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Bevel Gear Design Procedure

The document outlines the 16 step design procedure for bevel gears, including calculating gear ratios, selecting materials, determining gear life, calculating design torque and stresses, selecting number of teeth, determining quality, checking for bending and wear, and calculating basic gear dimensions. Key steps include selecting materials based on gear ratio, calculating design bending and contact stresses, checking that induced stresses don't exceed design stresses, and designing the driven gear separately if it is made of a different material.

Uploaded by

Szymon Rosik
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© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
550 views

Bevel Gear Design Procedure

The document outlines the 16 step design procedure for bevel gears, including calculating gear ratios, selecting materials, determining gear life, calculating design torque and stresses, selecting number of teeth, determining quality, checking for bending and wear, and calculating basic gear dimensions. Key steps include selecting materials based on gear ratio, calculating design bending and contact stresses, checking that induced stresses don't exceed design stresses, and designing the driven gear separately if it is made of a different material.

Uploaded by

Szymon Rosik
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Unit : III “Bevel Gears and Worm Gear”

Design Procedure for Bevel Gears

1. Calculation of gear ratio and pitch angles

Calculation of gear ratio


From page no: 8.6
𝑁1 𝑧2
𝑖= =
𝑁2 𝑧1
𝑁1 , 𝑧1 - Speed, No of teeth of driving gear
𝑁2, 𝑧2 - Speed, No of teeth of driven gear

Calculation of pitch angles

 2 = tan−1 𝑖
 1 = 90° −  2

i - Gear ratio
 1 ,  2 - Reference angle
Unit : III “Bevel Gears and Worm Gear”

2. Selection of Materials
Choose the suitable material for pinion and wheel
from PSG Data book page no: 1.40, 8.4, 8.5 using the i
value.
If the pinion and wheel are same design only for
pinion.
If they are made of different material design for
both pinion and wheel.
Most cases C45 for pinion and C.I grade 20 for
wheel (If material is not specified)

3. Gear Life
Calculate the gear life based on given data.
Gear life in (hours)
Gear life in (min)
Life in number of cycles = (gear life in min) x N
N- speed of gear
If gear life is not specified assume it as 20,000 hrs

4. Calculation of design torque [Mt]


From Page No: 8.15 – Table: 13
Design torque [Mt] = Mt k kd
60 𝑃
Mt=
2𝜋𝑁
Initially assume (k kd)= 1.3
Unit : III “Bevel Gears and Worm Gear”

5. Calculation of Eeq ,[b] ,[ c]


Calculation of Eeq
From page no. 8.14, Table: 9 for the given gear
material choose Equivalent young's modulus (kgf/cm2)
Convert the unit to N/mm2

Calculation of [b]-Design bending stress


From page no:8.18, Table:18, assuming the rotation is
in one direction unless specified, choose the formula.

Select the kbl value from page no:8.20, Table:22


Unit : III “Bevel Gears and Worm Gear”

Select the n value from page no:8.19, Table:20

Select the k value from page no:8.19, Table:21;


assuming addendum modification factor as 0.

Select the - 1 value from page no:8.19, Table:19 based


on the material.

Calculate - 1 value in kgf/cm2 and then convert it to


N/mm2
Unit : III “Bevel Gears and Worm Gear”

Select the u value from page no:8.5, Table:7

Convert the
unit to kgf/cm2

Calculation of [ c]
From Page no: 8.16, Table:15; based on the available
data for the gear material select the formula for
design contact stress

Select CR or CB Valve based on the material and its


properties From page no: 8.16, table:16
Unit : III “Bevel Gears and Worm Gear”

Select the life factor kcl based on the material and its
properties from page no:8.17, Table :17

6. Calculation of cone distance (R)


From Page no: 8.13

Assume value of y from Page no: 8.15; Table-13 (or


assume it as 3)

7. Selection of number of teeth and Calculation


of virtual number of teeth
Selection of number of teeth
If the number of teeth is not provided
Assume z1=17 for 20 pressure angle
Assume z1=32 for 141/2 pressure angle
Calculate the value for z2
𝑧2
𝑖=
𝑧1
Unit : III “Bevel Gears and Worm Gear”

Calculation of virtual number of teeth(𝑧𝑣1 , 𝑧𝑣2 )


𝑧1
𝑧𝑣1 =
cos 𝛿1

𝑧2
𝑧𝑣2 =
cos 𝛿2
𝛿1 , 𝛿2 - Reference angle
𝑧1 , 𝑧2 - Number of teeth

8. Calculation for transverse module (mt)

From Page no 8.38, Table:31

Rearranging it;
𝑅
𝑚𝑡 =
0.5 𝑧1 2 + 𝑧2 2
From Page no:8.2, Table 1; choose the std. value of
module

9. Revision of centre distance


From Page no: 8.38, Table-31; calculate the new
centre distance

𝑅 = 𝑚𝑡 0.5 𝑧1 2 + 𝑧2 2
Unit : III “Bevel Gears and Worm Gear”

10. Calculation of b, mm, dm , , y


Face width
From Page no: 8.15, Table-13
𝑅
b= 
𝑦
Average or mean module
From Page no: 8.38, Table:31 ; rearranging it

𝑏 sin 𝛿1
𝑚 𝑚 = 𝑚𝑡 −
𝑧1

Reference diameter (d)


From Page no: 8.38, Table:31

Pitch line velocity


𝜋𝑑𝑁
𝜐=
60
Calculation of p
From Page no: 8.15, Table:14
𝑏
p =
𝑑

11. Selection of Quality of Gear


From Page no: 8.3, table:2
Form the calculated pitch line velocity choose the IS
quality of gear
Unit : III “Bevel Gears and Worm Gear”

12. Revision of design torque


Revised [Mt]
From Page no:8.15
Design torque [Mt] = Mt k kd
60 𝑃
Mt=
2𝜋𝑁
Use the revised k kd values

Revised k
From Page no:8.15 for the p value choose k value

Revised kd
From Page No:8.16 using the IS quality, pitch line
velocity and surface hardness value choose kd
Unit : III “Bevel Gears and Worm Gear”

13. Check for bending


Calculation for induced bending stress
From Page no: 8.13A

The value of b (induced bending stress) should be


less than [b] (design bending stress) then the design
is safe

From page no:8.18 – Table 18; for the number of teeth


z1 value and assuming X as 0, choose the yv (form
factor) value

14. Check for wear strength


Calculation for induced contact stress
From Page no: 8.13

The value of c (induced contact stress) should be


less than [c] (design contact stress) then the design
is safe
Unit : III “Bevel Gears and Worm Gear”

15. Calculation of basic dimensions of


pinion and gear
Calculate the following values from Page no: 8.38; Table:31
Module (transverse, mean and normal)
Face width (b)
Number of teeth on crown wheel
Addendum and dedendum angle
Height factor(f0)
Clearance (c)
Pitch circle diameter (d1,d2)
Tip and root angle (a,f)

16. Check for wheel


If the material for wheel is different then this step is
needed
• Calculate N2
• Gear life based on N2
• Calculate the design values of [b] ,[ c] for wheel
• Calculate the induced values of b , c for wheel
• Verify that the wheel design is safe
• Then calculate the basic dimensions of wheel

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