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Analysis of Spur and Helical Gears
prepared by Wayne Book
based on Norton, Machine Design and
Mischke and Shigley
Mechanical Engineering Design
The Gnashing of Teeth
• Simple model for loaded gears
• Beam for bending stress
• Cylinders in contact for surface contact stress
Idealized Shape of a Tooth for Stress Analysis
• Simple model: cantilever beam with applied force W
• Tooth thickness t• Length l• Face width F• Max stress at root (a)
lWt
Ft
a23
6
)12/(
2/)(
Ft
lW
Ft
tlW
I
Mc tt
Consider the Shape of a Tooth
• Uncertainties include:– point of load application l– point of maximum stress– appropriate load component– beam thickness
• Depends on pitch P, number of teeth N and pressure angle
• Conservative assumptions are made• Y = Lewis form factor
Introduce Lewis Shape Factor
t
l
Wr
Wt
W
x
3
26
42/
2/
ianglessimilar trBy 2
126
2
2
22
xPY
FY
PW
lPt
F
PWl
tx
t
l
x
t
Pt
l
F
PW
Ft
lW
tt
tt
•Rather than calculate Y(P,, N), create a table, e.g. 14-2
•Lewis equation has been improved by AGMA
Velocity Effect(Its Barth not Barf)
• Purely empirical adjustment for non-zero velocity
• Barth’s equation (1800’s) has been modified to account for current practice and accuracy
• V is velocity in ft/sec at the pitch line
• Kv= 1200/(1200+V) (Modified Barth)
• Metric form Kv= 6.1/(6.1+V), V in m/sec
• Compare to endurance strength (reversing) or use Goodman diagram (one direction)
• Apply notch sensitivity, Marin factors…. the works
FYK
PW
v
t
Surface Durability: Contact Stress
• Analyzed as two cylinders of length l in rolling contact with specified force
• Cylinder radii r1 and r2 vary with contact point
• Depends on elastic material properties and radii of cylinders
• Translate into gear nomenclature as shown on right
factorvelocity C
pinion andgear refer to subscripts PG,
modulus sYoung' E
ratio sPoisson'
11
1
11
cos
v
2/1
22
2/1
21
G
G
p
p
p
V
tpc
EE
C
rrFC
WC
AGMA Approach
• AGMA formula calculates stress for– Bending– Contact
• Stress is compared to an “allowable stress” (also called strength by Norton) based on strength and conditions
Bending Stress
• Many terms are similar to the Lewis equation
• Additional terms account for the application, load sharing and size
factorgeometry tooth
factor backup rim
factoron distributi load
factor size
widthface
pitch diametral
Lewisin asfactor velocity
factorn applicatio
factoridler
load l tangentia
J
K
K
K
F
P
K
K
K
W
J
KKK
F
P
K
KKW
B
m
s
d
v
a
I
t
Bmsd
v
aIt
loading
gear geometry
tooth form
J factor sample tableTip loading (low precision)
Distributed loading (higher precision)
Kv Velocity Factor (similar to Barth)(also provided in equations 11.16 – 11.19)
Load Distribution Factor
• Loads are less evenly distributed for wide face teeth
• Keep F (face width)
8/pd < F < 16/pd
• Nominally F = 12/pd
Application Factor
• Created to account for known but unquantified shock in load
• Electric motors are smooth while single cylinder engines have shock
• Centrifugal pumps are smooth loads while rock crushers have shock
Other FactorsSize, Rim Thickness, Idler
• Size– Fatigue tests are done on small specimins and
indications are that size results in weaker parts– Very large teeth might warrant Ks=1.25 to 1.5– Material properties created directly for gears
account for this
• Rim thickness– In large diameter gears, the centers are
connected to a rim by spokes.– KB reflects failures across the radius
• Idler: use KI = 1.42
Allowable Bending Stress
• Incorporate material strength St specific to gear materials
• St based on Brinell hardness of material
• Environmental and application factors– KL = life factor
– KT = temperature factor
– KR = reliability factorRT
Ltall KK
KS
Life Factor KL
(a specialized S-N curve)
BendingTemperature and Reliability Factors
• Strength data is based on 99% reliability. Adjust up or down.
• Temperatures up to 250 deg F use KT = 1
– Adjust for higher temperatures
620
460 FT
TK
AGMA Bending Fatigue Strengths (uncorrected)
Contact Stress
• Based on rolling cylinder model
• Added terms for size, load distribution, surface condition
factorgeometry tooth
factorcondition surface
factoron distributi load
diameterpitch
factor size
factor (dynamic) velocity
factorn applicatio
tcoefficien elastic
2/1
I
C
C
d
C
C
C
C
I
CC
Fd
C
C
CWC
f
m
s
v
a
P
fms
v
atPc
loading
gear geometry
tooth condition & geometry
material
Surface Geometry Factor I
h)depth teet fullfor (0
elongation addendumfraction
gearfor curvature of radius
pinionfor curvature of radius
angle pressure
pinion of radiuspitch
pinion ofpitch diametrial
sin
coscos1
11
cos
2
2
p
g
p
p
d
pg
dp
d
ppp
pgp
x
r
p
C
pr
p
xr
d
I
AGMA Elastic Coefficient(also from basic material properties and (11.23))
Other Surface Stress Factors
• Cf = 1 for standard manufacturing methods
• Ca, Cm, Cv, Cs are equal to corresponding K values from bending
Allowable Contact Stress(Norton calls Strength)
• Material strength SC is the basis, specific to gear materials
• Sc based on Brinell hardness of material or on tables in Norton
• Adjust for conditions– CL = life factor
– CH = hardness-ratio factor (pinion rel to gear)
– CT = temperature factor
– CR = reliability factor
RT
HLfcfc CC
CCSS
'
Surface Fatigue Strengths
Surface Fatigue Life Factor
Hardness Ratio Factor• Only applied to the gear material (not pinion)• Accounts for work hardening of the gear during
run-in• Depends on previous hardening (through hardened
vs surface hardened)
gear pinion, of hardness Brinnel,
00698.07.1
00829.000898.07.12.1
02.1
ratiogear
)1(1
gp
g
p
g
p
g
p
g
p
G
GH
HBHB
AthenHB
HB
HB
HBAthen
HB
HB
AthenHB
HB
m
mAC
microinchin roughness surface rms
.).(00075.0
.).(00075.0
)450(1
052.0
0112.0
q
R
R
gH
R
ISeB
SUeB
HBBC
q
q
Both through hardened Pinion surface hardened
Helical Gears – Brief Overview
• The treatment of tooth stresses for helical gears is very similar to spur gears
• Bending and Surface stresses must be analyzed
• AGMA formulas are analagous
• Tables also consider helix angle in range of 10 to 30 degrees
• For this class, be able to perform force analysis but we will not cover tooth stresses
Forces, Helical(Equations 12.3 in Norton)
t
n
t
n
tan
tancos
anglehelix
involute)(for angle pressurecircular
angle pressure normal
force radial sin
force axial sincos
force dtransmittecoscos
force total
nr
na
nt
WW
WW
WW
W
Bevel Gears
• Treat force analysis of intersecting, straight tooth, bevel gears
• Equations (12.8 in Norton)
Forces, Bevel Gears(Shigley, Fig 13-34)
•Assume forces concentrated at average radius
•Net force surface
•Decompose into transmitted, radial and axial forces
sintan
costan
tan;/
angle-half conepitch
angle pressure
ta
tr
tavet
WW
WW
WWrTW
Bending Strength from Hardness(Fig 14-2 Shigley)
Contact Strength from Hardness(Fig 14-3 Shigley)
"I've had a wonderful time, but this wasn't it."
- Groucho Marx (1895-1977)