Gears

Spur Gears
Disclaimer: The information on this page has not been checked by an independent person. Use this
information at your own risk.
ROYMECH
Home
Drive_Index
Gears Gearboxes
Spur Gears
Introduction..... Standards..... Terminology..... Spur Gear Design..... Materials..... Basic Equations..... Module.....
Pressure Angle.....
Contact Ratio..... Forces- Torques etc..... Strength Durability calcs..... Design Process..... Internal Gears..... Table of
Lewis Form Factors.....
The notes below relate to spur gears. Notes specific to helical gears are included on a separate page Helical
Gears
Introduction
Gears are machine elements used to transmit rotary motion between two shafts, normally with a constant ratio.
The pinion is the smallest gear and the larger gear is called the gear wheel.. A rack is a rectangular prism with
gear teeth machined along one side- it is in effect a gear wheel with an infinite pitch circle diameter. In practice
the action of gears in transmitting motion is a cam action each pair of mating teeth acting as cams. Gear design
has evolved to such a level that throughout the motion of each contacting pair of teeth the velocity ratio of the
gears is maintained fixed and the velocity ratio is still fixed as each subsequent pair of teeth come into contact.
When the teeth action is such that the driving tooth moving at constant angular velocity produces a proportional
constant velocity of the driven tooth the action is termed a conjugate action. The teeth shape universally
selected for the gear teeth is the involute profile.
Consider one end of a piece of string is fastened to the OD of one cylinder and the other end of the string is
fastened to the OD of another cylinder parallel to the first and both cylinders are rotated in the opposite directions
to tension the string(see figure below). The point on the string midway between the cylinder P is marked. As
the left hand cylinder rotates CCW the point moves towards this cylinder as it wraps on . The point moves away
from the right hand cylinder as the string unwraps. The point traces the involute form of the gear teeth.
file:///C|/Documents%20and%20Settings/media/Desktop/Gears.html (1 of 14)2/7/2010 6:14:47 PM
Spur Gears
The lines normal to the point of contact of the gears always intersects the centre line joining the gear centres at
one point called the pitch point. For each gear the circle passing through the pitch point is called the pitch
circle. The gear ratio is proportional to the diameters of the two pitch circles. For metric gears (as adopted by
most of the worlds nations) the gear proportions are based on the module.
m =(Pitch Circle Diameter(mm)) / (Number of teeth on gear).
In the USA the module is not used and instead the Diametric Pitch d
p
is used
d
p
=(Number of Teeth) / Diametrical Pitch (inches)
Profile of a standard 1mm module gear teeth for a gear with Infinite radius (Rack ).
Other module teeth profiles are directly proportion . e.g. 2mm module teeth are 2 x this profile
Many gears trains are very low power applications with an object of transmitting motion with minium torque e.g.
watch and clock mechanisms, instruments, toys, music boxes etc. These applications do not require detailed
strength calculations.
Spur Gears
Standards
G AGMA 2001-C95 or AGMA-2101-C95 Fundamental Rating factors and Calculation Methods for
involute Spur Gear and Helical Gear Teeth
G BS 436-4:1996, ISO 1328-1:1995..Spur and helical gears. Definitions and allowable values of
deviations relevant to corresponding flanks of gear teeth
G BS 436-5:1997, ISO 1328-2:1997..Spur and helical gears. Definitions and allowable values of
deviations relevant to radial composite deviations and runout information
G BS ISO 6336-1:1996 ..Calculation of load capacity of spur and helical gears. Basic principles,
introduction and general influence factors
G BS ISO 6336-2:1996..Calculation of load capacity of spur and helical gears. Calculation of surface
durability (pitting)
G BS ISO 6336-3:1996..Calculation of load capacity of spur and helical gears. Calculation of tooth
bending strength
G BS ISO 6336-5:2003..Calculation of load capacity of spur and helical gears. Strength and quality of
materials
If it is necessary to design a gearbox from scratch the design process in selecting the gear size is not
complicated - the various design formulea have all been developed over time and are available in the relevant
standards. However significant effort, judgement and expertise is required in designing the whole system
including the gears, shafts , bearings, gearbox, lubrication. For the same duty many different gear options are
available for the type of gear , the materials and the quality. It is always preferable to procure gearboxes from
specialised gearbox manufacturers
Terminology - spur gears
G Diametral pitch (d
p
)...... The number of teeth per one inch of pitch circle
diameter.
G Module. (m) ...... The length, in mm, of the pitch circle diameter per tooth.
G Circular pitch (p)...... The distance between adjacent teeth measured along
the are at the pitch circle diameter
G Addendum ( h
a
)...... The height of the tooth above the pitch circle diameter.
G Centre distance (a)...... The distance between the axes of two gears in mesh.
G Circular tooth thickness (ctt)...... The width of a tooth measured along the are
at the pitch circle diameter.
G Dedendum ( h
f
)...... The depth of the tooth below the pitch circle diameter.
G Outside diameter ( D
o
)...... The outside diameter of the gear.
G Base Circle diameter ( D
b
) ...... The diameter on which the involute teeth
profile is based.
G Pitch circle dia ( p ) ...... The diameter of the pitch circle.
G Pitch point...... The point at which the pitch circle diameters of two gears in
mesh coincide.
G Pitch to back...... The distance on a rack between the pitch circle diameter
line and the rear face of the rack.
G Pressure angle ...... The angle between the tooth profile at the pitch circle
diameter and a radial line passing through the same point.
G Whole depth...... The total depth of the space between adjacent teeth.
Spur Gears
Spur Gear Design
The spur gear is is simplest type of gear manufactured and is generally used for transmission of rotary motion
between parallel shafts. The spur gear is the first choice option for gears except when high speeds, loads, and
ratios direct towards other options. Other gear types may also be preferred to provide more silent low-vibration
operation. A single spur gear is generally selected to have a ratio range of between 1:1 and 1:6 with a pitch line
velocity up to 25 m/s. The spur gear has an operating efficiency of 98-99%. The pinion is made from a harder
material than the wheel. A gear pair should be selected to have the highest number of teeth consistent with a
suitable safety margin in strength and wear. The minimum number of teeth on a gear with a normal pressure
angle of 20 desgrees is 18.
The preferred number of teeth are as follows
Spur Gears
12 13 14 15 16 18 20 22 24 25 28 30 32 34 38 40 45 50 54
60
64 70 72 75 80 84 90 96 100 120 140 150 180 200 220 250
Materials used for gears
Mild steel is a poor material for gears as as it has poor resistance to surface loading. The carbon content for
unhardened gears is generally 0.4%(min) with 0.55%(min) carbon for the pinions. Dissimilar materials should be
used for the meshing gears - this particularly applies to alloy steels. Alloy steels have superior fatigue properties
compared to carbon steels for comparable strengths. For extremely high gear loading case hardened steels are
used the surface hardening method employed should be such to provide sufficient case depth for the final
grinding process used.
Material Notes applications
Ferrous metals
Cast Iron
Low Cost easy to machine with high
damping
Large moderate power, commercial
gears
Cast Steels Low cost, reasonable strength
Power gears with medium rating to
commercial quality
Plain-Carbon Steels Good machining, can be heat treated
Power gears with medium rating to
commercial/medium quality
Alloy Steels
Heat Treatable to provide highest
strength and durability
Highest power requirement. For
precision and high precisiont
Stainless Steels (Aust)
Good corrosion resistance. Non-
magnetic
Corrosion resistance with low
power ratings. Up to precision
quality
Stainless Steels (Mart)
Hardenable, Reasonable corrosion
resistance, magnetic
Low to medium power ratings Up to
high precision levels of quality
Non-Ferrous metals
Aluminium alloys
Light weight, non-corrosive and good
machinability
Light duty instrument gears up to
high precision quality
Brass alloys
Low cost, non-corrosive, excellent
machinability
low cost commercial quality gears.
Quality up to medium precision
Bronze alloys
Excellent machinability, low friction
and good compatability with steel
For use with steel power gears.
Quality up to high precision
Magnesium alloys
Light weight with poor corrosion
resistance
Ligh weight low load gears. Quality
up to medium precision
Nickel alloys
Low coefficient of thermal expansion.
Poor machinability
Special gears for thermal
applications to commercial quality
Titanium alloys
High strength, for low weight, good
corrosion resistance
Special light weight high strength
gears to medium precision
Di-cast alloys
Low cost with low precision and
strength
High production, low quality gears
to commercial quality
Sintered powder
alloys
Low cost, low quality, moderate
strength
High production, low quality to
moderate commercial quality
Non metals
Acetal (Delrin Wear resistant, low water absorbtion
Long life , low load bearings to
commercial quality
Spur Gears
Phenolic laminates
Low cost, low quality, moderate
strength
High production, low quality to
moderate commercial quality
Nylons
No lubrication, no lubricant, absorbs
water
Long life at low loads to
commercial quality
PTFE Low friction and no lubrication
Special low friction gears to
commercial quality
Equations for basic gear relationships
It is acceptable to marginally modify these relationships e.g to modify the addendum /dedendum to allow Centre
Distance adjustments. Any changes modifications will affect the gear performance in good and bad ways...
Addendum h
a
=m =0.3183 p
Base Circle diameter D
b
= d.cos
Centre distance
a = ( d
g
+ d
p
) / 2
Circular pitch
p = m.
Circular tooth thickness ctt = p/2
Dedendum
h
f
= h - a = 1,25m = 0,3979 p
Module m = d /n
Number of teeth z = d / m
Outside diameter
D
o
= (z + 2) x m
Pitch circle diameter
d = n . m ... (d
g
= gear & d
p
= pinion )
Whole depth(min) h = 2.25 . m
Top land width(min)
t
o
= 0,25 . m
Module (m)
The module is the ratio of the pitch diameter to the number of teeth. The unit of the module is milli-metres.Below
is a diagram showing the relative size of teeth machined in a rack with module ranging from module values of 0,5
mm to 6 mm
The preferred module values are
0,5 0,8 1 1,25 1,5 2,5 3 4 5 6 8 10 12 16 20 25 32 40 50
Spur Gears
Normal Pressure angle
An important variable affecting the geometry of the gear teeth is the normal pressure angle. This is generally
standardised at 20
o
. Other pressure angles should be used only for special reasons and using considered
judgment. The following changes result from increasing the pressure angle
G Reduction in the danger of undercutting and interference
G Reduction of slipping speeds
G Increased loading capacity in contact, seizure and wear
G Increased rigidity of the toothing
G Increased noise and radial forces
Gears required to have low noise levels have pressure angles 15
o
to17.5
o

Contact Ratio
The gear design is such that when in mesh the rotating gears have more than one gear in contact and
transferring the torque for some of the time. This property is called the contact ratio. This is a ratio of the length
of the line-of-action to the base pitch. The higher the contact ratio the more the load is shared between teeth. It
is good practice to maintain a contact ratio of 1.2 or greater. Under no circumstances should the ratio drop below
1.1.
A contact ratio between 1 and 2 means that part of the time two pairs of teeth are in contact and during the
remaining time one pair is in contact. A ratio between 2 and 3 means 2 or 3 pairs of teeth are always in
contact. Such as high contact ratio generally is not obtained with external spur gears, but can be developed in
the meshing of an internal and external spur gear pair or specially designed non-standard external spur gears.
(R
go
2
- R
gb
2
)
1/2
+ (R
po
2
- R
pb
2
)
1/2
- a sin
contact ratio m =
p cos
R
go
=D
go
/ 2..Radius of Outside Dia of Gear
R
gb
=D
gb
/ 2..Radius of Base Dia of Gear
R
po
=D
po
/ 2..Radius of Outside Dia of Pinion
R
pb
=D
pb
/ 2..Radius of Base Dia of Pinion
p =circular pitch.
a =( d
g
+d
p
)/2 =center distance.
Spur gear Forces, torques, velocities & Powers
Spur Gears
G F =tooth force between contacting teeth (at angle pressure angle to pitch line tangent.
(N)
G F
t
=tangential component of tooth force (N)
G F
s
=Separating component of tooth force
G =Pressure angle
G d
1
=Pitch Circle Dia -driving gear (m)
G d
2
=Pitch Circle Dia -driven gear (m)
G
1
=Angular velocity of driver gear (Rads/s)
G
2
=Angular velocity of driven gear (Rads/s)
G z
1
=Number of teeth on driver gear
G z
2
=Number of teeth on driven gear
G P =power transmitted (Watts)
G M =torque (Nm)
G =efficiency
Tangential force on gears F
t
= F cos
Separating force on gears F
s
= F
t
tan
Torque on driver gear T
1
= F
t
d
1
/ 2
Torque on driver gear T
2
= F
t
d
2
/ 2
Speed Ratio =
1
/
2
= d
2
/ d
1
= z
2
/z
1

Input Power P
1
= T
1
.
1

Output Power P
2
=.T
1
.
2

Spur gear Strength and durability calculations
Designing spur gears is normally done in accordance with standards the two most popular series are listed under
standards above:
The notes below relate to approximate methods for estimating gear strengths. The methods are really only useful
for first approximations and/or selection of stock gears (ref links below). Detailed design of spur and helical
gears is best completed using the standards. Books are available providing the necessary guidance. Software
is also available making the process very easy. A very reasonably priced and easy to use package is included
in the links below (Mitcalc.com)
The determination of the capacity of gears to transfer the required torque for the desired operating life is
completed by determining the strength of the gear teeth in bending and also the durability i.e of the teeth
( resistance to wearing/bearing/scuffing loads ) .. The equations below are based on methods used by
Buckingham..
Spur Gears
Bending
The basic bending stress for gear teeth is obtained by using the Lewis formula
=F
t
/ ( b
a
. m. Y )
G F
t
=Tangential force on tooth
G =Tooth Bending stress (MPa)
G b
a
=Face width (mm)
G Y =Lewis Form Factor
G m =Module (mm)
Note: The Lewis formula is often expressed as
=F
t
/ ( b
a
. p. y )
Where y =Y/ and p =circular pitch
When a gear wheel is rotating the gear teeth come into contact with some degree of impact. To allow for this a
velocity factor is introduced into the equation. This is given by the Barth equation for milled profile gears.
K
v
=6,1 / (6,1 +V )
V =the pitch line velocity =d./2
Note: This factor is different for different gear conditions i.e K
v
=( 3.05 +V )/3.05 for cast iron, cast profile gears.
The Lewis formula is thus modified as follows
=K
v
.F
t
/ ( b
a
. m. Y )
Surface Durability
Spur Gears
This calculation involves determining the contact stress between the gear teeth and uses the Herz
Formula

w
=2.F / ( .b .l )

w
= largest surface pressure
F = force pressing the two cylinders (gears) together
l = length of the cylinders (gear)
b = halfwidth =
d
1
,d
2
Are the diameters for the two contacting cylinders.

1
,
2
Poisson ratio for the two gear materials
E
1
,E
2
Are the Young's Modulus Values for the two gears
To arrive at the formula used for gear calculations the following changes are made
F is replaced by F
t
/ cos
d is replaced by 2.r
l is replaced by W
The velocity factor K
v
as described above is introduced.
Also an elastic constant Z
E
is created

When the value of E used is in MPa then the units of C
p
are MPa = KPa The resulting formula
for the compressive stress developed is as shown below

The dynamic contact stress
c
developed by the transmitted torque must be less than the
allowable contact stress S
e
...
Note: Values for Allowable stress values S
e
and Z
E
for some materials are provided at Gear Table
r
1
= d
1
sin /2
r
2
= d
2
sin /2
Spur Gears
Important Note: The above equations do not take into account the various factors which are
integral to calculations completed using the relevant standards. These equations therefore yield
results suitable for first estimate design purposes only...
Design Process To select gears from a stock gear catalogue or do a first approximation for a gear design select the gear
material and obtain a safe working stress e.g Yield stress / Factor of Safety. /Safe fatigue stress
G Determine the input speed, output speed, ratio, torque to be transmitted
G Select materials for the gears (pinion is more highly loaded than gear)
G Determine safe working stresses (uts /factor of safety or yield stress/factor of safety or Fatigue strength / Factor of
safety )
G Determine Allowable endurance Stress S
e
G Select a module value and determine the resulting geometry of the gear
G Use the lewis formula and the endurance formula to establish the resulting face width
G If the gear proportions are reasonable then - proceed to more detailed evaluations
G If the resulting face width is excessive - change the module or material or both and start again
The gear face width should be selected in the range 9-15 x module or for straight spur gears-up to 60% of the pinion diameter.
Internal Gears
Advantages:
1. Geometry ideal for epicyclic gear design
2. Allows compact design since the center distance is less than for external gears.
3. A high contact ratio is possible.
4. Good surface endurance due to a convex profile surface working against a concave surface.
Disadvantages:
1. Housing and bearing supports are more complicated, because the external gear nests within the internal gear.
2. Low ratios are unsuitable and in many cases impossible because of interferences.
3. Fabrication is limited to the shaper generating process, and usually special tooling is required.
Spur Gears
Lewis form factor.
Table of lewis form factors for different tooth forms and pressure angles
No Teeth
Load Near Tip of Teeth Load at Near Middle of Teeth
14 1/2 deg 20 deg FD 20 deg Stub 25 deg 14 1/2 deg 20 deg FD
Y y Y y Y y Y y Y y Y y
10 0,176 0,056 0,201 0,064 0,261 0,083 0,238 0,076
11 0,192 0,061 0,226 0,072 0,289 0,092 0,259 0,082
12 0,21 0,067 0,245 0,078 0,311 0,099 0,277 0,088 0,355 0,113 0,415 0,132
13 0,223 0,071 0,264 0,084 0,324 0,103 0,293 0,093 0,377 0,12 0,443 0,141
14 0,236 0,075 0,276 0,088 0,339 0,108 0,307 0,098 0,399 0,127 0,468 0,149
15 0,245 0,078 0,289 0,092 0,349 0,111 0,32 0,102 0,415 0,132 0,49 0,156
16 0,255 0,081 0,295 0,094 0,36 0,115 0,332 0,106 0,43 0,137 0,503 0,16
17 0,264 0,084 0,302 0,096 0,368 0,117 0,342 0,109 0,446 0,142 0,512 0,163
Spur Gears
18 0,27 0,086 0,308 0,098 0,377 0,12 0,352 0,112 0,459 0,146 0,522 0,166
19 0,277 0,088 0,314 0,1 0,386 0,123 0,361 0,115 0,471 0,15 0,534 0,17
20 0,283 0,09 0,32 0,102 0,393 0,125 0,369 0,117 0,481 0,153 0,544 0,173
21 0,289 0,092 0,326 0,104 0,399 0,127 0,377 0,12 0,49 0,156 0,553 0,176
22 0,292 0,093 0,33 0,105 0,404 0,129 0,384 0,122 0,496 0,158 0,559 0,178
23 0,296 0,094 0,333 0,106 0,408 0,13 0,390 0,124 0,502 0,16 0,565 0,18
24 0,302 0,096 0,337 0,107 0,411 0,131 0,396 0,126 0,509 0,162 0,572 0,182
25 0,305 0,097 0,34 0,108 0,416 0,132 0,402 0,128 0,515 0,164 0,58 0,185
26 0,308 0,098 0,344 0,109 0,421 0,134 0,407 0,13 0,522 0,166 0,584 0,186
27 0,311 0,099 0,348 0,111 0,426 0,136 0,412 0,131 0,528 0,168 0,588 0,187
28 0,314 0,1 0,352 0,112 0,43 0,137 0,417 0,133 0,534 0,17 0,592 0,188
29 0,316 0,101 0,355 0,113 0,434 0,138 0,421 0,134 0,537 0,171 0,599 0,191
30 0,318 0,101 0,358 0,114 0,437 0,139 0,425 0,135 0,54 0,172 0,606 0,193
31 0,32 0,101 0,361 0,115 0,44 0,14 0,429 0,137 0,554 0,176 0,611 0,194
32 0,322 0,101 0,364 0,116 0,443 0,141 0,433 0,138 0,547 0,174 0,617 0,196
33 0,324 0,103 0,367 0,117 0,445 0,142 0,436 0,139 0,55 0,175 0,623 0,198
34 0,326 0,104 0,371 0,118 0,447 0,142 0,44 0,14 0,553 0,176 0,628 0,2
35 0,327 0,104 0,373 0,119 0,449 0,143 0,443 0,141 0,556 0,177 0,633 0,201
36 0,329 0,105 0,377 0,12 0,451 0,144 0,446 0,142 0,559 0,178 0,639 0,203
37 0,33 0,105 0,38 0,121 0,454 0,145 0,449 0,143 0,563 0,179 0,645 0,205
38 0,333 0,106 0,384 0,122 0,455 0,145 0,452 0,144 0,565 0,18 0,65 0,207
39 0,335 0,107 0,386 0,123 0,457 0,145 0,454 0,145 0,568 0,181 0,655 0,208
40 0,336 0,107 0,389 0,124 0,459 0,146 0,457 0,145 0,57 0,181 0,659 0,21
43 0,339 0,108 0,397 0,126 0,467 0,149 0,464 0,148 0,574 0,183 0,668 0,213
45 0,34 0,108 0,399 0,127 0,468 0,149 0,468 0,149 0,579 0,184 0,678 0,216
50 0,346 0,11 0,408 0,13 0,474 0,151 0,477 0,152 0,588 0,187 0,694 0,221
55 0,352 0,112 0,415 0,132 0,48 0,153 0,484 0,154 0,596 0,19 0,704 0,224
60 0,355 0,113 0,421 0,134 0,484 0,154 0,491 0,156 0,603 0,192 0,713 0,227
65 0,358 0,114 0,425 0,135 0,488 0,155 0,496 0,158 0,607 0,193 0,721 0,23
70 0,36 0,115 0,429 0,137 0,493 0,157 0,501 0,159 0,61 0,194 0,728 0,232
75 0,361 0,115 0,433 0,138 0,496 0,158 0,506 0,161 0,613 0,195 0,735 0,234
80 0,363 0,116 0,436 0,139 0,499 0,159 0,509 0,162 0,615 0,196 0,739 0,235
90 0,366 0,117 0,442 0,141 0,503 0,16 0,516 0,164 0,619 0,197 0,747 0,238
100 0,368 0,117 0,446 0,142 0,506 0,161 0,521 0,166 0,622 0,198 0,755 0,24
150 0,375 0,119 0,458 0,146 0,518 0,165 0,537 0,171 0,635 0,202 0,778 0,248
200 0,378 0,12 0,463 0,147 0,524 0,167 0,545 0,173 0,64 0,204 0,787 0,251
Spur Gears
300 0,38 0,122 0,471 0,15 0,534 0,17 0,554 0,176 0,65 0,207 0,801 0,255
Rack 0,39 0,124 0,484 0,154 0,55 0,175 0,566 0,18 0,66 0,21 0,823 0,262
Links to Gear Design
1. Gear Design ...A comprehensive source of Gear Design Information
2. Efunda ...Efunda ->Design Centre->Gears.. Some useful Notes.
3. Gear Design Topics ... A site providing amazing motion graphics of different gear types
4. SEW Eurodrive...All the information on Gearboxes you will need
5. Quality Transmission Components...Supplier with downloadable Gear Design Handbook
6. Stock Drive Products=Sterling Instruments...Supplier with large quantity of downloadable drive information
7. Mitcalc...Excel based software including coded gear design
8. Lenze...Drive system supplier with geared motor section
9. Davall Gears...UK Supplier of stock gears and gearboxes
10. Muffett gears...UK Supplier of stock gears and gearboxes
11. Gear Design Lecture Notes...Plymouth.ac.uk - Useful Notes on gear strength design
12. Gear Stress (PDF)...A very useful downloadable paper based on AGMA standards for gear design
13. DR Gears...One stop resource for gear manufacturers
This Page is being developed
Home
Drive_Index
Gears Gearboxes
Send Comments to Roy@roymech.co.uk
Last Updated 02/12/2009

Gears

Transféré par

Informations du document

Description originale:

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Gears

Transféré par

Droits d'auteur :

Formats disponibles

Spur Gears

Vous aimerez peut-être aussi