A pair of helical gears, subjected to heavy shock loading, is to 

 36, 318.095 
transmit 50 hp at 1750 rpm of the pinion; SR ≈ 4.25; ψ = 15o; 96.805 823.2   
minimum Dp = 4.375 in.; continuous service; 20o F.D. teeth with load Fd  823.2 
  Pd 
applied near the middle; material is AISI 4150 OQT 1200oF. Decide   36, 318.095 
1/ 2

upon the pitch, face width. 100.22  823.2   

  Pd 
Given:
Power = 50 Hp np = 1750 rpm * the gear beam strength is also computed using:
SR ≈ 4.25 Helix angle, ψ = 15o S (b )(Y )(cos )
Dp = 4.375 in. Tooth profile = 20o FD (load at middle) Fs  n
k f ( Pd )
Mat’l = SAE 0105 WQT (Table AT 9 p.579 FAIRES)
Su = 159 ksi (Sn = 0.4 Su = 63.6 ksi), BHN = 331
* where Y is the Lewis form factor for the equivalent number of teeth
Additional given and assumptions: in helical gears, Ne:
1. For loads applied “at the middle”, let kf = 1.7 (unless otherwise Np
specified). Ne 
(cos )
3

2. For shock loading and continuous service, let N sf = 1.5 minimum

(unless otherwise specified)
* and the number of teeth of pinion, Np, is computed using:
Solution: N p  Pd ( D p )
* Solving for the pitch line velocity, Vm
 ( Dp )( n p )  (4.375 in)(1750 rpm) * therefore, the gear beam strength equation becomes:
Vm  
12 12  2  o
63, 600 psi   (Y ) cos15
Vm  2004.401 ft/min S n (b)(Y )(cos )  Pd tan15 
o

Fs  
k f ( Pd ) 1.7 Pd
* the dynamic load equation for helical gears is given as:
847, 382.3(Y )
0.05Vm (Ft  Cb cos  ) cos 
2 Fs  2
Fd  Ft  Pd
0.05Vm  (Ft  Cb cos  )
2 2

Note: from this point forward, the correct diametral pitch (Pd) and
* where the transmitted load Ft, is: face width (b) values will be determined using trial and error method
33, 000 H p 33, 000 (50 Hp ) outlined below.
Ft  
Vm 2004.401 ft/min Step 1: Assign an initial value of Pd, then solve for both Fd and Fs. If
Ft  823.188 lbs. Fs < Fd, then the assigned Pd is not acceptable. Change Pd value and
recalculate Fs and Fd until (Fs > Fd) is satisfied.
* the recommended minimum face width as recommended by
Step 2: If Fs > Fd, check for the service factor (Nsf = Fs/Fd) and see if
FAIRES eq.(a) & eq.(d) p.399-400 is:
it satisfies the requirement (in this case, Nsf = 1.5 minimum).
    2  - if the computed service factor is lower than what is required,
b  2 Pa  2   
 Pd tan    Pd tan   decrease Pd value and re-evaluate!
- if the computed service factor is too much (over-design), try to
* to solve for the C constant, see method in previous example (Gear increase Pd value until the computed service factor is more or
design using Buckingham Equation); less equal to what is required in the problem.
- assume steel on steel, 20o FD, e = 0.001
therefore, C = 1660 Example: Let Pd = 9

* the dynamic load equation becomes: * therefore the dynamic load Fd, becomes:
0.05Vm (Ft  Cb cos  ) cos 
2 
96.805 823.2  
 36, 318.095 
 
Fd  Ft 
0.05Vm  (Ft  Cb cos  )
2 2
Fd  823.2 
 9 
  36, 318.095 
1/ 2

  2  o 2
100.22  823.2  
 
823.2  1660  P tan15o  (cos15 )  cos15  
o
0.05(2004.4) 9
Fd  823.2 
  d  
Fd  3591.104 lbs.
  2  o 2
1/ 2

0.05(2004.4)  823.2  1660  o 

(cos15 ) 
  Pd tan15   * for Pd = 9, the number of teeth on the pinion is
N p  Pd ( D p )  9 teeth/in (4.375 in)
N p  39.375 teeth  40 teeth
* for Np = 40 teeth, the equivalent number of teeth is: Pd comparison:
Np 40
Ne   Pd Y b Fd Fs Nsf
(cos )
3 o 3
(cos15 )
9 0.676 2.605 3591.091 7068.424 1.968
N e  44.38 teeth
10 0.690 2.345 3406.152 5848.908 1.717
11 0.703 2.132 3251.388 4921.410 1.514
* from Table AT 24 p.601 FAIRES
for Ne = 44.38 teeth, 20o FD with load near middle 12 0.711 1.954 3119.852 4183.105 1.341
Y = 0.6757 (interpolated)
Analysis:
* therefore, the gear beam strength equation becomes: Based on the summarized data, we can conclude that the
847, 382.3(0.6757) appropriate Pd to be used is Pd = 11. Also, notice that by increasing
Fs  2
the Pd, we were able to decrease the size of the face width (b) thus
(9) reducing the cost of manufacturing the gear.
Fs  7, 068.842 lbs.
Conclusion:
Let Pd = 11.
Fs > Fd, therefore Pass!
* therefore the dynamic load Fd, becomes:
* solving for the service factor,

96.805 823.2  
 36, 318.095 
 

F 7, 068.842 lbs.
N sf  s 
Fd  823.2 
 11
Fd 3, 591.104 lbs.
  36, 318.095 
1/ 2

100.22  823.2   
N sf  1.968   11 
Fd  3251.388 lbs.
Analysis:
For Pd = 9, the resulting service factor Nsf = 1.968 is quiet high as
compared to what is required (Nsf = 1.5 minimum). A larger factor * for Pd = 11, the number of teeth on the pinion is
of safety is always preferred but it usually entails a higher product N p  Pd ( D p )  11 teeth/in (4.375 in)
cost. As mechanical designers, we not only concern ourselves with N p  48.125 teeth  49 teeth
the functionality of the product but with the cost of the product as
well. A good designer always seeks out a product design that serves
its purpose while utilizing the least cost. * for Np = 49 teeth, the equivalent number of teeth is:
Np 49
Conclusion: Ne  
(cos )
3 o 3
(cos15 )
Service factor is too high (over-design)! Increase Pd value and
recalculate Fd and Fs. N e  54.37 teeth

* from Table AT 24 p.601 FAIRES

Note: calculation for different Pd values are not shown but are for Ne = 54.37 teeth, 20o FD with load near middle
summarized as follows Y = 0.7027 (interpolated)

For Pd = 9 * therefore, the gear beam strength equation becomes:

Fd = 3,591.104 lbs. 847, 382.3(0.7027)
Fs = 7,068.842 lbs. Fs  2
(11)
Nsf = 1.968
Fs  4, 921.410 lbs.
For Pd = 10 Fs > Fd, therefore Pass!
Fd = 3,406.166 lbs.
Fs = 5,848.908 lbs. * solving for the service factor,
Nsf = 1.717 F 4, 921.410 lbs.
N sf  s 
For Pd = 11 Fd 3, 251.388 lbs.
Fd = 3,251.388 lbs. N sf  1.514
Fs = 4,921.41 lbs.
Nsf = 1.514
* solving for the face width, b:
For Pd = 12 2 2
b 
Fd = 3119.852 lbs. Pd tan  (11)(tan15 )
o

Fs = 4,183.105 lbs.
b  2.132 in.
Nsf = 1.341
* solving for gear diameter, Dg
Dg  ( SR )( D p )  (4.25)(4.375 in.)
Dg  18.594 in.

* solving for the number of teeth of the gear, N g

N g  ( SR )( N p )  (4.25)(49 teeth)
N g  208.25  208 teeth

* solving for the gear rotative speed, ng

n p 1750 rpm
ng  
SR 4.25
ng  411.765 rpm

* the limiting wear load equation is:

D p (b)(Q )( K g )
Fw 
(cos )
2

* where Q is:
2( SR ) 2(4.25)
Q 
SR  1 4.25  1
Q  1.619

* also, the wear factor for gearing, Kg, is determined using Table
AT26, p.603 FAIRES:
BHN for both gear and pinion is 331
Sum of BHN is therefor: 331+331 = 662
For Sum of BHN = 662, 20o FD: Kg = 241.88 (interpolated)

* therefore, the limiting wear load Fw, is:

D p (b)(Q)( K g ) (4.375 in.)(2.132 in.)(1.619)(241.88)
Fw  
(cos )
2 o 2
(cos15 )
Fw  3, 914.935 lbs.
Fw > Fd , therefore, pass!

Summary:

Dp (inches) 4.375 Dg (inches) 18.59

Np (teeth) 49 Ng (teeth) 208
np (rpm) 1750 ng (rpm) 411.76
SR 4.25 Fd (lbs) 3,251.39
Pd 11 Fs (lbs) 4,921.41
b (inches) 2.13 Fw (lbs) 3,914.58
Nsf = 1.51

To do:

Recalculate everything using a helix angle of ψ = 20o