Chapter 2 : Helical Gears

Section 2.11 :

Example 2.4 :
A right-hand, 18 teeth helical pinion is to mesh with a left-hand, 40 teeth helical gear mounted
on parallel shaft. The pinion and gear are to be made of plain carbon steel having permissible
2
bending stress of 105 N/mm . The pinion is to be driven by 22 kW, 1440 r.p.m., three phase
induction motor. The gear pair is to be heat treated to a surface hardness of 250 BHN. The
starting torque of the motor is 25% more than the rated torque. The factor of safety required is
1.5. The tooth system is 20 full-depth involute, while the helix angle is 23.
(i) Assuming the velocity factor accounts for the dynamic load, design the gear pair.
(ii) If the arrangement is as shown in Fig. 2.4.1, determine the magnitude and direction
of forces acting on meshing gears. Also calculate the reactions at motor bearings A and
B. The thrust is taken by bearing at B.

Fig. 2.4.1

Use the following relations :

2.87
Y = 0.484 –
z
5.6
Kv =
5.6 + V
2
BHN
K = 0.16 ⎡ 100 ⎤ , N/mm
2
⎣ ⎦
Solution :
Given : zp = 18 ; zg = 40 ;
2
b = 105 N/mm ; BHN = 250 ;
P = 22,000 W ; np = 1440 r.p.m. ;
 Machine Design - II (GTU) 2-2 Helical Gears

Ka = 1.25 ; Nf = 1.5 ;
n = 20 ;  = 23.
(i) Design of gear pair :
 Beam strength : As both pinion and gear are made of same material, pinion is
weaker than gear in bending. Hence, it is necessary to design the pinion for
bending.
zp 18
zp = 3 = 3 = 23.078
cos  cos 23
2.87 2.87
Yp = 0.484 – = 0.484 – 23 = 0.3592
zp
The proportion for face width is not given in the example. Hence, from Equation (2.13),
1.15 mn
b 
sin 
1.15 mn
 sin 23
or b  9.246 mn
Let us assume b = 10 mn
 F b = b  b  m n  Y  p
= 105  10mn  mn  0.3592
2
or Fb = 377.16 mn , N ...(a)
 Wear strength :
mn zp mn  18
dp = mt  zp = = cos 23 = 19.5545mn
cos 
2zg 2  40
Q = z + z = 40 + 18 = 1.379
g p

2 2
K = 0.16 [BHN/100] = 0.16 [250/100]
2
or K = 1 N/mm
dp  b  Q  K
 Fw = 2
cos 

19.5545 mn  10 mn  1.379  1
= 2
cos 23
2
or Fw = 318.24 mn , N ...(b)
 Machine Design - II (GTU) 2-3 Helical Gears

As Fw < Fb , gear pair is weaker in pitting, and hence it should be designed for the safety
against pitting failure.
 Effective load :
dp np   19.5545mn  1440
V = = = 1.474mn, m /s
60  1000 60  1000
P 22000 14925.37
Ft = V = 1.474 m = mn ,N ...(c)
n

5.6 5.6
Kv = =
5.6 + V 5.6 + 1.474 mn
Ka  Km  Ft 1.25  1 14925.37
Feff = Kv =  mn
⎛ 5.6 ⎞
⎜ ⎟
⎝ 5.6 + 1.474 mn ⎠

3331.56 (5.6 + 1.474 mn )

or Feff = mn ,N ...(d)

 Estimation of module :

In order to avoid the pitting failure,

Fw = Nf  Feff ...(e)

Substituting Equations (b) and (d) in Equation (e),

2 1.5  3331.56 (5.6 + 1.474mn)

 318.24 mn = mn
3
mn = 87.94 + 19.065 mn

Solving above equation by trial and error, we get,

mn  5.1mm

From Table 2.1, the standard value of module under first choice is 6 mm.

 Dimensions of gear pair :

mn = 6 mm ;
mn 6
mt = = = 6.5181 mm ;
cos  cos 23

zp = 18 ;
 Machine Design - II (GTU) 2-4 Helical Gears

zg = 40 ;

b = 10 mn = 10  6 = 60 mm ;

dp = mt  zp = 6.5181  18 = 117.327 mm ;

dg = mt  zg = 6.5181  40 = 260.7264 mm ;

a = (dp + dg)/2 = (117.327 + 260.724)/2 = 189.026 mm ;

ha = 1mn = 6 mm ;

hf = 1.25 mn = 7.5 mm. ...Ans.

(ii) Forces acting on gear pair :

The tangential component of force is given by,

14925.37 14925.37
Ft = mn = 6 = 2487.56 N

Fig. 2.4.2

The radial component of force is given by,

tan n
Fr = Ft tan t = Ft
cos 
 Machine Design - II (GTU) 2-5 Helical Gears

tan 20
= 2487.56  cos 23 = 983.59 N

The axial component of force is given by,

Fa = Ft tan  = 2487.56  tan 23 = 1055.91 N
Ft = 2487.56 N

Fr = 983.59 N

Fa = 1055.91 N ...Ans.

Fig. 2.4.2 shows the components of force acting on gear pair.

(iii) Reactions of bearings :

Fig. 2.4.3

The forces acting on gear pair and the components of bearing reactions are shown in
Fig. 2.4.3.
 Machine Design - II (GTU) 2-6 Helical Gears

Fig. 2.4.4

Fig. 2.4.4 shows the vertical and horizontal loading diagrams of the motor shaft.

From Fig. 2.4.4(a);

Taking moments about point B,

RAV  300 – Ft  100 = 0

RAV  300 – 2487.56  100 = 0

 RAV = 829.18 N

Taking moments about point A,

RBV  300 – Ft  400 = 0

RBV  300 – 2487.56  400 = 0

 RBV = 3316.74 N
From Fig. 2.4.4(b);
Taking moments about point B,

RAH  300 – Fr  100 – Fa  dp / 2 = 0

117.327
RAH  300 – 983.59  100 – 1055.91  2 = 0

 RAH = 534.34 N
 Machine Design - II (GTU) 2-7 Helical Gears

Taking moments about point A,

RBH  300 – Fr  400 – Fa  dp / 2 = 0

117.327
RBH  300 – 983.59  400 – 1055.91  2 = 0

RBH = 1517.93 N

Again RBA – Fa = 0

 RBA = 1055.91 N

Resultant reaction at point A in the plane of rotation of bearing,

2 2 2 2
RA = (RAV) + (RAH) = (829.18) + (534.34) = 986.43 N

or RA = 986.43 N ...Ans.

Resultant reaction at point B in the plane of rotation of bearing,

2 2
RB = (RBV) + (RBH)
2 2
= (3316.74) + (1517.93)

or RB = 3647.58 N ...Ans.

Reaction at point B in axial direction,

RBA = 1055.91 N ...Ans.

Example 2.11 :

Fig. 2.11.1 shows a sluice gate operating system consisting of two stage gear train. The
first stage is a helical gear pair with a reduction ratio of 4 : 1, while the second stage is a
bevel gear pair with a reduction ratio of 3 : 1. It is powered by a geared motor having an
output speed of 120 r.p.m. The bevel gear is rigidly mounted on double start, square
threaded screw of 36 mm nominal diameter and 6 mm pitch. When the screw rotates, the nut
which is welded to the gate moves up. The gate, which weights 25 kN, is allowed to
slide in the guide slots. The coefficient of thread friction is 0.1. The resistance at the guide
slot may be assumed as equivalent to 15% of the screw friction torque.
 Machine Design - II (GTU) 2-8 Helical Gears

Fig. 2.11.1

The following data refers to a helical gear pair made of plain carbon steel.
 Tooth system = 20 full-depth involute

 Number of teeth on helical pinion = 24

 Face width = 14  transverse module

 Helix angle = 20

2
 Permissible bending stress for gear pair = 70 N/mm

 Surface hardness = 250 BHN

 Deformation factor = 550 N/mm

 Service factor = 1.25

(i) If the gear train efficiency is 90%, find the power rating of the geared motor.
(ii) Assuming the dynamic load is accounted by Buckingham's equation, design the helical
gear pair.
 Machine Design - II (GTU) 2-9 Helical Gears

Use the following relations :

2.87
Y = 0.484 –
z
5.6
Kv =
5.6 + V
2
BHN
K = 0.16 ⎡ 100 ⎤ , N/mm
2
⎣ ⎦
2
21V [bC cos  + Ftmax] cos 
Fd = 2 ,N
21V + bC cos  + Ftmax
Solution :

Given : W = 20,000 N ; d = 36 mm ;
p = 6 mm ; Nt = 2 ;
 = 0.1 ; Tc = 0.15 Tt ;

m = 0.9 ; G1 = 4 ;

G2 = 3 ; np = 120 r.p.m.

n = 20 ; zp = 24 ;

b = 14mt ;  = 20 ;
2
b = 70 N/mm ; BHN = 250 ;

C = 550 N/mm ; Ka = 1.25.

(i) Power Rating of Geared Motor :
For Screw :
mean diameter, dm = d – p / 2 = 36 – 6 / 2 = 33 mm

lead, l = Nt  p = 2  6 = 12 mm
l ⎤ –1 ⎡ 12 ⎤
 = tan ⎡⎢
–1
lead angle, ⎥ = tan ⎣  33⎦ = 6.603
 d
⎣ m⎦
–1 –1
friction angle,  = tan  = tan (0.1) = 5.711

Torque required to overcome the thread friction,

Wdm 20000  33
Tt = 2 tan ( + ) = 2 tan (5.711 + 6.603)

= 72036.11 N-mm
 Machine Design - II (GTU) 2-10 Helical Gears

or Tt = 72.036 N-m ...(a)

Torque required to overcome the guide slot friction,

Tc = 0.15 Tt = 0.15  72.036

or Tc = 10.805 N-m ...(b)

Total torque required to be applied on the screw,

T = Tt + Tc = 72.036 + 10.805

or T = 82.841 N-m ...(c)

np 120
Speed of screw, ns = = = 10 r.p.m.
G1  G2 4  3

Power required at screw,

2nsT 2   10  82.841
Po = = ...(d)
60  1000 60  1000

or Po = 0.08675 kW

Power rating of geared motor,

Po 0.08675
P = = 0.9 = 0.09639
m

or P = 0.09639 kW ...Ans.
(ii) Design of Helical Gear Pair :
 Beam strength :
As pinion and gear are made of same material, pinion is weaker than gear in bending.
Hence, it is necessary to design the pinion for bending.
zp 24
zp = 3 = 3 = 28.92
cos  cos 20

2.87 2.84
Yp = 0.484 – = 0.484 – 28.92 = 0.3847
zp

14 mn 14 mn
b = 14mt = = = 14.898 mn, mm
cos  cos 20

 Fb = b  b  mn  Yp
 Machine Design - II (GTU) 2-11 Helical Gears

= 70  14.898 mn  mn  0.3847
2
or Fb = 401.188 mn , N ...(e)

 Wear strength :
mn zp mn  24
dp = mtzp = = = 25.54 mn
cos  cos 20

zg = Gzp = 4  24 = 96

2zg 2  96
Q = z + z = 96 + 24 = 1.6
g p

2 2 2
K = 0.16 [BHN / 100] = 0.16 = [250 / 100] = 1 N/mm

dp  b  Q  K
 Fw = 2
cos 

25.54 mn  14.898 mn  1.6  1

= 2
cos 20
2
or Fw = 689.44 mn , N ...(f)

As Fb < FW, gear pair is weaker in bending, and hence it should be designed for the
safety against bending failure.
 Effective load :

dp np   25.54 mn  120

V = = = 0.16 mn, m/s
60  1000 60  1000
3
P 0.09639  10 602.44
Ft = V = 0.16 mn = m ,N ...(g)
n

5.6 5.6
Kv = =
5.6 + V 5.6 + 0.16 mn

Ka  Km  Ft 125  1 602.44
 Feff = Kv = 5.6  m
⎛ ⎞ n
⎜5.6 + 0.16 m ⎟
⎝ n ⎠

134.47 (5.6 + 0.16 mn)

or Feff = mn ,N ...(h)
 Machine Design - II (GTU) 2-12 Helical Gears

 Estimation of module :
In order to avoid the bending failure,

Fb = Nf  Feff ...(i)

Substituting Equations (e) and (h) in Equation (i),

2 1  134.47 (5.6 + 0.16 mn)

401.188 mn = mn
3
mn = 1.877 + 0.134 mn
Solving above equation by trial and error, we get,
mn  1.3 mm
From Table 2.1, the standard value of module under first choice is 1.5 mm.
 Dimensions of helical gear pair :

mn  1.5 mm;
mn 1.5
mt = = cos 20 = 1.596 mm ;
cos 

zp = 24 ;

zg = 96 ;

b = 14.898 mn = 14.898  1.5 = 22.347 mm ;

dp = mt  zp = 1.596  24 = 38.31 mm;

dg = mt  zg = 1.596  96 = 153.24 mm;

a = (dp + dg) / 2 = (38.31 + 153.22)/2 = 95.765 mm;

ha = 1mn = 1.5 mm;

hf = 1.25 mn = 1.25  1.5 = 1.875 mm.

 Precise estimation of dynamic load by Buckingham’s equation

(check for design) :

V = 0.16mn = 0.16  1.5 = 0.24 m/s

602.44 602.44
Ft = mn = 1.5 = 401.63 N ...(j)
 Machine Design - II (GTU) 2-13 Helical Gears

Ftmax = Ka  Km  Ft = 1.25  1  401.63 = 502.038 N

2
21 V (bCcos  + Ft max) cos 
Fd = 2
21 V bC cos  + Ft max
2
21  0.24 (22.347  550  cos 20 + 502.038) cos 20
= 2
21  0.24 + 22.347  550  cos 20 + 502.038

or Fd = 481.88 N ...(k)

 Feff = Ka  Km  Ft + Fd

= 1.25  1  401.63 + 481.88

or Feff = 983.92 N ...(l)

From Equation (e),
2 2
Fb = 401.188 mn = 401.188  (1.5)

or Fb = 902.67 N ...(m)
Hence, the available factor of safety is,
Fb 902.67
Nf = F = 983.92
eff

or Nf = 0.817 < 1 ...Ans.

As the available factor of safety is less than 1, the design is unsafe. Therefore, the
design is to be modified by increasing the module to the next standard value under first choice
i.e. 2 mm.
 Modified dimensions of helical gear pair :

mn = 2 mm ;
mn 2
mt = = cos 20 = 2.128 mm ;
cos 

zp = 24 ;

zg = 96 ;

b = 14.898 mn = 14.898  2 = 29.8 mm ;

dp = mt  zp = 2.128  24 = 51.07 mm ;

dg = mt  zg = 2.128  96 = 204.29 mm ;
 Machine Design - II (GTU) 2-14 Helical Gears

a = (dp + dg) / 2 = (51.07 + 204.29) / 2 = 127.68 mm ;

ha = 1 mn = 2 mm ;

hf = 1.25 mn = 1.25  2 = 2.5 mm

 Precise estimation of dynamic load by Buckingham’s equation

(check for design) :

V = 0.16mn = 0.16  2 = 0.32 mm

602.44 602.44
Ft = mn = 2 = 301.22 N ...(n)

Ftmax = Ka  Km  Ft = 1.25  1  301.22 = 376.53 N

2
21 V (bC cos  + Ft max) cos 
Fd = 2
21 V + bC cos  + Ft max
2
21  0.32 (29.8  550  cos 20 + 376.53) cos 20
= 2
21  0.32 + 29.8  550  cos 20 + 376.53

or Fd = 729.28 N ...(o)
 Feff = Ka  Km  Ft + Fd
= 1.25  1  301.22 + 729.28

or Feff = 1105.8 N ...(p)

From Equation (e),
2 2
Fb = 401.188 mn = 401.188  (2)

or Fb = 1604.75 N ...(q)
Hence, the available factor of safety is,
Fb 1604.75
Nf = F = 1105.8
eff

or Nf = 1.45 > 1 ...Ans.

As the available factor of safety is higher than the required factor of safety, the design is
safe.
 Machine Design - II (GTU) 2-15 Helical Gears

Example 2.12 :
The following data is given for a steel spur gear pair transmitting 5 kW power from a shaft
rotating at 5000 r.p.m. to another parallel shaft rotating at 2500 r.p.m.

 Module = 1.5 mm

 Number of pinion teeth = 18

2
 Permissible bending stress for pinion and gear = 210 N/mm
 Face width = 20 mm

 Surface hardness = 400 BHN

 Tooth system = 20 full-depth involute

 Combined teeth error = 8 microns

 Deformation factor = 11400 e, N/mm.

Workout the various strengths and load and comment on the safety of the design.
In order to improve the design, a spur gear pair is replaced by a helical gear pair having a
normal module of 1.5 mm and helix angle of 27.266. The material, surface hardness, tooth
system, accuracy, and face width of helical gear pair are kept same as that of spur gear pair.
Calculate the various strengths and load and comment on the safety of the design.
If the combined teeth error in both the cases is increased to 10 microns, what will be its effect
on the design ?
Assume that the dynamic load is account by Buckingham's equation.
Use the following relations :
2.87
Y = 0.484 –
z
2
BHN
K = 0.16 ⎡ 100 ⎤ , N/mm
2
⎣ ⎦
2
21 V [bC cos  + Ftmax] cos 
Fd = 2 ,N
21V + bC cos  + Ftmax
Solution :
Given : P = 5000 W ; np = 5000 r.p.m.;
ng = 2500 r.p.m. ; m = 1.5 mm ;
2
zp = 18 ; b = 210 N / mm ;
b = 20 mm ; BHN = 400 ;
 = 20 ; e = 0.008 mm ;
C = 11400 e N/mm ; Ka = 1.
 Machine Design - II (GTU) 2-16 Helical Gears

Spur Gear Pair Design :

 Effective load :
np 5000
G = n = 2500 = 2
g

 zg = Gzp= 2  18 = 36

dp = mzp = 1.5  18 = 27 mm

 dp np   27  5000
V = = = 7.0686 m/s
60  1000 60  1000
P 5000
Ft = V = 7.0686 = 707.354 N

Now, Ft max = Ka  Km  Ft = 1  1  707.354 = 707.354 N

C = 11400 e = 11400  0.008 = 91.2 N/mm

For spur gear pair,  = 0. Hence cos  = 1.

21 V (bC + Ft max)
 Fd =
21 V + bC + Ft max
21  7.0686 (20  91.2 + 707.354)
=
21  7.0686 + 20  91.2 + 707.354

or Fd = 1890.56 N

 Feff = Ka  Km  Ft + Fd

= 1  1  707.354 + 1890.56

or Feff = 2597.92 N ...(a)

 Beam strength :
As both pinion and gear are made of same material, pinion is weaker than gear in
bending. Hence, it is necessary to calculate the beam strength of pinion teeth.
2.87 2.87
Yp = 0.484 – z = 0.484 – 18 = 0.3245
p

 Fb = b  b  m  Yp

= 210  20  1.5  0.3245

 Machine Design - II (GTU) 2-17 Helical Gears

or Fb = 2044.35 N ...(b)

 Wear strength :
2 zg 2  36
Q = z + z = 36 + 18 = 1.3333
g p

2 2 2
K = 0.16 [BHN / 100] = 0.16 [400 / 100] = 2.56 N /mm

 Fw = dp  b  Q  K

= 27  20  1.3333  2.56

or Fw = 1843.15 N ...(c)

As Fw < Fb , the spur gear pair is weaker in wear (pitting).

Hence, the available factor of safety for spur gear pair is,
Fw 1843.15
Nfs = F = 2597.92
eff

or Nfs = 0.709 < 1 ...Ans.

As the available factor of safety is less than 1, the spur gear pair is unsafe.
 If combined teeth error for spur gear pair is increased to 10 microns :
If the combined teeth error is increased to 10 microns, the dynamic load, and hence
effective load would further increase. This will make the spur gear pair still more unsafe.
Helical Gear Pair Design :
mn = 1.5 mm ;  = 27.266
 Effective load :
mn  zp 1.5  18
dp = mt  zp = = cos (27.266) = 30.375 mm
cos 
 dp np   30.375  5000
V = = = 7.952 m/s
60  1000 60 1000
P 5000
Ft = V = 7.952 = 628.77 N

Now,

Ft max = Ka  Km  Ft = 1  1  628.77 = 628.77 N

 Machine Design - II (GTU) 2-18 Helical Gears

C = 11400 e = 11400  0.008 = 91.2 N/mm

21V[bC cos2  + Ft max] cos 

Fd =
21 V + bCcos2  + Ft max

21  7.952 [20  91.2  cos 2 (27.266) + 628.77] cos (27.266)

=
21  7.952 + 2
20  91.2  cos (27.266) + 628.77

or Fd = 1446 N

 Feff = Ka  Km  Ft + Fd

= 1  1  628.77 + 1446

or Feff = 2074.77 N ....(d)

 Beam strength :
As both pinion and gear are made of same material, pinion is weaker than gear in
bending. Hence, it is necessary to calculate the beam strength of pinion teeth.
zp 18
zp = = 3 = 25.63
cos  cos (27.266)
3

2.87 2.87
Yp = 0.484 – = 0.484 – 25.63 = 0.3720
zp

 Fb = b  b  mn  Yp

= 210  20  1.5  0.3720

or Fb = 2343.6 N ...(e)

 Wear strength :
2zg 2  36
Q = z + z = 36 + 18 = 1.3333
g p

2 2 2
K = 0.16 = [BHN / 100] = 0.16 [400 / 100] = 2.56 N /mm
dp  b  Q  K
 Fw = 2
cos 
 Machine Design - II (GTU) 2-19 Helical Gears

30.375  20  1.3333  2.56

= 2
cos (27.266)

or Fw = 2624.33 N ...(f)
As Fb < Fw the helical gear pair is weaker in bending.
Hence, the available factor of safety for helical gear pair is,
Fb 2343.6
Nfh = F = 2074.77
eff

or Nfh = 1.13 > 1 ...Ans.

As the available factor of safety is greater than 1, the helical gear pair is safe.
 If combined teeth error for helical gear pair is increased to 10 microns :

C = 11400 e = 11400  0.01 = 114 N/mm

21V[bC cos2  + Ft max] cos 
Fd =
21 V + bCcos2  + Ft max
2
21  7.952 [20  114  cos (27.266) + 628.77] cos (27.266)
= 2
21  7.952 + 20  114  cos (27.266 )+ 628.77

or Fd = 1667.858 N

 Feff = Ka  Km  Ft + Fd

= 1  1  628.77 + 1667.858

or Feff = 2296.628 N ...(g)

Hence, the available factor of safety is,

Fb 2343.6
Nfh = F = 2296.628
eff

or Nfh = 1.02 > 1 ...Ans.

As the available factor of safety is greater than 1, the helical gear pair is safe.
Hence, if the combined teeth error is increased to 10 microns, the helical gear pair will
be still safe, but it results in the reduction of factor of safety.
 Machine Design - II (GTU) 2-20 Helical Gears

Example 2.14 :

Fig. 2.14.1

The hoisting drum shown in Fig. 2.14.1 is to be driven by 720 r.p.m. electric motor through a
two-stage co-axial reduction gear unit. The first stage is a helical gear pair, while the second
stage is a spur gear pair. All the gears are made of steel. The spur gear is bolted to the hoisting
drum. The velocity factor accounts for the dynamic load. Select the electric motor and design
the gear pairs with the following data :
 Capacity of the hoist = 20 kN
 Hoisting speed = 41 m/min.
 Hoisting drum diameter = 290 mm
 Efficiency of the reduction gear unit = 92%
 Number of teeth on helical pinion = 18
 Number of teeth on spur pinion = 18
 Face width of helical gears = 10  normal module
 Face width of spur gears = 10  module
2
 Permissible bending stress for helical gear pair = 200 N /mm
2
 Permissible bending stress for spur gear pair = 280 N / mm
 Service factor = 1.25
 Factor of safety = 1.5
Specify the surface hardness of the gear pairs.
Select the module from first choice or second choice.
 Machine Design - II (GTU) 2-21 Helical Gears

Use the following relations :

1/3
⎡ 2 K1 ⎤ K1
G1  0.8 ⎢G K ⎥ , K = 0.75
⎣ 2⎦ 2

2.87
Y = 0.484 –
z
2
BHN
K = 0.16 ⎡ 100 ⎤
⎣ ⎦
6
Kv = 6 + V For spur gear pair
5.6
= For helical gear pair.
5.6 + V
Solution :
41
Given : WH = 20  103 N ; VH = 60 m/s ;

DH = 0.29 m ;  = 0.92 ;
zp = 18 ; z P2 = 18 ;
1

b1 = 10 mn ; b2 = 10 m ;
2
b = 200 N / mm ; b = 280 N / mm2 ;
1 2

Ka = 1.25 ; Nf = 1.5 ;
np = 720 r.p.m.
1

Reduction Ratio for Each Stage :

[Note : Suffix 1 indicates 1st stage and suffix 2 indicates 2nd stage.]
Power required to drive the hoisting drum is given by,
3 41
Po = WH  VH = 20  10  60

= 13666.667 W

= 13.6667 kW
Power input to the reduction gear unit is given by,
Po 13.6667
Pi = = 0.92 = 14.855 kW


Hence, the standard electric motor with 15 kW power rating is selected.

Use following relations :
 Machine Design - II (GTU) 2-22 Helical Gears

1/3
⎡ K1⎤ K1
G1 = 0.8 ⎢G2 K ⎥ , K = 0.75
⎣ 2⎦ 2

2.87
Y = 0.484 – 2
2
BHN
K = 0.16 ⎡ 100 ⎤
⎣ ⎦
6
Kv = 6 + V for spur gear pair

5.6
= for helical gear pair
5.6 + V
 DH nH
Now, VH = 60
41   0.29  nH
60 = 60

 nH = 45 r.p.m.
or ng = nH = 45 r.p.m.
2

np 720
1
Overall reduction ratio, G = n = 45 = 16
g
2

From Equation (1.52) (Chapter 1), for a two stage gear reduction, the first stage
reduction ratio is given by the empirical relation,
1/3
⎡ 2 K1⎤
G1  0.8 ⎢G K ⎥ ...(a)
⎣ 2⎦

K1
Assuming K2 = 0.75,
2 1/3
G1  0.8 [(16)  0.75]  4.61
G 16
 G2 = G = 4.61 = 3.47
1

In a co-axial reduction gear unit, a second stage spur gear pair is designed first. Then in
the design of a first stage helical gear pair centre distance is adjusted by varying the helix
angle.
 Machine Design - II (GTU) 2-23 Helical Gears

Second Stage Spur Gear Pair :

zg
2
G2 = z
p
2

zg
2
3.47 = 18

zg = 62.46 or 62
2

 zg = 62 ...Ans.
2

zg 62
2
hence, G2 = z = 18 = 3.444
p
2

G2 = 3.444 ...Ans.

G 16
and G1 = G = 3.444 = 4.645
2

G1 = 4.645 ...Ans.

np 720
1
np = G = 4.645 = 155 r.p.m.
2 1

or np = 155 r.p.m. ...Ans.

2

 Beam strength :
As pinion and gear are made of same material, pinion is weaker than gear in bending.
Hence, it is necessary to design the pinion for bending.
2.87 2.87
Yp = 0.484 – z = 0.484 – 18 = 0.3245
2 p
2

Fb = b  b2  m  Yp
2 2 2

= 280  10m  m  0.3245

2
or Fb = 908.6 m , N ...(b)
2

 Effective load :
dp np m zp np   m  18  155
2 2 2 2
V2 = = = = 0.146 m, m/s
60  1000 60  1000 60  1000
 Machine Design - II (GTU) 2-24 Helical Gears

3
P 14.855  10 101746.58
Ft = V = 0.146 m = m ...(c)
2 2

Assuming the spur gear pair is manufactured by hobbing, shaping or milling, the
velocity factor can be taken as,
6 6
Kv = 6 + V = 6 + 0.146 m
2 2

Ka  Km  Ft
2
 Feff = Kv2
2

1.25  1 101746.58
=  m
⎛ 6 ⎞
⎝6 + 0.146 m⎠
21197.2 (6 + 0.146 m)
or Feff = m ,N ...(d)
2

 Estimation of module :
In order to avoid the bending failure,
Fb = Nf  Feff
2 2

2 1.5  21197.2 (6 + 0.146 m)

908.6 m = m
3
m = 209.96 + 5.11 m

Solving above equation by trial and error, we get,

m  6.3 mm

From Table 2.1, the standard value of module under second choice is 7 mm.
 Dimensions of spur gear pair :

m = 7 mm ;
zp = 18 ;
2

zg = 62 ;
2

b2 = 10 m = 10  7 = 70 mm ;

dp = mzp = 7  18 = 126 mm ;
2 2
 Machine Design - II (GTU) 2-25 Helical Gears

dg = mzg = 7  62 = 434 mm ;
2 2

a2 = [dp + dg ] / 2 = (126 + 434) / 2 = 280 mm

2 2

ha = 1m = 7 mm ;
2

hf = 1.25m = 8.75 mm. ...Ans.

2

 Surface hardness :
2 zg 2  62
2
Q2 = z + z = 62 + 18 = 1.55
g p
2 2

2
K2 = 0.16 [(BHN)2 / 100]

Fw = dp  b2  Q2  K2
2 2

= 126  70  1.55  0.16 [(BHN)2 / 100]2

2
or Fw = 2187.36 [(BHN)2 / 100] , N ...(e)
2

In order to avoid the pitting failure,

Fw = Nf  Feff
2 2

21197.2 (6 + 0.146m)⎤
2187.36 [(BHN)2 / 100] = 1.5 ⎡
2
⎣ m ⎦
21197.2 (6 + 0.146  7)⎤
2187.36 [(BHN)2 / 100] = 1.5 ⎡
2
⎣ 7 ⎦
2
[(BHN)2 / 100] = 14.582

(BHN)2 = 381.86 or 385

(BHN)2 = 385 ...Ans.

First Stage Helical Gear Pair :

zg
1
G1 = z
p
1

zg
1
 4.645 = 18
 Machine Design - II (GTU) 2-26 Helical Gears

zg = 83.61 or 84
1

zg = 84 ...Ans.
1

 Estimation of module :
For a co-axial reduction gear unit,
st nd
1 stage centre distance = 2 stage centre distance

a1 = a2
dp + dg
1 1
 2 = a2

mt ( zp + zg )
1 1
 2 = a2

mn ( zp + zg )
1 1
= a2
2 cos 

mn ( 18 + 84)
= 280
2 cos 
mn 280  2
= 102
cos 
mn
or = 5.49
cos 

Assuming mn = 5 mm,
5
= 5.49
cos 

 cos  = 0.9107
–1
 = cos (0.9107) = 24.396

 = 24.396
mn 5
 mt = = = 5.49 mm
cos  cos 24.396

 Dimensions of helical gear pair :

mn = 5 mm ;
 Machine Design - II (GTU) 2-27 Helical Gears

mt = 5.49 mm ;
zp = 18 ;
1

zg = 84 ;
1

b1 = 10mn = 10  5 = 50 mm ;
dp = mt  zp = 5.49  18 = 98.82 mm ;
1 1

dg = mt  zg = 5.49  84 = 461.16 mm ;
1 1

a1 = (dp + dg ) / 2 = 279.99 mm ;
1 1

ha1 = 1mn = 5 mm ;

hf1 = 1.25 mn = 6.25 mm ;

 = 24.396. ...Ans.

 Beam strength :
As pinion and gear are made of same material, pinion is weaker than gear in bending.
Hence, it is necessary to design the pinion for bending.
zp 18
zp =
1
3 = 3 = 23.83
1 cos  cos 24.396
2.87 2.87
Yp = 0.484 – = 0.484 – 23.83 = 0.3635
1 
zp
1

Fb = b  b1 m  Yp
1 1 1

= 200  50  5  0.3635
or Fb = 18175 N ...(f)
1

 Effective load :
dp np   98.82  720
1 1
V1 = = = 3.725 m/ s
60  1000 60  1000
3
P 14.855  10
Ft = V = 3.725 = 3987.92 N ...(g)
1 1
 Machine Design - II (GTU) 2-28 Helical Gears

5.6 5.6
Kv = = = 0.7437
1 5.6 + V1 5.6 + 3.725

Ka  Km  Ft 1.25  1  3987.92
1
 Feff = Kv = 0.7437
1
1

or Feff = 6702.83 N ...(h)

1

The available factor of safety against bending failure is,

Fb 18175
1
Nfb = F = 6702.83
eff
1

or Nfb = 2.71 > 1.5 ...Ans.

As the available factor of safety is higher than the required factor of safety, the helical
gear pair is safe against bending failure.
 Surface hardness :
2 zg 2  84
1
Q1 = zg + zp = 84 + 18 = 1.647
1 1
2
K1 = 0.16 [(BHN)1 / 100]
dp  b1  Q1  K1
1
 Fw = 2
1 cos 
2
98.82  50  1.647  0.16 [(BHN)1 / 100]
= 2
cos 24.396
2
or Fw = 1569.88 [(BHN)1 / 100] , N ...(i)
1

In order to avoid the pitting failure,

Fw = Nf  Feff
1 1
2
1569.88 [(BHN)1 / 100] = 1.5  6702.83
2
[(BHN)1 / 100] = 6.404
(BHN)1 = 253 or 255

(BHN)1 = 255 ...Ans.