 ℎ
Equating equation (i) & (ii) 4

626.78

 = 1193.634 7
 , 7  = = 141.62 ℎ
110.46
cos 
=


 = 1.9044
cos 23

# ,
 = 0.124 −
0.684
7 
To find ‘m’

 = 0.124 −
0.684
Governing equation,

 ≥ 1.9044 … … … ;-
(<<<) 141.62

 = 0.1192
Trial 1:- Let select ‘
=3’ Now from equation ….. (iii)
7
 cos 
∴  = % &'. ,2 (* &+1 ) 7 = % &'. ,+ (* &+1 )

 ≥ 1.9044 … … … ;-
(<<<)
cos 

4 × 0.1192 ≥ 1.9044
 cos 
7 = =
480 × cos 23

1.9072 > 1.9044 ∴ 4.
= 147.28 ℎ
3
7 ∴ "
= 4
 , 7  = =
147.28
cos 
= 188.83 ℎ
b = 16
= 16 x 4= 64 mm.
 cos 23
∴ Face width ‘b’
# ,
 = 0.124 −  cos  480 × cos 23
0.684
7  ! = = 110.46 ≈ 112 "ℎ

=
4

 = 0.124 −
0.684
!
∴ ! = = = 28 "ℎ
188.83 112


 = 0.120377
4

AIT/Mech/CKM/9964676521 27 AIT/Mech/CKM/9964676521 28
 Helical Gear Helical Gear

Check for the stress Checking for dynamic load

Allowable stress by the equation Acc to bucking ham’s equation, Dynamic load#

 =   N $  4 cos   + # cos 

 (
 -
) # = # + … … % &'. +' (* &2( )
N $ + O 4 cos   + #
 = Gమ మ H (.
-
)

 -



 = 31 × 0.5028
N $ G 4 cos   + #మ H cos 
 = 15.5868  #మ = #మ + .
-

N $ + PG 4 cos   + #మ H

Induced stress
From Table (T 12.13) (P- 191) for carefully cut gears for
= 4 mm
# 

 =   = % &'. >? (* &+? ) (
 -
)


4 =
Machining error, e= 0.254 mm

#మ  From (T 12.12) (P- 190) for e = 0.254 mm  = 14.5
#.@ and pinion of

 =   = (.
-
)


4 6

cast steel –gear of cast iron


 =
1193.634 × 1.25 227.4

64 × 6 × 0. 1192 × 4
C =?
Error ‘e’ C 151.6 0.02 151.6


 = 15.56  0.02 151.6 0.0254 C

Since 
 <  15.56  < 15.587  , the design is satisfactory.
0.0254 ?
0.03 227.4
0.02 0.0254 0.03

Dimensions  × 0.02 = 151.6 × 0.0254

 =
Calculate all important geometric parameter of tooth profile by using the 151.6 × 0.0254
equations given in Table 0.02
 = 192.53 
Where,#మ = 1193.6 : ; N = 20.67 ; $ = 15.08 ⁄ ;
Properties of involutes teeth
Tooth Characteristics *<I<JI KL)M
material Cast steel Cast iron C = 192.53 MPa; b = 64 mm;
Module 
4 ௗమ = 1193.6 +
20.67 × 15.08 × 192.53 × 64 × cos ଶ 23 + 1193.6  × cos 23

Number of teeth z 28 112 20.67 × 15.08 + 192.53 × 64 × cos ଶ 23 + 1193.6 

# = 1193.6 +
3338174.2
Pitch circle diameter d 120 480
419.5
Face width b 64 # = 1193.6 + 7957.5
# = 9151.1 :

AIT/Mech/CKM/9964676521 29 AIT/Mech/CKM/9964676521 30
 Helical Gear Helical Gear

Check for wear load # select young’s modulus From table (T – 1.1)(P-7)
Acc to bucking ham’s equation, wear load Pinion Cast steel ; = 202 × 10 = 
 4 Q N ; = 100 × 10 = 
# = ≥ # … … % &'. +, (* &2( ) 
 -

gear Cast iron

cos  
 4 Q N 452.5 
14.5
# = .
-
 = T U
cos  
1 1

+
1.4 202 × 10 100 × 10
 = 120 ; 4 = 64  = 0.5475 

Q =
2 
=
2 !
=
2 ! 
… … % &'. +> (* &2( )  4 Q N 120 × 64 × 1.6 × 0.5475
 +  ! + ! !  + !  # = =
cos  cos 23 

= 7939.86 :

Q=
2  2 × 480 # = 7939.86 :
 +  120 + 480
=
Since # < #  7939.86 : < 9151.1 , the design will be unsatisfactory
Q = 1.6 from the point of wear or durability.
From table (T-12.7)(P-186) for BHN



 −   ; భ = 51.7  D: = 180 For safer design
  −  
; మ = 31  D: = 200 # ≥ #
180 + 200  4 Q N
D: = $ / ℎ
  ℎ   = ≥ #
2 cos  
D: = 190 D: 120 × 64 × 1.6 × N
≥ 9151.1
Surface endurance limit cos 23 

 = 2.75 D: − 70  … … % &'. B+ S (* &+2 ) N ≥ 0.631

 = 2.75 × 190 − 70 From the Table (T 12.16)(P- 193) for  = 14.5
, pinion − steel, gear − CI

 = 452.5   ≥ 0.631

Load stress factor Surface hardness number for pinion = 200 BHN

  
∝ 1 Surface hardness number for gear = 180 BHN
 = T + U … … % &'. B+ A (* &+2 )
1
1.4 ; ;

AIT/Mech/CKM/9964676521 31 AIT/Mech/CKM/9964676521 32
 Helical Gear Helical Gear

2. A pair of helical gears is to transmit 15 kW at 1000 rpm of the pinion with  =
 = 1000 
PCD 80 mm. The transmission ratio is 3:1. Pressure angle  = 20°, helix ⁄
$ = /ℎ 
 $/
 3  4, 
angle  = 45°,   =   = 193.2 , BHN = 250 for both pinion and
6 

gear, service factor = 1.5.Find the Module. (Dec.09/Jan. 10(02))( 15 Marks) $ = ⁄ (
 -
)
Data:  = 15  ;
 = 1000  ;  = 80 ;  = ;  = 3 1: ;
60000
6 
 6 × 80 × 1000
భ = మ = 139.2  ;
= 45
;  = 20
;  = 1.5 ; D: = 250. $ = = =
60000 60000
Solution: Velocity ratio (i) $ = 4.1888 ⁄

 !  1000 × 15 × 1.5
 = = = ∴ #భ =

 !  4.1888

 1000 #భ = 5371.466 : … … … ;-
(<)
 =



= =3

∴
 =
1000 1000

= = 333.33  (ii) Tangential tooth load from lewis equation:
  4 =

3
 80 # = … … % &'. >? (* &+? )
 = = 
 
= 3

 =  = 3 × 80 = 240
 =   
  ℎ 

    . !(" #$ )

b = face width 12.5

≤ b ≤ 20
% &'. >1 ) (* &+? )
Select, 4 = 16

= = 6

Identifying the weaker member
Lewis form factor,
Because gear & pinion are made of same materials, Design is based on pinion
 =  & 4/
/ 0 &'. '& (* &?+)
Design should be based on pinion (weaker member).
 = 1.25 /
 i4/
j 
/

 = C/
/ [ Dℎ   ]
Tangential tooth load#
1000 ×  ×   =  $ < 5 ⁄ % &'. +& ) (* &2( )
4.58
# = % &'. '( ) (* − &+, ) (
 -
) 4.58 + $
$
1000 ×  ×   = =
4.58 4.58
#భ = (.
-
) 4.58 + $
= 0.5223
$
4.58 + 4.1888
193.2 × 0.5223 × 16 ×
× 6 ×
 ×

Where, P = 15 kW Power in kW. #భ =

 = $/ /  # 0 &'. 1 * − &12
1.25
#భ = 4057.76

 : … … … ;-
(<<)
   ℎ/ 
 8 − 10 ℎ 
 
 = 1.5 ;

AIT/Mech/CKM/9964676521 33 AIT/Mech/CKM/9964676521 34
 Helical Gear Helical Gear

 cos 
7 = =
Equating equation (i) & (ii) 80 × cos 45

= 14.14 ℎ
4057.76

 = 5371.466
4
7
 

, 7  = = = 39.994 ℎ
14.14


 = 1.3237 … … … ;-
() cos 
 cos 45
Governing equation,

 ≥ 1.3237 … … … ;-
(<<<) % = 0.154 −
0.912
= 0.154 −
0.912
= 0.13119
 1 39.99
Now from equation ….. (iii)


 ≥ 1.3237 … … … ;-
(<<<)
0
To determine ‘y’ the lewis form factor, For 20 FDI profile
4 × 0.13119 ≥ 1.3237

= 0.154 −  20
@
$ 
 . (% − &'. &2A)( * − &+B)
0.912
7 2.099 > 1.3237 ∴ 4.
∴ "
= 4
∴ Face width ‘b’ b = 16
= 16 x 4= 64 mm.
To find module ‘
’
Trial 1:- Let select ‘
=3’ Take, 7 = 14 ℎ, 7 =  × 7 = 3 × 14 = 42 ℎ,
7
 cos 
∴  = % &'. ,2 (* &+1 ) 7 = % &'. ,+ (* &+1 )
cos 

 cos 
7 = =
80 × cos 45

= 18.856 ℎ
3 Check for the stress
7 Allowable stress by the equation
 

, 7  = = = 53.33 ℎ
18.856
cos 
 cos 45  =    (
 -
)

0.912 0.912  = Gభ భ H (.

-
)

% = 0.154 − = 0.154 −
 = 193.2 × 0.5223 = 100.908
= 0.1369
 1 53.33

Now from equation ….. (iii)


 ≥ 1.3237 … … … ;-
(<<<) Induced stress

% &'. >?(* &+? )( 

   )
 
3 × 0.1369 ≥ 1.3237   =  
  =
 & 
1.2321 < 1.3237 ∴
 4. #భ 

 =   = (.
-
)


4 6


Trial 2:- Let select ‘

=4’
7
 cos  
 =
5371.466 × 1.25
∴  = % &'. ,2 (* &+1 ) 7 = % &'. ,+ (* &+1 ) 64 × 6 × 0.13119 × 4
cos 


 = 63 
Since 
 <  63  < 100.908  , the design is satisfactory.

AIT/Mech/CKM/9964676521 35 AIT/Mech/CKM/9964676521 36
 Helical Gear Helical Gear

Dimensions  × 0.02 = 228.9 × 0.0254

 =
Calculate all important geometric parameter of tooth profile by using the 228 × 0.0254
equations given in Table 0.02

Properties of involutes teeth  = 290.703 

Where,#భ = 5371.466 : ; N = 20.67 ; $ = 4.1888 ⁄ ;
Tooth Characteristics *<I<JI KL)M
Module 
4 C = 290.703 MPa; b = 64 mm;
20.67 × 4.1888 × 290.703 × 64 × cos ଶ 45 + 5371.466  × cos 45
Number of teeth z 14 42
ௗభ = 5371.466 +
20.67 × 4.1888 + 290.703 × 64 × cos ଶ 45 + 5371.466 
Pitch circle diameter d 80 240
# = 5371.466 +
898385
Face width b 64 207.718
# = 9696.49 :

Checking for dynamic load

Check for wear load #
Acc to bucking ham’s equation, Dynamic load
N $  4 cos 2
+ # cos

Acc to bucking ham’s equation, wear load
# = # + … … % &'. +' (* &2( )  4 Q N
N $ + O 4 cos 2
+ # # = ≥ # … … % &'. +, (* &2( ) 
 -

cos 2

N $ G 4 cos 2
+ #భ H cos
 4 Q N
#భ = #భ + .
-
# = .
-

N $ + PG 4
+ #భ H
cos 2

cos 2

Q = = = … … % &'. +> (* &2( )

2  2 ! 2 ! 
From Table (T 12.13) (P- 191) for carefully cut gears for
= 4 mm  +  ! + ! !  + ! 

Q=
Machining error, e= 0.0254 mm 2 ! 2 × 42.42
! + ! 42.42 + 14.14
=
From (T 12.12) (P- 190) for e = 0.0254 mm  = 20
#.@ and steel pinion –steel
gear Q = 1.5
D
 ℎ
 : 4 = BHN = 250 (Given)
343.3
C =?
Error ‘e’ C 228.9
Surface endurance limit
 = 2.75 D: − 70  … … % &'. B+ S (* &+2 )
0.02 228.9

0.02 228.9 0.0254 C

0.0254 ?
 = 2.75 × 250 − 70
 = 617.5
0.03 343.3 0.03
0.02 0.0254

AIT/Mech/CKM/9964676521 37 AIT/Mech/CKM/9964676521 38
 Helical Gear

Load stress factor

  
∝ 1
 = T + U … … % &'. B+ A (* &+2 )
1
1.4 ; ;
Assume steel material for pinion & gear.
Take young’s modulus From table (T – 1.1)(P-7)
Pinion steel ; = 202 × 10 
gear steel ; = 202 × 10 
∝ = 20

617.5 
20

 = T U
1 1

+
1.4 202 × 10 202 × 10
 = 0.9223 
 4 Q N
# = = = 14166.528 :
80 × 64 × 1.5 × 0.9223
cos 2
cos 45 2
# = 14166.528 :
Since # > #  14166.528: > 9696.49 , the design will be
satisfactory from the point of wear or durability.
Hence used average surface hardness (250 BHN) for the gear pair is suitable.
The design will be satisfactory from the stand point of durability or wear also.

Note: If # < # , for safer design # ≥ # , i.e., ≥ #

భ   
cos 2

 ≥ … … 
Suggest surface hardness for the gear pair is suitable using Table (T 12.16)(P-
193) for the calculated value of K

AIT/Mech/CKM/9964676521 39